WR426F (2000) - Motorcycle YAMAHA - Free user manual and instructions

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USER MANUAL WR426F (2000) YAMAHA

©2000 by Yamaha Motor Co., Ltd. 1st Edition, September 2000 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in JapanWR426F(N)/WR400F(N) FAHRER-UND WARTUNGS- HANDBUCH © 2000 Yamaha Motor Co., Ltd.

PLEASE READ THIS MANUAL CAREFULLY

AND COMPLETELY BEFORE OPERATING

THIS MACHINE. DO NOT ATTEMPT TO

OPERATE THIS MACHINE UNTIL YOU

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 regula- tions before riding.

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 character- istics.

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 gog- gles or a face shield. Also wear heavy boots, gloves, and protective cloth- ing. Always wear proper fitting cloth- ing 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.

3. LLEVE SIEMPRE LA INDU-

SEGURIDAD5. GASOLINE IS HIGHLY FLAMMABLE. Always turn off the engine while refu- eling. Take care to not spill any gaso- line 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 VENTILA-

TION. Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are poisonous. These fumes contain carbon monoxide, which by itself is odorless and color- less. Carbon monoxide is a dangerous gas which can cause unconscious- ness 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, MUF-

FLER, 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.

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 perma- nent part of this machine and should remain with it even if the machine is subsequently sold. EC060000 NOTICE Some data in this manual may become out- dated 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 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. F.I.M. MACHINE WEIGHTS:WICHTIGER HINWEIS

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

BECOME ALERT! YOUR SAFETY IS

INVOLVED! 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. A CAUTION indicates special precautions that must be taken to avoid damage to the machine. NOTE: A NOTE provides key information to make pro- cedures easier or clearer. WARNING CAUTION: EC082000

FINDING THE REQUIRED PAGE

1. This manual consists of seven chapters;

“General Information”, “Specifications”, “Regular inspection and adjustments”, “Engine”, “Chassis”, “Electrical” and “Tun- ing”.

2. The table of contents is at the beginning of

Bearings Pitting/damage

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

is provided for removal and disassembly jobs.

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

. The meanings of the symbol marks are given on the next page.

4. A job instruction chart

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

5. Extent of removal

is provided in the job instruction chart to save the trouble of an unneces- sary removal job.

are designed as thumb tabs to indicate the chapter’s number and content.

General information Specifications Regular inspection and adjustments Engine Chassis Electrical Tuning Illustrated symbols

are used to identify the specifications appearing in the text.

With engine mounted Special tool Filling fluid Lubricant Tightening Specified value, Service limit Resistance ( ), Voltage (V), Electric current (A) Illustrated symbols

in the exploded diagrams indicate grade of lubricant and loca- tion of lubrication point.

Apply engine oil Apply molybdenum disulfide oil Apply lightweight lithium-soap base grease Apply molybdenum disulfide grease Illustrated symbols

in the exploded diagrams indicate where to apply a locking agent and where to install new parts. I Apply locking agent (LOCTITE

CHECKING OF CONNECTION

CLEANING AND STORAGE

KICK AXLE AND SHIFT SHAFT

............ 4-76 CDI MAGNETO ....................................... 4-83 ENGINE REMOVAL ................................ 4-87

CRANKCASE AND CRANKSHAFT

TRANSMISSION, SHIFT CAM

Oil filler plug/dipstick

Hot starter knob (red)

The machine you have purchased may differ slightly from those shown in the following.

Designs and specifications are subject to change without notice.

GEN INFO MACHINE IDENTIFICATION 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

stamped on the right of the steering head pipe. EC123001

ENGINE SERIAL NUMBER

The engine serial number

is stamped into the elevated part of the right-side of the engine. EC124000 MODEL LABEL The model label

is affixed to the frame under the rider’s seat. This information will be needed to order spare parts.GEN INFO

PREPARATION FOR REMOVAL AND

1. Remove all dirt, mud, dust, and foreign

material before removal and disassem- bly. When washing the machine with high pressured water, cover the parts as fol- lows.

Air filter intake hole

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.GEN

ALL REPLACEMENT PARTS

1. We recommend to use Yamaha genuine

parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. EC133000

GASKETS, OIL SEALS AND O-RINGS

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

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

2. Properly oil all mating parts and bearings

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

LOCK WASHERS/PLATES AND COTTER

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

BEARINGS AND OIL SEALS

1. Install the bearing(s)

1 and oil seal(s) 2 with their manufacturer’s marks or num- bers 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.GEN INFO INFORMATIONS IMPORTANTES WICHTIGE INFORMATIONEN

1. All circlips should be inspected carefully

before reassembly. Always replace pis- ton pin clips after one use. Replace dis- torted circlips. When installing a circlip 1, make sure that the sharp-edged cor- ner 2 is positioned opposite to the thrust 3 it receives. See the sectional view. 4 ShaftGEN INFO SICHERUNGSRINGE

CHECKING OF CONNECTION

CHECKING OF CONNECTION

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

2. Dry each terminal with an air blower.

3. Connect and disconnect the connector

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

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

1 and reinsert the terminal into the con- nector.

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

7. Check for continuity with a tester.

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

The “ENGINE STOP” button 1 is located on the left handlebar. Continue pushing the “ENGINE STOP” button till the engine comes to a stop. EC152000 CLUTCH LEVER The clutch lever 1 is located on the left han- dlebar; it disengages or engages the clutch. Pull the clutch lever to the handlebar to disen- gage the clutch, and release the lever to engage the clutch. The lever should be pulled rapidly and released slowly for smooth starts. EC153000 SHIFT PEDAL The gear ratios of the constant-mesh 5 speed transmission are ideally spaced. The gears can be shifted by using the shift pedal 1 on the left side of the engine. EC154000 KICK STARTER Rotate the kick starter 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 kick starter so the engine can be started in any gear if the clutch is disengaged. In normal practices, however, shift to neutral before starting. 1GEN INFO

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

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

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

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

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

1. If knocking or pinging occurs, use a dif-

ferent brand of gasoline or higher octane grade.

2. If unleaded gasoline is not available, then

leaded gasoline can be used. Recommended fuel: Except for AUS: Premium unleaded fuel with a research octane number of 95 or higher. For AUS: Unleaded fuel onlyGEN INFO

WARNING Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time. Always operate the machine in a well-ventilated area. CAUTION: ● The carburetor on this motorcycle has a built-in accelerator pump. Therefore, when starting the engine, do not operate the throttle or the spark plug will foul. ● Unlike a two-stroke engine, this engine cannot be kick started when the throttle is open because the kick starter may kick back. Also, if the throttle is open the air/ fuel mixture may be too lean for the engine to start. ● Never use the decompression lever after the engine is started. The engine may be damaged if you use the decompression lever while it is running. ● Before starting the machine, perform the checks in the pre-operation check list.

STARTING A COLD ENGINE

1. Inspect the coolant level.

2. Turn the fuel cock to “ON”.

3. Shift the transmission into neutral.

4. Fully open the cold starter knob.

5. Without pulling in the decompression

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

6. Pull the decompression lever to the han-

dlebar and depress the kick starter 10 ~ 20˚.

7. Release the decompression lever and

return the kick starter to its original posi- tion and then kick the kick starter. WARNING Do not open the throttle while kicking the kick starter. Otherwise, the kick starter may kick back.

8. Return the cold starter knob to its original

position and run the engine at 3,000 ~ 5,000 r/min for 1 or 2 minutes. NOTE: Since this model is equipped with an accelera- tor 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.GEN INFO

Do not operate the cold starter knob and throt- tle. Open the hot starter knob (red) and start the engine by kicking the kick starter forcefully with a firm stroke. As soon as the engine starts, push in the hot starter knob to close the air passage. Restarting an engine after a fall Pull the hot starter knob (red) and start the engine. As soon as the engine starts, push in the hot starter knob to close the air passage. The engine fails to start Pull the hot starter knob (red) all the way out, pull the decompression lever to the handlebar, and while holding the lever, kick the kickstarter 10 to 20 times to clear the engine. Then, restart the engine. Refer to “Restarting an engine after a fall”.

• 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. Throttle grip oper-ation*Cold starter knob Hot starter knob (red)Air temperature = less than 5 ˚C (41 ˚F)Open 3 or 4 timesON OFFAir temperature = more than 5 ˚C (41 ˚F)None ON OFFAir temperature (normal temperature) = between 5 ˚C (41 ˚F) and 25 ˚C (77 ˚F)None ON/OFF OFFAir temperature = more than 25 ˚C (77 ˚F)None OFF OFFStarting an engine after a long period of timeNone ON OFFRestarting a warm engine None OFF ONRestarting an engine after a fall None OFF ONStarting a cold engineGEN INFO

1. Before starting the engine, fill the fuel

2. Perform the pre-operation checks on the

3. Start and warm up the engine. Check the

idle speed, and check the operation of the controls and the “ENGINE STOP” button. Then, restart the engine and check its operation within no more than 5 minutes after it is restarted.

4. Operate the machine in the lower gears

at moderate throttle openings for five to eight minutes.

5. Check how the engine runs when the

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

6. Restart the engine and check the opera-

tion 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 care- fully during operation.

CLEANING AND STORAGE

CLEANING AND STORAGE

EC1B1000 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good over- all 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 bear- ings, front forks, brakes and transmission seals. Many expensive repair bills have resulted from improper high pressure detergent applications such as those avail- able 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 com- bination cleaner-waxes, as they may con- tain abrasives.

9. After completing the above, start the

engine and allow it to idle for several min- utes.GEN INFO

CLEANING AND STORAGE

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

spoon 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 thor-

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

4. Lubricate all control cables.

5. Block the frame up to raise the wheels off

6. Tie a plastic bag over the exhaust pipe

outlet to prevent moisture from entering.

7. If the machine is to be stored in a humid

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

SPEC GENERAL SPECIFICATIONS (WR426F) EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS (WR426F) Model name: WR426FN (USA) WR426F (EUROPE) WR426F(N) (CDN, AUS, NZ, ZA) Model code number: 5NG1 (USA) 5NG2 (EUROPE) 5NG4 (CDN, AUS, NZ, ZA) Dimensions: Overall length 2,171 mm (85.5 in) Overall width 827 mm (32.6 in) Overall height 1,303 mm (51.3 in) Seat height 998 mm (39.3 in) Wheelbase 1,490 mm (58.7 in) Minimum ground clearance 373 mm (14.7 in) Basic weight: With oil and full fuel tank 121.5 kg (268 lb) Engine: Engine type Liquid cooled 4-stroke, DOHC Cylinder arrangement Single cylinder, forward inclined Displacement 426 cm

Compression ratio 12.5 : 1 Starting system Kick starter Lubrication system: Dry sump Oil type or grade: Engine oil (For USA and CDN) At 5 ˚C (40 ˚F) or higher

Yamalube 4 (20W-40) or SAE 20W-40 type SH motor oil (Non-Friction modified) At 15 ˚C (60 ˚F) or lower

Yamalube 4 (10W-30) or SAE 10W-30 type SH motor oil (Non-Friction modified) and/or Yamalube 4-R (15W-50) (Non-Friction modified) (Except for USA and CDN) API “SH” or higher grade

SPEC GENERAL SPECIFICATIONS (WR426F) Oil capacity: Engine oil Periodic oil change 1.5 L (1.32 Imp qt, 1.59 US qt) With oil filter replacement 1.6 L (1.41 Imp qt, 1.69 US qt) Total amount 1.7 L (1.50 Imp qt, 1.80 US qt) Coolant capacity (including all routes): 1.2 L (1.06 Imp qt, 1.27 US qt) Air filter: Wet type element Fuel: Type Premium unleaded fuel with a research octane number of 95 or higher. (Except for AUS) Unleaded fuel only (For AUS) Tank capacity 12 L (2.64 Imp gal, 3.17 US gal) (For USA, CDN)

Gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) Clutch type: Wet, multiple-disc Transmission: Primary reduction system Gear Primary reduction ratio 62/21 (2.952) Secondary reduction system Chain drive Secondary reduction ratio 50/14 (3.571) Transmission type Constant mesh, 5-speed Operation Left foot operation Gear ratio: 1st 29/12 (2.416) 2nd 26/15 (1.733) 3rd 21/16 (1.312) 4th 21/20 (1.050) 5th 21/25 (0.840) Chassis: Frame type Semi double cradle Caster angle 27.8˚ Trail 123 mm (4.84 in)

(0.005 in) 2nd ring Type Taper ---- Dimensions (B

(0.005 in) Oil ring Dimensions (B

(0.007 in) Bypass valve setting pressure 40 ~ 80 kPa (0.4 ~ 0.8 kg/cm

Cylinder head cover M6

Clamp (air cleaner joint) M5

Clamp (carburetor joint) M4

Air filter joint clamp M6

Throttle cable cover M5

Air filter case cover M6

Radiator panel (upper) M6

Radiator hose clamp M6

Water pump housing cover M6 × 1.0 3 10 1.0 7.2 Coolant drain bolt M6 × 1.0 1 10 1.0 7.2 Oil pump cover M5 × 0.8 1 4 0.4 2.9 Oil pump M6 × 1.0 3 10 1.0 7.2 Engine oil drain bolt (oil filter) M6 × 1.0 1 10 1.0 7.2 Oil filter cover M6 × 1.0 2 10 1.0 7.2 Oil delivery pipe 1 M10 × 1.25 M8 × 1.25

K = 4.12 N/mm (0.42 kg/mm,

Optional spring/spacer Yes ← ---- Oil capacity 573 cm

<Min.~Max.> (From top of outer tube with inner tube and damper rod fully com- pressed without spring.) 80 ~ 150 mm (3.15 ~ 5.91 in)

Oil grade Suspension oil “01”

Spring rate, STD K = 49.0 N/mm (5.00 kg/mm,

K = 47.0 N/mm (4.80 kg/mm,

Optional spring Yes ← ---- Enclosed gas pressure 1,000 kPa (10 kg/cm

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

wrench, then loosen the ring nut one turn.

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

Part to be tightened Thread size Q’ty Tightening torque Nm m·kg ft·lb Handle crown and outer tube M8 × 1.25 4 23 2.3 17 Under bracket and outer tube M8 × 1.25 4 20 2.0 14 Handle crown and steering shaft M24 × 1.0 1 145 14.5 105 Handlebar holder (upper) M8 × 1.25 4 28 2.8 20 Steering ring nut M28 × 1.0 1 Refer to NOTE. Front fork and cap bolt M48 × 1.0 2 30 3.0 22 Front fork and base valve M30 × 1.0 2 55 5.5 40 Cap bolt and damper rod (front fork) M12 × 1.25 2 29 2.9 21 Bleed screw (front fork) and cap bolt M5 × 0.8 2 1 0.1 0.7 Front fork and protector M6 × 1.0 6 10 1.0 7.2 Meter cable holder and protector M5 × 0.8 2 4 0.4 2.9 Front fork and brake hose holder M6 × 1.0 2 10 1.0 7.2 Front fork and hose cover M8 × 1.25 1 16 1.6 11 Front fork and hose cover M6 × 1.0 1 7 0.7 5.1 Throttle cable cap M5 × 0.8 2 4 0.4 2.9 Clutch lever holder M5 × 0.8 2 4 0.4 2.9 Decompression lever holder M5 × 0.8 2 4 0.4 2.9 Lights switch M4 × 0.7 2 2 0.2 1.4 Front brake master cylinder and bracket M6 × 1.0 2 9 0.9 6.5 Front brake master cylinder cap M4 × 0.7 2 2 0.2 1.4 Brake lever mounting (bolt) M6 × 1.0 1 6 0.6 4.3 Brake lever mounting (nut) M6 × 1.0 1 6 0.6 4.3 Brake lever position locknut M6 × 1.0 1 5 0.5 3.6 Hose guide (front brake hose) M5 × 0.8 2 4 0.4 2.9 Front brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22 Front brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 22 Front brake caliper and front fork M8 × 1.25 2 23 2.3 17 Brake caliper (front and rear) and pad pin plug M10 × 1.0 1 3 0.3 2.2 Brake caliper (front and rear) and pad pin M10 × 1.0 1 18 1.8 13 Brake caliper (front and rear) and bleed screw M8 × 1.25 1 6 0.6 4.3 Front wheel axle and nut M16 × 1.5 1 105 10.5 75 Front wheel axle holder M8 × 1.25 4 23 2.3 17 Front brake disc and wheel hub M6 × 1.0 6 12 1.2 8.7 Rear brake disc and wheel hub M6 × 1.0 6 14 1.4 10 Brake pedal mounting M8 × 1.25 1 26 2.6 19 Rear brake master cylinder and frame M6 × 1.0 2 10 1.0 7.2 Rear brake reservoir tank and frame M6 × 1.0 1 10 1.0 7.2 Rear brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 222 - 16 SPEC MAINTENANCE SPECIFICATIONS (WR426F) NOTE: - marked portion shall be checked for torque tightening after break-in or before each race. Part to be tightened Thread size Q’ty Tightening torque Nm m·kg ft·lb Rear brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22 Rear wheel axle and nut M20 × 1.5 1 125 12.5 90 Driven sprocket and wheel hub M8 × 1.25 6 42 4.2 30 Nipple (spoke) — 72 3 0.3 2.2 Disc cover and rear brake caliper M6 × 1.0 2 7 0.7 5.1 Protector and rear brake caliper M6 × 1.0 2 7 0.7 5.1 Engine mounting: Engine bracket and frame M8 × 1.25 7 34 3.4 24 Engine and frame (front) M10 × 1.25 1 69 6.9 50 Engine and frame (upper) M10 × 1.25 1 55 5.5 40 Engine and frame (lower) M10 × 1.25 1 69 6.9 50 Engine guard (left and right) M8 × 1.25 2 23 2.3 17 Pivot shaft and nut M16 × 1.5 1 85 8.5 61 Relay arm and swingarm M14 × 1.5 1 80 8.0 58 Relay arm and connecting rod M14 × 1.5 1 80 8.0 58 Connecting rod and frame M14 × 1.5 1 80 8.0 58 Rear shock absorber and frame M10 × 1.25 1 56 5.6 40 Rear shock absorber and relay arm M10 × 1.25 1 53 5.3 38 Rear frame and frame M8 × 1.25 3 29 2.9 21 Swingarm and brake hose holder M5 × — 4 4 0.4 2.9 Drive chain tensioner mounting M8 × 1.25 2 19 1.9 13 Chain support and swingarm M6 × 1.0 3 7 0.7 5.1 Seal guard and swingarm M5 × 0.8 4 6 0.6 4.3 Fuel tank mounting M6 × 1.0 2 10 1.0 7.2 Fuel tank and fuel cock M6 × 1.0 2 7 0.7 5.1 Fuel tank and seat set bracket M6 × 1.0 1 7 0.7 5.1 Fuel tank and hooking screw (fitting band) M6 × 1.0 1 7 0.7 5.1 Fuel tank and fuel tank bracket M6 × 1.0 4 7 0.7 5.1 Seat mounting M8 × 1.25 2 23 2.3 17 Side cover mounting M6 × 1.0 2 7 0.7 5.1 Air scoop and fuel tank M6 × 1.0 4 4 0.4 2.9 Air scoop and radiator panel (lower) M6 × 1.0 2 4 0.4 2.9 Front fender mounting M6 × 1.0 4 7 0.7 5.1 Rear fender mounting M6 × 1.0 4 7 0.7 5.1 Headlight stay (under) and under bracket M6 × 1.0 2 7 0.7 5.1 Headlight M6 × 1.0 3 7 0.7 5.1 Tail light M6 × 1.0 3 4 0.4 2.9 Tail light lead clamp and rear fender M4 × 1.59 2 1 0.1 0.7 Coolant reservoir tank M6 × 1.0 2 7 0.7 5.1 Sidestand bracket and frame M10 × 1.25 2 64 6.4 46 Sidestand mounting M10 × 1.25 1 64 6.4 462 - 17 SPEC MAINTENANCE SPECIFICATIONS (WR426F) EC212300 ELECTRICAL Item Standard Limit Ignition system: Advancer type Electrical ---- CDI: Magneto-model/manufacturer F5NG 00/YAMAHA ---- Source coil 1 resistance (color) 640 ~ 960 Ω at 20 ˚C (68 ˚F) (Green – Brown)

Source coil 2 resistance (color) 464 ~ 696 Ω at 20 ˚C (68 ˚F) (Green – Pink)

Lighting coil resistance (color) 0.16 ~ 0.24 Ω at 20 ˚C (68 ˚F) (Black – Yellow) Pickup coil resistance (color) 248 ~ 372 Ω at 20 ˚C (68 ˚F) (White – Red)

Ignition coil: Model/manufacturer 5BE-00/YAMAHA ---- Minimum spark gap 6 mm (0.24 in) ---- Primary winding resistance 0.20 ~ 0.30 Ω at 20 ˚C (68 ˚F) ---- Secondary winding resistance 9.5 ~ 14.3 kΩ at 20 ˚C (68 ˚F) ---- Part to be tightened Thread size Q’ty Tightening torque Nm m·kg ft·lb Stator M6 × 1.0 3 10 1.0 7.2 Rotor M10 × 1.25 1 48 4.8 35 Ignition coil M6 × 1.0 2 7 0.7 5.12 - 18 SPEC GENERAL SPECIFICATIONS (WR400F) EC211000 GENERAL SPECIFICATIONS (WR400F) Model name: WR400F (EUROPE) WR400FN (AUS) Model code number: 5GS9 Dimensions: Overall length 2,171 mm (85.5 in) Overall width 827 mm (32.6 in) Overall height 1,303 mm (51.3 in) Seat height 998 mm (39.3 in) Wheelbase 1,490 mm (58.7 in) Minimum ground clearance 373 mm (14.7 in) Basic weight: With oil and full fuel tank 121.5 kg (268 lb) Engine: Engine type Liquid cooled 4-stroke, DOHC Cylinder arrangement Single cylinder, forward inclined Displacement 399 cm

(14.1 Imp oz, 13.5 US oz) Bore × stroke 92.0 × 60.1 mm (3.62 × 2.37 in) Compression ratio 12.5 : 1 Starting system Kick starter Lubrication system: Dry sump Oil type or grade: Engine oil API “SH” or higher grade Oil capacity: Engine oil Periodic oil change 1.5 L (1.32 Imp qt, 1.59 US qt) With oil filter replacement 1.6 L (1.41 Imp qt, 1.69 US qt) Total amount 1.7 L (1.50 Imp qt, 1.80 US qt) Coolant capacity (including all routes): 1.2 L (1.06 Imp qt, 1.27 US qt) Air filter: Wet type element

10W-30 10W-40 20W-40 20W-50 15W-402 - 19 SPEC GENERAL SPECIFICATIONS (WR400F) Fuel: Type Premium unleaded fuel with a research octane number of 95 or higher. (Except for AUS) Unleaded fuel only (For AUS) Tank capacity 8.0 L (1.76 Imp gal, 2.11 US gal) Reserve 1.4 L (0.31 Imp gal, 0.37 US gal) Carburetor: Type FCR-MX39 Manufacturer KEIHIN Spark plug: Type/manufacturer CR8E/NGK

Gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in) Clutch type: Wet, multiple-disc Transmission: Primary reduction system Gear Primary reduction ratio 62/21 (2.952) Secondary reduction system Chain drive Secondary reduction ratio 50/14 (3.571) Transmission type Constant mesh, 5-speed Operation Left foot operation Gear ratio: 1st 29/12 (2.416) 2nd 26/15 (1.733) 3rd 21/16 (1.312) 4th 21/20 (1.050) 5th 21/25 (0.840) Chassis: Frame type Semi double cradle Caster angle 27.8˚ Trail 123 mm (4.84 in) Tire: Type With tube Size (front) 90/90-21 54R Size (rear) 130/90-18 69R Tire pressure (front and rear) 100 kPa (1.0 kg/cm

(0.007 in) Bypass valve setting pressure 40 ~ 80 kPa (0.4 ~ 0.8 kg/cm

K = 4.12 N/mm (0.42 kg/mm,

Optional spring/spacer Yes ← ---- Oil capacity 573 cm

<Min.~Max.> (From top of outer tube with inner tube and damper rod fully com- pressed without spring.) 80 ~ 150 mm (3.15 ~ 5.91 in)

Oil grade Suspension oil “01”

Spring rate, STD K = 49.0 N/mm (5.00 kg/mm,

K = 47.0 N/mm (4.80 kg/mm,

Optional spring Yes ← ---- Enclosed gas pressure 1,000 kPa (10 kg/cm

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

wrench, then loosen the ring nut one turn.

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

Part to be tightened Thread size Q’ty Tightening torque Nm m·kg ft·lb Handle crown and outer tube M8 × 1.25 4 23 2.3 17 Under bracket and outer tube M8 × 1.25 4 20 2.0 14 Handle crown and steering shaft M24 × 1.0 1 145 14.5 105 Handlebar holder (upper) M8 × 1.25 4 28 2.8 20 Steering ring nut M28 × 1.0 1 Refer to NOTE. Front fork and cap bolt M48 × 1.0 2 30 3.0 22 Front fork and base valve M30 × 1.0 2 55 5.5 40 Cap bolt and damper rod (front fork) M12 × 1.25 2 29 2.9 21 Bleed screw (front fork) and cap bolt M5 × 0.8 2 1 0.1 0.7 Front fork and protector M6 × 1.0 6 10 1.0 7.2 Meter cable holder and protector M5 × 0.8 2 4 0.4 2.9 Front fork and brake hose holder M6 × 1.0 2 10 1.0 7.2 Front fork and hose cover M8 × 1.25 1 16 1.6 11 Front fork and hose cover M6 × 1.0 1 7 0.7 5.1 Throttle cable cap M5 × 0.8 2 4 0.4 2.9 Clutch lever holder M5 × 0.8 2 4 0.4 2.9 Decompression lever holder and protector M5 × 0.8 2 4 0.4 2.9 Lights switch M4 × 0.7 2 2 0.2 1.4 Front brake master cylinder and bracket M6 × 1.0 2 9 0.9 6.5 Front brake master cylinder cap M4 × 0.7 2 2 0.2 1.4 Brake lever mounting (bolt) M6 × 1.0 1 6 0.6 4.3 Brake lever mounting (nut) M6 × 1.0 1 6 0.6 4.3 Brake lever position locknut M6 × 1.0 1 5 0.5 3.6 Hose guide (front brake hose) M5 × 0.8 2 4 0.4 2.9 Front brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22 Front brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 22 Front brake caliper and front fork M8 × 1.25 2 23 2.3 17 Brake caliper (front and rear) and pad pin plug M10 × 1.0 1 3 0.3 2.2 Brake caliper (front and rear) and pad pin M10 × 1.0 1 18 1.8 13 Brake caliper (front and rear) and bleed screw M8 × 1.25 1 6 0.6 4.3 Front wheel axle and nut M16 × 1.5 1 105 10.5 75 Front wheel axle holder M8 × 1.25 4 23 2.3 17 Front brake disc and wheel hub M6 × 1.0 6 12 1.2 8.7 Rear brake disc and wheel hub M6 × 1.0 6 14 1.4 10 Brake pedal mounting M8 × 1.25 1 26 2.6 19 Rear brake master cylinder and frame M6 × 1.0 2 10 1.0 7.2 Rear brake reservoir tank and frame M6 × 1.0 1 10 1.0 7.2 Rear brake hose union bolt (caliper) M10 × 1.25 1 30 3.0 222 - 33 SPEC MAINTENANCE SPECIFICATIONS (WR400F) NOTE: - marked portion shall be checked for torque tightening after break-in or before each race. Part to be tightened Thread size Q’ty Tightening torque Nm m·kg ft·lb Rear brake hose union bolt (master cylinder) M10 × 1.25 1 30 3.0 22 Rear wheel axle and nut M20 × 1.5 1 125 12.5 90 Driven sprocket and wheel hub M8 × 1.25 6 42 4.2 30 Nipple (spoke) — 72 3 0.3 2.2 Disc cover and rear brake caliper M6 × 1.0 2 7 0.7 5.1 Protector and rear brake caliper M6 × 1.0 2 7 0.7 5.1 Engine mounting: Engine bracket and frame M8 × 1.25 7 34 3.4 24 Engine and frame (front) M10 × 1.25 1 69 6.9 50 Engine and frame (upper) M10 × 1.25 1 55 5.5 40 Engine and frame (lower) M10 × 1.25 1 69 6.9 50 Engine guard (left and right) M8 × 1.25 2 23 2.3 17 Pivot shaft and nut M16 × 1.5 1 85 8.5 61 Relay arm and swingarm M14 × 1.5 1 80 8.0 58 Relay arm and connecting rod M14 × 1.5 1 80 8.0 58 Connecting rod and frame M14 × 1.5 1 80 8.0 58 Rear shock absorber and frame M10 × 1.25 1 56 5.6 40 Rear shock absorber and relay arm M10 × 1.25 1 53 5.3 38 Rear frame and frame M8 × 1.25 3 29 2.9 21 Swingarm and brake hose holder M5 × — 4 4 0.4 2.9 Drive chain tensioner mounting M8 × 1.25 2 19 1.9 13 Chain support and swingarm M6 × 1.0 3 7 0.7 5.1 Seal guard and swingarm M5 × 0.8 4 6 0.6 4.3 Fuel tank mounting M6 × 1.0 2 10 1.0 7.2 Fuel tank and fuel cock M6 × 1.0 2 7 0.7 5.1 Fuel tank and seat set bracket M6 × 1.0 1 7 0.7 5.1 Fuel tank and hooking screw (fitting band) M6 × 1.0 1 7 0.7 5.1 Fuel tank and fuel tank bracket M6 × 1.0 4 7 0.7 5.1 Seat mounting M8 × 1.25 2 23 2.3 17 Side cover mounting M6 × 1.0 2 7 0.7 5.1 Air scoop and fuel tank M6 × 1.0 4 4 0.4 2.9 Air scoop and radiator panel (lower) M6 × 1.0 2 4 0.4 2.9 Front fender mounting M6 × 1.0 4 7 0.7 5.1 Rear fender mounting M6 × 1.0 4 7 0.7 5.1 Headlight stay (under) and under bracket M6 × 1.0 2 7 0.7 5.1 Headlight M6 × 1.0 3 7 0.7 5.1 Tail light M6 × 1.0 3 4 0.4 2.9 Tail light lead clamp and rear fender M4 × 1.59 2 1 0.1 0.7 Coolant reservoir tank M6 × 1.0 2 7 0.7 5.1 Sidestand bracket and frame M10 × 1.25 2 64 6.4 46 Sidestand mounting M10 × 1.25 1 64 6.4 462 - 34 SPEC MAINTENANCE SPECIFICATIONS (WR400F) EC212300 ELECTRICAL Item Standard Limit Ignition system: Advancer type Electrical ---- CDI: Magneto-model/manufacturer F5BF 00/YAMAHA ---- Source coil 1 resistance (color) 640 ~ 960 Ω at 20 ˚C (68 ˚F) (Green – Brown)

Source coil 2 resistance (color) 464 ~ 696 Ω at 20 ˚C (68 ˚F) (Green – Pink)

Lighting coil resistance (color) 0.16 ~ 0.24 Ω at 20 ˚C (68 ˚F) (Black – Yellow) Pickup coil resistance (color) 248 ~ 372 Ω at 20 ˚C (68 ˚F) (White – Red)

This chart specifies torque for standard fasten- ers with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sec- tions of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fash- ion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Com- ponents should be at room temperature. A: Distance between flats B: Outside thread diameter EC230000

Unit Read Definition Measure

gram Weight N Newton 1 kg × m/sec

1,0 2 10 1,0 Zylinder M6

Oil delivery pipeSPEC

Fuel tank breather hose

Oil tank breather hose

TPS (throttle position sensor) lead

Cylinder head breather hose

Carburetor breather hose

Coolant reservoir tank breather hose

Pass the fuel tank breather hose behind handlebar, then insert it into the steering shaft hole.

Pass the decompression cable, “ENGINE STOP” but- ton lead and lights switch lead under where the oil hose is attached.

Fasten the CDI magneto lead, neutral switch lead “ENGINE STOP” button lead and lights switch lead to the frame with a plastic locking tie.

Pass the “ENGINE STOP” but- ton lead and lights switch lead along the inner side of the oil tank breather hose.

Fasten the sub wire harness, “ENGINE STOP” button lead and lights switch lead to the frame in front of the protector of the sub wire harness with a plastic locking tie and cut off the tie end.

Pass the cylinder head breather hose along the right side of the oil tank breather hose.

Fasten the sub wire harness and “ENGINE STOP” button lead to the frame with a plas- tic locking tie and cut off the tie end.

Pass the sub wire harness between the engine brackets.SPEC

Fasten the TPS lead (in the sub wire harness) under the frame so that it does not con- tact the carburetor.

Fasten the TPS lead under the coupler to the frame with a plastic locking tie.

Pass the carburetor breather hose and overflow hose between the connecting rod and cross tube (frame).

Fasten the neutral switch lead and oil hose together with a plastic locking tie.

Fasten the neutral switch lead to the frame with a plastic band. ˆ Fasten the cylinder head breather hose with the hose holder. Ø Fasten the neutral switch lead and CDI magneto lead together with a plastic band. ∏ Pass the clutch cable through the cable guide. Œ Pass the cylinder head breather hose along the inner side of the radiator pipe.  Pass the clutch cable between the frame and radiator and over the lower boss on the radiator. Í Pass the neutral switch lead and CDI magneto lead over the middle radiator mounting boss. Then, pass the decom- pression cable under the mid- dle radiator mounting boss and along the left side of the neutral switch lead and CDI magneto lead. Ê Pass the clutch cable through the cable guide. Ë Fit the brake hose into the guide on the protector. ◊ Fasten the ignition coil lead (in the sub wire harness) on the upper inside of the frame and cut off the tie end. „ Pass the ignition coil lead (in the sub wire harness) under the cushion bracket (frame). ≈ Fasten the ignition coil lead (in the sub wire harness) to the frame with a plastic lock- ing tie and cut off the tie end. Á Pass the carburetor breather hoses and overflow hose so that all there hoses do not contact the rear shock absorber.SPEC

1 Coolant reservoir tank breather hose 2 Clamp 3 Ignition coil 4 High tension cord 5 CDI unit 6 CDI unit band 7 Radiator (left) 8 Radiator (right) 9 Decompression cable 0 CDI unit stay (frame) Å Fasten the coolant reservoir tank breather hose and carburetor breather hose together with a plastic locking tie. ı Fasten the ignition coil lead to the frame with a plastic band. Ç Pass the ignition coil lead (in the sub wire harness) so that it does not contact the carburetor and rear shock absorber and connect it with the lead from the ignition coil on the inside of the frame. Î Fasten the ignition coil and ground lead to the frame with the bolt. ‰ Pass the throttle cables over the high tension cord. Ï Pass the throttle cables along the outer side of the CDI unit leads. Ì Using a plastic locking tie, clamp to the frame the CDI unit leads at their protecting tubes. Ó Fit the boot over the coupler. È Pass the throttle cables between the top radiator mounting boss and middle radiator mounting boss. Ô Pass the CDI unit leads over the top radiator mounting boss. Cross the pull and return throttle cables before the radiator. Ò Pass the throttle cables through the cable guide. ˜ Insert the CDI unit band over the CDI unit stay (frame) as far as possible.SPEC

1 Throttle cable 2 Lights switch 3 Lights switch lead 4 Clamp 5 Decompression cable 6 Clutch cable 7 Hose guide 8 Trip meter 9 Brake hose 0 “ENGINE STOP” button lead Å Fasten the “ENGINE STOP” button lead to the handlebar with the plastic band. ı Pass the decompression cable between the brake hose and clutch cable. Ç Pass the throttle cables between the handle crown and trip meter. Î Pass the light switch leads behind the “ENGINE STOP” button lead, then pass the head light lead (of the light switch leads) in front of the head pipe. ‰ Install the trip meter cable so that its bent portion faces the chassis rear. Ï Install the brake hose so that it contacts the master cylinder projec- tion and that its bent portion faces downward.SPEC

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 break-inEvery race Every third 500 km(300 mi)Every fifth 1,000 km(600 mi) As re-quiredRemarksENGINE OILReplace

The engine must be cold.Check the valve seats and valve stems for wear.VALVE SPRINGSInspectReplace

Check for scratches and wear.CAMSHAFTSInspectReplace

Check for wear on the teeth and for damage.PISTONInspect CleanReplace

CYLINDER HEADInspect and clean

Inspect score marksInspect wearCLUTCHInspect and adjustReplace

Inspect housing, friction plate, clutch plate and springTRANSMISSIONInspectReplace bearing

SHIFT FORK, SHIFT CAM, GUIDE BAR

Inspect wear ROTOR NUT Retighten

*Whichever comes first *SPARK ARRESTER Clean (Every six months)

CRANK Inspect and clean

CARBURETOR Inspect, adjust and clean

When using a high-pres- sure washer, make sure that water does not enter the accelerator pump. SPARK PLUG Inspect and clean Replace

OUTSIDE NUTS AND BOLTS

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

Use foam air-filter oil OIL STRAINER (frame) Clean

FRAME Clean and inspect

Every one year Item After break-in Every race Every third 500 km(300 mi)Every fifth 1,000 km(600 mi) As re- quired Remarks

• marked: For USA FRONT FORKS Inspect and adjust Replace oil Replace oil seal

Inspect and adjust Lube Retighten

SWINGARM Inspect and retighten

Molybdenum disulfide grease STEERING HEAD Inspect free play and retighten Clean and lube Replace bearing

Lithium base grease TIRE, WHEELS Inspect air pressure, wheel run-out, tire wear and spoke looseness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate

Check routing and connection Lubricate

Yamaha cable lube or SAE 10W-30 motor oil Item After break-in Every race Every third 500 km(300 mi)Every fifth 1,000 km(600 mi) As re- quired RemarksINSP ADJ

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

GENERAL INSPECTION AND MAINTENANCE

Item Routine Page Coolant Check that coolant is filled up to the radiator filler cap. Check that the coolant level is correct in the coolant reservoir tank. Check the cooling system for leakage. P.3-5 ~ 9 Fuel Check that a fresh gasoline is filled in the fuel tank. Check the fuel line for leakage. P.1-13 Engine oil Check that the oil level is correct. Check the crankcase and frame oil line for leakage. P.3-14 ~ 18 Gear shifter and clutch Check that gears can be shifted correctly in order and that the clutch operates smoothly. P.3-10 Throttle grip/Housing Check that the throttle grip operation and free play are correctly adjusted. Lubricate the throttle grip and housing, if necessary. P.3-10 ~ 11 Brakes Check the play of front brake and effect of front and rear brake. P.3-26 ~ 32 Chain Check chain slack and alignment. Check that the chain is lubri- cated properly. P.3-33 ~ 35 Wheels Check for excessive wear and tire pressure. Check for loose spokes and have no excessive play. P.3-42 ~ 44 Steering Check that the handlebar can be turned smoothly and have no excessive play. P.3-44 ~ 45 Front forks and rear shock absorber Check that they operate smoothly and there is no oil leakage. P.3-35 ~ 42 Cables (wires) Check that the clutch and throttle cables move smoothly. Check that they are not caught when the handlebars are turned or when the front forks travel up and down.

Muffler Check that the muffler is tightly mounted and has no cracks. — Sprocket Check that the driven sprocket tightening bolt is not loose. P.3-33 Lubrication Check for smooth operation. Lubricate if necessary. P.3-46 Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-18 Lead connectors Check that the CDI magneto, CDI unit, and ignition coil are con- nected tightly. P.1-6 Settings Is the machine set suitably for the condition of the racing course and weather or by taking into account the results of test runs before racing? Are inspection and maintenance completely done?

, drain bolt and hoses when the engine and radia- tor 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 pres- sure to escape. When the hissing sound has stopped, press down on the cap while turning counterclockwise and remove it. CAUTION: Hard water or salt water is harmful to the engine parts. You may use distilled water, if you can’t get soft water.

1. Place the machine on a level place, and

hold it in an upright position.

Coolant level Coolant level should be between the maximum

marks. Coolant level is below the “LOW” level line

Add soft water (tap water) up to the proper level.

3. Start the engine and let it warm up for

4. Turn off the engine and check the coolant

level again. NOTE: Before checking the coolant level, wait a few minutes until the coolant settles. LOW FULL COOLANT

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

1. Place a container under the engine.

Coolant reservoir hose

Drain the coolant completely.

Coolant reservoir hose LOW FULL COOLANT

Radiator cap Drain the coolant completely.

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

Bolt [engine guard (front)]

Bolt [engine guard (rear)] New

● Radiator● Engine To specified level. CAUTION: ● Do not mix more than one type of ethyl- ene glycol antifreeze containing corro- sion inhibitors for aluminum engine. ● Do not use water containing impurities or oil. Recommended coolant: High quality ethylene glycol anti-freeze containing anti-corrosion for aluminum engine Coolant 1 and water (soft water) 2 mixing ratio: 50%/50% Coolant capacity:

1.2 L (1.06 Imp qt, 1.27 US qt)

Handling notes of coolant: The coolant is harmful so it should be han- dled 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. 10.Install: ● Radiator cap 11.Fill: ● Coolant reservoir tank Midway a between maximum and min- imum marks on the tank. LOW FULL COOLANT aINSP ADJ

12.Install: ● Coolant reservoir cap 13.Start the engine and let it warm up for several minutes. 14.Turn off the engine and inspect the cool- ant level. Refer to “COOLANT LEVEL INSPEC- TION” section. NOTE: Before checking the coolant level wait a few minutes until the coolant settles.

● Seal (radiator cap) 1 ● Valve and valve seat 2 Crack/damage → Replace. Fur deposits 3 → Clean or replace. EC356001

● Radiator cap tester 1 and adapter 2 NOTE: Apply water on the radiator cap seal. 3 Radiator cap

● Radiator cap tester 1 and adapter 2

● Pressure Impossible to maintain the specified pressure for 10 seconds → Repair. ● Radiator ● Radiator hose joint Coolant leakage → Repair or replace. ● Radiator hose Swelling → Replace.INSP ADJ

THROTTLE CABLE ADJUSTMENT

EC359020 CLUTCH ADJUSTMENT

● Clutch lever free play NOTE: ● Make minute adjustment on the lever side using the adjuster 2. ● After adjustment, check proper operation of clutch lever. Clutch lever free play adjustment steps: ● Loosen the locknuts 1. ● Adjust the free play by changing their tightening position. ● Tighten the locknuts. EC35A001

THROTTLE CABLE ADJUSTMENT

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

● Rubber cover 1 ● Throttle cable cap 2

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

● Throttle cable cap ● Screw (throttle cable cap) ● Rubber cover

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. Checking steps: ● Remove the timing plug. ● Turn the crankshaft counterclockwise to 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. ● Check the free play c. Free play: 5 ~ 9 mm (0.20 ~ 0.35 in) Adjustment steps: ● Loosen the locknut 1. ● Turn the adjuster 2 in or out until the adjustment is suitable. ● Tighten the locknut. CAUTION: After the adjustment, start the engine and make sure that the engine does not stop when the handlebars are turned fully both ways. If the decompression cable is too tense, the engine will stop by the decompression system.INSP ADJ REGLAGE DU LEVIER DE DECOMPRESSION/NETTOYAGE DU FILTRE A AIR

● Tail light lead connectors 1

● Air filter case cover 2

● 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 ele- ment may result in poor starting.

● Air filter element Damage → Replace.

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

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

● Lithium soap base grease On the matching surface a on air filter element. 10.Install: ● Air filter element 1 ● Washer ● Fitting bolt NOTE: Align the projection a on filter guide with the hole b in air filter case.

1. Stand the motorcycle on a level surface.

NOTE: ● When checking the oil level make sure that the motorcycle is upright. ● Place the motorcycle on a suitable stand. WARNING Never remove the oil tank cap just after high speed operation. The heated oil could spurt out. causing danger. Wait until the oil cools down to approximately 70 ˚C (158 ˚F).

2. Idle the engine more than 3 minutes

while keeping the motorcycle upright. Then stop the engine and inspect the oil level.

● Oil tank cap 1INSP ADJ

● Oil level Oil level should be between maximum a and minimum b marks. Oil level low → Add oil to proper level. NOTE: When inspecting the oil level, do not screw the oil level gauge into the oil tank. Insert the gauge lightly. (For USA and CDN) 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 CON- SERVING 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. Recommended oil: At 5 ˚C (40 ˚F) or higher Å Yamalube 4 (20W-40) or SAE 20W-40 type SH motor oil (Non-Friction modified) At 15 ˚C (60 ˚F) or lower ı Yamalube 4 (10W-30) or SAE 10W-30 type SH motor oil (Non-Friction modified) and/or Yamalube 4-R (15W-50) (Non-Friction modified) Recommended oil: Refer to the following chart for selection of oils which are suited to the atmospheric temperatures. Recommended engine oil classi- fication: API STANDARD: API “SH” or higher grade (Designed primarily for motor- cycles)

50) (Sans additits anti-

“CONSERVAN LA ENERGÍA II”

(“ENERGY CONSERVING II”) b o superior. El aceite de motor tam- bién lubrica el embrague y la utili- zación de aditivos podría causar el deslizamiento del embrague. ● No permita que se introduzcan materiales extraños en el cárter. Aceite recomendado: 5 ˚C (40 ˚F) o superior Å Yamalube 4 (20W-40) o aceite de motor SAE 20W-40 del tipo SH (Modelo sin fricción) 15 ˚C (60 ˚F) o inferior ı Yamalube 4 (10W-30) o aceite de motor SAE 10W-30 del tipo SH (Modelo sin fricción) y/o Yamalube 4-R (15W-50) (Modelo sin fricción) Aceite recomendado: Consulte la siguiente tabla para seleccionar el aceite que mejor se ade- cue a determinadas tem- peraturas atmosféricas. Clasificación del aceite de motor recomendado: API ESTÁNDAR: API “SH” o de grado superior (Diseñado principal- mente para motocicletas)3 - 16 INSP ADJ

ENGINE OIL REPLACEMENT

5. Start the engine and let it warm up for

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

6. Idle the engine more than 10 seconds

while keeping the motorcycle upright. Then stop the engine and add the oil to the maximum level.

ENGINE OIL REPLACEMENT

1. Start the engine and let it warm up for

2. Stop the engine and place an oil pan

● Oil filler plug 1 ● Drain bolt (with gasket) 2 ● Drain bolt (with gasket) 3 ● Oil filter drain bolt (O-ring) 4 Drain the crankcase and oil tank (frame) of its oil.

● Engine skidplate ● Engine oil hose clamp 1 ● Bolt (engine oil hose) 2 ● Engine oil hose 3 ● Oil strainer (frame) 4

● Oil strainer (frame)INSP ADJ

ENGINE OIL REPLACEMENT

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

oil change, remove the following parts and reinstall them. Replacement steps: ● Remove the exhaust pipe.● Remove the oil filter cover 1 and oil filter element 2. ● Check the O-rings 3, if cracked or dam- aged, replace them with a new one. ● Install the oil filter element and oil filter cover.

● Plain washer 1 ● Oil strainer (frame) 2 ● Engine oil hose 3 ● Bolt (engine oil hose) 4 ● Engine oil hose clamp 5 ● Engine skid plate New

● Gaskets● Oil filter drain bolt● Drain bolt (crankcase)● Drain bolt (frame) New

● Oil tank (frame) Oil quantity: Total amount:

1.7 L (1.50 Imp qt, 1.80 US qt)

Periodic oil change:

1.5 L (1.32 Imp qt, 1.59 US qt)

With oil filter replacement:

PILOT SCREW ADJUSTMENT

10.Install: ● Oil filler plug 11.Inspect: ● Engine (for oil leaks) ● Oil level Refer to “ENGINE OIL LEVEL INSPEC- TION”. 12.Check: ● Oil pressure

PILOT SCREW ADJUSTMENT

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

Oil gallery bolt: 18 Nm (1.8 m • kg, 13 ft • lb) Adjusting 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 num- ber 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: WR426F: 1-5/8 turns out

• 7/8 turns out WR400F: 1-1/2 turns out (example)INSP ADJ

VALVE CLEARANCE ADJUSTMENT

IDLE SPEED ADJUSTMENT

1. Start the engine and thoroughly warm it

● Idle speed Adjustment steps: ● Adjust the pilot screw. Refer to “PILOT SCREW ADJUSTMENT” section. ● Turn the throttle stop screw 1 until the engine runs at the lowest possible speed. To increase idle speed → Turn the throttle stop screw 1 in a. To decrease idle speed → Turn the throttle stop screw 1 out b. Engine idling speed: 1,700 ~ 1,900 r/min

VALVE CLEARANCE ADJUSTMENT

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

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

● Carburetor Refer to “CARBURETOR” section in the CHAPTER 4. ● Spark plug cap ● Engine stay (upper) ● Cylinder head cover Refer to “CAMSHAFTS” section in the

VALVE CLEARANCE ADJUSTMENT

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

Checking steps: ● Turn the crankshaft counterclockwise with a wrench. NOTE: Squeezing the decompressor lever allows the crankshaft to be turned easily. ● Align the T.D.C. mark a on the rotor with the align mark b on the crankcase cover when piston is at T.D.C. on compression stroke. NOTE: In order to be sure that the piston is at Top Dead Center, the punch mark c on the exhaust camshaft and the punch mark d on the intake camshaft must align with the cyl- inder head surface, as shown in the illustra- tion. ● Measure the valve clearance e using a feeler gauge 1. NOTE: Record the measured reading if the clear- ance is incorrect.INSP ADJ

VALVE CLEARANCE ADJUSTMENT

● Valve clearance Adjustment steps: ● Loosen the timing chain tensioner cap bolt. ● Remove the timing chain tensioner and camshaft caps. NOTE: Remove the camshaft cap bolts in a criss- cross pattern from the outside working inwards. ● Remove the camshaft (intake 1 and exhaust 2). NOTE: Attach a wire 3 to the timing chain to pre- vent it from falling into the crankcase. ● Remove the decompression guide 4, cable 5, bolt 6 and decompression shaft

● Remove the valve lifters 8 and the pads

NOTE: ● Place a rag in the timing chain space to prevent pads from falling into the crank- case. ● Identity each valve lifter and pad position very carefully so that they can be rein- stalled in their original place. ● Select the proper pad using the pad selecting table. Pad range Pad Availability: 25 increments No. 120

Pads are available in

NOTE: The thickness a of each pad is indicated in hundreths of millimeters on the pad upper surface.INSP ADJ

VALVE CLEARANCE ADJUSTMENT

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

EXAMPLE: Installed pad number = 148 Rounded off value = 150 NOTE: Pads can only be selected in 0.05 mm incre- ments. ● 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 adjust- ment. ● Install the new pads 0 and the valve lift- ers A. 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 decompression shaft B, plain washer C, bolt D, guide E, bolt F and decompression cable G. NOTE: Apply the engine oil on the decompression shaft.

VALVE CLEARANCE ADJUSTMENT

● All removed parts NOTE: Install all removed parts in reversed order of their removal. Note the following points. ● Install the camshafts (exhaust and intake), the timing chain and the camshaft caps. Refer to “CAMSHAFTS” section in the

Bolt (camshaft cap): 10 Nm (1.0 m • kg, 7.2 ft • lb) ● Install the timing chain tensioner. Refer to “CAMSHAFTS” section in the

NOTE: Turn the crankshaft counterclockwise sev- eral turns so that the installed parts settle into the right position. ● Recheck the valve clearance. ● If the clearance is still incorrect, repeat all the clearance adjustment steps until the specified clearance is obtained.INSP ADJ

VALVE CLEARANCE ADJUSTMENT

VALVE CLEARANCE (cold):

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

EXHAUST MEASURED CLEARANCE

VALVE CLEARANCE (cold):

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

INSP ADJ SPARK ARRESTER CLEANING (For USA) WARNING ● Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. ● Do not start the engine when cleaning the exhaust system.

● Spark arrester 1 Pull the spark arrester out of the muf- fler.

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

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

WARNING Bleed the brake system if: ● The system has been disassembled.● A brake hose has been loosened or removed. ● The brake fluid is very low.● The brake operation is faulty. A dangerous loss of braking performance may occur if the brake system is not prop- erly bleed.

● Master cylinder cap● Diaphragm● Protector (rear brake)

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

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

bubbles have been removed from the system.

● Protector (rear brake)● Diaphragm● Master cylinder cap 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 disap- peared. j. Add brake fluid to the level line on the reservoir. WARNING Check the operation of the brake after bleeding the brake system. EC362040

● 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.

Locknut: 5 Nm (0.5 m • kg, 3.6 ft • lb) CAUTION: Be sure to tighten the locknut, as it will cause poor brake performance.

● Brake pedal height Pedal height adjustment steps: ● Loosen the locknut 1. ● Turn the adjusting nut 2 until the pedal height a is within specified height. ● Tighten the locknut. WARNING ● Adjust the pedal height between the maximum Å and the minimum ı as shown. (In this adjustment the bolt 3 end b should protrude out of the lower adjusting nut 4 but not be less than 2 mm (0.08 in) c away from the brake pedal 5). ● After the pedal height adjustment, make sure that the rear brake does not drag.

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

● Loosen the pad pin 2.● Remove the brake hose holder 3 and cal- iper 4 from the front fork. ● Remove the pad pin and brake pads 5.● Connect the transparent hose 6 to the bleed screw 7 and place the suitable con- tainer under its end. ● Loosen the bleed screw and push the cali- per piston in. CAUTION: Do not reuse the drained brake fluid. ● Tighten the bleed screw.

Bleed screw: 6 Nm (0.6 m • kg, 4.3 ft • lb) ● Install the brake pads 8 and pad pin. NOTE: ● Install the brake pads with their projec- tions a into the caliper recesses b. ● Temporarily tighten the pad pin at this point. ● Install the brake hose holder 9 and cali- per 0 and tighten the pad pin A. NOTE: Fit the brake hose holder cut c over the projection d on the front fork and clamp the brake hose.

● Brake fluid level Refer to “BRAKE FLUID LEVEL INSPECTION” section. ● Install the pad pin plug B.

● Brake lever operation A softy or spongy feeling → Bleed brake system. Refer to “BRAKE SYSTEM AIR BLEEDING” section. EC366060

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

6.4 mm (0.25 in) 1.0 mm (0.04 in)

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

● Remove the pad pin 6 and brake pads 7. ● Connect the transparent hose 8 to the bleed screw 9 and place the suitable con- tainer under its end. ● Loosen the bleed screw and push the cali- per piston in. CAUTION: Do not reuse the drained brake fluid. ● Tighten the bleed screw.

Bleed screw: 6 Nm (0.6 m • kg, 4.3 ft • lb) ● Install the brake pad 0 and pad pin A. NOTE: ● Install the brake pads with their projec- tions a into the caliper recesses b. ● Temporarily tighten the pad pin at this point. ● Install the caliper B and rear wheel C. Refer to “FRONT WHEEL AND REAR WHEEL” section in the CHAPTER 5. ● Tighten the pad pin D.

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

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

● Brake pad Refer to “REAR BRAKE PAD INSPEC- TION AND REPLACEMENT” section.

● Rear brake pad insulator 1 Damage → Replace. EC367001

BRAKE FLUID LEVEL INSPECTION

1. Place the master cylinder so that its top is

in a horizontal position.

● Brake fluid level Fluid at lower level → Fill up. a Lower level Å Front ı Rear 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 refill- ing. ● Clean up spilled fluid immediately to avoid erosion of painted surfaces or plas- tic parts. Recommended brake fluid: DOT #4

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

● Master link clip ● Joint 1 ● O-rings 2 ● Drive chain 3

● Drive chain Place it in kerosene, and brush off as much dirt as possible. Then remove the chain from the kerosene and dry the chain.

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

● Drive chain stiffness a Clean and oil the chain and hold as illustrated. Stiff → Replace drive chain.INSP ADJ CONTROLE DES PIGNONS/CONTROLE DE LA CHAINE DE TRANSMISSION

● 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

1. Elevate the rear wheel by placing the

suitable stand under the engine.

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

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

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

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

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

ADJUSTMENT ● STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position.

• 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. Standard position: 8 clicks out *12 clicks out EC36J001

● Compression damping force By turning the adjuster 1. Stiffer a → Increase the compression damping force. (Turn the adjuster 1 in.) Softer b → Decrease the compression damping force. (Turn the adjuster 1 out.) Extent of adjustment: Maximum Minimum Fully turned in position 20 clicks out (from maximum posi- tion)INSP ADJ REGLAGE DE LA FORCE D’AMORTISSEMENT DE

● STANDARD POSITION:This is the position which is back by the spe-cific number of clicks from the fully turned-inposition.* For EUROPE CAUTION: Do not force the adjuster past the minimumor maximum extent of adjustment. Theadjuster may be damaged. WARNING Always adjust each front fork to the samesetting. Uneven adjustment can cause poorhandling and loss of stability.3. Install:● Rubber cap

1. Elevate the rear wheel by placing the

suitable stand under the engine.

• For EUROPE NOTE: ● Be sure to remove all dirt and mud from around the locknut and adjuster before adjustment. ● The length of the spring (installed) changes

1.5 mm (0.06 in) per turn of the adjuster.

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

● Rear frame Stiffer → Increase the spring preload. (Turn the adjuster 2 in.) Softer → Decrease the spring preload. (Turn the adjuster 2 out.) Spring length (installed) a: Standard length Extent of adjustment 241 mm (9.49 in) *244 mm (9.61 in)

DAMPING FORCE ADJUSTMENT

● Rebound damping force By turning the adjuster 1. Stiffer a → Increase the rebound damp- ing force. (Turn the adjuster 1 in.) Softer b → Decrease the rebound damp- ing force. (Turn the adjuster 1 out.) Extent of adjustment: Maximum Minimum Fully turned in position 20 clicks out (from maximum posi- tion) ● STANDARD POSITION: This is the position which is back by the spe- cific 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.) CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. Standard position: About 10 clicks outINSP ADJ REGLAGE DE LA FORCE D’AMORTISSEMENT DE

DAMPING FORCE ADJUSTMENT

● Low compression damping force By turning the adjuster 1. Stiffer a → Increase the low compres- sion damping force. (Turn the adjuster 1 in.) Softer b → Decrease the low compres- sion damping force. (Turn the adjuster 1 out.) Extent of adjustment: Maximum Minimum Fully turned in position 20 clicks out (from maximum posi- tion) ● STANDARD POSITION: This is the position which is back by the spe- cific 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.)

● High compression damping force By turning the adjuster 1. Stiffer a → Increase the high compres- sion damping force. (Turn the adjuster 1 in.) Softer b → Decrease the high compres- sion damping force. (Turn the adjuster 1 out.) Extent of adjustment: Maximum Minimum Fully turned in position 2 turns out (from maximum posi- tion) ● STANDARD POSITION: This is the position which is back by the spe- cific 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.)

• For EUROPE CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. Standard position: About 1-1/4 turns out *About 1-1/2 turns out

REAR SHOCK ABSORBER HIGH COMPRESSION

DAMPING FORCE ADJUSTMENTINSP

● Tire pressure Out of specification → Adjust. 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. Cor- rect the tire position. Standard tire pressure: 100 kPa (1.0 kg/cm

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

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

STEERING HEAD INSPECTION AND ADJUSTMENT

● Bearing free play Exist play → Replace.

1. Elevate the front wheel by placing a suit-

able stand under the engine.

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

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

● Steering ring nut Steering ring nut adjustment steps: ● Remove the headlight. ● Remove the handlebar and handle crown. ● Loosen the ring nut 1 using the ring nut wrench 2. Ring nut wrench:

STEERING HEAD INSPECTION AND ADJUSTMENT

● Tighten the ring nut 3 using ring nut wrench 4. NOTE: Set the torque wrench to the ring nut wrench so that they form a right angle. Ring nut wrench: YU-33975/90890-01403

Ring nut (initial tightening): 38 Nm (3.8 m • kg, 27 ft • lb) ● Loosen the ring nut one turn.● Retighten the ring nut using the ring nut wrench. WARNING Avoid over-tightening.

Ring nut (final tightening): 7 Nm (0.7 m • kg, 5.1 ft • lb) ● Check the steering shaft by turning it lock to lock. If there is any binding, remove the steering shaft assembly and inspect the steering bearings. ● Install the handle crown 5, steering shaft nut 6, handlebar 7, handlebar holder 8 and headlight 9. NOTE: ● The upper handlebar holder should be installed with the punched mark a for- ward. ● Insert the end of fuel breather hose 0 into the hole of the steering shaft. CAUTION: First tighten the bolts on the front side of the handlebar holder, and then tighten the bolts on the rear side.

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

● Plug gap a Use a wire gauge or thickness gauge. Out of specification → Re-gap. Spark plug gap:

0.7 ~ 0.8 mm (0.028 ~ 0.031 in)

4. Clean the plug with a spark plug cleaner

● Spark plug NOTE: ● Before installing a spark plug, clean the gas- ket surface and plug surface. ● Finger-tighten a the spark plug before torquing to specification b.

IGNITION TIMING CHECK

IGNITION TIMING CHECK

● Timing light ● Inductive tachometer To the spark plug lead.

● Ignition timing Timing light: YM-33277-A/90890-03141 Inductive tachometer: YU-08036-B Engine tachometer: 90890-03113 Checking steps: ● Start the engine and let it warm up. Let the engine run at the specified speed. Engine speed: 1,700 ~ 1,900 r/min ● Visually check the stationary pointer a is within the firing range b on the rotor. Incorrect firing range → Check rotor and pickup assembly.

● Timing plugINSP ADJ

REPLACING THE HEADLIGHT BULBS

REPLACING THE HEADLIGHT BULBS

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

● Headlight bulb holder cover 1

● Headlight bulb holder 1

● Headlight bulb 2 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb unit it has cooled down.

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

● Headlight bulb holder

● Headlight bulb holder cover

● Headlight Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAP- TER 4. New

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

Extent of removal: Seat removal Fuel tank removal Side covers removal Headlight removalExtent of removal Order Part name Q’ty RemarksPreparation for removal SEAT, FUEL TANK AND SIDE COVERS REMOVAL Turn the fuel cock to “OFF”.Disconnect the fuel hose.1 Seat 12 Air scoop (left and right) 23 Fitting band 1 Remove on fuel tank side.4 Bolt (fuel tank) 25 Fuel tank 16 Side cover (left) 17 Side cover (right) 18 Headlight coupler 19 Headlight 1

Except for USA Extent of removal:

Exhaust pipe removal Extent of removal Order Part name Q’ty Remarks

SILENCER REMOVAL Preparation for removal Side cover (right) Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. 1 Bolt (clamp) 1 Only loosening. 2 Bolt [silencer (front)] 1 3 Bolt [silencer (rear)] 1 4 Silencer 1 5 Clamp 1 6 Nut (exhaust pipe) 1 7 Bolt (exhaust pipe) 1 8 Exhaust pipe 1 9 Gasket 2

ASSEMBLY AND INSTALLATION

Exhaust pipe and silencer

RADIATOR EC450001 RADIATOR Extent of removal:

Coolant reservoir removal Extent of removal Order Part name Q’ty Remarks RADIATOR REMOVAL Preparation for removal Drain the coolant. Refer to “COOLANT REPLACEMENT” section in the CHAPTER 3. Seat, fuel tank and side cover Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Exhaust pipe Refer to “EXHAUST PIPE AND SILENCER” section. 1 Engine guard (right) 1 2 Panel 2 3 Clamp 8 4 Radiator (right) 1 5 Hose 2 1 6 Hose 3 1 7 Hose 4 1 8 Pipe 2/O-ring 1/1 9 Radiator breather hose 1 10 Radiator (left) 1

RADIATOR Extent of removal Order Part name Q’ty Remarks11 Hose 1 112 Pipe 1/O-ring 1/113 Coolant reservoir hose 1 Coolant reservoir tank

ENG RADIATOR EC456000 HANDLING NOTE WARNING Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radi- ator cap by the following procedure: Place a thick rag, like a towel, over the radi- ator cap, slowly rotate the cap counter- clockwise to the detent. This procedure allows any residual pressure to escape. When the hissing sound has stopped, press down on the cap while turning coun- terclockwise and remove it. EC454000 INSPECTION EC444100 Radiator

Blow out with com- pressed air through rear of the radiator. Bent fin

ASSEMBLY AND INSTALLATION

● Hose 2 1 ● Radiator (left) 2

● Tuyau 1 1 ● Flexible 1 2 ● Tuyau 2 3 ● Flexible 3 4 ● Flexible 4 5

● Radiator breather hose 1 ● Radiator (right) 2 Refer to “CABLE ROUTING DIA- GRAM” section in the CHAPTER 2.

● Panel 1 ● Bolt (radiator panel upper) 2 NOTE: Fit the hook a on the inner side first into the radiator.

CARBURETOR CARBURETOR Å WR426F ı WR400F Extent of removal: 1 Carburetor removal Extent of removal Order Part name Q’ty Remarks CARBURETOR REMOVAL Preparation for removal Fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. 1 Clamp 1 2 Band 1 3 TPS coupler 1 4 Throttle cable cover 1 5 Throttle cable 2 6 Throttle cable cap 1 7 Clamp (air cleaner joint) 1 Loosen the screw (air cleaner joint). 8 Clamp (carburetor joint) 2 Loosen the screws (carburetor joint). 9 Carburetor 1 10 Carburetor joint 1

CARBURETOR EC468000 CARBURETOR DISASSEMBLY Å WR426F ı WR400F Extent of removal: 1 Carburetor disassembly Extent of removal Order Part name Q’ty Remarks CARBURETOR DISASSEMBLY 1 Breather hose 4 2 Valve lever housing cover 1 3 Screw (throttle shaft) 1 4 Throttle valve 1 5 Needle holder 1 6 Jet needle 1 7 Accelerator pump cover 1 8 Spring (accelerator pump) 1 9 Diaphragm (accelerator pump) 1 0 Air cut valve cover 1 A Spring (air cut valve) 1 B Diaphragm (air cut valve) 1 C Float chamber 1

CARBURETOR Extent of removal Order Part name Q’ty Remarks D Pilot screw 1 Refer to “REMOVAL POINTS”. E Float pin 1 F Float 1 G Needle valve 1 H Valve seat 1 I Main jet 1 J Needle jet 1 K Spacer 1 L Pilot jet 1 M Starter jet 1 N Push rod 1 Pull the push rod. O Throttle shaft assembly 1 P Push rod link lever assembly 1 Q Intake joint 1 R Pilot air jet 1 S Main air jet 1 T Cold starter plunger 1 U Hot starter plunger (red) 1

ENG CARBURETOR EC466020 HANDLING NOTE CAUTION: Do not loosen the screws {TPS (throttle position sensor)} 1 except when changing the TPS (throttle position sensor) due to failure because it will cause a drop in engine performance. REMOVAL POINTS Pilot screw

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

● Carburetor body Contamination → Clean. NOTE: ● Use a petroleum based solvent for cleaning. Blow out all passages and jets with com- pressed air. ● Never use a wire.ENG

● Main jet 1 ● Pilot jet 2 ● Needle jet 3 ● Starter jet 4 ● Main air jet 5 ● Pilot air jet 6 Damage → Replace. Contamination → Clean. NOTE: ● Use a petroleum based solvent for cleaning. Blow out all passages and jets with com- pressed air. ● Never use a wire. EC464210 Needle valve

● Needle valve 1 ● Valve seat 2 Grooved wear a → Replace. Dust b and C → Clean. NOTE: Replace the needle valve and valve seat as a set. EC464300 Throttle valve

● Free movement Stick → Repair or replace. Insert the throttle valve 1 into the car- buretor body, and check for free move- ment. EC464400 Jet needle

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

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, result- ing 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 nee- dle valve, but not compressing the needle valve. ● If the float height is not within specifica- tion, inspect the valve seat and needle valve. ● If either is worn, replace them both. ● If both are fine, adjust the float height by bending the float tab b on the float. ● Recheck the float height. EC464600 Float

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

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

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

ASSEMBLY AND INSTALLATION

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

● Spring 1 1 ● Lever 1 2 To lever 2 3. NOTE: Make sure the spring 1 fits on the stopper a of the lever 2.

● Push rod link lever assembly 1 NOTE: Make sure the stopper a of the spring 2 fits into the recess b in the carburetor.

● Plain washer 1 ● Circlip 2

● Spring 1 ● Joint collar 2 To throttle shaft 3. NOTE: Install the bigger hook a of the spring fits on the stopper b of the throttle shaft pulley.

● Throttle shaft assembly 1 ● Plain washer (metal) 2 ● Plain washer (resin) 3 ● Valve lever 4 NOTE: ● Fit the projection a on the throttle shaft assembly into the slot b in the TPS (throttle position sensor). ● Make sure the stopper c of the spring fits into the recess in the carburetor. ● Turn the throttle shaft assembly left while holding down the lever 1 5 and fit the throt- tle stop screw tip d to the stopper e of the throttle shaft assembly pulley.

• Except for USA 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: WR426F: 1-5/8 turns out *7/8 turns out WR400F: 1-1/2 turns out (example) 13.Install: ● O-ring ● Float chamber 1 ● Screw (float chamber) 2 ● Cable holder (throttle stop screw cable)

● Hose holder (carburetor breather hose)

15.Install: ● Diaphragm (accelerator pump) 1 ● Spring 2 ● O-ring 3 ● Cover 4 ● Screw (cover) 5 NOTE: Install the diaphragm (accelerator pump) with its mark a facing the spring. 16.Install: ● Jet needle 1 ● Collar 2 ● Spring 3 ● Needle holder 4 ● Throttle valve plate 5 To throttle valve 6.

17.Install: ● Throttle valve assembly 1 ● Screw (throttle shaft) 2 NOTE: Install the valve lever rollers 3 into the slits a of the throttle valve. 18.Install: ● O-ring 1 ● Valve lever housing cover 2 ● Bolt (valve lever housing cover) 3ENG

Carburetor installation

● Carburetor joint 1 NOTE: Install the projection a on the cylinder between the carburetor joint slots b.

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

● Screw (air cleaner joint) 1 ● Screw (carburetor joint) 2

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

● Throttle cable cover 1 ● Screw (throttle cable cover) 2 NOTE: Install the throttle cable cover with its pawl a hung on the carburetor.

● TPS (throttle position sensor) coupler

● Band 2 Refer to “CABLE ROUTING DIA- GRAM” section in the CHAPTER 2.

● Clamp 1 Refer to “CABLE ROUTING DIA- GRAM” section in the CHAPTER 2. 1ENG

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

REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Carburetor Refer to “CARBURETOR” section. 1 Spark plug 1 2 Engine upper bracket (right) 1 3 Engine upper bracket (left) 1 4 Cylinder head breather hose 1 5 Oil tank breather hose 1 6 Bolt (cylinder head cover) 2 7 Cylinder head cover 1 8 Gasket 1 9 Timing chain guide (upper) 1

● Timing plug 1 ● Straight plug 2

● “I” mark With stationary pointer. Checking steps: ● Turn the crankshaft counterclockwise with a wrench. ● Align the “I” mark a on the rotor with the stationary pointer b on the crankcase cover. When the “I” mark is aligned with the stationary pointer, the piston is at the Top Dead Center (T.D.C.). 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. ● If there is no clearance, rotate the crank- shaft counterclockwise one turn.

● Timing chain tensioner 2

● Bolt (camshaft cap) 1 ● Camshaft caps 2 NOTE: Remove the bolts (camshaft cap) in a criss- cross pattern, working from the outside in. CAUTION: The bolts (camshaft cap) must be removed evenly to prevent damage to the cylinder head, camshafts or camshaft caps.ENG

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

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

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

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

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

1 onto the camshaft. ● Install the circlip, 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

● Bearing diameter (camshaft) a Out of specification → Replace the camshaft. Within specification → Replace cam- shaft case and camshaft caps as a set. Camshaft sprocket

● Camshaft sprocket 1 Wear/damage → Replace the camshaft assembly and timing chain as a set. Bearing diameter (camshaft):

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

ASSEMBLY AND INSTALLATION

● Exhaust camshaft 1 ● Intake camshaft 2 Installation steps: ● Turn the crankshaft counterclockwise until the “I” mark a on the rotor is aligned with the stationary pointer b on the crankcase cover. ● Fit the timing chain 3 onto both camshaft sprockets and install the camshafts on the cylinder head. NOTE: The camshafts should be installed onto the cylinder head so that the exhaust cam sprocket punch mark c and the intake cam sprocket punch mark d align with the sur- face of the cylinder head. CAUTION: Do not turn the crankshaft during the camshaft installation. Damage or improper valve timing will result.ENG

● Timing chain tensioner

● Crankshaft Counterclockwise several turns

● Rotor “I” mark Align with the crankcase stationary pointer. ● Camshaft match marks Align with the cylinder head surface. Out of alignment → Adjust. ● Install the dowel pins, clips and camshaft caps 4.

Bolt (camshaft cap): 10 Nm (1.0 m • kg, 7.2 ft • lb) NOTE: Tighten the bolts (camshaft cap) 5 in a crisscross pattern. CAUTION: The bolts (camshaft cap) must be tight- ened evenly or damage to the cylinder head, camshaft caps and camshaft will result. 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 chain ten- sioner 2, and tighten the bolt 3 to the specified torque.

Bolt (timing chain tensioner): 10 Nm (1.0 m • kg, 7.2 ft • lb) ● Release the screwdriver, check the ten- sioner rod to come out and tighten the gasket 4 and the cap bolt 5 to the speci- fied torque.

Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Exhaust pipe and silencer Refer to “EXHAUST PIPE AND SILENCER” section. Radiator Refer to “RADIATOR” section. Carburetor Refer to “CARBURETOR” section. Camshaft Refer to “CAMSHAFTS” section. 1 Decompression cable 1 2 Cable guide 1 3 Bolt 1 4 Decompression shaft 1 5 Oil delivery pipe 1 6 Nut (M6) 2 7 Nut (M8) 2 8 Bolt (L = 150 mm) 2 9 Bolt (L = 160 mm) 2 10 Cylinder head 1

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

● Cylinder head Scratches/damage → Replace.

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

ASSEMBLY AND INSTALLATION

● Cylinder head ● Bolts (1 ~ 4) ● Nuts (5, 6) ● Nuts (7, 8) NOTE: Follow the numerical order shown in the illus- tration. Tighten the bolts and nuts in two stages.

REMOVAL Preparation for removal Cylinder head Refer to “CYLINDER HEAD” section. 1 Valve lifter 5 Use special tool. Refer to “REMOVAL POINTS”. 2 Adjusting pad 5 3 Valve cotter 10 4 Valve retainer 5 5 Valve spring 5 6 Stem seal 5 7 Valve spring seat 5 8 Exhaust valve 2 9 Intake valve 3

● Valve lifters 1 ● Pads 2 NOTE: Identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place.

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

● Valve cotters NOTE: Attach a valve spring compressor 1 between the valve spring retainer and the cylinder head to remove the valve cotters. Valve spring compressor:

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

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

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

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

● Margin thickness a Out of specification → Replace. Margin thickness: Intake:

● Runout (valve stem) Out of specification → Replace. NOTE: ● When installing a new valve always replace the guide. ● If the valve is removed or replaced always replace the oil seal.

● Carbon deposits (from the valve face and valve seat)

● Valve seats Pitting/wear → Reface the valve seat. Runout limit:

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

<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.ENG

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

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

11.9 ~ 13.7 kg at 35.38 mm

● Valve lifter Scratches/damage → Replace both lift- ers and cylinder head.ENG

Combination of cylinder head and valve lifter

For this combination, match the paint color on the cylinder head with that on the valve lifter according to the chart below. NOTE: When you purchase a cylinder head, you can- not designate its size. Choose the valve lifter that matches the above chart. Combination Cylinder head mark a (color) Valve lifter mark b (color) Blue Blue Yellow Yellow Purple Black

ASSEMBLY AND INSTALLATION

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

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

● Valve cotters NOTE: While compressing the valve spring with a valve spring compressor 1 install the valve cotters.

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. Valve spring compressor: YM-04019/90890-04019

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

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

REMOVAL Preparation for removal Cylinder head Refer to “CYLINDER HEAD” section. 1 Bolt (cylinder) 1 2 Cylinder 1 3 Gasket 1 4 Dowel pin 2 5 Dowel pin/O-ring 1/1 6 Piston pin clip 2 Use special tool. Refer to “REMOVAL POINTS”. 7 Piston pin 1 8 Piston 1 9 Piston ring set 1

● Piston pin clips 1 ● Piston pin 2 ● Piston 3 NOTE: ● Put identification marks on each piston head for reference during reinstallation. ● Before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller 4. CAUTION: Do not use a hammer to drive the piston pin out. Piston ring

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

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

● Piston-to-cylinder clearance Piston pin puller: YU-1304/90890-01304 Measurement steps: 1st step: ● Measure the cylinder bore “C” with a cylin- der bore gauge. NOTE: Measure the cylinder bore “C” in parallel to and at right angles to the crankshaft. Then, find the average of the measurements.ENG

Cylinder bore “C” WR426F:

(3.6220 ~ 3.6224 in) Taper limit “T” 0.05 mm (0.002 in) Out of round “R” 0.05 mm (0.002 in) “C” = Maximum D “T” = (Maximum D 1 or D2) – (Maximum D 5 or D6) “R” = (Maximum D 1, 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 9 mm (0.35 in) from the piston bottom edge. Piston size P Standard WR426F:

(3.6199 ~ 3.6205 in) ● If out of specification, replace the piston and piston rings as a set.ENG

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:

(0.0016 ~ 0.0026 in) <Limit>: 0.1 mm (0.004 in) ● If out of specification, replace the cylinder, and replace the piston and piston rings as set. Piston ring

● Ring side clearance Use a feeler gauge 1. Out of specification → Replace the pis- ton and rings as a set. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance.

● Piston ring In cylinder. NOTE: Insert a ring into the cylinder and push it approximately 10 mm (0.39 in) into the cylin- der. 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) Side clearance Standard <Limit> Top ring

● Ring end gap Out of specification → Replace. NOTE: You cannot measure the end gap on the expander spacer of the oil control ring. If the oil control ring rails show excessive gap, replace all three rings. End gap Standard Limit Top ring WR426F:

(0.024 in) 2nd ring WR426F:

● Piston pin-to-piston clearance

ASSEMBLY AND INSTALLATION

● Piston rings Onto the piston. NOTE: ● Be sure to install the piston rings so that the manufacturer’s marks or numbers are located on the upper side of the rings. ● Lubricate the piston and piston rings liberally with engine oil. Measurement steps: ● Measure the outside diameter (piston pin)

● 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) 45°135° 135°

● Piston 1 ● Piston pin 2 ● Piston pin clips 3 NOTE: ● Apply engine oil onto the piston pin and pis- ton. ● 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 fac- ing downward.

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

● Dowel pins● O-ring● Gasket 1 ● Cylinder 2 NOTE: Install the cylinder with one hand while com- pressing the piston rings with the other hand. CAUTION: ● Pass the timing chain 3 through the tim- ing chain cavity. ● Be careful not to damage the timing chain guide 4 during installation. New

CLUTCH (WR426F) CLUTCH (WR426F) CLUTCH Extent of removal: 1 Push rod and push lever removal 2 Push pod 1 disassembly 3 Friction plate and clutch plate removal 4 Clutch housing removal Extent of removal Order Part name Q’ty Remarks CLUTCH REMOVAL Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Brake pedal Refer to “ENGINE REMOVAL” section. Clutch cable Disconnect at engine side. 1 Clutch cover 1 2 Gasket 1 3 Dowel pin 2 4 Clutch spring 6 5 Pressure plate 1 6 Push rod 1 1 7 Circlip 1 8 Plain washer 1 9 Bearing 1 10 Ball 1

● 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. Å For USA and CDN ı Except for USA and CDN Clutch holding tool: YM-91042/90890-04086

EC494000 INSPECTION EC484100 Clutch housing and boss

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

● Circumferential play Free play exists → Replace. ● Gear teeth a Wear/damage → Replace. EC484400 Clutch spring

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

ENG CLUTCH (WR426F) EC484500 Friction plate

Friction plate thickness Out of specification

Replace friction plate as a set. Measure at all four points. EC484600 Clutch plate

Clutch plate warpage Out of specification

Replace clutch plate as a set. Use a surface plate

Friction plate thickness:

ENG CLUTCH (WR426F) EC4A5000

ASSEMBLY AND INSTALLATION

Apply the lithium soap base grease on the oil seal lip.

Apply the engine oil on the push lever.

and tighten the bolt (seat plate).

Friction plate 1 [d = ø128 mm (5.04 in)]

NOTE: Install the clutch damper spring with the “OUT SIDE” mark

NOTE: Apply the engine oil on the primary driven gear inner circumference.ENG

NOTE: Use the clutch holding tool 3 to hold the clutch boss. Å For USA and CDN ı Except for USA and CDN Clutch holding tool: YM-91042/90890-04086 New

● Friction plate 2 [d = ø119 mm (4.69 in)] ● Clutch plate 2 NOTE: ● Install the clutch plates and friction plates 2 alternately on the clutch boss, starting with a friction plate and ending with a friction plate. ● Apply the engine oil on the friction plates and clutch plates.

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

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

● Clutch spring ● Bolt (clutch spring) NOTE: Tighten the bolts in stage, using a crisscross pattern.

CLUTCH (WR400F) CLUTCH (WR400F) CLUTCH Extent of removal: 1 Push rod and push lever removal 2 Push rod 1 disassembly 3 Friction plate and clutch plate removal 4 Clutch housing removal Extent of removal Order Part name Q’ty Remarks CLUTCH REMOVAL Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Brake pedal Refer to “ENGINE REMOVAL” section. Clutch cable Disconnect at engine side. 1 Clutch cover 1 2 Gasket 1 3 Dowel pin 2 4 Clutch spring 5 5 Pressure plate 1 6 Push rod 1 1 7 Circlip 1 8 Plain washer 1 9 Bearing 1

● 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. Å For USA and CDN ı Except for USA and CDN Clutch holding tool: YM-91042/90890-04086

EC494000 INSPECTION EC484100 Clutch housing and boss

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

● Circumferential play Free play exists → Replace. ● Gear teeth a Wear/damage → Replace. EC484400 Clutch spring

● Clutch spring free length a Out of specification → Replace springs as a set. Clutch spring free length: Standard <Limit> 44 mm (1.73 in) 43 mm (1.69 in)ENG

● Friction plate thickness Out of specification → Replace friction plate as a set. Measure at all four points. EC484600 Clutch plate

● Clutch plate warpage Out of specification → Replace clutch plate as a set. Use a surface plate 1 and thickness gauge 2. Friction plate thickness: Friction plate 1 [ø112 mm (4.41 in)]:

ENG CLUTCH (WR400F) EC4A5000

ASSEMBLY AND INSTALLATION

● Push lever 1 ● Bolt (push lever) NOTE: ● Apply the lithium soap base grease on the oil seal lip. ● Apply the engine oil on the push lever. ● Fit the seat plate 2 in the groove a of the push lever 1 and tighten the bolt (seat plate).

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

● Lock washer 1 ● Nut (clutch boss) 2 NOTE: Use the clutch holding tool 3 to hold the clutch boss. Å For USA and CDN ı Except for USA and CDN Clutch holding tool: YM-91042/90890-04086 New

● Friction plate 1 [d = ø112 mm (4.41 in)]

● Clutch plate 2 ● Friction plate 2 [d = ø116 mm (4.57 in)]

NOTE: ● Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate 1 and ending with a friction plate

● Apply the engine oil on the friction plates and clutch plates.

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

● Pressure plate 1 NOTE: Align the much mark a on the pressure plate with the punched mark b on the clutch boss.ENG

● Clutch spring ● Bolt (clutch spring) NOTE: Tighten the bolts in stage, using a crisscross pattern.

● Gasket (clutch cover) 1 ● Dowel pin 2 New 10.Install: ● Clutch cover 1 ● Bolt (clutch cover) NOTE: Tighten the bolts in stage, using a crisscross pattern.

OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) Extent of removal: 1 Oil filter removal 2 Water pump removal 3 Crankcase cover (right) removal Extent of removal Order Part name Q’ty Remarks

(RIGHT) REMOVAL Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Drain the coolant. Refer to “COOLANT REPLACEMENT” section in the CHAPTER 3. Exhaust pipe Refer to “EXHAUST PIPE AND SILENCER” section. Brake pedal Refer to “ENGINE REMOVAL” section. Clutch cover Refer to “CLUTCH” section. 1 Oil filter cover 1 2 Oil filter 1 3 Coolant pipe 2 1 4 Water pump housing 1 5 Pin 2 6 Oil delivery pipe 1

OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT) Extent of removal Order Part name Q’ty Remarks 7 Oil hose 1 8 Kick crank 1 9 Crankcase cover (right) 1 10 Gasket 1 11 Dowel pin/O-ring 4/2 12 Impeller 1 Refer to “REMOVAL POINTS”. 13 Plain washer 1 14 Impeller shaft 1 15 Oil seal 1 1 16 Oil seal 2 1 17 Bearing 1

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

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

● Oil seal Wear/damage → Replace.

ASSEMBLY AND INSTALLATION

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

● Bearing 1 NOTE: Install the bearing by pressing its outer race parallel. New OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT)ENG

● Impeller shaft 1 ● Plain washer 2 ● Impeller 3 NOTE: ● Take care so that the oil seal lip is not dam- aged or the spring does not slip off its posi- tion. ● When installing the impeller shaft, apply the engine oil on the oil seal lip, bearing and impeller shaft. And install the shaft while turning it. ● Hold the impeller shaft on its width across the flats a with spanners, etc. and remove the impeller.

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

● Crankcase cover (right) 1 ● Bolt NOTE: ● Apply the engine oil on the impeller shaft end. ● When installing the crankcase cover onto the crankcase, be sure that the impeller shaft end 2 aligns with the balancer end slot 3. ● Tighten the bolts in stage, using a crisscross pattern.

● Kick crank 1 ● Plain washer ● Bolt (kick crank) NOTE: Install the kick crank so that the kick crank is as vertical as possible with the distance a between the kick crank and the frame being 5 mm (0.20 in) or more.

● Oil hose 1 ● Bolt (oil hose) 2

● Copper washer 1 ● Oil delivery pipe 2 ● Union bolt (M8) 3 ● Union bolt (M10) 4 New

● Dowel pin 1 ● O-ring 2 NewENG

● Water pump housing 1 ● Bolt (water pump housing) 2 ● Plain washer 3 ● Coolant drain bolt 4

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

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

BALANCER BALANCER BALANCER Extent of removal: 1 Balancer drive gear 2 Balancer Extent of removal Order Part name Q’ty Remarks BALANCER REMOVAL Preparation for removal Clutch housing Refer to “CLUTCH” section. Crankcase cover (right) Refer to “OIL FILTER, WATER PUMP AND CRANKCASE COVER (RIGHT)” section. Stator Refer to “CDI MAGNETO” section. 1 Nut (primary drive gear) 1 Refer to “REMOVAL POINTS”. 2 Nut (balancer) 1 3 Lock washer 1 4 Primary drive gear 1 5 Balancer drive gear 1 6 Lock washer 1 7 Balancer driven gear 1 8 Balancer 1 Refer to “REMOVAL POINTS”.

ENG BALANCER REMOVAL POINTS Balancer drive gear and balancer driven gear

● Nut (primary drive gear) 1 ● Nut (balancer) 2 NOTE: Place an aluminum plate a between the teeth of the balancer drive gear 3 and driven gear

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

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

ASSEMBLY AND INSTALLATION

Balancer, balancer drive gear and balancer driven gear

● Balancer 1 NOTE: When installing the balancer shaft, align the center of the balancer shaft weight a along the line connecting the centers of the crank- shaft and balancer shaft.

● Balancer driven gear 1 NOTE: Install the balancer driven gear onto the bal- ancer while aligning the punch mark a on the balancer driven gear with the cut b in the bal- ancer end.

● Balancer drive gear 1 NOTE: ● Align the punched mark a on the balancer drive gear with the punched mark b on the balancer driven gear. ● Align the punched mark c on the balancer drive gear with the lower spline d on the crankshaft.

● Lock washer 1 ● Nut (balancer) 2 ● Primary drive gear 3 ● Nut (primary drive gear) 4 NOTE: ● Install the primary drive gear with its stepped side b facing the engine. ● Place an aluminum plate a between the teeth of the balancer drive gear 5 and driven gear 6.

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

OIL PUMP REMOVAL AND DIS-

ASSEMBLY Clutch housing Refer to “CLUTCH” section. Crankcase cover (right) Refer to “OIL FILTER, WATER PUMP

AND CRANKCASE COVER (RIGHT)”

section. 1 Circlip 1 2 Plate washer 1 3 Oil pump drive gear 1 4 Oil pump assembly 1 5 Dowel pin 1 6 Outer rotor 2 1 7 Circlip 1 8 Inner rotor 2 1 9 Pin 1 10 Oil pump cover 1 11 Outer rotor 1 1

Extent of removal Order Part name Q’ty Remarks 13 Pin 1 14 Washer 1 15 Oil pump drive shaft 1 16 Rotor housing 1

● Oil pump drive gear ● Oil pump driven gear ● Rotor housing ● Oil pump cover Cracks/wear/damage → Replace.

● Tip clearance a Between the inner rotor 1 and the outer rotor 2. ● Tip clearance b Between the outer rotor 2 and the rotor housing 3. Out of specification → Replace the oil pump. Tip clearance a:

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

ASSEMBLY AND INSTALLATION

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

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

● Oil pump cover 1 ● Screw (oil pump cover) 2 ● Pin 3 ● Inner rotor 2 4 ● Circlip 5 NOTE: ● Apply the engine oil on the oil pump drive shaft end and inner rotor 2. ● Fit the pin into the groove in the inner rotor 2.

● Outer rotor 2 1 ● Dowel pin 2 ● Oil pump assembly 3 ● Bolt (oil pump assembly) [L = 30 mm (1.18 in)] 4 ● Bolt (oil pump assembly) [L = 25 mm (0.98 in)] 5 NOTE: Apply the engine oil on the outer rotor 2.

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

KICK AXLE AND SHIFT SHAFT

KICK AXLE AND SHIFT SHAFT

KICK AXLE AND SHIFT SHAFT

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

KICK AXLE AND SHIFT SHAFT

REMOVAL Preparation for removal Shift pedal Refer to “CDI MAGNETO” section. Oil pump Refer to “OIL PUMP” section. 1 Kick idle gear 1 2 Kick axle assembly 1 Refer to “REMOVAL POINTS”. 3 Spring guide 1 4 Torsion spring 1 5 Ratchet wheel 1 6 Kick gear 1 7 Kick axle 1 8 Plain washer 1 9 Shift shaft 1

KICK AXLE AND SHIFT SHAFT

KICK AXLE AND SHIFT SHAFT

REMOVAL POINTS EC4B3101 Kick axle assembly

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

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

● Bolt (segment) 1 ● Segment 2 NOTE: Turn the segment counterclockwise until it stops and loosen the bolt. INSPECTION EC4C4200 Kick axle and ratchet wheel

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

KICK AXLE AND SHIFT SHAFT

ASSEMBLY AND INSTALLATION

● Segment 1 ● Bolt (segment) NOTE: Align the notch a on the segment with the pin b on the shift cam.

KICK AXLE AND SHIFT SHAFT

● Torsion spring 1 ● Stopper lever 2 ● Bolt (stopper lever) 3 NOTE: Align the stopper lever roller with the slot on segment.

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

● 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.ENG

KICK AXLE AND SHIFT SHAFT

● Bolt (shift guide) 1

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

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

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

KICK AXLE AND SHIFT SHAFT

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

● Kick axle assembly 1 ● Plain washer 2 NOTE: ● Apply the engine oil on the kick axle. ● Slide the kick axle assembly into the crank- case, make sure the kick axle stopper a fit into their home position 3.

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

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

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

Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Bolt [radiator (left)] Disconnect the CDI magneto lead. Refer to “RADIATOR” section. 1 Engine guard (left) 1 2 Shift pedal 1 3 Crankcase cover (left) 1 4 Gasket 1 5 Dowel pin 2 6 Nut (rotor) 1 Use special tool. Refer to “REMOVAL POINTS”. 7 Rotor 1 8 Stator 1

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

ASSEMBLY AND INSTALLATION

● Stator 1 ● Screw (stator) 2 NOTE: ● Apply the sealant to the grommet of the CDI magneto lead. ● Tighten the screws using the T30 bit. Quick gasket

● 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.

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

● Gasket [crankcase cover (left)] ● Crankcase cover (left) 1 ● Hose holder (cylinder head breather hose) 2 ● Bolt [crankcase cover (left)] NOTE: Tighten the screws in stage, using a crisscross pattern. New

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

● Engine guard (left) 1 ● Hose holder (cylinder head breather hose) 2 ● Bolt [engine guard (left)]

ENGINE REMOVAL EC4M0000 ENGINE REMOVAL Extent of removal Order Part name Q’ty Remarks ENGINE REMOVAL Preparation for removal Hold the machine by placing the suitable stand under the frame. WARNING Support the machine securely so there is nodanger of it falling over. Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Carburetor Refer to “CARBURETOR” section. Exhaust pipe and silencer Refer to “EXHAUST PIPE AND SILENCER” section. Clutch cable Disconnect at engine side. Decompression cable and guide Disconnect at engine side. Radiator Refer to “RADIATOR” section. Shift pedal Refer to “CDI MAGNETO” section. Cylinder head breather hose and oil tank breather hose Refer to “CAMSHAFTS” section. Drain the engine oil Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Spark plug cap Disconnect the CDI magneto lead.4 - 87 ENG

ENGINE REMOVAL Extent of removal: 1 Engine removal Extent of removal Order Part name Q’ty Remarks 1 Engine skidplate 1 2 Neutral switch 1 3 Oil hose 2 4 Chain cover 1 Refer to “REMOVAL POINTS”.5 Nut (drive sprocket) 1 6 Lock washer 1 7 Drive sprocket 1 8 Clip 1 9 Bolt (brake pedal) 1 10 Brake pedal 1 11 Engine upper bracket (right) 1 12 Engine upper bracket (left) 1 13 Engine lower bracket 2 14 Engine mounting bolt 3 15 Pivot shaft 1 Refer to “REMOVAL POINTS”. 16 Engine 1

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

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

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

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

ASSEMBLY AND INSTALLATION

EC4M5160 Engine installation

● Engine 1 Install the engine from right side. ● Pivot shaft 2 ● Engine mounting bolt (lower) 3 ● Engine lower bracket 4 ● Bolt (engine bracket) 5 ● Engine mounting bolt (front) 6 ● Engine upper bracket (right) 7 ● Engine upper bracket (left) 8 ● Bolt (engine bracket) 9 ● Engine mounting bolt (upper) 0 EC4M5211 Brake pedal

● Spring ● Brake pedal 1 ● O-ring 2 ● Bolt (brake pedal) 3 ● Clip 4 NOTE: ● Apply the lithium soap base grease on the bolt, O-rings and brake pedal bracket. ● Install the clip with its stopper portion a fac- ing inward.

● Lock washer 1 ● Nut (drive sprocket) 2 NOTE: Tighten the nut while applying the rear brake. New

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

● Oil hose 1 ● Bolt (oil hose) 2

● Spring 1 ● Pin 2 ● O-ring 3 ● Neutral switch 4 ● Bolt (neutral switch) 5 NOTE: Apply the lithium soap base grease on the O- ring. New

CRANKCASE AND CRANKSHAFT

CRANKCASE AND CRANKSHAFT

CRANKCASE AND CRANKSHAFT

Extent of removal: 1 Crankcase separation 2 Crankshaft removal Extent of removal Order Part name Q’ty Remarks CRANKCASE SEPARATION Preparation for removal Engine Refer to “ENGINE REMOVAL” section. Piston Refer to “CYLINDER AND PISTON” sec- tion. Balancer Refer to “BALANCER” section. Kick axle assembly Refer to “KICK AXLE AND SHIFT SHAFT” section. Segment Stator Refer to “CDI MAGNETO” section. 1 Timing chain guide (rear) 1 2 Timing chain 1 3 Bolt (40 mm) 3 Refer to “REMOVAL POINTS”. 4 Bolt (50 mm) 4 5 Bolt (60 mm) 2 6 Bolt (75 mm) 3 7 Hose guide 1 8 Clutch cable holder 1 9 Crankcase (right) 1 10 Crankcase (left) 1

CRANKCASE AND CRANKSHAFT

Extent of removal Order Part name Q’ty Remarks 11 Oil strainer 1 12 Oil delivery pipe 2 1 13 Crankshaft 1 Use special tool. Refer to “REMOVAL POINTS”.

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

CRANKCASE AND CRANKSHAFT

REMOVAL POINTS Crankcase

● Crankcase (right) ● Crankcase (left) Separation steps: ● Remove the crankcase bolts, hose guide and clutch cable holder. NOTE: Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them. ● Remove the crankcase (right). NOTE: ● Place the crankcase with its left side downward and split it by inserting a screw- driver tip into the splitting slit a in the crankcase. ● Lift the crankcase (right) horizontally while lightly patting the case splitting slit and engine mounting boss using a soft ham- mer, and leave the crankshaft and trans- mission with the crankcase (left). CAUTION: Use soft hammer to tap on the case half. Tap only on reinforced portions of case. Do not tap on gasket mating surface. Work slowly and carefully. Make sure the case halves separate evenly. If one end “hangs up”, take pressure off the push screw, realign, and start over. If the cases do not separate, check for a remaining case screw or fitting. Do not force. ● Remove the dowel pins and O-ring. aENG

● Crankshaft 1 Use the crankcase separating tool 2. CAUTION: Do not use a hammer to drive out the crankshaft. Crankshaft bearing

● Bearing 1 NOTE: ● Remove the bearing from the crankcase by pressing its inner race. ● Do not use the removed bearing. Crankcase separating tool: YU-1135-A/90890-01135 INSPECTION Timing chain and timing chain guide

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

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

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

● Oil seal Wear/damage → Replace.

CRANKCASE AND CRANKSHAFTENG

CRANKCASE AND CRANKSHAFT

(0.002 in) Small end free play:

(0.08 in) Side clearance:

● Oil strainer Damage → Replace. Oil delivery pipe

● Oil delivery pipe Cracks/damage → Replace. ● Oil delivery pipe holes 1 Clogged → Blow out with compressed air.ENG

ASSEMBLY AND INSTALLATION

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

● Crankshaft 1 Use the crankshaft installing tool 2, 3, 4, 5. Å For USA and CDN ı Except for USA and CDN NOTE: ● Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other. Operate the installing tool until the crankshaft bottoms against the bearing. ● Before installing the crankshaft, clean the contacting surface of crankcase. CAUTION: Do not use a hammer to drive in the crank- shaft. Crankshaft installing tool: Pot 2: YU-90050/90890-01274 Bolt 3: YU-90050/90890-01275 Adapter 4: YM-1277/90890-01277 Spacer 5: YM-91044/90890-04081 New

CRANKCASE AND CRANKSHAFTENG

CRANKCASE AND CRANKSHAFT

● Shifter operation ● Transmission operation Unsmooth operation → Repair.

● Oil strainer 1 ● Bolt (oil strainer) 2

● Sealant On the crankcase (right) 1. NOTE: Clean the contacting surface of crankcase (left and right) before applying the sealant.

● Dowel pin 1 ● O-ring 2 ● Crankcase (right) To crankcase (left). NOTE: ● Fit the crankcase (right) onto the crankcase (left). Tap lightly on the case with soft ham- mer. ● When installing the crankcase, the connect- ing rod should be positioned at TDC (top dead center). Quick gasket

CRANKCASE AND CRANKSHAFT

● Oil delivery pipe ● O-ring ● Bolt (oil delivery pipe)

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

● Sealant Forced out on the cylinder mating sur- face. 10.Apply: ● Engine oil To the crank pin, bearing and oil deliv- ery hole. 11.Check: ● Crankshaft and transmission operation. Unsmooth operation → Repair. New

TRANSMISSION, SHIFT CAM AND SHIFT FORK

TRANSMISSION, SHIFT CAM AND SHIFT FORK

TRANSMISSION, SHIFT CAM AND SHIFT FORK

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

TRANSMISSION, SHIFT CAM

AND SHIFT FORK REMOVAL

Preparation for removal Engine Refer to “ENGINE REMOVAL” section. Separate the crankcase. Refer to “CRANKCASE AND CRANK- SHAFT” section. 1 Shift fork 1 1 Refer to “REMOVAL POINTS”. 2 Shift fork 2 1 3 Shift fork 3 1 4 Shift cam 1 5 Main axle 1 6 Drive axle 1

TRANSMISSION, SHIFT CAM AND SHIFT FORK

EC4H3000 REMOVAL POINTS Shift fork, shaft cam and transmission

● Shift forks ● Shift cam ● Main axle ● Drive axle NOTE: ● Tap lightly on the transmission drive axle and shift cam with a soft hammer to remove. ● Remove assembly carefully. Note the posi- tion of each part. Pay particular attention to the location and direction of shift forks. EC4H4000 INSPECTION EC4H4200 Gears

● O-ring 1 Damage → Replace.

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

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

TRANSMISSION, SHIFT CAM AND SHIFT FORK

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

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

ASSEMBLY AND INSTALLATION

● 5th pinion gear (25T) 1 ● 3rd pinion gear (16T) 2 ● Collar 3 ● 4th pinion gear (20T) 4 ● 2nd pinion gear (15T) 5 To main axle 6. NOTE: ● Apply the molybdenum disulfide oil on the 4th and 5th pinion gears inner circumference and on the end surface. ● Apply the molybdenum disulfide oil on the 2nd and 3rd pinion gears inner circumfer- ence.ENG

TRANSMISSION, SHIFT CAM AND SHIFT FORK

● 2nd wheel gear (26T) 1 ● 4th wheel gear (21T) 2 ● 3rd wheel gear (21T) 3 ● 5th wheel gear (21T) 4 ● 1st wheel gear (29T) 5 ● O-ring 6 To drive axle 7. NOTE: ● Apply the molybdenum disulfide oil on the 1st, 2nd and 3rd wheel gears inner circum- ference and on the end surface. ● Apply the molybdenum disulfide oil on the 4th and 5th wheel gears inner circumfer- ence. ● Apply the lithium soap base grease on the O- ring.

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

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

TRANSMISSION, SHIFT CAM AND SHIFT FORK

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

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

● Shifter operation ● Transmission operation Unsmooth operation → Repair.ENG

EC598000 FRONT WHEEL Extent of removal: Front wheel removal Wheel bearing removal Break disc removalExtent of removal Order Part name Q’ty RemarksPreparation for removal FRONT WHEEL REMOVAL Hold the machine by placing thesuitable stand under the engine.WARNING Support the machine securely so there is no danger of it falling over. 1 Trip meter cable 12 Hose cover 13 Bolt (brake hose holder) 2 Only loosening.4 Bolt (axle holder) 4 Only loosening.5 Nut (front wheel axle) 16 Front wheel axle 17 Front wheel 18 Trip meter gear unit 19 Collar 110 Oil seal 111 Bearing 2 Refer to “REMOVAL POINTS”.12 Brake disc 1

Wheel bearing removal

Brake disc removal Extent of removal Order Part name Q’ty Remarks Preparation for 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. 1 Nut (rear wheel axle) 1 2 Rear wheel axle 1 3 Chain puller 2 4 Rear wheel 1 Refer to “REMOVAL POINTS”. 5 Collar 2 6 Driven sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 2 Refer to “REMOVAL POINTS”.

EC593000 REMOVAL POINTS EC523101 Rear wheel

NOTE: Push the wheel forward and remove the drive chain

NOTE: Remove the bearing using a general bearing puller

Wheel runout Out of limit

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

Replace. NOTE: Replace the bearings, oil seal and wheel collar as a set. Wheel runout limit: Radial

Wheel axle bends Out of specification

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

Brake disc deflection (only rear brake disc) Use the dial gauge

Out of specification

Inspect wheel runout. If wheel runout is in good condition, replace the brake disc.

Brake disc thickness

(0.006 in) Disc wear limit: Standard <Limit> Front

ASSEMBLY AND INSTALLATION

Apply the lithium soap base grease on the bearing and oil seal lip when installing.

Use a socket that matches the outside diam- eter of the race of the bearing.

Left side of bearing shall be installed first.

Install the oil seal with its manufacture’s marks or numbers facing outward. CAUTION: Do not strike the inner race of the bearing. Contact should be made only with the outer race.

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

● Trip meter gear unit 1 NOTE: Make sure the two projections a in the wheel hub are meshed with the two slots b in the trip meter gear unit.

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

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

● Nut (wheel axle) 1

● Bolt (axle holder) 1 NOTE: Before tightening the bolt, fit the wheel axle to the axle holder by stroking the front fork sev- eral times with the front brake applied.

● Brake hose 1 To brake hose holder 2. NOTE: Before tightening the bolt (brake hose holder), pass the brake hose in front of the axle boss a, then fit it into the hose groove b so that the brake hose does not contact the nut (wheel axle).

10 Nm (1.0 m · kg, 7.2 ft · lb) 10.Install: ● Hose cover 1 ● Plain washer 2 ● Bolt [hose cover (M8)] 3 ● Bolt [hose cover (M6)] 4

CHAS EC5251A0 Rear wheel

● 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 diam- eter 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. New New

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

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

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

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

● Chain puller (right) 1 ● Plain washer 2 ● Nut (wheel axle) 3 NOTE: Temporarily tighten the nut (wheel axle) at this point.5 - 9 CHAS

● Drive chain slack a Refer to “DRIVE CHAIN SLACK ADJUSTMENT” section in the CHAP- TER 3. Drive chain slack: 40 ~ 50 mm (1.6 ~ 2.0 in) 10.Tighten: ● Nut (wheel axle) 1 ● Locknut 2

EC5A8000 FRONT BRAKE Extent of removal: 1 Brake hose removal 2 Caliper removal 3 Master cylinder removal Extent of removal Order Part name Q’ty Remarks Preparation for removal

Hold the machine by placing the suitable stand under the engine. Drain the brake fluid. WARNINGSupport the machine securely so there is nodanger of it falling over. Refer to “REMOVAL POINTS”. 1 Hose cover 1 2 Brake hose holder 1 3 Bolt (brake hose holder) 2 Only loosening. 4 Union bolt 2 5 Brake hose 1 6 Pad pin plug 1 Remove when loosening the pad pin. 7 Pad pin 1 Loosen when disassembling the caliper. 8 Caliper 1 9 Brake lever 1 10 Master cylinder bracket 1 11 Master cylinder 1

CHAS EC5A8100 REAR BRAKE Extent of removal: 1 Caliper removal 2 Brake hose removal 3 Master cylinder removal Extent of removal Order Part name Q’ty Remarks Preparation for removal

Hold the machine by placing the suitable stand under the engine. WARNINGSupport the machine securely so there is nodanger of it falling over. Rear wheel Refer to “FRONT WHEEL AND REAR WHEEL” section. Drain the brake fluid. Refer to “REMOVAL POINTS”. 1 Pad pin plug 1 Remove when loosening the pad pin. 2 Pad pin 1 Loosen when disassembling the caliper. 3 Caliper 1 4 Brake hose holder 2 5 Union bolt 2 6 Brake hose 1 7 Brake pedal 1 8 Reservoir tank 1 9 Reservoir hose 1

CHAS EC5A8200 CALIPER DISASSEMBLY Å Front ı Rear Extent of removal: 1 Front caliper disassembly 2 Rear caliper disassembly Extent of removal Order Part name Q’ty Remarks

CALIPER DISASSEMBLY AB

1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Caliper piston 2 1 Refer to “REMOVAL POINTS”. 5 Dust seal 2 1 Refer to “REMOVAL POINTS”. 6 Piston seal 2 1

Å Front ı Rear Extent of removal: 1 Front master cylinder disassembly 2 Rear master cylinder disassembly Extent of removal Order Part name Q’ty Remarks

EC5A3000 REMOVAL POINTS Brake fluid

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

2. Connect the transparent hose 2 to the

bleed screw 1 and place a suitable con- tainer under its end. Å Frontı Rear

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.

● Caliper piston Use compressed air and proceed care- fully. WARNING ● Cover piston with rag and use extreme caution when expelling piston from cylin- der. ● Never attempt to pry out piston.Å Frontı Rear Caliper piston removal steps: ● Insert a piece of rag into the caliper to lock one caliper. ● Carefully force the piston out of the caliper cylinder with compressed air.

EC533402 Piston seal kit

● Dust seal 1 ● Piston seal 2 NOTE: Remove the piston seals and dust seals by pushing them with a finger. CAUTION: Never attempt to pry out piston seals and dust seals. WARNING Replace the piston seals and dust seals whenever a caliper is disassembled. Å Frontı Rear

● Master cylinder inner surface a Wear/scratches → Replace master cyl- inder assembly. Stains → Clean. WARNING Use only new brake fluid. Å Frontı Rear

● Master cylinder piston 1 ● Master cylinder cup 2 Wear/damage/score marks → Replace master cylinder kit. Å Frontı Rear

● Caliper cylinder inner surface a Wear/score marks → Replace caliper assembly. Å Front ı Rear

● Caliper piston 1 Wear/score marks → Replace caliper piston assembly. WARNING Replace the piston seals and dust seals 2 whenever a caliper is disassembled. EC534301 Brake hose

● Brake hose 1 Crack/damage → Replace. EC5A5000

ASSEMBLY AND INSTALLATION

WARNING ● All internal parts should be cleaned in new brake fluid only. ● Internal parts should be lubricated with brake fluid when installed. ● Replace the piston seals and dust seals whenever a caliper is disassembled. EC5A5800 Caliper piston

● Caliper● Piston seal● Dust seal● Caliper piston Clean them with brake fluid.

● Piston seal 1 ● Dust seal 2 WARNING Always use new piston seals and dust seals. NOTE: Fit the piston seals and dust seals onto the slot on caliper correctly. Å Frontı Rear

● Caliper piston 1 NOTE: Apply the brake fluid on the piston wall. CAUTION: ● For the front caliper, install the piston with its depressed side a facing the cali- per. For the rear caliper, install the piston with its shallow depressed side b facing the caliper. ● Never force to insert.Å Frontı RearEC5A5700 Front caliper

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

● Copper washer 1● Union bolt 2 WARNING Always use new copper washers. CAUTION: Install the brake hose so that its pipe por- tion a directs as show and lightly touches the projection b on the caliper. New

● Brake hose holder 1 ● Caliper 2 ● Bolt (caliper) 3 NOTE: Fit the brake hose holder cut a over the pro- jection b on the front fork and clamp the brake hose.

● Pad support 1 ● Brake pad 2 ● Pad pin 3 NOTE: ● Install the brake pads with their projections a into the caliper recesses b. ● Temporarily tighten the pad pin at this point.5 - 19 CHAS

● Disc cover 1 ● Bolt (disc cover) 2

● Copper washer 1 ● Brake hose 2 ● Union bolt 3 WARNING Always use new copper washers. CAUTION: Install the brake hose to the caliper with the paint a on the pipe facing the caliper and with the pipe contacting the caliper projec- tion b. New

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

● Master cylinder● Master cylinder kit Clean them with brake fluid.

● Master cylinder cup (primary) 1 ● Master cylinder cup (secondary) 2 To master cylinder piston 3. NOTE: Apply the brake fluid on the master cylinder cup. WARNING After installing, cylinder cup should be installed as shown direction. Wrong instal- lation cause improper brake performance. Å Front ı Rear

● Spring 1 To master cylinder piston 2. NOTE: Install the spring at the smaller dia. side. Å Front ı Rear

[Front] ● Master cylinder kit 1 ● Plain washer 2 ● Circlip 3 ● Master cylinder boot 4 To master cylinder 5. [Rear] ● Master cylinder kit 1 ● Push rod 2 ● Circlip 3 ● Master cylinder boot 4 To master cylinder 5. NOTE: ● Apply the brake fluid on the master cylinder kit. ● Apply the lithium soap base grease on the tip of the push rod. ● When installing the circlip, use a long nose circlip pliers. Å Front ı Rear

EC5A5310 Front master cylinder

● Master cylinder 1 ● Master cylinder bracket 2 ● Bolt (master cylinder bracket) 3 NOTE: ● Install the bracket so that the arrow mark a face upward. ● First tighten the bolts on the upper side of the master cylinder bracket, and then tighten the bolts on the lower side.

● Brake lever 1 ● Bolt (brake lever) 2 ● Nut (brake lever) 3 NOTE: Apply the lithium soap base grease on the brake lever sliding surface, bolt and contacting surface of the master cylinder piston. Rear master cylinder

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

● Master cylinder 1 ● Bolt (master cylinder) 2

● Spring 1 ● Brake pedal 2 ● O-ring 3 ● Bolt (brake pedal) 4 ● Clip 5 NOTE: ● Apply the lithium soap base grease on the bolt, O-ring and brake pedal bracket. ● Install the clip with its stopper portion a fac- ing inward. New

● Pin 1 ● Plain washer 2 ● Cotter pin 3 NOTE: After installing, check the brake pedal height. Refer to “REAR BRAKE ADJUSTMENT” sec- tion in the CHAPTER 3. New Front brake hose

● Brake hose 1 To brake hose holder 2. NOTE: Before tightening the bolt (brake hose holder), pass the brake hose in front of the axle boss a, then fit it into the hose groove b so that the brake hose does not contact the nut (wheel axle).

● Hose cover 1 ● Plain washer 2 ● Bolt [hose cover (M8)] 3 ● Bolt [hose cover (M6)] 4

3. Pass the brake hose through the cable

● Copper washer 1 ● Brake hose 2 ● Union bolt 3 WARNING Always use new copper washers. CAUTION: Install the brake hose so that its pipe por- tion a directs as show and lightly touches the projection b on the master cylinder. New

● Copper washer 1 ● Brake hose 2 ● Copper washer 3● Union bolt 4 WARNING Always use new copper washers. CAUTION: When installing the brake hose, first align the tooth a on the copper washer 1 with the projection b on the master cylinder. Then, align the pipe portion c on the end of the brake hose with the tooth d on the copper washer 1 and tighten the union bolt. New New

● Brake hose holder 1 ● Screw (brake hose holder) 2 CAUTION: After installing the brake hose holders, make sure the brake hose does not contact the spring (rear shock absorber). If it does, correct its twist.

● Brake fluid Until the fluid level reaches “LOWER” level line a. WARNING ● Use only the designated quality brake fluid: otherwise, the rubber seals may deterio- rate, causing leakage and poor brake per- formance. ● Refill with the same type of brake fluid; mixing fluids may result in a harmful chem- ical reaction and lead to poor performance. ● Be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. CAUTION: Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately. Å Front ı Rear Recommended brake fluid: DOT #4

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

[Front] ● Diaphragm● Master cylinder cap 1 ● Screw (master cylinder cap) 2 [Rear] ● Diaphragm● Reservoir tank cap 1 ● Screw (reservoir tank cap) 2 ● Master cylinder guard CAUTION: After installation, while pulling the lever in or pushing down on the pedal, check whether there is any brake fluid leaking where the union bolts are installed respec- tively at the master cylinder and caliper. Å Front ı Rear

5. Install: (rear brake only)

Hold the machine by placing the suitable stand under the engine. WARNINGSupport the machine securely so there is nodanger of it falling over. Front wheel Refer to “FRONT WHEEL AND REAR WHEEL” section. Front caliper Refer to “FRONT BRAKE AND REAR BRAKE” section. Headlight Handlebar Refer to “HANDLEBAR” section. 1 Protector 1 2 Brake hose holder 2 3 Pinch bolt (handle crown) 2 Only loosening. 4 Cap bolt 1 Loosen when disassembling the front fork. 5 Pinch bolt (under bracket) 2 Only loosening. 6 Front fork 1

Extent of removal: 1 Oil seal removal 2 Damper rod removal Extent of removal Order Part name Q’ty Remarks

FRONT FORK DISASSEMBLY

1 Cap bolt 1 Refer to “REMOVAL POINTS”. 2 Fork spring 1 Drain the fork oil. 3 Dust seal 1 Refer to “REMOVAL POINTS”.4 Stopper ring 1 5 Inner tube 1 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Plain washer 1 0 Oil seal 1 A Spring guide 1 B Base valve 1 Use special tool. Refer to “REMOVAL POINTS”. C Damper rod 1

CHAS FRONT FORK EC556000 HANDLING NOTE NOTE: The front fork requires careful attention. So it is recommended that the front fork be main- tained 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 con- struction 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 disas- sembled and reassembled. ● Before removing the cap bolts or front forks, be sure to extract the air from the air chamber completely. EC553000 REMOVAL POINTS EC553150 Cap bolt

● Dust seal 1 ● Stopper ring 2 Using slotted-head screwdriver. CAUTION: Take care not to scratch the inner tube.

● Damper rod 1 Bend/damage → Replace damper rod. CAUTION: The front fork with a built-in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material. Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled. Oil seal removal steps: ● Push in slowly a the inner tube just before it bottoms out and then pull it back quickly

● Repeat this step until the inner tube can be pulled out from the outer tube. Damper rod holder: YM-1423/90890-01423

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

ASSEMBLY AND INSTALLATION

1. Wash the all parts in a clean solvent.

● Damper rod 1 To inner tube 2. CAUTION: To install the damper rod into the inner tube, hold the inner tube aslant. If the inner tube is held vertically, the damper rod may fall into it, damaging the valve inside.

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

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

● Dust seal 1 ● Stopper ring 2 ● Oil seal 3 ● Plain 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. New New

● Slide metal 1 ● Plain washer 2 To outer tube slot. NOTE: Press the slide metal into the outer tube with fork seal driver 3. Fork seal driver: YM-01442/90890-01442 10.Install: ● Oil seal 1 NOTE: Press the oil seal into the outer tube with fork seal driver 2. Fork seal driver: YM-01442/90890-01442 11.Install: ● Stopper ring 1 NOTE: Fit the stopper ring correctly in the groove in the outer tube. 12.Install: ● Dust seal 1 NOTE: Apply the lithium soap base grease on the inner tube.5 - 35 CHAS FOURCHE AVANT TELESKOPGABEL HORQUILLA DELANTERA

● Guardapolvos 1 NOTA: Aplique grasa con base de jabón de litio en el tubo interno.5 - 36 CHAS FRONT FORK 13.Check: ● Inner tube smooth movement Tightness/binding/rough spots → Repeat the steps 2 to 12. 14.Compress the front fork fully. 15.Fill: ● Front fork oil Until outer tube top surface with recom- mended fork oil 1. 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. Recommended oil: Suspension oil “01” 16.After filling, pump the damper rod 1 slowly up and down more than 10 times to distribute the fork oil. 17.Fill: ● Front fork oil Until outer tube top surface with recom- mended fork oil once more. 18.After filling, pump the outer tube 1 slowly up and down (about 200 mm (7.9 in) stroke) to distribute the fork oil once more. NOTE: Be careful not to excessive full stroke. A stroke of 200 mm (7.9 in) or more will cause air to enter. In this case, repeat the steps 15 to 18.5 - 36 CHAS FOURCHE AVANT TELESKOPGABEL HORQUILLA DELANTERA

CHAS FRONT FORK 19.Wait ten minutes until the air bubbles have been removed from the front fork, and the oil has dispense evenly in system before setting recommended oil level. NOTE: Fill with the fork oil up to the top end of the outer tube, or the fork oil will not spread over to every part of the front forks, thus making it impossible to obtain the correct level. Be sure to fill with the fork oil up to the top of the outer tube and bleed the front forks. 20.Measure: ● Oil level (left and right) a Out of specification → Adjust.

• For EUROPE NOTE: Be sure to install the spring guide 2 when checking the oil level. WARNING Never fail to make the oil level adjustment between the maximum and minimum level and always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability. Standard oil level: 135 mm (5.31 in) *125 mm (4.92 in) Extent of adjustment: 80 ~ 150 mm (3.15 ~ 5.91 in) From top of outer tube with inner tube and damper rod 1 fully compressed without spring.5 - 37 CHAS FOURCHE AVANT TELESKOPGABEL HORQUILLA DELANTERA

● Front fork 1 NOTE: ● Temporarily tighten the pinch bolts (under bracket). ● Do not tighten the pinch bolts (handle crown) yet.

● Pinch bolt (handle crown) 1 ● Pinch bolt (under bracket) 2 CAUTION: Tighten the under bracket to specified torque. If torqued too much, it may cause the front fork to malfunction.

● Brake hose holder 1 ● Caliper 2 ● Bolt (caliper) 3 NOTE: Fit the brake hose holder cut a over the pro- jection b on the front fork and clamp the brake hose.

● Brake hose holder 1 ● Bolt (brake hose holder) 2 ● Protector 3 ● Bolt (protector) 4 NOTE: When installing the brake hose holder, pass the brake hose 5 in front of the axle boss a, then fit it into the hose groove b so that the brake hose does not contact the nut (wheel axle).

● Master cylinder bracket 1 ● Master cylinder 2 CAUTION: ● Do not let the master cylinder hang on the brake hose. ● Keep the master cylinder cap side hori- zontal to prevent air from coming in. EC5B3200 Grip

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

● Handlebar 1 Bends/cracks/damage → Replace. WARNING Do not attempt to straighten a bent handle- bar as this may dangerously weaken the handlebar. EC5B5000

ASSEMBLY AND INSTALLATION

● Handlebar 1 ● Handlebar holder 2 ● Bolt (handlebar holder) 3 NOTE: ● The upper handlebar holder should be installed with the punched mark a forward. ● First tighten the bolts on the front side of the handlebar holder, and then tighten the bolts on the rear side.

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

● Grip (right) 1 ● Collar 2 Apply the adhesive on the tube guide

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.

● Throttle cable cap 1 ● Screw (throttle cable cap) 2 ● Cover (throttle cable cap) 3 WARNING After tightening the screws, check that the throttle grip 4 moves smoothly. If it does not, retighten the bolts for adjustment.

● Master cylinder 1 ● Master cylinder bracket 2 ● Bolt (master cylinder bracket) 3 NOTE: ● Install the bracket so that the arrow mark a faces upward. ● First tighten the bolt on the upper side of the master cylinder bracket, and then tighten the bolt on the lower side.

4 Nm (0,4 m · kg, 2,9 ft · lb)5 - 45 CHAS HANDLEBAR NOTE: ● The “ENGINE STOP” button, clutch lever holder, decompression lever holder and clamp should be installed according to the dimensions shown. ● Pass the “ENGINE STOP” button lead in the middle of the clutch holder.

● Clutch cable 1 ● Decompression cable 2 NOTE: Apply the lithium soap base grease on the clutch cable end and decompression cable end. 10.Adjust: ● Clutch lever free play Refer to “CLUTCH ADJUSTMENT” section in the CHAPTER 3. ● Decompression lever free play Refer to “DECOMPRESSION LEVER ADJUSTMENT” section in the CHAP- TER 3.

CHAS STEERING Extent of removal Order Part name Q’ty Remarks 8 Bearing (upper) 1 9 Bearing (lower) 1 Refer to “REMOVAL POINTS”.

Refer to “REMOVAL POINTS”.

● Ring nut 1 Use the ring nut wrench 2. WARNING Support the steering shaft so that it may not fall down. Ring nut wrench: YU-33975/90890-01403 EC563300 Bearing (lower)

● Bearing (lower) 1 Use the floor chisel 2. CAUTION: Take care not to damage the steering shaft thread. EC563400 Ball race

1. Wash the bearings and ball races with a

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

ASSEMBLY AND INSTALLATION

● Bearing (lower) 1 NOTE: Apply the lithium soap base grease on the dust seal lip and bearing inner circumference.

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

● Plain washer 1 ● Ring nut 2 Tighten the ring nut using the ring nut wrench 3. Refer to “STEERING HEAD INSPEC- TION AND ADJUSTMENT” section in the CHAPTER 3.

5. Check the steering shaft by turning it lock

to lock. If there is any binding, remove the steering shaft assembly and inspect the steering bearings.

● Front fork 1 ● Handle crown 2 NOTE: ● Temporarily tighten the pinch bolts (under bracket). ● Do not tighten the pinch bolts (handle crown) yet.

● Plain washer 1 ● Steering shaft nut 2

9. After tightening the nut, check the steer-

ing for smooth movement. If not, adjust the steering by loosening the ring nut little by little. 10.Adjust: ● Front fork top end a Front fork top end (standard) a: Zero mm (Zero in) 11.Tighten: ● Pinch bolt (handle crown) 1 ● Pinch bolt (under bracket) 2 CAUTION: Tighten the under bracket to specified torque. If torqued too much, it may cause the front fork to malfunction.

20 Nm (2,0 m · kg, 14 ft · lb)5 - 52 CHAS SWINGARM EC570000 SWINGARM Extent of removal: 1 Swingarm removal Extent of removal Order Part name Q’ty Remarks STEERING REMOVAL WARNINGSupport the machine securely so there is nodanger of it falling over. Preparation for removal Hold the machine by placing the suitable stand under the engine. Brake hose holder Rear caliper Bolt (brake pedal) Drive chain Refer to “FRONT BRAKE AND REAR BRAKE” section. Shift the brake pedal backward. 1 Chain support 1 2 Chain tensioner (lower) 1 3 Bolt (rear shock absorber-relay arm) 1 Hold the swingarm. 4 Bolt (connecting rod) 1 5 Pivot shaft 1

CHAS SWINGARM EC578000 SWINGARM DISASSEMBLY Extent of removal: 1 Swingarm disassembly 2 Connecting rod removal and disassembly 3 Relay arm removal and disassembly Extent of removal Order Part name Q’ty Remarks SWINGARM DISASSEMBLY 1 Cap 2 2 Relay arm 1 3 Connecting rod 1 4 Collar 2 5 Oil seal 2 6 Thrust bearing 2 7 Bush 2 8 Oil seal 8 9 Bearing 8 Refer to “REMOVAL POINTS”.

● Bearing 1 NOTE: Install the bearing by pressing its outer race. EC574010 INSPECTION Wash the bearings, bushes, collars, and cov- ers in a solvent. EC574111 Swingarm

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

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

● Oil seal 3 Damage → Replace. EC574310 Connecting rod

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

ASSEMBLY AND INSTALLATION

EC575201 Bearing and oil seal

● Bearing 1 ● Oil seal 2 To swingarm. NOTE: ● Apply the molybdenum disulfide grease on the bearing when installing. ● Install the bearing by pressing it on the side having the manufacture’s marks or numbers. ● First install the outer and then the inner bear- ings to a specified depth from inside. Installed depth of bearings: Outer a: Zero mm (Zero in) Inner b: 8.5 mm (0.33 in)

● Bearing 1 ● Oil seal 2 To relay arm. NOTE: ● Apply the molybdenum disulfide grease on the bearing when installing. ● Install the bearing by pressing it on the side having the manufacture’s marks or numbers.

● Bearing 1 ● Oil seal 2 To connecting rod. NOTE: ● Apply the molybdenum disulfide grease on the bearing when installing. ● Install the bearing by pressing it on the side having the manufacture’s marks or numbers. Installed depth of bearings a: 5 mm (0.20 in) Installed depth of bearings a: 5 mm (0.20 in)5 - 55 CHAS BRAS OSCILLANT SCHWINGE PALANCA OSCILANTE

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

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

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

● Connecting rod 1 ● Bolt (connecting rod) 2 ● Plain washer 3 ● Nut (connecting rod) 4 To relay arm 5. NOTE: Apply the molybdenum disulfide grease on the bolt. CAUTION: Install the nut on the left side of the chas- sis. If you make a mistake in its installation position, the nut contacts the swingarm when stroking the rear shock absorber.

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

● Swingarm side play a Free play exists → Replace thrust bear- ing. ● Swingarm up and down movement b Unsmooth movement/binding/rough spots → Grease or replace bearings, bushes and collars.

● Bolt (connecting rod) 1 ● Plain washer 2 ● Nut (connecting rod) 3 NOTE: ● Apply the molybdenum disulfide grease on the bolt. ● Do not tighten the nut yet.

● Plain washer 1 ● Bolt (rear shock absorber-relay arm) 2 NOTE: ● Apply the molybdenum disulfide grease on the bolt. ● Insert the bolt from right side.

80 Nm (8.0 m · kg, 58 ft · lb) 12.Install: ● Cap 1 NOTE: Install the cap with its mark a facing forward. 13.Install: ● Bolt [chain tensioner (lower)] 1 ● Plain washer 2 ● Collar 3 ● Chain tensioner 4 ● Nut [chain tensioner (lower)] 5

19 Nm (1.9 m · kg, 13 ft · lb) 14.Install: ● Chain support 1 ● Support cover 2 ● Bolt {chain support [r= 50 mm (1.97 in)]}

● Nut (chain support) 4 ● Bolt {support cover [r= 10 mm (0.39 in)]}

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

REMOVAL Hold the machine by placing the suitable stand under the engine. WARNINGSupport the machine securely so there is nodanger of it falling over. Seat, fitting band and side covers Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 4. Silencer Refer to “EXHAUST PIPE AND SILENCER” section in the CHAPTER 4. Drain the coolant. Refer to “COOLANT REPLACEMENT” section in the CHAPTER 3. Coolant reservoir tank Refer to “RADIATOR” section in the

CHAS EC586000 HANDLING NOTE WARNING This shock absorber is provided with a separate type tank filled with high-pressure nitrogen gas. To prevent the danger of explosion, read and understand the follow- ing information before handling the shock absorber. The manufacturer can not be held respon- sible for property damage or personal injury that may result from improper han- dling.

1. Never tamper or attempt to disassem-

ble the cylinder or the tank.

2. Never throw the shock absorber into

an open flame or other high heat. The shock absorber may explode as a result of nitrogen gas expansion and/ or damage to the hose.

3. Be careful not to damage any part of

the gas tank. A damaged gas tank will impair the damping performance or cause a malfunction.

4. Take care not to scratch the contact

surface of the piston rod with the cylin- der; 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.

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

● Stopper ring (upper bearing) 1 NOTE: Press in the bearing while pressing its outer race and remove the stopper ring.

● Upper bearing 1 NOTE: Remove the bearing by pressing its outer race.

● Lower bearing 1 NOTE: Remove the bearing by pressing its outer race. EC584000 INSPECTION Rear shock absorber

● Damper rod 1 Bends/damage → Replace absorber assembly. ● Shock absorber 2 Oil leaks → Replace absorber assem- bly. Gas leaks → Replace absorber assem- bly. ● Spring 3 Damage → Replace spring. Fatigue → Replace spring. Move spring up and down. ● Spring guide 4 Wear/damage → Replace spring guide. ● Bearing 5 Free play exists/unsmooth revolution/ rust → Replace.

ASSEMBLY AND INSTALLATION

● Upper bearing 1 NOTE: Install the bearing parallel until the stopper ring groove appears by pressing its outer race. CAUTION: Do not apply the grease on the bearing outer race because it will wear the rear shock absorber surface on which the bear- ing is press fitted.

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

● 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) EC585111 Spring (rear shock absorber)

● Spring length (installed) a

• For EUROPE NOTE: The length of the spring (installed) changes

1.5 mm (0.06 in) per turn of the adjuster.

CAUTION: Never attempt to turn the adjuster beyond the maximum or minimum setting. Spring length (installed) a: Standard length Extent of adjustment 241 mm (9.49 in) *244 mm (9.61 in)

● Locknut 1 Rear shock absorber

● Dust seal 1 ● O-ring 2 ● Collar 3 NOTE: ● Apply the molybdenum disulfide grease on the bearing. ● Apply the lithium soap base grease on the dust seals, O-rings and collars. New5 - 64 CHAS AMORTISSEUR ARRIERE FEDERBEIN AMORTIGUADOR TRASERO

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

● Rear shock absorber

● Plain washer 1 ● Bolt (rear shock absorber-relay arm) 2 NOTE: ● Apply the molybdenum disulfide grease on the bolt. ● Insert the bolt from right side.

● Rear frame 1 ● Bolt (rear frame) 2 ● Bolt (reservoir tank) 3

● Screw (air cleaner joint) 1

TPS (throttle position sensor)

A map-controlled, CDI ignition system is used in the WR426F/WR400F. The microcomputer in the CDI unit detects the engine speed and throttle position, thus determining the optimum ignition timing through the entire operating range. In this way, quick throttle response can be achieved according to various riding conditions. CDI unit Throttle position sensor Pickup coil CDI magneto rotor Ignition coil

Function of Component

Component Function TPS (throttle position sensor) Detects throttle valve opening and inputs it into the computer in the CDI unit as a throttle opening signal. Pickup coil Detects signal rotor revolutions and inputs them into the computer in the CDI unit as engine revolution signals. CDI unit The signals of the TPS and pickup coil sensor are analyzed by the computer in the CDI unit, which then adjusts ignition timing for the operation requirements.

Principal of 3-Dimensional Control Conventionally, ignition timing was controlled only by engine revolutions (2-dimensional control). However, ignition timing needs advancement also by engine load. Thus, accurate ignition timing can be determined by adding throttle opening to deter- mine ignition timing (3-dimensional control). 3-D Image Map of Ignition Timing (different from actual characteristics) RevolutionsIgnition timingThrottle opening–+ ELEC

ELEC IGNITION SYSTEM EC620000 IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. *: Only when the ignition checker is used. NOTE:

Remove the following parts before inspection.

Use the following special tools in this inspection. Spark gap test *Clean or replace spark plug. Check entire ignition system for connection. Repair or replace. Check “ENGINE STOP” button. Replace. Check ignition coil. Primary coil Replace. Secondary coil Replace. Check CDI magneto. Pick-up coil Replace. Source coil Replace. Check neutral switch. Repair or replace. Replace CDI unit. Dynamic spark tester: YM-34487 Ignition checker: 90890-06754 Pocket tester: YU-3112-C/90890-03112 No Spark

1. Disconnect the spark plug cap from spark

Except for USA and CDN

3. Kick the kick starter.

4. Check the ignition spark gap.

5. Start engine, and increase spark gap

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

Couplers and leads connection Rust/dust/looseness/short-circuit

“ENGINE STOP” button conduct No continuity while being pushed

Replace. Continuity while being freed

Replace. Tester (+) lead

IGNITION COIL INSPECTION

Primary coil resistance Out of specification

Replace. Tester (+) lead

Tester (–) lead → Black lead 2 Primary coil resistance Tester selector position

● Secondary coil resistance Out of specification → Replace. NOTE: When inspecting the secondary coil resis- tance, remove the spark plug cap. EC627011

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

20 ˚C (68 ˚F) kΩ × 1 Tester (+) lead → Red lead 1 Tester (–) lead → White lead 2 Pick-up coil resistance Tester selector position 248 ~ 372 Ω at 20 ˚C (68 ˚F) Ω × 100–+ ELEC

● Source coil 1 resistance Out of specification → Replace.

● Source coil 2 resistance Out of specification → Replace. Tester (+) lead → Brown lead 1 Tester (–) lead → Green lead 2 Source coil 1 resistance Tester selector position 640 ~ 960 Ω at 20 ˚C (68 ˚F) Ω × 100 Tester (+) lead → Pink lead 1 Tester (–) lead → Green lead 2 Source coil 2 resistance Tester selector position 464 ~ 696 Ω at 20 ˚C (68 ˚F) Ω × 10

● Neutral switch conduct

• Except for USA No continuity while in neutral → Replace. Continuity while in gear → Replace. Å For USA ı Except for USA EC628000

Check all electrical components. If no fault is found, replace the CDI unit. Then check the electrical components again. Tester (+) lead → Blue/White lead 1 *Sky blue lead 1 Tester (–) lead → Ground L/W *Sb 1 Ground Tester selec- tor position NEU- TRAL Ω × 1 IN GEAR

INSPECTION STEPS If the TPS will not operate, use the following inspection steps. *marked: Refer to “IGNITION SYSTEM” section. NOTE: ● Remove the following parts before inspection.

● Use the following special tools in this inspection. Check entire ignition system for connection. Repair or replace. Check TPS. TPS coil Replace. *Check CDI magneto. Source coil Replace. Check CDI unit. TPS input voltage Replace. Pocket tester: YU-3112-C/90890-03112 Inductive tachometer: YU-08036-B Engine tachometer: 90890-03113 No good No good No good No good

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

● TPS coil resistance Out of specification → Replace.

● Throttle stop screw NOTE: Turn out the throttle stop screw until the throt- tle shaft is in the full close position. Tester (+) lead → Blue lead 1 Tester (–) lead → Black lead 2 TPS coil resistance Tester selector position 4 ~ 6 kΩ at 20 ˚C (68 ˚F) kΩ × 1

● TPS coil variable resistance Check that the resistance in increased as the throttle grip is moved from the full close position to the full open posi- tion. Out of specification → Replace. Tester (+) lead → Yellow lead 1 Tester (–) lead → Black lead 2 TPS coil variable resistance Tester selec- tor position Full closed Full opened kΩ × 1 0 ~ 2 kΩ at 20 ˚C (68 ˚F) 4 ~ 6 kΩ at 20 ˚C (68 ˚F)–+ ELEC

TPS REPLACEMENT AND ADJUSTMENT

● TPS coupler ● Screw (TPS) 1 ● Plain washer 2 ● TPS 3

● TPS 1 ● Plain washer 2 ● Screw (TPS) 3 ● TPS coupler NOTE: ● Align the slot a in the TPS with the projec- tion b on the carburetor. ● Temporarily tighten the screws (TPS).

● Idle speed Refer to “IDLE SPEED ADJUSTMENT” section in the CHAPTER 3.

● TPS coil resistance at idle speed. <Example> If the TPS coil resistance is 5 kΩ, then the TPS coil resistance at idle speed is: 5 kΩ × (0.13 ~ 0.15) = 650 ~ 750 Ω Refer to “TPS COIL INSPECTION” sec- tion about the TPS coil resistance. TPS coil resistance at idle speed: TPS coil resistance × (0.13 ~ 0.15)–+ ELEC

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

2. Start the engine.

● TPS input voltage Out of specification → Replace the CDI unit. Tester (+) lead → Blue lead 1 Tester (–) lead → Black/Blue lead 2 TPS input voltage Tester selector position 4 ~ 6 V DCV-20–+ ELEC

ELEC LIGHTING SYSTEM LIGHTING SYSTEM INSPECTION STEPS Refer to the following flow chart when inspecting the ignition system for possible ploblems. NOTE: ● Replace the bulb and/or bulb socket.

● Use the following special tool. Check the bulb and bulb socket. Replace the bulb and/ or bulb socket. Check the lights switch. Replace. Check the CDI magneto. Lighting coil Replace. Check the entire lighting sys- tem proper for connections. Repair or replace. Replace the regulator. Pocket tester: YU-3112-C/90890-03112

No good No good Improperly connected No good–+ ELEC

● Lights switch conduct No continuity while being → Replace. Continuity while being OFF → Replace. Tester (+) lead → Yellow lead 1 Tester (–) lead → Blue lead 2

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

TUN EC700000 TUNING EC710000 ENGINE Carburetor setting The air/fuel mixture will vary depending onatmospheric conditions. Therefore, it is nec-essary to take into consideration the air pres-sure, ambient temperature, humidity, etc.,when adjusting the carburetor. Perform a test run to check for proper engineperformance (e.g., throttle response) andspark plug(-s) discoloration or fouling. Usethese readings to determine the best possi-ble carburetor setting.NOTE: It is recommended to keep a record of all car-buretor settings and external conditions (e.g.,atmospheric conditions, track/surface condi-tions, lap times) to make future carburetor set- ting easier. WARNING

The carburetor is a part of the fuel line.Therefore, be sure to install it in a well-ventilated area, away from flammableobjects and any sources of fire. Never look into the carburetor intake.Flames may shoot out from the pipe if theengine backfires while it is being started.Gasoline may be discharged from theaccelerator pump nozzle when the carbu- retor has been removed. SETTING

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 carbure- tor parts may prevent the carburetor from functioning correctly. Carefully perform all servicing with the appropriate tools and without applying excessive force.

When the engine is stopped or when riding at no load, do not open and close the throttle unnecessarily. Otherwise, too much fuel may be discharged, starting may become difficult or the engine may not run well.

After installing the carburetor, check that the throttle operates correctly and opens and closes smoothly. Atmospheric conditions and carburetor settings The air density (i.e., concentration of oxygen in the air) determines the richness or lean- ness 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 oxy- gen in the air by so much of the water vapor in the same air.

Lower atmospheric pressure (at a high alti- tude) reduces the density of the air. Air temp. Humidity Air pressure (altitude) Mixture Setting High High Low (high) Richer Leaner Low Low High (low) Leaner Richer SETTINGTUN ACHTUNG:

Pilot screw/pilot jet

Throttle valve cutaway

Å Closed ı Fully open 1/2 3/41/41/8

Å ı Main system The FLATCR carburetor has a primary main jet. This type of main jet is perfect for racing motorcycles since it supplies an even flow of fuel, even at full load. The main air jet has almost no effect on the air-fuel mixture. Use the main jet and the jet needle to set the car- buretor.

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

N°175N°1557 - 5 TUN SETTING 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

. Turning in the pilot screw will make the mixture lean at low speeds, and turning it out will enrich it.

If the 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 num- ber as the factory-set number of turns out. Effects of adjusting the pilot screw (reference)

TUN SETTING Pilot jet adjustment The richness of the air-fuel mixture with the throttle open 1/4 or less can be set by adjust- ing the pilot jet

Effects of adjusting the pilot jet (reference)

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. Effects of changing the jet needle groove position (reference) Å Idle ı Fully open 1 No.5 groove 2 No.3 groove 3 No.4 groove Standard clip position No.4 groove 1/4 1/2 3/4 +10% –10%

1/4 1/2 3/4 +10% –10%

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

• Except for USA The tapered sections of all jet needles have the same starting positions, but the needles are available with different straight-portion diameters. Standard jet needle

<Example> OBDRR - 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. Å Idle ı Fully open Relationship with throttle opening The flow of the fuel through the carburetor main system is controlled by the main jet and then, it is further regulated by the area between the main nozzle and the jet needle. The fuel flow relates to the diameter of the straight portion of the jet needle with the throt- tle 1/8 to 1/4 open and relates to the clip posi- tion 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. 1/4 1/2 3/4 +10%

• For AUS and NZ (WR426F) Part name Size Part number Drive sprocket 1 (STD) 14T *15T 9383E-14215 9383E-15082 Driven sprocket 2 (STD) 48T 50T 52T 5GS-25448-50 5GS-25450-50 5GS-25452-50 EC721002 Tire pressure Tire pressure should be adjust to suit the road surface condition of the circuit. ● Under a rainy, muddy, sandy, or slippery condition, the tire pressure should be lower for a larger area of contact with the road sur- face. ● Under a stony or hard road condition, the tire pressure should be higher to prevent a flat tire. Standard tire pressure: 100 kPa (1.0 kg/cm

15 ~ 18 psi)7 - 13 TUN SETTING EC722011 Front fork setting The front fork setting should be made depend- ing on the rider’s feeling of an actual run and the circuit conditions. The front fork setting includes the following three factors:

1. Setting of air spring characteristics

● Change the fork oil level.

2. Setting of spring preload

● Change the spring.● Install the adjustment washer.

3. Setting of damping force

● Change the compression damping.● Change the rebound damping. The spring acts on the load and the damping force acts on the cushion travel speed. EC723001 Change in level and characteristics of fork oil Damping characteristic near the final stroke can be changed by changing the fork oil amount. CAUTION: Adjust the oil level in 5 mm (0.2 in) incre- ments or decrements. Too low oil level causes the front fork to produce a noise at full rebound or the rider to feel some pres- sure on his hands or body. Alternatively, too high oil level will develop unexpectedly early oil lock with the consequent shorter front fork travel and deteriorated perfor- mance an characteristics. Therefore, adjust the front fork within the specified range.

1. Use of soft spring

2. Use of stiff spring

Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, resulting in lack of a sense of contact with the road surface or in a vibrating handlebar. To set a stiff spring: ● Change the rebound damping. Turn in one or two clicks. ● Change the compression damping. Turn out one or two clicks. Å Coverage of spring by weight ı Rider weight 1 Soft 2 Standard 3 StiffTUN REGLAGE EINSTELLUNG AJUSTE

• For EUROPE [Unequal pitch spring] NOTE: ● The unequal pitch spring is softer in initial characteristic than the equal pitch spring and is difficult to bottom out under full compres- sion. ● The I.D. mark (slits) a is proved on the end of the spring. TYPE (thickness) PART NUMBER T = 2.3 mm (0.09 in) 4SS-23364-L0 TYPE SPRING RATE SPRING PART NUMBER I.D. MARK (slits) SOFT

TYPE SPRING RATE (approx.) SPRING PART NUMBER I.D. MARK (slits) SOFT STIFF

V-I V-II V-III V-IIII7 - 17 TUN EC72B000 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 fol- lowing 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. 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 adjust-

ment by turning the spring adjuster 2 to achieve the standard figure from the sub- traction of the length b from the length

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.

• For EUROPE [Unequal pitch spring] NOTE: ● The unequal pitch spring is softer in initial characteristic than the equal pitch spring and is difficult to bottom out under full compres- sion. ● The I.D. color a is marked at the end of the spring. TYPE SPRING RATE SPRING PART NUMBER I.D. COLOR/ POINT SPRING FREE LENGTH SOFT

RES- SORT (AP- PROX.)

STD 5,0 5DH-22212-30Negro/1

LONGITUD LIBRE DEL RESORTE ALCANCE DEL AJUSTE b 260 mm (10,24 in) 240,5 ~ 258,5 mm (9,47 ~ 10,18 in) 265 mm (10,43 in) 245,5 ~ 263,5 mm (9,49 ~ 10,37 in) 275 mm (10,83 in) 255,5 ~ 273,5 mm (10,06 ~ 10,77 in) 280 mm (11,02 in) 260,5 ~ 278,5 mm (10,26 ~ 10,96 in)7 - 21 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). Symptom Section Check Adjust Jump Large gap Medium gap Small gap Stiff over entire range CCC Compression damping Oil level (oil amount) Spring Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in). Replace with soft spring. Unsmooth movement over entire range CCCC Outer tube Inner tube Under bracket tightening torque Check for any bends, dents, and other noticeable scars, etc. If any, replace affected parts. Retighten to specified torque. Poor initial movement

Rebound damping Oil seal Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Apply grease in oil seal wall. Soft over entire range, bottoming out

Compression damping Oil level (oil amount) Spring Turn adjuster clockwise (about 2 clicks) to increase damping. Increase oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in). Replace with stiff spring. Stiff toward stroke end

Oil level (oil amount) Decrease oil level by about 5 mm (0.2 in). Soft toward stroke end, bottoming out

Oil level (oil amount) Increase oil level by about 5 mm (0.2 in). Stiff initial movement CCCC Compression damping Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Low front, tending to lower front posture

Compression damping Rebound damping Balance with rear end Oil level (oil amount) Turn adjuster clockwise (about 2 clicks) to increase damping. Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Set sunken length for 95 ~ 100 mm (3.7 ~ 3.9 in) when one passenger is astride seat (lower rear posture). Increase oil level by about 5 mm (0.2 in). “Obtrusive” front, tend- ing to upper front pos- ture

Compression damping Balance with rear end Spring Oil lever (oil amount) Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Set sunken length for 90 ~ 95 mm (3.5 ~ 3.7 in) when one passenger is astride seat (upper rear posture). Replace with soft spring. Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).7 - 22 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. Symptom Section Check Adjust Jump Large gap Medium gap Small gap Stiff, tending to sink

Rebound damping Spring set length Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when one passenger is astride seat. Spongy and unstable

Rebound damping Low compression damping Spring Turn adjuster clockwise (about 2 clicks) to increase damping. Turn adjuster clockwise (about 1 clicks) to increase damping. Replace with stiff spring. Heavy and dragging

Rebound damping Spring Turn adjuster counterclockwise (about 2 clicks) to decrease damping. Replace with soft spring. Poor road gripping

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

High compression damp- ing Spring set length Spring Turn adjuster clockwise (about 1/6 turn) to increase damping. Set sunken length for 90 ~ 100 mm (3.5 ~ 3.9 in) when one passenger in astride seat. Replace with stiff spring. Bouncing

Rebound damping Spring Turn adjuster clockwise (about 2 clicks) to increase damping. Replace with soft spring. Stiff travel

PRINTED ON RECYCLED PAPER