Мануал ямаха раптор 660

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Summary of Contents for Yamaha RAPTOR YFM660RP

YFM660RN

YFM660RNC

SERVICE MANUAL

LIT-11616-14-21 5LP-28197-E0

EB001000 NOTICE

This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers

and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one

manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on

Yamaha machine has a basic understanding of the mechanical ideas and the procedures of

machine repair. Repairs attempted by anyone without this knowledge are likely to render the

machine unsafe and unfit for use.

Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and sig-

nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers

and will appear in future editions of this manual where applicable.

NOTE:

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION

Particularly important information is distinguished in this manual by the following notations.

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.

A CAUTION indicates special precautions that must be taken to avoid dam-

age to the machine.

A NOTE provides key information to make procedures easier or clearer.

WARNING

CAUTION:

NOTE:

EB002000 HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)

1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.

2nd title 2: This title indicates the section of the chapter and only appears on the first page of each

section. It is located in the upper left corner of the page.

3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa-

nied by corresponding illustrations.

EXPLODED DIAGRAMS

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 4 is provided for removal and disassembly jobs.

2. Numbers 5 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

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

4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names

of parts, notes in jobs, etc.

5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition

to the exploded diagram and the job instruction chart.

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols 1 to 9 are printed on the

top right of each page and indicate the subject

of each chapter.

1General information

2Specifications

3Periodic checks and adjustments

4Chassis

5Engine

6Cooling system

7Carburetion

8Electrical

9Troubleshooting

Illustrated symbols 0 to G are used to identify

the specifications appearing in the text.

0Can be serviced with engine mounted

AFilling fluid

BLubricant

CSpecial tool

DTorque

EWear limit, clearance

FEngine speed

GΩ, V, A

Illustrated symbols H to N in the exploded

diagrams indicate the types of lubricants and

lubrication points.

HApply engine oil

IApply gear oil

JApply molybdenum disulfide oil

KApply wheel bearing grease

LApply lightweight lithium soap base grease

MApply molybdenum disulfide grease

NApply silicon grease

Illustrated symbols O to P in the exploded

diagrams indicate where to apply a locking

agent O and when to install a new part P.

OApply the locking agent (LOCTITE)

PReplace

12

34

56

78

90

AB

CD

EFG

HIJ

K

OP

GEN

INFO SPEC

CHK

ADJ

CHAS

ENG

COOL

CARB

–+

ELEC

TRBL

SHTG

T

R

.

.

EGM

BLS MS

LMN

LT New

TABLE OF CONTENTS

GENERAL INFORMATION GEN

INFO 1

SPECIFICATIONS SPEC 2

PERIODIC CHECKS AND

ADJUSTMENTS CHK

ADJ 3

CHASSIS CHAS 4

ENGINE ENG 5

COOLING SYSTEM COOL 6

CARBURETION CARB 7

ELECTRICAL ELEC 8

TROUBLESHOOTING TRBL

SHTG 9

–+

CHAPTER 1.

GENERAL INFORMATION

MACHINE IDENTIFICATION …………………………….………………………………..1-1

VEHICLE IDENTIFICATION NUMBER ………………………………………….1-1

MODEL LABEL ……………..……………………………………………………………1-1

IMPORTANT INFORMATION ……………………………………………….…………….1-2

PREPARATION FOR REMOVAL PROCEDURES ………………………….1-2

REPLACEMENT PARTS ………………………………………………………..……1-2

GASKETS, OIL SEALS AND O-RINGS …………………………………………1-2

LOCK WASHERS/PLATES AND COTTER PINS ……………………………1-3

BEARINGS AND OIL SEALS ……………………………………………………….1-3

CIRCLIPS ……………………………..……………………………………………..……1-3

CHECKING OF CONNECTIONS …………………………………………………………1-4

SPECIAL TOOLS …………………………………………….………………………………..1-5

CHAPTER 2.

SPECIFICATIONS

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

MAINTENANCE SPECIFICATIONS …………………………………………………….2-4

ENGINE ………………………………..……………………………………………..……2-4

CHASSIS ……………………………………………………………………………..….2-14

ELECTRICAL ………………………………….……………………………………….2-18

HOW TO USE THE CONVERSION TABLE ………………….…………………….2-20

GENERAL TORQUE SPECIFICATIONS ……………………………………………2-20

LUBRICATION POINTS AND LUBRICANT TYPES …………………………….2-21

ENGINE ………………………………..……………………………………………..….2-21

COOLANT FLOW DIAGRAMS ………………………………………………………….2-22

OIL FLOW DIAGRAMS ………………………………………………………………..….2-23

CABLE ROUTING …………………………………..……………………………………….2-27

GEN

INFO 1

SPEC 2

CHK

ADJ 3

CHAS 4

ENG 5

COOL 6

CARB 7

ELEC 8

TRBL

SHTG 9

–+

CHAPTER 3.

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION …………………………………….………………………………………… 3-1

PERIODIC MAINTENANCE/LUBRICATION INTERVALS …………………….. 3-1

SEAT, FENDERS AND FUEL TANK ……………………………………………………3-3

SEAT, FRONT PANEL, FOOTREST GUARDS

AND ENGINE SKID PLATE ………………………………………………………3-3

HEADLIGHTS AND FRONT FENDER …………………………….…………….3-4

REAR FENDER ……………………..…………………………………….…………….3-5

FUEL TANK ………………….……………………………………………………………3-6

ENGINE ……………………………………….…………………………………….…………….3-8

ADJUSTING THE VALVE CLEARANCE ……………….………………………3-8

ADJUSTING THE TIMING CHAIN ………………………..…………………….3-11

ADJUSTING THE IDLING SPEED ………………………..…………………….3-11

ADJUSTING THE THROTTLE LEVER FREE PLAY ………………….…. 3-12

ADJUSTING THE SPEED LIMITER ……………………………………………. 3-14

ADJUSTING THE STARTER CABLE ………….………………………………3-15

CHECKING THE SPARK PLUG ………..……………………………………….3-16

CHECKING THE IGNITION TIMING ……………………………………………3-17

MEASURING THE COMPRESSION PRESSURE …………………………3-18

CHECKING THE ENGINE OIL LEVEL ……………………………………..…. 3-19

CHANGING THE ENGINE OIL ………….……………………………………….3-20

ADJUSTING THE CLUTCH CABLE …………………………………………….3-23

CLEANING THE AIR FILTER ………………………………………………….….3-24

CHECKING THE COOLANT LEVEL ……………………………………………3-27

CHANGING THE COOLANT …………………………………………………..….3-27

CHECKING THE COOLANT TEMPERATURE WARNING LIGHT ….. 3-31

CLEANING THE SPARK ARRESTER …………………..…………………….3-31

CHASSIS ………………….……………………………………………..…………………….3-33

ADJUSTING THE FRONT BRAKE ……………..………………………………3-33

ADJUSTING THE REAR BRAKE ………………..………………………………3-33

ADJUSTING THE PARKING BRAKE …………………………………………..3-34

CHECKING THE BRAKE FLUID LEVEL ………………………………………3-35

CHECKING THE FRONT BRAKE PAD ……….………………………………3-36

CHECKING THE REAR BRAKE PAD ………………………………………….3-36

ADJUSTING THE REAR BRAKE LIGHT SWITCH ……………………….. 3-36

CHECKING THE BRAKE HOSE …………………………………………………3-37

BLEEDING THE HYDRAULIC BRAKE SYSTEM ………………………….3-38

ADJUSTING THE SHIFT PEDAL ………………………….…………………….3-39

ADJUSTING THE REVERSE CONTROL CABLE ……………………..…. 3-40

ADJUSTING THE DRIVE CHAIN SLACK …………………………………….3-40

CHECKING THE STEERING SYSTEM ……….………………………………3-42

ADJUSTING THE TOE-IN ………………………….………………………………3-42

ADJUSTING THE FRONT SHOCK ABSORBER ……………………….….3-44

ADJUSTING THE REAR SHOCK ABSORBER …………………………….3-45

CHECKING THE TIRE ………………………………………………………………3-47

CHECKING THE WHEEL …………………………..………………………………3-49

CHECKING AND LUBRICATING THE CABLE ………………………….….3-49

LUBRICATING THE LEVERS AND PEDAL ………………………………….3-50

ELECTRICAL ………………………………………………………………………………….3-51

CHECKING THE BATTERY …………………………………………..…………..3-51

CHECKING THE FUSE ……………………………………….…………………….3-56

ADJUSTING THE HEADLIGHT BEAM ………………….…………………….3-58

REPLACING THE HEADLIGHT BULB …………………………………………3-58

CHAPTER 4.

CHASSIS

FRONT WHEELS …………………………………………….………………………………..4-1

FRONT WHEELS ……………………………………………………………………….4-1

CHECKING THE WHEEL …………………………..………………………………..4-3

CHECKING THE WHEEL HUB …………………………………………………….4-3

CHECKING THE BRAKE DISC …………………………………………………….4-4

INSTALLING WHEEL HUB ………………………………….………………………4-5

INSTALLING THE WHEEL …………………………………………………………..4-5

REAR WHEELS, WHEEL AXLE AND HUB ………………………………………….4-6

REAR WHEELS ….……………………………………………..………………………4-6

WHEEL AXLE AND HUB ………..……………………………………………..……4-7

REMOVING THE REAR AXLE ……………………………………….…………….4-9

CHECKING THE WHEEL …………………………..………………………………4-10

CHECKING THE WHEEL HUB …………………………………………………..4-10

CHECKING THE REAR AXLE …………..……………………………………….4-10

CHECKING THE HUB ……………………………………………………………….4-11

CHECKING THE BRAKE DISC …………………………………………………..4-11

INSTALLING THE NUTS (REAR AXLE) ………………………………………4-11

INSTALLING THE WHEEL HUB …………………………………………………4-12

INSTALLING THE WHEEL …………………………………………………………4-12

FRONT AND REAR BRAKES …………………………………….…………………….4-13

FRONT BRAKE PADS …………………………………………………………..….4-13

REAR BRAKE PADS …………………………………………..…………………….4-14

REPLACING THE FRONT BRAKE PAD ………………………………………4-15

REPLACING THE REAR BRAKE PAD ………………………………………..4-17

FRONT BRAKE MASTER CYLINDER …………………………….…………..4-19

REAR BRAKE MASTER CYLINDER …………………….…………………….4-21

CHECKING THE MASTER CYLINDER ……………………………………….4-24

ASSEMBLING THE FRONT

AND REAR BRAKE MASTER CYLINDER ………………………………..4-25

INSTALLING THE FRONT BRAKE MASTER CYLINDER ………………4-25

INSTALLING THE REAR BRAKE MASTER CYLINDER ……………….. 4-27

FRONT BRAKE CALIPERS ……………………………………………………….4-29

REAR BRAKE CALIPER ……………………………………………….…………..4-31

DISASSEMBLING THE FRONT AND REAR BRAKE CALIPER ……..4-34

GEN

INFO 1

SPEC 2

CHK

ADJ 3

CHAS 4

ENG 5

COOL 6

CARB 7

ELEC 8

TRBL

SHTG 9

–+

CHECKING THE FRONT AND REAR BRAKE CALIPER ……………….4-34

ASSEMBLING THE FRONT BRAKE CALIPER ……………………………. 4-35

ASSEMBLING THE REAR BRAKE CALIPER ………………….…………..4-36

INSTALLING THE FRONT BRAKE CALIPER ………………….…………..4-37

INSTALLING THE REAR BRAKE CALIPER …………………….…………..4-38

STEERING SYSTEM ……………………………………………………………………….4-40

HANDLEBAR …………………………………..……………………………………….4-40

REMOVING THE FRONT BRAKE SWITCH, PARK SWITCH

AND CLUTCH SWITCH ……………………………………………………..….4-42

REMOVING THE HANDLEBAR GRIP …………………………………………4-42

CHECKING THE HANDLEBAR ……………………………………..…………..4-42

INSTALLING THE HANDLEBAR ………………………………………………..4-43

INSTALLING THE HANDLEBAR GRIP ………………………………………..4-43

INSTALLING THE CLUTCH LEVER ……………………………………………4-43

INSTALLING THE BRAKE MASTER CYLINDER ………………………….4-44

STEERING STEM ………………………………………………………..…………..4-45

REMOVING THE BEARING RETAINER ……..………………………………4-47

CHECKING THE STEERING STEM ……………………………………………4-47

INSTALLING THE BEARING RETAINER …………………………………….4-47

INSTALLING THE LOCK WASHER …………….………………………………4-47

TIE-ROD AND STEERING KNUCKLE …………………………….…………..4-48

REMOVING THE STEERING KNUCKLE …….………………………………4-49

CHECKING THE TIE-ROD …………………………………..…………………….4-49

CHECKING THE STEERING KNUCKLE …………………………………….. 4-49

INSTALLING THE TIE-ROD ……………………………………………………….4-49

FRONT ARMS AND FRONT SHOCK ABSORBERS …………………………..4-50

REMOVING THE FRONT ARM .……………………………………………..….4-52

CHECKING THE FRONT ARM …………………………………………………..4-52

CHECKING THE FRONT SHOCK ABSORBER ……………….…………..4-52

CHECKING THE BALL JOINT …………..……………………………………….4-53

INSTALLING THE FRONT ARM …………………………………………………4-54

REAR SHOCK ABSORBER AND RELAY ARM ………………………………….4-55

HANDLING THE REAR SHOCK ABSORBER

AND GAS CYLINDER ……………………………………………….…………..4-57

DISPOSING OF A REAR SHOCK ABSORBER

AND GAS CYLINDER ……………………………………………….…………..4-57

REMOVING THE REAR SHOCK ABSORBER ……………………………..4-58

CHECKING THE REAR SHOCK ABSORBER ………………………………4-58

CHECKING THE RELAY ARM AND CONNECTING ARM ……………..4-58

INSTALLING THE RELAY ARM AND CONNECTING ARM ……………4-59

INSTALLING THE REAR SHOCK ABSORBER …………………………….4-59

SWINGARM AND DRIVE CHAIN …………………………………………………..….4-60

REMOVING THE SWINGARM ……………………………………….…………..4-62

CHECKING THE SWINGARM ……………………………………….…………..4-62

CHECKING THE DRIVE CHAIN …………………………………………………4-63

INSTALLING THE SWINGARM ………………………………………………….4-65

INSTALLING THE DRIVE SPROCKET ………………………………………..4-65

CHAPTER 5.

ENGINE

ENGINE REMOVAL …………………………………………………………………………..5-1

MUFFLER AND EXHAUST PIPES ……………..………………………………..5-1

LEFT FOOTREST ………………………………………………………..…………….5-2

LEADS, CABLES AND HOSES .……………………………………………..……5-3

ENGINE MOUNTING BOLTS ………………………………………………………5-5

INSTALLING THE ENGINE ………………………………………………………….5-7

CYLINDER HEAD COVER ……………………………….………………………………..5-8

REMOVING THE CYLINDER HEAD COVER …………………..…………..5-10

CHECKING THE CYLINDER HEAD COVER ……………………………….5-10

CHECKING THE TAPPET COVER ………………………………………….…. 5-11

INSTALLING THE CYLINDER HEAD COVER ……….…………………….5-11

ROCKER ARMS ………………….………………………………………………………….5-12

REMOVING THE ROCKER ARM ……………………………………………….5-14

CHECKING THE ROCKER ARM ………………………………………………..5-14

INSTALLING THE ROCKER ARM ………………………………………………5-15

CAMSHAFT AND CYLINDER HEAD …………………………………………………5-16

REMOVING THE CAMSHAFT AND CYLINDER HEAD …………………5-18

CHECKING THE CAMSHAFT ………………………………………..…………..5-19

CHECKING THE CAMSHAFT SPROCKET ……………………..…………..5-19

CHECKING THE DECOMPRESSION SYSTEM ……………………………5-19

CHECKING THE TIMING CHAIN GUIDE …………………………………….5-20

CHECKING THE TIMING CHAIN TENSIONER …………………………….5-20

CHECKING THE CYLINDER HEAD ……………………………………………5-20

INSTALLING THE CAMSHAFT AND CYLINDER HEAD ………………..5-21

VALVES AND VALVE SPRINGS ………………………………………………………5-24

REMOVING THE VALVE AND VALVE SPRING …….…………………….5-25

CHECKING THE VALVE AND VALVE SPRING ……………….…………..5-26

INSTALLING THE VALVE AND VALVE SPRING ……………..…………..5-30

CYLINDER AND PISTON …………………………………………………….…………..5-32

REMOVING THE PISTON ……………………………………………………..….5-33

CHECKING THE CYLINDER AND PISTON …………..…………………….5-33

CHECKING THE PISTON RING …………………………………………………5-35

CHECKING THE PISTON PIN INSPECTION ……………………………….5-36

INSTALLING THE PISTON ………………………………….…………………….5-36

INSTALLING THE CYLINDER ……………………………………….…………..5-37

AC MAGNETO ………………………………………………………………………………..5-38

REMOVING THE AC MAGNETO ROTOR ……………………………………5-40

CHECKING THE COIL ………………………………………………………………5-40

CHECKING THE STARTER CLUTCH …………………………………………5-41

INSTALLING THE AC MAGNETO ROTOR ………………………………….5-42

GEN

INFO 1

SPEC 2

CHK

ADJ 3

CHAS 4

ENG 5

COOL 6

CARB 7

ELEC 8

TRBL

SHTG 9

–+

CLUTCH ……………………………..……………………………………………..…………..5-43

REMOVING THE CLUTCH ……..……………………………………………..….5-47

REMOVING THE PRIMARY DRIVE GEAR

AND BALANCER DRIVEN GEAR ……………………………………………5-47

CHECKING THE FRICTION PLATE ……………………………………………5-48

CHECKING THE CLUTCH PLATE …….……………………………………….5-48

CHECKING THE CLUTCH SPRING ……………………………………………5-49

CHECKING THE CLUTCH HOUSING …………………………………………5-49

CHECKING THE CLUTCH BOSS ……………….………………………………5-49

CHECKING THE PRESSURE PLATE …………………………………………5-49

CHECKING THE PULL LEVER SHAFT AND PULL ROD ….…………..5-50

CHECKING THE PRIMARY DRIVE …………………………………………….5-50

CHECKING THE BALANCER DRIVE ……………………………..…………..5-50

INSTALLING THE PRIMARY DRIVE GEAR

AND BALANCER DRIVEN GEAR ……………………………………………5-51

INSTALLING THE CLUTCH …………………………………………..…………..5-52

OIL PUMP ………………………………………………………………………….…………..5-54

CHECKING THE OIL PUMP …………………………………………………..….5-56

ASSEMBLING THE OIL PUMP……………………………………………………5-56

SHIFT SHAFT ………………………………………..……………………………………….5-57

CHECKING THE SHIFT SHAFT …………………………………………………5-59

CHECKING THE STOPPER LEVER ….……………………………………….5-59

CHECKING THE SHIFT GUIDE AND SHIFT LEVER …………………….5-59

CHECKING THE SEGMENT ………………………………..…………………….5-59

INSTALLING THE SHIFT LEVER ……………………………………………….5-59

INSTALLING THE STOPPER LEVER ..……………………………………….5-60

INSTALLING THE SHIFT SHAFT ……………………………………………….5-61

CRANKCASE ………………………………………………………………………………….5-62

TIMING CHAIN AND SPEED SENSOR ROTOR ……………………….….5-62

CRANKCASE ………………………………….……………………………………….5-64

CRANKCASE BEARING ………………………………………………………..….5-65

SEPARATING THE CRANKCASE……………….………………………………5-66

CHECKING THE TIMING CHAIN AND GUIDE ……………………………..5-66

CHECKING THE OIL STRAINER ……………………………………………….5-66

CHECKING THE CRANKCASE ………………………………………………….5-67

CHECKING THE BEARINGS ……………………………………………………..5-67

ASSEMBLING THE CRANKCASE ………………………………………………5-67

CRANKSHAFT AND BALANCER ………………………………………………….….5-69

REMOVING THE CRANKSHAFT ……………………………………………….5-70

CHECKING THE CRANKSHAFT ………………………………………………..5-70

INSTALLING THE CRANKSHAFT ………………………………….…………..5-71

TRANSMISSION ……………………………………………..………………………………5-72

MAIN AXLE .…………………………………………….………………………………5-74

DRIVE AXLE ……………………………………………………………………………5-75

CHECKING THE SHIFT FORK …………………………………………………..5-77

CHECKING THE SHIFT DRUM ………………………………………………….5-77

CHECKING THE TRANSMISSION ……………………………………………..5-77

ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ……………………..5-78

INSTALLING THE TRANSMISSION ……………………………….…………..5-79

CHAPTER 6.

COOLING SYSTEM

RADIATOR ……………………………………………………………………………………….6-1

CHECKING THE RADIATOR ……………………………………………………….6-3

INSTALLING THE RADIATOR ……………………………………….…………….6-4

THERMOSTAT ………………………………………………..………………………………..6-5

CHECKING THE THERMOSTAT …………………………………………….……6-7

ASSEMBLING THE THERMOSTAT ……………………..………………………6-7

WATER PUMP ………………………………………………..………………………………..6-8

DISASSEMBLING THE WATER PUMP ……………………………………….6-11

CHECKING THE WATER PUMP ………………………………………………..6-11

ASSEMBLING THE WATER PUMP …………………………………………….6-12

CHAPTER 7.

CARBURETION

CARBURETORS …………………………………….…………………………………………7-1

DISASSEMBLING THE CARBURETOR ………………………….…………….7-5

CHECKING THE CARBURETOR ………………………………………………… 7-5

ASSEMBLING THE CARBURETOR ……………………..………………………7-7

ADJUSTING THE FUEL LEVEL …………………………………………………… 7-8

GEN

INFO 1

SPEC 2

CHK

ADJ 3

CHAS 4

ENG 5

COOL 6

CARB 7

ELEC 8

TRBL

SHTG 9

–+

CHAPTER 8.

ELECTRICAL

ELECTRICAL COMPONENTS ……………………………………………………………8-1

CHECKING THE SWITCH ………………………………..………………………………..8-2

CHECKING THE SWITCH …………………………………..………………………8-2

CHECKING A SWITCH SHOWN IN THE MANUAL ………………………..8-2

CHECKING THE SWITCH CONTINUITY ………………………………………8-3

IGNITION SYSTEM ………………………………………….………………………………..8-5

CIRCUIT DIAGRAM ……………….……………………………………………..……8-5

TROUBLESHOOTING ………………………………………………………………..8-6

ELECTRIC STARTING SYSTEM ………………………………………………………8-11

CIRCUIT DIAGRAM ……………….……………………………………………..….8-11

STARTING CIRCUIT OPERATION ………………………………………….…. 8-12

TROUBLESHOOTING ………………………………………………………………8-13

STARTER MOTOR ……….……………………………………………..…………..8-16

CHECKING THE STARTER MOTOR ………….………………………………8-17

ASSEMBLING THE STARTER MOTOR ………………………….…………..8-18

CHARGING SYSTEM ………………………………………………………….…………..8-19

CIRCUIT DIAGRAM ……………….……………………………………………..….8-19

TROUBLESHOOTING ………………………………………………………………8-20

LIGHTING SYSTEM …………………………………………………………….…………..8-22

CIRCUIT DIAGRAM ……………….……………………………………………..….8-22

TROUBLESHOOTING ………………………………………………………………8-23

CHECKING THE LIGHTING SYSTEM …………………………………………8-25

SIGNAL SYSTEM ………………………………………………………………………..….8-27

CIRCUIT DIAGRAM ……………….……………………………………………..….8-27

TROUBLESHOOTING ………………………………………………………………8-28

CHECKING THE SIGNAL SYSTEM …..……………………………………….8-30

COOLING SYSTEM …………………………………………………..…………………….8-36

CIRCUIT DIAGRAM ……………….……………………………………………..….8-36

TROUBLESHOOTING ….……………………………………………..…………..8-37

CHAPTER 9.

TROUBLESHOOTING

STARTING FAILURE/HARD STARTING ……………………………………………..9-1

FUEL SYSTEM …………………………………………………………………………..9-1

ELECTRICAL SYSTEM ………………………………………………………….……9-1

COMPRESSION SYSTEM …………………………………………………………..9-2

POOR IDLE SPEED PERFORMANCE ………………………………………………..9-2

POOR IDLE SPEED PERFORMANCE ………………………………………….9-2

POOR MEDIUM AND HIGH-SPEED PERFORMANCE ………………………….9-2

POOR MEDIUM AND HIGH-SPEED PERFORMANCE …………………..9-2

FAULTY GEAR SHIFTING …………………………………………………..…………….9-3

HARD SHIFTING ………………………………………………..………………………9-3

SHIFT PEDAL DOES NOT MOVE ………………………………………………..9-3

JUMP-OUT GEAR ………………….…………………………………….…………….9-3

CLUTCH SLIPPING/DRAGGING ………………………………..………………………9-3

CLUTCH SLIPPING ……………………………………………………..…………….9-3

CLUTCH DRAGGING …………………………………………………..…………….9-3

OVERHEATING …………………………………………………………………………..……9-4

OVERHEATING …………………………………………………………………………9-4

OVER COOLING …………………………………….…………………………………………9-4

COOLING SYSTEM ……………….……………………………………………..……9-4

FAULTY BRAKE …………………………………….………………………………………… 9-4

POOR BRAKING EFFECT …………………………………………………………..9-4

SHOCK ABSORBER MALFUNCTION …………………………………………………9-5

MALFUNCTION ……………………………….…………………………………………9-5

UNSTABLE HANDLING …………………………………………….………………………9-5

UNSTABLE HANDLING ………………………………………………………………9-5

LIGHTING SYSTEM …………………………………………………………….…………….9-5

HEADLIGHT DARK …………………………………………………………………….9-5

BULB BURNT OUT ………………..……………………………………………..……9-5

1 — 1

GEN

INFO

MACHINE IDENTIFICATION

GENERAL INFORMATION

MACHINE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is

stamped into the left side of the frame.

MODEL LABEL

The model label 1 is affixed to the air filter

case cover. This information will be needed to

order spare parts.

1 — 2

GEN

INFO

EB101000

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL

PROCEDURES

1.Remove all dirt, mud, dust and foreign mate-

rial before removal and disassembly.

2.Use proper tools and cleaning equipment.

Refer to the “SPECIAL TOOLS” section.

3.When disassembling the machine, always

keep mated parts together. This includes

gears, cylinder, piston and other parts that

have been “mated” through normal wear.

Mated parts must always be reused or

replaced as an assembly.

4.During machine disassembly, clean all parts

and place them in trays in the order of disas-

sembly. This will speed up assembly and

allow for the correct installation of all parts.

5.Keep all parts away from any source of fire.

EB101010

REPLACEMENT PARTS

1.Use only genuine Yamaha parts for all

replacements. Use oil and grease recom-

mended by Yamaha for all lubrication jobs.

Other brands may be similar in function and

appearance, but inferior in quality.

EB101020

GASKETS, OIL SEALS AND O-RINGS

1.Replace all gaskets, seals and O-rings when

overhauling the engine. 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.

IMPORTANT INFORMATION

1 — 3

GEN

INFO

EB101030

LOCK WASHERS/PLATES AND COTTER

PINS

1.Replace all lock washers/plates 1 and cotter

pins after removal. Bend lock tabs along the

bolt or nut flats after the bolt or nut has been

tightened to specification.

EB101040

BEARINGS AND OIL SEALS

1.Install bearings and oil seals so that the

manufacturer’s marks or numbers are visible.

When installing oil seals, apply a light coat-

ing of lightweight lithium base grease to the

seal lips. Oil bearings liberally when install-

ing, if appropriate.

1Oil seal

CAUTION:

Do not use compressed air to spin the

bearings dry. This will damage the bearing

surfaces.

1Bearing

EB101050

CIRCLIPS

1.Check all circlips carefully before reassem-

bly. Always replace piston pin clips after one

use. Replace distorted circlips. When install-

ing a circlip 1, make sure that the sharp-

edged corner 2 is positioned opposite the

thrust 3 it receives. See sectional view.

4Shaft

IMPORTANT INFORMATION

1 — 4

GEN

INFO

CHECKING OF CONNECTIONS

EB801000

CHECKING OF CONNECTIONS

Check the connectors for stains, rust, mois-

ture, etc.

1.Disconnect:

●Connector

2.Check:

●Connector

Moisture → Dry each terminal with an air

blower.

Stains/rust → Connect and disconnect the

terminals several times.

3.Check:

●Connector leads

Looseness → Bend up the pin 1 and con-

nect the terminals.

4.Connect:

●Connector terminals

NOTE:

The two terminals “click” together.

5.Check:

●Continuity (using a pocket tester)

NOTE:

●If there is no continuity, clean the terminals.

●When checking the wire harness be sure to

perform steps 1 to 3.

●As a quick remedy, use a contact revitalizer

available at most part stores.

●Check the connector with a pocket tester as

shown.

1 — 5

GEN

INFO

SPECIAL TOOLS

EB102001

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use

only the appropriate special tools; this will help prevent damage caused by the use of inappropriate

tools or improvised techniques. Special tools may differ by shape and part number from country to

country. In such a case, two types are provided.

When placing an order, refer to the list provided below to avoid any mistakes.

For US and CDN

P/N. YM-, YU-, YS-, YK-, ACC-

Except for US and CDN

P/N. 90890-

Tool No. Tool name/How to use Illustration

Bolt

90890-01083

Weight

90890-01084

Set

YU-01083-A

Slide hammer bolt (M6)/weight/set

These tools are used to remove the rocker

arm shaft.

90890-01135

YU-01135-A

Crankcase separating tool

This tool is used to separate the crank-

case.

Pot

90890-01274

Bolt

90890-01275

Crankshaft installer pot

Crankshaft installer bolt

These tools are used to install the crank-

shaft.

YU-90050

Crankshaft installer set

These tools are used to install the crank-

shaft.

Adapter

90890-04059

YM-90069

Spacer

90890-04081

YM-91044

Adapter

Spacer (crankshaft installer)

These tools are used to install the crank-

shaft.

90890-01016

Spacer

This tool is used to install the crankshaft.

1 — 6

GEN

INFO

SPECIAL TOOLS

90890-01304

YU-01304

Piston pin puller

This tool is used to remove the piston pin.

90890-01311

YM-08035

Tappet adjusting tool (3 mm)

This tool is necessary for adjusting the

valve clearance.

90890-01312

YM-01312-A

Fuel level gauge

This gauge is used to measure the fuel

level in the float chamber.

90890-01325

YU-24460-01

Radiator cap tester

This tool is used to check the cooling sys-

tem.

90890-01352

YU-33984

Adapter

This tool is used to check the cooling sys-

tem.

90890-01327

YM-01327

Damper rod holder (30 mm)

This tool is needed to loosen and tighten

the steering stem bearing retainer.

90890-01362

YU-33270

Flywheel puller

These tools are needed to remove the

rotor.

90890-01419

YM-37132

Axle nut wrench (50 mm)

This tool is needed to loosen or tighten the

rear axle nut.

Tool No. Tool name/How to use Illustration

1 — 7

GEN

INFO

SPECIAL TOOLS

90890-01469

YM-01469

Oil filter wrench

This tool is needed to loosen or tighten

the oil filter cartridge.

90890-01474

YM-01474

Ball joint remover/installer set

These tools are used to removing or

installing the ball joint.

90890-01480

YM-01480

Ball joint remover/installer attachment set

These tools are used to removing or

installing the ball joint.

90890-01701

YS-01880

Sheave holder

This tool is needed to hold the AC mag-

neto rotor when removing or installing the

AC magneto rotor bolts.

Set

90890-03081

YU-33223

Adapter

90890-04082

YU-33223-3

Compression gauge set

Adapter

These tools are needed to measure

engine compression.

90890-03112

YU-03112

Pocket tester

This instrument is needed for checking the

electrical system.

90890-03141

YM-33277-A

Timing light

This tool is necessary for checking ignition

timing.

Compressor

90890-04019

YM-04019

Attachment

90890-01243

Valve spring compressor

Valve spring compressor attachment

This tool is needed to remove and install

the valve assemblies.

Tool No. Tool name/How to use Illustration

1 — 8

GEN

INFO

SPECIAL TOOLS

Middle driven shaft

bearing driver

90890-04058

YM-04058-1

Mechanical seal

installer

90890-04078

YM-33221

Middle driven shaft bearing driver

Mechanical seal installer

These tools are used to install the water

pump seal.

90890-04064

YM-4064-A

Valve guide remover (ø 6)

This tool is needed to remove and install

the valve guide.

90890-04065

YM-04065-A

Valve guide installer (ø 6)

This tool is needed to install the valve

guide.

90890-04066

YM-04066

Valve guide reamer (ø 6)

This tool is needed to rebore the new

valve guide.

90890-04086

YM-91042

Clutch holding tool

This tool is needed to hold the clutch car-

rier when removing or installing the carrier

nut.

90890-06754

Ignition checker

This instrument is necessary for checking

the ignition system components.

YM-34487

Dynamic spark tester

This instrument is necessary for checking

the ignition system components.

Bond

90890-85505

Sealant

ACC-11001-05-01

Yamaha bond No. 1215

Sealant (Quick Gasket®)

This sealant (bond) is used on crankcase

mating surfaces, etc.

Tool No. Tool name/How to use Illustration

2 — 1

SPEC

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard

Model code: 5LP1 : (Except for California)

5LP3 : (For California)

Dimensions:

Overall length 1,830 mm (72.0 in)

Overall width 1,100 mm (43.3 in)

Overall height 1,150 mm (45.3 in)

Seat height 860 mm (33.9 in)

Wheelbase 1,245 mm (49.0 in)

Minimum ground clearance 265 mm (10.4 in)

Minimum turning radius 3,300 mm (129.9 in)

Basic weight:

With oil and full fuel tank 193 kg (426 lb)

Engine:

Engine type Liquid-cooled 4-stroke, SOHC

Cylinder arrangement Forward-inclined single cylinder

Displacement 660 cm3

Bore × stroke 100.0 × 84.0 mm (3.94 × 3.31 in)

Compression ratio 9.2 : 1

Standard compression pressure (at sea level) 1,250 kPa (12.5 kg/cm2, 181 psi)

Starting system Electric starter

Lubrication system: Dry sump

Oil type or grade:

Engine oil

API service SE, SF, SG type or higher

Oil capacity:

Engine oil

Periodic oil change 1.9 L (1.67 lmp qt, 2.01 US qt)

With oil filter replacement 1.95 L (1.72 lmp qt, 2.06 US qt)

Total amount 2.3 L (2.02 lmp qt, 2.43 US qt)

Radiator capacity (including all routes) 1.3 L (1.14 lmp qt, 1.37 US qt)

Air filter: Wet type element

Fuel:

Type Unleaded fuel

Fuel tank capacity 12 L (2.64 lmp gal, 3.17 US gal)

Fuel reserve amount 2.6 L (0.57 lmp gal, 0.69 US gal)

0

°

10

°

30

°

50

°

70

°

90

°

110

°

YAMALUBE 4 (10W30) or SAE 10W30

-20

°

-10

°

0

°

10

°

20

°

30

°

40

°

YAMALUBE 4 (20W40) or SAE 20W40

SAE 5W30

130°F

50

°C

GENERAL SPECIFICATIONS

2 — 2

SPEC

Carburetor:

Type/quantity BSR33/2

Manufacturer MIKUNI

Spark plug:

Type/manufacturer DPR8EA-9/NGK

Spark plug gap 0.8 ~ 0.9 mm (0.031 ~ 0.035 in)

Clutch type: Wet, multiple disc

Transmission:

Primary reduction system Spur gear

Primary reduction ratio 71/34 (2.088)

Secondary reduction system Chain drive

Secondary reduction ratio 40/13 (3.076)

Transmission type Constant mesh, 5-speed/forward.

1-speed/reverse

Operation Left foot operation

Gear ratio

1st gear 34/14 (2.428)

2nd gear 29/19 (1.526)

3rd gear 26/21 (1.238)

4th gear 22/21 (1.047)

5th gear 19/21 (0.904)

Reverse gear 28/23 × 23 × 16 (1.750)

Chassis:

Frame type Steel tube frame

Caster angle 8°

Camber angle –1°

Kingpin angle 14.5°

Kingpin offset 5 mm (0.20 in)

Trail 47 mm (1.85 in)

Tread (STD) front 925 mm (36.42 in)

rear 840 mm (33.07 in)

Toe-in 0 ~ 10 mm (0 ~ 0.39 in)

Tire:

Type Tubeless

Size front AT21 × 7–10

rear AT20 × 10–9

Manufacturer front DUNLOP

rear DUNLOP

Type front KT331 Radial

rear KT335 Radial

Item Standard

GENERAL SPECIFICATIONS

2 — 3

SPEC

Tire pressure (cold tire):

Maximum load* 100 kg (220 lb)

Off-road riding front 27.5 kPa (0.275 kg/cm2, 4.0 psi)

rear 27.5 kPa (0.275 kg/cm2, 4.0 psi)

*Load in total weight of cargo, rider and acces-

sories

Brake:

Front brake type Dual disc brake

operation Right hand operation

Rear brake type Single disc brake

operation Right foot operation

Suspension:

Front suspension Double wishbone

Rear suspension Swingarm (link suspension)

Shock absorber:

Front shock absorber Coil spring/oil damper

Rear shock absorber Coil spring/gas-oil damper

Wheel travel:

Front wheel travel 230 mm (9.06 in)

Rear wheel travel 220 mm (8.66 in)

Electrical:

Ignition system DC-C.D.I.

Generator system A.C. magneto

Battery type YTX14-BS

Battery capacity 12 V 12 Ah

Headlight type: Krypton bulb

Bulb voltage/wattage × quantity:

Headlight 12 V 30 W/30 W × 2

Tail/brake light 12 V 5 W/21 W × 1

Indicator and warning lights

Neutral 12 V 1.7 W × 1

Reverse 12 V 1.7 W × 1

Coolant temperature 12 V 1.7 W × 1

Item Standard

GENERAL SPECIFICATIONS

2 — 4

SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Item Standard Limit

Cylinder head:

Warp limit —- 0.05 mm

(0.002 in)

Cylinder:

Bore size 100.005 ~ 100.045 mm

(3.9372 ~ 3.9388 in) 100.1 mm

(3.94 in)

Measuring point *50 mm (2.0 in) —-

Camshaft:

Drive method Chain drive (Left) —-

Camshaft cap inside diameter 23.000 ~ 23.021 mm

(0.9055 ~ 0.9063 in) —-

Camshaft journal diameter 22.967 ~ 22.980 mm

(0.9042 ~ 0.9047 in) —-

Camshaft journal-to-camshaft cap clearance 0.020 ~ 0.054 mm

(0.0008 ~ 0.0021 in) —-

Cam dimensions

Intake “A” 35.69 ~ 35.79 mm

(1.4051 ~ 1.4091 in) 35.59 mm

(1.4012 in)

“B” 30.15 ~ 30.25 mm

(1.1870 ~ 1.1909 in) 30.05 mm

(1.1831 in)

“C” 5.74 mm (0.2260 in) —-

Exhaust “A” 36.50 ~ 36.60 mm

(1.437 ~ 1.441 in) 36.40 mm

(1.4331 in)

“B” 30.15 ~ 30.25 mm

(1.187 ~ 1.191 in) 30.05 mm

(1.1831 in)

“C” 6.55 mm (0.2579 in) —-

C

A

B

MAINTENANCE SPECIFICATIONS

2 — 5

SPEC

Camshaft runout limit —- 0.03 mm

(0.0012 in)

Timing chain:

Timing chain type/No. of links 75-RH2015/126 —-

Timing chain adjustment method Automatic —-

Rocker arm/rocker arm shaft:

Shaft outside diameter 11.976 ~ 11.991 mm

(0.4715 ~ 0.4721 in) —-

Arm-to-shaft clearance 0.009 ~ 0.042 mm

(0.0004 ~ 0.0017 in) —-

Valve, valve seat, valve guide:

Valve clearance (cold) IN 0.10 ~ 0.15 mm

(0.0039 ~ 0.0059 in) —-

EX 0.15 ~ 0.20 mm

(0.0059 ~ 0.0079 in) —-

Valve dimensions

“A” head diameter IN 29.9 ~ 30.1 mm

(1.1772 ~ 1.1850 in) —-

EX 31.9 ~ 32.1 mm

(1.2559 ~ 1.2638 in) —-

“B” face width IN 2.25 mm (0.0886 in) —-

EX 2.26 mm (0.0890 in) —-

“C” seat width IN 0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in) 1.6 mm

(0.0630 in)

EX 0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in) 1.6 mm

(0.0630 in)

“D” margin thickness IN 0.85 ~ 1.15 mm

(0.0335 ~ 0.0453 in) —-

EX 0.85 ~ 1.15 mm

(0.0335 ~ 0.0453 in) —-

Stem outside diameter IN 5.975 ~ 5.990 mm

(0.2352 ~ 0.2358 in) 5.945 mm

(0.2341 in)

EX 5.960 ~ 5.975 mm

(0.2346 ~ 0.2352 in) 5.930 mm

(0.2335 in)

Guide inside diameter IN 6.000 ~ 6.012 mm

(0.2362 ~ 0.2367 in) 6.040 mm

(0.2378 in)

EX 6.000 ~ 6.012 mm

(0.2362 ~ 0.2367 in) 6.040 mm

(0.2378 in)

Item Standard Limit

Head Diameter

B

Face Width

C

Seat Width

D

Margin Thickness

A

MAINTENANCE SPECIFICATIONS

2 — 6

SPEC

Stem-to-guide clearance IN 0.010 ~ 0.037 mm

(0.0004 ~ 0.0015 in) 0.08 mm

(0.0031 in)

EX 0.025 ~ 0.052 mm

(0.0010 ~ 0.0020 in) 0.10 mm

(0.0039 in)

Stem runout limit —- 0.01 mm

(0.0004 in)

Valve seat width IN 0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in) 1.6 mm

(0.0630 in)

EX 0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in) 1.6 mm

(0.0630 in)

Valve spring:

Free length IN 35.95 mm (1.42 in) 34.15 mm

(1.34 in)

EX 37.75 mm (1.49 in) 35.86 mm

(1.41 in)

Set length (valve closed) IN 27.2 mm (1.07 in) —-

EX 30.7 mm (1.21 in) —-

Compressed pressure

(installed) IN 149 ~ 173 N (15.19 ~ 17.64 kg,

33.50 ~ 38.89 lb) —-

EX 165 ~ 191 N (16.83 ~ 19.49 kg,

37.09 ~ 42.94 lb) —-

Tilt limit IN 2.5°/1.6 mm

(2.5°/0.06 in)

EX 2.5°/1.6 mm

(2.5°/0.06 in)

Direction of winding

(top view) IN Clockwise —-

EX Clockwise —-

Item Standard Limit

*

MAINTENANCE SPECIFICATIONS

2 — 7

SPEC

Piston:

Piston to cylinder clearance 0.05 ~ 0.07 mm

(0.0020 ~ 0.0028 in) 0.15 mm

(0.0059 in)

Piston size “D” 99.945 ~ 99.995 mm

(3.9348 ~ 3.9368 in) —-

Measuring point “H” 2.5 mm (0.10 in) —-

Piston off-set 1.0 mm (0.04 in) —-

Piston pin bore inside diameter 22.004 ~ 22.015 mm

(0.8663 ~ 0.8667 in) 22.045 mm

(0.8679 in)

Piston pin outside diameter 21.991 ~ 22.000 mm

(0.8658 ~ 0.8661 in) 21.971 mm

(0.8650 in)

Piston rings:

Top ring

Type Barrel —-

Dimensions (B × T) 1.2 × 3.8 mm

(0.0472 × 0.1496 in) —-

End gap (installed) 0.30 ~ 0.45 mm

(0.0118 ~ 0.0177 in) 0.70 mm

(0.0276 in)

Side clearance (installed) 0.04 ~ 0.08 mm

(0.0016 ~ 0.0031 in) 0.13 mm

(0.0051 in)

2nd ring

Type Taper —-

Dimensions (B × T) 1.2 × 4.0 mm

(0.0472 × 0.1575 in) —-

End gap (installed) 0.30 ~ 0.45 mm

(0.0118 ~ 0.0177 in) 0.80 mm

(0.0315 in)

Side clearance 0.03 ~ 0.07 mm

(0.0012 ~ 0.0028 in) 0.13 mm

(0.0051 in)

Oil ring

Dimensions (B × T) 2.5 × 3.4 mm

(0.0984 × 0.1339 in) —-

End gap (installed) 0.2 ~ 0.7 mm

(0.0079 ~ 0.0276 in) —-

Item Standard Limit

H

D

T

B

B

T

B

T

MAINTENANCE SPECIFICATIONS

2 — 8

SPEC

Crankshaft:

Crank width “A” 74.95 ~ 75.00 mm

(2.9508 ~ 2.9528 in) —-

Runout limit C1 —- 0.03 mm

(0.0012 in)

C2 —- 0.03 mm

(0.0012 in)

Big end side clearance “D” 0.32 ~ 0.64 mm

(0.0126 ~ 0.0252 in) 1.0 mm

(0.0394 in)

Big end radial clearance “E” 0.010 ~ 0.025 mm

(0.0004 ~ 0.0010 in) —-

Small end free play “F” 0.8 mm (0.0315 in) —-

Balancer:

Balancer drive method Gear —-

Clutch:

Friction plate 1

Thickness 2.74 ~ 2.86 mm

(0.108 ~ 0.113 in) 2.6 mm

(0.102 in)

Quantity 6 —-

Friction plate 2

Thickness 2.94 ~ 3.06 mm

(0.116 ~ 0.120 in) 2.8 mm

(0.110 in)

Quantity 2 —-

Clutch plate

Thickness 1.1 ~ 1.3 mm

(0.043 ~ 0.051 in) —-

Quantity 7 —-

Max. warpage —- 0.2 mm

(0.008 in)

Clutch spring

Free length 42.8 mm (1.69 in) 40.7 mm

(1.60 in)

Quantity 5 —-

Min. length —- 40.8 mm

(1.61 in)

Clutch release method Outer pull, rack and pinion pull —-

Item Standard Limit

MAINTENANCE SPECIFICATIONS

2 — 9

SPEC

Transmission:

Main axle deflection limit —- 0.08 mm

(0.0031 in)

Drive axle deflection limit —- 0.08 mm

(0.0031 in)

Shifter:

Shifter type Shift drum and guide bar —-

Decompression device:

Device type Auto decomp —-

Air filter oil grade: Engine oil —-

Carburetors:

I. D. mark 5LP1 00 —-

Main jet (M.J) Carburetor #1 : #140

Carburetor #2 : #145 —-

Main air jet (M.A.J) #130 —-

Jet needle (J.N) 5ND16-56-3 —-

Needle jet (N.J) P-6M (#826) —-

Pilot air jet (P.A.J.1) Carburetor #1 : #80

Carburetor #2 : #150 —-

Pilot air jet (P.A.J.2) 1.3 —-

Pilot outlet (P.O) Carburetor #1 : 1.0

Carburetor #2 : 0.9 —-

Pilot jet (P.J) #22.5 —-

Bypass 1 (B.P.1) 0.8 —-

Bypass 2 (B.P.2) 0.8 —-

Valve seat size (V.S) 2.0 —-

Starter jet (G.S.1) #95 —-

Starter jet (G.S.2) 0.5

Throttle valve size (Th.V) #80 —-

Float height (F.H) 13 mm (0.51 in) —-

Fuel level (F.L) 3 ~ 4 mm (0.12 ~ 0.16 in) —-

Engine idle speed 1,450 ~ 1,550 r/min —-

Intake vacuum 32.0 ~ 33.3 kPa (240 ~ 250 mmHg,

9.45 ~ 9.83 inHg) —-

Oil pump:

Oil filter type Paper —-

Oil pump type Trochoid —-

Tip clearance “A” or “B” 0.12 mm (0.005 in) 0.2 mm

(0.008 in)

Side clearance 0.03 ~ 0.08 mm

(0.001 ~ 0.003 in) —-

Bypass valve setting pressure 80 ~ 120 kPa (0.8 ~ 1.2 kg/cm2,

11.6 ~ 17.4 psi) —-

Oil pressure (hot) 65 kPa (0.65 kg/cm2, 9.4 psi) at

1,500 r/min —-

Pressure check location Cylinder head —-

Item Standard Limit

MAINTENANCE SPECIFICATIONS

2 — 10

SPEC

Cooling system:

Radiator core

Width 219 mm (8.62 in) —-

Height 300 mm (11.8 in) —-

Depth 16 mm (0.63 in) —-

Radiator cap opening pressure 95 ~ 125 kPa (0.95 ~ 1.25 kg/cm2,

13.8 ~ 18.1 psi) —-

Radiator capacity 0.55 L (0.48 Imp qt, 0.58 US qt) —-

Coolant reservoir

Capacity 0.29 L (0.26 Imp qt, 0.31 US qt) —-

From low to full level 0.165 L (0.15 Imp qt, 0.17 US qt) —-

Water pump:

Type Single suction centrifugal pump —-

Reduction ratio 33/34 (0.971)

Lubrication chart:

Item Standard Limit

MAINTENANCE SPECIFICATIONS

2 — 11

SPEC

Cylinder head tightening sequence:

Item Standard Limit

MAINTENANCE SPECIFICATIONS

2 — 12

SPEC

Tightening torques

Part to be tightened Part

name Thread

size Q’ty Tightening torque Remarks

Nm m·kg ft·lb

Cylinder head (exhaust pipe) Stud bolt M6 4 7 0.7 5.1

Cylinder head Bolt M9 4 38 3.8 27

Bolt M9 2 38 3.8 27

Bolt M6 1 10 1.0 7.2

Spark plug — M12 1 18 1.8 13

Cylinder head cover Bolt M6 17 10 1.0 7.2

Camshaft end cap Bolt M6 1 10 1.0 7.2

Oil check bolt — M6 1 7 0.7 5.1

Tappet cover (exhaust) — M32 2 12 1.2 8.7

Tappet cover (intake) Bolt M6 4 10 1.0 7.2

Cylinder Bolt M10 2 42 4.2 30

Bolt M10 2 42 4.2 30

Bolt M6 2 10 1.0 7.2

Timing chain tensioner Bolt M6 2 10 1.0 7.2

Timing chain tensioner cap Bolt M16 1 22 2.2 16

Timing chain guide (intake) Bolt M6 2 8 0.8 5.8

Camshaft sprocket Bolt M7 2 20 2.0 14

Rocker arm shaft Bolt M6 2 10 1.0 7.2

Valve adjusting screw Nut M6 5 14 1.4 10

Radiator Bolt M6 2 7 0.7 5.1

Coolant drain bolt — M6 1 10 1.0 7.2

Engine oil drain bolt (oil tank) — M10 1 25 2.5 18

Engine oil drain bolt (engine) — M14 1 30 3.0 22

Oil filter bolt Union bolt M20 1 63 6.3 45 E

Oil filter cartridge — M20 1 17 1.7 12

Oil delivery pipe 1 Union bolt M10 2 20 2.0 14

Oil delivery pipe 2 Union bolt M8 2 18 1.8 13

Oil pipe joint — M14 1 50 5.0 36

Oil pipe 1 and oil pipe joint Nut M16 1 35 3.5 25

Oil pipe 2 and oil tank Nut M16 1 35 3.5 25

Air filter case Bolt M6 2 7 0.7 5.1

Carburetor clamp Bolt M4 4 5 0.5 3.6

Exhaust pipe 1 and exhaust pipe 2 Bolt M8 1 16 1.6 12

Exhaust pipe protector Bolt M6 4 10 1.0 7.2 LT

Spark arrester Bolt M6 1 8 0.8 5.8

Muffler and exhaust pipe 2 Bolt M8 1 20 2.0 14

Muffler Bolt M8 2 26 2.6 19

Silencer cap Bolt M6 3 10 1.0 7.2 LT

Exhaust pipe Nut M6 4 10 1.0 7.2

MAINTENANCE SPECIFICATIONS

2 — 13

SPEC

Bearing retainer Screw M6 4 7 0.7 5.1 LT

AC magneto rotor Nut M14 1 150 15.0 110

Starter clutch Bolt M6 6 16 1.6 11 LT

Balancer driven gear Nut M18 1 140 14.0 100 M

Use a lock

washer.

Primary drive gear Nut M20 1 150 15.0 110 M

Use a lock

washer.

Clutch spring Bolt M6 5 8 0.8 5.8

Clutch boss Nut M20 1 90 9.0 65 Use a lock

washer.

Pull lever shaft Bolt M6 1 7 0.7 5.1

Drive sprocket Nut M18 1 70 7.0 50 Use a lock

washer.

Oil seal retainer Bolt M6 2 10 1.0 7.2

Shift drum segment Bolt M8 1 30 3.0 22

Shift guide Bolt M6 2 10 1.0 7.2 LT

Stopper lever Bolt M6 1 10 1.0 7.2

Reverse shift lever Bolt M6 1 13 1.3 9.4

Shift arm Bolt M6 1 10 1.0 7.2

Shift pedal adjusting rod Nut M6 1 8 0.8 5.8 Left-hand

threads

Nut M6 1 8 0.8 5.8

Stator assembly Bolt M5 3 7 0.7 5.1 LT

Pick up coil Bolt M5 2 7 0.7 5.1 LT

AC magneto lead holder Bolt M6 2 10 1.0 7.2 LT

Ignition coil Bolt M6 2 7 0.7 5.1

Starter motor Bolt M6 2 10 1.0 7.2

Neutral switch — M10 1 20 2.0 14

Reverse switch — M10 1 20 2.0 14

Thermo switch 1 — M18 1 28 2.8 20

Thermo switch 2 — M18 1 28 2.8 20

Part to be tightened Part

name Thread

size Q’ty Tightening torque Remarks

Nm m·kg ft·lb

MAINTENANCE SPECIFICATIONS

2 — 14

SPEC

CHASSIS

Item Standard Limit

Steering system:

Steering bearing type Ball and race bearing —-

Front suspension:

Shock absorber travel 110 mm (4.33 in) —-

Fork spring free length 316.5 mm (12.46 in) —-

Spring fitting length 293.5 mm (11.56 in) —-

Spring rate (K1) 19.6 N/mm

(2.00 kg/mm, 111.92 lb/in) —-

Spring rate (K2) 29.4 N/mm

(3.00 kg/mm, 167.87 lb/in) —-

Optional spring No —-

Rear suspension:

Shock absorber travel 100 mm (3.94 in) —-

Spring free length 273 mm (10.75 in) —-

Spring fitting length 253 mm (9.96 in) —-

Spring rate (K1) 55 N/mm

(5.61 kg/mm, 314.05 lb/in) —-

Stroke (K1) 0 ~ 100 mm (0 ~ 3.94 in) —-

Optional spring No —-

Swingarm:

Free play limit end —- 1 mm

(0.04 in)

side —- 1 mm

(0.04 in)

Front wheel:

Type Panel wheel —-

Rim size 10 × 5.5 AT —-

Rim material Aluminum —-

Rim runout limit radial —- 2 mm

(0.08 in)

lateral —- 2 mm

(0.08 in)

Rear wheel:

Type Panel wheel —-

Rim size 9 × 8.5 AT —-

Rim material Aluminum —-

Rim runout limit radial —- 2 mm

(0.08 in)

lateral —- 2 mm

(0.08 in)

MAINTENANCE SPECIFICATIONS

2 — 15

SPEC

Front disc brake:

Type Dual —-

Disc outside diameter × thickness 161.0 × 3.5 mm (6.34 × 0.14 in) —-

Pad thickness inner 4.2 mm (0.17 in) 1 mm

(0.04 in)

Pad thickness outer 4.2 mm (0.17 in) 1 mm

(0.04 in)

Master cylinder inside diameter 12.7 mm (0.50 in) —-

Caliper cylinder inside diameter 32.03 mm (1.26 in) —-

Brake fluid type DOT 4 —-

Rear disc brake:

Type Single —-

Disc outside diameter × thickness 220.0 × 3.6 mm (8.66 × 0.14 in) —-

Pad thickness inner 4.5 mm (0.18 in) 1 mm

(0.04 in)

Pad thickness outer 4.5 mm (0.18 in) 1 mm

(0.04 in)

Master cylinder inside diameter 12.7 mm (0.50 in) —-

Caliper cylinder inside diameter 33.96 mm (1.34 in) —-

Brake fluid type DOT 4 —-

Brake lever and brake pedal:

Brake lever free play (at lever end) 0 mm (0 in) —-

Brake pedal position 4 mm (0.16 in)

(Below the top of footrest) —-

Throttle lever free play 3 ~ 5 mm (0.12 ~ 0.20 in) —-

Item Standard Limit

MAINTENANCE SPECIFICATIONS

2 — 16

SPEC

Tightening torques

Part to be tightened Thread size Tightening torque Remarks

Nm m·kg ft·lb

Engine bracket (upper) and frame M8 33 3.3 24

Engine bracket (upper) and engine M10 40 4.0 29

Engine bracket (lower) and frame M10 56 5.6 40

Engine bracket (lower) and engine M10 56 5.6 40

Engine bracket (middle and lower) and engine M10 56 5.6 40

Swingarm pivot shaft, engine and frame M16 95 9.5 68

Rear shock absorber and frame M10 32 3.2 23

Relay arm and swingarm M10 32 3.2 23

Connecting arm and frame M10 32 3.2 23

Relay arm and rear shock absorber M10 32 3.2 23

Relay arm and connecting arm M10 32 3.2 23

Drive chain guide and swingarm M6 7 0.7 5.1

Hub, brake caliper bracket and swingarm M12 90 9.0 65

Drive chain adjusting bolt and locknut M8 16 1.6 11

Front shock absorber and frame M10 45 4.5 32

Front shock absorber and front arm (lower) M10 45 4.5 32

Front arm (upper) and frame M10 38 3.8 27

Front arm (lower) and frame M10 32 3.2 23

Brake hose holder and front arm (upper) M6 7 0.7 5.1

Steering stem, pitman arm and frame M14 110 11 80

Steering stem bushing and frame M8 23 2.3 17 Use a lock

washer.

Steering stem and handlebar holder M8 23 2.3 17

Tie-rod end and locknut M10 15 1.5 11

Steering knuckle and front wheel hub M14 70 7.0 50

Steering knuckle and front arm (upper and lower) M10 25 2.5 18

Steering knuckle and tie-rod ball joint M10 25 2.5 18

Pitman arm and tie-rod ball joint M10 25 2.5 18

Frame and bearing retainer M42 40 4.0 29

Fuel tank and fuel cock M6 4 0.4 2.9

Fuel tank and frame M6 7 0.7 5.1

Front wheel and front wheel hub M10 45 4.5 32

Steering knuckle and front brake caliper M8 28 2.8 20

Front brake disc and front wheel hub M8 28 2.8 20 LT

Rear axle and rear wheel hub M14 120 12 85

Rear brake caliper and brake caliper bracket M8 28 2.8 20

Rear wheel and rear wheel hub M10 45 4.5 32

Driven sprocket and sprocket bracket M8 24 2.4 17

Front brake pipe nut M10 19 1.9 13

Front brake master cylinder and handlebar M6 7 0.7 5.1

MAINTENANCE SPECIFICATIONS

2 — 17

SPEC

HINWEIS:

NOTE:

Apply locking agent (LOCTITE®) to ring nuts threads.

1st: Tighten the inside ring nut 55 Nm (5.5 m • kg, 40 ft • lb).

2nd: Tighten the outside ring nut while holding the inside ring nut 190 Nm (19 m • kg, 140 ft • lb).

3rd: Loosen the inside ring nut while holding the outside ring nut 240 Nm (24 m • kg, 170 ft • lb).

Front brake master cylinder and brake lever M6 6 0.6 4.3

Front brake master cylinder and brake hose M10 27 2.7 19

Brake hose joint and frame M6 10 1.0 7.2

Bleed screw M8 6 0.6 4.3

Front brake pad holding bolt M10 18 1.8 13

Front brake caliper and brake hose M10 27 2.7 19

Front brake caliper retaining bolt M8 23 2.3 17

Rear axle ring nut M38 SEE NOTE

Rear brake pad holding bolt M10 18 1.8 13 Use a lock

washer.

Rear brake caliper and brake hose M10 30 3.0 22

Rear brake master cylinder and frame M8 20 2.0 14

Rear brake master cylinder and brake hose M10 30 3.0 22

Parking brake adjusting bolt and locknut M8 16 1.6 11

Rear brake disc and brake disc bracket M8 28 2.8 20

Rear brake fluid reservoir cover and bracket M6 4 0.4 2.9

Rear brake fluid reservoir and bracket M6 4 0.4 2.9

Brake hose holder and swingarm M6 7 0.7 5.1

Front bumper and frame M8 31 3.1 22

Front fender bracket and frame M8 16 1.6 11

Rear carrier bar and frame M8 23 2.3 17

Footrest and frame M10 65 6.5 48

Footrest guard bracket and frame M8 33 3.3 24

Footrest and footrest guard bracket M8 16 1.6 11

Footrest guard bracket and rear fender M6 7 0.7 5.1

Battery holding bracket and frame M6 7 0.7 5.1

Air filter case and frame M6 7 0.7 5.1

Carburetor clamp screw M4 5 0.5 3.6

Tail/brake light bracket and frame M6 7 0.7 5.1

Tail/brake light bracket and tail/brake light M6 7 0.7 5.1

Swingarm skid plate and swingarm M6 7 0.7 5.1

Swingarm skid plate and swingarm M8 16 1.6 11

Drive chain tensioner and frame M8 32 3.2 23

Engine skid plate and frame M6 7 0.7 5.1

Main frame and rear frame M10 53 5.3 38

Part to be tightened Thread size Tightening torque Remarks

Nm m·kg ft·lb

MAINTENANCE SPECIFICATIONS

2 — 18

SPEC

ELECTRICAL

Item Standard Limit

Voltage: 12 V —-

Ignition system:

Ignition timing (B.T.D.C.) 12°/ 1,500 r/min —-

Advancer type Digital type —-

C.D.I.:

Magneto model/manufacturer F4T260/MITSUBISHI —-

Pickup coil resistance/color 445 ~ 545 Ω at 20 °C (68 °F)/

White/Red – White/Green —-

Rotor rotation direction detection coil resis-

tance/color 0.069 ~ 0.085 Ω at 20 °C (68 °F)/

Red – White/Blue —-

C.D.I. unit model/manufacturer F8T37971/MITSUBISHI —-

Ignition coil:

Model/manufacturer 2JN/YAMAHA —-

Minimum spark gap 6 mm (0.24 in) —-

Primary winding resistance 0.18 ~ 0.28 Ω at 20 °C (68 °F) —-

Secondary winding resistance 6.32 ~ 9.48 kΩ at 20 °C (68 °F) —-

Spark plug cap:

Type Resin type —-

Resistance 10 kΩ—-

Charging system:

Type A.C. magneto generator —-

Model/manufacturer F4T260/MITSUBISHI —-

Nominal output 14 V 16 A at 5,000 r/min —-

Charging coil resistance/color 0.43 ~ 0.65 Ω at 20 °C (68 °F)/

White – White —-

Rectifier:

Type Semi conductor-short circuit —-

Model/manufacturer SH640E-11/SHINDENGEN —-

No load voltage (DC) 14.1 ~ 14.9 V —-

Capacity 14 A —-

Withstand voltage 200 V —-

Electric starter system:

Type Constantmesh type —-

Starter motor

Model/manufacturer SM-13/MITSUBA —-

Output 0.8 kW —-

Armature coil resistance 0.025 ~ 0.035 Ω at 20 °C (68 °F) —-

Brush overall length 12.5 mm (0.49 in) 5 mm

(0.20 in)

Spring force 7.65 ~ 10.01 N (27.54 ~ 36.03 oz) —-

Commutator diameter 28 mm (1.10 in) 27 mm

(1.06 in)

Mica undercut 0.7 mm (0.03 in) —-

MAINTENANCE SPECIFICATIONS

2 — 19

SPEC

Starter relay

Model/manufacturer MS5F-721/JIDECO —-

Amperage rating 180 A —-

Coil winding resistance 4.18 ~ 4.62 Ω at 20 °C (68 °F) —-

Thermostat switch:

Thermostat switch 1

Model/manufacturer 5GH/NIPPON THERMOSTAT —-

Thermostat switch 2

Model/manufacturer 5LP/NIPPON THERMOSTAT —-

Circuit breaker:

Type Fuse —-

Amperage for individual circuit

Fuse 20 A × 1 —-

Reserve 20 A × 1 —-

Item Standard Limit

MAINTENANCE SPECIFICATIONS

2 — 20

SPEC

EB201000

HOW TO USE THE CONVERSION

TABLE

All specification data in this manual are listed

in SI and METRIC UNITS.

Use this table to convert METRIC unit data to

IMPERIAL unit data.

Ex.

CONVERSION TABLE

EB202001

GENERAL TORQUE

SPECIFICATIONS

This chart specifies torque for standard fasten-

ers with standard I.S.O. pitch threads. Torque

specifications for special components or

assemblies are provided for each chapter of

this manual. To avoid warpage, tighten multi-

fastener assemblies in a crisscross fashion, in

progressive stages, until the specified torque is

reached. Unless otherwise specified, torque

specifications require clean, dry threads. Com-

ponents should be at room temperature.

A: Distance between flats

B: Outside thread diameter

METRIC MULTIPLIER IMPERIAL

** mm × 0.03937 = ** in

2 mm × 0.03937 = 0.08 in

METRIC TO IMPERIAL

Metric unit Multiplier Imperial unit

Torque

m·kg

m·kg

cm·kg

cm·kg

7.233

86.794

0.0723

0.8679

ft·lb

in·lb

ft·lb

in·lb

Weight kg

g2.205

0.03527 lb

oz

Speed km/hr 0.6214 mph

Distance

km

m

m

cm

mm

0.6214

3.281

1.094

0.3937

0.03937

mi

ft

yd

in

in

Volume/

Capacity

cc (cm3)

cc (cm3)

lt (liter)

lt (liter)

0.03527

0.06102

0.8799

0.2199

oz (IMP liq.)

cu·in

qt (IMP liq.)

gal (IMP liq.)

Misc.

kg/mm

kg/cm2

Centigrade

(°C)

55.997

14.2234

9/5+32

lb/in

psi (lb/in2)

Fahrenheit (°F)

A

(nut) B

(bolt)

General torque

specifications

Nm m•kg ft•lb

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 13.0 94

HOW TO USE THE CONVERSION TABLE/

GENERAL TORQUE SPECIFICATIONS

2 — 21

SPEC

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE

Lubrication points Lubricant type

Oil seal lips (all) LS

O-ring (all) LS

Bearings (all) E

Crank pin E

Connecting rod (bearing) E

Camshaft sprocket M

Crankshaft E

Piston surface/piston rings E

Piston pin E

Primary drive gear/primary driven gear E

Valve stem/valve stem end M

Rocker arm shaft E

Rocker arm M

Camshaft lobe/journal M

Oil pump shaft, rotor, housing E

Oil filter O-ring E

Starter idle gear/shaft E

Transmission gear (wheel/pinion) M

Axle (main/drive) M

Shift fork/guide bar E

Shift drum/shift shaft/shift cam stopper ball E

Shift lever/shift guide LS

Crankcase mating surfaces Sealant (Quick Gasket)

Yamaha bond No.1215

Cylinder head and cylinder head cover mating surfaces Sealant (Quick Gasket)

Yamaha bond No.1215

AC magneto lead grommet

(AC magneto cover) Sealant (Quick Gasket)

Yamaha bond No.1215

LUBRICATION POINTS AND LUBRICANT TYPES

2 — 22

SPEC

COOLANT FLOW DIAGRAMS

1Radiator

2Radiator fan

3Radiator outlet hose

4Water pump inlet hose

5Water pump

6Water jacket outlet pipe

7Thermostat inlet hose

8Thermostat

9Radiator inlet hose

0Thermo switch 2

AThermo switch 1

COOLANT FLOW DIAGRAMS

2 — 23

SPEC

OIL FLOW DIAGRAMS

1Oil tank

2Oil pipe 2

3Oil pipe 1

OIL FLOW DIAGRAMS

2 — 24

SPEC

1Oil delivery pipe 2

2Oil delivery pipe 1

3Oil filter

4Crankshaft

5Oil pump

OIL FLOW DIAGRAMS

2 — 25

SPEC

1Oil pipe 2

2Drive axle

3Main axle

4Engine oil drain bolt (engine)

5Oil pipe 1

6Oil strainer

7Shift drum

OIL FLOW DIAGRAMS

2 — 26

SPEC

1Oil delivery pipe 2

2Oil filter cartridge

3Oil pump rotor 1

4Oil pump rotor 2

5Oil pipe 1

6Main axle

OIL FLOW DIAGRAMS

2 — 27

SPEC

CABLE ROUTING

1Parking brake cable

2Starter cable

3Clutch cable

4Throttle cable

5Front brake hose

6Front brake switch

7Park switch

ÈFasten the handlebar switch lead, park switch

lead and clutch switch lead to the handlebar with

the plastic band.

ÉFasten the front brake switch lead to the handle-

bar with the plastic band.

CABLE ROUTING

2 — 28

SPEC

1Front brake hose

2Throttle cable

3Main switch lead

4Indicator light lead

5Clutch cable

6Parking brake cable

7Starter cable

8Coolant reservoir hose

9Wire harness

0Ignition coil lead

AHeadlight lead coupler (left)

BBrake pipe

CHeadlight lead coupler (right)

DRadiator fan breather hose

EHeadlight lead (right)

ÈPass the throttle cable through the cable guide.

ÉPass the clutch cable, parking brake cable and

starter cable through the cable guide.

ÊFasten the left and right headlight lead, radiator

fan lead and thermo switch 1 lead to the frame

with the plastic band.

CABLE ROUTING

2 — 29

SPEC

1Throttle cable

2Fuel tank breather hose

3Fuel hose

4Carburetor air vent hose

5Negative battery lead

6AC magneto lead

7Thermo switch 1

8Coolant reservoir hose

9Starter cable

ÈPut the wire harness and coolant reservoir hose

with the plastic holder.

ÉFasten the wire harness, AC magneto lead,

speed sensor lead, negative battery lead and

rear brake switch lead with the plastic band.

Ê70 mm (2.76 in)

Ë25 ~ 35 mm (0.98 ~ 1.38 in)

Ì60 mm (2.36 in)

Í0 ~ 5 mm (0 ~ 0.20 in)

Î80 ~ 90 mm (3.15 ~ 3.54 in)

CABLE ROUTING

2 — 30

SPEC

1Coolant reservoir hose

2Carburetor air vent hose

3Reservoir tank breather hose

4Rectifier/regulator

5CDI unit

6Negative battery lead

7AC magneto lead

8Wire harness

9Starter motor lead

0Tail/brake light lead

ARectifier/regulator lead

ÈPass the negative battery lead between the wire

harness and frame.

CABLE ROUTING

2 — 31

SPEC

1Radiator fan breather hose

2Reverse control cable

3Parking brake cable

4Clutch cable

ÈFasten the reverse control cable to the frame

with the plastic band.

É15 ~ 25 mm (0.59 ~ 0.98 in)

CABLE ROUTING

2 — 32

SPEC

1Rear brake hose

2Parking brake cable

3Negative battery lead

4AC magneto lead

5Crankcase breather hose

6Carburetor drain hose

7Rear brake switch

8Speed sensor

9Speed sensor lead

0Rear brake switch lead

CABLE ROUTING

2 — 33

SPEC

1Thermo switch 1 lead

2Headlight lead (right)

3Radiator fan breather hose

4Thermo switch 2 lead

5Carburetor breather hose

6Headlight lead (left)

7Wire harness

8Coolant reservoir hose

ÈFasten the fan motor lead, headlight lead (right)

and thermo switch 1 lead to the frame with the

plastic band.

CABLE ROUTING

2 — 34

SPEC

1Positive battery lead

2Tail/brake light lead

3Coolant reservoir breather hose

4Negative battery lead

5Coolant reservoir hose

6Starter motor lead

7Wire harness

8Rectifier/regulator lead

ÈFasten the wire harness with the plastic clamp.

ÉFasten the starter motor lead and starter relay

lead with the plastic clamp.

CABLE ROUTING

3 — 1

CHK

ADJ

INTRODUCTION/PERIODIC MAINTENANCE/

LUBRICATION INTERVALS

EB300000 PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION

This chapter includes all information necessary to perform recommended inspections and adjust-

ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle

operation and a longer service life. The need for costly overhaul work will be greatly reduced. This

information applies to vehicles already in service as well as to new vehicles that are being prepared

for sale. All service technicians should be familiar with this entire chapter.

EB301000

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

* It is recommended that these items be serviced by a Yamaha dealer.

** Lithium soap base grease

ITEM ROUTINE INITIAL EVERY

1

month 3

months 6

months 6

months 1

year

Valves*

(See page 3-8.) • Check valve clearance.

• Adjust if necessary.

Cooling system

(See page 3-27.)

• Check coolant leakage.

• Repair if necessary.

• Replace coolant every 24 months.

Spark plug

(See page 3-16.)

• Check condition.

• Adjust gap and clean.

• Replace if necessary.

Air filter

(See page 3-24.) • Clean.

• Replace if necessary.

Every 20~40 hours

(More often in wet or dusty areas.)

Carburetor*

(See page 3-11.) • Check and adjust idle speed/starter operation.

• Adjust if necessary.

Crankcase breather

system* • Check breather hose for cracks or damage.

• Replace if necessary.

Exhaust system* • Check for leakage.

• Retighten if necessary.

• Replace gasket if necessary.

Spark arrester

(See page 3-31.) • Clean.

Fuel line* • Check fuel hose for cracks or damage.

• Replace if necessary.

Engine oil

(See page 3-19.) • Replace (Warm engine before draining).

Engine oil filter • Replace if necessary.

Drive chain

(See page 3-40.) • Check and adjust slack/alignment/clean/lube.

Brake*

(See page 3-33.) • Check operation/fluid leakage/See NOTE page 3-2.

• Correct if necessary.

Clutch*

(See page 3-23.) • Check operation.

• Adjust if necessary.

Wheels*

(See page 4-3.) • Check balance/damage/runout.

• Replace if necessary.

Wheel bearings* • Check bearing assembly for looseness/damage.

• Replace if damaged.

Steering system*

(See page 3-42.)

• Check operation.

• Replace if damaged.

• Check toe-in.

• Adjust if necessary.

Upper and lower arm

pivot and steering

shaft* • Lubricate every 6 months.**

Rear arm pivot* • Lubricate every 6 months.**

Fittings and fasten-

ers* • Check all chassis fittings and fasteners.

• Correct if necessary.

3 — 2

CHK

ADJ

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

NOTE:

●Recommended brake fluid: DOT 4

●Brake fluid replacement:

1.When disassembling the master cylinder or caliper cylinder, replace the brake fluid.

Normally check the brake fluid level and add fluid as required.

2.On the inner parts of the master cylinder and caliper cylinder, replace the oil seals every two

years.

3.Replace the brake hoses every four years, or if cracked or damaged.

WARNING

Indicates a potential hazard that could result in serious injury or death.

3 — 3

CHK

ADJ

SEAT, FENDERS AND FUEL TANK

SEAT, FENDERS AND FUEL TANK

SEAT, FRONT PANEL, FOOTREST GUARDS AND ENGINE SKID PLATE

Order Job name/Part name Q’ty Remarks

Removing the seat, front panel, foot-

rest guard and engine skid plate Remove the parts in the order below.

1Seat 1

NOTE:

Pull back the seat lock lever, than pull up

on the rear of the seat.

2 Front panel 1

3 Left footrest guard 1

4 Right footrest guard 1

5 Engine skid plate 1

For installation, reverse the removal pro-

cedure.

3 — 4

CHK

ADJ

SEAT, FENDERS AND FUEL TANK

HEADLIGHTS AND FRONT FENDER

Order Job name/Part name Q’ty Remarks

Removing the headlight and front

fender Remove the parts in the order below.

Seat and front panel Refer to “SEAT, FRONT PANEL, FOOT-

REST GUARDS AND ENGINE SKID

PLATE”.

1 Headlight coupler 2 Disconnect.

2 Left headlight 1

3 Right headlight 1

4 Fuel tank top panel 1

5 Front fender 1

For installation, reverse the removal pro-

cedure.

3 — 5

CHK

ADJ

SEAT, FENDERS AND FUEL TANK

REAR FENDER

Order Job name/Part name Q’ty Remarks

Removing the rear fender Remove the parts in the order below.

Seat Refer to “SEAT, FRONT PANEL, FOOT-

REST GUARDS AND ENGINE SKID

PLATE”.

Front fender Refer to “HEADLIGHTS AND FRONT

FENDER”.

1 Battery holding bracket 1

2 Battery lead 2 Disconnect.

CAUTION:

First disconnect the negative lead,

then disconnect the positive lead.

3 Battery 1

4 Rear fender 1

For installation, reverse the removal pro-

cedure.

3 — 6

CHK

ADJ

SEAT, FENDERS AND FUEL TANK

FUEL TANK

Order Job name/Part name Q’ty Remarks

Removing the fuel tank Remove the parts in the order below.

Seat and front panel Refer to “SEAT, FRONT PANEL, FOOT-

REST GUARDS AND ENGINE SKID

PLATE”.

Front fender Refer to “HEADLIGHTS AND FRONT

FENDER”.

1 Fuel hose 1 NOTE:

Before disconnecting the fuel hose, turn

the fuel cock to “OFF”.

2 Fuel tank 1 NOTE:

When installing the fuel tank, pass the

fuel tank breather hose through the hole

in the handlebar protector.

3 Plastic band 2

3 — 7

CHK

ADJ

SEAT, FENDERS AND FUEL TANK

Order Job name/Part name Q’ty Remarks

4 Rubber cover 1 1

5 Rubber cover 2 1

6 Hose holder 2

For installation, reverse the removal pro-

cedure.

3 — 8

CHK

ADJ

ADJUSTING THE VALVE CLEARANCE

ENGINE

ADJUSTING THE VALVE CLEARANCE

NOTE:

●The valve clearance must be adjusted when

the engine is cool to the touch.

●Adjust the valve clearance when the piston is

at the Top Dead Center (T.D.C.) on the com-

pression stroke.

1.Remove:

●Seat

●Front fender

●Fuel tank

Refer to “SEAT, FENDERS AND FUEL

TANK”.

2.Remove:

●Tappet cover (intake) 1

●Tappet covers (exhaust) 2

3.Disconnect:

●Spark plug cap 3

4.Remove:

●Spark plug

5.Remove:

●Crankshaft end accessing screw 1

●Timing mark accessing screw 2

3 — 9

CHK

ADJ

ADJUSTING THE VALVE CLEARANCE

6.Check:

●Valve clearance

Out of specification → Adjust.

***********************************************

Checking steps:

●Turn the crankshaft counterclockwise with a

wrench.

●Align the “I” mark 1 on the rotor with the sta-

tionary pointer 2 on the crankcase cover.

When the “I” mark is aligned with the station-

ary pointer, the piston is at the Top Dead

Center (T.D.C.).

NOTE:

●When the piston is at the Top Dead Center

(T.D.C.) on the compression stroke, there

should be clearance between the valve stem

tips and their respective rocker arm adjusting

screws.

●If there is no clearance, rotate the crankshaft

counterclockwise one turn.

Valve clearance (cold):

Intake:

0.10 ~ 0.15 mm

(0.0039 ~ 0.0059 in)

Exhaust:

0.15 ~ 0.20 mm

(0.0059 ~ 0.0079 in)

●Measure the valve clearance using a feeler

gauge 3.

***********************************************

3 — 10

CHK

ADJ

ADJUSTING THE VALVE CLEARANCE

7.Adjust:

●Valve clearance

***********************************************

Adjustment steps:

●Loosen the locknut 1.

●Insert a feeler gauge 2 between the adjuster

end and the valve end.

●Turn the adjuster 3 clockwise or counter-

clockwise with the tappet adjusting tool 4

until the proper clearance is obtained.

●Hold the adjuster to prevent it from moving

and then tighten the locknut.

●Measure the valve clearance.

●If the clearance is incorrect, repeat the above

steps until the proper clearance is obtained.

***********************************************

Tappet adjusting tool:

P/N. YM-08035, 90890-01311

T

R

.

.

Locknut:

14 Nm (1.4 m • kg, 10 ft • lb)

8.Install:

●All removed parts

NOTE:

Install all removed parts in the reverse order of

their disassembly. Note the following points.

9.Install:

●Spark plug

●Tappet cover (intake)

●Tappet covers (exhaust)

T

R

.

.

18 Nm (1.8 m • kg, 13 ft • lb)

T

R

.

.

10 Nm (1.0 m • kg, 7.2 ft • lb)

T

R

.

.

12 Nm (1.2 m • kg, 8.7 ft • lb)

3 — 11

CHK

ADJ

ADJUSTING THE VALVE CLEARANCE/ADJUSTING THE

TIMING CHAIN/ADJUSTING THE IDLING SPEED

10.Install:

●Fuel tank

●Front fender

●Seat

Refer to “SEAT, FENDERS AND FUEL

TANK”.

ADJUSTING THE TIMING CHAIN

Adjustment free.

ADJUSTING THE IDLING SPEED

1.Start the engine and let it warm up for sev-

eral minutes.

2.Attach:

●Tachometer

(to the spark plug lead)

3.Check:

●Engine idling speed

Out of specification → Adjust.

Engine idling speed:

1,450 ~ 1,550 r/min

3 — 12

CHK

ADJ

ADJUSTING THE IDLING SPEED/

ADJUSTING THE THROTTLE LEVER FREE PLAY

4.Adjust:

●Engine idling speed

***********************************************

Adjustment steps:

●Turn the throttle stop screw 1 in or out until

the specified idling speed is obtained.

***********************************************

5.Detach:

●Tachometer

6.Adjust:

●Throttle lever free play

Refer to “ADJUSTING THE THROTTLE

LEVER FREE PLAY”.

Turning in Idling speed becomes

higher.

Turning out Idling speed becomes

lower.

ADJUSTING THE THROTTLE LEVER FREE

PLAY

NOTE:

Engine idling speed should be adjusted prop-

erly before adjusting the throttle lever free

play.

1.Check:

●Throttle lever free play a

Out of specification → Adjust.

Throttle lever free play:

3 ~ 5 mm (0.12 ~ 0.20 in)

3 — 13

CHK

ADJ

ADJUSTING THE THROTTLE LEVER FREE PLAY

2.Adjust:

●Throttle lever free play

***********************************************

Adjustment steps:

First step:

●Pull back the adjuster cover 1.

●Loosen the locknut 2 on the carburetor side.

●Turn the adjuster 3 in or out until the correct

free play is obtained.

●Tighten the locknut 2.

●Push in the adjuster cover 1.

NOTE:

If the free play cannot be adjusted here, adjust

it at the throttle lever side of the cable.

Second step:

●Pull back the adjuster cover 4.

●Loosen the locknut 5.

●Turn the adjuster 6 in or out until the correct

free play is obtained.

●Tighten the locknut 5.

●Push in the adjuster cover 4.

WARNING

After adjusting the free play, turn the handle-

bar to the right and left to make sure that the

engine idling speed does not increase.

***********************************************

Turning in Free play is increased.

Turning out Free play is decreased.

Turning in Free play is increased.

Turning out Free play is decreased.

3 — 14

CHK

ADJ

ADJUSTING THE SPEED LIMITER

ADJUSTING THE SPEED LIMITER

The speed limiter keeps the carburetor throttle

from becoming fully-opened even when the

throttle lever is applied to the maximum posi-

tion. Screwing in the adjuster stops the engine

speed from increasing.

1.Check:

●Speed limiter length a

Out of specification → Adjust.

Speed limiter length:

12 mm (0.47 in)

2.Adjust:

●Speed limiter length

***********************************************

Speed limiter length adjustment steps:

●Loosen the locknut 1.

●Turn the adjuster 2 in or out until the speci-

fied speed limiter length is obtained.

●Tighten the locknut.

WARNING

●Particularly for a beginner rider, the

speed limiter should be screwed in com-

pletely. Screw it out little by little as their

riding technique improves. Never remove

the speed limiter for a beginning rider.

●For proper throttle lever operation do not

turn out the adjuster more than 12 mm

(0.47 in). Also, always adjust the throttle

lever free play to 3 ~ 5 mm (0.12 ~ 0.20 in).

***********************************************

Turning in Speed limiter length is

decreased.

Turning out Speed limiter length is

increased.

3 — 15

CHK

ADJ

ADJUSTING THE STARTER CABLE

ADJUSTING THE STARTER CABLE

1.Adjust:

●Starter cable

***********************************************

Adjustment steps:

●Disconnect the starter cable 1 from the car-

buretor body.

NOTE:

Do not remove the starter plunger 2 from the

starter cable.

●Measure the starter plunger stroke distance

a of the starter lever 3 fully close-to-fully

open position.

If the distance is out of specification adjust it

as described below.

ÈFully closed position

ÉFully open position

●Pull back the boot 4.

●Loosen the locknut 5.

●Turn the adjuster 6 in or out until the correct

distance is obtained.

●Tighten the locknut 5.

●Push in the boot 4.

●Connect the starter cable.

WARNING

After adjusting the cable, turn the handle-

bar to right to left, and make sure that the

engine idling speed does not increase.

***********************************************

Starter plunger stroke distance a:

15 mm (0.59 in)

Turning in Distance increased.

Turning out Distance decreased.

3 — 16

CHK

ADJ

CHECKING THE SPARK PLUG

1.Remove:

●Spark plug

2.Check:

●Spark plug type

Incorrect → Replace.

Standard spark plug:

DPR8EA-9/NGK

3.Check:

●Electrode 1

Wear/damage → Replace.

●Insulator 2

Abnormal color → Replace.

Normal color is a medium-to-light tan color.

4.Clean the spark plug with a spark plug

cleaner or wire brush.

5.Measure:

●Plug gap a

Use a wire gauge or feeler gauge.

Out of specification → Regap.

6.Tighten:

●Spark plug

NOTE:

Before installing a spark plug, clean the gasket

surface and plug surface.

Spark plug gap:

0.8 ~ 0.9 mm (0.031 ~ 0.035 in)

T

R

.

.

18 Nm (1.8 m • kg, 13 ft • lb)

CHECKING THE SPARK PLUG

3 — 17

CHK

ADJ

CHECKING THE IGNITION TIMING

CHECKING THE IGNITION TIMING

NOTE:

Engine idling speed and throttle cable free play

should be adjusted properly before checking

the ignition timing.

1.Attach:

●Tachometer

●Timing light

(to spark plug lead)

Timing light:

P/N. YM-33277-A, 90890-03141

2.Check:

●Ignition timing

***********************************************

Checking steps:

●Warm up the engine and keep it at the speci-

fied speed.

●Remove the timing mark accessing screw 1.

●Visually check the stationary pointer 2 to

verify it is within the required firing range 3

indicated on the flywheel.

Incorrect firing range → Check the pulser coil

assembly.

●Install the timing mark accessing screw.

***********************************************

3.Detach:

●Timing light

●Tachometer

Engine speed:

1,450 ~ 1,550 r/min

3 — 18

CHK

ADJ

MEASURING THE COMPRESSION PRESSURE

MEASURING THE COMPRESSION

PRESSURE

NOTE:

Insufficient compression pressure will result in

a loss of performance.

1.Check:

●Valve clearance

Out of specification → Adjust.

Refer to “ADJUSTING THE VALVE CLEAR-

ANCE”.

2.Start the engine and let it warm up for sev-

eral minutes.

3.Stop the engine.

4.Remove:

●Spark plug

5.Attach:

●Adapter

●Compression gauge 1

Compression gauge:

P/N. YU-33223, 90890-03081

Adapter:

P/N. YU-33223-3, 90890-04082

6.Measure:

●Compression pressure

Above the maximum pressure:

Inspect the cylinder head, valve surfaces,

and piston crown for carbon deposits.

Below the minimum pressure:

Squirt a few drops of oil into the affected cyl-

inder and measure again.

●Refer to the table below.

Compression pressure

(with oil introduced into cylinder)

Reading Diagnosis

Higher than

without oil Worn or damaged piston,

rings or cylinder wall.

Same as

without oil Defective valves or

cylinder head gasket.

3 — 19

CHK

ADJ

MEASURING THE COMPRESSION PRESSURE/

CHECKING THE ENGINE OIL LEVEL

***********************************************

Measurement steps:

●Crank over the engine with the electric

starter (be sure the battery is fully charged)

with the throttle fully-open until the compres-

sion reading on the gauge stabilizes.

WARNING

When cranking the engine, ground the

spark plug lead to prevent sparking.

***********************************************

7.Install:

●Spark plug

Compression pressure (at sea level):

Standard:

1,250 kPa (12.5 kg/cm2, 181 psi)

Minimum:

1,050 kPa (10.5 kg/cm2, 149 psi)

Maximum:

1,350 kPa (13.5 kg/cm2, 192 psi)

T

R

.

.

18 Nm (1.8 m • kg, 13 ft • lb)

CHECKING THE ENGINE OIL LEVEL

1.Place the machine on a level surface.

2.Start the engine, warm it up until the engine

oil has reached a normal temperature of

60 °C (140 °F), let it continue to idle for ten

seconds, and then turn the engine off.

NOTE:

To achieve the proper engine oil temperature

for an accurate oil level reading, the engine

must have first completely cooled down, and

then warmed up again for several minutes to

normal operating temperature.

3 — 20

CHK

ADJ

CHECKING THE ENGINE OIL LEVEL/

CHANGING THE ENGINE OIL

3.Check:

●Engine oil level

Oil level should be between the minimum

level mark a and the maximum level mark

b.

Low oil level → Add oil to the proper level.

NOTE:

●Wait a few minutes until the oil settles before

inspecting the oil level.

●Do not screw the dipstick 1 in when inspect-

ing the oil level.

NOTE:

Recommended oil classification:

API Service “SE”, “SF”, “SG” type or equiva-

lent (e.g. “SF–SE–CC”, “SF–SE–SD” etc.)

CAUTION:

●Do not add any chemical additives.

Engine oil also lubricates the clutch and

additives could cause clutch slippage.

●Do not allow foreign material to enter the

crankcase.

4.Start the engine and let it warm up for sev-

eral minutes.

5.Stop the engine and inspect the oil level

again.

NOTE:

Wait a few minutes until the oil settles before

inspecting the oil level.

Recommended oil:

Follow the left chart.

CHANGING THE ENGINE OIL

1.Remove:

●Engine skid plate

Refer to “SEAT, FENDERS AND FUEL

TANK”.

2.Start the engine and let it warm up for sev-

eral minutes.

3.Stop the engine and place a container under

the engine oil drain bolt.

3 — 21

CHK

ADJ

CHANGING THE ENGINE OIL

4.Remove:

●Dipstick 1

●Engine oil drain bolt (oil tank) 2

●Engine oil drain bolt (crankcase) 3

Drain the engine oil from the oil tank and

crankcase.

5.If the oil filter cartridge is also to be replaced,

perform the following procedure.

***********************************************

Replacement steps:

●Remove the oil filter cartridge 1 with an oil

filter wrench 2.

●Apply a thin coat of engine oil to the O-ring

3 of the new oil filter cartridge.

CAUTION:

Make sure that the O-ring 3 is properly

seated in the groove of the oil filter car-

tridge.

Oil filter wrench:

P/N. YM-01469, 90890-01469

3 — 22

CHK

ADJ

CHANGING THE ENGINE OIL

●Tighten the new oil filter cartridge to specifi-

cation with an oil filter wrench.

***********************************************

6.Install:

●Engine oil drain bolt (crankcase)

●Engine oil drain bolt (oil tank)

7.Fill:

●Oil tank

(with the specified amount of the recom-

mended engine oil)

NOTE:

●Pour the engine oil in several stages.

●First, pour in 1.75 L (1.54 Imp qt, 1.85 US qt)

of oil, and then start the engine and rev it 3 to

5 times. Stop the engine, and then pour in

the remainder of the specified amount.

CAUTION:

When starting the engine make sure the

dipstick is securely fitted into the oil tank.

8.Install:

●Dipstick

9.Warm up the engine for a few minutes, then

stop the engine.

10.Check:

●Engine

(for engine oil leaks)

●Oil level

Refer to “CHECKING THE ENGINE OIL

LEVEL”.

T

R

.

.

Oil filter cartridge:

17 Nm (1.7 m • kg, 12 ft • lb)

Quantity:

Total amount:

2.3 L (2.02 Imp qt, 2.43 US qt)

Periodic oil replacement:

1.9 L (1.67 Imp qt, 2.01 US qt)

With oil filter cartridge replace-

ment:

1.95 L (1.72 Imp qt, 2.06 US qt)

T

R

.

.

30 Nm (3.0 m • kg, 22 ft • lb)

T

R

.

.

25 Nm (2.5 m • kg, 18 ft • lb)

3 — 23

CHK

ADJ

CHANGING THE ENGINE OIL/

ADJUSTING THE CLUTCH CABLE

11.Check:

●Engine oil pressure

***********************************************

●Slightly loosen the oil gallery bolt 1.

●Start the engine and keep it idling until

engine oil starts to seep from the oil gallery

bolt. If no engine oil comes out after one

minute, turn the engine off so that it will not

seize.

●Check the engine oil passages, the oil filter

cartridge and the oil pump for damage or

leakage.

Refer to “OIL PUMP” in CHAPTER 5.

●Start the engine after solving the problem(s)

and check the engine oil pressure again.

●Tighten the oil gallery bolt to specification.

***********************************************

12.Install:

●Engine skid plate

Refer to “SEAT, FENDERS AND FUEL

TANK”.

T

R

.

.

Oil gallery bolt:

7 Nm (0.7 m • kg, 5.1 ft • lb)

ADJUSTING THE CLUTCH CABLE

1.Check:

●Clutch lever free play a

Out of specification → Adjust.

Clutch lever free play

(at the clutch lever end):

5 ~ 10 mm (0.20 ~ 0.39 in)

3 — 24

CHK

ADJ

ADJUSTING THE CLUTCH CABLE/

CLEANING THE AIR FILTER

2.Adjust:

●Clutch lever free play

***********************************************

Adjustment steps:

●Pull the rubber cover 1 off.

●Loosen the locknut 2 and finger tighten the

adjusting bolt 3.

●Loosen the locknut 4.

●Turn the adjusting nut 5 until the clutch lever

free play is within the specified limits.

●Tighten the locknut 4.

NOTE:

If the specified clutch lever free play cannot be

obtained on it, use the adjusting bolt 3.

●Turn the adjusting bolt 3 until the clutch

lever free play is within the specified limits.

●Tighten the locknut 2.

●Pull the rubber cover 1 in.

***********************************************

Clutch lever free play

(at the clutch lever end):

5 ~ 10 mm (0.20 ~ 0.39 in)

CLEANING THE AIR FILTER

NOTE:

There is a check hose 1 at the bottom of the

air filter case. If dust and/or water collects in

this hose, clean the air filter element and air fil-

ter case.

1.Remove:

●Seat

Refer to “SEAT, FENDERS AND FUEL

TANK”.

2.Disconnect:

●Crankcase breather hose 1

3.Remove:

●Air filter case cover 2

3 — 25

CHK

ADJ

CLEANING THE AIR FILTER

4.Remove:

●Air filter element assembly 1

●Air filter element cap 2

●Air filter element 3

NOTE:

When removing the air filter element, rotate

the air filter element cap 1/4 of a turn and

remove the element.

CAUTION:

Never operate the engine with the air filter

element removed. This will allow unfiltered

air to enter, causing rapid wear and possible

engine damage. Additionally, operation

without the filter element will affect carbure-

tor tuning with subsequent poor perfor-

mance and possible engine overheating.

5.Check:

●Air filter element

Damaged → Replace.

6.Clean:

●Air filter element

***********************************************

Cleaning steps:

●Wash the element gently, but thoroughly in

solvent.

WARNING

Use a cleaning solvent which is designed

to clean parts only. Never use gasoline or

low flash point solvents as they may cause

a fire or explosion.

●Squeeze the excess solvent out of the ele-

ment and let it dry.

3 — 26

CHK

ADJ

CLEANING THE AIR FILTER

CAUTION:

Do not twist or wring out the element. This

could damage the foam material.

●Apply engine oil to the element.

●Squeeze out the excess oil.

NOTE:

The element should be wet but not dripping.

***********************************************

7.Install:

●Air filter element

●Air filter case cover

NOTE:

●Insert the lobes 1 on the filter element into

the receptacles 2 on the filter case.

●To prevent air leaks make sure that the seal-

ing surface of the element matches the seal-

ing surface of the case.

8.Connect:

●Crankcase breather hose 1

9.Install:

●Seat

Refer to “SEAT, FENDERS AND FUEL

TANK”.

3 — 27

CHK

ADJ

CHECKING THE COOLANT LEVEL

1.Place the machine on a level surface.

2.Check:

●Coolant level

The coolant level should be between the

minimum level mark a and maximum level

mark b.

Below the minimum level mark → Add the

recommended coolant to the proper level.

CAUTION:

●Adding water instead of coolant lowers

the antifreeze content of the coolant. If

water is used instead of coolant, check

and if necessary, correct the antifreeze

concentration of the coolant.

●Use only distilled water. However, soft

water may be used if distilled water is not

available.

3.Start the engine, warm it up for several min-

utes, and then turn it off.

4.Check:

●Coolant level

NOTE:

Before inspecting the coolant level, wait a few

minutes until the coolant has settled.

CHANGING THE COOLANT

1.Remove:

●Front panel

Refer to “SEAT, FENDERS AND FUEL

TANK”.

2.Remove:

●Coolant reservoir cap 1

3.Disconnect:

●Coolant reservoir hose 2

CHECKING THE COOLANT LEVEL/

CHANGING THE COOLANT

3 — 28

CHK

ADJ

CHANGING THE COOLANT

4.Drain:

●Coolant

(from the coolant reservoir)

5.Connect:

●Coolant reservoir hose

6.Remove:

●Radiator cap 1

WARNING

A hot radiator is under pressure. Therefore,

do not remove the radiator cap when the

engine is hot. Scalding hot fluid and steam

may be blown out, which could cause seri-

ous injury. When the engine has cooled,

open the radiator cap as follows:

Place a thick rag or a towel over the radia-

tor cap and slowly turn the radiator cap

counterclockwise toward the detent to

allow any residual pressure to escape.

When the hissing sound has stopped, turn

the radiator cap counterclockwise while

pressing down on it and then remove it.

7.Remove:

●Coolant drain bolt 1

(along with the copper washer)

8.Drain:

●Coolant

9.Check:

●Copper washer 1

●Coolant drain bolt 2

Damage → Replace.

10.Install:

●Coolant drain bolt

New

T

R

.

.

10 Nm (1.0 m • kg, 7.2 ft • lb)

3 — 29

CHK

ADJ

CHANGING THE COOLANT

11.Fill:

●Cooling system

(with the specified amount of the recom-

mended coolant)

Handling notes for coolant

Coolant is potentially harmful and should be

handled with special care.

WARNING

●If coolant splashes in your eyes, thor-

oughly wash them with water and consult

a doctor.

●If coolant splashes on your clothes,

quickly wash it away with water and then

with soap and water.

●If coolant is swallowed, induce vomiting

and get immediate medical attention.

CAUTION:

●Adding water instead of coolant lowers

the antifreeze content of the coolant. If

water is used instead of coolant, check,

and if necessary, correct the antifreeze

concentration of the coolant.

●Use only distilled water. However, soft

water may be used if distilled water is not

available.

●If coolant comes into contact with painted

surfaces, immediately wash them with

water.

●Do not mix different types of antifreeze.

12.Install:

●Radiator cap

Recommended antifreeze:

High-quality ethylene glycol

antifreeze containing corrosion

inhibitors for aluminum engines

Mixing ratio:

1:1 (antifreeze:water)

Quantity:

Total amount:

1.3 L

(1.14 lmp qt, 1.37 US qt)

Coolant reservoir capacity:

0.29 L

(0.26 lmp qt, 0.31 US qt)

3 — 30

CHK

ADJ

CHANGING THE COOLANT

13.Fill:

●Coolant reservoir

(with the recommended coolant to the proper

level)

14.Install:

●Coolant reservoir cap

15.Start the engine, warm it up for several min-

utes, and then turn it off.

16.Check:

●Coolant level

Refer to “CHECKING THE COOLANT

LEVEL”.

NOTE:

Before inspecting the coolant level, wait a few

minutes until the coolant has settled.

17.Install:

●Front panel

Refer to “SEAT, FENDERS AND FUEL

TANK”.

3 — 31

CHK

ADJ

CHECKING THE COOLANT TEMPERATURE WARNING

LIGHT/CLEANING THE SPARK ARRESTER

CHECKING THE COOLANT TEMPERATURE

WARNING LIGHT

1Coolant temperature warning light

CLEANING THE SPARK ARRESTER

1.Clean:

●Spark arrester

***********************************************

Cleaning steps:

WARNING

●Select a well-ventilated area free of com-

bustible materials.

●Always let the exhaust system cool

before performing this operation.

●Do not start the engine when removing

the tailpipe from the muffler.

●Remove the bolt 1.

●Remove the tailpipe 2 by pulling it out of the

muffler.

3 — 32

CHK

ADJ

●Tap the tailpipe lightly with a soft-face ham-

mer or suitable tool, then use a wire brush to

remove any carbon deposits from the spark

arrester portion of the tailpipe and the inner

contact surfaces of the muffler.

●Insert the tailpipe into the muffler and align

the bolt holes.

●Insert the bolt and tighten it.

●Remove the purging bolt 3.

●Start the engine and rev it up approximately

twenty times while momentarily creating

exhaust system back pressure by blocking

the end of the muffler with a shop towel.

●Stop the engine and allow the exhaust pipe

to cool.

●Install the purging bolt 3 and tighten it.

***********************************************

CLEANING THE SPARK ARRESTER

3 — 33

CHK

ADJ

ADJUSTING THE FRONT BRAKE/

ADJUSTING THE REAR BRAKE

CHASSIS

ADJUSTING THE FRONT BRAKE

1.Check:

●Brake lever free play a

Out of specification → Bleed the front brake

system.

Refer to “AIR BLEEDING (HYDRAULIC

BRAKE SYSTEM)”.

Brake lever free play (at the brake

lever end):

0 mm (0 in)

ADJUSTING THE REAR BRAKE

1.Check:

●Rear brake pedal height a

Out of specification → Adjust.

2.Adjust:

●Rear brake pedal height

***********************************************

Adjustment steps:

●Loosen the locknut 1.

●Turn the adjusting bolt 2 until the brake

pedal height is within the specified limits.

●Tighten the locknut 1.

NOTE:

When adjusting the brake pedal height make

sure the locknut-to-adjusting bolt clearance a

does not exceed 2.2 ~ 3.2 mm (0.09 ~ 0.13 in).

Rear brake pedal height:

4 mm (0.16 in)

Brake pedal height:

4 mm (0.16 in)

3 — 34

CHK

ADJ

ADJUSTING THE REAR BRAKE/

ADJUSTING THE PARKING BRAKE

WARNING

After this adjustment is performed, lift the

rear wheels off the ground by placing a

block under the engine, and spin the rear

wheels to ensure there is no brake drag. If

any brake drag is noticed perform the

above steps again.

***********************************************

ADJUSTING THE PARKING BRAKE

1.Check:

●Parking brake cable end length a

Out of specification → Adjust.

Parking brake cable end length:

64 ~ 68 mm (2.5 ~ 2.7 in)

2.Adjust:

●Parking brake cable end length

***********************************************

Adjustment steps:

●Loosen the locknut 1 and adjusting bolt 2.

●Pull the rubber cover 3 off.

●Loosen the locknut 4.

●Turn the adjuster 5 in or out until the speci-

fied brake cable end length is obtained.

●Tighten the locknut 4.

●Slowly turn the adjusting bolt 2 clockwise

until resistance is felt.

●Turn it 1/8 counterclockwise.

●Tighten the locknut 1.

●Check the parking brake cable free play a.

●If the free play is incorrect, adjust the free

play by adjuster 5.

●Pull the rubber cover 3 in.

T

R

.

.

Locknut:

16 Nm (1.6 m • kg, 11 ft • lb)

Free play (parking brake cable):

0 mm (0 in)

at parking brake lever pivot

3 — 35

CHK

ADJ

ADJUSTING THE PARKING BRAKE/

CHECKING THE BRAKE FLUID LEVEL

WARNING

After this adjustment is performed, lift the

rear wheels off the ground by placing a

block under the engine, and spin the rear

wheels to ensure there is no brake drag. If

any brake drag is noticed perform the

above steps again.

***********************************************

CHECKING THE BRAKE FLUID LEVEL

1.Place the machine on a level surface.

NOTE:

When inspecting the brake fluid level, make

sure that the top of the brake fluid reservoir top

is horizontal.

2.Check:

●Brake fluid level

Fluid level is below the “LOWER” level line

1 → Add the recommended brake fluid to

the proper level.

ÈFront brake

ÉRear brake

CAUTION:

Brake fluid may erode painted surfaces or

plastic parts. Always clean up spilled fluid

immediately.

WARNING

●Use only the designated quality brake

fluid: Otherwise, the rubber seals may

deteriorate, causing leakage and poor

brake performance.

●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 a vapor lock.

Recommended brake fluid:

DOT 4

È

É

3 — 36

CHK

ADJ

CHECKING THE FRONT BRAKE PAD/

CHECKING THE REAR BRAKE PAD/

ADJUSTING THE REAR BRAKE LIGHT SWITCH

CHECKING THE FRONT BRAKE PAD

1.Remove:

●Front wheels

2.Check:

●Brake pad

Wear indicators 1 almost in contact with the

brake disc → Replace the brake pads as a

set.

Refer to “FRONT AND REAR BRAKES” in

CHAPTER 4.

3.Operate the brake lever.

4.Install:

●Front wheels

Brake pad wear limit a:

1 mm (0.04 in)

CHECKING THE REAR BRAKE PAD

1.Check:

●Brake pad

Wear indicators 1 almost in contact with the

brake disc → Replace the brake pads as a

set.

Refer to “FRONT AND REAR BRAKES” in

CHAPTER 4.

2.Operate the brake pedal.

Brake pad wear limit a:

1 mm (0.04 in)

ADJUSTING THE REAR BRAKE LIGHT

SWITCH

NOTE:

The rear brake light switch is operated by

movement of the brake pedal.

The rear brake light switch is properly adjusted

when the brake light comes on just before the

braking effect starts.

3 — 37

CHK

ADJ

ADJUSTING THE REAR BRAKE LIGHT SWITCH/

CHECKING THE BRAKE HOSE

1.Check:

●Rear brake light operation timing

Incorrect → Adjust.

2.Adjust:

●Rear brake light operation timing

***********************************************

●Hold the main body 1 of the rear brake light

switch so that it does not rotate and turn the

adjusting nut 2 in direction a or b until the

rear brake light comes on at the proper time.

***********************************************

Direction a Brake light comes on

sooner.

Direction b Brake light comes on

later.

CHECKING THE BRAKE HOSE

1.Remove:

●Seat

●Front fender

Refer to “SEAT, FENDERS AND FUEL

TANK”.

2.Check:

●Front brake hoses 1

●Rear brake hoses 2

Cracks/wear/damage → Replace.

3.Check:

●Brake hose clamp

Loosen → Tighten.

4.Hold the machine in an upright position and

apply the front or rear brake.

5.Check:

●Brake hoses

Apply the brake lever several times.

Fluid leakage → Replace the hose.

Refer to “FRONT AND REAR BRAKE” in

CHAPTER 4.

3 — 38

CHK

ADJ

CHECKING THE BRAKE HOSE/

BLEEDING THE HYDRAULIC BRAKE SYSTEM

6.Install:

●Front fender

●Seat

Refer to “SEAT, FENDERS AND FUEL

TANK”.

BLEEDING THE HYDRAULIC BRAKE

SYSTEM

WARNING

Bleed the brake system if:

●The system has been disassembled.

●A brake hose or brake pipe have been

loosened or removed.

●The brake fluid has been very low.

●The brake operation has been faulty.

A loss of braking performance may occur if

the brake system is not properly bled.

1.Bleed:

●Brake system

***********************************************

Air bleeding steps:

a. Add the 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 hose 1 tightly to

the caliper bleed screw 2.

ÈFront

ÉRear

d. Place the other end of the hose into a con-

tainer.

e. Slowly apply the brake lever or pedal sev-

eral times.

f. Pull the lever in or push down on the pedal

and hold it.

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.

i. Repeat steps (e) to (h) until all the air bub-

bles have disappeared from the fluid.

È

É

3 — 39

CHK

ADJ

j. Tighten the bleed screw.

NOTE:

If bleeding is difficult, it may be necessary to

let the brake fluid settle for a few hours.

Repeat the bleeding procedure when the tiny

bubbles in the system have disappeared.

k. Add brake fluid to the proper level.

Refer to “CHECKING THE BRAKE FLUID

LEVEL”.

WARNING

Check the operation of the brake after

bleeding the brake system.

***********************************************

T

R

.

.

Bleed screw:

6 Nm (0.6 m • kg, 4.3 ft • lb)

ADJUSTING THE SHIFT PEDAL

1.Check:

●Shift pedal height a

Out of specification → Adjust.

Shift pedal height:

22 mm (0.89 in)

2.Adjust:

●Shift pedal height

***********************************************

Adjustment steps:

●Loosen the locknuts 1.

●Turn the adjusting rod 2 in direction a or b

until the specified shift pedal position

obtained.

●Tighten the locknuts.

***********************************************

Direction a Shift pedal position is

down.

Direction b Shift pedal position is

up.

T

R

.

.

Locknut:

8 Nm (0.8 m • kg, 5.8 ft • lb)

BLEEDING THE HYDRAULIC BRAKE SYSTEM/

ADJUSTING THE SHIFT PEDAL

3 — 40

CHK

ADJ

ADJUSTING THE REVERSE CONTROL CABLE/

ADJUSTING THE DRIVE CHAIN SLACK

ADJUSTING THE REVERSE CONTROL

CABLE

1.Check:

●Reverse knob free play a

Out of specification → Adjust.

Reverse knob free play:

0 mm (0 in)

2.Adjust:

***********************************************

Adjustment steps:

●Pull the boots 1 and 2 off.

●Loosen the locknut 3.

●Turn the adjusting nut 4 until the reverse

control cable 5 is taut or the length a is

135 mm (5.31 in).

NOTE:

Be sure to hold the reverse shift lever 6 when

make this adjustment so that it does not move.

●Tighten the locknut 3.

●Pull the boots 1 and 2 in.

***********************************************

ADJUSTING THE DRIVE CHAIN SLACK

NOTE:

The drive chain slack must be checked at the

tightest point on the chain.

CAUTION:

A drive chain that is too tight will overload

the engine and other vital parts, and one

that is too loose can skip and damage the

swingarm or cause an accident. Therefore,

keep the drive chain slack within the speci-

fied limits.

1.Elevate the rear wheels by placing the suit-

able stand under the frame.

2.Rotate the rear wheel several times and

check the drive chain to locate its tightest

point.

3 — 41

CHK

ADJ

ADJUSTING THE DRIVE CHAIN SLACK

3.Measure:

●Drive chain slack a

Out of specification → Adjust.

Drive chain slack:

30 ~ 45 mm (1.18 ~ 1.77 in)

4.Adjust:

●Drive chain slack

***********************************************

Adjustment steps:

●Loosen the hub nuts 1.

●Loosen the locknuts 2.

●Turn both adjusting bolts 3 in direction a or

b until the specified drive chain slack is

obtained.

NOTE:

To maintain the proper axle alignment, adjust

both sides evenly. (There are marks c on

each side of hub.)

CAUTION:

Excessive chain slack will overload the

engine and other vital parts; keep the slack

within the specified limits.

●If the chain slack cannot be adjusted, replace

the sprockets and drive chain as a set.

●Tighten the hub nuts and locknuts.

NOTE:

The chain should be cleaned and lubricated

after every use of the machine.

***********************************************

Direction a Drive chain slack is

reduced.

Direction b Drive chain slack is

increased.

T

R

.

.

Hub nut:

90 Nm (9.0 m • kg, 65 ft • lb)

Locknut (chain puller):

16 Nm (1.6 m • kg, 11 ft • lb)

3 — 42

CHK

ADJ

CHECKING THE STEERING SYSTEM/

ADJUSTING THE TOE-IN

CHECKING THE STEERING SYSTEM

1.Place the machine on a level surface.

2.Check:

●Steering assembly bushings

Move the handlebar up and down, and/or

back and forth.

Excessive play → Replace the steering stem

bushings.

3.Check:

●Tie-rod ends

Turn the handlebar to the left and/or right

until it stops completely, then move the han-

dlebar from the left to the right slightly. Tie-

rod end has any vertical play → Replace the

tie-rod end(s).

4.Raise the front end of the machine so that

there is no weight on the front wheels.

5.Check:

●Ball joints and/or wheel bearings

Move the wheels laterally back and forth.

Excessive free play → Replace the front

arms (upper and lower) and/or wheel bear-

ings.

ADJUSTING THE TOE-IN

1.Place the machine on a level surface.

2.Measure:

●Toe-in

Out of specification → Adjust.

Toe-in:

0 ~ 10 mm (0 ~ 0.39 in)

3 — 43

CHK

ADJ

***********************************************

Toe-in measurement steps:

NOTE:

Before measuring the toe-in, make sure that

the tire pressure is correct.

●Mark both front tire tread centers.

●Raise the front end of the machine so that

there is no weight on the front tires.

●Face the handlebar straight ahead.

●Measure the width È between the marks.

●Rotate the front tires 180° until the marks are