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Yamaha YZ125X 2022, Owner'S Service Manual

The Yamaha YZ125X 2022, a high-performance off-road motorcycle, comes with an exceptional Owner's Service Manual that provides comprehensive guidance for maintenance and repairs. This valuable manual, available for free download from manualshive.com, ensures that owners can effortlessly access the necessary information to keep their bike in top-notch condition.

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CHASSIS

GENERAL CHASSIS

........................................................................................4-1

REMOVING THE NUMBER PLATE ...........................................................4-2
REMOVING THE SIDE COVER.................................................................4-2

FRONT WHEEL

................................................................................................4-3

REMOVING THE FRONT WHEEL.............................................................4-4
DISASSEMBLING THE FRONT WHEEL ...................................................4-4
CHECKING THE FRONT WHEEL .............................................................4-4
ASSEMBLING THE FRONT WHEEL .........................................................4-4
INSTALLING THE FRONT WHEEL ...........................................................4-5

REAR WHEEL

..................................................................................................4-7

REMOVING THE REAR WHEEL ...............................................................4-8
DISASSEMBLING THE REAR WHEEL .....................................................4-8
CHECKING THE REAR WHEEL................................................................4-8
CHECKING AND REPLACING THE REAR WHEEL SPROCKET.............4-8
ASSEMBLING THE REAR WHEEL ...........................................................4-9
INSTALLING THE REAR WHEEL..............................................................4-9

FRONT BRAKE

..............................................................................................4-11

INTRODUCTION ......................................................................................4-15
CHECKING THE FRONT BRAKE DISC ..................................................4-15
REPLACING THE FRONT BRAKE PADS ...............................................4-15
REMOVING THE FRONT BRAKE CALIPER ...........................................4-17
DISASSEMBLING THE FRONT BRAKE CALIPER .................................4-17
CHECKING THE FRONT BRAKE CALIPER............................................4-17
ASSEMBLING THE FRONT BRAKE CALIPER .......................................4-17
INSTALLING THE FRONT BRAKE CALIPER..........................................4-18
REMOVING THE FRONT BRAKE MASTER CYLINDER ........................4-19
CHECKING THE FRONT BRAKE MASTER CYLINDER.........................4-19
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER.....................4-19
INSTALLING THE FRONT BRAKE MASTER CYLINDER.......................4-20

REAR BRAKE

................................................................................................4-22

INTRODUCTION ......................................................................................4-26
CHECKING THE REAR BRAKE DISC.....................................................4-26
REPLACING THE REAR BRAKE PADS..................................................4-26
REMOVING THE REAR BRAKE CALIPER .............................................4-28
DISASSEMBLING THE REAR BRAKE CALIPER....................................4-28
CHECKING THE REAR BRAKE CALIPER ..............................................4-28
ASSEMBLING THE REAR BRAKE CALIPER..........................................4-28
INSTALLING THE REAR BRAKE CALIPER ............................................4-29
REMOVING THE REAR BRAKE MASTER CYLINDER...........................4-29
CHECKING THE REAR BRAKE MASTER CYLINDER ...........................4-30
ASSEMBLING THE REAR BRAKE MASTER CYLINDER.......................4-30
INSTALLING THE REAR BRAKE MASTER CYLINDER .........................4-31

Summary of Contents for YZ125X 2022

Page 1: ...Read this manual carefully before operating this vehicle 2022 OWNER S SERVICE MANUAL YZ125X YZ125XN LIT 11626 35 18 B1B 2819U 11 ...

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

Page 3: ...MANUAL 2022 by Yamaha Motor Corporation U S A First edition May 2021 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited P N LIT 11626 35 18 ...

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

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

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

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

Page 8: ......

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

Page 10: ......

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

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

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

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

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

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

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

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

Page 19: ...owing out and is installed to the fuel tank breather hose NOTICE ECA27110 In this installation make sure the arrow fac es the fuel tank and also downward EAM30615 COLLAR tool for YPVS This collar 1 is used to remove and install the push rod of the engine NOTICE ECA27100 Be sure to use the collar If the collar is not used the power valve constituent parts will result in damage ...

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

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

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

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

Page 24: ...th YM YU or ACC For others use tool number starting with 90890 Tool name Tool No Illustration Reference pages Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 1 11 8 5 8 6 8 6 8 7 8 7 8 7 8 8 Steering nut wrench 90890 01403 Exhaust flange nut wrench YU A9472 3 17 4 51 Spoke nipple wrench 6 7 90890 01521 Spoke nipple wrench 6 7 YM 01521 3 23 Dial gauge stand set...

Page 25: ...5 17 Flywheel puller 90890 01189 Flywheel puller YM 01189 5 16 Clutch holder 90890 04199 Universal clutch holder YM 91042 5 28 5 30 Thickness gauge 90890 03268 Feeler gauge set YU 26900 9 5 28 Flywheel puller 90890 01362 Heavy duty puller YU 33270 B 5 37 Yamaha bond No 1215 90890 85505 Three bond No 1215 5 38 Tool name Tool No Illustration Reference pages YU 01304 ...

Page 26: ...ankshaft installer bolt 90890 01275 Bolt YU 90060 5 38 5 41 Adapter M8 90890 01499 Adapter M8 YM 01499 5 38 Crankcase separating tool 90890 01135 Crankcase separator YU 01135 B 5 41 Adapter M12 90890 01278 Adapter 3 YU 90063 5 41 Tool name Tool No Illustration Reference pages YU 90058 YU 90059 ...

Page 27: ...r 90890 01352 Pressure tester adapter YU 33984 6 3 6 3 Fuel level gauge adapter 90890 01470 Fuel level gauge adapter YM 01470 7 10 Fuel level gauge 90890 01312 Fuel level gauge YM 01312 A 7 10 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 6 Tool name Tool No Illustration Reference pages YU 24460 A YU 33984 ...

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

Page 29: ...ible EAM30444 STARTER KNOB CHOKE When cold the engine requires a richer air fuel mixture for starting A separate starter circuit which is controlled by the starter knob 1 sup plies this mixture Pull the starter knob out to open the circuit for starting When the engine has warmed up push it in to close the circuit EAM30190 SIDESTAND This sidestand 1 is used to support only the machine when standing...

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

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

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

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

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

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

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

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

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

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

Page 40: ...Model Model B1BD Dimensions Overall length 2140 mm 84 3 in Overall width 825 mm 32 5 in Overall height 1285 mm 50 6 in Seat height 955 mm 37 6 in Wheelbase 1455 mm 57 3 in Ground clearance 350 mm 13 78 in Weight Curb weight 95 kg 209 lb Riding capacity 1 person ...

Page 41: ...p qt Quantity 0 66 L 0 70 US qt 0 58 Imp qt Cooling system Coolant quantity Radiator including all routes 0 90 L 0 95 US qt 0 79 Imp qt Radiator cap valve opening pressure 93 3 122 7 kPa 0 93 1 23 kgf cm 13 5 17 8 psi Spark plug s Manufacturer model NGK BR9EVX Spark plug gap 0 6 0 7 mm 0 024 0 028 in Cylinder head Warpage limit 0 03 mm 0 0012 in Cylinder Bore 54 000 54 014 mm 2 1260 2 1265 in Wear...

Page 42: ...ary reduction ratio 3 368 64 19 Transmission type Constant mesh 6 speed Gear ratio 1st 2 385 31 13 2nd 1 933 29 15 3rd 1 588 27 17 4th 1 353 23 17 5th 1 200 24 20 6th 1 095 23 21 Main axle runout limit 0 01 mm 0 0004 in Drive axle runout limit 0 01 mm 0 0004 in Secondary reduction ratio 3 846 50 13 Final drive Chain Air filter Air filter element Wet element Air filter oil grade Yamaha foam air fil...

Page 43: ...ENGINE SPECIFICATIONS 2 4 Reed valve Thickness 0 470 mm 0 0185 in Valve stopper height 8 2 8 6 mm 0 32 0 34 in Valve bending limit 0 2 mm 0 01 in ...

Page 44: ...pressure measured on cold tires Front 100 kPa 1 00 kgf cm 15 psi Rear 100 kPa 1 00 kgf cm 15 psi Front brake Type Hydraulic single disc brake Brake disc thickness limit 2 5 mm 0 10 in Brake disc runout limit as measured on wheel 0 15 mm 0 0059 in Brake pad lining thickness limit 1 0 mm 0 04 in Master cylinder inside diameter 9 52 mm 0 37 in Caliper cylinder inside diameter Left 22 65 mm 22 65 mm 0...

Page 45: ... from the start position Soft 20 Adjustment value from the start position STD 15 Adjustment value from the start position Hard 0 Rear suspension Type Swingarm link suspension Spring Coil spring Shock absorber Gas hydraulic damper Wheel travel 315 mm 12 4 in Spring preload Adjusting system Mechanical adjustable type Adjustment value Soft 1 5 mm 0 06 in Adjustment value STD 6 0 mm 0 24 in Adjustment...

Page 46: ...ent Click Adjustment value from the start position Soft 20 Adjustment value from the start position STD 13 Adjustment value from the start position Hard 0 Drive chain Size 520 Chain type Sealed type Number of links 114 Drive chain slack Maintenance Stand 48 0 58 0 mm 1 89 2 28 in 15 link length limit 239 3 mm 9 42 in ...

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

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

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

Page 50: ... 7 4 lb ft Stopper lever bolt M6 1 10 N m 1 0 kgf m 7 4 lb ft Segment M8 1 30 N m 3 0 kgf m 22 lb ft Exhaust pipe bolt M6 2 12 N m 1 2 kgf m 8 9 lb ft Exhaust pipe stay bolt front M6 1 12 N m 1 2 kgf m 8 9 lb ft Exhaust pipe stay bolt rear M6 1 12 N m 1 2 kgf m 8 9 lb ft Silencer bolt M6 1 12 N m 1 2 kgf m 8 9 lb ft Fiber bolt M6 4 10 N m 1 0 kgf m 7 4 lb ft Stator coil screw M6 3 7 N m 0 7 kgf m ...

Page 51: ...ir cap screw M4 2 1 5 N m 0 15 kgf m 1 1 lb ft Front brake hose union bolt M10 1 30 N m 3 0 kgf m 22 lb ft Front brake caliper bolt M8 2 28 N m 2 8 kgf m 21 lb ft Grip cap bolt M6 2 4 3 N m 0 43 kgf m 3 2 lb ft Engine stop switch screw M3 1 0 5 N m 0 05 kgf m 0 37 lb ft Brake pad pin plug M10 2 2 5 N m 0 25 kgf m 1 8 lb ft Brake pad pin M10 2 17 N m 1 7 kgf m 13 lb ft Brake caliper bleed screw M8 ...

Page 52: ...r M8 1 32 N m 3 2 kgf m 24 lb ft Rear frame bolt lower M8 2 29 N m 2 9 kgf m 21 lb ft Brake hose holder screw M5 4 3 5 N m 0 35 kgf m 2 6 lb ft Swingarm and patch screw M4 4 2 0 N m 0 20 kgf m 1 5 lb ft Drive chain tensioner bolt M8 1 16 N m 1 6 kgf m 12 lb ft Drive chain tensioner nut M8 1 16 N m 1 6 kgf m 12 lb ft Drive chain support bolt M6 1 7 N m 0 7 kgf m 5 2 lb ft Drive chain support nut M6...

Page 53: ...the steering ring nut one turn 2 Retighten the steering ring nut 7 N m 0 7 kgf m 5 2 lb ft Screw mud flap 2 1 3 N m 0 13 kgf m 0 95 lb ft Side cover bolt M6 2 7 N m 0 7 kgf m 5 2 lb ft Seat bolt M8 2 19 N m 1 9 kgf m 14 lb ft Number plate bolt M6 1 7 N m 0 7 kgf m 5 2 lb ft Sidestand bolt M10 1 25 N m 2 5 kgf m 18 lb ft Item Thread size Q ty Tightening torques Remarks ...

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

Page 55: ...icle while the end should face the rear side of the vehicle Clamp the clutch cable below the positioning grommet G Pass the air vent hose back of the throttle cable H Pass the air vent hose overflow hose and crankcase breather hose between the frame and connecting rod I Pass the radiator breather hose and YPVS breather hose outside the engine bracket and inside the down tube Then pass the radiator...

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

Page 57: ... so doing clamp the ignition coil lead and engine stop switch lead at their protecting tubes D Face the joint connector with its open end downward and there is no pinching with peripheral parts E Pass the CDI magneto lead and radiator breather hose between the frame and the radiator right F Clamp the CDI magneto lead to the frame at its locating tape G After connecting the coupler make sure that t...

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

Page 59: ...e hose so that its pipe portion directs as shown and lightly touches the pro jection on the master cylinder B Pass the engine stop switch lead in the mid dle of the clutch holder C Clamp the engine stop switch lead to the handlebar D Pass the brake hose in front of the number plate and through the cable guide E Pass the clutch cable through the cable guide on the number plate ...

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

Page 61: ...3 Brake hose A Pass the brake hose into the brake hose holders B If the brake hose contacts the rear shock absorber spring correct its twist C Install the brake hose so that its pipe portion directs as shown and lightly touches the pro jection on the master cylinder ...

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

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

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

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

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

Page 67: ...bearing assemblies for looseness Lubricate with molybdenum disul fide grease 28 Sidestand Lubricate with lithium soap based grease 29 Steering head Check operation free play and tighten if necessary Clean and lubricate with lithium soap based grease Replace bearings 30 Tires and wheels Check tire air pressure wheel runout spokes for looseness and tires for wear Tighten sprocket bolts if neces sary...

Page 68: ... 13 3 13 3 14 3 14 3 14 3 14 3 15 3 15 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 16 4 64 4 64 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play 3 23 3 23 3 23 3 23 Steering Check that the handlebar can be turned smoothly and have no excessive play 3 17 Front forks and rear shock absorber C...

Page 69: ... b Turn the throttle stop screw 2 until the engine runs at the lowest possible speed c Tighten the locknut EAM30475 CHECKING THE THROTTLE GRIP TIP Prior to adjusting throttle grip free play the en gine idling speed should be adjusted 1 Check Throttle grip free play a Out of specification Regulate 2 Adjust Throttle grip free play a Slide the adjuster cover b Loosen the locknut 1 c Turn the adjuster...

Page 70: ... level a Remove the oil check bolt 1 b Inspect the oil level TIP Be sure the machine is positioned straight up when inspecting the oil level WARNING EWA21090 Never attempt to remove the oil check bolt just after high speed operation The heated oil could spout out causing danger Wait un til the oil cools down Oil flows out Oil level is correct Oil does not flow out Oil level is low Add transmission...

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

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

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

Page 74: ...cer in place with a vise etc b Remove the inner pipe 1 c Replace the fiber 2 d Install the inner pipe TIP Apply heat resistant sealant to the areas shown making sure that there are no gaps in the beads of sealant 5 Check Gasket 1 Damage Replace Refer to ENGINE REMOVAL on page 5 1 TIP Install the gaskets with their depressed a fac ing outward 6 Check Tightening torques 1 1 1 2 Fiber bolt 1 10 N m 1...

Page 75: ...ter is not available soft water may be used 4 Start the engine warm this up for several minutes and then stop it 5 Check Coolant level TIP Before checking the coolant level wait a few minutes until the coolant has settled EAM30211 CHECKING THE COOLING SYSTEM 1 Remove Seat Side cover left right Air scoop left right Refer to GENERAL CHASSIS on page 4 1 2 Check Radiator Radiator hose Crack damage Rep...

Page 76: ... of coolant lowers the antifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However if dis tilled water is not available soft water may be used If coolant comes into contact with painted surfaces immediately wash them with wa ter Do not mix different types of antifreeze 7 Install ...

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

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

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

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

Page 81: ...p the bottom of the front fork legs and gently rock the front fork Blinding looseness Adjust the steering head 3 Remove Handlebar Refer to HANDLEBAR on page 4 32 Upper bracket Refer to STEERING HEAD on page 4 50 4 Adjust Steering head a Remove the washer 1 b After loosening the ring nut 2 with a steering nut wrench 3 tighten it to the specified torque TIP Set the torque wrench at a right angle to ...

Page 82: ...ront fork leg Oil leaks between inner tube and outer tube Replace the oil seal 3 Hold the vehicle upright and apply the front brake 4 Check Front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly Unsmooth operation Correct or replace Refer to FRONT FORK on page 4 38 5 Check Protector guide 1 Out of specification Replace TIP The protector gui...

Page 83: ...nge 1 Adjust Compression damping a Turn the adjuster 1 in the direction of a or b to make an adjustment TIP Although the total number of clicks of a damping force adjusting mechanism may not exactly match the above specifications due to small dif ferences in production the actual number of clicks always represents the entire adjusting range To obtain a precise adjustment it would be advisable to c...

Page 84: ...ck absorber assembly smooth ac tion Rear suspension link smooth action Sit astride the seat and shake your body up and down several times to check whether the rear shock absorber assembly operates smoothly Unsmooth operation Correct or replace Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 54 EAM30242 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Use a maintenance stand to raise the rear wheel off ...

Page 85: ...chanism and to modify the specifications as necessary Compression damping for fast compres sion damping NOTICE ECA24370 Do not turn the adjuster forcibly beyond its adjusting range 1 Adjust Compression damping for fast compression damping a Turn the adjuster 1 in the direction of a or b to make an adjustment Direction b Spring preload is increased suspen sion is harder Direction c Spring preload i...

Page 86: ...o modify the specifications as necessary EAM30240 CHECKING THE SWINGARM OPERATION 1 Check Swingarm smooth action Swingarm free play Refer to SWINGARM on page 4 59 EAM30500 LUBRICATING THE SWINGARM PIVOT 1 Lubricate Oil seal Collar Refer to INSTALLING THE SWINGARM on page 4 60 EAM30501 CHECKING THE CONNECTING ARM AND RELAY ARM Refer to CHECKING THE CONNECTING ARM AND RELAY ARM on page 4 56 Directio...

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

Page 88: ...g points and metal to metal moving parts of the following parts Brake lever EAM30503 LUBRICATING THE CLUTCH LEVER 1 Lubricate the pivoting points and metal to metal moving parts of the following parts Clutch lever EAM30250 LUBRICATING THE PEDAL 1 Lubricate the pivoting point and metal to met al moving parts of the pedal EAM30504 CHECKING THE SIDESTAND 1 Check Sidestand operation Check that the sid...

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

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

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

Page 92: ...51 REAR SHOCK ABSORBER ASSEMBLY 4 54 HANDLING THE REAR SHOCK ABSORBER 4 56 DISPOSING OF A REAR SHOCK ABSORBER 4 56 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 56 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY 4 56 CHECKING THE CONNECTING ARM AND RELAY ARM 4 56 INSTALLING THE RELAY ARM 4 57 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 4 57 SWINGARM 4 59 REMOVING THE SWINGARM 4 60 CHECKING THE SWINGARM 4 ...

Page 93: ...Air scoop left and right 2 3 Side cover left 1 4 Side cover right 1 5 Number plate 1 1 5 2 4 3 2 19 N m 1 9 kgf m 14 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 6 N m 0 6 kgf m 4 4 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 6 N m 0 6 kgf m 4 4 lb ft 19 N m 1 9 kgf m 14 lb ft 7 N m 0 7 kgf m 5 2 lb ft ...

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

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

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

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

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

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

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

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

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

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

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

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

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

Page 107: ...15 minutes and get im mediate medical attention EAM30029 CHECKING THE FRONT BRAKE DISC 1 Check Front brake disc Damage galling Replace 2 Measure Brake disc thickness Measure the brake disc thickness at a few dif ferent locations Out of specification Replace 3 Measure Brake disc runout Out of specification Replace the brake disc a Place the vehicle on a maintenance stand so that the front wheel is ...

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

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

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

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

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

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

Page 114: ...t 1 3 Copper washer 2 4 Rear brake hose 1 5 Brake pad pin plug 1 6 Brake pad pin 1 7 Rear brake pad assembly 2 8 Rear brake caliper bracket 1 9 Brake pad spring 1 10 Rear brake disc cover 1 11 Rear brake caliper assembly 1 17 N m 1 7 kgf m 13 lb ft 2 5 N m 0 25 kgf m 1 8 lb ft 30 N m 3 0 kgf m 22 lb ft 7 N m 0 7 kgf m 5 2 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 11 10 7 9 7 8 6 ...

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

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

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

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

Page 119: ...3 and the pad pin 4 TIP Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point e Install the brake caliper 5 and the rear wheel 6 Refer to REAR WHEEL on page 4 7 f Tighten the pad pin 7 g Install the pad pin plug 8 and the protector 9 Brake pad lining thickness limit 1 0 mm 0 04 in Brake caliper bleed screw 6 N m 0 6 kgf m 4 ...

Page 120: ... the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston dust seal and the brake caliper piston seal EAM30044 CHECKING THE REAR BRAKE CALIPER 1 Check Brake caliper piston 1 Rust scratches wear Replace the brake caliper piston Brake caliper cylinder 2 Scratc...

Page 121: ...e causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540...

Page 122: ...Replace EAM30050 ASSEMBLING THE REAR BRAKE MASTER CYLINDER WARNING EWA13520 Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents 1 Wash the brake master cylinder with brake fluid 2 Install Primary cylinder cup 1 Secondary cylinder cup 2 to the brake master cylinder piston 3 WARNING EWA1930...

Page 123: ...seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor l...

Page 124: ...linder 1 5 Throttle cable cap 1 6 Throttle cable 1 7 Right grip 1 8 Cap cover 1 9 Collar 1 10 Left grip 1 11 Upper handlebar holder 2 12 Handlebar 1 13 Lower handlebar holder 2 0 5 N m 0 05 kgf m 0 37 lb ft 9 N m 0 9 kgf m 6 6 lb ft 28 N m 2 8 kgf m 21 lb ft 5 N m 0 5 kgf m 3 7 lb ft 0 5 N m 0 05 kgf m 0 37 lb ft 4 8 N m 0 48 kgf m 3 5 lb ft 4 3 N m 0 43 kgf m 3 2 lb ft 40 N m 4 0 kgf m 30 lb ft 1...

Page 125: ...vehicle upright on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Lower handlebar holder 1 Washer 2 Lower handlebar holder nut 3 TIP Install the lower handlebar holders with them side having the greater distance a from the mounting bolt center facing forward Apply the lithium soap based grease on the thread of the lower handleb...

Page 126: ... adhesive wipe off grease or oil on the handlebar surface a with a lac quer thinner Install the left grip to the handlebar so that the line b between the two arrow marks faces straight upward 6 Install Engine stop switch 1 Clutch lever holder 2 Clutch lever holder bolt 3 Clamp 4 TIP The engine stop switch clutch lever holder and clamp should be installed according to the di mensions shown Lower ha...

Page 127: ...2 TIP Before applying the adhesive wipe off grease or oil on the tube guide surface a with a lac quer thinner Align the mating mark b on the right grip with the slot c in the tube guide 10 Install Grip cap upper 1 Grip cap lower 2 Grip cap bolt 3 TIP Temporarily tighten the grip cap bolts 11 Install Collar 1 Grip cap cover 2 Throttle grip 3 TIP Apply the lithium soap based grease on the throttle g...

Page 128: ...nstall Throttle cable cap 1 Throttle cable cap screw 2 15 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 5 16 Install Cap cover 1 17 Install Brake master cylinder 1 Brake master cylinder holder 2 Front brake master cylinder holder bolt 3 TIP Install the holder so that the arrow mark a fac es upward First tighten the bolt on the upper side of the brake master cylinder ...

Page 129: ...7 18 Install Grip cap bolt 1 WARNING EWA21080 After tightening the bolts check that the throttle grip 2 moves smoothly If it does not retighten the bolts for adjustment Grip cap bolt 4 3 N m 0 43 kgf m 3 2 lb ft T R ...

Page 130: ...T WHEEL on page 4 3 Front brake caliper Refer to FRONT BRAKE on page 4 11 Number plate Refer to GENERAL CHASSIS on page 4 1 1 Protector 1 2 Upper bracket pinch bolt 2 Loosen 3 Damper assembly 1 Loosen 4 Lower bracket pinch bolt 2 Loosen 5 Front fork leg 1 5 N m 0 5 kgf m 3 7 lb ft 5 N m 0 5 kgf m 3 7 lb ft 9 N m 0 9 kgf m 6 6 lb ft 21 N m 2 1 kgf m 15 lb ft 21 N m 2 1 kgf m 15 lb ft 3 2 4 5 1 ...

Page 131: ... 5 Stopper ring 1 6 Inner tube 1 7 Outer tube 1 8 Piston metal 1 9 Protector guide 1 10 Slide metal 1 11 Washer 1 12 Oil seal 1 13 Base valve 1 14 Damper assembly 1 15 Upper spring seat 1 29 N m 2 9 kgf m 21 lb ft 30 N m 3 0 kgf m 22 lb ft 29 N m 2 9 kgf m 21 lb ft 55 N m 5 5 kgf m 41 lb ft 1 3 N m 0 13 kgf m 0 95 lb ft 10 7 15 2 14 6 1 4 5 8 11 12 3 13 9 ...

Page 132: ...ork leg EAM30056 DISASSEMBLING THE FRONT FORK LEGS 1 Drain Fork oil 2 Remove Adjuster 1 from the inner tube TIP While compressing the inner tube 2 set the cap bolt ring wrench 4 between the inner tube and locknut 3 Hold the locknut and remove the adjuster NOTICE ECA24520 Do not remove the locknut as the damper rod may go into the damper assembly and not be taken out 3 Remove Dust seal 1 Stopper ri...

Page 133: ...usly weaken it 2 Check Outer tube Scratches wear damage Replace 3 Measure Fork spring free length a Out of specification Replace 4 Check Damper assembly 1 Bend damage Replace O ring 2 Wear damage Replace NOTICE ECA14200 The front fork leg has a built in damper ad justing rod and a very sophisticated inter nal construction which are particularly sensitive to foreign material When disassembling and ...

Page 134: ...er Before assembling the front fork leg make sure that all of the components are clean 1 Stretch the damper assembly fully 2 Fill Damper assembly NOTICE ECA24530 Be sure to use the recommended oil Other oils may have an adverse effect on front fork performance When disassembling and assembling the front fork leg take care not to allow any for eign material to enter the front fork 3 After filling p...

Page 135: ... TIP First bring the damper rod pressure to a maxi mum Then install the base valve while releasing the damper rod pressure 8 Check Damper assembly Not fully stretched Repeat the steps 1 to 7 9 Tighten Base valve 1 TIP Hold the damper assembly with the cap bolt ring wrench 2 and use the cap bolt wrench 3 to tighten the base valve Standard oil level 145 148 mm 5 71 5 83 in From top of fully stretche...

Page 136: ...amper assembly TIP The overflow measures about 10 cm 0 34 US oz 0 35 Imp oz 13 Check Damper assembly smooth movement Tightness binding rough spots Repeat the steps 1 to 12 14 Install Dust seal 1 Stopper ring 2 Oil seal 3 Washer 4 Slide metal 5 to the inner tube 6 NOTICE ECA24550 Make sure that the numbered side of the oil seal faces bottom side TIP Apply the lithium soap based grease on the dust s...

Page 137: ... 18 Install Oil seal 1 TIP Using a fork seal driver 2 press the oil seal in until the stopper ring groove fully appears 19 Install Stopper ring 1 TIP Fit the stopper ring correctly in the groove in the outer tube 20 Install Dust seal 1 TIP Apply lithium soap based grease on the inner tube Fork seal driver 90890 01502 Fork seal driver 48 YM A0948 G088922 New New Fork seal driver 90890 01502 Fork se...

Page 138: ... tube 2 NOTICE ECA24560 Allow the damper assembly to slide slowly down the inner tube until it contacts the bot tom of the inner tube Be careful not to dam age the inner tube 25 Loosen Rebound damping force adjuster 1 TIP Before loosening the damping force adjuster record the setting position Unless the damping force adjuster is fully loos ened correct damping characteristic cannot be obtained aft...

Page 139: ...hten the adjuster 29 Install Adjuster 1 to the inner tube 30 Fill Front fork leg NOTICE ECA24570 Be sure to use the recommended oil Other oils may have an adverse effect on front fork performance When disassembling and assembling the front fork leg do not allow any foreign ma terial to enter the front fork Cap bolt ring wrench 90890 01501 Cap bolt ring wrench YM 01501 Gap a between the adjuster an...

Page 140: ...tighten the lower bracket pinch bolts Do not tighten the upper bracket pinch bolts yet 2 Tighten Damper assembly 1 TIP Use the cap bolt ring wrench 2 to tighten the damper assembly 3 Adjust Front fork top end a 4 Tighten Upper bracket pinch bolt 1 1 Damper assembly front fork 30 N m 3 0 kgf m 22 lb ft Cap bolt ring wrench 90890 01501 Cap bolt ring wrench YM 01501 Front fork top end standard a 5 mm...

Page 141: ...st Rebound damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 7 Adjust Compression damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position Upper bracket pinch bolt 21 N m 2 1 kgf m 15 lb ft Lower bracket pinch bolt 21 N m 2 1 kgf m 15 lb ft Front fork protector bolt 5 N m 0 5 kgf m 3 ...

Page 142: ...r to HANDLEBAR on page 4 32 1 Front fender 1 2 Steering stem nut 1 3 Front fork leg 2 4 Upper bracket 1 5 Steering ring nut 1 6 Lower bracket 1 7 Bearing race cover 1 8 Upper bearing 1 9 Lower bearing 1 10 Bearing race 2 5 4 2 10 7 8 9 3 6 1 10 N m 1 0 kgf m 7 4 lb ft 3 8 N m 0 38 kgf m 2 8 lb ft 21 N m 2 1 kgf m 15 lb ft 145 N m 14 5 kgf m 107 lb ft 21 N m 2 1 kgf m 15 lb ft 1st 2nd 38 N m 3 8 kg...

Page 143: ... Bearing race a Remove the bearing race from the steer ing head pipe 1 with a long rod 2 and a hammer b Remove the bearing race from the lower bracket 3 with a chisel 4 and a hammer c Install a new bearing race NOTICE ECA14270 If the bearing race is not installed properly the steering head pipe could be damaged TIP Always replace the bearing and the bearing race as a set 4 Check Upper bracket Lowe...

Page 144: ...g nut with its stepped side a facing downward Tighten the steering ring nut with a steering nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 17 5 Check the steering stem by turning this lock to lock If there is any binding remove the steering stem and check the steering bear ing 6 Install Washer 1 7 Install Front fork 1 Upper bracket 2 TIP Temporarily tighten the lower brac...

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

Page 146: ...lamp 1 2 Rear frame 1 3 Rear shock absorber assembly lower bolt 1 4 Rear shock absorber assembly upper bolt 1 5 Rear shock absorber assembly 1 6 Locknut 1 7 Adjusting nut 1 8 Lower spring guide 1 9 Upper spring guide 1 10 Spring 1 11 Dust seal 4 12 Collar 4 13 Bearing 1 14 Bushing 1 29 N m 2 9 kgf m 21 lb ft 32 N m 3 2 kgf m 24 lb ft 56 N m 5 6 kgf m 41 lb ft 2 3 N m 0 23 kgf m 1 7 lb ft 53 N m 5 ...

Page 147: ...BLY 4 55 Disassembling the relay arm Order Job Parts to remove Q ty Remarks 1 Relay arm 1 2 Connecting arm 1 3 Collar 3 4 Oil seal 6 5 Washer 8 6 Bearing 6 80 N m 8 0 kgf m 59 lb ft 4 6 3 6 6 5 5 6 1 4 4 3 5 2 4 4 5 5 4 5 3 6 6 ...

Page 148: ...G EWA19340 Wear protective glasses to prevent your eyes from damage due to possible gas or metal chips scattered To dispose of a damaged or a worn out rear shock absorber take the unit to your Yamaha dealer for this disposal procedure EAM30065 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1 Use a maintenance stand to raise the rear wheel off the ground WARNING EWA13120 Securely support the vehicle so ...

Page 149: ... it will wear the rear shock ab sorber surface on which the bearing is press fitted 2 Lubricate O ring 3 Install Bearing Stopper ring into the rear shock absorber assembly up per side TIP Install the bearing parallel until the stopper ring groove appears by pressing its outer race After installing the stopper ring push back the bearing until it contacts the stopper ring 4 Install Bearing 1 Bushing...

Page 150: ...t 7 Tighten Rear shock absorber assembly upper nut Connecting arm nut frame side Connecting arm nut relay arm side Relay arm nut swingarm side Rear shock absorber assembly lower nut 8 Install Rear frame 1 Rear frame bolt upper 2 Rear frame bolt lower 3 9 Tighten Air filter case joint clamp 1 Installed depth a 4 25 mm 0 17 in Recommended lubricant Molybdenum disulfide grease Rear shock absorber ass...

Page 151: ...fer to REAR BRAKE on page 4 22 Rear brake caliper Refer to REAR BRAKE on page 4 22 Bolt brake pedal Drive chain 1 Collar 2 2 Oil seal 2 3 Thrust bearing 2 4 Bushing 2 5 Oil seal 2 6 Bearing 4 6 N m 0 6 kgf m 4 4 lb ft 2 0 N m 0 20 kgf m 1 5 lb ft 70 N m 7 0 kgf m 52 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 85 N m 8 5 kgf m 63 lb ft 5 6 6 1 1 2 3 6 3 2 6 5 4 4 ...

Page 152: ...mage Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash with kerosene Pivot shaft Bushing Collar Bearing 4 Check Oil seal Damage Replace Bearing Thrust bearing Bushing Free play exists unsmooth revolution rust Replace bearing and bushing as a set EAM30074 INSTALLING THE SWINGARM 1 Lubricate Bearin...

Page 153: ...SWINGARM 4 61 4 Install Rear wheel Refer to REAR WHEEL on page 4 7 5 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 16 Drive chain slack Maintenance Stand 48 0 58 0 mm 1 89 2 28 in ...

Page 154: ...rder Job Parts to remove Q ty Remarks Drive sprocket Refer to ENGINE REMOVAL on page 5 1 1 Drive chain 1 2 Drive sprocket cover 1 3 Bracket 1 4 Drive sprocket nut 1 5 Lock washer 1 6 Drive sprocket 1 1 2 2 3 4 5 6 5 N m 0 5 kgf m 3 7 lb ft 75 N m 7 5 kgf m 55 lb ft ...

Page 155: ...ween pin outer sides 2 TIP When measuring a 15 link section of the drive chain make sure that the drive chain is taut Perform this procedure 2 3 times at a different location each time 2 Check Drive chain Stiffness Clean lubricate or replace 3 Clean Drive chain a Wipe the drive chain with a clean cloth b Put the drive chain in kerosene and re move any remaining dirt c Remove the drive chain from t...

Page 156: ...CHECKING AND REPLACING THE REAR WHEEL SPROCKET on page 4 8 EAM30079 INSTALLING THE DRIVE CHAIN 1 Install Drive chain NOTICE ECA17410 Be sure to put on safety goggles when work ing TIP Install the master link with the drive chain cut rivet tool Use goods on the market a When press fitting the master link plate 1 make sure the space a between the end of the connecting pin 2 and the mas ter link plat...

Page 157: ...prockets this will dramatically shorten the drive chain s life 4 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 16 NOTICE ECA24590 A drive chain that is too tight will overload the engine and other vital parts and one that is too loose can skip and damage the swing arm or cause an accident Therefore keep the drive chain slack within the specified lim its Recommended lubricant Chain ...

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

Page 159: ...12 INSTALLING THE CYLINDER HEAD 5 14 CDI MAGNETO 5 15 REMOVING THE ROTOR 5 16 CHECKING THE CDI MAGNETO 5 16 CHECKING THE WOODRUFF KEY 5 16 INSTALLING THE CDI MAGNETO 5 16 KICKSTARTER 5 18 REMOVING THE PRIMARY DRIVE GEAR 5 20 REMOVING THE KICK SHAFT ASSEMBLY 5 20 CHECKING THE KICK GEAR AND KICK IDLE GEAR 5 20 INSTALLING THE KICK SHAFT ASSEMBLY 5 20 INSTALLING THE KICK IDLE GEAR 5 21 INSTALLING THE ...

Page 160: ...NG THE SHIFT SHAFT 5 33 CHECKING THE STOPPER LEVER 5 33 INSTALLING THE SHIFT SHAFT 5 33 CRANKCASE 5 36 DISASSEMBLING THE CRANKCASE 5 37 CHECKING THE CRANKCASE 5 37 ASSEMBLING THE CRANKCASE 5 37 CRANKSHAFT 5 40 REMOVING THE CRANKSHAFT 5 41 CHECKING THE CRANKSHAFT 5 41 INSTALLING THE CRANKSHAFT 5 41 TRANSMISSION 5 43 REMOVING THE TRANSMISSION 5 44 CHECKING THE SHIFT FORKS 5 44 CHECKING THE SHIFT DRU...

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

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

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

Page 164: ...vot shaft nut 3 Engine mounting bolt lower side 4 Engine mounting nut lower side 5 Engine mounting bolt front side 6 Engine mounting nut front side 7 Engine bracket 8 Engine bracket bolt upper side 9 Engine bracket nut upper side 10 Engine bracket bolt lower side 11 Engine bracket nut lower side 12 TIP Apply the molybdenum disulfide grease on the pivot shaft Pivot shaft nut 85 N m 8 5 kgf m 63 lb ...

Page 165: ...t pipe Silencer Refer to ENGINE REMOVAL on page 5 1 Radiator hose 1 Disconnect at cylinder head side Carburetor Refer to CARBURETOR on page 7 3 1 Spark plug 1 2 Engine bracket 2 3 Cylinder head 1 4 Power valve housing 1 5 Push rod 1 6 Cylinder 1 1 2 3 4 5 4 5 6 13 N m 1 3 kgf m 9 6 lb ft 20 N m 2 0 kgf m 15 lb ft 34 N m 3 4 kgf m 25 lb ft 28 N m 2 8 kgf m 21 lb ft 4 5 N m 0 45 kgf m 3 3 lb ft 4 0 ...

Page 166: ... 1 3 Piston 1 4 Small end bearing 1 5 Piston ring 1 6 Power valve cover 1 7 Thrust plate 1 8 Power valve holder 1 9 Valve shaft 1 10 Collar 2 11 Link lever 1 12 Power valve 1 1 13 Power valve 2 1 1 2 3 4 5 1 6 7 8 9 10 11 12 13 4 0 N m 0 40 kgf m 3 0 lb ft 8 N m 0 8 kgf m 5 9 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 5 N m 0 5 kgf m 3 7 lb ft 10 ...

Page 167: ... PISTON 1 Remove Piston pin clip 1 TIP Before removing the piston pin clip cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase 2 Remove Piston pin 1 Piston 2 Small end bearing NOTICE ECA13810 Do not use a hammer to drive the piston pin out TIP Before removing the piston pin deburr the pis ton pin clip s groove and the piston s pin bore ar ea ...

Page 168: ...cylin der head using a figure eight sanding pat tern TIP To ensure an even surface rotate the cylinder head several times EAM30546 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical scratches Replace the cylinder and replace the piston and piston rings as a set 2 Measure Piston to cylinder clearance a Measure the cylinder bore C with the cyl inder bore gauge TIP Measure th...

Page 169: ...the piston that matches the above chart Diameter 53 957 53 972 mm 2 1243 2 1249 in a 17 5 mm 0 69 in from the bottom edge of the piston Piston to cylinder clearance Cylinder bore Piston skirt diameter Piston to cylinder clearance 0 040 0 045 mm 0 0016 0 0018 in Cylinder mark a Cylinder size A 54 000 54 002 mm 2 1260 2 1261 in B 54 004 54 006 mm 2 1261 2 1262 in C 54 008 54 010 mm 2 1263 2 1264 in ...

Page 170: ...discoloration grooves Replace the piston pin and then check the fuel and en gine mixing oil 2 Measure Piston pin outside diameter a Out of specification Replace the piston pin 3 Measure Piston pin bore inside diameter b Out of specification Replace the piston 4 Calculate Piston pin to piston pin bore clearance Out of specification Replace the piston pin and piston as a set Top ring Ring side clear...

Page 171: ...oid scratching the aluminum EAM30551 ASSEMBLING THE POWER VALVE 1 Install Power valve 1 1 Power valve 2 2 Bolt power valve 3 TIP Install the power valve at cut away faced a for down side 2 Install Spring 1 Link lever 2 Collar 3 Valve shaft 4 Power valve holder 5 Power valve link lever bolt 6 TIP Install the spring to the link lever and then to the cylinder Install the spring with its stopper porti...

Page 172: ...VS breather hose with its opening portion b facing backward EAM30554 INSTALLING THE PISTON AND CYLINDER 1 Install Piston ring 1 TIP Take care not to scratch the piston or damage the piston ring Align the piston ring gap with the pin 2 After installing the piston ring check the smooth movement of it 2 Install Cylinder gasket 1 Small end bearing 2 with the recommended lubricant Dowel pin 3 Thrust pl...

Page 173: ...linder with the recommended lubricant 5 Install Cylinder Cylinder nut 1 TIP While compressing the piston ring with one hand install the cylinder with the other hand Tighten the nuts in stage using a crisscross pattern 6 Install Collar 1 Push rod 2 Plain washer 3 Push rod bolt 4 NOTICE ECA27100 Be sure to use the collar If the collar is not used the power valve constituent parts will result in dama...

Page 174: ...y the lithium soap based grease on the O rings 3 Install Cylinder head 1 Copper washer 2 Cylinder head nut 3 TIP Tighten the cylinder head nut in stage using a crisscross pattern 4 Install Spark plug Spark plug cap Radiator hose Power valve housing bolt 4 0 N m 0 40 kgf m 3 0 lb ft Recommended lubricant Lithium soap based grease New T R New Cylinder head nut 28 N m 2 8 kgf m 21 lb ft Spark plug 20...

Page 175: ...GENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Radiator bolt Refer to RADIATOR on page 6 2 CDI magneto lead Disconnect 1 Crankcase cover left 1 2 Rotor nut 1 3 CDI magneto rotor 1 4 Stator 1 5 Woodruff key 1 7 N m 0 7 kgf m 5 2 lb ft 56 N m 5 6 kgf m 41 lb ft 5 N m 0 5 kgf m 3 7 lb ft 1 2 3 4 5 ...

Page 176: ...Check Rotor inner surface a Stator outer surface b Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace CDI magneto and or stator EAM30564 CHECKING THE WOODRUFF KEY 1 Check Woodruff key 1 Damage Replace EAM30565 INSTALLING THE CDI MAGNETO 1 Install Stator 1 Stator coil screw 2 TIP Temporarily tighten the screw at this point 2 Install Woodruff key 1 Rotor 2 Rotor holding...

Page 177: ...G THE IGNITION TIM ING on page 3 25 5 Tighten Stator coil screw 1 6 Check Ignition timing Re check the ignition timing 7 Connect CDI magneto lead 1 Refer to CABLE ROUTING DIAGRAM on page 2 15 8 Install Crankcase cover gasket left Crankcase cover left 1 Crankcase cover screw left 2 TIP Tighten the screws in stage using a crisscross pattern CDI magneto rotor nut 56 N m 5 6 kgf m 41 lb ft Rotor holdi...

Page 178: ... 3 6 Bolt brake pedal Shift the brake pedal downward Radiator hose 4 Disconnect at water pump side Push rod bolt Refer to CYLINDER HEAD CYLINDER AND PISTON on page 5 5 1 Kickstarter lever 1 2 Crankcase cover right 1 3 Bolt primary drive gear 1 4 Primary driven gear 1 5 Primary drive gear 1 1 2 3 4 5 10 N m 1 0 kgf m 7 4 lb ft 48 N m 4 8 kgf m 35 lb ft 10 N m 1 0 kgf m 7 4 lb ft ...

Page 179: ...KICKSTARTER 5 19 Removing the kickstarter shaft Order Job Parts to remove Q ty Remarks 1 Kick idle gear 1 2 Kick shaft assembly 1 1 2 ...

Page 180: ...ICK IDLE GEAR 1 Check Kick gear 1 Wear damage Replace the kick shaft as sembly Kick idle gear 2 Gear teeth a Wear damage Replace EAM30104 INSTALLING THE KICK SHAFT ASSEMBLY 1 Install Kick gear 1 Washer 2 Torsion spring 3 to kick shaft 4 TIP Make sure the stopper a of the torsion spring fits into the hole b on the kick shaft 2 Install Spring guide 1 TIP Slide the spring guide into the kick shaft ma...

Page 181: ...Apply the transmission oil on the kick idle gear inner circumference EAM30571 INSTALLING THE PRIMARY DRIVE GEAR 1 Install Spacer 1 Primary drive gear 2 Primary drive gear bolt 3 TIP Install the primary drive gear with its depressed side toward you 2 Install Primary driven gear Refer to CLUTCH on page 5 26 3 Tighten Primary drive gear bolt 1 TIP Place an aluminum plate a between the teeth of the pr...

Page 182: ... 1 Washer 2 Kickstarter lever bolt 3 TIP Install the kickstarter closest to but not contact ing the pillar tube 4 2 Install Shift pedal 1 Shift pedal bolt 2 TIP Align the upper line a of the shift pedal with the center b of the crankcase projection and rotate the shift pedal counterclockwise until it first en gages Then install the shift pedal Crankcase cover screw right 10 N m 1 0 kgf m 7 4 lb ft...

Page 183: ...ase cover right Refer to KICKSTARTER on page 5 18 1 Governor assembly 1 2 Dowel pin 1 3 Retainer 1 4 Ball 4 5 Retainer weight 1 6 Washer 3 7 Bearing 2 8 Collar 1 9 Plate 1 10 Compression spring 1 11 Governor gear 1 12 Governor shaft 1 13 Governor fork 1 1 2 3 4 5 6 7 8 9 10 11 12 5 N m 0 5 kgf m 3 7 lb ft 6 7 6 13 ...

Page 184: ... bearing 1 Washer 2 Wear damage Replace EAM30569 INSTALLING THE GOVERNOR 1 Install Governor gear 1 Compression spring 2 Plate 3 Washer 4 Thrust bearing 5 Collar 6 Retainer weight 7 to the governor shaft 8 TIP Apply the lithium soap based grease on the thrust bearing 2 Install Ball 1 Retainer 2 to the governor shaft 3 TIP Apply the transmission oil on the retainer and ball 1 1 2 1 2 2 Recommended l...

Page 185: ...e compressing the spring install the dowel pin Make sure the dowel pin fits into the groove a in the retainer 4 Install Governor assembly 1 TIP Align the groove a in the governor with the fork b and set the governor in the crankcase cover G 1 2 3 1 a ...

Page 186: ...RANSMISSION OIL on page 3 6 Bolt brake pedal Shift the brake pedal downward Rotor and stator Refer to CDI MAGNETO on page 5 15 Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Gasket 1 3 Clutch spring 5 4 Pressure plate 1 5 Friction plate 8 6 Clutch plate 7 1 2 5 3 4 5 6 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft ...

Page 187: ... Washer 1 4 Bearing 1 5 Ball 1 6 Push rod 2 1 7 Clutch boss nut 1 8 Lock washer 1 9 Clutch boss 1 10 Thrust washer 1 D ø34 mm 1 34 in 11 Primary driven gear 1 12 Bearing 1 13 Spacer 1 1 14 Thrust washer 1 D ø34 mm 1 34 in 15 Push lever shaft 1 1 2 3 4 5 6 7 8 9 10 11 12 14 15 80 N m 8 0 kgf m 59 lb ft 13 ...

Page 188: ... set EAM30111 CHECKING THE CLUTCH SPRINGS 1 Check Clutch spring Damage Replace the clutch springs as a set 2 Measure Clutch spring free length Out of specification Replace the clutch springs as a set EAM30112 CHECKING THE CLUTCH HOUSING 1 Check Clutch housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing TIP Pitting on the clutch housing dogs will cause er r...

Page 189: ... primary driven gears as a set Excessive noise during operation Replace the primary drive and primary driven gears as a set 2 Check Primary drive gear to primary driven gear free play Free play exists Replace the primary drive and primary driven gears as a set EAM30118 CHECKING THE PRIMARY DRIVEN GEAR 1 Check Primary driven gear Damage wear Replace the primary drive and primary driven gears as a s...

Page 190: ...utch plate 2 TIP Install the clutch plates and friction plates alter nately on the clutch boss starting with a friction plate and ending with a friction plate Apply the transmission oil on the friction plates and clutch plates 7 Install Bearing 1 Washer 2 Circlip 3 to the push rod 1 4 TIP Apply the transmission oil on the bearing wash er and push rod 1 8 Install Push rod 2 1 Ball 2 Push rod 1 3 Cl...

Page 191: ... using a crisscross pat tern 11 Install Dowel pin 1 Gasket clutch cover 2 12 Install Clutch cover Clutch cover bolt TIP Tighten the bolts in stage using a crisscross pat tern 13 Install O ring 1 Clutch cable 2 TIP Apply the lithium soap based grease on the O ring Clutch spring bolt 10 N m 1 0 kgf m 7 4 lb ft T R New Clutch cover bolt 10 N m 1 0 kgf m 7 4 lb ft T R New 1 2 ...

Page 192: ...r Order Job Parts to remove Q ty Remarks 1 Shift pedal 1 2 Shift shaft 1 3 Segment bolt 1 4 Roller 1 5 Shift guide 1 6 Shift lever assembly 1 7 Stopper lever 1 1 2 4 5 3 6 7 10 N m 1 0 kgf m 7 4 lb ft 30 N m 3 0 kgf m 22 lb ft 10 N m 1 0 kgf m 7 4 lb ft 12 N m 1 2 kgf m 8 9 lb ft ...

Page 193: ...amage wear Replace 2 Check Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear damage Replace EAM30127 CHECKING THE STOPPER LEVER 1 Check Stopper lever 1 Wear damage Replace Roller 2 Rotate outer race with a finger Rough spot seizure Replace the stopper lever Torsion spring 3 Broken Replace EAM30131 INSTALLING THE SHIFT SHAFT 1 Install Torsion spring 1 Holder 2 Holder bolt 3 Washer 4 Stopp...

Page 194: ...Spring 1 Pawl pin 2 Pawl 3 to the shift lever TIP Apply the transmission oil on the spring pawl pin and pawl 4 Install Shift lever assembly to the shift guide 5 Install Shift lever assembly 1 Shift guide 2 TIP The shift lever assembly is installed at the same time as the shift guide Apply the transmission oil on the segment bolt shaft 6 Tighten Shift guide bolt 1 7 Install Roller 1 Shift shaft 2 S...

Page 195: ...8 Install Shift pedal 1 Shift pedal bolt 2 TIP Align the upper line a of the shift pedal with the center b of the crankcase projection and rotate the shift pedal counterclockwise until it first en gages Then install the shift pedal Shift pedal bolt 12 N m 1 2 kgf m 8 9 lb ft T R ...

Page 196: ...Stopper lever Refer to SHIFT SHAFT on page 5 32 Rotor and stator Refer to CDI MAGNETO on page 5 15 1 Segment 1 2 Crankcase bolt 6 L 45 mm 1 77 in 3 Crankcase bolt 4 L 55 mm 2 17 in 4 Crankcase bolt 1 L 65 mm 2 56 in 5 Crankcase bolt 1 L 75 mm 2 95 in 6 Holder 1 7 Crankcase right 1 8 Crankcase left 1 9 Oil seal 2 10 Bearing 2 1 6 7 8 9 10 2 3 4 5 3 3 3 2 2 2 2 2 10 9 10 N m 1 0 kgf m 7 4 lb ft 30 N...

Page 197: ...t separate check for a remaining case bolt or fitting Do not force 2 Remove Bearing 1 TIP Remove the bearing from the crankcase by pressing its inner race Do not use the removed bearing EAM30150 CHECKING THE CRANKCASE 1 Wash Crankcase TIP Wash the crankcase in a mild solvent Remove any remaining gasket from the crank case mating surface 2 Check Crankcase Crack damage Replace Oil delivery passages ...

Page 198: ...laced on top of each other If you use the washers in the installation install the washers so that they do not deviate from the crankshaft center When installing the crankcase the connecting rod should be positioned at TDC top dead center Make sure that the dowel pin is in place 6 Install Holder 1 Holder bolt 2 Yamaha bond No 1215 90890 85505 Three bond No 1215 1 2 1 2 mm 0 04 0 08 in 1 2 mm 0 04 0...

Page 199: ...CRANKCASE 5 39 7 Install Clamp 1 Crankcase bolt 2 TIP Tighten the crankcase bolts in stage using a crisscross pattern Crankcase bolt 14 N m 1 4 kgf m 10 lb ft LT 1 2T R ...

Page 200: ...T 5 40 EAM20193 CRANKSHAFT Removing the crankshaft assembly Order Job Parts to remove Q ty Remarks Engine Refer to ENGINE REMOVAL on page 5 1 Crankcase Separate 1 Crankshaft 1 2 Oil seal 2 3 Bearing 2 1 3 3 2 2 ...

Page 201: ...olt 3 and adapter M12 4 NOTICE ECA26470 In order to prevent the crankshaft seizure apply molybdenum disulfide grease NOTICE ECA23810 Do not use a hammer to drive in the crank shaft TIP Hold the connecting rod at top dead center TDC with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft assembly bottoms against the...

Page 202: ...CRANKSHAFT 5 42 seal lip 4 1 2 3 M ...

Page 203: ...move Q ty Remarks Engine Refer to ENGINE REMOVAL on page 5 1 Crankcase Refer to CRANKCASE on page 5 36 1 Guide bar long 1 2 Guide bar short 1 3 Shift cam 1 4 Shift fork 3 R 1 5 Shift fork 1 L 1 6 Shift fork 2 C 1 7 Main axle 1 8 Drive axle 1 9 Collar 1 1 2 3 4 5 6 7 8 9 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft ...

Page 204: ...or a malfunctioning shift fork replace not only the shift fork itself but the two gears each adja cent to the shift fork EAM30155 CHECKING THE SHIFT DRUM ASSEMBLY 1 Check Shift drum groove Damage scratches wear Replace the shift drum assembly Shift drum segment Damage wear Replace the shift drum as sembly EAM30156 CHECKING THE TRANSMISSION 1 Measure Main axle runout with a centering device and dia...

Page 205: ...the in ner surface of the sliding gear then install 2 Install 2nd wheel gear 29T 1 5th wheel gear 24T 2 3rd wheel gear 27T 3 4th wheel gear 23T 4 6th wheel gear 23T 5 1st wheel gear 31T 6 to the drive axle 7 TIP Apply the molybdenum disulfide oil on the in ner and end surface of the idler gear and on the inner surface of the sliding gear then install Apply the molybdenum disulfide grease on the in...

Page 206: ...the drive axle Mesh the shift fork 2 C with the 3rd 4th pinion gear 5 on the main axle 6 Install Shift cam 1 TIP Apply the transmission oil on the shift cam Install the shift cam while holding up the 5th wheel gear 2 and keeping the shift fork 1 3 moved in the direction of the arrow 7 Install Guide bar short 1 Guide bar long 2 TIP Apply the transmission oil on the guide bars Be sure the long bar i...

Page 207: ... 10 COOLING SYSTEM COOLING SYSTEM DIAGRAMS 6 1 RADIATOR 6 2 CHECKING THE RADIATOR 6 3 INSTALLING THE RADIATOR 6 3 WATER PUMP 6 5 DISASSEMBLING THE WATER PUMP 6 6 CHECKING THE WATER PUMP 6 6 ASSEMBLING THE WATER PUMP 6 6 ...

Page 208: ...COOLING SYSTEM DIAGRAMS 6 1 EAM20186 COOLING SYSTEM DIAGRAMS 1 Radiator hose 1 2 Radiator right 3 Radiator hose 4 4 Water pump 5 Radiator left ...

Page 209: ...r to FUEL TANK on page 7 1 1 Radiator guard 2 2 Radiator hose clamp radiator hose 1 3 2 Only loosening 3 Radiator hose 2 1 4 Radiator left 1 5 Radiator hose 4 1 6 Radiator right 1 7 Radiator hose 1 1 8 Radiator hose 3 1 9 Radiator breather hose 1 1 2 3 4 5 6 7 8 9 1 5 N m 0 15 kgf m 1 1 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 5 N m 0 15 kgf m 1 1 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb...

Page 210: ...ck Radiator cap valve opening pressure a Install the radiator cap tester adapter 2 and the radiator cap tester 1 to the radi ator cap 3 and activate the tester to check whether it can stay for 5 to 10 sec onds within standard pressure values TIP Before attaching the cap to the tester apply wa ter to its sealing surface No stay Replace EAM30506 INSTALLING THE RADIATOR 1 Fill Cooling system with the...

Page 211: ...warm up Make sure that coolant is filled up to the up per level beforehand 5 Check Pressure value No stay for 5 to 10 seconds at the test pres sure value Correct Radiator Radiator hose connections Coolant leaks Correct or replace Radiator hose Bulges Replace WARNING EWA19090 When the radiator cap tester is removed coolant will spout therefore cover it with a cloth beforehand Test pressure value 12...

Page 212: ...Remarks Crankcase cover right Refer to KICKSTARTER on page 5 18 1 Water pump housing cover 1 2 Impeller shaft gear 1 3 Dowel pin 1 4 Washer 1 5 Impeller shaft assembly 1 6 Bearing 1 7 Oil seal 2 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 2 3 4 5 6 7 7 ...

Page 213: ...62 ASSEMBLING THE WATER PUMP 1 Install Oil seal 1 2 TIP Apply the lithium soap based grease on the oil seal lip Install the oil seal with its manufacture s marks or numbers facing the crankcase cover right 3 2 Install Bearing 1 TIP Install the bearing by pressing its outer race par allel 3 Install Impeller shaft 1 TIP Take care so that the oil seal lip is not dam aged or the spring does not slip o...

Page 214: ...dowel pin fitted in the groove a in the same gear 5 Install Dowel pin 1 Gasket 2 6 Install Water pump housing 1 Water pump housing cover bolt 2 Copper washer 3 Coolant drain bolt 4 Water pump housing cover bolt 10 N m 1 0 kgf m 7 4 lb ft Coolant drain bolt 10 N m 1 0 kgf m 7 4 lb ft New New T R New T R ...

Page 215: ...K 7 1 AIR FILTER 7 2 CARBURETOR 7 3 HANDLING NOTE 7 5 CHECKING THE CARBURETOR 7 5 CHECKING THE REED VALVE 7 6 INSTALLING THE REED VALVE 7 7 ASSEMBLING THE CARBURETOR 7 7 INSTALLING THE CARBURETOR 7 9 MEASURING AND ADJUSTING THE FUEL LEVEL 7 10 ...

Page 216: ... to GENERAL CHASSIS on page 4 1 Side cover left right Air scoop left right 1 Fitting band 1 2 Fuel cock assembly 1 3 O ring 1 4 Fuel tank 1 5 Fuel tank breather hose 2 6 Valve joint 1 10 N m 1 0 kgf m 7 4 lb ft 7 N m 0 7 kgf m 5 2 lb ft 4 0 N m 0 40 kgf m 3 0 lb ft 7 N m 0 7 kgf m 5 2 lb ft 2 1 4 5 6 4 2 3 ...

Page 217: ...eat Refer to GENERAL CHASSIS on page 4 1 1 Fitting bolt 1 2 Air filter element 1 3 Air filter guide 1 4 Guide holder 1 5 Band 1 6 Spacer 1 7 Air filter joint 1 8 Air filter case 1 2 3 4 5 6 7 3 3 1 8 8 N m 0 8 kgf m 5 9 lb ft 2 0 N m 0 20 kgf m 1 5 lb ft 8 N m 0 8 kgf m 5 9 lb ft 3 5 N m 0 35 kgf m 2 6 lb ft ...

Page 218: ...y Remarks Fuel tank Refer to FUEL TANK on page 7 1 1 Carburetor joint clamp 2 2 Carburetor 1 3 Carburetor joint 1 4 Reed valve assembly 1 5 Reed valve stopper 2 6 Reed valve 2 1 2 3 4 5 6 2 3 N m 0 23 kgf m 1 7 lb ft 10 N m 1 0 kgf m 7 4 lb ft 1 0 N m 0 10 kgf m 0 73 lb ft 2 3 N m 0 23 kgf m 1 7 lb ft 1 ...

Page 219: ...Throttle valve 1 3 Needle holder 1 4 Jet needle 1 5 Float chamber 1 6 Needle jet cover 1 7 Float pin 1 8 Float 1 9 Valve seat 1 10 Main jet 1 11 Main jet holder 1 12 Pilot jet 1 13 Starter plunger 1 14 Throttle stop screw 1 15 Pilot air screw 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 4 0 N m 0 40 kgf m 3 0 lb ft ...

Page 220: ...e a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air Never use a wire When cleaning the main air passage blow air through it while covering the nozzle with a clean rag 3 Check Fuel passages Obstruction Clean a Wash the carburetor in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages and jets with comp...

Page 221: ... the carbu retor Do not remove the filter except when re placing it 11 Check Free movement Stick Repair or replace TIP Insert the throttle valve 1 into the carburetor body and check for free movement 12 Check Hose joint Cracks damage Replace 13 Check Carburetor breather hose Fuel hose Cracks damage wear Replace Obstruction Clean Blow out the hoses with compressed air EAM30574 CHECKING THE REED VAL...

Page 222: ...avoid warping 2 Install Reed valve assembly 1 Reed valve spacer 2 3 Install Carburetor joint 1 Carburetor joint bolt 2 EAM30576 ASSEMBLING THE CARBURETOR 1 Install Throttle stop screw 1 Locknut 2 Pilot air screw 3 a Turn in the pilot air screw until it is lightly seated b Turn out the pilot air screw by the number of turns recorded before removing Valve stopper height 8 2 8 6 mm 0 32 0 34 in Reed ...

Page 223: ...the needle valve to the float in stall them to the carburetor Check the float for smooth movement 5 Install Float chamber 1 Plate 2 Screw float chamber 3 6 Install Jet needle 1 Needle holder 2 to the throttle valve 3 7 Install Throttle cable 1 Locknut 2 Mixing chamber top 3 Spring throttle valve 4 Ring 5 Throttle valve 6 TIP While compressing the spring connect the Locknut throttle cable carbureto...

Page 224: ... 3 Refer to CABLE ROUTING DIAGRAM on page 2 15 TIP Pass the air vent hose at the rear on the air cleaner side of the throttle cable 4 EAM30578 INSTALLING THE CARBURETOR 1 Install Carburetor 1 TIP Install the projection between the carburetor joint slots 2 Tighten Air filter case joint clamp 1 Carburetor joint clamp 2 3 Clamp Air vent hose 1 Overflow hose 2 Refer to CABLE ROUTING DIAGRAM on page 2 ...

Page 225: ...re the fuel level with the fuel level gauge TIP Keep the carburetor and fuel level gauge verti cally when measuring the fuel level e If the fuel level is not within specification inspect the valve seat and needle valve f If either is worn replace them both g If both are fine adjust the fuel level by bending the float tab b on the float h Recheck the fuel level Fuel level using fuel level gauge 9 5...

Page 226: ...CARBURETOR 7 11 ...

Page 227: ...LOR CODE 8 1 IGNITION SYSTEM 8 2 TROUBLESHOOTING 8 2 ELECTRICAL COMPONENTS 8 3 CHECKING THE SWITCHES 8 4 CHECKING THE IGNITION SPARK GAP 8 6 CHECKING THE SPARK PLUG CAP 8 6 CHECKING THE IGNITION COIL 8 6 CHECKING THE PICKUP COIL 8 7 CHECKING THE SOURCE COIL 8 7 ...

Page 228: ...5 WIRING DIAGRAM EAM30608 COLOR CODE 1 Engine stop switch 2 CDI unit 3 Ignition coil 4 CDI magneto 5 Spark plug B Black O Orange Y Yellow B R Black Red B W Black White G L Green Blue G W Green White W L White Blue W R White Red ...

Page 229: ...cap Refer to CHECKING THE SPARK PLUG CAP on page 8 6 NG Replace the spark plug cap OK 4 Check the ignition coil Refer to CHECKING THE IGNI TION COIL on page 8 6 NG Replace the ignition coil OK 5 Check the engine stop switch Refer to CHECKING THE SWITCHES on page 8 4 NG Replace the engine stop switch OK 6 Check the pickup coil Refer to CHECKING THE PICKUP COIL on page 8 7 NG Replace the pickup coil...

Page 230: ...ELECTRICAL COMPONENTS 8 3 EAM20147 ELECTRICAL COMPONENTS 1 2 3 1 Engine stop switch 2 CDI unit 3 Ignition coil ...

Page 231: ...ELECTRICAL COMPONENTS 8 4 EAM30289 CHECKING THE SWITCHES 1 1 Engine stop switch ...

Page 232: ...hecking for continuity switch back and forth between the switch positions a few times Terminal connections of the switch are shown in the terminal connection diagram below The switch positions a are shown in the far left column and the switch lead colors are shown in the top row in the switch illustration TIP indicates continuity between switch terminals i e a closed circuit at each switch positio...

Page 233: ... specification Replace a Connect the digital circuit tester to the spark plug cap b Measure the spark plug cap resistance EAM30296 CHECKING THE IGNITION COIL 1 Check Primary coil resistance Out of specification Replace a Disconnect the ignition coil connectors from the ignition coil terminals b Connect the digital circuit tester to the ignition coil as shown Minimum ignition spark gap 6 0 mm 0 24 ...

Page 234: ... the wire harness 2 Check Charging coil 1 resistance B R G W Out of specification Replace the CDI mag neto a Connect the digital circuit tester to the CDI magneto coupler as shown Secondary coil resistance 5 68 8 52 k Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Positive tester probe High tension cord 1 Negative tester probe Yellow 2 Pickup coil resistance...

Page 235: ...on Replace the CDI mag neto a Connect the digital circuit tester to the CDI magneto coupler as shown b Measure the source coil resistance G L B Charging coil 2 resistance 44 0 66 0 Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachom eter YU A1927 Positive tester probe Green Blue 1 Negative tester probe Black 2 ...

Page 236: ...ELECTRICAL COMPONENTS 8 9 ...

Page 237: ...NERAL INFORMATION 9 1 TROUBLESHOOTING OF ENGINE 9 1 TROUBLESHOOTING OF CLUTCH 9 6 TROUBLESHOOTING OF TRANSMISSION 9 7 TROUBLESHOOTING OF COOLING SYSTEM 9 8 TROUBLESHOOTING OF BRAKE 9 9 TROUBLESHOOTING OF SUSPENSION 9 9 TROUBLESHOOTING OF STEERING HANDLING 9 11 ...

Page 238: ...el not supplied Empty fuel tank Fill the fuel tank with fuel Clogged fuel tank cap breather hole Clean the fuel tank cap Clogged or damaged fuel hose Clean repair or replace the fuel hose Fuel leakage Check the fuel passage Repair or replace as necessary Clogged fuel cock strainer Clean or replace the fuel cock strainer Clogged fuel cock Clean or replace the fuel cock Cracked damaged or worn fuel ...

Page 239: ...g cap Defective ignition coil Replace the ignition coil CDI unit failure Replace the CDI unit Fuel not supplied Fuel leakage Check the fuel passage Repair or replace as necessary Clogged carburetor fuel passage Clean the carburetor Clogged needle valve or needle valve seat Clean the needle valve or needle valve seat Damaged float Replace the float Water or foreign material in fuel degraded fuel Ch...

Page 240: ... hose Replace the vacuum hose Damaged carburetor joint Replace the carburetor joint Loose carburetor joint Tighten the carburetor joint bolts to the specified torque Clogged air filter element Clean or replace the air filter ele ment Symptom Possible cause Actions Spark plug does not produce a spark Incorrect spark plug gap Adjust the spark plug gap Worn or damaged spark plug Replace the spark plu...

Page 241: ...ghten the main jet to the speci fied torque Bent damaged or worn jet needle Replace the jet needle Cracks or damage in the piston valve diaphragm Replace the piston valve dia phragm Problem with piston valve move ment movement is not smooth Replace the piston valve Damaged or worn needle valve seat Replace the needle valve seat Loose needle valve seat Tighten the needle valve seat to the specified...

Page 242: ...n rings as a set Worn or damaged piston Replace the piston and piston rings as a set Worn piston piston pin hole Replace the piston and piston pin as a set Worn or damaged piston pin Replace the piston pin Worn or damaged cylinder bore Replace the cylinder piston and piston rings as a set Carbon buildup in piston head and combustion chamber Clean the piston head and com bustion chamber Noise heard...

Page 243: ...ine oil Deteriorated oil Change to recommended engine oil Clutch drags Faulty clutch spring Replace the clutch springs as a set Warped pressure plate Replace the pressure plate Swollen friction plate Replace the friction plates as a set Warped clutch plate Replace the clutch plates as a set Bent pull rod outer pull type Replace the pull rod Worn pull rod tooth outer pull type Replace the pull rod ...

Page 244: ...e the shift drum Seized shift fork Replace the shift fork and shift fork guide bar as a set Bent shift fork guide bar Replace the shift fork guide bar Foreign object between transmis sion gears Remove foreign object from trans mission gears Seized transmission gear Replace the seized gear and the axle as a set Improperly assembled transmis sion Reassemble the transmission axle assembly Jumps out o...

Page 245: ...e the radiator Damaged or faulty water pump Replace the water pump Damaged hoses or pipes Replace the hose or pipe Improperly connected hoses or pipes Connect the hoses and pipes properly Clogged air filter element Clean or replace the air filter ele ment Brake drags Check the brake system and repair or replace faulty parts as necessary Incorrect spark plug gap Adjust to the specified spark plug g...

Page 246: ... Damaged brake hose and brake pipe Replace the brake hose and brake pipe Oil or grease on the brake disc or brake pad Clean the brake disc or brake pad Insufficient lubrication of brake lever or brake pedal pivot Lubricate the brake lever or brake pedal pivot Symptom Possible cause Actions Front fork is hard Bent or damaged inner tube Replace the inner tube Bent or damaged outer tube Replace the o...

Page 247: ...mper rod assembly bolt Tighten the damper rod assembly bolt to the specified torque Damaged damper rod assembly bolt copper washer Replace the damper rod assembly bolt copper washer Cracked or damaged cap bolt O ring Replace the cap bolt O ring Rear suspension is hard Bent or damaged rear shock absorber rod Replace the rear shock absorber Bent swingarm pivot shaft Replace the swingarm pivot shaft ...

Page 248: ...ied torque Worn bearing or bearing race Replace the bearing and bearing race as a set Warped front fork Repair or replace the front fork Bent front wheel axle Replace the front wheel axle Incorrect tire pressure Adjust to the specified tire pres sure Worn deformed or incorrect tire Replace the tire Heavy steering Steering ring nut is tightened too tight Tighten the steering ring nut to the specifi...

Page 249: ...ed or incorrect tire Replace the tire Loose wheel axle nut Tighten the wheel axle nut to the specified torque Loose swingarm pivot shaft Tighten the swingarm pivot shaft to the specified torque Bent or damaged swingarm Replace the swingarm bearing Damaged or worn swingarm bear ing or bushing Replace the swingarm bearing or bushing Symptom Possible cause Actions ...

Page 250: ...TROUBLESHOOTING 9 13 ...

Page 251: ...R SETTING 10 5 SPECIFICATIONS OF JET NEEDLE 10 5 EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM 10 5 CHANGE OF THE HEAT RANGE OF SPARK PLUGS 10 7 CHASSIS 10 8 SELECTION OF THE SECONDARY REDUCTION RATIO SPROCKET 10 8 DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS 10 8 TIRE PRESSURE 10 8 FRONT FORK SETTING 10 9 CHANGE IN AMOUNT AND CHARACTERISTICS OF FORK OIL 10 9 SETTING OF SPRING AFTER REPLACEM...

Page 252: ...ble to make a note of settings atmo spheric conditions road surface condition lap time etc so that the memorandum can be used as a reference useful for future EAM30591 ATMOSPHERIC CONDITIONS AND CARBURETOR SETTINGS The air density i e concentration of oxygen in the air determines the richness or leanness of the air fuel mixture Therefore refer to the above table for mixture settings That is Higher...

Page 253: ... 4 open can be set by turning the pilot air screw 1 Turning in the pilot air screw will make the mix ture enrich at low speeds and turning it out will lean it EAM30596 PILOT JET ADJUSTMENT The richness of air fuel mixture with the throttle fully closed to 1 2 open can be set by turning the pilot jet 1 It is changed when adjustment can not be made by the pilot air screw alone A larger size jet resu...

Page 254: ...iate 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 quickly In this case step down the jet needle clip by one groove or 0 5 groove and move up the needle to e...

Page 255: ... Pilot jet Rich 50 4KM 14142 50 47 5 4KM 14142 47 45 4KM 14142 45 42 5 4KM 14142 42 STD 40 4KM 14142 40 37 5 4KM 14142 37 35 4KM 14142 35 32 5 4KM 14142 32 Lean 30 4KM 14142 30 Throttle valve Rich STD 4 0 1C3 14112 40 Lean 4 25 1C3 14112 42 Jet needle Rich 6BFY44 72 284 14116 K2 6BFY44 73 284 14116 K3 6BFY44 74 284 14116 K4 6BFY44 75 284 14116 K5 Lean 6BFY44 76 284 14116 K6 Rich 6BFY43 72 284 1411...

Page 256: ...43 73 4 6BFY43 74 4 6BFY43 75 4 6BFY43 76 4 0 5 richer 6BFY44 72 3 6BFY44 73 3 6BFY44 74 3 6BFY44 75 3 6BFY44 76 3 6BFY42 72 4 6BFY42 73 4 6BFY42 74 4 6BFY42 75 4 6BFY42 76 4 STD 6BFY43 72 3 6BFY43 73 3 6BFY43 74 3 6BFY43 75 3 6BFY43 76 3 0 5 leaner 6BFY44 72 2 6BFY44 73 2 6BFY44 74 2 6BFY44 75 2 6BFY44 76 2 6BFY42 72 3 6BFY42 73 3 6BFY42 74 3 6BFY42 75 3 6BFY42 76 3 Lean 1 leaner 6BFY43 72 2 6BFY...

Page 257: ... clip position is the jet needle groove on which the clip is installed The positions are numbered from the top It a change in the clip position 1 groove is effective try another jet needle that provides a difference of 0 5 in the clip position Closed to 1 4 throttle Hard breathing Speed down Use jet needle having a smaller diam eter Closed to 1 4 throttle Poor acceleration White smoke Use jet need...

Page 258: ... No of the main jet must be changed by 30 it is advisable to change the heat range of spark plugs and newly select the proper main jet TIP When checking the discoloration of spark plugs be sure to stop the engine immediately after a run and check Avoid racing When changing the heat range of spark plugs never attempt to change it more than 1 rank When using a spark plug other than standard check it...

Page 259: ...an develop its maximum revolutions toward the end of the straight line with care taken to avoid the en gine over revving TIP Riding technique varies from rider to rider and the performance of a machine also vary from machine to machine Therefore do not imitate other rider s settings from the beginning but choose your own setting according to the level of your riding technique EAM30169 DRIVE AND RE...

Page 260: ...cs to have a ten dency to be stiffer with the consequent dete riorated performance and characteristics Therefore adjust the front fork within the specified range EAM30173 SETTING OF SPRING AFTER REPLACEMENT As the front fork setting can be easily affected by the rear suspension take care so that the front and the rear are balanced in position etc when setting the front fork 1 Use of soft spring Ch...

Page 261: ...ween 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 and make adjustment by turning the adjuster 2 to achieve the standard figure from the subtraction of the length b from the length a TIP If...

Page 262: ...an dard as it may result in faulty performance Never use one whose overall length is great er than standard EAM30178 REAR SHOCK ABSORBER SETTING PARTS Rear shock spring 1 Equal pitch steel spring Unequal pitch steel spring TIP The unequal pitch spring is softer in initial char acteristic than the equal pitch spring and is dif ficult to bottom out under full compression The I D mark a is marked at ...

Page 263: ...THE REAR SHOCK ABSORBER AS SEMBLY on page 3 20 Spring preload adjusting positions Minimum Position in which the spring is turned in 1 5 mm 0 06 in from its free length Standard Position in which the spring is turned in 6 0 mm 0 24 in from its free length Maximum Position in which the spring is turned in 18 0 mm 0 71 in from its free length ...

Page 264: ...noticeable scars etc If any replace affected parts Slide metal Replace with a new one for extended use Piston metal Replace with a new one for extended use Lower bracket tightening torque Retighten to specified torque Poor initial move ment Rebound damp ing force Turn adjuster counterclockwise about 2 clicks to decrease damping Oil seals Apply grease in oil seal wall Soft over entire range bottomi...

Page 265: ...mount Increase oil amount by about 5 cm 0 2 US oz 0 2 Imp oz Obtrusive front tending to upper front posture Compression damping force Turn adjuster counterclockwise about 2 clicks to decrease damping Balance with rear end Set sunken length for 90 95 mm 3 5 3 7 in when one passenger is astride seat upper rear pos ture Spring Replace with soft spring Oil amount Decrease oil amount by about 5 10 cm 0...

Page 266: ... senger is astride seat Spring Replace with soft spring Bottoming out High compres sion damping Turn adjuster clockwise about 1 6 turn to increase damping Spring set length Set sunken length for 90 100 mm 3 5 3 9 in when one pas senger is astride seat Spring Replace with stiff spring Bouncing Rebound damp ing force Turn adjuster clockwise about 2 clicks to increase damping Spring Replace with soft...

Page 267: ...ance Buy with confidence knowing your Genuine Yamaha Accessories will fit right and perform right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care products They re formulated and approved by the toughest judges we know the Yamaha engineering teams that know your Yamaha from the inside out Genuine Yamaha Service Manuals Get the same factory man...

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