WR450F-2007 - Off-road motorcycle YAMAHA - Free user manual and instructions

USER MANUAL WR450F-2007 YAMAHA

OWNER'S SERVICE MANUAL

MANUEL D'ATELIER DU

PROPRIETAIRE

FAHRER- UND

WARTUNGS-HANDBUCH

MANUAL DE SERVICIO

DEL PROPIETARIO

WR450F(W)

5TJ-28199-44

EC010010

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

WR450F(W)

MANUEL D'ATELIER

DU PROPRIETAIRE

©2006 Yamaha Motor Co., Ltd.

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

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.

1. THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY.

Do not carry passengers on this machine.

1. 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.

1. 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.

NOTICE IMPORTANTE

1. 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.
2. 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.
3. ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILA-TION.
   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.
4. 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.
5. 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.

6. 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.

7. L'ESSENCE EST HAUTE-MENT INFLAMMABLE.

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

NOTE:

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

EC060000

NOTICE

Some data in this manual may become outdated due to improvements made to this model in the future.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

EC070001

F.I.M. MACHINE WEIGHTS:

Weights of machines without fuel

The minimum weights for motocross machines are:

for the class 125 cc ...... minimum

88 kg (194 lb)

for the class 250 cc ...... minimum

98 kg (216 lb)

for the class 500 cc ...... minimum

102 kg (225 lb)

In modifying your machine (e.g., for weight reduction), take note of the above limits of weight.

AU NOUVEAU PROPRIETAIRE

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.

1 2 3 4 5 6 7 8 9

EC082000

FINDING THE REQUIRED PAGE

1. This manual consists of seven chapters; "General Information", "Specifications", "Regular inspection and adjustments", "Engine", "Chassis", "Electrical" and "Tuning".

2. The table of contents is at the beginning of the manual. Look over the general layout of the book before finding then required chapter and item.

Bend the book at its edge, as shown, to find the required fore edge symbol mark and go to a page for required item and description.

COMMENT UTILISER CE MANUEL

INFORMATIONS PARTICULIEREMENT IMPOR-TANTES

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.

CLUTCH CLUTCH ① ③ ④ ⑤ ⑥ CLUTCH ENG EC484000 REMOVAL POINTS EC484011 Clutch boss 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. A B Clutch holding tool: YM-91042/90890-04086 A For USA and CDN B Except for USA and CDN EC484000 INSPECTION EC484100 Clutch housing and boss 1. Inspect: • Clutch housing ① Cracks/wear/damage → Replace. • Clutch boss ② Scoring/wear/damage → Replace. EC484001 Primary driven gear 1. Check: • Circumferential play Free play exists → Replace. • Gear teeth ⑧ Wear/damage → Replace. EC484002 Clutch spring 1. Measure: • Clutch spring free length ⑨ Out of specification → Replace springs as a set. CLutch spring free length: Standard 50 mm (1.97 in) 49 mm (1.93 in) 4 - 48 4 - 50

FORMAT DU MANUEL

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 ⑭ are used to identify the specifications appearing in the text.

⑧ With engine mounted
⑨ Special tool
⑩ Filling fluid
⑪ Lubricant
⑫ Tightening
⑬ Specified value, Service limit
⑭ Resistance (Ω), Voltage (V), Electric current (A)

Illustrated symbols ⑮ to ⑱ in the exploded diagrams indicate grade of lubricant and location of lubrication point.

⑮ Apply engine oil
⑯ Apply molybdenum disulfide oil
⑰ Apply lightweight lithium-soap base grease
⑱ Apply molybdenum disulfide grease

Illustrated symbols ⑲ to ⑳ in the exploded diagrams indicate where to apply a locking agent and where to install new parts.

⑲ Apply locking agent (LOCTITE®)
⑳ Use new one

SYMBOLES GRAPHIQUES (Voir l'illustration)

CHECKING OF CONNECTION 1-6

SPECIAL TOOLS 1-7

CONTROL FUNCTIONS ...... 1-10

MULTI-FUNCTION DISPLAY 1-14

FUEL 1-21

STARTING AND BREAK-IN 1-22

TORQUE-CHECK POINTS 1-26

CLEANING AND STORAGE 1-27

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS ......2-1

MAINTENANCE SPECIFICATIONS .....2-4

GENERAL TORQUE

SPECIFICATIONS 2-20

DEFINITION OF UNITS ......2-20

LUBRICATION DIAGRAMS ......2-21

CABLE ROUTING DIAGRAM ......2-23

CHAPTER 3

REGULAR INSPECTION AND

ADJUSTMENTS

MAINTENANCE INTERVALS ......3-1

CONNEXIONS ...... 1-6

OUTILS SPECIAUX.... 1-7

FONCTIONS DES

COMMANDES 1-10

ECRAN MULTIFONCTION...... 1-14

CARBURANT......1-21

MISE EN MARCHE ET

RODAGE....1-22

POINTS DE VERIFICATION

DES COUPLES

DE SERRAGE 1-26

NETTOYAGE ET REMISAGE... 1-27

CHAPITRE 2 CARACTERISTIQUES

CARACTERISTIQUES

GENERALES....2-1

CARACTERISTIQUES

D'ENTRETIEN 2-4

CARACTERISTIQUES

GENERALES DE COUPLE ..... 2-20

DEFINITION DES UNITES ...... 2-20

DIAGRAMMES

DE LUBRIFICATION ...... 2-21

DIAGRAMME

DE CHEMINEMENT

DES CABLES 2-23

CHAPITRE 3 CONTROLES ET REGLAGES PERIODIQUES

PROGRAMME D'ENTRETIEN ... 3-1

CONTROLE ET ENTRETIEN

AVANT UTILISATION ...... 3-4

MOTEUR 3-5

CHASSIS 3-25

PARTIE ELECTRIQUE ...... 3-48

INHALT

KICK AXLE AND SHIFT SHAFT .....4-74

AC MAGNETO

AND STARTER CLUTCH 4-82

ENGINE REMOVAL 4-89

CRANKCASE AND CRANKSHAFT .....4-95

TRANSMISSION, SHIFT CAM

AND SHIFT FORK 4-104

CHAPTER 5 CHASSIS

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

FRONT BRAKE AND REAR BRAKE .....5-10

FRONT FORK 5-26

HANDLEBAR 5-39

STEERING 5-46

SWINGARM 5-52

REAR SHOCK ABSORBER 5-60

CHAPITRE 4 MOTEUR

SELLE, RESERVOIR

DE CARBURANT

ET CACHES LATERAUX......4-1

TUBE D'ECHAPPEMENT

ET SILENCIEUX 4-3

RADIATEUR 4-5

CARBURATEUR 4-8

SYSTEME D'INDUCTION

D'AIR......4-22

ARBRES A CAMES....4-24

CULASSE......4-33

SOUPAPES ET RESSORTS

DE SOUPAPES......4-37

CYLINDRE ET PISTON......4-46

EMBRAYAGE......4-52

FILTRE A HUILE, POMPE

A EAU ET COUVERCLE

DE CARTER MOTEUR

(DROIT) 4-59

BALANCIER 4-66

POMPE A HUILE 4-70

CHAPITRE 7 MISE AU POINT

MOTEUR 7-1
CHASSIS 7-9

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
⑩ Fuel tank cap
⑪ Taillight
⑫ Kickstarter
⑬ Fuel tank
⑭ Headlight
⑮ Radiator
⑯ Coolant drain bolt

⑰ Rear brake pedal
⑱ Valve joint
⑲ Fuel cock
⑳ Cold starter knob
②1 Air cleaner
② Catch tank
②3 Drive chain
⑳ Shift pedal
⑲ Oil dipstick
⑳ Front fork

NOTE:

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

Technical diagram of a mechanical assembly with numbered components for identification

Technical diagram of a motorcycle with numbered parts for identification

Technical diagram of a motorcycle with numbered parts for identification

RENSEIGNEMENTS GENERAUX DESCRIPTION

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.

Technical line drawing of a mechanical assembly with labeled component (1), no readable text or symbols present

Technical line drawing of a mechanical assembly with no visible text or symbols

Technical diagram of a vehicle's internal components with labeled parts ①

EC123001

ENGINE SERIAL NUMBER

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

EC124000

MODEL LABEL

The model label ① is affixed to the frame under the rider's seat. This information will be needed to order spare parts.

IDENTIFICATION DE LA MOTO

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.

2. Silencer exhaust port

3. Side cover air intake port
   • Water pump housing hole at the bottom
4. Drain hole on the cylinder head (right side)

5. All electrical components

6. Use proper tools and cleaning equipment. Refer to "SPECIAL TOOLS" section.

7. 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.
8. 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.
9. Keep away from fire.

INFORMATIONS IMPORTANTES

PREPARATION A LA DEPOSE ET AU DEMONTAGE

ALL REPLACEMENT PARTS

1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment.

EC133000

GASKETS, OIL SEALS AND O-RINGS

1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned.
2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.

Technical diagram showing two bolted components with a numbered connection point labeled '1'

Technical diagram of a mechanical valve assembly with labeled component ①

Technical mechanical diagram showing a cross-sectional view with labeled component ② and directional arrow

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.

EC135001

BEARINGS AND OIL SEALS

1. Install the bearing(s) ① and oil seal(s) ② with their manufacturer's marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of 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.

PIECES DE RECHANGE

Technical diagram showing a mechanical or structural assembly with numbered components and directional arrow indicating flow or movement.

EC136000

CIRCLIPS

1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip ①, make sure that the sharp-edged corner ② is positioned opposite to the thrust ③ it receives. See the sectional view.

④ Shaft

CIRCLIPS

Two-panel line drawing showing a hand holding a tool, with no text or symbols present.

Technical diagram showing two-step assembly steps for a mechanical component, with labeled parts ① and directional arrow.

Diagram of electrical testing setup with wires, probes, and a multimeter (no text or symbols)

Diagram of a hand connecting two cables to a multimeter connected by a cable (no text or symbols present)

EC1C0001

CHECKING OF CONNECTION

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

1. Disconnect:

- Connector

1. Dry each terminal with an air blower.

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

3. Pull the lead to check that it will not come off.

4. If the terminal comes off, bend up the pin ① and reinsert the terminal into the connector.

5. Connect:

- Connector

NOTE:

The two connectors "click" together.

1. 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.

VERIFICATION DES CONNEXIONS

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	Tool name/How to use	Illustration
YU-3097, 90890-01252YU-1256	Dial gauge and standStandThese tools are used to check each part for runout or bend.	YU-3097YU-1256	90890-01252
YU-90050, 90890-01274YU-90050, 90890-01275YM-91044, 90890-04081YU-90063, 90890-01278	Crankshaft installing toolCrankshaft installing potCrankshaft installing boltSpacer (crankshaft installer)Adapter (M12)These tools are used to install the crankshaft.	YU-90050YU-90063YM-	90890-0127490890-90890-90890-
YU-1304, 90890-01304	Piston pin pullerThis tool is used to remove the piston pin.	YU-1304	90890-01304
YU-24460-01, 90890-01325YU-33984, 90890-01352	Radiator cap testerAdapterThese tools are used for checking the cooling system.	YU-24460-01YU-33984	90890-0132590890-01352
YU-33975, 90890-01403	Ring nut wrenchThis tool is used when tighten the steering ring nut to specification.	YU-33975	90890-01403
YM-01494, 90890-01494	Damper rod holderUse this tool to remove and install the damper rod.	YM-01494	90890-01494
YM-A0948, 90890-01502	Fork seal driverThis tool is used when install the fork oil seal.	YM-A0948	90890-01502
YS-1880-A, 90890-01701	Sheave holderThis tool is used for when loosening or tightening the flywheel magneto securing nut.	YS-1880-A	90890-01701
YU-3112-C, 90890-03112	Pocket testerUse this tool to inspect the coil resistance, output voltage and amperage.	YU-3112-C	90890-03112
YM-33277-A, 90890-03141	Timing lightThis tool is necessary for checking ignition timing.	YM-33277-A	90890-03141
YM-4019, 90890-04019	Valve spring compressorThis tool is needed to remove and install the valve assemblies.	YM-4019	90890-04019
YM-91042, 90890-04086	Clutch holding toolThis tool is used to hold the clutch when removing or installing the clutch boss securing nut.	YM-91042	90890-04086
YM-4116, 90890-04116YM-4097, 90890-04097	Valve guide removerIntake 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-4116YM-4097	90890-0411690890-04097
YM-4117, 90890-04117YM-4098, 90890-04098	Valve guide installerIntakeExhaustThis tool is needed to install the valve guide.	YM-4117YM-409	90890-0411790890-(
YM-4118, 90890-04118YM-4099, 90890-04099	Valve guide reamerIntake 4.5 mm (0.18 in)Exhaust 5.0 mm (0.20 in)This tool is needed to rebore the new valve guide.	YM-4118 2G82	90890-04118§
YM-04142, 90890-04142	Rotor pullerThis tool is used to remove the flywheel magneto.	YM-04142	90890-04142
YU-A9642, 90890-04152	Crankcase separating toolThese tool is used to remove the crankshaft from either case.	YU-A9642	90890-04152
YM-3448790890-06754	Dynamic spark testerIgnition checkerThis instrument is necessary for checking the ignition system components.	YM-34487	90890-06754
YB-35956-A, 90890-06756	Vacuum/pressure pump gauge setThis tool is used to check the air induction system.	YB-35956-A	90890-06756
90890-85505	YAMAHA Bond No. 1215(ThreeBond® No. 1215)This sealant (Bond) is used for crankcase mating surface, etc.	90890-85505	90890-85505

OUTILS SPECIAUX

OFF ON ② ①

EC150000

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.

Technical line drawing of a mechanical device with labeled component (1), no readable text or symbols present.

EC151000

"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.

Technical diagram of a mechanical assembly with labeled component ①

START SWITCH

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

FONCTIONS DES COMMANDES

CONTACTEUR A CLE

Technical diagram of a firearm with labeled parts, showing mechanical assembly and component details

5 4 3 2 N 1

Technical diagram of a mechanical assembly with labeled component ①

Diagram illustrating fluid flow through a pipe with labeled component ① and directional arrows indicating flow direction.

Technical diagram of a mechanical component with labeled parts, showing a pipe fitting and a cylindrical shaft.

EC152000

CLUTCH LEVER

The clutch lever ① is located on the left handlebar; it disengages or engages the clutch. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth starts.

EC153000

SHIFT PEDAL

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

EC154000

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.

EC155001

THROTTLE GRIP

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

EC156000

FRONT BRAKE LEVER

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

LEVIER D'EMBRAYAGE

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.

Technical line drawing of a car interior showing dashboard, steering wheel, and gear mechanism (no text or symbols)

Technical diagram of a mechanical device with labeled component ①

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.

PEDALE DE FREIN ARRIERE

Technical diagram showing mechanical assembly with labeled component '1'

① TANK

Technical diagram of engine components with numbered parts and an inset showing a mechanical component labeled '①'

Technical diagram showing a hand operating a mechanical linkage or cable assembly with labeled component ①

Technical diagram showing a wrench tool interacting with a mechanical component, with labeled parts ① and ① (likely part numbers or annotations)

SIDESTAND

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

WARNING

• Never apply additional force to the side-stand.
• Hold up the sidestand before starting out.

EC15F000

VALVE JOINT

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

CAUTION:

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

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.

BEQUILLE LATERALE

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)

RST ① ⑥ ⑦ ⑧ SLCT 1 18:88:88 188 A 678.88 MPHkm/h SLCT 2 ③ ② ⑤ ④ ⑨

DESCRIPTION

Operation buttons:

① Select button "SLCT 1"
② Select button "SLCT 2"
③ Reset button "RST"

Screen display:

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

NOTE:

The operation buttons can be pushed in the following two manners:

Short push: Push the button. (☐)

Long push: Push the button for 2 seconds or more. (→)

ECRAN MULTIFONC-TION

! AVERTISSEMENT

RST SLCT1 SLCT2 12:00:00 A 10.0 MPH 12:00:00 A 16.0 km/h

graph TD
    A["RST"] --> B["SLCT1"]
    A --> C["SLCT2"]
    B --> D["12:00:00"]
    C --> D
    D --> E["12:00:00"]
    E --> F["RST"]
    style A fill:#f9f,stroke:#333
    style D fill:#ccf,stroke:#333
    style E fill:#cfc,stroke:#333

graph TD
    A["+"] --> B["SLCT1"]
    B --> C["SLCT2"]
    C --> D["-"]
    style A fill:#fff,stroke:#000
    style B fill:#fff,stroke:#000
    style C fill:#fff,stroke:#000
    style D fill:#fff,stroke:#000
    subgraph Display
        E["12:00:00 A 10.0 MPH"] --> F["Digital Display"]

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.

Setting the time

1. Push the "SLCT1" button for 2 seconds or more to enter the time setting mode.
2. Push the "RST" button to change the display for time indication. The display will change in the following order:
   Hour → Minute → Second → Hour.

NOTE:

The digits capable of setting go on flashing.

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

2. 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.

MODE DE BASE

graph TD
    A["SLCT1"] --> B["12:00:00 MPH"]
    C["SLCT2"] --> B
    B --> D["0 1025"]
    D --> E["A 10.0"]
    E --> F["B 20.0"]
    F --> G["RST"]
    G --> H["SLCT1"]
    G --> I["SLCT2"]
    H --> J["12:00:00 MPH"]
    I --> J
    J --> K["A 10.0"]
    K --> L["A 0.0"]

graph TD
    A["SLCT1"] --> B["12:00:00"]
    C["SLCT2"] --> D["10.0"]
    B --> E["MPH"]
    D --> E
    F["RST"] --> G["SLCT1"]
    F --> H["SLCT2"]
    G --> I["0:00:00"]
    H --> J["0.0"]
    I --> K["MPH"]

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 T 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 T and A to flash. (For manual start, refer to "Putting measurement on standby" in "RACE MODE".)

graph TD
    A["RST"] --> B["SLCT1"]
    A --> C["SLCT2"]
    B --> D["T 0: 15:08 A 10.3 MPH"]
    C --> D
    E["RST"] --> F["SLCT1"]
    E --> G["SLCT2"]
    F --> H["T 0:00:00 A 0.0 MPH"]
    G --> H
    H --> I["12:00:00 A 0.0 MPH"]

RST SLCT1 SLCT2 0:00:00 A 0.0 MPH

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, T and A will start flashing.

graph TD
    A["RST"] --> B["SLCT1"]
    A --> C["SLCT2"]
    B --> D["0: 15:08 A 10.3 MPH"]
    C --> E["0:00:00 A 0.0 MPH"]
    E --> F["0:00:00 A 0.0 MPH"]
    F --> G["0:15:08 A 10.3 MPH"]

1. Start timer measurement by pushing the "RST" button.
2. 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).

1. To resume the measurement, again push the "SLCT1" button and "SLCT2" button at the same time.

Auto start

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, T and A will start flashing. Timer display will turn on scrolling from left to right.

1. Run the machine and start timer measurement.
2. 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).

graph TD
    A["RST"] --> B["SLCT1"]
    A --> C["SLCT2"]
    B --> D["0:15:08"]
    C --> E["A 10.3 MPH"]
    D --> F["0:15:08"]
    E --> F
    G["0:15:08"] --> H["A -0.0 MPH"]

graph TD
    A["RST"] --> B["SLCT1"]
    A --> C["SLCT2"]
    B --> D["0: 15:08"]
    C --> E["A 10.3 MPH"]
    D --> F["0:00:00"]
    E --> F
    G["0:00:00"] --> H["A 0.0 MPH"]

graph TD
    A["+"] --> B["SLCT1"]
    B --> C["RST"]
    C --> D["SLCT2"]
    D --> E["+"]
    E --> F["0:15:08 50 MPH"]
    F --> G["+"]
    G --> H["10.4"]
    H --> I["SLCT2"]
    I --> J["+"]
    J --> K["10.2"]
    K --> L["-"]

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, A 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.

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

graph TD
    A["① BASIC MODE"] --> B["② Clock"]
    B --> C["SLCT1"]
    C --> D["③ Tripmeter"]
    D --> E["ODO → TRIP A → TRIP B → ODO"]
    C --> F["SLCT2"]
    F --> G["④ Speedometer (for U.K.)"]
    G --> H["MPH → km/h → MPH"]
    I["⑤ RACE MODE"] --> J["⑥ Putting measurement on standby"]
    J --> K["Manual start"]
    K --> L["SLCT1 + SLCT2"]
    L --> M["SLCT2"]
    M --> N["⑦ Manual start"]
    N --> O["RST"]
    O --> P["Measurement starts as the machine moves"]
    P --> Q["⑧ Auto start"]
    Q --> R["SLCT1 + SLCT2"]
    R --> S["SLCT2"]
    S --> T["⑨ Measurement starts as the machine moves"]
    T --> U["SLCT1 + SLCT2"]
    V["⑬ Reset TRIP A & timer"] --> W["⑭ Correct TRIP A"]
    W --> X["SLCT1 + SLCT2"]
    X --> Y["SLCT2"]
    Y --> Z["⑮ Timer not in operation"]
    Z --> AA["SLCT1 + SLCT2"]
    AB["A short push on button changes the operation in the arrowed direction."] --> AC["E Meter function"]
    AD["A short push on button changes the operation in both arrowed directions."] --> AE["F Function that can be performed whether the time is or is not in operation."]
    AF["A long push on button changes the operation in the arrowed direction."] --> AG["G Extent to which the meter can operate"]

DIAGRAMME DE FONCTIONNEMENT

N.B.:

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

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.

Technical diagram showing car engine components with numbered parts and directional arrow indicating rotation or movement

1. Inspect the coolant level.
2. Turn the fuel cock to "ON".
3. Push the main switch to "ON".
4. Shift the transmission into neutral.
5. Fully open the cold starter knob ①.
6. 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.

• 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.

N.B.:

Technical diagram of a mechanical device with labeled component ①

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".

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

* Operate the throttle grip before kick starting.

CAUTION:

Observe the following break-in procedures during initial operation to ensure optimum performance and avoid engine damage.

MISE EN MARCHE A CHAUD

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.

PROCEDURE DE RODAGE

PISTON, SEGMENT, SOUPAPES, ARBRES A CAMES ET PIGNONS:

graph TD
    A["Frame construction"] --> B["Combined seat and tank"]
    B --> C["Frame to rear frame"]
    B --> D["Fuel tank to frame"]
    E["Exhaust system"] --> F["Silencer to rear frame"]
    G["Engine mounting"] --> H["Frame to engine"]
    H --> I["Engine bracket to engine"]
    H --> J["Engine bracket to frame"]
    K["Steering"] --> L["Steering shaft to handlebar"]
    L --> M["Steering shaft to frame"]
    L --> N["Steering shaft to handle crown"]
    L --> O["Handle crown to handlebar"]
    P["Suspension"] --> Q["Front"]
    P --> R["Steering shaft to front fork"]
    R --> S["Front fork to handle crown"]
    R --> T["Front fork to under bracket"]
    U["Rear"] --> V["For link type"]
    V --> W["Assembly of links"]
    V --> X["Link to frame"]
    V --> Y["Link to shock absorber"]
    V --> Z["Link to swingarm"]
    AA["Rear"] --> AB["Installation of shock absorber"]
    AB --> AC["Shock absorber to frame"]
    AA --> AD["Rear"]
    AD --> AE["Installation of swingarm"]
    AE --> AF["Tightening of pivot shaft"]
    AG["Wheel"] --> AH["Installation of wheel"]
    AH --> AI["Front"]
    AH --> AJ["Rear"]
    AJ --> AK["Tightening of front axle"]
    AJ --> AL["Tightening of axle holder"]
    AJ --> AM["Wheel to sprocket"]
    AN["Brake"] --> AO["Front"]
    AO --> AP["Caliper to front fork"]
    AP --> AQ["Brake disc to wheel"]
    AQ --> AR["Tightening of union bolt"]
    AR --> AS["Master cylinder to handlebar"]
    AR --> AT["Tightening of air bleeder"]
    AR --> AU["Tightening of brake hose holde"]
    AN --> AV["Rear"]
    AV --> AW["Brake pedal to frame"]
    AW --> AX["Brake disc to wheel"]
    AX --> AY["Tightening of union bolt"]
    AY --> AZ["Master cylinder to frame"]
    AZ --> BA["Tightening of air bleeder"]
    AZ --> BB["Tightening of brake hose holde"]
    BC["Fuel system"] --> BD["Fuel tank to fuel cock"]
    BE["Lubrication system"] --> BF["Tightening of oil hose clamp"]

NOTE:

Concerning the tightening torque, refer to "MAINTENANCE SPECIFICATIONS" section in the CHAPTER 2.

POINTS DE VERIFICATION DES COUPLES DE SERRAGE

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.

1. 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.
2. Rinse the machine off immediately with clean water, and dry all surfaces with a soft towel or cloth.
3. Immediately after washing, remove excess water from the chain with a paper towel and lubricate the chain to prevent rust.
4. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy.

NETTOYAGE ET REMISAGE

NETTOYAGE

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.

Model name:	WR450FW (USA, CDN, AUS, NZ)WR450F (EUROPE, ZA)
Model code number:	5TJE (USA)5TJF (EUROPE)5TJG (CDN, AUS, NZ, ZA)
Dimensions:	USA, ZA, CDN	EUROPE, AUS, NZ
Overall length	2,175 mm (85.63 in)	2,190 mm (86.22 in)
Overall width	825 mm (32.48 in)	←
Overall height	1,295 mm (50.98 in)	1,300 mm (51.18 in)
Seat height	980 mm (38.58 in)	990 mm (38.98 in)
Wheelbase	1,485 mm (58.46 in)	←
Minimum ground clearance	365 mm (14.37 in)	370 mm (14.57 in)
Dry weight:Without oil and fuel	112.5 kg (248.0 lb)
Engine:Engine typeCylinder arrangementDisplacementBore × strokeCompression ratioStarting system	Liquid cooled 4-stroke, DOHCSingle cylinder, forward inclined449 cm3(15.8 Imp oz, 15.2 US oz)95.0 × 63.4 mm (3.74 × 2.50 in)12.3 : 1Kick and electric starter
Lubrication system:	Dry sump
Oil type or grade:Engine oil	(For USA and CDN)Yamalube 4, SAE10W30 or SAE20W40Yamalube 4-R, SAE10W50API service SG type or higher,JASO standard MA(Except for USA and CDN)SAE10W30, SAE10W40, SAE15W40,SAE20W40 or SAE20W50API service SG type or higher,JASO standard MA
Oil capacity:Engine oilPeriodic oil changeWith oil filter replacementTotal amount	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)
Coolant capacity (including all routes):	1.0 L (0.88 Imp qt, 1.06 US qt)
Air filter:	Wet type element
Fuel:TypeTank capacityReserve	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)
Carburetor:TypeManufacturer	FCR MX39KEIHIN
Spark plug:Type/manufacturerGap	CR8E/NGK (resistance type)0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
Clutch type:	Wet, multiple-disc
Transmission:Primary reduction systemPrimary reduction ratioSecondary reduction systemSecondary reduction ratioTransmission typeOperationGear ratio: 1st2nd3rd4th5th	Gear61/23 (2.652)Chain drive50/13 (3.846)Constant mesh, 5-speedLeft foot operation29/12 (2.417)26/15 (1.733)21/16 (1.313)21/20 (1.050)21/25 (0.840)
Chassis:Frame typeCaster angleTrail	USA, ZA, CDN	EUROPE, AUS, NZ
	Semi double cradle27.3°117 mm (4.61 in)	←27.0°116 mm (4.57 in)
Tire:TypeSize (front)Size (rear)Tire pressure (front and rear)	With tube80/100-21 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)
Brake:
Front brake type	Single disc brake
Operation	Right hand operation
Rear brake type	Single disc brake
Operation	Right foot operation
Suspension:
Front suspension	Telescopic fork
Rear suspension	Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber	Coil spring/oil damper
Rear shock absorber	Coil spring/gas, oil damper
Wheel travel:
Front wheel travel	300 mm (11.8 in)
Rear wheel travel	305 mm (12.0 in)
Electrical:
Ignition system	CDI
Generator system	AC magneto
Battery type	YTZ7S
Battery voltage/capacity	12 V/6 AH
Specific gravity	1.310
Headlight type:	Quartz bulb (halogen)
Bulb wattage × quantity:
Headlight	12 V 35/36.5 W × 1
Taillight	12 V 1.6/0.3 W × 1

MAINTENANCE SPECIFICATIONS

ENGINE

Item		Standard	Limit
Cylinder head:Warp limit		----	0.05 mm(0.002 in)
Cylinder:Bore sizeOut of round limit		95.00 ~ 95.01 mm(3.7402 ~ 3.7406 in)----	----0.05 mm(0.002 in)
Camshaft:Drive methodCamshaft cap inside diameterCamshaft journal diameterShaft-to-cap clearanceCam dimensions		Chain drive (Left)22.000 ~ 22.021 mm(0.8661 ~ 0.8670 in)21.959 ~ 21.972 mm(0.8645 ~ 0.8650 in)0.028 ~ 0.062 mm(0.0011 ~ 0.0024 in)	--------0.08 mm(0.003 in)
Intake	“A”	30.100 ~ 30.200 mm(1.1850 ~ 1.1890 in)	30.000 mm(1.1811 in)
	“B”	22.450 ~ 22.550 mm(0.8839 ~ 0.8878 in)	22.350 mm(0.8799 in)
Exhaust	“A”	30.200 ~ 30.300 mm(1.1890 ~ 1.1929 in)	30.100 mm(1.1850 in)
	“B”	22.450 ~ 22.550 mm(0.8839 ~ 0.8878 in)	22.350 mm(0.8799 in)
Camshaft runout limit		----	0.03 mm(0.0012 in)
Cam chain:
Cam chain type/No. of links		98XRH2010-118M/118	----
Cam chain adjustment method		Automatic	----
Valve, valve seat, valve guide:
Valve clearance (cold)	IN	0.10 ~ 0.15 mm(0.0039 ~ 0.0059 in)	----
	EX	0.20 ~ 0.25 mm(0.0079 ~ 0.0098 in)	----
Valve dimensions:
Head Diameter	Face Width	Seat Width	Margin Thickness
“A” head diameter	IN	26.9 ~ 27.1 mm(1.0591 ~ 1.0669 in)	----
	EX	27.9 ~ 28.1 mm(1.0984 ~ 1.1063 in)	----
“B” face width	IN	2.26 mm (0.089 in)	----
	EX	2.26 mm (0.089 in)	----
“C” seat width	IN	0.9 ~ 1.1 mm(0.0354 ~ 0.0433 in)	1.6 mm(0.0630 in)
	EX	0.9 ~ 1.1 mm(0.0354 ~ 0.0433 in)	1.6 mm(0.0630 in)
“D” margin thickness	IN	1 mm (0.0394 in)	0.85 mm(0.033 in)
	EX	1 mm (0.0394 in)	0.85 mm(0.033 in)
Stem outside diameter	IN	4.475 ~ 4.490 mm(0.1762 ~ 0.1768 in)	4.445 mm(0.1750 in)
	EX	4.965 ~ 4.980 mm(0.1955 ~ 0.1961 in)	4.935 mm(0.1943 in)
Guide inside diameter	IN	4.500 ~ 4.512 mm(0.1772 ~ 0.1776 in)	4.550 mm(0.1791 in)
	EX	5.000 ~ 5.012 mm(0.1969 ~ 0.1973 in)	5.050 mm(0.1988 in)
Stem-to-guide clearance	IN	0.010 ~ 0.037 mm(0.0004 ~ 0.0015 in)	0.08 mm(0.003 in)
	EX	0.020 ~ 0.047 mm(0.0008 ~ 0.0019 in)	0.10 mm(0.004 in)
Stem runout limit		----	0.01 mm(0.0004 in)
Valve spring:
Free length	IN	39.46 mm (1.55 in)	38.46 mm(1.51 in)
	EX	37.61 mm (1.48 in)	36.61 mm(1.44 in)
Set length (valve closed)	IN	27.87 mm (1.10 in)	----
	EX	28.38 mm (1.12 in)	----
Compressed force(installed)	IN	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)	----
	EX	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)	----
Tilt limit *	IN	----	2.5°/ 1.7 mm(2.5°/0.067 in)
	EX	----	2.5°/1.6 mm(2.5°/0.063 in)
Direction of winding (top view)	IN	Clockwise	----
	EX	Clockwise	----
Piston:
Piston to cylinder clearance		0.040 ~ 0.065 mm(0.0016 ~ 0.0026 in)	0.1 mm(0.004 in)
Piston size “D”		94.945 ~ 94.960 mm(3.738 ~ 3.739 in)	----
Measuring point “H”		8 mm (0.315 in)	----
Piston off-set		1 mm (0.0394 in)	----
Piston pin bore inside diameter		18.004 ~ 18.015 mm(0.7088 ~ 0.7093 in)	18.045 mm(0.7104 in)
Piston pin outside diameter		17.991 ~ 18.000 mm(0.7083 ~ 0.7087 in)	17.971 mm(0.7075 in)
Piston rings:Top ring:
TypeDimensions (B × T)End gap (installed)Side clearance (installed)2nd ring:		Barrel1.2 × 3.5 mm (0.05 × 0.14 in)0.20 ~ 0.30 mm(0.008 ~ 0.012 in)0.030 ~ 0.065 mm(0.0012 ~ 0.0026 in)	--------0.55 mm(0.022 in)0.12 mm(0.005 in)
TypeDimensions (B × T)End gap (installed)Side clearanceOil ring:		Taper1.00 × 3.35 mm (0.04 × 0.13 in)0.35 ~ 0.50 mm(0.014 ~ 0.020 in)0.020 ~ 0.055 mm(0.0008 ~ 0.0022 in)	--------0.85 mm(0.033 in)0.12 mm(0.005 in)
Dimensions (B × T)End gap (installed)		2.0 × 2.9 mm (0.08 × 0.11 in)0.2 ~ 0.5 mm (0.01 ~ 0.02 in)	----
Crankshaft:Crank width “A”Runout limit “C”Big end side clearance “D”Small end free play “F”		61.95 ~ 62.00 mm(2.439 ~ 2.441 in)0.03 mm (0.0012 in)0.15 ~ 0.45 mm(0.0059 ~ 0.0177 in)0.4 ~ 1.0 mm (0.02 ~ 0.04 in)	----0.05 mm(0.002 in)0.50 mm(0.02 in)2.0 mm(0.08 in)
Balancer:Balancer drive method		Gear	----
Air filter oil grade:		Foam-air-filter oil or equivalent oil	----
Item		Standard	Limit
Clutch:
Friction plate thickness		2.92 ~ 3.08 mm(0.115 ~ 0.121 in)	2.8 mm(0.110 in)
Quantity		8	----
Clutch plate 1 thickness		1.9 ~ 2.1 mm (0.075 ~ 0.083 in)	----
Quantity		4	----
Warp limit		----	0.1 mm(0.004 in)
Clutch plate 2 thickness		1.5 ~ 1.7 mm (0.059 ~ 0.067 in)	----
Quantity		3	----
Warp limit		----	0.1 mm(0.004 in)
Clutch spring free length		50.0 mm (1.97 in)	49.0 mm(1.93 in)
Quantity		6	----
Clutch housing thrust clearance		0.10 ~ 0.35 mm(0.0039 ~ 0.0138 in)	----
Clutch housing radial clearance		0.010 ~ 0.044 mm(0.0004 ~ 0.0017 in)	----
Clutch release method		Inner push, cam push	----
Shifter:
Shifter type		Cam drum and guide bar	----
Guide bar bending limit		----	0.05 mm(0.002 in)
Kickstarter:
Type		Ratchet type	----
Carburetor:
I. D. mark		5TJE E0	----
Main jet	(M.J)	#162	----
Main air jet	(M.A.J)	ø2.0	----
Jet needle	(J.N)	NFNT	----
Cutaway	(C.A)	1.5	----
Pilot jet	(P.J)	#45	----
Pilot air jet	(P.A.J)	#70	----
Pilot outlet	(P.O)	ø0.9	----
Bypass	(B.P)	ø1.0	----
Valve seat size	(V.S)	ø3.8	----
Starter jet	(G.S)	#65	----
Leak jet	(Acc.P)	#60	----
Float height	(F.H)	8 mm (0.31 in)	----
Engine idle speed		1,750 ~ 1,850 r/min	----
Intake vacuum		34.8 ~ 40.1 kPa(261 ~ 301 mmHg,10.28 ~ 11.85 inHg)	----
Hot starter lever free play		3 ~ 6 mm (0.12 ~ 0.24 in)	----
Item		Standard	Limit
Lubrication system:
Oil filter type		Paper type	----
Oil pump type		Trochoid type	----
Tip clearance “A”		0.12 mm or less(0.0047 in or less)	0.20 mm(0.008 in)
Tip clearance “B”		0.09 ~ 0.17 mm(0.0035 ~ 0.0067 in)	0.24 mm(0.009 in)
Side clearance “C”		0.03 ~ 0.10 mm(0.0012 ~ 0.0039 in)	0.17 mm(0.007 in)
Bypass valve setting pressure		40 ~ 80 kPa (0.4 ~ 0.8 kg/cm2,5.69 ~ 11.38 psi)	----
Cooling:
Radiator core size
Width		120.2 mm (4.73 in)	----
Height (Left/Right)		260 mm (10.24 in)/240 mm (9.45 in)	----
Thickness		22 mm (0.87 in)	----
Radiator cap opening pressure		110 kPa (1.1 kg/cm2, 15.6 psi)	----
Radiator capacity (total)		0.57 L (0.50 Imp qt, 0.60 US qt)	----
Water pump
Type		Single-suction centrifugal pump	----

graph TD
    A["Oil strainer"] --> B["Oil pump rotor 2"]
    B --> C["Oil pump rotor 1"]
    C --> D["Check ball"]
    D --> E["Oil filter"]
    E --> F["Cylinder head"]
    F --> G["Piston cooler nozzle"]
    G --> H["Piston"]
    H --> I["Crank pin"]
    I --> J["Piston pin"]
    J --> K["Piston"]
    K --> L["Valve lifter"]
    L --> M["Camshaft"]
    M --> N["Oil tank"]
    style A fill:#f9f,stroke:#333
    style N fill:#bbf,stroke:#333

Part to be tightened	Thread size	Q'ty	Tightening torque
			Nm	m·kg	ft·lb
Spark plug	M10S × 1.0	1	13	1.3	9.4
Camshaft cap	M6 × 1.0	10	10	1.0	7.2
Cylinder head blind plug screw	M12 × 1.0	1	28	2.8	20
Cylinder head (stud bolt)	M8 × 1.25	1	15	1.5	11
(bolt)	M10 × 1.25	4	Refer to NOTE.*1
(bolt)	M6 × 1.0	2	10	1.0	7.2
Cylinder head cover	M6 × 1.0	2	10	1.0	7.2
Cylinder	M6 × 1.0	1	10	1.0	7.2
Timing chain tensioner	M6 × 1.0	2	10	1.0	7.2
Tensioner cap bolt	M6 × 1.0	1	7	0.7	5.1
Timing chain guide (rear)	M6 × 1.0	2	10	1.0	7.2
Exhaust pipe (nut)	M8 × 1.25	1	20	2.0	14
(bolt)	M8 × 1.25	1	20	2.0	14
Silencer	M8 × 1.25	2	30	3.0	22
Silencer clamp	M8 × 1.25	1	16	1.6	11
Exhaust pipe protector	M6 × 1.0	3	10	1.0	7.2
Spark arrester	M5 × 0.8	4	7	0.7	5.1
Silencer cap	M5 × 0.8	6	5	0.5	3.6
Air induction pipe	M6 × 1.0	2	10	1.0	7.2
Air cut-off valve assembly and bracket	M6 × 1.0	2	10	1.0	7.2
Bracket (air cut-off valve) and frame	M6 × 1.0	2	7	0.7	5.1
Carburetor joint	M6 × 1.0	3	10	1.0	7.2
Carburetor joint clamp	M4 × 0.7	1	3	0.3	2.2
Air filter case	M6 × 1.0	2	8	0.8	5.8
Air filter joint clamp	M6 × 1.0	1	3	0.3	2.2
Air filter joint and air filter case	M5 × 0.8	1	4	0.4	2.9
Throttle cable adjust bolt and locknut	M6 × 0.75	1	4	0.4	2.9
Throttle cable (pull)	M6 × 1.0	1	4	0.4	2.9
Throttle cable (return)	M12 × 1.0	1	11	1.1	8.0
Throttle cable cover	M5 × 0.8	2	4	0.4	2.9
Hot starter plunger	M12 × 1.0	1	2	0.2	1.4
Hot starter cable adjust bolt and locknut	M6 × 0.75	1	4	0.4	2.9
Air filter element	M6 × 1.0	1	2	0.2	1.4
Radiator stay	M6 × 1.0	6	7	0.7	5.1
Radiator	M6 × 1.0	4	10	1.0	7.2
Radiator hose clamp	M6 × 1.0	8	2	0.2	1.4
Radiator pipe 1, 2	M10 × 1.0	2	10	1.0	7.2
Impeller	M8 × 1.25	1	14	1.4	10
Water pump housing cover	M6 × 1.0	3	10	1.0	7.2
Coolant drain bolt	M6 × 1.0	1	10	1.0	7.2
Oil pump cover	M4 × 0.7	1	2	0.2	1.4
Oil pump	M6 × 1.0	2	10	1.0	7.2
Oil pump drive gear shaft	M6 × 1.0	1	10	1.0	7.2

Part to be tightened	Thread size	Q'ty	Tightening torque
			Nm	m·kg	ft·lb
Engine oil drain bolt (oil filter)	M6 × 1.0	1	10	1.0	7.2
Oil filter cover	M6 × 1.0	2	10	1.0	7.2
Oil check bolt (cylinder head)	M6 × 1.0	1	10	1.0	7.2
Oil hose clamp	—	2	2	0.2	1.4
Clutch cover	M6 × 1.0	7	10	1.0	7.2
Crankcase cover (right)	M6 × 1.0	8	10	1.0	7.2
	M6 × 1.0	2	12	1.2	8.7
Crankcase cover (left)	M6 × 1.0	8	10	1.0	7.2
Idle gear cover (starter motor)	M6 × 1.0	2	10	1.0	7.2
Crankcase	M6 × 1.0	12	12	1.2	8.7
Clutch cable holder	M6 × 1.0	1	10	1.0	7.2
Oil drain bolt (crankcase right)	M10 × 1.25	1	20	2.0	14
(crankcase left)	M6 × 1.0	1	20	2.0	14
Oil check bolt (crankcase)	M6 × 1.0	1	10	1.0	7.2
Oil strainer	M6 × 1.0	1	10	1.0	7.2
Crankcase bearing stopper	M6 × 1.0	4	14	1.4	10
Crankcase bearing stopper	M6 × 1.0	8	10	1.0	7.2
Drive axle oil seal stopper	M6 × 1.0	2	10	1.0	7.2
Ratchet wheel guide	M6 × 1.0	2	12	1.2	8.7
Kickstarter	M8 × 1.25	1	33	3.3	24
Screw (kickstarter)	M6 × 1.0	1	7	0.7	5.1
Starter clutch	M6 × 1.0	6	16	1.6	11
Primary drive gear	M20 × 1.0	1	110	11.0	80
Clutch boss	M20 × 1.0	1	75	7.5	54
Clutch cable adjust bolt and locknut	M8 × 1.0	1	4	0.4	2.9
Clutch spring	M6 × 1.0	6	10	1.0	7.2
Balancer	M10 × 1.0	1	45	4.5	32
Balancer driven gear	M14 × 1.0	1	50	5.0	36
Balancer weight plate	M6 × 1.0	3	10	1.0	7.2
Drive sprocket	M20 × 1.0	1	75	7.5	54
Drive sprocket cover	M6 × 1.0	2	8	0.8	5.8
Shift pedal	M6 × 1.0	1	12	1.2	8.7
Shift guide	M6 × 1.0	2	10	1.0	7.2
Stopper lever	M6 × 1.0	1	10	1.0	7.2
Segment	M8 × 1.25	1	30	3.0	22

NOTE:

△ - 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.

EC212201

CHASSIS

Item	Standard			Limit
Steering system:Steering bearing type	Taper roller bearing			----
Front suspension:	USA, CDN	EUROPE	AUS, NZ, ZA
Front fork travel	300 mm (11.8 in)	←	←
Fork spring free length	460 mm (18.1 in)	←	←
Spring rate, STD	K = 4.5 N/mm(0.459 kg/mm,25.7 lb/in)	←	←
Optional spring/spacer	Yes	←	←
Oil capacity	648 cm ^3 (22.8 Imp oz,21.9 US oz)	655 cm ^3 (23.1 Imp oz,22.1 US oz)	←
Oil level	132 mm (5.20 in)	125 mm (4.92 in)	←
<Min.~Max.>(From top of outer tube with inner tube and damper rod fully compressed without spring.)	95 ~ 150 mm(3.74 ~ 5.91 in)	←	←
Oil grade	Suspension oil“S1”	←	←
Inner tube outer diameter	48 mm (1.89 in)	←	←
Front fork top end	Zero mm (Zero in)	←	←
Rear suspension:	USA, CDN	EUROPE	AUS, NZ, ZA
Shock absorber travel	130 mm (5.12 in)	←	←
Spring free length	260 mm (10.24 in)	←	←
Fitting length	252.5 mm (9.94 in)	251.5 mm (9.90 in)	252.5 mm (9.94 in)
<Min.~Max.>	238.5 ~ 258.5 mm(9.39 ~ 10.18 in)	←	←
Spring rate, STD	K = 54.0 N/mm(5.50 kg/mm,308.0 lb/in)	←	←
Optional spring	Yes	←	←
Enclosed gas pressure	1,000 kPa(10 kg/cm ^2 , 142 psi)	←	←
Swingarm:Swingarm free play limitEnd	----			1.0 mm(0.04 in)
Item	Standard			Limit
Wheel:
Front wheel type	Spoke wheel			----
Rear wheel type	Spoke wheel			----
Front rim size/material	21 × 1.60/Aluminum			----
Rear rim size/material	18 × 2.15/Aluminum			----
Rim runout limit:
Radial	----			2.0 mm(0.08 in)
Lateral	----			2.0 mm(0.08 in)
Drive chain:
Type/manufacturer	DID520VM/DAIDO			----
Number of links	113 links + joint			----
Chain slack	48 ~ 58 mm (1.9 ~ 2.3 in)			----
Chain length (15 links)	----			239.3 mm(9.42 in)
Front disc brake:
Disc outside dia. × Thickness	250 × 3.0 mm (9.84 × 0.12 in)			250 × 2.5 mm(9.84 × 0.10 in)
Pad thickness	4.4 mm (0.17 in)			1.0 mm(0.04 in)
Master cylinder inside dia.	11.0 mm (0.433 in)			----
Caliper cylinder inside dia.	27.0 mm (1.063 in) × 2			----
Brake fluid type	DOT #4			----
Rear disc brake:
Disc outside dia. × Thickness	245 × 4.0 mm (9.65 × 0.16 in)			245 × 3.5 mm(9.65 × 0.14 in)
Deflection limit	----			0.15 mm(0.006 in)
Pad thickness	6.4 mm (0.25 in)			1.0 mm(0.04 in)
Master cylinder inside dia.	11.0 mm (0.433 in)			----
Caliper cylinder inside dia.	25.4 mm (1.000 in) × 1			----
Brake fluid type	DOT #4			----
Brake lever and brake pedal:
Brake lever position	95 mm (3.74 in)			----
Brake pedal height(vertical height above footrest top)	10 mm (0.39 in)			----
Clutch lever free play (lever end)	8 ~ 13 mm (0.31 ~ 0.51 in)			----
Throttle grip free play	3 ~ 5 mm (0.12 ~ 0.20 in)			----

Part to be tightened	Thread size	Q'ty	Tightening torque
			Nm	m·kg	ft·lb
Handle crown and outer tube	M8 × 1.25	4	21	2.1	15
Under bracket and outer tube	M8 × 1.25	4	21	2.1	15
Handle crown and steering shaft	M24 × 1.0	1	145	14.5	105
Handlebar holder (upper)	M8 × 1.25	4	28	2.8	20
Handlebar holder (lower)	M12 × 1.25	2	34	3.4	24
Steering ring nut	M28 × 1.0	1	Refer to NOTE.
Front fork and cap bolt	M51 × 1.5	2	30	3.0	22
Front fork and base valve	M30 × 1.0	2	55	5.5	40
Cap bolt and damper rod (front fork)	M12 × 1.25	2	29	2.9	21
Bleed screw (front fork) and cap bolt	M5 × 0.8	2	1	0.1	0.7
Front fork and protector	M6 × 1.0	6	7	0.7	5.1
Front fork protector and brake hose holder	M6 × 1.0	2	7	0.7	5.1
Throttle cable cap	M5 × 0.8	2	4	0.4	2.9
Clutch lever holder mounting	M5 × 0.8	2	4	0.4	2.9
Clutch lever mounting	M6 × 1.0	1	4	0.4	2.9
Hot starter lever holder mounting	M5 × 0.8	2	4	0.4	2.9
Hot starter lever mounting	M5 × 0.8	1	2	0.2	1.4
Front brake master cylinder and bracket	M6 × 1.0	2	9	0.9	6.5
Front brake master cylinder cap	M4 × 0.7	2	2	0.2	1.4
Brake lever mounting (bolt)	M6 × 1.0	1	6	0.6	4.3
Brake lever mounting (nut)	M6 × 1.0	1	6	0.6	4.3
Brake lever position locknut	M6 × 1.0	1	5	0.5	3.6
Hose guide (front brake hose) and hose guide bracket	M5 × 0.8	1	4	0.4	2.9
Hose guide (front brake hose) and under bracket	M6 × 1.0	1	4	0.4	2.9
Front brake hose union bolt (master cylinder)	M10 × 1.25	1	30	3.0	22
Front brake hose union bolt (caliper)	M10 × 1.25	1	30	3.0	22
Front brake caliper and front fork	M8 × 1.25	2	23	2.3	17
Front brake caliper and brake hose holder	M6 × 1.0	1	10	1.0	7.2
Brake caliper (front and rear) and pad pin plug	M10 × 1.0	2	3	0.3	2.2
Brake caliper (front and rear) and pad pin	M10 × 1.0	2	18	1.8	13
Brake caliper (front and rear) and bleed screw	M8 × 1.25	2	6	0.6	4.3
Front wheel axle and nut	M16 × 1.5	1	90	9.0	65
Front wheel axle holder	M8 × 1.25	4	21	2.1	15
Front brake disc and wheel hub	M6 × 1.0	6	12	1.2	8.7
Rear brake disc and wheel hub	M6 × 1.0	6	14	1.4	10
Brake pedal mounting	M8 × 1.25	1	26	2.6	19
Rear brake master cylinder and frame	M6 × 1.0	2	10	1.0	7.2
Rear brake master cylinder cap	M4 × 0.7	2	2	0.2	1.4
Rear brake hose union bolt (caliper)	M10 × 1.25	1	30	3.0	22
Rear brake hose union bolt (master cylinder)	M10 × 1.25	1	30	3.0	22

NOTE:
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).

Part to be tightened	Thread size	Q'ty	Tightening torque
			Nm	m·kg	ft·lb
Rear wheel axle and nut	M20 × 1.5	1	125	12.5	90
Driven sprocket and wheel hub	M8 × 1.25	6	50	5.0	36
Nipple (spoke)	—	72	3	0.3	2.2
Disc cover and rear brake caliper	M6 × 1.0	2	10	1.0	7.2
Protector and rear brake caliper	M6 × 1.0	2	7	0.7	5.1
Chain puller adjust bolt and locknut	M8 × 1.25	2	19	1.9	13
Engine mounting:
Engine upper bracket and frame	M10 × 1.25	4	55	5.5	40
Engine lower bracket and frame	M8 × 1.25	4	34	3.4	24
Engine and engine bracket (lower)	M10 × 1.25	1	53	5.3	38
Engine and engine bracket (upper)	M10 × 1.25	1	55	5.5	40
Engine and frame (lower)	M10 × 1.25	1	53	5.3	38
Engine guard	M6 × 1.0	3	7	0.7	5.1
Regulator mounting	M6 × 1.0	2	7	0.7	5.1
Pivot shaft and nut	M16 × 1.5	1	85	8.5	61
Relay arm and swingarm	M14 × 1.5	1	70	7.0	50
Relay arm and connecting rod	M14 × 1.5	1	80	8.0	58
Connecting rod and frame	M14 × 1.5	1	80	8.0	58
Rear shock absorber and frame	M10 × 1.25	1	56	5.6	40
Rear shock absorber and relay arm	M10 × 1.25	1	53	5.3	38
Rear frame and frame (upper)	M8 × 1.25	1	38	3.8	27
Rear frame and frame (lower)	M8 × 1.25	2	32	3.2	23
Swingarm and brake hose holder	M5 × 0.8	4	2	0.2	1.4
Swingarm and patch	M4 × 0.7	4	2	0.2	1.4
Drive chain tensioner mounting (upper)	M8 × 1.25	1	16	1.6	11
Drive chain tensioner mounting (lower)	M8 × 1.25	1	16	1.6	11
Chain support and swingarm	M6 × 1.0	3	7	0.7	5.1
Seal guard and swingarm	M5 × 0.8	4	6	0.6	4.3
Fuel tank mounting	M6 × 1.0	2	9	0.9	6.5
Fuel tank and fuel cock	M6 × 1.0	2	4	0.4	2.9
Fuel tank and seat set bracket	M6 × 1.0	1	7	0.7	5.1
Fuel tank and fuel tank bracket	M6 × 1.0	4	7	0.7	5.1
Seat mounting	M8 × 1.25	2	23	2.3	17
Side cover mounting	M6 × 1.0	2	7	0.7	5.1
Air scoop and fuel tank	M6 × 1.0	6	7	0.7	5.1
Air scoop and radiator panel (lower)	M6 × 1.0	2	6	0.6	4.3
Front fender mounting	M6 × 1.0	4	7	0.7	5.1
Rear fender mounting (front)	M6 × 1.0	2	7	0.7	5.1
Rear fender mounting (rear)	M6 × 1.0	2	11	1.1	8.0
Multi-function display bracket mounting	M6 × 1.0	2	7	0.7	5.1
Multi-function display mounting	M5 × 0.8	2	4	0.4	2.9
Plate 1 and protector	M5 × 0.8	2	4	0.4	2.9
Plate 2 and protector	—	2	0.5	0.05	0.36
Speed sensor lead holder and under bracket	M6 × 1.0	1	13	1.3	9.4
Headlight body and headlight unit	—	2	1	0.1	0.7
Headlight mounting (left and right)	M6 × 1.0	2	7	0.7	5.1
Taillight mounting	—	3	1	0.1	0.7
Taillight lead clamp and rear fender	—	3	0.5	0.05	0.36
Catch tank (upper)	M6 × 1.0	1	16	1.6	11
Catch tank (lower)	M6 × 1.0	1	7	0.7	5.1
Footrest bracket and frame	M10 × 1.25	4	55	5.5	40
Sidestand mounting	M10 × 1.25	1	25	2.5	18

NOTE:

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

EC212300

ELECTRICAL

Item	Standard	Limit
Ignition system:
Advancer type	Electrical	----
C.D.I.:
Pickup coil resistance (color)	248 ~ 372 Ω at 20 °C (68 °F)(White – Red)	----
CDI unit-model/manufacturer	5TJ-E0/YAMAHA (For USA)5TJ-F0/YAMAHA(Except for USA)	----
Ignition coil:
Model/manufacturer	5TA-10/DENSO	----
Minimum spark gap	6 mm (0.24 in)	----
Primary winding resistance	0.08 ~ 0.10 Ω at 20 °C (68 °F)	----
Secondary winding resistance	4.6 ~ 6.8 kΩ at 20 °C (68 °F)	----
Charging system:
System type	AC magneto	----
Model (stator)/manufacturer	5TJ 40/YAMAHA	----
Normal output	14 V/120 W at 5,000 r/min	----
Charging coil resistance (color)	0.288 ~ 0.432 Ω at 20 °C (68 °F)(White – Ground)	----
Lighting coil resistance (color)	0.224 ~ 0.336 Ω at 20 °C (68 °F)(Yellow – Ground)	----
Rectifier/regulator:
Regulator type	Semiconductor short circuit	----
Model/manufacture	SH770AA/SHINDENGEN	----
Regulated voltage (AC)	12.5 ~ 13.5 V	----
Regulated voltage (DC)	14.0 ~ 15.0 V	----
Rectifier capacity (AC)	12 A	----
Rectifier capacity (DC)	8 A	----
Electric starting system:
Type	Constant mesh	----
Starter motor:
Model/manufacturer	5UM20/YAMAHA	----
Operation voltage	12 V	----
Output	0.48 kW	----
Armature coil resistance	0.0117 ~ 0.0143 Ω at 20 °C(68 °F)	----
Brush overall length	7 mm (0.28 in)	3.5 mm(0.14 in)
Brash quantity	2 pcs.	----
Spring force	3.92 ~ 5.88 N(400 ~ 600 g, 14.1 ~ 21.2 oz)	----
Commutator diameter	17.6 mm (0.69 in)	16.6 mm(0.65 in)
Mica undercut (depth)	1.5 mm (0.06 in)	----

MAINTENANCE SPECIFICATIONS

SPEC

Item	Standard	Limit
Starter relay:
Model/manufacturer	2768090-A/JIDECO	----
Amperage rating	180 A	----
Coil winding resistance	4.2 ~ 4.6 Ω at 20 °C (68 °F)	----
Starting circuit cut-off relay:
Model/manufacturer	ACM33221 M06/MATSUSHITA	----
Coil winding resistance	75.69 ~ 92.51 Ω at 20 °C (68 °F)	----
Fuse (amperage × quantity):
Main fuse	10 A × 1	----
Reserve fuse	10 A × 1	----

Part to be tightened	Thread size	Q'ty	Tightening torque
			Nm	m·kg	ft·lb
Stator	M5 × 0.8	2	7	0.7	5.1
Holder (AC magneto lead)	M5 × 0.8	2	10	1.0	7.2
Rotor	M12 × 1.25	1	Refer to NOTE.
Neutral switch	M5 × 0.8	2	4	0.4	2.9
Starter motor	M6 × 1.0	2	10	1.0	7.2
Starter relay terminal	M6 × 1.0	2	4	0.4	2.9
Pick-up coil	M6 × 1.0	2	10	1.0	7.2

NOTE:

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

GENERAL TORQUE SPECIFICATIONS/DEFINITION OF UNITS

EC220001

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(Nut)	B(Bolt)	TORQUE SPECIFICATION
		Nm	m•kg	ft•lb
10 mm	6 mm	6	0.6	4.3
12 mm	8 mm	15	1.5	11
14 mm	10 mm	30	3.0	22
17 mm	12 mm	55	5.5	40
19 mm	14 mm	85	8.5	61
22 mm	16 mm	130	13	94

A B

A: Distance between flats

B: Outside thread diameter

EC230000

DEFINITION OF UNITS

Unit	Read	Definition	Measure
mmcm	millimetercentimeter	10^-3 meter 10^-2 meter	LengthLength
kg	kilogram	10^3 gram	Weight
N	Newton	1kg × m/sec^2	Force
Nm m • kg	Newton meterMeter kilogram	N × m m × kg	TorqueTorque
Pa	Pascal	N/m^2	Pressure
N/mm	Newton per millimeter	N/mm	Spring rate
L cm^3	LiterCubic centimeter	——	Volume or capacityVolume or capacity
r/min	Revolution per minute	—	Engine speed

CARACTERISTIQUES

CARACTERISTIQUES GENERALES

LUBRICATION DIAGRAMS

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

Technical schematic diagram of a mechanical assembly with labeled components and cross-sectional views (A, B, C)

DIAGRAMMES DE LUBRIFICATION

① Intake camshaft
② Exhaust camshaft
A To main axle
B From oil pump

Technical schematic diagram of a mechanical assembly with labeled components and sectional views A-A

DIAGRAMMES DE LUBRIFICATION SCHMIERSYSTEM-SCHAUBILDER DIAGRAMAS DE ENGRASE

SPEC

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
⑩ Neutral switch lead
⑪ AC magneto lead
⑫ Brake hose
⑬ Rectifier/regulator lead

⑭ Carburetor breather hose
⑮ Carburetor overflow hose
⑯ Catch tank breather hose

15-25 mm (0.59-0.98 in) A N M L K 2 ① A ② B ③ ② C ④ ⑤ ⑥ ⑦ ⑧ ⑨ F G H 2 I 2 J ⑪ ⑫ ⑬ ⑭ ⑮ ⑯ ⑰ ⑱ ⑲ ⑳ ⑴ ⑵ ⑶ ⑷ ⑧ ⑨ ⑩ O

DIAGRAMME DE CHEMINEMENT DES CABLES

A Insert the end of the fuel tank breather hose into the hole in the steering stem.
B 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.
C 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.
D 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.

E 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.
F Pass the carburetor breather hoses, carburetor overflow hose and catch tank breather hose between the connecting rod and cross tube (frame).
G Pass the neutral switch lead on the inside of the engine bracket.
H 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.

Technical diagram of a mechanical assembly with numbered components and dimensional annotations in millimeters

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.
☐ Pass the neutral switch lead and AC magneto lead on the inside of the wire harness.
K Fasten the AC magneto lead and neutral switch lead onto the frame.
L Pass the wire harness through the cable guide.
M Locate the couplers in the frame recess.
N Pass the carburetor breather hoses, carburetor overflow hose and catch tank breather hose so that the hoses do not contact the rear shock absorber.
☐ Secure the coupler by pushing it into the hole in

the headlight unit.

Technical diagram of a mechanical assembly with numbered components and dimensional annotations in millimeters

DIAGRAMME DE CHEMINEMENT DES CABLES KABELFÜHRUNGS-SCHAUBILD DIAGRAMA DE CABLEADO

SPEC

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

A Cross the pull and push throttle cables.
B 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.
C Fasten the catch tank breather hose and carburetor breather hoses together.
D Pass the carburetor breather hose (of the throttle cable cover) through the hose holder.

YAMAHA D C 6 A B 5 ① ② ④ ③

DIAGRAMME DE CHEMINEMENT DES CABLES KABELFÜHRUNGS-SCHAUBILD DIAGRAMA DE CABLEADO

SPEC

① Brake master cylinder
② Brake hose holder
③ Brake hose

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

B ② ③ A ① D C

Technical diagram of a mechanical assembly with labeled parts A and 1, showing structural components and assembly details.

DIAGRAMME DE CHEMINEMENT DES CABLES KABELFÜHRUNGS-SCHAUBILD DIAGRAMA DE CABLEADO

SPEC

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)

A 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.
B 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.
☐ Pass the starter motor lead through the hole in the relay holder.
D Fit the cover securely.
E Connect the wire harness to the starter relay.

Technical diagram of a mechanical assembly with labeled components from 1 to 18

①M ①L ①G N ⑤ ⑥P O ⑦ Q ⑧

DIAGRAMME DE CHEMINEMENT DES CABLES KABELFÜHRUNGS-SCHAUBILD DIAGRAMA DE CABLEADO

SPEC

F 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.
G 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.
H Connect the negative battery lead to the battery negative terminal.
☐ Connect the negative battery lead to the wire harness.

☐ 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.
K Pass the wire harness, starter relay lead, starting circuit cut-off relay lead and negative battery lead through the hole in the relay holder.
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.

M 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.
N Do not allow the taillight lead to slacken.
☐ Locate the CDI unit lead between the CDI unit and rear fender.
P Locate the CDI unit coupler in the clearance between the upper side of the CDI unit and lower side of the catch tank stay.
☐ Locate the CDI unit lead between the CDI unit and rear frame.

Technical diagram of a mechanical assembly with numbered components for identification and assembly reference.

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
⑩ Multi-function display bracket
⑪ Main switch
⑫ Upper bracket
⑬ Clutch switch coupler
⑭ Engine stop switch coupler
⑮ Multi-function display coupler
⑯ Start switch coupler
⑰ Speed sensor coupler
⑱ Speed sensor lead

Technical diagram of a mechanical device with numbered components and angular specifications

DIAGRAMME DE CHEMINEMENT DES CABLES KABELFÜHRUNGS-SCHAUBILD DIAGRAMA DE CABLEADO

SPEC

A Fasten the start switch lead to the handlebar with the plastic bands.
B Fasten the engine stop switch lead and clutch switch lead to the handlebar with the plastic bands.
C Pass the brake hose through the hose guides.
☐ Secure the coupler by inserting it into the multifunction display bracket.
E Pass the throttle cables, clutch cable and hot starter cable between the upper bracket and multi-function display bracket.
F Fasten the multi-function display leads to the bracket. Cut off the tie end.
G Secure the coupler by pushing it into the hole in the multi-function display bracket.
H Secure the wire harness clip by pushing it into the hole in the multi-function display bracket on the inside.

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.

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

Technical diagram of a mechanical assembly with numbered components and angular specifications

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.

* marked: For USA

Item	After break-in	Every race	Every third (or 500 km)	Every fifth (or 1,000 km)	As required	Remarks
ENGINE OILReplace	●			●
VALVESCheck the valve clearancesInspectReplace	●		●	●	●	The engine must be cold.Check the valve seats and valve stems for wear.
VALVE SPRINGSInspectReplace				●	●	Check the free length and the tilt.
VALVE LIFTERSInspectReplace				●	●	Check for scratches and wear.
CAMSHAFTSInspectReplace				●	●	Inspect the camshaft surface.Inspect the decompression system
CAMSHAFT SPROCKETSInspectReplace				●	●	Check for wear on the teeth and for damage.
PISTONInspectCleanReplace				●	●●●	Inspect crackInspect carbon deposits and eliminate them.
PISTON RINGInspectReplace				●●	●	Check ring end gap
PISTON PINInspectReplace				●	●
CYLINDER HEADInspect and clean				●		Inspect carbon deposits and eliminate them.Change gasket
CYLINDERInspect and cleanReplace				●	●	Inspect score marksInspect wear
CLUTCHInspect and adjustReplace	●	●			●	Inspect housing, friction plate, clutch plate and spring
TRANSMISSIONInspectReplace bearing					●●
SHIFT FORK, SHIFT CAM, GUIDE BARInspect					●	Inspect wear
ROTOR NUTRetighten	●			●
MUFFLERInspect and retightenCleanReplace	●	●		●	●	* Whichever comes first
*SPARK ARRESTERClean					(Every six months)●
CRANKInspect and clean				●	●
CARBURETORInspect, adjust and clean	●	●
AIR INDUCTION SYSTEMInspect and clean	●	●		●	●
SPARK PLUGInspect and cleanReplace	●		●		●
DRIVE CHAINLubricate, slack, alignmentReplace	●	●			●	Use chain lubeChain slack: 48 ~ 58 mm(1.9 ~ 2.3 in)
COOLING SYSTEMCheck coolant level and leakageCheck radiator cap operationReplace coolantInspect hoses	●	●			●●	Every two years
OUTSIDE NUTS AND BOLTSRetighten	●	●				Refer to “STARTING AND BREAK-IN” section in the CHAPTER 1.
AIR FILTERClean and lubricateReplace	●	●			●	Use foam air-filter oil or equivalent oil
OIL FILTERReplace	●			●
OIL STRAINER (frame)Clean				●
FRAMEClean and inspect	●	●
FUEL TANK, COCKClean and inspect	●		●
BRAKESAdjust lever position and pedal heightLubricate pivot pointCheck brake disc surfaceCheck fluid level and leakageRetighten brake disc bolts, caliper bolts, master cylinder bolts and union boltsReplace padsReplace brake fluid	●●●●●	●●●●●			●●	Every one year
Item	After break-in	Every race	Every third (or 500 km)	Every fifth (or 1,000 km)	As re-quired	Remarks
FRONT FORKS
Inspect and adjust	●	●				Suspension oil “S1”
Replace oil	●			●	●
Replace oil seal
FRONT FORK OIL SEAL AND DUST SEAL						Lithium base grease
Clean and lube	●	●
PROTECTOR GUIDE
Replace					●
REAR SHOCK ABSORBER					(After rain ride)	Molybdenum disulfide grease
Inspect and adjust	●	●
Lube			●		●
Retighten	●	●
DRIVE CHAIN GUARD AND ROLLERS
Inspect	●	●
SWINGARM						Molybdenum disulfide grease
Inspect, lube and retighten	●	●
RELAY ARM, CONNECTING ROD						Molybdenum disulfide grease
Inspect, lube and retighten	●	●
SIDESTAND Lubricate					●	Lithium base grease
STEERING HEAD						Lithium base grease
Inspect free play and retighten	●	●		●	●
Clean and lube
Replace bearing
TIRE, WHEELS						Lithium base grease
Inspect air pressure, wheel run-out, tire wear and spoke looseness	●	●
Retighten sprocket bolt	●	●
Inspect bearings			●		●
Replace bearings Lubricate			●
THROTTLE, CONTROL CABLE						Yamaha cable lube or SAE 10W-30 motor oil
Check routing and connection	●	●
Lubricate	●	●
HOT STARTER, CLUTCH LEVER					●
Inspect free play
BATTERY					●
Check terminal for looseness and corrosion

CONTROLES ET REGLAGES PERIODIQUES PROGRAMME D'ENTRETIEN

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

Before using this machine, check the following points.

GENERAL INSPECTION AND MAINTENANCE

Item	Routine	Page
Coolant	Check that coolant is filled up to the radiator filler cap. Check the cooling system for leakage.	P.3-5 ~ 9
Fuel	Check that a fresh gasoline is filled in the fuel tank. Check the fuel line for leakage.	P.1-21
Engine oil	Check that the oil level is correct. Check the crankcase and oil line for leakage.	P.3-14 ~ 18
Gear shifter and clutch	Check that gears can be shifted correctly in order and that the clutch operates smoothly.	P.3-9 ~ 10
Throttle grip/Housing	Check that the throttle grip operation and free play are correctly adjusted. Lubricate the throttle grip and housing, if necessary.	P.3-10 ~ 11
Brakes	Check the play of front brake and effect of front and rear brake.	P.3-25 ~ 31
Chain	Check chain slack and alignment. Check that the chain is lubricated properly.	P.3-32 ~ 35
Wheels	Check for excessive wear and tire pressure. Check for loose spokes and have no excessive play.	P.3-43 ~ 44
Steering	Check that the handlebar can be turned smoothly and have no excessive play.	P.3-44 ~ 46
Front forks and rear shock absorber	Check that they operate smoothly and there is no oil leakage.	P.3-35 ~ 42
Cables (wires)	Check that the clutch and throttle cables move smoothly. Check that they are not caught when the handlebars are turned or when the front forks travel up and down.	—
Muffler	Check that the muffler is tightly mounted and has no cracks.	—
Sprocket	Check that the driven sprocket tightening bolt is not loose.	P.3-32
Lubrication	Check for smooth operation. Lubricate if necessary.	P.3-47
Bolts and nuts	Check the chassis and engine for loose bolts and nuts.	P.1-26
Lead connectors	Check that the AC magneto, CDI unit, and ignition coil are connected tightly.	P.1-6
Settings	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?	P.7-1 ~ 20

CONTROLE ET ENTRETIEN AVANT UTILISATION

Technical diagram showing a mechanical component with labeled parts, including a numbered callout.

a ①

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

1. Check:

- Coolant level ⓐ

Coolant level low → Add coolant.

① Radiator

COOLANT REPLACEMENT

WARNING

Do not remove the radiator cap when the engine is hot.

MOTEUR

CONTROLE DU NIVEAU DU LIQUIDE DE REFROIDISSEMENT

! AVERTISSEMENT

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:

3. Seat

4. Left side cover

5. Remove the catch tank hose from the catch tank and drain the tank of its coolant.

Technical line drawing of a mechanical component with no visible text or symbols

1. Remove:

- Coolant drain bolt ①

1. Remove:

- Radiator cap Drain the coolant completely.

1. Clean:

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

1. Install:

2. Copper washer New

3. Coolant drain bolt

10 Nm (1.0 m · kg, 7.2 ft · lb)

ATTENTION:

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.

9. Install:

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

10. Check:

- Coolant level Coolant level low → Add coolant.

CHANGEMENT DU LIQUIDE DE REFROIDISSEMENT KÜHLFLÜSSIGKEIT WECHSELN CAMBIO DEL REFRIGERANTE

① ② ③ I4110101

① ② ③ I4110202

EC355000

RADIATOR CAP INSPECTION

1. Inspect:

• Seal (radiator cap) ①
• Valve and valve seat ②

Crack/damage → Replace.

Exist fur deposits ③ → Clean or replace.

EC356001

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

1. Apply the specified pressure.

Radiator cap opening pressure: 110 kPa (1.1 kg/cm ^2 , 15.6 psi)

3. Inspect:

- Pressure

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

CONTROLE DU BOUCHON DE RADIATEUR

1. Contrôler:

Technical diagram showing mechanical assembly with labeled parts, including pressure gauge and tubing connections

EC357002

COOLING SYSTEM INSPECTION

1. Inspect:

- Coolant level

1. Attach:

- Radiator cap tester ① and adapter ②

Radiator cap tester: YU-24460-01/90890-01325

Adapter: YU-33984/90890-01352

1. Apply the specified pressure.

Standard pressure: 180 kPa (1.8 kg/cm ^2 , 25.6 psi)

NOTE:

• Do not apply pressure more than specified pressure.

• Radiator should be filled fully.

• 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.

a

EC359020

CLUTCH ADJUSTMENT

1. Check:

- Clutch lever free play @

Out of specification → Adjust.

Clutch lever free play ⓐ: 8 \~ 13 mm (0.31 \~ 0.51 in)

CONTROLE DU CIRCUIT DE REFROIDISSEMENT

1. Contrôler:

Technical diagram of a mechanical assembly with numbered components labeled ①, ②, and ③.

2. Adjust:

- Clutch lever free play

Clutch lever free play adjustment steps:

• Loosen the locknut ①.
• Turn the adjuster ② until free play ⓐ is within the specified limits.
• Tighten the locknut.

Locknut:

4 Nm (0.4 m · kg, 2.9 ft · lb)

NOTE:

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

a

EC35A001

THROTTLE CABLE ADJUSTMENT

1. Check:

• Throttle grip free play @
  Out of specification → Adjust.

Throttle grip free play ⓐ:

3 \~ 5 mm (0.12 \~ 0.20 in)

2. Adjust:

- Throttle grip free play

Technical diagram of a mechanical assembly with numbered components labeled ① and ②

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.

Locknut:

4 Nm (0.4 m • kg, 2.9 ft • lb)

NOTE:

Before adjusting the throttle cable free play, the engine idle speed should be adjusted.

WARNING

After adjusting the throttle cable free play, start the engine and turn the handlebar to right and left and make sure that the engine idling does not run faster.

2. Régler:

Technical diagram showing three labeled mechanical components with numbered annotations (①, ②, ③)

Technical diagram showing mechanical assembly with labeled parts a and B, likely illustrating a gear or cam mechanism.

Technical diagram of a mechanical lever assembly with labeled parts and dimension annotations

THROTTLE LUBRICATION

1. Remove:

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

2. Apply:

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

3. Install:

- Throttle cable cap - Screw (throttle cable cap)

4 Nm (0.4 m · kg, 2.9 ft · lb)

- Cover (grip cap) - Cover (throttle cable cap)

HOT STARTER LEVER ADJUSTMENT

1. Check:

- Hot starter lever free play @ Out of specification → Adjust.

Hot starter lever free play ⓐ: 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 @ is within the specified limits.Tighten the locknut.
	Locknut:4 Nm (0.4 m • kg, 2.9 ft • lb)

NOTE:

After adjustment, check proper operation of hot starter.

GRAISSAGE DE L'ACCELERATEUR

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.

Technical diagram of a vehicle's internal components with numbered parts and directional arrow indicating motion or flow.

Technical line drawing of a mechanical component with no visible text or symbols

Technical diagram showing two hands operating a mechanical component with labeled parts ① and ②

Illustration showing three steps of a hand holding a small object, with arrows indicating the process and falling droplets.

1. Unhook:

- Binder ①

1. Remove:

2. Air filter element ①

3. Filter guide ②

4. Clean:

- Air filter element

Clean them with solvent.

NOTE:

After cleaning, remove the remaining solvent by squeezing the element.

NETTOYAGE DU FILTRE A AIR

N.B.:

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

• Inspect:

- Air filter element

Damage → Replace.

1. 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.)

• Install:

- Filter guide ①

NOTE:

• Align the projection ⓐ on filter guide with the hole Ⓑ in air filter element.

• Apply the lithium soap base grease on the matching surface © on air filter element.

• Install:

- Air filter element ①

NOTE:

Align the projection ⓐ on filter guide with the hole ⓑ in air filter case.

Technical diagram of a mechanical assembly with labeled parts (a, b, c) and a tool labeled B

Technical diagram showing mechanical components with labeled parts a and b, likely illustrating a gear or valve mechanism.

Technical diagram of a mechanical component with labeled parts 1 and a, showing internal structure and motion lines.

1. Hook:

- Binder ①

NOTE:

Hook the binder ① so that it contacts the filter guide projections ⓐ.

ATTENTION:

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).

1. Idle the engine more than 3 minutes while keeping the machine upright. Then stop the engine and inspect the oil level.

Technical diagram of a mechanical assembly with labeled component 1

Technical diagram showing mechanical assembly with labeled component 'a' and a close-up of a screwdriver tool.

Technical line drawing of a mechanical assembly with gears and levers (no text or symbols)

1. Remove:

- Oil tank plug ①

1. Inspect:

- Oil level

Check that the engine oil is above the level mark ⓐ and that the oil does not come out when the check bolt ① is removed.

Below the level mark ⓐ → Add oil through the filler cap hole until it is above the level mark ⓐ.

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.

CONTROLE DU NIVEAU D'HUILE MOTEUR

• 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)

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

CAUTION:

• Do not add any chemical additives or use oils with a grade of CD ⓐ or higher.
• Do not use oils labeled “ENERGY CONSERVING II” ⑥ or higher. Engine oil also lubricates the clutch and additives could cause clutch slippage.

• Do not allow foreign materials to enter the crankcase.

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

CAUTION:

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

(USA et CDN)

Huile recommandée: Yamalube 4, SAE10W30 ou SAE20W40 Yamalube 4-R, SAE10W50 API Service de type SG et au-delà/JASO MA

ATTENTION:

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

2. Install:

- Oil tank plug

Technical diagram of a mechanical assembly with numbered parts labeled ①, ②, and ③

Technical line drawing of a mechanical assembly showing internal components and a close-up view (no text or symbols)

Technical diagram of a mechanical assembly with numbered components, likely illustrating a gear or cam mechanism.

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:
4. Engine guard ①
5. Oil tank plug ②
6. Oil filler cap ③
7. Drain bolt (with gasket) ④
8. Oil filter drain bolt (O-ring) ⑤
9. Drain bolt (with gasket) ⑥

Drain the crankcase and oil tank of its oil.

① ③ New ③ New ② ③ New ③ New

1. 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.

Oil filter cover: 10 Nm (1.0 m • kg, 7.2 ft • lb)

5. Install:

• Gaskets
  New
• Oil filter drain bolt

10 Nm (1.0 m · kg, 7.2 ft · lb)

- Drain bolt (crankcase right)

- Drain bolt (crankcase left)

Technical line drawing of a mechanical assembly with no visible text or symbols

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".

Technical diagram of a mechanical assembly with numbered component label

9. Check:

- 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.

Oil gallery bolt: 10 Nm (1.0 m • kg, 7.2 ft • lb)

Technical diagram showing mechanical assembly with labeled parts a and b, including directional arrows indicating motion or movement.

Technical diagram showing mechanical assembly with labeled parts (② and C) and a numbered annotation

EC35M021

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 © of the engine tachometer close to the ignition coil ②.

To increase idle speed → Turn the throttle stop screw ① in ⓐ.

To decrease idle speed → Turn the throttle stop screw ① out ⑥.

Engine idling speed: 1,750 \~ 1,850 r/min

VALVE CLEARANCE ADJUSTMENT

NOTE:

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

1. Remove:

• 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

Technical diagram of a mechanical assembly with numbered components and labeled parts

Technical diagram of a mechanical assembly with labeled parts and directional arrows indicating motion or flow.

4. Check:

• 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 ⓐ on the rotor with the align mark ⓑ on the crankcase cover when piston is at T.D.C. on compression stroke.

REGLAGE DU JEU AUX SOUPAPES

N.B.:

Technical diagram of a mechanical assembly with labeled parts (c) and d, showing gear and shaft components.

Technical diagram of a mechanical assembly with labeled components and directional arrows

Technical line drawing of a mechanical assembly with hands and components (no text or symbols)

Technical diagram of an internal combustion engine showing labeled components including crankshaft, gear heads, and wiring.

NOTE:

In order to be sure that the piston is at Top Dead Center, the punch mark © on the exhaust camshaft and the punch mark ⓐ on the intake camshaft must align with the cylinder head surface, as shown in the illustration.

- Measure the valve clearance ⓔ using a feeler gauge ①.

NOTE:

Record the measured reading if the clearance is incorrect.

5. Adjust:

- Valve clearance

Adjustment steps:

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

NOTE:

Remove the camshaft cap bolts in a criss-cross 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.

N.B.:

Technical diagram of an engine cylinder with numbered components for assembly or maintenance reference.

EX IN

a 175

• Remove the valve lifters ④ and the pads ⑤.
• Place a rag in the timing chain space to prevent pads from falling into the crank-case.
• 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.

NOTE:

Pad range		Pad Availability: 25 increments
No. 120 ~ No. 240	1.20 mm ~ 2.40 mm	Pads are available in 0.05 mm increments

NOTE:

The thickness @ of each pad is indicated inhundreds 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	Rounded value
0, 1 or 2	0
4, 5 or 6	5
8 or 9	10

EXAMPLE:

Installed pad number = 148

Rounded off value = 150

NOTE:

Pads can only be selected in 0.05 mm increments.

Technical diagram of a mechanical assembly with labeled parts and numbered annotations

- 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.

Bolt (camshaft cap): 10 Nm (1.0 m • kg, 7.2 ft • lb)

- 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.

Technical diagram of a car interior with labeled components and directional arrows indicating movement or flow.

Line drawing of a car interior showing steering wheel and dashboard (no text or symbols)

Technical diagram of a mechanical assembly with numbered components labeled 1 to 4

Diagram showing car head and steering wheel with labeled steering wheel positions (a, d, e) and a magnified inset of the steering wheel.

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.

• Remove:

- Screw (silencer cap) ①

1. Remove:

- Bolt (spark arrester) ①

1. Remove:

2. Tail pipe ①

3. Gasket (tail pipe) ②
4. Spark arrester ③
   Pull the spark arrester out of the silencer.

5. Gasket (spark arrester) ④

6. Clean:

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

1. Install:

2. Gasket (spark arrester)

3. Spark arrester Insert the spark arrester into the silencer and align the bolt holes.
4. Gasket (tail pipe)
5. Bolt (spark arrester)

7 Nm (0.7 m · kg, 5.1 ft · lb)

1. Install:

- Silencer cap

5 Nm (0.5 m · kg, 3.6 ft · lb)

NOTE:

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

NETTOYAGE DU PARE- ETINCELLES (USA)

! AVERTISSEMENT

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.

A ① ②

B ① ②

1. Remove:

• Master cylinder cap
• Diaphragm
• Reservoir float (front brake)
• Protector (rear brake)

2. Bleed:

- Brake fluid

A Front

B 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.

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

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

CHASSIS

PURGE D'AIR DU CIRCUIT DE FREINAGE

! AVERTISSEMENT

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

a

Technical diagram of a mechanical assembly with labeled parts 1 and 2

EC362040

Brake lever position adjustment steps:Loosen the locknut 1.Turn the adjusting bolt 2 until the lever position @ is within specified position.Tighten the locknut.
	Locknut:5 Nm (0.5 m • kg, 3.6 ft • lb)
CAUTION:Be sure to tighten the locknut, as it will cause poor brake performance.

4. Install:

- Lever cover

N.B.:

Technical diagram of a mechanical assembly with labeled parts 1 and 2

A ③ ④ b

B ③ ⑤ C

Technical diagram of a mechanical assembly with labeled parts and dimension annotations

Technical line drawing of a mechanical assembly with no visible text or symbols

EC364002 REAR BRAKE ADJUSTMENT

1. Check:

- Brake pedal height @ Out of specification → Adjust.

Brake pedal height ⓐ: 10 mm (0.39 in)

2. Adjust:

- Brake pedal height

Pedal height adjustment steps:

• Loosen the locknut ①.
• Turn the adjusting nut ② until the pedal height @ is within specified height.
• Tighten the locknut.

WARNING

• Adjust the pedal height between the maximum A and the minimum B as shown. (In this adjustment, the bolt ③ end ⑥ should protrude out of the threaded portion ④ but not be less than 2 mm (0.08 in) © away from the brake pedal ⑤).
  • After the pedal height adjustment, make sure that the rear brake does not drag.

EC365080 FRONT BRAKE PAD INSPECTION AND REPLACEMENT

1. Inspect:

- Brake pad thickness @ Out of specification → Replace as a set.

Brake pad thickness ⓐ:

Standard
4.4 mm (0.17 in)	1.0 mm (0.04 in)

2. Replace:

- Brake pad

Brake pad replacement steps:

- Remove the pad pin plug ①.

REGLAGE DU FREIN ARRIERE

1. Contrôler:

Technical diagram of a vehicle brake system with numbered components and assembly lines

Technical diagram showing mechanical assembly with numbered component labeled 4

Technical diagram showing hands using a tool to adjust or install a mechanical component, labeled with parts ⑤ and ⑥.

Technical diagram showing mechanical assembly with labeled parts and an inset detail view of a component

Technical diagram of a vehicle brake system with numbered components and assembly lines

• 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.

CAUTION:

Do not reuse the drained brake fluid.

- Tighten the bleed screw.

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

• Install the brake pads ⑦ and pad pin.

NOTE:

• Install the brake pads with their projections ① into the caliper recesses ②.
• Temporarily tighten the pad pin at this point.
• Install the caliper ⑧ and tighten the pad pin ⑨.

Bolt (caliper): 23 Nm (2.3 m • kg, 17 ft • lb)

Pad pin: 18 Nm (1.8 m • kg, 13 ft • lb)

Technical line drawing of a bicycle brake system with no visible text or symbols

• Install the pad pin plug 10.
	Pad pin plug:3 Nm (0.3 m • kg, 2.2 ft • lb)

3. Inspect:

- Brake fluid level

Refer to "BRAKE FLUID LEVEL INSPECTION" section.

4. Check:

- Brake lever operation

A softly 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 ⓐ

Out of specification → Replace as a set.

Technical diagram showing mechanical assembly with labeled parts 'a' and directional arrows indicating movement or force.

Brake pad thickness @:
Standard
6.4 mm (0.25 in)	1.0 mm (0.04 in)

Technical diagram of a mechanical component with numbered parts labeled ① and ②

2. Replace:

- 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.

Technical diagram of automotive suspension system components with numbered parts labeled 3, 4, and 5

Technical diagram of a mechanical assembly with numbered components, likely for assembly or maintenance instructions.

Technical diagram showing hands using a tool to adjust or install a mechanical component, with numbered annotations 8 and 9 indicating parts of the process.

Technical diagram showing mechanical assembly with numbered components and a magnified detail view labeled 'a'

Technical diagram of a mechanical assembly with numbered components labeled 12, 13, and 14

Technical diagram of a mechanical component with numbered parts labeled 15 and 16

• 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.

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

- Install the brake pad ⑩ and pad pin ⑪.

NOTE:

• Install the brake pads with their projections ① into the caliper recesses ⑥.
• Temporarily tighten the pad pin at this point.
• Install the caliper ⑫ and rear wheel ⑬. Refer to “FRONT WHEEL AND REAR WHEEL” section in the CHAPTER 5.
• Tighten the pad pin ⑭.

Pad pin: 18 Nm (1.8 m • kg, 13 ft • lb)

- Install the pad pin plug ⑮ and protector ⑯.

Pad pin plug: 3 Nm (0.3 m • kg, 2.2 ft • lb)

Bolt (protector): 7 Nm (0.7 m • kg, 5.1 ft • lb)

Technical line drawing of three mechanical clamping components (no text or symbols)

A T LWR a

B LOW a

3. Inspect:

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

4. Check:

- Brake pedal operation A softly 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.

EC367001

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.

① Lower level
A Front
B Rear

Recommended brake fluid: DOT #4

WARNING

• Use only designated quality brake fluid to avoid poor brake performance.
• Refill with same type and brand of brake fluid; mixing fluids could result in poor brake performance.
• Be sure that water or other contaminants do not enter master cylinder when refilling.

• Clean up spilled fluid immediately to avoid erosion of painted surfaces or plastic parts.

• Contrôler:

- Sprocket teeth @ 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) ⓐ Out of specification → Replace.

Drive chain length (15 links): : 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 ⑯ as shown.
• Perform this measurement at two or three different places.

Technical diagram showing a hand operating a chain link mechanism with labeled parts ① and ②

Technical diagram showing a hand using a tool to trim a chain, with an inset image of a mechanical component labeled '①'.

2. Remove:

- 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.

CONTROLE DES PIGNONS

1. Contrôler:

- Dents de pignon @ Usure excessive → Remplacer.

N.B.:

Technical diagram showing three labeled mechanical components with numbered annotations

graph TD
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    B --> C["Right Node"]
    C --> D["Bottom Node"]
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New ① ② ③ New ④ B B

Technical illustration showing two mechanical assembly steps: one for hand tooling a chain, the other for manual hand holding a chain (no text or symbols present)

Illustration of a hand using a tool to adjust a chain track with a gear (no text or symbols)

4. Inspect:

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

Damage/wear → Replace the drive chain.

5. Check:

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

6. Install:

• 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.

7. Install:

- 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

4. Contrôler:

Technical diagram showing mechanical assembly with labeled parts and directional arrows

DRIVE CHAIN SLACK ADJUSTMENT

1. Elevate the rear wheel by placing the suitable stand under the engine.
2. Check:

- Drive chain slack ⓐ

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.

Technical diagram of a mechanical assembly with labeled parts including a, 1, 2, and 3.

1. Adjust:

- 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 @ 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.

REGLAGE DE LA TENSION DE LA CHAINE DE TRANSMISSION

Technical line drawing of a motorcycle's front wheel and suspension mechanism (no text or symbols)

Technical line drawing of a mechanical component with no visible text or symbols

Technical diagram of a mechanical assembly with labeled parts a and b, showing directional arrows and a tool labeled B.

EC36C000

FRONT FORK INSPECTION

1. Inspect:

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

EC36D001

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 ⓐ
• Oil seal ⓑ

NOTE:

• Clean the dust seal and oil seal after every run.
• Apply the lithium soap base grease on the inner tube.

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

1 Nm (0.1 m · kg, 0.7 ft · lb)

① a H-S b

EC36H002

FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT

1. Adjust:

• Rebound damping force
  By turning the adjuster ①.

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

Softer ⓑ → Decrease the rebound damping force. (Turn the adjuster 1 out.)

Extent of adjustment:
Maximum	Minimum
Fully turned in position	20 clicks out (from maximum position)

REDUCTION DE LA PRESSION INTERNE DE LA FOURCHE

N.B.:

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.

Technical diagram of a mechanical component with labeled parts and directional arrows indicating rotation or movement.

EC36J001

FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT

1. Remove:
2. Rubber cap
3. Adjust:
4. Compression damping force By turning the adjuster ①.

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

Softer ⑥ → Decrease the compression damping force. (Turn the adjuster ① out.)

Extent of adjustment:

Maximum	Minimum
Fully turned in position	20 clicks out (from maximum position)

REGLAGE DE LA FORCE D'AMORTISSEMENT A LA COMPRESSION DE LA FOURCHE DRUCKSTUFEN-DÄMPFUNGSKRAFT DER TELESKOPGABEL EINSTELLEN AJUSTE DE LA AMORTIGUACIÓN EN COMPRESIÓN DE LA HORQUILLA DELANTERA

INSP ADJ

[NO TEXT]

- POSITION STANDARD:

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.

1. Install:

- Rubber cap

Mechanical assembly diagram showing a gear and chain mechanism with no visible text or symbols

EC36K000

REAR SHOCK ABSORBER INSPECTION

1. Inspect:

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

Technical diagram of a mechanical assembly with labeled parts ① and ②, showing components like a spring and housing.

Technical line drawing of a mechanical spring assembly with dimension label (a), no text or symbols present

REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT

1. Elevate the rear wheel by placing the suitable stand under the engine.
2. Remove:

- Rear frame

1. Loosen:

- Locknut ①

1. 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
252.5 mm (9.94 in)* 251.5 mm (9.90 in)		238.5 ~ 258.5 mm(9.39 ~ 10.18 in)

* For EUROPE

NOTE:

• Be sure to remove all dirt and mud from around the locknut and adjuster before adjustment.
• The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjuster.

CAUTION:

Never attempt to turn the adjuster beyond the maximum or minimum setting.

1. Tighten:

- Locknut

1. Install:

- Rear frame (upper)

- Rear frame (lower)

38 Nm (3.8 m · kg, 27 ft · lb)

32 Nm (3.2 m · kg, 23 ft · lb)

REGLAGE DE LA PRECONTRAINTE DU RESSORT DE L'AMORTISSEUR ARRIERE

- Rebound damping force By turning the adjuster ①.

Technical diagram showing mechanical assembly with labeled parts (a, b) and directional arrows indicating motion or movement.

Stiffer ① → Increase the rebound damping force. (Turn the adjuster ① in.) Softer ② → Decrease the rebound damping force. (Turn the adjuster ① out.)

Extent of adjustment:

Maximum	Minimum
Fully turned in position	20 clicks out (from maximum position)

S b a H

• 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 ⓐ on the adjuster with the punch mark ⓑ 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.

REGLAGE DE LA FORCE D'AMORTISSEMENT A LA DETENTE DE L'AMORTISSEUR ARRIERE

1. Régler:

- Low compression damping force By turning the adjuster ①.

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

Softer ⑥ → Decrease the low compression damping force. (Turn the adjuster ① out.)

Extent of adjustment:

Maximum	Minimum
Fully turned in position	20 clicks out (from maximum position)

a b

• 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 ⓐ on the adjuster with the punch mark ⓑ on the high compression damping adjuster.)

Standard position:

About 8 clicks out

*About 11 clicks out

**About 9 clicks out

* For EUROPE
** For AUS, NZ and ZA

CAUTION:

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

REGLAGE DE LA FORCE D'AMORTISSEMENT A LA COMPRESSION BASSE DE L'AMORTISSEUR ARRIERE

1. Régler:

Technical diagram showing mechanical assembly with labeled parts (a, b) and directional arrows indicating motion or movement.

EC36d000

REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT

1. Adjust:

- High compression damping force By turning the adjuster ①.

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

Softer ⑥ → Decrease the high compression damping force. (Turn the adjuster ① out.)

Extent of adjustment:

Maximum	Minimum
Fully turned in position	2 turns out (from maximum position)

a b

• 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 ⓐ on the adjuster with the punch mark ⓑ on the adjuster body.)

Standard position: 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.

REGLAGE DE LA FORCE D'AMORTISSEMENT A LA COMPRESSION HAUTE DE L'AMORTISSEUR ARRIERE

1. Régler:

Illustration of hands adjusting a pressure gauge with a tool (no text or symbols present)

EC36Q000

TIRE PRESSURE CHECK

1. Measure:

- Tire pressure

Out of specification → Adjust.

Standard tire pressure: 100 kPa (1.0 kgf/cm ^2 , 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.

1 I2010801

EC36S002

SPOKES INSPECTION AND TIGHTENING

1. Inspect:

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

2. Tighten:

- Spokes

3 Nm (0.3 m · kg, 2.2 ft · lb)

NOTE:

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

Mechanical diagram showing a hand operating a gear and rotating a wheel with a tool, no text or symbols present.

EC36T000

WHEEL INSPECTION

1. Inspect:

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

CONTROLE DE LA PRESSION DES PNEUS

1. Mesurer:

Mechanical diagram showing a hand operating a gear with rotating components and motion arrows (no text or symbols)

Diagram of a hand using a tool to lift a car wheel, showing motion arrows (no text or symbols)

Technical line drawing of a mechanical assembly with directional arrows indicating movement or force (no text or symbols)

Technical diagram of a mechanical assembly with labeled parts ① and ②

2. Inspect:

- 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.

4. Adjust:

- 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

CONTROLE ET REGLAGE DE LA TETE DE FOURCHE LENKKOPFLAGER KONTROLLIEREN UND EINSTELLEN REVISIÓN Y AJUSTE DE LA COLUMNÁ DE LA DIRECCIÓN

2. Contrôler:

Technical diagram of a mechanical assembly with labeled parts and directional arrows

Technical diagram showing a hand adjusting a mechanical component with labeled part 5

Technical diagram showing mechanical assembly with numbered components and FWD indicator

b H-9 H-2 H-1 H-9

- 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) ⑩ and headlight ⑪.

NOTE:

• The handlebar holder (upper) should be installed with the punched mark ⓐ forward.
• Install the handlebar so that the marks ⑥ are in place on both sides.

CONTROLE ET REGLAGE DE LA TETE DE FOURCHE LENKKOPFLAGER KONTROLLIEREN UND EINSTELLEN REVISIÓN Y AJUSTE DE LA COLUMNÁ DE LA DIRECCIÓN

Hakenschlüssel: YU-33975/90890-01403

-2 -1 +1 +2 C

• Install the handlebar so that the projection © of the handlebar holder (upper) is positioned at the mark on the handlebar as shown.
• Insert the end of the fuel breather hose ⑫ 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.

Steering shaft nut:
145 Nm (14.5 m • kg, 105 ft • lb)
Handlebar holder (upper):
28 Nm (2.8 m • kg, 20 ft • lb)
Pinch bolt (handle crown):
21 Nm (2.1 m • kg, 15 ft • lb)
Headlight:
7 Nm (0.7 m • kg, 5.1 ft • lb)

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
⑩ Hot starter cable end

A Use Yamaha cable lube or equivalent on these areas.
B Use SAE 10W-30 motor oil or suitable chain lubricants.
C Lubricate the following areas with high quality, lightweight lithium-soap base grease.

CAUTION:

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

A		A		A
A		A		B
C		C

LUBRIFICATION

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.

1. Measure:

- Plug gap ⓐ

Use a wire gauge or thickness gauge.

Out of specification → Regap.

Spark plug gap: 0.7 \~ 0.8 mm (0.028 \~ 0.031 in)

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

NG K b a I8040301

1. Tighten:

- Spark plug

13 Nm (1.3 m · kg, 9.4 ft · lb)

NOTE:

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

PARTIE ELECTRIQUE CONTROLE DE LA BOUGIE

1. Déposer:

- Bougie

1. Contrôler:

Technical diagram of a mechanical assembly with labeled parts, including a numbered component and circular features.

Technical line drawing of a mechanical assembly with an inset showing a close-up of a component (no text or symbols present)

IGNITION TIMING CHECK

1. Remove:

- Timing plug ①

2. Attach:

• Timing light
• Inductive tachometer

To the ignition coil lead (orange lead ①).

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

3. Adjust:

- Engine idling speed

Refer to "IDLE SPEED ADJUSTMENT".

a b

4. Check:

- Ignition timing

Visually check the stationary pointer ⓐ is within the firing range ⓑ on the rotor.

Incorrect firing range → Check rotor and pickup assembly.

5. Install:

- Timing plug

CONTROLE DE L'AVANCE A L'ALLUMAGE

1. Déposer:

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.
• Drink large quantities of water or milk followed with milk of magnesia, beaten egg or vegetable oil. Get immediate medical attention.

INTERNAL

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.

CONTROLE ET CHARGE DE LA BATTERIE

! AVERTISSEMENT

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

Technical diagram of a mechanical assembly with labeled components ① and ②

Diagram showing a battery connected to a multimeter with labeled connection point ①

2. Disconnect:

- 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 open-circuit voltage equals or exceeds 12.8 V.

CONTROLE ET CHARGE DE LA BATTERIE BATTERIE KONTROLLIEREN UND LADEN COMPROBACIÓN Y CARGA DE LA BATERÍA

N.B.:

- 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%

A 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.)

B Open-circuit voltage
C Charging time (hours)
D Time (minutes)
E Charging condition of the battery
F Ambient temperature 20 °C (68 °F)
① Charging
⑥ Check the open-circuit voltage.

1. Charge:

- Battery

(refer to the appropriate charging method illustration)

WARNING

Do not quick charge a battery.

CAUTION:

• 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.

Charging method using a variable voltage charger

graph TD
    A["Charger"] -->|YES| B["Adjust the voltage to obtain the standard charging amperage."]
    A -->|NO| C["Adjust the charging voltage to 20 ~ 25 V."]
    B --> D["Set the timer to the charging time determined by the open-circuit voltage.<br>Refer to &quot;BATTERY INSPECTION AND CHARGING&quot; section."]
    D --> E["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."]
    E --> F["Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage.<br>12.8 V → Charging is complete.<br>12.0 ~ 12.7 V → Recharging is required.<br>Under 12.0 V → Replace the battery."]
    F --> G["If the amperage does not exceed the standard charging amperage after 5 minutes, replace the battery."]
    G --> H["Monitor the amperage for 3 ~ 5 minutes. Is the standard charging amperage exceeded?"]
    H --> I["Adjust the charging voltage to 20 ~ 25 V."]
    I --> J["Is the amperage higher than the standard charging amperage written on the battery?"]
    J --> K["Connect a charger and ammeter to the battery and start charging."]
    K --> L["Measure the open-circuit voltage prior to charging."]
    L --> M["NOTE: Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage."]
    M --> N["NOTE: Set the charging voltage to 16-17 V. (If the charging voltage is lower, charging will be insufficient, if it is higher, the battery will be over-charged.)"]

Charging method using a constant voltage charger

graph TD
    A["Measure the open-circuit voltage prior to charging."] --> B["Connect a charger and ammeter to the battery and start charging."]
    B --> C{Is the amperage higher than the standard charging amperage written on the battery?}
    C -->|YES| D["Charge the battery until the charging voltage reaches 15 V."]
    C -->|NO| E["This type of battery charger cannot charge an MF battery. A variable voltage charger is recommended."]
    D --> F["Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage.<br>12.8 V → Charging is complete.<br>12.0 ~ 12.7 V → Recharging is required.<br>Under 12.0 V → Replace the battery."]
    F --> G["CAUTION: Constant amperage chargers are not suitable for charging MF batteries."]
    E --> H["Voltmeter"]
    E --> I["Charger"]
    I --> J["Ammeter"]
    J --> K["NOTE: Leave the battery unused for more than 30 minutes before measuring its open-circuit voltage."]

Technical diagram of a mechanical assembly with labeled components ① and ②

Technical diagram of a vehicle's internal components with numbered labels pointing to parts ① and ②.

1. Install:

2. Battery

3. Battery band

4. Connect:

- Battery leads (to the battery terminals)

CAUTION:

First, connect the positive lead ①, then the negative lead ②.

1. Check:

2. Battery terminals
   Dirt → Clean with a wire brush.
   Loose connection → Connect properly.

3. Lubricate:

- Battery terminal

Recommended lubricant: Lithium soap base grease

1. Install:

- Seat

EAS00181

FUSE INSPECTION

CAUTION:

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

1. Remove:
2. Seat
3. Fuse cover
4. Check:
5. Continuity

Checking steps:

• 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

Pure electrical circuit lines without any symbols

3. Replace:

- 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	Amperage rating	Q’ty
Main fuse	10 A	1

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

Technical line drawing of a mechanical assembly with labeled component (1), no readable text or symbols present

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

Technical diagram of a mechanical assembly with labeled component ①

3. Remove:

- Headlight bulb holder ①

NOTE:

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

REMPLACEMENT DES AMPOULES DE PHARE SCHEINWERFERLAMPE ERNEUERN CAMBIO DE LAS BOMBILLAS DEL FARO

3. Remplacer:

- Fusible grillé

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 head-light 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.

6. Install:

- Headlight bulb holder

7. Install:

• Headlight bulb holder cover

8. Install:

- Headlight 7 Nm (0.7 m · kg, 5.1 ft · lb) Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 4.

Technical diagram of a vehicle front panel with labeled parts and directional arrows indicating movement or rotation.

ADJUSTING THE HEADLIGHT BEAMS

1. Adjust:

- Headlight beam (vertically)

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

① Seat removal
③ Side covers removal

② Fuel tank removal
④ Headlight removal

Extent of removal		Order	Part name	Q'ty	Remarks
Preparation for removal			SEAT, FUEL TANK AND SIDE COVERS REMOVALTurn the fuel cock to “OFF”.Disconnect the fuel hose.
		1	Seat	1	Open the air filter case cover.Refer to “REMOVAL POINTS”.
		2	Air scoop (left and right)	2
		3	Bolt (fuel tank)	2
		4	Fuel tank	1
		5	Side cover (left)	1
		6	Side cover (right)	1
		7	Headlight coupler	1
		8	Headlight	1

MOTEUR

SELLE, RESERVOIR DE CARBURANT ET CACHES LATERAUX

Technical diagram showing a mechanical component with labeled parts (1) and (a), and an arrow indicating direction.

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 ⓐ is inserted in the air filter case.

SELLE, RESERVOIR DE CARBURANT ET CACHES LATERAUX SITZBANK, KRAFTSTOFFTANK UND SEITENABDECKUNGEN SILLÍN, DEPÓSITO DE COMBUSTIBLE Y CUBIERTAS LATERALES

POINTS DE DEPOSE

Cache latéral

Extent of removal:
① Silencer removal
② Exhaust pipe removal

Extent of removal		Order	Part name	Q'ty	Remarks
Preparation for removal			EXHAUST PIPE AND SILENCER REMOVALSide cover (right)		Refer to “SEAT, FUEL TANK AND SIDE COVERS” section.
		1	Bolt (clamp)	1	Only loosening.
		2	Bolt [silencer (front)]	1
		3	Bolt [silencer (rear)]	1
		4	Collar	1
		5	Silencer	1
		6	Clamp	1
		7	Nut (exhaust pipe)	1
		8	Bolt (exhaust pipe)	1
		9	Exhaust pipe	1
		10	Gasket	2

TUBE D'ECHAPPEMENT ET SILENCIEUX AUSPUFFKRÜMMER UND SCHALLDÄMPFER TUBO DE ESCAPE Y SILENCIADOR

TUBE D'ECHAPPEMENT ET SILENCIEUX

Technical line drawing of a pipe fitting with a separate inset showing a ring and a labeled part (1), no text or symbols present.

Technical diagram of a mechanical assembly with numbered components for identification

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

20 Nm (2.0 m · kg, 1.4 ft · lb)

- 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).

Technical diagram of a vehicle's engine assembly with numbered components and a 'New' label indicating new component.

2. Install:

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

30 Nm (3.0 m · kg, 22 ft · lb)

TUBE D'ECHAPPEMENT ET SILENCIEUX AUSPUFFKRÜMMER UND SCHALLDÄMPFER TUBO DE ESCAPE Y SILENCIADOR

CONTROLE

Extent of removal:
① Radiator removal
② Coolant reservoir removal

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		RADIATOR REMOVALDrain the coolant.Seat, fuel tank and side coverExhaust pipe		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.
[64E2]	1	Panel	2
	2	Clamp	8
	3	Radiator (right)	1
	4	Hose 2	1
	5	Hose 3	1
	6	Hose 4	1
	7	Pipe 2/O-ring	1/1
	8	Catch tank hose	1
	9	Radiator (left)	1
	10	Hose 1	1
	11	Pipe 1/O-ring	1/1
	12	Catch tank breather hose	1
	13	Catch tank	1

RADIATEUR

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.

Diagram illustrating a mechanical or structural assembly with labeled component ①, showing a hand interacting with layered components.

Technical diagram showing labeled mechanical components with numbered annotations

Technical diagram of a mechanical assembly with labeled components and cross-sectional views

EC454000

INSPECTION

EC444100

Radiator

1. Inspect:

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

EC455000

ASSEMBLY AND INSTALLATION

Radiator

1. Install:

• Pipe 1 ①
• Hose 1 ②
• Pipe 2 ③
• Hose 3 ④
• Hose 4 ⑤
  10 Nm (1.0 m · kg, 7.2 ft · lb)
  2 Nm (0.2 m · kg, 1.4 ft · lb)
  10 Nm (1.0 m · kg, 7.2 ft · lb)
  2 Nm (0.2 m · kg, 1.4 ft · lb)
  2 Nm (0.2 m · kg, 1.4 ft · lb)

2. Install:

- Hose 2 ① 2 Nm (0.2 m · kg, 1.4 ft · lb)

- Radiator (left) ②

10 Nm (1.0 m · kg, 7.2 ft · lb)

REMARQUES CONCERNANT LA MANIPULATION

! AVERTISSEMENT

Technical diagram of a mechanical assembly with labeled components, showing internal components and connections.

Technical diagram showing mechanical assembly with labeled parts (a, b) and directional arrows indicating movement or force.

Technical diagram of a mechanical assembly with numbered components for identification

3. Install:

• Catch tank hose ①
• Radiator (right) ②

10 Nm (1.0 m · kg, 7.2 ft · lb)

Refer to "CABLE ROUTING DIAGRAM" section in the CHAPTER 2.

4. Install:

- Panel ①

NOTE:

First fit the inner hook portion ⓐ and then the outer one ⓑ onto the radiator.

5. Install:

• Catch tank ①
• Bolt (catch tank) ②

7 Nm (0.7 m · kg, 5.1 ft · lb)

- Bolt (catch tank) ③

16 Nm (1.6 m · kg, 11 ft · lb)

• Catch tank hose ④
• Catcher tank breather hose ⑤ Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2.

3. Monter:

Extent of removal:
① Carburetor removal

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		CARBURETOR REMOVALFuel tankRear shock absorber		Refer to “SEAT, FUEL TANK AND SIDE COVERS” section.Refer to “REAR SHOCK ABSORBER” section in the CHAPTER 5.
1	1	Clamp	2
	2	TPS coupler	1
	3	Throttle cable cover	1
	4	Throttle cable	2
	5	Clamp (air cleaner joint)	1	Loosen the screw (air cleaner joint).
	6	Clamp (carburetor joint)	1	Loosen the screws (carburetor joint).
	7	Hot starter plunger	1
	8	Carburetor	1
	9	Cylinder head breather pipe	1
	10	Cylinder head breather hose 1	1

CARBURATEUR

Extent of removal:
① Carburetor removal

Exploded view diagram of a mechanical assembly with numbered parts for identification

Extent of removal:
① Carburetor disassembly

Extent of removal	Order	Part name	Q'ty	Remarks
		CARBURETOR DISASSEMBLY
	1	Breather hose	4
	2	Valve lever housing cover	1
	3	Screw (throttle shaft)	1
	4	Throttle valve	1
	5	Needle holder	1
	6	Jet needle	1
	7	Cover	1
	8	Spring	1
	9	Diaphragm (accelerator pump)	1
	10	Air cut valve cover	1
	11	Spring (air cut valve)	1
	12	Diaphragm (air cut valve)	1
	13	Float chamber	1
	14	Leak jet	1
	15	Float pin	1
	16	Float	1

DEMONTAGE DU CARBURATEUR

Exploded view diagram of a mechanical assembly with numbered parts for identification

Technical diagram of a mechanical device with labeled component 1

Line drawing of a hand using a tool to adjust or install a mechanical component (no text or symbols present)

EC466020

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.

Diagram showing exploded view of a mechanical component with numbered parts labeled ① through ⑥.

2. Inspect:

• 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.

REMARQUES CONCERNANT LA MANIPULATION

ATTENTION:

a ① ② b C

Technical diagram of a mechanical assembly with labeled component ① and directional arrow indicating movement or assembly.

Line drawing of a mechanical tool with a labeled component (1), no text or symbols present

Technical line drawing of a mechanical assembly with no visible text or symbols

Needle valve

1. Inspect:

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

EC464300

Throttle valve

1. Check:

• Free movement
  Stick → Repair or replace.

NOTE:

Insert the throttle valve ① into the carburetor body, and check for free movement.

EC464400

Jet needle

1. Inspect:

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

EC464511

Float height

1. Measure:

• Float height ⓐ
  Out of specification → Adjust.

Float height: 8.0 mm (0.31 in)

Pointeau

Technical line drawing of a mechanical device with two components and a labeled part (b), no text or symbols present.

Technical line drawing of a mechanical device with two components and a labeled connection point (no text or symbols present)

Technical diagram of two types of electrical connectors with labeled parts ① and ②

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 ⑥ on the float.
• Recheck the float height.

EC464600

Float

1. Inspect:

- Float ① Damage → Replace.

Starter plunger

1. Inspect:

2. Cold starter plunger ①

3. Hot starter plunger ②
   Wear/damage → Replace.

Technical diagram of a mechanical component with numbered parts for identification

Technical diagram of mechanical components with numbered parts for identification

Technical diagram of mechanical components with numbered parts labeled ①, ②, ③, and ④

Technical diagram of an engine component with numbered parts labeled ① and ②

Technical line drawing of a mechanical component with labeled parts (no text or symbols present)

Accelerator pump

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.

Air cut valve

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

2. Install:

- Pilot air jet ①

Pompe de reprise

Technical diagram of a mechanical component with numbered parts labeled ①, ②, and ③

Technical diagram of a mechanical component with labeled parts ① and ②

Technical diagram of automotive engine components with labeled parts a and b

Technical line drawing of a mechanical assembly with labeled parts (no text or symbols present)

Technical diagram of a car suspension system with labeled components including spring, damper, and valve parts

3. Install:

• Spring 1 ①
• Lever 1 ②

To lever 2 ③.

NOTE: \_\_\_\_

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

4. Install:

- Spring 2 ①

To lever 2 ②.

5. Install:

- Push rod link lever assembly ①

NOTE:

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

6. Install:

• Plain washer ①
• Circlip ②

7. Install:

- Spring ①

To throttle shaft ②.

NOTE:

Install the bigger hook ⓐ of the spring fits on the stopper Ⓑ of the throttle shaft pulley.

1. Monter:

- Ressort 1 ①

- Levier 1 ②

Sur le levier 2 ③.

N.B.:

Technical diagram showing mechanical assembly with numbered components and a close-up view of a component labeled 'a' and 'b'.

Technical line drawing of a mechanical assembly with no visible text or symbols

Technical diagram of a mechanical assembly with labeled parts (e, d, 5) and directional arrow indicating rotation or movement.

Technical diagram showing mechanical assembly with labeled parts, including numbered annotations

Technical diagram of a mechanical assembly with numbered components for identification

8. Install:

• Throttle shaft assembly ①
• Plain washer (metal) ②
• Plain washer (resin) ③
• Valve lever ④

NOTE:

• Apply the fluorochemical grease on the bearings.
• Fit the projection ⓐ on the throttle shaft assembly into the slot ⓑ in the TPS (throttle position sensor).
• Make sure the stopper © 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 ⓑ to the stopper Ⓔ of the throttle shaft assembly pulley.

9. Install:

- Push rod ①

NOTE:

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

10. Install:

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

8. Monter:

Technical diagram of a mechanical assembly with numbered components labeled ①, ②, and ③.

Technical diagram of a mechanical device with numbered parts for identification

Technical diagram of engine components with numbered parts for identification

Technical diagram of a mechanical assembly with numbered components and cross-sectional views

Technical diagram of a mechanical device with numbered parts and exploded view

11. Install:

• 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.

12. Install:

• 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

13. Install:

• 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

14. Install:

• 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 ⓐ facing the spring.

15. Install:

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

11. Monter:

Technical diagram showing mechanical assembly with numbered components and a magnified view of a component labeled 'a'.

Technical diagram of a mechanical valve or pump assembly with numbered components labeled ①, ②, and ③.

Technical diagram of a mechanical device with labeled parts, showing components like '1' and 'ODOL'

Technical diagram of a mechanical device with labeled parts and a magnified inset showing a circular component with dimension 'a'.

Technical diagram of a mechanical assembly with numbered components labeled ③, ④, and b

16. Install:

• Throttle valve assembly ①
• Screw (throttle shaft) ②

NOTE:

Install the valve lever rollers ③ into the slits ④ of the throttle valve.

17. Install:

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

18. Install:

- 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 ⓐ 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 ⑥ by pushing lightly on it.
• Gradually turn out the adjusting screw while moving the link lever until it has no more free play.

16. Monter:

- Papillon complet ①

Technical diagram of a mechanical assembly with numbered components for identification

Carburetor installation

1. Install:

• Carburetor joint ①
• Bracket (cylinder head breather pipe) ②
• Bolt (carburetor joint) ③

10 Nm (1.0 m · kg, 7.2 ft · lb)

• Cylinder head breather pipe ④
• Cylinder head breather hose 1 ⑤
• Cylinder head breather hose 2 ⑥
• Cylinder head breather hose 3 ⑦

Technical diagram of a mechanical assembly with labeled parts (a, 1) and numbered annotations

2. Install:

- Carburetor ①

NOTE:

Install the projection ⓐ between the carburetor joint slots.

Technical line drawing of a mechanical assembly with pipes and valves (no text or symbols)

3. Install:

- Hot starter plunger ①

2 Nm (0.2 m · kg, 1.4 ft · lb)

Technical diagram of a mechanical assembly with numbered components, likely for assembly or maintenance instructions.

4. Tighten:

• Bolt (carburetor joint) ①
  3 Nm (0.3 m · kg, 2.2 ft · lb)
• Bolt (air cleaner joint) ②
  3 Nm (0.3 m · kg, 2.2 ft · lb)

Technical diagram of a mechanical assembly with numbered components labeled ① and ②

Technical diagram of a mechanical assembly with numbered components and labeled parts

Technical diagram of a mechanical assembly with numbered components, likely for assembly or maintenance reference.

Technical diagram of a mechanical assembly with labeled component 1 and a circular annotation indicating a specific feature.

5. Install:

- Throttle cable (return) ②

11 Nm (1.1 m · kg, 8.0 ft · lb)

6. Adjust:

- Throttle grip free play

Refer to "THROTTLE CABLE ADJUSTMENT" section in the CHAPTER 3.

7. Install:

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

4 Nm (0.4 m · kg, 2.9 ft · lb)

8. Install:

• TPS (throttle position sensor) coupler ①
• Clamp ②

Refer to "CABLE ROUTING DIAGRAM" section in the CHAPTER 2.

9. Install:

- Clamp ①

Refer to "CABLE ROUTING DIAGRAM" section in the CHAPTER 2.

5. Monter:

Extent of removal:
① Air induction system removal

Extent of removal	Order	Part name	Q'ty	Remarks
		AIR INDUCTION SYSTEM REMOVAL
	1	Bracket	1
	2	Air cut-off valve assembly	1
	3	Air induction hose (air cut-off valve - front of cylinder head)	1
	4	Air induction pipe	1
	5	Gasket	1
	6	Air induction hose (air cut-off valve - rear of cylinder head)	1
	7	Air induction hose (air cut-off valve - air filter case)	1

SYSTEME D'INDUCTION D'AIR

Air induction system

1. Inspect:

• Air induction hose Crack/damage → Replace.
- Air induction pipe Crack/damage → Replace.

A ① → ↓ ②

B a b

C a → b c ①

2. Check:

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

a to b	Air passes.
b to a	Air does not pass.
a to b	Air does not pass when specified pressure is on ©.

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 Ⓒ, take care not to exceed the specified value.

① From air filter
⑥ To cylinder head (exhaust port)
© From cylinder head (intake port)

A Check for induction from air filter.
B Check for prevention of backflow into air filter.
☐ Check for prevention of afterburn. (When throttle is closed at sudden deceleration)

CONTROLE

Extent of removal:
① Cylinder head cover removal

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		CYLINDER HEAD COVER REMOVALSeat and fuel tankAir cut-off valve assemblyEngine upper bracket (right)Engine upper bracket (left)		Refer to “SEAT, FUEL TANK AND SIDE COVERS” section.Refer to “AIR INDUCTION SYSTEM” section.Refer to “ENGINE REMOVAL” section.
(bearful)	1	Spark plug	1
	2	Cylinder head breather hose	1
	3	Bolt (cylinder head cover)	2
	4	Cylinder head cover	1
	5	Cylinder head cover gasket	1

ARBRES A CAMES

COUVRE-CULASSE

Extent of removal:
① Camshaft removal

Extent of removal	Order	Part name	Q'ty	Remarks
		CAMSHAFTS REMOVAL
	1	Timing plug	1	Refer to “REMOVAL POINTS”.
	2	Straight plug	1
	3	Tensioner cap bolt	1
	4	Timing chain tensioner	1
	5	Gasket	1
	6	Bolt (camshaft cap)	10
	7	Camshaft cap	2
	8	Clip	2
	9	Exhaust camshaft	1
	10	Intake camshaft	1

ARBRES A CAMES

Technical diagram of a mechanical assembly with numbered components and labeled parts

Technical diagram of a mechanical assembly with labeled parts and directional arrow indicating rotation or movement

Technical diagram of a mechanical assembly with labeled parts (c) and d, showing gear and housing components.

Technical diagram of a mechanical assembly with numbered components, likely illustrating a valve or connector assembly.

Technical diagram of a mechanical assembly with numbered components, likely for assembly or maintenance reference.

REMOVAL POINTS Camshaft

1. Remove:

• Timing plug ①
• Straight plug ②

2. Align:

- "l" mark

With stationary pointer.

Checking steps:

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

NOTE:

• In order to be sure that the piston is at Top Dead Center, the punch mark © on the exhaust camshaft and the punch mark ⓐ 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.

3. Loosen:

- Tensioner cap bolt ①

4. Remove:

- Timing chain tensioner ②

5. Remove:

• Bolt (camshaft cap) ①
• Camshaft caps ②

NOTE:

Remove the bolts (camshaft cap) in a criss-cross 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.

POINTS DE DEPOSE

Arbre à cames

Technical diagram of an engine cylinder with labeled components including gears and shafts

a 11151001

b I1151002

6. Remove:

• Clips
• Exhaust camshaft ①
• Intake camshaft ②

NOTE:

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

INSPECTION

Camshaft

1. Inspect:

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

2. Measure:

• Cam lobes length ⓐ and ⓑ
  Out of specification → Replace.

Cam lobes length:

Intake:

① 30.100 \~ 30.200 mm
(1.1850 \~ 1.1890 in)
: 30.000 mm
(1.1811 in)
⑥ 22.450 \~ 22.550 mm
(0.8839 \~ 0.8878 in)
: 22.350 mm
(0.8799 in)

Exhaust:

① 30.200 \~ 30.300 mm
(1.1890 \~ 1.1929 in)
: 30.100 mm
(1.1850 in)
⑥ 22.450 \~ 22.550 mm
(0.8839 \~ 0.8878 in)
: 22.350 mm
(0.8799 in)

I1151402

3. Measure:

• Runout (camshaft)
  Out of specification → Replace.

Runout (camshaft):

Less than 0.03 mm (0.0012 in)

① 30,100–30,200 mm (1,1850–1,1890 in) : 30,000 mm (1,1811 in)

⑥ 22,450–22,550 mm (0,8839–0,8878 in) : 22,350 mm (0,8799 in)

Auslass:

① 30,200–30,300 mm (1,1890–1,1929 in) : 30,100 mm (1,1850 in)

⑥ 22,450–22,550 mm (0,8839–0,8878 in) : 22,350 mm (0,8799 in)

① 30,100 \~ 30,200 mm (1,1850 \~ 1,1890 in) : 30,000 mm (1,1811 in)

⑥ 22,450 \~ 22,550 mm (0,8839 \~ 0,8878 in) : 22,350 mm (0,8799 in)

Escape:

① 30,200 \~ 30,300 mm (1,1890 \~ 1,1929 in) : 30,100 mm (1,1850 in)

⑥ 22,450 \~ 22,550 mm (0,8839 \~ 0,8878 in) : 22,350 mm (0,8799 in)

1. Mesurer:

- 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)

: 0.08 mm (0.003 in)

Technical diagram of a mechanical component with labeled parts, including a numbered marker and section line.

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.

Bolt (camshaft cap):

10 Nm (1.0 m • kg, 7.2 ft • lb)

Technical diagram of a mechanical assembly with numbered component labels

NOTE:

• Tighten the bolts (camshaft cap) in a criss-cross 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.

a 11151003

5. Measure:

• Camshaft journal diameter ⓐ
  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)

Technical line drawing of two mechanical gears with internal components, no text or symbols present

Camshaft sprocket

1. Inspect:

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

4. Mesurer:

Technical diagram of a mechanical gear assembly with labeled parts ① and ②

Illustration of a hand holding a mechanical component with a tool, showing a curved arrow and numbered label (no text or symbols present)

Line drawing of a hand holding a small object with an arrow indicating motion (no text or symbols)

Technical diagram of a mechanical assembly with labeled parts (①, ②, E) and components like gears and levers.

Technical diagram of a mechanical assembly with labeled parts and directional arrow indicating motion or force

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 “l” mark ⓐ on the rotor is aligned with the stationary pointer ⓑ on the crankcase cover.

NOTE:

• Apply the molybdenum disulfide oil on the camshafts.
• Apply the engine oil on the decompression system.

Décompresseur

1. Contrôler:

- Décompresseur

Etapes du contrôle:

Technical diagram of a mechanical assembly with labeled components (c, 3, d)

Technical diagram of a mechanical assembly with numbered components and a labeled motor (M)

- 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 © and the intake cam sprocket punch mark ⓐ 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.

Bolt (camshaft cap): 10 Nm (1.0 m • kg, 7.2 ft • lb)

NOTE:

• 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.

Illustration of a hand holding a mechanical component with a curved arrow indicating rotation (no text or symbols)

2. Install:

- Timing chain tensioner

Installation steps:

- While pressing the tensioner rod lightly with fingers, use a thin screwdriver and wind the tensioner rod up fully clockwise.

New ① ② ③ ④ ⑤ ⑥ ⑦ New

⑤ New ⑥

Technical diagram of a mechanical assembly with numbered components, likely for assembly or maintenance reference.

- With the rod fully wound and the chain tensioner UP mark ⓐ facing upward, install the gasket ①, the chain tensioner ② and the gasket ③ and tighten the bolt ④ to the specified torque.

Bolt (timing chain tensioner): 10 Nm (1.0 m • kg, 7.2 ft • lb)

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

Tensioner cap bolt: 7 Nm (0.7 m • kg, 5.1 ft • lb)

3. Turn:

- 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

Technical diagram showing mechanical assembly steps with numbered components and a close-up view of the component being inserted.

Technical line drawing of a mechanical component with no visible text or symbols

6. Install:

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

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

Apply the sealant on the cylinder head cover gasket.

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

7. Install:

• Cylinder head breather hose
• Spark plug

13 Nm (1.3 m · kg, 9.4 ft · lb)

6. Monter:

• Joint de couvre-culasse ①
- Couvre-culasse ②
• Boulon (couvre-culasse) ③

10 Nm (1,0 m · kg, 7,2 ft · lb)

N.B.:

Extent of removal:
① Cylinder head removal

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		CYLINDER HEAD REMOVALSeat and fuel tankExhaust pipe and silencerRadiatorAir cut-off valve assemblyCarburetorCamshaft		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.
[72X48]	1	Bolt	2	Refer to NOTE.
	2*	Bolt	4
	3	Cylinder head	1
	4	Gasket	1
	5	Dowel pin	2
	6	Timing chain guide (front)	1

NOTE:

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.

CULASSE

CULASSE

Technical line drawing of an internal combustion engine cylinder with a tool inserted (no text or labels)

Technical line drawing of an internal combustion engine cylinder (no text or labels)

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.

3. Measure:

- Cylinder head warpage Out of specification → Resurface.

Cylinder head warpage: Less than 0.05 mm (0.002 in)

Warpage measurement and resurface-ment 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.

CONTROLE

Culasse

1. Eliminer:

① ② ③ ④ New ②

Technical diagram of a mechanical assembly with labeled parts and a motor symbol pointing to components

Technical diagram of an internal combustion engine component with numbered parts and directional arrows indicating flow or movement.

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 crank-case.
• 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.

Bolts (cylinder head):

1st:

30 Nm (3.0 m • kg, 22 ft • lb)

ASSEMBLAGE ET MONTAGE

1. Monter:

Technical diagram of an internal combustion engine with labeled components and directional arrows indicating flow or movement.

Technical diagram of a mechanical component with labeled parts ① and ②

Technical drawing showing a hexagonal bolt head before and after filleting, with 180° angle annotation

Technical diagram of a mechanical assembly with numbered component label

• Remove the bolts.
• 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.

Bolts (cylinder head):

2nd:

20 Nm (2.0 m • kg, 14 ft • lb)

- Put a mark on the corner ① of the bolt (cylinder head) and the cylinder head ② as shown.

NOTE:

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°

3. Install:

- Bolt (cylinder head) ①

10 Nm (1.0 m · kg, 7.2 ft · lb)

Boulons (culasse): Final:

1 2 3 4 5 6 7 New 8 9 M E New

Extent of removal:
① Valve removal

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		VALVES AND VALVE SPRINGS REMOVALCylinder head		Refer to “CYLINDER HEAD” section.
1	1	Valve lifter	5	Use special tool.Refer to “REMOVAL POINTS”.
	2	Adjusting pad	5
	3	Valve cotter	10
	4	Valve retainer	5
	5	Valve spring	5
	6	Stem seal	5
	7	Valve spring seat	5
	8	Exhaust valve	2
	9	Intake valve	3

SOUPAPES ET RESSORTS DE SOUPAPES SOUPAPES ET RESSORTS DE SOUPAPES

EX IN ① ②

Technical diagram of a mechanical assembly with labeled parts ① and ②

① 11171201

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.

3. Remove:

- 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

POINTS DE DEPOSE

Technical diagram of a dial indicator with labeled component 'a' and directional arrows indicating movement or force.

b 11172102

Technical diagram showing a mechanical assembly with labeled component ①

Technical diagram showing mechanical assembly with labeled parts 1 and 2

③ I1170601

INSPECTION

Valve

1. Measure:

- Stem-to-guide clearance

Stem-to-guide clearance = valve guide inside diameter ① - valve stem diameter ②

Out of specification → Replace the valve guide.

Clearance (stem to guide):

Intake:

0.010 \~ 0.037 mm

(0.0004 \~ 0.0015 in)

: 0.08 mm (0.003 in)

Exhaust:

0.020 \~ 0.047 mm

(0.0008 \~ 0.0019 in)

: 0.10 mm (0.004 in)

2. Replace:

- 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.

CONTROLE

Soupape

1. Mesurer:

- Jeu queue-guide

Intake: 4.5 mm (0.18 in)

YM-4116/90890-04116

Exhaust: 5.0 mm (0.20 in)

YM-4097/90890-04097

Valve guide installer:

Intake:

YM-4117/90890-04117

Exhaust:

YM-4098/90890-04098

Valve guide reamer:

Intake: 4.5 mm (0.18 in)

YM-4118/90890-04118

Exhaust: 5.0 mm (0.20 in)

YM-4099/90890-04099

NOTE:

After replacing the valve guide reface the valve seat.

3. Inspect:

- Valve face

Pitting/wear → Grind the face.

- Valve stem end

Mushroom shape or diameter larger than the body of the stem → Replace.

a 45°

4. Measure:

- Margin thickness ⓐ

Out of specification → Replace.

Margin thickness:

Intake:

1.0 mm (0.039 in)

: 0.85 mm (0.033 in)

Exhaust:

1.0 mm (0.039 in)

: 0.85 mm (0.033 in)

Technical diagram of a mechanical device with a dial indicator and rotating shaft (no text or symbols)

5. Measure:

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.

I1171603

8. Measure:

- Valve seat width ⓐ

Out of specification → Reface the valve seat.

Diagram of a circular object with a labeled point 'b' and a vertical line, no readable text or symbols present.

Valve seat width:

Intake:

0.9 \~ 1.1 mm

(0.0354 \~ 0.0433 in)

: 1.6 mm (0.0630 in)

Exhaust:

0.9 \~ 1.1 mm

(0.0354 \~ 0.0433 in)

: 1.6 mm (0.0630 in)

Measurement steps:

• Apply Mechanic's blueing dye (Dykem) ⑥ 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.

5. Mesurer:

After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped.

Simple line drawing of a circular object with two vertical lines extending outward (no text or symbols)

M

Technical line drawing of a mechanical assembly with rotating components and a central shaft (no text or symbols)

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.

SOUPAPES ET RESSORTS DE SOUPAPES VENTILE UND VENTILFEDERN VÁLVULAS Y MUELLES DE VÁLVULAS

ENG

I1171902 a

I1171904

Valve spring

1. Measure:

- Valve spring free length ⓐ

Out of specification → Replace.

Free length (valve spring):

Intake:

39.46 mm (1.55 in)

: 38.46 mm (1.51 in)

Exhaust:

37.61 mm (1.48 in)

: 36.61 mm (1.44 in)

2. Measure:

- Compressed spring force ⓐ

Out of specification → Replace.

⑥ 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)

a I1171903

3. Measure:

- Spring tilt ⓐ

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)

Simple line drawing of a cylinder (no text or symbols on the shape itself)

Valve lifter

1. Inspect:

- Valve lifter

Scratches/damage → Replace both lifters and cylinder head.

Ressort de soupape

1. Mesurer:

ASSEMBLY AND INSTALLATION

1. Apply:

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

a b b

① ⑤ ④ ③ New ② ③ d c M

① I1171201

Line drawing of a hand using a tool to adjust or install an engine component (no text or symbols present)

2. Install:

• 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) ⓐ: blue

Intake (right/left) ⓑ: gray

Exhaust: not paint

- Install the valve springs with the larger pitch © facing upward.

(d) Smaller pitch

3. Install:

- 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

1. 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.

ASSEMBLAGE ET MONTAGE

1. Appliquer:

Technical diagram showing mechanical assembly with labeled parts A, E, and M, including numbered annotations ① and ②.

5. Install:

• 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.

SOUPAPES ET RESSORTS DE SOUPAPES VENTILE UND VENTILFEDERN VÁLVULAS Y MUELLES DE VÁLVULAS

5. Monter:

Extent of removal:
① Cylinder removal
② Piston removal

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		CYLINDER AND PISTON REMOVALCylinder head		Refer to “CYLINDER HEAD” section.
2	1	Bolt (cylinder)	1	Use special tool.Refer to “REMOVAL POINTS”.
	2	Cylinder	1
	3	Gasket	1
	4	Dowel pin	2
	5	Piston pin clip	2
	6	Piston pin	1
	7	Piston	1
	8	Piston ring set	1

CYLINDRE ET PISTON

CYLINDRE ET PISTON

Technical line drawing of a piston assembly with labeled component (no text or symbols beyond label)

③ ② ④ I1221001

REMOVAL POINTS

Piston

1. Remove:

2. Piston pin clips ①

3. Piston pin ②
4. 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.

1. Measure:

- Piston-to-cylinder clearance

D₁ D₂ D₃ D₄ D₅ D₆ 11210102

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.

POINTS DE DEPOSE

Piston

Cylinder bore “C”	95.00 ~ 95.01 mm(3.7402 ~ 3.7406 in)
Taper limit “T”	0.05 mm (0.002 in)
Out of round “R”	0.05 mm (0.002 in)
“C” = Maximum D
“T” = (Maximum D1 or D2)– (Maximum D5 or D6)
“R” = (Maximum D1, D3 or D5)– (Minimum D2, D4 or D6)
• If out of specification, replace the cylinder,and replace the piston and piston rings as set.2nd step:• Measure the piston skirt diameter “P” witha micrometer.①8 mm (0.315 in) from the piston bottom edge
	Piston size “P”
Standard	94.945 ~ 94.960 mm(3.738 ~ 3.739 in)
• If out of specification, replace the pistonand piston rings as a set.3rd step:• Calculate the piston-to-cylinder clearancewith 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): 0.1 mm (0.004 in)
• If out of specification, replace the cylinder,and replace the piston and piston rings as set.

Line drawing of hands holding a circular object with a numbered label (1) on the top part, no text or symbols present.

I1221401

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
Top ring	0.030 ~ 0.065 mm(0.0012 ~ 0.0026 in)	0.12 mm(0.005 in)
2nd ring	0.020 ~ 0.055 mm(0.0008 ~ 0.0022 in)	0.12 mm(0.005 in)

2. Position:

- 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.

① 10 mm (0.39 in)

3. Measure:

- Ring end gap

Out of specification → Replace.

NOTE:

You cannot measure the end gap on the expander spacer of the oil control ring. If the oil control ring rails show excessive gap, replace all three rings.

	End gap:
	Standard
Top ring	0.20 ~ 0.30 mm(0.008 ~ 0.012 in)	0.55 mm(0.022 in)
2nd ring	0.35 ~ 0.50 mm(0.014 ~ 0.020 in)	0.85 mm(0.033 in)
Oil ring	0.20 ~ 0.50 mm(0.01 ~ 0.02 in)	—

Segment de piston

1. Mesurer:

Illustration of a hand using a micrometer to measure a tool, showing measurement setup (no text or symbols)

b

Simple line drawing of a loop with an upward arrow labeled 'UP' (no text or symbols beyond the label)

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.
	pin-to-piston clearance =de diameter (piston) b -side 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): 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.

Axe de piston

1. Contrôler:

① ② ③ New ④ E

③ New

① New ② ③ ④

2. Position:

• Top ring
• 2nd ring
• Oil ring

Offset the piston ring end gaps as shown.

① Top ring end
⑥ 2nd ring end
© Oil ring end (upper)
d Oil ring
© Oil ring end (lower)

3. Install:

• 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 ⓐ 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

NOTE:

Apply a liberal coating of engine oil.

Cylinder

1. Install:

New

• Gasket ①
• Cylinder ②

NOTE:

Install the cylinder with one hand while compressing the piston rings with the other hand.

CAUTION:

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

2. Install:

- Bolt (cylinder)

10 Nm (1.0 m · kg, 7.2 ft · lb)

2. Position:

Extent of removal:
① Push rod and push lever removal
② Push rod 1 disassembly
③ Friction plate and clutch plate removal
④ Clutch housing removal

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		CLUTCH REMOVALDrain the engine oil.Brake pedalClutch cable		Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3.Refer to “ENGINE REMOVAL” section.Disconnect at engine side.
1234↓1↓3↓4↓10↓11	1	Clutch cover	1
	2	Gasket	1
	3	Dowel pin	2
	4	Clutch spring	6
	5	Pressure plate	1
	6	Push rod 1	1
	7	Circlip	1
	8	Plain washer	1
	9	Bearing	1
	10	Ball	1
	11	Push rod 2	1

EMBRAYAGE

EMBRAYAGE

Technical diagram of a mechanical gear assembly with numbered components for identification

Line drawing of a pair of scissors or clips in a diagonal arrangement (no text or symbols)

Technical line drawing of a mechanical clamp or bracket (no text or symbols)

Technical line drawing of a mechanical gear assembly with no visible text or symbols

Technical diagram showing gear meshing with labeled component ②

Illustration of hands assembling a mechanical gear assembly (no text or symbols)

a 11412901

EC493000

REMOVAL POINTS

EC483211

Clutch boss

1. Remove:

2. Nut ①

3. Lock washer ②
4. Clutch boss ③

NOTE:

Straighten the lock washer tab and use the clutch holding tool ④ to hold the clutch boss.

Clutch holding tool: YM-91042/90890-04086

A For USA and CDN
B Except for USA and CDN

EC494000

INSPECTION

EC484100

Clutch housing and boss

1. Inspect:

2. Clutch housing ① Cracks/wear/damage → Replace.

3. Clutch boss ② Scoring/wear/damage → Replace.

EC484201

Primary driven gear

1. Check:

2. Circumferential play Free play exists → Replace.

3. Gear teeth ⓐ Wear/damage → Replace.

EC484400

Clutch spring

1. Measure:

2. Clutch spring free length @ Out of specification → Replace springs as a set.

Clutch spring free length:

Standard
50.0 mm (1.97 in)	49.0 mm (1.93 in)

POINTS DE DEPOSE

Noix d'embrayage

Line drawing of hands using a tool to cut a gear (no text or symbols)

① ② I1411901

EC484500

Friction plate

1. Measure:

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

Friction plate thickness:

2.92 \~ 3.08 mm

(0.115 \~ 0.121 in)

: 2.8 mm (0.110 in)

EC484600

Clutch plate

1. Measure:

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

Warp limit: 0.1 mm (0.004 in)

Technical line drawing of a mechanical component with labeled part (1), no text or symbols present

Exploded view diagram of a mechanical assembly with numbered parts for identification

Push lever

1. Inspect:

• Push lever ①
  Wear/damage → Replace.

EC484810

Push rod

1. Inspect:

• Push rod 1 ①
• Bearing ②
• Plain washer ③
• Push rod 2 ④
• Ball ⑤

Wear/damage/bend → Replace.

Disque garni

1. Mesurer:

Technical mechanical diagram showing cross-sectional and top views of a valve assembly with labeled components A, B, and E

EC4A5000

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.

Technical diagram of a mechanical assembly with numbered components and labeled parts

Clutch

1. Install:

• Primary driven gear ①
- Thrust washer ②
- Clutch boss ③

NOTE:

Apply the engine oil on the primary driven gear inner circumference.

① ② ③ New

1. Install:

- Lock washer ①

New

- Nut (clutch boss) ②

• 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.

Technical line drawings of two different clamp or tool holders (A and B) with no visible text or symbols

Clutch holding tool: YM-91042/90890-04086

A For USA and CDN
B Except for USA and CDN

ASSEMBLAGE ET MONTAGE

Tige de poussée

1. Monter:

- Tige de poussée ①

N.B.:

Technical line drawing of a mechanical gear assembly (no text or symbols)

Technical diagram of a mechanical assembly with labeled parts and a labeled component 'E'

Technical diagram showing mechanical assembly with labeled components a and b, likely from an engineering or manufacturing context.

New ③ ② ① ④ E

Technical diagram of a mechanical assembly with numbered components and a labeled component 'E'

1. Bend the lock washer ① tab.

2. Install:

3. Friction plate ①

4. Clutch plate 1 [t = 2.0 mm (0.079 in)] ②
5. Clutch plate 2 [t = 1.6 mm (0.063 in)] ③

NOTE:

• 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 ⓐ on the engine side and 3 thinner ones Ⓑ on the outside.

• Install:

• Bearing ①

• Plain washer ②
• Circlip ③ New

To push rod 1 ④.

NOTE:

Apply the engine oil on the bearing and plain washer.

1. Install:

2. Push rod 2 ①

3. Ball ②
4. Push rod 1 ③

NOTE:

Apply the engine oil on the push rod 1, 2 and ball.

1. Replier l'onglet de la rondelle-frein ①.

2. Die Lasche ① der Sicherungsscheibe umbiegen.

3. Doble la solapa de la arandela de seguridad ①.

4. Monter:

5. Disque garni ①

6. Plateau de pression 1 [t = 2,0 mm (0,079 in)] ②
7. Plateau de pression 2 [t = 1,6 mm (0,063 in)] ③

N.B.:

Mechanical assembly diagram showing a clamping mechanism with no visible text or symbols

Technical diagram of a mechanical clutch assembly with numbered components for identification

New ① ② ②

Technical diagram of a mechanical assembly with labeled components and directional arrows indicating motion or assembly.

7. Install:

- Pressure plate ①

8. Install:

• Clutch spring
• Bolt (clutch spring)

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

Tighten the bolts in stage, using a crisscross pattern.

9. Install:

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

10. Install:

• Clutch cover ①
• Bolt (clutch cover)

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

Tighten the bolts in stage, using a crisscross pattern.

7. Monter:

Extent of removal:
① Oil filter removal
③ Crankcase cover (right) removal

② Water pump removal

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) REMOVALDrain the engine oil.Drain the coolant.Exhaust pipeBrake pedalClutch cover		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.
	1	Oil filter cover	1
	2	Oil filter	1
	3	Coolant pipe 2	1
	4	Water pump housing	1
	5	Pin	2
	6	Oil tank breather hose	1

FILTRE A HUILE, POMPE A EAU ET COUVERCLE DE CARTER MOTEUR (DROIT)

FILTRE A HUILE, POMPE A EAU ET COUVERCLE DE CARTER MOTEUR (DROIT)

Technical diagram of a mechanical assembly with numbered parts labeled ① and ②

Technical diagram of a mechanical assembly with labeled parts (a) and (3)

Technical diagram of a mechanical component with labeled parts, showing internal gears and housing

Technical diagram of a mechanical assembly with labeled parts, showing components like gears and shafts.

Technical illustration of a mechanical component with a gear and threaded shaft (no text or symbols)

REMOVAL POINTS

EC4G3110

Impeller shaft

1. Remove:

2. Impeller ①

3. Plain washer ②
4. Impeller shaft ③

NOTE:

Hold the impeller shaft on its width across the flats ⓐ with spanners, etc. and remove the impeller.

EC4G3210

Oil seal

NOTE:

It is not necessary to disassemble the water pump, unless there is an abnormality such as excessive change in coolant level, discoloration of coolant, or milky transmission oil.

1. Remove:

2. Bearing ①

3. Oil seal ②

INSPECTION

EC444200

Impeller shaft

1. Inspect:

- Impeller shaft ①

Bend/wear/damage → Replace.

Fur deposits → Clean.

POINTS DE DEPOSE

Axe de pompe

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

EC444400

Oil seal

1. Inspect:

- Oil seal Wear/damage → Replace.

New ① B ① New ② B

Technical diagram of a mechanical component with labeled parts, showing internal gears and housing

ASSEMBLY AND INSTALLATION

EC4G5110

Oil seal

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.

Roulement

1. Contrôler:

- Roulement

Technical diagram of a mechanical assembly with labeled parts (①, a) and component E

Technical diagram of a mechanical assembly with numbered parts labeled ② and ③

① ④ New ③ ② New ① ② New ① ② New

Technical diagram of a mechanical assembly with numbered components and labeled parts

Technical diagram of a mechanical gear assembly with labeled parts and numbered annotations

EC4G5220

Impeller shaft

1. Install:

• Impeller shaft ①
• Plain washer ②
• Impeller ③

14 Nm (1.4 m · kg, 10 ft · lb)

NOTE:

• Take care so that the oil seal lip is not damaged or the spring does not slip off its position.
• When installing the impeller shaft, apply the 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 ⓐ with spanners, etc. and install the impeller.

Crankcase cover (right)

1. Install:

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

2. Install:

• Crankcase cover (right) ①
• Bolt ②
• Bolt

12 Nm (1.2 m · kg, 8.7 ft · lb) 10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

• 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.

Axe de pompe

1. Monter:

2. Axe de pompe ①

3. Rondelle pleine ②
4. Rotor ③

14 Nm (1,4 m · kg, 10 ft · lb)

N.B.:

Technical diagram of a mechanical assembly with numbered components and labeled parts

Kick crank

1. Install:

• Kickstarter ①
• Plain washer
• Bolt (kickstarter)

Install so that there is a clearance ⓐ 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.

Technical diagram of a mechanical assembly with labeled parts 1 and 2

2. Install:

• Oil tank breather hose ①
• Clamp ②

2 Nm (0.2 m · kg, 1.4 ft · lb)

① ② New ①

Water pump housing

1. Install:

• Dowel pin ①
• O-ring ② New

2. Install:

• Water pump housing ①
- Bolt (water pump housing) ②

10 Nm (1.0 m · kg, 7.2 ft · lb)

• Plain washer ③ New
• Coolant drain bolt ④

10 Nm (1.0 m · kg, 7.2 ft · lb)

① ② ③ ④ New

Lanceur au pied

1. Monter:

2. Kick ①

3. Rondelle pleine
4. Boulon (kick)

Technical diagram of a mechanical assembly with numbered parts labeled ① and ②

② New ② New ③ ① ② New

3. Install:

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

10 Nm (1.0 m · kg, 7.2 ft · lb)

Oil filter

1. Install:

• Oil filter ①
• O-ring ② New
• Oil filter cover ③
• Bolt (oil filter cover)

10 Nm (1.0 m · kg, 7.2 ft · lb)

3. Monter:

Extent of removal:
① Balancer drive gear
② Balancer

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		BALANCER REMOVALClutch housingCrankcase cover (right)Stator		Refer to “CLUTCH” section.Refer to “OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT)” section.Refer to “AC MAGNETO AND STARTER CLUTCH” section.
	1	Nut (balancer)	1	Refer to “REMOVAL POINTS”.
	2	Nut (primary drive gear)	1
	3	Nut (balancer driven gear)	1
	4	Lock washer	1
	5	Balancer	1
	6	Straight key	1

BALANCIER

BALANCIER

Extent of removal:
① Balancer drive gear
② Balancer

Extent of removal	Order	Part name	Q'ty	Remarks
1	7	Conical washer	1
	8	Primary drive gear	1
	9	Balancer drive gear	1
	10	Lock washer	1
	11	Balancer driven gear	1
Organisation de la dépose	Ordre	Nom de la pièce	Qté	Remarques
###	7	Rondelle conique	1
	8	Pignon menant de transmission primaire	1
	9	Pignon menant du balancier	1
	10	Rondelle-frein	1
	11	Pignon mené du balancier	1

Technical line drawing of a mechanical assembly with gears and springs (no text or symbols)

Technical diagram of a mechanical gear assembly with numbered components and labeled parts

Technical diagram of a mechanical gear assembly with numbered components labeled 3, 4, and 5

Technical diagram of three types of gear components with numbered labels ①, ②, and ③ indicating different gear configurations.

Technical line drawing of a mechanical component with a flanged circular base and central bore (no text or symbols)

REMOVAL POINTS

Balancer, balancer drive gear and balancer driven gear

1. Straighten the lock washer tab.

2. Loosen:

3. Nut (balancer) ①

4. Nut (primary drive gear) ②
5. Nut (balancer driven gear) ③

NOTE:

Place an aluminum plate ④ 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:

2. Primary drive gear ①

3. Balancer drive gear ②
4. Balancer driven gear ③

Wear/damage → Replace.

Balancer

1. Inspect:

- Balancer

Cracks/damage → Replace.

POINTS DE DEPOSE

Technical diagram of an engine assembly with labeled parts and component annotations

Technical diagram of a mechanical gear assembly with labeled components (a, b, c) and numbered parts (1, 2)

Technical diagram of a mechanical gear assembly with numbered components and labeled parts

Technical diagram of a mechanical gear assembly with numbered components and an inset view labeled 'E'

Technical diagram of engine components with numbered parts for identification

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 @ aligning with each other.

2. Install:

- Balancer drive gear ①

NOTE:

• Align the punched mark ⓐ on the balancer drive gear with the punched mark ⓑ on the balancer driven gear.
• Install the balancer driven gear and crankshaft with the lower splines © 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

• Straight key ⑥
• Balancer ⑦
• Lock washer ⑧
• Nut (balancer) ⑨

NOTE:

• Apply engine oil to the contact surface and threaded portion of the nut (primary drive gear).
• Place an aluminum plate ⓐ between the teeth of the balancer drive gear ⑩ and balancer driven gear ⑪.

• Install the conical washer with its convex surface ⑥ outward.

• Bend the lock washer tab.

Extent of removal:
① Oil pump removal
② Oil pump disassembly

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		OIL PUMP REMOVAL AND DISASSEMBLYClutch housingCrankcase cover (right)		Refer to “CLUTCH” section.Refer to “OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT)” section.
12	1	Circlip	1
	2	Plain washer	1
	3	Oil pump drive gear	1
	4	Oil pump assembly	1
	5	Dowel pin	2
	6	Outer rotor 2	1
	7	Circlip	1
	8	Inner rotor 2	1
	9	Pin	1
	10	Oil pump cover	1
	11	Outer rotor 1	1
	12	Inner rotor 1	1

POMPE A HUILE

POMPE A HUILE

• Oil pump drive gear
• Oil pump driven gear
• Rotor housing
• Oil pump cover

Cracks/wear/damage → Replace.

Technical diagram of a mechanical assembly with labeled components and dimensional annotations

Line drawing of a hand turning a gear with an arrow indicating rotational motion (no text or symbols)

E ① ② ③ ④

2. Measure:

- Tip clearance ⓐ

Between the inner rotor ① and the outer rotor ②.

- Tip clearance ⓑ

Between the outer rotor ② and the rotor housing ③.

Out of specification → Replace the oil pump.

Tip clearance ⓐ:

0.12 mm or less

(0.0047 in or less)

: 0.20 mm (0.008 in)

Tip clearance ⓑ:

0.09 \~ 0.17 mm

(0.0035 \~ 0.0067 in)

: 0.24 mm (0.009 in)

Side clearance ©:

0.03 \~ 0.10 mm

(0.0012 \~ 0.0039 in)

: 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.

CONTROLE

Pompe à huile

1. Contrôler:

E ① ② ③ ④ ⑤ New

2. Install:

- Outer rotor 1 ①

NOTE:

Apply the engine oil on the outer rotor 1.

3. Install:

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

2 Nm (0.2 m · kg, 1.4 ft · lb)

• Pin ③
• 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.

Technical diagram of a mechanical assembly with numbered components and a labeled component E

E ① ② ③ New

4. Install:

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

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

Apply the engine oil on the outer rotor 2.

5. Install:

• Oil pump drive gear ①
• Plain washer ②
• Circlip ③ New

NOTE:

Apply the engine oil on the oil pump drive gear inner circumference.

2. Monter:

- Rotor externe 1 ①

N.B.:

KICK AXLE AND SHIFT SHAFT

KICK AXLE AND SHIFT SHAFT

New 10 Nm (1.0 m · kg, 7.2 ft · lb) 12 Nm (1.2 m · kg, 8.7 ft · lb) 30 Nm (3.0 m · kg, 22 ft · lb) 10 Nm (1.0 m · kg, 7.2 ft · lb)

Extent of removal:
① Kick axle removal
③ Shift shaft removal
② Kick axle disassembly
④ Segment removal

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		KICK AXLE AND SHIFT SHAFT REMOVALOil pump		Refer to “OIL PUMP” section.
1↓2↓1↓3↓4↓	1	Kick idle gear	1	Refer to “REMOVAL POINTS”.
	2	Kick axle assembly	1
	3	Spring guide	1
	4	Torsion spring	1
	5	Ratchet wheel	1
	6	Kick gear	1
	7	Kick axle	1
	8	Plain washer	1
	9	Shift pedal	1
	10	Shift shaft	1
	11	Collar	1
	12	Torsion spring	1

Technical diagram of a mechanical gear assembly with labeled components and motion indicators

Technical diagram of engine cylinder components with numbered labels indicating parts of the engine assembly.

Technical diagram showing mechanical assembly with labeled parts and directional arrow

REMOVAL POINTS

EC4B3101

Kick axle assembly

1. Remove:

- Kick axle assembly ①

NOTE:

Unhook the torsion spring ② from the hole ④ in the crankcase.

EC4C3101

Shift guide and shift lever assembly

1. Remove:

2. Bolt (shift guide)

3. Shift guide ①
4. Shift lever assembly ②

NOTE:

The shift lever assembly is disassembled at the same time as the shift guide.

EC4N3100

Segment

1. Remove:

2. Bolt (segment) ①

3. 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.

Technical diagram of a mechanical gear assembly with numbered parts and directional arrow indicating rotation

INSPECTION

EC4C4200

Kick axle and ratchet wheel

1. Check:

2. Ratchet wheel ① smooth movement Unsmooth movement → Replace.

3. Kick axle ② Wear/damage → Replace.
4. Spring ③ Broken → Replace.

POINTS DE DEPOSE

Arbre de kick complet

1. Déposer:

1. Déposer:

2. Boulon (segment) ①

3. Segment ②

N.B.:

a b ① ③ ②

Technical diagram of a mechanical assembly with labeled parts ① and ②

Exploded view diagram of a mechanical assembly with numbered parts for identification

Technical diagram showing two mechanical components with labeled parts ① and ②

EC4C4300

Kick gear, kick idle gear and ratchet wheel

1. Inspect:

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

EC4B4400

Shift shaft

1. Inspect:

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

EC4C4100

Shift guide and shift lever assembly

1. Inspect:

• Shift guide ①
• Shift lever ②
• Pawl ③
• Pawl pin ④
• Spring ⑤
  Wear/damage → Replace.

EC4B4500

Stopper lever

1. Inspect:

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

Technical diagram of mechanical components with labeled parts a, b, and c

EC4C5000

ASSEMBLY AND INSTALLATION

Segment

1. Install:

2. Segment ①

3. Bolt (segment)

30 Nm (3.0 m · kg, 22 ft · lb)

NOTE:

Align the notch ⓐ on the segment with the pin ⓑ 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.

Technical diagram of a mechanical gear assembly with numbered components

EC4B5111

Stopper lever

1. Install:

2. Torsion spring ①

3. Plain washer ②
4. Stopper lever ③
5. Bolt (stopper lever) ④

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

Align the stopper lever roller with the slot on segment.

Diagram of a medical or laboratory procedure with labeled components and directional arrows indicating flow or movement.

Shift guide and shift lever assembly

1. Install:

2. Spring ①

3. Pawl pin ②
4. Pawl ③

To shift lever ④.

NOTE:

Apply the engine oil on the springs, pawl pins and pawls.

1. Install:

- Shift lever assembly ①

To shift guide ②.

Technical diagram of a mechanical component with labeled parts ① and ②

ASSEMBLAGE ET MONTAGE

Segment

1. Monter:

2. Segment ①

3. Boulon (segment)

30 Nm (3,0 m · kg, 22 ft · lb)

N.B.:

Technical diagram of engine cylinder assembly with labeled parts and a hand pointing to a component

Technical diagram of a mechanical assembly with labeled components, showing gear and shaft connections.

Technical diagram of an engine cylinder assembly with labeled parts and E-labeled ports

3. Install:

• 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.

4. Install:

- Bolt (shift guide) ①

10 Nm (1.0 m · kg, 7.2 ft · lb)

EC4C5301

Shift shaft

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.

3. Monter:

New ① ② ③ ④ ⑤ ⑥ ⑦ ⑧ M a b New

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 ⓐ on the ratchet wheel with the punch mark ⓑ on the kick axle.

Technical diagram showing gear and cable assembly with labeled parts ①, ②, and ③

2. Install:

• Torsion spring ①
  To kick axle ②.

NOTE:

Make sure the stopper Ⓐ of the torsion spring fits into the hole ⓑ on the kick axle.

Technical diagram of a mechanical gear assembly with labeled parts ① and ②

3. Install:

- Spring guide ①

NOTE:

Slide the spring guide into the kick axle, make sure the groove ⓐ in the spring guide fits on the stopper of the torsion spring.

Arbre de kick complet

1. Monter:

- Pignon de kick ①

- Rondelle pleine ②

- Circlip ③ New

- Roue à rochet ④

- Ressort ⑤

- Rondelle pleine ⑥

- Circlip ⑦ New

Technical diagram of engine gear assembly with labeled components and parts

4. Install:

• Kick axle assembly ①
• Plain washer ②

NOTE:

• Apply the molybdenum disulfide grease on the contacting surfaces of the kick axle stopper ⑨ and ratchet wheel guide ③.
• Apply the engine oil on the kick axle.
• Slide the kick axle assembly into the crank-case and make sure the kick axle stopper fits into the ratchet wheel guide.

Technical line drawing of a mechanical gear assembly with labeled components (a, 1, 2), no readable text or symbols beyond labels

5. Hook:

- Torsion spring ①

NOTE:

Turn the torsion spring clockwise and hook into the proper hole ⓐ in the crankcase.

Technical diagram of a mechanical gear assembly with labeled parts and a close-up view of the gear mechanism.

Kick idle gear

1. Install:

• Kick idle gear ①
• Plain washer ②
• Circlip ③ New

NOTE:

• Install the kick idle gear with its depressed side @ toward you.
• Apply the engine oil on the kick idle gear inner circumference.

4. Monter:

Extent of removal:
① Starter clutch/wheel gear removal
② Rotor removal
③ Pickup coil/stator removal

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		AC MAGNETO AND STATOR REMOVALDrain the engine oil.Seat and fuel tankDisconnect the AC magneto lead.		Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3.Refer to “SEAT, FUEL TANK AND SIDE COVERS” section.
13	1	Shift pedal	1	Do not disassemble.
	2	Cover (torque limiter)	1
	3	Torque limiter	1
	4	Crankcase cover (left)	1
	5	Gasket	1
	6	Dowel pin	2

ALTERNATEUR AVEC ROTOR A ALIMENTATION PERMANENTE ET EMBRAYAGE DU DEMARREUR

Extent of removal	Order	Part name	Q'ty	Remarks
	7	Idle gear	1
	8	Bearing	1
	9	Shaft	1
	10*	Nut (rotor)	1	Refer to NOTE.
	11	Rotor	1	Use special tool.
				Refer to “REMOVAL POINTS”.
	12	Woodruff key	1
	13	Starter clutch assembly cover	1	Refer to “REMOVAL POINTS”.
	14	Starter clutch	1
	15	Starter clutch drive gear	1
	16	Holder	1
	17	Pick-up coil	1
	18	Stator	1

NOTE:

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

Technical diagram of a mechanical assembly with numbered components labeled ① and ②

Technical diagram of a mechanical assembly with numbered components, likely illustrating a turning or kinematic mechanism.

Technical diagram of a mechanical component with labeled parts 1 and a, showing a tool inserted into a circular housing.

Technical diagram of a mechanical component with labeled parts ① and ②, showing internal structure and tool path.

Technical line drawing of a mechanical component with two views: top shows gear-like structure, bottom shows cylindrical housing (no text or symbols)

EC4L3000

REMOVAL POINTS

Rotor

1. Remove:

2. Nut (rotor) ①

3. Plain washer

Use the sheave holder ②.

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

1. Remove:

- Rotor ①

Use the rotor puller ②.

Rotor puller: YM-04142/90890-04142

Starter clutch

1. Remove:

- Starter clutch assembly cover ①

NOTE:

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

1. Remove:

- Starter clutch ①

NOTE:

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

EC4L4000

INSPECTION

AC magneto

1. Inspect:

2. Rotor inner surface ⓐ

3. Stator outer surface ⑥

Damage → Inspect the crankshaft runout and crankshaft bearing.

If necessary, replace AC magneto and/or stator.

POINTS DE DEPOSE

Rotor

Technical line drawing of a mechanical assembly with no visible text or symbols

Technical line drawing of two gear components (no text or symbols)

A B ① ②

EC4L4200

Woodruff key

1. Inspect:

- Woodruff key ① Damage → Replace.

Starter clutch

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 B, 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 A, it should turn freely. If the starter clutch drive gear does not turn freely, the starter clutch is faulty and must be replaced.

Technical line drawing of a mechanical component with concentric rings and a central hub (no text or symbols)

Torque limiter

1. Check:

- Torque limiter Damage/wear → Replace.

Clavette demi-lune

1. Contrôler:

- Clavette demi-lune ① Endommagement → Remplacer.

Scheibenfeder

1. Kontrollieren:

Technical diagram of a mechanical assembly with numbered components for identification

EC4L5000

ASSEMBLY AND INSTALLATION

AC magneto and starter clutch

1. Install:

2. Stator ①

3. Bolt (stator) ②

7 Nm (0.7 m · kg, 5.1 ft · lb)

• Pick-up coil ③
• Holder ④
• Bolt ⑤

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

• Pass the AC magneto lead ⑤ under the pick-up 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

Technical line drawing of a mechanical gear assembly with no visible text or symbols

1. Install:

- Starter clutch drive gear ①

NOTE:

Apply the engine oil on the starter clutch drive gear inner circumference.

1. Monter:

2. Stator ①

3. Boulon (stator) ②

7 Nm (0,7 m · kg, 5,1 ft · lb)

Technical diagram of a device with labeled parts, showing internal structure and numbered annotations.

① ② a b

Technical diagram of a mechanical assembly with labeled parts and an inset showing a close-up view of a component.

Technical diagram of a mechanical assembly with numbered components labeled ① and ②

3. Install:

- Starter clutch ① To rotor ②.

NOTE:

• Install the starter clutch with its plate side upward.
• While installing the starter clutch, push in the projections @ 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.

NOTE:

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

5. Install:

• 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 ⓐ is in parallel with the crankshaft center line ⓑ.
• When installing the rotor, align the keyway © of the rotor with the woodruff key.

6. Install:

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

Technical diagram of a mechanical assembly with numbered components and labeled parts E

Technical diagram of an automotive gear assembly with numbered component labels

Technical diagram showing mechanical assembly with labeled parts and a hanging component marked 'E'

Technical diagram of a mechanical assembly with labeled parts, including numbered annotations (a, 1, 2) and section line.

Technical diagram of a mechanical assembly with labeled parts and directional arrows indicating motion or force

7. Install:

• Shaft ①
• Bearing ②
• Idle gear 2 ③

NOTE: \_\_\_\_

Apply the engine oil on the shaft, bearing and idle gear inner circumference.

8. Install:

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

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE: \_\_\_\_

Tighten the bolts in stage, using a crisscross pattern.

9. Install:

• Plain washer
• Torque limiter ①
• Plain washer

NOTE:

Apply the engine oil to the shaft and plain washers.

10. Install:

• Cover (idle gear 1) ①
• Bolt ② 10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE: \_\_\_\_

Install the cover (idle gear 1) with its mark ⓐ 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)

12 Nm (1.2 m · kg, 8.7 ft · lb)

NOTE: \_\_\_\_

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) @ above the top of the footrest.

7. Monter:

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		ENGINE REMOVALHold the machine by placing the suitable stand under the frame.Drain the engine oilSeat, fuel tank and side coverRadiatorExhaust pipe and silencerAir cut-off valve assemblyClutch cable and guideShift pedalRear shock absorberCarburetor		⚠ WARNINGSupport 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 6Refer to “CARBURETOR” section.

DEPOSE DU MOTEUR

Extent of removal:
① Engine removal

Extent of removal	Order	Part name	Q'ty	Remarks
		Cylinder head breather hoseIgnition coilDisconnect the AC magneto lead.Disconnect the starter motor lead.Negative battery lead		Refer to “CAMSHAFTS” section.Refer to “ELECTRIC STARTING SYSTEM” section in the CHAPTER 6.Disconnect at the starter motor side.
1	1	Engine guard	1	Refer to “REMOVAL POINTS”.
	2	Neutral switch	1
	3	Chain cover	1
	4	Nut (drive sprocket)	1
	5	Lock washer	1
	6	Drive sprocket	1
	7	Clip	1
	8	Bolt (brake pedal)	1
	9	Brake pedal	1

Technical diagram of a mechanical gear assembly with labeled components 1 and 2

Technical diagram of a mechanical gear assembly with labeled parts ① and ②

Technical diagram showing mechanical assembly with labeled component ①

Technical line drawing of a mechanical assembly with hands operating a component (no text or symbols visible)

EC4M3000

REMOVAL POINTS

EC4F3100

Drive sprocket

1. Remove:

2. Nut (drive sprocket) ①

3. Lock washer ②

NOTE:

• Straighten the lock washer tab.

• Loosen the nut while applying the rear brake.

• Remove:

• Drive sprocket ①

• Drive chain ②

NOTE:

Remove the drive sprocket together with the drive chain.

EC4M3301

Engine removal

1. Remove:

- Pivot shaft ①

NOTE:

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

1. Remove:

- Engine ①

From right side.

NOTE:

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

POINTS DE DEPOSE

Couronne arrière

1. Déposer:

Technical diagram of a mechanical assembly with numbered components and labeled parts, including a motor and valve mechanism.

EC4M5000

ASSEMBLY AND INSTALLATION Engine installation

1. Install:

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

85 Nm (8.5 m · kg, 61 ft · lb)

- Engine mounting bolt (lower) ③

53 Nm (5.3 m · kg, 38 ft · lb)

• Engine lower bracket ④
• Bolt (engine lower bracket) ⑤

• Patch ⑥
  • Engine mounting bolt (front) ⑦

53 Nm (5.3 m · kg, 38 ft · lb)

• Engine upper bracket (right) ⑧
  • Engine upper bracket (left) ⑨
• Bolt (engine upper bracket) ⑩

55 Nm (5.5 m · kg, 40 ft · lb)

55 Nm (5.5 m · kg, 40 ft · lb)

• Engine mounting bolt (upper) ⑪

NOTE:

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

New ① ② ③ ④ B ⑤

Brake pedal

1. Install:

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

26 Nm (2.6 m · kg, 19 ft · lb)

- Clip ⑤

NOTE:

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

Technical diagram of a mechanical gear assembly with numbered components

① New ②

Technical diagram of a mechanical assembly with numbered components, likely for assembly or maintenance instructions.

New ① ② ③ ④ ⑤ B

Drive sprocket

1. Install:

• Drive sprocket ①
• Drive chain ②

NOTE: ____

Install the drive sprocket together with the drive chain.

2. Install:

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

Tighten the nut while applying the rear brake.

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

4. Install:

• Chain guide
• Chain cover ①
• Screw (chain cover) ②

8 Nm (0.8 m · kg, 5.8 ft · lb)

5. Install:

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

4 Nm (0.4 m · kg, 2.9 ft · lb)

NOTE: ____

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

Couronne arrière

CRANKCASE AND CRANKSHAFT

CRANKCASE AND CRANKSHAFT

12 Nm (1.2 m · kg, 8.7 ft · lb) New 10 Nm (1.0 m · kg, 7.2 ft · lb) 10 Nm (1.0 m · kg, 7.2 ft · lb)

Extent of removal:
① Crankcase separation
② Crankshaft removal

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		CRANKCASE SEPARATIONEnginePistonBalancerKick axle assemblySegmentStator		Refer to “ENGINE REMOVAL” section.Refer to “CYLINDER AND PISTON” section.Refer to “BALANCER” section.Refer to “KICK AXLE AND SHIFT SHAFT” section.Refer to “AC MAGNETO AND STARTER CLUTCH” section.
	1	Timing chain guide (rear)	1
	2	Timing chain	1
	3	Bolt (50 mm)	7
	4	Bolt (60 mm)	2
	5	Bolt (80 mm)	3
	6	Hose guide	1	Refer to “REMOVAL POINTS”.
	7	Clutch cable holder	1
	8	Crankcase (right)	1
	9	Crankcase (left)	1

Extent of removal:
① Crankcase bearing removal

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		CRANKCASE BEARING REMOVALTransmissionShift cam and shift fork		Refer to “TRANSMISSION, SHIFT CAM AND SHIFT FORK” section.
1	1	Oil seal	3	Refer to “REMOVAL POINTS”.
	2	Bearing	10

CARTER MOTEUR ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CÁRTER Y CIGÜEÑAL

ROULEMENT DE CARTER MOTEUR

Technical line drawing of a mechanical assembly with gears and housing (no text or symbols)

Technical line drawing of a mechanical component with no visible text or symbols

Technical line drawing of a mechanical assembly with no visible text or symbols

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 screw-driver tip into the splitting slit ⓐ 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).

CAUTION:

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

- Remove the dowel pins and O-ring.

Technical diagram showing mechanical assembly with labeled parts ① and ②, likely illustrating a tool or procedure.

Balancer shaft

1. Remove:

- Balancer shaft ①

NOTE:

Remove the balancer shaft with its flat side ⓐ facing the crankshaft.

POINTS DE DEPOSE

Carter moteur

Technical diagram of an engine cylinder assembly with labeled parts ① and ②

Technical line drawing of a mechanical assembly with no visible text or symbols

Technical diagram showing mechanical assembly with labeled components and a close-up view of a mechanical assembly.

Diagram of a mechanical linkage or chain structure with two circular components, no text or symbols present

Technical diagram of a mechanical component with labeled parts (a) and (b)

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.

Crankshaft bearing

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

Crankcase

1. Inspect:

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

CARTER MOTEUR ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CÁRTER Y CIGÜEÑAL

ENG

Vilebrequin

1. Déposer:

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

3. Inspect:

- Oil seal Wear/damage → Replace.

EC4N4201

Crankshaft

1. Measure:

• Runout limit ⓐ
• Small end free play limit ⓑ
• Connecting rod big end side clearance ©
• Crank width ⓓ

Out of specification → Replace.

Use the dial gauge and a thickness gauge.

Dial gauge and stand:YU-3097/90890-01252

	Standard
Runout limit:	0.03 mm(0.0012 in)	0.05 mm(0.002 in)
Small end free play:	0.4 ~ 1.0 mm(0.016 ~ 0.039 in)	2.0 mm(0.08 in)
Side clearance:	0.15 ~ 0.45 mm(0.0059 ~ 0.0177 in)	0.50 mm(0.02 in)
Crack width:	61.95 ~ 62.00 mm(2.439 ~ 2.441 in)	—

Technical line drawing of a mechanical component with a circular housing and mounting bracket (no text or symbols)

Oil strainer

1. Inspect:

- Oil strainer Damage → Replace.

CARTER MOTEUR ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CÁRTER Y CIGÜEÑAL

ENG

2. Contrôler:

Technical diagram of a mechanical assembly with labeled parts and component annotations

EC4N5000

ASSEMBLY AND INSTALLATION

Crankshaft bearing

1. Install:

• Bearing New
• Bearing stopper
• Bolt (bearing stopper)

10 Nm (1.0 m · kg, 7.2 ft · lb)

- Screw (bearing stopper)

10 Nm (1.0 m · kg, 7.2 ft · lb)

- Screw [bearing stopper (crankshaft)] ①

14 Nm (1.4 m · kg, 10 ft · lb)

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 ⓐ into the concave ⓑ using a punch etc. In so doing, take care not to damage the screwdriver receiving hole in the screw head.

Technical diagram of a mechanical assembly with numbered components for identification

Crankshaft

1. Install:

- Crankshaft ①

Use the crankshaft installing tool ②, ③, ④ and ⑤.

Crankshaft installing pot ②:

YU-90050/90890-01274

Crankshaft installing bolt ③:

YU-90050/90890-01275

Adaptor (M12) ④:

YU-90063/90890-01278

Spacer (crankshaft installer) ⑤:

YM-91044/90890-04081

A ② ③ ④ ⑤

B ② ③ ④ ⑤

A For USA and CDN
B Except for USA and CDN

CARTER MOTEUR ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CÁRTER Y CIGÜEÑAL

ENG

ASSEMBLAGE ET MONTAGE Roulement de vilebrequin

• 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.

Mechanical assembly diagram showing gear and shaft components (no text or labels)

Technical diagram showing mechanical assembly with labeled parts ① and ②, likely illustrating a valve or adjustment mechanism.

Technical line drawing of an automotive gear assembly (no text or labels)

2. Check:

• Shifter operation
• Transmission operation
  Unsmooth operation → Repair.

3. Install:

• Oil strainer ①
• Bolt (oil strainer) ②

10 Nm (1.0 m · kg, 7.2 ft · lb)

4. Apply:

• 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.

CARTER MOTEUR ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CÁRTER Y CIGÜEÑAL

ENG

N.B.:

① ① ② New

5. Install:

• 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).

Technical diagram of a mechanical assembly with numbered components, likely for engineering or manufacturing documentation.

6. Tighten:

• Hose guide ①
• Clutch cable holder ②
• Bolt (clutch cable holder)

10 Nm (1.0 m · kg, 7.2 ft · lb)

- Bolt (crankcase)

12 Nm (1.2 m · kg, 8.7 ft · lb)

NOTE:

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

7. Install:

• Timing chain
• Timing chain guide (rear)
• Bolt (timing chain guide)

10 Nm (1.0 m · kg, 7.2 ft · lb)

8. Remove:

- 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.

CARTER MOTEUR ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CÁRTER Y CIGÜEÑAL

5. Monter:

TRANSMISSION, SHIFT CAM AND SHIFT FORK

TRANSMISSION, SHIFT CAM AND SHIFT FORK

New B 7 2 E 4 3 6 1 M E M

Extent of removal:
① Shift fork, shift cam, main axle and drive axle removal

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVALEngineSeparate the crankcase.		Refer to “ENGINE REMOVAL” section.Refer to “CRANKCASE AND CRANK-SHAFT” section.
1	1	Main axle	1	Refer to “REMOVAL POINTS”.
	2	Drive axle	1
	3	Shift cam	1
	4	Shift fork 3	1
	5	Shift fork 2	1
	6	Shift fork 1	1
	7	Collar	1

BOITE DE VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN CAJA DE CAMBIOS, LEVA DE CAMBIO Y HORQUILLA DE CAMBIO

BOITE DE VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION

BOITE DE VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION

Technical diagram of a mechanical assembly with numbered components, likely for repair or maintenance instructions.

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.

a b c

EC4H4000

INSPECTION

EC4H4200

Gears

1. Inspect:

• Matching dog ⓐ
• Gear teeth ⓑ
• Shift fork groove ©
  Wear/damage → Replace.

Technical line drawing of a mechanical gear assembly with no visible text or symbols

2. Inspect:

• O-ring ①
  Damage → Replace.

3. Check:

• Gears movement
  Unsmooth movement → Repair or replace.

BOITE DE VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN CAJA DE CAMBIOS, LEVA DE CAMBIO Y HORQUILLA DE CAMBIO

POINTS DE DEPOSE

Technical drawing of a mechanical bearing assembly with sectional views and dimension annotations

Technical diagram of a mechanical linkage or assembly with labeled component ①

Technical diagram of a mechanical component with labeled parts ① and ②

Technical line drawing of a mechanical component being adjusted for assembly (no text or symbols)

EC4H4600

Bearing

1. Inspect:

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

EC4H4801

Shift fork, shift cam and segment

1. Inspect:

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

2. Inspect:

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

3. Check:

- 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.

BOITE DE VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN CAJA DE CAMBIOS, LEVA DE CAMBIO Y HORQUILLA DE CAMBIO

Roulement

1. Contrôler:

- Roulement ①

Exploded view diagram of a mechanical assembly with numbered components and a labeled component M

Technical diagram of a mechanical assembly with numbered components and a labeled component M

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.

2. 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 O-ring.

BOITE DE VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN CAJA DE CAMBIOS, LEVA DE CAMBIO Y HORQUILLA DE CAMBIO

New ① ② ③ a

Diagram showing two identical mechanical or structural configurations with labeled components 'C' and circular features, likely illustrating a mechanical or structural concept.

Technical line drawing of a mechanical component with labeled parts (no text or symbols present)

graph TD
    A["Component 1"] --> B["Component 2"]
    B --> C["Component 3"]
    C --> D["Component 4"]
    D --> E["Component 5"]
    E --> F["Component 6"]
    F --> G["Component 7"]
    G --> H["Component 8"]
    H --> I["Component 9"]
    I --> J["Component 10"]
    style A fill:#f9f,stroke:#333
    style B fill:#f9f,stroke:#333
    style C fill:#f9f,stroke:#333
    style D fill:#f9f,stroke:#333
    style E fill:#f9f,stroke:#333
    style F fill:#f9f,stroke:#333
    style G fill:#f9f,stroke:#333
    style H fill:#f9f,stroke:#333
    style I fill:#f9f,stroke:#333
    style J fill:#f9f,stroke:#333

3. Install:

• Plain washer ①
• Circlip ② New

NOTE:

• Be sure the circlip sharp-edged corner ⓐ is positioned opposite side to the plain washer and gear ⓑ.
• Install the circlip with its ends © settled evenly on the spline crests.

4. Install:

- 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.

5. Install:

• 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.

BOITE DE VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN CAJA DE CAMBIOS, LEVA DE CAMBIO Y HORQUILLA DE CAMBIO

3. Monter:

• Rondelle pleine ①
- Circlip ② New
- Circlip ② New

N.B.:

Technical diagram of a mechanical assembly with labeled parts, showing gears and shafts for assembly or maintenance.

Mechanical gear assembly diagram showing gear meshing and shaft alignment (no text or labels)

6. Install:

- Transmission assembly ① To crankcase (left) ②.

NOTE:

Apply the engine oil on the bearings and guide bars.

7. Check:

• Shifter operation
  • Transmission operation
  Unsmooth operation → Repair.

BOITE DE VITESSES, TAMBOUR ET FOURCHETTES DE SELECTION GETRIEBE, SCHALTWALZE UND SCHALTGABELN CAJA DE CAMBIOS, LEVA DE CAMBIO Y HORQUILLA DE CAMBIO

6. Monter:

① Front wheel removal

③ Brake disc removal

② Wheel bearing removal

Extent of removal			Order	Part name	Q'ty	Remarks
Preparation for removal				FRONT WHEEL REMOVALHold the machine by placing the suitable stand under the engine.		WARNINGSupport the machine securely so there is no danger of it falling over.
			1	Bolt (axle holder)	4	Only loosening.
			2	Nut (front wheel axle)	1
			3	Front wheel axle	1
			4	Front wheel	1
			5	Speed sensor	1
			6	Collar	1
			7	Oil seal	1
			8	Bearing	2	Refer to “REMOVAL POINTS”.
			9	Brake disc	1

CHASSIS

ROUE AVANT ET ROUE ARRIERE

ROUE AVANT

Extent of removal:
① Rear wheel removal
③ Brake disc removal
② Wheel bearing removal

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		REAR WHEEL REMOVALHold the machine by placing the suitable stand under the engine.		WARNINGSupport the machine securely so there is no danger of it falling over.
1323	1	Nut (rear wheel axle)	1	Refer to “REMOVAL POINTS”.
	2	Rear wheel axle	1
	3	Chain puller	2
	4	Rear wheel	1
	5	Collar	2
	6	Driven sprocket	1
	7	Oil seal	2
	8	Circlip	1
	9	Bearing	2	Refer to “REMOVAL POINTS”.
	10	Brake disc	1

ROUE AVANT ET ROUE ARRIERE

VORDER- UND HINTERRAD

RUEDA DELANTERA Y RUEDA TRASERA

CHAS

ROUE ARRIERE

Technical diagram of a mechanical gear system with labeled components and motion indicators

Technical diagram of a mechanical assembly with labeled parts ① and ②, showing components like bolts, springs, and a central housing.

Technical diagram showing mechanical assembly with labeled components and cross-sectional views

Technical diagram of two mechanical bearing assemblies with alignment arrows (no text or labels)

EC593000

REMOVAL POINTS

EC523101

Rear wheel

1. Remove:

- Wheel ①

NOTE:

Push the wheel forward and remove the drive chain ②.

EC513201

Wheel bearing (if necessary)

1. Remove:

- Bearing ①

NOTE:

Remove the bearing using a general bearing puller ②.

EC594000

INSPECTION

EC514100

Wheel

1. Measure:

- Wheel runout

Out of limit → Repair/replace.

Wheel runout limit:

Radial ①: 2.0 mm (0.08 in)

Lateral ②: 2.0 mm (0.08 in)

1. Inspect:

- Bearing

Rotate inner race with a finger.

Rough spot/seizure → Replace.

NOTE:

Replace the bearings, oil seal and wheel collar as a set.

POINTS DE DEPOSE

Roue arrière

1. Déposer:

- Roue ①

N.B.:

Technical diagram of a dial indicator measuring a mechanical setup with labeled component 1

EC514200

Wheel axle

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.

a ① I2210203

EC594200

Brake disc

1. Measure:

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

	Disc deflection limit:
	Standard
Rear	—	0.15 mm(0.006 in)

2. Measure:

- Brake disc thickness ⓐ Out of limit → Replace.

	Disc wear limit:
	Standard
Front	3.0 mm (0.12 in)	2.5 mm (0.10 in)
Rear	4.0 mm (0.16 in)	3.5 mm (0.14 in)

ROUE AVANT ET ROUE ARRIERE

VORDER- UND HINTERRAD

RUEDA DELANTERA Y RUEDA TRASERA

CHAS

Axe de roue

1. Mesurer:

① ② ③ ④ New

graph TD
    1["①"] --> 2["②"]
    2 --> 3["③"]
    3 --> 4["④"]
    4 --> 5["⑤"]
    5 --> 6["⑥"]
    6 --> 1
    style 1 fill:#f9f,stroke:#333
    style 2 fill:#f9f,stroke:#333
    style 3 fill:#f9f,stroke:#333
    style 4 fill:#f9f,stroke:#333
    style 5 fill:#f9f,stroke:#333
    style 6 fill:#f9f,stroke:#333

Technical diagram showing a hand using a tool to inspect a mechanical component with numbered parts and a labeled component B.

Technical diagram of a mechanical component with labeled parts (a, b, 1) and annotation B

EC595000

ASSEMBLY AND INSTALLATION

Front wheel

1. Install:

2. Bearing (left) ①

3. Spacer ②
4. Bearing (right) ③
5. 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.

1. Install:

2. Brake disc ①

3. Bolt (brake disc) ②

12 Nm (1.2 m · kg, 8.7 ft · lb)

NOTE:

Tighten the bolts in stage, using a crisscross pattern.

1. Install:

- Collar ①

NOTE:

Apply the lithium soap base grease on the oil seal lip.

1. Install:

- Speed sensor ①

NOTE:

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

Technical diagram showing mechanical assembly with labeled parts ① and ②

Technical diagram of a mechanical assembly with labeled parts a and b

Technical diagram of a mechanical assembly with labeled parts and a scale indicator

Technical diagram showing a mechanical assembly with labeled component '1'

5. Install:

- Wheel

NOTE:

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

6. Install:

- Wheel axle ①

NOTE:

Apply the lithium soap base grease on the wheel axle.

7. Install:

- Nut (wheel axle) ①

90 Nm (9.0 m · kg, 65 ft · lb)

ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD RUEDA DELANTERA Y RUEDA TRASERA

5. Monter:

- Roue

N.B.:

Technical diagram of a mechanical component with labeled parts, showing two circular ports and numbered callouts.

Line drawing of a motorcycle's front wheel and side-mounted gear assembly (no text or symbols)

New ⑤ ② New ① B ③ B ④ ⑤ New

8. Tighten:

- Bolt (axle holder) ①

23 Nm (2.3 m · kg, 17 ft · lb)

NOTE:

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

Rear wheel

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.

8. Serrer:

Technical diagram of a mechanical component with numbered parts and directional arrows indicating motion or flow.

graph TD
    A["1"] --> B["2"]
    B --> C["3"]
    C --> D["4"]
    D --> E["5"]
    E --> F["6"]
    F --> A
    style A fill:#f9f,stroke:#333
    style B fill:#f9f,stroke:#333
    style C fill:#f9f,stroke:#333
    style D fill:#f9f,stroke:#333
    style E fill:#f9f,stroke:#333
    style F fill:#f9f,stroke:#333

Technical diagram showing a hand operating a gear mechanism with labeled components and directional arrows

Technical diagram of a mechanical assembly with labeled parts ① and ②

Technical diagram showing mechanical assembly with labeled components, including chain link and gear mechanism

2. Install:

• Brake disc ①
• Bolt (brake disc) ②

14 Nm (1.4 m · kg, 10 ft · lb)

NOTE:

Tighten the bolts in stage, using a crisscross pattern.

3. Install:

• Driven sprocket ①
• Bolt (driven sprocket) ②
• Plain washer (driven sprocket) ③
• Nut (driven sprocket) ④

50 Nm (5.0 m · kg, 36 ft · lb)

NOTE:

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.

5. Install:

- Wheel

NOTE:

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

6. Install:

- Drive chain ①

NOTE:

Push the wheel ② forward and install the drive chain.

ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD RUEDA DELANTERA Y RUEDA TRASERA

2. Monter:

Technical diagram of a mechanical assembly with numbered components and labeled parts

Technical diagram of a mechanical assembly with numbered components, likely illustrating a gear or cam mechanism.

Technical diagram showing mechanical assembly with labeled component 'a' and directional arrow

Technical diagram of a mechanical assembly with labeled parts ① and ②

7. Install:

• 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.

8. Install:

• Chain puller (right) ①
• Plain washer ②
• Nut (wheel axle) ③

NOTE:

Temporarily tighten the nut (wheel axle) at this point.

9. Adjust:

- Drive chain slack ⓐ

Drive chain slack: 48 \~ 58 mm (1.9 \~ 2.3 in)

Refer to "DRIVE CHAIN SLACK ADJUSTMENT" section in the CHAPTER 3.

10. Tighten:

• Nut (wheel axle) ①
  125 Nm (12.5 m · kg, 90 ft · lb)
• Locknut ②
  19 Nm (1.9 m · kg, 13 ft · lb)

ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD RUEDA DELANTERA Y RUEDA TRASERA

7. Monter:

① Brake hose removal
③ Master cylinder removal

② Caliper removal

Extent of removal		Order	Part name	Q'ty	Remarks
Preparation for removal			FRONT BRAKE REMOVALHold the machine by placing the suitable stand under the engine.Drain the brake fluid.		WARNINGSupport the machine securely so there is no danger of it falling over.Refer to “REMOVAL POINTS”.
	3↑	1	Brake hose holder (protector)	2	Remove when loosening the pad pin.Loosen when disassembling the caliper.
		2	Brake hose holder (caliper)	1
		3	Union bolt	2
		4	Brake hose	1
		5	Pad pin plug	1
		6	Pad pin	1
		7	Caliper	1
		8	Brake lever	1
		9	Master cylinder bracket	1
		10	Master cylinder	1

FREIN AVANT ET FREIN ARRIERE

FREIN AVANT

Extent of removal:
① Master cylinder removal
③ Caliper removal
② Brake hose removal

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		REAR BRAKE REMOVALHold the machine by placing the suitable stand under the engine.Rear wheelDrain the brake fluid.		WARNINGSupport the machine securely so there is no danger of it falling over.Refer to “FRONT WHEEL AND REAR WHEEL” section.Refer to “REMOVAL POINTS”.
1↓1↑23↓3	1	Brake pedal	1
	2	Master cylinder	1
	3	Brake hose holder	2
	4	Union bolt	2
	5	Brake hose	1
	6	Pad pin plug	1	Remove when loosening the pad pin.Loosen when disassembling the caliper.
	7	Pad pin	1
	8	Caliper	1

FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN FRENO DELANTERO Y FRENO TRASERO

FREIN ARRIERE

A Front
B Rear
Extent of removal:
① Front caliper disassembly
② Rear caliper disassembly

Extent of removal		Order	Part name	Q'ty		Remarks
			CALIPER DISASSEMBLY	A	B
		1	Pad pin	1	1
		2	Brake pad	2	2
		3	Pad support	1	1
		4	Caliper piston	2	1
		5	Dust seal	2	1	Refer to “REMOVAL POINTS”.
		6	Piston seal	2	1

FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN FRENO DELANTERO Y FRENO TRASERO

DEMONTAGE DE L'ETRIER DE FREIN

A Avant
B Arrière

A Front
B Rear
Extent of removal:
① Front master cylinder disassembly
② Rear master cylinder disassembly

Extent of removal	Order	Part name	Q'ty	Remarks
1	12345678	MASTER CYLINDER DISASSEMBLYMaster cylinder capDiaphragmReservoir floatMaster cylinder bootCirclipPlain washerPush rodMaster cylinder kit	1111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111	Use a long nose circlip pliers.

FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN FRENO DELANTERO Y FRENO TRASERO

DEMONTAGE DU MAITRE-CYLINDRE DE FREIN

A Avant
B Arrière

Line drawing of a hand using a tool to adjust or install a mechanical component (no text or symbols present)

Line drawing of hands using a pliers to handle a mechanical component (no text or symbols)

EC5A3000

REMOVAL POINTS

Brake fluid

1. Remove:

[Front]

• Master cylinder cap ①
  [Rear]
• Master cylinder cap ①
• Protector

NOTE:

Do not remove the diaphragm.

A Front
B Rear

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

A Front
B Rear

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

CAUTION:

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

EC533301

Caliper piston

1. Remove:

2. Caliper piston
   Use compressed air and proceed carefully.

WARNING

• Cover piston with rag and use extreme caution when expelling piston from cylinder.
• Never attempt to pry out piston.

Caliper piston removal steps:

• Insert a piece of rag into the caliper to lock one caliper.
• Carefully force the piston out of the caliper cylinder with compressed air.

A Front
B Rear

POINTS DE DEPOSE

Liquide de frein

1. Déposer:

[Avant]

A ① ② ② ①

B ① ②

A B a a

A ① B ①

Isometric line drawing of a 3D object with a curved top surface and labeled point (1), no text or symbols present.

EC533402

Piston seal kit

1. Remove:

2. Dust seal ①

3. 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.

A Front
B Rear

EC5A4000

INSPECTION

EC534112

Master cylinder

1. Inspect:

- Master cylinder inner surface @ Wear/scratches → Replace master cylinder assembly. Stains → Clean.

WARNING

Use only new brake fluid.

A Front
B Rear

1. Inspect:

- Diaphragm ① Crack/damage → Replace.

A Front
B Rear

1. Inspect: (front brake only)

- Reservoir float ① Damage → Replace.

Kit joint de piston

1. Déposer:

2. Joint antipoussière ①

3. Joint de piston ②

N.B.:

Technical diagram showing three labeled components: a cylindrical part, two ring rings, and a separate ring with connection points.

Diagram of a curved cable or connector with labeled component 1 (no text or symbols beyond label)

4. Inspect:

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

A Front

B Rear

EC534214

Caliper

1. Inspect:

- Caliper cylinder inner surface ⓐ Wear/score marks → Replace caliper assembly.

A Front

B Rear

2. Inspect:

- Caliper piston ① Wear/score marks → Replace caliper piston assembly.

WARNING

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

EC534301

Brake hose

1. Inspect:

- Brake hose ① Crack/damage → Replace.

EC5A5000

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.

FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN FRENO DELANTERO Y FRENO TRASERO

CHAS

A ① ① New ② ② New

B ② New ① New

A ① a ①

B ① ① a

Technical diagram of a mechanical assembly with numbered parts and an inset view labeled a and b

EC5A5800

Caliper piston

1. Clean:

2. Caliper

3. Piston seal
4. Dust seal
5. Caliper piston

Clean them with brake fluid.

1. Install:

2. Piston seal ① New

3. 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.

A Front
B Rear

1. Install:

- Caliper piston ①

NOTE:

Apply the brake fluid on the piston wall.

CAUTION:

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

A Front
B Rear

Front caliper

1. Install:

2. Pad support ①

3. Brake pad ②
4. Pad pin ③

NOTE:

• Install the brake pads with their projections ① into the caliper recesses ②.
• Temporarily tighten the pad pin at this point.

Technical diagram of a mechanical assembly with numbered components for identification

2. Install:

• Caliper ①
• Bolt (caliper) ②

23 Nm (2.3 m · kg, 17 ft · lb)

3. Tighten:

- Pad pin ③

18 Nm (1.8 m · kg, 13 ft · lb)

4. Install:

- Pad pin plug ④

3 Nm (0.3 m · kg, 2.2 ft · lb)

Technical diagram of a mechanical assembly with numbered components and an inset view labeled a and b.

EC5A5100

Rear caliper

1. Install:

• Pad support ①
• Brake pad ②
• Pad pin ③

NOTE:

• Install the brake pads with their projections ① into the caliper recesses ⑥.
• Temporarily tighten the pad pin at this point.

Technical diagram of a mechanical component with numbered parts labeled 1, 2, and 3.

2. Install:

• Disc cover ①
• Bolt (disc cover) ②

10 Nm (1.0 m · kg, 7.2 ft · lb)

FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN FRENO DELANTERO Y FRENO TRASERO

Diagram showing a hand holding a small object with numbered parts around a bicycle wheel, likely illustrating a mechanical or electrical assembly.

3. Install:

• Caliper ①
• Rear wheel ②

Refer to “FRONT WHEEL AND REAR WHEEL” section.

4. Tighten:

- Pad pin ③

18 Nm (1.8 m · kg, 13 ft · lb)

5. Install:

- Pad pin plug ④

3 Nm (0.3 m · kg, 2.2 ft · lb)

A ② ① ③

B ① ② ③

A ② ① ③

B ① ② ③

A ② ①

B ② ①

Master cylinder kit

1. Clean:

• Master cylinder
  • Master cylinder kit Clean them with brake fluid.

2. Install:

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

NOTE:

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.

A Front
B Rear

3. Install:

- Spring ①

To master cylinder piston ②.

NOTE:

Install the spring at the smaller dia. side.

A Front
B Rear

FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN FRENO DELANTERO Y FRENO TRASERO

CHAS

1. Monter:

- Etrier ①

- Roue arrière ②

A ⑤ ① ② ③ ④

B ⑤ ① ③ ④ ② B

4. Install:

[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.

NOTE:

• 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.

A Front

B Rear

Technical diagram of a vehicle fuel system with labeled components and parts

EC5A5310

Front master cylinder

1. Install:

• Master cylinder ①
  • Master cylinder bracket ②
• Bolt (master cylinder bracket) ③

9 Nm (0.9 m · kg, 6.5 ft · lb)

NOTE:

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

FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN FRENO DELANTERO Y FRENO TRASERO

CHAS

4. Monter:

[Avant]

Technical diagram showing a hand operating a tool with labeled parts and a connector labeled B

New ① ② ③

Technical diagram of a mechanical component with labeled parts a and b, showing assembly or assembly details.

Technical diagram of a mechanical assembly with numbered components, likely for assembly or maintenance instructions.

New ① ② ③ ④ B ⑤

2. Install:

• Brake lever ①
• Bolt (brake lever) ②

6 Nm (0.6 m · kg, 4.3 ft · lb)

- Nut (brake lever) ③

6 Nm (0.6 m · kg, 4.3 ft · lb)

NOTE:

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

Rear master cylinder

1. Install:

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

30 Nm (3.0 m · kg, 22 ft · lb)

WARNING

Always use new copper washers.

CAUTION:

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

2. Install:

• Master cylinder ①
• Bolt (master cylinder) ②

10 Nm (1.0 m · kg, 7.2 ft · lb)

3. Install:

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

26 Nm (2.6 m · kg, 19 ft · lb)

- Clip ⑤

NOTE:

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

FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN FRENO DELANTERO Y FRENO TRASERO

CHAS

2. Monter:

Diagram showing a car seatbelt mechanism with labeled parts and a 'New' label

① ② ③ New

Technical diagram of a mechanical assembly with labeled parts a and b

Technical diagram of a bicycle brake system with labeled components

Technical diagram showing mechanical assembly with labeled parts and a magnified inset of a component detail

4. Install:

• 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.

Front brake hose

1. Install:

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

30 Nm (3.0 m · kg, 22 ft · lb)

WARNING

Always use new copper washers.

CAUTION:

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

2. Install:

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

10 Nm (1.0 m · kg, 7.2 ft · lb)

3. Install:

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

7 Nm (0.7 m · kg, 5.1 ft · lb)

NOTE:

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

FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN FRENO DELANTERO Y FRENO TRASERO

4. Monter:

Technical diagram of a motorcycle's front wheel assembly with labeled parts and numbered component

① New ② ③

Technical diagram of a vehicle's seat assembly with labeled parts a and b

New ① ② ③

Technical diagram of a mechanical assembly with labeled parts a, b, and c

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

2. Install:

3. Copper washer ① New

4. Brake hose ②
5. Union bolt ③

30 Nm (3.0 m · kg, 22 ft · lb)

WARNING

Always use new copper washers.

CAUTION:

Install the brake hose so that it contacts the master cylinder projection ① and that its bent portion ② faces downward.

Rear brake hose

1. Install:

2. Copper washer ① New

3. Brake hose ②
4. Union bolt ③

30 Nm (3.0 m · kg, 22 ft · lb)

WARNING

Always use new copper washers.

CAUTION:

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

FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN FRENO DELANTERO Y FRENO TRASERO

Technical diagram showing labeled components of a mechanical or electrical component with numbered parts and connection points.

Line drawing of a vehicle's wheel and gear assembly, showing gear and wheel components (no text or symbols)

Technical line drawing of a mechanical assembly with labeled parts (a and b), no readable text or symbols present.

B a

2. Install:

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

2 Nm (0.2 m · kg, 1.4 ft · lb)

CAUTION:

After installing the brake hose holders, make sure the brake hose does not contact the spring (rear shock absorber). If it does, correct its twist.

Brake fluid

1. Fill:

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

Recommended brake fluid: DOT #4

WARNING

• Use only the designated quality brake fluid:
  otherwise, the rubber seals may deteriorate, causing leakage and poor brake performance.
• Refill with the same type of brake fluid; mixing fluids may result in a harmful chemical reaction and lead to poor performance.
• Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock.

CAUTION:

Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately.

A Front
B Rear

FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN FRENO DELANTERO Y FRENO TRASERO

CHAS

2. Monter:

Fluid at lower level → Fill up.

Refer to "BRAKE FLUID LEVEL INSPECTION" section in the CHAPTER 3.

A ① ②

B ① ② LOW

Technical diagram of a car's front suspension system with numbered components

4. Install:

[Front]

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

2 Nm (0.2 m · kg, 1.4 ft · lb)

[Rear]

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

2 Nm (0.2 m · kg, 1.4 ft · lb)

CAUTION:

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.

A Front
B Rear

1. Install: (rear brake only)

2. Protector ①

3. Bolt (protector) ②

7 Nm (0.7 m · kg, 5.1 ft · lb)

FREIN AVANT ET FREIN ARRIERE VORDER- UND HINTERRADBREMSEN FRENO DELANTERO Y FRENO TRASERO

2. Purger l'air:

• Protection ①
• Boulon (protection) ②

7 Nm (0,7 m · kg, 5,1 ft · lb)

4. Montieren:

[Vorn]

Extent of removal:
① Front fork removal

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		FRONT FORK REMOVALHold the machine by placing the suitable stand under the engine.Front wheelFront caliperHeadlightHandlebar		WARNINGSupport 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.Refer to “HANDLEBAR” section.
1	1	Protector	1
	2	Pinch bolt (handle crown)	2	Only loosening.
	3	Cap bolt	1	Loosen when disassembling the front fork.
	4	Pinch bolt (under bracket)	2	Only loosening.
	5	Front fork	1

FOURCHE

Extent of removal:
① Oil seal removal
② Damper rod removal

Extent of removal	Order	Part name	Q'ty	Remarks
↓	12345678910111213	FRONT FORK DISASSEMBLYCap boltFork springDust sealStopper ringInner tubeOuter tubePiston metalSlide metalOil seal washerOil sealSpring guideBase valveDamper rod	1111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111	Refer to “REMOVAL POINTS”.Drain the fork oil.Refer to “REMOVAL POINTS”.Use special tool.Refer to “REMOVAL POINTS”.

DEMONTAGE DE LA FOURCHE

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.

Diagram showing a hand holding a cylindrical object with a labeled step number ①

Technical diagram of a mechanical assembly with labeled parts ① and ②, showing a spring and wrench.

EC553000

REMOVAL POINTS

EC553150

Cap bolt

1. Remove:

- Cap bolt ①

From the outer tube.

NOTE:

Before removing the front fork from the machine, loosen the cap bolt.

1. Remove:

- Cap bolt ①

NOTE:

Hold the locknut ② and remove the cap bolt.

REMARQUES CONCERNANT LA MANIPULATION

N.B.:

Technical diagram of a mechanical assembly with labeled parts ① and ②

Diagram showing a hand holding a mechanical component with labeled parts (a) and (b), and numbered annotations ① and ②.

Technical diagram of a mechanical device with numbered components labeled ①, ②, and ③.

Technical line drawing of a mechanical component with labeled part 1 (no text or symbols beyond label)

EC553201

Inner tube

1. Remove:

• Dust seal ①
• Stopper ring ②

Using slotted-head screwdriver.

CAUTION:

Take care not to scratch the inner tube.

2. Remove:

- Inner tube ①

Oil seal removal steps:

• Push in slowly ⓐ the inner tube just before it bottoms out and then pull it back quickly ⓑ.
• Repeat this step until the inner tube can be pulled out from the outer tube.

EC553311

Damper rod

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

INSPECTION

EC554100

Damper rod

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.

Tube plongeur

Technical diagram of a mechanical component with numbered parts labeled ① and ②

Diagram of a coiled spring with labeled dimension 'a' (no text or symbols beyond label)

Technical diagram of a mechanical device with labeled parts 1 and 2, showing components like a valve and adjustment knobs.

Technical line drawing of a cylindrical pipe fitting with labeled component (1), no text or symbols present

EC554200

Base valve

1. Inspect:

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

EC554400

Fork spring

1. Measure:

• Fork spring free length ⓐ Out of specification → Replace.

	Fork spring free length:
Standard		Limit
460 mm (18.1 in)		455 mm (17.9 in)

EC554502

Inner tube

1. Inspect:

• Inner tube surface @ 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

Outer tube

1. Inspect:

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

Soupape de base

1. Contrôler:

2. Soupape complète ①
   Usure/endommagement → Rem- placer.

3. Joint torique ②
   Endommagement → Remplacer.

Gabelventil

Technical diagram of a mechanical component with numbered parts labeled ①, ②, and ③.

EC554700

Cap bolt

1. Inspect:

• Cap bolt ①
• O-ring ②
• Air bleed screw ③

Wear/damage → Replace.

EC555000

ASSEMBLY AND INSTALLATION

Front fork assembly

1. Wash the all parts in a clean solvent.

Technical diagram of a mechanical device with labeled parts, showing two components and their assembly.

2. Install:

- 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.

④ ③ ① New ②

3. Install:

New

• Copper washer ①
• O-ring ②
• Base valve ③

To inner tube ④.

Technical diagram of a mechanical device with numbered components labeled ①, ②, and ③.

4. Tighten:

- Base valve ①

55 Nm (5.5 m · kg, 40 ft · lb)

NOTE:

• 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

Boulon capuchon

Technical diagram of a mechanical assembly with labeled parts and an inset showing a detailed cross-section view.

New ① ② ③ ④ ⑤ New ⑥ b

③ ④ I2311310

① New

Technical diagram of a mechanical component with labeled parts ① and ②

5. Install:

• Spring guide ①
• Locknut ②

To damper rod ③.

NOTE:

• Install the spring guide with its smaller dia. end @ facing downward.
• With its thread ⑥ 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 ⓐ 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 ⑥ facing upward.

7. Install:

- Piston metal ① New

NOTE:

Install the piston metal onto the slot on inner tube.

8. Install:

• Outer tube ①
  To inner tube ②.

5. Monter:

Technical diagram of a pipe joint with labeled components ① and ②

Technical diagram showing a hand operating a mechanical component with labeled part ③

Technical diagram showing a hand operating a mechanical component with labeled parts ① and ②

Technical line drawing of a mechanical joint or pipe connection (no text or symbols)

Technical diagram showing a pipe joint with labeled component B and numbered point 1

9. Install:

• 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

10. Install:

- Oil seal ①

NOTE:

Press the oil seal into the outer tube with fork seal driver ②.

Fork seal driver: YM-A0948/90890-01502

11. Install:

- Stopper ring ①

NOTE:

Fit the stopper ring correctly in the groove in the outer tube.

12. Install:

- Dust seal ①

NOTE:

Apply the lithium soap base grease on the inner tube.

9. Monter:

Illustration of a hand holding a mechanical component with directional arrows indicating movement (no text or symbols)

Technical diagram showing a pipe being cut with labeled component ①

13. Check:

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

14. Compress the front fork fully.

15. Fill:

- Front fork oil Until outer tube top surface with recommended fork oil ①.

Recommended oil: Suspension oil "S1"

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.

Diagram showing a hand holding a cylindrical object with a labeled step and directional arrow indicating movement or force.

Technical diagram showing a hand operating a mechanical device with labeled component ① and directional arrow indicating motion.

1. 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.

1. 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.

13. Contrôler:

1. 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.

Technical diagram of a mechanical device with labeled components and dimensional annotations

311404

20. Measure:

- Oil level (left and right) ⓐ

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.

Technical diagram of a mechanical component with numbered callouts and cross-sectional view

Diagram showing a hand holding a spring with labeled parts: ①, ②, and ③.

Technical diagram of a mechanical spring assembly with labeled parts ① and ②

Technical diagram of a mechanical assembly with labeled parts ① and ②, showing a spring and wrench.

21. Measure:

- Distance ⓐ

Out of specification → Turn into the locknut.

Distance ⓐ:

18 mm (0.71 in) or more

Between damper rod ① top and locknut ② top.

22. Loosen:

- Rebound damping adjuster ①

NOTE:

• Loosen the rebound damping adjuster finger tight.
• Record the set position of the adjuster (the amount of turning out the fully turned in position).

23. Install:

• 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.

24. Install:

• Spring seat ①
• Cap bolt ②

NOTE:

Fully finger tighten the cap bolt onto the damper rod.

25. Tighten:

- Cap bolt (locknut) ①

29 Nm (2.9 m · kg, 21 ft · lb)

NOTE:

Hold the locknut ② and tighten the cap bolt with specified torque.

21. Mesurer:

- Distance ⓐ

Diagram showing a hand holding a cylindrical object with a labeled step number 1 pointing to the component.

① ①

Technical diagram of a mechanical assembly with labeled component 1

Technical diagram showing mechanical assembly with labeled parts and directional arrows

Technical diagram showing mechanical assembly with numbered components, likely for vehicle or industrial control.

26. Install:

• Cap bolt ①
  To outer tube.

NOTE:

Temporarily tighten the cap bolt.

27. Install:

- Protector guide ①

NOTE:

Install the protector guide with its wider side ⓐ facing downward.

Installation

1. Install:

- Front fork ①

NOTE:

• Temporarily tighten the pinch bolts (under bracket).
• Do not tighten the pinch bolts (handle crown) yet.

2. Tighten:

- Cap bolt ①

30 Nm (3.0 m · kg, 22 ft · lb)

3. Adjust:

- Front fork top end ⓐ

Front fork top end (standard) ⓐ: Zero mm (zero in)

4. Tighten:

- Pinch bolt (handle crown) ①

- Pinch bolt (under bracket) ②

Tighten the under bracket to specified torque. If torqued too much, it may cause the front fork to malfunction.

1. Monter:

Technical diagram showing mechanical assembly with numbered components and a magnified detail view labeled a, b, and ①.

5. Install:

• Speed sensor lead ①
• Plate 1 ②
• Bolt (plate 1) ③

4 Nm (0.4 m · kg, 2.9 ft · lb)

To protector (right) ④.

NOTE:

Install the speed sensor lead so that its paint ① directs as shown and align the bottom ② of the plate 1 with the same paint.

Technical diagram showing labeled components of a mechanical or electrical component with numbered parts and an inset detail view.

6. Install:

• Speed sensor lead ①
• Plate 2 ②
• Screw (plate 2) ③

0.5 Nm (0.05 m · kg, 0.36 ft · lb)

To protector (right) ④.

NOTE:

Install the plate 2 in the direction as shown.

Technical diagram of a mechanical assembly with numbered components and labeled parts

7. Install:

• Protector ①
• Bolt (protector) ②

7 Nm (0.7 m · kg, 5.1 ft · lb)

H-S ①

8. Adjust:

- Rebound damping force

NOTE:

Turn in the damping adjuster ① finger-tight and then turn out to the originally set position.

5. Monter:

• Protection ①
• Boulon (protection) ②

7 Nm (0,7 m · kg, 5,1 ft · lb)

7. Montieren:

Extent of removal:
① Handlebar removal

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		HANDLEBAR REMOVALHeadlight
1	1	Hot starter cable	1	Disconnect at the lever side.
	2	Hot starter lever holder	1
	3	Clutch cable	1	Disconnect at the lever side.
	4	Clutch lever holder	1	Disconnect the clutch switch lead.
	5	“ENGINE STOP” button	1	Disconnect the “ENGINE STOP” button lead.
	6	Master cylinder	1	Refer to “REMOVAL POINTS”.
	7	Start switch	1	Disconnect the start switch lead.
	8	Throttle cable cap	1
	9	Throttle cable #1 (pulled)	1	Disconnect at the throttle side.
	10	Throttle cable #2 (pushed)	1	Disconnect at the throttle side.
	11	Grip (right)	1	Refer to “REMOVAL POINTS”.
	12	Tube guide	1
	13	Grip (left)	1	Refer to “REMOVAL POINTS”.
	14	Handlebar holder (upper)	2
	15	Handlebar	1
	16	Handlebar holder (lower)	2

GUIDON

Technical diagram of a mechanical assembly with labeled parts ① and ②, showing hoses and components.

EC5B3000

REMOVAL POINTS

EC5B3100

Master cylinder

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.

Illustration of a hand using a tool to adjust or install a mechanical component, no text or symbols present

EC5B3200

Grip

1. Remove:

- Grip ①

NOTE:

Blow in air between the handlebar or tube guide and the grip. Then remove the grip which has become loose.

Simple line drawing of a bent pipe or tube with a labeled point (1) on the end, no text or symbols present.

EC5B4000

INSPECTION

EC5B4100

Handlebar

1. Inspect:

- Handlebar ①

Bends/cracks/damage → Replace.

WARNING

Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar.

POINTS DE DEPOSE

Maître-cylindre

1. Déposer:

Technical diagram showing mechanical assembly with labeled parts and a tool labeled B

a FWD

Technical diagram showing three labeled components (①, ②, ③) of a mechanical or electrical assembly with connecting rods.

a FWD

b H-S H-S

EC5B5000

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 ⓐ 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.

2. Install:

• Handlebar ①
• Handlebar holder (upper) ②
• Bolt [handlebar holder (upper)] ③

• The handlebar holder (upper) should be installed with the punched mark @ forward.
• Install the handlebar so that the marks ⑥ are in place on both sides.
• Install the handlebar so that the projection © 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.

ASSEMBLAGE ET MONTAGE

Guidon

1. Monter:

C -2 -1 +1 +2

Technical line drawing of a mechanical assembly with no visible text or symbols

b R L ① ② a

Technical diagram of a mechanical component with labeled parts ①, ②, and ③

64° ① ② C ③

3. Tighten:

- Nut [handlebar holder (lower)] ①

Apply the adhesive to the handlebar ②.

NOTE:

• Before applying the adhesive, wipe off grease or oil on the handlebar surface ⓐ with a lacquer thinner.
• Install the grip (left) to the handlebar so that the line ⑥ 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 ⓐ with a lacquer thinner.
• Install the grip to the tube guide so that the grip match mark ⓑ and tube guide slot Ⓒ form the angle as shown.

3. Serrer:

- Lenkergriff links ①

Technical diagram of a mechanical device with labeled parts ① and ②, showing a tool and component assembly.

Technical diagram of a mechanical assembly with labeled parts 1 and 2, and component B indicated.

Technical diagram of a mechanical assembly with numbered components, likely illustrating a valve or connector assembly.

Diagram of a mechanical or fluid system with labeled component ③ and directional arrows indicating flow or movement.

Technical diagram of a cable connector with labeled parts ① and ②

6. Install:

• Cover (grip cap) ①
• Throttle grip ②

NOTE:

Apply the lithium soap base grease on the throttle grip sliding surface.

7. Install:

- 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.

8. Install:

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

4 Nm (0.4 m · kg, 2.9 ft · lb)

WARNING

After tightening the screws, check that the throttle grip ③ moves smoothly. If it does not, retighten the bolts for adjustment.

9. Install:

• Cover (grip cap) ①
• Cover (throttle cable cap) ②

6. Monter:

Technical diagram of a mechanical assembly with numbered components and labeled parts

Zero mm (Zero in) Zero mm (Zero in)

Technical diagram of a mechanical device with numbered components and labeled parts

Zero mm (Zero in) Zero mm (Zero in) 30~50° FWD

Technical diagram of a mechanical device with labeled parts, including lever and adjustment mechanism

10. Install:

• Start switch ①
• Master cylinder ②
  • Master cylinder bracket ③
• Bolt (master cylinder bracket) ④

9 Nm (0.9 m · kg, 6.5 ft · lb)

- Clamp ⑤

NOTE:

• The start switch and master cylinder bracket should be installed according to the dimensions shown.
• Install the bracket so that the arrow mark ⓐ faces upward.
• First tighten the bolt on the upper side of the master cylinder bracket, and then tighten the bolt on the lower side.

11. Install:

• “ENGINE STOP” button ①
• Clutch lever holder ②
• Bolt (clutch lever holder) ③

4 Nm (0.4 m · kg, 2.9 ft · lb)

• Hot starter lever holder ④
• Bolt (hot starter lever holder) ⑤

4 Nm (0.4 m · kg, 2.9 ft · lb)

- Clamp ⑥

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.

12. Install:

• Clutch cable ①
• Hot starter cable ②

NOTE:

Apply the lithium soap base grease on the clutch cable end and hot starter cable end.

10. Monter:

• 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.

13. Régler:

Extent of removal:
① Under bracket removal
② Bearing removal

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		STEERING REMOVALHold the machine by placing the suitable stand under the engine.HeadlightHandlebarHose guideFront fender		WARNINGSupport the machine securely so there is no danger of it falling over.Refer to “HANDLEBAR” section.
12	1	Multi-function meter	1
	2	Multi-function meter bracket	1
	3	Main switch	1	Disconnect the main switch lead.
	4	Steering shaft nut	1
	5	Front fork	2	Refer to “FRONT FORK” section.
	6	Handle crown	1
	7	Ring nut	1	Use special tool.Refer to “REMOVAL POINTS”.
	8	Under bracket	1
	9	Bearing race cover	1

DIRECTION

Technical diagram of a mechanical assembly with labeled parts ① and ②

EC563000

REMOVAL POINTS

EC563202

Ring nut

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.

Technical diagram showing two hands using a hammer to adjust a mechanical component, labeled with parts ① and ②.

EC563300

Bearing (lower)

1. Remove:

- Bearing (lower) ①

Use the floor chisel ②.

CAUTION:

Take care not to damage the steering shaft thread.

① ② I2460503

Bearing race

1. Remove:

- Bearing race ①

Remove the bearing race using long rod ② and the hammer.

Technical diagram of a mechanical component with labeled parts, showing a shaft and housing assembly.

EC564000

INSPECTION

EC564200

Steering shaft

1. Inspect:

- Steering shaft ①

Bend/damage → Replace.

POINTS DE DEPOSE

Ecrou de direction

1. Déposer:

Hakenschlüssel: YU-33975/90890-01403

WARNING

Illustration of a hand turning a ball bearing with a rotating arrow (no text or symbols)

Bearing and bearing race

1. Wash the bearings and bearing races with a solvent.

2. Inspect:

3. Bearing ①

4. 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.

Technical diagram of a mechanical assembly with labeled component 1

EC565000

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.

Technical diagram showing a hand holding a mechanical component with labeled parts ① and ②, and a tool labeled B.

1. Install:

2. Bearing race

3. Bearing (upper) ①
4. Bearing race cover ②

NOTE:

Apply the lithium soap base grease on the bearing and bearing race cover lip.

Technical diagram showing a hand holding a car seatbelt with labeled parts and an inset image of a mechanical component with labeled parts (a) and (1).

1. Install:

- Under bracket ①

NOTE:

Apply the lithium soap base grease on the bearing, the portion ⓐ and thread of the steering shaft.

- Cojinate (inferior) ①

NOTA:

Technical diagram of a mechanical assembly with labeled parts ① and ②

Line drawing of hands using a tool to adjust or install a mechanical component (no text or symbols present)

Technical diagram showing a hand adjusting a mechanical component with labeled part ①

Technical diagram of a mechanical device with numbered components labeled ① to ④

①

4. Install:

- Ring nut ①

7 Nm (0.7 m · kg, 5.1 ft · lb)

Tighten the ring nut using the ring nut wrench ②.

Refer to "STEERING HEAD INSPECTION AND ADJUSTMENT" section in the CHAPTER 3.

1. 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.

6. Install:

- Plain washer ①

7. Install:

• 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.

4. Monter:

- Ecrou de direction ①

7 Nm (0,7 m · kg, 5,1 ft · lb)

Technical diagram showing hands assembling a mechanical component with labeled parts ① and ②

Technical line drawing of mechanical components with no visible text or symbols

Technical diagram showing mechanical assembly with numbered components labeled ① and ②

Technical diagram of an automotive engine compartment with numbered parts for identification

Technical diagram showing a dial indicator and a mechanical component with labeled parts 1 and 2

9. Install:

• Plain washer ①
• Steering shaft nut ②

1. 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 ⓐ

Front fork top end (standard) ⓐ: Zero mm (Zero in)

12. Tighten:

- Pinch bolt (handle crown) ①

- 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

7 Nm (0.7 m · kg, 5.1 ft · lb)

- Multi-function meter ②

4 Nm (0.4 m · kg, 2.9 ft · lb)

NOTE:

Pass the throttle cables ③, clutch cable ④ and hot starter cable ⑤ between the multi-function meter bracket and handle crown.

14. Install:

• Holder ① | 13 Nm (1.3 m · kg, 9.4 ft · lb)
• Clamp ② 7 Nm (0.7 m · kg, 5.1 ft · lb)

NOTE:

• Install so that the marking @ on the speed sensor lead aligns with the holder edge.
• Fasten the speed sensor lead to the holder with the clamp.

9. Monter:

Extent of removal: removal
① Swingarm

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		SWINGARM REMOVALHold the machine by placing the suitable stand under the engine.Brake hose holderRear caliperBolt (brake pedal)Drive chain		WARNINGSupport 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	Chain support	1	Hold the swingarm.
	2	Chain tensioner (lower)	1
	3	Bolt (rear shock absorber-relay arm)	1
	4	Bolt (connecting rod)	1
	5	Pivot shaft	1
	6	Swingarm	1

BRAS OSCILLANT

Extent of removal:
① Swingarm disassembly
② Connecting rod removal and disassembly
③ Relay arm removal and disassembly

Extent of removal	Order	Part name	Q'ty	Remarks
		SWINGARM DISASSEMBLY
	1	Cap	2	Refer to “REMOVAL POINTS”.
	2	Relay arm	1
	3	Connecting rod	1
	4	Collar	2
	5	Oil seal	2
	6	Thrust bearing	2
	7	Bush	2
	8	Oil seal	8
	9	Bearing	10	Refer to “REMOVAL POINTS”.

DEMONTAGE DU BRAS OSCILLANT

Technical diagram showing mechanical assembly with labeled parts and a numbered component

Technical diagram showing mechanical assembly with labeled parts and directional arrow

Technical diagram showing a hand fastening a car seatbelt with labeled parts 1, 2, and 3.

Technical diagram showing a hand holding a mechanical component with numbered parts and directional arrows indicating motion or assembly.

EC573000

REMOVAL POINTS

Cap

1. Remove:

- Cap (left) ①

NOTE:

Remove with a slotted-head screwdriver inserted under the mark ⓐ on the cap (left).

EC573200

Bearing

1. Remove:

- Bearing ①

NOTE:

Remove the bearing by pressing its outer race.

EC574010

INSPECTION

Wash the bearings, bushes and collars in a solvent.

EC574111

Swingarm

1. Inspect:

2. Bearing ①

3. Bush ②

Free play exists/unsmooth revolution/rust → Replace bearing and bush as a set.

1. Inspect:

- Oil seal ③

Damage → Replace.

Relay arm

1. Inspect:

2. Bearing ①

3. Collar ②

Free play exists/unsmooth revolution/rust → Replace bearing and collar as a set.

1. Inspect:

- Oil seal ③

Damage → Replace.

POINTS DE DEPOSE

Capuchon

1. Déposer:

Diagram showing a hand holding a scroll with three labeled parts (①, ②, ③) indicating different positions or states.

Technical diagram showing a mechanical assembly with labeled components and directional arrow

① ② ① ② a b b a

① ② ③ ④ ⑤ ⑥ ⑦ ⑧ ⑨ ⑩ ⑪ ⑫ ⑬ ⑭ ⑮ ⑯ ⑰ ⑱ ⑲ ⑳ ㉑ ㉒ ㉓ ㉔ ㉕ ㉖ ㉗ ㉘ ㉙ ㉚ ㉛ ㉜ ㉝ ㉞ ㉟ ㉳ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟ ㉟

Connecting rod

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 ⓐ: Zero mm (Zero in)

Inner ⓑ: 6.5 mm (0.26 in)

2. Install:

• 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 ⓐ:

Zero mm (Zero in)

Bielle

① ② ② a a

3. Install:

• 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 ⓐ: Zero mm (Zero in)

Technical diagram showing mechanical assembly with numbered components and labeled parts (①–⑤)

Swingarm

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.

Technical diagram of a mechanical assembly with numbered components and labeled parts (M)

2. Install:

• Collar ①
• Washer ②
  To relay arm ③.

NOTE:

Apply the molybdenum disulfide grease on the collars and oil seal lips.

3. Monter:

Technical diagram showing assembly of cylindrical components with labeled parts ① and ②, and a motor symbol.

Technical diagram of a mechanical assembly with numbered parts and labeled parts

3. Install:

- Collar ①

To connecting rod ②.

NOTE:

Apply the molybdenum disulfide grease on the collar and oil seal lips.

4. Install:

• Connecting rod ①
• Bolt (connecting rod) ②
• Plain washer ③
• Nut (connecting rod) ④

80 Nm (8.0 m · kg, 58 ft · lb)

To relay arm ⑤.

NOTE:

Apply the molybdenum disulfide grease on the bolt.

Technical diagram of a mechanical assembly with numbered components and labeled parts

5. Install:

• 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.

3. Monter:

Technical diagram of a mechanical assembly with numbered components and a labeled component M

Technical diagram showing mechanical assembly with labeled parts (a, b) and directional arrows indicating motion or force

Technical diagram of a mechanical assembly with numbered components and labeled parts

Technical diagram showing mechanical assembly with labeled parts and a valve indicator

Technical line drawing of a mechanical assembly with labeled component (1), no readable text or symbols present

6. Install:

• Swingarm ①
• Pivot shaft ②

85 Nm (8.5 m · kg, 61 ft · lb)

NOTE:

• Apply the molybdenum disulfide grease on the pivot shaft.
• Insert the pivot shaft from right side.

7. Check:

• Swingarm side play ⓐ Free play exists → Replace thrust bearing.
• Swingarm up and down movement ⑥ Unsmooth movement/binding/rough spots → Grease or replace bearings, bushes and collars.

8. Install:

• 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.

9. Install:

• Bolt (rear shock absorber-relay arm) ①
• Nut (rear shock absorber-relay arm) ②

53 Nm (5.3 m · kg, 38 ft · lb)

NOTE:

Apply the molybdenum disulfide grease on the bolt.

10. Tighten:

- Nut (connecting rod) ①

80 Nm (8.0 m · kg, 58 ft · lb)

6. Monter:

• Bras oscillant ①
• Boulon-pivot ②

85 Nm (8,5 m · kg, 61 ft · lb)

N.B.:

Technical line drawing of a mechanical assembly with labeled component (1), no readable text or symbols present

① ① a -

Technical diagram of a mechanical assembly with numbered components for identification

Technical diagram of a mechanical assembly with numbered components for identification

11. Tighten:

- Nut (relay arm) ①

70 Nm (7.0 m · kg, 50 ft · lb)

12. Install:

- Cap ①

NOTE:

Install the cap (right) with its mark ⓐ facing forward.

13. Install:

• Bolt [chain tensioner (lower)] ①
• Plain washer ②
• Collar ③
• Chain tensioner ④
• Nut [chain tensioner (lower)] ⑤

16 Nm (1.6 m · kg, 11 ft · lb)

14. Install:

• Chain support ①
• Support cover ②
• Bolt {chain support [ = 50 mm (1.97 in)]} ③
• Nut (chain support) ④

7 Nm (0.7 m · kg, 5.1 ft · lb)

- Bolt {support cover [ = 10 mm (0.39 in)]}

⑤ 7 Nm (0.7 m · kg, 5.1 ft · lb)

11. Serrer:

Extent of removal:
① Rear shock absorber removal
② Rear shock absorber disassembly

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		REAR SHOCK ABSORBER REMOVALHold the machine by placing the suitable stand under the engine.Seat and side coversSilencerDrain the coolant.Catch tank breather hoseCatch tank hoseAir induction hose (air cut-off valve-air filter case)		WARNINGSupport 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.

AMORTISSEUR ARRIERE

Extent of removal		Order	Part name	Q'ty	Remarks
			Cylinder head breather hoseBatteryDisconnect the starter relay coupler.Starter motor lead		Disconnect at the air filter case side.Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3.Disconnect at the starter relay side.
1	2	1	Locking tie	4
		2	Taillight coupler	1
		3	CDI unit coupler	3
		4	Plastic band	1
		5	Clamp (air filter joint)	1	Only loosening.
		6	Rear frame	1
		7	Bolt (rear shock absorber-relay arm)	1	Hold the swingarm.
		8	Bolt (rear shock absorber-frame)	1

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.

Technical illustration of a mechanical assembly with coiled spring and housing (no text or symbols)

EC587000

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.

REMARQUES CONCERNANT LA MANIPULATION

! AVERTISSEMENT

Technical diagram of a mechanical assembly with labeled component 1 and directional arrow indicating motion

Technical diagram of a mechanical assembly with labeled component ① and directional arrow indicating motion

Technical diagram of a mechanical device with labeled component ① and directional arrow indicating flow or movement.

① ② ③ ④ I2340401

Diagram showing fluid flow around a circular object with labeled parts, including directional arrows and numbered annotations.

EC583000

REMOVAL POINTS

EC583320

Bearing

1. Remove:

- Stopper ring (upper bearing) ①

NOTE:

Press in the bearing while pressing its outer race and remove the stopper ring.

2. Remove:

- Upper bearing ①

NOTE: ____

Remove the bearing by pressing its outer race.

3. Remove:

- Lower bearing ①

NOTE:

Remove the bearing by pressing its outer race.

EC584000

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.

POINTS DE DEPOSE

Roulement

1. Déposer:

Technical diagram of a mechanical assembly with labeled component ①

EC585000

ASSEMBLY AND INSTALLATION

EC585300

Bearing

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.

① New

1. Install:

- Stopper ring (upper bearing) ① New

NOTE:

After installing the stopper ring, push back the bearing until it contacts the stopper ring.

Technical diagram of a mechanical device with labeled components and directional arrows, including parts marked ① and ②.

1. Install:

- Lower bearing ①

NOTE:

Install the bearing by pressing it on the side having the manufacture's marks or numbers.

Installed depth of the bearing ⓐ: 4 mm (0.16 in)

Technical diagram showing a hand holding a coiled spring with numbered parts labeled ①, ②, and ③.

EC585111

Spring (rear shock absorber)

1. Install:

2. Spring ①

3. Spring guide (upper) ②
4. Spring guide (lower) ③

ASSEMBLAGE ET MONTAGE

Roulement

1. Monter:

Technical illustration of a mechanical spring assembly with labeled component (1), no text or symbols present

2. Tighten:

- Adjuster ①

3. Adjust:

- Spring length (installed) Refer to “REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT” section in the CHAPTER 3.

Technical illustration of a mechanical spring assembly with labeled component (1), no text or symbols present

4. Tighten:

- Locknut ①

graph TD
    A["1"] --> B["2"]
    B --> C["3"]
    C --> D["M"]
    E["2"] --> F["3"]
    F --> G["M"]
    H["1"] --> I["2"]
    I --> J["3"]
    J --> K["M"]
    L["1"] --> M["2"]
    M --> N["3"]
    N --> O["M"]
    P["1"] --> Q["2"]
    Q --> R["M"]
    S["1"] --> T["3"]
    T --> U["M"]
    V["1"] --> W["2"]
    W --> X["M"]
    Y["1"] --> Z["3"]
    Z --> AA["M"]

Rear shock absorber

1. Install:

• Dust seal ①
• O-ring ②
• Collar ③

NOTE:

• Apply the molybdenum disulfide grease on the dust seal lips and collars.
• Apply the lithium soap base grease on the O-rings.

2. Serrer:

Diagram showing mechanical assembly with labeled parts and numbered components

Technical diagram of a mechanical assembly with numbered components and a labeled component M

Technical diagram showing mechanical assembly with labeled parts and a valve indicator

Technical diagram showing mechanical assembly with numbered components, likely illustrating a vehicle or gear mechanism.

Technical diagram of a vehicle engine assembly with labeled parts and numbered annotations

2. Install:

• 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.

3. Install:

- Rear shock absorber

4. Install:

• Bolt (rear shock absorber-frame) ①
• Washer ②
• Nut (rear shock absorber-frame) ③

56 Nm (5.6 m · kg, 40 ft · lb)

NOTE:

Apply the molybdenum disulfide grease on the bolt.

5. Install:

• Bolt (rear shock absorber-relay arm) ①
• Nut (rear shock absorber-relay arm) ②

53 Nm (5.3 m · kg, 38 ft · lb)

NOTE:

Apply the molybdenum disulfide grease on the bolt.

6. Install:

• Rear frame ①
• Bolt [rear frame (upper)] ②

38 Nm (3.8 m · kg, 27 ft · lb)

32 Nm (3.2 m · kg, 23 ft · lb)

• Bolt [rear frame (lower)] ③

7. Tighten:

- Screw (air filter joint) ①

3 Nm (0.3 m · kg, 2.2 ft · lb)

2. Monter:

• Plastic band
• Taillight coupler
• Locking tie

8. Monter:

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
⑩ Starting circuit cut-off relay

⑪ CDI unit
⑫ Taillight
⑬ Neutral switch
⑭ Starter motor
⑮ AC magneto
⑯ Rectifier/regulator
⑰ Ignition coil
⑱ Spark plug
⑲ Start switch
⑳ Main switch
②1 Speed sensor
② Battery

COLOR CODE

B .... Black
Br .... Brown
Ch......Chocolate
Dg ...... Dark green
G....Green
Gy ...... Gray
L......Blue
O....Orange
R....Red
Sb ...... Sky blue

W ...... White
Y......Yellow
B/L ...... Black/Blue
B/W...... Black/White
L/B ...... Blue/Black
L/R......Blue/Red
L/Y ...... Blue/Yellow
L/W ...... Blue/White
R/B......Red/Black
R/W......Red/White

Labeled diagram of a motorcycle showing numbered parts for identification

Technical diagram of a motorcycle with numbered parts for identification

EC612000

WIRING DIAGRAM

graph TD
    subgraph "1: For USA"
        A["1"] --> B["2"]
        C["3"] --> D["4"]
        E["5"] --> F["6"]
        G["7"] --> H["8"]
        I["9"] --> J["10"]
        K["11"] --> L["12"]
        M["13"] --> N["14"]
        O["15"] --> P["16"]
        Q["17"] --> R["18"]
    end

    subgraph "Except for USA"
        S["1"] --> T["2"]
        U["3"] --> V["4"]
        W["6"] --> X["7"]
        Y["9"] --> Z["10"]
        AA["11"] --> AB["12"]
        AC["13"] --> AD["14"]
        AE["15"] --> AF["16"]

    subgraph "Signal"
        AG["21"] --> AH["22"]
        AI["3"] --> AJ["6"]
        AK["4"] --> AL["7"]
        AM["5"] --> AN["8"]
        AO["6"] --> AP["9"]
        AQ["7"] --> AR["10"]
        AS["8"] --> AT["11"]
        AU["9"] --> AV["12"]
    end

    subgraph "Backup"
        AW["2"] --> AX["3"]
        AY["W"] --> AZ["B"]
        BA["R"] --> BB["B"]
        BC["RW"] --> BD["B"]
        BE["BW"] --> BF["BW"]
        BG["W"] --> BH["W"]
    end

    subgraph "Output"
        BI["R"] --> BJ["W"]
        BK["RW"] --> BL["W"]
    end

    subgraph "Control Signals"
        BM["R"] --> BN["W"]
        BO["RW"] --> BP["W"]
    end

    style 1 fill:#f9f,stroke:#333
    style 2 fill:#f9f,stroke:#333
    style 3 fill:#f9f,stroke:#333
    style 4 fill:#f9f,stroke:#333
    style 5 fill:#f9f,stroke:#333
    style 6 fill:#f9f,stroke:#333
    style 7 fill:#f9f,stroke:#333
    style 8 fill:#f9f,stroke:#333
    style 9 fill:#f9f,stroke:#333
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    style 12 fill:#f9f,stroke:#333
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    style 15 fill:#f9f,stroke:#333
    style 16 fill:#f9f,stroke:#333
    style 17 fill:#f9f,stroke:#333
    style 18 fill:#f9f,stroke:#333
    style 19 fill:#f9f,stroke:#333
    style 20 fill:#f9f,stroke:#333
    style 21 fill:#f9f,stroke:#333
    style 22 fill:#f9f,stroke:#333
    style 23 fill:#f9f,stroke:#333
    style 24 fill:#f9f,stroke:#333
    style 25 fill:#f9f,stroke:#333
    style 26 fill:#f9f,stroke:#333
    style 27 fill:#f9f,stroke:#333
    style 28 fill:#f9f,stroke:#333
    style 29 fill:#f9f,stroke:#333
    style 30 fill:#f9f,stroke:#333
    style 31 fill:#f9f,stroke:#333
    style 32 fill:#f9f,stroke:#333
    style 33 fill:#f9f,stroke:#333
    style 34 fill:#f9f,stroke:#333
    style 35 fill:#f9f,stroke:#333
    style 36 fill:#f9f,stroke:#333
    style 37 fill:#f9f,stroke:#333
    style 38 fill:#f9f,stroke:#333
    style 39 fill:#f9f,stroke:#333
    style 40 fill:#f9f,stroke:#333
    style 41 fill:#f9f,stroke:#333
    style 42 fill:#f9f,stroke:#333
    style 43 fill:#f9f,stroke:#333
    style 44 fill:#f9f,stroke:#333
    style 45 fill:#f9f,stroke:#333
    style 46 fill:#f9f,stroke:#333
    style 47 fill:#f9f,stroke:#333
    style 48 fill:#f9f,stroke:#333
    style 49 fill:#f9f,stroke:#333
    style 50 fill:#f9f,stroke:#333

*1:For USA
*2: Except for USA

PARTIE ELECTRIQUE COMPOSANTS ELECTRI- QUES ET SCHEMA DE CABLAGE

COMPOSANTS ELECTRIQUES

① Phare

⑳ Interruptor principal

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.

graph TD
    A["*1 Check fuse."] -->|OK| B["*2 Check battery"]
    B -->|OK| C["Spark gap test"]
    C -->|No spark| D["Check entire ignition system for connection. (couplers, leads and ignition coil)"]
    D -->|OK| E["Check "ENGINE STOP" button."]
    E -->|OK| F["Check main switch."]
    F -->|OK| G["Check ignition coil."]
    G -->|OK| H["Check AC magneto."]
    H -->|OK| I["Check neutral switch."]
    I -->|OK| J["Replace CDI unit."]

    K["Replace fuse and check wire harness."] --> L["Recharge or replace."]
    L --> M["*3 Clean or replace spark plug."]
    M --> N["Repair or replace."]

    O["No good"] --> P["No good"]
    Q["No good"] --> R["No good"]
    S["No good"] --> T["No good"]
    U["No good"] --> V["No good"]
    W["No good"] --> X["No good"]

    Y["No good"] --> Z["No good"]
    AA["No good"] --> AB["No good"]

    AC["Replace."] --> AD["Replace."]
    AE["No good"] --> AF["No good"]
    AG["No good"] --> AH["No good"]

    AI["Primary coil"] --> AJ["Secondary coil"]
    AK["No good"] --> AL["No good"]
    AM["Replace."] --> AN["Replace."]
    AO["No good"] --> AP["No good"]

    AQ["Pick-up coil"] --> AR["Repair or replace."]

*1 marked: Refer to “FUSE INSPECTION” section in the CHAPTER 3.
*2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3.
*3 marked: Only when the ignition checker is used.

NOTE:

- Remove the following parts before inspection.

1) Seat
2) Fuel tank

- Use the following special tools in this inspection.

Dynamic spark tester:

YM-34487

Ignition checker:

90890-06754

Pocket tester:

YU-3112-C/90890-03112

SYSTEME D'ALLUMAGE

ETAPES DU CONTROLE

Cross-sectional technical diagram of a mechanical assembly (no text or labels)

Technical diagram of a mechanical device with labeled components and a legend indicating parts 1 and 2.

Line drawing of a cable being inserted into a device with a labeled component (a), no text or symbols present.

SPARK GAP TEST

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.

4. Ignition coil ③

5. Spark plug ④

A For USA and CDN

B Except for USA and CDN

1. Kick the kickstarter.
2. Check the ignition spark gap.
3. 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:

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

3. 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

		B1	B2	Tester selec-tor position
	PUSH IN			Ω×1
	FREE

No continuity while being pushed → Replace. Continuity while being freed → Replace.

1. Inspect:

- Rubber part ⓐ Tears/damage → Replace.

TEST DE LA LONGUEUR D'ETINCELLE

Line drawing of a hand holding a handheld device with a circular button and labeled part (a), no text or symbols present.

Technical diagram showing a plug connector with labeled parts and corresponding electrical terminal symbols.

MAIN SWITCH INSPECTION

1. Inspect:

- Main switch conduct

Tester (+) lead → Red lead 1

Tester (−) lead → Brown lead 2

		R1	Br2	Tester selec-tor position
	ON			Ω × 1
	OFF

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 ⓐ Tears/damage → Replace.

EC626002

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
	0.08 ~ 0.10 Ω at 20 °C (68 °F)	Ω × 1

CONTROLE DU CONTACTEUR A CLE

1. Contrôler:

Diagram showing a connector pinout and its corresponding electrical terminal block with labeled terminals.

Technical diagram of two engine components with labeled parts a and b, showing internal structure and connection points.

① R W ②

① Sb L/W Ω×1 ②

3. Inspect:

• Secondary coil resistance Out of specification → Replace.

Tester (+) lead → Orange lead 1

Tester (−) lead → Spark plug terminal 2

	Secondary coil resistance	Tester selector position
	4.6 ~ 6.8 kΩ at 20 °C (68 °F)	kΩ × 1

4. Inspect:

• Sealed portion of ignition coil ⓐ
• Spark plug terminal pin ⑥
• Threaded portion of spark plug © 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
	248 ~ 372 Ω at 20 °C (68 °F)	Ω × 100

NEUTRAL SWITCH INSPECTION

1. Inspect:

- Neutral switch conduct

Tester (+) lead → Sky blue lead 1

Tester (−) lead → Ground 2

		Sb1	Ground2	Tester selec-tor position
	NEUTRAL			Ω × 1
	IN GEAR

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.

3. Contrôler:

Electrical circuit diagram with labeled components and directional arrows indicating connections or signal flow

If the main switch is set to "ON", the starter motor can only operate if at least one of the following conditions is met:

• The transmission is in neutral (the neutral switch is closed).
• The clutch lever is pulled to the handlebar (the clutch switch is closed).

The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met. In this instance, the starting circuit cut-off relay is open so current cannot reach the starter motor. When at least one of the above conditions has been met the starting circuit cut-off relay is closed and the engine can be started by pressing the start switch.

WHEN THE TRANSMISSION IS IN NEUTRAL

WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR

① Battery
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
⑩ Starter motor

DEMARRAGE

ELECTRIQUE

FONCTIONNEMENT DU DISPOSITIF DE COUPURE DU CIRCUIT DE DEMARRAGE

If the starter motor will not operate, use the following inspection steps.

graph TD
    A["*1 Check fuse."] -->|OK| B["*2 Check battery."]
    B -->|OK| C["Check each coupler and wire connection."]
    C -->|OK| D["*3 Check main switch."]
    D -->|OK| E["Check starter motor operation."]
    E -->|OK| F["Check starting circuit cut-off relay."]
    F -->|OK| G["Check starter relay."]
    G -->|OK| H["*4 Check neutral switch."]
    H -->|OK| I["Check clutch switch."]
    I -->|OK| J["Check diode."]
    J -->|OK| K["Check start switch."]
    A -->|No good| L["Replace fuse and check wire harness."]
    B -->|No good| M["Recharge or replace."]
    C -->|No good| N["Repair or replace."]
    D -->|No good| O["Replace."]
    E -->|No good| P["Repair or replace."]
    F -->|No good| Q["Replace."]
    G -->|No good| R["Replace."]
    H -->|No good| S["Replace."]
    I -->|No good| T["Replace."]
    J -->|No good| U["Replace."]
    K -->|No good| V["Replace."]

*1 marked: Refer to "FUSE INSPECTION" section in the CHAPTER 3.
*2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3.
*3 marked: Refer to "MAIN SWITCH INSPECTION" section.
*4 marked: Refer to “NEUTRAL SWITCH INSPECTION” section.

NOTE:

• Remove the following parts before inspection.
  1) Seat
  2) Rear fender
• Use 12 V battery in this inspection.
• Use the following special tools in this inspection.

Pocket tester: YU-3112-C/90890-03112

ETAPES DU CONTROLE

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

① ② ③ 18210801

Diagram of an electrical component with numbered parts and connections, including a battery and wiring.

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 1Battery (−) lead → Brown lead 2

Tester (+) lead → Blue/White lead 3Tester (−) lead → Black lead 4

		L/W3	B4	Tester selec-tor position
	Con- nected to battery			Ω × 1
	Not con- nected to battery

CONTROLE DES CONNEXIONS DES FICHES RAPIDES ET DES FILS

1. Contrôler:

- Starter relay conduct Use 12 V battery.

Battery (+) lead →Starter relay terminal 1Battery (−) lead →Starter relay terminal 2

Tester (+) lead → Starter relay terminal 3Tester (−) lead → Starter relay terminal 4

		Terminal3	Terminal4	Tester selector position
	Connected to battery			× 1
	Not connected to battery

Continuous while not connected to the battery Replace.

Not continuous while connected to the battery Replace.

Technical diagram of a mechanical device with labeled parts and an inset showing two labeled components (① and ②) marked as B.

CLUTCH SWITCH INSPECTION

1. Inspect:

- Clutch switch continuity

Tester (+) lead → Black lead 1

Tester (−) lead → Black lead 2

		B1	B2	Tester selec-tor position
	PULL			Ω × 1
	FREE

No continuous while being pulled → Replace.

Continuous while being freed → Replace.

CONTROLE DU RELAIS DE DEMARREUR

Technical diagram of an automotive electrical connector with labeled parts ①, ②, and ③

DIODE INSPECTION

1. Remove the diode from wire harness.
2. Inspect:

- Diode continuity

Use pocket tester (tester selection position × 1 )

Tester (+) →Blue/Red terminal 1Tester (−) →Sky blue terminal 2	Continuous
Tester (+) →Blue/Red terminal 1Tester (−) →Blue/Yellow terminal 3	Continuous
Tester (+) →Sky blue terminal 2Tester (−) →Blue/Red terminal 1	No continuous
Tester (+) →Blue/Yellow terminal 3Tester (−) →Blue/Red terminal 1	No continuous

Incorrect continuity → Replace.

Technical diagram of a mechanical device with labeled components and an inset showing two labeled parts (① and ②) marked with symbols B.

Line drawing of a hand holding a cable with a labeled connector (no text or symbols present)

START SWITCH INSPECTION

1. Inspect:

- Start switch continuity

Tester (+) lead → Black lead 1

Tester (−) lead → Black lead 2

		B1	B2	Tester selec-tor position
	PUSH IN			Ω × 1
	FREE

No continuous while being pushed → Replace. Continuous while being freed → Replace.

1. Inspect:

- Rubber part ⓐ

Tears/damage → Replace.

CONTROLE DE LA DIODE

Technical diagram of automotive gear assembly with numbered components and close-up views of the motor assembly

Extent of removal:

① Starter motor disassembly

Extent of removal	Order	Part name	Q'ty	Remarks
Preparation for removal		STARTER MOTOR REMOVALExhaust pipeStarter motor		Refer to “EXHAUST PIPE AND SILENCER” in the CHAPTER 3.
		STARTER MOTOR DISASSEMBLY
	12345	Starter motor front coverWasher (starter motor front cover)Plain washerCirclipO-ring	11113

DEMARREUR

Technical diagram of automotive engine components with numbered parts and a close-up inset showing mechanical assembly details.

Technical line drawing of a mechanical component with labeled dimension (a), no readable text or symbols beyond annotations

a 18210901

INSPECTION AND REPAIR

1. Check:

- Commutator Dirt → Clean with 600 grit sandpaper.

2. Measure:

- Commutator diameter @ Out of specification → Replace the starter motor.

Min. commutator diameter: 16.6 mm (0.65 in)

3. Measure:

- Mica undercut ⓐ 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.

① ② I8210201

4. Measure:

- Armature assembly resistances (commutator and insulation) Out of specification → Replace the starter motor.

• Measure the armature assembly resistances with the pocket tester.
	Pocket tester:YU-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.

CONTROLE ET REPARATION

1. Contrôler:

Two identical spiral-shaped mechanical springs shown in line drawing style (no text or symbols)

Technical diagram of a mechanical assembly with numbered components labeled ①, ②, and ②

Technical diagram of a mechanical assembly with labeled component 1 and directional arrow indicating motion or force.

5. Measure:

- Brush length ⓐ

Out of specification → Replace the brushes as a set.

Min. brush length: 3.5 mm (0.14 in)

6. Measure:

- 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)

ASSEMBLY

1. Install:

• Brush spring ①
• Brush ②

2. Install:

- Armature assembly ①

Install while holding down the brush using a thin screw driver.

CAUTION:

Be careful not to damage the brush during installation.

5. Mesurer:

① New ② a b c

New a b ① ② ③ ④

3. Install:

• O-ring ① New
• Starter motor yoke ②

NOTE:

• Align the match mark Ⓐ on the starter motor yoke with the match mark ⓑ on the starter motor rear cover.
• Install the starter motor yoke with its groove © facing rear cover.

4. Install:

• O-ring ① New
• Circlip
• Plain washer ②
• Washer (starter motor front cover) ③
• Starter motor front cover ④

NOTE:

• For installation, align the projections on the washer with the slots in the front cover.
• Align the match mark ⓐ on the starter motor yoke with the match mark ⓑ on the starter motor front cover.

① ② New B

5. Install:

• Bolt ①
• O-ring ② New

NOTE:

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

3. Monter:

If the battery is not charged, use the following inspection steps.

graph TD
    A["*1 Check fuse."] -->|OK| B["*2 Check battery."]
    B -->|OK| C["Check each coupler and wire connection."]
    C -->|OK| D["Check charging voltage."]
    D -->|No good| E["Check AC magneto."]
    E -->|OK| F["Charging coil"]
    F -->|No good| G["Replace."]
    A -->|No good| H["Replace fuse and check wire harness."]
    B -->|No good| I["Recharge or replace."]
    C -->|No good| J["Repair or replace."]
    D -->|OK| K["Charging system is good."]
    E -->|No good| L["Replace rectifier/regulator."]

*1 marked: Refer to "FUSE INSPECTION" section in the CHAPTER 3.
*2 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3.

NOTE:

• Remove the following parts before inspection.
  1) Seat
  2) Fuel tank
• Use the following special tool in this inspection.

Pocket tester:

YU-3112-C/90890-03112

SYSTEME DE CHARGE

ETAPES DU CONTROLE

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

Y W R ① B ②

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
	14.0 ~ 15.0 V at 5,000 r/min	DCV-20

Y W ① Ω×1 ②

3. Inspect:

- Charging coil resistance Out of specification → Replace.

Tester (+) lead → White lead 1

Tester (−) lead → Ground 2

	Charging coil resistance	Tester selector position
	0.288 ~ 0.432 Ω at 20 °C (68 °F)	Ω × 1

CONTROLE DES CONNEXIONS DES FICHES RAPIDES ET DES FILS

1. Contrôler:

If the TPS will not operate, use the following inspection steps.

graph TD
    A["Check entire ignition system for connection."] -->|OK| B["Check TPS."]
    B --> C["TPS coil"]
    C -->|No good| D["Replace."]
    B -->|OK| E["Check CDI unit."]
    E --> F["TPS input voltage"]
    F -->|No good| G["Replace."]
    A -->|No good| H["Repair or replace."]

NOTE:

Use the following special tools in this inspection.

Pocket tester: YU-3112-C/90890-03112

SYSTEME TPS (CAPTEUR DE POSITION DE PAPILLON DES GAZ)

ETAPES DU CONTROLE

Technical diagram of a mechanical device with labeled component 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.

EC624000

COUPLERS AND LEADS CONNECTION INSPECTION

1. Check:

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

① L Y B ②

TPS COIL INSPECTION

1. Inspect:

- TPS coil resistance Out of specification → Replace.

Tester (+) lead → Blue lead 1

Tester (−) lead → Black lead 2

Technical diagram showing mechanical assembly with labeled component 1 and directional arrow indicating rotation or movement

	TPS coil resistance	Tester selector position
	4 ~ 6 kΩ at 20 °C (68 °F)	kΩ × 1

2. Loosen:

- Throttle stop screw ①

NOTE:

Turn out the throttle stop screw until the throttle shaft is in the full close position.

SYSTEME TPS (CAPTEUR DE POSITION DE PAPILLON DES GAZ)

DROSSELKLAPPENSENSOR

① L Y B ②

3. Inspect:

- 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 selec-tor position
	Full closed	Full opened	kΩ × 1
	0 ~ 2 kΩ at 20 °C (68 °F)	4 ~ 6 kΩ at 20 °C (68 °F)

Technical diagram of a mechanical device with labeled parts ① and ②, showing components like lever and valve assembly.

TPS REPLACEMENT AND ADJUSTMENT

1. Remove:

• TPS coupler
• Carburetor

2. Remove:

• Screw (TPS) ①
• TPS ②

NOTE:

Loosen the screw (TPS) using the T25 bit.

3. Replace:

- TPS

4. Install:

• TPS ①
• Screw (TPS) ②

NOTE:

• Align the slot ⓐ in the TPS with the projection ⓑ on the carburetor.
• Temporarily tighten the screw (TPS).

5. Install:

• Carburetor
• TPS coupler

SYSTEME TPS (CAPTEUR DE POSITION DE PAPILLON DES GAZ)

DROSSELKLAPPENSENSOR

Refer to "IDLE SPEED ADJUSTMENT" section in the CHAPTER 3.

Technical diagram of a mechanical assembly with numbered parts, including a close-up view of the main component.

1. 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.

• Start the engine.

Technical diagram of a mechanical assembly with labeled parts and an inset showing a lever mechanism.

9. Adjust:

- 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.

	TPS output voltage	Tester selector position
	0.58 ~ 0.78 V	DCV

SYSTEME TPS (CAPTEUR DE POSITION DE PAPILLON DES GAZ)

DROSSELKLAPPENSENSOR

Technical diagram of a mechanical device with labeled component ①

① Y L B/L ②

1. Put the aligning marks ⓐ on the TPS and carburetor.
2. Stop the engine.

3. Remove the carburetor.

4. Tighten:

- Screw (TPS) ①

NOTE:

Tighten the screw (TPS) using the T25 bit.

1. Install the carburetor.

EC694000

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

	TPS input voltage	Tester selector position
	4 ~ 6 V	DCV-20

	TPS input voltage	Tester selector position
	4 ~ 6 V	DCV-20

Refer to the following flow chart when inspecting the lighting system for possible problems.

graph TD
    A["Check the bulb and bulb socket."] -->|OK| B["Check the taillight (LEDs)."]
    B -->|OK| C["Check the AC magneto."]
    C -->|OK| D["Check the entire lighting system proper for connections."]
    D -->|OK| E["Check the rectifier/regulator."]
    A -->|No good| F["Replace the bulb and/or bulb socket."]
    B -->|No good| G["Replace the taillight assembly."]
    C --> H["Lighting coil"]
    D --> I["Improperly connected"]
    E --> J["Out-put voltage"]
    H --> K["Repair or replace."]
    J --> L["Replace."]
    H --> M["Improperly connected"]

NOTE:

- 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

ECLAIRAGE

ETAPES DU CONTROLE

Technical diagram showing mechanical assembly and electrical component labeling with symbols and polarity indicators

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

3. Check:

• 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.

Technical diagram showing engine wiring and measurement setup with labeled components and connection points

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
	0.224 ~ 0.336 Ω at 20 °C (68 °F)	Ω × 1

CONTROLE DU FEU ARRIERE (DEL)

① Y W R B ②

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.

Tester (+) lead → Yellow lead 1

Tester (−) lead → Black lead 2

	Out-put voltage	Tester selector position
	12.5 ~ 13.5 V at 5,000 r/min	ACV-20

CONTROLE DU REDRESSEUR/ REGULATEUR

If the speedometer will not operate, use the following inspection steps.

graph TD
    A["*1 Check battery."] -->|OK| B["Check each coupler and wire connection."]
    B -->|OK| C["Check multi-function display."]
    C -->|OK| D["Check speed sensor."]
    A -->|No good| E["Recharge or replace."]
    B -->|No good| F["Repair or replace."]
    C --> G["Input voltage"]
    C --> H["Output voltage"]
    G -->|No good| I["Replace wire harness."]
    H -->|No good| J["Replace multi-function display."]
    D -->|No good| K["Replace."]

*1 marked: Refer to “BATTERY INSPECTION AND CHARGING” section in the CHAPTER 3.

NOTE:

• Remove the following parts before inspection.
  1) Headlight
• Use the following special tools in this inspection.

Pocket tester: YU-3112-C/90890-03112

SYSTEME DE SIGNALISATION

PROCEDURE DE CONTROLE

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

Technical diagram of a mechanical or electrical component with labeled parts and a numbered annotation box indicating 'B R/W Br'.

MULTI-FUNCTION DISPLAY INPUT VOLTAGE INSPECTION

1. Disconnect the multi-function display coupler.
2. Set the main switch to "ON".
3. Measure:
4. 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
	10 V or more	DCV-20

CAUTION:

Make sure that a short-circuit does not develop between the terminals because it may cause damage to electrical components.

MULTI-FUNCTION DISPLAY OUTPUT VOLTAGE INSPECTION

1. Disconnect the multi-function display coupler.
2. Set the main switch to "ON".

CONTROLE DES CONNEXIONS DES FICHES RAPIDES ET DES FILS

1. Contrôler:

Technical diagram of a mechanical or electrical component with labeled parts and a numbered inset showing symbols W, R, B/W.

3. Measure:

- Multi-function display output voltage Out of specification → Replace multi-function display.

Tester (+) lead → Red lead ① Tester (−) lead → Black/White lead ②

	Multi-function display output voltage	Tester selector position
	4.5 V or more	DCV-20

CAUTION:

Make sure that a short-circuit does not develop between the terminals because it may cause damage to electrical components.

Diagram showing electrical wiring connections to a DCV meter with labeled components and a digital display.

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.

• 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.

3. Mesurer:

• The air/fuel mixture will vary depending on atmospheric conditions. Therefore, it is necessary to take into consideration the air pressure, ambient temperature, humidity, etc., when adjusting the carburetor.
• Perform a test run to check for proper engine performance (e.g., throttle response) and spark plug(-s) discoloration or fouling. Use these readings to determine the best possible carburetor setting.

NOTE:

It is recommended to keep a record of all carburetor settings and external conditions (e.g., atmospheric conditions, track/surface conditions, lap times) to make future carburetor setting easier.

WARNING

• The carburetor is a part of the fuel line. Therefore, be sure to install it in a well-ventilated area, away from flammable objects and any sources of fire.
• Never look into the carburetor intake. Flames may shoot out from the pipe if the engine backfires while it is being started. Gasoline may be discharged from the accelerator pump nozzle when the carburetor has been removed.

MISE AU POINT MOTEUR

• The carburetor is extremely sensitive to foreign matter (dirt, sand, water, etc.). During installation, do not allow foreign matter to get into the carburetor.
• Always handle the carburetor and its components carefully. Even slight scratches, bends or damage to carburetor parts may prevent the carburetor from functioning correctly. Carefully perform all servicing with the appropriate tools and without applying excessive force.
• When the engine is stopped or when riding at no load, do not open and close the throttle unnecessarily. Otherwise, too much fuel may be discharged, starting may become difficult or the engine may not run well.
• After installing the carburetor, check that the throttle operates correctly and opens and closes smoothly.

Atmospheric conditions and carburetor settings

Air temp.	Humidity	Air pressure (altitude)	Mixture	Setting
High	High	Low (high)	Richer	Leaner
Low	Low	High (low)	Leaner	Richer

The air density (i.e., concentration of oxygen in the air) determines the richness or leanness of the air/fuel mixture. Therefore, refer to the above table for mixture settings.

That is:

• Higher temperature expands the air with its resultant reduced density.
• Higher humidity reduces the amount of oxygen in the air by so much of the water vapor in the same air.
• Lower atmospheric pressure (at a high altitude) reduces the density of the air.

ATTENTION:

Effects of the setting parts on the throttle valve opening

① ② ③ ④ A 1/8 1/4 1/2 3/4 B

① Pilot jet

② Throttle valve cutaway

③ Jet needle

④ Main jet

Technical schematic diagram of a mechanical assembly with numbered components and alignment indicators

Main system

The FLATCR carburetor has a primary main jet. This type of main jet is perfect for racing machines since it supplies an even flow of fuel, even at full load. Use the main jet and the jet needle to set the carburetor.

① Jet needle

② Pilot air jet

③ Needle jet

④ Main jet

⑤ Pilot jet

Technical line drawing of a mechanical assembly with labeled component (1), no readable text or symbols present.

Main jet adjustment

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

Standard main jet

#162

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)

A Idle
B Fully open

Technical diagram of a mechanical device with numbered components and labeled parts

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

#45

Effects of adjusting the pilot jet (reference)

A Idle
B Fully open

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.

1. 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)

A Idle
B 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

GDDUQ*GDDSQ

* 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.

GDDUQ - 4

Clip position Diameter @ of straight portion

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.

A Idle
B Fully open

Technical diagram of an internal mechanical component with numbered callouts pointing to specific parts.

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.

#60 → #55

1. Rough engine operation is felt in quick throttle opening.

Select a leak jet having higher calibrating No. than standard to lean out the mixture.

#60 → #65

Standard leak jet

#60

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

Examples of carburetor setting depending on symptom

Symptom	Setting	Checking
At full throttleHard breathingShearing noiseWhitish spark plug↓Lean mixture	Increase main jet calibration no.(Gradually)	Discoloration of spark plug →If tan color, it is in good condition.If cannot be corrected:Clogged float valve seatClogged fuel hoseClogged fuel cockCheck that the accelerator pump operates smoothly.
At full throttleSpeed pick-up stopsSlow speed pick-upSlow responseSooty spark plug↓Rich mixture	Decrease main jet calibration no.(Gradually)	Discoloration of spark plug →If tan color, it is in good condition.If cannot be corrected:Clogged air cleanerFuel overflow from carburetor
Lean mixture	Lower jet needle clip position.(1 groove down)	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).
Rich mixture	Raise jet needle clip position.(1 groove up)
1/4 ~ 3/4 throttleHard breathingLack of speed	Lower jet needle clip position.(1 groove down)
1/4 ~ 1/2 throttleSlow speed pick-upPoor acceleration	Raise jet needle clip position.(1 groove up)
Closed to 1/4 throttleHard breathingSpeed down	Use jet needle with a smaller diameter.	Slow-speed-circuit passageClogged → Clean.Overflow from carburetor
Closed to 1/4 throttlePoor acceleration	Use jet needle with a larger diameter.Raise jet needle clip position.(1 groove up)
Poor response in the low to intermediate speeds	Raise jet needle clip position.If this has no effect, lower the jet needle clip position.
Poor response when throttle is opened quickly	Check overall settings.Use main jet with a lower calibration no.Raise jet needle clip position.(1 groove up)If these have no effect, use a main jet with a higher calibration no. and lower the jet needle clip position.	Check air cleaner for fouling.Check that the accelerator pump operates smoothly.

* This should be taken simply for an example. It is necessary to set the carburetor while checking the operating conditions of the engine.

Selection of the secondary reduction ratio (Sprocket)

Secondary reduction ratio = of driven sprocket teethNumber of drive sprocket teeth

Standard secondary reduction ratio

50/13 (3.846)

• 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.

CHASSIS

Technical diagram showing gear and chain components with labeled parts ① and ②

EC72N000

Drive and driven sprockets setting parts

Part name	Size	Part number
Drive sprocket 1(STD)	13T	5TJ-17460-00
*(STD)	*13T	9383E-13233
	**14T	9383E-14215

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

Part name	Size	Part number
Driven sprocket 2	48T	5GS-25448-50
	*48T	1C3-25448-00
	*49T	1C3-25449-00
(STD)	50T	5TJ-25450-80
*(STD)	*50T	1C3-25450-00
	*51T	1C3-25451-00
	52T	5TJ-25452-80
	*52T	1C3-25452-00

* For AUS and NZ

EC721002

Tire pressure

Tire pressure should be adjust to suit the road surface condition of the circuit.

Standard tire pressure: 100 kPa (1.0 kgf/cm ^2 , 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)

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.

1. Setting of spring preload

2. Change the spring.
   • Install the adjustment washer.

3. Setting of damping force

4. Change the compression damping.

5. 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

A [kg (lb)] ① ② ③

A Air spring characteristics in relation to oil level change

B Load

C Stroke

① Max. oil level

② Standard oil level

③ Min. oil level

EC727020

Spring preload adjustment

The spring preload is adjusted by installing the adjustment washer ① between the fork spring ② and damper rod ③.

CAUTION:

Do not install three or more adjustment washers for each front fork.

WARNING

Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability.

Standard washer quantity:

Zero adjustment washers

Extent of adjustment:

Zero \~ 2 adjustment washers

A Load
B 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.

Exploded view diagram of a mechanical assembly with labeled parts and exploded view

EC72P000

Front fork setting parts

- Adjustment washer ①

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

- Front fork spring ②

TYPE	SPRING RATE	SPRING PART NUMBER	I.D. MARK (slits)
SOFT	0.408	5TJ-23141-00	I
	0.418	5TJ-23141-10	II
	0.428	5TJ-23141-20	III
	0.438	5TJ-23141-30	III
	0.449	5TJ-23141-40	III
STD	0.459	5TJ-23141-L0	-
STIFF	0.469	5TJ-23141-60	I-II

NOTE:

The I.D. mark (slits) ⓐ 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

2. Change the set length of the spring.

3. Change the spring.

4. Setting of damping force

5. Change the rebound damping.

6. Change the compression damping.

Technical diagram of a bicycle's front suspension system with labeled components and height dimension

b

Technical diagram showing a mechanical assembly with labeled parts ① and ②, likely illustrating a valve or spring mechanism.

EC72C001

Choosing set length

1. Place a stand or block under the engine to put the rear wheel above the floor, and measure the length ⓐ 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 ⓑ 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 ⑥ from the length ⑧.

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 re-evaluation.
• 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.

EC72G001

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.

1. 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.

N.B.:

Technical line drawing of a mechanical spring assembly with dimension lines (no text or symbols)

CAUTION:

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

Length ⓐ of standard shock: 488.5 mm (19.23 in)

ATTENTION:

Technical diagram of a mechanical assembly with labeled parts, showing exploded view of a spring and housing assembly.

Technical line drawing of a mechanical spring assembly with dimension label (b), no text or symbols present

EC72Q000

Rear shock absorber setting parts

- Rear shock spring ①

TYPE	SPRING RATE	SPRING PART NUMBER	I.D. COLOR/ POINT	SPRING FREE LENGTH
SOFT	4.3	5UN-22212-00	Brown/1	260
	4.5	5UN-22212-10	Green/1	260
	4.7	5UN-22212-20	Red/1	260
	4.9	5UN-22212-30	Black/1	260
	5.1	5UN-22212-40	Blue/1	260
	5.3	5UN-22212-50	Yellow/1	260
STD	5.5	5UN-22212-60	Pink/1	260
STIFF	5.7	5UN-22212-70	White/1	260

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

- Extent of adjustment (spring length)

SPRING FREE LENGTH	EXTENT OF ADJUSTMENT 6
260 mm (10.24 in)	238.5 ~ 258.5 mm(9.39 ~ 10.18 in)

• 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).

Symptom	Section				Check	Adjust
	Jump	Large gap	Medium gap	Small gap
Stiff over entire range	○	○	○		Compression dampingOil level (oil amount)Spring	Turn adjuster counterclockwise (about 2 clicks) to decrease damping.Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).Replace with soft spring.
Unsmooth movement over entire range	○	○	○	○	Outer tubeInner tubeUnder bracket tightening torque	Check for any bends, dents, and other noticeable scars, etc. If any, replace affected parts.Retighten to specified torque.
Poor initial movement				○	Rebound dampingOil seal	Turn adjuster counterclockwise (about 2 clicks) to decrease damping.Apply grease in oil seal wall.
Soft over entire range, bottoming out	○	○			Compression dampingOil level (oil amount)Spring	Turn adjuster clockwise (about 2 clicks) to increase damping.Increase oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).Replace with stiff spring.
Stiff toward stroke end	○				Oil level (oil amount)	Decrease oil level by about 5 mm (0.2 in).
Soft toward stroke end, bottoming out	○				Oil level (oil amount)	Increase oil level by about 5 mm (0.2 in).
Stiff initial movement	○	○	○	○	Compression damping	Turn adjuster counterclockwise (about 2 clicks) to decrease damping.
Low front, tending to lower front posture			○	○	Compression dampingRebound dampingBalance with rear endOil level (oil amount)	Turn adjuster clockwise (about 2 clicks) to increase damping.Turn adjuster counterclockwise (about 2 clicks) to decrease damping.Set sunken length for 95 ~ 100 mm (3.7 ~ 3.9 in) when one passenger is astride seat (lower rear pos-ture).Increase oil level by about 5 mm (0.2 in).
“Obtrusive” front, tending to upper front posture			○	○	Compression dampingBalance with rear endSpringOil lever (oil amount)	Turn adjuster counterclockwise (about 2 clicks) to decrease damping.Set sunken length for 90 ~ 95 mm (3.5 ~ 3.7 in) when one passenger is astride seat (upper rear pos-ture).Replace with soft spring.Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).

- Rear shock absorber

NOTE:

• If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart.
• Adjust the rebound damping in 2-click increments or decrements.
• Adjust the low compression damping in 1-click increments or decrements.
• Adjust the high compression damping in 1/6 turn increments or decrements.

Symptom	Section				Check	Adjust
	Jump	Large gap	Medium gap	Small gap
Stiff, tending to sink			○	○	Rebound dampingSpring set length	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.
Spongy and unstable			○	○	Rebound dampingLow compression dampingSpring	Turn adjuster clockwise (about 2 clicks) to increase damping.Turn adjuster clockwise (about 1 click) to increase damping.Replace with stiff spring.
Heavy and dragging			○	○	Rebound dampingSpring	Turn adjuster counterclockwise (about 2 clicks) to decrease damping.Replace with soft spring.
Poor road gripping				○	Rebound dampingLow compression dampingHigh compression dampingSpring set lengthSpring	Turn adjuster counterclockwise (about 2 clicks) to decrease damping.Turn adjuster clockwise (about 1 clicks) to increase damping.Turn adjuster clockwise (about 1/6 clicks) to increase damping.Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when one passenger is astride seat.Replace with soft spring.
Bottoming out	○	○			High compression dampingSpring set lengthSpring	Turn adjuster clockwise (about 1/6 turn) to increase damping.Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when one passenger in astride seat.Replace with stiff spring.
Bouncing	○	○			Rebound dampingSpring	Turn adjuster clockwise (about 2 clicks) to increase damping.Replace with soft spring.
Stiff travel	○	○			High compression dampingSpring set lengthSpring	Turn adjuster counterclockwise (about 1/6 turn) to decrease damping.Set sunken length for 95 ~ 100 mm (3.7 ~ 3.9 in) when one passenger is astride seat.Replace with soft spring.