manualshive.com logo in svg

Yamaha YZ125 2022, Owner'S Service Manual, Page: 159 / 278

Share
Download
Yamaha YZ125 2022 Owner'S Service Manual Download Page 159

1
2
3
4
5
6
7
8
9

10

ENGINE

ENGINE REMOVAL

..........................................................................................5-1

REMOVING THE ENGINE .........................................................................5-4
INSTALLING THE ENGINE........................................................................5-4
INSTALLING THE EXHAUST PIPE AND MUFFLER.................................5-4

CYLINDER HEAD, CYLINDER AND PISTON

.................................................5-6

REMOVING THE CYLINDER HEAD..........................................................5-8
REMOVING THE PUSH ROD ....................................................................5-8
REMOVING THE PISTON..........................................................................5-8
CHECKING THE CYLINDER HEAD ..........................................................5-9
CHECKING THE CYLINDER AND PISTON...............................................5-9
COMBINATION OF PISTON AND CYLINDER ........................................5-10
CHECKING THE PISTON RING ..............................................................5-11
CHECKING THE PISTON PIN .................................................................5-11
CHECKING THE SMALL END BEARING ................................................5-12
CHECKING THE POWER VALVE ...........................................................5-12
CHECKING THE POWER VALVE HOLE ON CYLINDER .......................5-12
ASSEMBLING THE POWER VALVE .......................................................5-12
INSTALLING THE PISTON AND CYLINDER ..........................................5-13
INSTALLING THE CYLINDER HEAD ......................................................5-15

CDI MAGNETO

...............................................................................................5-16

REMOVING THE ROTOR ........................................................................5-17
CHECKING THE CDI MAGNETO ............................................................5-17
CHECKING THE WOODRUFF KEY ........................................................5-17
INSTALLING THE CDI MAGNETO ..........................................................5-17

KICKSTARTER

...............................................................................................5-20

REMOVING THE PRIMARY DRIVE GEAR .............................................5-22
REMOVING THE KICK SHAFT ASSEMBLY ...........................................5-22
CHECKING THE KICK GEAR AND KICK IDLE GEAR............................5-22
INSTALLING THE KICK SHAFT ASSEMBLY ..........................................5-22
INSTALLING THE KICK IDLE GEAR .......................................................5-23
INSTALLING THE PRIMARY DRIVE GEAR ............................................5-23
INSTALLING THE KICKSTARTER LEVER..............................................5-24

YPVS GOVERNOR

.........................................................................................5-25

REMOVING THE GOVERNOR ................................................................5-26
CHECKING THE GOVERNOR GROOVE................................................5-26
CHECKING THE BEARING .....................................................................5-26
INSTALLING THE GOVERNOR...............................................................5-26

CLUTCH

..........................................................................................................5-28

REMOVING THE CLUTCH ......................................................................5-30
CHECKING THE FRICTION PLATES......................................................5-30
CHECKING THE CLUTCH PLATES ........................................................5-30
CHECKING THE CLUTCH SPRINGS......................................................5-30

Summary of Contents for YZ125 2022

Page 1: ...Read this manual carefully before operating this vehicle 2022 OWNER S SERVICE MANUAL YZ125 YZ125N2 LIT 11626 35 29 B4X 2819U 10 ...

Page 2: ... cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wear gloves or wash your hands frequently when servicing your vehicle For more information go to www P65Warnings ca gov passenger vehicle Read this manual carefully before operating this vehicle This ma...

Page 3: ...MANUAL 2022 by Yamaha Motor Corporation U S A First edition June 2021 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited P N LIT 11626 35 29 ...

Page 4: ...quested not to undertake inspection adjustment disassem bly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage WARNING EWA20270 PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU H...

Page 5: ...EAM20162 YAMAHA MOTOR CORPORATION U S A YZ MOTORCYCLE LIMITED WARRANTY ...

Page 6: ...steps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a removal or a disassembly step Symbols 5 indicate parts to be lubricated or replaced Refer to SYMBOLS A job instruction chart 6 accompanies the exploded diagram providing the order of jobs the names of parts the notes in j...

Page 7: ...ITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clearance Molybdenum disulfide grease Engine speed Silicone grease Electrical data Apply locking agent LOCTITE Engine oil Replace the part with a new one G M BF B T R LS M S LT E New ...

Page 8: ......

Page 9: ...GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 TUNING 10 EAM10003 TABLE OF CONTENTS ...

Page 10: ......

Page 11: ... FOR REMOVAL AND DISASSEMBLY 1 8 REPLACEMENT PARTS 1 8 GASKETS OIL SEALS AND O RINGS 1 8 LOCK WASHERS PLATES AND COTTER PINS 1 9 BEARINGS AND OIL SEALS 1 9 CIRCLIPS 1 9 BASIC SERVICE INFORMATION 1 10 ELECTRICAL SYSTEM 1 10 SPECIAL TOOLS 1 12 INSTRUMENT AND CONTROL FUNCTIONS 1 16 ENGINE STOP SWITCH 1 16 SHIFT PEDAL 1 16 KICKSTARTER LEVER 1 16 FRONT BRAKE LEVER 1 16 REAR BRAKE PEDAL 1 16 FUEL COCK 1...

Page 12: ...MAINTENANCE AFTER BREAK IN 1 20 MAJOR MAINTENANCE 1 20 AIR FILTER MAINTENANCE 1 20 TORQUE CHECK POINTS 1 21 MOTORCYCLE CARE AND STORAGE 1 23 CARE 1 23 STORAGE 1 24 ...

Page 13: ...re riding 2 This motorcycle is designed to carry the oper ator only No passengers 3 The failure of motorists to detect and recog nize motorcycles in traffic is the predominat ing cause of automobile motorcycle accidents Many accidents have been caused by an automobile driver who did not see the motorcycle Making yourself conspic uous appears to be very effective in reducing the chance of this type...

Page 14: ... Many companies with no connection to Yamaha manufacture parts and accessories or offer oth er modifications for Yamaha vehicles Yamaha is not in a position to test the products that these aftermarket companies produce Therefore Yamaha can neither endorse nor recommend the use of accessories not sold by Yamaha or modifications not specifically recommended by Yamaha even if sold and installed by a ...

Page 15: ...he fuel cock if equipped is in the OFF position and that there are no fuel leaks 3 Point the front wheel straight ahead on the trailer or in the truck bed and choke it in a rail to prevent movement 4 Shift the transmission in gear for models with a manual transmission 5 Secure the motorcycle with tie downs or suit able straps that are attached to solid parts of the motorcycle such as the frame or ...

Page 16: ...LOCATION OF IMPORTANT LABELS 1 4 EAM20085 LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle 1 2 3 4 5 ...

Page 17: ...for the vehicle you have purchased 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 Clutch lever 2 Engine stop switch 3 Front brake lever 4 Throttle grip 5 Radiator cap 6 Fuel tank cap 7 Kickstarter lever 8 Fuel tank 9 Radiator 10 Coolant drain bolt 11 Check bolt Transmission oil level 12 Rear brake pedal 13 Valve joint 14 Fuel cock 15 Starter knob 16 Drive chain 17 Air filter 18 Shift pedal 19 F...

Page 18: ...or positive identi fication of the model you own 2 If your vehicle is stolen the authorities will need the number to search for and identify your vehicle EAM30002 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the right side of the frame EAM30003 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the right side of the engine ...

Page 19: ...ipple wrench 1 is used to tighten the spoke EAM30534 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose NOTICE ECA27110 In this installation make sure the arrow fac es the fuel tank and also downward EAM30615 COLLAR tool for YPVS This collar 1 is used to remove and install the push rod of the engine NOTICE ECA27100 Be sure to use the colla...

Page 20: ...red to the chassis paint and plating will be damaged Therefore rinse it out with water in good time WARNING EWA18970 Coolant is potentially harmful and should be handled with special care If it enters your eyes wash it away with wa ter enough and then get medical attention If it splashes on your skin or clothes quick ly wash it away with water and then with soapy water If it is swallowed immediate...

Page 21: ...oil seal make sure that its main lip faces the oil chamber the target to be sealed Before installation always apply a light coat of grease to the oil seal lip NOTICE ECA13300 Do not spin the bearing with compressed air because this will damage the bearing surfac es EAM30014 CIRCLIPS When assembling parts always use new cir clips During installation of a circlip make sure that the edge 2 of the cir...

Page 22: ...est har ness Checking the connections Check the leads couplers and connectors for stains rust moisture etc 1 Disconnect Lead Coupler Connector NOTICE ECA16780 When disconnecting a coupler release the coupler lock hold both sections of the cou pler securely and then disconnect the cou pler There are many types of coupler locks therefore be sure to check the type of cou pler lock before disconnectin...

Page 23: ...nector TIP When connecting a coupler or connector make sure that both terminals are connected securely Make sure all connections are tight 5 Check No continuity TIP If there is no continuity clean the terminals When checking the wire harness perform steps 1 to 4 As a quick remedy use a contact revitalizer available at most part stores 1 Digital circuit tester CD732 90890 03243 Model 88 Multimeter ...

Page 24: ...h YM YU or ACC For others use tool number starting with 90890 Tool name Tool No Illustration Reference pages Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 1 11 8 7 8 8 8 8 8 9 8 9 8 9 8 10 Steering nut wrench 90890 01403 Exhaust flange nut wrench YU A9472 3 17 4 52 Spoke nipple wrench 6 7 90890 01521 Spoke nipple wrench 6 7 YM 01521 3 23 Dial gauge stand set...

Page 25: ...5 18 Flywheel puller 90890 01189 Flywheel puller YM 01189 5 17 Clutch holder 90890 04199 Universal clutch holder YM 91042 5 30 5 32 Thickness gauge 90890 03268 Feeler gauge set YU 26900 9 5 30 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 40 Yamaha bond No 1215 90890 85505 Three bond No 1215 5 41 Tool name Tool No Illustration Reference pages YU 01304 ...

Page 26: ...ankshaft installer bolt 90890 01275 Bolt YU 90060 5 41 5 44 Adapter M8 90890 01499 Adapter M8 YM 01499 5 41 Crankcase separating tool 90890 01135 Crankcase separator YU 01135 B 5 44 Adapter M12 90890 01278 Adapter 3 YU 90063 5 44 Tool name Tool No Illustration Reference pages YU 90058 YU 90059 ...

Page 27: ...oling system tester kit YU 24460 A 6 3 6 3 Radiator cap tester adapter 90890 01352 Pressure tester adapter YU 33984 6 3 6 3 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 8 Tool name Tool No Illustration Reference pages YU 24460 A YU 33984 ...

Page 28: ... has a primary kickstarter lever so the engine can be started in any gear if the clutch is disengaged In normal practices however shift to neutral be fore starting EAM30188 FRONT BRAKE LEVER The front brake lever 1 is located on the right handlebar Pull it toward the handlebar to acti vate the front brake EAM30189 REAR BRAKE PEDAL The rear brake pedal 1 is in the right of the chassis Press down on...

Page 29: ...E When cold the engine requires a richer air fuel mixture for starting A separate starter circuit which is controlled by the starter knob 1 sup plies this mixture Pull the starter knob out to open the circuit for starting When the engine has warmed up push it in to close the circuit ...

Page 30: ...gine push the engine stop switch TIP Continue pushing the engine stop switch till the engine comes to a full stop EAM30197 STARTING A WARM ENGINE Do not operate the starter knob CHOKE Open the throttle slightly and start the engine by kick ing the kickstarter forcefully with firm stroke EAM30198 BREAK IN PROCEDURES A break in is important so that rotating portion sliding surfaces and mounted areas...

Page 31: ...aced a break in is required Cylinder and Crankshaft A break in is re quired for about an hour Piston Piston ring Valve Camshaft and Gear A break in is required for about 30 minutes at a throttle opening of 1 2 or less Observe the condition of the engine carefully during a break in For checkpoints for a break in see MAIN TENANCE AFTER BREAK IN If any prob lem is found immediately stop the engine an...

Page 32: ... nuts Check for looseness in mounted areas of parts as well as engine mounting bolts and engine brackets 2 For the chassis Check welds and mounted areas of the frame the swingarm the link the bracket and so on for looseness and cracks Wheel s Check the wheel for runout Check the spoke for looseness Brake s Check the brake disc mounting bolt for loose ness Check that the reservoir contains the spec...

Page 33: ...k to swingarm Mounting of rear shock absorber Rear shock absorber and frame Mounting of swingarm Tightening of pivot shaft Wheel s Mounting of wheel Front Tightening of wheel axle Tightening of axle holder Tightening of spoke nipple Rear Tightening of wheel axle Wheel to rear wheel sprocket Tightening of spoke nipple Brake s Front Brake caliper to front fork Brake disc to wheel Tightening of union...

Page 34: ...UES on page 2 9 Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fender Tightening of mud flap Tightening of rear brake disc cover Tightening of rear brake caliper cover ...

Page 35: ...cted Also thorough ly rinse the area off with water immediately dry it and then apply a corrosion protec tion spray Improper cleaning can damage plastic parts such as cowlings panels wind shields headlight lenses meter lenses etc and the mufflers Use only a soft clean cloth or sponge with water to clean plastic However if the plastic parts cannot be thor oughly cleaned with water diluted mild de t...

Page 36: ...and nickel plated sur faces 5 Use spray oil as a universal cleaner to re move any remaining dirt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry completely before storing or covering it WARNING EWA19050 Contaminants on the brakes or tires can cause loss of control Make sure that there is no oil or wax on the brakes or tires If necessary clean ...

Page 37: ...ith the engine stop switch pushed in kick the engine over several times to coat the cylinder walls with oil 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of the sidestand 5 Check and if necessary correct the tire air pressure and then lift the motorcycle so that both of its wheels are off the ground Alterna tively turn the wheels a little every month in...

Page 38: ...MOTORCYCLE CARE AND STORAGE 1 26 ...

Page 39: ...CATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 5 ELECTRICAL SPECIFICATIONS 2 8 TIGHTENING TORQUES 2 9 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 9 ENGINE TIGHTENING TORQUES 2 10 CHASSIS TIGHTENING TORQUES 2 11 CABLE ROUTING DIAGRAM 2 15 ...

Page 40: ...el Model B4X1 B4X5 Dimensions Overall length 2135 mm 84 1 in Overall width 825 mm 32 5 in Overall height 1295 mm 51 0 in Seat height 980 mm 38 6 in Wheelbase 1445 mm 56 9 in Ground clearance 365 mm 14 37 in Weight Curb weight 95 kg 209 lb Riding capacity 1 person ...

Page 41: ...ooling system Coolant quantity Radiator including all routes 0 90 L 0 95 US qt 0 79 Imp qt Radiator cap valve opening pressure 93 3 122 7 kPa 0 93 1 23 kgf cm 13 5 17 8 psi Spark plug s Manufacturer model NGK BR9EVX Spark plug gap 0 6 0 7 mm 0 024 0 028 in Cylinder head Warpage limit 0 03 mm 0 0012 in Cylinder Bore 54 000 54 014 mm 2 1260 2 1265 in Wear limit 54 064 mm 2 1285 in Piston Piston to c...

Page 42: ... reduction ratio 3 368 64 19 Transmission type Constant mesh 6 speed Gear ratio 1st 2 385 31 13 2nd 1 933 29 15 3rd 1 588 27 17 4th 1 353 23 17 5th 1 176 20 17 6th 1 056 19 18 Main axle runout limit 0 01 mm 0 0004 in Drive axle runout limit 0 01 mm 0 0004 in Secondary reduction ratio 3 769 49 13 Final drive Chain Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter...

Page 43: ...ENGINE SPECIFICATIONS 2 4 Reed valve Thickness 0 400 mm 0 0157 in Valve bending limit 0 2 mm 0 01 in ...

Page 44: ... air pressure measured on cold tires Front 100 kPa 1 00 kgf cm 15 psi Rear 100 kPa 1 00 kgf cm 15 psi Front brake Type Hydraulic single disc brake Brake disc thickness limit 2 5 mm 0 10 in Brake disc runout limit as measured on wheel 0 15 mm 0 0059 in Brake pad lining thickness limit 1 0 mm 0 04 in Master cylinder inside diameter 9 52 mm 0 37 in Caliper cylinder inside diameter Left 25 40 mm 25 40...

Page 45: ... from the start position Soft 20 Adjustment value from the start position STD 10 Adjustment value from the start position Hard 0 Rear suspension Type Swingarm link suspension Spring Coil spring Shock absorber Gas hydraulic damper Wheel travel 315 mm 12 4 in Spring preload Adjusting system Mechanical adjustable type Adjustment value Soft 1 5 mm 0 06 in Adjustment value STD 7 0 mm 0 28 in Adjustment...

Page 46: ...t Click Adjustment value from the start position Soft 20 Adjustment value from the start position STD 12 Adjustment value from the start position Hard 0 Drive chain Size 520 Chain type Non sealed type Number of links 112 Drive chain slack Maintenance Stand 48 0 58 0 mm 1 89 2 28 in 15 link length limit 242 9 mm 9 56 in ...

Page 47: ...on timing B T D C 0 50 mm 0 02 in Pickup coil resistance 248 0 372 0 Charging coil 1 resistance 720 0 1080 0 Charging coil 2 resistance 44 0 66 0 Ignition coil Primary coil resistance 0 24 0 36 Secondary coil resistance 5 68 8 52 k Spark plug cap Resistance 5 00 k Charging system Charging system CDI magneto ...

Page 48: ...To avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifications re quire clean dry threads Components should be at room temperature A Distance between flats B Outside thread diameter A nut B bolt General tightening torques N m kgf m lb ft 10 mm 6 mm 6 0 6...

Page 49: ... 7 4 lb ft Coolant drain bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft Radiator bolt M6 6 10 N m 1 0 kgf m 7 4 lb ft Radiator guard bolt M6 2 10 N m 1 0 kgf m 7 4 lb ft Radiator hose clamp M6 8 1 5 N m 0 15 kgf m 1 1 lb ft Air filter element M6 1 2 0 N m 0 20 kgf m 1 5 lb ft Carburetor joint bolt M6 4 10 N m 1 0 kgf m 7 4 lb ft Carburetor joint clamp M4 1 2 3 N m 0 23 kgf m 1 7 lb ft Air filter case joint ...

Page 50: ...7 4 lb ft Segment M8 1 30 N m 3 0 kgf m 22 lb ft Exhaust pipe bolt M6 2 12 N m 1 2 kgf m 8 9 lb ft Exhaust pipe stay bolt front M6 1 12 N m 1 2 kgf m 8 9 lb ft Exhaust pipe stay bolt rear M6 1 12 N m 1 2 kgf m 8 9 lb ft Silencer bolt M6 1 12 N m 1 2 kgf m 8 9 lb ft Fiber bolt M6 4 10 N m 1 0 kgf m 7 4 lb ft Stator coil screw M6 3 7 N m 0 7 kgf m 5 2 lb ft CDI magneto rotor nut M12 1 56 N m 5 6 kgf...

Page 51: ...ont brake hose union bolt M10 1 30 N m 3 0 kgf m 22 lb ft Front brake caliper bolt M8 2 28 N m 2 8 kgf m 21 lb ft Grip cap bolt M6 2 3 8 N m 0 38 kgf m 2 8 lb ft Engine stop switch screw M3 1 0 5 N m 0 05 kgf m 0 37 lb ft Brake pad pin plug M10 2 2 5 N m 0 25 kgf m 1 8 lb ft Brake pad pin M10 2 17 N m 1 7 kgf m 13 lb ft Brake caliper bleed screw M8 2 6 N m 0 6 kgf m 4 4 lb ft Front wheel axle nut ...

Page 52: ...lt lower M8 2 29 N m 2 9 kgf m 21 lb ft Brake hose holder screw M5 4 3 5 N m 0 35 kgf m 2 6 lb ft Swingarm and patch screw M4 4 2 0 N m 0 20 kgf m 1 5 lb ft Drive chain tensioner bolt M8 1 16 N m 1 6 kgf m 12 lb ft Drive chain tensioner nut M8 1 16 N m 1 6 kgf m 12 lb ft Drive chain support bolt M6 1 7 N m 0 7 kgf m 5 2 lb ft Drive chain support nut M6 2 7 N m 0 7 kgf m 5 2 lb ft Drive chain guide...

Page 53: ... then loosen the steering ring nut one turn 2 Retighten the steering ring nut 7 N m 0 7 kgf m 5 2 lb ft Side cover bolt front side M6 2 7 N m 0 7 kgf m 5 2 lb ft Side cover bolt rear side M6 2 9 N m 0 9 kgf m 6 6 lb ft Seat bolt M6 1 11 N m 1 1 kgf m 8 1 lb ft Number plate bolt M6 1 7 N m 0 7 kgf m 5 2 lb ft Item Thread size Q ty Tightening torques Remarks ...

Page 54: ...CABLE ROUTING DIAGRAM 2 15 EAM20152 CABLE ROUTING DIAGRAM Frame and engine left side view ...

Page 55: ...hi cle while the end should face the rear side of the vehicle Make sure the connector cover does not contact with engine Do not cut the end of the clamp I Pass the air vent hose front of the throttle cable J Pass the air vent hose overflow hose and crankcase breather hose between the frame and connecting rod K Pass the radiator breather hose and YPVS breather hose on the outside of the engine brac...

Page 56: ...CABLE ROUTING DIAGRAM 2 17 Frame and engine right side view ...

Page 57: ...tle cable clutch cable and engine stop switch lead In so doing clamp the engine stop switch lead at its protecting tube After tightening the clamp cut off the end of the clamp so that the remaining end is 1 5 mm 0 04 0 20 in in length The tightening direction does not mat ter G Pass the radiator breather hose under the clamp ends H Face the CDI unit coupler projection outside of the vehicle when i...

Page 58: ...CABLE ROUTING DIAGRAM 2 19 Handlebar front view 0 mm 0 in 0 mm 0 in ...

Page 59: ...uches the pro jection on the master cylinder while the white paint side faces to the front of the vehicle B Pass the engine stop switch lead in the mid dle of the clutch holder C Pass the throttle cable upper side of the num ber plate D Pass the clutch cable rear of the number plate band E Clamp the engine stop switch lead to the handlebar Do not cut the end of the clamp F Pass the clutch cable th...

Page 60: ...CABLE ROUTING DIAGRAM 2 21 Rear brake right side view ...

Page 61: ...rs C Route the rear brake hose so that it is not bent as shown by the double dash line D Route the rear brake hose and spring so that they do not interfere with each other E Make sure that the rear brake hose is not excessively twisted F Make sure that the metal part of the rear brake hose contacts the stopper of the rear brake master cylinder G Install the rear brake hose so that the bended porti...

Page 62: ...CABLE ROUTING DIAGRAM 2 23 ...

Page 63: ... THE COOLANT 3 11 CHASSIS 3 13 ADJUSTING THE FRONT DISC BRAKE 3 13 ADJUSTING THE REAR DISC BRAKE 3 13 CHECKING THE BRAKE FLUID LEVEL 3 14 CHECKING THE FRONT BRAKE PADS 3 14 CHECKING THE REAR BRAKE PADS 3 14 CHECKING THE FRONT BRAKE HOSE 3 14 CHECKING THE REAR BRAKE HOSE 3 15 CHECKING THE BRAKE OPERATION 3 15 BLEEDING THE HYDRAULIC BRAKE SYSTEM 3 15 DRIVE CHAIN SLACK 3 16 CHECKING AND ADJUSTING THE...

Page 64: ...CHECKING AND LUBRICATING THE CABLES 3 24 LUBRICATING THE BRAKE LEVER 3 24 LUBRICATING THE CLUTCH LEVER 3 24 LUBRICATING THE PEDAL 3 24 ELECTRICAL SYSTEM 3 25 CHECKING THE IGNITION TIMING 3 25 ...

Page 65: ...ace about 7 5 hours Every fifth race about 12 5 hours As required 1 Piston Check piston for carbon deposits and cracks or damage Clean Replace 2 Piston rings Check piston ring end gap and rings for damage Replace 3 Piston pin and small end bearing Check piston pin and small end bearing for damage Replace 4 Cylinder head Check cylinder head for carbon deposits Clean Check cylinder head gasket for d...

Page 66: ... 17 Cooling system Check coolant level and for leak age Check hoses for cracks or dam age Check radiator cap spring opera tion Change coolant Every 2 years 18 Chassis fasteners Check all chassis fitting and fas teners Correct or tighten if necessary 19 Air filter element Clean Replace 20 Frame Clean and check for damage 21 Fuel line Clean and check for leakage 22 Brakes Adjust lever position and p...

Page 67: ...garm pivot bear ings Check bearing assemblies for looseness Lubricate with molybdenum disul fide grease 28 Steering head Check operation free play and tighten if necessary Clean and lubricate with lithium soap based grease Replace bearings 29 Tires and wheels Check tire air pressure wheel runout spokes for looseness and tires for wear Tighten sprocket bolts if neces sary Check wheel bearings for l...

Page 68: ...13 3 13 3 14 3 14 3 14 3 14 3 15 3 15 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 16 4 65 4 65 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play 3 23 3 23 3 23 3 23 Steering Check that the handlebar can be turned smoothly and have no excessive play 3 17 Front forks and rear shock absorber Ch...

Page 69: ...ten the locknut EAM30475 CHECKING THE THROTTLE GRIP TIP Prior to adjusting throttle grip free play the en gine idling speed should be adjusted 1 Check Throttle grip free play a Out of specification Regulate 2 Adjust Throttle grip free play a Slide the adjuster cover b Loosen the locknut 1 c Turn the adjuster 2 until the specified free play is obtained d Tighten the locknut WARNING EWA18470 After a...

Page 70: ...ned straight up when inspecting the oil level WARNING EWA21090 Never attempt to remove the oil check bolt just after high speed operation The heated oil could spout out causing danger Wait un til the oil cools down Oil flows out Oil level is correct Oil does not flow out Oil level is low Add transmission oil until oil flows out c Inspect the gasket oil check bolt replace if damaged d Tighten the o...

Page 71: ...lever free play cannot be obtained on the handlebar side use the adjuster on the clutch cable side Clutch cable side a Slide the clutch cable cover b Loosen the locknut 1 c Turn the adjuster 2 until the specified clutch lever free play is obtained d Tighten the locknut 1 e Return the clutch cable cover to its original position Oil drain bolt 20 N m 2 0 kgf m 15 lb ft Type Motor oil SAE 10W 40 type...

Page 72: ...filter element a After washing the element with air filter cleaner or kerosene squeeze and dry it completely WARNING EWA19110 Do not use gasoline or organic acid alka line volatile oil for washing NOTICE ECA24280 Do not twist the element when squeezing the element 4 Check Air filter element Damage Replace 5 Apply Yamaha foam air filter oil or other quality foam air filter oil a Put the air filter ...

Page 73: ...lter element is prop erly seated in the air filter case The engine should never be operated without the air fil ter element installed otherwise the piston s and or cylinder s may become excessively worn EAM30541 CHECKING THE CARBURETOR JOINT 1 Check Carburetor joint 1 Cracks damage Replace EAM30542 CHECKING THE CARBURETOR HOSES The following procedure applies to all of the fuel and vacuum hoses 1 ...

Page 74: ...orques EAM30210 CHECKING THE COOLANT LEVEL WARNING EWA13030 A hot radiator is under pressure Therefore do not remove the radiator cap when the en gine is hot Scalding hot fluid and steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap counter clockwise ...

Page 75: ...Seat Side cover left right Refer to GENERAL CHASSIS on page 4 1 EAM30212 CHANGING THE COOLANT WARNING EWA13030 A hot radiator is under pressure Therefore do not remove the radiator cap when the en gine is hot Scalding hot fluid and steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place a thick rag or a towel over the radiator cap ...

Page 76: ...tra tion of the coolant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 7 Install Radiator cap 8 Start the engine warm this up for several minutes stop it and then wait for it to cool down 9 Check Coolant level Refer to CHECKING...

Page 77: ...OTICE ECA13490 After adjusting the brake lever position make sure there is no brake drag 4 Install Brake lever cover EAM30480 ADJUSTING THE REAR DISC BRAKE 1 Adjust Brake pedal position a Loosen the locknut 1 b Turn the adjusting nut 2 until the brake pedal is in the correct position WARNING EWA20710 Adjust the pedal height between the maxi mum A and the minimum B as shown In this adjustment the b...

Page 78: ...brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately EAM3...

Page 79: ...d A brake hose is loosened disconnected or replaced The brake fluid level is very low Brake operation is faulty 1 Remove Brake master cylinder cap Reservoir diaphragm Reservoir float front brake Protector rear brake TIP Be careful not to spill any brake fluid or allow the reservoir to overflow Make sure that there is enough brake fluid be fore applying the brake Ignoring this precau tion could all...

Page 80: ...within the specified lim its Checking the drive chain slack 1 Use a maintenance stand to raise the rear wheel off the ground WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Shift the transmission into the neutral posi tion 3 Pull the drive chain up above the drive chain guide installation bolt with a force of about 50 N 5 0 kgf 37 lbf 4 Check Drive cha...

Page 81: ...oves smoothly c Turn the front fork to the right and left a few times and make sure that the steering ro tates smoothly If it does not turn smooth ly remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD on page 4 51 d Loosen the ring nut fully turn and then tighten it to specification with a steering nut wrench WARNING EWA21110 Do not overtighten the steering ring...

Page 82: ...wn hard on the handlebar several times and check if the front fork rebounds smoothly Unsmooth operation Correct or replace Refer to FRONT FORK on page 4 39 5 Check Protector guide 1 Out of specification Replace TIP The protector guide reaches the limit of its use when it is worn down to the same height a as of the outer tube circumference 6 Remove Protector Dust seal 1 NOTICE ECA24330 Be careful n...

Page 83: ...orce adjusting mechanism may not exactly match the above specifications due to small dif ferences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to check the number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary Air bleeding from front fork TIP If the fron...

Page 84: ...her the rear shock absorber assembly operates smoothly Unsmooth operation Correct or replace Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 55 EAM30242 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Use a maintenance stand to raise the rear wheel off the ground WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over Spring preload NOTICE ECA24360 Do not turn the a...

Page 85: ...ism and to modify the specifications as necessary Compression damping for fast compres sion damping NOTICE ECA24370 Do not turn the adjuster forcibly beyond its adjusting range 1 Adjust Compression damping for fast compression damping a Turn the adjuster 1 in the direction of a or b to make an adjustment Spring preload adjusting positions Minimum Position in which the spring is turned in 1 5 mm 0 ...

Page 86: ...e number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary EAM30240 CHECKING THE SWINGARM OPERATION 1 Check Swingarm smooth action Swingarm free play Refer to SWINGARM on page 4 60 EAM30500 LUBRICATING THE SWINGARM PIVOT 1 Lubricate Oil seal Collar Refer to INSTALLING THE SWINGARM on page 4 61 EAM30501 CHECKING THE CONNECTING ARM AND RELAY ARM Refer ...

Page 87: ... Do not give a half turn 180 or more for one tightening Make sure that tightening after a break in is done until the initial looseness in nipples disap pears Make sure that tightening is done in stages not at a time EAM30245 CHECKING THE WHEELS 1 Check Wheel Damage out of round Replace WARNING EWA13260 Never attempt to make any repairs to the wheel EAM30246 CHECKING THE WHEEL BEARINGS 1 Check Whee...

Page 88: ...r a few drops of lubricant into the cable sheath or use a suit able lubricating device EAM30483 LUBRICATING THE BRAKE LEVER 1 Lubricate the pivoting points and metal to metal moving parts of the following parts Brake lever EAM30503 LUBRICATING THE CLUTCH LEVER 1 Lubricate the pivoting points and metal to metal moving parts of the following parts Clutch lever EAM30250 LUBRICATING THE PEDAL 1 Lubric...

Page 89: ...n the same direction 4 Set the dial gauge to zero at TDC 5 From TDC rotate the rotor clockwise until the dial gauge indicates that the piston is at a specified distance from TDC 6 Check Ignition timing Punch mark a on rotor should be aligned with punch mark b on stator Not aligned Adjust 7 Adjust Ignition timing a Loosen the stator coil screws 1 b Align the punch mark on the rotor with punch mark ...

Page 90: ...ELECTRICAL SYSTEM 3 26 ...

Page 91: ... 17 DISASSEMBLING THE FRONT BRAKE CALIPER 4 17 CHECKING THE FRONT BRAKE CALIPER 4 17 ASSEMBLING THE FRONT BRAKE CALIPER 4 17 INSTALLING THE FRONT BRAKE CALIPER 4 18 REMOVING THE FRONT BRAKE MASTER CYLINDER 4 19 CHECKING THE FRONT BRAKE MASTER CYLINDER 4 19 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 19 INSTALLING THE FRONT BRAKE MASTER CYLINDER 4 20 REAR BRAKE 4 22 INTRODUCTION 4 26 CHECKING THE ...

Page 92: ...52 REAR SHOCK ABSORBER ASSEMBLY 4 55 HANDLING THE REAR SHOCK ABSORBER 4 57 DISPOSING OF A REAR SHOCK ABSORBER 4 57 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 57 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 57 CHECKING THE CONNECTING ARM AND RELAY ARM 4 57 INSTALLING THE RELAY ARM 4 58 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 58 SWINGARM 4 60 REMOVING THE SWINGARM 4 61 CHECKING THE SWINGARM 4 ...

Page 93: ... Remarks 1 Seat 1 2 Air scoop right 1 3 Air scoop left 1 4 Side cover left 1 5 Side cover right 1 6 Number plate 1 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 9 N m 0 9 kgf m 6 6 lb ft 11 N m 1 1 kgf m 8 1 lb ft 9 N m 0 9 kgf m 6 6 lb ft 6 3 4 1 5 2 ...

Page 94: ... on the number plate The projection c on the lower bracket is in serted into the number plate Remove the number plate by pulling it off the projection When installing the number plate insert the projection on the number plate into the hole in the upper side of the band EAM30459 REMOVING THE SIDE COVER 1 Remove Side cover bolt Side cover left right 1 TIP Draw the side cover backward to remove it be...

Page 95: ... to raise the front wheel off the ground 1 Front wheel axle pinch bolt 4 Loosen 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Oil seal 2 7 Bearing 2 8 Brake disc 1 5 6 5 6 8 2 1 1 3 4 21 N m 2 1 kgf m 15 lb ft 21 N m 2 1 kgf m 15 lb ft 105 N m 10 5 kgf m 77 lb ft 12 N m 1 2 kgf m 8 9 lb ft 7 7 6 ...

Page 96: ...CHECKING THE TIRES on page 3 23 and CHECKING THE WHEELS on page 3 23 3 Check Spoke Refer to CHECKING AND TIGHTENING THE SPOKES on page 3 23 4 Tighten Spoke Refer to CHECKING AND TIGHTENING THE SPOKES on page 3 23 TIP After tightening the spokes measure the wheel runout 5 Measure Radial wheel runout 1 Lateral wheel runout 2 Out of specification Repair replace 6 Check Collar Damage wear Replace 7 Ch...

Page 97: ...l Brake disc Front brake disc bolt TIP Tighten the bolts in stages and in a crisscross pattern 3 Install Collar 1 TIP Apply the lithium soap based grease on the oil seal lip Install the collars with their projections a fac ing the wheel EAM30617 INSTALLING THE FRONT WHEEL 1 Install Front wheel TIP Install the brake disc 1 between the brake pads 2 correctly 2 Install Front wheel axle 1 TIP Apply th...

Page 98: ...tening the front wheel axle nut push down hard on the handlebar s several times and check if the front fork rebounds smoothly 4 Tighten Front wheel axle pinch bolt 1 Front wheel axle nut 105 N m 10 5 kgf m 77 lb ft Front wheel axle pinch bolt 21 N m 2 1 kgf m 15 lb ft 1 T R T R ...

Page 99: ...f the ground 1 Rear wheel axle nut 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 2 10 Brake disc 1 2 5 7 6 4 6 1 6 3 8 9 10 5 3 19 N m 1 9 kgf m 14 lb ft 19 N m 1 9 kgf m 14 lb ft 125 N m 12 5 kgf m 92 lb ft 42 N m 4 2 kgf m 31 lb ft 12 N m 1 2 kgf m 8 9 lb ft 9 6 7 ...

Page 100: ... wear Replace Refer to CHECKING THE TIRES on page 3 23 and CHECKING THE WHEELS on page 3 23 3 Check Spoke Refer to CHECKING AND TIGHTENING THE SPOKES on page 3 23 4 Measure Radial wheel runout Lateral wheel runout Refer to CHECKING THE FRONT WHEEL on page 4 4 EAM30025 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1 Check Rear wheel sprocket More than 1 4 tooth wear a Replace the rear wheel sprock...

Page 101: ...440 Install the bearing by pressing its outer race parallel NOTICE ECA18110 Do not contact the wheel bearing inner race 1 or balls 2 Contact should be made only with the outer race 3 TIP Use a socket 4 that matches the diameter of the bearing outer race and that of the oil seal 2 Install Brake disc Rear brake disc bolt TIP Tighten the bolts in stages and in a crisscross pattern 3 Install Collar 1 ...

Page 102: ...p based grease to the rear wheel axle 4 Install Drive chain puller right 1 Washer 2 Rear wheel axle nut 3 TIP Temporarily tighten the rear wheel axle nut at this point 5 Adjust Drive chain slack a Refer to DRIVE CHAIN SLACK on page 3 16 6 Tighten Rear wheel axle nut 1 Locknut 2 2 1 2 1 2 Drive chain slack Maintenance Stand 48 0 58 0 mm 1 89 2 28 in Rear wheel axle nut 125 N m 12 5 kgf m 92 lb ft D...

Page 103: ...age 3 15 1 Union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Brake pad pin plug 1 5 Brake pad pin 1 6 Brake pad 2 7 Brake pad spring 1 8 Front brake caliper assembly 1 9 Front brake caliper bracket 1 10 Brake pad spring 1 3 9 1 2 8 4 5 7 6 28 N m 2 8 kgf m 21 lb ft 30 N m 3 0 kgf m 22 lb ft 6 N m 0 6 kgf m 4 4 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 17 N m 1 7 kgf m 13 lb ft 10 ...

Page 104: ... BRAKE 4 12 Disassembling the front brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston kit 2 2 Brake caliper piston seal kit 2 3 Bleed screw 1 3 6 N m 0 6 kgf m 4 4 lb ft 1 2 S S 2 1 ...

Page 105: ...ion bolt 1 3 Copper washer 2 4 Front brake hose 1 5 Brake master cylinder reservoir cap 1 6 Brake master cylinder reservoir diaphragm 1 7 Front brake master cylinder float 1 8 Front brake master cylinder holder 1 9 Front brake master cylinder 1 5 6 7 2 3 4 8 9 1 30 N m 3 0 kgf m 22 lb ft 6 N m 0 6 kgf m 4 4 lb ft 6 N m 0 6 kgf m 4 4 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 9 N m 0 9 kgf m 6 6 lb ft ...

Page 106: ...FRONT BRAKE 4 14 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 BF 1 S New ...

Page 107: ...minutes and get im mediate medical attention EAM30029 CHECKING THE FRONT BRAKE DISC 1 Check Front brake disc Damage galling Replace 2 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace 3 Measure Brake disc runout Out of specification Replace the brake disc a Place the vehicle on a maintenance stand so that the front wheel is ele...

Page 108: ...d brake fluid c Tighten the bleed screw d Install the brake pads 3 and the pad pin TIP Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point e Install the brake caliper 4 and tighten the pad pin 5 f Install the pad pin plug 6 Brake pad lining thickness limit 1 0 mm 0 04 in 4 a 2 1 Brake caliper bleed screw 6 N m 0 6 kgf m 4 ...

Page 109: ...per piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston dust seal and the brake caliper piston seal EAM30032 CHECKING THE FRONT BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scratches wear Repla...

Page 110: ...h its upper end a aligned with the paint b on the brake hose 4 Pour brake fluid to the brake master cylinder reservoir up to the specified level WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may res...

Page 111: ...er 1 Damage scratches wear Replace the brake master cylinder assembly Brake fluid delivery passages 2 brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder reservoir cap Damage scratches wear Replace 3 Check Brake hose Cracks damage wear Replace EAM30038 ASSEMBLING THE FRONT BRAKE MASTER CYLINDER WARNING EWA13520 Before installation all internal brake co...

Page 112: ...linder holder with the UP mark a facing up First tighten the upper bolt then the lower bolt 2 Install Copper washer 1 Brake hose 2 Union bolt 3 WARNING EWA13531 Proper brake hose routing is essential to in sure safe vehicle operation NOTICE ECA24470 During installation bring the brake hose into contact with the brake master cylinder pro jection a and make its bent portion b face downward TIP Turn ...

Page 113: ...nter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately 4 Bleed Brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 5 Check Brake fluid level The minimum level mark or below Add...

Page 114: ... 6 Brake pad pin 1 7 Rear brake pad assembly 1 8 Brake pad shim right 1 9 Brake pad shim left 1 10 Brake pad shim heat insulator 2 11 Brake pad shim bracket 1 12 Rear brake caliper bracket 1 13 Brake pad spring 1 14 Rear brake disc cover 1 15 Rear brake caliper assembly 1 2 3 4 15 6 13 1 12 11 14 S 7 N m 0 7 kgf m 5 2 lb ft 30 N m 3 0 kgf m 22 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 ...

Page 115: ...EAR BRAKE 4 23 Disassembling the rear brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston kit 1 2 Brake caliper piston seal kit 1 3 Bleed screw 1 1 2 6 N m 0 6 kgf m 4 4 lb ft S 3 ...

Page 116: ...page 3 15 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Split pin 1 5 Washer 1 6 Pin 1 7 Brake master cylinder reservoir cap 1 8 Brake master cylinder reservoir diaphragm plate 1 9 Brake master cylinder reservoir diaphragm 1 10 Rear brake master cylinder 1 1 2 3 7 5 8 6 9 4 10 30 N m 3 0 kgf m 22 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft ...

Page 117: ...REAR BRAKE 4 25 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder joint 1 2 Brake master cylinder kit 1 2 1 ...

Page 118: ...Flush with water for 15 minutes and get im mediate medical attention EAM30041 CHECKING THE REAR BRAKE DISC 1 Check Brake disc Damage galling Replace 2 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace Refer to CHECKING THE FRONT BRAKE DISC on page 4 15 3 Measure Brake disc runout Out of specification Replace the brake disc Refe...

Page 119: ... and the pad pin 4 TIP Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point e Install the brake caliper 5 and the rear wheel 6 Refer to REAR WHEEL on page 4 7 f Tighten the pad pin 7 g Install the pad pin plug 8 and the protector 9 Brake pad lining thickness limit 1 0 mm 0 04 in 7 6 a 2 1 Brake caliper bleed screw 6 N m 0 6...

Page 120: ...nt opening to force out the piston from the brake caliper WARNING EWA13550 Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston dust seal and the brake caliper piston seal EAM30044 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper piston 1 Rust...

Page 121: ...ke pad spring Brake pad Brake pad pin Brake pad pin plug Refer to CHECKING THE REAR BRAKE PADS on page 3 14 4 Pour brake fluid to the brake fluid reservoir up to the specified level WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in t...

Page 122: ...er cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage wear Replace 3 Check Master cylinder reservoir cap Crack damage Replace Brake master cylinder reservoir diaphragm holder Brake master cylinder reservoir diaphragm Crack damage Replace 4 Check Brake hose Cracks damage wear Replace EAM30050 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING EWA13520 Bef...

Page 123: ...the brake caliper 2 Pour brake fluid to the brake fluid reservoir up to the specified level WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor br...

Page 124: ...REAR BRAKE 4 32 LEVEL on page 3 14 5 Check Brake pedal operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15 ...

Page 125: ...1 5 Cap cover 1 6 Collar 1 7 Clutch cable 1 8 Clutch lever holder 1 9 Engine stop switch 1 10 Left grip 1 11 Upper handlebar holder 2 12 Handlebar 1 13 Lower handlebar holder 2 0 5 N m 0 05 kgf m 0 37 lb ft 9 N m 0 9 kgf m 6 6 lb ft 28 N m 2 8 kgf m 21 lb ft 5 N m 0 5 kgf m 3 7 lb ft 0 5 N m 0 05 kgf m 0 37 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 40 N m 4 0 kgf m 30 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 9...

Page 126: ...icle upright on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Lower handlebar holder 1 Washer 2 Lower handlebar holder nut 3 TIP Install the lower handlebar holders with them side having the greater distance a from the mounting bolt center facing forward Apply the lithium soap based grease on the thread of the lower handlebar ...

Page 127: ... adhesive wipe off grease or oil on the handlebar surface a with a lac quer thinner Install the left grip to the handlebar so that the line b between the two arrow marks faces straight upward 6 Install Engine stop switch 1 Clutch lever holder 2 Clutch lever holder bolt 3 Clamp 4 TIP The engine stop switch clutch lever holder and clamp should be installed according to the di mensions shown Lower ha...

Page 128: ...2 TIP Before applying the adhesive wipe off grease or oil on the tube guide surface a with a lac quer thinner Align the mating mark b on the right grip with the slot c in the tube guide 10 Install Grip cap upper 1 Grip cap lower 2 Grip cap bolt 3 TIP Temporarily tighten the grip cap bolts 11 Install Collar 1 Grip cap cover 2 Throttle grip 3 TIP Apply the lithium soap based grease on the throttle g...

Page 129: ...nstall Throttle cable cap 1 Throttle cable cap screw 2 15 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 5 16 Install Cap cover 1 17 Install Brake master cylinder 1 Brake master cylinder holder 2 Front brake master cylinder holder bolt 3 TIP Install the holder so that the arrow mark a fac es upward First tighten the bolt on the upper side of the brake master cylinder ...

Page 130: ...8 18 Install Grip cap bolt 1 WARNING EWA21080 After tightening the bolts check that the throttle grip 2 moves smoothly If it does not retighten the bolts for adjustment Grip cap bolt 3 8 N m 0 38 kgf m 2 8 lb ft T R ...

Page 131: ...T WHEEL on page 4 3 Front brake caliper Refer to FRONT BRAKE on page 4 11 Number plate Refer to GENERAL CHASSIS on page 4 1 1 Protector 1 2 Upper bracket pinch bolt 2 Loosen 3 Damper assembly 1 Loosen 4 Lower bracket pinch bolt 2 Loosen 5 Front fork leg 1 5 N m 0 5 kgf m 3 7 lb ft 5 N m 0 5 kgf m 3 7 lb ft 9 N m 0 9 kgf m 6 6 lb ft 21 N m 2 1 kgf m 15 lb ft 21 N m 2 1 kgf m 15 lb ft 3 2 4 5 1 ...

Page 132: ... 5 Stopper ring 1 6 Inner tube 1 7 Outer tube 1 8 Piston metal 1 9 Protector guide 1 10 Slide metal 1 11 Washer 1 12 Oil seal 1 13 Base valve 1 14 Damper assembly 1 15 Upper spring seat 1 29 N m 2 9 kgf m 21 lb ft 30 N m 3 0 kgf m 22 lb ft 29 N m 2 9 kgf m 21 lb ft 55 N m 5 5 kgf m 41 lb ft 1 3 N m 0 13 kgf m 0 95 lb ft 10 7 15 2 14 6 1 4 5 8 11 12 3 13 9 ...

Page 133: ...ork leg EAM30056 DISASSEMBLING THE FRONT FORK LEGS 1 Drain Fork oil 2 Remove Adjuster 1 from the inner tube TIP While compressing the inner tube 2 set the cap bolt ring wrench 4 between the inner tube and locknut 3 Hold the locknut and remove the adjuster NOTICE ECA24520 Do not remove the locknut as the damper rod may go into the damper assembly and not be taken out 3 Remove Dust seal 1 Stopper ri...

Page 134: ...usly weaken it 2 Check Outer tube Scratches wear damage Replace 3 Measure Fork spring free length a Out of specification Replace 4 Check Damper assembly 1 Bend damage Replace O ring 2 Wear damage Replace NOTICE ECA14200 The front fork leg has a built in damper ad justing rod and a very sophisticated inter nal construction which are particularly sensitive to foreign material When disassembling and ...

Page 135: ...er Before assembling the front fork leg make sure that all of the components are clean 1 Stretch the damper assembly fully 2 Fill Damper assembly NOTICE ECA24530 Be sure to use the recommended oil Other oils may have an adverse effect on front fork performance When disassembling and assembling the front fork leg take care not to allow any for eign material to enter the front fork 3 After filling p...

Page 136: ... TIP First bring the damper rod pressure to a maxi mum Then install the base valve while releasing the damper rod pressure 8 Check Damper assembly Not fully stretched Repeat the steps 1 to 7 9 Tighten Base valve 1 TIP Hold the damper assembly with the cap bolt ring wrench 2 and use the cap bolt wrench 3 to tighten the base valve Standard oil level 145 148 mm 5 71 5 83 in From top of fully stretche...

Page 137: ...amper assembly TIP The overflow measures about 10 cm 0 34 US oz 0 35 Imp oz 13 Check Damper assembly smooth movement Tightness binding rough spots Repeat the steps 1 to 12 14 Install Dust seal 1 Stopper ring 2 Oil seal 3 Washer 4 Slide metal 5 to the inner tube 6 NOTICE ECA24550 Make sure that the numbered side of the oil seal faces bottom side TIP Apply the lithium soap based grease on the dust s...

Page 138: ... 18 Install Oil seal 1 TIP Using a fork seal driver 2 press the oil seal in until the stopper ring groove fully appears 19 Install Stopper ring 1 TIP Fit the stopper ring correctly in the groove in the outer tube 20 Install Dust seal 1 TIP Apply lithium soap based grease on the inner tube Fork seal driver 90890 01502 Fork seal driver 48 YM A0948 G088922 New New Fork seal driver 90890 01502 Fork se...

Page 139: ...2 NOTICE ECA24560 Allow the damper assembly to slide slowly down the inner tube until it contacts the bot tom of the inner tube Be careful not to dam age the inner tube 25 Loosen Rebound damping force adjuster 1 TIP Before loosening the damping force adjuster record the setting position Unless the damping force adjuster is fully loos ened correct damping characteristic cannot be obtained after ins...

Page 140: ...e adjuster 29 Install Adjuster 1 to the inner tube 30 Fill Front fork leg NOTICE ECA24570 Be sure to use the recommended oil Other oils may have an adverse effect on front fork performance When disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork Cap bolt ring wrench 90890 01501 Cap bolt ring wrench YM 01501 Gap a between the adjuster and the l...

Page 141: ...tighten the lower bracket pinch bolts Do not tighten the upper bracket pinch bolts yet 2 Tighten Damper assembly 1 TIP Use the cap bolt ring wrench 2 to tighten the damper assembly 3 Adjust Front fork top end a 4 Tighten Upper bracket pinch bolt 1 1 Damper assembly front fork 30 N m 3 0 kgf m 22 lb ft Cap bolt ring wrench 90890 01501 Cap bolt ring wrench YM 01501 Front fork top end standard a 5 mm...

Page 142: ...st Rebound damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 7 Adjust Compression damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position Upper bracket pinch bolt 21 N m 2 1 kgf m 15 lb ft Lower bracket pinch bolt 21 N m 2 1 kgf m 15 lb ft Front fork protector bolt 5 N m 0 5 kgf m 3 ...

Page 143: ...r to HANDLEBAR on page 4 33 1 Front fender 1 2 Steering stem nut 1 3 Front fork leg 2 4 Upper bracket 1 5 Steering ring nut 1 6 Lower bracket 1 7 Bearing race cover 1 8 Upper bearing 1 9 Lower bearing 1 10 Bearing race 2 5 4 2 10 7 8 9 3 6 1 10 N m 1 0 kgf m 7 4 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 21 N m 2 1 kgf m 15 lb ft 145 N m 14 5 kgf m 107 lb ft 21 N m 2 1 kgf m 15 lb ft 1st 2nd 38 N m 3 8 kg...

Page 144: ... Bearing race a Remove the bearing race from the steer ing head pipe 1 with a long rod 2 and a hammer b Remove the bearing race from the lower bracket 3 with a chisel 4 and a hammer c Install a new bearing race NOTICE ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged TIP Always replace the bearing and the bearing race as a set 4 Check Upper bracket Lowe...

Page 145: ...g nut with its stepped side a facing downward Tighten the steering ring nut with a steering nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 17 5 Check the steering stem by turning this lock to lock If there is any binding remove the steering stem and check the steering bear ing 6 Install Washer 1 7 Install Front fork 1 Upper bracket 2 TIP Temporarily tighten the lower brac...

Page 146: ...e steering ring nut little by lit tle 10 Adjust Front fork top end a 11 Tighten Upper bracket pinch bolt 1 Lower bracket pinch bolt 2 WARNING EWA19330 Tighten the lower bracket to specified torque If torqued too much it may cause the front fork to malfunction Steering stem nut 145 N m 14 5 kgf m 107 lb ft Front fork top end standard a 5 mm 0 2 in T R a Upper bracket pinch bolt 21 N m 2 1 kgf m 15 ...

Page 147: ...lamp 1 2 Rear frame 1 3 Rear shock absorber assembly lower bolt 1 4 Rear shock absorber assembly upper bolt 1 5 Rear shock absorber assembly 1 6 Locknut 1 7 Adjusting nut 1 8 Lower spring guide 1 9 Upper spring guide 1 10 Spring 1 11 Dust seal 4 12 Collar 4 13 Bearing 1 14 Bushing 1 56 N m 5 6 kgf m 41 lb ft 32 N m 3 2 kgf m 24 lb ft 29 N m 2 9 kgf m 21 lb ft 53 N m 5 3 kgf m 39 lb ft 2 3 N m 0 23...

Page 148: ...BLY 4 56 Disassembling the relay arm Order Job Parts to remove Q ty Remarks 1 Relay arm 1 2 Connecting arm 1 3 Collar 3 4 Oil seal 6 5 Washer 8 6 Bearing 6 80 N m 8 0 kgf m 59 lb ft 4 6 3 6 6 5 5 6 1 4 4 3 5 2 4 4 5 5 4 5 3 6 6 ...

Page 149: ...WA19340 Wear protective glasses to prevent your eyes from damage due to possible gas or metal chips scattered To dispose of a damaged or a worn out rear shock absorber take the unit to your Yamaha dealer for this disposal procedure EAM30065 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Use a maintenance stand to raise the rear wheel off the ground WARNING EWA13120 Securely support the vehicle so tha...

Page 150: ...will wear the rear shock ab sorber surface on which the bearing is press fitted 2 Lubricate O ring 3 Install Bearing Stopper ring into the rear shock absorber assembly up per side TIP Install the bearing parallel until the stopper ring groove appears by pressing its outer race After installing the stopper ring push back the bearing until it contacts the stopper ring 4 Install Bearing 1 Bushing 2 C...

Page 151: ...ten Rear shock absorber assembly upper nut Connecting arm nut frame side Connecting arm nut relay arm side Relay arm nut swingarm side Rear shock absorber assembly lower nut 8 Install Rear frame 1 Rear frame bolt upper 2 Rear frame bolt lower 3 9 Tighten Air filter case joint clamp 1 Installed depth a 4 25 mm 0 17 in Recommended lubricant Molybdenum disulfide grease Rear shock absorber assembly up...

Page 152: ...e hose holder Rear brake caliper Refer to REAR BRAKE on page 4 22 Brake pedal bolt Drive chain 1 Collar 2 2 Oil seal 2 3 Thrust bearing 2 4 Bushing 2 5 Oil seal 2 6 Bearing 4 6 N m 0 6 kgf m 4 4 lb ft 2 0 N m 0 20 kgf m 1 5 lb ft 70 N m 7 0 kgf m 52 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 85 N m 8 5 kgf m 63 lb ft 5 6 6 1 1 2 3 6 3 2 6 5 4 4 ...

Page 153: ...mage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash with kerosene Pivot shaft Bushing Collar Bearing 4 Check Oil seal Damage Replace Bearing Thrust bearing Bushing Free play exists unsmooth revolution rust Replace bearing and bushing as a set EAM30074 INSTALLING THE SWINGARM 1 Lubricate Bearin...

Page 154: ...SWINGARM 4 62 4 Install Rear wheel Refer to REAR WHEEL on page 4 7 5 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 16 Drive chain slack Maintenance Stand 48 0 58 0 mm 1 89 2 28 in ...

Page 155: ...arts to remove Q ty Remarks Drive sprocket Refer to ENGINE REMOVAL on page 5 1 1 Master link clip 1 2 Drive chain 1 3 Drive sprocket cover 1 4 Bracket 1 5 Drive sprocket nut 1 6 Lock washer 1 7 Drive sprocket 1 2 1 7 6 5 4 3 5 N m 0 5 kgf m 3 7 lb ft 75 N m 7 5 kgf m 55 lb ft ...

Page 156: ...he 15 link sec tion of the drive chain using the following formula Drive chain 15 link section length c length a between pin inner sides length b between pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a different location each time 2 Check Drive chain Stiffness Clean lubricate or replace 3 Clean D...

Page 157: ...in sprockets this will dramatically shorten the drive chain s life 2 Lubricate Drive chain 3 Install Drive sprocket Lock washer Drive sprocket nut Refer to ENGINE REMOVAL on page 5 1 NOTICE ECA14300 Never install a new drive chain onto worn drive chain sprockets this will dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 16 NOTICE ECA24590 ...

Page 158: ...CHAIN DRIVE 4 66 ...

Page 159: ...2 INSTALLING THE PISTON AND CYLINDER 5 13 INSTALLING THE CYLINDER HEAD 5 15 CDI MAGNETO 5 16 REMOVING THE ROTOR 5 17 CHECKING THE CDI MAGNETO 5 17 CHECKING THE WOODRUFF KEY 5 17 INSTALLING THE CDI MAGNETO 5 17 KICKSTARTER 5 20 REMOVING THE PRIMARY DRIVE GEAR 5 22 REMOVING THE KICK SHAFT ASSEMBLY 5 22 CHECKING THE KICK GEAR AND KICK IDLE GEAR 5 22 INSTALLING THE KICK SHAFT ASSEMBLY 5 22 INSTALLING ...

Page 160: ...MENT 5 36 CHECKING THE SHIFT SHAFT 5 36 CHECKING THE STOPPER LEVER 5 36 INSTALLING THE SHIFT SHAFT 5 36 CRANKCASE 5 39 DISASSEMBLING THE CRANKCASE 5 40 CHECKING THE CRANKCASE 5 40 ASSEMBLING THE CRANKCASE 5 40 CRANKSHAFT 5 43 REMOVING THE CRANKSHAFT 5 44 CHECKING THE CRANKSHAFT 5 44 INSTALLING THE CRANKSHAFT 5 44 TRANSMISSION 5 46 REMOVING THE TRANSMISSION 5 47 CHECKING THE SHIFT FORKS 5 47 CHECKI...

Page 161: ...r 1 ø 26 mm 1 02 in 2 Washer 1 ø 22 mm 0 87 in 3 Silencer 1 4 Collar 1 L 15 5 mm 0 61 in 5 Collar 1 L 13 5 mm 0 53 in 6 Grommet front 1 7 Grommet rear 1 8 Tension spring 2 9 Exhaust pipe 1 1 2 3 4 5 6 7 8 9 12 N m 1 2 kgf m 8 9 lb ft 12 N m 1 2 kgf m 8 9 lb ft 12 N m 1 2 kgf m 8 9 lb ft 10 N m 1 0 kgf m 7 4 lb ft 12 N m 1 2 kgf m 8 9 lb ft 15 mm 0 59 in 17 mm 0 67 in 8 ...

Page 162: ...er to ENGINE REMOVAL on page 5 1 Exhaust pipe stay rear Clutch cable Disconnect at engine side Radiator Refer to RADIATOR on page 6 2 Spark plug CDI magneto lead Disconnect 1 Drive chain sprocket cover 1 2 Drive chain sprocket guide 1 3 Lock washer 1 4 Drive sprocket 1 5 Brake pedal 1 6 Spring 1 7 Engine bracket 2 8 Pivot shaft 1 34 N m 3 4 kgf m 25 lb ft 1 3 4 5 7 5 N m 0 5 kgf m 3 7 lb ft 64 N m...

Page 163: ...oving the engine Order Job Parts to remove Q ty Remarks 9 Engine 1 34 N m 3 4 kgf m 25 lb ft 9 5 N m 0 5 kgf m 3 7 lb ft 64 N m 6 4 kgf m 47 lb ft 75 N m 7 5 kgf m 55 lb ft 85 N m 8 5 kgf m 63 lb ft 26 N m 2 6 kgf m 19 lb ft ...

Page 164: ...gine mounting nut front side 7 Engine bracket 8 Engine bracket bolt upper side 9 Engine bracket nut upper side 10 Engine bracket bolt lower side 11 Engine bracket nut lower side 12 TIP Apply the molybdenum disulfide grease on the pivot shaft EAM30167 INSTALLING THE EXHAUST PIPE AND MUFFLER 1 Install Exhaust pipe 1 Exhaust joint 2 Silencer TIP Firmly insert the exhaust joint 2 into the bent portion...

Page 165: ...ENGINE REMOVAL 5 5 1 a 2 ...

Page 166: ...ipe Silencer Refer to ENGINE REMOVAL on page 5 1 Radiator hose 1 Disconnect at cylinder head side Carburetor Refer to CARBURETOR on page 7 3 1 Spark plug 1 2 Engine bracket 2 3 Cylinder head 1 4 Power valve housing 1 5 Push rod 1 6 Cylinder 1 34 N m 3 4 kgf m 25 lb ft 30 N m 3 0 kgf m 22 lb ft 13 N m 1 3 kgf m 9 6 lb ft 20 N m 2 0 kgf m 15 lb ft 28 N m 2 8 kgf m 21 lb ft 4 5 N m 0 45 kgf m 3 3 lb ...

Page 167: ... 1 3 Piston 1 4 Small end bearing 1 5 Piston ring 1 6 Power valve cover 1 7 Thrust plate 1 8 Power valve holder 1 9 Valve shaft 1 10 Collar 2 11 Link lever 1 12 Power valve 1 1 13 Power valve 2 1 4 0 N m 0 40 kgf m 3 0 lb ft 8 N m 0 8 kgf m 5 9 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 5 N m 0 5 kgf m 3 7 lb ft 1 2 3 4 5 1 6 7 8 9 10 11 12 13 10 ...

Page 168: ... PISTON 1 Remove Piston pin clip 1 TIP Before removing the piston pin clip cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase 2 Remove Piston pin 1 Piston 2 Small end bearing NOTICE ECA13810 Do not use a hammer to drive the piston pin out TIP Before removing the piston pin deburr the pis ton pin clip s groove and the piston s pin bore ar ea ...

Page 169: ...cylin der head using a figure eight sanding pat tern TIP To ensure an even surface rotate the cylinder head several times EAM30546 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure the cylinder bore C with the cyl inder bore gauge TIP Measure th...

Page 170: ... the piston that matches the above chart Diameter 53 957 53 972 mm 2 1243 2 1249 in a 17 5 mm 0 69 in from the bottom edge of the piston Piston to cylinder clearance Cylinder bore Piston skirt diameter Piston to cylinder clearance 0 040 0 045 mm 0 0016 0 0018 in Cylinder mark a Cylinder size A 54 000 54 002 mm 2 1260 2 1261 in B 54 004 54 006 mm 2 1261 2 1262 in C 54 008 54 010 mm 2 1263 2 1264 in...

Page 171: ...discoloration grooves Replace the piston pin and then check the fuel and en gine mixing oil 2 Measure Piston pin outside diameter a Out of specification Replace the piston pin 3 Measure Piston pin bore inside diameter b Out of specification Replace the piston 4 Calculate Piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set Top ring Ring side clear...

Page 172: ...atching the aluminum EAM30551 ASSEMBLING THE POWER VALVE 1 Install Power valve 2 1 Power valve 1 2 Bolt power valve 3 TIP Install the power valve at cut away faced a for down side 2 Install Link lever 1 Spring 2 Collar 3 Valve shaft 4 Power valve holder 5 Power valve link lever bolt 6 TIP Install the spring to the link lever and then to the cylinder Install the spring with its stopper portion a fa...

Page 173: ...ith its opening portion b facing backward EAM30554 INSTALLING THE PISTON AND CYLINDER 1 Install Piston ring 1 TIP Take care not to scratch the piston or damage the piston ring Align the piston ring gap with the pin 2 After installing the piston ring check the smooth movement of it 2 Install Cylinder gasket 1 Small end bearing 2 with the recommended lubricant Dowel pin 3 Thrust plate screw 4 0 N m ...

Page 174: ... with the recommended lubricant 5 Install Cylinder Cylinder nut 1 TIP While compressing the piston ring with one hand install the cylinder with the other hand Tighten the nuts in stage using a crisscross pattern 6 Install Collar 1 Push rod 2 Plain washer 3 Push rod bolt 4 NOTICE ECA27100 Be sure to use the collar If the collar is not used the power valve constituent parts will result in damage TIP...

Page 175: ...y the lithium soap based grease on the O rings 3 Install Cylinder head 1 Copper washer 2 Cylinder head nut 3 TIP Tighten the cylinder head nut in stage using a crisscross pattern 4 Install Spark plug Spark plug cap Radiator hose Power valve housing bolt 4 0 N m 0 40 kgf m 3 0 lb ft Recommended lubricant Lithium soap based grease New T R New Cylinder head nut 28 N m 2 8 kgf m 21 lb ft Spark plug 20...

Page 176: ...NERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Radiator bolt Refer to RADIATOR on page 6 2 CDI magneto lead Disconnect 1 Crankcase cover left 1 2 Rotor nut 1 3 CDI magneto rotor 1 4 Stator 1 5 Woodruff key 1 7 N m 0 7 kgf m 5 2 lb ft 56 N m 5 6 kgf m 41 lb ft 5 N m 0 5 kgf m 3 7 lb ft 1 2 3 4 5 4 3 ...

Page 177: ...e a Stator outer surface b Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace CDI magneto and or stator EAM30564 CHECKING THE WOODRUFF KEY 1 Check Woodruff key 1 Damage Replace EAM30565 INSTALLING THE CDI MAGNETO 1 Install Stator 1 Stator coil screw 2 TIP Temporarily tighten the screw at this point 2 Install Woodruff key 1 Rotor 2 TIP Clean the tapered portions of the...

Page 178: ...ith the ignition timing position mark b on the crankcase 3 Align the stator coil screws 1 with the center of the hole 6 Check Ignition timing Re check the ignition timing 7 Connect CDI magneto lead 1 Refer to CABLE ROUTING DIAGRAM on page 2 15 8 Install Crankcase cover gasket left Crankcase cover left 1 Crankcase cover screw left 2 TIP Tighten the screws in stage using a crisscross pattern CDI mag...

Page 179: ...CDI MAGNETO 5 19 ...

Page 180: ... bolt Shift the brake pedal downward Radiator hose 4 Disconnect at water pump side Push rod bolt Refer to CYLINDER HEAD CYLINDER AND PISTON on page 5 6 1 Kickstarter lever 1 2 Crankcase cover right 1 3 Primary drive gear bolt 1 4 Primary driven gear 1 Refer to CLUTCH on page 5 28 5 Primary drive gear 1 10 N m 1 0 kgf m 7 4 lb ft 48 N m 4 8 kgf m 35 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 2 3 4 5 6 ...

Page 181: ...KICKSTARTER 5 21 Removing the kickstarter shaft Order Job Parts to remove Q ty Remarks 1 Kick idle gear 1 2 Kick shaft assembly 1 1 2 ...

Page 182: ...K IDLE GEAR 1 Check Kick gear 1 Wear damage Replace the kick shaft as sembly Kick idle gear 2 Gear teeth a Wear damage Replace EAM30104 INSTALLING THE KICK SHAFT ASSEMBLY 1 Install Kick gear 1 Washer 2 Torsion spring 3 to the kick shaft 4 TIP Make sure the stopper a of the torsion spring fits into the hole b on the kick shaft 2 Install Spring guide 1 TIP Slide the spring guide into the kick shaft ...

Page 183: ...Apply the transmission oil on the kick idle gear inner circumference EAM30571 INSTALLING THE PRIMARY DRIVE GEAR 1 Install Spacer 1 Primary drive gear 2 Primary drive gear bolt 3 TIP Install the primary drive gear with its depressed side toward you 2 Install Primary driven gear Refer to CLUTCH on page 5 28 3 Tighten Primary drive gear bolt 1 TIP Place an aluminum plate a between the teeth of the pr...

Page 184: ... 1 Washer 2 Kickstarter lever bolt 3 TIP Install the kickstarter closest to but not contact ing the pillar tube 4 2 Install Shift pedal 1 Shift pedal bolt 2 TIP Align the upper line a of the shift pedal with the center b of the crankcase projection and rotate the shift pedal counterclockwise until it first en gages Then install the shift pedal Crankcase cover screw right 10 N m 1 0 kgf m 7 4 lb ft...

Page 185: ...er right Refer to KICKSTARTER on page 5 20 1 Governor assembly 1 2 Dowel pin 1 3 Retainer 1 4 Ball 4 5 Retainer weight 1 6 Washer 3 7 Bearing 2 8 Collar 1 9 Plate 1 10 Compression spring 1 11 Governor gear 1 12 Governor shaft 1 13 Governor fork Push rod 1 1 5 N m 0 5 kgf m 3 7 lb ft 1 2 3 4 5 6 7 8 9 10 11 12 6 7 6 13 13 ...

Page 186: ... bearing 1 Washer 2 Wear damage Replace EAM30569 INSTALLING THE GOVERNOR 1 Install Governor gear 1 Compression spring 2 Plate 3 Washer 4 Thrust bearing 5 Collar 6 Retainer weight 7 to the governor shaft 8 TIP Apply the lithium soap based grease on the thrust bearing 2 Install Ball 1 Retainer 2 to the governor shaft 3 TIP Apply the transmission oil on the retainer and ball 1 1 2 1 2 2 Recommended l...

Page 187: ...e compressing the spring install the dowel pin Make sure the dowel pin fits into the groove a in the retainer 4 Install Governor assembly 1 TIP Align the groove a in the governor with the fork b and set the governor in the crankcase cover G 1 2 3 1 a ...

Page 188: ...TRANSMISSION OIL on page 3 6 Brake pedal bolt Shift the brake pedal downward Rotor Stator Refer to CDI MAGNETO on page 5 16 Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Gasket 1 3 Clutch spring 5 4 Pressure plate 1 5 Friction plate 8 6 Clutch plate 7 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 2 5 3 4 5 6 5 ...

Page 189: ...ing 1 5 Ball 1 6 Push rod 2 1 7 Clutch boss nut 1 8 Lock washer 1 9 Clutch boss 1 10 Thrust washer 1 D ø34 mm 1 34 in 11 Primary driven gear 1 12 Bearing 1 13 Spacer 1 1 14 Thrust washer 1 D ø34 mm 1 34 in 15 Push lever shaft 1 16 Oil seal 1 17 Bearing 1 80 N m 8 0 kgf m 59 lb ft 1 2 3 4 5 6 7 8 9 10 11 12 14 15 13 16 17 ...

Page 190: ... set EAM30111 CHECKING THE CLUTCH SPRINGS 1 Check Clutch spring Damage Replace the clutch springs as a set 2 Measure Clutch spring free length Out of specification Replace the clutch springs as a set EAM30112 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing TIP Pitting on the clutch housing dogs will cause er r...

Page 191: ... Replace the primary drive and primary driven gears as a set Excessive noise during operation Replace the primary drive and primary driven gears as a set 2 Check Primary drive gear to primary driven gear free play Free play exists Replace the primary drive and primary driven gears as a set EAM30118 CHECKING THE PRIMARY DRIVEN GEAR 1 Check Primary driven gear Damage wear Replace the primary drive a...

Page 192: ... Clutch boss nut 2 TIP Use the clutch holder 3 to hold the clutch boss 5 Bend the lock washer 1 tab 6 Install Friction plate 1 Clutch plate 2 TIP Install the clutch plates and friction plates alter nately on the clutch boss starting with a friction plate and ending with a friction plate Apply the transmission oil on the friction plates and clutch plates G 1 2 3 G Clutch boss nut 80 N m 8 0 kgf m 5...

Page 193: ...IP Tighten the bolts in stage using a crisscross pat tern 11 Install Dowel pin 1 Gasket clutch cover 2 12 Install Clutch cover Clutch cover bolt TIP Tighten the bolts in stage using a crisscross pat tern 13 Install O ring 1 Clutch cable 2 TIP Insert the clutch cable 2 into the crankcase at a straight angle so that it does not pinch the O ring 1 Apply the lithium soap based grease on the O ring New...

Page 194: ...CLUTCH 5 34 1 2 ...

Page 195: ...stopper lever Order Job Parts to remove Q ty Remarks 1 Shift pedal 1 2 Shift shaft 1 3 Shift guide bolt 2 4 Roller 1 5 Shift guide 1 6 Shift lever assembly 1 7 Stopper lever 1 30 N m 3 0 kgf m 22 lb ft 10 N m 1 0 kgf m 7 4 lb ft 12 N m 1 2 kgf m 8 9 lb ft 1 2 4 5 3 6 7 ...

Page 196: ... wear Replace 2 Check Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear damage Replace EAM30127 CHECKING THE STOPPER LEVER 1 Check Stopper lever 1 Wear damage Replace Roller 2 Rotate outer race with a finger Rough spot seizure Replace the stopper lever Torsion spring 3 Broken Replace EAM30131 INSTALLING THE SHIFT SHAFT 1 Install Torsion spring 1 Holder 2 Holder bolt 3 Washer 4 Stopper le...

Page 197: ...Spring 1 Pawl pin 2 Pawl 3 to the shift lever TIP Apply the transmission oil on the spring pawl pin and pawl 4 Install Shift lever assembly to the shift guide 5 Install Shift lever assembly 1 Shift guide 2 TIP The shift lever assembly is installed at the same time as the shift guide Apply the transmission oil on the segment bolt shaft 6 Tighten Shift guide bolt 1 7 Install Roller 1 Shift shaft 2 S...

Page 198: ...8 Install Shift pedal 1 Shift pedal bolt 2 TIP Align the upper line a of the shift pedal with the center b of the crankcase projection and rotate the shift pedal counterclockwise until it first en gages Then install the shift pedal Shift pedal bolt 12 N m 1 2 kgf m 8 9 lb ft T R ...

Page 199: ...0 Stopper lever Refer to SHIFT SHAFT on page 5 35 Rotor Stator Refer to CDI MAGNETO on page 5 16 1 Segment 1 2 Crankcase bolt 6 L 45 mm 1 77 in 3 Crankcase bolt 4 L 55 mm 2 17 in 4 Crankcase bolt 1 L 65 mm 2 56 in 5 Crankcase bolt 1 L 75 mm 2 95 in 6 Holder 1 7 Crankcase right 1 8 Crankcase left 1 9 Oil seal 2 10 Bearing 2 10 N m 1 0 kgf m 7 4 lb ft 30 N m 3 0 kgf m 22 lb ft 14 N m 1 4 kgf m 10 lb...

Page 200: ...t separate check for a remaining case bolt or fitting Do not force 2 Remove Bearing 1 TIP Remove the bearing from the crankcase by pressing its inner race Do not use the removed bearing EAM30150 CHECKING THE CRANKCASE 1 Wash Crankcase TIP Wash the crankcase in a mild solvent Remove any remaining gasket from the crank case mating surface 2 Check Crankcase Crack damage Replace Oil delivery passages ...

Page 201: ...shers in the installation install the washers so that they do not deviate from the crankshaft center When installing the crankcase the connecting rod should be positioned at TDC top dead center Make sure that the dowel pin is in place 6 Install Holder 1 Holder bolt 2 TIP Install the holder 1 so that the flat surface faces to the right side of the vehicle Yamaha bond No 1215 90890 85505 Three bond ...

Page 202: ...CRANKCASE 5 42 7 Install Clamp 1 Crankcase bolt 2 TIP Tighten the crankcase bolts in stage using a crisscross pattern Crankcase bolt 14 N m 1 4 kgf m 10 lb ft LT 1 2T R 1 2 ...

Page 203: ...FT 5 43 EAM20193 CRANKSHAFT Removing the crankshaft assembly Order Job Parts to remove Q ty Remarks Engine Refer to ENGINE REMOVAL on page 5 1 Crankcase Separate 1 Oil seal 2 2 Crankshaft 1 3 Bearing 2 2 3 1 1 ...

Page 204: ...taller bolt 3 and adapter M12 4 NOTICE ECA26470 In order to prevent the crankshaft seizure apply molybdenum disulfide grease NOTICE ECA23810 Do not use a hammer to drive in the crank shaft TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft assembly bottoms aga...

Page 205: ...CRANKSHAFT 5 45 seal lip 4 1 2 3 M ...

Page 206: ...move Q ty Remarks Engine Refer to ENGINE REMOVAL on page 5 1 Crankcase Refer to CRANKCASE on page 5 39 1 Guide bar long 1 2 Guide bar short 1 3 Shift cam 1 4 Shift fork 3 R 1 5 Shift fork 1 L 1 6 Shift fork 2 C 1 7 Main axle 1 8 Drive axle 1 9 Collar 1 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 2 3 4 5 6 7 8 9 ...

Page 207: ...or a malfunctioning shift fork replace not only the shift fork itself but the two gears each adja cent to the shift fork EAM30155 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum groove Damage scratches wear Replace the shift drum assembly Shift drum segment Damage wear Replace the shift drum as sembly EAM30156 CHECKING THE TRANSMISSION 1 Measure Main axle runout with a centering device and dia...

Page 208: ...of the idler gear and on the in ner surface of the sliding gear then install 2 Install 2nd wheel gear 29T 1 5th wheel gear 20T 2 3rd wheel gear 27T 3 4th wheel gear 23T 4 6th wheel gear 19T 5 1st wheel gear 31T 6 to the drive axle 7 TIP Apply the molybdenum disulfide oil on the in ner and end surface of the idler gear and on the inner surface of the sliding gear then install Apply the molybdenum d...

Page 209: ...R with the 6th wheel gear 6 on the drive axle Mesh the shift fork 2 C with the 3rd 4th pinion gear 5 on the main axle 6 Install Shift cam 1 TIP Apply the transmission oil on the shift cam Install the shift cam while holding up the 5th wheel gear 2 and keeping the shift fork 1 3 moved in the direction of the arrow 7 Install Guide bar short 1 Guide bar long 2 TIP Apply the transmission oil on the gu...

Page 210: ...TRANSMISSION 5 50 ...

Page 211: ... 10 COOLING SYSTEM COOLING SYSTEM DIAGRAMS 6 1 RADIATOR 6 2 CHECKING THE RADIATOR 6 3 INSTALLING THE RADIATOR 6 3 WATER PUMP 6 5 DISASSEMBLING THE WATER PUMP 6 6 CHECKING THE WATER PUMP 6 6 ASSEMBLING THE WATER PUMP 6 6 ...

Page 212: ...COOLING SYSTEM DIAGRAMS 6 1 EAM20186 COOLING SYSTEM DIAGRAMS 1 Radiator hose 1 2 Radiator right 3 Radiator hose 4 4 Water pump 5 Radiator left ...

Page 213: ...uel tank Refer to FUEL TANK on page 7 1 1 Radiator guard 2 2 Radiator hose clamp radiator hose 1 3 2 Only loosening 3 Radiator hose 2 1 4 Radiator left 1 5 Radiator hose 4 1 6 Radiator right 1 7 Radiator hose 1 1 8 Radiator hose 3 1 9 Radiator breather hose 1 1 2 3 4 5 6 7 8 9 1 5 N m 0 15 kgf m 1 1 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 2 ...

Page 214: ...ck Radiator cap valve opening pressure a Install the radiator cap tester adapter 2 and the radiator cap tester 1 to the radi ator cap 3 and activate the tester to check whether it can stay for 5 to 10 sec onds within standard pressure values TIP Before attaching the cap to the tester apply wa ter to its sealing surface No stay Replace EAM30506 INSTALLING THE RADIATOR 1 Fill Cooling system with the...

Page 215: ...warm up Make sure that coolant is filled up to the up per level beforehand 5 Check Pressure value No stay for 5 to 10 seconds at the test pres sure value Correct Radiator Radiator hose connections Coolant leaks Correct or replace Radiator hose Bulges Replace WARNING EWA19090 When the radiator cap tester is removed coolant will spout therefore cover it with a cloth beforehand Test pressure value 12...

Page 216: ... remove Q ty Remarks Crankcase cover right Refer to KICKSTARTER on page 5 20 1 Water pump housing cover 1 2 Impeller shaft gear 1 3 Dowel pin 1 4 Washer 1 5 Impeller shaft assembly 1 6 Bearing 1 7 Oil seal 2 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 2 3 4 5 6 7 3 6 ...

Page 217: ...G THE WATER PUMP 1 Install Oil seal 1 2 TIP Apply the lithium soap based grease on the oil seal lip Install the oil seal with its manufacture s marks or numbers facing the crankcase cover right 3 2 Install Bearing 1 TIP Install the bearing by pressing its outer race par allel 3 Install Impeller shaft 1 TIP Take care so that the oil seal lip is not dam aged or the spring does not slip off its posit...

Page 218: ...n fitted in the groove a in the same gear 5 Install Dowel pin 1 Gasket 2 6 Install Water pump housing 1 Water pump housing cover bolt 2 Washer 3 Coolant drain bolt 4 Water pump housing cover bolt 10 N m 1 0 kgf m 7 4 lb ft Coolant drain bolt 10 N m 1 0 kgf m 7 4 lb ft New New T R New T R ...

Page 219: ... 7 1 AIR FILTER 7 2 CARBURETOR 7 3 HANDLING NOTE 7 6 CHECKING THE CARBURETOR 7 6 CHECKING THE REED VALVE 7 7 INSTALLING THE REED VALVE 7 7 ASSEMBLING THE CARBURETOR 7 7 INSTALLING THE CARBURETOR 7 10 MEASURING AND ADJUSTING THE FUEL LEVEL 7 11 ...

Page 220: ... left right Air scoop left right 1 Fuel cock assembly 1 2 O ring 1 3 Fuel tank 1 Install the fuel tank 3 so that the rubber cover a is placed behind the fuel tank 3 along the vehicle 4 Fuel tank breather hose 2 5 Valve joint 1 10 N m 1 0 kgf m 7 4 lb ft 7 N m 0 7 kgf m 5 2 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 7 N m 0 7 kgf m 5 2 lb ft 1 3 4 5 2 a 3 ...

Page 221: ...on page 4 1 1 Fitting bolt 1 2 Air filter element 1 3 Air filter guide 1 4 Guide holder 1 5 Band 1 6 Spacer 1 7 Air filter joint 1 8 Air filter case 1 Place the rubber cover into the guide of the air filter case 8 as shown a 2 3 4 5 6 7 3 3 1 8 2 0 N m 0 20 kgf m 1 5 lb ft 8 N m 0 8 kgf m 5 9 lb ft 3 5 N m 0 35 kgf m 2 6 lb ft a 8 8 a 8 ...

Page 222: ... valve Order Job Parts to remove Q ty Remarks Fuel tank Refer to FUEL TANK on page 7 1 1 Carburetor joint clamp 2 2 Carburetor 1 3 Carburetor joint 1 4 Reed valve assembly 1 2 3 4 2 3 N m 0 23 kgf m 1 7 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 2 3 N m 0 23 kgf m 1 7 lb ft 1 ...

Page 223: ...top 1 2 Gasket 1 3 Throttle valve 1 4 Ring 1 5 Throttle valve spring 1 6 Jet needle holder 1 7 Collar 1 8 Spring 1 9 Jet needle 1 10 Air vent hose 2 11 Air vent hose 2 12 Starter plunger 1 13 Fuel cut solenoid valve 1 14 Throttle position sensor 1 15 Lever comp 1 5 11 1 14 15 3 13 11 12 10 4 6 8 7 9 2 ...

Page 224: ...r Job Parts to remove Q ty Remarks 16 Throttle stop screw 1 17 Pilot air screw 1 18 Plug 1 19 Overflow hose 1 20 Float chamber 1 21 Float pin 1 22 Float 1 23 Needle valve 1 24 Main jet 1 25 Pilot jet 1 26 Power jet 1 21 17 16 26 25 24 23 22 20 18 19 ...

Page 225: ...ion Clean a Wash the carburetor in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages and jets with compressed air 3 Check Float chamber body Dirt Clean 4 Check Float chamber rubber gasket Cracks damage wear Replace 5 Check Float Damage Replace 6 Check Needle valve 1 Needle valve seat 2 Damage wear a Replace Obstruction b Clean 7 Check Jet ...

Page 226: ...air EAM30574 CHECKING THE REED VALVE 1 Check Reed valve assembly Cracks chipping Replace 2 Measure Reed valve thickness a Out of limit Replace EAM30577 INSTALLING THE REED VALVE 1 Install Gasket Reed valve assembly 1 2 Install Carburetor joint 1 Carburetor joint bolt 2 TIP Install the gasket so that the projection a is di rected as shown EAM30576 ASSEMBLING THE CARBURETOR 1 Install Power jet 1 to ...

Page 227: ...tall O ring Solenoid valve to the carburetor NOTICE ECA27130 Before installing the solenoid valve blow air on the solenoid valve and its installing loca tion on the carburetor in order to remove any foreign particles such as chips etc 6 Install Pilot air screw 1 Throttle stop screw 2 a Turn in the pilot air screw until it is lightly seated b Turn out the pilot air screw by the number of turns reco...

Page 228: ...chamber top 3 Gasket 4 Throttle valve spring 5 Ring 6 Throttle valve 7 Jet needle 8 TIP While compressing the spring connect the throttle cable Align the projection a on the ring with the groove b in the throttle valve 7 11 Install Mixing chamber top 1 Bolt mixing chamber top 2 to the carburetor 3 TIP Insert the throttle valve into the carburetor body while pulling up the lever 4 After installing ...

Page 229: ... 3 Tighten Carburetor joint bolt 1 TIP Place the bolt head a with its top as shown and secure the clamp in alignment with the horizon tal line b that passes the center of the carbure tor 4 Connect Throttle position sensor lead Solenoid valve lead Refer to CABLE ROUTING DIAGRAM on page 2 15 5 Clamp Air vent hose 1 Overflow hose 2 Refer to CABLE ROUTING DIAGRAM on page 2 15 6 Adjust Idle speed Refer...

Page 230: ...of the float using a vernier calipers TIP The float arm should be resting on the needle valve but not compressing the needle valve 2 Adjust Fuel level a Check the needle valve seat and needle valve b If either is worn replace them as a set c If both are fine adjust the float level by slightly bending the float tang 1 d Measure the fuel height again e Repeat steps c to d until the fuel level is wit...

Page 231: ...HECKING THE SWITCHES 8 6 CHECKING THE IGNITION SPARK GAP 8 8 CHECKING THE SPARK PLUG CAP 8 8 CHECKING THE IGNITION COIL 8 8 CHECKING THE PICKUP COIL 8 9 CHECKING THE SOURCE COIL 8 9 CHECKING THE SOLENOID VALVE OPERATION 8 10 CHECKING THE SOLENOID VALVE COIL 8 10 HANDLING NOTE 8 11 CHECKING THE THROTTLE POSITION SENSOR COIL 8 11 CHANGING AND ADJUSTING THE THROTTLE POSITION SENSOR 8 11 CHECKING THE ...

Page 232: ... G L O W R Y G W B B W B B W B O B Y B B R R R G L B R W L B G W W R L Y B L L Y B B G L B R W L B G W W R 1 CDI unit 2 Engine stop switch 3 Ignition coil 4 Throttle position sensor 5 Solenoid valve 6 Joint connector 7 CDI magneto 8 Spark plug B Black L Blue O Orange R Red Y Yellow B L Black Blue B R Black Red B W Black White G L Green Blue G W Green White W L White Blue W R White Red ...

Page 233: ...cap Refer to CHECKING THE SPARK PLUG CAP on page 8 8 NG Replace the spark plug cap OK 4 Check the ignition coil Refer to CHECKING THE IGNI TION COIL on page 8 8 NG Replace the ignition coil OK 5 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 6 NG Replace the engine stop switch OK 6 Check the pickup coil Refer to CHECKING THE PICKUP COIL on page 8 9 NG Replace the pickup coil...

Page 234: ...2 V battery in this inspection 1 Check each couplers and wire con nection NG Reconnect OK 2 Check solenoid valve Check sole noid valve operation Solenoid valve coil Refer to CHECKING THE SOLE NOID VALVE OPERATION on page 8 10 and CHECKING THE SOLENOID VALVE COIL on page 8 10 NG Replace the solenoid valve OK 3 Check CDI magneto Source coil Refer to CHECKING THE SOURCE COIL on page 8 9 NG Replace th...

Page 235: ...onnect OK 2 Check throttle position sensor Throttle position sensor coil Refer to CHECKING THE THROT TLE POSITION SENSOR COIL on page 8 11 and CHANGING AND ADJUSTING THE THROTTLE PO SITION SENSOR on page 8 11 NG Replace the throttle position sensor OK 3 Check CDI magneto Source coil Refer to CHECKING THE SOURCE COIL on page 8 9 NG Replace the source coil OK 4 Check CDI unit Throttle position senso...

Page 236: ...ELECTRICAL COMPONENTS 8 5 EAM20147 ELECTRICAL COMPONENTS 1 2 3 4 5 1 CDI unit 2 Engine stop switch 3 Ignition coil 4 Throttle position sensor 5 Solenoid valve ...

Page 237: ...ELECTRICAL COMPONENTS 8 6 EAM30289 CHECKING THE SWITCHES 1 1 Engine stop switch ...

Page 238: ...hecking for continuity switch back and forth between the switch positions a few times Terminal connections of the switch are shown in the terminal connection diagram below The switch positions a are shown in the far left column and the switch lead colors are shown in the top row in the switch illustration TIP indicates continuity between switch terminals i e a closed circuit at each switch positio...

Page 239: ... specification Replace a Connect the digital circuit tester to the spark plug cap b Measure the spark plug cap resistance EAM30296 CHECKING THE IGNITION COIL 1 Check Primary coil resistance Out of specification Replace a Disconnect the ignition coil connectors from the ignition coil terminals b Connect the digital circuit tester to the ignition coil as shown Minimum ignition spark gap 6 0 mm 0 24 ...

Page 240: ...from the wire harness 2 Check Charging coil 1 resistance B R B Out of specification Replace the CDI mag neto a Connect the digital circuit tester to the CDI magneto coupler as shown Secondary coil resistance 5 68 8 52 k Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Positive tester probe High tension cord 1 Negative tester probe Yellow 2 Pickup coil resistan...

Page 241: ...V to the solenoid valve coupler 3 Check Solenoid valve 1 No click when connecting the battery Re place EAM30586 CHECKING THE SOLENOID VALVE COIL 1 Check Solenoid valve coil resistance Out of specification Replace Charging coil 2 resistance 44 0 66 0 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Positive tester probe Green Blue 1 Negative tester probe Green ...

Page 242: ...ck that the resistance in increased as the lever a is moved from the full close position to the full open position Out of specification Replace EAM30589 CHANGING AND ADJUSTING THE THROTTLE POSITION SENSOR 1 Remove Carburetor Mixing chamber top Refer to CARBURETOR on page 7 3 2 Remove Throttle position sensor screw 1 Throttle position sensor 2 TIP Loosen the throttle position sensor screw using the...

Page 243: ...ord b Turn the throttle stop screw 1 until the specified idle speed Refer to CHECKING THE ENGINE IDLING SPEED on page 3 5 7 Insert the thin electric conductors 2 lead wire into the throttle position sensor coupler 1 as shown and connect the tester to them 8 Start the engine 9 Adjust Throttle position sensor output voltage a Adjust the installation angle of the throttle position sensor 1 to obtain ...

Page 244: ...ning the marks a that were put before re moval 14 Install Carburetor Refer to CARBURETOR on page 7 3 EAM30305 CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1 Disconnect Throttle position sensor coupler 2 Start the engine 3 Check Throttle position sensor input voltage Out of specification Replace the CDI unit Positive tester probe Blue 1 Negative tester probe Black Blue 2 Throttle position se...

Page 245: ...NERAL INFORMATION 9 1 TROUBLESHOOTING OF ENGINE 9 1 TROUBLESHOOTING OF CLUTCH 9 6 TROUBLESHOOTING OF TRANSMISSION 9 7 TROUBLESHOOTING OF COOLING SYSTEM 9 8 TROUBLESHOOTING OF BRAKE 9 9 TROUBLESHOOTING OF SUSPENSION 9 9 TROUBLESHOOTING OF STEERING HANDLING 9 11 ...

Page 246: ...el not supplied Empty fuel tank Fill the fuel tank with fuel Clogged fuel tank cap breather hole Clean the fuel tank cap Clogged or damaged fuel hose Clean repair or replace the fuel hose Fuel leakage Check the fuel passage Repair or replace as necessary Clogged fuel cock strainer Clean or replace the fuel cock strainer Clogged fuel cock Clean or replace the fuel cock Cracked damaged or worn fuel ...

Page 247: ...g cap Defective ignition coil Replace the ignition coil CDI unit failure Replace the CDI unit Fuel not supplied Fuel leakage Check the fuel passage Repair or replace as necessary Clogged carburetor fuel passage Clean the carburetor Clogged needle valve or needle valve seat Clean the needle valve or needle valve seat Damaged float Replace the float Water or foreign material in fuel degraded fuel Ch...

Page 248: ... hose Replace the vacuum hose Damaged carburetor joint Replace the carburetor joint Loose carburetor joint Tighten the carburetor joint bolts to the specified torque Clogged air filter element Clean or replace the air filter ele ment Symptom Possible cause Actions Spark plug does not produce a spark Incorrect spark plug gap Adjust the spark plug gap Worn or damaged spark plug Replace the spark plu...

Page 249: ...ghten the main jet to the speci fied torque Bent damaged or worn jet needle Replace the jet needle Cracks or damage in the piston valve diaphragm Replace the piston valve dia phragm Problem with piston valve move ment movement is not smooth Replace the piston valve Damaged or worn needle valve seat Replace the needle valve seat Loose needle valve seat Tighten the needle valve seat to the specified...

Page 250: ...n rings as a set Worn or damaged piston Replace the piston and piston rings as a set Worn piston piston pin hole Replace the piston and piston pin as a set Worn or damaged piston pin Replace the piston pin Worn or damaged cylinder bore Replace the cylinder piston and piston rings as a set Carbon buildup in piston head and combustion chamber Clean the piston head and com bustion chamber Noise heard...

Page 251: ...ine oil Deteriorated oil Change to recommended engine oil Clutch drags Faulty clutch spring Replace the clutch springs as a set Warped pressure plate Replace the pressure plate Swollen friction plate Replace the friction plates as a set Warped clutch plate Replace the clutch plates as a set Bent pull rod outer pull type Replace the pull rod Worn pull rod tooth outer pull type Replace the pull rod ...

Page 252: ...e the shift drum Seized shift fork Replace the shift fork and shift fork guide bar as a set Bent shift fork guide bar Replace the shift fork guide bar Foreign object between transmis sion gears Remove foreign object from trans mission gears Seized transmission gear Replace the seized gear and the axle as a set Improperly assembled transmis sion Reassemble the transmission axle assembly Jumps out o...

Page 253: ...e the radiator Damaged or faulty water pump Replace the water pump Damaged hoses or pipes Replace the hose or pipe Improperly connected hoses or pipes Connect the hoses and pipes properly Clogged air filter element Clean or replace the air filter ele ment Brake drags Check the brake system and repair or replace faulty parts as necessary Incorrect spark plug gap Adjust to the specified spark plug g...

Page 254: ... Damaged brake hose and brake pipe Replace the brake hose and brake pipe Oil or grease on the brake disc or brake pad Clean the brake disc or brake pad Insufficient lubrication of brake lever or brake pedal pivot Lubricate the brake lever or brake pedal pivot Symptom Possible cause Actions Front fork is hard Bent or damaged inner tube Replace the inner tube Bent or damaged outer tube Replace the o...

Page 255: ...mper rod assembly bolt Tighten the damper rod assembly bolt to the specified torque Damaged damper rod assembly bolt copper washer Replace the damper rod assembly bolt copper washer Cracked or damaged cap bolt O ring Replace the cap bolt O ring Rear suspension is hard Bent or damaged rear shock absorber rod Replace the rear shock absorber Bent swingarm pivot shaft Replace the swingarm pivot shaft ...

Page 256: ...ied torque Worn bearing or bearing race Replace the bearing and bearing race as a set Warped front fork Repair or replace the front fork Bent front wheel axle Replace the front wheel axle Incorrect tire pressure Adjust to the specified tire pres sure Worn deformed or incorrect tire Replace the tire Heavy steering Steering ring nut is tightened too tight Tighten the steering ring nut to the specifi...

Page 257: ...ed or incorrect tire Replace the tire Loose wheel axle nut Tighten the wheel axle nut to the specified torque Loose swingarm pivot shaft Tighten the swingarm pivot shaft to the specified torque Bent or damaged swingarm Replace the swingarm bearing Damaged or worn swingarm bear ing or bushing Replace the swingarm bearing or bushing Symptom Possible cause Actions ...

Page 258: ...TROUBLESHOOTING 9 13 ...

Page 259: ...TION AND EXAMPLES OF CARBURETOR SETTING 10 6 EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM 10 6 CHANGE OF THE HEAT RANGE OF SPARK PLUGS 10 8 CHASSIS 10 9 SELECTION OF THE SECONDARY REDUCTION RATIO SPROCKET 10 9 DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS 10 9 TIRE PRESSURE 10 9 FRONT FORK SETTING 10 10 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL 10 10 SETTING OF SPRING AFTER REPLACEMEN...

Page 260: ...ble to make a note of settings atmo spheric conditions road surface condition lap time etc so that the memorandum can be used as a reference useful for future EAM30591 ATMOSPHERIC CONDITIONS AND CARBURETOR SETTINGS The air density i e concentration of oxygen in the air determines the richness or leanness of the air fuel mixture Therefore refer to the above table for mixture settings That is Higher...

Page 261: ...0 r min to the extent of 1 2 to full opened throttle can be set by changing the power jet 1 A larger size jet results in a richer mixture and a smaller size in a leaner mixture EAM30595 PILOT AIR SCREW ADJUSTMENT The richness of the air fuel mixture with the throttle fully closed to 1 8 open can be set by turning the pilot air screw 1 Turning in the pilot air screw will make the mix ture enrich at...

Page 262: ...ame taper angle are available in different straight portion diameters and in different taper start ing positions 2 Effects of changing the jet needle reference Diameter of straight portion Changing the diameter of the straight portion adjusts the air fuel mixture when the throttle is 1 8 to 1 4 open Taper starting position Changing the taper starting position produc es the same effect as changing ...

Page 263: ...y one groove and move up the needle to enrich the mixture EAM30605 RELATIONSHIP WITH THROTTLE OPENING The flow of the fuel through the carburetor main system is controlled by the main jet and then it is further regulated by the area between the main nozzle and the jet needle On the relation ship between the fuel flow and the throttle open ing the fuel flow relates to the jet needle straight portio...

Page 264: ...62 4MX 14948 12 60 4MX 14948 11 58 4MX 14948 10 55 4MX 14948 09 52 4MX 14948 08 Lean 50 4MX 14948 07 Jet needle Rich NYFD B4X 14916 FD NYCD B4X 14916 CD NYDD B4X 14916 DD NYED B4X 14916 ED NYFE B4X 14916 FE NYCE B4X 14916 CE NYDE B4X 14916 DE NYEE B4X 14916 EE NYFF B4X 14916 FF NYCF B4X 14916 CF STD NYDF B4X 14916 DF NYEF B4X 14916 EF NYFG B4X 14916 FG NYCG B4X 14916 CG NYDG B4X 14916 DG NYEG B4X ...

Page 265: ... 2 NYDF 2 NYDF 2 NYEF 2 Pilot jet 75 75 72 75 75 72 Pilot air screw 0 0 1 4 0 0 1 4 Power jet 35 35 35 35 35 35 Symptom Setting Checking At full throttle Stall at high speeds Hard breathing Shearing noise Whitish spark plug Lean mixture Increase main jet calibration no Gradually Discoloration of spark plug If tan color it is in good condition If cannot be corrected Clogged float valve seat Clogged...

Page 266: ... clip position is the jet needle groove on which the clip is installed The positions are numbered from the top It a change in the clip position 1 groove is effective try another jet needle that provides a difference of 0 5 in the clip position Closed to 1 4 throttle Hard breathing Speed down Use jet needle having a smaller diam eter Closed to 1 4 throttle Poor acceleration White smoke Use jet need...

Page 267: ... No of the main jet must be changed by 30 it is advisable to change the heat range of spark plugs and newly select the proper main jet TIP When checking the discoloration of spark plugs be sure to stop the engine immediately after a run and check Avoid racing When changing the heat range of spark plugs never attempt to change it more than 1 rank When using a spark plug other than standard check it...

Page 268: ...he end of the straight line with care taken to avoid the en gine over revving TIP Riding technique varies from rider to rider and the performance of a machine also vary from machine to machine Therefore do not imitate other rider s settings from the beginning but choose your own setting according to the level of your riding technique EAM30169 DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS EAM30170 T...

Page 269: ... the air spring characteristics to have a ten dency to be stiffer with the consequent dete riorated performance and characteristics Therefore adjust the front fork within the specified range EAM30173 SETTING OF SPRING AFTER REPLACEMENT As the front fork setting can be easily affected by the rear suspension take care so that the front and the rear are balanced in position etc when setting the front...

Page 270: ...er and the rear fender holding bolt 2 Remove the stand or block from the engine and with a rider astride the seat measure the sunken length b between the rear wheel axle center and the rear fender holding bolt 3 Loosen the locknut 1 and make adjustment by turning the adjuster 2 to achieve the standard figure from the subtraction of the length b from the length a TIP If the machine is new and after...

Page 271: ...than currently installed use the one whose overall length a does not exceed the stan dard as it may result in faulty performance Never use one whose overall length is great er than standard EAM30178 REAR SHOCK ABSORBER SETTING PARTS Rear shock spring 1 Equal pitch steel spring 1 B4X1 2 B4X5 Unequal pitch steel spring Length a of standard shock 490 mm 19 29 in STD spring rate N mm 48 Type Spring ra...

Page 272: ...or and quantity of I D marks Spring preload adjusting positions TIP For the spring preload adjustment refer to AD JUSTING THE REAR SHOCK ABSORBER AS SEMBLY on page 3 20 Spring preload adjusting positions Minimum Position in which the spring is turned in 1 5 mm 0 06 in from its free length Standard Position in which the spring is turned in 7 0 mm 0 28 in from its free length Maximum Position in whi...

Page 273: ...noticeable scars etc If any replace affected parts Slide metal Replace with a new one for extended use Piston metal Replace with a new one for extended use Lower bracket tightening torque Retighten to specified torque Poor initial move ment Rebound damp ing force Turn adjuster counterclockwise about 2 clicks to decrease damping Oil seals Apply grease in oil seal wall Soft over entire range bottomi...

Page 274: ...mount Increase oil amount by about 5 cm 0 2 US oz 0 2 Imp oz Obtrusive front tending to upper front posture Compression damping force Turn adjuster counterclockwise about 2 clicks to decrease damping Balance with rear end Set sunken length for 90 95 mm 3 5 3 7 in when one passenger is astride seat upper rear pos ture Spring Replace with soft spring Oil amount Decrease oil amount by about 5 10 cm 0...

Page 275: ... senger is astride seat Spring Replace with soft spring Bottoming out High compres sion damping Turn adjuster clockwise about 1 6 turn to increase damping Spring set length Set sunken length for 90 100 mm 3 5 3 9 in when one pas senger is astride seat Spring Replace with stiff spring Bouncing Rebound damp ing force Turn adjuster clockwise about 2 clicks to increase damping Spring Replace with soft...

Page 276: ...CHASSIS 10 17 ...

Page 277: ...ance Buy with confidence knowing your Genuine Yamaha Accessories will fit right and perform right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha from the inside out Genuine Yamaha Service Manuals Get the same factory man...

Page 278: ......

Reviews:

No comments