EB001000 NOTICE This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on Yamaha machine has a basic understanding of the mechanical ideas and the procedures of machine repair.
EB002000 HOW TO USE THIS MANUAL MANUAL ORGANIZATION This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”) 1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title 2: This title indicates the section of the chapter and only appears on the first page of each section.
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EB003000 ILLUSTRATED SYMBOLS Illustrated symbols 1 to 9 are printed on the SPEC top right of each page and indicate the subject INFO of each chapter. 1 General information 2 Specifications 3 Periodic checks and adjustments CHAS 4 Chassis 5 Engine 6 Cooling system 7 Carburetion 8 Electrical...
SPEC GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Item Standard Model code: 5LP6 : (For CDN) 5LP7 : (For Europe) Transmission: Primary reduction system Spur gear Primary reduction ratio 71/34 (2.088) Secondary reduction system Chain drive Secondary reduction ratio 40/13 (3.076) Transmission type Constant mesh, 5-speed/forward.
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.03 mm (0.001 in) Timing chain: Timing chain type/No. of links 82RH2015/126 ---- Timing chain adjustment method Automatic ---- Rocker arm/rocker arm shaft: Bearing inside diameter 12.000 ~ 12.018 mm ---- (0.4724 ~ 0.4731 in)
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SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Stem outside diameter 5.975 ~ 5.990 mm 5.945 mm (0.2352 ~ 0.2358 in) (0.2341 in) 5.960 ~ 5.975 mm 5.930 mm (0.2346 ~ 0.2352 in) (0.2335 in) Guide inside diameter 6.000 ~ 6.012 mm 6.040 mm (0.2362 ~ 0.2367 in) (0.2378 in)
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SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Piston rings: Top ring Type Barrel ---- Dimensions (B × T) 1.2 × 3.8 mm ---- (0.0472 × 0.1496 in) End gap (installed) 0.30 ~ 0.45 mm 0.70 mm (0.0118 ~ 0.0177 in) (0.0276 in) Side clearance (installed) 0.04 ~ 0.08 mm 0.13 mm...
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SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Carburetors: I. D. mark 5LP5 20 ---- Main jet (M.J) Carburetor #1 : #140 ---- Carburetor #2 : #145 ---- Main air jet (M.A.J) #130 ---- Jet needle (J.N) 5ND16-56-3 ---- Needle jet (N.J) P-6M (#826) ---- Pilot air jet...
SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Brake lever and brake pedal: Brake lever free play (at lever end) 0 mm (0 in) ---- Brake pedal position 4 mm (0.16 in) ---- (Below the top of footrest) Throttle lever free play 3 ~ 5 mm (0.12 ~ 0.20 in) ---- Tightening torques...
SPEC CABLE ROUTING CABLE ROUTING 1 Carburetor air vent hose 0 Tail/brake light lead 2 Coolant reservoir hose A Rectifier/regulator lead 3 Reservoir tank breather hose 4 CDI unit È Pass the negative battery lead between the wire 5 Wire harness harness and frame.
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SPEC CABLE ROUTING 1 Positive battery lead È Fasten the wire harness with the plastic clamp. 2 Tail/brake light lead É Fasten the starter motor lead and starter relay 3 Coolant reservoir breather hose lead with the plastic clamp. 4 Negative battery lead 5 Coolant reservoir hose 6 Starter motor lead 7 Wire harness...
• Lubricate every 6 months.** Fittings and fasten- • Check all chassis fittings and fasteners. ers* • Correct if necessary. It is recommended that these items be serviced by a Yamaha dealer. ** Lithium soap base grease – 9 –...
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PERIODIC MAINTENANCE/LUBRICATION INTERVALS NOTE: Recommended brake fluid: DOT 4 Brake fluid replacement: 1.When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally check the brake fluid level and add fluid as required. 2.On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two years.
ADJUSTING THE REAR SHOCK ABSORBER CHASSIS ADJUSTING THE REAR SHOCK ABSORBER 1.Adjust: Spring preload *********************************************** Adjustment steps: Elevate the rear wheels by placing a suitable stand under the frame. Loosen the locknut 1. Turn the adjusting ring 2 in direction a or Spring preload is Direction a increased (suspension...
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ADJUSTING THE REAR SHOCK ABSORBER 2.Adjust: Rebound damping force *********************************************** Adjustment steps: Turn the adjusting screw 1 in direction a or Rebound damping force Direction a is increased. Rebound damping force Direction b is decreased. From the fully turned-out position: Standard: 7 clicks in Minimum: 1 clicks in Maximum: 12 clicks in...
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ADJUSTING THE REAR SHOCK ABSORBER CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. *********************************************** – 13 –...
CHAS REAR SHOCK ABSORBER AND RELAY ARM CHASSIS REAR SHOCK ABSORBER AND RELAY ARM Order Job name/Part name Q’ty Remarks Removing the rear shock absorber Remove the parts in the order below. and relay arm Muffler/exhaust pipe Refer to “ENGINE REMOVAL” in CHAP- TER 5.
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CHAS REAR SHOCK ABSORBER AND RELAY ARM Order Job name/Part name Q’ty Remarks Self-locking nut/bolt Relay arm Spacer/oil seal/bushing 1/2/2 Refer to “INSTALLING THE RELAY ARM AND CONNECTING ARM”. Connecting arm Dust cover Spacer Spacer Bushing Refer to “INSTALLING THE RELAY ARM AND CONNECTING ARM”.
CHAS REAR SHOCK ABSORBER AND RELAY ARM HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER WARNING This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you understand the following information.
CHAS REAR SHOCK ABSORBER AND RELAY ARM REMOVING THE REAR SHOCK ABSORBER 1.Remove: Connecting arm-to-frame bolt Rear shock absorber upper bolt NOTE: While removing the connecting arm-to-frame bolt, hold the swingarm so that it does not drop down. CHECKING THE REAR SHOCK ABSORBER 1.Check: Shock absorber Oil leaks →...
CHAS REAR SHOCK ABSORBER AND RELAY ARM INSTALLING THE RELAY ARM AND CONNECTING ARM 1.Install: Bushing 1 (to connecting arm) NOTE: Apply the lithium soap base grease on the bushing when installing. Installed depth of bushing a: 1 mm (0.04 in) 2.Install: Bushing 1 Oil seal 2...
CHAS SWINGARM AND DRIVE CHAIN SWINGARM AND DRIVE CHAIN Order Job name/Part name Q’ty Remarks Removing the swingarm and drive Remove the parts in the order below. chain Rear wheels and hub Refer to “REAR WHEELS, WHEEL AXLE AND HUB”. Rear shock absorber Refer to “REAR SHOCK ABSORBER AND RELAY ARM”.
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CHAS SWINGARM AND DRIVE CHAIN Order Job name/Part name Q’ty Remarks Refer to “INSTALLING THE DRIVE Lock washer SPROCKET”. Drive sprocket Drive chain Collar Spacer Oil seal Bearing Dust cover/oil seal/washer 1/1/1 Spacer Oil seal Bushing Refer to “INSTALLING THE SWING- ARM”.
AC MAGNETO AC MAGNETO Order Job name/Part name Q’ty Remarks Removing the AC magneto Remove the parts in the order below. Engine oil Drain. Shift pedal link Disconnect. Oil pipe 1 Disconnect. AC magneto coupler Starter idle gear cover/gasket Dowel pin Starter idle gear 1 Starter idle gear 1 shaft Bearing...
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AC MAGNETO Order Job name/Part name Q’ty Remarks Dowel pin/O-ring Lead holder Pickup coil Stator assembly Starter idle gear 2 Starter idle gear 2 shaft AC magneto rotor Refer to “REMOVING/INSTALLING THE AC MAGNETO ROTOR”. Starter wheel gear Woodruff key Bush/washer For installation, reverse the removal pro- cedure.
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