YZ250F-2007 - Moto tout-terrain YAMAHA - Free user manual and instructions

USER MANUAL YZ250F-2007 YAMAHA

YZ250F(W) OWNER’S SERVICE MANUAL ©2006 by Yamaha Motor Co., Ltd. 1st Edition, August 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan

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

IMPORTANT NOTICE THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding. SAFETY INFORMATION 1. THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY. Do not attempt to operate this machine at maximum power until you are totally familiar with its characteristics. 2. THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY. Do not carry passengers on this machine. 3. ALWAYS WEAR PROTECTIVE APPAREL. When operating this machine, always wear an approved helmet with goggles or a face shield. Also wear heavy boots, gloves, and protective clothing. Always wear proper fitting clothing that will not be caught in any of the moving parts or controls of the machine. 4. ALWAYS MAINTAIN YOUR MACHINE IN PROPER WORKING ORDER. For safety and reliability, the machine must be properly maintained. Always perform the pre-operation checks indicated in this manual. Correcting a mechanical problem before you ride may prevent an accident. 5. GASOLINE IS HIGHLY FLAMMABLE. Always turn off the engine while refueling. Take care to not spill any gasoline on the engine or exhaust system. Never refuel in the vicinity of an open flame, or while smoking.

6. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes. 7. ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILATION. Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are poisonous. These fumes contain carbon monoxide, which by itself is odorless and colorless. Carbon monoxide is a dangerous gas which can cause unconsciousness or can be lethal. 8. PARK THE MACHINE CAREFULLY; TURN OFF THE ENGINE. Always turn off the engine if you are going to leave the machine. Do not park the machine on a slope or soft ground as it may fall over. 9. THE ENGINE, EXHAUST PIPE, MUFFLER, AND OIL TANK WILL BE VERY HOT AFTER THE ENGINE HAS BEEN RUN. Be careful not to touch them or to allow any clothing item to contact them during inspection or repair. 10. PROPERLY SECURE THE MACHINE BEFORE TRANSPORTING IT. When transporting the machine in another vehicle, always be sure it is properly secured and in an upright position and that the fuel cock is in the “OFF” position. Otherwise, fuel may leak out of the carburetor or fuel tank.

TO THE NEW OWNER This manual will provide you with a good basic understanding of features, operation, and basic maintenance and inspection items of this machine. Please read this manual carefully and completely before operating your new machine. If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer. NOTE: This manual should be considered a permanent part of this machine and should remain with it even if the machine is subsequently sold.

NOTICE Some data in this manual may become outdated due to improvements made to this model in the future. If there is any question you have regarding this manual or your machine, please consult your Yamaha dealer. 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 Ce manuel vous apportera une connaissance de base des caractéristiques, du fonctionnement, et des entretiens de base et des délais d’inspection de cette machine. Veuillez lire soigneusement et entièrement ce manuel avant d’utiliser votre nouvelle machine. Si vous avez des questions concernant le fonctionnement ou l’entretien de votre machine, veuillez consulter votre concessionnaire Yamaha. N.B.: Ce manuel doit être considéré comme partie permanente de la machine et doit rester avec celle-ci si elle est revendue à une tierce personne.

HOW TO USE THIS MANUAL EC081000

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

FINDING THE REQUIRED PAGE 1. This manual consists of seven chapters; “General information”, “Specifications”, “Regular inspection and adjustments”, “Engine”, “Chassis”, “Electrical” and “Tuning”. 2. The table of contents is at the beginning of the manual. Look over the general layout of the book before finding then required chapter and item. Bend the book at its edge, as shown, to find the required fore edge symbol mark and go to a page for required item and description.

MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., • Bearings Pitting/damage → Replace. EC084002

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

FORMAT DU MANUEL AUFBAU Dans ce manuel, toutes les procédures sont décrites pas à pas. Les informations ont été condensées pour fournir au mécanicien un guide pratique et facile à lire, contenant des explications claires pour toutes les procédures de démontage, réparation, remontage et vérification. Dans ce nouveau format, l’état d’un composant défectueux est suivi d’une flèche qui indique les mesures à prendre. Exemple: • Roulements Piqûres/endommagement → Remplacer.

ILLUSTRATED SYMBOLS (Refer to the illustration)

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

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

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

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

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

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

J Illustrated symbols I to J in the exploded diagrams indicate where to apply a locking agent and where to install new parts. I Apply locking agent (LOCTITE®) J Use new one

SYMBOLES GRAPHIQUES (Voir l’illustration)

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

MACHINE IDENTIFICATION GEN INFO EC120001

MACHINE IDENTIFICATION There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own. 2. If your machine is stolen, the authorities will need the number to search for and identify your machine. EC121001

VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped on the right of the steering head pipe.

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

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

IMPORTANT INFORMATION EC131010

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

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

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

4. During the machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled. 5. Keep away from fire.

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

GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and Orings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips. EC134000

LOCK WASHERS/PLATES AND COTTER PINS 1. All lock washers/plates 1 and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened.

BEARINGS AND OIL SEALS 1. Install the bearing(s) 1 and oil seal(s) 2 with their manufacturer’s marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of light-weight lithium base grease to the seal lip(s). Oil the bearings liberally when installing. CAUTION: Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.

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

CHECKING OF CONNECTION GEN INFO EC1C0001

CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: • Connector 2. Dry each terminal with an air blower.

3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off. 5. If the terminal comes off, bend up the pin 1 and reinsert the terminal into the connector.

6. Connect: • Connector NOTE: The two connectors “click” together. 7. Check for continuity with a tester. NOTE: • If there in no continuity, clean the terminals. • Be sure to perform the steps 1 to 7 listed above when checking the wire harness. • For a field remedy, use a contact revitalizer available on the market. • Use the tester on the connector as shown.

SPECIAL TOOLS GEN INFO SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order. NOTE: • For U.S.A. and Canada, use part number starting with “YM-”, “YU-” or “ACC-”. • For others, use part number starting with “90890-”. Part number YU-1135-A, 90890-01135

These tool is used to remove the crankshaft from either case. YM-1189, 90890-01189

Dial gauge and stand Stand

These tools are used to check each part for runout or bent. YU-90050, 90890-01274 YU-90050, 90890-01275 YU-91044, 90890-04081 YU-90063, 90890-01278

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

These tools are used for checking the cooling system.

SPECIAL TOOLS Part number YU-33975, 90890-01403

Tool name/How to use Steering nut wrench

This tool is used when tighten the steering ring nut to specification. YM-01500, 90890-01500

This tool is used to loosen or tighten the base valve. YM-01501, 90890-01501

Cap bolt ring wrench

This tool is used to loosen or tighten the damper assembly. YM-A0948, 90890-01502

This tool is used when install the fork oil seal. YU-3112-C, 90890-03112

Use this tool to inspect the coil resistance, output voltage and amperage. YM-33277-A, 90890-03141

This tool is necessary for checking ignition timing. YM-4019, 90890-04019

Valve spring compressor

This tool is needed to remove and install the valve assemblies. YM-91042, 90890-04086

This tool is used to hold the clutch when removing or installing the clutch boss securing nut. YM-4111, 90890-04111 YM-4116, 90890-04116

Valve guide remover Intake 4.0 mm (0.16 in) Exhaust 4.5 mm (0.18 in) This tool is needed to remove and install the valve guide.

This tool is needed to rebore the new valve guide. YM-34487 90890-06754

Dynamic spark tester Ignition checker

This instrument is necessary for checking the ignition system components. 90890-85505

YAMAHA Bond No. 1215 (ThreeBond No. 1215)

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

CONTROL FUNCTIONS ENGINE STOP SWITCH The engine stop switch 1 is located on the left handlebar. Continue pushing the engine stop switch till the engine comes to a stop.

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

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

KICKSTARTER CRANK Rotate the kickstarter crank 1 away from the engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine. This model has a primary kickstarter crank so the engine can be started in any gear if the clutch is disengaged. In normal practices, however, shift to neutral before starting.

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

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

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

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

HOT STARTER LEVER The hot starter lever 1 is used when starting a warm engine. Use the hot starter lever when starting the engine again immediately after it was stopped (the engine is still warm). Pulling the hot starter lever injects secondary air to thin the air-fuel mixture temporarily, allowing the engine to be started more easily. 1 - 11

CONTROL FUNCTIONS GEN INFO EC15R001

DETACHABLE SIDESTAND This sidestand 1 is used to support only the machine when standing or transporting it. WARNING • Never apply additional force to the sidestand. • Remove this 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.

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

ATTENZIONE: Utilizzare solo benzina senza piombo. L’utilizzo di benzina con piombo provoca gravi danni ai componenti interni del motore, quali valvole, fasce elastiche dei pistoni, impianto di scarico, ecc. NOTA: In caso di rumori simili a battiti, utilizzare una marca diversa di benzina o un numero di ottano superiore. AVVERTENZA • Per effettuare il rifornimento di benzina, assicurarsi di arrestare il motore e prestare attenzione a non versare in alcun modo il carburante. Inoltre, evitare i rifornimenti in prossimità di una fiamma. • Effettuare il rifornimento dopo che il motore, il tubo di scarico ecc. si sono raffreddati.

STARTING AND BREAK-IN GEN INFO STARTING AND BREAK-IN WARNING Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time. Always operate the machine in a well-ventilated area. CAUTION: • The carburetor on this machine has a built-in accelerator pump. Therefore, when starting the engine, do not operate the throttle or the spark plug will foul. • Unlike a two-stroke engine, this engine cannot be kick started when the throttle is open because the kick starter 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.

STARTING A COLD ENGINE 1. Inspect the coolant level. 2. Turn the fuel cock to “ON”. 3. Shift the transmission into neutral. 4. Fully open the cold starter knob 1. 5. Kick the kickstarter crank. WARNING Do not open the throttle while kicking the kickstarter crank. Otherwise, the kickstarter may kick back.

6. Return the cold starter knob to its original position and run the engine at 3,000 ~ 5,000 r/min for 1 or 2 minutes. NOTE: Since this model is equipped with an accelerator pump, if the engine is raced (the throttle opened and closed), the air/fuel mixture will be too rich and the engine may stall. Also unlike a two-stroke engine, this model can idle. CAUTION: Do not warm up the engine for extended periods of time.

STARTING AND BREAK-IN GEN INFO STARTING A WARM ENGINE Do not operate the cold starter knob and throttle. Pull the hot starter lever 1 and start the engine by kicking the kickstarter crank forcefully with a firm stroke. As soon as the engine starts, Release the hot starter lever to close the air passage. Restarting an engine after a fall Pull the hot starter lever and start the engine. As soon as the engine starts, Release the hot starter lever to close the air passage. The engine fails to start Pull the hot starter lever all the way out and while holding the lever, kick the kickstarter crank 10 to 20 times to clear the engine. Then, restart the engine. Refer to “Restarting an engine after a fall”.

Starting a cold engine

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

OFF Hot starter lever

OFF OFF OFF OFF OFF ON ON

* Operate the throttle grip before kick starting.

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

ON OFF Nessuno ON/OFF OFF Nessuno

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

• Dopo il rodaggio o prima di ogni competizione, controllare che non ci siano dispositivi di montaggio e di serraggio allentati, come indicato in “PUNTI DI CONTROLLO SERRAGGIO”. Serrare tutti i dispositivi come richiesto. • Se una delle seguenti parti è stata sostituita, occorre eseguirne il rodaggio. CILINDRO E ALBERO MOTORE: Rodaggio di circa un’ora. PISTONE, FASCIA ELASTICA, VALVOLE, ALBERI A CAMME E INGRANAGGI: Rodaggio di circa 30 minuti a media o bassa velocità. Osservare attentamente le condizioni del motore durante il funzionamento.

TORQUE-CHECK POINTS GEN INFO TORQUE-CHECK POINTS Frame construction Combined seat and fuel tank

Frame to rear frame Fuel tank to frame

Silencer to rear frame

Frame to engine Engine bracket to engine Engine bracket to frame

Steering stem to frame Steering stem to upper bracket Upper bracket to handlebar

Steering stem to handlebar

Steering stem to front fork

Front fork to upper bracket Front fork to lower bracket

Assembly of links Link to frame Link to rear shock absorber Link to swingarm

Installation of rear shock absorber

Rear shock absorber to frame

Installation of swingarm

Tightening of pivot shaft

Installation of wheel

Tightening of wheel axle Tightening of axle holder

Tightening of wheel axle Wheel to rear wheel sprocket

Brake caliper to front fork Brake disc to wheel Tightening of union bolt Brake master cylinder to handlebar Tightening of bleed screw Tightening of brake hose holder

Brake pedal to frame Brake disc to wheel Tightening of union bolt Brake master cylinder to frame Tightening of bleed screw Tightening of brake hose holder

Fuel tank to fuel cock

Tightening of oil hose clamp

NOTE: Concerning the tightening torque, refer to “MAINTENANCE SPECIFICATIONS” section in the CHAPTER 2. 1 - 18

POINTS DE VERIFICATION DES COUPLES DE SERRAGE GEN INFO POINTS DE VERIFICATION DES COUPLES DE SERRAGE Cadre Selle et réservoir de carburant

NOTA: Per quanto riguarda le coppie di serraggio, fare riferimento al paragrafo “SPECIFICHE DI MANUTENZIONE” nel CAPITOLO 2. 1 - 18

CLEANING AND STORAGE GEN INFO EC1B0000

CLEANING AND STORAGE EC1B1000

CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many components. 1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering. A plastic bag secured with a rubber band may be used for this purpose. 2. If the engine is excessively greasy, apply some degreaser to it with a paint brush. Do not apply degreaser to the chain, sprockets, or wheel axles. 3. Rinse the dirt and degreaser off with a garden hose; use only enough pressure to do the job. CAUTION: Excessive hose pressure may cause water seepage and contamination of wheel bearings, front forks, brakes and transmission seals. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in coin-operated car washers. 4. After the majority of the dirt has been hosed off, wash all surfaces with warm water and a mild detergent. Use an old toothbrush to clean hard-to-reach places. 5. Rinse the machine off immediately with clean water, and dry all surfaces with a soft towel or cloth. 6. Immediately after washing, remove excess water from the chain with a paper towel and lubricate the chain to prevent rust. 7. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy. 8. Automotive wax may be applied to all painted or chromed surfaces. Avoid combination cleaner-waxes, as they may contain abrasives. 9. After completing the above, start the engine and allow it to idle for several minutes.

Dopo aver eliminato con la pompa la maggior parte dello sporco, lavare tutte le superfici con acqua tiepida e un detergente delicato. Per pulire le zone difficili da raggiungere, utilizzare un vecchio spazzolino da denti. Sciacquare immediatamente il mezzo con acqua pulita e asciugare tutte le superfici con un asciugamano o un panno morbidi. Subito dopo il lavaggio, eliminare con una salviettina di carta l’acqua in eccesso dalla catena e lubrificarla per evitare che si arrugginisca. Pulire la sella con un detergente vinilico da tappezzeria per mantenere il rivestimento flessibile e lucido. È possibile applicare cera per auto a tutte le superfici verniciate o cromate. Non utilizzare cere detergenti, poiché potrebbero contenere abrasivi. Dopo aver eseguito tutte le operazioni elencate sopra, avviare il motore e lasciarlo girare al minimo per alcuni minuti.

CLEANING AND STORAGE GEN INFO EC1B2001

STORAGE If your machine is to be stored for 60 days or more, some preventive measures must be taken to avoid deterioration. After cleaning the machine thoroughly, prepare it for storage as follows: 1. Drain the fuel tank, fuel lines, and the carburetor float bowl. 2. Remove the spark plug, pour a tablespoon of SAE 10W-30 motor oil in the spark plug hole, and reinstall the plug. With the engine stop switch pushed in, kick the engine over several times to coat the cylinder walls with oil. 3. Remove the drive chain, clean it thoroughly with solvent, and lubricate it. Reinstall the chain or store it in a plastic bag tied to the frame. 4. Lubricate all control cables. 5. Block the frame up to raise the wheels off 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.

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

YZ250FW (USA, CDN, AUS, NZ) YZ250F (EUROPE, ZA) 5XCG (USA, CDN) 5XCH (EUROPE) 5XCK (AUS, NZ, ZA) USA, CDN, EUROPE F ZA, AUS, NZ (Except for F) 2,160 mm 2,166 mm 2,165 mm (85.04 in) (85.28 in) (85.24 in) ← ← 825 mm (32.48 in) ← 1,299 mm 1,302 mm (51.14 in) (51.26 in) 984 mm 997 mm 996 mm (38.74 in) (39.25 in) (39.21 in) ← ← 1,469 mm (57.83 in) ← 370 mm 372 mm (14.57 in) (14.65 in) 92.7 kg (204 lb) Liquid cooled 4-stroke, DOHC Single cylinder, forward inclined 249 cm3 (8.76 Imp oz, 8.42 US oz) 77.0 × 53.6 mm (3.03 × 2.11 in) 12.5 : 1 Kickstarter Dry sump

GENERAL SPECIFICATIONS Oil type or grade: Engine oil 0

Oil capacity: Engine oil Periodic oil change With oil filter replacement Total amount Coolant capacity (including all routes): Air filter: Fuel: Type Tank capacity Carburetor: Type Manufacturer Spark plug: Type/manufacturer Gap Clutch type:

GENERAL SPECIFICATIONS Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio: 1st 2nd 3rd 4th 5th Chassis: Frame type Caster angle Trail Tire: Type Size (front)

Tire pressure (front and rear) Brake: Front brake type Operation Rear brake type Operation Suspension: Front suspension Rear suspension Shock absorber: Front shock absorber Rear shock absorber Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system

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

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

“B” face width “C” seat width

“D” margin thickness Stem outside diameter

EX Set length (valve closed) Compressed force (installed)

Direction of winding (top view)

SPEC Piston: Piston to cylinder clearance Piston size “D”

2.5°/1.7 mm (2.5°/0.067 in) 2.5°/1.6 mm (2.5°/0.063 in)

H D Measuring point “H” Piston off-set

MAINTENANCE SPECIFICATIONS Item

Piston pin bore inside diameter Piston pin outside diameter

Piston rings: Top ring:

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

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

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

0.15 ~ 0.45 mm (0.0059 ~ 0.0177 in) 0.4 ~ 1.0 mm (0.02 ~ 0.04 in)

Quantity Clutch housing thrust clearance

MAINTENANCE SPECIFICATIONS Item Lubrication system: Oil filter type Oil pump type Tip clearance Side clearance Housing and rotor clearance Cooling: Radiator core size Width Height Thickness Radiator cap opening pressure Radiator capacity Water pump Type

SPEC MAINTENANCE SPECIFICATIONS Part to be tightened Spark plug Camshaft cap Cylinder head blind plug screw Cylinder head (stud bolt) (stud bolt) (bolt) (nut) Cylinder head cover Cylinder Balancer weight Balancer shaft driven gear Timing chain guide (intake side) Timing chain tensioner Timing chain tensioner cap bolt Impeller Radiator hose clamp Coolant drain bolt Water pump housing Radiator Radiator guard Radiator pipe Oil pump cover Oil pump Oil filter element drain bolt Oil filter element cover Oil strainer (crankcase) Oil delivery pipe 1(M10) (M8) Oil hose Oil hose clamp Oil strainer (oil tank) Oil tank drain bolt Oil tank (upper) Oil tank and frame Carburetor joint clamp Air filter joint clamp Throttle cable adjust bolt and locknut Throttle cable (pull) Throttle cable (return) Throttle cable cover Hot starter plunger Hot starter cable adjust bolt and locknut

SPEC MAINTENANCE SPECIFICATIONS Part to be tightened Air filter case Air filter joint and air filter case Air filter element Exhaust pipe Exhaust pipe protector Silencer Silencer clamp Crankcase Crankcase bearing stopper Crankcase bearing stopper (crankshaft) Oil level check window holder Left crankcase cover Right crankcase cover Clutch cover Crankcase oil drain bolt Drive chain sprocket cover Kick shaft ratchet wheel guide Kickstarter crank Primary drive gear Clutch spring Clutch boss Clutch cable locknut Clutch cable adjust bolt and locknut Push lever shaft Drive sprocket Drive axle oil seal stopper Segment Shift guide Stopper lever Shift pedal

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

MAINTENANCE SPECIFICATIONS SPEC CHASSIS Item Steering system: Steering bearing type Front suspension: Front fork travel Fork spring free length Spring rate, STD Optional spring Oil capacity Oil grade Inner tube outer diameter Front fork top end Rear suspension: Shock absorber travel Spring free length Fitting length One I.D. mark Two I.D. marks Three I.D. marks <Min.~Max.>

Spring rate, STD Optional spring Enclosed gas pressure

Taper roller bearing

Spoke wheel Spoke wheel 21 × 1.60/Aluminum 19 × 1.85/Aluminum

250 × 2.5 mm (9.84 × 0.10 in) 1.0 mm (0.04 in) ----------

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

4.4 mm (0.17 in) 9.5 mm (0.374 in) 27.0 mm (1.063 in) × 2 DOT #4

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

SPEC MAINTENANCE SPECIFICATIONS Part to be tightened Upper bracket and outer tube Lower bracket and outer tube Upper bracket and steering stem Handlebar upper holder and handlebar lower holder Handlebar lower holder and upper bracket Steering stem and steering ring nut Front fork and damper assembly Front fork and adjuster Damper assembly and base valve Adjuster and damper assembly Front fork bleed screw and base valve Front fork and front fork protector Lower bracket and brake hose guide Front fork protector and brake hose holder Throttle grip cap Front brake master cylinder Brake lever mounting bolt Brake lever mounting nut Brake lever position locknut Clutch lever holder Clutch lever mounting nut Hot starter lever holder Front brake master cylinder cap Front brake hose union bolt Front brake caliper Pad pin plug Front brake caliper and pad pin Rear brake caliper and pad pin Brake caliper and bleed screw Front wheel axle and axle nut Front wheel axle holder Front brake disc Rear brake disc Footrest bracket and frame Brake pedal Rear brake master cylinder Rear brake master cylinder cap Rear brake hose union bolt Rear wheel axle and axle nut

SPEC MAINTENANCE SPECIFICATIONS Part to be tightened Nipple (spoke) Rear wheel sprocket Rear brake disc cover Rear brake caliper protector Drive chain puller adjust bolt and locknut Engine mounting: Engine and engine bracket (front) Engine and frame (lower) Upper engine bracket and frame Lower engine bracket and frame Engine and engine bracket (upper) Lower engine guard Right engine guard CDI unit bracket Cable guide and CDI unit bracket Cable guide and frame Pivot shaft and nut Relay arm and swingarm Relay arm and connecting rod Connecting rod and frame Rear shock absorber and frame Rear shock absorber and relay arm Rear frame (upper) Rear frame (lower) Swingarm and brake hose holder Swingarm and patch Upper drive chain tensioner Lower drive chain tensioner Drive chain support Seal guard and swingarm Fuel tank mounting boss and frame Fuel tank Fuel cock Seat set bracket and fuel tank Fuel tank bracket and fuel tank Air scoop and fuel tank Air scoop and radiator guard (lower) Front fender Rear fender (front) Rear fender (rear) Side cover Seat Number plate

NOTE: - marked portion shall be checked for torque tightening after break-in or before each race. 2 - 15

SPEC MAINTENANCE SPECIFICATIONS EC212300

ELECTRICAL Item Ignition system: Advancer type CDI: Magneto-model (stator)/manufacturer Charging coil 1 resistance (color) Charging coil 2 resistance (color) Pickup coil resistance (color) CDI unit-model/manufacturer Ignition coil: Model/manufacturer Minimum spark gap Primary coil resistance Secondary coil resistance

Part to be tightened Stator Rotor Neutral switch

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)

10 mm 12 mm 14 mm 17 mm 19 mm 22 mm

A: Distance between flats B: Outside thread diameter

Volume or capacity Volume or capacity

← 2-1/8 ← ← ← N°70 ← ←

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

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

77,00–77,01 mm (3,0315–3,0319 in) ----

30,246–30,346 mm (1,1908–1,1947 in) 22,45–22,55 mm (0,8839–0,8878 in) 30,399–30,499 mm (1,1968–1,2007 in) 22,45–22,55 mm (0,8839–0,8878 in) ----

EUROPE, ZA, AUS, NZ ←

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

← ← ← ← ← 2-1/8 ← ← ← N.70 ← ←

LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Oil filter element 2 Oil pump 3 Drive axle 4 Main axle 5 Intake camshaft 6 Exhaust camshaft 7 Oil tank 8 Oil delivery pipe È To oil tank

LUBRICATION DIAGRAMS 1 Crankshaft 2 Oil filter element 3 Oil tank 4 Oil hose È From oil pump

CABLE ROUTING DIAGRAM 1 Fuel tank breather hose 2 Radiator hose 1 3 Connector cover 4 Cylinder head breather hose 5 Radiator hose 4 6 Clutch cable 7 Throttle position sensor lead 8 Carburetor breather hose 9 Upper engine bracket

CABLE ROUTING DIAGRAM SPEC

Ì Pass the clutch cable through the cable guide. Í Pass the clutch cable in front of the radiator mounting boss. Î Pass the fuel hose between the hot starter cable and throttle position sensor lead. Ï Pass the carburetor breater hoses so that they are not pinched between the upper engine bracket and carburetor. Ð Pass the carburetor breather hoses and overflow hose so that all there hoses do not contact the rear shock absorber.

È Insert the end of the fuel tank breather hose into the hole in the steering stem. É Install the connector cover so that it does not come in between the radiator hose 1 and radiator. Ê Aligh the paint mark on the cylinder head breather hose with the front end of the hose guide. Ë Pass the cylinder head breather hose on the outside of the radiator hose 1 and then between the radiator 4 and frame.

È Inserire l’estremità del flessibile di sfiato del serbatoio carburante nel foro del rivestimento del fusto dello sterzo. É Installare la copertura connettore in modo che non si trovi tra il flessibile radiatore 1 ed il radiatore. Ê Allineare il segno di vernice sul flessibile di sfiato della testata con l’estremità anteriore della guida flessibile. Ë Far passare il flessibile di sfiato della testata sulla parte esterna del flessibile radiatore 1, quindi tra il radiatore 4 e il telaio. Ì Far passare il cavo della frizione attraverso il guida cavo. Í Far passare il cavo della frizione davanti alla sporgenza di montaggio del radiatore. Î Far passare il flessibile del carburante fra il cavo starter per partenze a caldo e il cavo sensore posizione farfalla. Ï Far passare i flessibili di sfiato del carburatore in modo tale che non siano pizzicati tra la staffa superiore motore e il carburatore. Ð Far passare i flessibili di sfiato carburatore e il flessibile di traboccamento carburatore in modo tale che gli stessi flessibili non entrino in contatto con l’ammortizzatore posteriore.

CABLE ROUTING DIAGRAM 1 Hot starter cable 2 Radiator hose 2 3 Clamp 4 Ignition coil lead 5 Throttle position sensor lead 6 Hump (frame) 7 Oil hose 8 Hose guide 9 Neutral switch lead 0 CDI magneto lead A Clutch cable B Radiator breather hose C Engine stop switch lead

D Sub-wire harness E CDI unit bracket F CDI unit G Throttle cable H Cylinder head breather hose È Fasten the hot starter cable, throttle cables, throttle position sensor lead and ignition coil lead. É Fasten the throttle position sensor lead behind the hump of the frame.

Ê Fasten the neutral switch lead on the oil hose. Ë Pass the neutral switch lead on the inside of the oil hose. Ì Fasten the neutral switch lead, CDI magneto lead and radiator breather hose. Í Fasten the neutral switch lead, CDI magneto lead, radiator breather hose and clutch cable over the radiator mounting boss.

È Fissare il cavo starter per partenze a caldo, i cavi dell’acceleratore, il cavo sensore posizione farfalla e il cavo bobina di accensione. É Fissare il cavo sensore posizione farfalla dietro la gobba del telaio. Ê Fissare il cavo dell’interruttore folle al flessibile olio. Ë Far passare il cavo dell’interruttore folle all’interno del flessibile olio. Ì Fissare il cavo dell’interruttore folle, il cavo magnete CDI e il flessibile di sfiato radiatore. Í Fissare il cavo dell’interruttore folle, il cavo magnete CDI, il flessibile di sfiato radiatore e il cavo frizione oltre la sporgenza di montaggio del radiatore.

CABLE ROUTING DIAGRAM Î Pass the radiator breather hose in front of the radiator, on the left of the chassis, and then between the frame and radiator hose 4. Ï Fasten the sub-wire harness and engine stop switch lead to the CDI unit bracket at the white-taped portion of the subwire harness and with the clamp ends facing downward.

Ð Locate the clamp ends in the arrowed range. Ñ Fasten the neutral switch lead and CDI magneto lead over the hump of the frame. Ò Fasten the hot starter cable and throttle cable onto the frame. Locate the clamp ends under the hot starter cable.

CABLE ROUTING DIAGRAM 1 Throttle cable (pull) 2 Throttle cable (return) 3 Radiator hose 2 4 Ignition coil 5 Cylinder head breather hose 6 Clamp 7 Rear arm bracket

È Pass the throttle cables over the radiator hose 2. É Pass the cylinder head breather hose so that it does not contact the ignition coil. Ê Fasten the throttle cables with the clamp so that the cables are not bent, and pass them under the rear arm bracket.

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

È Fasten the engine stop switch lead to the handlebar. É Pass the clutch cable and hot starter cable through the cable guide. Ê Pass the brake hose in front of the number plate. Ë Pass the throttle cables through the cable guide. Ì Pass the clutch cable and hot starter cable through the cable guide on the number plate.

MAINTENANCE INTERVALS INSP ADJ EC300000

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

After Every break-in race

ENGINE OIL Replace Inspect OIL FILTER ELEMENT, OIL STRAINER Clean VALVES Check the valve clearances Inspect Replace VALVE SPRINGS Inspect Replace VALVE LIFTERS Inspect Replace CAMSHAFTS Inspect Replace

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

The engine must be cold. Check the valve seats and valve stems for wear. Check the free length and the tilt. Check for scratches and wear. Inspect the camshaft surface. Inspect the decompression system.

TIMING CHAIN SPROCKETS, TIMING CHAIN Inspect Replace PISTON Inspect Clean Replace PISTON RING Inspect Replace PISTON PIN Inspect Replace CYLINDER HEAD Inspect and clean

Check for wear on the teeth and for damage.

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

Inspect carbon deposits and eliminate them. Change gasket

CYLINDER Inspect and clean Replace CLUTCH Inspect and adjust Replace TRANSMISSION Inspect Replace bearing

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

MAINTENANCE INTERVALS Item

After Every break-in race

SHIFT FORK, SHIFT CAM, GUIDE BAR Inspect ROTOR NUT Retighten EXHAUST PIPE, SILENCER, PROTECTOR Inspect and retighten Clean Replace CRANK Inspect and clean CARBURETOR Inspect, adjust and clean SPARK PLUG Inspect and clean Replace DRIVE CHAIN Lubricate, slack, alignment Replace COOLING SYSTEM Check coolant level and leakage Check radiator cap operation Replace coolant Inspect hoses OUTSIDE NUTS AND BOLTS Retighten

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

* Whichever comes first

Use chain lube Chain slack: 48 ~ 58 mm (1.9 ~ 2.3 in)

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

AIR FILTER Clean and lubricate Replace OIL FILTER Replace OIL STRAINER Clean FRAME Clean and inspect FUEL TANK, COCK Clean and inspect BRAKES Adjust lever position and pedal height Lubricate pivot point Check brake disc surface Check fluid level and leakage Retighten brake disc bolts, caliper bolts, master cylinder bolts and union bolts Replace pads Replace brake fluid FRONT FORKS Inspect and adjust Replace oil Replace oil seal

Use foam air-filter oil or equivalent oil

After Every break-in race

FRONT FORK OIL SEAL AND DUST SEAL Clean and lube PROTECTOR GUIDE Replace REAR SHOCK ABSORBER Inspect and adjust Lube

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

Molybdenum disulfide grease Every one year

Replace spring seat Retighten DRIVE CHAIN GUIDE AND ROLLERS Inspect SWINGARM Inspect, lube and retighten RELAY ARM, CONNECTING ROD Inspect, lube and retighten STEERING HEAD Inspect free play and retighten Clean and lube Replace bearing TIRE, WHEELS Inspect air pressure, wheel run-out, tire wear and spoke looseness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate THROTTLE, CONTROL CABLE Check routing and connection Lubricate Inspect and clean (throttle cable)

Molybdenum disulfide grease Molybdenum disulfide grease

Lithium base grease Yamaha cable lube or SAE 10W-30 motor oil Inspect dirt and wear on the throttle cable on the carburetor side.

HOT STARTER, CLUTCH LEVER Inspect free play

PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. GENERAL INSPECTION AND MAINTENANCE Item Coolant Fuel Engine oil Gear shifter and clutch Throttle grip/Housing Brakes Drive chain Wheels Steering Front forks and rear shock absorber Cables (wires) Exhaust pipe Rear wheel sprocket Lubrication Bolts and nuts Lead connectors

Routine Check that coolant is filled up to the radiator cap. Check the cooling system for leakage. Check that a fresh gasoline is filled in the fuel tank. Check the fuel line for leakage. Check that the oil level is correct. Check the crankcase and oil line for leakage. Check that gears can be shifted correctly in order and that the clutch operates smoothly. Check that the throttle grip operation and free play are correctly adjusted. Lubricate the throttle grip and housing, if necessary. Check the play of front brake and effect of front and rear brake. Check drive chain slack and alignment. Check that the drive chain is lubricated properly. Check for excessive wear and tire pressure. Check for loose spokes and have no excessive play. Check that the handlebar can be turned smoothly and have no excessive play. Check that they operate smoothly and there is no oil leakage. Check that the clutch and throttle cables move smoothly. Check that they are not caught when the handlebars are turned or when the front forks travel up and down. Check that the exhaust pipe is tightly mounted and has no cracks. Check that the rear wheel sprocket tightening bolt is not loose. Check for smooth operation. Lubricate if necessary. Check the chassis and engine for loose bolts and nuts. Check that the CDI magneto, CDI unit, and ignition coil are connected tightly. Is the machine set suitably for the condition of the racing course and weather or by taking into account the results of test runs before racing? Are inspection and maintenance completely done?

Seite 3-5–9 1-13 3-13–17 3-9–10 3-10–11 3-23–29 3-30–32 3-40–41 3-41–43 3-32–39 — 4-3–5 3-30 3-44 1-18 1-6 7-1–21

ENGINE/COOLANT LEVEL INSPECTION INSP ADJ EC350000

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

1. Place the machine on a level place, and hold it in an upright position. 2. Remove: • Radiator cap 3. Check: • Coolant level a Coolant level low → Add coolant.

COOLANT REPLACEMENT INSP ADJ COOLANT REPLACEMENT WARNING Do not remove the radiator cap when the engine is hot. CAUTION: Take care so that coolant does not splash on painted surfaces. If it splashes, wash it away with water. 1. Place a container under the engine. 2. Remove: • Coolant drain bolt 1 3. Remove: • Radiator cap Drain the coolant completely. 4. Clean: • Cooling system Thoroughly flush the cooling system with clean tap water. 5. Install: • Copper washer • Coolant drain bolt T.

10 Nm (1.0 m · kg, 7.2 ft · lb)

6. Fill: • Radiator • Engine To specified level. Recommended coolant: High quality ethylene glycol anti-freeze containing anticorrosion for aluminum engine Coolant 1 and water (soft water) 2 mixing ratio: 50%/50% Coolant capacity: 0.99 L (0.87 Imp qt, 1.05 US qt)

RADIATOR CAP INSPECTION INSP ADJ 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. 7. Install: • Radiator cap Start the engine and warm it up for a several minutes. 8. Check: • Coolant level Coolant level low → Add coolant.

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

CLUTCH ADJUSTMENT INSP ADJ NOTE: • Do not apply pressure more than specified pressure. • Radiator should be filled fully.

4. Inspect: • Pressure Impossible to maintain the specified pressure for 10 seconds → Repair. • Radiator 1 • Radiator hose joint 2 Coolant leakage → Repair or replace. • Radiator hose 3 Swelling → Replace. CLUTCH ADJUSTMENT 1. Check: • Clutch lever free play a Out of specification → Adjust. Clutch lever free play a: 8 ~ 13 mm (0.31 ~ 0.51 in)

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

NOTE: • Before adjustment, expose the adjuster by moving the boot 3 and cap 4 away. • Make minute adjustment on the lever side using the adjuster 5. • After adjustment, check proper operation of clutch lever.

Throttle grip free play adjustment steps: • Slide the adjuster cover. • Loosen the locknut 1. • Turn the adjuster 2 until the specified free play is obtained. • Tighten the locknut.

NOTE: Before adjusting the throttle cable free play, the engine idle speed should be adjusted. WARNING After adjusting, turn the handlebar to right and left and make sure that the engine idling does not run faster. THROTTLE LUBRICATION 1. Remove: • Cover (throttle cable cap) 1 • Cover (grip cap) 2 • Throttle grip cap 3

AIR FILTER CLEANING INSP ADJ

• Cover (grip cap) • Cover (throttle cable cap) HOT STARTER LEVER ADJUSTMENT 1. Check: • Hot starter lever free play a Out of specification → Adjust. Hot starter lever free play a: 3 ~ 6 mm (0.12 ~ 0.24 in) 2. Adjust: • Hot starter lever free play Hot starter lever free play adjustment steps: • Loosen the locknut 1. • Turn the adjuster 2 until free play a is within the specified limits. • Tighten the locknut. NOTE: After adjustment, check proper operation of hot starter. AIR FILTER CLEANING NOTE: Proper air filter maintenance is the biggest key to preventing premature engine wear and damage. CAUTION: Never run the engine without the air filter element in place; this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage. 1. Remove: • Seat • Fitting bolt 1 • Washer 2 • Air filter element 3 • Air filter guide 4 3 - 11

Togliere: • Sella • Bullone di montaggio 1 • Rondella 2 • Cartuccia del filtro dell’aria 3 • Guida del filtro dell’aria 4

AIR FILTER CLEANING INSP ADJ

2. Clean: • Air filter element Clean them with solvent. NOTE: After cleaning, remove the remaining solvent by squeezing the element. CAUTION: • Do not twist the element when squeezing the element. • Leaving too much of solvent in the element may result in poor starting. 3. Inspect: • Air filter element Damage → Replace. 4. Apply: • Foam-air-filter oil or equivalent oil to the element. NOTE: Squeeze out the excess oil. Element should be wet but not dripping.

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

6. Apply: • Lithium soap base grease On the matching surface a on air filter element.

2 Nm (0.2 m · kg, 1.4 ft · lb)

NOTE: Align the projection a on filter guide with the hole b in air filter case. ENGINE OIL LEVEL INSPECTION 1. Start the engine, warm it up for several minutes, and then turn off the engine and wait for five minutes. 2. Place the machine on a level place and hold it up on upright position by placing the suitable stand under the engine.

3. Inspect: • Oil level Oil should be up to the full level in the check window 1. Level check window is not full. → Add 0.2 L (0.18 Imp qt, 0.21 US qt) of oil.

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

(Except for USA and CDN)

CAUTION: • Do not add any chemical additives or use oils with a grade of CD a or higher. • Do not use oils labeled “ENERGY CONSERVING II” b or higher. Engine oil also lubricates the clutch and additives could cause clutch slippage. • Do not allow foreign materials to enter the crankcase.

4. Install: • Oil tank cap 5. Start the engine and let it warm up for several minutes. 6. Turn off the engine and inspect the oil level once again. NOTE: Wait a few minutes until the oil settles before inspecting the oil level.

ENGINE OIL REPLACEMENT INSP ADJ ENGINE OIL REPLACEMENT 1. Start the engine and warm it up for several minutes, and then turn off the engine and wait for five minute. 2. Place the machine on a level place and hold it on upright position by placing the suitable stand under the engine. 3. Place a suitable container under the engine. 4. Remove: • Lower engine guard 1 • Bolt (oil tank) 2 • Washer 3 • Oil filler cap 4 • Oil tank drain bolt 5 • Crankcase oil drain bolt 6 • Oil filter element drain bolt 7 Drain the crankcase and oil tank of its oil.

5. Remove: • Oil hose clamp 1 • Bolt (oil hose) • Oil hose 2 • Oil strainer 3 6. Inspect: • Oil strainer Clogged → Blow.

ENGINE OIL REPLACEMENT INSP ADJ

7. If the oil filter is to be replaced during this oil change, remove the following parts and reinstall them. Replacement steps: • Remove the oil filter element cover 1 and oil filter element 2. • Check the O-rings 3, if cracked or damaged, replace them with a new one. • Install the oil filter element and oil filter element cover.

• Oil hose • Bolt (oil hose) T.

• Crankcase oil drain bolt T.

20 Nm (2.0 m · kg, 14 ft · lb)

• Oil tank drain bolt T.

18 Nm (1.8 m · kg, 13 ft · lb)

• Lower engine guard T.

10 Nm (1.0 m · kg, 7.2 ft · lb)

10. Fill: • Engine oil Oil quantity: Periodic oil change: 1.05 L (0.92 Imp qt, 1.11 US qt) With oil filter replacement: 1.15 L (1.01 Imp qt, 1.22 US qt) Total amount: 1.30 L (1.14 Imp qt, 1.37 US qt) 11. Check: • Oil leakage 12. Install: • Oil filler cap • Washer (oil tank) • Bolt (oil tank) T.

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

PILOT SCREW ADJUSTMENT 1. Adjust: • Pilot screw 1 Adjustment steps: NOTE: To optimize the fuel flow at a smaller throttle opening, each machine’s pilot screw has been individually set at the factory. Before adjusting the pilot screw, turn it in fully and count the number of turns. Record this number as the factory-set number of turns out. • Turn in the pilot screw until it is lightly seated. • Turn out the pilot screw by the factory-set number of turns. Pilot screw (example): 1-7/8 turns out * 2-1/8 turns out * Except for USA and CDN

VALVE CLEARANCE INSPECTION AND ADJUSTMENT INSP ADJ ENGINE IDLING SPEED ADJUSTMENT 1. Start the engine and thoroughly warm it up. 2. Adjust: • Engine idling speed Adjustment steps: • Adjust the pilot screw. Refer to “PILOT SCREW ADJUSTMENT” section. • Turn the throttle stop screw 1 until the specified engine idling speed.

NOTE: Using a digital engine tachometer for idle speed adjustment, detect the engine idling speed by bringing the sensing element c of the engine tachometer close to the ignition coil 2.

To increase idle speed → Turn the throttle stop screw 1 in a. To decrease idle speed → Turn the throttle stop screw 1 out b. Engine idling speed: 1,900 ~ 2,100 r/min

VALVE CLEARANCE INSPECTION AND ADJUSTMENT NOTE: • The valve clearance should be adjusted when the engine is cool to the touch. • The piston must be at Top Dead Center (T.D.C.) on compression stroke to check or adjust the valve clearance. 1. Remove: • Seat • Fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 4.

Togliere: • Sella • Serbatoio del carburante Fare riferimento al paragrafo “SELLA, SERBATOIO CARBURANTE E FIANCHETTI” nel CAPITOLO 4.

VALVE CLEARANCE INSPECTION AND ADJUSTMENT INSP ADJ

2. Remove: • Spark plug • Cylinder head cover Refer to “CAMSHAFTS” section in the CHAPTER 4.

3. Remove: • Timing mark accessing screw 1 • Crankshaft end accessing screw 2 • O-ring 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: 0.17 ~ 0.22 mm (0.0067 ~ 0.0087 in)

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

Operazioni per il controllo: • Girare l’albero motore in senso antiorario con una chiave. • Allineare il riferimento PMS a sul rotore con il segno di allineamento b sul coperchio carter quando il pistone si trova nel PMS nella fase di compressione. NOTA: Per essere certi che il pistone si trovi nel PMS, il riferimento punzonato c sull’albero a camme di scarico e quello d sull’albero a camme di aspirazione devono essere allineati con la superficie della testata, come indicato in figura.

VALVE CLEARANCE INSPECTION AND ADJUSTMENT INSP ADJ

• Measure the valve clearance e using a feeler gauge 1. NOTE: Record the measured reading if the clearance is incorrect.

5. Adjust: • Valve clearance Adjustment steps: • Remove the camshaft (intake and exhaust). Refer to “CAMSHAFTS” section in the CHAPTER 4. • Remove the valve lifters 1 and the pads 2. NOTE: • Place a rag in the timing chain space to prevent pads from falling into the crankcase. • Identity each valve lifter and pad position very carefully so that they can be reinstalled in their original place. • Select the proper pad using the pad selecting table. Pad range No. 120 ~ No. 240

Pad Availability: 25 increments

VALVE CLEARANCE INSPECTION AND ADJUSTMENT INSP ADJ NOTE: The thickness a of each pad is indicated in hundreths of millimeters on the pad upper surface. • Round off the last digit of the installed pad number to the nearest increment. Last digit of pad number

EXAMPLE: Installed pad number = 148 Rounded off value = 150 NOTE: Pads can only be selected in 0.05 mm increments. • Locate the rounded-off value and the measured valve clearance in the chart “PAD SELECTION TABLE”. The field where these two coordinates intersect shows the new pad number to use. NOTE: Use the new pad number only as a guide when verifying the valve clearance adjustment. • Install the new pads 3 and the valve lifters 4. NOTE: • Apply the engine oil on the valve lifters. • Apply the molybdenum disulfide oil on the valve stem ends. • Valve lifter must turn smoothly when rotated with a finger. • Be careful to reinstall valve lifters and pads in their original place. • Install the camshafts (exhaust and intake). Refer to “CAMSHAFTS” section in the CHAPTER 4.

Example: Installed is 175

Measured clearance is 0.27 mm Replace 175 pad with 185 pad

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

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

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

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

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

Ripetere le operazioni dalla (e) alla (h) fino all’eliminazione delle bolle d’aria dal sistema.

FRONT BRAKE ADJUSTMENT INSP ADJ NOTE: If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared. j.

Add brake fluid to the level line on the reservoir.

WARNING Check the operation of the brake after bleeding the brake system. 3. Install: • Protector (rear brake) • Reservoir float (front brake) • Diaphragm • Brake master cylinder cap EC362040

FRONT BRAKE ADJUSTMENT 1. Check: • Brake lever position a Brake lever position a: Standard position

Extent of adjustment

76 ~ 97 mm (2.99 ~ 3.82 in)

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

CAUTION: Be sure to tighten the locknut, as it will cause poor brake performance. 4. Install: • Brake lever cover 3 - 24

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

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

FRONT BRAKE PAD INSPECTION AND REPLACEMENT 1. Inspect: • Brake pad thickness a Out of specification → Replace as a set. Brake pad thickness: 4.4 mm (0.17 in) <Limit>: 1.0 mm (0.04 in)

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

• Install the brake pads 7 and pad pin. NOTE: • Install the brake pads with their projections a into the brake caliper recesses b. • Temporarily tighten the pad pin at this point. • Install the brake caliper 8 and tighten the pad pin 9.

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

REAR BRAKE PAD INSPECTION AND REPLACEMENT 1. Inspect: • Brake pad thickness a Out of specification → Replace as a set. Brake pad thickness: 6.4 mm (0.25 in) <Limit>: 1.0 mm (0.04 in)

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 brake caliper 5. Refer to “FRONT WHEEL AND REAR WHEEL” section in the CHAPTER 5.

• Remove the pad pin 6 and brake pads 7. • Connect the transparent hose 8 to the bleed screw 9 and place the suitable container under its end. • Loosen the bleed screw and push the brake caliper piston in. CAUTION: Do not reuse the drained brake fluid. • Tighten the bleed screw.

• Install the brake pad 0 and pad pin A. NOTE: • Install the brake pads with their projections a into the brake caliper recesses b. • Temporarily tighten the pad pin at this point. • Install the brake caliper B and rear wheel C. Refer to “FRONT WHEEL AND REAR WHEEL” section in the CHAPTER 5. • Tighten the pad pin D.

• Install the pad pin plug E and protector F.

BRAKE FLUID LEVEL INSPECTION 1. Place the brake master cylinder so that its top is in a horizontal position. 2. Inspect: • Brake fluid level Fluid at lower level → Fill up.

a Lower level È Front É Rear

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.

AVVERTENZA • Utilizzare solo liquido dei freni di qualità certificata per evitare una diminuzione dell’efficienza della frenata. • Riempire con liquido dei freni dello stesso tipo e marca. Mischiare liquidi diversi riduce l’efficienza della frenata. • Assicurarsi che durante il riempimento non entrino nella pompa acqua o altri contaminanti. • Pulire immediatamente il liquido versato per evitare corrosione delle superfici verniciate o dei componenti di plastica.

SPROCKETS INSPECTION/DRIVE CHAIN INSPECTION INSP ADJ SPROCKETS INSPECTION 1. Inspect: • Sprocket teeth a Excessive wear → Replace. NOTE: Replace the drive sprocket, rear wheel sprocket and drive chain as a set.

DRIVE CHAIN INSPECTION 1. Measure: • Drive chain length (15 links) a Out of specification → Replace. Drive chain length (15 links): <Limit>: 242.9 mm (9.563 in) NOTE: • While measuring the drive chain length, push down on the drive chain to increase its tension. • Measure the length between drive chain roller 1 and F as shown. • Perform this measurement at two or three different places.

2. Remove: • Master link clip • Joint 1 • Drive chain 2

3. Clean: • Drive chain Place it in kerosene, and brush off as much dirt as possible. Then remove the drive chain from the kerosene and dry the drive chain.

DRIVE CHAIN SLACK ADJUSTMENT INSP ADJ

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

5. Install: • Drive chain 1 • Joint 2 • Master link clip 3 CAUTION: Be sure to install the master link clip to the direction as shown. a Turning direction

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

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

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

• Tighten the locknuts.

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

FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT INSP ADJ 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 a • Oil seal b NOTE: • Clean the dust seal and oil seal after every run. • Apply the lithium soap base grease on the inner tube.

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

1 Nm (0.1 m · kg, 0.7 ft · lb)

FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT 1. Adjust: • Rebound damping force By turning the adjuster 1. Stiffer a → Increase the rebound damping force. (Turn the adjuster 1 in.) Softer b → Decrease the rebound damping force. (Turn the adjuster 1 out.) 3 - 33

REGOLAZIONE DELLA FORZA DI SMORZAMENTO IN ESTENSIONE DELLA FORCELLA ANTERIORE 1. Regolare: • Forza di smorzamento in estensione Ruotando il dispositivo di regolazione 1. Rigido a → Aumentare la forza di smorzamento in estensione. (Avvitare il dispositivo di regolazione 1.) Morbido b → Diminuire la forza di smorzamento in estensione. (Svitare il dispositivo di regolazione1.)

FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT INSP ADJ Extent of adjustment Maximum Fully turned in position

Minimum 20 clicks out (from maximum position)

• STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. Standard position: 6 clicks out * 11 clicks out * For EUROPE CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. WARNING Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability.

FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: • Compression damping force By turning the adjuster 1. Stiffer a → Increase the compression damping force. (Turn the adjuster 1 in.) Softer b → Decrease the compression damping force. (Turn the adjuster 1 out.)

REGOLAZIONE DELLA FORZA DI SMORZAMENTO IN COMPRESSIONE DELLA FORCELLA ANTERIORE 1. Regolare: • Forza di smorzamento in compressione Ruotando il dispositivo di regolazione 1. Rigido a → Aumentare la forza di smorzamento in compressione. (Avvitare il dispositivo di regolazione 1.) Morbido b → Diminuire la forza di smorzamento in compressione. (Svitare il dispositivo di regolazione 1.)

REAR SHOCK ABSORBER INSPECTION INSP ADJ Extent of adjustment Maximum Fully turned in position

Minimum 20 clicks out (from maximum position)

• STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. Standard position: 11 clicks out * 6 clicks out * For EUROPE 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. EC36K000

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

* 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. • The I.D. mark b is marked at the end of the spring. • The standard length and extent of adjustment vary according to the quantity of I.D. marks. CAUTION: Never attempt to turn the adjuster beyond the maximum or minimum setting.

243,0–261,0 mm (9,57–10,28 in)

243,0 ~ 261,0 mm (9,57 ~ 10,28 in)

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

Minimum 20 clicks out (from maximum position)

• STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. (Which align the punch mark a on the adjuster with the punch mark b on the bracket.) Standard position: About 8 clicks out * About 7 clicks out * For EUROPE CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged.

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

Minimum 20 clicks out (from maximum position)

• STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. (Which align the punch mark a on the adjuster with the punch mark b on the high compression damping adjuster.)

Standard position: About 8 clicks out * About 9 clicks out

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

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

Minimum 2 turns out (from maximum position)

• STANDARD POSITION: This is the position which is back by the specific number of turns from the fully turned-in position. (Which align the punch mark a on the adjuster with the punch mark b on the adjuster body.)

Standard position: About 1-1/2 turns out

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

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

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

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

CONTROLLO DELLE RUOTE 1. Controllare: • Scentratura ruota Sollevare la ruota e farla ruotare. Scentratura anomala → Sostituire.

STEERING HEAD INSPECTION AND ADJUSTMENT INSP ADJ

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 stem Grasp the bottom of the forks and gently rock the fork assembly back and forth. Free play → Adjust steering head. 3. Check: • Steering smooth action Turn the handlebar lock to lock. Unsmooth action → Adjust steering ring nut.

Operazioni per la regolazione della ghiera dello sterzo: • Rimuovere la targa. • Togliere il manubrio e la staffa superiore. • Allentare la ghiera dello sterzo 1 con la chiave per ghiere 2. Chiave per ghiere: YU-33975/90890-01403

STEERING HEAD INSPECTION AND ADJUSTMENT INSP ADJ

• Tighten the steering ring nut 3 using steering nut wrench 4. NOTE: • Apply the lithium soap base grease on the thread of the steering stem. • Set the torque wrench to the steering nut wrench so that they form a right angle. Steering nut wrench: YU-33975/90890-01403

• Loosen the steering ring nut one turn. • Retighten the steering ring nut using the steering nut wrench. WARNING Avoid over-tightening.

• Check the steering stem by turning it lock to lock. If there is any binding, remove the steering stem assembly and inspect the steering bearings. • Install the washer 5, upper bracket 6, washer 7, steering stem nut 8, handlebar 9, handlebar upper holder 0 and number plate A. NOTE: • The handlebar upper holder should be installed with the punched mark a forward. • Install the handlebar so that the marks b are in place on both sides. • Install the handlebar so that the projection c of the handlebar upper holder is positioned at the mark on the handlebar as shown. • Insert the end of fuel breather hose B into the hole in the steering stem. CAUTION: First tighten the bolts on the front side of the handlebar upper holder, and then tighten the bolts on the rear side.

Hakenschlüssel: YU-33975/90890-01403

STEERING HEAD INSPECTION AND ADJUSTMENT T.

LUBRICATION To ensure smooth operation of all components, lubricate your machine during setup, after break-in, and after every race.

É Use SAE 10W-30 motor oil or suitable chain lubricants.

Ê Lubricate the following areas with high quality,

1 All control cable 2 Clutch lever pivot 3 Shift pedal pivot 4 Footrest pivot 5 Throttle-to-handlebar contact 6 Drive chain 7 Tube guide cable winding portion 8 Throttle cable end 9 Clutch cable end 0 Hot starter cable end

lightweight lithium-soap base grease.

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

SPARK PLUG INSPECTION 1. Remove: • Spark plug 2. Inspect: • Electrode 1 Wear/damage → Replace. • Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition. NOTE: When the engine runs for many hours at low speeds, the spark plug insulator will become sooty, even if the engine and carburetor are in good operating condition. 3. Measure: • Plug gap a Use a wire gauge or thickness gauge. Out of specification → Regap. Spark plug gap: 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) 4. Clean the plug with a spark plug cleaner if necessary.

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

NOTA: • Prima di installare una candela, pulire la superficie della guarnizione e quella della candela. • Avvitare con le dita a la candela prima di procedere al serraggio indicato nelle specifiche b.

IGNITION TIMING CHECK INSP ADJ IGNITION TIMING CHECK 1. Remove: • Timing mark accessing screw 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 “ENGINE IDLING ADJUSTMENT” section.

4. Check: • Ignition timing Visually check the stationary pointer a is within the firing range b on the rotor. Incorrect firing range → Check rotor and pickup assembly. 5. Install: • Timing mark accessing screw

1 Seat removal 3 Side covers removal

Preparation for removal

2 Fuel tank removal 4 Number plate removal Q’ty

SEAT, FUEL TANK AND SIDE COVERS REMOVAL Turn the fuel cock to “OFF”. Disconnect the fuel hose. Seat Air scoop (left and right) Bolt (fuel tank) Fuel tank Left side cover Right side cover Number plate

Refer to “REMOVAL POINTS”.

SEAT, FUEL TANK AND SIDE COVERS ENG REMOVAL POINTS Side cover 1. Remove: • Bolt (side cover) • Left side cover 1 • Right side cover 2 NOTE: Draw the side cover downward to remove it because its claws a are inserted in the air filter case.

Number plate 1. Remove: • Bolt (number plate) • Number plate 1 NOTE: • The projection a is inserted into the band of the number plate. Pull the band off the projection before removal. • Remove the hot starter cable 2 and clutch cable 3 from the cable guide b on the number plate. • The projection c on the lower bracket is inserted into the number plate. Remove the number plate by pulling it off the projection.

ASSEMBLY AND INSTALLATION Air scoop 1. Install: • Air scoop 1 • Bolt (air scoop) T.

NOTE: Put the portion a of the flap of the air filter case on the inside of the air scoop. 4-2

Extent of removal: Extent of removal

EXHAUST PIPE AND SILENCER REMOVAL Right side cover

Preparation for removal

2 Exhaust pipe removal

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

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

CAUTION: Take care not to damage the rivet fitting holes (ø4.9 mm) a in removal.

NOTE: • Apply heat resistant sealant along the plate edge a on the inside of the silencer and also along the silencer edge b as shown. • Take care not to allow the fiber out of place when installing the inner pipe.

NOTE: First, temporarily install both nuts, then tighten either of these nuts to 13 Nm (1.3 m • kg, 9.4 ft • lb) and the other to 20 Nm (2.0 m • kg, 14 ft • lb) and then come back to the first one and retighten it to 20 Nm (2.0 m • kg, 14 ft • lb).

NOTE: • Install the gasket with its meshed area a toward the exhaust pipe side. • The gasket should be installed according to the dimension shown.

Extent of removal: Extent of removal

RADIATOR REMOVAL Drain the coolant.

Preparation for removal

Refer to “COOLANT REPLACEMENT” section in the CHAPTER 3. Refer to “SEAT, FUEL TANK AND SIDE COVERS” section.

Radiator guard Radiator hose clamp Radiator hose 1 Left radiator Radiator hose 3 Right radiator Radiator hose 2 Radiator hose 4 Radiator breather hose Radiator pipe 1

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

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

NOTE: Apply the lithium soap base grease on the Oring. 2. Install: • Radiator breather hose 1 • Radiator hose 2 2 • Radiator hose 3 3 • Radiator hose 4 4 To right radiator 5.

• Radiator hose 3 3 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2.

Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. 5. Tighten: • Radiator hose clamp 4 T.

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

CARBURETOR ENG CARBURETOR

1 Carburetor removal

Extent of removal: Extent of removal

CARBURETOR REMOVAL Seat and fuel tank

Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Refer to “REAR SHOCK ABSORBER” section in the CHAPTER 5.

Preparation for removal Rear shock absorber 1 2

Clamp Throttle position sensor lead coupler Throttle cable cover Throttle cable Clamp (air filter joint) Clamp (carburetor joint) Hot starter plunger Carburetor assembly Carburetor joint

Loosen the screw (air filter joint). Loosen the screws (carburetor joint).

CARBURETOR DISASSEMBLY

1 Carburetor disassembly

Extent of removal: Extent of removal

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

Refer to “REMOVAL POINTS”.

ENG CARBURETOR Extent of removal

CARBURETOR ENG HANDLING NOTE CAUTION: Do not loosen the screws (throttle position sensor) 1 except when changing the throttle position sensor due to failure because it will cause a drop in engine performance.

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

INSPECTION Carburetor 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.

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.

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

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. EC464401

CARBURETOR ENG Float height 1. Measure: • Float height a Out of specification → Adjust. Float height: 8.0 mm (0.31 in) Measurement and adjustment steps: • Hold the carburetor in an upside down position. NOTE: • Slowly tilt the carburetor in the opposite direction, then take the measurement when the needle valve aligns with the float arm. • If the carburetor is level, the weight of the float will push in the needle valve, resulting in an incorrect measurement. • Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers. NOTE: The float arm should be resting on the needle valve, but not compressing the needle valve. • If the float height is not within specification, inspect the valve seat and needle valve. • If either is worn, replace them both. • If both are fine, adjust the float height by bending the float tab b on the float. • Recheck the float height.

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

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

b a 6. Install: • Washer 1 • Circlip 2

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

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

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: • Pilot screw 1 • Spring 2 • Washer 3 • O-ring 4 Note the following installation points: • Turn in the pilot screw until it is lightly seated. • Turn out the pilot screw by the number of turns recorded before removing. Pilot screw (example): 1-7/8 turns out * 2-1/8 turns out * Except for USA and CDN

13. 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 14. Install: • Diaphragm (accelerator pump) 1 • Spring 2 • O-ring 3 • Accelerator pump cover 4 • Hose holder (drain hose) 5 • Screw (accelerator pump cover) 6 NOTE: Install the diaphragm (accelerator pump) with its mark a facing the spring. 4 - 18

CARBURATEUR VERGASER CARBURATORE ENG

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

17. Install: • O-ring 1 • Valve lever housing cover 2 • Bolt (valve lever housing cover) 3

18. Install: • Carburetor breather hose 1 NOTE: Install the carburetor breather hoses to the carburetor so that the hoses do not bend near where they are installed.

NOTA: Installare i flessibili di sfiato del carburatore sul carburatore stesso in modo che non si pieghino in prossimità del punto di installazione.

CARBURETOR ENG Accelerator pump timing adjustment Adjustment steps: NOTE: In order for the throttle valve height a to achieve the specified value, tuck under the throttle valve plate 1 the rod 2 etc. with the same outer diameter as the specified value. Throttle valve height: 0.8 mm (0.031 in) • Fully turn in the accelerator pump adjusting screw 3. • Check that the link lever 4 has free play b by pushing lightly on it. • Gradually turn out the adjusting screw while moving the link lever until it has no more free play.

Carburetor installation 1. Install: • Carburetor joint 1 T.

10 Nm (1.0 m · kg, 7.2 ft · lb)

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

• Bolt (air filter joint) 2

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

CAMSHAFTS ENG CAMSHAFTS CYLINDER HEAD COVER

1 Cylinder head cover removal

Extent of removal: Extent of removal

CYLINDER HEAD COVER REMOVAL Seat and fuel tank

Preparation for removal

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

Extent of removal: Extent of removal

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

Refer to “REMOVAL POINTS”.

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

NOTE: Remove the bolts (camshaft cap) in a crisscross pattern, working from the outside in. CAUTION: The bolts (camshaft cap) must be removed evenly to prevent damage to the cylinder head, camshafts or camshaft caps. 4 - 24

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

3 INSPECTION Camshaft 1. Inspect: • Cam lobe Pitting/scratches/blue discoloration Replace. 2. Measure: • Cam lobe length a and b Out of specification → Replace. Cam lobes length: Intake: a 30.246 ~ 30.346 mm (1.1908 ~ 1.1947 in) <Limit>: 30.146 mm (1.1869 in) b 22.45 ~ 22.55 mm (0.8839 ~ 0.8878 in) <Limit>: 22.35 mm (0.8799 in) Exhaust: a 30.399 ~ 30.499 mm (1.1968 ~ 1.2007 in) <Limit>: 30.299 mm (1.1929 in) b 22.45 ~ 22.55 mm (0.8839 ~ 0.8878 in) <Limit>: 22.35 mm (0.8799 in)

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

4. Measure: • Camshaft-to-cap clearance Out of specification → Measure camshaft outside diameter. Camshaft-to-cap clearance: 0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in) <Limit>: 0.08 mm (0.003 in) Measurement steps: • Install the camshaft onto the cylinder head. • Position a strip of Plastigauge® 1 onto the camshaft. • Install the clip, dowel pins and camshaft caps.

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

NOTE: • Tighten the bolts (camshaft cap) in a crisscross pattern from innermost to outer caps. • Do not turn the camshaft when measuring clearance with the Plastigauge®. • Remove the camshaft caps and measure the width of the Plastigauge® 1.

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

Ruota dentata albero a camme 1. Controllare: • Ruota dentata albero a camme 1 Usura/danni →Sostituire in blocco il gruppo albero a camme e la catena di distribuzione.

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

ASSEMBLY AND INSTALLATION Camshaft 1. Install: • Exhaust camshaft 1 • Intake camshaft 2 Installation steps: • Turn the crankshaft counterclockwise with a wrench. NOTE: • Apply the molybdenum disulfide oil on the camshafts. • Apply the engine oil on the decompression system. • Squeezing the decompression lever allows the crankshaft to be turned easily. • Align the T.D.C. mark a on the rotor with the align mark b on the crankcase cover when piston is at T.D.C. on compression stroke. 4 - 27

ARBRES A CAMES NOCKENWELLEN ALBERI A CAMME Décompresseur 1. Contrôler: • Décompresseur

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

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

NOTE: • Before removing the clips, cover the cylinder head with a clean rag to prevent the clips from into the cylinder head cavity. • Apply the molybdenum disulfide oil on the thread of the bolts (camshaft cap). • Tighten the bolts to the specified torque in two or three steps in the proper tightening sequence as shown. CAUTION: The bolts (camshaft cap) must be tightened evenly, or damage to the cylinder head, camshaft caps, and camshaft will result.

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.

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

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

3. Turn: • Crankshaft Counterclockwise several turns. 4. Check: • Rotor T.D.C. mark Align with the crankcase align mark. • Camshaft match marks Align with the cylinder head surface. Out of alignment → Adjust. 5. Install: • Timing mark accessing screw 1 • Crankshaft end accessing screw 2

6. Install: • Timing chain guide (top side) 1 • Cylinder head cover gasket 2 • Cylinder head cover 3 • Bolt (cylinder head cover) 4 T.

CYLINDER HEAD ENG CYLINDER HEAD

1 Cylinder head removal

Extent of removal: Extent of removal

CYLINDER HEAD REMOVAL Seat and fuel tank

Preparation for removal

Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Refer to “EXHAUST PIPE AND SILENCER” section. Disconnect at cylinder head side. Refer to “CARBURETOR” section. Refer to “CAMSHAFTS” section. Refer to “ENGINE REMOVAL” section.

Exhaust pipe and silencer

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

CYLINDER HEAD ENG 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 resurfacement steps: • Place a straightedge and a feeler gauge across the cylinder head. • Use a feeler gauge to measure the warpage. • If the warpage is out of specification, resurface the cylinder head. • Place a 400 ~ 600 grit wet sandpaper on the surface plate, and resurface the head using a figure-eight sanding pattern. NOTE: To ensure an even surface rotate the cylinder head several times.

• Bolts [L = 135 mm (5.31 in)] 4 T.

NOTE: • Apply the molybdenum disulfide grease on the thread and contact surface of the bolts. • Follow the numerical order shown in the illustration. Tighten the bolts and nuts in two stages.

Extent of removal: Extent of removal

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

Preparation for removal

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

Utilizzare l’apposito attrezzo. Fare riferimento a “PUNTI DI RIMOZIONE”.

VALVES AND VALVE SPRINGS ENG REMOVAL POINTS Valve lifter and valve cotter 1. Remove: • Valve lifter 1 • Pad 2 NOTE: Identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place. 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 cotter NOTE: Attach a valve spring compressor 1 between the valve spring retainer and the cylinder head to remove the valve cotters. Valve spring compressor: YM-4019/90890-04019

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.

VALVES AND VALVE SPRINGS ENG Valve guide remover: Intake: 4.0 mm (0.16 in) YM-4111/90890-04111 Exhaust: 4.5 mm (0.18 in) YM-4116/90890-04116 Valve guide installer: Intake: 4.0 mm (0.16 in) YM-4112/90890-04112 Exhaust: 4.5 mm (0.18 in) YM-4117/90890-04117 Valve guide reamer: Intake: 4.0 mm (0.16 in) YM-4113/90890-04113 Exhaust: 4.5 mm (0.18 in) YM-4118/90890-04118 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.

4. Measure: • Margin thickness a Out of specification → Replace. Margin thickness: Intake: 0.8 mm (0.0315 in) Exhaust: 0.7 mm (0.0276 in)

VALVES AND VALVE SPRINGS ENG

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

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

9. Lap: • Valve face • Valve seat NOTE: After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. Lapping steps: • Apply a coarse lapping compound to the valve face. CAUTION: Do not let the compound enter the gap between the valve stem and the guide. • Apply molybdenum disulfide oil to the valve stem. • Install the valve into the cylinder head. • Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the compound. NOTE: For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands. • Apply a fine lapping compound to the valve face and repeat the above steps. NOTE: After every lapping operation be sure to clean off all of the compound from the valve face and valve seat. • Apply Mechanic’s blueing dye (Dykem) to the valve face. • Install the valve into the cylinder head. • Press the valve through the valve guide and onto the valve seat to make a clear pattern. • Measure the valve seat width again. If the valve seat width is out of specification, reface and relap the valve seat.

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

Alzavalvola 1. Controllare: • Alzavalvola Graffi/danni → Sostituire gli alzavalvole e la testata.

VALVES AND VALVE SPRINGS ENG ASSEMBLY AND INSTALLATION Valve and valve spring 1. Apply: • Molybdenum disulfide oil Onto the valve stem and valve stem seal.

2. Install: • Valve 1 • Valve spring seat 2 • Valve stem seal 3 • Valve spring 4 • Valve spring retainer 5 To cylinder head. NOTE: • Make sure that each valve is installed in its original place, also referring to the painted color as follows. Intake (middle) a: orange Intake (right/left) b: green Exhaust: no paint • Install the valve springs with the larger pitch c facing upward. d Smaller pitch

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

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

Extent of removal: Extent of removal

Preparation for removal

Refer to “CYLINDER HEAD” section. 1 1 2 1 1 1

Use special tool. Refer to “REMOVAL POINTS”.

CYLINDRE ET PISTON ZYLINDER UND KOLBEN CILINDRO E PISTONE ENG CYLINDRE ET PISTON 1 Dépose du cylindre

CYLINDER AND PISTON ENG REMOVAL POINTS Piston and piston ring 1. Remove: • Piston pin clip 1 • Piston pin 2 • Piston 3 NOTE: • Put identification marks on each piston head for reference during reinstallation. • Before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller set 4. Piston pin puller set: YU-1304/90890-01304 CAUTION: Do not use a hammer to drive the piston pin out. 2. Remove: • Piston ring 1 NOTE: Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown, as shown in the illustration. INSPECTION Cylinder and piston 1. Inspect: • Cylinder and piston walls Vertical scratches → Replace cylinder and piston. 2. Measure: • Piston-to-cylinder clearance Measurement steps: 1st step: • Measure the cylinder bore “C” with a cylinder bore gauge. NOTE: Measure the cylinder bore “C” in parallel to and at right angles to the crankshaft. Then, find the average of the measurements.

CYLINDER AND PISTON ENG Cylinder bore “C”

“C” = Maximum D “T” = (Maximum D1 or D2) – (Maximum D5 or D6) “R” = (Maximum D1, D3 or D5) – (Minimum D2, D4 or D6) • If out of specification, replace the cylinder, and replace the piston and piston rings as set. 2nd step: • Measure the piston skirt diameter “P” with a micrometer. a 8 mm (0.31 in) from the piston bottom edge Piston size “P” Standard

76.955 ~ 76.970 mm (3.0297 ~ 3.0303 in)

• If out of specification, replace the piston and piston rings as a set. 3rd step: • Calculate the piston-to-cylinder clearance with following formula: Piston-to-cylinder clearance = Cylinder bore “C” – Piston skirt diameter “P” Piston-to-cylinder clearance: 0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in) <Limit>: 0.1 mm (0.004 in) • If out of specification, replace the cylinder, and replace the piston and piston rings as set.

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

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. a 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:

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

2. Position: • Top ring • 2nd ring • Oil ring Offset the piston ring end gaps as shown. a Top ring end b 2nd ring end c Oil ring end (upper) d Oil ring e Oil ring end (lower) 3. Install: • Piston 1 • Piston pin 2 • Piston pin clip 3

NOTE: • Apply engine oil onto the piston pin and piston. • Be sure that the arrow mark a on the piston points to the exhaust side of the engine. • Before installing the piston pin clip, cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase. • Install the piston pin clips with their ends facing downward.

Cylinder 1. Lubricate: • Piston • Piston ring • Cylinder NOTE: Apply a liberal coating of engine oil.

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

3. Install: • Cylinder gasket 1 • Cylinder 2 NOTE: Install the cylinder with one hand while compressing the piston rings with the other hand. CAUTION: • Pass the timing chain 3 through the timing chain cavity. • Be careful not to damage the timing chain guide 4 during installation. 4. Install: • Bolt (cylinder) 5 T.

1 Push rod 1, 2 and push lever shaft removal 3 Friction plate and clutch plate removal

CLUTCH REMOVAL Drain the engine oil.

Preparation for removal

2 Push rod 1 disassembly 4 Primary driven gear removal Remarks Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Refer to “ENGINE REMOVAL” section. Disconnect at engine side.

CLUTCH Extent of removal

Part name Friction plate Clutch plate Cushion spring Seat plate Nut (clutch boss) Lock washer Clutch boss Thrust washer Primary driven gear Push lever shaft

Use special tool. Refer to “REMOVAL POINTS”.

REMOVAL POINTS 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. È

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

É Except for USA and CDN EC4A4000

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

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

Clutch spring 1. Measure: • Clutch spring free length a Out of specification → Replace springs as a set. Clutch spring free length: 40.4 mm (1.59 in) <Limit>: 39.4 mm (1.55 in)

Lunghezza libera della molla frizione: 40,4 mm (1,59 in) <Limite>: 39,4 mm (1,55 in)

CLUTCH ENG Friction plate 1. Measure: • Friction plate thickness Out of specification → Replace friction plate as a set. Measure at all four points. Friction plate thickness: 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) <Limit>: 2.7 mm (0.106 in) EC484600

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

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

10 Nm (1.0 m · kg, 7.2 ft · lb)

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

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

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

NOTE: Use the clutch holding tool 3 to hold the clutch boss. Clutch holding tool: YM-91042/90890-04086 È

NOTE: • Install the seat plate with its chamfered portion a facing the clutch boss 3. • Install the seat plate so that it is not caught on the step b. • Install the cushion spring with its concave surface c facing outward. 5. Install: • Friction plate 1 1 • Clutch plate 1 2 • Friction plate 2 3 • Clutch plate 2 4 NOTE: • Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate. • Use the friction plates 1 for the first and final while paying attention to the difference in surface pattern. • Apply the engine oil on the friction plates and clutch plates. • Unlike the clutch plate 2, the clutch plate 1 has no surface gloss. Use the clutch plate 1 for the first while paying attention to the difference in surface gloss.

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

1 Oil filter element removal 3 Right crankcase cover removal

OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER REMOVAL Drain the engine oil.

Preparation for removal

Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Refer to “COOLANT REPLACEMENT” section in the CHAPTER 3. Disconnect at water pump side. Refer to “EXHAUST PIPE AND SILENCER” section. Refer to “ENGINE REMOVAL” section.

Drain the coolant. Radiator hose 3 Exhaust pipe

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

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

Q’ty 1 1 1 1 1 1 1 1 2 1

Refer to “REMOVAL POINTS”.

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: • Bearing 1 2. Remove: • Oil seal 1

INSPECTION Oil delivery pipe 1. Inspect: • Oil delivery pipe 1 Bend/damage → Replace. Clogged → Blow.

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

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

ASSEMBLY AND INSTALLATION Oil seal 1. Install: • Oil seal 1 NOTE: • Apply the lithium soap base grease on the oil seal lip. • Install the oil seal with its manufacture’s marks or numbers facing the right crankcase cover 2. 4 - 60

ELEMENT DE FILTRE A HUILE, POMPE A EAU ET COUVERCLE DE CARTER DROIT

2. Install: • Bearing 1 NOTE: Install the bearing by pressing its outer race parallel.

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

2. Install: • Right crankcase cover 1 • Bolt (right crankcase cover) 2 T.

10 Nm (1.0 m · kg, 7.2 ft · lb)

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

NOTE: Install so that there is a clearance a of 5 mm (0.20 in) or more between the kick starter and frame and that the kick starter does not contact the crankcase cover when it is pulled. 2. Install: • Oil hose 1 • Bolt (oil hose) 2 T.

20 Nm (2,0 m · kg, 14 ft · lb)

OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER ENG Water pump housing 1. Install: • Dowel pin 1 • O-ring 2 NOTE: Apply the lithium soap base grease on the Oring.

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

10 Nm (1.0 m · kg, 7.2 ft · lb)

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

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE: Apply the lithium soap base grease on the Oring.

ENG BALANCER BALANCER

1 Balancer shaft drive gear

Extent of removal: Extent of removal

BALANCER REMOVAL Primary driven gear Right crankcase cover

Preparation for removal

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

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

Refer to “REMOVAL POINTS”.

Refer to “REMOVAL POINTS”.

BALANCIER AUSGLEICHSWELLE EQUILIBRATORE ENG BALANCIER 1 Pignon menant d’arbre de balancier

Fare riferimento a “PUNTI DI RIMOZIONE”.

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

Balancer shaft 1. Remove: • Balancer shaft 1 NOTE: When removing the balancer shaft, align the center a of the balancer shaft weight along the line connecting the centers of the crankshaft and balancer shaft.

INSPECTION Primary drive gear, balancer shaft drive gear and balancer shaft driven gear 1. Inspect: • Primary drive gear 1 • Balancer shaft drive gear 2 • Balancer shaft driven gear 3 Wear/damage → Replace.

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

BALANCER ENG ASSEMBLY AND INSTALLATION Balancer shaft, balancer shaft drive gear and balancer shaft driven gear 1. Install: • Balancer shaft 1 NOTE: • Apply the engine oil on the bearing. • When installing the balancer shaft, align the center a of the balancer shaft weight along the line connecting the centers of the crankshaft and balancer shaft. 2. Install: • Balancer shaft driven gear 1 NOTE: Install the balancer shaft driven gear onto the balancer shaft while aligning the punch mark a on the balancer shaft driven gear with the lower spline b on the balancer shaft end. 3. Install: • Balancer shaft drive gear 1 NOTE: • Align the punched mark a on the balancer shaft drive gear with the punched mark b on the balancer shaft driven gear 2. • Align the punched mark c on the balancer shaft drive gear with the lower spline d on the crankshaft end. 4. Install: • Lock washer 1 • Nut (balancer shaft driven gear) 2 T.

50 Nm (5.0 m · kg, 36 ft · lb)

• Primary drive gear 3 • Lock washer 4 • Nut (primary drive gear) 5 T.

75 Nm (7.5 m · kg, 54 ft · lb)

NOTE: • Install the primary drive gear with its stepped side a facing the engine. • Place an aluminum plate b between the teeth of the balancer shaft drive gear 6 and driven gear 7. 5. Bend the lock washer tab.

Extent of removal: Extent of removal

OIL PUMP REMOVAL AND DISASSEMBLY Primary driven gear Right crankcase cover

Preparation for removal

2 Oil pump disassembly

1 2 3 4 5 6 7 8 9 10 11

Circlip Washer Oil pump drive gear Oil pump assembly Outer rotor 2 Circlip Inner rotor 2 Dowel pin Oil pump cover Outer rotor 1 Inner rotor 1

Refer to “CLUTCH” section. Refer to “OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER” section. 1 1 1 1 1 1 1 1 1 1 1

Part name Dowel pin Washer Oil pump drive shaft Rotor housing

Extent of removal: Extent of removal

OIL TANK REMOVAL Drain the engine oil.

Preparation for removal

Oil hose 2 Oil hose 1 Dowel pin Oil tank breather hose Oil tank Oil strainer

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

ENG INSPECTION Oil pump 1. Inspect: • Oil pump drive gear 1 • Oil pump drive shaft 2 • Rotor housing 3 • Oil pump cover 4 Cracks/wear/damage → Replace.

2. Measure: • Tip clearance a (between the inner rotor 1 and outer rotor 2) • Side clearance b (between the outer rotor 2 and rotor housing 3) • Housing and rotor clearance c (between the rotor housing 3 and rotors 1 2) Out of specification → Replace the oil pump assembly. Tip clearance a: 0.12 mm or less (0.0047 in or less) <Limit>: 0.20 mm (0.008 in) Side clearance b: 0.09 ~ 0.17 mm (0.0035 ~ 0.0067 in) <Limit>: 0.24 mm (0.009 in) Housing and rotor clearance c: 0.03 ~ 0.10 mm (0.0012 ~ 0.0039 in) <Limit>: 0.17 mm (0.0067 in)

3. Check: • Unsmooth → Repeat steps #1 and #2 or replace the defective parts.

Controllare: • Non uniforme → Ripetere le operazioni n. 1 e n. 2 o sostituire i componenti difettosi.

OIL PUMP ENG ASSEMBLY AND INSTALLATION Oil pump 1. Install: • Oil pump drive shaft 1 • Washer 2 • Dowel pin 3 • Inner rotor 1 4 NOTE: • Apply the engine oil on the oil pump drive shaft and inner rotor 1. • Fit the dowel pin into the groove in the inner rotor 1.

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 T.

2 Nm (0.2 m · kg, 1.4 ft · lb)

• Dowel pin 3 • Inner rotor 2 4 • Circlip 5 NOTE: • Apply the engine oil on the inner rotor 2. • Fit the dowel pin into the groove in the inner rotor 2.

4. Install: • Outer rotor 2 1 • Dowel pin 2 • Oil pump assembly 3 • Bolt (oil pump assembly) [L = 25 mm (0.94 in)] 4 T.

10 Nm (1.0 m · kg, 7.2 ft · lb)

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

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

NOTA: Applicare l’olio motore sulla circonferenza interna dell’ingranaggio conduttore della pompa dell’olio.

KICK SHAFT AND SHIFT SHAFT ENG KICK SHAFT AND SHIFT SHAFT

1 Kick shaft removal 3 Shift shaft removal

Preparation for removal

Refer to “OIL PUMP” section. 1 1 1 1 1 1 1 1 1 1 1

Refer to “REMOVAL POINTS”.

ARBRE DE KICK ET AXE DE SELECTEUR KICKHEBELWELLE UND SCHALTWELLE ALBERO PEDALE E ALBERO DEL CAMBIO ENG ARBRE DE KICK ET AXE DE SELECTEUR 1 Dépose de l’arbre de kick 3 Dépose de l’axe de sélecteur

KICK SHAFT AND SHIFT SHAFT Extent of removal

Refer to “REMOVAL POINTS”.

Refer to “REMOVAL POINTS”.

ARBRE DE KICK ET AXE DE SELECTEUR KICKHEBELWELLE UND SCHALTWELLE ALBERO PEDALE E ALBERO DEL CAMBIO Organisation de la dépose

KICK SHAFT AND SHIFT SHAFT ENG REMOVAL POINTS Kick shaft assembly 1. Remove: • Kick shaft assembly 1 NOTE: Unhook the torsion spring 2 from the hole a in the crankcase.

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

Segment 1. Remove: • Bolt (segment) 1 • Segment 2 NOTE: Turn the segment counterclockwise until it stops and loosen the bolt. CAUTION: If the segment gets an impact, it may be damaged. Take care not to give an impact to the segment when removing the bolt. INSPECTION Kick shaft and ratchet wheel 1. Check: • Ratchet wheel 1 smooth movement Unsmooth movement → Replace. • Kick shaft 2 Wear/damage → Replace. • Spring 3 Broken → Replace. EC4C4300

KICK SHAFT AND SHIFT SHAFT ENG EC4B4400

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

KICK SHAFT AND SHIFT SHAFT ENG EC4B5111

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.

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 1.4 mm (0.06 in) a above the top of the footrest. Kick shaft assembly 1. Install: • Kick gear 1 • Washer 2 • Circlip 3 • Ratchet wheel 4 • Spring 5 • Washer 6 • Circlip 7 To kick shaft 8. NOTE: • Apply the molybdenum disulfide oil on the inner circumferences of the kick gear and ratchet wheel. • Align the punch mark a on the ratchet wheel with the punch mark b on the kick shaft.

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

NOTA: Accertarsi che l’elemento di arresto a della molla di torsione sia montato nel foro b nell’albero pedale.

KICK SHAFT AND SHIFT SHAFT ENG

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

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

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

Kick idle gear 1. Install: • Kick idle gear 1 • Washer 2 • Circlip 3 NOTE: • Apply the engine oil on the kick idle gear inner circumference. • Install the kick idle gear with its depressed side a toward you. 4 - 79

ARBRE DE KICK ET AXE DE SELECTEUR KICKHEBELWELLE UND SCHALTWELLE ALBERO PEDALE E ALBERO DEL CAMBIO 3.

1 CDI magneto removal

Extent of removal: Extent of removal

CDI MAGNETO REMOVAL Seat and fuel tank

Preparation for removal

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

Disconnect the CDI magneto lead. Shift pedal

Left crankcase cover Nut (rotor) Rotor Stator Woodruff key

Refer to “KICK SHAFT AND SHIFT SHAFT” section. 1 1 1 1 1

Use special tool. Refer to “REMOVAL POINTS”.

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

4. Connect: • CDI magneto lead Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2.

ENGINE REMOVAL Extent of removal Preparation for removal

Part name ENGINE REMOVAL Hold the machine by placing the suitable stand under the frame.

Seat and fuel tank Carburetor Exhaust pipe and silencer Clutch cable Radiator Shift pedal Cylinder head breather hose Drain the engine oil. Oil hose and oil tank breather hose

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

Extent of removal: Extent of removal

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

Refer to “REMOVAL POINTS”.

Refer to “REMOVAL POINTS”.

DEPOSE DU MOTEUR MOTOR DEMONTIEREN RIMOZIONE DEL MOTORE 1 Dépose du moteur

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. 2. Remove: • Engine 1 From right side.

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

ASSEMBLY AND INSTALLATION Engine installation 1. Install: • Engine 1 Install the engine from right side. • Pivot shaft 2 T.

85 Nm (8.5 m · kg, 61 ft · lb)

• Engine mounting bolt (lower) 3 T.

53 Nm (5.3 m · kg, 38 ft · lb)

• Lower engine bracket 4 • Bolt (lower engine bracket) 5 T.

38 Nm (3.8 m · kg, 27 ft · lb)

• Patch 6 • Engine mounting bolt (front) 7 T.

53 Nm (5.3 m · kg, 38 ft · lb)

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

34 Nm (3.4 m · kg, 25 ft · lb)

• Engine mounting bolt (upper) 0 T.

55 Nm (5.5 m · kg, 40 ft · lb)

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

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE: • Apply the molybdenum disulfide grease on the pivot shaft. • Install the patch with the claw a facing outside the chassis. Brake pedal 1. Install: • Spring 1 • Brake pedal 2 • O-ring 3 • Bolt (brake pedal) 4 T.

NOTE: Tighten the nut while applying the rear brake.

NOTE: Apply the lithium soap base grease on the Oring.

CRANKCASE AND CRANKSHAFT ENG CRANKCASE AND CRANKSHAFT

1 Crankcase separation

Extent of removal: Extent of removal

CRANKCASE AND CRANKSHAFT REMOVAL Engine Piston

Preparation for removal

2 Crankshaft removal

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

Refer to “ENGINE REMOVAL” section. Refer to “CYLINDER AND PISTON” section. Refer to “KICK SHAFT AND SHIFT SHAFT” section. Refer to “CDI MAGNETO” section. Refer to “BALANCER” section. 1 1 1

CRANKCASE AND CRANKSHAFT Extent of removal

Order 4 5 6 7 8 9 10 11 12

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

Q’ty 6 1 4 1 1 1 1 1 1

Refer to “REMOVAL POINTS”.

Use special tool. Refer to “REMOVAL POINTS”.

CARTER MOTEUR ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE Organisation de la dépose

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

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

CRANKCASE AND CRANKSHAFT ENG CRANKCASE BEARING

1 Crankcase bearing removal

Extent of removal: Extent of removal

Preparation for removal

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

Refer to “TRANSMISSION, SHIFT CAM AND SHIFT FORK” section. 2 10

Refer to “REMOVAL POINTS”.

CARTER MOTEUR ET VILEBREQUIN KURBELGEHÄUSE UND KURBELWELLE CARTER E ALBERO MOTORE ENG ROULEMENT DE CARTER MOTEUR 1 Dépose du roulement de carter moteur

CRANKCASE AND CRANKSHAFT ENG REMOVAL POINTS Crankcase 1. Separate: • Right crankcase • Left crankcase Separation steps: • Remove the crankcase bolts 1, hose guide 2 and clutch cable holder 3. NOTE: Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them. • Remove the right crankcase 4.

NOTE: • Place the crankcase with its left half downward and split the right half apart while lifting it horizontally by lightly tapping the projection a on it using a soft hammer. • When splitting it, leave the crankshaft and transmission with the left half.

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

ENG PUNTI DI RIMOZIONE Carter 1. Separare: • Carter destro • Carter sinistro Operazioni per la separazione: • Rimuovere i bulloni del carter 1, la guida flessibile 2 e il supporto cavo frizione 3. NOTA: Allentare ogni bullone di 1/4 di giro alla volta e dopo averli allentati tutti, rimuoverli. • Togliere il carter destro 4. NOTA: • Posizionare il carter con la parte sinistra rivolta verso il basso e separarlo dalla parte destra, sollevandola orizzontalmente, tramite leggeri martellamenti sulla sporgenza a utilizzando un mazzuolo a testa tenera. • Quando si effettua la divisione, lasciare la parte sinistra su carter e trasmissione. ATTENZIONE: Picchiettare sulla metà del carter con un martello morbido. Picchiettare solo sulle parti rinforzate del carter. Non picchiettare sulla superficie di contatto della guarnizione. Lavorare lentamente e con attenzione. Accertarsi che le metà del carter si separino uniformemente. Se le parti del carter non si separano, controllare che non vi siano viti o dispositivi di fissaggio ancora da togliere. Non forzare. • Rimuovere i grani di centraggio e la guarnizione circolare.

CRANKCASE AND CRANKSHAFT ENG Crankshaft 1. Remove: • Crankshaft 1 Use the crankcase separating tool 2. Crankcase separating tool: YU-1135-A/90890-01135 CAUTION: Do not use a hammer to drive out the crankshaft. Crankcase 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. Crankcase 1. Inspect: • Contacting surface a Scratches → Replace. • Engine mounting boss b, crankcase Cracks/damage → Replace.

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

CRANKCASE AND CRANKSHAFT ENG EC4N4201

55.95 ~ 56.00 mm (2.203 ~ 2.205 in)

Oil strainer 1. Inspect: • Oil strainer Damage → Replace.

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

CRANKCASE AND CRANKSHAFT ENG EC4N5000

• Screw [bearing stopper (crankshaft)] 1 T.

10 Nm (1.0 m · kg, 7.2 ft · lb)

To left and right crankcase. NOTE: • Install the bearing by pressing its outer race parallel. • To prevent the screw [bearing stopper (crankshaft)] from becoming loose, crush the screw head periphery a into the concave b using a punch etc. In so doing, take care not to damage the screwdriver receiving hole in the screw head. Crankshaft 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 Adapter (M12) 4: YU-90063/90890-01278 Spacer (crankshaft installer) 5: YU-91044/90890-04081

È For USA and CDN É Except for USA and CDN NOTE: • Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other. Operate the installing tool until the crankshaft bottoms against the bearing. • Before installing the crankshaft, clean the contacting surface of crankcase. CAUTION: Do not use a hammer to drive in the crankshaft. 4 - 95

ATTENZIONE: Non utilizzare un martello per far entrare l’albero motore.

CRANKCASE AND CRANKSHAFT ENG

2. Check: • Shifter operation • Transmission operation Unsmooth operation → Repair.

3. Install: • Oil strainer 1 • Bolt (oil strainer) 2 T.

5. Install: • Dowel pin 1 • O-ring 2 • Right crankcase To left crankcase. NOTE: • Fit the right crankcase onto the left crankcase. Tap lightly on the case with soft hammer. • When installing the crankcase, the connecting rod should be positioned at TDC (top dead center). 4 - 96

CRANKCASE AND CRANKSHAFT ENG

NOTE: Apply the lithium soap base grease on the Orings.

9. Remove: • Sealant Forced out on the cylinder mating surface. 10. Apply: • Engine oil To the crank pin, bearing and oil delivery hole. 11. Check: • Crankshaft and transmission operation. Unsmooth operation → Repair.

Togliere: • Sigillante Fatto fuoriuscire forzatamente dalla superficie di contatto del cilindro. 10. Applicare: • Olio motore Sul perno di biella, cuscinetto e foro di mandata dell’olio. 11. Controllare: • Funzionamento albero motore e trasmissione. Funzionamento non uniforme → Riparare.

TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG EC4H0000

TRANSMISSION, SHIFT CAM AND SHIFT FORK

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

Extent of removal: Extent of removal

TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVAL Engine Separate the crankcase.

Preparation for removal

Refer to “ENGINE REMOVAL” section. Refer to “CRANKCASE AND CRANKSHAFT” section. 1 1 1 1 1 1 1

Refer to “REMOVAL POINTS”.

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. EC4H4000

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

ASSEMBLY AND INSTALLATION Transmission 1. Install: • 5th pinion gear (24T) 1 • 3rd pinion gear (20T) 2 • Collar 3 • 4th pinion gear (22T) 4 • 2nd pinion gear (16T) 5 To main axle 6. NOTE: Apply the molybdenum disulfide oil on the inner and end surface of the idler gear and on the inner surface of the sliding gear, then install.

NOTA: Applicare l’olio al disolfuro di molibdeno sulla superficie interna e finale dell’ingranaggio folle e sulla superficie interna e finale dell’ingranaggio scorrevole, quindi installare.

TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG

2. Install: • 2nd wheel gear (28T) 1 • 4th wheel gear (27T) 2 • 3rd wheel gear (29T) 3 • 5th wheel gear (25T) 4 • 1st wheel gear (30T) 5 • O-ring 6 To drive axle 7. NOTE: • Apply the molybdenum disulfide oil on the inner and end surface of the idler gear and on the inner surface of the sliding gear, then install. • Apply the lithium soap base grease on the Oring.

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

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

NOTA: • Applicare il grasso a base di sapone di litio sul labbro del paraolio. • Quando si installa il collarino nel carter, prestare particolare attenzione al labbro del paraolio del carter.

TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG

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.

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

7. Check: • Shifter operation • Transmission operation Unsmooth operation → Repair.

1 Front wheel removal 3 Brake disc removal

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

Preparation for removal

2 Wheel bearing removal

Bolt (axle holder) Nut (front wheel axle) Front wheel axle Front wheel Collar Oil seal Bearing Brake disc

WARNING Support the machine securely so there is no danger of it falling over. 4 1 1 1 2 2 2 1

Refer to “REMOVAL POINTS”.

1 Rear wheel removal 3 Brake disc removal

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

Preparation for removal

2 Wheel bearing removal

1 2 3 4 5 6 7 8 9 10

Nut (rear wheel axle) Rear wheel axle Drive chain puller Rear wheel Collar Rear wheel sprocket Oil seal Circlip Bearing Brake disc

WARNING Support the machine securely so there is no danger of it falling over. 1 1 2 1 2 1 2 1 2 1

Refer to “REMOVAL POINTS”.

Refer to “REMOVAL POINTS”.

ROUE AVANT ET ROUE ARRIERE VORDER- UND HINTERRAD RUOTA ANTERIORE E POSTERIORE CHAS ROUE ARRIERE 1 Dépose de la roue arrière 3 Dépose du disque de frein

FRONT WHEEL AND REAR WHEEL CHAS 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.

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) 2. Inspect: • Bearing Rotate inner race with a finger. Rough spot/seizure → Replace. NOTE: Replace the bearings, oil seal and wheel collar as a set.

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.

Brake disc 1. Measure: • Brake disc deflection (only rear brake disc) Use the dial gauge 1. Out of specification → Inspect wheel runout. If wheel runout is in good condition, replace the brake disc. Brake disc deflection limit: Rear: <Limit>: 0.15 mm (0.006 in) 2. Measure: • Brake disc thickness a Out of limit → Replace. Brake disc thickness: Front: 3.0 mm (0.12 in) <Limit>: 2.5 mm (0.10 in) Rear: 4.0 mm (0.16 in) <Limit>: 3.5 mm (0.14 in)

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

12 Nm (1.2 m · kg, 8.7 ft · lb)

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

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

FRONT WHEEL AND REAR WHEEL CHAS

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

6. Install: • Nut (wheel axle) 1 T.

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.

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

FRONT WHEEL AND REAR WHEEL CHAS

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.

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

8. Install: • Right drive chain puller 1 • Washer 2 • Nut (wheel axle) 3 NOTE: Temporarily tighten the nut (wheel axle) at this point.

1 Brake hose removal 3 Brake master cylinder removal

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

Preparation for removal

2 Brake caliper removal

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

Drain the brake fluid. Brake hose holder (protector) Union bolt Brake hose Pad pin plug Pad pin

Refer to “REMOVAL POINTS”.

1 Brake master cylinder removal 3 Brake caliper removal

Preparation for removal

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

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

Refer to “FRONT WHEEL AND REAR WHEEL” section. Refer to “REMOVAL POINTS”.

1 Front brake caliper disassembly

Extent of removal: Extent of removal

Refer to “REMOVAL POINTS”.

1 Front brake master cylinder disassembly

Extent of removal: Extent of removal

2 Rear brake master cylinder disassembly Remarks

3. 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. Brake caliper piston 1. Remove: • Brake caliper piston Use compressed air and proceed carefully.

WARNING • Cover piston with rag and use extreme caution when expelling piston from cylinder. • Never attempt to pry out piston.

Caliper piston removal steps: • Insert a piece of rag into the brake caliper to lock one brake caliper. • Carefully force the piston out of the brake caliper cylinder with compressed air. È Front É Rear 5 - 14

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. È Front É Rear

INSPECTION Brake master cylinder 1. Inspect: • Brake master cylinder inner surface a Wear/scratches → Replace master cylinder assembly. Stains → Clean. WARNING Use only new brake fluid.

È Front É Rear 2. Inspect: • Diaphragm 1 Crack/damage → Replace. È Front É Rear 3. Inspect: (front brake only) • Reservoir float 1 Damage → Replace.

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

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

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

ASSEMBLY AND INSTALLATION WARNING • All internal parts should be cleaned in new brake fluid only. • Internal parts should be lubricated with brake fluid when installed. • Replace the piston seals and dust seals whenever a caliper is disassembled. 5 - 16

WARNING Always use new piston seals and dust seals. NOTE: Fit the piston seals and dust seals onto the slot on brake caliper correctly. È Front É Rear 3. Install: • Brake caliper piston 1

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

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

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

Brake master cylinder kit 1. Clean: • Brake master cylinder • Brake master cylinder kit Clean them with brake fluid. 2. Install: • Brake master cylinder cup (primary) 1 • Brake master cylinder cup (secondary) 2 To brake master cylinder piston 3. NOTE: Apply the brake fluid on the brake master cylinder cup. WARNING After installing, cylinder cup should be installed as shown direction. Wrong installation cause improper brake performance.

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

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

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

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 brake master cylinder.

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

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

7 Nm (0.7 m · kg, 5.1 ft · lb)

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

3. Pass the brake hose through the cable guide 1.

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

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

CAUTION: After installing the brake hose holders, make sure the brake hose does not contact the spring (rear shock absorber). If it does, correct its twist.

Brake fluid 1. Fill: • Brake fluid Until the fluid level reaches “LOWER” level line a.

Recommended brake fluid: DOT #4 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. È Front É Rear 5 - 24

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

[Rear] • Diaphragm • Brake master cylinder cap 1 • Bolt (brake master cylinder cap) 2

CAUTION: After installation, while pulling the brake lever in or pushing down on the brake pedal, check whether there is any brake fluid leaking where the union bolts are installed respectively at the brake master cylinder and brake caliper. È Front É Rear 5. Install: (rear brake only) • Protector 1 • Bolt (protector) 2 T.

1 Front fork removal

Extent of removal: Extent of removal

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

Preparation for removal

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

Refer to “FRONT WHEEL AND REAR WHEEL” section. Refer to “FRONT BRAKE AND REAR BRAKE” section. Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 4.

Pinch bolt (lower bracket) Front fork

Only loosening. Loosen when disassembling the front fork. Use special tool. Refer to “REMOVAL POINTS”. Only loosening.

Extent of removal: Extent of removal

2 Damper assembly removal

A B Fork spring Dust seal Stopper ring Inner tube Outer tube Piston metal Slide metal Oil seal washer Oil seal Base valve Damper assembly

1 1 1 1 1 1 1 1 1 1 1

Remarks Drain the fork oil. Use special tool. Refer to “REMOVAL POINTS”.

Refer to “REMOVAL POINTS”.

Drain the fork oil. Use special tool. Refer to “REMOVAL POINTS”.

FOURCHE TELESKOPGABEL FORCELLA ANTERIORE CHAS DEMONTAGE DE LA FOURCHE 1 Dépose de la bague d’étanchéité

HANDLING NOTE NOTE: The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers. CAUTION: To prevent an accidental explosion of air, the following instructions should be observed: • The front fork with a built-in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material. Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled. • Before removing the base valves or front forks, be sure to extract the air from the air chamber completely.

Chiave ad anello per tappo filettato: YM-01501/90890-01501

FRONT FORK CHAS Adjuster 1. Drain the outer tube of its front fork oil at its top. 2. Loosen: • Adjuster 1

3. Remove: • Adjuster 1 NOTE: • While compressing the inner tube 2, set the cap bolt ring wrench 4 between the inner tube and locknut 3. • Hold the locknut and remove the adjuster. CAUTION: Do not remove the locknut as the damper rod may go into the damper assembly and not be taken out. Cap bolt ring wrench: YM-01501/90890-01501

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 a the inner tube just before it bottoms out and then pull it back quickly b. • Repeat this step until the inner tube can be pulled out from the outer tube. 5 - 29

FOURCHE TELESKOPGABEL FORCELLA ANTERIORE CHAS Dispositif de réglage 1. Vidanger l’huile de fourche du fourreau par le haut. 2. Desserrer: • Dispositif de réglage 1

INSPECTION Damper assembly 1. Inspect: • Damper assembly 1 Bend/damage → Replace. • O-ring 2 Wear/damage → Replace. CAUTION: The front fork with a built-in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material. Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled.

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

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

FRONT FORK CHAS EC555000

ASSEMBLY AND INSTALLATION Front fork assembly 1. Wash the all parts in a clean solvent. 2. Stretch the damper assembly fully.

3. Fill: • Front fork oil 1 To damper assembly. Recommended oil: Suspension oil “S1” Oil capacity: 195 cm3 (6.86 Imp oz, 6.59 US oz) 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.

4. After filling, pump the damper assembly 1 slowly up and down (about 200 mm (7.9 in) stroke) several times to bleed the damper assembly of air. 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 2 to 4.

5. Measure: • Oil level (left and right) a Out of specification → Adjust. Standard oil level: 145 ~ 148 mm (5.71 ~ 5.83 in) From top of fully stretched damper assembly.

6. Tighten: • Locknut 1 NOTE: Fully finger tighten the locknut onto the damper assembly.

7. Loosen: • Compression damping adjuster 1 NOTE: • Loosen the compression damping adjuster finger tight. • Record the set position of the adjuster (the amount of turning out the fully turned in position).

8. Install: • Base valve 1 To damper assembly 2. NOTE: First bring the damper rod pressure to a maximum. Then install the base valve while releasing the damper rod pressure.

9. Check that the damper assembly is fully stretched. Not fully stretched → Repeat the steps 2 to 8.

29 Nm (2.9 m · kg, 21 ft · lb)

NOTE: Hold the damper assembly with the cap bolt ring wrench 2 and use the cap bolt wrench 3 to tighten the base valve with specified torque. Cap bolt wrench: YM-01500/90890-01500 Cap bolt ring wrench: YM-01501/90890-01501 11. After filling, pump the damper assembly 1 slowly up and down more than 10 times to distribute the fork oil.

12. While protecting the damper assembly 1 with a rag and compressing fully, allow excessive oil to overflow on the base valve side. CAUTION: Take care not to damage the damper assembly.

13. Allow the overflowing oil to escape at the hole a in the damper assembly.

14. Check: • Damper assembly smooth movement Tightness/binding/rough spots → Repeat the steps 2 to 13.

15. Install: • Dust seal 1 • Stopper ring 2 • Oil seal 3 • Oil seal washer 4 • Slide metal 5 To inner tube 6. NOTE: • Apply the fork oil on the inner tube. • When installing the oil seal, use vinyl seat a with fork oil applied to protect the oil seal lip. • Install the oil seal with its manufacture’s marks or number facing the axle holder side. • Install the oil seal washer with its projections b facing upward.

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

18. 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

19. 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

20. Install: • Stopper ring 1 NOTE: Fit the stopper ring correctly in the groove in the outer tube.

22. Check: • Inner tube smooth movement Tightness/binding/rough spots → Repeat the steps 15 to 21.

23. Measure: • Distance a Out of specification → Turn into the locknut. Distance a: 19 mm (0.75 in) or more Between the damper assembly 1 bottom and locknut 2 bottom. 24. Install: • Collar 1 • Fork spring 2 To damper assembly 3. NOTE: Install the collar with its larger dia. end a facing the fork spring.

25. Install: • Damper assembly 1 To inner tube 2. CAUTION: To install the damper assembly into the inner tube, hold the inner tube aslant. If the inner tube is held vertically, the damper assembly may fall into it, damaging the valve inside. 26. 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).

27. Install: • Push rod 1 • Copper washer 2 • Adjuster 3 To damper assembly 4. NOTE: • While compressing the inner tube 5, set the cap bolt ring wrench 7 between the inner tube and locknut 6. • Fully finger tighten the adjuster onto the damper assembly. Cap bolt ring wrench: YM-01501/90890-01501

28. Inspect: • Gap a between the adjuster 1 and locknut 2. Out of specification → Retighten and readjust the locknut. Gap a between the adjuster and locknut: 0.5 ~ 1.0 mm (0.02 ~ 0.04 in) NOTE: If the adjuster is installed out of specification, proper damping force cannot be obtained.

29. Tighten: • Adjuster (locknut) 1 T.

31. Fill: • Front fork oil 1 From outer tube top. Recommended oil: Suspension oil “S1” Standard oil amount: 340 cm3 (12.0 Imp oz, 11.5 US oz) Extent of adjustment: 300 ~ 380 cm3 (10.6 ~ 13.4 Imp oz, 10.1 ~ 12.8 US oz) WARNING Never fail to make the oil amount adjustment between the maximum and minimum amount and always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability. 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.

32. Install: • Damper assembly 1 To outer tube. NOTE: Temporarily tighten the damper assembly.

33. Install: • Protector guide 1 NOTE: Install the protector guide with its wider side a facing downward.

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

2. Tighten: • Damper assembly 1 T.

7 Nm (0.7 m · kg, 5.1 ft · lb)

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

7. Adjust: • Compression damping force NOTE: Turn in the damping adjuster 1 finger-tight and then turn out to the originally set position.

Extent of removal: Extent of removal

Preparation for removal

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Part name HANDLEBAR REMOVAL Number plate Hot starter cable Hot starter lever holder Clutch cable Clutch lever holder Engine stop switch Brake master cylinder Throttle cable cap Throttle cable #1 (pulled) Throttle cable #2 (pushed) Right grip Tube guide Collar Left grip Handlebar upper holder Handlebar Handlebar lower holder

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

Remarks Remove the band only. Disconnect at the lever side. Disconnect at the lever side.

Refer to “REMOVAL POINTS”. Disconnect at the throttle side. Disconnect at the throttle side. Refer to “REMOVAL POINTS”.

Refer to “REMOVAL POINTS”.

GUIDON LENKER MANUBRIO CHAS GUIDON 1 Dépose du guidon

HANDLEBAR CHAS EC5B3000

REMOVAL POINTS Brake master cylinder 1. Remove: • Brake master cylinder bracket 1 • Brake master cylinder 2 CAUTION: • Do not let the brake master cylinder hang on the brake hose. • Keep the brake master cylinder cap side horizontal to prevent air from coming in. EC5B3200

Grip 1. Remove: • Grip 1 NOTE: Blow in air between the handlebar or tube guide and the grip. Then remove the grip which has become loose. EC5B4000

Handlebar 1. Inspect: • Handlebar 1 Bends/cracks/damage → Replace. WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar. EC5B5000

ASSEMBLY AND INSTALLATION Handlebar 1. Install: • Handlebar lower holder 1 • Washer 2 • Nut (handlebar lower holder) 3 NOTE: • Install the handlebar lower holder with its side having the greater distance a from the mounting bolt center facing forward. • Apply the lithium soap base grease on the thread of the handlebar lower holder. • Installing the handlebar lower holder in the reverse direction allows the front-to-rear offset amount of the handlebar position to be changed. • Do not tighten the nut yet. 5 - 44

GUIDON LENKER MANUBRIO POINTS DE DEPOSE Maître-cylindre de frein 1. Déposer: • Support de maître-cylindre de frein 1 • Maître-cylindre de frein 2 ATTENTION: • Veiller à ce que le maître-cylindre de frein ne repose pas sur la durit de frein. • Maintenir le couvercle du maîtrecylindre de frein à l’horizontale afin d’éviter toute pénétration d’air. Poignée 1. Déposer: • Poignée 1 N.B.: Souffler de l’air entre le guidon ou le guide de tube et la poignée. Retirer ensuite la poignée ainsi libérée.

NOTE: • The handlebar upper holder should be installed with the punched mark a forward. • Install the handlebar so that the marks b are in place on both sides. • Install the handlebar so that the projection c of the handlebar upper holder is positioned at the mark on the handlebar as shown. • First tighten the bolts on the front side of the handlebar upper holder, and then tighten the bolts on the rear side.

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

5. Install: • Right grip 1 • Collar 2 Apply the adhesive on the tube guide 3. NOTE: • Before applying the adhesive, wipe off grease or oil on the tube guide surface a with a lacquer thinner. • Install the grip to the tube guide so that the grip match mark b and tube guide slot c form the angle as shown.

c 3 6. Install: • Collar 1 • Grip cap cover 2 • Throttle grip 3 NOTE: Apply the lithium soap base grease on the throttle grip sliding surface.

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: • Grip cap cover 1 • Cover (throttle cable cap) 2

10. Install: • Brake master cylinder 1 • Brake master cylinder bracket 2 • Bolt (brake master cylinder bracket) 3 T.

NOTE: • Install the bracket so that the arrow mark a faces upward. • First tighten the bolt on the upper side of the brake master cylinder bracket, and then tighten the bolt on the lower side. 5 - 47

• Clamp 6 NOTE: • The engine stop switch, clutch lever holder and clamp should be installed according to the dimensions shown. • Pass the engine stop switch lead in the middle of the clutch lever holder.

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.

13. Adjust: • Clutch lever free play Refer to “CLUTCH ADJUSTMENT” section in the CHAPTER 3. • Hot starter lever free play Refer to “HOT STARTER LEVER ADJUSTMENT” section in the CHAPTER 3.

1 Lower bracket removal

Extent of removal: Extent of removal

STEERING REMOVAL Hold the machine by placing the suitable stand under the engine. Number plate

Preparation for removal

2 Bearing removal Remarks WARNING Support the machine securely so there is no danger of it falling over. Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 4. Refer to “HANDLEBAR” section.

Lower bracket Bearing race cover Upper bearing Lower bearing Bearing race

Refer to “FRONT FORK” section. Use special tool. Refer to “REMOVAL POINTS”.

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

DIRECTION LENKUNG STERZO CHAS DIRECTION 1 Dépose du té inférieur

STEERING CHAS EC563000

REMOVAL POINTS Steering ring nut 1. Remove: • Steering ring nut 1 Use the steering nut wrench 2. Steering nut wrench: YU-33975/90890-01403 WARNING Support the steering stem so that it may not fall down.

Lower bearing 1. Remove: • Lower bearing 1 Use the floor chisel 2. CAUTION: Take care not to damage the steering shaft thread.

Bearing race 1. Remove: • Bearing race 1 Remove the bearing race using long rod 2 and the hammer.

STEERING CHAS Bearing and bearing race 1. Wash the bearings and bearing races with a solvent. 2. Inspect: • Bearing 1 • Bearing race Pitting/damage → Replace bearings and bearing races as a set. Install the bearing in the bearing races. Spin the bearings by hand. If the bearings hang up or are not smooth in their operation in the bearing races, replace bearings and bearing races as a set.

ASSEMBLY AND INSTALLATION Lower bracket 1. Install: • Lower bearing 1 NOTE: Apply the lithium soap base grease on the dust seal lip and bearing inner circumference.

2. Install: • Bearing race • Upper bearing 1 • Bearing race cover 2 NOTE: Apply the lithium soap base grease on the bearing and bearing race cover lip.

3. Install: • Lower bracket 1 NOTE: Apply the lithium soap base grease on the bearing, the portion a and thread of the steering stem.

7 Nm (0.7 m · kg, 5.1 ft · lb)

Tighten the steering ring nut using the steering nut wrench 2. Refer to “STEERING HEAD INSPECTION AND ADJUSTMENT” section in the CHAPTER 3.

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

6. Install: • Washer 1

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

Extent of removal: Extent of removal

SWINGARM REMOVAL Hold the machine by placing the suitable stand under the engine.

Preparation for removal

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

Brake hose holder Rear brake caliper

Bolt (brake pedal) Drive chain Drive chain support Lower chain tensioner Bolt (rear shock absorber-relay arm) Bolt (connecting rod) Pivot shaft Swingarm

1 Swingarm disassembly 3 Relay arm removal and disassembly

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

Q’ty 2 1 1 2 2 2 2 8 10

2 Connecting rod removal and disassembly Remarks Refer to “REMOVAL POINTS”.

Refer to “REMOVAL POINTS”.

BRAS OSCILLANT SCHWINGE FORCELLONE OSCILLANTE CHAS DEMONTAGE DU BRAS OSCILLANT 1 Démontage du bras oscillant 3 Dépose et démontage du bras relais

REMOVAL POINTS Cap 1. Remove: • Left cap 1 NOTE: Remove with a slotted-head screwdriver inserted under the mark a on the left cap.

Bearing 1. Remove: • Bearing 1 NOTE: Remove the bearing by pressing its outer race.

INSPECTION Wash the bearings, bushings and collars in a solvent. Swingarm 1. Inspect: • Bearing 1 • Bushing 2 Free play exists/unsmooth revolution/rust → Replace bearing and bushing as a set. 2. Inspect: • Oil seal 3 Damage → Replace.

Relay arm 1. Inspect: • Bearing 1 • Collar 2 Free play exists/unsmooth revolution/rust → Replace bearing and collar as a set. 2. Inspect: • Oil seal 3 Damage → Replace. 5 - 56

BRAS OSCILLANT SCHWINGE FORCELLONE OSCILLANTE CHAS POINTS DE DEPOSE Capuchon 1. Déposer: • Capuchon gauche 1

SWINGARM CHAS 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 a: Zero mm (Zero in) Inner b: 6.5 mm (0.26 in)

2. Install: • Bearing 1 • 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 washer. Installed depth of bearings a: Zero mm (Zero in)

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 a: Zero mm (Zero in)

Swingarm 1. Install: • Bushing 1 • Thrust bearing 2 • Oil seal 3 • Collar 4 To swingarm 5. NOTE: Apply the molybdenum disulfide grease on the bushings, thrust bearings, oil seal lips and contact surfaces of the collar and thrust bearing.

2. Install: • Collar 1 • Washer 2 To relay arm 3. NOTE: Apply the molybdenum disulfide grease on the collars and oil seal lips.

3. Install: • Collar 1 To connecting rod 2. NOTE: Apply the molybdenum disulfide grease on the collar and oil seal lips.

NOTE: • Apply the molybdenum disulfide grease on the pivot shaft. • Insert the pivot shaft from right side. 7. Check: • Swingarm side play a Free play exists → Replace thrust bearing. • Swingarm up and down movement b Unsmooth movement/binding/rough spots → Grease or replace bearings, bushings and collars.

9. Install: • Bolt (rear shock absorber-relay arm) 1 • Nut (rear shock absorber-relay arm) 2 T.

12. Install: • Cap 1 NOTE: Install the right cap with its mark a facing forward.

14. Install: • Drive chain support 1 • Drive chain support cover 2 • Bolt {drive chain support [ = 50 mm (1.97 in)]} 3 • Nut (drive chain support) 4 T.

7 Nm (0.7 m · kg, 5.1 ft · lb)

• Bolt {drive chain support cover [ = 10 mm (0.39 in)]} 5 T.

1 Rear shock absorber removal

Extent of removal: Extent of removal

2 Rear shock absorber disassembly Q’ty

REAR SHOCK ABSORBER REMOVAL Hold the machine by placing the suitable stand under the engine. Seat

Preparation for removal

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

Clamp (air filter joint) Rear frame Bolt (rear shock absorber-relay arm) Bolt (rear shock absorber-frame) Rear shock absorber Locknut Adjuster Spring seat Lower spring guide

Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 4. Refer to “EXHAUST PIPE AND SILENCER” section in the CHAPTER 4. Only loosening. Hold the swingarm.

Only loosening. Only loosening.

AMORTISSEUR ARRIERE FEDERBEIN AMMORTIZZATORE POSTERIORE CHAS AMORTISSEUR ARRIERE 1 Dépose de l’amortisseur arrière

Refer to “REMOVAL POINTS”.

Fare riferimento a “PUNTI DI RIMOZIONE”.

REAR SHOCK ABSORBER CHAS HANDLING NOTE WARNING This rear shock absorber is provided with a separate type tank filled with high-pressure nitrogen gas. To prevent the danger of explosion, read and understand the following information before handling the shock absorber. The manufacturer can not be held responsible for property damage or personal injury that may result from improper handling. 1. Never tamper or attempt to disassemble the cylinder or the tank. 2. Never throw the rear shock absorber into an open flame or other high heat. The rear shock absorber may explode as a result of nitrogen gas expansion and/ or damage to the hose. 3. Be careful not to damage any part of the gas tank. A damaged gas tank will impair the damping performance or cause a malfunction. 4. Take care not to scratch the contact surface of the piston rod with the cylinder; or oil could leak out. 5. Never attempt to remove the plug at the bottom of the nitrogen gas tank. It is very dangerous to remove the plug. 6. When scrapping the rear shock absorber, follow the instructions on disposal.

NOTES ON DISPOSAL (YAMAHA DEALERS ONLY) Before disposing the rear shock absorber, be sure to extract the nitrogen gas from valve 1. Wear eye protection to prevent eye damage from escaping gas and/or metal chips. WARNING To dispose of a damaged or worn-out rear shock absorber, take the unit to your Yamaha dealer for this disposal procedure. 5 - 64

AMORTISSEUR ARRIERE FEDERBEIN AMMORTIZZATORE POSTERIORE REMARQUES CONCERNANT LA MANIPULATION HANDHABUNGSHINWEISE WARNUNG AVERTISSEMENT Cet amortisseur arrière est équipé d’un réservoir indépendant contenant de l’azote sous haute pression. Afin d’éviter tout danger d’explosion, lire attentivement les informations ci-dessous avant de manipuler l’amortisseur arrière. Le fabricant décline toute responsabilité pour les dommages matériels ou corporels résultant d’une mauvaise manipulation. 1. Ne jamais essayer de démonter le cylindre ou le réservoir. 2. Ne jamais jeter un amortisseur usagé au feu ou l’exposer à une chaleur intense. L’amortisseur arrière risque d’exploser en raison de la dilatation de l’azote et/ou de l’endommagement de la durit. 3. Veiller à n’endommager aucune partie du réservoir de gaz. Un réservoir endommagé affectera la capacité d’amortissement ou entraînera un mauvais fonctionnement. 4. Veiller à ne pas rayer la surface de contact de la tige de piston avec le cylindre afin d’éviter tout risque de fuite d’huile. 5. Ne jamais essayer d’enlever le bouchon du fond du réservoir d’azote. Il est très dangereux d’enlever ce bouchon. 6. Pour la mise au rebut de l’amortisseur, suivre les instructions spécifiques.

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.

INSPECTION Rear shock absorber 1. Inspect: • Damper rod 1 Bends/damage → Replace rear shock absorber assembly. • Shock absorber 2 Oil leaks → Replace rear shock absorber assembly. Gas leaks → Replace rear shock absorber assembly. • Spring 3 Damage → Replace spring. Fatigue → Replace spring. Move spring up and down. • Spring guide 4 Wear/damage → Replace spring guide. • Spring seat 5 Cracks/damage → Replace. • Bearing 6 Free play exists/unsmooth revolution/rust → Replace. 5 - 65

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.

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

3. Install: • Lower bearing 1 NOTE: Install the bearing by pressing it on the side having the manufacture’s marks or numbers. Installed depth of the bearing a: 4 mm (0.16 in)

Spring (rear shock absorber) 1. Install: • Spring 1 • Upper spring guide 2 • Lower spring guide 3

2. Install: • Spring seat 1 NOTE: Install the spring seat with the projection a brought into contact with the spring end, as shown.

3. Tighten: • Adjuster 1

4. Adjust: • Spring length (installed) Refer to “REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT” section in the CHAPTER 3.

5. Tighten: • Locknut 1

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 Orings. 5 - 67

2. Install: • Bushing 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.

7. Tighten: • Bolt (air filter joint) 1

W White Y Yellow B/L Black/Blue B/W Black/White B/Y Black/Yellow G/BGreen/Black L/W Blue/White R/WRed/White

WIRING DIAGRAM B/W B/W G/B G/B L Y B/L Y Sb

Y W L L W G B/L B/L G P B/Y B/Y P Br

B/W G/B G/B B/W Y L Sb

IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. Spark

*Clean or replace spark plug.

No spark Check entire ignition system for connection. (couplers, leads and ignition coil)

Check engine stop switch.

OK Check ignition coil.

OK Check CDI magneto.

OK Primary coil Secondary coil

Pickup coil Charging coil

Check neutral switch.

OK Replace CDI unit. *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

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. • Ignition coil 3 • Spark plug 4

È For USA and CDN É Except for USA and CDN

4. Kick the kickstarter crank. 5. Check the ignition spark gap. 6. Start engine, and increase spark gap until misfire occurs. (for USA and CDN only) Minimum spark gap: 6.0 mm (0.24 in)

COUPLERS, LEADS AND IGNITION COIL CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. • Ignition coil and spark plug as they are fitted Push in the ignition coil until it closely contacts the spark plug hole in the cylinder head cover.

ENGINE STOP SWITCH INSPECTION 1. Inspect: • Engine stop switch conduct Tester (+) lead → Black/White lead 1 Tester (–) lead → Black lead 2

No continuous while being pushed → Replace. Continuous while being freed → Replace. 6-3

IGNITION COIL INSPECTION 1. Inspect: • Primary coil resistance Out of specification → Replace. Tester (+) lead → Orange lead 1 Tester (–) lead → Black lead 2 Primary coil resistance

0.08 ~ 0.10 Ω at 20 °C (68 °F)

2. Inspect: • Secondary coil resistance Out of specification → Replace. Tester (+) lead → Orange lead 1 Tester (–) lead → Spark plug terminal 2 Secondary coil resistance

4.6 ~ 6.8 kΩ at 20 °C (68 °F)

3. Inspect: • Sealed portion of ignition coil a • Spark plug terminal pin b • Threaded portion of spark plug c Wear → Replace. CDI MAGNETO INSPECTION 1. Inspect: • Pickup coil resistance Out of specification → Replace.

P R G B Tester (+) lead → Red lead 1 Tester (–) lead → White lead 2

Pickup coil resistance

2. Inspect: • Charging coil 1 resistance Out of specification → Replace.

Tester (+) lead → Brown lead 1 Tester (–) lead → Green lead 2

P R G B Charging coil 1 resistance

720 ~ 1,080 Ω at 20 °C (68 °F)

3. Inspect: • Charging coil 2 resistance Out of specification → Replace.

Tester (+) lead → Pink lead 1 Tester (–) lead → Black lead 2 Charging coil 2 resistance

Tester (+) lead → Sky blue lead 1 Tester (–) lead → Ground 2

No continuous while in neutral → Replace. Continuous 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. 6-5

SYSTEME D’ALLUMAGE ZÜNDSYSTEM IMPIANTO DI ACCENSIONE 2.

THROTTLE POSITION SENSOR SYSTEM INSPECTION STEPS If the throttle position sensor will not operate, use the following inspection steps. No good

Check entire ignition system for connection.

OK Check throttle position sensor.

Throttle position sensor coil

Throttle position sensor input voltage

* marked: Refer to “IGNITION SYSTEM” section.

NOTE: Use the following special tools in this inspection. Pocket tester: YU-3112-C/90890-03112

HANDLING NOTE CAUTION: Do not loosen the screws (throttle position sensor) 1 except when changing the throttle position sensor due to failure because it will cause a drop in engine performance.

COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace.

THROTTLE POSITION SENSOR COIL INSPECTION 1. Inspect: • Throttle position sensor coil resistance Out of specification → Replace. Tester (+) lead → Blue lead 1 Tester (–) lead → Black lead 2 Throttle position sensor coil resistance

Tester selector position

4 ~ 6 kΩ at 20 °C (68 °F)

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

3. Inspect: • Throttle position sensor coil variable resistance Check that the resistance in increased as the throttle grip is moved from the full close position to the full open position. Out of specification → Replace. Tester (+) lead → Yellow lead 1 Tester (–) lead → Black lead 2 Throttle position sensor coil variable resistance Full closed

NOTE: • Align the slot a in the throttle position sensor with the projection b on the carburetor. • Temporarily tighten the screws (throttle position sensor).

5. Install: • Carburetor • Throttle position sensor coupler 6. Adjust: • Engine idling speed Refer to “ENGINE IDLING SPEED ADJUSTMENT” section in the CHAPTER 3.

7. Insert the thin electric conductors 2 (lead) into the throttle position sensor coupler 1, as shown, and connect the tester to them. Tester (+) lead → Yellow lead 3 Tester (–) lead → Black lead 4 CAUTION: • Do not insert the electric conductors more than required because it may reduce the waterproof function of the coupler. • Make sure that a short-circuit does not develop between the terminals because it may cause damage to electrical components. 8. Start the engine.

9. Adjust: • Throttle position sensor output voltage Adjustment steps: Adjust the installation angle of the throttle position sensor 1 to obtain the specified output voltage. NOTE: Measure the output voltage accurately with a digital electronic voltmeter that gives an easy reading of a small voltage.

THROTTLE POSITION SENSOR INPUT VOLTAGE INSPECTION 1. Disconnect the throttle position sensor coupler. 2. Start the engine. 3. Inspect: • Throttle position sensor input voltage Out of specification → Replace the CDI unit. Tester (+) lead → Blue lead 1 Tester (–) lead → Black/Blue lead 2

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

TUN CAUTION: The carburetor is extremely sensitive to foreign matter (dirt, sand, water, etc.). During installation, do not allow foreign matter to get into the carburetor. Always handle the carburetor and its components carefully. Even slight scratches, bends or damage to carburetor parts may prevent the carburetor from functioning correctly. Carefully perform all servicing with the appropriate tools and without applying excessive force. When the engine is stopped or when riding at no load, do not open and close the throttle unnecessarily. Otherwise, too much fuel may be discharged, starting may become difficult or the engine may not run well. After installing the carburetor, check that the throttle operates correctly and opens and closes smoothly.

Atmospheric conditions and carburetor settings Air temp.

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.

SETTING TUN Effects of the setting parts on the throttle valve opening

È Closed É Fully open 1 Pilot screw/pilot jet 2 Throttle valve cutaway 3 Jet needle 4 Main jet

Main system The FLATCR carburetor has a primary main jet. This type of main jet is perfect for racing 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. Pilot system The FLATCR carburetor is manufactured with a pilot screw. The pilot screw adjustment ranges from fully closed throttle to 1/4 open throttle.

1 Jet needle 2 Pilot air jet 3 Needle jet 4 Main jet 5 Pilot jet 6 Pilot screw

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

If the air-fuel mixture is too rich or too lean, the engine power will drop, resulting in poor acceleration. Effects of changing the main jet (reference) È

SETTING TUN Pilot screw adjustment The richness of the air-fuel mixture with the throttle fully closed to 1/4 open can be set by turning the pilot screw 1. Turning in the pilot screw will make the mixture lean at low speeds, and turning it out will enrich it.

1 Standard pilot screw position (example)

* Except for USA and CDN NOTE: • If the engine idling speed fluctuates, turn the pilot screw only 1/2 of a turn in either direction. • To optimize the fuel flow at a smaller throttle opening, each machine’s pilot screw has been individually set at the factory. Before adjusting the pilot screw, turn it in fully and count the number of turns. Record this number as the factory-set number of turns out. Effects of adjusting the pilot screw (reference) È

Pilot jet adjustment The richness of the air-fuel mixture with the throttle open 1/4 or less can be set by adjusting the pilot jet 1. Standard pilot jet

SETTING TUN Effects of adjusting the pilot jet (reference) È

Jet needle groove position adjustment Adjusting the jet needle 1 position affects the acceleration when the throttle is 1/8 to 3/4 open. 1. Too rich at intermediate speeds Rough engine operation is felt and the engine will not pick up speed smoothly. In this case, step up the jet needle clip by one groove and move down the needle to lean out the mixture. 2. Too lean at intermediate speeds The engine breathes hard and will not pick up speed quickly. Step down the jet needle clip by one groove and move up the needle to enrich the mixture. Standard clip position

Effects of changing the jet needle groove position (reference) È

Minimo Completamente aperto Scanalatura n. 4 Scanalatura n. 2 Scanalatura n. 3

SETTING TUN Jet needle adjustment The jet needle is adjusted by changing it. Standard jet needle

OBEPQ The tapered sections of all jet needles have the same starting positions, but the needles are available with different straight-portion diameters. <Example> OBEPQ - 4 Clip position Diameter a 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. È

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.

SETTING TUN Leak jet adjustment (accelerator pump adjustment) The leak jet 1 is a setting part that adjusts the flow of fuel discharged by the accelerator pump. Since the accelerator pump operates only when throttle is open, the leak jet is used to adjust a fuel mixture ratio for quick throttle opening and is therefore different from other setting parts that adjust a fuel mixture for each throttle opening (each engine speed). 1. The engine breathes hard in quick throttle opening. Select a leak jet having lower calibrating No. than standard to enrich the mixture. <Example> #80 → #70 2. Rough engine operation is felt in quick throttle opening. Select a leak jet having higher calibrating No. than standard to lean out the mixture. <Example> #80 → #90

Standard leak jet * Except for USA and CDN

Carburetor setting parts Part name Main jet Rich

Size #188 #185 #182 #180 #178 #175 #172 #170 #168 #48 #45 #42 #40 #38 OBEPM OBEPN OBEPP OBEPQ OBEPR OBEPS OBEPT #50 #60 #70 #80 #90 #100 #110 #40 #50 #60 #70 #80 #90 #100

* Except for USA and CDN

OBEPM OBEPN OBEPP OBEPQ OBEPR OBEPS OBEPT

OBEPM OBEPN OBEPP OBEPQ OBEPR OBEPS OBEPT

OBEPM OBEPN OBEPP OBEPQ OBEPR OBEPS OBEPT

SETTING TUN Examples of carburetor setting depending on symptom Symptom

At full throttle Hard breathing Shearing noise Whitish spark plug

Increase main jet calibration no. (Gradually)

At full throttle Speed pick-up stops Slow speed pick-up Slow response Sooty spark plug Rich mixture Lean mixture Rich mixture 1/4 ~ 3/4 throttle Hard breathing Lack of speed 1/4 ~ 1/2 throttle Slow speed pick-up Poor acceleration

Closed to 1/4 throttle Hard breathing Speed down Closed to 1/4 throttle Poor acceleration

Decrease main jet calibration no. (Gradually)

Lower jet needle clip position. (1 groove down) Raise jet needle clip position. (1 groove up) Lower jet needle clip position. (1 groove down) Raise jet needle clip position. (1 groove up)

Use jet needle with a smaller diameter.

Discoloration of spark plug → If tan color, it is in good condition. If cannot be corrected: Clogged float valve seat Clogged fuel hose Clogged fuel cock Check that the accelerator pump operates smoothly. Discoloration of spark plug → If tan color, it is in good condition. If cannot be corrected: Clogged air filter Fuel overflow from carburetor

The clip position is the jet needle groove on which the clip is installed. The positions are numbered from the top. Check that the accelerator pump operates smoothly. (except for rich mixture symptom). Slow-speed-circuit passage Clogged → Clean. Overflow from carburetor

Use jet needle with a larger diameter. Raise jet needle clip position. (1 groove up) Poor response in the low to Raise jet needle clip position. intermediate speeds If this has no effect, lower the jet needle clip position. Check air filter for fouling. Poor response when throttle Check overall settings. is opened quickly Use main jet with a lower calibration no. Raise jet needle clip position. (1 groove up) If these have no effect, use a main jet with a higher calibration no. and lower Check that the accelerator pump operthe jet needle clip position. ates smoothly.

should be taken simply for an example. It is necessary to set the carburetor while checking * This the operating conditions of the engine.

CHASSIS Selection of the secondary reduction ratio (Sprocket) Secondary reduction ratio

Number of rear wheel sprocket teeth Number of drive sprocket teeth

Standard secondary reduction ratio

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

Tire pressure Tire pressure should be adjust to suit the road surface condition of the circuit. Standard tire pressure: 100 kPa (1.0 kgf/cm2, 15 psi) • Under a rainy, muddy, sandy, or slippery condition, the tire pressure should be lower for a larger area of contact with the road surface. Extent of adjustment: 60 ~ 80 kPa (0.6 ~ 0.8 kgf/cm2, 9.0 ~ 12 psi) • Under a stony or hard road condition, the tire pressure should be higher to prevent a flat tire. Extent of adjustment: 100 ~ 120 kPa (1.0 ~ 1.2 kgf /cm2, 15 ~ 18 psi)

SETTING TUN Front fork setting The front fork setting should be made depending on the rider’s feeling of an actual run and the circuit conditions. The front fork setting includes the following three factors: 1. Setting of air spring characteristics • Change the fork oil amount. 2. Setting of spring preload • Change the spring. 3. Setting of damping force • Change the compression damping. • Change the rebound damping. The spring acts on the load and the damping force acts on the cushion travel speed. Change in amount and characteristics of fork oil Damping characteristic near the final stroke can be changed by changing the fork oil amount. CAUTION: Adjust the oil amount in 5 cm3 (0.2 Imp oz, 0.2 US oz) increments or decrements. Too small oil amount 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 large oil amount will cause the air spring characteristics to have a tendency to be stiffer with the consequent deteriorated performance and characteristics. Therefore, adjust the front fork within the specified range. Standard oil amount: 340 cm3 (12.0 Imp oz, 11.5 US oz) Extent of adjustment: 300 ~ 380 cm3 (10.6 ~ 13.4 Imp oz, 10.1 ~ 12.8 US oz) È Air spring characteristics in relation to oil amount change É Load Ê Stroke 1 Max. oil amount 2 Standard oil amount 3 Min. oil amount

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.

SETTING TUN Front fork setting parts • Front fork spring 1

IIIII I-I I-II I-III I-IIII NOTE: The I.D. mark (slits) a is proved on the end of the spring.

Rear suspension setting The rear suspension setting should be made depending on the rider’s feeling of an actual run and the circuit conditions. The rear suspension setting includes the following two factors: 1. Setting of spring preload • Change the set length of the spring. • Change the spring. 2. Setting of damping force • Change the rebound damping. • Change the compression damping.

SETTING TUN EC72C001

Choosing set length 1. Place a stand or block under the engine to put the rear wheel above the floor, and measure the length a between the rear wheel axle center and the rear fender holding bolt.

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

3. Loosen the locknut 1 and make adjustment by turning the spring adjuster 2 to achieve the standard figure from the subtraction of the length b from the length a. Standard figure: 90 ~ 100 mm (3.5 ~ 3.9 in) NOTE: • If the machine is new and after it is broken in, the same set length of the spring may change because of the initial fatigue, etc. of the spring. Therefore, be sure to make reevaluation. • If the standard figure cannot be achieved by adjusting the spring adjuster and changing the spring set length, replace the spring with an optional one and make re-adjustment.

SETTING TUN Setting of spring after replacement After replacement, be sure to adjust the spring to the set length [sunken length 90 ~ 100 mm (3.5 ~ 3.9 in)] and set it. 1. Use of soft spring • Set the soft spring for less rebound damping to compensate for its less spring load. Run with the rebound damping adjuster one or two clicks on the softer side and readjust it to suit your preference. 2. Use of stiff spring • Set the soft spring for more rebound damping to compensate for its greater spring load. Run with the rebound damping adjuster one or two clicks on the stiffer side and readjust it to suit your preference. Adjusting the rebound damping will be followed more or less by a change in the compression damping. For correction, turn the low compression damping adjuster on the softer side.

CAUTION: When using a rear shock absorber other than currently installed, use the one whose overall length a does not exceed the standard as it may result in faulty performance. Never use one whose overall length is greater than standard. Length a of standard shock: 490 mm (19.29 in)

Rear shock absorber setting parts • Rear shock spring 1 [Equal-pitch titanium spring] SPRING TYPE SPRING RATE PART NUMBER SOFT STD

[Equal-pitch steel spring] SPRING TYPE SPRING RATE PART NUMBER

[Unequal-pitch steel spring] SPRING RATE (approx.) SOFT 4.5 4.7 4.9 5.1 5.3 5.5 STIFF 5.7

TYPE SPRING PART NUMBER 5UN-22212-A0 5UN-22212-B0 5UN-22212-C0 5UN-22212-D0 5UN-22212-E0 5UN-22212-F0 5UN-22212-G0

I.D. SPRING MARK/ FREE Q’TY LENGTH Green/2 275 Red/2 275 Black/2 275 Blue/2 275 Yellow/2 275 Pink/2 275 White/2 275

CAUTION: Install the spring seat 2 to the titanium spring. NOTE: • The unequal-pitch spring is softer in initial characteristic than the equal-pitch spring and is difficult to bottom out under full compression. • The I.D. mark a is marked at the end of the spring. • Spring specification varies according to the color and quantity of I.D. marks.

• Extent of adjustment (spring length) [Titanium spring]

TUN SETTING EC72H002

Suspension setting • Front fork NOTE: • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90 ~ 100 mm (3.5 ~ 3.9 in). Section Symptom

Stiff over entire range

Unsmooth movement over entire range

Poor initial movement

Soft over entire range, bottoming out

Turn adjuster counterclockwise (about 2 clicks) to decrease damping.

Decrease oil amount by about 5 ~ 10 cm3 (0.2 ~ 0.4 Imp oz, 0.2 ~ 0.3 US oz).

Replace with soft spring.

Outer tube Inner tube

Check for any bends, dents, and other noticeable scars, etc. If any, replace affected parts.

Replace with a new one for extended use.

Replace with a new one for extended use.

Under bracket tightening torque

Retighten to specified torque.

Turn adjuster counterclockwise (about 2 clicks) to decrease damping.

Apply grease in oil seal wall.

Turn adjuster clockwise (about 2 clicks) to increase damping.

Increase oil amount by about 5 ~ 10 cm3 (0.2 ~ 0.4 Imp oz, 0.2 ~ 0.3 US oz).

Replace with stiff spring.

Stiff toward stroke end

Decrease oil amount by about 5 cm3 (0.2 Imp oz, 0.2 US oz).

Soft toward stroke end, bottoming out

Increase oil amount by about 5 cm3 (0.2 Imp oz, 0.2 US oz).

Stiff initial movement

Turn adjuster counterclockwise (about 2 clicks) to decrease damping.

Low front, tending to lower front posture

“Obtrusive” front, tending to upper front posture

Turn adjuster clockwise (about 2 clicks) to increase damping.

Turn adjuster counterclockwise (about 2 clicks) to decrease damping.

Balance with rear end

Set sunken length for 95 ~ 100 mm (3.7 ~ 3.9 in) when one passenger is astride seat (lower rear posture).

Increase oil amount by about 5 cm3 (0.2 Imp oz, 0.2 US oz).

Turn adjuster counterclockwise (about 2 clicks) to decrease damping.

Balance with rear end

Set sunken length for 90 ~ 95 mm (3.5 ~ 3.7 in) when one passenger is astride seat (upper rear posture).

Replace with soft spring.

Decrease oil amount by about 5 ~ 10 cm3 (0.2 ~ 0.4 Imp oz, 0.2 ~ 0.3 US oz).

TUN SETTING • Rear shock absorber

NOTE: • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Adjust the rebound damping in 2-click increments or decrements. • Adjust the low compression damping in 1-click increments or decrements. • Adjust the high compression damping in 1/6 turn increments or decrements. Section Symptom

Stiff, tending to sink

Turn adjuster counterclockwise (about 2 clicks) to decrease damping.

Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when one passenger is astride seat.

Turn adjuster clockwise (about 2 clicks) to increase damping.

Low compression damping

Turn adjuster clockwise (about 1 click) to increase damping.

Replace with stiff spring.

Turn adjuster counterclockwise (about 2 clicks) to decrease damping.

Replace with soft spring.

Turn adjuster counterclockwise (about 2 clicks) to decrease damping.

Low compression damping

Turn adjuster clockwise (about 1 clicks) to increase damping.

High compression damp- Turn adjuster clockwise (about 1/6 clicks) to ing increase damping. Spring set length

Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when one passenger is astride seat.

Replace with soft spring.

High compression damp- Turn adjuster clockwise (about 1/6 turn) to increase ing damping. Bottoming out

Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when one passenger in astride seat.

Replace with stiff spring.

Turn adjuster clockwise (about 2 clicks) to increase damping.

Replace with soft spring.

High compression damp- Turn adjuster counterclockwise (about 1/6 turn) to ing decrease damping. Stiff travel

Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when one passenger is astride seat.

Replace with soft spring.