Service Manual: TT-R110E (X)

2008
SERVICE MANUAL
TT-R110E(X)
5B6-28197-E0
EAS20040
TT-R110E(X) 2008
SERVICE MANUAL
©2007 by Yamaha Motor Co., Ltd.
First edition, August 2007
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS20070
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles
should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehi-
cle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-
cle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
NOTE:
• This Service Manual contains information regarding periodic maintenance to the emission control sys-
tem. Please read this material carefully.
• Designs and specifications are subject to change without notice.
EAS20080
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death

WARNING to the vehicle operator, a bystander or a person checking or repairing the ve-
hicle.
A CAUTION indicates special precautions that must be taken to avoid dam-

CAUTION: age to the vehicle.
NOTE: A NOTE provides key information to make procedures easier or clearer.

EAS20090
HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
1 2
5
7
4
6
EAS20100
1. Serviceable with engine mounted
SYMBOLS 2. Filling fluid
The following symbols are used in this manual 3. Lubricant
for easier understanding. 4. Special tool
NOTE: 5. Tightening torque
The following symbols are not relevant to every 6. Wear limit, clearance
vehicle. 7. Engine speed
8. Electrical data
9. Engine oil
1 2 3 10. Gear oil
11. Molybdenum-disulfide oil
12. Brake fluid
13. Wheel-bearing grease
4 5 6 14. Lithium-soap-based grease
15. Molybdenum-disulfide grease
16. Silicone grease
17. Apply locking agent (LOCTITE®).
T.
R.
18. Replace the part with a new one.

7 8
9 10
E G
11 12
M BF
13 14
B LS
15 16
M S
17 18
LT New
EAS20110
TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
FUEL SYSTEM 6
ELECTRICAL SYSTEM 7
TROUBLESHOOTING 8
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1

VEHICLE IDENTIFICATION NUMBER ..................................................... 1-1
MODEL LABEL.......................................................................................... 1-1
IMPORTANT INFORMATION ......................................................................... 1-2

1
PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-2
REPLACEMENT PARTS........................................................................... 1-2
GASKETS, OIL SEALS AND O-RINGS .................................................... 1-2
LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-2
BEARINGS AND OIL SEALS .................................................................... 1-3
CIRCLIPS .................................................................................................. 1-3
CHECKING THE CONNECTIONS .................................................................. 1-4
SPECIAL TOOLS ............................................................................................ 1-5

IDENTIFICATION
EAS20130
IDENTIFICATION
EAS20140
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the right side of the steering head pipe.
EAS20150
MODEL LABEL
The model label “1” is affixed to the frame. This
information will be needed to order spare parts.
1
1-1
IMPORTANT INFORMATION
EAS20180
EAS20190
PREPARATION FOR REMOVAL AND

DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
EAS20210
GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfac-
es, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
2. Use only the proper tools and cleaning equip- lips with grease.
ment.
Refer to “SPECIAL TOOLS” on page 1-5.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mat-
ed” through normal wear. Mated parts must
always be reused or replaced as an assem-
bly.
1. Oil
2. Lip
3. Spring
4. Grease
EAS20220
LOCK WASHERS/PLATES AND COTTER

PINS
After removal, replace all lock washers/plates
4. During disassembly, clean all of the parts and “1” and cotter pins. After the bolt or nut has been
place them in trays in the order of disassem- tightened to specification, bend the lock tabs
bly. This will speed up assembly and allow for along a flat of the bolt or nut.
the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS20200
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
1-2
EAS20230
BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manu-
facturer’s marks or numbers are visible. When
installing oil seals “1”, lubricate the oil seal lips
with a light coat of lithium-soap-based grease.
Oil bearings liberally when installing, if appropri-
ate.
ECA13300
CAUTION:
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.
EAS20240
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways replace piston pin clips after one use.
When installing a circlip “1”, make sure the
sharp-edged corner “2” is positioned opposite
the thrust “3” that the circlip receives.
1-3
CHECKING THE CONNECTIONS
EAS20250
CHECKING THE CONNECTIONS Pocket tester

Check the leads, couplers, and connectors for 90890-03112
stains, rust, moisture, etc. Analog pocket tester
1. Disconnect: YU-03112-C
• Lead
• Coupler NOTE:
• Connector • If there is no continuity, clean the terminals.
2. Check: • When checking the wire harness, perform
• Lead steps (1) to (3).
• Coupler • As a quick remedy, use a contact revitalizer
• Connector available at most part stores.
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect sev-
eral times.
3. Check:
• All connections
Loose connection → Connect properly.
NOTE:
If the pin “1” on the terminal is flattened, bend it
up.
4. Connect:
• Lead
• Coupler
• Connector
NOTE:
Make sure all connections are tight.
5. Check:
• Continuity
(with the pocket tester)
1-4
SPECIAL TOOLS
EAS20260
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use only
the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools
or improvised techniques. Special tools, part numbers or both may differ depending on the country.
When placing an order, refer to the list provided below to avoid any mistakes.
NOTE:
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part number starting with “90890-”.
Reference
Tool name/Tool No. Illustration
pages
Pocket tester 1-4, 5-33, 7-21,
90890-03112 7-22, 7-25,
Analog pocket tester 7-26, 7-27,
YU-03112-C 7-28, 7-29
Thickness gauge 3-3

90890-03180
Feeler gauge set
YU-26900-9
Tappet adjusting tool 3-4

90890-01311
Six piece tappet set
YM-A5970
YM-A5970
ø8 ø9 ø10
ø3 ø4
Digital tachometer 3-5
90890-06760
YU-39951-B
Timing light 3-7

90890-03141
Inductive clamp timing light
YU-03141
Compression gauge 3-7

90890-03081
Engine compression tester
YU-33223
1-5
SPECIAL TOOLS
Reference
pages
Steering nut wrench 3-16, 4-31
90890-01403
Spanner wrench
YU-33975
Spoke nipple wrench (10-11) 3-19

90890-01523
YM-01523
Damper rod holder 4-25, 4-26

90890-01294
Damping rod holder set
YM-01300
YM-01300
T-handle 4-25, 4-26

90890-01326
T-handle 3/8" drive 60 cm long
YM-01326
Fork seal driver weight 4-26

90890-01184
Replacement hammer
YM-A9409-7
YM-A9409-7/YM-A5142-4
Fork seal driver attachment (ø33) 4-26

90890-01532
YM-01532
1-6
SPECIAL TOOLS
Reference
pages
Slide hammer bolt 5-12
90890-01085
Slide hammer bolt 8 mm
YU-01083-2
Weight 5-12
90890-01084
YU-01083-3
YU-01083-3
Valve spring compressor 5-15, 5-20

90890-04019
YM-04019
Valve spring compressor attachment 5-15, 5-20

90890-04108
Valve spring compressor adapter 22 mm
YM-04108
Valve guide remover (ø4.5) 5-16

90890-04116
Valve guide remover (4.5 mm)
YM-04116
Valve guide installer (ø4.5) 5-16

90890-04117
Valve guide installer (4.5 mm)
YM-04117
Valve guide reamer (ø4.5) 5-16

90890-04118
Valve guide reamer (4.5 mm)
YM-04118
1-7
SPECIAL TOOLS
Reference
pages
Piston pin puller set 5-22
90890-01304
Piston pin puller
YU-01304
YU-01304
Sheave holder 5-28, 5-29,

90890-01701 5-30, 5-40,
Primary clutch holder 5-43
YS-01880-A
Flywheel puller 5-28

90890-01362
Heavy duty puller
YU-33270-B
Yamaha bond No. 1215 5-30, 5-55

90890-85505
(Three Bond No.1215®)
Universal clutch holder 5-40, 5-43

90890-04086
YM-91042
1-8
SPECIAL TOOLS
Reference
pages
Crankcase separating tool 5-57
90890-01135
Crankcase separator
YU-01135-B
Crankshaft installer pot 5-58

90890-01274
Installing pot
YU-90058
YU-90058/YU-90059
Crankshaft installer bolt 5-58

90890-01275
Bolt
YU-90060
Adapter (M12) 5-58

90890-01278
Adapter #3
YU-90063
Spacer (crankshaft installer) 5-58

90890-04081
Pot spacer
YM-91044
YM-91044
1-9
SPECIAL TOOLS
Reference
pages
Fuel level gauge 6-7
90890-01312
YM-01312-A
Ignition checker 7-26

90890-06754
Opama pet-4000 spark checker
YM-34487
1-10
SPECIAL TOOLS
1-11
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................ 2-2
CHASSIS SPECIFICATIONS .......................................................................... 2-9
ELECTRICAL SPECIFICATIONS ................................................................. 2-12
TIGHTENING TORQUES .............................................................................. 2-14

2
GENERAL TIGHTENING TORQUE SPECIFICATIONS......................... 2-14
ENGINE TIGHTENING TORQUES......................................................... 2-15
CHASSIS TIGHTENING TORQUES....................................................... 2-17
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-19

ENGINE................................................................................................... 2-19
CHASSIS................................................................................................. 2-21
LUBRICATION SYSTEM CHART AND DIAGRAMS.................................... 2-23

LUBRICATION DIAGRAMS .................................................................... 2-23
CABLE ROUTING ......................................................................................... 2-27

GENERAL SPECIFICATIONS
EAS20280
GENERAL SPECIFICATIONS
Model
Model TT-R110E 5B63 (Europe)
TT-R110EX 5B62 (CDN)
TT-R110EX 5B64 (Oceania)
Dimensions
Overall length 1565 mm (61.6 in)
Overall width 680 mm (26.8 in)
Overall height 923 mm (36.3 in)
Seat height 670 mm (26.4 in)
Wheelbase 1080 mm (42.5 in)
Ground clearance 180 mm (7.09 in)
Minimum turning radius 1660 mm (65.4 in)
Weight
With oil and fuel 72.0 kg (159 lb)
2-1
ENGINE SPECIFICATIONS
EAS20290
Engine
Engine type Air cooled 4-stroke, SOHC
Displacement 110.0 cm³
Cylinder arrangement Forward-inclined single cylinder
Bore × stroke 51.0 × 54.0 mm (2.01 × 2.13 in)
Compression ratio 9.30 :1
Standard compression pressure (at sea level) 1300 kPa/500 r/min (185 psi/500 r/min) (13.0
kgf/cm²/500 r/min)
Minimum–maximum 1130–1460 kPa (161–208 psi) (11.3–14.6
kgf/cm²)
Starting system Electric starter and kickstarter
Fuel
Recommended fuel Regular unleaded gasoline only (Europe) (CDN)
Unleaded gasoline only (Oceania)
Fuel tank capacity 3.8 L (1.00 US gal) (0.84 Imp.gal)
Fuel reserve amount 0.5 L (0.13 US gal) (0.11 Imp.gal)
Engine oil
Lubrication system Wet sump
Type SAE 10W-30, SAE 10W-40, SAE15W-40, SAE
20W-40 or SAE 20W-50 (Europe) (Oceania)
YAMALUBE 4(10W-30) or SAE 10W-30,
YAMALUBE 4(20W-40) or SAE 20W-40 (CDN)
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Engine oil quantity
Total amount 1.00 L (1.06 US qt) (0.88 Imp.qt)
Periodic oil change 0.80 L (0.85 US qt) (0.70 Imp.qt)
Oil filter
Oil filter type Wire mesh
Oil pump
Oil pump type Trochoid
Inner-rotor-to-outer-rotor-tip clearance Less than 0.150 mm (0.0059 in)
Limit 0.23 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing clearance 0.13–0.18 mm (0.0051–0.0071 in)
Limit 0.25 mm (0.0098 in)
Oil-pump-housing-to-inner-and-outer-rotor
clearance 0.06–0.10 mm (0.0024–0.0039 in)
Limit 0.17 mm (0.0067 in)
Spark plug (s)

Manufacturer/model NGK/CR6HSA
Spark plug gap 0.6–0.7 mm (0.024–0.028 in)
Cylinder head
Volume 9.90–10.30 cm³ (0.60–0.63 cu.in)
2-2
Warpage limit 0.03 mm (0.0012 in)
Camshaft
Drive system Chain drive (left)
Camshaft lobe dimensions
Intake A 25.775–25.875 mm (1.0148–1.0187 in)
Limit 25.745 mm (1.0136 in)
Intake B 21.045–21.145 mm (0.8285–0.8325 in)
Limit 21.015 mm (0.8274 in)
Exhaust A 25.775–25.875 mm (1.0148–1.0187 in)
Limit 25.749 mm (1.0137 in)
Exhaust B 20.950–21.050 mm (0.8248–0.8287 in)
Limit 20.924 mm (0.8238 in)
B
Camshaft runout limit 0.03 mm (0.0012 in)
Timing chain
Model/number of links DID SCR-0404 SV/86
Tensioning system Automatic
Rocker arm/rocker arm shaft

Rocker arm inside diameter 10.000–10.015 mm (0.3937–0.3943 in)
Limit 10.030 mm (0.3949 in)
Rocker arm shaft outside diameter 9.981–9.991 mm (0.3930–0.3933 in)
Limit 9.950 mm (0.3917 in)
Rocker-arm-to-rocker-arm-shaft clearance 0.009–0.034 mm (0.0004–0.0013 in)
Limit 0.08 mm (0.0032 in)
Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.05–0.09 mm (0.0020–0.0035 in)
Exhaust 0.08–0.12 mm (0.0032–0.0047 in)
Valve dimensions
Valve head diameter A (intake) 22.90–23.10 mm (0.9016–0.9094 in)
2-3
Valve head diameter A (exhaust) 19.90–20.10 mm (0.7835–0.7913 in)
A
Valve face width B (intake) 1.200–2.500 mm (0.0472–0.0984 in)
Valve face width B (exhaust) 1.600–2.900 mm (0.0630–0.1142 in)
Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in)

Limit 1.6 mm (0.06 in)
Valve seat width C (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)
Valve margin thickness D (intake) 0.50–0.90 mm (0.0197–0.0354 in)

Valve margin thickness D (exhaust) 0.80–1.20 mm (0.0315–0.0472 in)
Valve stem diameter (intake) 4.475–4.490 mm (0.1762–0.1768 in)

Limit 4.450 mm (0.1752 in)
Valve stem diameter (exhaust) 4.460–4.475 mm (0.1756–0.1762 in)
Limit 4.435 mm (0.1746 in)
Valve guide inside diameter (intake) 4.500–4.512 mm (0.1772–0.1776 in)
Limit 4.542 mm (0.1788 in)
Valve guide inside diameter (exhaust) 4.500–4.512 mm (0.1772–0.1776 in)
Limit 4.542 mm (0.1788 in)
Valve-stem-to-valve-guide clearance (intake) 0.010–0.037 mm (0.0004–0.0015 in)
Limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance (exhaust) 0.025–0.052 mm (0.0010–0.0020 in)
Limit 0.100 mm (0.0039 in)
Valve stem runout 0.010 mm (0.0004 in)
Cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in)

Cylinder head valve seat width (exhaust) 0.90–1.10 mm (0.0354–0.0433 in)
2-4
Valve spring
Free length (intake) 33.75 mm (1.33 in)
Limit 32.06 mm (1.26 in)
Free length (exhaust) 33.75 mm (1.33 in)
Limit 32.06 mm (1.26 in)
Installed length (intake) 24.20 mm (0.95 in)
Installed length (exhaust) 24.20 mm (0.95 in)
Spring rate K1 (intake) 15.50 N/mm (88.51 lb/in) (1.58 kgf/mm)
Spring rate K2 (intake) 20.18 N/mm (115.23 lb/in) (2.06 kgf/mm)
Spring rate K1 (exhaust) 15.50 N/mm (88.51 lb/in) (1.58 kgf/mm)
Spring rate K2 (exhaust) 20.18 N/mm (115.23 lb/in) (2.06 kgf/mm)
Installed compression spring force (intake) 138.00–158.00 N (31.02–35.52 lbf) (14.07–
16.11 kgf)
Installed compression spring force (exhaust) 138.00–158.00 N (31.02–35.52 lbf) (14.07–
16.11 kgf)
Spring tilt (intake) 2.5°/1.5 mm (2.5°/0.059 in )
Spring tilt (exhaust) 2.5°/1.5 mm (2.5°/0.059 in )
Winding direction (intake) Clockwise

Winding direction (exhaust) Clockwise
Cylinder
Bore 51.000–51.015 mm (2.0079–2.0085 in)
Wear limit 51.05 mm (2.010 in)
Measuring point H 40 mm ( 1.57 in)
Warp limit 0.05 mm (0.0020 in)
Piston
Piston-to-cylinder clearance 0.020–0.025 mm (0.0008–0.0010 in)
Limit 0.15 mm (0.0059 in)
Diameter D 50.977–50.992 mm (2.0070–2.0076 in)
Height H 5.0 mm (0.20 in)
H
D
Offset 0.50 mm (0.0197 in)

Offset direction Intake side
Piston pin bore inside diameter 13.002–13.013 mm (0.5119–0.5123 in)
Limit 13.043 mm (0.5135 in)
Piston pin outside diameter 12.996–13.000 mm (0.5117–0.5118 in)
Limit 12.976 mm (0.5109 in)
Piston-pin-to-piston-pin-bore clearance 0.002–0.017 mm (0.0001–0.0007 in)
Limit 0.067 mm (0.0026 in)
2-5
Piston ring
Top ring
Ring type Barrel
Dimensions (B × T) 1.00 × 2.00 mm (0.04 × 0.08 in)
B
T
End gap (installed) 0.10–0.25 mm (0.0039–0.0098 in)

Limit 0.40 mm (0.0157 in)
Ring side clearance 0.030–0.070 mm (0.0012–0.0028 in)
Limit 0.120 mm (0.0047 in)
2nd ring
Ring type Taper
B
T

Limit 0.40 mm (0.0157 in)
Ring side clearance 0.020–0.060 mm (0.0008–0.0024 in)
Limit 0.120 mm (0.0047 in)
Oil ring
B
T
Connecting rod
Small end inside diameter 13.015–13.028 mm (0.5124–0.5129 in)
Crankshaft
Width A 42.95–43.00 mm (1.691–1.693 in)
Runout limit C 0.030 mm (0.0012 in)
Big end side clearance D 0.110–0.410 mm (0.0043–0.0161 in)
Limit 0.50 mm (0.0197 in)
Big end radial clearance E 0.004–0.014 mm (0.00016–0.00055 in)
2-6
Clutch
Clutch type Wet, multiple-disc and centrifugal automatic
Clutch release method Inner push, cam push
Friction plate thickness 2.70–2.90 mm (0.106–0.114 in)
Wear limit 2.60 mm (0.1024 in)
Plate quantity 5 pcs
Clutch plate thickness 1.10–1.30 mm (0.043–0.051 in)
Plate quantity 4 pcs
Warpage limit 0.05 mm (0.0020 in)
Clutch spring free length 30.30 mm (1.19 in)
Minimum length 28.30 mm (1.11 in)
Spring quantity 4 pcs
Push rod bending limit 0.500 mm (0.0197 in)
Automatic centrifugal clutch

Clutch housing inside diameter 105.0 mm (4.13 in)
Limit 106.0 mm (4.17 in)
Weight outside diameter 105.0 mm (4.13 in)
Limit 103.8 mm (4.09 in)
Clutch-in revolution 1800–2200 r/min
Clutch-stall revolution 2800–3400 r/min
Transmission
Transmission type Constant mesh 4-speed
Primary reduction system Spur gear
Primary reduction ratio 67/18 (3.722)
Secondary reduction system Chain drive
Secondary reduction ratio 35/14 (2.500)
Operation Left foot operation
Gear ratio
1st 38/12 (3.166)
2nd 33/17 (1.941)
3rd 29/21 (1.380)
4th 23/21 (1.095)
Shifting mechanism
Shift mechanism type Shift drum and guide bar
Shift fork thickness 4.76–4.89 mm (0.1874–0.1925 in)
Kickstarter
Kickstarter type Ratchet
Kick clip friction force 5.88–14.71 N (1.32–3.31 lbf) (0.60–1.50 kgf)
Air filter
Air filter element Wet element
Air filter oil grade Yamaha foam air filter oil or other quality foam
air filter oil
Carburetor
Type × quantity VM16 × 1
Manufacturer MIKUNI
ID mark 5B61 00
2-7
Main jet #95

Main air jet 0.7
Jet needle 4E18–1
Needle jet E-3M
Pilot outlet 0.8 (pitch:2.0)
Pilot jet #12.5
Valve seat size 1.5
Starter jet 1 #37.5
Fuel level A (using fuel level gauge) 1.0–2.0 mm (0.04–0.08 in) (below the float
chamber mating surface)
Idling condition
Engine idling speed 1600–1800 r/min
CO% 5.0–7.0 %
Intake vacuum 34.7–40.0 kPa (10.2–11.8 inHg) (260–300
mmHg)
Oil temperature 75.0–85.0 °C (167.00–185.00 °F)
Throttle cable free play 4.0–6.0 mm (0.16–0.24 in)
2-8
CHASSIS SPECIFICATIONS
EAS20300
Chassis
Frame type Steel tube backbone
Caster angle 26.00°
Trail 60.0 mm (2.36 in)
Front wheel
Wheel type Spoke wheel
Rim size 14 × 1.40
Rim material Steel
Wheel travel 115.0 mm (4.53 in)
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Rear wheel
Wheel type Spoke wheel
Rim size 12 × 1.60
Rim material Steel
Wheel travel 110.0 mm (4.33 in)
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Front tire
Type With tube
Size 2.50–14 4PR
Manufacturer/model CHEN SHIN/C-803
Wear limit (front) 4.0 mm (0.16 in)
Rear tire
Type With tube
Size 3.00–12 4PR
Manufacturer/model CHEN SHIN/C-803
Wear limit (rear) 4.0 mm (0.16 in)
Tire air pressure (measured on cold tires)

Front 100 kPa (15 psi) (1.00 kgf/cm²)
Rear 100 kPa (15 psi) (1.00 kgf/cm²)
Front brake
Type Drum brake
Operation Right hand operation
Front brake lever free play 10.0–20.0 mm (0.39–0.79 in)
Front drum brake
Drum brake type Leading, trailing
Brake drum inside diameter 95.0 mm (3.74 in)
Limit 96.0 mm (3.78 in)
Lining thickness 3.0 mm (0.12 in)
Shoe spring free length 32.7 mm (1.29 in)
2-9
Rear brake
Type Drum brake
Operation Right foot operation
Brake pedal free play 10.0–20.0 mm (0.39–0.79 in)
Rear drum brake
Drum brake type Leading, trailing
Brake drum inside diameter 110.0 mm (4.33 in)
Limit 111.0 mm (4.37 in)
Lining thickness 4.0 mm (0.16 in)
Shoe spring free length 50.5 mm (1.99 in)
Steering
Steering bearing type Angular and taper roller bearings
Center to lock angle (left) 45.0°
Center to lock angle (right) 45.0°
No./size of steel balls
(Upper) 19 pcs
Front suspension
Type Telescopic fork
Spring/shock absorber type Coil spring/oil damper
Front fork travel 115.0 mm (4.53 in)
Fork spring free length 290.0 mm (11.42 in)
Limit 284.2 mm (11.19 in)
Installed length 270.4 mm (10.65 in)
Spring rate K1 4.02 N/mm (22.95 lb/in) (0.41 kgf/mm)
Spring stroke K1 0.0–115.0 mm (0.00–4.53 in)
Inner tube outer diameter 31.0 mm (1.22 in)
Optional spring available No
Recommended oil Fork oil 10W or equivalent
Quantity 179.0 cm³ (6.05 US oz) (6.31 Imp.oz)
Level 92.0 mm (3.62 in)
Rear suspension
Type Swingarm (monocross)
Spring/shock absorber type Coil spring/gas-oil damper
Rear shock absorber assembly travel 52.0 mm (2.05 in)
Spring free length 147.0 mm (5.79 in)
Limit 144.1 mm (5.67 in)
Installed length 141.0 mm (5.55 in)
Spring rate K1 55.00 N/mm (314.04 lb/in) (5.61 kgf/mm)
Spring stroke K1 0.0–52.0 mm (0.00–2.05 in)
Optional spring available No
Swingarm
Swingarm end free play limit (radial) 0 mm (0 in)
Swingarm end free play limit (axial) 0 mm (0 in)
Drive chain
Type/manufacturer 420/DAIDO
Link quantity 90
2-10
Drive chain slack 40.0–56.0 mm (1.57–2.20 in)

15-link length limit 194.3 mm (7.65 in)
2-11
ELECTRICAL SPECIFICATIONS
EAS20310
Voltage
System voltage 12 V
Ignition system
Ignition system DC-CDI
Advancer type Digital
Ignition timing (B.T.D.C.) 10.0°/1700 r/min
DC-CDI
Pickup coil resistance 248–372 Ω at 20 °C (68 °F)
CDI unit model/manufacturer 5B6–00/YAMAHA
Ignition coil
Model/manufacturer 2JN/YAMAHA
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 0.18–0.28 Ω at 20 °C (68 °F)
Secondary coil resistance 6.32–9.48 kΩ at 20 °C (68 °F)
Spark plug cap

Material Resin
Resistance 10.0 kΩ
AC magneto
Model/manufacturer F5TP/YAMAHA
Standard output 14.0 V, 100 W at 5000 r/min
Charging coil resistance 0.32–0.48 Ω at 20 °C (68 °F)
Lighting coil resistance 0.24–0.36 Ω at 20 °C (68 °F)
Rectifier/regulator
Regulator type Semi conductor-short circuit
Model/manufacturer SH671–12/SHINDENGEN
Regulated voltage (DC) 14.0–15.0 V
Regulated voltage (AC) 12.3–13.3 V
Rectifier capacity (DC) 8.0 A
Rectifier capacity (AC) 12.0 A
Battery
Model GT4B-5
Voltage, capacity 12 V, 2.5 Ah
Specific gravity 1.350
Manufacturer GS YUASA
Electric starting system

System type Constant mesh
Starter motor
Model/manufacturer 5B6/YAMAHA
Power output 0.35 kW
Armature coil resistance 0.0180–0.0220 Ω
Brush overall length 7.0 mm (0.28 in)
2-12
Limit 3.50 mm (0.14 in)

Brush spring force 3.92–5.88 N (14.11–21.17 oz) (400–600 gf)
Commutator diameter 17.6 mm (0.69 in)
Limit 16.6 mm (0.65 in)
Mica undercut (depth) 1.35 mm (0.05 in)
Starter relay
Model/manufacturer ACA12115–1/MATSUSHITA
Amperage 30.0 A
Coil resistance 72.00–88.00 Ω
Thermostat switch
Model/manufacturer 5FU/NIPPON THERMOSTAT
Carburetor warmer
Model/manufacturer 5FU/NIPPON THERMOSTAT
Resistance 3.20–5.77 Ω at 20 °C (68 °F)
Fuse
Fuse 10.0 A
Spare fuse 10.0 A
2-13
TIGHTENING TORQUES
EAS20320
TIGHTENING TORQUES
EAS20330
GENERAL TIGHTENING TORQUE

SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch.
Tightening torque specifications for special com-
ponents or assemblies are provided for each
chapter of this manual. To avoid warpage, tight-
en multi-fastener assemblies in a crisscross pat-
tern and progressive stages until the specified
tightening torque is reached. Unless otherwise
specified, tightening torque specifications re-
quire clean, dry threads. Components should be
at room temperature.
A. Distance between flats

B. Outside thread diameter
General tightening
A (nut) B (bolt) torques
Nm m·kg ft·lb
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
2-14
TIGHTENING TORQUES
EAS20340
ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Cylinder head nut M8 4 22 Nm (2.2 m·kg, 16 ft·lb) E
Cylinder head bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) E
Spark plug M10 1 13 Nm (1.3 m·kg, 9.4 ft·lb)

Camshaft sprocket cover bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Tappet cover (intake and ex-
M45 2 18 Nm (1.8 m·kg, 13 ft·lb)
haust)
Cylinder head stud bolt (exhaust
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
pipe)
AC magneto rotor nut M12 1 70 Nm (7.0 m·kg, 50 ft·lb)
Timing chain guide (intake side) M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Locknut (valve clearance adjust-

M5 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
ing screw)
Camshaft sprocket bolt M8 1 20 Nm (2.0 m·kg, 14 ft·lb)
Camshaft retainer bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Timing chain tensioner bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)

Oil pump screw M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Engine oil drain bolt M12 1 20 Nm (2.0 m·kg, 14 ft·lb)
Intake manifold bolt (cylinder
M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
head side)
Intake manifold bolt (carburetor
M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
side)
Air filter case assembly and
M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
frame screw
Exhaust pipe/muffler nut M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Exhaust pipe/muffler bolt M8 1 24 Nm (2.4 m·kg, 17 ft·lb)
Exhaust pipe/muffler protector
M6 9 8 Nm (0.8 m·kg, 5.8 ft·lb) LT
screw
Spark arrester bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb)
Crankcase bolt M6 9 10 Nm (1.0 m·kg, 7.2 ft·lb)
AC magneto cover bolt M6 8 10 Nm (1.0 m·kg, 7.2 ft·lb)
Drive sprocket cover bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Clutch cover bolt M6 9 10 Nm (1.0 m·kg, 7.2 ft·lb)
Crankshaft end cover M32 1 3 Nm (0.3 m·kg, 2.2 ft·lb)
Timing mark accessing screw M14 1 3 Nm (0.3 m·kg, 2.2 ft·lb)
Starter motor cover bolt M8 4 23 Nm (2.3 m·kg, 17 ft·lb)
Kickstarter lever bolt M6 1 13 Nm (1.3 m·kg, 9.4 ft·lb)
Starter clutch assembly bolt M6 3 14 Nm (1.4 m·kg, 10 ft·lb) Stake
Primary clutch housing nut M12 1 50 Nm (5.0 m·kg, 36 ft·lb)
Clutch spring bolt M5 4 6 Nm (0.6 m·kg, 4.3 ft·lb)
2-15
TIGHTENING TORQUES
Thread
size
Clutch boss nut M14 1 70 Nm (7.0 m·kg, 50 ft·lb)
Locknut (clutch release adjusting
M6 1 8 Nm (0.8 m·kg, 5.8 ft·lb)
screw)
Shift pedal bolt M6 1 10 Nm (1.0 m·kg, 7.2 ft·lb)
Shift drum segment screw M6 1 12 Nm (1.2 m·kg, 8.7 ft·lb) LT
Shift fork guide bar retainer bolt M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Pickup coil/stator assembly lead

M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
holder bolt
Neutral switch screw M5 2 4 Nm (0.4 m·kg, 2.9 ft·lb) LT
Stator coil bolt M6 3 10 Nm (1.0 m·kg, 7.2 ft·lb) LT
Apply
Carburetor warmer M8 1 3 Nm (0.3 m·kg, 2.2 ft·lb) HEAT
SINKER.
2-16
TIGHTENING TORQUES
EAS20350
CHASSIS TIGHTENING TORQUES

Thread
size
Engine mounting nut (front side) M8 1 22 Nm (2.2 m·kg, 16 ft·lb)
Engine mounting nut (rear upper
M8 1 22 Nm (2.2 m·kg, 16 ft·lb)
side)
Engine mounting nut (rear lower
M8 1 22 Nm (2.2 m·kg, 16 ft·lb)
side)
Pivot shaft nut M10 1 53 Nm (5.3 m·kg, 38 ft·lb)
Locknut (drive chain puller) M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Lower ring nut (initial tightening See
M25 1 38 Nm (3.8 m·kg, 27 ft·lb)
torque) NOTE.
Lower ring nut (final tightening See
M25 1 13 Nm (1.3 m·kg, 9.4 ft·lb)
torque) NOTE.
Steering stem nut M22 1 110 Nm (11.0 m·kg, 80 ft·lb)
Upper bracket pinch bolt M8 2 25 Nm (2.5 m·kg, 18 ft·lb)
Handlebar holder bolt M8 4 23 Nm (2.3 m·kg, 17 ft·lb)
Cable guide bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Front fender bracket bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Front fender bolt M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)
Number plate bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Lower bracket pinch bolt M10 2 33 Nm (3.3 m·kg, 24 ft·lb)
Damper rod bolt M8 2 20 Nm (2.0 m·kg, 14 ft·lb) LT
Front brake cable holder bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)

Fuel cock screw M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Fuel tank bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Fuel tank bracket bolt M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)
Seat holder screw M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Air scoop bolt M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)
Rear fender bolt M6 4 7 Nm (0.7 m·kg, 5.1 ft·lb)
Side cover bolt (front side) M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Side cover bolt (rear side) M6 2 11 Nm (1.1 m·kg, 8.0 ft·lb)
Battery box bolt M6 3 7 Nm (0.7 m·kg, 5.1 ft·lb)
Rectifier/regulator bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Ground lead screw M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Ignition coil bolt M6 2 7 Nm (0.7 m·kg, 5.1 ft·lb)
Front brake camshaft lever bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Rear brake camshaft lever bolt M6 1 7 Nm (0.7 m·kg, 5.1 ft·lb)
Front wheel axle nut M10 1 35 Nm (3.5 m·kg, 25 ft·lb)
Brake torque rod nut (rear side) M8 1 26 Nm (2.6 m·kg, 19 ft·lb)
Brake torque rod nut (front side) M8 1 16 Nm (1.6 m·kg, 11 ft·lb)
2-17
TIGHTENING TORQUES
Thread
size
Rear wheel sprocket bolt M8 4 32 Nm (3.2 m·kg, 23 ft·lb)
Rear wheel axle nut M12 1 60 Nm (6.0 m·kg, 43 ft·lb)
Footrest bracket bolt M8 4 23 Nm (2.3 m·kg, 17 ft·lb)
Sidestand nut M10 1 40 Nm (4.0 m·kg, 29 ft·lb)
Rear reflector bracket bolt (For
M6 2 10 Nm (1.0 m·kg, 7.2 ft·lb)
CDN)
NOTE:
1. First, tighten the lower 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 lower ring nut completely.
2. Retighten the lower ring nut 13 Nm (1.3 m·kg, 9.4 ft·lb).
2-18
LUBRICATION POINTS AND LUBRICANT TYPES
EAS20360

EAS20370
ENGINE
Lubrication point Lubricant
Oil seal lips LS
Bearings E
Cylinder head bolts, nuts, and washers E
O-ring (camshaft sprocket cover) LS
O-rings (intake and exhaust tappet covers) LS
Timing chain sprocket M
Crankshaft pin E
Connecting rod big end thrust surface E
Piston pin E
Piston surface and ring grooves E
Crankshaft end (primary clutch housing side) E
Camshaft lobes M
O-ring (camshaft) LS
Valve stems (intake and exhaust) E
Valve stem ends (intake and exhaust) E
Rocker arm outer surface E
Rocker arm inner surface M
O-ring (crankshaft end cover) LS
O-ring (timing mark accessing screw) LS
O-ring (oil level gauge) LS
Kickstarter gear E
Kickstarter shaft E
Starter clutch idle gear inner surface E
Starter clutch gear inner surface M
Starter clutch inner surface E
O-ring (starter motor) LS
Primary driven gear inner surface (clutch housing) E
Long clutch push rod LS
Short clutch push rod E
Primary drive gear inner surface (primary clutch housing) E
Primary clutch inner surface E
Clutch boss nut and lock washer E
Short clutch push rod bearing LS
2-19

Main and drive axle M
Shift drum assembly E
Shift fork guide bar E
Clutch release shift arm M
Shift shaft outer surface E
Thrust bearing (shift shaft) LS
O-ring (clutch adjusting screw) LS
O-ring (neutral switch) LS
Yamaha bond
Pickup coil/stator assembly grommet No.1215 (Three Bond
No.1215®)
Yamaha bond
Crankcase mating surface No.1215 (Three Bond
No.1215®)
Yamaha bond
Cylinder head bolts No.1215 (Three Bond
No.1215®)
Yamaha bond
Crankcase bolt No.1215 (Three Bond
No.1215®)
Yamaha bond
Starter motor cover bolts No.1215 (Three Bond
No.1215®)
2-20
EAS20380
CHASSIS
Steering bearings and ball race cover lip LS
Rear shock absorber pins LS
Pivot shaft LS
Front wheel oil seal lip LS
Front brake camshaft LS
Front wheel axle LS
Rear wheel oil seal lip LS
Rear brake camshaft LS
Rear wheel axle and O-ring LS
Throttle grip inner tube guide inner surface and throttle cable end LS
Brake lever pivot bolt LS
Brake pedal outer surface LS
Sidestand pivoting point and sidestand pivot bolt LS
2-21
2-22
LUBRICATION SYSTEM CHART AND DIAGRAMS
EAS20390

EAS20410
LUBRICATION DIAGRAMS
2-23
1. Camshaft
2. Rotary filter
3. Main axle
4. Drive axle
5. Crankshaft
2-24
2-25
1. Oil strainer
2. Rotary filter
3. Crankshaft
4. Oil pump
2-26
CABLE ROUTING
EAS20430
CABLE ROUTING
4
3 B
A
2 B
A
1 5
C 1
F
A
B C
2
D
3 7
E
6 A-A
G 11 12 13 H
B-B
I 14
N
3
J
K
16 8
15 L
10
M
2-27
CABLE ROUTING
1. Air vent hose

2. Wire harness
3. Starter cable
4. Fuel tank breather hose
5. Thermo switch
6. Spark plug lead
7. Thermo switch lead
8. Carburetor warmer lead
9. Carburetor overflow hose
10. Fuel hose
11. Throttle cable (decelerator cable)
12. Throttle cable (accelerator cable)
13. Front brake cable
14. Engine stop switch lead
15. Main switch lead
16. Start switch lead
A. 40–50 mm (1.57–1.97 in)
B. Pass the starter cable through the guide.
C. Route the thermo switch lead to the front of the
thermo switch stay.
D. Fasten the crankcase breather hose with the
holder. Fasten the hose only, not the hose
protector. Face the catch of the holder outward.
E. Fasten the spark plug lead with the holder on the
air filter case.
F. Fasten the thermo switch lead, wire harness, and
starter cable to the frame with the plastic band.
Position the buckle of the plastic band on the inner
side of the frame tube so that the end of the band
is facing inward, angle upward.
G. 30–40 mm (1.18–1.57 in)
H. 20–30 mm (0.79–1.18 in)
I. Fasten the engine stop switch lead with the plastic
bands.
J. Pass the throttle cables through the guides,
making sure to route the throttle cable (accelerator
cable) to the left of the throttle cable (decelerator
cable)
K. Route the engine stop switch lead to the outside of
the cable guide.
L. Be sure to connect the couplers of the same color.
M. Fasten the main switch lead, start switch lead, and
engine stop switch lead with a clamp.
N. Fasten the start switch lead with the plastic bands.
2-28
CABLE ROUTING
4
3
2
A
1 5
6
7
8
9 13 14
B 10 11 12
15
I A 16
A
B
F B 17
19
H 11
18
G
E
12 10 D C
K L M 9 8
J N 21
20 11 12 E 13 22 23
C D
11 12
F 14
D
11
12
C
10
10 S 5 25 6 R 24 F
Q P E 16 15
T O
26
A-A B-B
22 23 29 9 W
5 9
12 9
U 11
28
21 30
6 6
27 V 30
C-C D-D E-E F-F
2-29
CABLE ROUTING
1. Front brake cable L. Make sure that there is no slack in the wire
2. Throttle cable (decelerator cable) harness in the area shown in the illustration.
3. Throttle cable (accelerator cable) M. Be sure to connect the thermo switch coupler to
the rear of the air filter case assembly duct.
4. Engine stop switch lead
N. Pass the starter motor lead and AC magneto lead
5. Starter cable through the guide on the battery box, and then
6. Air vent hose route the leads over the wire harness. Be sure to
7. Fuel hose pass the leads to the right of the wire harness
before routing them over the harness.
8. Ignition coil
O. Pass the AC magneto leads through the guide on
9. Wire harness the battery box.
10. Neutral switch lead P. Fasten the starter motor lead and starter relay lead
11. Starter motor lead with the plastic band, making sure to position the
12. AC magneto lead band 20–30 mm (0.79–1.18 in) from the starter
relay coupler.
13. Starter relay
Q. Place the slack in the wire harness in the area
14. CDI unit shown in the illustration.
15. Rectifier/regulator R. Make sure that the air vent hose is not slack or
16. Ground lead bent.
17. Battery S. Fasten the wire harness by sliding the plastic
18. Carburetor overflow hose holder on the wire harness onto the stud on the
frame.
19. Carburetor warmer
T. Face the catch of the neutral switch coupler
20. Thermo switch forward or rearward.
21. Starter relay lead U. Make sure that the wire harness or coupler does
22. CDI unit lead not deform the damper.
23. Rectifier/regulator lead V. Fasten the starter motor lead and starter relay lead
24. Spark plug lead with the plastic band, making sure to route the
starter motor lead to the inside of the starter relay
25. Carburetor warmer lead lead. Face the buckle of the plastic band outward
26. Spare fuse and place the end of the band between the wire
27. Crankcase breather hose harness and the battery box.
28. Thermo switch coupler W. Insert the projection on the wire harness holder
completely into the hole in the battery box.
29. Starter motor coupler
30. AC magneto coupler
A. Route the front brake cable to the front of the
number plate.
B. Fasten the wire harness with a plastic locking tie.
Face the end of the plastic locking tie downward,
and then cut off the excess end of the tie.
C. Fasten the neutral switch lead, AC magneto lead,
and starter motor lead with a plastic locking tie,
making sure to align the tie with the bottom of the
frame tube. Face the end of the plastic locking tie
rearward, and then cut off the excess end of the tie.
D. Place the slack in the neutral switch lead and AC
magneto lead in the area shown in the illustration.
E. Fasten the neutral switch lead and AC magneto
lead with a plastic locking tie. Face the end of the
plastic locking tie inward, and then cut off the
excess end of the tie.
F. 20–30 mm (0.79–1.18 in)
G. Face the catch of the holder outward.
H. Pass the air vent hose through the guide.
I. Pass the throttle cable (decelerator cable) through
the upper portion of the guide and pass the throttle
cable (accelerator cable) and wire harness through
the lower portion of the guide.
J. Fasten the thermo switch lead, carburetor warmer
lead, wire harness, and starter cable with a plastic
locking tie. Position the end of the plastic locking tie
to the inside of the damper, and then cut off the
excess end of the tie. Make sure that the end of the
plastic locking tie does not contact the air filter
case assembly.
K. Make sure that the wire harness does not deform
the damper.
2-30
CABLE ROUTING
2-31
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE ............................................................................ 3-1

INTRODUCTION ....................................................................................... 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM ................................................................................................... 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART ....................... 3-1
ENGINE ........................................................................................................... 3-3

ADJUSTING THE VALVE CLEARANCE .................................................. 3-3
ADJUSTING THE ENGINE IDLING SPEED ............................................. 3-5
ADJUSTING THE THROTTLE CABLE FREE PLAY ................................ 3-5
CHECKING THE SPARK PLUG ............................................................... 3-6
CHECKING THE IGNITION TIMING......................................................... 3-7
MEASURING THE COMPRESSION PRESSURE.................................... 3-7
CHECKING THE ENGINE OIL LEVEL...................................................... 3-8
CHANGING THE ENGINE OIL ................................................................. 3-9 3
CLEANING THE AIR FILTER ELEMENT................................................ 3-10
CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD...... 3-11
CHECKING THE FUEL LINE .................................................................. 3-11
CHECKING THE CRANKCASE BREATHER HOSE .............................. 3-11
CHECKING THE EXHAUST SYSTEM.................................................... 3-12
CLEANING THE SPARK ARRESTER .................................................... 3-12
CHASSIS ....................................................................................................... 3-13

ADJUSTING THE FRONT DRUM BRAKE.............................................. 3-13
ADJUSTING THE REAR DRUM BRAKE ................................................ 3-13
CHECKING THE FRONT BRAKE SHOES ............................................. 3-14
CHECKING THE REAR BRAKE SHOES................................................ 3-14
ADJUSTING THE DRIVE CHAIN SLACK ............................................... 3-14
LUBRICATING THE DRIVE CHAIN ........................................................ 3-15
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-15
CHECKING THE FRONT FORK ............................................................. 3-16
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY.................. 3-17
CHECKING THE TIRES.......................................................................... 3-17
CHECKING THE WHEELS ..................................................................... 3-19
CHECKING AND TIGHTENING THE SPOKES...................................... 3-19
CHECKING AND LUBRICATING THE CABLES .................................... 3-19
LUBRICATING THE BRAKE LEVER ...................................................... 3-19
LUBRICATING THE BRAKE PEDAL ...................................................... 3-20
LUBRICATING THE SIDESTAND........................................................... 3-20
LUBRICATING THE REAR SUSPENSION............................................. 3-20
ELECTRICAL SYSTEM................................................................................. 3-21

CHECKING AND CHARGING THE BATTERY....................................... 3-21
CHECKING THE FUSES ........................................................................ 3-21
PERIODIC MAINTENANCE
EAS20450
EAS20460
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments. If
followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a long-
er service life and reduce the need for costly overhaul work. This information applies to vehicles already
in service as well as to new vehicles that are being prepared for sale. All service technicians should be
familiar with this entire chapter.
EAU39943
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

NOTE:
• From 7000 km (4200 mi) or 18 months, repeat the maintenance intervals starting from 3000 km (1800
mi) or 6 months.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
INITIAL ODOMETER READINGS

1000 km 3000 km 5000 km
No. ITEM CHECKS AND MAINTENANCE JOBS (600 mi) or (1800 mi) or (3000 mi) or
1 month or 6 months or 12 months or
30 hours 90 hours 150 hours
• Check fuel hoses for cracks or damage.
1 * Fuel line √ √
• Replace if necessary.
• Check condition.
2 Spark plug • Adjust gap and clean. √ √
3 * Valve clearance • Check and adjust valve clearance when engine is √

cold.
• Clean with solvent.
4 * Air filter element √ √
• Check ventilation hose for cracks or damage and
5 * Crankcase breather drain any deposits. √ √ √
system
• Check engine idling speed and starter operation.
6 * Carburetor • Adjust if necessary. √ √ √
• Check for leakage.
7 Exhaust system • Tighten if necessary. √ √
• Replace gasket(s) if necessary.
8 Engine oil • Change (warm engine before draining). √ √ √
EAU35348
GENERAL MAINTENANCE AND LUBRICATION CHART

1000 km 3000 km 5000 km
• Check operation.
1 * Clutch √ √ √
• Adjust if necessary.
2 * Front brake • Adjust brake lever free play and replace brake √ √ √
shoes if necessary.
3 * Rear brake • Adjust brake pedal free play and replace brake √ √ √
shoes if necessary.
• Check runout, spoke tightness and for damage.
4 * Wheels • Tighten spokes if necessary. √ √ √
• Check tread depth and for damage.
5 * Tires • Check air pressure. √ √
• Correct if necessary.
• Check bearings for smooth operation.
6 * Wheel bearings • Replace if necessary. √ √
3-1

1000 km 3000 km 5000 km
Swingarm pivot bear- • Check bearing assemblies for looseness.
7 * √ √
ings • Moderately repack with lithium-soap-based grease.
• Check chain slack/alignment and condition.
8 Drive chain • Adjust and lubricate chain with Yamaha chain and Every ride
cable lube thoroughly.
• Check bearing assemblies for looseness.
9 * Steering bearings √ √
• Moderately repack with lithium-soap-based grease.
• Check all chassis fitting and fasteners.
10 * Chassis fasteners • Correct if necessary. √ √ √
11 Brake lever pivot shaft • Apply lithium-soap-based grease lightly. √ √
12 Brake pedal pivot shaft • Apply lithium-soap-based grease lightly. √ √
13 Sidestand pivot √ √
• Apply lithium-soap-based grease lightly.
14 * Spark arrester • Clean. √
• Check operation and for oil leakage.
15 * Front fork √ √
Shock absorber as- • Check operation and for oil leakage.
16 * sembly • Replace if necessary. √
17 * Control cables • Apply Yamaha chain and cable lube or engine oil √ √ √
10W-30 thoroughly.
• Check operation and free play.
Throttle grip housing
18 * and cable • Adjust the throttle cable free play if necessary. √ √ √
• Lubricate the throttle grip housing and cable.
EAU40000
NOTE:
The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
3-2
ENGINE
EAS20471
ENGINE Valve clearance (cold)

Intake
EAS20520
0.05–0.09 mm (0.0020–0.0035 in)
ADJUSTING THE VALVE CLEARANCE Exhaust
The following procedure applies to all of the 0.08–0.12 mm (0.0032–0.0047 in)
valves.
NOTE: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Valve clearance adjustment should be made a. Turn the crankshaft counterclockwise.
on a cold engine, at room temperature. b. When the piston is at TDC on the compres-
• When the valve clearance is to be measured or sion stroke, align the “I” mark “a” on the cam-
adjusted, the piston must be at the top dead shaft sprocket with the stationary pointer “b”
center (TDC) on the compression stroke. on the cylinder head.
1. Remove:
• Seat
• Right air scoop a
• Left air scoop
Refer to “GENERAL CHASSIS” on page 4-1. b
• Fuel tank
• Air filter case assembly
Refer to “FUEL TANK” on page 6-1.
2. Remove:
• Intake tappet cover “1” c. Align the “I” mark “c” on the AC magneto rotor
• Exhaust tappet cover “2” with the stationary pointer “d” on the AC mag-
• Camshaft sprocket cover “3” neto cover.
1
c d
3. Remove: d. Measure the valve clearance with a thickness

• Timing mark accessing screw “1” gauge “1”.
• Crankshaft end cover “2” Out of specification → Adjust.
• O-rings
Thickness gauge
90890-03180
Feeler gauge set
YU-26900-9
4. Measure:
• Valve clearance
Out of specification → Adjust.
3-3
ENGINE
• Hold the adjusting screw to prevent it from

1 moving and tighten the locknut to specifica-
tion.
Locknut
7 Nm (0.7 m·kg, 5.1 ft·lb)
T.
R.
d. Measure the valve clearance again.
e. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance adjust-
ment steps until the specified clearance is
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ obtained.
5. Adjust: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Valve clearance 6. Install:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “1”. • Crankshaft end cover
b. Insert a thickness gauge “2” between the end (along with the O-ring)
of the adjusting screw and the valve tip. • Timing mark accessing screw
(along with the O-ring)
1 2 NOTE:
Apply lithium-soap-based grease onto the O-
rings.
Crankshaft end cover

3 Nm (0.3 m·kg, 2.2 ft·lb)
T.
R.
Timing mark accessing screw

3 Nm (0.3 m·kg, 2.2 ft·lb)
c. Turn the adjusting screw “3” in direction “a” or 7. Install:

“b” with the tappet adjusting tool “4” until the • Camshaft sprocket cover
specified valve clearance is obtained. (along with the O-ring New )
• Exhaust tappet cover
4 (along with the O-ring New )
• Intake tappet cover
b 3
(along with the O-ring New )
NOTE:
a Apply lithium-soap-based grease onto the O-
rings.
Camshaft sprocket cover screw

7 Nm (0.7 m·kg, 5.1 ft·lb)
T.
R.
Direction “a” Exhaust tappet cover

Valve clearance is increased. 18 Nm (1.8 m·kg, 13 ft·lb)
Direction “b” Intake tappet cover
Valve clearance is decreased. 18 Nm (1.8 m·kg, 13 ft·lb)
8. Install:
Tappet adjusting tool • Air filter case assembly
90890-01311 • Fuel tank
Six piece tappet set Refer to “FUEL TANK” on page 6-1.
YM-A5970 • Left air scoop
• Right air scoop
3-4
ENGINE
• Seat
Refer to “GENERAL CHASSIS” on page 4-1. Throttle cable free play
4.0–6.0 mm (0.16–0.24 in)
EAS20620
ADJUSTING THE ENGINE IDLING SPEED EAS20640
NOTE: ADJUSTING THE THROTTLE CABLE FREE

Prior to adjusting the engine idling speed, the air PLAY
filter element should be clean, and the engine NOTE:
should have adequate compression. Prior to adjusting the throttle cable free play, the
1. Start the engine and let it warm up for several engine idling speed should be adjusted properly.
minutes. 1. Check:
2. Connect: • Throttle cable free play “a”
• Digital tachometer Out of specification → Adjust.
(onto the spark plug lead)
Digital tachometer
90890-06760
YU-39951-B
3. Check: a
• Engine idling speed
Engine idling speed

1600–1800 r/min
Throttle cable free play
4. Adjust: 4.0–6.0 mm (0.16–0.24 in)
• Engine idling speed
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 2. Remove:
a. Turn the throttle stop screw “1” in direction “a” • Seat
or “b” until the specified engine idling speed is • Left air scoop
obtained. Refer to “GENERAL CHASSIS” on page 4-1.
3. Adjust:
Direction “a” • Throttle cable free play
Engine idling speed is increased.
Direction “b” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Engine idling speed is decreased. Carburetor side
a. Slide back the rubber cover.
b. Loosen the locknut “1”.
1 c. Turn the adjusting nut “2” in direction “a” or “b”
until the specified throttle cable free play is
b obtained.
a Direction “a”
Throttle cable free play is increased.
Direction “b”
Throttle cable free play is decreased.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Adjust:
• Throttle cable free play
Refer to “ADJUSTING THE THROTTLE CA-
BLE FREE PLAY” on page 3-5.
3-5
ENGINE
4. Install:
b 2
1 • Left air scoop
• Seat
Refer to “GENERAL CHASSIS” on page 4-1.
a
EAS20690
CHECKING THE SPARK PLUG

1. Disconnect:
• Spark plug cap
2. Remove:
• Spark plug
d. Tighten the locknuts “1”. ECA13330
e. Slide the rubber cover to its original position. CAUTION:

NOTE: Before removing the spark plug, blow away
If the specified throttle cable free play cannot be any dirt accumulated in the spark plug well
obtained on the carburetor side of the cable, use with compressed air to prevent it from falling
the adjusting nut on the handlebar side. into the cylinder.
3. Check:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Spark plug type
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Incorrect → Change.
Handlebar side
a. Slide back the rubber cover. Manufacturer/model
b. Loosen the locknut “1”. NGK/CR6HSA
c. Turn the adjusting nut “2” in direction “a” or “b”
until the specified throttle cable free play is 4. Check:
obtained. • Electrode “1”
Damage/wear → Replace the spark plug.
• Insulator “2”
Abnormal color → Replace the spark plug.
2 a
Normal color is medium-to-light tan.
1 5. Clean:
• Spark plug
b (with a spark plug cleaner or wire brush)
6. Measure:
• Spark plug gap “a”
(with a wire thickness gauge)
Out of specification → Regap.
Direction “a”
Spark plug gap
Throttle cable free play is increased.
0.6–0.7 mm (0.024–0.028 in)
Direction “b”
Throttle cable free play is decreased.
d. Tighten the locknut “1”.

e. Slide the rubber cover to its original position.
EWA12920
WARNING
After adjusting the throttle cable free play,
start the engine and turn the handlebars to
the right and to the left to ensure that this
does not cause the engine idling speed to
change.
7. Install:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Spark plug
3-6
ENGINE
NOTE:
Spark plug
13 Nm (1.3 m·kg, 9.4 ft·lb) The ignition timing is not adjustable.
T.
R.
NOTE:
Before installing the spark plug, clean the spark a
plug and gasket surface.
8. Connect: b
• Spark plug cap
EAS20700
CHECKING THE IGNITION TIMING

NOTE:
Prior to checking the ignition timing, check the ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
wiring connections of the entire ignition system. 4. Disconnect:
Make sure all connections are tight and free of • Digital tachometer
corrosion. • Timing light
1. Remove: 5. Install:
• Timing mark accessing screw “1” • Timing mark accessing screw
EAS20710
MEASURING THE COMPRESSION

PRESSURE
NOTE:
Insufficient compression pressure will result in a
loss of performance.
1 1. Measure:
• Valve clearance
2. Connect: Refer to “ADJUSTING THE VALVE CLEAR-
• Timing light ANCE” on page 3-3.
• Digital tachometer 2. Start the engine, warm it up for several min-
utes, and then turn it off.
Timing light 3. Disconnect:
90890-03141 • Spark plug cap
Inductive clamp timing light 4. Remove:
YU-03141 • Spark plug
ECA5B61002
3. Check: CAUTION:
• Ignition timing Before removing the spark plug, use com-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ pressed air to blow away any dirt accumulat-
a. Start the engine, warm it up for several min- ed in the spark plug wells to prevent it from
utes, and then let it run at the specified en-
falling into the cylinder.
gine idling speed.
5. Install:
Engine idling speed • Compression gauge “1”
1600–1800 r/min
Compression gauge
b. Check that the stationary pointer “a” on the 90890-03081
AC magneto cover is within the firing range Engine compression tester
“b” on the AC magneto rotor. YU-33223
Incorrect firing range → Check the ignition
system.
3-7
ENGINE
Compression pressure (with oil applied into

1 the cylinder)
Reading Diagnosis
Higher than without Piston ring(s) wear or
oil damage → Repair.
Piston, valves, cylin-
der head gasket or
Same as without oil piston ring(s) possi-
bly defective → Re-
pair.
6. Measure:
• Compression pressure ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Out of specification → Refer to steps (c) and
7. Install:
(d).
• Spark plug
Standard compression pressure
Spark plug
(at sea level)
13 Nm (1.3 m·kg, 9.4 ft·lb)
T.
1300 kPa/500 r/min (185 psi/500
R.
r/min) (13.0 kgf/cm²/500 r/min)
8. Connect:
Minimum–maximum
1130–1460 kPa (161–208 psi) • Spark plug cap
(11.3–14.6 kgf/cm²) EAS5B61024
CHECKING THE ENGINE OIL LEVEL

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1. Stand the vehicle on a level surface.
a. Set the main switch to “ON”.
NOTE:
b. With the throttle wide open, crank the engine
or kick the kickstarter lever until the reading • Place the vehicle on a suitable stand.
on the compression gauge stabilizes. • Make sure the vehicle is upright.
EWA5B61001
2. Start the engine, warm it up for several min-
WARNING
To prevent sparking, ground the spark plug 3. Check:
lead before cranking the engine or kicking • Engine oil level
the kickstarter lever. The engine oil level should be between the
c. If the compression pressure is above the minimum level mark “a” and maximum level
maximum specification, check the cylinder mark “b”.
head, valve surfaces and piston crown for Below the minimum level mark → Add the
carbon deposits. recommended engine oil to the proper level.
Carbon deposits → Eliminate. NOTE:
d. If the compression pressure is below the min- • Before checking the engine oil level, wait a few
imum specification, pour a teaspoonful of en- minutes until the oil has settled.
gine oil into the spark plug bore and measure • Do not screw the dipstick “1” in when checking
again. the oil level.
Refer to the following table.
b
a
3-8
ENGINE
Type
SAE 10W-30, SAE 10W-40,
SAE15W-40, SAE 20W-40 or
SAE 20W-50 (Europe) (Oceania)
YAMALUBE 4(10W-30) or SAE
10W-30, YAMALUBE 4(20W-40)
or SAE 20W-40 (CDN)
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
4. Start the engine, warm it up for several min-
A utes, and then turn it off.
0 10 30 50 70 90 110 130 ˚F 5. Check the engine oil level again.
NOTE:
YAMALUBE 4 (10W-30)
or SAE 10W-30 Before checking the engine oil level, wait a few
minutes until the oil has settled.
YAMALUBE 4 (20W-40)
or SAE 20W-40
EAS20800
CHANGING THE ENGINE OIL

–20 –10 0 10 20 30 40 50 ˚C 1. Start the engine, warm it up for several min-
B -20 -10 0 10 20 30 40 50 ˚C 2. Place a container under the engine oil drain
SAE 10W-30
bolt.
3. Remove:
SAE 10W-40
• Dipstick “1”
SAE 10W-50
SAE 15W-40
SAE 20W-40
1
SAE 20W-50
A. For CDN
B. For Europe and Oceania
ECA5B61017
CAUTION:
• Engine oil also lubricates the clutch and the
4. Remove:
wrong oil types or additives could cause
• Engine oil drain bolt “1”
clutch slippage. Therefore, do not add any
(along with the gasket)
chemical additives or use engine oils with a
grade of CD “a” or higher and do not use
oils labeled “ENERGY CONSERVING II”
“b”.
• Do not allow foreign materials to enter the
crankcase.
5. Drain:
• Engine oil
(completely from the crankcase)
3-9
ENGINE
6. Check: 2. Remove:
• Engine oil drain bolt gasket • Air filter case cover “1”
Damage → Replace. • Air filter element
7. Install: • Air filter mesh
• Engine oil drain bolt
Engine oil drain bolt

20 Nm (2.0 m·kg, 14 ft·lb)
T.
R.
8. Fill:
• Crankcase
(with the specified amount of the recom- 1
mended engine oil)
Engine oil quantity 3. Clean:

Total amount • Air filter element
1.00 L (1.06 US qt) (0.88 Imp.qt) • Air filter mesh
Periodic oil change (with solvent)
0.80 L (0.85 US qt) (0.70 Imp.qt)
9. Install:
• Dipstick
10.Start the engine, warm it up for several min-
11.Check:
• Engine
(for engine oil leaks)
12.Check:
• Engine oil level EWA13020
Refer to “CHECKING THE ENGINE OIL WARNING

LEVEL” on page 3-8. Never use low flash point solvents, such as
EAS20941 gasoline, to clean the air filter element. Such
CLEANING THE AIR FILTER ELEMENT solvents may cause a fire or an explosion.
NOTE:
NOTE:
On the bottom of the air filter case are two check
After cleaning, gently squeeze the air filter ele-
hoses “1”. If dust or water or both collects in
ment to remove the excess solvent.
these hoses, clean the air filter element and air
ECA13430
filter case.
CAUTION:
Do not twist the air filter element when
squeezing it.
4. Check:
• Air filter element
• Air filter mesh
Damage → Replace.
1
1. Remove:
• Seat
• Right air scoop
3-10
ENGINE
5. Apply the recommended oil to the entire sur- 3. Install:

face of the air filter element and squeeze out • Left air scoop
the excess oil. The air filter element should be • Seat
wet but not dripping. Refer to “GENERAL CHASSIS” on page 4-1.
Air filter oil grade EAS21030
Yamaha foam air filter oil or oth- CHECKING THE FUEL LINE
er quality foam air filter oil 1. Remove:
• Seat
6. Install: • Left air scoop
• Air filter mesh Refer to “GENERAL CHASSIS” on page 4-1.
• Air filter element 2. Check:
• Air filter case cover • Fuel hose
ECA5B61003 • Fuel tank breather hose
CAUTION: Cracks/damage → Replace.
Never operate the engine without the air filter Loose connection → Connect properly.
element installed. Unfiltered air will cause ECA14940
rapid wear of engine parts and may damage CAUTION:

the engine. Operating the engine without the Make sure the fuel tank breather hose is rout-
air filter element will also affect carburetor ed correctly.
tuning, leading to poor engine performance 3. Install:
and possible overheating. • Left air scoop
NOTE: • Seat
Make sure that the spark plug lead is routed cor-
rectly. EAS21070
CHECKING THE CRANKCASE BREATHER

7. Install: HOSE
• Right air scoop 1. Remove:
• Seat • Seat
Refer to “GENERAL CHASSIS” on page 4-1. • Right air scoop
EAS20990 Refer to “GENERAL CHASSIS” on page 4-1.
CHECKING THE CARBURETOR JOINT AND 2. Check:
INTAKE MANIFOLD • Crankcase breather hose “1”
1. Remove: Cracks/damage → Replace.
• Seat Loose connection → Connect properly.
• Left air scoop ECA13450
Refer to “GENERAL CHASSIS” on page 4-1. CAUTION:

2. Check: Make sure the crankcase breather hose is
• Carburetor joint “1” routed correctly.
• Intake manifold “2”
Cracks/damage → Replace. 1
Refer to “CARBURETOR” on page 6-3.
3. Install:
1 • Right air scoop
• Seat
3-11
ENGINE
EAS21080
• Always let the exhaust system cool before
CHECKING THE EXHAUST SYSTEM
performing this operation.
1. Remove:
• Do not start the engine when removing the
• Right side cover
tailpipe from the muffler.
2. Check: a. Remove the spark arrester bolts “1”.
• Exhaust pipe/muffler “1”
Cracks/damage → Replace.
• Gasket “2”
Exhaust gas leaks → Replace.
3. Check:
Tightening torque 1
• Exhaust pipe nuts “3”
• Muffler bolt “4”
Exhaust pipe nut

7 Nm (0.7 m·kg, 5.1 ft·lb) b. Remove the tailpipe “2” by pulling it out of the
T.
R.
Muffler bolt muffler.

24 Nm (2.4 m·kg, 17 ft·lb)
1 c. Tap the tailpipe lightly with a soft-face ham-

mer or suitable tool, then use a wire brush to
remove any carbon deposits from the spark
arrester portion of the tailpipe and inside of
the tailpipe housing.
2 d. Insert the tailpipe into the muffler and align
the bolt holes.
3
e. Insert the spark arrester bolts and tighten
them.
3
Spark arrester bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
4. Install: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Right side cover
EAS28970
CLEANING THE SPARK ARRESTER

1. Clean:
• Spark arrester
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EWA14680
WARNING
• Select a well-ventilated area free of com-
bustible materials.
3-12
CHASSIS
EAS21140
NOTE:
CHASSIS
If the specified brake lever free play cannot be
EAS21181 obtained on the handlebar side of the brake ca-
ADJUSTING THE FRONT DRUM BRAKE ble, use the adjusting nut on the wheel side.
1. Check:
• Brake lever free play “a” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Out of specification → Adjust. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Wheel side
Front brake lever free play a. Loosen the locknut “1”.
10.0–20.0 mm (0.39–0.79 in) b. Turn the adjusting bolt “2” in direction “a” or
“b” until the specified brake lever free play is
obtained.
a
Direction “a”
Brake lever free play is increased.
Direction “b”
Brake lever free play is decreased.
2 a
2. Adjust: 1
• Brake lever free play b
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Handlebar side
a. Slide back the rubber cover.
b. Loosen the locknut “1”.
c. Turn the adjusting bolt “2” in direction “a” or c. Tighten the locknut.
“b” until the specified brake lever free play is ECA5B61004
obtained. CAUTION:
After adjusting the brake lever free play,
Direction “a” make sure there is no brake drag.
Brake lever free play is increased.
Direction “b” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Brake lever free play is decreased. EAS21220
ADJUSTING THE REAR DRUM BRAKE

1. Check:
2 1 • Brake pedal free play “a”
b
Brake pedal free play

a 10.0–20.0 mm (0.39–0.79 in)
d. Tighten the locknut.

e. Slide the rubber cover to its original position.
ECA5B61004
CAUTION:
After adjusting the brake lever free play, a
make sure there is no brake drag.
3-13
CHASSIS
2. Adjust:
• Brake pedal free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a
a. Turn the adjusting nut “1” in direction “a” or “b”
until the specified brake pedal free play is ob-
tained. 1
Direction “a”
Brake pedal free play is increased.
Direction “b”
Brake pedal free play is decreased.
EAS21410
ADJUSTING THE DRIVE CHAIN SLACK

ECA13550
CAUTION:
A drive chain that is too tight will overload
1
the engine and other vital parts, and one that
is too loose can skip and damage the swing-
arm or cause an accident. Therefore, keep
a the drive chain slack within the specified lim-
its.
b
1. Stand the vehicle on a level surface.
ECA13520 EWA13120
CAUTION: WARNING
After adjusting the brake pedal position and Securely support the vehicle so that there is
free play, make sure there is no brake drag. no danger of it falling over.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ NOTE:
EAS21300 Place the vehicle on a suitable stand so that the
CHECKING THE FRONT BRAKE SHOES rear wheel is elevated.
1. Operate the brake.
2. Check:
2. Check:
• Drive chain slack “a”
• Brake shoe wear indicator “1”
Reaches the wear limit line “a” → Replace the
brake shoes as a set. Drive chain slack
Refer to “FRONT BRAKE” on page 4-11. 40–56 mm (1.57–2.20 in)
1
NOTE:
a Measure the drive chain slack halfway between
the drive axle and the rear wheel axle.
EAS21310
CHECKING THE REAR BRAKE SHOES

1. Operate the brake. a
2. Check:
Reaches the wear limit line “a” → Replace the 3. Adjust:
brake shoes as a set. • Drive chain slack
Refer to “REAR BRAKE” on page 4-14.
3-14
CHASSIS
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the cotter pin “1”. Brake torque rod nut
b. Loosen the brake torque rod nut “2”. 26 Nm (2.6 m·kg, 19 ft·lb)
T.
R.
c. Loosen the adjusting nut “3”.
j. Install the new cotter pin.
EWA5B61002
WARNING
Always use a new cotter pin.
3 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2 1 4. Adjust:
Refer to “ADJUSTING THE REAR DRUM
BRAKE” on page 3-13.
EAS21450
d. Loosen the rear wheel axle nut “4”. LUBRICATING THE DRIVE CHAIN
e. Loosen both locknuts “5”. The drive chain consists of many interacting
f. Turn both adjusting nuts “6” in direction “a” or parts. If the drive chain is not maintained proper-
“b” until the specified drive chain slack is ob- ly, it will wear out quickly. Therefore, the drive
tained. chain should be serviced, especially when the
vehicle is used in dusty areas.
Direction “a”
Use only kerosene to clean the drive chain.
Drive chain is tightened.
Direction “b” Wipe the drive chain dry and thoroughly lubri-
Drive chain is loosened. cate it with engine oil or chain lubricant that is
suitable for non-O-ring chains.
NOTE: Recommended lubricant
Using the alignment marks “7” on each side of Engine oil or chain lubricant
the swingarm, make sure that both drive chain suitable for non-O-ring chains
pullers are in the same position for proper wheel
alignment. EAS21510
CHECKING AND ADJUSTING THE

STEERING HEAD
EWA13120
7 WARNING
a Securely support the vehicle so that there is
no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that the
4 6 5 b front wheel is elevated.
g. Tighten the rear wheel axle nut to specifica- 2. Check:
tion. • Steering head
Grasp the bottom of the front fork legs and
Rear wheel axle nut
60 Nm (6.0 m·kg, 43 ft·lb) gently rock the front fork.
Binding/looseness → Adjust the steering
T.
R.
h. Tighten both locknuts to specification. head.

3. Remove:
Locknut (drive chain puller) • Upper bracket
7 Nm (0.7 m·kg, 5.1 ft·lb) Refer to “STEERING HEAD” on page 4-29.
T.
R.
4. Adjust:
i. Tighten the brake torque rod nut to specifica- • Steering head
tion.
3-15
CHASSIS
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ e. Check the steering head for looseness or

a. Remove the lock washer “1”, the upper ring binding by turning the front fork all the way in
nut “2”, and the rubber washer “3”. both directions. If any binding is felt, remove
b. Loosen the lower ring nut “4” with the steering the lower bracket and check the upper and
nut wrench “5”. lower bearings.
Refer to “STEERING HEAD” on page 4-29.
Steering nut wrench
f. Install the rubber washer “3”.
90890-01403
Spanner wrench g. Install the upper ring nut “2”.
YU-33975 h. Finger tighten the upper ring nut, then align
the slots of both ring nuts. If necessary, hold
the lower ring nut and tighten the upper ring
nut until their slots are aligned.
i. Install the lock washer “1”.
1 NOTE:
2
Make sure the lock washer tabs “a” sit correctly
3 5 in the ring nut slots “b”.
4
4
3 1
a
c. Tighten the lower ring nut “4” with the steering
nut wrench “5”.
NOTE:
Set a torque wrench at a right angle to the steer-
2
ing nut wrench.
b
Lower ring nut (initial tightening
torque) ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
T.
R.
38 Nm (3.8 m·kg, 27 ft·lb) 5. Install:

• Upper bracket
Refer to “STEERING HEAD” on page 4-29.
EAS21530
CHECKING THE FRONT FORK

EWA13120
WARNING
Securely support the vehicle so that there is
2. Check:
• Inner tube
d. Loosen the lower ring nut completely, and
Damage/scratches → Replace.
then tighten it to specification with a steering
• Oil seal
nut wrench.
EWA13140
Oil leakage → Replace.
WARNING 3. Hold the vehicle upright and apply the front
brake.
Do not overtighten the lower ring nut.
4. Check:
• Front fork operation
Lower ring nut (final tightening Push down hard on the handlebar several
torque)
T.
times and check if the front fork rebounds

R.
13 Nm (1.3 m·kg, 9.4 ft·lb)

smoothly.
Rough movement → Repair.
Refer to “FRONT FORK” on page 4-21.
3-16
CHASSIS
EAS21590
d. While compressing the spring, install the
ADJUSTING THE REAR SHOCK ABSORBER spring guide.
ASSEMBLY e. Install the rear shock absorber.
EWA13120
Refer to “REAR SHOCK ABSORBER AS-
WARNING SEMBLY” on page 4-33.
Securely support the vehicle so that there is ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
no danger of it falling over. EAS21660
CHECKING THE TIRES

Spring preload The following procedure applies to both of the
1. Adjust: tires.
• Spring preload 1. Check:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Tire pressure
a. Remove the rear shock absorber. Out of specification → Regulate.
SEMBLY” on page 4-33.
b. While compressing the spring, remove the
spring guide “1”.
EWA5B61003
WARNING
• The tire pressure should only be checked
and regulated when the tire temperature
c. Install the circlip “2” into the groove of the de- equals the ambient air temperature.
sired position. • The tire pressure and the suspension must
NOTE: be adjusted according to the total weight
Do not spread the circlip too much. (including the rider) and the anticipated
riding speed.
• Operation of an overloaded vehicle could
Groove “a” cause tire damage, an accident or an injury.
Spring preload is harder. NEVER OVERLOAD THE VEHICLE.
Groove “b” (standard position)
Spring preload is softer.
3-17
CHASSIS
• Patching a punctured tube is not recom-

Tire air pressure (measured on mended. If it is absolutely necessary to do
cold tires) so, use great care and replace the tube as
Loading condition soon as possible with a good quality re-
0–60 kg (0–132 lb)
placement.
Front
100 kPa (15 psi) (1.00 kgf/cm²)
Rear
100 kPa (15 psi) (1.00 kgf/cm²)
EWA13190
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit, re-
place the tire immediately.
2. Check:
• Tire surfaces Tube wheel Tube tire only
Damage/wear → Replace the tire.
Tubeless wheel Tube or tubeless tire
1 EWA14090
WARNING
After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
2 Ltd. for this model. The front and rear tires
should always be by the same manufacturer
and of the same design. No guarantee con-
cerning handling characteristics can be giv-
en if a tire combination other than one
1. Tire tread depth approved by Yamaha is used on this vehicle.
2. Side wall
Front tire
Wear limit (front) Size
4.0 mm (0.16 in) 2.50–14 4PR
Wear limit (rear) Manufacturer/model
4.0 mm (0.16 in) CHEN SHIN/C-803
EWA14080
WARNING Rear tire

• Do not use a tubeless tire on a wheel de- Size
signed only for tube tires to avoid tire fail- 3.00–12 4PR
Manufacturer/model
ure and personal injury from sudden
CHEN SHIN/C-803
deflation.
• When using a tube tire, be sure to install the EWA5B61004
correct tube. WARNING

• Always replace a new tube tire and a new New tires have a relatively low grip on the
tube as a set. road surface until they have been slightly
• To avoid pinching the tube, make sure the worn. Therefore, approximately 100 km
wheel rim band and tube are centered in the should be traveled at normal speed before
wheel groove. any high-speed riding is done.
NOTE:
Align the mark “1” with the valve installation
point.
3-18
CHASSIS
Spoke
2 Nm (0.2 m·kg, 1.4 ft·lb)
T.
R.
Spoke nipple wrench (10-11)
90890-01523
YM-01523
EAS21670
CHECKING THE WHEELS

The following procedure applies to both of the
wheels.
1. Check: 1
• Wheel
Damage/out-of-round → Replace.
EWA13260
WARNING
NOTE:
Never attempt to make any repairs to the
Be sure to tighten the spokes before and after
wheel.
break-in.
NOTE:
After a tire or wheel has been changed or re- EAS21690
placed, always balance the wheel. CHECKING AND LUBRICATING THE

CABLES
EAS21680
The following procedure applies to all of the in-
CHECKING AND TIGHTENING THE SPOKES ner and outer cables.
EWA5B61009
The following procedure applies to all of the
WARNING
spokes.
1. Check: A damaged outer cable may cause the inner
• Spoke cable to corrode and interfere with its move-
Bends/damage → Replace. ment. Replace damaged outer cables and in-
Loose → Tighten. ner cables as soon as possible.
Tap the spoke with a screwdriver. 1. Check:
NOTE: • Outer cable
A tight spoke will emit a clear, ringing tone; a Damage → Replace.
loose spoke will sound flat. 2. Check:
• Cable operation
Rough movement → Lubricate.
Recommended lubricant
Engine oil or a suitable cable lu-
bricant
NOTE:
Hold the cable end upright and pour a few drops
of lubricant into the cable sheath or use a suit-
able lubricating device.
2. Tighten:
• Spoke EAS5B61004
(with a spoke nipple wrench “1”) LUBRICATING THE BRAKE LEVER

Lubricate the pivoting point and metal-to-metal
moving parts of the brake lever.
3-19
CHASSIS
Lithium-soap-based grease
EAS5B61005
LUBRICATING THE BRAKE PEDAL

moving parts of the brake pedal.
EAS21720
LUBRICATING THE SIDESTAND

moving parts of the sidestand.
EAS21740
LUBRICATING THE REAR SUSPENSION

Lubricate the pivoting points and metal-to-metal
moving parts of the rear suspension.
3-20
ELECTRICAL SYSTEM
EAS21750
ELECTRICAL SYSTEM
EAS21760
CHECKING AND CHARGING THE BATTERY

Refer to “ELECTRICAL COMPONENTS” on
page 7-17.
EAS21770
CHECKING THE FUSES

Refer to “ELECTRICAL COMPONENTS” on
page 7-17.
3-21
CHASSIS
GENERAL CHASSIS....................................................................................... 4-1
FRONT WHEEL............................................................................................... 4-3

REMOVING THE FRONT WHEEL (DRUM) ............................................. 4-5
CHECKING THE FRONT WHEEL ............................................................ 4-5
INSTALLING THE FRONT WHEEL (DRUM) ............................................ 4-6
REAR WHEEL ................................................................................................. 4-7

REMOVING THE REAR WHEEL (DRUM)................................................ 4-9
CHECKING THE REAR WHEEL............................................................... 4-9
CHECKING THE REAR WHEEL DRIVE HUB .......................................... 4-9
CHECKING AND REPLACING THE REAR WHEEL SPROCKET ........... 4-9
INSTALLING THE REAR WHEEL (DRUM) ............................................ 4-10
FRONT BRAKE ............................................................................................. 4-11

CHECKING THE FRONT BRAKE SHOES ............................................. 4-12
ASSEMBLING THE FRONT BRAKE SHOE PLATE............................... 4-12
CHECKING THE FRONT BRAKE DRUM WEAR ................................... 4-13
4
REAR BRAKE ............................................................................................... 4-14
CHECKING THE REAR BRAKE SHOES................................................ 4-15
ASSEMBLING THE REAR BRAKE SHOE PLATE ................................. 4-15
CHECKING THE REAR BRAKE DRUM WEAR LIMIT ........................... 4-16
HANDLEBAR ................................................................................................ 4-17

REMOVING THE HANDLEBAR.............................................................. 4-18
CHECKING THE HANDLEBAR .............................................................. 4-18
INSTALLING THE HANDLEBAR ............................................................ 4-18
FRONT FORK................................................................................................ 4-21

REMOVING THE FRONT FORK LEGS.................................................. 4-24
DISASSEMBLING THE FRONT FORK LEGS ........................................ 4-24
CHECKING THE FRONT FORK LEGS .................................................. 4-25
ASSEMBLING THE FRONT FORK LEGS .............................................. 4-25
INSTALLING THE FRONT FORK LEGS ................................................ 4-27
STEERING HEAD.......................................................................................... 4-29

REMOVING THE LOWER BRACKET..................................................... 4-31
CHECKING THE STEERING HEAD ....................................................... 4-31
INSTALLING THE STEERING HEAD ..................................................... 4-31
REAR SHOCK ABSORBER ASSEMBLY .................................................... 4-33
HANDLING THE REAR SHOCK ABSORBER ........................................ 4-34
DISPOSING OF A REAR SHOCK ABSORBER ..................................... 4-34
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY................... 4-34
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-34
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ................. 4-34
SWINGARM................................................................................................... 4-35
REMOVING THE SWINGARM................................................................ 4-36
CHECKING THE SWINGARM ................................................................ 4-36
INSTALLING THE SWINGARM .............................................................. 4-36
CHAIN DRIVE................................................................................................ 4-38

CHECKING THE DRIVE CHAIN ............................................................. 4-39
INSTALLING THE DRIVE CHAIN ........................................................... 4-40
GENERAL CHASSIS
EAS21830
GENERAL CHASSIS
Removing the seat, fenders, and battery
10 Nm (1.0 m • kg, 7.2 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
.
R.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T
T.
R.
5 6
9 7
16
3 15 4
16
2
7 Nm (0.7 m • kg, 5.1 ft • Ib)

(4)
T.
R.
11 Nm (1.1 m • kg, 8.0 ft • Ib)
T.
R.
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
(3)
14 13
7 Nm (0.7 m • kg, 5.1 ft • Ib)
12
T.
R.
11
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
8
10
Order Job/Parts to remove Q’ty Remarks

1 Number plate 1
2 Front fender 1
3 Front fender bracket 1
4 Left side cover 1
5 Right side cover 1
6 Seat 1
7 Rear fender 1
8 Left air scoop 1
9 Right air scoop 1
10 Battery coupler 1 Disconnect.
11 Battery band 1
12 Battery cover 1
13 Battery 1
14 Battery box 1
15 Rear reflector bracket 1 For CDN
4-1
GENERAL CHASSIS
Removing the seat, fenders, and battery

T.
.
R.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T
T.
R.
5 6
9 7
16
3 15 4
16
2
7 Nm (0.7 m • kg, 5.1 ft • Ib)

(4)
T.
R.
11 Nm (1.1 m • kg, 8.0 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
(3)
14 13
7 Nm (0.7 m • kg, 5.1 ft • Ib)
12
T.
R.
11
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
8
10

16 Rear reflector 3 For CDN
For installation, reverse the removal proce-
dure.
4-2
FRONT WHEEL
EAS21870
FRONT WHEEL
Removing the front wheel and brake shoe assembly
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
4
35 Nm (3.5 m • kg, 25 ft • Ib)

T.
R.
3 7
5

Front brake cable (handlebar side) Refer to “HANDLEBAR” on page 4-17.
1 Front brake cable holder 2
2 Front brake cable 1
3 Spring 1
4 Front wheel axle 1
5 Front wheel 1
6 Collar 1
7 Front brake shoe assembly 1
dure.
4-3
FRONT WHEEL
Disassembling the front wheel
1
2
3
6
5

1 Dust cover 1
2 Oil seal 1
3 Bearing 1
4 Bearing 1
5 Spacer 1
6 Spacer 1
For assembly, reverse the disassembly pro-
cedure.
4-4
FRONT WHEEL
EAS5B61012
REMOVING THE FRONT WHEEL (DRUM) Radial wheel runout limit

1. Stand the vehicle on a level surface. 2.0 mm (0.08 in)
EWA13120
Lateral wheel runout limit
WARNING 2.0 mm (0.08 in)
2. Elevate:
• Front wheel
NOTE:
front wheel is elevated.
EAS21930
CHECKING THE FRONT WHEEL

1. Check:
• Wheel axle 5. Check:
Roll the wheel axle on a flat surface. • Wheel bearings
Bends → Replace. Front wheel turns roughly or is loose → Re-
EWA13460 place the wheel bearings.
WARNING • Oil seal
Do not attempt to straighten a bent wheel ax- Damage/wear → Replace.
le.
6. Replace:
• Wheel bearings New
2. Check:
• Tire • Oil seal New
• Front wheel ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Damage/wear → Replace. a. Clean the outside surface of the front wheel
Refer to “CHECKING THE TIRES” on page hub.
3-17 and “CHECKING THE WHEELS” on b. Remove the oil seals “1” with a flat-head
page 3-19. screwdriver.
3. Check: NOTE:
• Spokes To prevent damaging the wheel, place a rag “2”
Bends/damage → Replace. between the screwdriver and the wheel surface.
Loose → Tighten.
Refer to “CHECKING AND TIGHTENING 2
THE SPOKES” on page 3-19.
4. Measure:
• Front wheel radial runout “1” 1
• Front wheel lateral runout “2”
Over the specified limits → Replace.
4-5
FRONT WHEEL
c. Remove the wheel bearings “3” with a gener-

al bearing puller.
3. Tighten:
• Wheel axle nut
d. Install the new wheel bearings and oil seal in
the reverse order of disassembly. Front wheel axle nut
ECA5B61005 35 Nm (3.5 m·kg, 25 ft·lb)
T.
R.
CAUTION:
EWA13490
Do not apply pressure on the wheel bearing WARNING
inner race “4” or balls “5”. Pressure should
Make sure the brake cable is routed properly.
only be applied to the outer race “6”.
ECA5B61006
NOTE: CAUTION:
Use a socket “7” that matches the diameter of Before tightening the wheel axle nut, push
the wheel bearing outer race and oil seal. down hard on the handlebar several times
and check if the front fork rebounds smooth-
ly.
4. Install:
• Front brake cable
NOTE:
Connect the front brake cable to the front brake
shoe, then to the brake camshaft lever.
5. Adjust:
• Brake lever free play
Refer to “ADJUSTING THE FRONT DRUM
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS21980
INSTALLING THE FRONT WHEEL (DRUM) Front brake lever free play
1. Lubricate: 10.0–20.0 mm (0.39–0.79 in)
• Wheel axle
• Wheel bearings
• Oil seal lips
2. Install:
• Front wheel
NOTE:
Align the slot “a” in the brake shoe plate with the
projection “b” of the front fork outer tube.
4-6
REAR WHEEL
EAS22020
REAR WHEEL
Removing the rear wheel and brake shoe assembly
LS
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
4 1
7 3
10 11
2
26 Nm (2.6 m • kg, 19 ft • Ib) 8
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
New 5
6 12
9 8
60 Nm (6.0 m • kg, 43 ft • Ib)

T.
R.

1 Brake rod adjusting nut 1
2 Brake rod 1
3 Spring 1
4 Pin 1
5 Cotter pin 1
6 Brake torque rod bolt 1
7 Rear wheel axle 1
8 Drive chain puller 2
9 Rear wheel 1
10 Spacer 1
11 Rear brake shoe assembly 1
12 Spacer 1
dure.
4-7
REAR WHEEL
Disassembling the rear wheel and wheel sprocket
3
5
4
(4) 11
7
LS
3
8
New 10
New 9 (4)
New 6
1
32 Nm (3.2 m • kg, 23 ft • Ib)
T.
R.

1 Rear wheel drive hub assembly 1
2 Rear wheel drive hub damper 4
3 Bearing 2
4 Spacer 1
5 Spacer 1
6 Lock washer 2
7 Rear wheel sprocket 1
8 Collar 1
9 Oil seal 1
10 Bearing 1
11 Rear wheel drive hub 1
cedure.
4-8
REAR WHEEL
EAS22060
3. Check:
REMOVING THE REAR WHEEL (DRUM)
• Spokes
EWA13120
Refer to “CHECKING THE FRONT WHEEL”
WARNING on page 4-5.
Securely support the vehicle so that there is 4. Measure:
no danger of it falling over. • Radial wheel runout
• Lateral wheel runout
NOTE: Refer to “CHECKING THE FRONT WHEEL”
Place the vehicle on a suitable stand so that the on page 4-5.
rear wheel is elevated. EAS22110
2. Remove: CHECKING THE REAR WHEEL DRIVE HUB

• Brake rod adjusting nut “1” 1. Check:
• Brake rod “2” • Rear wheel drive hub
• Spring “3” Cracks/damage → Replace.
• Pin “4” • Rear wheel drive hub dampers
Damage/wear → Replace.
NOTE:
Press down on the brake pedal to remove the EAS22120
pin from the brake rod. CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
1. Check:
• Rear wheel sprocket
More than 1/4 tooth “a” wear → Replace the
drive chain, drive sprocket rear wheel sprock-
et as a set.
1
Bent teeth → Replace the drive chain, drive
sprocket and rear wheel sprocket as a set.
2
3
4
3. Remove:
• Rear wheel
NOTE:
Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
EAS22100
CHECKING THE REAR WHEEL b. Correct

1. Check: 1. Drive chain roller
• Wheel axle 2. Rear wheel sprocket
• Rear wheel
• Wheel bearings 2. Replace:
• Oil seal • Rear wheel sprocket
Refer to “CHECKING THE FRONT WHEEL” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Straighten the lock washer tabs.
on page 4-5.
b. Remove the bolts, lock washers “1” and the
2. Check:
rear wheel sprocket.
• Tire
c. Clean the rear wheel drive hub with a clean
• Rear wheel
cloth, especially the surfaces in contact with
the sprocket.
Refer to “CHECKING THE TIRES” on page
d. Install the new rear wheel sprocket and new
3-17 and “CHECKING THE WHEELS” on
lock washers.
page 3-19.
4-9
REAR WHEEL
Rear wheel sprocket bolt Rear wheel axle nut

32 Nm (3.2 m·kg, 23 ft·lb) 60 Nm (6.0 m·kg, 43 ft·lb)
T.
T.
R.
R.
NOTE: 6. Install:
• Install the rear wheel sprocket with its manu- • Brake torque rod
facturer’s marks facing outward.
Brake torque rod nut
• Tighten the bolts in stages and in a crisscross 26 Nm (2.6 m·kg, 19 ft·lb)
T.
pattern.
R.
7. Adjust:
Brake pedal free play

10.0–20.0 mm (0.39–0.79 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS22180
INSTALLING THE REAR WHEEL (DRUM)

1. Lubricate:
• O-ring
• Oil seal
2. Install:
• Rear wheel sprocket
• Lock washers New
Refer to “CHECKING AND REPLACING
THE REAR WHEEL SPROCKET” on page
4-9.
3. Lubricate:
• Wheel axle
• Wheel bearings
4. Adjust:
• Drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” on page 3-14.
Drive chain slack

40.0–56.0 mm (1.57–2.20 in)
5. Tighten:
• Rear wheel axle nut
4-10
FRONT BRAKE
EAS22210
FRONT BRAKE
Disassembling the front brake
1
LS
LS
6 New
1 4
New 2
5
7
3
3
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.

Front brake shoe assembly Refer to “FRONT WHEEL” on page 4-3.
1 Brake shoe 2
2 Brake shoe spring 2
3 Brake camshaft lever 1
4 Brake shoe wear indicator 1
5 Brake camshaft 1
6 Oil seal 1
7 Brake shoe plate 1
cedure.
4-11
FRONT BRAKE
EAS22470
CHECKING THE FRONT BRAKE SHOES

1. Check:
• Brake shoe lining
a
Glazed areas → Repair.
Sand the glazed areas with coarse sandpa-
per.
NOTE:
After sanding the glazed areas, clean the brake
shoe with a cloth.
2. Measure: 4. Check:
• Brake shoe lining thickness “a” • Brake drum inner surface
Out of specification → Replace. Oil deposits → Clean.
Remove the oil with a rag soaked in lacquer
Lining thickness thinner or solvent.
3.0 mm (0.12 in) Scratches → Repair.
Limit Lightly and evenly polish the scratches with
1.5 mm (0.06 in) an emery cloth.
5. Check:
• Brake camshaft
EAS22480
ASSEMBLING THE FRONT BRAKE SHOE

PLATE
1. Install:
• Brake camshaft “1”
• Brake camshaft lever “3”
EWA13480 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
WARNING a. Install the brake camshaft so that the “I” mark
“a” is positioned as shown in the illustration.
Do not allow oil or grease to contact the
b. Install the brake shoe wear indicator so that
brake shoes.
its pointer “b” is aligned with the end “c” of the
NOTE: usable range indicator.
Replace the brake shoes as a set, if either is
worn to the wear limit.
3. Measure:
• Brake drum inside diameter “a” c
Out of specification → Replace the wheel.
Brake drum inside diameter b

95.0 mm (3.74 in) 2
Limit a
1
96.0 mm (3.78 in)
c. Align the “I” mark “a” on the brake camshaft
with the brake camshaft lever as shown in the
illustration.
4-12
FRONT BRAKE
3. While fully squeezing the brake lever so that

the brake camshaft lever is pulled, check that
the brake shoe wear indicator “1” does not
3 a reach the brake drum wear indicator “a”.
Not reaching → Still usable.
Reaching → Replace the front wheel.
a
d. Check that the brake shoes are properly po-
sitioned.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
• Brake shoe springs “1” New
• Brake shoes “2”
NOTE:
Lubricate the pivot pin with a thin coat of lithium-
soap-based grease.
EWA5B61005
WARNING
Do not apply grease to the brake shoe lin-
ings.
EAS5B61013
CHECKING THE FRONT BRAKE DRUM

WEAR
NOTE:
This check can only be performed with new
brake shoes installed.
1. Check:
• Brake camshaft lever
• Brake shoe wear indicator
• Brake camshaft
Inconnect installation → Reinstall.
2. Check:
4-13
REAR BRAKE
EAS22550
REAR BRAKE
Disassembling the rear brake
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
3
LS
7
5
1
4 2 New
New 6
LS
1
2 New

Rear brake shoe assembly Refer to “REAR WHEEL” on page 4-7.
1 Brake shoe 2
2 Brake shoe spring 2
3 Brake camshaft lever 1
4 Brake shoe wear indicator 1
5 Brake camshaft 1
6 Oil seal 1
7 Brake shoe plate 1
cedure.
4-14
REAR BRAKE
EAS22681
CHECKING THE REAR BRAKE SHOES

1. Check:
• Brake shoe lining
a
Glazed areas → Repair.
Sand the glazed areas with coarse sandpa-
per.
NOTE:
After sanding the glazed areas, clean the brake
shoe with a cloth.
• Brake shoe lining thickness “a” • Brake drum inner surface
Out of specification → Replace. Oil deposits → Clean.
Remove the oil with a rag soaked in lacquer
Lining thickness thinner or solvent.
4.0 mm (0.16 in) Scratches → Repair.
Limit Lightly and evenly polish the scratches with
1.5 mm (0.06 in) an emery cloth.
5. Check:
• Brake camshaft
EAS22690
ASSEMBLING THE REAR BRAKE SHOE

PLATE
1. Install:
• Brake camshaft “1”
• Brake camshaft lever “3”
EWA5B61007
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the brake camshaft so its punch mark
WARNING
“a” is positioned as shown.
Do not allow oil or grease to contact the b. Align the projection “b” on the brake shoe
brake shoes. wear indicator with the notch in the brake
NOTE: shoe camshaft.
Replace the brake shoes as a set, if either is
a
worn to the wear limit.
1
3. Measure:
• Brake drum inside diameter “a”
Out of specification → Replace the wheel.
b
Brake drum inside diameter 2
110.0 mm (4.33 in)
Limit
111.0 mm (4.37 in)
c. Align the punch mark “a” on the brake cam-
shaft with the brake camshaft lever as shown
in the illustration.
4-15
REAR BRAKE
3. While pressing the brake pedal all the way

68.4˚ down so that the brake camshaft lever is
pushed, check that the brake shoe wear indi-
cator “1” does not reach the brake drum wear
indicator “a”.
Does not reach → Still usable.
3 Reaches → Replace the rear wheel.
a a
3
d. Check that the brake shoes are properly po-

sitioned.
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install:
• Brake shoe springs “1” New
• Brake shoes “2”
NOTE:
Lubricate the pivot pin with a thin coat of lithium-
soap-based grease.
EWA5B61005
WARNING
Do not apply grease to the brake shoe lin-
ings.
EAS5B61014
CHECKING THE REAR BRAKE DRUM WEAR

LIMIT
NOTE:
This check can only be performed with new
brake shoes installed.
1. Check:
• Brake camshaft lever
• Brake shoe wear indicator
• Brake camshaft
Inconnect installation → Reinstall.
2. Check:
4-16
HANDLEBAR
EAS22840
HANDLEBAR
Removing the handlebar
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
7
LS 10
8
5
3
LS 11
5 1
6
9
12
4 LS
LS

Refer to “GENERAL CHASSIS” on page
Number plate 4-1.
1 Engine stop switch 1
2 Front brake cable 1 Disconnect.
3 Start switch/brake lever holder 1
4 Brake lever 1
5 Throttle cable housing 2
6 Throttle cable 2 Disconnect.
7 Throttle grip 1
8 Throttle grip tube guide 1
9 Handlebar grip 1
10 Main switch 1
11 Handlebar holder 2
12 Handlebar 1
dure.
4-17
HANDLEBAR
EAS22860
• The handlebar holders should be installed with
REMOVING THE HANDLEBAR
the punch marks “b” facing forward “A”.
EWA13120 ECA5B61007
WARNING CAUTION:
Securely support the vehicle so that there is First, tighten the bolt on the front side of the
no danger of it falling over. handlebar holders, and then on the rear side.
2. Remove:
• Handlebar grip “1”
NOTE:
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
2
b
EAS22880
CHECKING THE HANDLEBAR

1. Check:
• Handlebar
Bends/cracks/damage → Replace. 3. Install:
EWA13690 • Handlebar grip “1”
WARNING ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Do not attempt to straighten a bent handle- a. Apply a thin coat of rubber adhesive onto the
bar as this may dangerously weaken it. left end of the handlebar.
b. Slide the handlebar grip over the left end of
EAS22921 the handlebar.
INSTALLING THE HANDLEBAR NOTE:
1. Stand the vehicle on a level surface. Position the handlebar grip so that the line “a”
EWA13120
WARNING between the two arrow marks faces straight up-

ward.
2. Install:
• Handlebar “1”
• Handlebar holders “2”
• Main switch
Handlebar holder bolt

23 Nm (2.3 m·kg, 17 ft·lb)
T.
R.
NOTE:
• Align the match mark “a” on the handlebar with c. Wipe off any excess rubber adhesive with a
the upper surface of the upper bracket. clean rag.
4-18
HANDLEBAR
EWA5B61006
WARNING
Do not touch the handlebar grip until the rub-
ber adhesive has fully dried.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
• Collar “1”
1
• Throttle grip “2”
(to throttle grip tube guide “3”)
a
NOTE:
6. Install:
• Before applying the adhesive, wipe off grease • Brake lever “1”
or oil on the throttle grip tube guide “3” surface • Start switch/brake lever holder “2”
“a” with a lacquer thinner.
NOTE:
• Align the throttle grip tube guide with the mat-
ing mark “b” on the throttle grip as shown in the • There should be 0 mm (0 in) of clearance “a”
illustration. between the throttle grip housing and start
switch/brake lever holder.
• Install the brake lever within 15° of the horizon-
tal line shown in the illustration.
2
a
b
45˚
15˚
1
5. Install:
• Throttle grip “1”
(with throttle grip tube guide)
• Throttle cable 7. Position:
• Throttle cable housing • Throttle cable housing
NOTE: NOTE:
Make sure that there is enough clearance “a” be- Align the mating line of the throttle cable housing
tween the handlebar and the throttle grip so that with the mating line of the start switch/brake le-
the grip will turn smoothly. ver holder.
4-19
HANDLEBAR
8. Install:
• Engine stop switch “1”
NOTE:
Align the projection “a” on the engine stop switch
holder with the hole “b” on the handlebar.
9. Install:
• Plastic bands
Refer to “CABLE ROUTING” on page 2-27.
10.Adjust:
• Throttle cable free play
Refer to “ADJUSTING THE THROTTLE CA-
BLE FREE PLAY” on page 3-5.
Throttle cable free play

4.0–6.0 mm (0.16–0.24 in)
11.Adjust:
Front brake lever free play

10.0–20.0 mm (0.39–0.79 in)
4-20
FRONT FORK
EAS22950
FRONT FORK
Removing the front fork legs
25 Nm (2.5 m • kg, 18 ft • Ib)
T.
R.
1
3
2
33 Nm (3.3 m • kg, 24 ft • Ib)

T.
R.

The following procedure applies to both of
the front fork legs.
Front wheel Refer to “FRONT WHEEL” on page 4-3.
1 Upper bracket pinch bolt 1 Loosen.
2 Lower bracket pinch bolt 1 Loosen.
3 Front fork leg 1
dure.
4-21
FRONT FORK
Disassembling the front fork legs
1
2 New
3
4 New
5
14
6
15
8 New
9
16 New
17
7 18
12
LT
11 New
13
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
10

The following procedure applies to both of
the front fork legs.
1 Cap 1
2 Clip 1
3 Front fork cap 1
4 O-ring 1
5 Spacer 1
6 Washer 1
7 Fork spring 1
8 Dust seal 1
9 Oil seal clip 1
10 Damper rod bolt 1
11 Copper washer 1
12 Damper rod 1
13 Rebound spring 1
14 Inner tube 1
15 Oil flow stopper 1
16 Oil seal 1
4-22
FRONT FORK
Disassembling the front fork legs
1
2 New
3
4 New
5
14
6
15
8 New
9
16 New
17
7 18
12
LT
11 New
13
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
R.
10

17 Washer 1
18 Outer tube 1
cedure.
4-23
FRONT FORK
EAS22970
REMOVING THE FRONT FORK LEGS NOTE:

The following procedure applies to both of the Push the front fork cap in the direction of the ar-
front fork legs. row shown in the illustration to remove the clip.
EWA13120
WARNING 1 1
2
NOTE:
front wheel is elevated.
2. Loosen:
• Upper bracket pinch bolts “1” 2. Drain:
• Lower bracket pinch bolts “2” • Fork oil
EWA13640
WARNING
Before loosening the upper and lower brack-
et pinch bolts, support the front fork leg.
1
3. Remove:
• Dust seal “1”
• Oil seal clip “2”
(with a flat-head screwdriver)
ECA14180
CAUTION:
Do not scratch the inner tube.
2 1
2
EAS22990
DISASSEMBLING THE FRONT FORK LEGS

front fork legs.
1. Remove: 4. Remove:
• Cap • Damper rod bolt “1”
• Circlip “1” • Damper rod
• Front fork cap “2” • Rebound spring
(with O-ring) NOTE:
• Spacer While holding the damper rod with the damper
• Washer rod holder “2” and T-handle “3”, loosen the
• Fork spring damper rod bolt.
4-24
FRONT FORK
Obstruction → Blow out all of the oil passag-

Damper rod holder es with compressed air.
90890-01294 • Oil flow stopper
Damping rod holder set Damage → Replace.
YM-01300 ECA5B61008
T-handle CAUTION:
90890-01326
When disassembling and assembling the
YM-01326 front fork leg, do not allow any foreign mate-
rial to enter the front fork.
EAS23020
ASSEMBLING THE FRONT FORK LEGS

front fork legs.
EWA13660
WARNING
• Make sure the oil levels in both front fork
legs are equal.
• Uneven oil levels can result in poor han-
dling and a loss of stability.
EAS23010
CHECKING THE FRONT FORK LEGS NOTE:

The following procedure applies to both of the • When assembling the front fork leg, be sure to
front fork legs. replace the following parts:
1. Check: – Oil seal
• Inner tube – Dust seal
• Outer tube – Clip
Bends/damage/scratches → Replace. • Before assembling the front fork leg, make
EWA13650
sure all of the components are clean.
WARNING
Do not attempt to straighten a bent inner 1. Install:
tube as this may dangerously weaken it. • Damper rod “1”
• Rebound spring “2”
2. Measure: ECA5B61009
• Spring free length “a” CAUTION:

Out of specification → Replace. Allow the damper rod to slide slowly down
the inner tube “3” until it protrudes from the
Fork spring free length
290.0 mm (11.42 in) bottom of the inner tube. Be careful not to
Limit damage the inner tube.
284.2 mm (11.19 in)
2 1
3
2. Lubricate:
• Inner tube’s outer surface
3. Check:
• Damper rod Recommended oil
Damage/wear → Replace. Fork oil 10W or equivalent
4-25
FRONT FORK
3. Tighten: • Before installing the oil seal, cover the top of

• Damper rod bolt the front fork leg with a plastic bag to protect
the oil seal during installation.
Damper rod bolt
20 Nm (2.0 m·kg, 14 ft·lb)
T.
R.
LOCTITE®
NOTE:
While holding the damper rod with the damper
rod holder “1” and T-handle “2”, tighten the
damper rod bolt.
Damper rod holder

90890-01294
Damping rod holder set
YM-01300
T-handle
90890-01326
YM-01326
5. Install:
• Oil seal clip “1”
NOTE:
Adjust the oil seal clip so that it fits into the outer
tube groove.
4. Install:
• Washer
• Oil seal “1” New
(with the fork seal driver weight “2” and fork
seal driver attachment “3”)
Fork seal driver weight

90890-01184
Replacement hammer
YM-A9409-7 6. Install:
Fork seal driver attachment (ø33) • Dust seal “1” New
90890-01532 (with the fork seal driver weight “2”)
YM-01532
Fork seal driver weight
ECA14220
90890-01184
CAUTION:
Replacement hammer
Make sure the numbered side of the oil seal YM-A9409-7
faces up.
NOTE:
• Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.
• Lubricate the outer surface of the inner tube
with fork oil.
4-26
FRONT FORK
7. Fill: 10.Install:
• Front fork leg • O-ring New
(with the specified amount of the recom- (to front fork cap)
mended fork oil) • Front fork cap
Quantity • Clip New
179.0 cm³ (6.05 US oz) (6.31 NOTE:
Imp.oz) • Before installing the front fork cap, lubricate its
Recommended oil O-ring with grease.
Fork oil 10W or equivalent • Insert the front fork cap into the inner tube, and
then install the clip, making sure that the cap is
NOTE: securely held in place with the clip.
• While filling the front fork leg, keep it upright.
• After filling, slowly pump the inner tube up and EAS23060
down to distribute the fork oil. INSTALLING THE FRONT FORK LEGS
8. Measure:
front fork legs.
• Front fork leg oil level “a”
1. Install:
(from the top of the inner tube, with the inner
• Front fork leg “1”
tube fully compressed and without the fork
spring) NOTE:
Out of specification → Correct. Align the upper end of the inner tube with the up-
per bracket as shown in the illustration.
Level
92.0 mm (3.62 in)
2. Tighten:
• Lower bracket pinch bolt “1”
9. Install: Lower bracket pinch bolt
• Fork spring 33 Nm (3.3 m·kg, 24 ft·lb)
T.
R.
NOTE:
Install the fork spring with its smaller diameter • Upper bracket pinch bolt “2”
end “a” facing down “A”.
Upper bracket pinch bolt
25 Nm (2.5 m·kg, 18 ft·lb)
T.
R.
4-27
FRONT FORK
4-28
STEERING HEAD
EAS23090
STEERING HEAD
Removing the lower bracket
110 Nm (11.0 m • kg, 80 ft • lb)
2
T.
R.
3
7 Nm (0.7 m • kg, 5.1 ft • Ib)

1 4
T
.
R.
1st 38 Nm (3.8 m • kg, 27 ft • lb)

T.
2nd 13 Nm (1.3 m • kg, 9.4 ft • lb)

R.
5
14
6 6
15
LS
7
8 8
10
18
LS 11
12
19 17 9 13
16
18

Handlebar Refer to “HANDLEBAR” on page 4-17.
Front fork Refer to “FRONT FORK” on page 4-21.
1 Cable guide 1
2 Steering stem nut 1
3 Washer 1
4 Upper bracket 1
5 Lock washer 1
6 Upper ring nut 1
7 Rubber washer 1
8 Lower ring nut 1
9 Lower bracket 1
10 Bearing cover 1
11 Upper bearing inner race 1
12 Upper bearing 1
13 Upper bearing outer race 1
14 Lower bearing outer race 1
4-29
STEERING HEAD
Removing the lower bracket

110 Nm (11.0 m • kg, 80 ft • lb)
2
T.
R.
3
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T 1 4
.
R.
1st 38 Nm (3.8 m • kg, 27 ft • lb)

T.
2nd 13 Nm (1.3 m • kg, 9.4 ft • lb)

R.
5
14
6 6
15
LS
7
8 8
10
18
LS 11
12
19 17 9 13
16
18

15 Lower bearing/Inner race 1
16 Front left reflector bracket 1 For CDN
17 Front right reflector bracket 1 For CDN
18 Front reflector 2 For CDN
19 Washer 1 For CDN
dure.
4-30
STEERING HEAD
EAS23110
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
REMOVING THE LOWER BRACKET a. Remove the bearing races from the steering
1. Stand the vehicle on a level surface. head pipe with a long rod “1” and hammer.
EWA13120
b. Remove the bearing from the lower bracket
WARNING
with a floor chisel “2” and hammer.
Securely support the vehicle so that there is c. Install a dust seal and new bearing races.
no danger of it falling over. ECA14270
CAUTION:
2. Remove:
• Upper ring nut If the bearing race is not installed properly,
• Rubber washer the steering head pipe could be damaged.
• Lower ring nut “1” NOTE:
• Lower bracket
Always replace the bearings and bearing races
NOTE: as a set.
Remove the lower ring nut with the steering nut
wrench “2”.
Steering nut wrench

90890-01403
Spanner wrench
YU-33975
EWA13730
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
EAS23120
CHECKING THE STEERING HEAD • Upper bracket

1. Wash: • Lower bracket
• Bearings (along with the steering stem)
• Bearing races Bends/cracks/damage → Replace.
EAS23140
Recommended cleaning solvent INSTALLING THE STEERING HEAD
Kerosene 1. Lubricate:
• Upper bearing
2. Check:
• Lower bearing
• Bearings
• Bearing races
• Bearing races
Damage/pitting → Replace. Recommended lubricant
3. Replace: Lithium-soap-based grease
• Bearings
• Bearing races 2. Install:
• Lower ring nut “1”
• Rubber washer
4-31
STEERING HEAD
• Upper ring nut

• Lock washer
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” on page 3-15.
NOTE:
Install the lower ring nut with its larger cham-
fered portion “a” facing downward.
3. Install:
• Upper bracket
• Washer
• Steering stem nut
NOTE:
Temporarily tighten the steering stem nut.
4. Install:
• Front fork legs
Refer to “FRONT FORK” on page 4-21.
NOTE:
Temporarily tighten the upper and lower bracket
pinch bolts.
5. Tighten:
• Steering stem nut
Steering stem nut

110 Nm (11.0 m·kg, 80 ft·lb)
T.
R.
4-32
REAR SHOCK ABSORBER ASSEMBLY
EAS23160

Removing the rear shock absorber assembly
2
1 New
LS
1 New
3
LS

Seat/Rear fender 4-1.
1 Clip 2
2 Washer 2
3 Rear shock absorber pin (rear side) 1
4 Rear shock absorber pin (front side) 1
5 Rear shock absorber 1
dure.
4-33
EAS23180
HANDLING THE REAR SHOCK ABSORBER NOTE:

EWA13740 Place the vehicle on a suitable stand so that the
WARNING rear wheel is elevated.
This rear shock absorber contains highly
compressed nitrogen gas. Before handling EAS23240
the rear shock absorber, read and make sure CHECKING THE REAR SHOCK ABSORBER
you understand the following information. ASSEMBLY
The manufacturer cannot be held responsi- 1. Check:
ble for property damage or personal injury • Rear shock absorber rod
that may result from improper handling of Bends/damage → Replace the rear shock
the rear shock absorber. absorber assembly.
• Do not tamper or attempt to open the rear • Rear shock absorber
shock absorber. Gas leaks/oil leaks → Replace the rear shock
• Do not subject the rear shock absorber to absorber assembly.
an open flame or any other source of high • Spring
heat. High heat can cause an explosion due Damage/wear → Replace the rear shock ab-
to excessive gas pressure. sorber assembly.
• Do not deform or damage the rear shock • Bushings
absorber in any way. Rear shock absorber Damage/wear → Replace the rear shock ab-
damage will result in poor damping perfor- sorber assembly.
mance. EAS23300
INSTALLING THE REAR SHOCK

EAS23190 ABSORBER ASSEMBLY
DISPOSING OF A REAR SHOCK ABSORBER 1. Lubricate:
1. Gas pressure must be released before dis- • Rear shock absorber pins
posing of a rear shock absorber. To release
the gas pressure, drill a 2–3-mm (0.08–0.12 Recommended lubricant
in) hole through the rear shock absorber at a Lithium-soap-based grease
point 15–20 mm (0.59–0.79 in) from its end
as shown. 2. Install:
EWA13760 • Rear shock absorber assembly
WARNING NOTE:
Wear eye protection to prevent eye damage Install the rear shock absorber so that the end
from released gas or metal chips. with the label “a” is towards the front of the vehi-
cle with the label facing up.
a
WA RNIN G
EAS23210
REMOVING THE REAR SHOCK ABSORBER

ASSEMBLY
EWA13120
WARNING
4-34
SWINGARM
EAS23330
SWINGARM
Removing the swingarm
1 New
2
4 LS
5 9
11
53 Nm (5.3 m • kg, 38 ft • Ib)
T.
R.
16 Nm (1.6 m • kg, 11 ft • Ib) 3 New

T.
R.
11
8
10
LS
6

Seat/Rear fender 4-1.
Rear wheel Refer to “REAR WHEEL” on page 4-7.
Drive chain Refer to “CHAIN DRIVE” on page 4-38.
1 Clip 1
2 Rear shock absorber pin (rear side) 1
3 Cotter pin 1
4 Brake torque rod 1
5 Pivot shaft nut 1
6 Pivot shaft 1
7 Swingarm 1
8 Drive chain guide 1
9 Drive chain guard (upper side) 1
10 Drive chain guard (lower side) 1
11 Bushing 2
dure.
4-35
SWINGARM
EAS23350
2. Check:
REMOVING THE SWINGARM
• Pivot shaft
EWA13120
Roll the pivot shaft on a flat surface.
WARNING Bends → Replace.
EWA13770
Securely support the vehicle so that there is WARNING
Do not attempt to straighten a bent pivot
NOTE: shaft.
rear wheel is elevated.
2. Measure:
• Swingarm side play
• Swingarm vertical movement
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the rear shock absorber.
SEMBLY” on page 4-33.
b. Measure the tightening torque of the pivot
shaft nut. 3. Wash:
• Pivot shaft
Pivot shaft nut • Washer
53 Nm (5.3 m·kg, 38 ft·lb)
T.
R.
Recommended cleaning solvent

c. Measure the swingarm side play “A” by mov- Kerosene
ing the swingarm from side to side.
d. If the swingarm side play is out of specifica- EAS23380
tion, check the bushing and washer. INSTALLING THE SWINGARM

1. Lubricate:
Swingarm side play (at the end of • Pivot shaft
the swingarm)
0 mm (0 in) Recommended lubricant
e. Check the swingarm vertical movement “B”
by moving the swingarm up and down. 2. Install:
If swingarm vertical movement is not smooth • Brake torque rod
or if there is binding, check the bushing and
washer. Brake torque rod nut
16 Nm (1.6 m·kg, 11 ft·lb)
T.
R.
NOTE:
Install the brake torque rod with its manufacturer
mark “a” facing outward.
A
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS23360
CHECKING THE SWINGARM

1. Check:
• Swingarm a
Bends/cracks/damage → Replace.
4-36
SWINGARM
3. Adjust:
• Drive chain slack
Drive chain slack

40.0–56.0 mm (1.57–2.20 in)
4-37
CHAIN DRIVE
EAS23400
CHAIN DRIVE
Removing the drive chain
3
2 New
7 5
6 New
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.

1 Drive sprocket cover 1
2 Master link clip 1
3 Master link plate 1
4 Master link 1
5 Drive chain 1
6 Circlip 1
7 Drive sprocket 1
dure.
4-38
CHAIN DRIVE
EAS23451
CHECKING THE DRIVE CHAIN

1. Measure:
• 15-link section “a” of the drive chain
Out of specification → Replace the drive
chain.
15-link length limit

194.3 mm (7.65 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the length “a” between the inner 3. Clean:
sides of the pins and the length “b” between • Drive chain
the outer sides of the pins on a 15-link section ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
of the drive chain as shown in the illustration. a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
b. Calculate the length “c” of the 15-link section

of the drive chain using the following formula.
Drive chain 15-link section length “c” =
(length “a” between pin inner sides + length
“b” between pin outer sides)/2 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
NOTE: 4. Check:
• When measuring a 15-link section of the drive • Drive chain rollers “1”
chain, make sure that the drive chain is taut. Damage/wear → Replace the drive chain.
• Perform this procedure 2–3 times, at a different • Drive chain side plates “2”
location each time. Damage/wear → Replace the drive chain.
Cracks → Replace the drive chain.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Lubricate:
2. Check:
• Drive chain
• Drive chain
Stiffness → Clean and lubricate or replace. Recommended lubricant
Engine oil or chain lubricant
suitable for non-O-ring chains
4-39
CHAIN DRIVE
6. Check: • Master link clip “1” New

• Drive sprocket ECA14310
More than 1/4 tooth “a” wear → Replace the CAUTION:

drive chain, drive sprocket, and rear wheel • The closed end of the master link clip must
sprocket as a set. face in the direction of drive chain rotation.
Bent teeth → Replace the drive chain, drive • Never install a new drive chain onto worn
sprocket, and rear wheel sprocket as a set. drive chain sprockets; this will dramatically
shorten the drive chain’s life.
NOTE:
Install the master link plate with its manufacturer
mark facing outward.
b. Correct
1. Drive chain roller
2. Drive sprocket
EAS23500
INSTALLING THE DRIVE CHAIN

1. Lubricate: 4. Adjust:
• Drive chain • Drive chain slack
• Master link New
Drive chain slack
Engine oil or chain lubricant
40.0–56.0 mm (1.57–2.20 in)
suitable for non-O-ring chains
ECA13550
2. Install: CAUTION:
• Drive sprocket A drive chain that is too tight will overload
• Circlip “1” New the engine and other vital parts, and one that
NOTE: is too loose can skip and damage the swing-
• Install the drive sprocket with its manufacturer arm or cause an accident. Therefore, keep
mark facing outward. the drive chain slack within the specified lim-
• Align the gap between the ends of the circlip its.
with a groove in the drive axle. 5. Install:
• Drive sprocket cover
NOTE:
Be sure not to pinch the neutral switch lead
1 when installing the drive chain cover.
3. Install:
• Master link
• Master link plate
4-40
CHAIN DRIVE
4-41
ENGINE
ENGINE REMOVAL ........................................................................................ 5-1

INSTALLING THE ENGINE....................................................................... 5-4
INSTALLING THE EXHAUST PIPE/MUFFLER ........................................ 5-4
CYLINDER HEAD............................................................................................ 5-5

REMOVING THE CYLINDER HEAD......................................................... 5-7
CHECKING THE CYLINDER HEAD ......................................................... 5-7
CHECKING THE CAMSHAFT SPROCKET AND
TIMING CHAIN GUIDES .......................................................................... 5-8
CHECKING THE TIMING CHAIN TENSIONER........................................ 5-8
INSTALLING THE CYLINDER HEAD ....................................................... 5-8
CAMSHAFT ................................................................................................... 5-11

REMOVING THE ROCKER ARMS AND CAMSHAFT............................ 5-12
CHECKING THE CAMSHAFT................................................................. 5-12
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 5-12
INSTALLING THE CAMSHAFT AND ROCKER ARMS .......................... 5-13
VALVES AND VALVE SPRINGS.................................................................. 5-14

REMOVING THE VALVES...................................................................... 5-15
CHECKING THE VALVES AND VALVE GUIDES .................................. 5-15
CHECKING THE VALVE SEATS ............................................................ 5-17
CHECKING THE VALVE SPRINGS........................................................ 5-18
INSTALLING THE VALVES .................................................................... 5-19 5
CYLINDER AND PISTON.............................................................................. 5-21
REMOVING THE PISTON ...................................................................... 5-22
CHECKING THE CYLINDER AND PISTON ........................................... 5-22
CHECKING THE PISTON RINGS........................................................... 5-23
CHECKING THE PISTON PIN ................................................................ 5-24
INSTALLING THE PISTON AND CYLINDER ......................................... 5-24
GENERATOR AND STARTER CLUTCH...................................................... 5-26

REMOVING THE GENERATOR ............................................................. 5-28
REMOVING THE STARTER CLUTCH ................................................... 5-28
CHECKING THE STARTER CLUTCH .................................................... 5-28
INSTALLING THE STARTER CLUTCH .................................................. 5-29
INSTALLING THE GENERATOR............................................................ 5-29
ELECTRIC STARTER ................................................................................... 5-31

REMOVING THE STARTER MOTOR..................................................... 5-33
CHECKING THE STARTER MOTOR ..................................................... 5-33
ASSEMBLING THE STARTER MOTOR................................................. 5-34
INSTALLING THE STARTER MOTOR ................................................... 5-34
KICKSTARTER ............................................................................................. 5-35
CHECKING THE KICKSTARTER ........................................................... 5-36
INSTALLING THE KICKSTARTER ......................................................... 5-36
CLUTCH ........................................................................................................ 5-37

REMOVING THE CLUTCH ..................................................................... 5-40
CHECKING THE FRICTION PLATES..................................................... 5-40
CHECKING THE CLUTCH PLATES ....................................................... 5-41
CHECKING THE CLUTCH SPRINGS..................................................... 5-41
CHECKING THE CLUTCH HOUSING .................................................... 5-41
CHECKING THE CLUTCH BOSS........................................................... 5-41
CHECKING THE PRESSURE PLATE .................................................... 5-41
CHECKING THE CLUTCH PUSH RODS ............................................... 5-41
CHECKING THE PRIMARY DRIVE GEAR............................................. 5-41
CHECKING THE PRIMARY DRIVEN GEAR .......................................... 5-42
CHECKING THE PRIMARY CLUTCH HOUSING................................... 5-42
CHECKING THE CLUTCH SHOES ........................................................ 5-42
CHECKING THE PRIMARY CLUTCH .................................................... 5-42
INSTALLING THE CLUTCH.................................................................... 5-42
OIL PUMP...................................................................................................... 5-45

CHECKING THE OIL PUMP ................................................................... 5-46
CHECKING THE OIL STRAINER ........................................................... 5-46
CHECKING THE ROTARY FILTER ........................................................ 5-46
ASSEMBLING THE OIL PUMP............................................................... 5-46
INSTALLING THE OIL STRAINER ......................................................... 5-47
SHIFT SHAFT................................................................................................ 5-48

CHECKING THE SHIFT SHAFT ............................................................. 5-50
CHECKING THE STOPPER LEVER ...................................................... 5-50
CHECKING THE SHIFT LEVER ASSEMBLY......................................... 5-50
INSTALLING THE SHIFT SHAFT ........................................................... 5-50
CRANKCASE ................................................................................................ 5-51

DISASSEMBLING THE CRANKCASE.................................................... 5-54
CHECKING THE CRANKCASE .............................................................. 5-54
CHECKING THE TIMING CHAIN AND CHAIN GUIDE .......................... 5-54
CHECKING THE BEARINGS AND OIL SEAL ........................................ 5-54
CHECKING THE SHIFT DRUM SEGMENT ........................................... 5-54
ASSEMBLING THE CRANKCASE.......................................................... 5-54
CRANKSHAFT .............................................................................................. 5-56

REMOVING THE CRANKSHAFT ........................................................... 5-57
CHECKING THE CRANKSHAFT ............................................................ 5-57
INSTALLING THE CRANKSHAFT .......................................................... 5-57
TRANSMISSION............................................................................................ 5-59
CHECKING THE SHIFT FORKS............................................................. 5-62
CHECKING THE SHIFT DRUM .............................................................. 5-62
CHECKING THE TRANSMISSION ......................................................... 5-62
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE .............................. 5-62
INSTALLING THE TRANSMISSION ....................................................... 5-63
ENGINE REMOVAL
EAS23710
ENGINE REMOVAL
Removing the exhaust pipe/muffler
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
4
T.
R.
8 Nm (0.8 m • kg, 5.8 ft • Ib)
LT
LT 3
8 Nm (0.8 m • kg, 5.8 ft • Ib)

T.
R.
24 Nm (2.4 m • kg, 17 ft • Ib)

LT
T.
1
R.
3
3
2 New
LT
8 Nm (0.8 m • kg, 5.8 ft • Ib)

T.
R.
3
LT LT
LT 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.

Right side cover 4-1.
1 Exhaust pipe/muffler 1
2 Gasket 1
3 Exhaust pipe/muffler protector 4
4 Spark arrester 1
dure.
5-1
ENGINE REMOVAL
Removing the engine
22 Nm (2.2 m • kg, 16 ft • Ib) 12 4 1 New

T.
R.
13 New
6
7
3
2
LS
14
9 5
10
11
22 Nm (2.2 m • kg, 16 ft • Ib)
T.
R.
15

Fuel tank/Air filter case Refer to “FUEL TANK” on page 6-1.
Drive sprocket Refer to “CHAIN DRIVE” on page 4-38.
Carburetor Refer to “CARBURETOR” on page 6-3.
Starter motor assembly/Sidestand/footrest Refer to “ELECTRIC STARTER” on page
bracket assembly 5-31.
1 Rear brake rod 1
2 Brake pedal 1
3 Crankcase breather hose 1
4 Pickup coil/stator assembly coupler 2 Disconnect.
5 Neutral switch coupler 1 Disconnect.
6 Engine mounting nut (front side) 1
7 Washer 1
8 Engine mounting bolt (front side) 1
9 Engine mounting nut (rear lower side) 1
10 Washer 1
11 Engine mounting bolt (rear lower side) 1
12 Engine mounting nut (rear upper side) 1
13 Washer 1
5-2
ENGINE REMOVAL
Removing the engine
22 Nm (2.2 m • kg, 16 ft • Ib) 12 4 1 New

T.
R.
13 New
6
7
3
2
LS
14
9 5
10
11
22 Nm (2.2 m • kg, 16 ft • Ib)
T.
R.
15

14 Engine mounting bolt (rear upper side) 1
15 Engine 1
dure.
5-3
ENGINE REMOVAL
EAS23720
INSTALLING THE ENGINE

1. Install:
• Engine “1”
• Engine mounting bolt (rear upper side) “2”
• Washer “3”
• Engine mounting nut (rear upper side) “4”
• Engine mounting bolt (rear lower side) “5”
• Washer “6”
• Engine mounting nut (rear lower side) “7”
• Engine mounting bolt (front side) “8”
• Washer “9”
• Engine mounting nut (front side) “10”
NOTE:
Do not fully tighten the nuts at this stage.
4
3
10
9
7 2
6
1 5
8
2. Tighten:
• Engine mounting nut (rear upper side)
• Engine mounting nut (rear lower side)
• Engine mounting nut (front side)
Engine mounting nut (rear upper

side)
T.
R.
22 Nm (2.2 m·kg, 16 ft·lb)

Engine mounting nut (rear lower
side)
22 Nm (2.2 m·kg, 16 ft·lb)
Engine mounting nut (front side)
22 Nm (2.2 m·kg, 16 ft·lb)
EAS5B61015
INSTALLING THE EXHAUST PIPE/MUFFLER

1. Install:
• Washer
• Exhaust pipe/muffler protector
• Gasket New
• Exhaust pipe/muffler bolt
• Exhaust pipe/muffler nut
• Exhaust pipe/muffler
NOTE:
Install the washer with its chamfered side facing
the exhaust pipe/muffler.
5-4
CYLINDER HEAD
EAS24100
CYLINDER HEAD
Removing the cylinder head
8
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
LS
New 9
3
New 12
E
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
13
13 Nm (1.3 m • kg, 9.4 ft • Ib) 2
T.
R.
LS
18 Nm (1.8 m • kg, 13 ft • Ib)
T.
R.
5 3 Nm (0.3 m • kg, 2.2 ft • Ib)
T.
R.
13 E
15 14
New
1 10
LS
New
7
(4) New
E LS
11
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
New
R.
LS
6 4
7 Nm (0.7 m • kg, 5.1 ft • Ib)
E
T.
22 Nm (2.2 m • kg, 16 ft • Ib)

R.
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
T.
R.
R.

Exhaust pipe/muffler Refer to “ENGINE REMOVAL” on page 5-1.
Air filter case Refer to “FUEL TANK” on page 6-1.
Carburetor/Starter lever Refer to “CARBURETOR” on page 6-3.
1 Spark plug 1
2 Crankshaft end cover 1
3 Timing mark accessing screw 1
4 Camshaft sprocket cover 1
5 Intake tappet cover 1
6 Exhaust tappet cover 1
7 Camshaft sprocket bolt 1
8 Timing chain tensioner 1
9 Timing chain tensioner gasket 1
10 Camshaft sprocket 1
11 Cylinder head 1
12 Cylinder head gasket 1
13 Dowel pin 2
5-5
CYLINDER HEAD
Removing the cylinder head
8
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
LS
New 9
3
New 12
E
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
13
13 Nm (1.3 m • kg, 9.4 ft • Ib) 2
T.
R.
LS
18 Nm (1.8 m • kg, 13 ft • Ib)
T.
R.
5 3 Nm (0.3 m • kg, 2.2 ft • Ib)
T.
R.
13 E
15 14
New
1 10
LS
New
7
(4) New
E LS
11
20 Nm (2.0 m • kg, 14 ft • Ib)
T.
New
R.
LS
6 4
7 Nm (0.7 m • kg, 5.1 ft • Ib)
E
T.
22 Nm (2.2 m • kg, 16 ft • Ib)

R.
T.
R.
18 Nm (1.8 m • kg, 13 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
T.
R.
R.

14 Timing chain guide (exhaust side) 1
15 Intake manifold 1
dure.
* Apply Yamaha bond No. 1215 (Three Bond No. 1215®).
5-6
CYLINDER HEAD
EAS24130
REMOVING THE CYLINDER HEAD NOTE:

1. Align: To prevent the timing chain from falling into the
• “I” mark “a” on the AC magneto rotor crankcase, fasten it with a wire.
(with the stationary pointer “b” on the AC 4. Remove:
magneto cover) • Cylinder head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft counterclockwise. NOTE:
b. When the piston is at TDC on the compres- • Loosen the bolts and nuts in the proper se-
sion stroke, align the “I” mark “c” on the cam- quence as shown.
shaft sprocket with the stationary pointer “d” • Loosen each bolt and nut 1/2 of a turn at a
on the cylinder head. time. After all of the bolts and nuts are fully
loosened, remove them.
a b
1
5 3
4 6
2
EAS24160
CHECKING THE CYLINDER HEAD

c 1. Eliminate:
• Combustion chamber carbon deposits
d (with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damag-
ing or scratching:
• Spark plug bore threads
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Valve seats
2. Loosen:
• Camshaft sprocket bolt “1”
NOTE:
While holding the AC magneto nut with a
wrench, remove the camshaft sprocket bolt.
2. Check:
• Cylinder head
1 Damage/scratches → Replace.
3. Measure:
• Cylinder head warpage
3. Remove: Out of specification → Resurface the cylinder
• Timing chain tensioner head.
• Camshaft sprocket
5-7
CYLINDER HEAD
2. Check:
Warpage limit • Timing chain guide (exhaust side)
0.03 mm (0.0012 in) Damage/wear → Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ EAS24200
a. Place a straightedge “1” and a thickness CHECKING THE TIMING CHAIN TENSIONER
gauge “2” across the cylinder head. 1. Check:
• Timing chain tensioner
Cracks/damage/rough movement → Re-
place.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Lightly press the timing chain tensioner rod
into the timing chain tensioner housing by
hand.
NOTE:
While pressing the timing chain tensioner rod,
wind it clockwise with a thin screwdriver “1” until
b. Measure the warpage. it stops.
c. If the limit is exceeded, resurface the cylinder
head as follows.
d. Place a 400–600 grit wet sandpaper on the
surface plate and resurface the cylinder head
using a figure-eight sanding pattern.
NOTE: 1
To ensure an even surface, rotate the cylinder
head several times.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS5B61006
CHECKING THE CAMSHAFT SPROCKET b. Remove the screwdriver and slowly release
AND TIMING CHAIN GUIDES the timing chain tensioner rod.
The following procedure applies to all of the c. Make sure that the timing chain tensioner rod
camshaft sprockets and timing chain guides. comes out of the timing chain tensioner hous-
1. Check: ing smoothly. If there is rough movement, re-
• Camshaft sprocket place the timing chain tensioner.
More than 1/4 tooth wear “a” → Replace the
camshaft sprockets and the timing chain as a
set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24230
INSTALLING THE CYLINDER HEAD

b. Correct 1. Tighten:
1. Timing chain roller • Cylinder head nuts
2. Camshaft sprocket
Cylinder head nut
22 Nm (2.2 m·kg, 16 ft·lb)
T.
R.
5-8
CYLINDER HEAD
• Cylinder head bolts d. Install the timing chain onto the camshaft
sprocket, and then install the camshaft
Cylinder head bolt sprocket onto the camshaft.
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
NOTE:
R.
NOTE:
When installing the camshaft sprocket, be sure
to keep the timing chain as tight as possible on
• Lubricate the cylinder head bolts, nuts and
the exhaust side.
copper washers with engine oil.
ECA5B61011
• Apply locking agent (Three bond, No. 1215) to
CAUTION:
the threads of the bolts “a”.
• Tighten the cylinder head nuts and bolts in the Do not turn the crankshaft when installing
proper tightening sequence as shown and the camshaft to avoid damage or improper
torque them in two stages. valve timing.
e. While holding the camshaft, temporarily tight-
en the camshaft sprocket bolt.
6 f. Remove the wire from the timing chain.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2 4
3. Install:
a
• Timing chain tensioner gasket New
• Timing chain tensioner
3 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
5 a. While lightly pressing the timing chain ten-
sioner rod by hand, turn the tensioner rod ful-
2. Install: ly clockwise with a thin screwdriver “1”.
• Camshaft sprocket b. With the timing chain tensioner rod turned all
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ the way into the timing chain tensioner hous-
a. Turn the crankshaft counterclockwise. ing (with the thin screwdriver still installed), in-
b. Align the “I” mark “a” on the AC magneto rotor stall the gasket and the timing chain tensioner
with the stationary pointer “b” on the AC mag- “2” onto the cylinder block.
neto cover. c. Tighten the timing chain tensioner bolts to the
specified torque.
a Timing chain tensioner bolt

b
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
1
c. Align the “I” mark “c” on the camshaft sprock-
et with the stationary pointer “d” on the cylin-
der head.
5-9
CYLINDER HEAD
ECA5B61012
CAUTION:
1
Be sure to tighten the camshaft sprocket bolt
to the specified torque to avoid the possibil-
ity of the bolt coming loose and damaging
the engine.
NOTE:
2
While holding the AC magneto rotor nut with a
wrench, tighten the camshaft sprocket bolt.
d. Remove the screwdriver, make sure the tim- 7. Measure:

ing chain tensioner rod releases. • Valve clearance
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Refer to “ADJUSTING THE VALVE CLEAR-
4. Turn:
ANCE” on page 3-3.
• Crankshaft
(several turns counterclockwise)
5. Check:
• “I” mark “a”
Align the “I” mark on the AC magneto rotor
with the stationary pointer “b” on the AC mag-
neto cover.
• “I” mark “c”
Align the “I” mark on the camshaft sprocket
with the stationary pointer “d” on the cylinder
head.
Out of alignment → Correct.
Refer to the installation steps above.
a b
6. Tighten:
• Camshaft sprocket bolts
Camshaft sprocket bolt

20 Nm (2.0 m·kg, 14 ft·lb)
T.
R.
5-10
CAMSHAFT
EAS23730
CAMSHAFT
Removing the rocker arms and camshaft
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
M
1 2
5
E
E
LS M
5 6
New
4
2
1 M 3
E
M LT
E
T.
T.
R.
R.

Cylinder head Refer to “CYLINDER HEAD” on page 5-5.
1 Locknut 2
2 Valve clearance adjusting screw 2
3 Camshaft retainer 1
4 Rocker arm shaft 2
5 Rocker arm 2
6 Camshaft 1
dure.
5-11
CAMSHAFT
EAS23770
REMOVING THE ROCKER ARMS AND Camshaft lobe dimensions

CAMSHAFT Intake A
1. Remove: 25.775–25.875 mm (1.0148–
• Rocker arm shafts 1.0187 in)
• Rocker arms Limit
NOTE: 25.745 mm (1.0136 in)
Intake B
Remove the rocker arm shafts with the slide 21.045–21.145 mm (0.8285–
hammer bolt “1” and weight “2”. 0.8325 in)
Limit
Slide hammer bolt 21.015 mm (0.8274 in)
90890-01085 Exhaust A
Slide hammer bolt 8 mm 25.775–25.875 mm (1.0148–
YU-01083-2 1.0187 in)
Weight Limit
90890-01084 25.749 mm (1.0137 in)
YU-01083-3 Exhaust B
20.950–21.050 mm (0.8248–
0.8287 in)
Limit
1 20.924 mm (0.8238 in)
2
2. Remove:
• Camshaft “1”
NOTE:
Screw a 8-mm bolt “2” into the threaded end of
the camshaft and then pull out the camshaft.
1 2
3. Check:
• Camshaft oil passage
EAS23840
Obstruction → Blow out with compressed air.
CHECKING THE CAMSHAFT EAS23880
1. Check: CHECKING THE ROCKER ARMS AND
• Camshaft lobes ROCKER ARM SHAFTS
Blue discoloration/pitting/scratches → Re- The following procedure applies to all of the
place the camshaft. rocker arms and rocker arm shafts.
• Camshaft lobe dimensions “a” and “b” • Rocker arm
Out of specification → Replace the camshaft. Damage/wear → Replace.
5-12
CAMSHAFT
2. Check:
• Rocker arm shaft Rocker-arm-to-rocker-arm-shaft
Blue discoloration/excessive wear/pit- clearance
ting/scratches → Replace or check the lubri- 0.009–0.034 mm (0.0004–0.0013
in)
cation system.
Limit
3. Measure: 0.08 mm (0.0032 in)
• Rocker arm inside diameter “a”
Out of specification → Replace. EAS24040
INSTALLING THE CAMSHAFT AND ROCKER

Rocker arm inside diameter ARMS
10.000–10.015 mm (0.3937– 1. Lubricate:
0.3943 in)
• Camshaft
Limit
10.030 mm (0.3949 in) Recommended lubricant
Camshaft
Molybdenum disulfide grease
Camshaft bearing
Engine oil
2. Install:
• Camshaft retainer
Camshaft retainer bolt

10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
LOCTITE®
4. Measure:
3. Lubricate:
• Rocker arm shaft outside diameter “a”
• Rocker arms
Out of specification → Replace.
• Rocker arm shafts
Rocker arm shaft outside diame-
ter Recommended lubricant
9.981–9.991 mm (0.3930–0.3933 Rocker arm inner surface and
in) rocker arm shaft
Limit Molybdenum disulfide grease
9.950 mm (0.3917 in) Rocker arm hole
Engine oil
4. Install:
• Rocker arms
• Rocker arm shafts
NOTE:
Make sure the rocker arm shafts are completely
pushed into the cylinder head.
5. Calculate:
• Rocker-arm-to-rocker-arm-shaft clearance
NOTE:
Calculate the clearance by subtracting the rock-
er arm shaft outside diameter from the rocker
arm inside diameter.
Out of specification → Replace the defective
part(s).
5-13
VALVES AND VALVE SPRINGS
EAS24270

Removing the valves and valve springs
1 2 3 7
4
8
4
7
3
2
1

Rocker arms/Camshaft Refer to “CAMSHAFT” on page 5-11.
1 Valve cotter 4
2 Upper spring seat 2
3 Valve spring 2
4 Lower spring seat 2
5 Intake valve 1
6 Exhaust valve 1
7 Valve stem seal 2
8 Valve guide 2
dure.
5-14
EAS24280
REMOVING THE VALVES

The following procedure applies to all of the 2
valves and related components.
NOTE:
Before removing the internal parts of the cylinder
head (e.g., valves, valve springs, valve seats),
make sure the valves properly seal.
1. Check: 1
• Valve sealing
Leakage at the valve seat → Check the valve 3. Remove:
face, valve seat, and valve seat width. • Upper spring seat “1”
Refer to “CHECKING THE VALVE SEATS” • Valve spring “2”
on page 5-17. • Lower spring seat “3”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Valve “4”
a. Pour a clean solvent “a” into the intake and • Valve stem seal “5”
exhaust ports. NOTE:
b. Check that the valves properly seal. Identify the position of each part very carefully so
NOTE: that it can be reinstalled in its original place.
There should be no leakage at the valve seat “1”.
EAS24290
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ CHECKING THE VALVES AND VALVE

2. Remove: GUIDES
• Valve cotters “1” The following procedure applies to all of the
NOTE: valves and valve guides.
Remove the valve cotters by compressing the 1. Measure:
valve spring with the valve spring compressor • Valve-stem-to-valve-guide clearance
and the valve spring compressor attachment “2”. Out of specification → Replace the valve
guide.
Valve spring compressor • Valve-stem-to-valve-guide clearance =
90890-04019 Valve guide inside diameter “a” -
YM-04019 Valve stem diameter “b”
Valve spring compressor attach-
ment
90890-04108
Valve spring compressor adapt-
er 22 mm
YM-04108
5-15
b. Install the new valve guide with the valve

Valve-stem-to-valve-guide clear- guide installer “2” and valve guide remover
ance (intake) “1”.
0.010–0.037 mm (0.0004–0.0015
in)
Limit
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear-
ance (exhaust)
0.025–0.052 mm (0.0010–0.0020
in)
Limit
0.100 mm (0.0039 in)
c. After installing the valve guide, bore the valve

guide with the valve guide reamer “3” to ob-
tain the proper valve-stem-to-valve-guide
clearance.
NOTE:
After replacing the valve guide, reface the valve
seat.
Valve guide remover (ø4.5)

90890-04116
Valve guide remover (4.5 mm)
2. Replace: YM-04116
• Valve guide Valve guide installer (ø4.5)
NOTE: 90890-04117
To ease valve guide removal and installation, Valve guide installer (4.5 mm)
and to maintain the correct fit, heat the cylinder YM-04117
head to 100 °C (212 °F) in an oven. Valve guide reamer (ø4.5)
90890-04118
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Valve guide reamer (4.5 mm)
a. Remove the valve guide with the valve guide YM-04118
remover “1”.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
4. Check:
• Valve face
Pitting/wear → Grind the valve face.
5-16
• Valve stem end 2. Check:

Mushroom shape or diameter larger than the • Valve seat
body of the valve stem → Replace the valve. Pitting/wear → Replace the cylinder head.
5. Measure: 3. Measure:
• Valve margin thickness “a” • Valve seat width “a”
Out of specification → Replace the valve. Out of specification → Replace the cylinder
head.
Valve margin thickness D (intake)
0.50–0.90 mm (0.0197–0.0354 in) Valve seat width C (intake)
Valve margin thickness D (ex- 0.90–1.10 mm (0.0354–0.0433 in)
haust) Limit
0.80–1.20 mm (0.0315–0.0472 in) 1.6 mm (0.06 in)
Valve seat width C (exhaust)
0.90–1.10 mm (0.0354–0.0433 in)
Limit
1.6 mm (0.06 in)
6. Measure:
• Valve stem runout
Out of specification → Replace the valve.
NOTE:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• When installing a new valve, always replace a. Apply Mechanic’s blueing dye (Dykem) “b”
the valve guide. onto the valve face.
• If the valve is removed or replaced, always re-
place the valve stem seal.
Valve stem runout

0.010 mm (0.0004 in)
b. Install the valve into the cylinder head.

c. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
d. Measure the valve seat width.
NOTE:
EAS24300
CHECKING THE VALVE SEATS Where the valve seat and valve face contacted
The following procedure applies to all of the one another, the blueing will have been re-
valves and valve seats. moved.
1. Eliminate: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Carbon deposits 4. Lap:
(from the valve face and valve seat) • Valve face
• Valve seat
5-17
NOTE:
After replacing the cylinder head or replacing the
valve and valve guide, the valve seat and valve
face should be lapped.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound “a” to the
valve face.
ECA13790
CAUTION:
Do not let the lapping compound enter the
gap between the valve stem and the valve h. Install the valve into the cylinder head.
guide. i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width “c” again. If the
valve seat width is out of specification, reface
and lap the valve seat.
b. Apply molybdenum disulfide oil onto the

valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all of
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
the lapping compound.
EAS24310
NOTE: CHECKING THE VALVE SPRINGS
For the best lapping results, lightly tap the valve The following procedure applies to all of the
seat while rotating the valve back and forth be- valve springs.
tween your hands. 1. Measure:
• Valve spring free length “a”
Out of specification → Replace the valve
spring.
Free length (intake)

33.75 mm (1.33 in)
Limit
32.06 mm (1.26 in)
Free length (exhaust)
33.75 mm (1.33 in)
Limit
e. Apply a fine lapping compound to the valve 32.06 mm (1.26 in)
face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from the
valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) “b”
onto the valve face.
5-18
2. Measure: EAS24340
• Compressed valve spring force “a” INSTALLING THE VALVES

Out of specification → Replace the valve The following procedure applies to all of the
spring. valves and related components.
1. Deburr:
Installed compression spring • Valve stem end
force (intake) (with an oil stone)
138.00–158.00 N (31.02–35.52
lbf) (14.07–16.11 kgf)
Installed compression spring
force (exhaust)
138.00–158.00 N (31.02–35.52
lbf) (14.07–16.11 kgf)
Installed length (intake)
24.20 mm (0.95 in)
Installed length (exhaust)
24.20 mm (0.95 in)
2. Lubricate:
• Valve stem “1”
• Valve stem seal “2”
(with the recommended lubricant)
Engine oil
b. Installed length
3. Measure:
• Valve spring tilt “a”
Out of specification → Replace the valve
spring.
Spring tilt (intake)

2.5°/1.5 mm (2.5°/0.059 in ) 3. Install:
Spring tilt (exhaust)
• Valve stem seal “1” New
2.5°/1.5 mm (2.5°/0.059 in )
• Valve “2”
• Lower spring seat “3”
• Valve spring “4”
• Upper spring seat “5”
(into the cylinder head)
5-19
NOTE:
• Make sure each valve is installed in its original 2
place.
• Install the valve springs with the larger pitch “a”
facing up.
1
5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a soft-face
hammer.
ECA13800
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.
b. Smaller pitch
4. Install:
• Valve cotters “1”
NOTE:
Install the valve cotters by compressing the
valve spring with the valve spring compressor
and the valve spring compressor attachment “2”.
Valve spring compressor

90890-04019
YM-04019
Valve spring compressor attach-
ment
90890-04108
Valve spring compressor adapt-
er 22 mm
YM-04108
5-20
CYLINDER AND PISTON
EAS24350
CYLINDER AND PISTON

Removing the cylinder and piston
New 2 3
1 New
3
4 New
E 6
9
8
7
5
4 New

1 Cylinder 1
2 Cylinder gasket 1
3 Dowel pin 2
4 Piston pin clip 2
5 Piston pin 1
6 Piston 1
7 Top ring 1
8 2nd ring 1
9 Oil ring 1
dure.
5-21
CYLINDER AND PISTON
EAS24380
REMOVING THE PISTON NOTE:

1. Remove: When removing a piston ring, open the end gap
• Piston pin clips “1” with your fingers and lift the other side of the ring
• Piston pin “2” over the piston crown.
• Piston “3”
ECA13810
CAUTION:
Do not use a hammer to drive the piston pin
out.
NOTE:
• Before removing the piston pin clips, cover the
crankcase opening with a clean rag to prevent
them from falling into the crankcase.
• Before removing the piston pin, deburr the pis-
ton pin clip grooves and the piston pin bore ar- EAS24400
ea. If both areas are deburred and the piston CHECKING THE CYLINDER AND PISTON
pin is still difficult to remove, remove it with the 1. Check:
piston pin puller set “4”. • Piston wall
• Cylinder wall
Vertical scratches → Rebore or replace the
Piston pin puller set cylinder, and replace the piston and piston
90890-01304 rings as a set.
Piston pin puller
2. Measure:
YU-01304
• Piston-to-cylinder clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore “C” with the cylinder
bore gauge.
3
2
1
1. 40 mm (1.57 in) from the top of the cylinder
NOTE:
Measure cylinder bore “C” by taking side-to-side
and front-to-back measurements of the cylinder.
Then, find the average of the measurements.
Bore
2. Remove: 51.000–51.015 mm (2.0079–
• Top ring 2.0085 in)
• 2nd ring Wear limit
• Oil ring 51.05 mm (2.010 in)
“C” = (X + Y)/2
5-22
CYLINDER AND PISTON
b. If out of specification, rebore or replace the

cylinder, and replace the piston and piston Piston ring
rings as a set. Top ring
c. Measure piston skirt diameter D “a” with the Ring side clearance
0.030–0.070 mm (0.0012–
micrometer.
0.0028 in)
Diameter D Limit
50.977–50.992 mm (2.0070– 0.120 mm (0.0047 in)
2.0076 in) 2nd ring
Ring side clearance
0.020–0.060 mm (0.0008–
0.0024 in)
Limit
0.120 mm (0.0047 in)
b. 5 mm (0.20 in) from the bottom edge of the

piston
d. If out of specification, replace the piston and
piston rings as a set.
e. Calculate the piston-to-cylinder clearance 2. Install:
with the following formula. • Piston ring
(into the cylinder)
• Piston-to-cylinder clearance =
Cylinder bore “C” - NOTE:
Piston skirt diameter “D” Level the piston ring into the cylinder with the
piston crown.
Piston-to-cylinder clearance
0.020–0.025 mm (0.0008–0.0010
in)
Limit
0.15 mm (0.0059 in)
f. If out of specification, rebore or replace the

cylinder, and replace the piston and piston
rings as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS24430
a. 40 mm (1.57 in)
CHECKING THE PISTON RINGS
1. Measure: 3. Measure:
• Piston ring side clearance • Piston ring end gap
Out of specification → Replace the piston Out of specification → Replace the piston
and piston rings as a set. ring.
NOTE: NOTE:
Before measuring the piston ring side clearance, The oil ring expander spacer end gap cannot be
eliminate any carbon deposits from the piston measured. If the oil ring rail gap is excessive, re-
ring grooves and piston rings. place all three piston rings.
5-23
CYLINDER AND PISTON
End gap (installed)

0.10–0.25 mm (0.0039–0.0098 in)
Limit
0.40 mm (0.0157 in)
End gap (installed)
0.10–0.25 mm (0.0039–0.0098 in)
Limit
0.40 mm (0.0157 in)
End gap (installed)
0.20–0.70 mm (0.0079–0.0276 in)
4. Calculate:
EAS24440 • Piston-pin-to-piston-pin-bore clearance
CHECKING THE PISTON PIN Out of specification → Replace the piston pin
1. Check: and piston as a set.
• Piston pin
• Piston-pin-to-piston-pin-bore clearance =
Blue discoloration/grooves → Replace the Piston pin bore diameter “b” -
piston pin and then check the lubrication sys- Piston pin outside diameter “a”
tem.
2. Measure:
• Piston pin outside diameter “a” Piston-pin-to-piston-pin-bore
Out of specification → Replace the piston pin. clearance
0.002–0.017 mm (0.0001–0.0007
Piston pin outside diameter in)
12.996–13.000 mm (0.5117– Limit
0.5118 in) 0.067 mm (0.0026 in)
Limit
12.976 mm (0.5109 in) EAS24450
INSTALLING THE PISTON AND CYLINDER

1. Install:
• Top ring “1”
• 2nd ring “2”
• Oil ring expander “3”
• Lower oil ring rail “4”
• Upper oil ring rail “5”
NOTE:
Be sure to install the piston rings so that the
manufacturer marks or numbers face up.
3. Measure:
• Piston pin bore diameter “b”
Out of specification → Replace the piston.
Piston pin bore inside diameter

13.002–13.013 mm (0.5119–
0.5123 in)
Limit
13.043 mm (0.5135 in)
2. Install:
• Piston “1”
• Piston pin “2”
• Piston pin clips “3” New
NOTE:
• Apply engine oil onto the piston pin.
5-24
CYLINDER AND PISTON
• Make sure the arrow mark “a” on the piston

A
points towards the exhaust side of the cylinder.
• Before installing the piston pin clips, cover the g 120˚ c
crankcase opening with a clean rag to prevent
them from falling into the crankcase.
e
120˚ 120˚
90˚
h h
1 f d
2
a c. Top ring
d. Lower oil ring rail
New 3 e. Oil ring expander
f. Upper oil ring rail
g. 2nd ring
3. Lubricate: h. 10 mm (0.39 in)
• Piston A. Exhaust side
• Piston rings 5. Install:
• Cylinder • Dowel pins
• Cylinder gasket New
Recommended lubricant • Cylinder “1”
Engine oil NOTE:
• While compressing the piston rings with one
4. Offset: hand, install the cylinder with the other hand.
• Piston ring end gaps • Pass the timing chain and timing chain guide
NOTE: (intake side) through the timing chain cavity.
Fit the projection “a” on the end of the upper oil
ring rail into the groove “b” in the piston.
1
a b
5-25
GENERATOR AND STARTER CLUTCH
EAS5B61019

Removing the generator and starter clutch
2
3
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
2
LS
17 LT
13 11
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
15
10
9 6
14
8
(3)
M
E LS
New 12 E 7
14 Nm (1.4 m • kg, 10 ft • Ib)
T.
(3)
R.
16
70 Nm (7.0 m • kg, 50 ft • Ib)
T.
New
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib) LT

LT
T.
4
R.
6
3 Nm (0.3 m • kg, 2.2 ft • Ib)
New 5
T.
R.
8 Nm (0.8 m • kg, 5.8 ft • Ib)

T.
R.
LS
1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

Seat/Left side cover 4-1.
Drive sprocket cover Refer to “CHAIN DRIVE” on page 4-38.
1 Shift pedal 1
2 Pickup coil/stator assembly coupler 2 Disconnect.
3 Neutral switch coupler 1 Disconnect.
4 AC magneto cover 1
5 AC magneto cover gasket 1
6 Dowel pin 2
7 AC magneto rotor 1
8 Woodruff key 1
9 Starter clutch idle gear shaft 1
10 Starter clutch idle gear 1
11 Starter clutch gear 1
12 Starter clutch assembly 1
13 Shim 1
5-26
Removing the generator and starter clutch

2
3
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
2
LS
17 LT
13 11
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
15
10
9 6
14
8
(3)
M
E LS
New 12 E 7
14 Nm (1.4 m • kg, 10 ft • Ib)
T.
(3)
R.
16
70 Nm (7.0 m • kg, 50 ft • Ib)
T.
New
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib) LT

LT
T.
4
R.
6
3 Nm (0.3 m • kg, 2.2 ft • Ib)
New 5
T.
R.
8 Nm (0.8 m • kg, 5.8 ft • Ib)

T.
R.
LS
1
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

14 Pickup coil/stator assembly lead holder 1
15 Pickup coil 1
16 Stator coil 1
17 Clutch release adjusting screw 1
dure.
5-27
EAS24490
REMOVING THE GENERATOR

1. Remove:
• AC magneto cover
NOTE:
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern. After all of the
bolts are fully loosened, remove them.
2. Remove:
• AC magneto rotor nut “1”
• Washer EAS24560
NOTE:
REMOVING THE STARTER CLUTCH
1. Remove:
• While holding the AC magneto rotor “2” with
• Starter clutch bolts “1”
the sheave holder “3”, loosen the AC magneto
NOTE:
rotor nut.
• Do not allow the sheave holder to touch the • While holding the AC magneto rotor “2” with
projection on the AC magneto rotor. the sheave holder “3”, remove the starter
clutch bolts.
• Do not allow the sheave holder to touch the
Sheave holder
90890-01701 projection on the AC magneto rotor.
Primary clutch holder
YS-01880-A Sheave holder
90890-01701
2 YS-01880-A
1
3
3. Remove: 3
• AC magneto rotor “1” 2
(with the flywheel puller “2”)
• Woodruff key EAS24570
ECA13880 CHECKING THE STARTER CLUTCH

CAUTION: 1. Check:
To protect the end of the crankshaft, place an • Starter clutch rollers “1”
appropriate sized socket between the fly- • Starter clutch spring caps “2”
wheel puller set center bolt and the crank- • Starter clutch springs “3”
shaft. Damage/wear → Replace the defective
part(s).
NOTE:
Make sure the flywheel puller is centered over
the AC magneto rotor.
Flywheel puller
90890-01362
Heavy duty puller
YU-33270-B
5-28
2 NOTE:
1 3
the sheave holder “3”, tighten the starter clutch
1
bolts.
2 projection on the AC magneto rotor.
• Stake the end “a” of each starter clutch bolt.
3
3
2 1 Sheave holder
90890-01701
2. Check: Primary clutch holder
• Starter clutch idle gear YS-01880-A
• Starter clutch gear
Burrs/chips/roughness/wear → Replace the
defective part(s). 1 New
3. Check:
• Starter clutch gear contacting surfaces
Damage/pitting/wear → Replace the starter
clutch gear.
4. Check:
• Starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
3 2
a. Install the starter clutch gear onto the starter
clutch and hold the AC magneto rotor.
b. When turning the starter clutch gear clock- a
wise “A”, the starter clutch and the starter a
clutch gear should engage, otherwise the
starter clutch is faulty and must be replaced.
c. When turning the starter clutch gear counter-
clockwise “B”, it should turn freely, otherwise
the starter clutch is faulty and must be re-
placed. a
B EAS24500
INSTALLING THE GENERATOR

1. Install:
• Woodruff key
• AC magneto rotor
• Washer
A • AC magneto rotor nut
NOTE:
• Clean the tapered portion of the crankshaft and
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ the AC magneto rotor hub.
EAS24600
• When installing the AC magneto rotor, make
INSTALLING THE STARTER CLUTCH sure the woodruff key is properly seated in the
1. Install: keyway of the crankshaft.
• Starter clutch • Install the washer with its sharp-edged side
• Starter clutch bolts “1” New facing the AC magneto rotor.
2. Tighten:
Starter clutch bolt • AC magneto rotor nut “1”
14 Nm (1.4 m·kg, 10 ft·lb)
T.
R.
5-29
NOTE:
AC magneto rotor nut
70 Nm (7.0 m·kg, 50 ft·lb) Tighten the AC magneto cover bolts in stages
T.
and in a crisscross pattern.

R.
NOTE: 5. Adjust:
• While holding the AC magneto rotor “2” with • Clutch release system
the sheave holder “3”, tighten the AC magneto Refer to “CLUTCH” on page 5-37.
rotor nut. 6. Install:
• Do not allow the sheave holder to touch the • Neutral switch lead “1”
projection on the AC magneto rotor. NOTE:
Route the neutral switch lead as shown in the il-
Sheave holder lustration, and then use adhesive to affix the
90890-01701 lead to the AC magneto cover at the location “a”.
YS-01880-A
1
2
a
1
3 7. Install:
• Shift pedal “1”
3. Apply:
Shift pedal bolt
• Sealant
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
(onto the pickup coil/stator assembly lead

R.
grommet)
NOTE:
Yamaha bond No. 1215 Align the top of the shift pedal end with the line
90890-85505 “c” shown in the illustration between the fins “a”
(Three Bond No.1215®) and “b” on the AC magneto cover, and then
slightly rotate the pedal counterclockwise and in-
stall it at the position where the grooves in the
pedal hole first align with the splines on the shift
shaft.
c
4. Install: 1
• AC magneto cover
b
AC magneto cover bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
5-30
ELECTRIC STARTER
EAS24780
ELECTRIC STARTER
Removing the starter motor
* 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
2
R.
1
23 Nm (2.3 m • kg, 17 ft • Ib) (4)

T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)

T.
R.

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-9.
1 Sidestand/footrest bracket assembly 1
2 Starter motor cover 1
3 Starter motor assembly 1
4 Starter motor lead 1 Disconnect.
dure.
* Apply Yamaha bond No. 1215 (Three Bond No. 1215®).
5-31
ELECTRIC STARTER
Disassembling the starter motor
1 New
LS 4
2 5
6 3 New
7
8
5
4

1 O-ring 1
2 Starter motor front cover/brush holder set 1
3 Gasket 1
4 Brush 2
5 Spring 2
6 Washer 1
7 Armature assembly 1
8 Starter motor yoke 1
cedure.
5-32
ELECTRIC STARTER
EAS5B61016
REMOVING THE STARTER MOTOR

EWA5B61008
WARNING
2. Remove:
• Sidestand/footrest bracket assembly
EAS24790
CHECKING THE STARTER MOTOR 4. Measure:

1. Check: • Armature assembly resistances (commutator
• Commutator and insulation)
Dirt → Clean with 600 grit sandpaper. Out of specification → Replace the starter
2. Measure: motor.
• Commutator diameter “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Out of specification → Replace the starter a. Measure the armature assembly resistances
motor. with the pocket tester.
Limit Pocket tester

16.6 mm (0.65 in) 90890-03112
Analog pocket tester
YU-03112-C
Armature coil
Commutator resistance “1”
0.018–0.022 Ω
Insulation resistance “2”
Above 1 MΩ at 20 °C (68 °F)
b. If any resistance is out of specification, re-

place the starter motor.
3. Measure:
• Mica undercut “a”
Out of specification → Scrape the mica to the
proper measurement with a hacksaw blade
that has been grounded to fit the commutator.
Mica undercut (depth)

1.35 mm (0.05 in)
NOTE:
The mica of the commutator must be undercut to ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ensure proper operation of the commutator. 5. Measure:
• Brush length “a”
Out of specification → Replace the starter
motor front cover/brush holder set.
Limit
3.50 mm (0.14 in)
5-33
ELECTRIC STARTER
NOTE:
Be sure not to pinch the starter motor lead when
installing the sidestand/footrest assembly.
6. Measure:
• Brush spring force
Out of specification → Replace the brush
springs as a set.
Brush spring force

3.92–5.88 N (14.11–21.17 oz)
(400–600 gf)
7. Check:
• Gear teeth
Damage/wear → Replace the gear.
8. Check:
• Bearing
• Oil seal
Damage/wear → Replace the starter motor
front cover/brush holder set.
EAS24800
ASSEMBLING THE STARTER MOTOR

1. Install:
• Starter motor yoke “1”
• Starter motor front cover/brush holder set “2”
NOTE:
Align the match mark on the starter motor yoke
with the match mark on the starter motor front
cover/brush holder set.
EAS5B61017
INSTALLING THE STARTER MOTOR

1. Install:
• Sidestand/footrest assembly
5-34
KICKSTARTER
EAS24820
KICKSTARTER
Removing the kickstarter shaft
12
11
8 New
7
4
3 10
9
2
6
5 New

Clutch cover Refer to “CLUTCH” on page 5-37.
1 Kickstarter assembly 1
2 Spacer 1
3 Kickstarter spring 1
4 Spring guide 1
5 Circlip 1
6 Ratchet gear 1
7 Ratchet gear clip 1
8 Circlip 1
9 Washer 1
10 Wave washer 1
11 Kickstarter gear 1
12 Kickstarter shaft 1
dure.
5-35
KICKSTARTER
EAS24850
CHECKING THE KICKSTARTER

1. Check:
• Ratchet gear
2. Check:
• Kickstarter spring
3. Measure:
• Ratchet gear clip force
(with the spring gauge)
Out of specification → Replace the ratchet
gear clip.
Kick clip friction force

5.88–14.71 N (1.32–3.31 lbf)
(0.60–1.50 kgf)
EAS24880
INSTALLING THE KICKSTARTER

1. Install:
• Kickstarter shaft “1”
• Ratchet gear clip “2”
• Kickstarter spring “3”
NOTE:
• Install the kickstarter shaft “1” and ratchet gear
clip “2” as shown in the illustration.
• Turn the kickstarter spring “3” clockwise and in-
stall its end into the hole “a” in the crankcase.
a
2
1
3
5-36
CLUTCH
EAS25061
CLUTCH
Removing the clutch cover
0.5~1.0 mm
(0.02~0.04 in)
3 New
LS
4
6 New E
5 New
1
13 Nm (1.3 m • kg, 9.4 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib) 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
T.
T.
R.
R.
R.

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-9.
Refer to “ELECTRIC STARTER” on page
Sidestand/footrest bracket assembly 5-31.
1 Kickstarter lever 1
2 Clutch cover 1
3 Clutch cover gasket 1
4 Dowel pin 2
5 Oil seal 1
6 Oil seal 2
dure.
5-37
CLUTCH
Removing the clutch
LS
70 Nm (7.0 m • kg, 50 ft • Ib)
11
T.
R.
E
8
10 13
9 New 12 7
6
7
E
7 4
LS
3
2 5 4
5 4 16 18
1
5 4
4
(4) (4)
E 17
6 Nm (0.6 m • kg, 4.3 ft • Ib)
15
T.
R.
50 Nm (5.0 m • kg, 36 ft • Ib) 14 E

T.
R.

Refer to “GENERATOR AND STARTER
AC magneto cover CLUTCH” on page 5-26.
1 Clutch spring 4
2 Pressure plate 1
3 Short clutch push rod 1
4 Friction plate 5
5 Clutch plate 1 3
6 Clutch plate 2 1
7 Spring 3
8 Long clutch push rod 1
9 Lock washer 1
10 Clutch boss 1
11 Clutch housing 1
12 Spacer 1
13 Spacer 1
14 Spacer 1
15 Primary clutch housing 1
16 Primary clutch boss 1
5-38
CLUTCH
Removing the clutch
LS
70 Nm (7.0 m • kg, 50 ft • Ib)
11
T.
R.
E
8
10 13
9 New 12 7
6
7
E
7 4
LS
3
2 5 4
5 4 16 18
1
5 4
4
(4) (4)
E 17
6 Nm (0.6 m • kg, 4.3 ft • Ib)
15
T.
R.
50 Nm (5.0 m • kg, 36 ft • Ib) 14 E

T.
R.

17 Primary clutch assembly 1
18 Clutch carrier 1
dure.
5-39
CLUTCH
EAS25070
REMOVING THE CLUTCH

1. Remove:
• Clutch cover 1
NOTE:
2. Remove:
• Clutch spring bolts
NOTE:
2
3. Straighten the lock washer tab.
4. Loosen:
• Clutch boss nut “1”
NOTE: 3
While holding the clutch boss “2” with the univer-
sal clutch holder, loosen the clutch boss nut. EAS25100
CHECKING THE FRICTION PLATES

Universal clutch holder The following procedure applies to all of the fric-
90890-04086 tion plates.
YM-91042 1. Check:
• Friction plate
Damage/wear → Replace the friction plates
as a set.
2. Measure:
• Friction plate thickness
Out of specification → Replace the friction
plates as a set.
NOTE:
Measure the friction plate at four places.
2 1
Friction plate thickness
5. Loosen: 2.70–2.90 mm (0.106–0.114 in)
• Primary drive gear nut “1” Wear limit
NOTE: 2.60 mm (0.1024 in)
the sheave holder “3”, loosen the primary drive
gear nut.
projection on the AC magneto rotor.
Sheave holder
90890-01701
YS-01880-A
5-40
CLUTCH
EAS25110 EAS25150
CHECKING THE CLUTCH PLATES CHECKING THE CLUTCH HOUSING

The following procedure applies to all of the 1. Check:
clutch plates. • Clutch housing dogs
1. Check: Damage/pitting/wear → Deburr the clutch
• Clutch plate housing dogs or replace the clutch housing.
Damage → Replace the clutch plates as a NOTE:
set. Pitting on the clutch housing dogs will cause er-
2. Measure: ratic clutch operation.
• Clutch plate warpage
(with a surface plate and thickness gauge “1”) 2. Check:
Out of specification → Replace the clutch • Bearing
plates as a set. Damage/wear → Replace the bearing and
clutch housing.
Warpage limit
EAS25160
0.05 mm (0.0020 in) CHECKING THE CLUTCH BOSS
1. Check:
• Clutch boss splines
Damage/pitting/wear → Replace the clutch
boss.
NOTE:
Pitting on the clutch boss splines will cause er-
ratic clutch operation.
EAS25170
CHECKING THE PRESSURE PLATE

EAS25140
1. Check:
CHECKING THE CLUTCH SPRINGS • Pressure plate
The following procedure applies to all of the Cracks/damage → Replace.
clutch springs. EAS25190
1. Check: CHECKING THE CLUTCH PUSH RODS

• Clutch spring 1. Check:
Damage → Replace the clutch springs as a • Short clutch push rod
set. • Long clutch push rod
2. Measure: Cracks/damage/wear → Replace the defec-
• Clutch spring free length “a” tive part(s).
Out of specification → Replace the clutch 2. Measure:
springs as a set. • Long clutch push rod bending limit
Clutch spring free length
30.30 mm (1.19 in) Push rod bending limit
Minimum length 0.500 mm (0.0197 in)
28.30 mm (1.11 in)
EAS25200
CHECKING THE PRIMARY DRIVE GEAR

1. Check:
• Primary drive gear
Damage/wear → Replace the primary drive
and primary driven gears as a set.
Excessive noise during operation → Replace
the primary drive and primary driven gears as
a set.
5-41
CLUTCH
EAS25210
CHECKING THE PRIMARY DRIVEN GEAR Clutch shoe groove depth

1. Check: 1 mm (0.04 in)
• Primary driven gear Limit
Damage/wear → Replace the primary drive 0.1 mm (0.0039 in)
and primary driven gears as a set.
Excessive noise during operation → Replace
the primary drive and primary driven gears as
a set.
EAS28980
CHECKING THE PRIMARY CLUTCH

HOUSING
1. Check:
• Primary clutch housing
2. Measure:
• Primary clutch housing inside diameter “a” EAS29000
Out of specification → Replace. CHECKING THE PRIMARY CLUTCH

1. Check:
Clutch housing inside diameter • Primary clutch boss
105.0 mm (4.13 in) Damage/wear → Replace.
Limit 2. Check:
106.0 mm (4.17 in) • Primary clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the clutch boss onto the primary clutch
a and hold the primary clutch.
NOTE:
Fit the tabs on the primary clutch boss complete-
ly into the groove in the primary clutch housing.
b. When turning the primary clutch boss clock-
wise “A”, the primary clutch and the primary
clutch boss should engage, otherwise the pri-
mary clutch is faulty and must be replaced.
c. When turning the primary clutch boss coun-
EAS28990
CHECKING THE CLUTCH SHOES terclockwise “B”, it should turn freely, other-
The following procedure applies to all of the wise the primary clutch is faulty and must be
clutch shoes. replaced.
1. Check:
• Clutch shoe
Damage/wear → Replace the clutch shoes
and springs as a set.
Glazed areas → Sand with coarse sandpa- A
per. B
NOTE:
After sanding the glazed areas, clean the clutch
with a cloth.
2. Measure: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Clutch shoe groove depth “a” EAS25260
Out of specification → Replace. INSTALLING THE CLUTCH
1. Install:
• Washer
• Primary clutch
5-42
CLUTCH
• Primary clutch boss

NOTE: 2
When installing the primary clutch and primary
clutch boss into the primary clutch housing,
make sure that the pins “1” and spring “2” are in-
stalled as shown in the illustration.
1 3
1
4. Install:
• Clutch housing
• Clutch boss
2
• Lock washer New
• Clutch boss nut
1
NOTE:
2. Install: • Align the notch in the lock washer with a rib on
• Washer the clutch boss.
• Primary drive gear nut • Lubricate the lock washer and clutch boss nut
NOTE: with engine oil.
Install the washer with its sharp-edged side fac- 5. Tighten:
ing the primary drive gear. • Clutch boss nut
3. Tighten:
• Primary drive gear nut “1” Clutch boss nut
70 Nm (7.0 m·kg, 50 ft·lb)
T.
R.
Primary drive gear nut

50 Nm (5.0 m·kg, 36 ft·lb) NOTE:
T.
R.
While holding the clutch boss with the universal

NOTE: clutch holder “1”, tighten the clutch boss nut “2”.
the sheave holder “3”, tighten the primary drive Universal clutch holder
gear nut. 90890-04086
• Do not allow the sheave holder to touch the YM-91042
projection on the AC magneto rotor.
Sheave holder
90890-01701
YS-01880-A
1 1 2
6. Bend the lock washer tab along a flat side of
the nut.
7. Lubricate:
• Friction plates
• Clutch plates
5-43
CLUTCH
NOTE:
Engine oil Tighten the clutch cover bolts in stages and in a
crisscross pattern.
8. Install: 11.Install:
• Friction plates “1” • Kickstarter lever “1”
• Clutch plate 2 “2” NOTE:
• Clutch plates 1 “3”
Align the kickstarter lever with the frame joint “a”
NOTE:
as shown in the illustration, and then slightly ro-
• Align the pins “a” on clutch plate 2 with the tate the lever counterclockwise and install it at
notches “b” in the two inner clutch plates 1. the position where the grooves in the lever hole
• Align the pins “a” on clutch plate 2 with the first align with the splines on the kickstarter
holes “c” in the outermost clutch plate 1. shaft.
• Install the friction plates and clutch plates 1 and
2 as shown in the illustration.
a
a
c a
c b
1
a
b 12.Adjust:
c
• Clutch release system
1 1 1 1 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut “1”.
b. Turn the clutch release adjusting screw “2” in
until resistance is felt, and then turn it out the
specified number of turns.
Clutch release adjusting screw

1/8 turn out
2 3 3 3
9. Install:
• Nut
• Clutch springs 1
• Clutch spring bolts 2
Clutch spring bolt

6 Nm (0.6 m·kg, 4.3 ft·lb)
T.
R.
NOTE:
Tighten the clutch spring bolts in stages and in a c. Tighten the locknut.
crisscross pattern.
Locknut (clutch release adjusting
10.Install: screw)
T.
R.
• Clutch cover 8 Nm (0.8 m·kg, 5.8 ft·lb)

Clutch cover bolt NOTE:
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
Hold the adjusting screw and tighten the locknut.

R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5-44
OIL PUMP
EAS24911
OIL PUMP
Removing the oil pump
1 5
6
4 E
2 New 3
5 New 7
4
3 8
10
11
12
13
7 Nm (0.7 m • kg, 5.1 ft • Ib) E

T.
R.

Clutch housing/Clutch carrier Refer to “CLUTCH” on page 5-37.
1 Rotary filter 1
2 Circlip 1
3 Oil pump driven gear 1
4 Oil pump assembly 1
5 Oil pump gasket 1
6 Oil pump drive gear 1
7 Oil strainer 1
8 Oil pump housing cover 1
9 Pin 1
10 Oil pump shaft 1
11 Oil pump inner rotor 1
12 Oil pump outer rotor 1
13 Oil pump housing 1
dure.
5-45
OIL PUMP
EAS24960
2. Outer rotor
CHECKING THE OIL PUMP
3. Oil pump housing
1. Check:
• Oil pump drive gear 3. Check:
• Oil pump driven gear • Oil pump operation
• Oil pump housing Rough movement → Repeat steps (1) and
• Oil pump housing cover (2) or replace the defective part(s).
Cracks/damage/wear → Replace the defec-
tive part(s).
2. Measure:
• Inner-rotor-to-outer-rotor-tip clearance “a”
• Outer-rotor-to-oil-pump-housing clearance
“b”
• Oil-pump-housing-to-inner-rotor-and-outer-
rotor clearance “c”
Out of specification → Replace the oil pump.
Inner-rotor-to-outer-rotor-tip EAS24990
clearance CHECKING THE OIL STRAINER
Less than 0.150 mm (0.0059 in) 1. Check:
Limit
• Oil strainer
0.23 mm (0.0091 in)
Outer-rotor-to-oil-pump-housing Damage → Replace.
clearance Contaminants → Clean with solvent.
0.13–0.18 mm (0.0051–0.0071 in) EAS5B61007
Limit CHECKING THE ROTARY FILTER
0.25 mm (0.0098 in) 1. Check:
Oil-pump-housing-to-inner-and- • Rotary filter
outer-rotor clearance Cracks/damage/wear → Replace.
0.06–0.10 mm (0.0024–0.0039 in)
Contaminants → Clean with engine oil.
Limit
0.17 mm (0.0067 in) EAS25000
ASSEMBLING THE OIL PUMP

1. Lubricate:
• Oil pump inner rotor
• Oil pump outer rotor
• Oil pump shaft
Engine oil
2. Install:
• Oil pump outer rotor
• Oil pump inner rotor
• Oil pump shaft
• Pin
NOTE:
When installing the inner rotor, align the pin “1”
in the oil pump shaft with the groove “a” in the in-
ner rotor “2”.
1. Inner rotor
5-46
OIL PUMP
3. Check:
• Oil pump operation
Refer to “CHECKING THE OIL PUMP” on
page 5-46.
EAS25040
INSTALLING THE OIL STRAINER

1. Install:
• Oil pump gasket New
• Oil pump
Oil strainer screw

7 Nm (0.7 m·kg, 5.1 ft·lb)
T.
R.
ECA5B61013
CAUTION:
After tightening the screws, make sure the
oil pump turns smoothly.
2. Install:
• Rotary filter
NOTE:
Align the mark “a” on the oil filter with the oil hole
“b” in the crankshaft journal.
5-47
SHIFT SHAFT
EAS25410
SHIFT SHAFT
Removing the shift shaft and stopper lever
LS
B
E
15
New
New
11
12

Clutch housing/Clutch carrier Refer to “CLUTCH” on page 5-37.
AC magneto cover CLUTCH” on page 5-26.
Rotary filter/Oil pump driven gear Refer to “OIL PUMP” on page 5-45.
1 Shift guide bar 1
2 Clutch release shift arm 1
3 Shift guide spring 1
4 Shift guide 1
5 Pawl holder 1
6 Pawl holder guide 1
7 Pin 1
8 Bearing 1
9 Shift shaft 1
10 Shift lever assembly 1
11 Stopper lever 1
12 Stopper lever spring 1
5-48
SHIFT SHAFT
Removing the shift shaft and stopper lever
LS
B
E
15
New
New
11
12

13 Shift shaft spring 1
14 Shift shaft lever 1
15 Shift shaft spring stopper 1
dure.
A: Left side
B: Right side
5-49
SHIFT SHAFT
EAS25420
• Install the circlip with its chamfered side facing
CHECKING THE SHIFT SHAFT
the shift lever assembly.
1. Check:
• Shift shaft
Bends/damage/wear → Replace. b
2
• Shift shaft spring
a
EAS25430
CHECKING THE STOPPER LEVER 1

1. Check:
• Stopper lever
Bends/damage → Replace.
Roller turns roughly → Replace the stopper
lever.
• Stopper lever spring
EAS5B61018
CHECKING THE SHIFT LEVER ASSEMBLY

1. Check:
• Shift lever assembly
Bends/damage/wear → Replace.
EAS25450
INSTALLING THE SHIFT SHAFT

1. Install:
• Stopper lever “1”
• Stopper lever spring “2”
NOTE:
• Hook the ends “3” of the stopper lever spring
onto the stopper lever and the crankcase boss.
• Mesh the stopper lever with the shift drum seg-
ment.
2. Install:
• Shift shaft lever “1”
• Shift lever assembly “2”
• Circlip New
NOTE:
• Align the punch mark “a” on the shift shaft lever
with the punch mark “b” on the shift lever as-
sembly.
• Hook the end of the shift shaft spring onto the
shift shaft spring stopper.
5-50
CRANKCASE
EAS25540
CRANKCASE
Separating the crankcase
T.
10 Nm (1.0 m • kg, 7.2 ft • Ib)
R.
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.
LT
R.
LT
LT 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
8
LT
6
7
LS
LT
LT
10
9 5
4
New
3
LT
2
11
1
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib)

T.
R.

Engine Refer to “ENGINE REMOVAL” on page 5-1.
Refer to “CYLINDER AND PISTON” on page
Cylinder/Piston 5-21.
Clutch housing Refer to “CLUTCH” on page 5-37.
Oil pump assembly Refer to “OIL PUMP” on page 5-45.
Shift shaft Refer to “SHIFT SHAFT” on page 5-48.
Kickstarter assembly Refer to “KICKSTARTER” on page 5-35.
AC magneto rotor CLUTCH” on page 5-26.
1 Timing chain guide (intake side) 1
2 Timing chain 1
3 Neutral switch 1
4 Neutral position pointer 1
5 Spring 1
6 Shift fork guide bar retainer 1
7 Spring 1
5-51
CRANKCASE
Separating the crankcase
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.
LT
R.
LT
LT 10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
8
LT
6
7
LS
LT
LT
10
9 5
4
New
3
LT
2
11
1
LT
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
10 Nm (1.0 m • kg, 7.2 ft • Ib)

T.
R.
4 Nm (0.4 m • kg, 2.9 ft • Ib)

T.
R.

8 Shift drum segment 1
9 Right crankcase 1
10 Dowel pin 2
11 Left crankcase 1
dure.
5-52
CRANKCASE
Removing the oil seal and bearings
2
E
2 2
2
2
LS

Crankshaft Refer to “CRANKSHAFT” on page 5-56.
Transmission Refer to “TRANSMISSION” on page 5-59.
1 Oil seal 1
2 Bearing 5
dure.
5-53
CRANKCASE
EAS25560
DISASSEMBLING THE CRANKCASE

1. Remove:
• Crankcase bolts
NOTE:
es and in the proper sequence as shown. After
all of the bolts are fully loosened, remove them.
7 6
8 5 2. Check:
• Timing chain guide (intake side)
EAS5B61020
9 4 CHECKING THE BEARINGS AND OIL SEAL

1. Check:
1 3 • Bearings
2 Clean and lubricate the bearings, then rotate
2. Remove: the inner race with your finger.
• Right crankcase Rough movement → Replace.
ECA13900
• Oil seal
CAUTION: Damage/wear → Replace.
Tap on one side of the crankcase with a soft-
EAS5B61021
face hammer. Tap only on reinforced por- CHECKING THE SHIFT DRUM SEGMENT
tions of the crankcase, not on the crankcase 1. Check:
mating surfaces. Work slowly and carefully • Shift drum segment
and make sure the crankcase halves sepa- Damage/wear → Replace the shift drum seg-
rate evenly. ment.
EAS25580 EAS25700
CHECKING THE CRANKCASE ASSEMBLING THE CRANKCASE

1. Thoroughly wash the crankcase halves in a 1. Install:
mild solvent. • Oil seal “1”
2. Thoroughly clean all the gasket surfaces and NOTE:
crankcase mating surfaces. Install the oil seal “1” as shown in the illustration.
3. Check:
• Crankcase
• Oil delivery passages
Obstruction → Blow out with compressed air. 1
EAS5B61008
CHECKING THE TIMING CHAIN AND CHAIN

GUIDE
1. Check:
• Timing chain 2.0-2.5mm(0.079-0.098in)
Damage/stiffness → Replace the timing
chain and camshaft sprocket as a set. 2. Thoroughly clean all the gasket mating sur-
faces and crankcase mating surfaces.
3. Apply:
• Sealant
(onto the crankcase mating surfaces)
5-54
CRANKCASE
Yamaha bond No. 1215

90890-85505
(Three Bond No.1215®)
NOTE:
Do not allow any sealant to come into contact
with the oil gallery “a”.
4. Install:
• Right crankcase
(onto the left crankcase)
NOTE:
Tap lightly on the right crankcase with a soft-face
hammer.
5. Install:
• Crankcase bolts
Crankcase bolt
10 Nm (1.0 m·kg, 7.2 ft·lb)
T.
R.
NOTE:
• Apply sealant to the threads of the bolt “1”.
• Tighten the crankcase bolts in the proper tight-
ening sequence as shown.
• M6 × 80 mm : “4”
• M6 × 60 mm : “3”, “5”, “6”
• M6 × 40 mm : “1”, “2”, “7–9”
6 1
5 7
4 8
3 9
2
5-55
CRANKSHAFT
EAS5B61009
CRANKSHAFT
Removing the crankshaft

Separate.
Crankcase Refer to “CRANKCASE” on page 5-51.
1 Crankshaft 1
dure.
5-56
CRANKSHAFT
EAS5B61010
REMOVING THE CRANKSHAFT

1. Remove:
• Crankshaft “1”
NOTE:
• Remove the crankshaft with the crankcase
separating tool “2”.
• Make sure the crankcase separating tool is
centered over the crankshaft.
ECA5B61014
CAUTION: 2. Measure:
• To protect the end of the crankshaft, place • Big end side clearance
an appropriate sized socket between the Out of specification → Replace the crank-
crankcase separating tool bolt and the shaft.
crankshaft.
• Do not tap on the crankshaft. Big end side clearance D
0.110–0.410 mm (0.0043–0.0161
in)
Crankcase separating tool Limit
90890-01135 0.50 mm (0.0197 in)
Crankcase separator
YU-01135-B 3. Measure:
• Crankshaft width
Out of specification → Replace the crank-
shaft.
1 Width A
2 42.95–43.00 mm (1.691–1.693 in)
4. Check:
• Crankshaft sprocket
Damage/wear → Replace the crankshaft.
• Bearing
EAS5B61022
Cracks/damage/wear → Replace the crank-
CHECKING THE CRANKSHAFT shaft.
• Crankshaft runout • Crankshaft journal
Out of specification → Replace the crank- Scratches/wear → Replace the crankshaft.
shaft, bearing or both. • Crankshaft journal oil passage
NOTE: Obstruction → Blow out with compressed air.
Turn the crankshaft slowly. EAS3C11036
INSTALLING THE CRANKSHAFT

Runout limit C 1. Install:
0.030 mm (0.0012 in) • Crankshaft “1”
NOTE:
Install the crankshaft with the crankshaft installer
pot “2”, crankshaft installer bolt “3”, adapter
(M12) “4” and spacer (crankshaft installer) “5”.
5-57
CRANKSHAFT
Crankshaft installer pot

90890-01274
Installing pot
YU-90058
Crankshaft installer bolt
90890-01275
Bolt
YU-90060
Adapter (M12)
90890-01278
Adapter #3
YU-90063
Spacer (crankshaft installer)
90890-04081
Pot spacer
YM-91044
1 2
3
5 4
ECA5B61015
CAUTION:
To avoid scratching the crankshaft and to
ease the installation procedure, lubricate
each bearing with engine oil.
NOTE:
Hold the connecting rod at top dead center
(TDC) with one hand while turning the nut of the
crankshaft installer bolt with the other. Turn the
crankshaft installer bolt until the crankshaft bot-
toms against the bearing.
5-58
TRANSMISSION
EAS26241
TRANSMISSION
Removing the transmission, shift drum, and shift forks
3
E
4 E
5
1
2
E

Separate.
Crankcase Refer to “CRANKCASE” on page 5-51.
1 Shift fork guide bar 1
2 Spring 1
3 Shift drum 1
4 Shift fork-R 1
5 Shift fork-L 1
6 Drive axle assembly 1
7 Main axle assembly 1
dure.
5-59
TRANSMISSION
Disassembling the main axle
6
M
4
New 3

1 2nd pinion gear 1
2 3rd pinion gear 1
3 Circlip 1
4 Washer 1
5 4th pinion gear 1
6 Main axle/1st pinion gear 1
cedure.
5-60
TRANSMISSION
Disassembling the drive axle
New 1
2
3
5
New 6
7
8

1 Circlip 1
2 Washer 1
3 Spacer 1
4 1st wheel gear 1
5 4th wheel gear 1
6 Circlip 1
7 Washer 1
8 3rd wheel gear 1
9 Drive axle/2nd wheel gear 1
cedure.
5-61
TRANSMISSION
EAS26260 EAS5B61023
CHECKING THE SHIFT FORKS CHECKING THE SHIFT DRUM

The following procedure applies to all of the shift 1. Check:
forks. • Shift drum groove
1. Check: Damage/scratches/wear → Replace the shift
• Shift fork cam follower “1” drum.
• Shift fork pawl “2” • Shift drum bearing
Bends/damage/scoring/wear → Replace the Damage/pitting → Replace the shift drum.
shift fork.
EAS26300
CHECKING THE TRANSMISSION

1. Check:
• Transmission gears
Blue discoloration/pitting/wear → Replace
the defective gear(s).
• Transmission gear dogs
Cracks/damage/rounded edges → Replace
the defective gear(s).
2. Check:
• Shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends → Replace.
EWA12840
WARNING
Do not attempt to straighten a bent shift fork
guide bar.
2. Check:
• Transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission
axle assemblies.
3. Check:
• Transmission gear movement
Rough movement → Replace the defective
3. Check: part(s).
• Shift fork movement EAS29020
(along the shift fork guide bar) ASSEMBLING THE MAIN AXLE AND DRIVE
Rough movement → Replace the shift forks AXLE
and shift fork guide bar as a set. 1. Install:
• Washer “1”
• Circlip “2” New
NOTE:
• Be sure the circlip sharp-edged corner “a” is
positioned opposite side to the washer and
gear.
• Align the opening between the ends “b” of the
circlip with a groove “c” in the axle.
5-62
TRANSMISSION
b
New 2
a 1 c
EAS26340
INSTALLING THE TRANSMISSION

1. Install:
• Main axle assembly “1”
• Drive axle assembly “2
• Shift fork-L “3”
• Shift fork-R “4”
• Shift drum assembly “5”
• Shift fork guide bar “6”
NOTE:
Install the shift forks with the “L” mark and “R”
mark facing towards the left and right sides of
the crankcase respectively.
6 1
2
3
2. Check:
• Transmission
Rough movement → Repair.
NOTE:
• Apply engine oil to each gear and bearing thor-
oughly.
• Before assembling the crankcase, make sure
that the transmission is in neutral and that the
gears turn freely.
5-63
FUEL SYSTEM
FUEL TANK..................................................................................................... 6-1

CHECKING THE FUEL COCK.................................................................. 6-2
CHECKING THE FUEL COCK OPERATION............................................ 6-2
CARBURETOR................................................................................................ 6-3
CHECKING THE CARBURETOR ............................................................. 6-6
ASSEMBLING THE CARBURETOR......................................................... 6-6
INSTALLING THE CARBURETOR ........................................................... 6-7
MEASURING AND ADJUSTING THE FUEL LEVEL ................................ 6-7
6
FUEL TANK
EAS26620
FUEL TANK
Removing the fuel tank and air filter case assembly
(3) 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
New 8 5 3
2
New
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
1
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
NOTE:
Before disconnecting the fuel hose, turn the
fuel cock to “OFF”.

Seat/Left air scoop/Right air scoop 4-1.
1 Fuel hose 1 Disconnect.
2 Fuel tank 1
3 Fuel tank breather hose 1
4 Fuel cock 1
5 Crankcase breather hose 1 Disconnect.
6 Spark plug cap 1 Disconnect.
7 Air filter case joint clamp screw 1 Loosen.
8 Air filter case assembly 1
dure.
6-1
FUEL TANK
EAS26650
CHECKING THE FUEL COCK

1. Check:
• Fuel cock
Cracks/damage/wear → Replace.
2. Check:
• Fuel cock strainer
Obstruction → Clean.
Blow out the jets with compressed air.
Damage → Replace.
EAS26660
CHECKING THE FUEL COCK OPERATION

NOTE:
After installing the fuel cock, check its operation.
1. Check:
• Fuel cock operation
Out of specification → Replace the fuel cock.
Fuel flows.
Fuel cock is OK.
Fuel does not flow.
Replace the fuel cock.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check that the fuel cock lever is turned to
“ON” or “RES”.
b. Place a container under the end of the fuel
hose.
1
RES
FUEL
OFF 2
ON
3
1. “RES”
2. “OFF”
3. “ON”
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-2
CARBURETOR
EAS26730
CARBURETOR
Removing the carburetor
6
7
New
8
New
New
3
2
10
LS 2
New 9
5 New New
4
13
11 New
LS
New
12
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

Seat/Left air scoop/Right air scoop 4-1”.
Fuel tank Refer to “FUEL TANK” on page 6-1.
1 Air vent hose 1 Disconnect.
2 Carburetor warmer lead 2 Disconnect.
3 Starter plunger assembly 1
4 Throttle valve arm lever housing cover 1
5 Gasket 1
6 Throttle cable (accelerator cable) 1 Disconnect.
7 Throttle cable (decelerator cable) 1 Disconnect.
8 Throttle valve arm lever housing 1
9 Throttle valve assembly 1
10 Air filter case assembly joint clamp screw 1 Loosen.
11 Carburetor assembly 1
12 Carburetor joint 1
6-3
CARBURETOR
Removing the carburetor
6
7
New
8
New
New
3
2
10
LS 2
New 9
5 New New
4
13
11 New
LS
New
12
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.

13 Fuel hose 1
dure.
6-4
CARBURETOR
Disassembling the carburetor

3 Nm (0.3m • kg, 2.2 ft • Ib)
T.
R.
3
*
10
1
11 2
9
7
8
5 6
New
(4)

1 Throttle stop screw set 1
2 Fuel filter 1
3 Carburetor warmer 1
4 Float chamber 1
5 Float pin 1
6 Float 1
7 Needle valve 1
8 Main jet 1
9 Needle jet holder 1
10 Needle jet 1
11 Pilot jet 1
cedure.
* Apply HEAT SINKER.
6-5
CARBURETOR
EAS26770
CHECKING THE CARBURETOR

1. Check:
• Carburetor body
• Float chamber
2. Check:
• Fuel passages
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the carburetor in a petroleum-based
solvent. Do not use any caustic carburetor 10.Check:
cleaning solution. • Throttle valve assembly movement
b. Blow out all of the passages and jets with Insert the throttle valve assembly “1” into the
compressed air. carburetor body and move it up and down.
Tightness → Replace the throttle valve as-
sembly.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• Float chamber body 11.Check:
Dirt → Clean. • Starter plunger
4. Check: • Starter plunger spring
• Float chamber rubber gasket Bends/cracks/damage → Replace.
Cracks/damage/wear → Replace. 12.Check:
5. Check: • Air vent hose
• Float • Fuel hose
Damage → Replace. Cracks/damage/wear → Replace.
6. Check: Obstruction → Clean.
• Needle valve Blow out the hoses with compressed air.
Damage/contamination/wear → Replace. EAS26810
7. Check: ASSEMBLING THE CARBURETOR

ECA14110
• Throttle valve assembly
CAUTION:
Damage/scratches/wear → Replace.
8. Check: • Before assembling the carburetor, wash all
• Throttle valve arm lever housing cover of the parts in a petroleum-based solvent.
• Throttle valve arm lever housing • Always use a new gasket.
Cracks/damage → Replace. 1. Install:
9. Check: • Carburetor warmer terminal “1”
• Main jet “1” • Washer
• Pilot jet “2” • Carburetor warmer “2”
• Needle jet holder “3” NOTE:
• Needle jet “4”
• Apply HEAT SINKER to the threaded portion of
Bends/damage/wear → Replace.
the carburetor warmer.
• Blow out the jets with compressed air.
6-6
CARBURETOR
• Install the carburetor warmer terminal at a right EAS26910
MEASURING AND ADJUSTING THE FUEL

angle to the carburetor as shown in the illustra-
LEVEL
tion.
1. Measure:
• Fuel level “a”
2 Out of specification → Adjust.
Fuel level A (using fuel level

gauge)
1 1.0–2.0 mm (0.04–0.08 in) (be-
low the float chamber mating
40-50˚ surface)
EAS26890
INSTALLING THE CARBURETOR

1. Install: a
• Throttle valve assembly “1”
NOTE:
Align the slit “a” of the throttle valve assembly
with the tab “b” of the carburetor.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Stand the vehicle on a level surface.
a b. Place the vehicle on a suitable stand to en-
sure that the vehicle is standing straight up.
c. Install the fuel level gauge “1” onto the fuel
b drain pipe.
1 Fuel level gauge

90890-01312
YM-01312-A
2. Install:
• Starter plunger d. Loosen the fuel drain screw “2”.
• Air vent hose e. Hold the fuel level gauge vertically next to the
NOTE: line on the float chamber.
Make sure that the starter cable and air vent f. Measure the fuel level “a”.
hose are routed correctly. Refer to “CABLE
ROUTING” on page 2-27.
3. Adjust:
• Engine idling speed a
Refer to “ADJUSTING THE ENGINE IDLING
SPEED” on page 3-5.
Engine idling speed 1 2

1600–1800 r/min
4. Adjust: ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Throttle cable free play 2. Adjust:
Refer to “ADJUSTING THE THROTTLE CA- • Fuel level
BLE FREE PLAY” on page 3-5. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the carburetor assembly.
Throttle cable free play b. Check the needle valve.
4.0–6.0 mm (0.16–0.24 in) c. If it is worn, replace.
6-7
CARBURETOR
d. If it is fine, adjust the float level by slightly

bending the float tang “1”.
e. Install the carburetor assembly.

f. Measure the fuel level again.
g. Repeat steps (a) to (f) until the fuel level is
within specification.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-8
CARBURETOR
6-9
ELECTRICAL SYSTEM
IGNITION SYSTEM ......................................................................................... 7-1

CIRCUIT DIAGRAM .................................................................................. 7-1
TROUBLESHOOTING .............................................................................. 7-3
ELECTRIC STARTING SYSTEM .................................................................... 7-5

CIRCUIT DIAGRAM .................................................................................. 7-5
TROUBLESHOOTING .............................................................................. 7-7
CHARGING SYSTEM...................................................................................... 7-9

CIRCUIT DIAGRAM .................................................................................. 7-9
TROUBLESHOOTING ............................................................................ 7-11
CARBURETOR HEATING SYSTEM............................................................. 7-13

CIRCUIT DIAGRAM ................................................................................ 7-13
TROUBLESHOOTING ............................................................................ 7-15
ELECTRICAL COMPONENTS...................................................................... 7-17

CHECKING THE SWITCHES ................................................................. 7-19
CHECKING THE FUSES ........................................................................ 7-22
CHECKING AND CHARGING THE BATTERY....................................... 7-22
CHECKING THE RELAY......................................................................... 7-25
CHECKING THE SPARK PLUG CAP ..................................................... 7-25
CHECKING THE IGNITION COIL ........................................................... 7-26
CHECKING THE IGNITION SPARK GAP............................................... 7-26
CHECKING THE STARTER MOTOR OPERATION ............................... 7-27
CHECKING THE PICKUP COIL.............................................................. 7-27
CHECKING THE LIGHTING COIL .......................................................... 7-27
CHECKING THE CHARGING COIL........................................................ 7-28
CHECKING THE RECTIFIER/REGULATOR .......................................... 7-28
CHECKING THE THERMO SWITCH...................................................... 7-28
CHECKING THE CARBURETOR WARMER.......................................... 7-29
7
EAS27100
EAS27090
Br B O
R W
(BLACK) 13
W R R O O
11
Y/R W W 12 B B
Br 14
W W
Y/R
Y/R Y
W Y/R
B B
9
W R R W
Y Y/R B B
CIRCUIT DIAGRAM
W B R
R Y/R 1 B
R
(BLUE)
8 Y
IGNITION SYSTEM
ON
B R Br Br R
OFF
(BLACK) (BLACK)
Y
Br
10
Br
R R R
7
B B Br R/W
R R R B 2 3 (GRAY) (GRAY)
B
R/W
B
R R/W
7-1
B
L/W R
5 R/W R
4
R L/W
L/W
15
R
R
R Sb L/W B B
6
Sb
Sb
16
P W
Y/W Sb Sb
L/W
IGNITION SYSTEM
IGNITION SYSTEM
2. Battery
3. Fuse
7. Engine stop switch
8. Main switch
11.AC magneto
12.CDI unit
13.Ignition coil
14.Spark plug
7-2
IGNITION SYSTEM
EAS27130
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
NOTE:
• Before troubleshooting, remove the following part(s):
1. Left side cover
2. Seat
3. Fuel tank
4. Number plate
NG →
1. Check the fuse.
Refer to “CHECKING THE FUS- Replace the fuse.
ES” on page 7-22.
OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 7-22.
OK ↓
3. Check the spark plug. NG →
Refer to “CHECKING THE SPARK Re-gap or replace the spark plug.
PLUG” on page 3-6.
OK ↓
4. Check the ignition spark gap. OK →
Refer to “CHECKING THE IGNI- Ignition system is OK.
TION SPARK GAP” on page 7-26.
NG ↓
5. Check the spark plug cap. NG →
Refer to “CHECKING THE SPARK Replace the spark plug cap.
PLUG CAP” on page 7-25.
OK ↓
6. Check the ignition coil. NG →
Refer to “CHECKING THE IGNI- Replace the ignition coil.
TION COIL” on page 7-26.
OK ↓
7. Check the pickup coil. NG →
Refer to “CHECKING THE PICKUP Replace the pickup coil/stator assembly.
COIL” on page 7-27.
OK ↓
8. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 7-19.
OK ↓
7-3
IGNITION SYSTEM
9. Check the engine stop switch. NG →

Refer to “CHECKING THE Replace the engine stop switch.
OK ↓
10.Check the entire ignition system NG →
wiring. Properly connect or repair the ignition sys-
Refer to “CIRCUIT DIAGRAM” on tem wiring.
page 7-1.
OK ↓
Replace the CDI unit.
7-4
EAS27170
EAS27160
Br B O
R W
(BLACK) 13
W R R O O
11
Y/R W W 12 B B
Br 14
W W
Y/R
Y/R Y
W Y/R
B B
9
W R R W
Y Y/R B B
CIRCUIT DIAGRAM
W B R
R Y/R 1 B
R
(BLUE)
8 Y
ON
B R Br Br R
OFF
(BLACK) (BLACK)
Y
Br
10
Br
R R R
7
B B Br R/W
ELECTRIC STARTING SYSTEM
B
R/W
B
R R/W
7-5
B
L/W R
5 R/W R
4
R L/W
L/W
15
R
R
R Sb L/W B B
6
Sb
Sb
16
P W
Y/W Sb Sb
L/W
2. Battery
3. Fuse
5. Starter relay
6. Starter motor
8. Main switch
15.Start switch
16.Neutral switch
7-6
EAS27190
TROUBLESHOOTING
The starter motor fails to turn.
NOTE:
1. Left side cover
2. Seat
3. Number plate
4. Starter motor cover
NG →
1. Check the fuse.
ES” on page 7-22.
OK ↓
page 7-22.
OK ↓
3. Check the starter motor operation. NG →
Starter motor is OK. Perform the electric
Refer to “CHECKING THE START-
starting system troubleshooting, starting
ER MOTOR OPERATION” on page
with step 5.
7-27.
OK ↓
4. Check the starter motor. NG →
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-33.
OK ↓
5. Check the starter relay. NG →
Refer to “CHECKING THE RELAY” Replace the starter relay.
on page 7-25.
OK ↓
6. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch.
OK ↓
7. Check the engine stop switch. NG →
Refer to “CHECKING THE Replace the engine stop switch.
OK ↓
8. Check the neutral switch. NG →
Refer to “CHECKING THE Replace the neutral switch.
OK ↓
7-7
9. Check the start switch. NG →

Refer to “CHECKING THE Replace the start switch.
OK ↓
10.Check the entire starting system NG →
wiring. Properly connect or repair the starting sys-
Refer to “CIRCUIT DIAGRAM” on tem wiring.
page 7-5.
OK ↓
The starting system circuit is OK.
7-8
EAS27210
EAS27200
Br B O
R W
(BLACK) 13
W R R O O
11
Y/R W W 12 B B
Br 14
W W
Y/R
Y/R Y
W Y/R
B B
9
W R R W
Y Y/R B B
CIRCUIT DIAGRAM
W B R
R Y/R 1 B
R
(BLUE)
8 Y
ON
B R Br Br R
OFF
CHARGING SYSTEM
(BLACK) (BLACK)
Y
Br
10
Br
R R R
7
B B Br R/W
B
R/W
B
R R/W
7-9
B
L/W R
5 R/W R
4
R L/W
L/W
15
R
R
R Sb L/W B B
6
Sb
Sb
16
P W
Y/W Sb Sb
L/W
CHARGING SYSTEM
CHARGING SYSTEM
1. Rectifier/regulator
2. Battery
3. Fuse
11.AC magneto
7-10
CHARGING SYSTEM
EAS27230
TROUBLESHOOTING
The battery is not being charged.
NOTE:
1. Left side cover
2. Seat
NG →
1. Check the fuse.
ES” on page 7-22.
OK ↓
page 7-22.
OK ↓
3. Check the charging coil. NG →
Refer to “CHECKING THE Replace the pickup coil/stator assembly.
CHARGING COIL” on page 7-28.
OK ↓
4. Check the rectifier/regulator. NG →
Refer to “CHECKING THE RECTI- Replace the rectifier/regulator.
FIER/REGULATOR” on page 7-28.
OK ↓
5. Check the entire charging system NG →
wiring. Properly connect or repair the charging
Refer to “CIRCUIT DIAGRAM” on system wiring.
page 7-9.
OK ↓
The charging system circuit is OK.
7-11
CHARGING SYSTEM
7-12
EAS27500
EAS27490
Br B O
R W
(BLACK) 13
W R R O O
11
Y/R W W 12 B B
Br 14
W W
Y/R
Y/R Y
W Y/R
B B
9
W R R W
Y Y/R B B
CIRCUIT DIAGRAM
W B R
R Y/R 1 B
R
(BLUE)
8 Y
ON
B R Br Br R
OFF
(BLACK) (BLACK)
Y
Br
10
Br
R R R
7
B B Br R/W
B
R/W
B
CARBURETOR HEATING SYSTEM
R R/W
7-13
L/W R
5 R/W R
4
R L/W
L/W
15
R
R
R Sb L/W B B
6
Sb
Sb
16
P W
Y/W Sb Sb
L/W
9. Thermo switch
10.Carburetor warmer
11.AC magneto
7-14
EAS27510
TROUBLESHOOTING
The carburetor heater system fails to operate.
NOTE:
1. Left side cover
2. Seat
3. Fuel tank
1. Check the lighting coil. NG →

Refer to “CHECKING THE LIGHT- Replace the pickup coil/stator assembly.
ING COIL” on page 7-27.
OK ↓
2. Check the thermo switch. NG →
Refer to “CHECKING THE THER- Replace the thermo switch.
MO SWITCH” on page 7-28.
OK ↓
NG →
3. Check the carburetor warmer.
Refer to “CHECKING THE CARBU- Replace the carburetor warmer.
RETOR WARMER” on page 7-29.
OK ↓
4. Check the rectifier/regulator. NG →
Refer to “CHECKING THE RECTI- Replace the rectifier/regulator.
FIER/REGULATOR” on page 7-28.
OK ↓
5. Check the entire carburetor heat- NG →
ing system wiring. Properly connect or repair the carburetor
Refer to “CIRCUIT DIAGRAM” on heating system wiring.
page 7-13.
OK ↓
This carburetor heating system circuit

is OK.
7-15
7-16
ELECTRICAL COMPONENTS
EAS27971
7-17
1. Main switch
2. Thermo switch
3. Starter relay
4. CDI unit
6. Battery
7. Neutral switch
8. Fuse
9. Ignition coil
10. Spark plug cap
7-18
EAS27980
CHECKING THE SWITCHES
2
B B
B B
3 P W
R Br Y/W Sb
L/W
ON
R Br
OFF
(BLACK)
4
B B
B B
(GRAY)
7-19
1. Neutral switch
2. Start switch
3. Main switch
7-20
Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the
wiring connections and if necessary, replace the switch.
ECA14370
CAUTION:
Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from
the opposite end of the coupler, taking care not to loosen or damage the leads.
Pocket tester
90890-03112
YU-03112-C
NOTE:
• Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back and forth between the switch positions a few times.
The switches and their terminal connections are illustrated as in the following example of the main
switch.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in the
top row.
The continuity (i. e., a closed circuit) between switch terminals at a given switch position is indicated by
“ ”. There is continuity between red and brown when the switch is set to “ON”.
b
R Br
ON
a
OFF
R Br
7-21
EAS28000
cal system, cause the lighting and ignition
CHECKING THE FUSES
systems to malfunction and could possibly
The following procedure applies to all of the fus-
cause a fire.
es.
ECA13680
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CAUTION:
4. Install:
To avoid a short circuit, always set the main • Left side cover
switch to “OFF” when checking or replacing Refer to “GENERAL CHASSIS” on page 4-1.
a fuse.
EAS28030
1. Remove: CHECKING AND CHARGING THE BATTERY
• Left side cover EWA13290
Refer to “GENERAL CHASSIS” on page 4-1. WARNING

2. Check: Batteries generate explosive hydrogen gas
• Fuse and contain electrolyte which is made of poi-
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ sonous and highly caustic sulfuric acid.
a. Connect the pocket tester to the fuse and Therefore, always follow these preventive
check the continuity. measures:
NOTE: • Wear protective eye gear when handling or
Set the pocket tester selector to “Ω × 1”. working near batteries.
• Charge batteries in a well-ventilated area.
Pocket tester • Keep batteries away from fire, sparks or
90890-03112 open flames (e.g., welding equipment,
Analog pocket tester lighted cigarettes).
YU-03112-C • DO NOT SMOKE when charging or han-
dling batteries.
b. If the pocket tester indicates “∞”, replace the • KEEP BATTERIES AND ELECTROLYTE
fuse. OUT OF REACH OF CHILDREN.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ • Avoid bodily contact with electrolyte as it
3. Replace: can cause severe burns or permanent eye
• Blown fuse injury.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ FIRST AID IN CASE OF BODILY CONTACT:
a. Set the main switch to “OFF”. EXTERNAL
b. Install a new fuse of the correct amperage • Skin — Wash with water.
rating. • Eyes — Flush with water for 15 minutes and
c. Set on the switches to verify if the electrical get immediate medical attention.
circuit is operational. INTERNAL
d. If the fuse immediately blows again, check • Drink large quantities of water or milk fol-
the electrical circuit. lowed with milk of magnesia, beaten egg or
Amperage vegetable oil. Get immediate medical atten-
Fuses Q’ty tion.
rating
ECA5B61001
Fuse 10 A 1 CAUTION:
Spare fuse 10 A 1 • This is a sealed battery. Never remove the
EWA13310 sealing caps because the balance between
WARNING cells will not be maintained and battery per-
Never use a fuse with an amperage rating formance will deteriorate.
other than that specified. Improvising or us- • Charging time, charging amperage and
ing a fuse with the wrong amperage rating charging voltage for an MF battery are dif-
may cause extensive damage to the electri- ferent from those of conventional batteries.
The MF battery should be charged accord-
ing to the appropriate charging method. If
the battery is overcharged, the electrolyte
7-22
level will drop considerably. Therefore,

take special care when charging the bat-
tery.
NOTE:
Since MF batteries are sealed, it is not possible
to check the charge state of the battery by mea-
suring the specific gravity of the electrolyte.
Therefore, the charge of the battery has to be
checked by measuring the voltage at the battery
terminals.
A. Open-circuit voltage (V)
1. Remove: B. Charging time (hours)
• Left side cover C. Relationship between the open-circuit voltage
Refer to “GENERAL CHASSIS” on page 4-1. and the charging time at 20 °C (68 °F)
2. Disconnect: D. These values vary with the temperature, the
condition of the battery plates, and the
• Battery coupler electrolyte level.
(from the battery terminals)
3. Remove:
• Battery band
• Battery
4. Check:
• Battery charge
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a pocket tester to the battery termi-
nals.
• Positive tester probe →
positive battery terminal
• Negative tester probe → A. Open-circuit voltage (V)
negative battery terminal
B. Charging condition of the battery (%)
C. Ambient temperature 20 °C (68 °F)
NOTE:
• The charge state of an MF battery can be ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
checked by measuring its open-circuit voltage 5. Charge:
(i.e., the voltage when the positive battery ter- • Battery
minal is disconnected). (refer to the appropriate charging method)
• No charging is necessary when the open-cir- EWA13300
cuit voltage equals or exceeds 12.8 V. WARNING

Do not quick charge a battery.
b. Check the charge of the battery, as shown in
ECA13670
the charts and the following example.
CAUTION:
Example
Open-circuit voltage = 12.0 V • Never remove the MF battery sealing caps.
Charging time = 6.5 hours • Do not use a high-rate battery charger
Charge of the battery = 20–30% since it forces a high-amperage current
into the battery quickly and can cause bat-
tery overheating and battery plate damage.
• If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
• When charging a battery, be sure to remove
it from the vehicle. (If charging has to be
done with the battery mounted on the vehi-
cle, disconnect the negative battery lead
from the battery terminal.)
7-23
• To reduce the chance of sparks, do not NOTE:

plug in the battery charger until the battery Set the charging voltage to 16–17 V. If the set-
charger leads are connected to the battery. ting is lower, charging will be insufficient. If too
• Before removing the battery charger lead high, the battery will be over-charged.
clips from the battery terminals, be sure to
turn off the battery charger. c. Make sure that the current is higher than the
• Make sure the battery charger lead clips are standard charging current written on the bat-
in full contact with the battery terminal and tery.
that they are not shorted. A corroded bat- NOTE:
tery charger lead clip may generate heat in If the current is lower than the standard charging
the contact area and a weak clip spring may current written on the battery, set the charging
cause sparks. voltage adjust dial at 20–24 V and monitor the
• If the battery becomes hot to the touch at amperage for 3–5 minutes to check the battery.
any time during the charging process, dis-
connect the battery charger and let the bat- • Standard charging current is reached
tery cool before reconnecting it. Hot Battery is good.
batteries can explode! • Standard charging current is not reached.
• As shown in the following illustration, the Replace the battery.
open-circuit voltage of an MF battery stabi- d. Adjust the voltage so that the current is at the
lizes about 30 minutes after charging has standard charging level.
been completed. Therefore, wait 30 min- e. Set the time according to the charging time
utes after charging is completed before suitable for the open-circuit voltage.
measuring the open-circuit voltage. f. If charging requires more than 5 hours, it is
advisable to check the charging current after
a lapse of 5 hours. If there is any change in
the amperage, readjust the voltage to obtain
the standard charging current.
g. Measure the battery open-circuit voltage after
leaving the battery unused for more than 30
minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
A. Open-circuit voltage (V)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
B. Time (minutes)
C. Charging ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
D. Ambient temperature 20 °C (68 °F) Charging method using a constant volt-
E. Check the open-circuit voltage. age charger
a. Measure the open-circuit voltage prior to
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ charging.
Charging method using a variable-current NOTE:
(voltage) charger
Voltage should be measured 30 minutes after
a. Measure the open-circuit voltage prior to
the engine is stopped.
charging.
NOTE: b. Connect a charger and ammeter to the bat-
Voltage should be measured 30 minutes after tery and start charging.
the engine is stopped. c. Make sure that the current is higher than the
standard charging current written on the bat-
b. Connect a charger and ammeter to the battery.
tery and start charging.
7-24
NOTE: Starter relay

If the current is lower than the standard charging
current written on the battery, this type of battery 1 3
charger cannot charge the MF battery. A vari-
able voltage charger is recommended.
d. Charge the battery until the battery’s charg- 2 4
ing voltage is 15 V. L/W R
NOTE: R/W R
Set the charging time at 20 hours (maximum).
e. Measure the battery open-circuit voltage after
leaving the battery unused for more than 30 1. Positive battery terminal
minutes. 2. Negative battery terminal
3. Positive tester probe
12.8 V or more --- Charging is complete.
4. Negative tester probe
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
Result
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Continuity
6. Check: (between “3” and “4”)
• Battery terminals
Dirt → Clean with a wire brush. EAS28060
CHECKING THE SPARK PLUG CAP

7. Lubricate:
1. Check:
• Battery terminals
• Spark plug cap resistance
Recommended lubricant Out of specification → Replace.
Dielectric grease
Resistance
8. Install: 10.0 kΩ
• Battery
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Battery band a. Remove the spark plug cap from the spark
9. Connect: plug lead.
• Battery coupler b. Connect the pocket tester (Ω × 1k) to the
(to the battery terminals) spark plug cap as shown.
10.Install:
• Left side cover Pocket tester
Refer to “GENERAL CHASSIS” on page 4-1. 90890-03112
EAS28040
YU-03112-C
CHECKING THE RELAY
Check each switch for continuity with the pocket
tester. If the continuity reading is incorrect, re-
place the relay.
Pocket tester
90890-03112
YU-03112-C
1. Disconnect the relay from the wire harness.

2. Connect the pocket tester (Ω × 1) and battery
(12 V) to the relay terminal as shown. c. Measure the spark plug cap resistance.
Check the relay operation. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-25
EAS28090
CHECKING THE IGNITION COIL • Negative tester probe

1. Check: Orange “1”
• Positive tester probe
• Primary coil resistance
Spark plug lead “2”
Primary coil resistance

0.18–0.28 Ω at 20 °C (68 °F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the ignition coil connectors from
the ignition coil terminals.
b. Connect the pocket tester (Ω × 1) to the igni-
tion coil as shown.
Pocket tester
90890-03112 c. Measure the secondary coil resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
YU-03112-C
EAS28930
CHECKING THE IGNITION SPARK GAP

• Positive tester probe
1. Check:
Orange “1”
• Negative tester probe • Ignition spark gap
Ignition coil base “2” Out of specification → Perform the ignition
system troubleshooting, starting with step 3.
Refer to “TROUBLESHOOTING” on page
7-3.
Minimum ignition spark gap

6.0 mm (0.24 in)
NOTE:
If the ignition spark gap is within specification,
the ignition system circuit is operating normally.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
c. Measure the primary coil resistance. a. Disconnect the spark plug cap from the spark
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ plug.
2. Check: b. Connect the ignition checker “1” as shown.
• Secondary coil resistance
Out of specification → Replace. Ignition checker
90890-06754
Secondary coil resistance Opama pet-4000 spark checker
6.32–9.48 kΩ at 20 °C (68 °F) YM-34487
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the igni-
tion coil.
b. Connect the pocket tester (Ω × 1k) to the ig-
nition coil as shown.
Pocket tester
90890-03112
YU-03112-C
2. Spark plug cap
7-26
c. Turn the main switch to “ON” and engine stop

switch to “ ”. Pickup coil resistance
d. Measure the ignition spark gap “a”. 248–372 Ω at 20 °C (68 °F)
e. Crank the engine by pushing the start switch
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
“ ” or kicking down on the kickstarter lever a. Connect the pocket tester (Ω × 100) to the
and gradually increase the spark gap until a pickup coil terminal as shown.
misfire occurs.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Pocket tester
EAS28940
90890-03112
CHECKING THE STARTER MOTOR Analog pocket tester
OPERATION YU-03112-C
1. Check:
• Starter motor operation • Positive tester probe
Does not operate → Perform the electric White “1”
starting system troubleshooting, starting with • Negative tester probe
step 5. Red “2”
Refer to “TROUBLESHOOTING” on page
7-7.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive battery terminal “1” and
starter motor lead “2” with a jumper lead “3”.
EWA13810
WARNING
• A wire that is used as a jumper lead must R W
have at least the same capacity of the bat-
tery lead, otherwise the jumper lead may 2 1
burn.
• This check is likely to produce sparks, b. Measure the pickup coil resistance.
therefore, make sure no flammable gas or ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
fluid is in the vicinity. EAS5B61001
CHECKING THE LIGHTING COIL

1. Disconnect:
• Stator coil coupler
(from the wire harness)
2. Check:
• Lighting coil resistance
Out of specification → Replace the pickup
coil/stator assembly.
Lighting coil resistance

0.24–0.36 Ω at 20 °C (68 °F)
b. Check the starter motor operation.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
a. Connect the pocket tester (Ω × 1) to the stator
EAS28110
coil coupler as shown.
CHECKING THE PICKUP COIL
1. Disconnect: Pocket tester
• Pickup coil coupler 90890-03112
(from the wire harness) Analog pocket tester
2. Check: YU-03112-C
• Pickup coil resistance
Out of specification → Replace the pickup • Positive tester probe
coil/stator assembly. Yellow “1”
• Negative tester probe
Black “2”
7-27
EAS28170
CHECKING THE RECTIFIER/REGULATOR

1 1. Check:
• Charging coil voltage
W Out of specification → Replace the rectifi-
Y er/regulator.
2 B Charging voltage
14 V at 5000 r/min
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b. Measure the lighting coil resistance. a. Set the engine tachometer to the ignition coil.
b. Connect the pocket tester (DC 20 V) to the
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
rectifier/regulator coupler as shown.
EAS28960
CHECKING THE CHARGING COIL Pocket tester

1. Disconnect: 90890-03112
• Stator coil coupler Analog pocket tester
(from the wire harness) YU-03112-C
2. Check:
• Charging coil resistance • Positive tester probe
Out of specification → Replace the pickup Red “1”
coil/stator assembly. • Negative tester probe
Black “2”
Charging coil resistance
0.32–0.48 Ω at 20 °C (68 °F)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester (Ω × 1) to the
charging coil terminal as shown.
Pocket tester Y/R R 1

90890-03112 B W
Analog pocket tester 2
YU-03112-C
• Positive tester probe c. Start the engine and let it run at approximate-
White “1” ly 5000 r/min.
• Negative tester probe d. Measure the charging voltage.
Black “2” ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS5B61002
CHECKING THE THERMO SWITCH

1. Remove:
• Thermo switch
1 W EWA13830
WARNING
Y
• Handle the thermo switch with special care.
2 B • Never subject the thermo switch to strong
shocks. If the thermo switch is dropped, re-
place it.
b. Measure the charging coil resistance. 2. Check:

• Thermo switch continuity
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Out of specification → Replace the thermo
switch.
7-28
Continu- Resistance
Test step Water temperature
ity 3.20–5.77 Ω at 20 °C (68 °F)
Less than 16 ± 3 °C
1 YES ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
(60.8 ± 5.4 °F)
a. Disconnect the carburetor warmer lead from
More than 16 ± 3 °C the carburetor.
2 NO
(60.8 ± 5.4 °F) b. Connect the pocket tester (Ω × 1) to the car-
More than 11 ± 3 °C buretor warmer as shown.
3 NO
(51.8 ± 5.4 °F)
Less than 11 ± 3 °C Pocket tester
4 YES 90890-03112
(51.8 ± 5.4 °F)
Steps 1 and 2: Heating phase YU-03112-C
Steps 3 and 4: Cooling phase
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ • Positive tester probe
a. Connect the pocket tester (Ω × 1) to the ther- Carburetor warmer terminal “1”
mo switch “1” as shown. • Negative tester probe
b. Immerse the thermo switch in a container Carburetor warmer body “2”
filled with water “2”.
c. Place a thermometer “3” in the water.
c. Measure the carburetor warmer resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
A. Heating phase
B. Cooling phase
d. Slowly heat the water, then let it cool down to
the specified temperature.
e. Check the thermo switch for continuity.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS5B61003
CHECKING THE CARBURETOR WARMER

1. Check:
• Carburetor warmer resistance
7-29
TROUBLESHOOTING
TROUBLESHOOTING..................................................................................... 8-1
GENERAL INFORMATION ....................................................................... 8-1
STARTING FAILURES.............................................................................. 8-1
INCORRECT ENGINE IDLING SPEED .................................................... 8-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ........................... 8-2
FAULTY GEAR SHIFTING........................................................................ 8-2
SHIFT PEDAL DOES NOT MOVE ............................................................ 8-2
JUMPS OUT OF GEAR............................................................................. 8-2
FAULTY CLUTCH ..................................................................................... 8-2
OVERHEATING ........................................................................................ 8-3
POOR BRAKING PERFORMANCE.......................................................... 8-3
FAULTY FRONT FORK LEGS.................................................................. 8-3
UNSTABLE HANDLING ............................................................................ 8-3
8
TROUBLESHOOTING
EAS28450
• Damaged float
TROUBLESHOOTING • Worn needle valve
EAS28460
• Incorrect fuel level
GENERAL INFORMATION • Improperly installed pilot jet
NOTE: • Clogged starter jet
• Faulty starter plunger
The following guide for troubleshooting does not
• Improperly adjusted starter cable
cover all the possible causes of trouble. It should
be helpful, however, as a guide to basic trouble-
Electrical system
shooting. Refer to the relative procedure in this
1. Battery
manual for checks, adjustments, and replace-
• Discharged battery
ment of parts.
• Faulty battery
2. Fuse
EAS28470
STARTING FAILURES • Blown, damaged or incorrect fuse

• Improperly installed fuse
Engine 3. Spark plug
1. Cylinder and cylinder head • Incorrect spark plug gap
• Loose spark plug • Incorrect spark plug heat range
• Loose cylinder head or cylinder • Fouled spark plug
• Damaged cylinder head gasket • Worn or damaged electrode
• Damaged cylinder gasket • Worn or damaged insulator
• Worn or damaged cylinder • Faulty spark plug cap
• Incorrect valve clearance 4. Ignition coil
• Improperly sealed valve • Cracked or broken ignition coil body
• Incorrect valve-to-valve-seat contact • Broken or shorted primary or secondary coils
• Incorrect valve timing • Faulty spark plug lead
• Faulty valve spring 5. Ignition system
• Seized valve • Faulty CDI unit
2. Piston and piston ring • Faulty pickup coil
• Improperly installed piston ring • Broken AC magneto rotor woodruff key
• Damaged, worn or fatigued piston ring 6. Switches and wiring
• Seized piston ring • Faulty main switch
• Seized or damaged piston • Faulty engine stop switch
3. Air filter • Broken or shorted wiring
• Improperly installed air filter • Faulty neutral switch
• Clogged air filter element • Faulty start switch
4. Crankcase and crankshaft • Improperly grounded circuit
• Improperly assembled crankcase • Loose connections
• Seized crankshaft 7. Starting system
• Faulty starter motor
Fuel system • Faulty starter relay
1. Fuel tank • Faulty starter clutch
• Empty fuel tank EAS28490
• Clogged fuel filter INCORRECT ENGINE IDLING SPEED
• Clogged fuel tank breather hose
• Deteriorated or contaminated fuel Engine
2. Fuel cock 1. Cylinder and cylinder head
• Clogged or damaged fuel hose • Incorrect valve clearance
3. Carburetor • Damaged valve train components
• Deteriorated or contaminated fuel 2. Air filter
• Clogged pilot jet • Clogged air filter element
• Clogged pilot air passage
• Sucked-in air
8-1
TROUBLESHOOTING
Fuel system Shift drum and shift forks

1. Carburetor • Foreign object in a shift drum groove
• Faulty starter plunger • Seized shift fork
• Loose or clogged pilot jet • Bent shift fork guide bar
• Damaged or loose carburetor joint
• Improperly adjusted engine idling speed Transmission
(throttle stop screw) • Seized transmission gear
• Improper throttle cable free play • Foreign object between transmission gears
• Flooded carburetor • Improperly assembled transmission
EAS28550
Electrical system JUMPS OUT OF GEAR
1. Battery
• Discharged battery Shift shaft
• Faulty battery • Incorrect shift pedal position
2. Spark plug • Improperly returned stopper lever
• Incorrect spark plug gap
• Incorrect spark plug heat range Shift forks
• Fouled spark plug • Worn shift fork
• Worn or damaged electrode
• Worn or damaged insulator Shift drum
• Faulty spark plug cap • Incorrect axial play
3. Ignition coil • Worn shift drum groove
• Broken or shorted primary or secondary coils
• Faulty spark plug lead Transmission
• Cracked or broken ignition coil • Worn gear dog
4. Ignition system
EAS28560
• Faulty CDI unit FAULTY CLUTCH
• Faulty pickup coil
• Broken AC magneto rotor woodruff key Clutch slips
EAS28510
1. Clutch
POOR MEDIUM-AND-HIGH-SPEED • Improperly assembled clutch
PERFORMANCE • Loose or fatigued clutch spring
Refer to “STARTING FAILURES” on page 8-1. • Worn friction plate
• Worn clutch plate
Engine 2. Engine oil
1. Air filter • Incorrect oil level
• Clogged air filter element • Incorrect oil viscosity (low)
• Deteriorated oil
Fuel system
1. Carburetor Clutch drags
• Incorrect fuel level 1. Clutch
• Loose or clogged main jet • Unevenly tensioned clutch springs
• Warped pressure plate
EAS28530
FAULTY GEAR SHIFTING • Bent clutch plate

• Swollen friction plate
Shifting is difficult • Bent clutch push rod
Refer to “Clutch drags”. • Broken clutch boss
• Burnt primary driven gear bushing
EAS28540
• Match marks not aligned
SHIFT PEDAL DOES NOT MOVE
2. Engine oil
• Incorrect oil level
Shift shaft
• Incorrect oil viscosity (high)
• Bent shift shaft
• Deteriorated oil
8-2
TROUBLESHOOTING
EAS28590
Malfunction
OVERHEATING
• Bent or damaged inner tube
• Bent or damaged outer tube
Engine
• Damaged fork spring
1. Cylinder head and piston
• Bent or damaged damper rod
• Heavy carbon buildup
• Incorrect oil viscosity
2. Engine oil
• Incorrect oil viscosity EAS28690
• Inferior oil quality UNSTABLE HANDLING

1. Handlebar
Fuel system • Bent or improperly installed handlebar
1. Carburetor 2. Steering head components
• Incorrect main jet setting • Improperly installed upper bracket
• Incorrect fuel level • Improperly installed lower bracket
• Damaged or loose carburetor joint (improperly tightened ring nut)
2. Air filter • Bent steering stem
• Clogged air filter element • Damaged ball bearing or bearing race
3. Front fork leg(s)
Chassis • Uneven oil levels (both front fork legs)
1. Brake • Unevenly tensioned fork spring (both front
• Dragging brake fork legs)
• Broken fork spring
Electrical system • Bent or damaged inner tube
1. Spark plug • Bent or damaged outer tube
• Incorrect spark plug gap 4. Swingarm
• Incorrect spark plug heat range • Worn bearing or bushing
2. Ignition system • Bent or damaged swingarm
• Faulty CDI unit 5. Rear shock absorber assembly
EAS28630
• Faulty rear shock absorber spring
POOR BRAKING PERFORMANCE • Leaking oil or gas
• Worn brake shoe 6. Tire(s)
• Worn or rusty brake drum • Uneven tire pressures (front and rear)
• Incorrect brake pedal position • Incorrect tire pressure
• Incorrect brake pedal free play • Uneven tire wear
• Incorrect brake camshaft lever position 7. Wheel(s)
• Incorrect brake shoe position • Incorrect wheel balance
• Damaged or fatigued brake shoe spring • Broken or loose spoke
• Oil or grease on the brake shoe • Damaged wheel bearing
• Oil or grease on the brake drum • Bent or loose wheel axle
• Broken brake torque rod • Excessive wheel runout
8. Frame
EAS28660
• Bent frame
FAULTY FRONT FORK LEGS
• Damaged steering head pipe
• Improperly installed bearing race
Leaking oil
• Bent, damaged or rusty inner tube
• Cracked or damaged outer tube
• Improperly installed oil seal
• Damaged oil seal lip
• Incorrect oil level (high)
• Loose damper rod bolt
• Damaged damper rod bolt copper washer
• Cracked or damaged front fork cap O-ring
8-3
TROUBLESHOOTING
8-4
EAS28750
EAS28740
COLOR CODE
WIRING DIAGRAM
B Black
TT-R110E(X) 2008 Br Brown
1. Rectifier/regulator O Orange
2. Battery P Pink
3. Fuse R Red
4. Ground lead Sb Sky blue
5. Starter relay W White
6. Starter motor Y Yellow
7. Engine stop switch L/W Blue/White
8. Main switch R/W Red/White
Y/R Yellow/Red
9. Thermo switch
Y/W Yellow/White
11. AC magneto
12. CDI unit
13. Ignition coil
14. Spark plug
15. Start switch
16. Neutral switch
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
TT-R110E(X) 2008 TT-R110E(X) 2008 TT-R110E(X) 2008
WIRING DIAGRAM SCHÉMA DE CÂBLAGE SCHALTPLAN
Br B O
R W
(BLACK) 13
W R R O O
11
Y/R W W 12 B B
W W
Br 14
Y/R
Y/R Y
W Y/R
B B
9
W R R W
Y Y/R B B
W B R
R Y/R 1 R
B
(BLUE)
8 Y
ON
B R Br Br R
OFF
(BLACK) (BLACK)
Y
Br
10
Br
R R R
7
B B Br R/W
B
R/W
B
R R/W
B
L/W R
5 R/W R
4
R L/W
L/W
15
R
R
R Sb L/W B B
6
Sb
Sb
16
P W
Y/W Sb Sb
L/W

Service Manual: TT-R110E (X)

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Service Manual: TT-R110E (X)

Hochgeladen von

Copyright:

Verfügbare Formate

2008

IMPORTANT MANUAL INFORMATION

Failure to follow WARNING instructions could result in severe injury or death

A CAUTION indicates special precautions that must be taken to avoid dam-

NOTE: A NOTE provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL

18. Replace the part with a new one.

IDENTIFICATION ............................................................................................ 1-1

IMPORTANT INFORMATION ......................................................................... 1-2

CHECKING THE CONNECTIONS .................................................................. 1-4

SPECIAL TOOLS ............................................................................................ 1-5

VEHICLE IDENTIFICATION NUMBER

PREPARATION FOR REMOVAL AND

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS

CHECKING THE CONNECTIONS Pocket tester

Thickness gauge 3-3

Tappet adjusting tool 3-4

Timing light 3-7

Compression gauge 3-7

Spoke nipple wrench (10-11) 3-19

Damper rod holder 4-25, 4-26

T-handle 4-25, 4-26

Fork seal driver weight 4-26

Fork seal driver attachment (ø33) 4-26

Valve spring compressor 5-15, 5-20

Valve spring compressor attachment 5-15, 5-20

Valve guide remover (ø4.5) 5-16

Valve guide installer (ø4.5) 5-16

Valve guide reamer (ø4.5) 5-16

Sheave holder 5-28, 5-29,

Flywheel puller 5-28

Yamaha bond No. 1215 5-30, 5-55

Universal clutch holder 5-40, 5-43

Crankshaft installer pot 5-58

Crankshaft installer bolt 5-58

Adapter (M12) 5-58

Spacer (crankshaft installer) 5-58

Ignition checker 7-26

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

ENGINE SPECIFICATIONS ............................................................................ 2-2

CHASSIS SPECIFICATIONS .......................................................................... 2-9

ELECTRICAL SPECIFICATIONS ................................................................. 2-12

TIGHTENING TORQUES .............................................................................. 2-14

LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-19

LUBRICATION SYSTEM CHART AND DIAGRAMS.................................... 2-23

CABLE ROUTING ......................................................................................... 2-27

Spark plug (s)

Warpage limit 0.03 mm (0.0012 in)

Rocker arm/rocker arm shaft

Valve, valve seat, valve guide

Valve head diameter A (exhaust) 19.90–20.10 mm (0.7835–0.7913 in)

Valve seat width C (intake) 0.90–1.10 mm (0.0354–0.0433 in)

Valve margin thickness D (intake) 0.50–0.90 mm (0.0197–0.0354 in)

Valve stem diameter (intake) 4.475–4.490 mm (0.1762–0.1768 in)

Cylinder head valve seat width (intake) 0.90–1.10 mm (0.0354–0.0433 in)

Winding direction (intake) Clockwise

Offset 0.50 mm (0.0197 in)

End gap (installed) 0.10–0.25 mm (0.0039–0.0098 in)

End gap (installed) 0.10–0.25 mm (0.0039–0.0098 in)

End gap (installed) 0.20–0.70 mm (0.0079–0.0276 in)

Automatic centrifugal clutch