Yamaha YZ125(D) Page 151 Owner'S Service Manual Download | Manualshive

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ELECTRICAL

This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles
(e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are request-
ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to
servicing trouble and mechanical damage.

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Summary of Contents for YZ125(D)

Page 1: ...ECYCLED PAPER 2013 YZ125 D 2013 q Read this manual carefully before operating this vehicle q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule q Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch bevor Sie das Fahrzeug in Betrieb nehmen q Leggere attentamente questo manuale prima di utilizzare questo veicolo 1SR 9 31_cover indd 1 2012 09 15 15 56 32 ...

Page 2: ...t être remis avec le véhicule en cas de vente de ce dernier Q Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch bevor Sie das Fahrzeug in Betrieb nehmen Diese Bedienungsanleitung muss wenn das Fahrzeug verkauft wird beim Fahrzeug verbleiben Q Leggere attentamente questo manuale prima di utilizzare il veicolo Questo manuale dovrebbe accompagnare il veicolo se viene venduto 1P8 9 36 cover 1...

Page 3: ...YZ125 D 2013 2013 1SR 28199 31 E0 1SR 28199 31 E0 OWNER S SERVICE MANUAL OWNER S SERVICE MANUAL Read this manual carefully before operating this vehicle Read this manual carefully before operating this vehicle ...

Page 4: ......

Page 5: ...ERVICE MANUAL 2012 by Yamaha Motor Co Ltd 1st Edition September 2012 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ...

Page 6: ...IS MACHINE IS TO BE OPER ATED BY AN EXPERIENCED RID ER ONLY Do not attempt to operate this ma chine at maximum power until you are totally familiar with its character istics THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY Do not carry passengers on this machine ALWAYS WEAR PROTECTIVE APPAREL When operating this machine al ways wear an approved helmet with goggles or a face shield Also w...

Page 7: ...wn to find the required fore edge symbol mark and go to a page for required item and de scription MANUAL FORMAT All of the procedures in this manual are organized in a sequential step by step format The information has been complied to provide the me chanic with an easy to read handy reference that contains comprehen sive explanations of all disassembly repair assembly and inspection op erations I...

Page 8: ...step by step format sup plements 5 are given in addition to the exploded diagram and job instruction chart ILLUSTRATED SYMBOLS Refer to the illustration Illustrated symbols 1 to 7 are used to identify the specifications appear ing in the text 1 With engine mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening 6 Specified value Service limit 7 Resistance Ω Voltage V Electric current A Ill...

Page 9: ...TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 REGULAR INSPECTION AND ADJUSTMENTS 3 ENGINE 4 CHASSIS 5 ELECTRICAL 6 TUNING 7 ...

Page 10: ...TION INSPECTION AND MAINTENANCE 3 5 ENGINE 3 6 CHASSIS 3 9 ELECTRICAL 3 19 CHAPTER 4 ENGINE SEAT FUEL TANK AND SIDE COVERS 4 1 EXHAUST PIPE AND SILENCER 4 3 RADIATOR 4 5 CARBURETOR AND REED VALVE 4 7 CYLINDER HEAD CYLIN DER AND PISTON 4 12 CLUTCH 4 19 KICK SHAFT AND SHIFT SHAFT 4 23 YPVS GOVERNOR 4 28 WATER PUMP 4 30 CDI MAGNETO 4 33 ENGINE REMOVAL 4 35 CRANKCASE AND CRANKSHAFT 4 39 TRANSMISSION S...

Page 11: ...1 1 LOCATION OF IMPORTANT LABELS GENERAL INFORMATION LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle CANADA 1 ...

Page 12: ...1 2 LOCATION OF IMPORTANT LABELS ...

Page 13: ...1 3 LOCATION OF IMPORTANT LABELS EUROPE AUS NZ ZA ...

Page 14: ...ains high pressure nitrogen gas Mishandling can cause explosion Do not incinerate puncture or open Turn off the main switch after riding to avoid draining the battery Use unleaded gasoline only Measure tire pressure when tires are cold Adjust tire pressure Improper tire pressure can cause loss of control Loss of control can result in severe injury or death ...

Page 15: ... to change without notice 1 Clutch lever 2 Engine stop switch 3 Front brake lever 4 Throttle grip 5 Radiator cap 6 Fuel tank cap 7 Kickstarter crank 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 Air filter 16 Drive chain 17 Shift pedal 18 Starter knob 19 Front fork ...

Page 16: ...l force to the sidestand Remove this sidestand before starting out VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose In this installation make sure the arrow faces the fuel tank and also downward COLLAR tool for YPVS This collar 1 is used to remove and install the push rod of the engine NIPPLE WRENCH This nipple wrench 1 is used to tighte...

Page 17: ...amped letters must be on the side exposed to view When in stalling oil seal s apply a light coating of lightweight lithium base grease to the seal lip s Oil the bearings liberally when installing Do not use compressed air to spin the bearings dry This causes dam age to the bearing surfaces CIRCLIPS 1 All circlips should be inspected carefully before reassembly Al ways replace piston pin clips afte...

Page 18: ...ation Crankcase separating tool YU 1135 A 90890 01135 These tool is used to remove the crankshaft from either case Flywheel puller YM 1189 90890 01189 This tool is used to remove the fly wheel magneto Rotor holding tool YU 1235 90890 01235 This tool is used when loosening or tightening the flywheel magneto se curing nut Dial gauge and stand YU 3097 90890 01252 Stand YU 1256 These tools are used to...

Page 19: ...ols are used for checking the cooling system Flywheel puller YU 33270 B 90890 01362 These tool is used to split the crank case Steering nut wrench YU 33975 90890 01403 This tool is used when tighten the steering ring nut to specification Cap bolt wrench YM 01500 90890 01500 This tool is used to loosen or tighten the base valve Cap bolt ring wrench YM 01501 90890 01501 This tool is used to loosen o...

Page 20: ...is tance output voltage and amper age Clutch holding tool YM 91042 90890 04086 This tool is used to hold the clutch when removing or installing the clutch boss securing nut Dynamic spark tester YM 34487 Ignition checker 90890 06754 This instrument is necessary for checking the ignition system compo nents Yamaha Bond No 1215 Three Bond No 1215 90890 85505 This sealant Bond is used for crankcase mat...

Page 21: ...r shift to neutral before starting THROTTLE GRIP The throttle grip 1 is located on the right handlebar it accelerates or de celerates the engine For accelera tion turn the grip toward you for deceleration turn it away from you FRONT BRAKE LEVER The front brake lever 1 is located on the right handlebar Pull it toward the handlebar to activate the front brake REAR BRAKE PEDAL The rear brake pedal 1 ...

Page 22: ... as follows 2 Perform the pre operation checks on the machine 3 Start and warm up the engine Check the idle speed and check the operation of the controls and the ENGINE STOP button 4 Operate the machine in the lower gears at moderate throttle open ings for five to eight minutes Stop and check the spark plug condi tion it will show a rich condition during break in 5 Allow the engine to cool Restart...

Page 23: ...lower bracket Rear For link type Assembly of links Link to frame Link to rear shock absorber Link to swingarm Installation of rear shock absorber Rear shock absorber to frame Installation of swingarm Tightening of pivot shaft Wheel Installation of wheel Front Tightening of wheel axle Tightening of axle holder Rear Tightening of wheel axle Wheel to rear wheel sprocket Brake Front Brake caliper to f...

Page 24: ...ith a vinyl uphol stery cleaner to keep the cover pliable and glossy 8 Automotive wax may be applied to all painted or chromed surfac es Avoid combination cleaner waxes as they may contain abra sives 9 After completing the above start the engine and allow it to idle for several minutes STORAGE If your machine is to be stored for 60 days or more some preventive mea sures must be taken to avoid dete...

Page 25: ...acement 124 cm3 4 36 Imp oz 4 19 US oz Bore stroke 54 54 5 mm 2 1 2 1 in Compression ratio 8 6 10 7 1 Starting system Kick starter Lubrication system Premix 30 1 YAMALUBE 2 R Oil type or grade 2 stroke Transmission oil Recommended brand YAMALUBE SAE10W 40 API service SG type or higher JASO standard MA Periodic oil change 0 66 L 0 58 Imp qt 0 69 US qt Total amount 0 70 L 0 62 Imp qt 0 74 US qt Cool...

Page 26: ... Type With tube Size front 80 100 21 51M Size rear 100 90 19 57M Tire pressure front and rear 100 kPa 1 0 kgf cm2 15 psi Brake Front brake type Single disc brake Operation Right hand operation Rear brake type Single disc brake Operation Right foot operation Suspension Front suspension Telescopic fork Rear suspension Swingarm link type monocross suspension Shock absorber Front shock absorber Coil s...

Page 27: ...de Piston pin Piston pin outside diameter 14 995 15 000 mm 0 5904 0 5906 in 14 975 mm 0 5896 in Piston ring Sectional sketch Plain B 1 0 mm 0 039 in T 2 35 mm 0 093 in End gap installed 0 5 0 7 mm 0 020 0 028 in 1 2 mm 0 047 in Side clearance installed 0 035 0 070 mm 0 0014 0 0028 in 0 1 mm 0 004 in Crankshaft Crank width A 55 90 55 95 mm 2 201 2 203 in Runout limit C 0 03 mm 0 0012 in 0 05 mm 0 0...

Page 28: ...imit 0 01 mm 0 0004 in Shifter Shifting type Cam drum and guide bar Guide bar bending limit 0 05 mm 0 0020 in Kick starter type Kick and mesh type Kick clip friction force P 0 8 1 2 kg 1 8 2 6 lb Air filter oil grade oiled filter Foam air filter oil or equivalent oil Carburetor USA CDN EUROPE AUS NZ ZA Type Manufacturer TMXχ38SS MIKUNI I D mark 1C37 51 1C36 41 Main jet M J 430 Jet needle clip posi...

Page 29: ...4 1 N mm 0 418 kg mm 23 4 lb in Optional spring Yes Oil capacity 524 cm3 18 4 Imp oz 17 7 US oz 526 cm3 18 5 Imp oz 17 8 US oz Oil grade Suspension oil S1 Inner tube outer diameter 48 mm 1 9 in Front fork top end 5 mm 0 2 in Rear suspension USA CDN ZA AUS NZ EUROPE Shock absorber travel 131 5 mm 5 18 in Spring free length Approx 265 mm 10 43 in Fitting length I D mark Red 1 258 mm 10 16 in 252 mm ...

Page 30: ... 250 3 0 mm 9 84 0 12 in 250 2 5 mm 9 84 0 10 in Pad thickness 4 4 mm 0 17 in 1 0 mm 0 04 in Master cylinder inside dia 9 52 mm 0 375 in Caliper cylinder inside dia 22 65 mm 0 892 in 2 Brake fluid type DOT 4 Rear disc brake Disc outside dia Thickness 245 4 0 mm 9 65 0 16 in 245 3 5 mm 9 65 0 14 in Deflection limit 0 15 mm 0 006 in Pad thickness 6 4 mm 0 25 in 1 0 mm 0 04 in Master cylinder inside ...

Page 31: ...20 C 68 F Secondary winding resistance 5 7 8 5 kΩat 20 C 68 F Spark plug cap Resistance 4 6 kΩat 20 C 68 F Item Thread size Q ty Tightening torque Remarks Spark plug M14S 1 20 Nm 2 0 m kg 14 ft lb Cylinder head nut M8 5 28 Nm 2 8 m kg 20 ft lb Copper washer Cylinder head stud M8 5 13 Nm 1 3 m kg 9 4 ft lb Cylinder nut M8 4 30 Nm 3 0 m kg 22 ft lb Cylinder stud M10 4 13 Nm 1 3 m kg 9 4 ft lb Power ...

Page 32: ...ft lb Oil check bolt M6 1 10 Nm 1 0 m kg 7 2 ft lb Copper washer Oil drain bolt M10 1 20 Nm 2 0 m kg 14 ft lb Copper washer Kickstarter crank M6 1 10 Nm 1 0 m kg 7 2 ft lb Clutch cover M6 6 10 Nm 1 0 m kg 7 2 ft lb Primary drive gear M8 1 48 Nm 4 8 m kg 35 ft lb Clutch boss M16 1 80 Nm 8 0 m kg 58 ft lb Lock washer Clutch spring M6 5 10 Nm 1 0 m kg 7 2 ft lb Clutch cable adjust bolt and locknut M6...

Page 33: ... M4 2 0 5 Nm 0 05 m kg 0 36 ft lb Front brake master cylinder and bracket M6 2 9 Nm 0 9 m kg 6 5 ft lb Brake lever mounting bolt M6 1 6 Nm 0 6 m kg 4 3 ft lb Brake lever mounting nut M6 1 6 Nm 0 6 m kg 4 3 ft lb Brake lever position locknut M6 1 5 Nm 0 5 m kg 3 6 ft lb Clutch lever mounting nut M6 1 4 Nm 0 4 m kg 2 9 ft lb Clutch lever holder M5 2 4 Nm 0 4 m kg 2 9 ft lb Front brake master cylinde...

Page 34: ... m kg 50 ft lb Relay arm and connecting rod M14 1 80 Nm 8 0 m kg 58 ft lb Connecting rod and frame M14 1 80 Nm 8 0 m kg 58 ft lb Rear shock absorber and frame M10 1 56 Nm 5 6 m kg 40 ft lb Rear shock absorber and relay arm M10 1 53 Nm 5 3 m kg 38 ft lb Rear shock absorber adjust locknut M56 1 30 Nm 3 0 m kg 22 ft lb Rear frame and frame upper M8 1 32 Nm 3 2 m kg 23 ft lb Rear frame and frame lower...

Page 35: ...b ELECTRICAL Rear fender front M6 2 7 Nm 0 7 m kg 5 1 ft lb Rear fender rear M6 2 12 Nm 1 2 m kg 8 7 ft lb Side cover M6 2 7 Nm 0 7 m kg 5 1 ft lb Seat M8 2 19 Nm 1 9 m kg 13 ft lb Number plate M6 1 7 Nm 0 7 m kg 5 1 ft lb Item Thread size Q ty Tightening torque Remarks Item Thread size Q ty Tightening torque Remarks Stator M6 3 7 Nm 0 7 m kg 5 1 ft lb Rotor M12 1 56 Nm 5 6 m kg 40 ft lb Ignition ...

Page 36: ...nts should be at room temperature A Distance between flats B Outside thread diameter DEFINITION OF UNITS A Nut B Bolt TORQUE SPECIFI CATION Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 94 Unit Read Definition Measure mm millimeter 10 3 meter Length cm centimeter 10 2 meter Length kg kilogram 103 gram We...

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Page 38: ... CDI magneto lead 10 YPVS breather hose 11 Engine bracket right 12 Engine bracket left 13 Crankcase breather hose 14 Overflow hose 15 Connector cover A Pass the clutch cable on the out side of the throttle cable and en gine stop switch lead B Align the throttle cable locating tape with the cable guide C Pass the throttle cable clutch cable and engine stop switch lead above the radiator hose ...

Page 39: ...ather hose out side the engine bracket and in side the down tube Then pass the radiator breather hose inside the YPVS breather hose J Clamp the CDI magneto lead radiator breather hose and YPVS breather hose to the frame K Clamp to the frame the CDI magneto lead and radiator breather hose Take care to clamp them above the projection on the frame L Locate the clamp ends in the ar rowed range M Direc...

Page 40: ...ator hose B Using a plastic locking tie clamp the engine stop switch lead igni tion coil lead and CDI magneto lead together with the clamp ends backward and then cut off the tie end C Clamp to the frame the throttle cable clutch cable ignition coil lead and engine stop switch lead In so doing clamp the igni tion coil lead and engine stop switch lead at their protecting tubes Tighten the clamp so t...

Page 41: ...e connector cover into contact with the coupler G Locate the clamp ends in the ar rowed range H Insert the CDI unit band until it stops at the CDI unit stay I Pass the CDI magneto lead and radiator breather hose between the frame and the radiator hose so that they come within the ar row indicated range Also take care so that the CDI magneto lead passes on the left of the ra diator breather hose ...

Page 42: ...ion directs as shown and lightly touches the projec tion on the caliper B Pass the brake hose into the brake hose holders C If the brake hose contacts the spring rear shock absorber correct its twist D Install the brake hose so that its pipe portion directs as shown and lightly touches the projec tion on the master cylinder ...

Page 43: ...so that its pipe portion directs as shown and lightly touches the projec tion on the master cylinder B Pass the engine stop switch lead in the middle of the clutch holder C Clamp the engine stop switch lead to the handlebar D Pass the brake hose in front of the number plate and through the cable guide E Pass the clutch cable through the cable guide on the number plate 0 55 in 0 47 in ...

Page 44: ...inspection is required by reference to the list below Item After break in Every race about 2 5 hours Every third about 7 5 hours Every fifth about 12 5 hours As re quired Remarks PISTON Inspect and clean Inspect crack Replace Inspect carbon deposits and eliminate them PISTON RING Inspect Check ring end gap Replace PISTON PIN SMALL END BEARING Inspect Replace CYLINDER HEAD Inspect carbon deposits a...

Page 45: ... Chain slack 48 58 mm 1 9 2 3 in Replace COOLING SYSTEM Check coolant level and leakage Check radiator cap opera tion Replace coolant Every two years Inspect hoses OUTSIDE NUTS AND BOLTS Retighten Refer to STARTING AND BREAK IN section in the CHAPTER 1 AIR FILTER Clean and lubricate Use foam air filter oil or equiv alent oil Replace FRAME Clean and inspect FUEL TANK COCK Clean and inspect Item Aft...

Page 46: ...an and lube Lithium base grease PROTECTOR GUIDE Replace REAR SHOCK ABSORBER Inspect and adjust Lube After rain ride Molybdenum disulfide grease Replace spring seat Every one year Retighten DRIVE CHAIN GUIDE AND ROLLERS Inspect SWINGARM Inspect lube and retighten Molybdenum disulfide grease RELAY ARM CONNECT ING ROD Inspect lube and retighten Molybdenum disulfide grease STEERING HEAD Inspect free p...

Page 47: ...en sprocket bolt Inspect bearings Replace bearings Lubricate Lithium base grease THROTTLE CONTROL CA BLE Check routing and connec tion Lubricate Yamaha cable lube or SAE 10W 40 motor oil Item After break in Every race about 2 5 hours Every third about 7 5 hours Every fifth about 12 5 hours As re quired Remarks ...

Page 48: ... drive chain slack and alignment Check that the drive chain is lubricated properly P 3 12 13 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 16 17 Steering Check that the handlebar can be turned smoothly and have no ex cessive play P 3 17 Front forks and rear shock absorber Check that they operate smoothly and there is no oil leakage P 3 13 1...

Page 49: ...h clean tap water 5 Install Copper washer Coolant drain bolt 6 Fill Radiator Engine To specified level Do not mix more than one type of ethylene glycol antifreeze con taining corrosion inhibitors for aluminum engine Do not use water containing im purities or oil Handling notes of coolant The coolant is harmful so it should be handled with special care When coolant splashes to your eye Thoroughly w...

Page 50: ... and cap 4 away Make minute adjustment on the le ver side using the adjuster 5 After adjustment check proper op eration of clutch lever 3 Install Cap 1 Boot 2 Place the tip a of the cap in the boot ADJUSTING THE THROTTLE GRIP FREE PLAY 1 Check Throttle grip free play a Out of specification Adjust 2 Adjust Throttle grip free play Adjustment steps a Slide the adjuster cover b Loosen the locknut 1 c ...

Page 51: ...tall Air filter guide 1 Align the projection a on filter guide with the hole b in air filter element 6 Apply Lithium soap base grease On the matching surface a on air filter element 7 Install Air filter element 1 Washer Fitting bolt Align the projection a on filter guide with the hole b in air filter case CHECKING THE TRANSMISSION OIL LEVEL 1 Start the engine warm it up for several minutes and wai...

Page 52: ...en the locknut CHECKING THE EXHAUST PIPE 1 Inspect O ring 1 Damage Replace Install the O rings with their de pressed a facing outward CHASSIS BLEEDING THE HYDRAULIC BRAKE SYSTEM Bleed the brake system if The system has been disassem bled A brake hose has been loosened or removed The brake fluid is very low The brake operation is faulty A dangerous loss of braking per formance may occur if the brak...

Page 53: ...ake lever position adjustment steps a Loosen the locknut 1 b Turn the adjusting bolt 2 until the lever position a is within speci fied position c Tighten the locknut Be sure to tighten the locknut as it will cause poor brake perfor mance 4 Install Brake lever cover ADJUSTING THE REAR BRAKE 1 Check Brake pedal height a Out of specification Adjust 2 Adjust Brake pedal height Pedal height adjustment ...

Page 54: ...hten the pad pin 9 j Install the pad pin plug 10 3 Inspect Brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL section 4 Check Brake lever operation A softy or spongy feeling Bleed brake system Refer to BLEEDING THE HY DRAULIC BRAKE SYSTEM sec tion CHECKING AND REPLACING THE REAR BRAKE PADS 1 Inspect Brake pad thickness a Out of specification Replace as a set 2 Replace Brake pad Brake pad re...

Page 55: ...LEVEL 1 Place the brake master cylinder so that its top is in a horizontal po sition 2 Inspect Brake fluid level Fluid at lower level Fill up Use only designated quality brake fluid to avoid poor brake performance Refill with same type and brand of brake fluid mixing fluids could result in poor brake perfor mance Be sure that water or other con taminants do not enter master cylinder when refilling...

Page 56: ...n slack Drive chain slack adjustment steps a Loosen the axle nut 1 and lock nuts 2 b Adjust the drive chain slack by turning the adjusters 3 c Turn each adjuster exactly the same amount to maintain correct axle alignment There are marks a on each side of the drive chain puller alignment NOTICE Im proper drive chain slack will overload the engine as well as other vital parts of the motorcy cle and ...

Page 57: ...mpression damping force By turning the adjuster 1 STANDARD POSITION This is the position which is back by the specific number of clicks from the fully turned in position Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged Always adjust each front fork to the same setting Uneven adjust ment can cause poor handling and loss of stability CHECKING THE...

Page 58: ...ster may be damaged ADJUSTING THE REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE 1 Adjust Low compression damping force By turning the adjuster 1 Standard fitting length I D MARK Q TY Length Red 1 Red 2 Red 3 258 mm 10 16 in 252 mm 9 92 in 264 mm 10 39 in 258 mm 10 16 in 255 5 mm 10 06 in 249 5 mm 9 82 in For EUROPE Stiffer Increase the spring pre load Turn the adjuster 2 in Softer Decrease the...

Page 59: ...e tire pressure is low A tilted tire valve stem indicates that the tire slips off its position on the rim If the tire valve stem is found tilted the tire is considered to be slipping off its position Correct the tire posi tion CHECKING AND TIGHTENING THE SPOKES The following procedure applies to all of the spokes 1 Check Spoke Bend damage Replace Loose spoke Retighten Tap the spokes with a screw d...

Page 60: ...ench Avoid over tightening g Check the steering stem by turn ing it lock to lock If there is any binding remove the steering stem assembly and inspect the steer ing bearings h Install the washer 5 upper bracket 6 washer 7 steering stem nut 8 handlebar 9 han dlebar upper holders 10 and number plate 11 The handlebar upper holder should be installed with the punched mark a forward Install the handleb...

Page 61: ...dlebar contact 6 Drive chain 7 Throttle roller cable guide 8 Throttle roller sliding surface 9 Tube guide cable winding por tion 10 Throttle cable end 11 Clutch cable end A Use Yamaha cable lube or equivalent on these areas B Use SAE 10W 40 motor oil or suitable chain lubricants C Lubricate the following areas with high quality lightweight lith ium soap base grease Wipe off any excess grease and a...

Page 62: ...plug Crankcase cover left 2 Attach Dial gauge 1 Spark plug hole dial stand 2 3 Rotate the magneto rotor 1 until the piston reaches top dead cen ter TDC When this happens the needle on the dial gauge will stop and reverse directions even though the rotor is being turned in the same direction 4 Set the dial gauge to zero at TDC 5 From TDC rotate the rotor clock wise until the dial gauge indicates th...

Page 63: ...HE SEAT FUEL TANK AND SIDE COVERS Order Part name Q ty Remarks Turn the fuel cock to OFF Disconnect the fuel hose 1 Seat 1 2 Air scoop left and right 2 3 Fitting band 1 Remove on fuel tank side 4 Bolt fuel tank 2 5 Fuel tank 1 6 Left side cover 1 Refer to removal section 7 Right side cover 1 Refer to removal section 8 Number plate 1 Refer to removal section 19 Nm 1 9 m kg 13 ft lb 7 Nm 0 7 m kg 5 ...

Page 64: ...he air filter case REMOVING THE NUMBER PLATE 1 Remove Bolt number plate Number plate 1 The projection a is inserted into the band of the number plate Pull the band off the projection before removal Remove the clutch cable 2 from the cable guide b on the number plate The projection c on the lower bracket is inserted into the number plate Remove the number plate by pulling it off the projection ...

Page 65: ...OVERS section 1 Bolt silencer 2 2 Washer ø 26 mm 1 02 in 1 3 Washer ø 22 mm 0 87 in 1 4 Silencer 1 5 Collar L 15 5 mm 0 61 in 1 6 Collar L 13 5 mm 0 53 in 1 7 Grommet front 1 8 Grommet rear 1 9 Tension spring 2 10 Bolt exhaust pipe 2 11 Exhaust pipe 1 10 Nm 1 0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb 12 Nm 1 2 m kg 8 7 ft lb 12 Nm 1 2 m kg 8 7 ft lb 12 Nm 1 2 m kg 8 7 ft lb ...

Page 66: ...ipe Fully apply Quick gasket Yamaha bond No 1215 or equivalent as shown 5 Install Bolt fiber 1 Silencer 2 Bolt silencer front 3 Bolt silencer rear 4 Side cover right Yamaha bond No 1215 Three Bond No 1215 90890 85505 Bolt fiber 10 Nm 1 0 m kg 7 2 ft lb Bolt silencer front 12 Nm 1 2 m kg 8 7 ft lb Bolt silencer rear 12 Nm 1 2 m kg 8 7 ft lb Side cover right 7 Nm 0 7 m kg 5 1 ft lb ...

Page 67: ...AT FUEL TANK AND SIDE COVERS section 1 Radiator guard 2 2 Radiator hose clamp radiator hose 1 3 2 Only loosening 3 Radiator hose 2 1 4 Left radiator 1 5 Radiator hose 4 1 6 Right radiator 1 7 Radiator hose 1 1 8 Radiator hose 3 1 9 Radiator breather hose 1 10 Nm 1 0 m kg 7 2 ft lb 2 Nm 0 2 m kg 1 4 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 2 Nm 0 2 m kg 1 4 ft lb ...

Page 68: ...ATOR 1 Install Radiator breather hose 1 Radiator hose 3 2 Radiator hose 1 3 To right radiator 4 Clamp the radiator hose in the direc tion as shown 2 Install Right radiator 1 Washer 2 Bolt right radiator 3 Radiator hose 4 4 Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 3 Install Left radiator 1 Washer 2 Bolt left radiator 3 Radiator hose 2 4 Refer to CABLE ROUTING DIA GRAM section in the...

Page 69: ...marks Fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Clamp carburetor joint 2 Loosen the screw carburetor joint 2 Carburetor 1 3 Carburetor joint 1 4 Reed valve assembly 1 5 Stopper reed valve 2 6 Reed valve 2 10 Nm 1 0 m kg 7 2 ft lb 2 Nm 0 2 m kg 1 4 ft lb 2 Nm 0 2 m kg 1 4 ft lb 1 Nm 0 1 m kg 0 7 ft lb ...

Page 70: ...er top 1 Refer to removal section 2 Throttle valve 1 3 Needle holder 1 4 Jet needle 1 5 Float chamber 1 6 Needle jet cover 1 7 Float pin 1 8 Float 1 9 Valve seat 1 10 Main jet 1 11 Main jet holder 1 12 Pilot jet 1 13 Starter plunger 1 14 Throttle stop screw 1 15 Pilot air screw 1 4 Nm 0 4 m kg 2 9 ft lb ...

Page 71: ...ver use a wire CHECKING THE NEEDLE VALVE 1 Inspect Needle valve 1 Valve seat 2 Grooved wear a Replace Dust b Clean Always replace the needle valve and valve seat as a set CHECKING THE THROTTLE VALVE 1 Check Free movement Stick Repair or replace Insert the throttle valve 1 into the carburetor body and check for free movement CHECKING THE JET NEEDLE 1 Inspect Jet needle 1 Bends wear Replace Clip gro...

Page 72: ... Install the reed valve with the reed valve bending as shown Note the cut a in the lower corner of the reed and stopper plate Tighten each screw gradually to avoid warping 2 Install Reed valve assembly 1 Reed valve spacer 2 3 Install Carburetor joint 1 Bolt carburetor joint 2 ASSEMBLING THE CARBURETOR 1 Install Throttle stop screw 1 Locknut 2 Pilot air screw 3 Note the following installation point...

Page 73: ...ber top 1 Screw mixing chamber top 2 To carburetor 3 After installing check the throttle grip for smooth movement 9 Install Air vent hose 1 Overflow hose 2 Clamp 3 Pass the air vent hose at the rear on the air cleaner side of the throttle ca ble 4 INSTALLING THE CARBURETOR 1 Install Carburetor 1 Install the projection between the car buretor joint slots 2 Tighten Bolt air filter joint 1 Bolt carbu...

Page 74: ...AND SILENCER section Radiator Refer to RADIATOR section 1 Spark plug 1 2 Engine bracket 2 3 Nut cylinder head 5 Loosen each nut 1 4 turn and remove them after all nuts are loosened 4 Cylinder head 1 5 Power valve housing 1 6 Push rod 1 Refer to removal section 7 Nut cylinder 4 8 Cylinder 1 5 Nm 0 5 m kg 3 6 ft lb 4 Nm 0 4 m kg 2 9 ft lb 13 Nm 1 3 m kg 9 4 ft lb 28 Nm 2 8 m kg 20 ft lb 20 Nm 2 0 m ...

Page 75: ...3 Piston 1 Refer to removal section 4 Small end bearing 1 Refer to removal section 5 Piston ring 1 Refer to removal section 6 Power valve cover 1 7 Thrust plate 1 8 Bolt link lever 1 9 Valve holder 1 10 Valve shaft 1 11 Collar 2 12 Link lever 1 13 Spring 2 14 Power valve 1 1 15 Power valve 2 1 4 Nm 0 4 m kg 2 9 ft lb 4 Nm 0 4 m kg 2 9 ft lb 8 Nm 0 8 m kg 5 8 ft lb 5 Nm 0 5 m kg 3 6 ft lb ...

Page 76: ... sharp instrument Avoid scratching the aluminum 2 Inspect Cylinder head water jacket Crust of minerals Rust Re place 3 Measure Cylinder head warpage Out of specification Resurface Warpage measurement and resur facing steps a Attach a straightedge 1 and a thickness gauge 2 on the cylin der head b Measure the warpage c If the warpage is out of specifica tion resurface the cylinder head d Place a 400...

Page 77: ...d 5 Check Free play There should be no noticeable free play Free play exists Inspect the connecting rod for wear Replace the pin and or connecting rod as required CHECKING THE PISTON RING 1 Install Piston ring Into the cylinder Push the ring with the piston crown 2 Measure End gap Use a thickness gauge 1 Out of specification Replace 3 Measure Side clearance Use a thickness gauge 1 Out of specifica...

Page 78: ...e a Do not use a sharp instrument Avoid scratching the aluminum INSTALLING THE POWER VALVE 1 Install Power valve 1 1 Power valve 2 2 Bolt power valve 3 Install the power valve at cut away faced a for down side 2 Install Spring 1 Link lever 2 Collar 3 Valve shaft 4 Valve holder 5 Bolt link lever 6 PISTON CLEARANCE CYLIN DER BORE PISTON DIAME TER Piston clearance Standard Limit 0 040 0 045 mm 0 0016...

Page 79: ... Gasket cylinder 1 Small end bearing 2 Dowel pin 3 Apply the engine oil onto the bear ing crankshaft and connecting rod and connecting rod big end wash ers Install the gasket with the seal print side toward the crankcase 3 Install Piston 1 Piston pin 2 Piston pin clip 3 The arrow a on the piston dome must point to exhaust side Before installing the piston pin clip cover the crankcase with a clean ...

Page 80: ... Apply the lithium soap base grease on the O rings 7 Install Cylinder head 1 Copper washer 2 Nut cylinder head 3 Tighten the nuts cylinder head in stage using a crisscross pattern 8 Install Engine bracket 1 Bolt engine bracket 2 Engine mounting bolt upper 3 9 Install Spark plug 1 Spark plug cap 2 Nut cylinder 30 Nm 3 0 m kg 22 ft lb Bolt push rod 5 Nm 0 5 m kg 3 6 ft lb Bolt power valve hous ing 4...

Page 81: ...ION OIL section in the CHAPTER 3 Bolt brake pedal Shift the brake pedal downward Rotor and stator Refer to CDI MAGNETO section Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Bolt clutch spring 5 3 Clutch spring 5 4 Pressure plate 1 5 Friction plate 8 6 Clutch plate 7 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb ...

Page 82: ...ing 1 5 Ball 1 6 Push rod 2 1 7 Nut clutch boss 1 Refer to removal section 8 Lock washer 1 Refer to removal section 9 Clutch boss 1 Refer to removal section 10 Thrust washer D ø34 mm 1 34 in 1 11 Primary driven gear 1 12 Bearing 1 13 Thrust washer D ø34 mm 1 34 in 1 14 Push lever shaft 1 80 Nm 8 0 m kg 58 ft lb ...

Page 83: ...at all four points CHECKING THE CLUTCH PLATES 1 Measure Clutch plate warpage Out of specification Replace clutch plate as a set Use a surface plate 1 and thick ness gauge 2 CHECKING THE PUSH LEVER SHAFT 1 Inspect Push lever shaft 1 Wear Damage Replace CHECKING THE PUSH ROD 1 Inspect Push rod 1 1 Bearing 2 Washer 3 Push rod 2 4 Ball 5 Wear damage bend Replace INSTALLING THE PUSH LEVER SHAFT 1 Insta...

Page 84: ...r 2 Circlip 3 To push rod 1 4 Apply the lithium soap base grease on the bearing and washer 7 Install Push rod 2 1 Ball 2 Push rod 1 3 Apply the transmission oil on the push rod 1 2 and ball 8 Install Pressure plate 1 9 Install Clutch spring 1 Bolt clutch spring 2 Tighten the bolts in stage using a crisscross pattern 10 Install Dowel pin 1 Gasket clutch cover 2 11 Install Clutch cover 1 Bolt clutch...

Page 85: ...the CHAPTER 3 Clutch cable Disconnect at engine side Bolt brake pedal Shift the brake pedal downward Radiator hose 4 Disconnect at water pump side Bolt push rod Refer to CYLINDER HEAD CYLINDER AND PISTON section 1 Kickstarter crank 1 2 Crankcase cover right 1 3 Bolt Primary drive gear 1 Only loosening Refer to removal section 4 Primary driven gear 1 Refer to CLUTCH section 5 Primary drive gear 1 ...

Page 86: ... SHIFT SHAFT Order Part name Q ty Remarks 1 Kick idle gear 1 2 Kick shaft assembly 1 Refer to removal section 3 Shift pedal 1 4 Shift shaft 1 5 Roller 1 6 Shift guide 1 Refer to removal section 7 Shift lever assembly 1 Refer to removal section 8 Stopper lever 1 ...

Page 87: ...NG THE KICK SHAFT AND KICK GEAR 1 Check Kick gear smooth movement Unsmoothmovement Replace 2 Inspect Kick shaft 1 Wear damage Replace CHECKING THE KICK GEAR AND KICK IDLE GEAR 1 Inspect Kick gear 1 Kick idle gear 2 Gear teeth a Wear damage Replace CHECKING THE KICK GEAR CLIP 1 Measure Kick clip friction force Out of specification Replace Use a spring gauge 1 CHECKING THE SHIFT SHAFT 1 Inspect Shif...

Page 88: ...nstall Shift lever assembly 1 To shift guide 2 3 Install Shift lever assembly 1 Shift guide 2 The shift lever assembly is installed at the same time as the shift guide Apply the transmission oil on the bolt segment shaft 4 Install Bolt shift guide 1 INSTALLING THE SHIFT SHAFT 1 Install Roller 1 Shift shaft 2 Apply the transmission oil on the roll er and shift shaft INSTALLING THE KICK SHAFT ASSEMB...

Page 89: ...imary drive gear 1 Place an aluminum plate a between the teeth of the primary drive gear and driven gear 4 Install Dowel pin 1 Gasket crankcase cover right 2 5 Install Crankcase cover right 1 Mesh the governor gear 2 and im peller shaft gear 3 with primary drive gear 4 6 Install Bolt crankcase cover right 1 Tighten the bolts in stage using a crisscross pattern 7 Install Kick starter 1 Plain washer...

Page 90: ... Right crankcase cover Refer to KICK SHAFT AND SHIFT SHAFT section 1 Governor assembly 1 2 Dowel pin 1 Refer to removal section 3 Retainer 1 4 Ball 4 5 Retainer weight 1 6 Plain washer 3 7 Thrust bearing 2 8 Collar 1 9 Plate 1 10 Compression spring 1 11 Governor gear 1 12 Governor shaft 1 ...

Page 91: ...ompression spring 2 Plate 3 Washer 4 Thrust bearing 5 Collar 6 Retainer weight 7 To governor shaft 8 Apply the lithium soap base grease on the thrust bearing 2 Install Ball 1 Retainer 2 To governor shaft 3 Apply the transmission oil on the re tainer and ball 3 Install Dowel pin 1 While compressing the spring in stall the dowel pin Make sure the dowel pin fits into the groove a in the retainer 4 In...

Page 92: ...ame Q ty Remarks Crankcase cover right Refer to KICK SHAFT AND SHIFT SHAFT section 1 Water pump housing cover 1 2 Impeller shaft gear 1 3 Dowel pin 1 4 Plain washer 1 5 Impeller shaft assembly 1 6 Bearing 1 Refer to removal section 7 Oil seal 2 Refer to removal section ...

Page 93: ...E OIL SEAL 1 Install Oil seal inside 1 Oil seal outside 2 Apply the lithium soap base grease on the oil seal lip Install the oil seal with its manufac ture s marks or numbers facing the right crankcase cover 3 2 Install Bearing 1 Install the bearing by pressing its out er race parallel INSTALLING THE IMPELLER SHAFT 1 Install Impeller shaft 1 Take care so that the oil seal lip is not damaged or the...

Page 94: ...nstall Water pump housing cover 1 Bolt water pump housing cover 2 Copper washer coolant drain bolt 3 Coolant drain bolt 4 Bolt water pump hous ing cover 10 Nm 1 0 m kg 7 2 ft lb Coolant drain bolt 10 Nm 1 0 m kg 7 2 ft lb ...

Page 95: ...y Remarks Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Bolt Radiator Refer to RADIATOR section Disconnect the CDI magneto lead 1 Left crankcase cover 1 2 Nut rotor 1 Refer to removal section 3 Rotor 1 Refer to removal section 4 Stator 1 5 Woodruff key 1 ...

Page 96: ...e sure that its flat surface a is in parallel with the crankshaft center line b When installing the rotor align the keyway c of the rotor with the woodruff key 3 Install Washer 1 Nut rotor 2 Use the rotor holding tool 3 4 Adjust Ignition timing Refer to CHECKING THE IGNI TION TIMING section in the CHAPTER 3 5 Tighten Screw stator 1 6 Check Ignition timing Re check the ignition timing 7 Connect CDI...

Page 97: ... to EXHAUST PIPE AND SILENCER section Clutch cable Disconnect at the engine side Radiator Refer to RADIATOR section Spark plug cap Disconnect the CDI magneto lead 1 Drive chain sprocket cover 1 2 Nut drive sprocket 1 Refer to removal section 3 Lock washer 1 Refer to removal section 4 Drive sprocket 1 Refer to removal section 5 Clip 1 6 Bolt brake pedal 1 26 Nm 2 6 m kg 19 ft lb 64 Nm 6 4 m kg 46 f...

Page 98: ... 3 10 Pivot shaft 1 Refer to removal section 11 Engine 1 Refer to removal section Order Part name Q ty Remarks 26 Nm 2 6 m kg 19 ft lb 64 Nm 6 4 m kg 46 ft lb 64 Nm 6 4 m kg 46 ft lb 85 Nm 8 5 m kg 61 ft lb 75 Nm 7 5 m kg 54 ft lb 5 Nm 0 5 m kg 3 6 ft lb 34 Nm 3 4 m kg 24 ft lb ...

Page 99: ...ide Pivot shaft 2 Nut pivot shaft 3 Engine mounting bolt lower 4 Nut engine mounting bolt lower 5 Engine mounting bolt front 6 Nut engine mounting bolt front 7 Engine bracket 8 Bolt engine bracket 9 Nut engine bracket 10 Engine mounting bolt upper 11 Nut engine mounting bolt up per 12 Apply the molybdenum disulfide grease on the pivot shaft INSTALLING THE BRAKE PEDAL 1 Install Spring 1 Brake pedal...

Page 100: ...ut while applying the rear brake 3 Bend the lock washer tab to lock the nut 4 Install Drive chain sprocket guide 1 Drive chain sprocket cover 2 Screw drive chain sprocket cov er 3 Nut drive sprocket 75 Nm 7 5 m kg 54 ft lb Screw drive chain sprocket cover 5 Nm 0 5 m kg 3 6 ft lb ...

Page 101: ...r Refer to KICK SHAFT AND SHIFT SHAFT section Stopper lever Refer to KICK SHAFT AND SHIFT SHAFT section Rotor and stator Refer to CDI MAGNETO section 1 Segment 1 Refer to removal section 2 Bolt L 45 mm 1 77 in 6 3 Bolt L 55 mm 2 17 in 4 4 Bolt L 65 mm 2 56 in 1 5 Bolt L 75 mm 2 95 in 1 6 Holder 1 7 Crankcase right 1 Refer to removal section 8 Crankcase left 1 Refer to removal section 30 Nm 3 0 m k...

Page 102: ...KSHAFT 9 Crankshaft 1 Refer to removal section 10 Oil seal 2 11 Bearing 2 Refer to removal section Order Part name Q ty Remarks 30 Nm 3 0 m kg 22 ft lb 10 Nm 1 0 m kg 7 2 ft lb 20 Nm 2 0 m kg 14 ft lb 14 Nm 1 4 m kg 10 ft lb ...

Page 103: ... If the cases do not separate check for a remaining case bolt or fitting Do not force REMOVING THE CRANKSHAFT 1 Remove Crankshaft 1 Use the crankcase separating tool 2 Make appropriate bolts 3 as shown available by yourself and attach the tool with them Do not use a hammer to drive out the crankshaft REMOVING THE CRANKCASE BEARING 1 Remove Bearing 1 Remove the bearing from the crankcase by pressin...

Page 104: ...haft and bearing come in contact Apply the lithium soap base grease on the oil seal lip Do not use a hammer to drive in the crankshaft A For USA and CDN B Except for USA and CDN 2 Check Shifter operation Transmission operation Unsmooth operation Repair 3 Apply Sealant On the right crankcase 1 Clean the contacting surface of left and right crankcase before applying the sealant 4 Install Dowel pin 1...

Page 105: ...using a crisscross pat tern 7 Install Holder 1 Bolt holder 2 8 Install Segment 1 Bolt segment 2 When installing the segment onto the shift cam 3 align the punch mark a with the dowel pin b Turn the segment clockwise until it stops and tighten the bolt If the segment gets an impact it may be damaged Take care not to give an impact to the segment when tightening the bolt 9 Remove Sealant Forced out ...

Page 106: ...emarks Engine Refer to ENGINE REMOVAL section Separate the crankcase Refer to CRANKCASE AND CRANK SHAFT section 1 Guide bar long 1 2 Guide bar short 1 3 Shift cam 1 4 Shift fork 3 1 5 Shift fork 1 1 6 Shift fork 2 1 7 Main axle 1 Refer to removal section 8 Drive axle 1 Refer to removal section 9 Collar 1 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb ...

Page 107: ...rk and or guide bar For a malfunctioning shift fork re place not only the shift fork itself but the two gears each adjacent to the shift fork INSTALLING THE TRANSMISSION 1 Install 6th pinion gear 21T 1 3rd 4th pinion gear 17T 17T 2 5th pinion gear 20T 3 2nd pinion gear 15T 4 To main axle 5 Apply the molybdenum disulfide oil on the inner and end surface of the idler gear and on the inner surface of...

Page 108: ...e shift fork 1 L with the 5th wheel gear 4 and 3 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 2 Install Shift cam 1 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 di rection of the arrow 3 Install Guide bar short 1 Guide bar l...

Page 109: ...ertake inspection adjustment disassembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage FRONT WHEEL AND REAR WHEEL REMOVING THE FRONT WHEEL Order Part name Q ty Remarks Hold the machine by placing the suitable stand under the engine Refer to HANDLING NOTE 1 Bolt axle holder 4 Only loosening 2 Nut front wheel axle 1 3 Front wheel axle 1 4 Front...

Page 110: ...achine by placing the suitable stand under the engine Refer to HANDLING NOTE 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 Refer to removal section 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 2 Refer to removal section 10 Brake disc 1 ...

Page 111: ...Brake disc deflection only rear brake disc Use the dial gauge 1 Out of specification Inspect wheel runout If wheel runout is in good condi tion replace the brake disc 2 Measure Brake disc thickness a Outofspecification Replace INSTALLING THE FRONT WHEEL 1 Install Bearing left 1 Spacer 2 Bearing right 3 Oil seal 4 Apply the lithium soap base grease on the bearing and oil seal lip when installing Us...

Page 112: ...eal 5 Apply the lithium soap base grease on the bearing and oil seal lip when installing Install the bearing with seal facing outward Use a socket that matches the out side diameter of the race of the bearing Right side of bearing shall be in stalled first Install the oil seal with its manufac ture s marks or numbers facing out ward Do not strike the inner race of the bearing Contact should be mad...

Page 113: ...l axle 2 Install the left drive chain puller and insert the wheel axle from left side Apply the lithium soap base grease on the wheel axle 8 Install Right drive chain puller 1 Washer 2 Nut wheel axle 3 Temporarily tighten the nut wheel axle at this point 9 Adjust Drive chain slack a Refer to ADJUSTING THE DRIVE CHAIN SLACK section in the CHAPTER 3 10 Tighten Nut wheel axle 1 Locknut 2 Drive chain ...

Page 114: ...tand under the engine Refer to HANDLING NOTE Drain the brake fluid Refer to removal section 1 Brake hose holder protector 2 2 Union bolt 2 3 Brake hose 1 4 Pad pin plug 1 Remove when loosening the pad pin 5 Pad pin 1 Loosen when disassembling the brake cali per 6 Brake caliper 1 7 Brake lever 1 8 Brake master cylinder bracket 1 9 Brake master cylinder 1 ...

Page 115: ...ne Refer to HANDLING NOTE Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section Drain the brake fluid Refer to removal section 1 Brake pedal 1 2 Brake master cylinder 1 3 Brake hose holder 2 4 Union bolt 2 5 Brake hose 1 6 Pad pin plug 1 Remove when loosening the pad pin 7 Pad pin 1 Loosen when disassembling the brake cali per 8 Brake caliper 1 ...

Page 116: ...rder Part name Q ty Remarks A Front B Rear A B 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Brake caliper piston 2 1 Refer to removal section 5 Brake caliper piston dust seal 2 1 Refer to removal section 6 Brake caliper piston seal 2 1 Refer to removal section ...

Page 117: ...LINDER Order Part name Q ty Remarks A Front B Rear 1 Brake master cylinder cap 1 2 Diaphragm 1 3 Reservoir float 1 4 Push rod Front 1 5 Brake master cylinder boot 1 6 Circlip 1 Use a long nose circlip pliers 7 Washer 1 8 Push rod Rear 1 9 Brake master cylinder kit 1 ...

Page 118: ...oval steps a Insert a piece of rag into the brake caliper to lock one brake caliper b Carefully force the piston out of the brake caliper cylinder with compressed air A Front B Rear REMOVING THE BRAKE CALIPER PISTON SEAL KIT 1 Remove Brake caliper piston dust seal 1 Brake caliper piston seal 2 Remove the brake caliper piston seals and brake caliper piston dust seals by pushing them with a finger N...

Page 119: ...on Clean them with brake fluid 2 Install Brake caliper piston seal 1 Brake caliper piston dust seal 2 Always use new brake caliper pis ton seals and brake caliper piston dust seals Apply the brake fluid on the brake caliper piston seal Apply the silicone grease on the brake caliper piston dust seal Fit the brake caliper piston seals and brake caliper piston dust seals onto the slot on brake calipe...

Page 120: ...installation cause improper brake performance 3 Install Spring 1 To brake master cylinder piston 2 Install the spring at the smaller diam eter side 4 Install Brake master cylinder kit 1 Washer front brake 2 Push rod rear brake 2 Circlip 3 Brake master cylinder boot 4 Push rod front brake 5 To brake master cylinder Apply the brake fluid on the brake master cylinder kit Apply the silicone grease on ...

Page 121: ... Install Pin 1 Washer 2 Cotter pin 3 After installing check the brake pedal height Refer to ADJUSTING THE REAR BRAKE section in the CHAP TER 3 INSTALLING THE FRONT BRAKE HOSE 1 Install Copper washer 1 Brake hose 2 Union bolt 3 Always use new copper washers Install the brake hose so that its pipe portion a directs as shown and lightly touches the projection b on the brake caliper 2 Install Brake ho...

Page 122: ...uid level reaches LOWER level line a Use only the designated quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid mixing fluids may result in a harmful chemical reaction and lead to poor performance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the ...

Page 123: ...ling the brake lever in or pushing down on the brake pedal check whether there is any brake fluid leaking where the union bolts are installed respectively at the brake master cylinder and brake caliper A Front B Rear 5 Install rear brake only Protector 1 Bolt protector 2 Screw bolt brake mas ter cylinder cap 2 Nm 0 2 m kg 1 4 ft lb Bolt protector 7 Nm 0 7 m kg 5 1 ft lb ...

Page 124: ...r to FRONT WHEEL AND REAR WHEEL section Front brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Number plate Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 1 Protector 1 2 Pinch bolt upper bracket 2 Only loosening 3 Damper assembly 1 Loosen when disassembling the front fork Refer to removal section 4 Pinch bolt lower bracket 2 Only loosening 5 Front fork 1 ...

Page 125: ...ring 1 Refer to removal section 5 Inner tube 1 Refer to removal section 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Oil seal washer 1 10 Oil seal 1 11 Base valve 1 Drain the fork oil Refer to removal section 12 Damper assembly 1 Drain the fork oil Refer to removal section 30 Nm 3 0 m kg 22 ft lb 29 Nm 2 9 m kg 21 ft lb 1 Nm 0 1 m kg 0 7 ft lb 29 Nm 2 9 m kg 21 ft lb 55 Nm 5 5 m kg 40 ft lb ...

Page 126: ...n the inner tube and locknut 3 Hold the locknut and remove the adjuster Do not remove the locknut as the damper rod may go into the damp er assembly and not be taken out REMOVING THE INNER TUBE 1 Remove Dust seal 1 Stopper ring 2 Using slotted head screwdriver Take care not to scratch the inner tube 2 Remove Inner tube 1 Oil seal removal steps a Push in slowly a the inner tube just before it botto...

Page 127: ...amage Replace CHECKING THE ADJUSTER 1 Inspect Adjuster 1 O ring 2 Wear damage Replace ASSEMBLING THE FRONT FORK 1 Wash the all parts in a clean sol vent 2 Stretch the damper assembly ful ly 3 Fill Front fork oil 1 To damper assembly Be sure to use recommended fork oil If other oils are used they may have an excessively ad verse effect on the front fork per formance Never allow foreign materials to...

Page 128: ...mes to distribute the fork oil 12 While protecting the damper as sembly 1 with a rag and com pressing fully allow excessive oil to overflow on the base valve side Take care not to damage the damp er assembly 13 Allow the overflowing oil to es cape at the hole a in the damper assembly The overflow measures about 8 cm3 0 28 Imp oz 0 27 US oz 14 Check Damper assembly smooth move ment Tightness bindin...

Page 129: ...ame ter end a facing the fork spring 25 Install Damper assembly 1 To inner tube 2 To install the damper assembly into the inner tube hold the inner tube aslant If the inner tube is held vertically the damper assembly may fall into it damaging the valve inside 26 Loosen Rebound damping adjuster 1 Loosen the rebound damping ad juster finger tight Record the set position of the ad juster the amount o...

Page 130: ...ormance Never allow foreign materials to enter the front fork 32 Install Damper assembly 1 To outer tube Temporarily tighten the damper as sembly 33 Install Protector guide 1 INSTALLING THE FRONT FORK 1 Install Front fork 1 Temporarily tighten the pinch bolts lower bracket Do not tighten the pinch bolts up per bracket yet 2 Tighten Damper assembly 1 Use the cap bolt ring wrench 2 to tighten the da...

Page 131: ...1 Bolt protector 2 6 Adjust Rebound damping force Turn in the damping adjuster 1 fin ger tight and then turn out to the orig inally set position 7 Adjust Compression damping force Turn in the damping adjuster 1 fin ger tight and then turn out to the orig inally set position Pinch bolt upper brack et 21 Nm 2 1 m kg 15 ft lb Pinch bolt lower brack et 21 Nm 2 1 m kg 15 ft lb Bolt protector 5 Nm 0 5 m...

Page 132: ...hrottle cable cap 1 Turn over the cap cover 6 Throttle cable 1 Disconnect at the throttle side 7 Throttle 1 Loosen the bolts 8 Cap cover 1 9 Collar 1 10 Left grip 1 Refer to removal section 11 Handlebar upper holder 2 12 Handlebar 1 13 Handlebar lower holder 2 4 Nm 0 4 m kg 2 9 ft lb 4 Nm 0 4 m kg 2 9 ft lb 4 Nm 0 4 m kg 2 9 ft lb 9 Nm 0 9 m kg 6 5 ft lb 28 Nm 2 8 m kg 20 ft lb 40 Nm 4 0 m kg 29 f...

Page 133: ...5 25 HANDLEBAR DISASSEMBLING THE THROTTLE Order Part name Q ty Remarks 1 Grip cap lower 1 2 Grip cap upper 1 3 Grip assembly 1 4 Grip right 1 Refer to removal section 5 Tube guide 1 ...

Page 134: ...p lower 2 Bolt grip cap 3 Temporarily tighten the bolts grip cap INSTALLING THE HANDLEBAR 1 Install Handlebar lower holder 1 Washer 2 Nut handlebar lower holder 3 Install the handlebar lower holder with its side having the greater dis tance a from the mounting bolt center facing forward Apply the lithium soap base grease on the thread of the handlebar low er holders Installing the handlebar lower ...

Page 135: ...Collar 2 Apply the lithium soap base grease on the roller sliding surface and ca ble guide Install the roller so that the UP PER mark a faces upward Pass the throttle cable in the groove b in the roller 8 Install Throttle cable cap 1 Screw throttle cable cap 2 9 Adjust Throttle grip free play Refer to ADJUSTING THE THROTTLE GRIP FREE PLAY section in the CHAPTER 3 10 Install Cap cover 1 11 Install ...

Page 136: ...gine stop switch clutch lever holder and clamp should be in stalled according to the dimensions shown Pass the engine stop switch lead in the middle of the clutch lever hold er 14 Install Clutch cable 1 Apply the lithium soap base grease on the clutch cable end 15 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH LEVER FREE PLAY section in the CHAPTER 3 Bolt clutch lever holder 4 Nm 0 4 ...

Page 137: ...the suitable stand under the engine Refer to HANDLING NOTE Number plate Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 Handlebar Refer to HANDLEBAR section Front fender 1 Steering stem nut 1 2 Front fork 2 Refer to FRONT FORK section 3 Upper bracket 1 4 Steering ring nut 1 Refer to removal section 5 Lower bracket 1 6 Bearing race cover 1 7 Upper bearing 1 8 Lower bearing 1 Refer ...

Page 138: ...5 30 STEERING 9 Bearing race 2 Refer to removal section Order Part name Q ty Remarks ...

Page 139: ...g races Spin the bearings by hand If the bearings hang up or are not smooth in their operation in the bearing races replace bearings and bearing races as a set INSTALLING THE LOWER BRACKET 1 Install Lower bearing 1 Apply the lithium soap base grease on the dust seal lip and bearing inner circumference 2 Install Bearing race Upper bearing 1 Bearing race cover 2 Apply the lithium soap base grease on...

Page 140: ... If not adjust the steering by loosen ing the steering ring nut little by lit tle 10 Adjust Front fork top end a 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 Tighten the lower bracket to speci fied torque If torqued too much it may cause the front fork to mal function Steering stem nut 145 Nm 14 5 m kg 105 ft lb Front fork top end stan dard a 5 mm 0 20 in Pinch bolt upper brack...

Page 141: ...ING NOTE Brake hose holder Refer to FRONT BRAKE AND REAR BRAKE section Rear brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Bolt brake pedal Shift the brake pedal backward Drive chain 1 Drive chain support 1 2 Lower chain tensioner 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt connecting rod 1 5 Pivot shaft 1 6 Swingarm 1 ...

Page 142: ...s 1 Cap 2 Refer to removal section 2 Relay arm 1 3 Connecting rod 1 4 Collar 2 5 Oil seal 2 6 Thrust bearing 2 7 Bushing 2 8 Oil seal 8 9 Bearing 10 Refer to removal section 70 Nm 7 0 m kg 50 ft lb 80 Nm 8 0 m kg 58 ft lb 2 Nm 0 2 m kg 1 4 ft lb 6 Nm 0 6 m kg 4 3 ft lb ...

Page 143: ...Inspect Oil seal 3 Damage Replace INSTALLING THE BEARING AND OIL SEAL 1 Install Bearing 1 Oil seal 2 To swingarm Apply the molybdenum disulfide grease on the bearing when install ing Install the bearing by pressing it on the side having the manufacture s marks or numbers First install the outer and then the inner bearings to a specified depth from inside 2 Install Bearing 1 Washer 2 Oil seal 3 To ...

Page 144: ...ut relay arm 4 To swingarm Apply the molybdenum disulfide grease on the bolt circumference and threaded portion Do not tighten the nut yet 6 Install Swingarm 1 Pivot shaft 2 Apply the molybdenum disulfide grease on the pivot shaft Insert the pivot shaft from right side 7 Check Swingarm side play a Free play exists Replace thrust bearing Swingarm up and down move ment b Unsmooth movement binding ro...

Page 145: ...r chain tensioner 5 14 Install Drive chain support 1 Drive chain support cover 2 Bolt drive chain support L 50 mm 1 97 in 3 Nut drive chain support 4 Bolt drive chain support cover L 10 mm 0 39 in 5 Nut connecting rod 80 Nm 8 0 m kg 58 ft lb Nut relay arm 70 Nm 7 0 m kg 50 ft lb Nut lower chain tension er 16 Nm 1 6 m kg 11 ft lb Nut drive chain sup port 7 Nm 0 7 m kg 5 1 ft lb Bolt drive chain sup...

Page 146: ...ST PIPE AND SILENCER section in the CHAPTER 4 1 Clamp air filter joint 1 Only loosening 2 Rear frame 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt rear shock absorber frame 1 5 Rear shock absorber 1 6 Locknut 1 Only loosening 7 Adjuster 1 Only loosening 8 Spring seat 2 9 Lower spring guide 1 10 Upper spring guide 1 11 Spring rear shock absorber 1 53 Nm 5 3 m kg 38 ft lb 56 Nm 5...

Page 147: ...REAR SHOCK ABSORBER 12 Bearing 2 Refer to removal section Order Part name Q ty Remarks 53 Nm 5 3 m kg 38 ft lb 56 Nm 5 6 m kg 40 ft lb 2 Nm 0 2 m kg 1 4 ft lb 32 Nm 3 2 m kg 23 ft lb 29 Nm 2 9 m kg 21 ft lb ...

Page 148: ...MAHA DEALERS ONLY Before disposing the rear shock ab sorber be sure to extract the nitrogen gas from valve 1 Wear eye protec tion to prevent eye damage from es caping gas and or metal chips To dispose of a damaged or worn out rear shock absorber take the unit to your Yamaha dealer for this disposal procedure REMOVING THE BEARING 1 Remove Stopper ring upper bearing 1 Press in the bearing while pres...

Page 149: ...ghten Locknut 1 INSTALLING THE REAR SHOCK ABSORBER 1 Install Dust seal 1 O ring 2 Collar 3 Apply the molybdenum disulfide grease on the dust seal lips and col lars Apply the lithium soap base grease on the O rings 2 Install Bushing 1 Collar 2 Dust seal 3 Apply the molybdenum disulfide grease on the bearing and dust seal lips Install the dust seals with their lips facing inward 3 Install Rear shock...

Page 150: ...l Rear frame 1 Bolt rear frame upper 2 Bolt rear frame lower 3 7 Tighten Bolt air filter joint 1 Bolt rear frame upper 32 Nm 3 2 m kg 23 ft lb Bolt rear frame lower 29 Nm 2 9 m kg 21 ft lb Bolt air filter joint 2 Nm 0 2 m kg 1 4 ft lb ...

Page 151: ...rvicing of Yamaha motorcycles e g Yamaha dealers service engineers etc Those who have little knowledge and skill concerning servicing are request ed not to undertake inspection adjustment disassembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage 6 ...

Page 152: ...MPONENTS 1 Engine stop switch 2 CDI unit 3 Ignition coil 4 CDI magneto 5 Spark plug WIRING DIAGRAM 1 Engine stop switch 2 CDI unit 3 Ignition coil 4 CDI magneto 5 Spark plug COLOR CODE B Black O Orange Y Yellow 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 153: ...at 2 Fuel tank Use the following special tools in this inspection Spark gap test Spark Clean or replace spark plug No spark Check entire ignition system for connection No good Repair or replace OK Check engine stop switch No good Replace OK Check ignition coil primary coil and secondary coil No good Replace OK Check spark plug cap No good Replace OK Check CDI magneto pickup coil and charging coil ...

Page 154: ...Out of specification Replace 2 Inspect Secondary coil resistance Out of specification Replace Remove the spark plug cap by turn ing it counterclockwise and inspect Install the spark plug cap by turning it clockwise until it is tight CHECKING THE SPARK PLUG CAP 1 Inspect Spark plug cap Loose connection Tighten Deteriorated damaged Re place Spark plug cap resistance Out of specification Replace Mini...

Page 155: ... fault is found replace the CDI unit Then check the electrical compo nents again Tester lead White Red lead 1 Tester lead White Blue lead 2 Pickup coil resistance Tester se lector posi tion 248 372 Ω at 20 C 68 F Ω 100 Tester lead Black Red lead 1 Tester lead Green White lead 2 Charging coil 1 resis tance Tester se lector posi tion 720 1 080 Ω at 20 C 68 F Ω 100 Tester lead Green Blue lead 1 Teste...

Page 156: ...ltant reduced density Higher humidity reduces the amount of oxygen in the air by so much of the water vapor in the same air Lower atmospheric pressure at a high altitude reduces the density of the air TEST RUN After warming up the engine equipped with the standard type car buretor s and spark plug s run two or three laps of the circuit and check the smooth operation of the engine and discoloration...

Page 157: ... are available in different straight por tion diameters and in different ta per starting positions In the case of the same number of clip position changing from 6BFY43 74 to 6BFY42 74 has the same effect as a lowering of 0 5 clip position And in the case of the same number of clip position changing from 6BFY43 74 to 6BFY44 74 has the same effect as a rising of 0 5 clip position A Difference in str...

Page 158: ...4KM 32 Lean 30 4KM 30 Throttle valve 3 Size Part number 14112 Rich STD 4 0 1C3 40 Lean 4 25 1C3 42 For USA and CDN Except for USA and CDN Jet nee dle 4 Size Part number 14116 Rich 6BFY44 72 284 K2 6BFY44 73 284 K3 6BFY44 74 284 K4 6BFY44 75 284 K5 Lean 6BFY44 76 284 K6 Rich 6BFY43 72 284 J2 6BFY43 73 284 J3 STD 6BFY43 74 284 J4 6BFY43 75 284 J5 Lean 6BFY43 76 284 J6 Rich 6BFY42 72 284 H2 6BFY42 73...

Page 159: ... 75 3 6BFY44 76 3 6BFY42 72 4 6BFY42 73 4 6BFY42 74 4 6BFY42 75 4 6BFY42 76 4 STD 6BFY43 72 3 6BFY43 73 3 6BFY43 74 3 6BFY43 75 3 6BFY43 76 3 0 5 leaner 6BFY44 72 2 6BFY44 73 2 6BFY44 74 2 6BFY44 75 2 6BFY44 76 2 6BFY42 72 3 6BFY42 73 3 6BFY42 74 3 6BFY42 75 3 6BFY42 76 3 Lean 1 leaner 6BFY43 72 2 6BFY43 73 2 6BFY43 74 2 6BFY43 75 2 6BFY43 76 2 Symptom Setting Checking At full throttle Stall at hi...

Page 160: ...r acceleration Raise jet needle clip position 1 groove up 0 1 4 throttle Hard breathing Speed down Use jet needle having a smaller diameter Number of turns back Correct properly Overflow from carburetor 0 1 4 throttle Poor acceleration White smoke Use jet needle with a larger diameter Unstable at low speeds Pinking noise Lower jet needle clip position 1 groove down Turn in pilot air screw Poor res...

Page 161: ...n ratio If a course has a long straight por tion where a machine can run at maximum speed the machine is generally set such that it can devel op its maximum revolutions toward the end of the straight line with care taken to avoid the engine over rev ving Riding technique varies from rider to rider and the performance of a ma chine also vary from machine to ma chine Therefore do not imitate other r...

Page 162: ...pring 1 The I D mark slits a is proved on the end of the spring REAR SUSPENSION SETTING The rear suspension setting should be made depending on the rider s feeling of an actual run and the circuit conditions The rear suspension setting includes the following two factors 1 Setting of spring preload Change the set length of the spring Change the spring 2 Setting of damping force Change the rebound d...

Page 163: ...exceed the standard as it may result in faulty performance Never use one whose overall length is greater than standard REAR SHOCK ABSORBER SETTING PARTS Rear shock spring 1 Equal pitch titanium spring Equal pitch steel spring Unequal pitch steel spring Install the spring seat 2 to the ti tanium spring The unequal pitch spring is softer in initial characteristic than the equal pitch spring and is d...

Page 164: ...titanium and steel springs SPRING PART NUMBER 22212 Maximum Minimum 1C3 00 1C3 10 1C3 20 1C3 30 5UN 00 5UN A0 5UN B0 5UN C0 5UN D0 5UN E0 5UN F0 5UN G0 Position in which the spring is turned in 18 mm 0 71 in from its free length Position in which the spring is turned in 1 5 mm 0 06 in from its free length 5UN 50 5UN 60 5UN 70 Position in which the spring is turned in 20 mm 0 79 in from its free le...

Page 165: ...ntire range bottoming out Compression damping Turn adjuster clockwise about 2 clicks to in crease damping Oil amount Increase oil amount by about 5 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz Spring Replace with stiff spring Stiff toward stroke end Oil amount Decrease oil amount by about 5 cm3 0 2 Imp oz 0 2 US oz Soft toward stroke end bottoming out Oil amount Increase oil amount by about 5 cm3 0 2 Imp o...

Page 166: ...eavy and dragging Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Spring Replace with soft spring Poor road gripping Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Low compression damping Turn adjuster clockwise about 1 clicks to in crease damping High compression damping Turn adjuster clockwise about 1 6 turn to in crease dampin...

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Page 168: ...PRINTED IN JAPAN E PRINTED ON RECYCLED PAPER ...

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