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2022 OWNER’S SERVICE MANUAL YZ125 Read this manual carefully before operating this vehicle. YZ125N2 B4X-2819U-10 ■ LIT-11626-35-29...
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EAM20161 Read this manual carefully Operating, servicing and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.
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EAM20180 IMPORTANT Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.
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EAM20162 YAMAHA MOTOR CORPORATION, U.S.A. YZ MOTORCYCLE LIMITED WARRANTY...
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EAM20082 HOW TO USE THIS MANUAL In this manual, descriptions of installation, removal, disassembly, assembly, check, and adjustment procedures are laid out with the individual steps in sequential order. • The manual is divided into chapters and each chapter is divided into sections. The current section title “1”...
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EAM20083 SYMBOLS The following symbols are used in this manual for easier understanding. The following symbols are not relevant to every vehicle. SYMBOL DEFINITION SYMBOL DEFINITION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque...
TABLE OF CONTENTS EAM10003 GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM FUEL SYSTEM ELECTRICAL SYSTEM TROUBLESHOOTING TUNING...
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GENERAL INFORMATION SAFETY INFORMATION ..................1-1 FOR SAFETY, BE SURE TO OBEY THE FOLLOWING:......1-1 LOCATION OF IMPORTANT LABELS.............1-4 DESCRIPTION....................1-5 IDENTIFICATION ....................1-6 VEHICLE IDENTIFICATION NUMBER ............1-6 ENGINE SERIAL NUMBER................1-6 INCLUDED PARTS ...................1-7 SIDESTAND ....................1-7 NIPPLE WRENCH ..................1-7 VALVE JOINT .....................1-7 COLLAR (tool for YPVS) ................1-7 IMPORTANT INFORMATION ................1-8 PREPARATION FOR REMOVAL AND DISASSEMBLY ......1-8 REPLACEMENT PARTS ................1-8...
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MAINTENANCE AFTER BREAK-IN ..............1-20 MAJOR MAINTENANCE ................1-20 AIR FILTER MAINTENANCE ..............1-20 TORQUE-CHECK POINTS................1-21 MOTORCYCLE CARE AND STORAGE............1-23 CARE ......................1-23 STORAGE ....................1-24...
Yamaha ma- accidents. Many accidents have been chine, and take care to maintain it properly and caused by an automobile driver who did not operate it safely.
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1. Always wear an approved helmet. Yamaha can neither endorse nor recommend 2. Wear a face shield or goggles. Wind in your the use of accessories not sold by Yamaha or unprotected eyes could contribute to an im- modifications not specifically recommended by...
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SAFETY INFORMATION Aftermarket Tires and Rims The tires and rims that came with your motorcy- cle were designed to match the performance ca- pabilities and to provide the best combination of handling, braking, and comfort. Other tires, rims, sizes, and combinations may not be appropriate. Refer to “CHECKING THE TIRES”...
LOCATION OF IMPORTANT LABELS EAM20085 LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle. 3, 4...
There are two significant reasons for knowing the serial number of your vehicle: 1. When ordering parts, you can give the num- ber to your Yamaha dealer for positive identi- fication of the model you own. 2. If your vehicle is stolen, the authorities will need the number to search for and identify your vehicle.
INCLUDED PARTS EAM20088 INCLUDED PARTS EAM30372 SIDESTAND This sidestand “1” is used to support only the machine when standing or transporting it. EWA20260 WARNING • Never apply additional force to the sides- tand. • Remove this sidestand before starting out. EAM30615 COLLAR (tool for YPVS) This collar “1”...
2. Use proper special tools and equipment. Re- used for repair of the vehicle, including periodic fer to “SPECIAL TOOLS” on page 1-12. replacement parts, are new YAMAHA genuine parts and recommended parts. Do not use any used parts, because these may...
IMPORTANT INFORMATION 1. Oil 2. Lip 3. Spring 4. Grease EAM30012 LOCK WASHERS/PLATES AND COTTER PINS After removal, replace lock washers/plates “1” and cotter pins with new ones. After the bolt or nut has been tightened to specification, firmly bend the lock tabs along a flat of the bolt or nut. EAM30014 CIRCLIPS When assembling parts, always use new cir-...
BASIC SERVICE INFORMATION • There are many types of coupler locks; EAM20120 BASIC SERVICE INFORMATION therefore, be sure to check the type of cou- pler lock before disconnecting the coupler. EAM30181 ELECTRICAL SYSTEM Checking the electrical system ECA14371 NOTICE Never insert the tester probes into the cou- pler terminal slots.
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BASIC SERVICE INFORMATION • If the pin “1” on the terminal is flattened, bend it up. • After disassembling or assembling a coupler, pull on the leads to make sure that they are in- stalled securely. 5. Check: • No continuity Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachom-...
SPECIAL TOOLS EAM20121 SPECIAL TOOLS The following special tools are required for accurate and complete adjustment and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised tech- niques. The shape and tool number used for the special tool differ by country, so two types are provid- ed.
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90890-01189 Flywheel puller YM-01189 Clutch holder 5-30, 5-32 90890-04199 Universal clutch holder YM-91042 Thickness gauge 5-30 90890-03268 Feeler gauge set YU-26900-9 Flywheel puller 5-40 90890-01362 Heavy duty puller YU-33270-B Yamaha bond No. 1215 5-41 90890-85505 Three bond No. 1215® 1-13...
INSTRUMENT AND CONTROL FUNCTIONS EAM20181 INSTRUMENT AND CONTROL FUNCTIONS EAM30182 ENGINE STOP SWITCH The engine stop switch “1” is located on the left handlebar. Continue pushing the engine stop switch till the engine comes to a stop. EAM30188 FRONT BRAKE LEVER The front brake lever “1”...
INSTRUMENT AND CONTROL FUNCTIONS in this position. EAM30444 STARTER KNOB (CHOKE) When cold, the engine requires a richer air-fuel mixture for starting. A separate starter circuit, which is controlled by the starter knob “1”, sup- plies this mixture. Pull the starter knob out to open the circuit for starting.
STARTING AND BREAK-IN 4. Run the engine at idle or slightly higher until it EAM20123 STARTING AND BREAK-IN warms up: this usually takes about one or two minutes. EAM30538 5. The engine is warmed up when it responds FUEL AND ENGINE MIXING OIL normally to the throttle with the starter knob Mix oil with the gas at the ratio specified below.
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STARTING AND BREAK-IN ECA25821 NOTICE After a break-in or after each race, always check the points shown in “TORQUE- CHECK POINTS” for tightening torques and retighten them. Also when the following parts are replaced, a break-in is required. • Cylinder and Crankshaft: A break-in is re- quired for about an hour.
Disassemble the carburetor and clean the AIR FILTER MAINTENANCE small holes, blowing them with compressed Apply the Yamaha foam air filter oil or other qual- air. ity foam air filter oil to the element. (Excess oil in • CDI magneto...
TORQUE-CHECK POINTS EAM20125 TORQUE-CHECK POINTS Frame construction Combined seat and fuel tank Fuel tank to frame Frame to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Seat Seat to frame Steering Steering stem to handlebar Steering stem to frame Steering stem to upper bracket Upper bracket to handlebar...
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TORQUE-CHECK POINTS Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fender Tightening of mud flap Tightening of rear brake disc cover Tightening of rear brake caliper cover Concerning the tightening torque, refer to “TIGHTENING TORQUES”...
MOTORCYCLE CARE AND STORAGE ucts are used on hard-to-remove dirt, do EAM20126 MOTORCYCLE CARE AND STOR- not leave the cleaner on the affected area any longer than instructed. Also, thorough- ly rinse the area off with water, immediately dry it, and then apply a corrosion protec- EAM30200 CARE tion spray.
Salt sprayed on roads in the winter may remain well into spring. • Consult a Yamaha dealer for advice on what 1. Clean the motorcycle with cold water and a products to use.
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MOTORCYCLE CARE AND STORAGE stored. Long-term Before storing your motorcycle for several months: 1. Follow all the instructions in “CARE” on page 1-23. 2. Drain the fuel tank, fuel lines, and the carbu- retor float bowl. 3. Perform the following steps to protect the cyl- inder, piston rings, etc.
GENERAL SPECIFICATIONS EAM20127 GENERAL SPECIFICATIONS Model Model B4X1 B4X5 Dimensions Overall length 2135 mm (84.1 in) Overall width 825 mm (32.5 in) Overall height 1295 mm (51.0 in) Seat height 980 mm (38.6 in) Wheelbase 1445 mm (56.9 in) Ground clearance 365 mm (14.37 in) Weight Curb weight...
ENGINE SPECIFICATIONS EAM20128 ENGINE SPECIFICATIONS Engine Combustion cycle 2-stroke Cooling system Liquid cooled Induction system Reed valve Displacement 125 cm³ Number of cylinders Single cylinder Bore stroke 54.0 54.5 mm (2.13 2.15 in) Compression ratio 8.2–10.1 : 1 Starting system Kickstarter Fuel...
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3.769 (49/13) Final drive Chain Air filter Air filter element Wet element Air filter oil grade Yamaha foam air filter oil or other quality foam air filter oil Carburetor Type quantity PWK38S 1 ID mark B4X1 00 Main jet...
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ENGINE SPECIFICATIONS Reed valve Thickness 0.400 mm (0.0157 in) Valve bending limit 0.2 mm (0.01 in)
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CHASSIS SPECIFICATIONS EAM20129 CHASSIS SPECIFICATIONS Chassis 26.0 Caster angle Trail 109 mm (4.3 in) Front wheel Wheel type Spoke wheel Rim size 21 x 1.60 Radial wheel runout limit 2.0 mm (0.08 in) Lateral wheel runout limit 2.0 mm (0.08 in) Wheel axle bending limit 0.50 mm (0.02 in) Rear wheel...
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Fork spring free length limit 492.0 mm (19.37 in) Inner tube bending limit 0.2 mm (0.01 in) Recommended oil Yamaha Suspension Oil S1 Quantity (left) 500.0 cm³ (16.91 US oz, 17.64 Imp.oz) Quantity (right) 500.0 cm³ (16.91 US oz, 17.64 Imp.oz)
CHASSIS SPECIFICATIONS Adjustment value from the start position (Hard) Slow compression damping Unit for adjustment Click Adjustment value from the start position (Soft) Adjustment value from the start position (STD) Adjustment value from the start position (Hard) Drive chain Size Chain type Non-sealed type Number of links...
TIGHTENING TORQUES EAM20131 TIGHTENING TORQUES EAM30205 GENERAL TIGHTENING TORQUE SPECIFICATIONS This chart specifies tightening torques for stan- dard fasteners with a standard ISO thread pitch. Tightening torque specifications for special com- ponents or assemblies are provided for each chapter of this manual. To avoid warpage, tight- en multi-fastener assemblies in a crisscross pat- tern and progressive stages until the specified tightening torque is reached.
CABLE ROUTING DIAGRAM EAM20152 CABLE ROUTING DIAGRAM Frame and engine (left side view) 2-15...
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CABLE ROUTING DIAGRAM K. Pass the radiator breather hose and YPVS 1. Engine stop switch lead breather hose on the outside of the engine 2. Throttle cable bracket and then inside of the down tube. 3. Clutch cable Then pass the radiator breather hose inside 4.
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CABLE ROUTING DIAGRAM Frame and engine (right side view) 2-17...
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CABLE ROUTING DIAGRAM J. Pass the CDI magneto lead and radiator 1. High tension cord breather hose between the frame and the 2. Clamp radiator (right). 3. Ignition coil lead K. Place the clamp end so that it is located out- 4.
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CABLE ROUTING DIAGRAM 1. Brake hose 2. Master cylinder 3. Engine stop switch lead 4. Engine stop switch 5. Throttle cable 6. Clutch cable 7. Clamp 8. Cable guide A. Install the brake hose so that its pipe portion directs as shown and lightly touches the pro- jection on the master cylinder, while the white paint side faces to the front of the vehicle.
PERIODIC CHECKS AND ADJUSTMENTS MAINTENANCE INTERVALS ................3-1 MAINTENANCE INTERVALS..............3-1 PRE-OPERATION INSPECTION AND MAINTENANCE .........3-4 GENERAL INSPECTION AND MAINTENANCE ........3-4 ENGINE......................3-5 ADJUSTING THE PILOT AIR SCREW ............3-5 CHECKING THE ENGINE IDLING SPEED..........3-5 CHECKING THE THROTTLE GRIP ............3-5 CHECKING THE SPARK PLUG..............3-5 CHECKING THE TRANSMISSION OIL LEVEL .........3-6 CHANGING THE TRANSMISSION OIL .............3-6 ADJUSTING THE CLUTCH LEVER FREE PLAY ........3-7...
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CHECKING AND LUBRICATING THE CABLES........3-24 LUBRICATING THE BRAKE LEVER ............3-24 LUBRICATING THE CLUTCH LEVER .............3-24 LUBRICATING THE PEDAL..............3-24 ELECTRICAL SYSTEM..................3-25 CHECKING THE IGNITION TIMING ............3-25...
(e.g., rain, dirt, etc.). Therefore, earlier inspection is required by reference to the list below. Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
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• Check chain slack, alignment and condition. • Adjust and thoroughly lubricate 16 * Drive chain chain with Yamaha chain and cable lube or equivalent. • Replace. • Check coolant level and for leak- ...
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MAINTENANCE INTERVALS Every Every Every After race third race fifth race Item Routine break-in (about 2.5 (about 7.5 (about 12.5 required hours) hours) hours) • Check operation and for oil leak- age. • Adjust if necessary. • Clean dust seal and lubricate with lithium-soap-based grease.
PRE-OPERATION INSPECTION AND MAINTENANCE EAM20134 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating con- dition. Before using this machine, check the following points. EAM30209 GENERAL INSPECTION AND MAINTENANCE Item Inspect Page...
ENGINE gine idling speed should be adjusted. EAM20135 ENGINE 1. Check: • Throttle grip free play “a” EAM30607 ADJUSTING THE PILOT AIR SCREW Out of specification Regulate. 1. Adjust: Throttle grip free play • Pilot air screw “1” 3.0–5.0 mm (0.12–0.20 in) 1 1 1 G088895 To optimize the fuel flow at a smaller throttle...
ENGINE into the cylinder. 3. Check: • Transmission oil level 3. Check: a. Remove the oil check bolt “1”. • Spark plug type b. Inspect the oil level. Incorrect Change. Manufacturer/model Be sure the machine is positioned straight up NGK/BR9EVX when inspecting the oil level.
ENGINE Clutch lever free play 7.0–12.0 mm (0.28–0.47 in) G088887 2. Adjust: • Clutch lever free play Handlebar side a. Turn the adjuster “1” until the specified clutch lever free play is obtained. 5. Drain: • Transmission oil 6. Install: •...
4. Check: • Air filter element Damage Replace. 5. Apply: Yamaha foam air filter oil or other quality 2. Tighten: foam air filter oil. • Locknut a. Put the air filter element into a plastic bag Locknut (clutch lever position) and drip the filter oil into the bag.
ENGINE ECA26420 6. Install: NOTICE • Air filter guide “1” Make sure that the air filter element is prop- erly seated in the air filter case. The engine Align the projection “a” on filter guide with the should never be operated without the air fil- hole “b”...
ENGINE Crack/damage Replace. Refer to “RADIATOR” on page 6-2. 3. Install: • Air scoop (left/right) • Seat • Side cover (left/right) Refer to “GENERAL CHASSIS” on page 4-1. EAM30212 CHANGING THE COOLANT EWA13030 WARNING 3. Check: A hot radiator is under pressure. Therefore, •...
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ENGINE Coolant drain bolt 10 N·m (1.0 kgf·m, 7.4 lb·ft) 6. Pour coolant. Recommended coolant High quality ethylene glycol anti-freeze containing anti-cor- rosion for aluminum engine Radiator (including all routes) 0.90 L (0.95 US qt, 0.79 Imp.qt) Coolant mixing ratio 1:1 (Coolant:Water) EWA13040 WARNING...
CHASSIS air must be removed by bleeding the brake EAM20136 CHASSIS system. Air in the brake system will consid- erably reduce braking performance. EAM30479 ADJUSTING THE FRONT DISC BRAKE ECA13490 NOTICE There should be no free play at the brake lever After adjusting the brake lever position, end.
CHASSIS EWA19150 ECA13540 NOTICE WARNING A soft or spongy feeling in the brake pedal Brake fluid may damage painted surfaces can indicate the presence of air in the brake and plastic parts. Therefore, always clean up system. Before running, bleed the brake sys- any spilt brake fluid immediately.
CHASSIS 2. Check: • Reservoir float (front brake) • Brake hose clamp • Protector (rear brake) Loose connection Tighten the clamp bolt. 3. Stand the vehicle upright and apply the front • Be careful not to spill any brake fluid or allow brake several times.
CHASSIS ver to contact the throttle grip or the brake pedal N (5.0 kgf, 37 lbf). to fully extend. 4. Check: • Drive chain slack “a” g. Tighten the bleed screw and then release Out of specification Regulate. the brake lever or brake pedal. h.
CHASSIS Rear wheel axle nut 125 N·m (12.5 kgf·m, 92 lb·ft) e. Tighten the drive chain puller locknut. Drive chain puller locknut 19 N·m (1.9 kgf·m, 14 lb·ft) EAM30247 CHECKING AND ADJUSTING THE STEERING HEAD 1. Use a maintenance stand to raise the front Steering nut wrench wheel off the ground.
CHASSIS of the outer tube circumference. 5. Install: • Upper bracket 6. Remove: Refer to “STEERING HEAD” on page 4-51. • Protector • Handlebar • Dust seal “1” Refer to “HANDLEBAR” on page 4-33. ECA24330 NOTICE EAM30502 LUBRICATING THE STEERING HEAD Be careful not to damage the dust seal and 1.
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CHASSIS have poor stability. Compression damping • Securely support the vehicle so that there ECA24350 NOTICE is no danger of it falling over. Do not turn the adjuster forcibly beyond its Rebound damping adjusting range. ECA24340 NOTICE 1. Adjust: Do not turn the adjuster forcibly beyond its •...
CHASSIS wheel off the ground. off the ground. EWA13120 EWA13120 WARNING WARNING Securely support the vehicle so that there is Securely support the vehicle so that there is no danger of it falling over. no danger of it falling over. Spring preload 2.
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CHASSIS Spring preload adjusting positions Rebound damping Minimum Minimum (soft) Position in which the spring is 20 click(s) in direction “b”* turned in 1.5 mm (0.06 in) from Standard its free length. 10 click(s) in direction “b”* Standard Maximum (hard) Position in which the spring is 0 click(s) in direction “b”* turned in 7.0 mm (0.28 in) from...
CHASSIS Fast compression damping Slow compression damping Minimum (soft) Minimum (soft) 2 turn(s) in direction “b”* 20 click(s) in direction “b”* Standard Standard 1-1/2 turn(s) in direction “b”* 12 click(s) in direction “b”* Maximum (hard) Maximum (hard) 0 turn(s) in direction “b”* 0 click(s) in direction “b”* * With the adjusting screw fully turned in di- * With the adjusting screw fully turned in di-...
CHASSIS loose spoke will sound flat. EAM30243 CHECKING THE TIRES 2. Tighten: 1. Measure: • Spoke • Tire pressure (with a spoke nipple wrench “1”) Out of specification Regulate. Tire air pressure (measured on cold tires) Front 100 kPa (1.00 kgf/cm², 15 psi) Rear 100 kPa (1.00 kgf/cm², 15 psi) •...
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CHASSIS Refer to “CHASSIS TIGHTENING TORQUES” on page 2-11. EAM30248 CHECKING AND LUBRICATING THE CABLES The following procedure applies to all of the in- ner and outer cables. EWA13270 WARNING Damaged outer cable may cause the cable to corrode and interfere with its movement. Re- place damaged outer cable and inner cables as soon as possible.
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ELECTRICAL SYSTEM Punch mark “a” on rotor should be aligned EAM20137 ELECTRICAL SYSTEM with punch mark “b” on stator. Not aligned Adjust. EAM30255 CHECKING THE IGNITION TIMING 1. Remove: • Fuel tank Refer to “FUEL TANK” on page 7-1. •...
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CHASSIS GENERAL CHASSIS..................4-1 REMOVING THE NUMBER PLATE ............4-2 REMOVING THE SIDE COVER ..............4-2 FRONT WHEEL ....................4-3 REMOVING THE FRONT WHEEL .............4-4 DISASSEMBLING THE FRONT WHEEL ...........4-4 CHECKING THE FRONT WHEEL .............4-4 ASSEMBLING THE FRONT WHEEL ............4-4 INSTALLING THE FRONT WHEEL ............4-5 REAR WHEEL ....................4-7 REMOVING THE REAR WHEEL ...............4-8 DISASSEMBLING THE REAR WHEEL .............4-8...
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HANDLEBAR....................4-33 REMOVING THE HANDLEBAR ...............4-34 CHECKING THE HANDLEBAR..............4-34 INSTALLING THE HANDLEBAR..............4-34 FRONT FORK....................4-39 REMOVING THE FRONT FORK LEGS ...........4-41 DISASSEMBLING THE FRONT FORK LEGS .........4-41 CHECKING THE FRONT FORK LEGS............4-42 ASSEMBLING THE FRONT FORK LEGS ..........4-43 INSTALLING THE FRONT FORK LEGS..........4-49 STEERING HEAD...................4-51 REMOVING THE LOWER BRACKET ............4-52 CHECKING THE STEERING HEAD ............4-52...
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GENERAL CHASSIS EAM20094 GENERAL CHASSIS Removing the seat and side cover Order Job/Parts to remove Q’ty Remarks Seat Air scoop (right) Air scoop (left) Side cover (left) Side cover (right) Number plate...
GENERAL CHASSIS EAM30371 REMOVING THE NUMBER PLATE 1. Remove: • Number plate bolt • Number plate “1” • The projection “a” is inserted into the band of the number plate. Pull the band off the projec- tion before removal. • Remove the clutch cable “2” from the cable guide “b”...
FRONT WHEEL EAM20095 FRONT WHEEL Removing the front wheel 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 21 N ・ m (2.1 kgf ・ m, 15 lb ・ ft) 105 N ・ m (10.5 kgf ・ m, 77 lb ・ ft) 12 N ・...
FRONT WHEEL Refer to “CHECKING AND TIGHTENING EAM30017 REMOVING THE FRONT WHEEL THE SPOKES” on page 3-23. 1. Use a maintenance stand to raise the front 4. Tighten: wheel off the ground. • Spoke EWA13120 Refer to “CHECKING AND TIGHTENING WARNING THE SPOKES”...
FRONT WHEEL or numbers facing outward. Tighten the bolts in stages and in a crisscross ECA24420 pattern. NOTICE Install the bearing by pressing its outer race 3. Install: parallel. • Collar “1” • Apply the lithium-soap-based grease on the oil seal lip.
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FRONT WHEEL 3. Tighten: • Front wheel axle nut “1” Front wheel axle nut 105 N·m (10.5 kgf·m, 77 lb·ft) ECA24430 NOTICE Before tightening the front wheel axle nut, push down hard on the handlebar(s) several times and check if the front fork rebounds smoothly.
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REAR WHEEL EAM20096 REAR WHEEL Removing the rear wheel 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 125 N ・ m (12.5 kgf ・ m, 92 lb ・ ft) 19 N ・ m (1.9 kgf ・ m, 14 lb ・ ft) 42 N ・...
REAR WHEEL Refer to “CHECKING THE TIRES” on page EAM30022 REMOVING THE REAR WHEEL 3-23 and “CHECKING THE WHEELS” on 1. Use a maintenance stand to raise the rear page 3-23. wheel off the ground. 3. Check: EWA13120 • Spoke WARNING Refer to “CHECKING AND TIGHTENING Securely support the vehicle so that there is...
FRONT BRAKE EAM20097 FRONT BRAKE Removing the front brake caliper 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 28 N ・ m (2.8 kgf ・ m, 21 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 17 N ・...
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FRONT BRAKE Disassembling the front brake caliper 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake caliper piston kit Brake caliper piston seal kit Bleed screw 4-12...
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FRONT BRAKE Removing the front brake master cylinder 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) 9 N ・...
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FRONT BRAKE Disassembling the front brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder kit 4-14...
FRONT BRAKE b. Remove the brake caliper. EAM30028 INTRODUCTION c. Hold the dial gauge at a right angle against EWA19210 the brake disc surface. WARNING d. Measure the runout 1.5 mm (0.06 in) If you need to disassemble the disc brake above the brake disc edge.
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FRONT BRAKE d. Remove the pad pin and brake pads “4”. Brake caliper bleed screw 6 N·m (0.6 kgf·m, 4.4 lb·ft) d. Install the brake pads “3” and the pad pin. • Install the brake pads with their projections “a” into the brake caliper recesses “b”.
FRONT BRAKE 4. Check: • Brake fluid level Refer to “CHECKING THE BRAKE FLUID LEVEL” on page 3-14. 5. Check: • Brake lever operation A softy or spongy feeling Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-15. b.
FRONT BRAKE cleaning and lubricating. Brake pad pin • Never use solvents on internal brake com- 17 N·m (1.7 kgf·m, 13 lb·ft) ponents as they will cause the piston seals to swell and distort. Refer to “CHECKING THE FRONT BRAKE •...
FRONT BRAKE Refer to “BLEEDING THE HYDRAULIC 3. Check: • Brake hose BRAKE SYSTEM” on page 3-15. Cracks/damage/wear Replace. 6. Check: • Brake fluid level EAM30038 The minimum level mark or below Add. ASSEMBLING THE FRONT BRAKE MASTER Refer to “CHECKING THE BRAKE FLUID CYLINDER LEVEL”...
FRONT BRAKE • First, tighten the upper bolt, then the lower bolt. Install the spring with a smaller inside diameter to the brake master cylinder piston. 2. Install: • Copper washer “1” • Brake hose “2” 4. Install: • Union bolt “3” •...
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FRONT BRAKE EWA13090 WARNING • Use only the designated brake fluid. Other brake fluids may cause the rubber seals to deteriorate, causing leakage and poor brake performance. • Refill with the same type of brake fluid that is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
REAR BRAKE EAM20098 REAR BRAKE Removing the rear brake caliper 2.5 N ・ m (0.25 kgf ・ m, 1.8 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 17 N ・ m (1.7 kgf ・ m, 13 lb ・ ft) 30 N ・...
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REAR BRAKE Disassembling the rear brake caliper 6 N ・ m (0.6 kgf ・ m, 4.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Brake caliper piston kit Brake caliper piston seal kit Bleed screw 4-23...
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REAR BRAKE Removing the rear brake master cylinder 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) Order Job/Parts to remove Q’ty...
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REAR BRAKE Disassembling the rear brake master cylinder Order Job/Parts to remove Q’ty Remarks Brake master cylinder joint Brake master cylinder kit 4-25...
REAR BRAKE EAM30040 INTRODUCTION Brake disc runout limit (as mea- sured on wheel) EWA19260 0.15 mm (0.0059 in) WARNING If you need to disassemble the disc brake 4. Replace: components, observe the following precau- • Brake disc tions. Refer “ASSEMBLING REAR •...
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REAR BRAKE Brake caliper bleed screw 6 N·m (0.6 kgf·m, 4.4 lb·ft) d. Install the brake pad “3” and the pad pin “4”. • Install the brake pads with their projections “a” into the brake caliper recesses “b”. • Temporarily tighten the pad pin at this point. 2.
REAR BRAKE the brake caliper. EWA13550 WARNING • Cover the brake caliper piston with a rag. Be careful not to get injured when the pis- ton is expelled from the brake caliper. • Never try to pry out the brake caliper pis- ton.
REAR BRAKE 2. Check: • Brake caliper bracket Crack/damage Replace. EAM30045 ASSEMBLING THE REAR BRAKE CALIPER EWA19280 WARNING • Before installation, clean and lubricate the internal parts. Use new brake fluid for cleaning and lubricating. • Never use solvents on internal brake com- 3.
REAR BRAKE 3. Install: EWA13531 WARNING • Spring “1” Proper brake hose routing is essential to in- (to the brake master cylinder piston “2”) sure safe vehicle operation. Install the spring with a smaller inside diameter ECA24500 to the brake master cylinder piston. NOTICE Make sure that the pipe portion of the brake hose touches the projection “a”...
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REAR BRAKE LEVEL” on page 3-14. 5. Check: • Brake pedal operation A softy or spongy feeling Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” on page 3-15. 4-32...
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HANDLEBAR EAM20099 HANDLEBAR Removing the handlebar Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Number plate 4-1. Brake master cylinder Throttle cable cap Throttle cable Right grip Cap cover Collar Clutch cable Clutch lever holder Engine stop switch Left grip Upper handlebar holder Handlebar...
HANDLEBAR EAM30052 EWA13120 REMOVING THE HANDLEBAR WARNING 1. Stand the vehicle upright on a level surface. Securely support the vehicle so that there is EWA13120 no danger of it falling over. WARNING 2. Install: Securely support the vehicle so that there is •...
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HANDLEBAR in place on both sides. Lower handlebar holder nut • Install the handlebar so that the projection “c” 40 N·m (4.0 kgf·m, 30 lb·ft) of the upper handlebar holders is positioned at the mark on the handlebar as shown. •...
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HANDLEBAR • Pass the engine stop switch lead in the middle of the clutch lever holder. 0 mm (0 in) 0 mm (0 in) 10.Install: • Grip cap (upper) “1” • Grip cap (lower) “2” 7. Install: • Grip cap bolt “3” •...
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HANDLEBAR Throttle cable cap screw 0.5 N·m (0.05 kgf·m, 0.37 lb·ft) 12.Install: • Throttle cable “1” (to the tube guide “2”) 15.Adjust: Apply the lithium-soap-based grease on the • Throttle grip free play throttle cable end and tube guide cable winding Refer to “CHECKING THE THROTTLE portion.
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HANDLEBAR 18.Install: • Grip cap bolt “1” Grip cap bolt 3.8 N·m (0.38 kgf·m, 2.8 lb·ft) EWA21080 WARNING After tightening the bolts, check that the throttle grip “2” moves smoothly. If it does not, retighten the bolts for adjustment. 4-38...
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FRONT FORK EAM20100 FRONT FORK Removing the front fork legs Order Job/Parts to remove Q’ty Remarks Use a maintenance stand to raise the front wheel off the ground. Front wheel Refer to “FRONT WHEEL” on page 4-3. Front brake caliper Refer to “FRONT BRAKE”...
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FRONT FORK Disassembling the front fork leg Order Job/Parts to remove Q’ty Remarks Adjuster Fork spring Damper adjusting rod Dust seal Stopper ring Inner tube Outer tube Piston metal Protector guide Slide metal Washer Oil seal Base valve Damper assembly Upper spring seat 4-40...
FRONT FORK • Hold the locknut and remove the adjuster. EAM30055 REMOVING THE FRONT FORK LEGS 1. Use a maintenance stand to raise the front ECA24520 NOTICE wheel off the ground. Do not remove the locknut as the damper rod EWA13120 may go into the damper assembly and not be WARNING...
FRONT FORK dial gauge reading. EWA13650 WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken it. 2. Check: • Outer tube Scratches/wear/damage Replace. 3. Measure: • Fork spring free length “a” 5. Remove: Out of specification ...
1. Stretch the damper assembly fully. 2. Fill: • Damper assembly Recommended oil Yamaha Suspension Oil S1 Standard oil amount 205 cm³ (6.93 US oz, 7.21 Imp.oz) 6. Check: • Upper spring seat “1”...
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FRONT FORK Standard oil level 145–148 mm (5.71–5.83 in) From top of fully stretched damper assembly. 7. Install: • Base valve “1” (to the damper assembly “2”) First bring the damper rod pressure to a maxi- mum. Then install the base valve while releasing the damper rod pressure.
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FRONT FORK 10.After filling, pump the damper assembly “1” 13.Check: slowly up and down more than 10 times to • Damper assembly smooth movement Tightness/binding/rough spots Repeat the distribute the fork oil. steps (1) to (12). 11.While protecting the damper assembly “1” with a cloth and compressing fully, allow ex- 14.Install: •...
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FRONT FORK G088922 G088923 15.Install: 18.Install: • Piston metal “1” • Oil seal “1” Install the piston metal onto the slot on inner Using a fork seal driver “2”, press the oil seal in until the stopper ring groove fully appears. tube.
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FRONT FORK 21.Check: 24.Install: • Inner tube smooth movement • Damper assembly “1” Tightness/binding/rough spots Repeat the (to the inner tube “2”) steps (14) to (20). ECA24560 NOTICE Allow the damper assembly to slide slowly down the inner tube until it contacts the bot- tom of the inner tube.
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30.Fill: • Front fork leg Recommended oil If it is installed with a gap out of specification, Yamaha Suspension Oil S1 correct damping force cannot be obtained. Standard oil amount 305 cm³ (10.3 US oz, 10.8 Imp.oz) Extent of adjustment 280–365 cm³...
FRONT FORK 31.Install: 2. Tighten: • Damper assembly “1” • Damper assembly “1” (to the outer tube) Damper assembly (front fork) 30 N·m (3.0 kgf·m, 22 lb·ft) Temporarily tighten the damper assembly. Use the cap bolt ring wrench “2” to tighten the damper assembly.
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FRONT FORK Upper bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) • Lower bracket pinch bolt “2” Lower bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) EWA19320 WARNING Tighten the lower bracket to specified 7. Adjust: torque. If torqued too much, it may cause the •...
STEERING HEAD EAM20101 STEERING HEAD Removing the lower bracket 38 N ・ m (3.8 kgf ・ m, 28 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Use a maintenance stand to raise the front wheel off the ground.
STEERING HEAD EAM30060 ECA14270 REMOVING THE LOWER BRACKET NOTICE 1. Use a maintenance stand to raise the front If the bearing race is not installed properly, wheel off the ground. the steering head pipe could be damaged. EWA13120 WARNING Always replace the bearing and the bearing race Securely support the vehicle so that there is as a set.
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STEERING HEAD • Upper bearing “1” • Bearing race cover “2” Apply the lithium-soap-based grease on the bearing and bearing race cover lip. 5. Check the steering stem by turning this lock to lock. If there is any binding, remove the steering stem and check the steering bear- ing.
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STEERING HEAD Upper bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) • Lower bracket pinch bolt “2” Lower bracket pinch bolt 21 N·m (2.1 kgf·m, 15 lb·ft) EWA19330 WARNING Tighten the lower bracket to specified 8. Install: torque. If torqued too much, it may cause the •...
REAR SHOCK ABSORBER ASSEMBLY EAM20102 REAR SHOCK ABSORBER ASSEMBLY Removing the rear shock absorber assembly 2.3 N ・ m (0.23 kgf ・ m, 1.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Refer to “GENERAL CHASSIS” on page Seat 4-1.
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REAR SHOCK ABSORBER ASSEMBLY Disassembling the relay arm Order Job/Parts to remove Q’ty Remarks Relay arm Connecting arm Collar Oil seal Washer Bearing 4-56...
• To dispose of a damaged or a worn-out rear • Spring shock absorber, take the unit to your Damage/wear Replace. Yamaha dealer for this disposal procedure. • Spring guide Damage/wear Replace. • Bearing Damage/wear Replace.
REAR SHOCK ABSORBER ASSEMBLY Damage/pitting/scratches Replace the Installed depth “a” bearings and collars as a set. 0 mm (0 in) 3. Check: • Oil seal Damage/pitting Replace. EAM30069 INSTALLING THE RELAY ARM 1. Lubricate: • Oil seal • Bearing •...
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REAR SHOCK ABSORBER ASSEMBLY Connecting arm nut (relay arm Install the dust seals with their lips facing inward. side) 80 N·m (8.0 kgf·m, 59 lb·ft) Installed depth “a” 4.25 mm (0.17 in) • Relay arm nut (swingarm side) Relay arm nut (swingarm side) 70 N·m (7.0 kgf·m, 52 lb·ft) •...
SWINGARM EAM20103 SWINGARM Removing the swingarm Order Job/Parts to remove Q’ty Remarks Use a maintenance stand to raise the rear wheel off the ground. Brake hose holder Rear brake caliper Refer to “REAR BRAKE” on page 4-22. Brake pedal bolt Drive chain Collar Oil seal...
SWINGARM • Bearing EAM30071 REMOVING THE SWINGARM 4. Check: 1. Use a maintenance stand to raise the rear • Oil seal wheel off the ground. Damage Replace. EWA13120 • Bearing WARNING • Thrust bearing Securely support the vehicle so that there is •...
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SWINGARM 4. Install: • Rear wheel Refer to “REAR WHEEL” on page 4-7. 5. Adjust: • Drive chain slack Refer to “DRIVE CHAIN SLACK” on page 3-16. Drive chain slack (Maintenance Stand) 48.0–58.0 mm (1.89–2.28 in) 4-62...
CHAIN DRIVE EAM20104 CHAIN DRIVE Removing the drive chain 75 N ・ m (7.5 kgf ・ m, 55 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Drive sprocket Refer to “ENGINE REMOVAL”...
CHAIN DRIVE EAM30075 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. EWA13120 WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • Master link clip • Master link “1” G088938 •...
CHAIN DRIVE G088942 G089069 5. Lubricate: • Drive chain EAM30077 CHECKING THE DRIVE SPROCKET 1. Check: • Drive sprocket More than 1/4 tooth wear “a” Replace the drive sprocket and the rear wheel sprocket as a set. G089070 Bent tooth Replace the drive sprocket and 2.
ENGINE ENGINE REMOVAL ..................5-1 REMOVING THE ENGINE .................5-4 INSTALLING THE ENGINE ................5-4 INSTALLING THE EXHAUST PIPE AND MUFFLER .........5-4 CYLINDER HEAD, CYLINDER AND PISTON ..........5-6 REMOVING THE CYLINDER HEAD ............5-8 REMOVING THE PUSH ROD ..............5-8 REMOVING THE PISTON................5-8 CHECKING THE CYLINDER HEAD ............5-9 CHECKING THE CYLINDER AND PISTON..........5-9 COMBINATION OF PISTON AND CYLINDER ........5-10 CHECKING THE PISTON RING ..............5-11...
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CHECKING THE CLUTCH HOUSING .............5-30 CHECKING THE CLUTCH BOSS ............5-30 CHECKING THE PRESSURE PLATE .............5-31 CHECKING THE PUSH LEVER SHAFT ..........5-31 CHECKING THE PUSH RODS ..............5-31 CHECKING THE PRIMARY DRIVE GEAR ..........5-31 CHECKING THE PRIMARY DRIVEN GEAR..........5-31 INSTALLING THE CLUTCH ..............5-31 SHIFT SHAFT ....................5-35 REMOVING THE SEGMENT ..............5-36 CHECKING THE SHIFT SHAFT ..............5-36...
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ENGINE REMOVAL EAM20105 ENGINE REMOVAL Removing the exhaust pipe 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 15 mm (0.59 in) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 12 N ・...
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ENGINE REMOVAL Removing the engine 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 64 N ・ m (6.4 kgf ・ m, 47 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 85 N ・...
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ENGINE REMOVAL Removing the engine 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 64 N ・ m (6.4 kgf ・ m, 47 lb ・ ft) 26 N ・ m (2.6 kgf ・ m, 19 lb ・ ft) 85 N ・...
CYLINDER HEAD, CYLINDER AND PISTON EAM20190 CYLINDER HEAD, CYLINDER AND PISTON Removing the cylinder head and cylinder 20 N ・ m (2.0 kgf ・ m, 15 lb ・ ft) 34 N ・ m (3.4 kgf ・ m, 25 lb ・ ft) 28 N ・...
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CYLINDER HEAD, CYLINDER AND PISTON Disassembling the YPVS system 4.0 N ・ m (0.40 kgf ・ m, 3.0 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) 4.0 N ・...
CYLINDER HEAD, CYLINDER AND PISTON EAM30086 REMOVING THE CYLINDER HEAD 1. Remove: • Cylinder head nut Loosen each nut 1/2 of a turn at a time. After all of the nuts are fully loosened, remove them. EAM30543 REMOVING THE PUSH ROD 1.
CYLINDER HEAD, CYLINDER AND PISTON b. Measure the warpage. c. If the limit is exceeded, resurface the cylin- der head as follows. d. Place a 400–600 grit wet sandpaper on the surface plate and resurface the cylin- der head using a figure-eight sanding pat- tern.
CYLINDER HEAD, CYLINDER AND PISTON Diameter 53.957–53.972 mm (2.1243– 2.1249 in) 2. Check: • Piston mark “a” Piston mark “a” Piston size (color) a. 17.5 mm (0.69 in) from the bottom edge of 53.957–53.960 mm A (red) the piston (2.1243–2.1244 in) e.
CYLINDER HEAD, CYLINDER AND PISTON EAM30548 EAM30549 CHECKING THE PISTON RING CHECKING THE PISTON PIN 1. Measure: 1. Check: • Piston ring side clearance • Piston pin Out of specification Replace the piston Blue discoloration/grooves Replace the and piston ring as a set. piston pin, and then check the fuel and en- gine mixing oil.
CYLINDER HEAD, CYLINDER AND PISTON the aluminum. Piston-pin-to-piston-pin-bore clearance 0.008–0.023 mm (0.0003–0.0009 Limit 0.065 mm (0.0026 in) EAM30550 CHECKING THE SMALL END BEARING 1. Check: • Small end bearing Signs of heat discoloration Replace. EAM30551 ASSEMBLING THE POWER VALVE 1.
CDI MAGNETO EAM20191 CDI MAGNETO Removing the CDI magneto 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 56 N ・ m (5.6 kgf ・ m, 41 lb ・ ft) 5 N ・ m (0.5 kgf ・ m, 3.7 lb ・ ft) Order Job/Parts to remove Q’ty...
CDI MAGNETO Damage Inspect the crankshaft runout and EAM30562 REMOVING THE ROTOR crankshaft bearing. 1. Remove: If necessary, replace CDI magneto and/or • Rotor nut “1” stator. • Washer “2” While holding the rotor with the rotor holding tool “3”, loosen the rotor nut.
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CDI MAGNETO and rotor. of the hole. • When installing the woodruff key, make sure that its flat surface “a” is in parallel with the Stator coil screw crankshaft center line “b”. 7 N·m (0.7 kgf·m, 5.2 lb·ft) • When installing the rotor, align the keyway “c” of the rotor with the woodruff key.
KICKSTARTER EAM20112 KICKSTARTER Removing the primary drive gear 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 48 N ・ m (4.8 kgf ・ m, 35 lb ・ ft) Order Job/Parts to remove Q’ty...
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KICKSTARTER Removing the kickstarter shaft Order Job/Parts to remove Q’ty Remarks Kick idle gear Kick shaft assembly 5-21...
KICKSTARTER EAM30570 REMOVING THE PRIMARY DRIVE GEAR 1. Loosen: • Primary drive gear bolt “1” Place an aluminum plate “a” between the teeth of the primary drive gear “2” and driven gear “3”. EAM30104 INSTALLING THE KICK SHAFT ASSEMBLY 1. Install: •...
KICKSTARTER • Slide the kick shaft assembly into the crank- • Primary drive gear “2” • Primary drive gear bolt “3” case, make sure the clip “2” and kick shaft stopper “a” fit into their home position “b”, “c”. Install the primary drive gear with its depressed side toward you.
YPVS GOVERNOR EAM30566 EAM30569 REMOVING THE GOVERNOR INSTALLING THE GOVERNOR 1. Remove: 1. Install: • Dowel pin “1” • Governor gear “1” • Compression spring “2” • Plate “3” While compressing the spring, remove the dow- • Washer “4” el pin. •...
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YPVS GOVERNOR 3. Install: • Dowel pin “1” • While compressing the spring, install the dowel pin. • Make sure the dowel pin fits into the groove “a” in the retainer. 4. Install: • Governor assembly “1” Align the groove “a” in the governor with the fork “b”...
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CLUTCH EAM20111 CLUTCH Removing the clutch 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Drain. Transmission oil Refer to “CHANGING THE TRANSMISSION OIL”...
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CLUTCH Removing the clutch boss 80 N ・ m (8.0 kgf ・ m, 59 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Push rod 1 Circlip Washer Bearing Ball Push rod 2 Clutch boss nut Lock washer Clutch boss Thrust washer [D = ø34 mm (1.34 in)] Primary driven gear...
CLUTCH Out of specification Replace the clutch EAM30108 REMOVING THE CLUTCH plates as a set. 1. Remove: • Clutch boss nut “1” Thickness gauge 90890-03268 • Lock washer Feeler gauge set • Clutch boss “2” YU-26900-9 • While holding the clutch boss with the clutch holder “3”, loosen the clutch boss nut.
CLUTCH 2. Measure: • Push rod 2 bending limit Pitting on the clutch boss splines will cause er- Out of specification Replace. ratic clutch operation. Push rod bending limit 0.30 mm (0.012 in) EAM30117 CHECKING THE PRIMARY DRIVE GEAR 1.
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CLUTCH 4. Install: • Lock washer “1” • Clutch boss nut “2” Clutch boss nut 80 N·m (8.0 kgf·m, 59 lb·ft) Use the clutch holder “3” to hold the clutch boss. Clutch holder 90890-04199 Universal clutch holder YM-91042 2. Install: •...
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CLUTCH 7. Install: 10.Install: • Bearing “1” • Clutch spring • Washer “2” • Clutch spring bolt • Circlip “3” Clutch spring bolt (to the push rod 1 “4”) 10 N·m (1.0 kgf·m, 7.4 lb·ft) Apply the transmission oil on the bearing, wash- er and push rod 1.
SHIFT SHAFT EAM20113 SHIFT SHAFT Removing the shift shaft and stopper lever 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 12 N ・ m (1.2 kgf ・ m, 8.9 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty...
SHIFT SHAFT EAM30124 REMOVING THE SEGMENT 1. Remove: • Segment bolt “1” • Segment “2” Turn the segment counterclockwise until it stops and loosen the bolt. ECA24670 NOTICE If the segment gets an impact, the stopper le- EAM30127 ver may be damaged. Take care not to give CHECKING THE STOPPER LEVER an impact to it when removing the bolt.
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SHIFT SHAFT 2. Install: 4. Install: • Segment “1” • Shift lever assembly • Segment bolt (to the shift guide) 5. Install: Segment • Shift lever assembly “1” 30 N·m (3.0 kgf·m, 22 lb·ft) • Shift guide “2” • The shift lever assembly is installed at the •...
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SHIFT SHAFT Apply the transmission oil on the roller and shift shaft. 8. Install: • Shift pedal “1” • Shift pedal bolt “2” Shift pedal bolt 12 N·m (1.2 kgf·m, 8.9 lb·ft) Align the upper line “a” of the shift pedal with the center “b”...
CRANKCASE EAM20116 CRANKCASE Separating the crankcase 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 14 N ・ m (1.4 kgf ・ m, 10 lb ・ ft) 30 N ・ m (3.0 kgf ・ m, 22 lb ・ ft) 20 N ・...
CRANKCASE EAM30147 DISASSEMBLING THE CRANKCASE 1. Remove: • Crankcase (right) “1” (with the flywheel puller “2”) Flywheel puller 90890-01362 Heavy duty puller YU-33270-B • Make appropriate bolts “3” as shown available EAM30150 CHECKING THE CRANKCASE by yourself and attach the tool with them. 1.
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• If you use the tools starting from “90890-”, in- stead of the spacer “5” use two plain washers (Yamaha genuine: 90201-243K3) “6” or the Clean the contacting surface of crankcase ones of a size as shown placed on top of each (left/right) before applying the sealant.
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CRANKCASE 7. Install: • Clamp “1” • Crankcase bolt “2” Crankcase bolt 14 N·m (1.4 kgf·m, 10 lb·ft) Tighten the crankcase bolts in stage, using a crisscross pattern. 5-42...
CRANKSHAFT EAM20193 CRANKSHAFT Removing the crankshaft assembly Order Job/Parts to remove Q’ty Remarks Engine Refer to “ENGINE REMOVAL” on page 5-1. Crankcase Separate. Oil seal Crankshaft Bearing 5-43...
CRANKSHAFT shaft. EAM30491 REMOVING THE CRANKSHAFT 1. Remove: Crank assembly width 55.90–55.95 mm (2.201–2.203 in) • Crankshaft “1” (with the crankcase separating tool “2”) Crankcase separating tool 90890-01135 Crankcase separator YU-01135-B Make appropriate bolts “3” as shown available by yourself and attach the tool with them. ECA22290 NOTICE Do not use a hammer to drive out the crank-...
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TRANSMISSION EAM20118 TRANSMISSION Removing the transmission, shift drum assembly, and shift forks 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Engine...
TRANSMISSION EAM30153 REMOVING THE TRANSMISSION 1. Remove: • Main axle “1” • Drive axle “2” • Tap lightly on the transmission drive axle with a soft hammer to remove. • Remove assembly carefully. Note the position of each part. Pay particular attention to the lo- cation and direction of shift forks.
TRANSMISSION • Apply the molybdenum disulfide oil on the in- ner and end surface of the idler gear and on the inner surface of the sliding gear, then install. • Apply the molybdenum disulfide grease on the inner surface of the 4th wheel gear, then install. 3.
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TRANSMISSION 6. Install: • Shift cam “1” • Apply the transmission oil on the shift cam. • Install the shift cam while holding up the 5th wheel gear “2” and keeping the shift fork 1 “3” moved in the direction of the arrow. 4.
COOLING SYSTEM COOLING SYSTEM DIAGRAMS ..............6-1 RADIATOR......................6-2 CHECKING THE RADIATOR ..............6-3 INSTALLING THE RADIATOR ..............6-3 WATER PUMP ....................6-5 DISASSEMBLING THE WATER PUMP .............6-6 CHECKING THE WATER PUMP ...............6-6 ASSEMBLING THE WATER PUMP ............6-6...
COOLING SYSTEM DIAGRAMS EAM20186 COOLING SYSTEM DIAGRAMS 1. Radiator hose 1 2. Radiator (right) 3. Radiator hose 4 4. Water pump 5. Radiator (left)
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RADIATOR EAM20138 RADIATOR Removing the radiator 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 1.5 N ・ m (0.15 kgf ・ m, 1.1 lb ・ ft) 10 N ・...
RADIATOR EAM30341 CHECKING THE RADIATOR Radiator cap valve opening pres- sure EWA13030 93.3–122.7 kPa (0.93–1.23 WARNING kgf/cm², 13.5–17.8 psi) A hot radiator is under pressure. Therefore, do not remove the radiator cap when the en- No stay Replace. gine is hot. Scalding hot fluid and steam may be blown out, which could cause serious in- Radiator cap tester jury.
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RADIATOR G089031 4. Activate the tester to apply the test pressure. Test pressure value 122.7 kPa (1.23 kgf/cm², 17.8 psi) ECA24270 NOTICE • Do not apply such a high pressure as ex- ceeds the test pressure. • Make sure that a checkup after the cylinder head gasket is replaced is made after 3 min- utes of warm-up.
WATER PUMP EAM20139 WATER PUMP Removing the water pump 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) Order Job/Parts to remove Q’ty Remarks Crankcase cover (right) Refer to “KICKSTARTER”...
WATER PUMP EAM30494 DISASSEMBLING THE WATER PUMP • Remove the oil seal when the coolant level changes frequently more than usual, coolant has discolored, or engine oil has become milky. • Do not use the removed oil seal. 1. Remove: •...
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WATER PUMP • Collar “4” • Circlip “6” Install the impeller shaft gear with the dowel pin fitted in the groove “a” in the same gear. 5. Install: • Dowel pin “1” • Gasket “2” 6. Install: • Water pump housing “1” •...
FUEL SYSTEM FUEL TANK ......................7-1 AIR FILTER .......................7-2 CARBURETOR ....................7-3 HANDLING NOTE ..................7-6 CHECKING THE CARBURETOR ..............7-6 CHECKING THE REED VALVE ..............7-7 INSTALLING THE REED VALVE ...............7-7 ASSEMBLING THE CARBURETOR ............7-7 INSTALLING THE CARBURETOR ............7-10 MEASURING AND ADJUSTING THE FUEL LEVEL........7-11...
FUEL TANK EAM20140 FUEL TANK Removing the fuel tank 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 7 N ・ m (0.7 kgf ・ m, 5.2 lb ・ ft) 4.0 N ・...
AIR FILTER EAM20201 AIR FILTER Removing the air filter element 2.0 N ・ m (0.20 kgf ・ m, 1.5 lb ・ ft) 3.5 N ・ m (0.35 kgf ・ m, 2.6 lb ・ ft) 8 N ・ m (0.8 kgf ・ m, 5.9 lb ・ ft) Order Job/Parts to remove Q’ty...
CARBURETOR EAM20194 CARBURETOR Removing the carburetor and reed valve 10 N ・ m (1.0 kgf ・ m, 7.4 lb ・ ft) 2.3 N ・ m (0.23 kgf ・ m, 1.7 lb ・ ft) 2.3 N ・ m (0.23 kgf ・ m, 1.7 lb ・ ft) Order Job/Parts to remove Q’ty...
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CARBURETOR Disassembling the carburetor Order Job/Parts to remove Q’ty Remarks Mixing chamber top Gasket Throttle valve Ring Throttle valve spring Jet needle holder Collar Spring Jet needle Air vent hose Air vent hose Starter plunger Fuel cut solenoid valve Throttle position sensor Lever comp...
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CARBURETOR Disassembling the carburetor Order Job/Parts to remove Q’ty Remarks Throttle stop screw Pilot air screw Plug Overflow hose Float chamber Float pin Float Needle valve Main jet Pilot jet Power jet...
CARBURETOR EAM30580 HANDLING NOTE ECA27120 NOTICE Do not loosen the screw (throttle position sensor) “1” except when changing the throt- tle position sensor due to failure because it will cause a drop in engine performance. 6. Check: • Needle valve “1” •...
CARBURETOR EAM30577 8. Check: INSTALLING THE REED VALVE • Free movement 1. Install: Stick Repair or replace. • Gasket • Reed valve assembly “1” Insert the throttle valve “2” into the carburetor body while pulling up the lever “1”, and check for free movement.
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CARBURETOR 2. Install: 5. Install: • Pilot jet “1” • O-ring • Main jet “2” • Solenoid valve (to the carburetor) ECA27130 NOTICE Before installing the solenoid valve, blow air on the solenoid valve and its installing loca- tion on the carburetor in order to remove any foreign particles such as chips etc.
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CARBURETOR • Mixing chamber top “3” • Gasket “4” • Throttle valve spring “5” • Ring “6” • Throttle valve “7” • Jet needle “8” • While compressing the spring, connect the throttle cable. • Align the projection “a” on the ring with the groove “b”...
CARBURETOR 1 1 1 3. Tighten: EAM30578 INSTALLING THE CARBURETOR • Carburetor joint bolt “1” 1. Install: • Carburetor “1” Place the bolt head “a” with its top as shown and secure the clamp in alignment with the horizon- • Install the projection between the carburetor tal line “b”...
CARBURETOR EAM30579 MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: • Float height “a” Out of specification Adjust. Float height 6.5 mm (0.26 in) a. Hold the carburetor in an upside down po- sition. b. Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers.
ELECTRICAL SYSTEM WIRING DIAGRAM ...................8-1 COLOR CODE....................8-1 IGNITION SYSTEM...................8-2 TROUBLESHOOTING................8-2 SOLENOID VALVE SYSTEM ................8-3 TROUBLESHOOTING................8-3 THROTTLE POSITION SENSOR SYSTEM .............8-4 TROUBLESHOOTING................8-4 ELECTRICAL COMPONENTS.................8-5 CHECKING THE SWITCHES..............8-6 CHECKING THE IGNITION SPARK GAP ..........8-8 CHECKING THE SPARK PLUG CAP ............8-8 CHECKING THE IGNITION COIL ..............8-8 CHECKING THE PICKUP COIL ..............8-9 CHECKING THE SOURCE COIL ...............8-9 CHECKING THE SOLENOID VALVE OPERATION ........8-10...
IGNITION SYSTEM EAM20142 IGNITION SYSTEM EAM30278 TROUBLESHOOTING The ignition system fails to operate (no spark or intermittent spark). Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 1. Check the spark plug. Refer to “CHECKING THE SPARK Re-gap or replace the spark plug. NG...
SOLENOID VALVE SYSTEM EAM20196 SOLENOID VALVE SYSTEM EAM30581 TROUBLESHOOTING If the solenoid valve will not operate, use the following inspection steps. Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank Use 12 V battery in this inspection. 1. Check each couplers and wire con- Reconnect.
THROTTLE POSITION SENSOR SYSTEM EAM20197 THROTTLE POSITION SENSOR SYSTEM EAM30582 TROUBLESHOOTING If the throttle position sensor will not operate, use the following inspection steps. Before troubleshooting, remove the following part(s): 1. Seat 2. Fuel tank 1. Check entire ignition system for Reconnect.
ELECTRICAL COMPONENTS EAM30289 CHECKING THE SWITCHES 1. Engine stop switch...
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ELECTRICAL COMPONENTS Check each switch for continuity with the digital circuit tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. ECA14371 NOTICE Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end “a”...
ELECTRICAL COMPONENTS EAM30294 CHECKING THE IGNITION SPARK GAP Digital circuit tester (CD732) 90890-03243 1. Check: Model 88 Multimeter with tachom- • Ignition spark gap eter Out of specification Perform the ignition YU-A1927 system troubleshooting, starting with step (3). Refer to “TROUBLESHOOTING” on page 8-2.
ELECTRICAL COMPONENTS a. Connect the digital circuit tester () to the pickup coil coupler as shown. Digital circuit tester (CD732) 90890-03243 Model 88 Multimeter with tachom- eter YU-A1927 • Positive tester probe White/Red “1” • Negative tester probe c.
ELECTRICAL COMPONENTS • Positive battery lead Red “1” • Negative battery lead Red “2” 1 1 1 b. Measure the source coil resistance (B/R– 3. Check: • Charging coil 2 resistance (G/L–G/W) 3. Check: Out of specification Replace the CDI mag- •...
ELECTRICAL COMPONENTS Out of specification Replace. EAM30587 HANDLING NOTE • Positive tester probe ECA27120 Yellow “1” NOTICE • Negative tester probe Do not loosen the screw (throttle position Black “2” sensor) “1” except when changing the throt- tle position sensor due to failure because it Throttle position sensor coil vari- will cause a drop in engine performance.
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ELECTRICAL COMPONENTS 1 1 1 3. Replace: 7. Insert the thin electric conductors “2” (lead • Throttle position sensor wire) into the throttle position sensor coupler 4. Install: “1”, as shown, and connect the tester to them. • Throttle position sensor “1” •...
ELECTRICAL COMPONENTS a a a 11.Stop the engine. 12.Remove: • Carburetor Refer to “CARBURETOR” on page 7-3. 13.Tighten: • Throttle position sensor screw “1” Tighten the throttle position sensor screws using the T20 bit (tamper resistant fastener type) by aligning the marks “a” that were put before re- moval.
TROUBLESHOOTING TROUBLESHOOTING ..................9-1 GENERAL INFORMATION ................9-1 TROUBLESHOOTING OF ENGINE ............9-1 TROUBLESHOOTING OF CLUTCH ............9-6 TROUBLESHOOTING OF TRANSMISSION ..........9-7 TROUBLESHOOTING OF COOLING SYSTEM ........9-8 TROUBLESHOOTING OF BRAKE ............9-9 TROUBLESHOOTING OF SUSPENSION ..........9-9 TROUBLESHOOTING OF STEERING/HANDLING.........9-11...
TROUBLESHOOTING EAM20148 TROUBLESHOOTING EAM30309 GENERAL INFORMATION Troubleshooting information provided here does not cover all the trouble symptoms, possible causes, and remedial actions. Some items may not apply depending on the model. Use this information as a guide and quick reference matrix when performing basic troubleshooting. Refer to the each chapter for detailed information on checking, adjustment, and replacement.
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TROUBLESHOOTING Symptom Possible cause Actions Measure the compression pres- — sure. Tighten the spark plugs to the Loose spark plug specified torque. Tighten bolts or nuts on cylinder Loose cylinder head or cylinder head and cylinder to the specified torque. Compression pressure is low Damaged cylinder head gasket Replace the cylinder head gasket.
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TROUBLESHOOTING Symptom Possible cause Actions Damaged or worn needle valve Replace the needle valve. Adjust the fuel level to the proper Incorrect fuel level level. Bent, worn, or damaged starter Replace the starter plunger. plunger Incorrectly adjusted starter cable Adjust the starter cable. Clogged or damaged carburetor Clean, repair, or replace the car- breather hose...
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TROUBLESHOOTING Symptom Possible cause Actions Water or foreign material in fuel, Change fuel. degraded fuel Clogged carburetor air passage Clean the carburetor. Incorrectly adjusted throttle cable Adjust the throttle grip free play. Improperly synchronized carbure- Adjust synchronization of carbure- tors tors.
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TROUBLESHOOTING Symptom Possible cause Actions Check the air induction system. Failed air induction system Repair or replace faulty parts. Clogged vacuum hose Clean the vacuum hose. Cracks and damage in vacuum Replace the vacuum hose. hose — Damaged carburetor joint Replace the carburetor joint.
TROUBLESHOOTING EAM30510 TROUBLESHOOTING OF CLUTCH Manual clutch Symptom Possible cause Actions Improperly assembled clutch Reassemble the clutch. Improperly adjusted clutch cable Adjust the clutch lever free play. Tighten the clutch spring bolts to Loose clutch spring the specified torque. Replace the clutch springs as a Fatigued clutch spring set.
TROUBLESHOOTING Symptom Possible cause Actions Replace the primary drive gear or Damaged or worn primary driven crankshaft, and the clutch housing gear as a set. Tighten the clutch boss nut to the Loose clutch boss nut specified torque. Clutch noise Fatigued clutch damper Replace the clutch housing.
TROUBLESHOOTING EAM30512 TROUBLESHOOTING OF COOLING SYSTEM Symptom Possible cause Actions Carbon buildup in piston head and Clean the piston head and com- combustion chamber bustion chamber. Clogged engine cooling water Check and clean the engine cool- passages ing water passages. Damaged or leaking radiator Replace the radiator.
TROUBLESHOOTING EAM30513 TROUBLESHOOTING OF BRAKE Symptom Possible cause Actions Worn brake pad Replace the brake pads as a set. Worn or deflected brake disc Replace the brake disc. Air in hydraulic brake system Bleed the hydraulic brake system. Check the hydraulic brake system Brake fluid leakage and repair or replace faulty parts as necessary.
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TROUBLESHOOTING Symptom Possible cause Actions Fatigued or broken fork spring Replace the fork spring. Incorrect oil viscosity (low) Change to recommended fork oil. Incorrect oil level (low) Adjust to the specified oil level. Improperly adjusted spring pre- Adjust the spring preload. Front fork is soft load (soft) Improperly adjusted rebound...
TROUBLESHOOTING Symptom Possible cause Actions Oil leaking from rear shock Replace the rear shock absorber. absorber Gas leaking from rear shock Replace the rear shock absorber. absorber Fatigued or damaged rear shock Replace the rear shock absorber. absorber spring Rear suspension is soft Improperly adjusted rear shock Adjust the spring preload.
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TROUBLESHOOTING Symptom Possible cause Actions Tighten the spoke and adjust the Loose spoke runout. Damaged or worn wheel bearing Replace the wheel bearing. Worn, deformed, or incorrect tire Replace the tire. Tighten the wheel axle nut to the Loose wheel axle nut Rear wheel vibration specified torque.
TUNING ENGINE......................10-1 CARBURETOR SETTING ................10-1 ATMOSPHERIC CONDITIONS AND CARBURETOR SETTINGS ..10-1 TEST RUN ....................10-1 EFFECTS OF THE SETTING PARTS ON THE THROTTLE VALVE OPENING ....................10-2 MAIN JET ADJUSTMENT ................10-2 ADJUSTING THE POWER JET ...............10-2 PILOT AIR SCREW ADJUSTMENT ............10-2 PILOT JET ADJUSTMENT ...............10-3 JET NEEDLE ADJUSTMENT ..............10-3 JET NEEDLE GROOVE POSITION ADJUSTMENT ........10-4 RELATIONSHIP WITH THROTTLE OPENING........10-4...
ENGINE • Lower atmospheric pressure (at a high alti- EAM20198 ENGINE tude) reduces the density of the air. EAM30590 EAM30592 CARBURETOR SETTING TEST RUN • The role of fuel is to cool the engine, and in the After warming up the engine equipped with the case of a 2-stroke engine, to lubricate the en- standard type carburetor(s) and spark plug(s), gine in addition to power generation.
ENGINE EAM30593 EFFECTS OF THE SETTING PARTS ON THE THROTTLE VALVE OPENING EAM30604 ADJUSTING THE POWER JET The richness of air-fuel mixture under 8500 r/min to the extent of 1/2 to full opened throttle can be set by changing the power jet “1”. A larger size jet results in a richer mixture, and a smaller size in a leaner mixture.
ENGINE EAM30596 PILOT JET ADJUSTMENT The richness of air-fuel mixture with the throttle fully closed to 1/2 open can be set by turning the pilot jet “1”. It is changed when adjustment can- NYDD not be made by the pilot air screw alone. NYDE A larger size jet results in a richer mixture at low NYDF...
ENGINE system is controlled by the main jet and then, it is further regulated by the area between the main nozzle and the jet needle. On the relation- ship between the fuel flow and the throttle open- NYDF ing, the fuel flow relates to the jet needle straight portion diameter around 1/8 to 1/4 throttle open- ing, whereas around 1/4 to 1/1 throttle opening it relates to the taper starting position and to the...
ENGINE EAM30599 Part name Size Part number CARBURETOR SETTING PARTS Jet needle Rich NYFD B4X-14916-FD Part name Size Part number NYCD B4X-14916-CD Main jet Rich #175 4MX-14943-42 NYDD B4X-14916-DD #172 4MX-14943-92 NYED B4X-14916-ED #170 4MX-14943-41 NYFE B4X-14916-FE #168 4MX-14943-91 NYCE B4X-14916-CE #165 4MX-14943-40...
ENGINE EAM30603 CHANGE OF THE HEAT RANGE OF SPARK PLUGS Judging from the discoloration of spark plugs, if they are found improper, it can be corrected by the following two methods; changing carburetor settings and changing the heat range of spark plug.
CHASSIS EAM20119 Part name Type Part number CHASSIS Rear wheel 17D-25447-50 EAM30168 sprocket “2” SELECTION OF THE SECONDARY 17D-25448-50 REDUCTION RATIO (SPROCKET) (STD) B2W-25449-00 Secondary reduction ratio = Number of B2W-25450-00 rear wheel sprocket teeth/Number of B2W-25451-00 drive sprocket teeth 17D-25452-50 Secondary reduction ratio 3.769 (49/13)
(in position etc.) when Recommended oil setting the front fork. Yamaha Suspension Oil S1 1. Use of soft spring Standard oil amount • Change the rebound damping force.
CHASSIS Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, re- sulting in lack of a sense of contact with the road surface or in a vibrating handlebar. EAM30174 FRONT FORK SETTING PARTS • Front fork spring STD spring rate (N/mm) 2.
CHASSIS [Equal-pitch steel spring] EAM30177 SETTING OF SPRING AFTER STD spring rate REPLACEMENT (N/mm) After replacement, be sure to adjust the spring to the set length [sunken length 90–100 mm (3.5– Spring I.D. Type rate Part number 3.9 in)] and set it. mark/Q’ty (N/mm) 1.
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CHASSIS • The unequal-pitch spring is softer in initial char- acteristic than the equal-pitch spring and is dif- ficult to bottom out under full compression. • The I.D. mark “a” is marked at the end of the spring. • Spring specification varies according to the color and quantity of I.D.
CHASSIS EAM30179 SUSPENSION SETTING (FRONT FORK) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in).
CHASSIS Section Symptom Check Adjust Large Medium Small Jump Compression Turn adjuster clockwise (about 2 damping force clicks) to increase damping. Turn adjuster counterclockwise Rebound damp- (about 2 clicks) to decrease ing force damping. Low front, tend- ing to lower front Set sunken length for 95–100 posture Balance with rear...
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CHASSIS Section Symptom Check Adjust Large Medium Small Jump Turn adjuster counterclockwise Rebound damp- (about 2 clicks) to decrease Heavy and drag- ing force damping. ging Spring Replace with soft spring. Turn adjuster counterclockwise Rebound damp- (about 2 clicks) to decrease ing force damping.
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