WR250F - Off-road motorcycle YAMAHA - Free user manual and instructions

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USER MANUAL WR250F YAMAHA

PRINTED ON RECYCLED PAPER

OWNER’S SERVICE MANUAL

©2006 by Yamaha Motor Co., Ltd. 1st Edition, August 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan INTRODUCTION Congratulations on your purchase of a Yamaha WR series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader. This manual explains operation, inspection, basic maintenance and tuning of your machine. If you have any questions about this manual or your machine, please contact your Yamaha dealer. NOTE: Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your machine and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer. WARNING

PLEASE READ THIS MANUAL

CAREFULLY AND COMPLETELY

BEFORE OPERATING THIS

MACHINE. DO NOT ATTEMPT TO

OPERATE THIS MACHINE UNTIL

YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS

CONTROLS AND OPERATING

FEATURES AND UNTIL YOU

HAVE BEEN TRAINED IN SAFE

AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS

AND CAREFUL MAINTENANCE,

ALONG WITH GOOD RIDING

SKILLS, WILL ENSURE THAT YOU

SAFETY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE. IMPORTANT NOTICE

THIS MACHINE IS DESIGNED

STRICTLY FOR COMPETITION

USE, ONLY ON A CLOSED

COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding. SAFETY INFORMATION

THIS MACHINE IS TO BE

OPERATED BY AN EXPERIENCED RIDER ONLY. Do not attempt to operate this machine at maximum power until you are totally familiar with its characteristics. THIS MACHINE

DESIGNED TO BE RIDDEN

BY THE OPERATOR ONLY. Do not carry passengers on this machine. ALWAYS WEAR PROTECTIVE APPAREL. When operating this machine, always wear an approved helmet with goggles or a face shield. Also wear heavy boots, gloves, and protective clothing. Always wear proper fitting clothing that will not be caught in any of the moving parts or controls of the machine.

ALWAYS MAINTAIN YOUR

MACHINE PROPER WORKING ORDER. For safety and reliability, the machine must be properly maintained. Always perform the pre-operation checks indicated in this manual. Correcting mechanical problem before you ride may prevent an accident. GASOLINE HIGHLY FLAMMABLE. Always turn off the engine while refueling. Take care to not spill any gasoline on the engine or exhaust system. Never refuel in the vicinity of an open flame, or while smoking.

GASOLINE CAN CAUSE

INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes.

7. ONLY

MACHINE IN AN AREA

WITH ADEQUATE VENTILATION. Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are poisonous. These fumes contain carbon monoxide, which by itself is odorless and colorless. Carbon monoxide is a dangerous gas which can cause unconsciousness or can be lethal.

8. PARK

CAREFULLY; TURN OFF

THE ENGINE. Always turn off the engine if you are going to leave the machine. Do not park the machine on a slope or soft ground as it may fall over.

9. THE ENGINE, EXHAUST

PIPE, MUFFLER, AND OIL

TANK WILL BE VERY HOT

AFTER THE ENGINE HAS

BEEN RUN. Be careful not to touch them or to allow any clothing item to contact them during inspection or repair.

10. PROPERLY SECURE THE

MACHINE BEFORE TRANSPORTING IT. When transporting the machine in another vehicle, always be sure it is properly secured and in an upright position and that the fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the carburetor or fuel tank.

TO THE NEW OWNER

This manual will provide you with a good basic understanding of features, operation, and basic maintenance and inspection items of this machine. Please read this manual carefully and completely before operating your new machine. If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer. NOTE: This manual should be considered a permanent part of this machine and should remain with it even if the machine is subsequently sold. EC060000 NOTICE Some data in this manual may become outdated due to improvements made to this model in the future. If there is any question you have regarding this manual or your machine, please consult your Yamaha dealer. EC070001 F.I.M. MACHINE WEIGHTS: Weights of machines without fuel The minimum weights for motocross machines are: for the class 125 cc ..... minimum 88 kg (194 lb) for the class 250 cc ..... minimum 98 kg (216 lb) for the class 500 cc ..... minimum 102 kg (225 lb) In modifying your machine (e.g., for weight reduction), take note of the above limits of weight.

HOW TO USE THIS

MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! COMMENT UTILISER CE MANUEL INFORMATIONS PARTICULIEREMENT IMPORTANTES WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the machine. NOTE: A NOTE provides key information to make procedures easier or clearer. EC082000

FINDING THE REQUIRED

1. This manual consists of seven

chapters; “General information”, “Specifications”, “Regular inspection and adjustments”, “Tuning”, “Engine”, “Chassis” and “Electrical”.

2. The table of contents is at the

beginning of the manual. Look over the general layout of the book before finding then required chapter and item. Bend the book at its edge, as shown, to find the required fore edge symbol mark and go to a page for required item and description.

CÓMO UTILIZAR

ESTE MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g.,

• Bearings Pitting/damage → Replace. EC084002

HOW TO READ DESCRIPTIONS

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

1. An easy-to-see exploded diagram 1 is provided for

removal and disassembly jobs.

2. Numbers 2 are given in the order of the jobs in the

exploded diagram. A number that is enclosed by a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an

easy-to-read way by the use of symbol marks 3. The meanings of the symbol marks are given on the next page.

4. A job instruction chart 4 accompanies the exploded

diagram, providing the order of jobs, names of parts, notes in jobs, etc.

5. Extent of removal 5 is provided in the job instruction

chart to save the trouble of an unnecessary removal job.

6. For jobs requiring more information, the step-by-step

format supplements 6 are given in addition to the exploded diagram and job instruction chart.

FORMATO DEL MANUAL

ILLUSTRATED SYMBOLS (Refer to the illustration)

GEN INFO Illustrated symbols 1 to 7 are designed as thumb tabs to indicate the chapter’s number and content. SPEC

General information Specifications Regular inspection and adjustments Tuning Engine Chassis Electrical CHAS ENG Illustrated symbols 8 to D are used to identify the specifications appearing in the text. With engine mounted Special tool Filling fluid Lubricant Tightening Specified value, Service limit Resistance (Ω), Voltage (V), Electric current (A) Illustrated symbols E to H in the exploded diagrams indicate grade of lubricant and location of lubrication point. E Apply engine oil F Apply molybdenum disulfide oil G Apply lightweight lithium-soap base grease H Apply molybdenum disulfide grease Illustrated symbols I to J in the exploded diagrams indicate where to apply a locking agent and where to install new parts. I Apply locking agent (LOCTITE®) J Use new one REGULAR INSPECTION AND ADJUSTMENTS

CHAPITRE 4

MISE AU POINT

GEN INFO Clutch lever Hot starter lever Engine stop switch Multi-function display Main switch Start switch Front brake lever Throttle grip Radiator cap Fuel tank cap Taillight Kickstarter crank Fuel tank Headlight Radiator Coolant drain bolt Rear brake pedal Valve joint Fuel cock Cold starter knob Air cleaner Catch tank Drive chain Oil level check window Shift pedal Front fork NOTE:

• The machine you have purchased may differ slightly from those shown in the following.
• Designs and specifications are subject to change without notice. 1-1

MACHINE IDENTIFICATION There are two significant reasons for knowing the serial number of your machine:

1. When ordering parts, you can

give the number to your Yamaha dealer for positive identification of the model you own.

2. If your machine is stolen, the

authorities will need the number to search for and identify your machine. EC121001 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped on the right of the steering head pipe. EC123001

ENGINE SERIAL NUMBER

The engine serial number 1 is stamped into the elevated part of the right-side of the engine. EC124000 MODEL LABEL The model label 1 is affixed to the frame under the rider’s seat. This information will be needed to order spare parts. 1-3 GEN INFO IMPORTANT INFORMATION INFORMATIONS IMPORTANTES EC130000 IMPORTANT INFORMATION GEN INFO INFORMATIONS IMPORTANTES

PREPARATION FOR REMOVAL

1. Remove all dirt, mud, dust, and

foreign material before removal and disassembly. When washing the machine with high pressured water, cover the parts follows.

• Silencer exhaust port
• Side cover air intake port
• Water pump housing hole at the bottom
• Drain hole on the cylinder head (right side)
• All electrical components

2. Use proper tools and cleaning

equipment. Refer to “SPECIAL TOOLS” section. When disassembling the machine, keep mated parts together. They include gears, cylinders, pistons, and other mated parts that have been “mated” through normal wear. Mated parts must be reused as an assembly or replaced.

During the machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled. Keep away from fire.

ALL REPLACEMENT PARTS

1. We recommend to use Yamaha

genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. 1-5

IMPORTANT INFORMATION INFORMATIONS IMPORTANTES EC133000

GASKETS, OIL SEALS AND ORINGS

1. All gaskets, oil seals, and Orings should be replaced when

an engine is overhauled. All gasket surfaces, oil seal lips, and Orings must be cleaned.

2. Properly oil all mating parts and

bearings during reassembly. Apply grease to the oil seal lips. EC134000

LOCK WASHERS/PLATES AND

1. All lock washers/plates 1 and

cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened. EC135001

BEARINGS AND OIL SEALS

1. Install the bearing(s) 1 and oil

seal(s) 2 with their manufacturer’s marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of lightweight lithium base grease to the seal lip(s). Oil the bearings liberally when installing. CAUTION: Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces. EC136000 CIRCLIPS

1. All circlips should be inspected

carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1, make sure that the sharpedged corner 2 is positioned opposite to the thrust 3 it receives. See the sectional view. 4 Shaft 1-7 GEN INFO

CHECKING OF CONNECTION

VERIFICATION DES CONNEXIONS

EC1C0001 CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on the connector.

1. Disconnect:

2. Dry each terminal with an air

3. Connect and disconnect the connector two or three times.

4. Pull the lead to check that it will

5. If the terminal comes off, bend

up the pin 1 and reinsert the terminal into the connector.

• Connector GEN INFO NOTE: The two connectors “click” together. Check for continuity with a tester. NOTE:
• If there in no continuity, clean the terminals.
• Be sure to perform the steps 1 to 7 listed above when checking the wire harness.
• For a field remedy, use a contact revitalizer available on the market.
• Use the tester on the connector as shown. 1-9 SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order. NOTE:
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-” or “ACC-”.
• For others, use part number starting with “90890-”. Part number YU-1135-A, 90890-01135 Tool name/How to use Illustration These tool is used to remove the crankshaft from either case. YU-3097, 90890-01252 YU-1256 Dial gauge and stand Stand These tools are used to check each part for runout or bent. Crankshaft installing tool Crankshaft installing pot Crankshaft installing bolt Spacer (crankshaft installer) Adapter (M12) These tools are used to install the crankshaft. YU-1304, 90890-01304 This tool is used to remove the piston pin. YU-24460-01, 90890-01325 Radiator cap tester YU-33984, 90890-01352 Radiator cap tester adapter 90890-01325 90890-01352 These tools are used for checking the cooling system. YU-33975, 90890-01403 Steering nut wrench This tool is used when tighten the steering ring nut to specification. YM-01494, 90890-01494 Use this tool to remove and install the damper rod. YM-A0948, 90890-01502 Fork seal driver This tool is used when install the fork oil seal.

1 - 11

SPECIAL TOOLS Part number YS-1880-A, 90890-01701 Tool name/How to use GEN INFO Illustration Sheave holder This tool is used for when loosening or tightening the flywheel magneto securing nut. YU-3112-C, 90890-03112 Pocket tester 90890-03112 Use this tool to inspect the coil resistance, output voltage and amperage. YM-33277-A, 90890-03141 Timing light This tool is necessary for checking ignition timing. YM-4019, 90890-04019 Valve spring compressor This tool is needed to remove and install the valve assemblies. YM-91042, 90890-04086 Clutch holding tool This tool is used to hold the clutch when removing or installing the clutch boss securing nut. YM-4111, 90890-04111 YM-4116, 90890-04116 This tool is needed to remove and install the valve guide. YM-4112, 90890-04112 YM-4117, 90890-04117 This tool is needed to install the valve guide. YM-4113, 90890-04113 YM-4118, 90890-04118 This tool is needed to rebore the new valve guide. YM-04141, 90890-04141 Rotor puller 90890-04141 This tool is used to remove the flywheel magneto.

1 - 12

Tool name/How to use GEN INFO Illustration Dynamic spark tester Ignition checker 90890-06754 This instrument is necessary for checking the ignition system components. YB-35956-A, 90890-06756 Vacuum/pressure pump gauge set This tool is used to check the air induction system. 90890-85505 YAMAHA Bond No. 1215 (ThreeBond® No. 1215) This sealant (Bond) is used for crankcase mating surface, etc.

1 - 13

YB-35956-A 90890-06756 OUTILS SPECIAUX GEN INFO GEN INFO Figura GEN INFO Figura CONTROL FUNCTIONS MAIN SWITCH Functions of the respective switch positions are as follows: ON: The engine can be started only at this position. OFF: All electrical circuits are switched off. Main switch indicator light The main switch 1 is equipped with an indicator light 2 to avoid forgetting to turn it off. This light functions as follows.

• It lights up with the main switch “ON”.
• It goes out when the engine increases its speed after being started.
• It lights up again when the engine is stopped. NOTE: If the indicator light will not light up with the main switch “ON”, it shows a lack of the battery voltage. Recharge the battery. GEN INFO

ENGINE STOP SWITCH

The engine stop switch 1 is located on the left handlebar. Continue pushing the engine stop switch till the engine comes to a stop. START SWITCH The start switch 1 is located on the right handlebar. Push this switch to crank the engine with the starter. CLUTCH LEVER The clutch lever 1 is located on the left handlebar; it disengages or engages the clutch. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth starts.

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SHIFT PEDAL The gear ratios of the constant-mesh 5 speed transmission are ideally spaced. The gears can be shifted by using the shift pedal 1 on the left side of the engine.

GEN INFO KICKSTARTER CRANK Rotate the kickstarter crank 1 away from the engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine. This model has a primary kickstarter crank so the engine can be started in any gear if the clutch is disengaged. In normal practices, however, shift to neutral before starting. THROTTLE GRIP The throttle grip 1 is located on the right handlebar; it accelerates or decelerates the engine. For acceleration, turn the grip toward you; for deceleration, turn it away from you. EC156000

FRONT BRAKE LEVER

The front brake lever 1 is located on the right handlebar. Pull it toward the handlebar to activate the front brake. EC157000

REAR BRAKE PEDAL

The rear brake pedal 1 is located on the right side of the machine. Press down on the brake pedal to activate the rear brake.

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FUEL COCK The fuel cock supplies fuel from the tank to carburetor and also filters the fuel. The fuel cock has three positions: OFF: With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running. ON: With the lever in this position fuel flows to the carburetor. Normal riding is done with the lever in this position. RES: With the lever in this position fuel flows to the carburetor from the reserve section of the fuel tank after the main supply of the fuel has been depleted. Normal riding is possible with the lever is in this position, but it is recommended to add fuel as soon as possible.

COLD STARTER KNOB

When cold, the engine requires a richer air-fuel mixture for starting. A separate starter circuit, which is controlled by the cold starter knob 1, supplies this mixture. Pull the cold starter knob out to open the circuit for starting. When the engine has warmed up, push it in to close the circuit.

HOT STARTER LEVER

The hot starter lever 1 is used when starting a warm engine. Use the hot starter lever when starting the engine again immediately after it was stopped (the engine is still warm). Pulling the hot starter lever injects secondary air to thin the air-fuel mixture temporarily, allowing the engine to be started more easily. CONTROL FUNCTIONS

FONCTIONS DES COMMANDES

SIDESTAND This sidestand 1 is used to support only the machine when standing or transporting it.

• Never apply additional force to the sidestand.
• Hold up the sidestand before starting out. VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose. ATTENTION: CAUTION: In this installation, make sure the arrow faces the fuel tank and also downward.

SPARK PLUG WRENCH

This spark plug wrench 1 is used to remove and install the spark plug. NIPPLE WRENCH This nipple wrench 1 is used to tighten the spoke.

JET NEEDLE PULL-UP TOOL

The jet needle pull-up tool 1 is used to pull the jet needle out of the carburetor. MULTI-FUNCTION DISPLAY ECRAN MULTIFONCTION MULTI-FUNCTION DISPLAY WARNING Be sure to stop the machine before making any setting changes to the multi-function display. The multi-function display equipped with the following: BASIC MODE:

• Two tripmeters (which shows the distance that has been traveled since it was last set to zero) RACE MODE:
• Timer (which shows the time that has been accumulated since the start of timer measurement)
• Tripmeter (which shows the accumulated travel distance in timer measurement)
• Change tripmeter digits (capable of change to any given ones) GEN INFO DESCRIPTION Operation buttons: Tripmeter indicator Tripmeter indicator Timer indicator Clock/Timer Speedometer Odometer/Tripmeter NOTE: The operation buttons can be pushed in the following two manners: Short push: Push the button. ( Long push: Push the button for 2 seconds or more. (

BASIC MODE Changing speedometer display (for U.K.)

1. Push the “SLCT2” button for 2

seconds or more to change the speedometer units. The speedometer display will change in the following order: MPH → km/h → MPH.

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MULTI-FUNCTION DISPLAY ECRAN MULTIFONCTION Setting the time

1. Push the “SLCT1” button for 2

seconds or more to enter the time setting mode.

2. Push the “RST” button to change

the display for time indication. The display will change in the following order: Hour → Minute → Second → Hour. NOTE: The digits capable of setting go on flashing.

Push the “SLCT1” button (plus) or “SLCT2” button (minus) and change the time. A long push on the button will fast-forward the time. To end the setting, push the “RST” button for 2 seconds or more. NOTE:

• In a 30-second absence of button operation, the setting will come to an end with the indicated time.
• To reset the seconds, push the “SLCT1” button or “SLCT2” button. Changing odometer and tripmeter A/B (TRIP A/B)

1. Push the “SLCT2” button to

change the tripmeter display. The display will change in the following order: Odometer → TRIP A → TRIP B

• TRIP A → Odometer. NOTE: To reset the digits, select the tripmeter involved and push the “RST” button for 2 seconds or more.

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GEN INFO MULTI-FUNCTION DISPLAY ECRAN MULTIFONCTION GEN INFO

PASSAGE DU MODE DE BASE AU

• Measurement using the timer function can be made in RACE MODE.
• Indicator will light up as an identifier that shows RACE MODE has been selected.
• RACE MODE cannot display the functions as in BASIC MODE.
• Changeover to RACE MODE forces the digits for tripmeter A (TRIP A) in BASIC MODE to be reset. Changeover from BASIC MODE to RACE MODE

1. Push the “SLCT1” button and

“SLCT2” button for 2 seconds or more at the same time to change over to RACE MODE. NOTE: Changeover to RACE MODE will put manual start measurement on standby causing and to flash. (For manual start, refer to “Putting measurement on standby” in “RACE MODE”.) Returning to BASIC MODE from RACE MODE NOTE: It is possible to return to BASIC MODE with timer measurement at a stop. Check that the timer is not in operation. If the timer is in operation, stop the timer by pushing the “SLCT1” button and “SLCT2” button at the same time. Push the “SLCT1” button and “SLCT2” button for 2 seconds or more at the same time to change over to BASIC MODE.

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PASSAGGIO DALLA MODALITÀ

DI BASE ALLA MODALITÀ

CORSA GEN INFO MULTI-FUNCTION DISPLAY ECRAN MULTIFONCTION GEN INFO RACE MODE Putting measurement on standby NOTE: Starting measurement consists of the following two starts, either of which can be selected.

• Manual start Starting measurement by the rider himself operating the button. (A long push on “SLCT2” button will put measurement on standby.)
• Auto start Starting timer measurement automatically on detection of the movement of the machine. (A long push on “SLCT1” button will put measurement on standby.) NOTE: Initial setting at changeover to RACE MODE will remain for manual start. Check that changeover to RACE MODE has been made. (Refer to “Changeover from BASIC MODE to RACE MODE”.) NOTE: When the machine is made ready for a run by manual start, and will start flashing.

Start timer measurement by pushing the “RST” button. When stopping timer measurement, pushing the “SLCT1” button and “SLCT2” button at the same time. NOTE: If the machine is run while timer measurement is not made, no change will occur to the digit in tripmeter A (TRIP A). To resume the measurement, again push the “SLCT1” button and “SLCT2” button at the same time.

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MULTI-FUNCTION DISPLAY ECRAN MULTIFONCTION GEN INFO Auto start

1. Check that changeover has

been made to RACE MODE. (Refer to “Changeover from BASIC MODE RACE MODE”.)

2. Make the machine ready for a

run by pushing the “SLCT1” button for 2 seconds or more. NOTE: When measurement is made ready for a run by auto start, and will start flashing. Timer display will turn on scrolling from left to right. Run the machine and start timer measurement. To stop timer measurement, pushing the “SLCT1” button and the “SLCT2” button at the same time.

NOTE: If the machine is run while timer measurement is not made, no change will occur to the digit in tripmeter A (TRIP A). To resume the measurement, again pushing the “SLCT1” button and “SLCT2” button at the same time. Resetting measurement data NOTE: Resetting can be made in the following two manners. Resetting is possible while timer measurement is made:

• Reset tripmeter A. Resetting is possible while timer measurement is not made:
• Reset tripmeter A and timer. Resetting tripmeter A (TRIP A)

1. Check that the timer is in operation. If the timer is not in operation, start the timer by pushing

the “SLCT1” button and “SLCT2” button at the same time.

2. Reset tripmeter A (TRIP A) display by pushing the “RST” button

for 2 seconds or more. NOTE: If reset, and travel distance display will go on flashing for four seconds.

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MULTI-FUNCTION DISPLAY ECRAN MULTIFONCTION Resetting tripmeter A (TRIP A) and timer

1. Check that the timer is not in

operation. If the timer is in operation, stop it by pushing the “SLCT1” button and “SLCT2” button at the same time.

2. Reset all measured data by

pushing the “RST” button for 2 seconds or more. NOTE:

• Resetting will reset the timer display and travel distance display and put measurement on standby.
• Auto start attempt will put measurement on standby as such. Likewise, manual start attempt will put measurement on standby as such. Correcting tripmeter A (TRIP A)

1. Change the travel distance display by pushing the “SLCT1”

button (plus) or “SLCT2” button (minus). A long push on the button will fast-forward the change. NOTE: Change can be made any time while timer measurement is or is not being made.

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GEN INFO MULTI-FUNCTION DISPLAY GEN INFO FUNCTION DIAGRAM NOTE: The following diagram illustrates the multi-function display regarding the direction and operation condition involved in each of its functions. A short push on the button changes the operation in the arrowed direction. A short push on the button changes the operation in both arrowed directions. A long push on the button changes the operation in the arrowed direction. Meter function Function that can be performed whether the time is or is not in operation. Extent to which the meter can operate A long push on the button changes the operation in both arrowed directions. 2 Clock 1 BASIC MODE 4 Speedometer (for U.K.) MPH → km/h → MPH 6 Putting measurement on standby 7 Manual start 8 Auto start 9 Measurement starts as the machine moves 5 RACE MODE C Timer not in operation 0 Timer in operation A Reset TRIP A Always use the recommended fuel as stated below. Also, be sure to use new gasoline. Recommended fuel: Premium unleaded gasoline only with a research octane number of 95 or higher. ATTENTION: CAUTION: Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine internal parts such as valves, piston rings, and exhaust system, etc. NOTE: If knocking or pinging occurs, use a different brand of gasoline or higher octane grade. WARNING

• For refueling, be sure to stop the engine and use enough care not to spill any fuel. Also be sure to avoid refueling close to a fire.
• Refuel after the engine, exhaust pipe, etc. have cooled off. Gasohol (For Canada) There are two types of gasohol: gasohol containing ethanol and that containing methanol. Gasohol containing ethanol can be used if the ethanol content does not exceed 10%. Gasohol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance problems.

1 - 49

KRAFTSTOFF CARBURANTE COMBUSTIBLE GEN INFO KRAFTSTOFF CARBURANTE COMBUSTIBLE STARTING AND BREAK-IN WARNING Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time. Always operate the machine in a well-ventilated area. CAUTION: GEN INFO

• The carburetor on this machine has a built-in accelerator pump. Therefore, when starting the engine, do not operate the throttle or the spark plug will foul.
• Unlike a two-stroke engine, this engine cannot be kick started when the throttle is open because the kickstarter may kick back. Also, if the throttle is open the air/fuel mixture may be too lean for the engine to start.
• Before starting the machine, perform the checks in the preoperation check list.

AIR FILTER MAINTENANCE

According to “AIR FILTER CLEANING” section in the CHAPTER 3, apply the foam-air-filter oil or its equivalent to the element. (Excess oil in the element may adversely affect engine starting.)

STARTING A COLD ENGINE

NOTE: This model is equipped with an ignition circuit cut-off system. The engine can be started under the following conditions.

• When the transmission is in neutral.
• When the clutch is disengaged with the transmission in any position. However, it is recommended to shift into neutral before starting the engine. Inspect the coolant level. Turn the fuel cock to “ON”. Push on the main switch to “ON”. Shift the transmission into neutral. Fully open the cold starter knob Start the engine by pushing the start switch or by kicking the kickstarter crank. NOTE: If the engine fails to start by pushing the start switch, release the switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt. If the engine does not start with the starter motor, try using the kickstarter crank. WARNING
• If the starter motor will not turn when pushing the start switch, stop pushing it immediately and kick start the engine in order to avoid the load on the motor.
• Do not open the throttle while kicking the kickstarter crank. Otherwise, the kickstarter crank may kick back.

Return the cold starter knob to its original position and run the engine at 3,000 ~ 5,000 r/min for 1 or 2 minutes. NOTE: Since this model is equipped with an accelerator pump, if the engine is raced (the throttle opened and closed), the air/fuel mixture will be too rich and the engine may stall. Also unlike a two-stroke engine, this model can idle.

GEN INFO CAUTION: Do not warm up the engine for extended periods of time.

1 - 53

STARTING A WARM ENGINE

Do not operate the cold starter knob and throttle. Pull the hot starter lever 1 and start the engine by pushing the start switch or by kicking the kickstarter crank forcefully with a firm stroke. As soon as the engine starts, Release the hot starter lever to close the air passage. Restarting an engine after a fall Pull the hot starter lever and start the engine. As soon as the engine starts, Release the hot starter lever to close the air passage. The engine fails to start Pull the hot starter lever all the way out and while holding the lever, kick the kickstarter crank 10 to 20 times to clear the engine. Then, restart the engine. Refer to “Restarting an engine after a fall”. Hot starter lever Air temperature = less than 5 °C (41 °F) Open 3 4 times

OFF Air temperature = more than 5 °C (41 °F) None

OFF Starting a cold engine Air temperature (normal temperature) = between 5 °C (41 °F) and 25 °C (77 °F) None Air temperature = more than 25 °C (77 °F) None OFF OFF Starting an engine after a long period of time None

OFF Restarting a warm engine OFF OFF

Restarting an engine after a fall Aucune OFF

• Operate the throttle grip before kick starting. CAUTION: Observe the following break-in procedures during initial operation to ensure optimum performance and avoid engine damage.

1 - 55

STARTING AND BREAK-IN

MISE EN MARCHE ET RODAGE

1. Before starting the engine, fill the

fuel tank with the fuel.

2. Perform

the pre-operation checks on the machine.

3. Start and warm up the engine.

Check the idle speed, and check the operation of the controls and the engine stop switch. Then, restart the engine and check its operation within no more than 5 minutes after it is restarted.

4. Operate the machine in the

lower gears at moderate throttle openings for five to eight minutes.

5. Check how the engine runs

when the machine is ridden with the throttle 1/4 to 1/2 open (low to medium speed) for about one hour.

6. Restart the engine and check

the operation of the machine throughout its entire operating range. Restart the machine and operate it for about 10 to 15 more minutes. GEN INFO CAUTION: After the break-in or before each ride, you must check the entire machine for loose fittings and fasteners as per “TORQUE-CHECK POINTS”. Tighten all such fasteners as required.

1 - 57

TORQUE-CHECK POINTS Frame construction Frame to rear frame Fuel tank to frame Combined seat and fuel tank Exhaust system Silencer to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Suspension Wheel Steering stem to handlebar Steering stem to frame Steering stem to upper bracket Upper bracket to handlebar Front Steering stem to front fork Front fork to upper bracket Front fork to lower bracket Rear For link type Assembly of links Link to frame Link to rear shock absorber Link to swingarm Rear Installation of rear shock absorber Rear shock absorber to frame Rear Installation of swingarm Tightening of pivot shaft Installation of wheel Brake Front Tightening of wheel axle Tightening of axle holder Rear Tightening of wheel axle Wheel to rear wheel sprocket Front Brake caliper to front fork Brake disc to wheel Tightening of union bolt Brake master cylinder to handlebar Tightening of bleed screw Tightening of brake hose holder Rear Brake pedal to frame Brake disc to wheel Tightening of union bolt Brake master cylinder to frame Tightening of bleed screw Tightening of brake hose holder Fuel system Fuel tank to fuel cock Lubrication system Tightening of oil hose clamp NOTE: Concerning the tightening torque, refer to “MAINTENANCE SPECIFICATIONS” section in the CHAPTER 2.

1 - 59

CLEANING AND STORAGE EC1B1000 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many components.

1. Before washing the machine,

block off the end of the exhaust pipe to prevent water from entering. A plastic bag secured with a rubber band may be used for this purpose.

2. If the engine is excessively

greasy, apply some degreaser to it with a paint brush. Do not apply degreaser to the chain, sprockets, or wheel axles.

3. Rinse the dirt and degreaser off

with a garden hose; use only enough pressure to do the job. CAUTION: Excessive hose pressure may cause water seepage and contamination of wheel bearings, front forks, brakes and transmission seals. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coinoperated car washers.

After the majority of the dirt has been hosed off, wash all surfaces with warm water and a mild detergent. Use an old toothbrush to clean hard-to-reach places. Rinse the machine off immediately with clean water, and dry all surfaces with a soft towel or cloth. Immediately after washing, remove excess water from the chain with a paper towel and lubricate the chain to prevent rust. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. Automotive wax may be applied to all painted or chromed surfaces. Avoid combination cleaner-waxes, as they may contain abrasives. After completing the above, start the engine and allow it to idle for several minutes.

1 - 65

GEN INFO STORAGE If your machine is to be stored for 60 days or more, some preventive measures must be taken to avoid deterioration. After cleaning the machine thoroughly, prepare it for storage as follows:

1. Drain the fuel tank, fuel lines,

and the carburetor float bowl.

2. Remove the spark plug, pour a

tablespoon of SAE 10W-30 motor oil in the spark plug hole, and reinstall the plug. With the engine stop switch pushed in, kick the engine over several times to coat the cylinder walls with oil.

3. Remove the drive chain, clean it

thoroughly with solvent, and lubricate it. Reinstall the chain or store it in a plastic bag tied to the frame.

4. Lubricate all control cables.

5. Block the frame up to raise the

wheels off the ground.

6. Tie a plastic bag over the

exhaust pipe outlet to prevent moisture from entering.

7. If the machine is to be stored in a

humid or salt-air environment, coat all exposed metal surfaces with a film of light oil. Do not apply oil to rubber parts or the seat cover. NOTE: Make any necessary repairs before the machine is stored. GEN INFO GENERAL SPECIFICATIONS Model name: Model code number:

Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Dry weight: Without oil and fuel Engine: Engine type Cylinder arrangement Displacement Bore × stroke Compression ratio Starting system Lubrication system: Oil type or grade: Engine oil

106.0 kg (233.7 lb)

Liquid cooled 4-stroke, DOHC Single cylinder, forward inclined 249 cm3 (8.76 Imp oz, 8.42 US oz)

77.0 × 53.6 mm (3.03 × 2.11 in)

12.5 : 1

Kick and electric starter Dry sump 110 130 ˚F (For USA and CDN) Yamalube 4, SAE10W30 or SAE20W40 Yamalube 4-R, SAE10W50 API service SG type or higher, JASO standard MA (Except for USA and CDN) SAE10W30, SAE10W40, SAE15W40, SAE20W40 or SAE20W50 API service SG type or higher, JASO standard MA SAE 15W-40 SAE 20W-40 SAE 20W-50 2-1 GENERAL SPECIFICATIONS Oil capacity: Engine oil Periodic oil change With oil filter replacement Total amount Coolant capacity (including all routes): Air filter: Fuel: Type Tank capacity Reserve Carburetor: Type Manufacturer Spark plug: Type/manufacturer Gap Clutch type: Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio: 1st 2nd 3rd 4th 5th Chassis: Frame type Caster angle Trail Tire: Type Size (front) Size (rear) Tire pressure (front and rear) SPEC Premium unleaded gasoline only with a research octane number of 95 or higher.

8.0 L (1.76 Imp gal, 2.11 US gal)

1.1 L (0.24 Imp gal, 0.29 US gal)

GENERAL SPECIFICATIONS Brake: Front brake type Operation Rear brake type Operation Suspension: Front suspension Rear suspension Shock absorber: Front shock absorber Rear shock absorber Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system Battery type Battery voltage/capacity Specific gravity Headlight type: Bulb wattage × quantity: Headlight Taillight SPEC Single disc brake Right hand operation Single disc brake Right foot operation Telescopic fork Swingarm (link type monocross suspension) Coil spring/oil damper Coil spring/gas, oil damper 300 mm (11.8 in) 310 mm (12.2 in) CDI AC magneto YTX5L-BS 12 V/4 AH Quartz bulb (halogen) 12 V 35/36.5 W × 1 12 V 1.6/0.3 W × 1 2-3 MAINTENANCE SPECIFICATIONS SPEC Cylinder head: Warp limit Cylinder: Bore size Out of round limit Camshaft: Drive method Camshaft cap inside diameter Camshaft outside diameter Shaft-to-cap clearance Limit

0.05 mm

(0.002 in) Camshaft runout limit Timing chain: Timing chain type/No. of links Timing chain adjustment method Valve, valve seat, valve guide: Valve clearance (cold)

Limit 92RH2010-114M/114 Automatic

“A” head diameter Face width

“B” face width “C” seat width

“D” margin thickness Stem outside diameter

Guide inside diameter

Stem-to-guide clearance

Seat width Stem runout limit Valve seat width

0.01 mm

29.13 mm (1.15 in)

29.30 mm (1.15 in)

103 ~ 118 N at 29.13 mm (10.50 ~ 12.09 kg at 29.13 mm,

23.15 ~ 26.66 lb at 1.15 in)

126 ~ 144 N at 29.30 mm (12.85 ~ 14.68 kg at 29.30 mm,

28.32 ~ 32.37 lb at 1.15 in)

Set length (valve closed) Compressed force (installed)

Direction of winding (top view) Limit

Piston: Piston to cylinder clearance Piston size “D”

Measuring point “H” Piston off-set 2-6 Piston pin bore inside diameter Piston pin outside diameter Limit Piston rings: Top ring:

Type Dimensions (B × T) End gap (installed) Side clearance (installed) 2nd ring:

Type Dimensions (B × T) End gap (installed) Side clearance Oil ring:

Dimensions (B × T) End gap (installed) Crankshaft: Crank width “A” Runout limit “C” Big end side clearance “D” Small end free play “F” Clutch: Friction plate thickness Quantity Clutch plate thickness Quantity Warp limit Clutch spring free length

37.0 mm (1.46 in)

Quantity Clutch housing thrust clearance Clutch housing radial clearance Clutch release method Shifter: Shifter type Guide bar bending limit Kickstarter: Type Carburetor: Type/manufacturer

I. D. mark

Main jet Main air jet Jet needle Cutaway Pilot jet Pilot air jet Pilot outlet Bypass Valve seat size Starter jet Leak jet Float height Engine idle speed Intake vacuum Hot starter lever free play Cam drum and guide bar

---0.05 mm (0.002 in) Kick and ratchet type

MAINTENANCE SPECIFICATIONS Item Lubrication system: Oil filter type Oil pump type Tip clearance Side clearance Housing and rotor clearance Cooling: Radiator core size Width Height Thickness Radiator cap opening pressure Radiator capacity (total) Water pump Type SPEC Standard Limit Single-suction centrifugal pump

2-9 MAINTENANCE SPECIFICATIONS Part to be tightened Spark plug Camshaft cap Cylinder head blind plug screw Cylinder head (stud bolt) (stud bolt) (bolt) (nut) Cylinder head cover Cylinder Balancer weight Balancer shaft driven gear Timing chain guide (intake side) Timing chain tensioner Timing chain tensioner cap bolt Impeller Radiator hose clamp Coolant drain bolt Water pump housing Radiator stay Radiator Radiator pipe Oil pump cover Oil pump Oil filter element drain bolt Oil filter element cover Oil strainer (crankcase) Oil delivery pipe 1(M10) (M8) Oil hose Oil hose clamp Oil strainer (oil tank) Oil tank drain bolt Oil tank (upper) Oil tank and frame Oil pressure check bolt Carburetor joint Carburetor joint clamp Air filter joint clamp Throttle cable adjust bolt and locknut Throttle cable (pull) Throttle cable (return) Throttle cable cover Hot starter plunger Thread size Q’ty M10S × 1.0 M6 × 1.0 M12 × 1.0 M6 × 1.0 M8 × 1.25 M9 × 1.25 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M14 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M8 × 1.25 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M4 × 0.7 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M10 × 1.25 M8 × 1.25 M6 × 1.0 M6 × 1.0 M8 × 1.25 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M4 × 0.7 M6 × 1.0 M6 × 0.75 M6 × 1.0 M12 × 1.0 M5 × 0.8 M12 × 1.0

2 - 10

SPEC Tightening torque

MAINTENANCE SPECIFICATIONS Part to be tightened Hot starter cable adjust bolt and locknut Air filter case Air filter joint and air filter case Exhaust pipe Exhaust pipe protector Silencer Silencer clamp Spark arrester Silencer cap Air induction pipe Air induction pipe clamp Air cut-off valve assembly and bracket Bracket (air cut-off valve) and frame Crankcase Crankcase bearing stopper Crankcase bearing stopper (crankshaft) Left crankcase cover Idle gear cover (starter motor) Idle gear plate Right crankcase cover Clutch cover Crankcase oil drain bolt Drive chain sprocket cover Kick shaft ratchet wheel guide Kickstarter crank Primary drive gear Clutch spring Clutch boss Clutch cable locknut Push lever shaft Drive sprocket Drive axle oil seal stopper Segment Shift guide Stopper lever Shift pedal Thread size Q’ty M6 × 0.75 M6 × 1.0 M5 × 0.8 M8 × 1.25 M6 × 1.0 M8 × 1.25 M8 × 1.25 M5 × 0.8 M5 × 0.8 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M10 × 1.25 M6 × 1.0 M6 × 1.0 M8 × 1.25 M18 × 1.0 M6 × 1.0 M16 × 1.0 M8 × 1.25 M6 × 1.0 M18 × 1.0 M6 × 1.0 M8 × 1.25 M6 × 1.0 M6 × 1.0 M6 × 1.0

NOTE: - marked portion shall be checked for torque tightening after break-in.

2 - 11

SPEC Tightening torque

CHASSIS Item Steering system: Steering bearing type Front suspension: Front fork travel Fork spring free length Spring rate, STD Optional spring/spacer Oil capacity Oil level <Min. ~ Max.> (From top of outer tube with inner tube and damper rod fully compressed without spring.) Oil grade Inner tube outer diameter Front fork top end Rear suspension: Shock absorber travel Spring free length Fitting length <Min. ~ Max.> Spring rate, STD Optional spring Enclosed gas pressure Limit

---AUS, NZ, ZA

AUS, NZ, ZA

248.5 mm (9.78 in) 245.0 mm (9.65 in)

1.0 mm

2 - 12

MAINTENANCE SPECIFICATIONS Item Wheel: Front wheel type Rear wheel type Front rim size/material Rear rim size/material Rim runout limit: Radial Lateral SPEC Standard

USA, CDN, ZA

Spoke wheel Spoke wheel 21 × 1.60/Aluminum 18 × 1.85/Aluminum

EUROPE, AUS, NZ

Drive chain: Type/manufacturer Number of links Chain slack Chain length (15 links)

DID520VM/DAIDO

113 links + joint 48 ~ 58 mm (1.9 ~ 2.3 in)

---------239.3 mm (9.42 in) Front disc brake: Disc outside dia. × Thickness Pad thickness Master cylinder inside dia. Caliper cylinder inside dia. Brake fluid type Rear disc brake: Disc outside dia. × Thickness Master cylinder inside dia. Caliper cylinder inside dia. Brake fluid type Brake lever and brake pedal: Brake lever position Brake pedal height (vertical height above footrest top) Clutch lever free play (lever end) Throttle grip free play

2 - 13

MAINTENANCE SPECIFICATIONS Part to be tightened Upper bracket and outer tube Lower bracket and outer tube Upper bracket and steering stem Handlebar upper holder and handlebar lower holder Handlebar lower holder and upper bracket Steering stem and steering ring nut Front fork and front fork cap bolt Front fork and base valve Front fork cap bolt and damper rod Front fork bleed screw and front fork cap bolt Front fork and front fork protector Front fork protector and brake hose holder Throttle grip cap Front brake master cylinder Brake lever mounting bolt Brake lever mounting nut Brake lever position locknut Front brake hose guide and front brake hose guide bracket Front brake hose guide and lower bracket Clutch lever holder Clutch lever mounting nut Hot starter lever holder Hot starter lever mounting nut Front brake master cylinder cap Front brake hose union bolt Front brake caliper Front brake caliper and brake hose holder Pad pin plug Front brake caliper and pad pin Rear brake caliper and pad pin Brake caliper and bleed screw Front wheel axle and axle nut Front wheel axle holder Front brake disc Rear brake disc Brake pedal Rear brake master cylinder Rear brake master cylinder cap Rear brake hose union bolt Rear wheel axle and axle nut Thread size Q’ty M8 × 1.25 M8 × 1.25 M24 × 1.0 SPEC Tightening torque

M10 × 1.25 M28 × 1.0 M51 × 1.5 M30 × 1.0 M12 × 1.25 M5 × 0.8 M6 × 1.0 M6 × 1.0 M5 × 0.8 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0

M6 × 1.0 M5 × 0.8 M6 × 1.0 M5 × 0.8 M5 × 0.8 M4 × 0.7 M10 × 1.25 M8 × 1.25 M6 × 1.0 M10 × 1.0 M10 × 1.0 M10 × 1.0 M8 × 1.25 M16 × 1.5 M8 × 1.25 M6 × 1.0 M6 × 1.0 M8 × 1.25 M6 × 1.0 M4 × 0.7 M10 × 1.25 M20 × 1.5

NOTE: 1. First, tighten the steering ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the steering nut wrench, then loosen the steering ring nut one turn.

2. Retighten the steering ring nut 7 Nm (0.7 m • kg, 5.1 ft • lb).

2 - 14

MAINTENANCE SPECIFICATIONS Part to be tightened Nipple (spoke) Rear wheel sprocket Rear brake disc cover Rear brake caliper protector Drive chain puller adjust bolt and locknut Engine mounting: Engine and engine bracket (front) Engine and frame (lower) Upper engine bracket and frame Lower engine bracket and frame Engine and engine bracket (upper) Engine guard Regulator Pivot shaft and nut Relay arm and swingarm Relay arm and connecting rod Connecting rod and frame Rear shock absorber and frame Rear shock absorber and relay arm Rear frame (upper) Rear frame (lower) Swingarm and brake hose holder Swingarm and patch Upper drive chain tensioner Lower drive chain tensioner Drive chain support Seal guard and swingarm Fuel tank Fuel cock Seat set bracket and fuel tank Fuel tank bracket and fuel tank Air scoop and fuel tank Air scoop and radiator guard (lower) Front fender Rear fender (front) Rear fender (rear) Side cover Seat Multi-function display bracket and upper bracket Multi-function display Plate 1 and front fork protector Plate 2 and front fork protector Thread size Q’ty

M8 × 1.25 M6 × 1.0 M6 × 1.0 M8 × 1.25 SPEC Tightening torque

M10 × 1.25 M10 × 1.25 M8 × 1.25 M8 × 1.25 M10 × 1.25 M6 × 1.0 M6 × 1.0 M16 × 1.5 M14 × 1.5 M14 × 1.5 M14 × 1.5 M10 × 1.25 M10 × 1.25 M8 × 1.25 M8 × 1.25 M5 × 0.8 M4 × 0.7 M8 × 1.25 M8 × 1.25 M6 × 1.0 M5 × 0.8 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M8 × 1.25

MAINTENANCE SPECIFICATIONS Part to be tightened Speed sensor lead holder and lower bracket Headlight body and headlight unit Headlight (left and right) Taillight Taillight lead clamp and rear fender Catch tank (upper) Catch tank (lower) Footrest bracket and frame Sidestand Thread size Q’ty M6 × 1.0 M6 × 1.0

M6 × 1.0 M6 × 1.0 M10 × 1.25 M10 × 1.25

NOTE: - marked portion shall be checked for torque tightening after break-in.

2 - 16

SPEC Tightening torque

ELECTRICAL Item Ignition system: Advancer type CDI: Pickup coil resistance (color) CDI unit-model/manufacturer Ignition coil: Model/manufacturer Minimum spark gap Primary coil resistance Secondary coil resistance Charging system: System type Model (stator)/manufacturer Normal output Charging coil resistance (color) Lighting coil resistance (color) Rectifier/regulator: Regulator type Model/manufacture Regulated voltage (AC) Regulated voltage (DC) Rectifier capacity (AC) Rectifier capacity (DC) Electric starting system: Type Starter motor: Model/manufacturer Operation voltage Output Armature coil resistance Brush overall length Brush quantity Spring force Commutator diameter Mica undercut (depth) Standard Limit Electrical

AC magneto 5UM 20/YAMAHA 14 V/120 W at 5,000 r/min

0.288 ~ 0.432 Ω at 20 °C (68 °F)

0.224 ~ 0.336 Ω at 20 °C (68 °F)

Semiconductor short circuit

SH770AA/SHINDENGEN

12.5 ~ 13.5 V

14.0 ~ 15.0 V

MAINTENANCE SPECIFICATIONS Item Starter relay: Model/manufacturer Amperage rating Coil winding resistance Starting circuit cut-off relay: Model/manufacturer Coil winding resistance Fuse (amperage × quantity): Main fuse Reserve fuse Part to be tightened Stator Holder (AC magneto lead) Rotor Neutral switch Starter motor Starter relay terminal Negative lead and cylinder head Pickup coil SPEC Standard Limit 2768090-A/JIDECO 180 A

4.2 ~ 4.6 Ω at 20 °C (68 °F)

M5 × 0.8 M5 × 0.8 M12 × 1.25 M5 × 0.8 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0

m·kg ft·lb NOTE: Tighten the rotor nut to 65 Nm (6.5 m • kg, 47 ft • lb), loosen and retighten the rotor nut to 65 Nm (6.5 m • kg, 47 ft • lb).

2 - 18

GENERAL TORQUE SPECIFICATIONS

This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature. (Nut)

(Bolt) A: Distance between flats B: Outside thread diameter Definition meter 10-2 meter 103 gram 1 kg × m/sec2 N×m m × kg N/m2 N/mm

2 - 19

Measure Length Length Weight Force Torque Torque Pressure Spring rate Volume or capacity Volume or capacity Engine speed CARACTERISTIQUES GENERALES SPEC SAE 15W-40 SAE 20W-40 SAE 20W-50

2 - 20

Dimensions de la came

Admission “A” “B” Echappement “A” “B” M6 × 1,0 M5 × 0,8 M8 × 1,25 M6 × 1,0 M8 × 1,25 M8 × 1,25 M5 × 0,8 M5 × 0,8 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M10 × 1,25 M6 × 1,0 M6 × 1,0 M8 × 1,25 M18 × 1,0 M6 × 1,0 M16 × 1,0 M8 × 1,25 M6 × 1,0 M18 × 1,0 M6 × 1,0 M8 × 1,25 M6 × 1,0 M6 × 1,0 M6 × 1,0

---AUS, NZ, ZA

AUS, NZ, ZA

248,5 mm (9,78 in) 245,0 mm (9,65 in)

2 - 31

M8 × 1,25 M8 × 1,25 M24 × 1,0 M8 × 1,25 M10 × 1,25 M28 × 1,0 M51 × 1,5 M30 × 1,0 M12 × 1,25 M5 × 0,8 M6 × 1,0 M6 × 1,0 M5 × 0,8 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0

0,4 2,9 M6 × 1,0 M5 × 0,8 M6 × 1,0 M5 × 0,8 M5 × 0,8 M4 × 0,7 M10 × 1,25 M8 × 1,25 M6 × 1,0 M10 × 1,0 M10 × 1,0 M10 × 1,0 M8 × 1,25 M16 × 1,5 M8 × 1,25 M6 × 1,0 M6 × 1,0 M8 × 1,25 M6 × 1,0 M4 × 0,7 M10 × 1,25 M20 × 1,5

M8 × 1,25 M6 × 1,0 M6 × 1,0 SPEC M10 × 1,25 M10 × 1,25 M8 × 1,25 M8 × 1,25 M10 × 1,25 M6 × 1,0 M6 × 1,0 M16 × 1,5 M14 × 1,5 M14 × 1,5 M14 × 1,5 M10 × 1,25 M10 × 1,25 M8 × 1,25 M8 × 1,25 M5 × 0,8 M4 × 0,7 M8 × 1,25 M8 × 1,25 M6 × 1,0 M5 × 0,8 M6 × 1,0 M6 × 1,0

M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M8 × 1,25 M6 × 1,0 M5 × 0,8

0,7 0,7 1,1 0,7 2,3 0,7 0,4 5,1 5,1 8,0 5,1 5,1 2,9

2 - 34

M5 × 0,8 M6 × 1,0 M6 × 1,0

M6 × 1,0 M6 × 1,0 M10 × 1,25 M10 × 1,25

M12 × 1,25 M5 × 0,8 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0

SAE 15W-40 SAE 20W-40 SAE 20W-50

2 - 39

M10S × 1,0 M6 × 1,0 M12 × 1,0 M6 × 1,0 M8 × 1,25 M9 × 1,25 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M14 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M8 × 1,25 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M4 × 0,7 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M10 × 1,25 M8 × 1,25 M6 × 1,0 M6 × 1,0 M8 × 1,25 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M4 × 0,7 M6 × 1,0 SPEC Anzugsmoment

M6 × 1,0 M12 × 1,0 M5 × 0,8

0,4 1,1 0,4 2,9 8,0 2,9

2 - 48

M8 × 1,25 M6 × 1,0 M8 × 1,25 M8 × 1,25 M5 × 0,8 M5 × 0,8 M6 × 1,0 M6 × 1,0 M6 × 1,0

M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M10 × 1,25 M6 × 1,0 M6 × 1,0 M8 × 1,25 M18 × 1,0 M6 × 1,0 M16 × 1,0 M8 × 1,25 M6 × 1,0 M18 × 1,0 M6 × 1,0 M8 × 1,25 M6 × 1,0 M6 × 1,0 M6 × 1,0

---AUS, NZ, ZA

AUS, NZ, ZA

248,5 mm (9,78 in) 245,0 mm (9,65 in)

2 - 50

M8 × 1,25 M8 × 1,25 M24 × 1,0 M8 × 1,25 M10 × 1,25 M28 × 1,0 M51 × 1,5 M30 × 1,0 M12 × 1,25 M5 × 0,8 M6 × 1,0 M6 × 1,0 M5 × 0,8 M6 × 1,0 M6 × 1,0 M6 × 1,0

0,4 2,9 M5 × 0,8 M6 × 1,0 M5 × 0,8 M5 × 0,8 M4 × 0,7 M10 × 1,25 M8 × 1,25

0,4 0,4 0,4 0,2 0,2 3,0 2,3 2,9 2,9 2,9 1,4 1,4

1,0 7,2 M10 × 1,0 M10 × 1,0 M10 × 1,0 M8 × 1,25 M16 × 1,5 M8 × 1,25 M6 × 1,0 M6 × 1,0 M8 × 1,25 M6 × 1,0 M4 × 0,7 M10 × 1,25 M20 × 1,5

M8 × 1,25 M6 × 1,0 M6 × 1,0 SPEC Anzugsmoment

0,3 5,0 1,0 0,7 2,2 7,2 5,1 M8 × 1,25

M10 × 1,25 M10 × 1,25 M8 × 1,25 M8 × 1,25 M10 × 1,25 M6 × 1,0 M6 × 1,0 M16 × 1,5 M14 × 1,5 M14 × 1,5 M14 × 1,5 M10 × 1,25 M10 × 1,25 M8 × 1,25 M8 × 1,25 M5 × 0,8 M4 × 0,7 M8 × 1,25 M8 × 1,25 M6 × 1,0 M5 × 0,8 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M8 × 1,25

M5 × 0,8 M5 × 0,8 M12 × 1,25 M5 × 0,8 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0

SAE 15W-40 SAE 20W-40 SAE 20W-50

2 - 58

INT EST INT EST INT EST INT EST Limite

---AUS, NZ, ZA

AUS, NZ, ZA

248,5 mm (9,78 in) 245,0 mm (9,65 in)

2 - 69

EUROPE, AUS, NZ

M8 × 1,25 M8 × 1,25 M24 × 1,0 M8 × 1,25 M10 × 1,25 M28 × 1,0 M51 × 1,5 M30 × 1,0 M12 × 1,25 M5 × 0,8 M6 × 1,0

0,7 5,1 M5 × 0,8 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0

0,4 0,9 0,6 0,6 0,5 2,9 6,5 4,3 4,3 3,6 M5 × 0,8

0,4 2,9 M5 × 0,8 M6 × 1,0 M5 × 0,8 M5 × 0,8 M4 × 0,7 M10 × 1,25 M8 × 1,25

0,4 0,4 0,4 0,2 0,2 3,0 2,3 2,9 2,9 2,9 1,4 1,4

1,0 7,2 M10 × 1,0 M10 × 1,0 M10 × 1,0 M8 × 1,25 M16 × 1,5 M8 × 1,25 M6 × 1,0 M6 × 1,0 M8 × 1,25 M6 × 1,0 M4 × 0,7 M10 × 1,25 M20 × 1,5

M8 × 1,25 M6 × 1,0 M6 × 1,0 SPEC M10 × 1,25 M10 × 1,25 M8 × 1,25 M8 × 1,25 M10 × 1,25 M6 × 1,0 M6 × 1,0 M16 × 1,5 M14 × 1,5 M14 × 1,5 M14 × 1,5 M10 × 1,25 M10 × 1,25 M8 × 1,25 M8 × 1,25 M5 × 0,8 M4 × 0,7 M8 × 1,25 M8 × 1,25 M6 × 1,0 M5 × 0,8 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M8 × 1,25 M6 × 1,0 M5 × 0,8 M5 × 0,8 M6 × 1,0

M6 × 1,0 M6 × 1,0 M10 × 1,25 M10 × 1,25

M5 × 0,8 M5 × 0,8 M12 × 1,25 M5 × 0,8 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0

SAE 15W-40 SAE 20W-40 SAE 20W-50

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Anchura frontal “B” Anchura frontal “C” M10S × 1,0 M6 × 1,0 M12 × 1,0 M6 × 1,0 M8 × 1,25 M9 × 1,25 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M14 × 1,0 M8 × 1,25 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M4 × 0,7 M6 × 1,0

M6 × 1,0 M6 × 1,0 M10 × 1,25 M8 × 1,25 M6 × 1,0 M6 × 1,0 M8 × 1,25 M6 × 1,0 M6 × 1,0

M6 × 1,0 M4 × 0,7 M6 × 1,0

1,0 0,3 0,3 7,2 2,2 2,2 M6 × 0,75

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M12 × 1,0 M5 × 0,8 M12 × 1,0 M6 × 1,0 M5 × 0,8 M8 × 1,25 M6 × 1,0 M8 × 1,25 M8 × 1,25 M5 × 0,8 M5 × 0,8 M6 × 1,0 M6 × 1,0

M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0

0,7 1,2 1,0 1,0 1,0 5,1 8,7 7,2 7,2 7,2 M6 × 1,0

1,0 7,2 M6 × 1,0 M6 × 1,0 M6 × 1,0 M10 × 1,25 M6 × 1,0

1,0 1,0 1,0 2,0 0,8 7,2 7,2 7,2 5,8 M6 × 1,0

1,2 8,7 M8 × 1,25 M18 × 1,0 M6 × 1,0 M16 × 1,0 M8 × 1,25 M6 × 1,0 M18 × 1,0 M6 × 1,0 M8 × 1,25 M6 × 1,0 M6 × 1,0 M6 × 1,0

AUS, NZ, ZA

248,5 mm (9,78 in) 245,0 mm (9,65 in)

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EUROPE, AUS, NZ

M8 × 1,25 M8 × 1,25 M24 × 1,0 M6 × 1,0 M5 × 0,8 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0

0,7 0,4 0,9 0,6 0,6 0,5 5,1 2,9 6,5 4,3 4,3 3,6 M5 × 0,8

0,4 2,9 M6 × 1,0 M5 × 0,8 M6 × 1,0 M5 × 0,8

0,4 0,4 0,4 0,4 2,9 2,9 2,9 2,9 M5 × 0,8

0,2 1,4 M4 × 0,7 M10 × 1,25 M8 × 1,25

1,0 7,2 M10 × 1,0 M10 × 1,0 M10 × 1,0 M8 × 1,25 M16 × 1,5 M8 × 1,25 M6 × 1,0 M6 × 1,0 M8 × 1,25 M6 × 1,0 M4 × 0,7 M10 × 1,25 M20 × 1,5

M10 × 1,25 M10 × 1,25 M8 × 1,25 M8 × 1,25 M10 × 1,25 M6 × 1,0 M6 × 1,0 M16 × 1,5 M14 × 1,5 M14 × 1,5 M14 × 1,5 M10 × 1,25 M10 × 1,25 M8 × 1,25 M8 × 1,25 M5 × 0,8 M4 × 0,7 M8 × 1,25 M8 × 1,25 M6 × 1,0 M5 × 0,8 M6 × 1,0 M6 × 1,0

M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M8 × 1,25

0,7 0,7 1,1 0,7 2,3 5,1 5,1 8,0 5,1

0,7 5,1 M5 × 0,8 M5 × 0,8

0,5 0,4 0,4 0,05 2,9 2,9 0,36 M6 × 1,0

1,3 9,4 M5 × 0,8 M5 × 0,8 M12 × 1,25 M5 × 0,8 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0

Oil filter element Oil pump Drive axle Main axle Intake camshaft Exhaust camshaft Oil tank Oil delivery pipe È To oil tank

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SPEC Crankshaft Oil filter element Oil tank Oil hose Fuel tank breather hose Clamp Diode Hot starter cable Wire harness Hump (frame) Cylinder head breather hose Throttle position sensor lead Neutral switch lead Oil hose Clutch cable Starter motor lead Cable guide

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Negative battery lead AC magneto lead Brake hose Rectifier/regulator lead Carburetor breather hose Carburetor overflow hose Catch tank breather hose SPEC

SCHEMA PERCORSO DEI CAVI

CABLE ROUTING DIAGRAM

È Insert the end of the fuel tank breather hose into the hole in the steering stem. É Fasten the throttle cable, hot starter cable and rectifier/regulator lead onto the frame. Locate the clamp end facing the lower side of the hot starter cable and cut off the tie end. Ê Fasten the diode (at the marking), throttle cable and hot starter cable onto the frame. Locate the clamp end facing toward the lower right of the frame and with the tie end facing downward. Ë Fasten the wire harness, throttle position sensor lead, starter motor lead and negative battery lead onto the frame. Pass the clamp through the hole in the stay (air cut-off valve). Locate the clamp end facing toward the lower side of the frame and cut off the tie end. SPEC Ì Fasten the throttle position sensor lead onto the frame. Locate the clamp end facing toward the lower side of the frame and cut off the tie end. Í Pass the carburetor breather hoses, carburetor overflow hose and catch tank breather hose between the connecting rod and cross tube (frame). Î Fasten the neutral switch lead and oil hose together with the plastic locking ties and cut off the tie ends. Ï Fasten the neutral switch lead and AC magneto lead onto the frame. Locate the clamp end facing toward the outside of the frame and tie end facing toward the rear of the frame.

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CABLE ROUTING DIAGRAM

Ð Pass the clutch cable through the cable guide. Ñ Fasten the starter motor lead, AC magneto lead and neutral switch lead onto the frame. Locate the clamp end facing toward the rear of the frame and cut off the tie end. Ò Fasten the clutch cable, starter motor lead, negative battery lead, AC magneto lead and neutral switch lead onto the frame. Locate the clamp end facing toward the rear of the frame and cut off the tie end. Ó Pass the neutral switch lead and AC magneto lead on the inside of the wire harness. Ô Fasten the clutch cable, AC magneto lead and neutral switch lead onto the frame. Locate the clamp end near the clutch cable and cut off the tie end. SPEC Õ Pass the clutch cable and wire harness through the cable guide. Ö Locate the couplers in the frame recess. × Pass the carburetor breather hoses, carburetor overflow hose and catch tank breather hose so that the hoses do not contact the rear shock absorber. Ø Secure the coupler by pushing it into the hole in the headlight unit.

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Throttle cable (pull) Throttle cable (return) Catch tank hose Ignition coil Clamp Air induction hose (air cut-off valve - rear of cylinder head) Catch tank breather hose SPEC È Cross the pull and push throttle cables. É Fasten the catch tank hose and air induction hose (air cut-off valve - rear of cylinder head) onto the frame. Locate the clamp end facing toward the lower side of the frame and cut off the tie end. Ê Fasten the catch tank breather hose and carburetor breather hoses together. Ë Pass the carburetor breather hose (of the throttle cable cover) through the hose holder.

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CABLE ROUTING DIAGRAM

1 Brake master cylinder 2 Brake hose holder 3 Brake hose SPEC È Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the brake caliper. É Pass the brake hose into the brake hose holders. Ê If the brake hose contacts the spring (rear shock absorber), correct its twist. Ë Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the brake master cylinder.

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Clamp Positive battery lead Battery Negative battery lead Taillight coupler CDI unit coupler (6-pin) CDI unit coupler (3-pin) CDI unit coupler (6-pin) SPEC È Fasten the wire harness, negative battery lead and starter motor lead to the upper engine bracket (left side). Locate the clamp end facing toward the upper side of the frame with the tie end cut off on the inside of the frame. É Fasten the wire harness, negative battery lead and starter motor lead to the upper engine bracket (left side). Locate the clamp end facing toward the upper side of the frame with the tie end cut off on the inside of the frame. Clamp the wire harness and negative lead at the marking. Ê Pass the starter motor lead through the hole in the relay holder. Ë Fit the cover securely. Ì Connect the wire harness to the starter relay.

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CABLE ROUTING DIAGRAM

Í Fasten the catch tank breather hose and catch tank hose to the rear frame. Clamp them close to where they are joined to the frame. Fasten the pipe tightly enough not to crush it. Locate the clamp end facing toward the rear of the frame with the tie end facing downward. Î Fasten the (three) CDI unit leads and taillight lead to the rear frame. Locate the clamp end facing toward the upper side of the frame and cut off the tie end. Ï Connect the negative battery lead to the battery negative terminal. Ð Connect the negative battery lead to the wire harness. Ñ Fasten the wire harness to the rear frame. Locate the clamp end facing toward the upper side of the frame and the tie end toward the inside of the frame. Clamp the wire harness at the marking. Ò Pass the wire harness, starter relay lead, starting circuit cut-off relay lead and negative battery lead through the hole in the relay holder. Ó Fasten the (three) CDI unit leads and taillight lead to the rear frame. Locate the clamp end facing toward the lower side of the frame and cut off the tie end.

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SPEC Ô Fasten the taillight lead to the rear frame. Locate the clamp end facing toward the upper side of the frame and cut off the time end. Õ Do not allow the taillight lead to slacken. Ö Locate the CDI unit lead between the CDI unit and rear fender. × Locate the CDI unit coupler in the clearance between the upper side of the CDI unit and lower side of the catch tank stay. Ø Locate the CDI unit lead between the CDI unit and rear frame. Throttle cable Clamp Brake hose Clutch cable Hose guide Main switch coupler Wire harness Headlight coupler Hot starter cable Multi-function display bracket Main switch Upper bracket Clutch switch coupler Engine stop switch coupler Multi-function display coupler Start switch coupler Speed sensor coupler H Speed sensor lead 10˚ 40˚±

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CABLE ROUTING DIAGRAM

È Fasten the start switch lead to the handlebar with the plastic bands. É Fasten the engine stop switch lead and clutch switch lead to the handlebar with the plastic bands. Ê Pass the brake hose through the hose guides. Ë Secure the coupler by inserting it into the multi-function display bracket. Ì Pass the throttle cables, clutch cable and hot starter cable between the upper bracket and multi-function display bracket. Í Fasten the multi-function display leads to the bracket. Cut off the tie end. Î Secure the coupler by pushing it into the hole in the multi-function display bracket. Ï Secure the wire harness clip by pushing it into the hole in the multi-function display bracket on the inside. Ð Fasten the wire harness to the multi-function display bracket. Cut off the tie end. SPEC Ñ Fasten the main switch lead (wire harness side) to the multifunction display bracket. Locate the clamp end facing toward the lower side of the frame and cut off the tie end. Ò Pass the speed sensor lead through the guide on the outside of the front fork. 10˚ 40˚±

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REGULAR INSPECTION AND ADJUSTMENTS

MAINTENANCE INTERVALS NOTE: The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. Item After break-in Every race ENGINE OIL Replace VALVES Check the valve clearances Inspect Replace VALVE SPRINGS Inspect Replace VALVE LIFTERS Inspect Replace CAMSHAFTS Inspect Replace Every third Every fifth (or (or required 500 km) 1,000 km) Remarks The engine must be cold. Check the valve seats and valve stems for wear. Check the free length and the tilt. Check for scratches and wear. Inspect the camshaft surface. Inspect the decompression system. CAMSHAFT SPROCKETS Inspect Replace PISTON Inspect Clean Replace PISTON RING Inspect Replace PISTON PIN Inspect Replace CYLINDER HEAD Inspect and clean Check for wear on the teeth and for damage. Inspect crack Inspect carbon deposits and eliminate them. Check ring end gap Inspect carbon deposits and eliminate them. Change gasket CYLINDER Inspect and clean Replace CLUTCH Inspect and adjust Replace TRANSMISSION Inspect Replace bearing

SHIFT FORK, SHIFT CAM, GUIDE BAR

Inspect Inspect score marks Inspect wear Inspect housing, friction plate, clutch plate and spring Inspect wear 3-1 MAINTENANCE INTERVALS Item After break-in Every race ROTOR NUT Retighten MUFFLER Inspect and retighten Clean Replace CRANK Inspect and clean CARBURETOR Inspect, adjust and clean

AIR INDUCTION SYSTEM

Inspect and clean SPARK PLUG Inspect and clean Replace DRIVE CHAIN Lubricate, slack, alignment Replace COOLING SYSTEM Check coolant level and leakage Check radiator cap operation Replace coolant Inspect hoses

OUTSIDE NUTS AND BOLTS

Retighten Every third Every fifth (or (or required 500 km) 1,000 km) INSP ADJ Remarks Every two years Refer to “STARTING AND BREAK-IN” section in the

CHAPTER 1.

AIR FILTER Clean and lubricate Replace OIL FILTER Replace OIL STRAINER Clean FRAME Clean and inspect

FUEL TANK, COCK

Clean and inspect BRAKES Adjust lever position and pedal height Lubricate pivot point Check brake disc surface Check fluid level and leakage Retighten brake disc bolts, caliper bolts, master cylinder bolts and union bolts Replace pads Replace brake fluid Use foam air-filter oil or equivalent oil

Every one year 3-2 MAINTENANCE INTERVALS Item After break-in Every race FRONT FORKS Inspect and adjust Replace oil Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube PROTECTOR GUIDE Replace

REAR SHOCK ABSORBER

Inspect and adjust Lube Every third Every fifth (or (or required 500 km) 1,000 km) INSP ADJ Remarks Suspension oil “S1” Lithium base grease (After rain ride) Retighten

DRIVE CHAIN GUIDE AND ROLLERS

Inspect SWINGARM Inspect, lube and retighten

RELAY ARM, CONNECTING ROD

Inspect, lube and retighten SIDESTAND Lubricate STEERING HEAD Inspect free play and retighten Clean and lube Replace bearing TIRE, WHEELS Inspect air pressure, wheel run-out, tire wear and spoke looseness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate

THROTTLE, CONTROL CABLE

Check routing and connection Lubricate

HOT STARTER, CLUTCH LEVER

Inspect free play BATTERY Check terminal for looseness and corrosion Molybdenum disulfide grease Molybdenum disulfide grease Molybdenum disulfide grease Lithium base grease Lithium base grease Lithium base grease Yamaha cable lube or SAE 10W-30 motor oil 3-3

PROGRAMME D’ENTRETIEN

PRE-OPERATION INSPECTION AND MAINTENANCE

Before riding for break-in operation, practice, make sure the machine is in good operating condition. Before using this machine, check the following points.

GENERAL INSPECTION AND MAINTENANCE

Item Routine Page Coolant Check that coolant is filled up to the radiator cap. Check the cooling system for leakage. Fuel Check that a fresh gasoline is filled in the fuel tank. Check the fuel line for leakage. Engine oil Check that the oil level is correct. Check the crankcase and frame oil line for leakage. P.3-51 ~ 59 Gear shifter and clutch Check that gears can be shifted correctly in order and that the clutch operates smoothly. P.3-41 ~ 43 Throttle grip/Housing Check that the throttle grip operation and free play are correctly adjusted. Lubricate the throttle grip and housing, if necessary. P.3-43 ~ 45 Brakes Check the play of front brake and effect of front and rear brake. P.3-77 ~ 89 Drive chain Check drive chain slack and alignment. Check that the drive chain is lubricated properly. P.3-91 ~ 95 Wheels Check for excessive wear and tire pressure. Check for loose spokes and have no excessive play. P.3-111 ~ 113 Steering Check that the handlebar can be turned smoothly and have no excessive play. P.3-113 ~ 117 Front forks and rear shock absorber Check that they operate smoothly and there is no oil leakage. P.3-97 ~ 109 Cables (wires) Check that the clutch and throttle cables move smoothly. Check that they are not caught when the handlebars are turned or when the front forks travel up and down. Exhaust pipe Check that the exhaust pipe is tightly mounted and has no cracks. Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-89 Lubrication Check for smooth operation. Lubricate if necessary. P.3-119 Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-59 Lead connectors Check that the AC magneto, CDI unit, and ignition coil are connected tightly. P.1-9 Settings Is the machine set suitably for the condition of the course and weather or by taking into account the results of test runs before riding? Are inspection and maintenance completely done?

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P.3-27 ~ 31 P.4-1 ~ 40 1 Seat removal 3 Side covers removal Extent of removal: Extent of removal Order 2 Fuel tank removal 4 Headlight removal Part name Q’ty Remarks

SEAT, FUEL TANK AND SIDE COVERS

REMOVAL Preparation for removal

Turn the fuel cock to “OFF”. Disconnect the fuel hose.

Air scoop (left and right)

Open the air filter case cover.

Refer to “REMOVAL POINTS”.

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MOTEUR MOTOR INSP ADJ REMOVAL POINTS Side cover

1. Remove:

• Right side cover 1 NOTE: Draw the side cover backward to remove it because its claw a is inserted in the air filter case. Extent of removal: Extent of removal Order 2 Exhaust pipe removal Part name Q’ty Remarks

EXHAUST PIPE AND SILENCER

REMOVAL Preparation for removal

Right side cover Refer to “SEAT, FUEL TANK AND SIDE COVERS” section.

Bolt (silencer clamp)

Bolt [silencer (front)]

Bolt [silencer (rear)]

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Only loosening. INSP ADJ MOTEUR MOTOR INSPECTION Silencer and exhaust pipe

1. Inspect:

• Gasket 1 Damage → Replace.

ASSEMBLY AND INSTALLATION

Silencer and exhaust pipe

1. Install:

• Nut (exhaust pipe) 2 NOTE: First, temporarily install both nuts, then tighten either of these nuts to 13 Nm (1.3 m • kg, 9.4 ft • lb) and the other to 20 Nm (2.0 m • kg, 14 ft • lb) and then come back to the first one and retighten it to 20 Nm (2.0 m • kg, 14 ft • lb). Gasket 2 New Silencer Washer 4 Bolt (silencer) 5

WARNING Do not remove the radiator cap 1, drain bolt and hoses when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, place a thick towel over the radiator cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it. CAUTION: Hard water or salt water is harmful to the engine parts. You may use distilled water, if you can’t get soft water.

Place the machine on a level place, and hold it in an upright position. Remove:

• Coolant level a Coolant level low → Add coolant. ENGINE MOTEUR COOLANT REPLACEMENT INSP ADJ WARNING Do not remove the radiator cap when the engine is hot. CAUTION: Take care so that coolant does not splash on painted surfaces. If it splashes, wash it away with water.

Place a container under the engine. Remove:

• Left side cover Remove the catch tank hose from the catch tank and drain the tank of its coolant. Remove:
• Coolant drain bolt 1 Remove:
• Radiator cap Drain the coolant completely. Clean:
• Cooling system Thoroughly flush the cooling system with clean tap water. Install:

Recommended coolant: High quality ethylene glycol anti-freeze containing anti-corrosion for aluminum engine Coolant 1 and water (soft water) 2 mixing ratio: 50%/50% Coolant capacity:

0.99 L

1.05 US qt)

• Do not mix more than one type of ethylene glycol antifreeze containing corrosion inhibitors for aluminum engine.
• Do not use water containing impurities or oil. Handling notes of coolant: The coolant is harmful so it should be handled with special care. WARNING
• When coolant splashes to your eye. Thoroughly wash your eye with water and see your doctor.
• When coolant splashes to your clothes. Quickly wash it away with water and then with soap.
• When coolant is swallowed. Quickly make him vomit and take him to a doctor.

• Radiator cap Start the engine and warm it up for a several minutes.

10. Check:

• Coolant level Coolant level low → Add coolant.

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RADIATOR CAP INSPECTION

1. Inspect:

• Seal (radiator cap) 1
• Valve and valve seat 2 Crack/damage → Replace. Exist fur deposits 3 → Clean or replace.

RADIATOR CAP OPENING

1. Attach:

• Radiator cap tester 1 and adapter 2 Radiator cap tester: YU-24460-01/ 90890-01325 Radiator cap tester adapter: YU-33984/90890-01352 NOTE: Apply water on the radiator cap seal. 3 Radiator cap

• Pressure Impossible to maintain the specified pressure for 10 seconds → Replace.

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INSP ADJ ENGINE MOTEUR

COOLING SYSTEM INSPECTION

1. Inspect:

2. Attach:

• Radiator cap tester 1 and adapter 2 Radiator cap tester: YU-24460-01/ 90890-01325 Radiator cap tester adapter: YU-33984/90890-01352

• Do not apply pressure more than specified pressure.
• Radiator should be filled fully.

• Pressure Impossible to maintain the specified pressure for 10 seconds → Repair.
• Radiator hose joint 2 Coolant leakage → Repair or replace.
• Radiator hose 3 Swelling → Replace. CLUTCH ADJUSTMENT

1. Check:

• Clutch lever free play a Out of specification → Adjust. Clutch lever free play a: 8 ~ 13 mm (0.31 ~ 0.51 in)

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• Clutch lever free play Clutch lever free play adjustment steps:
• Loosen the locknuts 1.
• Adjust the free play by changing their tightening position.
• Tighten the locknuts.

• Make minute adjustment on the lever side using the adjuster 2.
• After adjustment, check proper operation of clutch lever.

THROTTLE CABLE ADJUSTMENT

1. Check:

• Throttle grip free play a Out of specification → Adjust. Adjust:
• Throttle grip free play Throttle grip free play adjustment steps:
• Slide the adjuster cover.
• Loosen the locknut 1.
• Turn the adjuster 2 until the specified free play is obtained.
• Tighten the locknut.

NOTE: Before adjusting the throttle cable free play, the engine idle speed should be adjusted. WARNING After adjusting the throttle cable free play, start the engine and turn the handlebar to right and left and make sure that the engine idling does not run faster.

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THROTTLE LUBRICATION

1. Remove:

• Cover (throttle cable cap) 1
• Throttle grip cap 3 Apply:
• Lithium soap base grease On the throttle cable end a. Install:
• Screw (throttle grip cap)

HOT STARTER LEVER

1. Check:

• Hot starter lever free play a Out of specification → Adjust.

• Cover (throttle cable cap) Adjust:
• Hot starter lever free play Hot starter lever free play adjustment steps:
• Loosen the locknut 1.
• Turn the adjuster 2 until free play a is within the specified limits.
• Tighten the locknut.

NOTE: After adjustment, check proper operation of hot starter.

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AIR FILTER CLEANING

NOTE: Proper air filter maintenance is the biggest key to preventing premature engine wear and damage. CAUTION: Never run the engine without the air filter element in place; this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage.

Open the air filter case cover 1 NOTE: Loosen the quick screw 2 and pull on it to open the air filter case cover. Remove:

• Air filter element 1

• Air filter element Clean them with solvent.

NOTE: After cleaning, remove the remaining solvent by squeezing the element. CAUTION:

• Do not twist the element when squeezing the element.
• Leaving too much of solvent in the element may result in poor starting.

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• Air filter element Damage → Replace. Apply:
• Foam-air-filter oil or equivalent oil to the element

• Squeeze out the excess oil. Element should be wet but not dripping.
• Wipe off the oil left on the element surface using a clean dry cloth. (Excess oil in the element may adversely affect engine starting.) NOTE:
• Align the projection a on filter guide with the hole b in air filter element.
• Apply the lithium soap base grease on the matching surface c on air filter element. Install:
• Air filter element 1 NOTE: Align the projection a on filter guide with the hole b in air filter case. NOTE: Hook the binder 1 so that it contacts the filter guide projections a.

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ENGINE OIL LEVEL INSPECTION

1. Start the engine, warm it up for

several minutes, and then turn off the engine and wait for five minutes.

2. Place the machine on a level

place and hold it up on upright position by placing the suitable stand under the engine.

3. Inspect:

• Oil level Oil should be up to the full level in the check window 1. Level check window is not full.
• Add 0.2 L (0.18 Imp qt, 0.21 US qt) of oil. (For USA and CDN) (USA et CDN) Recommended oil: Yamalube 4, SAE10W30 or SAE 20W40 Yamalube 4-R, SAE10W50 API service SG type or higher, JASO standard

• Do not add any chemical additives. Engine oil also lubricates the clutch and additives could cause clutch slippage.
• Do not allow foreign material to enter the crankcase.

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(Except for USA and CDN) Recommended oil: SAE10W30, SAE10W40, SAE15W40, SAE20W40 or SAE20W50 API service SG type or higher, JASO standard

SAE 10W-30 SAE 10W-40 SAE 15W-40 SAE 20W-40 SAE 20W-50

• Do not add any chemical additives or use oils with a grade of CD a or higher.
• Do not use oils labeled “ENERGY CONSERVING II” b or higher. Engine oil also lubricates the clutch and additives could cause clutch slippage.
• Do not allow foreign materials to enter the crankcase. Install:
• Oil tank cap Start the engine and let it warm up for several minutes. Turn off the engine and inspect the oil level once again. NOTE: Wait a few minutes until the oil settles before inspecting the oil level.

ENGINE OIL REPLACEMENT

1. Start the engine and warm it up

for several minutes, and then turn off the engine and wait for five minute.

2. Place the machine on a level

place and hold it on upright position by placing the suitable stand under the engine.

3. Place a suitable container under

3 - 53

• Oil tank drain bolt 5
• Crankcase oil drain bolt 6
• Oil filter element drain bolt 7 Drain the crankcase and oil tank of its oil.

• Oil strainer 3 Inspect:
• Oil strainer Clogged → Blow. If the oil filter is to be replaced during this oil change, remove the following parts and reinstall them.

• Remove the oil filter element cover 1 and oil filter element

• Check the O-rings 3, if cracked or damaged, replace them with a new one.
• Install the oil filter element and oil filter element cover. Oil filter element cover: 10 Nm (1.0 m • kg, 7.2 ft • lb)

13. Check:

11. Check:

12. Install:

• Bolt (oil tank) Oil quantity: Periodic oil change:

1.1 L

1.16 US qt)

With oil filter replacement:

1.2 L

1.27 US qt)

1.4 L

1.48 US qt)

10. Fill:

• Crankcase oil drain bolt Install:
• Oil filter element drain bolt

• Oil strainer 2 INSP ADJ ENGINE MOTEUR

OIL PRESSURE INSPECTION

1. Check:

• Oil pressure Checking steps:
• Slightly loosen the oil pressure check bolt 1.
• Start the engine and keep it idling until oil starts to seep from the oil pressure check bolt. If no oil comes out after one minute, turn the engine off so it will not seize.
• Check oil passages and oil pump for damage or leakage.
• Start the engine after solving the problem(s) and recheck the oil pressure.
• Tighten the oil pressure check bolt.

NOTE: Using a digital engine tachometer for idle speed adjustment, detect the engine idling speed by bringing the sensing element c of the engine tachometer close to the ignition coil 2. To increase idle speed → Turn the throttle stop screw 1 in a. To decrease idle speed → Turn the throttle stop screw 1 out b. Engine idling speed: 1,750 ~ 1,950 r/min Adjustment steps:

• Turn the throttle stop screw 1 until the specified engine idling speed.

ENGINE IDLING SPEED

1. Start the engine and thoroughly

2. Adjust:

• Engine idling speed INSP ADJ

VALVE CLEARANCE INSPECTION

AND ADJUSTMENT NOTE: This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are requested not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical damage. NOTE:

• The valve clearance should be adjusted when the engine is cool to the touch.
• The piston must be at Top Dead Center (T.D.C.) on compression stroke to check or adjust the valve clearance. Remove:
• Fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Drain:
• Coolant Refer “COOLANT REPLACEMENT” section. Remove:
• Right radiator Refer to “RADIATOR” section in the CHAPTER 5.
• Carburetor Refer to “CARBURETOR” section in the CHAPTER 5.
• Upper engine bracket
• Cylinder head cover Refer to “CAMSHAFTS” section in the CHAPTER 5. Remove:
• Timing mark accessing screw

• Crankshaft end accessing screw 2

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• Valve clearance Out of specification → Adjust. Valve clearance (cold): Intake valve:

0.10 ~ 0.15 mm

(0.0039 ~ 0.0059 in) Exhaust valve:

0.17 ~ 0.22 mm

(0.0067 ~ 0.0087 in) Checking steps:

• Turn the crankshaft counterclockwise with a wrench.
• Align the T.D.C. mark a on the rotor with the align mark b on the crankcase cover when piston is at T.D.C. on compression stroke. NOTE: In order to be sure that the piston is at Top Dead Center, the punch mark c on the exhaust camshaft and the punch mark d on the intake camshaft must align with the cylinder head surface, as shown in the illustration.
• Measure the valve clearance e using a feeler gauge 1. NOTE: Record the measured reading if the clearance is incorrect.

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• Remove the camshaft (intake and exhaust). Refer to “CAMSHAFTS” section in the CHAPTER 5.
• Remove the valve lifters 1 and the pads 2. NOTE:
• Place a rag in the timing chain space to prevent pads from falling into the crankcase.
• Identity each valve lifter and pad position very carefully so that they can be reinstalled in their original place.

• Select the proper pad using the pad selecting table. Pad range Pad Availability: 25 increments No. 120 1.20 mm

No. 240 2.40 mm Pads are available in

0.05 mm

increments NOTE: The thickness a of each pad is indicated in hundredths of millimeters on the pad upper surface.

• Round off the last digit of the installed pad number to the nearest increment. Last digit of pad Rounded value number 0, 1 or 2

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EXAMPLE: Installed pad number = 148 Rounded off value = 150 NOTE: Pads can only be selected in

0.05 mm increments.

• Locate the rounded-off value and the measured valve clearance in the chart “PAD SELECTION TABLE”. The field where these two coordinates intersect shows the new pad number to use. NOTE: Use the new pad number only as a guide when verifying the valve clearance adjustment.

• Install the new pads 3 and the valve lifters 4. NOTE:
• Apply the engine oil on the valve lifters.
• Apply the molybdenum disulfide oil on the valve stem ends.
• Valve lifter must turn smoothly when rotated with a finger.
• Be careful to reinstall valve lifters and pads in their original place.

• Install the camshafts (exhaust and intake). Refer to “CAMSHAFTS” section in the CHAPTER 5.

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INSTALLED PAD NUMBER

VALVE CLEARANCE (cold):

0.10 ~ 0.15 mm

Example: Installed is 175 Measured clearance is 0.22 mm Replace 175 pad with 185 pad Pad number: (example) Pad No. 175 = 1.75 mm Pad No. 185 = 1.85 mm

INSTALLED PAD NUMBER

VALVE CLEARANCE (cold):

0.17 ~ 0.22 mm

Example: Installed is 175

Measured clearance is 0.27 mm Replace 175 pad with 185 pad Pad number: (example) Pad No. 175 = 1.75 mm Pad No. 185 = 1.85 mm

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MOTEUR INSP ADJ WARNING

• Be sure the exhaust pipe and silencer are cool before cleaning the spark arrester.
• Do not start the engine when cleaning the exhaust system.

• Screw (silencer cap) 1 Remove:
• Bolt (spark arrester) 1 Remove:
• Gasket (tail pipe) 2
• Spark arrester 3 Pull the spark arrester out of the silencer.
• Gasket (spark arrester) 4

• Spark arrester Tap the spark arrester lightly, then use a wire brush to remove any carbon deposits. Install:
• Gasket (spark arrester)
• Spark arrester Insert the spark arrester into the silencer and align the bolt holes.
• Bolt (spark arrester)

NOTE: First tighten the two screws a located horizontally apart, and then tighten the others.

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WARNING Bleed the brake system if:

• The system has been disassembled.
• A brake hose has been loosened or removed.
• The brake fluid is very low.
• The brake operation is faulty. A dangerous loss of braking performance may occur if the brake system is not properly bled.

• Brake master cylinder cap
• Reservoir float (front brake)
• Protector (rear brake) Bleed:
• Brake fluid È Front É Rear

INSP ADJ Air bleeding steps: a. Add proper brake fluid to the reservoir. b. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow. c. Connect the clear plastic tube 2 tightly to the caliper bleed screw 1. d. Place the other end of the tube into a container. e. Slowly apply the brake lever or pedal several times. f. Pull the lever in or push down on the pedal. Hold the lever or pedal in position. g. Loosen the bleed screw and allow the lever or pedal to travel towards its limit. h. Tighten the bleed screw when the lever or pedal limit has been reached; then release the lever or pedal.

Bleed screw: 6 Nm (0.6 m • kg, 4.3 ft • lb)

i. Repeat steps (e) to (h) until of

the air bubbles have been removed from the system.

SPURGO ARIA SISTEMA

FRENANTE NOTE: If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared. j. Add brake fluid to the level line on the reservoir. WARNING Check the operation of the brake after bleeding the brake system.

• Protector (rear brake)
• Reservoir float (front brake)
• Brake master cylinder cap Extent of adjustment 95 mm (3.74 in) Remove:
• Brake lever cover Adjust:
• Brake lever position Brake lever position adjustment steps:
• Loosen the locknut 1.
• Turn the adjusting bolt 2 until the lever position a is within specified position.
• Tighten the locknut.

Be sure to tighten the locknut, as it will cause poor brake performance.

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CHASSIS CHÂSSIS EC364002

REAR BRAKE ADJUSTMENT

1. Check:

• Brake pedal height a Out of specification → Adjust. Adjust:
• Brake pedal height Pedal height adjustment steps:
• Loosen the locknut 1.
• Turn the adjusting nut 2 until the pedal height a is within specified height.
• Tighten the locknut.

• Adjust the pedal height between the maximum È and the minimum É as shown. (In this adjustment, the bolt 3 end b should protrude out of the threaded portion 4 but not be less than 2 mm (0.08 in) c away from the brake pedal 5).
• After the pedal height adjustment, make sure that the rear brake does not drag.

FRONT BRAKE PAD INSPECTION

1. Inspect:

• Brake pad thickness a Out specification Replace as a set. Brake pad thickness:

4.4 mm (0.17 in)

1.0 mm (0.04 in)

• Brake pad Brake pad replacement steps:
• Remove the pad pin plug 1.

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• Loosen the pad pin 2.
• Remove the brake caliper 3 from the front fork.
• Remove the pad pin and brake pads 4.
• Connect the transparent hose 5 to the bleed screw 6 and place the suitable container under its end.
• Loosen the bleed screw and push the brake caliper piston in. INSP ADJ Do not reuse the drained brake fluid.

• Tighten the bleed screw. Bleed screw: 6 Nm (0.6 m • kg, 4.3 ft • lb)

• Install the brake pads 7 and pad pin. NOTE:
• Install the brake pads with their projections a into the brake caliper recesses b.
• Temporarily tighten the pad pin at this point.

• Install the brake caliper 8 and tighten the pad pin 9. Inspect:
• Brake fluid level Refer to “BRAKE FLUID LEVEL INSPECTION” section.

• Install the pad pin plug 0.

• Brake lever operation A softy or spongy feeling → Bleed brake system. Refer to “BRAKE SYSTEM AIR BLEEDING” section.

REAR BRAKE PAD INSPECTION

1. Inspect:

• Brake pad thickness a Out of specification → Replace as a set. Brake pad thickness:

6.4 mm (0.25 in)

1.0 mm (0.04 in)

• Brake pad Brake pad replacement steps:
• Remove the protector 1 and pad pin plug 2.
• Loosen the pad pin 3.
• Remove the rear wheel 4 and brake caliper 5. Refer to “FRONT WHEEL AND REAR WHEEL” section in the

CHAPTER 6.

• Remove the pad pin 6 and brake pads 7.
• Connect the transparent hose 8 to the bleed screw 9 and place the suitable container under its end.
• Loosen the bleed screw and push the brake caliper piston in.

INSP ADJ CAUTION: Do not reuse the drained brake fluid.

• Tighten the bleed screw.

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Bleed screw: 6 Nm (0.6 m • kg, 4.3 ft • lb)

• Install the brake pad 0 and pad pin A. NOTE:
• Install the brake pads with their projections a into the brake caliper recesses b.
• Temporarily tighten the pad pin at this point.

• Install the brake caliper B and rear wheel C. Refer to “FRONT WHEEL AND REAR WHEEL” section in the

CHAPTER 6.

• Tighten the pad pin D.

REAR BRAKE PAD INSULATOR

1. Remove:

• Brake pad Refer to “REAR BRAKE PAD INSPECTION AND REPLACEMENT” section.

2. Inspect:

• Rear brake pad insulator 1 Damage → Replace.

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• Brake fluid level Refer to “BRAKE FLUID LEVEL INSPECTION” section. Check:
• Brake pedal operation A softy or spongy feeling → Bleed brake system. Refer to “BRAKE SYSTEM AIR BLEEDING” section.

• Install the pad pin plug E and protector F.

BRAKE FLUID LEVEL

1. Place the brake master cylinder

so that its top is in a horizontal position.

2. Inspect:

• Brake fluid level Fluid at lower level → Fill up. a Lower level È Front É Rear INSP ADJ Recommended brake fluid: DOT #4 WARNING
• Use only designated quality brake fluid to avoid poor brake performance.
• Refill with same type and brand of brake fluid; mixing fluids could result in poor brake performance.
• Be sure that water or other contaminants do not enter master cylinder when refilling.
• Clean up spilled fluid immediately to avoid erosion of painted surfaces or plastic parts. SPROCKETS INSPECTION

1. Inspect:

• Sprocket teeth a Excessive wear → Replace. NOTE: Replace the drive sprocket, rear wheel sprocket and drive chain as a set. CHASSIS CHÂSSIS

DRIVE CHAIN INSPECTION

1. Measure:

• Drive chain length (15 links) a Out of specification → Replace. Drive chain length (15 links): <Limit>:

239.3 mm (9.42 in)

• While measuring the drive chain length, push down on the drive chain to increase its tension.
• Measure the length between drive chain roller 1 and F as shown.
• Perform this measurement at two or three different places.

• Drive chain 1 NOTE: Remove the drive chain using a drive chain cutter 2.

• Drive chain Brush off as much dirt as possible. Then clean the drive chain using the chain cleaner. CAUTION: This machine has a drive chain with small rubber O-rings 1 between the side plates. Steam cleaning, high-pressure washes, certain solvent and kerosene can damage these O-rings. INSP ADJ Inspect:
• O-ring 1 (drive chain) Damage → Replace the drive chain.
• Side plate 3 Damage/wear → Replace the drive chain.

• Drive chain stiffness a Clean and oil the drive chain and hold as illustrated. Stiff → Replace the drive chain.

• Drive chain 3 NOTE: When installing the drive chain, apply the lithium soap base grease on the chain joint and O-rings.

• Link plate 4 New NOTE:
• Press the link plate onto the chain joint using a drive chain riveter 5.
• Rivet the end of the chain joint using a drive chain riveter.
• After riveting the chain joint, make sure its movement is smooth.

• Drive chain Drive chain lubricant: SAE 10W-30 motor oil or suitable chain lubricants

DRIVE CHAIN SLACK

1. Elevate the rear wheel by placing the suitable stand under the

2. Check:

• Drive chain slack a Above the seal guard installation bolt. Out of specification → Adjust. Drive chain slack: 48 ~ 58 mm (1.9 ~ 2.3 in) NOTE: Before checking and/or adjusting, rotate the rear wheel through several revolutions and check the slack several times to find the tightest point. Check and/or adjust the drive chain slack with the rear wheel in this “tight chain” position.

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INSP ADJ CHASSIS CHÂSSIS

• Drive chain slack Drive chain slack adjustment steps:
• Loosen the axle nut 1 and locknuts 2.
• Adjust the drive chain slack by turning the adjusters 3. To tighten → Turn the adjuster 3 counterclockwise. To loosen → Turn the adjuster 3 clockwise and push wheel forward.
• Turn each adjuster exactly the same amount to maintain correct axle alignment. (There are marks a on each side of the drive chain puller alignment.) NOTE: Turn the adjuster so that the drive chain is in line with the sprocket, as viewed from the rear. CAUTION: Too small drive chain slack will overload the engine and other vital parts; keep the slack within the specified limits.
• Tighten the axle nut while pushing down the drive chain.

• Tighten the locknuts.

CHASSIS CHÂSSIS EC36C000

FRONT FORK INSPECTION

1. Inspect:

• Front fork smooth action Operate the front brake and stroke the front fork. Unsmooth action/oil leakage
• Repair or replace. EC36D001 INSP ADJ

FRONT FORK OIL SEAL AND

DUST SEAL CLEANING

1. Remove:

• Dust seal 1 NOTE: Use a thin screw driver, and be careful not to damage the inner fork tube and dust seal. Clean:
• Clean the dust seal and oil seal after every run.
• Apply the lithium soap base grease on the inner tube. NOTE: If the front fork initial movement feels stiff during a run, relieve the front fork internal pressure. Elevate the front wheel by placing a suitable stand under the engine. Remove the air bleed screw 1 and release the internal pressure from the front fork. Install:
• Air bleed screw CHASSIS CHÂSSIS EC36H002

FRONT FORK REBOUND

DAMPING FORCE ADJUSTMENT

1. Adjust:

• Rebound damping force By turning the adjuster 1. Stiffer a → Increase the rebound damping force. (Turn the adjuster 1 in.) Softer b → Decrease the rebound damping force. (Turn the adjuster 1 out.) Extent of adjustment: Maximum INSP ADJ 20 clicks out Fully turned in (from maximum position position)
• STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. Standard position: 9 clicks out CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. ATTENTION: WARNING Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability. CHASSIS CHÂSSIS EC36J001

FRONT FORK COMPRESSION

DAMPING FORCE ADJUSTMENT

1. Remove:

2. Adjust:

• Compression damping force By turning the adjuster 1. Stiffer a → Increase the compression damping force. (Turn the adjuster 1 in.) Softer b → Decrease the compression damping force. (Turn the adjuster 1 out.) Extent of adjustment: Maximum INSP ADJ 20 clicks out Fully turned in (from maximum position position)
• STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. Standard position: 10 clicks out
• Except for USA and CDN Minimum CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. Maximum WARNING Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability.

• Rubber cap Installare:

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CHASSIS CHÂSSIS EC36K000

REAR SHOCK ABSORBER

1. Inspect:

• Swingarm smooth action Abnormal noise/unsmooth action → Grease the pivoting points or repair the pivoting points. Damage/oil leakage → Replace.

REAR SHOCK ABSORBER

SPRING PRELOAD ADJUSTMENT

1. Elevate the rear wheel by placing the suitable stand under the

2. Remove:

3. Loosen:

4. Adjust:

• Spring preload By turning the adjuster 2. Stiffer → Increase the spring preload. (Turn the adjuster 2 in.) Softer → Decrease the spring preload. (Turn the adjuster 2 out.) Spring length (installed) Standard length Extent of adjustment

• For EUROPE ** For AUS, NZ and ZA NOTE:
• Be sure to remove all dirt and mud from around the locknut and adjuster before adjustment.
• The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjuster. CAUTION: Never attempt to turn the adjuster beyond the maximum or minimum setting.

• EUROPE ** AUS, NZ e ZA CHASSIS CHÂSSIS EC36N014

REAR SHOCK ABSORBER

REBOUND DAMPING FORCE

1. Adjust:

• Rebound damping force By turning the adjuster 1. Stiffer a → Increase the rebound damping force. (Turn the adjuster 1 in.) Softer b → Decrease the rebound damping force. (Turn the adjuster 1 out.) Extent of adjustment: Maximum INSP ADJ 20 clicks out Fully turned in (from maximum position position)

• STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. (Which align the punch mark a on the adjuster with the punch mark b on the bracket.) Standard position: About 11 clicks out CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged.

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CHASSIS CHÂSSIS EC36c000

REAR SHOCK ABSORBER LOW

COMPRESSION DAMPING FORCE

1. Adjust:

• Low compression damping force By turning the adjuster 1.

Stiffer a → Increase the low compression damping force. (Turn the adjuster 1 in.) Softer b → Decrease the low compression damping force. (Turn the adjuster 1 out.) Extent of adjustment: Maximum Minimum 20 clicks out Fully turned in (from maximum position position)

• STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. (Which align the punch mark a on the adjuster with the punch mark b on the high compression damping adjuster.) Standard position: About 12 clicks out
• For AUS, NZ and ZA INSP ADJ CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged.

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REAR SHOCK ABSORBER HIGH

COMPRESSION DAMPING FORCE

1. Adjust:

• High compression damping force By turning the adjuster 1.

Stiffer a → Increase the high compression damping force. (Turn the adjuster 1 in.) Softer b → Decrease the high compression damping force. (Turn the adjuster 1 out.) Extent of adjustment: Maximum Minimum 2 turns out Fully turned in (from maximum position position)

• STANDARD POSITION: This is the position which is back by the specific number of turns from the fully turned-in position. (Which align the punch mark a on the adjuster with the punch mark b on the adjuster body.) Standard position: About 1-1/8 turns out
• About 1-1/4 turns out
• For EUROPE INSP ADJ CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged.

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CHASSIS CHÂSSIS EC36Q000

TIRE PRESSURE CHECK

1. Measure:

• Tire pressure Out of specification → Adjust. Standard tire pressure: 100 kPa (1.0 kgf/cm2, 15 psi) NOTE:
• Check the tire while it is cold.
• Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low.
• A tilted tire valve stem indicates that the tire slips off its position on the rim.
• If the tire valve stem is found tilted, the tire is considered to be slipping off its position. Correct the tire position. EC36S002

SPOKES INSPECTION AND

1. Inspect:

• Spokes 1 Bend/damage → Replace. Loose spoke → Retighten.

2. Tighten:

NOTE: Be sure to retighten these spokes before and after break-in. After a practice check spokes for looseness. EC36T000 WHEEL INSPECTION

1. Inspect:

• Wheel runout Elevate the wheel and turn it. Abnormal runout → Replace.

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INSP ADJ CHASSIS CHÂSSIS

• Bearing free play Exist play → Replace. EC36U013

STEERING HEAD INSPECTION

1. Elevate the front wheel by placing a suitable stand under the

2. Check:

• Steering stem Grasp the bottom of the forks and gently rock the fork assembly back and forth. Free play → Adjust steering head.

3. Check:

• Steering smooth action Turn the handlebar lock to lock. Unsmooth action → Adjust steering ring nut.

4. Adjust:

• Steering ring nut Steering ring nut adjustment steps:
• Remove the headlight.
• Remove the handlebar and upper bracket.
• Loosen the steering ring nut 1 using the steering nut wrench

Steering nut wrench: YU-33975/90890-01403

• Tighten the steering ring nut 3 using steering nut wrench 4. NOTE:
• Apply the lithium soap base grease on the thread of the steering stem.
• Set the torque wrench to the steering nut wrench so that they form a right angle. Steering nut wrench: YU-33975/90890-01403 Steering ring nut (initial tightening): 38 Nm (3.8 m • kg, 27 ft • lb)

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INSP ADJ Hakenschlüssel: YU-33975/90890-01403 Hakenschlüssel: YU-33975/90890-01403

• Loosen the steering ring nut one turn.
• Retighten the steering ring nut using the steering nut wrench. INSP ADJ Avoid over-tightening. NOTE:
• Install the collar 6 with the larger inside diameter facing downwards.
• The handlebar upper holder should be installed with the punched mark a forward.
• Install the handlebar so that the marks b are in place on both sides.
• Install the handlebar so that the projection c of the handlebar upper holder is positioned at the mark on the handlebar as shown.
• Insert the end of the fuel breather hose C into the hole in the steering stem. CAUTION: First tighten the bolts on the front side of the handlebar upper holder, and then tighten the bolts on the rear side.

• Check the steering stem by turning it lock to lock. If there is any binding, remove the steering stem assembly and inspect the steering bearings.
• Install the washer 5, collar 6, upper bracket 7, washer 8, steering stem nut 9, handlebar 0, handlebar upper holder A and headlight B.

Steering ring nut (final tightening): 7 Nm (0.7 m • kg, 5.1 ft • lb) LUBRICATION To ensure smooth operation of all components, lubricate your machine during setup, after break-in, and after every ride. All control cable Clutch lever pivot Shift pedal pivot Footrest pivot Throttle-to-handlebar contact Drive chain Tube guide cable winding portion Throttle cable end Clutch cable end Hot starter cable end È Use Yamaha cable lube or equivalent on these areas. É Use SAE 10W-30 motor oil or suitable chain lubricants. Ê Lubricate the following areas with high quality, lightweight lithium-soap base grease. CAUTION: Wipe off any excess grease, and avoid getting grease on the brake discs.

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SPARK PLUG INSPECTION

1. Remove:

2. Inspect:

• Electrode 1 Wear/damage → Replace.
• Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition. NOTE: When the engine runs for many hours at low speeds, the spark plug insulator will become sooty, even if the engine and carburetor are in good operating condition.

• Plug gap a Use a wire gauge or thickness gauge. Out of specification → Regap. Clean the plug with a spark plug cleaner if necessary.

• Before installing a spark plug, clean the gasket surface and plug surface.
• Finger-tighten a the spark plug before torquing to specification b.

IGNITION TIMING CHECK

1. Remove:

• Timing mark accessing screw

• Inductive tachometer To the ignition coil (orange lead 1).

lead Timing light: YM-33277-A/ 90890-03141

• Engine idling speed Refer to “ENGINE IDLING SPEED ADJUSTMENT” section. Check:
• Ignition timing Visually check the stationary pointer a is within the firing range b on the rotor. Incorrect firing range → Check rotor and pickup assembly. Install:
• Timing mark accessing screw ELECTRICAL PARTIE ELECTRIQUE

BATTERY INSPECTION AND

CHARGING WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures:

• Wear protective eye gear when handling or working near batteries.
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).
• DO NOT SMOKE when charging or handling batteries.
• KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury.

FIRST AID IN CASE OF BODILY

• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes and get immediate medical attention. INTERNAL
• Drink large quantities of water or milk followed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention. INSP ADJ CAUTION: Charging time, charging amperage and charging voltage for an MF battery are different from those of conventional batteries. The MF battery should be charged as explained in the charging method illustrations. If the battery is overcharged, the electrolyte level will drop considerably. Therefore, take special care when charging the battery. NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.

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• Battery leads (from the battery terminals) CAUTION:

• Battery charge Measurement steps:
• Connect a pocket tester 1 to the battery terminals. Tester positive probe → battery positive terminal Tester negative probe → battery negative terminal

First, disconnect the negative battery lead 1, and then the positive battery lead 2.

• The charge state of an MF battery can be checked by measuring its open-circuit voltage (i.e., the voltage when the positive terminal is disconnected).
• No charging is necessary when the open-circuit voltage equals or exceeds 12.8 V.

• Check the charge of the battery, as shown in the charts and the following example. Example Open-circuit voltage = 12.0 V Charging time = 6.5 hours Charge of the battery = 20 ~ 30% È Relationship between the open-circuit voltage and the charging time at 20 °C (68 °F) (These values vary with the temperature, the condition of the battery plates, and the electrolyte level.) É Open-circuit voltage Ê Charging time (hours) Ë Time (minutes) Ì Charging condition of the battery Í Ambient temperature 20 °C (68 °F) a Charging b Check the open-circuit voltage

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• Battery (refer to the appropriate charging method illustration) WARNING Do not quick charge a battery.

• Never remove the MF battery sealing caps.
• Do not use a high-rate battery charger since it forces a highamperage current into the battery quickly and can cause battery 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 machine. (If charging has to be done with the battery mounted on the machine, disconnect the negative battery lead from the battery terminal.)
• To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery.
• Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger.
• Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks.
• If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode!
• As shown in the following illustration, the open-circuit voltage of an MF battery stabilizes about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage.

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ELECTRICAL Charging method using a variable voltage charger Charger Measure the open-circuit voltage prior to charging. NOTE: Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging. NOTE: Set the charging voltage to 1617 V. (If the charging voltage is lower, charging will be insufficient, if it is higher, the battery will be over-charged.) Ammeter Is the amperage higher than the standard charging amperage written on the battery? YES

Adjust the charging voltage to 20 ~ 25 V. Adjust the voltage to obtain the standard charging amperage. Monitor the amperage for 3 ~ 5 minutes. Is the standard charging amperage exceeded? YES

If the amperage does not exceed the standard charging amperage after 5 minutes, replace the battery. Set the timer to the charging time determined by the opencircuit voltage. Refer “BATTERY INSPECTION AND CHARGING” section. If the required charging time exceeds 5 hours, it is advisable to check the charging amperage after 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging amperage. Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage.

12.8 V → Charging is complete.

12.0 ~ 12.7 V → Recharging is required.

Under 12.0 V → Replace the battery.

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INSP ADJ ELECTRICAL Charging method using a constant voltage charger Measure the open-circuit voltage prior to charging. NOTE: Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. Connect a charger and ammeter to the battery and start charging. YES Is the amperage higher than the standard charging amperage written on the battery? Charge the battery until the charging voltage reaches 15 V.

This type of battery charger cannot charge an MF battery. A variable voltage charger is recommended. NOTE: Set the charging time to a maximum of 20 hours. Charger Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage.

12.8 V → Charging is complete.

12.0 ~ 12.7 V → Recharging is required.

Under 12.0 V → Replace the battery. Ammeter Voltmeter CAUTION: Constant amperage chargers are not suitable for charging MF batteries.

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• Battery band Connect:
• Battery leads (to the battery terminals) CAUTION:

INSP ADJ First, connect the positive lead 1, then the negative lead 2. Check:

• Battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. Lubricate:

Recommended lubricant: Lithium soap base grease

10. Install:

• Seat BATTERY REPLACEMENT

1. Replace:

• Battery CAUTION: This battery is for YAMAHA WR250F. After filling the battery with electrolyte, either charge it for at least 3 hours at the amperage specified on the battery or let it sit for at least 15 hours before using it. EAS00181 FUSE INSPECTION CAUTION: To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse. Remove:

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• Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω × 1”.

• If the pocket tester indicates “∞”, replace the fuse. Replace:

• Set the main switch to “OFF”.
• Install a new fuse of the correct amperage.
• Set on the switches to verify if the electrical circuit is operational.
• If the fuse immediately blows again, check the electrical circuit. Items Amperage rating Q’ty Main fuse 10 A

WARNING Never use a fuse with an amperage rating other than that specified. Improvising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system, cause the starting and ignition systems to malfunction and could possibly cause a fire. Install:

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REPLACING THE HEADLIGHT

1. Remove:

• Headlight Refer to “SEAT, FUEL TANK AND SIDE COVERS”. Remove:
• Headlight bulb holder cover 1

• Headlight bulb holder 1

NOTE: Remove the headlight bulb holder by pushing it in and turning it counterclockwise. Remove:

• Headlight bulb AVERTISSEMENT WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb unit it has cooled down.

• Headlight bulb ATTENTION: CAUTION: Avoid touching the glass part of the headlight bulb to keep it free form oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected. If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner.

• Headlight bulb holder Install:
• Headlight bulb holder cover Install:

Refer to “SEAT, FUEL TANK AND SIDE COVERS”. ELECTRICAL PARTIE ELECTRIQUE

ADJUSTING THE HEADLIGHT

1. Adjust:

• Headlight beam (vertically) Adjusting steps:
• Turn the adjusting screw 1 in direction a or b. Direction a Direction b Headlight beam is raised. Headlight beam is lowered.

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INSP ADJ ENGINE Carburetor setting

• The air/fuel mixture will vary depending on atmospheric conditions. Therefore, it is necessary to take into consideration the air pressure, ambient temperature, humidity, etc., when adjusting the carburetor.
• Perform a test run to check for proper engine performance (e.g., throttle response) and spark plug(s) discoloration or fouling. Use these readings to determine the best possible carburetor setting. NOTE: It is recommended to keep a record of all carburetor settings and external conditions (e.g., atmospheric conditions, track/surface conditions, lap times) to make future carburetor setting easier. WARNING
• The carburetor is a part of the fuel line. Therefore, be sure to install it in a well-ventilated area, away from flammable objects and any sources of fire.
• Never look into the carburetor intake. Flames may shoot out from the pipe if the engine backfires while it is being started. Gasoline may be discharged from the accelerator pump nozzle when the carburetor has been removed. 4-1 SETTING REGLAGE CAUTION: TUN ATTENTION:

• The carburetor is extremely sensitive to foreign matter (dirt, sand, water, etc.). During installation, do not allow foreign matter to get into the carburetor.
• Always handle the carburetor and its components carefully. Even slight scratches, bends or damage to carburetor parts may prevent the carburetor from functioning correctly. Carefully perform all servicing with the appropriate tools and without applying excessive force.
• When the engine is stopped or when riding at no load, do not open and close the throttle unnecessarily. Otherwise, too much fuel may be discharged, starting may become difficult or the engine may not run well.
• After installing the carburetor, check that the throttle operates correctly and opens and closes smoothly. Atmospheric conditions and carburetor settings Air Air temp. Humidity pressure Mixture Setting (altitude) High High Low (high) Richer Leaner Low Low High (low) Leaner Richer The air density (i.e., concentration of oxygen in the air) determines the richness or leanness of the air/ fuel mixture. Therefore, refer to the above table for mixture settings. That is:
• Higher temperature expands the air with its resultant reduced density.
• Higher humidity reduces the amount of oxygen in the air by so much of the water vapor in the same air.
• Lower atmospheric pressure (at a high altitude) reduces the density of the air. 4-3 Effects of the setting parts on the throttle valve opening Closed Fully open Pilot jet Throttle valve cutaway Jet needle Main jet Main system The FLATCR carburetor has a primary main jet. This type of main jet is perfect for racing machines since it supplies an even flow of fuel, even at full load. Use the main jet and the jet needle to set the carburetor.

Jet needle Pilot air jet Needle jet Main jet Pilot jet

Main jet adjustment The richness of the air-fuel mixture at full throttle can be set by changing the main jet 1. Standard main jet

–10% Effects of changing the main jet (reference)

Idle Fully open #180 #160 #170 If the air-fuel mixture is too rich or too lean, the engine power will drop, resulting in poor acceleration.

Gicleur principal standard N°170 SETTING REGLAGE Pilot jet adjustment The richness of the air-fuel mixture with the throttle open 1/4 or less can be set by adjusting the pilot jet 1. Standard pilot jet TUN Effects of adjusting the pilot jet (reference) Idle Fully open #45 #40 #42 Jet needle groove position adjustment NOTE: For setting adjustment, replace the standard jet needle with the one designed for setting. Adjusting the jet needle 1 position affects the acceleration when the throttle is 1/8 to 3/4 open.

1. Too rich at intermediate speeds

Rough engine operation is felt and the engine will not pick up speed smoothly. In this case, step up the jet needle clip by one groove and move down the needle to lean out the mixture.

2. Too lean at intermediate speeds

The engine breathes hard and will not pick up speed quickly. Step down the jet needle clip by one groove and move up the needle to enrich the mixture.

–10% N°42 Effects of changing the jet needle groove position (reference) Idle Fully open No.6 groove No.4 groove No.5 groove 4-7 SETTING REGLAGE Jet needle adjustment The jet needle is adjusted by changing it. Supplied jet needle GDEPS

• For AUS, NZ, CDN and ZA The tapered sections of all jet needles have the same starting positions, but the needles are available with different straight-portion diameters. Diameter a of straight portion 1/2 3/4

–10 % Effects of changing the jet needle (reference) (Diameter of the straight portion) Changing the diameter of the straight portion adjusts the air-fuel mixture when the throttle is 1/8 to 1/4 open. È Idle É Fully open

Aiguille fournie GDEPS

• GDEPR Leak jet adjustment (accelerator pump adjustment) The leak jet 1 is a setting part that adjusts the flow of fuel discharged by the accelerator pump. Since the accelerator pump operates only when throttle is open, the leak jet is used to adjust a fuel mixture ratio for quick throttle opening and is therefore different from other setting parts that adjust a fuel mixture for each throttle opening (each engine speed). 4-9 The engine breathes hard in quick throttle opening. Select a leak jet having lower calibrating No. than standard to enrich the mixture. <Example> #70 → #65 Rough engine operation is felt in quick throttle opening. Select a leak jet having higher calibrating No. than standard to lean out the mixture. <Example> #70 → #85 Standard leak jet #70 Relationship with throttle opening The flow of the fuel through the carburetor main system is controlled by the main jet and then, it is further regulated by the area between the main nozzle and the jet needle. The fuel flow relates to the diameter of the straight portion of the jet needle with the throttle 1/8 to 1/4 open and relates to the clip position with the throttle 1/8 to 3/4 open. Therefore, the fuel flow is balanced at each stage of throttle opening by the combination of the jet needle straight portion diameter and clip position.

4 - 11

TUN Carburetor setting parts Part name Main jet Rich (STD) Lean Pilot jet Rich (STD) Lean Jet needle Rich Lean Leak jet Rich (STD) Lean Size Part number #182 #180 #178 #175 #172 #170 #168 #165 #162 #160 #158 #EPN #EPP #EPQ #EPR #EPS #EPT #EPU #EPV 5UM-14916-BN 5UM-14916-BP 5UM-14916-B1 5UM-14916-BR 5UM-14916-BS 5UM-14916-BT 5UM-14916-BU 5UM-14916-BV #60 #70 #80 #90 #100 #110 #120 Gicleur principal Riche 5UM-14916-BN 5UM-14916-BP 5UM-14916-B1 5UM-14916-BR 5UM-14916-BS 5UM-14916-BT 5UM-14916-BU 5UM-14916-BV 5UM-14916-BN 5UM-14916-BP 5UM-14916-B1 5UM-14916-BR 5UM-14916-BS 5UM-14916-BT 5UM-14916-BU 5UM-14916-BV 5UM-14916-BN 5UM-14916-BP 5UM-14916-B1 5UM-14916-BR 5UM-14916-BS 5UM-14916-BT 5UM-14916-BU 5UM-14916-BV 5UM-14916-BN 5UM-14916-BP 5UM-14916-B1 5UM-14916-BR 5UM-14916-BS 5UM-14916-BT 5UM-14916-BU 5UM-14916-BV Examples of carburetor setting depending on symptom Symptom Setting Checking At full throttle Hard breathing Shearing noise Whitish spark plug Lean mixture Increase main jet calibration no. (Gradually) Discoloration of spark plug → If tan color, it is in good condition. If cannot be corrected: Clogged float valve seat Clogged fuel hose Clogged fuel cock Check that the accelerator pump operates smoothly. At full throttle Speed pick-up stops Slow speed pick-up Slow response Sooty spark plug Rich mixture Decrease main jet calibration no. (Gradually) Discoloration of spark plug → If tan color, it is in good condition. If cannot be corrected: Clogged air filter Fuel overflow from carburetor Lean mixture Lower jet needle clip position. (1 groove down) Rich mixture Raise jet needle clip position. (1 groove up) 1/4 ~ 3/4 throttle Hard breathing Lack of speed Lower jet needle clip position. (1 groove down) 1/4 ~ 1/2 throttle Slow speed pick-up Poor acceleration Raise jet needle clip position. (1 groove up) Closed to 1/4 throttle Hard breathing Speed down Use jet needle with a smaller diameter. Closed to 1/4 throttle Poor acceleration Use jet needle with a larger diameter. Raise jet needle clip position. (1 groove up) Poor response in the low to intermediate speeds Raise jet needle clip position. If this has no effect, lower the jet needle clip position. Poor response when throttle is opened quickly Check overall settings. Use main jet with a lower calibration no. Raise jet needle clip position. (1 groove up) If these have no effect, use a main jet with a higher calibration no. and lower the jet needle clip position.

Leaner (Standard) Richer The clip position is the jet needle groove on which the clip is installed. The positions are numbered from the top. Check that the accelerator pump operates smoothly. (except for rich mixture symptom). Slow-speed-circuit passage Clogged → Clean. Overflow from carburetor Check air filter for fouling. Check that the accelerator pump operates smoothly. This should be taken simply for an example. It is necessary to set the carburetor while checking the operating conditions of the engine.

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REGLAGE TUN Rainure 1 Rainure 2 Rainure 3 Rainure 4 Rainure 5 Rainure 6 Rainure 7 Clip Aiguille Nut 1 Nut 2 Nut 3 Nut 4 Nut 5 Nut 6 Nut 7 Düsennadel Clip Povera (Standard) Ricca CHASSIS Selection of the secondary reduction ratio (Sprocket) Number of rear Secondary wheel sprocket teeth reduction Number of drive ratio sprocket teeth Standard secondary reduction ratio 50/13 (3.846) <Requirement for selection of secondary gear reduction ratio>

• It is generally said that the secondary gear ratio should be reduced for a longer straight portion of a speed course and should be increased for a course with many corners. Actually, however, as the speed depends on the ground condition of the day of the ride, be sure to run through the circuit to set the machine suitable for the entire course.
• In actuality, it is very difficult to achieve settings suitable for the entire course and some settings may be sacrificed. Thus, the settings should be matched to the portion of the course that has the greatest effect on the ride result. In such a case, run through the entire course while making notes of lap times to find the best balance; then, determine the secondary reduction ratio.
• If a course has a long straight portion where a machine can run at maximum speed, the machine is generally set such that it can develop its maximum revolutions toward the end of the straight line, with care taken to avoid the engine over-revving. NOTE: Riding technique varies from rider to rider and the performance of a machine also vary from machine to machine. Therefore, do not imitate other rider’s settings from the beginning but choose your own setting according to the level of your riding technique.

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Drive and rear wheel sprockets setting parts Part name Drive sprocket 1 (STD) Rear wheel sprocket 2 (STD)

• (STD) Size Part number 13T
• 14T 9383B-13218 9383B-14222 48T

• For AUS and NZ Taille 48T
• 52T Tire pressure Tire pressure should be adjust to suit the road surface condition of the circuit. Standard tire pressure: 100 kPa (1.0 kgf/cm2, 15 psi)
• Under a rainy, muddy, sandy, or slippery condition, the tire pressure should be lower for a larger area of contact with the road surface. Extent of adjustment: 60 ~ 80 kPa (0.6 ~ 0.8 kgf/cm2,

9.0 ~ 12 psi)

• Under a stony or hard road condition, the tire pressure should be higher to prevent a flat tire. Extent of adjustment: 100 ~ 120 kPa (1.0 ~ 1.2 kgf /cm2, 15 ~ 18 psi)

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48T *48T *49T 50T *50T *51T 52T *52T 48T

• 52T Front fork setting The front fork setting should be made depending on the rider’s feeling of an actual run and the circuit conditions. The front fork setting includes the following three factors:

1. Setting of air spring characteristics

• Change the fork oil level.

2. Setting of spring preload

• Install the adjustment washer.

3. Setting of damping force

• Change the compression damping.
• Change the rebound damping. The spring acts on the load and the damping force acts on the cushion travel speed. EC723001 Change in level and characteristics of fork oil Damping characteristic near the final stroke can be changed by changing the fork oil amount. CAUTION: Adjust the oil level in 5 mm (0.2 in) increments or decrements. Too low oil level causes the front fork to produce a noise at full rebound or the rider to feel some pressure on his hands or body. Alternatively, too high oil level will develop unexpectedly early oil lock with the consequent shorter front fork travel and deteriorated performance and characteristics. Therefore, adjust the front fork within the specified range. Standard oil level: 132 mm (5.20 in) Extent of adjustment: 95 ~ 150 mm (3.74 ~ 5.91 in) From top of outer tube with inner tube and damper rod fully compressed without spring.

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TUN È Air spring characteristics in relation to oil level change É Load Ê Stroke 1 Max. oil level 2 Standard oil level 3 Min. oil level Spring preload adjustment The spring preload is adjusted by installing the adjustment washer 1 between the fork spring 2 and damper rod 3. ATTENTION: CAUTION: Do not install three or more adjustment washers for each front fork. WARNING Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability. Standard washer quantity: Zero adjustment washers Extent of adjustment: Zero ~ 2 adjustment washers È Load É Fork stroke 1 Without adjustment washer (standard) 2 1 adjustment washer 3 2 adjustment washers

4 - 27

Setting of spring after replacement As the front fork setting can be easily affected by rear suspension, take care so that the machine front and rear are balanced (in position, etc.) when setting the front fork.

1. Use of soft spring

Generally a soft spring gives a soft riding feeling. Rebound damping tends to become stronger and the front fork may sink deeply over a series of gaps. To set a soft spring:

• Change the rebound damping. Turn out one or two clicks.
• Change the compression damping. Turn in one or two clicks.

2. Use of stiff spring

Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, resulting in lack of a sense of contact with the road surface or in a vibrating handlebar. To set a stiff spring:

• Change the rebound damping. Turn in one or two clicks.
• Change the compression damping. Turn out one or two clicks.

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TUN Front fork setting parts

• Adjustment washer 1 TYPE (thickness) T = 2.3 mm (0.09 in) PART NUMBER 5XE-23364-00

• Front fork spring 2 TYPE TUN TYPE SPRING SPRING

I.D. MARK

RATE PART NUMBER (slits) SOFT

5TJ-23141-00 5TJ-23141-10 5TJ-23141-20 5TJ-23141-30 STD

5TJ-23141-50 5TJ-23141-60 I-I I-II NOTE: The I.D. mark (slits) a is proved on the end of the spring. CAUTION: When using a spring with a spring rate of 0.469 kg/mm, do not install two or more adjustment washers for each front fork.

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Rear suspension setting The rear suspension setting should be made depending on the rider’s feeling of an actual run and the circuit conditions. The rear suspension setting includes the following two factors:

1. Setting of spring preload

• Change the set length of the spring.

2. Setting of damping force

• Change the rebound damping.
• Change the compression damping. EC72C001 Choosing set length

1. Place a stand or block under the

engine to put the rear wheel above the floor, and measure the length a between the rear wheel axle center and the rear fender holding bolt. TUN Remove the stand or block from the engine and with a rider astride the seat, measure the sunken length b between the rear wheel axle center and the rear fender holding bolt.

Loosen the locknut 1 and make adjustment by turning the spring adjuster 2 to achieve the standard figure from the subtraction of the length b from the length

Standard figure: 90 ~ 100 mm (3.5 ~ 3.9 in) NOTE:

• If the machine is new and after it is broken in, the same set length of the spring may change because of the initial fatigue, etc. of the spring. Therefore, be sure to make reevaluation.
• If the standard figure cannot be achieved by adjusting the spring adjuster and changing the spring set length, replace the spring with an optional one and make readjustment.

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SETTING REGLAGE Setting of spring after replacement After replacement, be sure to adjust the spring to the set length [sunken length 90 ~ 100 mm (3.5 ~ 3.9 in)] and set it.

1. Use of soft spring

• Set the soft spring for less rebound damping to compensate for its less spring load. Run with the rebound damping adjuster one or two clicks on the softer side and readjust it to suit your preference.

2. Use of stiff spring

• Set the soft spring for more rebound damping to compensate for its greater spring load. Run with the rebound damping adjuster one or two clicks on the stiffer side and readjust it to suit your preference. Adjusting the rebound damping will be followed more or less by a change in the compression damping. For correction, turn the low compression damping adjuster on the softer side.

CAUTION: When using a rear shock absorber other than currently installed, use the one whose overall length a does not exceed the standard as it may result in faulty performance. Never use one whose overall length is greater than standard. Length a of standard shock:

488.5 mm (19.23 in)

TUN Rear shock absorber setting parts

• Rear shock spring 1 TYPE SPRING PART NUMBER SPRING RATE I.D. SPRING COLOR/ FREE POINT LENGTH SOFT

NOTE: The I.D. color a is marked at the end of the spring.

• Extent of adjustment (spring length) SPRING FREE LENGTH EXTENT OF ADJUSTMENT

260 mm (10.24 in) REFERENCE DU RESSORT Suspension setting

• If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart.
• Before any change, set the rear shock absorber sunken length to the standard figure 90 ~ 100 mm (3.5 ~ 3.9 in). Section Symptom Jump Check Large Medium Small gap gap gap Compression damping Stiff over entire range Unsmooth movement over entire range Poor initial movement Oil level (oil amount) Spring Adjust Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in). Replace with soft spring. Outer tube Inner tube Under bracket tightening torque Check for any bends, dents, and other noticeable scars, etc. If any, replace affected parts. Retighten to specified torque. Rebound damping Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Apply grease in oil seal wall. Oil seal Compression damping Oil level (oil amount) Spring Turn adjuster clockwise (about 2 clicks) to increase damping. Increase oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in). Replace with stiff spring. Stiff toward stroke end Oil level (oil amount) Decrease oil level by about 5 mm (0.2 in). Soft toward stroke end, bottoming out Oil level (oil amount) Increase oil level by about 5 mm (0.2 in). Stiff initial movement Compression damping Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Soft over entire range, bottoming out Compression damping Rebound damping Low front, tending to lower front posture Balance with rear end Oil level (oil amount) Compression damping “Obtrusive” front, tending to upper front posture Balance with rear end Spring Oil lever (oil amount)

4 - 39

Turn adjuster clockwise (about 2 clicks) to increase damping. Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Set sunken length for 95 ~ 100 mm (3.7 ~ 3.9 in) when one passenger is astride seat (lower rear posture). Increase oil level by about 5 mm (0.2 in). Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Set sunken length for 90 ~ 95 mm (3.5 ~ 3.7 in) when one passenger is astride seat (upper rear posture). Replace with soft spring. Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in). SETTING TUN

• Rear shock absorber NOTE:
• If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart.
• Adjust the rebound damping in 2-click increments or decrements.
• Adjust the low compression damping in 1-click increments or decrements.
• Adjust the high compression damping in 1/6 turn increments or decrements. Section Symptom Jump Check Large Medium Small gap gap gap Rebound damping Stiff, tending to sink Spring set length Rebound damping Spongy and unstable Low compression damping Spring Rebound damping Heavy and dragging Spring Rebound damping Poor road gripping Low compression damping High compression damping Spring set length Spring Bottoming out High compression damping Spring set length Spring Rebound damping Bouncing Spring Stiff travel High compression damping Spring set length Spring

4 - 40

Adjust Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when one passenger is astride seat. Turn adjuster clockwise (about 2 clicks) to increase damping. Turn adjuster clockwise (about 1 click) to increase damping. Replace with stiff spring. Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Replace with soft spring. Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Turn adjuster clockwise (about 1 clicks) to increase damping. Turn adjuster clockwise (about 1/6 clicks) to increase damping. Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when one passenger is astride seat. Replace with soft spring. Turn adjuster clockwise (about 1/6 turn) to increase damping. Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when one passenger in astride seat. Replace with stiff spring. Turn adjuster clockwise (about 2 clicks) to increase damping. Replace with soft spring. Turn adjuster counterclockwise (about 1/6 turn) to decrease damping. Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when one passenger is astride seat. Replace with soft spring. REGLAGE TUN NOTE: This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are requested not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical damage. EC450001 RADIATOR 1 Radiator removal Extent of removal: Extent of removal ENG Order Part name Q’ty Remarks RADIATOR REMOVAL Preparation for removal

Drain the coolant. Refer to “COOLANT REPLACEMENT” section in the

CHAPTER 3.

Seat, fuel tank and left side cover Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 3.

Catch tank breather hose

5-1 Only loosening. RADIATEUR KÜHLER MOTEUR ENG RADIATEUR HANDLING NOTE WARNING ENG Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radiator cap by the following procedure: Place a thick rag, like a towel, over the radiator cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it. EC454000 INSPECTION EC444100 Radiator

1. Inspect:

• Radiator core 1 Obstruction → Blow out with compressed air through rear of the radiator. Bent fin → Repair/replace. EC455000

ASSEMBLY AND INSTALLATION

1. Install:

• Bolt (radiator pipe) 3 NOTE: Apply the lithium soap base grease on the O-ring. 5-5 Install:
• Radiator hose 4 6 To right radiator 7.

• Bolt (right radiator) 2

• Bolt (left radiator) 2

• Catcher tank breather hose 5 Refer to “CABLE ROUTING DIAGRAM” section in the

CHAPTER 2.

• Radiator guard 1 NOTE: First fit the inner hook portion a and then the outer one b onto the radiator.

• Radiator hose 1 3 Refer to “CABLE ROUTING DIAGRAM” section in the

CHAPTER 2.

• Radiator hose clamp 4

• Radiator hose 5 3 Refer to “CABLE ROUTING DIAGRAM” section in the

CHAPTER 2.

Extent of removal: Extent of removal Order Part name Q’ty Remarks CARBURETOR REMOVAL Preparation for removal

Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 3. Rear shock absorber Refer to “REAR SHOCK ABSORBER” section in the

CHAPTER 6.

Throttle position sensor lead coupler

Throttle cable cover

Clamp (air filter joint)

Loosen the screw (air filter joint).

Clamp (carburetor joint)

Loosen the screws (carburetor joint).

5-9 CARBURATEUR VERGASER ENG Extent of removal: Extent of removal Order Part name Q’ty CARBURETOR DISASSEMBLY

Carburetor breather hose

Valve lever housing cover

Screw (throttle shaft)

Accelerator pump cover

Diaphragm (accelerator pump)

Spring (air cut valve)

Diaphragm (air cut valve)

5 - 13

Remarks CARBURATEUR VERGASER ENG Extent of removal

Order Part name Q’ty

Throttle shaft assembly

Cold starter plunger

5 - 17

ENG Remarks Pull the push rod. CARBURATEUR VERGASER CARBURETOR CARBURATEUR HANDLING NOTE ENG Do not loosen the screws (throttle position sensor) 1 except when changing the throttle position sensor due to failure because it will cause a drop in engine performance. INSPECTION Carburetor

1. Inspect:

• Carburetor body Contamination → Clean. NOTE:
• Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air.
• Never use a wire. Inspect:
• Main air jet 7 Damage → Replace. Contamination → Clean. NOTE:
• Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air.
• Never use a wire. Needle valve

1. Inspect:

• Valve seat 2 Grooved wear a → Replace. Dust b → Clean.
• Filter c Clogged → Clean. CARBURETOR CARBURATEUR EC464301 ENG Throttle valve

1. Check:

• Free movement Stick → Repair or replace. NOTE: Insert the throttle valve 1 into the carburetor body, and check for free movement. Jet needle

1. Inspect:

• Jet needle 1 Bends/wear → Replace.
• Clip groove Free play exists/wear → Replace. Float height

1. Measure:

• Float height a Out of specification → Adjust. Float height:

8.0 mm (0.31 in)

Measurement and adjustment steps:

• Hold the carburetor in an upside down position. NOTE:
• Slowly tilt the carburetor in the opposite direction, then take the measurement when the needle valve aligns with the float arm.
• If the carburetor is level, the weight of the float will push in the needle valve, resulting in an incorrect measurement.

5 - 23

• Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers. NOTE: The float arm should be resting on the needle valve, but not compressing the needle valve.

• If the float height is not within specification, inspect the valve seat and needle valve.
• If either is worn, replace them both.
• If both are fine, adjust the float height by bending the float tab b on the float.
• Recheck the float height. EC464600 Float

1. Inspect:

• Float 1 Damage → Replace. Starter plunger

1. Inspect:

• Cold starter plunger 1
• Hot starter plunger 2 Wear/damage → Replace. Accelerator pump

1. Inspect:

• Diaphragm (accelerator pump) 1
• Spring (accelerator pump) 2
• Accelerator pump cover 3
• Push rod 5 Tears (diaphragm)/damage → Replace. Dirt → Clean. CARBURETOR CARBURATEUR

1. Inspect:

• Diaphragm (air cut valve) 1
• Spring (air cut valve) 2
• Air cut valve cover 3
• O-ring 4 Tears (diaphragm)/damage → Replace.

• Spring 2 6 Dirt → Clean.

ASSEMBLY AND INSTALLATION

1. Install:

• Cold starter plunger 1

• Lever 1 2 To lever 2 3.

NOTE: Make sure the spring 1 fits on the stopper a of the lever 2. Install:

• Spring 2 1 To lever 2 2.

NOTE: Make sure the stopper a of the spring 2 fits into the recess b in the carburetor.

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• Spring 1 To throttle shaft 2.

NOTE: Install the bigger hook a of the spring fits on the stopper b of the throttle shaft pulley. NOTE:

• Apply the fluorochemical grease on the bearings.
• Fit the projection a on the throttle shaft assembly into the slot b in the throttle position sensor.
• Make sure the stopper c of the spring fits into the recess in the carburetor.
• Turn the throttle shaft assembly left while holding down the lever 1 5 and fit the throttle stop screw tip d to the stopper e of the throttle shaft assembly pulley. NOTE: While holding down the lever 1 2, insert the push rod farthest into the carburetor.

10. Install:

11. Install:

• After installing the needle valve to the float, install them to the carburetor.
• Check the float for smooth movement.

12. Install:

• Bolt (float chamber) 3
• Cable holder (throttle stop screw cable) 4
• Hose holder (carburetor breather hose) 5

13. Install:

• Diaphragm (air cut valve) 1
• Spring (air cut valve) 2
• Air cut valve cover 4
• Holder (cylinder head breather hose) 5
• Screw (air cut valve cover) 6

14. Install:

• Diaphragm (accelerator pump) 1
• Accelerator pump cover 4
• Hose holder (drain hose) 5
• Screw (accelerator pump cover) 6 NOTE: Install the diaphragm (accelerator pump) with its mark a facing the spring.

15. Install:

• Throttle valve plate 5 To throttle valve 6.

16. Install:

• Throttle valve assembly 1
• Screw (throttle shaft) 2 NOTE: Install the valve lever rollers 3 into the slits a of the throttle valve.

17. Install:

• Valve lever housing cover 2
• Bolt (valve lever housing cover) 3

18. Install:

• Carburetor breather hose 1 NOTE: Install the carburetor breather hoses to the carburetor so that the hoses do not bend near where they are installed. Accelerator pump timing adjustment NOTE: In order for the throttle valve height a to achieve the specified value, tuck under the throttle valve plate 1 the rod 2 etc. with the same outer diameter as the specified value. Throttle valve height:

0.8 mm (0.03 in)

• Fully turn in the accelerator pump adjusting screw 3.
• Check that the link lever 4 has free play b by pushing lightly on it.
• Gradually turn out the adjusting screw while moving the link lever until it has no more free play.

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CARBURETOR CARBURATEUR Carburetor installation

1. Install:

• Carburetor joint 1 NOTE: Install the projection a between the carburetor joint slots. Install:
• Hot starter plunger 1

• Bolt (carburetor joint) 1

• Bolt (air filter joint) 2

• Throttle cable (return) 2 Adjust:
• Throttle grip free play Refer to “THROTTLE CABLE ADJUSTMENT” section in the

CHAPTER 3.

• Throttle cable cover 1
• Bolt (throttle cable cover) 2

• Throttle position sensor lead coupler 1
• Clamp 2 Refer to “CABLE ROUTING DIAGRAM” section in the

CHAPTER 2.

• Clamp 1 Refer to “CABLE ROUTING DIAGRAM” section in the

CHAPTER 2.

1 Air induction system removal Extent of removal: Extent of removal Order Part name Q’ty

AIR INDUCTION SYSTEM REMOVAL

Air cut-off valve assembly

Air induction hose (air cut-off valve - front of cylinder head)

Air induction hose (air cut-off valve - rear of cylinder head)

Air induction hose (air cut-off valve - air filter case)

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Remarks INSPECTION Air induction system

1. Inspect:

• Air induction hose Crack/damage → Replace.
• Air induction pipe Crack/damage → Replace. Check:
• Operation of air cut valve Pass air through the pipe and check the air cut valve for operation. Does not meet the following condition → Replace the air cut valve assembly. a to b Air passes. b to a Air does not pass. a to b Air does not pass when specified pressure is on c.

• Blow in air to check for operation.
• When using vacuum, check by the use of the vacuum/pressure pump gauge set 1. Vacuum/pressure pump gauge set: YB-35956-A/ 90890-06756 Vacuum specifying pressure:

46.7 ~ 86.7 kPa

13.8 ~ 25.6 inHg)

CAUTION: When using vacuum on the pipe c, take care not to exceed the specified value. a From air filter b To cylinder head (exhaust port) c From cylinder head (intake port) È Check for induction from air filter. É Check for prevention of backflow into air filter. Ê Check for prevention of afterburn. (When throttle is closed at sudden deceleration)

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1 Cylinder head cover removal Extent of removal: Extent of removal Order Part name Q’ty Remarks

CYLINDER HEAD COVER REMOVAL

Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 3. Air cut-off valve assembly

Refer to “AIR INDUCTION SYSTEM” section.

Cylinder head breather hose

Bolt (cylinder head cover)

Cylinder head cover gasket

Timing chain guide (top side)

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Extent of removal: Extent of removal Order Part name Q’ty Remarks CAMSHAFTS REMOVAL

Timing mark accessing screw

Crankshaft end accessing screw

Timing chain tensioner cap bolt

Timing chain tensioner

5 - 49

Refer to “REMOVAL POINTS”.

DEPOSE DES ARBRES A CAMES

REMOVAL POINTS Camshaft

1. Remove:

• Timing mark accessing screw

• Crankshaft end accessing screw 2 Checking steps:
• Turn the crankshaft counterclockwise with a wrench.
• Align the T.D.C. mark a on the rotor with the align mark b on the crankcase cover when piston is at T.D.C. on compression stroke. NOTE: In order to be sure that the piston is at Top Dead Center, the punch mark c on the exhaust camshaft and the punch mark d on the intake camshaft must align with the cylinder head surface, as shown in the illustration. Remove:
• Timing chain tensioner cap bolt 1
• Timing chain tensioner 2

• Bolt (camshaft cap) 1

NOTE: Remove the bolts (camshaft cap) in a crisscross pattern, working from the outside in. CAUTION: The bolts (camshaft cap) must be removed evenly to prevent damage to the cylinder head, camshafts or camshaft caps.

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ENG NOTE: Attach a wire 3 to the timing chain to prevent it from falling into the crankcase. INSPECTION Camshaft

1. Inspect:

• Cam lobe Pitting/scratches/blue discoloration → Replace.

2. Measure:

• Cam lobe length a and b Out of specification → Replace. Measure:
• Runout (camshaft) Out of specification → Replace. Runout (camshaft): Less than 0.03 mm (0.0012 in)

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• Camshaft-to-cap clearance Out of specification → Measure camshaft outside diameter.

Camshaft-to-cap clearance:

0.028 ~ 0.062 mm

(0.0011 ~ 0.0024 in) <Limit>:

0.08 mm (0.003 in)

• Install the camshaft onto the cylinder head.
• Position a strip of Plastigauge® 1 onto the camshaft.
• Install the clip, dowel pins and camshaft caps. Camshaft sprocket

1. Inspect:

• Camshaft sprocket 1 Wear/damage → Replace the camshaft assembly and timing chain as a set.

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• Camshaft outside diameter a Out of specification → Replace the camshaft. Within specification → Replace camshaft case and camshaft caps as a set.

• Remove the camshaft caps and measure the width of the Plastigauge® 1.

• Tighten the bolts (camshaft cap) in a crisscross pattern from innermost to outer caps.
• Do not turn the camshaft when measuring clearance with the Plastigauge®. ENG CAMSHAFTS

ARBRES A CAMES

Decompression system

1. Check:

• Decompression system ENG Checking steps:
• Check that the decompression mechanism cam 1 moves smoothly.
• Check that the decompression mechanism cam lever pin 2 projects from the camshaft. Timing chain tensioner

1. Check:

• While pressing the tensioner rod lightly with fingers, use a thin screwdriver 1 and wind the tensioner rod up fully clockwise.
• When releasing the screwdriver by pressing lightly with fingers, make sure that the tensioner rod will come out smoothly.
• If not, replace the tensioner assembly.

ASSEMBLY AND INSTALLATION

1. Install:

• Intake camshaft 2 Installation steps:
• Turn the crankshaft counterclockwise with a wrench. NOTE:
• Apply the molybdenum disulfide oil on the camshafts.
• Apply the engine oil on the decompression system.
• Squeezing the decompression lever allows the crankshaft to be turned easily.
• Align the T.D.C. mark a on the rotor with the align mark b on the crankcase cover when piston is at T.D.C. on compression stroke.

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• Fit the timing chain 3 onto both camshaft sprockets and install the camshafts on the cylinder head. NOTE: The camshafts should be installed onto the cylinder head so that the punch mark c on the exhaust camshaft and the punch mark d on the intake camshaft must align with the cylinder head surface, as shown in the illustration. CAUTION: Do not turn the crankshaft during the camshaft installation. Damage or improper valve timing will result.
• Install the clips, camshaft caps 4 and bolts (camshaft cap) 5.

The bolts (camshaft cap) must be tightened evenly, or damage to the cylinder head, camshaft caps, and camshaft will result. NOTE:

• Before removing the clips, cover the cylinder head with a clean rag to prevent the clips from into the cylinder head cavity.
• Apply the molybdenum disulfide oil on the thread of the bolts (camshaft cap).
• Tighten the bolts to the specified torque in two or three steps in the proper tightening sequence as shown. ATTENTION: Install:
• Timing chain tensioner Installation steps:
• While pressing the tensioner rod lightly with fingers, use a thin screwdriver and wind the tensioner rod up fully clockwise.

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ARBRES A CAMES

• With the rod fully wound and the chain tensioner UP mark a facing upward, install the gasket 1 and the timing chain tensioner 2, and tighten the bolt 3 to the specified torque.

• Release the screwdriver, check the tensioner rod to come out and tighten the gasket 4 and the cap bolt 5 to the specified torque. Turn:
• Crankshaft Counterclockwise several turns. Check:
• Rotor T.D.C. mark Align with the crankcase align mark.
• Camshaft match marks Align with the cylinder head surface. Out of alignment → Adjust.

• Timing mark accessing screw

• Crankshaft end accessing screw 2

• Timing chain guide (top side)

• Cylinder head cover gasket 2
• Cylinder head cover 3
• Bolt (cylinder head cover) 4

YAMAHA Bond No. 1215 (ThreeBond® No. 1215): 90890-85505

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NOTE: Apply the sealant on the cylinder head cover gasket.

• Cylinder head breather hose

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1 Cylinder head removal Extent of removal: Extent of removal Order Part name Q’ty Remarks

CYLINDER HEAD REMOVAL

Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 3. Exhaust pipe and silencer Refer to “EXHAUST PIPE AND SILENCER” section in the CHAPTER 3. Radiator hose 1 Disconnect at cylinder head side. Carburetor Refer to “CARBURETOR” section. Air cut-off valve assembly Refer to “AIR INDUCTION SYSTEM” section. Camshaft Refer to “CAMSHAFTS” section. Upper engine bracket

Refer to “ENGINE REMOVAL” section. Radiator pipe

Bolt [L=135 mm (5.31 in)]

Bolt [L=145 mm (5.71 in)]

Timing chain guide (exhaust side)

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CULASSE ZYLINDERKOPF ENG Boulon [L=135 mm (5,31 in)]

Boulon [L=145 mm (5,71 in)]

Bullone [L=135 mm (5,31 in)]

Bullone [L=145 mm (5,71 in)]

CYLINDER HEAD CULASSE INSPECTION Cylinder head

1. Eliminate:

• Carbon deposits (from the combustion chambers) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damaging or scratching:

• Cylinder head Scratches/damage → Replace.

• Cylinder head warpage Out of specification → Resurface. Cylinder head warpage: Less than 0.05 mm (0.002 in) Warpage measurement and resurfacing steps:
• Place a straightedge and a feeler gauge across the cylinder head.
• Use a feeler gauge to measure the warpage.
• If the warpage is out of specification, resurface the cylinder head.
• Place a 400 ~ 600 grit wet sandpaper on the surface plate, and resurface the head using a figure-eight sanding pattern. NOTE: To ensure an even surface rotate the cylinder head several times.

ASSEMBLY AND INSTALLATION

1. Install:

• Cylinder head gasket 2 New

• Timing chain guide (exhaust side) 3
• Cylinder head 4 NOTE: While pulling up the timing chain, install the timing chain guide (exhaust side) and cylinder head.

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• Bolts [L=145 mm (5.71 in)] 3

• Boulons [L=135 mm (5,31 in)] 4

• Bolts [L=135 mm (5.31 in)] 4

• Apply the molybdenum disulfide grease on the thread and contact surface of the bolts.
• Follow the numerical order shown in the illustration. Tighten the bolts and nuts in two stages. Install:
• Union bolt (M8) 3 New

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• Bolt (radiator pipe) 2

• Bulloni [L=135 mm (5,31 in)] 4

VALVES AND VALVE SPRINGS

VALVES AND VALVE SPRINGS

1 Valve removal Extent of removal: Extent of removal Order Part name Q’ty Remarks

VALVES AND VALVE SPRINGS

REMOVAL Preparation for removal

Cylinder head Refer to “CYLINDER HEAD” section.

Valve spring retainer

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Use special tool. Refer to “REMOVAL POINTS”.

VALVES AND VALVE SPRINGS

SOUPAPES ET RESSORTS DE SOUPAPES

REMOVAL POINTS Valve lifter and valve cotter

1. Remove:

• Pad 2 NOTE: Identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place.

• Valve sealing Leakage at the valve seat → Inspect the valve face, valve seat and valve seat width. Checking steps:
• Pour a clean solvent 1 into the intake and exhaust ports.
• Check that the valve seals properly. There should be no leakage at the valve seat 2.

• Valve cotter NOTE: Attach a valve spring compressor 1 between the valve spring retainer and the cylinder head to remove the valve cotters. Valve spring compressor: YM-4019/90890-04019

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VALVES AND VALVE SPRINGS

SOUPAPES ET RESSORTS DE SOUPAPES

1. Measure:

• Stem-to-guide clearance Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b Out of specification → Replace the valve guide. NOTE: To ease guide removal, installation and to maintain correct fit heat the cylinder head in an over to 100 °C (212 °F).

• Remove the valve guide using a valve guide remover 1.
• Install the new valve guide using a valve guide remover 1 and valve guide installer 2.
• After installing the valve guide, bore the valve guide using a valve guide reamer 3 to obtain proper stem-to-guide clearance.

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VALVES AND VALVE SPRINGS

SOUPAPES ET RESSORTS DE SOUPAPES

NOTE: After replacing the valve guide reface the valve seat.

• Valve face Pitting/wear → Grind the face.
• Valve stem end Mushroom shape or diameter larger than the body of the stem → Replace.

• Margin thickness a Out of specification → Replace.

Margin thickness: Intake:

0.8 mm (0.0315 in)

0.7 mm (0.0276 in)

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VALVES AND VALVE SPRINGS

SOUPAPES ET RESSORTS DE SOUPAPES

• Runout (valve stem) Out of specification → Replace.

0.01 mm (0.0004 in)

• When installing a new valve always replace the guide.
• If the valve is removed or replaced always replace the oil seal.

• Carbon deposits (from the valve face and valve seat) Inspect:
• Valve seat Pitting/wear → Reface the valve seat. Measure:
• Valve seat width a Out of specification → Reface the valve seat. Valve seat width: Intake:

0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in) <Limit>:

1.6 mm (0.0630 in)

0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in) <Limit>:

1.6 mm (0.0630 in)

• Apply Mechanic’s blueing dye (Dykem) b to the valve face.
• Install the valve into the cylinder head.
• Press the valve through the valve guide and onto the valve seat to make a clear pattern.
• Measure the valve seat width. Where the valve seat and valve face made contact, blueing will have been removed.
• If the valve seat is too wide, too narrow, or the seat is not centered, the valve seat must be refaced.

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VALVES AND VALVE SPRINGS

SOUPAPES ET RESSORTS DE SOUPAPES

ENG NOTE: After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. Lapping steps:

• Apply a coarse lapping compound to the valve face. Do not let the compound enter the gap between the valve stem and the guide.

• Apply molybdenum disulfide oil to the valve stem.
• Install the valve into the cylinder head.
• Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the compound. NOTE: For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands.
• Apply a fine lapping compound to the valve face and repeat the above steps. NOTE: After every lapping operation be sure to clean off all of the compound from the valve face and valve seat.
• Apply Mechanic’s blueing dye (Dykem) to the valve face.
• Install the valve into the cylinder head.
• Press the valve through the valve guide and onto the valve seat to make a clear pattern.
• Measure the valve seat width again. If the valve seat width is out of specification, reface and relap the valve seat.

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VALVES AND VALVE SPRINGS

SOUPAPES ET RESSORTS DE SOUPAPES

1. Measure:

• Valve spring free length a Out of specification → Replace. Measure:
• Compressed spring force a Out of specification → Replace. b Installed length Measure:
• Spring tilt a Out of specification → Replace. Spring tilt limit: Intake: 2.5°/1.6 mm (0.063 in) Exhaust: 2.5°/1.6 mm (0.063 in) Valve lifter

1. Inspect:

• Valve lifter Scratches/damage → Replace both lifters and cylinder head.

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Compressed spring force: Intake: 103 ~ 118 N at

29.13 mm

(10.50 ~ 12.09 kg at

29.13 mm,

23.15 ~ 26.66 lb at

1.15 in)

Exhaust: 126 ~ 144 N at

29.30 mm

(12.85 ~ 14.68 kg at

29.30 mm,

28.32 ~ 32.37 lb at

1.15 in)

VALVES AND VALVE SPRINGS

SOUPAPES ET RESSORTS DE SOUPAPES

ASSEMBLY AND INSTALLATION

Valve and valve spring

1. Apply:

• Molybdenum disulfide oil Onto the valve stem and valve stem seal. Install:
• Valve stem seal 3 New
• Valve spring retainer 5 To cylinder head. NOTE:
• Make sure that each valve is installed in its original place, also referring to the painted color as follows. Intake (middle) a: Orange Intake (right/left) b: Green Exhaust: no paint
• Install the valve springs with the larger pitch c facing upward. d Smaller pitch NOTE: While compressing the valve spring with a valve spring compressor 1 install the valve cotters. Valve spring compressor: YM-4019/90890-04019

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VALVES AND VALVE SPRINGS

SOUPAPES ET RESSORTS DE SOUPAPES

To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood.

ENG CAUTION: Hitting the valve tip with excessive force could damage the valve.

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

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CYLINDER AND PISTON

CYLINDER AND PISTON

1 Cylinder removal Extent of removal: Extent of removal Order 2 Piston removal Part name Q’ty Remarks

CYLINDER AND PISTON REMOVAL

Preparation for removal

Cylinder head Refer to “CYLINDER HEAD” section.

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Use special tool. Refer to “REMOVAL POINTS”. REMOVAL POINTS Piston and piston ring

1. Remove:

• Put identification marks on each piston head for reference during reinstallation.
• Before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller set 4. CAUTION: Do not use a hammer to drive the piston pin out. Remove:

NOTE: Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown, as shown in the illustration. INSPECTION Cylinder and piston

1. Inspect:

• Cylinder and piston walls Vertical scratches → Replace cylinder and piston.

2. Measure:

• Piston-to-cylinder clearance Measurement steps: 1st step:
• Measure the cylinder bore “C” with a cylinder bore gauge. NOTE: Measure the cylinder bore “C” in parallel to and at right angles to the crankshaft. Then, find the average of the measurements.

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Cylinder bore “C” Taper limit “T”

0.05 mm (0.002 in)

0.05 mm (0.002 in)

Ovalisation “R” 0,05 mm (0,002 in) “C” = Maximum D “C” = Maximum D “T” = (Maximum D1 or D2) – (Maximum D5 or D6) “R” = (Maximum D1, D3 or D5) – (Minimum D2, D4 or D6)

• If out of specification, replace the cylinder, and replace the piston and piston rings as set. 2nd step:
• Measure the piston skirt diameter “P” with a micrometer. a 8 mm (0.31 in) from the piston bottom edge Piston size “P” Standard

• If out of specification, replace the piston and piston rings as a set. 3rd step:
• Calculate the piston-to-cylinder clearance with following formula: Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance:

0.030 ~ 0.055 mm

(0.0012 ~ 0.0022 in) <Limit>:

0.1 mm (0.004 in)

• If out of specification, replace the cylinder, and replace the piston and piston rings as set.

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Zylinderboh rung “C”

CYLINDER AND PISTON

CYLINDRE ET PISTON

1. Measure:

• Ring side clearance Use a feeler gauge 1. Out of specification → Replace the piston and rings as a set. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance. ENG Side clearance: Standard Top ring Position:
• Piston ring (in cylinder) Standard <Limite> Segment de feu NOTE: Insert a ring into the cylinder and push it approximately 10 mm (0.39 in) into the cylinder. Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore. Measure:
• Ring end gap Out of specification → Replace. NOTE: You cannot measure the end gap on the expander spacer of the oil control ring. If the oil control ring rails show excessive gap, replace all three rings.

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1. Inspect:

• Piston pin Blue discoloration/grooves → Replace, then inspect the lubrication system.

2. Measure:

• Piston pin-to-piston clearance Measurement steps:
• Measure the outside diameter (piston pin) a. If out of specification, replace the piston pin. Outside diameter (piston pin):

15.991 ~ 16.000 mm

(0.6296 ~ 0.6299 in)

• Measure the inside diameter (piston) b. Inside diameter (piston):

16.002 ~ 16.013 mm

(0.6300 ~ 0.6304 in)

• Calculate the piston pin-to-piston clearance with the following formula. Piston pin-to-piston clearance = Inside diameter (piston) b – Outside diameter (piston pin)

• If out of specification, replace the piston. Piston pin-to-piston clearance:

0.002 ~ 0.022 mm

(0.0001 ~ 0.0009 in) <Limit>:

0.07 mm (0.003 in)

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ASSEMBLY AND INSTALLATION

Piston ring and piston

1. Install:

• Piston ring Onto the piston. NOTE:
• Be sure to install the piston rings so that the manufacturer’s marks or numbers are located on the upper side of the rings.
• Lubricate the piston and piston rings liberally with engine oil. Position:
• Oil ring Offset the piston ring end gaps as shown. Top ring end 2nd ring end Oil ring end (upper) Oil ring Oil ring end (lower) NOTE:
• Apply engine oil onto the piston pin and piston.
• Be sure that the arrow mark a on the piston points to the exhaust side of the engine.
• Before installing the piston pin clip, cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase.
• Install the piston pin clips with their ends facing downward.

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1. Lubricate:

• Cylinder NOTE: Apply a liberal coating of engine oil. Install:
• O-ring 2 New NOTE: Apply the lithium soap base grease on the O-ring. NOTE: Install the cylinder with one hand while compressing the piston rings with the other hand. CAUTION: New

• Pass the timing chain 3 through the timing chain cavity.
• Be careful not to damage the timing chain guide 4 during installation.

1 Push rod 1, 2 and push lever shaft removal 3 Friction plate and clutch plate removal Extent of removal: Extent of removal Order Part name 2 Push rod 1 disassembly 4 Primary driven gear removal Q’ty Remarks CLUTCH REMOVAL Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Brake pedal Refer to “ENGINE REMOVAL” section. Clutch cable

Disconnect at engine side. Clutch cover

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EMBRAYAGE KUPPLUNG ENG Extent of removal

Order Part name Q’ty Friction plate ENG Remarks

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Use special tool. Refer to “REMOVAL POINTS”. EMBRAYAGE KUPPLUNG REMOVAL POINTS Clutch boss

1. Remove:

NOTE: Straighten the lock washer tab and use the clutch holding tool 4 to hold the clutch boss. Clutch holding tool: YM-91042/90890-04086 È For USA and CDN É Except for USA and CDN EC4A4000 INSPECTION EC484100 Clutch housing and boss

1. Inspect:

• Clutch housing 1 Cracks/wear/damage → Replace.
• Clutch boss 2 Scoring/wear/damage → Replace. EC484201 Primary driven gear

1. Check:

• Circumferential play Free play exists → Replace.
• Gear teeth a Wear/damage → Replace. Clutch spring

1. Measure:

• Clutch spring free length a Out of specification → Replace springs as a set. Clutch spring free length:

37.0 mm (1.46 in)

36.0 mm (1.42 in)

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ENG CLUTCH EMBRAYAGE Friction plate

1. Measure:

• Friction plate thickness Out of specification → Replace friction plate as a set. Measure at all four points. Friction plate thickness:

2.9 ~ 3.1 mm

(0.114 ~ 0.122 in) <Limit>:

2.7 mm (0.106 in)

EC484600 Clutch plate

1. Measure:

• Clutch plate warpage Out of specification → Replace clutch plate as a set. Use a surface plate 1 and thickness gauge 2. Warp limit:

0.1 mm (0.004 in)

ENG Push lever shaft

1. Inspect:

• Push lever shaft 1 Wear/damage → Replace. Push rod

1. Inspect:

• Ball 5 Wear/damage/bend → Replace.

ASSEMBLY AND INSTALLATION

1. Install:

• Bolt (push lever shaft) 2

• Apply the lithium soap base grease on the oil seal lip.
• Apply the engine oil on the push lever shaft.
• Fit the seat plate 3 in the groove a of the push lever shaft and tighten the bolt (seat plate). Clutch

1. Install:

• Primary driven gear 1
• Clutch boss 3 NOTE: Apply the engine oil on the primary driven gear inner circumference.

• Nut (clutch boss) 2 Clutch holding tool: YM-91042/90890-04086

NOTE: Use the clutch holding tool 3 to hold the clutch boss.

ENG È For USA and CDN É Except for USA and CDN Bend the lock washer 1 tab.

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• Install the seat plate with its chamfered portion a facing the clutch boss 3.
• Install the seat plate so that it is not caught on the step b.
• Install the cushion spring with the paint c facing out. Install:
• Clutch plate 2 4 NOTE:
• Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate.
• Use the friction plates 1 for the first and final while paying attention to the difference in surface pattern.
• Apply the engine oil on the friction plates and clutch plates.
• Unlike the clutch plate 2, the clutch plate 1 has no surface gloss. Use the clutch plate 1 for the first while paying attention to the difference in surface gloss. Install:
• Circlip 3 New To push rod 1 4. NOTE: Apply the engine oil on the bearing and washer. NOTE: Apply the engine oil on the push rod 1, 2 and ball.

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• Bolt (clutch spring) 2

NOTE: Tighten the bolts in stage, using a crisscross pattern.

10. Install:

• Gasket (clutch cover) 2

11. Install:

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NOTE: Tighten the bolts in stage, using a crisscross pattern.

1 Oil filter element removal 3 Right crankcase cover removal Extent of removal: Extent of removal Order Part name 2 Water pump removal Q’ty Remarks

OIL FILTER ELEMENT, WATER PUMP

AND RIGHT CRANKCASE COVER

REMOVAL Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Drain the coolant. Refer to “COOLANT REPLACEMENT” section in the

CHAPTER 3.

Radiator hose 3 Disconnect at water pump side. Exhaust pipe Refer to “EXHAUST PIPE AND SILENCER” section in the CHAPTER 3. Brake pedal Refer to “ENGINE REMOVAL” section. Engine guard

Oil filter element cover

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Extent of removal Order

Part name Q’ty Water pump housing ENG Remarks

Right crankcase cover

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Refer to “REMOVAL POINTS”. NOTE: Hold the impeller shaft on its width across the flats a with spanners, etc. and remove the impeller. Oil seal NOTE: It is not necessary to disassemble the water pump, unless there is an abnormality such as excessive change in coolant level, discoloration of coolant, or milky transmission oil.

• Oil seal 1 INSPECTION Oil delivery pipe

1. Inspect:

• Oil delivery pipe 1 Bend/damage → Replace. Clogged → Blow. Impeller shaft

1. Inspect:

• Impeller shaft 1 Bend/wear/damage → Replace. Fur deposits → Clean.

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1. Inspect:

• Gear teeth a Wear/damage → Replace. EC4H4600 Bearing

1. Inspect:

• Bearing Rotate inner race with a finger. Rough spot/seizure Replace. EC444400 ENG Oil seal

1. Inspect:

• Oil seal 1 Wear/damage → Replace.

ASSEMBLY AND INSTALLATION

1. Install:

• Oil seal 1 New NOTE:
• Apply the lithium soap base grease on the oil seal lip.
• Install the oil seal with its manufacture’s marks or numbers facing the right crankcase cover 2. NOTE: Install the bearing by pressing its outer race parallel.

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• Take care so that the oil seal lip is not damaged or the spring does not slip off its position.
• When installing the impeller shaft, apply the lithium soap base grease on the oil seal lip and impeller shaft. And install the shaft while turning it.
• Hold the impeller shaft on its width across the flats a with spanners, etc. and install the impeller. Right crankcase cover

1. Install:

• Gasket 4 New NOTE: Apply the lithium soap base grease on the O-ring. Install:
• Right crankcase cover 1
• Bolt (right crankcase cover) 2

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• Apply the engine oil on the impeller shaft end.
• Mesh the impeller shaft gear 3 with primary drive gear 4.
• Tighten the bolts in stage, using a crisscross pattern.

NOTE: Install so that there is a clearance a of 13 mm (0.51 in) or more between the kick starter and frame and that the kick starter does not contact the crankcase cover when it is pulled. Install:

1. Install:

• O-ring 2 New NOTE: Apply the lithium soap base grease on the O-ring. Install:
• Water pump housing 1
• Bolt (water pump housing) 2

1. Install:

• Oil filter element 1
• Oil filter element cover 3
• Bolt (oil filter element cover)

NOTE: Apply the lithium soap base grease on the O-ring. New 1 Balancer shaft drive gear Extent of removal: Extent of removal Order Part name BALANCER REMOVAL Preparation for removal

Primary driven gear Refer to “CLUTCH” section. Right crankcase cover Refer to “OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER” section. Stator Refer to “AC MAGNETO AND STARTER CLUTCH” section.

Nut (primary drive gear)

Nut (balancer shaft driven gear)

Balancer shaft drive gear

Balancer shaft driven gear

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Refer to “REMOVAL POINTS”. Refer to “REMOVAL POINTS”. BALANCIER AUSGLEICHSWELLE ENG BALANCER BALANCIER REMOVAL POINTS Balancer shaft drive gear and balancer shaft driven gear

1. Straighten the lock washer tab.

2. Loosen:

• Nut (primary drive gear) 1
• Nut (balancer shaft driven gear) 2 NOTE: Place an aluminum plate a between the teeth of the balancer shaft drive gear 3 and driven gear 4. ENG Balancer shaft

1. Remove:

• Balancer shaft 1 NOTE: When removing the balancer shaft, align the center a of the balancer shaft weight along the line connecting the centers of the crankshaft and balancer shaft. INSPECTION Primary drive gear, balancer shaft drive gear and balancer shaft driven gear

1. Inspect:

• Primary drive gear 1
• Balancer shaft drive gear 2
• Balancer shaft driven gear 3 Wear/damage → Replace. Balancer shaft

1. Inspect:

• Balancer shaft Cracks/damage → Replace. BALANCER BALANCIER

ASSEMBLY AND INSTALLATION

Balancer shaft, balancer shaft drive gear and balancer shaft driven gear

1. Install:

• Balancer shaft 1 NOTE:
• Apply the engine oil on the bearing.
• When installing the balancer shaft, align the center a of the balancer shaft weight along the line connecting the centers of the crankshaft and balancer shaft.

• Balancer shaft driven gear 1 NOTE: Install the balancer shaft driven gear onto the balancer shaft while aligning the punch mark a on the balancer shaft driven gear with the lower spline b on the balancer shaft end.

• Balancer shaft drive gear 1 NOTE:
• Align the punched mark a on the balancer shaft drive gear with the punched mark b on the balancer shaft driven gear 2.
• Align the punched mark c on the balancer shaft drive gear with the lower spline d on the crankshaft end. Install:
• Nut (balancer shaft driven gear) 2

• Primary drive gear 3
• Nut (primary drive gear) 4

• Install the primary drive gear with its stepped side a facing the engine.
• Place an aluminum plate b between the teeth of the balancer shaft drive gear 5 and driven gear

Bend the lock washer tab.

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1 Oil pump removal Extent of removal: Extent of removal Order 2 Oil pump disassembly Part name Q’ty Remarks

OIL PUMP REMOVAL AND

DISASSEMBLY Preparation for removal

Primary driven gear Refer to “CLUTCH” section. Right crankcase cover Refer to “OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER” section.

Oil pump drive shaft

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1 Oil tank removal Extent of removal: Extent of removal Order Part name Q’ty Remarks

OIL TANK REMOVAL

Preparation for removal

Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3.

Oil tank breather hose

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1. Inspect:

• Oil pump drive gear 1
• Oil pump drive shaft 2
• Oil pump cover 4 Cracks/wear/damage → Replace. Measure:
• Tip clearance a (between the inner rotor 1 and outer rotor 2)
• Side clearance b (between the outer rotor 2 and rotor housing 3)
• Housing and rotor clearance (between the rotor housing 3 and rotors 1 2) Out of specification → Replace the oil pump assembly. Check:
• Unsmooth → Repeat steps #1 and #2 or replace the defective parts.

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RÉSERVOIR D’HUILE

ASSEMBLY AND INSTALLATION

1. Install:

• Oil pump drive shaft 1
• Inner rotor 1 4 NOTE:
• Apply the engine oil on the oil pump drive shaft and inner rotor 1.
• Fit the dowel pin into the groove in the inner rotor 1.

• Outer rotor 1 1 ENG NOTE: Apply the engine oil on the outer rotor 1. Install:
• Screw (oil pump cover) 2

• Bolt (oil pump assembly) [L = 25 mm (0.94 in)] 4 NOTE: Apply the engine oil on the outer rotor 2.

• Bolt (oil pump assembly) [L = 30 mm (1.18 in)] 5

• Apply the engine oil on the inner rotor 2.
• Fit the dowel pin into the groove in the inner rotor 2.

• Ölpumpen-Schraube [L = 30 mm (1,18 in)] 5

• Oil pump drive gear 1
• Circlip 3 New NOTE: Apply the engine oil on the oil pump drive gear inner circumference.

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KICK SHAFT AND SHIFT SHAFT

KICK SHAFT AND SHIFT SHAFT

1 Kick shaft removal 3 Shift shaft removal Extent of removal: Extent of removal Order 2 Kick shaft disassembly 4 Segment removal Part name Q’ty Remarks

KICK SHAFT AND SHIFT SHAFT

REMOVAL Preparation for removal Oil pump

Refer to “OIL PUMP” section. Kick idle gear

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Refer to “REMOVAL POINTS”.

KICK SHAFT AND SHIFT SHAFT

Extent of removal Order

Shift lever assembly

Bolt (stopper lever)

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ENG Remarks Refer to “REMOVAL POINTS”. Refer to “REMOVAL POINTS”. REMOVAL POINTS Kick shaft assembly

1. Remove:

• Kick shaft assembly 1 NOTE: Unhook the torsion spring 2 from the hole a in the crankcase. Shift guide and shift lever assembly

1. Remove:

• Shift lever assembly 2 NOTE: The shift lever assembly is disassembled at the same time as the shift guide. EC4N3100 Segment

1. Remove:

• Segment 2 NOTE: Turn the segment counterclockwise until it stops and loosen the bolt. CAUTION: If the segment gets an impact, it may be damaged. Take care not to give an impact to the segment when removing the bolt. INSPECTION Kick shaft and ratchet wheel

1. Check:

• Ratchet wheel 1 smooth movement Unsmooth movement → Replace.
• Kick shaft 2 Wear/damage → Replace.
• Spring 3 Broken → Replace. Kick gear, kick idle gear and ratchet wheel

1. Inspect:

• Ratchet teeth b Wear/damage → Replace. EC4B4400 Shift shaft

1. Inspect:

• Shift shaft 1 Bend/damage → Replace.
• Spring 2 Broken → Replace. EC4C4100 Stopper lever

1. Inspect:

• Stopper lever 1 Wear/damage → Replace.
• Torsion spring 2 Broken → Replace.

ASSEMBLY AND INSTALLATION

1. Install:

• Bolt (segment) NOTE: Align the notch a on the segment with the pin b on the shift cam. ENG If the segment gets an impact, it may be damaged. Take care not to give an impact to the segment when tightening the bolt.

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1. Install:

• Bolt (stopper lever) 3 ENG NOTE: Align the stopper lever roller with the slot on segment. NOTE: Apply the engine oil on the spring, pawl pin and pawl. NOTE:
• The shift lever assembly is installed at the same time as the shift guide.
• Apply the engine oil on the bolt (segment) shaft.

• Bolt (shift guide) 1 Shift shaft

1. Install:

• Shift shaft 4 NOTE: Apply the engine oil on the roller and shift shaft. Install:
• Shift pedal Refer to “AC MAGNETO AND STARTER CLUTCH” section. Kick shaft assembly

1. Install:

• Circlip 7 New To kick shaft 8. NOTE:
• Apply the molybdenum disulfide oil on the inner circumferences of the kick gear and ratchet wheel.
• Align the punch mark a on the ratchet wheel with the punch mark b on the kick shaft. Install:
• Torsion spring 1 To kick shaft 2. NOTE: Make sure the stopper a of the torsion spring fits into the hole b on the kick shaft. NOTE: Slide the spring guide into the kick shaft, make sure the groove a in the spring guide fits on the stopper of the torsion spring.

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• Kick shaft assembly 1

• Apply the molybdenum disulfide grease on the contacting surfaces of the kick shaft stopper a and kick shaft ratchet wheel guide 3.
• Apply the engine oil on the kick shaft.
• Slide the kick shaft assembly into the crankcase and make sure the kick shaft stopper a fits into the kick shaft ratchet wheel guide. NOTE: Turn the torsion spring clockwise and hook into the proper hole a in the crankcase. Kick idle gear

1. Install:

• Apply the engine oil on the kick idle gear inner circumference.
• Install the kick idle gear with its depressed side a toward you. 1 Starter clutch/wheel gear removal 3 Pickup coil/stator removal Extent of removal: Extent of removal Order Part name 2 Rotor removal Q’ty Remarks

AC MAGNETO AND STATOR REMOVAL

Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 3. Disconnect the AC magneto lead.

Cover (torque limiter)

Crankcase cover (left)

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Do not disassemble. Extent of removal

Order Part name Q’ty ENG Remarks

Use special tool. Refer to “REMOVAL POINTS”.

Starter clutch drive gear

Starter clutch assembly cover

Refer to “REMOVAL POINTS”. NOTE: Tighten the rotor nut to 65 Nm (6.5 m • kg, 47 ft • lb), loosen and retighten the rotor nut to 65 Nm (6.5 m • kg, 47 ft • lb).

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REMOVAL POINTS Rotor

1. Remove:

• Washer Use the sheave holder 2. Sheave holder: YS-1880-A/ 90890-01701

1. Remove:

• Starter clutch assembly cover

NOTE: Insert a thin screwdriver or the like under the convexity a and remove the starter clutch assembly cover by prying it gently to void damage to the cover. Remove:

• Starter clutch 1 NOTE: Using a thin screwdriver or the like, remove the plate a while prying it upward little by little.

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INSPECTION AC magneto

1. Inspect:

• Rotor inner surface a
• Stator outer surface b Damage → Inspect the crankshaft runout and crankshaft bearing. If necessary, replace AC magneto and/or stator. EC4L4200 Woodruff key

1. Inspect:

• Woodruff key 1 Damage → Replace. ENG Starter clutch

1. Check:

• Starter clutch Damage/wear → Replace. Check:
• Starter clutch drive gear Pitting/burrs/chips/roughness/ wear → Replace the defective parts.

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• Starter clutch operation

• Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch.
• When turning the starter clutch drive gear counterclockwise É, the starter clutch and the starter clutch drive gear should engage. If the starter clutch drive gear and starter clutch do not engage, the starter clutch is faulty and must be replaced.
• When turning the starter clutch drive gear clockwise È, it should turn freely. If the starter clutch drive gear does not turn freely, the starter clutch is faulty and must be replaced.

1. Check:

• Torque limiter Damage/wear → Replace.

ASSEMBLY AND INSTALLATION

AC magneto and starter clutch

1. Install:

• Bolt (pickup coil) 4

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• Bullone (bobina pickup) 4

NOTE: Apply the sealant to the grommet of the AC magneto lead. Pass the pickup coil lead and charging coil lead under the holder while taking care not to allow these leads to get caught with each other. Also take care to pass the leads so that they do not become loose at the bend of the holder a in order to avoid their contacting the starter clutch drive gear. YAMAHA Bond No. 1215 (ThreeBond® No. 1215): 90890-85505

• Dowel pin 2 NOTE: Apply the engine oil on the idle gear

• Bolt (idle gear plate) 2

NOTE: Apply the engine oil on the washer, bearing and starter clutch drive gear inner circumference.

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• Starter clutch drive gear 3

• Install the starter clutch with its plate side upward.
• While installing the starter clutch, push in the projections a one by one on the clutch circumference.
• Push in the starter clutch until it hits the rotor.

• Starter clutch assembly cover To rotor 2. NOTE: Install the starter clutch assembly cover by fitting its pawls a into the groove b in the rotor. Install:
• Degrease the contact surfaces of the tapered portions of the crankshaft and rotor.
• When installing the woodruff key, make sure that its flat surface a is in parallel with the crankshaft center line b.
• When installing the rotor, align the keyway c of the rotor with the woodruff key.

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NOTE: Tighten the rotor nut to 65 Nm (6.5 m • kg, 47 ft • lb), loosen and retighten the rotor nut to 65 Nm (6.5 m • kg, 47 ft • lb).

Use the sheave holder 2.

10. Install:

• Gasket [crankcase cover (left)]

NOTE: Apply the engine oil to the shaft and washers.

12. Install:

• Cover (idle gear 1) 1
• Apply the lithium soap base grease on the O-ring.
• Install the cover (idle gear 1) with its mark a facing upward.

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NOTE: Tighten the bolts in stage, using a crisscross pattern.

• Bolt [crankcase cover (left)] 3

• Crankcase cover (left) 1
• Bolt [crankcase cover (left)] 2

New Sheave holder: YS-1880-A/ 90890-01701

13. Connect:

• AC magneto lead Refer to “CABLE ROUTING DIAGRAM” section in the

CHAPTER 2.

14. Install:

• Bolt (shift pedal) NOTE: When installing the shift pedal onto the shift shaft, be sure that the center of the shift pedal is about 1.4 mm (0.06 in) a above the top of the footrest.

Extent of removal Order Part name Q’ty Remarks ENGINE REMOVAL Preparation for removal Hold the machine by placing the suitable stand under the frame. WARNING Support the machine securely so there is no danger of it falling over. Drain the engine oil Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 3. Carburetor Refer to “CARBURETOR” section. Exhaust pipe and silencer Refer to “EXHAUST PIPE AND SILENCER” section in the CHAPTER 3. Air cut-off valve assembly Refer to “AIR INDUCTION SYSTEM” section. Clutch cable Disconnect at the engine side. Radiator Refer to “RADIATOR” section. Shift pedal Refer to “AC MAGNETO AND STARTER CLUTCH” section. Cylinder head breather hose Refer to “CAMSHAFTS” section. Oil hose and oil tank breather hose Refer to “OIL PUMP” section.

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Extent of removal: Extent of removal ENG Order Part name Q’ty Remarks Ignition coil Disconnect the AC magneto lead. Starter motor lead Disconnect at the starter motor side. Negative battery lead

Disconnect at the engine side. Engine guard

Drive chain sprocket cover

Upper engine bracket

Lower engine bracket

Engine mounting bolt

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Refer to “REMOVAL POINTS”. Refer to “REMOVAL POINTS”. ENGINE REMOVAL

DEPOSE DU MOTEUR

EC4M3000 REMOVAL POINTS EC4F3100 Drive sprocket

1. Remove:

• Nut (drive sprocket) 1
• Straighten the lock washer tab.
• Loosen the nut while applying the rear brake.

NOTE: Remove the drive sprocket together with the drive chain. Engine removal

1. Remove:

• Pivot shaft 1 NOTE: If the pivot shaft is pulled all the way out, the swingarm will come loose. If possible, insert a shaft of similar diameter into the other side of the swingarm to support it.

• Engine 1 From right side. NOTE: Make sure that the couplers, hoses and cables are disconnected.

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DEPOSE DU MOTEUR

ASSEMBLY AND INSTALLATION

1. Install:

• Engine 1 Install the engine from right side.

• Engine mounting bolt (lower)

1. Install:

• Bolt (brake pedal) 4 NOTE:
• Apply the molybdenum disulfide grease on the pivot shaft.
• Install the patch with the claw a facing outside the chassis.

• Lower engine guard A
• Bolt (lower engine guard) B

• Engine mounting bolt (upper)

• Upper engine bracket 8
• Bolt (upper engine bracket) 9

• Engine mounting bolt (front) 7

• Lower engine bracket 4
• Bolt (lower engine bracket) 5 NOTE: Apply the lithium soap base grease on the bolt, O-rings and brake pedal bracket. NOTE: Install the drive sprocket together with the drive chain. ENGINE REMOVAL

DEPOSE DU MOTEUR

• Nut (drive sprocket) 2

NOTE: Tighten the nut while applying the rear brake. Bend the lock washer tab to lock the nut. Install:

• Drive chain sprocket guide 1
• Drive chain sprocket cover 2
• Screw (drive chain sprocket cover) 3

1. Install:

• Screw (neutral switch) 5

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

CRANKCASE AND CRANKSHAFT

CRANKCASE AND CRANKSHAFT

1 Crankcase separation Extent of removal: Extent of removal Order 2 Crankshaft removal Part name Q’ty Remarks

CRANKCASE AND CRANKSHAFT

REMOVAL Preparation for removal Engine Refer to “ENGINE REMOVAL” section. Piston Refer to “CYLINDER AND PISTON” section. Kick shaft assembly Refer to “KICK SHAFT AND SHIFT SHAFT” section. Segment Stator Refer to “AC MAGNETO AND STARTER CLUTCH” section. Balancer shaft

Refer to “BALANCER” section.

Timing chain guide (intake side)

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CRANKCASE AND CRANKSHAFT

Order Part name Q’ty

Bolt [L = 45 mm (1.77 in)]

Bolt [L = 55 mm (2.17 in)]

Bolt [L = 70 mm (2.76 in)]

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ENG Remarks Refer to “REMOVAL POINTS”. Use special tool. Refer to “REMOVAL POINTS”. Boulon [L = 45 mm (1,77 in)]

Boulon [L = 55 mm (2,17 in)]

Boulon [L = 70 mm (2,76 in)]

Schraube [L = 45 mm (1,77 in)]

Schraube [L = 55 mm (2,17 in)]

Schraube [L = 70 mm (2,76 in)]

Kupplungszug-Halterung

Kurbelgehäuseteil rechts

Kurbelgehäuseteil links

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ENG Remarques Bullone [L = 45 mm (1,77 in)]

Bullone [L = 55 mm (2,17 in)]

Bullone [L = 70 mm (2,76 in)]

CRANKCASE AND CRANKSHAFT

ENG CRANKCASE BEARING 1 Crankcase bearing removal Extent of removal: Extent of removal Order Part name Q’ty Remarks

CRANKCASE BEARING REMOVAL

Preparation for removal Transmission Refer to “TRANSMISSION, SHIFT CAM AND SHIFT FORK” section. Shift cam and shift fork

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Refer to “REMOVAL POINTS”.

CRANKCASE AND CRANKSHAFT

CARTER MOTEUR ET VILEBREQUIN

REMOVAL POINTS Crankcase

1. Separate:

ENG Separation steps:

• Remove the crankcase bolts 1, hose guide 2 and clutch cable holder 3. NOTE: Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them.

• Remove the right crankcase 4. NOTE:
• Place the crankcase with its left side downward and split it by inserting a screwdriver tip into the splitting slit a in the crankcase.
• Lift the right crankcase horizontally while lightly patting the case splitting slit and engine mounting boss using a soft hammer, and leave the crankshaft and transmission with the left crankcase. CAUTION: Use soft hammer to tap on the case half. Tap only on reinforced portions of case. Do not tap on gasket mating surface. Work slowly and carefully. Make sure the case halves separate evenly. If the cases do not separate, check for a remaining case bolt or fitting. Do not force.
• Remove the dowel pins and Oring.

CRANKCASE AND CRANKSHAFT

CARTER MOTEUR ET VILEBREQUIN

1. Remove:

• Crankshaft 1 Use the crankcase separating tool 2. ENG Crankcase separating tool: YU-1135-A/ 90890-01135 ATTENTION: CAUTION: Do not use a hammer to drive out the crankshaft. Crankcase bearing

1. Remove:

• Remove the bearing from the crankcase by pressing its inner race.
• Do not use the removed bearing. INSPECTION Timing chain and timing chain guide

1. Inspect:

• Timing chain Cracks/stiff → Replace the timing chain and camshaft sprocket as a set.

2. Inspect:

• Timing chain guide Wear/damage → Replace. Crankcase

1. Inspect:

• Contacting surface a Scratches → Replace.
• Engine mounting boss b, crankcase Cracks/damage → Replace. Inspect:
• Bearing Rotate inner race with a finger. Rough spot/seizure → Replace. Inspect:
• Oil seal Damage → Replace.

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1. Measure:

• Small end free play limit b
• Connecting rod big end side clearance c
• Crank width d Out of specification → Replace. Use the dial gauge and a thickness gauge. Dial gauge and stand: YU-3097/90890-01252 Standard Runout limit: Small end free play: Oil strainer

1. Inspect:

• Oil strainer Damage → Replace. Oil delivery pipe 2

1. Inspect:

• Oil delivery pipe 2 1
• O-ring 2 Damage → Replace.
• Oil orifice a Clogged → Blow.

ASSEMBLY AND INSTALLATION

1. Install:

• Bolt (bearing stopper)

• Screw (bearing stopper)

To left and right crankcase.

• Screw [bearing stopper (crankshaft)] 1 ENG NOTE:
• Install the bearing by pressing its outer race parallel.
• To prevent the screw [bearing stopper (crankshaft)] from becoming loose, crush the screw head periphery a into the concave b using a punch etc. In so doing, take care not to damage the screwdriver receiving hole in the screw head. Crankshaft

1. Install:

• Crankshaft 1 Use the crankshaft installing tool 2, 3, 4 and 5. Crankshaft installing pot YU-90050/90890-01274 Crankshaft installing bolt 3: YU-90050/90890-01275 Adapter (M12) 4: YU-90063/90890-01278 Spacer (crankshaft installer) 5: YM-91044/90890-04081 È For USA and CDN É Except for USA and CDN NOTE:
• Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other. Operate the installing tool until the crankshaft bottoms against the bearing.
• Before installing the crankshaft, clean the contacting surface of crankcase. CAUTION: Do not use a hammer to drive in the crankshaft.

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• Transmission operation Unsmooth operation → Repair.

• Bolt (oil strainer) 2

• Sealant On the right crankcase 1.

YAMAHA Bond No. 1215 (ThreeBond® No. 1215): 90890-85505 NOTE: Clean the contacting surface of left and right crankcase before applying the sealant. Install:

• Right crankcase To left crankcase. NOTE:
• Apply the lithium soap base grease on the O-ring.
• Fit the right crankcase onto the left crankcase. Tap lightly on the case with soft hammer.
• When installing the crankcase, the connecting rod should be positioned at TDC (top dead center).

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• Clutch cable holder 2

NOTE: Tighten the crankcase tightening bolts in stage, using a crisscross pattern. Install:

• Oil delivery pipe 2 1
• Bolt (oil delivery pipe 2) 3

NOTE: Apply the lithium soap base grease on the O-rings. Install:

• Timing chain guide (intake side) 2
• Bolt (timing chain guide) 3

• Sealant Forced out on the cylinder mating surface.

10. Apply:

• Engine oil To the crank pin, bearing and oil delivery hole.

11. Check:

• Crankshaft and transmission operation. Unsmooth operation → Repair.

TRANSMISSION, SHIFT CAM AND SHIFT FORK

TRANSMISSION, SHIFT CAM AND SHIFT FORK

1 Shift fork, shift cam, main axle and drive axle removal Extent of removal: Extent of removal Order Part name Q’ty Remarks

TRANSMISSION, SHIFT CAM AND

SHIFT FORK REMOVAL

Preparation for removal

Engine Refer to “ENGINE REMOVAL” section. Separate the crankcase. Refer to “CRANKCASE AND CRANKSHAFT” section.

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Refer to “REMOVAL POINTS”.

TRANSMISSION, SHIFT CAM AND SHIFT FORK

BOITE DE VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION EC4H3000 REMOVAL POINTS EC4H3230 Transmission

1. Remove:

• Remove assembly with the collar 3 installed to the crankcase.
• Remove assembly carefully. Note the position of each part. Pay particular attention to the location and direction of shift forks.
• Remove the main axle, drive axle, shift cam and shift fork all together by tapping lightly on the transmission drive axle with a soft hammer. EC4H4000 ENG Gears

1. Inspect:

• Shift fork groove c Wear/damage → Replace. Inspect:
• O-ring 1 Damage → Replace. Check:
• Gears movement Unsmooth movement → Repair or replace. EC4H4600 Bearing

1. Inspect:

• Bearing 1 Rotate inner race with a finger. Rough spot/seizure → Replace. EC4H4810 Shift fork, shift cam and segment

1. Inspect:

• Shift fork 1 Wear/damage/scratches → Replace.

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TRANSMISSION, SHIFT CAM AND SHIFT FORK

BOITE DE VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION ENG

• Segment 2 Wear/damage → Replace.

• Shift fork movement Unsmooth operation → Replace shift fork.

NOTE: For a malfunctioning shift fork, replace not only the shift fork itself but the two gears each adjacent to the shift fork.

ASSEMBLY AND INSTALLATION

1. Install:

• 5th pinion gear (19T) 1
• 3rd pinion gear (17T) 2
• 4th pinion gear (21T) 4
• 2nd pinion gear (16T) 5 To main axle 6. NOTE: Apply the molybdenum disulfide oil on the inner and end surface of the idler gear and on the inner surface of the sliding gear, then install.

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TRANSMISSION, SHIFT CAM AND SHIFT FORK

BOITE DE VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION

• 2nd wheel gear (28T) 1
• 4th wheel gear (23T) 2
• 3rd wheel gear (23T) 3
• 5th wheel gear (17T) 4
• 1st wheel gear (31T) 5
• O-ring 6 New To drive axle 7.

• Apply the molybdenum disulfide oil on the inner and end surface of the idler gear and on the inner surface of the sliding gear, then install.
• Apply the lithium soap base grease on the O-ring. Install:
• Be sure the circlip sharp-edged corner a is positioned opposite side to the washer and gear b.
• Install the circlip with its ends c settled evenly on the spline crests. NOTE:
• Apply the lithium soap base grease on the oil seal lip.
• When installing the collar into the crankcase, pay careful attention to the crankcase oil seal lip.

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TRANSMISSION, SHIFT CAM AND SHIFT FORK

BOITE DE VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION

• Shift cam 4 To main axle and drive axle. NOTE:
• Apply the molybdenum disulfide oil on the shift fork grooves.
• Mesh the shift fork #1 (L) with the 4th wheel gear 5 and #3 (R) with the 5th wheel gear 7 on the drive axle.
• Mesh the shift fork #2 (C) with the 3rd pinion gear 6 on the main axle.

• Transmission assembly 1 To left crankcase 2.

ENG NOTE: Apply the engine oil on the bearings and guide bars. Check:

• Transmission operation Unsmooth operation → Repair.

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FRONT WHEEL AND REAR WHEEL

EC500000 CHAS NOTE: This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are requested not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical damage. CHASSIS EC590000 FRONT WHEEL

AND REAR WHEEL

EC598000 FRONT WHEEL 1 Front wheel removal 3 Brake disc removal Extent of removal: Extent of removal Order 2 Wheel bearing removal Part name Q’ty

FRONT WHEEL REMOVAL

Preparation for removal

WARNING Hold the machine by placing the suitable stand under the engine. Support the machine securely so there is no danger of it falling over.

Nut (front wheel axle)

6-1 Remarks Only loosening. Refer to “REMOVAL POINTS”.

FRONT WHEEL AND REAR WHEEL

CHAS EC598100 REAR WHEEL 1 Rear wheel removal 3 Brake disc removal Extent of removal: Extent of removal Order 2 Wheel bearing removal Part name Q’ty

REAR WHEEL REMOVAL

Preparation for removal

WARNING Hold the machine by placing the suitable stand under the engine.

Support the machine securely so there is no danger of it falling over.

Nut (rear wheel axle)

6-5 Remarks Refer to “REMOVAL POINTS”. Refer to “REMOVAL POINTS”. REMOVAL POINTS EC523101 Rear wheel

1. Remove:

• Wheel 1 NOTE: Push the wheel forward and remove the drive chain 2. EC513201 Wheel bearing (if necessary)

1. Remove:

• Bearing 1 NOTE: Remove the bearing using a general bearing puller 2. EC594000 INSPECTION EC514100 Wheel

1. Measure:

• Wheel runout Out of limit → Repair/replace. Inspect:
• Bearing Rotate inner race with a finger. Rough spot/seizure → Replace. NOTE: Replace the bearings, oil seal and wheel collar as a set. 6-9 CHAS

1. Measure:

• Wheel axle bends Out of specification → Replace. Use the dial gauge 1. Wheel axle bending limit:

0.5 mm (0.020 in)

NOTE: The bending value is shown by one half of the dial gauge reading. CHAS WARNING Do not attempt to straighten a bent axle. EC594200 Brake disc

1. Measure:

• Brake disc deflection (only rear brake disc) Use the dial gauge 1. Out of specification → Inspect wheel runout. If wheel runout is in good condition, replace the brake disc. Brake disc deflection limit: Rear: <Limit>:

0.15 mm (0.006 in)

• Brake disc thickness a Out of limit → Replace. Brake disc thickness: Front:

3.0 mm (0.12 in)

2.5 mm (0.10 in)

4.0 mm (0.16 in)

3.5 mm (0.14 in)

6 - 11

ASSEMBLY AND INSTALLATION

1. Install:

• Oil seal 4 New NOTE:
• Apply the lithium soap base grease on the bearing and oil seal lip when installing.
• Use a socket that matches the outside diameter of the race of the bearing.
• Left side of bearing shall be installed first.
• Install the oil seal with its manufacture’s marks or numbers facing outward. Do not strike the inner race of the bearing. Contact should be made only with the outer race. Install:

NOTE: Tighten the bolts in stage, using a crisscross pattern.

NOTE: Apply the lithium soap base grease on the oil seal lip. Install:

• Speed sensor 1 NOTE:
• Apply the lithium soap base grease on the oil seal lip of the speed sensor.
• Make sure the two projections a in the wheel hub are meshed with the two slots b in the speed sensor.

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• Install the brake disc 1 between the brake pads 2 correctly.
• Make sure that the projections a in the speed sensor fits over the stopper b on the front fork inner tube. Install:
• Wheel axle 1 NOTE: Apply the lithium soap base grease on the wheel axle. Install:

6 - 15

NOTE: Before tightening the bolt, fit the wheel axle to the axle holder by stroking the front fork several times with the front brake applied.

• Bolt (axle holder) 1

1. Install:

• Oil seal 5 New NOTE:
• Apply the lithium soap base grease on the bearing and oil seal lip when installing.
• Install the bearing with seal facing outward.
• Use a socket that matches the outside diameter of the race of the bearing.
• Right side of bearing shall be installed first.
• Install the oil seal with its manufacture’s marks or numbers facing outward. Do not strike the inner race of the bearing. Contact should be made only with the outer race. Install:

• Rear wheel sprocket 1
• Bolt (rear wheel sprocket) 2
• Washer (rear wheel sprocket) 3
• Nut (rear wheel sprocket) 4

NOTE: Tighten the bolts in stage, using a crisscross pattern.

NOTE: Tighten the nuts in stage, using a crisscross pattern. NOTE: Apply the lithium soap base grease on the oil seal lip.

6 - 17

NOTE: Install the brake disc 1 between the brake pads 2 correctly. Install:

• Drive chain 1 NOTE: Push the wheel 2 forward and install the drive chain. Install:
• Left drive chain puller 1
• Install the left drive chain puller, and insert the wheel axle from left side.
• Apply the lithium soap base grease on the wheel axle.

• Right drive chain puller 1
• Nut (wheel axle) 3 NOTE: Temporarily tighten the nut (wheel axle) at this point.

• Drive chain slack a Drive chain slack: 48 ~ 58 mm (1.9 ~ 2.3 in) Refer to “DRIVE CHAIN SLACK ADJUSTMENT” section in the CHAPTER 3.

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1 Brake hose removal 3 Brake master cylinder removal Extent of removal: Extent of removal Order Part name 2 Brake caliper removal Q’ty

FRONT BRAKE REMOVAL

Preparation for removal WARNING Hold the machine by placing the suitable stand under the engine. Support the machine securely so there is no danger of it falling over. Drain the brake fluid.

Remarks Refer to “REMOVAL POINTS”.

Brake hose holder (protector)

Brake hose holder (brake caliper)

Remove when loosening the pad pin.

Loosen when disassembling the brake caliper.

Brake master cylinder bracket

Brake master cylinder

6 - 23

Support de durit de frein (protection)

1 Brake master cylinder removal 3 Brake caliper removal Extent of removal: Extent of removal Order Part name 2 Brake hose removal Q’ty

REAR BRAKE REMOVAL

Preparation for removal WARNING Hold the machine by placing the suitable stand under the engine. Support the machine securely so there is no danger of it falling over. Rear wheel Refer to “FRONT WHEEL AND REAR WHEEL” section. Drain the brake fluid.

Remarks Refer to “REMOVAL POINTS”.

Brake master cylinder

Remove when loosening the pad pin.

Loosen when disassembling the brake caliper.

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1 Front brake caliper disassembly Extent of removal: Extent of removal

Order 2 Rear brake caliper disassembly Part name Q’ty Remarks Refer to “REMOVAL POINTS”. Support de plaquette

1 Front brake master cylinder disassembly Extent of removal: Extent of removal Order Part name 2 Rear brake master cylinder disassembly Q’ty Remarks Brake master cylinder cap

Brake master cylinder boot

Brake master cylinder kit

6 - 35

Use a long nose circlip pliers. REMOVAL POINTS Brake fluid

1. Remove:

• Brake master cylinder cap 1 [Rear]
• Brake master cylinder cap 1
• Protector NOTE: Do not remove the diaphragm.

CHAS Connect the transparent hose 2 to the bleed screw 1 and place a suitable container under its end.

Loosen the bleed screw and drain the brake fluid while pulling the lever in or pushing down on the pedal. ATTENTION: CAUTION:

• Do not reuse the drained brake fluid.
• Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately.

Brake caliper piston

1. Remove:

• Brake caliper piston Use compressed air and proceed carefully. WARNING

• Cover piston with rag and use extreme caution when expelling piston from cylinder.
• Never attempt to pry out piston. Caliper piston removal steps:
• Insert a piece of rag into the brake caliper to lock one brake caliper.
• Carefully force the piston out of the brake caliper cylinder with compressed air. È Front É Rear Brake caliper piston seal kit

1. Remove:

• Piston seal 2 NOTE: Remove the piston seals and dust seals by pushing them with a finger. Never attempt to pry out piston seals and dust seals. Replace the piston seals and dust seals whenever a caliper is disassembled. INSPECTION Brake master cylinder

1. Inspect:

• Brake master cylinder inner surface a Wear/scratches → Replace master cylinder assembly. Stains → Clean. WARNING

CHAS AVERTISSEMENT Use only new brake fluid. Inspect:

• Diaphragm 1 Crack/damage → Replace. È Front É Rear

Inspect: (front brake only)

• Reservoir float 1 Damage → Replace.

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• Brake master cylinder piston

• Brake master cylinder cup 2 Wear/damage/score marks → Replace brake master cylinder kit. È Front É Rear

1. Inspect:

• Brake caliper cylinder inner surface a Wear/score marks → Replace brake caliper assembly. È Front É Rear

• Brake caliper piston 1 Wear/score marks → Replace brake caliper piston assembly. WARNING

Replace the piston seals and dust seals 2 whenever a caliper is disassembled. Brake hose

1. Inspect:

• Brake hose 1 Crack/damage → Replace.

ASSEMBLY AND INSTALLATION

• All internal parts should be cleaned in new brake fluid only.
• Internal parts should be lubricated with brake fluid when installed.
• Replace the piston seals and dust seals whenever a caliper is disassembled. Brake caliper piston

1. Clean:

• Brake caliper piston Clean them with brake fluid.

6 - 43

Always use new piston seals and dust seals. NOTE: Fit the piston seals and dust seals onto the slot on brake caliper correctly. NOTE: Apply the brake fluid on the piston wall. CAUTION:

• Install the piston with its shallow depressed side a facing the brake caliper.
• Never force to insert. Front brake caliper

1. Install:

• Install the brake pads with their projections a into the brake caliper recesses b.
• Temporarily tighten the pad pin at this point. Install:

1. Install:

• Install the brake pads with their projections a into the brake caliper recesses b.
• Temporarily tighten the pad pin at this point. Install:
• Bolt (brake disc cover) 2

• Rear wheel 2 Refer to “FRONT WHEEL AND REAR WHEEL” section. Tighten:

• Pad pin plug 4 Brake master cylinder kit

1. Clean:

• Brake master cylinder
• Brake master cylinder kit Clean them with brake fluid.

2. Install:

• Brake master cylinder cup (primary) 1
• Brake master cylinder cup (secondary) 2 To brake master cylinder piston 3. NOTE: Apply the brake fluid on the brake master cylinder cup. CHAS WARNING After installing, cylinder cup should be installed as shown direction. Wrong installation cause improper brake performance. È Front É Rear

• Spring 1 To brake master cylinder piston 2. NOTE: Install the spring at the smaller dia. side. È Front É Rear

• Brake master cylinder kit 1
• Brake master cylinder boot 4 To brake master cylinder 5. [Rear]
• Brake master cylinder kit 1
• Brake master cylinder boot 4 To brake master cylinder 5. NOTE:
• Apply the brake fluid on the brake master cylinder kit.
• Apply the lithium soap base grease on the tip of the push rod.
• When installing the circlip, use a long nose circlip pliers. È Front É Rear

FRONT BRAKE AND REAR BRAKE

FREIN AVANT ET FREIN ARRIERE

Front brake master cylinder

1. Install:

• Brake master cylinder 1
• Brake master cylinder bracket

• Bolt (brake master cylinder bracket) 3 CHAS NOTE:
• Install the bracket so that the arrow mark a face upward.
• First tighten the bolts on the upper side of the brake master cylinder bracket, and then tighten the bolts on the lower side. Install:
• Bolt (brake lever) 2

NOTE: Apply the lithium soap base grease on the brake lever sliding surface, bolt and contacting surface of the brake master cylinder piston. Rear brake master cylinder

1. Install:

• Union bolt 3 WARNING Always use new copper washers. CAUTION: Install the brake hose so that its pipe portion a directs as shown and lightly touches the projection b on the brake master cylinder.

• Brake master cylinder 1
• Bolt (brake master cylinder) 2

• Bolt (brake pedal) 4

• Clip 5 NOTE: Apply the lithium soap base grease on the bolt, O-ring and brake pedal bracket. Install:
• Cotter pin 3 New NOTE: After installing, check the brake pedal height. Refer to “REAR BRAKE ADJUSTMENT” section in the CHAPTER 3. Front brake hose

1. Install:

• Union bolt 3 WARNING Always use new copper washers. New CAUTION: Install the brake hose so that its pipe portion a directs as shown and lightly touches the projection b on the brake caliper.

• Bolt (brake hose holder) 2

• Nut (brake hose holder) 2

NOTE: Align the top a of the brake hose holder with the paint b of the brake hose. Pass the brake hose through the front brake hose guides 1.

WARNING Always use new copper washers. CAUTION: Install the brake hose so that it contacts the brake master cylinder projection a and that its bent portion b faces downward. Rear brake hose

1. Install:

• Union bolt 3 New Always use new copper washers.

WARNING CAUTION: Install the brake hose so that its pipe portion a directs as shown and lightly touches the projection b on the brake caliper.

6 - 55

• Screw (brake hose holder) 2

CAUTION: After installing the brake hose holders, make sure the brake hose does not contact the spring (rear shock absorber). If it does, correct its twist. Brake fluid

1. Fill:

• Brake fluid Until the fluid level reaches “LOWER” level line a. Recommended brake fluid: DOT #4

• Use only the designated quality brake fluid: otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance.
• Refill with the same type of brake fluid; mixing fluids may result in a harmful chemical reaction and lead to poor performance.
• Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. CAUTION: Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately. Air bleed:
• Brake system Refer to “BRAKE SYSTEM AIR BLEEDING” section in the

CHAPTER 3.

• Brake fluid level Fluid at lower level → Fill up. Refer to “BRAKE FLUID LEVEL INSPECTION” section in the CHAPTER 3.

• Brake master cylinder cap 1
• Screw (brake master cylinder cap) 2

After installation, while pulling the brake lever in or pushing down on the brake pedal, check whether there is any brake fluid leaking where the union bolts are installed respectively at the brake master cylinder and brake caliper. [Rear]

• Brake master cylinder cap 1
• Bolt (brake master cylinder cap) 2 CHAS Install: (rear brake only)

6 - 59

1 Front fork removal Extent of removal: Extent of removal Order Part name Q’ty

FRONT FORK REMOVAL

Preparation for removal Remarks WARNING Hold the machine by placing the suitable stand under the engine. Support the machine securely so there is no danger of it falling over. Front wheel Refer to “FRONT WHEEL AND REAR WHEEL” section. Front brake caliper Refer to “FRONT BRAKE AND REAR BRAKE” section. Headlight Handlebar

Refer to “HANDLEBAR” section.

Pinch bolt (upper bracket)

Loosen when disassembling the front fork.

Pinch bolt (lower bracket)

6 - 61

Only loosening. FOURCHE TELESKOPGABEL CHAS 1 Oil seal removal Extent of removal: Extent of removal Order 2 Damper rod removal Part name Q’ty Remarks Front fork cap bolt

Refer to “REMOVAL POINTS”.

Refer to “REMOVAL POINTS”.

6 - 65

Refer to “REMOVAL POINTS”. FOURCHE TELESKOPGABEL CHAS NOTE: The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers. To prevent an accidental explosion of air, the following instructions should be observed:

• The front fork with a built-in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material. Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled.
• Before removing the cap bolts or front forks, be sure to extract the air from the air chamber completely. EC553000 REMOVAL POINTS Front fork cap bolt

1. Remove:

• Front fork cap bolt 1 From the outer tube. NOTE: Before removing the front fork from the machine, loosen the front fork cap bolt.

• Front fork cap bolt 1 Inner tube

1. Remove:

• Stopper ring 2 Using slotted-head driver. screw- CAUTION: Take care not to scratch the inner tube.

• Inner tube 1 Oil seal removal steps:
• Push in slowly a the inner tube just before it bottoms out and then pull it back quickly b.
• Repeat this step until the inner tube can be pulled out from the outer tube. EC553311 Damper rod

1. Remove:

• Damper rod 2 NOTE: Use a damper rod holder 3 to lock the damper rod. Damper rod holder: YM-01494/90890-01494 EC554000 INSPECTION EC554100 Damper rod

1. Inspect:

• Damper rod 1 Bend/damage damper rod. CAUTION: The front fork with a built-in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material. Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled.

6 - 71

• Tubo interior 1 Base valve

1. Inspect:

• Valve assembly 1 Wear/damage → Replace.
• O-ring 2 Damage → Replace. EC554400 Fork spring

1. Measure:

• Fork spring free length a Out of specification → Replace. Fork spring free length: 460 mm (18.1 in) <Limit>: 455 mm (17.9 in) EC554502 Inner tube

1. Inspect:

• Inner tube surface a Score marks → Repair or replace. Use #1,000 grit wet sandpaper. Damaged oil lock piece → Replace.
• Inner tube bends Out of specification → Replace. Use the dial gauge 1. Inner tube bending limit:

0.2 mm (0.008 in)

NOTE: The bending value is shown by one half of the dial gauge reading. CHAS WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube. EC554600 Outer tube

1. Inspect:

• Outer tube 1 Score marks/wear/damage → Replace.

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1. Inspect:

• Front fork cap bolt 1
• Air bleed screw 3 Wear/damage → Replace.

ASSEMBLY AND INSTALLATION

1. Wash the all parts in a clean solvent.

2. Install:

• Damper rod 1 To inner tube 2. ATTENTION: CAUTION: To install the damper rod into the inner tube, hold the inner tube aslant. If the inner tube is held vertically, the damper rod may fall into it, damaging the valve inside. Install:
• Base valve 3 To inner tube 4. New Tighten:
• Use a damper rod holder 2 to lock the damper rod 3.
• Apply the LOCTITE® on the base valve thread.

• Install the spring guide with its smaller dia. end a facing downward.
• With its thread b facing upward, fully finger tighten the locknut onto the damper rod. Install:
• Slide metal 5 New To inner tube 6. NOTE:
• Apply the fork oil on the inner tube.
• When installing the oil seal, use vinyl seat a with fork oil applied to protect the oil seal lip.
• Install the oil seal with its manufacture’s marks or number facing the axle holder side.
• Install the oil seal washer with its projections b facing upward.

• Outer tube 1 To inner tube 2.

6 - 77

NOTE: Install the piston metal onto the slot on inner tube. Install:

• Oil seal washer 2 To outer tube slot. NOTE: Press the slide metal into the outer tube with fork seal driver 3. Fork seal driver: YM-A0948/ 90890-01502

10. Install:

• Oil seal 1 NOTE: Press the oil seal into the outer tube with fork seal driver 2. Fork seal driver: YM-A0948/ 90890-01502 NOTE: Fit the stopper ring correctly in the groove in the outer tube.

12. Install:

• Dust seal 1 NOTE: Apply the lithium soap base grease on the inner tube.

13. Check:

• Inner tube smooth movement Tightness/binding/rough spots
• Repeat the steps 2 to 12.

14. Compress the front fork fully.

15. Fill:

• Front fork oil Until outer tube top surface with recommended fork oil 1. Recommended oil: Suspension oil “S1” CHAS CAUTION:
• Be sure to use recommended fork oil. If other oils are used, they may have an excessively adverse effect on the front fork performance.
• Never allow foreign materials to enter the front fork.

16. After filling, pump the damper

rod 1 slowly up and down more than 10 times to distribute the fork oil.

17. Fill:

• Front fork oil Until outer tube top surface with recommended fork oil once more.

18. After filling, pump the outer tube

1 slowly up and down (about 200 mm (7.9 in) stroke) to distribute the fork oil once more. NOTE: Be careful not to excessive full stroke. A stroke of 200 mm (7.9 in) or more will cause air to enter. In this case, repeat the steps 15 to 18.

19. Wait ten minutes until the air

bubbles have been removed from the front fork, and the oil has dispense evenly in system before setting recommended oil level. NOTE: Fill with the fork oil up to the top end of the outer tube, or the fork oil will not spread over to every part of the front forks, thus making it impossible to obtain the correct level. Be sure to fill with the fork oil up to the top of the outer tube and bleed the front forks.

6 - 81

20. Measure:

• Oil level (left and right) a Out of specification → Adjust. Standard oil level: 130 mm (5.12 in) Extent of adjustment: 95 ~ 150 mm (3.74 ~ 5.91 in) From top of outer tube with inner tube and damper rod 1 fully compressed without spring. NOTE: Be sure to install the spring guide 2 when checking the oil level. CHAS WARNING Never fail to make the oil level adjustment between the maximum and minimum level and always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability.

21. Measure:

• Distance a Out of specification → Turn into the locknut. Distance a: 18 mm (0.71 in) or more Between damper rod 1 top and locknut 2 top.

22. Loosen:

• Rebound damping adjuster 1 NOTE:
• Loosen the rebound damping adjuster finger tight.
• Record the set position of the adjuster (the amount of turning out the fully turned in position).

6 - 83

• Install the fork spring with the damper rod 3 pulled up.
• After installing the fork spring, hold the damper rod end so that it will not go down.

24. Install:

• Front fork cap bolt 2 NOTE: Fully finger tighten the front fork cap bolt onto the damper rod. NOTE: Hold the locknut 2 and tighten the front fork cap bolt with specified torque.

26. Install:

• Front fork cap bolt 1 To outer tube. NOTE: Install the protector guide with its wider side a facing downward. NOTE:
• Temporarily tighten the pinch bolts (lower bracket).
• Do not tighten the pinch bolts (upper bracket) yet. Adjust:
• Front fork top end a

1. Install:

• Front fork 1 Tighten:
• Pinch bolt (upper bracket) 1

NOTE: Install the speed sensor lead so that its paint a directs as shown and align the bottom b of the plate 1 with the same paint.

6 - 87

Tighten the lower bracket to specified torque. If torqued too much, it may cause the front fork to malfunction.

• Pinch bolt (lower bracket) 2

NOTE: Install the plate 2 in the direction as shown. Install:

• Bolt (protector) 2 NOTE: Turn in the damping adjuster 1 finger-tight and then turn out to the originally set position.

6 - 89

• Rebound damping force

• Boulon (protection) 2

Extent of removal: Extent of removal Order Preparation for removal

Part name Q’ty Remarks HANDLEBAR REMOVAL Headlight

Hot starter lever holder

Disconnect at the lever side.

Disconnect at the lever side.

Disconnect the clutch switch lead.

Disconnect the engine stop switch lead.

Brake master cylinder

Refer to “REMOVAL POINTS”.

Disconnect the start switch lead.

Throttle cable #1 (pulled)

Disconnect at the throttle side.

Throttle cable #2 (pushed)

Disconnect at the throttle side. Refer to “REMOVAL POINTS”.

Handlebar lower holder

6 - 91

Refer to “REMOVAL POINTS”. GUIDON LENKER CHAS

DEPOSE DU GUIDON

REMOVAL POINTS Brake master cylinder

1. Remove:

• Brake master cylinder bracket

• Brake master cylinder 2 CHAS CAUTION:
• Do not let the brake master cylinder hang on the brake hose.
• Keep the brake master cylinder cap side horizontal to prevent air from coming in. EC5B3200 Grip

1. Remove:

• Grip 1 NOTE: Blow in air between the handlebar or tube guide and the grip. Then remove the grip which has become loose. EC5B4000 Handlebar

1. Inspect:

• Handlebar 1 Bends/cracks/damage → Replace. WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar.

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ASSEMBLY AND INSTALLATION

1. Install:

• Handlebar lower holder 1
• Nut (handlebar lower holder) NOTE:
• Install the handlebar lower holder with its side having the greater distance a from the mounting bolt center facing forward.
• Apply the lithium soap base grease on the thread of the handlebar lower holder.
• Installing the handlebar lower holder in the reverse direction allows the front-to-rear offset amount of the handlebar position to be changed.
• Do not tighten the nut yet.

• Handlebar upper holder 2
• Bolt (handlebar upper holder) 3

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• The handlebar upper holder should be installed with the punched mark a forward.
• Install the handlebar so that the marks b are in place on both sides.
• Install the handlebar so that the projection c of the handlebar upper holder is positioned at the mark on the handlebar as shown.
• First tighten the bolts on the front side of the handlebar upper holder, and then tighten the bolts on the rear side. HANDLEBAR GUIDON

• Nut (handlebar lower holder)

• Left grip 1 Apply the adhesive to the handlebar 2.

• Before applying the adhesive, wipe off grease or oil on the handlebar surface a with a lacquer thinner.
• Install the left grip to the handlebar so that the line b between the two arrow marks faces straight upward. Install:
• Collar 2 Apply the adhesive on the tube guide 3. NOTE:
• Before applying the adhesive, wipe off grease or oil on the tube guide surface a with a lacquer thinner.
• Install the grip to the tube guide so that the grip match mark b and tube guide slot c form the angle as shown. Install:
• Throttle grip 2 NOTE: Apply the lithium soap base grease on the throttle grip sliding surface.

NOTE: Apply the lithium soap base grease on the throttle cable end and tube guide cable winding portion.

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• Throttle cable cap 1
• Screw (throttle cable cap) 2

• Cover (throttle cable cap) 2

10. Install:

• Brake master cylinder 2
• Brake master cylinder bracket

• Bolt (brake master cylinder bracket) 4 Zero mm (Zero in)

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Zero mm (Zero in) NOTE:

• The start switch and brake master cylinder bracket should be installed according to the dimensions shown.
• Install the bracket so that the arrow mark a faces upward.
• First tighten the bolt on the upper side of the brake master cylinder bracket, and then tighten the bolt on the lower side. WARNING After tightening the screws, check that the throttle grip 3 moves smoothly. If it does not, retighten the bolts for adjustment. CHAS HANDLEBAR GUIDON

11. Install:

• Engine stop switch 1
• Clutch lever holder 2
• Bolt (clutch lever holder) 3

• The engine stop switch, clutch lever holder and clamp should be installed according to the dimensions shown.
• Pass the engine stop switch lead in the middle of the clutch lever holder.

• Hot starter lever holder 4
• Bolt (hot starter lever holder) 5 CHAS NOTE: Apply the lithium soap base grease on the clutch cable end and hot starter cable end.

13. Adjust:

• Clutch lever free play Refer to “CLUTCH ADJUSTMENT” section in the CHAPTER 3.
• Hot starter lever free play Refer to “HOT STARTER LEVER ADJUSTMENT” section in the CHAPTER 3. 1 Lower bracket removal Extent of removal: Extent of removal Order 2 Bearing removal Part name Q’ty STEERING REMOVAL Preparation for removal Remarks WARNING Hold the machine by placing the suitable stand under the engine. Support the machine securely so there is no danger of it falling over. Headlight Handlebar Refer to “HANDLEBAR” section. Front brake hose guide Front fender

Disconnect the main switch lead. Refer to “FRONT FORK” section. Use special tool. Refer to “REMOVAL POINTS”. DIRECTION LENKUNG CHAS Extent of removal

Order Part name Q’ty

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CHAS Remarks Refer to “REMOVAL POINTS”. REMOVAL POINTS Steering ring nut

1. Remove:

• Steering ring nut 1 Use the steering nut wrench Steering nut wrench: YU-33975/90890-01403 CHAS WARNING Support the steering stem so that it may not fall down. Lower bearing

1. Remove:

• Lower bearing 1 Use the floor chisel 2. CAUTION: Take care not to damage the steering shaft thread. Bearing race

1. Remove:

• Bearing race 1 Remove the bearing race using long rod 2 and the hammer. INSPECTION Steering stem

1. Inspect:

• Steering stem 1 Bend/damage → Replace. Bearing and bearing race

1. Wash the bearings and bearing

races with a solvent.

2. Inspect:

• Bearing race Pitting/damage → Replace bearings and bearing races as a set. Install the bearing in the bearing races. Spin the bearings by hand. If the bearings hang up or are not smooth in their operation in the bearing races, replace bearings and bearing races as a set.

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ASSEMBLY AND INSTALLATION

1. Install:

• Lower bearing 1 CHAS NOTE: Apply the lithium soap base grease on the dust seal lip and bearing inner circumference. Install:
• Bearing race cover 2 NOTE: Apply the lithium soap base grease on the bearing and bearing race cover lip. Install:
• Lower bracket 1 NOTE: Apply the lithium soap base grease on the bearing, the portion a and thread of the steering stem. Tighten the steering ring nut using the steering nut wrench Refer to “STEERING HEAD INSPECTION AND ADJUSTMENT” section in the CHAPTER 3. Check the steering stem by turning it lock to lock. If there is any binding, remove the steering stem assembly and inspect the steering bearings.

NOTE: Install the collar 2 with the larger inside diameter facing downward.

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• Front brake hose guide bracket 4

• Temporarily tighten the pinch bolts (lower bracket).
• Do not tighten the pinch bolts (upper bracket) yet. Install:
• Guide (speed sensor lead) 1 NOTE: After installing the guide as shown, pass the speed sensor lead through the guide.

10. After tightening the nut, check

the steering for smooth movement. If not, adjust the steering by loosening the steering ring nut little by little.

11. Adjust:

• Front fork top end a Front fork top end (standard) a: 5 mm (0.20 in)

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Tighten the lower bracket to specified torque. If torqued too much, it may cause the front fork to malfunction.

• Pinch bolt (lower bracket) 2 CHAS NOTE: Pass the throttle cables 3, clutch cable 4 and hot starter cable 5 between the multi-function display bracket and upper bracket.

14. Monter:

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• Install so that the marking a on the speed sensor lead aligns with the holder edge.
• Fasten the speed sensor lead to the holder with the clamp.

Extent of removal: Extent of removal Order Part name Q’ty SWINGARM REMOVAL Preparation for removal Remarks WARNING Hold the machine by placing the suitable stand under the engine. Support the machine securely so there is no danger of it falling over. Brake hose holder Refer to “FRONT BRAKE AND REAR BRAKE” section. Rear brake caliper Bolt (brake pedal) Shift the brake pedal backward. Drive chain

Lower chain tensioner

Bolt (rear shock absorber-relay arm)

Bolt (connecting rod)

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Hold the swingarm. 1 Swingarm disassembly 3 Relay arm removal and disassembly Extent of removal: Extent of removal Order Part name 2 Connecting rod removal and disassembly Q’ty Remarks SWINGARM DISASSEMBLY

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Refer to “REMOVAL POINTS”. Refer to “REMOVAL POINTS”. REMOVAL POINTS Cap

1. Remove:

• Left cap 1 NOTE: Remove with a slotted-head screwdriver inserted under the mark a on the left cap. EC573200 Bearing

1. Remove:

• Bearing 1 NOTE: Remove the bearing by pressing its outer race. CHAS INSPECTION Wash the bearings, bushings and collars in a solvent. Swingarm

1. Inspect:

• Bushing 2 Free play exists/unsmooth revolution/rust → Replace bearing and bushing as a set.

2. Inspect:

• Oil seal 3 Damage → Replace. Relay arm

1. Inspect:

• Collar 2 Free play exists/unsmooth revolution/rust → Replace bearing and collar as a set.

2. Inspect:

• Oil seal 3 Damage → Replace. Connecting rod

1. Inspect:

• Collar 2 Free play exists/unsmooth revolution/rust → Replace bearing and collar as a set.

2. Inspect:

• Oil seal 3 Damage → Replace.

ASSEMBLY AND INSTALLATION

Bearing and oil seal

1. Install:

• Oil seal 2 To swingarm. NOTE:
• Apply the molybdenum disulfide grease on the bearing when installing.
• Install the bearing by pressing it on the side having the manufacture’s marks or numbers.
• First install the outer and then the inner bearings to a specified depth from inside. Installed depth of bearings: Outer a: Zero mm (Zero in) Inner b:

6.5 mm (0.26 in)

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• Oil seal 3 To relay arm. NOTE:
• Apply the molybdenum disulfide grease on the bearing when installing.
• Install the bearing by pressing it on the side having the manufacture’s marks or numbers.
• Apply the molybdenum disulfide grease on the washer.

• Oil seal 2 To connecting rod. NOTE:
• Apply the molybdenum disulfide grease on the bearing when installing.
• Install the bearing by pressing it on the side having the manufacture’s marks or numbers. Installed depth of bearings a: Zero mm (Zero in) Installed depth of bearings a: Zero mm (Zero in)

1. Install:

• Collar 4 To swingarm 5. NOTE: Apply the molybdenum disulfide grease on the bushings, thrust bearings, oil seal lips and contact surfaces of the collar and thrust bearing. Install:
• Washer 2 To relay arm 3.

CHAS NOTE: Apply the molybdenum disulfide grease on the collars and oil seal lips. Install:

• Collar 1 To connecting rod 2. NOTE: Apply the molybdenum disulfide grease on the collar and oil seal lips. Install:
• Bolt (connecting rod) 2
• Nut (connecting rod) 4

• Nut (relay arm) 4 To swingarm. NOTE:
• Apply the molybdenum disulfide grease on the bolt circumference and threaded portion.
• Do not tighten the nut yet.

• Apply the molybdenum disulfide grease on the pivot shaft.
• Insert the pivot shaft from right side.

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To relay arm 5. NOTE: Apply the molybdenum grease on the bolt. Check:

• Swingarm side play a Free play exists → Replace thrust bearing.
• Swingarm up and down movement b Unsmooth movement/binding/ rough spots → Grease or replace bearings, bushings and collars.

• Bolt (connecting rod) 1
• Nut (connecting rod) 3

• Apply the molybdenum disulfide grease on the bolt.
• Do not tighten the nut yet. Install:
• Bolt (rear shock absorberrelay arm) 1
• Nut (rear shock absorber-relay arm) 2 disulfide

10. Tighten:

• Nut (connecting rod) 1

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11. Tighten:

• Nut (relay arm) 1 NOTE: Apply the molybdenum grease on the bolt.

NOTE: Install the right cap with its mark a facing forward.

13. Install:

• Bolt (lower chain tensioner) 1
• Lower chain tensioner 4
• Nut (lower chain tensioner) 5

14. Install:

• Drive chain support 1
• Drive chain support cover 2
• Bolt {drive chain support [ = 50 mm (1.97 in)]} 3
• Nut (drive chain support) 4

• Bolt {drive chain support cover [ = 10 mm (0.39 in)]} 5

1 Rear shock absorber removal Extent of removal: Extent of removal Order Part name Q’ty

REAR SHOCK ABSORBER REMOVAL

Preparation for removal 2 Rear shock absorber disassembly Hold the machine by placing the suitable stand under the engine. Remarks WARNING Support the machine securely so there is no danger of it falling over. Seat and side covers Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 3. Silencer Refer to “EXHAUST PIPE AND SILENCER” section in the CHAPTER 3. Drain the coolant. Refer to “COOLANT REPLACEMENT” section in the

CHAPTER 3.

Catch tank breather hose Disconnect at the catch tank side. Catch tank hose Disconnect at the catch tank side. Air induction hose (air cut-off valve-air filter case) Disconnect at the air filter case side. Cylinder head breather hose Disconnect at the air filter case side. Battery Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3. Disconnect the starter relay coupler. Starter motor lead Disconnect at the starter relay side.

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Order Part name Q’ty

Clamp (air filter joint)

Bolt (rear shock absorber-relay arm)

Bolt (rear shock absorber-frame)

Spring (rear shock absorber)

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Only loosening. Hold the swingarm. Only loosening. Refer to “REMOVAL POINTS”. WARNING This rear shock absorber is provided with a separate type tank filled with high-pressure nitrogen gas. To prevent the danger of explosion, read and understand the following information before handling the shock absorber. The manufacturer can not be held responsible for property damage or personal injury that may result from improper handling.

1. Never tamper or attempt to

disassemble the cylinder or the tank.

2. Never throw the rear shock

absorber into an open flame or other high heat. The rear shock absorber may explode as a result of nitrogen gas expansion and/or damage to the hose.

3. Be careful not to damage any

part of the gas tank. A damaged gas tank will impair the damping performance cause a malfunction.

4. Take care not to scratch the

contact surface of the piston rod with the cylinder; or oil could leak out.

5. Never attempt to remove the

plug at the bottom of the nitrogen gas tank. It is very dangerous to remove the plug.

6. When scrapping the rear

shock absorber, follow the instructions on disposal.

NOTES ON DISPOSAL

(YAMAHA DEALERS ONLY) Before disposing the rear shock absorber, be sure to extract the nitrogen gas from valve 1. Wear eye protection to prevent eye damage from escaping gas and/or metal chips. WARNING To dispose of a damaged or wornout rear shock absorber, take the unit to your Yamaha dealer for this disposal procedure.

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REMOVAL POINTS EC583320 Bearing

1. Remove:

• Stopper ring (upper bearing) 1 NOTE: Press in the bearing while pressing its outer race and remove the stopper ring.

• Upper bearing 1 NOTE: Remove the bearing by pressing its outer race.

• Lower bearing 1 CHAS NOTE: Remove the bearing by pressing its outer race. INSPECTION Rear shock absorber

1. Inspect:

• Damper rod 1 Bends/damage → Replace rear shock absorber assembly.
• Shock absorber 2 Oil leaks → Replace rear shock absorber assembly. Gas leaks → Replace rear shock absorber assembly.
• Spring 3 Damage → Replace spring. Fatigue → Replace spring. Move spring up and down.
• Spring guide 4 Wear/damage → Replace spring guide.
• Bearing 5 Free play exists/unsmooth revolution/rust → Replace.

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ASSEMBLY AND INSTALLATION

1. Install:

• Upper bearing 1 NOTE: Install the bearing parallel until the stopper ring groove appears by pressing its outer race. CHAS CAUTION: Do not apply the grease on the bearing outer race because it will wear the rear shock absorber surface on which the bearing is press fitted. Install:
• Stopper ring (upper bearing) 1 New NOTE: After installing the stopper ring, push back the bearing until it contacts the stopper ring. Install:
• Lower bearing 1 NOTE: Install the bearing by pressing it on the side having the manufacture’s marks or numbers. Installed depth of the bearing a: 4 mm (0.16 in) Spring (rear shock absorber)

1. Install:

• Upper spring guide 2
• Lower spring guide 3 Adjust:
• Spring length (installed) Refer to “REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT” section in the CHAPTER 3.

1. Install:

• Apply the molybdenum disulfide grease on the dust seal lips and collars.
• Apply the lithium soap base grease on the O-rings. Install:
• Apply the molybdenum disulfide grease on the bearing and dust seal lips.
• Install the dust seals with their lips facing outward.

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• Rear shock absorber Install:
• Bolt (rear shock absorberframe) 1
• Nut (rear shock absorberframe) 3

• Bolt [rear frame (upper)] 2

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• Screw (air filter joint) 1

• Bolt [rear frame (lower)] 3

• Bolt (rear shock absorberrelay arm) 1
• Nut (rear shock absorber-relay arm) 2 NOTE: Apply the molybdenum grease on the bolt.

NOTE: Apply the molybdenum grease on the bolt.

• Rahmenheck-Schraube (unten) 3

ELECTRICAL COMPONENTS AND WIRING DIAGRAM

EC600000 ELECTRICAL NOTE: This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are requested not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical damage. EC610000

ELECTRICAL COMPONENTS AND WIRING DIAGRAM

EC611000 ELECTRICAL COMPONENTS

Headlight Multi-function display Engine stop switch Clutch switch Diode Starter relay diode

Throttle position sensor Starter relay Fuse Starting circuit cut-off relay CDI unit Taillight

7-1 Neutral switch Starter motor AC magneto Rectifier/regulator Ignition coil Spark plug

Start switch Main switch Speed sensor Battery

ELECTRICAL COMPONENTS AND WIRING DIAGRAM

EC612000 WIRING DIAGRAM

Headlight Multi-function display Engine stop switch Clutch switch Diode Starter relay diode Throttle position sensor Starter relay Fuse Starting circuit cut-off relay CDI unit

Taillight Neutral switch Starter motor AC magneto Rectifier/regulator Ignition coil Spark plug Start switch Main switch Speed sensor Battery

IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. No good *1 Check fuse. Replace fuse and check wire harness.

No good *2 Check battery. Recharge or replace.

Spark Spark gap test No spark Check entire ignition system for connection. (couplers, leads and ignition coil) No good Repair or replace.

No good Check engine stop switch. Replace.

No good Check main switch. Replace.

Check ignition coil.

Primary coil Secondary coil No good No good No good Replace. Replace. Replace.

Check neutral switch. No good

Replace CDI unit. *1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3. *2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3. *3 marked: Only when the ignition checker is used. NOTE:

• Remove the following parts before inspection.

1) Seat

2) Fuel tank

• Use the following special tools in this inspection. Dynamic spark tester: YM-34487 Ignition checker: 90890-06754 Pocket tester: YU-3112-C/ 90890-03112 7-5 Repair or replace.

SYSTEME D’ALLUMAGE

SPARK GAP TEST

1. Disconnect the ignition coil from

2. Remove the ignition coil cap.

3. Connect the dynamic spark

tester 1 (ignition checker 2) as shown.

• Spark plug 4 È For USA and CDN É Except for USA and CDN

Kick the kickstarter crank. Check the ignition spark gap. Start engine, and increase spark gap until misfire occurs. (for USA and CDN only)

COUPLERS, LEADS AND

IGNITION COIL CONNECTION

1. Check:

• Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace.
• Ignition coil and spark plug as they are fitted Push in the ignition coil until it closely contacts the spark plug hole in the cylinder head cover.

ENGINE STOP SWITCH

1. Inspect:

• Engine stop switch conduct Tester (+) lead → Black lead 1 Tester (–) lead → Black lead 2

PUSH IN Tester selector position Ω×1 FREE No continuity while being pushed → Replace. Continuity while being freed → Replace.

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• Rubber part a Tears/damage → Replace.

MAIN SWITCH INSPECTION

1. Inspect:

• Main switch conduct Tester (+) lead → Red lead 1 Tester (–) lead → Brown lead 2

Tester selector position Inspect:

• Main switch indicator light Use 12 V battery. Battery (+) lead → Red/Black lead 1 Battery (–) lead → Black lead 2 Indicator light does not come on → Replace.

• Rubber part a Tears/damage → Replace.

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Continuous while the main switch is moved to “OFF” → Replace. Not continuous while the main switch is moved to “ON” → Replace.

IGNITION COIL INSPECTION

1. Remove the ignition coil cap.

2. Inspect:

• Primary coil resistance Out of specification → Replace. Tester (+) lead → Orange lead 1 Tester (–) lead → Black lead 2

Primary coil resistance Tester selector position Inspect:

• Secondary coil resistance Out of specification → Replace. Tester (+) lead → Orange lead 1 Tester (–) lead → Spark plug terminal 2

Secondary coil resistance Tester selector position Inspect:

• Sealed portion of ignition coil

• Spark plug terminal pin b
• Threaded portion of spark plug Wear → Replace.

7 - 15

SYSTEME D’ALLUMAGE

AC MAGNETO INSPECTION

1. Inspect:

• Pickup coil resistance Out of specification → Replace. Tester (+) lead → Red lead 1 Tester (–) lead → White lead 2 Pickup coil resistance 248 ~ 372 Ω at 20 °C (68 °F) Tester selector position Ω × 100 ELEC Tester (+) lead → Sky blue lead 1 Tester (–) lead → Ground 2 Tester Sb Ground selector

position NEUTRAL No continuity while in neutral → Replace. Continuity while in gear → Replace. Ω × 100

CDI UNIT INSPECTION

Check all electrical components. If no fault is found, replace the CDI unit. Then check the electrical components again.

7 - 17

STARTING CIRCUIT CUT-OFF

SYSTEM OPERATION If the main switch is set to “ON”, the starter motor can only operate if at least one of the following conditions is met:

• The transmission is in neutral (the neutral switch is closed).
• The clutch lever is pulled to the handlebar (the clutch switch is closed). The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the starter motor. When at least one of the above conditions has been met the starting circuit cut-off relay is closed and the engine can be started by pressing the start switch.

WHEN THE TRANSMISSION IS IN NEUTRAL

WHEN THE CLUTCH

LEVER IS PULLED

TO THE HANDLEBAR

Battery Main fuse Main switch Starting circuit cut-off relay Start switch Diode Clutch switch Neutral switch Starter relay Starter motor

7 - 19

INSPECTION STEPS If the starter motor will not operate, use the following inspection steps. *1 Check fuse. No good Replace fuse and check wire harness.

*2 Check battery. No good Recharge or replace.

Check each coupler and wire connection. No good Repair or replace.

*3 Check main switch. No good Replace.

Check starter motor operation. No good Repair or replace.

Check starting circuit cut-off relay. No good Replace.

Check starter relay. No good Replace.

*4 Check neutral switch. No good Replace.

Check clutch switch. No good Replace.

Check start switch. No good *1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3. *2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3. *3 marked: Refer to “MAIN SWITCH INSPECTION” section. *4 marked: Refer to “NEUTRAL SWITCH INSPECTION” section. NOTE:

• Remove the following parts before inspection.

1) Seat

2) Rear fender

• Use 12 V battery in this inspection.
• Use the following special tools in this inspection. Pocket tester: YU-3112-C/ 90890-03112

7 - 21

Replace. DEMARRAGE ELECTRIQUE ELEC

COUPLERS AND LEADS

CONNECTION INSPECTION

1. Check:

• Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace.

STARTER MOTOR OPERATION

1. Connect the positive battery terminal 1 and starter motor lead

2 with a jumper lead 3. Not operate → Repair or replace the starter motor. ELEC

• A wire that is used as a jumper lead must have at least the same capacity or more as that of the battery lead, otherwise the jumper lead may burn.
• This check is likely to produce sparks, therefore make sure nothing flammable is in the vicinity.

STARTING CIRCUIT CUT-OFF

1. Remove:

• Starting circuit cut-off relay

2. Inspect:

• Starting circuit cut-off relay conduct Use 12 V battery. Battery (+) lead → Blue/Black lead 1 Battery (–) lead → Brown lead 2 Tester (+) lead → Blue/White lead 3 Tester (–) lead → Black lead 4 L/W

Tester selector position Connected to battery Ω×1 Not connected to battery

ELECTRIC STARTING SYSTEM

DEMARRAGE ELECTRIQUE

STARTER RELAY INSPECTION

1. Remove:

2. Inspect:

• Starter relay conduct Use 12 V battery. Battery (+) lead → Starter relay terminal 1 Battery (–) lead → Starter relay terminal 2 Tester (+) lead → Starter relay terminal 3 Tester (–) lead → Starter relay terminal 4 Continuous while not connected to the battery → Replace. Not continuous while connected to the battery → Replace.

CLUTCH SWITCH INSPECTION

1. Inspect:

• Clutch switch continuity Tester (+) lead → Black lead 1 Tester (–) lead → Black lead 2

PULL Tester selector position No continuous while being pulled → Replace. Continuous while being freed → Replace.

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Ω×1 Connected to battery Ω×1

Ter- Ter- Tester minal minal selector 4 position Not connected to battery ELEC

ELECTRIC STARTING SYSTEM

DEMARRAGE ELECTRIQUE DIODE INSPECTION

1. Remove the diode from wire harness.

2. Inspect:

• Diode continuity Use pocket tester (tester selection position Ω × 1)

Tester (+) → Blue/Red terminal 1 Tester (–) → Sky blue terminal 2 Continuous Tester (+) → Blue/Red terminal 1 Tester (–) → Blue/Yellow terminal 3 Continuous Tester (+) → Sky blue terminal 2 Tester (–) → Blue/Red terminal 1 No continuous Tester (+) → Blue/Yellow terminal 3 Tester (–) → Blue/Red terminal 1 No continuous Incorrect continuity → Replace.

START SWITCH INSPECTION

1. Inspect:

• Start switch continuity Tester (+) lead → Black lead 1 Tester (–) lead → Black lead 2

PUSH IN Tester selector position No continuous while being pushed → Replace. Continuous while being freed → Replace.

• Rubber part a Tears/damage → Replace.

7 - 31

1 Starter motor disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks

STARTER MOTOR REMOVAL

Preparation for removal Exhaust pipe

Refer to “EXHAUST PIPE AND SILENCER” section in the CHAPTER 3. Starter motor

Starter motor front cover

Washer (starter motor front cover)

Starter motor rear cover

7 - 33

INSPECTION AND REPAIR

1. Check:

• Commutator Dirt → Clean with 600 grit sandpaper. Measure:
• Commutator diameter a Out of specification → Replace the starter motor. Min. commutator diameter:

16.6 mm (0.65 in)

• Mica undercut a Out of specification → Scrape the mica to the proper measurement with a hacksaw blade which has been grounded to fit the commutator. Mica undercut:

1.5 mm (0.06 in)

NOTE: The mica must be undercut to ensure proper operation of the commutator. Measure:

• Armature assembly resistances (commutator and insulation) Out of specification → Replace the starter motor.

• Measure the armature assembly resistances with the pocket tester. Pocket tester: YU-3112-C/ 90890-03112 Armature assembly: Commutator resistance 1: 0.0189 ~ 0.0231 Ω at 20 °C (68 °F) Insulation resistance Above 1 MΩ at 20 °C (68 °F)
• If any resistance is out of specification, replace the starter motor.

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Tester tascabile: YU-3112-C/ 90890-03112 Measure:

• Brush length a Out of specification → Replace the brushes as a set.

3.5 mm (0.14 in)

• Brush spring force Out of specification → Replace the brush springs as a set. ELEC

1. Install:

• Armature assembly 1 Install while holding down the brush using a thin screw driver.

ATTENTION: CAUTION: Be careful not to damage the brush during installation.

• Starter motor yoke 2 NOTE:
• Install the starter motor yoke with its groove a facing front cover.
• Align the match mark b on the starter motor yoke with the match mark c on the starter motor rear cover.

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• Washer (starter motor front cover) 3
• Starter motor front cover 4

• For installation, align the projections on the washer with the slots in the front cover.
• Align the match mark a on the starter motor yoke with the match mark b on the starter motor front cover. Install:
• O-ring 2 New NOTE: Apply the lithium soap base grease on the O-ring.

7 - 41

INSPECTION STEPS If the battery is not charged, use the following inspection steps. *1 Check fuse. No good Replace fuse and check wire harness.

*2 Check battery. No good Recharge or replace.

Check each coupler and wire connection. No good Repair or replace.

Check charging voltage.

Charging system is good.

Replace rectifier/regulator. *1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3. *2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3. NOTE:

• Remove the following parts before inspection.

1) Seat

2) Fuel tank

• Use the following special tool in this inspection. Pocket tester: YU-3112-C/ 90890-03112

7 - 43

COUPLERS AND LEADS

CONNECTION INSPECTION

1. Check:

• Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. Y W

CHARGING VOLTAGE INSPECTION

1. Start the engine.

2. Inspect:

• Charging voltage Out of specification → If no failure is found in checking the source coil resistance, replace the rectifier/regulator. Tester (+) lead → Red lead 1 Tester (–) lead → Black lead 2 Charging voltage

14.0 ~ 15.0 V

Tester selector position Tester (+) lead → White lead 1 Tester (–) lead → Ground 2 Charging coil resistance Tester selector position Inspect:

• Charging coil resistance Out of specification → Replace.

7 - 49

THROTTLE POSITION SENSOR SYSTEM

INSPECTION STEPS If the throttle position sensor will not operate, use the following inspection steps. Check entire ignition system for connection. No good Repair or replace.

Check throttle position sensor. Throttle position sensor coil No good Replace. Throttle position sensor input voltage NOTE: Use the following special tools in this inspection. Pocket tester: YU-3112-C/ 90890-03112

7 - 51

Do not loosen the screw (throttle position sensor) 1 except when changing the throttle position sensor due to failure because it will cause a drop in engine performance. EC624000

COUPLERS AND LEADS

CONNECTION INSPECTION

1. Check:

• Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace.

THROTTLE POSITION SENSOR

1. Inspect:

• Throttle position sensor coil resistance Out of specification → Replace. Tester (+) lead → Blue lead 1 Tester (–) lead → Black lead 2 Throttle position sensor coil resistance Tester selector position Loosen:
• Throttle stop screw 1 NOTE: Turn out the throttle stop screw until the throttle shaft is in the full close position.

7 - 57

• Throttle position sensor coil variable resistance Check that the resistance in increased as the throttle grip is moved from the full close position to the full open position. Out of specification → Replace. Tester (+) lead → Yellow lead 1 Tester (–) lead → Black lead 2 Throttle Tester position sensor selector coil variable position resistance

NOTE: Loosen the screw (throttle position sensor) using the T25 bit.

• Throttle position sensor

• Throttle position sensor 1
• Screw (throttle position sensor) 2 NOTE:
• Align the slot a in the throttle position sensor with the projection b on the carburetor.
• Temporarily tighten the screw (throttle position sensor).

7 - 59

THROTTLE POSITION SENSOR

REPLACEMENT AND ADJUSTMENT

1. Remove:

• Throttle position sensor coupler

2. Remove:

• Screw (throttle position sensor) 1
• Throttle position sensor 2

Full Full closed opened Zero ~ 4 ~ 6 kΩ 3 kΩ at at 20 °C 20 °C (68 °F) (68 °F) ELEC Install:

• Throttle position sensor coupler Adjust:
• Engine idling speed Refer to “ENGINE IDLING SPEED ADJUSTMENT” section in the CHAPTER 3.

Insert the thin electric conductors 2 (lead) into the throttle position sensor coupler 1, as shown, and connect the tester to them.

Tester (+) lead → Yellow lead 3 Tester (–) lead → Black lead 4

• Do not insert the electric conductors more than required because it may reduce the waterproof function of the coupler.
• Make sure that a short-circuit does not develop between the terminals because it may cause damage to electrical components.

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Start the engine. Adjust:

• Throttle position sensor output voltage

Adjustment steps: Adjust the installation angle of the throttle position sensor 1 to obtain the specified output voltage. NOTE: Measure the output voltage accurately with a digital electronic voltmeter that gives an easy reading of a small voltage. Throttle position sensor output voltage Tester selector position

0.58 ~ 0.78 V

10. Put the aligning marks a on the

throttle position sensor and carburetor.

11. Stop the engine.

12. Remove the carburetor.

13. Tighten:

• Screw (throttle position sensor) 1 NOTE: Tighten the screw (throttle position sensor) using the T25 bit.

14. Install the carburetor.

THROTTLE POSITION SENSOR SYSTEM

SYSTEME DU CAPTEUR DE POSITION DE PAPILLON DES GAZ

THROTTLE POSITION SENSOR

INPUT VOLTAGE INSPECTION

1. Disconnect the throttle position

2. Start the engine.

3. Inspect:

• Throttle position sensor input voltage Out of specification → Replace the CDI unit. Tester (+) lead → Blue lead 1 Tester (–) lead → Black/Blue lead 2 Throttle position sensor input voltage Tester selector position 4~6V DCV-20 ELEC

LIGHTING SYSTEM INSPECTION STEPS Refer to the following flow chart when inspecting the lighting system for possible problems. Check the bulb and bulb socket. No good Replace the bulb and/or bulb socket. No good Replace the taillight assembly.

Check the entire lighting system proper for connections. Improperly connected Repair or replace.

Check the rectifier/regulator. Out-put voltage NOTE:

• Replace the bulb and/or bulb socket.

1) Seat

2) Fuel tank

3) Left side cover

• Use the following special tool. Pocket tester: YU-3112-C/ 90890-03112

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No good Replace. ECLAIRAGE ELEC

LIGHTING SYSTEM ECLAIRAGE

CHECKING THE TAILLIGHT

1. Disconnect the taillight coupler.

2. Connect two jumper leads 1

from the battery terminals to the respective coupler terminal as shown. Battery (+) terminal → Blue lead 2 Battery (–) terminal → Black lead 3

• LED (for proper operation) Does not light → Replace the taillight assembly. WARNING

• A wire that is used as a jumper lead must have at least the same capacity of the battery lead, otherwise the jumper lead may burn.
• This check is likely to produce sparks, therefore, make sure no flammable gas or fluid is in the vicinity.

AC MAGNETO INSPECTION

1. Inspect:

• Lighting coil resistance Out of specification → Replace. Tester (+) lead → Yellow lead 1 Tester (–) lead → Ground 2 Lighting coil resistance Tester selector position RECTIFIER/REGULATOR INSPECTION

1. Connect the battery leads.

2. Start the engine.

3. Turn on the headlight and taillight by turning on the light

4. Inspect:

• Out-put voltage Out of specification → Replace rectifier/regulator. Tester (+) lead → Yellow lead 1 Tester (–) lead → Black lead 2 Out-put voltage Tester selector position

12.5 ~ 13.5 V

at 5,000 r/min ACV-20 SIGNALING SYSTEM INSPECTION STEPS If the speedometer will not operate, use the following inspection steps. No good *1 Check battery. Recharge or replace.

No good Check each coupler and wire connection. Repair or replace. Input voltage Output voltage Check speed sensor. No good No good Replace wire harness. Replace multi-function display. No good *1 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3. NOTE:

• Remove the following parts before inspection.

1) Headlight

• Use the following special tools in this inspection. Pocket tester: YU-3112-C/ 90890-03112

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COUPLERS AND LEADS

CONNECTION INSPECTION

1. Check:

• Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace.

MULTI-FUNCTION DISPLAY INPUT

1. Disconnect the multi-function

2. Set the main switch to “ON”.

• Multi-function display input voltage Out specification Replace wire harness. Tester (+) lead → Brown lead 1 Tester (–) lead → Black lead 2 Multi-function display input voltage Tester selector position 10 V or more DCV-20 CAUTION: Make sure that a short-circuit does not develop between the terminals because it may cause damage to electrical components. MULTI-FUNCTION DISPLAY

OUTPUT VOLTAGE INSPECTION

1. Disconnect the multi-function

2. Set the main switch to “ON”.

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Tester (+) lead → Red lead 1 Tester (–) lead → Black/White lead 2 Multi-function display output voltage Tester selector position

4.5 V or more

ATTENTION: CAUTION: Make sure that a short-circuit does not develop between the terminals because it may cause damage to electrical components.

SPEED SENSOR OUTPUT

1. Insert the thin electric conductors 1 (lead) into the speed sensor coupler 2, as shown, and

connect the tester to them. Tester (+) lead → White lead 3 Tester (–) lead → Black lead 4 CAUTION:

• Do not insert the electric conductors more than required because it may reduce the waterproof function of the coupler.
• Make sure that a short-circuit does not develop between the terminals because it may cause damage to electrical components. Set the main switch to “ON”.

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• Speed sensor output voltage Output voltage not correct → Replace the speed sensor. Measurement steps:
• Elevate the front wheel and slowly rotate it.
• Measure the voltage (DCV) of white lead and black lead. With each full rotation of the front wheel, the voltage reading should cycle from 0.6 V to 4.8 V to 0.6 V to 4.8 V.

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