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Genuine YAMAHA

Parts And Accessories

YAMAHA MOTOR CO., LTD.

2500 SHINGAI IWATA SHIZUOKA JAPAN

TZ250N1/(N)

OWNER’S SERVICE MANUAL

1st Edition, September 2000

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-11626-14-44

EC010000

EC020000

INTRODUCTION

Congratulations on your purchase of a

Yamaha TZ series. This model is the culmina-

tion of Yamaha’s vast experience in the pro-

duction of pacesetting racing machines. It rep-

resents the highest grade of craftsmanship

and reliability that have made Yamaha a

leader.

This manual explains operation, inspection,

basic maintenance and tuning of your

machine. If you have any questions about this

manual or your machine, please contact your

Yamaha dealer.

NOTE:

As improvements are made on this model,

some data in this manual may become outdat-

ed. If you have any questions, please consult

your Yamaha dealer.

PLEASE READ THIS MANUAL CAREFULLY

AND COMPLETELY BEFORE OPERATING

THIS MACHINE. DO NOT ATTEMPT TO

OPERATE THIS MACHINE UNTIL YOU HAVE

ATTAINED A SATISFACTORY KNOWLEDGE

OF ITS CONTROLS AND OPERATING FEA-

TURES AND UNTIL YOU HAVE BEEN

TRAINED IN SAFE AND PROPER RIDING

TECHNIQUES. REGULAR INSPECTIONS

AND CAREFUL MAINTENANCE, ALONG

WITH GOOD RIDING SKILLS, WILL

ENSURE THAT YOU SAFELY ENJOY THE

CAPABILITIES AND THE RELIABILITY OF

THIS MACHINE.

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.

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.

1. THIS MACHINE IS TO BE OPERATED

BY AN EXPERIENCED RIDER ONLY.

Do not attempt to operate this

machine at maximum power until you

are totally familiar with its character-

istics.

2. THIS MACHINE IS DESIGNED TO BE

RIDDEN BY THE OPERATOR ONLY.

Do not carry passengers on this

machine.

3. ALWAYS WEAR PROTECTIVE APPAR-

EL.

When operating this machine, always

wear an approved helmet with gog-

gles or a face shield. Also wear heavy

boots, gloves, and protective cloth-

ing. Always wear proper fitting cloth-

ing that will not be caught in any of

the moving parts or controls of the

machine.

4. ALWAYS MAINTAIN YOUR MACHINE

IN PROPER WORKING ORDER.

For safety and reliability, the machine

must be properly maintained. Always

perform the pre-operation checks

indicated in this manual. Correcting a

mechanical problem before you ride

may prevent an accident.

5. GASOLINE IS HIGHLY FLAMMABLE.

Always turn off the engine while refu-

eling. Take care to not spill any gaso-

line on the engine or exhaust system.

Never refuel in the vicinity of an open

flame, or while smoking.

&SAFETY INFORMATION

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.

7. ONLY OPERATE THE MACHINE IN AN

AREA WITH ADEQUATE VENTILA-

TION.

Never start the engine or let it run for

any length of time in an enclosed

area. Exhaust fumes are poisonous.

These fumes contain carbon monox-

ide, which by itself is odorless and

colorless. Carbon monoxide is a dan-

gerous gas which can cause uncon-

sciousness or can be lethal.

8. PARK THE MACHINE CAREFULLY;

TURN OFF THE ENGINE.

Always turn off the engine if you are

going to leave the machine. Do not

park the machine on a slope or soft

ground as it may fall over.

9. PROPERLY SECURE THE MACHINE

BEFORE TRANSPORTING IT.

When transporting the machine in

another vehicle, always be sure it is

properly secured and in an upright

position and that the fuel cock is in

the “OFF” position. Otherwise, fuel

may leak out of the carburetor or fuel

tank.

EC050000

TO THE NEW OWNER

This manual will provide you with a good basic

understanding of features, operation, and

basic maintenance and inspection items of

this machine. Please read this manual careful-

ly and completely before operating your new

machine. 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.

EC060000

NOTICE

Some data in this manual may become out-

dated due to improvements made to this

model in the future. If there is any question

you have regarding this manual or your

machine, please consult your Yamaha dealer.

Weights of machines without fuel

The minimum weights for road race

machines are:

for the class 125 cc . . . . . . . . . . . .minimum

70 kg (154 lb)

for the class 250 cc . . . . . . . . . . . .minimum

95 kg (209 lb)

for the class 500 cc . . . . . . . . . . . .minimum

131 kg (289 lb)

In modifying your machine (e.g., for weight

reduction), take note of the above limits of

weight.

EC070011

F.I.M. MACHINE WEIGHTS:

EC080000

HOW TO USE

THIS MANUAL

EC081000

PARTICULARLY IMPORTANT INFOR-

MATION

The Safety Alert Symbol means ATTENTION!

BECOME ALERT! YOUR SAFETY IS

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.

CAUTION:

A CAUTION indicates special precautions that

must be taken to avoid damage to the

machine.

NOTE:

A NOTE provides key information to make pro-

cedures easier or clearer.

EC082000

FINDING THE REQUIRED PAGE

1. This manual consists of seven chapters;

“General Information”, “Specifications”,

“Regular inspection and adjustments”,

“Engine”, “Chassis”, “Electrical” and

“Tuning”.

2. The table of contents is at the beginning of

the manual. Look over the general layout of

the book before finding then required chap-

ter and item.

Bend the book at its edge, as shown, to

find the required fore edge symbol mark

and go to a page for required item and

description.

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.,

• Bearings

Pitting/Damage ≥ Replace.

EC084002

HOW TO READ DESCRIPTIONS

To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each

removal and disassembly section.

1. An easy-to-see exploded diagram

1 is provided for removal and disassembly jobs.

2. Numbers 2 are given in the order of the jobs in the exploded diagram. A number that is

enclosed by a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol

marks 3.The meanings of the symbol marks are given on the next page.

4. A job instruction chart 4 accompanies the exploded diagram, providing the order of jobs,

names of parts, notes in jobs, etc.

5. Extent of removal 5 is provided in the job instruction chart to save the trouble of an unneces-

sary removal job.

6. For jobs requiring more information, the step-by-step format supplements 6 are given in addi-

tion to the exploded diagram and job instruction chart.

CLUTCH

4-25

ENG

EC4A8100

CLUTCH HOUSING AND PUSH LEVER AXLE

Extend of removal: 1 Clutch housing removal 2 Push lever axle removal

Extend of removal Order Part name Q’ty Remarks

CLUTCH HOUSING AND

PUSH LEVER AXLE

REMOVAL

1 Nut (clutch boss) 1

2 Lock washer 1

Use special tool.

3 Clutch boss 1

Refer to “REMOVAL POINTS”.

4 Spacer 2 1

5 O-ring (small) 1

6 Clutch housing 1

7 O-ring (large) 1

8 Bearing 1

9 Spacer 1 1

10 Ball 1

11 Push rod 1

12 Bolt (seat plate) 1

13 Seat plate 1

14 Push lever axle 1

50 Nm (5.0 mdkg, 36 ftdlb)

11 Nm (1.1 mdkg, 8.0 ftdlb)

CLUTCH

4-26

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 . . . . . . . . . . . . . . . .

90890-04086 . . . . . . . . . . . . .

A For USA and CDN

B Except for USA and CDN

EC4A4000

INSPECTION

EC484100

Clutch housing and boss

1. Inspect:

• Clutch housing 1

Cracks/Wear/Damage ≥ Replace.

• Clutch boss 2

Scoring/Wear/Damage ≥ Replace.

EC4A4100

Clutch housing

1. Check:

• Circumferential play

Free play exists ≥ Replace.

• Gear teeth a

Wear/Damage ≥ Replace.

• O-ring 1

Damage ≥ Replace.

EC484400

Clutch spring

1. Measure:

• Clutch spring free length a

Out of specification ≥ Replace springs as

a set.

Clutch spring free length:

Standard <Limit>

36.0 mm (1.417 in) 35.0 mm (1.378 in)

{

ENG

EC085002

ILLUSTRATED SYMBOLS

(Refer to the illustration)

Illustrated symbols 1 to 7 are designed as

thumb tabs to indicate the chapter’s number

and content.

1 General information

2 Specifications

3 Regular inspection and adjustments

4 Engine

5 Chassis

6 Electrical

7 Tuning

Illustrated symbols 8 to ¢ are used to identi-

fy the specifications appearing in the text.

8 With engine mounted

9 Special tool

0 Filling fluid

¡ Lubricant

™ Tightening

£ Specified value, Service limit

¢ Resistance ( Ω ), Voltage ( V ), Electric cur-

rent ( A )

Illustrated symbols ∞ to ª in the exploded

diagrams indicate grade of lubricant and loca-

tion of lubrication point.

∞ Apply transmission oil

§ Apply engine mixing oil

¶ Apply molybdenum disulfide oil

• Apply lightweight lithium-soap base grease

ª Apply molybdenum disulfide grease

Illustrated symbols º to ! in the exploded

diagrams indicate where to apply a locking

agent and where to install new parts.

º Apply locking agent (LOCTITE

)

! Use new one

GEN

INFO

INSP

ADJ

CHAS

TUN

ELEC

ENG

SPEC

∞

º !

•

¶§

™

MEMO

EC090000

INDEX

GENERAL INFORMATION

GEN

INFO

TUNING

TUN

CHASSIS

CHAS

ELECTRICAL

ELEC

ENGINE

ENG

REGULAR INSPECTION AND ADJUSTMENTS

INSP

ADJ

SPECIFICATION

SPEC

EC0A0000

CONTENTS

CHAPTER 1

GENERAL INFORMATION

DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . 1-1

MACHINE IDENTIFICATION . . . . . . . . . . . 1-2

IMPORTANT INFORMATION . . . . . . . . . . 1-3

CHECKING OF CONNECTION. . . . . . . . . 1-5

SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . 1-6

CONTROL FUNCTIONS . . . . . . . . . . . . . . 1-8

FUEL AND ENGINE MIXING OIL . . . . . . 1-14

INFORMATION BEFORE

PRE-OPERATION . . . . . . . . . . . . . . . . . . 1-15

STARTING AND BREAK-IN . . . . . . . . . . 1-16

TORQUE-CHECK POINTS . . . . . . . . . . . 1-19

CLEANING AND STORAGE . . . . . . . . . . 1-21

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS. . . . . . . . . . 2-1

MAINTENANCE SPECIFICATIONS . . . . . 2-3

GENERAL TORQUE SPECIFICATIONS . 2-12

DEFINITION OF UNITS . . . . . . . . . . . . . . 2-12

CABLE ROUTING DIAGRAM . . . . . . . . . 2-13

CHAPTER 3

REGULAR INSPECTION

AND ADJUSTMENTS

MAINTENANCE INTERVALS . . . . . . . . . . 3-1

PRE-OPERATION INSPECTION AND

MAINTENANCE. . . . . . . . . . . . . . . . . . . . . 3-4

LOCKING WIRE INSTALLATION GUIDE . 3-5

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . 3-17

ELECTRICAL. . . . . . . . . . . . . . . . . . . . . . 3-42

CHAPTER 4

ENGINE

COWLING, INDUCTION GUIDE, SEAT

AND FUEL TANK. . . . . . . . . . . . . . . . . . . . 4-1

EXHAUST PIPE AND SILENCER . . . . . . . 4-3

RADIATOR. . . . . . . . . . . . . . . . . . . . . . . . . 4-4

CARBURETOR AND REED VALVE . . . . . 4-7

CYLINDER HEAD,CYLINDER AND

PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18

CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . 4-31

PRIMARY DRIVEN GEAR, PRIMARY

DRIVE GEAR AND BALANCER

SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38

SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . 4-44

WATER PUMP . . . . . . . . . . . . . . . . . . . . . 4-51

TRANSMISSION, SHIFT CAM AND

SHIFT FORK . . . . . . . . . . . . . . . . . . . . . . 4-55

OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . 4-64

CDI MAGNETO . . . . . . . . . . . . . . . . . . . . 4-68

ENGINE REMOVAL. . . . . . . . . . . . . . . . . 4-71

CRANKCASE AND CRANKSHAFT . . . . 4-76

CHAPTER 5

CHASSIS

FRONT WHEEL AND REAR WHEEL . . . . 5-1

FRONT BRAKE AND REAR BRAKE . . . 5-10

FRONT FORK . . . . . . . . . . . . . . . . . . . . . 5-26

HANDLEBAR. . . . . . . . . . . . . . . . . . . . . . 5-40

STEERING. . . . . . . . . . . . . . . . . . . . . . . . 5-46

SWINGARM. . . . . . . . . . . . . . . . . . . . . . . 5-53

REAR SHOCK ABSORBER . . . . . . . . . . 5-60

CHAPTER 6

ELECTRICAL

ELECTRICAL COMPONENTS AND

WIRING DIAGRAM . . . . . . . . . . . . . . . . . . 6-1

IGNITION SYSTEM . . . . . . . . . . . . . . . . . . 6-2

CHARGING SYSTEM . . . . . . . . . . . . . . . . 6-7

YPVS SYSTEM . . . . . . . . . . . . . . . . . . . . 6-10

SOLENOID VALVE SYSTEM. . . . . . . . . . 6-12

THERMO UNIT SYSTEM. . . . . . . . . . . . . 6-14

FUEL PUMP SYSTEM. . . . . . . . . . . . . . . 6-16

CHAPTER 7

TUNING

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

DESCRIPTION

1-1

NOTE:

• The machine you have purchased may differ

slightly from those shown in the following.

• Designs and specifications are subject to

change without notice.

GEN

INFO

EC100000

GENERAL INFORMATION

EC110000

DESCRIPTION

1 Clutch lever

2 Valve joint

3 Main switch

4 Water temperature gauge

5 Front brake lever

6 Throttle grip

7 Radiator cap

8 Fuel tank cap

9 Starter lever (Choke)

0 Battery

¡ Fuel pump

™ Fuel cock

£ Steering damper

¢ Servomotor

∞ Radiator

§ Check bolt (Transmission oil level)

¶ Rear brake pedal

• Rear shock absorber

ª Drive chain

º Shift pedal

! CDI magneto

@ Front fork

MACHINE IDENTIFICATION

1-2

EC120001

MACHINE IDENTIFICATION

There are two significant reasons for knowing

the serial number of your machine:

1. When ordering parts, you can give the

number to your Yamaha dealer for positive

identification of the model you own.

2. If your machine is stolen, the authorities

will need the number to search for and

identify your machine.

EC121001

VEHICLE IDENTIFICATION NUMBER

(For USA, CDN, AUS, NZ and E)

The vehicle identification number 1 is

stamped on the right of the steering head

pipe.

EC122001

FRAME SERIAL NUMBER

(Except for USA, CDN, AUS, NZ and E)

The frame serial number 1 is stamped on the

right of the steering head pipe.

EC123020

ENGINE SERIAL NUMBER

The engine serial number 1 is stamped into

the elevated part of the rear-side of the

engine.

EC124000

MODEL LABEL

The model label 1 is affixed to the frame

under the rider’s seat. This information will be

needed to order spare parts.

GEN

INFO

IMPORTANT INFORMATION

1-3

EC130000

IMPORTANT INFORMATION

EC131002

PREPARATION FOR REMOVAL AND DIS-

ASSEMBLY

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. They include gears,

cylinders, pistons, and other mated parts

that have been “mated” through normal

wear. Mated parts must be reused as an

assembly or replaced.

4. During the machine disassembly, clean all

parts and place them in trays in the order

of disassembly. This will speed up assem-

bly time and help assure that all parts are

correctly reinstalled.

5. Keep away from fire.

GEN

INFO

IMPORTANT INFORMATION

1-4

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.

All gasket surfaces, oil seal lips, and O-

rings must be cleaned.

2. Properly oil all mating parts and bearings

during reassembly. Apply grease to the oil

seal lips.

EC134000

LOCK WASHERS/PLATES AND COTTER

PINS

1. All lock washers/plates 1 and cotter pins

must be replaced when they are removed.

Lock tab(s) should be bent along the bolt

or nut flat(s) after the bolt or nut has been

properly tightened.

EC135001

BEARINGS AND OIL SEALS

1. Install the bearing(s) 1 and oil seal(s) 2

with their manufacturer’s marks or numbers

facing outward. (In other words, the

stamped letters must be on the side

exposed to view.) When installing oil

seal(s), apply a light coating of light-weight

lithium base grease to the seal lip(s). Oil

the bearings liberally when installing.

CAUTION:

Do not use compressed air to spin the

bearings dry. This causes damage to the

bearing surfaces.

EC136000

CIRCLIPS

1. All circlips should be inspected carefully

before reassembly. Always replace piston

pin clips after one use. Replace distorted

circlips. When installing a circlip 1, make

sure that the sharp-edged corner 2 is

positioned opposite to the thrust 3 it

receives. See the sectional view.

4 Shaft

GEN

INFO

CHECKING OF CONNECTION

1-5

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.

5. If the terminal comes off, bend up the pin

1 and reinsert the terminal into the con-

nector.

6. Connect:

• Connector

NOTE:

The two connectors “click” together.

7. Check for continuity with a tester.

NOTE:

• If there in no continuity, clean the terminals.

• Be sure to perform the steps 1 to 7 listed

above when checking the wireharness.

• For a field remedy, use a contact revitalizer

available on the market.

• Use the tester on the connector as shown.

GEN

INFO

SPECIAL TOOLS

1-6

GEN

INFO

EC140002

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. Refer to the list provided to avoid errors when placing an order.

NOTE:

• For U.S.A. and Canada, use part number starting with “YM-”, “YU-” or “ACC-”.

• For others, use part number starting with “90890-”.

Part number Tool name / How to use Illustration

YM-1189, 90890-01189 Flywheel puller YM-1189 90890-01189

This tool is used to remove the flywheel magneto.

YU-1235, 90890-01235 Rotor holding tool YU-1235 90890-01235

This tool is used when loosening or tightening the

flywheel magneto securing nut.

YU-3097, 90890-01252 Dial gauge and stand YU-3097 90890-01252

YU-1256 Spark plug hole dial stand YU-1256

YU-1037 Offset dial stand YU-1037

These tools are used to set the ignition timing.

YU-1304, 90890-01304 Piston pin puller YU-1304 90890-01304

This tool is used to remove the piston pin.

YM-1312-A, 90890-01312 Fuel level gauge YM-1312-A 90890-01312

YM-1470, 90890-01470 Fuel level gauge adapter YM-1470 90890-01470

This gauge is used to measure the fuel level in the

float chamber.

YU-24460-01, 90890-01325

Radiator cap tester YU-24460-01 90890-01325

YU-33984, 90890-01352 Adapter YU-33984 90890-01352

These tools are used for checking the cooling system.

YU-33975, 90890-01403 Ring nut wrench YU-33975 90890-01403

This tool is used when tighten the steering ring nut

to specification.

SPECIAL TOOLS

1-7

GEN

INFO

Part number Tool name / How to use Illustration

YM-1425, 90890-01425 Damper rod holder YM-1425 90890-01425

Use this tool to remove and install the damper rod.

YM-1434, 90890-01434 Rod holder YM-1434 90890-01434

This tool is used to hold the fork spring.

90890-01435 Rod puller attachment YM-1437 90890-01435

YM-1437, 90890-01437 Rod puller 90890-01437

These tools are used to pull up the fork damper rod.

YM-1441, 90890-01441 Fork spring compressor YM-1441 90890-01441

This tool is used to compress the fork spring.

YM-1442, 90890-01442 Fork seal driver YM-1442 90890-01442

This tool is used when install the fork oil seal.

YM-1455, 90890-01455 Pivot shaft wrench YM-1455 90890-01455

YM-1476, 90890-01476 Pivot shaft wrench adapter YM-1476 90890-01476

These tools are used to loosen or tighten the pivot

adjust bolt.

YU-3112-C, 90890-03112 Yamaha pocket tester YU-3112-C 90890-03112

Use this tool to inspect the coil resistance, output

voltage and amperage.

YM-91042, 90890-04086 Clutch holding tool YM-91042 90890-04086

This tool is used to hold the clutch when removing or

installing the clutch boss securing nut.

YM-34487 Dynamic spark tester YM-34487 90890-06754

90890-06754 Ignition checker

This instrument is necessary for checking the ignition

system components.

ACC-YAMAB-ON-D4 Quick gasket

ACC-YAMAB-ON-D4 90890-05143

90890-05143 YAMAHA Bond No.4

This sealant (Bond) is used for crankcase mating

surface, etc.

CONTROL FUNCTIONS

1-8

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” except when the engine is

started or when electric parts are checked.

EC152000

CLUTCH LEVER

The clutch lever 1 is located on the left han-

dlebar; it disengages or engages the clutch.

Pull the clutch lever to the handlebar to disen-

gage the clutch, and release the lever to

engage the clutch. The lever should be pulled

rapidly and released slowly for smooth starts.

EC153000

SHIFT PEDAL

The gear ratios of the constant-mesh 6 speed

transmission are ideally spaced. The gears

can be shifted by using the shift pedal 1 on

the left side of the engine.

EC155001

THROTTLE GRIP

The throttle grip 1 is located on the right han-

dlebar; it accelerates or decelerates the

engine. For acceleration, turn the grip toward

you; for deceleration, turn it away from you.

EC156000

FRONT BRAKE LEVER

The front brake lever 1 is located on the right

handlebar. Pull it toward the handlebar to acti-

vate the front brake.

GEN

INFO

CONTROL FUNCTIONS

1-9

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. The fuel cock

has the two positions:

OFF: With the lever in this position, fuel will

not flow. Always return the lever to this

position when the engine is not run-

ning.

ON: With the lever in this position, fuel

flows to the carburetor. Normal riding is

done with the lever in this position.

EC15A020

STARTER LEVER (CHOKE)

When cold, the engine requires a richer air-

fuel mixture for starting. A separate starter cir-

cuit, which is controlled by the starter lever 1,

supplies this mixture. Push the starter lever

out to open the circuit for starting. When the

engine has warmed up pull it in to close the

circuit.

EC15V011

TACHOMETER

A stepping motor type tachometer with greater

accuracy and response is provide for the

tachometer 1. This tachometer features the

following:

Sweeping:

Moving the main switch to “RUN”, the

tachometer hand sweeps widely once over the

tachometer face and then returns to the zero

position, as initial operation. This is called

“sweeping”. When the engine is started during

sweeping, the tachometer indicates the cor-

rect revolutions after sweeping is over.

Out-of-step indication:

If this tachometer is subjected to impact, etc, it

may allow its hand to point to the position b

stepping out of the position a where the hand

should be for correct indication. This is called

an “out-of-step” indication. A similar phenom-

enon may take place when the main switch is

moved to “OFF” during sweeping or at high

rpm (as in a plug chop) or while the machine

is transported, though it never happens in nor-

mal riding.

GEN

INFO

CONTROL FUNCTIONS

1-10

GEN

INFO

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

normal 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.

EC15B010

WATER TEMPERATURE GAUGE

The water temperature gauge 1 displays dif-

ferent indications according to the change in

the water temperature.

NOTE:

Water temperature may be 70 ˚C (158 ˚F)

when engine is operated in good conditions.

Cooling water

Display Conditions

temp.

~19 ˚C

“LO” is display.

(~66 ˚F)

20~119 ˚C Temperature is

(68~247 ˚F) displayed.

120~140 ˚C Temperature

(248~284 ˚F) flash.

141 ˚C~ Message “HI”

(285 ˚F~) flash.

EC15F000

VALVE JOINT

This valve joint 1 prevents fuel from flowing

out and is installed to the fuel tank breather

hose.

CAUTION:

In this installation, make sure the arrow

faces the fuel tank and also downward.

EC15X000

BATTERY

The battery 1 is provided as power supply for

the electric parts. Except when the machine is

run, disconnect the power supply coupler 2 of

the wireharness to prevent battery discharge.

CONTROL FUNCTIONS

1-11

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.

NOTE:

Be sure to fix the induction guides with band

3 or hooks 4 so that they do not come off by

wind pressure while running.

EC15Z000

FUEL PUMP

The fuel pump 1, is provided in order to pro-

vide steady supply of fuel even when the pres-

sure inside the carburetor float chamber

becomes higher than inside the fuel tank

because of the induction box intake system.

If the fuel level is not up to the specified level

in the float chamber, this pump is activated

(with an operation sound) and stops operating

when the specified level is reached.

CAUTION:

Do not idle run the fuel pump with no fuel

flowing as when the fuel tank is empty or

when the fuel cock is “OFF”. It may dam-

age the fuel pump.

GEN

INFO

CONTROL FUNCTIONS

1-12

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” which allow electric

current to flow in the coil 3 inside the relay,

causing the relay switch 4 to turn “OFF” and

shutting of the electric current flow to the fuel

pump 5.Thus, the pump comes to a stop.

Fuel pump Fuel pump

Fuel pump 5

stop switch 1 relay switch 4

During run OFF ON ON

During

ON OFF OFF

turnover

NOTE:

• When the machine is picked up from

turnover, the fuel pump is restored to an

operation condition.

• Install the fuel pump stop switch so that

“UPPER” mark a faces upward.

EC15M011

CATCH TANK

Put the tip of the breather hose into the catch

tank 1 and frame 2. Take care not to allow

the fuel, oil and cooling water to spill on the

course.

3 Radiator breather hose

4 Fuel tank breather hose

5 Transmission oil breather hose

NOTE:

When putting in the transmission oil breather

hose, its tip having a cut a should be on the

frame side.

GEN

INFO

CONTROL FUNCTIONS

1-13

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.

2. Stand shaft (with supplying parts):

Insert the stand shaft 3 through the hole

of the mainstand and rear wheel axle. Be

sure to install the clip 4 in the end of the

stand shaft.

• Never apply additional force to the main-

stand.

• Remove this mainstand before starting

out.

EC15R001

DETACHABLE SIDESTAND

This sidestand 1 is used to support only the

machine when standing or transporting it.

• Never apply additional force to the side-

stand.

• Remove this sidestand before starting

out.

EC15T003

FIRE RETARDANT MATERIAL

For racing, be sure to fill the fuel tank 2 com-

pletely with fire retardant material (with sup-

plying parts) 1.

EC15b000

COUPLER FOR SPEED SHIFT

If an after-marked speed shift is installed, the

coupler 1 should be used.

NOTE:

If the speed shift is not installed, be sure to fix

the coupler to the wireharness using a vinyl

tape, for protection against water entry as well

because if the coupler contacts the frame,

sparks will be shut off, causing the engine to

stop.

GEN

INFO

FUEL AND ENGINE MIXING OIL

1-14

EC160040

FUEL AND ENGINE MIXING OIL

Mix oil with the gas at the ratio specified

below. Always use fresh, name-brand gaso-

line, and mix the oil and gas the day of the

race. Do not use premix that is more than a

few hours old.

Recommended fuel:

Except for AUS:

Premium unleaded fuel with

a research octane number of

95 or higher.

For AUS:

Unleaded fuel only

NOTE:

Except for AUS:

1. If knocking or pinging occurs, use a differ-

ent brand of gasoline or higher octane

grade.

2. If unleaded gasoline is not available, then

leaded gasoline can be used.

CAUTION:

Never mix two types of oil in the same

batch; clotting of the oil could result. If you

wish to change oil types, be sure to drain

the fuel tank and the carburetor float bowl

of old premix prior to filling with the new

type.

Fuel tank capacity:

23.0 L (5.06 Imp gal, 6.08 US gal)

Mixing oil

Recommended oil:

Castrol A747

Mixing ratio: 30 : 1

GEN

INFO

INFORMATION BEFORE PRE-OPERATION

1-15

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. Take care not to spill any

lacquer thinner on the engine or exhaust

system.

Never use it in the vicinity of an open

flame, or while smoking.

• LACQUER THINNER CAN CAUSE INJURY.

Always use lacquer thinner in a well venti-

lated area. If you should swallow some

lacquer thinner, inhale excess lacquer

thinner vapors, or allow any lacquer thin-

ner to get into your eyes, contact a doctor

immediately.

NOTE:

• When the machine is not in use for a long

time, apply a rust inhibitor to the brake disc.

•After riding in the rainy weather, wipe the

moisture completely off the disc.

• If rust appears on the brake disc, carefully

remove it using #400 sand paper.

2. The cooling system is filled with coolant at

the factory to prevent rusting. Be sure to

replace coolant with soft water before rid-

ing.

CAUTION:

Hard water or salt water is harmful to the

engine parts.You may use distilled water, if

you can’t get soft water.

GEN

INFO

STARTING AND BREAK-IN

1-16

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. Always operate

the machine in a well-ventilated area.

EC191032

STARTING A COLD ENGINE

1. Connect the power supply coupler.

2. Turn the fuel cock to “ON” and push the

starter lever (CHOKE).

3. Move the main switch to “RUN”.

4. Shift the transmission into “1st” gear.

5. Apply the clutch lever and push the

machine.

6. After gaining some momentum, release the

clutch lever.

7. As soon as the engine starts, quickly apply

the clutch lever again and open the throttle

grip slightly at the same time so as to sus-

tain idling of the engine. Then, shift the

transmission into neutral.

8. After applying full-throttle a few times, turn

the starter lever (CHOKE) to the original

position. Take some time to allow the

engine to warm up.

EC192000

WARMING UP

Run the engine at varying speeds 5,000~6,000

r/min for 1~2 minutes. Fully warm up until the

water temperature gauge reads 70 ˚C (158 ˚F)

or so.

CAUTION:

Do not warm up the engine for extended

periods.

GEN

INFO

STARTING AND BREAK-IN

1-17

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. Before starting the engine, fill the fuel tank

with a break-in oil-fuel mixture as follows.

Mixing oil

Recommended oil:

Castrol A747

Mixing ratio: 30 : 1

2. Perform the pre-operation checks on the

machine.

3. Start and warm up the engine. Check the

operation of the controls and check that the

engine comes to a stop when moving the

main switch to “OFF”.

NOTE:

During break-in, mask part of the radiator core

so that the water temperature is 55 ~ 65˚C

(131 ~ 149˚F).

4. Operate the machine under 8,000 r/min

and run on a course about 10 km (6 miles).

While making a straight-line run, open the

throttle from time to time, taking care not to

exceed the revolution limit.

5. Go back to the pit to check for looseness,

leakage, and other failures in installation.

6. Next, operate the machine under 9,000

r/min and run about 10 km (6 miles).

(While running in this way, get an idea of

the riding position and approximate set-

tings.)

7. Go back to the pit again, check the

machine fully for looseness, leakage, and

other failures in installation, especially for

loose cables and wires, excessive brake

free play, and a chain slack. Also make

adjustment for a riding position according

to your preference.

GEN

INFO

STARTING AND BREAK-IN

1-18

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).

9. Increase the engine speed up to 11,000

r/min and run about 10 km (6 miles).

10.Increase the engine speed up to 12,000

r/min and run about 10 km (6 miles). Then

do the plug chop. Check the piston head for

burning to see if there is any problem.

Refer to “SETTING” section in the CHAP-

TER 7.

11.Run about 10 km (6 miles) in a usual man-

ner. Then do the plug chop. Check the pis-

ton head for burning to see if there is any

problem.

EC195001

BREAKING IN AFTER REPLACEMENT

After a part is replaced with a new one, it is

necessary to break it in as in a new machine.

This is required especially when the following

engine-related parts are replaced.

•Cylinder •Piston •Piston ring

•Crankshaft •Clutch •Transmission gear

•Shift fork

$ For warming up and inspection during

break-in, refer to “PRE-OPERATION

CHECK LIST” and if there is any problem,

stop the engine immediately and check.

GEN

INFO

TORQUE-CHECK POINTS

1-19

GEN

INFO

EC1A0060

TORQUE-CHECK POINTS

Frame construction Frame to rear frame

Engine mounting Frame to engine

Steering Steering shaft to handlebar Steering damper stay to front fork

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 For link type Assembly of links

Link to frame

Link to shock absorber

Link to swingarm

Rear Installation of shock absorber Shock absorber to upper bracket

Adjuster to upper bracket

Adjuster to locknut

Rear Installation of swingarm Tightening of pivot shaft

Wheel Installation of wheel Front Tightening of front axle

Rear Tightening of rear axle

Sprocket damper to sprocket

Brake Hydraulic type Front Caliper to front fork

Brake disc to wheel

Tightening of union bolt

Caliper to adapter

Brake hose to adapter

Master cylinder to handlebar

Tightening of air bleeder

Caliper to pad pin

Rear Caliper to caliper bracket

Brake disc to wheel

Tightening of union bolt

Caliper to adapter

Brake hose to adapter

Master cylinder to footrest bracket

Footrest bracket to frame

Footrest bracket to footrest

Brake pedal to master cylinder

Tightening of air bleeder

Caliper to pad pin

TORQUE-CHECK POINTS

1-20

GEN

INFO

NOTE:

Concerning the tightening torque, refer to

“MAINTENANCE SPECIFICATIONS” section

in the CHAPTER 2.

Fuel system Fuel tank to fuel cock

CLEANING AND STORAGE

1-21

EC1B0000

CLEANING AND STORAGE

EC1B1000

CLEANING

Frequent cleaning of your machine will

enhance its appearance, maintain good over-

all performance, and extend the life of many

components.

1. Before washing the machine, block off the

end of the exhaust pipe to prevent water

from entering. A plastic bag secured with a

rubber band may be used for this purpose.

2. If the engine is excessively greasy, apply

some degreaser to it with a paint brush. Do

not apply degreaser to the chain, sprock-

ets, or wheel axles.

3. Rinse the dirt and degreaser off with a gar-

den hose; use only enough pressure to do

the job.

CAUTION:

Excessive hose pressure may cause water

seepage and contamination of wheel bear-

ings, front forks, brakes and transmission

seals. Many expensive repair bills have

resulted from improper high pressure

detergent applications such as those avail-

able in coin-operated car washers.

4. After the majority of the dirt has been

hosed off, wash all surfaces with warm

water and a mild detergent. Use an old

toothbrush to clean hard-to-reach places.

5. Rinse the machine off immediately with

clean water, and dry all surfaces with a soft

towel or cloth.

6. Immediately after washing, remove excess

water from the chain with a paper towel

and lubricate the chain to prevent rust.

7. Clean the seat with a vinyl upholstery

cleaner to keep the cover pliable and

glossy.

8. Automotive wax may be applied to all paint-

ed or chromed surfaces. Avoid combination

cleaner-waxes, as they may contain abra-

sives.

9. After completing the above, start the

engine and allow it to idle for several min-

utes.

GEN

INFO

CLEANING AND STORAGE

1-22

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.

2. Remove the spark plugs, pour a table-

spoon of SAE 10W30 motor oil in the spark

plug hole, and reinstall the plug. With the

engine stop switch pushed in, kick the

engine over several times to coat the cylin-

der walls with oil.

3. Remove the drive chain, clean it thoroughly

with solvent, and lubricate it. Reinstall the

chain or store it in a plastic bag tied to the

frame.

4. Lubricate all control cables.

5. Block the frame up to raise the wheels off

the ground.

6. Tie a plastic bag over the exhaust pipe out-

let to prevent moisture from entering.

7. If the machine is to be stored in a humid or

salt-air environment, coat all exposed

metal surfaces with a film of light oil. Do not

apply oil to rubber parts or the seat cover.

8. Drain the cooling water completely. And

then fill the coolant and water (50%:50%)

in the engine and radiator.

NOTE:

Make any necessary repairs before the

machine is stored.

GEN

INFO

GENERAL SPECIFICATIONS

2-1

EC200000

SPECIFICATIONS

EC211000

GENERAL SPECIFICATIONS

SPEC

Model name: TZ250N1 (USA)

TZ250(N) (OTHERS)

Model code number: 5KE2

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)

Minimum ground clearance 112 mm (4.4 in)

Basic weight:

With oil and full fuel tank 119.5 kg (263 lb)

Engine:

Engine type Liquid cooled 2-stroke, gasoline

Cylinder arrangement V-type, 2-cylinder

Displacement 249 cm

(8.76 lmp oz, 8.42 US oz)

Bore

XStroke 54X54.5 mm (2.126X2.146 in)

Compression ratio 7.2 : 1

Starting system Push to start

Lubrication system: Premix (30 : 1) (Castrol A747)

Oil type or grade (2-Cycle) :

Transmission oil Castrol R30

Periodic oil change 0.5 L (0.44 lmp qt, 0.53 US qt)

Total amount 0.5 L (0.44 lmp qt, 0.53 US qt)

Cooling water capacity (including all routes) : 1.4 L (1.23 lmp qt, 1.48 US qt)

Fuel:

Type Except for AUS: Premium unleaded fuel with a

research octane number of

95 or higher

For AUS: Unleaded fuel only

Tank capacity 23.0 L (5.06 lmp gal, 6.08 US gal)

Carburetor:

Type/Manufacturer TMX*38/MIKUNI

Spark plug:

Type/Manufacturer R6179A-105P/NGK

Gap 0.5~0.6 mm (0.020~0.024 in)

Clutch type: Dry, multiple-disc

GENERAL SPECIFICATIONS

2-2

SPEC

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)

2nd 31/21 (1.476)

3rd 29/23 (1.261)

4th 27/25 (1.080)

5th 26/27 (0.963)

6th 20/22 (0.909)

Chassis:

Frame type Delta box

Caster angle 22˚

Trail 82 mm (3.23 in)

Tire:

Type Tubeless

Size (front) 3.10/4.80 R17

Size (rear) 165/55 R17

Tire pressure (front and rear) 200 kPa (2.0 kg/cm

, 29 psi)

Brake:

Front brake type Dual disc brake

Operation Right hand operation

Rear brake type Single disc brake

Operation Right foot operation

Suspension:

Front suspension Telescopic fork

Rear suspension Swingarm (link type monocross suspension)

Shock absorber:

Front shock absorber Coil spring/oil damper

Rear shock absorber Coil spring/gas, oil damper

Wheel travel:

Front wheel travel 113 mm (4.45 in)

Rear wheel travel 118 mm (4.65 in)

Electrical:

Ignition system CDI magneto

MAINTENANCE SPECIFICATIONS

2-3

EC212000

MAINTENANCE SPECIFICATIONS

EC212112

ENGINE

SPEC

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) (0.5896 in)

Piston ring:

Sectional sketch Keystone ?

B=1.0 mm (0.039 in) ?

T=2.2 mm (0.087 in) ?

End gap (installed) 0.22~0.37 mm (0.009~0.015 in) 0.59 mm (0.023 in)

Side clearance (installed) Zero~0.06 mm (Zero~0.0024 in) ?

Crankshaft:

Crank width “A”

49.975~50.025 mm (1.968~1.969 in)

Runout limit “C” 0.03 mm (0.0012 in) 0.05 mm (0.0020 in)

Connecting rod big end

side clearance “D” 0.45~0.95 mm (0.018~0.037 in) ?

Small end free play “F” 0.8~1.0 mm (0.031~0.039 in) 2.0 mm (0.08 in)

Clutch:

Friction plate thickness 2.9~3.1 mm (0.114~0.122 in) 2.7 mm (0.106 in)

Quantity 6 ?

Clutch plate thickness 2.2~2.4 mm (0.087~0.094 in) ?

Quantity 5 ?

Warp limit ? 0.1 mm (0.004 in)

Clutch spring free length 30.6 mm (1.205 in) 29.6 mm (1.165 in)

Quantity 6 ?

Clutch housing thrust clearance 0.07~0.18 mm (0.003~0.007 in) ?

Clutch housing radial clearance

0.009~0.071 mm(0.0004~0.0028 in)

Clutch release method Inner push, cam push ?

Push rod bending limit ? 0.2mm (0.008 in)

Transmission:

Main axle deflection limit ? 0.01 mm (0.0004 in)

Drive axle deflection limit ? 0.01 mm (0.0004 in)

Shifter:

Shifting type Cam drum and guide bar ?

Guide bar bending limit ? 0.04 mm (0.0016 in)

MAINTENANCE SPECIFICATIONS

2-4

SPEC

Item Standard Limit

Carburetor:

Type/Manufacturer TMX*38/MIKUNI ?

I.D. mark (left side/right side) 5KE2 10L/5KE2 10R ?

Main jet (M.J.) #560 ?

Jet needle (J.N.) 6DGJ1 ?

Main nozzle (N.J.) S-4 ?

Cutaway (C.A.) 5.0 ?

Pilot jet (P.J.) #40 ?

Pilot air screw (P.A.S.) 1-1/2 ?

Valve seat size (V.S.) 1.5 ?

Starter jet (G.S.) #80 ?

Power jet (P.W.J.) #55 ?

Float height (F.H.) 6.0~7.0 mm (0.24~0.28 in) ?

Reed valve:

Thickness* reed valve 1 0.42 mm (0.017 in) ?

reed valve 2 0.34 mm (0.013 in) ?

Valve stopper height 6.5~6.9 mm (0.256~0.272 in) ?

Valve bending limit ? 0.2 mm (0.008 in)

Cooling:

Radiator core size:

Width 380 mm (14.96 in) ?

Height 198 mm (7.80 in) ?

Thickness 24 mm (0.94 in) ?

Radiator cap opening pressure 95~125 kPa ?

(0.95~1.25 kg/cm

, 13.5~17.8 psi)

Radiator capacity 0.5 L (0.44 lmp qt, 0.53 US qt) ?

Water pump:

Type Single-suction centrifugal pump ?

MAINTENANCE SPECIFICATIONS

2-5

SPEC

Part to be tightened Thread size Q’ty

Tightening torque

Nm mdkg ftdlb

Spark plug

M14S

X 1.25 2 19 1.9 13

Cylinder head (bolt) M 6 X 1.0 12 11 1.1 8.0

Cylinder (nut) M 8 X 1.25 8 20 2.0 14

(stud) M 8 X 1.25 8 15 1.5 11

Power valve:

Cover M 5 X 0.8 8 4 0.4 2.9

Holder (power valve) M 5 X 0.8 2 9 0.9 6.5

Pulley M 5 X 0.8 2 4 0.4 2.9

Cable stay M 5 X 0.8 4 7 0.7 5.1

Air bleeding bolt (cylinder) M 6 X 1.0 2 12 1.2 8.7

Balance weight gear M14 X 1.0 1 50 5.0 36

Water pump housing cover M 6 X 1.0 4 11 1.1 8.0

Air bleeding bolt (water pump) M 6 X 1.0 1 11 1.1 8.0

Radiator M 6 X 1.0 3 7 0.7 5.1

Radiator and thermo unit M16 X 1.5 1 11 1.1 8.0

Radiator hose clamp – 6 2 0.2 1.4

Oil pump cover M 5 X 0.8 3 8 0.8 5.8

Oil strainer M 6 X 1.0 4 7 0.7 5.1

Carburetor joint M 6 X 1.0 9 11 1.1 8.0

Clamp (carburetor joint) M 4 X 0.7 2 2 0.2 1.4

Reed valve M 3 X 0.5 12 1 0.1 0.7

Mixing chamber top M 4 X 0.7 2 2 0.2 1.4

Exhaust pipe M 8 X 1.25 2 21 2.1 15

Silencer M 6 X 1.0 4 11 1.1 8.0

Crankcase M 8 X 1.25 6

Refer to NOTE

Crankcase M 6 X 1.0 9

Transmission housing M 6 X 1.0 6 16 1.6 11

Oil check bolt M 6 X 1.0 1 9 0.9 6.5

Oil drain bolt M12 X 1.25 1 23 2.3 17

Crankcase cover (right) M 6 X 1.0 10 11 1.1 8.0

Crankcase cover (left) M 6 X 1.0 3 11 1.1 8.0

Primary drive gear M10 X 1.25 1 55 5.5 40

Clutch boss M20 X 1.0 1 75 7.5 54

Clutch spring M 6 X 1.0 6 9 0.9 6.5

Push rod adjuster M 6 X 1.0 1 6 0.6 4.3

Seat plate (push lever) M 5 X 0.8 1 7 0.7 5.1

Clutch cable holder M 6 X 1.0 2 8 0.8 5.8

Bearing plate cover M 6 X 1.0 3 10 1.0 7.2

Oil seal plate cover M 5 X 0.8 2 7 0.7 5.1

Drive sprocket M20 X 1.0 1 75 7.5 54

Bearing plate cover (shift cam) M 5 X 0.8 1 4 0.4 2.9

Segment M 8 X 1.25 1 23 2.3 17

Shift guide M 6 X 1.0 2 11 1.1 8.0

Shift lever adjuster and locknut M 6 X 1.0 1 9 0.9 6.5

Stopper bolt (torsion spring) M 8 X 1.25 1 8 0.8 5.8

Shift arm M 6 X 1.0 1 14 1.4 10

MAINTENANCE SPECIFICATIONS

2-6

SPEC

Part to be tightened Thread size Q’ty

Tightening torque

Nm mdkg ftdlb

Joint rod 1 and shift rod M 6 X 1.0 1 9 0.9 6.5

Joint rod 2 and shift rod M 6 X 1.0 1 9 0.9 6.5

Joint rod 1,2 M 6 X 1.0 2 11 1.1 8.0

Shift pedal pivot bolt M 8 X 1.25 1 22 2.2 16

Front pedal M 6 X 1.0 1 10 1.0 7.2

CAUTION:

The M6 bolt comes in two lengths. Use the

correct one for installation.

L=30 mm (1.18 in) (green)

7 0 ¡ £ ¢ ∞

Mark $:L=35 mm (1.38 in) (silver) 8 9 ™

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~∞ (M6) 6 Nm (0.6 m•kg, 4.3 ft•lb)

•Final: 1~6 (M8) 26 Nm (2.6 m•kg, 19 ft•lb)

7~∞ (M6) 11 Nm (1.1 m•kg, 8.0 ft•lb)

Crankcase tightening sequence

MAINTENANCE SPECIFICATIONS

2-7

EC212201

CHASSIS

SPEC

Item Standard Limit

Steering system:

Steering bearing type Taper roller bearing ?

Front suspension:

Front fork travel 113 mm (4.45 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 No ?

Oil capacity 386 cm

(13.6 lmp oz, 13.1 US oz) ?

Oil level 135 mm (5.31 in) ?

<Min.~Max.> 80~140 mm (3.15~5.51 in) ?

(From top of outer tube with inner tube

and damper rod fully compressed

without spring.)

Oil grade Suspension oil “01” ?

Inner tube outer diameter 41 mm (1.61 in) ?

Front fork top end 13 mm (0.51 in) ?

Rear suspension:

Shock absorber travel 53 mm (2.09 in) ?

Spring free length 150 mm (5.91 in) ?

Fitting length 137 mm (5.39 in) ?

<Min.~Max.> 133~142 mm (5.24~5.59 in) ?

Spring rate, STD K=72 N/mm ?

(7.2 kg/mm, 403 lb/in)

Optional spring No ?

Enclosed gas pressure 1,200 kPa (12 kg/cm

, 171 psi) ?

Swingarm:

Swingarm free play limit

End ? 1.0 mm (0.04 in)

Side clearance ? 0.05~0.35 mm

(0.002~0.014 in)

Wheel:

Front wheel type Cast wheel ?

Rear wheel type Cast wheel ?

Front rim size/Material MT 3.75X17/Magnesium ?

Rear rim size/Material MT 5.50X17/Magnesium ?

Wheel runout limit:

Radial ? 1.0 mm (0.04 in)

Lateral ? 0.5 mm (0.02 in)

Drive chain

Type/Manufacturer RKGB520TRU/RK EXCEL ?

Number of links 109 links + joint ?

Chain slack 40~50 mm (1.6~2.0 in) ?

Chain length (10 links) ? 150.1 mm (5.909 in)

MAINTENANCE SPECIFICATIONS

2-8

SPEC

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 ?

Rear disc brake:

Disc outside dia.XThickness 185X4.0 mm (7.28X0.16 in) ?

Deflection limit ? 0.15 mm (0.006 in)

Pad thickness 4.0 mm (0.16 in) 1.0 mm (0.04 in)

Master cylinder inside dia. 12.7 mm (0.500 in) ?

Caliper cylinder inside dia. 25.4 mm (1.000 in) ?

Brake fluid type DOT #4 ?

Brake lever & brake pedal:

Brake pedal position 148~152 mm (5.8~6.0 in) ?

Clutch lever free play (at lever pivot) 2~3 mm (0.08~0.12 in) ?

Throttle grip free play 2~4 mm (0.08~0.16 in) ?

MAINTENANCE SPECIFICATIONS

2-9

SPEC

Part to be tightened Thread size Q’ty

Tightening torque

Nm mdkg ftdlb

Handle crown and outer tube M 8 X 1.25 2 20 2.0 14

Under bracket and outer tube M 8 X 1.25 4 23 2.3 17

Steering shaft and steering shaft nut M22 X 1.0 1 80 8.0 58

Handlebar and outer tube M 6 X 1.0 4 7 0.7 5.1

Steering ring nut M25 X 1.0 1 Refer to NOTE

Steering damper and fame M 8 X 1.25 1 23 2.3 17

Steering damper and damper bracket M 6 X 1.0 1 5 0.5 3.6

Steering damper stay and outer tube M 6 X 1.0 1 10 1.0 7.2

Steering damper stay and pin M 5 X 0.8 1 5 0.5 3.6

Steering stopper bolt and locknut M 6 X 1.0 2 11 1.1 8.0

Fuel tank fitting bolt and locknut M 8 X 1.25 1 20 2.0 14

Clutch lever holder M 5 X 0.8 2 5 0.5 3.6

Front master cylinder and master cylinder M 6 X 1.0 2 8 0.8 5.8

bracket

Front brake reservoir tank and stay M 6 X 1.0 1 5 0.5 3.6

Brake lever (bolt) M 6 X 1.0 1 1 0.1 0.7

Brake lever (nut) M 6 X 1.0 1 6 0.6 4.3

Main switch and handleber M 4 X 0.7 2 2 0.2 1.4

Front fork and cap bolt M44 X 1.0 2 23 2.3 17

Front fork and damper rod M12 X 1.25 2 40 4.0 29

Cap bolt and damper rod M12 X 1.25 2 29 2.9 21

Front fork and front fender M 6 X 1.0 4 8 0.8 5.8

Brake hose holder and swingarm M 6 X 1.0 2 8 0.8 5.8

Brake hose (front and rear) and union bolt M10 X 1.25 2 30 3.0 22

(master cylinder)

Brake hose (front and rear) and adapter M10 X 1.25 3 14 1.4 10

Brake caliper (front and rear) and adapter M10 X 1.25 3 26 2.6 19

Front brake caliper and front fork M10 X 1.25 4 35 3.5 25

Front master cylinder and bleed screw M 8 X 1.25 1 6 0.6 4.3

Brake caliper (front and rear) and pad pin M10 X 1.25 3 18 1.8 13

Brake caliper (front and rear) and bleed screw M 8 X 1.25 4 6 0.6 4.3

Front wheel axle and nut M18 X 1.5 1 80 8.0 58

Front wheel axle holder M 6 X 1.0 4 11 1.1 8.0

Front brake disc and wheel hub M 8 X 1.25 12 20 2.0 14

Footrest bracket and frame M 8 X 1.25 4 20 2.0 14

Footrest bracket and plate (left and right) M 5 X 0.8 4 8 0.8 5.8

Footrest and footrest bracket M 6 X 1.0 2 10 1.0 7.2

Brake pedal and master cylinder M 6 X 1.0 1 12 1.2 8.7

Rear master cylinder and footrest bracket M 8 X 1.25 2 20 2.0 14

Rear master cylinder and reservoir connector M 4 X 0.7 1 2 0.2 1.4

Rear brake reservoir tank and bolt (rear frame)

M 6 X 1.0 1 7 0.7 5.1

∆

NOTE:

1. First, tighten the ring nut approximately 46 Nm (4.6 m•kg, 33 ft•lb) by using the ring nut wrench,

then loosen the ring nut one turn.

2. Retighten the ring nut 1 Nm (0.1 m•kg, 0.7 ft•lb).

MAINTENANCE SPECIFICATIONS

2-10

SPEC

Part to be tightened Thread size Q’ty

Tightening torque

Nm mdkg ftdlb

Rear brake caliper and caliper bracket M 8 X 1.25 2 23 2.3 17

Rear wheel axle and nut M18 X 1.5 1 80 8.0 58

Driven sprocket and sprocket damper M 8 X 1.25 5 32 3.2 23

Rear brake disc and wheel hub M 8 X 1.25 3 23 2.3 17

Chain puller adjust bolt and locknut M 8 X 1.25 2 16 1.6 11

Chain puller adjust bolt M 8 X 1.25 2 2 0.2 1.4

Engine mounting:

Engine and frame (upper) M10 X 1.25 1 30 3.0 22

Engine and frame (lower) M10 X 1.25 1 30 3.0 22

Engine bracket and frame M10 X 1.25 2 30 3.0 22

Engine bracket and engine M 8 X 1.25 4 23 2.3 17

Pinch bolt (engine mounting collar) M 6 X 1.0 2 11 1.1 8.0

Engine mounting adjust bolt M16 X 1.0 2 8 0.8 5.8

Pivot adjust bolt M25 X 1.0 1 5 0.5 3.6

Pivot shaft and nut M18 X 1.5 1 115 11.5 85

Relay arm and frame M10 X 1.25 1 34 3.4 24

Relay arm and connecting rod M10 X 1.25 1 34 3.4 24

Connecting rod and swingarm M10 X 1.25 1 34 3.4 24

Rear shock absorber and upper bracket M10 X 1.25 1 34 3.4 24

Rear shock absorber and relay arm M10 X 1.25 1 34 3.4 24

Seal guard and swingarm M 6 X 1.0 4 8 0.8 5.8

Swingarm and hook M 6 X 1.0 2 10 1.0 7.2

Swingarm and chain guard M 6 X 1.0 2 8 0.8 5.8

Rear shock absorber and locknut (preload) M52 X 1.5 1 20 2.0 14

Seat height adjuster and locknut M22 X 1.0 1 38 3.8 27

Seat height adjuster and upper bracket M10 X 1.25 1 40 4.0 29

Radiator stay and frame M 6 X 1.0 1 8 0.8 5.8

Cowling stay bracket and frame M 6 X 1.0 2 8 0.8 5.8

Cowling stay and cowling stay bracket M 6 X 1.0 2 8 0.8 5.8

Cowling stay (left and right) and frame M 6 X 1.0 2 8 0.8 5.8

Upper cowl and screen M 4 X 0.7 6 4 0.4 2.9

Fuel tank and fuel cock M 6 X 1.0 2 7 0.7 5.1

Seat and rear frame M 6 X 1.0 4 8 0.8 5.8

Rear frame and frame M 6 X 1.0 4 11 1.1 8.0

∆

NOTE:

∆ - marked portion shall be checked for torque tightening after break-in or before each race.

MAINTENANCE SPECIFICATIONS

2-11

EC212300

ELECTRICAL

SPEC

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 …

Source coil resistance (color) 2.3~3.5 Ω at 20˚C (68˚F) …

(White-White)

Pickup coil resistance (left cylinder) 94~140 Ω at 20˚C (68˚F) …

(color) (White/Black-White/Blue)

(right cylinder) 94~140 Ω at 20˚C (68˚F) …

(White/Black-White/Green)

CDI unit-model/Manufacturer 5KE-10/DENSO …

Ignition coil:

Model/Manufacturer (left cylinder) TJ0285/DENSO …

(right cylinder) TJ0277/DENSO …

Minimum spark gap 5 mm (0.20 in) …

Primary winding resistance 0.14~0.18 Ω at 20˚C (68˚F) …

Secondary winding resistance 5.0~7.4 kΩ at 20˚C (68˚F) …

Battery:

Model/Manufacturer PE12V0.8/ …

JAPAN STORAGE BATTERY

Capacity 12V0.8Ah …

Voltage when charged 12.8V or more …

Fuel pump:

Model/Manufacturer UC-Z6V/MITSUBISHI …

Coil resistance 1~3 Ω at 20˚C (68˚F) …

Fuel pump relay:

Model/Manufacturer 1UY-92/MATSUSHITADENKO …

Coil resistance 72~88 Ω at 20˚C (68˚F) …

Circuit breaker:

Type Fuse …

Main 10AX1 …

Part to be tightened Thread size Q’ty

Tightening torque

Nm mdkg ftdlb

Stator M 6 X 1.0 2 7 0.7 5.1

Rotor M12 X 1.25 1 53 5.3 38

CDI unit M 6 X 1.0 2 8 0.8 5.8

Servomotor pulley M 5 X 0.8 1 8 0.8 5.8

Servomotor M 6 X 1.0 2 7 0.7 5.1

Voltage regulator M 6 X 1.0 2 7 0.7 5.1

Fuel pump and bracket M 5 X 0.8 1 5 0.5 3.6

GENERAL TORQUE SPECIFICATIONS/

DEFINITION OF UNITS

2-12

EC220001

GENERAL TORQUE SPECIFICATIONS

A: Distance across flats

B: Outside thread diameter

SPEC

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. Unless otherwise specified, torque

specifications call for clean, dry threads.

Components should be at room temperature.

A B

TORQUE SPECIFICATION

(Nut) (Bolt)

Nm mdkg ftdlb

10 mm 6 mm 6 0.6 4.3

12 mm 8 mm 15 1.5 11

14 mm 10 mm 30 3.0 22

17 mm 12 mm 55 5.5 40

19 mm 14 mm 85 8.5 61

22 mm 16 mm 130 13 94

EC230000

DEFINITION OF UNITS

Unit Read Definition Measure

mm millimeter 10

-3

meter Length

cm centimeter 10

-2

meter Length

kg kilogram 10

gram Weight

N Newton 1 kgXm/sec

Force

Nm Newton meter NXm Torque

mdkg Meter kilogram mXkg Torque

Pa Pascal N/m

Pressure

N/mm Newton per millimeter N/mm Spring rate

L Liter – Volume or capacity

Cubic centimeter – Volume or capacity

r/min Revolution per minute – Engine speed

CABLE ROUTING DIAGRAM

2-13

EC240000

CABLE ROUTING DIAGRAM

SPEC

1 Brake hose

2 Clamp

3 Cable

4 Frame

5 Radiator breather hose

6 YPVS cable 1, 2 (right cylinder)

7 Ignition coil lead

8 Starter cable

9 Solenoid valve lead

0 Fuel hose

¡ Clutch cable

™ Fuel pump lead

£ Throttle cable

¢ Transmission oil breather hose

A Pass the brake hose through the hole in the inner fender.

B Cut the clamp so that the protruding portion is less than 5 mm (0.20 in).

C Install the clamp with its ends facing backward.

D Position the cable from bottom to top in the following order.

• Starter cable

• Throttle cable

• Solenoid valve lead

CABLE ROUTING DIAGRAM

2-14

SPEC

1 Fuel pump lead

2 Clamp

3 Fuse holder

4 Servomotor

5 Front brake hose (right)

6 YPVS cable 1, 2 (right cylinder)

7 Clutch cable

A Clamp the fuel hose and clutch cable. Position the upside ends of the

clamp inside of the seat rail.

B Clamp the radiator hose 3 and ignition coil lead.

C Clamp the radiator hose 3 and YPVS cable (right cylinder).

D Do not cut the end of the clamp.

E Connect the left cylinder YPVS cables (silver cables) to the inner YPVS

servomotor pulley and right cylinder YPVS cables (black cables) to the

outer.The sleeved cables must be connected to the top side (open side)

of the YPVS servomotor.

F Align the end of the cover with that of the meter stay.

G Be sure the brake hose is not twisted.

CABLE ROUTING DIAGRAM

2-15

SPEC

1 Clamp

2 Throttle cable

3 Fuel tank breather hose

4 Fuel pump stop switch lead

5 Battery lead

6 Fuel pump relay lead

7 Power supply coupler

8 CDI magneto lead

9 Front brake hose (left)

A Clamp the wireharness together with couplers of the fuse lead under the

cowling stay mounting bolt so that the tape on the wireharness aligns

with the bolt.

B Fasten the primary ground lead together with the cowling stay bracket

mounting bolt.

C Do not cut the end of the clamp.

D Clamp the couplers of the main switch lead together with the wirehar-

ness.

E Disconnect the power supply coupler except when the engine is started

or when electric parts are checked.

F Be sure the brake hose is not twisted.

CABLE ROUTING DIAGRAM

2-16

SPEC

1 Tachometer assembly

2 Coupler for speed shift

3 CDI unit

4 Voltage regulator

5 Servomotor

6 Brake hose holder

7 Reservoir hose

8 Rear brake hose

9 Clamp

A Install the tachometer assembly with its figures standing upright.

B Do not make the clamp grip face outside of the chassis.

C Position the reservoir hose with its paint mark upward.

D Make the clamp grip face inside of the chassis.

E Be sure the brake hose is not twisted.

F Do not cut the end of the clamp.

MAINTENANCE INTERVALS

3-1

EC300000

REGULAR INSPECTION AND ADJUSTMENTS

EC310070

MAINTENANCE INTERVALS

The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind

that such factors as weather, terrain, geographical location, and individual usage will alter the

required maintenance and lubrication intervals. 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.

INSP

ADJ

After

Every Every

Every

As re-

Item break-

race 500km

1,000

quired

Remarks

in km

PISTON

Inspect and clean

∂∂ Inspect crack

Replace ∂∂

PISTON PIN, SMALL END BEARING

Inspect ∂∂

Replace ∂∂

PISTON RING

Inspect ∂∂ Check ring end gap

Replace ∂∂

CYLINDER HEAD

Inspect and clean ∂∂ Remove carbon

Retighten ∂∂ Check O-ring

CYLINDER

Inspect and clean ∂∂

(3,000 km) Inspect score marks

Replace ∂∂Inspect wear

Retighten ∂∂

YPVS

Inspect ∂∂

Retighten ∂∂

CLUTCH Inspect housing, friction

Inspect and adjust ∂∂ plate, clutch plate and

Replace ∂ spring

TRANSMISSION

Replace oil ∂∂ Castrol R30

Inspect transmission ∂

Replace bearing ∂

SHIFT FORK, SHIFT CAM, GUIDE BAR

Inspect ∂ Inspect wear

ROTOR NUT

Retighten ∂

MUFFLER

Inspect ∂∂ Inspect crack

Clean ∂

CRANK

(1,500 km)

Inspect and replace ∂∂

CARBURETOR

Inspect, adjust and clean ∂∂

Inspect jet needle clip groove

MAINTENANCE INTERVALS

3-2

INSP

ADJ

After

Every Every

Every

As re-

Item break-

race 500km

1,000

quired

Remarks

in km

SPARK PLUG

Inspect and clean ∂ ∂

Replace ∂

PLUG CAP

(1,500 km)

Inspect and replace ∂ ∂

COOLING SYSTEM

Check cooling level and leakage ∂ ∂

Check radiator cap operation ∂

Replace cooling water ∂ Use soft water

Replace hoses ∂

OUTSIDE NUTS AND BOLTS Refer to “STARTING AND

Retighten ∂ ∂ BREAK-IN” section in the

CHAPTER 1.

OIL PUMP STRAINER

Clean ∂ ∂

REED VALVE

Inspect ∂ ∂

Replace ∂

FRAME

Clean and inspect ∂ ∂

FUEL TANK, COCK

Clean and inspect ∂ ∂

BRAKES

Adjust lever position and pedal position ∂ ∂

Check brake disc surface ∂ ∂

Check brake fluid level and leakage ∂ ∂

Retighten brake disc bolts, caliper bolts ∂

and master cylinder bolts

Replace pads ∂

Replace brake fluid ∂ Every one year

FRONT FORKS

Inspect and adjust ∂ ∂

Replace oil ∂ Suspension oil “01”

Replace oil seal ∂

REAR SHOCK ABSORBER

(After rain

Inspect and adjust ∂ ∂

race)

Lube ∂ Molybdenum disulfide

Retighten ∂ ∂ grease

CHAIN GUARD

Replace ∂

SWINGARM

Inspect and retighten ∂ ∂

RELAY ARM, CONNECTING ROD

Inspect and retighten ∂ ∂

STEERING HEAD

Inspect free play and retighten ∂ ∂

Clean and lube ∂ Lithium base grease

Replace bearings ∂

MAINTENANCE INTERVALS

3-3

INSP

ADJ

After

Every Every

Every

As re-

Item break-

race 500km

1,000

quired

Remarks

in km

TIRE, WHEELS

Inspect air pressure, wheel run-out and ∂ ∂

tire wear

Inspect bearings ∂ ∂

Replace bearings ∂

Lubricate ∂ Lithium base grease

DRIVE CHAIN Use chain lube

Lubricate, slack, alignment ∂ ∂ Chain slack: 40~50 mm

Replace ∂ (1.6~2.0 in)

DRIVE, DRIVEN SPROCKET

Inspect and replace ∂ Inspect wear

DRIVEN SPROCKET DAMPER

Inspect and retighten ∂ ∂

Replace ∂

THROTTLE, CONTROL CABLE

Check routing and connection ∂ ∂ Yamaha cable lube or SAE

Lubricate ∂ ∂ 10W30 motor oil

BATTERY

Check battery voltage ∂ ∂ 12.5V or more

Replace ∂

PRE-OPERATION INSPECTION AND MAINTENANCE

3-4

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.

• For storage, a coolant is used. Before riding the machine remove it with cooling water.

Refer to “INFORMATION BEFORE PRE-OPERATION”.

INSP

ADJ

EC321020

GENERAL INSPECTION AND MAINTENANCE

Item Routine Page

Cooling water Check that cooling water is filled up to the radiator filler cap.

Check the cooling system for leakage.

P3-6~9

Fuel Check that a fresh mixture of oil and gasoline is filled in the

fuel tank. Check the fuel line for leakage.

P1-14

Transmission oil Check that the oil level is correct. Check the crankcase for

leakage.

P3-13~15

YPVS Check operation. P3-12~13

Gear shifter and clutch Check that gears can be shifted correctly in order and that

the clutch operates smoothly.

P3-9~10

Throttle grip/Housing Check that the throttle grip operation and free play are

correctly adjusted. Lubricate the throttle grip and housing, P3-10~11

if necessary.

Brakes Check the effect of front and rear brake. Check brake disc

surface.

P3-17~22

Chain Check chain slack and alignment. Check that the chain is

lubricated properly.

P3-23~25

Wheels Check for excessive wear, tire pressure and tire wear. P3-36

Steering Check that the handlebars can be turned smoothly and

have no excessive play.

P3-37~38

Front forks and Check that they operate smoothly and there is no oil

rear shock absorber leakage.

P3-27~35

Cables (wires) Check that the clutch and throttle cables move smoothly.

Check that they are not caught when the handlebars are P3-39

turned or when the front forks travel up and down.

Muffler Check that the muffler is tightly mounted and has no cracks. P3-16

Sprocket Check that the driven sprocket damper is not loose. P3-22

Lubrication Check for smooth operation. Lubricate if necessary. P3-41

Bolts and nuts Check the chassis and engine for loose bolts and nuts.

Check that the locking wire is correct.

P1-19~20

Lead connectors Check that the CDI magneto, CDI unit, and ignition coil are

connected tightly.

P1-5

Battery Check the battery voltage. P3-44~46

Cowling Check that the cowling is tightly mounted and has no cracks

in it. Check that it dose not contact other parts by stroking. P3-39

Check that the screen is clean.

Settings Is the machine set suitably for the condition of the racing

course and weather or by taking into account the results of

test runs before racing? Are inspection and maintenance

P7-1~22

completely done?

LOCKING WIRE INSTALLATION GUIDE

3-5

EC340000

LOCKING WIRE INSTALLATION GUIDE

INSP

ADJ

Bolt to bolt

Oil drain bolt and check bolt

YPVS pulley

Oil filler cap

Bolt

Tank rail drain bolt

Throttle cable adjuster

Starter cable

ENGINE/COOLING WATER LEVEL INSPECTION/

COOLING WATER REPLACEMENT

3-6

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

riding.

• Take care so that coolant does not splash

on painted surfaces. If it splashes, wash it

away with water.

EC352000

COOLING WATER LEVEL INSPECTION

Do not remove the radiator cap 1, drain

bolt and hoses when the engine and radia-

tor are hot. Scalding hot fluid and steam

may be blown out under pressure, which

could cause serious injury.

When the engine has cooled, place a thick

towel over the radiator cap, slowly rotate

the cap counterclockwise to the detent.

This procedure allows any residual pres-

sure to escape. When the hissing sound

has stopped, press down on the cap while

turning counterclockwise and remove it.

CAUTION:

Hard water or salt water is harmful to the

engine parts.You may use distilled water, if

you can’t get soft water.

1. Place the machine on a level place, and

hold it in an upright position.

2. Remove:

• Radiator cap

3. Check:

• Cooling water level a

Cooling water level low ≥ Add cooling

water.

1 Radiator

INSP

ADJ

EC354013

COOLING WATER REPLACEMENT

Do not remove the radiator cap when the

engine is hot.

1. Remove the lower cowl.

2. Place a container under the radiator hose.

COOLING WATER REPLACEMENT

3-7

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. Fill:

• Radiator

• Engine

To specified level.

Recommended cooling water:

Soft water

Cooling water capacity:

1.4 L (1.23 Imp qt, 1.48 US qt)

CAUTION:

• When filling the radiator with anti-freeze,

tilt the motorcycle so that the filler hole b

is at the highest position. If the radiator is

positioned upright, air a is difficult to

escape which may result in excessive

engine heating.

• Hard water or salt water is harmful to the

engine parts. You may use distilled water,

if you can’t get soft water.

8. Remove:

• Air bleeding bolt (right cylinder) 1

Bleeding the air until coming out the cool-

ing water.

9. Install:

• Copper washerN

• Air bleeding bolt (right cylinder)

12 Nm (1.2 mdkg, 8.7 ftdlb)

10.Remove:

• Air bleeding bolt (water pump) 1

Bleeding the air until coming out the cool-

ing water.

11.Install:

• Copper washerN

• Air bleeding bolt (water pump)

11 Nm (1.1 mdkg, 8.0 ftdlb)

INSP

ADJ

RADIATOR CAP INSPECTION/

RADIATOR CAP OPENING PRESSURE INSPECTION

3-8

12.Fill:

• Radiator

• Engine

To specified level.

13.Install:

• Radiator cap

Start the engine and warm it up for a sever-

al minute.

14.Check:

• Cooling water level

Cooling water level low ≥ Add cooling

water.

15.Install the lower cowl.

EC355000

RADIATOR CAP INSPECTION

1. Inspect:

• Seal (radiator cap) 1

• Valve and valve seat 2

Crack/Damage ≥ Replace.

Exist fur deposits 3 ≥ Clean or replace.

INSP

ADJ

EC356002

RADIATOR CAP OPENING PRESSURE

INSPECTION

1. Attach:

• Radiator cap tester 1 and adapter 2

Radiator cap tester:

YU-24460-01/90890-01325

Adapter:

YU-33984/90890-01352

NOTE:

Apply water on the radiator cap seal.

3 Radiator cap

2. Apply the specified pressure.

Radiator cap opening pressure:

95~125 kPa (0.95~1.25 kg/cm

13.5~17.8 psi)

COOLING SYSTEM INSPECTION/CLUTCH CARE

3-9

INSP

ADJ

EC357003

COOLING SYSTEM INSPECTION

1. Inspect:

• Coolant level

2. Attach:

• Radiator cap tester 1 and adapter 2

Radiator cap tester:

YU-24460-01/90890-01325

Adapter:

YU-33984/90890-01352

3. Apply the specified pressure.

Standard pressure:

180 kPa (1.8 kg/cm

, 25.6 psi)

NOTE:

• Do not apply pressure more than specified

pressure.

• Radiator should be filled fully.

4. Inspect:

• Pressure

Impossible to maintain the specified pres-

sure for 10 seconds ≥ Repair.

• Radiator 1

• Radiator hose joint 2

Coolant leakage ≥ Repair or replace.

• Radiator hose 3

Swelling ≥ Replace.

EC358000

CLUTCH CARE

NOTE:

This machine is equipped with a dry type

clutch. Be sure to clean with solvent or replace

if grease or oil contacts either clutch or friction

plates.

3. Inspect:

• Pressure

Impossible to maintain the specified pres-

sure for 10 seconds ≥ Replace.

CLUTCH ADJUSTMENT/

THROTTLE CABLE ADJUSTMENT

3-10

EC359001

CLUTCH ADJUSTMENT

1. Check:

• Clutch lever free play a

Out of specification ≥ Adjust.

Clutch lever free play a:

2~3 mm (0.08~0.12 in)

2. Adjust:

• Clutch lever free play

Clutch lever free play adjustment steps:

• Loosen the locknut 1.

• Turn the adjuster 2 until free play a is

within the specified limits.

• Tighten the locknut.

INSP

ADJ

NOTE:

After adjustment, check proper operation of

clutch lever.

EC35A040

THROTTLE CABLE ADJUSTMENT

1. Check:

• Throttle grip free play a

Out of specification ≥ Adjust.

Throttle grip free play a:

2~4 mm (0.08~0.16 in)

2. Remove:

• Lower cowl

• Fuel tank

• Induction guide (right cylinder)

3. Loosen the screw (right carburetor joint

clamp), then take out the carburetor 1.

STARTER CABLE ADJUSTMENT

3-11

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.

• Tighten the right carburetor locknut 2.

• Turn out the left carburetor adjuster 6

until the left throttle valve moves together

with the right throttle valve.

NOTE:

• When adjusting left throttle cable, watch

the right throttle valve and touch the left

throttle valve.

• After adjusting the throttle cables, open

the throttle grip and check that both throt-

tle valves are completely open.

• Tighten the left carburetor locknut 3.

• Tighten the locknuts 1.

After adjusting, turn the handlebar to

right and left and make sure that the

engine idling dose not run faster.

INSP

ADJ

EC35B002

STARTER CABLE ADJUSTMENT

1. Check:

• Starter lever free play a

Out of specification ≥ Adjust.

Starter lever free play a:

5~10 mm (0.20~0.39 in)

2. Adjust:

• Starter lever free play

Starter lever free play adjustment steps:

• Loosen the locknuts 1.

• Turn the adjusters 2 until the specified

free play is obtained.

• Tighten the locknuts.

YPVS OPEN SIDE CABLE ADJUSTMENT

3-12

INSP

ADJ

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”.

• The servomotor will be fully opened.

NOTE:

After the main switch is moved to “RUN”,

the servomotor will be operated as follows.

1. The servomotor will be fully closed

about 1 second.

2. And then, it will be kept fully opened.

• Check the free play a for the YPVS open

side cables 1.

Out of specification ≥ Adjust.

YPVS open side cable free

play a:

2~3 mm (0.08~0.12 in)

3. Adjust:

• YPVS open side cable free play

Adjusting steps:

• Fully open the servomotor.

• Loosen the locknuts 1.

• Turn the adjusters 2 until the specified

free play is obtained.

• Tighten the locknuts.

YPVS CLOSE SIDE CABLE ADJUSTMENT/YPVS COMPO-

NENTS RETIGHTENING/TRANSMISSION OIL LEVEL CHECK

3-13

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:

• Move the main switch to “RUN”.

• The servomotor will be fully closed about

1 second.

• During this 1 second, move the main

switch to “OFF”.

• The servomotor will be kept fully closed.

• Check the free play a for the YPVS close

side cables 1.

Out of specification ≥ Adjust.

YPVS close side cable free

play a:

2~3 mm (0.08~0.12 in)

3. Adjust:

• YPVS close side cable free play

Adjusting steps:

• Fully close the servomotor.

• Loosen the locknuts 1.

• Turn the adjusters 2 until the specified

free play is obtained.

• Tighten the locknuts.

INSP

ADJ

EC35F000

YPVS COMPONENTS RETIGHTENING

NOTE:

Before riding the machine, retighten all YPVS

components.

1. Retighten:

• Valve cover 1

4 Nm (0.4 mdkg, 2.9 ftdlb)

• Pulley 2

4 Nm (0.4 mdkg, 2.9 ftdlb)

• Cable stay 3

7 Nm (0.7 mdkg, 5.1 ftdlb)

EC35H030

TRANSMISSION OIL LEVEL CHECK

1. Start the engine, warm it up for several

minutes and wait for five minutes.

2. Place the machine on a level place and

hold it up on upright position by placing the

suitable stand.

TRANSMISSION OIL REPLACEMENT

3-14

3. Check:

• Transmission oil level

INSP

ADJ

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. The

heated oil could spout out, causing dan-

ger.Wait until the oil cools down.

Oil flows out ≥ Oil level is correct.

Oil does not flow out ≥ Oil level is low.

Add transmis-

sion oil until

oil flows out.

Recommended oil:

Castrol R30

• Inspect the gasket (oil check bolt), replace

if damaged.

• Tighten the oil check bolt.

Oil check bolt:

9 Nm (0.9 m•kg, 6.5 ft•lb)

EC35K021

TRANSMISSION OIL REPLACEMENT

1. Start the engine and warm it up for several

minutes and wait for five minutes.

2. Place the machine on a level place and

hold it on upright position by placing the

suitable stand.

3. Place a suitable container under the

engine.

PILOT AIR SCREW ADJUSTMENT

3-15

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.

6. Fill:

• Transmission oil

Recommended oil:

Castrol R30

Oil capacity

(periodic oil change):

0.50 L (0.44 Imp qt, 0.53 US qt)

7. Check:

• Oil leakage

8. Check:

• Transmission oil level

9. Install:

• Oil filler cap 2

EC35L002

PILOT AIR SCREW ADJUSTMENT

1. Adjust:

• Pilot air screw 1

Adjustment steps:

• Screw in the pilot air screw until it is lightly

seated.

• Back out by the specified number of turns.

Ω

Pilot air screw:

1-1/2 turns out

INSP

ADJ

MUFFLER INSPECTION/SILENCER INSPECTION

3-16

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.

INSP

ADJ

CHASSIS/BRAKE SYSTEM AIR BLEEDING

3-17

EC360000

CHASSIS

EC361002

BRAKE SYSTEM AIR BLEEDING

Bleed the brake system if:

• The system has been disassembled.

• A brake hose has been loosened or

removed.

• The brake fluid is very low.

• The brake operation is faulty.

A dangerous loss of braking performance

may occur if the brake system is not prop-

erly bleed.

1. Remove:

• Reservoir tank cap

• Diaphragm

2. Bleed:

• Brake fluid

A Front

B Rear

Air bleeding steps:

a. Add proper brake fluid to the reservoir.

b. Install the diaphragm. Be careful not to

spill any fluid or allow the reservoir to

overflow.

c. Connect the clear plastic tube 2 tightly

to the caliper bleed screw 1.

d. Place the other end of the tube into a

container.

e. Slowly apply the brake lever or pedal

several times.

f. Pull the lever in or push down on the

pedal. Hold the lever or pedal in posi-

tion.

g. Loosen the bleed screw and allow the

lever or pedal to travel towards its limit.

h. Tighten the bleed screw when the lever

or pedal limit has been reached; then

release the lever or pedal.

Bleed screw:

6 Nm (0.6 m•kg, 4.3 ft•lb)

i. Repeat steps ( e ) to ( h ) until of the air

bubbles have been removed from the

system.

INSP

ADJ

FRONT BRAKE ADJUSTMENT/

REAR BRAKE ADJUSTMENT

3-18

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

disappeared.

j. Add brake fluid to the level line on the

reservoir.

Check the operation of the brake after

bleeding the brake system.

3. Install:

• Diaphragm

• Reservoir tank cap

EC363020

FRONT BRAKE ADJUSTMENT

1. Adjust:

• Brake lever position a

Adjustment steps:

• Turn the adjuster 1 while pushing the

brake lever 2 forward until the desired

lever position is obtained.

Closer ≥ Turn the adjuster to a larger

number.

Farther ≥ Turn the adjuster to a smaller

number.

NOTE:

Align the number b on the adjuster with

the mark c on the brake lever.

EC364011

REAR BRAKE ADJUSTMENT

1. Check:

• Brake pedal height a

Out of specification ≥ Adjust.

Brake pedal height a:

148~152 mm (5.8~6.0 in)

INSP

ADJ

FRONT BRAKE PAD INSPECTION AND REPLACEMENT

3-19

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

1. Inspect:

• Brake pad thickness a

Out of specification ≥ Replace as a set.

Brake pad thickness a:

Standard <Limit>

5.3 mm (0.21 in) 1.0 mm (0.04 in)

{

2. Replace:

• Brake pad

Brake pad replacement steps:

• Loosen the pad pin 1 and remove the

caliper 2.

• 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.

• Loosen the bleed screw and push the

caliper piston in.

CAUTION:

Do not reuse the drained brake fluid.

• Tighten the bleed screw.

Bleed screw:

6 Nm (0.6 m•kg, 4.3 ft•lb)

INSP

ADJ

REAR BRAKE PAD INSPECTION AND REPLACEMENT

3-20

• 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.

• Install the caliper £ and tighten the pad

pin ¢.

™

Bolt (caliper):

35 Nm (3.5 m•kg, 25 ft•lb)

Pad pin:

18 Nm (1.8 m•kg, 13 ft•lb)

3. Inspect:

• Brake fluid level

Refer to “BRAKE FLUID LEVEL INSPEC-

TION” section.

4. Check:

• Brake lever operation

A softy or spongy feeling ≥ Bleed brake

system.

Refer to “BRAKE SYSTEM AIR BLEED-

ING” section.

EC366031

REAR BRAKE PAD INSPECTION AND

REPLACEMENT

1. Inspect:

• Brake pad thickness a

Out of specification ≥ Replace as a set.

Brake pad thickness a:

Standard <Limit>

4.0 mm (0.16 in) 1.0 mm (0.04 in)

{

2. Replace:

• Brake pad

Brake pad replacement steps:

• Loosen the pad pin 1 and remove the

caliper 2.

NOTE:

Before removing the caliper from the

swingarm, loosen the pad pin.

INSP

ADJ

REAR BRAKE PAD INSPECTION AND REPLACEMENT

3-21

• 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.

• Loosen the bleed screw and push the

caliper piston in.

CAUTION:

Do not reuse the drained brake fluid.

• Tighten the bleed screw.

Bleed screw:

6 Nm (0.6 m•kg, 4.3 ft•lb)

• 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.

• Install the caliper £ and tighten the pad

pin ¢.

™

Bolt (caliper):

23 Nm (2.3 m•kg, 17 ft•lb)

Pad pin:

18 Nm (1.8 m•kg, 13 ft•lb)

3. Inspect:

• Brake fluid level

Refer to “BRAKE FLUID LEVEL INSPEC-

TION” section.

4. Check:

• Brake pedal operation

A softy or spongy feeling ≥ Bleed brake

system.

Refer to “BRAKE SYSTEM AIR BLEED-

ING” section.

INSP

ADJ

BRAKE FLUID LEVEL INSPECTION/

SPROCKETS INSPECTION

3-22

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:

DOT #4

• Use only designated quality brake fluid to

avoid poor brake performance.

• Refill with same type and brand of brake

fluid; mixing fluids could result in poor

brake performance.

• Be sure that water or other contaminants

do not enter master cylinder when refill-

ing.

• Clean up spilled fluid immediately to

avoid erosion of painted surfaces or plas-

tic parts.

EC368011

SPROCKETS INSPECTION

1. Inspect:

• Sprocket teeth a

Excessive wear ≥ Replace.

NOTE:

Replace the drive, driven sprockets and drive

chain as a set.

2. Inspect:

• Sprocket damper 1

Wear/Damage ≥ Replace.

INSP

ADJ

DRIVE CHAIN INSPECTION

3-23

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 between the chain

plates. Steam cleaning, high-pressure

washes, certain solvent and kerosene can

damage these O-rings.

3. Inspect:

• O-rings 1 (drive chain)

Damage ≥ Replace drive chain.

• Rollers 2

• Side plates 3

Damage/Wear ≥ Replace drive chain.

4. Measure:

• Drive chain length (10 links) a

Out of specification ≥ Replace.

Drive chain length (10 links):

Limit: 150.1 mm (5.909 in)

INSP

ADJ

DRIVE CHAIN SLACK ADJUSTMENT

3-24

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-rings.

7. Install:

• Link plate 4N

NOTE:

• Press the link plate onto the chain joint using

a chain rivetter 5.

• Rivet the end of the chain joint using a chain

rivetter 6.

• After rivetting the chain joint, make sure its

movement is smooth.

8. Lubricate:

• Drive chain

Drive chain lubricant:

SAE 30~50W motor oil or chain

lubricants suitable for “O-ring”

chains

EC36A042

DRIVE CHAIN SLACK ADJUSTMENT

1. Hold the machine on upright position by

placing the suitable stand.

2. Check:

• Drive chain slack a

Out of specification ≥ Adjust.

Drive chain slack:

40~50 mm (1.6~2.0 in)

INSP

ADJ

DRIVE CHAIN SLACK ADJUSTMENT

3-25

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. Adjust:

• Drive chain slack

Drive chain slack adjustment steps:

• Loosen the axle nut 1 and locknuts 2.

• Adjust chain slack by turning the adjusters

To tighten ≥ Turn adjuster 3 counter-

clockwise.

To loosen ≥ Turn adjuster 3 clockwise.

• Turn each adjuster exactly the same

amount to maintain correct axle align-

ment. (There are marks a on each side of

chain puller alignment.)

NOTE:

Turn the adjuster so that the chain is in line

with the sprocket, as viewed from the rear.

CAUTION:

Too small chain slack will overload the

engine and other vital parts; keep the

slack within the specified limits.

• Tighten the axle nut while pushing down

the drive chain.

Axle nut:

80 Nm (8.0 m•kg, 58 ft•lb)

• Turn out the adjusters to the specified

torque.

Adjuster:

2 Nm (0.2 m•kg, 1.4 ft•lb)

• Tighten the locknuts.

Locknut:

16 Nm (1.6 m•kg, 11 ft•lb)

INSP

ADJ

WHEEL ALIGNMENT ADJUSTMENT

3-26

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.

4. Turn the handlebar left and right to make

the front wheel straight.

NOTE:

• To make the front wheel straight, provide b

and c with the same distance as seen along

the extension of the line a connecting the

rear end of the front wheel 1 and the front

end of the rear wheel 2.

• Figure A shows that the front wheel is

turned clockwise (b > c).

• Figure B shows that the front wheel is

straight (b = c).

5. Check:

• Wheel alignment

With the front wheel straight (b = c),

check whether the distances d and e are

equal.

If not ≥ Adjust.

INSP

ADJ

FRONT FORK INSPECTION/

FRONT FORK TOP END ADJUSTMENT

3-27

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).

• After the adjustment, record the difference in

the graduation between the left and right

chain pullers as it will provide convenience in

your future similar adjustment.

7. Install:

• Lower cowl

EC36C000

FRONT FORK INSPECTION

1. Inspect:

• Front fork smooth action

Operate the front brake and stroke the front

fork.

Unsmooth action/oil leakage ≥ Repair or

replace.

EC36E021

FRONT FORK TOP END ADJUSTMENT

1. Hold the machine on upright position by

placing the suitable stand.

2. Remove:

• Cowling

• Induction guide (left cylinder)

• Front wheel

• Front fender

3. Adjust:

• Front fork top end

INSP

ADJ

Adjustment steps:

• Loosen the pinch bolts (handlebar and

steering damper stay).

• Loosen the pinch bolts (handle crown and

under bracket).

FRONT FORK TOP END ADJUSTMENT

3-28

• Adjust the front fork top end a.

Front fork top end a:

Standard

Extent of adjustment

13 mm (0.51 in)

Zero~13 mm

(Zero~0.51 in)

≠

CAUTION:

Never attempt to install the front fork

beyond the maximum or minimum set-

ting.

Always adjust each front fork to the

same setting. Uneven adjustment can

cause poor handling and loss of stabili-

ty.

• Tighten the pinch bolts (handle crown and

under bracket).

Pinch bolt (handle crown):

20 Nm (2.0 m•kg, 14 ft•lb)

Pinch bolt (under bracket):

23 Nm (2.3 m•kg, 17 ft•lb)

CAUTION:

Tighten the under bracket to specified

torque. If torqued too much, it may

cause the front fork to malfunction.

• Adjust the handlebar position b and

steering damper stay position c.

Handlebar position b:

9 mm (0.35 in)

Steering damper stay position c:

73 mm (2.87 in)

• Tighten the pinch bolts (handlebar and

steering damper stay).

Pinch bolt (handlebar):

7 Nm (0.7 m•kg, 5.1 ft•lb)

Pinch bolt (steering damper stay):

10 Nm (1.0 m•kg, 7.2 ft•lb)

INSP

ADJ

FRONT FORK SPRING PRELOAD ADJUSTMENT

3-29

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.

4. Check:

• Steering smooth action

Turn the handlebar to make sure no parts

are being contacted with others.

Contact ≥ Repair.

5. Install:

• Front fender

• Front wheel

• Induction guide (left cylinder)

• Cowling

EC36F012

FRONT FORK SPRING PRELOAD ADJUST-

MENT

1. Adjust:

• Spring preload

By turning the adjuster 1.

Stiffer a ≥ Increase the spring preload.

(Turn the adjuster 1 in.)

Softer b ≥ Decrease the spring preload.

(Turn the adjuster 1 out.)

INSP

ADJ

Extent of adjustment:

Maximum Minimum

Fully turned-in Fully turned-out

position position

]

FRONT FORK REBOUND DAMPING FORCE

ADJUSTMENT

3-30

• 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 . If a click is heard

just when the adjuster is fully turned out, this

position is zero.

• Preload is 0.5 mm (0.02 in) changed per click

of the adjuster.

CAUTION:

Do not force the adjuster past the minimum

or maximum extent of adjustment. The

adjuster may be damaged.

Always adjust each front fork to the same

setting. Uneven adjustment can cause poor

handling and loss of stability.

Stiffer a ≥ Increase the rebound

damping force. (Turn the

adjuster 1 in.)

Softer b ≥ Decrease the rebound

damping force. (Turn the

adjuster 1 out.)

Extent of adjustment:

Maximum Minimum

Fully turned-in Fully turned-out

position position

]

INSP

ADJ

EC36H010

FRONT FORK REBOUND DAMPING FORCE

ADJUSTMENT

1. Adjust:

• Rebound damping force

By turning the adjuster 1.

FRONT FORK COMPRESSION DAMPING FORCE

ADJUSTMENT

3-31

• STANDARD POSITION:

This is the position which is back by the spe-

cific number of clicks from the fully turned-in

position.

Standard position:

12 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. If a click is heard

just when the adjuster is fully turned in, this

position is zero.

CAUTION:

Do not force the adjuster past the minimum

or maximum extent of adjustment. The

adjuster may be damaged.

Always adjust each front fork to the same

setting. Uneven adjustment can cause poor

handling and loss of stability.

INSP

ADJ

Stiffer a ≥ Increase the compression

damping force. (Turn the

adjuster 1 in.)

Softer b ≥ Decrease the compression

damping force. (Turn the

adjuster 1 out.)

Extent of adjustment:

Maximum Minimum

Fully turned-in Fully turned-out

position position

]

EC36J030

FRONT FORK COMPRESSION DAMPING

FORCE ADJUSTMENT

1. Adjust:

• Compression damping force

By turning the adjuster 1.

REAR SHOCK ABSORBER INSPECTION/

SEAT HEIGHT ADJUSTMENT

3-32

• STANDARD POSITION:

This is the position which is back by the spe-

cific number of clicks from the fully turned-in

position.

Standard position:

12 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. If a click is heard

just when the adjuster is fully turned in, this

position is zero.

CAUTION:

Do not force the adjuster past the minimum

or maximum extent of adjustment. The

adjuster may be damaged.

Always adjust each front fork to the same

setting. Uneven adjustment can cause poor

handling and loss of stability.

EC36K000

REAR SHOCK ABSORBER INSPECTION

1. Inspect:

• Swingarm smooth action

Abnormal noise/Unsmooth action ≥

Grease the pivoting points or repair the piv-

oting points.

Damage/Oil leakage ≥ Replace.

INSP

ADJ

EC36L001

SEAT HEIGHT ADJUSTMENT

1. Remove:

• Fuel tank

2. Adjust:

• Seat height

REAR SHOCK ABSORBER SPRING PRELOAD

ADJUSTMENT

3-33

INSP

ADJ

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:

Standard length

Extent of adjustment

27 mm (1.06 in)

21~33 mm

(0.83~1.30 in)

≠

NOTE:

If the adjuster set length a is changed, the

seat height will be increased or decreased

by twice the change.

CAUTION:

Never attempt to turn the adjuster

beyond the maximum or minimum

length.

• Tighten the lock bolt and locknut.

Lock bolt:

40 Nm (4.0 m•kg, 29 ft•lb)

Locknut:

38 Nm (3.8 m•kg, 27 ft•lb)

• Install the cap.

3. Install:

• Fuel tank

EC36M051

REAR SHOCK ABSORBER SPRING PRE-

LOAD ADJUSTMENT

1. Hold the machine on upright position by

placing the suitable stand.

2. Loosen:

• Locknut 1

NOTE:

When loosening the locknut, use the special

tool 2 which is included in the owner’s tool kit.

3. Adjust:

• Spring preload

By turning the adjuster 3.

Stiffer ≥ Increase the spring preload.

(Turn the adjuster 3 in.)

Softer ≥ Decrease the spring preload.

(Turn the adjuster 3 out.)

REAR SHOCK ABSORBER REBOUND DAMPING

FORCE ADJUSTMENT

3-34

Spring length (installed) a:

Standard length

Extent of adjustment

137 mm (5.39 in)

133~142 mm

(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.

4. Tighten:

• Locknut

20 Nm (2.0 mdkg, 14 ftdlb)

EC36N040

REAR SHOCK ABSORBER REBOUND

DAMPING FORCE ADJUSTMENT

1. Adjust:

• Rebound damping force

By turning the adjuster 1.

INSP

ADJ

Stiffer a ≥ Increase the rebound damp-

ing force. (Turn the adjuster

1 in.)

Softer b ≥ Decrease the rebound

damping force. (Turn the

adjuster 1 out.)

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-in

position.

Standard position:

20 clicks out

REAR SHOCK ABSORBER COMPRESSION DAMPING

FORCE ADJUSTMENT

3-35

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.

CAUTION:

Do not force the adjuster past the minimum

or maximum extent of adjustment. The

adjuster may be damaged.

EC36P040

REAR SHOCK ABSORBER COMPRESSION

DAMPING FORCE ADJUSTMENT

1. Adjust:

• Compression damping force

By turning the adjuster 1.

INSP

ADJ

Stiffer a ≥ Increase the compression

damping force. (Turn the

adjuster 1 in.)

Softer b ≥ Decrease the compression

damping force. (Turn the

adjuster 1 out.)

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-in

position.

Standard position:

12 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. If a click is heard

just when the adjuster is fully turned in, this

position is zero.

CAUTION:

Do not force the adjuster past the minimum

or maximum extent of adjustment. The

adjuster may be damaged.

TIRE PRESSURE CHECK/TIRE INSPECTION/

WHEEL INSPECTION

3-36

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.

1Air gauge

EC36R000

TIRE INSPECTION

1. Inspect:

• Tire surfaces

Wear/Damage ≥ Replace.

Minimum tire tread depth a:

2 mm (0.08 in)

EC36T000

WHEEL INSPECTION

1. Inspect:

• Wheel runout

Elevate the wheel and turn it.

Abnormal runout ≥ Replace.

INSP

ADJ

2. Inspect:

• Bearing free play

Exist play ≥ Replace.

STEERING HEAD INSPECTION AND ADJUSTMENT

3-37

EC36U060

STEERING HEAD INSPECTION AND

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.

Free play ≥ Adjust steering head.

4. Check:

• Steering smooth action

Turn the handlebar lock to lock.

Unsmooth action ≥ Adjust steering ring

nut.

Steering ring nut adjustment steps:

• Remove the cowling.

• Remove the reservoir tank and handle

crown.

• Loosen the ring nut 1 using ring nut

wrench 2.

Ring nut wrench:

YU-33975/90890-01403

INSP

ADJ

5. Adjust:

• Steering ring nut

STEERING DAMPER ADJUSTMENT

3-38

• 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.

Ring nut wrench:

YU-33975/90890-01403

Ring nut (initial tightening):

46 Nm (4.6 m•kg, 33 ft•lb)

• Loosen the ring nut one turn.

• Retighten the ring nut using the ring nut

wrench.

Avoid over-tightening.

Ring nut (final tightening):

1 Nm (0.1 m•kg, 0.7 ft•lb)

• Check the steering shaft by turning it lock

to lock. If there is any binding, remove the

steering shaft assembly and inspect the

steering bearings.

• Install the handle crown 5 and reservoir

tank 6.

Steering shaft nut 7:

80 Nm (8.0 m•kg, 58 ft•lb)

Pinch bolt (front fork) 8:

20 Nm (2.0 m•kg, 14 ft•lb)

Bolt (reservoir tank) 9:

5 Nm (0.5 m•kg, 3.6 ft•lb)

• Install the cowling.

6. Install:

• Steering damper

EC36V002

STEERING DAMPER ADJUSTMENT

1. Adjust:

• Damping force

By turning the adjuster 1.

INSP

ADJ

Stiffer a ≥ Increase the compression

damping force. (Turn the

adjuster 1 in.)

Softer b ≥ Decrease the compression

damping force. (Turn the

adjuster 1 out.)

WIRES, CABLES/

COWLING INSTALLATION INSPECTION

3-39

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.

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 out, this

position is zero.

CAUTION:

Do not force the adjuster past the minimum

or maximum extent of adjustment. The

adjuster may be damaged.

EC36X001

WIRES, CABLES

1. Inspect:

• Smooth movement for steering handle

By turning the handlebar lock to lock.

If any caught/rubbed ≥ Repair/Replace.

INSP

ADJ

EC36Z001

COWLING INSTALLATION INSPECTION

1. Inspect:

• Cowling

Loose ≥ Tighten.

Stroke the front fork to make sure no parts

are being contacted with others.

Contact ≥ Repair or replace.

• Screen

Scratches/fogging ≥ Clean or replace.

FUEL TANK INSTALLATION INSPECTION

3-40

EC36e000

FUEL TANK INSTALLATION INSPECTION

1. Inspect:

• Looseness in the installed fuel tank

Loose ≥ Adjust.

2. Loose the nut 1 and screw in the bolt 2 a

half turn. Then fasten the bolt with the nut.

Repeat this until tight.

CAUTION:

Take care so that the bolt protruding length

a is not 29 mm (1.14 in) or over.

INSP

ADJ

LUBRICATION

3-41

EC36a023

LUBRICATION

To ensure smooth operation of all components

lubricate your machine during setup, after

break-in, and after every race.

1 All control cable

2 Brake and clutch lever pivots

3 Throttle-to-handlebar contact

4 Drive chain

5 Throttle cable end

6 Clutch cable end

INSP

ADJ

A Use Yamaha cable lube or equivalent on

these areas.

B Use SAE 10W30 motor oil or suitable chain

lubricants.

C Lubricate the following areas with high

quality, lightweight lithium-soap base

grease.

CAUTION:

Wipe off any excess grease, and avoid get-

ting grease on the brake discs.

A A A

B C C

ELECTRICAL/SPARK PLUG INSPECTION

3-42

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.

NOTE:

When the engine runs for many hours at low

speeds, the spark plug insulator will become

sooty, even if the engine and carburetor are in

good operating condition.

3. Measure:

• Plug gap a

Use a wire gauge or thickness gauge.

Out of specification ≥ Regap.

Spark plug gap:

0.5~0.6 mm (0.020~0.024 in)

Standard spark plug:

R6179A-105P

4. Clean the plug with a spark plug cleaner if

necessary.

5. Tighten:

• Spark plug

19 Nm (1.9 mdkg, 13 ftdlb)

NOTE:

• Before installing a spark plug, clean the gas-

ket surface and plug surface.

• Finger-tighten a the spark plug before

torquing to specification b.

INSP

ADJ

IGNITION TIMING CHECK

3-43

2. Attach:

• Dial gauge 1

• Dial gauge stand 2

To left cylinder head.

Dial gauge:

YU-3097/90890-01252

Stand:

YU-1256

3. Rotate the magneto rotor 1 until the piston

reaches top dead center (TDC). When this

happens, the needle on the dial gauge will

stop and reverse directions even though

the rotor is being turned in the same direc-

tion.

4. Set the dial gauge to zero at TDC.

5. From TDC, rotate the rotor clockwise until

the dial gauge indicates that the piston is at

a specified distance from TDC.

Ignition timing:

2.4 mm (0.094 in)

INSP

ADJ

EC372071

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) 2.

• When the portion a of the right pick-up coil

aligns with the punch mark b on the stator,

the right pick-up coil forms an angle of 90˚

with the left pick-up coil, indicating that the

ignition timing is the same for both cylinders.

1. Remove:

• Cowling

• Fuel tank

• Spark plugs (left and right cylinder)

BATTERY INSPECTION

3-44

INSP

ADJ

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:

• Loosen the screws (stator) 1.

• Align the punch marks by turning the sta-

tor 2.

• Tighten the screws (stator).

Screw (stator):

7 Nm (0.7 m•kg, 5.8 ft•lb)

EC375000

BATTERY INSPECTION

To prevent danger, read the battery label

carefully before handling the battery.

1. Connect the checking lead (supplying

parts) 2 to the power supply coupler 1.

2. Check:

• Battery voltage

Out of specification ≥ Replace.

Tester (+) lead ≥ Red lead 3

Tester (-) lead ≥ Black lead 4

Battery voltage

Tester selector

position

12.5V or more DCV-20

RECHARGING BATTERY

3-45

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.

• Do not quick charge the battery.

• For battery replacement, be sure to use a

sealed type specified for the TZ250.

NOTE:

Battery can be recharged using either an MF

battery devoted charger or automobile battery.

[Using the MF battery devoted charger]

1. Remove:

• Seat

• Battery

2. Connect the battery charger 1 for MF bat-

teries to the battery 2 using the checking

lead (supplying parts) 3, and recharge the

battery.

Battery charger (+) lead ≥ Red lead 4

Battery charger (-) lead ≥ Black lead 5

Battery charger for MF batteries:

GS TYPE BC-601-12V

Charging time:

5 hours

Voltage when charged:

12.8V or more

CAUTION:

Make sure that the red and black leads do

not contact each other during recharge.

INSP

ADJ

RECHARGING BATTERY

3-46

[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 ≥

Red lead 4

Automobile battery (-) lead ≥

Black lead 5

Charge time:

3 hours

Voltage when charged:

12.8V or more

(or 12.5V or more)

Voltage of the automobile battery

for power supply:

12.8~13.8V (maximum 14.9V)

NOTE:

If the battery is recharging using an automo-

bile battery, the charge may not exceed 12.8V.

Then, 12.5V or more will be OK.

CAUTION:

• For an automobile battery for supply, use

a battery with a capacity of 12V20Ah or

more with a voltage 12.8 to 13.2.

• During the battery recharge, do not

recharge the power supply battery by

starting or running the engine.

• Connect only one battery for recharge.

INSP

ADJ

COWLING, INDUCTION GUIDE, SEAT AND FUEL TANK

4-1

ENG

EC400000

ENGINE

EC4V0000

COWLING, INDUCTION GUIDE, SEAT AND FUEL TANK

Extend of removal: 1 Cowling removal 2 Induction guide removal

3 Seat removal 4 Fuel tank removal

Extend of removal Order Part name Q’ty Remarks

COWLING, INDUCTION GUIDE,

SEAT AND FUEL TANK

REMOVAL

Preparation for Turn the fuel cock to “OFF”.

removal Disconnect the fuel hose.

1 Clip (lower cowl) 1

2 Quick fastener 5

3 Lower cowl 1

4 Clip (upper cowl) 3

5 Upper cowl 1

6 Induction guide (left cylinder) 1

7 Induction guide (right cylinder) 1

8 Screw (seat) 4

9 Seat 1

10 Fuel tank breather hose 1 Refer to “REMOVAL POINTS”.

11 Clip (fuel tank) 1

12 Fuel tank 1

8 Nm (0.8 mdkg, 5.8 ftdlb)

4 Nm (0.4 mdkg, 2.9 ftdlb)

COWLING, INDUCTION GUIDE, SEAT AND FUEL TANK

4-2

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.

ENG

EXHAUST PIPE AND SILENCER

4-3

ENG

EC4S0000

EXHAUST PIPE AND SILENCER

Extend of removal: 1 Exhaust pipe removal 2 Silencer removal

Extend of removal Order Part name Q’ty Remarks

EXHAUST PIPE AND

SILENCER REMOVAL

Preparation for Lower cowl Refer to “COWLING, INDUCTION

removal GUIDE, SEAT AND FUEL TANK”

section.

1 Tension spring 2ea.

2 Bolt (exhaust pipe) 1ea.

3 Exhaust pipe 1ea.

4 Bolt (silencer) 2ea.

5 Silencer 1ea.

11 Nm (1.1 mdkg, 8.0 ftdlb)

21 Nm (2.1 mdkg, 15 ftdlb)

RADIATOR

4-4

ENG

EC450001

RADIATOR

Extend of removal: 1 Radiator removal

Extend of removal Order Part name Q’ty Remarks

RADIATOR REMOVAL

Preparation for Cowling, induction guide Refer to “COWLING, INDUCTION

removal and fuel tank GUIDE, SEAT AND FUEL TANK”

section.

Drain the cooling water. Refer to “COOLANT REPLACEMENT”

section in the CHAPTER 3.

1 Water temperature gauge lead 1

2 Thermo unit 1

3 Radiator hose 2 1

4 Radiator hose 4 1

5 Radiator hose 3 1

6 Radiator breather hose 1

7 Radiator 1

2 Nm (0.2 mdkg, 1.4 ftdlb)

7 Nm (0.7 mdkg, 5.1 ftdlb)

11 Nm (1.1 mdkg, 8.0 ftdlb)

RADIATOR

4-5

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

radiator cap by the following procedure:

Place a thick rag, like a towel, over the radi-

ator cap, slowly rotate the cap counter-

clockwise to the detent. This procedure

allows any residual pressure to escape.

When the hissing sound has stopped,

press down on the cap while turning coun-

terclockwise and remove it.

EC454000

INSPECTION

EC444100

Radiator

1. Inspect:

• Radiator core 1

Obstruction ≥ Blow out with compressed

air through rear of the radiator.

Bent fin ≥Repair/replace.

ENG

EC455000

ASSEMBLY AND INSTALLATION

EC455141

Radiator

1. Install:

• Radiator 1

• Bolt (radiator) 2

7 Nm (0.7 mdkg, 5.1 ftdlb)

• Nut (radiator) 3

7 Nm (0.7 mdkg, 5.1 ftdlb)

RADIATOR

4-6

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)

• Gasket 5N

• Thermo unit 6

11 Nm (1.1 mdkg, 8.0 ftdlb)

• Water temperature gauge lead 7

NOTE:

Insert the end of the radiator breather hose

into the frame. Refer to “CONTROL FUNC-

TION” section in the CHAPTER 1.

ENG

CARBURETOR AND REED VALVE

4-7

ENG

EC460000

CARBURETOR AND REED VALVE

Extend of removal Order Part name Q’ty Remarks

CARBURETOR AND

REED VALVE REMOVAL

Preparation for Cowling, induction guide Refer to “COWLING, INDUCTION

removal and fuel tank GUIDE, SEAT AND FUEL TANK”

section.

Spark plug cap (left cylinder)

Radiator hose 3 Refer to “RADIATOR”

section.

Bolt (radiator stay) Shift the radiator Servicing the

forward. right cylinder

Tension spring [exhaust pipe

(left cylinder)]

2 Nm (0.2 mdkg, 1.4 ftdlb)

11 Nm (1.1 mdkg, 8.0 ftdlb)

1 Nm (0.1 mdkg, 0.7 ftdlb)

CARBURETOR AND REED VALVE

4-8

ENG

Extend of removal: 1 Carburetor removal 2 Reed valve removal

Extend of removal Order Part name Q’ty Remarks

1 Induction cap (left cylinder) 1 Servicing the left cylinder

2 Solenoid valve lead 1ea. Disconnect the solenoid valve lead.

3 Clamp (carburetor joint) 1ea. Loosen the screw (carburetor joint).

4 Carburetor 1ea.

5 Fuel hose 1ea.

6 Grommet 2 Pull up by slit end. Servicing the

7 Induction cap (right cylinder) 1 right cylinder

8 Induction box 1ea.

9 Carburetor joint 1ea.

10 Reed valve assembly 1ea.

11 Stopper (reed valve) 2ea.

12 Reed valve 2 2ea.

13 Reed valve 1 2ea.

2 Nm (0.2 mdkg, 1.4 ftdlb)

11 Nm (1.1 mdkg, 8.0 ftdlb)

1 Nm (0.1 mdkg, 0.7 ftdlb)

CARBURETOR AND REED VALVE

4-9

ENG

EC468000

CARBURETOR DISASSEMBLY

Extend of removal: 1 Carburetor disassembly

Extend of removal Order Part name Q’ty Remarks

CARBURETOR DISASSEMBLY

1 Mixing chamber top 1

2 Throttle valve 1 Refer to “REMOVAL POINTS”.

3 Needle holder 1

4 Jet needle 1

5 Starter plunger 1

6 Float chamber 1

7 Power jet 1

8 Float pin 1

9 Float 1

0 Valve seat 1

¡ Main jet 1

™ Main nozzle 1

£ Pilot jet 1

¢ Pilot air screw 1

∞ Solenoid valve 1

2 Nm (0.2 mdkg, 1.4 ftdlb)

CARBURETOR AND REED VALVE

4-10

EC466010

HANDLING NOTE

CAUTION:

Do not disassemble the venturi block 1

because it will cause a drop in carburetor

performance.

EC463000

REMOVAL POINTS

EC463110

Throttle valve

1. Remove:

• Throttle valve 1

• Ring 2

• Spring (throttle valve) 3

• Mixing chamber top 4

• Throttle cable 5

NOTE:

While compressing the spring (throttle valve),

disconnect the throttle cable.

ENG

EC464000

INSPECTION

EC464120

Carburetor

1. Inspect:

• Carburetor body

Contamination ≥ Clean.

NOTE:

• Use a petroleum based solvent for cleaning.

Blow out all passages and jets with com-

pressed air.

• Never use a wire.

2. Inspect:

• Main jet 1

• Main nozzle 2

• Pilot jet 3

• Power jet 4

Contamination ≥ Clean.

NOTE:

• Use a petroleum based solvent for cleaning.

Blow out all passages and jets with com-

pressed air.

• Never use a wire.

CARBURETOR AND REED VALVE

4-11

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. Check:

• Free movement

Stick ≥ Repair or replace.

NOTE:

Insert the throttle valve 1 into the carburetor

body, and check for free movement.

EC464420

Jet needle

1. Inspect:

• Jet needle 1

Bends/Wear ≥ Replace.

• Clip groove

Free play exists/Wear ≥ Replace.

ENG

EC464802

FUEL LEVEL

1. Measure:

• Fuel level a

Out of specification ≥ Adjust.

Fuel level:

6.0~7.0 mm (0.24~0.28 in)

Above the float chamber mat-

ing surface

Measurement and adjustment steps:

• Remove the drain plug.

• Connect the fuel level gauge adapter 2

and fuel level gauge 1 to the float cham-

ber.

Fuel level gauge adapter:

YM-1470/90890-01470

Fuel level gauge:

YM-1312-A/90890-01312

≤

CARBURETOR AND REED VALVE

4-12

EC464600

Float

1. Inspect:

• Float 1

Damage ≥ Replace.

ENG

• 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.

• If the fuel level is not within specification,

inspect the valve seat and needle valve.

• If either is worn, replace them both.

• If both are fine, adjust the fuel level by

bending the float tab b on the float.

• Recheck the fuel level.

EC464701

Reed valve

1. Measure:

• Reed valve bending a

Out of specification ≥ Replace.

Reed valve bending limit:

0.2 mm (0.008 in)

• Valve stopper height b

Out of specification ≥ Adjust stopper/Replace

valve stopper.

Valve stopper height:

6.5~6.9 mm (0.256~0.272 in)

CARBURETOR AND REED VALVE

4-13

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

• Stopper (reed valve) 3

• Screw (reed valve) 4

1 Nm (0.1 mdkg, 0.7 ftdlb)

NOTE:

• Install the reed valve with the reed valve

bending as shown.

• Note the cut a in the lower corner of the

reed and stopper plate.

CAUTION:

Tighten each screw gradually to avoid

warping.

2. Install:

• Gasket (reed valve assembly) 1N

• Reed valve assembly 2

NOTE:

Install the gasket (left cylinder) with its projec-

tion a facing upward and the seal print side

toward the crankcase.

ENG

CARBURETOR AND REED VALVE

4-14

ENG

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. Install:

• Solenoid valve 1

To carburetor 2.

Note the following installation points:

• Screw in the pilot air screw until it is lightly

seated.

• Back out it by the specified number of

turns.

Ω

Pilot air screw:

1-1/2 of turns out

3. Install:

• Main nozzle 1

• Main jet 2

• Pilot jet 3

• Valve seat 4

• Screw (valve seat) 5

2. Install:

• Pilot air screw 1

8. Install:

• Induction cap 1 (right cylinder only)

• Starter plunger 2

To carburetor 3.

NOTE:

Install the stater plunger (right cylinder) after

passing it through the hole a of the induction

cap. Refer to “CABLE ROUTING DIAGRAM”

section in the CHAPTER 2.

CARBURETOR AND REED VALVE

4-15

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. Install:

• Power jet 1

To float chamber 2.

CAUTION:

Do not tighten the power jet too hard, or

you may not remove it when checking and

replacing it.

6. Install:

• Float chamber 1

• Screw (float chamber) 2

CAUTION:

Do not confuse the left and right float

chambers in installation because they are

different from each other.The overflow hole

a is in the bottom of the float chamber for

the left cylinder and for the right one in the

side.

7. Install:

• Air vent hose 1

• Joint 2

ENG

CARBURETOR AND REED VALVE

4-16

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

• Ring 4

• Throttle valve 5

NOTE:

• Install the throttle cable (right cylinder) after

passing it through the hole a of the induction

cap. Refer to “CABLE ROUTING DIAGRAM”

section in the CHAPTER 2.

• While compressing the spring, connect the

throttle cable.

• Align the projection b on the ring with the

groove c in the needle holder 6.

11.Install:

• Mixing chamber top 1

• Screw (mixing chamber top) 2

2 Nm (0.2 mdkg, 1.4 ftdlb)

• Fuel hose 3

To carburetor 4.

NOTE:

• Install the fuel hose (right cylinder) after

passing it through the hole a of the induction

cap. Refer to “CABLE ROUTING DIAGRAM”

section in the CHAPTER 2.

• After installing, check the throttle grip for

smooth movement.

ENG

CARBURETOR AND REED VALVE

4-17

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

induction cap. Refer to “CABLE ROUTING

DIAGRAM” section in the CHAPTER 2.

4. Install:

• Induction cap 1 (left cylinder only)

ENG

5. Install:

• Grommet 1 (right cylinder only)

• Band 2 (right cylinder only)

CYLINDER HEAD, CYLINDER AND PISTON

4-18

ENG

EC470000

CYLINDER HEAD, CYLINDER AND PISTON

EC478000

CYLINDER HEAD AND CYLINDER

Extend of removal: 1 Cylinder head removal 2 Cylinder removal

Extend of removal Order Part name Q’ty Remarks

CYLINDER HEAD AND

CYLINDER REMOVAL

Preparation for Cowling and fuel tank Refer to “COWLING, INDUCTION

removal GUIDE, SEAT AND FUEL TANK”

section.

Exhaust pipe Refer to “EXHAUST PIPE AND

SILENCER” section.

Radiator hose 3, 4 Disconnect at cylinder head side.

Carburetor (left cylinder)

Servicing the left cylinder

Induction guide (left cylinder)

1 Spark plug 1ea.

2 Cable stay 1ea.

Refer to “REMOVAL POINTS”.

3 YPVS cable 2ea.

4 Bolt (cylinder head) 6ea. Loosen each bolt 1/4 turn, and

remove them after all bolts are

loosened.

5 Cylinder head 1ea.

6 Nut (cylinder) 4ea.

7 Cylinder 1ea.

20 Nm (2.0 mdkg, 14 ftdlb)

15 Nm (1.5 mdkg, 11 ftdlb)

7 Nm (0.7 mdkg, 5.1 ftdlb)

19 Nm (1.9 mdkg, 13 ftdlb)

11 Nm (1.1 mdkg, 8.0 ftdlb)

CYLINDER HEAD, CYLINDER AND PISTON

4-19

ENG

EC478100

PISTON AND POWER VALVE

Extend of removal: 1 Piston and piston ring removal 2 Power valve removal

Extend of removal Order Part name Q’ty Remarks

PISTON REMOVAL

1 Piston pin clip 2ea.

2 Piston pin 1ea.

3 Piston 1ea. Refer to “REMOVAL POINTS”.

4 Small end bearing 1ea.

5 Piston ring 1ea.

6 Valve cover 1ea.

7 Valve shaft 1ea.

8 Power valve 1ea.

9 Valve pulley 1ea.

10 Circlip 2ea.

11 Plain washer 2ea.

12 Oil seal 2ea.

13 Solid bush 2ea.

12 Nm (1.2 mdkg, 8.7 ftdlb)

4 Nm (0.4 mdkg, 2.9 ftdlb)

9 Nm (0.9 mdkg, 6.5 ftdlb)

4 Nm (0.4 mdkg, 2.9 ftdlb)

CYLINDER HEAD, CYLINDER AND PISTON

4-20

EC473000

REMOVAL POINTS

EC473310

YPVS cable

1. Remove:

• Bolt (cable stay) 1

EC473402

Piston and piston ring

1. Remove:

• Piston pin clip 1

NOTE:

Before removing the piston pin clip, cover the

crankcase with a clean rag to prevent the pis-

ton pin clip from falling into the crankcase cav-

ity.

2. Remove:

• Piston pin 1

• Piston 2

• Small end bearing 3

NOTE:

Before removing the piston pin, deburr the clip

groove and pin hole area. If the piston pin

groove is deburred and piston pin is still diffi-

cult to remove, use the piston pin puller 4.

Piston pin puller:

YU-1304/90890-01304

CAUTION:

Do not use a hammer to drive the piston

pin out.

ENG

2. Remove:

• YPVS cable 1

From the valve pulley 2.

NOTE:

Remove the YPVS cable together with the

cable stay 3.

CYLINDER HEAD, CYLINDER AND PISTON

4-21

3. Remove:

• Piston ring 1

NOTE:

Take care not to scratch the piston or damage

the piston ring by expanding it more than nec-

essary.

EC474000

INSPECTION

EC474110

Cylinder head

1. Remove:

• Carbon deposits

Use #400~600 grit wet sandpaper.

2. Inspect:

• Cylinder head water jacket

Crust of minerals/Rust ≥ Remove.

• Cylinder head contact surface

Wear/Damage ≥ Replace.

• Recess of insert portion a

The contact surface b of the insert portion

is recessed below the aluminum portion c

≥ Replace.

EC474211

Cylinder

1. Remove:

• Carbon deposits

Use a rounded scraper 1.

NOTE:

Do not use a sharp instrument. Avoid scratch-

ing the aluminum.

2. Inspect:

• Cylinder inner surface

Score marks ≥ Repair or replace.

Using wet sandpaper (#240), repair in the

same crisscross patterns as the honed

ones.

CAUTION:

• Do not rebore the cylinder.

• Minimize modification by wet sandpaper.

Do not rub too much.

ENG

CYLINDER HEAD, CYLINDER AND PISTON

4-22

3. Inspect:

• Travel distance for cylinder

3,000 km (1,800 miles) or more ≥ Replace.

EC474B00

Piston

1. Inspect:

• Piston crown

Damage and crack due to detonation≥Replace.

• Piston pin hole

Crack≥ Replace.

• Contact with cylinder

Excessive scuffing, score a ≥ Use

#240~320 grit wet sandpaper in a criss-

cross manner b.

• Heat discoloration≥ Replace.

2. Inspect:

• Travel distance for piston

500 km (300 miles) or more≥ Replace.

EC474A00

Contact surface roughening for piston

replacement

NOTE:

• Roughening the cylinder wall for a replaced

piston helps toward smoother contact sur-

faces and prevents trouble that would other-

wise occur.

• If a new piston is installed to a cylinder with-

out honed patterns, the contact surfaces will

not fit properly because of eccentric wear

caused by sliding motion.

1. Inspect:

• Honed patterns on the cylinder wall

Using wet sandpaper (#240), rub the area

without honed patterns in the same criss-

cross patterns as the honed ones (espe-

cially, along the periphery of the exhaust

port).

CAUTION:

Minimize modification by wet sandpaper.

Do not rub too much.

ENG

CYLINDER HEAD, CYLINDER AND PISTON

4-23

2. Measure:

• Piston pin outside diameter

Use micrometer 1.

Out of limit ≥ Replace.

Piston pin outside diameter:

Standard <Limit>

14.995~15.000 mm 14.975 mm

(0.5904~0.5906 in) (0.5896 in)

]

3. Check:

• Free play (when the piston pin 1 is in

place in the piston 2)

There should be no noticeable for the play.

Free play exists ≥ Replace piston pin

and/or piston.

4. Install:

• Small end bearing

• Piston pin

Into the small end of connecting rod.

5. Check:

• Free play

There should be no noticeable free play.

Free play exists ≥ Inspect the connecting

rod for wear/Replace the pin and/or con-

necting rod as required.

ENG

EC474402

Piston pin and small end bearing

1. Inspect:

• Piston pin

• Small end bearing

Signs of heat discoloration ≥ Replace.

CYLINDER HEAD, CYLINDER AND PISTON

4-24

EC474530

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>

0.22~0.37 mm 0.59 mm

(0.009~0.015 in) (0.023 in)

]

ENG

3. Measure:

• Side clearance

Use a thickness gauge 1.

Out of specification ≥ Replace piston

and/or ring.

Side clearance:

Standard <Limit>

Zero~0.06 mm

–

(Zero~0.0024 in)

]

NOTE:

• Insert the thickness gauge deep in the piston

ring groove. Then measure the clearance

with both sliding surfaces being flush with

each other.

• Check at several points.

EC474720

Combination of piston and cylinder

1. Check:

• Cylinder mark a

Cylinder mark a

CYLINDER HEAD, CYLINDER AND PISTON

4-25

ENG

2. Check:

• Piston mark a

Piston mark 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 A(red)

B B(orange)

C C (green)

(

NOTE:

When you purchase a cylinder, you cannot

designate a specific one. Choose the piston

that matches the above chart.

EC474821

Power valve

1. Inspect:

• Power valve 1

Wear/Damage ≥ Replace.

Carbon deposits ≥ Remove.

• Valve shaft 2

• Solid bush 3

• Oil seal 4

Wear/Damage ≥ Replace.

EC474901

Power valve hole on cylinder

1. Remove:

• Carbon deposits

From power valve hole surface a.

NOTE:

Do not use a sharp instrument. Avoid scratch-

ing the aluminum.

EC475000

ASSEMBLY AND INSTALLATION

EC475181

Power valve

1. Install:

• Power valve 1

• Bolt (power valve) 2

9 Nm (0.9 mdkg, 6.5 ftdlb)

NOTE:

Install the power valve at cut-away faced a for

down side.

CYLINDER HEAD, CYLINDER AND PISTON

4-26

ENG

2. Install:

• Solid bush1

• Oil seal 2

• Plain washer 3

• Circlip 4N

• Valve pulley 5

• Screw (valve pulley) 6

4 Nm (0.4 mdkg, 2.9 ftdlb)

To valve shaft 7.

NOTE:

Apply the lithium soap base grease on the

valve shaft and oil seal lip.

3. Lock the pulley holding screw using an

appropriate wire around the groove on the

valve pulley.

4. Install:

• Valve shaft 1

• Valve cover 2

• Screw (valve cover) 3

4 Nm (0.4 mdkg, 2.9 ftdlb)

NOTE:

• Install the valve shaft so that its pulley faces

left of the chassis for the left cylinder and

right of the chassis for the right cylinder.

• When installing the valve shaft into the cylin-

der, lightly touch the solid bush 4 with the oil

seal 5 and provide an equal gap a for the

power valve 6 and valve shaft.

• Clean the contacting surface of the valve

cover and cylinder before applying the

sealant.

Quick gasket®

ACC-YAMAB-ON-D4

YAMAHA Bond No.4

90890-05143

CYLINDER HEAD, CYLINDER AND PISTON

4-27

5. Check:

• Power valve smooth movement

Unsmooth movement ≥ Repair or replace.

EC475271

Piston ring and piston

1. Install:

• Piston ring 1

NOTE:

• Take care not to scratch the piston or dam-

age the piston ring by expanding it more than

necessary.

• Install the piston ring with its mark “N”

upward.

• Align the piston ring gap with the pin 2.

• After installing the piston ring, check the

smooth movement of it.

2. Install:

• Gasket (cylinder) 1N

• Small end bearing 2

• Dowel pin 3

NOTE:

Apply the engine oil on the bearing (crank-

shaft and connecting rod) and connecting rod

big end washers.

CAUTION:

Install the gasket with the letter “CASE” a

on it toward the crankcase.

ENG

CYLINDER HEAD, CYLINDER AND PISTON

4-28

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.

CAUTION:

• When installing the piston pin clip, use

the hand so that it may not be distorted.

• Do not allow the clip open ends to meet

the piston pin slot b.

EC475351

Cylinder head and cylinder

1. Apply:

• Engine oil

To piston 1, piston ring 2 and cylinder

inner surface.

ENG

2. Install:

• Cylinder 1

CAUTION:

Make sure the piston ring is properly posi-

tioned. Install the cylinder with one hand

while compressing the piston ring with the

other hand.

NOTE:

After installing, check the smooth movement

of the piston.

3. Install:

• Nut (cylinder) 1

20 Nm (2.0 mdkg, 14 ftdlb)

NOTE:

Tighten the nuts in stages, using a crisscross

pattern.

CYLINDER HEAD, CYLINDER AND PISTON

4-29

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:

• Apply the lithium soap base grease on the

thread and contact surface of the bolt (cylin-

der head).

• Tighten the bolts (cylinder head) in stage,

using a crisscross pattern.

6. Install:

• YPVS cable 2, 4 (open side) 1

• YPVS cable 1, 3 (close side) 2

To cable stay 3.

NOTE:

Install the open side cables (sleeve a cables)

to the “0” marked b side of the cable stay.

ENG

7. Connect:

• YPVS cable 2, 4 (open side) 1

• YPVS cable 1, 3 (close side) 2

To valve pulley 3.

NOTE:

Connect thhe silver cables to the left side

cylinder and the black cables to the right cylin-

der. Refer to “CABLE ROUTING DIAGRAM”

section in the CHAPTER 2.

CYLINDER HEAD, CYLINDER AND PISTON

4-30

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.

10.Install:

• Spark plug 1

19 Nm (1.9 mdkg, 13 ftdlb)

• Spark plug cap 2

• Radiator hose 3 3

2 Nm (0.2 mdkg, 1.4 ftdlb)

• Radiator hose 4 4

2 Nm (0.2 mdkg, 1.4 ftdlb)

ENG

CLUTCH

4-31

ENG

EC4A0000

CLUTCH

EC4A8000

CLUTCH PLATE AND FRICTION PLATE

Extend of removal: 1 Clutch plate and friction plate removal

Extend of removal Order Part name Q’ty Remarks

CLUTCH PLATE AND

FRICTION PLATE REMOVAL

Preparation for Lower cowl Refer to “COWLING, SEAT AND

removal FUEL TANK” section.

1 Screw (clutch spring) 6

2 Clutch spring 6

3 Pressure plate 1

4 Friction plate 6

5 Clutch plate 5

6 Nm (0.6 mdkg, 4.3 ftdlb)

9 Nm (0.9 mdkg, 6.5 ftdlb)

CLUTCH

4-32

ENG

EC4A8200

CLUTCH HOUSING AND PUSH ROD

Extend of removal: 1 Clutch housing removal 2 Push rod removal

Extend of removal Order Part name Q’ty Remarks

CLUTCH HOUSING AND

PUSH ROD REMOVAL

1 Nut (clutch boss) 1

2 Lock washer 1

Use special tool.

3 Clutch boss 1

Refer to “REMOVAL POINTS”.

4 Plain washer 1

5 Clutch housing 1

6 O-ring 1

7 Bearing 1

8 Spacer 1 1

9 Ball 1

10 Push rod 1

75 Nm (7.5 mdkg, 54 ftdlb)

CLUTCH

4-33

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 . . . . . . . . . . . . . . . .4

90890-04086 . . . . . . . . . . . . . .5

A For USA and CDN

B Except for USA and CDN

EC4A4000

INSPECTION

EC484100

Clutch housing and boss

1. Inspect:

• Clutch housing 1

Cracks/Wear/Damage ≥ Replace.

• Clutch boss 2

Scoring/Wear/Damage ≥ Replace.

EC4A4100

Clutch housing

1. Check:

• Circumferential play

Free play exists ≥ Replace.

• Gear teeth a

Wear/Damage ≥ Replace.

• O-ring 1

Damage ≥ Replace.

EC484400

Clutch spring

1. Measure:

• Clutch spring free length a

Out of specification ≥ Replace springs as

a set.

Clutch spring free length:

Standard <Limit>

30.6 mm (1.205 in) 29.6 mm (1.165 in)

{

ENG

CLUTCH

4-34

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. Measure:

• Clutch plate warpage

Out of specification ≥ Replace clutch

plate as a set.

Use a surface plate 1 and thickness

gauge 2.

Warp limit:

0.1 mm (0.004 in)

ENG

EC4A4301

Push rod

1. Inspect:

• Push rod 1

• Ball 2

Wear/Damage/Bend ≥ Replace.

Bending limit:

0.2 mm (0.008 in)

NOTE:

The bending value is shown by one half of the

dial gauge reading.

CLUTCH

4-35

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.

3. Install:

• O-ring 1N

To clutch housing 2.

NOTE:

Apply the lithium soap base grease on the O-

ring.

ENG

4. Install:

• Clutch housing 1

5. Install:

• Plain washer 1

• Clutch boss 2

CLUTCH

4-36

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 in the clutch boss.

Clutch holding tool:

YM-91042 . . . . . . . . . . . . . . . .3

90890-04086 . . . . . . . . . . . . . .4

A For USA and CDN

B Except for USA and CDN

7. Bend the lock washer 1 tab.

8. Install:

• Friction plate (yellow) 1

• Clutch plate 2

• Friction plate (brown) 3

NOTE:

• Install the clutch plates and friction plates

alternately on the clutch boss, starting with a

friction plate and ending with a friction plate.

• Yellow colored friction plates are used for the

first and final.

• This machine is equipped with a dry type

clutch. Be sure to clean with solvent or

replace if grease or oil contacts either clutch

or friction plates.

ENG

CLUTCH

4-37

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.Install:

• Clutch spring 1

• Screw (clutch spring) 2

9 Nm (0.9 mdkg, 6.5 ftdlb)

NOTE:

Tighten the screws in stages, using a criss-

cross pattern.

ENG

12.Check:

• Push lever position

Push the push lever 1 upward until it

stops. With the push lever in this position,

the rear edge a of the push lever should

be aligned with the center of the push lever

installation bolt 2.

Not aligned ≥ Adjust.

13.Adjust:

• Push lever position

Push lever position adjustment steps:

• Loosen the locknut 1.

• Turn the adjuster 2 to align the rear edge

of the push lever with the center of the

push lever installation bolt.

• Tighten the locknut.

Locknut:

6 Nm (0.6 m•kg, 4.3 ft•lb)

PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR

AND BALANCER SHAFT

4-38

ENG

EC4D0002

PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR

AND BALANCER SHAFT

EC4D8000

PRIMARY DRIVEN GEAR

Extend of removal: 1 Primary driven gear removal

Extend of removal Order Part name Q’ty Remarks

PRIMARY DRIVEN GEAR REMOVAL

Preparation for Cowling Refer to “COWLING, INDUCTION

removal GUIDE, SEAT AND FUEL TANK”

section.

Clutch Refer to “CLUTCH” section.

Drain the transmission oil. Refer to “TRANSMISSION OIL

REPLACEMENT” section in the

CHAPTER 3.

1 Crankcase cover (right) 1

2 Primary driven gear 1

3 Oil pump drive gear 1

4 Thrust plate 1

11 Nm (1.1 mdkg, 8.0 ftdlb)

PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR

AND BALANCER SHAFT

ENG

EC4D8100

PRIMARY DRIVE GEAR AND BALANCER SHAFT

Extend of removal: 1 Primary drive gear removal 2 Balancer shaft removal

Extend of removal Order Part name Q’ty Remarks

PRIMARY DRIVE GEAR AND

BALANCER SHAFT REMOVAL

1 Bolt (primary drive gear) 1

2 Primary drive gear 1

3 Balancer drive gear 1

4 Nut (balancer weight gear) 1

Refer to “REMOVAL POINTS”.

5 Lock washer 1

6 Balancer weight gear 1

7 Collar 1

8 Crankcase cover (left) 1

9 Balancer shaft 1

11 Nm (1.1 mdkg, 8.0 ftdlb)

50 Nm (5.0 mdkg, 36 ftdlb)

55 Nm (5.5 mdkg, 40 ftdlb)

4-39

PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR

AND BALANCER SHAFT

4-40

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.

2. Loosen:

• Nut (balancer weight gear) 1

NOTE:

Straighten the lock washer 2 tab and place

an aluminum plate a between the teeth of the

balancer drive gear 3 and balancer weight

gear 4.

3. Remove:

• Bolt (primary drive gear) 1

• Primary drive gear 2

• Balancer drive gear 3

• Nut (balancer weight gear) 4

• Lock washer 5

• Balancer weight gear 6

NOTE:

It may sometimes happens that the primary

drive gear and balancer drive gear are fitted

too tight as in force fitting. In that case, use a

general gear puller to remove them without

too much force on the crankshaft.

EC4D4000

INSPECTION

EC4D4100

Primary drive gear, primary driven gear

and oil pump drive gear

1. Inspect:

• Primary drive gear 1

• Primary driven gear 2

• Oil pump drive gear 3

Wear/Damage ≥ Replace.

ENG

PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR

AND BALANCER SHAFT

4-41

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 ≥ Replace.

• Crankcase cover (right)

Cracks/Damage ≥ Replace.

• Oil seal 1

Wear/Damage ≥ Replace.

EC4D4500

Balancer shaft

1. Inspect:

• Balancer shaft 1

Bend/Wear/Damage ≥ Replace.

EC4D5000

ASSEMBLY AND INSTALLATION

EC4D5130

Balancer shaft and primary drive gear

1. Install:

• Balancer shaft 1

• Collar 2

2. Install:

• Gasket [crankcase cover (left)]N

• Crankcase cover (left) 1

• Bolt [crankcase cover (left)] 2

11 Nm (1.1 mdkg, 8.0 ftdlb)

NOTE:

Install the gasket and crankcase cover (left)

with their recesses a facing the rotor 3.

ENG

PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR

AND BALANCER SHAFT

4-42

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

drive gear) with d (balancer weight gear) as

shown.

5. Install:

• Lock washer 1N

• Nut (balancer weight gear) 2

• Primary drive gear 3

• Plain washer 4

• Bolt (primary drive gear) 5

NOTE:

Install the plain washer with its chamfered por-

tion a toward you.

6. Tighten:

• Nut (balancer weight gear) 1

50 Nm (5.0 mdkg, 36 ftdlb)

NOTE:

Place an aluminum plate a between the teeth

of the balancer drive gear 2 and balancer

weight gear 3.

ENG

7. Bend the lock washer 1 tab.

PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR

AND BALANCER SHAFT

4-43

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.

EC4D5212

Primary driven gear

1. Install:

• Primary driven gear 1

• Oil pump drive gear 2

To crankcase cover (right) 3.

NOTE:

Apply the lithium soap base grease on the oil

seal lip.

2. Install:

• Thrust plate 1

• Dowel pin 2

• Gasket [crankcase cover (right)] 3N

NOTE:

Install the thrust plate with its larger diameter

side a toward the transmission.

3. Install:

• Crankcase cover (right) 1

NOTE:

Mesh the primary drive gear 2 with the prima-

ry driven gear 3, and the oil pump drive gear

4 with the oil pump driven gear 5 by turning

the rotor.

4. Install:

• Bolt [crankcase cover (right)] 1

11 Nm (1.1 mdkg, 8.0 ftdlb)

NOTE:

Tighten the bolts in stages, using a crisscross

pattern.

ENG

SHIFT SHAFT

4-44

ENG

EC4F0000

SHIFT SHAFT

22 Nm (2.2 mdkg, 16 ftdlb)

8 Nm (0.8 mdkg, 5.8 ftdlb)

75 Nm (7.5 mdkg, 54 ftdlb)

11 Nm (1.1 mdkg, 8.0 ftdlb)

16 Nm (1.6 mdkg, 11 ftdlb)

10 Nm (1.0 mdkg, 7.2 ftdlb)

11 Nm (1.1 mdkg, 8.0 ftdlb)

14 Nm (1.4 mdkg, 10 ftdlb)

9 Nm (0.9 mdkg, 6.5 ftdlb)

Extend of removal: 1 Shift shaft removal 2 Stopper lever removal

Extend of removal Order Part name Q’ty Remarks

SHIFT SHAFT REMOVAL

Preparation for Crankcase cover (right) Refer to “PRIMARY DRIVEN GEAR,

removal PRIMARY DRIVE GEAR AND

BALANCER SHAFT” section.

1 Nut (drive sprocket) 1

2 Lock washer 1 Refer to “REMOVAL POINTS”.

3 Drive sprocket 1

4 Shift arm 1

5 Transmission housing 1 Refer to “REMOVAL POINTS”.

6 Circlip 1

7 Shift shaft 1

8 Roller 1

9 Shift guide 1

10 Shift lever assembly 1

Refer to “REMOVAL POINTS”.

11 Stopper lever 1

SHIFT SHAFT

4-45

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

• Drive chain 2

NOTE:

Remove the drive sprocket together with the

drive chain.

EC4F3201

Transmission housing

1. Remove:

• Bolt (transmission housing)

• Transmission housing 1

NOTE:

Remove the transmission housing together

with the transmission, shift cam, shift fork and

shift shaft.

EC4C3101

Shift guide and shift lever assembly

1. Remove:

• Bolt (shift guide)

• Shift guide 1

• Shift lever assembly 2

NOTE:

The shift lever assembly is disassembled at

the same time as the shift guide.

EC4F3401

Stopper lever

1. Remove:

• Stopper lever assembly 1

• Torsion spring 2

• Plain washer

NOTE:

Remove the stopper lever assembly with its

roller aligning with the top a of the segment.

ENG

SHIFT SHAFT

4-46

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. Inspect:

• Shift guide 1

• Shift lever 2

• Pawl 3

• Pawl pin 4

• Spring 5

Wear/Damage ≥ Replace.

EC4B4500

Stopper lever

1. Inspect:

• Stopper lever 1

Wear/Damage ≥ Replace.

• Torsion spring 2

Broken ≥ Replace.

EC4F5000

ASSEMBLY AND INSTALLATION

EC4F5100

Stopper lever

1. Install:

• Stopper lever 1

• Plain washer 2

• Circlip 3N

To collar 4.

NOTE:

Be sure the circlip sharp-edged corner a is

positioned opposite side to the plain washer.

ENG

SHIFT SHAFT

4-47

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:

• When installing the pawl into the shift lever,

make sure the chamfered side a face the

pawl pin side.

• Apply the transmission oil on the pawl pin.

2. Install:

• Shift lever assembly 1

To shift guide 2.

3. Install:

• Shift lever assembly 1

• Shift guide 2

NOTE:

• The shift lever assembly is installed at the

same time as the shift guide.

• Apply the transmission oil on the bolt (seg-

ment) shaft.

4. Install:

• Bolt (shift guide) 1

11 Nm (1.1 mdkg, 8.0 ftdlb)

ENG

SHIFT SHAFT

4-48

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.

3. Check:

• Shift lever position

Checking steps:

• Attach the collar (with supplying parts) 2

onto the roller 1.

• Check the shift lever position.

Gaps a and b are not equal ≥ Adjust.

4. Adjust:

• Shift lever position

ENG

Adjusting steps:

• Loosen the locknut 3.

• Turn the adjuster 4 in or out.

• Tighten the locknut.

Locknut:

9 Nm (0.9 m•kg, 6.5 ft•lb)

• Remove the collar.

SHIFT SHAFT

4-49

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.

3. Install:

•

Bolt {transmission housing [L=40 mm (1.57 in)]}

16 Nm (1.6 mdkg, 11 ftdlb)

•

Bolt {transmission housing [L=30 mm (1.18 in)]}

16 Nm (1.6 mdkg, 11 ftdlb)

NOTE:

• Tighten the bolts in stages, using a criss-

cross pattern.

• Apply the transmission oil on the thread and

contact surface of the bolt (transmission

housing).

4. Install:

• Plain washer 1

• Spacer 2

• Shift arm 3

• Bolt (shift arm) 4

14 Nm (1.4 mdkg, 10 ftdlb)

NOTE:

• Make sure that the joint rod distance a is

104.5~106.5 mm (4.1~4.2 in).

• Install the shift arm so that the shift pedal

center b is highest without exceeding the

inside line c of the footrest bracket.

ENG

SHIFT SHAFT

4-50

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:

• Lock washer 1N

• Nut (drive sprocket) 2

75 Nm (7.5 mdkg, 54 ftdlb)

NOTE:

Tighten the nut while applying the rear brake.

3. Bend the lock washer tab to lock the nut.

ENG

WATER PUMP

4-51

ENG

EC4G0000

WATER PUMP

Extend of removal: 1 Impeller shaft removal 2 Oil seal removal

Extend of removal Order Part name Q’ty Remarks

WATER PUMP DISASSEMBLY

Preparation for Cowling Refer to “COWLING, INDUCTION

removal GUIDE, SEAT AND FUEL TANK”

section.

Drain the cooling water. Refer to “COOLING WATER

REPLACEMENT” section in the

CHAPTER 3.

Transmission housing Refer to “SHIFT SHAFT” section.

1 Radiator hose 2 1

2 Water pump housing cover 1

3 Circlip 1

4 Plain washer 1

5 Impeller shaft 1

6 Bearing 1

7 Oil seal 2

Refer to “REMOVAL POINTS”.

2 Nm (0.2 mdkg, 1.4 ftdlb)

11 Nm (1.1 mdkg, 8.0 ftdlb)

WATER PUMP

4-52

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:

• Bearing 1

2. Remove:

• Oil seal 1

EC4G4000

INSPECTION

EC444200

Impeller shaft

1. Inspect:

• Impeller shaft 1

Bend/Wear/Damage ≥ Replace.

Fur deposits ≥ Clean.

EC4H4600

Bearing

1. Inspect:

• Bearing 1

Rotate inner race with a finger.

Rough spot/Seizure ≥ Replace.

ENG

WATER PUMP

4-53

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.

• Install the oil seal with its manufacture’s

marks or numbers facing the crankcase 2.

2. Install:

• Bearing 1

NOTE:

Install the bearing by pressing its outer race

parallel.

EC4G5203

Impeller shaft

1. Install:

• Impeller shaft 1

NOTE:

• Take care so that the oil seal lip is not dam-

aged or the spring does not slip off its posi-

tion.

• When installing the impeller shaft, apply the

lithium soap base grease on the oil seal lip

and impeller shaft. And install the shaft while

turning it.

2. Install:

• Plain washer 1

• Circlip 2N

To impeller shaft 3.

NOTE:

Be sure the circlip sharp-edged corner a is

positioned opposite side to the plain washer.

ENG

WATER PUMP

4-54

3. Install:

• Dowel pin 1

• Gasket (water pump housing cover) 2N

4. Install:

• Water pump housing cover 1

• Bolt (water pump housing cover) 2

11 Nm (1.1 mdkg, 8.0 ftdlb)

• Copper washer 3N

• Air bleeding bolt (water pump) 4

11 Nm (1.1 mdkg, 8.0 ftdlb)

5. Install:

• Radiator hose 2 1

2 Nm (0.2 mdkg, 1.4 ftdlb)

ENG

TRANSMISSION, SHIFT CAM AND SHIFT FORK

4-55

ENG

EC4H0000

TRANSMISSION, SHIFT CAM AND SHIFT FORK

Extend of removal Order Part name Q’ty Remarks

TRANSMISSION, SHIFT CAM AND

SHIFT FORK REMOVAL

Preparation for Cowling Refer to “COWLING, INDUCTION

removal GUIDE, SEAT AND FUEL TANK”

section.

Transmission housing

Shift shaft and shift lever

Refer to “SHIFT SHAFT” section.

assembly

Stopper lever

7 Nm (0.7 mdkg, 5.1 ftdlb)

23 Nm (2.3 mdkg, 17 ftdlb)

10 Nm (1.0 mdkg, 7.2 ftdlb)

4 Nm (0.4 mdkg, 2.9 ftdlb)

Extend of removal Order Part name Q’ty Remarks

1 Guide bar 1 (short) 1

2 Guide bar 2 (long) 1

3 Shift fork 1 1

4 Shift fork 2 1

5 Shift fork 3 1

6 Thrust plate 1

7 Main axle 1

8 Drive axle 1

Refer to “REMOVAL POINTS”.

9 Bolt (segment) 1

10 Segment 1

Refer to “REMOVAL POINTS”.

11 Shift cam 1

TRANSMISSION, SHIFT CAM AND SHIFT FORK

4-56

ENG

Extend of removal: 1 Shift fork removal 2 Main axle and drive axle removal

3 Shift cam removal

7 Nm (0.7 mdkg, 5.1 ftdlb)

23 Nm (2.3 mdkg, 17 ftdlb)

10 Nm (1.0 mdkg, 7.2 ftdlb)

4 Nm (0.4 mdkg, 2.9 ftdlb)

TRANSMISSION, SHIFT CAM AND SHIFT FORK

4-57

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. Pay particular attention to the

location and direction of shift forks.

EC4H3400

Segment

1. Remove:

• Bolt (segment) 1

• Segment 2

NOTE:

Clamp the shift cam 3 securely in a vise,

using soft protecting material 4 to loosen the

bolt (segment).

EC4H4000

INSPECTION

EC4H4210

Gears

1. Inspect:

• Matching dog a

• Gear teeth b

Wear/Damage ≥ Replace.

ENG

2. Check:

• Gears movement

Unsmooth movement ≥ Repair or replace.

TRANSMISSION, SHIFT CAM AND SHIFT FORK

4-58

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:

Standard <Limit>

5.05~5.18 mm 5.35 mm

(0.199~0.204 in) (0.211 in)

]

EC4H4400

Thrust clearance

1. Check:

• After assembling the transmission, check

whether the idle gear turns smoothly with-

out a thrust.

If the thrust clearance is too large or the

idle gear moves with difficulty ≥ Replace

the shim 1, 2 and 3.

Choose the shims by the following chart.

Part name

Size (thickness)

Part number

Shim 1 STD t=1.0 mm 90201-253K0

(0.039 in)

t=0.9 mm 90201-256E6

(0.035 in)

Shim 2 STD t=1.0 mm 90201-20276

(0.039 in)

t=0.9 mm 90201-206E5

(0.035 in)

Shim 3 STD t=0.7 mm 5F7-17136-00

(0.028 in)

t=0.5 mm 90209-22082

(0.020 in)

NOTE:

It is necessary to adjust the thrust clearance

when the transmission gear, axle, washer, cir-

clip, bearing or crankcase is replaced.

ENG

TRANSMISSION, SHIFT CAM AND SHIFT FORK

4-59

EC4H4501

Dog clearance

NOTE:

• It is necessary to adjust the dog clearance

when the transmission gear, axle, washer,

circlip, 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. But if there are in good condition,

the dog clearance should be inspected.

1. Install the transmission, shift cam and shift

fork into the transmission housing.

2. Position the transmission is neutral.

3. Pull the main axle toward the clutch side.

4. Bring the 3rd/4th pinion gear 1 into light

contact with the 6th pinion gear 2 to the

extent that they are not engaged, and mea-

sure the clearance a between 3rd/4th pin-

ion gear and 6th pinion gear.

Bring the 3rd/4th pinion gear into light con-

tact with the 5th pinion gear 3 to the

extent that they are not engaged and mea-

sure the clearance b between 3rd/4th pin-

ion gear and 5th pinion gear.

Dog clearance a, b:

0.5 mm (0.020 in) or more

Out of specification or clearance a and b

are not equal ≥ Replace the shim 4.

Choose the shim by the following chart.

Part name

Size (thickness)

Part number

Shim 4 STD t=1.0 mm 90201-253K0

(0.039 in)

t=0.9 mm 90201-256E6

(0.035 in)

EC4H4600

Bearing

1. Inspect:

• Bearing 1

Rotate inner race with a finger.

Rough spot/Seizure ≥ Replace.

ENG

TRANSMISSION, SHIFT CAM AND SHIFT FORK

4-60

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:

• Shift fork movement

On its guide bar.

Unsmooth operation ≥ Replace shift fork

and/or guide bar.

NOTE:

For a malfunctioning shift fork, replace not

only the shift fork itself but the two gears each

adjacent to the shift fork.

EC4H5000

ASSEMBLY AND INSTALLATION

EC4H5112

Shift cam

1. Install:

• Shift cam 1

NOTE:

Apply the transmission oil on the shift cam

bearing.

ENG

TRANSMISSION, SHIFT CAM AND SHIFT FORK

4-61

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.

• Clamp the shift cam 3 securely in a vise,

using soft protecting material 4 to tighten

the bolt (segment).

EC4H5232

Transmission

1. Install:

• 6th pinion gear (22T) 1

• 3rd/4th pinion gear (23T/25T) 2

• 5th pinion gear (27T) 3

• 2nd pinion gear (21T) 4

To main axle 5.

NOTE:

Apply the molybdenum disulfide oil on the

gears inner circumference.

2. Install:

• 2nd wheel gear (31T) 1

• 5th wheel gear (26T) 2

• 3rd wheel gear (29T) 3

• 4th wheel gear (27T) 4

• 6th wheel gear (20T) 5

• 1st wheel gear (34T) 6

To drive axle 7.

NOTE:

Apply the molybdenum disulfide oil on the

gears inner circumference.

ENG

TRANSMISSION, SHIFT CAM AND SHIFT FORK

4-62

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.

ENG

TRANSMISSION, SHIFT CAM AND SHIFT FORK

4-63

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. Install:

• Shift fork 1 1

• Shift fork 2 2

• Shift fork 3 3

NOTE:

• Mesh the shift fork #1 with the 5th wheel

gear 4 and #3 with the 6th gear 6 on the

drive axle.

• Mesh the shift fork #2 with the 3rd/4th pinion

gear 5 on the main axle.

6. Install:

• Guide bar 1 (short) 1

• Guide bar 2 (long) 2

NOTE:

• Apply the transmission oil on the guide bars.

• Be sure the short bar is inserted into the shift

fork #2 and the long one into #1 and #3.

7. Check:

• Shift operation

• Transmission operation

Unsmooth operation ≥ Repair.

8. Install:

• Thrust plate 1

• Spacer 1 2

• O-ring 3N

NOTE:

Apply the lithium soap base grease on the O-

ring.

ENG

OIL PUMP

4-64

ENG

EC4J0000

OIL PUMP

Extend of removal: 1 Oil pump removal and disassembly

Extend of removal Order Part name Q’ty Remarks

OIL PUMP REMOVAL

Preparation for Transmission housing

Refer to “SHIFT SHAFT” section.

removal Shift shaft and Stopper lever

Transmission and shift fork Refer to “TRANSMISSION, SHIFT

CAM AND SHIFT FORK” section.

1 Strainer 1

2 Oil pump cover 1

3 Outer rotor 1

4 Inner rotor 1

5 Dowel pin 1

6 Plain washer 1

[D=ø15 mm (0.59 in)]

7 Plain washer 1

[D=ø22 mm (0.87 in)]

8 Oil pump gear shaft 1

9 Oil delivery pipe 1

7 Nm (0.7 mdkg, 5.1 ftdlb)

8 Nm (0.8 mdkg, 5.8 ftdlb)

OIL PUMP

4-65

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

1. Clean:

• Strainer 1

Use compressed air.

NOTE:

• Clean the strainer every 500 km (300 miles).

• If a lot of metallic dust in noticed, disassem-

ble the engine and check.

EC4J4200

Oil pump gear shaft

1. Inspect:

• Oil pump gear shaft 1

Wear/Damage ≥ Replace.

EC4H4100

Oil delivery pipe

1. Inspect:

• Oil delivery pipe 1

• O-ring 2

Damage ≥ Replace.

• Oil orifice a

Clogged ≥ Blow.

EC4J5000

ASSEMBLY AND INSTALLATION

EC4J5102

Oil pump

1. Install:

• O-ring 1N

To oil delivery pipe 2.

NOTE:

Apply the lithium soap base grease on the O-

rings.

ENG

OIL PUMP

4-66

2. Install:

• Oil delivery pipe 1

NOTE:

When installing the oil delivery pipe, fit the

projection a of the oil delivery pipe into the

hole b on the crankcase.

3. Install:

• Plain washer [D=ø22 mm (0.87 in)] 1

• Oil pump gear shaft 2

To transmission housing 3.

4. Install:

• Plain washer [D=ø15 mm (0.87 in)] 1

• Dowel pin 2

• Inner rotor 3

• Outer rotor 4

To oil pump gear shaft 5.

NOTE:

• Apply the transmission oil on the inner rotor

and outer rotor.

• Make sure the dowel pin fits into the groove

a in the inner rotor.

• When installing the outer rotor, make sure

the punch mark b on the outer rotor face the

transmission housing side.

5. Install:

• Dowel pin 1

ENG

OIL PUMP

4-67

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:

• Strainer 1

• Screw (strainer) 2

7 Nm (0.7 mdkg, 5.1 ftdlb)

NOTE:

Strainer is installed with the mesh a facing

outward.

ENG

CDI MAGNETO

ENG

EC4L0000

CDI MAGNETO

Extend of removal: 1 CDI magneto 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”

section.

Disconnect the CDI magneto lead.

1 Nut (rotor) 1 Use special tool.

2 Rotor 1 Refer to “REMOVAL POINTS”.

3 Stator 1

4 Woodruff key 1

53 Nm (5.3 mdkg, 38 ftdlb)

7 Nm (0.7 mdkg, 5.1 ftdlb)

4-68

CDI MAGNETO

4-69

EC4L3000

REMOVAL POINTS

EC4L3102

Rotor

1. Remove:

• Nut (rotor) 1

• Plain washer 2

Use the rotor holding tool 3.

Rotor holding tool:

YU-1235/90890-01235

2. Remove:

• Rotor 1

Use the flywheel puller 2.

Flywheel puller:

YM-1189/90890-01189

NOTE:

When installing the flywheel puller, turn it

counterclockwise.

EC4L4000

INSPECTION

EC4L4101

CDI magneto

1. Inspect:

• Rotor inner surface a

• Stator outer surface b

Damage ≥ Inspect the crankshaft runout

and crankshaft bearing.

If necessary, replace CDI magneto and/or

stator.

EC4L4200

Woodruff key

1. Inspect:

• Woodruff key 1

Damage ≥ Replace.

EC4L5000

ASSEMBLY AND INSTALLATIO

EC4L5191

CDI magneto

1. Install:

• Stator 1

• Screw (stator) 2

NOTE:

Temporarily tighten the screw (stator) at this

point.

ENG

CDI MAGNETO

4-70

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.

• When installing the rotor, align the keyway c

of the rotor with the woodruff key.

3. Install:

• Plain washer 1

• Nut (rotor) 2

53 Nm (5.3 mdkg, 38 ftdlb)

Use the rotor holding tool 3.

Rotor holding tool:

YU-1235/90890-01235

4. Adjust:

• Ignition timing

Ignition timing:

2.4 mm (0.094 in)

Refer to “IGNITION TIMING CHECK” sec-

tion in the CHAPTER 3.

5. Connect:

• CDI magneto lead 1

Refer to “CABLE ROUTING DIAGRAM”

section in the CHAPTER 2.

ENG

ENGINE REMOVAL

4-71

ENG

EC4M0000

ENGINE REMOVAL

Extend of removal Order Part name Q’ty Remarks

ENGINE REMOVAL

Preparation for Hold the machine by placing

removal the suitable stand.

Cowling and fuel tank Refer to “COWLING, INDUCTION

GUIDE, SEAT AND FUEL TANK” sec-

tion.

Carburetor and carburetor box Refer to “CARBURETOR AND REED

VALVE” section.

Exhaust pipe Refer to “EXHAUST PIPE AND

SILENCER” section.

Clutch cable Disconnect at engine side.

Radiator hose 2 Disconnect at water pump side.

Radiator hose 3, 4 Disconnect at cylinder head side.

Drive sprocket

Refer to “SHIFT SHAFT” section.

Shift arm

Spark plug cap

YPVS cable

Disconnect the CDI magneto lead.

30 Nm (3.0 mdkg, 22 ftdlb)

23 Nm (2.3 mdkg, 17 ftdlb)

30 Nm (3.0 mdkg, 22 ftdlb)

8 Nm (0.8 mdkg, 5.8 ftdlb)

11 Nm (1.1 mdkg, 8.0 ftdlb)

Support the machine securely so there

is no danger of it falling over.

ENGINE REMOVAL

4-72

ENG

Extend of removal: 1 Engine removal

Extend of removal Order Part name Q’ty Remarks

Pinch bolt (engine mounting collar)

2 Only loosening.

2 Nut (engine mounting bolt) 4

3 Engine mounting adjust bolt 2

4 Engine mounting bolt 4 Refer to “REMOVAL POINTS.”

5 Engine 1

6 Engine bracket 2

30 Nm (3.0 mdkg, 22 ftdlb)

23 Nm (2.3 mdkg, 17 ftdlb)

30 Nm (3.0 mdkg, 22 ftdlb)

8 Nm (0.8 mdkg, 5.8 ftdlb)

11 Nm (1.1 mdkg, 8.0 ftdlb)

ENGINE REMOVAL

4-73

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

Engine removal

1. Loosen:

• Engine mounting adjust bolt 1

NOTE:

Use the adjust bolt wrench 2 to loosen the

engine mounting adjust bolt.

2. Remove:

• Engine mounting bolt 1

• Engine 2

NOTE:

• Before removing the engine, make sure that

the couplers, hoses and cables are discon-

nected.

• Remove the engine by lowering it with a jack

EC4M5000

ASSEMBLY AND INSTALLATION

EC4M5190

Engine installation

1. Install:

• Engine bracket 1

• Bolt (engine bracket) 2

NOTE:

• Install the engine brackets with their “OUT-

SIDE” marks a facing outward.

• Tighten the bolts (engine brackets) to 23 Nm

(2.3 m•kg, 17 ft•lb), then loosen them by 1/4

turn, for temporary fitting.

ENG

ENGINE REMOVAL

4-74

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:

• Use the adjust bolt wrench 2 to tighten the

engine mounting adjust bolts.

• Tighten the adjust bolts to specified torque

alternately two times.

5. Install:

• Nut (engine mounting bolt) (upper) 1

30 Nm (3.0 mdkg, 22 ftdlb)

• Nut (engine mounting bolt) (lower) 2

30 Nm (3.0 mdkg, 22 ftdlb)

ENG

ENGINE REMOVAL

4-75

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. Tighten:

• Pinch bolt (engine mounting collar) (left) 5

11 Nm (1.1 mdkg, 8.0 ftdlb)

9. Install:

• Engine mounting collar (right) 1

• Engine mounting bolt (right) 2

• Engine mounting nut (right) 3

30 Nm (3.0 mdkg, 22 ftdlb)

10.Tighten:

• Bolt (engine bracket) (right) 4

23 Nm (2.3 mdkg, 17 ftdlb)

11.Tighten:

• Pinch bolt (engine mounting collar) (right) 5

11 Nm (1.1 mdkg, 8.0 ftdlb)

ENG

CRANKCASE AND CRANKSHAFT

4-76

ENG

EC4N0000

CRANKCASE AND CRANKSHAFT

Extend of removal Order Part name Q’ty Remarks

CRANKCASE AND

CRANK SHAFT REMOVAL

Preparation for Engine Refer to “ENGINE REMOVAL”

removal section.

Reed valve Refer to “CARBURETOR AND REED

VALVE” section.

Piston Refer to “CYLINDER HEAD, CYLIN-

DER AND PISTON” section.

Primary drive gear Refer to “PRIMARY DRIVEN GEAR,

PRIMARY DRIVE GEAR AND

BALANCER SHAFT” section.

Rotor and stator Refer to “CDI MAGNETO” section.

Engine bracket

50 Nm (5.0 mdkg, 36 ftdlb)

26 Nm (2.6 mdkg, 19 ftdlb)

11 Nm (1.1 mdkg, 8.0 ftdlb)

7 Nm (0.7 mdkg, 5.1 ftdlb)

8 Nm (0.8 mdkg, 5.8 ftdlb)

CRANKCASE AND CRANKSHAFT

4-77

ENG

Extend of removal: 1 Crankcase separation 2 Crankshaft removal

3 Oil seal removal 4 Push lever axle removal

Extend of removal Order Part name Q’ty Remarks

1 Bolt [crankcase (M6)] 6

[L=30 mm (1.18 in)]

2 Bolt [crankcase (M6)] 3

[L=35 mm (1.38 in)]

3 Bolt [crankcase (M8)] 6

Refer to “REMOVAL POINTS”.

[L=45 mm (1.77 in)]

4 Crankcase (upper) 1

5 Crankcase (lower) 1

6 Crankshaft 1

7 Oil seal (crankshaft) 2

8 Bolt (seat plate) 1

9 Seat plate 1

10 Push lever axle 1

50 Nm (5.0 mdkg, 36 ftdlb)

26 Nm (2.6 mdkg, 19 ftdlb)

11 Nm (1.1 mdkg, 8.0 ftdlb)

7 Nm (0.7 mdkg, 5.1 ftdlb)

8 Nm (0.8 mdkg, 5.8 ftdlb)

CRANKCASE AND CRANKSHAFT

4-78

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:

• Crankcase (upper) 1

From crankcase (lower) 2.

CAUTION:

Use soft hammer to tap on the case half.

Tap only on reinforced portions of case. Do

not tap on gasket mating surface. Work

slowly and carefully. If the cases do not

separate, check for a remaining case screw

or fitting. Do not force.

EC4N4000

INSPECTION

EC4N4112

Crankcase

1. Inspect:

• Contacting surface a

Scratches ≥ Replace crankcase assembly.

• Engine mounting boss b, crankcase

Cracks/Damage ≥ Replace crankcase

assembly.

EC4N4214

Crankshaft

1. Inspect:

• Bearing 1

Rotate outer race with a finger.

Rough spot/Seizure ≥ Replace crankshaft

assembly.

ENG

CRANKCASE AND CRANKSHAFT

4-79

2. Inspect:

• Oil seal 1

Wear/Damage ≥ Replace.

3. Measure:

• Runout limit a

• Small end free play limit b

• Connecting rod big end side clearance c

• Crank width (crank pin side) d

Out of specification ≥ Replace.

Use the dial gauge and thickness gauge.

Dial gauge:

YU-3097/90890-01252

Standard <Limit>

Runout 0.03 mm 0.05 mm

limit (0.0012 in) (0.0020 in)

Small end 0.8~1.0 mm 2.0 mm

free play (0.031~0.039 in) (0.08 in)

Side 0.45~0.95 mm

–

clearance (0.018~0.037 in)

Crank

49.975~50.025 mm

–

width (1.968~1.969 in)

EC4A4200

Push lever axle

1. Inspect:

• Push lever axle 1

Wear/Damage ≥ Replace.

• Torsion spring 2

Broken/Damage ≥ Replace.

EC4N5000

ASSEMBLY AND INSTALLATION

EC4N5291

Crankshaft

1. Install:

• Oil seal 1

To crankshaft 2.

NOTE:

Apply the lithium soap base grease on the oil

seal lip.

ENG

CRANKCASE AND CRANKSHAFT

4-80

2. Install:

• Circlip 1

To crankcase (lower) 2.

3. Install:

• Crankshaft 1

To crankcase (lower) 2.

NOTE:

• When installing the crankshaft into the

crankcase (lower), apply the transmission oil

on the oil seal 3 outer circumference.

• Align the bearing knock pin with the pin slot

a in the crankcase (lower) and the projec-

tion of oil seal with the groove b in the

crankcase (lower).

• After installing the crankshaft, push the oil

seal to the crankcase (lower).

4. Install:

• Dowel pin 1

• O-ring 2

To crankcase (lower) 3.

ENG

5. Apply:

• Sealant

On the crankcase (upper) 1.

Quick gasket®:

ACC-YAMAB-ON-D4

YAMAHA Bond No.4

90890-05143

NOTE:

Clean the contacting surface of crankcase

(upper and lower) before applying the sealant.

CRANKCASE AND CRANKSHAFT

4-81

6. Install:

• Crankcase (upper) 1

To crankcase (lower).

NOTE:

After installation, tap the crankcase (upper)

with a soft hammar to settle it.

7. Tighten:

• Bolt [crankcase (M8)] 1~6

• Bolt [crankcase (M6)] 7~∞

CAUTION:

The M6 bolt comes in two lengths. Use the

correct one for installation.

L=30 mm (1.18 in) (green) 7 0 ¡ £ ¢ ∞

Mark $:L=35 mm (1.38 in) (silver) 8 9 ™

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~∞ (M6) 6 Nm (0.6 m•kg, 4.3 ft•lb)

•Final: 1~6 (M8) 26 Nm (2.6 m•kg, 19 ft•lb)

7~∞ (M6) 11 Nm (1.1 m•kg, 8.0 ft•lb)

8. Remove:

• Sealant

Forced out on the crankcase mating sur-

face.

CAUTION:

If any sealant remains, especially where

the stator is installed, it may cause the sta-

tor to be installed improperly, resulting in

an electrical problem.

ENG

9. Apply:

• Engine oil

To the crank pin, bearing and oil delivery

hole.

10.Check:

• Crankshaft operation

Unsmooth operation ≥ Repair.

CRANKCASE AND CRANKSHAFT

4-82

EC4A5101

Push lever axle

1. Install:

• Seat plate 1

• Torsion spring 2

• Push lever axle 3

NOTE:

Apply the lithium soap base grease on the

push lever axle, oil seal lip and bearing.

2. Install:

• Bolt (seat plate) 1

7 Nm (0.7 mdkg, 5.1 ftdlb)

NOTE:

Fit the seat plate 2 in the groove a of the

push lever axle 3 and tighten the bolt (seat

plate).

ENG

FRONT WHEEL AND REAR WHEEL

5-1

EC500000

CHASSIS

EC590000

FRONT WHEEL AND REAR WHEEL

EC598000

FRONT WHEEL

Extend of removal: 1 Front wheel removal 2 Wheel bearing removal

3 Brake disc removal

Extend of removal Order Part name Q’ty Remarks

FRONT WHEEL REMOVAL

Preparation for Hold the machine by placing

removal the suitable stand.

1 Bolt (axle holder) 4 Only loosening.

2 Nut (front wheel axle) 1

3 Front wheel axle 1

4 Caliper 2

5 Front wheel 1

6 Collar 2 Refer to “REMOVAL POINTS”.

7 Bearing 2 Refer to “REMOVAL POINTS”.

8 Brake disk 2

CHAS

20 Nm (2.0 mdkg, 14 ftdlb)

11 Nm (1.1 mdkg, 8.0 ftdlb)

35 Nm (3.5 mdkg, 25 ftdlb)

11 Nm (1.1 mdkg, 8.0 ftdlb)

80 Nm (8.0 mdkg, 58 ftdlb)

Support the machine securely so there

is no danger of it falling over.

FRONT WHEEL AND REAR WHEEL

5-2

EC598100

REAR WHEEL

Extend of removal: 1 Rear wheel removal 2 Wheel bearing removal

3 Brake disc removal

Extend of removal Order Part name Q’ty Remarks

REAR WHEEL REMOVAL

Preparation for Hold the machine by placing

removal the suitable stand.

1 Nut (rear wheel axle) 1

2 Rear wheel axle 1

3 Rear wheel 1 Refer to “REMOVAL POINTS”.

4 Collar 1

5 Clutch hub 1

6 Shim 1

7 Driven sprocket 1

8 Sprocket damper 5

9 Collar 1 Refer to “REMOVAL POINTS”.

10 Bearing 2 Refer to “REMOVAL POINTS”.

11 Brake disc 1

CHAS

23 Nm (2.3 mdkg, 17 ftdlb)

16 Nm (1.6 mdkg, 11 ftdlb)

32 Nm (3.2 mdkg, 23 ftdlb)

80 Nm (8.0 mdkg, 58 ftdlb)

2 Nm (0.2 mdkg, 1.4 ftdlb)

16 Nm (1.6 mdkg, 11 ftdlb)

Support the machine securely so there

is no danger of it falling over.

FRONT WHEEL AND REAR WHEEL

5-3

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.

EC513201

Wheel bearing (if necessary)

1. Remove:

• Bearing 1

NOTE:

Remove the bearing using a general bearing

puller 2.

EC594000

INSPECTION

EC514110

Wheel

1. Measure:

• Wheel runout

Out of limit ≥ Replace.

Wheel runout limit:

Radial: 1.0 mm (0.04 in)

Lateral: 0.5 mm (0.02 in)

2. Inspect:

• Bearing

Rotate inner race with a finger.

Rough spot/Seizure ≥ Replace.

NOTE:

Replace the bearings and wheel collar as a

set.

CHAS

FRONT WHEEL AND REAR WHEEL

5-4

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.

Do not attempt to straighten a bent axle.

EC594100

Brake disc

1. Measure:

• Brake disc deflection (only rear brake disc)

Use the dial gauge 1.

Out of specification ≥ Inspect wheel

runout.

If wheel runout is in good condition,

replace the brake disc.

Disc deflection limit:

Standard <Limit>

Rear – 0.15 mm (0.006 in)

≈

2. Measure:

• Brake disc thickness

Use the micrometer 1.

Out of limit ≥ Replace.

Disc wear limit:

Standard <Limit>

Front

5.0 mm (0.20 in)

4.5 mm (0.18 in)

Rear

4.0 mm (0.16 in)

3.5 mm (0.14 in)

∆

3. Inspect:

• Brake disc surface

Score marks/Damege≥Replace.

CHAS

FRONT WHEEL AND REAR WHEEL

5-5

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

• Bearing (left) 3

NOTE:

• Apply the lithium soap base grease on the

bearing when installing.

• Use a socket that matches the outside diam-

eter of the race of the bearing.

• Right side of bearing shall be installed first.

CAUTION:

Do not strike the inner race of the bearing.

Contact should be made only with the

outer race.

CHAS

EC594300

Clucth hub clearance

1. Inspect:

• Clucth hub clearance a

Out of specification ≥ Adjust by adding

the supplyed shim [0.3 mm (0.012 in)].

Clucth hub clearance:

Zero~0.3 mm (Zero~0.012 in)

NOTE:

• When inspecting the clutch hub clearance,

measure it as it is assembled to the body at

specified torque.

• Measurement may be made of the clearance

either between the shim 1 and clutch hub 2

or between the shim and sprocket 3.

FRONT WHEEL AND REAR WHEEL

5-6

2. Install:

• Brake disc 1

• Bolt (brake disc) 2

20 Nm (2.0 mdkg, 14 ftdlb)

NOTE:

Tighten the bolts in stage, using a crisscross

pattern.

3. Install:

• Collar 1

NOTE:

If the collar is hard to install, apply the lithium

soap base grease on the collar and press it in.

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.

• Insert the wheel axle from right side.

6. Install:

• Plain washer 1

• Nut (wheel axle) 2

80 Nm (8.0 mdkg, 58 ftdlb)

NOTE:

Apply the lithium soap base grease on the

wheel axle thread.

CHAS

FRONT WHEEL AND REAR WHEEL

5-7

7. Tighten:

• Bolt (axle holder) 1

11 Nm (1.1 mdkg, 8.0 ftdlb)

EC5251C0

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.

• Use a socket that matches the outside diam-

eter of the race of the bearing.

• Right side of bearing shall be installed first.

CAUTION:

Do not strike the inner race of the bearing.

Contact should be made only with the

outer race.

2. Install:

• Brake disc 1

• Bolt (brake disc) 2

23 Nm (2.3 mdkg, 17 ftdlb)

NOTE:

Tighten the bolts in stage, using a crisscross

pattern.

3. Install:

• Collar 1

NOTE:

If the collar is hard to install, apply the lithium

soap base grease on the collar and press it in.

CHAS

FRONT WHEEL AND REAR WHEEL

5-8

4. Install:

• Sprocket damper 1

• Nut (sprocket damper) 2

32 Nm (3.2 mdkg, 23 ftdlb)

To driven sprocket 3.

NOTE:

Make sure that the nut is on the side of the

sprocket bearing the manufacturer’s mark a.

5. Install:

• Driven sprocket 1

To wheel.

NOTE:

Apply the lithium soap base grease on the

sprocket damper.

6. Install:

• Shim 1

• Clutch hub 2

• Collar 3

NOTE:

Apply the lithium soap base grease on the

shim and clutch hub outer circumference.

7. Install:

• Wheel

NOTE:

Install the brake disc 1 between the brake

pads 2 correctly.

CHAS

8. Install:

• Drive chain 1

NOTE:

Push the wheel 2 forward and install the drive

chain.

FRONT WHEEL AND REAR WHEEL

5-9

9. Install:

• Wheel axle 1

NOTE:

• Apply the lithium soap base grease on the

wheel axle.

• Insert the wheel axle from left side.

10.Install:

• Plain washer 1

• Nut (wheel axle) 2

NOTE:

• Apply the lithium soap base grease on the

wheel axle thread.

• Temporarily tighten the nut (wheel axle) at

this point.

CHAS

11.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.

12.Tighten:

• Nut (wheel axle) 1

80 Nm (8.0 mdkg, 58 ftdlb)

• Adjuster 2

2 Nm (0.2 mdkg, 1.4 ftdlb)

• Locknut 3

16 Nm (1.6 mdkg, 11 ftdlb)

NOTE:

• Tighten the axle nut while pushing down the

drive chain.

• After tightening the axle nut, tighten the lock-

nut with the turned out the adjuster.

13.Adjust:

• Wheel alignment

Refer to “WHEEL ALIGNMENT ADJUST-

MENT” section in the CHAPTER 3.

Extend of removal Order Part name Q’ty Remarks

FRONT BRAKE REMOVAL

Preparation for Hold the machine by placing

removal the suitable stand.

Cowling Refer to “COWLING, INDUCTION

Induction guide (left cylinder) GUIDE, SEAT AND FUEL TANK”

section in the CHAPTER 4.

Drain the brake fluid. Refer to “REMOVAL POINTS”.

1 Adapter 1ea.

2 Union bolt 1 Loosen by moving the master cylinder

mounting position either way.

3 Brake hose 1ea.

4 Pad pin 1ea.

Loosen when disassembling the caliper.

5 Caliper 1ea.

6 Brake lever 1

7 Reservoir tank 1

8 Reservoir hose 1

9 Master cylinder bracket 1

10 Master cylinder 1

FRONT BRAKE AND REAR BRAKE

EC5A0000

FRONT BRAKE AND REAR BRAKE

EC5A8000

FRONT BRAKE

Extend of removal: 1 Brake hose removal 2 Caliper removal

3 Master cylinder removal

CHAS

35 Nm (3.5 mdkg, 25 ftdlb)

18 Nm (1.8 mdkg, 13 ftdlb)

6 Nm (0.6 mdkg, 4.3 ftdlb)

26 Nm (2.6 mdkg, 19 ftdlb)

14 Nm (1.4 mdkg, 10 ftdlb)

26 Nm (2.6 mdkg, 19 ftdlb)

14 Nm (1.4 mdkg, 10 ftdlb)

1 Nm (0.1 mdkg, 0.7 ftdlb)

6 Nm (0.6 mdkg, 4.3 ftdlb)

30 Nm (3.0 mdkg, 22 ftdlb)

8 Nm (0.8 mdkg, 5.8 ftdlb)

5 Nm (0.5 mdkg, 3.6 ftdlb)

Support the machine securely so there

is no danger of it falling over.

5-10

FRONT BRAKE AND REAR BRAKE

5-11

EC5A8100

REAR BRAKE

Extend of removal: 1 Brake hose removal 2 Caliper removal

3 Master cylinder removal

Extend of removal Order Part name Q’ty Remarks

REAR BRAKE REMOVAL

Preparation for Hold the machine by placing

removal the suitable stand.

Drain the brake fluid. Refer to “REMOVAL POINTS”.

1 Brake hose holder 2

2 Adapter 1

3 Union bolt 1

4 Brake hose 1

5 Pad pin 1

Loosen when disassembling the caliper.

6 Caliper 1

7 Brake pedal connecting bolt 1

8 Reservoir tank 1

9 Reservoir hose 1

10 Master cylinder 1

Support the machine securely so there

is no danger of it falling over.

CHAS

6 Nm (0.6 mdkg, 4.3 ftdlb)

18 Nm (1.8 mdkg, 13 ftdlb)

12 Nm (1.2 mdkg, 8.7 ftdlb)

20 Nm (2.0 mdkg, 14 ftdlb)

26 Nm (2.6 mdkg, 19 ftdlb)

14 Nm (1.4 mdkg, 10 ftdlb)

30 Nm (3.0 mdkg, 22 ftdlb)

8 Nm (0.8 mdkg, 5.8 ftdlb)

7 Nm (0.7 mdkg, 5.1 ftdlb)

23 Nm (2.3 mdkg, 17 ftdlb)

2 Nm (0.2 mdkg, 1.4 ftdlb)

FRONT BRAKE AND REAR BRAKE

5-12

EC5A8200

CALIPER DISASSEMBLY

A Front

B Rear

Extend of removal: 1 Front caliper disassembly 2 Rear caliper disassembly

Extend of removal Order Part name Q’ty Remarks

CALIPER DISASSEMBLY A B

1 Cotter pin

1ea.

2 Pad pin

1ea.

3 Pad support

1ea.

4 Brake pad

2ea.

5 Caliper piston

4ea.

2 Refer to “REMOVAL POINTS”.

6 Dust seal

4ea.

Refer to “REMOVAL POINTS”.

7 Piston seal

4ea.

CHAS

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)

1 2

FRONT BRAKE AND REAR BRAKE

5-13

EC5A8300

MASTER CYLINDER DISASSEMBLY

A Front

B Rear

Extend of removal: 1 Front master cylinder disassembly 2 Rear master cylinder disassembly

Extend of removal Order Part name Q’ty Remarks

MASTER CYLINDER DISASSEMBLY

1 Master cylinder boot 1

2 Circlip 1

3 Master cylinder kit 1

CHAS

2 Nm (0.2 mdkg, 1.4 ftdlb)

6 Nm (0.6 mdkg, 4.3 ftdlb)

FRONT BRAKE AND REAR BRAKE

5-14

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.

A Front

B Rear

2. Connect the transparent hose 2 to the

bleed screw 1 and place a suitable con-

tainer under its end.

A Front

B Rear

3. Loosen the bleed screw and drain the

brake fluid while pulling the lever in or

pushing down on the pedal.

CAUTION:

• Do not reuse the drained brake fluid.

• Brake fluid may erode painted surfaces or

plastic parts. Always clean up spilled fluid

immediately.

CHAS

FRONT BRAKE AND REAR BRAKE

5-15

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:

• Insert a piece of rag into the caliper to lock

one caliper.

• Carefully force the piston out of the caliper

cylinder with compressed air.

A Front

B Rear

EC543411

Piston seal kit

1. Remove:

• Dust seal 1

• Piston seal 2

NOTE:

Remove the piston seals and dust seals by

pushing them with a finger.

CAUTION:

• Never attempt to pry out piston seals and

dust seals.

• Do not loosen the bolts 3 and nuts 4.

Replace the piston seals and dust seals

whenever a caliper is disassembled.

A Front

B Rear

CHAS

FRONT BRAKE AND REAR BRAKE

5-16

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:

• Diaphragm 1

Crack/Damage ≥ Replace.

A Front

B Rear

3. Inspect:

• Master cylinder piston 1

• Master cylinder cup 2

Wear/Damage/Score marks ≥ Replace

master cylinder kit.

A Front

B Rear

EC534214

Caliper

1. Inspect:

• Caliper cylinder inner surface a

Wear/Score marks ≥ Replace caliper

assembly.

A Front

B Rear

CHAS

FRONT BRAKE AND REAR BRAKE

5-17

2. Inspect:

• Caliper piston 1

Wear/Score marks ≥ Replace caliper pis-

ton assembly.

Replace the piston seals and dust seals 2

whenever a caliper is disassembled.

EC534301

Brake hose

1. Inspect:

• Brake hose 1

Crack/Damage ≥ Replace.

EC5A5000

ASSEMBLY AND INSTALLATION

• All internal parts should be cleaned in

new brake fluid only.

• Internal parts should be lubricated with

brake fluid when installed.

• Replace the piston seals and dust seals

whenever a caliper is disassembled.

EC535113

Caliper piston

1. Clean:

• Caliper

• Piston seal

• Dust seal

• Caliper piston

Clean them with brake fluid.

2. Install:

• Piston seal 1N

• Dust seal 2N

Always use new piston seals and dust

seals.

NOTE:

Fit the piston seals and dust seals onto the

slot on caliper correctly.

A Front

B Rear

CHAS

FRONT BRAKE AND REAR BRAKE

5-18

3. Install:

• Caliper piston 1

NOTE:

Apply the brake fluid on the piston wall.

CAUTION:

• Install the piston with its shallow

depressed side a facing the caliper.

• Never force to insert.

A Front

B Rear

EC535241

Front caliper

1. Install:

• Brake pad 1

• Pad support 2

• Pad pin 3

• Cotter pin 4N

NOTE:

Temporarily tighten the pad pin at this point.

2. Install:

• Caliper 1

• Bolt (caliper) 2

35 Nm (3.5 mdkg, 25 ftdlb)

3. Tighten:

• Pad pin 3

18 Nm (1.8 mdkg, 13 ftdlb)

CHAS

EC545141

Rear caliper

1. Install:

• Brake pad 1

• Pad support 2

• Pad pin 3

• Cotter pin 4N

NOTE:

Temporarily tighten the pad pin at this point.

FRONT BRAKE AND REAR BRAKE

5-19

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)

EC5A5230

Master cylinder kit

1. Clean:

• Master cylinder

• Master cylinder kit

Clean them with brake fluid.

2. Install:

• Master cylinder cup (primary) 1

• Master cylinder cup (secondary) 2

To master cylinder piston 3.

NOTE:

Apply the brake fluid on the master cylinder

cup.

After installing, cylinder cup should be

installed as shown direction. Wrong instal-

lation cause improper brake performance.

A Front

B Rear

CHAS

3. Install:

• Spring 1

To master cylinder piston 2.

NOTE:

Install the spring at the smaller dia. side.

A Front

B Rear

FRONT BRAKE AND REAR BRAKE

5-20

4. Install:

• Spring guide 1

• Master cylinder kit 2

• Circlip 3

• Master cylinder boot 4

To master cylinder 5.

NOTE:

• Apply the brake fluid on the master cylinder

kit.

• Install the spring guide with the projection a

aligning with the master cylinder hole b.

• Apply the lithium soap base grease on the tip

c of the push rod.

• When installing the circlip, use a long nose

circlip pliers.

A Front

B Rear

EC545270

Rear master cylinder

1. Install:

• Reservoir hose 1

• Reservoir tank 2

• Nut (reservoir tank) 3

7 Nm (0.7 mdkg, 5.1 ftdlb)

CHAS

2. Install:

• Master cylinder 1

• Bolt (master cylinder) 2

20 Nm (2.0 mdkg, 14 ftdlb)

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.

FRONT BRAKE AND REAR BRAKE

5-21

EC5A5A00

Front brake hose and master cylinder

1. Install:

• Copper washer 1N

• Brake hose 2

• Union bolt 3

Always use new copper washers.

NOTE:

• Position the brake hoses with their paint

marks a downward.

• Temporarily tighten the union bolt.

2. Install:

• Master cylinder 1

• Master cylinder bracket 2

• Bolt (master cylinder bracket) 3

NOTE:

• Install the bracket so that the arrow mark a

face upward.

• Temporarily tighten the bolt (master cylinder

bracket).

CAUTION:

• Take care not to allow the brake hose

metal fittings and union bolts to contact

with other parts. If they are installed in

contact with other parts, it will result in

brake failure.

• Install the brake hoses with a clearance b

of 2 mm (0.008 in) provided between their

metal fittings.

• Install the brake hoses with a clearance c

of 3 mm (0.012 in) between the union bolt

and steering damper stay and a clearance

d of 3 mm (0.012 in) between the brake

hose (for the left caliper) and front fork.

3. Tighten:

• Union bolt

30 Nm (3.0 mdkg, 22 ftdlb)

• Bolt (master cylinder bracket)

8 Nm (0.8 mdkg, 5.8 ftdlb)

CHAS

FRONT BRAKE AND REAR BRAKE

5-22

4. Install:

• Copper washer 1N

• Adapter 2

26 Nm (2.6 mdkg, 19 ftdlb)

• Brake hose 3

14 Nm (1.4 mdkg, 10 ftdlb)

Always use a new copper washer.

NOTE:

When turning the adapter over the brake hose,

hold the brake hose so that it may not be twist-

ed.

5. Install:

• Reservoir tank 1

• Bolt (reservoir tank) 2

5 Nm (0.5 mdkg, 3.6 ftdlb)

• Reservoir hose 3

6. Install:

• Brake lever 1

• Bolt (brake lever) 2

1 Nm (0.1 mdkg, 0.7 ftdlb)

• Nut (brake lever) 3

6 Nm (0.6 mdkg, 4.3 ftdlb)

NOTE:

• Apply the lithium soap base grease on the

bolt.

• When installing the brake lever, apply the

molybdenum disulfide grease on the contact-

ing surface of the master cylinder piston.

CHAS

FRONT BRAKE AND REAR BRAKE

5-23

EC545451

Rear brake hose

1. Install:

• Copper washer 1N

• Brake hose 2

• Union bolt 3

30 Nm (3.0 mdkg, 22 ftdlb)

Always use new copper washers.

CAUTION:

When installing the brake hose to the mas-

ter cylinder, lightly touch the brake pipe a

with the projection b on the master cylin-

der.

2. Install:

• Copper washer 1N

• Adapter 2

26 Nm (2.6 mdkg, 19 ftdlb)

• Brake hose 3

14 Nm (1.4 mdkg, 10 ftdlb)

Always use a new copper washer.

NOTE:

When turning the adapter over the brake hose,

hold the brake hose so that it may not be twist-

ed.

3. Install:

• Brake hose holder 1

• Bolt (brake hose holder) 2

8Nm (0.8 mdkg,5.8 ftdlb)

CHAS

4. Install:

• Brake hose 1

Refer to “CABLE ROUTING DIAGRAM”

section in the CHAPTER 2.

FRONT BRAKE AND REAR BRAKE

5-24

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.

• Refill with the same type of brake fluid;

mixing fluids may result in a harmful

chemical reaction and lead to poor perfor-

mance.

• Be careful that water does not enter the

master cylinder when refilling. Water will

significantly lower the boiling point of the

fluid and may result in vapor lock.

CAUTION:

Brake fluid may erode painted surfaces or

plastic parts. Always clean up spilled fluid

immediately.

A Front

B Rear

2. Air bleed:

• Brake system

Refer to “BRAKE SYSTEM AIR BLEED-

ING” section in the CHAPTER 3.

3. Inspect:

• Brake fluid level

Fluid at lower level ≥ Fill up.

Refer to “BRAKE FLUID LEVEL INSPEC-

TION” section in the CHAPTER 3.

CHAS

FRONT BRAKE AND REAR BRAKE

5-25

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.

A Front

B Rear

CHAS

FRONT FORK

5-26

EC550000

FRONT FORK

Extend of removal: 1 Front fork removal

Extend of removal Order Part name Q’ty Remarks

FRONT FORK REMOVAL

Preparation for Hold the machine by placing

removal the suitable stand.

Cowling Refer to “COWLING, INDUCTION

Induction guide (left cylinder) GUIDE, SEAT AND FUEL TANK”

section in the CHAPTER 4.

Front caliper Refer to “FRONT BRAKE AND

REAR BRAKE” section.

Front wheel Refer to “FRONT WHEEL AND

REAR WHEEL” section.

1 Front fender 1

2 Pinch bolt

(steering damper stay)

1 Only loosening. (right side only)

3 Pinch bolt (handlebar) 2 Only loosening.

4 Pinch bolt (handle crown) 1 Only loosening.

5 Cap bolt 1

Loosen when disassembling the front fork.

6 Pinch bolt (under bracket) 2 Only loosening.

7 Front fork 1

Support the machine securely so there

is no danger of it falling over.

CHAS

8 Nm (0.8 mdkg, 5.8 ftdlb)

20 Nm (2.0 mdkg, 14 ftdlb)

7 Nm (0.7 mdkg, 5.1 ftdlb)

10 Nm (1.0 mdkg, 7.2 ftdlb)

23 Nm (2.3 mdkg, 17 ftdlb)

FRONT FORK

5-27

EC558000

FRONT FORK DISASSEMBLY

Extend of removal: 1 Oil seal removal 2 Damper rod removal

Extend of removal Order Part name Q’ty Remarks

FRONT FORK DISASSEMBLY

1 Cap bolt 1 Use special tool.

Refer to “REMOVAL POINTS”.

2 Spacer 1

3 Spacer guide 1

4 Fork spring 1 Drain the fork oil.

5 Inner tube 1

6 Stopper ring 1

Refer to “REMOVAL POINTS”.

7 Oil seal 1

8 Oil seal washer 1

9 Bolt (damper rod) 1 Use special tool.

0 Damper rod 1 Refer to “REMOVAL POINTS”.

CHAS

40 Nm (4.0 mdkg, 29 ftdlb)

23 Nm (2.3 mdkg, 17 ftdlb)

29 Nm (2.9 mdkg, 21 ftdlb)

FRONT FORK

5-28

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).

• The front fork requires careful attention. So it

is recommended that the front fork be main-

tained at the dealers.

CAUTION:

To prevent an accidental explosion of air,

the following instructions should be

observed:

• The front fork with a built-in piston rod

has a very sophisticated internal con-

struction and is particularly sensitive to

foreign material.

Use enough care not to allow any foreign

material to come in when the oil is

replaced or when the front fork is disas-

sembled and reassembled.

• Before removing the cap bolts or front

forks, be sure to extract the air from the

air chamber completely.

EC553000

REMOVAL POINTS

EC553144

Cap bolt

1. Remove:

• Cap bolt 1

From the outer tube.

NOTE:

Before removing the front fork from the

machine, loosen the cap bolt.

CHAS

2. Loosen:

• Spring preload adjuster 1

NOTE:

Record the set position of the adjuster (the

amount of turning out the adjuster to the fully

turned out position) before loosening it.

FRONT FORK

5-29

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.

Fork spring compressor:

YM-1441/90890-01441

Rod holder:

YM-1434/90890-01434

EC553212

Oil seal

1. Remove:

• Inner tube 1

Pull out the inner tube from the outer tube

2. Remove:

• Stopper ring 1

Using slotted-head screwdriver.

3. Remove:

• Oil seal 1

• Oil seal washer

Using slotted-head screwdriver.

CAUTION:

• Take care not to scratch the outer tube

inner surface.

• Replace the oil seal whenever removed.

CHAS

FRONT FORK

5-30

EC553322

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-1425/90890-01425

EC554000

INSPECTION

EC554100

Damper rod

1. Inspect:

• Damper rod 1

Bend/Damage ≥ Replace damper rod.

CAUTION:

The front fork with a built-in piston rod has

a very sophisticated internal construction

and is particularly sensitive to foreign

material.

Use enough care not to allow any foreign

material to come in when the oil is

replaced or when the front fork is disas-

sembled and reassembled.

EC554400

Fork spring

1. Measure:

• Fork spring free length a

Out of specification ≥ Replace.

Fork spring free length:

Standard <Limit>

212.5 mm 210.5 mm

(8.37 in) (8.29 in)

]

CHAS

FRONT FORK

5-31

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:

The bending value is shown by one half of the

dial gauge reading.

Do not attempt to straighten a bent inner

tube as this may dangerously weaken the

tube.

EC554611

Outer tube

1. Inspect:

• Outer tube 1

• Piston metal 2

• Slide metal 3

Damage/Score marks/Wear ≥ Replace

outer tube assembly.

EC554710

Cap bolt

1. Inspect:

• Cap bolt 1

• O-ring 2

Wear/Damage ≥ Replace.

CHAS

FRONT FORK

5-32

EC555000

ASSEMBLY AND INSTALLATION

EC555191

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.

3. Install:

• Copper washer 1N

• Bolt (damper rod) 2

To inner tube 3.

4. Tighten:

• Bolt (damper rod) 1

40 Nm (4.0 mdkg, 29 ftdlb)

NOTE:

Use a damper rod holder 3 to lock the

damper rod 2.

Damper rod holder:

YM-1425/90890-01425

5. Install:

• Locknut 1

To damper rod 2.

NOTE:

Install the locknut with its width across flat a

facing upward.

CHAS

FRONT FORK

5-33

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.

• Install the oil seal with its manufacture’s

marks or number facing the axle holder side.

7. Install:

• Inner tube 1

To outer tube 2.

CAUTION:

When installing the inner tube, slowly and

take care to insert it carefully so that the

slide metal 3 and piston metal 4 will not

be scratched.

8. Install:

• Oil seal washer 1

To outer tube slot.

9. Install:

• Oil seal 1

NOTE:

Press the oil seal into the outer tube with fork

seal driver 2.

Fork seal driver:

YM-1442/90890-01442

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:

• Front fork oil

Until outer tube top surface with recom-

mended fork oil 1.

Recommended oil:

Suspension oil “01”

CAUTION:

• Be sure to use recommended fork oil. If

other oils are used, they may have an

excessively adverse effect on the front

fork performance.

• Never allow foreign materials to enter the

front fork.

CHAS

14.After filling, pump the damper rod 1 slowly

up and down more than 10 times to distrib-

ute the fork oil.

NOTE:

Use the rod puller 2 and rod puller attach-

ment 3 to pull up and down the damper rod.

Rod puller 2:

YM-1437/90890-01437

Rod puller attachment 3:

90890-01435

5-34

FRONT FORK

5-35

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. A stroke

of 60 mm (2.4 in) or more will cause air to

enter. In this case, repeat the steps 13 to 16.

17.Wait ten minutes until the air bubbles have

been removed from the front fork, and the

oil has dispense evenly in system before

setting recommended oil level.

NOTE:

Fill with the fork oil up to the top end of the

outer tube, or the fork oil will not spread over

to every part of the front forks, thus making it

impossible to obtain the correct level. Be sure

to fill with the fork oil up to the top of the outer

tube and bleed the front forks.

18.Measure:

• Oil level (left and right) a

Out of specification ≥ Adjust.

Standard oil level:

135 mm (5.31 in)

Extent of adjustment:

97~157 mm (3.82~6.18 in)

From top of outer tube with inner

tube and damper rod 1 fully

compressed without spring.

Never fail to make the oil level adjustment

between the maximum and minimum level

and always adjust each front fork to the

same setting. Uneven adjustment can

cause poor handling and loss of stability.

CHAS

FRONT FORK

5-36

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

• Rod holder 4

NOTE:

• Pull up the damper rod with the rod puller

and rod puller attachment.

• While pressing down the spacer 5 with the

fork spring compressor, set the rod holder

between the locknut 6 and spacer.

Rod puller 1:

YM-1437/90890-01437

Rod puller attachment 2:

90890-01435

Fork spring compressor 3:

YM-1441/90890-01441

Rod holder 4:

YM-1434/90890-01434

21.Adjust:

• Distance a

Out of specification ≥ Turn the locknut 2

until the specified distance is obtained.

Distance a:

13 mm (0.51 in)

Between damper rod 1 top and

locknut 2 top.

22.Adjust:

• Rebound damping adjuster position a

Out of specification ≥ Turn the adjuster 1

until the specified position is obtained.

Rebound damping adjuster posi-

tion a:

Zero mm (Zero in)

CHAS

FRONT FORK

5-37

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.

23.Install:

• Push rod 1

• Cap bolt 2

NOTE:

Turn in the cap bolt fully by holding the spring

preload adjuster 4 with your hand until the

rebound damping adjuster 3 hits the push rod

tip.

24.Check:

• Cap bolt clearance a

Out of specification ≥ Repeat the steps 21

to 23.

Cap bolt clearance a:

Zero~2 mm (Zero~0.08 in)

CAUTION:

If the cap bolt is installed out of specifica-

tion, proper damping force cannot be

obtained.

25.Install:

• Cap bolt (locknut) 1

29 Nm (2.9 mdkg, 21 ftdlb)

NOTE:

Hold the locknut 2 and tighten the cap bolt by

turning the spring preload adjuster 3 with

specified torque.

CAUTION:

Do not tighten the cap bolt. It may cause

damage to the spring preload adjuster.

CHAS

FRONT FORK

5-38

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).

• Do not tighten the pinch bolts (handle crown,

steering damper stay and handlebar) yet.

2. Tighten:

• Cap bolt 1

23 Nm (2.3 mdkg, 17 ftdlb)

3. Adjust:

• Front fork top end a

• Handlebar position b

• Steering damper stay position c (left 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” in the CHAPTER 3.

CHAS

FRONT FORK

5-39

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)

• Pinch bolt (steering damper stay) 4 (right

side only)

10 Nm (1.0 mdkg, 7.2 ftdlb)

Refer to “FRONT FORK TOP END

ADJUSTMENT” in the CHAPTER 3.

5. Check:

• Steering smooth action

Turn the handlebar to make sure no parts

are being contacted with others.

Contact ≥ Repair.

6. Adjust:

• Rebound damping force

• Spring preload

NOTE:

• Turn in the rebound damping adjuster 1

fully, then turn out it to the originally set posi-

tion.

• Turn in the spring preload adjuster 2 to the

originally set position.

7. Install:

• Front fender 1

• Bolt (front fender) 2

8 Nm (0.8 mdkg, 5.8 ftdlb)

CHAS

HANDLEBAR

5-40

EC5B0000

HANDLEBAR

Extend of removal: 1 Handlebar removal 2 Throttle disassembly

Extend of removal Order Part name Q’ty Remarks

HANDLEBAR REMOVAL

Preparation for Cowling Refer to “COWLING, INDUCTION

removal Induction guide (left cylinder) GUIDE, SEAT AND FUEL TANK”

section in the CHAPTER 4.

Handle crown Refer to “STEERING” section.

1 Clutch cable 1 Disconnect at the lever side.

2 Clutch lever holder 1

3 Main switch 1

4 Grip (left) 1 Refer to “REMOVAL POINTS”.

5 Starter cable 2 Disconnect at the lever side.

6 Starter lever 1

7 Master cylinder 1

8 Grip cap (upper) 1

9 Throttle cable 2

10 Throttle 1

11 Grip cap (lower) 1

12 Grip end 2

13 Handlebar 2

14 Grip (right) 1 Refer to “REMOVAL POINTS”.

15 Tube guide 1

CHAS

2 Nm (0.2 mdkg, 1.4 ftdlb)

7 Nm (0.7 mdkg, 5.1 ftdlb)

8 Nm (0.8 mdkg, 5.8 ftdlb)

HANDLEBAR

5-41

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 ≥ Replace.

Do not attempt to straighten a bent handle-

bar as this may dangerously weaken the

handlebar.

EC5B5000

ASSEMBLY AND INSTALLATION

EC5B5110

Throttle assembly

1. Install:

• Ring plate 1

• Grip (right) 2

Apply the adhesive on the tube guide 3.

NOTE:

Before applying the adhesive, wipe off grease

or oil on the tube guide surface a with a lac-

quer thinner.

EC5B5230

Handlebar

1. Install:

• Handlebar 1

• Grip end 2

NOTE:

Temporarily tighten the bolts (handlebar).

CHAS

HANDLEBAR

5-42

2. Install:

• Throttle cable [carburetor (left cylinder)] 1

• Throttle cable [carburetor (right cylinder)]

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).

3. Install:

• Throttle 1

NOTE:

Apply the lithium soap base grease on the

throttle grip sliding surface.

4. Install:

• Throttle cable [carburetor (left cylinder)] 1

• Throttle cable [carburetor (right cylinder)] 2

To tube guide 3.

NOTE:

• Apply the lithium soap base grease on the

throttle cable ends and tube guide cable wid-

ing portions.

• Install the throttle cable [carburetor (left cylin-

der)] in the grip side slit a in the tube guide.

5. Install:

• Grip cap (upper) 1

• Bolt (grip cap) 2

NOTE:

• Align the contacting surface a of the grip

cap (upper) with the punch mark b on the

handlebar.

• Tighten the bolts so that the upper side con-

tacting surface c is closed.

6. Adjust:

• Throttle grip free play

Refer to “THROTTLE CABLE ADJUST-

MENT” section in the CHAPTER 3.

CHAS

HANDLEBAR

5-43

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

• Screw (starter lever) 2

NOTE:

The starter lever should be installed according

to the dimension shown.

CHAS

9. Install:

• Starter cable [carburetor (left cylinder)] 1

• Starter cable [carburetor (right cylinder)] 2

To starter lever 3.

NOTE:

• Apply the lithium soap base grease on the

starter lever ends.

• Install the starter cable [carburetor (left cylin-

der)] in the upper side slit a in the starter

lever.

10.Install:

• Grip (left) 1

Apply the adhesive to the handlebar 2.

NOTE:

Before applying the adhesive, wipe off grease

or oil on the handlebar surface a with a lac-

quer thinner.

HANDLEBAR

5-44

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 dimen-

sions shown.

12.Install:

• Clutch cable 1

NOTE:

Apply the lithium soap base grease on the

clutch cable end.

13.Install:

• Handle crown 1

Refer to “STEERING” section.

14.Adjust:

• Handlebar position a

Handlebar position:

9 mm (0.35 in)

CHAS

HANDLEBAR

5-45

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” section

in the CHAPTER 3.

17.Lock the throttle cables and starter cables

using a locking wire.

Refer to “LOCKING WIRE INSTALLATION

GUIDE” section in the CHAPTER 3.

CHAS

STEERING

5-46

EC560000

STEERING

EC568000

HANDLE CROWN AND STEERING DAMPER

Extend of removal: 1 Handle crown removal 2 Steering damper removal

Extend of removal Order Part name Q’ty Remarks

HANDLE CROWN AND

STEERING DAMPER REMOVAL

Preparation for Hold the machine by placing

removal the suitable stand.

Cowling Refer to “COWLING, INDUCTION

Induction guide (left cylinder) GUIDE, SEAT AND FUEL TANK”

section in the CHAPTER 4.

Bolt (Front brake reservoir tank)

Front brake caliper Refer to “FRONT BRAKE AND

REAR BRAKE” section.

Front wheel Refer to “FRONT WHEEL AND

REAR WHEEL” section.

Front fender

1 Steering shaft nut 1

2 Pinch bolt (handle crown) 2 Only loosening.

3 Handle crown 1

4 Clip 1

5 Bolt (steering damper) 1

6 Steering damper 1

7 Steering damper bracket 1

Support the machine securely so there

is no danger of it falling over.

CHAS

80 Nm (8.0 mdkg, 58 ftdlb)

20 Nm (2.0 mdkg, 14 ftdlb)

23 Nm (2.3 mdkg, 17 ftdlb)

5 Nm (0.5 mdkg, 3.6 ftdlb)

STEERING

5-47

EC568100

UNDER BRACKET

Extend of removal: 1 Under bracket removal 2 Bearing removal

Extend of removal Order Part name Q’ty Remarks

UNDER BRACKET REMOVAL

1 Pinch bolt

(steering damper stay)

1 Only loosening.

2 Pin 1

3 Pinch bolt (handlebar) 4 Only loosening.

4 Pinch bolt (under bracket) 4 Only loosening.

5 Front fork 2 Refer to “FRONT FORK” section.

6 Ring nut 1 Use special tool.

Refer to “REMOVAL POINTS”.

7 Under bracket 1

8 Inner fender 1

9 Ball race cover 1

10 Bearing (upper) 1

11 Bearing (lower) 1 Refer to “REMOVAL POINTS”.

12 Ball race 2 Refer to “REMOVAL POINTS”.

CHAS

10 Nm (1.0 mdkg, 7.2 ftdlb)

23 Nm (2.3 mdkg, 17 ftdlb)

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)

STEERING

5-48

EC563000

REMOVAL POINTS

EC563202

Ring nut

1. Remove:

• Ring nut 1

Use the ring nut wrench 2.

Ring nut wrench:

YU-33975/90890-01403

Support the steering shaft so that it may

not fall down.

EC563300

Bearing (lower)

1. Remove:

• Bearing (lower) 1

Use the floor chisel 2.

CAUTION:

Take care not to damage the steering shaft

thread.

EC563400

Ball race

1. Remove:

• Ball race 1

Remove the ball race using long rod 2 and

the hammer.

EC564000

INSPECTION

EC564200

Steering shaft

1. Inspect:

• Steering shaft 1

Bend/Damage ≥ Replace.

CHAS

STEERING

5-49

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. If the bearings hang

up or are not smooth in their operation in

the ball races, replace bearings and ball

races as a set.

EC564300

Steering damper

1. Inspect:

• Steering damper 1

Bend/Damage ≥ Replace.

Oil leaks/Unsmooth movement ≥ Replace.

EC565000

ASSEMBLY AND INSTALLATION

EC565190

Under bracket

1. Install:

• Bearing (lower) 1

NOTE:

Apply the lithium soap base grease on the

dust seal lip and bearing inner circumference.

2. Install:

• Inner fender 1

• Screw (inner fender) 2

To under bracket 3.

NOTE:

Install the inner fender with its brake hose

through hole a facing to the right.

3. Install:

• Ball race

• Bearing 1

• Ball race cover 2

NOTE:

Apply the lithium soap base grease on the

bearing.

CHAS

STEERING

5-50

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” section in the CHAP-

TER 3.

6. Check the steering shaft by turning it lock

to lock. If there is any binding, remove the

steering shaft assembly and inspect the

steering bearings.

8. Install:

• Front fork 1

• Steering damper stay 2 (right side only)

• Handlebar 3

• Handle crown 4

NOTE:

• Temporarily tighten the pinch bolts (under

bracket).

• Do not tighten the pinch bolts (handle crown,

steering damper stay and handlebar) yet.

CHAS

7. Install:

• Plain washer 1

STEERING

5-51

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

little.

11.Install:

• Steering damper bracket 1

• Pinch bolt (steering damper bracket) 2

5 Nm (0.5 mdkg, 3.6 ftdlb)

To steering damper 3.

NOTE:

When installing the steering damper bracket,

provide a distance a of 9 mm (0.35 in) from

its edge.

CAUTION:

Tighten the pinch bolt to specified torque.

If torqued too much, it may cause the steer-

ing damper to malfunction.

CHAS

12.Install:

• Pin 1

• Plain washer 2

• Steering damper 3

• Clip 4

• Bolt (steering damper) 5

23 Nm (2.3 mdkg, 17 ftdlb)

STEERING

5-52

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” in the CHAPTER 3.

14.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)

• Pinch bolt (steering damper stay) 4 (right

side only)

10 Nm (1.0 mdkg, 7.2 ftdlb)

Refer to “FRONT FORK TOP END

ADJUSTMENT” in the CHAPTER 3.

15.Check:

• Steering smooth action

Turn the handlebar to make sure no parts

are being contacted with others.

Contact ≥ Repair.

CHAS

SWINGARM

5-53

EC570000

SWINGARM

Extend of removal: 1 Swingarm removal 2 Swingarm disassembly

Extend of removal Order Part name Q’ty Remarks

SWINGARM REMOVAL

Preparation for Hold the machine by placing

removal the suitable stand.

Lower cowl and fuel tank Refer to “COWLING, INDUCTION

GUIDE, SEAT AND FUEL TANK” sec-

tion in the CHAPTER 4.

Exhaust pipe Refer to “EXHAUST PIPE AND

SILENCER” section.

Brake hose holder Refer to “FRONT BRAKE AND

REAR BRAKE” section.

Drive chain

Rear wheel Refer to “FRONT WHEEL AND

REAR WHEEL” section.

1 Connecting rod 2 Hold the swingarm.

2 Bolt (rear shock absorber 1

– relay arm)

3 Pivot shaft adjust bolt 1

4 Pivot shaft 1

Use special tool.

5 Swingarm 1

Refer to “REMOVAL POINTS”.

6 Relay arm 1

7 Cover 2

8 Thrust bearing 2

9 Bush 1

10 Bearing 5 Refer to “REMOVAL POINTS”.

Support the machine securely so there

is no danger of it falling over.

CHAS

10 Nm (1.0 mdkg, 7.2 ftdlb)

115 Nm (11.5 mdkg, 85 ftdlb)

8 Nm (0.8 mdkg, 5.8 ftdlb)

34 Nm (3.4 mdkg, 24 ftdlb)

8 Nm (0.8 mdkg, 5.8 ftdlb)

5 Nm (0.5 mdkg, 3.6 ftdlb)

SWINGARM

5-54

EC573000

REMOVAL POINTS

EC573153

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-1455/90890-01455

Pivot shaft wrench adapter:

YM-1476/90890-01476

2. Remove:

• Pivot shaft 1

• Swingarm 2

EC573210

Bearing

1. Remove:

• Bearing 1

Use a general bearing puller 2.

EC574010

INSPECTION

Wash the bearings, bushes, collars, and cov-

ers in a solvent.

EC574131

Swingarm

1. Inspect:

• Bearing 1

• Bush 2

Free play exists/Unsmooth revolution/Rust

≥ Replace bearing and bush as a set.

2. Inspect:

• Bearing 1

• Collar 2

Free play exists/Unsmooth revolution/Rust

≥ Replace bearing and collar as a set.

CHAS

SWINGARM

5-55

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. Measure:

• Bush length a

2. Measure:

• Thrust bearing (right) thickness b

• Thrust bearing (left) thickness c

3. Measure:

• Swingarm head pipe length d

CHAS

SWINGARM

5-56

4. Calculate:

• Swingarm side clearance “A + B”

Out of specification ≥ Adjust side clear-

ance using shim.

By using formula given below.

“A + B” = a – ( b + c + d )

Side clearance “A + B”:

0.05~0.35 mm (0.002~0.014 in)

If the side clearance is out of specification,

adjust it to specification by installing the adjust

shim 1 at position, A and B.

NOTE:

• The adjust shim is available only in the 0.3

mm (0.012 in)-thick type.

• When only one shim is required, install it on

the left side, and when two shims are neces-

sary, install them on both right and left sides.

EC575000

ASSEMBLY AND INSTALLATION

EC575300

Bearing

1. Install:

• Bearing 1

To swingarm.

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:

For head pipe a:

1.0 mm (0.04 in)

For connecting rod bracket b:

0.5 mm (0.02 in)

CHAS

SWINGARM

5-57

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:

Zero mm (Zero in)

EC575142

Swingarm

1. Install:

• Collar 1

To relay arm 2.

NOTE:

Apply the molybdenum disulfide grease on the

collars and bearings.

2. Install:

• Relay arm 1

• Bolt (relay arm) 2

• Nut (relay arm) 3

34 Nm (3.4 mdkg, 24 ftdlb)

NOTE:

Apply the molybdenum disulfide grease on the

bolt.

3. Install:

• Bush 1

• Thrust bearing 2

• Cover 3

To swingarm 4.

NOTE:

Apply the molybdenum disulfide grease on the

bush, bearings and cover lips.

CHAS

SWINGARM

5-58

4. Install:

• Swingarm 1

• Pivot shaft 2

NOTE:

• Apply the molybdenum disulfide 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

bolt.

Pivot shaft wrench:

YM-1455/90890-01455

Pivot shaft wrench adapter:

YM-1476/90890-01476

6. Install:

• Plain washer 1

• Nut (pivot shaft) 2

115 Nm (11.5 mdkg, 85 ftdlb)

7. Check:

• Swingarm side play a

Free play exists ≥ Check side clearance.

• Swingarm up and down movement b

Unsmooth movement/Binding/Rough spots

≥ Grease or replace bearings, bushes

and collars.

8. Install:

• Bolt (rear shock absorber – relay arm) 1

• Nut (rear shock absorber – relay arm) 2

34 Nm (3.4 mdkg, 24 ftdlb)

NOTE:

Apply the molybdenum disulfide grease on the

bolt.

CHAS

SWINGARM

5-59

9. Install:

• Collar (swingarm) 1

NOTE:

Apply the molybdenum disulfide grease on the

collars and bearings.

10.Install:

• Connecting rod 1

• Bolt (connecting rod) 2

• Nut (connecting rod) 3

34 Nm (3.4 mdkg, 24 ftdlb)

NOTE:

• Install the connecting rods with the mark a

outward of the chassis.

• Apply the molybdenum disulfide grease on

the bolts.

CHAS

REAR SHOCK ABSORBER

5-60

EC580000

REAR SHOCK ABSORBER

Extend of removal: 1 Rear shock absorber removal 2 Rear shock absorber disassembly

Extend of removal Order Part name Q’ty Remarks

REAR SHOCK ABSORBER

REMOVAL

Preparation for Hold the machine by placing

removal the suitable stand.

Lower cowl, seat and fuel tank Refer to “COWLING, INDUCTION

GUIDE SEAT AND FUEL TANK”

section in the CHAPTER 4.

Exhaust pipe Refer to “EXHAUST PIPE AND

SILENCER” section in the

CHAPTER 4.

1 Bolt (rear shock absober 1 Hold the swingarm.

– relay arm)

2 Cap 1

3 Bolt (Upper bracket) 1

4 Rear shock absober 1 Refer to “REMOVAL POINTS”.

5 Bolt (rea shock absober 1

– upper bracket)

6 Upper bracket 1

7 Locknut 1 Loosen.

8 Adjuster 1 Loosen.

9 Spring guide 1

10 Spring (rear shock absober) 1

Support the machine securely so there

is no danger of it falling over.

CHAS

34 Nm (3.4 mdkg, 24 ftdlb)

40 Nm (4.0 mdkg, 29 ftdlb)

38 Nm (3.8 mdkg, 27 ftdlb)

34 Nm (3.4 mdkg, 24 ftdlb)

20 Nm (2.0 mdkg, 14 ftdlb)

REAR SHOCK ABSORBER

5-61

EC586000

HANDLING NOTE

This shock absorber is provided with a

separate type tank filled with high-pressure

nitrogen gas. To prevent the danger of

explosion, read and understand the follow-

ing information before handling the shock

absorber.

The manufacturer can not be held respon-

sible for property damage or personal

injury that may result from improper han-

dling.

1. Never tamper or attempt to disassemble

the cylinder or the tank.

2. Never throw the shock absorber into an

open flame or other high heat. The

shock absorber may explode as a result

of nitrogen gas expansion and/or dam-

age to the hose.

3. Be careful not to damage any part of the

gas tank. A damaged gas tank will

impair the damping performance or

cause a malfunction.

4. Take care not to scratch the contact sur-

face of the piston rod with the cylinder;

or oil could leak out.

5. Never attempt to remove the plug at the

bottom of the nitrogen gas tank. It is

very dangerous to remove the plug.

6. When scrapping the shock absorber,

follow the instructions on disposal.

EC587011

NOTES ON DISPOSAL (YAMAHA DEALERS

ONLY)

Before disposing of the shock absorber, be

sure to extract the nitrogen gas. To do so, drill

a 2 or 3 mm (0.08~0.12 in) hole through the

tank at a position 30 mm (1.2 in) from the bot-

tom end of the tank. 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.

CHAS

REAR SHOCK ABSORBER

5-62

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.

EC584000

INSPECTION

EC584130

Rear shock absorber

1. Inspect:

• Damper rod 1

Bends/Damage ≥ Replace absorber

assembly.

• Shock absorber 2

Oil leaks ≥ Replace absorber assembly.

Gas leaks ≥ Replace absorber assembly.

• Spring 3

Damage ≥ Replace spring.

Fatigue ≥ Replace spring.

Move spring up and down.

• Spring guide 4

Wear/Damage ≥ Replace spring guide.

• Plate 5

Wear/Damage ≥ Replace plate.

CHAS

EC583221

Spring (rear shock absorber)

1. Remove:

•Spring guide 1

•Spring 2

NOTE:

Remove the spring guide while compressing

the spring by using the spring compressor 3.

REAR SHOCK ABSORBER

5-63

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. Tighten:

• Adjuster 1

3. Adjust:

• Spring length (installed) a

Spring length (installed) a:

Standard length

Extent of adjustment

137 mm (5.39 in)

133~142 mm

(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.

CHAS

REAR SHOCK ABSORBER

5-64

4. Tighten:

• Locknut 1

20 Nm (2.0 mdkg, 14 ftdlb)

EC5852A1

Rear shock absorber

1. Install:

• Upper bracket 1

• Bolt (rear shock absorber – upper bracket)

• Plain washer (rear shock absorber – upper

bracket) 3

• Nut (rear shock absorber – upper bracket) 4

34 Nm (3.4 mdkg, 24 ftdlb)

NOTE:

Apply the molybdenum disulfide grease on the

bolt.

2. Install:

• Rear shock absorber

3. Install:

• Bolt (upper bracket) 1

40 Nm (4.0 mdkg, 29 ftdlb)

• Cap 2

CHAS

4. Install:

• Bolt (rear shock absorber – relay arm) 1

• Nut (rear shock absorber – relay arm) 2

34 Nm (3.4 mdkg, 24 ftdlb)

NOTE:

Apply the molybdenum disulfide grease on the

bolt.

ELECTRICAL COMPONENTS AND WIRING DIAGRAM

6-1

EC600000

ELECTRICAL

EC610000

ELECTRICAL COMPONENTS AND WIRING DIAGRAM

EC611000

ELECTRICAL COMPONENTS

ELEC

1 CDI unit

2 Voltage regulator

3 Tachometer assembly

4 Fuse

5 Main switch

6 Ignition coil

7 Solenoid valve

8 Fuel pump

9 Fuel pump relay

0 Fuel pump stop switch

¡ Battery

™ CDI magneto

£ Spark pulg

¢ Thermo unit

∞ Servomotor

COLOR CODE

B . . . . . .Black

Br . . . . . .Brown

G . . . . . .Green

Gy . . . . .Gray

O . . . . . .Orange

P . . . . . .Pink

R . . . . . .Red

Y . . . . . .Yellow

W . . . . . .White

B/Br . . . .Black/Brown

B/L . . . . .Black/Blue

B/R . . . . .Black/Red

B/W . . . .Black/White

G/W . . . .Green/White

W/B . . . .White/Black

W/G . . . .White/Green

W/L . . . .White/Blue

W/R . . . .White/Red

Y/L . . . . .Yellow/Blue

EC612000

WIRING DIAGRAM

IGNITION SYSTEM

6-2

EC620000

IGNITION SYSTEM

EC621031

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.

ELEC

*1 marked : Refer to “BATTERY INSPECTION” section in the CHAPTER 3.

*2 marked : Only when the ignition checker is used.

NOTE:

• Remove the following parts before inspection.

1) Cowling 3) Seat

2) Fuel tank

• Use the following special tools in this inspection.

Dynamic spark tester:

YM-34487

Ignition checker:

90890-06754

*1 Check battery Recharge or replace.

No good

Check fuse.

Replace fuse and

check wireharness.

No good

Repair or replace.

Check entire ignition

system for connection.

No good

Replace CDI unit.

Check ignition coil.

Primary coil

No good

Replace.

Secondary coil

No good

Replace.

Check CDI magneto.

Pick-up coil

No good

Replace.

Source coil

No good

Replace.

Pocket tester:

YU-3112-C/90890-03112

Check spark plug cap. Replace.

No good

Spark gap test

*2 Clean or replace

spark plug.

No spark

Spark

Check main switch.

Replace.

No good

IGNITION SYSTEM

6-3

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. Disconnect the fuel pump coupler to pre-

vent the fuel pump operating.

2. Disconnect the spark plug cap from spark

plug.

3. Connect the dynamic spark tester 1 (igni-

tion checker 2) as shown.

• Spark plug cap 3

• Spark plug 4

A For USA and CDN

B Except for USA and CDN

4. Start the engine and increase the spark

gap until misfire occurs. (for USA and CDN)

5. Move the main switch to “RUN” and rotate

the rear wheel with gear in 3rd and check

the spark gap. (except for USA and CDN)

Minimum spark gap:

5.0 mm(0.20 in)

EC623001

SPARK PLUG CAP INSPECTION

1. Remove:

• Spark plug cap

CAUTION:

Do not pull the spark plug lead out of the

spark plug cap. Turn the spark plug cap

counterclockwise to remove it and clock-

wise to install it.

2. Check:

• Spark plug cap resistance

Out of specification ≥ Replace.

Spark plug cap Tester selector

resistance position

4~6 kΩ at

kΩ X 1

20˚C (68˚F)

ELEC

IGNITION SYSTEM

6-4

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

Tester (+) lead ≥ Red lead 1

Tester (-) lead ≥ Brown lead 2

R Br Tester selector

1 2 position

RUN

Ω X 1

OFF

Continuous while the main switch is moved to

“OFF” ≥ Replace.

Not continuous while the main switch is moved

to “RUN” ≥ Replace.

EC626002

IGNITION COIL INSPECTION

1. Inspect:

• Primary coil resistance

Out of specification ≥ Replace.

Tester (+) lead ≥ Orange (Gray) lead 1

Tester (–) lead ≥ Black lead 2

Primary coil Tester selector

resistance position

0.14~0.18 Ω at

Ω X 1

20˚C (68˚F)

ELEC

IGNITION SYSTEM

6-5

2. Inspect:

• Secondary coil resistance

Out of specification ≥ Replace.

Tester (+) lead ≥ Spark plug lead 1

Tester (–) lead ≥ Orange (Gray) lead 2

Secondary coil Tester selector

resistance position

5.0~7.4 kΩ at

kΩ X 1

20˚C (68˚F)

NOTE:

When inspecting the secondary coil resis-

tance, remove the spark plug cap.

EC627031

CDI MAGNETO INSPECTION

1. Inspect:

• Pick-up coil resistance (left cylinder)

Out of specification ≥ Replace.

Tester (+) lead ≥ White/Blue lead 1

Tester (-) lead ≥ White/Black lead 2

Pick-up coil Tester selector

resistance position

94~140 Ω at

Ω X 100

20˚C (68˚F)

2. Inspect:

• Pick-up coil resistance (right cylinder)

Out of specification ≥ Replace.

Tester (+) lead ≥ White/Green lead 1

Tester (-) lead ≥ White/Black lead 2

Pick-up coil Tester selector

resistance position

94~140 Ω at

Ω X 100

20˚C (68˚F)

ELEC

IGNITION SYSTEM

6-6

3. Inspect:

• Source coil resistance

Out of specification ≥ Replace.

Tester (+) lead ≥ White lead 1

Tester (-) lead ≥ White lead 2

Source coil Tester selector

resistance position

2.3~3.5 Ω at

Ω X 1

20˚C (68˚F)

EC628000

CDI UNIT INSPECTION

Check all electrical components. If no fault is

found, replace the CDI unit. Then check the

electrical components again.

ELEC

CHARGING SYSTEM

6-7

EC680000

CHARGING SYSTEM

EC681001

INSPECTION STEPS

If the battery is not charged, use the following inspection steps.

ELEC

*1 marked : Refer to “IGNITION SYSTEM” section.

*2 marked : Refer to “BATTERY INSPECTION” section in the CHAPTER 3.

NOTE:

• Remove the following parts before inspection.

1) Cowling

2) Fuel tank

• Use the following special tool in this inspection.

Pocket tester:

YU-3112-C/90890-03112

*2 Check battery Recharge or replace.

No good

*1 Check fuse.

Replace fuse and

check wireharness.

No good

Repair or replace.

Check each coupler and

wire connection.

No good

*1 Check CDI magneto.

Source coil

No good

Replace.

Check charging voltage.

Charging system is

good.

No good

Check voltage regulator. Replace.

CHARGING SYSTEM

6-8

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.

Tester (+) lead ≥ Red lead 1

Tester (-) lead ≥ Black lead 2

Charging Tester selector

voltage position

14.2~15.2 V

DCV-20

at 5,000 r/min

EC683000

VOLTAGE REGULATOR INSPECTION

1. Check:

• Voltage regulator conduct

Use pocket tester (tester selection posi-

tion Ω X 1).

ELEC

W1 W2 R B

1 2 3 4

W1 1 X D X

W2 2 X D X

R 3 X X X

B 4 D D D

“D” indicates continuity and “X” non-continu-

ity.

In case of continuity for “X” ≥ Replace.

In case of non-continuity for “D” ≥ Replace.

Tester (+)

lead

Tester

(-) lead

CHARGING SYSTEM

6-9

NOTE:

If nothing is wrong with the continuity of the

voltage regulator and with all the others in the

charging system, replace the voltage regula-

tor.

ELEC

YPVS SYSTEM

6-10

EC640000

YPVS SYSTEM

EC641021

INSPECTION STEPS

If the servomotor will not turn, use the following inspection steps.

ELEC

*1 marked : Refer to “IGNITION SYSTEM” section.

*2 marked : Refer to “BATTERY INSPECTION” section in the CHAPTER 3.

NOTE:

• Remove the following parts before inspection.

1) Cowling

2) Fuel tank

• Use 12V battery in this inspection.

• Use the following special tool in this inspection.

Pocket tester:

YU-3112-C/90890-03112

*2 Check battery Recharge or replace.

No good

*1 Check fuse.

Replace fuse and

check wireharness.

No good

Repair or replace.

Check each coupler and

wire connection.

No good

*1 Check main switch. Replace.

No good

Check servomotor

operation.

Check servomotor.

No good

Replace.

No good

Replace CDI unit.

YPVS SYSTEM

6-11

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:

• Servomotor 1

Operative when the main switch is moved

to “RUN” ≥ OK

EC643001

SERVOMOTOR INSPECTION

1. Disconnect the YPVS cable from the servo-

motor.

2. Disconnect the servomotor lead.

3. Connect 12V battery to the servomotor

lead.

Battery (+) lead ≥ Black/Red lead 1

Battery (-) lead ≥ Black/Brown lead 2

4. Inspect:

• Servomotor 1

Not operate ≥ Replace servomotor.

ELEC

SOLENOID VALVE SYSTEM

6-12

EC650001

SOLENOID VALVE SYSTEM

EC651021

INSPECTION STEPS

If the solenoid valve will not operate, use the following inspection steps.

ELEC

*1 marked : Refer to “IGNITION SYSTEM” section.

*2 marked : Refer to “BATTERY INSPECTION” section in the CHAPTER 3.

NOTE:

• Remove the following parts before inspection.

1) Cowling 4) Induction guide (right cylinder)

2) Fuel tank 5) Seat

3) Induction cap (left cylinder)

• Use l2V battery in this inspection.

• Use the following special tools in this inspection.

Pocket tester:

YU-3112-C/90890-03112

*2 Check battery Recharge or replace.

No good

*1 Check fuse.

Replace fuse and

check wireharness.

No good

Repair or replace.

Check each coupler and

wire connection.

No good

*1 Check main switch. Replace.

No good

Check solenoid valve

operation.

Check solenoid valve coil.

No good

Replace.

No good

Replace CDI unit.

SOLENOID VALVE SYSTEM

6-13

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.

2. Inspect:

• Solenoid valve 1

Click when the main switch is moved to

“RUN” ≥ OK

NOTE:

Before checking the solenoid valve, discon-

nect the other solenoid valve lead.

EC653002

SOLENOID VALVE COIL INSPECTION

1. Inspect:

• Solenoid valve coil resistance

Out of specification ≥ Replace.

Tester (+) lead ≥ Yellow lead 1

Tester (–) lead ≥ White lead 2

Solenoid Tester selector

resistance position

52.0~63.6 Ω at

Ω X 10

20˚C (68˚F)

ELEC

THERMO UNIT SYSTEM

6-14

EC6A0000

THERMO UNIT SYSTEM

EC6A1011

INSPECTION STEPS

If the water temperature gauge (thermo unit) will not operate, use the following inspection steps.

ELEC

*1 marked : Refer to “IGNITION SYSTEM” section.

*2 marked : Refer to “BATTERY INSPECTION” section in the CHAPTER 3.

NOTE:

• Remove the following parts before inspection.

1) Cowling

• Use the following special tools in this inspection.

Pocket tester:

YU-3112-C/90890-03112

*2 Check battery Recharge or replace.

No good

*1 Check fuse.

Replace fuse and

check wireharness.

No good

Repair or replace.

Check each coupler and

wire connection.

No good

*1 Check main switch. Replace.

No good

Check thermo unit.

Replace.

No good

Replace tachometer assembly.

THERMO UNIT SYSTEM

6-15

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.

2 Water temperature gauge

3 Poket tester

4. Inspect:

• Thermo unit resistance

Measure the resistance while gradually

heating the cooling water.

Out of specification ≥ Replace .

Cooling Thermo Tester

water unit selector

temperature resistance position

50˚C (122˚F)

9.72~11.4 kΩ

kΩ X 1

80˚C (176˚F)

3.41~4.01 kΩ

NOTE:

Do not allow the thermo unit to contact the

test container bottom.

ELEC

FUEL PUMP SYSTEM

6-16

EC670000

FUEL PUMP SYSTEM

EC671001

INSPECTION STEPS

If the fuel pump will not operate, use the following inspection steps.

ELEC

*1 marked : Refer to “IGNITION SYSTEM” section.

*2 marked : Refer to “BATTERY INSPECTION” section in the CHAPTER 3.

NOTE:

• Remove the following parts before inspection.

1) Cowling 3) Seat

2) Fuel tank 4) Induction cap (left cylinder)

• Use 12V battery in this inspection.

• Use the following special tool in this inspection.

Pocket tester:

YU-3112-C/90890-03112

*2 Check battery Recharge or replace.

No good

*1 Check fuse.

Replace fuse and

check wireharness.

No good

Repair or replace.

Check each coupler and

wire connection.

No good

*1 Check main switch. Replace.

No good

Check fuel pump stop

switch.

Replace.

No good

Check fuel pump operation.

Fuel pump coil

No good

Replace.

No good

Check fuel pump.

Check fuel pump relay.

Replace.

No good

Replace.

FUEL PUMP SYSTEM

6-17

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:

• Fuel pump stop switch conduct

To inspect, tilt the fuel pump stop switch to

the right and left.

Tester (+) lead ≥ Black lead 1

Tester (-) lead ≥ Black lead 2

B B Tester selector

1 2 position

Tilted 90˚

Ω X 1

Normal

Continuous if normal ≥ Replace.

Not continuous if tilted 90˚ ≥ Replace.

EC673000

FUEL PUMP RELAY INSPECTION

1. Remove:

• Fuel pump relay 1

ELEC

FUEL PUMP SYSTEM

6-18

2. Inspect:

• Fuel pump relay conduct

Use 12V battery.

Battery (+) lead ≥ Black lead 1

Battery (-) lead ≥ Green lead 2

Tester (+) lead ≥ Black/Blue lead 3

Tester (-) lead ≥ Brown lead 4

B/L Br Tester selector

3 4 position

Connected

to battery

Not

Ω X 1

connected

to battery

Continuous while connected to the battery ≥

Replace.

Not continuous while not connected to the bat-

tery ≥ Replace.

3. Inspect:

• Fuel pump relay resistance

Out of specification ≥ Replace.

Tester (+) lead ≥ Green lead 1

Tester (-) lead ≥ Black lead 2

Fuel pump relay Tester selector

resistance position

72~80 Ω at

Ω X 10

20˚C (68˚F)

EC674000

FUEL PUMP OPERATION

CAUTION:

Do not operate the fuel pump on an empty

fuel tank because it may damage the

pump.

1. Loosen the drain plug (carburetor) and

drain the fuel from the float chamber.

ELEC

FUEL PUMP SYSTEM

6-19

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. Inspect:

• Fuel pump coil resistance

Out of specification ≥ Replace.

Tester (+) lead ≥ Black/Blue lead 1

Tester (-) lead ≥ Black lead 2

Fuel pump coil Tester selector

resistance position

1~3 Ω at

Ω X 1

20˚C (68˚F)

EC676000

FUEL PUMP INSPECTION

CAUTION:

Do not operate the fuel pump on an empty

fuel tank because it may damage the

pump.

1. Remove the fuel outlet hose from the fuel

pump.

2. Connect another plastic hose 1 to the fuel

pump and place its other end into a con-

tainer.

ELEC

FUEL PUMP SYSTEM

6-20

3. Turn the fuel cock to “ON”.

4. Disconnect the fuel pump coupler.

5. Connect 12V battery to the fuel pump cou-

pler.

Battery (+) lead ≥ Black/Blue lead 1

Battery (-) lead ≥ Black lead 2

6. Inspect:

• Fuel pump 1

No fuel flows from the plastic hose 2 ≥

Replace.

ELEC

SETTING

7-1

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

full performance, with the result that in some

cases the spark plug may be fouled, causing

the engine to stop running.

• The richness of the air-fuel mixture required

for the engine will vary with atmospheric con-

ditions of the day and therefore, the settings

of the carburetor must be properly suited to

the atmospheric conditions (air pressure,

humidity and temperature).

• As a basic setting method, only the factory

set main jet is first changed to check for the

discoloration of the spark plug(s) and pis-

ton(s) at full throttle in 6th and then the set-

ting is determined at mid-open throttle.

$ Recording and storing the data on the set-

tings, weather conditions, road surface con-

ditions of the circuit, lap times, etc. will

enable quick setting under different condi-

tions at a later time.

EC712000

Atmospheric conditions and carburetor

setting

TUN

Air

Air temp. Humidity pressure Mixture Setting

(altitude)

High High

Low

Richer Leaner

(high)

Low Low

High

Leaner Richer

(low)

The reason for the above tendency is that the

richness or leanness of a fuel mixture

depends on the density of the air (i.e. the con-

centration of oxygen in it).

SETTING

7-2

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.

EC714000

Effects of setting parts in relation to throt-

tle valve opening

1 Throttle valve opening

2 Full-open

3 Full-closed

EC71E003

Basic process of carburetor setting

Ex-factory setting is on the richer side, which

should basically have no problems with the

brake-in procedure.

Refer to “STARTING AND BREAK-IN” section

in the CHAPTER 1.

1. Adjustment of main jet

Use a main jet 1 with a smaller calibration

number if the engine does not develop

more than 12,000 rpm after a few laps of

the circuit when the water temperature

becomes stable [55°C (131°F) or more].

Example:#560 ≥ #540

TUN

SETTING

7-3

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: #540 ≥ #500

Factory-set main jet #560

2. Checking of spark plug and piston for dis-

coloration

Repeat the adjustment in the above “1”

several times. If the engine begins to run at

more than 12,000 rpm at full throttle, pro-

ceed to the “spark plug chopping” step

(refer to P7-9) to check for the discoloration

of the spark plug(s) and piston(s).

Refer to the photo for judgment on the dis-

coloration.

As a novice will find it difficult to determine

how much smaller number main jet can be

used just by looking at discoloration, he

should consult an experienced person for

his own experience, too.

Whether the setting is proper or not can be

judged by engine revolutions.

Approximate criteria for such judgment are

given below, on condition that the sec-

ondary reduction ratio is fit for conditions of

the circuit.

•13,000 rpm in 1st and 2nd

•12,500 rpm in 5th and 6th

A Normal

B Over burned (too lean)

C Oil fouled (too rich)

3. Adjustment of main nozzle

The main nozzle 1 adjustment follows the

completion of the adjustment of the main

jet. Check that engine revolutions smoothly

respond to throttle opening from where

throttle is about to be opened to 1/2 throttle

opening. Use a main nozzle of a smaller

size if engine revolutions appear to falter at

the beginning of throttle opening and then

suddenly respond to further throttle open-

ing.

Example:S-4 ≥ S-3

TUN

SETTING

7-4

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).

Use a main jet of a smaller size if good

response to engine revolutions is achieved

with an allowance for the discoloration of

the spark plug(s) and piston(s).

On the other hand, if the use of a different

main nozzle appears to produce less

power, change to a main nozzle of a larger

size.

Example:S-1 ≥ S-2

Factory-set main nozzle S-4

NOTE:

Difference between individual riders or differ-

ence between circuit layouts greatly affect the

main nozzle setting.

1. Rider who frequently uses mid-open throt-

tle

2. Circuit that requires frequent throttle open-

ing and closing

3. Wet environment

Conditions as mentioned above require a

longer period of throttle closing, resulting in

the drawn in mixture staying longer in the

crankcase. Such setting in turn will inevitably

cause the mixture to be richer at the next

throttle opening, a main nozzle of a smaller

size has to be used.

TUN

SETTING

7-5

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.

NOTE:

• Before this correction coefficient can be

used, satisfactory carburetor setting must

have been made.

• This correction coefficient can not be used if

there is a change in specification (e.g., igni-

tion timing, compression ratio, etc.).

Illustration:

Suppose the best setting was represented by

a #450 main jet at an air pressure of 1013 hPa

(760 mmHg) and an air temperature of 20°C

(68°F) in the previous riding.

In this riding, there has been a substantial

change in conditions; namely, an air pressure

of 1007 hPa (755 mmHg) and an air tempera-

ture of 30°C (86°F).

1. Refer to a table of correction coefficients

(P7-6) to find the correction coefficient for

the previous riding.

The correction coefficient A=100.0

2. Find the correction coefficient for this time.

The correction coefficient B=96.1

3. Use the following equation to calculate the

size of a main jet needed in this particular

case.

Previous main jet size X B/A

= Currently required main jet size

450 X 96.1/100 = 432.5

Thus, a #430 main jet can be selected.

TUN

SETTING

7-6

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

and carburetor setting’’ (P7-1).

• As the main nozzle is more susceptible to

other than atmospheric conditions, no correc-

tion coefficient is used for main nozzle set-

ting.

TUN

EC71G002

Table of correction coefficients for carburetor setting

Air

pressure

Air temperature °C (°F)

Altitude

hPa (mmHg)

-5 (23) Zero (32) 5 (41) 10 (50) 15 (59) 20 (68) 25 (77) 30 (86) 35 (95) 40(104)

m (ft)

1040 (780) 112.2 110.2 108.2 106.3 104.4 102.6 100.9 99.3 97.7 96.1 -220 (-722)

1033 (775) 111.5 109.4 107.5 105.6 103.7 102.0 100.3 98.6 97.0 95.5 -165 (-541)

1027 (770) 110.8 108.7 106.8 104.9 103.1 101.3 99.6 98.0 96.4 94.8 -110 (-361)

1020 (765) 110.0 108.0 106.1 104.2 102.4 100.7 99.0 97.3 95.8 94.2 -55 (-180)

1013 (760) 109.3 107.3 105.4 103.5 101.7 100.0 98.3 96.7 95.1 93.6 Zero (Zero)

1007 (755) 108.6 106.6 104.7 102.9 101.1 99.3 97.7 96.1 94.5 93.0 56 (184)

1000 (750) 107.9 105.9 104.0 102.2 100.4 98.7 97.0 95.4 93.9 92.4 112 (367)

993 (745) 107.2 105.2 103.3 101.5 99.7 98.0 96.4 94.8 93.3 91.8 168 (551)

987 (740) 106.5 104.5 102.6 100.8 99.1 97.4 95.7 94.2 92.6 91.1 224 (735)

980 (735) 105.7 103.8 101.9 100.1 98.4 96.7 95.1 93.5 92.0 90.5 281 (922)

973 (730) 105.0 103.1 101.2 99.4 97.7 96.1 94.4 92.9 91.4 89.9 338 (1,109)

967 (725) 104.3 102.4 100.5 98.8 97.1 95.4 93.8 92.2 90.7 89.3 396 (1,299)

960 (720) 103.6 101.7 99.8 98.1 96.4 94.7 93.1 91.6 90.1 88.7 453 (1,486)

953 (715) 102.9 101.0 99.2 97.4 95.7 94.1 92.5 91.0 89.5 88.1 512 (1,680)

947 (710) 102.1 100.3 98.5 96.7 95.0 93.4 91.9 90.3 88.9 87.5 570 (1,870)

940 (705) 101.4 99.6 97.8 96.0 94.4 92.8 91.2 89.7 88.2 86.8 629 (2,064)

933 (700) 100.7 98.9 97.1 95.4 93.7 92.1 90.6 89.1 87.6 86.2 688 (2,257)

927 (695) 100.0 98.1 96.4 94.7 93.0 91.4 89.9 88.4 87.0 85.6 747 (2,451)

920 (690) 99.3 97.4 95.7 94.0 92.4 90.8 89.3 87.8 86.4 85.0 807 (2,648)

913 (685) 98.5 96.7 95.0 93.3 91.7 90.1 88.6 87.2 85.7 84.4 867 (2,845)

907 (680) 97.8 96.0 94.3 92.6 91.0 89.5 88.0 86.5 85.1 83.8 928 (3,045)

900 (675) 97.1 95.3 93.6 92.0 90.4 88.8 87.3 85.9 84.5 83.1 989 (3,245)

893 (670) 96.4 94.6 92.9 91.3 89.7 88.2 86.7 85.2 83.9 82.5 1,050 (3,445)

887 (665) 95.7 93.9 92.2 90.6 89.0 87.5 86.0 84.6 83.2 81.9 1,111 (3,645)

880 (660) 94.9 93.2 91.5 89.9 88.3 86.8 85.4 84.0 82.6 81.3 1,173 (3,848)

873 (655) 94.2 92.5 90.8 89.2 87.7 86.2 84.7 83.2 82.0 80.7 1,236 (4,055)

867 (650) 93.5 91.8 90.1 88.5 87.0 85.5 84.1 82.7 81.4 80.1 1,299 (4,262)

860 (645) 92.8 91.1 89.4 87.9 86.3 84.9 83.4 82.1 80.7 79.4 1,362 (4,469)

853 (640) 92.1 90.4 88.8 87.2 85.7 84.2 82.8 81.4 80.1 78.8 1,425 (4,675)

847 (635) 91.3 89.7 88.1 86.5 85.0 83.6 82.2 80.8 79.5 78.2 1,489 (4,885)

840 (630) 90.6 89.0 87.4 85.8 84.3 82.9 81.5 80.2 78.9 77.6 1,554 (5,099)

SETTING

7-7

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.

Factory-set power jet #55

2. Pilot jet 1

The pilot jet is used in relation to the

engine response at small throttle opening.

This is changed when the main nozzle set-

ting is not enough.

A larger size results in a richer mixture and

a smaller size in a leaner mixture.

Factory-set pilot jet #40

3. Pilot air screw 1

The pilot air screw relates to the engine

response at a smaller opening than for the

pilot jet.

This setting may be changed for want of

time or in emergency, but it is basically set

at the factory-set pilot air screw position.

Factory-set pilot air

1-1/2 turns out

screw position

4. Spark plug

The spark plug heat range is not basically

changed.

Constant attention to the discoloration of

the spark plug and piston head will enable

you to tell to some extent whether the set-

ting is good or bad.

Standard spark plug

R6179A-105P/NGK

NOTE:

For the effects each setting part has, refer to

“Effects of setting parts in relation to throttle

valve opening” (P7-2).

TUN

SETTING

7-8

EC71Q021

Carburetor setting parts

Part name Size Part number

Main jet 1 Lean #350 137-14143-70

#360 137-14143-72

#370 137-14143-74

#380 137-14143-76

#390 137-14143-78

#400 137-14143-80

#410 137-14143-82

#420 137-14143-84

#430 137-14143-86

#440 137-14143-88

#450 137-14143-90

#460 137-14143-92

#470 137-14143-94

#480 137-14143-96

#490 137-14143-98

#500 137-1414K-00

#540 137-1414K-08

* Rich #560 137-1414K-12

Pilot jet 2 Lean #25 4KM-14142-25

#30 4KM-14142-30

#35 4KM-14142-35

* Rich #40 4KM-14142-40

Main nozzle Lean R-7 5KE-14141-R7

3 R-8 5KE-14141-R8

R-9 5KE-14141-R9

S-0 5KE-14141-S0

S-1 5KE-14141-S1

S-2 5KE-14141-S2

S-3 5KE-14141-S3

* Rich S-4 5KE-14141-S4

Jet needle

4 *

6DGJ1-63

275-14116-R0

Power jet 5 Lean #50 830-14231-10

* Rich #55 830-14231-11

TUN

NOTE:

Use a #500 main jet when selecting a next

smaller size jet than a #540.

* Factory installed

SETTING

7-9

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. This is

called a “plug chop”.

CAUTION:

• When you do a “plug chop”, pay attention

to your surrounding environment to avoid

interference with other riders.

• Do not shift down while riding your

machine by inertia (as it may cause a

seizure of the clutch push rod and ball).

EC71K010

Setting of cylinder gasket

The use of the supplied gaskets of different

thicknesses makes it possible to change the

combustion chamber volume.

Not much torque is felt with slow engine accel-

eration ≥ Reduce the combustion chamber

volume.

Torque is felt with no higher revolutions ≥

Expand the combustion chamber volume.

Thickness

Actual combustion

Type

chamber volume

0.6 mm Approx. 9.66 cm

STD

(0.024 in)

(0.340 lmp oz, 0.327 US oz)

0.5 mm Approx. 9.43 cm

(0.020 in)

(0.332 lmp oz, 0.319 US oz)

0.38 mm Approx. 9.20 cm

(0.015 in)

(0.324 lmp oz, 0.311 US oz)

Supplying

0.3 mm Approx. 8.98 cm

parts

(0.012 in)

(0.316 lmp oz, 0.304 US oz)

0.2 mm Approx. 8.75 cm

(0.008 in)

(0.308 lmp oz, 0.296 US oz)

TUN

SETTING

7-10

EC71T000

Cylinder gasket setting parts

Part number Size (thickness)

5KE-11351-60 * t=0.6 mm (0.024 in)

5KE-11351-50 t=0.5 mm (0.020 in)

5KE-11351-40 t=0.38 mm (0.015 in)

5KE-11351-30 t=0.3 mm (0.012 in)

5KE-11351-20 t=0.2 mm (0.008 in)

TUN

* Factory installed

EC71L003

Measuring piston protrusion

1. Install the dial gauge 1 and dial gauge

stand 2 to the cylinder contact surface and

set the scale of the dial gauge to zero.

Dial gauge and stand:

YU-3097/90890-01252

Offset dial stand:

YU-1037

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.

• After break-in, change to an appropriate gas-

ket to allow the piston protrusion to be -0.15

mm (-0.006 in) to 0.05 mm (0.002 in).

CAUTION:

• Piston protruding amount must be a maxi-

mum 0.15 mm (0.006 in). Above this value,

the piston and cylinder head may contact

each other.

• Too much random piston protrusion at

low temperature may develop an abnor-

mal combustion (detonation), which may

adversely affect the intended performance

of the engine.

A Air temperature

B Piston protruding amount

SETTING

7-11

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.

3. Set the piston at top dead center (TDC),

then measure the piston protrusion.

NOTE:

For measurement, avoid the top center pro-

jected area a on the piston head but measure

several positions above the piston pin as close

to the center as possible. The average of

these measurements indicates the piston pro-

trusion.

EC71N001

Selection of transmission gear ratio

The following gear sets are contained in the

packing (or optional) to allow the rider to

change the gear ratios according to the circuit

condition or rider’s preference.

CAUTION:

Select the transmission gears so that the

number of grooves in the wheel gear

match that of the pinion gear as shown

below. Trouble may be occurred if the

selection is different than that listed below.

a Groove

TUN

2nd gear

Gear ratio Part number

Number of

groove

Factory installed 31/21 (1.476) 4DP-17221-11/4DP-17121-11 1

Optional part 27/19 (1.421) 5F7-17221-21/5F7-17121-21 2

Optional part 28/18 (1.556) 5F7-17221-00/5F7-17121-00 –

1st gear

Gear ratio Part number

Number of

groove

Factory installed 34/18 (1.889) 5KE-17211-20/5KE-17411-20 2

Supplying part 28/14 (2.000) 5KE-17211-10/5KE-17411-10 1

SETTING

7-12

TUN

3rd gear

Gear ratio Part number

Number of

groove

Factory installed 29/23 (1.261) 5KE-17231-00/5KE-17131-00 –

Optional part/

25/21 (1.190) 5KE-17231-20/5KE-17131-10 2/1

Supplying part

Supplying part 26/21 (1.238) 5KE-17231-10/5KE-17131-10 1

6th gear

Gear ratio Part number

Number of

groove

Factory installed 20/22 (0.909) 5KE-17261-00/5KE-17191-00 1

Supplying part 22/25 (0.880) 5KE-17261-10/5KE-17161-10 2

SETTING

7-13

EC71U011

Transmission setting parts

Part name Size Part number

Main axle 1 14T 5KE-17411-10

* 18T 5KE-17411-20

2nd pinion gear 2 ∆ 18T 5F7-17121-00

∆ 19T 5F7-17121-21

* 21T 4DP-17121-11

3rd/4th pinion 21T/25T 5KE-17131-10

gear 3 * 23T/25T 5KE-17131-00

5th pinion gear 4 * 27T 5F7-17151-01

6th pinion gear 5 * 22T 5KE-17161-00

25T 5KE-17161-10

1st wheel gear 6 28T 5KE-17211-10

* 34T 5KE-17211-20

2nd wheel gear 7 ∆ 27T 5F7-17221-21

∆ 28T 5F7-17221-00

* 31T 4DP-17221-11

3rd wheel gear 8 ∆ 25T 5KE-17231-20

26T 5KE-17231-10

* 29T 5KE-17231-00

4th wheel gear 9 * 27T 5KE-17241-00

5th wheel gear 0 * 26T 3YL-17251-00

6th wheel gear ¡ * 20T 5KE-17261-00

22T 5KE-17261-10

* Factory installed

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 or 5KE-17231-20. No combination can be

selected for the factory installed 5KE-17231-

00.

TUN

SETTING

7-14

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.

(On the other hand, the stroke decreases on

rainy weather.)

• Rider’s position and posture affect the stroke.

• Be careful not to allow the suspension to bot-

tom out.

• Start the setting with the preload.

Next, go to the damping force adjustment,

and if this not enough, then adjust the

machine height.

(On the side where the machine height is

greater the stroke increases; whereas it

decreases on the side with a smaller

machine height.)

• If the damping force is increased either on

the compression or the expansion side, it

results in less smooth movement, so do not

depart too far from the standard settings.

• Adjust the machine height in an increment of

mm (in).

• If you lose your way while doing the setting,

go back to the standard settings.

• Oil level adjustment in the front fork produces

a greater effect in further stroke than in mid

stroke.

(Increase or decrease the oil level in an

approximately 5~10 mm (0.20~0.39 in) inter-

val.)

TUN

SETTING

7-15

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.

Example:

If the front tire radius is 1 mm (0.04 in) larger,

lower the front posture by 1 mm (0.04 in) by

increasiry the front fork top end a by 1 mm

(0.04 in). If the rear tire radius is 2 mm (0.08

in) smaller, raise the rear posture by 2 mm

(0.08 in) by decreasiry the adjuster set length

b by 1 mm (0.04 in).

NOTE:

• Find the tire radius by calculating the mea-

sured circumference of the tire.

• A change of 1 mm (0.04 in) in the front fork

top end results in a change of about 1 mm

(0.04 in) in the front posture. A change of 1

mm (0.04 in) in the adjuster set length results

in a change of about 2 mm (0.08 in) in the

rear posture.

TUN

[Front]

*Designated tire

Tire circumference Tire radius Front fork top end

*3.10/4.80 R17

About 1,875 mm (73.8 in) About 298.5 mm (11.8 in) 13 mm (0.51 in)

DUNLOP KR106

120/70 R17

About 1,885 mm (74.2 in) About 300 mm (11.8 in) 11.5 mm (0.45 in)

DUNLOP MR977

Tire

brand

[Rear]

*Designated tire

Tire circumference Tire radius Seat height

*165/55 R17

About 1,975 mm (77.8 in) About 314.5 mm (12.4 in) 24 mm (0.94 in)

DUNLOP KR108

165/50 R17

About 1,957 mm (77.0 in) About 311.5 mm (12.3 in) 25.5 mm (1.00 in)

DUNLOP KR244

Tire

brand

SETTING

7-16

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. Preparations

To check for the remaining stroke in the

front and rear suspension, either install a

thin insu-lock tie or apply a small amount of

grease at the front fork inner tube and at

the rear shock absorber rod.

2. Settings

At the beginning of the break-in period,

always record the remaining stroke as

data.

To judge front and rear balance in relation

to the machine height, the usual way is to

shift from full braking to turning and get the

feel when the clipper riding.

After making an actual run, proceed to the

settings for a target of a 5~10 mm

(0.20~0.39 in) remaining stroke for front

and a 10 ~ 20 mm (0.39~0.79 in) remain-

ing stroke for rear.

Basically, the best settings can be obtained

by repeating the following steps.

NOTE:

The figures show the bottom-out positions of

the front and rear suspension.

A Front

B Rear

TUN

SETTING

7-17

TUN

SETTING CHART

ACTUAL RUN

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

Decrease the spring

preload.

•Front

Every two clicks

[1 mm (0.04 in)]

•Rear

Every one turn

[1.5 mm (0.06 in)]

Too much stroke

Increase the spring

preload.

•Front

Every two clicks

[1 mm (0.04 in)]

•Rear

Every one turn

[1.5 mm (0.06 in)]

Too stiff from the

beginning and not

smooth in mid range

as well.

Decrease damping force

on compression side.

•Front

Every one turn

•Rear

Every two clicks

Unstable and spongy

Increase damping force

both on compression

and rebound.

•Front

Every one turn

•Rear

Every two clicks

Check stroke

YESNO

NOTE:

Preload increase results in relative

lack of damping force. If the preload

is increased two times, increase the

damping force a little.

NOTE:

The remaining stroke value is provid-

ed just as a guide and may change

according to the riding style.

* Factory installed

SETTING

7-18

EC71P011

Selection of the secondary reduction ratio

(Sprocket)

Secondary

Number of driven sprocket teeth

reduction =

ratio

Number of drive sprocket teeth

Factory-set secondary

36/14 (2.571)

reduction ratio

The larger value, the higher speed ratio

The smaller value, the lower speed ratio

EC72N000

Drive and driven sprockets setting parts

Part name Size Part number

Drive sprocket 1 * 14T 93834-14178

15T 93834-15079

16T 93834-16104

Driven sprocket 2 35T 5KE-25435-10

* 36T 5KE-25436-10

37T 5KE-25437-10

38T 5KE-25438-10

39T 5KE-25439-10

40T 5KE-25440-10

Driven sprocket

35T 36T 37T 38T 39T 40T

Drive sprocket

14T 2.500 2.571 2.643 2.714 2.786 2.857

15T 2.333 2.400 2.467 2.534 2.600 2.666

16T 2.188 2.250 2.313 2.375 2.438 2.500

TUN

SETTING

7-19

TUN

EC72L003

Chassis setting troubleshooting

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) • Decrease spring preload.

• Decrease damping force for compression.

• Down the oil level (for front fork only).

Looseness in parts • Check bolts, bearings, etc. as well as their

installation.

Tire/Rim • Recheck balance.

• Check deformation (runout).

Too stiff

Poor operation • Check the shock absorber.

feeling

(Check rod, inner tube, etc. for bending. If

bent, replace.)

• Check for any deviation from center after

tightening front wheel axle.

(Replace if deviated in any way.)

• Too much tightened bolts for front

fork outer tube ≥ Retorque the bolts to

specification (handle crown, under bracket,

steering damper stay, handlebar).

Too stiff (poor stroke) • Decrease spring preload.

• Decrease damping force (for both compres-

sion and rebound).

Bottoming (full stroke) • Increase spring preload.

• Increase oil level (for front fork only).

• Increase damping force for compression, or

decrease damping force for rebound.

Spongy feeling Poor of damping force • Increase damping force (for both compres-

sion and rebound).

Too soft • Increase spring preload.

SETTING

7-20

TUN

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).

• Increase damping force (for front).

Poor corner

Machine tends to incline • Increase rear height.

maneuvering

too much backward. • Increase spring preload (for rear).

(Too big caster angle) • Decrease damping force for rebound (for

rear).

• Increase front fork top end.

• Decrease spring preload (for front).

Too much knifing

Machine tend to incline • Decrease front fork top end.

at cornering

too much forward. • Decrease rear height.

(Too small caster angle) • Increase spring preload (for front).

• Increase damping force for compression (for

front).

Front dives in too early • Increase damping force for compression (for

front).

Swinging on

(bounding) Too much damping force • Decrease damping force for rebound.

over gaps for rebound

Bottoming • Increase spring preload.

SETTING

7-21

TUN

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

Float height

Gearing

1st

2nd

3rd

4th

5th

6th

Secondary

Front fork

Spring rate

Spring preload

Rebound damping

Compression damping

Top end

Oil capacity

Oil level

Rear shock

Spring fitting length

Spring rate

Rebound damping

Compression damping

Seat height

Front tire (pressure)

Rear tire (pressure)

Fuel consumption

SETTING

7-22

TUN

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

1st

2nd

3rd

4th

5th

6th

Secondary

Front fork

Spring rate

Spring preload

Rebound damping

Compression damping

Top end

Oil capacity

Oil level

Rear shock

Spring fitting length

Spring rate

Rebound damping

Compression damping

Seat height

Front tire (pressure)

Rear tire (pressure)

Fuel consumption

NOTE:

1. Make setting changes in small increments.

2. When the proper settings have been determined for a particular track, they should be written

down for reference upon returning to that track.

3. Always make adjustment in cold state.

PROTECT YOUR INVESTMENT

Use

Genuine YAMAHA

Parts And Accessories

YAMAHA MOTOR CO., LTD.

2500 SHINGAI IWATA SHIZUOKA JAPAN

TZ250N1/(N)

Yamaha TZ250 Handleiding

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