WR250FN - Off-road motorcycle YAMAHA - Free user manual and instructions

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USER MANUAL WR250FN YAMAHA

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©2000 by Yamaha Motor Co., Ltd. 1st Edition, November 2000 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan WR250F(N)

MANUALE DI SERVIZIO DEL

PROPRIETARIO ©2000 by Yamaha Motor Co., Ltd. 1a edizione, novembre 2000 Tutti i diritti sono riservati. La ristampa o l’uso non autorizzato senza previo permesso scritto di Yamaha Motor Co., Ltd. sono espressamente vietati. Stampato in Giappone EC020000 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 NOTE: As improvements are made on this model, some data in this manual may become outdated. If you have any questions, 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

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

1. 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.

2. THIS MACHINE IS DESIGNED TO BE

RIDDEN BY THE OPERATOR ONLY. Do not carry passengers on this machine.

3. 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.

4. ALWAYS MAINTAIN YOUR MACHINE

IN PROPER WORKING ORDER. For safety and reliability, the machine must be properly maintained. Always perform the pre-operation checks indicated in this manual. Correcting a mechanical problem before you ride may prevent an accident.

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 OPERATE THE 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 THE MACHINE CAREFULLY;

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

9. THE ENGINE EXHAUST PIPE, 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.

THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION!

BECOME ALERT! YOUR SAFETY IS

INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the machine. NOTE: A NOTE provides key information to make procedures easier or clearer. EC082000

FINDING THE REQUIRED PAGE

1. This manual consists of seven chapters;

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

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. COMMENT UTILISER CE MANUEL BENUTZERHINWEISE COME UTILIZZARE QUESTO MANUALE

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.

ILLUSTRATED SYMBOLS (Refer to the illustration)

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

1 General information 2 Specifications 3 Regular inspection and adjustments 4 Engine 5 Chassis 6 Electrical 7 Tuning

Illustrated symbols 8 to D are used to identify the specifications appearing in the text.

8 With engine mounted 9 Special tool 0 Filling fluid A Lubricant B Tightening C Specified value, Service limit D Resistance (Ω), Voltage (V), Electric current (A)

E Apply engine oil F Apply molybdenum disulfide oil G Apply lightweight lithium-soap base grease H Apply molybdenum disulfide grease

Illustrated symbols E to H in the exploded diagrams indicate grade of lubricant and location of lubrication point.

KICK SHAFT AND SHIFT SHAFT ......... 4-71

CDI MAGNETO ....................................... 4-78

ENGINE REMOVAL ................................ 4-82

CRANKCASE AND CRANKSHAFT ....... 4-87

TRANSMISSION, SHIFT CAM

AND SHIFT FORK .................................. 4-96

1 Clutch lever 2 Decompression lever 3 Trip meter 4 Light switch 5 Front brake lever 6 Throttle grip 7 Radiator cap 8 Fuel tank cap 9 Oil tank cap 0 Engine stop switch A Taillight B Kickstarter crank C Fuel tank D Headlight E Radiator F Coolant drain bolt G Rear brake pedal H Valve joint I Fuel cock J Cold starter knob K Hot starter knob (red) L Drive chain M Air filter N Shift pedal O 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 DESCRIPTION FAHRZEUGBESCHREIBUNG DESCRIZIONE GEN INFO RENSEIGNEMENTS GENERAUX ALLGEMEINE ANGABEN INFORMAZIONI GENERALI DESCRIPTION FAHRZEUGBESCHREIBUNG DESCRIZIONE

MACHINE IDENTIFICATION GEN INFO EC120001 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. 1-2

PREPARATION FOR REMOVAL AND

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 end ● Air filter intake hole ● Water pump housing hole at the bottom ● Carburetor accelerator pump

2. Use proper tools and cleaning equipment. Refer to “SPECIAL TOOLS” section.

3. When disassembling the machine, keep

mated parts together. They include gears, cylinders, pistons, and other mated parts that have been “mated” through normal wear. Mated parts must be reused as an assembly or replaced.

4. During the machine disassembly, clean

all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled.

5. Keep away from fire.

1-3 INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFORMAZIONI IMPORTANTI GEN INFO INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFORMAZIONI IMPORTANTI

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. EC133000

GASKETS, OIL SEALS AND O-RINGS

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

be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned.

2. Properly oil all mating parts and bearings

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

LOCK WASHERS/PLATES AND COTTER

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. 1-4 INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFORMAZIONI IMPORTANTI GEN INFO

produttrice rivolto verso l’esterno. (In altre parole, le lettere stampigliate devono venirsi a trovare sul lato a vista). Quando si montano i paraolio, applicarvi un leggero strato di grasso a base di litio leggero. Oliare liberamente i cuscinetti durante il montaggio. ACHTUNG: Lager nie mit Druckluft trockenblasen, da hierdurch die Lagerflächen beschädigt werden. ATTENTION: Ne pas sécher les roulements à l’air comprimé. Cela endommagerait les surfaces de roulement. 1-4 ATTENZIONE: Non utilizzare aria compressa per provare se i cuscinetti sono liberi di ruotare a secco. Ciò provoca danni alle superfici dei cuscinetti. IMPORTANT INFORMATION GEN INFO 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 sharp-edged corner 2 is positioned opposite to the thrust 3 it receives. See the sectional view. 4 Shaft 1-5 INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN INFORMAZIONI IMPORTANTI CIRCLIPS

1. Avant remontage, tous les circlips

CHECKING OF CONNECTION

CHECKING OF CONNECTION

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

2. Dry each terminal with an air blower.

3. Connect and disconnect the connector

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

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

1 and reinsert the terminal into the connector.

● Connector NOTE: The two connectors “click” together.

7. Check for continuity with a tester.

NOTE: ● If there in no continuity, clean the terminals. ● Be sure to perform the steps 1 to 7 listed above when checking the wireharness. ● For a field remedy, use a contact revitalizer available on the market. ● Use the tester on the connector as shown. 1-6

The engine stop switch 1 is located on the left handlebar. Continue pushing the engine stop switch till the engine comes to a stop. EC152000 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. EC153000 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. 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.

DEL MOTORE L’interruttore di arresto del motore 1 è posto sul manubrio a sinistra. Tenere premuto l’interruttore di arresto del motore finché il motore non si arresta completamente. CONTROL FUNCTIONS GEN INFO DECOMPRESSION LEVER CAUTION: Never use the decompression lever after the engine is started. The engine may be damaged if you use the decompression lever while it is running. The decompression lever 1 is located on the left handlebar and is used when starting the engine. Squeezing the decompression lever presses down on the exhaust valve and releases the pressure in the cylinder head. This enables the vehicle to be kickstarted more easily. EC155001 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

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

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.

CONTROL FUNCTIONS GEN INFO EC158010 FUEL COCK The fuel cock supplies fuel from the tank to carburetor while filtering the fuel. The fuel cock has the three positions: OFF:With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running. ON: With the lever in this position, fuel flows to the carburetor. Normal riding is done with the lever in this position. RES:This indicates reserve. If you run out of fuel while riding, move the lever to this position. FILL THE TANK AT THE FIRST

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.

The hot starter knob (red) 1 is used when starting a warm engine. Use the hot starter knob when starting the engine again immediately after it was stopped (the engine is still warm). Pulling out the hot starter knob injects secondary air to thin the air-fuel mixture temporarily, allowing the engine to be started more easily. CAUTION: After the engine has started, be sure to push the hot starter knob back in.

METTERE LA LEVA SU “ON”

CONTROL FUNCTIONS/FUEL

GEN INFO EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose. CAUTION: In this installation, make sure the arrow faces the fuel tank and also downward. LIGHTS SWITCH The lights switch 1 is located on the handlebar. FLAP In order to prevent water from entering the carburetor while the motorcycle is operated in the rain, attach the accessory flap 1 to the frame at the rear of the fuel tank. NOTE: Riding with the flap attached when it is not raining can help keep out dust, dirt and sand. FUEL Always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race. Recommended fuel: Except for AUS: Premium unleaded fuel with a research octane number of 95 or higher. For AUS: Unleaded fuel only NOTE: Except for AUS:

1. If knocking or pinging occurs, use a different brand of gasoline or higher octane

2. If unleaded gasoline is not available, then

leaded gasoline can be used.

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:

The carburetor on this motorcycle 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 kick starter may kick back. Also, if the throttle is open the air/ fuel mixture may be too lean for the engine to start. Never use the decompression lever after the engine is started. The engine may be damaged if you use the decompression lever while it is running. Before starting the machine, perform the checks in the pre-operation check list.

STARTING A COLD ENGINE

1. Inspect the coolant level.

2. Turn the fuel cock to “ON”.

3. Shift the transmission into neutral.

4. Fully open the cold starter knob.

5. Without pulling in the decompression

lever, slowly depress the kickstarter crank until the compression stroke is found. When considerable resistance of the kickstarter crank is felt, the engine is on the compression stroke. If the engine is on the exhaust stroke, resistance will only be felt when the kickstarter crank is initially depressed, not through the entire range of depression (as when the engine is on the compression stroke); therefore, depress the kickstarter crank a few more times.

6. Pull the decompression lever to the handlebar and depress the kickstarter crank

7. Release the decompression lever and

return the kickstarter crank to its original position and then kick the kickstarter crank. WARNING Do not open the throttle while kicking the kickstarter crank. Otherwise, the kick starter may kick back.

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

Do not operate the cold starter knob and throttle. Open the hot starter knob (red) and start the engine by kicking the kickstarter crank forcefully with a firm stroke. As soon as the engine starts, push in the hot starter knob to close the air passage. Restarting an engine after a fall Pull the hot starter knob (red) and start the engine. As soon as the engine starts, push in the hot starter knob to close the air passage. The engine fails to start Pull the hot starter knob (red) all the way out, pull the decompression lever to the handlebar, 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”. Throttle grip operation* Cold starter knob Starting a cold engine Air temperature = less than Open 3 or 4 times 5 ˚C (41 ˚F) Air temperature = more None than 5 ˚C (41 ˚F) Air temperature (normal temperature) = between 5 ˚C None ON/OFF (41 ˚F) and 25 ˚C (77 ˚F) Air temperature = more None OFF than 25 ˚C (77 ˚F) Starting an engine after a long None period of time Restarting a warm engine None OFF Restarting an engine after a fall None OFF Hot starter knob (red) OFF OFF OFF OFF 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. Before starting the engine, fill the fuel

2. Perform the pre-operation checks on the

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

motorcycle 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. The machine will now be ready to race. CAUTION:

After the break-in or before each race, you must check the entire machine for loose fittings and fasteners as per “TORQUE-CHECK POINTS”. Tighten all such fasteners as required. When any of the following parts have been replaced, they must be broken in. CYLINDER AND CRANKSHAFT: About one hour of break-in operation is necessary.

PISTON, RING, VALVES, CAMSHAFTS

AND GEARS: These parts require about 30 minutes of break-in operation at half-throttle or less. Observe the condition of the engine carefully during operation.

CLEANING AND STORAGE

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 coin-operated car washers.

4. 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.

5. Rinse the machine off immediately with

clean water, and dry all surfaces with a soft towel or cloth.

6. Immediately after washing, remove

excess water from the chain with a paper towel and lubricate the chain to prevent rust.

7. Clean the seat with a vinyl upholstery

cleaner to keep the cover pliable and glossy.

8. Automotive wax may be applied to all

painted or chromed surfaces. Avoid combination cleaner-waxes, as they may contain abrasives.

9. After completing the above, start the

engine and allow it to idle for several minutes.

CLEANING AND STORAGE

GEN INFO EC1B2001 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

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.

GENERAL SPECIFICATIONS SPEC EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: WR250FN (USA) WR250F (EUROPE) WR250F(N) (CDN, AUS, NZ, ZA) 5PH1 (USA) 5PH2 (EUROPE) 5PH4 (CDN, AUS, NZ, ZA) Model code number: Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Basic weight: With oil and full fuel tank Engine: Engine type Cylinder arrangement Displacement Bore × stroke Compression ratio Starting system Lubrication system: Oil type or grade: Engine oil

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

(For USA and CDN) At 5 ˚C (40 ˚F) or higher Å Yamalube 4 (20W-40) or SAE 20W-40 type SH motor oil (Non-Friction modified) At 15 ˚C (60 ˚F) or lower ı Yamalube 4 (10W-30) or SAE 10W-30 type SH motor oil (Non-Friction modified) and/or Yamalube 4-R (15W-50) (Non-Friction modified)

(Except for USA and CDN) API “SH” or higher grade 10W-30 10W-40 15W-40 20W-40 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 SPEC

Wet type element Premium unleaded fuel with a research octane number of 95 or higher. (Except for AUS) Unleaded fuel only (For AUS) 12 L (2.64 Imp gal, 3.17 US gal) (For USA, CDN)

---0.05 mm (0.002 in) Chain drive (Left)

Intake “A” “B” Exhaust “A” “B” Camshaft runout limit 2-4 MAINTENANCE SPECIFICATIONS Item SPEC Standard Timing chain: Timing chain type/No. of links Timing chain adjustment method Valve, valve seat, valve guide: Valve clearance (cold)

Head Diameter “A” head diameter

“B” face width “C” seat width

“D” margin thickness Stem outside diameter

(0.9606 ~ 0.9685 in)

Valve spring: Free length Set length (valve closed) Compressed pressure (installed)

Direction of winding (top view) SPEC

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” Decompression device: Type Cable free play

Quantity Clutch housing thrust clearance

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 Wire mesh type Trochoid type

0.6 L (0.53 lmp qt, 0.63 US qt)

2-9 SPEC 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 Oil pressure check bolt Cylinder Balancer weight Balancer shaft driven gear Timing chain guide (intake side) Decompression shaft Decompression cable guide Timing chain tensioner Timing chain tensioner cap bolt Impeller Radiator hose clamp Coolant drain bolt Water pump housing Radiator Radiator guard Radiator pipe Oil pump cover Oil pump Oil filter element drain bolt Oil filter element cover Oil strainer Oil delivery pipe 1 (M10) (M8) Oil delivery pipe 2 Oil hose Oil hose clamp Oil strainer and frame Carburetor joint clamp Air filter joint clamp Throttle cable cover Air filter joint Air filter joint and air filter case Air filter element Air filter case cover Exhaust pipe (nut) (bolt) Exhaust pipe protector 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 M6 × 1.0 M14 × 1.0 M6 × 1.0 M6 × 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 M18 × 1.5 M4 × 0.7 M6 × 1.0 M5 × 0.8 M5 × 0.8 M5 × 0.8 M6 × 1.0 M6 × 1.0 M8 × 1.25 M8 × 1.25 M6 × 1.0

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

MAINTENANCE SPECIFICATIONS SPEC 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 Swingarm: Swingarm free play limit End Standard Taper roller bearing USA, CDN EUROPE 300 mm (11.8 in) ← 460 mm (18.1 in) ← K = 4.31 N/mm K = 4.12 N/mm (0.44 kg/mm, (0.42 kg/mm,

113 links + joint 40 ~ 50 mm (1.6 ~ 2.0 in)

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 below footrest top) Clutch lever free play (at lever pivot) Throttle grip free play

MAINTENANCE SPECIFICATIONS Part to be tightened Upper bracket and outer tube Lower bracket and outer tube Upper bracket and steering stem Handlebar 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 Meter cable holder and front fork protector Front fork and brake hose guide Front fork and brake hose holder Front fork and brake hose cover (M8) (M6) Throttle grip cap Front brake master cylinder Brake lever mounting bolt Brake lever mounting nut Brake lever position locknut Front brake hose guide Clutch lever holder Clutch lever mounting bolt Decompression lever holder Light switch Front brake master cylinder cap Front brake hose union bolt Front brake caliper 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 Thread size Q’ty M8 × 1.25 M8 × 1.25 M24 × 1.0 M8 × 1.25 M28 × 1.0 M48 × 1.0 M30 × 1.0 M12 × 1.25 M5 × 0.8 M6 × 1.0 M5 × 0.8 M5 × 0.8 M6 × 1.0 M8 × 1.25 M6 × 1.0 M5 × 0.8 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M5 × 0.8 M5 × 0.8 M6 × 1.0 M5 × 0.8 M4 × 0.7 M4 × 0.7 M10 × 1.25 M8 × 1.25 M10 × 1.0 M10 × 1.0 M10 × 1.0 M8 × 1.25 M16 × 1.5 M8 × 1.25 M6 × 1.0

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

MAINTENANCE SPECIFICATIONS Part to be tightened Rear brake disc Brake pedal Rear brake master cylinder Rear brake reservoir tank Rear brake reservoir tank cap Rear brake hose union bolt Rear wheel axle and axle nut Nipple (spoke) Rear wheel sprocket Rear brake disc cover Rear brake caliper protector Engine mounting: Engine and engine bracket (front) Engine and frame (lower) Engine bracket and frame Engine and engine bracket (upper) Lower engine guard Left engine guard Right engine guard 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 Swingarm and brake hose holder Drive chain tensioner Drive chain case Seal guard and swingarm Fuel tank Fuel cock Seat set bracket and fuel tank Hooking screw (fitting band) and fuel tank Radiator cover Front fender Rear fender Side cover Seat Thread size Q’ty M6 × 1.0 M8 × 1.25 M6 × 1.0 M6 × 1.0 M4 × 0.7 M10 × 1.25 M20 × 1.5 M8 × 1.25 M6 × 1.0 M6 × 1.0 M10 × 1.25 M10 × 1.25 M8 × 1.25 M10 × 1.25 M6 × 1.0 M8 × 1.25 M8 × 1.25 M16 × 1.5 M14 × 1.5 M14 × 1.5 M14 × 1.5 M10 × 1.25 M10 × 1.25 M8 × 1.25 M5 × — 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 M8 × 1.25

MAINTENANCE SPECIFICATIONS Part to be tightened Headlight stay (lower) and lower bracket Headlight (left and right) Headlight (lower) Taillight Taillight lead clamp and rear fender Coolant reservoir Sidestand bracket and frame Sidestand Thread size Q’ty M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M4 × 1.59 M6 × 1.0 M10 × 1.25 M10 × 1.25

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

MAINTENANCE SPECIFICATIONS SPEC EC212300 ELECTRICAL Item Ignition system: Advancer type CDI: Magneto-model/manufacturer Charging coil 1 resistance (color) Charging coil 2 resistance (color) Lighting coil resistance (color) Pickup coil resistance (color) CDI unit-model/manufacturer Ignition coil: Model/manufacturer Minimum spark gap Primary coil resistance Secondary coil resistance Part to be tightened Stator Rotor Neutral switch Ignition coil Standard Limit Electrical

640 ~ 960 Ω at 20 ˚C (68 ˚F) (Green – Brown) 464 ~ 696 Ω at 20 ˚C (68 ˚F) (Green – Pink)

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)

Unit Read Definition Measure

Newton 1 kg × m/sec2 Force

1 Hose guide 2 Brake hose 3 Voltage regulator 4 Light switch lead 5 Fuel tank breather hose 6 Clamp 7 Oil tank breather hose 8 Engine stop switch lead 9 Sub-wire harness 0 Taillight lead A Throttle position sensor lead B Neutral switch lead C Oil hose D Cylinder head breather hose E CDI magneto lead F Clutch cable G Cable guide H Carburetor breather hose Î Fasten the engine stop switch I Carburetor overflow hose lead and ignition coil lead of the J Coolant reservoir breather hose sub-wire harness. K Decompression cable ‰ Fasten the sub-wire harness L CDI unit lead and engine stop switch lead. M Ignition coil lead Ï Pass the cylinder head breather N Voltage regulator lead hose along the right side of the oil tank breather hose. Å Pass the fuel tank breather hose Fasten the sub-wire harness behind handlebar, then insert it and engine stop switch lead in into the steering stem hole. front of the upper engine brackı Pass the decompression cable, ets. engine stop switch lead and light Fasten the sub-wire harness. switch lead under where the oil Pass the sub-wire harness hose is attached. between the upper engine Ç Pass the voltage regulator lead, brackets. engine stop switch lead and light Fasten the sub-wire harness. switch lead over the radiator Fasten the throttle position senhose. sor lead.

Ò Pass the carburetor breather hose and overflow hose between the connecting rod and cross tube (frame). ˜ Pass the cylinder head breather hose through the hose guide. ˆ Pass the clutch cable through the cable guide. Ø Fasten the neutral switch lead and CDI magneto lead. ∏ Pass the clutch cable along the inner side of the cylinder head breather hose. Œ Pass the cylinder head breather hose along the inner side of the radiator hose.  Pass the clutch cable in front of the radiator mounting boss. Í Fit the brake hose into the guides on the protector. Ê Fasten the ground lead together with the ignition coil lead. Ë Do not allow the engine stop switch leads and light switch lead to slacken between the two clamps. ◊ Pass the decompression cable along the right side of the cylinder head breather hose. „ Pass the clutch cable through the cable guides.

SPEC Ù Pass the carburetor breather hoses and overflow hose so that all there hoses do not contact the rear shock absorber. Á Position each lead at the lower left of the main tube (frame).

1 Coolant reservoir breather hose 2 Radiator breather hose 3 Ignition coil 4 CDI unit 5 CDI unit band 6 Throttle cable (return) 7 Throttle cable (pull) 8 Cable guide 9 CDI unit lead 0 Spark plug lead A CDI unit stay SPEC Å Fasten the coolant reservoir breather hose and carburetor breather hose together. ı Pass the throttle cables along inner side of the spark plug lead. Ç Pass the CDI unit lead between the radiator hose and radiator mounting boss. Î Pass the throttle cables through the cable guide. ‰ Insert the CDI unit band over the CDI unit stay (frame) as far as possible.

SPEC Å Fasten the coolant reservoir hose and coolant reservoir breather hose. ı Do not allow the taillight lead to slacken. Ç Pass the coolant reservoir hose and coolant reservoir breather hose through the hose guide. 1 Coolant reservoir hose 2 Coolant reservoir breather hose 3 Clamp 4 Taillight lead 5 Hose guide

SPEC Å Install the brake hose to the brake caliper with the paint on the pipe facing the brake caliper and with the pipe contacting the brake caliper projection. ı Pass the brake hose into the brake hose holders. Ç If the brake hose contacts the spring (rear shock absorber), correct its twist. Î Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the brake master cylinder. 1 Brake hose 2 Brake hose holder 3 Brake master cylinder

1 Throttle cable 2 Light switch 3 Light switch lead 4 Clamp 5 Decompression cable 6 Clutch cable 7 Hose guide 8 Trip meter 9 Brake hose 0 Engine stop switch lead SPEC Å Fasten the engine stop switch lead to the handlebar with the plastic band. ı Pass the decompression cable between the brake hose and clutch cable. Ç Pass the throttle cables between the upper bracket and trip meter. Î Pass the light switch leads behind the engine stop switch lead, then pass the headlight lead (of the light switch leads) in front of the head pipe. ‰ Install the trip meter cable so that its bent portion faces the chassis rear. Ï Install the brake hose so that it contacts the master cylinder projection and that its bent portion faces downward.

MAINTENANCE INTERVALS The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. Item

Clean VALVES Check the valve clearances. Inspect Replace VALVE SPRINGS Inspect Replace VALVE LIFTERS Inspect Replace CAMSHAFTS Inspect Replace

TIMING CHAIN SPROCKETS, TIMING

CHAIN Inspect Replace PISTON Inspect Clean Replace PISTON RING Inspect Replace PISTON PIN Inspect Replace CYLINDER HEAD Inspect and clean CYLINDER Inspect and clean Replace CLUTCH Inspect and adjust Replace TRANSMISSION Inspect Replace bearing After Every break-in race

Every Every third race fifth race

Check for scratches and wear. Inspect the camshaft surface. Check for wear on the teeth and for damage. Inspect crack Remove carbon Check ring end gap Remove carbon Change gasket

3-1 Check the free length and the tilt.

The engine must be cold. Check the valve seats and valve stems for wear. Inspect score marks Inspect wear Inspect housing, friction plate, clutch plate and spring MAINTENANCE INTERVALS Item

SHIFT FORK, SHIFT CAM, GUIDE BAR

Inspect ROTOR NUT Retighten

EXHAUST PIPE, SILENCER, PROTECTOR

Inspect and retighten Clean Replace *SPARK ARRESTER Clean CRANK Inspect and clean CARBURETOR Inspect, adjust 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 AIR FILTER Clean and lubricate Replace FRAME Clean and inspect

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 FRONT FORKS Inspect and adjust Replace oil Replace oil seal After Every break-in race Every Every third race fifth race

As required INSP ADJ Remarks

• Whichever comes first

When using a high-pressure washer, make sure that water does not enter the accelerator pump.

Every two years Refer to “STARTING AND BREAK-IN” section in the CHAPTER 1.

Use foam air-filter oil

Every one year Suspension oil “01”

Inspect and adjust Lube Retighten

CHAIN GUARD AND ROLLERS

Inspect SWINGARM Inspect and retighten

RELAY ARM, CONNECTING ROD

Inspect and lube 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 After Every break-in race

Every Every third race fifth race

As required INSP ADJ

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

GENERAL INSPECTION AND MAINTENANCE

Item Coolant Fuel Engine oil Gear shifter and clutch Throttle grip/Housing Brakes Drive chain Wheels Steering Front forks and rear shock absorber Cables (wires) Exhaust pipe Rear wheel sprocket Lubrication Bolts and nuts Lead connectors Settings Routine Check that coolant is filled up to the radiator cap. Check that the coolant level is correct in the coolant reservoir. Check the cooling system for leakage. Check that a fresh gasoline is filled in the fuel tank. Check the fuel line for leakage. Check that the oil level is correct. Check the crankcase and frame oil line for leakage. Check that gears can be shifted correctly in order and that the clutch operates smoothly. Check that the throttle grip operation and free play are correctly adjusted. Lubricate the throttle grip and housing, if necessary. Check the play of front brake and effect of front and rear brake. Check drive chain slack and alignment. Check that the drive chain is lubricated properly. Check for excessive wear and tire pressure. Check for loose spokes and have no excessive play. Check that the handlebar can be turned smoothly and have no excessive play. Check that they operate smoothly and there is no oil leakage. 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. Check that the exhaust pipe is tightly mounted and has no cracks. Check that the rear wheel sprocket tightening bolt is not loose. Check for smooth operation. Lubricate if necessary. Check the chassis and engine for loose bolts and nuts. Check that the CDI magneto, CDI unit, and ignition coil are connected tightly. Is the machine set suitably for the condition of the racing course and weather or by taking into account the results of test runs before racing? Are inspection and maintenance completely done? 3-4 Page P.3-5 ~ 9 P.1-13 P.3-14 ~ 17 P.3-9 P.3-10 ~ 11 P.3-26 ~ 32 P.3-33 ~ 35 P.3-43 ~ 44 P.3-44 ~ 45 P.3-35 ~ 42 P.4-2 P.3-33 P.3-46 P.1-18 P.1-6 P.7-1 ~ 22

COOLANT LEVEL INSPECTION

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.

1. Place the machine on a level place, and

hold it in an upright position.

● Coolant level Coolant level should be between the maximum a and minimum b marks. Coolant level is below the “LOW” level line → Add soft water (tap water) up to the proper level.

3. Start the engine and let it warm up for

4. Turn off the engine and check the coolant

level again. COOLANT FULL LOW

NOTE: Before checking the coolant level, wait a few minutes until the coolant settles. COOLANT REPLACEMENT WARNING Do not remove the radiator cap when the engine is hot. 3-5 MOTEUR/CONTROLE DU NIVEAU DU LIQUIDE DE REFROIDISSEMENT/

1. Place a container under the engine.

● Seat ● Left side cover Refer to ”SEAT FUEL TANK AND SIDE COVERS” section in the CHAPTER 4.

● Coolant reservoir hose 1 Drain the coolant completely.

● Coolant reservoir hose COOLANT FULL

● Coolant drain bolt 1

● Radiator cap Drain the coolant completely.

● Cooling system Thoroughly flush the cooling system with clean tap water.

● Copper washer ● Coolant drain bolt

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

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.

● Coolant reservoir Midway a between maximum and minimum marks on the tank.

● Coolant reservoir cap

13. Start the engine and let it warm up for

14. Turn off the engine and inspect the coolant level.

Refer to “COOLANT LEVEL INSPECTION” section. COOLANT FULL LOW 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.

NOTE: Before checking the coolant level wait a few minutes until the coolant settles. EC355000

RADIATOR CAP INSPECTION

● Seal (radiator cap) 1 ● Valve and valve seat 2 Crack/damage → Replace. Exist fur deposits 3 → Clean or replace. 3-7

● Pressure Impossible to maintain the specified pressure for 10 seconds → Repair. ● Radiator 1 ● Radiator hose joint 2 Coolant leakage → Repair or replace. ● Radiator hose 3 Swelling → Replace. CLUTCH ADJUSTMENT

● 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.

NOTE: ● Make minute adjustment on the lever side using the adjuster 2. ● After adjustment, check proper operation of clutch lever. 3-9

THROTTLE CABLE ADJUSTMENT

THROTTLE CABLE ADJUSTMENT

● Throttle grip free play Throttle grip free play adjustment steps: Remove the throttle cable cap 1 and throttle cable cover 2.

NOTE: ● Before adjusting the throttle cable free play, the engine idle speed should be adjusted. ● When the motorcycle is accelerating, throttle cable #1 3 is pulled and throttle cable #2 4 is pushed. 1st step: ● Loosen the locknuts 5 on throttle cable #2. ● Adjust the free play by changing their tightening position. 2nd step: ● Loosen the locknuts 6 on throttle cable #1. ● Adjust the free play by changing their tightening position. ● Tighten the locknuts. WARNING After adjusting, turn the handlebar to right and left and make sure that the engine idling does not run faster.

Install the throttle cable cover and throttle cable cap.

● Rubber cover 1 ● Throttle grip cap 2

● Lithium soap base grease On the throttle cable end a.

● Throttle grip cap ● Screw (throttle grip cap)

● Decompression lever free play a Out of specification → Adjust. Checking steps: Remove the timing mark accessing screw 1 and crankshaft end accessing screw ● Turn the crankshaft counterclockwise with a wrench.

NOTE: Squeezing the decompression lever allows the crankshaft to be turned easily.

Align the T.D.C. mark b on the rotor with the align mark c on the crankcase cover when piston is at T.D.C. on compression stroke. Check the free play. Free play a: 5 ~ 9 mm (0.20 ~ 0.35 in)

● Decompression lever free play Adjustment steps: Loosen the locknut 1. ● Turn the adjuster 2 in or out until the adjustment is suitable. ● Tighten the locknut.

CAUTION: After the adjustment, start the engine and make sure that the engine does not stop when the handlebar is turned fully both ways. If the decompression cable is too tense, the engine will stop by the decompression system.

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.

● Taillight lead connectors 1

● Air filter case cover 2

● Fitting bolt 1 ● Washer 2 ● Air filter element 3 ● Air filter guide 4

● 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.

● Air filter element Damage → Replace.

● Foam-air-filter oil or engine oil to the element. NOTE: Squeeze out the excess oil. Element should be wet but not dripping.

● Air filter guide 1 NOTE: Align the projection a on air filter guide with the hole b in air filter element.

● Lithium soap base grease On the matching surface a on air filter element.

● Air filter element 1 ● Washer ● Fitting bolt

2 Nm (0.2 m · kg, 1.4 ft · lb) NOTE: Align the projection a on filter guide with the hole b in air filter case.

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.

● Oil level Oil level should be between maximum a and minimum b marks. Oil level is low → Add oil to proper level. NOTE: When inspecting the oil level, do not screw the oil tank cap into the oil tank. Insert the gauge lightly.

INSP ADJ (For USA and CDN) Recommended oil: At 5 ˚C (40 ˚F) or higher Å Yamalube 4 (20W-40) or SAE 20W-40 type SH motor oil (Non-Friction modified) At 15 ˚C (60 ˚F) or lower ı Yamalube 4 (10W-30) or SAE 10W-30 type SH motor oil (Non-Friction modified) and/or Yamalube 4-R (15W-50) (Non-Friction modified) CAUTION:

(Except for USA and CDN)

Recommended oil: Refer to the following chart for selection of oils which are suited to the atmospheric temperatures. Recommended engine oil classification: API STANDARD: API “SH” or higher grade (Designed primarily for motorcycles) 10W-30 10W-40 15W-40 20W-40 20W-50

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.

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.

6. Start the engine and let it warm up for

7. Turn off the engine and inspect the oil

level once again. NOTE: Wait a few minutes until the oil settles before inspecting the oil level.

ENGINE OIL REPLACEMENT

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 the

● Oil tank cap 1 ● Frame oil drain bolt 2 ● Crankcase oil drain bolt 3 ● Oil filter element drain bolt 4 Drain the crankcase and oil tank (frame) of its oil.

● Lower engine bracket ● Oil hose clamp 1 ● Bolt (oil hose) 2 ● Oil hose 3 ● Oil strainer (frame) 4

● Oil strainer (frame) ● Clogged → Blow.

ENGINE OIL REPLACEMENT

7. If the oil filter is to be replaced during this

oil change, remove the following parts and reinstall them. Replacement steps: ● Remove the oil filter element cover 1 and oil filter element 2. ● 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.

Copper washer 1 Oil strainer (frame) 2

Oil hose 3 Bolt (oil hose) 4

● Copper washer ● Oil filter element drain bolt

● Engine oil Oil quantity: Total amount:

1.7 L (1.50 Imp qt, 1.80 US qt)

Periodic oil change:

1.5 L (1.32 Imp qt, 1.59 US qt)

With oil filter replacement:

PILOT SCREW ADJUSTMENT

● Oil pressure Checking steps: ● Slightly loosen the oil pressure check bolt ● 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.

PILOT SCREW ADJUSTMENT

● Pilot screw 1 Adjustment steps: NOTE: To optimize the fuel flow at a smaller throttle opening, each machine’s pilot screw has been individually set at the factory. Before adjusting the pilot screw, turn it in fully and count the number of turns. Record this number as the factory-set number of turns out.

Turn in the pilot screw until it is lightly seated. Turn out the pilot screw by the factory-set number of turns. Pilot screw: 1-3/4 turns out (example)

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

1. Start the engine and thoroughly warm it

● Inductive tachometer To spark plug lead.

● Engine idling speed Adjustment steps: Adjust the pilot screw. Refer to “PILOT SCREW ADJUSTMENT” section. ● Turn the throttle stop screw 1 until the engine runs at the lowest possible speed.

To increase idle speed → Turn the throttle stop screw 1 in a. To decrease idle speed → Turn the throttle stop screw 1 out b. Inductive tachometer: YU-08036-B Engine tachometer: 90890-03113 Engine idling speed: 1,700 ~ 1,900 r/min

VALVE CLEARANCE INSPECTION AND

ADJUSTMENT NOTE: ● The valve clearance should be adjusted when the engine is cool to the touch. ● The piston must be at Top Dead Center (T.D.C.) on compression stroke to check or adjust the valve clearance.

● Seat ● Fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 4.

● Coolant Refer to “COOLANT REPLACEMENT” section.

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

● Right radiator Refer to “RADIATOR” section in the

● Carburetor Refer to “CARBURETOR” section in the CHAPTER 4. ● Spark plug ● Upper engine bracket ● Cylinder head cover Refer to “CAMSHAFTS” section in the

● Timing mark accessing screw 1 ● Crankshaft end accessing screw 2 ● O-ring

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

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

INSP ADJ Checking steps: ● Turn the crankshaft counterclockwise with a wrench. NOTE: 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. 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.

● Valve clearance Adjustment steps: ● Remove the camshaft (intake and exhaust). Refer to “CAMSHAFTS” section in the

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

INSP ADJ Remove the decompression cable 1, guide 2, bolt 3 and decompression shaft Remove the valve lifters 5 and the pads

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 No. 120 No. 240 Pad Availability: 25 increments

Pads are available in

NOTE: The thickness a of each pad is indicated in hundreths 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 or 2 (NOT ROUNDED OFF)

EXAMPLE: Installed pad number = 148 Rounded off value = 150 NOTE: Pads can only be selected in 0.05 mm increments.

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

INSP ADJ 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 7 and the valve lifters 8. NOTE: ● Apply the engine oil on the valve lifters. ● Apply the molybdenum disulfied 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 decompression shaft 9, copper washer 0, bolt (decompression shaft) A, guide B, bolt (guide) C and decompression cable D. NOTE: Apply the engine oil on the decompression shaft.

VALVE CLEARANCE INSPECTION AND ADJUSTMENT

VALVE CLEARANCE (cold):

Example: Installed is 175 Measured clearance is 0.23 mm

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

EXHAUST MEASURED CLEARANCE

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

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

● Spark arrester 1 Pull the spark arrester out of the muffler.

● Spark arrester Tap the spark arrester lightly, then use a wire brush to remove any carbon deposits.

● Spark arrester Insert the spark arrester into the muffler and align the bolt holes. ● Bolt (spark arrester)

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 bleed.

● Reservoir cap ● Diaphragm ● Protector (rear brake)

Å Front ı Rear 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.

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

bubbles have been removed from the system.

SPURGO DELL’ARIA DAL

INSP ADJ 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) ● Diaphragm ● Reservoir cap EC362040

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.

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

● 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.

WARNING Adjust the pedal height between the maximum Å and the minimum ı as shown. (In this adjustment the bolt 3 end b should protrude out of the lower adjusting nut 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.

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

<Limit>: 1.0 mm (0.04 in)

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

INSP ADJ Loosen the pad pin 2. Remove the brake hose holder 3 and brake caliper 4 from the front fork. Remove the pad pin and brake pads 5. Connect the transparent hose 6 to the bleed screw 7 and place the suitable container under its end. Loosen the bleed screw and push the brake caliper piston in. CAUTION: Do not reuse the drained brake fluid.

Tighten the bleed screw.

Install the brake pads 8 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 hose holder 9 and brake caliper 0 and tighten the pad pin A. NOTE: Fit the brake hose holder cut c over the projection d on the front fork and clamp the brake hose.

INSP ADJ Install the pad pin plug B.

● Brake fluid level Refer to “BRAKE FLUID INSPECTION” section. LEVEL

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

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

<Limit>: 1.0 mm (0.04 in)

● Brake pad Brake pad replacement steps: ● Remove the protector 1 and pad pin plug ● 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 5.

“SPURGO DELL’ARIA DAL

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

Tighten the bleed screw.

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 Refer to “FRONT WHEEL AND REAR WHEEL” section in the CHAPTER 5. Tighten the pad pin D.

Install the pad pin plug E and protector F.

● Brake fluid level Refer to “BRAKE FLUID LEVEL INSPECTION” section.

● Brake pedal operation A softy or spongy feeling → Bleed brake system. Refer to “BRAKE SYSTEM AIR BLEEDING” section. EC36b000

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

● Rear brake pad insulator 1 Damage → Replace.

1. Place the brake master cylinder (reservoir tank) so that its top is in a horizontal

● Brake fluid level Fluid at lower level → Fill up.

a Lower level Å Front ı Rear 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. CONTROLE DE L’ISOLANT DE LA PLAQUETTE DE FREIN ARRIERE/ CONTROLE DU NIVEAU DU LIQUIDE DE FREIN

“SPURGO DELL’ARIA DAL

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

DRIVE CHAIN INSPECTION

● Drive chain 1 NOTE: Remove the drive chain using a chain cutter

● Drive chain Brush off as much dirt as possible. Then clean the chain using the chain cleaner.

CAUTION: This machine has a drive chain with small rubber O-rings 1 between the chain plates. Steam cleaning, high-pressure washes, certain solvent and kerosene can damage these O-rings.

● Drive chain length (10 links) a Out of specification → Replace. Drive chain length (10 links): <Limit>: 150.1 mm (5.91 in)

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

● Chain joint 1 ● O-ring 2 ● 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 NOTE: ● Press the link plate onto the chain joint using a chain rivetter 5. ● Rivet the end of the chain joint using a chain rivetter 6. ● After rivetting the chain joint, make sure its movement is smooth.

DRIVE CHAIN SLACK ADJUSTMENT

1. Elevate the rear wheel by placing the

suitable stand under the engine.

● Drive chain slack a Above the seal guard installation bolt. Out of specification → Adjust. Drive chain slack: 40 ~ 50 mm (1.6 ~ 2.0 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 chain slack with rear wheel in this “tight chain” position.

● Drive chain slack Drive chain slack adjustment steps: Loosen the axle nut 1 and locknuts 2. ● Adjust chain slack by turning the adjusters

To tighten → Turn adjuster 3 counterclockwise. To loosen → Turn 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 chain puller alignment.) NOTE: Turn the adjuster so that the chain is in line with the sprocket, as viewed from the rear. CAUTION: Too small chain slack will overload the engine and other vital parts; keep the slack within the specified limits.

Tighten the axle nut while pushing down the drive chain.

Tighten the locknuts. EC36C000

FRONT FORK INSPECTION

● Front fork smooth action Operate the front brake and stroke the front fork. Unsmooth action/oil leakage → Repair or replace.

● Protector ● Dust seal 1 NOTE: Use a thin screw driver, and be careful not to damage the inner fork tube and dust seal.

● Dust seal a ● Oil seal b NOTE: ● Clean the dust seal and oil seal after every run. ● Apply the lithium soap base grease on the inner tube. EC36H002

● 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 Fully turned in position

Minimum 20 clicks out (from maximum position) STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. Standard position: 14 clicks out

ADJUSTMENT INSP ADJ CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. WARNING Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability. EC36J001

● 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 Fully turned in position

INSP ADJ STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position.

• For EUROPE ** For AUS, NZ and ZA CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. WARNING Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability.

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

ADJUSTMENT INSP ADJ EC36M013

REAR SHOCK ABSORBER SPRING

1. Elevate the rear wheel by placing the

suitable stand under the engine.

● 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) a: 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.

DAMPING FORCE ADJUSTMENT

DAMPING FORCE ADJUSTMENT

● 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 Fully turned in position

Minimum 20 clicks out (from maximum 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 7 clicks out *, **About 10 clicks out

• For EUROPE ** For AUS, NZ and ZA CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged.

DAMPING FORCE ADJUSTMENT

● 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 Fully turned in position

Minimum 20 clicks out (from maximum 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 9 clicks out *, **About 12 clicks out

• For EUROPE ** For AUS, NZ and ZA CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged.

DAMPING FORCE ADJUSTMENT

● 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 Fully turned in position

Minimum 2 turns out (from maximum 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 turns out *About 1-1/2 turns out

• For EUROPE CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged.

● Tire pressure Out of specification → Adjust. Standard tire pressure: 100 kPa (1.0 kg/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 1 Bend/damage → Replace. Loose spoke → Retighten.

3 Nm (0.3 m · kg, 2.2 ft · lb) ● Spokes NOTE: Be sure to retighten these spokes before and after break-in. After a practice or a race check spokes for looseness. EC36T000 WHEEL INSPECTION

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

STEERING HEAD INSPECTION AND ADJUSTMENT

● Bearing free play Exist play → Replace.

STEERING HEAD INSPECTION AND

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

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

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

● 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 2.

STEERING HEAD INSPECTION AND ADJUSTMENT

INSP ADJ Tighten the steering ring nut 3 using steering nut wrench 4. NOTE: 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 (final tightening): 7 Nm (0.7 m • kg, 5.1 ft • lb) 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 upper bracket 5, steering stem nut 6, handlebar 7, handlebar holder 8 and headlight 9. NOTE: ● The upper handlebar holder should be installed with the punched mark a forward. ● Insert the end of fuel breather hose 0 into the hole of the steering stem. CAUTION: First tighten the bolts on the front side of the handlebar holder, and then tighten the bolts on the rear side.

Dado cannotto dello sterzo: 145 Nm (14,5 m • kg, 105 ft • lb) Supporto manubrio superiore: 28 Nm (2,8 m • kg, 20 ft • lb) Bullone di serraggio (corona del manubrio): 23 Nm (2,3 m • kg, 17 ft • lb) Faro: 7 Nm (0,7 m • kg, 5,1 ft • lb) LUBRICATION INSP ADJ Å Use Yamaha cable lube or equivalent on these areas. ı Use SAE 10W-30 motor oil or suitable chain lubricants. Ç Lubricate the following areas with high quality, lightweight lithium-soap base grease. LUBRICATION To ensure smooth operation of all components, lubricate your machine during setup, after break-in, and after every race. 1 All control cable 2 Clutch lever pivot 3 Shift pedal pivot 4 Footrest pivot 5 Throttle-to-handlebar contact 6 Drive chain 7 Tube guide cable winding portion 8 Throttle cable end 9 Clutch cable end 0 Decompression cable end CAUTION: Wipe off any excess grease, and avoid getting grease on the brake discs.

● 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. Spark plug gap:

4. Clean the plug with a spark plug cleaner

13 Nm (1.3 m · kg, 9.4 ft · lb) NOTE: ● 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

IGNITION TIMING CHECK

● Timing mark accessing screw 1

● Ignition timing Checking steps: ● Start the engine and let it warm up. Let the engine run at the specified speed. Engine speed: 1,700 ~ 1,900 r/min

Visually check the stationary pointer a is within the firing range b on the rotor. Incorrect firing range → Check rotor and pickup assembly.

● Timing mark accessing screw

REPLACING THE HEADLIGHT BULBS

REPLACING THE HEADLIGHT BULBS

● Headlight Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 4.

● Headlight bulb holder cover 1

● Headlight bulb holder 1

● Headlight bulb 2 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 Secure the new headlight bulb with the headlight bulb holder. 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

● Headlight bulb holder cover

● Headlight bolt (left and right)

● Headlight beam (vertically) Adjusting steps: Turn the adjusting screw 1 in direction a or b.

Direction a Headlight beam is raised. Direction b Headlight beam is lowered.

Extent of removal: 1 Seat removal 3 Side covers removal Extent of removal Order Preparation for removal

Part name 2 Fuel tank removal 4 Headlight removal Q’ty

SEAT, FUEL TANK AND SIDE

COVERS REMOVAL Turn the fuel cock to “OFF”. Disconnect the fuel hose. Seat Air scoop (left and right) Fitting band Bolt (fuel tank) Fuel tank Left side cover Right side cover Headlight coupler Headlight 4-1

Å Except for USA Extent of removal: Extent of removal 1 Silencer removal Order

SILENCER REMOVAL Right side cover Preparation for removal

2 Exhaust pipe removal

Bolt (silencer clamp) Bolt [silencer (front)] Bolt [silencer (rear)] Silencer Silencer clamp Nut (exhaust pipe) Bolt (exhaust pipe) Exhaust pipe Gasket

4-2 Remarks Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Only loosening.

ASSEMBLY AND INSTALLATION

Silencer and exhaust pipe

● Gasket ● Exhaust pipe 1 ● Nut (exhaust pipe) 2

● Joint 1 Endommagement → Remplacer. 35 Nm (3,5 m · kg, 25 ft · lb) RADIATOR ENG EC450001 RADIATOR Extent of removal: Extent of removal 1 Radiator removal Order Part name Q’ty RADIATOR REMOVAL Drain the coolant. Preparation for removal Refer to “COOLANT REPLACEMENT” section in the CHAPTER 3. Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Seat, fuel tank and left

Side cover Radiator guard Radiator hose clamp Radiator hose 1 Left radiator Radiator hose 3 Coolant reservoir hose Right radiator Radiator hose 2 Radiator hose 4 Radiator pipe Coolant reservoir breather hose Coolant reservoir 4-4 Remarks

Allentare soltanto. RADIATOR ENG EC456000 HANDLING NOTE WARNING 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

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

ASSEMBLY AND INSTALLATION

● O-ring 1 ● Radiator pipe 2 ● Bolt (radiator pipe) 3

● Radiator hose 4 (longer) 1 ● Radiator hose 2 (shorter) 2 To right radiator 3. 4-5 RADIATEUR KÜHLER RADIATORE

● Right radiator 1 ● Bolt (right radiator) 2

● Left radiator 1 ● Bolt (left radiator) 2

● Radiator hose clamp 4

● Radiator guard 1 ● Bolt (radiator guard) 2

● Coolant reservoir 1 ● Clamp 2 ● Bolt (coolant reservoir) 3

FULL 7 Nm (0.7 m · kg, 5.1 ft · lb) Coolant reservoir hose 4 ● Coolant reservoir breather hose 5 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2.

● Radiator ● Engine ● Coolant reservoir Refer to “COOLANT REPLACEMENT” section in the CHAPTER 3.

CARBURETOR ENG CARBURETOR Extent of removal: Extent of removal 1 Carburetor removal Order Q’ty CARBURETOR REMOVAL Seat and fuel tank Preparation for removal

Clamp Throttle position sensor lead coupler Throttle cable cover Throttle cable Throttle cable cap Clamp (air filter joint) Clamp (carburetor joint) Carburetor assembly Carburetor joint 4-7 Remarks Refer to “SEAT, FUEL TANK AND SIDE COVERS” section.

4-7 CARBURETOR ENG EC468000 CARBURETOR DISASSEMBLY Extent of removal: 1 Carburetor disassembly Extent of removal Order Part name Q’ty

CARBURETOR DISASSEMBLY Carburetor breather hose Valve lever housing cover Screw (throttle shaft) Throttle valve Needle holder Jet needle Accelerator pump cover Spring Diaphragm (accelerator pump) Air cut valve cover Spring (air cut valve) Diaphragm (air cut valve) Float chamber Leak jet Pilot screw Float pin

● Pilot screw 1 NOTE: To optimize the fuel flow at a small throttle opening, each machine’s pilot screw has been individually set at the factory. Before removing the pilot screw, turn it in fully and count the number of turns. Record this number as the factory-set number of turns out. INSPECTION Carburetor

● 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.

● Main jet 1 ● Pilot jet 2 ● Needle jet 3 ● Starter jet 4 ● Main air jet 5 ● Pilot air jet 6 ● Leak 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

● Needle valve 1 ● Valve seat 2 Grooved wear a → Replace. Dust b and c → Clean. NOTE: Replace the needle valve and valve seat as a set. EC464301 Throttle valve

● Free movement Stick → Repair or replace. NOTE: Insert the throttle valve 1 into the carburetor body, and check for free movement. EC464401 Jet needle

● Jet needle 1 Bends/wear → Replace. ● Clip groove Free play exists/wear → Replace. ● Clip position Standard clip position: No.3 Groove *, ** No.4 Groove

• For EUROPE ** For CDN, ZA, AUS and NZ

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.

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

● Cold starter plunger 1 ● Hot starter plunger (red) 2 Wear/damage → Replace. Accelerator pump

● Diaphragm (accelerator pump) 1 ● Spring (accelerator pump) 2 ● Accelerator pump cover 3 ● O-ring 4 ● Push rod 5 Tears (diaphragm)/damage → Replace. Dirt → Clean.

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

ASSEMBLY AND INSTALLATION

● Hot starter plunger (red) 1 ● Cold starter plunger 2

● Main air jet 1 ● Pilot air jet 2 ● Intake joint 3

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

● Washer 1 ● Circlip 2

● Spring 1 ● Joint collar 2 To throttle shaft 3. 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.

● Starter jet 1 ● Pilot jet 2 ● Spacer 3 ● Needle jet 4 ● Main jet 5

● Valve seat ● Screw (valve seat) 1 ● Needle valve 2 ● Float 3 ● Float pin 4 NOTE: ● After installing the needle valve to the float, install them to the carburetor. ● Check the float for smooth movement.

● Pilot screw 1 ● Spring 2 ● Washer 3 ● O-ring 4 Note the following installation points: ● Turn in the pilot screw until it is lightly seated. ● Turn out the pilot screw by the number of turns recorded before removing. Pilot screw: 1-3/4 turns out (example)

● O-ring ● Leak jet 1 ● Float chamber 2 ● Bolt (float chamber) 3 ● Cable holder (throttle stop screw cable) ● Hose holder (carburetor breather hose)

● Diaphragm (air cut valve) 1 ● Spring (air cut valve) 2 ● O-ring 3 ● Air cut valve cover 4 ● Screw (air cut valve cover) 5

● Diaphragm (accelerator pump) 1 ● Spring 2 ● O-ring 3 ● Accelerator pump cover 4 ● Bolt (accelerator pump cover) 5 NOTE: Install the diaphragm (accelerator pump) with its mark a facing the spring.

● Jet needle 1 ● Collar 2 ● Spring 3 ● Needle holder 4 ● Throttle valve plate 5 To throttle valve 6.

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

● O-ring 1 ● Valve lever housing cover 2 ● Bolt (valve lever housing cover) 3

● 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. Carburetor installation

NOTE: Install the projections a on the carburetor joint between the clamp ends.

● Carburetor joint 1

3 Nm (0.3 m · kg, 2.2 ft · lb) NOTE: Install the projection a on the cylinder head between the carburetor joint slots b.

NOTE: Install the projection between the carburetor joint slots.

● Screw (air filter joint) 1

● Throttle grip free play Refer to “THROTTLE CABLE ADJUSTMENT” section in the CHAPTER 3.

● Throttle cable cover 1 ● Screw (throttle cable cover) 2

4 Nm (0.4 m · kg, 2.9 ft · lb) NOTE: Install the throttle cable cover with its pawl a hung on the carburetor.

● 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.

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

REMOVAL Seat and fuel tank Preparation for removal

Carburetor Spark plug Cylinder head breather hose Oil tank breather hose Bolt (cylinder head cover) Cylinder head cover Cylinder head cover gasket Timing chain guide (top side)

Remarks Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Refer to “CARBURETOR” section.

CAMSHAFTS REMOVAL Timing mark accessing screw Crankshaft end accessing screw Timing chain tensioner cap bolt Timing chain tensioner Camshaft cap Clip Exhaust camshaft Intake camshaft

Remarks Refer to “REMOVAL POINTS”.

● Timing mark accessing screw 1 ● Crankshaft end accessing screw 2

● T.D.C. mark With align mark. Checking steps: Turn the crankshaft counterclockwise with a wrench.

NOTE: 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. 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.

● Timing chain tensioner cap bolt 1 ● Timing chain tensioner 2 ● Gasket

● Bolt (camshaft cap) 1 ● Camshaft cap 2 ● Clip 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.

● Exhaust camshaft 1 ● Intake camshaft 2 NOTE: Attach a wire 3 to the timing chain to prevent it from falling into the crankcase. INSPECTION Camshaft

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

● Runout (camshaft) Out of specification → Replace. Runout (camshaft): Less than 0.03 mm (0.0012 in)

● Camshaft-to-cap clearance Out of specification → Measure bearing diameter (camshaft) Camshaft-to-cap clearance:

(0.0008 ~ 0.0021 in) <Limit>: 0.08 mm (0.003 in) Measurement steps: ● Install the camshaft onto the cylinder head. ● Position a strip of Plastigauge 1 onto the camshaft. ● Install the clip, dowel pins and camshaft caps.

NOTE: ● 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®.

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

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

(0.8648 ~ 0.8654 in) Camshaft sprocket

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

● 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

● Exhaust camshaft 1 ● Intake camshaft 2 Installation steps: Turn the crankshaft counterclockwise with a wrench.

NOTE: 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. 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.

Install the clips, camshaft caps 4 and bolts (camshaft cap) 5.

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 engine oil on the thread and contact surface of the bolts (camshaft cap). ● Tighten the bolts (camshaft cap) 5 in a crisscross pattern. CAUTION: The bolts (camshaft cap) must be tightened evenly or damage to the cylinder head, camshaft caps and camshaft will result.

● 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. ● 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.

ENG Release the screwdriver, check the tensioner rod to come out and tighten the gasket 4 and the cap bolt 5 to the specified torque.

● Crankshaft Counterclockwise several turns

● 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 1 ● Crankshaft end accessing screw 2

● Timing chain guide (top side) 1 ● Cylinder head cover gasket 2 ● Cylinder head cover 3 ● Bolt (cylinder head cover) 4

● Oil tank breather hose ● Cylinder head breather hose ● Spark plug

Seat and fuel tank Preparation for removal Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Refer to “EXHAUST PIPE AND SILENCER” section. Disconnect at cylinder head side. Refer to “CARBURETOR” section. Refer to “CAMSHAFTS” section. Refer to “ENGINE REMOVAL” section. Exhaust pipe and silencer

Radiator hose 1 Carburetor Camshaft Upper engine bracket Radiator pipe Decompression cable guide Oil delivery pipe Nut Bolt [L=135 mm (5.31 in)] Bolt [L=145 mm (5.71 in)] Cylinder head Timing chain guard (exhaust side) Bolt (decompression shaft) Decompression shaft

● Carbon deposits (from the combustion chambers) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damaging or scratching: ● Spark plug threads ● Valve seats

● 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 resurfacement 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

● Decompression shaft 1 ● Copper washer 2 ● Bolt (decompression shaft) 3

● Dowel pin 1 ● Cylinder head gasket 2 ● Timing chain guide (exhaust side) 3 ● Decompression cable 4 ● Cylinder head 5 NOTE: ● Install the decompression cable to the cylinder head, and then to the cylinder. ● While pulling up the timing chain, install the timing chain guide (exhaust side) and cylinder head.

● Copper washer 1 ● Oil delivery pipe 2 ● Union bolt (M8) 3

● Radiator pipe 1 ● Bolt (radiator pipe) 2

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

REMOVAL Cylinder head Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Exhaust valve Intake valve

Preparation for removal

Remarks Refer to “CYLINDER HEAD” section. Use special tool. Refer to “REMOVAL POINTS”.

ENG REMOVAL POINTS Valve lifter and valve cotter

● Valve lifter 1 ● 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-04019/90890-04019

● Stem-to-guide clearance Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b Out of specification → Replace the valve guide. Clearance (stem to guide): Intake:

● Valve guide Replacement steps: NOTE: To ease guide removal, installation and to maintain correct fit heat the cylinder head in an over to 100 ˚C (212 ˚F). Remove the valve guide using a valve guide remover 1. ● Install the new valve guide using a valve guide remover 1 and valve guide installer After installing the valve guide, bore the valve guide using a valve guide reamer 3 to obtain proper stem-to-guide clearance.

● 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:

NOTE: ● 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)

● Valve seat Pitting/wear → Reface the valve seat.

● Valve seat width a Out of specification → Reface the valve seat. Valve seat width: Intake:

<Limit>: 1.6 mm (0.0630 in) Exhaust:

<Limit>: 1.6 mm (0.0630 in) Measurement steps: Apply Mechanic’s blueing dye (Dykem) b to the valve face. ● Install the valve into the cylinder head. ● Press the valve through the valve guide and onto the valve seat to make a clear pattern. ● Measure the valve seat width. Where the valve seat and valve face made contact, blueing will have been removed. ● If the valve seat is too wide, too narrow, or the seat is not centered, the valve seat must be refaced.

● Valve face ● Valve seat NOTE: After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. Lapping steps: Apply a coarse lapping compound to the valve face.

CAUTION: Do not let the compound enter the gap between the valve stem and the guide.

Apply molybdenum disulfide oil to the valve stem. Install the valve into the cylinder head. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the compound. NOTE: For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands.

Apply a fine lapping compound to the valve face and repeat the above steps. NOTE: After every lapping operation be sure to clean off all of the compound from the valve face and valve seat.

Apply Mechanic’s blueing dye (Dykem) to the valve face. Install the valve into the cylinder head. Press the valve through the valve guide and onto the valve seat to make a clear pattern. Measure the valve seat width again. If the valve seat width is out of specification, reface and relap the valve seat.

● Compressed spring force a Out of specification → Replace. b Installed length Compressed spring force: Intake:

10.1 ~ 11.6 kg at 29.13 mm

(22.27 ~ 25.57 lb at 1.15 in) Exhaust:

12.9 ~ 14.7 kg at 29.30 mm

(28.44 ~ 32.41 lb at 1.15 in)

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

ENG Combination of cylinder head and valve lifter

For this combination, match the paint color on the cylinder head with that on the valve lifter according to the chart below.

Combination Cylinder head mark a (color) Valve lifter mark b (color) Red Red Blue Blue Yellow Yellow Purple Black NOTE: When you purchase a cylinder head, you cannot designate its size. Choose the valve lifter that matches the above chart.

ASSEMBLY AND INSTALLATION

Valve and valve spring

● Molybdenum disulfide oil Onto the valve stem and valve stem seal.

● Valve 1 ● Valve spring seat 2 ● Valve stem seal 3 ● Valve spring 4 ● 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: yellow Intake (right/left) b: white Exhaust: no paint ● Install the valve springs with the larger pitch c facing upward. d Smaller pitch

● Valve cotter NOTE: While compressing the valve spring with a valve spring compressor 1 install the valve cotters. Valve spring compressor: YM-04019/90890-04019

4. To secure the valve cotters onto the

valve stem, lightly tap the valve tip with a piece of wood. CAUTION: Hitting the valve tip with excessive force could damage the valve.

● Adjusting pad 1 ● Valve lifter 2 NOTE: ● Apply the molybdenum disulfied 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.

Extent of removal: Extent of removal 1 Cylinder removal Order Preparation for removal

2 Piston removal Part name

Q’ty Remarks Refer to “CYLINDER HEAD” section.

Use special tool. Refer to “REMOVAL POINTS”.

ENG REMOVAL POINTS Piston and piston ring

● Piston pin clip 1 ● Piston pin 2 ● Piston 3 NOTE: ● 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. Piston pin puller set: YU-1304/90890-01304 CAUTION: Do not use a hammer to drive the piston pin out.

● Piston ring 1 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

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

● 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.

ENG Cylinder bore “C”

“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

(3.0297 ~ 3.0303 in) If out of specification, replace the piston and piston rings as a set. 3rd step: ● Calculate the piston-to-cylinder clearance with following formula:

Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance:

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

● 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. Side clearance: Standard <Limit> Top ring

● Piston ring (in cylinder) 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. a 10 mm (0.39 in)

● Ring end gap Out of specification → Replace. NOTE: You cannot measure the end gap on the expander spacer of the oil control ring. If the oil control ring rails show excessive gap, replace all three rings. End gap:

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

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

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

ASSEMBLY AND INSTALLATION

Piston ring and piston

● 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.

● Top ring ● 2nd ring ● Oil ring Offset the piston ring end gaps as shown.

ENG 135° a Top ring end b 2nd ring end c Oil ring end (upper) d Oil ring e Oil ring end (lower)

● Piston 1 ● Piston pin 2 ● Piston pin clip 3 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. 3 New Cylinder

● Piston ● Piston ring ● Cylinder NOTE: Apply a liberal coating of engine oil.

● Dowel pin 1 ● O-ring 2 NOTE: Apply the lithium soap base grease on the Oring.

● Cylinder gasket 1 ● Cylinder 2 NOTE: Install the cylinder with one hand while compressing the piston rings with the other hand. CAUTION:

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

10 Nm (1,0 m · kg, 7,2 ft · lb) CLUTCH ENG EC4A0000 CLUTCH Extent of removal: 1 Push rod 1, 2 and push lever shaft removal 3 Friction plate and clutch plate removal Extent of removal Order

Q’ty CLUTCH REMOVAL Drain the engine oil. Preparation for removal

2 Push pod 1 disassembly 4 Primary driven gear removal Remarks Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Refer to “ENGINE REMOVAL” section. Disconnect at engine side. Brake pedal Clutch cable Clutch cover Clutch spring Pressure plate Push rod 1 Circlip Washer Bearing Ball Push rod 2

CLUTCH Extent of removal

● Nut 1 ● Lock washer 2 ● Clutch boss 3 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 Å For USA and CDN ı Except for USA and CDN EC4A4000 INSPECTION EC484100 Clutch housing and boss

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

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

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

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

(0.114 ~ 0.122 in) <Limit>: 2.7 mm (0.106 in) EC484600 Clutch plate

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

ASSEMBLY AND INSTALLATION

10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: ● 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

● Primary driven gear 1 ● Thrust washer 2 ● Clutch boss 3 NOTE: Apply the engine oil on the primary driven gear inner circumference.

● Lock washer 1 ● Nut (clutch boss) 2

Å For USA and CDN ı Except for USA and CDN

● Seat plate 1 ● Cushion spring 2

NOTE: ● Install the seat plate with its chamfered portion a facing the clutch boss 3. ● Install the cushion spring with the paint b facing out.

● Friction plate 1 1 ● Clutch plate 1 2 ● Friction plate 2 3 ● 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.

● Bearing 1 ● Washer 2 ● Circlip 3 To push rod 1 4. NOTE: Apply the engine oil on the bearing and washer.

● Push rod 2 1 ● Ball 2 ● Push rod 1 3 NOTE: Apply the engine oil on the push rod 1, 2 and ball.

● Clutch spring 1 ● Bolt (clutch spring) 2

● Dowel pin 1 ● Gasket (clutch cover) 2

● Clutch cover 1 ● Bolt (clutch cover)

Drain the engine oil. Preparation for removal Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Refer to “COOLANT REPLACEMENT” section in the CHAPTER 3. Disconnect at water pump side. Refer to “EXHAUST PIPE AND SILENCER” section. Refer to “ENGINE REMOVAL” section. Drain the coolant. Radiator hose 3 Exhaust pipe

Brake pedal Right engine guard Oil filter element cover Oil filter element

Part name Water pump housing Oil delivery pipe Bolt (oil hose) Kickstarter crank Right crankcase cover Impeller Washer Impeller shaft Oil seal Bearing

● Impeller 1 ● Washer 2 ● Impeller shaft 3 NOTE: Hold the impeller shaft on its width across the flats a with spanners, etc. and remove the impeller. EC4G3210 Oil seal NOTE: It is not necessary to disassemble the water pump, unless there is an abnormality such as excessive change in coolant level, discoloration of coolant, or milky transmission oil.

● Oil seal 1 INSPECTION Oil delivery pipe

● Oil delivery pipe 1 Bend/damage → Replace. Clogged → Blow.

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

● Oil seal 1 Wear/damage → Replace.

ASSEMBLY AND INSTALLATION

● Oil seal 1 NOTE: ● Apply the lithium soap base grease on the oil seal lip. ● Install the oil seal with its manufacture’s marks or numbers facing the right crankcase cover 2.

● Bearing 1 NOTE: Install the bearing by pressing its outer race parallel. Impeller shaft

14 Nm (1.4 m · kg, 10 ft · lb) NOTE: ● 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 remove the impeller. Right crankcase cover

● Dowel pin 1 ● O-ring 2 ● Collar 3 ● Gasket 4 NOTE: Apply the lithium soap base grease on the Oring.

● Right crankcase cover 1 ● Bolt (right crankcase cover) 2

10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: ● 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. Kickstarter crank

33 Nm (3.3 m · kg, 24 ft · lb) NOTE: Install the kickstarter crank so that the kickstarter crank is as vertical as possible with the distance a between the kickstarter crank and the frame being 8 mm (0.31 in) or more.

● Oil hose 1 ● Bolt (oil hose) 2

● Copper washer 1 ● Oil delivery pipe 2 ● Union bolt (M8) 3

● Dowel pin 1 ● O-ring 2 NOTE: Apply the lithium soap base grease on the Oring.

● Water pump housing 1 ● Bolt (water pump housing) 2

● Oil filter element 1 ● O-ring 2 ● Oil filter element cover 3 ● Bolt (oil filter element cover)

Q’ty BALANCER REMOVAL Primary driven gear Right crankcase cover Preparation for removal

Stator Nut (primary drive gear) Nut (balancer shaft driven gear) Lock washer Primary drive gear Balancer shaft drive gear Lock washer Balancer shaft driven gear Balancer shaft

Remarks Refer to “CLUTCH” section. Refer to “OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER” section. Refer to “CDI MAGNETO” section.

● 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. Balancer shaft

● 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

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

● Balancer shaft Cracks/damage → Replace.

ASSEMBLY AND INSTALLATION

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

● 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.

● Lock washer 1 ● Nut (balancer shaft driven gear) 2

75 Nm (7.5 m · kg, 54 ft · lb) NOTE: ● 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 6.

Primary driven gear Right crankcase cover Preparation for removal

2 Oil pump disassembly

Circlip Washer Oil pump drive gear Oil pump assembly Outer rotor 2 Circlip Inner rotor 2 Dowel pin Oil pump cover Outer rotor 1 Inner rotor 1 Refer to “CLUTCH” section. Refer to “OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER” section.

Part name Dowel pin Washer Oil pump drive shaft Rotor housing Q’ty

ENG INSPECTION Oil pump

● Oil pump drive gear 1 ● Oil pump drive shaft 2 ● Rotor housing 3 ● Oil pump cover 4 Cracks/wear/damage → Replace.

● 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 c (between the rotor housing 3 and rotors 1 2) Out of specification → Replace the oil pump assembly. Tip clearance a:

(0.0047 in or less) <Limit>: 0.20 mm (0.008 in) Side clearance b:

<Limit>: 0.24 mm (0.009 in) Housing and rotor clearance c:

● Unsmooth → Repeat steps #1 and #2 or replace the defective parts.

ASSEMBLY AND INSTALLATION

● Oil pump drive shaft 1 ● Washer 2 ● Dowel pin 3 ● 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 NOTE: Apply the engine oil on the outer rotor 1.

● Oil pump cover 1 ● Screw (oil pump cover) 2

3 Nm (0.3 m · kg, 2.2 ft · lb) Dowel pin 3 Inner rotor 2 4 Circlip 5 NOTE: ● Apply the engine oil on the inner rotor 2. ● Fit the dowel pin into the groove in the inner rotor 2.

● Outer rotor 2 1 ● Dowel pin 2 ● Oil pump assembly 3 ● Bolt (oil pump assembly) [L = 25 mm (0.94 in)] 4

10 Nm (1.0 m · kg, 7.2 ft · lb) Bolt (oil pump assembly) [L = 30 mm (1.18 in)] 5

● Oil pump drive gear 1 ● Washer 2 ● Circlip 3 NOTE: Apply the engine oil on the oil pump drive gear inner circumference.

KICK SHAFT AND SHIFT SHAFT

KICK SHAFT AND SHIFT SHAFT

Extent of removal: 1 Kick shaft removal 3 Shift shaft removal Extent of removal Order Preparation for removal

KICK SHAFT AND SHIFT

2 Kick shaft disassembly 4 Segment removal Q’ty Remarks Refer to “OIL PUMP” section.

KICK SHAFT AND SHIFT SHAFT

KICK SHAFT AND SHIFT SHAFT

ENG REMOVAL POINTS Kick shaft assembly

● Kick shaft assembly 1 NOTE: Unhook the torsion spring 2 from the hole a in the crankcase. EC4C3101 Shift guide and shift lever assembly

● Bolt (shift guide) ● Shift guide 1 ● Shift lever assembly 2 NOTE: The shift lever assembly is disassembled at the same time as the shift guide. EC4N3100 Segment

● Bolt (segment) 1 ● Segment 2 NOTE: Turn the segment counterclockwise until it stops and loosen the bolt. INSPECTION Kick shaft and ratchet wheel

● Ratchet wheel 1 smooth movement Unsmooth movement → Replace. ● Kick shaft 2 Wear/damage → Replace. ● Spring 3 Broken → Replace. EC4C4300 Kick gear, kick idle gear and ratchet wheel

● Kick gear 1 ● Kick idle gear 2 ● Ratchet wheel 3 ● Gear teeth a ● Ratchet teeth b Wear/damage → Replace.

● Schraube (segment) 1 ● Segment 2 Segmento

KICK SHAFT AND SHIFT SHAFT

ASSEMBLY AND INSTALLATION

● Segment 1 ● Bolt (segment)

● Segment 1 ● Schraube (segment)

KICK SHAFT AND SHIFT SHAFT

● Spring 1 ● Pawl pin 2 ● Pawl 3 To shift lever 4. NOTE: Apply the engine oil on the spring, pawl pin and pawl.

● Shift lever assembly 1 ● Shift guide 2 NOTE: ● The shift lever assembly is installed at the same time as the shift guide. ● Apply the engine oil on the bolt (segment) shaft.

KICK SHAFT AND SHIFT SHAFT

● Bolt (shift guide) 1

● Roller 1 ● Collar 2 ● Torsion spring 3 ● Shift shaft 4 NOTE: Apply the engine oil on the roller and shift shaft.

● Shift pedal 1 ● Bolt (shift pedal) 2 NOTE: When installing the shift pedal onto the shift shaft, be sure that the center of the shift pedal is about 2 mm a above the top of the footrest. Kick shaft assembly

● Kick gear 1 ● Washer 2 ● Circlip 3 ● Ratchet wheel 4 ● Spring 5 ● Washer 6 ● Circlip 7 To kick shaft 8. NOTE: ● Apply the molybdenum disulfide oil on the kick gear inner circumference. ● Align the punch mark a on the ratchet wheel with the punch mark b on the kick shaft.

KICK SHAFT AND SHIFT SHAFT

● 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.

● Spring guide 1 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.

● Kick shaft assembly 1 ● Washer 2 NOTE: ● Apply the engine oil on the kick shaft. ● Slide the kick shaft assembly into the crankcase, make sure the kick shaft stopper a fit into their home position 3.

● Torsion spring 1 NOTE: Turn the torsion spring clockwise and hook into the proper hole a in the crankcase. Kick idle gear

● Kick idle gear 1 ● Washer 2 ● Circlip 3 NOTE: ● Apply the engine oil on the kick idle gear inner circumference. ● Install the kick idle gear with its depressed side a toward you.

CDI MAGNETO ENG EC4L0000 CDI MAGNETO Extent of removal: Extent of removal 1 CDI magneto removal Order Part name Q’ty

Seat and fuel tank Preparation for removal Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Refer to “RADIATOR” section. Bolt (left radiator) Disconnect the CDI magneto lead. Shift pedal

Left engine guard Left crankcase cover Nut (rotor) Rotor Stator Woodruff key Refer to “KICK SHAFT AND SHIFT SHAFT” section.

Remarks Use special tool. Refer to “REMOVAL POINTS”.

● Rotor 1 Use the flywheel puller 2. Flywheel puller: YU-33270-B/90890-01362 NOTE: Install three bolts 3 of the proper size, as shown in illustration. EC4L4000 INSPECTION EC4L4101 CDI magneto

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

ASSEMBLY AND INSTALLATION

● Stator 1 ● Screw (stator) 2

● Woodruff key 1 ● Rotor 2 NOTE: ● Clean the tapered portions of the crankshaft and rotor. ● When installing the woodruff key, make sure that its flat surface a is in parallel with the crankshaft center line b. ● When installing the rotor, align the keyway c of the rotor with the woodruff key.

● Stator 1 ● Vis (stator) 2

● CDI magneto lead Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2.

● Dowel pin ● Gasket (left crankcase cover) ● Left crankcase cover 1 ● Hose guide (cylinder head breather hose) 2 ● Bolt (left crankcase cover) 3

● Left engine guard 1 ● Hose holder (cylinder head breather hose) 2 ● Bolt (left engine guard) 3

23 Nm (2,3 m · kg, 17 ft · lb) Tubetto di sfiato della testa del cilindro 4 ENGINE REMOVAL ENG EC4M0000 ENGINE REMOVAL Extent of removal Preparation for removal Order Part name ENGINE REMOVAL Hold the machine by placing the suitable stand under the frame. Seat and fuel tank Carburetor Exhaust pipe and silencer Clutch cable Decompression cable and guide Radiator Shift pedal Cylinder head breather hose and oil tank breather hose Drain the engine oil

Q’ty Remarks WARNING Support the machine securely so there is no danger of it falling over. Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Refer to “CARBURETOR” section. Refer to “EXHAUST PIPE AND SILENCER” section. Disconnect at engine side. Disconnect at engine side. Refer to “RADIATOR” section. Refer to “KICK SHAFT AND SHIFT SHAFT” section. Refer to “CAMSHAFTS” section. Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3.

Spark plug cap Disconnect the CDI magneto lead. Right engine guard Neutral switch Bolt (oil hose) Drive chain sprocket cover Nut (drive sprocket) Lock washer Drive sprocket Clip Bolt (brake pedal) Brake pedal Upper engine bracket Lower engine bracket Engine mounting bolt Pivot shaft Engine

Remarks Refer to “REMOVAL POINTS”. Refer to “REMOVAL POINTS”.

● Nut (drive sprocket) 1 ● Lock washer 2 NOTE: ● Straighten the lock washer tab. ● Loosen the nut while applying the rear brake.

● Drive sprocket 1 ● Drive chain 2 NOTE: Remove the drive sprocket together with the drive chain. EC4M3301 Engine removal

● 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.

ASSEMBLY AND INSTALLATION

● Engine 1 Install the engine from right side. ● Pivot shaft 2

Engine mounting bolt (front) 6

Upper engine bracket 7 Engine mounting bolt (upper) 8

● Spring 1 ● Brake pedal 2 ● O-ring 3 ● Bolt (brake pedal) 4

26 Nm (2.6 m · kg, 19 ft · lb) Clip 5 NOTE: ● Apply the lithium soap base grease on the bolt, O-rings and brake pedal bracket. ● Install the clip with its stopper portion a facing inward. Drive sprocket

● Lock washer 1 ● Nut (drive sprocket) 2

● O-ring 1 ● Dowel pin 2 ● Oil hose 3 ● Bolt (oil hose) 4

● Spring 1 ● Pin 2 ● O-ring 3 ● Neutral switch 4 ● Bolt (neutral switch) 5

CRANKCASE AND CRANKSHAFT

CRANKCASE AND CRANKSHAFT

Extent of removal: Extent of removal 1 Crankcase separation Order

CRANKCASE AND CRANKSHAFT REMOVAL

Engine Piston Preparation for removal

Part name 2 Crankshaft removal

Kick shaft assembly Segment Stator Balancer shaft Timing chain guide (intake side) Timing chain Oil delivery pipe 2

Remarks Refer to “ENGINE REMOVAL” section. Refer to “CYLINDER AND PISTON” section. Refer to “KICK SHAFT AND SHIFT SHAFT” section. Refer to “CDI MAGNETO” section. Refer to “BALANCER” section.

CRANKCASE AND CRANKSHAFT

Part name Bolt [L = 45 mm (1.77 in)] Bolt [L = 55 mm (2.17 in)] Bolt [L = 70 mm (2.76 in)] Hose guide Clutch cable holder Right crankcase Left crankcase Oil strainer Crankshaft

ENG Remarks Refer to “REMOVAL POINTS”. Use special tool. Refer to “REMOVAL POINTS”.

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

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

CRANKCASE AND CRANKSHAFT

ENG CRANKCASE BEARING Extent of removal: Extent of removal 1 Crankcase bearing removal Order Preparation for removal

Part name CRANKCASE BEARING REMOVAL Transmission Shift cam and shift fork Oil seal Bearing

Q’ty Remarks Refer to “TRANSMISSION, SHIFT CAM AND SHIFT FORK” section.

Refer to “REMOVAL POINTS”.

CRANKCASE AND CRANKSHAFT

ENG REMOVAL POINTS Crankcase

● Right crankcase ● Left crankcase 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 one end “hangs up”, take pressure off the push screw, realign, and start over. If the cases do not separate, check for a remaining case screw or fitting. Do not force.

Remove the dowel pins and O-ring.

CRANKCASE AND CRANKSHAFT

● Bearing 1 NOTE: ● Remove the bearing from the crankcase by pressing its inner race. ● Do not use the removed bearing. INSPECTION Timing chain and timing chain guide

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

● Timing chain guide Wear/damage → Replace. Crankcase

● Contacting surface a Scratches → Replace. ● Engine mounting boss b, crankcase Cracks/damage → Replace.

● Bearing Rotate inner race with a finger. Rough spot/seizure → Replace.

● Oil seal Damage → Replace.

CRANKCASE AND CRANKSHAFT

clearance: (0.0059 ~ 0.0177 in) (0.02 in) Crack width:

● Oil strainer Damage → Replace. Oil delivery pipe 2

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

CRANKCASE AND CRANKSHAFT

ASSEMBLY AND INSTALLATION

● Bearing ● Bearing stopper ● Screw (bearing stopper)

10 Nm (1.0 m · kg, 7.2 ft · lb) To left and right crankcase. 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

Å For USA and CDN ı 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.

CRANKCASE AND CRANKSHAFT

● Shifter operation ● Transmission operation Unsmooth operation → Repair.

● Oil strainer 1 ● Bolt (oil strainer) 2

● Dowel pin 1 ● O-ring 2 ● Right crankcase To left crankcase. NOTE: ● 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).

CRANKCASE AND CRANKSHAFT

● Oil delivery pipe 2 1 ● O-ring 2 ● Bolt (oil delivery pipe 2) 3

● Timing chain 1 ● Timing chain guide (intake side) 2 ● Bolt (timing chain guide) 3

● Sealant Forced out on the cylinder mating surface.

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

● Crankshaft and transmission operation. Unsmooth operation → Repair.

TRANSMISSION, SHIFT CAM AND SHIFT FORK

TRANSMISSION, SHIFT CAM AND SHIFT FORK

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

TRANSMISSION, SHIFT CAM

AND SHIFT FORK REMOVAL

Engine Separate the crankcase. Preparation for removal

Main axle Drive axle Shift cam Shift fork 3 Shift fork 2 Shift fork 1 Collar Refer to “ENGINE REMOVAL” section. Refer to “CRANKCASE AND CRANKSHAFT” section.

TRANSMISSION, SHIFT CAM AND SHIFT FORK

ENG EC4H3000 REMOVAL POINTS EC4H3230 Transmission

● Main axle 1 ● Drive axle 2 ● Shift cam ● Shift fork 3 ● Shift fork 2 ● Shift fork 1 NOTE: ● 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 INSPECTION EC4H4200 Gears

● O-ring 1 Damage → Replace.

● Gears movement Unsmooth movement → Repair or replace. EC4H4600 Bearing

● Bearing 1 Rotate inner race with a finger. Rough spot/seizure → Replace.

TRANSMISSION, SHIFT CAM AND SHIFT FORK

ENG EC4H4810 Shift fork, shift cam and segment

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

● Shift cam 1 ● Segment 2 Wear/damage → Replace.

ASSEMBLY AND INSTALLATION

● 5th pinion gear (27T) 1 ● 3rd pinion gear (21T) 2 ● Collar 3 ● 4th pinion gear (24T) 4 ● 2nd pinion gear (16T) 5 To main axle 6. NOTE: ● Apply the molybdenum disulfide oil on the 4th and 5th pinion gears inner circumference and on the end surface. ● Apply the molybdenum disulfide oil on the 2nd and 3rd pinion gears inner circumference.

TRANSMISSION, SHIFT CAM AND SHIFT FORK

● 2nd wheel gear (28T) 1 ● 4th wheel gear (25T) 2 ● 3rd wheel gear (28T) 3 ● 5th wheel gear (22T) 4 ● 1st wheel gear (31T) 5 ● O-ring 6 To drive axle 7. NOTE: ● Apply the molybdenum disulfide oil on the 1st, 2nd and 3rd wheel gears inner circumference and on the end surface. ● Apply the molybdenum disulfide oil on the 4th and 5th wheel gears inner circumference. ● Apply the lithium soap base grease on the Oring.

● Washer 1 ● Circlip 2 NOTE: ● Be sure the circlip sharp-edged corner a is positioned opposite side to the washer and gear b. ● Be sure the circlip end c is positioned at axle spline groove d.

● Collar 1 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.

TRANSMISSION, SHIFT CAM AND SHIFT FORK

● Shift fork 1 (L) 1 ● Shift fork 2 (C) 2 ● Shift fork 3 (R) 3 ● 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. NOTE: Apply the engine oil on the bearings and guide bars.

● Shifter operation ● Transmission operation Unsmooth operation → Repair.

Extent of removal: 1 Front wheel removal 3 Brake disc removal Extent of removal Order

Hold the machine by placing the suitable stand under the engine. Preparation for removal

Part name 2 Wheel bearing removal

Trip meter cable Brake hose cover Bolt (brake hose holder) Bolt (axle holder) Nut (front wheel axle) Front wheel axle Front wheel Trip meter gear unit Collar Oil seal Bearing Brake disc 5-1 Remarks WARNING Support the machine securely so there is no danger of it falling over.

Only loosening. Only loosening. Refer to “REMOVAL POINTS”.

CHAS EC598100 REAR WHEEL Extent of removal: 1 Rear wheel removal 3 Brake disc removal Extent of removal Order

Nut (rear wheel axle) Rear wheel axle Drive chain puller Rear wheel Collar Rear wheel sprocket Oil seal Circlip Bearing Brake disc Support the machine securely so there is no danger of it falling over.

Hold the machine by placing the suitable stand under the engine. Preparation for removal

Part name 2 Wheel bearing removal Refer to “REMOVAL POINTS”. Refer to “REMOVAL POINTS”.

CHAS EC593000 REMOVAL POINTS EC523101 Rear wheel

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

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

● Wheel runout Out of limit → Repair/replace. Wheel runout limit: Radial 1: 2.0 mm (0.08 in) Lateral 2: 2.0 mm (0.08 in)

● Bearing Rotate inner race with a finger. Rough spot/seizure → Replace. NOTE: Replace the bearings, oil seal and wheel collar as a set. 5-3

CHAS EC514200 Wheel axle

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

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

● 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:

<Limit>: 2.5 mm (0.10 in) Rear:

ASSEMBLY AND INSTALLATION

● Bearing (left) 1 ● Spacer 2 ● Bearing (right) 3 ● Oil seal 4 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. CAUTION: Do not strike the inner race of the bearing. Contact should be made only with the outer race.

● Collar 1 NOTE: ● Apply the lithium soap base grease on the oil seal lip. ● Install the collar with their projection a facing the wheel.

NOTE: Make sure the two projections a in the wheel hub are meshed with the two slots b in the trip meter gear unit.

● Wheel NOTE: ● Install the brake disc between the brake pads correctly. ● Make sure that the projections a in the trip meter gear unit fits over the stopper b on the front fork outer tube.

● Wheel axle 1 NOTE: Apply the lithium soap base grease on the wheel axle.

● Nut (wheel axle) 1

● Bolt (axle holder) 1

23 Nm (2.3 m · kg, 17 ft · lb) 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. 5-6

10 Nm (1.0 m · kg, 7.2 ft · lb) To brake hose holder 2. NOTE: Before tightening the bolt (brake hose holder), pass the brake hose in front of the axle boss a, then fit it into the hose groove b so that the brake hose does not contact the nut (wheel axle).

● Brake hose cover 1 ● Washer 2 ● Bolt [brake hose cover (M8)] 3

CHAS EC5251A0 Rear wheel

Circlip 2 Spacer 3 Bearing (left) 4

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. CAUTION: Do not strike the inner race of the bearing. Contact should be made only with the outer race.

● Collar 1 NOTE: Apply the lithium soap base grease on the oil seal lip.

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

● Drive chain 1 NOTE: Push the wheel 2 forward and install the drive chain.

● Left drive chain puller 1 ● Wheel axle 2 NOTE: ● 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 ● Washer 2 ● Nut (wheel axle) 3 NOTE: Temporarily tighten the nut (wheel axle) at this point. 5-9

● Nut (wheel axle) 1

EC5A8000 FRONT BRAKE Extent of removal: 1 Brake hose removal 3 Brake master cylinder removal Extent of removal Order

Hold the machine by placing the suitable stand under the engine. Drain the brake fluid. Preparation for removal

Brake hose cover Brake hose holder Bolt (brake hose holder) Union bolt Brake hose Pad pin plug Pad pin Brake caliper Brake lever Brake master cylinder bracket Brake master cylinder

Remarks WARNING Support the machine securely so there is no danger of it falling over. Refer to “REMOVAL POINTS”.

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

Drain the brake fluid. Pad pin plug Pad pin Brake caliper Brake hose holder Union bolt Brake hose Brake pedal Reservoir tank Reservoir hose Brake master cylinder

Refer to “FRONT WHEEL AND REAR WHEEL” section. Refer to “REMOVAL POINTS”. Remove when loosening the pad pin. Loosen when disassembling the caliper.

Å Front ı Rear Extent of removal: Extent of removal

1 Front brake caliper disassembly Order

Pad pin Brake pad Pad support Brake caliper piston Dust seal Piston seal

Remarks Refer to “REMOVAL POINTS”. Refer to “REMOVAL POINTS”.

Å Front ı Rear Extent of removal: Extent of removal

1 Front brake master cylinder disassembly Order

[Front] ● Brake master cylinder cap 1 [Rear] ● Brake master cylinder guard 1 ● Reservoir tank cap 2 NOTE: Do not remove the diaphragm.

2. Connect the transparent hose 2 to the

bleed screw 1 and place a suitable container under its end. Å Front ı Rear

3. Loosen the bleed screw and drain the

brake fluid while pulling the lever in or pushing down on the pedal.

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

● Brake caliper piston Use compressed air and proceed carefully.

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. Å Front ı Rear

● Dust seal 1 ● Piston seal 2

NOTE: Remove the piston seals and dust seals by pushing them with a finger. CAUTION: Never attempt to pry out piston seals and dust seals.

WARNING Replace the piston seals and dust seals whenever a caliper is disassembled. Å Front ı Rear

● Brake master cylinder inner surface a Wear/scratches → Replace master cylinder assembly. Stains → Clean. WARNING Use only new brake fluid.

● Diaphragm 1 Crack/damage → Replace. Å Front ı Rear

● Brake master cylinder piston 1 ● Brake master cylinder cup 2 Wear/damage/score marks → Replace brake master cylinder kit.

● Brake caliper cylinder inner surface a Wear/score marks → Replace brake caliper assembly.

● 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. EC534301 Brake hose

● Brake hose 1 Crack/damage → Replace. EC5A5000

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

● Brake caliper ● Piston seal ● Dust seal ● Brake caliper piston Clean them with brake fluid.

Dust seal 2 WARNING Always use new piston seals and dust seals.

NOTE: Fit the piston seals and dust seals onto the slot on brake caliper correctly. Å Front ı Rear

NOTE: Apply the brake fluid on the piston wall. CAUTION:

For the front brake caliper, install the piston with its depressed side a facing the brake caliper. For the rear brake caliper, install the piston with its shallow depressed side b facing the caliper. Never force to insert. Å Front ı Rear Front brake caliper

● Pad support 1 ● Brake pad 2 ● Pad pin 3 NOTE: ● Install the brake pads with their projections a into the brake caliper recesses b. ● Temporarily tighten the pad pin at this point.

● Copper washer 1 ● Union bolt 2

30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers. CAUTION: Install the brake hose so that its pipe portion a directs as show and lightly touches the projection b on the brake caliper.

23 Nm (2.3 m · kg, 17 ft · lb) NOTE: Fit the brake hose holder cut a over the projection b on the front fork and clamp the brake hose.

● Pad support 1 ● Brake pad 2 ● Pad pin 3 NOTE: ● Install the brake pads with their projections a into the brake caliper recesses b. ● Temporarily tighten the pad pin at this point.

● Brake disc cover 1 ● Bolt (brake disc cover) 2

● Copper washer 1 ● Brake hose 2 ● Union bolt 3

30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers. CAUTION: Install the brake hose to the brake caliper with the paint a on the pipe facing the brake caliper and with the pipe contacting the brake caliper projection b.

● Brake caliper 1 ● Rear wheel 2 Refer to “FRONT WHEEL AND REAR WHEEL” section.

CHAS Brake master cylinder kit

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

● Brake master cylinder cup (primary) 1 ● Brake master cylinder cup (secondary) To brake master cylinder piston 3.

NOTE: Apply the brake fluid on the brake master cylinder cup.

After installing, cylinder cup should be installed as shown direction. Wrong installation cause improper brake performance. Å Front ı Rear

NOTE: Install the spring at the smaller dia. side. Å Front ı Rear

[Front] ● Brake master cylinder kit 1 ● Washer 2 ● Circlip 3 ● Brake master cylinder boot 4 To brake master cylinder 5. [Rear] ● Brake master cylinder kit 1 ● Push rod 2 ● Circlip 3 ● 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. Å Front ı Rear Front brake master cylinder

● Brake master cylinder 1 ● Brake master cylinder bracket 2 ● Bolt (brake master cylinder bracket) 3

9 Nm (0.9 m · kg, 6.5 ft · lb) 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.

6 Nm (0.6 m · kg, 4.3 ft · lb) 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

● Reservoir hose 1 ● Reservoir tank 2 ● Bolt (reservoir tank) 3

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

● Spring 1 ● Brake pedal 2 ● O-ring 3 ● Bolt (brake pedal) 4

26 Nm (2.6 m · kg, 19 ft · lb) Clip 5 NOTE: ● Apply the lithium soap base grease on the bolt, O-ring and brake pedal bracket. ● Install the clip with its stopper portion a facing inward.

● Pin 1 ● Washer 2 ● Cotter pin 3 NOTE: After installing, check the brake pedal height. Refer to “REAR BRAKE ADJUSTMENT” section in the CHAPTER 3. Front brake hose

10 Nm (1.0 m · kg, 7.2 ft · lb) To brake hose holder 2. NOTE: Before tightening the bolt (brake hose holder), pass the brake hose in front of the axle boss a, then fit it into the hose groove b so that the brake hose does not contact the nut (wheel axle).

● Brake hose cover 1 ● Washer 2 ● Bolt [brake hose cover (M8)] 3

3. Pass the brake hose through the cable

guides 1, then through the guides a on the protector 2.

● Copper washer 1 ● Brake hose 2 ● Union bolt 3

30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers. CAUTION: Install the brake hose so that it contacts the master cylinder projection a and that its bent portion b faces downward. Rear brake hose

● Copper washer 1 ● Brake hose 2 ● Copper washer 3 ● Union bolt 4

30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers. CAUTION: When installing the brake hose, first align the tooth a on the copper washer 1 with the projection b on the brake master cylinder. Then, align the pipe portion c on the end of the brake hose with the tooth d on the copper washer 1 and tighten the union bolt.

● Brake hose holder 1 ● Screw (brake hose holder) 2

4 Nm (0.4 m · kg, 2.9 ft · lb) 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

● Brake fluid Until the fluid level reaches “LOWER” level line a.

Recommended brake fluid: DOT #4 WARNING

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. Å Front ı Rear

● Brake fluid level Fluid at lower level → Fill up. Refer to “BRAKE FLUID LEVEL INSPECTION” section in the CHAPTER 3.

[Front] ● Diaphragm ● Brake master cylinder cap 1 ● Screw (brake master cylinder cap) 2

2 Nm (0.2 m · kg, 1.4 ft · lb) [Rear] ● Diaphragm ● Reservoir tank cap 1 ● Screw (reservoir tank cap) 2

10 Nm (1.0 m · kg, 7.2 ft · lb) CAUTION: 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. Å Front ı Rear

5. Install: (rear brake only)

“SPURGO DELL’ARIA DAL

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

Refer to “HANDLEBAR” section.

DEPOSE DE LA FOURCHE AVANT

Extent of removal: Extent of removal

1 Oil seal removal Order

Remarks Refer to “REMOVAL POINTS”. Drain the fork oil. Refer to “REMOVAL POINTS”. Use special tool. Refer to “REMOVAL POINTS”. FOURCHE AVANT TELESKOPGABEL FORCELLA ANTERIORE CHAS

Fare riferimento a “PUNTI DI RIMOZIONE”. FRONT FORK CHAS EC556000 HANDLING NOTE NOTE: The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers. CAUTION: 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

● 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 NOTE: ● While compressing the fork spring, set the thin type spanners 2 between the spacer 3 and spring guide 4. ● Hold the locknut 5 and remove the front fork cap bolt.

● Dust seal 1 ● Stopper ring 2 Using slotted-head screwdriver. 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 ● Repeat this step until the inner tube can be pulled out from the outer tube.

● Damper rod 1 Bend/damage → Replace 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.

● 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:

NOTE: The bending value is shown by one half of the dial gauge reading. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube. EC554600 Outer tube

● Outer tube 1 Score marks/wear/damage → Replace.

ASSEMBLY AND INSTALLATION

1. Wash the all parts in a clean solvent.

● Damper rod 1 To inner tube 2. 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.

● Copper washer 1 ● O-ring 2 ● Base valve 3 To inner tube 4.

● Spring guide 1 ● Locknut 2 To damper rod 3. NOTE: ● Install the spring guide with its cut a facing upward. ● With its thread b facing upward, fully finger tighten the locknut onto the damper rod.

● Dust seal 1 ● Stopper ring 2 ● Oil seal 3 ● Oil seal washer 4 ● Slide metal 5 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.

● Outer tube 1 To inner tube 2.

● Slide metal 1 ● 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-01442/90890-01442

● Oil seal 1 NOTE: Press the oil seal into the outer tube with fork seal driver 2. Fork seal driver: YM-01442/90890-01442

● Stopper ring 1 NOTE: Fit the stopper ring correctly in the groove in the outer tube.

● Dust seal 1 NOTE: Apply the lithium soap base grease on the inner tube.

● Inner tube smooth movement Tightness/binding/rough spots → Repeat the steps 2 to 12.

14. Compress the front fork fully.

● Front fork oil Until outer tube top surface with recommended fork oil 1. Recommended oil: Suspension oil “01” 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.

● 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.

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.

● Oil level (left and right) a Out of specification → Adjust. Standard oil level: 140 mm (5.51 in)

• 130 mm (5.12 in) Extent of adjustment: 80 ~ 150 mm (3.15 ~ 5.91 in) From top of outer tube with inner tube and damper rod 1 fully compressed without spring.
• For EUROPE NOTE: Be sure to install the spring guide 2 when checking the oil level. 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.

● Distance a Out of specification → Turn into the locknut. Distance a: 20 mm (0.79 in) or more Between damper rod 1 top and locknut 2 top.

● 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).

● Cushion rubber 1 ● Washer 2 ● Spacer 3 To front fork cap bolt 4. NOTE: Install the cushion rubber with its smaller dia.end a facing the front fork cap bolt.

● Push rod 1 ● Fork spring 2 NOTE: ● 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.

● Front fork cap bolt 1 Fully tighten the front fork cap bolt onto the damper rod by hand.

● Front fork 1 NOTE: ● Temporarily tighten the pinch bolts (lower bracket). ● Do not tighten the pinch bolts (upper bracket) yet.

• For EUROPE ** For AUS, NZ and ZA

23 Nm (2.3 m · kg, 17 ft · lb) NOTE: Fit the brake hose holder cut a over the projection b on the front fork and clamp the brake hose.

● Brake hose holder 1 ● Bolt (brake hose holder) 2

10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: When installing the brake hose holder, pass the brake hose 5 in front of the axle boss a, then fit it into the hose groove b so that the brake hose does not contact the nut (wheel axle).

● Rebound damping force NOTE: Turn in the damping adjuster 1 finger-tight and then turn out to the originally set position.

Part name HANDLEBAR REMOVAL Headlight Decompression cable Decompression lever holder Clutch cable Clutch lever holder Engine stop switch Light switch Brake master cylinder Throttle cable cap Throttle cable #2 (pushed) Throttle cable #1 (pulled) Right grip Tube guide Collar Left grip Handlebar upper holder Handlebar

● Brake master cylinder bracket 1 ● Brake master cylinder 2 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

● Grip 1 NOTE: Blow in air between the handlebar or tube guide and the grip. Then remove the grip which has become loose. EC5B4000 INSPECTION EC5B4100 Handlebar

● Handlebar 1 Bends/cracks/damage → Replace. WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar.

ASSEMBLY AND INSTALLATION

28 Nm (2.8 m · kg, 20 ft · lb) NOTE: ● The handlebar upper holder should be installed with the punched mark a forward. ● First tighten the bolts on the front side of the handlebar upper holder, and then tighten the bolts on the rear side.

● Left grip 1 Apply the adhesive to the handlebar 2. NOTE: ● Before applying the adhesive, wipe off grease or oil on the handlebar surface a with a lacquer thinner. ● Install the left grip to the handlebar so that the line b between the two arrow marks faces straight upward.

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.

● Collar 1 ● Throttle cables 2 To tube guide 3. NOTE: Apply the lithium soap base grease on the throttle cable end and tube guide cable winding portion.

● Throttle cable cap 1 ● Screw (throttle cable cap) 2

4 Nm (0.4 m · kg, 2.9 ft · lb) Cover (throttle cable cap) 3 WARNING After tightening the screws, check that the throttle grip 4 moves smoothly. If it does not, retighten the bolts for adjustment.

● Brake master cylinder 1 ● Brake master cylinder bracket 2 ● Bolt (brake master cylinder bracket) 3

9 Nm (0.9 m · kg, 6.5 ft · lb) NOTE: ● 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.

4 Nm (0.4 m · kg, 2.9 ft · lb) Decompression lever holder 4 Bolt (decompression lever holder) 5 4 Nm (0.4 m · kg, 2.9 ft · lb) Clamp 6 NOTE: ● The engine stop switch, clutch lever holder, decompression lever holder and clamp should be installed according to the dimensions shown. ● Pass the engine stop switch lead in the middle of the clutch holder.

NOTE: Apply the lithium soap base grease on the clutch cable end and decompression cable end.

● Clutch lever free play Refer to “CLUTCH ADJUSTMENT” section in the CHAPTER 3. ● Decompression lever free play Refer to “DECOMPRESSION LEVER ADJUSTMENT” section in the CHAPTER 3.

clutch cable 2 with a clamp 3.

12. Insert the end of the fuel breather hose

1 into the hole of the steering stem.

STEERING CHAS EC560000 STEERING Extent of removal: Extent of removal 1 Lower bracket removal Order Part name

STEERING REMOVAL Hold the machine by placing the suitable stand under the engine. Headlight Handlebar Cable guide Front fender Trip meter Steering stem nut Front fork Upper bracket Steering ring nut

Lower bracket Ball race cover

Preparation for removal

Part name Upper bearing Lower bearing Ball race Q’ty

● Steering ring nut 1 Use the steering nut wrench 2. Steering nut wrench: YU-33975/90890-01403 WARNING Support the steering stem so that it may not fall down. Lower bearing

● Lower bearing 1 Use the floor chisel 2. CAUTION: Take care not to damage the steering stem thread. EC563400 Ball race

1. Wash the bearings and ball races with a

● Bearing 1 ● Ball race Pitting/damage → Replace bearings and ball races as a set. Install the bearing in the ball races. Spin the bearings by hand. If the bearings hang up or are not smooth in their operation in the ball races, replace bearings and ball races as a set. EC565000

ASSEMBLY AND INSTALLATION

● Lower bearing 1 NOTE: Apply the lithium soap base grease on the dust seal lip and bearing inner circumference.

● Ball race ● Upper bearing 1 ● Ball race cover 2 NOTE: Apply the lithium soap base grease on the bearing and ball race cover lip.

● Lower bracket 1 NOTE: Apply the lithium soap base grease on the bearing and the portion a of the steering stem.

7 Nm (0.7 m · kg, 5.1 ft · lb) Tighten the steering ring nut using the steering nut wrench 3. Refer to “STEERING HEAD INSPECTION AND ADJUSTMENT” section in the CHAPTER 3.

5. 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.

● Front fork 1 ● Upper bracket 2 NOTE: ● Temporarily tighten the pinch bolts (lower bracket). ● Do not tighten the pinch bolts (upper bracket) yet.

9. After tightening the nut, check the steering for smooth movement. If not, adjust

the steering by loosening the steering ring nut little by little.

● Front fork top end a Front fork top end (standard) a: 7 mm (0.28 in)

• For EUROPE ** For AUS, NZ and ZA

● Contachilometri parziale 1 SWINGARM CHAS EC570000 SWINGARM Extent of removal: Extent of removal 1 Swingarm removal Order Part name Q’ty STEERING REMOVAL Hold the machine by placing the suitable stand under the engine. Preparation for removal

Brake hose holder Rear brake caliper Bolt (brake pedal) Drive chain Drive chain case Lower chain tensioner Bolt (rear shock absorber-relay arm) Bolt (connecting rod) Pivot shaft Swingarm

Remarks WARNING Support the machine securely so there is no danger of it falling over. Refer to “FRONT BRAKE AND REAR BRAKE” section. Shift the brake pedal backward.

Part name SWINGARM DISASSEMBLY Cap Relay arm Connecting rod Collar Oil seal Thrust bearing Bushing Oil seal Bearing

● Bearing 1 NOTE: Install the bearing by pressing its outer race. INSPECTION Wash the bearings, bushings, collars, and covers in a solvent. Swingarm

● Bearing 1 ● Bushing 2 Free play exists/unsmooth revolution/ rust → Replace bearing and bushing as a set.

● Oil seal 3 Damage → Replace. EC574210 Relay arm

● Bearing 1 ● Collar 2 Free play exists/unsmooth revolution/rust

• Replace bearing and collar as a set.

● Oil seal 3 Damage → Replace. EC574310 Connecting rod

● Bearing 1 ● Collar 2 Free play exists/unsmooth revolution/rust

• Replace bearing and collar as a set.

● Oil seal 3 Damage → Replace.

ASSEMBLY AND INSTALLATION

EC575201 Bearing and oil seal

● Bearing 1 ● 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: 8.5 mm (0.33 in)

● Bearing 1 ● Oil seal 2 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. Installed depth of bearings a: 5 mm (0.20 in)

● Bearing 1 ● 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: 5 mm (0.20 in)

● Bushing 1 ● Thrust bearing 2 ● Oil seal 3 ● Collar 4 To swingarm 5. NOTE: Apply the molybdenum disulfide grease on the bushings, thrust bearings and oil seal lips.

● Collar 1 To relay arm 2. NOTE: Apply the molybdenum disulfide grease on the collars, bearings and oil seal lips.

● Collar 1 To connecting rod 2. NOTE: Apply the molybdenum disulfide grease on the collar, bearings and oil seal lips.

● Connecting rod 1 ● Bolt (connecting rod) 2 ● Washer 3 ● Nut (connecting rod) 4

80 Nm (8.0 m · kg, 58 ft · lb) To relay arm 5. NOTE: Apply the molybdenum disulfide grease on the bolt. CAUTION: Install the nut on the left side of the chassis. If you make a mistake in its installation position, the nut contacts the swingarm when stroking the rear shock absorber.

● Relay arm 1 ● Bolt (relay arm) 2 ● Washer 3 ● Nut (relay arm) 4 To swingarm. NOTE: ● Apply the molybdenum disulfide grease on the bolt. ● Do not tighten the nut yet.

● 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 ● Washer 2 ● Nut (connecting rod) 3 NOTE: ● Apply the molybdenum disulfide grease on the bolt. ● Do not tighten the nut yet.

● Washer 1 ● Bolt (rear shock absorber-relay arm) 2

● Cap 1 NOTE: Install the cap with its mark a facing forward.

● Bolt (lower chain tensioner) 1 ● Washer 2 ● Collar 3 ● Lower chain tensioner 4 ● Nut (lower chain tensioner) 5

● Drive chain case 1 ● Drive chain case cover 2 ● Bolt {drive chain case [r= 50 mm (1.97 in)]} 3 ● Nut (drive chain case) 4

Extent of removal: Extent of removal 1 Rear shock absorber removal Order Part name 2 Rear shock absorber disassembly Q’ty

REMOVAL Hold the machine by placing the suitable stand under the engine. Seat and side covers Preparation for removal WARNING Support the machine securely so there is no danger of it falling over. Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 4. Refer to “EXHAUST PIPE AND SILENCER” section in the CHAPTER 4. Refer to “COOLANT REPLACEMENT” section in the CHAPTER 3. Refer to “RADIATOR” section in the

Silencer Drain the coolant. Coolant reservoir

Taillight connector Band Bolt (reservoir tank) Clamp (air filter joint) Rear frame Bolt (rear shock absorber-relay arm) Bolt (rear shock absorber-frame) Rear shock absorber

CHAS HANDLING NOTE 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 or 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 worn-out rear shock absorber, take the unit to your Yamaha dealer for this disposal procedure.

MISE AU REBUT (TRAVAIL A

● 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 NOTE: Remove the bearing by pressing its outer race. EC584000 INSPECTION Rear shock absorber

● 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.

ASSEMBLY AND INSTALLATION

● Upper bearing 1 NOTE: Install the bearing parallel until the stopper ring groove appears by pressing its outer race. 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.

● Stopper ring (upper bearing) 1 NOTE: After installing the stopper ring, push back the bearing until it contacts the stopper ring.

● 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)

● Spring length (installed) a Spring length (installed) a: Standard length Extent of adjustment

• For EUROPE ** For AUS, NZ and ZA NOTE: 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.

● Locknut 1 Rear shock absorber

● Dust seal 1 ● O-ring 2 ● Collar 3 NOTE: ● Apply the molybdenum disulfide grease on the bearing. ● Apply the lithium soap base grease on the dust seals, O-rings and collars.

● Bushing 1 ● Collar 2 ● Dust seal 3 NOTE: ● Apply the molybdenum disulfide grease on the bearing. ● Apply the lithium soap base grease on the bushing, collars and dust seals. ● Install the dust seals with their lips facing outward.

● Rear shock absorber

● Bolt (rear shock absorber-frame) 1 ● Nut (rear shock absorber-frame) 2

● Washer 1 ● Bolt (rear shock absorber-relay arm) 2

● Rear frame 1 ● Bolt (rear frame) 2

● Screw (air filter joint) 1

A map-controlled, CDI ignition system is used in the WR250F. The microcomputer in the CDI unit detects the engine speed and throttle position, thus determining the optimum ignition timing through the entire operating range. In this way, quick throttle response can be achieved according to various riding conditions. Ignition coil Throttle position sensor CDI unit Pickup coil CDI magneto rotor ■ Function of Component Component Function Throttle position sensor Detects throttle valve opening and inputs it into the computer in the CDI unit as a throttle opening signal. Pickup coil Detects signal rotor revolutions and inputs them into the computer in the CDI unit as engine revolution signals. CDI unit The signals of the throttle position sensor and pickup coil sensor are analyzed by the computer in the CDI unit, which then adjusts ignition timing for the operation requirements. Ignition timing ■ Principal of 3-Dimensional Control Conventionally, ignition timing was controlled only by engine revolutions (2-dimensional control). However, ignition timing needs advancement also by engine load. Thus, accurate ignition timing can be determined by adding throttle opening to determine ignition timing (3-dimensional control). Throttle opening

3-D Image Map of Ignition Timing (different from actual characteristics) 6-2

EC620000 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. Spark gap test Spark *Clean or replace spark plug. No spark Check entire ignition system for connection. No good Repair or replace.

Check engine stop switch. No good Replace.

Check ignition coil.

Check neutral switch. Primary coil Secondary coil Pickup coil Charging coil No good No good No good No good No good Replace. Replace. Replace. Replace. Repair or replace.

Replace CDI unit. *marked: Only when the ignition checker is used. NOTE: ● Remove the following parts before inspection.

1. Disconnect the spark plug cap from spark

2. Connect the dynamic spark tester 1

(ignition checker 2) as shown. ● Spark plug cap 3 ● Spark plug 4

Å For USA and CDN ı Except for USA and CDN

3. Kick the kickstarter crank.

4. Check the ignition spark gap.

5. Start engine, and increase spark gap until

misfire occurs. (for USA and CDN only) Minimum spark gap:

● Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace.

ENGINE STOP SWITCH INSPECTION

● Engine stop switch conduct Tester (+) lead → Black/White lead 1 Tester (–) lead → Black lead 2 B/W PUSH IN FREE

Tester selector position Ω ×1 No continuous while being pushed → Replace. Continuous while being freed → Replace. 6-4

IGNITION COIL INSPECTION

● Primary coil resistance Out of specification → Replace. Tester (+) lead → Orange lead 1 Tester (–) lead → Black lead 2 Primary coil resistance Tester selector position

● Secondary coil resistance Out of specification → Replace. Tester (+) lead → Spark plug lead 1 Tester (–) lead → Orange lead 2 Secondary coil resistance Tester selector position

20 ˚C (68 ˚F) kΩ × 1 NOTE: When inspecting the secondary coil resistance, remove the spark plug cap.

CDI MAGNETO INSPECTION

● Pickup coil resistance Out of specification → Replace. Tester (+) lead → Red lead 1 Tester (–) lead → White lead 2 6-5 Pickup coil resistance Tester selector position 248 ~ 372 Ω at 20 ˚C (68 ˚F) Ω × 100

● Charging coil 1 resistance Out of specification → Replace. Tester (+) lead → Brown lead 1 Tester (–) lead → Green lead 2 Charging coil 1 resistance Tester selector position 640 ~ 960 Ω at 20 ˚C (68 ˚F) Ω × 100

● Charging coil 2 resistance Out of specification → Replace. Tester (+) lead → Pink lead 1 Tester (–) lead → Green lead 2 Charging coil 2 resistance Tester selector position 464 ~ 696 Ω at 20 ˚C (68 ˚F) Ω × 100

NEUTRAL SWITCH INSPECTION

● Neutral switch conduct Tester (+) lead → Sky blue lead 1 Tester (–) lead → Ground 2

tor position Ω ×1 No continuous while in neutral → Replace. Continuous while in gear → Replace. EC628000

Check all electrical components. If no fault is found, replace the CDI unit. Then check the electrical components again. 6-6

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.

*Check CDI magneto. Charging coil No good Replace.

Check CDI unit. Throttle position sensor input voltage No good Replace. *marked: Refer to “IGNITION SYSTEM” section. NOTE: ● Remove the following parts before inspection.

● Use the following special tools in this inspection. Pocket tester: YU-3112-C/90890-03112 Inductive tachometer: YU-08036-B Engine tachometer: 90890-03113 6-7

● Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace.

THROTTLE POSITION SENSOR COIL

● 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 4 ~ 6 kΩ at 20 ˚C (68 ˚F) kΩ × 1

● Throttle stop screw 1 NOTE: Turn out the throttle stop screw until the throttle shaft is in the full close position.

● 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 position sensor coil variable resistance Tester selector position Full closed Full opened Zero ~ 3 kΩ 4 ~ 6 kΩ at at 20 ˚C 20 ˚C (68 ˚F) (68 ˚F) 6-8 kΩ × 1 CIRCUIT DU CAPTEUR DE PAPILLON DES GAZ DROSSELKLAPPEN-POSITIONSSENSOR SISTEMA SENSORE DELLA POSIZIONE DELLA VALVOLA A FARFALLA

REPLACEMENT AND ADJUSTMENT

● Throttle position sensor coupler ● Screw (throttle position sensor) 1 ● Washer 2 ● Throttle position sensor 3 NOTE: Loosen the screws (throttle position sensor) using the T20 bit (tamper resistant fastener type).

● Throttle position sensor

● Throttle position sensor 1 ● Washer 2 ● Screw (throttle position sensor) 3 NOTE: ● Align the slot a in the throttle position sensor with the projection b on the carburetor. ● Temporarily tighten the screws (throttle position sensor).

● Engine idling speed Refer to “ENGINE IDLE SPEED ADJUSTMENT” section in the CHAPTER 3.

● Throttle position sensor coil resistance at idle speed Throttle position sensor coil resistance at idle speed: Throttle position sensor coil resistance × (0.13 ~ 0.15) <Example> If the throttle position sensor coil resistance is 5 kΩ, then the throttle position sensor coil resistance at idle speed is: 5 kΩ × (0.13 ~ 0.15) = 650 ~ 750 Ω Refer to “THROTTLE POSITION SENSOR COIL INSPECTION” section about the throttle position sensor coil resistance. 6-9 CIRCUIT DU CAPTEUR DE PAPILLON DES GAZ DROSSELKLAPPEN-POSITIONSSENSOR SISTEMA SENSORE DELLA POSIZIONE DELLA VALVOLA A FARFALLA

● Throttle position sensor coil resistance at idle speed Adjustment steps: Adjust the angle of the throttle position sensor 1 to obtain the resistance calculated (example: 650 ~ 750 Ω) Tester (+) lead → Yellow lead 2 Tester (–) lead → Black lead 3

● Screw (throttle position sensor) 1 NOTE: Tighten the screws (throttle position sensor) using the T20 bit (tamper resistant fastener type).

● Throttle position sensor coupler

THROTTLE POSITION SENSOR INPUT

1. Disconnect the throttle position sensor

2. Start the engine.

● Throttle position sensor input voltage Out of specification → Replace the CDI unit. Tester (+) lead → Blue lead 1 Tester (–) lead → Black/Blue lead 2

LIGHTING SYSTEM INSPECTION STEPS Refer to the following flow chart when inspecting the ignition system for possible problems. Check the bulb and bulb socket. No good Replace the bulb and/ or bulb socket.

Check the light switch. No good Replace.

Check the CDI magneto. Lighting coil No good Replace.

Check the entire lighting system proper for connections. Improperly connected Repair or replace.

Check the voltage regulator. Out-put voltage No good Replace. NOTE: ● Replace the bulb and/or bulb socket.

● Light switch continuity Tester (+) lead → Yellow lead 1 Tester (–) lead → Blue lead 2

Tester selector position Ω×1 OFF No continuous while being

• Replace. Continuous while being OFF → Replace.

CDI MAGNETO INSPECTION

● Lighting coil resistance Out of specification → Replace. Tester (+) lead → Yellow lead 1 Tester (–) lead → Black lead 2 Lighting coil resistance Tester selector position

VOLTAGE REGULATOR INSPECTION

1. Start the engine.

2. Turn on the headlight and taillight by turning on the light switch.

● Out-put voltage Out of specification → Replace voltage regulator.

Tester (+) lead → Blue lead 1 Tester (–) lead → Black lead 2

VAC-20 SETTING TUN EC700000 TUNING EC710000 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

7-1 The carburetor is a part of the fuel line. Therefore, be sure to install it in a wellventilated 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. REGLAGE EINSTELLUNG REGISTRAZIONE TUN

SETTING TUN CAUTION:

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 temp. Humidity High Low High Low Air pressure (altitude) Low (high) High (low) Mixture Setting Richer Leaner 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. 7-2 REGLAGE EINSTELLUNG REGISTRAZIONE ATTENTION:

TUN Effects of the setting parts on the throttle valve opening 4/4 3/4 1/2

Å Closed ı Fully open 1 Pilot screw/pilot jet 2 Throttle valve cutaway 3 Jet needle 4 Main jet Main system The FLATCR carburetor has a primary main jet. This type of main jet is perfect for racing motorcycles since it supplies an even flow of fuel, even at full load. The main air jet has almost no effect on the air-fuel mixture. Use the main jet and the jet needle to set the carburetor. Pilot system The FLATCR carburetor is manufactured with a pilot screw. The pilot screw adjustment ranges from fully closed throttle to 1/4 open throttle. 7-3 REGLAGE EINSTELLUNG REGISTRAZIONE TUN Effets des réglages sur l’ouverture du papillon des gaz Wirkung der Einstellteile in Bezug auf die Öffnung der Drosselklappe Effetti della registrazione sull’apertura della valvola a farfalla

TUN –10% SETTING TUN Pilot screw adjustment The richness of the air-fuel mixture with the throttle fully closed to 1/4 open can be set by turning the pilot screw 1. Turning in the pilot screw will make the mixture lean at low speeds, and turning it out will enrich it. Standard pilot screw position 1-3/4 (example) NOTE: ● If the engine idling speed fluctuates, turn the pilot screw only 1/2 of a turn in either direction. ● To optimize the fuel flow at a smaller throttle opening, each machine’s pilot screw has been individually set at the factory. Before adjusting the pilot screw, turn it in fully and count the number of turns. Record this number as the factory-set number of turns out. Effects of adjusting the pilot screw (reference)

+5% #45 #42 #40 –5% Å Idle ı Fully open Jet needle groove position adjustment 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. No.3 groove *, ** No. 4 groove Standard clip position

• For EUROPE ** For CDN, ZA, AUS and NZ NOTE: It is recommended that in the summer the clip position be changed from the 4th (STD) to the 2nd groove for a leaner air-fuel mixture. (For AUS and NZ only) Effects of changing the jet needle groove position (reference)

• For EUROPE ** For CDN, ZA, AUS and NZ The tapered sections of all jet needles have the same starting positions, but the needles are available with different straight-portion diameters. <Example> OBELP - 4 Clip position Diameter a of straight portion 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).

1. The engine breathes hard in quick throttle opening.

Select a leak jet having lower calibrating No. than standard to enrich the mixture. <Example> #105 → #95

2. 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> #105 → #115

• Per l’EUROPE ** Per CDN, ZA, AUS e NZ SETTING TUN 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.

–10 % Å Idle ı Fully open Relationship with throttle opening The flow of the fuel through the carburetor main system is controlled by the main jet and then, it 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. 7-8 REGLAGE EINSTELLUNG REGISTRAZIONE Effets du changement d’aiguille (référence) (Diamètre de la partie recriligne) Une modification du diamètre de la partie droite modifie l’émulsion air-essence à une ouverture des gaz de 1/8 à 1/4.

• Per l’EUROPE ** Per CDN, ZA, AUS e NZ SETTING TUN Examples of carburetor setting depending on symptom Symptom At full throttle Hard breathing Shearing noise Whitish spark plug Setting 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. 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 At full throttle Speed pick-up stops Slow speed pick-up Slow response Sooty spark plug Checking Rich mixture Lean mixture Rich mixture Lower jet needle clip position. (1 groove down) Raise jet needle clip position. (1 groove up) Groobe 1 Groobe 2 Groobe 3 Groobe 4 Groobe 5 Groobe 6 Groobe 7 Clip Leaner

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) 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). Closed to 1/4 throttle Hard breathing Speed down Use jet needle with a smaller diameter. Slow-speed-circuit passage Clogged → Clean. Overflow from carburetor 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. Jet needle Richer Poor response when throttle Check overall settings. Check air filter for fouling. is opened quickly 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 Check that the accelerator pump operthe jet needle clip position. ates smoothly. should be taken simply for an example. It is necessary to set the carburetor while checking

• This the operating conditions of the engine.

SETTING TUN EC720000 CHASSIS Selection of the secondary reduction ratio (Sprocket) Secondary Number of rear wheel sprocket teeth reduction = Number of drive sprocket teeth ratio Standard secondary reduction ratio 52/13 (4.000) <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 race, 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 race result. In such a case, run through the entire course while making notes of lap times to find the best balance; then, determine the secondary reduction ratio. ● If a course has a long straight portion where a machine can run at maximum speed, the machine is generally set such that it can develop its maximum revolutions toward the end of the 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.

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 kg/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 kg/cm2, 15 ~ 18 psi)

SETTING TUN EC722011 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

● Change the spring. ● 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 an characteristics. Therefore, adjust the front fork within the specified range. Standard oil level: 140 mm (5.51 in)

• 130 mm (5.12 in) Extent of adjustment: 80 ~ 150 mm (3.15 ~ 5.91 in) From top of outer tube with inner tube and damper rod fully compressed without spring.
• For EUROPE Å Air spring characteristics in relation to oil level change ı Load Ç Stroke 1 Max. oil level 2 Standard oil level 3 Min. oil level

● Modifica dello smorzamento di compressione. ● Modifica dello smorzamento di espansione. La molla agisce sul carico e la forza di smorzamento agisce sulla velocità corsa dell’ammortizzatore. Modifica del livello e delle caratteristiche dell’olio della forcella Le caratteristiche di smorzamento vicino alla corsa finale possono essere modificate cambiando la quantità d’olio nella forcella. ATTENZIONE: Regolare il livello dell’olio in incrementi o decrementi di 5 mm (0,2 in). Un livello dell’olio troppo basso fa sì che la forcella anteriore produca un rumore in piena espansione o che il pilota avverta una certa pressione sulle mani o sul corpo. Al contrario, un livello dell’olio troppo alto svilupperebbe molto presto un blocco dell’olio con una conseguente corsa della forcella anteriore più corta e deterioramento delle prestazioni e delle caratteristiche. Pertanto, regolare la forcella anteriore entro l’intervallo specificato. Livello olio standard: 140 mm (5,51 in) *130 mm (5,12 in) Portata della regolazione: 80 ~ 150 mm (3,15 ~ 5,91 in) Dalla parte superiore del fodero con il tubo di forza e l’asta pompante completamente compressi senza molla.

• Per l’EUROPE Å Caratteristiche della molla pneumatica in relazione alle modifiche del livello dell’olio ı Carico Ç Corsa 1 Livello olio max. 2 Livello olio standard 3 Livello olio min. SETTING TUN EC727020 Spring preload adjustment The spring preload is adjusted by installing the adjustment washer 1 between the fork spring 2 and damper rod 3. 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 Å Load ı Fork stroke 1 Without adjustment washer (standard) 2 1 adjustment washer 3 2 adjustment washers EC72A001 Setting of spring after replacement As the front fork setting can be easily affected by rear suspension, take care so that the machine front and rear are balanced (in 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. Å Coverage of spring by weight ı Rider weight 1 Soft 2 Standard 3 Stiff

I.D. MARK (slits) SOFT

• For EUROPE ** For AUS, NZ and ZA [Unequal pitch spring] TYPE SOFT STIFF SPRING SPRING RATE PART NUMBER (approx.)

5ET-23141-20 5ET-23141-00 5ET-23141-30 5ET-23141-10 5ET-23141-40 I.D. MARK (slits) V-I V-II V-III V-IIII NOTE: ● The unequal pitch spring is softer in initial characteristic than the equal pitch spring and is difficult to bottom out under full compression. ● The I.D. mark (slits) a is proved on the end of the spring.

1. Setting of spring preload

● Change the set length of the spring. ● Change 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.

2. 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.

3. 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)

Regolazione standard: 90 ~ 100 mm (3,5 ~ 3,9 in) SETTING TUN 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 re-adjustment. 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.

SETTING TUN 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:

Å Coverage of spring by weight ı Rider weight 1 Soft 2 Standard 3 Stiff

[Unequal pitch spring] SPRING I.D. SPRING SPRING COLOR/ FREE TYPE RATE PART NUMBER POINT LENGTH (approx.) SOFT STIFF

NOTE: ● The unequal pitch spring is softer in initial characteristic than the equal pitch spring and is difficult to bottom out under full compression. ● The I.D. color a is marked at the end of the spring.

EXTENT OF ADJUSTMENT b

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.

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

Stiff toward stroke end

Compression damping Low front, tending to lower front posture

Rebound damping 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)

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 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. Rebound damping Spongy and unstable

Turn adjuster clockwise (about 2 clicks) to increase damping. Low compression damping Turn adjuster clockwise (about 1 click) to increase damping. Spring Replace with stiff spring. Rebound damping Spring Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Replace with soft spring. Rebound damping

Poor road gripping Bottoming out

Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Low compression damping Turn adjuster clockwise (about 1 clicks) to increase damping. High compression damp- Turn adjuster clockwise (about 1/6 clicks) to increase ing damping. Spring set length Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when one passenger is astride seat. Spring Replace with soft spring. High compression damping Spring set length Spring Bouncing Stiff travel

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