Yamaha TZ250M1 Owner's Service Manual
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Yamaha TZ250M1 Owner's Service Manual

Yamaha TZ250M1 Owner's Service Manual

Motorcycle yamaha tz250m1/(m)
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OWNER'S SERVICE MANUAL
TZ250M1/(M)
LIT-11626-13-41
5KE-28199-10

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  • Page 1 OWNER’S SERVICE MANUAL TZ250M1/(M) LIT-11626-13-41 5KE-28199-10...
  • Page 2 EC010000 TZ250M1/(M) OWNER’S SERVICE MANUAL ©1999 by Yamaha Motor Corporation, U.S.A. 1st Edition, September 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-11626-13-41...
  • 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 INFORMATION .
  • Page 14 CHAPTER 4 ENGINE COWLING, INDUCTION GUIDE, SEAT AND FUEL TANK....4-1 EXHAUST PIPE AND SILENCER ..4-3 RADIATOR .
  • Page 15 CHAPTER 7 TUNING ENGINE ......7-1 CHASSIS ......7-14...

  • Page 16: General Information

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

  • Page 17: 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 18: 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 19: Insp

    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 20: 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 21: 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 22 YM-34487 Dynamic spark tester YM-34487 90890-06754 90890-06754 Ignition checker This instrument is necessary for checking the ignition system components. 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.
  • Page 23 INFO SPECIAL TOOLS Part number Tool name / How to use Illustration 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 24: Control Functions

    INFO CONTROL FUNCTIONS EC150000 CONTROL FUNCTIONS EC15W000 MAIN SWITCH While the battery is connected, moving the main switch 1 to “RUN” causes the tachome- ter, servomotor, fuel pump and solenoid valves to be initially activated. To prevent the battery from being discharge, do not move the main switch to “RUN”...
  • Page 25 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 26 INFO CONTROL FUNCTIONS NOTE: • If an out-of-step indication takes place, mov- ing the main switch to “OFF” once and then to “RUN”, brings the tachometer back to a nor- mal indication through its corrective 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 27 INFO CONTROL FUNCTIONS EC15Y000 INDUCTION BOX INTAKE SYSTEM The induction boxes 1 and induction guides 2 are provided for the purpose of applying pressure inside the carburetor float chamber and thereby improving the intake performance. If the machine is run without them, the carbu- retor settings will become faulty.
  • Page 28 INFO CONTROL FUNCTIONS EC15a000 FUEL PUMP STOP SWITCH, FUEL PUMP RELAY The fuel pump stop switch 1 and fuel pump relay 2 are provided so as to control the fuel pump and prevent the carburetor overflowing during a turnover. If the machine is turned over, the fuel pump stop switch is turned “ON”...
  • Page 29 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 30: 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 31: 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 32: 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 33 INFO STARTING AND BREAK-IN EC193031 STARTING A WARM ENGINE Do not push the starter lever (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. EC194020 BREAK-IN PROCEDURES 1.
  • Page 34 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 35: 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 36: 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 37 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 38: Specifications

    SPEC GENERAL SPECIFICATIONS EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: TZ250M1 (USA) TZ250(M) (OTHERS) Model code number: 5KE1 Dimensions: Overall length 1,955 mm (77.0 in) Overall width 650 mm (25.6 in) Overall height 1,083 mm (42.6 in) Seat height 788 mm (31.0 in) Wheelbase 1,342 mm (52.8 in)
  • Page 39 SPEC GENERAL SPECIFICATIONS Transmission: primary reduction system Spur gear Primary reduction ratio 53/21 (2.524) Secondary reduction system Chain drive Secondary reduction ratio 36/14 (2.571) Transmission type Constant mesh, 6-speed Operation Left foot operation Gear ratio: 1st 34/18 (1.889) 31/21 (1.476) 29/23 (1.261) 27/25 (1.080) 26/27 (0.963)

  • Page 40: Maintenance Specifications

    SPEC MAINTENANCE SPECIFICATIONS EC212000 MAINTENANCE SPECIFICATIONS EC212111 ENGINE Item Standard Limit Cylinder head: Combustion chamber capacity 9.0 cm (0.317 lmp oz, 0.304 US oz) Piston: Piston clearance 0.090~0.100 mm (0.0035~0.0039 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 41 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Carburetor: Type/Manufacturer TMX*38/MIKUNI I.D. mark (left side/right side) 5KE1 00L/5KE1 00R Main jet (M.J.) #580 Jet needle (J.N.) 6EGJ4-63 Main nozzle (N.J.) Cutaway (C.A.) Pilot jet (P.J.) Pilot air screw (P.A.S.) 1-1/2 Valve seat size (V.S.) Starter jet (G.S.)
  • Page 42 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 Power valve: Cover M 5 X 0.8 Holder (power valve) M 5 X 0.8...
  • Page 43 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty mdkg ftdlb Joint rod 2 and shift rod M 6 X 1.0 Joint rod 1,2 M 6 X 1.0 Shift pedal pivot bolt M 8 X 1.25 Front pedal M 6 X 1.0 Crankcase tighten sequence NOTE:...
  • Page 44 SPEC MAINTENANCE SPECIFICATIONS EC212201 CHASSIS Item Standard Limit Steering system: Steering bearing type Taper roller bearing Front suspension: Front fork travel 110 mm (4.33 in) Fork spring free length 212.5 mm (8.37 in) 210.5 mm (8.29 in) Spring rate, STD K=7.00 N/mm (0.700 kg/mm, 39 lb/in) Optional spring...
  • Page 45 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. 15.87 mm (0.625 in) Caliper cylinder inside dia. 33.96 + 30.23 mm (1.337 + 1.190 in) Brake fluid type DOT #4...
  • Page 46 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 M 8 X 1.25 ∆ Steering shaft and steering shaft nut M22 X 1.0 ∆...
  • Page 47 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty mdkg ftdlb ∆ Rear wheel axle and nut M18 X 1.5 ∆ Driven sprocket and sprocket damper M 8 X 1.25 ∆ Rear brake disc and wheel hub M 8 X 1.25 Chain puller adjust bolt and locknut M 8 X 1.25...
  • Page 48 SPEC MAINTENANCE SPECIFICATIONS EC212300 ELECTRICAL Item Standard Limit Ignition system: Ignition timing (B.T.D.C) 2.4 mm (0.094 in) … Advancer type Electrical … CDI: Magneto-model/Manufacturer 5KE-00 (TLGZ06)/DENSO … 2.3~3.5 Ω at 20˚C (68˚F) Source coil resistance (color) … (White-White) 94~140 Ω at 20˚C (68˚F) Pickup coil resistance (left cylinder) …...

  • Page 49: 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 50: Cable Routing Diagram

    SPEC CABLE ROUTING DIAGRAM EC240000 CABLE ROUTING DIAGRAM £ Throttle cable 1 Brake hose ¢ Transmission oil breather hose 2 Clamp A Cut the clamp so that the protruding portion is less than 5 mm (0.20 in). 3 Cable B Position the cable from bottom to top in the following order. 4 Frame 5 Radiator breather hose •...
  • Page 51 SPEC CABLE ROUTING DIAGRAM A Clamp the fuel hose and clutch cable. Position the upside ends of the 1 Fuel pump lead 2 Clamp clamp inside of the seat rail. B Clamp the radiator hose 3 and ignition coil lead. 3 Fuse holder C Clamp the radiator hose 3 and YPVS cable (right cylinder).
  • Page 52 SPEC CABLE ROUTING DIAGRAM A Clamp the wireharness together with couplers of the fuse lead under the 1 Clamp 2 Throttle cable cowling stay mounting bolt so that the tape on the wireharness aligns with the bolt. 3 Fuel tank breather hose B Fasten the primary ground lead together with the cowling stay bracket 4 Fuel pump stop switch lead 5 Battery lead...
  • Page 53 SPEC CABLE ROUTING DIAGRAM A Install the tachometer assembly with its figures standing upright. 1 Tachometer assembly B Do not make the clamp grip face outside of the chassis. 2 Coupler for speed shift C Position the reservoir hose with its paint mark upward. 3 CDI unit D Be sure the brake hose is not twisted.

  • Page 54: 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 55 INSP MAINTENANCE INTERVALS After Every Every Every As re- Item break- 1,000 Remarks race 500km quired SPARK PLUG Inspect and clean ∂ ∂ Replace ∂ PLUG CAP (1,500 km) Inspect and replace ∂ ∂ COOLING SYSTEM Check cooling level and leakage ∂...
  • Page 56 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 ∂ ∂ BATTERY Check battery voltage 12.5V or more ∂...

  • Page 57: 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 58: Locking Wire Installation Guide

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

  • Page 59: 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 60 INSP COOLING WATER REPLACEMENT 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 61 RADIATOR CAP INSPECTION/ INSP RADIATOR CAP OPENING PRESSURE INSPECTION 12.Check: • Cooling water level Cooling water level low ≥ Add cooling water. 13.Install the lower cowl. EC355000 RADIATOR CAP INSPECTION 1. Inspect: • Seal (radiator cap) 1 • Valve and valve seat 2 Crack/Damage ≥...
  • Page 62 INSP COOLING SYSTEM INSPECTION/CLUTCH CARE EC357002 COOLING SYSTEM INSPECTION 1. Inspect: • Coolant level 2. Attach: • Radiator cap tester 1 and adapter 2 Radiator cap tester: YU-24460-1/90890-01325 Adapter: YU-33984/90890-01352 3. Apply the specified pressure. Standard pressure: 180 kPa (1.8 kg/cm , 25.6 psi) NOTE: •...
  • Page 63 CLUTCH ADJUSTMENT/ INSP THROTTLE CABLE ADJUSTMENT EC359001 CLUTCH ADJUSTMENT 1. Check: • Clutch lever free play a Out of specification ≥ Adjust. Clutch lever free play a a : 2~3 mm (0.08~0.12 in) 2. Adjust: • Clutch lever free play Clutch lever free play adjustment steps: •...
  • Page 64 INSP STARTER CABLE ADJUSTMENT 4. Adjust: • Throttle grip free play Throttle grip free play adjustment steps: • Loosen the locknuts 1, 2, 3. • Turn the adjusters 4, 5, 6 fully in. • Turn out the right carburetor adjuster 5 until the specified free play is obtained.
  • Page 65 INSP YPVS OPEN SIDE CABLE ADJUSTMENT EC35D012 YPVS OPEN SIDE CABLE ADJUSTMENT 1. Disconnect the fuel pump coupler to pre- vent the fuel pump operation. 2. Check: • YPVS open side cable free play a Checking steps: • Move the main switch to “RUN”. •...
  • Page 66 INSP YPVS CLOSE SIDE CABLE ADJUSTMENT/YPVS COMPO- NENTS RETIGHTENING/TRANSMISSION OIL LEVEL CHECK EC35E011 YPVS CLOSE SIDE CABLE ADJUSTMENT 1. Disconnect the fuel pump coupler to pre- vent the fuel pump operation. 2. Check: • YPVS close side cable free play a Checking steps: •...
  • Page 67 INSP TRANSMISSION OIL REPLACEMENT 3. Check: • Transmission oil level Transmission oil level checking steps: • Remove the oil check bolt 1. • Inspect the oil level. NOTE: Be sure the machine is positioned straight up when inspecting the oil level. Never attempt to remove the checking bolt just after high speed operation.
  • Page 68 INSP PILOT AIR SCREW ADJUSTMENT 4. Remove: • Oil drain bolt 1 • Oil filler cap 2 Drain the transmission oil. 5. Install: • Copper washerN • Oil drain bolt 1 23 Nm (2.3 mdkg, 17 ftdlb) NOTE: After tightening the oil drain bolt to specified torque, lock it using a wire.
  • Page 69 INSP MUFFLER INSPECTION/SILENCER INSPECTION EC35P010 MUFFLER INSPECTION 1. Inspect: • O-ring 1 Damage ≥ Replace. EC35Q001 SILENCER INSPECTION 1. Inspect: • Silencer Inside of silencer loose ≥ Repair. Silencer repair steps: • Drill the silencer for riveting. • Rivet the silencer using the rivet. NOTE: Rivet the silencer in a different area than previously riveted.

  • Page 70: Chassis

    INSP CHASSIS/BRAKE SYSTEM AIR BLEEDING EC360000 CHASSIS EC361021 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 71 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 72 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 73 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 74 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 75 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 76 INSP DRIVE CHAIN INSPECTION EC369040 DRIVE CHAIN INSPECTION 1. Remove: • Drive chain 1 NOTE: Remove the drive chain using a chain cutter 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 77 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: • Chain joint 1N • O-ring 2 • Drive chain 3 NOTE: When installing the drive chain, apply the lithi- um soap base grease on the chain joint and O-...
  • Page 78 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 79 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 80 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 81 INSP FRONT FORK TOP END ADJUSTMENT • Adjust the front fork top end a. ≠ Front fork top end a a : Standard Extent of adjustment Zero~16 mm 13 mm (0.51 in) (Zero~0.63 in) CAUTION: Never attempt to install the front fork beyond the maximum or minimum set- ting.
  • Page 82 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 right.
  • Page 83 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: 6 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 84 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: 10 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 85 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: 10 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 86 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 21~33 mm...
  • Page 87 REAR SHOCK ABSORBER REBOUND DAMPING INSP FORCE ADJUSTMENT Spring length (installed) a a : Standard length Extent of adjustment 133~142 mm 137 mm (5.39 in) (5.24~5.59 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 88 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 89 TIRE PRESSURE CHECK/TIRE INSPECTION/ INSP WHEEL INSPECTION EC36Q011 TIRE PRESSURE CHECK 1. Measure: • Tire pressure Out of specification ≥ Adjust. Standard tire pressure: Front Rear 200 kPa 200 kPa (2.0 kg/cm , 29 psi) (2.0 kg/cm , 29 psi) NOTE: Check the tire while it is cold.
  • Page 90 INSP STEERING HEAD INSPECTION AND ADJUSTMENT 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. Check: • Steering stem Grasp the bottom of the forks and gently rock the fork assembly back and forth.
  • Page 91 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 92 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 93 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 94: Electrical

    INSP ELECTRICAL/SPARK PLUG INSPECTION 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 95 INSP IGNITION TIMING CHECK EC372070 IGNITION TIMING CHECK NOTE: • The right pick-up coil 1 is provided so that ignition timing can be set for both cylinders by adjusting for the left cylinder only. Therefore, do not loosen the screws (right pick-up coil) •...
  • Page 96 INSP BATTERY INSPECTION 6. Check: • Ignition timing Punch mark a on rotor should be aligned with punch mark b on stator. Not aligned ≥ Adjust. NOTE: Be sure to use the punch mark “F1”. 7. Adjust: • Ignition timing Adjustment steps: •...
  • Page 97 INSP RECHARGING BATTERY EC376000 RECHARGING BATTERY • Keep the battery away from fire. • When charging the battery, be sure to remove it from the chassis and use the checking lead (supplying parts). • Be sure to use the specific charging cur- rent and voltage when charging the bat- tery.
  • Page 98 INSP RECHARGING BATTERY [Using the automobile battery] 1. Remove: • Seat • Battery 2. Connect an automobile battery 1 to the battery 2 using the checking lead (supply- ing parts) 3, and recharge the battery. & Automobile battery (+) lead ≥ ≥...

  • Page 99: Cowling, Induction Guide, Seat And Fuel Tank

    COWLING, INDUCTION GUIDE, SEAT AND FUEL TANK EC400000 ENGINE EC4V0000 COWLING, INDUCTION GUIDE, SEAT AND FUEL TANK 4 Nm (0.4 mdkg, 2.9 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 1 Cowling removal 2 Induction guide removal Extend of removal: 3 Seat removal 4 Fuel tank removal Extend of removal Order...
  • Page 100 COWLING, INDUCTION GUIDE, SEAT AND FUEL TANK EC4V3000 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 101: 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) 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...

  • Page 102: Radiator

    RADIATOR EC450001 RADIATOR 2 Nm (0.2 mdkg, 1.4 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 2 Nm (0.2 mdkg, 1.4 ftdlb) 7 Nm (0.7 mdkg, 5.1 ftdlb) 7 Nm (0.7 mdkg, 5.1 ftdlb) 2 Nm (0.2 mdkg, 1.4 ftdlb) 1 Radiator removal Extend of removal: Extend of removal Order...
  • Page 103 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 104 RADIATOR 2. Install: • Radiator breather hose 1 • Radiator hose 3 2 2 Nm (0.2 mdkg, 1.4 ftdlb) • Radiator hose 4 3 2 Nm (0.2 mdkg, 1.4 ftdlb) • Radiator hose 2 4 2 Nm (0.2 mdkg, 1.4 ftdlb) •...

  • Page 105: Carburetor And Reed Valve

    CARBURETOR AND REED VALVE EC460000 CARBURETOR AND REED VALVE 2 Nm (0.2 mdkg, 1.4 ftdlb) 2 Nm (0.2 mdkg, 1.4 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 1 Nm (0.1 mdkg, 0.7 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 1 Nm (0.1 mdkg, 0.7 ftdlb) Extend of removal Order Part name...
  • Page 106 CARBURETOR AND REED VALVE 2 Nm (0.2 mdkg, 1.4 ftdlb) 2 Nm (0.2 mdkg, 1.4 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 1 Nm (0.1 mdkg, 0.7 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:...
  • Page 107 CARBURETOR AND REED VALVE EC468000 CARBURETOR DISASSEMBLY 2 Nm (0.2 mdkg, 1.4 ftdlb) 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 Starter plunger Float chamber...
  • Page 108 CARBURETOR AND REED VALVE EC466010 HANDLING NOTE CAUTION: Do not disassemble the venturi block 1 1 because it will cause a drop in carburetor performance. EC463000 REMOVAL POINTS EC463110 Throttle valve 1. Remove: • Throttle valve 1 • Ring 2 •...
  • Page 109 CARBURETOR AND REED VALVE EC464200 Needle valve 1. Inspect: • Needle valve 1 • Valve seat 2 Grooved wear a ≥ Replace. Dust b ≥ Clean. NOTE: Always replace the needle valve and valve seat as a set. EC464301 Throttle valve 1.
  • Page 110 CARBURETOR AND REED VALVE • Hold the fuel level gauge vertically next to the float chamber mating surface. • Measure the fuel level with the fuel level gauge. NOTE: Keep the carburetor and fuel level gauge vertically when measuring the fuel level. •...
  • Page 111 CARBURETOR AND REED VALVE EC464900 Induction box 1. Inspect: • Seal 1 Peeled ≥ Stick using the instantaneous adhesive Crack/Wear/Damage ≥ Replace. EC465000 ASSEMBLY AND INSTALLATION EC465180 Reed valve 1. Install: • Reed valve 1 1 • Reed valve 2 2 •...
  • Page 112 CARBURETOR AND REED VALVE 3. Install: • Carburetor joint 1 • Induction box 2 • Bolt {carburetor joint [L=25 mm (0.98 in)]} 3 11 Nm (1.1 mdkg, 8.0 ftdlb) • Bolt {carburetor joint [L=20 mm (0.79 in)]} 4 11 Nm (1.1 mdkg, 8.0 ftdlb) EC4652E0 Carburetor 1.
  • Page 113 CARBURETOR AND REED VALVE 4. Install: • Needle valve 1 • Float 2 • Float pin 3 • Screw (float pin) 4 NOTE: • After installing the needle valve to the float, install them to the carburetor. • Check the float for smooth movement. 5.
  • Page 114 CARBURETOR AND REED VALVE 9. Install: • Collar 1 • Jet needle 2 • Spring guide 3 • Spring 4 • Needle holder 5 To throttle valve 6. 10.Install: • Throttle cable 1 • Mixing chamber top 2 • Spring (throttle valve) 3 •...
  • Page 115 CARBURETOR AND REED VALVE EC465370 Carburetor installation 1. Install: • Carburetor 1 NOTE: Install the projection between the carburetor joint slots. 2. Tighten: • Clamp (carburetor joint) 1 2 Nm (0.2 mdkg, 1.4 ftdlb) 3. Connect: • Solenoid valve lead 1 NOTE: Install the solenoid valve lead (right cylinder) after passing it through the hole a of the...

  • Page 116: Cylinder Head,Cylinder And Piston

    CYLINDER HEAD, CYLINDER AND PISTON EC470000 CYLINDER HEAD, CYLINDER AND PISTON EC478000 CYLINDER HEAD AND CYLINDER 19 Nm (1.9 mdkg, 13 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 20 Nm (2.0 mdkg, 14 ftdlb) 15 Nm (1.5 mdkg, 11 ftdlb) 7 Nm (0.7 mdkg, 5.1 ftdlb) 1 Cylinder head removal 2 Cylinder removal...
  • Page 117 CYLINDER HEAD, CYLINDER AND PISTON EC478100 PISTON AND POWER VALVE 12 Nm (1.2 mdkg, 8.7 ftdlb) 9 Nm (0.9 mdkg, 6.5 ftdlb) 4 Nm (0.4 mdkg, 2.9 ftdlb) 4 Nm (0.4 mdkg, 2.9 ftdlb) 1 Piston and piston ring removal 2 Power valve removal Extend of removal: Extend of removal...
  • Page 118 CYLINDER HEAD, CYLINDER AND PISTON EC473000 REMOVAL POINTS EC473310 YPVS cable 1. Remove: • Bolt (cable stay) 1 2. Remove: • YPVS cable 1 From the valve pulley 2. NOTE: Remove the YPVS cable together with the cable stay 3. EC473400 Piston and piston ring 1.
  • Page 119 CYLINDER HEAD, CYLINDER AND PISTON 3. Remove: • Piston ring 1 NOTE: Take care not to scratch the piston and dam- age the piston ring. EC474000 INSPECTION EC474110 Cylinder head 1. Remove: • Carbon deposits Use #400~600 grit wet sandpaper. 2.
  • Page 120 CYLINDER HEAD, CYLINDER AND PISTON 3. Inspect: • Travel distance for cylinder 3,000 km (1,800 miles) or more≥ Replace. EC474313 Piston 1. Inspect: • Piston crown Damage and crack due to detonation≥Replace. • Piston pin hole Crack≥ Replace. • Contact with cylinder Excessive scuffing, score a ≥...
  • Page 121 CYLINDER HEAD, CYLINDER AND PISTON EC474402 Piston pin and small end bearing 1. Inspect: • Piston pin • Small end bearing Signs of heat discoloration ≥ Replace. 2. Measure: • Piston pin outside diameter Use micrometer 1. Out of limit ≥ Replace. Piston pin outside diameter: Standard Limit...
  • Page 122 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 123 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 124 • Clean the contacting surface of the valve cover and cylinder before applying the sealant. CAUTION: If the engine is started soon sfter reinstalla- tion, use this quick drying Quick gasket® (ACC-11001-30-00) or YAMAHA Bond No.4 Quick gasket® ACC-11001-05-01 ACC-11001-30-00 YAMAHA Bond No. 1215: 90890-85505 YAMAHA Bond No.4...
  • Page 125 CYLINDER HEAD, CYLINDER AND PISTON 5. Check: • Power valve smooth movement Unsmooth movement ≥ Repair or replace. EC475270 Piston ring and piston 1. Install: • Piston ring 1 NOTE: • Take care not to scratch the piston or damage the piston ring.
  • Page 126 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 127 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 128 CYLINDER HEAD, CYLINDER AND PISTON 8. Install: • Cable stay 1 • Bolt (cable stay) 2 7 Nm (0.7 mdkg, 5.1 ftdlb) 9. Adjust: • YPVS cable Refer to “YPVS OPEN SIDE CABLE ADJUSTMENT” and “YPVS CLOSE SIDE CABLE ADJUSTMENT” section in the CHAPTER 3.

  • Page 129: Clutch

    CLUTCH EC4A0000 CLUTCH EC4A8000 CLUTCH PLATE AND FRICTION PLATE 6 Nm (0.6 mdkg, 4.3 ftdlb) 9 Nm (0.9 mdkg, 6.5 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 130 CLUTCH EC4A8200 CLUTCH HOUSING AND PUSH ROD 75 Nm (7.5 mdkg, 54 ftdlb) 1 Clutch housing removal 2 Push rod removal Extend of removal: Extend of removal Order Part name Q’ty Remarks CLUTCH HOUSING AND PUSH ROD REMOVAL Nut (clutch boss) Use special tool.
  • Page 131 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 132 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 133 CLUTCH EC4A5000 ASSEMBLY AND INSTALLATION EC4A5213 Clutch 1. Install: • Spacer 1 1 • Bearing 2 NOTE: Apply the transmission oil on the spacer 1 and bearing. 2. Install: • O-ring 1N NOTE: Apply the lithium soap base grease on the O- ring.
  • Page 134 CLUTCH 6. Install: • Lock washer 1N • Nut (clutch boss) 2 75 Nm (7.5 mdkg, 54 ftdlb) NOTE: Use the clutch holding tool 3, 4 to hold the clutch boss. CAUTION: Align the projections on the lock washer with the holes a a in the clutch boss. Clutch holding tool: YM-91042 .
  • Page 135 CLUTCH 9. Install: • Push rod 1 • Ball 2 NOTE: Apply the lithium soap base grease on the push rod and ball. 10.Install: • Pressure plate 1 NOTE: Align the arrow marks a on the pressure plate the arrow marks b on the clutch boss. 11.

  • Page 136: 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) 1 Primary driven gear removal Extend of removal: Extend of removal Order Part name Q’ty...
  • Page 137 PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT EC4D8100 PRIMARY DRIVE GEAR AND BALANCER SHAFT 50 Nm (5.0 mdkg, 36 ftdlb) 55 Nm (5.5 mdkg, 40 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 1 Primary drive gear removal 2 Balancer shaft removal Extend of removal: Extend of removal Order...
  • Page 138 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 139 PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT EC4D4200 Balancer weight gear and balancer drive gear 1. Inspect: • Balancer weight gear 1 • Balancer drive gear 2 Wear/Damage ≥ Replace. EC4D4300 Crankcase cover (right) 1. Inspect: • Contacting surface Scratches ≥...
  • Page 140 PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT 3. Install: • Balancer weight gear 1 NOTE: Align the punch mark a on the balancer shaft with the hole b of the balancer weight gear. 4. Install: • Balancer drive gear 1 NOTE: Align the punch marks, a (balancer drive gear) with b (crankshaft) and c (balancer...
  • Page 141 PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT 8. Tighten: • Bolt (primary drive gear) 1 55 Nm (5.5 mdkg, 40 ftdlb) NOTE: Place an aluminum plate a between the teeth of the balancer drive gear 2 and balancer weight gear 3.

  • Page 142: Shift Shaft

    SHIFT SHAFT EC4F0000 SHIFT SHAFT 9 Nm (0.9 mdkg, 6.5 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 10 Nm (1.0 mdkg, 7.2 ftdlb) 22 Nm (2.2 mdkg, 16 ftdlb) 9 Nm (0.9 mdkg, 6.5 ftdlb) 16 Nm (1.6 mdkg, 11 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 75 Nm (7.5 mdkg, 54 ftdlb)
  • Page 143 SHIFT SHAFT EC4F3000 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: • Drive sprocket 1 •...
  • Page 144 SHIFT SHAFT 2. Remove: • Circlip 1 • Plain washer 2 • Stopper lever 3 EC4F4000 INSPECTION EC4B4400 Shift shaft 1. Inspect: • Shift shaft 1 Bend/Damage ≥ Replace. • Spring 2 Broken ≥ Replace. EC4C4100 Shift guide and shift lever assembly 1.
  • Page 145 SHIFT SHAFT 2. Install: • Plain washer 1 • Torsion spring 2 • Stopper lever assembly 3 EC4F5202 Shift guide and shift lever assembly 1. Install: • Spring 1 • Pawl pin 2 • Pawl 3 To shift lever 4. NOTE: •...
  • Page 146 SHIFT SHAFT EC4F5302 Shift shaft 1. Install: • Roller 1 • Torsion spring 2 • Shift shaft 3 NOTE: Apply the transmission oil on the roller and shift shaft. 2. Install: • Plain washer 1 • Circlip 2N To shift shaft 3. NOTE: Be sure the circlip sharp-edged corner a is positioned opposite side to the plain washer.
  • Page 147 SHIFT SHAFT EC4F5411 Transmission housing 1. Apply: • Transmission oil On the bearing (crankcase lower) and impeller shaft. 2. Install: • Dowel pin 1 • Transmission housing 2 NOTE: When installing the transmission housing, turn the oil pump driven gear 3 until the key end a of the oil pump gear shaft 4 is in the recess b of the impeller shaft 5.
  • Page 148 SHIFT SHAFT EC4F5510 Drive sprocket 1. Install: • Drive sprocket 1 • Drive chain 2 NOTE: • Install the drive sprocket with its depressed side a facing the engine. • Install the drive sprocket together with the drive chain. 2. Install: •...

  • Page 149: Water Pump

    WATER PUMP EC4G0000 WATER PUMP 2 Nm (0.2 mdkg, 1.4 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 1 Impeller shaft removal 2 Oil seal removal Extend of removal: Extend of removal Order Part name Q’ty Remarks WATER PUMP DISASSEMBLY Preparation for Cowling Refer to “COWLING, INDUCTION removal...
  • Page 150 WATER PUMP EC4G3000 REMOVAL POINTS EC4G3210 Oil seal NOTE: It is not necessary to disassemble the water pump, unless there is an abnormality such as excessive change in coolant level, discol- oration of coolant, or milky transmission oil. 1. Remove: •...
  • Page 151 WATER PUMP EC444400 Oil seal 1. Inspect: • Oil seal 1 Wear/Damage ≥ Replace. EC4G5000 ASSEMBLY AND INSTALLATION EC4G5120 Oil seal 1. Install: • Oil seal 1N NOTE: • Apply the lithium soap base grease on the oil seal lip. •...
  • Page 152 WATER PUMP 3. Install: • Dowel pin 1 • Gasket (water pump housing cover) 2 4. Install: • Water pump housing cover 1 • Bolt (water pump housing cover) 2 11 Nm (1.1 mdkg, 8.0 ftdlb) 5. Install: • Radiator hose 2 1 2 Nm (0.2 mdkg, 1.4 ftdlb) 4-54...

  • Page 153: Transmission, Shift Cam And Shift Fork

    TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H0000 TRANSMISSION, SHIFT CAM AND SHIFT FORK 23 Nm (2.3 mdkg, 17 ftdlb) 4 Nm (0.4 mdkg, 2.9 ftdlb) 10 Nm (1.0 mdkg, 7.2 ftdlb) 10 Nm (1.0 mdkg, 7.2 ftdlb) 7 Nm (0.7 mdkg, 5.1 ftdlb) Extend of removal Order Part name...
  • Page 154 TRANSMISSION, SHIFT CAM AND SHIFT FORK 23 Nm (2.3 mdkg, 17 ftdlb) 4 Nm (0.4 mdkg, 2.9 ftdlb) 10 Nm (1.0 mdkg, 7.2 ftdlb) 10 Nm (1.0 mdkg, 7.2 ftdlb) 7 Nm (0.7 mdkg, 5.1 ftdlb) 1 Shift fork removal 2 Main axle and drive axle removal Extend of removal: 3 Shift cam removal...
  • Page 155 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H3000 REMOVAL POINTS EC4H3210 Transmission 1. Remove: • Main axle 1 • Drive axle 2 NOTE: • Remove the main axle together with the drive axle from the transmission housing 3. • Remove assembly carefully. Note the position of each part.
  • Page 156 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 157 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H4501 Dog clearance NOTE: • It is necessary to adjust the dog clearance when the transmission gear, axle, washer, cir- clip, bearing or crankcase is replaced. • If there is any shifting trouble, it is necessary to check the shift fork, shift cam, shift lever and gears.
  • Page 158 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H4801 Shift fork, shift cam and segment 1. Inspect: • Shift fork 1 Wear/Damage/Scratches ≥ Replace. 2. Inspect: • Shift cam 1 • Segment 2 • Guide bar 3 Bend/Wear/Damage ≥ Replace. 3. Check: •...
  • Page 159 TRANSMISSION, SHIFT CAM AND SHIFT FORK 2. Install: • Segment 1 • Bolt (segment) 2 23 Nm (2.3 mdkg, 17 ftdlb) NOTE: • When installing the segment onto the shift cam, align the punch mark a with the dowel pin b. •...
  • Page 160 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 161 TRANSMISSION, SHIFT CAM AND SHIFT FORK 4. Install: • Main axle 1 • Drive axle 2 NOTE: • Apply the transmission oil on the main axle and drive axle bearings. • Install the main axle together with the drive axle into the transmission housing 3. 5.

  • Page 162: Oil Pump

    OIL PUMP EC4J0000 OIL PUMP 8 Nm (0.8 mdkg, 5.8 ftdlb) 7 Nm (0.7 mdkg, 5.1 ftdlb) 1 Oil pump removal and disassembly Extend of removal: Extend of removal Order Part name Q’ty Remarks OIL PUMP REMOVAL Preparation for Transmission housing Refer to “SHIFT SHAFT”...
  • Page 163 OIL PUMP EC4J4000 INSPECTION EC4J4100 Oil pump 1. Measure: • Tip clearance Measure the clearance between the inner rotor 1 and outer rotor 2. Out of limit ≥ Replace the inner rotor and outer rotor as a set. Tip clearance limit: 0.15 mm (0.0059 in) EC4E4310 Strainer...
  • Page 164 OIL PUMP 2. Install: • Oil delivery pipe 1 NOTE: When installing the oil delivery pipe, fit the pro- jection a of the oil delivery pipe into the hole b on the crankcase. 3. Install: • Plain washer [D=ø22 mm (0.87 in)] 1 •...
  • Page 165 OIL PUMP 6. Install: • Oil pump cover 1 • Plain washer 2 • Bolt (oil pump cover) 3 8 Nm (0.8 mdkg, 5.8 ftdlb) NOTE: While turning the oil pump gear shaft, install the oil pump cover. 7. Install: •...

  • Page 166: Cdi Magneto

    CDI MAGNETO EC4L0000 CDI MAGNETO 7 Nm (0.7 mdkg, 5.1 ftdlb) 53 Nm (5.3 mdkg, 38 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, INDUCTION removal GUIDE, SEAT AND FUEL TANK”...
  • Page 167 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 168 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 169: Engine Removal

    ENGINE REMOVAL EC4M0000 ENGINE REMOVAL 30 Nm (3.0 mdkg, 22 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 23 Nm (2.3 mdkg, 17 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 30 Nm (3.0 mdkg, 22 ftdlb) 23 Nm (2.3 mdkg, 17 ftdlb) Extend of removal Order...
  • Page 170 ENGINE REMOVAL 30 Nm (3.0 mdkg, 22 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 23 Nm (2.3 mdkg, 17 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 30 Nm (3.0 mdkg, 22 ftdlb) 23 Nm (2.3 mdkg, 17 ftdlb) 1 Engine removal Extend of removal: Extend of removal...
  • Page 171 ENGINE REMOVAL EC4M6000 HANDLING NOTE When the frame alone is stored, insert the engine mounting collars 1 into the brackets and tighten them with the pinch bolts 2 to 6 Nm (0.6 m•kg, 4.3 ft•lb) in order to prevent the brackets a from damage. EC4M3000 REMOVAL POINTS EC4M3331...
  • Page 172 ENGINE REMOVAL 2. Install: • Engine 1 NOTE: Install the engine by raising it into the frame with a jack 2. 3. Install: • Engine mounting bolt (upper) 1 • Engine mounting bolt (lower) 2 4. Tighten: • Engine mounting adjust bolt 1 8 Nm (0.8 mdkg, 5.8 ftdlb) NOTE: •...
  • Page 173 ENGINE REMOVAL 6. Install: • Engine mounting collar (left) 1 • Engine mounting bolt (left) 2 • Engine mounting nut (left) 3 30 Nm (3.0 mdkg, 22 ftdlb) 7. Tighten: • Bolt (engine bracket) (left) 4 23 Nm (2.3 mdkg, 17 ftdlb) 8.

  • Page 174: Crankcase And Crankshaft

    CRANKCASE AND CRANKSHAFT EC4N0000 CRANKCASE AND CRANKSHAFT 11 Nm (1.1 mdkg, 8.0 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 7 Nm (0.7 mdkg, 5.1 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 26 Nm (2.6 mdkg, 19 ftdlb) 50 Nm (5.0 mdkg, 36 ftdlb) Extend of removal Order Part name...
  • Page 175 CRANKCASE AND CRANKSHAFT 11 Nm (1.1 mdkg, 8.0 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 7 Nm (0.7 mdkg, 5.1 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 26 Nm (2.6 mdkg, 19 ftdlb) 50 Nm (5.0 mdkg, 36 ftdlb) 1 Crankcase separation 2 Crankshaft removal Extend of removal: 3 Crankshaft bearing removal...
  • Page 176 CRANKCASE AND CRANKSHAFT EC4N3000 REMOVAL POINTS EC4N3230 Crankcase 1. Remove: • Bolt [crankcase (M6)] 1 • Bolt [crankcase (M8)] 2 NOTE: • The M6 size bolts should be removed first. • Loosen the bolts from the outer sides inward. 2. Remove: •...
  • Page 177 CRANKCASE AND CRANKSHAFT EC4N4213 Crankshaft 1. Inspect: • Bearing 1 Rotate outer race with a finger. Rough spot/Seizure ≥ Replace. 2. Inspect: • Oil seal 1 Wear/Damage ≥ Replace. 3. Measure: • Runout limit a • Small end free play limit b •...
  • Page 178 CRANKCASE AND CRANKSHAFT EC4N5000 ASSEMBLY AND INSTALLATION EC4N5310 Crankshaft bearing 1. Install: • Bearing 1N To crankshaft. NOTE: Install the bearing by pressing its inner race parallel. EC4N5290 Crankshaft 1. Install: • Oil seal 1 To crankshaft 2. NOTE: Apply the lithium soap base grease on the oil seal lip.
  • Page 179 Clean the contacting surface of crankcase (upper and lower) before applying the sealant. 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. 6. Install: • Crankcase (upper) 1 To crankcase (lower). NOTE: After installation, tap the crankcase (upper) with a soft hammar to settle it.
  • Page 180 CRANKCASE AND CRANKSHAFT 7. Tighten: • Bolt [crankcase (M8)] 1~6 • Bolt [crankcase (M6)] 7~¢ NOTE: Tighten all bolts in 2 steps as follows and be sure to tighten in numbered order as shown. •First: 1~6 (M8) 11 Nm (1.1 m•kg, 8.0 ft•lb) 7~¢...

  • Page 181: Chassis

    CHAS FRONT WHEEL AND REAR WHEEL EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL 35 Nm (3.5 mdkg, 25 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 35 Nm (3.5 mdkg, 25 ftdlb) 80 Nm (8.0 mdkg, 58 ftdlb) 11 Nm (1.1 mdkg, 8.0 ftdlb) 20 Nm (2.0 mdkg, 14 ftdlb) 20 Nm (2.0 mdkg, 14 ftdlb)
  • Page 182 CHAS FRONT WHEEL AND REAR WHEEL EC598100 REAR WHEEL 16 Nm (1.6 mdkg, 11 ftdlb) 80 Nm (8.0 mdkg, 58 ftdlb) 2 Nm (0.2 mdkg, 1.4 ftdlb) 23 Nm (2.3 mdkg, 17 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...
  • Page 183 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. EC513300 Collar 1. Remove: • Collar 1 Knock out of wheel on inside. NOTE: Knock the collar out of the wheel gradually not to deform it.
  • Page 184 CHAS FRONT WHEEL AND REAR WHEEL EC514200 Wheel axle 1. Measure: • Wheel axle bends Out of specification ≥ Replace. Use the dial gauge 1. Wheel axle bending limit: 0.25 mm (0.010 in) NOTE: The bending value is shown by one half of the dial gauge reading.
  • Page 185 CHAS FRONT WHEEL AND REAR WHEEL EC524100 Clutch hub 1. Inspect: • Bearing 1 Rotate inner race with a finger. Rough spot/Seizure ≥ Replace. EC595000 ASSEMBLY AND INSTALLATION EC515172 Front wheel 1. Install: • Bearing (right) 1 • Spacer 2 •...
  • Page 186 CHAS FRONT WHEEL AND REAR WHEEL 4. Install: • Wheel 1 • Caliper 2 • Bolt (caliper) 35 Nm (3.5 mdkg, 25 ftdlb) NOTE: Before installing the wheel axle, install the caliper. 5. Install: • Wheel axle 1 NOTE: • Apply the lithium soap base grease on the wheel axle.
  • Page 187 CHAS FRONT WHEEL AND REAR WHEEL EC5251B0 Rear wheel 1. Install: • Fitting plate (right) 1 • Bearing (right) 2 • Spacer 3 • Fitting plate (left) 4 • Bearing (left) 5 NOTE: • Apply the lithium soap base grease on the bearing when installing.
  • Page 188 CHAS FRONT WHEEL AND REAR WHEEL 5. Install: • Driven sprocket 1 • Collar 2 To wheel. NOTE: Apply the lithium soap base grease on the sprocket damper. 6. Install: • Wheel NOTE: Install the brake disc 1 between the brake pads 2 correctly.
  • Page 189 CHAS FRONT WHEEL AND REAR WHEEL 10.Adjust: • Drive chain slack a Drive chain slack: 40~50 mm (1.6~2.0 in) Refer to “DRIVE CHAIN SLACK ADJUST- MENT” section in the CHAPTER 3. 11. Tighten: • Nut (wheel axle) 1 80 Nm (8.0 mdkg, 58 ftdlb) •...

  • Page 190: 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) 8 Nm (0.8 mdkg, 5.8 ftdlb) 1 Nm (0.1 mdkg, 0.7 ftdlb) 6 Nm (0.6 mdkg, 4.3 ftdlb) 7 Nm (0.7 mdkg, 5.1 ftdlb) 30 Nm (3.0 mdkg, 22 ftdlb) 14 Nm (1.4 mdkg, 10 ftdlb) 14 Nm (1.4 mdkg, 10 ftdlb)
  • Page 191 CHAS FRONT BRAKE AND REAR BRAKE EC5A8100 REAR BRAKE 8 Nm (0.8 mdkg, 5.8 ftdlb) 7 Nm (0.7 mdkg, 5.1 ftdlb) 14 Nm (1.4 mdkg, 10 ftdlb) 26 Nm (2.6 mdkg, 19 ftdlb) 23 Nm (2.3 mdkg, 17 ftdlb) 30 Nm (3.0 mdkg, 22 ftdlb) 2 Nm (0.2 mdkg, 1.4 ftdlb) 12 Nm (1.2 mdkg, 8.7 ftdlb) 18 Nm (1.8 mdkg, 13 ftdlb)
  • Page 192 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 193 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 194 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 195 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 196 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 197 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 198 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 199 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 200 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 201 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. 3.
  • Page 202 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 203 CHAS FRONT BRAKE AND REAR BRAKE EC545451 Rear brake hose 1. Install: • Copper washer 1N • Brake hose 2 • Union bolt 3 T 30 Nm (3.0 mdkg, 22 ftdlb) Always use new copper washers. CAUTION: When installing the brake hose to the mas- ter cylinder, lightly touch the brake pipe a a with the projection b b on the master cylin- der.
  • Page 204 CHAS FRONT BRAKE AND REAR BRAKE EC5A5610 Brake fluid 1. Fill: • Brake fluid Until the fluid level reaches “LOWER” level line a. Recommended brake fluid: DOT #4 • Use only the designated quality brake fluid: otherwise, the rubber seals may deterio- rate, causing leakage and poor brake per- formance.
  • Page 205 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: • Diaphragm • Reservoir tank cap 1 CAUTION: After installation, while pulling the lever in or pushing down on the pedal, check whether there is any brake fluid leaking where the union bolts are installed respec- tively at the master cylinder and caliper.

  • Page 206: Front Fork

    CHAS FRONT FORK EC550000 FRONT FORK 7 Nm (0.7 mdkg, 5.1 ftdlb) 20 Nm (2.0 mdkg, 14 ftdlb) 10 Nm (1.0 mdkg, 7.2 ftdlb) 23 Nm (2.3 mdkg, 17 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 1 Front fork removal Extend of removal: Extend of removal Order...
  • Page 207 CHAS FRONT FORK EC558000 FRONT FORK DISASSEMBLY 23 Nm (2.3 mdkg, 17 ftdlb) 29 Nm (2.9 mdkg, 21 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 208 CHAS FRONT FORK EC556010 HANDLING NOTE NOTE: • With the 97 or later models, the dampar rod diameter is 12.5 mm (0.49 in). If the dimen- sion a of your dampar rod holders is 12 mm (0.47 in), drill it to expand its diameter to 14 mm (0.55 in).
  • Page 209 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 210 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 211 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 212 CHAS FRONT FORK EC555000 ASSEMBLY AND INSTALLATION EC555190 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 213 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 214 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 215 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 216 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 217 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 218 CHAS FRONT FORK 26.Install: • Cap bolt 1 To outer tube. NOTE: Temporarily tighten the cap bolt. EC555290 Installation 1. Install: • Front fork 1 • Steering damper stay 2 (right side only) • Handlebar 3 NOTE: • Temporarily tighten the pinch bolt (under bracket).
  • Page 219 CHAS FRONT FORK 4. Tighten: • Pinch bolt (handle crown) 1 20 Nm (2.0 mdkg, 14 ftdlb) • Pinch bolt (under bracket) 2 23 Nm (2.3 mdkg, 17 ftdlb) • Pinch bolt (handlebar) 3 7 Nm (0.7 mdkg, 5.1 ftdlb) •...

  • Page 220: Handlebar

    CHAS HANDLEBAR EC5B0000 HANDLEBAR 7 Nm (0.7 mdkg, 5.1 ftdlb) 7 Nm (0.7 mdkg, 5.1 ftdlb) 2 Nm (0.2 mdkg, 1.4 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 221 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 222 CHAS HANDLEBAR 2. Install: • Throttle cable [carburetor (left cylinder)] 1 • Throttle cable [carburetor (right cylinder)] 2 To grip cap (lower) 3. NOTE: Install the throttle cable [carburetor (left cylin- der)] in the grip side slit a in the grip cap (lower).
  • Page 223 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. 8. Install: • Starter lever 1 •...
  • Page 224 CHAS HANDLEBAR 11. Install: • Main switch 1 • Main switch holder 2 • Screw (main switch holder) 3 2 Nm (0.2 mdkg, 1.4 ftdlb) • Clutch lever holder 4 • Bolt (clutch lever holder) 5 5 Nm (0.5 mdkg, 3.6 ftdlb) NOTE: The main switch and clutch lever holder should be installed according to the dimensions...
  • Page 225 CHAS HANDLEBAR 15.Tighten: • Pinch bolt (handlebar) 1 7 Nm (0.7 mdkg, 5.1 ftdlb) CAUTION: Tighten the pinch bolts to specified torpue. If torpue too much, it may cause the front fork to malfunction. 16.Adjust: • Clutch lever free play Refer to “CLUTCH ADJUSTMENT”...

  • Page 226: Steering

    CHAS STEERING EC560000 STEERING EC568000 HANDLE CROWN AND STEERING DAMPER 80 Nm (8.0 mdkg, 58 ftdlb) 20 Nm (2.0 mdkg, 14 ftdlb) 5 Nm (0.5 mdkg, 3.6 ftdlb) 18 Nm (1.8 mdkg, 13 ftdlb) 1 Handle crown removal 2 Steering damper removal Extend of removal: Extend of removal Order...
  • Page 227 CHAS STEERING EC568100 UNDER BRACKET 7 Nm (0.7 mdkg, 5.1 ftdlb) 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) 10 Nm (1.0 mdkg, 7.2 ftdlb) 23 Nm (2.3 mdkg, 17 ftdlb) 1 Under bracket removal 2 Bearing removal...
  • Page 228 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 229 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 230 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 231 CHAS STEERING 9. 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. 10.After tightening the nut, check the steering for smooth movement. If not, adjust the steering by loosening the ring nut little by lit- tle.
  • Page 232 CHAS STEERING 13.Adjust: • Front fork top end a • Handlebar position b • Steering damper stay position c (right side only) Front fork top end: 13 mm (0.51 in) Handlebar position: 9 mm (0.35 in) Steering damper stay position: 73 mm (2.87 in) Refer to “FRONT FORK TOP END ADJUSTMENT”...

  • Page 233: Swingarm

    CHAS SWINGARM EC570000 SWINGARM 10 Nm (1.0 mdkg, 7.2 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 115 Nm (11.5 mdkg, 85 ftdlb) 5 Nm (0.5 mdkg, 3.6 ftdlb) 34 Nm (3.4 mdkg, 24 ftdlb) 8 Nm (0.8 mdkg, 5.8 ftdlb) 1 Swingarm removal 2 Swingarm disassembly Extend of removal:...
  • Page 234 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 235 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 236 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 237 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) EC575141 Swingarm...
  • Page 238 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 239 CHAS SWINGARM 9. Install: • Collar (swingarm) 1 NOTE: Apply the lithium soap base grease on the col- lars and bearings. 10.Install: • Connecting rod 1 • Bolt (connecting rod) 2 • Nut (connecting rod) 3 34 Nm (3.4 mdkg, 24 ftdlb) NOTE: •...

  • Page 240: Rear Shock Absorber

    CHAS REAR SHOCK ABSORBER EC580000 REAR SHOCK ABSORBER 38 Nm (3.8 mdkg, 27 ftdlb) 40 Nm (4.0 mdkg, 29 ftdlb) 34 Nm (3.4 mdkg, 24 ftdlb) 20 Nm (2.0 mdkg, 14 ftdlb) 34 Nm (3.4 mdkg, 24 ftdlb) 1 Rear shock absorber removal 2 Rear shock absorber disassembly Extend of removal: Extend of removal...
  • Page 241 At this time, wear eye pro- tection 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. 5-61...
  • Page 242 CHAS REAR SHOCK ABSORBER EC583000 REMOVAL POINTS EC583160 Rear shock absorber 1. Remove: • Rear shock absorber 1 NOTE: Remove the rear shock absorber between the rear frame and swingarm. EC583221 Spring (rear shock absorber) 1. Remove: •Spring guide 1 •Spring 2 NOTE: Remove the spring guide while compressing...
  • Page 243 CHAS REAR SHOCK ABSORBER EC585000 ASSEMBLY AND INSTALLATION EC585143 Spring (rear shock absorber) 1. Install: • Plate 1 • Spring 2 • Spring guide 3 NOTE: Install the spring guide while compressing the spring by using the spring compressor 4. 2.
  • Page 244 CHAS REAR SHOCK ABSORBER 4. Tighten: • Locknut 1 20 Nm (2.0 mdkg, 14 ftdlb) EC5852A0 Rear shock absorber 1. Install: • Upper bracket 1 • Bolt (rear shock absorber – upper bracket) 2 • Plain washer (rear shock absorber – upper bracket) 3 •...

  • Page 245: Electrical

    ELEC ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 CDI unit 9 Fuel pump relay COLOR CODE 2 Voltage regulator 0 Fuel pump stop switch B ..Black B/L .

  • Page 246: Ignition System

    ELEC IGNITION SYSTEM EC620000 IGNITION SYSTEM EC621030 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. No good Replace fuse and Check fuse.
  • Page 247 ELEC IGNITION SYSTEM EC629000 FUSE INSPECTION 1. Remove: • Fuse 1 2. Check: • Fuse conduct Use pocket tester (tester selector position Ω X 1). Not continuous ≥ Replace fuse and check that the wireharness is not shorted. EC622020 SPARK GAP TEST 1.
  • Page 248 ELEC IGNITION SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/ Dust/ Looseness/Short-circuit ≥ Repair or replace. EC62A000 MAIN SWITCH INSPECTION 1. Inspect: • Main switch conduct ≥ Red lead 1 1 Tester (+) lead ≥ ≥...
  • Page 249 ELEC IGNITION SYSTEM 2. Inspect: • Secondary coil resistance Out of specification ≥ Replace. ≥ Spark plug lead 1 1 Tester (+) lead ≥ ≥ Orange (Gray) lead 2 2 Tester (–) lead ≥ Secondary coil Tester selector resistance position 5.0~7.4 kΩ...
  • Page 250 ELEC IGNITION SYSTEM 3. Inspect: • Source coil resistance Out of specification ≥ Replace. ≥ White lead 1 1 Tester (+) lead ≥ ≥ White lead 2 2 Tester (-) lead ≥ Source coil Tester selector resistance position 2.3~3.5 Ω at Ω...

  • Page 251: Charging System

    ELEC CHARGING SYSTEM EC680000 CHARGING SYSTEM EC681000 INSPECTION STEPS If the battery is not charged, use the following inspection steps. No good Replace fuse and *1 Check fuse. check wireharness. No good *2 Check battery Recharge or replace. No good Check each coupler and Repair or replace.
  • Page 252 ELEC CHARGING SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/ Dust/ Looseness/Short-circuit ≥ Repair or replace. EC682000 CHARGING VOLTAGE INSPECTION 1. Start the engine. 2. Inspect: • Charging voltage Out of specification ≥ If no failure is found in checking the source coil resistance, check the voltage regulator.
  • Page 253 ELEC CHARGING SYSTEM NOTE: If nothing is wrong with the continuity of the voltage regulator and with all the others in the charging system, replace the voltage regulator.

  • Page 254: Ypvs System

    ELEC YPVS SYSTEM EC640000 YPVS SYSTEM EC641020 INSPECTION STEPS If the servomotor will not turn, use the following inspection steps. No good Replace fuse and *1 Check fuse. check wireharness. No good *2 Check battery Recharge or replace. No good Check each coupler and Repair or replace.
  • Page 255 ELEC YPVS SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/ Dust/ Looseness/Short-circuit ≥ Repair or replace. EC642020 SERVOMOTOR OPERATION 1. Disconnect the fuel pump coupler to pre- vent the fuel pump operating. 2. Inspect: •...

  • Page 256: Solenoid Valve System

    ELEC SOLENOID VALVE SYSTEM EC650001 SOLENOID VALVE SYSTEM EC651020 INSPECTION STEPS If the solenoid valve will not operate, use the following inspection steps. No good Replace fuse and *1 Check fuse. check wireharness. No good *2 Check battery Recharge or replace. No good Check each coupler and Repair or replace.
  • Page 257 ELEC SOLENOID VALVE SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/ Dust/ Looseness/Short-circuit ≥ Repair or replace. EC652020 SOLENOID VALVE OPERATION 1. Disconnect the fuel pump and servomotor coupler to prevent the fuel pump and ser- vomotor operating.

  • Page 258: Thermo Unit System

    ELEC THERMO UNIT SYSTEM EC6A0000 THERMO UNIT SYSTEM EC6A1010 INSPECTION STEPS If the water temperature gauge (thermo unit) will not operate, use the following inspection steps. No good Replace fuse and *1 Check fuse. check wireharness. No good *2 Check battery Recharge or replace.
  • Page 259 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 260: Fuel Pump System

    ELEC FUEL PUMP SYSTEM EC670000 FUEL PUMP SYSTEM EC671000 INSPECTION STEPS If the fuel pump will not operate, use the following inspection steps. No good Replace fuse and *1 Check fuse. check wireharness. No good *2 Check battery Recharge or replace. No good Check each coupler and Repair or replace.
  • Page 261 ELEC FUEL PUMP SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/ Dust/ Looseness/Short-circuit ≥ Repair or replace. EC672000 FUEL PUMP STOP SWITCH INSPECTION 1. Remove: • Fuel pump stop switch 1 2. Inspect: •...
  • Page 262 ELEC FUEL PUMP SYSTEM 2. Inspect: • Fuel pump relay conduct Use 12V battery. & ≥ Black lead 1 1 Battery (+) lead ≥ ≥ Green lead 2 2 Battery (-) lead ≥ ≥ Black/Blue lead 3 3 Tester (+) lead ≥ ≥...
  • Page 263 ELEC FUEL PUMP SYSTEM 2. Install: • Drain plug 3. Turn the fuel cock to “ON”. 4. Inspect: • Fuel pump 1 Operation sound when the main switch is moved to “RUN” ≥ OK EC675000 FUEL PUMP COIL INSPECTION 1. Disconnect the fuel pump coupler. 2.
  • Page 264 ELEC FUEL PUMP SYSTEM 3. Turn the fuel cock to “ON”. 4. Disconnect the fuel pump coupler. 5. Connect 12V battery to the fuel pump cou- pler. ≥ Black/Blue lead 1 1 Battery (+) lead ≥ ≥ Black lead 2 2 Battery (-) lead ≥...
  • Page 265 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 266 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 267 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: #560 ≥ #540 Factory-set main jet #580 2.
  • Page 268 SETTING If the main jet is fully adjusted with not much allowance for discoloration, use a main jet which is approximately #20 lager. Run a few laps of the circuit to check the engine for response to revolutions. Also check for the discoloration of the spark plug(s) and piston(s).
  • Page 269 SETTING EC71F002 Carburetor settings by correction coeffi- cient Now you should be able to understand the essentials of basic carburetor setting from an explanation given under “Basic process of car- buretor setting” (P7-2). Next is an explanation of how to select a main jet to deal with changes in weather conditions by means of a correction coefficient.
  • Page 270 SETTING CAUTION: If a change in conditions require a main jet of a larger size, use the size to which #20 is added for safety. NOTE: • Since this correction coefficient table lacks a column for humidity, it is advisable to check the degree of discoloration of the spark plug(s) for final selection according to an explanation under “Atmospheric conditions...
  • Page 271 SETTING EC71H040 Other setting parts 1. Power jet 1 Power jet is not basically changed. Since the areas of the main jet and main nozzle overlap each other, special knowledge is required for a setting change. A larger size results in a richer mixture and a smaller size in a leaner mixture.
  • Page 272 Lean 830-14231-10 Rich 830-14231-11 NOTE: • The parts marked ∆ are not supplied togeth- er. There are available on order as YAMAHA genuine parts. • Use a #500 main jet when selecting a next smaller size jet than a #540.
  • Page 273 SETTING EC71J010 Plug chop When checking the discoloration of the spark plug and piston head, move the main switch to “OFF” 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 274 SETTING NOTE: • Finish the break-in before changing the gas- ket. • A change of 0.1 mm (0.004 in) for the gasket causes a change of approximately 0.23 cm (0.008 lmp oz, 0.008 US oz) of the combus- tion chamber volume. •...
  • Page 275 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 276 SETTING 3rd gear Number of Gear ratio Part number groove Factory installed 29/23 (1.261) 5KE-17231-00/5KE-17131-00 – Supplying part 25/21 (1.190) 5KE-17231-20/5KE-17131-10 Supplying part 26/21 (1.238) 5KE-17231-10/5KE-17131-10 6th gear Number of Gear ratio Part number groove Factory installed 20/22 (0.909) 5KE-17261-00/5KE-17191-00 Supplying part 22/25 (0.880) 5KE-17261-10/5KE-17161-10...
  • Page 277 NOTE: • The mark ∆ shows that this part is not sup- plied together and that it is available on order as a YAMAHA genuine part. • 3rd/4th pinion gear 5KE-17131-10 allows for a combination of 3rd wheel gear 5KE-17231- 10 and 5KE-17231-20.
  • Page 278 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 279 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 280 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 170 cm (66.9 in) in height and approxi- mately 60 kg (132 lb) in weight.) 1.
  • Page 281 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 10 to 20 mm (0.39 ~ 0.79 in) Poor stroke Too much stroke...
  • Page 282 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 36/14 (2.571) reduction ratio Driven sprocket Drive sprocket 2.500 2.571 2.643 2.714 2.786 2.857 2.333 2.400 2.467 2.534...
  • Page 283 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 284 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 285 SETTING EC740002 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 Main nozzle Pilot jet Pilot air screw...
  • Page 286 SETTING Event name Date Weather Place Setting specs: Ignition timing Spark plug Carburetor Main jet Power jet Jet needle Main nozzle 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...
  • Page 287 99.9-0.1x1...

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