Raptor 660

User Manual: Raptor 660

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YFM660RN
YFM660RNC
SERVICEMANUAL
LIT-11616-14-21

5LP-28197-E0

EB001000

NOTICE
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on
Yamaha machine has a basic understanding of the mechanical ideas and the procedures of
machine repair. Repairs attempted by anyone without this knowledge are likely to render the
machine unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!

WARNING

CAUTION:
NOTE:

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.
A NOTE provides key information to make procedures easier or clearer.

EB002000

HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.
2nd title 2: This title indicates the section of the chapter and only appears on the first page of each
section. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompanied by corresponding illustrations.
EXPLODED DIAGRAMS
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 4 is provided for removal and disassembly jobs.
2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed
by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
6. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition
to the exploded diagram and the job instruction chart.

EB003000

GEN
INFO

ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 9 are printed on the
top right of each page and indicate the subject
of each chapter.

SPEC

CHK
ADJ

1 General information
2 Specifications
3 Periodic checks and adjustments
4 Chassis
5 Engine
6 Cooling system
7 Carburetion
8 Electrical
9 Troubleshooting

CHAS

ENG

COOL

8
–

ELEC

CARB
9

Illustrated symbols 0 to G are used to identify
the specifications appearing in the text.

TRBL
SHTG
A

0 Can be serviced with engine mounted
A Filling fluid
B Lubricant
C Special tool
D Torque
E Wear limit, clearance
F Engine speed
G Ω, V, A

E
K

L
B

N
M

Illustrated symbols H to N in the exploded
diagrams indicate the types of lubricants and
lubrication points.

New

H Apply engine oil
I Apply gear oil
J Apply molybdenum disulfide oil
K Apply wheel bearing grease
L Apply lightweight lithium soap base grease
M Apply molybdenum disulfide grease
N Apply silicon grease

Illustrated symbols O to P in the exploded
diagrams indicate where to apply a locking
agent O and when to install a new part P.
O Apply the locking agent (LOCTITE)
P Replace

TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
COOLING SYSTEM
CARBURETION

GEN
INFO

SPEC

CHK
ADJ

CHAS

ENG

COOL

CARB

–

ELECTRICAL
TROUBLESHOOTING

ELEC

TRBL
SHTG

CHAPTER 1.
GENERAL INFORMATION
MACHINE IDENTIFICATION ........................................................................ 1-1
VEHICLE IDENTIFICATION NUMBER ................................................. 1-1
MODEL LABEL ...................................................................................... 1-1
IMPORTANT INFORMATION ....................................................................... 1-2
PREPARATION FOR REMOVAL PROCEDURES ............................... 1-2
REPLACEMENT PARTS ....................................................................... 1-2
GASKETS, OIL SEALS AND O-RINGS ................................................ 1-2
LOCK WASHERS/PLATES AND COTTER PINS ................................. 1-3
BEARINGS AND OIL SEALS ................................................................ 1-3
CIRCLIPS .............................................................................................. 1-3
CHECKING OF CONNECTIONS .................................................................. 1-4
SPECIAL TOOLS .......................................................................................... 1-5

CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS ...................................................................... 2-1
MAINTENANCE SPECIFICATIONS ............................................................. 2-4
ENGINE ................................................................................................. 2-4
CHASSIS ............................................................................................. 2-14
ELECTRICAL ...................................................................................... 2-18
HOW TO USE THE CONVERSION TABLE ............................................... 2-20
GENERAL TORQUE SPECIFICATIONS ................................................... 2-20
LUBRICATION POINTS AND LUBRICANT TYPES .................................. 2-21
ENGINE ............................................................................................... 2-21
COOLANT FLOW DIAGRAMS ................................................................... 2-22
OIL FLOW DIAGRAMS .............................................................................. 2-23
CABLE ROUTING ....................................................................................... 2-27

CHAPTER 3.
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION ........................................................................................... 3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS .......................... 3-1
SEAT, FENDERS AND FUEL TANK ............................................................ 3-3
SEAT, FRONT PANEL, FOOTREST GUARDS
AND ENGINE SKID PLATE ............................................................... 3-3
HEADLIGHTS AND FRONT FENDER .................................................. 3-4
REAR FENDER ..................................................................................... 3-5
FUEL TANK ........................................................................................... 3-6
ENGINE ......................................................................................................... 3-8
ADJUSTING THE VALVE CLEARANCE .............................................. 3-8
ADJUSTING THE TIMING CHAIN ...................................................... 3-11
ADJUSTING THE IDLING SPEED ...................................................... 3-11
ADJUSTING THE THROTTLE LEVER FREE PLAY .......................... 3-12
ADJUSTING THE SPEED LIMITER .................................................... 3-14
ADJUSTING THE STARTER CABLE ................................................. 3-15
CHECKING THE SPARK PLUG ......................................................... 3-16
CHECKING THE IGNITION TIMING ................................................... 3-17
MEASURING THE COMPRESSION PRESSURE .............................. 3-18
CHECKING THE ENGINE OIL LEVEL ................................................ 3-19
CHANGING THE ENGINE OIL ........................................................... 3-20
ADJUSTING THE CLUTCH CABLE .................................................... 3-23
CLEANING THE AIR FILTER .............................................................. 3-24
CHECKING THE COOLANT LEVEL ................................................... 3-27
CHANGING THE COOLANT ............................................................... 3-27
CHECKING THE COOLANT TEMPERATURE WARNING LIGHT ..... 3-31
CLEANING THE SPARK ARRESTER ................................................ 3-31
CHASSIS .................................................................................................... 3-33
ADJUSTING THE FRONT BRAKE ..................................................... 3-33
ADJUSTING THE REAR BRAKE ........................................................ 3-33
ADJUSTING THE PARKING BRAKE .................................................. 3-34
CHECKING THE BRAKE FLUID LEVEL ............................................. 3-35
CHECKING THE FRONT BRAKE PAD .............................................. 3-36
CHECKING THE REAR BRAKE PAD ................................................. 3-36
ADJUSTING THE REAR BRAKE LIGHT SWITCH ............................. 3-36
CHECKING THE BRAKE HOSE ......................................................... 3-37
BLEEDING THE HYDRAULIC BRAKE SYSTEM ............................... 3-38
ADJUSTING THE SHIFT PEDAL ........................................................ 3-39
ADJUSTING THE REVERSE CONTROL CABLE .............................. 3-40
ADJUSTING THE DRIVE CHAIN SLACK ........................................... 3-40
CHECKING THE STEERING SYSTEM .............................................. 3-42
ADJUSTING THE TOE-IN ................................................................... 3-42
ADJUSTING THE FRONT SHOCK ABSORBER ................................ 3-44
ADJUSTING THE REAR SHOCK ABSORBER .................................. 3-45

GEN
INFO

SPEC

CHK
ADJ

CHAS

ENG

COOL

CARB

–

ELEC

TRBL
SHTG

CHECKING THE TIRE ........................................................................ 3-47
CHECKING THE WHEEL .................................................................... 3-49
CHECKING AND LUBRICATING THE CABLE ................................... 3-49
LUBRICATING THE LEVERS AND PEDAL ........................................ 3-50
ELECTRICAL .............................................................................................. 3-51
CHECKING THE BATTERY ................................................................ 3-51
CHECKING THE FUSE ....................................................................... 3-56
ADJUSTING THE HEADLIGHT BEAM ............................................... 3-58
REPLACING THE HEADLIGHT BULB ................................................ 3-58

CHAPTER 4.
CHASSIS
FRONT WHEELS .......................................................................................... 4-1
FRONT WHEELS .................................................................................. 4-1
CHECKING THE WHEEL ...................................................................... 4-3
CHECKING THE WHEEL HUB ............................................................. 4-3
CHECKING THE BRAKE DISC ............................................................. 4-4
INSTALLING WHEEL HUB ................................................................... 4-5
INSTALLING THE WHEEL .................................................................... 4-5
REAR WHEELS, WHEEL AXLE AND HUB ................................................. 4-6
REAR WHEELS .................................................................................... 4-6
WHEEL AXLE AND HUB ...................................................................... 4-7
REMOVING THE REAR AXLE .............................................................. 4-9
CHECKING THE WHEEL .................................................................... 4-10
CHECKING THE WHEEL HUB ........................................................... 4-10
CHECKING THE REAR AXLE ............................................................ 4-10
CHECKING THE HUB ......................................................................... 4-11
CHECKING THE BRAKE DISC ........................................................... 4-11
INSTALLING THE NUTS (REAR AXLE) ............................................. 4-11
INSTALLING THE WHEEL HUB ......................................................... 4-12
INSTALLING THE WHEEL .................................................................. 4-12
FRONT AND REAR BRAKES .................................................................... 4-13
FRONT BRAKE PADS ........................................................................ 4-13
REAR BRAKE PADS ........................................................................... 4-14
REPLACING THE FRONT BRAKE PAD ............................................. 4-15
REPLACING THE REAR BRAKE PAD ............................................... 4-17
FRONT BRAKE MASTER CYLINDER ................................................ 4-19
REAR BRAKE MASTER CYLINDER .................................................. 4-21
CHECKING THE MASTER CYLINDER .............................................. 4-24
ASSEMBLING THE FRONT
AND REAR BRAKE MASTER CYLINDER ...................................... 4-25
INSTALLING THE FRONT BRAKE MASTER CYLINDER .................. 4-25
INSTALLING THE REAR BRAKE MASTER CYLINDER .................... 4-27
FRONT BRAKE CALIPERS ................................................................ 4-29
REAR BRAKE CALIPER ..................................................................... 4-31
DISASSEMBLING THE FRONT AND REAR BRAKE CALIPER ........ 4-34

CHECKING THE FRONT AND REAR BRAKE CALIPER ................... 4-34
ASSEMBLING THE FRONT BRAKE CALIPER .................................. 4-35
ASSEMBLING THE REAR BRAKE CALIPER .................................... 4-36
INSTALLING THE FRONT BRAKE CALIPER .................................... 4-37
INSTALLING THE REAR BRAKE CALIPER ....................................... 4-38
STEERING SYSTEM .................................................................................. 4-40
HANDLEBAR ....................................................................................... 4-40
REMOVING THE FRONT BRAKE SWITCH, PARK SWITCH
AND CLUTCH SWITCH .................................................................. 4-42
REMOVING THE HANDLEBAR GRIP ................................................ 4-42
CHECKING THE HANDLEBAR .......................................................... 4-42
INSTALLING THE HANDLEBAR ........................................................ 4-43
INSTALLING THE HANDLEBAR GRIP ............................................... 4-43
INSTALLING THE CLUTCH LEVER ................................................... 4-43
INSTALLING THE BRAKE MASTER CYLINDER ............................... 4-44
STEERING STEM ............................................................................... 4-45
REMOVING THE BEARING RETAINER ............................................ 4-47
CHECKING THE STEERING STEM ................................................... 4-47
INSTALLING THE BEARING RETAINER ........................................... 4-47
INSTALLING THE LOCK WASHER .................................................... 4-47
TIE-ROD AND STEERING KNUCKLE ................................................ 4-48
REMOVING THE STEERING KNUCKLE ........................................... 4-49
CHECKING THE TIE-ROD .................................................................. 4-49
CHECKING THE STEERING KNUCKLE ............................................ 4-49
INSTALLING THE TIE-ROD ................................................................ 4-49
FRONT ARMS AND FRONT SHOCK ABSORBERS ................................ 4-50
REMOVING THE FRONT ARM .......................................................... 4-52
CHECKING THE FRONT ARM ........................................................... 4-52
CHECKING THE FRONT SHOCK ABSORBER ................................. 4-52
CHECKING THE BALL JOINT ............................................................ 4-53
INSTALLING THE FRONT ARM ......................................................... 4-54
REAR SHOCK ABSORBER AND RELAY ARM ........................................ 4-55
HANDLING THE REAR SHOCK ABSORBER
AND GAS CYLINDER ..................................................................... 4-57
DISPOSING OF A REAR SHOCK ABSORBER
AND GAS CYLINDER ..................................................................... 4-57
REMOVING THE REAR SHOCK ABSORBER ................................... 4-58
CHECKING THE REAR SHOCK ABSORBER .................................... 4-58
CHECKING THE RELAY ARM AND CONNECTING ARM ................. 4-58
INSTALLING THE RELAY ARM AND CONNECTING ARM ............... 4-59
INSTALLING THE REAR SHOCK ABSORBER .................................. 4-59
SWINGARM AND DRIVE CHAIN ............................................................... 4-60
REMOVING THE SWINGARM ............................................................ 4-62
CHECKING THE SWINGARM ............................................................ 4-62
CHECKING THE DRIVE CHAIN ......................................................... 4-63
INSTALLING THE SWINGARM .......................................................... 4-65
INSTALLING THE DRIVE SPROCKET ............................................... 4-65

GEN
INFO

SPEC

CHK
ADJ

CHAS

ENG

COOL

CARB

–

ELEC

TRBL
SHTG

CHAPTER 5.
ENGINE
ENGINE REMOVAL ...................................................................................... 5-1
MUFFLER AND EXHAUST PIPES ....................................................... 5-1
LEFT FOOTREST ................................................................................. 5-2
LEADS, CABLES AND HOSES ............................................................ 5-3
ENGINE MOUNTING BOLTS ............................................................... 5-5
INSTALLING THE ENGINE ................................................................... 5-7
CYLINDER HEAD COVER ........................................................................... 5-8
REMOVING THE CYLINDER HEAD COVER ..................................... 5-10
CHECKING THE CYLINDER HEAD COVER ..................................... 5-10
CHECKING THE TAPPET COVER ..................................................... 5-11
INSTALLING THE CYLINDER HEAD COVER ................................... 5-11
ROCKER ARMS ......................................................................................... 5-12
REMOVING THE ROCKER ARM ....................................................... 5-14
CHECKING THE ROCKER ARM ........................................................ 5-14
INSTALLING THE ROCKER ARM ...................................................... 5-15
CAMSHAFT AND CYLINDER HEAD ......................................................... 5-16
REMOVING THE CAMSHAFT AND CYLINDER HEAD ..................... 5-18
CHECKING THE CAMSHAFT ............................................................. 5-19
CHECKING THE CAMSHAFT SPROCKET ........................................ 5-19
CHECKING THE DECOMPRESSION SYSTEM ................................. 5-19
CHECKING THE TIMING CHAIN GUIDE ........................................... 5-20
CHECKING THE TIMING CHAIN TENSIONER .................................. 5-20
CHECKING THE CYLINDER HEAD ................................................... 5-20
INSTALLING THE CAMSHAFT AND CYLINDER HEAD .................... 5-21
VALVES AND VALVE SPRINGS ............................................................... 5-24
REMOVING THE VALVE AND VALVE SPRING ................................ 5-25
CHECKING THE VALVE AND VALVE SPRING ................................. 5-26
INSTALLING THE VALVE AND VALVE SPRING ............................... 5-30
CYLINDER AND PISTON ........................................................................... 5-32
REMOVING THE PISTON .................................................................. 5-33
CHECKING THE CYLINDER AND PISTON ....................................... 5-33
CHECKING THE PISTON RING ......................................................... 5-35
CHECKING THE PISTON PIN INSPECTION ..................................... 5-36
INSTALLING THE PISTON ................................................................. 5-36
INSTALLING THE CYLINDER ............................................................ 5-37
AC MAGNETO ............................................................................................ 5-38
REMOVING THE AC MAGNETO ROTOR .......................................... 5-40
CHECKING THE COIL ........................................................................ 5-40
CHECKING THE STARTER CLUTCH ................................................ 5-41
INSTALLING THE AC MAGNETO ROTOR ........................................ 5-42

CLUTCH ...................................................................................................... 5-43
REMOVING THE CLUTCH ................................................................. 5-47
REMOVING THE PRIMARY DRIVE GEAR
AND BALANCER DRIVEN GEAR ................................................... 5-47
CHECKING THE FRICTION PLATE ................................................... 5-48
CHECKING THE CLUTCH PLATE ..................................................... 5-48
CHECKING THE CLUTCH SPRING ................................................... 5-49
CHECKING THE CLUTCH HOUSING ................................................ 5-49
CHECKING THE CLUTCH BOSS ....................................................... 5-49
CHECKING THE PRESSURE PLATE ................................................ 5-49
CHECKING THE PULL LEVER SHAFT AND PULL ROD .................. 5-50
CHECKING THE PRIMARY DRIVE .................................................... 5-50
CHECKING THE BALANCER DRIVE ................................................. 5-50
INSTALLING THE PRIMARY DRIVE GEAR
AND BALANCER DRIVEN GEAR ................................................... 5-51
INSTALLING THE CLUTCH ................................................................ 5-52
OIL PUMP ................................................................................................... 5-54
CHECKING THE OIL PUMP ............................................................... 5-56
ASSEMBLING THE OIL PUMP............................................................ 5-56
SHIFT SHAFT ............................................................................................. 5-57
CHECKING THE SHIFT SHAFT ......................................................... 5-59
CHECKING THE STOPPER LEVER .................................................. 5-59
CHECKING THE SHIFT GUIDE AND SHIFT LEVER ......................... 5-59
CHECKING THE SEGMENT ............................................................... 5-59
INSTALLING THE SHIFT LEVER ....................................................... 5-59
INSTALLING THE STOPPER LEVER ................................................ 5-60
INSTALLING THE SHIFT SHAFT ....................................................... 5-61
CRANKCASE .............................................................................................. 5-62
TIMING CHAIN AND SPEED SENSOR ROTOR ................................ 5-62
CRANKCASE ...................................................................................... 5-64
CRANKCASE BEARING ..................................................................... 5-65
SEPARATING THE CRANKCASE....................................................... 5-66
CHECKING THE TIMING CHAIN AND GUIDE ................................... 5-66
CHECKING THE OIL STRAINER ....................................................... 5-66
CHECKING THE CRANKCASE .......................................................... 5-67
CHECKING THE BEARINGS .............................................................. 5-67
ASSEMBLING THE CRANKCASE ...................................................... 5-67
CRANKSHAFT AND BALANCER .............................................................. 5-69
REMOVING THE CRANKSHAFT ....................................................... 5-70
CHECKING THE CRANKSHAFT ........................................................ 5-70
INSTALLING THE CRANKSHAFT ...................................................... 5-71

GEN
INFO

SPEC

CHK
ADJ

CHAS

ENG

COOL

CARB

–

ELEC

TRBL
SHTG

TRANSMISSION ......................................................................................... 5-72
MAIN AXLE ......................................................................................... 5-74
DRIVE AXLE ....................................................................................... 5-75
CHECKING THE SHIFT FORK ........................................................... 5-77
CHECKING THE SHIFT DRUM .......................................................... 5-77
CHECKING THE TRANSMISSION ..................................................... 5-77
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE .......................... 5-78
INSTALLING THE TRANSMISSION ................................................... 5-79

CHAPTER 6.
COOLING SYSTEM
RADIATOR .................................................................................................... 6-1
CHECKING THE RADIATOR ................................................................ 6-3
INSTALLING THE RADIATOR .............................................................. 6-4
THERMOSTAT .............................................................................................. 6-5
CHECKING THE THERMOSTAT .......................................................... 6-7
ASSEMBLING THE THERMOSTAT ..................................................... 6-7
WATER PUMP .............................................................................................. 6-8
DISASSEMBLING THE WATER PUMP .............................................. 6-11
CHECKING THE WATER PUMP ........................................................ 6-11
ASSEMBLING THE WATER PUMP .................................................... 6-12

CHAPTER 7.
CARBURETION
CARBURETORS ........................................................................................... 7-1
DISASSEMBLING THE CARBURETOR ............................................... 7-5
CHECKING THE CARBURETOR ......................................................... 7-5
ASSEMBLING THE CARBURETOR ..................................................... 7-7
ADJUSTING THE FUEL LEVEL ............................................................ 7-8

CHAPTER 8.
ELECTRICAL
ELECTRICAL COMPONENTS ..................................................................... 8-1

GEN
INFO

SPEC

CHK
ADJ

CHAS

ENG

LIGHTING SYSTEM .................................................................................... 8-22
CIRCUIT DIAGRAM ............................................................................ 8-22
TROUBLESHOOTING ........................................................................ 8-23
CHECKING THE LIGHTING SYSTEM ................................................ 8-25

COOL

SIGNAL SYSTEM ....................................................................................... 8-27
CIRCUIT DIAGRAM ............................................................................ 8-27
TROUBLESHOOTING ........................................................................ 8-28
CHECKING THE SIGNAL SYSTEM ................................................... 8-30

CARB

CHECKING THE SWITCH ............................................................................ 8-2
CHECKING THE SWITCH .................................................................... 8-2
CHECKING A SWITCH SHOWN IN THE MANUAL ............................. 8-2
CHECKING THE SWITCH CONTINUITY ............................................. 8-3
IGNITION SYSTEM ....................................................................................... 8-5
CIRCUIT DIAGRAM .............................................................................. 8-5
TROUBLESHOOTING .......................................................................... 8-6
ELECTRIC STARTING SYSTEM ............................................................... 8-11
CIRCUIT DIAGRAM ............................................................................ 8-11
STARTING CIRCUIT OPERATION ..................................................... 8-12
TROUBLESHOOTING ........................................................................ 8-13
STARTER MOTOR ............................................................................. 8-16
CHECKING THE STARTER MOTOR ................................................. 8-17
ASSEMBLING THE STARTER MOTOR ............................................. 8-18
CHARGING SYSTEM ................................................................................. 8-19
CIRCUIT DIAGRAM ............................................................................ 8-19
TROUBLESHOOTING ........................................................................ 8-20

COOLING SYSTEM .................................................................................... 8-36
CIRCUIT DIAGRAM ............................................................................ 8-36
TROUBLESHOOTING ....................................................................... 8-37

–

ELEC

TRBL
SHTG

CHAPTER 9.
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING ..................................................... 9-1
FUEL SYSTEM ...................................................................................... 9-1
ELECTRICAL SYSTEM ......................................................................... 9-1
COMPRESSION SYSTEM .................................................................... 9-2
POOR IDLE SPEED PERFORMANCE ........................................................ 9-2
POOR IDLE SPEED PERFORMANCE ................................................. 9-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE ............................... 9-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE ....................... 9-2
FAULTY GEAR SHIFTING ........................................................................... 9-3
HARD SHIFTING ................................................................................... 9-3
SHIFT PEDAL DOES NOT MOVE ........................................................ 9-3
JUMP-OUT GEAR ................................................................................. 9-3
CLUTCH SLIPPING/DRAGGING ................................................................. 9-3
CLUTCH SLIPPING .............................................................................. 9-3
CLUTCH DRAGGING ........................................................................... 9-3
OVERHEATING ............................................................................................ 9-4
OVERHEATING .................................................................................... 9-4
OVER COOLING ........................................................................................... 9-4
COOLING SYSTEM .............................................................................. 9-4
FAULTY BRAKE ........................................................................................... 9-4
POOR BRAKING EFFECT .................................................................... 9-4
SHOCK ABSORBER MALFUNCTION ......................................................... 9-5
MALFUNCTION ..................................................................................... 9-5
UNSTABLE HANDLING ............................................................................... 9-5
UNSTABLE HANDLING ........................................................................ 9-5
LIGHTING SYSTEM ...................................................................................... 9-5
HEADLIGHT DARK ............................................................................... 9-5
BULB BURNT OUT ............................................................................... 9-5

MACHINE IDENTIFICATION

GEN
INFO

GENERAL INFORMATION
MACHINE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1
stamped into the left side of the frame.

MODEL LABEL
The model label 1 is affixed to the air filter
case cover. This information will be needed to
order spare parts.

1-1

IMPORTANT INFORMATION

GEN
INFO

EB101000

IMPORTANT INFORMATION
PREPARATION FOR REMOVAL
PROCEDURES
1.Remove all dirt, mud, dust and foreign material before removal and disassembly.
2.Use proper tools and cleaning equipment.
Refer to the “SPECIAL TOOLS” section.
3.When disassembling the machine, always
keep mated parts together. This includes
gears, cylinder, piston and other parts that
have been “mated” through normal wear.
Mated parts must always be reused or
replaced as an assembly.
4.During machine disassembly, clean all parts
and place them in trays in the order of disassembly. This will speed up assembly and
allow for the correct installation of all parts.
5.Keep all parts away from any source of fire.

EB101010

REPLACEMENT PARTS
1.Use only genuine Yamaha parts for all
replacements. Use oil and grease recommended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.

EB101020

GASKETS, OIL SEALS AND O-RINGS
1.Replace all gaskets, seals and O-rings when
overhauling the engine. 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.

1-2

IMPORTANT INFORMATION

GEN
INFO

EB101030

LOCK WASHERS/PLATES AND COTTER
PINS
1.Replace all lock washers/plates 1 and cotter
pins after removal. Bend lock tabs along the
bolt or nut flats after the bolt or nut has been
tightened to specification.

EB101040

BEARINGS AND OIL SEALS
1.Install bearings and oil seals so that the
manufacturer’s marks or numbers are visible.
When installing oil seals, apply a light coating of lightweight lithium base grease to the
seal lips. Oil bearings liberally when installing, if appropriate.
1 Oil seal

CAUTION:
Do not use compressed air to spin the
bearings dry. This will damage the bearing
surfaces.
1 Bearing

EB101050

CIRCLIPS
1.Check all circlips carefully before reassembly. Always replace piston pin clips after one
use. Replace distorted circlips. When installing a circlip 1, make sure that the sharpedged corner 2 is positioned opposite the
thrust 3 it receives. See sectional view.
4 Shaft

1-3

CHECKING OF CONNECTIONS

GEN
INFO

EB801000

CHECKING OF CONNECTIONS
Check the connectors for stains, rust, moisture, etc.
1.Disconnect:
● Connector
2.Check:
● Connector
Moisture → Dry each terminal with an air
blower.
Stains/rust → Connect and disconnect the
terminals several times.
3.Check:
● Connector leads
Looseness → Bend up the pin 1 and connect the terminals.

4.Connect:
● Connector terminals
NOTE:
The two terminals “click” together.

5.Check:
● Continuity (using a pocket tester)
NOTE:
● If there is no continuity, clean the terminals.
● When checking the wire harness be sure to
perform steps 1 to 3.
● As a quick remedy, use a contact revitalizer
available at most part stores.
● Check the connector with a pocket tester as
shown.

1-4

SPECIAL TOOLS

GEN
INFO

EB102001

SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools; this will help prevent damage caused by the use of inappropriate
tools or improvised techniques. Special tools may differ by shape and part number from country to
country. In such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.
For US and CDN
P/N. YM-, YU-, YS-, YK-, ACCExcept for US and CDN
P/N. 90890Tool No.
Bolt
90890-01083
Weight
90890-01084
Set
YU-01083-A

Tool name/How to use
Slide hammer bolt (M6)/weight/set

These tools are used to remove the rocker
arm shaft.
Crankcase separating tool

90890-01135
YU-01135-A
This tool is used to separate the crankcase.
Pot
90890-01274
Bolt
90890-01275

Crankshaft installer pot
Crankshaft installer bolt

These tools are used to install the crankshaft.
Crankshaft installer set

YU-90050
These tools are used to install the crankshaft.
Adapter
90890-04059
YM-90069
Spacer
90890-04081
YM-91044

Adapter
Spacer (crankshaft installer)

These tools are used to install the crankshaft.
Spacer

90890-01016
This tool is used to install the crankshaft.

1-5

Illustration

SPECIAL TOOLS
Tool No.

Tool name/How to use
Piston pin puller

90890-01304
YU-01304
This tool is used to remove the piston pin.
Tappet adjusting tool (3 mm)
90890-01311
YM-08035
This tool is necessary for adjusting the
valve clearance.
Fuel level gauge
90890-01312
YM-01312-A
This gauge is used to measure the fuel
level in the float chamber.
Radiator cap tester
90890-01325
YU-24460-01
This tool is used to check the cooling system.
Adapter
90890-01352
YU-33984
This tool is used to check the cooling system.
Damper rod holder (30 mm)
90890-01327
YM-01327
This tool is needed to loosen and tighten
the steering stem bearing retainer.
Flywheel puller
90890-01362
YU-33270
These tools are needed to remove the
rotor.
Axle nut wrench (50 mm)
90890-01419
YM-37132
This tool is needed to loosen or tighten the
rear axle nut.

1-6

GEN
INFO

Illustration

SPECIAL TOOLS
Tool No.

Tool name/How to use
Oil filter wrench

90890-01469
YM-01469
This tool is needed to loosen or tighten
the oil filter cartridge.
Ball joint remover/installer set
90890-01474
YM-01474
These tools are used to removing or
installing the ball joint.
Ball joint remover/installer attachment set
90890-01480
YM-01480
These tools are used to removing or
installing the ball joint.
Sheave holder
90890-01701
YS-01880

Set
90890-03081
YU-33223
Adapter
90890-04082
YU-33223-3

This tool is needed to hold the AC magneto rotor when removing or installing the
AC magneto rotor bolts.
Compression gauge set
Adapter

These tools are needed to measure
engine compression.
Pocket tester

90890-03112
YU-03112
This instrument is needed for checking the
electrical system.
Timing light
90890-03141
YM-33277-A
This tool is necessary for checking ignition
timing.
Compressor
90890-04019
YM-04019
Attachment
90890-01243

Valve spring compressor
Valve spring compressor attachment

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

1-7

GEN
INFO

Illustration

SPECIAL TOOLS
Tool No.
Middle driven shaft
bearing driver
90890-04058
YM-04058-1
Mechanical seal
installer
90890-04078
YM-33221

Tool name/How to use
Middle driven shaft bearing driver
Mechanical seal installer

These tools are used to install the water
pump seal.
Valve guide remover (ø 6)

90890-04064
YM-4064-A
This tool is needed to remove and install
the valve guide.
Valve guide installer (ø 6)
90890-04065
YM-04065-A
This tool is needed to install the valve
guide.
Valve guide reamer (ø 6)
90890-04066
YM-04066
This tool is needed to rebore the new
valve guide.
Clutch holding tool
90890-04086
YM-91042

This tool is needed to hold the clutch carrier when removing or installing the carrier
nut.
Ignition checker

90890-06754
This instrument is necessary for checking
the ignition system components.
Dynamic spark tester
YM-34487
This instrument is necessary for checking
the ignition system components.
Bond
90890-85505
Sealant
ACC-11001-05-01

Yamaha bond No. 1215
Sealant (Quick Gasket®)

This sealant (bond) is used on crankcase
mating surfaces, etc.

1-8

GEN
INFO

Illustration

GENERAL SPECIFICATIONS

SPEC

SPECIFICATIONS
GENERAL SPECIFICATIONS
Item

Standard

Model code:

5LP1 : (Except for California)
5LP3 : (For California)

Dimensions:
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Minimum turning radius
Basic weight:
With oil and full fuel tank
Engine:
Engine type
Cylinder arrangement
Displacement
Bore × stroke
Compression ratio
Standard compression pressure (at sea level)
Starting system
Lubrication system:
Oil type or grade:
Engine oil
0°

10°

30°

50°

70°

90°

110°

1,830 mm (72.0 in)
1,100 mm (43.3 in)
1,150 mm (45.3 in)
860 mm (33.9 in)
1,245 mm (49.0 in)
265 mm (10.4 in)
3,300 mm (129.9 in)
193 kg (426 lb)
Liquid-cooled 4-stroke, SOHC
Forward-inclined single cylinder
660 cm3
100.0 × 84.0 mm (3.94 × 3.31 in)
9.2 : 1
1,250 kPa (12.5 kg/cm2, 181 psi)
Electric starter
Dry sump

130°F

YAMALUBE 4 (20W40) or SAE 20W40

API service SE, SF, SG type or higher

YAMALUBE 4 (10W30) or SAE 10W30
SAE 5W30

-20°

-10°

0°

10°

20°

30°

40°

50°C

Oil capacity:
Engine oil
Periodic oil change
With oil filter replacement
Total amount
Radiator capacity (including all routes)
Air filter:
Fuel:
Type
Fuel tank capacity
Fuel reserve amount

1.9 L (1.67 lmp qt, 2.01 US qt)
1.95 L (1.72 lmp qt, 2.06 US qt)
2.3 L (2.02 lmp qt, 2.43 US qt)
1.3 L (1.14 lmp qt, 1.37 US qt)
Wet type element
Unleaded fuel
12 L (2.64 lmp gal, 3.17 US gal)
2.6 L (0.57 lmp gal, 0.69 US gal)

2-1

GENERAL SPECIFICATIONS
Item

Standard

Carburetor:
Type/quantity
Manufacturer
Spark plug:
Type/manufacturer
Spark plug gap
Clutch type:
Transmission:
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Transmission type
Operation
Gear ratio
1st gear
2nd gear
3rd gear
4th gear
5th gear
Reverse gear
Chassis:
Frame type
Caster angle
Camber angle
Kingpin angle
Kingpin offset
Trail
Tread (STD)
Toe-in
Tire:
Type
Size
Manufacturer
Type

SPEC

BSR33/2
MIKUNI
DPR8EA-9/NGK
0.8 ~ 0.9 mm (0.031 ~ 0.035 in)
Wet, multiple disc
Spur gear
71/34 (2.088)
Chain drive
40/13 (3.076)
Constant mesh, 5-speed/forward.
1-speed/reverse
Left foot operation
34/14 (2.428)
29/19 (1.526)
26/21 (1.238)
22/21 (1.047)
19/21 (0.904)
28/23 × 23 × 16 (1.750)

front
rear

front
rear
front
rear
front
rear

Steel tube frame
8°
–1°
14.5°
5 mm (0.20 in)
47 mm (1.85 in)
925 mm (36.42 in)
840 mm (33.07 in)
0 ~ 10 mm (0 ~ 0.39 in)
Tubeless
AT21 × 7–10
AT20 × 10–9
DUNLOP
DUNLOP
KT331 Radial
KT335 Radial

2-2

GENERAL SPECIFICATIONS
Item
Tire pressure (cold tire):
Maximum load*
Off-road riding

SPEC

Standard

front
rear
*Load in total weight of cargo, rider and accessories
Brake:
Front brake
type
operation
Rear brake
type
operation
Suspension:
Front suspension
Rear suspension
Shock absorber:
Front shock absorber
Rear shock absorber
Wheel travel:
Front wheel travel
Rear wheel travel
Electrical:
Ignition system
Generator system
Battery type
Battery capacity
Headlight type:
Bulb voltage/wattage × quantity:
Headlight
Tail/brake light
Indicator and warning lights
Neutral
Reverse
Coolant temperature

100 kg (220 lb)
27.5 kPa (0.275 kg/cm2, 4.0 psi)
27.5 kPa (0.275 kg/cm2, 4.0 psi)

Dual disc brake
Right hand operation
Single disc brake
Right foot operation
Double wishbone
Swingarm (link suspension)
Coil spring/oil damper
Coil spring/gas-oil damper
230 mm (9.06 in)
220 mm (8.66 in)
DC-C.D.I.
A.C. magneto
YTX14-BS
12 V 12 Ah
Krypton bulb
12 V 30 W/30 W × 2
12 V 5 W/21 W × 1
12 V 1.7 W × 1
12 V 1.7 W × 1
12 V 1.7 W × 1

2-3

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS
ENGINE
Item

Standard

Cylinder head:
Warp limit

Cylinder:
Bore size
Measuring point

Camshaft:
Drive method
Camshaft cap inside diameter
Camshaft journal diameter
Camshaft journal-to-camshaft cap clearance

Limit

----

0.05 mm
(0.002 in)

100.005 ~ 100.045 mm
(3.9372 ~ 3.9388 in)
50 mm (2.0 in)

100.1 mm
(3.94 in)
----

Chain drive (Left)
23.000 ~ 23.021 mm
(0.9055 ~ 0.9063 in)
22.967 ~ 22.980 mm
(0.9042 ~ 0.9047 in)
0.020 ~ 0.054 mm
(0.0008 ~ 0.0021 in)

-------

35.69 ~ 35.79 mm
(1.4051 ~ 1.4091 in)
30.15 ~ 30.25 mm
(1.1870 ~ 1.1909 in)
5.74 mm (0.2260 in)
36.50 ~ 36.60 mm
(1.437 ~ 1.441 in)
30.15 ~ 30.25 mm
(1.187 ~ 1.191 in)
6.55 mm (0.2579 in)

35.59 mm
(1.4012 in)
30.05 mm
(1.1831 in)
---36.40 mm
(1.4331 in)
30.05 mm
(1.1831 in)
----

-------

Cam dimensions

C
A

Intake

“A”
“B”

Exhaust

“C”
“A”
“B”
“C”

2-4

MAINTENANCE SPECIFICATIONS
Item

SPEC

Standard

Camshaft runout limit

Timing chain:
Timing chain type/No. of links
Timing chain adjustment method
Rocker arm/rocker arm shaft:
Shaft outside diameter
Arm-to-shaft clearance
Valve, valve seat, valve guide:
Valve clearance (cold)

IN
EX

Limit

----

0.03 mm
(0.0012 in)

75-RH2015/126
Automatic

-------

11.976 ~ 11.991 mm
(0.4715 ~ 0.4721 in)
0.009 ~ 0.042 mm
(0.0004 ~ 0.0017 in)

----

0.10 ~ 0.15 mm
(0.0039 ~ 0.0059 in)
0.15 ~ 0.20 mm
(0.0059 ~ 0.0079 in)

----

-------

Valve dimensions

C
D

A
Head Diameter

“A” head diameter

IN
EX

“B” face width
“C” seat width

IN
EX
IN
EX

“D” margin thickness

IN
EX

Stem outside diameter

IN
EX

Guide inside diameter

Seat Width

Face Width

IN
EX

29.9 ~ 30.1 mm
(1.1772 ~ 1.1850 in)
31.9 ~ 32.1 mm
(1.2559 ~ 1.2638 in)
2.25 mm (0.0886 in)
2.26 mm (0.0890 in)
0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)
0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)
0.85 ~ 1.15 mm
(0.0335 ~ 0.0453 in)
0.85 ~ 1.15 mm
(0.0335 ~ 0.0453 in)
5.975 ~ 5.990 mm
(0.2352 ~ 0.2358 in)
5.960 ~ 5.975 mm
(0.2346 ~ 0.2352 in)
6.000 ~ 6.012 mm
(0.2362 ~ 0.2367 in)
6.000 ~ 6.012 mm
(0.2362 ~ 0.2367 in)
2-5

Margin Thickness

------------1.6 mm
(0.0630 in)
1.6 mm
(0.0630 in)
------5.945 mm
(0.2341 in)
5.930 mm
(0.2335 in)
6.040 mm
(0.2378 in)
6.040 mm
(0.2378 in)

MAINTENANCE SPECIFICATIONS
Item
Stem-to-guide clearance

Standard
IN

0.08 mm
(0.0031 in)
0.10 mm
(0.0039 in)
0.01 mm
(0.0004 in)

0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)
0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)

1.6 mm
(0.0630 in)
1.6 mm
(0.0630 in)

35.95 mm (1.42 in)

37.75 mm (1.49 in)

IN
EX

27.2 mm (1.07 in)
30.7 mm (1.21 in)

34.15 mm
(1.34 in)
35.86 mm
(1.41 in)
-------

149 ~ 173 N (15.19 ~ 17.64 kg,
33.50 ~ 38.89 lb)
165 ~ 191 N (16.83 ~ 19.49 kg,
37.09 ~ 42.94 lb)

Stem runout limit

IN
EX

Valve spring:
Free length

Set length (valve closed)
Compressed pressure
(installed)

EX
Tilt limit

IN
EX

------2.5°/1.6 mm
(2.5°/0.06 in)
2.5°/1.6 mm
(2.5°/0.06 in)

Direction of winding
(top view)

Limit

0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
0.025 ~ 0.052 mm
(0.0010 ~ 0.0020 in)
----

Valve seat width

SPEC

Clockwise
Clockwise

2-6

-------

MAINTENANCE SPECIFICATIONS
Item

SPEC

Standard

Piston:
Piston to cylinder clearance
Piston size “D”

Limit

0.05 ~ 0.07 mm
(0.0020 ~ 0.0028 in)
99.945 ~ 99.995 mm
(3.9348 ~ 3.9368 in)

0.15 mm
(0.0059 in)
----

2.5 mm (0.10 in)
1.0 mm (0.04 in)
22.004 ~ 22.015 mm
(0.8663 ~ 0.8667 in)
21.991 ~ 22.000 mm
(0.8658 ~ 0.8661 in)

------22.045 mm
(0.8679 in)
21.971 mm
(0.8650 in)

Barrel
1.2 × 3.8 mm
(0.0472 × 0.1496 in)
0.30 ~ 0.45 mm
(0.0118 ~ 0.0177 in)
0.04 ~ 0.08 mm
(0.0016 ~ 0.0031 in)

-------

Taper
1.2 × 4.0 mm
(0.0472 × 0.1575 in)
0.30 ~ 0.45 mm
(0.0118 ~ 0.0177 in)
0.03 ~ 0.07 mm
(0.0012 ~ 0.0028 in)

-------

2.5 × 3.4 mm
(0.0984 × 0.1339 in)
0.2 ~ 0.7 mm
(0.0079 ~ 0.0276 in)

----

H
D

Measuring point “H”
Piston off-set
Piston pin bore inside diameter
Piston pin outside diameter
Piston rings:
Top ring
B
T

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

0.70 mm
(0.0276 in)
0.13 mm
(0.0051 in)

2nd ring
B
T

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

0.80 mm
(0.0315 in)
0.13 mm
(0.0051 in)

Oil ring
B
T

Dimensions (B × T)
End gap (installed)

2-7

----

MAINTENANCE SPECIFICATIONS
Item

SPEC

Standard

Limit

Crankshaft:

Crank width “A”
Runout limit C1
C2
Big end side clearance “D”
Big end radial clearance “E”
Small end free play “F”
Balancer:
Balancer drive method
Clutch:
Friction plate 1
Thickness
Quantity
Friction plate 2
Thickness
Quantity
Clutch plate
Thickness
Quantity
Max. warpage
Clutch spring
Free length
Quantity
Min. length
Clutch release method

74.95 ~ 75.00 mm
(2.9508 ~ 2.9528 in)
------0.32 ~ 0.64 mm
(0.0126 ~ 0.0252 in)
0.010 ~ 0.025 mm
(0.0004 ~ 0.0010 in)
0.8 mm (0.0315 in)

---0.03 mm
(0.0012 in)
0.03 mm
(0.0012 in)
1.0 mm
(0.0394 in)
-------

Gear

----

2.74 ~ 2.86 mm
(0.108 ~ 0.113 in)
6

2.6 mm
(0.102 in)
----

2.94 ~ 3.06 mm
(0.116 ~ 0.120 in)
2

2.8 mm
(0.110 in)
----

1.1 ~ 1.3 mm
(0.043 ~ 0.051 in)
7
----

----

42.8 mm (1.69 in)
5
---Outer pull, rack and pinion pull

2-8

---0.2 mm
(0.008 in)
40.7 mm
(1.60 in)
---40.8 mm
(1.61 in)
----

MAINTENANCE SPECIFICATIONS
Item

Standard

Transmission:
Main axle deflection limit

----

Drive axle deflection limit

----

Shifter:
Shifter type
Decompression device:
Device type
Air filter oil grade:
Carburetors:
I. D. mark
Main jet

(M.J)

Main air jet
Jet needle
Needle jet
Pilot air jet

(M.A.J)
(J.N)
(N.J)
(P.A.J.1)

Pilot air jet
Pilot outlet

(P.A.J.2)
(P.O)

Pilot jet
Bypass 1
Bypass 2
Valve seat size
Starter jet
Starter jet
Throttle valve size
Float height
Fuel level
Engine idle speed
Intake vacuum

(P.J)
(B.P.1)
(B.P.2)
(V.S)
(G.S.1)
(G.S.2)
(Th.V)
(F.H)
(F.L)

Oil pump:
Oil filter type
Oil pump type
Tip clearance “A” or “B”
Side clearance
Bypass valve setting pressure
Oil pressure (hot)
Pressure check location

SPEC
Limit
0.08 mm
(0.0031 in)
0.08 mm
(0.0031 in)

Shift drum and guide bar

----

Auto decomp
Engine oil

-------

5LP1 00
Carburetor #1 : #140
Carburetor #2 : #145
#130
5ND16-56-3
P-6M (#826)
Carburetor #1 : #80
Carburetor #2 : #150
1.3
Carburetor #1 : 1.0
Carburetor #2 : 0.9
#22.5
0.8
0.8
2.0
#95
0.5
#80
13 mm (0.51 in)
3 ~ 4 mm (0.12 ~ 0.16 in)
1,450 ~ 1,550 r/min
32.0 ~ 33.3 kPa (240 ~ 250 mmHg,
9.45 ~ 9.83 inHg)

-------

Paper
Trochoid
0.12 mm (0.005 in)
0.03 ~ 0.08 mm
(0.001 ~ 0.003 in)
80 ~ 120 kPa (0.8 ~ 1.2 kg/cm2,
11.6 ~ 17.4 psi)
65 kPa (0.65 kg/cm2, 9.4 psi) at
1,500 r/min
Cylinder head

2-9

-------------------------------------------------

------0.2 mm
(0.008 in)
-------------

MAINTENANCE SPECIFICATIONS
Item
Cooling system:
Radiator core
Width
Height
Depth
Radiator cap opening pressure
Radiator capacity
Coolant reservoir
Capacity
From low to full level
Water pump:
Type
Reduction ratio
Lubrication chart:

SPEC

Standard

Limit

219 mm (8.62 in)
300 mm (11.8 in)
16 mm (0.63 in)
95 ~ 125 kPa (0.95 ~ 1.25 kg/cm2,
13.8 ~ 18.1 psi)
0.55 L (0.48 Imp qt, 0.58 US qt)

-------------

0.29 L (0.26 Imp qt, 0.31 US qt)
0.165 L (0.15 Imp qt, 0.17 US qt)

-------

Single suction centrifugal pump
33/34 (0.971)

----

2 - 10

----

MAINTENANCE SPECIFICATIONS
Item
Cylinder head tightening sequence:

Standard

2 - 11

SPEC
Limit

MAINTENANCE SPECIFICATIONS

SPEC

Tightening torques
Part to be tightened
Cylinder head (exhaust pipe)
Cylinder head

Spark plug
Cylinder head cover
Camshaft end cap
Oil check bolt
Tappet cover (exhaust)
Tappet cover (intake)
Cylinder

Timing chain tensioner
Timing chain tensioner cap
Timing chain guide (intake)
Camshaft sprocket
Rocker arm shaft
Valve adjusting screw
Radiator
Coolant drain bolt
Engine oil drain bolt (oil tank)
Engine oil drain bolt (engine)
Oil filter bolt
Oil filter cartridge
Oil delivery pipe 1
Oil delivery pipe 2
Oil pipe joint
Oil pipe 1 and oil pipe joint
Oil pipe 2 and oil tank
Air filter case
Carburetor clamp
Exhaust pipe 1 and exhaust pipe 2
Exhaust pipe protector
Spark arrester
Muffler and exhaust pipe 2
Muffler
Silencer cap
Exhaust pipe

Part
name
Stud bolt

Bolt
Bolt
Bolt
—
Bolt
Bolt
—
—
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
Bolt
—
—
—
Union bolt

—
Union bolt
Union bolt

—
Nut
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Nut

Thread
Q’ty
size
M6
M9
M9
M6
M12
M6
M6
M6
M32
M6
M10
M10
M6
M6
M16
M6
M7
M6
M6
M6
M6
M10
M14
M20
M20
M10
M8
M14
M16
M16
M6
M4
M8
M6
M6
M8
M8
M6
M6

2 - 12

4
4
2
1
1
17
1
1
2
4
2
2
2
2
1
2
2
2
5
2
1
1
1
1
1
2
2
1
1
1
2
4
1
4
1
1
2
3
4

Tightening torque
Nm

m·kg

ft·lb

7
38
38
10
18
10
10
7
12
10
42
42
10
10
22
8
20
10
14
7
10
25
30
63
17
20
18
50
35
35
7
5
16
10
8
20
26
10
10

0.7
3.8
3.8
1.0
1.8
1.0
1.0
0.7
1.2
1.0
4.2
4.2
1.0
1.0
2.2
0.8
2.0
1.0
1.4
0.7
1.0
2.5
3.0
6.3
1.7
2.0
1.8
5.0
3.5
3.5
0.7
0.5
1.6
1.0
0.8
2.0
2.6
1.0
1.0

5.1
27
27
7.2
13
7.2
7.2
5.1
8.7
7.2
30
30
7.2
7.2
16
5.8
14
7.2
10
5.1
7.2
18
22
45
12
14
13
36
25
25
5.1
3.6
12
7.2
5.8
14
19
7.2
7.2

Remarks

MAINTENANCE SPECIFICATIONS
Part to be tightened
Bearing retainer
AC magneto rotor
Starter clutch
Balancer driven gear

Part
name
Screw
Nut
Bolt
Nut

Thread
Q’ty
size
M6
M14
M6
M18

4
1
6
1

SPEC

Tightening torque
Nm

m·kg

ft·lb

7
150
16
140

0.7
15.0
1.6
14.0

5.1
110
11
100

Remarks
LT

Use a lock
washer.

Primary drive gear

Nut

M20

150

15.0

110

Use a lock
washer.

Clutch spring
Clutch boss

Bolt
Nut

M6
M20

5
1

8
90

0.8
9.0

5.8
65

Pull lever shaft
Drive sprocket

Bolt
Nut

M6
M18

1
1

7
70

0.7
7.0

5.1
50

Oil seal retainer
Shift drum segment
Shift guide
Stopper lever
Reverse shift lever
Shift arm
Shift pedal adjusting rod

Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Nut

M6
M8
M6
M6
M6
M6
M6

2
1
2
1
1
1
1

10
30
10
10
13
10
8

1.0
3.0
1.0
1.0
1.3
1.0
0.8

7.2
22
7.2
7.2
9.4
7.2
5.8

Stator assembly
Pick up coil
AC magneto lead holder
Ignition coil
Starter motor
Neutral switch
Reverse switch
Thermo switch 1
Thermo switch 2

Nut
Bolt
Bolt
Bolt
Bolt
Bolt
—
—
—
—

M6
M5
M5
M6
M6
M6
M10
M10
M18
M18

1
3
2
2
2
2
1
1
1
1

8
7
7
10
7
10
20
20
28
28

0.8
0.7
0.7
1.0
0.7
1.0
2.0
2.0
2.8
2.8

5.8
5.1
5.1
7.2
5.1
7.2
14
14
20
20

2 - 13

Use a lock
washer.
Use a lock
washer.

Left-hand
threads
LT
LT
LT

MAINTENANCE SPECIFICATIONS

SPEC

CHASSIS
Item
Steering system:
Steering bearing type
Front suspension:
Shock absorber travel
Fork spring free length
Spring fitting length
Spring rate
Spring rate
Optional spring
Rear suspension:
Shock absorber travel
Spring free length
Spring fitting length
Spring rate
Stroke
Optional spring
Swingarm:
Free play limit

Front wheel:
Type
Rim size
Rim material
Rim runout limit

Rear wheel:
Type
Rim size
Rim material
Rim runout limit

Standard

Limit

Ball and race bearing

----

110 mm (4.33 in)
316.5 mm (12.46 in)
293.5 mm (11.56 in)
19.6 N/mm
(2.00 kg/mm, 111.92 lb/in)
29.4 N/mm
(3.00 kg/mm, 167.87 lb/in)
No

-------------

100 mm (3.94 in)
273 mm (10.75 in)
253 mm (9.96 in)
55 N/mm
(5.61 kg/mm, 314.05 lb/in)
0 ~ 100 mm (0 ~ 3.94 in)
No

-------------

end

----

side

----

1 mm
(0.04 in)
1 mm
(0.04 in)

radial

Panel wheel
10 × 5.5 AT
Aluminum
----

lateral

----

radial

Panel wheel
9 × 8.5 AT
Aluminum
----

lateral

----

(K1)
(K2)

(K1)
(K1)

2 - 14

-------

---------2 mm
(0.08 in)
2 mm
(0.08 in)
---------2 mm
(0.08 in)
2 mm
(0.08 in)

MAINTENANCE SPECIFICATIONS
Item

Standard

Front disc brake:
Type
Disc outside diameter × thickness
Pad thickness
inner
Pad thickness

outer

Master cylinder inside diameter
Caliper cylinder inside diameter
Brake fluid type
Rear disc brake:
Type
Disc outside diameter × thickness
Pad thickness
inner
Pad thickness

outer

Master cylinder inside diameter
Caliper cylinder inside diameter
Brake fluid type
Brake lever and brake pedal:
Brake lever free play (at lever end)
Brake pedal position
Throttle lever free play

SPEC

Dual
161.0 × 3.5 mm (6.34 × 0.14 in)
4.2 mm (0.17 in)
4.2 mm (0.17 in)
12.7 mm (0.50 in)
32.03 mm (1.26 in)
DOT 4
Single
220.0 × 3.6 mm (8.66 × 0.14 in)
4.5 mm (0.18 in)
4.5 mm (0.18 in)
12.7 mm (0.50 in)
33.96 mm (1.34 in)
DOT 4
0 mm (0 in)
4 mm (0.16 in)
(Below the top of footrest)
3 ~ 5 mm (0.12 ~ 0.20 in)

2 - 15

Limit
------1 mm
(0.04 in)
1 mm
(0.04 in)
---------------1 mm
(0.04 in)
1 mm
(0.04 in)
-------------------

MAINTENANCE SPECIFICATIONS

SPEC

Tightening torques
Part to be tightened

Thread size

Tightening torque
Nm

m·kg

ft·lb

Engine bracket (upper) and frame
Engine bracket (upper) and engine
Engine bracket (lower) and frame
Engine bracket (lower) and engine
Engine bracket (middle and lower) and engine
Swingarm pivot shaft, engine and frame
Rear shock absorber and frame
Relay arm and swingarm
Connecting arm and frame
Relay arm and rear shock absorber
Relay arm and connecting arm
Drive chain guide and swingarm
Hub, brake caliper bracket and swingarm
Drive chain adjusting bolt and locknut
Front shock absorber and frame
Front shock absorber and front arm (lower)
Front arm (upper) and frame
Front arm (lower) and frame
Brake hose holder and front arm (upper)
Steering stem, pitman arm and frame
Steering stem bushing and frame

M8
M10
M10
M10
M10
M16
M10
M10
M10
M10
M10
M6
M12
M8
M10
M10
M10
M10
M6
M14
M8

33
40
56
56
56
95
32
32
32
32
32
7
90
16
45
45
38
32
7
110
23

3.3
4.0
5.6
5.6
5.6
9.5
3.2
3.2
3.2
3.2
3.2
0.7
9.0
1.6
4.5
4.5
3.8
3.2
0.7
11
2.3

24
29
40
40
40
68
23
23
23
23
23
5.1
65
11
32
32
27
23
5.1
80
17

Steering stem and handlebar holder
Tie-rod end and locknut
Steering knuckle and front wheel hub
Steering knuckle and front arm (upper and lower)
Steering knuckle and tie-rod ball joint
Pitman arm and tie-rod ball joint
Frame and bearing retainer
Fuel tank and fuel cock
Fuel tank and frame
Front wheel and front wheel hub
Steering knuckle and front brake caliper
Front brake disc and front wheel hub
Rear axle and rear wheel hub
Rear brake caliper and brake caliper bracket
Rear wheel and rear wheel hub
Driven sprocket and sprocket bracket
Front brake pipe nut
Front brake master cylinder and handlebar

M8
M10
M14
M10
M10
M10
M42
M6
M6
M10
M8
M8
M14
M8
M10
M8
M10
M6

23
15
70
25
25
25
40
4
7
45
28
28
120
28
45
24
19
7

2.3
1.5
7.0
2.5
2.5
2.5
4.0
0.4
0.7
4.5
2.8
2.8
12
2.8
4.5
2.4
1.9
0.7

17
11
50
18
18
18
29
2.9
5.1
32
20
20
85
20
32
17
13
5.1

2 - 16

Remarks

Use a lock
washer.

MAINTENANCE SPECIFICATIONS
Part to be tightened

Thread size

SPEC

Tightening torque
Nm

m·kg

ft·lb

Front brake master cylinder and brake lever
Front brake master cylinder and brake hose
Brake hose joint and frame
Bleed screw
Front brake pad holding bolt
Front brake caliper and brake hose
Front brake caliper retaining bolt
Rear axle ring nut
Rear brake pad holding bolt

M6
M10
M6
M8
M10
M10
M8
M38
M10

0.6
4.3
2.7
19
1.0
7.2
0.6
4.3
1.8
13
2.7
19
2.3
17
SEE NOTE
18
1.8
13

Rear brake caliper and brake hose
Rear brake master cylinder and frame
Rear brake master cylinder and brake hose
Parking brake adjusting bolt and locknut
Rear brake disc and brake disc bracket
Rear brake fluid reservoir cover and bracket
Rear brake fluid reservoir and bracket
Brake hose holder and swingarm
Front bumper and frame
Front fender bracket and frame
Rear carrier bar and frame
Footrest and frame
Footrest guard bracket and frame
Footrest and footrest guard bracket
Footrest guard bracket and rear fender
Battery holding bracket and frame
Air filter case and frame
Carburetor clamp screw
Tail/brake light bracket and frame
Tail/brake light bracket and tail/brake light
Swingarm skid plate and swingarm
Swingarm skid plate and swingarm
Drive chain tensioner and frame
Engine skid plate and frame
Main frame and rear frame

M10
M8
M10
M8
M8
M6
M6
M6
M8
M8
M8
M10
M8
M8
M6
M6
M6
M4
M6
M6
M6
M8
M8
M6
M10

30
20
30
16
28
4
4
7
31
16
23
65
33
16
7
7
7
5
7
7
7
16
32
7
53

Remarks

6
27
10
6
18
27
23

3.0
2.0
3.0
1.6
2.8
0.4
0.4
0.7
3.1
1.6
2.3
6.5
3.3
1.6
0.7
0.7
0.7
0.5
0.7
0.7
0.7
1.6
3.2
0.7
5.3

Use a lock
washer.

22
14
22
11
20
2.9
2.9
5.1
22
11
17
48
24
11
5.1
5.1
5.1
3.6
5.1
5.1
5.1
11
23
5.1
38

HINWEIS:
NOTE:
Apply locking agent (LOCTITE®) to ring nuts threads.
1st: Tighten the inside ring nut 55 Nm (5.5 m • kg, 40 ft • lb).
2nd: Tighten the outside ring nut while holding the inside ring nut 190 Nm (19 m • kg, 140 ft • lb).
3rd: Loosen the inside ring nut while holding the outside ring nut 240 Nm (24 m • kg, 170 ft • lb).

2 - 17

MAINTENANCE SPECIFICATIONS

SPEC

ELECTRICAL
Item
Voltage:
Ignition system:
Ignition timing (B.T.D.C.)
Advancer type
C.D.I.:
Magneto model/manufacturer
Pickup coil resistance/color
Rotor rotation direction detection coil resistance/color
C.D.I. unit model/manufacturer
Ignition coil:
Model/manufacturer
Minimum spark gap
Primary winding resistance
Secondary winding resistance
Spark plug cap:
Type
Resistance
Charging system:
Type
Model/manufacturer
Nominal output
Charging coil resistance/color
Rectifier:
Type
Model/manufacturer
No load voltage (DC)
Capacity
Withstand voltage
Electric starter system:
Type
Starter motor
Model/manufacturer
Output
Armature coil resistance
Brush overall length
Spring force
Commutator diameter
Mica undercut

Standard

Limit

12 V

----

12°/ 1,500 r/min
Digital type

-------

F4T260/MITSUBISHI
445 ~ 545 Ω at 20 °C (68 °F)/
White/Red – White/Green
0.069 ~ 0.085 Ω at 20 °C (68 °F)/
Red – White/Blue
F8T37971/MITSUBISHI

-------

2JN/YAMAHA
6 mm (0.24 in)
0.18 ~ 0.28 Ω at 20 °C (68 °F)
6.32 ~ 9.48 kΩ at 20 °C (68 °F)

-------------

Resin type
10 kΩ

-------

A.C. magneto generator
F4T260/MITSUBISHI
14 V 16 A at 5,000 r/min
0.43 ~ 0.65 Ω at 20 °C (68 °F)/
White – White

-------------

Semi conductor-short circuit
SH640E-11/SHINDENGEN
14.1 ~ 14.9 V
14 A
200 V

----------------

Constantmesh type

----

SM-13/MITSUBA
0.8 kW
0.025 ~ 0.035 Ω at 20 °C (68 °F)
12.5 mm (0.49 in)

-------

---------5 mm
(0.20 in)
7.65 ~ 10.01 N (27.54 ~ 36.03 oz) ---28 mm (1.10 in)
27 mm
(1.06 in)
0.7 mm (0.03 in)
----

2 - 18

MAINTENANCE SPECIFICATIONS
Item
Starter relay
Model/manufacturer
Amperage rating
Coil winding resistance
Thermostat switch:
Thermostat switch 1
Model/manufacturer
Thermostat switch 2
Model/manufacturer
Circuit breaker:
Type
Amperage for individual circuit
Fuse
Reserve

SPEC

Standard

Limit

MS5F-721/JIDECO
180 A
4.18 ~ 4.62 Ω at 20 °C (68 °F)

----------

5GH/NIPPON THERMOSTAT

----

5LP/NIPPON THERMOSTAT

----

Fuse

----

20 A × 1
20 A × 1

-------

2 - 19

HOW TO USE THE CONVERSION TABLE/
GENERAL TORQUE SPECIFICATIONS

SPEC

EB201000

EB202001

HOW TO USE THE CONVERSION
TABLE

GENERAL TORQUE
SPECIFICATIONS

All specification data in this manual are listed
in SI and METRIC UNITS.
Use this table to convert METRIC unit data to
IMPERIAL unit data.

This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque
specifications for special components or
assemblies are provided for each chapter of
this manual. To avoid warpage, tighten multifastener assemblies in a crisscross fashion, in
progressive stages, until the specified torque is
reached. Unless otherwise specified, torque
specifications require clean, dry threads. Components should be at room temperature.

Ex.
METRIC
MULTIPLIER
** mm ×
0.03937
=
×
2 mm
0.03937
=

IMPERIAL
** in
0.08 in

CONVERSION TABLE
METRIC TO IMPERIAL
Metric unit

Multiplier

Imperial unit

Torque

m·kg
m·kg
cm·kg
cm·kg

7.233
86.794
0.0723
0.8679

ft·lb
in·lb
ft·lb
in·lb

Weight

kg
g

2.205
0.03527

lb
oz

Speed

km/hr

0.6214

mph

Distance

km
m
m
cm
mm

0.6214
3.281
1.094
0.3937
0.03937

mi
ft
yd
in
in

0.03527
0.06102
0.8799
0.2199

oz (IMP liq.)
cu·in
qt (IMP liq.)
gal (IMP liq.)

Volume/
Capacity

cc (cm )
cc (cm3)
lt (liter)
lt (liter)

Misc.

kg/mm
55.997
kg/cm2
14.2234
Centigrade
9/5+32
(°C)

A: Distance between flats
B: Outside thread diameter

lb/in
psi (lb/in2)
Fahrenheit (°F)

2 - 20

A
(nut)

B
(bolt)

10 mm

General torque
specifications
Nm

m•kg

ft•lb

6 mm

0.6

4.3

12 mm

8 mm

1.5

14 mm

10 mm

3.0

17 mm

12 mm

5.5

19 mm

14 mm

8.5

22 mm

16 mm

130

13.0

LUBRICATION POINTS AND LUBRICANT TYPES

SPEC

LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication points

Lubricant type

Oil seal lips (all)

O-ring (all)

Bearings (all)

Crank pin

Connecting rod (bearing)

Camshaft sprocket

Crankshaft

Piston surface/piston rings

Piston pin

Primary drive gear/primary driven gear

Valve stem/valve stem end

Rocker arm shaft

Rocker arm

Camshaft lobe/journal

Oil pump shaft, rotor, housing

Oil filter O-ring

Starter idle gear/shaft

Transmission gear (wheel/pinion)

Axle (main/drive)

Shift fork/guide bar

Shift drum/shift shaft/shift cam stopper ball

Shift lever/shift guide

Crankcase mating surfaces

Sealant (Quick Gasket)
Yamaha bond No.1215

Cylinder head and cylinder head cover mating surfaces

Sealant (Quick Gasket)
Yamaha bond No.1215

AC magneto lead grommet
(AC magneto cover)

Sealant (Quick Gasket)
Yamaha bond No.1215

2 - 21

COOLANT FLOW DIAGRAMS
COOLANT FLOW DIAGRAMS
1 Radiator
2 Radiator fan
3 Radiator outlet hose
4 Water pump inlet hose
5 Water pump
6 Water jacket outlet pipe
7 Thermostat inlet hose
8 Thermostat

9 Radiator inlet hose
0 Thermo switch 2
A Thermo switch 1

2 - 22

SPEC

OIL FLOW DIAGRAMS
OIL FLOW DIAGRAMS
1 Oil tank
2 Oil pipe 2
3 Oil pipe 1

2 - 23

SPEC

OIL FLOW DIAGRAMS
1 Oil delivery pipe 2
2 Oil delivery pipe 1
3 Oil filter
4 Crankshaft
5 Oil pump

2 - 24

SPEC

OIL FLOW DIAGRAMS
1 Oil pipe 2
2 Drive axle
3 Main axle
4 Engine oil drain bolt (engine)
5 Oil pipe 1
6 Oil strainer
7 Shift drum

2 - 25

SPEC

OIL FLOW DIAGRAMS
1 Oil delivery pipe 2
2 Oil filter cartridge
3 Oil pump rotor 1
4 Oil pump rotor 2
5 Oil pipe 1
6 Main axle

2 - 26

SPEC

CABLE ROUTING

SPEC

CABLE ROUTING
1 Parking brake cable
2 Starter cable
3 Clutch cable
4 Throttle cable
5 Front brake hose
6 Front brake switch
7 Park switch

È Fasten the handlebar switch lead, park switch
lead and clutch switch lead to the handlebar with
the plastic band.
É Fasten the front brake switch lead to the handlebar with the plastic band.

2 - 27

CABLE ROUTING
1 Front brake hose
2 Throttle cable
3 Main switch lead
4 Indicator light lead
5 Clutch cable
6 Parking brake cable
7 Starter cable
8 Coolant reservoir hose
9 Wire harness
0 Ignition coil lead
A Headlight lead coupler (left)

SPEC

B Brake pipe
C Headlight lead coupler (right)
D Radiator fan breather hose
E Headlight lead (right)
È Pass the throttle cable through the cable guide.
É Pass the clutch cable, parking brake cable and
starter cable through the cable guide.
Ê Fasten the left and right headlight lead, radiator
fan lead and thermo switch 1 lead to the frame
with the plastic band.

2 - 28

CABLE ROUTING
1 Throttle cable
2 Fuel tank breather hose
3 Fuel hose
4 Carburetor air vent hose
5 Negative battery lead
6 AC magneto lead
7 Thermo switch 1
8 Coolant reservoir hose
9 Starter cable

SPEC

È Put the wire harness and coolant reservoir hose
with the plastic holder.
É Fasten the wire harness, AC magneto lead,
speed sensor lead, negative battery lead and
rear brake switch lead with the plastic band.
Ê 70 mm (2.76 in)
Ë 25 ~ 35 mm (0.98 ~ 1.38 in)
Ì 60 mm (2.36 in)
Í 0 ~ 5 mm (0 ~ 0.20 in)
Î 80 ~ 90 mm (3.15 ~ 3.54 in)

2 - 29

CABLE ROUTING
1 Coolant reservoir hose
2 Carburetor air vent hose
3 Reservoir tank breather hose
4 Rectifier/regulator
5 CDI unit
6 Negative battery lead
7 AC magneto lead
8 Wire harness
9 Starter motor lead
0 Tail/brake light lead
A Rectifier/regulator lead

SPEC

È Pass the negative battery lead between the wire
harness and frame.

2 - 30

CABLE ROUTING
1 Radiator fan breather hose
2 Reverse control cable
3 Parking brake cable
4 Clutch cable

SPEC

È Fasten the reverse control cable to the frame
with the plastic band.
É 15 ~ 25 mm (0.59 ~ 0.98 in)

2 - 31

CABLE ROUTING
1 Rear brake hose
2 Parking brake cable
3 Negative battery lead
4 AC magneto lead
5 Crankcase breather hose
6 Carburetor drain hose
7 Rear brake switch
8 Speed sensor
9 Speed sensor lead
0 Rear brake switch lead

2 - 32

SPEC

CABLE ROUTING
1 Thermo switch 1 lead
2 Headlight lead (right)
3 Radiator fan breather hose
4 Thermo switch 2 lead
5 Carburetor breather hose
6 Headlight lead (left)
7 Wire harness
8 Coolant reservoir hose

SPEC

È Fasten the fan motor lead, headlight lead (right)
and thermo switch 1 lead to the frame with the
plastic band.

2 - 33

CABLE ROUTING
1 Positive battery lead
2 Tail/brake light lead
3 Coolant reservoir breather hose
4 Negative battery lead
5 Coolant reservoir hose
6 Starter motor lead
7 Wire harness
8 Rectifier/regulator lead

SPEC

È Fasten the wire harness with the plastic clamp.
É Fasten the starter motor lead and starter relay
lead with the plastic clamp.

2 - 34

INTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION INTERVALS

CHK
ADJ

EB300000

PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle
operation and a longer service life. The need for costly overhaul work will be greatly reduced. This
information applies to vehicles already in service as well as to new vehicles that are being prepared
for sale. All service technicians should be familiar with this entire chapter.
EB301000

PERIODIC MAINTENANCE/LUBRICATION INTERVALS
INITIAL
ITEM

ROUTINE

1
month

Valves*
(See page 3-8.)

• Check valve clearance.
• Adjust if necessary.

Cooling system
(See page 3-27.)

• Check coolant leakage.
• Repair if necessary.
• Replace coolant every 24 months.

Spark plug
(See page 3-16.)

• Check condition.
• Adjust gap and clean.
• Replace if necessary.

Air filter
(See page 3-24.)

• Clean.
• Replace if necessary.

Carburetor*
(See page 3-11.)

• Check and adjust idle speed/starter operation.
• Adjust if necessary.

Crankcase breather
system*

• Check breather hose for cracks or damage.
• Replace if necessary.

Exhaust system*

• Check for leakage.
• Retighten if necessary.
• Replace gasket if necessary.

Spark arrester
(See page 3-31.)

• Clean.

Fuel line*

• Check fuel hose for cracks or damage.
• Replace if necessary.

Engine oil
(See page 3-19.)

• Replace (Warm engine before draining).

Engine oil filter

• Replace if necessary.

Drive chain
(See page 3-40.)

• Check and adjust slack/alignment/clean/lube.

Brake*
(See page 3-33.)

• Check operation/fluid leakage/See NOTE page 3-2.
• Correct if necessary.

Clutch*
(See page 3-23.)

• Check operation.
• Adjust if necessary.

Wheels*
(See page 4-3.)

• Check balance/damage/runout.
• Replace if necessary.

Wheel bearings*

• Check bearing assembly for looseness/damage.
• Replace if damaged.

Steering system*
(See page 3-42.)

•
•
•
•

3
months

EVERY
6
months

6
months

Every 20~40 hours
(More often in wet or dusty areas.)

Check operation.
Replace if damaged.
Check toe-in.
Adjust if necessary.

Upper and lower arm
pivot and steering
• Lubricate every 6 months.**
shaft*
Rear arm pivot*

• Lubricate every 6 months.**

Fittings and fasteners*

• Check all chassis fittings and fasteners.
• Correct if necessary.

* It is recommended that these items be serviced by a Yamaha dealer.
** Lithium soap base grease
3-1

1
year

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

CHK
ADJ

NOTE:
● Recommended brake fluid: DOT 4
● Brake fluid replacement:
1.When disassembling the master cylinder or caliper cylinder, replace the brake fluid.
Normally check the brake fluid level and add fluid as required.
2.On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two
years.
3.Replace the brake hoses every four years, or if cracked or damaged.

WARNING
Indicates a potential hazard that could result in serious injury or death.

3-2

SEAT, FENDERS AND FUEL TANK

CHK
ADJ

SEAT, FENDERS AND FUEL TANK
SEAT, FRONT PANEL, FOOTREST GUARDS AND ENGINE SKID PLATE

Order

2
3
4
5

Job name/Part name
Q’ty
Remarks
Removing the seat, front panel, footRemove the parts in the order below.
rest guard and engine skid plate
Seat
1 NOTE:
Pull back the seat lock lever, than pull up
on the rear of the seat.
Front panel
Left footrest guard
Right footrest guard
Engine skid plate

1
1
1
1
For installation, reverse the removal procedure.

3-3

SEAT, FENDERS AND FUEL TANK

CHK
ADJ

HEADLIGHTS AND FRONT FENDER

Order

1
2
3
4
5

Job name/Part name
Removing the headlight and front
fender
Seat and front panel

Q’ty

Headlight coupler
Left headlight
Right headlight
Fuel tank top panel
Front fender

2
1
1
1
1

Remarks
Remove the parts in the order below.
Refer to “SEAT, FRONT PANEL, FOOTREST GUARDS AND ENGINE SKID
PLATE”.
Disconnect.

For installation, reverse the removal procedure.

3-4

SEAT, FENDERS AND FUEL TANK

CHK
ADJ

REAR FENDER

Order

Job name/Part name
Removing the rear fender
Seat

Q’ty

Front fender
1
2

Battery holding bracket
Battery lead

1
2

Remarks
Remove the parts in the order below.
Refer to “SEAT, FRONT PANEL, FOOTREST GUARDS AND ENGINE SKID
PLATE”.
Refer to “HEADLIGHTS AND FRONT
FENDER”.
Disconnect.

CAUTION:
First disconnect the negative lead,
then disconnect the positive lead.
3
4

Battery
Rear fender

1
1
For installation, reverse the removal procedure.
3-5

SEAT, FENDERS AND FUEL TANK

CHK
ADJ

FUEL TANK

Order

Job name/Part name
Removing the fuel tank
Seat and front panel

Q’ty

Front fender
1

Fuel hose

Fuel tank

Plastic band

3-6

Remarks
Remove the parts in the order below.
Refer to “SEAT, FRONT PANEL, FOOTREST GUARDS AND ENGINE SKID
PLATE”.
Refer to “HEADLIGHTS AND FRONT
FENDER”.
NOTE:
Before disconnecting the fuel hose, turn
the fuel cock to “OFF”.
NOTE:
When installing the fuel tank, pass the
fuel tank breather hose through the hole
in the handlebar protector.

SEAT, FENDERS AND FUEL TANK

Order
4
5
6

Job name/Part name
Rubber cover 1
Rubber cover 2
Hose holder

Q’ty
1
1
2

CHK
ADJ

Remarks

For installation, reverse the removal procedure.

3-7

ADJUSTING THE VALVE CLEARANCE

CHK
ADJ

ENGINE
ADJUSTING THE VALVE CLEARANCE
NOTE:
● The valve clearance must be adjusted when
the engine is cool to the touch.
● Adjust the valve clearance when the piston is
at the Top Dead Center (T.D.C.) on the compression stroke.
1.Remove:
● Seat
● Front fender
● Fuel tank
Refer to “SEAT, FENDERS AND FUEL
TANK”.

2.Remove:
● Tappet cover (intake) 1
● Tappet covers (exhaust) 2
3.Disconnect:
● Spark plug cap 3
4.Remove:
● Spark plug

5.Remove:
● Crankshaft end accessing screw 1
● Timing mark accessing screw 2

3-8

ADJUSTING THE VALVE CLEARANCE

CHK
ADJ

6.Check:
● Valve clearance
Out of specification → Adjust.
Valve clearance (cold):
Intake:
0.10 ~ 0.15 mm
(0.0039 ~ 0.0059 in)
Exhaust:
0.15 ~ 0.20 mm
(0.0059 ~ 0.0079 in)

***********************************************
Checking steps:
● Turn the crankshaft counterclockwise with a
wrench.
● Align the “I” mark 1 on the rotor with the stationary pointer 2 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:
● When the piston is at the Top Dead Center
(T.D.C.) on the compression stroke, there
should be clearance between the valve stem
tips and their respective rocker arm adjusting
screws.
● If there is no clearance, rotate the crankshaft
counterclockwise one turn.

● Measure

the valve clearance using a feeler
gauge 3.

***********************************************

3-9

ADJUSTING THE VALVE CLEARANCE

CHK
ADJ

7.Adjust:
● Valve clearance

***********************************************
Adjustment steps:
● Loosen the locknut 1.
● Insert a feeler gauge 2 between the adjuster
end and the valve end.
● Turn the adjuster 3 clockwise or counterclockwise with the tappet adjusting tool 4
until the proper clearance is obtained.
Tappet adjusting tool:
P/N. YM-08035, 90890-01311
● Hold

the adjuster to prevent it from moving
and then tighten the locknut.

Locknut:
14 Nm (1.4 m • kg, 10 ft • lb)

● Measure

the valve clearance.
the clearance is incorrect, repeat the above
steps until the proper clearance is obtained.

● If

***********************************************

8.Install:
● All removed parts
NOTE:
Install all removed parts in the reverse order of
their disassembly. Note the following points.

9.Install:
18 Nm (1.8 m • kg, 13 ft • lb)
● Spark plug
● Tappet cover (intake)
R.

T.
R.

●

Tappet covers (exhaust)
T.
R.

3 - 10

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

ADJUSTING THE VALVE CLEARANCE/ADJUSTING THE
TIMING CHAIN/ADJUSTING THE IDLING SPEED

CHK
ADJ

10.Install:
● Fuel tank
● Front fender
● Seat
Refer to “SEAT, FENDERS AND FUEL
TANK”.

ADJUSTING THE TIMING CHAIN
Adjustment free.

ADJUSTING THE IDLING SPEED
1.Start the engine and let it warm up for several minutes.
2.Attach:
● Tachometer
(to the spark plug lead)
3.Check:
● Engine idling speed
Out of specification → Adjust.
Engine idling speed:
1,450 ~ 1,550 r/min

3 - 11

ADJUSTING THE IDLING SPEED/
ADJUSTING THE THROTTLE LEVER FREE PLAY

CHK
ADJ

4.Adjust:
● Engine idling speed

***********************************************
Adjustment steps:
● Turn the throttle stop screw 1 in or out until
the specified idling speed is obtained.
Turning in

Idling speed becomes
higher.

Turning out

Idling speed becomes
lower.

***********************************************
5.Detach:
● Tachometer
6.Adjust:
● Throttle lever free play
Refer to “ADJUSTING THE THROTTLE
LEVER FREE PLAY”.

ADJUSTING THE THROTTLE LEVER FREE
PLAY
NOTE:
Engine idling speed should be adjusted properly before adjusting the throttle lever free
play.

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

3 - 12

ADJUSTING THE THROTTLE LEVER FREE PLAY

CHK
ADJ

2.Adjust:
● Throttle lever free play

***********************************************
Adjustment steps:
First step:
● Pull back the adjuster cover 1.
● Loosen the locknut 2 on the carburetor side.
● Turn the adjuster 3 in or out until the correct
free play is obtained.
Turning in

Free play is increased.

Turning out Free play is decreased.
the locknut 2.
in the adjuster cover 1.

● Tighten
● Push

NOTE:
If the free play cannot be adjusted here, adjust
it at the throttle lever side of the cable.
Second step:
● Pull back the adjuster cover 4.
● Loosen the locknut 5.
● Turn the adjuster 6 in or out until the correct
free play is obtained.
Turning in

Free play is increased.

Turning out Free play is decreased.
the locknut 5.
● Push in the adjuster cover 4.
● Tighten

WARNING
After adjusting the free play, turn the handlebar to the right and left to make sure that the
engine idling speed does not increase.

***********************************************

3 - 13

ADJUSTING THE SPEED LIMITER

CHK
ADJ

ADJUSTING THE SPEED LIMITER
The speed limiter keeps the carburetor throttle
from becoming fully-opened even when the
throttle lever is applied to the maximum position. Screwing in the adjuster stops the engine
speed from increasing.

1.Check:
● Speed limiter length a
Out of specification → Adjust.
Speed limiter length:
12 mm (0.47 in)

2.Adjust:
● Speed limiter length

***********************************************
Speed limiter length adjustment steps:
● Loosen the locknut 1.
● Turn the adjuster 2 in or out until the specified speed limiter length is obtained.
Turning in

Speed limiter length is
decreased.

Turning out

Speed limiter length is
increased.

● Tighten

the locknut.

WARNING
●

●

Particularly for a beginner rider, the
speed limiter should be screwed in completely. Screw it out little by little as their
riding technique improves. Never remove
the speed limiter for a beginning rider.
For proper throttle lever operation do not
turn out the adjuster more than 12 mm
(0.47 in). Also, always adjust the throttle
lever free play to 3 ~ 5 mm (0.12 ~ 0.20 in).

***********************************************

3 - 14

ADJUSTING THE STARTER CABLE

CHK
ADJ

ADJUSTING THE STARTER CABLE
1.Adjust:
● Starter cable

***********************************************
Adjustment steps:
● Disconnect the starter cable 1 from the carburetor body.
NOTE:
Do not remove the starter plunger 2 from the
starter cable.
● Measure

the starter plunger stroke distance
a of the starter lever 3 fully close-to-fully
open position.
If the distance is out of specification adjust it
as described below.
Starter plunger stroke distance a:
15 mm (0.59 in)

È Fully closed position
É Fully open position

back the boot 4.
● Loosen the locknut 5.
● Turn the adjuster 6 in or out until the correct
distance is obtained.
● Pull

Turning in

Distance increased.

Turning out Distance decreased.
the locknut 5.
in the boot 4.
● Connect the starter cable.
● Tighten
● Push

WARNING
After adjusting the cable, turn the handlebar to right to left, and make sure that the
engine idling speed does not increase.

***********************************************

3 - 15

CHECKING THE SPARK PLUG

CHK
ADJ

CHECKING THE SPARK PLUG
1.Remove:
● Spark plug
2.Check:
● Spark plug type
Incorrect → Replace.
Standard spark plug:
DPR8EA-9/NGK
3.Check:
● Electrode 1
Wear/damage → Replace.
● Insulator 2
Abnormal color → Replace.
Normal color is a medium-to-light tan color.
4.Clean the spark plug with a spark plug
cleaner or wire brush.

5.Measure:
● Plug gap a
Use a wire gauge or feeler gauge.
Out of specification → Regap.
Spark plug gap:
0.8 ~ 0.9 mm (0.031 ~ 0.035 in)

6.Tighten:
● Spark plug

18 Nm (1.8 m • kg, 13 ft • lb)

NOTE:
Before installing a spark plug, clean the gasket
surface and plug surface.

3 - 16

CHECKING THE IGNITION TIMING

CHK
ADJ

CHECKING THE IGNITION TIMING
NOTE:
Engine idling speed and throttle cable free play
should be adjusted properly before checking
the ignition timing.
1.Attach:
● Tachometer
● Timing light
(to spark plug lead)
Timing light:
P/N. YM-33277-A, 90890-03141

2.Check:
● Ignition timing

***********************************************
Checking steps:
● Warm up the engine and keep it at the specified speed.
Engine speed:
1,450 ~ 1,550 r/min
the timing mark accessing screw 1.
● Visually check the stationary pointer 2 to
verify it is within the required firing range 3
indicated on the flywheel.
Incorrect firing range → Check the pulser coil
assembly.
● Install the timing mark accessing screw.
● Remove

***********************************************
3.Detach:
● Timing light
● Tachometer

3 - 17

MEASURING THE COMPRESSION PRESSURE

CHK
ADJ

MEASURING THE COMPRESSION
PRESSURE
NOTE:
Insufficient compression pressure will result in
a loss of performance.
1.Check:
● Valve clearance
Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE CLEARANCE”.
2.Start the engine and let it warm up for several minutes.
3.Stop the engine.
4.Remove:
● Spark plug

5.Attach:
● Adapter
● Compression gauge 1
Compression gauge:
P/N. YU-33223, 90890-03081
Adapter:
P/N. YU-33223-3, 90890-04082

6.Measure:
● Compression pressure
Above the maximum pressure:
Inspect the cylinder head, valve surfaces,
and piston crown for carbon deposits.
Below the minimum pressure:
Squirt a few drops of oil into the affected cylinder and measure again.
● Refer to the table below.
Compression pressure
(with oil introduced into cylinder)
Reading

3 - 18

Diagnosis

Higher than
without oil

Worn or damaged piston,
rings or cylinder wall.

Same as
without oil

Defective valves or
cylinder head gasket.

MEASURING THE COMPRESSION PRESSURE/
CHECKING THE ENGINE OIL LEVEL

CHK
ADJ

Compression pressure (at sea level):
Standard:
1,250 kPa (12.5 kg/cm2, 181 psi)
Minimum:
1,050 kPa (10.5 kg/cm2, 149 psi)
Maximum:
1,350 kPa (13.5 kg/cm2, 192 psi)

***********************************************
Measurement steps:
● Crank over the engine with the electric
starter (be sure the battery is fully charged)
with the throttle fully-open until the compression reading on the gauge stabilizes.

WARNING
When cranking the engine, ground the
spark plug lead to prevent sparking.

***********************************************
T.
R.

7.Install:
● Spark plug

18 Nm (1.8 m • kg, 13 ft • lb)

CHECKING THE ENGINE OIL LEVEL
1.Place the machine on a level surface.
2.Start the engine, warm it up until the engine
oil has reached a normal temperature of
60 °C (140 °F), let it continue to idle for ten
seconds, and then turn the engine off.
NOTE:
To achieve the proper engine oil temperature
for an accurate oil level reading, the engine
must have first completely cooled down, and
then warmed up again for several minutes to
normal operating temperature.

3 - 19

CHECKING THE ENGINE OIL LEVEL/
CHANGING THE ENGINE OIL

CHK
ADJ

3.Check:
● Engine oil level
Oil level should be between the minimum
level mark a and the maximum level mark
b.
Low oil level → Add oil to the proper level.
NOTE:
● Wait a few minutes until the oil settles before
inspecting the oil level.
● Do not screw the dipstick 1 in when inspecting the oil level.
Recommended oil:
Follow the left chart.
NOTE:
Recommended oil classification:
API Service “SE”, “SF”, “SG” type or equivalent (e.g. “SF–SE–CC”, “SF–SE–SD” etc.)

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.

4.Start the engine and let it warm up for several minutes.
5.Stop the engine and inspect the oil level
again.
NOTE:
Wait a few minutes until the oil settles before
inspecting the oil level.

CHANGING THE ENGINE OIL
1.Remove:
● Engine skid plate
Refer to “SEAT, FENDERS AND FUEL
TANK”.
2.Start the engine and let it warm up for several minutes.
3.Stop the engine and place a container under
the engine oil drain bolt.
3 - 20

CHANGING THE ENGINE OIL

CHK
ADJ

4.Remove:
● Dipstick 1

●

Engine oil drain bolt (oil tank) 2

Engine oil drain bolt (crankcase) 3
Drain the engine oil from the oil tank and
crankcase.

5.If the oil filter cartridge is also to be replaced,
perform the following procedure.

***********************************************
Replacement steps:
● Remove the oil filter cartridge 1 with an oil
filter wrench 2.
Oil filter wrench:
P/N. YM-01469, 90890-01469
● Apply

a thin coat of engine oil to the O-ring
3 of the new oil filter cartridge.

CAUTION:
Make sure that the O-ring 3 is properly
seated in the groove of the oil filter cartridge.

3 - 21

CHANGING THE ENGINE OIL

CHK
ADJ

● Tighten

the new oil filter cartridge to specification with an oil filter wrench.

Oil filter cartridge:
17 Nm (1.7 m • kg, 12 ft • lb)

***********************************************
6.Install:
● Engine oil drain bolt (crankcase)
T.
R.

●

30 Nm (3.0 m • kg, 22 ft • lb)

Engine oil drain bolt (oil tank)
T.
R.

25 Nm (2.5 m • kg, 18 ft • lb)

7.Fill:
● Oil tank
(with the specified amount of the recommended engine oil)
Quantity:
Total amount:
2.3 L (2.02 Imp qt, 2.43 US qt)
Periodic oil replacement:
1.9 L (1.67 Imp qt, 2.01 US qt)
With oil filter cartridge replacement:
1.95 L (1.72 Imp qt, 2.06 US qt)
NOTE:
● Pour the engine oil in several stages.
● First, pour in 1.75 L (1.54 Imp qt, 1.85 US qt)
of oil, and then start the engine and rev it 3 to
5 times. Stop the engine, and then pour in
the remainder of the specified amount.

CAUTION:
When starting the engine make sure the
dipstick is securely fitted into the oil tank.
8.Install:
● Dipstick
9.Warm up the engine for a few minutes, then
stop the engine.
10.Check:
● Engine
(for engine oil leaks)
● Oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.

3 - 22

CHANGING THE ENGINE OIL/
ADJUSTING THE CLUTCH CABLE

CHK
ADJ

11.Check:
● Engine oil pressure

***********************************************
loosen the oil gallery bolt 1.
● Start the engine and keep it idling until
engine oil starts to seep from the oil gallery
bolt. If no engine oil comes out after one
minute, turn the engine off so that it will not
seize.
● Check the engine oil passages, the oil filter
cartridge and the oil pump for damage or
leakage.
Refer to “OIL PUMP” in CHAPTER 5.
● Start the engine after solving the problem(s)
and check the engine oil pressure again.
● Tighten the oil gallery bolt to specification.
● Slightly

Oil gallery bolt:
7 Nm (0.7 m • kg, 5.1 ft • lb)

***********************************************
12.Install:
● Engine skid plate
Refer to “SEAT, FENDERS AND FUEL
TANK”.

ADJUSTING THE CLUTCH CABLE
1.Check:
● Clutch lever free play a
Out of specification → Adjust.
Clutch lever free play
(at the clutch lever end):
5 ~ 10 mm (0.20 ~ 0.39 in)

3 - 23

ADJUSTING THE CLUTCH CABLE/
CLEANING THE AIR FILTER

CHK
ADJ

2.Adjust:
● Clutch lever free play

***********************************************
Adjustment steps:
● Pull the rubber cover 1 off.
● Loosen the locknut 2 and finger tighten the
adjusting bolt 3.
● Loosen the locknut 4.
● Turn the adjusting nut 5 until the clutch lever
free play is within the specified limits.
Clutch lever free play
(at the clutch lever end):
5 ~ 10 mm (0.20 ~ 0.39 in)
● Tighten

the locknut 4.

NOTE:
If the specified clutch lever free play cannot be
obtained on it, use the adjusting bolt 3.
the adjusting bolt 3 until the clutch
lever free play is within the specified limits.
● Tighten the locknut 2.
● Pull the rubber cover 1 in.
● Turn

***********************************************

CLEANING THE AIR FILTER
NOTE:
There is a check hose 1 at the bottom of the
air filter case. If dust and/or water collects in
this hose, clean the air filter element and air filter case.

1.Remove:
● Seat
Refer to “SEAT, FENDERS AND FUEL
TANK”.
2.Disconnect:
● Crankcase breather hose 1
3.Remove:
● Air filter case cover 2

3 - 24

CLEANING THE AIR FILTER

CHK
ADJ

4.Remove:
● Air filter element assembly 1
● Air filter element cap 2
● Air filter element 3
NOTE:
When removing the air filter element, rotate
the air filter element cap 1/4 of a turn and
remove the element.

CAUTION:
Never operate the engine with the air filter
element removed. This will allow unfiltered
air to enter, causing rapid wear and possible
engine damage. Additionally, operation
without the filter element will affect carburetor tuning with subsequent poor performance and possible engine overheating.
5.Check:
● Air filter element
Damaged → Replace.

6.Clean:
● Air filter element

***********************************************
Cleaning steps:
● Wash the element gently, but thoroughly in
solvent.

WARNING
Use a cleaning solvent which is designed
to clean parts only. Never use gasoline or
low flash point solvents as they may cause
a fire or explosion.
● Squeeze

the excess solvent out of the element and let it dry.

3 - 25

CLEANING THE AIR FILTER

CHK
ADJ

CAUTION:
Do not twist or wring out the element. This
could damage the foam material.
● Apply

engine oil to the element.
out the excess oil.

● Squeeze

NOTE:
The element should be wet but not dripping.

***********************************************

7.Install:
● Air filter element
● Air filter case cover
NOTE:
● Insert the lobes 1 on the filter element into
the receptacles 2 on the filter case.
● To prevent air leaks make sure that the sealing surface of the element matches the sealing surface of the case.
8.Connect:
● Crankcase breather hose 1
9.Install:
● Seat
Refer to “SEAT, FENDERS AND FUEL
TANK”.

3 - 26

CHECKING THE COOLANT LEVEL/
CHANGING THE COOLANT

CHK
ADJ

CHECKING THE COOLANT LEVEL
1.Place the machine on a level surface.
2.Check:
● Coolant level
The coolant level should be between the
minimum level mark a and maximum level
mark b.
Below the minimum level mark → Add the
recommended coolant to the proper level.

CAUTION:
●

●

Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant, check
and if necessary, correct the antifreeze
concentration of the coolant.
Use only distilled water. However, soft
water may be used if distilled water is not
available.

3.Start the engine, warm it up for several minutes, and then turn it off.
4.Check:
● Coolant level
NOTE:
Before inspecting the coolant level, wait a few
minutes until the coolant has settled.

CHANGING THE COOLANT
1.Remove:
● Front panel
Refer to “SEAT, FENDERS AND FUEL
TANK”.

2.Remove:
● Coolant reservoir cap 1
3.Disconnect:
● Coolant reservoir hose 2

3 - 27

CHANGING THE COOLANT

CHK
ADJ

4.Drain:
● Coolant
(from the coolant reservoir)
5.Connect:
● Coolant reservoir hose

6.Remove:
● Radiator cap 1

WARNING
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the
engine is hot. Scalding hot fluid and steam
may be blown out, which could cause serious injury. When the engine has cooled,
open the radiator cap as follows:
Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap
counterclockwise toward the detent to
allow any residual pressure to escape.
When the hissing sound has stopped, turn
the radiator cap counterclockwise while
pressing down on it and then remove it.

7.Remove:
● Coolant drain bolt 1
(along with the copper washer)
8.Drain:
● Coolant

9.Check:
● Copper washer 1
New
● Coolant drain bolt 2
Damage → Replace.
10.Install:
● Coolant drain bolt
T.
R.

3 - 28

10 Nm (1.0 m • kg, 7.2 ft • lb)

CHANGING THE COOLANT

CHK
ADJ

11.Fill:
● Cooling system
(with the specified amount of the recommended coolant)
Recommended antifreeze:
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio:
1:1 (antifreeze:water)
Quantity:
Total amount:
1.3 L
(1.14 lmp qt, 1.37 US qt)
Coolant reservoir capacity:
0.29 L
(0.26 lmp qt, 0.31 US qt)
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.

WARNING
●

●

If coolant splashes in your eyes, thoroughly wash them with water and consult
a doctor.
If coolant splashes on your clothes,
quickly wash it away with water and then
with soap and water.
If coolant is swallowed, induce vomiting
and get immediate medical attention.

CAUTION:
●

●

Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant, check,
and if necessary, correct the antifreeze
concentration of the coolant.
Use only distilled water. However, soft
water may be used if distilled water is not
available.
If coolant comes into contact with painted
surfaces, immediately wash them with
water.
Do not mix different types of antifreeze.

12.Install:
● Radiator cap

3 - 29

CHANGING THE COOLANT

CHK
ADJ

13.Fill:
● Coolant reservoir
(with the recommended coolant to the proper
level)
14.Install:
● Coolant reservoir cap
15.Start the engine, warm it up for several minutes, and then turn it off.

16.Check:
● Coolant level
Refer to “CHECKING
LEVEL”.

THE

COOLANT

NOTE:
Before inspecting the coolant level, wait a few
minutes until the coolant has settled.
17.Install:
● Front panel
Refer to “SEAT, FENDERS AND FUEL
TANK”.

3 - 30

CHECKING THE COOLANT TEMPERATURE WARNING
LIGHT/CLEANING THE SPARK ARRESTER

CHK
ADJ

CHECKING THE COOLANT TEMPERATURE
WARNING LIGHT
1 Coolant temperature warning light

CLEANING THE SPARK ARRESTER
1.Clean:
● Spark arrester

***********************************************
Cleaning steps:

WARNING
●

●

Select a well-ventilated area free of combustible materials.
Always let the exhaust system cool
before performing this operation.
Do not start the engine when removing
the tailpipe from the muffler.

● Remove
● Remove

muffler.

3 - 31

the bolt 1.
the tailpipe 2 by pulling it out of the

CLEANING THE SPARK ARRESTER

CHK
ADJ

● Tap

the tailpipe lightly with a soft-face hammer or suitable tool, then use a wire brush to
remove any carbon deposits from the spark
arrester portion of the tailpipe and the inner
contact surfaces of the muffler.
● Insert the tailpipe into the muffler and align
the bolt holes.
● Insert the bolt and tighten it.
● Remove the purging bolt 3.
● Start the engine and rev it up approximately
twenty times while momentarily creating
exhaust system back pressure by blocking
the end of the muffler with a shop towel.
● Stop the engine and allow the exhaust pipe
to cool.
● Install the purging bolt 3 and tighten it.

***********************************************

3 - 32

ADJUSTING THE FRONT BRAKE/
ADJUSTING THE REAR BRAKE

CHK
ADJ

CHASSIS
ADJUSTING THE FRONT BRAKE
1.Check:
● Brake lever free play a
Out of specification → Bleed the front brake
system.
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)”.
Brake lever free play (at the brake
lever end):
0 mm (0 in)

ADJUSTING THE REAR BRAKE
1.Check:
● Rear brake pedal height a
Out of specification → Adjust.
Rear brake pedal height:
4 mm (0.16 in)
2.Adjust:
● Rear brake pedal height

***********************************************
Adjustment steps:
● Loosen the locknut 1.
● Turn the adjusting bolt 2 until the brake
pedal height is within the specified limits.
Brake pedal height:
4 mm (0.16 in)
● Tighten

the locknut 1.

NOTE:
When adjusting the brake pedal height make
sure the locknut-to-adjusting bolt clearance a
does not exceed 2.2 ~ 3.2 mm (0.09 ~ 0.13 in).

3 - 33

ADJUSTING THE REAR BRAKE/
ADJUSTING THE PARKING BRAKE

CHK
ADJ

WARNING
After this adjustment is performed, lift the
rear wheels off the ground by placing a
block under the engine, and spin the rear
wheels to ensure there is no brake drag. If
any brake drag is noticed perform the
above steps again.

***********************************************
ADJUSTING THE PARKING BRAKE
1.Check:
● Parking brake cable end length a
Out of specification → Adjust.
Parking brake cable end length:
64 ~ 68 mm (2.5 ~ 2.7 in)

2.Adjust:
● Parking brake cable end length

***********************************************
Adjustment steps:
● Loosen the locknut 1 and adjusting bolt 2.
● Pull the rubber cover 3 off.
● Loosen the locknut 4.
● Turn the adjuster 5 in or out until the specified brake cable end length is obtained.
● Tighten the locknut 4.
● Slowly turn the adjusting bolt 2 clockwise
until resistance is felt.
● Turn it 1/8 counterclockwise.
● Tighten the locknut 1.

Locknut:
16 Nm (1.6 m • kg, 11 ft • lb)

● Check

the parking brake cable free play a.
Free play (parking brake cable):
0 mm (0 in)
at parking brake lever pivot

● If

the free play is incorrect, adjust the free
play by adjuster 5.
● Pull the rubber cover 3 in.

3 - 34

ADJUSTING THE PARKING BRAKE/
CHECKING THE BRAKE FLUID LEVEL

CHK
ADJ

***********************************************
CHECKING THE BRAKE FLUID LEVEL
1.Place the machine on a level surface.
NOTE:
When inspecting the brake fluid level, make
sure that the top of the brake fluid reservoir top
is horizontal.

2.Check:
● Brake fluid level
Fluid level is below the “LOWER” level line
1 → Add the recommended brake fluid to
the proper level.

Recommended brake fluid:
DOT 4
È Front brake
É Rear brake

CAUTION:
Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.

WARNING
●

●

3 - 35

Use only the designated quality brake
fluid: Otherwise, the rubber seals may
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid:
Mixing fluids may result in a harmful
chemical reaction and lead to poor performance.
Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in a vapor lock.

CHECKING THE FRONT BRAKE PAD/
CHECKING THE REAR BRAKE PAD/
ADJUSTING THE REAR BRAKE LIGHT SWITCH

CHK
ADJ

CHECKING THE FRONT BRAKE PAD
1.Remove:
● Front wheels
2.Check:
● Brake pad
Wear indicators 1 almost in contact with the
brake disc → Replace the brake pads as a
set.
Refer to “FRONT AND REAR BRAKES” in
CHAPTER 4.
Brake pad wear limit a:
1 mm (0.04 in)
3.Operate the brake lever.
4.Install:
● Front wheels

CHECKING THE REAR BRAKE PAD
1.Check:
● Brake pad
Wear indicators 1 almost in contact with the
brake disc → Replace the brake pads as a
set.
Refer to “FRONT AND REAR BRAKES” in
CHAPTER 4.
Brake pad wear limit a:
1 mm (0.04 in)
2.Operate the brake pedal.

ADJUSTING THE REAR BRAKE LIGHT
SWITCH
NOTE:
The rear brake light switch is operated by
movement of the brake pedal.
The rear brake light switch is properly adjusted
when the brake light comes on just before the
braking effect starts.

3 - 36

ADJUSTING THE REAR BRAKE LIGHT SWITCH/
CHECKING THE BRAKE HOSE

CHK
ADJ

1.Check:
● Rear brake light operation timing
Incorrect → Adjust.
2.Adjust:
● Rear brake light operation timing

***********************************************
the main body 1 of the rear brake light
switch so that it does not rotate and turn the
adjusting nut 2 in direction a or b until the
rear brake light comes on at the proper time.

● Hold

Direction a

Brake light comes on
sooner.

Direction b

Brake light comes on
later.

***********************************************

CHECKING THE BRAKE HOSE
1.Remove:
● Seat
● Front fender
Refer to “SEAT, FENDERS AND FUEL
TANK”.

2.Check:
● Front brake hoses 1
● Rear brake hoses 2
Cracks/wear/damage → Replace.
3.Check:
● Brake hose clamp
Loosen → Tighten.
4.Hold the machine in an upright position and
apply the front or rear brake.
5.Check:
● Brake hoses
Apply the brake lever several times.
Fluid leakage → Replace the hose.
Refer to “FRONT AND REAR BRAKE” in
CHAPTER 4.

3 - 37

CHECKING THE BRAKE HOSE/
BLEEDING THE HYDRAULIC BRAKE SYSTEM

CHK
ADJ

6.Install:
● Front fender
● Seat
Refer to “SEAT, FENDERS AND FUEL
TANK”.

BLEEDING THE HYDRAULIC BRAKE
SYSTEM

WARNING
Bleed the brake system if:
● The system has been disassembled.
● A brake hose or brake pipe have been
loosened or removed.
● The brake fluid has been very low.
● The brake operation has been faulty.
A loss of braking performance may occur if
the brake system is not properly bled.
1.Bleed:
● Brake system

***********************************************
Air bleeding steps:
a. Add the 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 hose 1 tightly to
the caliper bleed screw 2.

È Front
É Rear

d. Place the other end of the hose into a container.
e. Slowly apply the brake lever or pedal several times.
f. Pull the lever in or push down on the pedal
and hold it.
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 all the air bubbles have disappeared from the fluid.

3 - 38

BLEEDING THE HYDRAULIC BRAKE SYSTEM/
ADJUSTING THE SHIFT PEDAL

CHK
ADJ

j. Tighten the bleed screw.

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

NOTE:
If bleeding is difficult, it may be necessary to
let the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the system have disappeared.
k. Add brake fluid to the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.

WARNING
Check the operation of the brake after
bleeding the brake system.

***********************************************
ADJUSTING THE SHIFT PEDAL
1.Check:
● Shift pedal height a
Out of specification → Adjust.
Shift pedal height:
22 mm (0.89 in)

2.Adjust:
● Shift pedal height

***********************************************
Adjustment steps:
● Loosen the locknuts 1.
● Turn the adjusting rod 2 in direction a or b
until the specified shift pedal position
obtained.
Direction a

Shift pedal position is
down.

Direction b

Shift pedal position is
up.

● Tighten

the locknuts.

Locknut:
8 Nm (0.8 m • kg, 5.8 ft • lb)

***********************************************
3 - 39

ADJUSTING THE REVERSE CONTROL CABLE/
ADJUSTING THE DRIVE CHAIN SLACK

CHK
ADJ

ADJUSTING THE REVERSE CONTROL
CABLE
1.Check:
● Reverse knob free play a
Out of specification → Adjust.
Reverse knob free play:
0 mm (0 in)

2.Adjust:

***********************************************
Adjustment steps:
● Pull the boots 1 and 2 off.
● Loosen the locknut 3.
● Turn the adjusting nut 4 until the reverse
control cable 5 is taut or the length a is
135 mm (5.31 in).
NOTE:
Be sure to hold the reverse shift lever 6 when
make this adjustment so that it does not move.
the locknut 3.
● Pull the boots 1 and 2 in.
● Tighten

***********************************************

ADJUSTING THE DRIVE CHAIN SLACK
NOTE:
The drive chain slack must be checked at the
tightest point on the chain.

CAUTION:
A drive chain that is too tight will overload
the engine and other vital parts, and one
that is too loose can skip and damage the
swingarm or cause an accident. Therefore,
keep the drive chain slack within the specified limits.
1.Elevate the rear wheels by placing the suitable stand under the frame.
2.Rotate the rear wheel several times and
check the drive chain to locate its tightest
point.

3 - 40

ADJUSTING THE DRIVE CHAIN SLACK

CHK
ADJ

3.Measure:
● Drive chain slack a
Out of specification → Adjust.
Drive chain slack:
30 ~ 45 mm (1.18 ~ 1.77 in)

4.Adjust:
● Drive chain slack

***********************************************
Adjustment steps:
● Loosen the hub nuts 1.
● Loosen the locknuts 2.
● Turn both adjusting bolts 3 in direction a or
b until the specified drive chain slack is
obtained.
Direction a

Drive chain slack is
reduced.

Direction b

Drive chain slack is
increased.

NOTE:
To maintain the proper axle alignment, adjust
both sides evenly. (There are marks c on
each side of hub.)

CAUTION:
Excessive chain slack will overload the
engine and other vital parts; keep the slack
within the specified limits.
● If

the chain slack cannot be adjusted, replace
the sprockets and drive chain as a set.
● Tighten the hub nuts and locknuts.

Hub nut:
90 Nm (9.0 m • kg, 65 ft • lb)
Locknut (chain puller):
16 Nm (1.6 m • kg, 11 ft • lb)

NOTE:
The chain should be cleaned and lubricated
after every use of the machine.

***********************************************

3 - 41

CHECKING THE STEERING SYSTEM/
ADJUSTING THE TOE-IN

CHK
ADJ

CHECKING THE STEERING SYSTEM
1.Place the machine on a level surface.
2.Check:
● Steering assembly bushings
Move the handlebar up and down, and/or
back and forth.
Excessive play → Replace the steering stem
bushings.

3.Check:
● Tie-rod ends
Turn the handlebar to the left and/or right
until it stops completely, then move the handlebar from the left to the right slightly. Tierod end has any vertical play → Replace the
tie-rod end(s).

4.Raise the front end of the machine so that
there is no weight on the front wheels.
5.Check:
● Ball joints and/or wheel bearings
Move the wheels laterally back and forth.
Excessive free play → Replace the front
arms (upper and lower) and/or wheel bearings.

ADJUSTING THE TOE-IN
1.Place the machine on a level surface.
2.Measure:
● Toe-in
Out of specification → Adjust.
Toe-in:
0 ~ 10 mm (0 ~ 0.39 in)

3 - 42

ADJUSTING THE TOE-IN

CHK
ADJ

***********************************************
Toe-in measurement steps:
NOTE:
Before measuring the toe-in, make sure that
the tire pressure is correct.
● Mark

both front tire tread centers.
the front end of the machine so that
there is no weight on the front tires.
● Face the handlebar straight ahead.
● Measure the width È between the marks.
● Rotate the front tires 180° until the marks are
exactly opposite one another.
● Measure the width É between the marks.
● Calculate the toe-in using the formula given
below.
● Raise

Toe-in = É – È
● If

the toe-in is incorrect, adjust it.

Ê Forward

***********************************************
3.Adjust:
● Toe-in

WARNING
●

●

3 - 43

Be sure that both tie-rods are turned the
same amount. If not, the machine will drift
right or left even though the handlebar is
positioned straight. This may lead to mishandling and an accident.
After setting the toe-in to specification, run
the machine slowly for some distance with
both hands lightly holding the handlebar
and check that the handlebar responds correctly. If not, turn either the right or left tierod within the toe-in specification.

ADJUSTING THE TOE-IN/
ADJUSTING THE FRONT SHOCK ABSORBER

CHK
ADJ

***********************************************
Adjustment steps:
● Mark both tie-rods ends.
This reference point will be needed during
adjustment.
● Loosen the locknuts (tie-rod end) 1 of both
tie-rods.
● The same number of turns should be given
to both the right and left tie-rods 2 until the
specified toe-in is obtained. This is to keep
the length of the rods the same.
● Tighten the rod end locknuts of both tie rods.

Locknut (rod end):
15 Nm (1.5 m • kg, 11 ft • lb)

NOTE:
Adjust the rod ends so that A and B are equal.

***********************************************
ADJUSTING THE FRONT SHOCK
ABSORBER

WARNING
Always adjust both front shock absorber
spring preload to the same setting. Uneven
adjustment can cause poor handling and
loss of stability.

1.Adjust:
● Spring preload
Turn the adjuster 1 in direction a or b.
Direction a

Spring preload is
increased (suspension
is harder).

Direction b

Spring preload is
decreased (suspension
is softer).

Standard position: 3
Minimum position: 1
Maximum position: 5

3 - 44

ADJUSTING THE REAR SHOCK ABSORBER

CHK
ADJ

ADJUSTING THE REAR SHOCK
ABSORBER
1.Adjust:
● Spring preload

***********************************************
Adjustment steps:
● Elevate the rear wheels by placing a suitable
stand under the frame.
● Loosen the locknut 1.
● Turn the adjusting ring 2 in direction a or
b.
Direction a

Spring preload is
increased (suspension
is harder).

Direction b

Spring preload is
decreased (suspension
is softer).

Adjusting length c:
Standard: 253 mm (9.96 in)
Minimum: 245 mm (9.65 in)
Maximum: 260 mm (10.24 in)
NOTE:
● Be sure to remove all dirt and mud from
around the locknut and adjusting ring 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 adjusting ring
beyond the maximum or minimum setting.
● Tighten

the locknut 1.

Locknut:
42 Nm (4.2 m • kg, 30 ft • lb)

NOTE:
Always tighten the locknut against the adjusting ring, then torque it to specification.

***********************************************

3 - 45

ADJUSTING THE REAR SHOCK ABSORBER

CHK
ADJ

2.Adjust:
● Rebound damping force

***********************************************
Adjustment steps:
● Turn the adjusting screw 1 in direction a or
b.
Direction a

Rebound damping force
is increased.

Direction b

Rebound damping force
is decreased.

From the fully turned-in position:
Standard: 10 clicks out
Minimum: 20 clicks out
Maximum: 3 clicks out

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

***********************************************

3.Adjust:
● Compression damping force

***********************************************
Adjustment steps:
● Turn the adjusting screw 1 in direction a or
b.
Direction a

Compression damping
force is increased.

Direction b

Compression damping
force is decreased.

From the fully turned-out position:
Standard: 7 clicks in
Minimum: 1 click in
Maximum: 12 clicks in

3 - 46

ADJUSTING THE REAR SHOCK ABSORBER/
CHECKING THE TIRE

CHK
ADJ

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

***********************************************

CHECKING THE TIRE

WARNING
This model is equipped with low pressure
tires. It is important that they be inflated correctly and maintained at the proper pressures.
● TIRE CHARACTERISTICS
1)Tire characteristics influence the handling
of ATV’s. The tires listed below have been
approved by Yamaha Motor Co., Ltd. for
this model. If other tire combinations are
used, they can adversely affect your
machine’s handling characteristics and
are therefore not recommended.
Manufacturer

Size

Front

DUNLOP

AT21×7-10

Rear

DUNLOP

AT20×10-9

Type
KT311
Radial
KT335
Radial

● TIRE PRESSURE
1)Recommended tire pressure
Front 27.5 kPa (0.275 kg/cm2, 4.0 psi)
Rear 27.5 kPa (0.275 kg/cm2, 4.0 psi)
2)Tire pressure below the minimum specification could cause the tire to dislodge
from the rim under severe riding conditions.
The following are minimums:
Front 24.5 kPa (0.245 kg/cm2, 3.5 psi)
Rear 24.5 kPa (0.245 kg/cm2, 3.5 psi)
3)Use no more than
Front 250 kPa (2.5 kg/cm2, 36 psi)
Rear 250 kPa (2.5 kg/cm2, 36 psi)
when seating the tire beads. Higher pressures may cause the tire to burst.
Inflate the tires slowly and carefully.
Fast inflation could cause the tire to
burst.

3 - 47

CHECKING THE TIRE

CHK
ADJ

MAXIMUM LOADING LIMIT
1)Vehicle load limit (total weight of cargo,
rider and accessories, and tongue
weight): 100 kg (220 lb)
●

1.Measure:
Tire pressure (cold tire pressure)
Out of specification → Adjust.

●

NOTE:
● The low-pressure tire gauge 1 is included
as standard equipment.
● If dust or the like is stuck to this gauge, it will
not provide the correct readings. Therefore,
take two measurements of the tire’s pressure
and use the second reading.
Cold tire
pressure
Standard

Minimum

Maximum

Front

Rear

27.5 kPa
(0.275 kg/cm2,
4.0 psi)
24.5 kPa
(0.245 kg/cm2,
3.5 psi)
30.5 kPa
(0.305 kg/cm2,
4.4 psi)

WARNING
Uneven or improper tire pressure may
adversely affect the handling of this
machine and may cause loss of control.
● Maintain proper tire pressures.
● Set tire pressures when the tires are cold.
● Tire pressures must be equal in both front
tires and equal in both rear tires.

3 - 48

CHECKING THE TIRE/CHECKING THE WHEEL/
CHECKING AND LUBRICATING THE CABLE

CHK
ADJ

2.Check:
● Tire surfaces
Wear/damage → Replace.
Tire wear limit a:
Front and rear: 3.0 mm (0.12 in)

WARNING
It is dangerous to ride with a worn-out tire.
When tire wear is out of specification,
replace the tire immediately.

CHECKING THE WHEEL
1.Check:
● Wheels 1
Damage/bends → Replace.
NOTE:
Always balance the wheel when a tire or wheel
has been changed or replaced.

WARNING
●

●

Never attempt even small repairs to the
wheel.
Ride conservatively after installing a tire
to allow it to seat itself properly on the
rim.

CHECKING AND LUBRICATING THE
CABLE

WARNING
A damaged cable sheath may cause corrosion and interfere with the cable movement. An unsafe condition may result so
replace a damaged cable as soon as possible.
3 - 49

CHECKING AND LUBRICATING THE CABLE/
LUBRICATING THE LEVERS AND PEDAL

CHK
ADJ

1.Check:
● Cable sheath
Damage → Replace.
2.Check:
● Cable operation
Unsmooth operation → Lubricate or replace.
Recommended lubricant:
Yamaha chain and cable lube or
Engine oil
NOTE:
Hold the cable end up and apply several drops
of lubricant to the cable.
3.Apply:
● Lithium soap base grease
(onto end of the cable)

LUBRICATING THE LEVERS AND PEDAL
1.Lubricate the pivoting parts.
Recommended lubricant:
Lithium soap base grease

3 - 50

CHECKING THE BATTERY

CHK
ADJ

EB305000

ELECTRICAL
CHECKING THE BATTERY
NOTE:
Since the MF battery is a sealed type battery, it
is not possible to measure the specific gravity
of the electrolyte in order to check the charge
state of the battery. Therefore the charge of
the battery has to be checked by measuring
the voltage at the battery terminals.

CAUTION:
CHARGING METHOD
● This is a sealed type battery. Never
remove the sealing caps. If the sealing
caps have been removed, the balance will
not be maintained and battery performance will deteriorate.
time, charging current and
● Charging
charging voltage for the MF battery are
different from those of general type batteries. The MF battery should be charged
as explained in “CHARGING METHOD”. If
the battery is overcharged, the electrolyte
level will drop considerably. Therefore,
take special care when charging the battery.

WARNING
Battery electrolyte is dangerous; it contains sulfuric acid which is poisonous and
highly caustic.
Always follow these preventive measures:
● Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
● Wear protective eye gear when handling
or working near batteries.
Antidote (EXTERNAL):
● SKIN - Wash with water.
● EYES - Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
● Drink large quantities of water or milk followed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.

3 - 51

CHECKING THE BATTERY

CHK
ADJ

Batteries generate explosive hydrogen gas.
Always follow these preventive measures:
● Charge batteries in a well-ventilated area.
● Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes, etc.).
● DO NOT SMOKE when charging or handling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
1.Remove:
● Seat
● Battery holding bracket
Refer to “SEAT, FENDERS AND FUEL
TANK”.

2.Disconnect:
● Battery leads

CAUTION:
First disconnect the negative lead 1, then
disconnect the positive lead 2.
3.Remove:
● Battery

4.Check:
● Battery condition

***********************************************
Battery condition checking steps:
● Connect a digital voltmeter to the battery terminals.
Tester (+) lead → battery (+) terminal
Tester (–) lead → battery (–) terminal
NOTE:
The charge state of an MF battery can be
checked by measuring the open-circuit voltage
(i.e. the voltage when the positive terminal is
disconnected).

3 - 52

Open-circuit
voltage

Charging time

12.8 V or higher

No charging is
necessary.

CHECKING THE BATTERY

CHK
ADJ

● Check

the condition of the battery using the
following charts.
Example:
● Open-circuit voltage = 12.0 V
● Charging time = 6.5 hours
● Charge condition of the battery = 20 ~ 30%
● Charging method for MF batteries

CAUTION:
●

●

If it is impossible to set the standard
charging current, be careful not to overcharge.
When charging the battery, be sure to
remove it from the motorcycle. (If charging has to be done with the battery
mounted on the motorcycle, be sure to
disconnect the wire at the negative terminal.)
Never remove the sealing caps of an MF
battery.
Make sure that the charging clips are in
full contact with the terminal and that they
are not shorted together. (A corroded clip
on the charger may cause the battery to
generate heat in the contact area. A weak
clip spring may cause sparks.)
Before removing the clips from the battery terminals, be sure to turn off the
charger’s power switch.
The open-circuit voltage variation for the
MF battery, after charging, is shown
below. As shown in the figure, the opencircuit voltage stabilizes about 30 minutes after charging has been completed.
Therefore, wait 30 minutes after charging
is completed before measuring the opencircuit voltage.

***********************************************

3 - 53

CHECKING THE BATTERY
Charging method using a variable voltage charger

3 - 54

CHK
ADJ

CHECKING THE BATTERY
Charging method using a constant voltage charger

3 - 55

CHK
ADJ

CHECKING THE BATTERY/CHECKING THE FUSE

CHK
ADJ

5.Check:
● Battery terminals
Dirty → Clean with a wire brush.
Poor connection → Correct.
NOTE:
After cleaning the terminals, apply a light coat
of grease.

6.Install:
● Battery
7.Connect:
● Battery leads

CAUTION:
First, connect the positive lead 1, then
connect the negative lead 2.
8.Install:
● Battery holding bracket
● Seat
Refer to “SEAT, FENDERS AND FUEL
TANK”.

CHECKING THE FUSE

CAUTION:
Always turn off the main switch when
checking or replacing a fuse. Otherwise, a
short circuit may occur.
1.Remove:
● Seat
Refer to “SEAT, FENDERS AND FUEL
TANK”.
2.Check:
● Fuse

***********************************************
Checking steps:
● Connect the pocket tester to the fuse and
check it for continuity.

3 - 56

CHECKING THE FUSE

CHK
ADJ

NOTE:
Set the tester to the “Ω × 1” position.
Pocket tester:
P/N. YU-03112, 90890-03112
● If

the tester indicates 0, replace the fuse.

***********************************************
3.Replace:
● Blown fuse

***********************************************
Replacement steps:
● Turn off the ignition.
● Install a new fuse of the proper amperage.
● Turn on switches to verify operation of the
related electrical devices.
● If the fuse immediately blows again, check
the electrical circuit.

***********************************************
Description

Current rating

Quantity

Main

20 A

Reserve

20 A

WARNING
Never use a fuse with a rating other than
that specified. Never use other materials in
place of a fuse. An improper fuse may
cause extensive damage to the electrical
system, a malfunction of the lighting and
ignition systems and could possibly cause
a fire.
4.Install:
● Seat
Refer to “SEAT, FENDERS AND FUEL
TANK”.

3 - 57

ADJUSTING THE HEADLIGHT BEAM/
REPLACING THE HEADLIGHT BULB

CHK
ADJ

ADJUSTING THE HEADLIGHT BEAM
1.Adjust:
● Headlight beam (vertically)

***********************************************
Adjustment steps:
● Loosen the screw 1.
● Slide the headlight lens unit under.
Slide forward
Slide backward
● Tighten

Headlight beam raises.
Headlight beam lowers.

the screw 1.

***********************************************

REPLACING THE HEADLIGHT BULB
1.Remove:
● Headlight
Refer to “SEAT, FENDERS AND FUEL
TANK”.
2.Remove:
● Cover 1
● Headlight unit 2
● Case 3
NOTE:
Pull outward on the rear of the headlight unit
2, and then pull out ward on the front.

3 - 58

REPLACING THE HEADLIGHT BULB

CHK
ADJ

3.Remove:
● Cover 1
● Bulb holder 2
● Bulb
NOTE:
Turn the bulb holder counterclockwise and
remove the defective bulb.

WARNING
Keep flammable products and your hands
away from the bulb while it is on, since it
will be hot. Do not touch the bulb until it
cools down.

4.Install:
● Bulb
New
Secure the new bulb with the headlight unit.

CAUTION:
Avoid touching the glass part of the bulb.
Keep it free from oil; otherwise, the transparency of the glass, life of the bulb, and
luminous flux will be adversely affected. If
oil gets on the bulb, thoroughly clean it
with a cloth moistened with alcohol or lacquer thinner.
5.Install:
● Bulb holder
● Cover
● Cover
6.Install:
● Headlight
Refer to “SEAT, FENDERS AND FUEL
TANK”.

3 - 59

FRONT WHEELS

CHAS

CHASSIS
FRONT WHEELS
FRONT WHEELS

Order

Job name/Part name
Removing the front wheel

Q’ty

Remarks
Remove the parts in the order below.
Place the machine on a level surface.

WARNING
Securely support the machine so there
is no danger of it falling over.
1
2
3
4
5

Cotter pin
Axle nut
Front wheel
Brake disc guard (outer)
Brake caliper assembly

1
1
1
1
1

4-1

Refer to “INSTALLING THE WHEEL
HUB”.
Refer to “INSTALLING THE WHEEL”.
NOTE:
Do not apply the brake lever after the
brake calipers have been removed, otherwise the brake pads will be forced shut.

FRONT WHEELS

Order
6
7

Job name/Part name
Wheel hub
Brake disc

Q’ty
1
1

CHAS

Remarks

For installation, reverse the removal procedure.

4-2

FRONT WHEELS

CHAS

CHECKING THE WHEEL
1.Check:
● Wheel
2.Measure:
● Wheel runout
Over the specified limit → Replace the wheel
or check the wheel bearing play 1.
Wheel runout limit:
Radial 2: 2.0 mm (0.08 in)
Lateral 3: 2.0 mm (0.08 in)
3.Check:
● Wheel balance
Out of balance → Adjust.

WARNING
After replacing the tire, ride conservatively
to allow the tire to be properly seated in the
rim. Failure to do so may cause an accident
resulting in machine damage and possible
operator injury.

CHECKING THE WHEEL HUB
1.Check:
● Wheel hub 1
Cracks/damage → Replace.

4-3

FRONT WHEELS

CHAS

2.Check:
● Wheel bearings
Wheel hub play/wheel turns roughly →
Replace.

***********************************************
Wheel bearing replacement steps:
● Clean wheel hub exterior.
● Drive bearing out by pushing spacer aside
and tapping around perimeter of bearing
inner race. Use soft metal drift punch and
hammer. The spacer 1 “floats” between
bearings. Remove both bearings as
described.

WARNING
Eye protection is recommended when
using striking tools.
● To

install the wheel bearings, reverse the
above sequence. Use a socket that matches
outside diameter of bearing outer race to
drive in bearing.

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

***********************************************
CHECKING THE BRAKE DISC
1.Check:
● Brake disc
Galling/damage → Replace.
2.Measure:
● Brake disc deflection
Out of specification → Replace.
Brake disc maximum deflection:
0.15 mm (0.006 in)
●

Brake disc thickness a
Out of specification → Replace.
Brake disc minimum thickness:
3 mm (0.12 in)

4-4

FRONT WHEELS

CHAS

INSTALLING WHEEL HUB
1.Install:
70 Nm (7.0 m • kg, 50 ft • lb)
● Axle nut 1
● Cotter pin 2 New
R.

NOTE:
Do not loosen the axle nut after torquing it. If
the axle nut groove is not aligned with the cotter pin hole, align the groove with the hole by
tightening the axle nut.

INSTALLING THE WHEEL
1.Install:
● Brake disc guard (outer) 1
NOTE:
Install the brake disc guard (outer) with
punched burrs 2 on the wheel hub side.

2.Install:
● Wheel
NOTE:
The arrow mark 1 on the tire must point in the
direction of rotation È of the wheel.

4-5

REAR WHEELS, WHEEL AXLE AND HUB

CHAS

REAR WHEELS, WHEEL AXLE AND HUB
REAR WHEELS

Order

Job name/Part name
Removing the rear wheel

Q’ty

Remarks
Remove the parts in the order below.
Place the machine on a level surface.

WARNING
Securely support the machine so there
is no danger of it falling over.
1
2
3
4

Rear wheel
Cotter pin
Axle nut
Wheel hub

2
2
2
2

Refer to “INSTALLING THE WHEEL”.
Refer to “INSTALLING THE WHEEL
HUB”.
For installation, reverse the removal procedure.

4-6

REAR WHEELS, WHEEL AXLE AND HUB

CHAS

WHEEL AXLE AND HUB

Order
1

Job name/Part name
Removing the wheel axle and hub
Nut

2
3
4
5

Locknut
Adjusting bolt
Rear axle
Brake caliper

Q’ty
2
2
2
1
1

4-7

Remarks
Remove the parts in the order below.
Refer to “INSTALLING THE NUTS
(REAR AXLE)”.
Refer to “REMOVING THE REAR AXLE”.

NOTE:
Do not apply the brake pedal and do not
use the parking brake when the brake
caliper is off of the brake disc as the
brake pad will be force shut.

REAR WHEELS, WHEEL AXLE AND HUB

Order
6
7
8
9

Job name/Part name
Brake disc
Driven sprocket
Brake caliper bracket
Hub

Q’ty
1
1
1
1

CHAS

Remarks

For installation, reverse the removal procedure.

4-8

REAR WHEELS, WHEEL AXLE AND HUB

CHAS

REMOVING THE REAR AXLE
1.Place the machine on a level surface.
2.Loosen:
● Nuts (rear axle) 1
NOTE:
● Apply the brake pedal so that the rear axle
does not turn, when loosening the nuts.
● Use a axle nut wrench (50 mm) 2.
Axle nut wrench (50 mm):
P/N. YM-37132, 90890-01419

3.Elevate the rear wheels by placing the suitable stand under the frame.
4.Remove:
● Rear wheels
● Wheel hubs
● Nuts (rear axle)

5.Loosen:
● Hub nuts 1

6.Loosen:
● Locknuts 1
● Adjusting bolts 2

4-9

REAR WHEELS, WHEEL AXLE AND HUB

CHAS

7.Remove:
● Rear axle 1

CAUTION:
●

●

Never directly tap the axle end with a
hammer, since this will result in damage
to the axle thread and spline.
Attach a suitable socket 2 on the axle
end and tap it with a soft hammer. Pull out
the rear axle to the right.

CHECKING THE WHEEL
Refer to “FRONT WHEELS”.

CHECKING THE WHEEL HUB
1.Check:
● Wheel hub 1
Cracks/damage → Replace.
● Splines (wheel hub) 2
Wear/damage → Replace the wheel hub.

CHECKING THE REAR AXLE
1.Check:
● Rear axle runout a
Out of specification → Replace.

WARNING
Do not attempt to straighten a bent axle.
Rear axle runout limit:
1.5 mm (0.06 in)
4 - 10

REAR WHEELS, WHEEL AXLE AND HUB

CHAS

CHECKING THE HUB
1.Check:
● Hub bearings
Refer to “FRONT WHEELS-WHEEL HUB
INSPECTION”.
CHECKING THE BRAKE DISC
Refer to “FRONT WHEELS”.

INSTALLING THE NUTS (REAR AXLE)
1.Tighten:
Nuts (rear axle) 1, 2

***********************************************
Nuts tightening steps:
NOTE:
Before tightening the nuts, apply the LOCTITE® to the thread portion of the rear axle.
tighten the inside nut 1 while checking the ring gear engagement.
● Tighten the inside nut with rear axle nut
wrench to specification while holding the rear
axle.
● Finger

Axle nut wrench (50 mm):
P/N. YM-37132, 90890-01419

Inside nut (first tightening):
55 Nm (5.5 m • kg, 40 ft • lb)

the inside nut 1 and tighten the outside
nut 2 with rear axle nut wrench to specification.

● Hold

Outside nut:
190 Nm (19.0 m • kg, 140 ft • lb)

the line a on inside and outside nut.
● Hold the outside nut 2 and tighten back the
inside nut 1 with rear axle nut wrench to
specification.
● Draw

Inside nut (final tightening):
240 Nm (24.0 m • kg, 170 ft • lb)

the distance b between lines. If
distance b is less than 15 mm (0.59 in),
retighten back the inside nut.

● Measure

***********************************************
4 - 11

REAR WHEELS, WHEEL AXLE AND HUB

CHAS

INSTALLING THE WHEEL HUB
Refer to “FRONT WHEELS”.

INSTALLING THE WHEEL
1.Install:
● Wheel
NOTE:
The wording on the tire “SIDE FACING OUTWARDS” 1 must be facing outwards.

4 - 12

FRONT AND REAR BRAKES

CHAS

FRONT AND REAR BRAKES
FRONT BRAKE PADS

Order

1
2
3

Job name/Part name
Removing the front brake pad
Front wheel/wheel hub
Brake pad holding bolt
Brake pad/pad shim
Brake pad spring

Q’ty

2
2/1
1

Remarks
Remove the parts in the order below.
Refer to “FRONT WHEELS”.
Refer to “REPLACING THE FRONT
BRAKE PAD”.
For installation, reverse the removal procedure.

4 - 13

FRONT AND REAR BRAKES

CHAS

REAR BRAKE PADS

Order
1
2
3
4
5
6

Job name/Part name
Removing rear brake pad
Brake caliper mounting bolt
Brake caliper mounting bolt
Brake pad holding bolt
Lock washer
Brake pad/pad shim
Brake pad spring

Q’ty
1
1
2
1
2/1
1

Remarks
Remove the parts in the order below.

Refer to “REPLACING THE REAR
BRAKE PAD”.

For installation, reverse the removal procedure.

4 - 14

FRONT AND REAR BRAKES

CHAS

CAUTION:
Disc brake components rarely require disassembly. DO NOT:
● disassemble components unless absolutely necessary;
● use solvents on internal brake components;
● use spent brake fluid for cleaning; (use
only clean brake fluid)
● allow brake fluid to come in contact with
the eyes, as this may cause eye injury;
● splash brake fluid onto painted surfaces or
plastic parts, as this may cause damage;
● disconnect any hydraulic connection, as
this would require the entire brake system to be disassembled, drained,
cleaned, properly filled and bled after
reassembly.
REPLACING THE FRONT BRAKE PAD
NOTE:
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.

1.Remove:
● Brake pads
a Wear limit

NOTE:
Replace the brake pads as a set if either is
found to be worn to the wear limit.

2.Install:
● Brake pads
● Brake pad spring
NOTE:
Always install new brake pads, brake pad shim
and brake pad spring as a set.

4 - 15

FRONT AND REAR BRAKES

CHAS

***********************************************
Installation steps:
● Connect a suitable hose 1 tightly to the
brake caliper bleed screw 2. Put the other
end of this hose into an open container.
● Loosen the brake caliper bleed screw and,
using a finger, push the caliper piston into
the brake caliper.
● Tighten the brake caliper bleed screw.

Brake caliper bleed screw:
6 Nm (0.6 m • kg, 4.3 ft • lb)

new brake pads, new pad shim 3 and
a new brake pad spring.
● Install the holding bolts and brake caliper.
● Install

NOTE:
The arrow mark a on the pad shim must point
in the direction of the disc rotation.

Brake pad holding bolt:
18 Nm (1.8 m • kg, 13 ft • lb)
Brake caliper mounting bolt:
28 Nm (2.8 m • kg, 20 ft • lb)

***********************************************

3.Check:
● Brake fluid level
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in CHAPTER 3.
4.Check:
● Brake lever operation
Soft or spongy feeling → Bleed the front
brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in CHAPTER 3.

4 - 16

FRONT AND REAR BRAKES

CHAS

REPLACING THE REAR BRAKE PAD
NOTE:
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.

1.Remove:
● Brake pads
a Wear limit

NOTE:
Replace the brake pads as a set if either is
found to be worn to the wear limit.

2.Install:
● Brake pads
● Brake pad spring
NOTE:
Always install new brake pads, brake pad shim
and brake pad spring as a set.

Brake caliper bleed screw:
6 Nm (0.6 m • kg, 4.3 ft • lb)

new brake pads, new pad shim 3 and
a new brake pad spring.
● Install a new lock washer, holding bolts and
brake caliper.
● Install

NOTE:
The arrow mark a on the pad shim must point
in the direction of the disc rotation.

4 - 17

FRONT AND REAR BRAKES

CHAS

Brake pad holding bolt:
18 Nm (1.8 m • kg, 13 ft • lb)
Brake caliper mounting bolt:
28 Nm (2.8 m • kg, 20 ft • lb)

● Bend

the lock washer tabs along a flat side
of the bolts.

***********************************************

3.Check:
● Brake fluid level
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in CHAPTER 3.
4.Check:
● Brake pedal operation
Soft or spongy feeling → Bleed the rear
brake system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in CHAPTER 3.

4 - 18

FRONT AND REAR BRAKES

CHAS

FRONT BRAKE MASTER CYLINDER

Order

1
2
3
4
5
6
7
8
9

Job name/Part name
Removing front brake master cylinder
Brake fluid
Brake fluid reservoir cap
Brake fluid reservoir diaphragm
Front brake switch
Brake lever
Union bolt
Copper washer
Brake hose
Brake master cylinder bracket
Brake master cylinder

Q’ty

Remarks
Remove the parts in the order below.
Drain.

1
1
1
1
1
2
1
1
1

Refer to “INSTALLING THE FRONT
BRAKE MASTER CYLINDER”.

For installation, reverse the removal procedure.

4 - 19

FRONT AND REAR BRAKES

Order

1
2
3

Job name/Part name
Disassembling the front brake master cylinder
Dust boot
Circlip
Brake master cylinder kit

Q’ty

4 - 20

1
1
1

CHAS

Remarks
Remove the parts in the order below.
Refer to “ASSEMBLING THE FRONT
AND REAR BRAKE MASTER CYLINDER”.
For assembly, reverse the disassembly
procedure.

FRONT AND REAR BRAKES

CHAS

REAR BRAKE MASTER CYLINDER

Order

1
2
3
4
5
6
7

Job name/Part name
Q’ty
Remarks
Removing the rear brake master cylRemove the parts in the order below.
inder
Right footrest guard
Refer to “SEAT, FENDERS AND FUEL
TANK” in CHAPTER 3.
Brake fluid
Drain.
Brake fluid reservoir cover
1
Brake fluid reservoir cap
1
Brake fluid reservoir diaphragm holder
1
Brake fluid reservoir diaphragm
1
Brake fluid reservoir
1
Brake fluid reservoir hose
1
Right footrest guard bracket
1

4 - 21

FRONT AND REAR BRAKES

Order
8
9
10
11

Job name/Part name
Union bolt
Copper washer
Brake hose
Brake master cylinder

CHAS

Q’ty
Remarks
1
2
Refer to “INSTALLING THE REAR
BRAKE MASTER CYLINDER”.
1
1
For installation, reverse the removal procedure.

4 - 22

FRONT AND REAR BRAKES

Order

1
2
3

Job name/Part name
Disassembling the rear brake master cylinder
Hose joint
Brake master cylinder kit
Brake master cylinder

Q’ty

1
1
1

4 - 23

CHAS

Remarks
Remove the parts in the order below.

Refer to “ASSEMBLING THE FRONT
AND REAR BRAKE MASTER CYLINDER”.
For assembly, reverse the disassembly
procedure.

FRONT AND REAR BRAKES

CHAS

CHECKING THE MASTER CYLINDER
1.Check:
● Brake master cylinder 1
Wear/scratches → Replace the brake master
cylinder assembly.
● Brake master cylinder body
Cracks/damage → Replace.
● Brake fluid delivery passage
(brake master cylinder body)
Blockage → Blow out with compressed air.

È Front
É Rear

2.Check:
● Brake master cylinder kit
Scratches/wear/damage → Replace as a set.

È Front
É Rear

3.Check:
● Front brake master cylinder reservoir 1
● Front brake master cylinder reservoir diaphragm 2
Cracks/damage → Replace.

4.Check:
● Rear brake fluid reservoir 1
● Rear brake fluid reservoir diaphragm 2
Cracks/damage → Replace.

4 - 24

FRONT AND REAR BRAKES

CHAS

EB702060

ASSEMBLING THE FRONT AND REAR
BRAKE MASTER CYLINDER

WARNING
●

All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.
Recommended brake fluid:
DOT 4

●

Whenever a master cylinder is disassembled, replace the piston seals and dust
seals.

INSTALLING THE FRONT BRAKE MASTER
CYLINDER
1.Install:
● Brake master cylinder 1
T.
R.

7 Nm (0.7 m • kg, 5.1 ft • lb)

NOTE:
The “UP” mark on the brake master cylinder
bracket should face up.

2.Install:
● Copper washers New
● Brake hose
27 Nm (2.7 m • kg, 19 ft • lb)
● Union bolt
R.

NOTE:
● Tighten the union bolt while holding the
brake hose as shown.
● Turn the handlebar to the left and to the right
to check that the brake hose does not touch
other parts (throttle cable, wire harness,
leads, etc.). Correct if necessary.

WARNING
Proper brake hose routing is essential to
insure safe machine operation. Refer to
“CABLE ROUTING”.

4 - 25

FRONT AND REAR BRAKES

CHAS

3.Fill:
● Brake fluid reservoir
Recommended brake fluid:
DOT 4

CAUTION:
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.

WARNING
●

●

Use only the designated quality brake
fluid: Other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.
Refill with the same type of brake fluid:
Mixing brake fluids may result in a harmful chemical reaction and lead to poor
brake performance.
Be careful that water does not enter the
brake master cylinder when refilling.
Water will significantly lower the boiling
point of the brake fluid and may result in
vapor lock.

4.Air bleed:
● Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in CHAPTER 3.
5.Check:
● Brake fluid level
Brake fluid level is below the “LOWER” level
line → Add the recomended brake fluid to the
proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in CHAPTER 3.

4 - 26

FRONT AND REAR BRAKES

CHAS

INSTALLING THE REAR BRAKE MASTER
CYLINDER
1.Install:
● Copper washers 1 New
● Brake hose 2
30 Nm (3.0 m • kg, 22 ft • lb)
● Union bolt 3
R.

CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection a as shown.

WARNING
Proper brake hose routing is essential to
insure safe machine operation. Refer to
“CABLE ROUTING”.
2.Fill:
● Brake fluid reservoir
Recommended brake fluid:
DOT 4

CAUTION:
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.

WARNING
●

●

4 - 27

FRONT AND REAR BRAKES

CHAS

3.Air bleed:
● Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in CHAPTER 3.
4.Check:
● Brake fluid level
Brake fluid level is below the “LOWER” level
line → Add the recommended brake fluid to
the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in CHAPTER 3.

4 - 28

FRONT AND REAR BRAKES

CHAS

FRONT BRAKE CALIPERS

Order

1
2
3
4
5
6
7

Job name/Part name
Removing the front brake caliper
Brake fluid
Front wheel
Union bolt
Copper washer
Brake hose
Cap/retaining bolt
Brake pad holding bolt
Brake caliper mounting bolt
Brake caliper assembly

Q’ty

1
2
1
1/1
2
2
1

Remarks
Remove the parts in the order below.
Drain.
Refer to “FRONT WHEELS”.

Disconnect.
Loosen.
Loosen.

Refer to “INSTALLING
THE FRONT BRAKE CALIPER”.

For installation, reverse the removal procedure.

4 - 29

FRONT AND REAR BRAKES

Order

1
2
3
4

5
6
7
8
9

Job name/Part name
Disassembling the front brake caliper
Brake pad holding bolt
Brake pad/pad shim
Brake pad spring
Retaining bolt
Caliper bracket
Brake caliper piston
Dust seal
Caliper piston seal
Bleed screw

Q’ty

2
2/1
1
1
1
1
1
1
1

CHAS

Remarks
Remove the parts in the order below.

Refer to “DISASSEMBLING THE FRONT
AND REAR BRAKE CALIPER/ASSEMBLING THE FRONT BRAKE CALIPER”.
For assembly, reverse the disassembly
procedure.

4 - 30

FRONT AND REAR BRAKES

CHAS

REAR BRAKE CALIPER

Order

1
2
3
4
5
6
7

Job name/Part name
Removing the rear brake caliper
Brake fluid
Parking brake cable
Union bolt
Copper washer
Brake hose
Brake caliper mounting bolt
Brake caliper mounting bolt
Brake caliper assembly

Q’ty

1
1
2
1
1
1
1

Remarks
Remove the parts in the order below.
Drain.
Disconnect.

Disconnect.

Refer to “INSTALLING
THE REAR BRAKE CALIPER”.

For installation, reverse the removal procedure.

4 - 31

FRONT AND REAR BRAKES

Order
1
2
3
4

5
6
7
8
9
0
A

CHAS

Job name/Part name
Q’ty
Remarks
Disassembling the rear brake caliper
Remove the parts in the order below.
Adjusting bolt
1
Locknut
1
Parking brake lever
1
Parking brake case mounting bolt
2
Parking brake case
1
Gasket
1
Spring
1
Nut
1
Bearing
1
Refer to “ASSEMBLING THE REAR
Brake pad holding bolt
2
BRAKE CALIPER”.
Lock washer
1

4 - 32

FRONT AND REAR BRAKES

Order
B
C
D
E
F
G
H
I
J

Job name/Part name
Brake pad/pad shim
Brake pad spring
Retaining bolt
Caliper bracket
Brake caliper piston
Dust seal
Caliper piston seal
O-ring
Bleed screw

CHAS

Q’ty
Remarks
2/1
1
1
1
1
Refer to “DISASSEMBLING THE FRONT
1
AND REAR BRAKE CALIPER/ASSEM1
BLING THE REAR BRAKE CALIPER”.
1
1
For assembly, reverse the disassembly
procedure.

4 - 33

FRONT AND REAR BRAKES

CHAS

DISASSEMBLING THE FRONT AND REAR
BRAKE CALIPER
1.Remove:
● Brake caliper piston
● Dust seal 1
● Caliper piston seal 2

***********************************************
Removal steps:
● Blow compressed air into the hose joint
opening to force out the caliper piston from
the brake caliper body.

WARNING
●
●

Never try to pry out the caliper piston.
Cover the caliper piston with a rag. Be
careful not to get injured when the piston
is expelled from the master cylinder.

● Remove

the caliper piston seals.

***********************************************
EB702040

CHECKING THE FRONT AND REAR BRAKE
CALIPER
Recommended brake component
replacement schedule:
Brake pads

As required

Piston seal, dust seal Every two years
Brake hoses

Every two years

Brake fluid

Replace when
brakes are disassembled.

WARNING
All internal brake components should be
cleaned in new brake fluid only. Do not use
solvents as they will cause seals to swell
and distort.

4 - 34

FRONT AND REAR BRAKES

CHAS

1.Check:
● Brake caliper piston 1
Scratches/rust/wear → Replace the brake
caliper assembly.
● Brake caliper cylinder 2
Wear/scratches → Replace the brake caliper
assembly.
● Brake caliper body 3
Cracks/damage → Replace.
● Brake fluid delivery passage (brake caliper
body)
Blockage → Blow out with compressed air.

WARNING
Replace the caliper piston seal and dust
seal whenever the brake caliper is disassembled.
È Front
É Rear

ASSEMBLING THE FRONT BRAKE
CALIPER

WARNING
●

All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.
Recommended brake fluid:
DOT 4

●

Replace the caliper piston seal whenever
a brake caliper is disassembled.

1.Install:
● Caliper piston seal 1 New
● Dust seal 2 New

2.Install:
● Brake caliper piston 1

4 - 35

FRONT AND REAR BRAKES

CHAS

ASSEMBLING THE REAR BRAKE CALIPER

WARNING
●

All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.
Recommended brake fluid:
DOT 4

●

Replace the caliper piston seal whenever
a brake caliper is disassembled.

1.Install:
● O-ring 1
New
● Caliper piston seal 2
● Dust seal 3
New

New

2.Install:
● Brake caliper piston 1

3.Install:
● Lock washer 1
New
● Brake pad holding bolts 2
T.
R.

18 Nm (1.8 m • kg, 13 ft • lb)

4.Bend the lock washer tabs along a flat side
of the bolts.

5.Mesh the bearing race tab 1 with parking
brake case slit.

4 - 36

FRONT AND REAR BRAKES

CHAS

INSTALLING THE FRONT BRAKE CALIPER
1.Install:
● Brake caliper assembly
● Brake caliper mounting bolts 1
T.
R.

●
●
●

28 Nm (2.8 m • kg, 20 ft • lb)

Brake hose 2
Copper washers 3 New
Union bolt 4
27 Nm (2.7 m • kg, 19 ft • lb)
R.

CAUTION:
When installing the brake hose on the
brake caliper, make sure that the brake
pipe touches the projection a on the brake
caliper.

WARNING
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
2.Fill:
● Brake reservoir
Recommended brake fluid:
DOT 4

CAUTION:
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.

WARNING
●

●

Use only the designated quality brake
fluid: Other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.
Refill with the same type of brake fluid:
Mixing brake fluids may result in a harmful chemical reaction and lead to poor
brake performance.
Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
brake fluid and may result in vapor lock.

3.Air bleed
● Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in CHAPTER 3.

4 - 37

FRONT AND REAR BRAKES

CHAS

4.Check:
● Brake fluid level
Brake fluid level is below the “LOWER” level
line → Add the recommended brake fluid to
the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in CHAPTER 3.

INSTALLING THE REAR BRAKE CALIPER
1.Install:
● Brake caliper assembly
● Brake caliper mounting bolts 1
T.
R.

●
●
●

28 Nm (2.8 m • kg, 20 ft • lb)

Brake hose 2
Copper washers 3 New
Union bolt 4
30 Nm (3.0 m • kg, 22 ft • lb)
R.

CAUTION:
When installing the brake hose on the
brake caliper, make sure that the brake
pipe touches the projection a on the brake
caliper.

WARNING
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
2.Fill:
● Brake reservoir
Recommended brake fluid:
DOT 4

CAUTION:
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.

4 - 38

FRONT AND REAR BRAKES

CHAS

WARNING
●

●

Use only the designated quality brake
fluid: Other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.
Refill with the same type of brake fluid:
Mixing brake fluids may result in a harmful
chemical reaction and lead to poor brake
performance.
Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
brake fluid and may result in vapor lock.

3.Air bleed
● Brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in CHAPTER 3.
4.Check:
● Brake fluid level
Brake fluid level is below the “LOWER” level
line → Add the recommended brake fluid to
the proper level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in CHAPTER 3.
5.Adjust:
● Parking brake cable end length
Refer to “ADJUSTING THE PARKING
BRAKE” in CHAPTER 3.

4 - 39

STEERING SYSTEM

CHAS

STEERING SYSTEM
HANDLEBAR

Order

Q’ty

1
2
3

Job name/Part name
Removing the handlebar
Handlebar cover
Band
Front brake switch

4
5
6
7
8

Brake master cylinder/bracket
Throttle lever assembly/bracket
Collar
Park switch
Clutch switch

1/1
1/1
1
1
1

9
10

Clutch lever/bracket
Handlebar switch

1/1
1

1
2
1

4 - 40

Remarks
Remove the parts in the order below.

Refer to “REMOVING THE FRONT
BRAKE SWITCH, PARK SWITCH AND
CLUTCH SWITCH”.
Refer to “INSTALLING THE BRAKE
MASTER CYLINDER”.
Refer to “REMOVING THE FRONT
BRAKE SWITCH, PARK SWITCH AND
CLUTCH SWITCH”.
Refer to “INSTALLING THE CLUTCH
LEVER”.

STEERING SYSTEM

Order
11
12
13
14

Job name/Part name
Handlebar grip
Handlebar cover bracket
Handlebar holder
Handlebar

CHAS

Q’ty
Remarks
2
Refer to “REMOVING/INSTALLING THE
HANDLEBAR GRIP”.
2
Refer to “INSTALLING THE HANDLE2
BAR”.
1
For installation, reverse the removal procedure.

4 - 41

STEERING SYSTEM

CHAS

REMOVING THE FRONT BRAKE SWITCH,
PARK SWITCH AND CLUTCH SWITCH
1.Remove:
● Front brake switch 1
● Park switch
● Clutch switch
NOTE:
● Push the fastener when removing the front
brake switch out of the brake master cylinder.
● Push the fastener when removing the park
switch and clutch switch out of the clutch
lever holder.

REMOVING THE HANDLEBAR GRIP
1.Remove:
● Handlebar grips 1
NOTE:
Blow compressed air between the handlebar
and handlebar grip, and gradually push the
grip off the handlebar.

CHECKING THE HANDLEBAR
1.Check:
● Handlebar 1
Bends/cracks/damage → Replace.

WARNING
Do not attempt to straighten a bent handlebar as this may dangerously weaken the
handlebar.

4 - 42

STEERING SYSTEM

CHAS

INSTALLING THE HANDLEBAR
1.Install:
● Handlebar
● Handlebar holders
● Handlebar cover brackets
T.
R.

23 Nm (2.3 m • kg, 17 ft • lb)

NOTE:
The upper handlebar holder should be
installed with the punched mark 1 forward 2.

CAUTION:
First tighten the bolts 3 on the front side of
the handlebar holder, and then tighten the
bolts 4 on the rear side.

INSTALLING THE HANDLEBAR GRIP
1.Install:
● Handlebar grips 1
NOTE:
● Before
applying the adhesive, wipe off
grease or oil on the handlebar surface a
with a lacquer thinner.
● Install the handlebar grips to the handlebar
so that the line b between the two arrow
marks faces straight upward.

INSTALLING THE CLUTCH LEVER
1.Install:
● Handlebar switch 1
● Clutch lever
● Lever bracket 2
NOTE:
Install the lever bracket as shown.
a 80 mm (3.1 in)
4 - 43

STEERING SYSTEM

CHAS

INSTALLING THE BRAKE MASTER
CYLINDER
1.Install:
● Throttle lever assembly
● Collar
● Brake master cylinder
T.
R.

7 Nm (0.7 m • kg, 5.1 ft • lb)

NOTE:
● Engage the indentations a in the collar with
the lobes b on the throttle lever assembly
and brake master cylinder.
● The “UP” mark on the brake master cylinder
bracket should face up.

4 - 44

STEERING SYSTEM

CHAS

STEERING STEM

Order

1
2

Job name/Part name
Removing the steering stem
Front fender
Fuel tank
Handlebar
Pitman arm
Lock washer

3
4
5
6
7
8

Steering stem bushing
Collar
Oil seal
Steering stem
Oil seal
Oil seal

Q’ty

Remarks
Remove the parts in the order below.
Refer to “SEAT, FENDERS AND FUEL
TANK” in CHAPTER 3.
Refer to “HANDLEBAR”.

1
1
2
2
2
1
1
1

4 - 45

Refer to “INSTALLING THE LOCK
WASHER”.

STEERING SYSTEM

Order
9
10

Job name/Part name
Bearing retainer
Bearing

CHAS

Q’ty
Remarks
1
Refer to “REMOVING/INSTALLING THE
BEARING RETAINER”.
1
For installation, reverse the removal procedure.

4 - 46

STEERING SYSTEM

CHAS

REMOVING THE BEARING RETAINER
1.Remove:
● Bearing retainer (steering stem)
Damper rod holder:
P/N. YM-01327, 90890-01327

CHECKING THE STEERING STEM
1.Check:
● Steering stem 1
Bends → Replace.

WARNING
Do not attempt to straighten a bent stem;
this may dangerously weaken the stem.

2.Check:
● Oil seals 1
New
● Steering stem bushings 2
Wear/damage → Replace.

INSTALLING THE BEARING RETAINER
1.Install:
● Bearing retainer (steering stem)
T.
R.

40 Nm (4.0 m • kg, 29 ft • lb)

Damper rod holder:
P/N. YM-01327, 90890-01327

INSTALLING THE LOCK WASHER
1.Install:
● Lock washer New
T.
R.

23 Nm (2.3 m • kg, 17 ft • lb)

2.Bend the lock washer tab along a flat side of
the bolt.

4 - 47

STEERING SYSTEM

CHAS

TIE-ROD AND STEERING KNUCKLE

Order

1
2
3
4
5
6
7

Job name/Part name
Removing the tie-rod and steering
knuckle
Front wheel/brake disc
Tie-rod
Pitman arm
Brake disc guard (inner)
Front bumper
Front arm (lower)
Front arm (upper)
Steering knuckle

Q’ty

2
1
1
1
1
1
1

4 - 48

Remarks
Remove the parts in the order below.
Refer to “FRONT WHEELS”.
Refer to “INSTALLING THE TIE-ROD”.

Refer to “REMOVING THE STEERING
KNUCKLE”.
For installation, reverse the removal procedure.

STEERING SYSTEM

CHAS

REMOVING THE STEERING KNUCKLE
1.Remove:
● Steering knuckle 1
NOTE:
Use a general puller to separate the ball joint
2 and steering knuckle.

CHECKING THE TIE-ROD
1.Check:
● Tie-rod free play and movement
Free play → Replace the tie-rod end.
Turns roughly → Replace the tie-rod end.
2.Check:
● Tie-rod
● Bends/damage → Replace.

CHECKING THE STEERING KNUCKLE
1.Check:
● Steering knuckle
Damage/pitting → Replace.

INSTALLING THE TIE-ROD
1.Install:
● Tie-rods (left and right)
T.
R.

25 Nm (2.5 m • kg, 18 ft • lb)

NOTE:
The tie-rod which must be installed on the out
side has grooves 1.

2.Adjust:
● Toe-in
Refer to “ADJUSTING THE TOE-IN” in
CHAPTER 3.

4 - 49

FRONT ARMS AND FRONT SHOCK ABSORBERS

CHAS

FRONT ARMS AND FRONT SHOCK ABSORBERS

Order

1
2
3
4
5
6
7
8
9
10
11

Job name/Part name
Removing the front arm and front
shock absorber
Front wheel/brake disc
Front bumper
Brake disc guard (inner)
Nut
Tie-rod
Nut
Nut
Nut/bolt
Nut/bolt
Front arm (lower)
Nut/bolt
Front arm (upper)

Q’ty

Remarks
Remove the parts in the order below.
Refer to “FRONT WHEELS”.

1
1
1
1
1
1
1/1
2/2
1
1/1
1

4 - 50

Disconnect.

Refer to “REMOVING/INSTALLING THE
FRONT ARMS”.

FRONT ARMS AND FRONT SHOCK ABSORBERS

Order
12
13
14
15
16
17
18
19
20
21

Job name/Part name
Nut/bolt
Front shock absorber/collar
Steering knuckle
Dust cover
Collar
Collar
Bushing
Circlip
Rubber boot
Ball joint

Q’ty
1/1
1/1
1
6
1
2
6
1
1
1

CHAS

Remarks

For installation, reverse the removal procedure.

4 - 51

FRONT ARMS AND FRONT SHOCK ABSORBERS

CHAS

REMOVING THE FRONT ARM
1.Check:
● Front arm free play

***********************************************
Checking steps:
● Check the front arm side play È by moving it
from side to side.
If side play is noticeable, check the bushings.
● Check the front arm vertical movement É by
moving it up and down.
If the vertical movement is tight or rough, or if
there is binding, check the bushings.

***********************************************
2.Remove:
● Front arms

CHECKING THE FRONT ARM
1.Check:
● Front arms 1
Bends/damage → Replace.
2.Check:
● Bushings 2
Wear/damage → Replace.

CHECKING THE FRONT SHOCK
ABSORBER
1.Check:
● Shock absorber rod
Bends/damage → Replace the shock
absorber assembly.
● Shock absorber assembly
Oil leaks → Replace the shock absorber
assembly.
● Spring
Fatigue → Replace the shock absorber
assembly.
Move the spring up and down.

4 - 52

FRONT ARMS AND FRONT SHOCK ABSORBERS

CHAS

CHECKING THE BALL JOINT
1.Check:
● Ball joint (front arm-upper)
Damage/pitting → Replace the front arm
(upper).
Free play → Replace the front arm.
Turns roughly → Replace the front arm
(upper).

2.Check:
● Ball joint (front arm-lower)
Damage/pitting → Replace the ball joint.
Free play → Replace the ball joint.
Turns roughly → Replace the ball joint.

***********************************************
Ball joint replacement steps:
● Clean the outside of the front lower arm.
● Remove the circlip 1 and rubber boot 2.
Use the ball joint remover and installer set.
Ball joint remover/installer set:
P/N. YM-01474, 90890-01474
Ball joint remover/installer attachment set:
P/N. YM-01480, 90890-01480
3 Body
4 Long bolt

YM-01474
90890-01474

5 Base
6 Remover attachment
7 Installer spacer

YM-01480
90890-01480

8 Installer washer

the body 3, long bolt 4, base 5 and
attachment 6 onto ball joint.
● Hold the body 3 in place while turning in the
long bolt 4 to remove the ball joint 9 from
the front lower arm 0.
● Remove the ball joint remover/installer.
● Install

4 - 53

FRONT ARMS AND FRONT SHOCK ABSORBERS

CHAS

● Attach

the assembled ball joint remover/
installer, new ball joint A, installer spacer 7
and installer washer 8 to the front lower arm
0.

NOTE:
● Do not tap or damage the top of the ball joint.
● Installer spacer 7 must be aligned with the
projection on the head of the ball joint A.
● Remove

the ball joint remover/installer.
● Apply lithium-soap base grease to the new
ball joint A.
● Install a new rubber boot and new circlip.
NOTE:
Always use a new ball joint set.

***********************************************

INSTALLING THE FRONT ARM
1.Install:
● Front upper arm 1
T.
R.

●

38 Nm (3.8 m • kg, 27 ft • lb)

Front lower arm 2
T.
R.

32 Nm (3.2 m • kg, 23 ft • lb)

NOTE:
Be sure to position the bolts (upper and lower)
so that the bolt head faces outward.

4 - 54

REAR SHOCK ABSORBER AND RELAY ARM

CHAS

REAR SHOCK ABSORBER AND RELAY ARM

Order

1
2
3
4
5
6
7
8

Job name/Part name
Removing the rear shock absorber
and relay arm
Rear wheels and hub

Q’ty

Metal screw clamp
Self-locking nut/bolt
Self-locking nut/bolt
Self-locking nut/bolt
Self-locking nut/bolt
Rear shock absorber
Collar/oil seal
Collar/oil seal

2
1/1
1/1
1/1
1/1
1
2/2
2/2

Remarks
Remove the parts in the order below.
Refer to “REAR WHEELS, WHEEL AXLE
AND HUB”.

4 - 55

Refer to “REMOVING THE REAR
SHOCK ABSORBER”.

REAR SHOCK ABSORBER AND RELAY ARM

Order
9
10
11
12
13
14
15
16

Job name/Part name
Self-locking nut/bolt
Relay arm
Spacer/oil seal/bushing
Connecting arm
Dust cover
Spacer
Spacer
Bushing

CHAS

Q’ty
Remarks
1/1
1
1/2/2 Refer to “INSTALLING THE RELAY ARM
AND CONNECTING ARM”.
1
4
1
1
4
Refer to “INSTALLING THE RELAY ARM
AND CONNECTING ARM”.
For installation, reverse the removal procedure.

4 - 56

REAR SHOCK ABSORBER AND RELAY ARM

CHAS

HANDLING THE REAR SHOCK ABSORBER
AND GAS CYLINDER

WARNING
This rear shock absorber and gas cylinder
contain highly compressed nitrogen gas.
Before handling the rear shock absorber or
gas cylinder, read and make sure you
understand the following information. The
manufacturer cannot be held responsible
for property damage or personal injury that
may result from improper handling of the
rear shock absorber and gas cylinder.
● Do not tamper or attempt to open the rear
shock absorber or gas cylinder.
● Do not subject the rear shock absorber or
gas cylinder to an open flame or any
other source of high heat. High heat can
cause an explosion due to excessive gas
pressure.
● Do not deform or damage the rear shock
absorber or gas cylinder in any way. If the
rear shock absorber, gas cylinder or both
are damaged, damping performance will
suffer.

DISPOSING OF A REAR SHOCK
ABSORBER AND GAS CYLINDER
Gas pressure must be released before disposing of a rear shock absorber and gas cylinder.
To release the gas pressure, press on the gas
valve needle with a suitable tool as shown,
until all of the gas is released (the hissing has
stopped).

WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.

4 - 57

REAR SHOCK ABSORBER AND RELAY ARM

CHAS

REMOVING THE REAR SHOCK ABSORBER
1.Remove:
● Connecting arm-to-frame bolt
● Rear shock absorber upper bolt
NOTE:
While removing the connecting arm-to-frame
bolt, hold the swingarm so that it does not drop
down.

CHECKING THE REAR SHOCK ABSORBER
1.Check:
● Shock absorber
Oil leaks → Replace the rear shock absorber
assembly.
● Shock absorber rod
Bends/damage → Replace the rear shock
absorber assembly.
● Spring
Fatigue → Replace the rear shock absorber
assembly.
Move the spring up and down.
● Gas cylinder
Damage/gas leaks → Replace the rear
shock absorber assembly.

CHECKING THE RELAY ARM AND
CONNECTING ARM
1.Check:
● Relay arm
● Connecting arm
Damage/wear → Replace.
● Bushings
● Spacers
● Oil seals
Damage/pitting/scratches → Replace.

4 - 58

REAR SHOCK ABSORBER AND RELAY ARM

CHAS

INSTALLING THE RELAY ARM AND
CONNECTING ARM
1.Install:
● Bushing 1
(to connecting arm)
NOTE:
Apply the lithium soap base grease on the
bushing when installing.
Installed depth of bushing a:
1 mm (0.04 in)

2.Install:
● Bushing 1
● Oil seal 2
New
(to relay arm)
NOTE:
Apply the lithium soap base grease on the
bushing when installing.
Installed depth of bushing a:
6.5 mm (0.26 in)

INSTALLING THE REAR SHOCK
ABSORBER
1.Install:
● Connecting arm
● Relay arm
● Rear shock absorber
NOTE:
When installing the rear shock absorber, lift up
the swingarm.
4 - 59

SWINGARM AND DRIVE CHAIN

CHAS

SWINGARM AND DRIVE CHAIN

Order

Job name/Part name
Removing the swingarm and drive
chain
Rear wheels and hub

Q’ty

Refer to “REAR WHEELS, WHEEL AXLE
AND HUB”.
Refer to “REAR SHOCK ABSORBER
AND RELAY ARM”.
Refer to “ENGINE REMOVAL” in CHAPTER 5.

Rear shock absorber

1
2
3
4
5
6
7

Left footrest and left footrest guard
bracket
Adjusting bolt/nut
Swingarm skid plate
Drive chain guide
Pivot shaft nut/washer
Pivot shaft
Swingarm
Drive sprocket cover

Remarks
Remove the parts in the order below.

2/2
1
1
1/1
1
1
1

4 - 60

Refer to “REMOVING THE SWINGARM”.

SWINGARM AND DRIVE CHAIN

Order
8
9
10
11
12
13
14
15
16
17
18
19
20

Job name/Part name
Nut
Lock washer
Drive sprocket
Drive chain
Collar
Spacer
Oil seal
Bearing
Dust cover/oil seal/washer
Spacer
Oil seal
Bushing
Bearing

Q’ty
1
1
1
1
1
1
1
1
1/1/1
1
2
2
2

4 - 61

CHAS

Remarks
Refer to “INSTALLING THE DRIVE
SPROCKET”.

Refer to “INSTALLING THE SWINGARM”.
For installation, reverse the removal procedure.

SWINGARM AND DRIVE CHAIN

CHAS

NOTE:
Before removing the drive chain and the
sprockets, measure the drive chain slack and
a ten link section of the drive chain.

REMOVING THE SWINGARM
1.Check:
● Swingarm free play

***********************************************
Checking steps:
● Check the tightening torque of the pivot shaft
nut.

Pivot shaft nut:
95 Nm (9.5 m • kg, 68 ft • lb)

the swingarm side play È by moving
it from side to side.
If side play is noticeable, check the collar,
spacers, bearings, bushings and frame pivot.
● Check the swingarm vertical movement É
by moving it up and down.
If vertical movement is tight or rough, or if
there is binding, check the collar, spacers,
bearings, bushings and frame pivot.
● Check

***********************************************
2.Remove:
● Pivot shaft nut
● Pivot shaft
● Swingarm

CHECKING THE SWINGARM
1.Check:
● Swingarm
Bends/cracks/damage → Replace.

4 - 62

SWINGARM AND DRIVE CHAIN

CHAS

2.Check:
● Pivot shaft
Roll the axle on a flat surface.
Bends → Replace.

WARNING
Do not attempt to straighten a bent pivot
shaft.

3.Clean:
● Pivot shaft
● Collar
● Spacers
● Bearings
● Bushings
Recommended cleaning solvent:
Kerosine
4.Check:
● Spacers
● Oil seals
Damage/wear → Replace.
● Bearings
● Bushings
Damage/pitting → Replace.

CHECKING THE DRIVE CHAIN
1.Measure:
● Ten-link section a of the drive chain
Out of specification → Replace the drive
chain.
Max. ten-link drive chain section:
150.1 mm (5.91 in)
NOTE:
● While measuring the ten-link section, push
down on the drive chain to increase its tension.
● Measure the length between drive chain
roller 1 and A as shown.
● Perform this measurement at two or three
different places.

4 - 63

SWINGARM AND DRIVE CHAIN

CHAS

2.Check:
● Drive chain
Stiffness → Clean and lubricate or replace.

3.Clean:
● Drive chain

***********************************************
● Wipe

the drive chain with a clean cloth.
the drive chain in kerosine and remove
any remaining dirt.

● Put

● Remove

the drive chain from the kerosine
and completely dry it.

CAUTION:
This machine has a drive chain with small
rubber O-rings 1 between the drive chain
side plates. Never use high-pressure water
or air, steam, gasoline, certain solvents
(e.g., benzine), or a coarse brush to clean
the drive chain. High-pressure methods
could force dirt or water into the drive
chain’s internals, and solvents will deteriorate the O-rings. A coarse brush can also
damage the O-rings. Therefore, use only
kerosine to clean the drive chain.

***********************************************

4.Check:
● O-rings 1
Damage → Replace the drive chain.
● Drive chain rollers 2
Damage/wear → Replace the drive chain.
● Drive chain side plates 3
Cracks/damage/wear → Replace the drive
chain.

4 - 64

SWINGARM AND DRIVE CHAIN

CHAS

5.Lubricate:
● Drive chain
Recommended lubricant:
Engine oil or chain lubricant
suitable for O-ring chains

6.Check:
● Drive sprocket
● Driven sprocket
More than 1/4 tooth a wear → Replace the
drive chain sprockets as a set.
Bent teeth → Replace the drive chain
sprockets as a set.
b Correct
1 Drive chain roller
2 Drive chain sprocket

INSTALLING THE SWINGARM
1.Install:
● Bearings 1
● Bushings 2
(to swingarm)
NOTE:
Apply the lithium soap base grease on the
bearing and bushing when installing.
Installed depth of bearing:
Left a: 0 mm (0 in)
Right b: 4 mm (0.16 in)
Installed depth of bushing c:
8 mm (0.31 in)

INSTALLING THE DRIVE SPROCKET
1.Install:
● Drive sprocket 1
● Lock washer 2
New
● Nut 3
70 Nm (7.0 m • kg, 50 ft • lb)
2.Bend the lock washer tab along a flat side of
the nut.
R.

4 - 65

ENGINE REMOVAL

ENG

ENGINE
ENGINE REMOVAL
MUFFLER AND EXHAUST PIPES

Order

1
2
3

Job name/Part name
Removing the muffler and exhaust
pipes
Seat/left footrest guard/engine
Skid plate
Front and rear fenders
Fuel tank and rubber covers
Muffler
Exhaust pipe 1
Exhaust pipe 2

Q’ty

Remarks
Remove the parts in the order below.

Refer to “SEAT, FENDERS AND FUEL
TANK” in CHAPTER 3.
1
1
1
For installation, reverse the removal procedure.

5-1

ENGINE REMOVAL

ENG

LEFT FOOTREST

Order
1
2
3
4
5

Job name/Part name
Removing the left footrest
Locknut
Locknut
Adjusting rod
Left footrest guard bracket
Left footrest

Q’ty
1
1
1
1
1

Remarks
Remove the parts in the order below.
Left-hand threads

For installation, reverse the removal procedure.

5-2

ENGINE REMOVAL

ENG

LEADS, CABLES AND HOSES

Order

Job name/Part name
Removing the leads, cables and
hoses
Engine oil
Coolant
Water jacket outlet pipe
Radiator outlet hose
Carburetors

Q’ty

Drain.
Drain.
Refer to “THERMOSTAT” in CHAPTER 6.
Refer to “WATER PUMP” in CHAPTER 6.
Refer to “CARBURETORS” in CHAPTER
7.
Refer to “REAR SHOCK ABSORBER
AND RELAY ARM” in CHAPTER 4.
Refer to “SWINGARM AND DRIVE
CHAIN” in CHAPTER 4.

Rear shock absorber and connecting
arm
Drive sprocket and swingarm
1
2
3

Remarks
Remove the parts in the order below.

Spark plug cap
Starter motor lead
Band

1
1
1

5-3

ENGINE REMOVAL

Order
4
5
6
7
8
9
10
11
12
13
14

Job name/Part name

Q’ty
Coupler
5
Speed sensor/O-ring
1/1
Neutral switch lead/reverse switch lead 1/1
Ground lead
1
Clutch cable
1
Parking brake cable
1
Reverse control cable
1
Oil pipe 2
1
Oil pipe 1
1
Oil tank breather hose
1
Crankcase breather hose
1

5-4

ENG

Remarks
Disconnect.

Disconnect.
Disconnect.
Disconnect.
Disconnect.
For installation, reverse the removal procedure.

ENGINE REMOVAL

ENG

ENGINE MOUNTING BOLTS

Order
1
2
3
4
5
6
7
8
9
10

Job name/Part name
Removing the engine mounting bolt
Engine mounting bolt (upper)/nut
Engine bracket bolt (upper)
Engine bracket (upper)
Engine mounting bolt (middle)/nut
Engine mounting bolt (lower)/nut
Engine bracket (middle-left)
Engine bracket (middle-right)
Engine bracket bolt (lower)
Engine bracket (lower-left)
Engine bracket (lower-right)

Q’ty
1/1
4
1
1/1
1/1
1
1
4
1
1

5-5

Remarks
Remove the parts in the order below.

CAUTION:
Install all of the bolts/nuts and then
tighten them to full torque specifications.
Refer to “INSTALLING THE ENGINE”.

ENGINE REMOVAL

Order
11

Job name/Part name
Engine assembly

ENG

Q’ty
Remarks
1 NOTE:
Remove the engine assembly from the
left side of the machine.
For installation, reverse the removal procedure.

5-6

ENGINE REMOVAL

ENG

INSTALLING THE ENGINE
1.Install:
● Engine brackets (lower) 1
● Engine bracket bolts (lower) 2
● Engine brackets (middle) 3
● Engine mounting bolt (lower)/nut 4
● Engine mounting bolt (middle)/nut 5
● Engine bracket (upper) 6
● Engine bracket bolts (upper) 7
● Engine mounting bolt (upper)/nut 8
NOTE:
Do not fully tighten the bolts and nuts.
2.Install:
● Swingarm
● Pivot shaft/nut 9
NOTE:
Do not fully tighten the pivot shaft nut.
3.Tighten:
● Engine bracket bolt (lower) 2
T.
R.

●

Engine bracket bolt (upper) 7
T.
R.

●

R.
R.
R.

40 Nm (4.0 m • kg, 29 ft • lb)

Pivot shaft/nut 9
T.
R.

5-7

56 Nm (5.6 m • kg, 40 ft • lb)

Engine mounting bolt (upper)/nut 8
T.

●

56 Nm (5.6 m • kg, 40 ft • lb)

Engine mounting bolt (middle)/nut 5
T.

●

33 Nm (3.3 m • kg, 24 ft • lb)

Engine mounting bolt (lower)/nut 4
T.

●

56 Nm (5.6 m • kg, 40 ft • lb)

95 Nm (9.5 m • kg, 68 ft • lb)

CYLINDER HEAD COVER

ENG

CYLINDER HEAD COVER

Order

1
2
3
4
5
6
7
8
9

Job name/Part name
Removing the cylinder head cover
Seat/front fender
Fuel tank/rubber cover 2
Engine mounting bolt/nut
Engine bracket (front-upper)
Oil tank breather hose
Union bolt
Copper washer
Oil delivery pipe 1
Spark plug
Tappet cover (intake)
Tappet cover (exhaust)

Q’ty

1/1
1
1
2
4
1
1
1
2

5-8

Remarks
Remove the parts in the order below.
Refer to “SEAT, FENDERS AND FUEL
TANK” in CHAPTER 3.

CYLINDER HEAD COVER

Order
10
11

Job name/Part name
Cylinder head cover
Dowel pin

ENG

Q’ty
Remarks
1
Refer to “REMOVING/INSTALLING CYLINDER HEAD COVER”.
2
For installation, reverse the removal procedure.

5-9

CYLINDER HEAD COVER

ENG

REMOVING THE CYLINDER HEAD COVER
1.Align:
● “I” mark
(with stationary pointer)

***********************************************
Checking steps:
● Turn the crankshaft counterclockwise with a
wrench.
● Align the “I” mark 1 on the rotor with the stationary pointer 2 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:
● When the piston is at the top dead center
(T.D.C.) on the compression stroke, there
should be clearance between the valve stem
tips and their respective rocker arm adjusting
screws.
● If there is no clearance, rotate the crankshaft
counterclockwise one turn.

***********************************************
2.Remove:
● Cylinder head cover
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all the
bolts are loosened, remove them.

CHECKING THE CYLINDER HEAD COVER
1.Check:
● Cylinder head cover
Cracks/damage → Replace the cylinder
head cover and cylinder head as a set.

5 - 10

CYLINDER HEAD COVER

ENG

CHECKING THE TAPPET COVER
1.Check:
● Tappet cover (intake) 1
● Tappet cover (exhaust) 2
● O-ring 3
New

INSTALLING THE CYLINDER HEAD COVER
1.Apply:

● Sealant (Quick Gasket ) 1
(to the mating surfaces of the cylinder head
and cylinder head cover)
Sealant (Quick Gasket) 1:
P/N. ACC-11001-05-01
Yamaha bond No. 1215:
P/N. 90890-85505

2.Install:
● Cylinder head cover
● Cable guides 1
● Washers 2
10 Nm (1.0 m • kg, 7.2 ft • lb)
● Bolts
R.

3 Bolt:
4 Bolt:
5 Bolt:
6 Bolt:
7 Bolt:

= 25 mm
= 40 mm
= 55 mm
= 115 mm
= 130 mm

NOTE:
Tighten the cylinder head cover bolts in
stages, using a crisscross pattern.

5 - 11

ROCKER ARMS

ENG

ROCKER ARMS

Order

1
2
3
4
5
6
7
8
9

Job name/Part name
Removing the rocker arm
Cylinder head cover
Plug/O-ring
Bolt
Rocker arm shaft 2/O-ring
Rocker arm 3
Rocker arm shaft 3/O-ring
Rocker arm 4
Rocker arm shaft 1/O-ring
Rocker arm 1
Rocker arm 2

Q’ty

1/1
2
1/1
1
1/1
1
1/1
1
1

5 - 12

Remarks
Remove the parts in the order below.
Refer to “CYLINDER HEAD COVER”.

Refer to “REMOVING/INSTALLING THE
ROCKER ARM”.

ROCKER ARMS

Order
10
11
12

Job name/Part name
Spring
Locknut
Valve adjuster

Q’ty
4
5
5

ENG

Remarks

For installation, reverse the removal procedure.

5 - 13

ROCKER ARMS

ENG

REMOVING THE ROCKER ARM
1.Remove:
● Rocker arm shafts 1
● Rocker arms 2
NOTE:
Use a slide hammer bolt 3 and weight 4 to
remove the rocker arm shafts.
Slide hammer set:
P/N. YU-01083-A
Slide hammer bolt (M6):
P/N. 90890-01083
Weight:
P/N. 90890-01084

CHECKING THE ROCKER ARM
1.Check:
● Rocker arm lobes 1
● Valve adjusters 2
Blue discoloration/pitting/scratches →
Replace.
2.Check:
● Rocker arms
● Rocker arm shafts
Damage/wear → Replace.

***********************************************
Checking steps:
● Check the two contact areas on the rocker
arms for signs of abnormal wear.
1) Rocker arm shaft hole.
2) Camshaft lobe contact surface.
Excessive wear → Replace.
● Check the surface of the rocker arm shafts.
Blue discoloration/pitting/scratches →
Replace/check lubrication.
● Measure the inside diameter a of the rocker
arm holes.
Out of specification → Replace.
Rocker arm inside diameter:
12.000 ~ 12.018 mm
(0.4724 ~ 0.4731 in)

5 - 14

ROCKER ARMS

ENG

the outside diameter b of the
rocker arm shafts.
Out of specification → Replace.

● Measure

Rocker arm outside diameter:
11.976 ~ 11.991 mm
(0.4715 ~ 0.4721 in)
● Calculate

the clearance by subtracting the
rocker arm shaft outside diameter from the
rocker arm inside diameter.
Clearance greater than 0.08 mm (0.003 in)
→ Replace the defective part(s).
Rocker arm to shaft standard
clearance:
0.009 ~ 0.042 mm
(0.0004 ~ 0.0017 in)

***********************************************
INSTALLING THE ROCKER ARM
1.Apply:
● Engine oil
(onto the rocker arm shafts)
2.Install:
● Rocker arms 1
● Rocker arm shafts 2
NOTE:
● The thread hole a of the rocker arm shaft
must face to the outside.
● After installation, make sure that the thread
hole a of the rocker arm shaft is positioned
correctly, as shown in the illustration.

5 - 15

CAMSHAFT AND CYLINDER HEAD

ENG

CAMSHAFT AND CYLINDER HEAD

Order

1
2
3
4
5

Job name/Part name
Removing the camshaft and cylinder head
Seat/front fender
Fuel tank/rubber covers
Carburetors
Water jacket outlet pipe
Muffler/exhaust pipe
Cylinder head cover
Timing chain tensioner cap bolt
Timing chain tensioner/gasket
Timing chain guide (exhaust)
Decompressor cam guide plate
Camshaft sprocket

Q’ty

Remarks
Remove the parts in the order below.
Refer to “SEAT, FENDERS AND FUEL
TANK” in CHAPTER 3.
Refer to “CARBURETORS” in CHAPTER
7.
Refer to “THERMOSTAT” in CHAPTER 6.
Refer to “ENGINE REMOVAL”.
Refer to “CYLINDER HEAD COVER”.

1
1/1
1
2
1

5 - 16

Refer to “REMOVING/INSTALLING THE
CAMSHAFT AND CYLINDER HEAD”.

CAMSHAFT AND CYLINDER HEAD

Order
6
7
8
9
10
11

Job name/Part name
Camshaft
Cylinder head
Cylinder head gasket
Dowel pin
Carburetor joint 1
Carburetor joint 2

ENG

Q’ty
Remarks
1
Refer to “CAMSHAFT AND CYLINDER
HEAD”.
1
1
2
1
1
For installation, reverse the removal procedure.

5 - 17

CAMSHAFT AND CYLINDER HEAD

ENG

REMOVING THE CAMSHAFT AND CYLINDER HEAD
1.Loosen:
● Camshaft sprocket bolts 1
2.Loosen:
● Timing chain tensioner cap bolt
3.Remove:
● Timing chain tensioner
● Timing chain guide (exhaust)
● Decompressor cam guide plates
● Camshaft sprocket
NOTE:
● Fasten a safety wire to the timing chain to
prevent it from falling into the crankcase.
● When removing the camshaft sprocket, it is
not necessary to separate the timing chain.

4.Remove:
● Cylinder head
NOTE:
● Loosen the bolts in the proper sequence.
● Follow the numerical order shown in the illustration. Loosen each bolt 1/4 of a turn at a
time until all of the bolts are loose.

5 - 18

CAMSHAFT AND CYLINDER HEAD

ENG

CHECKING THE CAMSHAFT
1.Check:
● Cam lobes
Pitting/scratches/blue discoloration →
Replace.
2.Measure:
● Cam lobes length a and b.
Out of specification → Replace.
Camshaft lobe limit:
Intake:
a 35.59 mm (1.4012 in)
b 30.05 mm (1.1831 in)
Exhaust:
a 36.40 mm (1.4331 in)
b 30.05 mm (1.1831 in)

CHECKING THE CAMSHAFT SPROCKET
1.Check:
● Camshaft sprocket
Wear/damage → Replace the camshaft
sprocket and timing chain as a set.
a 1/4 of a tooth
b Correct
1 Timing chain
2 Sprocket

CHECKING THE DECOMPRESSION SYSTEM
1.Check:
● Decompression system

***********************************************
Checking steps:
Check while the camshaft sprocket is installed
on the camshaft.
● Check that the decompressor lever pin 1
projects from the camshaft.
● Check that the decompressor cam 2 moves
smoothly.

***********************************************

5 - 19

CAMSHAFT AND CYLINDER HEAD

ENG

CHECKING THE TIMING CHAIN GUIDE
1.Check:
● Exhaust side timing chain guide
Wear/damage → Replace.

CHECKING THE TIMING CHAIN TENSIONER
1.Check:
● One-way cam operation (tensioner)
Unsmooth operation → Replace.

CHECKING THE CYLINDER HEAD
1.Eliminate:
● Carbon deposits (from the combustion
chambers)
Use a rounded scraper.
NOTE:
Do not use a sharp instrument to avoid damaging or scratching:
● Spark plug threads
● Valve seats
2.Check:
● Cylinder head
Scratches/damage → Replace the cylinder
head cover and cylinder head as a set.
● Cylinder head water jacket
Mineral deposits/rust → Eliminate.

5 - 20

CAMSHAFT AND CYLINDER HEAD

ENG

3.Measure:
● Cylinder head warpage
Out of specification → Resurface.
Cylinder head warpage:
Less than 0.05 mm (0.002 in)

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

***********************************************

INSTALLING THE CAMSHAFT AND CYLINDER HEAD
1.Install:
● Cylinder head
● Bolts (M9 : 1 ~ 6)
T.
R.
R.

Bolt (M6 : 7)

●

38 Nm (3.8 m · kg, 27 ft · lb)
10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:
● Tighten the bolts in the proper sequence.
● Follow the numerical order shown in the illustration. Tighten the bolts in two stages.

5 - 21

CAMSHAFT AND CYLINDER HEAD

ENG

2.Install:
● Camshaft
● Camshaft sprocket

***********************************************
Installation steps:
● Turn the crankshaft counterclockwise with a
wrench.
● Align the “I” mark 1 on the rotor with the stationary pointer 2 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.).

CAUTION:
Do not turn the crankshaft during the camshaft installation.

● Temporarily

install the camshaft sprocket on
the camshaft. (Do not install the bolts.) Then,
install the timing chain on the camshaft
sprocket.

NOTE:
Make sure the small holes 3 on the camshaft
face upward.

the notches 4 on the decompressor
cams with the projections 5 on the decompressor spring lever, then install the camshaft sprocket on the camshaft.

● Align

NOTE:
Check that each part is positioned as shown in
the illustration.
6 Small holes on camshaft sprocket
7 Punch mark on decompressor spring lever
8 Top front of cylinder head

5 - 22

CAMSHAFT AND CYLINDER HEAD

ENG

the decompressor cam guide plates 9
and camshaft sprocket bolts 0.

● Install

Camshaft sprocket bolt:
20 Nm (2.0 m • kg, 14 ft • lb)

● Remove

the retaining wire.

***********************************************

3.Install:
● Timing chain tensioner

***********************************************
Installation steps:
● Remove the timing chain tensioner cap bolt
1, washer 2 and spring 3.
● Release the timing chain tensioner one-way
cam 4 and push the tensioner rod 5 all the
way in.
● Install the tensioner 6 with a new gasket into
the cylinder.

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

WARNING
Always use a new gasket.
● Install

the spring, washer and timing chain
tensioner cap bolt.

Timing chain tensioner cap bolt:
22 Nm (2.2 m • kg, 16 ft • lb)

***********************************************
4.Check:
● Small holes on camshaft sprocket
● Rotor “I” mark
Out of alignment → Adjust.

5 - 23

VALVES AND VALVE SPRINGS

ENG

VALVES AND VALVE SPRINGS

Order

1
2
3
4
5
6
7
8

Job name/Part name
Removing the valve and valve
spring
Cylinder head
Valve cotter
Valve spring retainer
Intake valve spring
Exhaust valve spring
Intake valve
Exhaust valve
Valve stem seal
Valve spring seat

Q’ty

Remarks
Remove the parts in the order below.
Refer to “CAMSHAFT AND CYLINDER
HEAD”.

10
5
3
2
3
2
5
5

Refer to “REMOVING/INSTALLING THE
VALVE AND VALVE SPRING”.

For installation, reverse the removal procedure.

5 - 24

VALVES AND VALVE SPRINGS

ENG

REMOVING THE VALVE AND VALVE
SPRING
1.Check:
● Valve sealing
Leakage at the valve seat → Inspect the
valve face, valve seat and valve seat width.
Refer to “VALVE AND VALVE SPRING
INSPECTION”.

***********************************************
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.

***********************************************

2.Remove:
● Valve cotters
NOTE:
Attach a valve spring compressor 1 and
attachment 2 between the valve spring
retainer and the cylinder head to remove the
valve cotters.
Valve spring compressor:
P/N. YM-04019, 90890-04019
Valve spring compressor
attachment:
P/N. 90890-01243

5 - 25

VALVES AND VALVE SPRINGS

ENG

CHECKING THE VALVE AND VALVE
SPRING
1.Measure:
● Stem-to-guide clearance
Stem-to-guide clearance =
valve guide inside diameter a –
valve stem diameter b
Out of specification → Replace the valve
guide.
Clearance (stem to guide):
Intake:
0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
: 0.08 mm (0.0031 in)
Exhaust:
0.025 ~ 0.052 mm
(0.0010 ~ 0.0020 in)
: 0.10 mm (0.0039 in)

2.Replace:
● Valve guide

***********************************************
Replacement steps:
NOTE:
To ease guide removal, installation and to
maintain correct fit, heat the cylinder head to
100 °C (212 °F) in an oven.
● Remove

the valve guide using a valve guide
remover 1.
● Install the new valve guide using a valve
guide remover 1 and valve guide installer
2.
● After installing the valve guide, bore the
valve guide using a valve guide reamer 3 to
obtain proper stem-to-guide clearance.
Valve guide remover (ø 6):
P/N. YM-4064-A, 90890-04064
Valve guide installer (ø 6):
P/N. YM-04065-A, 90890-04065
Valve guide reamer (ø 6):
P/N. YM-04066, 90890-04066
NOTE:
After replacing the valve guide reface the valve
seat.

***********************************************
5 - 26

VALVES AND VALVE SPRINGS

ENG

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

4.Measure:
● Margin thickness a
Out of specification → Replace.
Margin thickness:
Intake:
0.85 ~ 1.15 mm
(0.0335 ~ 0.0453 in)
Exhaust:
0.85 ~ 1.15 mm
(0.0335 ~ 0.0453 in)

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

5 - 27

VALVES AND VALVE SPRINGS

ENG

8.Measure:
● Valve seat width a
Out of specification → Reface the valve seat.
Valve seat width:
Intake:
0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)
: 1.6 mm (0.0630 in)
Exhaust:
0.9 ~ 1.1 mm
(0.0354 ~ 0.0433 in)
: 1.6 mm (0.0630 in)

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

***********************************************

9.Lap:
● Valve face
● Valve seat
NOTE:
After refacing the valve seat or replacing the
valve and valve guide, the valve seat and
valve face should be lapped.

***********************************************
Lapping steps:
● Apply a coarse lapping compound to the
valve face.

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

stem.

5 - 28

molybdenum disulfide oil to the valve

VALVES AND VALVE SPRINGS

ENG

● 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.

***********************************************

10.Measure:
● Valve spring free length a
Out of specification → Replace.
Free length (valve spring):
Inner:
35.95 mm (1.42 in)
: 34.15 mm (1.34 in)
Outer:
37.75 mm (1.49 in)
: 35.86 mm (1.41 in)

5 - 29

VALVES AND VALVE SPRINGS

ENG

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

Compressed spring force:
Inner:
149 ~ 173 N at 27.2 mm
(15.19 ~ 17.64 kg,
33.50 ~ 38.89 lb at 1.07 in)
Outer:
165 ~ 191 N at 30.7 mm
(16.83 ~ 19.49 kg,
37.09 ~ 42.94 lb at 1.21 in)

12.Measure:
● Spring tilt a
Out of specification → Replace.
Spring tilt limit:
Inner:
2.5°/1.6 mm (0.06 in)
Outer:
2.5°/1.6 mm (0.06 in)

INSTALLING THE VALVE AND VALVE
SPRING
1.Apply:
● Molybdenum disulfide oil
(onto the valve stem and valve stem seal)
2.Install:
● Valve spring seats
● Valve stem seals New
● Valves
● Valve springs
● Valve spring retainers
NOTE:
Install the valve springs with the larger pitch a
facing upwards.
b Smaller pitch

5 - 30

VALVES AND VALVE SPRINGS

ENG

3.Install:
● Valve cotters
NOTE:
Install the valve cotters while compressing the
valve spring with the valve spring compressor
1 and attachment 2.
Valve spring compressor:
P/N. YM-04019, 90890-04019
Valve spring compressor
attachment:
P/N. 90890-01243

4.To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a piece of
wood.

CAUTION:
Hitting the valve tip with excessive force
could damage the valve.

5 - 31

CYLINDER AND PISTON

ENG

CYLINDER AND PISTON

Order

1
2
3
4
5
6
7
8

Job name/Part name
Removing the cylinder and piston
Water jacket inlet housing
Cylinder head

Q’ty

Cable guide
Cylinder/O-ring
Cylinder gasket
Dowel pin
Piston pin clip
Piston pin
Piston
Piston ring set

1
1/1
1
2
2
1
1
1

Remarks
Remove the parts in the order below.
Refer to “WATER PUMP” in CHAPTER 6.
Refer to “CAMSHAFT AND CYLINDER
HEAD”.
Refer to “INSTALLING THE CYLINDER”.

Refer to “REMOVING/INSTALLING THE
PISTON”.
For installation, reverse the removal procedure.

5 - 32

CYLINDER AND PISTON

ENG

REMOVING THE PISTON
1.Remove:
● Piston pin clips 1
● Piston pin 2
● Piston 3
NOTE:
● Put identification marks on each piston head
for reference during reinstallation.
● Before removing each piston pin, deburr the
clip groove and pin hole area. If the piston
pin groove is deburred and the piston pin is
still difficult to remove, use the piston pin
puller 4.
Piston pin puller:
P/N. YU-01304, 90890-01304

CAUTION:
Do not use a hammer to drive the piston
pin out.
2.Remove:
● Piston rings
NOTE:
Spread the end gaps apart while at the same
time lifting the piston ring over the top of the
piston crown, as shown in the illustration.

CHECKING THE CYLINDER AND PISTON
1.Check:
● Cylinder and piston walls
Vertical scratches → Rebore or replace the
cylinder and the piston.

2.Measure:
● Piston-to-cylinder clearance

***********************************************
Measurement steps:
1st step:
● Measure the cylinder bore “C” with a cylinder
bore gauge 1.
a 50 mm (2.0 in) from the top of the cylinder

5 - 33

ENG

CYLINDER AND PISTON

NOTE:
Measure cylinder bore “C” in parallel to and at
right angles to the cylinder matching surface.
Then, find the average of the measurements.
Standard
Cylinder
bore “C”

Wear limit

100.005 ~
100.100 mm
100.045 mm
(3.9404 in)
(3.9372 ~ 3.9388 in)
C = X+Y
2

● If

out of specification, rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
2nd step:
● Measure piston skirt diameter “P” with a
micrometer.
b 5.0 mm (0.20 in) from the piston bottom edge

Piston skirt diameter “P”:
Standard

99.945 ~ 99.995 mm
(3.9348 ~ 3.9368 in)

● If

out of specification, replace the piston and
piston rings as a set.
3rd step:
● Find the piston-to-cylinder clearance with the
following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance:
0.05 ~ 0.07 mm
(0.0020 ~ 0.0028 in)
: 0.15 mm (0.0059 in)
● If

out of specification, rebore or replace the
cylinder, and replace the piston and piston
rings as a set.

***********************************************

5 - 34

CYLINDER AND PISTON

ENG

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

Limit

Top
ring

0.04 ~ 0.08 mm
(0.0016 ~ 0.0031 in)

0.13 mm
(0.0051 in)

2nd
ring

0.03 ~ 0.07 mm
(0.0012 ~ 0.0028 in)

0.13 mm
(0.0051 in)

2.Position:
● Piston ring
(in cylinder)
NOTE:
Insert a ring into the cylinder and push it
approximately 50 mm (2.0 in) into the cylinder.
Push the ring with the piston crown so that the
ring will be at a right angle to the cylinder bore.
a 50 mm (2.0 in)

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

5 - 35

Standard

Limit

Top
ring

0.30 ~ 0.45 mm
(0.0118 ~ 0.0177 in)

0.70 mm
(0.0276 in)

2nd
ring

0.30 ~ 0.45 mm
(0.0118 ~ 0.0177 in)

0.80 mm
(0.0315 in)

Oil
ring

0.2 ~ 0.7 mm
(0.0079 ~ 0.0276 in)

—

CYLINDER AND PISTON

ENG

CHECKING THE PISTON PIN INSPECTION
1.Check:
● Piston pin
Blue discoloration/grooves → Replace, then
inspect the lubrication system.
2.Measure:
● Piston pin-to-piston clearance

***********************************************
Measurement steps:
● Measure the piston pin outside diameter a.
If out of specification, replace the piston pin.
Outside diameter (piston pin):
21.991 ~ 22.000 mm
(0.8658 ~ 0.8661 in)
● Measure

the piston inside diameter b.

Piston pin bore inside diameter:
22.004 ~ 22.015 mm
(0.8663 ~ 0.8667 in)
● Calculate

the piston pin-to-piston clearance
with the following formula.

Piston pin-to-piston clearance =
Bore size (piston pin) b –
Outside diameter (piston pin) a
● If

out of specification, replace the piston.
Piston pin-to-piston clearance:
0.004 ~ 0.024 mm
(0.00016 ~ 0.00094 in)
: 0.07 mm (0.003 in)

***********************************************

INSTALLING THE PISTON
1.Install:
● Piston rings
(onto the piston)
NOTE:
● Be sure to install the piston rings so that the
manufacturer’s marks or numbers are
located on the upper side of the rings.
● Lubricate the piston and piston rings liberally
with engine oil.

5 - 36

CYLINDER AND PISTON

ENG

2.Position:
● Top ring
● 2nd ring
● Oil ring
Offset the piston ring end gaps as shown.
a Top ring end
b Oil ring end (lower)
c Oil ring end (upper)
d 2nd ring end

3.Install:
● Piston 1
● Piston pin 2
● Piston pin clips 3

New

NOTE:
● Apply engine oil onto the piston pin, piston
ring and piston.
● Be sure that the arrow mark a on the piston
points to the exhaust side of the engine.
● Before installing the piston pin clip, cover the
crankcase with a clean rag to prevent the
piston pin clip from falling into the crankcase.
4.Lubricate:
● Piston
● Piston rings
● Cylinder
NOTE:
Apply a liberal coating of engine oil.

INSTALLING THE CYLINDER
1.Install:
● Cylinder
● O-ring New
42 Nm (4.2 m · kg, 30 ft · lb)
● Bolts (M10)
10 Nm (1.0 m · kg, 7.2 ft · lb)
● Bolts (M6)
R.

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

CAUTION:
●

●

5 - 37

Be careful not to damage the timing chain
damper during installation.
Pass the timing chain through the timing
chain cavity.

AC MAGNETO

ENG

AC MAGNETO

Order

1
2
3
4
5
6
7
8

Job name/Part name
Removing the AC magneto
Engine oil
Shift pedal link
Oil pipe 1
AC magneto coupler
Starter idle gear cover/gasket
Dowel pin
Starter idle gear 1
Starter idle gear 1 shaft
Bearing
AC magneto cover/gasket

Q’ty

1
2
1/1
1
1
1
1
1/1

5 - 38

Remarks
Remove the parts in the order below.
Drain.
Disconnect.
Disconnect.

Refer to “REMOVING/INSTALLING THE
AC MAGNETO ROTOR”.

AC MAGNETO

Order
9
10
11
12
13
14
15
16
17
18
19

Job name/Part name
Dowel pin/O-ring
Lead holder
Pickup coil
Stator assembly
Starter idle gear 2
Starter idle gear 2 shaft
Bearing
AC magneto rotor
Starter wheel gear
Woodruff key
Bearing/washer

ENG

Q’ty
Remarks
3/2
1
1
1
1
1
1
1
Refer to “REMOVING/INSTALLING THE
AC MAGNETO ROTOR”.
1
1
1/1
For installation, reverse the removal procedure.

5 - 39

AC MAGNETO

ENG

REMOVING THE AC MAGNETO ROTOR
1.Remove:
● AC magneto cover
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.

2.Remove:
● AC magneto rotor nut 1
● Washer
NOTE:
● While holding the AC magneto rotor 2 with
the sheave holder 3, loosen the generator
rotor nut.
● Do not allow the sheave holder to touch the
projection 4 on the rotor.
Sheave holder:
P/N. YS-01880, 90890-01701

3.Remove:
● AC magneto rotor 1
NOTE:
Use the flywheel puller 2.
Flywheel puller:
P/N. YU-33270, 90890-01362

CHECKING THE COIL
1.Check:
● Stator assembly
● Pickup coil
Damage → Replace.

5 - 40

AC MAGNETO

ENG

CHECKING THE STARTER CLUTCH
1.Check:
● Starter one-way clutch 1
Cracks/damage → Replace.
● Bolts 2 (starter clutch)
Loose → Replace.
NOTE:
The arrow mark on the starter clutch must face
inward, away from the AC magneto rotor.

Bolts (starter clutch):
16 Nm (1.6 m • kg, 11 ft • lb)
LOCTITE®

***********************************************
Checking steps:
● Install the starter wheel gear to the starter
clutch, and hold the starter clutch.
● When turning the starter wheel gear counter
clockwise È, the starter clutch and the wheel
gear should be engaged.
If not, the starter clutch is faulty. Replace it.
● When turning the starter wheel gear clockwise É, the starter wheel gear should turn
freely.
If not, the starter clutch is faulty. Replace it.

***********************************************

2.Check:
● Gear teeth (starter idle) 1
● Gear teeth (starter wheel) 2
Burrs/chips/roughness/wear → Replace.

3.Check:
● Starter wheel gear
(contacting surface)
Damage/pitting/wear → Replace.

5 - 41

AC MAGNETO

ENG

INSTALLING THE AC MAGNETO ROTOR
1.Apply:
®
● Sealant (Quick Gasket ) 1
(into the slit)
Sealant (Quick Gasket®):
P/N. ACC-11001-05-01
Yamaha bond No. 1215®:
P/N. 90890-85505

2.Install:
● Woodruff key
● AC magneto rotor
NOTE:
● Before installing the rotor, clean the outside
of the crankshaft and the inside of the rotor.
● After installing the rotor, check that the rotor
rotates smoothly. If not, reinstall the key and
rotor.
3.Tighten:
● AC magneto rotor nut 1
T.
R.

150 Nm (15.0 m • kg, 110 ft • lb)

NOTE:
● While holding the AC magneto rotor 2 with
the sheave holder 3, tighten the generator
rotor nut.
● Do not allow the sheave holder to touch the
projection 4 on the rotor.
Sheave holder:
P/N. YS-01880, 90890-01701

4.Install:
● AC magneto cover
● Oil pipe holder 1
● Ground lead 2
10 Nm (1.0 m • kg, 7.2 ft • lb)
● Bolts
R.

NOTE:
Tighten the AC magneto cover bolts in stages,
using a crisscross pattern.

5 - 42

CLUTCH

ENG

CLUTCH

Order

1
2
3
4
5
6
7
8

Job name/Part name
Removing the clutch cover
Engine assembly
Oil filter bolt
Union bolt
Copper washer
Oil delivery pipe 1
Union bolt
Copper washer
Oil delivery pipe 2
Clutch cover

9
10

Clutch cover gasket
Dowel pin

Q’ty

1
2
4
1
2
4
1
1

Remarks
Remove the parts in the order below.
Refer to “ENGINE REMOVAL”.

Refer to “REMOVING/INSTALLING THE
CLUTCH”.

1
2
For installation, reverse the removal procedure.

5 - 43

CLUTCH

Order
1
2
3
4
5
6
7
8

Job name/Part name
Removing the pull lever shaft
Circlip
Pull lever
Pull lever spring
Bolt
Pull lever shaft
Oil seal
Bearing
Bearing

Q’ty

ENG

Remarks
Remove the parts in the order below.

1
1
1
1
1
1
1
1
For installation, reverse the removal procedure.

5 - 44

CLUTCH

Order
1
2
3
4
5
6
7
8
9
10

Job name/Part name
Removing the clutch
Clutch spring
Pressure plate
Pull rod
Bearing
Friction plate 2
Clutch plate
Friction plate 1
Cushion spring
Lock washer
Clutch boss

Q’ty
5
1
1
1
2
7
6
1
1
1

5 - 45

ENG

Remarks
Remove the parts in the order below.
Refer to “INSTALLING THE CLUTCH”.

Inside diameter = 116 mm (4.57 in)
Inside diameter = 112 mm (4.41 in)
Refer to “REMOVING/INSTALLING THE
CLUTCH”.

CLUTCH

Order
11
12
13
14
15
16
17
18
19
20
21
22
23

Job name/Part name
Thrust washer
Clutch housing
Lock washer
Balancer driven gear
Straight key
Lock washer
Primary drive gear
Balancer drive gear
Spring
Dowel pin
Plate
Straight key
Washer

Q’ty
1
1
1
1
1
1
1
1
16
16
1
1
1

ENG

Remarks
Refer to “INSTALLING THE CLUTCH”.

Refer to “REMOVING/INSTALLING THE
PRIMARY DRIVE GEAR AND BALANCER DRIVEN GEAR”.

For installation, reverse the removal procedure.

5 - 46

CLUTCH

ENG

REMOVING THE CLUTCH
1.Remove:
● Clutch cover
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.

2.Straighten the lock washer tab.
3.Loosen:
● Clutch boss nut 1
NOTE:
While holding the clutch boss 2 with the clutch
holding tool 3, loosen the clutch boss nut.
Clutch holding tool:
P/N. YM-91042, 90890-04086

REMOVING THE PRIMARY DRIVE GEAR
AND BALANCER DRIVEN GEAR
1.Straighten the lock washer tabs.
2.Loosen:
● Primary drive gear nut 1
● Balancer driven gear nut 2
NOTE:
Place an aluminum plate 3 between the teeth
of the balancer drive gear 4 and balancer
driven gear 5.

5 - 47

CLUTCH

ENG

CHECKING THE FRICTION PLATE
The following procedure applies to all of the
friction plates.
1.Check:
● Friction plate
Damage/wear → Replace the friction plates
as a set.

2.Measure:
● Friction plate thickness
Out of specification → Replace the friction
plates as a set.
NOTE:
Measure the friction plate at four places.
Friction plate 1 thickness:
2.74 ~ 2.86 mm (0.108 ~ 0.113 in)
: 2.6 mm (0.102 in)
Friction plate 2 thickness:
2.94 ~ 3.06 mm (0.116 ~ 0.120 in)
: 2.8 mm (0.110 in)

CHECKING THE CLUTCH PLATE
The following procedure applies to all of the
clutch plates.
1.Check:
● Clutch plate
Damage → Replace the clutch plates as a
set.
2.Measure:
● Clutch plate warpage
(with a surface plate and thickness gauge 1)
Out of specification → Replace the clutch
plates as a set.
Maximum clutch plate warpage:
0.2 mm (0.008 in)

5 - 48

CLUTCH

ENG

CHECKING THE CLUTCH SPRING
The following procedure applies to all of the
clutch springs.
1.Check:
● Clutch spring
Damage → Replace the clutch springs as a
set.

2.Measure:
● Clutch spring free length a
Out of specification → Replace the clutch
springs as a set.
Clutch spring free length:
42.8 mm (1.69 in)
: 40.7 mm (1.60 in)

CHECKING THE CLUTCH HOUSING
1.Check:
● Clutch housing dogs
Damage/pitting/wear → Deburr the clutch
housing dogs or replace the clutch housing.
NOTE:
Pitting on the clutch housing dogs will cause
erratic clutch operation.

CHECKING THE CLUTCH BOSS
1.Check:
● Clutch boss splines
Damage/pitting/wear → Replace the clutch
boss.
NOTE:
Pitting on the clutch boss splines will cause
erratic clutch operation.

CHECKING THE PRESSURE PLATE
1.Check:
● Pressure plate
Cracks/damage → Replace.

5 - 49

CLUTCH

ENG

CHECKING THE PULL LEVER SHAFT AND
PULL ROD
1.Check:
● Pull lever shaft pinion gear teeth a
● Pull rod teeth b
Damage/wear → Replace the pull lever shaft
and pull rod as a set.
2.Check:
● Pull rod bearing
Damage/wear → Replace.

CHECKING THE PRIMARY DRIVE
1.Check:
● Primary drive gear 1
● Primary driven gear 2
Damage/wear → Replace the primary drive
gear and clutch housing as a set.
Excessive noise during operation → Replace
the primary drive gear and clutch housing as
a set.
CHECKING THE BALANCER DRIVE
1.Check:
● Balancer drive gear 1
● Balancer driven gear 2
Damage/wear → Replace the balancer drive
gear and balancer driven gear as a set.
Excessive noise during operation → Replace
the balancer drive gear and balancer driven
gear as a set.

5 - 50

CLUTCH

ENG

INSTALLING THE PRIMARY DRIVE GEAR
AND BALANCER DRIVEN GEAR
1.Install:
● Dowel pin
● Spring
● Balancer drive gear
(onto the primary drive gear)
NOTE:
Align the punch mark a on the balancer drive
gear with the punch mark b on the primary
drive gear.

2.Install:
● Primary drive gear
● Balancer driven gear
NOTE:
Align the punch mark a on the balancer driven
gear with the punch mark b on the primary
drive gear.

3.Tighten:
● Balancer driven gear nut 1
T.
R.

●

140 Nm (14.0 m • kg, 100 ft • lb)

Primary drive gear nut 2
T.
R.

150 Nm (15.0 m • kg, 110 ft • lb)

NOTE:
● Place an aluminum plate 3 between the
teeth of the balancer drive gear 4 and balancer driven gear 5.
● Apply the molybdenum disulfide grease to
the thread of axles and nuts.
4.Bend the lock washer tabs along the balancer driven gear nut.
5.Bend the lock washer tabs along a flat side
of the primary drive gear nut.

5 - 51

CLUTCH

ENG

INSTALLING THE CLUTCH
1.Install:
● Clutch housing 1
NOTE:
● Make sure that the primary driven gear teeth
and primary drive gear teeth mesh correctly.
● Make sure that the oil pump drive gear teeth
and oil pump driven gear teeth mesh correctly.

2.Tighten:
● Clutch boss nut 1
T.
R.

90 Nm (9.0 m • kg, 65 ft • lb)

NOTE:
While holding the clutch boss 2 with the clutch
holding tool 3, tighten the clutch boss nut.
Clutch holding tool:
P/N. YM-91042, 90890-04086
3.Bend the lock washer tab along a flat side of
the nut.

4.Install:
● Pressure plate 1
NOTE:
Align the punch mark a on the pressure plate
with the punch mark b on the clutch boss.

5 - 52

CLUTCH

T.
R.

5.Install:
● Clutch spring

ENG

8 Nm (0.8 m • kg, 5.8 ft • lb)

NOTE:
Tighten the bolts in stages, using a crisscross
pattern.

6.Install:
● Clutch cover
NOTE:
Be sure to mesh the pull lever shaft with the
pull rod teeth to ensure that the mark a on pull
lever 1 is at the closest position to stationary
pointer b onto the clutch cover when the
clutch is engaged.

7.Install:
● Clutch cable holder 1
● Bolts
10 Nm (1.0 m • kg, 7.2 ft • lb)
R.

2 Bolt:
3 Bolt:
4 Bolt:
5 Bolt:

= 25 mm
= 30 mm
= 35 mm
= 50 mm

NOTE:
Tighten the bolts in stages, using a crisscross
pattern.

5 - 53

OIL PUMP

ENG

OIL PUMP

Order

1
2
3
4
5

Job name/Part name
Removing the oil pump
Clutch
Circlip
Oil pump driven gear
Oil pump
Oil pump gasket
O-ring

Q’ty

Remarks
Remove the parts in the order below.
Refer to “CLUTCH”.

1
1
1
1
2
For installation, reverse the removal procedure.

5 - 54

OIL PUMP

Order
1
2
3
4
5
6
7
8
9
0
A

Job name/Part name
Disassembling the oil pump
Oil pump housing 1/oil seal
Oil pump outer rotor 1
Dowel pin
Oil pump inner rotor 1
Oil pump housing cover/oil seal
Dowel pin
Oil pump shaft
Dowel pin
Oil pump inner rotor 2
Oil pump outer rotor 2
Oil pump housing 2

Q’ty
1/1
1
1
1
1/1
2
1
1
1
1
1

ENG

Remarks
Remove the parts in the order below.

Refer to “ASSEMBLING THE OIL
PUMP”.
For assembly, reverse the disassembly
procedure.

5 - 55

OIL PUMP

ENG

CHECKING THE OIL PUMP
1.Check:
● Oil pump driven gear
● Oil pump housings
● Oil pump housing cover
Cracks/wear/damage → Replace.

2.Measure:
● Tip clearance a
(between the inner rotor 1 and the outer
rotor 2)
● Side clearance b
(between the outer rotor 2 and the pump
housing 3)
Out of specification → Replace the oil pump.
Tip clearance a:
0.12 mm (0.005 in)
: 0.2 mm (0.008 in)
Side clearance b:
0.03 ~ 0.08 mm (0.001 ~ 0.003 in)

3.Check:
● Oil pump operation
Unsmooth → Repeat steps (1) and (2) or
replace the defective parts.

ASSEMBLING THE OIL PUMP
1.Install:
● Oil pump inner rotor 2
● Oil pump outer rotor 2
NOTE:
Align the match mark a on the inner rotor 2
with the match mark b on the outer rotor 2.

5 - 56

SHIFT SHAFT

ENG

SHIFT SHAFT

Order

1
2
3
4
5
6
7
8

Job name/Part name
Removing the shift shaft
Clutch
Shift arm
Shift shaft
Shift shaft spring
Collar
Roller
Stopper lever
Stopper lever spring
Roller

Q’ty

1
1
1
1
1
1
1
1

5 - 57

Remarks
Remove the parts in the order below.
Refer to “CLUTCH”.

Refer to “INSTALLING THE SHIFT
SHAFT”.

Refer to “INSTALLING THE STOPPER
LEVER”.

SHIFT SHAFT

Order
9
10
11
12
13
14
15

Job name/Part name
Shift guide
Shift lever
Pawl
Pawl pin
Spring
Segment
Oil seal

ENG

Q’ty
Remarks
1
1
2
Refer to “INSTALLING THE SHIFT
LEVER”.
2
2
1
1
For installation, reverse the removal procedure.

5 - 58

SHIFT SHAFT

ENG

CHECKING THE SHIFT SHAFT
1.Check:
● Shift shaft 1
Bends/damage/wear → Replace.
● Shift shaft spring 2
Damage/wear → Replace.

CHECKING THE STOPPER LEVER
1.Check:
● Stopper lever 1
Bends/damage → Replace.
Roller turns roughly → Replace the stopper
lever.
● Stopper spring 2
Damage → Replace.

CHECKING THE SHIFT GUIDE AND SHIFT
LEVER
1.Check:
● Shift guide 1
● Shift lever 2
● Pawl 3
● Pawl pin 4
● Spring 5
Damage/wear → Replace.
CHECKING THE SEGMENT
1.Check:
● Segment
Damage/wear → Replace.

INSTALLING THE SHIFT LEVER
1.Install:
● Segment 1
● Segment bolt
30 Nm (3.0 m • kg, 22 ft • lb)
R.

NOTE:
Align the notch a on the segment with the pin
b on the shift cam.

5 - 59

SHIFT SHAFT

ENG

2.Install:
● Springs 1
● Pawl pins 2
● Pawls 3
● Shift guide 4
(to the shift lever)

3.Install:
● Shift lever assembly 1
● Shift guide 2
NOTE:
The shift lever assembly is installed at the
same time as the shift guide.

INSTALLING THE STOPPER LEVER
1.Install:
● Roller
● Stopper lever spring 1
● Stopper lever 2
NOTE:
● Hook the ends of the stopper lever spring
onto the stopper lever and the crankcase
boss.
● Mesh the stopper lever with the shift drum
segment.

5 - 60

SHIFT SHAFT

ENG

INSTALLING THE SHIFT SHAFT
1.Install:
● Roller 1
● Collar
● Shift shaft spring
● Shift shaft 2
NOTE:
● Install the end of the shift shaft spring onto
the shift shaft spring stopper 3.
● Install the end of the shift shaft lever onto the
roller 1.

T.
R.

2.Install:
● Shift arm 1
● Bolt 2

10 Nm (1.0 m • kg, 7.2 ft • lb)

NOTE:
Be sure to install the shaft arm so that position
a is horizontal.

5 - 61

CRANKCASE

ENG

CRANKCASE
TIMING CHAIN AND SPEED SENSOR ROTOR

Order

1
2

Job name/Part name
Removing the timing chain and
speed sensor rotor
Engine assembly
Cylinder head cover
Cylinder head

Q’ty

Remarks
Remove the parts in the order below.
Refer to “ENGINE REMOVAL”.
Refer to “CYLINDER HEAD COVER”.
Refer to “CAMSHAFT AND CYLINDER
HEAD”.
Refer to “CYLINDER AND PISTON”.
Refer to “AC MAGNETO”.
Refer to “CLUTCH”.

Cylinder and piston
AC rotor
Clutch, balancer drive gear and balancer driven gear
Oil pump
Shift shaft and shift drum segment
Timing chain guide (intake)
Timing chain

Refer to “OIL PUMP”.
Refer to “SHIFT SHAFT”.
1
1

5 - 62

CRANKCASE

Order
3
4
5
6
7
8
9
10
11
12

Job name/Part name
Reverse shift lever
Reverse shift lever spring
Circlip
Neutral switch
Reverse switch
Oil pipe joint
Circlip
Wave washer
Speed sensor rotor
Circlip

Q’ty
1
1
1
1
1
1
1
1
1
1

ENG

Remarks

For installation, reverse the removal procedure.

5 - 63

CRANKCASE

ENG

CRANKCASE

Order
1
2
3
4
5
6
7

Job name/Part name
Separating the crankcase
Right crankcase
Dowel pin
Dowel pin/O-ring
Left crankcase
Oil strainer
Cover
Oil strainer gasket

Q’ty
1
2
1/1
1
1
1
1

Remarks
Remove the parts in the order below.
Refer to “CRANKCASE”.

For installation, reverse the removal procedure.

5 - 64

CRANKCASE

ENG

CRANKCASE BEARING

Order

1
2
3
4

Job name/Part name
Removing the crankcase bearing
Crankshaft and balancer

Q’ty

Transmission
Oil seal retainer
Oil seal
Bearing retainer
Bearing

Remarks
Remove the parts in the order below.
Refer to “CRANKSHAFT AND BALANCER”.
Refer to “TRANSMISSION”.

1
3
3
8
For installation, reverse the removal procedure.

5 - 65

CRANKCASE

ENG

SEPARATING THE CRANKCASE
1.Separate:
● Left crankcase
● Right crankcase

***********************************************
Separation steps:
● Remove the crankcase bolts.
NOTE:
● Loosen each bolt 1/4 of a turn at a time and
after all the bolts are loosened, remove
them.
● Loosen the bolts in stages, using a crisscross pattern.

È Left crankcase
É Right crankcase
● Remove

the right crankcase.

CAUTION:
Use a soft hammer to tap on one side of the
crankcase. Tap only on reinforced portions
of the crankcase. Do not tap on the crankcase mating surfaces. Work slowly and
carefully. Make sure that the crankcase
halves separate evenly.
● Remove

the dowel pins and O-ring.

***********************************************
CHECKING THE TIMING CHAIN AND GUIDE
1.Check:
● Timing chain
Cracks/stiff → Replace the timing chain and
camshaft sprocket as a set.
2.Check:
● Intake side timing chain guide
Wear/damage → Replace.

CHECKING THE OIL STRAINER
1.Check:
● Oil strainer
Damage → Replace.
Contaminations → Clean with engine oil.

5 - 66

CRANKCASE

ENG

CHECKING THE CRANKCASE
1.Thoroughly wash the case halves in a mild
solvent.
2.Clean all the gasket mating surfaces and
crankcase mating surfaces thoroughly.
3.Check:
● Crankcase
Cracks/damage → Replace.
● Oil delivery passages
Clogged → Blow out with compressed air.

CHECKING THE BEARINGS
1.Check:
● Bearing
Clean and lubricate, then rotate the inner
race with a finger.
Roughness → Replace.

ASSEMBLING THE CRANKCASE
1.Apply:
®
● Sealant (Quick Gasket ) 1
(to the mating surfaces of both case halves)
Sealant (Quick Gasket®):
P/N. ACC-11001-05-01
Yamaha bond No. 1215:
P/N. 90890-85505
2.Install:
● Dowel pin 2
● O-ring 3
New

5 - 67

CRANKCASE

ENG

3.Fit the right crankcase onto the left crankcase. Tap lightly on the case with a soft hammer.

CAUTION:
Before installing and torquing the crankcase holding bolts, be sure to check
whether the transmission is functioning
properly by manually rotating the shift cam
in both directions.

4.Install:
● Lead guides 1
● Hose guide 2
● Crankcase bolts
5.Tighten:
● Crankcase bolts
(follow the proper tightening sequence)

T.
R.

10 Nm (1.0 m • kg, 7.2 ft • lb)

È Right crankcase
É Left crankcase
3 Bolt: = 30 mm
4 Bolt: = 45 mm
5 Bolt: = 60 mm
6 Bolt: = 65 mm
7 Bolt: = 80 mm

NOTE:
Tighten the bolts in stages, using a crisscross
pattern.

6.Apply:
● 4-stroke engine oil
(to the crank pin, bearing and oil delivery
hole)
7.Check:
● Crankshaft and transmission operation
Unsmooth operation → Repair.

5 - 68

CRANKSHAFT AND BALANCER

ENG

CRANKSHAFT AND BALANCER

Order

1
2

Job name/Part name
Removing the crankshaft and balancer
Crankcase
Balancer
Crankshaft

Q’ty

Remarks
Remove the parts in the order below.
Separate. Refer to “CRANKCASE”.

1
1

5 - 69

Refer to “REMOVING/INSTALLING THE
CRANKSHAFT”.
For installation, reverse the removal procedure.

CRANKSHAFT AND BALANCER

ENG

REMOVING THE CRANKSHAFT
1.Remove:
● Crankshaft
Use a crankcase separating tool 1.
Crankcase separating tool:
P/N. YU-01135-A, 90890-01135

CHECKING THE CRANKSHAFT
1.Measure:
● Crank width A
Out of specification → Replace the crankshaft.
Crank width:
74.95 ~ 75.00 mm
(2.9508 ~ 2.9528 in)
●

Side clearance D
Out of specification → Replace the crankshaft.
Big end side clearance:
0.32 ~ 0.64 mm
(0.0126 ~ 0.0252 in)
: 1.0 mm (0.040 in)

●

Runout C
Out of specification → Replace the crankshaft.
Runout limit:
C1: 0.03 mm (0.0012 in)
C2: 0.03 mm (0.0012 in)

***********************************************
Crankshaft reassembling point:
The crankshaft 1 and the crank pin 2 oil passages must be properly interconnected with a
tolerance of less than 1 mm (0.04 in).

***********************************************
CAUTION:
The buffer boss and woodruff key should
be replaced when removed from the crankshaft.

5 - 70

CRANKSHAFT AND BALANCER

ENG

INSTALLING THE CRANKSHAFT
1.Install:
● Crankshaft
Crankshaft installer pot 1:
P/N. 90890-01274
Crankshaft installer bolt 2:
P/N. 90890-01275
Crankshaft installer set 3:
P/N. YU-90050
Adapter 4:
P/N. YM-90069, 90890-04059
Spacer (crankshaft installer) 5:
P/N. YM-91044, 90890-04081
Spacer 6:
P/N. 90890-01016
NOTE:
Hold the connecting rod at the Top Dead Center (TDC) 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.

CAUTION:
Apply engine oil to each bearing to protect
the crankshaft against scratches and to
make installation easier.

5 - 71

TRANSMISSION

ENG

TRANSMISSION

Order

1
2
3
4
5
6
7
8
9
10

Job name/Part name
Removing the transmission
Crankcase
Shift fork guide bar (short)
Shift fork “C”
Shift fork guide bar (long)
Shift fork “R”
Shift fork “L”
Shift drum
Reverse shift shaft
Main axle assembly
Spacer/O-ring
Drive axle

Q’ty

1
1
1
1
1
1
1
1
1/1
1

5 - 72

Remarks
Remove the parts in the order below.
Separate. Refer to “CRANKCASE”.

Refer to “INSTALLING THE TRANSMISSION”.

TRANSMISSION

Order
11
12

Job name/Part name
Counter axle
Counter gear

Q’ty
1
1

ENG

Remarks

For installation, reverse the removal procedure.

5 - 73

TRANSMISSION

ENG

MAIN AXLE

Order
1
2
3
4
5
6
7

Job name/Part name
Disassembling the main axle
Reverse pinion gear
4th pinion gear
2nd/3rd pinion gear
Circlip
Toothed washer
5th pinion gear
Main axle/1st pinion gear

Q’ty
1
1
1
1
1
1
1

Remarks
Remove the parts in the order below.

Refer to “ASSEMBLING THE MAIN
AXLE AND DRIVE AXLE”.

For assembly, reverse the disassembly
procedure.

5 - 74

TRANSMISSION

ENG

DRIVE AXLE

Order
1
2
3
4
5
6
7
8
9
0

Job name/Part name
Disassembling the drive axle
Washer
1st wheel gear
5th wheel gear
Circlip
Toothed washer
3rd wheel gear
Toothed collar
Toothed lock washer
Toothed lock washer retainer
2nd wheel gear

Q’ty
1
1
1
3
3
1
2
1
1
1

5 - 75

Remarks
Remove the parts in the order below.

Refer to “ASSEMBLING THE MAIN
AXLE AND DRIVE AXLE”.

TRANSMISSION

Order
A
B
C
D

Job name/Part name
4th wheel gear
Reverse wheel gear
Collar
Drive axle

Q’ty
1
1
1
1

ENG

Remarks

For assembly, reverse the disassembly
procedure.

5 - 76

TRANSMISSION

ENG

CHECKING THE SHIFT FORK
1.Check:
● Shift fork cam follower 1
● Shift fork pawl 2
Scoring/bends/wear/damage → Replace.

2.Check:
● Guide bar
Roll the guide bar on a flat surface.
Bends → Replace.

WARNING
Do not attempt to straighten a bent guide
bar.

3.Check:
● Shift fork movement
(on the guide bar)
Unsmooth operation → Replace the shift fork
and the guide bar as a set.

CHECKING THE SHIFT DRUM
1.Check:
● Shift cam grooves
Scratches/wear/damage → Replace.

CHECKING THE TRANSMISSION
1.Measure:
● Main axle runout
(with a centering device and dial gauge 1)
Out of specification → Replace the main axle.
Maximum main axle runout:
0.08 mm (0.0031 in)

5 - 77

TRANSMISSION

ENG

2.Measure:
● Drive axle runout
(with a centering device and dial gauge 1)
Out of specification → Replace the drive axle.
Maximum drive axle runout:
0.08 mm (0.0031 in)

3.Check:
● Transmission gears
Blue discoloration/pitting/wear → Replace
the defective gear(s).
● Transmission gear dogs
Cracks/damage/rounded edges → Replace
the defective gear(s).
4.Check:
● Transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission
axle assemblies.
5.Check:
● Transmission gear movement
Rough movement → Replace the defective
part(s).
6.Check:
● Circlips
Bends/damage/looseness → Replace.
ASSEMBLING THE MAIN AXLE AND DRIVE
AXLE
1.Install:
● Toothed washer 1
● Circlip 2
New
NOTE:
● Be sure the circlip shap-edged corner a is
positioned opposite side to the toothed
washer and gear.
● Be sure the circlip end b is positioned at
axle spline groove c.

5 - 78

TRANSMISSION

ENG

2.Install:
● Reverse pinion gear 1
NOTE:
Press the reverse pinion gear into the main
axle 2, as shown in the illustration.
a 115.65 ~ 115.85 mm (4.553 ~ 4.561 in)

INSTALLING THE TRANSMISSION
1.Install:
● Shift drum 1
● Shift fork “L” 2
● Shift fork “R” 3
● Shift fork guide bar (long) 4
● Shift fork “C” 5
● Shift fork guide bar (short) 6
NOTE:
The embossed marks on the shift forks should
face towards the right side of the engine and
be in the following sequence: “R”, “C”, “L”.

2.Check:
● Transmission
Rough movement → Repair.
NOTE:
● Oil each gear and bearing thoroughly.
● Before assembling the crankcase, be sure
that the transmission is in neutral and that
the gears turn freely.

5 - 79

RADIATOR

COOL

COOLING SYSTEM
RADIATOR

Order

1
2
3
4
5
6
7
8
9
10

Job name/Part name
Removing the radiator
Front panel and front fender

Q’ty

Coolant
Radiator fan coupler
Thermo switch coupler
Coolant reservoir hose
Radiator fan breather hose
Radiator outlet hose
Radiator inlet hose
Radiator
Radiator fan
Thermo switch 1
Coolant reservoir breather hose

1
1
1
1
1
1
1
1
1
1

6-1

Remarks
Remove the parts in the order below.
Refer to “SEAT, FENDERS AND FUEL
TANK” in CHAPTER 3.
Drain.
Disconnect.
Disconnect.
Disconnect.
Disconnect.
Disconnect.

RADIATOR

Order
11
12

Job name/Part name
Coolant reservoir
Coolant reservoir cap

Q’ty
1
1

COOL

Remarks

For installation, reverse the removal procedure.

6-2

RADIATOR

COOL

CHECKING THE RADIATOR
1.Check:
● Radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the radiator.
Damage → Repair or replace.
OTE:
Straighten any flattened fins with a thin, flathead screwdriver.
2.Check:
● Radiator hoses
Cracks/damage → Replace.

3.Measure:
● Radiator cap opening pressure
Below the specified pressure → Replace the
radiator cap.
Radiator cap opening pressure:
95 ~ 125 kPa
(0.95 ~ 1.25 kg/cm2,
13.8 ~ 18.1 psi)

***********************************************
Measurement steps:
● Install the radiator cap tester 1 and adapter
2 onto the radiator cap 3.
Radiator cap tester:
P/N. YU-24460-01, 90890-01325
Adapter:
P/N. YU-33984, 90890-01352
● Apply

the specified pressure for ten seconds
and make sure that there is no drop in pressure.

***********************************************
4.Check:
● Radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” in CHAPTER
9.
6-3

RADIATOR

COOL

INSTALLING THE RADIATOR
1.Fill:
● Cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
CHAPTER 3.
2.Check:
● Cooling system
Leaks → Repair or replace any faulty part.

6-4

THERMOSTAT

COOL

THERMOSTAT

Order

1
2
3
4
5
6
7

Job name/Part name
Removing the thermostat
Front panel and front fender

Q’ty

Coolant
Radiator
Radiator inlet hose
Front fender bracket
Thermostat inlet hose
Water jacket outlet pipe
O-ring
Thermostat assembly
Thermo switch 2

Remarks
Remove the parts in the order below.
Refer to “SEAT, FENDERS AND FUEL
TANK” in CHAPTER 3.
Drain.
Refer to “RADIATOR”.

1
1
1
1
1
1
1
For installation, reverse the removal procedure.

6-5

THERMOSTAT

Order
1
2
3
4

Job name/Part name
Disassembling the thermostat
Thermostat cover
O-ring
Thermostat
Thermostat housing

Q’ty
1
1
1
1

COOL

Remarks
Remove the parts in the order listed.
Refer to “ASSEMBLING THE THERMOSTAT”.
For assembly, reverse the disassembly
procedure.

6-6

THERMOSTAT

COOL

CHECKING THE THERMOSTAT
1.Check:
● Thermostat 1
Does not open at 69 ~ 73 °C (156.2 ~
163.4 °F) → Replace.

***********************************************
Checking steps:
● Suspend the thermostat in a container filled
with water.
● Slowly heat the water.
● Place a thermometer in the water.
● While stirring the water, observe the thermostat and thermometer’s indicated temperature.

***********************************************
1 Thermostat
2 Thermometer
3 Water
4 Container
È Fully closed
É Fully open

OTE:
If the accuracy of the thermostat is in doubt,
replace it. A faulty thermostat could cause serious overheating or overcooling.
2.Check:
● Thermostat housing cover
● Thermostat housing
Cracks/damage → Replace.
ASSEMBLING THE THERMOSTAT
1.Install:
● Thermostat 1
● Thermostat housing cover
OTE:
Install the thermostat with its breather hole a
toward the projection b.
2.Fill:
● Cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
CHAPTER 3.
3.Check:
● Cooling system
Leak → Repair or replace any faulty part.

6-7

WATER PUMP

COOL

WATER PUMP

Order

1
2
3
4
5
6

Job name/Part name
Removing the water pump
Coolant
Radiator outlet hose
Water pump outlet hose
Water pump assembly
O-ring
Water jacket inlet housing
O-ring

Q’ty

1
1
1
1
1
1

Remarks
Remove the parts in the order below.
Drain.
Disconnect.

For installation, reverse the removal procedure.

6-8

WATER PUMP

Order
1
2
3
4
5
6
7
8
9

Job name/Part name
Disassembling the water pump
Water pump housing cover
O-ring
Circlip
Impeller shaft gear
Pin
Circlip
Impeller
Impeller shaft
Rubber damper holder

Q’ty
1
1
1
1
1
1
1
1
1

6-9

COOL

Remarks
Remove the parts in the order below.

Refer to “DISASSEMBLING/ASSEMBLING THE THERMOSTAT”.

WATER PUMP

Order
0
A
B
C
D

Job name/Part name
Rubber damper
Water pump seal
Oil seal
Bearing
Water pump housing

COOL

Q’ty
Remarks
1
1
Refer to “DISASSEMBLING/ASSEM1
BLING THE THERMOSTAT”.
1
1
For assembly, reverse the disassembly
procedure.

6 - 10

WATER PUMP

COOL

DISASSEMBLING THE WATER PUMP
1.Remove:
● Impeller shaft 1
OTE:
Tap out the impeller shaft from the impeller.

2.Remove:
● Rubber damper holder 1
● Rubber damper 2
(from the impeller, with a thin, flathead
screwdriver)
OTE:
Do not scratch the impeller.

3.Remove:
● Water pump seal 1
OTE:
Tap out the water pump seal from the inside of
the water pump housing.
2 Water pump housing

4.Remove:
● Oil seal 1
● Bearing 2
OTE:
Tap out the bearing and oil seal from the outside of the water pump housing.
3 Water pump housing

CHECKING THE WATER PUMP
1.Check:
● Water pump housing cover 1
● Water pump housing 2
● Impeller 3
● Impeller shaft 4
● Rubber damper 5
● Rubber damper holder 6
Cracks/damage/wear → Replace.
6 - 11

WATER PUMP

COOL

2.Check:
● Water pump seal
● Oil seal
New
● Water pump outlet pipe
Cracks/damage/wear → Replace.
● Bearing
Rough movement → Replace.

ASSEMBLING THE WATER PUMP
1.Install:
● Oil seal 1
New
(into the water pump housing 2)
OTE:
Before installing the oil seal, apply tap water
or coolant onto its outer surface.
● Install the oil seal with a socket 3 that
matches its outside diameter.
●

2.Install:
● Water pump seal 1
New
(into the water pump housing 2)

CAUTION:
Never lubricate the water pump seal surface with oil or grease.
OTE:
Install the water pump seal with the special
tools.
Mechanical seal installer 3:
P/N. YM-33221, 90890-04078
Middle driven shaft bearing driver
4:
P/N. YM-04058-1, 90890-04058
È Push down.

3.Install:
● Rubber damper 1
New
● Rubber damper holder 2

New

OTE:
Before installing the rubber damper, apply tap
water or coolant onto its outer surface.

6 - 12

WATER PUMP

COOL

4.Measure:
● Impeller shaft tilt
Out of specification → Repeat steps (3) and
(4).

CAUTION:
Make sure that the rubber damper and rubber damper holder are bottom with the
impeller.
Max. impeller shaft tilt:
0.15 mm (0.006 in)
1 Straightedge
2 Impeller

6 - 13

CARBURETORS

CARB

CARBURETION
CARBURETORS

Order

1
2
3
4
5
6
7
8
9

Job name/Part name
Removing the carburetors
Seat/front fender/fuel tank/rubber cover
2
Air vent hose
Float chamber breather hose
Starter cable/starter plunger
Throttle valve cover
Throttle cable end
Throttle cable
Clamp screw (air filter case)
Clamp screw (carburetor joint)
Carburetors

Q’ty

2
1
1/1
1
1
1
2
2
1

Remarks
Remove the parts in the order below.
Refer to “SEAT, FENDERS AND FUEL
TANK” in CHAPTER 3.

Loosen.
Loosen.
For installation, reverse the removal procedure.

7-1

CARBURETORS

Order
1
2
3
4
5
6
7
8

Job name/Part name
Separating the carburetors
Drain hose
Plate
Connecting bolt/spacer
Spring
Hose joint
Pipe
Carburetor 2
Carburetor 1

Q’ty

CARB

Remarks
Remove the parts in the order below.

2
1
2/2
1
1
1
1
1
For installation, reverse the separating
procedure.

7-2

CARBURETORS

Order
1
2
3
4
5
6
7
8
9
0

Job name/Part name
Disassembling the carburetor
Throttle stop screw
Vacuum chamber cover
Spring
Jet needle holder
Spring
Jet needle set
Piston valve
Float chamber
Drain screw
Float

Needle valve set

Q’ty
1
1
1
1
1
1
1
1
1
1
1

7-3

CARB

Remarks
Remove the parts in the order below.

Refer to “ASSEMBLING THE CARBURETOR”.

CARBURETORS

Order
B
C

Job name/Part name
Pilot jet
Pilot screw set

CARB

Q’ty
Remarks
1
1
Refer to “DISASSEMBLING/
ASSEMBLING THE CARBURETOR”.
OTE:
Before disassembling the carburetor,
make sure to note the number of times
the pilot screw is turned out from the
seated position to its set position.

D
E

Main jet
Needle jet

1
1

F
G

Starter jet
Pilot air jet

1
1

Refer to “ASSEMBLING THE CARBURETOR”.

For assembly, reverse the disassembly
procedure.

7-4

CARBURETORS

CARB

DISASSEMBLING THE CARBURETOR
OTE:
Before disassembling the carburetor, make
sure to note the number of times the pilot
screw is turned out from the seated position to
its set position.

CHECKING THE CARBURETOR
1.Check:
● Carburetor body
● Float chamber
Cracks/damage → Replace.
● Fuel passage
Contamination → Clean as indicated.
● Fuel chamber body
Contamination → Clean.

***********************************************
Cleaning steps:
● Wash the carburetor in a petroleum based
solvent.
(Do not use any caustic carburetor cleaning
solution.)
● Blow out all of the passages and jets with
compressed air.

***********************************************
2.Check:
● Float 1
● Float tang 2
Damage → Replace.

3.Check:
● Valve seat 1
● Needle valve 2
● O-ring 3
Contamination/wear/damage → Replace as
a set.
OTE:
Always replace the needle valve and valve
seat as a set.
7-5

CARBURETORS

CARB

4.Check:
● Piston valve 1
Scratches/wear/damage → Replace.
● Rubber diaphragm 2
Tears → Replace.

5.Check:
● Vacuum chamber cover 1
● Spring 2
Cracks/damage → Replace.

6.Check:
● Jet needle 1
● Main jet 2
● Needle jet 3
● Pilot air jet 4
● Pilot jet 5
● Pilot screw 6
● Starter jet 7
● Starter plunger 8
Bends/wear/damage → Replace.
● Blockage
→ Blow out the jets
compressed air.

with

7.Check:
● Free movement (piston valve)
Sticks → Replace the piston valve guide and
the piston valve.
Insert the piston valve into the carburetor
body, and check for free movement.
8.Check:
● Free movement (throttle valve)
Sticks → Replace.
7-6

CARBURETORS

CARB

ASSEMBLING THE CARBURETOR

CAUTION:
Before reassembling, wash all of the parts
in a clean petroleum based solvent.

1.Install:
● Pilot screw 1
OTE:
Before assembling the carburetor, make sure
to turn out the pilot screw the same number of
times, as noted before disassembly, from the
seated position to the set position.

2.Measure:
● Float height a
Out of specification → Adjust.
Float height (F.H.):
13 mm (0.51 in)

***********************************************
Measurement and adjustment steps:
● Hold the carburetor in an upside down
position.
● Measure the distance from the front mating
surface of the float chamber (gasket
removed) to the top of the float.
OTE:
The float arm should be resting on the needle
valve, but not compressing it.
● If

the float height is not within the
specification, inspect the valve seat and
needle valve.
● If either is worn, replace them both.
● If both are fine, adjust the float height by
bending the float tang 1 on the float.
● Recheck the float height.

***********************************************

7-7

CARBURETORS

CARB

3.Install:
● Carburetor 1
● Carburetor 2
● Pipe
● Hose joint
● Spring
OTE:
Install the throttle valve lever 1 onto
carburetor 2 between the spring 2 and
synchronizing screw 3.
● Make
sure the throttle valves operate
smoothly and that the synchronization is
correct.
●

ADJUSTING THE FUEL LEVEL
1.Measure:
● Fuel level a
Out of specification → Adjust.
Fuel level:
3 ~ 4 mm (0.12 ~ 0.16 in)
Below the float chamber mating
surface

***********************************************
Fuel level measurement and adjustment
steps:
● Place the machine on a level surface.
● Connect the fuel level gauge 1 to the drain
pipe 2.
Fuel level gauge:
P/N. YM-01312-A, 90890-01312
the drain screw 3.
the gauge vertically next to the float
chamber line.
● Measure the fuel level a with the gauge.
● If the fuel level is incorrect, adjust the fuel
level.
● Loosen
● Hold

7-8

CARBURETORS

CARB

● Remove

the carburetor.
● Inspect the valve seat and needle valve.
● If either is worn, replace them both.
● If both are fine, adjust the float level by
bending the float tang 4 slightly.
● Install the carburetor.
● Recheck the fuel level.

***********************************************

7-9

ELECTRICAL COMPONENTS

ELEC

EB800000

ELECTRICAL
ELECTRICAL COMPONENTS
1 Main switch
2 Front brake switch
3 Indicator light
4 Circuit breaker (fan)
5 Park switch
6 Clutch switch
7 Handlebar switch (left)
8 Fuse

9 Starter relay
0 Tail/brake light
A Rectifier/regulator
B CDI unit
C Battery
D Neutral switch
E Reverse switch
F Speed sensor

8-1

G Rear brake switch
H Ignition coil
I Headlight
J Thermo switch 1
K Fan
L Thermo switch 2
M Diode

–

CHECKING THE SWITCH

ELEC

–

CHECKING THE SWITCH
CHECKING THE SWITCH
Use a pocket tester to check the terminals for
continuity. If the continuity is faulty at any
point, replace the switch.
Pocket tester:
P/N. YU-03112, 90890-03112
OTE:
Set the pocket tester to “0” before starting
the test.
● The pocket tester should be set to the “Ω × 1”
range when testing the switch for continuity.
● Turn the switch on and off a few times when
checking it.
●

CHECKING A SWITCH SHOWN IN THE
MANUAL
The terminal connections for switches (main
switch, handlebar switch, engine stop switch,
light switch, etc.) are shown in a chart similar
to the one on the left.
This chart shows the switch positions in the
column and the switch lead colors in the top
row.
For each switch position, “
” indicates
the terminals with continuity.
The example chart shows that:
1 There is continuity between the “Red and
Brown” leads when the switch is set to “ON”.

8-2

CHECKING THE SWITCH

ELEC

CHECKING THE SWITCH CONTINUITY
Refer to “CHECKING THE SWITCH” and check for continuity between lead terminals.
Poor connection, no continuity → Correct or replace.
The coupler locations are circled.

8-3

–

CHECKING THE SWITCH
1 Lights switch
2 Engine stop switch
3 Start switch
4 Main switch
5 Front brake switch
6 Clutch switch
7 Park switch
8 Fuse
9 Reverse switch
0 Neutral switch
A Rear brake switch

8-4

ELEC

–

1 AC magneto
3 Main switch
4 Battery
5 Fuse
0 CDI unit
A Ignition coil
B Spark plug
P Engine stop switch

IGNITION SYSTEM

8-5

ELEC
–
+

EB802000

IGNITION SYSTEM

CIRCUIT DIAGRAM

IGNITION SYSTEM

ELEC

–

EB802010

TROUBLESHOOTING
IF THE IGNITION SYSTEM FAILS TO OPERATE (NO SPARK OR INTERMITTENT SPARK):

Procedure
Check:
1.Fuse
2.Battery
3.Spark plug
4.Ignition spark gap
5.Spark plug cap resistance
6.Ignition coil resistance

7.Engine stop switch
8.Main switch
9.Pickup coil resistance
10.Charging/rotor rotation direction detection
coil resistance
11.Wiring connection (the entire ignition system)

OTE:
Remove the following part(s) before troubleshooting:
1)Seat
2)Front fender
● Use the following special tool(s) for troubleshooting.

Dynamic spark tester:
P/N. YM-34487
Ignition checker:
P/N. 90890-06754
Pocket tester:
P/N. YU-03112, 90890-03112

●

EB802011

NO CONTINUITY

1.Fuse
Refer to “CHECKING THE SWITCH”.
CONTINUITY

Replace the fuse.

EB802012

2.Battery
●

INCORRECT

Check the battery condition.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
●

Open-circuit voltage:
12.8 V or more at 20 °C (68 °F)

●

Clean the battery terminals.
Recharge or replace the battery.

CORRECT
Standard spark plug:
DPR8EA-9/NGK

3.Spark plug
●
●
●

Check the spark plug condition.
Check the spark plug type.
Check the spark plug gap.
Refer to “CHECKING THE SPARK PLUG”
in CHAPTER 3.
8-6

IGNITION SYSTEM

ELEC

INCORRECT

Spark plug gap:
0.8 ~ 0.9 mm (0.031 ~ 0.035 in)
CORRECT

Repair or replace the spark plug.
For USA and CDN
4.Ignition spark gap
●

●

Disconnect the spark plug cap from the
spark plug.
Connect the dynamic spark tester 1 as
shown.

2 Spark plug cap
3 Spark plug
●
●
●

Turn the main switch to “ON”.
Check the ignition spark gap.
Crank the engine by pushing the starter
switch, and increase the spark gap until a
misfiring occurs.

MEETS SPECIFICATION

Minimum spark gap:
6.0 mm (0.24 in)

The ignition system is not faulty.

For Europe
4.Ignition spark gap
●

●

Disconnect the spark plug cap from the
spark plug.
Connect the ignition checker 1 as shown.

2 Spark plug cap
●
●
●

Turn the main switch to “ON”.
Check the ignition spark gap a.
Crank the engine by pushing the starter
switch, and increase the spark gap until a
misfiring occurs.

MEETS SPECIFICATION

Minimum spark gap:
6.0 mm (0.24 in)

The ignition system is not faulty.

OUT OF
SPECIFICATION
OR NO SPARK

8-7

–

IGNITION SYSTEM

ELEC

*
5.Spark plug cap resistance
●
●

●

Remove the spark plug cap.
Connect the pocket tester (Ω × 1k) to the
spark plug cap.

OUT OF SPECIFICATION

Check that the spark plug cap has the
specified resistance.
Spark plug cap resistance:
10 kΩ at 20 °C (68 °F)

Replace the spark plug cap.

MEETS
SPECIFICATION
6.Ignition coil resistance
●

●

Disconnect the ignition coil connector from
the wire harness.
Connect the pocket tester (Ω × 1) to the
ignition coil.
Tester (+) lead → Orange lead terminal
Tester (–) lead → Ignition coil base

●

Check that the primary coil has the specified resistance.
Primary coil resistance:
0.18 ~ 0.28 Ω at 20 °C (68 °F)

8-8

–

IGNITION SYSTEM
●

ELEC

–

Connect the pocket tester (Ω × 1k) to the
ignition coil.
Tester (+) lead → Orange lead terminal
Tester (–) lead → Spark plug lead

●

Check that the secondary coil has the
specified resistance.
Secondary coil resistance:
6.32 ~ 9.48 kΩ at 20 °C (68 °F)
BOTH MEET
SPECIFICATION
Replace the ignition coil.
INCORRECT

7.Engine stop switch
Refer to “CHECKING THE SWITCH”.
CORRECT

Replace the handlebar switch (left).

INCORRECT

8.Main switch
Refer to “CHECKING THE SWITCH”.
CORRECT

Replace the main switch.

9.Pickup coil resistance
●

●

Disconnect the AC magneto coupler from
the wire harness.
Connect the pocket tester (Ω × 100) to the
pickup coil terminal.
Tester (+) lead → White/Red terminal 1
Tester (–) lead → White/Green terminal 2

●

Check the pickup coil for the specified
resistance.

OUT OF SPECIFICATION

Pickup coil resistance:
445 ~ 545 Ω at 20 °C (68 °F)
(White/Red – White/Green)

Replace the pickup coil/starter assembly.

MEETS
SPECIFICATION

*
8-9

IGNITION SYSTEM

ELEC

–

C0NTINUITY

10.Charging/rotor rotation direction detection coil resistance
●

●

Disconnect the AC magneto coupler from
the wire harness.
Connect the pocket tester (Ω × 100) to the
charging/rotor rotation direction detection
coil terminal.
Tester (+) lead → Red terminal 1
Tester (–) lead → White/Blue terminal 2

●

Check the charging/rotor rotation direction
detection coil for the specified resistance.

OUT OF SPECIFICATION

Rotor rotation direction detection coil resistance:
0.069 ~ 0.085 Ω at 20 °C (68 °F)
(Red – White/Blue)

Replace the pickup coil/stator assembly.

MEETS
SPECIFICATION
11.Wiring connection
●

POOR CONNECTION

Check the connections of the entire ignition
system.
Refer to “CIRCUIT DIAGRAM”.

Properly connect the ignition system.

CORRECT
Replace the CDI unit.

8 - 10

3 Main switch
4 Battery
5 Fuse
6 Starter relay
7 Starter motor
8 Clutch switch
9 Park switch
0 CDI unit
J Neutral switch
P Engine stop switch
Q Start switch

ELECTRIC STARTING SYSTEM

8 - 11

ELEC
–
+

EB803000

ELECTRIC STARTING SYSTEM

CIRCUIT DIAGRAM

ELECTRIC STARTING SYSTEM

ELEC

–

STARTING CIRCUIT OPERATION
The starting circuit on this model consists of
the starter motor, starter relay, clutch switch,
CDI unit and neutral switch. If the main switch
is on and the engine stop switch is in the RUN
position, the starter motor can be operated
only if:
●

●

The transmission is in neutral (the neutral
switch is closed).
or
You pull in the clutch lever (the clutch
switch is closed).

1 Fuse
2 Battery
3 Starter relay
4 Starter motor
5 Start switch
6 CDI unit
7 Engine stop switch
8 Neutral switch
9 Clutch switch
È TO MAIN SWITCH
É FROM MAIN SWITCH

8 - 12

ELECTRIC STARTING SYSTEM

ELEC

–

EB803020

TROUBLESHOOTING
IF THE STARTER MOTOR FAILS TO OPERATE:

Procedure
Check:
1.Fuse
2.Battery
3.Starter motor
4.Starter relay
5.Main switch
6.Engine stop switch

7.Start switch
8.Neutral switch
9.Clutch switch
10.Wiring connection (the entire starting system)

OTE:
Remove the following part(s) before troubleshooting:
1)Seat
2)Front fender
3)Rear fender
4)Exhaust pipe
● Use the following special tool(s) for troubleshooting.

Pocket tester:
P/N. YU-03112, 90890-03112

●

EB802011

NO CONTINUITY

1.Fuse
Refer to “CHECKING THE SWITCH”.
CONTINUITY

Replace the fuse.

EB802012

2.Battery
●

INCORRECT

Check the battery condition.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
●

Open-circuit voltage:
12.8 V or more at 20 °C (68 °F)

●

CORRECT

*
8 - 13

Clean the battery terminals.
Recharge or replace the battery.

ELECTRIC STARTING SYSTEM

C0NTINUITY

●

Connect the battery positive terminal 1
and starter motor cable 2 using a jumper
lead 3 .
Check the operation of the starter motor.

●

A wire that is used as a jumper lead must
have the equivalent capacity or more as
that of the battery lead, otherwise the
jumper lead may burn.
This check is likely to produce sparks, so
be sure that no flammable gas or fluid is
in the vicinity.

Repair or replace the starter motor.
TURNS
4.Starter relay

●

Remove the starter relay from the wire harness.
Connect the pocket tester (Ω × 1) and the
battery (12 V) to the starter relay terminals.

Battery (+) terminal →
Yellow/Black terminal 1
Battery (–) terminal →
Blue/Black terminal 2

NO CONTINUITY

Tester (+) lead → Red terminal 3
Tester (–) lead → Black terminal 4
●

WARNING

DOES NOT TURN

●

–

3.Starter motor
●

ELEC

Replace the starter relay.

Check the starter relay for continuity.
CONTINUITY

INCORRECT

5.Main switch
Refer to “CHECKING THE SWITCH”.
CORRECT

Replace the main switch.

*
8 - 14

ELECTRIC STARTING SYSTEM

ELEC

C0NTINUITY
INCORRECT

6.Engine stop switch
Refer to “CHECKING THE SWITCH”.
CORRECT

Replace the handlebar switch (right).
INCORRECT

7.Start switch
Refer to “CHECKING THE SWITCH”.
CORRECT

Replace the handlebar switch (left).
INCORRECT

8.Neutral switch
Refer to “CHECKING THE SWITCH”.
CORRECT

Replace the neutral switch.

INCORRECT

9.Clutch switch
Refer to “CHECKING THE SWITCH”.
CORRECT

Replace the clutch switch.

EB803028

POOR CONNECTION

10.Wiring connection
●

Check the connections of the entire starting
system.
Refer to “CIRCUIT DIAGRAM”.

Properly connect the starting system.

8 - 15

–

ELECTRIC STARTING SYSTEM

ELEC

–

STARTER MOTOR

Order

1
2
3
1
2
3
4
5
6
7
8

Job name/Part name
Removing the starter motor
Exhaust pipe
Parking brake cable
Starter motor lead
Starter motor/O-ring
Disassembling the starter motor
Starter motor drive gear
Bracket 1
Washer kit
Bracket 2
Shims
Brush seat 1/brush seat 2
Armature coil
Yoke

Q’ty

1
1
1/1

Remarks
Remove the parts in the order below.
Refer to “ENGINE REMOVAL”.
Disconnect.

Remove the parts in the order below.
1
1
1
1/1
1
1

Refer to “ASSEMBLING THE STARTER
MOTOR”.

For assembly, reverse the disassembly
procedure.
8 - 16

ELECTRIC STARTING SYSTEM

ELEC

–

CHECKING THE STARTER MOTOR
1.Check:
● Commutator
Dirty → Clean it with #600 grit sandpaper.
2.Measure:
● Commutator diameter a
Out of specification → Replace the starter
motor.
Outside diameter:
28 mm (1.10 in)

27 mm (1.06 in)
3.Measure:
● Mica undercut b
Out of specification → Scrape the mica using
a hacksaw blade.
Mica undercut:
0.7 mm (0.03 in)
OTE:
Scrape the mica to the proper measurement
using a hacksaw blade which has been
grounded to fit the commutator.

4.Check:
● Armature coil (insulation/continuity)
Defects → Replace the starter motor.

***********************************************
Armature coil checking steps:
● Connect the pocket tester for the continuity
check 1 and insulation check 2.
● Measure the armature resistances.
Armature coil resistance:
Continuity check 1:
0.025 ~ 0.035 Ω at 20 °C (68 °F)
Insulation check 2:
More than 1 MΩ at 20 °C (68 °F)
● If

the resistance is incorrect, replace the
starter motor.

***********************************************

8 - 17

ELECTRIC STARTING SYSTEM

ELEC

–

5.Measure:
● Brush length a (each)
Out of specification → Replace the brush.
Brush length:
12.5 mm (0.49 in)

5 mm (0.20 in)

6.Measure:
● Brush spring force
Fatigue/out of specification → Replace as a
set.
Brush spring force:
7.65 ~ 10.01 Nm
(27.5 ~ 36.0 oz)

7.Check:
● Oil seal
● Bushing
● O-rings
Wear/damage → Replace.

ASSEMBLING THE STARTER MOTOR
1.Install:
● Brush seat 1
OTE:
Align the projection a on the brush seat with
the slot b on the housing.

2.Install:
● Yoke
● Brackets
OTE:
Align the match marks a on the yoke with the
match marks b on the brackets.

8 - 18

CHARGING SYSTEM

ELEC

–

EB804000

CHARGING SYSTEM
CIRCUIT DIAGRAM

1 AC magneto
2 Rectifier/regulator
4 Battery
5 Fuse
8 - 19

CHARGING SYSTEM

ELEC

–

EB804010

TROUBLESHOOTING
IF THE BATTERY IS NOT CHARGED:

Procedure
Check:
1.Fuse
2.Battery
3.Charging voltage

4.Charging coil resistance
5.Wiring connections
(the entire charging system)

OTE:
Remove the following part(s) before troubleshooting:
1)Seat
● Use the following special tool(s) for troubleshooting.

Pocket tester:
P/N. YU-03112, 90890-03112

●

EB802011

NO CONTINUITY

1.Fuse
Refer to “CHECKING THE SWITCH”.
CONTINUITY

Replace the fuse.

EB802012

2.Battery
●

INCORRECT

Check the battery condition.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
●

Open-circuit voltage:
12.8 V or more at 20 °C (68 °F)

●

CORRECT
EB804011

3.Charging voltage
●

●

Connect the tachometer to the spark plug
lead.
Connect the pocket tester (DC 20V) to the
battery.
Tester (+) lead → Battery (+) terminal
Tester (–) lead → Battery (–) terminal

8 - 20

Clean the battery terminals.
Recharge or replace the battery.

CHARGING SYSTEM
●

ELEC

–

Start the engine and accelerate to about
5,000 r/min.
MEETS SPECIFICATION

Charging voltage:
14 V at 5,000 r/min
OUT OF
SPECIFICATION

The charging circuit is not faulty.

EB804012

4.Charging coil resistance
●

●

Disconnect the AC magneto coupler from
the wire harness.
Connect the pocket tester (Ω × 1) to the
charging coils.
Tester (+) lead → White terminal 1
Tester (–) lead → White terminal 2
Tester (+) lead → White terminal 1
Tester (–) lead → White terminal 3
Tester (+) lead → White terminal 2
Tester (–) lead → White terminal 3

●

OUT OF SPECIFICATION

Measure the stator coil resistance.
Charging coil resistance:
0.43 ~ 0.65 Ω at 20 °C (68 °F)

Replace the pickup coil/stator assembly.

MEETS
SPECIFICATION
EB804015

5.Wiring connections
●

POOR CONNECTION

Check the connections of the entire charging system.
Refer to “CIRCUIT DIAGRAM”.

Properly connect the charging system.

CORRECT

Replace the rectifier/regulator.

8 - 21

LIGHTING SYSTEM

ELEC

–

EB805000

LIGHTING SYSTEM
CIRCUIT DIAGRAM

3 Main switch
4 Battery
5 Fuse
O Lights switch
R Headlight
S Tail/brake light
8 - 22

LIGHTING SYSTEM

ELEC

–

EB805010

TROUBLESHOOTING
IF THE HEADLIGHT AND/OR TAIL/BRAKE LIGHT FAIL TO COME ON:

Procedure
Check:
1.Fuse
2.Battery
3.Main switch

4.Lights switch
5.Wiring connections
(the entire lighting system)

OTE:
Remove the following part(s) before troubleshooting:
1)Seat
2)Front fender
● Use the following special tool(s) for troubleshooting.

Pocket tester:
P/N. YU-03112, 90890-03112

●

EB802011

NO CONTINUITY

1.Fuse
Refer to “CHECKING THE SWITCH”.
CONTINUITY

Replace the fuse.

EB802012

2.Battery
●

INCORRECT

Check the battery condition.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
●

Open-circuit voltage:
12.8 V or more at 20 °C (68 °F)

●

CORRECT

8 - 23

Clean the battery terminals.
Recharge or replace the battery.

LIGHTING SYSTEM

ELEC

–

C0NTINUITY
INCORRECT

3.Main switch
Refer to “CHECKING THE SWITCH”.
CORRECT

Replace the main switch.
INCORRECT

4.Lights switch
Refer to “CHECKING THE SWITCH”.

Lights switch is faulty, replace the handlebar
switch (left).

CORRECT

EB805013

5.Wiring connection
●

POOR CONNECTION

Check the connections of the entire lighting
system.
Refer to “WIRING DIAGRAM”.

Properly connect the lighting system.

CORRECT
Check the condition of each of the lighting
system’s circuits.
Refer to “CHECKING THE LIGHTING SYSTEM”.

8 - 24

LIGHTING SYSTEM

ELEC

–

EB805020

CHECKING THE LIGHTING SYSTEM
1.If the headlights fail to come on:
NO CONTINUITY

1.Bulb and bulb socket
●

Check the bulb and bulb socket for continuity.
Replace the bulb and/or bulb socket.
CONTINUITY

2.Voltage
●

Connect the pocket tester (DC 20V) to the
headlight couplers.

Tester (+) lead →
Green terminal 1 or Yellow terminal 2
Tester (–) lead → Black terminal 3
È When the lights switch is on “LO”.
É When the lights switch is on “HI”.

●
●
●

OUT OF SPECIFICATION

Turn the main switch to “ON”.
Turn the lights switch to “LO” or “HI”.
Check the voltage (12 V) of the “Green”
and “Yellow” leads on the bulb socket connector.

The wiring circuit from the main switch to the
bulb socket connector is faulty, repair it.

MEETS
SPECIFICATION
This circuit is not faulty.

8 - 25

LIGHTING SYSTEM

ELEC

–

EB805021

2.If the tail/brake light fails to come on:
NO CONTINUITY

1.Bulb and bulb socket
●

Check the bulb and bulb socket for continuity.
Replace the bulb and/or bulb socket.
CONTINUITY

2.Voltage
●

Connect the pocket tester (20 V) to the bulb
socket coupler.
Tester (+) lead → Blue terminal 1
Tester (–) lead → Black terminal 2

●
●
●

OUT OF SPECIFICATION

Turn the main switch to “ON”.
Turn the lights switch to “LO” or “HI”.
Check the voltage (12 V) of the “Blue” lead
on the bulb socket connector.

The wiring circuit from the main switch to the
bulb socket connector is faulty, repair it.

MEETS
SPECIFICATION
This circuit is not faulty.

8 - 26

3 Main switch
4 Battery
5 Fuse
0 CDI unit
C Speed sensor
G Coolant temperature
warning light
H Reverse indicator light
I Neutral indicator light
J Neutral switch
K Reverse switch
L Diode
M Thermo switch 2
P Engine stop switch
Q Start switch
S Tail/brake light
T Rear brake switch
U Front brake switch

SIGNAL SYSTEM

8 - 27

ELEC
–
+

EB806000

SIGNAL SYSTEM

CIRCUIT DIAGRAM

SIGNAL SYSTEM

ELEC

–

EB806010

TROUBLESHOOTING
IF THE TAIL/BRAKE LIGHT AND/OR INDICATOR LIGHT FAILS TO COME ON:

Procedure
Check:
1.Fuse
2.Battery
3.Main switch
4.Wiring connections
(the entire signal system)

OTE:
Remove the following part(s) before troubleshooting:
1)Seat
2)Front fender
3)Rear fender
● Use the following special tool(s) for troubleshooting.

Pocket tester:
P/N. YU-03112, 90890-03112

●

EB802011

NO CONTINUITY

1.Fuse
Refer to “CHECKING THE SWITCH”.
CONTINUITY

Replace the fuse.

EB802012

2.Battery
●

INCORRECT

Check the battery condition.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
●

Open-circuit voltage:
12.8 V or more at 20 °C (68 °F)

●

CORRECT

8 - 28

Clean the battery terminals.
Recharge or replace the battery.

SIGNAL SYSTEM

ELEC

C0NTINUITY
INCORRECT

3.Main switch
Refer to “CHECKING THE SWITCH”.
CORRECT

Replace the main switch.

EB806011

POOR CONNECTION

4.Wiring connections
●

Check the connections of the entire signal
system.
Refer to “CIRCUIT DIAGRAM”.

Properly connect the signal system.

CORRECT

Check the condition of each of the signal system’s circuits.
Refer to “CHECKING THE SIGNAL SYSTEM”.

8 - 29

–

SIGNAL SYSTEM

ELEC

–

CHECKING THE SIGNAL SYSTEM
1.If the tail/brake light fails to come on:
1.Bulb and bulb socket
●

NO CONTINUITY

Check the bulb and bulb socket for continuity.
CONTINUITY

Replace the bulb and/or bulb socket.

NO CONTINUITY

2.Brake switches
Refer to “CHECKING THE SWITCH”.
CONTINUITY

Replace the brake switch.

3.Voltage
●

Connect the pocket tester (DC 20V) to the
bulb socket coupler.
Tester (+) lead → Yellow terminal 1
Tester (–) lead → Black terminal 2

●
●
●

OUT OF SPECIFICATION

Turn the main switch to “ON”.
Turn the lights switch to “LO” or “HI”.
Check the voltage (12 V) of the “Yellow”
lead on the bulb socket connector.

The wiring circuit from the main switch to the
bulb socket connector is faulty, repair it.

MEETS
SPECIFICATION
This circuit is not faulty.

8 - 30

SIGNAL SYSTEM

ELEC

–

EB806024

2.If the neutral indicator light fails to come on:
1.Bulb and bulb socket
●

NO CONTINUITY

Check the bulb and bulb socket for continuity.
Replace the bulb and/or bulb socket.

CONTINUITY

NO CONTINUITY

2.Neutral switch
Refer to “CHECKING THE SWITCH”.
CONTINUITY

Replace the neutral switch.

3.Voltage
●

Connect the pocket tester (DC 20V) to the
bulb socket coupler.
Tester (+) lead → Brown terminal 1
Tester (–) lead → Sky blue terminal 2

●
●

OUT OF SPECIFICATION

Turn the main switch to “ON”.
Check the voltage (12 V).
MEETS
SPECIFICATION

The wiring circuit from the main switch to the
bulb socket connector is faulty, repair it.

This circuit is not faulty.

8 - 31

SIGNAL SYSTEM

ELEC

–

3.If the reverse indicator light fails to come on:
NO CONTINUITY

1.Bulb and bulb socket
●

Check the bulb and bulb socket for continuity.
Replace the bulb and/or bulb socket.

CONTINUITY

NO CONTINUITY

2.Reverse switch
Refer to “CHECKING THE SWITCH”.
CONTINUITY

Replace the reverse switch.

3.Voltage
●

Connect the pocket tester (DC 20V) to the
bulb socket coupler.
Tester (+) lead → Brown terminal 1
Tester (–) lead → Green/Blue terminal 2

●
●

OUT OF SPECIFICATION

Turn the main switch to “ON”.
Check the voltage (12 V).
MEETS
SPECIFICATION

The wiring circuit from the main switch to the
bulb socket connector is faulty, repair it.

This circuit is not faulty.

8 - 32

SIGNAL SYSTEM

ELEC

–

4.If the coolant temperature warning light does not come on when the start switch is pushed on, or if
the coolant temperature warning light does not come on when the temperature is high (more than
117 ~ 123 °C (242.6 ~ 253.4 °F)):
NO CONTINUITY

1.Bulb and bulb socket
●

Check the bulb and bulb socket for continuity.
Replace the bulb and/or bulb socket.

CONTINUITY
2.Thermo switch 2
●

●

●
●

Remove the thermo switch from the thermostat housing.
Connect the pocket tester (Ω × 1) to the
thermo switch 1.
Immerse the thermo switch in coolant 2.
Check the thermo switch for continuity.
While heating the coolant use a thermometer 3 to record the temperatures.

Water temperature
Good
condition
Thermo switch
0 ~ 115 ± 3 °C
1
×
(32 ~ 239 ± 5.4 °F)
More than 120 ± 3 °C
2
(248 ± 5.4 °F)
120 ± 3 to 115 ± 3 °C
3*
(248 ± 5.4 to
239 ± 5.4 °F)
Less than 115 ± 3 °C
4*
×
(239 ± 5.4 °F)
Tests 1 & 2; Heat-up tests
Tests 3* & 4*; Cool-down tests
: Continuity
× : No continuity
Test
step

WARNING
Handle the thermo switch with special
care.
Never subject it to a strong shock or
allow it to be dropped. Should it be
dropped, it must be replaced.

BAD CONDITION

Thermo switch:
2.8 Nm (2.8 m • kg, 20 ft • lb)
Three bond sealock® #10

Replace the thermo switch 2.

GOOD
CONDITION

*
8 - 33

SIGNAL SYSTEM

ELEC

–

C0NTINUITY

3.Voltage
●

Connect the pocket tester (DC 20V) to the
bulb socket coupler.
Tester (+) lead → Red/Black terminal 1
Tester (–) lead → White/Blue terminal 2

●
●

OUT OF SPECIFICATION

Turn the main switch to “ON”.
Check the voltage (12 V).
MEETS
SPECIFICATION

The wiring circuit from the main switch to the
bulb socket connector is faulty, repair it.

4.Diode
• Remove the diode from the coupler.
• Connect the pocket tester (Ω × 1) to the
diode terminals as shown.
• Check the diode for continuity as follows.
Tester positive probe →
Blue/Black 1 ContinuTester negative probe →
ity
White/Blue 2

OTE:
When you switch the tester’s positive and
negative probes, the readings in the left
chart will be reversed.

Tester positive probe →
White/Blue 2 No contiTester negative probe →
nuity
Blue/Black 1

INCORRECT

CORRECT

Replace the diode.

8 - 34

SIGNAL SYSTEM

ELEC

C0NTINUITY
INCORRECT

5.Start switch
Refer to “CHECKING THE SWITCH”.
CORRECT

Replace the handlebar switch (left).

This circuit is not faulty.

8 - 35

–

3 Main switch
4 Battery
5 Fuse
D Circuit breaker (fan motor)
E Thermo switch 1
F Fan motor

COOLING SYSTEM

COOLING SYSTEM
CIRCUIT DIAGRAM

8 - 36

ELEC
–
+

COOLING SYSTEM

ELEC

–

TROUBLESHOOTING
IF THE FAN MOTOR DOES NOT MOVE:

Procedure
Check:
1.Fuse
2.Battery
3.Main switch
4.Fan motor
5.Circuit breaker (fan motor)

6.Thermo switch 1
7.Wiring connection
(the entire cooling system)

OTE:
Remove the following part(s) before troubleshooting.
1)Seat
2)Front fender
● Use the following special tool(s) for troubleshooting.

Pocket tester:
P/N. YU-03112, 90890-03112

●

EB802011

NO CONTINUITY

1.Fuse
Refer to “CHECKING THE SWITCH”.
CONTINUITY

Replace the fuse.

EB802012

2.Battery
●

INCORRECT

Check the battery condition.
Refer to “CHECKING THE BATTERY” in
CHAPTER 3.
●

Open-circuit voltage:
12.8 V or more at 20 °C (68 °F)

●

Clean the battery terminals.
Recharge or replace the battery.

CORRECT
INCORRECT

3.Main switch
Refer to “CHECKING THE SWITCH”.
CORRECT

Replace the main switch.

*
8 - 37

COOLING SYSTEM

ELEC

C0NTINUITY

4.Fan motor
●
●

Disconnect the fan motor coupler.
Connect the battery (12 V) as shown.
Battery (+) lead → Blue terminal 1
Battery (–) lead → Black terminal 2

DOES NOT TURN

●

Replace the fan motor.

Check the operation of the fan motor.
TURNS

5.Circuit breaker (fan motor)
●

●

Remove the circuit breaker from the wire
harness.
Connect the pocket tester (Ω × 1) to the circuit breaker.

OUT OF SPECIFICATION

Circuit breaker resistance:
Zero Ω at 20 °C (68 °F)

Replace the circuit breaker.

MEETS
SPECIFICATION

8 - 38

–

COOLING SYSTEM

ELEC

C0NTINUITY

6.Thermo switch 1
●

●

●
●

Remove the thermo switch from the radiator.
Connect the pocket tester (Ω × 10) to the
thermo switch 1.
Immerse the thermo switch in coolant 2.
Check the thermo switch for continuity.
While heating the coolant use a thermometer 3 to record the temperatures.

Water temperature
Good
condition
Thermo switch
0 ~ 92 ± 3 °C
1
×
(32 ~ 197.6 ± 5.4 °F)
More than 98 ± 3 °C
2
(208.4 ± 5.4 °F)
98 ± 3 to 92 ± 3 °C
3*
(208.4 ± 5.4 to
197.6 ± 5.4 °F)
Less than 92 ± 3 °C
4*
×
(197.6 ± 5.4 °F)
Tests 1 & 2; Heat-up tests
Tests 3* & 4*; Cool-down tests
: Continuity
× : No continuity
Test
step

WARNING
Handle the thermo switch with special
care.
Never subject it to a strong shock or
allow it to be dropped. Should it be
dropped, it must be replaced.

BAD CONDITION

Thermo switch:
28 Nm (2.8 m • kg, 20 ft • lb)
Three bond sealock® #10

Replace the thermo switch 1.

GOOD
CONDITION

8 - 39

–

COOLING SYSTEM

ELEC

*
C0NTINUITY
EB803028

POOR CONNECTION

7.Wiring connection
●

Check the connections of the entire starting
system.
Refer to “CIRCUIT DIAGRAM”.

Properly connect the cooling system.

CORRECT

This circuit is not faulty.

8 - 40

–

STARTING FAILURE/HARD STARTING

TRBL
SHTG

TROUBLESHOOTING
NOTE:
The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,
however, as a guide to troubleshooting. Refer to the relative procedure in this manual for inspection,
adjustment and replacement of parts.

STARTING FAILURE/HARD STARTING
FUEL SYSTEM
Fuel tank
● Empty
● Clogged fuel filter
● Clogged fuel strainer
● Clogged fuel breather hose
● Deteriorated or contaminated fuel
Fuel cock
● Clogged fuel hose

Carburetor
● Deteriorated or contaminated fuel
● Clogged pilot jet
● Clogged pilot air passage
● Sucked-in air
● Deformed float
● Worn needle valve
● Improperly sealed valve seat
● Improperly adjusted fuel level
● Improperly set pilot jet
● Clogged starter jet
● Starter plunger malfunction
Air filter
● Clogged air filter element

ELECTRICAL SYSTEM
Spark plug
● Improper plug gap
● Worn electrodes
● Wire between terminals broken
● Improper heat range
● Faulty spark plug cap
Ignition coil
● Broken or shorted primary/secondary
● Faulty spark plug lead
● Broken body
CDI system
● Faulty CDI unit
● Faulty pickup coil
● Broken woodruff key

Switches and wiring
● Faulty main switch
● Faulty engine stop switch
● Broken or shorted wiring
● Faulty neutral switch
● Faulty start switch
● Faulty clutch switch
Starter motor
● Faulty starter motor
● Faulty starter relay
● Faulty starter circuit cut-off relay
● Faulty starter clutch
Battery
● Faulty battery

9-1

STARTING FAILURE/HARD STARTING/POOR IDLE SPEED
PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE
COMPRESSION SYSTEM
Cylinder and cylinder head
● Loose spark plug
● Loose cylinder head or cylinder
● Broken cylinder head gasket
● Broken cylinder gasket
● Worn, damaged or seized cylinder
Valve, camshaft and crankshaft
● Improperly sealed valve
● Improperly contacted valve and valve seat
● Improper valve timing
● Broken valve spring
● Seized camshaft
● Seized crankshaft

TRBL
SHTG

Piston and piston rings
● Improperly installed piston ring
● Worn, fatigued or broken piston ring
● Seized piston ring
● Seized or damaged piston
Crankcase and crankshaft
● Improperly seated crankcase
● Seized crankshaft
Valve train
● Improperly adjusted valve clearance
● Improperly adjusted valve timing

POOR IDLE SPEED PERFORMANCE
POOR IDLE SPEED PERFORMANCE
Carburetor
● Improperly returned starter plunger
● Loose pilot jet
● Clogged pilot jet
● Clogged pilot air jet
● Improperly adjusted idle speed
(Throttle stop screw)
● Improper throttle cable play
● Flooded carburetor

Electrical system
● Faulty spark plug
● Faulty CDI unit
● Faulty pickup coil
● Faulty ignition coil
Valve train
● Improperly adjusted valve clearance
Air filter
● Clogged air filter element

POOR MEDIUM AND HIGH-SPEED PERFORMANCE
POOR MEDIUM AND HIGH-SPEED PERFORMANCE
Refer to “STARTING FAILURE/HARD STARTING” and “POOR IDLE SPEED PERFORMANCEVALVE TRAIN”.
Carburetor
Air filter
● Improper jet needle clip position
● Clogged air filter element
● Improperly adjusted fuel level
● Clogged or loose main jet
● Deteriorated or contaminated fuel

9-2

FAULTY GEAR SHIFTING/
CLUTCH SLIPPING/DRAGGING

TRBL
SHTG

FAULTY GEAR SHIFTING
HARD SHIFTING
Refer to “CLUTCH DRAGGING”.

SHIFT PEDAL DOES NOT MOVE
Shift shaft
● Bent shift shaft
Shift drum and shift fork
● Groove jammed with impurities
● Seized shift fork
● Bent shift fork guide bar

Transmission
● Seized transmission gear
● Jammed impurities
● Incorrectly assembled transmission
Shift guide
● Broken shift guide

JUMP-OUT GEAR
Shift shaft
● Improperly adjusted shift lever position
● Improperly returned stopper lever
Shift fork
● Worn shift fork

Shift drum
● Improper thrust play
● Worn shift drum groove
Transmission
● Worn gear dog

CLUTCH SLIPPING/DRAGGING
CLUTCH SLIPPING
Clutch
● Loose clutch spring
● Fatigued clutch spring
● Worn friction plate
● Worn clutch plate
● Incorrectly assembled clutch

Engine oil
● Low oil level
● Improper quality (low viscosity)
● Deterioration

CLUTCH DRAGGING
Clutch
● Warped pressure plate
● Unevenly tensioned clutch springs
● Match marks not aligned
● Loose clutch boss nut
● Burnt primary driven gear bushing
● Bent clutch plate
● Swollen friction plate
● Broken clutch boss

Transmission oil
● High oil level
● Improper quality (high viscosity)
● Deterioration

9-3

OVERHEATING/OVER COOLING/
FAULTY BRAKE

TRBL
SHTG

OVERHEATING
OVERHEATING
Ignition system
● Improper spark plug gap
● Improper spark plug heat range
● Faulty CDI unit
Fuel system
● Improper carburetor main jet
(improper setting)
● Improper fuel level
● Clogged air filter element
Compression system
● Heavy carbon deposit

Engine oil
● Improper oil level
● Improper oil viscosity
● Inferior oil quality
Brake
● Brake drag
Cooling system
● Low coolant level
● Clogged or damaged radiator
● Damaged or faulty water pump
● Thermostat stays closed

OVER COOLING
COOLING SYSTEM
Thermostat
● Thermostat stays open

FAULTY BRAKE
POOR BRAKING EFFECT
Disc brake
● Worn brake pads
● Worn disc
● Air in brake fluid
● Leaking brake fluid
● Faulty master cylinder kit cup
● Faulty caliper kit seal
● Loose union bolt
● Broken brake hose and pipe
● Oily or greasy disc/brake pads
● Improper brake fluid level

9-4

SHOCK ABSORBER MALFUNCTION/
UNSTABLE HANDLING/LIGHTING SYSTEM

TRBL
SHTG

SHOCK ABSORBER MALFUNCTION
MALFUNCTION
● Bent or damaged damper rod
● Damaged oil seal lip
● Fatigued shock absorber spring

UNSTABLE HANDLING
UNSTABLE HANDLING
Handlebar
● Improperly installed or bent
Steering
● Incorrect toe-in
● Bent steering stem
● Improperly installed steering stem
● Damaged bearing or bearing race
● Bent tie rods
● Deformed steering knuckles
Tires
● Uneven tire pressures on both sides
● Incorrect tire pressure
● Uneven tire wear

Wheels
● Deformed wheel
● Loose bearing
● Bent or loose wheel axle
● Excessive wheel runout
Frame
● Bent
● Damaged frame
Swingarm
● Worn bearing or bushing
● Bent or damaged

LIGHTING SYSTEM
BULB BURNT OUT
● Improper bulb
● Faulty battery
● Faulty rectifier/regulator
● Improperly grounded
● Faulty main and/or lights switch
● Bulb life expired

HEADLIGHT DARK
● Improper bulb
● Too many electric accessories
● Hard charging (broken charging coil and/or
faulty rectifier/regulator)
● Incorrect connection
● Improperly grounded
● Poor contacts (main or lights switch)
● Bulb life expired

9-5

YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN

PRINTED IN U.S.A.

YFM660R WIRING DIAGRAM

COLOR CODE
B ............Black
Br ...........Brown
G............Green
L.............Blue
O............Orange
P ............Pink
R ............Red
Sb ..........Sky blue

W ...........White
Y ............Yellow
B/W........Black/White
B/Y.........Black/Yellow
Br/L ........Brown/Blue
Br/R .......Brown/Red
Br/W.......Brown/White
G/L.........Green/Blue

G/W........Green/White
G/Y.........Green/Yellow
L/B .........Blue/Black
L/G .........Blue/Green
L/R .........Blue/Red
L/W ........Blue/White
L/Y .........Blue/Yellow
O/R ........Orange/Red

R/B ........ Red/Black
R/W ....... Red/White
R/Y ........ Red/Yellow
W/B ....... White/Black
W/G....... White/Green
W/L ....... White/Blue
W/R ....... White/Red
Y/B ........ Yellow/Black

1 AC magneto
2 Rectifier/regulator
3 Main switch
4 Battery
5 Fuse
6 Starter relay
7 Starter motor
8 Clutch switch
9 Park switch
0 CDI unit
A Ignition coil
B Spark plug
C Speed sensor
D Circuit breaker (fan motor)
E Thermo switch 1
F Fan motor
G Coolant temperature warning light
H Reverse indicator light
I Neutral indicator light
J Neutral switch
K Reverse switch
L Diode
M Thermo switch 2
N Handlebar switch (left)
O Lights switch
P Engine stop switch
Q Start switch
R Headlight
S Tail/brake light
T Rear brake switch
U Front brake switch

Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.4
Linearized                      : Yes
Create Date                     : 2001:04:16 11:13:19Z
Modify Date                     : 2002:02:03 12:53:37-07:00
Page Count                      : 328
Creation Date                   : 2001:04:16 11:13:19Z
Producer                        : Acrobat Distiller 4.0 for Windows
Mod Date                        : 2002:02:03 12:53:37-07:00
Metadata Date                   : 2002:02:03 12:53:37-07:00
Has XFA                         : No

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