Yamaha YZ125N1 Service Manual Download | Manualshive

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2-13

SPEC

CABLE ROUTING DIAGRAM

EC240000

CABLE ROUTING DIAGRAM

1

Brake hose

2

Fuel tank breather hose

3

Cable guide

4

Clamp

5

“ENGINE STOP” button lead

6

Throttle cable

7

Air vent hose (right)

8

Air vent hose (left)

9

Transmission oil breather
hose

0

Overflow hose

q

Radiator breather hose

w

CDI magneto lead

e

YPVS breather hose

A

Pass the fuel tank breather
hose between the handlebar
and tension bar, then insert
its end into the hole of the
number plate.

B

Pass the throttle cable and
“ENGINE STOP” button lead
into the cable guide. Align
with the cable guide the
front end of the tape on the
throttle cable.

C

Clamp the throttle cable and
“ENGINE STOP” button lead
to the frame. With the clamp
ends downward, tighten the
throttle cable to the extent
that it moves smoothly.

D

Clamp the “ENGINE STOP”
button lead (where there is
no protector), wireharness and
throttle cable all together to the
frame. With the clamp ends
downward, pass the
wireharness on the outer side
of the chassis in relation to the
“ENGINE STOP” button lead.

E

Pass the air vent hose at
the rear of the throttle cable.

F

Pass the transmission oil
breather hose, air vent hoses
and overflow hose between
the frame and connecting rod.

G

Pass the radiator breather
hose and YPVS breather hose
outside the engine bracket
and inside the frame. Then
pass the radiator breather

hose inside the YPVS
breather hose.

H

Clamp the radiater breather
hose and CDI magneto lead
on the rear of the down-tube.

I

Pass the radiater breather
hose and CDI magneto
lead between the frame and
radiator.

J

Align the top of the brake hose
neck with the brake hose
holder bottom.

K

Pass the brake hose in front
of the axle boss, then fit it
into the hose groove so that
the brake hose does not
contact the nut (wheel axle).

L

Fit the brake hose into the
guide on the protector.

M

Pass the throttle cable and
“ENGINE STOP” button lead
over the radiator hose.

N

Tighten the clamp with its
ends sideways as shown.

5MV-9-10-2 6/12/00 7:24 PM Page 2-13

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Summary of Contents for YZ125N1

Page 1: ...5MV 28199 10 LIT 11626 14 36 PAN YZ125N1 YZ125N1 OWNER S SERVICE MANUAL 5MV 10 00 6 130 53PM y W 1 2 1 ...

Page 2: ...5MV 10 00 6 130 53PM y W 2 1 1 ...

Page 3: ...ration U S A 1st Edition June 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 14 36 EC010000 5MV 9 10 0 6 13 00 3 11 PM Page 1 ...

Page 4: ...your Yamaha dealer NOTE As improvements are made on this model some data in this manual may become outdated If you have any questions please consult your Yama ha dealer w PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OP ERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWL EDGE OF ITS CONTROLS AND OPERAT ING FEATURES AND UNTIL YOU HAVE B...

Page 5: ... of abnormal strain neglect or abuse A These terms are general and overlap each other in areas Specific examples include Running the machine without oil operating the machine with a broken or damaged part which causes another part to fail damage or failure due to improper or careless transportation and or tie down and so on If you have any specific questions on operation or maintenance please cont...

Page 6: ...ED TO BE RIDDEN BY THE OPERATOR ONLY Do not carry passengers on this ma chine 3 ALWAYS WEAR PROTECTIVE APPAR EL When operating this machine always wear an approved helmet with goggles or a face shield Also wear heavy boots gloves and protective clothing Always wear proper fitting clothing that will not be caught in any of the moving parts or controls of the machine 4 ALWAYS MAINTAIN YOUR MACHINE I...

Page 7: ... AREA WITH ADEQUATE VENTILATION Never start the engine or let it run for any length of time in an enclosed area Exhaust fumes are poisonous These fumes contain carbon monoxide which by itself is odorless and color l e s s Carbon monoxide is a dangerous gas which can cause unconsciousness or can be lethal 8 PARK THE MACHINE CAREFULLY TURN OFF THE ENGINE Always turn off the engine if you are going t...

Page 8: ...hould remain with it even if the machine is subsequently sold EC060000 NOTICE Some data in this manual may become out dated due to improvements made to this model in the future If there is any question you have regarding this manual or your machine please consult your Yamaha dealer Weights of machines without fuel The minimum weights for motocross ma chines are for the class 125 cc minimum 88 kg 1...

Page 9: ...oid damage to the machine NOTE A NOTE provides key information to make pro cedures easier or clearer EC082000 FINDING THE REQUIRED PAGE 1 This manual consists of seven chapters General Information Specifications Regular inspection and adjustments Engine Chassis Electrical and Tuning 2 The table of contents is at the beginning of the manual Look over the general layout of the book before finding th...

Page 10: ...O K 7 0Y O M hf W2 M W2 M W2 M he W2 M W2 0Y O 0Y O 0Y O 0YhfO L 3 0Y O M O2 M W2 0M W2 MhfW2 X V M W2 0Y hfW2 0Y O M O 0Y he O 1 V 0Y O M hf O M W2 0Y W2 0M he W2 L V M W2 0Yhf O2 0Y O M O M hfO 1 V 0Y O Mhf W2 M W2 0Y W2 0YhfO2 V40M W2 0Y hfW 0Y O M O MhfW2 O M hf O M W2 0Y W2 0Y he O 5 O2 0Yhf W2 0Y O M O M he W2 0Y W2 M W M W2 0Y W2 0YhfO M O 0Y hf O 0Y O M O MhfW2 0Y W2 M hf O2 M W2 0Y W2 0Y ...

Page 11: ...e Specified value Service limit r Resistance Voltage V Electric current A Illustrated symbols t to o in the exploded dia grams indicate grade of lubricant and location of lubrication point t Apply transmission oil y Apply engine mixing oil u Apply molybdenum disulfide oil i Apply lightweight lithium soap base grease o Apply molybdenum disulfide grease Illustrated symbols p to a in the exploded dia...

Page 12: ...INE CHASSIS ELECTRICAL TUNING REGULAR INSPECTION AND ADJUSTMENTS SPECIFICATIONS EC090000 INDEX GENERAL INFORMATION GEN INFO 1 2 3 4 5 6 7 SPEC INSP ADJ ENG CHAS ELEC TUN 5MV 9 10 0 6 13 00 3 11 PM Page 11 ...

Page 13: ...ND BREAK IN 1 13 TORQUE CHECK POINTS 1 16 CLEANING AND STORAGE 1 17 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 3 GENERAL TORQUE SPECIFICATIONS 2 12 DEFINITION OF UNITS 2 12 CABLE ROUTING DIAGRAM 2 13 CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS 3 1 PRE OPERATION INSPECTION AND MAINTENANCE 3 4 ENGINE 3 5 CHASSIS 3 17 ELECTRICAL 3 38 5MV 9 ...

Page 14: ... 30 KICK AXLE SHIFT SHAFT AND PRIMARY DRIVE GEAR 4 38 YPVS GOVERNOR 4 46 WATER PUMP 4 49 CDI MAGNETO 4 53 ENGINE REMOVAL 4 57 CRANKCASE AND CRANKSHAFT 4 62 TRANSMISSION SHIFT CAM AND SHIFT FORK 4 69 CHAPTER 5 CAHSSIS FRONT WHEEL AND REAR WHEEL 5 1 FRONT BRAKE AND REAR BRAKE 5 10 FRONT FORK 5 27 HANDLEBAR 5 40 STEERING 5 47 SWINGARM 5 52 REAR SHOCK ABSORBER 5 59 5MV 9 10 0 6 13 00 3 11 PM Page 13 ...

Page 15: ...CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM 6 1 IGNITION SYSTEM 6 2 CHAPTER 7 TUNING ENGINE 7 1 CHASSIS 7 13 5MV 9 10 0 6 13 00 3 11 PM Page 14 ...

Page 16: ...er 8 Fuel tank 9 Radiator 0 Coolant drain bolt q Check bolt Transmission oil level w Rear brake pedal e Valve joint r Fuel cock t Air cleaner y Drive chain u Shift pedal i Starter knob o Front fork NOTE 9The machine you have purchased may differ slightly from those shown in the following 9Designs and specifications are subject to change without notice 1 5MV 9 10 1 6 12 00 7 32 PM Page 1 1 ...

Page 17: ...EC121001 VEHICLE IDENTIFICATION NUMBER For USA CDN AUS NZ and E The vehicle identification number 1 is stamped on the right of the steering head pipe EC122001 FRAME SERIAL NUMBER For F D GB I and ZA The frame serial number 1 is stamped on the right of the steering head pipe EC123001 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the right side of the engine EC...

Page 18: ...ousing hole at the bottom 2 Use proper tools and cleaning equipment Refer to SPECIAL TOOLS section 3 When disassembling the machine keep mated parts together They include gears cylinders pistons and other mated parts that have been mated through normal wear Mated parts must be reused as an as sembly or replaced 4 During the machine disassembly clean all parts and place them in trays in the order o...

Page 19: ...after the bolt or nut has been properly tightened EC135001 BEARINGS AND OIL SEALS 1 Install the bearing s 1 and oil seal s 2 with their manufacturer s marks or numbers facing outward In other words the stamped letters must be on the side ex posed to view When installing oil seal s apply a light coating of light weight lithium base grease to the seal lip s Oil the bear ings liberally when installin...

Page 20: ... carefully be fore reassembly Always replace piston pin clips after one use Replace distorted cir clips When installing a circlip 1 make sure that the sharp edged corner 2 is positioned opposite to the thrust 3 it receives See the sectional view 4 Shaft 5MV 9 10 1 6 12 00 7 34 PM Page 1 5 ...

Page 21: ...l not come off 5 If the terminal comes off bend up the pin 1 and reinsert the terminal into the connector 6 Connect 9Connector NOTE The two connectors click together 7 Check for continuity with a tester NOTE 9If there in no continuity clean the terminals 9Be sure to perform the steps 1 to 7 listed above when checking the wireharness 9For a field remedy use a contact revitalizer available on the ma...

Page 22: ... well as remove the crankshaft from either case YM 1189 90890 01189 Flywheel puller YM 1189 90890 01189 This tool is used to remove the flywheel magneto YU 1235 90890 01235 Rotor holding tool YU 1235 90890 01235 This tool is used when loosening or tightening the flywheel magneto securing nut YU 3097 90890 01252 Dial gauge and stand YU 3097 90890 01252 YU 1256 Stand YU 1256 These tools are used to ...

Page 23: ...al driver YM 01442 90890 01442 This tool is used when install the fork oil seal YU 3112 C Yamaha pocket tester YU 3112 C 90890 03112 90890 03112 Use this tool to inspect the coil resistance output voltage and amperage YM 91042 90890 04086 Clutch holding tool YM 91042 90890 04086 This tool is used to hold the clutch when removing or installing the clutch boss securing nut YM 34487 Dynamic spark tes...

Page 24: ...s of the constant mesh 6 speed transmission are ideally spaced The gears can be shifted by using the shift pedal 1 on the left side of the engine EC154000 KICK STARTER Rotate the kick starter 1 away from the engine Push the starter down lightly with your foot until the gears engage then kick smoothly and force fully to start the engine This model has a prima ry kick starter so the engine can be st...

Page 25: ...The fuel cock has the two positions OFF With the lever in this position fuel will not flow Always return the lever to this posi tion when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position EC159000 STARTER KNOB CHOKE When cold the engine requires a richer air fuel mixture for starting A separate starter ci...

Page 26: ...orting it w 9Never apply additional force to the side stand 9Remove this sidestand before starting out EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose cC In this installation make sure the arrow faces the fuel tank and also downward 5MV 9 10 1 6 12 00 7 36 PM Page 1 11 ...

Page 27: ...able then leaded gasoline can be used cC Never mix two types of oil in the same batch clotting of the oil could result If you wish to change oil types be sure to drain the fuel tank and the carburetor float bowl of old premix prior to filling with the new type Fuel tank capacity 8 0 L 1 76 Imp gal 2 11 US gal Mixing oil Recommended oil Yamalube 2 R Yamalube racing 2 cycle oil Mixing ratio 30 1 If ...

Page 28: ...hrottle completely closed start the engine by kicking the kick starter forcefully with firm stroke 4 Run the engine at idle or slightly higher until it warms up this usually takes about one or two minutes 5 The engine is warmed up when it responds normally to the throttle with the starter knob CHOKE turned off cC Do not warm up the engine for extended peri ods EC193001 STARTING A WARM ENGINE Do no...

Page 29: ... response Stop and check the spark plug 6 After again allowing the engine to cool restart and run the machine for five more minutes Full throttle and the higher gears may be used but sustained full throttle op eration should be avoided Check the spark plug condition 7 Allow the engine to cool remove the top end and inspect the piston and cylinder Remove any high spots on the piston with 600 grit w...

Page 30: ...ll such fasteners as required 9When any of the following parts have been replaced they must be broken in CYLINDER AND CRANKSHAFT About one hour of break in operation is necessary PISTON RING AND GEARS These parts require about 30 minutes of break in operation at half throttle or less Observe the condition of the engine careful ly during operation 5MV 9 10 1 6 12 00 7 36 PM Page 1 15 ...

Page 31: ...Link to swingarm Rear Installation of shock Shock absorber to frame absorber Rear Installation of swingarm Tightening of pivot shaft Wheel Installation of wheel Front Tightening of front axle Tightening of axle holder Rear Tightening of rear axle Wheel to sprocket Brake Front Caliper to front fork Brake disc to wheel Tightening of union bolt Master cylinder to handlebar Tightening of air bleeder R...

Page 32: ... front forks brakes and transmission seals Many expensive repair bills have re sulted from improper high pressure deter gent applications such as those available in coin operated car washers 4 After the majority of the dirt has been hosed off wash all surfaces with warm water and a mild detergent Use an old toothbrush to clean hard to reach places 5 Rinse the machine off immediately with clean wat...

Page 33: ...ick the engine over several times to coat the cylinder walls with oil 3 Remove the drive chain clean it thoroughly with solvent and lubricate it Reinstall the chain or store it in a plastic bag tied to the frame 4 Lubricate all control cables 5 Block the frame up to raise the wheels off the ground 6 Tie a plastic bag over the exhaust pipe out let to prevent moisture from entering 7 If the machine ...

Page 34: ... Cylinder arrangement Single cylinder forward inclined Displacement 124 cm3 4 36 lmp oz 4 19 US oz Bore Stroke 54 54 5 mm 2 126 2 146 in Compression ratio 8 7 10 8 1 Starting system Kick starter Lubrication system Premix 30 1 Yamalube 2 R Oil type or grade 2 Cycle Transmission oil Yamalube 4 10W 30 or SAE 10W 30 type SE motor oil Periodic oil change 0 65 L 0 57 Imp qt 0 69 US qt Total amount 0 70 ...

Page 35: ...A AUS NZ EUROPE Frame type Semi double cradle Caster angle 25 6 25 4 Trail 107 mm 4 21 in 104 mm 4 09 in Tire Type With tube Size front 80 100 21 51M Size rear 100 90 19 57M Tire pressure front and rear 100 kPa 1 0 kg 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 Telesc...

Page 36: ...lled 0 5 0 7 mm 0 020 0 028 in 1 2 mm 0 047 in Side clearance installed 0 035 0 080 mm 0 1 mm 0 004 in 0 0014 0 0031 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 0020 in Connecting rod big end side clearance D 0 20 0 70 mm 0 008 0 028 in Small end free play F 0 8 1 0 mm 0 031 0 039 in 2 0 mm 0 08 in Clutch Friction plate thickness 2 9 3 1 mm ...

Page 37: ...5MV2 10 Main jet M J 460 450 Jet needle clip position J N 6BGK9 75 3 6BHY1 75 3 Cutaway C A 5 75 Pilot jet P J 25 30 Pilot air screw P A S 1 1 4 1 1 2 Valve seat size V S ø3 8 mm 0 15 in Starter jet G S 80 Fuel level F L 13 5 14 5 mm 0 53 0 57 in Reed valve Thickness 0 42 mm 0 017 in Valve stopper height 8 2 8 6 mm 0 323 0 339 in Valve bending limit 0 2 mm 0 008 in Cooling Radiator core size Width...

Page 38: ...4 Carburetor joint M 6 1 0 4 10 1 0 7 2 Air filter case M 6 1 0 2 4 0 4 2 9 Air filter joint M 5 0 8 5 1 0 1 0 7 Read valve M 3 0 5 6 1 0 1 0 7 Crankcase M 6 1 0 12 14 1 4 10 Crankcase cover right M 6 1 0 8 10 1 0 7 2 Crankcase cover left M 6 1 0 5 5 0 5 3 6 Chain cover M 6 1 0 2 5 0 5 3 6 Bearing plate cover M 6 1 0 3 10 1 0 7 2 Holder M 6 1 0 1 10 1 0 7 2 Oil check bolt M 6 1 0 1 10 1 0 7 2 Oil ...

Page 39: ... torque Nm m kg ft lb Exhaust pipe M 6 1 0 2 12 1 2 8 7 Exhaust pipe stay front M 6 1 0 1 12 1 2 8 7 Exhaust pipe stay rear M 6 1 0 1 12 1 2 8 7 Silencer front M 6 1 0 1 12 1 2 8 7 Silencer rear M 6 1 0 1 7 0 7 5 1 Fiber silencer M 6 1 0 2 10 1 0 7 2 5MV 9 10 2 6 12 00 7 23 PM Page 2 6 ...

Page 40: ...inner tube 3 15 5 91 in and damper rod fully compressed without spring Oil grade Suspension oil 01 Inner tube outer diameter 46 mm 1 81 in Front fork top end 5 mm 0 20 in Rear suspension USA CDN ZA EUROPE AUS NZ Shock absorber travel 132 mm 5 20 in Spring free length 260 mm 10 24 in 275 mm 10 83 in Fitting length 248 mm 9 76 in 262 mm 10 31 in Min Max 242 260 mm 257 275 mm 9 53 10 24 in 10 12 10 8...

Page 41: ... in Pad thickness 4 4 mm 0 17 in 1 0 mm 0 04 in Master cylinder inside dia 11 0 mm 0 433 in Caliper cylinder inside dia 27 0 mm 1 063 in 2 Brake fluid type DOT 4 Rear disc brake Disc outside dia Thickness 240 4 0 mm 9 45 0 16 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 dia 12 7 mm 0 500 in Caliper cylinder insdie dia 27 0 mm 1 063 in Brak...

Page 42: ...and hose cover M 8 1 25 1 16 1 6 11 Front fork and hose cover M 6 1 0 1 7 0 7 5 1 Throttle cable cap M 4 0 7 2 1 0 1 0 7 Front brake master cylinder and bracket M 6 1 0 2 9 0 9 6 5 Brake lever bolt M 6 1 0 1 6 0 6 4 3 nut M 6 1 0 1 6 0 6 4 3 Brake lever position locknut M 6 1 0 1 5 0 5 3 6 Clutch lever bolt M 6 1 0 1 2 0 2 1 4 Clutch lever holder M 5 0 8 2 4 0 4 2 9 Front brake master cylinder cap...

Page 43: ...80 8 0 58 Relay arm and connecting rod M14 1 5 1 80 8 0 58 Connecting rod and frame M14 1 5 1 80 8 0 58 Rear shock absorber and frame M10 1 25 1 56 5 6 40 Rear shock absorber and relay arm M10 1 25 1 53 5 3 38 Rear frame and frame M 8 1 25 3 29 2 9 21 Swingarm and brake hose holder M 5 4 4 0 4 2 9 Chain tensioner mounting M 8 1 25 2 19 1 9 13 Chain support and swingarm M 6 1 0 3 7 0 7 5 1 Seal gua...

Page 44: ...al CDI Magneto model Manufacturer F4SS00 YAMAHA Source coil 1 resistance color 720 1 080 Ω at 20 C 68 F Green White Black Red Source coil 2 resistance color 44 66 Ω at 20 C 68 F Black Green Blue Pickup coil resistance color 248 372 Ω at 20 C 68 F White Blue White Red CDI unit model Manufacturer 5MV 00 YAMAHA Ignition coil Model Manufacturer 4SS 00 YAMAHA Minimum spark gap 6 mm 0 24 in Primary wind...

Page 45: ...stance across flats B Outside thread diameter EC230000 DEFINITION OF UNITS EC220001 GENERAL TORQUE SPECIFICATIONS A B TORQUE SPECIFICATION Nut Bolt 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 milimeter 10 3 meter Length cm centimeter 10 2 meter Length kg kilogram 103 ...

Page 46: ... frame With the clamp ends downward pass the wireharness on the outer side of the chassis in relation to the ENGINE STOP button lead E Pass the air vent hose at the rear of the throttle cable F Pass the transmission oil breather hose air vent hoses and overflow hose between the frame and connecting rod G Pass the radiator breather hose and YPVS breather hose outside the engine bracket and inside t...

Page 47: ...nd swingarm bracket E Put the CDI unit fully in the CDI unit band F Fasten the ground lead together with the ignition coil G Pass the cluch cable into the cable guide H Clamp the CDI magneto lead on the upper part of the frame gusset at its protecting tube I Pass the clutch cable over the radiator hose J Clamp the wireharness on the top of the CDI unit with the clamp end downward K Cut the clamp e...

Page 48: ...s the clutch cable in front of the throttle cable D Clamp the ENGINE STOP button lead to the handlebar to 3 clicks E Pass the brake hose in front of the number plate and through the cable guide F Cross the clutch cable and throttle cable over the number plate boss 1 Brake hose 2 Master cylinder 3 ENGINE STOP button lead 4 ENGINE STOP button 5 Throttle cable 6 Clutch cable 7 Clamp 8 Cable guide 5MV...

Page 49: ...ap Replace PISTON PIN SMALL END BEARING Inspect Replace CYLINDER HEAD Inspect and clean Remove carbon Retighten Check gasket CYLINDER Inspect and clean Inspect score marks Replace Inspect wear YPVS Inspect and clean CLUTCH Inspect housing friction Inspect and adjust plate clutch plate and Replace spring TRANSMISSION Replace oil Yamalube 4 10W 30 or Inspect SAE 10W 30 SE motor oil Replace bearing S...

Page 50: ...r FRONT FORKS Inspect and adjust Replace oil Suspension oil 01 Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube Lithium base grease REAR SHOCK ABSORBER Inspect and adjust Lube Molybdenum disulfide grease Retighten CHAIN GUARD AND ROLLERS Inspect SWINGARM Inspect and retighten RELAY ARM CONNECTING ROD Inspect and lube Molybdenum disulfide grease STEERING HEAD Inspect free play and ...

Page 51: ... Chain Check chain slack and alignment Check that the chain is lubricated properly P3 24 26 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P3 34 35 Steering Check that the handlebar can be turned smoothly and have no excessive play P3 35 36 Front forks and Check that they operate smoothly and there is no oil rear shock absorber leakage P3 26 33 ...

Page 52: ...he cap counterclockwise to the detent This procedure allows any residual pres sure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remove it cC Hard water or salt water is harmful to the engine parts You may use distilled water if you can t get soft water 1 Place the machine on a level place and hold it in an upright position 2 Remove 9Radiator...

Page 53: ...ompletely 4 Clean 9Cooling system Thoroughly flush the cooling system with clean tap water 5 Install 9Copper washer 9Coolant drain bolt 6 Fill 9Radiator 9Engine To specified level Recommended coolant High quality ethylene glycol anti freeze containing anti corrosion for aluminum engine Coolant 1 1 and water soft water 2 2 mixing ratio 50 50 Coolant capacity 1 00 L 0 88 Imp qt 1 06 US qt 10 Nm 1 0 ...

Page 54: ...nt EC355000 RADIATOR CAP INSPECTION 1 Inspect 9Seal radiator cap 1 9Valve and valve seat 2 Crack Damage Replace Exist fur deposits 3 Clean or replace Handling notes of coolant The coolant is harmful so it should be handled with special care w 9When coolant splashes to your eye Thoroughly wash your eye with water and see your doctor 9When coolant splashes to your clothes Quickly wash it away with w...

Page 55: ... to maintain the specified pres sure for 10 seconds Replace EC357003 COOLING SYSTEM INSPECTION 1 Inspect 9Coolant level 2 Attach 9Radiator cap tester 1 and adapter 2 3 Apply the specified pressure Radiator cap tester YU 24460 01 90890 01325 Adapter YU 33984 90890 01352 Radiator cap tester YU 24460 01 90890 01325 Adapter YU 33984 90890 01352 Radiator cap opening pressure 95 125 kPa 0 95 1 25 kg cm2...

Page 56: ...welling Replace 2 Adjust 9Clutch lever free play EC359020 CLUTCH ADJUSTMENT 1 Check 9Clutch lever free play a Out of specification Adjust NOTE 9Make minute adjustment on the lever side using the adjuster 3 9After adjustment check proper operation of clutch lever Clutch lever free play a a 2 4 mm 0 08 0 16 in Clutch lever free play adjustment steps 9Loosen the locknut 1 9Turn the adjuster 2 until f...

Page 57: ...le cable end a tube guide ca ble winding portion b and roller sliding surface c Throttle grip free play adjustment steps 9Loosen the locknut 1 9Turn the adjuster 2 until the specified free play is obtained 9Tighten the locknut NOTE Before adjusting the throttle cable free play the engine idle speed should be adjusted w After adjusting turn the handlebar to right and left and make sure that the en ...

Page 58: ...ir filter element in place this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage 1 Remove 9Seat 9Fitting bolt 1 9Washer 2 9Air filter element 3 9Filter guide 4 2 Clean 9Air filter element Clean them with solvent NOTE After cleaning remove the remaining solvent by squeezing the element cC Do not twist the element when squeezing the element 1 Nm 0 1 m kg ...

Page 59: ...ter element 6 Apply 9Lithium soap base grease On the matching surface a on air filter ele ment 7 Install 9Air filter element 1 9Washer 9Fitting bolt NOTE Align the projection a on filter guide with the hole b in air filter case EC35H002 TRANSMISSION OIL LEVEL CHECK 1 Start the engine warm it up for several min utes and wait for five minutes 2 Place the machine on a level place and hold it up on up...

Page 60: ...check bolt 1 9Inspect the oil level NOTE Be sure the machine is positioned straight up when inspecting the oil level w Never attempt to remove the oil check bolt just after high speed operation The heat ed oil could spout out causing danger Wait until 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 9Inspect the g...

Page 61: ... 9Oil filler cap 2 EC35L002 PILOT AIR SCREW ADJUSTMENT 1 Adjust 9Pilot air screw 1 Recommended oil Yamalube 4 10W 30 or SAE 10W 30 type SE motor oil Oil capacity periodic oil change 0 65 L 0 57 Imp qt 0 69 US qt Adjustment steps 9Screw in the pilot air screw until it is lightly seated 9Back out by the specified number of turns Pilot air screw 1 1 4 turns out 1 1 2 turns out 20 Nm 2 0 m kg 14 ft lb...

Page 62: ...1 Damage Replace EC35R041 SILENCER FIBER REPLACEMENT 1 Remove 9Seat 9Side cover right 9Bolt silencer 1 9Silencer 2 9Bolt fiber 3 Adjustment steps 9Loosen the locknut 1 9Turn the throttle stop screw 2 until the en gine runs at the lowest possible speed 9Tighten the locknut To increase idle speed Turn the throttle stop screw 2 2 in To decrease idle speed Turn the throttle stop screw 2 2 out 5MV 9 10...

Page 63: ...m 1 0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb 7 Nm 0 7 m kg 5 1 ft lb 2 Remove 9Inner pipe 1 3 Replace 9Fiber 2 4 Install 9Inner pipe NOTE Fully apply Quick gasket Yamaha bond No 1215 or equivalent as shown Quick gasket ACC QUICK GS KT Yamaha bond No 1215 90890 85505 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 5MV 9 10 3A 6 12 00 8 26 PM Page 17 ...

Page 64: ...eservoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic tube 2 tightly to the caliper bleed screw 1 d Place the other end of the tube into a container e Slowly apply the brake lever or pedal several times f Pull the lever in or push down on the ped al Hold the lever or pedal in position g Loosen the bleed screw and allow the...

Page 65: ...in the system have disappeared j Add brake fluid to the level line on the reservoir w Check the operation of the brake after bleeding the brake system Brake lever position a a Standard position Extent of adjutment 95 mm 3 74 in 76 97 mm 2 99 3 82 in Brake lever position adjustment steps 9Loosen the locknut 1 9Turn the adjusting bolt 2 until the lever position a is within specified position 9Tighte...

Page 66: ...ght a Out of specification Adjust 2 Adjust 9Brake pedal height Brake pedal height a a 5 mm 0 20 in Pedal height adjustment steps 9Loosen the locknut 1 9Turn the adjusting nut 2 until the pedal height a is within specified height 9Tighten the locknut w 9Adjust the pedal height between the maximum Å Å and the minimum ı ı as shown In this adjustment the bolt 3 3 end b b should protrude out of the low...

Page 67: ...o not reuse the drained brake fluid 9Tighten the bleed screw 9Install the brake pads 8 and pad pin NOTE 9Install the brake pads with their projections a into the caliper recesses b 9Temporarily tighten the pad pin at this point 9Install the brake hose holder 9 and caliper 0 and tighten the pad pin q NOTE Fit the brake hose holder cut c over the pro jection d on the front fork and clamp the brake h...

Page 68: ...SPECTION AND REPLACEMENT 1 Inspect 9Brake pad thickness a Out of specification Replace as a set 2 Replace 9Brake pad 9Install the pad pin plug w Pad pin plug 3 Nm 0 3 m kg 2 2 ft lb Brake pad thickness a a Standard 6 4 mm 0 25 in Limit 1 0 mm 0 04 in Brake pad replacement steps 9Remove the protector 1 and pad pin plug 2 9Loosen the pad pin 3 9Remove the rear wheel 4 and caliper 5 Refer to FRONT WH...

Page 69: ...to the caliper recesses b 9Temporarily tighten the pad pin at this point 9Install the caliper w and rear wheel e Refer to FRONT WHEEL AND REAR WHEEL section in the CHAPTER 5 9Tighten the pad pin r 9Install the pad pin plug t and protector y Bleed screw 6 Nm 0 6 m kg 4 3 ft lb Pad pin 18 Nm 1 8 m kg 13 ft lb Pad pin plug 3 Nm 0 3 m kg 2 2 ft lb Bolt protector 7 Nm 0 7 m kg 5 1 ft lb 3 Inspect 9Brak...

Page 70: ... top is in a horizontal position 2 Inspect 9Brake fluid level Fluid at lower level Fill up a Lower level ÅFront ıRear w 9Use only designated quality brake fluid to avoid poor brake performance 9Refill with same type and brand of brake flu id mixing fluids could result in poor brake performance 9Be sure that water or other contaminants do not enter master cylinder when refilling 9Clean up spilled f...

Page 71: ... 9Master link clip 9Joint 1 9Drive chain 2 2 Clean 9Drive chain Place it in kerosene and brush off as much dirt as possible Then remove the chain from the kerosene and dry the chain 3 Measure 9Drive chain length 10 links a Out of specification Replace 4 Check 9Drive chain stiffness a Clean and oil the chain and hold as illustrated Stiff Replace drive chain Drive chain length 10 links Limit 152 5 m...

Page 72: ...e the rear wheel through several revolutions and check the slack several times to find the tightest point Check and or adjust chain slack with rear wheel in this tight chain position Drive chain slack 40 50 mm 1 6 2 0 in Drive chain lubricant SAE 10W 30 motor oil or suitable chain lubricants 5 Install 9Drive chain 1 9Joint 2 9Master link clip 3 cC Be sure to install the master link clip to the dir...

Page 73: ...3 counter clockwise To loosen Turn adjuster 3 3 clockwise and push wheel forward 9Turn each adjuster exactly the same amount to maintain correct axle alignment There are marks a on each side of chain puller align ment NOTE Turn the adjuster so that the chain is in line with the sprocket as viewed from the rear cC Too small chain slack will overload the engine and other vital parts keep the slack w...

Page 74: ... and oil seal after every run 9Apply the lithium soap base grease on the in ner tube EC36H002 FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT 1 Adjust 9Rebound damping force 9STANDARD POSITION This is the position which is back by the spe cific number of clicks from the fully turned in position Stiffer a a Increase the rebound damping force Turn the adjuster 1 1 in Softer b b Decrease the rebound damp...

Page 75: ...handling and loss of stability EC36J001 FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT 1 Remove 9Rubber cap 2 Adjust 9Compression damping force By turning the adjuster 1 Stiffer a a Increase the compression damping force Turn the adjuster 1 1 in Softer b b Decrease the compression damping force Turn the adjuster 1 1 out Minimum 20 clicks out from maximum position Extent of adjustment Maximum Full...

Page 76: ...he ad juster may be damaged w Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability 3 Install 9Rubber cap EC36K000 REAR SHOCK ABSORBER INSPECTION 1 Inspect 9Swingarm smooth action Abnormal noise Unsmooth action Grease the pivoting points or repair the pivoting points Damage Oil leakage Replace Standard position 14 clicks out 12 clicks out...

Page 77: ...before adjustment 9The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster cC Never attempt to turn the adjuster beyond the maximum or minimum setting 5 Tighten 9Locknut 6 Install 9Rear frame Stiffer Increase the spring preload Turn the adjuster 2 2 in Softer Decrease the spring pre load Turn the adjuster 2 2 out Extent of adjustment 242 260 mm 9 53 10 24 in 257 275 mm 1...

Page 78: ...the punch mark a on the ad juster with the punch mark b on the bracket For EUROPE cC Do not force the adjuster past the mini mum or maximum extent of adjustment The adjuster may be damaged Stiffer a a Increase the rebound damping force Turn the adjuster 1 1 in Softer b b Decrease the rebound damping force Turn the adjuster 1 1 out Minimum 20 clicks out from maximum position Extent of adjustment Ma...

Page 79: ...a on the ad juster with the punch mark b on the high com pression damping adjuster cC Do not force the adjuster past the mini mum or maximum extent of adjustment The adjuster may be damaged q a b a b Stiffer a a Increase the low compression damping force Turn the ad juster 1 1 in Softer b b Decrease the low compres sion damping force Turn the adjuster 1 1 out Minimum 20 clicks out from maximum pos...

Page 80: ...unch mark a on the ad juster with the punch mark b on the adjuster body cC Do not force the adjuster past the mini mum or maximum extent of adjustment The adjuster may be damaged q a b a b Stiffer a a Increase the high compression damping force Turn the ad juster 1 1 in Softer b b Decrease the high compres sion damping force Turn the adjuster 1 1 out Minimum 2 turns out from maximum position Exten...

Page 81: ...the rim 9If the tire valve stem is found tilted the tire is considered to be slipping off its position Correct the tire position EC36S002 SPOKES INSPECTION AND TIGHTENING 1 Inspect 9Spokes 1 Bend Damage Replace Loose spoke Retighten 2 Tighten 9Spokes NOTE Be sure to retighten these spokes before and af ter break in After a practice or a race check spokes for looseness EC36T000 WHEEL INSPECTION 1 I...

Page 82: ...orth Free play Adjust steering head 3 Check 9Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steering ring nut 4 Adjust 9Steering ring nut Steering ring nut adjustment steps 9Remove the number plate 9Remove the handlebar and handle crown 9Loosen the ring nut 1 using the ring nut wrench 2 9Tighten the ring nut 3 using ring nut wrench 4 NOTE Set the torque wrench to the...

Page 83: ... upper handlebar holder should be installed with the punched mark a forward 9Insert the end of fuel breather hose 0 into the hole of the number plate cC First tighten the bolts on the front side of the handlebar holder and then tighten the bolts on the rear side Ring nut wrench YU 33975 90890 01403 Ring nut initial tightening 38 Nm 3 8 m kg 27ft lb Steering shaft nut 145 Nm 14 5 m kg 105 t lb Hand...

Page 84: ...dlebar contact 6 Drive chain 7 Throttle roller sliding surface 8 Tube guide cable winding portion 9 Throttle cable end 0 Clutch cable end Å Use Yamaha cable lube or equivalent on these areas ı Use SAE10W 30 motor oil or suitable chain lubricants Ç Lubricate the following areas with high quali ty lightweight lithium soap base grease cC Wipe off any excess grease and avoid get ting grease on the bra...

Page 85: ...park plug insulator will become sooty even if the engine and carburetor are in good operating condition 3 Measure 9Plug gap a Use a wire gauge or thickness gauge Out of specification Regap 4 Clean the plug with a spark plug cleaner if necessary 5 Tighten 9Spark plug NOTE 9Before installing a spark plug clean the gasket surface and plug surface 9Finger tighten a the spark plug before torquing to sp...

Page 86: ...ns 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 clockwise until the dial gauge indicates that the piston is at a specified distance from TDC 6 Check 9Ignition timing Punch mark a on rotor should be aligned with punch mark b on stator Not aligned Adjust Dial g...

Page 87: ...Ignition timing Adjustment steps 9Loosen the screws stator 1 9Align the punch mark on the rotor with punch mark on the stator 2 by moving the stator 9Tighten the screws stator Screw stator 8 Nm 0 8 m kg 5 8 ft lb 5MV 9 10 3B 6 12 00 8 23 PM Page 21 ...

Page 88: ... band 1 Remove on fuel tank side 4 Bolt fuel tank 2 5 Fuel tank 1 6 Side cover left 1 Refer to REMOVAL POINTS 7 Side cover right 1 8 Number plate 1 1 4 3 Extent of removal 1 Seat removal 2 Fuel tank removal 3 Side covers removal 4 Number plate removal 2 3 7 Nm 0 7 m kg 5 1 ft lb 3 Nm 0 3 m kg 2 2 ft lb 3 Nm 0 3 m kg 2 2 ft lb 3 Nm 0 3 m kg 2 2 ft lb 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb ...

Page 89: ...cover 1 Remove 9 Side cover left and right 1 cC Be sure to remove the seat before remov ing the side cover If you remove the side cover with force without removing the seat the panel 2 2 on the inside may contact the air cleaner case and come off 5MV 9 10 4A 6 12 00 8 16 PM Page 3 ...

Page 90: ...er right Refer to SEAT FUEL TANK AND removal SIDE COVERS section 1 Bolt silencer 2 2 Silencer 1 3 Tension spring 2 4 Bolt exhaust pipe 2 5 Exhaust pipe 1 1 Extent of removal 1 Silencer removal 2 Exhaust pipe removal 2 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 10 Nm 1 0 m kg 7 2 ft lb 7 Nm 0 7 m kg 5 1 ft lb 5MV 9 10 4A 6 12 00 8 16 PM Page 4 ...

Page 91: ... to SEAT FUEL TANK AND SIDE COVERS section 1 Panel 2 Refer to REMOVAL POINTS 2 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 EC450001 RADIATOR Extent of removal 1 Radiator removal 1 1 Nm 0 1 m kg 0 7 ft lb 1 Nm 0 1 m kg 0 7 ft lb 5MV 9 10 4A 6 12 00 8 16 PM Pag...

Page 92: ...r clockwise to the detent This procedure al lows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning coun terclockwise and remove it EC453000 REMOVAL POINTS EC453200 Panel 1 Remove 9Panel 1 NOTE 9Unhook the panel first on the outer side a and then on the inner side 9Take care not to bend the panel more than nec essary EC454000 INSPECTION EC444100 ...

Page 93: ...diator hose 4 3 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 3 Install 9Radiator left 1 9Bolt radiator left 2 9Radiator hose 2 3 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 4 Tighten 9Clamp radiator hose 1 3 4 5 Install 9Panel 1 NOTE 9Take care not to bend the panel more than nec essary 9Hook the panel first on the inner side a and then on the outer side 1 Nm 0 1 m kg 0 7 ft...

Page 94: ...l tank Refer to SEAT FUEL TANK AND removal SIDE COVERS section 1 Clamp carburetor joint 2 Loosen the screws carburetor joint 2 Carburetor 1 3 Carburetor joint 1 4 Reed valve assembly 1 5 Stopper reed valve 2 6 Reed valve 2 1 Extent of removal 1 Carburetor removal 2 Reed valve removal 2 10 Nm 1 0 m kg 7 2 ft lb 1 Nm 0 1 m kg 0 7 ft lb 5MV 9 10 4A 6 12 00 8 16 PM Page 8 ...

Page 95: ...r top 1 2 Throttle valve 1 Refer to REMOVAL POINTS 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 0 Main jet 1 q Main jet holder 1 w Pilot jet 1 e Starter plunger 1 r Throttle stop screw 1 t Pilot air screw 1 Extent of removal 1 Carburetor disassembly 1 5MV 9 10 4A 6 12 00 8 16 PM Page 9 ...

Page 96: ... compressing the spring throttle valve disconnect the throttle cable EC464000 INSPECTION EC464140 Carburetor 1 Inspect 9Carburetor body Contamination Clean cC When cleaning the main air passage a a do not blow air at the filter side because it will clog the passage with mud or sand NOTE 9Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air 9Never use a wir...

Page 97: ...TE Insert the throttle valve 1 into the carburetor body and check for free movement EC464401 Jet needle 1 Inspect 9Jet needle 1 Bends Wear Replace 9Clip groove Free play exists Wear Replace 9Clip position Standard clip position No 3 Groove 2 Inspect 9Main jet 1 9Main jet holder 2 9Pilot jet 3 Contamination Clean NOTE 9Use a petroleum based solvent for cleaning Blow out all passages and jets with c...

Page 98: ...el gauge ver tically when measuring the fuel level 9If the fuel level is not within specification in spect the valve seat and needle valve 9If either is worn replace them both 9If both are fine adjust the fuel level by bend ing the float tab b on the float 9Recheck the fuel level EC464802 Fuel level 1 Measure 9Fuel level a Out of specification Adjust Fuel level 13 5 14 5 mm 0 53 0 57 in Above the ...

Page 99: ...all the reed valve with the reed valve bend ing as shown 9Note the cut a in the lower corner of the reed and stopper plate cC Tighten each screw gradually to avoid warping Valve stopper height 8 2 8 6 mm 0 323 0 339 in 1 Nm 0 1 m kg 0 7 ft lb EC464600 Float 1 Inspect 9Float 1 Damage Replace EC464701 Reed valve 1 Measure 9Reed valve bending a Out of specification Replace Reed valve bending limit 0 ...

Page 100: ...nt 1 9Bolt carburetor joint 2 EC4652C2 Carburetor 1 Install 9Throttle stop screw 1 9Locknut 2 9Pilot air screw 3 Pilot air screw 1 1 4 turns out 1 1 2 turns out Note the following installation points 9Screw in the pilot air screw until it is lightly seated 9Back out it by the specified number of turns For EUROPE 10 Nm 1 0 m kg 7 2 ft lb 2 Install 9Starter plunger 1 5MV 9 10 4A 6 12 00 8 17 PM Page...

Page 101: ...lve 1 9Float 2 9Float pin 3 9Screw float pin 4 9Needle jet cover 5 NOTE 9After installing the needle valve to the float in stall them to the carburetor 9Check the float for smooth movement 5 Install 9Float chamber 1 9Plate 2 9Screw float chamber 3 6 Install 9Jet needle 1 9Needle holder 2 To throttle valve 3 5MV 9 10 4A 6 12 00 8 17 PM Page 15 ...

Page 102: ...he needle holder 6 8 Install 9Mixing chamber top 1 9Screw mixing chamber top 2 To carburetor 3 NOTE After installing check the throttle grip for smooth movement 9 Install 9Air vent hose 1 9Overflow hose 2 9Clamp 3 NOTE Pass the air vent hose at the rear on the air cleaner side of the throttle cable 4 EC465352 Carburetor installation 1 Install 9Carburetor 1 NOTE Install the projection between the c...

Page 103: ...ir filter joint 1 9Screw carburetor joint 2 3 Clamp 9Air vent hose 1 9Overflow hose 2 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 4 Adjust 9Idle speed Refer to IDLE SPEED ADJUSTMENT section in the CHAPTER 3 5MV 9 10 4A 6 12 00 8 17 PM Page 17 ...

Page 104: ...adiator Refer to RADIATOR section Radiator hose 3 Disconnect at right side radiator then shift the radiators forward 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 POINTS 7 Nut cylinder 4 8 Cylinder 1 Extent of removal 1 Cylinder head removal 2 Cylin...

Page 105: ...MOVAL POINTS 4 Small end bearing 1 5 Piston ring 1 6 Power valve cover 1 7 Thrust plate 1 8 Bolt link lever 1 9 Valve shaft 1 10 Collar 2 11 Link lever 1 12 Spring 2 13 Power valve 1 1 14 Power valve 2 1 Extent of removal 1 Piston and piston ring removal 2 Power valve removal 2 1 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 8 Nm 0 8 m kg 5 8 ft lb 5MV 9 10 4A 6 12 00 8 1...

Page 106: ...an rag to prevent the pis ton pin clip from falling into the crankcase cav ity 2 Remove 9Piston pin 1 9Piston 2 9Small end bearing 3 NOTE Before removing the piston pin deburr the clip groove and pin hole area If the piston pin groove is deburred and piston pin is still difficult to remove use the piston pin puller 4 cC Do not use a hammer to drive the piston pin out 3 Remove 9Piston ring 1 NOTE T...

Page 107: ...d re surface ment steps 9Attach a straightedge 1 and a thickness gauge 2 on the cylinder head 9Measure the warpage 9If the warpage is out of specification resur face the cylinder head 9Place 400 600 grit wet sandpaper 3 on the surface plate and re surface the head 4 using a figure eight sanding pattern NOTE Rotate the cylinder head several times to avoid removing too much material from one side EC...

Page 108: ... Repair or replace Use 400 600 grit wet sandpaper cC Do not rebore the cylinder 3 Measure 9Cylinder bore C Use cylinder gauge 1 Out of limit Replace NOTE Measure the cylinder bore C in parallel A B C to and at right angles to the crankshaft a b Then find the average of the measurements 17 5 mm 53 957 53 972 mm 0 69 in 2 1243 2 1249 in Standard Wear limit Cylinder 54 000 54 014mm 54 1 mm bore C 2 1...

Page 109: ...place in the piston 2 There should be no noticeable for the play Free play exists Replace piston pin and or piston 4 Install 9Small end bearing 9Piston pin Into the small end of connecting rod 5 Check 9Free play There should be no noticeable free play Free play exists Inspect the connecting rod for wear Replace the pin and or con necting rod as required Piston pin outside diameter Standard Limit 1...

Page 110: ... 1 Out of limit Replace piston and or ring NOTE Check at several points EC474602 Piston clearance 1 Calculate 9Piston clearance Out of limit Replace piston and piston ring and or cylinder Refer to Cylinder and Piston Ring end gap installed Standard Limit 0 5 0 7 mm 1 2mm 0 020 0 028 in 0 047 in Side clearance Standard Limit 0 035 0 080 mm 0 1mm 0 0014 0 0031 in 0 004 in PISTON CLEARANCE CYLINDER B...

Page 111: ...rd Limit 0 040 0 045 mm 0 1 mm 0 0016 0 0018 in 0 004 in Cylinder mark a 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 D 54 012 54 014 mm 2 1265 2 1265 in Piston mark a a color Piston size A red 53 957 53 960 mm 2 1243 2 1244 in B orange 53 961 53 964 mm 2 1244 2 1246 in C green 53 965 53 968 mm 2 1246 2 1247 in D purple...

Page 112: ...n Replace EC474901 Power valve hole on cylinder 1 Remove 9Carbon deposits From power valve hole surface a NOTE Do not use a sharp instrument Avoid scratching the aluminum EC475000 ASSEMBLY AND INSTALLATION EC4751A0 Power valve 1 Install 9Power valve 1 1 9Power valve 2 2 9Bolt power valve 3 NOTE Install the power valve at cut away faced a for down side 8 Nm 0 8 m kg 5 8 ft lb 5MV 9 10 4B 6 12 00 8 ...

Page 113: ...l lip 3 Install 9Thrust plate 1 9Screw thrust plate 2 4 Check 9Power valve smooth movement Unsmooth movement Repair or replace 5 Install 9Gasket power valve cover 1 9Power valve cover 2 9Screw power valve cover 3 9YPVS breather hose 4 NOTE 9Install the power valve cover so that the arrow mark a faces upward 9Install the clamp of the YPVS breather hose with its opening portion b facing backward 4 N...

Page 114: ...OTE 9Apply the engine oil onto the bearing crank shaft and connecting rod and connecting rod big end washers 9Install the gasket with the seal print side toward the crankcase 3 Install 9Piston 1 9Piston pin 2 9Piston pin clip 3 NOTE 9The arrow a on the piston dome must point to exhaust side 9Before installing the piston pin clip cover the crankcase with a clean rag to prevent the pis ton pin clip ...

Page 115: ...bolt push rod 9Do not forget to remove the collar EC4753A1 Cylinder head and cylinder 1 Apply 9Engine oil To piston 1 piston ring 2 and cylinder surface 2 Install 9Cylinder 1 cC Make sure the piston ring is properly posi tioned Install the cylinder with one hand while compressing the piston ring with the other hand NOTE After installing check the smooth movement of the piston 30 Nm 3 0 m kg 22 ft ...

Page 116: ...racket 3 9Engine mounting bolt upper 4 9 Install 9Spark plug 1 9Spark plug cap 2 9Radiator hose 2 3 28 Nm 2 8 m kg 20 ft lb 34 Nm 3 4 m kg 24 ft lb 34 Nm 3 4 m kg 24 ft lb 20 Nm 2 0 m kg 14 ft lb 5 Install 9Gasket power valve housing 9Power valve housing 1 9Bolt power valve housing 2 6 Install 9O ring 1 NOTE Apply the lithium soap base grease on the O rings 5 Nm 0 5 m kg 3 6 ft lb 1 Nm 0 1 m kg 0 ...

Page 117: ...al Shift the brake pedal downward Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Screw clutch spring 5 3 Clutch spring 5 4 Pressure plate 1 5 Push rod 1 6 Plain washer 2 7 Bearing 1 8 Friction plate 8 9 Clutch plate 7 Extent of removal 1 Clutch plate and friction plate removal EC490000 CLUTCH AND PRIMARY DRIVEN GEAR EC498000 CLUTCH PLATE AND FRICTION PLATE 1 10 Nm 1 0 m kg 7 2 ft lb 10 ...

Page 118: ...tch boss 1 Use special tool 2 Lock washer 1 Refer to REMOVAL POINTS 3 Clutch boss 1 4 Plain washer φ34 mm 1 34 in 1 5 Primary driven gear 1 6 Bearing 1 7 Thrust plate φ36 mm 1 42 in 1 8 Push lever 1 Extent of removal 1 Primary driven gear removal 2 Push lever removal 1 2 80 Nm 8 0 m kg 58 ft lb 7 Nm 0 7 m kg 5 1 ft lb 5MV 9 10 4B 6 12 00 8 39 PM Page 12 ...

Page 119: ... housing and boss 1 Inspect 9Clutch housing 1 Cracks Wear Damage Replace 9Clutch boss 2 Scoring Wear Damage Replace EC484201 Primary driven gear 1 Check 9Circumferential play Free play exists Replace 9Gear teeth a Wear Damage Replace EC484400 Clutch spring 1 Measure 9Clutch spring free length a Out of specification Replace springs as a set Clutch holding tool YM 91042 4 4 90890 04086 5 5 Clutch sp...

Page 120: ...plate warpage Out of specification Replace clutch plate as a set Use a surface plate 1 and thickness gauge 2 EC494100 Push lever and push rod 1 Inspect 9Push lever 1 9Push rod 2 Wear Damage Replace EC494200 Clutch cover 1 Inspect 9Push rod bearing portion a Wear Damage Replace Friction plate thickness Standard Limit 2 9 3 1 mm 2 8 mm 0 114 0 122 in 0 110 in Warp limit 0 2 mm 0 008 in 5MV 9 10 4B 6...

Page 121: ... on the spacer bearing and primary driven gear inner circumference 2 Install 9Plain washer φ34 mm 1 34 in 1 9Clutch boss 2 3 Install 9Lock washer 1 9Nut clutch boss 2 NOTE Use the clutch holding tool 3 4 to hold the clutch boss å For USA and CDN Except for USA and CDN 4 Bend the lock washer 1 tab 80 Nm 8 0 m kg 58 ft lb Clutch holding tool YM 91042 3 3 90890 04086 4 4 å 5MV 9 10 4B 6 12 00 8 40 PM...

Page 122: ...rst and final while paying attention to the difference in sur face pattern 9Apply the transmission oil on the friction plates and clutch plates 10 Nm 1 0 m kg 7 2 ft lb 8 Install 9Clutch spring 1 9Screw clutch spring 2 NOTE Tighten the screws in stage using a crisscross pattern 6 Install 9Push rod 1 9Plain washer 2 9Bearing 3 To pressure plate 4 NOTE Apply the lithium soap base grease on the bear ...

Page 123: ... should be within the range a If not rein stall the push lever 3 Adjust 9Push lever position 10 Install 9Clutch cover 1 9Bolt clutch cover 2 NOTE Tighten the bolts in stage using a crisscross pattern 10 Nm 1 0 m kg 7 2 ft lb Adjustment steps 9Remove the push lever 1 from the push lever axle 2 9Re install the push lever so that the projec tion is positioned between alignment marks when pushing the ...

Page 124: ...4 37 ENG CLUTCH AND PRIMARY DRIVEN GEAR 4 Install 9Plain washer 1 9Circlip 2 5MV 9 10 4B 6 12 00 8 40 PM Page 18 ...

Page 125: ...e 4 Disconnect at water pump side Bolt push rod Refer to CYLINDER HEAD CYLINDER AND PISTON section 1 Kick starter 1 2 Crankcase cover right 1 3 Bolt Primary drive gear 1 Only loosening Refer to REMOVAL POINTS 4 Primary driven gear 1 Refer to CLUTCH AND PRIMARY DRIVEN GEAR section 5 Primary drive gear 1 EC4C0000 KICK AXLE SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C8000 PRIMARY DRIVE GEAR 1 Extent of re...

Page 126: ... 1 2 kick axle assembly 1 Refer to REMOVAL POINTS 3 Shift pedal 1 4 Shift shaft 1 5 Roller 1 6 Shift guide 1 7 Shift lever assembly 1 Refer to REMOVAL POINTS 8 Stopper lever 1 1 Extent of removal 1 Kick axle and kick idle gear removal 2 Shift shaft and stopper lever removal 2 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 5MV 9 10 4B 6 12 00 8 40 PM Page 20 ...

Page 127: ...rom the hole a in the crankcase EC4C3101 Shift guide and shift lever assembly 1 Remove 9Bolt shift guide 9Shift guide 1 9Shift lever assembly 2 NOTE The shift lever assembly is disassembled at the same time as the shift guide EC4C4000 INSPECTION EC4B4100 Kick axle and kick gear 1 Check 9Kick gear smooth movement Unsmooth movement Replace 2 Inspect 9Kick axle 1 Wear Damage Replace EC4B4200 Kick gea...

Page 128: ...sembly 1 Inspect 9Shift guide 1 9Shift lever 2 9Pawl 3 9Pawl pin 4 9Spring 5 Wear Damage Replace EC4E4100 Stopper lever 1 Inspect 9Stopper lever 1 Wear Damage Replace 9Bearing 2 Rotate outer race with a finger Rough spot Seizure Replace the stopper lever 9Torsion spring 3 Broken Replace EC484300 Primary drive gear and primary driven gear 1 Inspect 9Primary drive gear 1 9Primary driven gear 2 Wear ...

Page 129: ...stopper lever make sure that the torsion spring is in the position as shown EC4C5202 Shift guide and shift lever assembly 1 Install 9Spring 1 9Pawl pin 2 9Pawl 3 To shift lever 4 2 Install 9Shift lever assembly 1 To shift guide 2 3 Install 9Shift lever assembly 1 9Shift guide 2 NOTE 9The shift lever assembly is installed at the same time as the shift guide 9Apply the transmission oil on the bolt s...

Page 130: ...ake sure the stopper a of the torsion spring fits into the hole b on the kick axle 2 Install 9Spring guide 1 NOTE Slide the spring guide into the kick axle make sure the groove a in the spring guide fits on the stopper of the torsion spring 3 Install 9Kick axle assembly 1 NOTE 9Apply the transmission oil on the kick axle 9Slide the kick axle assembly into the crankcase make sure the clip 2 and kic...

Page 131: ...ference 9Install the kick idle gear with its depressed side a toward you EC4C5502 Primary drive gear 1 Install 9Primary drive gear 1 9Bolt 2 NOTE Temporarily tighten the bolt at this point 2 Install 9Primary driven gear Refer to CLUTCH AND PRIMARY DRI VEN GEAR section 3 Tighten 9Bolt primary drive gear 1 NOTE Place an aluminum plate a between the teeth of the primary drive gear 2 and driven gear 3...

Page 132: ...9Plain washer 2 9Bolt kick starter 3 NOTE Install the kick starter closest to but not contact ing the pillar tube 4 8 Install 9Shift pedal 1 9Bolt shift pedal 2 NOTE Install the shift pedal so that the top of the shift pedal outer diameter a is highest without ex ceeding the line b connecting the center of the shift shaft and screw crankcase cover left 3 9 Check 9Push lever position Refer to CLUTC...

Page 133: ...DRIVE GEAR section 1 Governor assembly 1 2 Dowel pin 1 Refer to REMOVAL POINTS 3 Retainer 1 4 Ball 4 5 Retainer weight 1 6 Plain washer 4 7 Thrust bearing 2 8 Collar 1 9 Plate 1 10 Compression spring 1 11 Governor gear 1 12 Governor shaft 1 EC4K0000 YPVS GOVERNOR 1 Extent of removal 1 YPVS governor removal and disassembly 5 Nm 0 5 m kg 3 6 ft lb 5MV 9 10 4C 6 12 00 8 33 PM Page 7 ...

Page 134: ...sher 1 9Collar 2 Wear Damage Replace EC4K4200 Bearing 1 Inspect 9Thrust bearing 1 9Plain washer 2 Wear Damage Replace EC4K5000 ASSEMBLY AND INSTALLATION EC4K5120 Governor 1 Install 9Governor gear 1 9Compression spring 2 9Plate 3 9Plain washer 4 9Thrust bearing 5 9Collar 6 9Retainer weight 7 To governor shaft 8 NOTE Apply the lithium soap base grease on the thrust bearing 5MV 9 10 4C 6 12 00 8 33 P...

Page 135: ...r and ball 3 Install 9Dowel pin 1 NOTE 9While compressing the spring install the dowel pin 9Make sure the dowel pin fits into the groove a in the retainer 4 Install 9Governor assembly 1 NOTE Align the groove a in the governor with the fork b and set the governor in the crankcase cover 5MV 9 10 4C 6 12 00 8 33 PM Page 9 ...

Page 136: ...PRIMARY DRIVE GEAR section 1 Water pump housing cover 1 2 Impeller 1 3 Plain washer 1 Refer to REMOVAL POINTS 4 Impeller shaft 1 5 Bearing 1 6 Oil seal 2 Refer to REMOVAL POINTS EC4G0000 WATER PUMP 1 2 Extent of removal 1 Impeller shaft removal 2 Oil seal removal 14 Nm 1 4 m kg 10 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 5MV 9 10 4C 6 12 00 8 33 PM Page 10 ...

Page 137: ...emove the im peller EC4G3210 Oil seal NOTE It is not necessary to disassemble the water pump unless there is an abnormality such as excessive change in coolant level discoloration of coolant or milky transmission oil 1 Remove 9Bearing 1 2 Remove 9Oil seal 1 EC4G4000 INSPECTION EC444200 Impeller shaft 1 Inspect 9Impeller shaft 1 Bend Wear Damage Replace Fur deposits Clean 5MV 9 10 4C 6 12 00 8 33 P...

Page 138: ...il seal 1 Inspect 9Oil seal 1 Wear Damage Replace EC4G5000 ASSEMBLY AND INSTALLATION EC4G5111 Oil seal 1 Install 9Oil seal 1 NOTE 9Apply the lithium soap base grease on the oil seal lip 9Install the oil seal with its manufacture s marks or numbers facing the crankcase cover right 2 2 Install 9Bearing 1 NOTE Install the bearing by pressing its outer race par allel 5MV 9 10 4C 6 12 00 8 34 PM Page 1...

Page 139: ...ft And install the shaft while turn ing it 2 Install 9Plain washer 1 9Impeller 2 NOTE Hold the impeller shaft on its width across the flats a with spanners etc and install the im peller 3 Install 9Dowel pin 1 9Gasket water pump housing cover 2 4 Install 9Water pump housing cover 1 9Bolt water pump housing cover 2 9Copper washer coolant drain bolt 3 9Coolant drain bolt 4 10 Nm 1 0 m kg 7 2 ft lb 10...

Page 140: ...section Bolt Radiator left Refer to RADIATOR section Disconnect the CDI magneto lead 1 Crankcase cover left 1 2 Nut rotor 1 Use special tool 3 Rotor 1 Refer to REMOVAL POINTS 4 Stator 1 5 Woodruff key 1 EC4L0000 CDI MAGNETO 1 Extent of removal 1 CDI magneto removal 8 Nm 0 8 m kg 5 8 ft lb 33 Nm 3 3 m kg 24 ft lb 5 Nm 0 5 m kg 3 6 ft lb 5MV 9 10 4C 6 12 00 8 34 PM Page 14 ...

Page 141: ...Inspect 9Rotor inner surface a 9Stator outer surface b Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace CDI magneto and or stator EC4L4200 Woodruff key 1 Inspect 9Woodruff key 1 Damage Replace EC4L5000 ASSEMBLY AND INSTALLATION EC4L5172 CDI magneto 1 Install 9Stator 1 9Screw stator 2 NOTE Temporarily tighten the screw stator at this point Rotor holding tool YU 1235 ...

Page 142: ... rotor align the keyway c of the rotor with the woodruff key 3 Install 9Plain washer 1 9Nut rotor 2 Use the rotor holding tool 3 4 Adjust 9Ignition timing Refer to IGNITION TIMING CHECK sec tion in the CHAPTER 3 5 Tighten 9Screw stator 1 6 Check 9Ignition timing Re check the ignition timing 33 Nm 3 3 m kg 24 ft lb Rotor holding tool YU 1235 90890 01235 8 Nm 0 8 m kg 5 8 ft lb Ignition timing B T D...

Page 143: ...cover left 9Crankcase cover left 1 9Screw crankcase cover left 2 NOTE Tighten the screws in stage using a crisscross pattern 8 Install 9Gasket crankcase cover left 9Crankcase cover left 1 9Screw crankcase cover left 2 NOTE Tighten the screws in stage using a crisscross pattern 5 Nm 0 5 m kg 3 6 ft lb 5MV 9 10 4C 6 12 00 8 34 PM Page 17 ...

Page 144: ... Disconnect at engine side Radiator hose 2 Disconnect at cylinder head side Radiator hose 4 Disconnect at water pump side Bolt radiator Refer to RADIATOR section Radiator hose 3 Disconnect at right side radiator then shift the radiators forward Spark plug cap Disconnect the CDI magneto lead EC4M0000 w Support the machine securely so there is no dan ger of it falling over 26 Nm 2 6 m kg 19 ft lb 34...

Page 145: ...AL POINTS 4 Drive sprocket 1 5 Clip 1 6 Bolt brake pedal 1 7 Brake pedal 1 8 Engine bracket 2 9 Engine mounting bolt 3 10 Pivot shaft 1 Refer to REMOVAL POINTS 11 Engine 1 1 26 Nm 2 6 m kg 19 ft lb 34 Nm 3 4 m kg 24 ft lb 69 Nm 6 9 m kg 50 ft lb 69 Nm 6 9 m kg 50 ft lb 85 Nm 8 5 m kg 61 ft lb 60 Nm 6 0 m kg 43 ft lb 5 Nm 0 5 m kg 3 6 ft lb 5MV 9 10 4C 6 12 00 8 34 PM Page 19 ...

Page 146: ...ve chain 2 NOTE Remove the drive sprocket together with the dri ve chain EC4M3301 Engine removal 1 Remove 9Pivot shaft 1 NOTE If the pivot shaft is pulled all the way out the swingarm will come loose If possible insert a shaft of similar diameter into the other side of the swingarm to support it 2 Remove 9Engine 1 From right side NOTE Make sure that the couplers hoses and cables are disconnected 5...

Page 147: ... pivot shaft EC4M5211 Brake pedal 1 Install 9Spring 1 9Brake pedal 2 9O ring 3 9Bolt brake pedal 4 9Clip 5 NOTE 9Apply the lithium soap base grease on the bolt O rings and brake pedal bracket 9Install the clip with its stopper portion a facing inward EC4M5311 Drive sprocket 1 Install 9Drive sprocket 1 9Drive chain 2 NOTE Install the drive sprocket together with the drive chain 85 Nm 8 5 m kg 61 ft...

Page 148: ... 1 9Nut drive sprocket 2 NOTE Tighten the nut while applying the rear brake 3 Bend the lock washer tab to lock the nut 4 Install 9Chain cover 1 9Screw chain cover 2 5 Nm 0 5 m kg 3 6 ft lb 60 Nm 6 0 m kg 43 ft lb 5MV 9 10 4C 6 12 00 8 34 PM Page 22 ...

Page 149: ...to CDI MAGNETO section 1 Segment 1 Refer to REMOVAL POINTS 2 Bolt L 50 mm 1 97 in 4 3 Bolt L 60 mm 2 36 in 6 4 Bolt L 70 mm 2 76 in 2 5 Holder 1 6 Crankcase right 1 Use special tool 7 Crankcase left 1 Refer to REMOVAL POINTS 8 Crankshaft 1 Use special tool Refer to REMOVAL POINTS 9 Oil seal 2 10 Bearing 2 Refer to REMOVAL POINTS EC4N0000 1 2 3 Extent of removal 1 Crankcase separation 2 Crankshaft ...

Page 150: ...may be backed out slightly to level tool body 9As pressure is applied alternately tap on the front engine mounting boss and transmission shafts cC Use soft hammer to tap on the case half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If one end hangs up take pressure off the push screw re align and sta...

Page 151: ...e crankcase by pressing its inner race as shown in å 9If the bearing is removed together with the crankshaft remove the bearing using a general bearing puller 2 as shown in 9Do not use the removed bearing EC4N4000 INSPECTION EC4N4101 Crankcase 1 Inspect 9Contacting surface a Scratches Replace 9Engine mounting boss b crankcase Cracks Damage Replace Crankcase separating tool YU 1135 A 90890 01135 Cr...

Page 152: ...ugh spot Seizure Replace 3 Inspect 9Oil seal 1 Damage Replace EC4N4202 Crankshaft 1 Measure 9Runout limit a 9Small end free play limit b 9Connecting rod big end side clearance c 9Crank width d Out of specification Replace Use the dial gauge and a thickness gauge EC4N5000 ASSEMBLY AND INSTALLATION EC4N5300 Crankshaft bearing 1 Install 9Bearing 1 To crankcase left and right NOTE Install the bearing ...

Page 153: ...USA and CDN NOTE 9Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other Operate the installing tool until the crankshaft bottoms against the bear ing 9Before installing the crankshaft clean the con tacting surface of crankcase 9Apply the lithium soap base grease on the oil seal lip cC Do not use a hammer to drive in the crank shaft Cra...

Page 154: ...ring 2 9Crankcase right 3 To crankcase left 4 NOTE 9Fit the crankcase right onto the crankcase left Tap lightly on the case with soft hammer 9When installing the crankcase the connecting rod should be positioned at TDC top dead center 5 Install 9Clamp 1 9Bolt crankcase 2 NOTE Tighten the crankcase tightening bolts in stage using a crisscross pattern Quick gasket ACC QUICK GS KT Yamaha bond No 1215...

Page 155: ...e dowel pin b 9Turn the segment clockwise until it stops and tighten the bolt 8 Remove 9Sealant Forced out on the cylinder mating surface 9 Apply 9Engine oil To the crank pin bearing oil delivery hole and connecting rod big end washer 10 Check 9Crankshaft and transmission operation Unsmooth operation Repair 30 Nm 3 0 m kg 22 ft lb 10 Nm 1 0 m kg 7 2 ft lb 5MV 9 10 4D 6 13 00 3 19 PM Page 7 ...

Page 156: ...ate 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 8 Drive axle 1 Refer to REMOVAL POINTS EC4H0000 Extent of removal 1 Shift cam and shift fork removal 2 Main axle and drive axle removal 1 2 ü ý þ 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 5MV 9 10 4D 6 13 00 3 19 ...

Page 157: ...ly carefully Note the position of each part Pay particular attention to the lo cation and direction of shift forks EC4H4000 INSPECTION EC4H4200 Gears 1 Inspect 9Matching dog a 9Gear teeth b 9Shift fork groove c Wear Damage Replace 2 Check 9Gears movement Unsmooth movement Repair or replace EC4H4600 Bearing 1 Inspect 9Bearing 1 Rotate inner race with a finger Rough spot Seizure Replace 5MV 9 10 4D ...

Page 158: ...TE For a malfunctioning shift fork replace not only the shift fork itself but the two gears each adja cent to the shift fork EC4H5000 ASSEMBLY AND INSTALLATION EC4H5202 Transmission 1 Install 95th pinion gear 23T 1 93rd 4th pinion gear 17T 21T 2 96th pinion gear 24T 3 92nd pinion gear 15T 4 To main axle 5 NOTE 9Apply the molybdenum disulfide oil on the 5th and 6th pinion gears inner circumference ...

Page 159: ...ansmission oil on the 5th and 6th wheel gears inner circumference 3 Install 9Plain washer 1 9Circlip 2 NOTE 9Be sure the circlip sharp edged corner a is po sitioned opposite side to the plain washer and gear b 9Be sure the circlip end c is positioned at axle spline groove d 4 Install 9Main axle 1 9Drive axle 2 NOTE 9Apply the lithium soap base grease on the crankcase oil seal lip 9When installing ...

Page 160: ... axle 9Mesh the shift fork 2 with the 3rd 4th pinion gear 5 on the main axle 2 Install 9Shift cam 1 NOTE Apply the transmission oil on the shift cam 3 Install 9Guide bar short 1 9Guide bar long 2 NOTE 9Apply the transmission oil on the guide bars 9Be sure the long bar is inserted into the shift forks 1 and 3 and the short one into 2 4 Check 9Shifter operation 9Transmission operation Unsmooth opera...

Page 161: ...ront wheel 1 7 Collar 2 8 Oil seal 2 9 Bearing 2 Refer to REMOVAL POINTS 10 Brake disk 1 EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL 2 1 3 3 Extent of removal 1 Front wheel removal 2 Wheel bearing removal 3 Break disc removal w Support the machine securely so there is no dan ger of it falling over 23 Nm 2 3 m kg 17 ft lb 23 Nm 2 3 m kg 17 ft lb 10 Nm 1 0 m kg 7 2 ft l...

Page 162: ...cing the removal suitable stand under the engine 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Chain puller 2 4 Rear wheel 1 Refer to REMOVAL POINTS 5 Collar 2 6 Driven sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 2 Refer to REMOVAL POINTS 10 Brake disk 1 2 1 3 3 w Support the machine securely so there is no dan ger of it falling over 125 Nm 12 5 m kg 90 ft lb 14 Nm 1 4 m kg 10 ft lb 42 Nm 4 2 m ...

Page 163: ... 9Bearing 1 NOTE Remove the bearing using a general bearing puller 2 EC594000 INSPECTION EC514100 Wheel 1 Measure 9Wheel runout Out of limit Repair Replace 2 Inspect 9Bearing Rotate inner race with a finger Rough spot Seizure Replace NOTE Replace the bearings oil seal and wheel collar as a set Wheel runout limit Radial 1 1 2 0mm 0 08 in Lateral 2 2 2 0mm 0 08 in 5MV 9 10 5A 6 12 00 8 45 PM Page 5 ...

Page 164: ... Measure 9Brake disc deflection only rear brake disc Use the dial gauge 1 Out of specification Inspect wheel runout If wheel runout is in good condition re place the brake disc 2 Measure 9Brake disc thickness a Out of limit Replace Wheel axle bending limit 0 5 mm 0 020 in Disc wear limit Standard Limit Front 3 0 mm 0 12 in 2 5 mm 0 10 in Rear 4 0 mm 0 16 in 3 5 mm 0 14 in Disc deflection limit Sta...

Page 165: ...rst 9Install the oil seal with its manufacture s marks or numbers facing outward cC Do not strike the inner race of the bearing Contact should be made only with the out er race 2 Install 9Brake disc 1 9Bolt brake disc 2 NOTE Tighten the bolts in stage using a crisscross pattern 3 Install 9Collar 1 NOTE 9Apply the lithium soap base grease on the oil seal lip 9Install the collars with their projecti...

Page 166: ... several times with the front brake applied 8 Install 9Brake hose 1 To brake hose holder 2 NOTE Before tightening the bolt brake hose holder align the top a of the brake hose neck with the brake hose holder bottom b Then pass the brake hose in front of the axle boss c and fit it into the hose groove d so that the brake hose does not contact the nut wheel axle 105 Nm 10 5 m kg 75 ft lb 23 Nm 2 3 m ...

Page 167: ...f the bearing 9Right side of bearing shall be installed first 9Install the oil seal with its manufacture s marks or numbers facing outward cC Do not strike the inner race of the bearing Contact should be made only with the out er race 2 Install 9Brake disc 1 9Bolt brake disc 2 NOTE Tighten the bolts in stage using a crisscross pattern 9 Install 9Hose cover 1 9Plain washer 2 9Bolt hose cover M8 3 9...

Page 168: ...hium soap base grease on the oil seal lip 5 Install 9Wheel NOTE Install the brake disc 1 between the brake pads 2 correctly 6 Install 9Drive chain 1 NOTE Push the wheel 2 forward and install the drive chain 7 Install 9Chain puller left 1 9Wheel axle 2 NOTE 9Install the chain puller left and insert the wheel axle from left side 9Apply the lithium soap base grease on the wheel axle 42 Nm 4 2 m kg 30...

Page 169: ...xle 3 NOTE Temporarily tighten the nut wheel axle at this point 9 Adjust 9Drive chain slack a Refer to DRIVE CHAIN SLACK ADJUSTMENT section in the CHAPTER 3 10 Tighten 9Nut wheel axle 1 9Locknut 2 125 Nm 12 5 m kg 90 ft lb Drive chain slack 40 50 mm 1 6 2 0 in 5MV 9 10 5A 6 12 00 8 46 PM Page 5 9 ...

Page 170: ...he caliper 8 Caliper 1 9 Brake lever 1 10 Master cylinder bracket 1 11 Master cylinder 1 EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE Extent of removal 1 Brake hose removal 2 Caliper removal 3 Master cyilinder removal w Support the machine securely so there is no dan ger of it falling over 2 1 3 3 2 9 Nm 0 9 m kg 6 5 ft lb 6 Nm 0 6 m kg 4 3 ft lb 6 Nm 0 6 m kg 4 3 ft lb 6 Nm 0 6 m kg 4...

Page 171: ...1 Loosen when disassembling the caliper 3 Caliper 1 4 Brake hose holder 2 5 Union bolt 2 6 Brake hose 1 7 Brake pedal 1 8 Reservoir tank 1 9 Reservoir hose 1 10 Master cylinder 1 Extent of removal 1 Caliper removal 2 Brake hose removal 3 Master cylinder removal w Support the machine securely so there is no dan ger of it falling over 2 1 3 3 1 4 Nm 0 4 m kg 2 9 ft lb 7 Nm 0 7 m kg 5 1 ft lb 30 Nm 3...

Page 172: ...er to REMOVAL POINTS 5 Dust seal 2 1 Refer to REMOVAL POINTS 6 Piston seal 2 1 EC5A8200 CALIPER DISASSEMBLY A Front B Rear Extent of removal 1 Front caliper disassembly 2 Rear caliper disassembly 2 1 6 Nm 0 6 m kg 4 3 ft lb 3 Nm 0 3 m kg 2 2 ft lb 18 Nm 1 8 m kg 13 ft lb 6 Nm 0 6 m kg 4 3 ft lb 18 Nm 1 8 m kg 13 ft lb 3 Nm 0 3 m kg 2 2 ft lb 5MV 9 10 5A 6 12 00 8 46 PM Page 5 12 ...

Page 173: ...aphragm 1 3 Master cylinder boot 1 4 Circlip 1 Use a long nose circlip pliers 5 Plain washer 1 6 Push rod 1 7 Master cylinder kit 1 EC5A8300 MASTER CYLINDER DISASSEMBLY A Front B Rear Extent of removal 1 Front master cylinder disassembly 2 Rear master cylinder disassembly 1 1 2 2 2 Nm 0 2 m kg 1 4 ft lb 5MV 9 10 5A 6 12 00 8 46 PM Page 5 13 ...

Page 174: ...in or pushing down on the pedal cC 9Do not reuse the drained brake fluid 9Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately EC533301 Caliper piston 1 Remove 9Caliper piston Use compressed air and proceed carefully w 9Cover piston with rag and use extreme cau tion when expelling piston from cylinder 9Never attempt to pry out piston A Front B Rear Cali...

Page 175: ...eals whenever a caliper is disassembled A Front B Rear EC5A4000 INSPECTION EC534112 Master cylinder 1 Inspect 9Master cylinder inner surface a Wear Scratches Replace master cylinder assembly Stains Clean w Use only new brake fluid A Front B Rear 2 Inspect 9Diaphragm 1 Crack Damage Replace A Front B Rear 3 Inspect 9Master cylinder piston 1 9Master cylinder cup 2 Wear Damage Score marks Replace mast...

Page 176: ...ver a caliper is disassembled EC534301 Brake hose 1 Inspect 9Brake hose 1 Crack Damage Replace EC5A5000 ASSEMBLY AND INSTALLATION w 9All internal parts should be cleaned in new brake fluid only 9Internal parts should be lubricated with brake fluid when installed 9Replace the piston seals and dust seals whenever a caliper is disassembled EC5A5800 Caliper piston 1 Clean 9Caliper 9Piston seal 9Dust s...

Page 177: ...n wall cC 9For the front caliper install the piston with its depressed side a a facing the caliper For the rear caliper install the pis ton with its shallow depressed side b b facing the caliper 9Never force to insert A Front B Rear EC5A5700 Front caliper 1 Install 9Pad support 1 9Brake pad 2 9Pad pin 3 NOTE 9Install the brake pads with their projections a into the caliper recesses b 9Temporarily ...

Page 178: ...t 1 9Brake pad 2 9Pad pin 3 NOTE 9Install the brake pads with their projections a into the caliper recesses b 9Temporarily tighten the pad pin at this point 2 Install 9Copper washer 1 9Union bolt 2 w Always use new copper washers cC Install the brake hose so that its pipe por tion a a directs as show and lightly touches the projection b b on the caliper 30 Nm 3 0 m kg 22 ft lb 23 Nm 2 3 m kg 17 ft...

Page 179: ...e hose to the caliper with the paint a a on the pipe facing the caliper and with the pipe contacting the caliper projection b b 7 Nm 0 7 m kg 5 1 ft lb 30 Nm 3 0 m kg 22 ft lb 4 Install 9Caliper 1 9Rear wheel 2 Refer to FRONT WHEEL AND REAR WHEEL section 5 Tighten 9Pad pin 3 6 Install 9Pad pin plug 4 18 Nm 1 8 m kg 13 ft lb 3 Nm 0 3 m kg 2 2 ft lb 5MV 9 10 5A 6 12 00 8 46 PM Page 5 19 ...

Page 180: ...linder cup secondary 2 To master cylinder piston 3 NOTE Apply the brake fluid on the master cylinder cup w After installing cylinder cup should be in stalled as shown direction Wrong installa tion cause improper brake performance A Front B Rear 3 Install 9Spring 1 To master cylinder piston 2 NOTE Install the spring at the smaller dia side A Front B Rear 5MV 9 10 5A 6 12 00 8 46 PM Page 5 20 ...

Page 181: ...9Apply the lithium soap base grease on the tip of the push rod 9When installing the circlip use a long nose circlip pliers A Front B Rear EC5A5310 Front master cylinder 1 Install 9Master cylinder 1 9Master cylinder bracket 2 9Bolt master cylinder bracket 3 NOTE 9Install the bracket so that the arrow mark a face upward 9First tighten the bolts on the upper side of the master cylinder bracket and th...

Page 182: ... 1 9Brake pedal 2 9O ring 3 9Bolt brake pedal 4 9Clip 5 NOTE 9Apply the lithium soap base grease on the bolt O ring and brake pedal bracket 9Install the clip with its stopper portion a fac ing inward 2 Install 9Brake lever 1 9Bolt brake lever 2 9Nut brake lever 3 NOTE Apply the lithium soap base grease on the brake lever sliding surface bolt and contacting surface of the master cylinder piston 6 N...

Page 183: ...se groove d so that the brake hose does not contact the nut wheel axle 2 Install 9Hose cover 1 9Plain washer 2 9Bolt hose cover M8 3 9Bolt hose cover M6 4 10 Nm 1 0 m kg 7 2 ft lb 16 Nm 1 6 m kg 11 ft lb 7 Nm 0 7 m kg 5 1 ft lb 4 Install 9Pin 1 9Plain washer 2 9Cotter pin 3 NOTE After installing check the brake pedal height Refer to REAR BRAKE ADJUSTMENT section in the CHAPTER 3 3 Pass the brake h...

Page 184: ...r tion a a directs as show and lightly touches the projection b b on the master cylinder 30 Nm 3 0 m kg 22 ft lb 4 Install 9Copper washer 1 9Brake hose 2 9Union bolt 3 w Always use new copper washers cC Install the brake hose so that its pipe por tion a a directs as show and lightly touches the projection b b on the master cylinder 30 Nm 3 0 m kg 22 ft lb 5MV 9 10 5B 6 13 00 3 16 PM Page 5 24 ...

Page 185: ...rwise the rubber seals may deterio rate causing leakage and poor brake per formance 9Refill with the same type of brake fluid mixing fluids may result in a harmful chemi cal reaction and lead to poor performance 9Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock cC Brake fluid may erode...

Page 186: ...r cap 1 9Screw master cylinder cap 2 Rear 9Diaphragm 9Reservoir tank cap 1 9Bolt reservoir tank 2 cC After installation while pulling the lever in or pushing down on the pedal check whether there is any brake fluid leaking where the union bolts are installed respec tively at the master cylinder and caliper A Front B Rear 5 Install rear brake only 9Protector 1 9Bolt protector 2 7 Nm 0 7 m kg 5 1 ft...

Page 187: ...e 1 Protector 1 2 Brake hose holder 2 3 Pinch bolt handle crown 2 Only loosening 4 Cap bolt 1 Loosen when disassembling the front fork 5 Pinch bolt under bracket 2 Only loosening 6 Front fork 1 EC550000 1 w Support the machine securely so there is no dan ger of it falling over Extent of removal 1 Front fork removal 4 Nm 0 4 m kg 2 9 ft lb 20 Nm 2 0 m kg 14 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 ...

Page 188: ...5 Inner tube 1 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Plain washer 1 0 Oil seal 1 q Spring guide 1 w Base valve 1 Use special tool e Damper rod 1 Refer to REMOVAL POINTS EC558000 FRONT FORK DISASSEMBLY 1 Extent of removal 1 Oil seal removal 2 Damper rod removal 2 ü ý þ ü ý þ 29 Nm 2 9 m kg 21 ft lb 1 Nm 0 1 m kg 0 7 ft lb 30 Nm 3 0 m kg 22 ft lb 55 Nm 5 5 m kg 40 ft lb 5MV 9 10 5B 6 13 ...

Page 189: ... care not to allow any foreign material to come in when the oil is re placed or when the front fork is disassem bled and reassembled 9Before removing the cap bolts or front forks be sure to extract the air from the air chamber completely EC553000 REMOVAL POINTS EC553151 Cap bolt 1 Remove 9Cap bolt 1 From the outer tube NOTE Before removing the front fork from the machine loosen the cap bolt 2 Remo...

Page 190: ...ace damper rod cC The front fork with a built in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign ma terial Use enough care not to allow any foreign material to come in when the oil is re placed or when the front fork is disassem bled and reassembled Oil seal removal steps 9Push in slowly a the inner tube just be fore it bottoms out and then pull i...

Page 191: ...t wet sandpaper Damaged oil lock piece Replace 9Inner tube bends Out of specification Replace Use the dial gauge 1 NOTE The bending value is shown by one half of the dial gauge reading w Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube EC554600 Outer tube 1 Inspect 9Outer tube 1 Score marks Wear Damage Replace Standard Limit 460 mm 455 mm 18 1 in 17 9 in Fork ...

Page 192: ...To install the damper rod into the inner tube hold the inner tube aslant If the inner tube is held vertically the damper rod may fall into it damaging the valve inside 3 Install 9Copper washer 1 9O ring 2 9Base valve 3 To inner tube 4 4 Tighten 9Base valve 1 NOTE 9Use a damper rod holder 2 to lock the damper rod 3 9Apply the LOCTITE on the base valve thread Damper rod holder YM 1423 90890 01423 55...

Page 193: ...ing 2 9Oil seal 3 9Plain washer 4 9Slide metal 5 To inner tube 6 NOTE 9Apply the fork oil on the inner tube 9When installing the oil seal use vinyl seat a with fork oil applied to protect the oil seal lip 9Install the oil seal with its manufacture s marks or number facing the axle holder side 7 Install 9Piston metal 1 NOTE Install the piston metal onto the slot on inner tube 8 Install 9Outer tube ...

Page 194: ...l seal 1 NOTE Press the oil seal into the outer tube with fork seal driver 2 11 Install 9Stopper ring 1 NOTE Fit the stopper ring correctly in the groove in the outer tube 12 Install 9Dust seal 1 NOTE Apply the lithium soap base grease on the inner tube Fork seal driver YM 01442 90890 01442 Fork seal driver YM 01442 90890 01442 5MV 9 10 5B 6 13 00 3 17 PM Page 5 34 ...

Page 195: ...low foreign materials to enter the front fork 16 After filling pump the damper rod 1 slowly up and down more than 10 times to distrib ute the fork oil 17 Fill 9Front fork oil Until outer tube top surface with recom mended fork oil once more 18 After filling pump the outer tube 1 slowly up and down about 200 mm 7 9 in stroke to distribute the fork oil once more NOTE Be careful not to excessive full...

Page 196: ...up to the top of the outer tube and bleed the front forks 20 Measure 9Oil level left and right a Out of specification Adjust NOTE Be sure to install the spring guide 2 when checking the oil level w Never fail to make the oil level adjustment between the maximum and minimum level and always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability St...

Page 197: ...fork spring with its smaller pitch end facing the cap bolt For EUROPE 9After installing the fork spring hold the damper rod end so that it will not go down 25 Install 9Cap bolt 1 Fully tighten the cap bolt onto the damper rod by hand 22 Loosen 9Rebound damping adjuster 1 NOTE 9Loosen the rebound damping adjuster finger tight 9Record the set position of the adjuster the amount of turning out the fu...

Page 198: ...panners 2 between the spacer 3 and spring guide 4 9Hold the locknut 5 and tighten the cap bolt with specified torque 27 Install 9Cap bolt 1 To outer tube NOTE Temporarily tighten the cap bolt 28 Install 9Protector guide 1 EC5552A1 Installation 1 Install 9Front fork 1 NOTE 9Temporarily tighten the pinch bolts under bracket 9Do not tighten the pinch bolts handle crown yet 29 Nm 2 9 m kg 21 ft lb 5MV...

Page 199: ...rake hose holder cut a over the projec tion b on the front fork and clamp the brake hose 6 Install 9Brake hose holder 1 9Bolt brake hose holder 2 9Protector 3 9Bolt protector 4 NOTE When installing the brake hose holder align the top a of the brake hose neck with the brake hose holder bottom b Then pass the brake hose 5 in front of the axle boss c and fit it into the hose groove d so that the brak...

Page 200: ...MOVAL POINTS 5 Throttle 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 Grip left 1 Refer to REMOVAL POINTS 11 Handlebar holder upper 2 12 Handlebar 1 1 Extent of removal 1 Handlebar removal 1 Nm 0 1 m kg 0 7 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 4 Nm 0 4 m kg 2 ...

Page 201: ...nt of removal Order Part name Q ty Remarks THROTTLE DISASSEMBLY 1 Grip cap lower 1 2 Grip cap upper 1 3 Grip assembly 1 4 Grip right 1 Refer to REMOVAL POINTS 5 Tube guide 1 1 EC5B8000 THROTTLE DISASSEMBLY 4 Nm 0 4 m kg 2 9 ft lb 5MV 9 10 5B 6 13 00 3 17 PM Page 5 41 ...

Page 202: ...e the grip which has become loose EC5B4000 INSPECTION EC5B4100 Handlebar 1 Inspect 9Handlebar 1 Bends Cracks Damage Replace w Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar EC5B5000 ASSEMBLY AND INSTALLATION EC5B5100 Throttle assembly 1 Install 9Grip right 1 Apply the adhesive on the tube guide 2 NOTE 9Before applying the adhesive wipe off grease or oil ...

Page 203: ...n the bolts on the rear side 2 Install 9Grip left 1 Apply the adhesive to the handlebar 2 NOTE 9Before applying the adhesive wipe off grease or oil on the handlebar surface a with a lac quer thinner 9Install the grip left to the handlebar so that the line b between the two arrow marks faces straight upward 3 Install 9Collar 1 9Cap cover 2 9Throttle 3 NOTE 9Apply the lithium soap base grease on the...

Page 204: ...he groove b in the roller 6 Install 9Throttle cable cap 1 9Screw throttle cable cap 2 7 Adjust 9Throttle grip free play Refer to THROTTLE CABLE ADJUST MENT section in the CHAPTER 3 8 Install 9Cap cover 1 9 Install 9Master cylinder 1 9Master cylinder bracket 2 9Bolt master cylinder bracket 3 NOTE 9Install the bracket so that the arrow mark a faces upward 9First tighten the bolt on the upper side of...

Page 205: ...s not retighten the bolts for adjustment 11 Install 9 ENGINE STOP button 1 9Clutch lever holder 2 9Bolt clutch lever holder 3 9Clamp 4 NOTE 9The ENGINE STOP button clutch lever hold er and clamp should be installed according to the dimensions shown 9Pass the ENGINE STOP button lead in the middle of the clutch holder 12 Install 9Clutch cable 1 NOTE Apply the lithium soap base grease on the clutch c...

Page 206: ... 46 CHAS HANDLEBAR 14 Clamp the clamp portion a of the number plate to the handlebar 15 Insert the end of the fuel breather hose 1 into the hole of the number plate 5MV 9 10 5C 6 12 00 8 51 PM Page 5 46 ...

Page 207: ...ecial tool Refer to REMOVAL POINTS 5 Under bracket 1 6 Ball race cover 1 7 Bearing upper 1 8 Bearing lower 1 Refer to REMOVAL POINTS 9 Ball race 2 Refer to REMOVAL POINTS Extent of removal 1 Under bracket removal 2 Bearing removal 2 1 w Support the machine securely so there is no dan ger of it falling over 23 Nm 2 3 m kg 17 ft lb 145 Nm 14 5 m kg 105 ft lb 9 Tighten ring nut 38 Nm 3 8 m kg 27 ft l...

Page 208: ...Bearing lower 1 Remove 9Bearing lower 1 Use the floor chisel 2 cC Take care not to damage the steering shaft thread EC563400 Ball race 1 Remove 9Ball race 1 Remove the ball race using long rod 2 and the hammer EC564000 INSPECTION EC564200 Steering shaft 1 Inspect 9Steering shaft 1 Bend Damage Replace Ring nut wrench YU 33975 90890 01403 5MV 9 10 5C 6 12 00 8 51 PM Page 5 48 ...

Page 209: ... races replace bearings and ball races as a set EC565000 ASSEMBLY AND INSTALLATION EC565113 Under bracket 1 Install 9Bearing lower 1 NOTE Apply the lithium soap base grease on the dust seal lip and bearing inner circumference 2 Install 9Ball race 9Bearing upper 1 9Ball race cover 2 NOTE Apply the lithium soap base grease on the bear ing and ball race cover lip 3 Install 9Under bracket 1 NOTE Apply...

Page 210: ...g it lock to lock If there is any binding remove the steering shaft assembly and inspect the steering bearings 6 Install 9Plain washer 1 7 Install 9Front fork 1 9Handle crown 2 NOTE 9Temporarily tighten the pinch bolts under bracket 9Do not tighten the pinch bolts handle crown yet 8 Install 9Plain washer 1 9Steering shaft nut 2 7 Nm 0 7 m kg 5 1 ft lb 145 Nm 14 5 m kg 105 ft lb 5MV 9 10 5C 6 12 00...

Page 211: ... little 10 Adjust 9Front fork top end a 11 Tighten 9Pinch bolt handle crown 1 9Pinch bolt under bracket 2 cC Tighten the under bracket to specified torque If torqued too much it may cause the front fork to malfunction Front fork top end standard a a 5 mm 0 20 in 23 Nm 2 3 m kg 17 ft lb 20 Nm 2 0 m kg 14 ft lb 5MV 9 10 5C 6 12 00 8 51 PM Page 5 51 ...

Page 212: ... the brake pedal backward Drive chain 1 Chain support 1 2 Chain tensioner lower 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt connecting rod 1 5 Pivot shaft 1 6 Swingarm 1 Extent of removal 1 Swingarm removal 1 w Support the machine securely so there is no dan ger of it falling over 53 Nm 5 3 m kg 38 ft lb 80 Nm 8 0 m kg 58 ft lb 19 Nm 1 9 m kg 13 ft lb 7 Nm 0 7 m kg 51 ft lb 8...

Page 213: ...al 2 6 Thrust bearing 2 7 Bush 2 8 Oil seal 8 9 Bearing 8 Refer to REMOVAL POINTS EC578000 SWINGARM DISASSEMBLY Extent of removal 1 Swingarm disassembly 2 Connecting rod removal and disassembly 3 Relay arm removal and disassembly 1 2 3 2 3 80 Nm 8 0 m kg 58 ft lb 5 Nm 0 5 m kg 3 6 ft lb 80 Nm 8 0 m kg 58 ft lb 5MV 9 10 5C 6 12 00 8 51 PM Page 5 53 ...

Page 214: ...ts Unsmooth revolution Rust Replace bearing and bush as a set 2 Inspect 9Oil seal 3 Damage Replace EC574210 Relay arm 1 Inspect 9Bearing 1 9Collar 2 Free play exists Unsmooth revolution Rust Replace bearing and collar as a set 2 Inspect 9Oil seal 3 Damage Replace EC574310 Connecting rod 1 Inspect 9Bearing 1 9Collar 2 Free play exists Unsmooth revolution Rust Replace bearing and collar as a set 2 I...

Page 215: ...seal 2 To relay arm NOTE 9Apply the molybdenum disulfide grease on the bearing when installing 9Install the bearing by pressing it on the side hav ing the manufacture s marks or numbers 3 Install 9Bearing 1 9Oil seal 2 To connecting rod NOTE 9Apply the molybdenum disulfide grease on the bearing when installing 9Install the bearing by pressing it on the side hav ing the manufacture s marks or numbe...

Page 216: ...ps 3 Install 9Collar 1 To connecting rod 2 NOTE Apply the molybdenum disulfide grease on the collar bearings and oil seal lips 4 Install 9Connecting rod 1 9Bolt connecting rod 2 9Plain washer 3 9Nut connecting rod 4 To relay arm 5 NOTE Apply the molybdenum disulfide grease on the bolt cC Install the nut on the left side of the chas sis If you make a mistake in its installation position the nut con...

Page 217: ...ay a Free play exists Replace thrust bearing 9Swingarm up and down movement b Unsmooth movement Binding Rough spots Grease or replace bearings bushes and collars 8 Install 9Bolt connecting rod 1 9Plain washer 2 9Nut connecting rod 3 NOTE 9Apply the molybdenum disulfide grease on the bolt 9Do not tighten the nut yet 9 Install 9Plain washer 1 9Bolt rear shock absorber relay arm 2 NOTE 9Apply the mol...

Page 218: ...ner lower 1 9Plain washer 2 9Collar 3 9Chain tensioner 4 9Nut chain tensioner lower 5 14 Install 9Chain support 1 9Support cover 2 9Bolt chain support R 50mm 1 97in 3 9Nut chain support 4 9Bolt support cover R 10mm 0 39in 5 80 Nm 8 0 m kg 58 ft lb 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 19 Nm 1 9 m kg 13 ft lb 80 Nm 8 0 m kg 58 ft lb 5MV 9 10 5C 6 12 00 8 51 PM Page 5 58 ...

Page 219: ... joint 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 7 Adjuster 1 8 Spring guide lower 1 9 Spring guide upper 1 10 Spring rear shock absorber 1 11 Bearing 2 Refer to REMOVAL POINTS 2 w Support the machine securely so there is no dan ger of it falling over Extent of removal 1 Rear shock absorber removal...

Page 220: ...r damage to the hose 3 Be careful not to damage any part of the gas tank A damaged gas tank will impair the damping performance or cause a malfunction 4 Take care not to scratch the contact sur face of the piston rod with the cylinder or oil could leak out 5 Never attempt to remove the plug at the bottom of the nitrogen gas tank It is very dangerous to remove the plug 6 When scrapping the shock ab...

Page 221: ...ION EC584110 Rear shock absorber 1 Inspect 9Damper rod 1 Bends Damage Replace absorber assembly 9Shock absorber 2 Oil leaks Replace absorber assembly Gas leaks Replace absorber assembly 9Spring 3 Damage Replace spring Fatigue Replace spring Move spring up and down 9Spring guide 4 Wear Damage Replace spring guide 9Bearing 5 Free play exists Unsmooth revolution Rust Replace 3 Remove 9Lower bearing 1...

Page 222: ...ressing its outer race cC Do not apply the grease on the bearing outer race because it will wear the rear shock absorber surface on which the bear ing is press fitted 2 Install 9Stopper ring upper bearing 1 NOTE After installing the stopper ring push back the bearing until it contacts the stopper ring 3 Install 9Lower bearing 1 NOTE Install the bearing by pressing it on the side hav ing the manufa...

Page 223: ...xtent of adjustment 242 260 mm 9 53 10 24 in 257 275 mm 10 12 10 83 in EC5852B3 Rear shock absorber 1 Install 9Dust seal 1 9O ring 2 9Collar 3 NOTE 9Apply the molybdenum disulfide grease on the bearing 9Apply the lithium soap base grease on the dust seals O rings and collars 2 Install 9Bush 1 9Collar 2 9Dust seal 3 NOTE 9Apply the molybdenum disulfide grease on the bearing 9Apply the lithium soap ...

Page 224: ...ulfide grease on the bolt 5 Install 9Plain washer 1 9Bolt rear shock absorber relay arm 2 NOTE 9Apply the molybdenum disulfide grease on the bolt 9Insert the bolt from right side 6 Install 9Rear frame 1 9Bolt rear frame 2 7 Tighten 9Screw air cleaner joint 1 56 Nm 5 6 m kg 40 ft lb 53 Nm 5 3 m kg 38 ft lb 29 Nm 2 9 m kg 21 ft lb 5MV 9 10 5C 6 12 00 8 52 PM Page 5 64 ...

Page 225: ... AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 ENGINE STOP button 2 Ignition coil 3 CDI unit 4 CDI magneto 5 Spark plug EC612000 WIRING DIAGRAM COLOR CODE B Black O Orange B R Brack Red B W Black White G L Green Blue G W Green White W L White Blue W R White Red 5MV 9 10 6 6 12 00 9 05 PM Page 6 1 ...

Page 226: ...nition system for connection Spark gap test No good No good No good No good No good No good No Spark Check ENGINE STOP button Pick up coil Source coil Check ignition coil Check CDI magneto Replace CDI unit Replace Replace Replace Replace Replace marked Only when the ignition checker is used NOTE 9Remove the following parts before inspection 1 Seat 2 Fuel tank 9Use the following special tools in th...

Page 227: ...rk gap until misfire occurs for USA and CDN only EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check 9Couplers and leads connection Rust Dust Looseness Short circuit Repair or replace EC625002 ENGINE STOP BUTTON INSPECTION 1 Inspect 9 ENGINE STOP button conduct Not continuous while being pushed Replace Continuous while being freed Replace Minimum spark gap 6 0 mm 0 24 in Tester lead Black Wh...

Page 228: ...eplace NOTE When inspecting the secondary coil resistance remove the spark plug cap Tester lead Orange lead 1 Tester lead Black lead 2 Tester lead Spark plug lead 1 Tester lead Orange lead 2 Primary coil Tester selector resistance position 0 14 0 20Ω at Ω 1 20 C 68 F Secondary coil Tester selector resistance position 6 7 10 1kΩ at kΩ 1 20 C 68 F 5MV 9 10 6 6 12 00 9 05 PM Page 6 4 ...

Page 229: ...fault is found replace the CDI unit Then check the electrical components again Tester lead White Red lead 1 Tester lead White Blue lead 2 Pick up coil Tester selector resistance position 248 372Ω at Ω 100 20 C 68 F Tester lead Black Red lead 1 Tester lead Green White lead 2 Source coil 1 Tester selector resistance position 720 1 080Ω at Ω 100 20 C 68 F Tester lead Green Blue lead 1 Tester lead Bla...

Page 230: ...uited to the atmos pheric conditions air pressure humidity and temperature 9Finally the rider himself must make a test run and check his machine for conditions pick up of engine speed road surface conditions and for the discoloration of the spark plug s After taking these into consideration he must select the best possible carburetor settings It is advisable to make a note of settings atmospheric ...

Page 231: ...13001 Test run After warming up the engine equipped with the standard type carburetor s and spark plug s run two or three laps of the circuit and check the smooth operation of the engine and discoloration of spark plug s å Normal Over burned too lean ç Oil fouled too rich Discoloration Condition of spark plug Normal Insulator is dry and burnt brown Over burned Insulator is whitish too lean Oil fou...

Page 232: ...ain jet 1 1 Spark plug is too hot Select a main jet having higher calibrating No than standard To be enriched 2 Spark plug is wet Select a main jet having lower calibrating No than standard To be leaned out Setting part Throttle valve opening Full closed 1 4 1 2 3 4 Full open Pilot air screw Pilot jet Diameter of straight portion Clip position Throttle valve Main jet Jet needle Standard main jet 4...

Page 233: ...mixture EC71R000 Pilot jet adjustment The air fuel mixture can basically be adjusted by the pilot air screw from full closed to 1 2 throttle If the pilot air screw is not enough for this adjust ment the pilot jet 1 is changed A larger size jet results in a richer mixture at low speeds and a smaller size in a leaner mixture Standard pilot air 1 1 4 turns out screw position 1 1 2 turns out For EUROP...

Page 234: ... plug and therefore it should be judged from your feeling of actual engine operation 1 Too rich at intermediate speeds Rough engine operation is felt and the engine will not pick up speed smoothly In this case step up the jet needle clip by one groove or 0 5 groove and move down the needle to lean out the mixture 2 Too lean at intermediate speeds The engine breathes hard and will not pick up speed...

Page 235: ...e effect as a raise of 0 5 clip position A Difference in straight portion dia B Difference in clip position a 0 5 richer b Reference needle 6BGK9 74 6BGK9 75 6BGK9 76 6BGK9 75 6BGK10 75 Standard jet needle 6BGK9 75 Diameter of straight Rich Lean Clip position portion ø2 740 mm 0 1079 in ø2 750 mm 0 1083 in ø2 760 mm 0 1087 in Rich 1 richer 6BGK9 74 4th groove 6BGK9 75 4th groove 6BGK9 76 4th groov...

Page 236: ... as a raise of 0 5 clip posi tion A Difference in straight portion dia B Difference in clip position a 0 5 richer b Reference needle 6BHY1 74 6BHY1 75 6BHY1 76 6BHY1 75 6BHY25 75 Standard jet needle 6BHY1 75 Diameter of straight Rich Lean Clip position portion ø2 740 mm 0 1079 in ø2 750 mm 0 1083 in ø2 760 mm 0 1087 in Rich 1 richer 6BHY1 74 4th groove 6BHY1 75 4th groove 6BHY1 76 4th groove 0 5 r...

Page 237: ...o the 1st tapered portion at 1 4 throttle to the second tapered portion at 1 2 throttle to the third tapered portion at 3 4 throttle and to the fourth tapered portion at full open Therefore the fuel flow is balanced at each stage of throttle opening by a combination of the jet needle diameter and clip position Example 6BGK9 75 3rd groove 6BGK9 75 2nd groove 6BGK9 76 3rd groove å Lean larger diamet...

Page 238: ...valve 3 3 5 5 5MV 14112 55 STD 5 75 5MV 14112 57 6 0 5MV 14112 60 Lean Jet needle 4 4 Rich 6BGK9 73 5A0 14116 H8 6BGK9 74 5A0 14116 H9 STD 6BGK9 75 5A0 14116 H0 6BGK9 76 5A0 14116 H1 Lean 6BGK9 77 5A0 14116 H2 Rich 6BGK10 73 5A0 14116 K8 6BGK10 74 5A0 14116 K9 6BGK10 75 5A0 14116 K0 6BGK10 76 5A0 14116 K1 Lean 6BGK10 77 5A0 14116 K2 Jet needle 4 4 Rich 6BHY1 73 5A0 14116 J8 6BHY1 74 5A0 14116 J9 S...

Page 239: ...ixture Raise jet needle clip position 1 groove up 1 4 3 4 throttle Lower jet needle clip position Hard breathing 1 groove down Lack of speed 1 4 1 2 throttle Raise jet needle clip position Slow speed pick up 1 groove up White smoke Poor acceleration Conditions General condition Sandy condition Under 10 C 15 25 C Over 30 C Under 10 C 15 25 C Over 30 C 50 F 59 77 F 86 F 50 F 59 77 F 86 F Parts Winte...

Page 240: ...te speeds procedures Poor response when Check overall settings Check air cleaner for fouling throttle is opened quickly Use main jet having lower calibration No Raise jet needle clip position 1 groove up If no effect reverse the above procedures Poor engine operation Turn in pilot air screw Check throttle valve operation This should be taken simply for an example It is necessary to set the carbure...

Page 241: ... 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 NOTE 9When checking the discoloration of spark plugs be sure to stop the engine immediately after a run and check 9Avoid racing 9When changing the heat range of spark plugs never attempt to change it more than 1 rank 9When using spark plugs other than standard make sure of t...

Page 242: ...some settings may be sacrificed Thus the settings should be matched to the portion of the course that has the greatest effect on the race result In such a case run through the entire course while mak ing notes of lap times to find the best balance then determine the secondary reduction ratio 9If a course has a long straight portion where a machine can run at maximum speed the machine is generally ...

Page 243: ...r a stony or hard road condition the tire pressure should be higher to prevent a flat tire Part name Size Part number Drive sprocket 1 1 12T 9383A 12017 STD 13T 9383A 13031 14T 9383A 14054 Driven sprocket 2 2 47T 5ET 25447 00 STD 48T 5ET 25448 00 49T 5ET 25449 00 50T 5ET 25450 00 51T 5ET 25451 00 52T 5ET 25452 00 Standard tire pressure 100 kPa 1 0 kg cm2 15 psi Extent of adjustment 60 80 kPa 0 6 0...

Page 244: ...ar the final stroke can be changed by changing the fork oil amount cC Adjust the oil level in 5 mm 0 2 in incre ments or decrements Too low oil level causes the front fork to produce a noise at full rebound or the rider to feel some pres sure on his hands or body Alternatively too high oil level will develop unexpectedly early oil lock with the consequent shorter front fork travel and deteriorated...

Page 245: ...s EC72A001 Setting of spring after replacement As the front fork setting can be easily affected by rear suspension take care so that the machine front and rear are balanced in position etc when setting the front fork 1 Use of soft spring Generally a soft spring gives a soft riding feeling Rebound damping tends to become stronger and the front fork may sink deeply over a series of gaps To set a sof...

Page 246: ...r resulting in lack of a sense of con tact with the road surface or in a vibrating handlebar To set a stiff spring 9Change the rebound damping Turn in one or two clicks 9Change the compression damping Turn out one or two clicks å Coverage of spring by weight Rider weight 1 Soft 2 Standard 3 Stiff 5MV 9 10 7 6 12 00 9 02 PM Page 18 ...

Page 247: ...f the spring SPRING SPRING I D TYPE RATE PART NUMBER MARK slits 0 380 4SS 23141 10 I I SOFT 0 390 4SS 23141 20 I II 0 400 4SS 23141 30 I III STD 0 410 4XM 23141 L0 0 420 4SS 23141 50 II STIFF 0 430 4SS 23141 60 III 0 440 4SS 23141 70 IIII TYPE thickness PART NUMBER T 2 3 mm 0 09 in 4SS 23364 L0 SPRING SPRING I D TYPE RATE PART NUMBER MARK approx slits SOFT 0 400 5ET 23141 20 V STD 0 410 5ET 23141 ...

Page 248: ...72C001 Choosing set length 1 Place a stand or block under the engine to put the rear wheel above the floor and mea sure the length a between the rear wheel axle center 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 an...

Page 249: ...ength 90 100 mm 3 5 3 9 in and set it 1 Use of soft spring 9Set the soft spring for less rebound damp ing to compensate for its less spring load Run with the rebound damping adjuster one or two clicks on the softer side and readjust it to suit your preference 2 Use of stiff spring 9Set the soft spring for more rebound damp ing to compensate for its greater spring load Run with the rebound damping ...

Page 250: ...overall length a a does not exceed the standard as it may result in faulty performance Never use one whose overall length is greater than standard å Coverage of spring by weight Rider weight 1 Soft 2 Standard 3 Stiff Length a a of standard shock 485 5 mm 19 11 in 5MV 9 10 7 6 12 00 9 02 PM Page 22 ...

Page 251: ...5DH 22212 70 Brown 1 260 STD 4 6 5DH 22212 10 Green 1 260 4 8 5DH 22212 20 Red 1 260 5 0 5DH 22212 30 Black 1 260 STIFF 5 2 5DH 22212 40 Blue 1 260 5 4 5DH 22212 50 Yellow 1 265 5 6 5DH 22212 60 Pink 1 265 SPRING SPRING I D SPRING TYPE RATE PART NUMBER COLOR FREE approx POINT LENGTH SOFT 4 6 5ET 22212 20 Green 2 275 STD 4 8 5ET 22212 00 Red 2 275 5 0 5ET 22212 10 Black 2 275 STIFF 5 2 5ET 22212 30...

Page 252: ... in Soft over entire crease damping range bottoming 1 1 Oil level oil amount Increase oil level by about 5 10 mm 0 2 0 4 out in Spring Replace with stiff spring Stiff toward stroke 1 Oil level oil amount Decrease oil level by about 5 mm 0 2 in end Soft toward stroke 1 Oil level oil amount Increase oil level by about 5 mm 0 2 in end bottoming out Stiff initial 1 1 1 1 Compression damping Turn adjus...

Page 253: ...g Turn adjuster counterclockwise about 2 clicks dragging 1 1 to decrease damping Spring Replace with soft spring Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Low compression Turn adjuster clockwise about 1 click to in damping crease damping Poor road gripping 1 High compression Turn adjuster clockwise about 1 6 turn to damping increase damping Spring set length...

Page 254: ...N JAPAN 2000 6 2 9 1 i E j YZ125N1 PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories 5MV 10 00 6 130 53PM y W 1 1 1 ...

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