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Yamaha YZ450F(T), Owner'S Service Manual

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Yamaha YZ450F(T) Owner'S Service Manual Download Page 249

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CHAS

EC5B3000

REMOVAL POINTS

EC5B3100

Master cylinder

1. Remove:

• Master cylinder bracket 

1

 

• Master cylinder 

2

 

CAUTION:

• Do not let the master cylinder hang on the

brake hose.

• Keep the master cylinder cap side hori-

zontal to prevent air from coming in.

EC5B3200

Grip

1. Remove:

• Grip 

1

 

NOTE:

Blow in air between the handlebar or tube
guide and the grip. Then remove the grip
which has become loose.

EC5B4000

INSPECTION

EC5B4100

Handlebar

1. Inspect:

• Handlebar 

1

 

Bends/cracks/damage 

→

 Replace.

WARNING

Do not attempt to straighten a bent handle-
bar as this may dangerously weaken the
handlebar.

HANDLEBAR

Summary of Contents for YZ450F(T)

Page 1: ...LIT 11626 18 44 YZ450FT 5XD 28199 11 OWNER S SERVICE MANUAL ...

Page 2: ......

Page 3: ...2004 by Yamaha Motor Corporation U S A 1st Edition June 2004 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 18 44 ...

Page 4: ...please contact your Yamaha dealer NOTE As improvements are made on this model some data in this manual may become out dated If you have any questions please con sult your Yamaha dealer WARNING 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 A...

Page 5: ......

Page 6: ... PROTECTIVE APPAREL When operating this machine always wear an approved helmet with gog gles or a face shield Also wear heavy boots gloves and protective cloth ing Always wear proper fitting cloth ing that will not be caught in any of the moving parts or controls of the machine 4 ALWAYS MAINTAIN YOUR MACHINE IN PROPER WORKING ORDER For safety and reliability the machine must be properly maintained...

Page 7: ...s Carbon monoxide is a danger ous gas which can cause unconsciousness or can be lethal 8 PARK THE MACHINE CAREFULLY TURN OFF THE ENGINE Always turn off the engine if you are going to leave the machine Do not park the machine on a slope or soft ground as it may fall over 9 THE ENGINE EXHAUST PIPE MUF FLER AND OIL TANK WILL BE VERY HOT AFTER THE ENGINE HAS BEEN RUN Be careful not to touch them or to...

Page 8: ...his machine and should remain with it even if the machine is subsequently sold EC060000 NOTICE Some data in this manual may become out dated due to improvements made to this model in the future If there is any question you have regarding this manual or your machine please consult your Yamaha dealer EC070001 F I M MACHINE WEIGHTS Weights of machines without fuel The minimum weights for motocross ma...

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

Page 10: ... start of each removal and disassembly section 1 An easy to see exploded diagram 1 is provided for removal and disassembly jobs 2 Numbers 2 are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy to read way by the use of symbol marks 3 The meanings of the symbol marks a...

Page 11: ...ubricant B Tightening C Specified value Service limit D Resistance Ω Voltage V Electric current A Illustrated symbols E to H in the exploded diagrams indicate grade of lubricant and loca tion of lubrication point E Apply engine oil F Apply molybdenum disulfide oil G Apply lightweight lithium soap base grease H Apply molybdenum disulfide grease Illustrated symbols I to J in the exploded diagrams in...

Page 12: ...EC090000 INDEX GENERAL INFORMATION 1 SPECIFICATIONS SPEC 2 REGULAR INSPECTION AND ADJUSTMENTS 3 ENGINE ENG 4 CHASSIS CHAS 5 ELECTRICAL ELEC 6 TUNING TUN 7 GEN INFO INSP ADJ ...

Page 13: ...AK IN 1 14 TORQUE CHECK POINTS 1 18 CLEANING AND STORAGE 1 19 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 GENERAL TORQUE SPECIFICATIONS 2 18 DEFINITION OF UNITS 2 18 LUBRICATION DIAGRAMS 2 19 CABLE ROUTING DIAGRAM 2 21 CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS 3 1 PRE OPERATION INSPECTION AND MAINTENANCE 3 4 ENGINE 3 5 CHASSIS 3 24 EL...

Page 14: ... CLUTCH 4 48 OIL FILTER WATER PUMP AND CRANKCASE COVER RIGHT 4 55 BALANCER 4 62 OIL PUMP 4 65 KICK AXLE AND SHIFT SHAFT 4 69 CDI MAGNETO 4 76 ENGINE REMOVAL 4 80 CRANKCASE AND CRANKSHAFT 4 85 TRANSMISSION SHIFT CAM AND SHIFT FORK 4 94 CHAPTER 5 CHASSIS FRONT WHEEL AND REAR WHEEL 5 1 FRONT BRAKE AND REAR BRAKE 5 10 FRONT FORK 5 26 HANDLEBAR 5 42 STEERING 5 48 SWINGARM 5 53 REAR SHOCK ABSORBER 5 61 ...

Page 15: ...CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM 6 1 MAP CONTROLLED CDI UNIT 6 2 IGNITION SYSTEM 6 3 TPS THROTTLE POSITION SENSOR SYSTEM 6 7 CHAPTER 7 TUNING ENGINE 7 1 CHASSIS 7 11 ...

Page 16: ...cap 7 ENGINE STOP button 8 Kick starter 9 Fuel tank 0 Radiator A Coolant drain bolt B Rear brake pedal C Valve joint D Fuel cock E Cold starter knob F Drive chain G Air cleaner H Shift pedal I Oil dipstick J Front fork NOTE The machine you have purchased may differ slightly from those shown in the following Designs and specifications are subject to change without notice 1 ...

Page 17: ...chine is stolen the authorities will need the number to search for and identify your machine EC121001 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped on the right of the steering head pipe EC123001 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the right side of the engine EC124000 MODEL LABEL The model label 1 is affixed to the fr...

Page 18: ...he bottom Drain hole on the cylinder head right side 2 Use proper tools and cleaning equipment Refer to SPECIAL TOOLS section 3 When disassembling the machine keep mated parts together They include gears cylinders pistons and other mated parts that have been mated through normal wear Mated parts must be reused as an assembly or replaced 4 During the machine disassembly clean all parts and place th...

Page 19: ... EC134000 LOCK WASHERS PLATES AND COTTER PINS 1 All lock washers plates 1 and cotter pins must be replaced when they are removed Lock tab s should be bent along the bolt or nut flat s after the bolt or nut has been properly tightened EC135001 BEARINGS AND OIL SEALS 1 Install the bearing s 1 and oil seal s 2 with their manufacturer s marks or numbers facing outward In other words the stamped letter...

Page 20: ...hould be inspected carefully before reassembly Always replace piston pin clips after one use Replace distorted circlips When installing a circlip 1 make sure that the sharp edged corner 2 is posi tioned opposite to the thrust 3 it receives See the sectional view 4 Shaft ...

Page 21: ...o check that it will not come off 5 If the terminal comes off bend up the pin 1 and reinsert the terminal into the con nector 6 Connect Connector NOTE The two connectors click together 7 Check for continuity with a tester NOTE If there in no continuity clean the terminals Be sure to perform the steps 1 to 7 listed above when checking the wire harness For a field remedy use a contact revitalizer av...

Page 22: ...This tool is used when loosening or tightening the fly wheel magneto securing nut YU 1235 90890 01235 YU 3097 90890 01252 YU 1256 Dial gauge and stand Stand These tools are used to check each part for runout or bend YU 3097 YU 1256 90890 01252 YU 90050 90890 01274 YU 90050 90890 01275 YU 91044 90890 04081 YU 90063 90890 01278 Crankshaft installing tool Crankshaft installing pot Crankshaft installi...

Page 23: ...se this tool to inspect the coil resistance output voltage and amperage YU 3112 C 90890 03112 YM 33277 A 90890 03141 Timing light This tool is necessary for checking ignition timing YM 33277 A 90890 03141 YM 4019 90890 04019 Valve spring compressor This tool is needed to remove and install the valve assemblies YM 4019 90890 04019 YM 91042 90890 04086 Clutch holding tool This tool is used to hold t...

Page 24: ... 18 in Exhaust 5 0 mm 0 20 in This tool is needed to rebore the new valve guide YM 4118 YM 4099 90890 04118 90890 04099 YM 34487 90890 06754 Dynamic spark tester Ignition checker This instrument is necessary for checking the ignition system components YM 34487 90890 06754 ACC QUICK GS KT 90890 85505 Quick gasket YAMAHA Bond No 1215 This sealant Bond is used for crankcase mating sur face etc ACC QU...

Page 25: ...EDAL The gear ratios of the constant mesh 4 speed transmission are ideally spaced The gears can be shifted by using the shift pedal 1 on the left side of the engine EC154000 KICK STARTER Rotate the kick starter 1 away from the engine Push the starter down lightly with your foot until the gears engage then kick smoothly and forcefully to start the engine This model has a primary kick starter so the...

Page 26: ... is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position COLD STARTER KNOB When cold the engine requires a richer air fuel mixture for starting A separate starter circuit which is controlled by the cold starter knob 1 supplies this mixture Pull the cold starter knob out to open the circuit for starting When the engine has...

Page 27: ... Remove this sidestand before starting out EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose CAUTION In this installation make sure the arrow faces the fuel tank and also downward SPARK PLUG WRENCH This spark plug wrench 1 is used to remove and install the spark plug 1 1 NIPPLE WRENCH This nipple wrench 1 is used to tighten the s...

Page 28: ...uch as valves piston rings and exhaust system etc NOTE If knocking or pinging occurs use a different brand of gasoline or higher octane grade WARNING For refueling be sure to stop the engine and use enough care not to spill any fuel Also be sure to avoid refueling close to a fire Refuel after the engine exhaust pipe etc have cooled off Recommended fuel Premium unleaded gasoline only with a researc...

Page 29: ... the spark plug will foul Unlike a two stroke engine this engine cannot be kick started when the throttle is open because the kick starter may kick back Also if the throttle is open the air fuel mixture may be too lean for the engine to start Before starting the machine perform the checks in the pre operation check list STARTING A COLD ENGINE 1 Inspect the coolant level 2 Turn the fuel cock to ON ...

Page 30: ...5 000 r min for 1 or 2 minutes NOTE Since this model is equipped with an accelera tor pump if the engine is raced the throttle opened and closed the air fuel mixture will be too rich and the engine may stall Also unlike a two stroke engine this model can idle CAUTION Do not warm up the engine for extended periods of time ...

Page 31: ... kick the kick starter 10 to 20 times to clear the engine Then restart the engine Refer to Restarting an engine after a fall Operate the throttle grip before kick starting CAUTION Observe the following break in procedures during initial operation to ensure optimum performance and avoid engine damage Throttle grip oper ation Cold starter knob Hot starter lever Starting a cold engine Air temperature...

Page 32: ...speed for about one hour 6 Restart the engine and check the operation of the machine throughout its entire operat ing range Restart the machine and oper ate it for about 10 to 15 more minutes The machine will now be ready to race CAUTION After the break in or before each race you must check the entire machine for loose fittings and fasteners as per TORQUE CHECK POINTS Tighten all such fasteners as...

Page 33: ...t axle Tightening of axle holder Tightening of rear axle Wheel to sprocket Caliper to front fork Brake disc to wheel Tightening of union bolt Master cylinder to handlebar Tightening of air bleeder Tightening of brake hose holder Brake pedal to frame Brake disc to wheel Tightening of union bolt Master cylinder to frame Tightening of air bleeder Tightening of brake hose holder Fuel tank to fuel cock...

Page 34: ... use only enough pressure to do the job CAUTION Excessive hose pressure may cause water seepage and contamination of wheel bear ings front forks brakes and transmission seals Many expensive repair bills have resulted from improper high pressure detergent applications such as those avail able in coin operated car washers 4 After the majority of the dirt has been hosed off wash all surfaces with war...

Page 35: ...pour a tablespoon of SAE 10W 30 motor oil in the spark plug hole and reinstall the plug With the engine stop switch pushed in kick the engine over several times to coat the cylinder walls with oil 3 Remove the drive chain clean it thoroughly with solvent and lubricate it Reinstall the chain or store it in a plastic bag tied to the frame 4 Lubricate all control cables 5 Block the frame up to raise ...

Page 36: ... 1 300 mm 51 2 in 1 302 mm 51 3 in 1 303 mm 51 3 in Seat height 999 mm 39 3 in 1 001 mm 39 4 in Wheelbase 1 493 mm 58 8 in Minimum ground clearance 379 mm 14 9 in 381 mm 15 0 in Dry weight Without oil and fuel 100 0 kg 220 lb Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement Single cylinder forward inclined Displacement 449 cm3 15 8 Imp oz 15 2 US oz Bore stroke 95 0 63 4 mm 3 74...

Page 37: ...06 US qt With oil filter replacement 1 1 L 0 97 Imp qt 1 16 US qt Total amount 1 2 L 1 06 Imp qt 1 27 US qt Coolant capacity including all routes 1 2 L 1 06 Imp qt 1 27 US qt Air filter Wet type element Fuel Type Premium unleaded gasoline only with a research octane number of 95 or higher Tank capacity 7 0 L 1 54 Imp gal 1 85 US gal Carburetor Type FCR MX39 Manufacturer KEIHIN Spark plug Type manu...

Page 38: ... 100 21 51M For USA CDN ZA AUS NZ and F 80 100 21 51R For EUROPE except F Size rear 110 90 19 62M For USA CDN ZA AUS NZ and F 110 90 19 NHS For EUROPE except F Tire pressure front and rear 100 kPa 1 0 kgf cm2 15 psi Brake Front brake type Single disc brake Operation Right hand operation Rear brake type Single disc brake Operation Right foot operation Suspension Front suspension Telescopic fork Rea...

Page 39: ...mm 0 8661 0 8670 in Camshaft journal diameter 21 967 21 980 mm 0 8648 0 8654 in Shaft to cap clearance 0 020 0 054 mm 0 0008 0 0021 in 0 08 mm 0 003 in Cam dimensions Intake A 31 200 31 300 mm 1 2283 1 2323 in 31 100 mm 1 2244 in B 22 550 22 650 mm 0 8878 0 8917 in 22 450 mm 0 8839 in Exhaust A 30 950 31 050 mm 1 2185 1 2224 in 30 850 mm 1 2146 in B 22 494 22 594 mm 0 8856 0 8895 in 22 394 mm 0 88...

Page 40: ...354 0 0433 in 1 6 mm 0 0630 in D margin thickness IN 1 mm 0 0394 in 0 85 mm 0 033 in EX 1 mm 0 0394 in 0 85 mm 0 033 in Stem outside diameter IN 4 475 4 490 mm 0 1762 0 1768 in 4 445 mm 0 1750 in EX 4 965 4 980 mm 0 1955 0 1961 in 4 935 mm 0 1943 in Guide inside diameter IN 4 500 4 512 mm 0 1772 0 1776 in 4 550 mm 0 1791 in EX 5 000 5 012 mm 0 1969 0 1973 in 5 050 mm 0 1988 in Stem to guide cleara...

Page 41: ... lb at 1 08 in Tilt limit IN 2 5 1 61mm 2 5 0 063 in EX 2 5 1 65mm 2 5 0 065 in Direction of winding top view IN Clockwise EX Clockwise Piston Piston to cylinder clearance 0 040 0 065 mm 0 0016 0 0026 in 0 1 mm 0 004 in Piston size D 94 945 94 960 mm 3 738 3 739 in Measuring point H 8 mm 0 315 in Piston off set 1 mm 0 0394 in Piston pin bore inside diameter 18 004 18 015 mm 0 7088 0 7093 in 18 045...

Page 42: ...Side clearance 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in Oil ring Dimensions B T 2 0 2 9 mm 0 08 0 11 in End gap installed 0 2 0 5 mm 0 01 0 02 in Crankshaft Crank width A 61 95 62 00 mm 2 439 2 441 in Runout limit C 0 03 mm 0 0012 in 0 05 mm 0 002 in Big end side clearance D 0 15 0 45 mm 0 0059 0 0177 in 0 50 mm 0 02 in Small end free play F 0 4 1 0 mm 0 02 0 04 in 2 0 mm 0 08 in Balancer ...

Page 43: ...hifter Shifter type Cam drum and guide bar Guide bar bending limit 0 05 mm 0 002 in Kick starter Type Ratchet type Carburetor I D mark 5XD5 50 Main jet M J 165 Main air jet M A J ø2 0 Jet needle clip position J N NFLR 4 Cutaway C A 1 5 Pilot jet P J 45 Pilot air jet P A J 100 Pilot outlet P O ø0 9 Pilot screw example P S 1 3 4 Bypass B P ø1 0 Valve seat size V S ø3 8 Starter jet G S 72 Leak jet Ac...

Page 44: ...rance 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 007 in Bypass valve setting pressure 40 80 kPa 0 4 0 8 kg cm2 5 69 11 38 psi Cooling Radiator core size Width 117 8 mm 4 6 in Height 260 mm 10 2 in Thickness 32 mm 1 26 in Radiator cap opening pressure 110 kPa 1 1 kg cm2 15 6 psi Radiator capacity total 0 71 L 0 62 Imp qt 0 75 US qt Water pump Type Single suction centrifugal pump Item Standard Limit MA...

Page 45: ...essure feed Splashed scavenge Oil strainer Oil pan Oil pump rotor 2 Oil pump rotor 1 Oil tank Oil filter Check ball Cylinder head Crank pin Piston pin Piston Drive axle Main axle Transmission gears Camshaft Valve lifter MAINTENANCE SPECIFICATIONS ...

Page 46: ...0 7 1 3 0 3 2 2 Air filter case M6 1 0 2 8 0 8 5 8 Air filter joint clamp M6 1 0 1 3 0 3 2 2 Air filter joint and air filter case M5 0 8 1 4 0 4 2 9 Throttle cable pull M6 1 0 1 4 0 4 2 9 Throttle cable return M12 1 0 1 11 1 1 8 0 Throttle cable cover M5 0 8 2 4 0 4 2 9 Hot starter plunger M12 1 0 1 2 0 2 1 4 Air filter element M6 1 0 1 2 0 2 1 4 Radiator panel upper M6 1 0 2 10 1 0 7 2 Radiator M...

Page 47: ...2 0 14 crankcase left M6 1 0 1 10 1 0 7 2 Oil drain bolt frame M8 1 25 1 23 2 3 17 Oil strainer frame M14 1 5 1 70 7 0 50 Crankcase bearing stopper M6 1 0 15 10 1 0 7 2 Drive axle oil seal stopper M6 1 0 2 10 1 0 7 2 Ratchet wheel guide M6 1 0 2 12 1 2 8 7 Kick starter M8 1 25 1 33 3 3 24 Screw kick starter M6 1 0 1 7 0 7 5 1 Primary drive gear M20 1 0 1 110 11 0 80 Clutch boss M20 1 0 1 75 7 5 54...

Page 48: ...oz 15 0 US oz 455 cm3 16 0 Imp oz 15 4 US oz Oil grade Suspension oil S1 Inner tube outer diameter 48 mm 1 89 in Front fork top end Zero mm Zero in Rear suspension USA CDN AUS NZ ZA EUROPE Shock absorber travel 132 mm 5 20 in Spring free length 260 mm 10 24 in Fitting length 248 mm 9 76 in 245 mm 9 65 in Min Max 240 5 258 5 mm 9 47 10 18 in Spring rate STD K 52 0 N mm 5 30 kg mm 296 8 lb in K 50 0...

Page 49: ... in 1 0 mm 0 04 in Master cylinder inside dia 11 0 mm 0 433 in Caliper cylinder inside dia 27 0 mm 1 063 in 2 Brake fluid type DOT 4 Rear disc brake Disc outside dia Thickness 245 4 0 mm 9 65 0 16 in 245 3 5 mm 9 65 0 14 in Deflection limit 0 15 mm 0 006 in Pad thickness 6 4 mm 0 25 in 1 0 mm 0 04 in Master cylinder inside dia 11 0 mm 0 433 in Caliper cylinder inside dia 25 4 mm 1 000 in 1 Brake f...

Page 50: ...2 9 Front brake master cylinder and bracket M6 1 0 2 9 0 9 6 5 Front brake master cylinder cap M4 0 7 2 2 0 2 1 4 Brake lever mounting bolt M6 1 0 1 6 0 6 4 3 Brake lever mounting nut M6 1 0 1 6 0 6 4 3 Brake lever position locknut M6 1 0 1 5 0 5 3 6 Cable guide front brake hose and under bracket M6 1 0 1 4 0 4 2 9 Front brake hose union bolt master cylinder M10 1 25 1 30 3 0 22 Front brake hose u...

Page 51: ...g rod M14 1 5 1 80 8 0 58 Connecting rod and frame M14 1 5 1 80 8 0 58 Rear shock absorber and frame M10 1 25 1 56 5 6 40 Rear shock absorber and relay arm M10 1 25 1 53 5 3 38 Rear frame and frame upper M8 1 25 1 32 3 2 23 Rear frame and frame lower M8 1 25 2 29 2 9 21 Swingarm and brake hose holder M5 0 8 4 1 0 1 0 7 Swingarm and patch M4 0 7 4 2 0 2 1 4 Drive chain tensioner mounting upper M8 1...

Page 52: ...istance color 248 372 Ω at 20 C 68 F White Red CDI unit model manufacturer 5XD 50 YAMAHA For USA 5XD 60 YAMAHA Except for USA Ignition coil Model manufacturer 5TA 10 DENSO Minimum spark gap 6 mm 0 24 in Primary winding resistance 0 08 0 10 Ω at 20 C 68 F Secondary winding resistance 4 6 6 8 kΩ at 20 C 68 F Part to be tightened Thread size Q ty Tightening torque Nm m kg ft lb Stator M6 1 0 3 10 1 0...

Page 53: ...e A Distance between flats B Outside thread diameter EC230000 DEFINITION OF UNITS A Nut B Bolt TORQUE SPECIFICATION Nm m kg ft lb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 6 15 30 55 85 130 0 6 1 5 3 0 5 5 8 5 13 4 3 11 22 40 61 94 Unit Read Definition Measure mm cm millimeter centimeter 10 3 meter 10 2 meter Length Length kg kilogram 103 gram Weight N Newton 1 kg m sec...

Page 54: ... 19 SPEC LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Oil delivery pipe 2 Intake camshaft 3 Exhaust camshaft 4 Oil cleaner element 5 Oil pump 6 Main axle 7 Drive axle 7 6 5 4 3 2 1 4 5 A A D D G G D D A A ...

Page 55: ...2 20 SPEC LUBRICATION DIAGRAMS 1 Camshaft 2 Connecting rod 3 Oil cleaner element 4 Crankshaft 5 Main axle 6 Drive axle 7 Oil delivery pipe ...

Page 56: ...aft cap É Pass the hot starter cable between the cylinder head breather hose oil tank breather hose and ignition coil then on the outside of the left engine bracket Ê Pass the clutch cable through the cable guides Ë Pass the cylinder head breather hose on the outside of the radia tor hose 1 and on the inside of the radiator pipe radiator hose 4 Ì Pass the clutch cable in front of the lower radiato...

Page 57: ...ther with a plastic locking tie and cut off the tie end Õ Fasten the neutral switch lead to the frame with a plastic band Ö Fasten the neutral switch lead CDI magneto lead and radiator breather hose to the frame with a plastic band Fasten the neutral switch lead CDI magneto lead and radiator breather hose to the frame with a plastic locking tie and cut off the tie end Ø Pass the neutral switch lea...

Page 58: ...on the neutral switch lead CDI magneto lead and radiator breather hose at the left of the frame B 0 C C D D B A A B D D C C F D G F D A G A A F A E A D C A A A A B A 0 1 2 3 4 5 6 7 8 9 Ì Ë Ê É È Ù Í Î Ï Ð Ð Ñ A Ô Õ Ø Ú H I H E Û Ò Ö Ê Ê Ê Ó ...

Page 59: ...and throttle cables between the radi ator and frame then over the middle radiator mounting boss Ë Pass the throttle cables on the outside of the ignition coil Ì Pass the carburetor breather hose throttle cable cover through the hose holder Í Pass the radiator breather hose at the rear of the radiator on the left of the chassis and then between the frame and radiator hose 4 Î Insert the CDI unit ba...

Page 60: ...ortion directs as shown and lightly touches the projec tion on the caliper É Pass the brake hose into the brake hose holders Ê If the brake hose contacts the spring rear shock absorber correct its twist Ë Install the brake hose so that its pipe portion directs as shown and lightly touches the projec tion on the master cylinder ...

Page 61: ...ther hose 3 Clamp 4 Clutch cable 5 Hot starter cable 6 ENGINE STOP button lead 7 Brake hose 8 Hose guide È Fasten the ENGINE STOP but ton lead to the handlebar with the plastic band É Pass the brake hose in front of the number plate 3 6 40 10 A 1 2 3 4 5 6 7 8 È É A ...

Page 62: ...he valve seats and valve stems for wear Check the valve clearances Inspect Replace VALVE SPRINGS Check the free length and the tilt Inspect Replace VALVE LIFTERS Check for scratches and wear Inspect Replace CAMSHAFTS Inspect the camshaft sur face Inspect the decompres sion system Inspect Replace CAMSHAFT SPROCKETS Check for wear on the teeth and for damage Inspect Replace PISTON Inspect crack Insp...

Page 63: ...DE NUTS AND BOLTS Refer to STARTING AND BREAK IN section in the CHAPTER 1 Retighten AIR FILTER Use foam air filter oil or equivalent oil Clean and lubricate Replace OIL FILTER Replace OIL STRAINER frame Clean FRAME Clean and inspect FUEL TANK COCK Clean and inspect BRAKES Adjust lever position and pedal height Lubricate pivot point Check brake disc surface Check fluid level and leakage Retighten b...

Page 64: ...enum disulfide grease Inspect lube and retighten STEERING HEAD Inspect free play and retighten Clean and lube Lithium base grease Replace bearing TIRE WHEELS Inspect air pressure wheel run out tire wear and spoke looseness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate Lithium base grease THROTTLE CONTROL CABLE Yamaha cable lube or SAE 10W 30 motor oil Check routing and connec...

Page 65: ...e P 3 24 30 Chain Check chain slack and alignment Check that the chain is lubri cated properly P 3 31 33 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 41 42 Steering Check that the handlebar can be turned smoothly and have no excessive play P 3 42 44 Front forks and rear shock absorber Check that they operate smoothly and there is no oil le...

Page 66: ...cap slowly rotate the cap counterclockwise to the detent This procedure allows any residual pres sure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remove it CAUTION Hard water or salt water is harmful to the engine parts You may use distilled water if you can t get soft water 1 Place the machine on a level place and hold it in an upright pos...

Page 67: ...2 3 Remove Radiator cap Drain the coolant completely 4 Clean Cooling system Thoroughly flush the cooling system with clean tap water 5 Install Copper washer Coolant drain bolt Engine guard Bolt engine guard 6 Fill Radiator Engine To specified level Recommended coolant High quality ethylene glycol anti freeze containing anti corrosion for aluminum engine Coolant 1 and water soft water 2 mixing rati...

Page 68: ...vel low Add coolant Handling notes of coolant The coolant is harmful so it should be han dled with special care WARNING When coolant splashes to your eye Thoroughly wash your eye with water and see your doctor When coolant splashes to your clothes Quickly wash it away with water and then with soap When coolant is swallowed Quickly make him vomit and take him to a doctor EC355000 RADIATOR CAP INSPE...

Page 69: ...spect Pressure Impossible to maintain the specified pres sure for 10 seconds Replace Radiator cap tester YU 24460 01 90890 01325 Adapter YU 33984 90890 01352 Radiator cap opening pressure 110 kPa 1 1 kg cm2 15 6 psi EC357002 COOLING SYSTEM INSPECTION 1 Inspect Coolant level 2 Attach Radiator cap tester 1 and adapter 2 3 Apply the specified pressure Radiator cap tester YU 24460 01 90890 01325 Adapt...

Page 70: ... Swelling Replace EC359020 CLUTCH ADJUSTMENT 1 Check Clutch lever free play a Out of specification Adjust Clutch lever free play a 8 13 mm 0 31 0 51 in 2 Adjust Clutch lever free play NOTE Make minute adjustment on the lever side using the adjuster 2 After adjustment check proper operation of clutch lever Clutch lever free play adjustment steps Loosen the locknuts 1 Adjust the free play by changin...

Page 71: ...l the specified free play is obtained Tighten the locknut NOTE Before adjusting the throttle cable free play the engine idle speed should be adjusted WARNING After adjusting turn the handlebar to right and left and make sure that the engine idling does not run faster 2 1 THROTTLE LUBRICATION 1 Remove Cover throttle cable cap 1 Cover grip cap 2 Throttle cable cap 3 2 Apply Lithium soap base grease ...

Page 72: ...r lever free play adjustment steps Loosen the locknut 1 Turn the adjuster 2 until free play a is within the specified limits Tighten the locknut EC35G040 AIR FILTER CLEANING NOTE Proper air filter maintenance is the biggest key to preventing premature engine wear and damage CAUTION Never run the engine without the air filter element in place this would allow dirt and dust to enter the engine and c...

Page 73: ... too much of solvent in the ele ment may result in poor starting 3 Inspect Air filter element Damage Replace 4 Apply Foam air filter oil or equivalent oil to the element NOTE Squeeze out the excess oil Element should be wet but not dripping 5 Install Filter guide 1 NOTE Align the projection a on filter guide with the hole b in air filter element 6 Apply Lithium soap base grease On the matching sur...

Page 74: ...en checking the oil level make sure that the machine is upright Place the machine on a suitable stand WARNING Never remove the oil tank cap just after high speed operation The heated oil could spurt out causing danger Wait until the oil cools down to approximately 70 C 158 F 2 Idle the engine more than 3 minutes while keeping the machine upright Then stop the engine and inspect the oil level 3 Rem...

Page 75: ... not use oils labeled ENERGY CON SERVING II b or higher Engine oil also lubricates the clutch and additives could cause clutch slippage Do not allow foreign materials to enter the crankcase Recommended oil At 5 C 40 F or higher È Yamalube 4 20W 40 or SAE 20W 40 type SG motor oil Non Friction modified At 15 C 60 F or lower É Yamalube 4 10W 30 or SAE 10W 30 type SG motor oil Non Friction modified an...

Page 76: ...ll Oil tank cap ENGINE OIL REPLACEMENT 1 Start the engine and let it warm up for sev eral minutes 2 Stop the engine and place an oil pan under the drain bolt 3 Remove Oil tank plug 1 Oil filler cap 2 Drain bolt with gasket 3 Oil filter drain bolt O ring 4 Drain bolt with gasket 5 Drain bolt with gasket 6 Drain the crankcase and oil tank frame of its oil 4 Remove Engine skid plate Engine oil hose c...

Page 77: ...Remove the oil filter cover 1 and oil filter element 2 Check the O rings 3 if cracked or dam aged replace them with a new one Install the oil filter element and oil filter cover T R Oil filter cover 10 Nm 1 0 m kg 7 2 ft lb Oil quantity Periodic oil change 1 0 L 0 88 Imp qt 1 06 US qt With oil filter replacement 1 1 L 0 97 Imp qt 1 16 US qt Total amount 1 2 L 1 06 Imp qt 1 27 US qt New T R 70 Nm 7...

Page 78: ...age Start the engine after solving the prob lem s and recheck the oil pressure Tighten the oil gallery bolt to specification T R Oil gallery bolt 10 Nm 1 0 m kg 7 2 ft lb PILOT SCREW ADJUSTMENT 1 Adjust Pilot screw 1 Adjusting steps NOTE To optimize the fuel flow at a smaller throttle opening each machine s pilot screw has been individually set at the factory Before adjusting the pilot screw turn ...

Page 79: ...ER 4 2 Remove Carburetor Refer to CARBURETOR section in the CHAPTER 4 Spark plug Engine stay upper Cylinder head cover Refer to CAMSHAFTS section in the CHAPTER 4 Adjustment steps Adjust the pilot screw Refer to PILOT SCREW ADJUSTMENT section Turn the throttle stop screw 1 until the specified engine idling speed NOTE Using a digital engine tachometer for idle speed adjustment detect the engine idl...

Page 80: ...rclockwise with a wrench Align the T D C mark a on the rotor with the align mark b on the crankcase cover when piston is at T D C on compression stroke NOTE In order to be sure that the piston is at Top Dead Center the punch mark c on the exhaust camshaft and the punch mark d on the intake camshaft must align with the cyl inder head surface as shown in the illustra tion Measure the valve clearance...

Page 81: ...e vent it from falling into the crankcase Remove the valve lifters 4 and the pads 5 NOTE Place a rag in the timing chain space to prevent pads from falling into the crank case Identity each valve lifter and pad position very carefully so that they can be rein stalled in their original place Select the proper pad using the pad selecting table Pad range Pad Availability 25 increments No 120 No 240 1...

Page 82: ...e these two coordinates intersect shows the new pad number to use NOTE Use the new pad number only as a guide when verifying the valve clearance adjust ment Install the new pads 6 and the valve lift ers 7 NOTE Apply the engine oil on the valve lifters Apply the molybdenum disulfide oil on the valve stem ends Valve lifter must turn smoothly when rotated with a finger Be careful to reinstall valve l...

Page 83: ...oner Refer to CAMSHAFTS section in the CHAPTER 4 NOTE Turn the crankshaft counterclockwise sev eral turns so that the installed parts settle into the right position Recheck the valve clearance If the clearance is still incorrect repeat all the clearance adjustment steps until the specified clearance is obtained VALVE CLEARANCE ADJUSTMENT ...

Page 84: ...30 235 240 1 31 1 35 240 EXHAUST MEASURED CLEARANCE INSTALLED PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 0 05 0 09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0 10 0 14 120 125 130 135 140 145 1...

Page 85: ... Add proper brake fluid to the reservoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic tube 2 tightly to the caliper bleed screw 1 d Place the other end of the tube into a container e Slowly apply the brake lever or pedal several times f Pull the lever in or push down on the pedal Hold the lever or pedal in position g Loose...

Page 86: ...G Check the operation of the brake after bleeding the brake system EC362040 FRONT BRAKE ADJUSTMENT 1 Check Brake lever position a Brake lever position a Standard position Extent of adjustment 95 mm 3 74 in 76 97 mm 2 99 3 82 in 2 Remove Lever cover 3 Adjust Brake lever position 4 Install Lever cover Brake lever position adjustment steps Loosen the locknut 1 Turn the adjusting bolt 2 until the leve...

Page 87: ...nut WARNING Adjust the pedal height between the maximum È and the minimum É as shown In this adjustment the bolt 3 end b should protrude out of the threaded portion 4 but not be less than 2 mm 0 08 in c away from the brake pedal 5 After the pedal height adjustment make sure that the rear brake does not drag È É EC365080 FRONT BRAKE PAD INSPECTION AND REPLACEMENT 1 Inspect Brake pad thickness a Out...

Page 88: ...end Loosen the bleed screw and push the cali per piston in CAUTION Do not reuse the drained brake fluid Tighten the bleed screw T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb Install the brake pads 7 and pad pin NOTE Install the brake pads with their projections a into the caliper recesses b Temporarily tighten the pad pin at this point Install the caliper 8 and tighten the pad pin 9 T R Bolt caliper 23 ...

Page 89: ... the pad pin plug 0 T R Pad pin plug 3 Nm 0 3 m kg 2 2 ft lb EC366060 REAR BRAKE PAD INSPECTION AND REPLACEMENT 1 Inspect Brake pad thickness a Out of specification Replace as a set 2 Replace Brake pad Brake pad thickness a Standard Limit 6 4 mm 0 25 in 1 0 mm 0 04 in Brake pad replacement steps Remove the protector 1 and pad pin plug 2 Loosen the pad pin 3 Remove the rear wheel 4 and caliper 5 Re...

Page 90: ... the bleed screw T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb Install the brake pad 0 and pad pin A NOTE Install the brake pads with their projections a into the caliper recesses b Temporarily tighten the pad pin at this point Install the caliper B and rear wheel C Refer to FRONT WHEEL AND REAR WHEEL section in the CHAPTER 5 Tighten the pad pin D T R Pad pin 18 Nm 1 8 m kg 13 ft lb Install the pad pin ...

Page 91: ...e pad insulator 1 Damage Replace EC367001 BRAKE FLUID LEVEL INSPECTION 1 Place the master cylinder so that its top is in a horizontal position 2 Inspect Brake fluid level Fluid at lower level Fill up a Lower level È Front É Rear WARNING Use only designated quality brake fluid to avoid poor brake performance Refill with same type and brand of brake fluid mixing fluids could result in poor brake per...

Page 92: ...ecification Replace NOTE While measuring the drive chain length push down on the drive chain to increase its ten sion Measure the length between drive chain roller 1 and F as shown Perform this measurement at two or three different places Drive chain length 15 links Limit 242 9 mm 9 563 in 2 Remove Master link clip Joint 1 Drive chain 2 3 Clean Drive chain Place it in kerosene and brush off as muc...

Page 93: ...e chain lubricant SAE 10W 30 motor oil or suitable chain lubricants DRIVE CHAIN SLACK ADJUSTMENT 1 Elevate the rear wheel by placing the suit able stand under the engine 2 Check Drive chain slack a Above the seal guard installation bolt Out of specification Adjust NOTE Before checking and or adjusting rotate the rear wheel through several revolutions and check the slack several times to find the t...

Page 94: ...marks a on each side of chain puller alignment NOTE Turn the adjuster so that the chain is in line with the sprocket as viewed from the rear CAUTION Too small chain slack will overload the engine and other vital parts keep the slack within the specified limits Tighten the axle nut while pushing down the drive chain T R Axle nut 125 Nm 12 5 m kg 90 ft lb Tighten the locknuts T R Locknut 16 Nm 1 6 m...

Page 95: ...grease on the inner tube FRONT FORK INTERNAL PRESSURE RELIEVING NOTE If the front fork initial movement feels stiff dur ing a run relieve the front fork internal pres sure 1 Elevate the front wheel by placing a suit able stand under the engine 2 Remove the air bleed screw 1 and release the internal pressure from the front fork 3 Install Air bleed screw EC36H002 FRONT FORK REBOUND DAMPING FORCE ADJ...

Page 96: ...ways adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability Extent of adjustment Maximum Minimum Fully turned in position 20 clicks out from maximum position Standard position 13 clicks out 14 clicks out EC36J001 FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT 1 Adjust Compression damping force By turning the adjuster 1 Stiffer a Increase the com...

Page 97: ...ter may be damaged WARNING Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability Extent of adjustment Maximum Minimum Fully turned in position 20 clicks out from maximum position Standard position 8 clicks out 11 clicks out EC36K000 REAR SHOCK ABSORBER INSPECTION 1 Inspect Swingarm smooth action Abnormal noise unsmooth action Grease the p...

Page 98: ...adjuster before adjustment The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster CAUTION Never attempt to turn the adjuster beyond the maximum or minimum setting 5 Tighten Locknut 6 Install Rear frame upper Rear frame lower Stiffer Increase the spring preload Turn the adjuster 2 in Softer Decrease the spring preload Turn the adjuster 2 out Spring length installed a Sta...

Page 99: ...urn the adjuster 1 out Extent of adjustment Maximum Minimum Fully turned in position 20 clicks out from maximum position STANDARD POSITION This is the position which is back by the spe cific number of clicks from the fully turned in position Which align the punch mark a on the adjuster with the punch mark b on the bracket For EUROPE CAUTION Do not force the adjuster past the minimum or maximum ext...

Page 100: ...n damping force Turn the adjuster 1 out Extent of adjustment Maximum Minimum Fully turned in position 20 clicks out from maximum position a b 1 STANDARD POSITION This is the position which is back by the spe cific number of clicks from the fully turned in position Which align the punch mark a on the adjuster with the punch mark b on the high compression damping adjuster CAUTION Do not force the ad...

Page 101: ...mum Minimum Fully turned in position 2 turns out from maximum position 1 a b STANDARD POSITION This is the position which is back by the spe cific number of turns from the fully turned in position Which align the punch mark a on the adjuster with the punch mark b on the adjuster body For EUROPE CAUTION Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be d...

Page 102: ...its position on the rim If the tire valve stem is found tilted the tire is considered to be slipping off its position Cor rect the tire position Standard tire pressure 100 kPa 1 0 kgf cm2 15 psi EC36S002 SPOKES INSPECTION AND TIGHTENING 1 Inspect Spokes 1 Bend damage Replace Loose spoke Retighten 2 Tighten Spokes NOTE Be sure to retighten these spokes before and after break in After a practice or ...

Page 103: ... shaft Grasp the bottom of the forks and gently rock the fork assembly back and forth Free play Adjust steering head 3 Check Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steering ring nut 4 Adjust Steering ring nut Steering ring nut adjustment steps Remove the number plate Remove the handlebar and handle crown Loosen the ring nut 1 using the ring nut wrench 2 Ring ...

Page 104: ...ghtening 7 Nm 0 7 m kg 5 1 ft lb Check the steering shaft by turning it lock to lock If there is any binding remove the steering shaft assembly and inspect the steering bearings Install the plain washer 5 handle crown 6 plain washer 7 steering shaft nut 8 steering shaft cap 9 handlebar 0 han dlebar holder A and number plate B NOTE The upper handlebar holder should be installed with the punched mar...

Page 105: ... Steering shaft nut 145 Nm 14 5 m kg 105 ft lb Handlebar upper holder 28 Nm 2 8 m kg 20 ft lb Pinch bolt handle crown 23 Nm 2 3 m kg 17 ft lb Number plate 7 Nm 0 7 m kg 5 1 ft lb STEERING HEAD INSPECTION AND ADJUSTMENT ...

Page 106: ...5 Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding portion 8 Throttle cable end 9 Clutch cable end 0 Hot starter cable end È Use Yamaha cable lube or equivalent on these areas É Use SAE 10W 30 motor oil or suitable chain lubricants Ê Lubricate the following areas with high quality lightweight lithium soap base grease CAUTION Wipe off any excess grease and avoid get ting greas...

Page 107: ...many hours at low speeds the spark plug insulator will become sooty even if the engine and carburetor are in good operating condition 3 Measure Plug gap a Use a wire gauge or thickness gauge Out of specification Regap Spark plug gap 0 7 0 8 mm 0 028 0 031 in 4 Clean the plug with a spark plug cleaner if necessary 5 Tighten Spark plug NOTE Before installing a spark plug clean the gas ket surface an...

Page 108: ...ignition coil lead orange lead 1 Timing light YM 33277 A 90890 03141 3 Adjust Engine idling speed Refer to IDLE SPEED ADJUSTMENT 4 Check Ignition timing Visually check the stationary pointer a is within the firing range b on the rotor Incorrect firing range Check rotor and pickup assembly 5 Install Timing plug ...

Page 109: ...l Order Part name Q ty Remarks SEAT FUEL TANK AND SIDE COVERS REMOVAL Preparation for removal Turn the fuel cock to OFF Disconnect the fuel hose 1 Seat 1 2 Air scoop left and right 2 3 Fitting band 1 Remove on fuel tank side 4 Bolt fuel tank 2 5 Fuel tank 1 6 Side cover left 1 Refer to REMOVAL POINTS 7 Side cover right 1 8 Number plate 1 1 3 4 2 3 SEAT FUEL TANK AND SIDE COVERS ...

Page 110: ... POINTS Side cover 1 Remove Bolt side cover Side cover left 1 Side cover right 2 NOTE Draw the side cover downward to remove it because its claws a are inserted in the air fil ter case SEAT FUEL TANK AND SIDE COVERS 4 ...

Page 111: ...t of removal Order Part name Q ty Remarks EXHAUST PIPE AND SILENCER REMOVAL Preparation for removal Side cover right Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Bolt clamp 1 Only loosening 2 Bolt silencer front 1 3 Bolt silencer rear 1 4 Collar 1 5 Silencer 1 6 Clamp 1 7 Nut exhaust pipe 1 8 Bolt exhaust pipe 1 9 Exhaust pipe 1 10 Gasket 2 2 1 2 ...

Page 112: ... 0 m kg 14 ft lb After that retighten the nut exhaust pipe 13 Nm 1 3 m kg 9 4 ft lb and then the bolt exhaust pipe 24 Nm 2 4 m kg 17 ft lb 3 1 2 New T R 13 Nm 1 3 m kg 9 4 ft lb T R 24 Nm 2 4 m kg 17 ft lb 2 Install Clamp 1 Gasket 2 Washer 3 Silencer 4 Plain washer 5 Bolt silencer 6 NOTE Install the gasket with its meshed area a toward the exhaust pipe side The gasket should be installed according...

Page 113: ...oolant Refer to COOLANT REPLACEMENT section in the CHAPTER 3 Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section 1 Engine guard 1 2 Panel 2 3 Clamp 8 4 Radiator right 1 5 Hose 2 1 6 Hose 3 1 7 Hose 4 1 8 Pipe 2 O ring 1 1 9 Radiator breather hose 1 10 Radiator left 1 11 Hose 1 1 12 Pipe 1 O ring 1 1 1 ...

Page 114: ... residual pressure to escape When the hissing sound has stopped press down on the cap while turning coun terclockwise and remove it EC454000 INSPECTION EC444100 Radiator 1 Inspect Radiator core 1 Obstruction Blow out with compressed air through rear of the radiator Bent fin Repair replace EC455000 ASSEMBLY AND INSTALLATION Radiator 1 Install Pipe 1 1 Hose 1 2 Pipe 2 3 Hose 3 4 Hose 4 5 T R 10 Nm 1...

Page 115: ... hose 1 Radiator right 2 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 T R 10 Nm 1 0 m kg 7 2 ft lb 4 Install Panel 1 Bolt radiator panel upper 2 NOTE Fit the hook a on the inner side first into the radiator T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 116: ...removal 1 Carburetor removal Extent of removal Order Part name Q ty Remarks CARBURETOR REMOVAL Preparation for removal Fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Band 1 2 TPS coupler 1 3 Throttle cable cover 1 4 Throttle cable 2 5 Clamp air cleaner joint 1 Loosen the screw air cleaner joint 6 Clamp carburetor joint 2 Loosen the screws carburetor joint 7 Hot starter plunger 1 8 Car...

Page 117: ...y Remarks CARBURETOR DISASSEMBLY 1 Breather hose 4 2 Valve lever housing cover 1 3 Screw throttle shaft 1 4 Throttle valve 1 5 Needle holder 1 6 Jet needle 1 7 Cover 1 8 Spring 1 9 Diaphragm accelerator pump 1 0 Float chamber 1 A Leak jet 1 B Pilot screw 1 Refer to REMOVAL POINTS C Float pin 1 D Float 1 E Needle valve 1 1 ...

Page 118: ...al Order Part name Q ty Remarks F Main jet 1 G Needle jet 1 H Spacer 1 I Pilot jet 1 J Starter jet 1 K Push rod 1 Pull the push rod L Throttle shaft assembly 1 M Push rod link lever assembly 1 N Pilot air jet 1 O Cold starter plunger 1 1 ...

Page 119: ...e Pilot screw 1 NOTE To optimize the fuel flow at a small throttle opening each machine s pilot screw has been individually set at the factory Before removing the pilot screw turn it in fully and count the number of turns Record this number as the factory set number of turns out INSPECTION Carburetor 1 Inspect Carburetor body Contamination Clean NOTE Use a petroleum based solvent for cleaning Blow...

Page 120: ...d air Never use a wire Needle valve 1 Inspect Needle valve 1 Valve seat 2 Grooved wear a Replace Dust b Clean Filter c Clogged Clean EC464300 Throttle valve 1 Check Free movement Stick Repair or replace Insert the throttle valve 1 into the carbu retor body and check for free movement EC464400 Jet needle 1 Inspect Jet needle 1 Bends wear Replace Clip groove Free play exists wear Replace Clip positi...

Page 121: ...ht of the float will push in the needle valve resulting in an incorrect measurement Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers NOTE The float arm should be resting on the nee dle valve but not compressing the needle valve If the float height is not within specification inspect the valve seat and needle valve If either is worn ...

Page 122: ...spect Diaphragm accelerator pump 1 Spring 2 Cover 3 O ring 4 Push rod 5 Tears diaphragm damage Replace Dirt Clean 2 Inspect Throttle shaft 1 Spring 2 Lever 1 3 Spring 1 4 Lever 2 5 Spring 2 6 Dirt Clean 1 2 3 4 5 6 ASSEMBLY AND INSTALLATION Carburetor 1 Install Cold starter plunger 1 2 Install Pilot air jet 1 1 CARBURETOR ...

Page 123: ...nstall Spring 2 1 To lever 2 2 1 2 5 Install Push rod link lever assembly 1 NOTE Make sure the stopper a of the spring 2 fits into the recess b in the carburetor 1 a b 6 Install Plain washer 1 Circlip 2 2 1 7 Install Spring 1 To throttle shaft 2 NOTE Install the bigger hook a of the spring fits on the stopper b of the throttle shaft pulley ...

Page 124: ...sition sensor Make sure the stopper c of the spring fits into the recess in the carburetor Turn the throttle shaft assembly left while holding down the lever 1 5 and fit the throt tle stop screw tip d to the stopper e of the throttle shaft assembly pulley 1 2 3 4 b a c e d 5 9 Install Push rod 1 NOTE While holding down the lever 1 2 insert the push rod farthest into the carburetor 1 2 10 Install S...

Page 125: ...stall Pilot screw 1 Spring 2 Washer 3 O ring 4 Note the following installation points Turn in the pilot screw until it is lightly seated Turn out the pilot screw by the number of turns recorded before removing Pilot screw 1 3 4 turns out example 13 Install O ring Leak jet 1 Float chamber 2 Screw float chamber 3 Cable holder throttle stop screw cable 4 Hose holder carburetor breather hose 5 ...

Page 126: ... Jet needle 1 Collar 2 Spring 3 Needle holder 4 Throttle valve plate 5 To throttle valve 6 5 6 1 2 3 4 16 Install Throttle valve assembly 1 Screw throttle shaft 2 NOTE Install the valve lever rollers 3 into the slits a of the throttle valve 17 Install O ring 1 Valve lever housing cover 2 Bolt valve lever housing cover 3 18 Install Carburetor breather hose 1 Refer to CABLE ROUTING DIAGRAM section i...

Page 127: ...erator pump adjust ing screw 3 Check that the link lever 4 has free play b by pushing lightly on it Gradually turn out the adjusting screw while moving the link lever until it has no more free play Carburetor installation 1 Install Carburetor joint 1 NOTE Install the projection a on the cylinder head between the carburetor joint slots b T R 3 Nm 0 3 m kg 2 2 ft lb 2 Install Carburetor 1 NOTE Insta...

Page 128: ...urn 2 6 Adjust Throttle grip free play Refer to THROTTLE CABLE ADJUST MENT section in the CHAPTER 3 2 1 T R 4 Nm 0 4 m kg 2 9 ft lb T R 11 Nm 1 1 m kg 8 0 ft lb 7 Install Throttle cable cover 1 Screw throttle cable cover 2 2 1 T R 4 Nm 0 4 m kg 2 9 ft lb 8 Install TPS throttle position sensor coupler 1 Clamp 2 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 CARBURETOR ...

Page 129: ...ER HEAD COVER REMOVAL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Carburetor Refer to CARBURETOR section 1 Spark plug 1 2 Engine upper bracket right 1 3 Engine upper bracket left 1 4 Cylinder head breather hose 1 5 Oil tank breather hose 1 6 Bolt cylinder head cover 2 7 Cylinder head cover 1 8 Gasket 1 1 ...

Page 130: ...nt of removal Order Part name Q ty Remarks CAMSHAFTS REMOVAL 1 Timing plug 1 Refer to REMOVAL POINTS 2 Straight plug 1 3 Tensioner cap bolt 1 4 Timing chain tensioner 1 5 Gasket 1 6 Bolt camshaft cap 10 7 Camshaft cap 2 8 Clip 2 9 Exhaust camshaft 1 10 Intake camshaft 1 1 ...

Page 131: ...e that the piston is at Top Dead Center the punch mark c on the exhaust camshaft and the punch mark d on the intake camshaft must align with the cylinder head surface as shown in the illustration If there is no clearance rotate the crank shaft counterclockwise one turn 3 Loosen Tensioner cap bolt 1 4 Remove Timing chain tensioner 2 5 Remove Bolt camshaft cap 1 Camshaft caps 2 NOTE Remove the bolts...

Page 132: ...ace 2 Measure Cam lobes length a and b Out of specification Replace Cam lobes length Intake a 31 200 31 300 mm 1 2283 1 2323 in Limit 31 100 mm 1 2244 in b 22 550 22 650 mm 0 8878 0 8917 in Limit 22 450 mm 0 8839 in Exhaust a 30 950 31 050 mm 1 2185 1 2224 in Limit 30 850 mm 1 2146 in b 22 494 22 594 mm 0 8856 0 8895 in Limit 22 394 mm 0 8817 in 3 Measure Runout camshaft Out of specification Repla...

Page 133: ...0 Nm 1 0 m kg 7 2 ft lb NOTE Tighten the bolts camshaft cap in a criss cross pattern from innermost to outer caps Do not turn the camshaft when measuring clearance with the Plastigauge Remove the camshaft caps and measure the width of the Plastigauge 1 5 Measure Camshaft journal diameter a Out of specification Replace the cam shaft Within specification Replace camshaft case and camshaft caps as a ...

Page 134: ... tensioner rod up fully clock wise When releasing the screwdriver by press ing lightly with fingers make sure that the tensioner rod will come out smoothly If not replace the tensioner assembly ASSEMBLY AND INSTALLATION 1 Install Exhaust camshaft 1 Intake camshaft 2 Installation steps Turn the crankshaft counterclockwise until the I mark a on the rotor is aligned with the stationary pointer b on t...

Page 135: ... Damage or improper valve timing will result Install the clips and camshaft caps 4 T R Bolt camshaft cap 10 Nm 1 0 m kg 7 2 ft lb NOTE Apply the engine oil on the thread and contact surface of the bolts camshaft cap 5 Tighten the bolts camshaft cap in a criss cross pattern CAUTION The bolts camshaft cap must be tight ened evenly or damage to the cylinder head camshaft caps and camshaft will result...

Page 136: ... Nm 1 0 m kg 7 2 ft lb Release the screwdriver check the ten sioner rod to come out and tighten the gasket 4 and the cap bolt 5 to the speci fied torque T R Tensioner cap bolt 7 Nm 0 7 m kg 5 1 ft lb 5 4 New 3 Turn Crankshaft Counterclockwise several turns 4 Check Rotor I mark Align with the crankcase stationary pointer Camshaft match marks Align with the cylinder head surface Out of alignment Adj...

Page 137: ...ch the specified angle 180 in the proper tightening sequence Extent of removal Order Part name Q ty Remarks CYLINDER HEAD REMOVAL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section Radiator Refer to RADIATOR section Carburetor Refer to CARBURETOR section Camshaft Refer to CAMSHAFTS section ...

Page 138: ...ead warpage Out of specification Resurface Cylinder head warpage Less than 0 05 mm 0 002 in Warpage measurement and resurface ment steps Place a straightedge and a feeler gauge across the cylinder head Use a feeler gauge to measure the warpage If the warpage is out of specification resurface the cylinder head Place a 400 600 grit wet sandpaper on the surface plate and resurface the head using a fi...

Page 139: ... the rota tion angle procedure to obtain uniform tightening torque Wash the threads and contact surfaces of the bolts the contact surfaces of the plain washers the contact surface of the cylin der head and the threads of the crank case Apply the molybdenum disulfide grease on the threads and contact surfaces of the bolts and on both contact surfaces of the plain washers Install the plain washers a...

Page 140: ... 2nd 20 Nm 2 0 m kg 14 ft lb Put a mark on the corner 1 of the bolt cylinder head and the cylinder head 2 as shown NOTE Tighten the bolts 90 in each of the two steps to reach the specified angle of 180 in the proper tightening sequence as shown T R Bolts cylinder head Final Specified angle 180 1 2 180 3 Install Cable guide 1 Nut cylinder head 2 T R 10 Nm 1 0 m kg 7 2 ft lb 4 Install Copper washer ...

Page 141: ...l Order Part name Q ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Valve lifter 5 Use special tool Refer to REMOVAL POINTS 2 Adjusting pad 5 3 Valve cotter 10 4 Valve retainer 5 5 Valve spring 5 6 Stem seal 5 7 Valve spring seat 5 8 Exhaust valve 2 9 Intake valve 3 1 ...

Page 142: ...alve sealing Leakage at the valve seat Inspect the valve face valve seat and valve seat width Checking steps Pour a clean solvent 1 into the intake and exhaust ports Check that the valve seals properly There should be no leakage at the valve seat 2 3 Remove Valve cotters NOTE Attach a valve spring compressor 1 between the valve spring retainer and the cylinder head to remove the valve cotters Valv...

Page 143: ...03 in Exhaust 0 020 0 047 mm 0 0008 0 0019 in Limit 0 10 mm 0 004 in 2 Replace Valve guide Replacement steps NOTE To ease guide removal installation and to maintain correct fit heat the cylinder head in an over to 100 C 212 F Remove the valve guide using a valve guide remover 1 Install the new valve guide using a valve guide remover 1 and valve guide installer 2 After installing the valve guide bo...

Page 144: ...ake 4 5 mm 0 18 in YM 4118 90890 04118 Exhaust 5 0 mm 0 20 in YM 4099 90890 04099 NOTE After replacing the valve guide reface the valve seat 3 Inspect Valve face Pitting wear Grind the face Valve stem end Mushroom shape or diameter larger than the body of the stem Replace 4 Measure Margin thickness a Out of specification Replace Margin thickness Intake 1 0 mm 0 039 in Limit 0 85 mm 0 033 in Exhaus...

Page 145: ...h a Out of specification Reface the valve seat Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Measurement steps Apply Mechanic s blueing dye Dykem b to the valve face Install the valve into the cylinder head Press the valve through the valve guide and onto the valve seat to make a clear pattern Measure the valve...

Page 146: ...alve seat are evenly polished then clean off all of the compound NOTE For best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands Apply a fine lapping compound to the valve face and repeat the above steps NOTE After every lapping operation be sure to clean off all of the compound from the valve face and valve seat Apply Mechanic s blueing dye Dyke...

Page 147: ...2 in Exhaust 37 68 mm 1 48 in Limit 36 68 mm 1 44 in Compressed spring force Intake 111 3 127 9 N at 27 87 mm 11 3 13 0 kg at 27 87 mm 24 91 28 66 lb at 1 10 in Exhaust 127 4 146 4 N at 27 38 mm 13 0 14 9 kg at 27 38 mm 28 66 32 85 lb at 1 08 in 3 Measure Spring tilt a Out of specification Replace Spring tilt limit Intake 2 5 1 61 mm 0 063 in Exhaust 2 5 1 65 mm 0 065 in Valve lifter 1 Inspect Val...

Page 148: ...o the painted color as follows Intake middle a blue Intake right left b gray Exhaust not paint Install the valve springs with the larger pitch c facing upward d Smaller pitch New 3 Install Valve cotters NOTE While compressing the valve spring with a valve spring compressor 1 install the valve cotters 4 To secure the valve cotters onto the valve stem lightly tap the valve tip with a piece of wood C...

Page 149: ... pad 1 Valve lifter 2 NOTE Apply the engine oil on the valve lifters Apply the molybdenum disulfide oil on the valve stem end Valve lifter must turn smoothly when rotated with a finger Be careful to reinstall valve lifters and pads in their original place ...

Page 150: ...nt of removal Order Part name Q ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Bolt cylinder 1 2 Cylinder 1 3 Gasket 1 4 Dowel pin 2 5 Dowel pin O ring 1 1 6 Piston pin clip 2 Use special tool Refer to REMOVAL POINTS 7 Piston pin 1 8 Piston 1 9 Piston ring set 1 2 1 ...

Page 151: ...to drive the piston pin out Piston ring 1 Remove Piston rings NOTE Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown as shown in the illustration INSPECTION Cylinder and piston 1 Inspect Cylinder and piston walls Vertical scratches Replace cylinder and piston 2 Measure Piston to cylinder clearance Piston pin puller YU 1304 90890 01304 Measure...

Page 152: ...ure the piston skirt diameter P with a micrometer a 8 mm 0 315 in from the piston bottom edge Piston size P Standard 94 945 94 960 mm 3 738 3 739 in If out of specification replace the piston and piston rings as a set 3rd step Calculate the piston to cylinder clearance with following formula Piston to cylinder clearance Cylinder bore C Piston skirt diameter P Piston to cylinder clearance 0 040 0 0...

Page 153: ... crown so that the ring will be at a right angle to the cylinder bore a 10 mm 0 39 in Side clearance Standard Limit Top ring 0 030 0 065 mm 0 0012 0 0026 in 0 12 mm 0 005 in 2nd ring 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in 3 Measure Ring end gap Out of specification Replace NOTE You cannot measure the end gap on the expander spacer of the oil control ring If the oil control ring rails sho...

Page 154: ...and piston rings liberally with engine oil Measurement steps Measure the outside diameter piston pin a If out of specification replace the piston pin Outside diameter piston pin 17 991 18 000 mm 0 7083 0 7087 in Measure the inside diameter piston b Inside diameter piston 18 004 18 015 mm 0 7088 0 7093 in Calculate the piston pin to piston clear ance with the following formula Piston pin to piston ...

Page 155: ...ver the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase Install the piston pin clips with their ends fac ing downward 4 Lubricate Piston Piston rings Cylinder NOTE Apply a liberal coating of engine oil Cylinder 1 Install Dowel pins O ring Gasket 1 Cylinder 2 NOTE Install the cylinder with one hand while com pressing the piston rings with the other hand CAU...

Page 156: ...er Part name Q ty Remarks CLUTCH REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Brake pedal Refer to ENGINE REMOVAL section Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Gasket 1 3 Dowel pin 2 4 Clutch spring 6 5 Pressure plate 1 6 Push rod 1 1 7 Circlip 1 8 Plain washer 1 9 Bearing 1 10 Ball 1 11 Push rod 2 1 4 1 2 3 1 ...

Page 157: ... of removal Order Part name Q ty Remarks 12 Clutch plate 8 13 Friction plate 9 14 Nut 1 Use special tool Refer to REMOVAL POINTS 15 Look washer 1 16 Clutch boss 1 17 Thrust washer 1 18 Clutch housing 1 19 Push lever 1 4 1 3 ...

Page 158: ...91042 90890 04086 È É EC494000 INSPECTION EC484100 Clutch housing and boss 1 Inspect Clutch housing 1 Cracks wear damage Replace Clutch boss 2 Scoring wear damage Replace EC484201 Primary driven gear 1 Check Circumferential play Free play exists Replace Gear teeth a Wear damage Replace EC484400 Clutch spring 1 Measure Clutch spring free length a Out of specification Replace springs as a set Clutch...

Page 159: ...e Clutch plate warpage Out of specification Replace clutch plate as a set Use a surface plate 1 and thickness gauge 2 Friction plate thickness 2 92 3 08 mm 0 115 0 121 in Limit 2 8 mm 0 110 in Warp limit 0 1 mm 0 004 in Push lever 1 Inspect Push lever 1 Wear damage Replace 1 EC484810 Push rod 1 Inspect Push rod 1 1 Bearing 2 Plain washer 3 Push rod 2 4 Ball 5 Wear damage bend Replace ...

Page 160: ...late T R 10 Nm 1 0 m kg 7 2 ft lb Clutch 1 Install Primary driven gear 1 Thrust washer 2 Clutch boss 3 NOTE Apply the engine oil on the primary driven gear inner circumference 2 Install Lock washer 1 Nut clutch boss 2 NOTE Install the lock washer with its concaves fit ted over the convexes of the clutch boss Use the clutch holding tool 3 to hold the clutch boss È For USA and CDN É Except for USA a...

Page 161: ...clutch boss starting with a friction plate and ending with a friction plate Apply the engine oil on the friction plates and clutch plates 5 Install Bearing 1 Plain washer 2 Circlip 3 To push rod 1 4 NOTE Apply the engine oil on the bearing and plain washer New 6 Install Push rod 2 1 Ball 2 Push rod 1 3 NOTE Apply the engine oil on the push rod 1 2 and ball ...

Page 162: ...tch spring NOTE Tighten the bolts in stage using a crisscross pattern T R 8 Nm 0 8 m kg 5 8 ft lb 9 Install Gasket clutch cover 1 Dowel pin 2 New 10 Install Clutch cover 1 Bolt clutch cover NOTE Tighten the bolts in stage using a crisscross pattern T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 163: ...emarks OIL FILTER WATER PUMP AND CRANKCASE COVER RIGHT REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Drain the coolant Refer to COOLANT REPLACEMENT section in the CHAPTER 3 Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section Brake pedal Refer to ENGINE REMOVAL section Clutch cover Refer to CLUTCH section 1 Oil filter cover 1 2 Oil...

Page 164: ...ent of removal Order Part name Q ty Remarks 7 Oil hose 1 8 Kick starter 1 9 Crankcase cover right 1 10 Gasket 1 11 Dowel pin O ring 4 2 12 Impeller 1 Refer to REMOVAL POINTS 13 Plain washer 1 14 Impeller shaft 1 15 Oil seal 1 1 16 Oil seal 2 1 17 Bearing 1 2 3 2 ...

Page 165: ...cross the flats a with spanners etc and remove the impeller EC4G3210 Oil seal NOTE It is not necessary to disassemble the water pump unless there is an abnormality such as excessive change in coolant level discolora tion of coolant or milky transmission oil 1 Remove Bearing 1 Oil seal 2 INSPECTION EC444200 Impeller shaft 1 Inspect Impeller shaft 1 Bend wear damage Replace Fur deposits Clean ...

Page 166: ...e EC444400 Oil seal 1 Inspect Oil seal Wear damage Replace ASSEMBLY AND INSTALLATION EC4G5110 Oil seal 1 Install Oil seal 1 NOTE Apply the lithium soap base grease on the oil seal lip Install the oil seal with its manufacture s marks or numbers facing inward Bearing 1 Install Bearing 1 NOTE Install the bearing by pressing its outer race parallel New ...

Page 167: ... install the shaft while turning it Hold the impeller shaft on its width across the flats a with spanners etc and install the impeller T R 14 Nm 1 4 m kg 10 ft lb Crankcase cover right 1 Install Dowel pin 1 O ring 2 Collar 3 Gasket 4 New New 2 Install Crankcase cover right 1 Bolt NOTE Apply the engine oil on the impeller shaft end When installing the crankcase cover onto the crankcase be sure that...

Page 168: ...tical as possible with the distance a between the kick starter and the frame being 5 mm 0 20 in or more T R 33 Nm 3 3 m kg 24 ft lb 2 Install Oil hose 1 Bolt oil hose 2 T R 8 Nm 0 8 m kg 5 8 ft lb 3 Install Copper washer 1 Oil delivery pipe 2 Union bolt M8 3 Union bolt M10 4 New T R 18 Nm 1 8 m kg 13 ft lb T R 20 Nm 2 0 m kg 14 ft lb Water pump housing 1 Install Dowel pin 1 O ring 2 New ...

Page 169: ...housing 2 Plain washer 3 Coolant drain bolt 4 T R 10 Nm 1 0 m kg 7 2 ft lb New T R 10 Nm 1 0 m kg 7 2 ft lb 3 Install O ring Coolant pipe 1 Bolt coolant pipe 2 T R 10 Nm 1 0 m kg 7 2 ft lb Oil filter 1 Install Oil filter 1 O ring 2 Oil filter cover 3 Bolt oil filter cover New T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 170: ...lutch housing Refer to CLUTCH section Crankcase cover right Refer to OIL FILTER WATER PUMP AND CRANKCASE COVER RIGHT section Stator Refer to CDI MAGNETO section 1 Nut primary drive gear 1 Refer to REMOVAL POINTS 2 Nut balancer 1 3 Conical washer 1 4 Primary drive gear 1 5 Balancer drive gear 1 6 Lock washer 1 7 Balancer driven gear 1 8 Balancer 1 Refer to REMOVAL POINTS 2 1 2 ...

Page 171: ... driven gear 4 a 3 1 4 2 4 3 a Balancer 1 Remove Balancer 1 NOTE When removing the balancer shaft align the center of the balancer shaft weight a along the line connecting the centers of the crank shaft and balancer shaft INSPECTION Primary drive gear balancer drive gear and balancer driven gear 1 Inspect Primary drive gear 1 Balancer drive gear 2 Balancer driven gear 3 Wear damage Replace Balance...

Page 172: ...hed mark a on the balancer drive gear with the punched mark b on the balancer driven gear Align the punched mark c on the balancer drive gear with the lower spline d on the crankshaft 4 Install Lock washer 1 Nut balancer 2 Primary drive gear 3 Conical washer 4 Nut primary drive gear 5 NOTE Apply engine oil to the contact surface and threaded portion of the nut primary drive gear Place an aluminum ...

Page 173: ...S ASSEMBLY Preparation for removal Clutch housing Refer to CLUTCH section Crankcase cover right Refer to OIL FILTER WATER PUMP AND CRANKCASE COVER RIGHT section 1 Circlip 1 2 Plate washer 1 3 Oil pump drive gear 1 4 Oil pump assembly 1 5 Dowel pin 1 6 Outer rotor 2 1 7 Circlip 1 8 Inner rotor 2 1 9 Pin 1 10 Oil pump cover 1 11 Outer rotor 1 1 12 Inner rotor 1 1 2 1 ...

Page 174: ...4 66 ENG OIL PUMP Extent of removal Order Part name Q ty Remarks 13 Pin 1 14 Washer 1 15 Oil pump drive shaft 1 16 Rotor housing 1 2 ...

Page 175: ... the oil pump Tip clearance a 0 12 mm or less 0 0047 in or less Limit 0 20 mm 0 008 in Tip clearance b 0 09 0 17 mm 0 0035 0 0067 in Limit 0 24 mm 0 009 in Side clearance c 0 03 0 10 mm 0 0012 0 0039 in Limit 0 17 mm 0 007 in 3 Check Unsmooth Repeat steps 1 and 2 or replace the defective parts ASSEMBLY AND INSTALLATION Oil pump 1 Install Oil pump drive shaft 1 Washer 2 Pin 3 Inner rotor 1 4 NOTE A...

Page 176: ... the pin into the groove in the inner rotor 2 4 Install Outer rotor 2 1 Dowel pin 2 Oil pump assembly 3 Bolt oil pump assembly L 30 mm 1 18 in 4 Bolt oil pump assembly L 25 mm 0 98 in 5 NOTE Apply the engine oil on the outer rotor 2 T R 2 Nm 0 2 m kg 1 4 ft lb New T R 9 Nm 0 9 m kg 6 5 ft lb T R 9 Nm 0 9 m kg 6 5 ft lb 5 Install Oil pump drive gear 1 Plate washer 2 Circlip 3 NOTE Apply the engine ...

Page 177: ...moval Extent of removal Order Part name Q ty Remarks KICK AXLE AND SHIFT SHAFT REMOVAL Preparation for removal Oil pump Refer to OIL PUMP section 1 Kick idle gear 1 2 Kick axle assembly 1 Refer to REMOVAL POINTS 3 Spring guide 1 4 Torsion spring 1 5 Ratchet wheel 1 6 Kick gear 1 7 Kick axle 1 8 Plain washer 1 9 Shift pedal 1 10 Shift shaft 1 11 Collar 1 12 Torsion spring 1 3 2 1 4 1 ...

Page 178: ...r Part name Q ty Remarks 13 Roller 1 14 Shift guide 1 Refer to REMOVAL POINTS 15 Shift lever assembly 1 16 Shift lever 1 17 Pawl 2 18 Pawl pin 2 19 Spring 2 20 Bolt stopper lever 1 21 Stopper lever 1 22 Torsion spring 1 23 Segment 1 Refer to REMOVAL POINTS 4 ...

Page 179: ...embly is disassembled at the same time as the shift guide EC4N3100 Segment 1 Remove Bolt segment 1 Segment 2 NOTE Turn the segment counterclockwise until it stops and loosen the bolt INSPECTION EC4C4200 Kick axle and ratchet wheel 1 Check Ratchet wheel 1 smooth movement Unsmooth movement Replace Kick axle 2 Wear damage Replace Spring 3 Broken Replace EC4C4300 Kick gear kick idle gear and ratchet w...

Page 180: ...embly 1 Inspect Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear damage Replace EC4B4500 Stopper lever 1 Inspect Stopper lever 1 Wear damage Replace Torsion spring 2 Broken Replace EC4C5000 ASSEMBLY AND INSTALLATION Segment 1 Install Segment 1 Bolt segment NOTE Align the notch a on the segment with the pin b on the shift cam T R 30 Nm 3 0 m kg 22 ft lb ...

Page 181: ...nstall Spring 1 Pawl pin 2 Pawl 3 To shift lever 4 NOTE Apply the engine oil on the springs pawl pins and pawls T R 10 Nm 1 0 m kg 7 2 ft lb 2 Install Shift lever assembly 1 To shift guide 2 1 2 3 Install Shift lever assembly 1 Shift guide 2 NOTE The shift lever assembly is installed at the same time as the shift guide Apply the engine oil on the bolt segment shaft 4 Install Bolt shift guide 1 T R...

Page 182: ...mm 0 04 in a above the top of the footrest T R 12 Nm 1 2 m kg 8 7 ft lb Kick axle assembly 1 Install Kick gear 1 Plain washer 2 Circlip 3 Ratchet wheel 4 Spring 5 Plain washer 6 Circlip 7 To kick axle 8 NOTE Apply the molybdenum disulfide oil on the inner circumferences of the kick gear and ratchet wheel Align the punch mark a on the ratchet wheel with the punch mark b on the kick axle New New 2 I...

Page 183: ...ick axle stop per a and ratchet wheel guide 3 Apply the engine oil on the kick axle Slide the kick axle assembly into the crank case and make sure the kick axle stopper fits into the ratchet wheel guide 5 Hook Torsion spring 1 NOTE Turn the torsion spring clockwise and hook into the proper hole a in the crankcase Kick idle gear 1 Install Kick idle gear 1 Plain washer 2 Circlip 3 NOTE Install the k...

Page 184: ...DI MAGNETO REMOVAL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Bolt radiator left Disconnect the CDI magneto lead Refer to RADIATOR section 1 Crankcase cover left 1 2 Gasket 1 3 Dowel pin 2 4 Nut rotor 1 Use special tool Refer to REMOVAL POINTS 5 Rotor 1 6 Stator 1 7 Woodruff key 1 1 ...

Page 185: ...g the flywheel puller turn it counterclockwise Rotor holding tool YU 1235 90890 01235 Flywheel puller YM 1189 90890 01189 EC4L4000 INSPECTION EC4L4101 CDI magneto 1 Inspect Rotor inner surface a Stator outer surface b Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace CDI magneto and or stator EC4L4200 Woodruff key 1 Inspect Woodruff key 1 Damage Replace ...

Page 186: ...0 85505 T R 10 Nm 1 0 m kg 7 2 ft lb 2 Install Woodruff key 1 Rotor 2 NOTE Clean the tapered portions of the crankshaft and rotor When installing the woodruff key make sure that its flat surface a is in parallel with the crankshaft center line b When installing the rotor align the keyway c of the rotor with the woodruff key 3 Install Plain washer Nut rotor 1 Use the rotor holding tool 2 Rotor hold...

Page 187: ...NG DIAGRAM section in the CHAPTER 2 5 Install Dowel pin Gasket crankcase cover left Crankcase cover left 1 Hose holder cylinder head breather hose 2 Bolt crankcase cover left NOTE Tighten the bolts in stage using a crisscross pattern New 2 1 T R 10 Nm 1 0 m kg 7 2 ft lb ...

Page 188: ...fer to SEAT FUEL TANK AND SIDE COVERS section Carburetor Refer to CARBURETOR section Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section Clutch cable and guide Disconnect at engine side Radiator Refer to RADIATOR section Shift pedal Refer to KICK AXLE AND SHIFT SHAFT section Cylinder head breather hose and oil tank breather hose Refer to CAMSHAFTS section Drain the engine oil Refe...

Page 189: ...tral switch 1 3 Oil hose 2 4 Chain cover 1 5 Nut drive sprocket 1 Refer to REMOVAL POINTS 6 Lock washer 1 7 Drive sprocket 1 8 Clip 1 9 Bolt brake pedal 1 10 Brake pedal 1 11 Engine upper bracket right 1 12 Engine upper bracket left 1 13 Engine lower bracket 2 14 Engine mounting bolt 3 15 Pivot shaft 1 Refer to REMOVAL POINTS 16 Engine 1 1 ...

Page 190: ... sprocket 1 Drive chain 2 NOTE Remove the drive sprocket together with the drive chain EC4M3301 Engine removal 1 Remove Pivot shaft 1 NOTE If the pivot shaft is pulled all the way out the swingarm will come loose If possible insert a shaft of similar diameter into the other side of the swingarm to support it 2 Remove Engine 1 From right side NOTE Make sure that the couplers hoses and cables are di...

Page 191: ... engine skid plate C NOTE Apply the molybdenum disulfide grease on the pivot shaft Brake pedal 1 Install Spring 1 Brake pedal 2 O ring 3 Bolt brake pedal 4 Clip 5 NOTE Apply the lithium soap base grease on the bolt O rings and brake pedal bracket T R 85 Nm 8 5 m kg 61 ft lb T R 69 Nm 6 9 m kg 50 ft lb T R 34 Nm 3 4 m kg 24 ft lb T R 69 Nm 6 9 m kg 50 ft lb T R 34 Nm 3 4 m kg 24 ft lb T R 55 Nm 5 5...

Page 192: ...ut 4 Install Chain guide Chain cover 1 Screw chain cover 2 2 1 T R 8 Nm 0 8 m kg 5 8 ft lb 5 Install O ring 1 Dowel pin 2 Oil hose 3 Bolt oil hose 4 NOTE Apply the lithium soap base grease on the O ring 6 Install Spring 1 Pin 2 O ring 3 Neutral switch 4 Screw neutral switch 5 NOTE Apply the lithium soap base grease on the O ring New T R 8 Nm 0 8 m kg 5 8 ft lb New T R 4 Nm 0 4 m kg 2 9 ft lb ...

Page 193: ...n for removal Engine Refer to ENGINE REMOVAL section Piston Refer to CYLINDER AND PISTON sec tion Balancer Refer to BALANCER section Kick axle assembly Refer to KICK AXLE AND SHIFT SHAFT section Segment Stator Refer to CDI MAGNETO section 1 Timing chain guide rear 1 2 Timing chain 1 3 Bolt 50 mm 6 Refer to REMOVAL POINTS 4 Bolt 60 mm 2 5 Bolt 65 mm 1 6 Bolt 75 mm 2 7 Bolt 80 mm 1 8 Hose guide 1 9 ...

Page 194: ...RANKSHAFT Extent of removal Order Part name Q ty Remarks 10 Crankcase right 1 Refer to REMOVAL POINTS 11 Crankcase left 1 12 Oil strainer 1 13 Oil delivery pipe 2 1 14 Crankshaft 1 Use special tool Refer to REMOVAL POINTS 2 1 ...

Page 195: ... 1 Crankcase bearing removal Extent of removal Order Part name Q ty Remarks CRANKCASE BEARING REMOVAL Preparation for removal Transmission Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section Shift cam and shift fork 1 Oil seal 3 2 Bearing 10 Refer to REMOVAL POINTS 1 ...

Page 196: ...tting slit a in the crankcase Lift the crankcase right horizontally while lightly patting the case splitting slit and engine mounting boss using a soft ham mer and leave the crankshaft and trans mission with the crankcase left CAUTION Use soft hammer to tap on the case half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halv...

Page 197: ...oved bearing Crankcase separating tool YU 1135 A 90890 01135 INSPECTION Timing chain and timing chain guide 1 Inspect Timing chain Cracks stiff Replace the timing chain and camshaft sprocket as a set 2 Inspect Timing chain guide Wear damage Replace EC4N4101 Crankcase 1 Inspect Contacting surface a Scratches Replace Engine mounting boss b crankcase Cracks damage Replace 2 Inspect Bearing Rotate inn...

Page 198: ... and stand YU 3097 90890 01252 Standard Limit Runout limit 0 03 mm 0 0012 in 0 05 mm 0 002 in Small end free play 0 4 1 0 mm 0 016 0 039 in 2 0 mm 0 08 in Side clearance 0 15 0 45 mm 0 0059 0 0177 in 0 50 mm 0 02 in Crack width 61 95 62 00 mm 2 439 2 441 in Oil strainer 1 Inspect Oil strainer Damage Replace Oil delivery pipe 2 1 Inspect Oil delivery pipe 2 Cracks damage Replace Oil delivery pipe h...

Page 199: ...crush the screw head periphery a into the concave b using a punch etc In so doing take care not to damage the screwdriver receiving hole in the screw head New T R 10 Nm 1 0 m kg 7 2 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb Crankshaft 1 Install Crankshaft 1 Use the crankshaft installing tool 2 3 4 and 5 È For USA and CDN É Except for USA and CDN Crankshaft installing pot 2 YU...

Page 200: ...the crankshaft clean the contacting surface of crankcase CAUTION Do not use a hammer to drive in the crank shaft 2 Check Shifter operation Transmission operation Unsmooth operation Repair 3 Install Oil strainer 1 Bolt oil strainer 2 4 Apply Sealant On the crankcase right 1 NOTE Clean the contacting surface of crankcase left and right before applying the sealant Quick gasket ACC QUICK GS KT YAMAHA ...

Page 201: ... holder 2 Bolt crankcase NOTE Tighten the crankcase tightening bolts in stage using a crisscross pattern 7 Install Oil delivery pipe 2 O ring Bolt oil delivery pipe 2 8 Install Timing chain Timing chain guide rear Bolt timing chain guide 9 Remove Sealant Forced out on the cylinder mating sur face 10 Apply Engine oil To the crank pin bearing and oil delivery hole 11 Check Crankshaft and transmissio...

Page 202: ...ain axle and drive axle removal Extent of removal Order Part name Q ty Remarks TRANSMISSION SHIFT CAM AND SHIFT FORK REMOVAL Preparation for removal Engine Refer to ENGINE REMOVAL section Separate the crankcase Refer to CRANKCASE AND CRANK SHAFT section 1 Shift fork 1 1 Refer to REMOVAL POINTS 2 Shift fork 2 1 3 Shift cam 1 4 Main axle 1 5 Drive axle 1 6 Collar 1 1 ...

Page 203: ...r to remove Remove assembly carefully Note the posi tion of each part Pay particular attention to the location and direction of shift forks EC4H4000 INSPECTION EC4H4200 Gears 1 Inspect Matching dog a Gear teeth b Shift fork groove c Wear damage Replace 2 Inspect O ring 1 Damage Replace 3 Check Gears movement Unsmooth movement Repair or replace EC4H4600 Bearing 1 Inspect Bearing 1 Rotate inner race...

Page 204: ...peration Replace shift fork NOTE For a malfunctioning shift fork replace not only the shift fork itself but the two gears each adja cent to the shift fork ASSEMBLY AND INSTALLATION Transmission 1 Install Collar 1 4th pinion gear 20T 2 3rd pinion gear 18T 3 2nd pinion gear 16T 4 To main axle 5 NOTE Apply the molybdenum disulfide oil on the inner and end surface of the idler gear and on the inner su...

Page 205: ...face of the sliding gear then install Apply the lithium soap base grease on the O ring 3 Install Plain washer 1 Circlip 2 NOTE Be sure the circlip sharp edged corner a is positioned opposite side to the plain washer and gear b Install the circlip with its ends c settled evenly on the spline crests c c New 4 Install Collar 1 NOTE Apply the lithium soap base grease on the oil seal lip When installin...

Page 206: ...isulfide oil on the shift fork grooves Mesh the shift fork 1 L with the 3rd pinion gear 4 on the main axle Mesh the shift fork 2 R with the 4th wheel gear 5 on the drive axle 6 Install Transmission assembly 1 To crankcase left 2 NOTE Apply the engine oil on the bearings and guide bars 7 Check Shifter operation Transmission operation Unsmooth operation Repair ...

Page 207: ...f removal Order Part name Q ty Remarks FRONT WHEEL REMOVAL WARNING Support the machine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine 1 Bolt axle holder 4 Only loosening 2 Nut front wheel axle 1 3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Oil seal 2 7 Bearing 2 Refer to REMOVAL POINTS 8 Brake disc 1 2 ...

Page 208: ... the machine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Chain puller 2 4 Rear wheel 1 Refer to REMOVAL POINTS 5 Collar 2 6 Driven sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 2 Refer to REMOVAL POINTS 10 Brake disc 1 2 3 1 3 FRONT WHEEL AND REAR WHEEL 5 ...

Page 209: ...f necessary 1 Remove Bearing 1 NOTE Remove the bearing using a general bearing puller 2 EC594000 INSPECTION EC514100 Wheel 1 Measure Wheel runout Out of limit Repair replace 2 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace NOTE Replace the bearings oil seal and wheel collar as a set Wheel runout limit Radial 1 2 0 mm 0 08 in Lateral 2 2 0 mm 0 08 in ...

Page 210: ... Wheel axle bending limit 0 5 mm 0 020 in EC594200 Brake disc 1 Measure Brake disc deflection only rear brake disc Use the dial gauge 1 Out of specification Inspect wheel runout If wheel runout is in good condition replace the brake disc 2 Measure Brake disc thickness a Out of limit Replace Disc deflection limit Standard Limit Rear 0 15 mm 0 006 in Disc wear limit Standard Limit Front 3 0 mm 0 12 ...

Page 211: ...alled first Install the oil seal with its manufacture s marks or numbers facing outward CAUTION Do not strike the inner race of the bearing Contact should be made only with the outer race 2 Install Brake disc 1 Bolt brake disc 2 NOTE Tighten the bolts in stage using a crisscross pattern New T R 12 Nm 1 2 m kg 8 7 ft lb 3 Install Collar 1 NOTE Apply the lithium soap base grease on the oil seal lip ...

Page 212: ...p base grease on the wheel axle 6 Install Nut wheel axle 1 T R 105 Nm 10 5 m kg 75 ft lb 7 Tighten Bolt axle holder 1 NOTE Before tightening the bolt fit the wheel axle to the axle holder by stroking the front fork sev eral times with the front brake applied T R 23 Nm 2 3 m kg 17 ft lb ...

Page 213: ... of bearing shall be installed first Install the oil seal with its manufacture s marks or numbers facing outward CAUTION Do not strike the inner race of the bearing Contact should be made only with the outer race New New 2 Install Brake disc 1 Bolt brake disc 2 NOTE Tighten the bolts in stage using a crisscross pattern 3 Install Driven sprocket 1 Bolt driven sprocket 2 Plain washer driven sprocket...

Page 214: ... chain 1 NOTE Push the wheel 2 forward and install the drive chain 7 Install Chain puller left 1 Wheel axle 2 NOTE Install the chain puller left and insert the wheel axle from left side Apply the lithium soap base grease on the wheel axle 8 Install Chain puller right 1 Plain washer 2 Nut wheel axle 3 NOTE Temporarily tighten the nut wheel axle at this point FRONT WHEEL AND REAR WHEEL ...

Page 215: ...WHEEL 9 Adjust Drive chain slack a Refer to DRIVE CHAIN SLACK ADJUSTMENT section in the CHAPTER 3 Drive chain slack 48 58 mm 1 9 2 3 in 10 Tighten Nut wheel axle 1 Locknut 2 T R 125 Nm 12 5 m kg 90 ft lb T R 16 Nm 1 6 m kg 11 ft lb ...

Page 216: ...hine securely so there is no danger of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine Drain the brake fluid Refer to REMOVAL POINTS 1 Brake hose holder protector 2 2 Brake hose holder caliper 1 3 Union bolt 2 4 Brake hose 1 5 Pad pin plug 1 Remove when loosening the pad pin 6 Pad pin 1 Loosen when disassembling the caliper 7 Caliper 1 8 Brak...

Page 217: ...it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section Drain the brake fluid Refer to REMOVAL POINTS 1 Brake pedal 1 2 Master cylinder 1 3 Brake hose holder 2 4 Union bolt 2 5 Brake hose 1 6 Pad pin plug 1 Remove when loosening the pad pin 7 Pad pin 1 Loosen when disassembling the caliper 8 Cali...

Page 218: ...nt caliper disassembly 2 Rear caliper disassembly Extent of removal Order Part name Q ty Remarks CALIPER DISASSEMBLY A B 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Caliper piston 2 1 Refer to REMOVAL POINTS 5 Dust seal 2 1 6 Piston seal 2 1 1 2 FRONT BRAKE AND REAR BRAKE ...

Page 219: ... cylinder disassembly 2 Rear master cylinder disassembly Extent of removal Order Part name Q ty Remarks MASTER CYLINDER DISAS SEMBLY 1 Master cylinder cap 1 2 Diaphragm 1 3 Reservoir float 1 4 Master cylinder boot 1 5 Circlip 1 Use a long nose circlip pliers 6 Plain washer 1 7 Push rod 1 8 Master cylinder kit 1 1 2 1 2 2 ...

Page 220: ...he lever in or pushing down on the pedal CAUTION Do not reuse the drained brake fluid Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately EC533301 Caliper piston 1 Remove Caliper piston Use compressed air and proceed care fully WARNING Cover piston with rag and use extreme caution when expelling piston from cylin der Never attempt to pry out piston È F...

Page 221: ...eals WARNING Replace the piston seals and dust seals whenever a caliper is disassembled È Front É Rear È É EC5A4000 INSPECTION EC534112 Master cylinder 1 Inspect Master cylinder inner surface a Wear scratches Replace master cylin der assembly Stains Clean WARNING Use only new brake fluid È Front É Rear 2 Inspect Diaphragm 1 Crack damage Replace È Front É Rear È É È É 3 Inspect front brake only Res...

Page 222: ...iston 1 Wear score marks Replace caliper pis ton assembly WARNING Replace the piston seals and dust seals 2 whenever a caliper is disassembled EC534301 Brake hose 1 Inspect Brake hose 1 Crack damage Replace EC5A5000 ASSEMBLY AND INSTALLATION WARNING All internal parts should be cleaned in new brake fluid only Internal parts should be lubricated with brake fluid when installed Replace the piston se...

Page 223: ...caliper correctly È Front É Rear 3 Install Caliper piston 1 NOTE Apply the brake fluid on the piston wall CAUTION Install the piston with its shallow depressed side a facing the caliper Never force to insert È Front É Rear EC5A5700 Front caliper 1 Install Pad support 1 Brake pad 2 Pad pin 3 NOTE Install the brake pads with their projections a into the caliper recesses b Temporarily tighten the pad...

Page 224: ...m kg 17 ft lb T R 18 Nm 1 8 m kg 13 ft lb T R 3 Nm 0 3 m kg 2 2 ft lb EC5A5100 Rear caliper 1 Install Pad support 1 Brake pad 2 Pad pin 3 NOTE Install the brake pads with their projections a into the caliper recesses b Temporarily tighten the pad pin at this point 2 Install Disc cover 1 Bolt disc cover 2 T R 7 Nm 0 7 m kg 5 1 ft lb ...

Page 225: ...8 m kg 13 ft lb T R 3 Nm 0 3 m kg 2 2 ft lb 2 Install Master cylinder cup primary 1 Master cylinder cup secondary 2 To master cylinder piston 3 NOTE Apply the brake fluid on the master cylinder cup WARNING After installing cylinder cup should be installed as shown direction Wrong instal lation cause improper brake performance È Front É Rear È É È É 3 Install Spring 1 To master cylinder piston 2 NO...

Page 226: ... cylinder kit Apply the lithium soap base grease on the tip of the push rod When installing the circlip use a long nose circlip pliers È Front É Rear È É EC5A5310 Front master cylinder 1 Install Master cylinder 1 Master cylinder bracket 2 Bolt master cylinder bracket 3 NOTE Install the bracket so that the arrow mark a face upward First tighten the bolts on the upper side of the master cylinder bra...

Page 227: ...lways use new copper washers CAUTION Install the brake hose so that its pipe por tion a directs as shown and lightly touches the projection b on the master cylinder T R 6 Nm 0 6 m kg 4 3 ft lb T R 6 Nm 0 6 m kg 4 3 ft lb New T R 30 Nm 3 0 m kg 22 ft lb 2 Install Master cylinder 1 Bolt master cylinder 2 3 Install Spring 1 Brake pedal 2 O ring 3 Bolt brake pedal 4 Clip 5 NOTE Apply the lithium soap ...

Page 228: ...on bolt 3 WARNING Always use new copper washers CAUTION Install the brake hose so that its pipe por tion a directs as shown and lightly touches the projection b on the caliper New T R 30 Nm 3 0 m kg 22 ft lb 2 Install Brake hose holder 1 Bolt brake hose holder 2 T R 10 Nm 1 0 m kg 7 2 ft lb 3 Install Brake hose holder 1 Nut brake hose holder 2 NOTE Align the top a of the brake hose holder with the...

Page 229: ...se so that its pipe por tion a directs as shown and lightly touches the projection b on the master cylinder New T R 30 Nm 3 0 m kg 22 ft lb Rear brake hose 1 Install Copper washer 1 Brake hose 2 Union bolt 3 WARNING Always use new copper washers CAUTION Install the brake hose so that its pipe por tion a directs as shown and lightly touches the projection b on the caliper New T R 30 Nm 3 0 m kg 22 ...

Page 230: ...e fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per formance Refill with the same type of brake fluid mixing fluids may result in a harmful chemical reaction and lead to poor perfor mance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock CAUTION Brake ...

Page 231: ... Master cylinder cap 1 Screw master cylinder cap 2 Rear Diaphragm Master cylinder cap 1 Bolt master cylinder cap 2 CAUTION After installation while pulling the lever in or pushing down on the pedal check whether there is any brake fluid leaking where the union bolts are installed respec tively at the master cylinder and caliper È Front É Rear 5 Install rear brake only Protector 1 Bolt protector 2 ...

Page 232: ...ngine WARNING Support the machine securely so there is no danger of it falling over Front wheel Refer to FRONT WHEEL AND REAR WHEEL section Front caliper Refer to FRONT BRAKE AND REAR BRAKE section Number plate 1 Protector 1 2 Pinch bolt handle crown 2 Only loosening 3 Damper assembly 1 Loosen when disassembling the front fork Use special tool Refer to REMOVAL POINTS 4 Pinch bolt under bracket 2 O...

Page 233: ...s FRONT FORK DISASSEMBLY 1 Adjuster 1 Drain the fork oil Use special tool Refer to REMOVAL POINTS 2 Fork spring 1 3 Dust seal 1 Refer to REMOVAL POINTS 4 Stopper ring 1 5 Inner tube 1 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Oil seal washer 1 0 Oil seal 1 A Base valve 1 Drain the fork oil Use special tool Refer to REMOVAL POINTS B Damper assembly 1 1 2 ...

Page 234: ... con struction and is particularly sensitive to foreign material Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disas sembled and reassembled Before removing the base valves or front forks be sure to extract the air from the air chamber completely EC553000 REMOVAL POINTS Damper assembly 1 Loosen Damper assembly 1 NOTE Before removing...

Page 235: ...t remove the locknut as it may go into the damper assembly and not be taken out Cap bolt ring wrench YM 01501 90890 01501 EC553201 Inner tube 1 Remove Dust seal 1 Stopper ring 2 Using slotted head screwdriver CAUTION Take care not to scratch the inner tube 2 Remove Inner tube 1 Oil seal removal steps Push in slowly a the inner tube just before it bottoms out and then pull it back quickly b Repeat ...

Page 236: ...ench YM 01501 90890 01501 EC554000 INSPECTION Damper assembly 1 Inspect Damper assembly 1 Bend damage Replace O ring 2 Wear damage Replace CAUTION The front fork with a built in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is di...

Page 237: ...cification Replace EC554502 Inner tube 1 Inspect Inner tube surface a Score marks Repair or replace Use 1 000 grit wet sandpaper Damaged oil lock piece Replace Inner tube bends Out of specification Replace Use the dial gauge 1 NOTE The bending value is shown by one half of the dial gauge reading WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube Fork spr...

Page 238: ... assembly 1 Wash the all parts in a clean solvent 2 Stretch the damper assembly fully 3 Fill Front fork oil 1 To damper assembly CAUTION Be sure to use recommended fork oil If other oils are used they may have an excessively adverse effect on the front fork performance Never allow foreign materials to enter the front fork Recommended oil Suspension oil S1 Oil capacity 195 cm3 6 86 Imp oz 6 59 US o...

Page 239: ...tretched check that the oil is above the step a on the damper assembly Below the step Replenish fork oil above the step 6 Tighten Locknut 1 NOTE Fully finger tighten the locknut onto the damper assembly 7 Loosen Compression damping adjuster 1 NOTE Loosen the compression damping adjuster finger tight Record the set position of the adjuster the amount of turning out the fully turned in posi tion 8 I...

Page 240: ...t ring wrench YM 01501 90890 01501 T R 29 Nm 2 9 m kg 21 ft lb 10 After filling pump the damper assembly 1 slowly up and down more than 10 times to distribute the fork oil 11 While protecting the damper assembly 1 with a rag and compressing fully allow excessive oil to overflow on the base valve side CAUTION Take care not to damage the damper assembly 12 Allow the overflowing oil to escape at the ...

Page 241: ...Apply the fork oil on the inner tube When installing the oil seal use vinyl seat a with fork oil applied to protect the oil seal lip Install the oil seal with its manufacture s marks or number facing the axle holder side Install the oil seal washer with its projections b facing upward New New 15 Install Piston metal 1 NOTE Install the piston metal onto the slot on inner tube New 16 Install Outer t...

Page 242: ...river 3 Fork seal driver YM 01442 90890 01442 18 Install Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver 2 Fork seal driver YM 01442 90890 01442 19 Install Stopper ring 1 NOTE Fit the stopper ring correctly in the groove in the outer tube 20 Install Dust seal 1 NOTE Apply the lithium soap base grease on the inner tube ...

Page 243: ...r resin 3 To damper assembly 4 NOTE Install the spacer with the plate a facing the fork spring 24 Install Damper assembly 1 To inner tube 2 CAUTION To install the damper assembly into the inner tube hold the inner tube aslant If the inner tube is held vertically the damper assembly may fall into it damaging the valve inside 25 Loosen Rebound damping adjuster 1 NOTE Loosen the rebound damping adjus...

Page 244: ...per assembly Cap bolt ring wrench YM 01501 90890 01501 New 27 Inspect Gap a between adjuster 1 and locknut 2 Out of specification Retighten and readjust the locknut NOTE If the adjuster is installed out of specification proper damping force cannot be obtained Gap a between adjuster and locknut 0 5 1 0 mm 0 02 0 04 in 28 Tighten Adjuster locknut 1 NOTE Hold the locknut 2 and tighten the adjuster wi...

Page 245: ...r handling and loss of stabil ity CAUTION Be sure to use recommended fork oil If other oils are used they may have an excessively adverse effect on the front fork performance Never allow foreign materials to enter the front fork Recommended oil Suspension oil S1 Standard oil amount 260 cm3 9 15 Imp oz 8 79 US oz 270 cm3 9 50 Imp oz 9 13 US oz Extent of adjustment 200 300 cm3 7 04 10 6 Imp oz 6 76 ...

Page 246: ...cket Do not tighten the pinch bolts handle crown yet 2 Tighten Damper assembly 1 NOTE Use the cap bolt ring wrench 2 to tighten the damper assembly with specified torque Cap bolt ring wrench YM 01501 90890 01501 T R 30 Nm 3 0 m kg 22 ft lb 3 Adjust Front fork top end a Front fork top end standard a Zero mm Zero in FRONT FORK ...

Page 247: ...R 23 Nm 2 3 m kg 17 ft lb T R 20 Nm 2 0 m kg 14 ft lb 5 Install Protector 1 Bolt protector 2 T R 10 Nm 1 0 m kg 7 2 ft lb 6 Adjust Rebound damping force NOTE Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 7 Adjust Compression damping force NOTE Turn in the damping adjuster 1 finger tight and then turn out to the originally set position FRONT FORK ...

Page 248: ... holder 1 3 Clutch cable 1 Disconnect at the lever side 4 Clutch lever holder 1 5 ENGINE STOP button 1 6 Master cylinder 1 Refer to REMOVAL POINTS 7 Throttle cable cap 1 8 Throttle cable 2 pushed 1 Disconnect at the throttle side 9 Throttle cable 1 pulled 1 Disconnect at the throttle side 10 Grip right 1 Refer to REMOVAL POINTS 11 Tube guide 1 12 Cover grip cap 1 13 Collar 1 14 Grip left 1 Refer t...

Page 249: ...inder cap side hori zontal to prevent air from coming in EC5B3200 Grip 1 Remove Grip 1 NOTE Blow in air between the handlebar or tube guide and the grip Then remove the grip which has become loose EC5B4000 INSPECTION EC5B4100 Handlebar 1 Inspect Handlebar 1 Bends cracks damage Replace WARNING Do not attempt to straighten a bent handle bar as this may dangerously weaken the handlebar HANDLEBAR ...

Page 250: ... marks b are in place on both sides First tighten the bolts on the front side of the handlebar holder and then tighten the bolts on the rear side T R 28 Nm 2 8 m kg 20 ft lb 2 Install Grip left 1 Apply the adhesive to the handlebar 2 NOTE Before applying the adhesive wipe off grease or oil on the handlebar surface a with a lacquer thinner Install the grip left to the handlebar so that the line b b...

Page 251: ...nstall the grip to the tube guide so that the grip match mark b and tube guide slot c form the angle as shown R L 90 3 1 b c 4 Install Collar 1 Cover grip cap 2 Throttle grip 3 NOTE Apply the lithium soap base grease on the throttle grip sliding surface 5 Install Throttle cables 1 To tube guide 2 NOTE Apply the lithium soap base grease on the throttle cable end and tube guide cable wind ing portio...

Page 252: ...lts for adjustment T R 4 Nm 0 4 m kg 2 9 ft lb 7 Install Cover grip cap 1 Cover throttle cable cap 2 8 Install Master cylinder 1 Master cylinder bracket 2 Bolt master cylinder bracket 3 NOTE Install the bracket so that the arrow mark a faces upward First tighten the bolt on the upper side of the master cylinder bracket and then tighten the bolt on the lower side T R 9 Nm 0 9 m kg 6 5 ft lb ...

Page 253: ... lever holder T R 4 Nm 0 4 m kg 2 9 ft lb T R 4 Nm 0 4 m kg 2 9 ft lb 10 Install Clutch cable 1 Hot starter cable 2 NOTE Apply the lithium soap base grease on the clutch cable end and hot starter cable end 11 Adjust Clutch lever free play Refer to CLUTCH ADJUSTMENT sec tion in the CHAPTER 3 Hot starter lever free play Refer to HOT STARTER LEVER ADJUSTMENT section in the CHAPTER 3 12 Clamp the clam...

Page 254: ...ration for removal Hold the machine by placing the suitable stand under the engine Number plate Handlebar Refer to HANDLEBAR section Front fender 1 Steering shaft cap 1 2 Steering shaft nut 1 3 Front fork 2 Refer to FRONT FORK section 4 Handle crown 1 5 Ring nut 1 Use special tool Refer to REMOVAL POINTS 6 Under bracket 1 7 Bearing race cover 1 8 Bearing upper 1 9 Bearing lower 1 Refer to REMOVAL ...

Page 255: ...wn Ring nut wrench YU 33975 90890 01403 EC563300 Bearing lower 1 Remove Bearing lower 1 Use the floor chisel 2 CAUTION Take care not to damage the steering shaft thread Bearing race 1 Remove Bearing race 1 Remove the bearing race using long rod 2 and the hammer EC564000 INSPECTION EC564200 Steering shaft 1 Inspect Steering shaft 1 Bend damage Replace STEERING ...

Page 256: ...ra tion in the bearing races replace bear ings and bearing races as a set EC565000 ASSEMBLY AND INSTALLATION Under bracket 1 Install Bearing lower 1 NOTE Apply the lithium soap base grease on the dust seal lip and bearing inner circumference 2 Install Bearing race Bearing upper 1 Bearing race cover 2 NOTE Apply the lithium soap base grease on the bearing and bearing race cover lip 3 Install Under ...

Page 257: ... the steering shaft by turning it lock to lock If there is any binding remove the steering shaft assembly and inspect the steering bearings 6 Install Plain washer 1 7 Install Front fork 1 Handle crown 2 NOTE Temporarily tighten the pinch bolts under bracket Do not tighten the pinch bolts handle crown yet 8 Install Plain washer 1 Steering shaft nut 2 T R 145 Nm 14 5 m kg 105 ft lb STEERING ...

Page 258: ...osening the ring nut little by little 11 Adjust Front fork top end a Front fork top end standard a Zero mm Zero in 12 Tighten Pinch bolt handle crown 1 Pinch bolt under bracket 2 CAUTION Tighten the under bracket to specified torque If torqued too much it may cause the front fork to malfunction T R 23 Nm 2 3 m kg 17 ft lb T R 20 Nm 2 0 m kg 14 ft lb ...

Page 259: ... of it falling over Preparation for removal Hold the machine by placing the suitable stand under the engine Brake hose holder Refer to FRONT BRAKE AND REAR BRAKE section Rear caliper Bolt brake pedal Shift the brake pedal backward Drive chain 1 Chain support 1 2 Chain tensioner lower 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt connecting rod 1 5 Pivot shaft 1 6 Swingarm 1 1 ...

Page 260: ...d removal and disassembly 3 Relay arm removal and disassembly Extent of removal Order Part name Q ty Remarks SWINGARM DISASSEMBLY 1 Cap 2 Refer to REMOVAL POINTS 2 Relay arm 1 3 Connecting rod 1 4 Collar 2 5 Oil seal 2 6 Thrust bearing 2 7 Bush 2 8 Oil seal 8 9 Bearing 10 Refer to REMOVAL POINTS 1 2 3 2 3 ...

Page 261: ... by pressing its outer race EC574010 INSPECTION Wash the bearings bushes collars and cov ers in a solvent EC574111 Swingarm 1 Inspect Bearing 1 Bush 2 Free play exists unsmooth revolution rust Replace bearing and bush as a set 2 Inspect Oil seal 3 Damage Replace Relay arm 1 Inspect Bearing 1 Collar 2 Free play exists unsmooth revolution rust Replace bearing and collar as a set 2 Inspect Oil seal 3...

Page 262: ...bearing by pressing it on the side having the manufacture s marks or numbers First install the outer and then the inner bear ings to a specified depth from inside Installed depth of bearings Outer a Zero mm Zero in Inner b 8 5 mm 0 33 in 2 Install Bearing 1 Plain washer 2 Oil seal 3 To relay arm NOTE Apply the molybdenum disulfide grease on the bearing when installing Install the bearing by pressi...

Page 263: ...acture s marks or numbers Installed depth of bearings a 5 mm 0 20 in Swingarm 1 Install Bush 1 Thrust bearing 2 Oil seal 3 Collar 4 To swingarm 5 NOTE Apply the molybdenum disulfide grease on the bushes thrust bearings oil seal lips and con tact surfaces of the collar and thrust bearing 2 Install Collar 1 Washer 2 To relay arm 3 NOTE Apply the molybdenum disulfide grease on the collars and oil sea...

Page 264: ...b 5 Install Relay arm 1 Bolt relay arm 2 Plain washer 3 Nut relay arm 4 To swingarm NOTE Apply the molybdenum disulfide grease on the bolt Do not tighten the nut yet 6 Install Swingarm 1 Pivot shaft 2 NOTE Apply the molybdenum disulfide grease on the pivot shaft Insert the pivot shaft from right side T R 85 Nm 8 5 m kg 61 ft lb 7 Check Swingarm side play a Free play exists Replace thrust bear ing ...

Page 265: ...nut yet 9 Install Bolt rear shock absorber relay arm 1 Nut rear shock absorber relay arm 2 NOTE Apply the molybdenum disulfide grease on the bolt T R 53 Nm 5 3 m kg 38 ft lb 10 Tighten Nut connecting rod 1 T R 80 Nm 8 0 m kg 58 ft lb 11 Tighten Nut relay arm 1 T R 80 Nm 8 0 m kg 58 ft lb 12 Install Cap 1 NOTE Install the cap right with its mark a facing forward ...

Page 266: ...3 Chain tensioner 4 Nut chain tensioner lower 5 T R 20 Nm 2 0 m kg 14 ft lb 14 Install Chain support 1 Support cover 2 Bolt chain support 50 mm 1 97 in 3 Nut chain support 4 Bolt support cover 10 mm 0 39 in 5 T R 7 Nm 0 7 m kg 5 1 ft lb T R 7 Nm 0 7 m kg 5 1 ft lb SWINGARM ...

Page 267: ...reparation for removal Hold the machine by placing the suitable stand under the engine Seat and fitting band Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 Silencer Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 4 1 Clamp air filter joint 1 Only loosening 2 Rear frame 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt rear shock absorber frame 1 5 Rear s...

Page 268: ...5 62 CHAS REAR SHOCK ABSORBER Extent of removal Order Part name Q ty Remarks 9 Spring guide upper 1 10 Spring rear shock absorber 1 11 Bearing 2 Refer to REMOVAL POINTS 2 ...

Page 269: ...am age to the hose 3 Be careful not to damage any part of the gas tank A damaged gas tank will impair the damping performance or cause a malfunction 4 Take care not to scratch the contact sur face of the piston rod with the cylinder or oil could leak out 5 Never attempt to remove the plug at the bottom of the nitrogen gas tank It is very dangerous to remove the plug 6 When scrapping the shock abso...

Page 270: ...wer bearing 1 NOTE Remove the bearing by pressing its outer race EC584000 INSPECTION Rear shock absorber 1 Inspect Damper rod 1 Bends damage Replace absorber assembly Shock absorber 2 Oil leaks Replace absorber assembly Gas leaks Replace absorber assem bly Spring 3 Damage Replace spring Fatigue Replace spring Move spring up and down Spring guide 4 Wear damage Replace spring guide Bearing 5 Free pl...

Page 271: ...ll wear the rear shock absorber surface on which the bear ing is press fitted 2 Install Stopper ring upper bearing 1 NOTE After installing the stopper ring push back the bearing until it contacts the stopper ring New 3 Install Lower bearing 1 NOTE Install the bearing by pressing it on the side having the manufacture s marks or numbers Installed depth of the bearing a 4 mm 0 16 in EC585111 Spring r...

Page 272: ...ttempt to turn the adjuster beyond the maximum or minimum setting Spring length installed a Standard length Extent of adjustment 248 mm 9 76 in 245 mm 9 65 in 240 5 258 5 mm 9 47 10 18 in 4 Tighten Locknut 1 Rear shock absorber 1 Install Dust seal 1 O ring 2 Collar 3 NOTE Apply the molybdenum disulfide grease on the bearing Apply the lithium soap base grease on the dust seals O rings and collars N...

Page 273: ...rear shock absorber frame 1 Nut rear shock absorber frame 2 NOTE Apply the molybdenum disulfide grease on the bolt 5 Install Bolt rear shock absorber relay arm 1 Nut rear shock absorber relay arm 2 NOTE Apply the molybdenum disulfide grease on the bolt T R 56 Nm 5 6 m kg 40 ft lb T R 53 Nm 5 3 m kg 38 ft lb 6 Install Rear frame 1 Bolt rear frame upper 2 Bolt rear frame lower 3 T R 32 Nm 3 2 m kg 2...

Page 274: ...park plug 7 CDI unit COLOR CODE B Black Br Brown G Green L Blue O Orange P Pink R Red Sb Sky blue EC612000 WIRING DIAGRAM 7 1 5 6 2 3 4 B W B W B L B Y Sb Sb G B L Y L Y P B B B B G O W R P G W R P P B Br W W B Y G Br G R R O B Sb Sb Y Y W Y W G G B P P Br Br R R O L B Sb Y L L B L B W B W G B B B B L L Sb B L G B B Y B Y G B B W O B W Br Br W White Y Yellow B L Black Blue B W Black White B Y Blac...

Page 275: ...puter in the CDI unit as a throttle opening signal Pickup coil Detects signal rotor revolutions and inputs them into the computer in the CDI unit as engine revolution signals CDI unit The signals of the TPS and pickup coil sensor are analyzed by the computer in the CDI unit which then adjusts ignition timing for the operation requirements Principal of 3 Dimensional Control Conventionally ignition ...

Page 276: ...following special tools in this inspection Dynamic spark tester YM 34487 Ignition checker 90890 06754 Pocket tester YU 3112 C 90890 03112 Spark gap test Clean or replace spark plug Check entire ignition system for connection couplers leads and ignition coil Repair or replace Check ENGINE STOP button Replace Check ignition coil Primary coil Replace Secondary coil Replace Check CDI magneto Pick up c...

Page 277: ... spark gap 6 0 mm 0 24 in È É COUPLERS LEADS AND IGNITION COIL CONNECTION INSPECTION 1 Check Couplers and leads connection Rust dust looseness short circuit Repair or replace Ignition coil and spark plug as they are fit ted Push in the ignition coil until it closely contacts the spark plug hole in the cylin der head cover EC625001 ENGINE STOP BUTTON INSPECTION 1 Inspect ENGINE STOP button conduct ...

Page 278: ... of specification Replace 4 Inspect Sealed portion of ignition coil a Spark plug terminal pin b Threaded portion of spark plug c Wear Replace EC627011 CDI MAGNETO INSPECTION 1 Inspect Pick up coil resistance Out of specification Replace Tester lead Orange lead 1 Tester lead Spark plug terminal 2 Secondary coil resistance Tester selector position 4 6 6 8 kΩ at 20 C 68 F kΩ 1 Tester lead Red lead 1 ...

Page 279: ...Black lead 2 Source coil 2 resistance Tester selector position 44 66 Ω at 20 C 68 F Ω 10 W R Br G P B 2 1 2 1 2 1 W R Br G P B 2 1 NEUTRAL SWITCH INSPECTION 1 Inspect Neutral switch conduct No continuity while in neutral Replace Continuity while in gear Replace EC628000 CDI UNIT INSPECTION Check all electrical components If no fault is found replace the CDI unit Then check the electrical component...

Page 280: ...nspection steps marked Refer to IGNITION SYSTEM section NOTE Use the following special tools in this inspection Pocket tester YU 3112 C 90890 03112 Check entire ignition system for connection Repair or replace Check TPS TPS coil Replace Check CDI magneto Source coil Replace Check CDI unit TPS input voltage Replace OK OK OK No good No good No good No good ...

Page 281: ... COUPLERS AND LEADS CONNECTION INSPECTION 1 Check Couplers and leads connection Rust dust looseness short circuit Repair or replace TPS COIL INSPECTION 1 Inspect TPS coil resistance Out of specification Replace 2 Loosen Throttle stop screw 1 NOTE Turn out the throttle stop screw until the throt tle shaft is in the full close position Tester lead Blue lead 1 Tester lead Black lead 2 TPS coil resist...

Page 282: ...ellow lead 1 Tester lead Black lead 2 TPS coil variable resistance Tester selec tor position Full closed Full opened kΩ 1 0 2 kΩ at 20 C 68 F 4 6 kΩ at 20 C 68 F TPS REPLACEMENT AND ADJUSTMENT 1 Remove TPS coupler Screw TPS 1 TPS 2 NOTE Loosen the screws TPS using the T25 bit 2 Replace TPS 3 Install TPS 1 Screw TPS 2 TPS coupler NOTE Align the slot a in the TPS with the projec tion b on the carbur...

Page 283: ...f function of the coupler Make sure that a short circuit does not develop between the terminals because it may cause damage to electrical compo nents 6 Start the engine 7 Adjust TPS output voltage Tester lead Yellow lead 3 Tester lead Black lead 4 Adjustment steps Adjust the installation angle of the TPS 1 to obtain the specified output voltage NOTE Measure the output voltage accurately with a dig...

Page 284: ...he engine 1 EC694000 TPS INPUT VOLTAGE INSPECTION 1 Disconnect the TPS coupler 2 Start the engine 3 Inspect TPS input voltage Out of specification Replace the CDI unit Tester lead Blue lead 1 Tester lead Black Blue lead 2 TPS input voltage Tester selector position 4 6 V DCV 20 ...

Page 285: ... best possi ble carburetor setting NOTE It is recommended to keep a record of all car buretor settings and external conditions e g atmospheric conditions track surface condi tions lap times to make future carburetor set ting easier WARNING The carburetor is a part of the fuel line Therefore be sure to install it in a well ventilated area away from flammable objects and any sources of fire Never lo...

Page 286: ...ed starting may become difficult or the engine may not run well After installing the carburetor check that the throttle operates correctly and opens and closes smoothly Atmospheric conditions and carburetor settings The air density i e concentration of oxygen in the air determines the richness or lean ness of the air fuel mixture Therefore refer to the above table for mixture settings That is High...

Page 287: ...Closed É Fully open 1 2 3 4 1 4 1 8 1 2 3 4 È É Main system The FLATCR carburetor has a primary main jet This type of main jet is perfect for racing machines since it supplies an even flow of fuel even at full load Use the main jet and the jet needle to set the carburetor 1 Jet needle 2 Pilot air jet 3 Needle jet 4 Main jet 5 Pilot jet 6 Pilot screw ...

Page 288: ...4 open throttle Main jet adjustment The richness of the air fuel mixture at full throt tle can be set by changing the main jet 1 If the air fuel mixture is too rich or too lean the engine power will drop resulting in poor accel eration Effects of changing the main jet reference È Idle É Fully open Standard main jet 165 1 4 1 2 3 4 10 165 10 168 162 È É ...

Page 289: ... pilot screw only 1 2 of a turn in either direction To optimize the fuel flow at a smaller throttle opening each machine s pilot screw has been individually set at the factory Before adjusting the pilot screw turn it in fully and count the number of turns Record this num ber as the factory set number of turns out Effects of adjusting the pilot screw reference È Idle É Fully open 1 2 1 4 turns out ...

Page 290: ...ngine operation is felt and the engine will not pick up speed smoothly In this case step up the jet needle clip by one 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 Step down the jet needle clip by one groove and move up the needle to enrich the mixture Effects of changing the jet needle groove ...

Page 291: ...5 richer Changing from NFLR 4 to NFPR 4 has the same effect as a rising of 0 5 clip position Standard jet needle NFLR b c NFPR 4 NFLR 4 Diameter of straight portion Clip position Rich Lean N P Q R S T U Rich Lean 1 richer NFLN 5 NFLP 5 NFLQ 5 NFLR 5 NFLS 5 NFLT 5 NFLU 5 0 5 richer NFPN 4 NFPP 4 NFPQ 4 NFPR 4 NFPS 4 NFPT 4 NFPU 4 STD NFLN 4 NFLP 4 NFLQ 4 NFLR 4 NFLS 4 NFLT 4 NFLU 4 0 5 leaner NFPN ...

Page 292: ...ng No than standard to lean out the mixture Example 40 45 Effects of changing the jet needle reference Diameter of the straight portion Changing the diameter of the straight portion adjusts the air fuel mixture when the throttle is 1 8 to 1 4 open È Idle É Fully open Relationship with throttle opening The flow of the fuel through the carburetor main system is controlled by the main jet and then it...

Page 293: ... 52 50 48 45 42 40 38 4MX 14948 08 4MX 14948 07 4MX 14948 06 4MX 14948 05 4MX 14948 04 4MX 14948 03 4MX 14948 02 Jet needle Rich Lean NFPN NFPP NFPQ NFPR NFPS NFPT NFPU 5TA 14916 PN 5TA 14916 PP 5TA 14916 P1 5TA 14916 PR 5TA 14916 PS 5TA 14916 PT 5TA 14916 PU Rich STD Lean NFLN NFLP NFLQ NFLR NFLS NFLT NFLU 5TA 14916 LN 5TA 14916 LP 5TA 14916 L1 5TA 14916 LR 5TA 14916 LS 5TA 14916 LT 5TA 14916 LU ...

Page 294: ...op Check that the accelerator pump oper ates smoothly except for rich mixture symptom Rich mixture Raise jet needle clip position 1 groove up 1 4 3 4 throttle Hard breathing Lack of speed Lower jet needle clip position 1 groove down 1 4 1 2 throttle Slow speed pick up Poor acceleration Raise jet needle clip position 1 groove up Closed to 1 4 throttle Hard breathing Speed down Use jet needle with a...

Page 295: ...ion of the course that has the greatest effect on the race result In such a case run through the entire course while making notes of lap times to find the best balance then determine the secondary reduction ratio If a course has a long straight portion where a machine can run at maximum speed the machine is generally set such that it can develop its maximum revolutions toward the end of the straig...

Page 296: ...e Tire pressure should be adjust to suit the road surface condition of the circuit Under a rainy muddy sandy or slippery condition the tire pressure should be lower for a larger area of contact with the road sur face Under a stony or hard road condition the tire pressure should be higher to prevent a flat tire Standard tire pressure 100 kPa 1 0 kgf cm2 15 psi Extent of adjustment 60 80 kPa 0 6 0 8...

Page 297: ... near the final stroke can be changed by changing the fork oil amount CAUTION Adjust the oil amount in 5 cm3 0 2 Imp oz 0 2 US oz increments or decrements Too small oil amount causes the front fork to produce a noise at full rebound or the rider to feel some pressure on his hands or body Alternatively too large oil amount will develop unexpectedly early oil lock with the consequent shorter front f...

Page 298: ... 3 2 adjustment washers Standard washer quantity Zero adjustment washers Extent of adjustment Zero 2 adjustment washers EC72A001 Setting of spring after replacement As the front fork setting can be easily affected by rear suspension take care so that the machine front and rear are balanced in posi tion etc when setting the front fork 1 Use of soft spring Generally a soft spring gives a soft riding...

Page 299: ...come weaker resulting in lack of a sense of contact with the road surface or in a vibrating handlebar To set a stiff spring Change the rebound damping Turn in one or two clicks Change the compression damping Turn out one or two clicks È Coverage of spring by weight É Rider weight 1 Soft 2 Standard 3 Stiff SETTING ...

Page 300: ...C3 23141 30 1C3 23141 40 I II III IIII IIIII STD 0 449 5XD 23141 P0 STD 0 459 5XD 23141 N0 STIFF 0 469 0 479 1C3 23141 70 1C3 23141 80 I III I IIII EC72B000 Rear suspension setting The rear suspension setting should be made depending on the rider s feeling of an actual run and the circuit conditions The rear suspension setting includes the fol lowing two factors 1 Setting of spring preload Change ...

Page 301: ... ing bolt 3 Loosen the locknut 1 and make adjust ment by turning the spring adjuster 2 to achieve the standard figure from the sub traction of the length b from the length a NOTE If the machine is new and after it is broken in the same set length of the spring may change because of the initial fatigue etc of the spring Therefore be sure to make re evaluation If the standard figure cannot be achiev...

Page 302: ...sate for its greater spring load Run with the rebound damp ing adjuster one or two clicks on the stiffer side and readjust it to suit your preference Adjusting the rebound damping will be fol lowed more or less by a change in the com pression damping For correction turn the low compression damping adjuster on the softer side CAUTION When using a rear cushion other than cur rently installed use the...

Page 303: ... 22212 20 5UN 22212 30 Brown 1 Green 1 Red 1 Black 1 260 260 260 260 STD 5 1 5UN 22212 40 Blue 1 260 STD 5 3 5UN 22212 50 Yellow 1 260 STIFF 5 5 5 7 5UN 22212 60 5UN 22212 70 Pink 1 White 1 260 260 TYPE SPRING RATE approx SPRING PART NUMBER I D COLOR POINT SPRING FREE LENGTH SOFT STIFF 4 5 4 7 4 9 5 1 5 3 5 5 5 7 5UN 22212 A0 5UN 22212 B0 5UN 22212 C0 5UN 22212 D0 5UN 22212 E0 5UN 22212 F0 5UN 222...

Page 304: ...t over entire range bottoming out Compression damping Turn adjuster clockwise about 2 clicks to increase damping Oil amount Increase oil amount by about 5 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz Spring Replace with stiff spring Stiff toward stroke end Oil amount Decrease oil amount by about 5 cm3 0 2 Imp oz 0 2 US oz Soft toward stroke end bottoming out Oil amount Increase oil amount by about 5 cm3 0 ...

Page 305: ...d dragging Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Spring Replace with soft spring Poor road gripping Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Low compression damp ing Turn adjuster clockwise about 1 clicks to increase damping High compression damp ing Turn adjuster clockwise about 1 6 clicks to increase damping Spr...

Page 306: ...PRINTED IN JAPAN 2004 06 1 9 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

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