WR450F - Moto tout-terrain YAMAHA - Free user manual and instructions

USER MANUAL WR450F YAMAHA

PRINTED ON RECYCLED PAPER WR450F(W)

OWNER’S SERVICE MANUAL ©2006 by Yamaha Motor Co., Ltd. 1st Edition, August 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan

INTRODUCTION Congratulations on your purchase of a

Yamaha WR series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader. This manual explains operation, inspection, basic maintenance and tuning of your machine. If you have any questions about this manual or your machine, please contact your Yamaha dealer. NOTE: Yamaha continually seeks advancements in product design and quality. Therefore, while this manual contains the most current product information available at the time of printing, there may be minor discrepancies between your machine and this manual. If you have any questions concerning this manual, please consult your Yamaha dealer. WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES. REGULAR INSPECTIONS AND CAREFUL MAINTENANCE, ALONG WITH GOOD RIDING SKILLS, WILL ENSURE THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.

INTRODUCTION VORWORT INTRODUCCIÓN IMPORTANT NOTICE THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding.

SAFETY INFORMATION 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.

5. GASOLINE IS HIGHLY FLAMMABLE.

Always turn off the engine while refueling. Take care to not spill any gasoline on the engine or exhaust system. Never refuel in the vicinity of an open flame, or while smoking. 6. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes. 7. ONLY 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.

TO THE NEW OWNER This manual will provide you with a good basic understanding of features, operation, and basic maintenance and inspection items of this machine. Please read this manual carefully and completely before operating your new machine. If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer.

NOTE: This manual should be considered a permanent part of this machine and should remain with it even if the machine is subsequently sold.

NOTICE Some data in this manual may become outdated due to improvements made to this model in the future. If there is any question you have regarding this manual or your machine, please consult your Yamaha dealer.

F.I.M. MACHINE WEIGHTS:

Weights of machines without fuel The minimum weights for motocross machines are: for the class 125 cc minimum 88 kg (194 lb) for the class 250 cc minimum 98 kg (216 lb) for the class 500 cc minimum 102 kg (225 lb) In modifying your machine (e.g., for weight reduction), take note of the above limits of weight.

HOW TO USE THIS MANUAL EC081000

PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION!

BECOME ALERT! YOUR SAFETY IS INVOLVED! 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.

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 INFORMATIONS PARTICULIEREMENT IMPORTANTES MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.

In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., • Bearings Pitting/damage → Replace. EC084002

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

1. An easy-to-see exploded diagram 1 is provided for removal and disassembly jobs. 2. Numbers 2 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step. 3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 3. The meanings of the symbol marks are given on the next page. 4. A job instruction chart 4 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc. 5. Extent of removal 5 is provided in the job instruction chart to save the trouble of an unnecessary removal job. 6. For jobs requiring more information, the step-by-step format supplements 6 are given in addition to the exploded diagram and job instruction chart.

FORMAT DU MANUEL AUFBAU FORMATO DEL MANUAL ILLUSTRATED SYMBOLS

(Refer to the illustration)

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 G M H E Apply engine oil

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

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

Illustrated symbols I to J in the exploded diagrams indicate where to apply a locking agent and where to install new parts.

I Apply locking agent (LOCTITE®) J Use new one

INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL TUNING INDEX INDEX INDEX RENSEIGNEMENTS GENERAUX ALLGEMEINE ANGABEN INFORMACIÓN GENERAL CARACTERISTIQUES TECHNISCHE DATEN ESPECIFICACIONES DESCRIPTION

1 Clutch lever 2 Hot starter lever 3 “ENGINE STOP” button 4 Multi-function display 5 Main switch 6 Start switch 7 Front brake lever 8 Throttle grip 9 Radiator cap 0 Fuel tank cap A Taillight B Kickstarter C Fuel tank D Headlight E Radiator F Coolant drain bolt

H Valve joint I Fuel cock J Cold starter knob K Air cleaner L Catch tank M Drive chain N Shift pedal O Oil dipstick P Front fork

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

2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P

2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P

A B C D E F G H I J K L M N O P 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.

ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the right-side of the engine.

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.

PREPARATION FOR REMOVAL AND DISASSEMBLY

1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. When washing the machine with high pressured water, cover the parts as follows. • Silencer exhaust port • Side cover air intake port • Water pump housing hole at the bottom • Drain hole on the cylinder head (right side) • All electrical components

2. Use proper tools and cleaning equipment.

Refer to “SPECIAL TOOLS” section.

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.

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.

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 Orings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips. EC134000

LOCK WASHERS/PLATES AND COTTER PINS

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.

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 light-weight lithium base grease to the seal lip(s). Oil the bearings liberally when installing. CAUTION: Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.

1. 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

CHECKING OF CONNECTION GEN INFO EC1C0001

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

1. Disconnect: • Connector 2. Dry each terminal with an air blower.

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

4. Pull the lead to check that it will not come off. 5. If the terminal comes off, bend up the pin 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 wire harness. • For a field remedy, use a contact revitalizer available on the market. • Use the tester on the connector as shown.

SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order.

NOTE: • For U.S.A. and Canada, use part number starting with “YM-”, “YU-” or “ACC-”. • For others, use part number starting with “90890-”. Part number YU-3097, 90890-01252 YU-1256

Tool name/How to use

Dial gauge and stand Stand

These tools are used to check each part for runout or bend.

YU-90050, 90890-01274 YU-90050, 90890-01275 YM-91044, 90890-04081 YU-90063, 90890-01278

Crankshaft installing tool

Crankshaft installing pot Crankshaft installing bolt Spacer (crankshaft installer) Adapter (M12) These tools are used to install the crankshaft.

90890-01275 90890-01278 90890-04081

YU-1304, 90890-01304

This tool is used to remove the piston pin.

YU-24460-01, 90890-01325 Radiator cap tester YU-33984, 90890-01352 Adapter

These tools are used for checking the cooling system.

YU-33975, 90890-01403

This tool is used when tighten the steering ring nut to specification.

YM-01494, 90890-01494

Use this tool to remove and install the damper rod.

YM-A0948, 90890-01502

This tool is used when install the fork oil seal.

SPECIAL TOOLS Part number

YS-1880-A, 90890-01701

Tool name/How to use

GEN INFO Illustration

This tool is used for when loosening or tightening the flywheel magneto securing nut.

YU-3112-C, 90890-03112

Use this tool to inspect the coil resistance, output voltage and amperage.

YM-33277-A, 90890-03141

This tool is necessary for checking ignition timing.

YM-4019, 90890-04019

Valve spring compressor

This tool is needed to remove and install the valve assemblies.

YM-91042, 90890-04086

This tool is used to hold the clutch when removing or installing the clutch boss securing nut.

YM-4116, 90890-04116 YM-4097, 90890-04097

Intake 4.5 mm (0.18 in) Exhaust 5.0 mm (0.20 in) This tool is needed to remove and install the valve guide.

YM-4117, 90890-04117

YM-4098, 90890-04098

Valve guide installer

This tool is needed to install the valve guide.

YM-4118, 90890-04118 YM-4099, 90890-04099

This tool is needed to rebore the new valve guide.

YM-04142, 90890-04142

This tool is used to remove the flywheel magneto.

Tool name/How to use

Crankcase separating tool

GEN INFO Illustration

These tool is used to remove the crankshaft from either case.

YM-34487 90890-06754

Dynamic spark tester

This instrument is necessary for checking the ignition system components.

YB-35956-A, 90890-06756

Vacuum/pressure pump gauge set

This tool is used to check the air induction system.

YAMAHA Bond No. 1215

(ThreeBond® No. 1215)

This sealant (Bond) is used for crankcase mating surface, etc.

OUTILS SPECIAUX GEN INFO Illustration

CONTROL FUNCTIONS MAIN SWITCH Functions of the respective switch positions are as follows:

ON: The engine can be started only at this position. OFF: All electrical circuits are switched off. Main switch indicator light The main switch 1 is equipped with an indicator light 2 to avoid forgetting to turn it off. This light functions as follows. • It lights up with the main switch “ON”. • It goes out when the engine increases its speed after being started. • It lights up again when the engine is stopped. NOTE: If the indicator light will not light up with the main switch “ON”, it shows a lack of the battery voltage. Recharge the battery.

“ENGINE STOP” BUTTON The “ENGINE STOP” button 1 is located on the left handlebar. Continue pushing the

“ENGINE STOP” button till the engine comes to a stop.

START SWITCH The start switch 1 is located on the right handlebar. Push this switch to crank the engine with the starter.

CLUTCH LEVER The clutch lever 1 is located on the left handlebar; it disengages or engages the clutch.

Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth starts.

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 Rotate the kickstarter 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 so the engine can be started in any gear if the clutch is disengaged.

In normal practices, however, shift to neutral before starting.

THROTTLE GRIP The throttle grip 1 is located on the right handlebar; it accelerates or decelerates the engine. For acceleration, turn the grip toward you; for deceleration, turn it away from you.

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

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

FUEL COCK The fuel cock supplies fuel from the tank to carburetor and also filters the fuel. The fuel cock has three positions:

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

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

HOT STARTER LEVER The hot starter lever 1 is used when starting a warm engine.

Use the hot starter lever when starting the engine again immediately after it was stopped (the engine is still warm). Pulling the hot starter lever injects secondary air to thin the air-fuel mixture temporarily, allowing the engine to be started more easily. 1 - 12

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

WARNING • Never apply additional force to the sidestand. • Hold up the sidestand before starting out.

VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose.

CAUTION: In this installation, make sure the arrow faces the fuel tank and also downward.

SPARK PLUG WRENCH This spark plug wrench 1 is used to remove and install the spark plug.

NIPPLE WRENCH This nipple wrench 1 is used to tighten the spoke.

JET NEEDLE PULL-UP TOOL The jet needle pull-up tool 1 is used to pull the jet needle out of the carburetor.

MULTI-FUNCTION DISPLAY GEN INFO MULTI-FUNCTION DISPLAY WARNING Be sure to stop the machine before making any setting changes to the multi-function display.

The multi-function display is equipped with the following: BASIC MODE: • Speedometer • Clock • Two tripmeters (which shows the distance that has been traveled since it was last set to zero) RACE MODE: • Timer (which shows the time that has been accumulated since the start of timer measurement) • Tripmeter (which shows the accumulated travel distance in timer measurement) • Change tripmeter digits (capable of change to any given ones)

DESCRIPTION Operation buttons:

1 Select button “SLCT 1” 2 Select button “SLCT 2” 3 Reset button “RST”

4 Tripmeter indicator 5 Tripmeter indicator 6 Timer indicator 7 Clock/Timer 8 Speedometer 9 Odometer/Tripmeter

The operation buttons can be pushed in the following two manners: Short push: Push the button. ( ) Long push: Push the button for 2 seconds or more. ( )

MULTI-FUNCTION DISPLAY GEN INFO BASIC MODE Changing speedometer display (for U.K.)

1. Push the “SLCT2” button for 2 seconds or more to change the speedometer units. The speedometer display will change in the following order: MPH → km/h → MPH.

1. Push the “SLCT1” button for 2 seconds or more to enter the time setting mode. 2. Push the “RST” button to change the display for time indication. The display will change in the following order: Hour → Minute → Second → Hour. NOTE: The digits capable of setting go on flashing.

3. Push the “SLCT1” button (plus) or “SLCT2” button (minus) and change the time. A long push on the button will fast-forward the time.

4. To end the setting, push the “RST” button for 2 seconds or more. NOTE: • In a 30-second absence of button operation, the setting will come to an end with the indicated time. • To reset the seconds, push the “SLCT1” button or “SLCT2” button.

MULTI-FUNCTION DISPLAY GEN INFO Changing odometer and tripmeter A/B

(TRIP A/B) 1. Push the “SLCT2” button to change the tripmeter display. The display will change in the following order: Odometer → TRIP A → TRIP B → TRIP A → Odometer. NOTE: To reset the digits, select the tripmeter involved and push the “RST” button for 2 seconds or more.

CHANGEOVER TO BASIC MODE/RACE MODE NOTE:

• Measurement using the timer function can be made in RACE MODE. • Indicator will light up as an identifier that shows RACE MODE has been selected. • RACE MODE cannot display the functions as in BASIC MODE. • Changeover to RACE MODE forces the digits for tripmeter A (TRIP A) in BASIC MODE to be reset. Changeover from BASIC MODE to RACE MODE 1. Push the “SLCT1” button and “SLCT2” button for 2 seconds or more at the same time to change over to RACE MODE. NOTE: Changeover to RACE MODE will put manual start measurement on standby causing and to flash. (For manual start, refer to “Putting measurement on standby” in “RACE MODE”.)

PASSAGE DU MODE DE BASE AU MODE COURSE MULTI-FUNCTION DISPLAY GEN INFO Returning to BASIC MODE from RACE MODE NOTE:

It is possible to return to BASIC MODE with timer measurement at a stop.

1. Check that the timer is not in operation. If the timer is in operation, stop the timer by pushing the “SLCT1” button and “SLCT2” button at the same time.

2. Push the “SLCT1” button and “SLCT2” button for 2 seconds or more at the same time to change over to BASIC MODE.

RACE MODE Putting measurement on standby

NOTE: Starting measurement consists of the following two starts, either of which can be selected. • Manual start Starting measurement by the rider himself operating the button. (A long push on “SLCT2” button will put measurement on standby.) • Auto start Starting timer measurement automatically on detection of the movement of the machine. (A long push on “SLCT1” button will put measurement on standby.) Manual start NOTE: Initial setting at changeover to RACE MODE will remain for manual start. 1. Check that changeover to RACE MODE has been made. (Refer to “Changeover from BASIC MODE to RACE MODE”.) NOTE: When the machine is made ready for a run by manual start, and will start flashing.

MULTI-FUNCTION DISPLAY GEN INFO

2. Start timer measurement by pushing the

“RST” button. 3. When stopping timer measurement, pushing the “SLCT1” button and “SLCT2” button at the same time. NOTE: If the machine is run while timer measurement is not made, no change will occur to the digit in tripmeter A (TRIP A). 4. To resume the measurement, again push the “SLCT1” button and “SLCT2” button at the same time.

1. Check that changeover has been made to RACE MODE. (Refer to “Changeover from BASIC MODE to RACE MODE”.) 2. Make the machine ready for a run by pushing the “SLCT1” button for 2 seconds or more. NOTE: When measurement is made ready for a run by auto start, and will start flashing. Timer display will turn on scrolling from left to right. 3. Run the machine and start timer measurement. 4. To stop timer measurement, pushing the “SLCT1” button and the “SLCT2” button at the same time. NOTE: If the machine is run while timer measurement is not made, no change will occur to the digit in tripmeter A (TRIP A). 5. To resume the measurement, again pushing the “SLCT1” button and “SLCT2” button at the same time.

MULTI-FUNCTION DISPLAY GEN INFO Resetting measurement data

NOTE: Resetting can be made in the following two manners. Resetting is possible while timer measurement is made: • Reset tripmeter A. Resetting is possible while timer measurement is not made: • Reset tripmeter A and timer. Resetting tripmeter A (TRIP A) 1. Check that the timer is in operation. If the timer is not in operation, start the timer by pushing the “SLCT1” button and “SLCT2” button at the same time. 2. Reset tripmeter A (TRIP A) display by pushing the “RST” button for 2 seconds or more. NOTE: If reset, and travel distance display will go on flashing for four seconds. Resetting tripmeter A (TRIP A) and timer 1. Check that the timer is not in operation. If the timer is in operation, stop it by pushing the “SLCT1” button and “SLCT2” button at the same time. 2. Reset all measured data by pushing the “RST” button for 2 seconds or more. NOTE: • Resetting will reset the timer display and travel distance display and put measurement on standby. • Auto start attempt will put measurement on standby as such. Likewise, manual start attempt will put measurement on standby as such. Correcting tripmeter A (TRIP A) 1. Change the travel distance display by pushing the “SLCT1” button (plus) or “SLCT2” button (minus). A long push on the button will fast-forward the change. NOTE: Change can be made any time while timer measurement is or is not being made.

MULTI-FUNCTION DISPLAY GEN INFO FUNCTION DIAGRAM NOTE:

The following diagram illustrates the multi-function display regarding the direction and operation condition involved in each of its functions.

A short push on the button changes the operation in the arrowed direction.

A short push on the button changes the operation in both arrowed directions. A long push on the button changes the operation in the arrowed direction.

Function that can be performed whether the time is or is not in operation. Extent to which the meter can operate

A long push on the button changes the operation in both arrowed directions.

6 Putting measurement on standby

9 Measurement starts as the machine moves

5 RACE MODE C Timer not in operation

0 Timer in operation

TRIP A FUEL Always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race.

Recommended fuel: Premium unleaded gasoline only with a research octane number of 95 or higher. CAUTION: Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine internal parts such as valves, piston rings, and exhaust system, etc. NOTE: If knocking or pinging occurs, use a different brand of gasoline or higher octane grade. WARNING • For refueling, be sure to stop the engine and use enough care not to spill any fuel. Also be sure to avoid refueling close to a fire. • Refuel after the engine, exhaust pipe, etc. have cooled off.

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

CAUTION: • The carburetor on this machine has a built-in accelerator pump. Therefore, when starting the engine, do not operate the throttle or the spark plug will foul. • Unlike a two-stroke engine, this engine cannot be kick started when the throttle is open because the kickstarter may kick back. Also, if the throttle is open the air/ fuel mixture may be too lean for the engine to start. • Before starting the machine, perform the checks in the pre-operation check list. AIR FILTER MAINTENANCE According to “AIR FILTER CLEANING” section in the CHAPTER 3, apply the foam-air-filter oil or its equivalent to the element. (Excess oil in the element may adversely affect engine starting.) STARTING A COLD ENGINE NOTE: This model is equipped with an ignition circuit cut-off system. The engine can be started under the following conditions. • When the transmission is in neutral. • When the clutch is disengaged with the transmission in any position. However, it is recommended to shift into neutral before starting the engine. 1. 2. 3. 4. 5. 6.

Inspect the coolant level.

Turn the fuel cock to “ON”. Push the main switch to “ON”. Shift the transmission into neutral. Fully open the cold starter knob 1. Start the engine by pushing the start switch or by kicking the kickstarter.

If the engine fails to start by pushing the start switch, release the switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt. If the engine does not start with the starter motor, try using the kickstarter. WARNING • If the starter motor will not turn when pushing the start switch, stop pushing it immediately and kick start the engine in order to avoid the load on the motor. • Do not open the throttle while kicking the kickstarter. Otherwise, the kickstarter may kick back. 7. 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.

STARTING A WARM ENGINE Do not operate the cold starter knob and throttle. Pull the hot starter lever 1 and start the engine by pushing the start switch or by kicking the kickstarter forcefully with a firm stroke.

As soon as the engine starts, release the hot starter lever to close the air passage. Restarting an engine after a fall Pull the hot starter lever and start the engine. As soon as the engine starts, release the hot starter lever to close the air passage. The engine fails to start Pull the hot starter lever all the way out and while holding the lever, kick the kickstarter 10 to 20 times to clear the engine. Then, restart the engine. Refer to “Restarting an engine after a fall”.

Starting a cold engine

Throttle grip oper- starter knob ation* Air temperature = less than Open 3 or ON 4 times 5 °C (41 °F) Air temperature = more None ON than 5 °C (41 °F) Air temperature (normal temperature) = between None ON/OFF 5 °C (41 °F) and 25 °C (77 °F) Air temperature = more None OFF than 25 °C (77 °F) Starting an engine after a long None ON period of time Restarting a warm engine None OFF Restarting an engine after a fall None

OFF Hot starter lever

OFF OFF OFF OFF OFF ON ON

* Operate the throttle grip before kick starting.

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 tank with the fuel. 2. Perform the pre-operation checks on the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the “ENGINE STOP” button. Then, restart the engine and check its operation within no more than 5 minutes after it is restarted. 4. Operate the machine in the lower gears at moderate throttle openings for five to eight minutes. 5. Check how the engine runs when the machine is ridden with the throttle 1/4 to 1/2 open (low to medium speed) for about one hour. 6. Restart the engine and check the operation of the machine throughout its entire operating range. Restart the machine and operate it for about 10 to 15 more minutes. 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.

TORQUE-CHECK POINTS Frame construction

Combined seat and tank

Silencer to rear frame

Engine bracket to engine Engine bracket to frame

Steering shaft to handlebar

Steering shaft to frame

Steering shaft to handle crown Handle crown to handlebar

Steering shaft to front fork

Front fork to handle crown

Front fork to under bracket

Link to frame Link to shock absorber Link to swingarm

Installation of shock absorber

Shock absorber to frame

Installation of swingarm

Tightening of pivot shaft

Installation of wheel

Tightening of front axle

Tightening of axle holder

Tightening of rear axle

Caliper to front fork

Brake disc to wheel Tightening of union bolt Master cylinder to handlebar Tightening of air bleeder Tightening of brake hose holder

Brake pedal to frame

Brake disc to wheel Tightening of union bolt Master cylinder to frame Tightening of air bleeder Tightening of brake hose holder

Fuel tank to fuel cock

Tightening of oil hose clamp

Concerning the tightening torque, refer to “MAINTENANCE SPECIFICATIONS” section in the CHAPTER 2. 1 - 26

CLEANING AND STORAGE GEN INFO EC1B0000

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.

CLEANING AND STORAGE GEN INFO

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.

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

1. Drain the fuel tank, fuel lines, and the carburetor float bowl. 2. Remove the spark plug, pour a tablespoon of SAE 10W-30 motor oil in the spark plug hole, and reinstall the plug. With the engine stop switch pushed in, kick the engine over several times to coat the cylinder walls with oil. 3. Remove the drive chain, clean it thoroughly with solvent, and lubricate it. Reinstall the chain or store it in a plastic bag tied to the frame. 4. Lubricate all control cables. 5. Block the frame up to raise the wheels off the ground. 6. Tie a plastic bag over the exhaust pipe outlet to prevent moisture from entering. 7. If the machine is to be stored in a humid or salt-air environment, coat all exposed metal surfaces with a film of light oil. Do not apply oil to rubber parts or the seat cover. NOTE: Make any necessary repairs before the machine is stored.

GENERAL SPECIFICATIONS Model name:

Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Dry weight: Without oil and fuel Engine: Engine type Cylinder arrangement Displacement Bore × stroke Compression ratio Starting system Lubrication system: Oil type or grade: Engine oil 0

Liquid cooled 4-stroke, DOHC Single cylinder, forward inclined 449 cm3 (15.8 Imp oz, 15.2 US oz) 95.0 × 63.4 mm (3.74 × 2.50 in) 12.3 : 1 Kick and electric starter Dry sump

Yamalube 4, SAE10W30 or SAE20W40 Yamalube 4-R, SAE10W50 API service SG type or higher, JASO standard MA

(Except for USA and CDN)

SAE10W30, SAE10W40, SAE15W40, SAE20W40 or SAE20W50 API service SG type or higher,

JASO standard MA SAE 10W-40

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

GENERAL SPECIFICATIONS Oil capacity:

Engine oil Periodic oil change With oil filter replacement Total amount Coolant capacity (including all routes): Air filter: Fuel: Type Tank capacity Reserve Carburetor: Type Manufacturer Spark plug: Type/manufacturer Gap Clutch type: Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio: 1st 2nd 3rd 4th 5th Chassis: Frame type Caster angle Trail Tire: Type Size (front) Size (rear) Tire pressure (front and rear)

0.95 L (0.84 Imp qt, 1.00 US qt)

1.0 L (0.88 Imp qt, 1.06 US qt) 1.2 L (1.06 Imp qt, 1.27 US qt) 1.0 L (0.88 Imp qt, 1.06 US qt) Wet type element Premium unleaded gasoline only with a research octane number of 95 or higher. 8.0 L (1.76 Imp gal, 2.11 US gal) 1.1 L (0.24 Imp gal, 0.29 US gal) FCR MX39 KEIHIN CR8E/NGK (resistance type) 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) Wet, multiple-disc Gear 61/23 (2.652) Chain drive 50/13 (3.846) Constant mesh, 5-speed Left foot operation 29/12 (2.417) 26/15 (1.733) 21/16 (1.313) 21/20 (1.050) 21/25 (0.840) USA, ZA, CDN EUROPE, AUS, NZ Semi double cradle ← 27.3° 27.0° 117 mm (4.61 in) 116 mm (4.57 in) With tube 80/100-21 51M (USA, CDN, ZA) 90/90-21 54R (EUROPE, AUS, NZ) 110/100-18 64M (USA, CDN, ZA) 130/90-18 69R (EUROPE, AUS, NZ) 100 kPa (1.0 kgf/cm2, 15 psi)

GENERAL SPECIFICATIONS Brake:

Front brake type Operation Rear brake type Operation Suspension: Front suspension Rear suspension Shock absorber: Front shock absorber Rear shock absorber Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system Battery type Battery voltage/capacity Specific gravity Headlight type: Bulb wattage × quantity: Headlight Taillight

SPEC Single disc brake

Right hand operation Single disc brake Right foot operation Telescopic fork Swingarm (link type monocross suspension) Coil spring/oil damper Coil spring/gas, oil damper 300 mm (11.8 in) 305 mm (12.0 in) CDI AC magneto YTZ7S 12 V/6 AH 1.310 Quartz bulb (halogen) 12 V 35/36.5 W × 1 12 V 1.6/0.3 W × 1

MAINTENANCE SPECIFICATIONS SPEC Cylinder head:

Bore size Out of round limit Camshaft: Drive method Camshaft cap inside diameter Camshaft journal diameter Shaft-to-cap clearance

Camshaft runout limit

Cam chain type/No. of links Cam chain adjustment method Valve, valve seat, valve guide: Valve clearance (cold)

“B” face width “C” seat width

“D” margin thickness

Stem outside diameter

Stem-to-guide clearance

IN EX Stem runout limit

Set length (valve closed)

Compressed force (installed)

Direction of winding (top view)

130.2 ~ 149.8 N at 27.87 mm

(13.28 ~ 15.28 kg at 27.87 mm, 29.27 ~ 33.68 lb at 1.10 in) 123.1 ~ 141.7 N at 28.38 mm (12.55~ 14.45 kg at 28.38 mm, 27.67 ~ 31.85 lb at 1.12 in) ----

Piston to cylinder clearance Piston size “D”

D Measuring point “H”

Piston off-set Piston pin bore inside diameter Piston pin outside diameter

Dimensions (B × T) End gap (installed) Side clearance (installed)

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

B T Dimensions (B × T)

End gap (installed) Crankshaft: Crank width “A” Runout limit “C” Big end side clearance “D” Small end free play “F” Balancer: Balancer drive method Air filter oil grade:

Foam-air-filter oil or equivalent oil

Friction plate thickness Quantity Clutch plate 1 thickness Quantity Warp limit

Clutch plate 2 thickness

Clutch spring free length

Clutch housing thrust clearance

Clutch housing radial clearance

Clutch release method Shifter: Shifter type Guide bar bending limit Kickstarter: Type Carburetor: I. D. mark Main jet Main air jet Jet needle Cutaway Pilot jet Pilot air jet Pilot outlet Bypass Valve seat size Starter jet Leak jet Float height Engine idle speed Intake vacuum

Hot starter lever free play

Cam drum and guide bar

MAINTENANCE SPECIFICATIONS Item

Lubrication system: Oil filter type Oil pump type Tip clearance “A” Tip clearance “B” Side clearance “C” Bypass valve setting pressure Cooling: Radiator core size Width Height (Left/Right) Thickness Radiator cap opening pressure Radiator capacity (total) Water pump Type

Single-suction centrifugal pump

Piston cooler nozzle

Transmission gears Piston pin Main axle Oil filter

Check ball Oil pump rotor 1 Oil pump rotor 2

SPEC MAINTENANCE SPECIFICATIONS Part to be tightened

Spark plug Camshaft cap Cylinder head blind plug screw Cylinder head (stud bolt) (bolt) (bolt) Cylinder head cover Cylinder Timing chain tensioner Tensioner cap bolt Timing chain guide (rear) Exhaust pipe (nut) (bolt) Silencer Silencer clamp Exhaust pipe protector Spark arrester Silencer cap Air induction pipe Air cut-off valve assembly and bracket Bracket (air cut-off valve) and frame Carburetor joint Carburetor joint clamp Air filter case Air filter joint clamp Air filter joint and air filter case Throttle cable adjust bolt and locknut Throttle cable (pull) Throttle cable (return) Throttle cable cover Hot starter plunger Hot starter cable adjust bolt and locknut Air filter element Radiator stay Radiator Radiator hose clamp Radiator pipe 1, 2 Impeller Water pump housing cover Coolant drain bolt Oil pump cover Oil pump Oil pump drive gear shaft

M6 × 1.0 M12 × 1.0 M8 × 1.25 M10 × 1.25 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M8 × 1.25 M8 × 1.25 M8 × 1.25 M8 × 1.25 M6 × 1.0 M5 × 0.8 M5 × 0.8 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M4 × 0.7 M6 × 1.0 M6 × 1.0 M5 × 0.8 M6 × 0.75 M6 × 1.0 M12 × 1.0 M5 × 0.8 M12 × 1.0 M6 × 0.75 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M10 × 1.0 M8 × 1.25 M6 × 1.0 M6 × 1.0 M4 × 0.7 M6 × 1.0 M6 × 1.0

10 1 1 4 2 2 1 2 1 2 1 1 2 1 3 4 6 2 2 2 3 1 2 1 1 1 1 1 2 1 1 1 6 4 8 2 1 3 1 1 2 1

MAINTENANCE SPECIFICATIONS Part to be tightened

Engine oil drain bolt (oil filter) Oil filter cover Oil check bolt (cylinder head) Oil hose clamp Clutch cover Crankcase cover (right) Crankcase cover (left) Idle gear cover (starter motor) Crankcase Clutch cable holder Oil drain bolt (crankcase right) (crankcase left) Oil check bolt (crankcase) Oil strainer Crankcase bearing stopper Crankcase bearing stopper Drive axle oil seal stopper Ratchet wheel guide Kickstarter Screw (kickstarter) Starter clutch Primary drive gear Clutch boss Clutch cable adjust bolt and locknut Clutch spring Balancer Balancer driven gear Balancer weight plate Drive sprocket Drive sprocket cover Shift pedal Shift guide Stopper lever Segment

M6 × 1.0 M6 × 1.0 — M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M10 × 1.25 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M8 × 1.25 M6 × 1.0 M6 × 1.0 M20 × 1.0 M20 × 1.0 M8 × 1.0 M6 × 1.0 M10 × 1.0 M14 × 1.0 M6 × 1.0 M20 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M6 × 1.0 M8 × 1.25

2 1 2 7 8 2 8 2 12 1 1 1 1 1 4 8 2 2 1 1 6 1 1 1 6 1 1 3 1 2 1 2 1 1

10 10 2 10 10 12 10 10 12 10 20 20 10 10 14 10 10 12 33 7 16 110 75 4 10 45 50 10 75 8 12 10 10 30

- marked portion shall be checked for torque tightening after break-in or before each race. NOTE: *1: Tighten the cylinder head bolts to 30 Nm (3.0 m • kg, 22 ft • lb) in the proper tightening sequence, remove and retighten the cylinder head bolts to 20 Nm (2.0 m • kg, 14 ft • lb) in the proper tightening sequence, and then tighten the cylinder head bolts further to reach the specified angle 180° in the proper tightening sequence.

MAINTENANCE SPECIFICATIONS SPEC EC212201

Steering system: Steering bearing type Front suspension: Front fork travel Fork spring free length

Spring rate, STD Optional spring/spacer

<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

---AUS, NZ, ZA ← ← ← ← ← ← ←

← EUROPE AUS, NZ, ZA ← ← ← ← 251.5 mm (9.90 in) 252.5 mm (9.94 in) ← ← ←

MAINTENANCE SPECIFICATIONS Item

Wheel: Front wheel type Rear wheel type Front rim size/material Rear rim size/material Rim runout limit: Radial Lateral

Spoke wheel 21 × 1.60/Aluminum 18 × 2.15/Aluminum

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

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

Disc outside dia. × Thickness

Master cylinder inside dia. Caliper cylinder inside dia. Brake fluid type Rear disc brake: Disc outside dia. × Thickness

Master cylinder inside dia.

Caliper cylinder inside dia. Brake fluid type Brake lever and brake pedal: Brake lever position Brake pedal height (vertical height above footrest top) Clutch lever free play (lever end) Throttle grip free play

MAINTENANCE SPECIFICATIONS Part to be tightened

Handle crown and outer tube

Under bracket and outer tube Handle crown and steering shaft Handlebar holder (upper) Handlebar holder (lower) Steering ring nut Front fork and cap bolt Front fork and base valve Cap bolt and damper rod (front fork) Bleed screw (front fork) and cap bolt Front fork and protector Front fork protector and brake hose holder Throttle cable cap Clutch lever holder mounting Clutch lever mounting Hot starter lever holder mounting Hot starter lever mounting Front brake master cylinder and bracket Front brake master cylinder cap Brake lever mounting (bolt) Brake lever mounting (nut) Brake lever position locknut Hose guide (front brake hose) and hose guide bracket Hose guide (front brake hose) and under bracket Front brake hose union bolt (master cylinder) Front brake hose union bolt (caliper) Front brake caliper and front fork Front brake caliper and brake hose holder Brake caliper (front and rear) and pad pin plug Brake caliper (front and rear) and pad pin Brake caliper (front and rear) and bleed screw Front wheel axle and nut Front wheel axle holder Front brake disc and wheel hub Rear brake disc and wheel hub Brake pedal mounting Rear brake master cylinder and frame Rear brake master cylinder cap Rear brake hose union bolt (caliper) Rear brake hose union bolt (master cylinder)

M8 × 1.25 M24 × 1.0 M8 × 1.25 M12 × 1.25 M28 × 1.0 M51 × 1.5 M30 × 1.0 M12 × 1.25 M5 × 0.8 M6 × 1.0 M6 × 1.0 M5 × 0.8 M5 × 0.8 M6 × 1.0 M5 × 0.8 M5 × 0.8 M6 × 1.0 M4 × 0.7 M6 × 1.0 M6 × 1.0 M6 × 1.0 M5 × 0.8 M6 × 1.0 M10 × 1.25 M10 × 1.25 M8 × 1.25 M6 × 1.0 M10 × 1.0 M10 × 1.0 M8 × 1.25 M16 × 1.5 M8 × 1.25 M6 × 1.0 M6 × 1.0 M8 × 1.25 M6 × 1.0 M4 × 0.7 M10 × 1.25 M10 × 1.25

4 1 4 2 1 2 2 2 2 6 2 2 2 1 2 1 2 2 1 1 1 1 1 1 1 2 1 2 2 2 1 4 6 6 1 2 2 1 1

SPEC Tightening torque

Nm 21 21 145 28 34 30 55 29 1 7 7 4 4 4 4 2 9 2 6 6 5 4 4 30 30 23 10 3 18 6 90 21 12 14 26 10 2 30 30

1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut wrench, then loosen the ring nut one turn. 2. Retighten the ring nut 7 Nm (0.7 m • kg, 5.1 ft • lb). 2 - 15

MAINTENANCE SPECIFICATIONS Part to be tightened

Rear wheel axle and nut Driven sprocket and wheel hub Nipple (spoke) Disc cover and rear brake caliper Protector and rear brake caliper Chain puller adjust bolt and locknut Engine mounting: Engine upper bracket and frame Engine lower bracket and frame Engine and engine bracket (lower) Engine and engine bracket (upper) Engine and frame (lower) Engine guard Regulator mounting 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 and frame (upper) Rear frame and frame (lower) Swingarm and brake hose holder Swingarm and patch Drive chain tensioner mounting (upper) Drive chain tensioner mounting (lower) Chain support and swingarm Seal guard and swingarm Fuel tank mounting Fuel tank and fuel cock Fuel tank and seat set bracket Fuel tank and fuel tank bracket Seat mounting Side cover mounting Air scoop and fuel tank Air scoop and radiator panel (lower) Front fender mounting Rear fender mounting (front) Rear fender mounting (rear) Multi-function display bracket mounting Multi-function display mounting Plate 1 and protector Plate 2 and protector

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

SPEC Tightening torque

4 1 1 1 3 2 1 1 1 1 1 1 1 2 4 4 1 1 3 4 2 2 1 4 2 2 6 2 4 2 2 2 2 2 2

34 53 55 53 7 7 85 70 80 80 56 53 38 32 2 2 16 16 7 6 9 4 7 7 23 7 7 6 7 7 11 7 4 4 0.5

MAINTENANCE SPECIFICATIONS Part to be tightened

Speed sensor lead holder and under bracket Headlight body and headlight unit Headlight mounting (left and right) Taillight mounting Taillight lead clamp and rear fender Catch tank (upper) Catch tank (lower) Footrest bracket and frame Sidestand mounting

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

SPEC Tightening torque

1 7 1 0.5 16 7 55 25

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

MAINTENANCE SPECIFICATIONS SPEC EC212300

Ignition system: Advancer type C.D.I.: Pickup coil resistance (color) CDI unit-model/manufacturer

Model/manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance Charging system: System type Model (stator)/manufacturer Normal output Charging coil resistance (color) Lighting coil resistance (color) Rectifier/regulator: Regulator type Model/manufacture Regulated voltage (AC) Regulated voltage (DC) Rectifier capacity (AC) Rectifier capacity (DC) Electric starting system: Type Starter motor: Model/manufacturer Operation voltage Output Armature coil resistance Brush overall length Brash quantity Spring force

5TJ 40/YAMAHA 14 V/120 W at 5,000 r/min 0.288 ~ 0.432 Ω at 20 °C (68 °F) (White – Ground) 0.224 ~ 0.336 Ω at 20 °C (68 °F) (Yellow – Ground)

Semiconductor short circuit

SH770AA/SHINDENGEN 12.5 ~ 13.5 V 14.0 ~ 15.0 V 12 A 8A

Mica undercut (depth)

MAINTENANCE SPECIFICATIONS Item

Starter relay: Model/manufacturer Amperage rating Coil winding resistance Starting circuit cut-off relay: Model/manufacturer Coil winding resistance Fuse (amperage × quantity): Main fuse Reserve fuse

Part to be tightened

Stator Holder (AC magneto lead) Rotor Neutral switch Starter motor Starter relay terminal Pick-up coil

180 A 4.2 ~ 4.6 Ω at 20 °C (68 °F)

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

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

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

A: Distance between flats

B: Outside thread diameter

WR450FW (USA, CDN, AUS, NZ)

WR450F (EUROPE, ZA) 5TJE (USA) 5TJF (EUROPE) 5TJG (CDN, AUS, NZ, ZA) USA, ZA, CDN EUROPE, AUS, NZ 2.175 mm (85,63 in) 2.190 mm (86,22 in) 825 mm (32,48 in) ← 1.295 mm (50,98 in) 1.300 mm (51,18 in) 980 mm (38,58 in) 990 mm (38,98 in) 1.485 mm (58,46 in) ← 360 mm (14,37 in) 370 mm (14,57 in)

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

Dimensions de la came

M6 × 1,0 M12 × 1,0 M8 × 1,25 M10 × 1,25 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M8 × 1,25 M8 × 1,25 M8 × 1,25 M8 × 1,25 M6 × 1,0 M5 × 0,8 M5 × 0,8 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M4 × 0,7 M6 × 1,0 M6 × 1,0 M5 × 0,8 M6 × 0,75 M6 × 1,0 M12 × 1,0 M5 × 0,8 M12 × 1,0

10 1 1 4 2 2 1 2 1 2 1 1 2 1 3 4 6 2 2 2 3 1 2 1 1 1 1 1 2 1

M6 × 1,0 M6 × 1,0 M6 × 1,0 M10 × 1,0 M8 × 1,25 M6 × 1,0 M6 × 1,0 M4 × 0,7 M6 × 1,0

7 10 2 10 14 10 10 2 10

M6 × 1,0 M6 × 1,0 M6 × 1,0 — M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M10 × 1,25 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M8 × 1,25 M6 × 1,0 M6 × 1,0 M20 × 1,0 M20 × 1,0 M8 × 1,0 M6 × 1,0 M10 × 1,0 M14 × 1,0 M6 × 1,0 M20 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M8 × 1,25

---AUS, NZ, ZA ← ← ← ← ← ← ←

← ← 251,5 mm (9,90 in) ←

← ← 252,5 mm (9,94 in) ←

M8 × 1,25 M24 × 1,0 M8 × 1,25 M12 × 1,25 M28 × 1,0 M51 × 1,5 M30 × 1,0

M6 × 1,0 M6 × 1,0 M5 × 0,8 M5 × 0,8 M6 × 1,0 M5 × 0,8 M5 × 0,8 M6 × 1,0 M4 × 0,7 M6 × 1,0 M6 × 1,0 M6 × 1,0

6 2 2 2 1 2 1 2 2 1 1 1

7 7 4 4 4 4 2 9 2 6 6 5

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

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

6 90 21 12 14 26 10 2 30

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

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

4 1 1 1 3 2 1 1 1 1 1 1 1 2 4 4

34 53 55 53 7 7 85 70 80 80 56 53 38 32 2 2

M5 × 0,8 M6 × 1,0 M6 × 1,0 M6 × 1,0

M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M5 × 0,8 M5 × 0,8 —

7 7 6 7 7 11 7 4 4 0,5

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

M5 × 0,8 M6 × 1,0 M6 × 1,0 M6 × 1,0

Volume ou contenance

Volume ou contenance

WR450FW (USA, CDN, AUS, NZ)

WR450F (EUROPE, ZA) 5TJE (USA) 5TJF (EUROPE) 5TJG (CDN, AUS, NZ, ZA) USA, ZA, CDN EUROPE, AUS, NZ 2.175 mm (85,63 in) 2.190 mm (86,22 in) 825 mm (32,48 in) ← 1.295 mm (50,98 in) 1.300 mm (51,18 in) 980 mm (38,58 in) 990 mm (38,98 in) 1.485 mm (58,46 in) ← 365 mm (14,37 in) 370 mm (14,57 in)

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

M6 × 1,0 M6 × 1,0 M6 × 1,0 — M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M10 × 1,25 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M8 × 1,25 M6 × 1,0 M6 × 1,0 M20 × 1,0 M20 × 1,0

1 2 1 2 7 8 2 8 2 12 1 1 1 1 1 4 8 2 2 1 1 6 1 1

10 10 10 2 10 10 12 10 10 12 10 20 20 10 10 14 10 10 12 33 7 16 110 75

M10 × 1,0 M14 × 1,0 M6 × 1,0 M20 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M8 × 1,25

45 50 10 75 8 12 10 10 30

← ← EUROPE AUS, NZ, ZA ← ← ← ← 251,5 mm (9,90 in) 252,5 mm (9,94 in) ← ← ←

M6 × 1,0 M5 × 0,8 M5 × 0,8 M6 × 1,0 M5 × 0,8 M5 × 0,8 M6 × 1,0 M4 × 0,7 M6 × 1,0 M6 × 1,0

M10 × 1,25 M8 × 1,25

M8 × 1,25 M6 × 1,0 M6 × 1,0 M8 × 1,25 M6 × 1,0 M4 × 0,7 M10 × 1,25 M10 × 1,25

21 12 14 26 10 2 30 30

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

4 1 1 1 3 2 1 1 1 1 1 1 1 2 4 4 1 1 3 4 2 2 1 4 2 2 6 2 4 2 2

34 53 55 53 7 7 85 70 80 80 56 53 38 32 2 2 16 16 7 6 9 4 7 7 23 7 7 6 7 7 11

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

WR450FW (USA, CDN, AUS, NZ)

WR450F (EUROPE, ZA) 5TJE (USA) 5TJF (EUROPE) 5TJG (CDN, AUS, NZ, ZA) USA, ZA, CDN EUROPE, AUS, NZ 2.175 mm (85,63 in) 2.190 mm (86,22 in) 825 mm (32,48 in) ← 1.295 mm (50,98 in) 1.300 mm (51,18 in) 980 mm (38,58 in) 990 mm (38,98 in) 1.485 mm (58,46 in) ← 365 mm (14,37 in) 370 mm (14,57 in)

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

M6 × 1,0 M12 × 1,0 M8 × 1,25 M10 × 1,25 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M8 × 1,25 M8 × 1,25 M8 × 1,25 M8 × 1,25 M6 × 1,0 M5 × 0,8 M5 × 0,8 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M4 × 0,7 M6 × 1,0 M6 × 1,0 M5 × 0,8

10 1 1 4 2 2 1 2 1 2 1 1 2 1 3 4 6 1 2 2 3 1 2 1 1

M12 × 1,0 M5 × 0,8 M12 × 1,0

M6 × 1,0 M6 × 1,0 M6 × 1,0 M10 × 1,0 M8 × 1,25 M6 × 1,0 M6 × 1,0 M4 × 0,7 M6 × 1,0

7 10 2 10 14 10 10 2 10

M6 × 1,0 M6 × 1,0 M6 × 1,0 — M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M10 × 1,25 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M8 × 1,25 M6 × 1,0 M6 × 1,0 M20 × 1,0 M20 × 1,0 M8 × 1,0 M6 × 1,0 M6 × 1,0 M14 × 1,0 M6 × 1,0 M20 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M6 × 1,0 M8 × 1,25

---AUS, NZ, ZA ← ← ← ← ← ← ←

EUROPE AUS, NZ, ZA M8 × 1,25

M8 × 1,25 M24 × 1,0 M8 × 1,25 M12 × 1,25 M28 × 1,0 M51 × 1,5 M30 × 1,0

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

2 1 2 1 2 2 1 1 1 1 1 1 1 2 1

4 4 4 2 9 2 6 6 5 4 4 30 30 23 10

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

6 90 21 12 14 26 10 2 30 30

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

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

LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS

1 Oil filter element 2 Oil pump 3 Drive axle 4 Main axle 5 Crankshaft 6 Connecting rod È From cylinder É To oil tank

SPEC LUBRICATION DIAGRAMS

1 Intake camshaft 2 Exhaust camshaft È To main axle É From oil pump

SPEC CABLE ROUTING DIAGRAM

1 Fuel tank breather hose 2 Clamp 3 Diode 4 Hot starter cable 5 Throttle position sensor lead 6 Wire harness 7 Hump (frame) 8 Negative battery lead 9 Starter motor lead 0 Neutral switch lead A AC magneto lead B Brake hose C Rectifier/regulator lead

D Carburetor breather hose

E Carburetor overflow hose F Catch tank breather hose

Ì Fasten the throttle position sensor lead onto the frame. Locate the clamp end facing toward the lower side of the frame and cut off the tie end.

Í Pass the carburetor breather hoses, carburetor overflow hose and catch tank breather hose between the connecting rod and cross tube (frame). Î Pass the neutral switch lead on the inside of the engine bracket. Ï Fasten the neutral switch lead and AC magneto lead onto the frame. Locate the clamp end facing toward the outside of the frame and tie end facing toward the rear of the frame.

È Insert the end of the fuel tank breather hose into the hole in the steering stem.

É Fasten the throttle cable, hot starter cable and rectifier/regulator lead onto the frame. Locate the clamp end facing the lower side of the hot starter cable and cut off the tie end. Ê Fasten the diode (at the marking), throttle cable and hot starter cable onto the frame. Locate the clamp end facing toward the lower right of the frame and with the tie end facing downward. Ë Fasten the wire harness, throttle position sensor lead and clutch cable onto the frame. Pass the clamp through the hole in the stay (air cut-off valve). Locate the clamp end facing toward the lower side of the frame and cut off the tie end.

CABLE ROUTING DIAGRAM

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

CABLE ROUTING DIAGRAM

1 Throttle cable (pull) 2 Throttle cable (return) 3 Catch tank hose 4 Ignition coil 5 Clamp 6 Air induction hose (air cut-off valve - rear of cylinder head) 7 Catch tank breather hose

È Cross the pull and push throttle cables.

É Fasten the catch tank hose and air induction hose (air cut-off valve - rear of cylinder head) onto the frame. Locate the clamp end facing toward the lower side of the frame and cut off the tie end. Ê Fasten the catch tank breather hose and carburetor breather hoses together. Ë Pass the carburetor breather hose (of the throttle cable cover) through the hose holder.

CABLE ROUTING DIAGRAM

1 Brake master cylinder 2 Brake hose holder 3 Brake hose

È Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the brake caliper.

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

CABLE ROUTING DIAGRAM

1 Clamp 2 Positive battery lead 3 Battery 4 Negative battery lead 5 Taillight coupler 6 CDI unit coupler (6-pin) 7 CDI unit coupler (3-pin) 8 CDI unit coupler (6-pin)

È Fasten the wire harness to the upper engine bracket (left side). Locate the clamp end facing toward the upper side of the frame with the tie end cut off on the inside of the frame.

É Fasten the wire harness to the upper engine bracket (left side). Locate the clamp end facing toward the upper side of the frame with the tie end cut off on the inside of the frame. Clamp the wire harness at the marking. Ê Pass the starter motor lead through the hole in the relay holder. Ë Fit the cover securely. Ì Connect the wire harness to the starter relay.

CABLE ROUTING DIAGRAM

Í Fasten the catch tank breather hose and catch tank hose to the rear frame. Clamp them close to where they are joined to the frame. Fasten the pipe tightly enough not to crush it. Locate the clamp end facing toward the rear of the frame with the tie end facing downward. Î Fasten the (three) CDI unit leads and taillight lead to the rear frame. Locate the clamp end facing toward the upper side of the frame and cut off the tie end. Ï Connect the negative battery lead to the battery negative terminal. Ð Connect the negative battery lead to the wire harness.

Ñ Fasten the wire harness to the rear frame. Locate the clamp end facing toward the upper side of the frame and the tie end toward the inside of the frame. Clamp the wire harness at the marking.

Ò Pass the wire harness, starter relay lead, starting circuit cut-off relay lead and negative battery lead through the hole in the relay holder. Ó Fasten the (three) CDI unit leads and taillight lead to the rear frame. Locate the clamp end facing toward the lower side of the frame and cut off the tie end.

Ô Fasten the taillight lead to the rear frame. Locate the clamp end facing toward the upper side of the frame and cut off the tie end.

Õ Do not allow the taillight lead to slacken. Ö Locate the CDI unit lead between the CDI unit and rear fender. × Locate the CDI unit coupler in the clearance between the upper side of the CDI unit and lower side of the catch tank stay. Ø Locate the CDI unit lead between the CDI unit and rear frame.

CABLE ROUTING DIAGRAM

1 Throttle cable 2 Clamp 3 Brake hose 4 Clutch cable 5 Hose guide 6 Main switch coupler 7 Wire harness 8 Headlight coupler 9 Hot starter cable 0 Multi-function display bracket A Main switch B Upper bracket C Clutch switch coupler D Engine stop switch coupler E Multi-function display coupler F Start switch coupler G Speed sensor coupler H Speed sensor lead

A B C D E F G H SPEC

Ð Fasten the main switch lead (wire harness side) to the multi-function display bracket. Locate the clamp end facing toward the lower side of the frame and cut off the tie end.

Ñ Pass the speed sensor lead through the guide on the outside of the front fork.

È Fasten the start switch lead to the handlebar with the plastic bands.

É Fasten the engine stop switch lead and clutch switch lead to the handlebar with the plastic bands. Ê Pass the brake hose through the hose guides. Ë Secure the coupler by inserting it into the multifunction display bracket. Ì Pass the throttle cables, clutch cable and hot starter cable between the upper bracket and multi-function display bracket. Í Fasten the multi-function display leads to the bracket. Cut off the tie end. Î Secure the coupler by pushing it into the hole in the multi-function display bracket. Ï Secure the wire harness clip by pushing it into the hole in the multi-function display bracket on the inside.

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

After Every break-in race

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

Every fifth third (or (or 500 km) 1,000 km)

The engine must be cold.

Check the valve seats and valve stems for wear. Check the free length and the tilt. Check for scratches and wear. Inspect the camshaft surface. Inspect the decompression system

CAMSHAFT SPROCKETS Inspect

Replace PISTON Inspect Clean Replace PISTON RING Inspect Replace PISTON PIN Inspect Replace CYLINDER HEAD Inspect and clean

Check for wear on the teeth and for damage.

Inspect crack Inspect carbon deposits and eliminate them. Check ring end gap

Inspect carbon deposits and eliminate them.

CYLINDER Inspect and clean

Replace CLUTCH Inspect and adjust Replace TRANSMISSION Inspect Replace bearing SHIFT FORK, SHIFT CAM, GUIDE BAR Inspect

Inspect wear Inspect housing, friction plate, clutch plate and spring

After Every break-in race

MUFFLER Inspect and retighten Clean Replace *SPARK ARRESTER Clean CRANK Inspect and clean CARBURETOR Inspect, adjust and clean AIR INDUCTION SYSTEM Inspect and clean SPARK PLUG Inspect and clean Replace DRIVE CHAIN Lubricate, slack, alignment Replace COOLING SYSTEM Check coolant level and leakage Check radiator cap operation Replace coolant Inspect hoses OUTSIDE NUTS AND BOLTS Retighten

Every fifth third (or (or 500 km) 1,000 km)

* Whichever comes first

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

AIR FILTER Clean and lubricate

Replace OIL FILTER Replace OIL STRAINER (frame) Clean FRAME Clean and inspect FUEL TANK, COCK Clean and inspect BRAKES Adjust lever position and pedal height Lubricate pivot point Check brake disc surface Check fluid level and leakage Retighten brake disc bolts, caliper bolts, master cylinder bolts and union bolts Replace pads Replace brake fluid

Use foam air-filter oil or equivalent oil

After Every break-in race

FRONT FORKS Inspect and adjust

Replace oil Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube PROTECTOR GUIDE Replace REAR SHOCK ABSORBER Inspect and adjust Lube Retighten DRIVE CHAIN GUARD AND ROLLERS Inspect SWINGARM Inspect, lube and retighten RELAY ARM, CONNECTING ROD Inspect, lube and retighten SIDESTAND Lubricate STEERING HEAD Inspect free play and retighten Clean and lube Replace bearing TIRE, WHEELS Inspect air pressure, wheel run-out, tire wear and spoke looseness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate THROTTLE, CONTROL CABLE Check routing and connection Lubricate HOT STARTER, CLUTCH LEVER Inspect free play BATTERY Check terminal for looseness and corrosion

Every fifth third (or (or 500 km) 1,000 km)

Molybdenum disulfide grease

Molybdenum disulfide grease

Molybdenum disulfide grease Lithium base grease

Yamaha cable lube or SAE 10W-30 motor oil

PROGRAMME D’ENTRETIEN INSP ADJ PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition.

Before using this machine, check the following points. GENERAL INSPECTION AND MAINTENANCE Item Coolant Fuel Engine oil Gear shifter and clutch Throttle grip/Housing Brakes Chain Wheels Steering Front forks and rear shock absorber Cables (wires) Muffler Sprocket Lubrication Bolts and nuts Lead connectors

Check that coolant is filled up to the radiator filler cap. 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 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 chain slack and alignment. Check that the 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 muffler is tightly mounted and has no cracks. Check that the driven 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 AC 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?

ENGINE/COOLANT LEVEL INSPECTION/

COOLANT REPLACEMENT INSP ADJ EC350000

ENGINE 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. 2. Remove: • Radiator cap 3. Check: • Coolant level a Coolant level low → Add coolant. 1 Radiator

COOLANT REPLACEMENT WARNING Do not remove the radiator cap when the engine is hot.

Take care so that coolant does not splash on painted surfaces. If it splashes, wash it away with water. 1. Place a container under the engine. 2. Remove: • Seat • Left side cover 3. Remove the catch tank hose from the catch tank and drain the tank of its coolant.

• Coolant drain bolt 1 5. Remove: • Radiator cap Drain the coolant completely. 6. Clean: • Cooling system Thoroughly flush the cooling system with clean tap water. 7. Install: • Copper washer New • Coolant drain bolt T.

• 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: 1.0 L (0.88 Imp qt, 1.06 US qt) CAUTION: • Do not mix more than one type of ethylene glycol antifreeze containing corrosion inhibitors for aluminum engine. • Do not use water containing impurities or oil. Handling notes of coolant: The coolant is harmful so it should be handled with special care. WARNING • When coolant splashes to your eye. Thoroughly wash your eye with water and see your doctor. • When coolant splashes to your clothes. Quickly wash it away with water and then with soap. • When coolant is swallowed. Quickly make him vomit and take him to a doctor.

• Radiator cap Start the engine and warm it up for a several minutes. 10. Check: • Coolant level Coolant level low → Add coolant.

RADIATOR CAP INSPECTION

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

RADIATOR CAP OPENING PRESSURE INSPECTION

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

2. Apply the specified pressure.

Radiator cap opening pressure: 110 kPa (1.1 kg/cm2, 15.6 psi) 3. Inspect: • Pressure Impossible to maintain the specified pressure for 10 seconds → Replace.

COOLING SYSTEM INSPECTION/

CLUTCH ADJUSTMENT INSP ADJ EC357002

COOLING SYSTEM INSPECTION

1. Inspect: • Coolant level 2. Attach: • Radiator cap tester 1 and adapter 2 Radiator cap tester: YU-24460-01/90890-01325 Adapter: YU-33984/90890-01352 3. Apply the specified pressure. Standard pressure: 180 kPa (1.8 kg/cm2, 25.6 psi) NOTE: • Do not apply pressure more than specified pressure. • Radiator should be filled fully. 4. Inspect: • Pressure Impossible to maintain the specified pressure for 10 seconds → Repair. • Radiator • Radiator hose joint Coolant leakage → Repair or replace. • Radiator hose Swelling → Replace.

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

THROTTLE CABLE ADJUSTMENT INSP ADJ

• Clutch lever free play Clutch lever free play adjustment steps: • Loosen the locknut 1. • Turn the adjuster 2 until free play a is within the specified limits. • Tighten the locknut.

• Make minute adjustment on the lever side using the adjuster 3. • After adjustment, check proper operation of clutch lever.

THROTTLE CABLE ADJUSTMENT

1. Check: • Throttle grip free play a Out of specification → Adjust. Throttle grip free play a: 3 ~ 5 mm (0.12 ~ 0.20 in) 2. Adjust: • Throttle grip free play

Throttle grip free play adjustment steps:

• Slide the adjuster cover. • Loosen the locknut 1. • Turn the adjuster 2 until the specified free play is obtained. • Tighten the locknut.

Before adjusting the throttle cable free play, the engine idle speed should be adjusted. WARNING After adjusting the throttle cable free play, start the engine and turn the handlebar to right and left and make sure that the engine idling does not run faster. 3 - 10

THROTTLE LUBRICATION/

HOT STARTER LEVER ADJUSTMENT INSP ADJ THROTTLE LUBRICATION

1. Remove: • Cover (throttle cable cap) 1 • Cover (grip cap) 2 • Throttle cable cap 3

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

• Cover (throttle cable cap) HOT STARTER LEVER ADJUSTMENT 1. Check: • Hot starter lever free play a Out of specification → Adjust. Hot starter lever free play a: 3 ~ 6 mm (0.12 ~ 0.24 in) 2. Adjust: • Hot starter lever free play Hot starter lever free play adjustment steps: • Loosen the locknut 1. • Turn the adjuster 2 until free play a is within the specified limits. • Tighten the locknut.

After adjustment, check proper operation of hot starter.

AIR FILTER CLEANING INSP ADJ AIR FILTER CLEANING NOTE:

Proper air filter maintenance is the biggest key to preventing premature engine wear and damage. CAUTION: Never run the engine without the air filter element in place; this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage. 1. Open the air filter case cover 1 NOTE: Loosen the quick screw 2 and pull on it to open the air filter case cover.

• Air filter element Clean them with solvent. NOTE: After cleaning, remove the remaining solvent by squeezing the element.

AIR FILTER CLEANING INSP ADJ CAUTION:

• Do not twist the element when squeezing the element. • Leaving too much of solvent in the element may result in poor starting. 5. Inspect: • Air filter element Damage → Replace. 6. Apply: • Foam-air-filter oil or equivalent oil to the element. NOTE: • Squeeze out the excess oil. Element should be wet but not dripping. • Wipe off the oil left on the element surface using a clean dry cloth. (Excess oil in the element may adversely affect engine starting.) 7. Install: • Filter guide 1 NOTE: • Align the projection a on filter guide with the hole b in air filter element. • Apply the lithium soap base grease on the matching surface c on air filter element.

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

• Binder 1 NOTE: Hook the binder 1 so that it contacts the filter guide projections a.

ENGINE OIL LEVEL INSPECTION

1. Stand the machine on a level surface. NOTE: • When checking the oil level make sure that the machine is upright. • Place the machine on a suitable stand. WARNING Never remove the oil tank cap just after high speed operation. The heated oil could spurt out. causing danger. Wait until the oil cools down to approximately 70 °C (158 °F). 2. Idle the engine more than 3 minutes while keeping the machine upright. Then stop the engine and inspect the oil level.

• Oil level Check that the engine oil is above the level mark a and that the oil does not come out when the check bolt 1 is removed. Below the level mark a → Add oil through the filler cap hole until it is above the level mark a. Oil comes out at the check bolt → Drain the oil until it stops coming out. NOTE: When inspecting the oil level, do not screw the oil level gauge into the oil tank. Insert the gauge lightly.

110 130 ˚F Recommended oil:

Yamalube 4, SAE10W30 or SAE20W40 Yamalube 4-R, SAE10W50 API service SG type or higher,

JASO standard MA CAUTION:

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

SAE10W30, SAE10W40, SAE15W40, SAE20W40 or SAE20W50 API service SG type or higher, JASO standard MA

• 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.

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

5. Start the engine and let it warm up for several minutes.

CAUTION: When the oil tank is empty, never start the engine.

ENGINE OIL REPLACEMENT INSP ADJ

6. Idle the engine more than 10 seconds while keeping the machine upright. Then stop the engine and add the oil to the maximum level.

7. Install: • Oil tank plug

ENGINE OIL REPLACEMENT

1. Start the engine and let it warm up for several minutes. 2. Stop the engine and place an oil pan under the drain bolt. 3. Remove: • Engine guard 1 • Oil tank plug 2 • Oil filler cap 3 • Drain bolt (with gasket) 4 • Oil filter drain bolt (O-ring) 5 • Drain bolt (with gasket) 6 Drain the crankcase and oil tank of its oil.

ENGINE OIL REPLACEMENT INSP ADJ

4. 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 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 cover.

10 Nm (1.0 m • kg, 7.2 ft • lb)

• Gaskets New • Oil filter drain bolt T.

• Drain bolt (crankcase right)

• Drain bolt (crankcase left)

• Crankcase Oil quantity: Periodic oil change: 0.95 L (0.84 Imp qt, 1.00 US qt) With oil filter replacement: 1.0 L (0.88 Imp qt, 1.06 US qt) Total amount: 1.2 L (1.06 Imp qt, 1.27 US qt) 7. Install: • Oil filler cap 1 8. Inspect: • Engine (for oil leaks) • Oil level Refer to “ENGINE OIL LEVEL INSPECTION”.

IDLE SPEED ADJUSTMENT INSP ADJ

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

IDLE SPEED ADJUSTMENT

1. Start the engine and thoroughly warm it up. 2. Adjust: • Idle speed Adjustment steps: • Turn the throttle stop screw 1 until the specified engine idling speed. NOTE: Using a digital engine tachometer for idle speed adjustment, detect the engine idling speed by bringing the sensing element c of the engine tachometer close to the ignition coil 2.

To increase idle speed →

Turn the throttle stop screw 1 in a. To decrease idle speed → Turn the throttle stop screw 1 out b.

Engine idling speed:

VALVE CLEARANCE ADJUSTMENT INSP ADJ VALVE CLEARANCE ADJUSTMENT NOTE:

• The valve clearance should be adjusted when the engine is cool to the touch. • The piston must be at Top Dead Center (T.D.C.) on compression stroke to check or adjust the valve clearance. 1. Remove: • Seat • Fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 4. 2. Remove: • Air cut-off valve assembly Refer to “AIR INDUCTION SYSTEM” section in the CHAPTER 4. • Spark plug • Engine stay (upper) • Cylinder head cover Refer to “CAMSHAFTS” section in the CHAPTER 4. 3. Remove: • Timing plug 1 • Straight plug 2 • O-ring

• Valve clearance Out of specification → Adjust. Valve clearance (cold): Intake valve: 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) Exhaust valve: 0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in) Checking steps: • Turn the crankshaft counterclockwise with a wrench. • Align the T.D.C. mark a on the rotor with the align mark b on the crankcase cover when piston is at T.D.C. on compression stroke.

VALVE CLEARANCE ADJUSTMENT INSP ADJ 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.

• Loosen the timing chain tensioner cap bolt. • Remove the timing chain tensioner and camshaft caps.

Remove the camshaft cap bolts in a crisscross pattern from the outside working inwards. • Remove the camshaft (exhaust 1 and intake 2). NOTE: Attach a wire 3 to the timing chain to prevent it from falling into the crankcase.

VALVE CLEARANCE ADJUSTMENT INSP ADJ

• Remove the valve lifters 4 and the pads

5. 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

Pads are available in ~ 0.05 mm increments 2.40 mm

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 number

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

VALVE CLEARANCE 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 6 and the valve lifters 7. NOTE: • Apply the engine oil on the valve lifters. • Apply the molybdenum disulfide oil on the valve stem ends. • Valve lifter must turn smoothly when rotated with a finger. • Be careful to reinstall valve lifters and pads in their original place. • Install the camshafts (exhaust and intake), the timing chain and the camshaft caps. Refer to “CAMSHAFTS” section in the CHAPTER 4.

• Install the timing chain tensioner.

Refer to “CAMSHAFTS” section in the CHAPTER 4. NOTE: Turn the crankshaft counterclockwise several turns so that the installed parts settle into the right position. • Recheck the valve clearance. • If the clearance is still incorrect, repeat all the clearance adjustment steps until the specified clearance is obtained. 6. Install: • All removed parts NOTE: Install all removed parts in reversed order of their removal.

VALVE CLEARANCE ADJUSTMENT INSP ADJ INSTALLED PAD NUMBER

120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 STANDARD CLEARANCE 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 175 180 185 190 195 200 205 210 215 220 225 230 235 240 180 185 190 195 200 205 210 215 220 225 230 235 240 185 190 195 200 205 210 215 220 225 230 235 240 VALVE CLEARANCE (cold): 190 195 200 205 210 215 220 225 230 235 240 0.10 ~ 0.15 mm 195 200 205 210 215 220 225 230 235 240 Example: Installed is 175 200 205 210 215 220 225 230 235 240 Measured clearance is 0.22 mm 205 210 215 220 225 230 235 240 210 215 220 225 230 235 240 Replace 175 pad with 185 pad 215 220 225 230 235 240 Pad number: (example) 220 225 230 235 240 Pad No. 175 = 1.75 mm 225 230 235 240 Pad No. 185 = 1.85 mm 230 235 240 235 240 240

INSTALLED PAD NUMBER

165 170 175 180 185 190 195 145 150 155 160 165 170 175 150 155 160 165 170 175 180 155 160 165 170 175 180 185 160 165 170 175 180 185 190 STANDARD CLEARANCE 170 175 180 185 190 195 200 175 180 185 190 195 200 205 180 185 190 195 200 205 210 185 190 195 200 205 210 215 190 195 200 205 210 215 220 195 200 205 210 215 220 225 200 205 210 215 220 225 230 205 210 215 220 225 230 235 210 215 220 225 230 235 240 215 220 225 230 235 240 220 225 230 235 240 225 230 235 240 230 235 240 VALVE 235 240 0.20 240

210 215 220 225 230 235 240

215 220 225 230 235 240

230 235 240 235 240 240

~ 0.25 mm Example: Installed is 175 Measured clearance is 0.32 mm Replace 175 pad with 185 pad Pad number: (example) Pad No. 175 = 1.75 mm Pad No. 185 = 1.85 mm

SPARK ARRESTER CLEANING (For USA)

INSP ADJ SPARK ARRESTER CLEANING (For USA)

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

• Screw (silencer cap) 1 2. Remove: • Bolt (spark arrester) 1

• Tail pipe 1 • Gasket (tail pipe) 2 • Spark arrester 3 Pull the spark arrester out of the silencer. • Gasket (spark arrester) 4 4. Clean: • Spark arrester Tap the spark arrester lightly, then use a wire brush to remove any carbon deposits. 5. Install: • Gasket (spark arrester) • Spark arrester Insert the spark arrester into the silencer and align the bolt holes. • Gasket (tail pipe) • Bolt (spark arrester)

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

BRAKE SYSTEM AIR BLEEDING WARNING Bleed the brake system if:

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

• Master cylinder cap • Diaphragm • Reservoir float (front brake) • Protector (rear brake) 2. Bleed: • Brake fluid È Front É 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.

6 Nm (0.6 m • kg, 4.3 ft • lb)

i. Repeat steps (e) to (h) until of the air bubbles have been removed from the system.

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. 3. Install: • Protector (rear brake) • Reservoir float (front brake) • Diaphragm • Master cylinder cap EC362040

Extent of adjustment

• Lever cover 3. Adjust: • Brake lever position Brake lever position adjustment steps: • Loosen the locknut 1. • Turn the adjusting bolt 2 until the lever position a is within specified position. • Tighten the locknut.

Be sure to tighten the locknut, as it will cause poor brake performance. 4. Install: • Lever cover 3 - 26

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

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

FRONT BRAKE PAD INSPECTION AND REPLACEMENT

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

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

Loosen the pad pin 2.

Remove the caliper 3 from the front fork. Remove the pad pin and brake pads 4. Connect the transparent hose 5 to the bleed screw 6 and place the suitable container under its end. • Loosen the bleed screw and push the caliper piston in.

Do not reuse the drained brake fluid. • Tighten the bleed screw.

6 Nm (0.6 m • kg, 4.3 ft • lb)

• Install the brake pads 7 and pad pin.

NOTE: • Install the brake pads with their projections a into the caliper recesses b. • Temporarily tighten the pad pin at this point. • Install the caliper 8 and tighten the pad pin 9.

REAR BRAKE PAD INSPECTION AND REPLACEMENT INSP ADJ

• Install the pad pin plug 0.

• Brake fluid level Refer to “BRAKE FLUID LEVEL INSPECTION” section. 4. Check: • Brake lever operation A softy or spongy feeling → Bleed brake system. Refer to “BRAKE SYSTEM AIR BLEEDING” section. EC366060

REAR BRAKE PAD INSPECTION AND REPLACEMENT

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

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

REAR BRAKE PAD INSPECTION AND REPLACEMENT 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 caliper piston in. CAUTION: Do not reuse the drained brake fluid. • Tighten the bleed screw.

6 Nm (0.6 m • kg, 4.3 ft • lb)

• Install the brake pad 0 and pad pin A.

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

• Brake fluid level Refer to “BRAKE FLUID LEVEL INSPECTION” section. 4. Check: • Brake pedal operation A softy or spongy feeling → Bleed brake system. Refer to “BRAKE SYSTEM AIR BLEEDING” section. EC36b000

REAR BRAKE PAD INSULATOR INSPECTION

1. Remove: • Brake pad Refer to “REAR BRAKE PAD INSPECTION AND REPLACEMENT” section. 2. Inspect: • Rear brake pad insulator 1 Damage → Replace. È

BRAKE FLUID LEVEL INSPECTION

1. Place the master cylinder so that its top is in a horizontal position. 2. Inspect: • Brake fluid level Fluid at lower level → Fill up. a Lower level È Front É Rear

Recommended brake fluid:

WARNING Use only designated quality brake fluid to avoid poor brake performance.

Refill with same type and brand of brake fluid; mixing fluids could result in poor brake performance. Be sure that water or other contaminants do not enter master cylinder when refilling. Clean up spilled fluid immediately to avoid erosion of painted surfaces or plastic parts.

SPROCKETS INSPECTION

1. Inspect: • Sprocket teeth a Excessive wear → Replace. NOTE: Replace the drive, driven sprockets and drive chain as a set.

DRIVE CHAIN INSPECTION

1. Measure: • Drive chain length (15 links) a Out of specification → Replace. Drive chain length (15 links): <Limit>: 239.3 mm (9.42 in) NOTE: • While measuring the drive chain length, push down on the drive chain to increase its tension. • Measure the length between drive chain roller 1 and F as shown. • Perform this measurement at two or three different places.

• Drive chain 1 NOTE: Remove the drive chain using a chain cutter 2. 3. Clean: • 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 side plates. Steam cleaning, high-pressure washes, certain solvent and kerosene can damage these O-rings.

• O-ring 1 (drive chain) Damage → Replace the drive chain. • Roller 2 • Side plate 3 Damage/wear → Replace the drive chain.

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

• Joint 1 New • O-ring 2 • Drive chain 3 NOTE: When installing the drive chain, apply the lithium soap base grease on the joint and O-rings.

• Link plate 4 New NOTE: • Press the link plate onto the joint using a chain riveter 5. • Rivet the end of the joint using a chain riveter. • After riveting the joint, make sure its movement is smooth. 8. Lubricate: • Drive chain Drive chain lubricant: SAE 10W-30 motor oil or suitable chain lubricants

DRIVE CHAIN SLACK ADJUSTMENT

1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Check: • Drive chain slack a Above the seal guard installation bolt. Out of specification → Adjust. Drive chain slack: 48 ~ 58 mm (1.9 ~ 2.3 in) NOTE: Before checking and/or adjusting, rotate the rear wheel through several revolutions and check the slack several times to find the tightest point. Check and/or adjust the chain slack with the rear wheel in this “tight chain” position.

• Drive chain slack Drive chain slack adjustment steps: • Loosen the axle nut 1 and locknuts 2. • Adjust the chain slack by turning the adjusters 3. To tighten →Turn the adjuster 3 counterclockwise. To loosen → Turn the adjuster 3 clockwise and push wheel forward. • Turn each adjuster exactly the same amount to maintain correct axle alignment. (There are marks a on each side of the 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.

FRONT FORK INSPECTION/

FRONT FORK OIL SEAL AND DUST SEAL CLEANING INSP ADJ

• Tighten the axle nut while pushing down the drive chain.

• Tighten the locknuts.

FRONT FORK INSPECTION

1. Inspect: • Front fork smooth action Operate the front brake and stroke the front fork. Unsmooth action/oil leakage → Repair or replace.

FRONT FORK OIL SEAL AND DUST SEAL CLEANING

1. Remove: • Protector • Dust seal 1 NOTE: Use a thin screw driver, and be careful not to damage the inner fork tube and dust seal. 2. Clean: • 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.

FRONT FORK INTERNAL PRESSURE RELIEVING NOTE:

If the front fork initial movement feels stiff during a run, relieve the front fork internal pressure. 1. Elevate the front wheel by placing a suitable stand under the engine. 2. Remove the air bleed screw 1 and release the internal pressure from the front fork. 3. Install: • Air bleed screw T.

FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT

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

20 clicks out (from maximum position)

FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT INSP ADJ

• STANDARD POSITION:

This is the position which is back by the specific number of clicks from the fully turned-in position. Standard position: 8 clicks out 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.

FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT

1. Remove: • Rubber cap 2. Adjust: • Compression damping force By turning the adjuster 1. Stiffer a → Increase the compression damping force. (Turn the adjuster 1 in.) Softer b → Decrease the compression damping force. (Turn the adjuster 1 out.) Extent of adjustment: Maximum Fully turned in position

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: 9 clicks out 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. 3. Install: • Rubber cap

REAR SHOCK ABSORBER INSPECTION

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

REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT INSP ADJ REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT

1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Remove: • Rear frame 3. Loosen: • Locknut 1 4. Adjust: • Spring preload By turning the adjuster 2. Stiffer → Increase the spring preload. (Turn the adjuster 2 in.) Softer → Decrease the spring preload. (Turn the adjuster 2 out.) Spring length (installed) a: Standard length

Extent of adjustment

• 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. 5. Tighten: • Locknut 6. Install: • Rear frame (upper) T.

• Rear frame (lower)

REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT INSP ADJ EC36N014

REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT

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

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 11 clicks out CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged.

REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT INSP ADJ EC36c000

REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT

1. Adjust: • Low compression damping force By turning the adjuster 1.

Stiffer a → Increase the low compression damping force. (Turn the adjuster 1 in.)

Softer b → Decrease the low compression damping force. (Turn the adjuster 1 out.) Extent of adjustment: Maximum Fully turned in position

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.)

About 8 clicks out *About 11 clicks out **About 9 clicks out

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

REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT INSP ADJ EC36d000

REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT

1. Adjust: • High compression damping force By turning the adjuster 1.

Stiffer a → Increase the high compression damping force. (Turn the adjuster 1 in.)

Softer b → Decrease the high compression damping force. (Turn the adjuster 1 out.) Extent of adjustment: Maximum Fully turned in position

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.)

About 1-1/8 turns out * About 1-1/4 turns out

* For AUS, NZ and ZA CAUTION:

Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged.

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

SPOKES INSPECTION AND TIGHTENING

1. Inspect: • Spokes 1 Bend/damage → Replace. Loose spoke → Retighten. 2. Tighten: 3 Nm (0.3 m · kg, 2.2 ft · lb) • Spokes R.

Be sure to retighten these spokes before and after break-in. After a practice or a race check spokes for looseness.

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

STEERING HEAD INSPECTION AND ADJUSTMENT INSP ADJ

• Bearing free play Exist play → Replace.

STEERING HEAD INSPECTION AND ADJUSTMENT

1. Elevate the front wheel by placing a suitable stand under the engine. 2. Check: • Steering shaft Grasp the bottom of the forks and gently rock the fork assembly back and forth. Free play → Adjust steering head. 3. Check: • Steering smooth action Turn the handlebar lock to lock. Unsmooth action → Adjust steering ring nut.

• Steering ring nut Steering ring nut adjustment steps: • Remove the headlight. • Remove the handlebar and handle crown. • Loosen the ring nut 1 using the ring nut wrench 2. Ring nut wrench: YU-33975/90890-01403

STEERING HEAD INSPECTION AND ADJUSTMENT INSP ADJ

• Tighten the ring nut 3 using ring nut wrench 4.

NOTE: • Apply the lithium soap base grease on the thread of the steering shaft. • Set the torque wrench to the ring nut wrench so that they form a right angle. Ring nut wrench: YU-33975/90890-01403

Ring nut (initial tightening):

38 Nm (3.8 m • kg, 27 ft • lb)

• Loosen the ring nut one turn.

• Retighten the ring nut using the ring nut wrench. WARNING Avoid over-tightening.

Ring nut (final tightening):

7 Nm (0.7 m • kg, 5.1 ft • lb)

• Check the steering shaft by turning it lock to lock. If there is any binding, remove the steering shaft assembly and inspect the steering bearings.

• Install the plain washer 5, handle crown 6, plain washer 7, steering shaft nut 8, handlebar 9, handlebar holder (upper) 0 and headlight A. NOTE: • The handlebar holder (upper) should be installed with the punched mark a forward. • Install the handlebar so that the marks b are in place on both sides.

YU-33975/90890-01403

STEERING HEAD INSPECTION AND ADJUSTMENT INSP ADJ

• Install the handlebar so that the projection c of the handlebar holder (upper) is positioned at the mark on the handlebar as shown.

• Insert the end of the fuel breather hose B into the hole in the steering shaft. CAUTION: First tighten the bolts on the front side of the handlebar holder (upper), and then tighten the bolts on the rear side.

È Use Yamaha cable lube or equivalent on these areas.

É Use SAE 10W-30 motor oil or suitable chain lubricants. Ê Lubricate the following areas with high quality, lightweight lithium-soap base grease.

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 Hot starter cable end

Wipe off any excess grease, and avoid getting grease on the brake discs.

SPARK PLUG INSPECTION

1. Remove: • Spark plug 2. Inspect: • Electrode 1 Wear/damage → Replace. • Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition. NOTE: When the engine runs for many hours at low speeds, the spark plug insulator will become sooty, even if the engine and carburetor are in good operating condition. 3. Measure: • Plug gap a Use a wire gauge or thickness gauge. Out of specification → Regap. Spark plug gap: 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)

4. Clean the plug with a spark plug cleaner if necessary.

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

IGNITION TIMING CHECK INSP ADJ IGNITION TIMING CHECK

1. Remove: • Timing plug 1

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

YM-33277-A/90890-03141

• Engine idling speed Refer to “IDLE SPEED ADJUSTMENT”.

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

BATTERY INSPECTION AND CHARGING INSP ADJ BATTERY INSPECTION AND CHARGING WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid.

Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries. • Charge batteries in a well-ventilated area. • Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes). • DO NOT SMOKE when charging or handling batteries. • KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN. • Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. FIRST AID IN CASE OF BODILY CONTACT: EXTERNAL • Skin — Wash with water. • Eyes — Flush with water for 15 minutes and get immediate medical attention. INTERNAL • Drink large quantities of water or milk followed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention. CAUTION: Charging time, charging amperage and charging voltage for an MF battery are different from those of conventional batteries. The MF battery should be charged as explained in the charging method illustrations. If the battery is overcharged, the electrolyte level will drop considerably. Therefore, take special care when charging the battery.

BATTERY INSPECTION AND CHARGING INSP ADJ NOTE:

Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: • Seat

• Battery leads (from the battery terminals) CAUTION: First, disconnect the negative battery lead 1, and then the positive battery lead 2. 3. Remove: • Battery band • Battery 4. Measure: • Battery charge Measurement steps: • Connect a pocket tester 1 to the battery terminals. Tester positive probe → battery positive terminal Tester negative probe → battery negative terminal NOTE: • The charge state of an MF battery can be checked by measuring its open-circuit voltage (i.e., the voltage when the positive terminal is disconnected). • No charging is necessary when the opencircuit voltage equals or exceeds 12.8 V.

• Check the charge of the battery, as shown in the charts and the following example.

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

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

Never remove the MF battery sealing caps. Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage. If it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery. When charging a battery, be sure to remove it from the machine. (If charging has to be done with the battery mounted on the machine, disconnect the negative battery lead from the battery terminal.) To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery.

BATTERY INSPECTION AND CHARGING INSP ADJ

• Before removing the battery charger lead clips from the battery terminals, be sure to turn off the battery charger.

• Make sure the battery charger lead clips are in full contact with the battery terminal and that they are not shorted. A corroded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks. • If the battery becomes hot to the touch at any time during the charging process, disconnect the battery charger and let the battery cool before reconnecting it. Hot batteries can explode! • As shown in the following illustration, the open-circuit voltage of an MF battery stabilizes about 30 minutes after charging has been completed. Therefore, wait 30 minutes after charging is completed before measuring the open-circuit voltage.

BATTERY INSPECTION AND CHARGING Charging method using a variable voltage charger

Measure the open-circuit voltage prior to charging.

Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage.

Connect a charger and ammeter to the battery and start charging.

Set the charging voltage to 1617 V. (If the charging voltage is lower, charging will be insufficient, if it is higher, the battery will be over-charged.)

Is the amperage higher than the standard charging amperage written on the battery?

YES NO Adjust the charging voltage to

Adjust the voltage to obtain the standard charging amperage.

Monitor the amperage for 3 ~

5 minutes. Is the standard charging amperage exceeded?

YES NO If the amperage does not exceed the standard charging amperage after 5 minutes, replace the battery.

Set the timer to the charging time determined by the opencircuit voltage.

Refer to “BATTERY INSPECTION AND CHARGING” section.

If the required charging time exceeds 5 hours, it is advisable to check the charging amperage after 5 hours. If there is any change in the amperage, readjust the voltage to obtain the standard charging amperage.

Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage.

12.8 V → Charging is complete. 12.0 ~ 12.7 V → Recharging is required. Under 12.0 V → Replace the battery.

INSP ADJ BATTERY INSPECTION AND CHARGING Charging method using a constant voltage charger

Measure the open-circuit voltage prior to charging.

Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage.

Connect a charger and ammeter to the battery and start charging.

YES Is the amperage higher than the standard charging amperage written on the battery?

Charge the battery until the charging voltage reaches 15 V.

NO This type of battery charger cannot charge an MF battery. A variable voltage charger is recommended.

Set the charging time to a maximum of 20 hours.

Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage. 12.8 V → Charging is complete. 12.0 ~ 12.7 V → Recharging is required. Under 12.0 V → Replace the battery.

Constant amperage chargers are not suitable for charging MF batteries.

• Battery • Battery band 7. Connect: • Battery leads (to the battery terminals) CAUTION: First, connect the positive lead 1, then the negative lead 2. 8. Check: • Battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. 9. Lubricate: • Battery terminal Recommended lubricant: Lithium soap base grease 10. Install: • Seat EAS00181

FUSE INSPECTION CAUTION:

To avoid a short circuit, always set the main switch to “OFF” when checking or replacing a fuse.

• Seat • Fuse cover 2. Check: • Continuity

• Remove the fuse 1. • Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester: YU-3112-C/90890-03112 • If the pocket tester indicates “∞”, replace the fuse. 2 Reserve fuse

REPLACING THE HEADLIGHT BULBS INSP ADJ

• Blown fuse Replacement steps: • Set the main switch to “OFF”. • Install a new fuse of the correct amperage. • Set on the switches to verify if the electrical circuit is operational. • If the fuse immediately blows again, check the electrical circuit. Items

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

4. Install: • Fuse cover • Seat

REPLACING THE HEADLIGHT BULBS

1. Remove: • Headlight Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 4. 2. Remove: • Headlight bulb holder cover 1

• Headlight bulb holder 1 NOTE: Remove the headlight bulb holder by pushing it in and turning it counterclockwise.

ADJUSTING THE HEADLIGHT BEAMS INSP ADJ

• Headlight bulb WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb unit it has cooled down. 5. Install: • Headlight bulb New 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 7. Install: • Headlight bulb holder cover 8. Install: 7 Nm (0.7 m · kg, 5.1 ft · lb) • Headlight Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 4. R.

ADJUSTING THE HEADLIGHT BEAMS

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

Headlight beam is raised.

Headlight beam is lowered.

3 Side covers removal

Preparation for 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) Bolt (fuel tank) Fuel tank Side cover (left) Side cover (right) Headlight coupler Headlight

Open the air filter case cover.

Refer to “REMOVAL POINTS”.

REMOVAL POINTS Side cover

1. Remove: • Bolt (side cover) • Side cover (right) 1 NOTE: Draw the side cover backward to remove it because its claw a is inserted in the air filter case.

EXHAUST PIPE AND SILENCER REMOVAL Side cover (right)

Preparation for removal

2 Exhaust pipe removal

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

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

INSPECTION Exhaust pipe and silencer

1. Inspect: • Gasket 1 Damage → Replace.

ASSEMBLY AND INSTALLATION Exhaust pipe and silencer

1. Install: • Gasket New • Exhaust pipe 1 • Nut (exhaust pipe) 2

• Bolt (exhaust pipe) 3

First, temporarily tighten the nut (exhaust pipe), then tighten the bolt (exhaust pipe) 13 Nm (1.3 m • kg, 9.4 ft • lb). After that, retighten the nut (exhaust pipe) 20 Nm (2.0 m • kg, 14 ft • lb) and then the bolt (exhaust pipe) 20 Nm (2.0 m • kg, 14 ft • lb).

16 Nm (1.6 m · kg, 11 ft · lb) • Clamp 1 • Gasket 2 New • Silencer 3 • Plain washer 4 • Bolt (silencer) 5 R.

2 Coolant reservoir removal

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. Refer to “EXHAUST PIPE AND SILENCER” section.

Seat, fuel tank and side cover

2 3 4 5 6 7 8 9 10 11 12 13

Clamp Radiator (right) Hose 2 Hose 3 Hose 4 Pipe 2/O-ring Catch tank hose Radiator (left) Hose 1 Pipe 1/O-ring Catch tank breather hose Catch tank

8 1 1 1 1 1/1 1 1 1 1/1 1 1

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.

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

2 Nm (0.2 m · kg, 1.4 ft · lb) • Hose 2 1 • Radiator (left) 2 R.

• Catch tank hose 1 • Radiator (right) 2 T.

Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2.

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

• Catch tank 1 • Bolt (catch tank) 2 T.

• Bolt (catch tank) 3

• Catcher tank breather hose 5 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2.

CARBURETOR REMOVAL Fuel tank

Preparation for removal

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

Refer to “REAR SHOCK ABSORBER” section in the CHAPTER 5.

TPS coupler Throttle cable cover Throttle cable Clamp (air cleaner joint) Clamp (carburetor joint) Hot starter plunger Carburetor Cylinder head breather pipe Cylinder head breather hose 1

Loosen the screw (air cleaner joint).

Loosen the screws (carburetor joint).

Cylinder head breather hose 2

Cylinder head breather hose 3 Bracket (cylinder head breather pipe) Carburetor joint

A B C D E F CARBURETOR DISASSEMBLY Breather hose

Valve lever housing cover Screw (throttle shaft) Throttle valve Needle holder Jet needle Cover Spring Diaphragm (accelerator pump) Air cut valve cover Spring (air cut valve) Diaphragm (air cut valve) Float chamber Leak jet Float pin Float

1 1 1 1 1 1 1 1 1 1 1 1 1 1 1

G H I J K L M N O P Q Part name

Needle valve Main jet Needle jet Spacer Pilot jet Starter jet Push rod Throttle shaft assembly Push rod link lever assembly Pilot air jet Cold starter plunger

1 1 1 1 1 1 1 1 1 1 1

HANDLING NOTE CAUTION:

Do not loosen the screw {TPS (throttle position sensor)} 1 except when changing the TPS (throttle position sensor) due to failure because it will cause a drop in engine performance.

INSPECTION Carburetor

1. Inspect: • Carburetor body Contamination → Clean. NOTE: • Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air. • Never use a wire.

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

1. Inspect: • Needle valve 1 • Valve seat 2 Grooved wear a → Replace. Dust b → Clean. • Filter c Clogged → Clean.

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

1. Inspect: • Jet needle 1 Bends/wear → Replace. • Clip groove Free play exists/wear → Replace.

1. Measure: • Float height a Out of specification → Adjust. Float height: 8.0 mm (0.31 in)

Measurement and adjustment steps:

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

1. Inspect: • Float 1 Damage → Replace.

1. Inspect: • Cold starter plunger 1 • Hot starter plunger 2 Wear/damage → Replace.

1. Inspect: • Diaphragm (accelerator pump) 1 • Spring 2 • Cover 3 • O-ring 4 • Push rod 5 Tears (diaphragm)/damage → Replace. Dirt → Clean. 2. Inspect: • Throttle shaft 1 • Spring 2 • Lever 1 3 • Spring 1 4 • Lever 2 5 • Spring 2 6 Dirt → Clean.

1. Inspect: • 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 Carburetor

1. Install: • Cold starter plunger 1

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

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

6. Install: • Plain washer 1 • Circlip 2

7. Install: • Spring 1 To throttle shaft 2. NOTE: Install the bigger hook a of the spring fits on the stopper b of the throttle shaft pulley.

• Apply the fluorochemical grease on the bearings. • Fit the projection a on the throttle shaft assembly into the slot b in the TPS (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.

While holding down the lever 1 2, insert the push rod farthest into the carburetor.

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

• Needle valve 1 • Float 2 • Float pin 3 NOTE: • After installing the needle valve to the float, install them to the carburetor. • Check the float for smooth movement.

• O-ring • Leak jet 1 • Float chamber 2 • Bolt (float chamber) 3 • Cable holder (throttle stop screw cable) 4 • Hose holder (carburetor breather hose) 5

• Diaphragm (air cut valve) 1 • Spring (air cut valve) 2 • O-ring 3 • Air cut valve cover 4 • Holder (cylinder head breather hose) 5 • Screw (air cut valve cover) 6

• Diaphragm (accelerator pump) 1 • Spring 2 • O-ring 3 • Cover 4 • Hose holder (drain hose) 5 • Screw (cover) 6 NOTE: Install the diaphragm (accelerator pump) with its mark a facing the spring.

15. Install: • 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 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2.

Accelerator pump timing adjustment

Adjustment steps: NOTE: In order for the throttle valve height a to achieve the specified value, tuck under the throttle valve plate 1 the rod 2 etc. with the same outer diameter as the specified value. Throttle valve height: 3.1 mm (0.122 in) • Fully turn in the accelerator pump adjusting screw 3. • Check that the link lever 4 has free play b by pushing lightly on it. • Gradually turn out the adjusting screw while moving the link lever until it has no more free play.

Carburetor installation

1. Install: • Carburetor joint 1 • Bracket (cylinder head breather pipe) 2 • Bolt (carburetor joint) 3 T.

Cylinder head breather pipe 4

Cylinder head breather hose 1 5 Cylinder head breather hose 2 6 Cylinder head breather hose 3 7

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

• Bolt (carburetor joint) 1

• Bolt (air cleaner joint) 2

• Throttle cable (return) 2

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

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

8. Install: • TPS (throttle position sensor) coupler 1 • Clamp 2 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2.

• Clamp 1 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2.

1 Air induction system removal

AIR INDUCTION SYSTEM REMOVAL Bracket Air cut-off valve assembly Air induction hose (air cut-off valve - front of cylinder head) Air induction pipe Gasket Air induction hose (air cut-off valve - rear of cylinder head) Air induction hose (air cut-off valve - air filter case)

INSPECTION Air induction system

1. Inspect: • Air induction hose Crack/damage → Replace. • Air induction pipe Crack/damage → Replace.

• Operation of air cut valve Pass air through the pipe and check the air cut valve for operation. Does not meet the following condition → Replace the air cut valve assembly.

Air does not pass when specified pressure is on c.

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

Vacuum specifying pressure:

46.7 ~ 86.7 kPa (350 ~ 650 mmHg, 13.8 ~ 25.6 inHg) CAUTION: When using vacuum on the pipe c, take care not to exceed the specified value. a From air filter b To cylinder head (exhaust port) c From cylinder head (intake port) È Check for induction from air filter. É Check for prevention of backflow into air filter. Ê Check for prevention of afterburn. (When throttle is closed at sudden deceleration)

1 Cylinder head cover removal

CYLINDER HEAD COVER REMOVAL Seat and fuel tank

Preparation for removal

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

Refer to “AIR INDUCTION SYSTEM” section. Refer to “ENGINE REMOVAL” section.

Air cut-off valve assembly

Engine upper bracket (right)

Engine upper bracket (left) Spark plug Cylinder head breather hose Bolt (cylinder head cover) Cylinder head cover Cylinder head cover gasket

CAMSHAFTS REMOVAL Timing plug Straight plug Tensioner cap bolt Timing chain tensioner Gasket Bolt (camshaft cap) Camshaft cap Clip Exhaust camshaft Intake camshaft

1 1 1 1 1 10 2 2 1 1

Refer to “REMOVAL POINTS”.

DEPOSE DES ARBRES A CAMES

REMOVAL POINTS Camshaft

1. Remove: • Timing plug 1 • Straight plug 2 2. Align: • “I” mark With stationary pointer.

• Turn the crankshaft counterclockwise with a wrench. • Align the “I” mark a on the rotor with the stationary pointer b on the crankcase cover. When the “I” mark is aligned with the stationary pointer, the piston is at the Top Dead Center (T.D.C.).

• 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. • If there is no clearance, rotate the crankshaft counterclockwise one turn.

• Bolt (camshaft cap) 1 • Camshaft caps 2 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.

• Clips • Exhaust camshaft 1 • Intake camshaft 2

Attach a wire 3 to the timing chain to prevent it from falling into the crankcase.

INSPECTION Camshaft 1. Inspect: • Cam lobes Pitting/scratches/blue discoloration → Replace. 2. Measure: • Cam lobes length a and b Out of specification → Replace. Cam lobes length: Intake: a 30.100 ~ 30.200 mm (1.1850 ~ 1.1890 in) <Limit>: 30.000 mm (1.1811 in) b 22.450 ~ 22.550 mm (0.8839 ~ 0.8878 in) <Limit>: 22.350 mm (0.8799 in) Exhaust: a 30.200 ~ 30.300 mm (1.1890 ~ 1.1929 in) <Limit>: 30.100 mm (1.1850 in) b 22.450 ~ 22.550 mm (0.8839 ~ 0.8878 in) <Limit>: 22.350 mm (0.8799 in)

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

• Camshaft-to-cap clearance Out of specification → Measure camshaft journal diameter. Camshaft-to-cap clearance: 0.028 ~ 0.062 mm (0.0011 ~ 0.0024 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 circlip, dowel pins and camshaft caps.

• 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 journal diameter a Out of specification → Replace the camshaft. Within specification → Replace camshaft case and camshaft caps as a set. Camshaft journal diameter: 21.959 ~ 21.972 mm (0.8645 ~ 0.8650 in) Camshaft sprocket 1. Inspect: • Camshaft sprocket 1 Wear/damage → Replace the camshaft assembly and timing chain as a set.

Decompression system

1. Check: • Decompression system Checking steps: • Check that the decompressor cam 1 moves smoothly. • Check that the decompressor lever pin 2 projects from the camshaft. Timing chain tensioner 1. Check: • While pressing the tensioner rod lightly with fingers, use a thin screwdriver 1 and wind the tensioner rod up fully clockwise. • When releasing the screwdriver by pressing lightly with fingers, make sure that the tensioner rod will come out smoothly. • If not, replace the tensioner assembly.

ASSEMBLY AND INSTALLATION

1. Install: • Exhaust camshaft 1 • Intake camshaft 2 Installation steps: • Turn the crankshaft counterclockwise until the “I” mark a on the rotor is aligned with the stationary pointer b on the crankcase cover. NOTE: • Apply the molybdenum disulfide oil on the camshafts. • Apply the engine oil on the decompression system.

• 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 exhaust cam sprocket punch mark c and the intake cam sprocket punch mark d align with the surface of the cylinder head. CAUTION: Do not turn the crankshaft during the camshaft installation. Damage or improper valve timing will result. • Install the clips and camshaft caps 4.

• Apply the molybdenum disulfide oil on the thread of the bolts (camshaft cap) 5. • Tighten the bolts to the specified torque in two or three steps in the proper tightening sequence as shown. 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, the chain tensioner 2 and the gasket 3 and tighten the bolt 4 to the specified torque.

• Release the screwdriver, check the tensioner rod to come out and tighten the gasket 5 and the cap bolt 6 to the specified torque.

• Crankshaft Counterclockwise several turns 4. Check: • Rotor “I” mark Align with the crankcase stationary pointer. • Camshaft match marks Align with the cylinder head surface. Out of alignment → Adjust. 5. Install: • Timing plug 1 • Straight plug 2

• Cylinder head cover gasket 1 • Cylinder head cover 2 • Bolt (cylinder head cover) 3 T.

Apply the sealant on the cylinder head cover gasket. YAMAHA Bond No. 1215 (ThreeBond® No. 1215): 90890-85505

• Cylinder head breather hose • Spark plug T.

1 Cylinder head removal

CYLINDER HEAD REMOVAL Seat and fuel tank

Preparation for removal

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

Refer to “EXHAUST PIPE AND SILENCER” section. Refer to “RADIATOR” section. Refer to “AIR INDUCTION SYSTEM” section. Refer to “CARBURETOR” section. Refer to “CAMSHAFTS” section.

Exhaust pipe and silencer

Air cut-off valve assembly Carburetor Camshaft Bolt Bolt Cylinder head Gasket Dowel pin Timing chain guide (front)

Tighten the cylinder head bolts to 30 Nm (3.0 m • kg, 22 ft • lb) in the proper tightening sequence, remove and retighten the cylinder head bolts to 20 Nm (2.0 m • kg, 14 ft • lb) in the proper tightening sequence, and then tighten the cylinder head bolts further to reach the specified angle 180° in the proper tightening sequence. 4 - 33

INSPECTION Cylinder head

1. Eliminate: • Carbon deposits (from the combustion chambers) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damaging or scratching: • Spark plug threads • Valve seats 2. Inspect: • 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

1. Install: • Timing chain guide (front) 1 • Dowel pin 2 • Cylinder head gasket 3 New • Cylinder head 4 NOTE: While pulling up the timing chain, install the timing chain guide (front) and cylinder head. 2. Install: • Plain washer 1 • Bolt 2 Installation steps: CAUTION: Tighten the cylinder head using the rotation angle procedure to obtain uniform tightening torque. • Wash the threads and contact surfaces of the bolts, the contact surfaces of the plain washers, the contact surface of the cylinder head, and the threads of the crankcase. • Apply the molybdenum disulfide grease on the threads and contact surfaces of the bolts and on both contact surfaces of the plain washers. • Install the plain washers and bolts. • Tighten the bolts to the specified torque in two or three steps in the proper tightening sequence as shown.

• Again apply the molybdenum disulfide grease on the threads and contact surfaces of the bolts and on both contact surfaces of the plain washers. • Retighten the bolts. NOTE: Tighten the bolts to the specified torque in two or three steps in the proper tightening sequence as shown.

• Put a mark on the corner 1 of the bolt

(cylinder head) and the cylinder head 2 as shown.

Tighten the bolts 90° in each of the two steps to reach the specified angle of 180° in the proper tightening sequence as shown.

Bolts (cylinder head):

Final: Specified angle 180°

VALVES AND VALVE SPRINGS ENG VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS

VALVES AND VALVE SPRINGS REMOVAL Cylinder head

Valve lifter Adjusting pad Valve cotter Valve retainer Valve spring Stem seal Valve spring seat Exhaust valve Intake valve

Preparation for removal

Refer to “CYLINDER HEAD” section.

Use special tool. Refer to “REMOVAL POINTS”.

VALVES AND VALVE SPRINGS ENG REMOVAL POINTS Valve lifter and valve cotter

1. Remove: • Valve lifters 1 • Pads 2 NOTE: Identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place. 2. Check: • 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 cotters NOTE: Attach a valve spring compressor 1 between the valve spring retainer and the cylinder head to remove the valve cotters. Valve spring compressor: YM-4019/90890-04019

VALVES AND VALVE SPRINGS ENG INSPECTION Valve

1. Measure: • Stem-to-guide clearance Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b Out of specification → Replace the valve guide. Clearance (stem to guide): Intake: 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) <Limit>: 0.08 mm (0.003 in) Exhaust: 0.020 ~ 0.047 mm (0.0008 ~ 0.0019 in) <Limit>: 0.10 mm (0.004 in)

• 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 2. • After installing the valve guide, bore the valve guide using a valve guide reamer 3 to obtain proper stem-to-guide clearance.

VALVES AND VALVE SPRINGS ENG

• 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: 1.0 mm (0.039 in) <Limit>: 0.85 mm (0.033 in) Exhaust: 1.0 mm (0.039 in) <Limit>: 0.85 mm (0.033 in)

VALVES AND VALVE SPRINGS ENG

• Runout (valve stem) Out of specification → Replace. Runout limit: 0.01 mm (0.0004 in) NOTE: • When installing a new valve always replace the guide. • If the valve is removed or replaced always replace the oil seal. 6. Eliminate: • Carbon deposits (from the valve face and valve seat) 7. Inspect: • Valve seats Pitting/wear → Reface the valve seat.

• Valve seat width a Out of specification → Reface the valve seat. Valve seat width: Intake: 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) <Limit>: 1.6 mm (0.0630 in) Exhaust: 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) <Limit>: 1.6 mm (0.0630 in) Measurement steps: • Apply Mechanic’s blueing dye (Dykem) b to the valve face. • Install the valve into the cylinder head. • Press the valve through the valve guide and onto the valve seat to make a clear pattern. • Measure the valve seat width. Where the valve seat and valve face made contact, blueing will have been removed. • If the valve seat is too wide, too narrow, or the seat is not centered, the valve seat must be refaced.

VALVES AND VALVE SPRINGS ENG

• 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.

VALVES AND VALVE SPRINGS ENG Valve spring

1. Measure: • Valve spring free length a Out of specification → Replace. Free length (valve spring): Intake: 39.46 mm (1.55 in) <Limit>: 38.46 mm (1.51 in) Exhaust: 37.61 mm (1.48 in) <Limit>: 36.61 mm (1.44 in) 2. Measure: • Compressed spring force a Out of specification → Replace. b Installed length

Compressed spring force:

Intake: 130.2 ~ 149.8 N at 27.87 mm (13.28 ~ 15.28 kg at 27.87 mm, 29.27 ~ 33.68 lb at 1.10 in) Exhaust: 123.1 ~ 141.7 N at 28.38 mm (12.55 ~ 14.45 kg at 28.38 mm, 27.67 ~ 31.85 lb at 1.12 in)

• Spring tilt a Out of specification → Replace. Spring tilt limit: Intake: 2.5°/1.7 mm (0.067 in) Exhaust: 2.5°/1.6 mm (0.063 in)

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

VALVES AND VALVE SPRINGS ENG ASSEMBLY AND INSTALLATION

1. Apply: • Molybdenum disulfide oil Onto the valve stem and valve stem seal.

• Valves 1 • Valve spring seats 2 • Valve stem seals 3 New • Valve springs 4 • Valve spring retainers 5 NOTE: • Make sure that each valve is installed in its original place, also referring to the painted color as follows. Intake (middle) a: blue Intake (right/left) b: gray Exhaust: not paint • Install the valve springs with the larger pitch c facing upward. d Smaller pitch

• Valve cotters NOTE: While compressing the valve spring with a valve spring compressor 1 install the valve cotters. Valve spring compressor: YM-4019/90890-04019 4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood. CAUTION: Hitting the valve tip with excessive force could damage the valve.

VALVES AND VALVE SPRINGS ENG

• Adjusting pad 1 • Valve lifter 2 NOTE: • Apply the engine oil on the valve lifters. • Apply the molybdenum disulfide oil on the valve stem end. • Valve lifter must turn smoothly when rotated with a finger. • Be careful to reinstall valve lifters and pads in their original place.

CYLINDER AND PISTON CYLINDER AND PISTON CYLINDER AND PISTON

Preparation for removal

CYLINDER AND PISTON REMOVAL Cylinder head Bolt (cylinder) Cylinder Gasket Dowel pin Piston pin clip Piston pin Piston Piston ring set

Refer to “CYLINDER HEAD” section.

Refer to “REMOVAL POINTS”.

CYLINDER AND PISTON ENG REMOVAL POINTS Piston

1. Remove: • Piston pin clips 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 4. Piston pin puller: YU-1304/90890-01304 CAUTION: Do not use a hammer to drive the piston pin out. Piston ring 1. Remove: • Piston rings NOTE: Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown, as shown in the illustration.

INSPECTION Cylinder and piston

1. Inspect: • Cylinder and piston walls Vertical scratches → Replace cylinder and piston. 2. Measure: • Piston-to-cylinder clearance Measurement steps: 1st step: • Measure the cylinder bore “C” with a 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.

CYLINDER AND PISTON ENG Cylinder bore “C”

“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.

• Measure the piston skirt diameter “P” with a micrometer. a 8 mm (0.315 in) from the piston bottom edge Piston size “P” Standard

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

3rd step: • Calculate the piston-to-cylinder clearance with following formula: Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance: 0.040 ~ 0.065 mm (0.0016 ~ 0.0026 in) <Limit>: 0.1 mm (0.004 in) • If out of specification, replace the cylinder, and replace the piston and piston rings as set.

Ovalisation “R” 0,05 mm (0,002 in)

CYLINDER AND PISTON ENG Piston ring

1. Measure: • Ring side clearance Use a feeler gauge 1. Out of specification → Replace the piston and rings as a set. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance. Side clearance: Standard

• 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:

CYLINDER AND PISTON ENG Piston pin

1. Inspect: • Piston pin Blue discoloration/grooves → Replace, then inspect the lubrication system. 2. Measure: • Piston pin-to-piston clearance Measurement steps: • Measure the outside diameter (piston pin) a. If out of specification, replace the piston pin. Outside diameter (piston pin): 17.991 ~ 18.000 mm (0.7083 ~ 0.7087 in) • Measure the inside diameter (piston) b. Inside diameter (piston): 18.004 ~ 18.015 mm (0.7088 ~ 0.7093 in) • Calculate the piston pin-to-piston clearance with the following formula. Piston pin-to-piston clearance = Inside diameter (piston) b – Outside diameter (piston pin) a • If out of specification, replace the piston. Piston pin-to-piston clearance: 0.004 ~ 0.024 mm (0.00016 ~ 0.00094 in) <Limit>: 0.07 mm (0.003 in)

ASSEMBLY AND INSTALLATION Piston

1. Install: • Piston rings Onto the piston. NOTE: • Be sure to install the piston rings so that the manufacturer’s marks or numbers are located on the upper side of the rings. • Lubricate the piston and piston rings liberally with engine oil. 4 - 50

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

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 clips 3 New 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. 4. Lubricate: • Piston • Piston rings • Cylinder

Apply a liberal coating of engine oil. Cylinder 1. Install: • Gasket 1 New • 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. 2. Install: • Bolt (cylinder) T.

1 Push rod and push lever removal

2 Push rod 1 disassembly 3 Friction plate and clutch plate removal 4 Clutch housing removal

CLUTCH REMOVAL Drain the engine oil.

Preparation for removal

2 3 4 5 6 7 8 9 10 11

Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Refer to “ENGINE REMOVAL” section. Disconnect at engine side.

Clutch cable Clutch cover Gasket Dowel pin Clutch spring Pressure plate Push rod 1 Circlip Plain washer Bearing Ball Push rod 2

12 13 14 15 16 17 18 19

Clutch plate Friction plate Nut Lock washer Clutch boss Thrust washer Clutch housing Push lever

Refer to “REMOVAL POINTS”.

REMOVAL POINTS EC483211

1. Remove: • 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. È

Clutch holding tool: YM-91042/90890-04086 È For USA and CDN

É Except for USA and CDN EC494000

Clutch housing and boss

1. Inspect: • Clutch housing 1 Cracks/wear/damage → Replace. • Clutch boss 2 Scoring/wear/damage → Replace.

1. Check: • Circumferential play Free play exists → Replace. • Gear teeth a Wear/damage → Replace. EC484400

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

1. Measure: • Friction plate thickness Out of specification → Replace friction plate as a set. Measure at all four points. Friction plate thickness: 2.92 ~ 3.08 mm (0.115 ~ 0.121 in) <Limit>: 2.8 mm (0.110 in) EC484600

1. Measure: • Clutch plate warpage Out of specification → Replace clutch plate as a set. Use a surface plate 1 and thickness gauge 2. Warp limit: 0.1 mm (0.004 in)

1. Inspect: • Push lever 1 Wear/damage → Replace.

1. Inspect: • Push rod 1 1 • Bearing 2 • Plain washer 3 • Push rod 2 4 • Ball 5 Wear/damage/bend → Replace. 4 - 55

ASSEMBLY AND INSTALLATION Push lever

1. Install: • Push lever 1 NOTE: • Apply the lithium soap base grease on the oil seal lip. • Apply the engine oil on the push lever.

1. Install: • 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 New • Nut (clutch boss) 2 T.

• Install the lock washer with its concaves fitted over the convexes of the clutch boss. • Use the clutch holding tool 3 to hold the clutch boss. È

Clutch holding tool:

YM-91042/90890-04086 È For USA and CDN É Except for USA and CDN

• Friction plate 1 • Clutch plate 1 [t = 2.0 mm (0.079 in)] 2 • Clutch plate 2 [t = 1.6 mm (0.063 in)] 3

• Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate. • Apply the engine oil on the friction plates and clutch plates. • Check the clutch plate for thickness and install 4 thicker ones a on the engine side and 3 thinner ones b on the outside.

• Bearing 1 • Plain washer 2 • Circlip 3 New To push rod 1 4. NOTE: Apply the engine oil on the bearing and plain washer.

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

• Disque garni 1 • Plateau de pression 1 [t = 2,0 mm (0,079 in)] 2 • Plateau de pression 2 [t = 1,6 mm (0,063 in)] 3

• Clutch spring • Bolt (clutch spring) T.

Tighten the bolts in stage, using a crisscross pattern.

• Gasket (clutch cover) 1 New • Dowel pin 2

• Clutch cover 1 • Bolt (clutch cover) T.

Tighten the bolts in stage, using a crisscross pattern.

OIL FILTER, WATER PUMP AND CRANKCASE COVER

ENG OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT)

OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT)

1 Oil filter removal

3 Crankcase cover (right) removal

2 Water pump removal

OIL FILTER, WATER PUMP AND CRANKCASE COVER

(RIGHT) REMOVAL 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. Refer to “EXHAUST PIPE AND SILENCER” section. Refer to “ENGINE REMOVAL” section. Refer to “CLUTCH” section.

Clutch cover Oil filter cover Oil filter Coolant pipe 2 Water pump housing Pin Oil tank breather hose

OIL FILTER, WATER PUMP AND CRANKCASE COVER

8 9 10 11 12 13 14 15 16

Kickstarter Crankcase cover (right) Gasket Dowel pin/O-ring Impeller Plain washer Impeller shaft Oil seal 1 Oil seal 2 Bearing

1 1 1 3/1 1 1 1 1 1 1

Refer to “REMOVAL POINTS”.

OIL FILTER, WATER PUMP AND CRANKCASE COVER

ENG REMOVAL POINTS EC4G3110

1. Remove: • Impeller 1 • Plain washer 2 • Impeller shaft 3 NOTE: Hold the impeller shaft on its width across the flats a with spanners, etc. and remove the impeller.

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. 1. Remove: • Bearing 1 • Oil seal 2

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

OIL FILTER, WATER PUMP AND CRANKCASE COVER

1. Inspect: • Bearing Rotate inner race with a finger. Rough spot/seizure → Replace.

1. Inspect: • Oil seal Wear/damage → Replace.

ASSEMBLY AND INSTALLATION EC4G5110

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

OIL FILTER, WATER PUMP AND CRANKCASE COVER

• 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 engine oil on the oil seal lip, bearing and impeller shaft. And install the shaft while turning it. • Hold the impeller shaft on its width across the flats a with spanners, etc. and install the impeller.

Crankcase cover (right)

1. Install: • Dowel pin 1 • O-ring 2 New • Collar 3 • Gasket 4 New

• Crankcase cover (right) 1 12 Nm (1.2 m · kg, 8.7 ft · lb) • Bolt 2 10 Nm (1.0 m · kg, 7.2 ft · lb) • Bolt R.

• Apply the engine oil on the impeller shaft end. • When installing the crankcase cover onto the crankcase, be sure that the impeller shaft end 2 aligns with the balancer end slot 3. • Tighten the bolts in stage, using a crisscross pattern.

OIL FILTER, WATER PUMP AND CRANKCASE COVER

1. Install: • Kickstarter 1 • Plain washer • Bolt (kickstarter) T.

Install so that there is a clearance a of 8 mm (0.31 in) or more between the kickstarter and frame and that the kickstarter does not contact the crankcase cover when it is pulled.

• Oil tank breather hose 1 • Clamp 2 T.

1. Install: • Dowel pin 1 • O-ring 2 New

• Water pump housing 1 • Bolt (water pump housing) 2 T.

• Plain washer 3 New

• Coolant drain bolt 4 T.

OIL FILTER, WATER PUMP AND CRANKCASE COVER

• O-ring • Coolant pipe 1 • Bolt (coolant pipe) 2 T.

1. Install: • Oil filter 1 • O-ring 2 New • Oil filter cover 3 • Bolt (oil filter cover) T.

1 Balancer drive gear

BALANCER REMOVAL Clutch housing

Crankcase cover (right)

Preparation for removal

Refer to “CLUTCH” section.

Refer to “OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT)” section. Refer to “AC MAGNETO AND STARTER CLUTCH” section.

Nut (primary drive gear) Nut (balancer driven gear) Lock washer Balancer Straight key

Refer to “REMOVAL POINTS”.

1 Balancer drive gear

Conical washer Primary drive gear Balancer drive gear Lock washer Balancer driven gear

REMOVAL POINTS Balancer, balancer drive gear and balancer driven gear

1. Straighten the lock washer tab. 2. Loosen: • Nut (balancer) 1 • Nut (primary drive gear) 2 • Nut (balancer driven gear) 3 NOTE: Place an aluminum plate a between the teeth of the balancer drive gear 4 and balancer driven gear 5.

INSPECTION Primary drive gear, balancer drive gear and balancer driven gear

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

1. Inspect: • Balancer Cracks/damage → Replace.

ASSEMBLY AND INSTALLATION Balancer, balancer drive gear and balancer driven gear

1. Install: • Balancer driven gear 1 NOTE: Install the balancer driven gear and balancer shaft with their lower splines a aligning with each other. 2. Install: • Balancer drive gear 1 NOTE: • Align the punched mark a on the balancer drive gear with the punched mark b on the balancer driven gear. • Install the balancer driven gear and crankshaft with the lower splines c aligning with each other. 3. Install: • Lock washer 1 • Nut (balancer driven gear) 2

• Primary drive gear 3

• Conical washer 4 • Nut (primary drive gear) 5 T.

Balancer 7 Lock washer 8 Nut (balancer) 9 T.

• Apply engine oil to the contact surface and threaded portion of the nut (primary drive gear). • Place an aluminum plate a between the teeth of the balancer drive gear 0 and balancer driven gear A. • Install the conical washer with its convex surface b outward. 4. Bend the lock washer tab.

OIL PUMP REMOVAL AND DISASSEMBLY Clutch housing

Crankcase cover (right)

Preparation for removal

2 Oil pump disassembly

2 3 4 5 6 7 8 9 10 11 12

Plain washer Oil pump drive gear Oil pump assembly Dowel pin Outer rotor 2 Circlip Inner rotor 2 Pin Oil pump cover Outer rotor 1 Inner rotor 1

Refer to “CLUTCH” section.

Refer to “OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT)” section. 1 1 1 1 2 1 1 1 1 1 1 1

Pin Washer Oil pump drive shaft Rotor housing

1. Inspect: • Oil pump drive gear • Oil pump driven gear • Rotor housing • Oil pump cover Cracks/wear/damage → Replace.

• Tip clearance a Between the inner rotor 1 and the outer rotor 2. • Tip clearance b Between the outer rotor 2 and the rotor housing 3. Out of specification → Replace the oil pump. Tip clearance a: 0.12 mm or less (0.0047 in or less) <Limit>: 0.20 mm (0.008 in) Tip clearance b: 0.09 ~ 0.17 mm (0.0035 ~ 0.0067 in) <Limit>: 0.24 mm (0.009 in) Side clearance c: 0.03 ~ 0.10 mm (0.0012 ~ 0.0039 in) <Limit>: 0.17 mm (0.007 in) 3. Check: • Unsmooth → Repeat steps #1 and #2 or replace the defective parts.

ASSEMBLY AND INSTALLATION Oil pump

1. Install: • Oil pump drive shaft 1 • Washer 2 • Pin 3 • Inner rotor 1 4 NOTE: • Apply the engine oil on the oil pump drive shaft and inner rotor 1. • Fit the pin into the groove in the inner rotor 1. 4 - 72

• Outer rotor 1 1 NOTE: Apply the engine oil on the outer rotor 1.

• Oil pump cover 1 • Screw (oil pump cover) 2 T.

• Inner rotor 2 4 • Circlip 5 New NOTE: • Apply the engine oil on the oil pump drive shaft end and inner rotor 2. • Fit the pin into the groove in the inner rotor 2.

• Outer rotor 2 1 • Dowel pin 2 • Oil pump assembly 3 • Bolt (oil pump assembly) 4 T.

Apply the engine oil on the outer rotor 2.

• Oil pump drive gear 1 • Plain washer 2 • Circlip 3 New NOTE: Apply the engine oil on the oil pump drive gear inner circumference.

KICK AXLE AND SHIFT SHAFT ENG KICK AXLE AND SHIFT SHAFT KICK AXLE AND SHIFT SHAFT

3 Shift shaft removal

2 3 4 5 6 7 8 9 10 11 12

KICK AXLE AND SHIFT SHAFT REMOVAL Oil pump

Kick idle gear Kick axle assembly Spring guide Torsion spring Ratchet wheel Kick gear Kick axle Plain washer Shift pedal Shift shaft Collar Torsion spring

1 1 1 1 1 1 1 1 1 1 1

Preparation for removal

2 Kick axle disassembly

Refer to “OIL PUMP” section.

Refer to “REMOVAL POINTS”.

KICK AXLE AND SHIFT SHAFT Extent of removal

13 14 15 16 17 18 19 20 21 22 23

Roller Shift guide Shift lever assembly Shift lever Pawl Pawl pin Spring Bolt (stopper lever) Stopper lever Torsion spring Segment

1 1 1 1 2 2 2 1 1 1 1

Refer to “REMOVAL POINTS”.

Refer to “REMOVAL POINTS”.

KICK AXLE AND SHIFT SHAFT ENG Kick axle assembly

1. Remove: • Kick axle assembly 1 NOTE: Unhook the torsion spring 2 from the hole a in the crankcase.

Shift guide and shift lever assembly

1. Remove: • 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

1. Remove: • Bolt (segment) 1 • Segment 2 NOTE: Turn the segment counterclockwise until it stops and loosen the bolt. CAUTION: If the segment gets an impact, it may be damaged. Take care not to give an impact to the segment when removing the bolt.

Kick axle and ratchet wheel

1. Check: • Ratchet wheel 1 smooth movement Unsmooth movement → Replace. • Kick axle 2 Wear/damage → Replace. • Spring 3 Broken → Replace. 4 - 76

1. Déposer: • Boulon (segment) 1 • Segment 2

KICK AXLE AND SHIFT SHAFT ENG EC4C4300

Kick gear, kick idle gear and ratchet wheel

1. Inspect: • Kick gear 1 • Kick idle gear 2 • Ratchet wheel 3 • Gear teeth a • Ratchet teeth b Wear/damage → Replace. EC4B4400

1. Inspect: • Shift shaft 1 Bend/damage → Replace. • Spring 2 Broken → Replace.

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

KICK AXLE AND SHIFT SHAFT ENG EC4C5000

ASSEMBLY AND INSTALLATION Segment

1. Install: • Segment 1 • Bolt (segment) T.

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

1. Install: • Torsion spring 1 • Plain washer 2 • Stopper lever 3 • Bolt (stopper lever) 4

Align the stopper lever roller with the slot on segment. Shift guide and shift lever assembly 1. Install: • Spring 1 • Pawl pin 2 • Pawl 3 To shift lever 4. NOTE: Apply the engine oil on the springs, pawl pins and pawls. 2. Install: • Shift lever assembly 1 To shift guide 2.

KICK AXLE AND SHIFT SHAFT ENG

• 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.

• Bolt (shift guide) 1 T.

1. Install: • Roller 1 • Collar 2 • Torsion spring 3 • Plain washer 4 • Shift shaft 5 NOTE: Apply the engine oil on the roller and shift shaft. 2. Install: • Shift pedal Refer to “AC MAGNETO AND STARTER CLUTCH” section.

KICK AXLE AND SHIFT SHAFT ENG Kick axle assembly

1. Install: • Kick gear 1 • Plain washer 2 • Circlip 3 New • Ratchet wheel 4 • Spring 5 • Plain washer 6 • Circlip 7 New To kick axle 8. NOTE: • Apply the molybdenum disulfide oil on the inner circumferences of the kick gear and ratchet wheel. • Align the punch mark a on the ratchet wheel with the punch mark b on the kick axle.

• Torsion spring 1 To kick axle 2. NOTE: Make sure the stopper a of the torsion spring fits into the hole b on the kick axle.

• Spring guide 1 NOTE: Slide the spring guide into the kick axle, make sure the groove a in the spring guide fits on the stopper of the torsion spring.

KICK AXLE AND SHIFT SHAFT ENG

• Kick axle assembly 1 • Plain washer 2 NOTE: • Apply the molybdenum disulfide grease on the contacting surfaces of the kick axle stopper a and ratchet wheel guide 3. • Apply the engine oil on the kick axle. • Slide the kick axle assembly into the crankcase and make sure the kick axle stopper fits into the ratchet wheel guide.

• Torsion spring 1 NOTE: Turn the torsion spring clockwise and hook into the proper hole a in the crankcase.

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

1 Starter clutch/wheel gear removal

3 Pickup coil/stator removal

AC MAGNETO AND STATOR REMOVAL Drain the engine oil.

Preparation for removal

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

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

Disconnect the AC magneto lead.

Shift pedal Cover (torque limiter) Torque limiter Crankcase cover (left) Gasket Dowel pin

Bearing Shaft Nut (rotor) Rotor

Starter clutch assembly cover Starter clutch Starter clutch drive gear Holder Pick-up coil Stator

Use special tool. Refer to “REMOVAL POINTS”.

Refer to “REMOVAL POINTS”.

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

REMOVAL POINTS Rotor

1. Remove: • Nut (rotor) 1 • Plain washer Use the sheave holder 2.

1. Remove: • Starter clutch assembly cover 1

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

Using a thin screwdriver or the like, remove the plate a while prying it upward little by little.

INSPECTION AC magneto

1. Inspect: • Rotor inner surface a • Stator outer surface b Damage → Inspect the crankshaft runout and crankshaft bearing. If necessary, replace AC magneto and/or stator. 4 - 84

1. Inspect: • Woodruff key 1 Damage → Replace.

1. Check: • Starter clutch Damage/wear → Replace. 2. Check: • Idle gear • Idle gear shaft • Starter clutch gear Pitting/burrs/chips/roughness/wear → Replace the defective parts. 3. Check: • Starter clutch operation • Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch. • When turning the starter clutch drive gear counterclockwise É, the starter clutch and the starter clutch drive gear should engage. If the starter clutch drive gear and starter clutch do not engage, the starter clutch is faulty and must be replaced. • When turning the starter clutch drive gear clockwise È, it should turn freely. If the starter clutch drive gear does not turn freely, the starter clutch is faulty and must be replaced.

1. Check: • Torque limiter Damage/wear → Replace.

ASSEMBLY AND INSTALLATION AC magneto and starter clutch

1. Install: • Stator 1 • Bolt (stator) 2 T.

• Holder 4 • Bolt 5 T.

• Pass the AC magneto lead 5 under the pickup coil. • Pass the AC magneto lead 4 under the holder as shown. • Take care not to catch the AC magneto lead between crankcase cover ribs. • Tighten the bolt (stator) using the T25 bit. • Apply the sealant to the grommet of the AC magneto lead. YAMAHA Bond No. 1215 (ThreeBond® No. 1215): 90890-85505

• Starter clutch drive gear 1 NOTE: Apply the engine oil on the starter clutch drive gear inner circumference.

• Install the starter clutch with its plate side upward. • While installing the starter clutch, push in the projections a one by one on the clutch circumference. • Push in the starter clutch until it hits the rotor. 4. Install: • Starter clutch assembly cover 1 To rotor 2.

Install the starter clutch assembly cover by fitting its pawls a into the groove b in the rotor.

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

• Plain washer (rotor) • Nut (rotor) 1 T.

Use the sheave holder 2.

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

YS-1880-A/90890-01701 4 - 87

• Shaft 1 • Bearing 2 • Idle gear 2 3 NOTE: Apply the engine oil on the shaft, bearing and idle gear inner circumference.

• Dowel pin • Gasket [crankcase cover (left)] New • Crankcase cover (left) 1 • Bolt [crankcase cover (left)] T.

Tighten the bolts in stage, using a crisscross pattern. 9. Install: • Plain washer • Torque limiter 1 • Plain washer

Apply the engine oil to the shaft and plain washers.

Install the cover (idle gear 1) with its mark a facing upward. 11. Connect: • AC magneto lead Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. 12. Install: • Shift pedal 1 • Bolt (shift pedal) T.

When installing the shift pedal onto the shift shaft, be sure that the center of the shift pedal is about 5.1 mm (0.2 in) a above the top of the footrest. 4 - 88

Preparation for removal

ENGINE REMOVAL Hold the machine by placing the suitable stand under the frame. Drain the engine oil Seat, fuel tank and side cover Radiator Exhaust pipe and silencer Air cut-off valve assembly Clutch cable and guide Shift pedal Rear shock absorber Carburetor

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

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

Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Refer to “RADIATOR” section. Refer to “EXHAUST PIPE AND SILENCER” section. Refer to “AIR INDUCTION SYSTEM” section. Disconnect at the engine side. Refer to “AC MAGNETO AND STARTER CLUTCH” section. Refer to “REAR SHOCK ABSORBER” section in the CHAPTER 6 Refer to “CARBURETOR” section.

Cylinder head breather hose

Ignition coil Disconnect the AC magneto lead. Disconnect the starter motor lead. Negative battery lead Engine guard Neutral switch Chain cover Nut (drive sprocket) Lock washer Drive sprocket Clip Bolt (brake pedal) Brake pedal

Refer to “CAMSHAFTS” section.

Refer to “ELECTRIC STARTING SYSTEM” section in the CHAPTER 6.

Disconnect at the starter motor side. 1 1 1 1 1 1 1 1 1

Refer to “REMOVAL POINTS”.

Engine upper bracket (right) Engine upper bracket (left) Engine lower bracket Engine mounting bolt Pivot shaft Engine

Refer to “REMOVAL POINTS”.

REMOVAL POINTS EC4F3100

1. Remove: • Nut (drive sprocket) 1 • Lock washer 2 NOTE: • Straighten the lock washer tab. • Loosen the nut while applying the rear brake. 2. Remove: • Drive sprocket 1 • Drive chain 2 NOTE: Remove the drive sprocket together with the drive chain.

1. Remove: • Pivot shaft 1 NOTE: If the pivot shaft is pulled all the way out, the swingarm will come loose. If possible, insert a shaft of similar diameter into the other side of the swingarm to support it. 2. Remove: • Engine 1 From right side.

Make sure that the couplers, hoses and cables are disconnected.

ASSEMBLY AND INSTALLATION Engine installation

1. Install: • Engine 1 Install the engine from right side. • Pivot shaft 2 T.

• Engine mounting bolt (lower) 3

• Engine lower bracket 4

• Bolt (engine lower bracket) 5 T.

• Engine mounting bolt (front) 7 T.

• Engine upper bracket (right) 8

• Engine upper bracket (left) 9 • Bolt (engine upper bracket) 0 T.

• Engine mounting bolt (upper) A T.

• Apply the molybdenum disulfide grease on the pivot shaft. • Install the patch with the claw a facing outside the chassis.

1. Install: • Spring 1 • Brake pedal 2 • O-ring 3 New • Bolt (brake pedal) 4 T.

NOTE: Apply the lithium soap base grease on the bolt, O-rings and brake pedal bracket.

1. Install: • Drive sprocket 1 • Drive chain 2 NOTE: Install the drive sprocket together with the drive chain.

• Lock washer 1 New • Nut (drive sprocket) 2 T.

Tighten the nut while applying the rear brake.

3. Bend the lock washer tab to lock the nut.

4. Install: • Chain guide • Chain cover 1 • Screw (chain cover) 2

• Spring 1 • Pin 2 • O-ring 3 New • Neutral switch 4 • Screw (neutral switch) 5 T.

Apply the lithium soap base grease on the Oring.

CRANKCASE AND CRANKSHAFT ENG CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT

1 Crankcase separation

2 Crankshaft removal

CRANKCASE SEPARATION Engine

Preparation for removal

Refer to “ENGINE REMOVAL” section.

Refer to “CYLINDER AND PISTON” section. Refer to “BALANCER” section.

Kick axle assembly Segment Stator

Refer to “KICK AXLE AND SHIFT SHAFT” section.

Refer to “AC MAGNETO AND STARTER CLUTCH” section.

Timing chain guide (rear)

Timing chain Bolt (50 mm) Bolt (60 mm) Bolt (80 mm) Hose guide Clutch cable holder Crankcase (right) Crankcase (left)

Refer to “REMOVAL POINTS”.

CRANKCASE AND CRANKSHAFT Extent of removal

Oil strainer Balancer shaft Crankshaft

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

CRANKCASE AND CRANKSHAFT ENG CRANKCASE BEARING

1 Crankcase bearing removal

Preparation for removal

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

Refer to “TRANSMISSION, SHIFT CAM AND SHIFT FORK” section.

Refer to “REMOVAL POINTS”.

CRANKCASE AND CRANKSHAFT ENG REMOVAL POINTS Crankcase

1. Separate: • Crankcase (right) • Crankcase (left) Separation steps: • Remove the crankcase bolts, hose guide and clutch cable holder. NOTE: Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them. • Remove the crankcase (right). 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 crankcase (right) horizontally while lightly patting the case splitting slit and engine mounting boss using a soft hammer, and leave the crankshaft and transmission with the crankcase (left).

Use soft hammer to tap on the case half. Tap only on reinforced portions of case. Do not tap on gasket mating surface. Work slowly and carefully. Make sure the case halves separate evenly. If the cases do not separate, check for a remaining case screw or fitting. Do not force. • Remove the dowel pins and O-ring.

1. Remove: • Balancer shaft 1 NOTE: Remove the balancer shaft with its flat side a facing the crankshaft.

CRANKCASE AND CRANKSHAFT ENG Crankshaft

1. Remove: • Crankshaft 1 Use the crankcase separating tool 2. Crankcase separating tool: YU-A9642/90890-04152 CAUTION: Do not use a hammer to drive out the crankshaft.

1. Remove: • 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

1. Inspect: • Timing chain Cracks/stiff → Replace the timing chain and camshaft sprocket as a set. 2. Inspect: • Timing chain guide Wear/damage → Replace. EC4N4101

1. Inspect: • Contacting surface a Scratches → Replace. • Engine mounting boss b, crankcase Cracks/damage → Replace.

CRANKCASE AND CRANKSHAFT ENG

• Bearing Rotate inner race with a finger. Rough spot/seizure → Replace. 3. Inspect: • Oil seal Wear/damage → Replace.

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

Small end free play:

1. Inspect: • Oil strainer Damage → Replace.

CRANKCASE AND CRANKSHAFT ENG EC4N5000

ASSEMBLY AND INSTALLATION Crankshaft bearing

1. Install: • Bearing New • Bearing stopper • Bolt (bearing stopper) T.

• Screw (bearing stopper)

• Screw [bearing stopper (crankshaft)] 1

To crankcase (left and right).

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.

1. Install: • Crankshaft 1 Use the crankshaft installing tool 2, 3, 4 and 5.

É Except for USA and CDN

CRANKCASE AND CRANKSHAFT ENG 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.

• Shifter operation • Transmission operation Unsmooth operation → Repair.

• Oil strainer 1 • Bolt (oil strainer) 2 T.

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

CRANKCASE AND CRANKSHAFT ENG

• Dowel pin 1 • O-ring 2 New • Crankcase (right) To crankcase (left). NOTE: • Fit the crankcase (right) onto the crankcase (left). Tap lightly on the case with soft hammer. • When installing the crankcase, the connecting rod should be positioned at TDC (top dead center).

Tighten the crankcase tightening bolts in stage, using a crisscross pattern. 7. Install: • Timing chain • Timing chain guide (rear) • Bolt (timing chain guide) T.

• Sealant Forced out on the cylinder mating surface. 9. Apply: • Engine oil To the crank pin, bearing and oil delivery hole. 10. Check: • Crankshaft and transmission operation. Unsmooth operation → Repair.

TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK

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

TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVAL Engine

Separate the crankcase.

Preparation for removal

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. 1 1 1 1 1 1 1

Refer to “REMOVAL POINTS”.

TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG EC4H3000

REMOVAL POINTS Shift fork, shaft cam and transmission

1. Remove: • 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.

1. Inspect: • Matching dog a • Gear teeth b • Shift fork groove c Wear/damage → Replace.

• O-ring 1 Damage → Replace. 3. Check: • Gears movement Unsmooth movement → Repair or replace.

TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG EC4H4600

1. Inspect: • Bearing 1 Rotate inner race with a finger. Rough spot/seizure → Replace.

Shift fork, shift cam and segment

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

• Shift cam 1 • Segment 2 Bend/wear/damage → Replace.

• Shift fork movement Unsmooth operation → Replace shift fork. NOTE: For a malfunctioning shift fork, replace not only the shift fork itself but the two gears each adjacent to the shift fork.

TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG ASSEMBLY AND INSTALLATION Transmission

1. Install: • 5th pinion gear (25T) 1 • 3rd pinion gear (16T) 2 • Collar 3 • 4th pinion gear (20T) 4 • 2nd pinion gear (15T) 5 To main axle 6. NOTE: Apply the molybdenum disulfide oil on the inner and end surface of the idler gear and on the inner surface of the sliding gear, then install.

• Collar 1 • 2nd wheel gear (26T) 2 • 4th wheel gear (21T) 3 • 3rd wheel gear (21T) 4 • 5th wheel gear (21T) 5 • Collar 6 • 1st wheel gear (29T) 7 • O-ring 8 To drive axle 9. NOTE: • Apply the molybdenum disulfide oil on the inner and end surface of the idler gear and on the inner surface of the sliding gear, then install. • Apply the lithium soap base grease on the Oring.

TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG

• Plain washer 1 • Circlip 2 New NOTE: • Be sure the circlip sharp-edged corner a is positioned opposite side to the plain washer and gear b. • Install the circlip with its ends c settled evenly on the spline crests.

• Collar 1 NOTE: • Apply the lithium soap base grease on the oil seal lip. • When installing the spacer into the crankcase, pay careful attention to the crankcase oil seal lip.

• 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, SHIFT CAM AND SHIFT FORK ENG

• Transmission assembly 1 To crankcase (left) 2. NOTE: Apply the engine oil on the bearings and guide bars.

• Shifter operation • Transmission operation Unsmooth operation → Repair.

FRONT WHEEL AND REAR WHEEL CHAS EC500000

FRONT WHEEL AND REAR WHEEL EC598000

1 Front wheel removal

3 Brake disc removal

FRONT WHEEL REMOVAL Hold the machine by placing the suitable stand under the engine.

Preparation for removal

2 Wheel bearing removal

Nut (front wheel axle) Front wheel axle Front wheel Speed sensor Collar Oil seal Bearing Brake disc

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

Refer to “REMOVAL POINTS”.

FRONT WHEEL AND REAR WHEEL CHAS EC598100

1 Rear wheel removal

3 Brake disc removal

REAR WHEEL REMOVAL Hold the machine by placing the suitable stand under the engine.

Preparation for removal

2 Wheel bearing removal

Nut (rear wheel axle)

Rear wheel axle Chain puller Rear wheel Collar Driven sprocket Oil seal Circlip Bearing Brake disc

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

Refer to “REMOVAL POINTS”.

Refer to “REMOVAL POINTS”.

FRONT WHEEL AND REAR WHEEL CHAS EC593000

REMOVAL POINTS EC523101

1. Remove: • Wheel 1 NOTE: Push the wheel forward and remove the drive chain 2. EC513201

Wheel bearing (if necessary)

1. Remove: • Bearing 1 NOTE: Remove the bearing using a general bearing puller 2.

1. Measure: • Wheel runout Out of limit → Repair/replace. Wheel runout limit: Radial 1: 2.0 mm (0.08 in) Lateral 2: 2.0 mm (0.08 in) 2. Inspect: • Bearing Rotate inner race with a finger. Rough spot/seizure → Replace. NOTE: Replace the bearings, oil seal and wheel collar as a set.

FRONT WHEEL AND REAR WHEEL CHAS EC514200

1. Measure: • Wheel axle bends Out of specification → Replace. Use the dial gauge 1. Wheel axle bending limit: 0.5 mm (0.020 in) NOTE: The bending value is shown by one half of the dial gauge reading. WARNING Do not attempt to straighten a bent axle.

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

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

FRONT WHEEL AND REAR WHEEL CHAS EC595000

ASSEMBLY AND INSTALLATION Front wheel

1. Install: • Bearing (left) 1 • Spacer 2 • Bearing (right) 3 • Oil seal 4 New NOTE: • Apply the lithium soap base grease on the bearing and oil seal lip when installing. • Use a socket that matches the outside diameter of the race of the bearing. • Left side of bearing shall be installed first. • Install the oil seal with its manufacture’s marks or numbers facing outward. CAUTION: Do not strike the inner race of the bearing. Contact should be made only with the outer race. 2. Install: • Brake disc 1 • Bolt (brake disc) 2 T.

Tighten the bolts in stage, using a crisscross pattern. 3. Install: • Collar 1 NOTE: Apply the lithium soap base grease on the oil seal lip.

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

FRONT WHEEL AND REAR WHEEL CHAS

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

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

• Nut (wheel axle) 1 T.

FRONT WHEEL AND REAR WHEEL CHAS

• Bolt (axle holder) 1 T.

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

1. Install: • Bearing (right) 1 • Circlip 2 New • Spacer 3 • Bearing (left) 4 • Oil seal 5 New NOTE: • Apply the lithium soap base grease on the bearing and oil seal lip when installing. • Install the bearing with seal facing outward. • Use a socket that matches the outside diameter of the race of the bearing. • Right side of bearing shall be installed first. • Install the oil seal with its manufacture’s marks or numbers facing outward. CAUTION: Do not strike the inner race of the bearing. Contact should be made only with the outer race.

FRONT WHEEL AND REAR WHEEL CHAS

• Brake disc 1 • Bolt (brake disc) 2 T.

Tighten the bolts in stage, using a crisscross pattern.

Tighten the nuts in stage, using a crisscross pattern. 4. Install: • 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.

FRONT WHEEL AND REAR WHEEL CHAS

• Chain puller (left) 1 • Wheel axle 2 NOTE: • Install the chain puller (left), and insert the wheel axle from left side. • Apply the lithium soap base grease on the wheel axle.

• Chain puller (right) 1 • Plain washer 2 • Nut (wheel axle) 3 NOTE: Temporarily tighten the nut (wheel axle) at this point.

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

• Nut (wheel axle) 1 T.

1 Brake hose removal

3 Master cylinder removal

FRONT BRAKE REMOVAL Hold the machine by placing the suitable stand under the engine.

Preparation for removal

Drain the brake fluid.

Brake hose holder (protector) Brake hose holder (caliper) Union bolt Brake hose Pad pin plug Pad pin Caliper Brake lever Master cylinder bracket Master cylinder

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

Refer to “REMOVAL POINTS”.

Remove when loosening the pad pin.

Loosen when disassembling the caliper.

Support de durit de frein (protection)

1 Master cylinder removal

2 Brake hose removal

REAR BRAKE REMOVAL 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.

Refer to “FRONT WHEEL AND REAR WHEEL” section.

Refer to “REMOVAL POINTS”.

Drain the brake fluid.

Brake pedal Master cylinder Brake hose holder Union bolt Brake hose Pad pin plug Pad pin Caliper

Remove when loosening the pad pin.

Loosen when disassembling the caliper.

1 Front caliper disassembly

CALIPER DISASSEMBLY Pad pin Brake pad Pad support Caliper piston Dust seal Piston seal

2 Rear caliper disassembly

Refer to “REMOVAL POINTS”.

Support de plaquette

1 Front master cylinder disassembly

MASTER CYLINDER DISASSEMBLY Master cylinder cap Diaphragm Reservoir float Master cylinder boot Circlip Plain washer Push rod Master cylinder kit

2 Rear master cylinder disassembly

Use a long nose circlip pliers.

REMOVAL POINTS Brake fluid

1. Remove: [Front] • Master cylinder cap 1 [Rear] • Master cylinder cap 1 • Protector 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.

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. EC533301

1. Remove: • 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 caliper to lock one caliper. • Carefully force the piston out of the caliper cylinder with compressed air. È Front É Rear

1. Remove: • 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.

1. Inspect: • Master cylinder inner surface a Wear/scratches → Replace master cylinder assembly. Stains → Clean.

WARNING Use only new brake fluid.

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

3. Inspect: (front brake only)

• Reservoir float 1 Damage → Replace.

• Master cylinder piston 1 • Master cylinder cup 2 Wear/damage/score marks → Replace master cylinder kit.

1. Inspect: • Caliper cylinder inner surface a Wear/score marks → Replace caliper assembly. È Front É Rear

• Caliper piston 1 Wear/score marks → Replace caliper piston assembly. WARNING Replace the piston seals and dust seals 2 whenever a caliper is disassembled.

1. Inspect: • Brake hose 1 Crack/damage → Replace.

ASSEMBLY AND INSTALLATION WARNING

• 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. 5 - 16

1. Clean: • Caliper • Piston seal • Dust seal • Caliper piston Clean them with brake fluid. 2. Install: • Piston seal 1 New • Dust seal 2 New

WARNING Always use new piston seals and dust seals.

NOTE: Fit the piston seals and dust seals onto the slot on caliper correctly. È Front É Rear

• Caliper piston 1 NOTE: Apply the brake fluid on the piston wall. CAUTION: • Install the piston with its shallow depressed side a facing the caliper. • Never force to insert. È Front É Rear

1. Install: • Pad support 1 • Brake pad 2 • Pad pin 3 NOTE: • Install the brake pads with their projections a into the caliper recesses b. • Temporarily tighten the pad pin at this point. 5 - 17

• Caliper 1 • Bolt (caliper) 2 T.

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

• Disc cover 1 • Bolt (disc cover) 2 T.

• Caliper 1 • Rear wheel 2 Refer to “FRONT WHEEL AND REAR WHEEL” section. 4. Tighten: • Pad pin 3 T.

1. Clean: • Master cylinder • Master cylinder kit Clean them with brake fluid. È

• Master cylinder cup (primary) 1 • Master cylinder cup (secondary) 2 To master cylinder piston 3.

Apply the brake fluid on the master cylinder cup.

WARNING After installing, cylinder cup should be installed as shown direction. Wrong installation cause improper brake performance.

• Spring 1 To master cylinder piston 2.

Install the spring at the smaller dia. side. È Front É Rear

[Front] • Master cylinder kit 1 • Plain washer 2 • Circlip 3 • Master cylinder boot 4 To master cylinder 5. [Rear] • Master cylinder kit 1 • Push rod 2 • Circlip 3 • Master cylinder boot 4 To master cylinder 5.

• Apply the brake fluid on the master cylinder kit. • Apply the lithium soap base grease on the tip of the push rod. • When installing the circlip, use a long nose circlip pliers. È Front É Rear

Front master cylinder

1. Install: • Master cylinder 1 • Master cylinder bracket 2 • Bolt (master cylinder bracket) 3 T.

• Install the bracket so that the arrow mark a face upward. • First tighten the bolts on the upper side of the master cylinder bracket, and then tighten the bolts on the lower side.

• Brake lever 1 • Bolt (brake lever) 2 T.

• Nut (brake lever) 3

Apply the lithium soap base grease on the brake lever sliding surface, bolt and contacting surface of the master cylinder piston. Rear master cylinder 1. Install: • Copper washer 1 New • Brake hose 2 • Union bolt 3 T.

WARNING Always use new copper washers.

CAUTION: Install the brake hose so that its pipe portion a directs as shown and lightly touches the projection b on the master cylinder.

• Master cylinder 1 • Bolt (master cylinder) 2 T.

• Spring 1 • Brake pedal 2 • O-ring 3 New • Bolt (brake pedal) 4 T.

NOTE: Apply the lithium soap base grease on the bolt, O-ring and brake pedal bracket. 5 - 21

• Pin 1 • Plain washer 2 • Cotter pin 3 New NOTE: After installing, check the brake pedal height. Refer to “REAR BRAKE ADJUSTMENT” section in the CHAPTER 3.

1. Install: • Copper washer 1 New • Brake hose 2 • Union bolt 3 T.

WARNING Always use new copper washers.

CAUTION: Install the brake hose so that its pipe portion a directs as shown and lightly touches the projection b on the caliper.

• Brake hose holder 1 • Bolt (brake hose holder) 2 T.

• Brake hose holder 1 • Nut (brake hose holder) 2 T.

Align the top a of the brake hose holder with the paint b of the brake hose.

4. Pass the brake hose through the hose guides 1.

• Copper washer 1 New • Brake hose 2 • Union bolt 3 T.

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.

1. Install: • Copper washer 1 New • Brake hose 2 • Union bolt 3 T.

WARNING Always use new copper washers.

CAUTION: Install the brake hose so that its pipe portion a directs as shown and lightly touches the projection b on the caliper.

• Brake hose holder 1 • Screw (brake hose holder) 2 T.

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.

1. Fill: • 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.

Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately. È Front É Rear

• Brake system Refer to “BRAKE SYSTEM AIR BLEEDING” section in the CHAPTER 3.

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

[Front] • Reservoir float • Diaphragm • Master cylinder cap 1 • Screw (master cylinder cap) 2

• Diaphragm • Master cylinder cap 1 • Bolt (master cylinder cap) 2

After installation, while pulling the lever in or pushing down on the pedal, check whether there is any brake fluid leaking where the union bolts are installed respectively at the master cylinder and caliper. È Front É Rear

5. Install: (rear brake only)

• Protector 1 • Bolt (protector) 2 T.

1 Front fork removal

FRONT FORK REMOVAL 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.

Refer to “FRONT WHEEL AND REAR WHEEL” section.

Refer to “FRONT BRAKE AND REAR BRAKE” section.

Handlebar Protector Pinch bolt (handle crown) Cap bolt Pinch bolt (under bracket) Front fork

Refer to “HANDLEBAR” section.

Loosen when disassembling the front fork. Only loosening.

1 2 3 4 5 6 7 8 9 0 A B C

2 Damper rod removal

FRONT FORK DISASSEMBLY Cap bolt Fork spring Dust seal Stopper ring Inner tube Outer tube Piston metal Slide metal Oil seal washer Oil seal Spring guide Base valve Damper rod

1 1 1 1 1 1 1 1 1 1 1 1 1

Refer to “REMOVAL POINTS”. Drain the fork oil. Refer to “REMOVAL POINTS”.

Refer to “REMOVAL POINTS”.

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.

REMOVAL POINTS EC553150

1. Remove: • Cap bolt 1 From the outer tube. NOTE: Before removing the front fork from the machine, loosen the cap bolt. 2. Remove: • Cap bolt 1 NOTE: Hold the locknut 2 and remove the cap bolt.

1. Remove: • 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 b. • Repeat this step until the inner tube can be pulled out from the outer tube. EC553311

1. Remove: • Base valve 1 • Damper rod 2 NOTE: Use a damper rod holder 3 to lock the damper rod. Damper rod holder: YM-01494/90890-01494 EC554000

1. Inspect: • 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.

1. Inspect: • Valve assembly 1 Wear/damage → Replace. • O-ring 2 Damage → Replace.

1. Measure: • Fork spring free length a Out of specification → Replace. Fork spring free length: Standard

1. Inspect: • Inner tube surface a Score marks → Repair or replace. Use #1,000 grit wet sandpaper. Damaged oil lock piece → Replace. • Inner tube bends Out of specification → Replace. Use the dial gauge 1. Inner tube bending limit: 0.2 mm (0.008 in) NOTE: The bending value is shown by one half of the dial gauge reading. WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube. EC554600

1. Inspect: • Outer tube 1 Score marks/wear/damage → Replace.

1. Inspect: • Cap bolt 1 • O-ring 2 • Air bleed screw 3 Wear/damage → Replace.

ASSEMBLY AND INSTALLATION Front fork assembly

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. 3. Install: • Copper washer 1 New • O-ring 2 • Base valve 3 To inner tube 4.

• Use a damper rod holder 2 to lock the damper rod 3. • Apply the LOCTITE® on the base valve thread. Damper rod holder: YM-01494/90890-01494 5 - 31

• Spring guide 1 • Locknut 2 To damper rod 3. NOTE: • Install the spring guide with its smaller dia. end a facing downward. • With its thread b facing upward, fully finger tighten the locknut onto the damper rod. 6. Install: • Dust seal 1 • Stopper ring 2 • Oil seal 3 New • Oil seal washer 4 • Slide metal 5 New To inner tube 6. NOTE: • Apply the fork oil on the inner tube. • When installing the oil seal, use vinyl seat a with fork oil applied to protect the oil seal lip. • Install the oil seal with its manufacture’s marks or number facing the axle holder side. • Install the oil seal washer with its projections b facing upward.

• Piston metal 1 New NOTE: Install the piston metal onto the slot on inner tube.

• 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-A0948/90890-01502

• Oil seal 1 NOTE: Press the oil seal into the outer tube with fork seal driver 2. Fork seal driver: YM-A0948/90890-01502

• 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.

15. Fill: • Front fork oil Until outer tube top surface with recommended fork oil 1. Recommended oil: Suspension oil “S1” CAUTION: • Be sure to use recommended fork oil. If other oils are used, they may have an excessively adverse effect on the front fork performance. • Never allow foreign materials to enter the front fork.

16. After filling, pump the damper rod 1 slowly up and down more than 10 times to distribute the fork oil.

17. Fill: • Front fork oil Until outer tube top surface with recommended fork oil once more.

18. After filling, pump the outer tube 1 slowly up and down (about 200 mm (7.9 in) stroke) to distribute the fork oil once more.

NOTE: Be careful not to excessive full stroke. A stroke of 200 mm (7.9 in) or more will cause air to enter. In this case, repeat the steps 15 to 18.

19. Wait ten minutes until the air bubbles have been removed from the front fork, and the oil has dispense evenly in system before setting recommended oil level.

NOTE: Fill with the fork oil up to the top end of the outer tube, or the fork oil will not spread over to every part of the front forks, thus making it impossible to obtain the correct level. Be sure to fill with the fork oil up to the top of the outer tube and bleed the front forks.

• Oil level (left and right) a Out of specification → Adjust. Standard oil level: 132 mm (5.20 in) * 125 mm (4.92 in) Extent of adjustment: 95 ~ 150 mm (3.74 ~ 5.91 in) From top of outer tube with inner tube and damper rod 1 fully compressed without spring. * Except for USA and CDN 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: 18 mm (0.71 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).

• 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.

• Spring seat 1 • Cap bolt 2 NOTE: Fully finger tighten the cap bolt onto the damper rod.

Hold the locknut 2 and tighten the cap bolt with specified torque.

• Protector guide 1 NOTE: Install the protector guide with its wider side a facing downward.

1. Install: • Front fork 1 NOTE: • Temporarily tighten the pinch bolts (under bracket). • Do not tighten the pinch bolts (handle crown) yet.

• Pinch bolt (under bracket) 2

Tighten the under bracket to specified torque. If torqued too much, it may cause the front fork to malfunction. 5 - 37

• Speed sensor lead 1 • Plate 1 2 • Bolt (plate 1) 3

To protector (right) 4.

Install the speed sensor lead so that its paint a directs as shown and align the bottom b of the plate 1 with the same paint.

• Speed sensor lead 1 • Plate 2 2 • Screw (plate 2) 3

To protector (right) 4.

NOTE: Install the plate 2 in the direction as shown.

• Protector 1 • Bolt (protector) 2 T.

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

• Protection 1 • Boulon (protection) 2

HANDLEBAR REMOVAL Headlight

Hot starter cable Hot starter lever holder Clutch cable Clutch lever holder “ENGINE STOP” button

7 8 9 10 11 12 13 14 15 16

Start switch Throttle cable cap Throttle cable #1 (pulled) Throttle cable #2 (pushed) Grip (right) Tube guide Grip (left) Handlebar holder (upper) Handlebar Handlebar holder (lower)

Preparation for removal

Disconnect at the lever side.

Disconnect at the lever side. Disconnect the clutch switch lead. Disconnect the “ENGINE STOP” button lead. Refer to “REMOVAL POINTS”. Disconnect the start switch lead. Disconnect at the throttle side. Disconnect at the throttle side. Refer to “REMOVAL POINTS”. Refer to “REMOVAL POINTS”.

1. Remove: • Master cylinder bracket 1 • Master cylinder 2 CAUTION: • Do not let the master cylinder hang on the brake hose. • Keep the master cylinder cap side horizontal to prevent air from coming in.

1. Remove: • Grip 1 NOTE: Blow in air between the handlebar or tube guide and the grip. Then remove the grip which has become loose.

1. Inspect: • 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 Handlebar

1. Install: • Handlebar holder (lower) 1 • Plain washer 2 • Nut [handlebar holder (lower)] 3 NOTE: • Install the handlebar holder (lower) with its side having the greater distance a from the mounting bolt center facing forward. • Apply the lithium soap base grease on the thread of the handlebar holder (lower). • Installing the handlebar holder (lower) in the reverse direction allows the front-to-rear offset amount of the handlebar position to be changed. • Do not tighten the nut yet.

• Handlebar 1 • Handlebar holder (upper) 2 • Bolt [handlebar holder (upper)] 3 T.

• The handlebar holder (upper) should be installed with the punched mark a forward. • Install the handlebar so that the marks b are in place on both sides. • Install the handlebar so that the projection c of the handlebar holder (upper) is positioned at the mark on the handlebar as shown. • First tighten the bolts on the front side of the handlebar holder (upper), and then tighten the bolts on the rear side.

• Nut [handlebar holder (lower)] 1 T.

• Grip (left) 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 grip (left) to the handlebar so that the line b between the two arrow marks faces straight upward. 5. Install: • Grip (right) 1 • Collar 2 Apply the adhesive on the tube guide 3. NOTE: • Before applying the adhesive, wipe off grease or oil on the tube guide surface a with a lacquer thinner. • Install the grip to the tube guide so that the grip match mark b and tube guide slot c form the angle as shown.

• Cover (grip cap) 1 • Throttle grip 2 NOTE: Apply the lithium soap base grease on the throttle grip sliding surface.

• Throttle cables 1 To tube guide 2. 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 T.

WARNING After tightening the screws, check that the throttle grip 3 moves smoothly. If it does not, retighten the bolts for adjustment.

• Cover (grip cap) 1 • Cover (throttle cable cap) 2

• Start switch 1 • Master cylinder 2 • Master cylinder bracket 3 • Bolt (master cylinder bracket) 4 T.

NOTE: • The start switch and master cylinder bracket should be installed according to the dimensions shown. • Install the bracket so that the arrow mark a faces upward. • First tighten the bolt on the upper side of the master cylinder bracket, and then tighten the bolt on the lower side. Zero mm (Zero in)

• “ENGINE STOP” button 1 • Clutch lever holder 2 • Bolt (clutch lever holder) 3 T.

• Hot starter lever holder 4

• Bolt (hot starter lever holder) 5 T.

NOTE: • The “ENGINE STOP” button, clutch lever holder and clamp should be installed according to the dimensions shown. • Pass the “ENGINE STOP” button lead in the middle of the clutch lever holder.

• Clutch cable 1 • Hot starter cable 2 NOTE: Apply the lithium soap base grease on the clutch cable end and hot starter cable end.

• Clutch lever free play Refer to “CLUTCH ADJUSTMENT” section in the CHAPTER 3. • Hot starter lever free play Refer to “HOT STARTER LEVER ADJUSTMENT” section in the CHAPTER 3.

1 Under bracket removal

STEERING REMOVAL 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.

Refer to “HANDLEBAR” section.

Disconnect the main switch lead.

Refer to “FRONT FORK” section. Use special tool. Refer to “REMOVAL POINTS”.

Bearing (upper) Bearing (lower) Bearing race

Refer to “REMOVAL POINTS”.

REMOVAL POINTS EC563202

1. Remove: • Ring nut 1 Use the ring nut wrench 2. Ring nut wrench: YU-33975/90890-01403 WARNING Support the steering shaft so that it may not fall down.

1. Remove: • Bearing (lower) 1 Use the floor chisel 2. CAUTION: Take care not to damage the steering shaft thread.

1. Remove: • Bearing race 1 Remove the bearing race using long rod 2 and the hammer.

1. Inspect: • Steering shaft 1 Bend/damage → Replace.

Bearing and bearing race

1. Wash the bearings and bearing races with a solvent. 2. Inspect: • Bearing 1 • Bearing race Pitting/damage → Replace bearings and bearing races as a set. Install the bearing in the bearing races. Spin the bearings by hand. If the bearings hang up or are not smooth in their operation in the bearing races, replace bearings and bearing races as a set.

ASSEMBLY AND INSTALLATION Under bracket

1. Install: • Bearing (lower) 1 NOTE: Apply the lithium soap base grease on the dust seal lip and bearing inner circumference.

• Bearing race • Bearing (upper) 1 • Bearing race cover 2 NOTE: Apply the lithium soap base grease on the bearing and bearing race cover lip.

• Under bracket 1 NOTE: Apply the lithium soap base grease on the bearing, the portion a and thread of the steering shaft.

Tighten the ring nut using the ring nut wrench 2.

Refer to “STEERING HEAD INSPECTION AND ADJUSTMENT” section in the CHAPTER 3.

5. Check the steering shaft by turning it lock to lock. If there is any binding, remove the steering shaft assembly and inspect the steering bearings.

• Front fork 1 • Handle crown 2 • Main switch 3 • Hose guide bracket 4 NOTE: • Temporarily tighten the pinch bolts (under bracket). • Do not tighten the pinch bolts (handle crown) yet. 8. Install: • Guide (speed sensor lead) 1 NOTE: After installing the guide as shown, pass the speed sensor lead through the guide.

• Plain washer 1 • Steering shaft nut 2 T.

10. After tightening the nut, check the steering for smooth movement. If not, adjust the steering by loosening the ring nut little by little.

11. Adjust: • Front fork top end a Front fork top end (standard) a: Zero mm (Zero in) 12. Tighten: • Pinch bolt (handle crown) 1 T.

• Pinch bolt (under bracket) 2

Tighten the under bracket to specified torque. If torqued too much, it may cause the front fork to malfunction. 13. Install: • Multi-function meter bracket 1 T.

Pass the throttle cables 3, clutch cable 4 and hot starter cable 5 between the multi-function meter bracket and handle crown.

• Install so that the marking a on the speed sensor lead aligns with the holder edge. • Fasten the speed sensor lead to the holder with the clamp.

Extent of removal: removal

SWINGARM REMOVAL Hold the machine by placing the suitable stand under the engine.

Preparation for removal

Rear caliper Bolt (brake pedal) Drive chain Chain support Chain tensioner (lower) Bolt (rear shock absorber-relay arm) Bolt (connecting rod) Pivot shaft Swingarm

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. 1 1 1 1 1 1

1 Swingarm disassembly

3 Relay arm removal and disassembly

SWINGARM DISASSEMBLY Cap Relay arm Connecting rod Collar Oil seal Thrust bearing Bush Oil seal Bearing

2 Connecting rod removal and disassembly

Remarks Refer to “REMOVAL POINTS”.

Refer to “REMOVAL POINTS”.

1. Remove: • Cap (left) 1 NOTE: Remove with a slotted-head screwdriver inserted under the mark a on the cap (left).

1. Remove: • Bearing 1 NOTE: Remove the bearing by pressing its outer race.

INSPECTION Wash the bearings, bushes and collars in a solvent.

1. Inspect: • Bearing 1 • Bush 2 Free play exists/unsmooth revolution/rust → Replace bearing and bush as a set. 2. Inspect: • Oil seal 3 Damage → Replace.

1. Inspect: • Bearing 1 • Collar 2 Free play exists/unsmooth revolution/rust → Replace bearing and collar as a set. 2. Inspect: • Oil seal 3 Damage → Replace. 5 - 54

1. Inspect: • Bearing 1 • Collar 2 Free play exists/unsmooth revolution/rust → Replace bearing and collar as a set. 2. Inspect: • Oil seal 3 Damage → Replace. EC575000

ASSEMBLY AND INSTALLATION Bearing and oil seal

1. Install: • 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: 6.5 mm (0.26 in)

• Bearing 1 • Plain washer 2 • Oil seal 3 To relay arm. NOTE: • Apply the molybdenum disulfide grease on the bearing when installing. • Install the bearing by pressing it on the side having the manufacture’s marks or numbers. • Apply the molybdenum disulfide grease on the plain washer. Installed depth of bearings a: Zero mm (Zero 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: Zero mm (Zero in)

1. Install: • Bush 1 • Thrust bearing 2 • Oil seal 3 • Collar 4 To swingarm 5. NOTE: Apply the molybdenum disulfide grease on the bushes, thrust bearings, oil seal lips and contact surfaces of the collar and thrust bearing.

• Collar 1 • Washer 2 To relay arm 3. NOTE: Apply the molybdenum disulfide grease on the collars and oil seal lips.

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

• Connecting rod 1 • Bolt (connecting rod) 2 • Plain washer 3 • Nut (connecting rod) 4 T.

NOTE: Apply the molybdenum disulfide grease on the bolt.

• Relay arm 1 • Bolt (relay arm) 2 • Plain washer 3 • Nut (relay arm) 4 To swingarm. NOTE: • Apply the molybdenum disulfide grease on the bolt circumference and threaded portion. • Do not tighten the nut yet.

• Apply the molybdenum disulfide grease on the pivot shaft. • Insert the pivot shaft from right side.

• 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, bushes and collars.

• Bolt (connecting rod) 1 • Plain washer 2 • Nut (connecting rod) 3 NOTE: • Apply the molybdenum disulfide grease on the bolt. • Do not tighten the nut yet.

• Bolt (rear shock absorber-relay arm) 1 • Nut (rear shock absorber-relay arm) 2 T.

Apply the molybdenum disulfide grease on the bolt.

• Nut (connecting rod) 1 T.

• Nut (relay arm) 1 T.

• Cap 1 NOTE: Install the cap (right) with its mark a facing forward.

• Bolt [chain tensioner (lower)] 1 • Plain washer 2 • Collar 3 • Chain tensioner 4 • Nut [chain tensioner (lower)] 5 T.

• Chain support 1 • Support cover 2 • Bolt {chain support [ = 50 mm (1.97 in)]} 3 • Nut (chain support) 4 T.

• Bolt {support cover [ = 10 mm (0.39 in)]}

7 Nm (0.7 m · kg, 5.1 ft · lb) 5 R.

• Boulon {couvercle du support

[ = 10 mm (0,39 in)]} 5

1 Rear shock absorber removal

Preparation for removal

REAR SHOCK ABSORBER REMOVAL Hold the machine by placing the suitable stand under the engine. Seat and side covers Silencer Drain the coolant. Catch tank breather hose Catch tank hose Air induction hose (air cut-off valve-air filter case)

2 Rear shock absorber disassembly

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. Disconnect at the catch tank side. Disconnect at the catch tank side. Disconnect at the air filter case side.

Cylinder head breather hose

Disconnect the starter relay coupler.

Starter motor lead Locking tie Taillight coupler CDI unit coupler Plastic band Clamp (air filter joint) Rear frame Bolt (rear shock absorber-relay arm) Bolt (rear shock absorber-frame)

Disconnect at the air filter case side. Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3.

Disconnect at the starter relay side.

Rear shock absorber Locknut Adjuster Spring guide (lower) Spring guide (upper) Spring (rear shock absorber) Bearing

Only loosening. Only loosening.

Refer to “REMOVAL POINTS”.

HANDLING NOTE WARNING This 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 shock absorber into an open flame or other high heat. The 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 shock absorber, follow the instructions on disposal.

NOTES ON DISPOSAL (YAMAHA DEALERS ONLY)

Before disposing the 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 shock absorber, take the unit to your Yamaha dealer for this disposal procedure. 5 - 63

REMOVAL POINTS EC583320

1. Remove: • Stopper ring (upper bearing) 1 NOTE: Press in the bearing while pressing its outer race and remove the stopper ring.

• Upper bearing 1 NOTE: Remove the bearing by pressing its outer race.

• Lower bearing 1 NOTE: Remove the bearing by pressing its outer race.

INSPECTION Rear shock absorber

1. Inspect: • Damper rod 1 Bends/damage → Replace absorber assembly. • Shock absorber 2 Oil leaks → Replace absorber assembly. Gas leaks → Replace 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. 5 - 64

ASSEMBLY AND INSTALLATION EC585300

1. Install: • 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 New 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)

1. Install: • Spring 1 • Spring guide (upper) 2 • Spring guide (lower) 3

• Spring length (installed) Refer to “REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT” section in the CHAPTER 3.

1. Install: • Dust seal 1 • O-ring 2 New • Collar 3 NOTE: • Apply the molybdenum disulfide grease on the dust seal lips and collars. • Apply the lithium soap base grease on the Orings.

• Bush 1 • Collar 2 • Dust seal 3 NOTE: • Apply the molybdenum disulfide grease on the bearing and dust seal lips. • Install the dust seals with their lips facing outward.

• Rear shock absorber 4. Install: • Bolt (rear shock absorber-frame) 1 • Washer 2 • Nut (rear shock absorber-frame) 3

Apply the molybdenum disulfide grease on the bolt. 5. Install: • Bolt (rear shock absorber-relay arm) 1 • Nut (rear shock absorber-relay arm) 2 T.

Apply the molybdenum disulfide grease on the bolt.

• Rear frame 1 • Bolt [rear frame (upper)] 2 T.

• Bolt [rear frame (lower)] 3

• Screw (air filter joint) 1 T.

• Rahmenheck-Schraube

8. Install: • Plastic band • Taillight coupler • Locking tie

CHAS ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELEC

ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000

ELECTRICAL COMPONENTS

1 Headlight 2 Multi-function display 3 “ENGINE STOP” button 4 Clutch switch 5 Diode 6 Starter relay diode 7 TPS (throttle position sensor) 8 Starter relay 9 Fuse 0 Starting circuit cut-off relay

B Taillight C Neutral switch D Starter motor E AC magneto F Rectifier/regulator G Ignition coil H Spark plug I Start switch J Main switch K Speed sensor L Battery

2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L

A B C D E F G H I J K L COMPOSANTS ELECTRIQUES

A B C D E F G H I J K L 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.

Replace fuse and check wire harness.

Recharge or replace.

Check entire ignition system for connection. (couplers, leads and ignition coil)

OK Check main switch.

OK Check ignition coil.

OK Check AC magneto. OK Check neutral switch.

Secondary coil Pick-up coil No good

OK Replace CDI unit.

*1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3. *2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3. *3 marked: Only when the ignition checker is used.

• Remove the following parts before inspection. 1) Seat 2) Fuel tank • Use the following special tools in this inspection. Dynamic spark tester: YM-34487 Ignition checker: 90890-06754

1. Disconnect the ignition coil from spark plug. 2. Remove the ignition coil cap. 3. Connect the dynamic spark tester 1 (ignition checker 2) as shown. • Ignition coil 3 • Spark plug 4

É Except for USA and CDN

4. Kick the kickstarter.

5. Check the ignition spark gap. 6. Start engine, and increase spark gap until misfire occurs. (for USA and CDN only) Minimum spark gap: 6.0 mm (0.24 in)

COUPLERS, LEADS AND IGNITION COIL CONNECTION INSPECTION

1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. • Ignition coil and spark plug as they are fitted Push in the ignition coil until it closely contacts the spark plug hole in the cylinder head cover. EC625001

“ENGINE STOP” BUTTON INSPECTION

1. Inspect: • “ENGINE STOP” button conduct Tester (+) lead → Black lead 1 Tester (–) lead → Black lead 2 B 1 PUSH IN FREE

Tester selector position

No continuity while being pushed → Replace.

Continuity while being freed → Replace. 2. Inspect: • Rubber part a Tears/damage → Replace. 6-3

MAIN SWITCH INSPECTION

1. Inspect: • Main switch conduct Tester (+) lead → Red lead 1 Tester (–) lead → Brown lead 2 R 1

Tester selector position

Continuous while the main switch is moved to

“OFF” → Replace. Not continuous while the main switch is moved to “ON” → Replace. 2. Inspect: • Main switch indicator light Use 12 V battery. Battery (+) lead → Red/Black lead 1 Battery (–) lead → Black lead 2

Indicator light does not come on → Replace.

3. Inspect: • Rubber part a Tears/damage → Replace.

IGNITION COIL INSPECTION

1. Remove the ignition coil cap. 2. Inspect: • Primary coil resistance Out of specification → Replace. Tester (+) lead → Orange lead 1 Tester (–) lead → Black lead 2

Primary coil resistance

Tester selector position

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

Tester selector position

• Sealed portion of ignition coil a • Spark plug terminal pin b • Threaded portion of spark plug c Wear → Replace. AC MAGNETO INSPECTION 1. Inspect: • Pick-up coil resistance Out of specification → Replace. Tester (+) lead → Red lead 1 Tester (–) lead → White lead 2 Pick-up coil resistance

Tester selector position

NEUTRAL SWITCH INSPECTION

1. Inspect: • Neutral switch conduct Tester (+) lead → Sky blue lead 1 Tester (–) lead → Ground 2 Sb 1

NEUTRAL IN GEAR Ground Tester selec-

No continuity while in neutral → Replace.

Continuity while in gear → Replace. EC628000

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

STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is set to “ON”, the starter motor can only operate if at least one of the following conditions is met:

• The transmission is in neutral (the neutral switch is closed).

• The clutch lever is pulled to the handlebar (the clutch switch is closed).

The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the starter motor. When at least one of the above conditions has been met the starting circuit cut-off relay is closed and the engine can be started by pressing the start switch.

0 M WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR

2 Main fuse 3 Main switch 4 Starting circuit cut-off relay 5 Start switch 6 Diode 7 Clutch switch 8 Neutral switch 9 Starter relay 0 Starter motor

INSPECTION STEPS If the starter motor will not operate, use the following inspection steps.

Replace fuse and check wire harness.

Recharge or replace.

OK Check each coupler and wire connection.

*3 Check main switch.

OK Check starter motor operation.

OK Check starting circuit cut-off relay.

OK Check starter relay.

*4 Check neutral switch.

OK Check clutch switch.

OK Check start switch.

*1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3.

*2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3. *3 marked: Refer to “MAIN SWITCH INSPECTION” section. *4 marked: Refer to “NEUTRAL SWITCH INSPECTION” section.

• Remove the following parts before inspection. 1) Seat 2) Rear fender • Use 12 V battery in this inspection. • Use the following special tools in this inspection.

COUPLERS AND LEADS CONNECTION INSPECTION

1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace.

STARTER MOTOR OPERATION

1. Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3. Not operate → Repair or replace the starter motor. WARNING • A wire that is used as a jumper lead must have at least the same capacity or more as that of the battery lead, otherwise the jumper lead may burn. • This check is likely to produce sparks, therefore make sure nothing flammable is in the vicinity.

STARTING CIRCUIT CUT-OFF RELAY INSPECTION

1. Remove: • Starting circuit cut-off relay 2. Inspect: • Starting circuit cut-off relay conduct Use 12 V battery.

Battery (+) lead → Blue/Black lead 1

Battery (–) lead → Brown lead 2 Tester (+) lead → Blue/White lead 3 Tester (–) lead → Black lead 4

3 Connected to battery Not connected to battery 6-8

Tester selector position

STARTER RELAY INSPECTION

1. Remove: • Starter relay 2. Inspect: • Starter relay conduct Use 12 V battery. Battery (+) lead → Starter relay terminal 1 Battery (–) lead → Starter relay terminal 2 Tester (+) lead → Starter relay terminal 3 Tester (–) lead → Starter relay terminal 4 Terminal

Tester selector position

Connected to battery

Not connected to battery

Continuous while not connected to the battery

→ Replace. Not continuous while connected to the battery → Replace.

CLUTCH SWITCH INSPECTION

1. Inspect: • Clutch switch continuity Tester (+) lead → Black lead 1 Tester (–) lead → Black lead 2 B 1

Tester selector position

No continuous while being pulled → Replace.

Continuous while being freed → Replace.

1. Remove the diode from wire harness. 2. Inspect: • Diode continuity Use pocket tester (tester selection position Ω × 1) Tester (+) → Blue/Red terminal 1 Tester (–) → Sky blue terminal 2

Blue/Red terminal 1 Tester (–) → Blue/Yellow terminal 3

Sky blue terminal 2 No continuous Tester (–) → Blue/Red terminal 1 Tester (+) → Blue/Yellow terminal 3 No continuous Tester (–) → Blue/Red terminal 1 Incorrect continuity → Replace.

START SWITCH INSPECTION

1. Inspect: • Start switch continuity Tester (+) lead → Black lead 1 Tester (–) lead → Black lead 2 B 1

Tester selector position

No continuous while being pushed → Replace.

Continuous while being freed → Replace. 2. Inspect: • Rubber part a Tears/damage → Replace.

1 Starter motor disassembly

Preparation for removal

STARTER MOTOR REMOVAL Exhaust pipe

STARTER MOTOR DISASSEMBLY Starter motor front cover Washer (starter motor front cover) Plain washer Circlip O-ring

Refer to “EXHAUST PIPE AND SILENCER” in the CHAPTER 3.

Starter motor yoke Armature assembly Starter motor rear cover Brush Brush spring

INSPECTION AND REPAIR

1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Commutator diameter a Out of specification → Replace the starter motor. Min. commutator diameter: 16.6 mm (0.65 in) 3. Measure: • Mica undercut a Out of specification → Scrape the mica to the proper measurement with a hacksaw blade which has been grounded to fit the commutator. Mica undercut: 1.5 mm (0.06 in) NOTE: The mica must be undercut to ensure proper operation of the commutator.

• Armature assembly resistances (commutator and insulation) Out of specification → Replace the starter motor. • Measure the armature assembly resistances with the pocket tester. Pocket tester: YU-03112-C/90890-03112 Armature assembly: Commutator resistance 1: 0.0117 ~ 0.0143 Ω at 20 °C (68 °F) Insulation resistance 2: Above 1 MΩ at 20 °C (68 °F) • If any resistance is out of specification, replace the starter motor.

• Brush length a Out of specification → Replace the brushes as a set. Min. brush length: 3.5 mm (0.14 in)

• Brush spring force Out of specification → Replace the brush springs as a set. Brush spring force: 3.92 ~ 5.88 N (400 ~ 600 gf, 14.1 ~ 21.2 oz)

1. Install: • Brush spring 1 • Brush 2

• Armature assembly 1 Install while holding down the brush using a thin screw driver. CAUTION: Be careful not to damage the brush during installation.

• O-ring 1 New • Starter motor yoke 2

• Align the match mark a on the starter motor yoke with the match mark b on the starter motor rear cover. • Install the starter motor yoke with its groove c facing rear cover. 4. Install: • O-ring 1 New • Circlip • Plain washer 2 • Washer (starter motor front cover) 3 • Starter motor front cover 4

• For installation, align the projections on the washer with the slots in the front cover. • Align the match mark a on the starter motor yoke with the match mark b on the starter motor front cover.

• Bolt 1 • O-ring 2 New NOTE: Apply the lithium soap base grease on the Oring.

INSPECTION STEPS If the battery is not charged, use the following inspection steps.

Replace fuse and check wire harness.

Recharge or replace.

OK Check each coupler and wire connection.

OK OK Check charging voltage.

Charging system is good.

OK Replace rectifier/regulator.

*1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3. *2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3.

• Remove the following parts before inspection. 1) Seat 2) Fuel tank • Use the following special tool in this inspection. Pocket tester: YU-3112-C/90890-03112

COUPLERS AND LEADS CONNECTION INSPECTION

1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace.

CHARGING VOLTAGE INSPECTION

1. Start the engine. 2. Inspect: • Charging voltage Out of specification → If no failure is found in checking the source coil resistance, replace the rectifier/regulator.

Tester (+) lead → Red lead 1

Tester (–) lead → Black lead 2 Charging voltage

Tester selector position

• Charging coil resistance Out of specification → Replace. Tester (+) lead → White lead 1 Tester (–) lead → Ground 2

Charging coil resistance

Tester selector position

TPS (THROTTLE POSITION SENSOR) SYSTEM INSPECTION STEPS If the TPS will not operate, use the following inspection steps.

Check entire ignition system for connection.

Use the following special tools in this inspection. Pocket tester: YU-3112-C/90890-03112

HANDLING NOTE CAUTION:

Do not loosen the screw {TPS (throttle position sensor)} 1 except when changing the TPS (throttle position sensor) due to failure because it will cause a drop in engine performance.

COUPLERS AND LEADS CONNECTION INSPECTION

1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace.

1. Inspect: • TPS coil resistance Out of specification → Replace. Tester (+) lead → Blue lead 1 Tester (–) lead → Black lead 2 TPS coil resistance

Tester selector position

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

• TPS 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 TPS coil variable resistance

Tester selector position

Full closed Full opened

0 ~ 2 kΩ at 20 °C (68 °F)

TPS REPLACEMENT AND ADJUSTMENT

1. Remove: • TPS coupler • Carburetor 2. Remove: • Screw (TPS) 1 • TPS 2

Loosen the screw (TPS) using the T25 bit. 3. Replace: • TPS 4. Install: • TPS 1 • Screw (TPS) 2

• Align the slot a in the TPS with the projection b on the carburetor. • Temporarily tighten the screw (TPS). 5. Install: • Carburetor • TPS coupler

• Idle speed Refer to “IDLE SPEED ADJUSTMENT” section in the CHAPTER 3.

7. Insert the thin electric conductors 2 (lead) into the TPS coupler 1, as shown, and connect the tester to them.

Tester (+) lead → Yellow lead 3 Tester (–) lead → Black lead 4 CAUTION: • Do not insert the electric conductors more than required because it may reduce the waterproof function of the coupler. • Make sure that a short-circuit does not develop between the terminals because it may cause damage to electrical components. 8. Start the engine.

• TPS output voltage Adjustment steps: Adjust the installation angle of the TPS 1 to obtain the specified output voltage. NOTE: Measure the output voltage accurately with a digital electronic voltmeter that gives an easy reading of a small voltage.

Tester selector position

10. Put the aligning marks a on the TPS and carburetor.

11. Stop the engine. 12. Remove the carburetor.

• Screw (TPS) 1 NOTE: Tighten the screw (TPS) using the T25 bit.

14. Install the carburetor.

TPS INPUT VOLTAGE INSPECTION

1. Disconnect the TPS coupler. 2. Start the engine. 3. Inspect: • TPS input voltage Out of specification → Replace the CDI unit. Tester (+) lead → Blue lead 1 Tester (–) lead → Black/Blue lead 2

Tester selector position

LIGHTING SYSTEM INSPECTION STEPS Refer to the following flow chart when inspecting the lighting system for possible problems.

Check the bulb and bulb socket.

Replace the bulb and/or bulb socket.

Replace the taillight assembly.

OK Check the entire lighting system proper for connections.

Improperly connected

OK Check the rectifier/regulator.

• Remove the following parts before inspection. 1) Seat 2) Fuel tank 3) Left side cover • Use the following special tool in this inspection. Pocket tester: YU-3112-C/90890-03112

CHECKING THE TAILLIGHT (LEDs)

1. Disconnect the taillight coupler. 2. Connect two jumper leads 1 from the battery terminals to the respective coupler terminal as shown. Battery (+) terminal → Blue lead 2 Battery (–) terminal → Black lead 3

• LED (for proper operation) Does not light → Replace the taillight assembly. WARNING • A wire that is used as a jumper lead must have at least the same capacity of the battery lead, otherwise the jumper lead may burn. • This check is likely to produce sparks, therefore, make sure no flammable gas or fluid is in the vicinity.

AC MAGNETO INSPECTION

1. Inspect: • Lighting coil resistance Out of specification → Replace. Tester (+) lead → Yellow lead 1 Tester (–) lead → Ground 2

Lighting coil resistance

Tester selector position

RECTIFIER/REGULATOR INSPECTION

1. Connect the battery leads. 2. Start the engine. 3. Turn on the headlight and taillight by turning on the lights switch. 4. Inspect: • Out-put voltage Out of specification → Replace rectifier/ regulator.

Y W R B Tester (+) lead → Yellow lead 1

Tester (–) lead → Black lead 2

Tester selector position

SIGNALING SYSTEM INSPECTION STEPS If the speedometer will not operate, use the following inspection steps.

Recharge or replace.

OK Check each coupler and wire connection.

OK Check multi-function display.

OK Check speed sensor.

Replace wire harness.

Replace multi-function display.

*1 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3.

• Remove the following parts before inspection. 1) Headlight • Use the following special tools in this inspection. Pocket tester: YU-3112-C/90890-03112

COUPLERS AND LEADS CONNECTION INSPECTION

1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace.

MULTI-FUNCTION DISPLAY INPUT VOLTAGE INSPECTION

1. Disconnect the multi-function display coupler. 2. Set the main switch to “ON”. 3. Measure: • Multi-function display input voltage Out of specification → Replace wire harness. Tester (+) lead → Brown lead 1 Tester (–) lead → Black lead 2 Multi-function display input voltage

Tester selector position

Make sure that a short-circuit does not develop between the terminals because it may cause damage to electrical components.

MULTI-FUNCTION DISPLAY OUTPUT VOLTAGE INSPECTION

1. Disconnect the multi-function display coupler. 2. Set the main switch to “ON”.

• Multi-function display output voltage Out of specification → Replace multifunction display. Tester (+) lead → Red lead 1 Tester (–) lead → Black/White lead 2 Multi-function display output voltage

Tester selector position

Make sure that a short-circuit does not develop between the terminals because it may cause damage to electrical components.

SPEED SENSOR OUTPUT VOLTAGE INSPECTION

1. Insert the thin electric conductors 1 (lead) into the speed sensor coupler 2, as shown, and connect the tester to them. Tester (+) lead → White lead 3 Tester (–) lead → Black lead 4 CAUTION: • Do not insert the electric conductors more than required because it may reduce the waterproof function of the coupler. • Make sure that a short-circuit does not develop between the terminals because it may cause damage to electrical components. 2. Set the main switch to “ON”.

• Speed sensor output voltage Output voltage not correct → Replace the speed sensor. Measurement steps: • Elevate the front wheel and slowly rotate it. • Measure the voltage (DCV) of white lead and black lead. With each full rotation of the front wheel, the voltage reading should cycle from 0.6 V to 4.8 V to 0.6 V to 4.8 V.

ENGINE Carburetor setting

• The air/fuel mixture will vary depending on atmospheric conditions. Therefore, it is necessary to take into consideration the air pressure, ambient temperature, humidity, etc., when adjusting the carburetor. • Perform a test run to check for proper engine performance (e.g., throttle response) and spark plug(-s) discoloration or fouling. Use these readings to determine the best possible carburetor setting. NOTE: It is recommended to keep a record of all carburetor settings and external conditions (e.g., atmospheric conditions, track/surface conditions, lap times) to make future carburetor setting easier. WARNING • The carburetor is a part of the fuel line. Therefore, be sure to install it in a 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.

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

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.

Effects of the setting parts on the throttle valve opening

2 Throttle valve cutaway 3 Jet needle 4 Main jet

The FLATCR carburetor has a primary main jet. This type of main jet is perfect for racing machines since it supplies an even flow of fuel, even at full load. Use the main jet and the jet needle to set the carburetor. 1 Jet needle 2 Pilot air jet 3 Needle jet 4 Main jet 5 Pilot jet

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

If the air-fuel mixture is too rich or too lean, the engine power will drop, resulting in poor acceleration.

Effects of changing the main jet (reference) È

Pilot jet adjustment

The richness of the air-fuel mixture with the throttle open 1/4 or less can be set by adjusting the pilot jet 1. Standard pilot jet

Effects of adjusting the pilot jet (reference)

Jet needle groove position adjustment

NOTE: For setting adjustment, replace the standard jet needle with the one designed for setting. Adjusting the jet needle 1 position affects the acceleration when the throttle is 1/8 to 3/4 open. 1. Too rich at intermediate speeds Rough engine operation is felt and the engine will not pick up speed smoothly. In this case, step up the jet needle clip by one groove and move down the needle to lean out the mixture. 2. Too lean at intermediate speeds The engine breathes hard and will not pick up speed quickly. Step down the jet needle clip by one groove and move up the needle to enrich the mixture. Effects of changing the jet needle groove position (reference) È

É Fully open 1 No.5 groove 2 No.3 groove 3 No.4 groove

Jet needle adjustment

The jet needle is adjusted by changing it. Supplied jet needle

* For CDN, AUS, NZ and ZA The tapered sections of all jet needles have the same starting positions, but the needles are available with different straight-portion diameters.

<Example> GDDUQ - 4 Clip position Diameter a of straight portion 7-5

Effects of changing the jet needle (reference)

(Diameter of the straight portion) Changing the diameter of the straight portion adjusts the air-fuel mixture when the throttle is 1/8 to 1/4 open. È

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> #60 → #55 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> #60 → #65

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.

Carburetor setting parts

Part name Main jet Rich

#185 #182 #180 #178 #175 #172 #170 #168 #165 #162 #55 #52 #50 #48 #45 GDDUM GDDUN GDDUP GDDUQ GDDUR GDDUS GDDUT GDDSM GDDSN GDDSP GDDSQ GDDSR GDDSS GDDST #35 #40 #45 #50 #55 #60 #65

5TJ-14916-AN 5TJ-14916-AP 5TJ-14916-A1 5TJ-14916-AR 5TJ-14916-AS 5TJ-14916-AT

5TJ-14916-AN 5TJ-14916-AP 5TJ-14916-A1 5TJ-14916-AR 5TJ-14916-AS

5TJ-14916-AT Surtidor principal

5TJ-14916-AN 5TJ-14916-AP 5TJ-14916-A1 5TJ-14916-AR 5TJ-14916-AS

5TJ-14916-AT Examples of carburetor setting depending on symptom

Symptom At full throttle Hard breathing Shearing noise Whitish spark plug

Increase main jet calibration no. (Gradually)

Speed pick-up stops Slow speed pick-up Slow response Sooty spark plug Rich mixture Lean mixture Rich mixture 1/4 ~ 3/4 throttle Hard breathing Lack of speed 1/4 ~ 1/2 throttle Slow speed pick-up Poor acceleration

Closed to 1/4 throttle

Hard breathing Speed down Closed to 1/4 throttle Poor acceleration

Decrease main jet calibration no.

Lower jet needle clip position.

(1 groove down) Raise jet needle clip position. (1 groove up) Lower jet needle clip position. (1 groove down) Raise jet needle clip position. (1 groove up)

Use jet needle with a smaller diameter.

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. Discoloration of spark plug → If tan color, it is in good condition. If cannot be corrected: Clogged air cleaner Fuel overflow from carburetor

The clip position is the jet needle groove on which the clip is installed.

The positions are numbered from the top. Check that the accelerator pump operates smoothly (except for rich mixture symptom). Slow-speed-circuit passage Clogged → Clean. Overflow from carburetor

Use jet needle with a larger diameter.

Raise jet needle clip position. (1 groove up) Poor response in the low to Raise jet needle clip position. intermediate speeds If this has no effect, lower the jet needle clip position. Check air cleaner for fouling. Poor response when throttle Check overall settings. 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 Check that the accelerator pump operwith a higher calibration no. and lower ates smoothly. the jet needle clip position.

should be taken simply for an example. It is necessary to set the carburetor while checking

* This the operating conditions of the engine.

Nut 2 Nut 3 Nut 4 Nut 5 Nut 6 Nut 7

Selection of the secondary reduction ratio

(Sprocket) Secondary reduction ratio

Number of driven sprocket teeth

Number of drive sprocket teeth

Standard secondary reduction ratio

<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.

Drive and driven sprockets setting parts

Part name Drive sprocket 1 (STD) *(STD)

*13T 9383E-13233 **14T 9383E-14215

* For CDN, EUROPE, AUS, NZ and ZA

** For AUS and NZ Part name Driven sprocket 2 (STD) *(STD)

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

* For AUS and NZ EC721002

Tire pressure should be adjust to suit the road surface condition of the circuit. Standard tire pressure: 100 kPa (1.0 kgf/cm2, 15 psi) • Under a rainy, muddy, sandy, or slippery condition, the tire pressure should be lower for a larger area of contact with the road surface. Extent of adjustment: 60 ~ 80 kPa (0.6 ~ 0.8 kgf/cm2, 9.0 ~ 12 psi) • Under a stony or hard road condition, the tire pressure should be higher to prevent a flat tire. Extent of adjustment: 100 ~ 120 kPa (1.0 ~ 1.2 kgf/cm2, 15 ~ 18 psi)

*48T *49T (STD) 50T *(STD) *50T *51T 52T

(STD) 13T 5TJ-17460-00 *(STD) *13T 9383E-13233 **14T 9383E-14215

*48T *49T (STD) 50T *(STD) *50T *51T 52T *52T

*48T *49T (STD) 50T *(STD) *50T *51T 52T

*52T Front fork setting

The front fork setting should be made depending on the rider’s feeling of an actual run and the circuit conditions. The front fork setting includes the following three factors: 1. Setting of air spring characteristics • Change the fork oil level. 2. Setting of spring preload • 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 and characteristics. Therefore, adjust the front fork within the specified range. Standard oil level: 132 mm (5.20 in) * 125 mm (4.92 in) Extent of adjustment: 95 ~ 150 mm (3.74 ~ 5.91 in) From top of outer tube with inner tube and damper rod fully compressed without spring. * Except for USA and CDN

È Air spring characteristics in relation to oil level change

É Load Ê Stroke 1 Max. oil level 2 Standard oil level 3 Min. oil level

Spring preload adjustment

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

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.

Front fork setting parts

• Adjustment washer 1 TYPE (thickness)

PART NUMBER T = 2.3 mm (0.09 in)

• Front fork spring 2

TYPE SPRING SPRING PART RATE NUMBER I.D.

0.418 0.428 0.438 0.449

5TJ-23141-10 5TJ-23141-20 5TJ-23141-30 5TJ-23141-40

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

Rear suspension setting

The rear suspension setting should be made depending on the rider’s feeling of an actual run and the circuit conditions. The rear suspension setting includes the following two factors: 1. Setting of spring preload • Change the set length of the spring. • Change the spring. 2. Setting of damping force • Change the rebound damping. • Change the compression damping.

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 a.

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

• 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.

When using a rear cushion other than currently installed, use the one whose overall length a does not exceed the standard as it may result in faulty performance. Never use one whose overall length is greater than standard. Length a of standard shock: 488.5 mm (19.23 in)

Rear shock absorber setting parts

• Rear shock spring 1 I.D. SPRING SPRING TYPE SPRING COLOR/

FREE RATE PART NUMBER POINT LENGTH SOFT

Green/1 Red/1 Black/1 Blue/1 Yellow/1

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

• Extent of adjustment (spring length)

EXTENT OF ADJUSTMENT b

• Front fork 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. • Before any change, set the rear shock absorber sunken length to the standard figure 90 ~ 100 mm (3.5 ~ 3.9 in). Section Symptom

Large Medium Small gap gap gap

Stiff over entire range

Unsmooth movement over entire range

Poor initial movement

Soft over entire range, bottoming out

Turn adjuster counterclockwise (about 2 clicks) to decrease damping.

Oil level (oil amount)

Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).

Replace with soft spring.

Check for any bends, dents, and other noticeable scars, etc. If any, replace affected parts.

Under bracket tightening torque

Turn adjuster counterclockwise (about 2 clicks) to decrease damping.

Apply grease in oil seal wall.

Turn adjuster clockwise (about 2 clicks) to increase damping.

Oil level (oil amount)

Increase oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).

Replace with stiff spring.

Stiff toward stroke end

Oil level (oil amount)

Decrease oil level by about 5 mm (0.2 in).

Soft toward stroke end, bottoming out

Oil level (oil amount)

Increase oil level by about 5 mm (0.2 in).

Stiff initial movement

Turn adjuster counterclockwise (about 2 clicks) to decrease damping.

Low front, tending to lower front posture

“Obtrusive” front, tending to upper front posture

Turn adjuster clockwise (about 2 clicks) to increase damping.

Turn adjuster counterclockwise (about 2 clicks) to decrease damping.

Balance with rear end

Set sunken length for 95 ~ 100 mm (3.7 ~ 3.9 in) when one passenger is astride seat (lower rear posture).

Oil level (oil amount)

Increase oil level by about 5 mm (0.2 in).

Turn adjuster counterclockwise (about 2 clicks) to decrease damping.

Balance with rear end

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.

Oil lever (oil amount)

Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).

• Rear shock absorber

• 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

Stiff, tending to sink

Large Medium Small gap gap gap

Turn adjuster counterclockwise (about 2 clicks) to decrease damping.

Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when one passenger is astride seat.

Turn adjuster clockwise (about 2 clicks) to increase damping.

Low compression damping

Turn adjuster clockwise (about 1 click) to increase damping.

Replace with stiff spring.

Turn adjuster counterclockwise (about 2 clicks) to decrease damping.

Replace with soft spring.

Turn adjuster counterclockwise (about 2 clicks) to decrease damping.

Low compression damping

Turn adjuster clockwise (about 1 clicks) to increase damping.

High compression damp- Turn adjuster clockwise (about 1/6 clicks) to ing increase damping.

Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when one passenger is astride seat.

Replace with soft spring.

High compression damp- Turn adjuster clockwise (about 1/6 turn) to increase ing damping.

Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when one passenger in astride seat.

Replace with stiff spring.

Turn adjuster clockwise (about 2 clicks) to increase damping.

Replace with soft spring.

High compression damp- Turn adjuster counterclockwise (about 1/6 turn) to ing decrease damping.

Set sunken length for 95 ~ 100 mm (3.7 ~ 3.9 in) when one passenger is astride seat.

Replace with soft spring.

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