Yamaha TZ125M1 Owner's Service Manual
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Yamaha TZ125M1 Owner's Service Manual

Yamaha TZ125M1 Owner's Service Manual

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OWNER'S SERVICE MANUAL
TZ125M1/(M)
LIT-11626-13-42
4JT-28199-16

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Summary of Contents for Yamaha TZ125M1

  • Page 1 OWNER’S SERVICE MANUAL TZ125M1/(M) LIT-11626-13-42 4JT-28199-16...
  • Page 2 EC010000 TZ125M1/(M) OWNER’S SERVICE MANUAL ©1999 by Yamaha Motor Corporation, U.S.A. 1st Edition, August 1999 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U.S.A. is expressly prohibited. Printed in Japan P/N. LIT-11626-13-42...
  • Page 3 EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha TZ 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.

  • Page 4: Warranty Information

    EC030010 WARRANTY INFORMATION This model is sold AS IS, WITHOUT ANY WARRANTIES EXPRESSED OR IMPLIED REGARD- LESS OF THE INTENDED USE. THE PURCHASER OF THIS MACHINE, which is intended for competition purposes, IS RESPON- SIBLE FOR ALL COSTS, SERVICE AND/OR REPAIR.

  • Page 5: Important Notice

    EC040001 IMPORTANT NOTICE THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regula- tions before riding.
  • Page 6 6. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes.
  • Page 7 If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer. NOTE: This manual should be considered a perma- nent part of this machine and should remain with it even if the machine is subsequently sold.
  • Page 8 EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFOR- MATION The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine.
  • Page 9 EC083000 MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The infor- mation has been complied to provide the mechanic with an easy to read, handy reference that con- tains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., •...
  • Page 10 EC085002 ILLUSTRATED SYMBOLS (Refer to the illustration) SPEC Illustrated symbols 1 to 7 are designed as INFO thumb tabs to indicate the chapter’s number and content. 1 General information INSP 2 Specifications 3 Regular inspection and adjustments 4 Engine 5 Chassis 6 Electrical CHAS ELEC...
  • Page 11 MEMO...
  • Page 12 EC090000 INDEX GENERAL INFORMATION INFO SPECIFICATION SPEC REGULAR INSPECTION AND ADJUSTMENTS INSP ENGINE CHASSIS CHAS ELECTRICAL ELEC TUNING...

  • Page 13: Table Of Contents

    EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION..... 1-1 MACHINE IDENTIFICATION ..1-2 IMPORTANT INFOMATION .
  • Page 14 CHAPTER 4 ENGINE COWLING, SEAT AND FUEL TANK ..4-1 EXHAUST PIPE AND SILENCER ..4-3 RADIATOR ..... . . 4-4 CARBURETOR AND REED VALVE .

  • Page 15: General Information

    INFO DESCRIPTION EC100000 GENERAL INFORMATION EC110000 DESCRIPTION 1 Clutch lever NOTE: 2 “ENGINE STOP” button • The machine you have purchased may differ 3 Water temperature gauge slightly from those shown in the following. 4 Front brake lever • Designs and specifications are subject to 5 Throttle grip change without notice.

  • Page 16: Machine Identification

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

  • Page 17: Important Information

    INFO IMPORTANT INFORMATION EC130000 IMPORTANT INFORMATION EC131002 PREPARATION FOR REMOVAL AND DISAS- SEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. Refer to “SPECIAL TOOLS” section. 3. When disassembling the machine, keep mated parts together.
  • Page 18 INFO IMPORTANT INFORMATION EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled.

  • Page 19: Checking Of Connection

    INFO CHECKING OF CONNECTION EC1C0001 CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: • Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off.

  • Page 20: Special Tools

    INFO SPECIAL TOOLS EC140001 SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided.
  • Page 21 Pivot shaft wrench adapter YM-01476 90890-01476 These tools are used to loosen or tighten the pivot adjust bolt. YU-03112, 90890-03112 Yamaha pocket tester YU-03112 90890-03112 Use this tool to inspect the coil resistance, output voltage and amperage. YM-91042, 90890-04086 Clutch holding tool...
  • Page 22 Part number Tool name / How to use Illustration ACC-11001-05-01 Quick gasket ® ACC-11001-05-01 90890-85505 90890-85505 YAMAHA Bond No. 1215 This sealant (Bond) is used for crankcase mating surface, etc. ACC-11001-30-00 Quick gasket ® ACC-11001-30-00 90890-05143 90890-05143 YAMAHA Bond No.4 This sealant (Bond) is used for crankcase mating surface, etc.

  • Page 23: Control Functions

    INFO CONTROL FUNCTIONS EC150000 CONTROL FUNCTIONS EC151000 “ENGINE STOP” BUTTON The “ENGINE STOP” button 1 is located on the left handlebar. Continue pushing the “ENGINE STOP” button till the engine comes to a stop. EC152000 CLUTCH LEVER The clutch lever 1 is located on the left han- dlebar;...
  • Page 24 INFO CONTROL FUNCTIONS EC157000 REAR BRAKE PEDAL The rear brake pedal 1 is located on the right side of the machine. Press down on the brake pedal to activate the rear brake. EC158001 FUEL COCK The fuel cock supplies fuel from the tank to carburetor while filtering the fuel.
  • Page 25 INFO CONTROL FUNCTIONS NOTE: • If an out-of-step indication takes place, restarting the engine brings the tachometer back to a normal indication through its cor- rective action. • There is no functional problem involved with the out-of-step indication, which can be brought back to a normal indication through the corrective action of the tachometer.
  • Page 26 INFO CONTROL FUNCTIONS EC15H000 CARBURETOR COVER The carburetor cover 1 is provided for carbu- retor space. CAUTION: If the machine is run without this cover, the carburetor settings will become faulty. EC15L000 LOWER COWL Make sure that the lower cowl 1 is installed before riding the machine.
  • Page 27 INFO CONTROL FUNCTIONS EC15Q001 DETACHABLE MAINSTAND This mainstand 1 is used to support only the machine when standing or transporting it. NOTE: The mainstand can be used to support the machine two ways. 1. Hook the bracket of the mainstand onto the swingarm hooks 2.

  • Page 28: Fuel And Engine Mixing Oil

    INFO FUEL AND ENGINE MIXING OIL EC160040 FUEL AND ENGINE MIXING OIL Mix oil with the gas at the ratio specified below. Always use fresh, name-brand gasoline, and mix the oil and gas the day of the race. Do not use premix that is more than a few hours old.

  • Page 29: Information Before Pre-Operation

    INFO INFORMATION BEFORE PRE-OPERATION EC170011 INFORMATION BEFORE PRE- OPERATION 1. The brake disc 1 is coated with a rust inhibitor. Before riding the machine, thor- oughly remove it using a lacquer thinner. • LACQUER THINNER IS HIGHLY FLAMMA- BLE. Always turn off the engine while using lacquer thinner.

  • Page 30: Starting And Break-In

    INFO STARTING AND BREAK-IN EC190000 STARTING AND BREAK-IN CAUTION: Before starting the machine, perform the checks in the pre-operation check list. Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time.
  • Page 31 INFO STARTING AND BREAK-IN EC193021 STARTING A WARM ENGINE Do not pull the starter knob (CHOKE). Open the throttle slightly and start the engine. CAUTION: Observe the following break-in procedure during initial operation to ensure optimum performance and avoid engine damage. EC194013 BREAK-IN PROCEDURES 1.
  • Page 32 INFO STARTING AND BREAK-IN CAUTION: After the break-in or before each race, you must check the entire machine for loose fit- tings and fasteners as per “TORQUE- CHECK POINTS”. Tighten all such fasteners as required. 8. Increase the engine speed up to 10,000 r/min and run about 10 km (6 miles).

  • Page 33: Torque-Check Points

    INFO TORQUE-CHECK POINTS EC1A0032 TORQUE-CHECK POINTS Frame construction Frame to rear frame Engine mounting Frame to engine Steering Steering shaft to handlebar Steering shaft to frame Steering shaft to handle crown Front fork to handlebar Suspension Front Steering shaft to front fork Front fork to handle crown Front fork to under bracket Rear...

  • Page 34: Cleaning And Storage

    INFO CLEANING AND STORAGE EC1B0000 CLEANING AND STORAGE EC1B1000 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many com- ponents. 1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering.
  • Page 35 INFO CLEANING AND STORAGE EC1B2010 STORAGE If your machine is to be stored for 60 days or more, some preventive measures must be taken to avoid deterioration. After cleaning the machine thoroughly, prepare it for storage as follows: 1. Drain the fuel tank, fuel lines, and the car- buretor float chambers.

  • Page 36: Specifications

    SPEC GENERAL SPECIFICATIONS EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: TZ125M1 (USA) TZ125(M) (OTHERS) Model code number: 4JT7 Dimensions: Overall length 1,828 mm (72.0 in) Overall width 510 mm (20.1 in) Overall height 1,033 mm (40.7 in) Seat height 701 mm (27.6 in) Wheelbase 1,242 mm (48.9 in)
  • Page 37 SPEC GENERAL SPECIFICATIONS Transmission: primary reduction system Spur gear Primary reduction ratio 60/21 (2.857) Secondary reduction system Chain drive Secondary reduction ratio 36/17 (2.118) Transmission type Constant mesh, 6-speed Operation Left foot operation Gear ratio: 1st 30/15 (2.000) 31/19 (1.632) 24/17 (1.412) 25/20 (1.250) 24/21 (1.143)

  • Page 38: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS EC212000 MAINTENANCE SPECIFICATIONS EC212100 ENGINE Item Standard Limit Cylinder head: Combustion chamber capacity 9.05 cm (0.319 lmp oz, 0.306 US oz) Piston: Piston clearance 0.075~0.085 mm (0.0030~0.0033 in) Piston offset 1.0 mm (0.039 in)/EX-side Piston pin: Piston pin outside diameter 14.995~15.000 mm 14.975 mm (0.5904~0.5906 in)
  • Page 39 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Carburetor: Type/Manufacturer PWM38/KEIHIN I.D. mark 4JT7 60 Main jet (M.J.) #220 Jet needle-clip position (J.N.) N8VH-3 Main nozzle (N.J.) ø2.9 Cutaway (C.A.) Pilot jet (P.J.) Pilot air screw (P.A.S.) Factory set Valve seat size (V.S.) ø3.8 Starter jet...
  • Page 40 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty mdkg ftdlb Spark plug M14S X 1.25 Cylinder head (bolt) M 6 X 1.0 Cylinder (nut) M 8 X 1.25 (stud) M 8 X 1.25 Balance weight gear M14 X 1.0 Water pump housing cover M 6 X 1.0...
  • Page 41 SPEC MAINTENANCE SPECIFICATIONS EC212201 CHASSIS Item Standard Limit Steering system: Steering bearing type Taper roller bearing Front suspension: Front fork travel 100 mm (3.94 in) Fork spring free length 195 mm (7.68 in) 193 mm (7.60 in) Spring rate, STD K=6.00 N/mm (0.600 kg/mm, 33.7 lb/in) Optional spring...
  • Page 42 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Front disc brake: Disc outside dia.XThickness 298X5.0 mm (11.73X0.20 in) Pad thickness 5.3 mm (0.21 in) 1.0 mm (0.04 in) Master cylinder inside dia. 14.0 mm (0.551 in) Caliper cylinder inside dia. 33.96 + 30.23 mm (1.337 + 1.190 in) Brake fluid type DOT #4...
  • Page 43 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty mdkg ftdlb ∆ Handle crown and outer tube M 8 X 1.25 ∆ Under bracket and outer tube M10 X 1.25 ∆ Handle crown and steering shaft M22 X 1.0 ∆...
  • Page 44 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty mdkg ftdlb ∆ Engine mounting : ∆ Engine and frame (front) M10 X 1.25 ∆ Engine and frame (upper) M10 X 1.25 ∆ Engine and frame (lower) M10 X 1.25 ∆...
  • Page 45 SPEC MAINTENANCE SPECIFICATIONS EC212300 ELECTRICAL Item Standard Limit Ignition system: Ignition timing (B.T.D.C) 2.3 mm (0.091 in) … Advancer type Electrical … CDI: Magneto-model/Manufacturer 4JT-00/DENSO … 1.3~1.9 Ω at 20˚C (68˚F) Source coil resistance (color) … (White-White) 94~140 Ω at 20˚C (68˚F) Pickup coil resistance (color) …...

  • Page 46: General Torque Specifications

    GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasten- ers with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sec- tions of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fash- ion, in progressive stages, until full torque is reached.

  • Page 47: Cable Routing Diagram

    SPEC CABLE ROUTING DIAGRAM EC240000 CABLE ROUTING DIAGRAM A Do not cut the end of the clamp. 1 Clamp B Install the clamp with its ends facing backward. 2 Throttle cable C Install the clamp with its ends facing upward. 3 Wireharness D Clamp only the wireharness with the clamp ends downward.
  • Page 48 SPEC CABLE ROUTING DIAGRAM A Install the tachometer assembly with its figures standing upright. 1 Tachometer assembly B Align the tape on the wireharness with the CDI unit mounting boss. 2 Clamp C Install the CDI magneto lead so that it is not loose. 3 CDI unit D Clamp the coupler with the clamp ends facing backward on the inside of 4 Water temperature gauge lead...
  • Page 49 SPEC CABLE ROUTING DIAGRAM A Clamp the water temperature lead at its coupler portion. 1 Throttle cable B Position the end of the clamp to the front of the front fork. 2 Clamp C Be sure the brake hose is not twisted. 3 Front brake hose D Do not tighten the clamp too much.
  • Page 50 SPEC CABLE ROUTING DIAGRAM A Position the reservoir hose with the paint facing upward. 1 Brake hose holder B Be sure the brake hose is not twisted. 2 Reservoir hose C Clamp the brake hose with the end of the clamp forward. Do not cut the 3 Rear brake hose 4 Clamp end of the clamp.

  • Page 51: Regular Inspection And Adjustments

    If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. NOTE: Replace earlier depending on the operating condition.
  • Page 52 INSP MAINTENANCE INTERVALS After Every Every Every As re- Item break- 1,000 Remarks race 500km quired PLUG CAP (1,500 km) Inspect and replace ∂ ∂ COOLING SYSTEM Check cooling level and leakage ∂ ∂ Check radiator cap operation ∂ Replace cooling water Use soft water ∂...
  • Page 53 ∂ DRIVE, DRIVEN SPROCKET Inspect and replace Inspect wear ∂ DRIVEN SPROCKET DAMPER Inspect and retighten ∂ ∂ Replace ∂ THROTTLE, CONTROL CABLE Check routing and connection Yamaha cable lube or SAE ∂ ∂ Lubricate 10W30 motor oil ∂ ∂...

  • Page 54: Pre-Operation Inspection And Maintenance

    INSP PRE-OPERATION INSPECTION AND MAINTENANCE EC320010 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. NOTE: • The brake disc is coated with a rush inhibitor. Before pre-operation thoroughly remove it using a lacquer thinner.

  • Page 55: Locking Wire Installation Guide

    INSP LOCKING WIRE INSTALLATION GUIDE EC340000 LOCKING WIRE INSTALLATION GUIDE Bolt to bolt Bolt Oil filler cap and check bolt Throttle cable adjuster Oil drain bolt Tank rail drain bolt...

  • Page 56: Engine

    ENGINE/COOLING WATER LEVEL INSPECTION/ INSP COOLING WATER REPLACEMENT EC350011 ENGINE CAUTION: • The cooling system is filled with coolant at the factory to prevent rusting. Be sure to replace coolant with soft water before rid- ing. • Take care so that coolant does not splash on painted surfaces.
  • Page 57 INSP RADIATOR CAP INSPECTION 3. Disconnect: • Radiator hose 2 1 4. Remove: • Radiator cap Drain the cooling water completely. 5. Clean: • Cooling system Thoroughly flush the cooling system with clean tap water. 6. Connect: • Radiator hose 2 2 Nm (0.2 mdkg, 1.4 ftdlb) 7.
  • Page 58 RADIATOR CAP OPENING PRESSURE INSPECTION/ INSP COOLING SYSTEM INSPECTION EC356001 RADIATOR CAP OPENING PRESSURE INSPECTION 1. Attach: • Radiator cap tester 1 and adapter 2 Radiator cap tester: YU-24460-1/90890-01325 Adapter: YU-33984/90890-01352 NOTE: Apply water on the radiator cap seal. 3 Radiator cap 2.
  • Page 59 CLUTCH CARE/CLUTCH ADJUSTMENT/ INSP THROTTLE CABLE ADJUSTMENT 4. Inspect: • Pressure Impossible to maintain the specified pres- sure for 10 seconds ≥ Repair. • Radiator 1 • Radiator hose joint 2 Coolant leakage ≥ Repair or replace. • Radiator hose 3 Swelling ≥...
  • Page 60 INSP TRANSMISSION OIL LEVEL CHECK 2. Adjust: • Throttle grip free play Throttle grip free play adjustment steps: • Loosen the locknut 1. • Turn the adjuster 2 until the specified free play is obtained. • Tighten the locknut. After adjusting, turn the handlebar to right and left and make sure that the engine idling does not run faster.
  • Page 61 INSP TRANSMISSION OIL REPLACEMENT EC35K012 TRANSMISSION OIL REPLACEMENT 1. Start the engine and warm it up for several minutes and wait for five minutes. 2. Place the machine on a level place and hold it on upright position by placing the suitable stand.
  • Page 62 PILOT AIR SCREW ADJUSTMENT/ INSP MUFFLER INSPECTION/SILENCER INSPECTION EC35L030 PILOT AIR SCREW ADJUSTMENT 1. Adjust: •Pilot air screw 1 Adjusting steps: • Turn in the pilot air screw until it is lightly seated. • Turn out the pilot air screw by the factory- set number of turns.

  • Page 63: Chassis

    INSP CHASSIS/BRAKE SYSTEM AIR BLEEDING EC360000 CHASSIS EC361002 BRAKE SYSTEM AIR BLEEDING Bleed the brake system if: • The system has been disassembled. • A brake hose has been loosened or removed. • The brake fluid is very low. • The brake operation is faulty. A dangerous loss of braking performance may occur if the brake system is not prop- erly bleed.
  • Page 64 FRONT BRAKE ADJUSTMENT/ INSP REAR BRAKE ADJUSTMENT NOTE: If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disap- peared.
  • Page 65 INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT 2. Adjust: • Brake pedal height Pedal height adjustment steps: • Loosen the locknut 1. • Turn the adjusting nut 2 until the pedal height is within specified height. • Tighten the locknut. EC365050 FRONT BRAKE PAD INSPECTION AND REPLACEMENT...
  • Page 66 INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT • Install the brake pads 9, pad support 0, pad pin ¡ and cotter pin ™. NOTE: • Always use a new cotter pin. ™ • Temporarily tighten the pad pin at this point.
  • Page 67 INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT • Remove the cotter pin 3, pad pin 4, pad support 5 and brake pads 6. • Connect the transparent hose 7 to the bleed screw 8 and place the suitable con- tainer under its end. •...
  • Page 68 BRAKE FLUID LEVEL INSPECTION/ INSP SPROCKETS INSPECTION EC367001 BRAKE FLUID LEVEL INSPECTION 1. Place the master cylinder so that its top is in a horizontal position. 2. Inspect: • Brake fluid level Fluid at lower level ≥ Fill up. a Lower level A Front B Rear Recommended brake fluid:...
  • Page 69 INSP DRIVE CHAIN INSPECTION EC369051 DRIVE CHAIN INSPECTION 1. Remove: • Master link clip • Joint 1 • O-ring 2 • Drive chain 3 2. Clean: • Drive chain Brush off as much dirt as possible. Then clean the chain using the chain cleaner. CAUTION: This machine has a drive chain with small rubber O-rings 1 1 between the chain plates.
  • Page 70 INSP DRIVE CHAIN SLACK ADJUSTMENT 5. Check: • Drive chain stiffness a Clean and oil the chain and hold as illus- trated. Stiff ≥ Replace drive chain. 6. Install: • Joint 1 • O-ring 2 • Drive chain 3 • Master link clip 4N CAUTION: Be sure to install the master link clip to the direction as shown.
  • Page 71 INSP DRIVE CHAIN SLACK ADJUSTMENT NOTE: Before checking and/or adjusting, rotate the rear wheel through several revolutions and check the slack several times to find the tight- est point. Check and/or adjust chain slack with rear wheel in this “tight chain” position. 3.
  • Page 72 INSP WHEEL ALIGNMENT ADJUSTMENT EC36B000 WHEEL ALIGNMENT ADJUSTMENT 1. Remove: • Lower cowl 2. Place the machine on a level place and hold it up on upright position. 3. Sit 1~2 m (3.3~6.6 ft) behind the machine and look at both sides of the wheels below the rear wheel axle.
  • Page 73 FRONT FORK INSPECTION/ INSP FRONT FORK TOP END ADJUSTMENT 6. Adjust: • Wheel alignment Turn the chain puller adjuster while paying attention to the drive chain slack and make adjustment while moving the rear wheel. NOTE: • Figure C shows that the wheel alignment has been correctly made (b = c and d = e).
  • Page 74 INSP FRONT FORK TOP END ADJUSTMENT • Adjust the front fork top end a. ≠ Front fork top end a a : Standard Extent of adjustment Zero~20 mm 18 mm (0.71 in) (Zero~0.79 in) CAUTION: Never attempt to install the front fork beyond the maximum or minimum set- ting.
  • Page 75 INSP FRONT FORK SPRING PRELOAD ADJUSTMENT CAUTION: Tighten the pinch bolts to specified torque. If torqued too much, it may cause the front fork to malfunction. NOTE: • Adjust the installation angle of the steering damper stay so that the dimension d is between 3 mm (0.12 in) and 5 mm (0.20 in) when the handlebar is turned fully to the left.
  • Page 76 FRONT FORK REBOUND DAMPING FORCE INSP ADJUSTMENT • STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-out position. Standard position: 2 clicks in NOTE: • Fully turn out the adjuster and then turn it in. Specify the position in which the first click is heard as the zero position .
  • Page 77 FRONT FORK COMPRESSION DAMPING FORCE INSP ADJUSTMENT • STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position. Standard position: 8 clicks out NOTE: Fully turn in the adjuster and then turn it out. Specify the position in which the first click is heard as the zero position.
  • Page 78 REAR SHOCK ABSORBER INSPECTION/ INSP SEAT HEIGHT ADJUSTMENT • STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position. Standard position: 8 clicks out NOTE: Fully turn in the adjuster and then turn it out. Specify the position in which the first click is heard as the zero position.
  • Page 79 REAR SHOCK ABSORBER SPRING PRELOAD INSP ADJUSTMENT Seat height adjustment steps: • Remove the cap 1. • Loosen the lock bolt 2 and locknut 3. • Turn the adjuster 4 in or out. ≠ Adjuster set length a a : Standard length Extent of adjustment 15~25 mm...
  • Page 80 REAR SHOCK ABSORBER REBOUND DAMPING INSP FORCE ADJUSTMENT Spring length (installed) a a : Standard length Extent of adjustment 130~150 mm 138 mm (5.43 in) (5.12~5.91 in) NOTE: The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjuster. CAUTION: Never attempt to turn the adjuster beyond the maximum or minimum setting.
  • Page 81 REAR SHOCK ABSORBER COMPRESSION DAMPING INSP FORCE ADJUSTMENT NOTE: Fully turn in the adjuster and then turn it out. Specify the position in which the first click is heard as the zero position. If a click is heard just when the adjuster is fully turned in, this position is zero.
  • Page 82 TIRE PRESSURE CHECK/TIRE INSPECTION/ INSP WHEEL INSPECTION CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. EC36Q011 TIRE PRESSURE CHECK 1. Measure: • Tire pressure Out of specification ≥ Adjust. Standard tire pressure: Front Rear...
  • Page 83 INSP STEERING HEAD INSPECTION AND ADJUSTMENT 2. Inspect: • Bearing free play Exist play ≥ Replace. EC36U060 STEERING HEAD INSPECTION ADJUSTMENT 1. Remove the steering damper at front fork side. 2. Elevate the front wheel by placing a suit- able stand. 3.
  • Page 84 INSP STEERING DAMPER ADJUSTMENT • Tighten the ring nut 3 using ring nut wrench 4. NOTE: Set the torque wrench to the ring nut wrench so that they form a right angle. ª Ring nut wrench: YU-33975/90890-01403 Ring nut (initial tightening): 46 Nm (4.6 m•kg, 33 ft•lb) •...
  • Page 85 WIRES, CABLES/ INSP COWLING INSTALLATION INSPECTION Extent of adjustment: Maximum Minimum Fully turned-in Fully turned-out position position • STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-out position. Standard position: 0 click in NOTE: Fully turn out the adjuster and then turn it in.
  • Page 86 INSP LUBRICATION A Use Yamaha cable lube or equivalent on EC36a023 LUBRICATION these areas. To ensure smooth operation of all components B Use SAE 10W30 motor oil or suitable chain lubricate your machine during setup, after lubricants. break-in, and after every race.

  • Page 87: Electrical

    ELECTRICAL/SPARK PLUG INSPECTION/ INSP IGNITION TIMING CHECK EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: • Spark plug 2. Inspect: • Electrode 1 Wear/Damage ≥ Replace. • Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color ≥ Check the engine condition.
  • Page 88 INSP IGNITION TIMING CHECK 2. Attach: • Dial gauge 1 • Dial gauge stand 2 Dial gauge: YU-03097/90890-01252 Stand: YU-01256 3. Rotate the magneto rotor 1 until the piston reaches top dead center (TDC). When this happens, the needle on the dial gauge will stop and reverse directions even though the rotor is being turned in the same direc- tion.

  • Page 89: Cowling, Seat And Fuel Tank

    COWLING, SEAT AND FUEL TANK EC400000 ENGINE EC4U0000 COWLING, SEAT AND FUEL TANK 8 Nm (0.8 mdkg, 5.8 ftdlb) 1 Cowling removal 2 Seat removal Extend of removal: 3 Fuel tank removal Extend of removal Order Part name Q’ty Remarks COWLING, SEAT AND FUEL TANK REMOVAL Preparation for...
  • Page 90 COWLING, SEAT AND FUEL TANK EC4U3000 REMOVAL POINTS EC4U3100 Fuel tank breather hose 1. Disconnect: • Fuel tank breather hose 1 NOTE: Disconnect the fuel tank breather hose with the valve joint 2 remaining on the fuel tank side so as to prevent fuel from spurting out by the tank inner pressure.

  • Page 91: Exhaust Pipe And Silencer

    EXHAUST PIPE AND SILENCER EC4S0000 EXHAUST PIPE AND SILENCER 11 Nm (1.1 mdkg, 8.0 ftdlb) 21 Nm (2.1 mdkg, 15 ftdlb) 1 Exhaust pipe removal 2 Silencer removal Extend of removal: Extend of removal Order Part name Q’ty Remarks EXHAUST PIPE AND SILENCER REMOVAL Preparation for Lower cowl...
  • Page 92 RADIATOR EC450001 RADIATOR 2 Nm (0.2 mdkg, 1.4 ftdlb) 2 Nm (0.2 mdkg, 1.4 ftdlb) 7 Nm (0.7 mdkg, 5.1 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 2 Nm (0.2 mdkg, 1.4 ftdlb) 2 Nm (0.2 mdkg, 1.4 ftdlb) 1 Radiator removal Extend of removal: Extend of removal Order...

  • Page 93: Radiator

    RADIATOR EC456000 HANDLING NOTE Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radi- ator cap by the following procedure: Place a thick rag, like a towel, over the radi- ator cap, slowly rotate the cap counter-...
  • Page 94 RADIATOR 2. Install: • Radiator breather hose 1 • Radiator hose 4 2 2 Nm (0.2 mdkg, 1.4 ftdlb) • Radiator hose 2 3 2 Nm (0.2 mdkg, 1.4 ftdlb) • Thermo unit 4 11 Nm (1.1 mdkg, 8.0 ftdlb) •...

  • Page 95: Carburetor And Reed Valve

    CARBURETOR AND REED VALVE EC460000 CARBURETOR AND REED VALVE 2 Nm (0.2 mdkg, 1.4 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 1 Nm (0.1 mdkg, 0.7 ftdlb) 1 Carburetor removal 2 Reed valve removal Extend of removal: Extend of removal Order Part name Q’ty...
  • Page 96 CARBURETOR AND REED VALVE EC468000 CARBURETOR DISASSEMBLY 1 Carburetor disassembly Extend of removal: Extend of removal Order Part name Q’ty Remarks CARBURETOR DISASSEMBLY Mixing chamber top Throttle valve Refer to “REMOVAL POINTS”. Needle holder Jet needle Float chamber Float pin Float Needle valve Main jet...
  • Page 97 CARBURETOR AND REED VALVE EC463000 REMOVAL POINTS EC463110 Throttle valve 1. Remove: • Throttle valve 1 • Ring 2 • Spring (throttle valve) 3 • Mixing chamber top 4 • Throttle cable 5 NOTE: While compressing the spring (throttle valve), disconnect the throttle cable.
  • Page 98 CARBURETOR AND REED VALVE 2. Inspect: • Main jet 1 • Pilot jet 2 • Power jet 3 Contamination ≥ Clean. NOTE: • Use a petroleum based solvent for cleaning. Blow out all passages and jets with com- pressed air. •...
  • Page 99 CARBURETOR AND REED VALVE Measurement and adjustment steps: • Hold the carburetor in an upside down position. • Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers. NOTE: The float arm should be resting on the nee- dle valve, but not compressing the needle valve.
  • Page 100 CARBURETOR AND REED VALVE EC465000 ASSEMBLY AND INSTALLATION EC465140 Reed valve 1. Install: • Reed valve 1 1 • Reed valve 2 2 • Stopper (reed valve) 3 • Screw (reed valve) 4 1 Nm (0.1 mdkg, 0.7 ftdlb) NOTE: •...
  • Page 101 CARBURETOR AND REED VALVE 2. Install: • O-ring 1 • Solenoid valve 2 • Clamp 3 • Screw (clamp) 4 To carburetor 5. CAUTION: • Before installing the solenoid valve, blow air on the solenoid valve and its installing location on the carburetor in order to remove any foreign particles such as chips etc.
  • Page 102 CARBURETOR AND REED VALVE 6. Install: • Needle valve 1 • Float 2 • Float pin 3 NOTE: • After installing the needle valve to the float, install them to the carburetor. • Check the float for smooth movement. 7. Install: •...
  • Page 103 CARBURETOR AND REED VALVE 10.Install: • Throttle cable 1 • Mixing chamber top 2 • Spring (throttle valve) 3 • Ring 4 • Throttle valve 5 NOTE: • While compressing the spring, connect the throttle cable. • Align the projection a on the ring with the groove b in the needle holder 6.
  • Page 104 CARBURETOR AND REED VALVE 3. Tighten: • Clamp (carburetor joint) 1 2 Nm (0.2 mdkg, 1.4 ftdlb) 4. Connect: • Solenoid valve lead 1 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. 4-16...

  • Page 105: Cylinder Head,Cylinder And Piston

    CYLINDER HEAD, CYLINDER AND PISTON EC470000 CYLINDER HEAD, CYLINDER AND PISTON EC478000 CYLINDER HEAD AND CYLINDER 11 Nm (1.1 mdkg, 8.0 ftdlb) 19 Nm (1.9 mdkg, 13 ftdlb) 20 Nm (2.0 mdkg, 14 ftdlb) 1 Cylinder head removal 2 Cylinder removal Extend of removal: Extend of removal Order...
  • Page 106 CYLINDER HEAD, CYLINDER AND PISTON EC478200 PISTON 15 Nm (1.5 mdkg, 11 ftdlb) 1 Piston and piston ring removal Extend of removal: Extend of removal Order Part name Q’ty Remarks PISTON REMOVAL Piston pin clip Piston pin Piston Refer to “REMOVAL POINTS”. Small end bearing Piston ring 4-18...
  • Page 107 CYLINDER HEAD, CYLINDER AND PISTON EC473000 REMOVAL POINTS EC473400 Piston and piston ring 1. Remove: • Piston pin clip 1 NOTE: Before removing the piston pin clip, cover the crankcase with a clean rag to prevent the pis- ton pin clip from falling into the crankcase cav- ity.
  • Page 108 CYLINDER HEAD, CYLINDER AND PISTON 2. Inspect: • Cylinder head water jacket Crust of minerals/Rust ≥ Remove. • Cylinder head contact surface Wear/Damage ≥ Replace. • Recess of insert portion a The contact surface b of the insert portion is recessed below the aluminum portion c ≥...
  • Page 109 CYLINDER HEAD, CYLINDER AND PISTON 2. Inspect: • Travel distance for piston 500 km (300 miles) or more≥ Replace. 3. Check: • Piston ring free movement Mechanical stick ≥ Repair. Install the piston ring 1 to the piston, and check for free movement. Repairing steps: •...
  • Page 110 CYLINDER HEAD, CYLINDER AND PISTON 2. Measure: • Piston pin outside diameter Use micrometer 1. Out of limit ≥ Replace. Piston pin outside diameter: Standard Limit 14.995~15.000 mm 14.975 mm (0.5904~0.5906 in) (0.5896 in) 3. Check: • Free play (when the piston pin 1 is in place in the piston 2) There should be no noticeable for the play.
  • Page 111 CYLINDER HEAD, CYLINDER AND PISTON EC474520 Piston ring 1. Install: • Piston ring Into the cylinder. Push the ring with the piston crown. 2. Measure: • End gap Use a thickness gauge 1. Out of limit ≥ Replace. Ring end gap (installed): Standard <Limit>...
  • Page 112 CYLINDER HEAD, CYLINDER AND PISTON 2. Check: • Piston mark a Piston mark a a (color) A (red) B (orange) C (green) 3. Combination: Combine the piston and cylinder by the fol- lowing chart. Cylinder mark Piston mark (color) A(red) B(orange) C (green) NOTE:...
  • Page 113 CYLINDER HEAD, CYLINDER AND PISTON 3. Install: • Piston 1 • Piston pin 2 • Piston pin clip 3N NOTE: • The arrow a on the piston dome must point to exhaust side. • Before installing the piston pin clip, cover the crankcase with a clean rag to prevent the pis- ton pin clip from falling into the crankcase cavity.
  • Page 114 CYLINDER HEAD, CYLINDER AND PISTON 4. Install: • O-ring 1N • Dowel pin 2 NOTE: Apply the lithium soap base grease on the O- rings. 5. Install: • Cylinder head 1 • Copper washer 2 • Bolt (cylinder head) 3 11 Nm (1.1 mdkg, 8.0 ftdlb) NOTE: •...

  • Page 115: Clutch

    CLUTCH EC4A0000 CLUTCH EC4A8000 CLUTCH PLATE AND FRICTION PLATE 6 Nm (0.6 mdkg, 4.3 ftdlb) 6 Nm (0.6 mdkg, 4.3 ftdlb) 1 Clutch plate and friction plate removal Extend of removal: Extend of removal Order Part name Q’ty Remarks CLUTCH PLATE AND FRICTION PLATE REMOVAL Preparation for Lower cowl...
  • Page 116 CLUTCH EC4A8100 CLUTCH HOUSING AND PUSH LEVER AXLE 11 Nm (1.1 mdkg, 8.0 ftdlb) 50 Nm (5.0 mdkg, 36 ftdlb) 1 Clutch housing removal 2 Push lever axle removal Extend of removal: Extend of removal Order Part name Q’ty Remarks CLUTCH HOUSING AND PUSH LEVER AXLE REMOVAL...
  • Page 117 CLUTCH EC4A3000 REMOVAL POINTS EC483211 Clutch boss 1. Remove: • Nut 1 • Lock washer 2 • Clutch boss 3 NOTE: Straighten the lock washer tab and use the clutch holding tool 4, 5 to hold the clutch boss. Clutch holding tool: YM-91042 .
  • Page 118 CLUTCH EC484500 Friction plate 1. Measure: • Friction plate thickness Out of specification ≥ Replace friction plate as a set. Measure at all four points. Friction plate thickness: Standard <Limit> 2.9~3.1 mm 2.7 mm (0.114~0.122 in) (0.106 in) EC484600 Clutch plate 1.
  • Page 119 CLUTCH EC4A5000 ASSEMBLY AND INSTALLATION EC4A5101 Push lever axle 1. Install: • Seat plate 1 • Torsion spring 2 • Push lever axle 3 NOTE:      Apply the lithium soap base grease on the push lever axle, oil seal lip and bearing. 2.
  • Page 120 CLUTCH 3. Install: • O-ring 1N • Spacer 2 2 To clutch housing 3. NOTE: • Apply the lithium soap base grease on the O- ring and oil seal lip. • When installing the spacer 2, pay careful    attention to the clutch housing oil seal lip a.
  • Page 121 CLUTCH 6. Bend the lock washer 1 tab. 7. Install: • Friction plate {yellow [d=ø95 mm (3.7 in)]} 1 • Clutch plate 2 • Friction plate {brown [d=ø100mm (3.9 in)]} 3 • Cushion spring 4 • Friction plate {brown [d=ø95 mm (3.7 in)]} 5 NOTE: •...
  • Page 122 CLUTCH 9. Install: • Pressure plate 1 NOTE: Align the punch mark a on the pressure plate with the punch mark b on the clutch boss. 10.Install: • Clutch spring 1 • Screw (clutch spring) 2 6 Nm (0.6 mdkg, 4.3 ftdlb) NOTE: Tighten the screws in stages, using a criss- cross pattern.

  • Page 123: Primary Driven Gear, Primary Drive Gear And Balancer Shaft

    PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT EC4D0002 PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT EC4D8000 PRIMARY DRIVEN GEAR 11 Nm (1.1 mdkg, 8.0 ftdlb) 9 Nm (0.9 mdkg, 6.5 ftdlb) 1 Primary driven gear removal Extend of removal: Extend of removal Order...
  • Page 124 PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT EC4D8100 PRIMARY DRIVE GEAR AND BALANCER SHAFT 11 Nm (1.1 mdkg, 8.0 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 50 Nm (5.0 mdkg, 36 ftdlb) 55 Nm (5.5 mdkg, 40 ftdlb) 1 Primary drive gear removal 2 Balancer shaft removal Extend of removal:...
  • Page 125 PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT EC4D3000 REMOVAL POINTS EC4D3101 Primary drive gear and balancer weight gear 1. Loosen: • Bolt (primary drive gear) 1 NOTE: Place an aluminum plate a between the teeth of the balancer drive gear 2 and balancer weight gear 3.
  • Page 126 PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT EC4D4000 INSPECTION EC484300 Primary drive gear and primary driven gear 1. Inspect: • Primary drive gear 1 • Primary driven gear 2 Wear/Damage ≥ Replace. EC4D4200 Balancer weight gear and balancer drive gear 1.
  • Page 127 PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT 2. Install: • Gasket [crankcase cover (left)]N • Crankcase cover (left) 1 • Screw [crankcase cover (left)] 2 11 Nm (1.1 mdkg, 8.0 ftdlb) • Bolt [crankcase cover (left)] 3 11 Nm (1.1 mdkg, 8.0 ftdlb) NOTE: •...
  • Page 128 PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT 6. Install: • Lock washer 1N • Nut (balancer weight gear) 2 • Primary drive gear 3 • Plain washer 4 • Bolt (primary drive gear) 5 7. Tighten: • Nut (balancer weight gear) 1 50 Nm (5.0 mdkg, 36 ftdlb) NOTE: Place an aluminum plate a between the teeth...
  • Page 129 PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT 2. Install: • Dowel pin 1 • Gasket [crankcase cover (right)] 2N • Thrust plate 3 NOTE: Install the thrust plate with its chamfered por- tion a toward the transmission. 3. Install: •...

  • Page 130: Shift Shaft And Oil Pump

    SHIFT SHAFT AND OIL PUMP EC4E0000 SHIFT SHAFT AND OIL PUMP EC4E8000 SHIFT SHAFT 22 Nm (2.2 mdkg, 16 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 9 Nm (0.9 mdkg, 0.9 ftdlb) 14 Nm (1.4 mdkg, 10 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 1 Shift shaft removal 2 Stopper lever removal...
  • Page 131 SHIFT SHAFT AND OIL PUMP EC4E8100 OIL PUMP 4 Nm (0.4 mdkg, 2.9 ftdlb) 7 Nm (0.7 mdkg, 5.1 ftdlb) 1 Oil pump removal and disassembly 2 Strainer removal Extend of removal: Extend of removal Order Part name Q’ty Remarks OIL PUMP REMOVAL Circlip Plain washer...
  • Page 132 SHIFT SHAFT AND OIL PUMP EC4E4000 INSPECTION EC4B4400 Shift shaft 1. Inspect: • Shift shaft 1 Bend/Damage ≥ Replace. • Spring 2 Broken ≥ Replace. EC4E4100 Stopper lever 1. Inspect: • Stopper lever 1 Wear/Damage ≥ Replace. • Bearing 2 Rotate outer race with a finger.
  • Page 133 SHIFT SHAFT AND OIL PUMP EC4E5000 ASSEMBLY AND INSTALLATION EC4E5101 Strainer 1. Install: • Strainer 1 1 • Strainer 2 2 NOTE: • Each strainer is installed with the rounded corner a facing inward. • Strainer 1 is installed with the flange b facing downward.
  • Page 134 SHIFT SHAFT AND OIL PUMP 4. Install: • Gasket (oil pump) 1N NOTE: Install the gasket in accordance with the shapes of the oil passages a. 5. Install: • Oil pump assembly 1 NOTE: • Apply the molybdenum disulfide oil on the oil pump shaft 2.
  • Page 135 SHIFT SHAFT AND OIL PUMP EC4B5111 Stopper lever 1. Install: • Torsion spring 1 • Stopper lever 2 • Bolt (stopper lever) 3 11 Nm (1.1 mdkg, 8.0 ftdlb) NOTE: Align the stopper lever roller with the slot on segment. EC4E5310 Shift shaft 1.

  • Page 136: Transmission, Shift Cam And Shift Fork

    TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H0000 TRANSMISSION, SHIFT CAM AND SHIFT FORK 8 Nm (0.8 mdkg, 5.8 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 14 Nm (1.4 mdkg, 10 ftdlb) 60 Nm (6.0 mdkg, 43 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) Extend of removal Order Part name...
  • Page 137 TRANSMISSION, SHIFT CAM AND SHIFT FORK 8 Nm (0.8 mdkg, 5.8 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 14 Nm (1.4 mdkg, 10 ftdlb) 60 Nm (6.0 mdkg, 43 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 1 Oil delivery pipe removal 2 Shift cam and shift fork removal Extend of removal: 3 Main axle and drive axle removal...
  • Page 138 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H3000 REMOVAL POINTS EC4F3100 Drive sprocket 1. Remove: • Nut (drive sprocket) 1 • Lock washer 2 NOTE: • Straighten the lock washer tab. • Loosen the nut while applying the rear brake. 2. Remove: •...
  • Page 139 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H3300 Shift cam 1. Remove: • Bearing plate cover 1 2. Remove: • Shift cam 1 NOTE: Turn the segment 2 to the position shown in the figure so that it does not contact the trans- mission housing.
  • Page 140 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H4300 Shift fork groove 1. Measure: • 3rd/4th pinion gear 1 • 5th wheel gear 2 • 6th wheel gear 3 • Shift fork groove a Out of specification ≥ Replace. Shift fork groove a a : Standard <Limit>...
  • Page 141 TRANSMISSION, SHIFT CAM AND SHIFT FORK 3. Check: • Shift fork movement On its guide bar. Unsmooth operation ≥ Replace shift fork and/or guide bar. NOTE: For a malfunctioning shift fork, replace not only the shift fork itself but the two gears each adja- cent to the shift fork.
  • Page 142 TRANSMISSION, SHIFT CAM AND SHIFT FORK 2. Install: • 2nd wheel gear (31 T) 1 • 5th wheel gear (24 T) 2 • 4th wheel gear (25 T) 3 • 3rd wheel gear (24 T) 4 • 6th wheel gear (26 T) 5 •...
  • Page 143 TRANSMISSION, SHIFT CAM AND SHIFT FORK 3. Install: • Plain washer 1 • Circlip 2N NOTE: • Be sure the circlip sharp-edged corner a is positioned opposite to the plain washer and gear b. • Be sure the circlip end c is positioned at axle spline groove d.
  • Page 144 TRANSMISSION, SHIFT CAM AND SHIFT FORK 7. Check: • Shift operation • Transmission operation Unsmooth operation ≥ Repair. 8. Install: • O-ring 1N To oil delivery pipe 2. NOTE: Apply the lithium soap base grease on the O- rings. 9. Install: •...
  • Page 145 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4F5500 Drive sprocket 1. Install: • Drive sprocket 1 • Drive chain 2 NOTE: • Install the drive sprocket with its stepped por- tion a facing the engine. • Install the drive sprocket together with the drive chain.

  • Page 146: Cdi Magneto

    CDI MAGNETO EC4L0000 CDI MAGNETO 7 Nm (0.7 mdkg, 5.1 ftdlb) 53 Nm (5.3 mdkg, 38 ftdlb) 2 Nm (0.2 mdkg, 1.4 ftdlb) 1 CDI magneto removal Extend of removal: Extend of removal Order Part name Q’ty Remarks CDI MAGNETO REMOVAL Preparation for Cowling and fuel tank Refer to “COWLING, SEAT AND...
  • Page 147 CDI MAGNETO EC4L3000 REMOVAL POINTS EC4L3101 Rotor 1. Remove: • Nut (rotor) 1 • Plain washer 2 Use the rotor holding tool 3. Rotor holding tool: YU-01235/90890-01235 2. Remove: • Rotor 1 Use the flywheel puller 2. Flywheel puller: YM-01189/90890-01189 NOTE: When installing the flywheel puller, turn it coun- terclockwise.
  • Page 148 CDI MAGNETO 2. Install: • Woodruff key 1 • Rotor 2 NOTE: • Clean the tapered portions of the crankshaft and rotor. • When installing the woodruff key, make sure that its flat surface a is in parallel with the crankshaft center line b.

  • Page 149: Engine Removal

    ENGINE REMOVAL EC4M0000 ENGINE REMOVAL 30 Nm (3.0 mdkg, 22 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 30 Nm (3.0 mdkg, 22 ftdlb) 30 Nm (3.0 mdkg, 22 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) Extend of removal Order Part name...
  • Page 150 ENGINE REMOVAL 30 Nm (3.0 mdkg, 22 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 30 Nm (3.0 mdkg, 22 ftdlb) 30 Nm (3.0 mdkg, 22 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 1 Engine removal Extend of removal: Extend of removal Order...
  • Page 151 ENGINE REMOVAL EC4M3000 REMOVAL POINTS EC4M3331 Engine removal 1. Loosen: • Engine mounting adjust bolt 1 NOTE: Use the adjust bolt wrench 2 to loosen the engine mounting adjust bolt. 2. Remove: • Engine mounting bolt 1 • Engine 2 NOTE: •...
  • Page 152 ENGINE REMOVAL 4. Install: • Nut (engine mounting bolt) (upper) 1 30 Nm (3.0 mdkg, 22 ftdlb) • Nut (engine mounting bolt) (lower) 2 30 Nm (3.0 mdkg, 22 ftdlb) • Nut (engine mounting bolt) (front) 3 30 Nm (3.0 mdkg, 22 ftdlb) 5.

  • Page 153: Crankcase, Crankshaft And Water Pump

    CRANKCASE, CRANKSHAFT AND WATER PUMP EC4Q0000 CRANKCASE, CRANKSHAFT AND WATER PUMP 16 Nm (1.6 mdkg, 11 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 23 Nm (2.3 mdkg, 17 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) Extend of removal Order Part name...
  • Page 154 CRANKCASE, CRANKSHAFT AND WATER PUMP 16 Nm (1.6 mdkg, 11 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 23 Nm (2.3 mdkg, 17 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 1 Crankcase separation 2 Crankshaft removal Extend of removal: 3 Crankshaft bearing removal 4 Impeller shaft removal...
  • Page 155 CRANKCASE, CRANKSHAFT AND WATER PUMP EC4Q3000 REMOVAL POINTS EC4Q3100 Crankcase 1. Remove: • Holder 1 • Blind plug 2 2. Remove: • Crankcase (right) 1 Use the crankcase separating tool 2. Crankcase separating tool: YU-01135-A/90890-01135 NOTE: • Fully tighten the tool holding bolts, but make sure the tool body is parallel with the case.
  • Page 156 CRANKCASE, CRANKSHAFT AND WATER PUMP EC4N3401 Crankshaft bearing 1. Remove: • Bearing 1 NOTE: • Remove the bearing from the crankcase by pressing its inner race as shown in A. • If the bearing is removed together with the crankshaft, remove the bearing using a gen- eral bearing puller 2 as shown in B.
  • Page 157 CRANKCASE, CRANKSHAFT AND WATER PUMP 3. Inspect: • Oil seal 1 Damage ≥ Replace. EC4N4201 Crankshaft 1. Measure: • Runout limit a • Small end free play limit b • Connecting rod big end side clearance c • Crank width d Out of specification ≥...
  • Page 158 CRANKCASE, CRANKSHAFT AND WATER PUMP EC4Q5000 ASSEMBLY AND INSTALLATION EC4Q5101 Oil seal (impeller shaft) 1. Install: • Oil seal 1N To crankcase (right). NOTE: • Install the oil seal with the “WATER SIDE” mark a on the outside. • Apply the lithium soap base grease on oil seal lip.
  • Page 159 CRANKCASE, CRANKSHAFT AND WATER PUMP 4. Install: • Water pump housing cover 1 • Copper washer 2N • Bolt (water pump housing cover) 3 11 Nm (1.1 mdkg, 8.0 ftdlb) EC4N5300 Crankshaft bearing 1. Install: • Bearing 1N To crankcase (left and right). NOTE: Install the bearing by pressing its outer race parallel.
  • Page 160 CAUTION: If the engine is started soon after reinstalla- tion, use this quick drying Quick gasket ® (ACC-11001-30-00) or YAMAHA Bond No.4. 3. Install: • Dowel pin 1 • O-ring 2 To crankcase (right).
  • Page 161 CRANKCASE, CRANKSHAFT AND WATER PUMP 4. Install: • Crankcase (left) 1 To crankcase (right). NOTE: • Fit the crankcase (left) to the crankcase (right). Tap lightly on the case with soft ham- mer. • When installing the crankcase, the connect- ing rod should be positioned at TDC (top dead center).

  • Page 162: Chassis

    CHAS FRONT WHEEL AND REAR WHEEL EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL 23 Nm (2.3 mdkg, 17 ftdlb) 20 Nm (2.0 mdkg, 14 ftdlb) 20 Nm (2.0 mdkg, 14 ftdlb) 48 Nm (4.8 mdkg, 35 ftdlb) 1 Front wheel removal 2 Wheel bearing removal Extend of removal:...
  • Page 163 CHAS FRONT WHEEL AND REAR WHEEL EC598100 REAR WHEEL 23 Nm (2.3 mdkg, 17 ftdlb) 63 Nm (6.3 mdkg, 45 ftdlb) 16 Nm (1.6 mdkg, 11 ftdlb) 32 Nm (3.2 mdkg, 23 ftdlb) 2 Nm (0.2 mdkg, 1.4 ftdlb) 1 Rear wheel removal 2 Wheel bearing removal Extend of removal: 3 Brake disc removal...
  • Page 164 CHAS FRONT WHEEL AND REAR WHEEL EC593000 REMOVAL POINTS EC523101 Rear wheel 1. Remove: • Wheel 1 NOTE: Push the wheel forward and remove the drive chain 2. EC513201 Wheel bearing (if necessary) 1. Remove: • Bearing 1 NOTE: Remove the bearing using a general bearing puller 2.
  • Page 165 CHAS FRONT WHEEL AND REAR WHEEL NOTE: The bending value is shown by one half of the dial gauge reading. Do not attempt to straighten a bent axle. EC594100 Brake disc 1. Measure: • Brake disc deflection (only rear brake disc) Use the dial gauge 1.
  • Page 166 CHAS FRONT WHEEL AND REAR WHEEL EC595000 ASSEMBLY AND INSTALLATION EC515142 Front wheel 1. Install: • Bearing (right) 1 • Spacer 2 • Bearing (left) 3 NOTE: • Apply the lithium soap base grease on the bearing when installing. • Use a socket that matches the outside diam- eter of the race of the bearing.
  • Page 167 CHAS FRONT WHEEL AND REAR WHEEL 5. Install: • Wheel axle 1 NOTE: • Apply the lithium soap base grease on the wheel axle. • Insert the wheel axle from right side. 6. Install: • Plain washer 1 • Nut (wheel axle) 2 48 Nm (4.8 mdkg, 35 ftdlb) 7.
  • Page 168 CHAS FRONT WHEEL AND REAR WHEEL 2. Install: • Brake disc 1 • Bolt (brake disc) 2 23 Nm (2.3 mdkg, 17 ftdlb) NOTE: Tighten the bolts in stage, using a crisscross pattern. 3. Install: • Sprocket damper 1 • Nut (sprocket damper) 2 32 Nm (3.2 mdkg, 23 ftdlb) To driven sprocket 3.
  • Page 169 CHAS FRONT WHEEL AND REAR WHEEL 7. Install: • Drive chain 1 NOTE: Push the wheel 2 forward and install the drive chain. 8. Install: • Wheel axle 1 NOTE: • Apply the lithium soap base grease on the wheel axle. •...

  • Page 170: Front Brake And Rear Brake

    CHAS FRONT BRAKE AND REAR BRAKE EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE 5 Nm (0.5 mdkg, 3.6 ftdlb) 1 Nm (0.1 mdkg, 0.7 ftdlb) 6 Nm (0.6 mdkg, 4.3 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 30 Nm (3.0 mdkg, 22 ftdlb) 35 Nm (3.5 mdkg, 25 ftdlb) 18 Nm (1.8 mdkg, 13 ftdlb) 14 Nm (1.4 mdkg, 10 ftdlb)
  • Page 171 CHAS FRONT BRAKE AND REAR BRAKE EC5A8100 REAR BRAKE 30 Nm (3.0 mdkg, 22 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 3 Nm (0.3 mdkg, 2.2 ftdlb) 2 Nm (0.2 mdkg, 1.4 ftdlb) 12 Nm (1.2 mdkg, 8.7 ftdlb) 23 Nm (2.3 mdkg, 17 ftdlb) 14 Nm (1.4 mdkg, 10 ftdlb) 26 Nm (2.6 mdkg, 19 ftdlb) 12 Nm (1.2 mdkg, 8.7 ftdlb)
  • Page 172 CHAS FRONT BRAKE AND REAR BRAKE EC5A8200 CALIPER DISASSEMBLY 6 Nm (0.6 mdkg, 4.3 ftdlb) 18 Nm (1.8 mdkg, 13 ftdlb) 6 Nm (0.6 mdkg, 4.3 ftdlb) 18 Nm (1.8 mdkg, 13 ftdlb) A Front B Rear 1 Front caliper disassembly 2 Rear caliper disassembly Extend of removal: Extend of removal...
  • Page 173 CHAS FRONT BRAKE AND REAR BRAKE EC5A8300 MASTER CYLINDER DISASSEMBLY 2 Nm (0.2 mdkg, 1.4 ftdlb) A Front B Rear 1 Front master cylinder disassembly 2 Rear master cylinder disassembly Extend of removal: Extend of removal Order Part name Q’ty Remarks MASTER CYLINDER DISASSEMBLY Master cylinder boot...
  • Page 174 CHAS FRONT BRAKE AND REAR BRAKE EC536000 HANDLING NOTE The brake components of this machine are suit for closed circuit use only. Never use on any public road. EC5A3000 REMOVAL POINTS EC5A3200 Brake fluid 1. Remove: • Reservoir tank cap 1 NOTE: Do not remove the diaphragm.
  • Page 175 CHAS FRONT BRAKE AND REAR BRAKE EC533301 Caliper piston 1. Remove: • Caliper piston Use compressed air and proceed carefully. • Cover piston with rag and use extreme caution when expelling piston from cylin- der. • Never attempt to pry out piston. Caliper piston removal steps: •...
  • Page 176 CHAS FRONT BRAKE AND REAR BRAKE EC5A4000 INSPECTION EC534112 Master cylinder 1. Inspect: • Master cylinder inner surface a Wear/Scratches ≥ Replace master cylin- der assembly. Stains ≥ Clean. Use only new brake fluid. A Front B Rear 2. Inspect: •...
  • Page 177 CHAS FRONT BRAKE AND REAR BRAKE 2. Inspect: • Caliper piston 1 Wear/Score marks ≥ Replace caliper pis- ton assembly. Replace the piston seals and dust seals 2 2 whenever a caliper is disassembled. EC534301 Brake hose 1. Inspect: • Brake hose 1 Crack/Damage ≥...
  • Page 178 CHAS FRONT BRAKE AND REAR BRAKE 3. Install: • Caliper piston 1 NOTE: Apply the brake fluid on the piston wall. CAUTION: • Install piston with shallow depressed side a a facing the caliper. • Never force to insert. A Front B Rear EC535241 Front caliper...
  • Page 179 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: • Caliper 1 • Bolt (caliper) 2 23 Nm (2.3 mdkg, 17 ftdlb) 3. Tighten: • Pad pin 3 18 Nm (1.8 mdkg, 13 ftdlb) EC5A5210 Master cylinder kit 1. Clean: • Master cylinder •...
  • Page 180 CHAS FRONT BRAKE AND REAR BRAKE 3. Install: [Front] • Spring 1 To master cylinder cup (secondary) 2. [Rear] • Spring 1 To master cylinder piston 2. NOTE: Install the spring at the smaller dia. side. After installing, cylinder cup should be installed as shown direction.
  • Page 181 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: • Master cylinder 1 • Master cylinder bracket 2 • Bolt (master cylinder bracket) 3 8 Nm (0.8 mdkg, 5.8 ftdlb) NOTE: • Install the bracket so that the arrow mark a face upward.
  • Page 182 CHAS FRONT BRAKE AND REAR BRAKE 3. Install: • Brake pedal 1 • Brake pedal connecting bolt 2 • Nut (brake pedal connecting bolt) 3 12 Nm (1.2 mdkg, 8.7 ftdlb) NOTE: After installing, check the brake pedal height. Refer to “REAR BRAKE ADJUSTMENT” sec- tion in the CHAPTER 3.
  • Page 183 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: • Clamp 1 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. EC545442 Rear brake hose 1. Install: • Copper washer 1N • Brake hose 2 • Union bolt 3 30 Nm (3.0 mdkg, 22 ftdlb) Always use new copper washers.
  • Page 184 CHAS FRONT BRAKE AND REAR BRAKE 3. Install: • Brake hose holder 1 • Bolt (brake hose holder) 2 8Nm (0.8 mdkg,5.8 ftdlb) 4. Install: • Brake hose 1 NOTE: Clamp the brake hose with the end of the clamp a forward. Refer to “CABLE ROUTING DIAGRAM”...
  • Page 185 CHAS FRONT BRAKE AND REAR BRAKE 2. Air bleed: • Brake system Refer to “BRAKE SYSTEM AIR BLEED- ING” section in the CHAPTER 3. 3. Inspect: • Brake fluid level Fluid at lower level ≥ Fill up. Refer to “BRAKE FLUID LEVEL INSPEC- TION”...
  • Page 186 CHAS FRONT FORK EC550000 FRONT FORK 15 Nm (1.5 mdkg, 11 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 20 Nm (2.0 mdkg, 14 ftdlb) 7 Nm (0.7 mdkg, 5.1 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 1 Front fork removal Extend of removal: Extend of removal Order...
  • Page 187 CHAS FRONT FORK EC558000 FRONT FORK DISASSEMBLY 23 Nm (2.3 mdkg, 17 ftdlb) 15 Nm (1.5 mdkg, 11 ftdlb) 40 Nm (4.0 mdkg, 29 ftdlb) 1 Oil seal removal 2 Damper rod removal Extend of removal: Extend of removal Order Part name Q’ty Remarks...
  • Page 188 CHAS FRONT FORK EC556000 HANDLING NOTE NOTE: The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers. CAUTION: To prevent an accidental explosion of air, the following instructions should be observed: •...
  • Page 189 CHAS FRONT FORK 3. Remove: • Cap bolt 1 NOTE: • While pressing down the spacer 3 with the fork spring compressor 2, set the rod holder 5 between the locknut 4 and spacer. • Hold the locknut and remove the cap bolt by turning the spring preload adjuster 6.
  • Page 190 CHAS FRONT FORK EC553321 Damper rod 1. Remove: • Locknut 1 2. Remove: • Bolt (damper rod) 1 • Damper rod 2 NOTE: Use a damper rod holder 3 to lock the damper rod. Damper rod holder: YM-01425/90890-01425 EC554000 INSPECTION EC554100 Damper rod 1.
  • Page 191 CHAS FRONT FORK EC554502 Inner tube 1. Inspect: • Inner tube surface a Score marks ≥ Repair or replace. Use #1,000 grit wet sandpaper. Damaged oil lock piece ≥ Replace. • Inner tube bends Out of specification ≥ Replace. Use the dial gauge 1. Inner tube bending limit: 0.2 mm (0.008 in) NOTE:...
  • Page 192 CHAS FRONT FORK EC555000 ASSEMBLY AND INSTALLATION EC5551C0 Front fork assembly 1. Wash the all parts in a clear solvent. 2. Install: • Damper rod 1 To inner tube 2. CAUTION: To install the damper rod into the inner tube, hold the inner tube aslant. If the inner tube is held vertically, the damper rod may fall into it, damaging the valve inside.
  • Page 193 CHAS FRONT FORK 6. Install: • Stopper ring 1 • Oil seal 2N • Oil seal washer 3 To inner tube 4. NOTE: • Apply the fork oil on the inner tube. • When installing the oil seal, use vinyl seat a with fork oil applied to protect the oil seal lip.

  • Page 194: Front Fork

    CHAS FRONT FORK 10.Install: • Stopper ring 1 NOTE: Fit the stopper ring correctly in the groove in the outer tube. 11. Check: • Inner tube smooth movement Tightness/Binding/Rough spots ≥ Repeat the steps 2 to 10. 12.Compress the front fork fully. 13.Fill: •...
  • Page 195 CHAS FRONT FORK 15.Fill: • Front fork oil Until outer tube top surface with recom- mended fork oil once more. 16.After filling, pump the outer tube 1 slowly up and down (about 60 mm (2.4 in) stroke) to distribute the fork oil once more. NOTE: Be careful not to excessive full stroke.
  • Page 196 CHAS FRONT FORK 19.Install: • Fork spring 1 • Spacer guide 2 • Spacer 3 NOTE: Install the fork spring with its smaller dia. por- tion upward. 20.Attach: • Rod puller 1 • Rod puller attachment 2 • Fork spring compressor 3 •...
  • Page 197 CHAS FRONT FORK NOTE: Record the set position of the adjuster (the amount of turning in the adjuster to the fully turned in position) before adjusting it. CAUTION: If the rebound damping adjuster position is out of specification, proper damping force cannot be obtained.
  • Page 198 CHAS FRONT FORK 26.Install: • Cap bolt 1 To outer tube. NOTE: Temporarily tighten the cap bolt. EC555263 Installation 1. Install: • Front fork 1 • Steering damper stay 2 (left side only) • Handlebar 3 NOTE: • Temporarily tighten the pinch bolt (under bracket).
  • Page 199 CHAS FRONT FORK 4. Tighten: • Pinch bolt (handle crown) 1 15 Nm (1.5 mdkg, 11 ftdlb) • Pinch bolt (under bracket) 2 20 Nm (2.0 mdkg, 14 ftdlb) • Pinch bolt (handle bracket) 3 8 Nm (0.8 mdkg, 5.8 ftdlb) •...
  • Page 200 CHAS HANDLEBAR EC5B0000 HANDLEBAR 8 Nm (0.8 mdkg, 5.8 ftdlb) 5 Nm (0.5 mdkg, 3.6 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 1 Handlebar removal 2 Throttle disassembly Extend of removal: Extend of removal Order Part name Q’ty...

  • Page 201: Handlebar

    CHAS HANDLEBAR EC5B3000 REMOVAL POINTS EC5B3200 Grip 1. Remove: • Grip 1 NOTE: Blow in air between the handlebar or tube guide and the grip. Then remove the grip which has become loose. EC5B4000 INSPECTION EC5B4100 Handlebar 1. Inspect: • Handlebar 1 Bends/Cracks /Damage ≥...
  • Page 202 CHAS HANDLEBAR 2. Install: • Throttle cable 1 To grip cap (lower) 2. NOTE: Install the throttle cable in the grip side slit a in the grip cap (lower). 3. Install: • Throttle 1 NOTE: Apply the lithium soap base grease on the throttle grip sliding surface.
  • Page 203 CHAS HANDLEBAR 7. Install: • Master cylinder 1 • Master cylinder bracket 2 • Bolt (master cylinder bracket) 3 8 Nm (0.8 mdkg, 5.8 ftdlb) NOTE: • Install the bracket so that the arrow mark a faces upward. • When installing master cylinder, align the contacting surface b of the master cylinder bracket with the punch mark c on the han- dlebar.
  • Page 204 CHAS HANDLEBAR 11. Adjust: • Clutch lever free play Refer to “CLUTCH ADJUSTMENT” section in the CHAPTER 3. 12.Lock the throttle cables using a locking wire. Refer to “LOCKING WIRE INSTALLATION GUIDE” section in the CHAPTER 3. 5-43...

  • Page 205: Steering

    CHAS STEERING EC560000 STEERING EC568000 HANDLE CROWN AND STEERING DAMPER 15 Nm (1.5 mdkg, 11 ftdlb) 80 Nm (8.0 mdkg, 58 ftdlb) 15 Nm (1.5 mdkg, 11 ftdlb) 18 Nm (1.8 mdkg, 13 ftdlb) 5 Nm (0.5 mdkg, 3.6 ftdlb) 1 Handle crown removal 2 Steering damper removal Extend of removal:...
  • Page 206 CHAS STEERING EC568100 UNDER BRACKET TIGHTENING STEPS: • Tighten ring nut. 46 Nm (4.6 mdkg, 33 ftdlb) • Loosen it one turn. • Retighten it. 1 Nm (0.1 mdkg, 0.7 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 7 Nm (0.7 mdkg, 5.1 ftdlb) 20 Nm (2.0 mdkg, 14 ftdlb) 20 Nm (2.0 mdkg, 14 ftdlb)
  • Page 207 CHAS STEERING EC563000 REMOVAL POINTS EC563202 Ring nut 1. Remove: • Ring nut 1 Use the ring nut wrench 2. Ring nut wrench: YM-33975/90890-01403 Support the steering shaft so that it may not fall down. EC563300 Bearing (lower) 1. Remove: •...
  • Page 208 CHAS STEERING EC564101 Bearing and ball race 1. Wash the bearings and ball races with a solvent. 2. Inspect: • Bearing 1 • Ball race Pitting/Damage ≥ Replace bearings and ball races as a set. Install the bearing in the ball races. Spin the bearings by hand.
  • Page 209 CHAS STEERING 4. Install: • Under bracket 1 NOTE: Apply the lithium soap base grease on the bearing. 5. Install: • Ring nut 1 1 Nm (0.1 mdkg, 0.7 ftdlb) Tighten the ring nut using the ring nut wrench 2. Refer to “STEERING HEAD INSPECTION AND ADJUSTMENT”...
  • Page 210 CHAS STEERING 8. Install: • Plain washer 1 • Steering shaft nut 2 80 Nm (8.0 mdkg, 58 ftdlb) NOTE: Apply the lithium soap base grease on the steering shaft nut thread. 9. After tightening the nut, check the steering for smooth movement.
  • Page 211 CHAS STEERING 12.Adjust: • Front fork top end a • Handlebar position b • Steering damper stay position c (left side only) Front fork top end: 18 mm (0.71 in) Handlebar position: 20 mm (0.79 in) Steering damper stay position: Zero mm (Zero in) Refer to “FRONT FORK TOP END ADJUSTMENT”...
  • Page 212 CHAS SWINGARM EC570000 SWINGARM 2 Nm (0.2 mdkg, 1.4 ftdlb) 63 Nm (6.3 mdkg, 45 ftdlb) 5 Nm (0.5 mdkg, 3.6 ftdlb) 34 Nm (3.4 mdkg, 24 ftdlb) 2 Nm (0.2 mdkg, 1.4 ftdlb) 10 Nm (1.0 mdkg, 7.2 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 34 Nm (3.4 mdkg, 24 ftdlb) 1 Swingarm removal...

  • Page 213: Swingarm

    CHAS SWINGARM EC573000 REMOVAL POINTS EC573152 Swingarm 1. Loosen: • Pivot shaft adjust bolt 1 NOTE: Loosen the pivot shaft adjust bolt using the pivot shaft wrench 2 and pivot shaft wrench adapter 3. Pivot shaft wrench: YM-01455/90890-01455 Pivot shaft wrench adapter: YM-01476/90890-01476 2.
  • Page 214 CHAS SWINGARM EC574220 Relay arm 1. Inspect: • Bearing 1 • Collar 2 Free play exists/Unsmooth revolution/Rust ≥ Replace bearing and collar as a set. EC574320 Connecting rod 1. Inspect: • Connecting rod 1 Wear/Damage ≥ Replace. EC574520 Swingarm side clearance 1.
  • Page 215 CHAS SWINGARM 4. Calculate: • Swingarm side clearance “A A + B B ” Out of specification ≥ Adjust side clear- ance using shim. By using formula given below. “A A + B B ” = a a – ( b b + c c + d d ) Side clearance “A A + B B ”: 0.05~0.35 mm (0.002~0.014 in) If the side clearance is out of specification,...
  • Page 216 CHAS SWINGARM 2. Install: • Bearing 1 To relay arm. NOTE: • Apply the lithium soap base grease on the bearing when installing. • Install the bearing by pressing it on the side having the manufacture’s marks or numbers. Installed depth of bearings a a : Zero mm (Zero in) EC575163 Swingarm...
  • Page 217 CHAS SWINGARM 4. Install: • Swingarm 1 • Pivot shaft 2 NOTE: • Apply the lithium soap base grease on the pivot shaft. • Insert the pivot shaft from left side. 5. Tighten: • Pivot adjust bolt 1 5 Nm (0.5 mdkg, 3.6 ftdlb) NOTE: Use the pivot shaft wrench 2 and pivot shaft wrench adapter 3 to tighten the pivot adjust...
  • Page 218 CHAS SWINGARM 9. Install: • Connecting rod 1 • Bolt (connecting rod) 2 • Nut (connecting rod) 3 34 Nm (3.4 mdkg, 24 ftdlb) NOTE: • Install the connecting rods with the mark a outward of the chassis. • Apply the lithium soap base grease on the bolts.

  • Page 219: Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER EC580000 REAR SHOCK ABSORBER 40 Nm (4.0 mdkg, 29 ftdlb) 38 Nm (3.8 mdkg, 27 ftdlb) 34 Nm (3.4 mdkg, 24 ftdlb) 23 Nm (2.3 mdkg, 17 ftdlb) 40 Nm (4.0 mdkg, 29 ftdlb) 34 Nm (3.4 mdkg, 24 ftdlb) 1 Rear shock absorber removal 2 Rear shock absorber disassembly Extend of removal:...
  • Page 220 1 of the tank. At this time, wear eye protection to prevent eye damage from escaping gas and/or metal chips. To dispose of a damaged or worn-out shock absorber, take the unit to your Yamaha dealer for this disposal procedure. 5-59...
  • Page 221 CHAS REAR SHOCK ABSORBER EC583000 REMOVAL POINTS EC583310 Bearing 1. Remove: • Stopper ring 1 2. Remove: • Bearing 1 NOTE: Remove the bearing by pressing its outer race. EC584000 INSPECTION EC584110 Rear shock absorber 1. Inspect: • Damper rod 1 Bends/Damage ≥...
  • Page 222 CHAS REAR SHOCK ABSORBER EC585000 ASSEMBLY AND INSTALLATION EC585310 Bearing 1. Install: • Stopper ring 1N • Bearing 2 NOTE: • Apply the lithium soap base grease on the bearing when installing. • Install the bearing parallel until it contacts the stopper ring by pressing its outer race.
  • Page 223 CHAS REAR SHOCK ABSORBER NOTE: The length of the spring (installed) changes 1.5mm (0.06 in) per turn of the adjuster. CAUTION: Never attempt to turn the adjuster beyond the maximum or minimum setting. 4. Tighten: • Locknut 1 40 Nm (4.0 mdkg, 29 ftdlb) EC585262 Rear shock absorber 1.
  • Page 224 CHAS REAR SHOCK ABSORBER 5. Install: • Bolt (rear shock absorber–relay arm) 1 • Nut (rear shock absorber–relay arm) 2 34 Nm (3.4 mdkg, 24 ftdlb) NOTE: Apply the lithium soap base grease on the bolt. 6. Install: • Rear frame 1 •...

  • Page 225: Electrical

    ELEC ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 CDI unit 6 Ignition coil COLOR CODE 2 Voltage regulator 7 Spark pulg B ..Black B/L ..Black/Blue 3 Condenser 8 Solenoid valve Br .

  • Page 226: Ignition System

    ELEC IGNITION SYSTEM EC620000 IGNITION SYSTEM EC621022 INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. Spark *Clean or replace Spark gap test spark plug.
  • Page 227 ELEC IGNITION SYSTEM EC622010 SPARK GAP TEST 1. Disconnect the spark plug cap from spark plug. 2. Connect the dynamic spark tester 1 (igni- tion checker 2) as shown. • Spark plug cap 3 • Spark plug 4 A For USA and CDN B Except for USA and CDN 3.
  • Page 228 ELEC IGNITION SYSTEM EC625002 “ENGINE STOP” BUTTON INSPECTION 1. Inspect: • “ENGINE STOP” button conduct ≥ Black/White lead 1 1 Tester (+) lead ≥ ≥ Black lead 2 2 Tester (–) lead ≥ Tester selector position PUSH IN Ω X X 1 FREE Not continuous while being pushed ≥...
  • Page 229 ELEC IGNITION SYSTEM EC627001 CDI MAGNETO INSPECTION 1. Inspect: • Pick-up coil resistance Out of specification ≥ Replace. ≥ White/Green lead 1 1 Tester (+) lead ≥ ≥ White/Black lead 2 2 Tester (–) lead ≥ Pick-up coil Tester selector resistance position 94~140 Ω...

  • Page 230: Solenoid Valve System

    ELEC SOLENOID VALVE SYSTEM EC650001 SOLENOID VALVE SYSTEM EC651012 INSPECTION STEPS If the solenoid valve will not operate, use the following inspection steps. Check each couplers and No good Repair or replace. wire connection. No good No good Check solenoid valve Check solenoid valve coil.
  • Page 231 ELEC SOLENOID VALVE SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/ Dust/ Looseness/Short-circuit ≥ Repair or replace. EC652030 SOLENOID VALVE OPERATION 1. Check: • Solenoid valve operation Checking steps: • Disconnect the condenser lead 1. •...
  • Page 232 ELEC SOLENOID VALVE SYSTEM EC635002 VOLTAGE REGULATOR INSPECTION 1. Disconnect the condenser lead. 2. Start the engine. 3. Inspect: • Out-put voltage Out of specification ≥ Replace voltage regulator. ≥ Red lead 1 1 Tester (+) lead ≥ ≥ Black lead 2 2 Tester (–) lead ≥...

  • Page 233: Thermo Unit System

    ELEC THERMO UNIT SYSTEM EC6A0000 THERMO UNIT SYSTEM EC6A1000 INSPECTION STEPS If the water temperature gauge (thermo unit) will not operate, use the following inspection steps. Check each couplers and No good Repair or replace. wire connection. No good Check thermo unit Replace.
  • Page 234 ELEC THERMO UNIT SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/ Dust/ Looseness/Short-circuit ≥ Repair or replace. EC6A2000 THERMO UNIT INSPECTION 1. Drain the cooling water. 2. Remove: • Thermo unit 1 3. Immerse the thermo unit with a tester lead connected in a container containing cooling (tap) water 1 down to the upper threaded portion a.

  • Page 235: Tuning

    SETTING EC700000 TUNING EC710000 ENGINE EC711011 Carburetor setting • The role of fuel is not only to produce motive power but also to cool the engine and, in the case of a 2-stroke engine, to lubricate it. Therefore, too lean a mixture (of air and fuel) tends to cause an abnormal combustion (i.e., detonation), whereas too rich a mixture makes it difficult for the engine to develop its...
  • Page 236 SETTING That is: • Higher temperature expands the air with its resultant reduced density. • Higher humidity reduces the amount of oxy- gen in the air by so much of the water vapor in the same air. • Lower atmospheric pressure (at a high alti- tude) reduces the density of the air.
  • Page 237 SETTING Next run a few laps of the circuit with this setting and check for any difference in engine revolutions. If no difference is noticed, use a main jet with a much smaller calibration number. Example: #215 ≥ #210 Factory-set main jet #220 2.
  • Page 238 SETTING Run a few laps of the circuit to check the engine for response to revolutions. On the other hand, if the use of a different jet needle appears to produce less power, change to a jet needle of a smaller size. Example:N8VW ≥...
  • Page 239 SETTING 4. Adjustment of jet needle clip position Mid-open adjustment for the jet needle clip position 1 follows the completion of the adjustment of the jet needle. If the mixture is too rich or too lean in the mid-open posi- tion, irregular engine operation and poor acceleration will result.
  • Page 240 SETTING EC71B030 Relationship with throttle opening The flow of the fuel through the carburetor main system is controlled by the main jet and then, it is further regulated by the area between the main nozzle and the jet needle. On the relationship between the fuel flow and the throttle opening, the fuel flow relates to the jet needle straight portion diameter around 1/8 throttle opening, whereas around 1/4 to 1/2...
  • Page 241 SETTING 2. Pilot jet 1 The pilot jet is used in relation to the engine response at small throttle opening. This is changed when the jet needle setting is not enough. A larger size results in a richer mixture and a smaller size in a leaner mixture.
  • Page 242 SETTING EC71Q000 Carburetor setting parts Part name Size Part number Main jet 1 1 Lean #160 4MX-14943-39 #162 4MX-14943-90 #165 4MX-14943-40 #168 4MX-14943-91 #170 4MX-14943-41 #172 4MX-14943-92 #175 4MX-14943-42 #178 4MX-14943-93 #180 4MX-14943-43 #182 4MX-14943-94 #185 4MX-14943-44 #188 4MX-14943-95 #190 4MX-14943-45 #192 4MX-14943-96...
  • Page 243 SETTING EC71J001 Plug chop When checking the discoloration of the spark plug and piston head, push the “ENGINE STOP” button while running along a straight lane at full throttle, disengage the clutch at the same time and stop the engine. Then let your machine go back to the pit by inertia.
  • Page 244 SETTING When the cylinder gasket is changed, measure the protruding (or sinking) amount of the piston above (below) the cylinder top and then change the cylinder gasket so that the follow- ing approximate relation can be achieved between the temperature and the piston pro- truding amount.
  • Page 245 SETTING 2. Loosen the stand installation bolt 1, then rotate the dial gauge stand and set it close to the center of the piston. Tighten the stand installation bolt again. NOTE: Do not loosen the dial gauge installation bolt 2 while doing the above.
  • Page 246 SETTING 3rd gear Number of Gear ratio Part number groove Supplying part 23/16 (1.438) 4JT-17231-00/4JT-17131-00 – Factory installed 24/17 (1.412) 4JT-17231-30/4JT-17131-30 – Supplying part 26/19 (1.316) 4JT-17231-10/4JT-17131-10 4th gear Number of Gear ratio Part number groove Supplying part 28/22 (1.278) 4JT-17241-00/4JT-17131-00 –...
  • Page 247 4JT-17251-10 ∆ 4JT-17251-00 ∆ 6th wheel gear ¡ ¡ 4JT-17261-00 4JT-17261-30 4JT-17261-11 * Factory installed NOTE: The mark ∆ shows that this part is not supplied together and that it is available on order as a YAMAHA genuine part. 7-13...

  • Page 248: Chassis

    SETTING EC720000 CHASSIS EC72J001 Chassis setting How to go about setting the chassis • Measure the stroke of the front and rear sus- pension to get an idea of the operation. • If the time increases, the stroke increases. • If the tire grip becomes firmer, the stroke increases.
  • Page 249 SETTING EC72M001 Tire and machine’s posture If a non-designated tire is used, the difference in radius between the front and the rear tire may affect the machine’s posture. To keep the machine in a proper posture, adjust the front fork top end or seat height. Basically, with a larger radius tire, lower the machine’s posture and vice versa.
  • Page 250 SETTING EC72K014 Settings For full use of engine performance and safe riding, set the suspension as follows. (Ex-fac- tory settings are intended for a rider approxi- mately 164 cm (64.6 in) in height and approxi- mately 53 kg (117 lb) in weight.) 1.
  • Page 251 SETTING SETTING CHART ACTUAL RUN Check stroke NOTE: The remaining stroke value is provid- ed just as a guide and may change according to the riding style. Front remaining stroke 5 to 10 mm (0.20 ~ 0.39 in) Rear remaining stroke 20 to 30 mm (0.79 ~ 1.18 in) Poor stroke Too much stroke...
  • Page 252 SETTING EC71P011 Selection of the secondary reduction ratio (Sprocket) Secondary Number of driven sprocket teeth reduction = Number of drive sprocket teeth ratio Factory-set secondary 36/17 (2.118) reduction ratio Driven sprocket Drive sprocket 2.188 2.250 2.313 2.375 2.438 2.059 2.118 2.177 2.235 2.294...
  • Page 253 SETTING EC72L003 Chassis setting troubleshooting <Symptom> <Cause> <Measures> Chattering (Small rebounds, Bottoming (full stroke) • Increase spring preload. up-and-down • Increase damping force for compression. movements) Further in stroke • Increase damping force for compression, or decrease damping force for rebound. Too stiff (poor stroke) •...
  • Page 254 SETTING <Symptom> <Cause> <Measures> Handlebar Poor of front load • Decrease spring preload (for front). fluctuating • Increase front fork top end. • Increase rear height. • Increase spring preload (for rear). Too soft of front • Increase spring preload (for front). •...
  • Page 255 SETTING EC740010 Setting record table The data shown here is an example of entry. For your actual use, copy the necessary data. Event name Date Weather Place Setting specs: Ignition timing Spark plug Carburetor Main jet Power jet Jet needle Pilot jet Pilot air screw Float height...
  • Page 256 SETTING Event name Date Weather Place Setting specs: Ignition timing Spark plug Carburetor Main jet Power jet Jet needle Pilot jet Pilot air screw Float height Gearing Secondary Front fork Spring rate Spring preload Rebound damping Compression damping Top end Oil capacity Oil level Rear shock...
  • Page 257 99.8-0.1x1...

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