Yamaha Video Game Controller 5HN 28199 13 User Manual

OWNER’S SERVICE MANUAL

TT-R90R

LIT-11626-16-27

5HN-28199-13

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EC010000

TT-R90R

OWNER’S SERVICE MANUAL

1st Edition, April 2002

unauthorized use without the written

permission of Yamaha Motor Corporation

U.S.A. is expressly prohibited.

Printed in Japan

P/N. LIT-11626-16-27

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INTRODUCTION

Congratulations on your purchase of a

Yamaha TT-R90R. This model is the culmina-

tion of Yamaha’s vast experience in the pro-

duction of pacesetting racing machines. It

represents the highest grade of craftsmanship

and reliability that have made Yamaha a

leader.

This manual explains operation, inspection,

basic maintenance and tuning of your

machine. If you have any questions about this

manual or your machine, 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

READ THIS MANUAL CAREFULLY FOR

INSTRUCTIONS ON HOW TO PROPERLY

OPERATE THIS MACHINE.

ADULT INSTRUCTION AND SUPERVI-

SION ARE REQUIRED.

WEIGHT OF THE RIDER SHOULD NOT

EXCEED 40 kg (88 lb).

ALWAYS WEAR A HELMET AND SUIT-

ABLE PROTECTIVE CLOTHING WHEN

RIDING.

DO NOT TOUCH ANY MOVING PARTS OR

HEATED AREAS.

ALWAYS PERFORM PRE-OPERATION

CHECKS. REFER TO PAGE 15.

THIS MACHINE IS DESIGNED TO CARRY

THE OPERATOR ONLY.

NO PASSENGERS.

THIS MACHINE IS DESIGNED OFF-ROAD

USE ONLY.

IT IS NOT SUITABLE FOR ON-ROAD USE.

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IMPORTANT NOTICE

This machine is designed for off-road use only

by young operators under adult instruction and

supervision. It is illegal for this machine to be

operated on any public street, road, or high-

way.

Off-road use on public lands may be illegal.

Please check local regulations before riding.

SAFETY INFORMATION

1. GASOLINE IS HIGHLY FLAMMABLE:

* Always turn off the engine when

refueling.

* Take care not to spill on the engine

or exhaust pipe/muffler, when refu-

eling.

* Never refuel while smoking or in

the vicinity of an open flame.

2. If you should swallow some gasoline

or inhale a lot of gasoline vapor, or

allow some gasoline to get in your

eye(s), see your doctor immediately.

If any gasoline spills on your skin or

clothing, immediately wash it with

soap and water, and change your

clothes.

3. Always turn off the engine before

leaving the machine unattended.

When parking the machine, note the

following:

* The engine and exhaust pipe(s)/

muffler(s) may be hot. Park the

machine in a place where pedestri-

ans or children are not likely to

touch the machine.

* Do not park the machine on a slope

or soft ground; the machine may

overturn.

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4. When transporting the machine in

another vehicle, be sure is kept

upright and that the fuel cock is

turned to the “OFF”. If it should lean

over, gasoline may leak out of the car-

buretor or fuel tank.

5. Never start your engine or let it run for

any length of time in a closed area.

The exhaust fumes are poisonous and

may cause loss of consciousness and

death within a short time. Always

operate your machine in an area with

adequate ventilation.

6. Always wear a helmet, gloves, boots,

trousers, and jacket for motocross

riding.

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SAFETY INFORMATION

1. Don’t ride it on the street.

2. Don’t run the engine inside a building.

3. This is a one-seater motorbike. Don’t give

any person a ride.

4. Let’s learn how to ride properly. Ask your

parents for any question.

5. When riding the machine, be sure to wear

the protective apparel as illustrated.

1Helmet

2Goggles

3Mouth guard

4Gloves

5Boots

6Motocross pants

7Long sleeved trainer

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6. When going for riding, be sure to be with

your family.

Never go alone.

7. Before riding the machine, ask your par-

ents to check the machine very carefully.

8. Don’t touch the areas shown, or you’ll get

burnt in the hand.

9. Don’t touch rotating or moving parts.

10. Before starting the engine, be sure to shift

the transmission into neutral.

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EC080000

EC081000

HOW TO USE

THIS MANUAL

PARTICULARLY IMPORTANT

INFORMATION

The Safety Alert Symbol means ATTENTION!

BECOME ALERT! YOUR SAFETY IS

INVOLVED!

WARNING

Failure to follow WARNING instructions could

result in severe injury or death to the machine

operator, a bystander, or a person inspecting

or repairing the machine.

CAUTION:

A CAUTION indicates special precautions that

must be taken to avoid damage to the

machine.

NOTE:

A NOTE provides key information to make pro-

cedures easier or clearer.

EC082000

FINDING THE REQUIRED PAGE

1. This manual consists of six chapters;

“General Information”, “Specifications”,

“Regular inspection and adjustments”,

“Engine”, “Chassis” and “Electrical”.

2. The table of contents is at the beginning

of the manual. Look over the general lay-

out of the book before finding then

required chapter and item.

Bend the book at its edge, as shown, to

find the required fore edge symbol mark

and go to a page for required item and

description.

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EC083000

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-

tion has been complied to provide the mechanic with an easy to read, handy reference that contains

comprehensive explanations of all disassembly, repair, assembly, and inspection operations.

In this revised format, the condition of a faulty component will precede an arrow symbol and the

course of action required will follow the symbol, e.g.

Bearings

Pitting/damage → Replace.

EC084002

HOW TO READ DESCRIPTIONS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

1. An easy-to-see exploded diagram 1is provided for removal and disassembly jobs.

2. Numbers 2are 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 are given on the next page.

4. A job instruction chart 4accompanies the exploded diagram, providing the order of jobs,

names of parts, notes in jobs, etc.

5. Extent of removal 5is provided in the job instruction chart to save the trouble of an unneces-

sary removal job.

6. For jobs requiring more information, the step-by-step format supplements 6are given in addi-

tion to the exploded diagram and job instruction chart.

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ILLUSTRATED SYMBOLS

(Refer to the illustration)

Illustrated symbols 1to 6are designed as

thumb tabs to indicate the chapter’s number

and content.

GEN

INFO

SPEC

1General information

2Specifications

3Regular inspection and adjustments

4Engine

INSP

ADJ

ENG

5Chassis

6Electrical

–

CHAS

ELEC

Illustrated symbols 7to Dare used to identify

the specifications appearing in the text.

7With engine mounted

8Special tool

9Filling fluid

0Lubricant

ATightening

BSpecified value, Service limit

CEngine speed

DResistance (Ω), Voltage (V), Electric current (A)

Illustrated symbols Eto Hin the exploded

diagram indicate grade of lubricant and loca-

tion of lubrication point.

EApply engine oil

FApply molybdenum disulfide oil

GApply lightweight lithium-soap base grease

HApply molybdenum disulfide grease

Illustrated symbols Ito Jin the exploded

diagrams indicate where to apply a locking

agent and when to install new parts.

New

IApply locking agent (LOCTITE )

JUse new one

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INDEX

GENERAL INFORMATION

GEN

INFO

SPECIFICATIONS

SPEC

REGULAR INSPECTION AND ADJUSTMENTS

INSP

ADJ

ENGINE

ENG

CHASSIS

ELECTRICAL

CHAS

–

ELEC

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CONTENTS

CHAPTER 1

GENERAL INFORMATION

DESCRIPTION ..........................................1-1

MACHINE IDENTIFICATION ....................1-2

IMPORTANT INFORMATION ...................1-3

CHECKING OF CONNECTION .................1-5

SPECIAL TOOLS ......................................1-6

CONTROL FUNCTIONS ...........................1-9

FUEL .......................................................1-11

STARTING AND OPERATION ...............1-12

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS ...................2-1

MAINTENANCE SPECIFICATIONS .........2-4

GENERAL TORQUE

SPECIFICATIONS ...................................2-15

DEFINITION OF UNITS ...........................2-15

CABLE ROUTING DIAGRAM .................2-16

CHAPTER 3

REGULAR INSPECTION AND

ADJUSTMENTS

MAINTENANCE INTERVALS ...................3-1

PERIODIC MAINTENANCE AND

LUBRICATION ..........................................3-1

PRE-OPERATION INSPECTION AND

MAINTENANCE ........................................3-2

ENGINE .....................................................3-3

CHASSIS .................................................3-11

ELECTRICAL ..........................................3-19

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CHAPTER 4

ENGINE

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

CYLINDER HEAD .....................................4-8

CAMSHAFT AND ROCKER ARMS ........4-13

VALVES AND VALVE SPRINGS ...........4-16

CYLINDER AND PISTON .......................4-21

CLUTCH ..................................................4-27

KICK AXLE .............................................4-33

SHIFT SHAFT .........................................4-34

OIL PUMP ...............................................4-36

CDI MAGNETO .......................................4-39

CRANKCASE AND CRANKSHAFT .......4-41

SHIFT FORK, SHIFT CAM AND

TRANSMISSION .....................................4-44

CHAPTER 5

CHASSIS

FRONT WHEEL AND REAR WHEEL .......5-1

FRONT FORK ...........................................5-6

HANDLEBAR ............................................5-9

STEERING ..............................................5-10

SWINGARM ............................................5-11

CHAPTER 6

ELECTRICAL

ELECTRICAL COMPONENTS AND

WIRING DIAGRAM ...................................6-1

IGNITION SYSTEM ...................................6-2

CARBURETOR HEATING SYSTEM ........6-6

NOISE REGULATION ...............................6-9

MAINTENANCE RECORD ........................6-9

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GEN

INFO

DESCRIPTION

EC100000

GENERAL INFORMATION

EC110000

DESCRIPTION

1“ENGINE STOP” button

2Front brake lever

3Throttle grip

4Fuel tank cap

5Kick starter

6Fuel tank

7Air cleaner

8Rear brake pedal

9Fuel cock

0Starter lever (choke)

ADrive chain

BShift pedal

CFront 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 - 1

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GEN

MACHINE IDENTIFICATION

INFO

^EM^C12A⁰⁰⁰C¹HINE IDENTIFICATION

There are two significant reasons for knowing

the serial number of your machine:

1. When ordering parts, you can give the

number to your Yamaha dealer for posi-

tive identification of the model you own.

2. If your machine is stolen, the authorities

will need the number to search for and

identify your machine.

^EV^CE¹²H¹⁰⁰I¹CLE IDENTIFICATION NUMBER

The vehicle identification number 1 is

stamped on the right of the steering head pipe.

ENGINE SERIAL NUMBER

The engine serial number 1is stamped into

the elevated part of the left-side of the engine.

EC124000

MODEL LABEL

The model label 1is affixed to the frame

under the rider’s seat. This information will be

needed to order spare parts.

1 - 2

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GEN

IMPORTANT INFORMATION

INFO

^EIM^C130P⁰⁰O⁰RTANT INFORMATION

^EP^CR¹³¹E⁰⁰P²ARATION FOR REMOVAL AND

DISASSEMBLY

1. Remove all dirt, mud, dust, and foreign

material before removal and disassem-

bly.

When washing the machine with high

pressured water, cover the parts as fol-

lows.

Silencer exhaust port

2. Use proper tools and cleaning equip-

ment. Refer to “SPECIAL TOOLS” sec-

tion.

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 them in trays in the

order of disassembly. This will speed up

assembly time and help assure that all

parts are correctly reinstalled.

5. Keep away from fire.

1 - 3

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GEN

IMPORTANT INFORMATION

INFO

^EA^CL¹³L²⁰⁰R⁰EPLACEMENT PARTS

1. We recommend to use Yamaha genuine

parts for all replacements. Use oil and/or

grease recommended by Yamaha for

assembly and adjustment.

EC133000

GASKETS, OIL SEALS AND O-RINGS

1. All gaskets, oil seals, and O-rings should

be replaced when an engine is over-

hauled. All gasket surfaces, oil seal lips,

and O-rings must be cleaned.

2. Properly oil all mating parts and bearings

during reassembly. Apply grease to the

oil seal lips.

EC134000

LOCK WASHERS/PLATES AND COTTER

PINS

1. All lock washers/plates 1and 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.

^EB^CE¹³⁵A⁰⁰R¹INGS AND OIL SEALS

1. Install the bearing(s) 1and oil seal(s) 2

with their manufacturer’s marks or num-

bers facing outward. (In other words, the

stamped letters must be on the side

exposed to view.) When installing oil

seal(s), apply a light coating of light-

weight lithium base grease to the seal

lip(s). Oil the bearings liberally when

installing.

CAUTION:

Do not use compressed air to spin the

bearings dry. This causes damage to the

bearing surfaces.

1 - 4

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IMPORTANT INFORMATION/

CHECKING OF CONNECTION

GEN

INFO

^EC^CI¹R³⁶⁰C⁰⁰LIPS

1. All circlips should be inspected carefully

before reassembly. Always replace pis-

ton pin clips after one use. Replace dis-

torted circlips. When installing a circlip

1, make sure that the sharp-edged cor-

ner 2is positioned opposite to the thrust

3it receives. See the sectional view.

4Shaft

CHECKING OF CONNECTION

Dealing with stains, rust, moisture, etc. on the

connector.

1. Disconnect:

Connector

2. Dry each terminal with an air bower.

3. Connect and disconnect the connector

two or three times.

4. Pull the lead to check that it will not come

off.

5. If the terminal comes off, bend up the pin

1and 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 wireharness.

For a field remedy, use a contact revitalizer

available on the market.

Use the tester on the connector as shown.

1 - 5

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GEN

INFO

SPECIAL TOOLS

The proper special tools are necessary for complete and accurate tune-up and assembly. Using the

correct special tool will help prevent damage caused by the use of improper tools or improvised

techniques. The shape and part number used for the special tool differ by country, so two types are

provided. Refer to the list provided to avoid errors when placing an order.

NOTE:

For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, “YS-” or “ACC-”.

For others, use part number starting with “90890-”.

Part number

Tool name/How to use

Illustration

YU-1083-A

Slide hammer set

90890-01084 Weight

90890-01085 Slide hammer bolt

YU-1083-A

90890-01084

90890-01085

These tools are used when removing or installing the

rocker arm shafts.

YU-1268, 90890-01268

YU-3112-C, 90890-03112

YU-8036-B

Ring nut wrench

YU-1268

90890-01268

This tool is used when loosen the steering ring nut to

specification.

Pocket tester

YU-3112-C

YU-8036-B

YM-4019

YM-1300

YU-1304

90890-03112

90890-03113

90890-04019

90890-01294

90890-01304

Use this tool to inspect the coil resistance, output

voltage and amperage.

Inductive tachometer

90890-03113 Engine tachometer

This tool is needed for observing engine rpm.

Valve spring compressor

YM-4019, 90890-04019

This tool is needed to remove and install the valve

assemblies.

YM-1300

Damper rod holder set

90890-01294 Damper rod holder

Use this tool to remove and install the damper rod.

Piston pin puller set

YU-1304, 90890-01304

This tool is used to remove the piston pin.

1 - 6

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GEN

INFO

SPECIAL TOOLS

Part number

Tool name/How to use

Illustration

YM-1312-A, 90890-01312

Fuel level gauge

YM-1312-A

90890-01312

90890-01326

90890-01186

90890-01311

90890-01184

90890-06754

90890-01403

90890-04086

90890-01701

This gauge is used to measure the fuel level in the

float chamber.

YM-1326, 90890-01326

T-handle

YM-1326

This tool is used for holding the damper rod holder

when removing or installing the damper rod holder.

90890-01186

Fork seal driver attachment

This tool is used to installing the oil seal.

Valve adjusting tool

YM-8035, 90890-01311

YM-33963, 90890-01184

YM-34487

YM-8035

This tool is necessary for adjusting valve clearance.

Fork seal driver weight

YM-33963

YM-34487

YM-33975

YM-91042

YS-1880-A

This tool is used to installing the oil seal.

Dynamic spark tester

90890-06754 Ignition checker

This instrument is necessary for checking the ignition

system components.

YM-33975, 90890-01403

YM-91042, 90890-04086

YS-1880-A, 90890-01701

Ring nut wrench

This tool is used when tighten the steering ring nut to

specification.

Clutch holding tool

This tool is used to hold the clutch when removing or

installing the clutch boss securing nut.

Sheave holder

This tool is used for when loosening or tightening the

flywheel magneto securing nut.

1 - 7

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GEN

INFO

SPECIAL TOOLS

Part number

Tool name/How to use

Illustration

YU-33270-B, 90890-01362 Flywheel puller

YU-33270-B

90890-01362

This tool is used to remove the rotor.

Quick gasket^®

90890-85505 YAMAHA Bond No. 1215

ACC-QUICK-GS-KT

90890-85505

This sealant (Bond) is used for crankcase mating

surface, etc.

1 - 8

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GEN

INFO

CONTROL FUNCTIONS

EC150000

CONTROL FUNCTIONS

“ENGINE STOP” SWITCH

Make sure that the engine stop switch 1is

positioned to “ ”. The engine stop switch has

been equipped to ensure safety in an emer-

gency such when the machine is up set or

trouble takes place in the throttle system. The

engine will not start or run when the engine

stop switch is turned to “

”.

SHIFT PEDAL

The gear ratios of the constant-mesh 3 speed

transmission are ideally spaced. The gears

can be shifted by using the shift pedal 1on

the left side of the engine.

WARNING

When starting out on the machine, shift the

transmission into 1st after pulling in the

front brake lever and closing the throttle

grip.

KICK STARTER

WARNING

Before starting the engine, be sure to shift

the transmission into neutral.

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.

EC155001

THROTTLE GRIP

The throttle grip 1is located on the right han-

dlebar; it accelerates or decelerates the

engine. For acceleration, turn the grip toward

you; for deceleration, turn it away from you.

1 - 9

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GEN

INFO

CONTROL FUNCTIONS

EC156000

FRONT BRAKE LEVER

The front brake lever 1is located on the right

handlebar. Pull it toward the handlebar to acti-

vate the front brake.

^ER^CE¹⁵⁷A⁰⁰R⁰BRAKE PEDAL

The rear brake pedal 1is located on the right

side of the machine. Press down on the brake

pedal to activate the rear brake.

FUEL COCK

The fuel cock supplies fuel from the tank to

carburetor while filtering the fuel. The fuel cock

has the three positions:

OFF: With the lever in this position, fuel will

not flow. Always return the lever to this

position when the engine is not running.

ON: With the lever in this position, fuel flows

to the carburetor. Normal riding is done

with the lever in this position.

RES: This indicates reserve. If you run out of

fuel while riding, move the lever to this

position. FILL THE TANK AT THE

FIRST OPPORTUNITY. BE SURE TO

SET THE LEVER TO “ON” AFTER

REFUELING.

STARTER LEVER (CHOKE)

When cold, the engine requires a richer air/fuel

mixture for starting. A separate starter circuit,

which is controlled by the starter lever 1, sup-

plies this mixture.

Pull the lever out to open the circuit (for start-

ing) and push the lever in to close the circuit.

1 - 10

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GEN

INFO

CONTROL FUNCTIONS/FUEL

FUEL TANK CAP

Remove the fuel tank cap 1 by turning

counter-clockwise.

WARNING

Do not overfill the fuel tank. Avoid spilling

fuel on the hot engine.

FUEL

Use regular gasoline. Always use fresh, name

brand gasoline.

WARNING

Do not overfill the fuel tank. Avoid spilling

fuel on the hot engine. Do not fill the fuel

tank above the bottom of the filler tube 1

as shown in the illustration or it may over-

flow when the fuel heats up later and

expands.

a Fuel level

Recommended fuel:

For USA, AUS and NZ:

Unleaded gasoline only

For CDN and EUROPE:

Regular unleaded gasoline

only

For ZA:

Regular gasoline

Fuel tank capacity:

Total:

4.1 L (0.90 lmp gal, 1.08 US gal)

Reserve:

0.5 L (0.11 lmp gal, 0.13 US gal)

CAUTION:

Use only unleaded gasoline. The use of

leaded gasoline will cause severe damage

to the engine internal parts such as valves,

piston rings, and exhaust system, etc.

1 - 11

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GEN

INFO

STARTING AND OPERATION

WARMING UP

STARTING AND OPERATION

To get maximum engine life, always “warm-up”

the engine before starting off. Never acceler-

ate hard with a cold engine! To see whether or

not the engine is warm, see if it responds to

throttle normally with the stater (choke) turned

off.

CAUTION:

Prior to operating the machine, perform

steps listed in pre-operation check list.

WARNING

Never start your engine or let it run for any

length of time in a closed area. The exhaust

fumes are poisonous and can cause loss of

consciousness and death within a short

time. Always operate your machine in an

area with adequate ventilation.

WARNING

Before starting off, be sure to turn up or

remove the side stand.

Failure to retract the side stand completely

can result in a serious accident when you

try to turn a corner.

STARTING A COLD ENGINE

ENGINE BREAK-IN

Brake-in is important to better fit the moving

and sliding parts as well as the installed parts.

It is also important to accustom the rider to the

machine better.

Avoid full-throttle run on a new machine for the

first 5 hours.

After the trial run, check for loose parts, oil

leakage and other problems.

Make full inspection and adjustment especially

of slack cables and drive chain and loose

spokes.

WARNING

Before starting the engine, be sure to shift

the transmission into neutral.

1. Turn the fuel cock to “ON”.

2. Operate the starter (choke) and com-

pletely close the throttle grip.

3. Slide the “ENGINE STOP” switch to the

“

”.

4. Kick the kick starter with full strength to

start the engine.

5. After the engine starts, warm up for one

or two minutes. Make sure the stater

(choke) is returned to the original position

before riding.

CAUTION:

After the break-in period, check every fit-

ting and fastener for looseness.

If any loose is found, retighten it securely.

STARTING A WARM ENGINE

To start a warm engine, refer to the “Starting a

cold engine” section. The starter (choke)

should not be used. The throttle should be

opened slightly.

CAUTION:

See “Engine break-in Section” prior to

operating engine for the first time.

1 - 12

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SPEC

GENERAL SPECIFICATIONS

^ES^C2P⁰⁰⁰E⁰⁰CIFICATIONS

^EG^C2E¹¹⁰N⁰⁰ERAL SPECIFICATIONS

Model name:

TT-R90R (USA, CDN, AUS, NZ)

TT-R90 (Europe, ZA)

Model code number:

5HNB (USA)

5HNC (Europe, AUS, NZ, ZA)

5HND (CDN)

Dimensions:

Overall length

Overall width

Overall height

Seat height

1,525 mm (57.0 in)

605 mm (23.8 in)

865 mm (34.1 in)

625 mm (24.6 in)

1,040 mm (40.9 in)

160 mm (6.3 in)

Wheelbase

Minimum ground clearance

Basic weight:

With oil and full fuel tank

Engine:

64 kg (141 lb)

Engine type

Cylinder arrangement

Displacement

Air cooled 4-stroke, SOHC

Single cylinder, forward inclined

89 cm³(5.43 cu.in)

Bore × stroke

47.0 × 51.8 mm (1.85 × 2.04 in)

8.5 : 1

1,000 kPa (10 kg/cm², 145 psi) at 1,000 r/min

Kick starter

Compression ratio

Compression pressure (STD)

Starting system

Lubrication system:

Oil type or grade:

Engine oil

Wet sump

(For USA and CDN)

At –10 ˚C (10 ˚F) or higher Å

Yamalube 4 (10W-30) or SAE 10W-30 type

SE/SF motor oil

˚F

10 30 50 70 90 110 130

At 5 ˚C (40 ˚F) or higher ı

Yamalube 4 (20W-40) or SAE 20W-40 type

SE/SF motor oil

10 20

-20 -10

30 40 50

˚C

(Except for USA and CDN)

API “SE/SF” or higher grade

2 - 1

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SPEC

GENERAL SPECIFICATIONS

Oil capacity:

Engine oil

Periodic oil change

Total amount

Air ﬁlter:

Fuel:

Type

0.8 L (0.70 Imp qt, 0.85 US qt)

1.0 L (0.88 Imp qt, 1.06 US qt)

Wet type element

Unleaded gasoline only (USA, AUS and NZ)

Regular unleaded gasoline only (CDN, Europe)

Regular gasoline (ZA)

Tank capacity

Reserve amount

Carburetor:

4.1 L (0.90 lmp gal, 1.08 US gal)

0.5 L (0.11 Imp gal, 0.13 US gal)

Type

Manufacturer

VM16SH

MIKUNI

Spark plug:

Type

CR6HSA/U20FSR-U

Manufacturer

NGK/DENSO

Gap

Clutch type:

0.6 ~ 0.7 mm (0.02 ~ 0.03 in)

Wet, multiple-disc and centrifugal automatic

Transmission:

Primary reduction system

Primary reduction ratio

Secondary reduction system

Secondary reduction ratio

Transmission type

Operation

Spur gear

67/18 (3.722)

Chain drive

35/14 (2.500)

Constant mesh, 3-speed

Left foot operation

37/13 (2.846)

33/19 (1.736)

28/23 (1.217)

Gear ratio:

1st

2nd

3rd

Chassis:

Frame type

Caster angle

Trail

Double cradle

24.83˚

56.0 mm (2.2 in)

Tire:

Type

With tube

Size (front)

2.50-14 4PR

Size (rear)

3.00-12 4PR

Manufacturer (front and rear)

Type (front and rear)

Tire pressure (front and rear)

CHENG SHIN

KNOBBY

100 kPa (1.00 kgf/cm², 14.5 psi)

2 - 2

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SPEC

GENERAL SPECIFICATIONS

Brake:

Front brake type

Drum brake

Operation

Rear brake type

Operation

Right hand operation

Drum brake

Right foot operation

Suspension:

Front suspension

Rear suspension

Shock absorber:

Front shock absorber

Rear shock absorber

Wheel travel:

Telescopic fork

Swingarm (monocross suspension)

Coil spring/oil damper

Coil spring/gas, oil damper

Front wheel travel

Rear wheel travel

Electrical:

110 mm (4.33 in)

93 mm (3.66 in)

Ignition system

CDI magneto

2 - 3

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SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Item

Standard

Limit

Cylinder head:

Warp limit

----

0.03 mm

(0.0012 in)

Cylinder:

Bore size

47.000 ~ 47.005 mm

(1.8504 ~ 1.8506 in)

----

47.05 mm

(1.8524 in)

0.05 mm

Out of round limit

(0.0020 in)

Camshaft:

Drive method

Cam dimensions

Chain drive (left)

----

Intake

“A”

“B”

“A”

“B”

25.428 ~ 25.528 mm

(1.0011 ~ 1.0050 in)

21.034 ~ 21.134 mm

(0.8281 ~ 0.8320 in)

25.286 ~ 25.386 mm

(0.9955 ~ 0.9994 in)

21.047 ~ 21.147 mm

(0.8286 ~ 0.8326 in)

----

25.398 mm

(0.9999 in)

21.004 mm

(0.8269 in)

25.256 mm

(0.9943 in)

21.017 mm

(0.8274 in)

0.03 mm

Exhaust

Camshaft runout limit

(0.0012 in)

2 - 4

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SPEC

MAINTENANCE SPECIFICATIONS

Item

Standard

Limit

Cam chain:

Cam chain type/No. of links

Cam chain adjustment method

Rocker arm/rocker arm shaft:

Shaft outside diameter

92RH2005-84M/84

Automatic

----

9.981 ~ 9.991 mm

(0.3930 ~ 0.3933 in)

10.000 ~ 10.015 mm

(0.3937 ~ 0.3943 in)

9.95 mm

(0.3917 in)

10.03 mm

(0.3949 in)

Rocker arm inside diameter

Valve, valve seat, valve guide:

Valve clearance (cold)

0.05 ~ 0.09 mm

(0.0020 ~ 0.0035 in)

0.08 ~ 0.12 mm

----

(0.0031 ~ 0.0047 in)

Valve dimensions:

Head Diameter

Face Width

Seat Width

Margin Thickness

“A” head diameter

22.9 ~ 23.1 mm

(0.9016 ~ 0.9094 in)

19.9 ~ 20.1 mm

(0.7835 ~ 0.7913 in)

1.19 ~ 2.51 mm

(0.0469 ~ 0.0989 in)

1.49 ~ 3.07 mm

(0.0587 ~ 0.1209 in)

0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in)

0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in)

0.5 ~ 0.9 mm

(0.0197 ~ 0.354 in)

0.8 ~ 1.2 mm

(0.0315 ~ 0.0472 in)

4.475 ~ 4.490 mm

(0.1762 ~ 0.1768 in)

4.460 ~ 4.475 mm

(0.1756 ~ 0.1762 in)

4.500 ~ 4.512 mm

(0.1772 ~ 0.1776 in)

4.500 ~ 4.512 mm

(0.1772 ~ 0.1776 in)

0.010 ~ 0.037 mm

(0.0004 ~ 0.0015 in)

0.025 ~ 0.052 mm

(0.0010 ~ 0.0020 in)

----

“B” face width

“C” seat width

1.6 mm

(0.0630 in)

1.6 mm

(0.0630 in)

----

“D” margin thickness

Stem outside diameter

Guide inside diameter

Stem-to-guide clearance

----

4.450 mm

(0.1752 in)

4.435 mm

(0.1746 in)

4.542 mm

(0.1788 in)

4.542 mm

(0.1788 in)

0.08 mm

(0.003 in)

0.10 mm

(0.004 in)

2 - 5

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SPEC

MAINTENANCE SPECIFICATIONS

Item

Standard

----

Limit

Stem runout limit

0.02 mm

(0.0008 in)

Valve seat width

0.9 ~ 1.1 mm

1.6 mm

(0.0354 ~ 0.0433 in)

(0.0630 in)

0.9 ~ 1.1 mm

1.6 mm

(0.0354 ~ 0.0433 in)

(0.0630 in)

Valve spring:

Free length

28.32 mm (1.11 in)

26.9 mm

(1.06 in)

26.9 mm

(1.06 in)

----

Set length (valve closed)

24.2 mm (0.95 in)

----

Compressed pressure

(installed)

90.4 ~ 104.1 N

(9.22 ~ 10.62 kg, 20.33 ~ 23.41 lb)

90.4 ~ 104.1 N

(9.22 ~ 10.62 kg, 20.33 ~ 23.41 lb)

----

Tilt limit

2.5˚/1.2 mm

(2.5˚/0.05 in)

2.5˚/1.2 mm

(2.5˚/0.05 in)

----

Direction of winding

(top view)

Clockwise

----

2 - 6

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SPEC

MAINTENANCE SPECIFICATIONS

Item

Standard

Limit

Piston:

Piston to cylinder clearance

0.025 ~ 0.045 mm

(0.0010 ~ 0.0018 in)

46.960 ~ 46.975 mm

(1.8488 ~ 1.8494 in)

0.15 mm

(0.0059 in)

----

Piston size “D”

Piston over size

(2nd)

(4th)

47.5 mm (1.8701 in)

48.0 mm (1.8898 in)

4 mm (0.16 in)

0.75 mm (0.0295 in)

13.002 ~ 13.013 mm

(0.5119 ~ 0.5123 in)

12.996 ~ 13.000 mm

(0.5117 ~ 0.5118 in)

----

13.045 mm

(0.5136 in)

12.976 mm

(0.5109 in)

Measuring point “H”

Piston off-set

Piston pin bore inside diameter

Piston pin outside diameter

Piston rings:

Top ring

Type

Barrel

----

Dimensions (B × T)

End gap (installed)

1.0 × 2.0 mm (0.04 × 0.08 in)

0.10 ~ 0.25 mm

(0.004 ~ 0.010 in)

0.030 ~ 0.065 mm

(0.0012 ~ 0.0026 in)

----

0.4 mm

(0.016 in)

0.12 mm

(0.005 in)

Side clearance (installed)

2nd ring

Type

Taper

----

Dimensions (B × T)

End gap (installed)

1.0 × 2.0 mm (0.04 × 0.08 in)

0.10 ~ 0.25 mm

(0.004 ~ 0.010 in)

0.020 ~ 0.055 mm

(0.0008 ~ 0.0022 in)

----

0.4 mm

(0.016 in)

0.12 mm

(0.005 in)

Side clearance

Oil ring

Dimensions (B × T)

End gap (installed)

2.0 × 2.3 mm (0.08 × 0.09 in)

0.2 ~ 0.7 mm (0.01 ~ 0.03 in)

----

2 - 7

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SPEC

MAINTENANCE SPECIFICATIONS

Item

Standard

Limit

Crankshaft:

Crank width “A”

42.95 ~ 43.00 mm

(1.691 ~ 1.693 in)

----

Runout limit C

----

0.03 mm

(0.0012 in)

0.50 mm

(0.02 in)

0.05 mm

(0.002 in)

Big end side clearance “D”

Big end radial clearance “E”

0.10 ~ 0.40 mm

(0.0039 ~ 0.0157 in)

0.010 ~ 0.025 mm

(0.0004 ~ 0.0010 in)

Clutch:

Friction plate thickness

2.7 ~ 2.9 mm

(0.106 ~ 0.114 in)

2.6 mm

(0.102 in)

----

Quantity

Clutch plate thickness

Quantity

1.1 ~ 1.3 mm (0.043 ~ 0.051 in)

----

Warp limit

----

0.2 mm

(0.008 in)

24.2 mm

(0.95 in)

----

Clutch spring free length

26.2 mm (1.03 in)

Quantity

Clutch release method

Push rod bending limit

Inner push, cam push

----

0.5 mm

(0.02 in)

Automatic centrifugal clutch:

Clutch-in revolution

Clutch-stall revolution

Shifter:

2,160 ~ 2,560 r/min

3,300 ~ 3,800 r/min

----

Shifter type

Cam drum and guide bar

----

Kick starter:

Type

Ratchet type

5.8 ~ 14.7 N

----

Kick clip friction force

(0.59 ~ 1.50 kg, 1.3 ~ 3.3 lb)

Carburetor:

I. D. mark

5HN1 01

#90

ø 1.1

4E9-2

2.5

ø 1.0 × 2.0

#12.5

ø 1.5

----

Main jet

(M.J)

(M.A.J)

(J.N)

(C.A)

(P.O)

(P.J)

Main air jet

Jet needle

Cutaway

Pilot outlet

Pilot jet

Valve seat size

Starter jet 1

Pilot air screw

Float height

Fuel level

(V.S)

(G.S.1)

#37.5

1-3/4 turns out

15.5 ~ 16.5 mm (0.61 ~ 0.65 in)

2 ~ 3 mm (0.08 ~ 0.1 in)

1,400 ~ 1,600 r/min

(F.H)

(F.L)

Engine idle speed

2 - 8

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SPEC

MAINTENANCE SPECIFICATIONS

Item

Standard

Limit

Lubrication system:

Oil ﬁlter type

Wire mesh type

Trochoid type

----

Oil pump type

Tip clearance “A” or “B”

0.15 mm

0.2 mm

(0.0059 in)

(0.0079 in)

0.23 mm

(0.0091 in)

0.15 mm

(0.0059 in)

Side clearance

0.13 ~ 0.18 mm

(0.0051 ~ 0.0071 in)

0.06 ~ 0.10 mm

(0.0024 ~ 0.0039 in)

Housing and rotor clearance

2 - 9

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SPEC

MAINTENANCE SPECIFICATIONS

Tightening torque

Part to be tightened

Cylinder head nut

Cylinder head bolt

Spark plug

Camshaft sprocket cover bolt

Tappet cover

Exhaust pipe stud bolt

Rotor nut

Timing chain guide (rear)

Valve clearance adjust screw locknut

Camshaft sprocket

Camshaft bearing retainer

Timing chain tensioner cap bolt

Timing chain tensioner

Oil pump

Thread size

Q’ty

m•kg

ft•lb

M8 × 1.25

M6 × 1.0

M10 × 1.0

M6 × 1.0

M45 × 1.5

M6 × 1.0

M12 × 1.25

M6 × 1.0

M5 × 0.5

M8 × 1.25

M6 × 1.0

M8 × 1.25

M6 × 1.0

M12 × 1.5

M6 × 1.0

M8 × 1.25

M5 × 0.8

M6 × 1.0

M14 × 1.5

M32 × 1.5

M8 × 1.25

M6 × 1.0

M12 × 1.0

M5 × 0.8

M14 × 1.0

M6 × 1.0

2.2

1.0

1.3

0.7

1.8

0.7

4.8

1.0

0.7

2.0

1.0

0.8

1.0

0.7

2.0

0.7

2.4

0.4

1.0

0.7

1.3

1.0

5.0

0.6

7.0

1.0

0.8

1.0

7.2

9.4

5.1

7.2

5.1

7.2

5.8

7.2

5.1

2.9

7.2

5.1

9.4

7.2

Drain bolt

Carburetor joint (cylinder head side)

Carburetor joint (carburetor side)

Air ﬁlter case

Exhaust pipe

Exhaust pipe protector

Silencer

Silencer protector

Crankcase

Crankcase cover (left)

Drive sprocket cover

Crankcase cover (right)

Timing plug

Crankshaft end cover

Cylinder head stud bolt

Kick crank

Primary drive gear

Pressure plate

4.3

Clutch boss

Main axle bearing retainer

Shift pedal

Clutch adjust screw locknut

Pickup coil

Stator assembly

7.2

5.8

7.2

2 - 10

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SPEC

MAINTENANCE SPECIFICATIONS

CHASSIS

Item

Standard

Limit

Steering system:

Steering bearing type

Front suspension:

Angular bearing

----

Front fork travel

110 mm (4.33 in)

425.1 mm (16.74 in)

415.1 mm (16.34 in)

K = 3.4 N/mm

----

Fork spring free length

Fork spring ﬁtting length

Spring rate, STD

417 mm (16.4 in)

----

(0.35 kg/mm, 19.41 lb/in)

Optional spring/spacer

Oil capacity

64 cm³

----

(2.26 lmp oz, 2.16 US oz)

185 mm (7.28 in)

Fork oil 15W or equivalent

Oil level

Oil grade

----

Rear suspension:

Shock absorber travel

Spring free length

Fitting length

48 mm (1.89 in)

169 mm (6.65 in)

165 mm (6.5 in)

K = 45.6 N/mm

(4.65 kg/mm, 260 lb/in)

----

Spring rate, STD

Optional spring

Enclosed gas pressure

----

2,000 kPa

(20 kg/cm², 290 psi)

Swingarm:

Swingarm free play limit

End

Side clearance

Wheel:

----

1.0 mm (0.04 in)

0.3 mm (0.01 in)

Front wheel type

Rear wheel type

Front rim size/material

Rear rim size/material

Rim runout limit:

Radial

Spoke wheel

14 × 1.40/steel

12 × 1.60/steel

----

2.0 mm (0.08 in)

Lateral

Drive chain:

Type/manufacturer

Number of links

Chain slack

DID420(I)/DAIDO

86 links

40 ~ 53 mm (1.6 ~ 2.1 in)

----

121.9 mm

(4.80 in)

Chain length (10 links)

2 - 11

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SPEC

MAINTENANCE SPECIFICATIONS

Item

Standard

Limit

Drum brake:

Front drum brake type

Rear drum brake type

Front drum inside diameter

Rear drum inside diameter

Front lining thickness

Leading, trailing

95 mm (3.74 in)

110 mm (4.33 in)

3 mm (0.12 in)

4 mm (0.16 in)

----

96 mm (3.78 in)

111 mm (4.37 in)

2 mm (0.08 in)

----

Rear lining thickness

Front shoe spring free length

Rear shoe spring free length

Brake lever and brake pedal:

Brake lever free play (lever end)

Brake pedal free play

32.7 mm (1.29 in)

50.5 mm (1.99 in)

----

10 ~ 20 mm (0.39 ~ 0.79 in)

3 ~ 5 mm (0.12 ~ 0.20 in)

----

Throttle grip free play

2 - 12

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SPEC

MAINTENANCE SPECIFICATIONS

Tightening torque

Part to be tightened

Engine mounting:

Thread size Q’ty

m•kg

ft•lb

Engine and frame (front-upper)

Engine and frame (rear-upper)

Engine and frame (rear-lower)

Starter cable and frame

Pivot shaft and nut

Handle crown and steering shaft

Front fork cap bolt

Under bracket and front fork

Damper rod bolt

Handle crown and handlebar holder (lower)

Handlebar holder (upper)

Front brake cable holder and front fork

Steering ring nut

Fuel tank and fuel cock

Fuel tank and frame

Grab bar and frame

Front brake camshaft lever and camshaft

Rear brake camshaft lever and camshaft

Front wheel axle nut

Rear brake shoe plate tension bar

Wheel drive hub and driven sprocket

Rear wheel axle nut

M8 × 1.25

M10 × 1.25

M11 × 1.25

M10 × 1.25

M20 × 1.0

M10 × 1.25

M8 × 1.25

M10 × 1.25

M6 × 1.0

M25

M6 × 1.0

M10 × 1.25

M8 × 1.25

M12 × 1.25

—

3.0

2.6

4.0

0.1

3.0

4.0

3.3

2.0

4.0

1.3

0.7

9.4

5.1

Refer to NOTE.

0.7

1.3

0.7

3.5

2.6

2.5

6.0

0.2

0.4

0.3

3.0

5.1

9.4

5.1

1.4

2.9

2.2

Wheel nipple (spoke)

Drive chain guard

Drive chain support

Chain puller locknut

M5 × 0.8

M6 × 1.0

M8 × 1.25

Footrest and frame

NOTE:

1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut

wrench and turn the steering right and left a few times; then loosen the ring nut one turn.

2. Retighten the ring nut 1 Nm (0.1 m • kg, 0.7 ft • lb).

-marked portion shall be checked for torque tightening after break-in or before each ride.

2 - 13

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SPEC

MAINTENANCE SPECIFICATIONS

^EE^CL²¹E²³C⁰⁰TRICAL

Item

Standard

Limit

CDI:

Magneto-model/manufacturer

Source coil resistance (color)

F5HN 00/YAMAHA

688 ~ 1,032 Ω at 20 ˚C (68 ˚F)

(Brown – Green)

248 ~ 372 Ω at 20 ˚C (68 ˚F)

(Red – White)

4GL-20/YAMAHA

----

Pickup coil resistance (color)

CDI unit-model/manufacturer

Ignition coil:

Model/manufacturer

Minimum spark gap

Primary winding resistance

Secondary winding resistance

Spark plug cap:

2JN-00/YAMAHA

6 mm (0.24 in)

0.18 ~ 0.28 Ω at 20 ˚C (68 ˚F)

6.3 ~ 9.5 kΩ at 20 ˚C (68 ˚F)

----

Type

Resistance

Resin

10 kΩ at 20 ˚C (68 ˚F)

----

2 - 14

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GENERAL TORQUE SPECIFICATIONS/

DEFINITION OF UNITS

SPEC

^EG^C2E²⁰⁰N⁰¹ERAL TORQUE SPECIFICATIONS

This chart specifies torque for standard fasten-

ers with standard I.S.O. pitch threads. Torque

specifications for special components or

assemblies are included in the applicable sec-

tions of this book. To avoid warpage, tighten

multi-fastener assemblies in a crisscross fash-

ion, in progressive stages, until full torque is

reached. Unless otherwise specified, torque

specifications call for clean, dry threads. Com-

ponents should be at room temperature.

A: Distance between flats

B: Outside thread diameter

TORQUE

SPECIFICATION

(Nut)

(Bolt)

m•kg

ft•lb

10 mm 6 mm

12 mm 8 mm

14 mm 10 mm

17 mm 12 mm

19 mm 14 mm

22 mm 16 mm

130

0.6

1.5

3.0

5.5

8.5

4.3

EC230000

DEFINITION OF UNITS

Unit

Read

Definition

Measure

millimeter

10^-3meter

Length

centimeter

kilogram

Newton

10^-2meter

10³gram

Length

Weight

Force

1 kg × m/sec²

m • kg

Newton meter

Meter kilogram

N × m

Torque

m × kg

Pascal

N/m²

Pressure

N/mm

Newton per millimeter N/mm

Spring rate

Liter

Cubic centimeter

—

Volume or capacity

cm³

r/min

Revolution per minute

—

Engine speed

2 - 15

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SPEC

CABLE ROUTING DIAGRAM

1Crankcase breather hose

2Wire harness

3CDI magneto lead

4Starter cable

ACable holder

BFuel tank breather hose

CBrake cable

5Carburetor heating lead

6Engine stop switch lead

7Thermo switch

Å After fastening the starter cable, CDI magneto lead, wire harness and

thermo switch lead, cut off any excess from the plastic locking tie end.

ı Pass the ignition coil lead through the lead guide.

8Thermo switch lead

9Spark plug lead

Ç Fasten the engine stop switch lead with the plastic bands.

Î Pass the brake cable through the cable guides.

0Throttle cable

20 ~ 30 mm

(0.79 ~ 1.18 in)

2 - 16

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SPEC

CABLE ROUTING DIAGRAM

1Cable guide

BCDI unit lead

2Brake cable

CCDI unit

3Throttle cable

4Fuel tank breather hose

5Engine stop switch lead

6Air vent hose

7Air intake duct

8Ignition coil

DRectifier/regulator lead

ERectifier/regulator

FCrankcase breather hose

GCarburetor breather hose

HSpark plug lead

IFuel hose

9Cable guide

JStarter cable

0Wire harness

ADamper

KCDI magneto lead

LThermo switch

‰

8 A

L J

B - B

C - C

D - D

F - F

2 - 17

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SPEC

CABLE ROUTING DIAGRAM

Å Pass the fuel tank breather hose through the

cable guide.

Ì Pass the CDI unit lead through the lead guide.

ı Pass the throttle cable and engine stop switch

lead through the cable guide.

Ç Pass the air vent hose through the hose guide.

Î Fasten the CDI unit lead and rectifier/regulator

lead with the plastic clamp.

‰ Align the tape on the rectifier/regulator lead with

the plastic clamp.

Ï After fastening the engine stop switch lead, cut

off any excess from the plastic locking tie end.

8 A

‰

L J

B - B

C - C

D - D

F - F

2 - 18

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MAINTENANCE INTERVALS/

INSP

ADJ

PERIODIC MAINTENANCE AND LUBRICATION

^ER^C3E⁰⁰⁰⁰G⁰ULAR INSPECTION AND ADJUSTMENTS

MAINTENANCE INTERVALS

The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind

that such factors as weather, terrain, geographical location, and individual usage will alter the

required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in

maintaining and lubricating your machine, consult your Yamaha dealer.

PERIODIC MAINTENANCE AND LUBRICATION

Initial

Every

60 hours 120 hours

Dealer

Note

Item

Checks and maintenance jobs

10 hours

(1 month) (6 months) (12 months)

Check fuel hoses for cracks or damage.

Replace if necessary.

Fuel line

Check condition.

Clean, regap or replace if necessary.

Spark plug

Check valve clearance.

Adjust if necessary.

Valves

Air filter

Carburetor

Clean or replace if necessary.

Check engine idling speed and starter operation.

Adjust if necessary.

Check for leakage.

Retighten if necessary.

Replace gasket if necessary.

Exhaust systems

Check oil level and vehicle for oil leakage.

Correct if necessary.

Change. (Warm engine before draining.)

Engine oil

Clutch

Check operation.

Adjust or replace cable.

Check operation.

Front brake

Adjust brake lever free play and replace brake

shoes if necessary.

Every ride

Check operation.

Adjust brake pedal free play and replace brake

shoes if necessary.

Rear brake

Wheels

Check balance, runout, spoke tightness and for

damage.

Tighten spokes and rebalance, replace if

necessary.

Check tread depth and for damage.

Replace if necessary.

Check air pressure.

Tires

Correct if necessary.

Check bearing for looseness or damage.

Replace if necessary.

Wheel bearings

Swingarm

Check swingarm pivoting point for play.

Correct if necessary.

Lubricate with lithium soap base grease.

Check chain slack.

Adjust if necessary. Make sure that the rear wheel

is properly aligned.

Drive chain

Every ride

Clean and lubricate.

Check bearing play and steering for roughness.

Correct accordingly.

Lubricate with lithium soap base grease every 120

hours.

Steering bearings

3 - 1

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INSP

ADJ

Every

60 hours 120 hours

(1 month) (6 months) (12 months)

PRE-OPERATION INSPECTION AND MAINTENANCE

Initial

Dealer

Note

Item

Checks and maintenance jobs

10 hours

Make sure that all nuts, bolts and screws are

properly tightened.

Chassis fasteners

Tighten if necessary.

Check operation.

Lubricate and repair if necessary.

Sidestand

Spark arrester*¹

Front fork

Clean.

Check operation and for oil leakage.

Correct accordingly.

Check operation and shock absorber for oil

leakage.

Replace shock absorber assembly if necessary.

Rear shock

absorber assembly

*: Since these items requires special tools data and technical skills, they should be serviced.

*¹:For USA

SERVICE NOTES:

No. 1. DRIVE CHAIN: In addition to tension and alignment, chain must be lubricated every

0.5 ~ 1.0 hour. If unit is subjected to extremely hard usage and wet weather riding, chain

must be checked constantly. See “Lubrication Intervals” for additional details.

No. 2. AIR FILTER: Remove and clean filter every 20 ~ 40 hours.

PRE-OPERATION INSPECTION AND MAINTENANCE

Before riding for break-in operation, practice or a race, make sure the machine is in good operating

condition.

Before using this machine, check the following points.

GENERAL INSPECTION AND MAINTENANCE

Item

Routine

Page

P3-11

Brake

Check operation/adjustment.

Change oil as required.

Engine oil

P3-5 ~ 7

P3-12 ~ 13

P3-19

Drive chain

Spark plug

Check alignment/adjustment/lubrication.

Check color/condition.

Throttle

Check for proper throttle cable operation.

Foam type – must be clean and damp oil always

Check pressure/runout/spoke tightness/bead stopper/axle nuts.

Check all – tighten as necessary.

P3-3

Air filter

P3-3 ~ 4

P3-14 ~ 17

P2-13

Wheels and tires

Fittings/fasteners

3 - 2

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ENGINE/THROTTLE CABLE ADJUSTMENT/

AIR FILTER CLEANING

INSP

ADJ

EC350000

ENGINE

THROTTLE CABLE ADJUSTMENT

1. Check:

Throttle grip free play a

Out of specification → Adjust.

Throttle grip free play a:

3 ~ 5 mm (0.12 ~ 0.20 in)

2. Adjust:

Throttle grip free play

Throttle grip free play adjustment steps:

NOTE:

Before adjusting the throttle cable free play,

the engine idle speed should be adjusted.

Loosen the locknut 1on throttle cable.

Turn the adjuster 2in or out until the

specified free play is obtained.

Turning in:

Free play is increased.

Free play is decreased.

Turning out:

Tighten the locknut.

WARNING

After adjusting, turn the handlebar to

right and left and make sure that the

engine idling does not run faster.

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 cause rapid

wear and possible engine damage.

3 - 3

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AIR FILTER CLEANING

1. Install:

Air scoop (right) 1

2. Install:

Air filter case cover 1

3. Clean:

Air filter element

Clean them with solvent.

NOTE:

After cleaning, remove the remaining solvent

by squeezing the element.

CAUTION:

Do not twist the element when squeezing

the element.

Leaving too much of solvent in the ele-

ment may result in poor starting.

4. Inspect:

Air filter element

Damage → Replace.

5. Apply:

Foam-air-filter oil or engine mixing oil

To the element.

NOTE:

Squeeze out the excess oil. Element should

be wet but not dripping.

6. Install:

Air filter element 1

NOTE:

Align the projection a on the air filter case with

the hole b in the air filter element.

7. Install:

Air filter case cover

8. Install:

Air scoop (right)

3 - 4

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ENGINE OIL LEVEL INSPECTION

1. Start the engine, warm it up for several

minutes and wait for five minutes.

2. Place the machine on a level place and

hold it up on upright position by placing

the suitable stand under the engine.

3. Remove:

Dipstick 1

4. Check:

Oil level

Oil level should be between maximum

a and minimum b marks.

Oil level is low → Add oil to proper

level.

NOTE:

When inspecting the oil level, do not screw the

dipstick into the oil tank. Insert the gauge

lightly.

(For USA and CDN)

˚F

130

10 30 50 70

90 110

Recommended oil:

At –10 ˚C (10 ˚F) or higher Å:

Yamalube 4 (10W-30) or SAE

10W-30 type SE/SF motor oil

At 5 ˚C (40 ˚F) or higher ı:

Yamalube 4 (20W-40) or SAE

20W-40 type SE/SF motor oil

-20

-10

20 30 40 50

˚C

CAUTION:

Do not add any chemical additives.

Engine oil also lubricates the clutch and

additives could cause clutch slippage.

Do not allow foreign material to enter the

crankcase.

3 - 5

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ENGINE OIL REPLACEMENT

(Except for USA and CDN)

Recommended oil:

Refer to the following chart for

selection of oils which are suited

to the atmospheric temperatures.

Recommended engine oil classi-

fication:

API STANDARD:

API “SE/SF” or higher grade

(Designed primarily for motor-

cycles)

CAUTION:

Do not add any chemical additives or use

oils with a grade of CD a or higher.

Do 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.

5. Install:

Dipstick

6. Start the engine and let it warm up for

several minutes.

7. Turn off the engine and inspect the oil

level once again.

NOTE:

Wait a few minutes until the oil settles before

inspecting the oil level.

ENGINE OIL REPLACEMENT

1. Start the engine and warm it up for sev-

eral minutes and wait for five minutes.

2. Place the machine on a level place and

hold it on upright position by placing the

suitable stand under the engine.

3. Place a suitable container under the

engine.

4. Remove:

Dipstick 1

Drain bolt (with gasket) 2

Drain the crankcase of its oil.

3 - 6

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PILOT AIR SCREW ADJUSTMENT

5. Install:

Gasket New

Drain bolt

20 Nm (2.0 m · kg, 14 ft · lb)

6. Fill:

Crankcase

Oil quantity:

Periodic oil change:

0.8 L (0.70 Imp qt, 0.85 US qt)

7. Install:

Dipstick

8. Inspect:

Engine (for oil leaks)

Oil level

Refer to “ENGINE OIL LEVEL INSPEC-

TION”.

PILOT AIR SCREW ADJUSTMENT

1. Adjust:

Pilot air screw 1

Adjusting steps:

Screw in the pilot air screw until it is lightly

seated.

Back out by the specified number of turns.

Pilot air screw:

1-3/4 turns out

3 - 7

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IDLE SPEED ADJUSTMENT/

INSP

ADJ

VALVE CLEARANCE ADJUSTMENT

IDLE SPEED ADJUSTMENT

1. Start the engine and thoroughly warm it

up.

2. Attach:

Inductive tachometer

To spark plug lead.

3. Adjust:

Idle speed

Adjustment steps:

Adjust the pilot screw.

Refer to “PILOT AIR SCREW ADJUST-

MENT” section.

Turn the throttle stop screw 1until the

engine runs at the lowest possible speed.

To increase idle speed →

Turn the throttle stop screw 1in a.

To decrease idle speed →

Turn the throttle stop screw 1out b.

Inductive tachometer:

YU-8036-B/90890-03113

Engine idling speed:

1,400 ~ 1,600 r/min

VALVE CLEARANCE ADJUSTMENT

NOTE:

The valve clearance should be adjusted

when the engine is cool to the touch.

The piston must be at Top Dead Center

(T.D.C.) on compression stroke to check or

adjust the valve clearance.

1. Remove:

Air scoop (right) 1

Air filter case 2

2. Remove:

Spark plug

Tappet cover (intake side) 1

Tappet cover (exhaust side) 2

3. Remove:

Timing plug 1

Crankshaft end cover 2

O-rings

3 - 8

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VALVE CLEARANCE ADJUSTMENT

4. Check:

Valve clearance

Out of specification → Adjust.

Valve clearance (cold):

Intake valve:

0.05 ~ 0.09 mm

(0.0020 ~ 0.0035 in)

Exhaust valve:

0.08 ~ 0.12 mm

(0.031 ~ 0.047 in)

Checking steps:

Turn the crankshaft counterclockwise 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.

Measure the valve clearance using a

feeler gauge 1.

Out of specification → Adjust clearance.

5. Adjust:

Valve clearance

Adjustment steps:

3 2

Loosen the locknut 1.

Turn the adjuster 3in or out with the

valve adjusting tool 2until specified clear-

ance is obtained.

Turning in →

Valve clearance is decreased.

Turning out →

Valve clearance is increased.

Valve adjusting tool:

YM-8035/90890-01311

Hold the adjuster to prevent it from moving

and tighten the locknut.

7 Nm (0.7 m · kg, 5.1 ft · lb)

Measure the valve clearance.

If the clearance is incorrect, repeat above

steps until specified clearance is obtained.

3 - 9

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SPARK ARRESTER CLEANING (For USA)

6. Install:

Tappet cover (intake side) 1

18 Nm (1.8 m · kg, 13 ft · lb)

O-ring 2

New

NOTE:

Apply the lithium soap base grease on the O-ring.

7. Install:

Tappet cover (exhaust side)

18 Nm (1.8 m · kg, 13 ft · lb)

O-ring

New

Spark plug

13 Nm (1.3 m · kg, 9.4 ft · lb)

7 Nm (0.7 m · kg, 5.1 ft · lb)

Timing plug

Crankshaft end cover

7 Nm (0.7 m · kg, 5.1 ft · lb)

NOTE:

Apply the lithium soap base grease on the O-ring.

8. Install:

Air filter case

Air scoop (right)

SPARK ARRESTER CLEANING (For USA)

WARNING

Be sure the exhaust pipe and muffler are

cool before cleaning the spark arrester.

Do not start the engine when cleaning the

exhaust system.

1. Remove:

Bolt (tailpipe) 1

2. Remove:

Tailpipe 2

Pull the tailpipe out of the muffler.

3. Clean:

Spark arrester

Use a wire brush to remove any carbon

deposits from the spark arrester portion

of the muffler body 3inner surface.

Tap the tailpipe lightly and remove the

carbon deposits from the outside por-

tion a of the tailpipe.

4. Install:

Tailpipe

Insert the tailpipe into the muffler and

align the bolt hole.

Bolt (tailpipe)

7 Nm (0.7 m · kg, 5.1 ft · lb)

3 - 10

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CHASSIS/FRONT BRAKE ADJUSTMENT/

REAR BRAKE ADJUSTMENT

INSP

ADJ

CHASSIS

FRONT BRAKE ADJUSTMENT

1. Check:

Brake lever free play a

Out of specification → Adjust.

Free play (brake lever):

10 ~ 20 mm (0.39 ~ 0.79 in)

(at brake lever end)

2. Adjust:

Brake lever free play

Adjustment steps:

Loosen the locknuts 1.

Turn the adjusters 2in or out until the

specified free play is obtained.

Turning in:

Free play is increased.

Free play is decreased.

Turning out:

Tighten the locknuts.

CAUTION:

Make sure that there is no brake drag

after adjusting the front brake lever free

play.

REAR BRAKE ADJUSTMENT

1. Check:

Brake pedal free play a

Out of specification → Adjust.

Free play:

10 ~ 20 mm (0.39 ~ 0.79 in)

2. Adjust:

Brake pedal free play

Adjustment steps:

Turn the adjuster 1in or out until the

specified free play is obtained.

Turning in:

Free play is decreased.

Free play is increased.

Turning out:

CAUTION:

Make sure that the brake does not drag

after adjusting it.

3 - 11

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DRIVE CHAIN SLACK ADJUSTMENT

1. Elevate the rear wheel by placing the

suitable stand under the engine.

2. Check:

Drive chain slack a

In the center between the drive axle

and rear wheel axle.

Out of specification → Adjust.

Drive chain slack:

40 ~ 53 mm (1.6 ~ 2.1 in)

NOTE:

Before checking and/or adjusting, rotate the

rear wheel through several revolutions and

check the slack several times to find the tight-

est point. Check and/or adjust chain slack with

rear wheel in this “tight chain” position.

3. Adjust:

Drive chain slack

Drive chain slack adjustment steps:

Loosen the wheel axle nut 1.

Adjust chain slack by turning the adjusters

To tighten → Turn adjuster 2clockwise.

To loosen → Turn adjuster 2counter-

clockwise and push wheel

forward.

Turn each adjuster exactly the same

amount to maintain correct axle alignment.

(There are 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.

3 - 12

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FRONT FORK INSPECTION/REAR SHOCK ABSORBER INSPECTION/ INSP

REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT

ADJ

Tighten the wheel axle nut while pushing

down the drive chain.

Axle nut:

60 Nm (6.0 m • kg, 43 ft • lb)

EC36C000

FRONT FORK INSPECTION

1. Inspect:

Front fork smooth action

Operate the front brake and stroke the

front fork.

Unsmooth action/oil leakage → Repair

or replace.

^ER^CE^36KA⁰⁰R⁰SHOCK ABSORBER INSPECTION

1. Inspect:

Swingarm smooth action

Abnormal noise/unsmooth action →

Grease the pivoting points or repair the

pivoting points.

Damage/oil leakage → Replace.

REAR SHOCK ABSORBER SPRING

PRELOAD ADJUSTMENT

1. Elevate the rear wheel by placing the

suitable stand under the engine.

2. Remove:

Rear shock absorber

Refer to “SWINGARM” section in the

CHAPTER 5.

3. Remove:

Spring guide 1

NOTE:

While compressing the spring, remove the

spring guide.

3 - 13

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TIRE PRESSURE CHECK

4. To stiffen the spring preload, install the

circlip 1into the groove a. To soften the

spring preload, install the circlip into the

groove b.

NOTE:

Do not spread the circlip too much.

Standard installation position:

Groove b

5. Install:

Spring guide 1

NOTE:

While compressing the spring, install the

spring guide.

6. Install:

Rear shock absorber

Refer to “SWINGARM” section in the

CHAPTER 5.

EC36Q000

TIRE PRESSURE CHECK

1. Measure:

Tire pressure

Out of specification → Adjust.

Standard tire pressure:

100 kPa (1.00 kgf/cm², 14.5 psi)

NOTE:

Check the tire while it is cold.

Loose bead stoppers allow the tire to slip off

its position on the rim when the tire pressure

is low.

A tilted tire valve stem indicates that the tire

slips off its position on the rim.

If the tire valve stem is found tilted, the tire is

considered to be slipping off its position. Cor-

rect the tire position.

3 - 14

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SPOKES INSPECTION AND TIGHTENING/WHEEL INSPECTION/

STEERING HEAD INSPECTION AND ADJUSTMENT

SPOKES INSPECTION AND TIGHTENING

1. Inspect:

Spokes 1

Bend/damage → Replace.

Loose spoke → Retighten.

2. Tighten:

2 Nm (0.2 m · kg, 1.4 ft · lb)

Spokes

NOTE:

Be sure to retighten these spokes before and

after break-in. After a practice or a race check

spokes for looseness.

EC36T000

WHEEL INSPECTION

1. Inspect:

Wheel runout

Elevate the wheel and turn it.

Abnormal runout → Replace.

2. Inspect:

Bearing free play

Exist play → Replace.

STEERING HEAD INSPECTION AND

ADJUSTMENT

1. Elevate the front wheel by placing a suit-

able stand under the engine.

2. Check:

Steering shaft

Grasp the bottom of the forks and gen-

tly rock the fork assembly back and

forth.

Free play → Adjust steering head.

3 - 15

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STEERING HEAD INSPECTION AND ADJUSTMENT

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 front fender 1.

Remove the handlebar and handle crown.

Loosen the ring nut 2using the ring nut

wrench 3.

Ring nut wrench:

YU-1268/90890-01268

Tighten the ring nut 4 using ring nut

wrench 5and turn the steering right and

left a few times.

NOTE:

Set the torque wrench to the ring nut wrench

so that they form a right angle.

Ring nut wrench:

YM-33975/90890-01403

Ring nut (initial tightening):

38 Nm (3.8 m • kg, 27 ft • lb)

Loosen the ring nut one turn.

Retighten the ring nut using the ring nut

wrench.

WARNING

Avoid over-tightening.

Ring nut (final tightening):

1 Nm (0.1 m • kg, 0.7 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 handle crown 6, handlebar 7,

and front fender.

3 - 16

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STEERING HEAD INSPECTION AND ADJUSTMENT

CAUTION:

Install the handlebar holder with its

groove a facing outward, and tighten

the bolts so that the gaps b are equal.

Steering stem bolt:

40 Nm (4.0 m • kg, 2.9 ft • lb)

Front fork cap bolt:

40 Nm (4.0 m • kg, 2.9 ft • lb)

Handlebar upper holder:

13 Nm (1.3 m • kg, 9.4 ft • lb)

3 - 17

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LUBRICATION

Å Use Yamaha cable lube or equivalent on these

areas.

LUBRICATION

To ensure smooth operation of all compo-

nents, lubricate your machine during setup,

after break-in, and after every race.

1All control cable

ı Use SAE 10W-30 motor oil or suitable chain

lubricants.

Ç Lubricate the following areas with high quality,

lightweight lithium-soap base grease.

2Brake lever pivot

3Shift pedal pivot

4Footrest pivot

5Throttle-to-handlebar contact

6Drive chain

7Tube guide cable winding portion

8Throttle cable end

9Brake cable end

7 8

3 - 18

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ELECTRICAL/SPARK PLUG INSPECTION

EC370000

ELECTRICAL

^ES^CP³⁷A¹⁰⁰R¹K PLUG INSPECTION

1. Remove:

Spark plug

2. Inspect:

Electrode 1

Wear/damage → Replace.

Insulator color 2

Normal condition is a medium to light

tan color.

Distinctly different color → Check the

engine condition.

NOTE:

When the engine runs for 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:

0.6 ~ 0.7 mm (0.02 ~ 0.03 in)

Standard spark plug:

CR6HSA (NGK)

U20FSR-U (DENSO)

4. Clean the plug with a spark plug cleaner

if necessary.

5. Tighten:

Spark plug

13 Nm (1.3 m · kg, 9.4 ft · lb)

NOTE:

Before installing a spark plug, clean the gas-

ket surface and plug surface.

Finger-tighten a the spark plug before

torquing to specification b.

3 - 19

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ENG

CARBURETOR

ENGINE

CARBURETOR

Extent of removal:

Extent of removal

1Carburetor removal

Order

Part name

Q’ty

Remarks

CARBURETOR REMOVAL

Fuel tank

Preparation for removal

Clamp (air filter joint)

Carburetor heater lead

Air vent hose

Loosen the screw (air filter joint).

Fuel hose

Bolt

Carburetor assembly

O-ring

Spacer

Carburetor top

Starter plunger assembly

4 - 1

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ENG

CARBURETOR

EC468000

CARBURETOR DISASSEMBLY

Extent of removal:

Extent of removal

1Carburetor disassembly

Order

Part name

Q’ty

Remarks

CARBURETOR DISASSEMBLY

Throttle valve

Throttle cable

Spring

Gasket

Carburetor top cover

Jet needle stopper

Jet needle assembly

Starter plunger assembly

Starter cable

Float chamber

4 - 2

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ENG

CARBURETOR

Extent of removal

Order

Part name

Q’ty

Remarks

Float pin

Float

Needle valve

Main jet

Pilot jet

Needle jet

Throttle stop screw assembly

Pilot air screw assembly

Carburetor heater

4 - 3

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ENG

CARBURETOR

EC464000

INSPECTION

Carburetor

1. Inspect:

Carburetor body

Contamination → Clean.

NOTE:

Use a petroleum based solvent for cleaning.

Blow out all passages and jets with com-

pressed air.

Never use a wire.

2. Inspect:

Main jet 1

Pilot jet 2

Needle jet 3

Damage → Replace.

Contamination → Clean.

NOTE:

Use a petroleum based solvent for cleaning.

Blow out all passages and jets with com-

pressed air.

Never use a wire.

Needle valve

1. Inspect:

Needle valve 1

Valve seat 2

Grooved wear a→ Replace.

Dust b→ Clean.

EC464301

Throttle valve

1. Check:

Free movement

Stick → Repair or replace.

NOTE:

Insert the throttle valve 1into the carburetor

body, and check for free movement.

4 - 4

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ENG

CARBURETOR

EC464401

Jet needle

1. Inspect:

Jet needle 1

Bends/wear → Replace.

Clip groove

Free play exists/wear → Replace.

Clip position

Standard clip position:

No.2 Groove

Float height

1. Measure:

Float height a

Out of specification → Adjust.

Float height:

15.5 ~ 16.5 mm (0.61 ~ 0.65 in)

Measurement and adjustment steps:

Hold the carburetor in an upside down

position.

NOTE:

Slowly tilt the carburetor in the opposite

direction, then take the measurement

when the needle valve aligns with the float

arm.

If the carburetor is level, the weight of the

float will push in the needle valve, result-

ing 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 specifica-

tion, inspect the valve seat and needle

valve.

If either is worn, replace them both.

If both are fine, adjust the float height by

bending the float tab 1on the float.

Recheck the float height.

4 - 5

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ENG

CARBURETOR

EC464600

Float

1. Inspect:

Float 1

Damage → Replace.

ASSEMBLY AND INSTALLATION

Carburetor

1. Install:

Pilot air screw 1

Note the following installation points:

Screw in the pilot air screw until it is lightly

seated.

Back out it by the specified number of

turns.

Pilot air screw:

1-3/4 turns out

2. Install:

Throttle valve 1

Starter plunger 2

NOTE:

Align the slit aof the throttle valve with the tab

bof the carburetor top.

FUEL LEVEL ADJUSTMENT

WARNING

Gasoline (fuel) and its vapors are highly

flammable and explosive. Keep away from

sparks, cigarettes, flames or other sources

of ignition.

4 - 6

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ENG

CARBURETOR

1. Measure:

Fuel level a

Use a fuel level gauge 1.

Out of specification → Adjust.

Fuel level gauge:

YM-1312-A/90890-01312

Fuel level:

2 ~ 3 mm (0.08 ~ 0.12 in) below

the float chamber line

4 - 7

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ENG

CYLINDER HEAD

Extent of removal:

1Cylinder head removal

Extent of removal

Order

Part name

Q’ty

Remarks

CYLINDER HEAD REMOVAL

Seat, fuel tank and rear fender

Exhaust pipe

Preparation for removal

Carburetor

Refer to “CARBURETOR” section.

Air filter case and starter lever

Plug cap/spark plug

1/1

Crankshaft end cover/O-ring

Timing plug/O-ring

Camshaft sprocket cover/O-ring

Tappet cover (intake)/O-ring

Tappet cover (exhaust)/O-ring

Camshaft sprocket bolt/washer

Timing chain tensioner

Gasket

Refer to “REMOVAL POINTS”.

4 - 8

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ENG

CYLINDER HEAD

Extent of removal

Order

Part name

Camshaft sprocket

Q’ty

Remarks

Refer to “REMOVAL POINTS”.

Timing chain

Cylinder head

Gasket

Dowel pin

4 - 9

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ENG

CYLINDER HEAD

REMOVAL POINTS

Cylinder head

1. Align:

“I” mark

(with stationary pointer)

Checking steps:

Turn the crankshaft counterclockwise with

a wrench.

Align the “I” mark a on the rotor with the

stationary pointer b on the crankcase

cover. When the “I” mark is aligned with

the stationary pointer, the piston is at the

Top Dead Center (T.D.C.).

NOTE:

In order to be sure that the piston is at Top

Dead Center, the match mark c on the

camshaft sprocket must align with the sta-

tionary pointer d on the cylinder head as

shown in the illustration.

If there is no valve clearance, rotate the

crankshaft counterclockwise one turn.

2. Loosen:

Camshaft sprocket bolt 1

3. Remove:

Timing chain tensioner

Camshaft sprocket 2

NOTE:

Fasten a safety wire to the timing chain 3to

prevent it from falling into the crankcase.

Remove the bolt 1while holding the rotor

nut with a wrench.

4 - 10

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ENG

CYLINDER HEAD

4. Remove:

Cylinder head

NOTE:

Loosen the bolts and nuts in their proper

loosening sequence.

Start by loosening each bolt and nut 1/2 turn

until all are loose.

ASSEMBLY AND INSTALLATION

1. Install:

Cylinder head

2. Tighten:

22 Nm (2.2 m · kg, 16 ft · lb)

Nuts

Bolts

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

Apply the engine oil on the contact surfaces

of the nuts, bolts and copper washers.

Follow the numerical order shown in the illus-

tration. Tighten the bolts and nuts in two

stages.

3. Install:

Camshaft sprocket 1

Installation steps:

Turn the crankshaft counterclockwise until

the “I” mark a on the rotor is aligned with

the stationary pointer b on the crankcase

cover.

Align the “I” mark c on the camshaft

sprocket with the stationary pointer d on

the cylinder head.

Fit the timing chain 2 onto camshaft

sprocket and install the camshaft sprocket

on the camshaft.

NOTE:

When installing the camshaft sprocket, keep

the timing chain as tense as possible on the

exhaust side.

4 - 11

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ENG

CYLINDER HEAD

CAUTION:

.Do not turn the crankshaft during instal-

lation of the camshaft. Damage or

improper valve timing will result.

Remove the safety wire from the timing

chain.

4. Install:

Washer

Bolt 1

20 Nm (2.0 m · kg, 14 ft · lb)

NOTE:

Install the bolt 1while holding the rotor nut

with a wrench.

5. Install:

Timing chain tensioner

Installation steps:

Remove the tensioner cap bolt 1 and

spring 2.

Release the timing chain tensioner one-

way cam 3and push the tensioner rod 4

all the way in.

Install the tensioner with a new gasket 5

onto the cylinder.

Timing chain tensioner bolt:

10 Nm (1.0 m • kg, 7.2 ft • lb)

Install the spring 2and cap bolt 1.

Tighten the bolt (with gasket) to the speci-

fied torque.

Cap bolt:

8 Nm (0.8 m • kg, 5.8 ft • lb)

6. Check:

Rotor “I” mark

Align with the crankcase stationary

pointer.

Valve clearance

Out of specification → Adjust.

Refer to the “VALVE CLEARANCE

ADJUSTMENT” section in CHAPTER

4 - 12

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ENG

CAMSHAFT AND ROCKER ARMS

Extent of removal:

Extent of removal

1Rocker arm

Part name

2Camshaft removal

Remarks

Order

Q’ty

CAMSHAFT AND ROCKER

ARMS

Preparation for removal

Cylinder head

Refer to “CYLINDER HEAD” section.

Rocker arm shaft (intake)

Use special tool.

Rocker arm shaft (exhaust)

Rocker arm

Refer to “REMOVAL POINTS”.

Camshaft bearing retainer

Camshaft

Valve clearance adjust screw

locknut

Valve clearance adjust screw

4 - 13

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ENG

CAMSHAFT AND ROCKER ARMS

REMOVAL POINTS

Rocker arm shaft

1. Remove:

Rocker arm shafts

NOTE:

Use a slide hammer bolt 1and weight 2to

slide out the rocker arm shafts.

Slide hammer set:

YU-1083-A

Slide hammer bolt:

90890-01085

Weight:

90890-01084

INSPECTION

Camshaft

1. Measure:

Cam lobes length aand b

Out of specification → Replace.

Cam lobes length limit:

Intake:

a25.398 mm (0.9999 in)

b21.004 mm (0.8269 in)

Exhaust:

a25.256 mm (0.9943 in)

b21.017 mm (0.8274 in)

ASSEMBLY AND INSTALLATION

1. Apply:

Molybdenum disulfide oil

(onto the camshaft cam lobe)

Engine oil

(onto the camshaft bearing)

2. Install:

Camshaft 1

4 - 14

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ENG

CAMSHAFT AND ROCKER ARMS

3. Apply:

Molybdenum disulfide oil

(onto the rocker arm and rocker arm

shaft)

4. Install:

Rocker arm 1

Rocker arm shaft 2

4 - 15

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ENG

VALVES AND VALVE SPRINGS

Extent of removal:

Extent of removal

1Valves removal

Part name

Order

Q’ty

Remarks

VALVES AND VALVE SPRINGS

REMOVAL

Preparation for removal

Cylinder head

Refer to “CYLINDER HEAD” section.

Rocker arm and camshaft

Refer to “CAMSHAFT AND ROCKER

ARMS” section.

Valve cotter

Use special tool.

Refer to “REMOVAL POINTS”.

Spring retainer

Valve spring

Intake valve

Exhaust valve

Valve stem seal

4 - 16

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ENG

VALVES AND VALVE SPRINGS

REMOVAL POINTS

Valve removal

1. Remove:

Valve cotters 1

NOTE:

Attach a valve spring compressor 2between

the valve spring retainer and the cylinder head

to remove the valve cotters.

Valve spring compressor:

YM-4019/90890-04019

INSPECTION

Valve

1. Measure:

Stem-to-guide clearance

Stem-to-guide clearance =

valve guide inside diameter a–

valve stem diameter b

Out of specification → Replace the

valve guide.

Clearance (stem to guide):

Intake:

0.010 ~ 0.037 mm

(0.0004 ~ 0.0015 in)

<Limit>: 0.08 mm (0.003 in)

Exhaust:

0.025 ~ 0.052 mm

(0.0010 ~ 0.0020 in)

<Limit>: 0.10 mm (0.004 in)

2. Measure:

Runout (valve stem)

Out of specification → Replace.

Runout limit:

0.02 mm (0.0008 in)

4 - 17

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ENG

VALVES AND VALVE SPRINGS

Valve spring

1. Measure:

Valve spring free length a

Out of specification → Replace.

Free length (valve spring):

Intake:

28.32 mm (1.11 in)

<Limit>: 26.9 mm (1.06 in)

Exhaust:

28.32 mm (1.11 in)

<Limit>: 26.9 mm (1.06 in)

2. Measure:

Spring tilt a

Out of specification → Replace.

Spring tilt limit:

Intake:

2.5˚/1.2 mm (0.05 in)

Exhaust:

2.5˚/1.2 mm (0.05 in)

Valve seat

1. Measure:

Valve seat width 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 seat width. Where the

valve seat and valve face made contact,

blueing will have been removed.

If the valve seat is too wide, too narrow, or

the seat is not centered, the valve seat

must be refaced.

4 - 18

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ENG

VALVES AND VALVE SPRINGS

2. Lap:

Valve face

Valve seat

NOTE:

After refacing the valve seat or replacing the

valve and valve guide, the valve seat and

valve face should be lapped.

Lapping steps:

Apply a coarse lapping compound to the

valve face.

CAUTION:

Do not let the compound enter the gap

between the valve stem and the guide.

Apply molybdenum disulfide oil to the

valve stem.

Install the valve into the cylinder head.

Turn the valve until the valve face and

valve 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 (Dykem) 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 seat width again. If the

valve seat width is out of specification,

reface and relap the valve seat.

4 - 19

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ENG

VALVES AND VALVE SPRINGS

ASSEMBLY AND INSTALLATION

1. Apply:

Molybdenum disulfide oil

(onto the valve stem and valve stem

seal)

2. Install:

Valve stem seats New

Valves

Valve springs

Valve spring retainers

NOTE:

Make sure that each valve is installed in its

original place, also referring to the embossed

mark as follows.

Intake: “G”

Exhaust: “L”

Install the valve springs with the larger pitch

afacing upwards.

bSmaller pitch

3. Install:

Valve cotters

NOTE:

While compressing the valve spring with a

valve spring compressor and attachment 1

install the valve cotters.

Valve spring compressor:

YM-4019/90890-04019

4. To secure the valve cotters onto the

valve stem, lightly tap the valve tip with a

piece of wood.

CAUTION:

Hitting the valve tip with excessive force

could damage the valve.

4 - 20

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ENG

CYLINDER AND PISTON

Extent of removal:

1Cylinder removal

2Piston removal

Remarks

Extent of removal

Order

Part name

Q’ty

CYLINDER AND PISTON

REMOVAL

Preparation for removal

Cylinder head

Timing chain guide (exhaust)

Cylinder

Refer to “CYLINDER HEAD” section.

Dowel pin

Gasket

Piston pin clip

Piston pin

Use special tool.

Refer to “REMOVE POINTS”.

Piston

Piston ring (top)

Piston ring (2nd)

Side rail/spacer

Refer to “REMOVAL POINTS”.

2/1

4 - 21

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ENG

CYLINDER AND PISTON

REMOVAL POINTS

Piston

1. Remove:

Piston pin clips 1

Piston pin 2

Piston 3

NOTE:

Before removing the piston pin clip, cover the

crankcase opening with a clean towel or rag

to prevent the clip from falling into the crank-

case cavity.

Before removing each piston pin, deburr the

clip groove and pin hole area. If the piston

pin groove is deburred and the piston pin is

still difficult to remove, use the piston pin

puller set 4.

Piston pin puller set:

YU-1304/90890-01304

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

Measurement steps:

1st step:

Measure the cylinder bore “C” with a cylin-

der bore gauge.

NOTE:

Measure the cylinder bore “C” in parallel to

and at right angles to the crankshaft. Then,

find the average of the measurements.

4 - 22

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ENG

CYLINDER AND PISTON

47.000 ~ 47.005 mm

(1.8504 ~ 1.8506 in)

Cylinder bore “C”

Taper limit “T”

Out of round “R”

“C” = Maximum D

0.05 mm (0.002 in)

“T” = (Maximum D¹or D2

)

– (Maximum D⁵or D6

)

“R” = (Maximum D¹, D3 or D5

)

– (Minimum D2, D4 or D6

)

If out of specification, replace the cylinder,

and replace the piston and piston rings as

set.

2nd step:

Measure the piston skirt diameter “P” with

a micrometer.

a4 mm (0.16 in) from the piston bottom edge.

Piston size P

46.960 ~ 46.975 mm

Standard

(1.8488 ~ 1.8494 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:

0.025 ~ 0.045 mm

(0.0010 ~ 0.0018 in)

<Limit>: 0.15 mm (0.0059 in)

If out of specification, replace the cylinder,

and replace the piston and piston rings as

set.

4 - 23

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ENG

CYLINDER AND PISTON

Piston ring

1. Measure:

Ring side clearance

Use a feeler gauge.

Out of specification → Replace the pis-

ton and rings as a set.

NOTE:

Clean carbon from the piston ring grooves and

rings before measuring the side clearance.

Side clearance

Standard

Limit

0.030 ~ 0.065 mm

0.12 mm

Top ring

2nd ring

(0.0012 ~ 0.0026 in) (0.005 in)

0.12 mm

(0.005 in)

0.020 ~ 0.055 mm

(0.0008 ~ 0.0022 in)

2. Position:

Piston ring

(in cylinder)

NOTE:

Insert a ring into the cylinder and push it

approximately 5 mm (0.20 in) into the cylinder.

Push the ring with the piston crown so that the

ring will be at a right angle to the cylinder bore.

a5 mm (0.20 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 show excessive gap, replace

all three rings.

End gap

Standard

Limit

0.10 ~ 0.25 mm

0.4 mm

Top ring

2nd ring

Oil ring

(0.004 ~ 0.010 in)

(0.016 in)

0.10 ~ 0.25 mm

(0.004 ~ 0.010 in)

0.4 mm

(0.016 in)

0.2 ~ 0.7 mm

(0.01 ~ 0.03 in)

—

4 - 24

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ENG

CYLINDER AND PISTON

Piston pin

1. Inspect:

Piston pin

Blue discoloration/grooves →

Replace, then inspect the lubrication

system.

2. Measure:

Piston pin outside diameter

Piston pin bore inside diameter

Measurement steps:

Measure the piston pin outside diameter

If out of specification, replace the piston

Outside diameter (piston pin):

12.996 ~ 13.000 mm

(0.5117 ~ 0.5118 in)

<Limit>:12.976 mm (0.5109 in)

Measure the piston inside diameter b.

If out of specification, replace the piston.

Inside diameter (piston):

13.002 ~ 13.013 mm

(0.5119 ~ 0.5123 in)

<Limit>: 13.045 mm (0.5136 in)

ASSEMBLY AND INSTALLATION

Piston

1. Install:

Piston rings

(onto the piston)

NOTE:

Be sure to install the piston rings so that the

manufacturer’s marks or numbers are

located on the upper side of the rings.

Lubricate the piston and piston rings liberally

with engine oil.

4 - 25

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ENG

CYLINDER AND PISTON

2. Position:

Top ring

2nd ring

Oil ring

Offset the piston ring end gaps as

shown.

aTop ring end

bOil ring end (lower)

cOil ring end (upper)

d2nd ring end

3. Install:

Piston 1

Piston pin 2

Piston pin clips 3 New

NOTE:

Apply engine oil onto the piston pin, piston

ring and piston.

Be sure that the arrow mark aon the piston

points to the exhaust side of the engine.

Before installing the piston pin clip, cover the

crankcase with a clean rag to prevent the

piston pin clip from falling into the crankcase.

4. Lubricate:

Piston

Piston rings

Cylinder

NOTE:

Apply a liberal coating of engine oil.

Cylinder

1. Install:

Dowel pins

Gasket New

Cylinder 1

NOTE:

Install the cylinder with one hand while com-

pressing the piston rings with the other hand.

CAUTION:

Be careful not to damage the timing chain

damper during installation.

Pass the timing chain through the timing

chain cavity.

4 - 26

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ENG

CLUTCH

CRANKCASE COVER (LEFT AND RIGHT)

Extent of removal:

Extent of removal

1Crankcase cover (left) removal

2Crankcase cover (right) removal

Order

Part name

Q’ty

Remarks

CRANKCASE COVER (LEFT

AND RIGHT) REMOVAL

Preparation for removal

Drain the engine oil.

Refer to “ENGINE OIL REPLACEMENT”

section in the CHAPTER 3.

Shift pedal

Drive sprocket cover

Crankcase cover (left)

Gasket

Dowel pin

Clutch adjusting screw

Kick crank

Crankcase cover (right)

Gasket

Dowel pin

4 - 27

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ENG

CLUTCH

Extent of removal:

Extent of removal

1Friction plate and clutch plate removal 2Clutch housing removal

3Primary clutch removal

Order

Part name

Q’ty

Remarks

CLUTCH REMOVAL

Bolt/clutch spring

Pressure plate

Washer

4/4

Push rod #1

Friction plate

Clutch plate

2 3

Push rod #2

Clutch boss nut

Lock washer

Clutch boss

Use special tool.

Refer to “REMOVAL POINTS”.

Washer

Clutch housing

4 - 28

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ENG

CLUTCH

Extent of removal

Order

Part name

Q’ty

Remarks

Spacer

Primary clutch nut

Use special tool.

Refer to “REMOVAL POINTS”.

Washer

Spacer

Primary clutch housing

Primary clutch boss

Clutch carrier

One-way clutch assembly

Washer

4 - 29

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ENG

CLUTCH

REMOVAL POINTS

Clutch boss

1. Remove:

Clutch boss nut 1

Lock washer 2

Clutch boss

NOTE:

Straighten the lock washer tab and use the

clutch holding tool 3to hold the clutch boss.

Clutch holding tool:

YM-91042/90890-04086

ÅFor USA and CDN

ıExcept for USA and CDN

Primary clutch

1. Remove:

Primary clutch nut 1

NOTE:

Loosen the nut while holding the magnet rotor

with the sheave holder 2.

Sheave holder:

YS-1880-A/90890-01701

INSPECTION

EC484500

Friction plate

1. Measure:

Friction plate thickness

Out of specification → Replace friction

plate as a set.

Measure at all four points.

Friction plate thickness

Standard

Limit

2.7 ~ 2.9 mm

(0.106 ~ 0.114 in)

2.6 mm

(0.102 in)

4 - 30

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ENG

CLUTCH

^EC^Cl⁴u⁸⁴t⁶c⁰⁰h plate

1. Measure:

Clutch plate warpage

Out of specification → Replace clutch

plate as a set.

Use a surface plate 1and thickness

gauge 2.

Warp limit:

0.2 mm (0.008 in)

^EC^Cl⁴u⁸⁴t⁴c⁰⁰h spring

1. Measure:

Clutch spring free length a

Out of specification → Replace springs

as a set.

Clutch spring free length

Standard

Limit

26.2 mm

(1.03 in)

24.2 mm

(0.95 in)

Push rod

1. Measure:

Push rod #2 bend

Out of specification → Replace.

Bending limit:

0.5 mm (0.02 in)

Primary clutch

1. Measure:

Primary clutch housing inside diameter

Out of specification → Replace.

Primary clutch housing inside

diameter:

105 mm (4.13 in)

<Limit>: 106 mm (4.17 in)

2. Measure:

Clutch shoe groove depth a

Out of specification → Replace.

Clutch shoe groove depth:

1.0 ~ 1.3 mm (0.039 ~ 0.051 in)

<Limit>: 0.1 mm (0.004 in)

4 - 31

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ENG

CLUTCH

ASSEMBLY AND INSTALLATION

Primary clutch

1. Install:

Washer 1

Nut (primary clutch) 2

50 Nm (5.0 m · kg, 36 ft · lb)

NOTE:

Tighten the nut while holding the magneto

rotor with the sheave holder 3.

Sheave holder:

YS-1880-A/90890-01701

Clutch

1. Install:

Lock washer 1 New

Nut (clutch boss) 2

70 Nm (7.0 m · kg, 50 ft · lb)

NOTE:

Use the clutch holding tool 3to hold the clutch

boss.

Clutch holding tool:

YM-91042/90890-04086

ÅFor USA and CDN

ıExcept for USA and CDN

2. Bend:

Lock washer tab

Clutch release adjustment

1. Adjust:

Clutch release

Adjustment steps:

Loosen the locknut 1.

Turn in the adjuster 2until it is lightly

seated.

Turn out by 1/8 turn.

Tighten the locknut.

Locknut:

8 Nm (0.8 m • kg, 5.8 ft • lb)

4 - 32

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ENG

KICK AXLE

Extent of removal:

Extent of removal

1Kick axle removal

2Kick axle disassembly

Order

Part name

Q’ty

Remarks

KICK AXLE REMOVAL AND

DISASSEMBLY

Preparation for removal

Crankcase cover (right)

Kick axle assembly

Circlip

Refer to “CLUTCH” section.

Spring cover

Torsion spring

Spring guide

Circlip

Ratchet wheel

Clip

Circlip

Washer/wave washer

Kick gear

1/1

Kick axle

4 - 33

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ENG

SHIFT SHAFT

Extent of removal:

Extent of removal

1Shift shaft removal

Order

Part name

Q’ty

Remarks

Refer to “CLUTCH” section.

SHIFT SHAFT REMOVAL

Clutch housing and clutch carrier

Shift fork guide bar

Shift arm 3

Preparation for removal

Plate washer

Compression spring

Shift guide

Ball holder

Guide

Dowel pin

Plate washer

Thrust bearing

Circlip

Shift lever assembly

Shift shaft

4 - 34

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ENG

SHIFT SHAFT

Extent of removal

Order

Part name

Stopper lever

Q’ty

Remarks

Torsion spring

Circlip

Plate washer

Torsion spring

Shift lever

4 - 35

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ENG

OIL PUMP

Extent of removal:

Extent of removal

1Oil pump removal

3Oil pump disassembly

2Oil strainer removal

Order

Part name

Q’ty

Remarks

OIL PUMP REMOVAL AND DIS-

ASSEMBLY

Preparation for removal

Clutch housing and clutch carrier

Shift shaft

Refer to “CLUTCH” section.

Refer to “SHIFT SHAFT” section.

Rotary filter

Oil pump assembly

Gasket

Oil pump drive gear

Oil strainer

Circlip

Oil pump driven gear

Spring washer

Circlip

Washer

4 - 36

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ENG

OIL PUMP

Extent of removal

Order

Part name

Oil pump cover

Q’ty

Remarks

Dowel pin

Oil pump drive shaft

Inner rotor

Outer rotor

Rotor housing

4 - 37

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ENG

OIL PUMP

INSPECTION

Oil pump

1. Measure:

Tip clearance a

(between the inner rotor 1 and the

outer rotor 2)

Side clearance b

(between the outer rotor 2and the

rotor housing 3)

Out of specification → Replace the oil

pump assembly.

Rotor housing and rotor clearance c

(between the rotor housing 3and the

rotors 12)

Out of specification → Replace the oil

pump assembly.

Tip clearance a:

0.15 mm (0.0059 in)

<Limit>: 0.2 mm (0.0079 in)

Side clearance b:

0.13 ~ 0.18 mm

(0.0051 ~ 0.0071 in)

<Limit>: 0.23 mm (0.0091 in)

Rotor housing and rotor clear-

ance c:

0.06 ~ 0.10 mm

(0.0024 ~ 0.0039 in)

<Limit>: 0.15 mm (0.006 in)

Rotary filter and oil strainer

1. Inspect:

Rotary filter 1

Oil strainer 2

Damage → Replace.

3Upper side

4Lower side

ASSEMBLY AND INSTALLATION

Rotary filter

1. Install:

Rotary filter 1

NOTE:

When installing the rotary filter, align the match

mark a on the rotary filter with the hole b of

the crankshaft.

4 - 38

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ENG

CDI MAGNETO

Extent of removal:

Extent of removal

1Pickup coil/stator assembly removal 2Rotor removal

Order

Part name

Q’ty

Remarks

CDI MAGNETO AND STATOR

REMOVAL

Preparation for removal

Fuel tank

Crankcase cover (left)

CDI magneto coupler

Pickup coil/stator assembly

Rotor nut

Refer to “CLUTCH” section.

Use special tool.

Refer to “REMOVAL POINTS”.

Rotor

Woodruff key

4 - 39

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ENG

CDI MAGNETO

REMOVAL POINTS

Rotor

1. Remove:

Rotor nut 1

Washer 2

NOTE:

Loosen the rotor nut while holding the rotor

with sheave holder 3.

Do not allow the sheave holder to touch the

projection on the rotor.

Sheave holder:

YS-1880-A/90890-01701

2. Remove:

Rotor 1

Woodruff key

NOTE:

Use the flywheel puller 2.

Center the flywheel puller over the rotor.

Make sure after installing the holding bolts

that the clearance between the flywheel

puller and the rotor is the same everywhere.

If necessary, one holding bolt may be turned

out slightly to adjust the flywheel puller’s

position.

CAUTION:

Cover the crankshaft end with the box

wrench for protection.

Flywheel puller:

YU-33270-B/90890-01362

4 - 40

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ENG

CRANKCASE AND CRANKSHAFT

Extent of removal

Order

Part name

Q’ty

Remarks

CRANKCASE SEPARATION

AND CRANKSHAFT REMOVAL

Preparation for removal

Seat, fuel tank and rear fender

Exhaust pipe

Air filter case

Carburetor

Refer to “CARBURETOR” section.

Drain the engine oil

Refer to “ENGINE OIL REPLACEMENT”

section in the CHAPTER 3.

Engine guard and drive sprocket

Engine assembly

From the chassis.

Cylinder head

Refer to “CYLINDER HEAD” section.

Cylinder and piston

Refer to “CYLINDER AND PISTON” sec-

tion.

Clutch housing and clutch carrier

Kick axle assembly

Refer to “CLUTCH” section.

Refer to “KICK AXLE” section.

4 - 41

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ENG

CRANKCASE AND CRANKSHAFT

Extent of removal:

Extent of removal

1Timing chain removal

3Crankshaft removal

2Crankcase separation

Order

Part name

Q’ty

Remarks

Shift shaft

Refer to “SHIFT SHAFT” section.

Refer to “OIL PUMP” section.

Oil pump and oil strainer

Rotor

Refer to “CDI MAGNETO” section.

Timing chain guide (intake)

Timing chain

Crankcase (right)

Dowel pin

Crankshaft

Crankcase (left)

4 - 42

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ENG

CRANKCASE AND CRANKSHAFT

INSPECTION

Crankshaft

1. Measure:

Runout limit a

Connecting rod big end side clearance

Connecting rod big end radial clear-

ance c

Crank width d

Out of specification → Replace.

Use the dial gauge and a thickness

gauge.

Standard

Limit

Runout

limit

0.03 mm

(0.0012 in)

—

Side

clearance

0.10 ~ 0.40 mm

(0.0039 ~ 0.0157 in)

—

Radial

clearance

0.010 ~ 0.025 mm

0.05 mm

(0.0004 ~ 0.0010 in) (0.002 in)

Crack

width

42.95 ~ 43.00 mm

(1.691 ~ 1.693 in)

—

ASSEMBLY AND INSTALLATION

Crankcase

1. Apply:

Sealant

On the crankcase (left).

Quick gasket :

ACC-QUICK-GS-KT

YAMAHA Bond No. 1215:

90890-85505

NOTE:

Clean the contacting surface of crankcase

(left and right) before applying the sealant.

DO NOT ALLOW any sealant to come in

contact with the oil gallery a.

4 - 43

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ENG

SHIFT FORK, SHIFT CAM AND TRANSMISSION

Extent of removal:

Extent of removal

1Shift fork, shift cam, main axle and drive axle removal

2Main axle disassembly

3Drive axle disassembly

Order

Part name

Q’ty

Remarks

SHIFT FORK, SHIFT CAM

TRANSMISSION REMOVAL

Preparation for removal

Engine assembly

Separate the crankcase.

Refer to “CRANKCASE AND CRANK-

SHAFT” section.

Guide bar

Shift cam

Shift fork 2 “R”

Shift fork 1 “L”

Drive axle assembly

Main axle assembly

2nd pinion gear

Circlip

Refer to “REMOVAL POINTS”.

Washer

4 - 44

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ENG

SHIFT FORK, SHIFT CAM AND TRANSMISSION

Extent of removal

Order

Part name

3th pinion gear

Q’ty

Remarks

Main axle

Circlip

Washer

Collar

1st wheel gear

3rd wheel gear

Circlip

Washer

2nd wheel gear

Drive axle

4 - 45

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ENG

SHIFT FORK, SHIFT CAM AND TRANSMISSION

^ER^CE^4HM³⁰⁰O⁰VAL POINTS

Shift fork, shift cam and transmission

1. Remove:

Shift forks

Shift cam

Drive axle assembly

Main axle assembly

NOTE:

Tap lightly on the transmission drive axle and

shift cam with a soft hammer to remove.

Remove assembly carefully. Note the posi-

tion of each part. Pay particular attention to

the location and direction of shift forks.

ASSEMBLY AND INSTALLATION

Transmission, shift cam shift fork

1. Install:

Main axle assembly 1

Drive axle assembly 2

2. Install:

Shift fork 1 “L” 1

Shift fork 2 “R” 2

Shift cam 3

Guide bar 4

NOTE:

The embossed marks on the shift forks should

face towards the right side of the engine and

be in the following sequence: “R”, “L”.

3. Check:

Shifter operation

Transmission operation

Unsmooth operation → Repair.

4 - 46

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CHAS

FRONT WHEEL AND REAR WHEEL

^EC^C5H⁰⁰⁰⁰A⁰SSIS

FRONT WHEEL AND REAR WHEEL

FRONT WHEEL AND FRONT BRAKE

Extent of removal:

1Front wheel removal

2Wheel bearing removal

3Brake shoe plate assembly removal and disassembly

Extent of removal

Order

Part name

Q’ty

Remarks

FRONT WHEEL REMOVAL

Hold the machine by placing the

suitable stand under the engine.

WARNING

Preparation for removal

Support the machine securely so there is no

danger of it falling over.

Bolt (brake cable holder)

Brake cable

Wheel axle nut

Front wheel axle

Front wheel

Collar set

Brake shoe plate assembly

Oil seal

Only loosening.

Disconnect at the lever side.

Bearing

Refer to “REMOVAL POINTS”.

5 - 1

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CHAS

FRONT WHEEL AND REAR WHEEL

Extent of removal

Order

Part name

Q’ty

Remarks

Brake shoe

Brake camshaft lever

Brake camshaft

5 - 2

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CHAS

FRONT WHEEL AND REAR WHEEL

REAR WHEEL AND REAR BRAKE

Extent of removal:

1Rear wheel removal

2Wheel bearing removal

3Brake shoe plate assembly removal and disassembly

Extent of removal

Order

Part name

Q’ty

Remarks

REAR WHEEL REMOVAL

Hold the machine by placing the

suitable stand under the engine.

WARNING

Preparation for removal

Support the machine securely so there is no

danger of it falling over.

Brake rod

Cotter pin

Nut (tension bar)

Bolt (tension bar)

Wheel axle nut

Rear wheel axle

Drive chain puller

Rear wheel

Collar (right)

Brake shoe plate assembly

5 - 3

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CHAS

FRONT WHEEL AND REAR WHEEL

Extent of removal

Order

Part name

Q’ty

Remarks

Collar (left)

Wheel drive hub assembly

Bearing

Brake shoe

Brake camshaft lever

Brake camshaft

Refer to “REMOVAL POINTS”.

5 - 4

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CHAS

FRONT WHEEL AND REAR WHEEL

^ER^CE⁵⁹³M⁰⁰O⁰VAL POINTS

EC513201

Wheel bearing (if necessary)

1. Remove:

Bearing 1

NOTE:

Remove the bearing using a general bearing

puller 2.

^EIN^C5S⁹⁴⁰P⁰⁰ECTION

EC514100

Wheel

1. Measure:

Wheel runout

Out of limit → Repair/replace.

Wheel runout limit:

Radial 1: 2.0 mm (0.08 in)

Lateral 2: 2.0 mm (0.08 in)

Brake lining

1. Inspect:

Brake shoe lining surface

Glazed areas → Polish.

Use coarse sand paper.

NOTE:

After polishing, wipe the polished particles with

a cloth.

2. Measure:

Brake shoe lining thickness

Brake shoe lining thickness a:

Standard:

Front: 3.0 mm (0.12 in)

Rear: 4.0 mm (0.16 in)

Limit:

2.0 mm (0.08 in)

Out of specification → Replace.

NOTE:

Replace the brake shoes and springs as a set

if either is worn to the limit.

5 - 5

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CHAS

FRONT FORK

EC550000

FRONT FORK

Extent of removal:

Extent of removal

1Front fork removal

Order

Part name

Q’ty

Remarks

FRONT FORK REMOVAL

Hold the machine by placing the

suitable stand under the engine.

WARNING

Preparation for removal

Support the machine securely so there is no

danger of it falling over.

Front wheel

Refer to “FRONT WHEEL AND REAR

WHEEL” section.

Handlebar

Refer to “HANDLEBAR” section.

Front fender

Brake cable holder

Cap bolt

Adjuster

Pinch bolt (under bracket)

Front fork

Only loosening.

5 - 6

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CHAS

FRONT FORK

EC558000

FRONT FORK DISASSEMBLY

Extent of removal:

Extent of removal

1Oil seal removal

2Damper rod removal

Remarks

Order

Part name

Q’ty

FRONT FORK DISASSEMBLY

Preparation for disas-

sembly

Drain the fork oil.

Adjuster

Fork spring

Dust cover

Stopper ring

Bolt (damper rod)

Use special tool.

Refer to “REMOVAL POINTS”.

Inner tube

Damper rod

Oil seal

Outer tube

5 - 7

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CHAS

FRONT FORK

REMOVAL POINTS

Inner tube

1. Remove:

Bolt (damper rod)

NOTE:

While holding the damper rod with the damper

rod holder 1and T-handle 2, loosen the bolt

(damper rod).

Damper rod holder:

YM-1300/90890-01294

T-handle:

YM-1326/90890-01326

^EA^CS⁵⁵⁵S⁰⁰E⁰MBLY AND INSTALLATION

Front fork assembly

1. Install:

Oil seal 1

NOTE:

Press the oil seal into the outer tube with fork

seal driver weight 2 and fork seal driver

attachment 3.

Fork seal driver weight:

YM-33963/90890-01184

Fork seal driver attachment:

90890-01186

2. Fill:

Fork oil

Oil quantity:

64 cm³(2.26 Imp oz, 2.16 US oz)

Recommended oil:

Fork oil 15W or equivalent

3. After filling up, slowly pump the fork up

and down to distribute the fork oil.

5 - 8

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CHAS

HANDLEBAR

EC5B0000

HANDLEBAR

Extent of removal:

Extent of removal

1Handlebar removal

Order

Part name

Q’ty

Remarks

HANDLEBAR REMOVAL

“ENGINE STOP” switch

Brake lever cable

Brake lever

Grip cap (lower)

Grip cap (upper)

Throttle cable

Grip (right)

Tube guide

Grip (left)

Handlebar holder (upper)

Handlebar

Disconnect at the lever side.

Disconnect at the throttle side.

Handlebar holder (lower)

5 - 9

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CHAS

STEERING

EC560000

STEERING

40 Nm (4.0 m • kg, 29 ft • Ib)

TIGHTENING STEPS:

•Tighten ring nut.

38 Nm (3.8 m • kg, 27 ft • Ib)

•Loosen it completely.

•Retighten it.

1 Nm (0.1 m • kg, 0.7 ft • Ib)

Extent of removal:

1Under bracket removal

2Bearing removal

Extent of removal

Order

Part name

Q’ty

Remarks

STEERING REMOVAL

WARNING

Preparation for removal

Hold the machine by placing the

suitable stand under the engine.

Support the machine securely so there is no

danger of it falling over.

Front fork

Refer to “FRONT FORK” section.

Steering stem bolt

Handle crown

Ring nut

Use special tool.

Refer to “STEERING HEAD INSPEC-

TION AND ADJUSTMENT” section in

the CHAPTER 3.

Ball race cover

Under bracket

Bearing inner race

Upper bearing ball

Lower bearing ball

Dust seal

Bearing outer race

5 - 10

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CHAS

SWINGARM

EC570000

SWINGARM

Extent of removal:

Extent of removal

1Swingarm removal

2Rear shock absorber removal

Order

Part name

Q’ty

Remarks

SWINGARM REMOVAL

Hold the machine by placing the

suitable stand under the engine.

WARNING

Preparation for removal

Support the machine securely so there is no

danger of it falling over.

Rear wheel

Refer to “FRONT WHEEL AND REAR

WHEEL” section.

Rear fender

Drive chain

Cotter pin

Rear shock absorber

Pivot shaft

Swing arm

Drive chain guide

Drive chain guard

Drive chain support

Hold the swingarm.

5 - 11

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CHAS

SWINGARM

Extent of removal

Order

Part name

Q’ty

Remarks

Cotter pin

Nut (tension bar)

Bolt (tension bar)

Tension bar

5 - 12

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–

ELEC

ELECTRICAL COMPONENTS AND WIRING DIAGRAM

^EE^C6L⁰⁰⁰E⁰⁰CTRICAL

EC610000

ELECTRICAL COMPONENTS AND WIRING DIAGRAM

^EE^CL⁶¹E¹⁰C⁰⁰TRICAL COMPONENTS

1CDI magneto

2CDI unit

3Ignition coil

COLOR CODE

B/R...................Black/Red

B...................... Black

Br .................... Brown

G ..................... Green

O ..................... Orange

R ..................... Red

W..................... White

B/W..................Black/White

G/W..................Green/White

W/L ..................White/Blue

W/R..................White/Red

4Spark plug

5“ENGINE STOP” switch

6Thermo switch

7Carburetor heater

8Rectifier/regulator

EC612000

WIRING DIAGRAM

G/W

B/R

Y/R

W/L

W/R

B/W

Y/R

G/W B/R

W/L W/R

Y/R

B/W

OFF

RUN

Y/R

6 - 1

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–

ELEC

IGNITION SYSTEM

^EIG^C62N⁰⁰⁰I⁰TION SYSTEM

INSPECTION STEPS

Use the following steps for checking the possibility of the malfunctioning engine being attributable to

ignition system failure and for checking the spark plug which will not spark.

Spark

Clean or replace

spark plug.

Spark gap test

No Spark

Check entire ignition

system for connection.

No good

Repair or replace.

Replace.

Check “ENGINE STOP”

switch.

No good

Check ignition coil.

Primary coil

Replace.

Secondary coil

Check CDI magneto.

No good

Pickup coil

Source coil

Replace.

Replace CDI unit.

NOTE:

Remove the following parts before inspection.

1) Seat

2) Fuel tank

Use the following special tools in this inspection.

Dynamic spark tester:

YM-34487

Pocket tester:

YU-3112-C/90890-03112

Ignition checker:

90890-06754

6 - 2

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–

ELEC

IGNITION SYSTEM

^ES^CP⁶²A²⁰⁰R¹K GAP TEST

1. Disconnect the spark plug cap from spark

plug.

2. Connect the dynamic spark tester 1

(ignition checker 2) as shown.

Spark plug cap 3

Spark plug 4

ÅFor USA and CDN

ıExcept for USA and CDN

3. Kick the kick starter.

4. Check the ignition spark gap.

5. Start engine, and increase spark gap until

misfire occurs. (for USA and CDN only)

Minimum spark gap:

6.0 mm (0.24 in)

^EC^CO⁶²⁴U⁰⁰P⁰LERS AND LEADS CONNECTION

INSPECTION

1. Check:

Couplers and leads connection

Rust/dust/looseness/short-circuit →

Repair or replace.

“ENGINE STOP” SWITCH INSPECTION

1. Inspect:

“ENGINE STOP” switch continuity

Tester (+) lead → Black/White lead 1

Tester (–) lead → Black lead 2

Tester selec-

tor position

B/W B

1 2

Ω × 1

No continuous while being pushed “

” →

Replace.

Continuous while being pushed “ ” →

Replace.

6 - 3

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–

ELEC

IGNITION SYSTEM

^EIG^C6N²⁶⁰I⁰T²ION COIL INSPECTION

1. Inspect:

Primary coil resistance

Out of specification → Replace.

Tester (+) lead → Orange lead 1

Tester (–) lead → Black lead 2

Primary coil

resistance

Tester selector

position

0.18 ~ 0.28 Ω at

20 ˚C (68 ˚F)

Ω × 1

2. Inspect:

Secondary coil resistance

Out of specification → Replace.

Tester (+) lead → Spark plug lead 1

Tester (–) lead → Orange lead 2

Secondary coil

resistance

Tester selector

position

6.3 ~ 9.5 kΩ at

20 ˚C (68 ˚F)

kΩ × 1

NOTE:

When inspecting the secondary coil resis-

tance, remove the spark plug cap.

CDI MAGNETO INSPECTION

1. Inspect:

Pickup coil resistance

Out of specification → Replace.

Tester (+) lead → Red lead 1

Tester (–) lead → White lead 2

Pickup coil

resistance

Tester selector

position

248 ~ 372 Ω at

20 ˚C (68 ˚F)

Ω × 100

6 - 4

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–

ELEC

IGNITION SYSTEM

2. Inspect:

Source coil resistance

Out of specification → Replace.

Tester (+) lead → Brown lead 1

Tester (–) lead → Green lead 2

Source coil

resistance

Tester selector

position

688 ~ 1,032 Ω

at 20 ˚C (68 ˚F)

Ω × 100

6 - 5

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–

ELEC

CARBURETOR HEATING SYSTEM

INSPECTION STEPS

Use the following steps for checking the possibility of the malfunctioning carburetor heating system.

Check entire carburetor

No good

heating system for connec-

tion.

Repair or replace.

No good

Check thermo switch.

Replace.

Check carburetor heater.

No good

Check CDI magneto.

Source coil

Replace rectifier/regulator.

NOTE:

Remove the following parts before inspection.

1) Seat

2) Fuel tank

Use the following special tools in this inspection.

Pocket tester:

YU-3112-C/90890-03112

6 - 6

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–

ELEC

CARBURETOR HEATING SYSTEM

^EC^CO⁶²⁴U⁰⁰P⁰LERS AND LEADS CONNECTION

INSPECTION

1. Check:

Couplers and leads connection

Rust/dust/looseness/short-circuit →

Repair or replace.

CDI MAGNETO INSPECTION

1. Inspect:

Source coil resistance

Refer to “IGNITION SYSTEM” section.

THERMO SWITCH INSPECTION

1. Inspect:

Thermo switch operation

Faulty operation → Replace.

Inspection steps:

Remove the thermo switch.

Connect the pocket tester to the thermo

switch coupler as shown.

Tester (+) lead → Black 1

Tester (–) lead → Black 2

Immerse the thermo switch in a container

filled with water 3.

Place a thermometer 4in the water.

Slowly heat the water, and then let it cool to

the specified temperature as indicated in

the table.

Check the thermo switch for continuity at

the temperatures indicated in the table.

6 - 7

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–

ELEC

CARBURETOR HEATING SYSTEM

ÅThe thermo switch circuit is open.

ıThe thermo switch circuit is closed.

Test step Water temperature Continuity

Less than 23 3 ˚C

YES

(73.4 5.4 ˚F)

More than 23 3 ˚C

(73.4 5.4 ˚F)

More than 12 4 ˚C

(53.6 7.2 ˚F)

Less than 12 4 ˚C

(53.6 7.2 ˚F)

YES

Test steps 1 & 2: Heating phase

Test steps 3 & 4: Cooling phase

WARNING

Handle the thermo switch with special

care.

Never subject the thermo switch to

strong shocks. If the thermo switch is

dropped, replace it.

Check the thermo switch operation.

CARBURETOR HEATER INSPECTION

1. Inspect:

Carburetor heater resistance

Out of specification → Replace.

Tester (+) probe →

Carburetor heater terminal 1

Tester (–) probe →

Carburetor heater body 2

Carburetor

heater resistance

Tester selector

position

6 ~ 10 Ω at

20 ˚C (68 ˚F)

Ω × 1

6 - 8

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–

ELEC

NOISE REGULATION/MAINTENANCE RECORD

NOISE REGULATION

TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:

Federal law prohibits the following acts or the causing thereof: (1)

The removal or rendering inoperative by any person other than for purposes of maintenance, repair,

or replacement of any device or element of design incorporated into any new vehicle for the pur-

pose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or (2)

the use of the vehicle after such device or element of design has been removed or rendered inoper-

ative by any person.

“AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED

BELOW.”

These acts include tampering with the following systems; i.e., modification, removal, etc.

Muffler

Exhaust system

Intake system

Exhaust pipe

Silencer

Air cleaner case

Air cleaner element

Intake duct

MAINTENANCE RECORD

Copies of work orders and/or receipts for parts you purchase and install will be required to docu-

ment maintenance done in accordance with the emission warranty. The chart below is printed only

as a reminder to you that the maintenance work is required. It is not acceptable proof of mainte-

nance work.

MAINTE-

NANCE

INTERVAL

DATE OF

SERVICE

SERVICING DEALER

NAME AND ADDRESS

MILEAGE

REMARKS

1 Month

4 Months

7 Months

13 Months

19 Months

25 Months

31 Months

37 Months

43 Months

49 Months

55 Months

61 Months

6 - 9

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PRINTED ON RECYCLED PAPER

PRINTED IN JAPAN

2002.04-3.0×1 CR

(E)

YAMAHA MOTOR CO., LTD.

2500 SHINGAI IWATA SHIZUOKA JAPAN

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