Yamaha YZ85W1 Service Manual Download Page 98

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CHAS

4-26

EAS00592

CHECKING THE FRONT AND REAR BRAKE
MASTER CYLINDERS

The following procedure applies to the both of
the brake master cylinders.
1. Check:

• brake master cylinder

Damage / scratches / wear

→

Replace.

• brake fluid delivery passages

(brake master cylinder body)

Obstruction

→

Blow out with compressed

air.

Front
Rear

2. Check:

• brake master cylinder kit

Damage / scratches / wear

→

Replace.

Front
Rear

3. Check:

• rear brake fluid reservoir

Cracks / damage

→

Replace.

• rear brake fluid reservoir diaphragm

Cracks / damage

→

Replace.

4. Check:

• front brake master cylinder reservoir

Cracks/damage

→

Replace.

• front brake master cylinder reservoir dia-

phragm

Damage / wear

→

Replace.

5. Check:

• brake hoses

Cracks / damage / wear

→

Replace.

Refer to “CHECKING THE FRONT AND
REAR BRAKE HOSES” in chapter 3.

FRONT AND REAR BRAKES

Summary of Contents for YZ85W1

Page 1: ...2007 YZ85W1 5PA 28197 E0 SERVICE MANUAL YZ85 W YZ85LW W...

Page 2: ...5LW W SERVICE MANUAL 2006 by Yamaha Motor Co Ltd First edition April 2006 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly pr...

Page 3: ...models Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal ers and will appear in future editions of this manual where applicable NOTE...

Page 4: ...op of each page except in Chapter 3 PERIODIC CHECKS AND ADJUSTMENTS where the sub section title s appears Sub section titles appear in smaller print than the section title To help identify parts and c...

Page 5: ...cate the following Serviceable with engine mounted Filling fluid Lubricant Special tool Tightening torque Wear limit clearance Engine speed Electrical data Symbols to in the exploded diagrams indicate...

Page 6: ...ENERAL INFORMATION GEN INFO 1 SPECIFICATIONS SPEC 2 PERIODIC CHECKS AND ADJUSTMENTS CHK ADJ 3 CHASSIS CHAS 4 ENGINE ENG 5 COOLING SYSTEM COOL 6 CARBURETOR CARB 7 ELECTRICAL SYSTEM ELEC 8 TUNING TUN 9...

Page 7: ...MODEL LABEL 1 1 IMPORTANT INFORMATION 1 2 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 2 REPLACEMENT PARTS 1 2 GASKETS OIL SEALS AND O RINGS 1 2 LOCK WASHERS PLATES AND COTTER PINS 1 3 BEARINGS AND OIL S...

Page 8: ...AS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped into the right side of the steering head pipe EAS00018 MODEL LABEL The model label is affixed to the frame This infor...

Page 9: ...n trays in the order of dis assembly This will speed up assembly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EAS00021 REPLACEMENT PARTS Use only g...

Page 10: ...ling oil seals lubricate the oil seal lips with a light coat of lithium soap based grease Oil bearings liberally when installing if appro priate Oil seal CAUTION Do not spin the bearing with compresse...

Page 11: ...er mix two types of oil in the same batch clotting of the oil could result If you wish to change oil types be sure to drain the fuel tank and the carburetor float bowl of old premix prior to filling w...

Page 12: ...ll connections Loose connection Connect properly NOTE NOTE If the pin on the terminal is flattened bend it up 4 Connect lead coupler connector NOTE NOTE Make sure all connections are tight 5 Check con...

Page 13: ...ase as well as remove the crankshaft from either case 90890 01189 YM 1189 Flywheel puller This tool is used to remove the flywheel magneto 90890 01235 YU 1235 Rotor holding tool This tool is used when...

Page 14: ...tachment 90890 01436 YM 01436 Rod puller Rod puller attachment M10 These tools are used to pull up the fork damper rod 90890 01442 YM 01442 Fork seal diver This tool is used when install the fork oil...

Page 15: ...0890 06754 YM 34487 Dynamic spark tester Ignition checker This instrument is necessary for checking the ignition system components 90890 85505 Yamaha bond No 1215 Three Bond No 1215 This sealant Bond...

Page 16: ...PECIFICATIONS 2 7 ELECTRICAL SPECIFICATIONS 2 11 CONVERSION TABLE 2 12 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 12 TIGHTENING TORQUES 2 13 ENGINE TIGHTENING TORQUES 2 13 CHASSIS TIGHTENING TORQUES 2...

Page 17: ...1 903 mm 74 9 in YZ85LW Overall width 758 mm 29 8 in Overall height 1 161mm 45 7 in YZ85 1 205 mm 47 4 in YZ85LW Seat height 864 mm 34 0 in YZ85 904 mm 35 6 in YZ85LW Wheelbase 1 255 mm 49 4 in YZ85 1...

Page 18: ...JASO standard MA Periodic oil change 0 50 L 0 44 Imp qt 0 53 US qt Total amount 0 55 L 0 48 Imp qt 0 58 US qt Cooling system Coolant capacity including all routes 0 54 L 0 48 Imp qt 0 57 US qt Radiat...

Page 19: ...n 0 1 mm 0 004 in Height H 20 0 mm 0 79 in Piston pin bore in the piston Diameter 14 004 14 015 mm 0 5513 0 5518 in 14 040 mm 0 5528 in Offset 1 0 mm 0 039 in Offset direction Exhaust side Piston pin...

Page 20: ...h release method Inner push cam push Clutch cable free play at the end of the clutch lever 10 0 15 0 mm 0 39 0 59 in Friction plates Thickness 2 9 3 1 mm 0 114 0 122 in 2 7 mm 0 106 in Plate quantity...

Page 21: ...0 Max main axle runout 0 01 mm 0 004 in Max drive axle runout 0 01 mm 0 004 in Shifting mechanism Shift mechanism type Cam drum Guide bar Guide bar bending limit 0 05 mm 0 002 in Air filter type Wet e...

Page 22: ...SPEC 2 6 Item Standard Limit Reed valve Thickness T 0 42 mm 0 017 in Valve stopper height 7 4 7 8 mm 0 291 0 307 in Valve bending limit 0 2 mm 0 008 in ENGINE SPECIFICATIONS...

Page 23: ...7 1 40 YZ85 19 1 40 YZ85LW Material Aluminum Wheel travel 275 mm 10 83 in Wheel runout Radial wheel runout limit 2 0 mm 0 08 in Lateral wheel runout limit 2 0 mm 0 08 in Rear wheel Wheel type Spoke wh...

Page 24: ...r thickness 220 3 mm 8 66 0 12 in Thickness limit 2 5 mm 0 10 in Deflection limit 0 15 mm 0 006 in Brake pad lining thickness 4 0 mm 0 16 in 0 8 mm 0 03 in Master cylinder inside diameter 11 0 mm 0 43...

Page 25: ...0 30 kg mm 16 8 lb in YZ85LW Spring stroke K1 0 275 mm 0 10 82 in Inner tube outer diameter 36 mm 1 42 in Inner tube bending limit 0 2 mm 0 008 in Optional spring available Yes Fork oil Recommended oi...

Page 26: ...W for AUS NZL Spring stroke STD K1 102 mm 4 02 in Optional spring available Yes Standard spring preload gas air pressure 1 000 kPa 10 0 kg cm2 142 psi Rebound damping adjusting positions Minimum 20 St...

Page 27: ...2 at 20 C 68 F W L W R Charging coil 1 resistance color 720 1 080 at 20 C 68 F G W B R Charging coil 2 resistance color 44 66 at 20 C 68 F B G L C D I unit model manufacturer 5PA 01 YAMAHA Ignition co...

Page 28: ...threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter METRIC MULTIPLIER IMPERIAL mm 0 03937 in 2 mm 0 03937 0 08 in METRIC TO IMPERIAL Metric unit Multip...

Page 29: ...2 12 1 2 8 7 Exhaust pipe stay Bolt M6 1 12 1 2 8 7 Silencer Bolt M6 1 12 1 2 8 7 Fiber silencer Bolt M6 2 12 1 2 8 7 Crankcase Screw M6 11 8 0 8 5 8 Left crankcase cover Screw M6 4 5 0 5 3 6 Right c...

Page 30: ...Nut M6 1 5 0 5 3 6 Clutch lever holder Bolt M5 2 4 0 4 2 9 Front brake master cylinder cap Screw M4 2 2 0 2 1 4 Front brake hose union bolt Bolt M10 2 26 2 6 19 Front fork and brake caliper bracket B...

Page 31: ...rame upper Bolt M8 1 26 2 6 19 Rear frame lower Bolt M8 2 16 1 6 12 Swingarm and brake hose holder Screw M5 4 1 0 1 0 7 Drive chain support Nut M8 2 16 1 6 12 Drive chain support cover Nut M6 1 7 0 7...

Page 32: ...surface Yamaha bond No 1215 Lubrication point Lubricant Steeling bearings and bearing race upper and lower Brake lever pivoting point and metal to metal moving parts Clutch lever pivoting point and me...

Page 33: ...er hose Engine stop switch lead Ground lead Ignition coil Primary coil lead orange color Damper Clamp Air vent hoses CDI magneto lead Carburetor overflow hose Transmission oil breather hose Radiator b...

Page 34: ...hose through the wire holder located at the right side of the vehi cle Route the air vent hose and carburetor over flow hose from the left side of the vehicle Do not flatten out the radiator breather...

Page 35: ...oil breather hose through the hose guide Clamp it between these parts Clamp it using the white PVC tape as a guide Pass the sub wire harness on the left side of the CDI unit Cut the tip of the clamp...

Page 36: ...he clamp section to the rear side Touch the brake pipe to the stopper When installing the brake hose install it so that the bend section of the brake hose attachment is pointed in the direction as sho...

Page 37: ...cable shall be routed crossways above the number plate attaching sec tion At this time make sure to route the clutch cable to the front side of the throttle cable Route the clutch cable in front of th...

Page 38: ...KING THE EXHAUST SYSTEM 3 13 CHECKING THE COOLANT LEVEL 3 14 CHECKING THE COOLING SYSTEM 3 15 CHANGING THE COOLANT 3 15 CHASSIS 3 17 ADJUSTING THE FRONT BRAKE 3 17 ADJUSTING THE REAR BRAKE 3 18 CHECKI...

Page 39: ...Piston pin and small end bearing Check piston pin and small end bearing for damage Replace 4 Cylinder head Check cylinder head for carbon deposits Clean Check cylinder head gasket for damage Tighten c...

Page 40: ...rake fluid Every year 22 Front fork Check operation and for oil leakage Adjust if necessary Clean dust seal and lubricate with lithium soap based grease Replace fork oil Replace oil seals 23 Shock abs...

Page 41: ...covers left and right 2 3 Air scoop 1 4 Fuel pipe 1 Disconnect 5 Fuel cock 1 6 O ring 1 7 Grommet 2 8 Collar 2 9 Hose 1 Disconnect 10 Joint pipe 1 11 Hose 1 Disconnect 12 Fuel tank cap 1 13 Fuel tank...

Page 42: ...14 Number plate 1 For installation reverse the removal procedure 4 Nm 0 4 m kg 2 9 ft lb 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 4 Nm 0 4 m kg 2 9 ft lb 7 Nm 0 7 m kg 5...

Page 43: ...ENGINE IDLING SPEED NOTE NOTE Prior to adjusting the engine idling speed the air filter element should be clean and the engine should have adequate compression 1 Start the engine and let it warm up fo...

Page 44: ...sting nut in direction or until the specified throttle cable free play is obtained c Tighten the locknut WARNING After adjusting the throttle cable free play start the engine and turn the handlebar to...

Page 45: ...ar Replace the spark plug insulator Abnormal color Replace the spark plug Normal color is medium to light tan 5 Clean spark plug with a spark plug cleaner or wire brush 6 Measure spark plug gap with a...

Page 46: ...direction b Set the dial gauge to zero at TDC c From TDC rotate the rotor clockwise until the dial gauge indicates that the piston in at a specified distance from TDC 4 Check ignition timing Punch mar...

Page 47: ...iller cap transmission drain bolt 5 Drain transmission oil completely from the crankcase 6 Install transmission oil drain bolt gasket transmission oil drain bolt along with the new gasket 7 Fill trans...

Page 48: ...RS AND FUEL TANK 2 Remove air filter case cover a Set the air filter case cover as shown and install it to the seat rail of the rear frame while rotating air filter case cover in the direction of the...

Page 49: ...ormance and possible overheat ing 3 Clean air filter element with solvent NOTE NOTE After cleaning remove the remaining solvent by squeezing the element CAUTION Do not twist the element when squeezing...

Page 50: ...NG THE CARBURETOR JOINT 1 Remove carburetor Refer to CARBURETOR in chapter 7 2 Check carburetor joint Cracks damage Replace Refer to CARBURETOR in chapter 7 3 Install carburetor joint carburetor EAS00...

Page 51: ...ing procedure applies to all of the exhaust pipes mufflers and gaskets 1 Remove seat side cover right Refer to SEAT SIDE COVERS AND FUEL TANK 2 Remove silencer exhaust joint exhaust pipe gasket 3 Chec...

Page 52: ...wise toward the detent to allow any residual pressure to escape When the hissing sound has stopped press down on the radiator cap and turn it counterclockwise to remove 3 Check coolant level Coolant l...

Page 53: ...iator cap when the engine is hot Scalding hot fluid and steam may be blown out which could cause seri ous injury When the engine has cooled open the radiator cap as follows Place a thick rag or a towe...

Page 54: ...lowers the antifreeze content of the coolant If water is used instead of coolant check and if necessary correct the antifreeze concentration of the coolant Use only distilled water However if dis till...

Page 55: ...ke lever a Loosen the locknut b Turn the adjusting bolt in direction or until the brake lever is in the desired position c Tighten the locknut CAUTION After adjusting the brake lever position make sur...

Page 56: ...t between the maxi mum and the minimum as shown In this adjustment the bolt end should protrude out of the lower adjusting nut but not be less than 2 0 mm 0 08 in away from the brake pedal c Tighten t...

Page 57: ...l with the same type of brake fluid that is already in the system Mixing brake flu ids may result in a harmful chemical reac tion leading to poor brake performance When refilling be careful that water...

Page 58: ...e applies to all of the brake hoses and brake hose clamps 1 Check brake hose Cracks damage wear Replace 2 Check brake hose holder Loose Tighten the holder bolt NOTE NOTE Align the brake hose holder wi...

Page 59: ...to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubbles in the hose have disappeared 1 Bleed hydraulic brake system a Fill the brake fluid reservoir to the pr...

Page 60: ...l a Install the shift pedal with the bottom of the pedal outer diameter as close to the center of the engine mounting bolt as possible EAS00138 ADJUSTING THE DRIVE CHAIN SLACK NOTE NOTE The drive chai...

Page 61: ...djusting nuts in direction or until the specified drive chain slack is obtained NOTE NOTE To maintain the proper wheel alignment adjust both sides evenly Turn each adjuster exactly the same amount to...

Page 62: ...147 CHECKING AND ADJUSTING THE STEERING HEAD 1 Stand the vehicle on a level surface WARNING Securely support the vehicle so that there is no danger of it falling over NOTE NOTE Place the vehicle on a...

Page 63: ...binding by turning the front fork all the way in both directions If any binding is felt remove the lower bracket and check the upper and lower bearings Refer to STEERING HEAD in chapter 4 5 Install up...

Page 64: ...fork legs evenly Uneven adjustment can result in poor han dling and loss of stability Securely support the vehicle so that there is no danger of it falling over Front fork internal pressure bleeding N...

Page 65: ...ension is softer Adjusting positions Minimum 20 clicks in direction Standard 7 clicks in direction Maximum 1 clicks in direction with the adjusting screw fully turned in direction Direction Compressio...

Page 66: ...ove all dirt and mud from around the locknut and adjuster before adjustment The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster b Turn the adjusting nut in direction or...

Page 67: ...nd damping is increased suspension is harder Direction Rebound damping is decreased suspension is softer Adjusting positions Minimum 20 clicks in direction Standard YZ85 6 clicks in direction Standard...

Page 68: ...temperature The tire pressure and the suspension must be adjusted according to the total weight including rider and the antici pated riding speed WARNING It is dangerous to ride with a worn out tire...

Page 69: ...at care and replace the tube as soon as possible with a good quality replacement After extensive tests the tires listed below have been approved by Yamaha Motor Co Ltd for this model The front and rea...

Page 70: ...en spoke with a spoke wrench NOTE NOTE Be sure to tighten the spokes before and after break in After a practice or a race check spokes for looseness EAS00171 LUBRICATING THE LEVERS AND PEDALS Lubricat...

Page 71: ...TER CYLINDER 4 23 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER 4 25 DISASSEMBLING THE REAR BRAKE MASTER CYLINDER 4 25 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS 4 26 ASSEMBLING AND INSTALLING...

Page 72: ...HOCK ABSORBER AND GAS CYLINDER 4 66 DISPOSING OF A REAR SHOCK ABSORBER AND GAS CYLINDER 4 66 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 67 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND GAS CYLINDER 4...

Page 73: ...isc Remove the parts in the order listed NOTE NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 1 Front wheel axle 1 2 Front wheel 1 3 Collar 2 4 Front brake disc 1 For in...

Page 74: ...Order Job Part Q ty Remarks Disassembling the front wheel Disassemble the parts in the order listed Oil seal 2 Wheel bearing 2 Collar 1 For assembly reverse the disassembly procedure FRONT WHEEL AND B...

Page 75: ...ever when removing the brake caliper 3 Elevate front wheel NOTE NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 4 Remove front wheel axle nut front wheel axle front whee...

Page 76: ...specified limits Replace 5 Check collars Damage wear Replace 6 Check wheel bearings Front wheel turns roughly or is loose Replace the wheel bearings oil seals Damage wear Replace 7 Replace wheel bear...

Page 77: ...l bearings and oil seals in the reverse order of disassembly CAUTION Do not contact the wheel bearing inner race or balls Contact should be made only with the outer race NOTE NOTE Use a socket that ma...

Page 78: ...ove the brake caliper d Hold the dial gauge at a right angle against the brake disc surface e Measure the deflection 1 5 mm 0 06 in below the edge of the brake disc 3 Measure brake disc thickness Meas...

Page 79: ...hin specification replace the brake disc EAS00546 INSTALLING THE FRONT WHEEL 1 Lubricate front wheel axle oil seal lips 2 Install collar front wheel front wheel axle NOTE NOTE Install the brake disc b...

Page 80: ...vehicle on a suitable stand so that the rear wheel is elevated Rear brake caliper Remove Refer to REMOVING THE REAR BRAK PADS 1 Rear wheel axle nut 1 2 Locknut 2 Loosen 3 Adjusting bolt 2 Loosen 4 Re...

Page 81: ...CHAS 4 9 Order Job Part Q ty Remarks 8 Collar 2 For installation reverse the removal procedure 16 Nm 1 6 m kg 11 ft lb 16 Nm 1 6 m kg 11 ft lb 90 Nm 9 0 m kg 65 ft lb REAR WHEEL AND BRAKE DISC...

Page 82: ...marks Removing the rear brake disc and rear wheel sprocket Remove the parts in the order listed 1 Rear brake disc 1 2 Rear wheel sprocket 1 3 Rear wheel 1 For installation reverse the disassembly proc...

Page 83: ...rder Job Part Q ty Remarks Disassembling the rear wheel Disassemble the parts in the order listed Oil seal 2 Circlip 1 Bearing 2 Collar 1 For assembly reverse the disassembly procedure REAR WHEEL AND...

Page 84: ...on a suitable stand so that the rear wheel is elevated 2 Remove protector brake caliper NOTE NOTE Do not depress the brake pedal when remov ing the brake caliper 3 Loosen locknut adjusting bolt 4 Remo...

Page 85: ...r 3 3 Check spokes Refer to CHECKING THE FRONT WHEEL 4 Measure radial wheel runout lateral wheel runout Refer to CHECKING THE FRONT WHEEL EAS00568 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1 Chec...

Page 86: ...NOTE NOTE Tighten the self locking nuts in stages and in a crisscross pattern EAS00572 INSTALLING THE REAR WHEEL 1 Lubricate rear wheel axle wheel bearings oil seal lips 2 Tighten rear wheel axle nut...

Page 87: ...rt Q ty Remarks Removing the front brake pads Remove the parts in the order listed 1 Brake caliper 1 2 Brake pad 2 3 Brake pad support 2 4 Bleed screw 1 For installation reverse the removal procedure...

Page 88: ...d 1 Protector 1 2 Spacer 1 3 Brake pad pin 2 4 Rear brake caliper 1 5 Brake pad 2 6 Brake pad shim 1 7 Brake pad spring 1 8 Bleed screw 1 For installation reverse the removal procedure 23 Nm 2 3 m kg...

Page 89: ...nts Use only clean or new brake fluid for cleaning brake components Brake fluid may damage painted surfaces and plastic parts Therefore always clean up any spilt brake fluid immediately Avoid brake fl...

Page 90: ...per with your finger c Tighten the bleed screw d Install new brake pads and a new brake pad support 5 Lubricate brake pad bolts brake caliper guide bar CAUTION Do not allow grease to contact the brake...

Page 91: ...ble the brake caliper 1 Loosen brake pad pins 2 Remove brake caliper 3 Remove brake pad pins brake pads along with the brake pad shims brake pad spring 4 Measure brake pad wear limit Out of specificat...

Page 92: ...tall the brake pad pins 6 Tighten brake pad pins brake caliper front rear LOCK TITE 7 Check brake fluid level Below the minimum level mark Add the recommended brake fluid to the proper level Refer to...

Page 93: ...ain Refer to CHANGING THE BRAKE FLUID in chapter 3 1 Union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Brake lever cover 1 5 Brake lever 1 6 Brake master cylinder holder 1 7 Brake master cylinder...

Page 94: ...rts in the order listed Brake master cylinder cap 1 Brake master cylinder reservoir dia phragm 1 Brake master cylinder reservoir float 1 Brake master cylinder boot 1 Circlip 1 Washer 1 Brake master cy...

Page 95: ...e fluid reservoir cap 1 2 Brake fluid reservoir diaphragm holder 1 3 Brake fluid reservoir diaphragm 1 4 Brake fluid reservoir tank 1 5 Brake fluid reservoir hose 1 6 Hose holder 1 7 Union bolt 1 8 Co...

Page 96: ...ty Remarks Removing the rear brake master cylinder Remove the parts in the order listed Brake master cylinder kit 1 Circlip 1 Brake master cylinder joint 1 O ling 1 For assembly reverse the disassemb...

Page 97: ...iner under the master cylinder and the end of the brake hose 2 Remove brake master cylinder bracket brake master cylinder 3 Remove brake master cylinder boot circlip EAS00589 DISASSEMBLING THE REAR BR...

Page 98: ...compressed air Front Rear 2 Check brake master cylinder kit Damage scratches wear Replace Front Rear 3 Check rear brake fluid reservoir Cracks damage Replace rear brake fluid reservoir diaphragm Crac...

Page 99: ...ake master cylinder holder with the UP mark facing up First tighten the upper bolt then the lower bolt 2 Install copper washers brake hose union bolt WARNING Proper brake hose routing is essential to...

Page 100: ...already in the system Mixing brake flu ids may result in a harmful chemical reac tion leading to poor brake performance When refilling be careful that water does not enter the brake master cylinder re...

Page 101: ...r to CABLE ROUTING in chapter 2 CAUTION When installing the brake hose onto the brake master cylinder make sure the brake pipe touches the projection as shown 3 Fill brake fluid reservoir to the maxim...

Page 102: ...fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 6 Check brake pedal operation WARNING A soft or spongy feeling in the brake pedal can indicate the presence of air in th...

Page 103: ...ke fluid Drain Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 1 Protector 1 2 Brake hose holder 1 3 Union bolt 1 4 Copper washer 2 5 Brake hose 1 6 Brake caliper 1 For installation reverse...

Page 104: ...the parts in the order listed Brake pad 2 Brake caliper bracket 1 Brake pad support 2 Sleeve boot 1 Brake caliper piston 2 Brake caliper piston seal 4 Pin boot 1 Bleed screw 1 For assembly reverse the...

Page 105: ...Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM in chapter 3 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Brake pad pin 2 Loosen 5 Protector 1 6 Brake caliper 1 For installation reverse the removal...

Page 106: ...r brake caliper Remove the parts in the order listed Brake pad pin 2 Brake pad 2 Brake pad shim 1 Brake caliper seal 2 Brake caliper piston 1 Brake pad spring 1 Bleed screw 1 For assembly reverse the...

Page 107: ...ons brake caliper piston seals a Blow compressed air into the brake hose joint opening to force out the pistons from the brake caliper WARNING Cover the brake caliper pistons with a rag Be careful not...

Page 108: ...ke caliper WARNING Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove t...

Page 109: ...iper piston seals Front Rear 2 Check front brake caliper bracket Cracks damage Replace guide pin Rust damage Replace sleeve boot Crack damage Replace pin boot Wear damage Replace EAS00634 ASSEMBLING A...

Page 110: ...ake fluids may cause the rubber seals to deteriorate causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake flu ids may result i...

Page 111: ...AR BRAKE CALIPER WARNING Before installation all internal brake com ponents should be cleaned and lubricated with clean or new brake fluid Never use solvents on internal brake com ponents as they will...

Page 112: ...te causing leakage and poor brake performance Refill with the same type of brake fluid that is already in the system Mixing brake flu ids may result in a harmful chemical reac tion leading to poor bra...

Page 113: ...k Add the recommended brake fluid to the proper level Refer to CHECKING THE BRAKE FLUID LEVEL in chapter 3 6 Check brake lever operation Soft or spongy feeling Bleed the brake system Refer to BLEEDING...

Page 114: ...Protector Front brake caliper Number plate Refer to SEAT SIDE COVERS AND FUEL TANK in chapter 3 1 Cap bolt 1 Loosen 2 Upper bracket pinch bolt 1 Loosen 3 Lower bracket pinch bolt 2 Loosen 4 Front fork...

Page 115: ...ed Guide protector 1 Cap bolt 1 O ring 1 Damper adjusting rod 1 Nut 1 Washer 1 Fork spring 1 Spring guide 1 Dust seal 1 Oil seal clip 1 Inner tube 1 Outer tube 1 Piston metal 1 Slide metal 1 Oil seal...

Page 116: ...l seal 1 Plug 1 Base valve 1 Gasket 1 O ring 2 Damper rod 1 O ring 1 Air bleed screw 1 For assembly reverse the disassembly procedure 55 Nm 5 5 m kg 40 ft lb 15 Nm 1 5 m kg 11 ft lb 28 Nm 2 8 m kg 20...

Page 117: ...t there is no danger of it falling over NOTE NOTE Place the vehicle on a suitable stand so that the front wheel is elevated 2 Remove front wheel protector front brake caliper number plate 3 Loosen cap...

Page 118: ...t c Remove the cap bolt 2 Remove nut washer fork spring spring guide 3 Drain fork oil NOTE NOTE Stroke the damper rod several times while draining the fork oil 4 Remove dust seal oil seal clip with a...

Page 119: ...h of the front fork legs 1 Check inner tube outer tube Bends damage scratches Replace WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it 2 Measure spring free len...

Page 120: ...eck cap bolt Damage wear Replace air bleed screw Damage wear Replace EAS00661 ASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs WARNING Make sure the oil le...

Page 121: ...the inner tube 2 Install gasket base valve 3 Tighten base valve LOCTITE NOTE NOTE While holding the damper rod with the damper rod holder tighten the base valve 4 Lubricate inner tube s outer surface...

Page 122: ...sed grease Lubricate the outer surface of the inner tube with fork oil Before installing the oil seal cover the top of the front fork leg with a plastic bag to protect the oil seal during installation...

Page 123: ...OTE While filling the front fork leg keep it upright After filling slowly pump the front fork leg up and down to distribute the fork oil Fork seal driver 90890 01442 YM 01442 Quantity each front fork...

Page 124: ...nd the washer NOTE NOTE Use the side of the rod holder that is marked A d Remove the rod puller and adapter e Install the nut and position it as specified f Loosen the rebound damping force adjust ing...

Page 125: ...ke sure that there is a clearance of 0 1 mm 0 0 04 in between the front fork cap bolt and locknut h Hold the cap bolt and tighten the nut to specification i Remove the rod holder j Temporarily tighten...

Page 126: ...holder 2 Tighten cap bolt 3 Adjust front fork top end 4 Tighten upper bracket pinch bolt lower bracket pinch bolt WARNING Make sure the brake hoses are routed prop erly 5 Install protector 6 Adjust s...

Page 127: ...tch cable 1 2 Clutch lever holder 1 3 Clutch lever 1 4 Engine stop switch 1 5 Brake master cylinder cap 1 6 Brake master cylinder 1 7 Throttle cable cap 1 8 Grip cap lower 1 9 Grip cap upper 1 10 Thro...

Page 128: ...14 Left grip 1 15 Handlebar upper holder 2 16 Handlebar 1 For installation reverse the removal procedure 1 Nm 0 1 m kg 0 7 ft lb 4 Nm 0 4 m kg 2 9 ft lb 4 Nm 0 4 m kg 2 9 ft lb 27 Nm 2 7 m kg 1 9 ft...

Page 129: ...damage Replace WARNING Do not attempt to straighten a bent handle bar as this may dangerously weaken it EAS00670 INSTALLING THE HANDLEBAR 1 Stand the vehicle on a level surface WARNING Securely suppor...

Page 130: ...on the handlebar surface with a lac quer thinner Install the left grip to the handlebar so that the arrow mark L faces straight upward 4 Install right grip apply the adhesive on the tube guide NOTE N...

Page 131: ...ll the bracket so that the arrow mark face upward 9 Install engine stop switch clutch lever holder clamp NOTE NOTE The engine stop switch and clutch lever holder should be installed according to the d...

Page 132: ...er free play Refer to ADJUSTING THE CLUTCH CABLE FREE PRAY in chapter 3 12 Clamp the clamp portion of the number plate to the handlebar 13 Insert the end of the fuel tank breather hose into the hole o...

Page 133: ...to HANDLEBAR Front fender 1 Steering stem nut 1 2 Washer 1 3 Upper bracket 1 4 Steering ring nut 1 5 Lower bracket 1 6 Bearing race cover 1 7 Washer 1 8 Upper bearing 1 9 Lower bearing 1 10 Bearing ra...

Page 134: ...teering stem nut washer upper bracket steering ring nut with the ring nut wrench WARNING Securely support the lower bracket so that there is no danger of it falling EAS00682 CHECKING THE STEERING HEAD...

Page 135: ...teering head pipe could be damaged NOTE NOTE Always replace the bearing balls and bearing races as a set Whenever the steering head is disassembled replace the dust seal 4 Check upper bracket lower br...

Page 136: ...g nut 4 Install upper bracket washer steering stem nut 5 Install front fork legs Refer to INSTALLING THE FRONT FORK LEGS NOTE NOTE Temporarily tighten the upper and lower bracket pinch bolts 4 Nm 0 4...

Page 137: ...PE in chapter 5 1 Clamp 1 Loosen 2 Rear frame 1 3 Washer bolt 1 1 4 Self locking nut washer bolt 1 1 1 5 Rear shock absorber 1 6 Spring guide 1 7 Spring 1 8 Adjuster 1 9 Locknut 1 For installation rev...

Page 138: ...as cylinder Do not subject the rear shock absorber or gas cylinder to an open flame or any other source of high heat High heat can cause an explosion due to excessive gas pres sure Do not deform or da...

Page 139: ...vehicle on a suitable stand so that the rear wheel is elevated 2 Remove seat and right side cover Refer to SEAT SIDE COVERS AND FUEL TANK in chapter 3 silencer Refer to EXHAUST PIPE in chapter 5 3 Lo...

Page 140: ...e dust seals Damage wear Replace bolts Bends damage wear Replace EAS00698 INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY 1 Lubricate spacers bolts 2 Install rear shock absorber NOTE NOTE When installing...

Page 141: ...T PIPE in chapter 5 seat and right side cover Refer to SEAT SIDE COVERS AND FUEL TANK in chapter 3 6 Adjust spring preload rebound damping compression damping Refer to ADJUSTING THE REAR SHOCK ABSORBE...

Page 142: ...holder Rear brake caliper Left crankcase cover Refer to CDI MAGNETO in chapter 5 1 Drive chain 1 2 Drive chain support 1 3 Drive chain support cover 1 4 Pivot shaft 1 5 Swingarm 1 For installation re...

Page 143: ...s in the order listed Relay arm 1 Connecting rod 1 Cover 2 Dust seal 2 Collar 5 Bushing 5 Oil seal 8 Bearing 9 Bushing 2 Drive chain guide 1 For assembly reverse the disassembly procedure 53 Nm 5 3 m...

Page 144: ...chapter 5 3 Measure swingarm side play swingarm vertical movement a Measure the tightening torque of the pivot shaft nut b Measure the swingarm side play by moving the swingarm from side to side c If...

Page 145: ...and so that the rear wheel is elevated 2 Remove master link clip master link master link plate drive chain EAS00707 CHECKING THE SWINGARM 1 Check swingarm Bends cracks damage Replace 2 Check pivot sha...

Page 146: ...acers Damage scratches Replace EAS00710 CHECKING THE DRIVE CHAIN 1 Measure Measure the dimension between 15 links on the inner side and outer side of the roller and calculate the dimension between pin...

Page 147: ...chain in kerosene and remove any remaining dirt c Remove the drive chain from the kerosene and completely dry it 4 Check drive chain rollers Damage wear Replace the drive chain drive chain side plates...

Page 148: ...aches indicator Replace EAS00711 INSTALLING THE SWINGARM 1 Install bearing bushing swingarm oil seal with the swingarm NOTE NOTE Apply the molybdenum disulfide grease on the bearing and bushing when i...

Page 149: ...Install bearing oil seal with the connecting rod NOTE NOTE Apply the molybdenum disulfide grease on the bearing when installing Install the bearing by pressing it on the side having the manufacture s...

Page 150: ...in slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 EAS00714 INSTALLING THE DRIVE CHAIN 1 Lubricate drive chain master link 2 Install master link master link plate 54 Nm 5 4 m kg 39 ft lb 6...

Page 151: ...cally shorten the drive chain s life 4 Adjust drive chain slack Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 CAUTION A drive chain that is too tight will overload the engine and other vital...

Page 152: ...ECKING THE CYLINDER AND PISTON 5 11 COMBINATION OF PISTON AND CYLINDER 5 13 CHECKING THE PISTON RING 5 14 CHECKING THE PISTON PIN 5 14 CHECKING THE SMALL END BEARING 5 15 INSTALLING THE PISTON AND CYL...

Page 153: ...EAR 5 34 CDI MAGNETO 5 36 REMOVING THE ROTOR 5 37 CHECKING THE CDI MAGNETO 5 37 CHECKING THE WOODRUFF KEY 5 37 INSTALLING THE CDI MAGNETO 5 38 CRANKCASE AND CRANKSHAFT 5 40 CRANKCASE AND CRANKSHAFT 5...

Page 154: ...ocket Remove the parts in the order listed Drive chain Loosen Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 1 Left crank case cover 1 2 Nut 1 3 Lock washer 1 4 Drive sprocket 1 For installatio...

Page 155: ...t side cover 1 Silencer 1 2 Exhaust pipe joint 1 3 Exhaust pipe spring 2 4 Exhaust pipe 1 5 Exhaust pipe gasket 2 For installation reverse the removal procedure 12 Nm 1 2 m kg 8 7 ft lb 12 Nm 1 2 m kg...

Page 156: ...4 Install inner pipe NOTE NOTE Fully apply Yamaha bond No 1215 Three bond No 1215 or equivalent as shown 5 Install washer bolt fiber LOCTITE silencer bolt silencer right side cover seat Yamaha bond N...

Page 157: ...in Refer to CHANGING THE COOLANT in chapter 3 Seat Fuel tank Carburetor Refer to CARBURETOR in chapter 7 Exhaust pipe Silencer Clutch cable Refer to HANDLEBAR in chapter 4 Radiator hose Refer to RADIA...

Page 158: ...Drive chain Loosen Refer to ADJUSTING THE DRIVE CHAIN SLACK in chapter 3 1 Engine mount nut 2 2 Engine mount bolt 2 3 Pivot shaft nut 1 4 Pivot shaft 1 5 Engine 1 For installation reverse the removal...

Page 159: ...e pivot shaft engine mount bolt front engine mount bolt lower NOTE NOTE Do not fully tighten the bolts 2 Tighten pivot shaft nut engine mount nut front engine mount nut lower 63 Nm 6 3 m kg 46 ft lb 6...

Page 160: ...n Refer to CHANGING THE COOLANT in chapter 3 Seat Fuel tank Radiator hose Refer to RADIATOR in chapter 6 1 Spark plug 1 2 Cylinder head nut 4 3 Copper washer 4 4 Cylinder head 1 5 O ring 2 For install...

Page 161: ...r NOTE NOTE Do not use a sharp instrument to avoid damag ing or scratching spark plug bore threads 2 Check cylinder head Damage scratches Replace cylinder head water jacket Mineral deposits rust Elimi...

Page 162: ...er head several times EAS00233 INSTALLING THE CYLINDER HEAD 1 Lubricate O rings 2 Install O rings 3 Install cylinder head copper washer cylinder head nuts NOTE NOTE Tighten the cylinder head nuts in s...

Page 163: ...linder head Refer to CYLINDER HEAD 1 Cylinder nut 4 2 Cylinder 1 3 Dowel pin 4 4 Cylinder gasket 1 5 Piston pin clip 2 6 Piston pin 1 7 Piston 1 8 Small end bearing 1 9 Piston ring 1 For installation...

Page 164: ...n deburr the pis ton pin clip s groove and the piston s pin bore area If both areas are deburred and the piston pin is still difficult to remove remove it with the piston pin puller set 3 Remove pisto...

Page 165: ...iston and piston rings as a set e Calculate the piston to cylinder clearance with the following formula f If out of specification replace the cylinder and the piston and piston rings as a set Standard...

Page 166: ...inder mark Cylinder size A 47 500 47 502 mm 1 8701 1 8702 in B 47 504 47 506 mm 1 8702 1 8703 in C 47 508 47 510 mm 1 8704 1 8705 in D 47 512 47 514 mm 1 87055 1 87063 in Piston mark color Piston size...

Page 167: ...ring into the cylinder with the piston crown 3 Measure piston ring end gap Out of specification Replace the piston ring CHECKING THE PISTON PIN 1 Check piston pin Blue discoloration grooves Replace th...

Page 168: ...small end bearing Signs of heat discoloration Replace Piston pin outside diameter 13 996 14 000 mm 0 5510 0 5512 in Limit 13 975 mm 0 5502 in Piston pin bore inside diameter 14 004 14 015 mm 0 5513 0...

Page 169: ...bearing with the recomended lubricant dowel pin 3 Install piston piston pin piston pin clip NOTE NOTE Apply engine oil the piston pin Make sure the arrow mark on the piston points towards the exhaust...

Page 170: ...nt 5 Install cylinder cylinder nut NOTE NOTE While compressing the piston ring with one hand install the cylinder with the other hand Tighten the nuts in stage using a crisscross pattern Recommended l...

Page 171: ...IL in chapter 3 Clutch cable Disconnect 1 Clutch cover 1 2 Clutch cover gasket 1 3 Dowel pin 2 4 Compression spring 5 5 Pressure plate 1 6 Push rod 1 1 7 Ball 1 8 Push rod 2 1 9 Friction plate 1 2 10...

Page 172: ...lutch boss 1 15 Washer 1 16 Primary drive gear 1 17 Spacer 1 18 Washer 1 19 Push lever shaft 1 20 Spring 1 21 Oil seal 1 22 Bearing 1 For installation reverse the removal procedure 70 Nm 7 0 m kg 51 f...

Page 173: ...them 2 Remove compression spring bolts compression springs pressure plate 3 Remove push rod 1 ball push rod 2 4 Remove friction plate 1 clutch plate friction plate 2 5 Remove clutch boss nut washer cl...

Page 174: ...a set NOTE NOTE Measure the friction plate at four places EAS00281 CHECKING THE CLUTCH PLATES The following procedure applies to all of the clutch plates 1 Check clutch plate Damage Replace the clutch...

Page 175: ...housing dogs Damage pitting wear Deburr the clutch housing dogs or replace the clutch housing NOTE NOTE Pitting on the clutch housing dogs will cause erratic clutch operation EAS00285 CHECKING THE CL...

Page 176: ...ush rod 1 ball push rod 2 Wear damage bend Replace EAS00298 INSTALLING THE CLUTCH 1 Install washer spacer primary driven gear with the recommended lubricant 2 Install washer clutch boss 3 Install wash...

Page 177: ...TE Install the clutch plates and friction plates alternately on the clutch boss starting with a friction plate and ending with a friction plate Use the friction plate for the first and final while pay...

Page 178: ...the clutch boss 9 Install clutch spring clutch spring bolt NOTE NOTE Tighten the clutch spring bolts in stages and in a crisscross pattern 10 Install dowel pin clutch cover gasket clutch cover NOTE NO...

Page 179: ...r 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 Water pump housing Refer to WATER PUMP in chapter 6 Radiator hose 2 Refer to RADIATOR in chapter 6 Brake pedal Clutch Refer to CLUTCH 1 Kic...

Page 180: ...b Part Q ty Remarks 7 Primary drive gear 1 For installation reverse the removal procedure 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 79 Nm 7 9 m kg 57 ft lb KICK STARTE...

Page 181: ...parts in the order listed shaft 1 Circlip 1 2 Washer 2 3 Kick idle gear 1 4 Spring guide 1 5 Torsion spring 1 6 Washer 1 7 Kick starter gear clip 1 8 Kick starter gear 1 9 Kick starter shaft 1 10 Shif...

Page 182: ...ob Part Q ty Remarks 14 Washer 1 15 Stopper lever 1 16 Collar 1 17 Shift shaft spring 1 18 Oil seal 1 19 Oil seal 1 For installation reverse the removal procedure 10 Nm 1 0 m kg 7 2 ft lb KICK STARTER...

Page 183: ...ankcase CHECKING THE KICK STARTER 1 Check kick starter gear smooth movement Unsmooth movement Replace kick starter shaft Wear damage Replace 2 Check kick starter gear Wear damage Replace kick idle gea...

Page 184: ...CKING THE PRIMARY DRIVE GEAR AND PRIMARY DRIVEN GEAR 1 Check primary drive gear Damage wear Replace primary driven gear Damage wear Replace 2 Check primary driven gear circumferencial play Free play e...

Page 185: ...aft NOTE NOTE Apply transmission oil on the shift shaft When installing the shift shaft align the stop per lever roller with the slot on segment When installing the shift shaft make sure that the tors...

Page 186: ...shaft assembly NOTE NOTE Apply the transmission oil on the kick shaft Apply the lithium soap base grease on the kick shaft stopper Slide the kick starter shaft assembly into the crankcase make sure th...

Page 187: ...stration 3 Tighten primary drive gear nut NOTE NOTE Hold the drive gear holder onto the crank case using the M6 bolts 4 Install primary driven gear Refer to CLUTCH 5 Install dowel pin gasket right cra...

Page 188: ...crank NOTE NOTE Install the kick starter crank closest to but not contacting the pillar tube and exhaust pipe 9 Install shift pedal NOTE NOTE Install the shift pedal with the bottom of the pedal oute...

Page 189: ...rts in the order listed Seat Fuel tank 1 CDI magneto lead 1 Disconnect 2 Left crankcase cover 1 3 Left crankcase cover gasket 1 4 Rotor 1 5 Stator 1 6 Woodruff key 1 For installation reverse the remov...

Page 190: ...NOTE When installing the flywheel puller turn it counterclockwise CHECKING THE CDI MAGNETO 1 Check rotor inner surface stator outer surface Damage Inspect the crankshaft runout and crankshaft bearing...

Page 191: ...ling the woodruff key make sure that its flat surface is in parallel with the crankshaft center line When installing the rotor align the keyway of the rotor with the woodruff key 3 Install washer nut...

Page 192: ...he ignition timing 7 Connect CDI magneto lead Refer to CABLE ROUTING in chapter 2 8 Install gasket left crankcase cover left crankcase cover NOTE NOTE Tighten the screws in stage using a crisscross pa...

Page 193: ...AND PISTON Primary drive gear Refer to CLUTCH Kick idle gear Stopper lever Rotor and stator Refer to CDI MAGNETO 1 Crank case oil seal holder 1 2 Right crankcase 1 3 Left crankcase 1 4 Dowel pin 2 5 C...

Page 194: ...case half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If one end hangs up take pressure off the pus...

Page 195: ...puller as shown in CAUTION Do not use the removed bearing EAS00394 CHECKING THE CRANKSHAFT AND CONNECTING ROD 1 Measure crankshaft runout Out of specification Replace the crank shaft bearing or both...

Page 196: ...ASE 1 Check contacting surface Scratches Replace engine mounting boss crankcase Cracks damage Replace EAS00401 CHECKING THE BEARINGS AND OIL SEALS 1 Check bearings Clean and lubricate the bearings the...

Page 197: ...the connecting rod at top dead center with one hand while turning the nut of the crankshaft installer bolt with the other Turn the crankshaft installer bolt until the crankshaft assembly bottoms again...

Page 198: ...crankcase the connect ing rod should be positioned at TDC 3 Install clamp screw NOTE NOTE Tighten the crankcase tightening screws in stage using a crisscross pattern 4 Install crankcase oil seal holde...

Page 199: ...parts in the order listed Engine Refer to ENGINE Crankcase Separate Refer to CRANKCASE AND CRANKSHAFT 1 Shift fork guide bar 2 2 Shift drum 1 3 Shift fork R 1 4 Shift fork L 1 5 Shift fork C 1 6 Bear...

Page 200: ...1 13 Circlip 1 14 Washer 1 15 5TH pinion gear 1 16 Main axle 1 17 Bearing 1 18 Circlip 1 19 Washer 1 20 1ST wheel gear 1 21 5TH wheel gear 1 22 Circlip 1 23 Washer 1 24 4TH wheel gear 1 25 3RD wheel...

Page 201: ...ENG 5 48 Order Job Part Q ty Remarks 28 2ND wheel gear 1 29 Washer 1 30 Bearing 1 31 Oil seal 1 32 Bearing 2 For installation reverse the removal procedure TRANSMISSION...

Page 202: ...transmission drive axle with a soft hammer AS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks 1 Check shift fork pin shift fork cam follower Bends damage scori...

Page 203: ...runout with a centering device and dial gauge Out of specification Replace the main axle 2 Measure drive axle runout with a centering device and dial gauge Out of specification Replace the drive axle...

Page 204: ...ion gear onto the main axle NOTE NOTE Apply the molybdenum disulfide oil on the 5TH and 6TH pinion gears inner circumfer ence and on the end surface Apply the transmission oil on the 3RD 4TH and 2ND p...

Page 205: ...the circlip end is positioned at axle spline groove 4 Install collar NOTE NOTE Apply the lithium soap base grease on the oil seal lip When installing the collar into the crankcase pay careful attenti...

Page 206: ...H pinion gear on the main axle 7 Install shift cam NOTE NOTE Apply the transmission oil on the shift cam 8 Install shift fork guide bar NOTE NOTE Apply the transmission oil on the guide bars Be sure t...

Page 207: ...COOL CHAPTER 6 COOLING SYSTEM RADIATOR 6 1 CHECKING THE RADIATOR 6 2 INSTALLING THE RADIATOR 6 2 WATER PUMP 6 4 CHECKING THE WATER PUMP 6 5 INSTALLING THE WATER PUMP 6 5...

Page 208: ...AT SIDECOVERS AND FUEL TANK in chapter 3 Coolant Drain Refer to CHANGING THE COOLANT in chapter 3 1 Radiator guard 1 2 Radiator inlet hose 1 3 Radiator outlet hose 1 4 Radiator breather hose 1 5 Radia...

Page 209: ...essure Replace the radiator cap a Install the radiator cap tester and radia tor cap tester adapter to the radiator cap b Apply the specified pressure for ten sec onds and make sure there is no drop in...

Page 210: ...faulty part a Attach the radiator cap tester to the radi ator b Apply 100 kPa 1 0 kg cm2 14 22 psi of pressure c Measure the indicated pressure with the gauge Radiator cap tester 90890 01325 YU 24460...

Page 211: ...unless the coolant level is extremely low or the coolant contains engine oil Right crankcase cover Refer to PRIMARY DRIVE GEAR in chapter 5 1 Water pump housing 1 2 Gasket 1 3 Impeller 1 4 Water pump...

Page 212: ...movement Replace 3 Check impeller Cracks damage wear Replace 4 Check water pump impeller shaft Damage wear Replace water pump drive gear Damage wear Replace EAS00479 INSTALLING THE WATER PUMP 1 Instal...

Page 213: ...hium soap base grease on the oil seal lip and water pump impeller shaft And install the shaft while turning it Hold the impeller shaft on its width across the flats with spanners etc and install the i...

Page 214: ...E 7 1 CHECKING THE CARBURETOR 7 4 CHECKING THE REED VALVE 7 5 ASSEMBLY THE REED VALVE 7 6 ASSEMBLING THE CARBURETOR 7 6 INSTALLING THE REED VALVE 7 8 INSTALLING THE CARBURETOR 7 8 MEASURING AND ADJUST...

Page 215: ...etor and reed valve Remove the parts in the order listed 1 Clamp 2 Loosen 2 Carburetor assembly 1 3 Carburetor joint 1 4 Reed valve assembly 1 5 Reed valve stopper 2 6 Reed valve 2 For installation re...

Page 216: ...the order listed Mixing chamber top 1 Throttle valve 1 Jet needle 1 Ring 1 Throttle valve spring 1 Gascket mixing chamber top 1 Float chamber 1 Gascket float chamber 1 Float pin 1 Float 1 Needle valve...

Page 217: ...CARB 7 3 Order Job Part Q ty Remarks Starter plunger 1 Throttle stop screw 1 Pilot air screw 1 For assembly reverse the disassembly procedure CARBURETOR AND REED VALVE...

Page 218: ...in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages and jets with compressed air 3 Check float chamber body Dirt Clean 4 Check float chambe...

Page 219: ...ve it up and down Tightness Replace the piston valve 9 Check hose joints Cracks damage Replace 10 Check carburetor breather hoses fuel hoses Cracks damage wear Replace Obstruction Clean Blow out the h...

Page 220: ...adually to avoid warp ing EAS00487 ASSEMBLING THE CARBURETOR CAUTION Before assembling the carburetor wash all of the parts in a petroleum based sol vent Always use a new gasket 1 Install pilot air sc...

Page 221: ...buretor 4 Install needle valve float float pin NOTE NOTE After installing the needle valve to the float install them to the carburetor Check the float for smooth movement 5 Install float chamber gasck...

Page 222: ...able Align the cut in the ring with the throttle cable INSTALLING THE REED VALVE 1 Install reed valve assembly NOTE NOTE Install the reed valve assembly with its projec tion facing upward 2 Install ca...

Page 223: ...e needle valve but not compressing the needle valve 2 Adjust fuel level a Check the needle valve seat and needle valve b If either is worn replace them as a set c If both are fine adjust the float lev...

Page 224: ...ELEC CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS 8 1 CHECKING SWITCH CONTINUITY 8 2 IGNITION SYSTEM 8 3 TROUBLESHOOTING 8 3...

Page 225: ...ELEC 8 1 EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS Ignition coil Engine stop switch CDI unit CDI magneto ELECTRICAL COMPONENTS...

Page 226: ...Never insert the tester probes into the cou pler terminal slots Always insert the probes from the opposite end of the cou pler taking care not to loosen or damage the leads NOTE NOTE Before checking f...

Page 227: ...Spark plug Check the condition of the spark plug Check the spark plug type Measure the spark plug gap Refer to CHECKING THE SPARK PLUG in chapter 3 Standard spark plug BR10EG NGK Spark plug gap 0 5 0...

Page 228: ...plug cap 4 Ignition coil resistance Disconnect the ignition coil connectors from the ignition coil terminals Connect the pocket tester 1 to the ignition coil as shown Positive tester probe orange Neg...

Page 229: ...ontinuity Is the engine stop switch OK YES NO Replace the engine stop switch 6 Pickup coil resistance Disconnect the pickup coil coupler from the wire harness Connect the pocket tester 100 to the pick...

Page 230: ...080 at 20 C 68 F Connect the pocket tester 10 to the charging coil Positive tester probe green blue Negative tester probe black Measure the charging coil resistance Charging coil resistance 44 66 at...

Page 231: ...AND EXAMPLES OF CARBURETOR SETTING 9 5 EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM 9 5 CHANGE OF THE HEAT RANGE OF SPARK PLUGS 9 6 CHASSIS 9 7 SELECTION OF THE SECONDARY REDUCTION RATIO SPROCK...

Page 232: ...cle for conditions pick up of engine speed road surface con ditions and for the discoloration of the spark plug s After taking these into consideration he must select the best possible carburetor sett...

Page 233: ...l fouled too rich EFFECTS OF THE SETTING PARTS ON THE THROTTLE VALVE OPENING Throttle valve opening Full open Full closed Discoloration Condition of spark plug Normal Insulator is dry and burnt brown...

Page 234: ...e enrich at low speeds and turning it out will lean it PILOT JET ADJUSTMENT The richness of air fuel mixture with the throttle fully closed to 1 2 open can be set by turning the pilot jet It is change...

Page 235: ...eedle 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 In this case step down the jet n...

Page 236: ...gh speeds Hard breathing Shearing noise Whitish spark plug Lean mixture Increase main jet calibration no Gradually Discoloration of spark plug If tan color it is in good condition If cannot be correct...

Page 237: ...gher calibration no and lower the jet needle clip position Check air filter for fouling Poor engine operation Turn in pilot air screw Adjust the throttle stop screw Check throttle valve operation This...

Page 238: ...S SELECTION OF THE SECONDARY REDUCTION RATIO SPROCKET Requirement for selection of secondary gear reduction ratio It is generally said that the secondary gear ratio should be reduced for a longer stra...

Page 239: ...d the end of the straight line with care taken to avoid the engine over revving NOTE NOTE Riding technique varies from rider to rider and the performance of a vehicle also vary from vehicle to vehicle...

Page 240: ...end ing on the rider s feeling of an actual run and the circuit conditions The front fork setting includes the following three factors 1 Setting of air spring characteristics Change the fork oil level...

Page 241: ...n relation to oil level change Load Stroke Max oil level Standard oil level Min oil level SETTING OF SPRING AFTER REPLACEMENT As the front fork setting can be easily affected by rear suspension take c...

Page 242: ...urn in one or two clicks Change the compression damping Turn out one or two clicks FRONT FORK SETTING PARTS Front fork spring YZ85 YZ85LW NOTE NOTE The I D mark slits is proved on the end of the sprin...

Page 243: ...nder hold ing bolt 2 Remove the stand or block from the engine and with a rider astride the seat measure the sunken length between the rear wheel axle center and the rear fender hold ing bolt 3 Loosen...

Page 244: ...ound damp ing to compensate for its greater spring load Run with the rebound damping adjuster one or two clicks on the stiffer side and readjust it to suit your preference Adjusting the rebound dampin...

Page 245: ...2 M0 Brown STD 4 6 4ES 22212 K0 Green STIFF 4 8 4ES 22212 G0 Red TYPE SPRING RATE SPRING PART NUMBER I D COLOR SOFT 4 8 4ES 22212 G0 Red STD 5 0 4ES 22212 F0 STIFF 5 2 4ES 22212 H0 Blue TYPE SPRING RA...

Page 246: ...g Turn adjuster clockwise about 2 clicks to increase damping Oil level oil amount Increase oil level by about 5 10 mm 0 2 0 4 in Spring Replace with stiff spring Stiff toward stroke end Oil level oil...

Page 247: ...to decrease damping Spring Replace with soft spring Poor road gripping Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Compression damping Turn adjuster clockwise abo...

Page 248: ...PERFORMANCE 10 2 ENGINE 10 2 FUEL SYSTEM 10 2 FAULTY GEAR SHIFTING 10 2 SHIFTING IS DIFFICULT 10 2 SHIFT PEDAL DOES NOT MOVE 10 2 JUMPS OUT OF GEAR 10 2 FAULTY CLUTCH 10 3 CLUTCH SLIPS 10 3 CLUTCH DR...

Page 249: ...aged reed valve FUEL SYSTEM Fuel tank Empty fuel tank Clogged fuel strainer Clogged fuel tank drain hose Clogged rollover valve Clogged rollover valve hose Deteriorated or contaminated fuel Fuel cock...

Page 250: ...t Faulty pickup coil Broken generator rotor woodruff key EAS00848 POOR MEDIUM AND HIGH SPEED PERFORMANCE Refer to STARTING FAILURES ENGINE Air filter Clogged air filter element FUEL SYSTEM Carburetor...

Page 251: ...AS00855 OVERHEATING ENGINE Clogged coolant passages Cylinder head s and piston s Heavy carbon buildup Transmission oil Incorrect oil level Incorrect oil viscosity Inferior oil quality COOLING SYSTEM C...

Page 252: ...viscosity Incorrect oil level EAS00864 UNSTABLE HANDLING Handlebar Bent or improperly installed handlebar Steering head components Improperly installed upper bracket Improperly installed lower bracke...

Page 253: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN...

Page 254: ...chwarz Rot B W Schwarz Wei G L Gr n Blau G W Gr n Wei W L Wei Blau W R Wei Rot ELECTRICAL COMPONENTS Engine stop switch Ignition coil CDI unit CDI magneto Spark plug COLOR CODE B Black O Orange B R Bl...

Page 255: ...nder CDI Magnet Z ndkerze FARB CODIERUNG B Schwarz O Orange B R Schwarz Rot B W Schwarz Wei G L Gr n Blau G W Gr n Wei W L Wei Blau W R Wei Rot ELECTRICAL COMPONENTS Engine stop switch Ignition coil...

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