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OWNER’S SERVICE MANUALTZ250N1/(N)LIT-11626-14-445KE-28199-11

EC010000TZ250N1/(N)OWNER’S SERVICE MANUAL©2000 by Yamaha Motor Corporation, U.S.A.1st Edition, September 2000All rights reserved.Any reprinting or unauthorized usewithout the written permission ofYamaha Motor Corporation U.S.A.is expressly prohibited.Printed in JapanP/N. LIT-11626-14-44

EC020000INTRODUCTIONCongratulations on your purchase of aYamaha TZ series. This model is the culminationof Yamaha’s vast experience in the productionof pacesetting racing machines. It representsthe highest grade of craftsmanshipand reliability that have made Yamaha aleader.This manual explains operation, inspection,basic maintenance and tuning of yourmachine. If you have any questions about thismanual or your machine, please contact yourYamaha dealer.NOTE:As improvements are made on this model,some data in this manual may become outdated.If you have any questions, please consultyour Yamaha dealer.WPLEASE READ THIS MANUAL CAREFULLYAND COMPLETELY BEFORE OPERATINGTHIS MACHINE. DO NOT ATTEMPT TOOPERATE THIS MACHINE UNTIL YOU HAVEATTAINED A SATISFACTORY KNOWLEDGEOF ITS CONTROLS AND OPERATING FEA-TURES AND UNTIL YOU HAVE BEENTRAINED IN SAFE AND PROPER RIDINGTECHNIQUES. REGULAR INSPECTIONSAND CAREFUL MAINTENANCE, ALONGWITH GOOD RIDING SKILLS, WILLENSURE THAT YOU SAFELY ENJOY THECAPABILITIES AND THE RELIABILITY OFTHIS MACHINE.

EC030010WARRANTY INFORMATIONThis model is sold AS IS, WITHOUT ANY WARRANTIES EXPRESSED OR IMPLIED REGARD-LESS OF THE INTENDED USE.THE PURCHASER OF THIS MACHINE, which is intended for competition purposes, IS RESPON-SIBLE FOR ALL COSTS, SERVICE AND/OR REPAIR.

EC040001IMPORTANT NOTICETHIS MACHINE IS DESIGNED STRICTLYFOR COMPETITION USE, ONLY ON ACLOSED COURSE. It is illegal for thismachine to be operated on any public street,road, or highway. Off-road use on public landsmay also be illegal. Please check local regulationsbefore riding.&SAFETY INFORMATION1. THIS MACHINE IS TO BE OPERATEDBY AN EXPERIENCED RIDER ONLY.Do not attempt to operate thismachine at maximum power until youare totally familiar with its characteristics.2. THIS MACHINE IS DESIGNED TO BERIDDEN BY THE OPERATOR ONLY.Do not carry passengers on thismachine.3. ALWAYS WEAR PROTECTIVE APPAR-EL.When operating this machine, alwayswear an approved helmet with gogglesor a face shield. Also wear heavyboots, gloves, and protective clothing.Always wear proper fitting clothingthat will not be caught in any ofthe moving parts or controls of themachine.4. ALWAYS MAINTAIN YOUR MACHINEIN PROPER WORKING ORDER.For safety and reliability, the machinemust be properly maintained. Alwaysperform the pre-operation checksindicated in this manual. Correcting amechanical problem before you ridemay prevent an accident.5. GASOLINE IS HIGHLY FLAMMABLE.Always turn off the engine while refueling.Take care to not spill any gasolineon the engine or exhaust system.Never refuel in the vicinity of an openflame, or while smoking.

6. GASOLINE CAN CAUSE INJURY.If you should swallow some gasoline,inhale excess gasoline vapors, orallow any gasoline to get into youreyes, contact a doctor immediately. Ifany gasoline spills onto your skin orclothing, immediately wash skinareas with soap and water, andchange your clothes.7. ONLY OPERATE THE MACHINE IN ANAREA WITH ADEQUATE VENTILA-TION.Never start the engine or let it run forany length of time in an enclosedarea. Exhaust fumes are poisonous.These fumes contain carbon monoxide,which by itself is odorless andcolorless. Carbon monoxide is a dangerousgas which can cause unconsciousnessor can be lethal.8. PARK THE MACHINE CAREFULLY;TURN OFF THE ENGINE.Always turn off the engine if you aregoing to leave the machine. Do notpark the machine on a slope or softground as it may fall over.9. PROPERLY SECURE THE MACHINEBEFORE TRANSPORTING IT.When transporting the machine inanother vehicle, always be sure it isproperly secured and in an uprightposition and that the fuel cock is inthe “OFF” position. Otherwise, fuelmay leak out of the carburetor or fueltank.

EC050000TO THE NEW OWNERThis manual will provide you with a good basicunderstanding of features, operation, andbasic maintenance and inspection items ofthis machine. Please read this manual carefullyand completely before operating your newmachine. If you have any questions regardingthe operation or maintenance of yourmachine, please consult your Yamaha dealer.NOTE:This manual should be considered a permanentpart of this machine and should remainwith it even if the machine is subsequentlysold.EC060000NOTICESome data in this manual may become outdateddue to improvements made to thismodel in the future. If there is any questionyou have regarding this manual or yourmachine, please consult your Yamaha dealer.EC070011F.I.M. MACHINE WEIGHTS:Weights of machines without fuelThe minimum weights for road racemachines are:for the class 125 cc . . . . . . . . . . . .minimum70 kg (154 lb)for the class 250 cc . . . . . . . . . . . .minimum95 kg (209 lb)for the class 500 cc . . . . . . . . . . . .minimum131 kg (289 lb)In modifying your machine (e.g., for weightreduction), take note of the above limits ofweight.

EC080000HOW TO USETHIS MANUALEC081000PARTICULARLY IMPORTANT INFOR-MATION!The Safety Alert Symbol means ATTENTION!BECOME ALERT! YOUR SAFETY ISINVOLVED!WFailure to follow WARNING instructions couldresult in severe injury or death to the machineoperator, a bystander, or a person inspectingor repairing the machine.CCAUTION:A CAUTION indicates special precautions thatmust be taken to avoid damage to themachine.NOTE:A NOTE provides key information to make procedureseasier or clearer.EC082000FINDING THE REQUIRED PAGE1. This manual consists of seven chapters;“General Information”, “Specifications”,“Regular inspection and adjustments”,“Engine”, “Chassis”, “Electrical” and“Tuning”.2. The table of contents is at the beginning ofthe manual. Look over the general layout ofthe book before finding then required chapterand item.Bend the book at its edge, as shown, tofind the required fore edge symbol markand go to a page for required item anddescription.

EC083000MANUAL FORMATAll of the procedures in this manual are organized in a sequential, step-by-step format. The informationhas been complied to provide the mechanic with an easy to read, handy reference that containscomprehensive explanations of all disassembly, repair, assembly, and inspection operations.In this revised format, the condition of a faulty component will precede an arrow symbol and thecourse of action required will follow the symbol, e.g.,• BearingsPitting/Damage ≥ Replace.EC084002HOW TO READ DESCRIPTIONSTo help identify parts and clarify procedure steps, there are exploded diagrams at the start of eachremoval and disassembly section.1. An easy-to-see exploded diagram 1 is provided for removal and disassembly jobs.2. Numbers 2 are given in the order of the jobs in the exploded diagram. A number that isenclosed 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 symbolmarks 3. The meanings of the symbol marks are given on the next page.4. A job instruction chart 4 accompanies the exploded diagram, providing the order of jobs,names of parts, notes in jobs, etc.5. Extent of removal 5 is provided in the job instruction chart to save the trouble of an unnecessaryremoval job.6. For jobs requiring more information, the step-by-step format supplements 6 are given in additionto the exploded diagram and job instruction chart.1CLUTCHENGCLUTCHENG2EC4A8100CLUTCH HOUSING AND PUSH LEVER AXLEEC4A3000REMOVAL POINTSEC483211Clutch boss1. Remove:• Nut 1• Lock washer 2• Clutch boss 3NOTE:Straighten the lock washer tab and use theclutch holding tool 4, 5 to hold the clutchboss.Clutch holding tool:YM-91042 . . . . . . . . . . . . . . . .490890-04086 . . . . . . . . . . . . .5BA For USA and CDNB Except for USA and CDN6T 50 Nm (5.0 mdkg, 36 ftdlb)T 11 Nm (1.1 mdkg, 8.0 ftdlb)3EC4A4000INSPECTIONEC484100Clutch housing and boss1. Inspect:• Clutch housing 1Cracks/Wear/Damage ≥ Replace.• Clutch boss 2Scoring/Wear/Damage ≥ Replace.45Extend of removal: 1 Clutch housing removal 2 Push lever axle removalExtend of removal Order Part name Q’ty RemarksCLUTCH HOUSING ANDPUSH LEVER AXLEREMOVAL1 Nut (clutch boss) 1Use special tool.2 Lock washer 1Refer to “REMOVAL POINTS”.3 Clutch boss 14 Spacer 2 115 O-ring (small) 16 Clutch housing 17 O-ring (large) 18 Bearing 19 Spacer 1 110 Ball 111 Push rod 12 12 Bolt (seat plate) 113 Seat plate 114 Push lever axle 14-254-26EC4A4100Clutch housing1. Check:• Circumferential playFree play exists ≥ Replace.• Gear teeth aWear/Damage ≥ Replace.• O-ring 1Damage ≥ Replace.EC484400Clutch spring1. Measure:• Clutch spring free length aOut of specification ≥ Replace springs asa set.Clutch spring free length:Standard36.0 mm (1.417 in) 35.0 mm (1.378 in){

1GENINFO3INSPADJ5CHAS79¡TUN2SPEC46ELEC80ENGEC085002ILLUSTRATED SYMBOLS(Refer to the illustration)Illustrated symbols 1 to 7 are designed asthumb tabs to indicate the chapter’s numberand content.1 General information2 Specifications3 Regular inspection and adjustments4 Engine5 Chassis6 Electrical7 TuningIllustrated symbols 8 to ¢ are used to identifythe specifications appearing in the text.8 With engine mounted9 Special tool0 Filling fluid¡ Lubricant Tightening£ Specified value, Service limit¢ Resistance ( Ω ), Voltage ( V ), Electric current( A )£¢∞§• ªº !Illustrated symbols ∞ to ª in the explodeddiagrams indicate grade of lubricant and locationof lubrication point.∞ Apply transmission oil§ Apply engine mixing oil Apply molybdenum disulfide oil• Apply lightweight lithium-soap base greaseª Apply molybdenum disulfide greaseIllustrated symbols º to ! in the explodeddiagrams indicate where to apply a lockingagent and where to install new parts.º Apply locking agent (LOCTITE ® )! Use new one

MEMO

EC090000INDEXGENERAL INFORMATIONSPECIFICATIONGENINFO 1SPEC 2REGULAR INSPECTION AND ADJUSTMENTSENGINEINSPADJ 3ENG 4CHASSISCHAS 5ELECTRICALELEC 6TUNINGTUN7

EC0A0000CONTENTSCHAPTER 1GENERAL INFORMATIONDESCRIPTION. . . . . . . . . . . . . . . . . . . . . . 1-1MACHINE IDENTIFICATION . . . . . . . . . . . 1-2IMPORTANT INFORMATION . . . . . . . . . . 1-3CHECKING OF CONNECTION . . . . . . . . . 1-5SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . 1-6CONTROL FUNCTIONS . . . . . . . . . . . . . . 1-8FUEL AND ENGINE MIXING OIL . . . . . . 1-14INFORMATION BEFOREPRE-OPERATION . . . . . . . . . . . . . . . . . . 1-15STARTING AND BREAK-IN . . . . . . . . . . 1-16TORQUE-CHECK POINTS . . . . . . . . . . . 1-19CLEANING AND STORAGE . . . . . . . . . . 1-21CHAPTER 2SPECIFICATIONSGENERAL SPECIFICATIONS . . . . . . . . . . 2-1MAINTENANCE SPECIFICATIONS . . . . . 2-3GENERAL TORQUE SPECIFICATIONS . 2-12DEFINITION OF UNITS . . . . . . . . . . . . . . 2-12CABLE ROUTING DIAGRAM . . . . . . . . . 2-13CHAPTER 3REGULAR INSPECTIONAND ADJUSTMENTSMAINTENANCE INTERVALS . . . . . . . . . . 3-1PRE-OPERATION INSPECTION ANDMAINTENANCE. . . . . . . . . . . . . . . . . . . . . 3-4LOCKING WIRE INSTALLATION GUIDE . 3-5ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . 3-17ELECTRICAL. . . . . . . . . . . . . . . . . . . . . . 3-42

CHAPTER 4ENGINECOWLING, INDUCTION GUIDE, SEATAND FUEL TANK . . . . . . . . . . . . . . . . . . . . 4-1EXHAUST PIPE AND SILENCER . . . . . . . 4-3RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . 4-4CARBURETOR AND REED VALVE . . . . . 4-7CYLINDER HEAD,CYLINDER ANDPISTON . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . 4-31PRIMARY DRIVEN GEAR, PRIMARYDRIVE GEAR AND BALANCERSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . 4-44WATER PUMP . . . . . . . . . . . . . . . . . . . . . 4-51TRANSMISSION, SHIFT CAM ANDSHIFT FORK . . . . . . . . . . . . . . . . . . . . . . 4-55OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . 4-64CDI MAGNETO . . . . . . . . . . . . . . . . . . . . 4-68ENGINE REMOVAL . . . . . . . . . . . . . . . . . 4-71CRANKCASE AND CRANKSHAFT . . . . 4-76CHAPTER 5CHASSISFRONT WHEEL AND REAR WHEEL . . . . 5-1FRONT BRAKE AND REAR BRAKE . . . 5-10FRONT FORK . . . . . . . . . . . . . . . . . . . . . 5-26HANDLEBAR. . . . . . . . . . . . . . . . . . . . . . 5-40STEERING . . . . . . . . . . . . . . . . . . . . . . . . 5-46SWINGARM . . . . . . . . . . . . . . . . . . . . . . . 5-53REAR SHOCK ABSORBER . . . . . . . . . . 5-60CHAPTER 6ELECTRICALELECTRICAL COMPONENTS ANDWIRING DIAGRAM . . . . . . . . . . . . . . . . . . 6-1IGNITION SYSTEM . . . . . . . . . . . . . . . . . . 6-2CHARGING SYSTEM . . . . . . . . . . . . . . . . 6-7YPVS SYSTEM . . . . . . . . . . . . . . . . . . . . 6-10SOLENOID VALVE SYSTEM. . . . . . . . . . 6-12THERMO UNIT SYSTEM. . . . . . . . . . . . . 6-14FUEL PUMP SYSTEM. . . . . . . . . . . . . . . 6-16

CHAPTER 7TUNINGENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . 7-14

DESCRIPTIONGENINFOEC100000GENERAL INFORMATIONEC110000DESCRIPTION1 Clutch lever2 Valve joint3 Main switch4 Water temperature gauge5 Front brake lever6 Throttle grip7 Radiator cap8 Fuel tank cap9 Starter lever (Choke)0 Battery¡ Fuel pump Fuel cock£ Steering damper¢ Servomotor∞ Radiator§ Check bolt (Transmission oil level) Rear brake pedal• Rear shock absorberª Drive chainº Shift pedal! CDI magneto@ Front forkNOTE:• The machine you have purchased may differslightly from those shown in the following.• Designs and specifications are subject tochange without notice.11-1

MACHINE IDENTIFICATIONGENINFO1EC120001MACHINE IDENTIFICATIONThere are two significant reasons for knowingthe serial number of your machine:1. When ordering parts, you can give thenumber to your Yamaha dealer for positiveidentification of the model you own.2. If your machine is stolen, the authoritieswill need the number to search for andidentify your machine.EC121001VEHICLE IDENTIFICATION NUMBER(For USA, CDN, AUS, NZ and E)The vehicle identification number 1 isstamped on the right of the steering headpipe.EC122001FRAME SERIAL NUMBER(Except for USA, CDN, AUS, NZ and E)The frame serial number 1 is stamped on theright of the steering head pipe.EC123020ENGINE SERIAL NUMBERThe engine serial number 1 is stamped intothe elevated part of the rear-side of theengine.EC124000MODEL LABELThe model label 1 is affixed to the frameunder the rider’s seat. This information will beneeded to order spare parts.1-2

IMPORTANT INFORMATIONGENINFOEC130000IMPORTANT INFORMATIONEC131002PREPARATION FOR REMOVAL AND DIS-ASSEMBLY1. Remove all dirt, mud, dust, and foreignmaterial before removal and disassembly.2. Use proper tools and cleaning equipment.Refer to “SPECIAL TOOLS” section.3. When disassembling the machine, keepmated parts together. They include gears,cylinders, pistons, and other mated partsthat have been “mated” through normalwear. Mated parts must be reused as anassembly or replaced.4. During the machine disassembly, clean allparts and place them in trays in the orderof disassembly. This will speed up assemblytime and help assure that all parts arecorrectly reinstalled.5. Keep away from fire.1-3

IMPORTANT INFORMATIONGENINFOEC132000ALL REPLACEMENT PARTS1. We recommend to use Yamaha genuineparts for all replacements. Use oil and/orgrease recommended by Yamaha forassembly and adjustment.EC133000GASKETS, OIL SEALS AND O-RINGS1. All gaskets, oil seals, and O-rings shouldbe replaced when an engine is overhauled.All gasket surfaces, oil seal lips, and O-rings must be cleaned.2. Properly oil all mating parts and bearingsduring reassembly. Apply grease to the oilseal lips.EC134000LOCK WASHERS/PLATES AND COTTERPINS1. All lock washers/plates 1 and cotter pinsmust be replaced when they are removed.Lock tab(s) should be bent along the boltor nut flat(s) after the bolt or nut has beenproperly tightened.EC135001BEARINGS AND OIL SEALS1. Install the bearing(s) 1 and oil seal(s) 2with their manufacturer’s marks or numbersfacing outward. (In other words, thestamped letters must be on the sideexposed to view.) When installing oilseal(s), apply a light coating of light-weightlithium base grease to the seal lip(s). Oilthe bearings liberally when installing.CCAUTION:Do not use compressed air to spin thebearings dry. This causes damage to thebearing surfaces.EC136000CIRCLIPS1. All circlips should be inspected carefullybefore reassembly. Always replace pistonpin clips after one use. Replace distortedcirclips. When installing a circlip 1, makesure that the sharp-edged corner 2 ispositioned opposite to the thrust 3 itreceives. See the sectional view.4 Shaft1-4

CHECKING OF CONNECTIONGENINFOEC1C0001CHECKING OF CONNECTIONDealing with stains, rust, moisture, etc. on theconnector.1. Disconnect:• Connector2. Dry each terminal with an air blower.3. Connect and disconnect the connector twoor three times.4. Pull the lead to check that it will not comeoff.5. If the terminal comes off, bend up the pin1 and reinsert the terminal into the connector.6. Connect:• ConnectorNOTE:The two connectors “click” together.7. Check for continuity with a tester.NOTE:• If there in no continuity, clean the terminals.• Be sure to perform the steps 1 to 7 listedabove when checking the wireharness.• For a field remedy, use a contact revitalizeravailable on the market.• Use the tester on the connector as shown.1-5

SPECIAL TOOLSGENINFOEC140002SPECIAL TOOLSThe proper special tools are necessary for complete and accurate tune-up and assembly. Using thecorrect special tool will help prevent damage caused by the use of improper tools or improvisedtechniques. The shape and part number used for the special tool differ by country, so two types areprovided. Refer to the list provided to avoid errors when placing an order.NOTE:• For U.S.A. and Canada, use part number starting with “YM-”, “YU-” or “ACC-”.• For others, use part number starting with “90890-”.Part number Tool name / How to use IllustrationYM-1189, 90890-01189 Flywheel puller YM-1189 90890-01189This tool is used to remove the flywheel magneto.YU-1235, 90890-01235 Rotor holding tool YU-1235 90890-01235This tool is used when loosening or tightening theflywheel magneto securing nut.YU-3097, 90890-01252 Dial gauge and stand YU-3097 90890-01252YU-1256 Spark plug hole dial stand YU-1256YU-1037 Offset dial stand YU-1037These tools are used to set the ignition timing.YU-1304, 90890-01304 Piston pin puller YU-1304 90890-01304This tool is used to remove the piston pin.YM-1312-A, 90890-01312 Fuel level gauge YM-1312-A 90890-01312YM-1470, 90890-01470 Fuel level gauge adapter YM-1470 90890-01470This gauge is used to measure the fuel level in thefloat chamber.YU-24460-01, 90890-01325 Radiator cap tester YU-24460-01 90890-01325YU-33984, 90890-01352 Adapter YU-33984 90890-01352These tools are used for checking the cooling system.YU-33975, 90890-01403 Ring nut wrench YU-33975 90890-01403This tool is used when tighten the steering ring nutto specification.1-6

SPECIAL TOOLSGENINFOPart number Tool name / How to use IllustrationYM-1425, 90890-01425 Damper rod holder YM-1425 90890-01425Use this tool to remove and install the damper rod.YM-1434, 90890-01434 Rod holder YM-1434 90890-01434This tool is used to hold the fork spring.90890-01435 Rod puller attachment YM-1437 90890-01435YM-1437, 90890-01437 Rod puller 90890-01437These tools are used to pull up the fork damper rod.YM-1441, 90890-01441 Fork spring compressor YM-1441 90890-01441This tool is used to compress the fork spring.YM-1442, 90890-01442 Fork seal driver YM-1442 90890-01442This tool is used when install the fork oil seal.YM-1455, 90890-01455 Pivot shaft wrench YM-1455 90890-01455YM-1476, 90890-01476 Pivot shaft wrench adapter YM-1476 90890-01476These tools are used to loosen or tighten the pivotadjust bolt.YU-3112-C, 90890-03112 Yamaha pocket tester YU-3112-C 90890-03112Use this tool to inspect the coil resistance, outputvoltage and amperage.YM-91042, 90890-04086 Clutch holding tool YM-91042 90890-04086This tool is used to hold the clutch when removing orinstalling the clutch boss securing nut.YM-34487 Dynamic spark tester YM-34487 90890-0675490890-06754 Ignition checkerThis instrument is necessary for checking the ignitionsystem components.ACC-YAMAB-ON-D4 Quick gasket ® ACC-YAMAB-ON-D4 90890-0514390890-05143 YAMAHA Bond No.4This sealant (Bond) is used for crankcase matingsurface, etc.1-7

CONTROL FUNCTIONSGENINFOEC150000CONTROL FUNCTIONSEC15W000MAIN SWITCHWhile the battery is connected, moving themain switch 1 to “RUN” causes the tachometer,servomotor, fuel pump and solenoid valvesto be initially activated. To prevent the batteryfrom being discharge, do not move the mainswitch to “RUN” except when the engine isstarted or when electric parts are checked.EC152000CLUTCH LEVERThe clutch lever 1 is located on the left handlebar;it disengages or engages the clutch.Pull the clutch lever to the handlebar to disengagethe clutch, and release the lever toengage the clutch. The lever should be pulledrapidly and released slowly for smooth starts.EC153000SHIFT PEDALThe gear ratios of the constant-mesh 6 speedtransmission are ideally spaced. The gearscan be shifted by using the shift pedal 1 onthe left side of the engine.EC155001THROTTLE GRIPThe throttle grip 1 is located on the right handlebar;it accelerates or decelerates theengine. For acceleration, turn the grip towardyou; for deceleration, turn it away from you.EC156000FRONT BRAKE LEVERThe front brake lever 1 is located on the righthandlebar. Pull it toward the handlebar to activatethe front brake.1-8

CONTROL FUNCTIONSGENINFONOTE:• If an out-of-step indication takes place, movingthe main switch to “OFF” once and thento “RUN”, brings the tachometer back to anormal indication through its correctiveaction.• There is no functional problem involved withthe out-of-step indication, which can bebrought back to a normal indication throughthe corrective action of the tachometer.EC15B010WATER TEMPERATURE GAUGEThe water temperature gauge 1 displays differentindications according to the change inthe water temperature.NOTE:Water temperature may be 70 ˚C (158 ˚F)when engine is operated in good conditions.Cooling watertemp.~19 ˚C(~66 ˚F)DisplayConditions“LO” is display.20~119 ˚C Temperature is(68~247 ˚F) displayed.120~140 ˚C Temperature(248~284 ˚F) flash.141 ˚C~ Message “HI”(285 ˚F~) flash.EC15F000VALVE JOINTThis valve joint 1 prevents fuel from flowingout and is installed to the fuel tank breatherhose.CCAUTION:In this installation, make sure the arrowfaces the fuel tank and also downward.EC15X000BATTERYThe battery 1 is provided as power supply forthe electric parts. Except when the machine isrun, disconnect the power supply coupler 2 ofthe wireharness to prevent battery discharge.1-10

CONTROL FUNCTIONSGENINFOEC15Y000INDUCTION BOX INTAKE SYSTEMThe induction boxes 1 and induction guides2 are provided for the purpose of applyingpressure inside the carburetor float chamberand thereby improving the intake performance.If the machine is run without them, the carburetorsettings will become faulty.NOTE:Be sure to fix the induction guides with band3 or hooks 4 so that they do not come off bywind pressure while running.EC15Z000FUEL PUMPThe fuel pump 1, is provided in order to providesteady supply of fuel even when the pressureinside the carburetor float chamberbecomes higher than inside the fuel tankbecause of the induction box intake system.If the fuel level is not up to the specified levelin the float chamber, this pump is activated(with an operation sound) and stops operatingwhen the specified level is reached.CCAUTION:Do not idle run the fuel pump with no fuelflowing as when the fuel tank is empty orwhen the fuel cock is “OFF”. It may damagethe fuel pump.1-11

CONTROL FUNCTIONSGENINFOEC15a000FUEL PUMP STOP SWITCH, FUEL PUMPRELAYThe fuel pump stop switch 1 and fuel pumprelay 2 are provided so as to control the fuelpump and prevent the carburetor overflowingduring a turnover.If the machine is turned over, the fuel pumpstop switch is turned “ON” which allow electriccurrent to flow in the coil 3 inside the relay,causing the relay switch 4 to turn “OFF” andshutting of the electric current flow to the fuelpump 5. Thus, the pump comes to a stop.Fuel pump Fuel pumpFuel pump 5stop switch 1 relay switch 4During run OFF ON ONDuringON OFF OFFturnoverqNOTE:• When the machine is picked up fromturnover, the fuel pump is restored to anoperation condition.• Install the fuel pump stop switch so that“UPPER” mark a faces upward.EC15M011CATCH TANKPut the tip of the breather hose into the catchtank 1 and frame 2. Take care not to allowthe fuel, oil and cooling water to spill on thecourse.3 Radiator breather hose4 Fuel tank breather hose5 Transmission oil breather hoseNOTE:When putting in the transmission oil breatherhose, its tip having a cut a should be on theframe side.1-12

CONTROL FUNCTIONSGENINFOEC15Q001DETACHABLE MAINSTANDThis mainstand 1 is used to support only themachine when standing or transporting it.NOTE:The mainstand can be used to support themachine two ways.1. Hook the bracket of the mainstand onto theswingarm hooks 2.2. Stand shaft (with supplying parts):Insert the stand shaft 3 through the holeof the mainstand and rear wheel axle. Besure to install the clip 4 in the end of thestand shaft.W• Never apply additional force to the mainstand.• Remove this mainstand before startingout.EC15R001DETACHABLE SIDESTANDThis sidestand 1 is used to support only themachine when standing or transporting it.W• Never apply additional force to the sidestand.• Remove this sidestand before startingout.EC15T003FIRE RETARDANT MATERIALFor racing, be sure to fill the fuel tank 2 completelywith fire retardant material (with supplyingparts) 1.EC15b000COUPLER FOR SPEED SHIFTIf an after-marked speed shift is installed, thecoupler 1 should be used.NOTE:If the speed shift is not installed, be sure to fixthe coupler to the wireharness using a vinyltape, for protection against water entry as wellbecause if the coupler contacts the frame,sparks will be shut off, causing the engine tostop.1-13

FUEL AND ENGINE MIXING OILGENINFOEC160040FUEL AND ENGINE MIXING OILMix oil with the gas at the ratio specifiedbelow. Always use fresh, name-brand gasoline,and mix the oil and gas the day of therace. Do not use premix that is more than afew hours old.Recommended fuel:Except for AUS:Premium unleaded fuel witha research octane number of95 or higher.For AUS:Unleaded fuel only5NOTE:Except for AUS:1. If knocking or pinging occurs, use a differentbrand of gasoline or higher octanegrade.2. If unleaded gasoline is not available, thenleaded gasoline can be used.CCAUTION:Never mix two types of oil in the samebatch; clotting of the oil could result. If youwish to change oil types, be sure to drainthe fuel tank and the carburetor float bowlof old premix prior to filling with the newtype.0Fuel tank capacity:23.0 L (5.06 Imp gal, 6.08 US gal)Mixing oilRecommended oil:Castrol A747Mixing ratio: 30 : 121-14

INFORMATION BEFORE PRE-OPERATIONGENINFOEC170011INFORMATION BEFORE PRE-OPERATION1. The brake disc 1 is coated with a rustinhibitor. Before riding the machine, thoroughlyremove it using a lacquer thinner.W• LACQUER THINNER IS HIGHLY FLAMMA-BLE.Always turn off the engine while usinglacquer thinner. Take care not to spill anylacquer thinner on the engine or exhaustsystem.Never use it in the vicinity of an openflame, or while smoking.• LACQUER THINNER CAN CAUSE INJURY.Always use lacquer thinner in a well ventilatedarea. If you should swallow somelacquer thinner, inhale excess lacquerthinner vapors, or allow any lacquer thinnerto get into your eyes, contact a doctorimmediately.NOTE:• When the machine is not in use for a longtime, apply a rust inhibitor to the brake disc.•After riding in the rainy weather, wipe themoisture completely off the disc.• If rust appears on the brake disc, carefullyremove it using #400 sand paper.2. The cooling system is filled with coolant atthe factory to prevent rusting. Be sure toreplace coolant with soft water before riding.CCAUTION:Hard water or salt water is harmful to theengine parts. You may use distilled water, ifyou can’t get soft water.1-15

STARTING AND BREAK-INGENINFOEC190000STARTING AND BREAK-INCCAUTION:Before starting the machine, perform thechecks in the pre-operation check list.WNever start or run the engine in a closedarea. The exhaust fumes are poisonous;they can cause loss of consciousness anddeath in a very short time. Always operatethe machine in a well-ventilated area.EC191032STARTING A COLD ENGINE1. Connect the power supply coupler.2. Turn the fuel cock to “ON” and push thestarter lever (CHOKE).3. Move the main switch to “RUN”.4. Shift the transmission into “1st” gear.5. Apply the clutch lever and push themachine.6. After gaining some momentum, release theclutch lever.7. As soon as the engine starts, quickly applythe clutch lever again and open the throttlegrip slightly at the same time so as to sustainidling of the engine. Then, shift thetransmission into neutral.8. After applying full-throttle a few times, turnthe starter lever (CHOKE) to the originalposition. Take some time to allow theengine to warm up.EC192000WARMING UPRun the engine at varying speeds 5,000~6,000r/min for 1~2 minutes. Fully warm up until thewater temperature gauge reads 70 ˚C (158 ˚F)or so.CCAUTION:Do not warm up the engine for extendedperiods.1-16

STARTING AND BREAK-INGENINFOEC193031STARTING A WARM ENGINEDo not push the starter lever (CHOKE). Openthe throttle slightly and start the engine.CCAUTION:Observe the following break-in procedureduring initial operation to ensure optimumperformance and avoid engine damage.EC194020BREAK-IN PROCEDURES1. Before starting the engine, fill the fuel tankwith a break-in oil-fuel mixture as follows.Mixing oilRecommended oil:Castrol A747Mixing ratio: 30 : 122. Perform the pre-operation checks on themachine.3. Start and warm up the engine. Check theoperation of the controls and check that theengine comes to a stop when moving themain switch to “OFF”.NOTE:During break-in, mask part of the radiator coreso that the water temperature is 55 ~ 65˚C(131 ~ 149˚F).4. Operate the machine under 8,000 r/minand run on a course about 10 km (6 miles).While making a straight-line run, open thethrottle from time to time, taking care not toexceed the revolution limit.5. Go back to the pit to check for looseness,leakage, and other failures in installation.6. Next, operate the machine under 9,000r/min and run about 10 km (6 miles).(While running in this way, get an idea ofthe riding position and approximate settings.)7. Go back to the pit again, check themachine fully for looseness, leakage, andother failures in installation, especially forloose cables and wires, excessive brakefree play, and a chain slack. Also makeadjustment for a riding position accordingto your preference.1-17

STARTING AND BREAK-INGENINFOCCAUTION:After the break-in or before each race, youmust check the entire machine for loose fittingsand fasteners as per “TORQUE-CHECK POINTS”.Tighten all such fasteners as required.8. Increase the engine speed up to 10,000r/min and run about 10 km (6 miles).9. Increase the engine speed up to 11,000r/min and run about 10 km (6 miles).10.Increase the engine speed up to 12,000r/min and run about 10 km (6 miles). Thendo the plug chop. Check the piston head forburning to see if there is any problem.Refer to “SETTING” section in the CHAP-TER 7.11.Run about 10 km (6 miles) in a usual manner.Then do the plug chop. Check the pistonhead for burning to see if there is anyproblem.EC195001BREAKING IN AFTER REPLACEMENTAfter a part is replaced with a new one, it isnecessary to break it in as in a new machine.This is required especially when the followingengine-related parts are replaced.•Cylinder •Piston •Piston ring•Crankshaft •Clutch •Transmission gear•Shift fork$ For warming up and inspection duringbreak-in, refer to “PRE-OPERATIONCHECK LIST” and if there is any problem,stop the engine immediately and check.1-18

TORQUE-CHECK POINTSGENINFOEC1A0060TORQUE-CHECK POINTSFrame constructionFrame to rear frameEngine mountingFrame to engineSteering Steering shaft to handlebar Steering damper stay to front forkSteering shaft to handle crownFront fork to handlebarSuspension Front Steering shaft to front fork Front fork to handle crownFront fork to under bracketRear For link type Assembly of linksLink to frameLink to shock absorberLink to swingarmRear Installation of shock absorber Shock absorber to upper bracketAdjuster to upper bracketAdjuster to locknutRear Installation of swingarm Tightening of pivot shaftWheel Installation of wheel Front Tightening of front axleRearTightening of rear axleSprocket damper to sprocketBrake Hydraulic type Front Caliper to front forkBrake disc to wheelTightening of union boltCaliper to adapterBrake hose to adapterMaster cylinder to handlebarTightening of air bleederCaliper to pad pinRear1-19Caliper to caliper bracketBrake disc to wheelTightening of union boltCaliper to adapterBrake hose to adapterMaster cylinder to footrest bracketFootrest bracket to frameFootrest bracket to footrestBrake pedal to master cylinderTightening of air bleederCaliper to pad pin

TORQUE-CHECK POINTSGENINFOFuel systemFuel tank to fuel cockNOTE:Concerning the tightening torque, refer to“MAINTENANCE SPECIFICATIONS” sectionin the CHAPTER 2.1-20

CLEANING AND STORAGEGENINFOEC1B0000CLEANING AND STORAGEEC1B1000CLEANINGFrequent cleaning of your machine willenhance its appearance, maintain good overallperformance, and extend the life of manycomponents.1. Before washing the machine, block off theend of the exhaust pipe to prevent waterfrom entering. A plastic bag secured with arubber band may be used for this purpose.2. If the engine is excessively greasy, applysome degreaser to it with a paint brush. Donot apply degreaser to the chain, sprockets,or wheel axles.3. Rinse the dirt and degreaser off with a gardenhose; use only enough pressure to dothe job.CCAUTION:Excessive hose pressure may cause waterseepage and contamination of wheel bearings,front forks, brakes and transmissionseals. Many expensive repair bills haveresulted from improper high pressuredetergent applications such as those availablein coin-operated car washers.4. After the majority of the dirt has beenhosed off, wash all surfaces with warmwater and a mild detergent. Use an oldtoothbrush to clean hard-to-reach places.5. Rinse the machine off immediately withclean water, and dry all surfaces with a softtowel or cloth.6. Immediately after washing, remove excesswater from the chain with a paper toweland lubricate the chain to prevent rust.7. Clean the seat with a vinyl upholsterycleaner to keep the cover pliable andglossy.8. Automotive wax may be applied to all paintedor chromed surfaces. Avoid combinationcleaner-waxes, as they may contain abrasives.9. After completing the above, start theengine and allow it to idle for several minutes.1-21

CLEANING AND STORAGEGENINFOEC1B2010STORAGEIf your machine is to be stored for 60 days ormore, some preventive measures must betaken to avoid deterioration. After cleaning themachine thoroughly, prepare it for storage asfollows:1. Drain the fuel tank, fuel lines, and the carburetorfloat chambers.2. Remove the spark plugs, pour a tablespoonof SAE 10W30 motor oil in the sparkplug hole, and reinstall the plug. With theengine stop switch pushed in, kick theengine over several times to coat the cylinderwalls with oil.3. Remove the drive chain, clean it thoroughlywith solvent, and lubricate it. Reinstall thechain or store it in a plastic bag tied to theframe.4. Lubricate all control cables.5. Block the frame up to raise the wheels offthe ground.6. Tie a plastic bag over the exhaust pipe outletto prevent moisture from entering.7. If the machine is to be stored in a humid orsalt-air environment, coat all exposedmetal surfaces with a film of light oil. Do notapply oil to rubber parts or the seat cover.8. Drain the cooling water completely. Andthen fill the coolant and water (50%:50%)in the engine and radiator.NOTE:Make any necessary repairs before themachine is stored.1-22

GENERAL SPECIFICATIONSSPECEC200000SPECIFICATIONSEC211000GENERAL SPECIFICATIONSModel name:TZ250N1 (USA)TZ250(N) (OTHERS)Model code number:5KE2Dimensions:Overall length1,955 mm (77.0 in)Overall width650 mm (25.6 in)Overall height1,083 mm (42.6 in)Seat height788 mm (31.0 in)Wheelbase1,342 mm (52.8 in)Minimum ground clearance112 mm (4.4 in)Basic weight:With oil and full fuel tank119.5 kg (263 lb)Engine:Engine typeLiquid cooled 2-stroke, gasolineCylinder arrangementV-type, 2-cylinderDisplacement249 cm 3 (8.76 lmp oz, 8.42 US oz)BoreXStroke54X54.5 mm (2.126X2.146 in)Compression ratio 7.2 : 1Starting systemPush to startLubrication system: Premix (30 : 1) (Castrol A747)Oil type or grade (2-Cycle) :Transmission oilCastrol R30Periodic oil change0.5 L (0.44 lmp qt, 0.53 US qt)Total amount0.5 L (0.44 lmp qt, 0.53 US qt)Cooling water capacity (including all routes) : 1.4 L (1.23 lmp qt, 1.48 US qt)Fuel:TypeTank capacityCarburetor:Type/ManufacturerSpark plug:Type/ManufacturerGapClutch type:Except for AUS: Premium unleaded fuel with aresearch octane number of95 or higherFor AUS: Unleaded fuel only23.0 L (5.06 lmp gal, 6.08 US gal)TMX*38/MIKUNIR6179A-105P/NGK0.5~0.6 mm (0.020~0.024 in)Dry, multiple-disc22-1

GENERAL SPECIFICATIONSSPEC2Transmission:primary reduction systemSpur gearPrimary reduction ratio 53/21 (2.524)Secondary reduction systemChain driveSecondary reduction ratio 36/14 (2.571)Transmission typeConstant mesh, 6-speedOperationLeft foot operationGear ratio: 1st 34/18 (1.889)2nd 31/21 (1.476)3rd 29/23 (1.261)4th 27/25 (1.080)5th 26/27 (0.963)6th 20/22 (0.909)Chassis:Frame typeDelta boxCaster angle22˚Trail82 mm (3.23 in)Tire:TypeTubelessSize (front)3.10/4.80 R17Size (rear)165/55 R17Tire pressure (front and rear)200 kPa (2.0 kg/cm 2 , 29 psi)Brake:Front brake typeDual disc brakeOperationRight hand operationRear brake typeSingle disc brakeOperationRight foot operationSuspension:Front suspensionTelescopic forkRear suspensionSwingarm (link type monocross suspension)Shock absorber:Front shock absorberCoil spring/oil damperRear shock absorberCoil spring/gas, oil damperWheel travel:Front wheel travel113 mm (4.45 in)Rear wheel travel118 mm (4.65 in)Electrical:Ignition systemCDI magneto2-2

MAINTENANCE SPECIFICATIONSSPECEC212000MAINTENANCE SPECIFICATIONSEC212112ENGINEItem Standard LimitCylinder head:Combustion chamber capacity 9.0 cm 3 ?(0.317 lmp oz, 0.304 US oz)Piston:Piston clearance 0.090~0.100 mm ?(0.0035~0.0039 in)Piston offset 1.0 mm (0.039 in)/EX-side ?Piston pin:Piston pin outside diameter 14.995~15.000 mm 14.975 mm(0.5904~0.5906 in) (0.5896 in)Piston ring:Sectional sketch Keystone ?B=1.0 mm (0.039 in) ?T=2.2 mm (0.087 in) ?End gap (installed) 0.22~0.37 mm (0.009~0.015 in) 0.59 mm (0.023 in)Side clearance (installed) Zero~0.06 mm (Zero~0.0024 in) ?Crankshaft:Crank width “A” 49.975~50.025 mm (1.968~1.969 in) ?Runout limit “C” 0.03 mm (0.0012 in) 0.05 mm (0.0020 in)Connecting rod big endside clearance “D” 0.45~0.95 mm (0.018~0.037 in) ?Small end free play “F” 0.8~1.0 mm (0.031~0.039 in) 2.0 mm (0.08 in)Clutch:Friction plate thickness 2.9~3.1 mm (0.114~0.122 in) 2.7 mm (0.106 in)Quantity 6 ?Clutch plate thickness 2.2~2.4 mm (0.087~0.094 in) ?Quantity 5 ?Warp limit ? 0.1 mm (0.004 in)Clutch spring free length 30.6 mm (1.205 in) 29.6 mm (1.165 in)Quantity 6 ?Clutch housing thrust clearance 0.07~0.18 mm (0.003~0.007 in) ?Clutch housing radial clearance 0.009~0.071 mm(0.0004~0.0028 in) ?Clutch release method Inner push, cam push ?Push rod bending limit ? 0.2mm (0.008 in)Transmission:Main axle deflection limit ? 0.01 mm (0.0004 in)Drive axle deflection limit ? 0.01 mm (0.0004 in)Shifter:Shifting type Cam drum and guide bar ?Guide bar bending limit ? 0.04 mm (0.0016 in)2-3

MAINTENANCE SPECIFICATIONSSPECItem Standard LimitCarburetor:Type/Manufacturer TMX*38/MIKUNI ?I.D. mark (left side/right side) 5KE2 10L/5KE2 10R ?Main jet (M.J.) #560 ?Jet needle (J.N.) 6DGJ1 ?Main nozzle (N.J.) S-4 ?Cutaway (C.A.) 5.0 ?Pilot jet (P.J.) #40 ?Pilot air screw (P.A.S.) 1-1/2 ?Valve seat size (V.S.) 1.5 ?Starter jet (G.S.) #80 ?Power jet (P.W.J.) #55 ?Float height (F.H.) 6.0~7.0 mm (0.24~0.28 in) ?Reed valve:Thickness* reed valve 1 0.42 mm (0.017 in) ?reed valve 2 0.34 mm (0.013 in) ?Valve stopper height 6.5~6.9 mm (0.256~0.272 in) ?Valve bending limit ? 0.2 mm (0.008 in)Cooling:Radiator core size:Width 380 mm (14.96 in) ?Height 198 mm (7.80 in) ?Thickness 24 mm (0.94 in) ?Radiator cap opening pressure 95~125 kPa ?(0.95~1.25 kg/cm 2 , 13.5~17.8 psi)Radiator capacity 0.5 L (0.44 lmp qt, 0.53 US qt) ?Water pump:Type Single-suction centrifugal pump ?2-4

MAINTENANCE SPECIFICATIONSSPECPart to be tightened Thread size Q’tyTightening torqueNm mdkg ftdlbSpark plug M14S X 1.25 2 19 1.9 13Cylinder head (bolt) M 6 X 1.0 12 11 1.1 8.0Cylinder (nut) M 8 X 1.25 8 20 2.0 14(stud) M 8 X 1.25 8 15 1.5 11Power valve:Cover M 5 X 0.8 8 4 0.4 2.9Holder (power valve) M 5 X 0.8 2 9 0.9 6.5Pulley M 5 X 0.8 2 4 0.4 2.9Cable stay M 5 X 0.8 4 7 0.7 5.1Air bleeding bolt (cylinder) M 6 X 1.0 2 12 1.2 8.7Balance weight gear M14 X 1.0 1 50 5.0 36Water pump housing cover M 6 X 1.0 4 11 1.1 8.0Air bleeding bolt (water pump) M 6 X 1.0 1 11 1.1 8.0Radiator M 6 X 1.0 3 7 0.7 5.1Radiator and thermo unit M16 X 1.5 1 11 1.1 8.0Radiator hose clamp – 6 2 0.2 1.4Oil pump cover M 5 X 0.8 3 8 0.8 5.8Oil strainer M 6 X 1.0 4 7 0.7 5.1Carburetor joint M 6 X 1.0 9 11 1.1 8.0Clamp (carburetor joint) M 4 X 0.7 2 2 0.2 1.4Reed valve M 3 X 0.5 12 1 0.1 0.7Mixing chamber top M 4 X 0.7 2 2 0.2 1.4Exhaust pipe M 8 X 1.25 2 21 2.1 15Silencer M 6 X 1.0 4 11 1.1 8.0Crankcase M 8 X 1.25 6Crankcase M 6 X 1.0 9Refer to NOTETransmission housing M 6 X 1.0 6 16 1.6 11Oil check bolt M 6 X 1.0 1 9 0.9 6.5Oil drain bolt M12 X 1.25 1 23 2.3 17Crankcase cover (right) M 6 X 1.0 10 11 1.1 8.0Crankcase cover (left) M 6 X 1.0 3 11 1.1 8.0Primary drive gear M10 X 1.25 1 55 5.5 40Clutch boss M20 X 1.0 1 75 7.5 54Clutch spring M 6 X 1.0 6 9 0.9 6.5Push rod adjuster M 6 X 1.0 1 6 0.6 4.3Seat plate (push lever) M 5 X 0.8 1 7 0.7 5.1Clutch cable holder M 6 X 1.0 2 8 0.8 5.8Bearing plate cover M 6 X 1.0 3 10 1.0 7.2Oil seal plate cover M 5 X 0.8 2 7 0.7 5.1Drive sprocket M20 X 1.0 1 75 7.5 54Bearing plate cover (shift cam) M 5 X 0.8 1 4 0.4 2.9Segment M 8 X 1.25 1 23 2.3 17Shift guide M 6 X 1.0 2 11 1.1 8.0Shift lever adjuster and locknut M 6 X 1.0 1 9 0.9 6.5Stopper bolt (torsion spring) M 8 X 1.25 1 8 0.8 5.8Shift arm M 6 X 1.0 1 14 1.4 102-5

MAINTENANCE SPECIFICATIONSSPECPart to be tightened Thread size Q’tyTightening torqueNm mdkg ftdlbJoint rod 1 and shift rod M 6 X 1.0 1 9 0.9 6.5Joint rod 2 and shift rod M 6 X 1.0 1 9 0.9 6.5Joint rod 1,2 M 6 X 1.0 2 11 1.1 8.0Shift pedal pivot bolt M 8 X 1.25 1 22 2.2 16Front pedal M 6 X 1.0 1 10 1.0 7.2Crankcase tightening sequenceCCAUTION:The M6 bolt comes in two lengths. Use thecorrect one for installation.L=30 mm (1.18 in) (green) 7 0 ¡ £ ¢ ∞Mark $:L=35 mm (1.38 in) (silver) 8 9 NOTE:Tighten all bolts in 2 steps as follows and besure to tighten in numbered order as shown.•First: 1~6 (M8) 11 Nm (1.1 m•kg, 8.0 ft•lb)7~∞ (M6) 6 Nm (0.6 m•kg, 4.3 ft•lb)•Final: 1~6 (M8) 26 Nm (2.6 m•kg, 19 ft•lb)7~∞ (M6) 11 Nm (1.1 m•kg, 8.0 ft•lb)2-6

MAINTENANCE SPECIFICATIONSSPECEC212201CHASSISItem Standard LimitSteering system:Steering bearing type Taper roller bearing ?Front suspension:Front fork travel 113 mm (4.45 in) ?Fork spring free length 212.5 mm (8.37 in) 210.5 mm (8.29 in)Spring rate, STD K=7.00 N/mm ?(0.700 kg/mm, 39 lb/in)Optional spring No ?Oil capacity 386 cm 3 (13.6 lmp oz, 13.1 US oz) ?Oil level 135 mm (5.31 in) ? 80~140 mm (3.15~5.51 in) ?(From top of outer tube with inner tubeand damper rod fully compressedwithout spring.)Oil grade Suspension oil “01” ?Inner tube outer diameter 41 mm (1.61 in) ?Front fork top end 13 mm (0.51 in) ?Rear suspension:Shock absorber travel 53 mm (2.09 in) ?Spring free length 150 mm (5.91 in) ?Fitting length 137 mm (5.39 in) ? 133~142 mm (5.24~5.59 in) ?Spring rate, STD K=72 N/mm ?(7.2 kg/mm, 403 lb/in)Optional spring No ?Enclosed gas pressure 1,200 kPa (12 kg/cm 3 , 171 psi) ?Swingarm:Swingarm free play limitEnd ? 1.0 mm (0.04 in)Side clearance ? 0.05~0.35 mm(0.002~0.014 in)Wheel:Front wheel type Cast wheel ?Rear wheel type Cast wheel ?Front rim size/Material MT 3.75X17/Magnesium ?Rear rim size/Material MT 5.50X17/Magnesium ?Wheel runout limit:Radial ? 1.0 mm (0.04 in)Lateral ? 0.5 mm (0.02 in)Drive chainType/Manufacturer RKGB520TRU/RK EXCEL ?Number of links 109 links + joint ?Chain slack 40~50 mm (1.6~2.0 in) ?Chain length (10 links) ? 150.1 mm (5.909 in)2-7

MAINTENANCE SPECIFICATIONSSPECItem Standard LimitFront disc brake:Disc outside dia.XThickness 298X5.0 mm (11.73X0.20 in) ?Pad thickness 5.3 mm (0.21 in) 1.0 mm (0.04 in)Master cylinder inside dia. 15.87 mm (0.625 in) ?Caliper cylinder inside dia. 33.96 + 30.23 mm ?(1.337 + 1.190 in)Brake fluid type DOT #4 ?Rear disc brake:Disc outside dia.XThickness 185X4.0 mm (7.28X0.16 in) ?Deflection limit ? 0.15 mm (0.006 in)Pad thickness 4.0 mm (0.16 in) 1.0 mm (0.04 in)Master cylinder inside dia. 12.7 mm (0.500 in) ?Caliper cylinder inside dia. 25.4 mm (1.000 in) ?Brake fluid type DOT #4 ?Brake lever & brake pedal:Brake pedal position 148~152 mm (5.8~6.0 in) ?Clutch lever free play (at lever pivot) 2~3 mm (0.08~0.12 in) ?Throttle grip free play 2~4 mm (0.08~0.16 in) ?2-8

MAINTENANCE SPECIFICATIONSSPEC∆∆∆∆∆∆∆∆∆∆∆∆∆∆∆∆∆∆∆Part to be tightened Thread size Q’tyTightening torqueNm mdkg ftdlbHandle crown and outer tube M 8 X 1.25 2 20 2.0 14Under bracket and outer tube M 8 X 1.25 4 23 2.3 17Steering shaft and steering shaft nut M22 X 1.0 1 80 8.0 58Handlebar and outer tube M 6 X 1.0 4 7 0.7 5.1Steering ring nut M25 X 1.0 1 Refer to NOTESteering damper and fame M 8 X 1.25 1 23 2.3 17Steering damper and damper bracket M 6 X 1.0 1 5 0.5 3.6Steering damper stay and outer tube M 6 X 1.0 1 10 1.0 7.2Steering damper stay and pin M 5 X 0.8 1 5 0.5 3.6Steering stopper bolt and locknut M 6 X 1.0 2 11 1.1 8.0Fuel tank fitting bolt and locknut M 8 X 1.25 1 20 2.0 14Clutch lever holder M 5 X 0.8 2 5 0.5 3.6Front master cylinder and master cylinder M 6 X 1.0 2 8 0.8 5.8bracketFront brake reservoir tank and stay M 6 X 1.0 1 5 0.5 3.6Brake lever (bolt) M 6 X 1.0 1 1 0.1 0.7Brake lever (nut) M 6 X 1.0 1 6 0.6 4.3Main switch and handleber M 4 X 0.7 2 2 0.2 1.4Front fork and cap bolt M44 X 1.0 2 23 2.3 17Front fork and damper rod M12 X 1.25 2 40 4.0 29Cap bolt and damper rod M12 X 1.25 2 29 2.9 21Front fork and front fender M 6 X 1.0 4 8 0.8 5.8Brake hose holder and swingarm M 6 X 1.0 2 8 0.8 5.8Brake hose (front and rear) and union bolt M10 X 1.25 2 30 3.0 22(master cylinder)Brake hose (front and rear) and adapter M10 X 1.25 3 14 1.4 10Brake caliper (front and rear) and adapter M10 X 1.25 3 26 2.6 19Front brake caliper and front fork M10 X 1.25 4 35 3.5 25Front master cylinder and bleed screw M 8 X 1.25 1 6 0.6 4.3Brake caliper (front and rear) and pad pin M10 X 1.25 3 18 1.8 13Brake caliper (front and rear) and bleed screw M 8 X 1.25 4 6 0.6 4.3Front wheel axle and nut M18 X 1.5 1 80 8.0 58Front wheel axle holder M 6 X 1.0 4 11 1.1 8.0Front brake disc and wheel hub M 8 X 1.25 12 20 2.0 14Footrest bracket and frame M 8 X 1.25 4 20 2.0 14Footrest bracket and plate (left and right) M 5 X 0.8 4 8 0.8 5.8Footrest and footrest bracket M 6 X 1.0 2 10 1.0 7.2Brake pedal and master cylinder M 6 X 1.0 1 12 1.2 8.7Rear master cylinder and footrest bracket M 8 X 1.25 2 20 2.0 14Rear master cylinder and reservoir connector M 4 X 0.7 1 2 0.2 1.4Rear brake reservoir tank and bolt (rear frame) M 6 X 1.0 1 7 0.7 5.1NOTE:1. First, tighten the ring nut approximately 46 Nm (4.6 m•kg, 33 ft•lb) by using the ring nut wrench,then loosen the ring nut one turn.2. Retighten the ring nut 1 Nm (0.1 m•kg, 0.7 ft•lb).2-9

MAINTENANCE SPECIFICATIONSSPEC∆∆∆∆∆∆∆∆∆∆∆∆∆∆∆∆∆∆∆Part to be tightened Thread size Q’tyTightening torqueNm mdkg ftdlbRear brake caliper and caliper bracket M 8 X 1.25 2 23 2.3 17Rear wheel axle and nut M18 X 1.5 1 80 8.0 58Driven sprocket and sprocket damper M 8 X 1.25 5 32 3.2 23Rear brake disc and wheel hub M 8 X 1.25 3 23 2.3 17Chain puller adjust bolt and locknut M 8 X 1.25 2 16 1.6 11Chain puller adjust bolt M 8 X 1.25 2 2 0.2 1.4Engine mounting:Engine and frame (upper) M10 X 1.25 1 30 3.0 22Engine and frame (lower) M10 X 1.25 1 30 3.0 22Engine bracket and frame M10 X 1.25 2 30 3.0 22Engine bracket and engine M 8 X 1.25 4 23 2.3 17Pinch bolt (engine mounting collar) M 6 X 1.0 2 11 1.1 8.0Engine mounting adjust bolt M16 X 1.0 2 8 0.8 5.8Pivot adjust bolt M25 X 1.0 1 5 0.5 3.6Pivot shaft and nut M18 X 1.5 1 115 11.5 85Relay arm and frame M10 X 1.25 1 34 3.4 24Relay arm and connecting rod M10 X 1.25 1 34 3.4 24Connecting rod and swingarm M10 X 1.25 1 34 3.4 24Rear shock absorber and upper bracket M10 X 1.25 1 34 3.4 24Rear shock absorber and relay arm M10 X 1.25 1 34 3.4 24Seal guard and swingarm M 6 X 1.0 4 8 0.8 5.8Swingarm and hook M 6 X 1.0 2 10 1.0 7.2Swingarm and chain guard M 6 X 1.0 2 8 0.8 5.8Rear shock absorber and locknut (preload) M52 X 1.5 1 20 2.0 14Seat height adjuster and locknut M22 X 1.0 1 38 3.8 27Seat height adjuster and upper bracket M10 X 1.25 1 40 4.0 29Radiator stay and frame M 6 X 1.0 1 8 0.8 5.8Cowling stay bracket and frame M 6 X 1.0 2 8 0.8 5.8Cowling stay and cowling stay bracket M 6 X 1.0 2 8 0.8 5.8Cowling stay (left and right) and frame M 6 X 1.0 2 8 0.8 5.8Upper cowl and screen M 4 X 0.7 6 4 0.4 2.9Fuel tank and fuel cock M 6 X 1.0 2 7 0.7 5.1Seat and rear frame M 6 X 1.0 4 8 0.8 5.8Rear frame and frame M 6 X 1.0 4 11 1.1 8.0NOTE:∆ - marked portion shall be checked for torque tightening after break-in or before each race.2-10

MAINTENANCE SPECIFICATIONSSPECEC212300ELECTRICALItem Standard LimitIgnition system:Ignition timing (B.T.D.C) 2.4 mm (0.094 in) …Advancer type Electrical …CDI:Magneto-model/Manufacturer 5KE-00 (TLGZ06)/DENSO …Source coil resistance (color) 2.3~3.5 Ω at 20˚C (68˚F) …(White-White)Pickup coil resistance (left cylinder) 94~140 Ω at 20˚C (68˚F) …(color)(White/Black-White/Blue)(right cylinder) 94~140 Ω at 20˚C (68˚F) …(White/Black-White/Green)CDI unit-model/Manufacturer 5KE-10/DENSO …Ignition coil:Model/Manufacturer (left cylinder) TJ0285/DENSO …(right cylinder) TJ0277/DENSO …Minimum spark gap 5 mm (0.20 in) …Primary winding resistance 0.14~0.18 Ω at 20˚C (68˚F) …Secondary winding resistance 5.0~7.4 kΩ at 20˚C (68˚F) …Battery:Model/Manufacturer PE12V0.8/ …JAPAN STORAGE BATTERYCapacity 12V0.8Ah …Voltage when charged 12.8V or more …Fuel pump:Model/Manufacturer UC-Z6V/MITSUBISHI …Coil resistance 1~3 Ω at 20˚C (68˚F) …Fuel pump relay:Model/Manufacturer 1UY-92/MATSUSHITADENKO …Coil resistance 72~88 Ω at 20˚C (68˚F) …Circuit breaker:Type Fuse …Main 10AX1 …Part to be tightened Thread size Q’tyTightening torqueNm mdkg ftdlbStator M 6 X 1.0 2 7 0.7 5.1Rotor M12 X 1.25 1 53 5.3 38CDI unit M 6 X 1.0 2 8 0.8 5.8Servomotor pulley M 5 X 0.8 1 8 0.8 5.8Servomotor M 6 X 1.0 2 7 0.7 5.1Voltage regulator M 6 X 1.0 2 7 0.7 5.1Fuel pump and bracket M 5 X 0.8 1 5 0.5 3.62-11

GENERAL TORQUE SPECIFICATIONS/DEFINITION OF UNITSSPECEC220001GENERAL TORQUE SPECIFICATIONSThis chart specifies torque for standard fastenerswith standard I.S.O. pitch threads. Torquespecifications for special components orassemblies are included in the applicable sectionsof this book. To avoid warpage, tightenmulti-fastener assemblies in a crisscross fashion,in progressive stages, until full torque isreached. Unless otherwise specified, torquespecifications call for clean, dry threads.Components should be at room temperature.A B TORQUE SPECIFICATION(Nut) (Bolt) Nm mdkg ftdlb10 mm 6 mm 6 0.6 4.312 mm 8 mm 15 1.5 1114 mm 10 mm 30 3.0 2217 mm 12 mm 55 5.5 4019 mm 14 mm 85 8.5 6122 mm 16 mm 130 13 94A: Distance across flatsB: Outside thread diameterEC230000DEFINITION OF UNITSUnit Read Definition Measuremm millimeter 10 -3 meter Lengthcm centimeter 10 -2 meter Lengthkg kilogram 10 3 gram WeightN Newton 1 kgXm/sec 2 ForceNm Newton meter NXm Torquemdkg Meter kilogram mXkg TorquePa Pascal N/m 2 PressureN/mm Newton per millimeter N/mm Spring rateL Liter – Volume or capacitycm 3 Cubic centimeter – Volume or capacityr/min Revolution per minute – Engine speed2-12

CABLE ROUTING DIAGRAMSPECEC240000CABLE ROUTING DIAGRAM1 Brake hose2 Clamp3 Cable4 Frame5 Radiator breather hose6 YPVS cable 1, 2 (right cylinder)7 Ignition coil lead8 Starter cable9 Solenoid valve lead0 Fuel hose¡ Clutch cable Fuel pump lead£ Throttle cable¢ Transmission oil breather hoseA Pass the brake hose through the hole in the inner fender.B Cut the clamp so that the protruding portion is less than 5 mm (0.20 in).C Install the clamp with its ends facing backward.D Position the cable from bottom to top in the following order.• Starter cable• Throttle cable• Solenoid valve lead2-13

CABLE ROUTING DIAGRAMSPEC1 Fuel pump lead2 Clamp3 Fuse holder4 Servomotor5 Front brake hose (right)6 YPVS cable 1, 2 (right cylinder)7 Clutch cableA Clamp the fuel hose and clutch cable. Position the upside ends of theclamp inside of the seat rail.B Clamp the radiator hose 3 and ignition coil lead.C Clamp the radiator hose 3 and YPVS cable (right cylinder).D Do not cut the end of the clamp.E Connect the left cylinder YPVS cables (silver cables) to the inner YPVSservomotor pulley and right cylinder YPVS cables (black cables) to theouter. The sleeved cables must be connected to the top side (open side)of the YPVS servomotor.F Align the end of the cover with that of the meter stay.G Be sure the brake hose is not twisted.2-14

CABLE ROUTING DIAGRAMSPEC1 Clamp2 Throttle cable3 Fuel tank breather hose4 Fuel pump stop switch lead5 Battery lead6 Fuel pump relay lead7 Power supply coupler8 CDI magneto lead9 Front brake hose (left)A Clamp the wireharness together with couplers of the fuse lead under thecowling stay mounting bolt so that the tape on the wireharness alignswith the bolt.B Fasten the primary ground lead together with the cowling stay bracketmounting bolt.C Do not cut the end of the clamp.D Clamp the couplers of the main switch lead together with the wireharness.E Disconnect the power supply coupler except when the engine is startedor when electric parts are checked.F Be sure the brake hose is not twisted.2-15

CABLE ROUTING DIAGRAMSPEC1 Tachometer assembly2 Coupler for speed shift3 CDI unit4 Voltage regulator5 Servomotor6 Brake hose holder7 Reservoir hose8 Rear brake hose9 ClampA Install the tachometer assembly with its figures standing upright.B Do not make the clamp grip face outside of the chassis.C Position the reservoir hose with its paint mark upward.D Make the clamp grip face inside of the chassis.E Be sure the brake hose is not twisted.F Do not cut the end of the clamp.2-16

MAINTENANCE INTERVALSINSPADJEC300000REGULAR INSPECTION AND ADJUSTMENTSEC310070MAINTENANCE INTERVALSThe following schedule is intended as a general guide to maintenance and lubrication. Bear in mindthat such factors as weather, terrain, geographical location, and individual usage will alter therequired maintenance and lubrication intervals. If you are a doubt as to what intervals to follow inmaintaining and lubricating your machine, consult your Yamaha dealer.NOTE:Replace earlier depending on the operating condition.ItemAfterbreak-inEveryEvery Every As rerace500km 1,000 quiredkmRemarksPISTONInspect and clean ∂ ∂ Inspect crackReplace ∂ ∂PISTON PIN, SMALL END BEARINGInspect ∂ ∂Replace ∂ ∂PISTON RINGInspect ∂ ∂ Check ring end gapReplace ∂ ∂CYLINDER HEADInspect and clean ∂ ∂ Remove carbonRetighten ∂ ∂ Check O-ringCYLINDERInspect and clean ∂ ∂ (3,000 km) Inspect score marksReplace ∂ ∂ Inspect wearRetighten ∂ ∂YPVSInspect ∂ ∂Retighten ∂ ∂CLUTCHInspect housing, frictionInspect and adjust ∂ ∂ plate, clutch plate andReplace ∂ springTRANSMISSIONReplace oil ∂ ∂ Castrol R30Inspect transmission∂Replace bearing∂SHIFT FORK, SHIFT CAM, GUIDE BARInspect ∂ Inspect wearROTOR NUTRetighten∂MUFFLERInspect ∂ ∂ Inspect crackClean∂CRANK(1,500 km)Inspect and replace ∂ ∂CARBURETORInspect, adjust and clean ∂ ∂ Inspect jet needle clip groove33-1

MAINTENANCE INTERVALSINSPADJ3ItemAfterbreak-inEveryEvery Every As rerace500km 1,000 quiredkmRemarksSPARK PLUGInspect and clean ∂ ∂Replace∂PLUG CAP(1,500 km)Inspect and replace ∂ ∂COOLING SYSTEMCheck cooling level and leakage ∂ ∂Check radiator cap operation∂Replace cooling water ∂ Use soft waterReplace hoses∂OUTSIDE NUTS AND BOLTSRefer to “STARTING ANDRetighten ∂ ∂ BREAK-IN” section in theCHAPTER 1.OIL PUMP STRAINERClean ∂ ∂REED VALVEInspect ∂ ∂Replace∂FRAMEClean and inspect ∂ ∂FUEL TANK, COCKClean and inspect ∂ ∂BRAKESAdjust lever position and pedal position ∂ ∂Check brake disc surface ∂ ∂Check brake fluid level and leakage ∂ ∂Retighten brake disc bolts, caliper bolts ∂and master cylinder boltsReplace pads∂Replace brake fluid ∂ Every one yearFRONT FORKSInspect and adjust ∂ ∂Replace oil ∂ Suspension oil “01”Replace oil seal∂REAR SHOCK ABSORBER(After rainrace)Inspect and adjust ∂ ∂Lube ∂ Molybdenum disulfideRetighten ∂ ∂ greaseCHAIN GUARDReplace∂SWINGARMInspect and retighten ∂ ∂RELAY ARM, CONNECTING RODInspect and retighten ∂ ∂STEERING HEADInspect free play and retighten ∂ ∂Clean and lube ∂ Lithium base greaseReplace bearings∂3-2

MAINTENANCE INTERVALSINSPADJItemAfterbreak-inEveryEvery Every As rerace500km 1,000 quiredkmRemarksTIRE, WHEELSInspect air pressure, wheel run-out and ∂ ∂tire wearInspect bearings ∂ ∂Replace bearings∂Lubricate ∂ Lithium base greaseDRIVE CHAINUse chain lubeLubricate, slack, alignment ∂ ∂ Chain slack: 40~50 mmReplace ∂ (1.6~2.0 in)DRIVE, DRIVEN SPROCKETInspect and replace ∂ Inspect wearDRIVEN SPROCKET DAMPERInspect and retighten ∂ ∂Replace∂THROTTLE, CONTROL CABLECheck routing and connection ∂ ∂ Yamaha cable lube or SAELubricate ∂ ∂ 10W30 motor oilBATTERYCheck battery voltage ∂ ∂ 12.5V or moreReplace∂3-3

PRE-OPERATION INSPECTION AND MAINTENANCEINSPADJEC320010PRE-OPERATION INSPECTION AND MAINTENANCEBefore riding for break-in operation, practice or a race, make sure the machine is in good operatingcondition.Before using this machine, check the following points.NOTE:• The brake disc is coated with a rush inhibitor. Before pre-operation thoroughly remove it using alacquer thinner.• For storage, a coolant is used. Before riding the machine remove it with cooling water.Refer to “INFORMATION BEFORE PRE-OPERATION”.EC321020GENERAL INSPECTION AND MAINTENANCEItem Routine PageCooling waterCheck that cooling water is filled up to the radiator filler cap.Check the cooling system for leakage.P3-6~9FuelCheck that a fresh mixture of oil and gasoline is filled in thefuel tank. Check the fuel line for leakage.P1-14Transmission oilCheck that the oil level is correct. Check the crankcase forleakage.P3-13~15YPVS Check operation. P3-12~13Gear shifter and clutch Check that gears can be shifted correctly in order and thatthe clutch operates smoothly.P3-9~10Throttle grip/Housing Check that the throttle grip operation and free play arecorrectly adjusted. Lubricate the throttle grip and housing, P3-10~11if necessary.BrakesCheck the effect of front and rear brake. Check brake discsurface.P3-17~22ChainCheck chain slack and alignment. Check that the chain islubricated properly.P3-23~25Wheels Check for excessive wear, tire pressure and tire wear. P3-36SteeringCheck that the handlebars can be turned smoothly andhave no excessive play.P3-37~38Front forks andCheck that they operate smoothly and there is no oilrear shock absorber leakage.P3-27~35Cables (wires)Check that the clutch and throttle cables move smoothly.Check that they are not caught when the handlebars are P3-39turned or when the front forks travel up and down.Muffler Check that the muffler is tightly mounted and has no cracks. P3-16Sprocket Check that the driven sprocket damper is not loose. P3-22Lubrication Check for smooth operation. Lubricate if necessary. P3-41Bolts and nutsCheck the chassis and engine for loose bolts and nuts.Check that the locking wire is correct.P1-19~20Lead connectorsCheck that the CDI magneto, CDI unit, and ignition coil areconnected tightly.P1-5Battery Check the battery voltage. P3-44~46CowlingCheck that the cowling is tightly mounted and has no cracksin it. Check that it dose not contact other parts by stroking. P3-39Check that the screen is clean.SettingsIs the machine set suitably for the condition of the racingcourse and weather or by taking into account the results oftest runs before racing? Are inspection and maintenanceP7-1~22completely done?3-4

LOCKING WIRE INSTALLATION GUIDEINSPADJEC340000LOCKING WIRE INSTALLATION GUIDEBolt to boltBoltYPVS pulleyThrottle cable adjusterOil drain bolt and check boltTank rail drain boltOil filler capStarter cable3-5

ENGINE/COOLING WATER LEVEL INSPECTION/COOLING WATER REPLACEMENTINSPADJEC350011ENGINECCAUTION:• The cooling system is filled with coolantat the factory to prevent rusting. Be sureto replace coolant with soft water beforeriding.• Take care so that coolant does not splashon painted surfaces. If it splashes, wash itaway with water.EC352000COOLING WATER LEVEL INSPECTIONWDo not remove the radiator cap 1, drainbolt and hoses when the engine and radiatorare hot. Scalding hot fluid and steammay be blown out under pressure, whichcould cause serious injury.When the engine has cooled, place a thicktowel over the radiator cap, slowly rotatethe cap counterclockwise to the detent.This procedure allows any residual pressureto escape. When the hissing soundhas stopped, press down on the cap whileturning counterclockwise and remove it.CCAUTION:Hard water or salt water is harmful to theengine parts. You may use distilled water, ifyou can’t get soft water.1. Place the machine on a level place, andhold it in an upright position.2. Remove:• Radiator cap3. Check:• Cooling water level aCooling water level low ≥ Add coolingwater.1 RadiatorEC354013COOLING WATER REPLACEMENTWDo not remove the radiator cap when theengine is hot.1. Remove the lower cowl.2. Place a container under the radiator hose.3-6

COOLING WATER REPLACEMENTINSPADJ3. Disconnect:• Radiator hose 2 14. Remove:• Radiator capDrain the cooling water completely.5. Clean:• Cooling systemThoroughly flush the cooling system withclean tap water.6. Connect:• Radiator hose 2T2 Nm (0.2 mdkg, 1.4 ftdlb)7. Fill:• Radiator• EngineTo specified level.Recommended cooling water:Soft waterCooling water capacity:1.4 L (1.23 Imp qt, 1.48 US qt)2CCAUTION:• When filling the radiator with anti-freeze,tilt the motorcycle so that the filler hole bis at the highest position. If the radiator ispositioned upright, air a is difficult toescape which may result in excessiveengine heating.• Hard water or salt water is harmful to theengine parts. You may use distilled water,if you can’t get soft water.8. Remove:• Air bleeding bolt (right cylinder) 1Bleeding the air until coming out the coolingwater.9. Install:• Copper washerN• Air bleeding bolt (right cylinder)T12 Nm (1.2 mdkg, 8.7 ftdlb)10.Remove:• Air bleeding bolt (water pump) 1Bleeding the air until coming out the coolingwater.11.Install:• Copper washerN• Air bleeding bolt (water pump)T11 Nm (1.1 mdkg, 8.0 ftdlb)3-7

RADIATOR CAP INSPECTION/RADIATOR CAP OPENING PRESSURE INSPECTIONINSPADJ12.Fill:• Radiator• EngineTo specified level.13.Install:• Radiator capStart the engine and warm it up for a severalminute.14.Check:• Cooling water levelCooling water level low ≥ Add coolingwater.15.Install the lower cowl.EC355000RADIATOR CAP INSPECTION1. Inspect:• Seal (radiator cap) 1• Valve and valve seat 2Crack/Damage ≥ Replace.Exist fur deposits 3 ≥ Clean or replace.EC356002RADIATOR CAP OPENING PRESSUREINSPECTION1. Attach:• Radiator cap tester 1 and adapter 2Radiator cap tester:YU-24460-01/90890-01325CAdapter:YU-33984/90890-01352NOTE:Apply water on the radiator cap seal.3 Radiator cap2. Apply the specified pressure.Radiator cap opening pressure:95~125 kPa (0.95~1.25 kg/cm 2 ,13.5~17.8 psi)b3-8

COOLING SYSTEM INSPECTION/CLUTCH CAREINSPADJ3. Inspect:• PressureImpossible to maintain the specified pressurefor 10 seconds ≥ Replace.EC357003COOLING SYSTEM INSPECTION1. Inspect:• Coolant level2. Attach:• Radiator cap tester 1 and adapter 2Radiator cap tester:YU-24460-01/90890-01325CAdapter:YU-33984/90890-013523. Apply the specified pressure.aStandard pressure:180 kPa (1.8 kg/cm 2 , 25.6 psi)NOTE:• Do not apply pressure more than specifiedpressure.• Radiator should be filled fully.4. Inspect:• PressureImpossible to maintain the specified pressurefor 10 seconds ≥ Repair.• Radiator 1• Radiator hose joint 2Coolant leakage ≥ Repair or replace.• Radiator hose 3Swelling ≥ Replace.EC358000CLUTCH CARENOTE:This machine is equipped with a dry typeclutch. Be sure to clean with solvent or replaceif grease or oil contacts either clutch or frictionplates.3-9

CLUTCH ADJUSTMENT/THROTTLE CABLE ADJUSTMENTINSPADJEC359001CLUTCH ADJUSTMENT1. Check:• Clutch lever free play aOut of specification ≥ Adjust.aClutch lever free play a:2~3 mm (0.08~0.12 in)2. Adjust:• Clutch lever free playClutch lever free play adjustment steps:• Loosen the locknut 1.• Turn the adjuster 2 until free play a iswithin the specified limits.• Tighten the locknut.NOTE:After adjustment, check proper operation ofclutch lever.EC35A040THROTTLE CABLE ADJUSTMENT1. Check:• Throttle grip free play aOut of specification ≥ Adjust.aThrottle grip free play a:2~4 mm (0.08~0.16 in)2. Remove:• Lower cowl• Fuel tank• Induction guide (right cylinder)3. Loosen the screw (right carburetor jointclamp), then take out the carburetor 1.3-10

STARTER CABLE ADJUSTMENT4. Adjust:• Throttle grip free playINSPADJThrottle grip free play adjustment steps:• Loosen the locknuts 1, 2, 3.• Turn the adjusters 4, 5, 6 fully in.• Turn out the right carburetor adjuster 5until the specified free play is obtained.• Tighten the right carburetor locknut 2.• Turn out the left carburetor adjuster 6until the left throttle valve moves togetherwith the right throttle valve.NOTE:• When adjusting left throttle cable, watchthe right throttle valve and touch the leftthrottle valve.• After adjusting the throttle cables, openthe throttle grip and check that both throttlevalves are completely open.• Tighten the left carburetor locknut 3.• Tighten the locknuts 1.WAfter adjusting, turn the handlebar toright and left and make sure that theengine idling dose not run faster.EC35B002STARTER CABLE ADJUSTMENT1. Check:• Starter lever free play aOut of specification ≥ Adjust.aStarter lever free play a:5~10 mm (0.20~0.39 in)2. Adjust:• Starter lever free playStarter lever free play adjustment steps:• Loosen the locknuts 1.• Turn the adjusters 2 until the specifiedfree play is obtained.• Tighten the locknuts.3-11

YPVS OPEN SIDE CABLE ADJUSTMENTINSPADJEC35D012YPVS OPEN SIDE CABLE ADJUSTMENT1. Disconnect the fuel pump coupler to preventthe fuel pump operation.2. Check:• YPVS open side cable free play aChecking steps:• Move the main switch to “RUN”.• The servomotor will be fully opened.NOTE:After the main switch is moved to “RUN”,the servomotor will be operated as follows.1. The servomotor will be fully closedabout 1 second.2. And then, it will be kept fully opened.• Check the free play a for the YPVS openside cables 1.Out of specification ≥ Adjust.µYPVS open side cable freeplay a:2~3 mm (0.08~0.12 in)3. Adjust:• YPVS open side cable free playAdjusting steps:• Fully open the servomotor.• Loosen the locknuts 1.• Turn the adjusters 2 until the specifiedfree play is obtained.• Tighten the locknuts.3-12

YPVS CLOSE SIDE CABLE ADJUSTMENT/YPVS COMPO-NENTS RETIGHTENING/TRANSMISSION OIL LEVEL CHECKINSPADJEC35E011YPVS CLOSE SIDE CABLE ADJUSTMENT1. Disconnect the fuel pump coupler to preventthe fuel pump operation.2. Check:• YPVS close side cable free play aChecking steps:• Move the main switch to “RUN”.• The servomotor will be fully closed about1 second.• During this 1 second, move the mainswitch to “OFF”.• The servomotor will be kept fully closed.• Check the free play a for the YPVS closeside cables 1.Out of specification ≥ Adjust.µYPVS close side cable freeplay a:2~3 mm (0.08~0.12 in)3. Adjust:• YPVS close side cable free playAdjusting steps:• Fully close the servomotor.• Loosen the locknuts 1.• Turn the adjusters 2 until the specifiedfree play is obtained.• Tighten the locknuts.EC35F000YPVS COMPONENTS RETIGHTENINGNOTE:Before riding the machine, retighten all YPVScomponents.1. Retighten:• Valve cover 1 T4 Nm (0.4 mdkg, 2.9 ftdlb)• Pulley 2 T4 Nm (0.4 mdkg, 2.9 ftdlb)• Cable stay 3 T7 Nm (0.7 mdkg, 5.1 ftdlb)EC35H030TRANSMISSION OIL LEVEL CHECK1. Start the engine, warm it up for severalminutes and wait for five minutes.2. Place the machine on a level place andhold it up on upright position by placing thesuitable stand.3-13

TRANSMISSION OIL REPLACEMENT3. Check:• Transmission oil levelINSPADJTransmission oil level checking steps:• Remove the oil check bolt 1.• Inspect the oil level.NOTE:Be sure the machine is positioned straightup when inspecting the oil level.WNever attempt to remove the checkingbolt just after high speed operation. Theheated oil could spout out, causing danger.Wait until the oil cools down.SOil flows out ≥ Oil level is correct.Oil does not flow out ≥ Oil level is low.Add transmissionoil untiloil flows out.RRecommended oil:Castrol R30• Inspect the gasket (oil check bolt), replaceif damaged.• Tighten the oil check bolt.TOil check bolt:9 Nm (0.9 m•kg, 6.5 ft•lb)EC35K021TRANSMISSION OIL REPLACEMENT1. Start the engine and warm it up for severalminutes and wait for five minutes.2. Place the machine on a level place andhold it on upright position by placing thesuitable stand.3. Place a suitable container under theengine.3-14

PILOT AIR SCREW ADJUSTMENT4. Remove:• Oil drain bolt 1• Oil filler cap 2Drain the transmission oil.5. Install:• Copper washerN• Oil drain bolt 1T23 Nm (2.3 mdkg, 17 ftdlb)NOTE:After tightening the oil drain bolt to specifiedtorque, lock it using a wire.6. Fill:• Transmission oilINSPADJRecommended oil:Castrol R30Oil capacity(periodic oil change):0.50 L (0.44 Imp qt, 0.53 US qt)37. Check:• Oil leakage8. Check:• Transmission oil level9. Install:• Oil filler cap 2EC35L002PILOT AIR SCREW ADJUSTMENT1. Adjust:• Pilot air screw 1Adjustment steps:• Screw in the pilot air screw until it is lightlyseated.• Back out by the specified number of turns.ΩPilot air screw:1-1/2 turns out3-15

MUFFLER INSPECTION/SILENCER INSPECTIONINSPADJEC35P010MUFFLER INSPECTION1. Inspect:• O-ring 1Damage ≥ Replace.EC35Q001SILENCER INSPECTION1. Inspect:• SilencerInside of silencer loose ≥ Repair.Silencer repair steps:• Drill the silencer for riveting.• Rivet the silencer using the rivet.NOTE:Rivet the silencer in a different area thanpreviously riveted.3-16

CHASSIS/BRAKE SYSTEM AIR BLEEDINGINSPADJEC360000CHASSISEC361002BRAKE SYSTEM AIR BLEEDINGWBleed the brake system if:• The system has been disassembled.• A brake hose has been loosened orremoved.• The brake fluid is very low.• The brake operation is faulty.A dangerous loss of braking performancemay occur if the brake system is not properlybleed.1. Remove:• Reservoir tank cap• Diaphragm2. Bleed:• Brake fluidA FrontB RearAir bleeding steps:a. Add proper brake fluid to the reservoir.b. Install the diaphragm. Be careful not tospill any fluid or allow the reservoir tooverflow.c. Connect the clear plastic tube 2 tightlyto the caliper bleed screw 1.d. Place the other end of the tube into acontainer.e. Slowly apply the brake lever or pedalseveral times.f. Pull the lever in or push down on thepedal. Hold the lever or pedal in position.g. Loosen the bleed screw and allow thelever or pedal to travel towards its limit.h. Tighten the bleed screw when the leveror pedal limit has been reached; thenrelease the lever or pedal.UBleed screw:6 Nm (0.6 m•kg, 4.3 ft•lb)i. Repeat steps ( e ) to ( h ) until of the airbubbles have been removed from thesystem.3-17

FRONT BRAKE ADJUSTMENT/REAR BRAKE ADJUSTMENTINSPADJNOTE:If bleeding is difficult, it may be necessaryto let the brake fluid system stabilize for afew hours. Repeat the bleeding procedurewhen the tiny bubbles in the system havedisappeared.j. Add brake fluid to the level line on thereservoir.WCheck the operation of the brake afterbleeding the brake system.3. Install:• Diaphragm• Reservoir tank capEC363020FRONT BRAKE ADJUSTMENT1. Adjust:• Brake lever position aAdjustment steps:• Turn the adjuster 1 while pushing thebrake lever 2 forward until the desiredlever position is obtained. SCloser ≥ Turn the adjuster to a largernumber.Farther ≥ Turn the adjuster to a smallernumberṠNOTE:Align the number b on the adjuster withthe mark c on the brake lever.EC364011REAR BRAKE ADJUSTMENT1. Check:• Brake pedal height aOut of specification ≥ Adjust.aBrake pedal height a:148~152 mm (5.8~6.0 in)3-18

FRONT BRAKE PAD INSPECTION AND REPLACEMENT2. Adjust:• Brake pedal heightINSPADJPedal height adjustment steps:• Loosen the locknut 1.• Turn the adjusting nut 2 until the pedalheight is within specified height.• Tighten the locknut.EC365050FRONT BRAKE PAD INSPECTION ANDREPLACEMENT1. Inspect:• Brake pad thickness aOut of specification ≥ Replace as a set.Brake pad thickness a:{Standard5.3 mm (0.21 in) 1.0 mm (0.04 in)2. Replace:• Brake padBrake pad replacement steps:• Loosen the pad pin 1 and remove thecaliper 2.• Remove the cotter pin 3, pad pin 4, padsupport 5 and brake pads 6.• Connect the transparent hose 7 to thebleed screw 8 and place the suitable containerunder its end.• Loosen the bleed screw and push thecaliper piston in.CCAUTION:Do not reuse the drained brake fluid.• Tighten the bleed screw.UBleed screw:6 Nm (0.6 m•kg, 4.3 ft•lb)3-19

REAR BRAKE PAD INSPECTION AND REPLACEMENTINSPADJ• Install the brake pads 9, pad support 0,pad pin ¡ and cotter pin .NOTE:• Always use a new cotter pin.• Temporarily tighten the pad pin at thispoint.• Install the caliper £ and tighten the padpin ¢.Bolt (caliper):35 Nm (3.5 m•kg, 25 ft•lb)Pad pin:18 Nm (1.8 m•kg, 13 ft•lb)3. Inspect:• Brake fluid levelRefer to “BRAKE FLUID LEVEL INSPEC-TION” section.4. Check:• Brake lever operationA softy or spongy feeling ≥ Bleed brakesystem.Refer to “BRAKE SYSTEM AIR BLEED-ING” section.EC366031REAR BRAKE PAD INSPECTION ANDREPLACEMENT1. Inspect:• Brake pad thickness aOut of specification ≥ Replace as a set.Brake pad thickness a:{Standard4.0 mm (0.16 in) 1.0 mm (0.04 in)2. Replace:• Brake padBrake pad replacement steps:• Loosen the pad pin 1 and remove thecaliper 2.NOTE:Before removing the caliper from theswingarm, loosen the pad pin.3-20

REAR BRAKE PAD INSPECTION AND REPLACEMENTINSPADJ• Remove the cotter pin 3, pad pin 4, padsupport 5 and brake pads 6.• Connect the transparent hose 7 to thebleed screw 8 and place the suitable containerunder its end.• Loosen the bleed screw and push thecaliper piston in.CCAUTION:Do not reuse the drained brake fluid.• Tighten the bleed screw.UBleed screw:6 Nm (0.6 m•kg, 4.3 ft•lb)• Install the brake pads 9, pad support 0,pad pin ¡ and cotter pin .NOTE:• Always use a new cotter pin.• Temporarily tighten the pad pin at thispoint.• Install the caliper £ and tighten the padpin ¢.Bolt (caliper):23 Nm (2.3 m•kg, 17 ft•lb)Pad pin:18 Nm (1.8 m•kg, 13 ft•lb)3-213. Inspect:• Brake fluid levelRefer to “BRAKE FLUID LEVEL INSPEC-TION” section.4. Check:• Brake pedal operationA softy or spongy feeling ≥ Bleed brakesystem.Refer to “BRAKE SYSTEM AIR BLEED-ING” section.

BRAKE FLUID LEVEL INSPECTION/SPROCKETS INSPECTIONINSPADJEC367001BRAKE FLUID LEVEL INSPECTION1. Place the master cylinder so that its top isin a horizontal position.2. Inspect:• Brake fluid levelFluid at lower level ≥ Fill up.a Lower levelA FrontB RearRecommended brake fluid:DOT #40W• Use only designated quality brake fluid toavoid poor brake performance.• Refill with same type and brand of brakefluid; mixing fluids could result in poorbrake performance.• Be sure that water or other contaminantsdo not enter master cylinder when refilling.• Clean up spilled fluid immediately toavoid erosion of painted surfaces or plasticparts.EC368011SPROCKETS INSPECTION1. Inspect:• Sprocket teeth aExcessive wear ≥ Replace.NOTE:Replace the drive, driven sprockets and drivechain as a set.2. Inspect:• Sprocket damper 1Wear/Damage ≥ Replace.3-22

DRIVE CHAIN INSPECTIONINSPADJEC369040DRIVE CHAIN INSPECTION1. Remove:• Drive chain 1NOTE:Remove the drive chain using a chain cutter2.2. Clean:• Drive chainBrush off as much dirt as possible. Thenclean the chain using the chain cleaner.CCAUTION:This machine has a drive chain with smallrubber O-rings 1 between the chainplates. Steam cleaning, high-pressurewashes, certain solvent and kerosene candamage these O-rings.3. Inspect:• O-rings 1 (drive chain)Damage ≥ Replace drive chain.• Rollers 2• Side plates 3Damage/Wear ≥ Replace drive chain.4. Measure:• Drive chain length (10 links) aOut of specification ≥ Replace.aDrive chain length (10 links):Limit: 150.1 mm (5.909 in)3-23

DRIVE CHAIN SLACK ADJUSTMENTINSPADJ5. Check:• Drive chain stiffness aClean and oil the chain and hold as illustrated.Stiff ≥ Replace drive chain.6. Install:• Chain joint 1N• O-ring 2• Drive chain 3NOTE:When installing the drive chain, apply the lithiumsoap base grease on the chain joint andO-rings.7. Install:• Link plate 4NNOTE:• Press the link plate onto the chain joint usinga chain rivetter 5.• Rivet the end of the chain joint using a chainrivetter 6.• After rivetting the chain joint, make sure itsmovement is smooth.8. Lubricate:• Drive chainDrive chain lubricant:SAE 30~50W motor oil or chainlubricants suitable for “O-ring”chains$3-24EC36A042DRIVE CHAIN SLACK ADJUSTMENT1. Hold the machine on upright position byplacing the suitable stand.2. Check:• Drive chain slack aOut of specification ≥ Adjust.aDrive chain slack:40~50 mm (1.6~2.0 in)

DRIVE CHAIN SLACK ADJUSTMENTINSPADJNOTE:Before checking and/or adjusting, rotate therear wheel through several revolutions andcheck the slack several times to find the tightestpoint. Check and/or adjust chain slack withrear wheel in this “tight chain” position.3. Adjust:• Drive chain slackDrive chain slack adjustment steps:• Loosen the axle nut 1 and locknuts 2.• Adjust chain slack by turning the adjusters3ṠTo tighten ≥ Turn adjuster 3 counterclockwise.To loosen ≥ Turn adjuster 3 clockwise. S• Turn each adjuster exactly the sameamount to maintain correct axle alignment.(There are marks a on each side ofchain puller alignment.)NOTE:Turn the adjuster so that the chain is in linewith the sprocket, as viewed from the rear.CCAUTION:Too small chain slack will overload theengine and other vital parts; keep theslack within the specified limits.• Tighten the axle nut while pushing downthe drive chain.UAxle nut:80 Nm (8.0 m•kg, 58 ft•lb)• Turn out the adjusters to the specifiedtorque.UAdjuster:2 Nm (0.2 m•kg, 1.4 ft•lb)• Tighten the locknutsṪLocknut:16 Nm (1.6 m•kg, 11 ft•lb)3-25

WHEEL ALIGNMENT ADJUSTMENTINSPADJEC36B000WHEEL ALIGNMENT ADJUSTMENT1. Remove:• Lower cowl2. Place the machine on a level place andhold it up on upright position.3. Sit 1~2 m (3.3~6.6 ft) behind the machineand look at both sides of the wheels belowthe rear wheel axle.4. Turn the handlebar left and right to makethe front wheel straight.NOTE:• To make the front wheel straight, provide band c with the same distance as seen alongthe extension of the line a connecting therear end of the front wheel 1 and the frontend of the rear wheel 2.• Figure A shows that the front wheel isturned clockwise (b > c).• Figure B shows that the front wheel isstraight (b = c).5. Check:• Wheel alignmentWith the front wheel straight (b = c),check whether the distances d and e areequal.If not ≥ Adjust.3-26

FRONT FORK INSPECTION/FRONT FORK TOP END ADJUSTMENT6. Adjust:• Wheel alignmentTurn the chain puller adjuster while payingattention to the drive chain slack and makeadjustment while moving the rear wheel.NOTE:• Figure C shows that the wheel alignmenthas been correctly made (b = c and d =e).• After the adjustment, record the difference inthe graduation between the left and rightchain pullers as it will provide convenience inyour future similar adjustment.7. Install:• Lower cowlINSPADJEC36C000FRONT FORK INSPECTION1. Inspect:• Front fork smooth actionOperate the front brake and stroke the frontfork.Unsmooth action/oil leakage ≥ Repair orreplace.EC36E021FRONT FORK TOP END ADJUSTMENT1. Hold the machine on upright position byplacing the suitable stand.2. Remove:• Cowling• Induction guide (left cylinder)• Front wheel• Front fender3. Adjust:• Front fork top endAdjustment steps:• Loosen the pinch bolts (handlebar andsteering damper stay).• Loosen the pinch bolts (handle crown andunder bracket).3-27

FRONT FORK TOP END ADJUSTMENTINSPADJ• Adjust the front fork top end a.Front fork top end a:StandardExtent of adjustment≠Zero~13 mm13 mm (0.51 in)(Zero~0.51 in)CCAUTION:Never attempt to install the front forkbeyond the maximum or minimum setting.WAlways adjust each front fork to thesame setting. Uneven adjustment cancause poor handling and loss of stability.• Tighten the pinch bolts (handle crown andunder bracket).Pinch bolt (handle crown):20 Nm (2.0 m•kg, 14 ft•lb)Pinch bolt (under bracket):23 Nm (2.3 m•kg, 17 ft•lb)CCAUTION:Tighten the under bracket to specifiedtorque. If torqued too much, it maycause the front fork to malfunction.• Adjust the handlebar position bsteering damper stay position c.andHandlebar position b:9 mm (0.35 in)Steering damper stay position c:73 mm (2.87 in)§• Tighten the pinch bolts (handlebar andsteering damper stay).Pinch bolt (handlebar):7 Nm (0.7 m•kg, 5.1 ft•lb)Pinch bolt (steering damper stay):10 Nm (1.0 m•kg, 7.2 ft•lb)3-28

FRONT FORK SPRING PRELOAD ADJUSTMENTINSPADJCCAUTION:Tighten the pinch bolts to specifiedtorque. If torqued too much, it maycause the front fork to malfunction.NOTE:Adjust the installation angle of the steeringdamper stay so that the dimension d isbetween 3 mm (0.12 in) and 5 mm (0.20 in)when the handlebar is turned fully to theright.4. Check:• Steering smooth actionTurn the handlebar to make sure no partsare being contacted with others.Contact ≥ Repair.5. Install:• Front fender• Front wheel• Induction guide (left cylinder)• CowlingEC36F012FRONT FORK SPRING PRELOAD ADJUST-MENT1. Adjust:• Spring preloadBy turning the adjuster 1.Stiffer a ≥ Increase the spring preload.(Turn the adjuster 1 in.)Softer b ≥ Decrease the spring preload.(Turn the adjuster 1 out.)Extent of adjustment:MaximumMinimum]Fully turned-in Fully turned-outpositionposition3-29

FRONT FORK REBOUND DAMPING FORCEADJUSTMENT• STANDARD POSITION:This is the position which is back by the specificnumber of clicks from the fully turned-outposition.Standard position:6 clicks inaNOTE:• Fully turn out the adjuster and then turn it in.Specify the position in which the first click isheard as the zero position . If a click is heardjust when the adjuster is fully turned out, thisposition is zero.• Preload is 0.5 mm (0.02 in) changed per clickof the adjuster.CCAUTION:INSPADJDo not force the adjuster past the minimumor maximum extent of adjustment. Theadjuster may be damaged.WAlways adjust each front fork to the samesetting. Uneven adjustment can cause poorhandling and loss of stability.EC36H010FRONT FORK REBOUND DAMPING FORCEADJUSTMENT1. Adjust:• Rebound damping forceBy turning the adjuster 1.Stiffer a ≥ Increase the rebounddamping force. (Turn theadjuster 1 in.)Softer b ≥ Decrease the rebounddamping force. (Turn theadjuster 1 out.)Extent of adjustment:MaximumMinimum]Fully turned-in Fully turned-outpositionposition3-30

FRONT FORK COMPRESSION DAMPING FORCEADJUSTMENT• STANDARD POSITION:This is the position which is back by the specificnumber of clicks from the fully turned-inposition.aStandard position:12 clicks outNOTE:Fully turn in the adjuster and then turn it out.Specify the position in which the first click isheard as the zero position. If a click is heardjust when the adjuster is fully turned in, thisposition is zero.CCAUTION:INSPADJDo not force the adjuster past the minimumor maximum extent of adjustment. Theadjuster may be damaged.WAlways adjust each front fork to the samesetting. Uneven adjustment can cause poorhandling and loss of stability.EC36J030FRONT FORK COMPRESSION DAMPINGFORCE ADJUSTMENT1. Adjust:• Compression damping forceBy turning the adjuster 1.Stiffer a ≥ Increase the compressiondamping force. (Turn theadjuster 1 in.)Softer b ≥ Decrease the compressiondamping force. (Turn theadjuster 1 out.)3-31Extent of adjustment:MaximumMinimum]Fully turned-in Fully turned-outpositionposition

REAR SHOCK ABSORBER INSPECTION/SEAT HEIGHT ADJUSTMENT• STANDARD POSITION:This is the position which is back by the specificnumber of clicks from the fully turned-inposition.aStandard position:12 clicks outNOTE:Fully turn in the adjuster and then turn it out.Specify the position in which the first click isheard as the zero position. If a click is heardjust when the adjuster is fully turned in, thisposition is zero.CCAUTION:INSPADJDo not force the adjuster past the minimumor maximum extent of adjustment. Theadjuster may be damaged.WAlways adjust each front fork to the samesetting. Uneven adjustment can cause poorhandling and loss of stability.EC36K000REAR SHOCK ABSORBER INSPECTION1. Inspect:• Swingarm smooth actionAbnormal noise/Unsmooth action ≥Grease the pivoting points or repair the pivotingpoints.Damage/Oil leakage ≥ Replace.EC36L001SEAT HEIGHT ADJUSTMENT1. Remove:• Fuel tank2. Adjust:• Seat height3-32

REAR SHOCK ABSORBER SPRING PRELOADADJUSTMENTINSPADJSeat height adjustment steps:• Remove the cap 1.• Loosen the lock bolt 2 and locknut 3.• Turn the adjuster 4 in or out.Adjuster set length a:Standard length Extent of adjustment≠21~33 mm27 mm (1.06 in)(0.83~1.30 in)NOTE:If the adjuster set length a is changed, theseat height will be increased or decreasedby twice the change.CCAUTION:Never attempt to turn the adjusterbeyond the maximum or minimumlength.• Tighten the lock bolt and locknut.Lock bolt:40 Nm (4.0 m•kg, 29 ft•lb)Locknut:38 Nm (3.8 m•kg, 27 ft•lb)• Install the cap.3. Install:• Fuel tankEC36M051REAR SHOCK ABSORBER SPRING PRE-LOAD ADJUSTMENT1. Hold the machine on upright position byplacing the suitable stand.2. Loosen:• Locknut 1NOTE:When loosening the locknut, use the specialtool 2 which is included in the owner’s tool kit.3. Adjust:• Spring preloadBy turning the adjuster 3.Stiffer ≥ Increase the spring preload.(Turn the adjuster 3 in.)Softer ≥ Decrease the spring preload.(Turn the adjuster 3 out.)3-33

REAR SHOCK ABSORBER REBOUND DAMPINGFORCE ADJUSTMENTINSPADJSpring length (installed) a:Standard length Extent of adjustment]133~142 mm137 mm (5.39 in)(5.24~5.59 in)NOTE:The length of the spring (installed) changes1.5 mm (0.06 in) per turn of the adjuster.CCAUTION:Never attempt to turn the adjuster beyondthe maximum or minimum setting.4. Tighten:• LocknutT20 Nm (2.0 mdkg, 14 ftdlb)EC36N040REAR SHOCK ABSORBER REBOUNDDAMPING FORCE ADJUSTMENT1. Adjust:• Rebound damping forceBy turning the adjuster 1.Stiffer a ≥ Increase the rebound dampingforce. (Turn the adjuster1 in.)Softer b ≥ Decrease the rebounddamping force. (Turn theadjuster 1 out.)Extent of adjustment:MaximumMinimum]Fully turned-in Fully turned-outpositionposition• STANDARD POSITION:This is the position which is back by the specificnumber of clicks from the fully turned-inposition.aStandard position:20 clicks out3-34

REAR SHOCK ABSORBER COMPRESSION DAMPINGFORCE ADJUSTMENTNOTE:Fully turn in the adjuster and then turn it out.Specify the position in which the first click isheard as the zero position. If a click is heardjust when the adjuster is fully turned in, thisposition is zero.CCAUTION:INSPADJDo not force the adjuster past the minimumor maximum extent of adjustment. Theadjuster may be damaged.EC36P040REAR SHOCK ABSORBER COMPRESSIONDAMPING FORCE ADJUSTMENT1. Adjust:• Compression damping forceBy turning the adjuster 1.Stiffer a ≥ Increase the compressiondamping force. (Turn theadjuster 1 in.)Softer b ≥ Decrease the compressiondamping force. (Turn theadjuster 1 out.)Extent of adjustment:MaximumMinimum]Fully turned-in Fully turned-outpositionposition• STANDARD POSITION:This is the position which is back by the specificnumber of clicks from the fully turned-inposition.aStandard position:12 clicks outNOTE:Fully turn in the adjuster and then turn it out.Specify the position in which the first click isheard as the zero position. If a click is heardjust when the adjuster is fully turned in, thisposition is zero.CCAUTION:Do not force the adjuster past the minimumor maximum extent of adjustment. Theadjuster may be damaged.3-35

TIRE PRESSURE CHECK/TIRE INSPECTION/WHEEL INSPECTIONINSPADJEC36Q011TIRE PRESSURE CHECK1. Measure:• Tire pressureOut of specification ≥ Adjust.Standard tire pressure:FrontRear]200 kPa 200 kPa(2.0 kg/cm 2 , 29 psi) (2.0 kg/cm 2 , 29 psi)NOTE:Check the tire while it is cold.1Air gaugeEC36R000TIRE INSPECTION1. Inspect:• Tire surfacesWear/Damage ≥ Replace.aMinimum tire tread depth a:2 mm (0.08 in)EC36T000WHEEL INSPECTION1. Inspect:• Wheel runoutElevate the wheel and turn it.Abnormal runout ≥ Replace.2. Inspect:• Bearing free playExist play ≥ Replace.3-36

STEERING HEAD INSPECTION AND ADJUSTMENTINSPADJEC36U060STEERING HEAD INSPECTION ANDADJUSTMENT1. Remove the steering damper at front forkside.2. Elevate the front wheel by placing a suitablestand.3. Check:• Steering stemGrasp the bottom of the forks and gentlyrock the fork assembly back and forth.Free play ≥ Adjust steering head.4. Check:• Steering smooth actionTurn the handlebar lock to lock.Unsmooth action ≥ Adjust steering ringnut.5. Adjust:• Steering ring nutSteering ring nut adjustment steps:• Remove the cowling.• Remove the reservoir tank and handlecrown.• Loosen the ring nut 1 using ring nutwrench 2.÷Ring nut wrench:YU-33975/90890-014033-37

STEERING DAMPER ADJUSTMENTINSPADJ• Tighten the ring nut 3 using ring nutwrench 4.NOTE:Set the torque wrench to the ring nutwrench so that they form a right angle.Ring nut wrench:YU-33975/90890-01403Ring nut (initial tightening):46 Nm (4.6 m•kg, 33 ft•lb)ª• Loosen the ring nut one turn.• Retighten the ring nut using the ring nutwrench.WAvoid over-tightening.URing nut (final tightening):1 Nm (0.1 m•kg, 0.7 ft•lb)• Check the steering shaft by turning it lockto lock. If there is any binding, remove thesteering shaft assembly and inspect thesteering bearings.• Install the handle crown 5 and reservoirtank 6.Steering shaft nut 7:80 Nm (8.0 m•kg, 58 ft•lb)Pinch bolt (front fork) 8:20 Nm (2.0 m•kg, 14 ft•lb)Bolt (reservoir tank) 9:5 Nm (0.5 m•kg, 3.6 ft•lb)º• Install the cowling.6. Install:• Steering damperEC36V002STEERING DAMPER ADJUSTMENT1. Adjust:• Damping forceBy turning the adjuster 1.Stiffer a ≥Softer b ≥Increase the compressiondamping force. (Turn theadjuster 1 in.)Decrease the compressiondamping force. (Turn theadjuster 1 out.)3-38

WIRES, CABLES/COWLING INSTALLATION INSPECTIONINSPADJExtent of adjustment:MaximumMinimum]Fully turned-in Fully turned-outpositionposition• STANDARD POSITION:This is the position which is back by the specificnumber of clicks from the fully turned-outposition.Standard position:0 click inaNOTE:Fully turn out the adjuster and then turn it in.Specify the position in which the first click isheard as the zero position . If a click is heardjust when the adjuster is fully turned out, thisposition is zero.CCAUTION:Do not force the adjuster past the minimumor maximum extent of adjustment. Theadjuster may be damaged.EC36X001WIRES, CABLES1. Inspect:• Smooth movement for steering handleBy turning the handlebar lock to lock.If any caught/rubbed ≥ Repair/Replace.EC36Z001COWLING INSTALLATION INSPECTION1. Inspect:• CowlingLoose ≥ Tighten.Stroke the front fork to make sure no partsare being contacted with others.Contact ≥ Repair or replace.• ScreenScratches/fogging ≥ Clean or replace.3-39

FUEL TANK INSTALLATION INSPECTIONINSPADJEC36e000FUEL TANK INSTALLATION INSPECTION1. Inspect:• Looseness in the installed fuel tankLoose ≥ Adjust.2. Loose the nut 1 and screw in the bolt 2 ahalf turn. Then fasten the bolt with the nut.Repeat this until tight.CCAUTION:Take care so that the bolt protruding lengtha is not 29 mm (1.14 in) or over.3-40

LUBRICATIONINSPADJEC36a023LUBRICATIONTo ensure smooth operation of all componentslubricate your machine during setup, afterbreak-in, and after every race.1 All control cable2 Brake and clutch lever pivots3 Throttle-to-handlebar contact4 Drive chain5 Throttle cable end6 Clutch cable endA Use Yamaha cable lube or equivalent onthese areas.B Use SAE 10W30 motor oil or suitable chainlubricants.C Lubricate the following areas with highquality, lightweight lithium-soap basegrease.CCAUTION:Wipe off any excess grease, and avoid gettinggrease on the brake discs.A A AB C C3-41

ELECTRICAL/SPARK PLUG INSPECTIONINSPADJEC370000ELECTRICALEC371001SPARK PLUG INSPECTION1. Remove:• Spark plug2. Inspect:• Electrode 1Wear/Damage ≥ Replace.• Insulator color 2Normal condition is a medium to light tancolor.Distinctly different color ≥ Check theengine condition.NOTE:When the engine runs for many hours at lowspeeds, the spark plug insulator will becomesooty, even if the engine and carburetor are ingood operating condition.3. Measure:• Plug gap aUse a wire gauge or thickness gauge.Out of specification ≥ Regap.aSpark plug gap:0.5~0.6 mm (0.020~0.024 in)%Standard spark plug:R6179A-105P4. Clean the plug with a spark plug cleaner ifnecessary.5. Tighten:• Spark plug T19 Nm (1.9 mdkg, 13 ftdlb)NOTE:• Before installing a spark plug, clean the gasketsurface and plug surface.• Finger-tighten a the spark plug beforetorquing to specification b.3-42

IGNITION TIMING CHECKINSPADJEC372071IGNITION TIMING CHECKNOTE:• The right pick-up coil 1 is provided so thatignition timing can be set for both cylindersby adjusting for the left cylinder only.Therefore, do not loosen the screws (rightpick-up coil) 2.• When the portion a of the right pick-up coilaligns with the punch mark b on the stator,the right pick-up coil forms an angle of 90˚with the left pick-up coil, indicating that theignition timing is the same for both cylinders.1. Remove:• Cowling• Fuel tank• Spark plugs (left and right cylinder)2. Attach:• Dial gauge 1• Dial gauge stand 2To left cylinder head.Dial gauge:YU-3097/90890-01252Stand:YU-1256C3. Rotate the magneto rotor 1 until the pistonreaches top dead center (TDC). When thishappens, the needle on the dial gauge willstop and reverse directions even thoughthe rotor is being turned in the same direction.4. Set the dial gauge to zero at TDC.5. From TDC, rotate the rotor clockwise untilthe dial gauge indicates that the piston is ata specified distance from TDC.aIgnition timing:2.4 mm (0.094 in)3-43

BATTERY INSPECTIONINSPADJ6. Check:• Ignition timingPunch mark a on rotor should be alignedwith punch mark b on stator.Not aligned ≥ Adjust.NOTE:Be sure to use the punch mark “F1”.7. Adjust:• Ignition timingAdjustment steps:• Loosen the screws (stator) 1.• Align the punch marks by turning the stator2.• Tighten the screws (stator).TScrew (stator):7 Nm (0.7 m•kg, 5.8 ft•lb)3-44EC375000BATTERY INSPECTIONWTo prevent danger, read the battery labelcarefully before handling the battery.1. Connect the checking lead (supplyingparts) 2 to the power supply coupler 1.2. Check:• Battery voltageOut of specification ≥ Replace.%Tester (+) lead ≥ Red lead 3Tester (-) lead ≥ Black lead 4Tester selectorBattery voltageposition?12.5V or more DCV-20

RECHARGING BATTERYINSPADJEC376000RECHARGING BATTERYW• Keep the battery away from fire.• When charging the battery, be sure toremove it from the chassis and use thechecking lead (supplying parts).• Be sure to use the specific charging currentand voltage when charging the battery.• Do not quick charge the battery.• For battery replacement, be sure to use asealed type specified for the TZ250.NOTE:Battery can be recharged using either an MFbattery devoted charger or automobile battery.[Using the MF battery devoted charger]1. Remove:• Seat• Battery2. Connect the battery charger 1 for MF batteriesto the battery 2 using the checkinglead (supplying parts) 3, and recharge thebattery.%Battery charger (+) lead ≥ Red lead 4Battery charger (-) lead ≥ Black lead 5Battery charger for MF batteries:GS TYPE BC-601-12VCharging time:5 hourspVoltage when charged:12.8V or moreCCAUTION:Make sure that the red and black leads donot contact each other during recharge.3-45

RECHARGING BATTERY[Using the automobile battery]1. Remove:• Seat• Battery2. Connect an automobile battery 1 to thebattery 2 using the checking lead (supplyingparts) 3, and recharge the battery.Automobile battery (+) lead ≥Red lead 4&Automobile battery (-) lead ≥Black lead 5Charge time:3 hoursVoltage when charged:12.8V or more(or 12.5V or more)Voltage of the automobile batteryfor power supply:12.8~13.8V (maximum 14.9V)oNOTE:If the battery is recharging using an automobilebattery, the charge may not exceed 12.8V.Then, 12.5V or more will be OK.CCAUTION:INSPADJ• For an automobile battery for supply, usea battery with a capacity of 12V20Ah ormore with a voltage 12.8 to 13.2.• During the battery recharge, do notrecharge the power supply battery bystarting or running the engine.• Connect only one battery for recharge.3-46

COWLING, INDUCTION GUIDE, SEAT AND FUEL TANKENGEC400000ENGINEEC4V0000COWLING, INDUCTION GUIDE, SEAT AND FUEL TANKT 4 Nm (0.4 mdkg, 2.9 ftdlb)T 8 Nm (0.8 mdkg, 5.8 ftdlb)4Extend of removal: 1 Cowling removal 2 Induction guide removal3 Seat removal 4 Fuel tank removalExtend of removal Order Part name Q’ty RemarksCOWLING, INDUCTION GUIDE,SEAT AND FUEL TANKREMOVALPreparation forTurn the fuel cock to “OFF”.removalDisconnect the fuel hose.1 Clip (lower cowl) 12 Quick fastener 513 Lower cowl 124 Clip (upper cowl) 35 Upper cowl 16 Induction guide (left cylinder) 17 Induction guide (right cylinder) 138 Screw (seat) 49 Seat 110 Fuel tank breather hose 1 Refer to “REMOVAL POINTS”.4 11 Clip (fuel tank) 112 Fuel tank 14-1

COWLING, INDUCTION GUIDE, SEAT AND FUEL TANKENGEC4V3000REMOVAL POINTSEC4U3100Fuel tank breather hose1. Disconnect:• Fuel tank breather hose 1NOTE:Disconnect the fuel tank breather hose withthe valve joint 2 remaining on the fuel tankside so as to prevent fuel from spurting out bythe tank inner pressure.44-2

EXHAUST PIPE AND SILENCERENGEC4S0000EXHAUST PIPE AND SILENCERT 11 Nm (1.1 mdkg, 8.0 ftdlb)T 21 Nm (2.1 mdkg, 15 ftdlb)T 11 Nm (1.1 mdkg, 8.0 ftdlb)T 21 Nm (2.1 mdkg, 15 ftdlb)Extend of removal: 1 Exhaust pipe removal 2 Silencer removalExtend of removal Order Part name Q’ty RemarksEXHAUST PIPE ANDSILENCER REMOVALPreparation for Lower cowl Refer to “COWLING, INDUCTIONremovalGUIDE, SEAT AND FUEL TANK”section.1 Tension spring 2ea.12 Bolt (exhaust pipe) 1ea.3 Exhaust pipe 1ea.24 Bolt (silencer) 2ea.5 Silencer 1ea.4-3

RADIATORENGEC450001RADIATORT 2 Nm (0.2 mdkg, 1.4 ftdlb)T 11 Nm (1.1 mdkg, 8.0 ftdlb)T 2 Nm (0.2 mdkg, 1.4 ftdlb)T 7 Nm (0.7 mdkg, 5.1 ftdlb)T 7 Nm (0.7 mdkg, 5.1 ftdlb)T 2 Nm (0.2 mdkg, 1.4 ftdlb)Extend of removal:1 Radiator removalExtend of removal Order Part name Q’ty RemarksRADIATOR REMOVALPreparation for Cowling, induction guide Refer to “COWLING, INDUCTIONremoval and fuel tank GUIDE, SEAT AND FUEL TANK”section.Drain the cooling water.Refer to “COOLANT REPLACEMENT”section in the CHAPTER 3.1 Water temperature gauge lead 12 Thermo unit 13 Radiator hose 2 114 Radiator hose 4 15 Radiator hose 3 16 Radiator breather hose 17 Radiator 14-4

RADIATORENGEC456000HANDLING NOTEWDo not remove the radiator cap when theengine and radiator are hot. Scalding hotfluid and steam may be blown out underpressure, which could cause seriousinjury.When the engine has cooled, open theradiator cap by the following procedure:Place a thick rag, like a towel, over the radiatorcap, slowly rotate the cap counterclockwiseto the detent. This procedureallows any residual pressure to escape.When the hissing sound has stopped,press down on the cap while turning counterclockwiseand remove it.EC454000INSPECTIONEC444100Radiator1. Inspect:• Radiator core 1Obstruction ≥ Blow out with compressedair through rear of the radiator.Bent fin ≥Repair/replace.EC455000ASSEMBLY AND INSTALLATIONEC455141Radiator1. Install:• Radiator 1• Bolt (radiator) 2T7 Nm (0.7 mdkg, 5.1 ftdlb)• Nut (radiator) 3T7 Nm (0.7 mdkg, 5.1 ftdlb)4-5

RADIATORENG2. Install:• Radiator breather hose 1• Radiator hose 3 2T2 Nm (0.2 mdkg, 1.4 ftdlb)• Radiator hose 4 3T2 Nm (0.2 mdkg, 1.4 ftdlb)• Radiator hose 2 4T2 Nm (0.2 mdkg, 1.4 ftdlb)• Gasket 5N• Thermo unit 6T11 Nm (1.1 mdkg, 8.0 ftdlb)• Water temperature gauge lead 7NOTE:Insert the end of the radiator breather hoseinto the frame. Refer to “CONTROL FUNC-TION” section in the CHAPTER 1.4-6

CARBURETOR AND REED VALVEENGEC460000CARBURETOR AND REED VALVET 2 Nm (0.2 mdkg, 1.4 ftdlb)T 2 Nm (0.2 mdkg, 1.4 ftdlb)T 11 Nm (1.1 mdkg, 8.0 ftdlb)T 1 Nm (0.1 mdkg, 0.7 ftdlb)T 11 Nm (1.1 mdkg, 8.0 ftdlb)T 1 Nm (0.1 mdkg, 0.7 ftdlb)Extend of removal Order Part name Q’ty RemarksCARBURETOR ANDREED VALVE REMOVALPreparation for Cowling, induction guide Refer to “COWLING, INDUCTIONremoval and fuel tank GUIDE, SEAT AND FUEL TANK”section.Spark plug cap (left cylinder)Radiator hose 3Refer to “RADIATOR”section.Bolt (radiator stay) Shift the radiator Servicing theTension spring [exhaust pipe(left cylinder)]forward.right cylinder4-7

CARBURETOR AND REED VALVEENGT 2 Nm (0.2 mdkg, 1.4 ftdlb)T 2 Nm (0.2 mdkg, 1.4 ftdlb)T 11 Nm (1.1 mdkg, 8.0 ftdlb)T 1 Nm (0.1 mdkg, 0.7 ftdlb)T 11 Nm (1.1 mdkg, 8.0 ftdlb)T 1 Nm (0.1 mdkg, 0.7 ftdlb)Extend of removal: 1 Carburetor removal 2 Reed valve removalExtend of removal Order Part name Q’ty Remarks1 Induction cap (left cylinder) 1 Servicing the left cylinder122 Solenoid valve lead 1ea. Disconnect the solenoid valve lead.3 Clamp (carburetor joint) 1ea. Loosen the screw (carburetor joint).4 Carburetor 1ea.5 Fuel hose 1ea.6 Grommet 2 Pull up by slit end. Servicing the7 Induction cap (right cylinder) 1 right cylinder8 Induction box 1ea.29 Carburetor joint 1ea.10 Reed valve assembly 1ea.11 Stopper (reed valve) 2ea.12 Reed valve 2 2ea.13 Reed valve 1 2ea.4-8

CARBURETOR AND REED VALVEENGEC468000CARBURETOR DISASSEMBLYT2 Nm (0.2 mdkg, 1.4 ftdlb)Extend of removal:1 Carburetor disassemblyExtend of removal Order Part name Q’ty Remarks1CARBURETOR DISASSEMBLY1 Mixing chamber top 12 Throttle valve 1 Refer to “REMOVAL POINTS”.3 Needle holder 14 Jet needle 15 Starter plunger 16 Float chamber 17 Power jet 18 Float pin 19 Float 10 Valve seat 1¡ Main jet 1 Main nozzle 1£ Pilot jet 1¢ Pilot air screw 1∞ Solenoid valve 14-9

CARBURETOR AND REED VALVEENGEC466010HANDLING NOTECCAUTION:Do not disassemble the venturi block 1because it will cause a drop in carburetorperformance.EC463000REMOVAL POINTSEC463110Throttle valve1. Remove:• Throttle valve 1• Ring 2• Spring (throttle valve) 3• Mixing chamber top 4• Throttle cable 5NOTE:While compressing the spring (throttle valve),disconnect the throttle cable.EC464000INSPECTIONEC464120Carburetor1. Inspect:• Carburetor bodyContamination ≥ Clean.NOTE:• Use a petroleum based solvent for cleaning.Blow out all passages and jets with compressedair.• Never use a wire.2. Inspect:• Main jet 1• Main nozzle 2• Pilot jet 3• Power jet 4Contamination ≥ Clean.NOTE:• Use a petroleum based solvent for cleaning.Blow out all passages and jets with compressedair.• Never use a wire.4-10

CARBURETOR AND REED VALVEENGEC464200Needle valve1. Inspect:• Needle valve 1• Valve seat 2Grooved wear a ≥ Replace.Dust b ≥ Clean.NOTE:Always replace the needle valve and valveseat as a set.EC464301Throttle valve1. Check:• Free movementStick ≥ Repair or replace.NOTE:Insert the throttle valve 1 into the carburetorbody, and check for free movement.EC464420Jet needle1. Inspect:• Jet needle 1Bends/Wear ≥ Replace.• Clip grooveFree play exists/Wear ≥ Replace.EC464802FUEL LEVEL1. Measure:• Fuel level aOut of specification ≥ Adjust.Fuel level:6.0~7.0 mm (0.24~0.28 in)Above the float chamber matingsurfacecMeasurement and adjustment steps:• Remove the drain plug.• Connect the fuel level gauge adapter 2and fuel level gauge 1 to the float chamber.Fuel level gauge adapter:YM-1470/90890-01470Fuel level gauge:YM-1312-A/90890-01312≤4-11

CARBURETOR AND REED VALVEENG• Hold the fuel level gauge vertically next tothe float chamber mating surface.• Measure the fuel level with the fuel levelgauge.NOTE:Keep the carburetor and fuel level gaugevertically when measuring the fuel level.• If the fuel level is not within specification,inspect the valve seat and needle valve.• If either is worn, replace them both.• If both are fine, adjust the fuel level bybending the float tab b on the float.• Recheck the fuel level.EC464600Float1. Inspect:• Float 1Damage ≥ Replace.EC464701Reed valve1. Measure:• Reed valve bending aOut of specification ≥ Replace.aReed valve bending limit:0.2 mm (0.008 in)• Valve stopper height bOut of specification ≥ Adjust stopper/Replacevalve stopper.aValve stopper height:6.5~6.9 mm (0.256~0.272 in)4-12

CARBURETOR AND REED VALVEENGEC464900Induction box1. Inspect:• Seal 1Peeled ≥ Stick using the instantaneousadhesiveCrack/Wear/Damage ≥ Replace.EC465000ASSEMBLY AND INSTALLATIONEC465180Reed valve1. Install:• Reed valve 1 1• Reed valve 2 2• Stopper (reed valve) 3• Screw (reed valve) 4GT1 Nm (0.1 mdkg, 0.7 ftdlb)NOTE:• Install the reed valve with the reed valvebending as shown.• Note the cut a in the lower corner of thereed and stopper plate.CCAUTION:Tighten each screw gradually to avoidwarping.2. Install:• Gasket (reed valve assembly) 1N• Reed valve assembly 2NOTE:Install the gasket (left cylinder) with its projectiona facing upward and the seal print sidetoward the crankcase.4-13

CARBURETOR AND REED VALVEENG3. Install:• Carburetor joint 1• Induction box 2• Bolt {carburetor joint [L=25 mm (0.98 in)]} 3T11 Nm (1.1 mdkg, 8.0 ftdlb)• Bolt {carburetor joint [L=20 mm (0.79 in)]} 4T11 Nm (1.1 mdkg, 8.0 ftdlb)EC4652E0Carburetor1. Install:• Solenoid valve 1To carburetor 2.2. Install:• Pilot air screw 1Note the following installation points:• Screw in the pilot air screw until it is lightlyseated.• Back out it by the specified number ofturns.ΩPilot air screw:1-1/2 of turns out3. Install:• Main nozzle 1• Main jet 2• Pilot jet 3• Valve seat 4• Screw (valve seat) 54-14

CARBURETOR AND REED VALVEENG4. Install:• Needle valve 1• Float 2• Float pin 3• Screw (float pin) 4NOTE:• After installing the needle valve to the float,install them to the carburetor.• Check the float for smooth movement.5. Install:• Power jet 1To float chamber 2.CCAUTION:Do not tighten the power jet too hard, oryou may not remove it when checking andreplacing it.6. Install:• Float chamber 1• Screw (float chamber) 2CCAUTION:Do not confuse the left and right floatchambers in installation because they aredifferent from each other. The overflow holea is in the bottom of the float chamber forthe left cylinder and for the right one in theside.7. Install:• Air vent hose 1• Joint 28. Install:• Induction cap 1 (right cylinder only)• Starter plunger 2To carburetor 3.NOTE:Install the stater plunger (right cylinder) afterpassing it through the hole a of the inductioncap. Refer to “CABLE ROUTING DIAGRAM”section in the CHAPTER 2.4-15

CARBURETOR AND REED VALVEENG9. Install:• Collar 1• Jet needle 2• Spring guide 3• Spring 4• Needle holder 5To throttle valve 6.10.Install:• Throttle cable 1• Mixing chamber top 2• Spring (throttle valve) 3• Ring 4• Throttle valve 5NOTE:• Install the throttle cable (right cylinder) afterpassing it through the hole a of the inductioncap. Refer to “CABLE ROUTING DIAGRAM”section in the CHAPTER 2.• While compressing the spring, connect thethrottle cable.• Align the projection b on the ring with thegroove c in the needle holder 6.11.Install:• Mixing chamber top 1• Screw (mixing chamber top) 2T2 Nm (0.2 mdkg, 1.4 ftdlb)• Fuel hose 3To carburetor 4.NOTE:• Install the fuel hose (right cylinder) afterpassing it through the hole a of the inductioncap. Refer to “CABLE ROUTING DIAGRAM”section in the CHAPTER 2.• After installing, check the throttle grip forsmooth movement.4-16

CARBURETOR AND REED VALVEENGEC465370Carburetor installation1. Install:• Carburetor 1NOTE:Install the projection between the carburetorjoint slots.2. Tighten:• Clamp (carburetor joint) 1T2 Nm (0.2 mdkg, 1.4 ftdlb)3. Connect:• Solenoid valve lead 1NOTE:Install the solenoid valve lead (right cylinder)after passing it through the hole a of theinduction cap. Refer to “CABLE ROUTINGDIAGRAM” section in the CHAPTER 2.4. Install:• Induction cap 1 (left cylinder only)5. Install:• Grommet 1 (right cylinder only)• Band 2 (right cylinder only)4-17

CYLINDER HEAD, CYLINDER AND PISTONENGEC470000CYLINDER HEAD, CYLINDER AND PISTONEC478000CYLINDER HEAD AND CYLINDERT 11 Nm (1.1 mdkg, 8.0 ftdlb)T 19 Nm (1.9 mdkg, 13 ftdlb)T 20 Nm (2.0 mdkg, 14 ftdlb)T 7 Nm (0.7 mdkg, 5.1 ftdlb)T 15 Nm (1.5 mdkg, 11 ftdlb)Extend of removal: 1 Cylinder head removal 2 Cylinder removalExtend of removal Order Part name Q’ty RemarksCYLINDER HEAD ANDCYLINDER REMOVALPreparation for Cowling and fuel tank Refer to “COWLING, INDUCTIONremovalGUIDE, SEAT AND FUEL TANK”section.Exhaust pipeRefer to “EXHAUST PIPE ANDSILENCER” section.Radiator hose 3, 4Disconnect at cylinder head side.Carburetor (left cylinder)Induction guide (left cylinder)Servicing the left cylinder1 Spark plug 1ea.2 Cable stay 1ea.3 YPVS cable 2ea.Refer to “REMOVAL POINTS”.14 Bolt (cylinder head) 6ea. Loosen each bolt 1/4 turn, and2remove them after all bolts areloosened.5 Cylinder head 1ea.6 Nut (cylinder) 4ea.7 Cylinder 1ea.4-18

CYLINDER HEAD, CYLINDER AND PISTONENGEC478100PISTON AND POWER VALVET 12 Nm (1.2 mdkg, 8.7 ftdlb)T 9 Nm (0.9 mdkg, 6.5 ftdlb)T 4 Nm (0.4 mdkg, 2.9 ftdlb)T 4 Nm (0.4 mdkg, 2.9 ftdlb)Extend of removal: 1 Piston and piston ring removal 2 Power valve removalExtend of removal Order Part name Q’ty RemarksPISTON REMOVAL1 Piston pin clip 2ea.2 Piston pin 1ea.13 Piston 1ea. Refer to “REMOVAL POINTS”.4 Small end bearing 1ea.5 Piston ring 1ea.6 Valve cover 1ea.7 Valve shaft 1ea.8 Power valve 1ea.29 Valve pulley 1ea.10 Circlip 2ea.11 Plain washer 2ea.12 Oil seal 2ea.13 Solid bush 2ea.4-19

CYLINDER HEAD, CYLINDER AND PISTONENGEC473000REMOVAL POINTSEC473310YPVS cable1. Remove:• Bolt (cable stay) 12. Remove:• YPVS cable 1From the valve pulley 2.NOTE:Remove the YPVS cable together with thecable stay 3.EC473402Piston and piston ring1. Remove:• Piston pin clip 1NOTE:Before removing the piston pin clip, cover thecrankcase with a clean rag to prevent the pistonpin clip from falling into the crankcase cavity.2. Remove:• Piston pin 1• Piston 2• Small end bearing 3NOTE:Before removing the piston pin, deburr the clipgroove and pin hole area. If the piston pingroove is deburred and piston pin is still difficultto remove, use the piston pin puller 4.APiston pin puller:YU-1304/90890-01304CCAUTION:Do not use a hammer to drive the pistonpin out.4-20

CYLINDER HEAD, CYLINDER AND PISTONENG3. Remove:• Piston ring 1NOTE:Take care not to scratch the piston or damagethe piston ring by expanding it more than necessary.EC474000INSPECTIONEC474110Cylinder head1. Remove:• Carbon depositsUse #400~600 grit wet sandpaper.2. Inspect:• Cylinder head water jacketCrust of minerals/Rust ≥ Remove.• Cylinder head contact surfaceWear/Damage ≥ Replace.• Recess of insert portion aThe contact surface b of the insert portionis recessed below the aluminum portion c≥ Replace.EC474211Cylinder1. Remove:• Carbon depositsUse a rounded scraper 1.NOTE:Do not use a sharp instrument. Avoid scratchingthe aluminum.2. Inspect:• Cylinder inner surfaceScore marks ≥ Repair or replace.Using wet sandpaper (#240), repair in thesame crisscross patterns as the honedones.CCAUTION:• Do not rebore the cylinder.• Minimize modification by wet sandpaper.Do not rub too much.4-21

CYLINDER HEAD, CYLINDER AND PISTONENG3. Inspect:• Travel distance for cylinder3,000 km (1,800 miles) or more ≥ Replace.EC474B00Piston1. Inspect:• Piston crownDamage and crack due to detonation≥Replace.• Piston pin holeCrack≥ Replace.• Contact with cylinderExcessive scuffing, score a ≥ Use#240~320 grit wet sandpaper in a crisscrossmanner b.• Heat discoloration≥ Replace.2. Inspect:• Travel distance for piston500 km (300 miles) or more≥ Replace.4-22EC474A00Contact surface roughening for pistonreplacementNOTE:• Roughening the cylinder wall for a replacedpiston helps toward smoother contact surfacesand prevents trouble that would otherwiseoccur.• If a new piston is installed to a cylinder withouthoned patterns, the contact surfaces willnot fit properly because of eccentric wearcaused by sliding motion.1. Inspect:• Honed patterns on the cylinder wallUsing wet sandpaper (#240), rub the areawithout honed patterns in the same crisscrosspatterns as the honed ones (especially,along the periphery of the exhaustport).CCAUTION:Minimize modification by wet sandpaper.Do not rub too much.

CYLINDER HEAD, CYLINDER AND PISTONENGEC474402Piston pin and small end bearing1. Inspect:• Piston pin• Small end bearingSigns of heat discoloration ≥ Replace.2. Measure:• Piston pin outside diameterUse micrometer 1.Out of limit ≥ Replace.Piston pin outside diameter:Standard]14.995~15.000 mm 14.975 mm(0.5904~0.5906 in) (0.5896 in)3. Check:• Free play (when the piston pin 1 is inplace in the piston 2)There should be no noticeable for the play.Free play exists ≥ Replace piston pinand/or piston.4. Install:• Small end bearing• Piston pinInto the small end of connecting rod.5. Check:• Free playThere should be no noticeable free play.Free play exists ≥ Inspect the connectingrod for wear/Replace the pin and/or connectingrod as required.4-23

CYLINDER HEAD, CYLINDER AND PISTONENGEC474530Piston ring1. Install:• Piston ringInto the cylinder.Push the ring with the piston crown.2. Measure:• End gapUse a thickness gauge 1.Out of limit ≥ Replace.Ring end gap (installed):Standard]0.22~0.37 mm 0.59 mm(0.009~0.015 in) (0.023 in)3. Measure:• Side clearanceUse a thickness gauge 1.Out of specification ≥ Replace pistonand/or ring.Side clearance:StandardZero~0.06 mm–(Zero~0.0024 in)]NOTE:• Insert the thickness gauge deep in the pistonring groove. Then measure the clearancewith both sliding surfaces being flush witheach other.• Check at several points.EC474720Combination of piston and cylinder1. Check:• Cylinder mark aCylinder mark aABC*4-24

CYLINDER HEAD, CYLINDER AND PISTONENG2. Check:• Piston mark aPiston mark a (color)A (red)*B (orange)C (green)3. Combination:Combine the piston and cylinder by the followingchart.Cylinder mark Piston mark (color)AA(red)(BB(orange)CC (green)NOTE:When you purchase a cylinder, you cannotdesignate a specific one. Choose the pistonthat matches the above chart.EC474821Power valve1. Inspect:• Power valve 1Wear/Damage ≥ Replace.Carbon deposits ≥ Remove.• Valve shaft 2• Solid bush 3• Oil seal 4Wear/Damage ≥ Replace.EC474901Power valve hole on cylinder1. Remove:• Carbon depositsFrom power valve hole surface a.NOTE:Do not use a sharp instrument. Avoid scratchingthe aluminum.4-25EC475000ASSEMBLY AND INSTALLATIONEC475181Power valve1. Install:• Power valve 1• Bolt (power valve) 2GT9 Nm (0.9 mdkg, 6.5 ftdlb)NOTE:Install the power valve at cut-away faced a fordown side.

CYLINDER HEAD, CYLINDER AND PISTONENG2. Install:• Solid bush1• Oil seal 2• Plain washer 3• Circlip 4N• Valve pulley 5• Screw (valve pulley) 6T4 Nm (0.4 mdkg, 2.9 ftdlb)To valve shaft 7.NOTE:Apply the lithium soap base grease on thevalve shaft and oil seal lip.3. Lock the pulley holding screw using anappropriate wire around the groove on thevalve pulley.4. Install:• Valve shaft 1• Valve cover 2• Screw (valve cover) 3T4 Nm (0.4 mdkg, 2.9 ftdlb)NOTE:• Install the valve shaft so that its pulley facesleft of the chassis for the left cylinder andright of the chassis for the right cylinder.• When installing the valve shaft into the cylinder,lightly touch the solid bush 4 with the oilseal 5 and provide an equal gap a for thepower valve 6 and valve shaft.• Clean the contacting surface of the valvecover and cylinder before applying thesealant.Quick gasket®ACC-YAMAB-ON-D4YAMAHA Bond No.490890-05143C4-26

CYLINDER HEAD, CYLINDER AND PISTONENG5. Check:• Power valve smooth movementUnsmooth movement ≥ Repair or replace.EC475271Piston ring and piston1. Install:• Piston ring 1NOTE:• Take care not to scratch the piston or damagethe piston ring by expanding it more thannecessary.• Install the piston ring with its mark “N”upward.• Align the piston ring gap with the pin 2.• After installing the piston ring, check thesmooth movement of it.2. Install:• Gasket (cylinder) 1N• Small end bearing 2• Dowel pin 3NOTE:Apply the engine oil on the bearing (crankshaftand connecting rod) and connecting rodbig end washers.CCAUTION:Install the gasket with the letter “CASE” aon it toward the crankcase.4-27

CYLINDER HEAD, CYLINDER AND PISTONENG3. Install:• Piston 1• Piston pin 2• Piston pin clip 3NNOTE:• The arrow a on the piston dome must pointto exhaust side.• Before installing the piston pin clip, cover thecrankcase with a clean rag to prevent the pistonpin clip from falling into the crankcasecavity.CCAUTION:• When installing the piston pin clip, usethe hand so that it may not be distorted.• Do not allow the clip open ends to meetthe piston pin slot b.EC475351Cylinder head and cylinder1. Apply:• Engine oilTo piston 1, piston ring 2 and cylinderinner surface.2. Install:• Cylinder 1CCAUTION:Make sure the piston ring is properly positioned.Install the cylinder with one handwhile compressing the piston ring with theother hand.NOTE:After installing, check the smooth movementof the piston.3. Install:• Nut (cylinder) 1T20 Nm (2.0 mdkg, 14 ftdlb)NOTE:Tighten the nuts in stages, using a crisscrosspattern.4-28

CYLINDER HEAD, CYLINDER AND PISTONENG4. Install:• O-ring 1N• Dowel pin 2NOTE:Apply the lithium soap base grease on the O-rings.5. Install:• Cylinder head 1• Copper washer 2• Bolt (cylinder head) 3T11 Nm (1.1 mdkg, 8.0 ftdlb)NOTE:• Apply the lithium soap base grease on thethread and contact surface of the bolt (cylinderhead).• Tighten the bolts (cylinder head) in stage,using a crisscross pattern.6. Install:• YPVS cable 2, 4 (open side) 1• YPVS cable 1, 3 (close side) 2To cable stay 3.NOTE:Install the open side cables (sleeve a cables)to the “0” marked b side of the cable stay.7. Connect:• YPVS cable 2, 4 (open side) 1• YPVS cable 1, 3 (close side) 2To valve pulley 3.NOTE:Connect thhe silver cables to the left sidecylinder and the black cables to the right cylinder.Refer to “CABLE ROUTING DIAGRAM”section in the CHAPTER 2.4-29

CYLINDER HEAD, CYLINDER AND PISTONENG8. Install:• Cable stay 1• Bolt (cable stay) 2T7 Nm (0.7 mdkg, 5.1 ftdlb)9. Adjust:• YPVS cableRefer to “YPVS OPEN SIDE CABLEADJUSTMENT” and “YPVS CLOSE SIDECABLE ADJUSTMENT” section in theCHAPTER 3.10.Install:• Spark plug 1 T19 Nm (1.9 mdkg, 13 ftdlb)• Spark plug cap 2• Radiator hose 3 3T2 Nm (0.2 mdkg, 1.4 ftdlb)• Radiator hose 4 4T2 Nm (0.2 mdkg, 1.4 ftdlb)4-30

CLUTCHENGEC4A0000CLUTCHEC4A8000CLUTCH PLATE AND FRICTION PLATET 6 Nm (0.6 mdkg, 4.3 ftdlb)T 9 Nm (0.9 mdkg, 6.5 ftdlb)Extend of removal: 1 Clutch plate and friction plate removalExtend of removal Order Part name Q’ty RemarksCLUTCH PLATE ANDFRICTION PLATE REMOVALPreparation for Lower cowl Refer to “COWLING, SEAT ANDremovalFUEL TANK” section.1 Screw (clutch spring) 62 Clutch spring 613 Pressure plate 14 Friction plate 65 Clutch plate 54-31

CLUTCHENGEC4A8200CLUTCH HOUSING AND PUSH RODT 75 Nm (7.5 mdkg, 54 ftdlb)Extend of removal: 1 Clutch housing removal 2 Push rod removalExtend of removal Order Part name Q’ty RemarksCLUTCH HOUSING ANDPUSH ROD REMOVAL1 Nut (clutch boss) 1Use special tool.2 Lock washer 1Refer to “REMOVAL POINTS”.3 Clutch boss 114 Plain washer 15 Clutch housing 16 O-ring 17 Bearing 18 Spacer 1 129 Ball 110 Push rod 14-32

CLUTCHENGEC4A3000REMOVAL POINTSEC483211Clutch boss1. Remove:• Nut 1• Lock washer 2• Clutch boss 3NOTE:Straighten the lock washer tab and use theclutch holding tool 4, 5 to hold the clutchboss.Clutch holding tool:YM-91042 . . . . . . . . . . . . . . . .490890-04086 . . . . . . . . . . . . . .5BA For USA and CDNB Except for USA and CDNEC4A4000INSPECTIONEC484100Clutch housing and boss1. Inspect:• Clutch housing 1Cracks/Wear/Damage ≥ Replace.• Clutch boss 2Scoring/Wear/Damage ≥ Replace.EC4A4100Clutch housing1. Check:• Circumferential playFree play exists ≥ Replace.• Gear teeth aWear/Damage ≥ Replace.• O-ring 1Damage ≥ Replace.EC484400Clutch spring1. Measure:• Clutch spring free length aOut of specification ≥ Replace springs asa set.Clutch spring free length:{Standard30.6 mm (1.205 in) 29.6 mm (1.165 in)4-33

CLUTCHENGEC484500Friction plate1. Measure:• Friction plate thicknessOut of specification ≥ Replace frictionplate as a set.Measure at all four points.Friction plate thickness:Standard]2.9~3.1 mm 2.7 mm(0.114~0.122 in) (0.106 in)EC484600Clutch plate1. Measure:• Clutch plate warpageOut of specification ≥ Replace clutchplate as a set.Use a surface plate 1 and thicknessgauge 2.aWarp limit:0.1 mm (0.004 in)EC4A4301Push rod1. Inspect:• Push rod 1• Ball 2Wear/Damage/Bend ≥ Replace.aBending limit:0.2 mm (0.008 in)NOTE:The bending value is shown by one half of thedial gauge reading.4-34

CLUTCHENGEC4A5000ASSEMBLY AND INSTALLATIONEC4A5213Clutch1. Install:• Spacer 1 1• Bearing 2NOTE:Apply the transmission oil on the spacer 1 andbearing.2. Install:• O-ring 1NNOTE:Apply the lithium soap base grease on the O-ring.3. Install:• O-ring 1NTo clutch housing 2.NOTE:Apply the lithium soap base grease on the O-ring.4. Install:• Clutch housing 15. Install:• Plain washer 1• Clutch boss 24-35

CLUTCHENG6. Install:• Lock washer 1N• Nut (clutch boss) 2T75 Nm (7.5 mdkg, 54 ftdlb)NOTE:Use the clutch holding tool 3, 4 to hold theclutch boss.CCAUTION:Align the projections on the lock washerwith the holes a in the clutch boss.Clutch holding tool:YM-91042 . . . . . . . . . . . . . . . .390890-04086 . . . . . . . . . . . . . .4BA For USA and CDNB Except for USA and CDN7. Bend the lock washer 1 tab.8. Install:• Friction plate (yellow) 1• Clutch plate 2• Friction plate (brown) 3NOTE:• Install the clutch plates and friction platesalternately on the clutch boss, starting with afriction plate and ending with a friction plate.• Yellow colored friction plates are used for thefirst and final.• This machine is equipped with a dry typeclutch. Be sure to clean with solvent orreplace if grease or oil contacts either clutchor friction plates.4-36

CLUTCHENG9. Install:• Push rod 1• Ball 2NOTE:Apply the lithium soap base grease on thepush rod and ball.10.Install:• Pressure plate 1NOTE:Align the arrow marks a on the pressure platethe arrow marks b on the clutch boss.11.Install:• Clutch spring 1• Screw (clutch spring) 2T9 Nm (0.9 mdkg, 6.5 ftdlb)NOTE:Tighten the screws in stages, using a crisscrosspattern.12.Check:• Push lever positionPush the push lever 1 upward until itstops. With the push lever in this position,the rear edge a of the push lever shouldbe aligned with the center of the push leverinstallation bolt 2.Not aligned ≥ Adjust.13.Adjust:• Push lever positionPush lever position adjustment steps:• Loosen the locknut 1.• Turn the adjuster 2 to align the rear edgeof the push lever with the center of thepush lever installation bolt.• Tighten the locknutṪLocknut:6 Nm (0.6 m•kg, 4.3 ft•lb)4-37

PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEARAND BALANCER SHAFTENGEC4D0002PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEARAND BALANCER SHAFTEC4D8000PRIMARY DRIVEN GEART 11 Nm (1.1 mdkg, 8.0 ftdlb)Extend of removal:1 Primary driven gear removalExtend of removal Order Part name Q’ty RemarksPRIMARY DRIVEN GEAR REMOVALPreparation for Cowling Refer to “COWLING, INDUCTIONremovalGUIDE, SEAT AND FUEL TANK”section.ClutchRefer to “CLUTCH” section.Drain the transmission oil.Refer to “TRANSMISSION OILREPLACEMENT” section in theCHAPTER 3.1 Crankcase cover (right) 112 Primary driven gear 13 Oil pump drive gear 14 Thrust plate 14-38

PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEARAND BALANCER SHAFTENGEC4D8100PRIMARY DRIVE GEAR AND BALANCER SHAFTT 50 Nm (5.0 mdkg, 36 ftdlb)T55 Nm (5.5 mdkg, 40 ftdlb)T 11 Nm (1.1 mdkg, 8.0 ftdlb)Extend of removal: 1 Primary drive gear removal 2 Balancer shaft removalExtend of removal Order Part name Q’ty Remarks12PRIMARY DRIVE GEAR ANDBALANCER SHAFT REMOVAL1 Bolt (primary drive gear) 12 Primary drive gear 13 Balancer drive gear 14 Nut (balancer weight gear) 15 Lock washer 16 Balancer weight gear 17 Collar 18 Crankcase cover (left) 19 Balancer shaft 1Refer to “REMOVAL POINTS”.4-39

PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEARAND BALANCER SHAFTENGEC4D3000REMOVAL POINTSEC4D3101Primary drive gear and balancer weightgear1. Loosen:• Bolt (primary drive gear) 1NOTE:Place an aluminum plate a between the teethof the balancer drive gear 2 and balancerweight gear 3.2. Loosen:• Nut (balancer weight gear) 1NOTE:Straighten the lock washer 2 tab and placean aluminum plate a between the teeth of thebalancer drive gear 3 and balancer weightgear 4.3. Remove:• Bolt (primary drive gear) 1• Primary drive gear 2• Balancer drive gear 3• Nut (balancer weight gear) 4• Lock washer 5• Balancer weight gear 6NOTE:It may sometimes happens that the primarydrive gear and balancer drive gear are fittedtoo tight as in force fitting. In that case, use ageneral gear puller to remove them withouttoo much force on the crankshaft.EC4D4000INSPECTIONEC4D4100Primary drive gear, primary driven gearand oil pump drive gear1. Inspect:• Primary drive gear 1• Primary driven gear 2• Oil pump drive gear 3Wear/Damage ≥ Replace.4-40

PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEARAND BALANCER SHAFTENGEC4D4200Balancer weight gear and balancer drivegear1. Inspect:• Balancer weight gear 1• Balancer drive gear 2Wear/Damage ≥ Replace.EC4D4300Crankcase cover (right)1. Inspect:• Contacting surfaceScratches ≥ Replace.• Crankcase cover (right)Cracks/Damage ≥ Replace.• Oil seal 1Wear/Damage ≥ Replace.EC4D4500Balancer shaft1. Inspect:• Balancer shaft 1Bend/Wear/Damage ≥ Replace.EC4D5000ASSEMBLY AND INSTALLATIONEC4D5130Balancer shaft and primary drive gear1. Install:• Balancer shaft 1• Collar 22. Install:• Gasket [crankcase cover (left)]N• Crankcase cover (left) 1• Bolt [crankcase cover (left)] 2T11 Nm (1.1 mdkg, 8.0 ftdlb)NOTE:Install the gasket and crankcase cover (left)with their recesses a facing the rotor 3.4-41

PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEARAND BALANCER SHAFTENG3. Install:• Balancer weight gear 1NOTE:Align the punch mark a on the balancer shaftwith the hole b of the balancer weight gear.4. Install:• Balancer drive gear 1NOTE:Align the punch marks, a (balancer drivegear) with b (crankshaft) and c (balancerdrive gear) with d (balancer weight gear) asshown.5. Install:• Lock washer 1N• Nut (balancer weight gear) 2• Primary drive gear 3• Plain washer 4• Bolt (primary drive gear) 5NOTE:Install the plain washer with its chamfered portiona toward you.6. Tighten:• Nut (balancer weight gear) 1T50 Nm (5.0 mdkg, 36 ftdlb)NOTE:Place an aluminum plate a between the teethof the balancer drive gear 2 and balancerweight gear 3.7. Bend the lock washer 1 tab.4-42

PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEARAND BALANCER SHAFTENG8. Tighten:• Bolt (primary drive gear) 1T55 Nm (5.5 mdkg, 40 ftdlb)NOTE:Place an aluminum plate a between the teethof the balancer drive gear 2 and balancerweight gear 3.EC4D5212Primary driven gear1. Install:• Primary driven gear 1• Oil pump drive gear 2To crankcase cover (right) 3.NOTE:Apply the lithium soap base grease on the oilseal lip.2. Install:• Thrust plate 1• Dowel pin 2• Gasket [crankcase cover (right)] 3NNOTE:Install the thrust plate with its larger diameterside a toward the transmission.3. Install:• Crankcase cover (right) 1NOTE:Mesh the primary drive gear 2 with the primarydriven gear 3, and the oil pump drive gear4 with the oil pump driven gear 5 by turningthe rotor.4. Install:• Bolt [crankcase cover (right)] 1T11 Nm (1.1 mdkg, 8.0 ftdlb)NOTE:Tighten the bolts in stages, using a crisscrosspattern.4-43

SHIFT SHAFTENGEC4F0000SHIFT SHAFTT 9 Nm (0.9 mdkg, 6.5 ftdlb)T 8 Nm (0.8 mdkg, 5.8 ftdlb)T 11 Nm (1.1 mdkg, 8.0 ftdlb)T 10 Nm (1.0 mdkg, 7.2 ftdlb)T 22 Nm (2.2 mdkg, 16 ftdlb)T 16 Nm (1.6 mdkg, 11 ftdlb)T 9 Nm (0.9 mdkg, 6.5 ftdlb)T 75 Nm (7.5 mdkg, 54 ftdlb)T 14 Nm (1.4 mdkg, 10 ftdlb)T 11 Nm (1.1 mdkg, 8.0 ftdlb)Extend of removal: 1 Shift shaft removal 2 Stopper lever removalExtend of removal Order Part name Q’ty RemarksSHIFT SHAFT REMOVALPreparation for Crankcase cover (right) Refer to “PRIMARY DRIVEN GEAR,removalPRIMARY DRIVE GEAR ANDBALANCER SHAFT” section.1 Nut (drive sprocket) 12 Lock washer 1 Refer to “REMOVAL POINTS”.3 Drive sprocket 114 Shift arm 15 Transmission housing 1 Refer to “REMOVAL POINTS”.2 6 Circlip 17 Shift shaft 18 Roller 19 Shift guide 110 Shift lever assembly 1Refer to “REMOVAL POINTS”.11 Stopper lever 14-44

SHIFT SHAFTENGEC4F3000REMOVAL POINTSEC4F3100Drive sprocket1. Remove:• Nut (drive sprocket) 1• Lock washer 2NOTE:• Straighten the lock washer tab.• Loosen the nut while applying the rear brake.2. Remove:• Drive sprocket 1• Drive chain 2NOTE:Remove the drive sprocket together with thedrive chain.EC4F3201Transmission housing1. Remove:• Bolt (transmission housing)• Transmission housing 1NOTE:Remove the transmission housing togetherwith the transmission, shift cam, shift fork andshift shaft.EC4C3101Shift guide and shift lever assembly1. Remove:• Bolt (shift guide)• Shift guide 1• Shift lever assembly 2NOTE:The shift lever assembly is disassembled atthe same time as the shift guide.EC4F3401Stopper lever1. Remove:• Stopper lever assembly 1• Torsion spring 2• Plain washerNOTE:Remove the stopper lever assembly with itsroller aligning with the top a of the segment.4-45

SHIFT SHAFTENG2. Remove:• Circlip 1• Plain washer 2• Stopper lever 3EC4F4000INSPECTIONEC4B4400Shift shaft1. Inspect:• Shift shaft 1Bend/Damage ≥ Replace.• Spring 2Broken ≥ Replace.EC4C4100Shift guide and shift lever assembly1. Inspect:• Shift guide 1• Shift lever 2• Pawl 3• Pawl pin 4• Spring 5Wear/Damage ≥ Replace.EC4B4500Stopper lever1. Inspect:• Stopper lever 1Wear/Damage ≥ Replace.• Torsion spring 2Broken ≥ Replace.EC4F5000ASSEMBLY AND INSTALLATIONEC4F5100Stopper lever1. Install:• Stopper lever 1• Plain washer 2• Circlip 3NTo collar 4.NOTE:Be sure the circlip sharp-edged corner a ispositioned opposite side to the plain washer.4-46

SHIFT SHAFTENG2. Install:• Plain washer 1• Torsion spring 2• Stopper lever assembly 3EC4F5202Shift guide and shift lever assembly1. Install:• Spring 1• Pawl pin 2• Pawl 3To shift lever 4.NOTE:• When installing the pawl into the shift lever,make sure the chamfered side a face thepawl pin side.• Apply the transmission oil on the pawl pin.2. Install:• Shift lever assembly 1To shift guide 2.3. Install:• Shift lever assembly 1• Shift guide 2NOTE:• The shift lever assembly is installed at thesame time as the shift guide.• Apply the transmission oil on the bolt (segment)shaft.4. Install:• Bolt (shift guide) 1T11 Nm (1.1 mdkg, 8.0 ftdlb)4-47

SHIFT SHAFTENGEC4F5302Shift shaft1. Install:• Roller 1• Torsion spring 2• Shift shaft 3NOTE:Apply the transmission oil on the roller andshift shaft.2. Install:• Plain washer 1• Circlip 2NTo shift shaft 3.NOTE:Be sure the circlip sharp-edged corner a ispositioned opposite side to the plain washer.3. Check:• Shift lever positionChecking steps:• Attach the collar (with supplying parts) 2onto the roller 1.• Check the shift lever position.Gaps a and b are not equal ≥ Adjust.4. Adjust:• Shift lever positionAdjusting steps:• Loosen the locknut 3.• Turn the adjuster 4 in or out.• Tighten the locknut.ULocknut:9 Nm (0.9 m•kg, 6.5 ft•lb)• Remove the collar.4-48

SHIFT SHAFTENGEC4F5411Transmission housing1. Apply:• Transmission oilOn the bearing (crankcase lower) andimpeller shaft.2. Install:• Dowel pin 1• Transmission housing 2NOTE:When installing the transmission housing, turnthe oil pump driven gear 3 until the key enda of the oil pump gear shaft 4 is in therecess b of the impeller shaft 5.3. Install:• Bolt {transmission housing [L=40 mm (1.57 in)]} 1T16 Nm (1.6 mdkg, 11 ftdlb)• Bolt {transmission housing [L=30 mm (1.18 in)]} 2T16 Nm (1.6 mdkg, 11 ftdlb)NOTE:• Tighten the bolts in stages, using a crisscrosspattern.• Apply the transmission oil on the thread andcontact surface of the bolt (transmissionhousing).4. Install:• Plain washer 1• Spacer 2• Shift arm 3• Bolt (shift arm) 4T14 Nm (1.4 mdkg, 10 ftdlb)NOTE:• Make sure that the joint rod distance a is104.5~106.5 mm (4.1~4.2 in).• Install the shift arm so that the shift pedalcenter b is highest without exceeding theinside line c of the footrest bracket.4-49

SHIFT SHAFTENGEC4F5510Drive sprocket1. Install:• Drive sprocket 1• Drive chain 2NOTE:• Install the drive sprocket with its depressedside a facing the engine.• Install the drive sprocket together with thedrive chain.2. Install:• Lock washer 1N• Nut (drive sprocket) 2T75 Nm (7.5 mdkg, 54 ftdlb)NOTE:Tighten the nut while applying the rear brake.3. Bend the lock washer tab to lock the nut.4-50

WATER PUMPENGEC4G0000WATER PUMPT2 Nm (0.2 mdkg, 1.4 ftdlb)T11 Nm (1.1 mdkg, 8.0 ftdlb)Extend of removal: 1 Impeller shaft removal 2 Oil seal removalExtend of removal Order Part name Q’ty RemarksWATER PUMP DISASSEMBLYPreparation for Cowling Refer to “COWLING, INDUCTIONremovalGUIDE, SEAT AND FUEL TANK”section.Drain the cooling water.Refer to “COOLING WATERREPLACEMENT” section in theCHAPTER 3.Transmission housingRefer to “SHIFT SHAFT” section.1 Radiator hose 2 12 Water pump housing cover 113 Circlip 12 4 Plain washer 15 Impeller shaft 16 Bearing 17 Oil seal 2Refer to “REMOVAL POINTS”.4-51

WATER PUMPENGEC4G3000REMOVAL POINTSEC4G3210Oil sealNOTE:It is not necessary to disassemble the waterpump, unless there is an abnormality such asexcessive change in coolant level, discolorationof coolant, or milky transmission oil.1. Remove:• Bearing 12. Remove:• Oil seal 1EC4G4000INSPECTIONEC444200Impeller shaft1. Inspect:• Impeller shaft 1Bend/Wear/Damage ≥ Replace.Fur deposits ≥ Clean.EC4H4600Bearing1. Inspect:• Bearing 1Rotate inner race with a finger.Rough spot/Seizure ≥ Replace.4-52

WATER PUMPENGEC444400Oil seal1. Inspect:• Oil seal 1Wear/Damage ≥ Replace.EC4G5000ASSEMBLY AND INSTALLATIONEC4G5120Oil seal1. Install:• Oil seal 1NNOTE:• Apply the lithium soap base grease on the oilseal lip.• Install the oil seal with its manufacture’smarks or numbers facing the crankcase 2.2. Install:• Bearing 1NOTE:Install the bearing by pressing its outer raceparallel.EC4G5203Impeller shaft1. Install:• Impeller shaft 1NOTE:• Take care so that the oil seal lip is not damagedor the spring does not slip off its position.• When installing the impeller shaft, apply thelithium soap base grease on the oil seal lipand impeller shaft. And install the shaft whileturning it.2. Install:• Plain washer 1• Circlip 2NTo impeller shaft 3.NOTE:Be sure the circlip sharp-edged corner a ispositioned opposite side to the plain washer.4-53

WATER PUMPENG3. Install:• Dowel pin 1• Gasket (water pump housing cover) 2N4. Install:• Water pump housing cover 1• Bolt (water pump housing cover) 2T11 Nm (1.1 mdkg, 8.0 ftdlb)• Copper washer 3N• Air bleeding bolt (water pump) 4T11 Nm (1.1 mdkg, 8.0 ftdlb)5. Install:• Radiator hose 2 1T2 Nm (0.2 mdkg, 1.4 ftdlb)4-54

TRANSMISSION, SHIFT CAM AND SHIFT FORKENGEC4H0000TRANSMISSION, SHIFT CAM AND SHIFT FORKT 23 Nm (2.3 mdkg, 17 ftdlb)T 4 Nm (0.4 mdkg, 2.9 ftdlb)T 10 Nm (1.0 mdkg, 7.2 ftdlb)T 10 Nm (1.0 mdkg, 7.2 ftdlb)T 7 Nm (0.7 mdkg, 5.1 ftdlb)Extend of removal Order Part name Q’ty RemarksTRANSMISSION, SHIFT CAM ANDSHIFT FORK REMOVALPreparation for Cowling Refer to “COWLING, INDUCTIONremovalGUIDE, SEAT AND FUEL TANK”section.Transmission housingShift shaft and shift leverassemblyRefer to “SHIFT SHAFT” section.Stopper lever4-55

TRANSMISSION, SHIFT CAM AND SHIFT FORKENGT 23 Nm (2.3 mdkg, 17 ftdlb)T 4 Nm (0.4 mdkg, 2.9 ftdlb)T 10 Nm (1.0 mdkg, 7.2 ftdlb)T 10 Nm (1.0 mdkg, 7.2 ftdlb)T 7 Nm (0.7 mdkg, 5.1 ftdlb)Extend of removal: 1 Shift fork removal 2 Main axle and drive axle removal3 Shift cam removalExtend of removal Order Part name Q’ty Remarks1 Guide bar 1 (short) 12 Guide bar 2 (long) 113 Shift fork 1 124 Shift fork 2 15 Shift fork 3 16 Thrust plate 17 Main axle 18 Drive axle 1Refer to “REMOVAL POINTS”.9 Bolt (segment) 110 Segment 1Refer to “REMOVAL POINTS”.11 Shift cam 14-56

TRANSMISSION, SHIFT CAM AND SHIFT FORKENGEC4H3000REMOVAL POINTSEC4H3210Transmission1. Remove:• Main axle 1• Drive axle 2NOTE:• Remove the main axle together with the driveaxle from the transmission housing 3.• Remove assembly carefully. Note the positionof each part. Pay particular attention to thelocation and direction of shift forks.EC4H3400Segment1. Remove:• Bolt (segment) 1• Segment 2NOTE:Clamp the shift cam 3 securely in a vise,using soft protecting material 4 to loosen thebolt (segment).EC4H4000INSPECTIONEC4H4210Gears1. Inspect:• Matching dog a• Gear teeth bWear/Damage ≥ Replace.2. Check:• Gears movementUnsmooth movement ≥ Repair or replace.4-57

TRANSMISSION, SHIFT CAM AND SHIFT FORKENGEC4H4300Shift fork groove1. Measure:• 3rd/4th pinion gear 1• 5th wheel gear 2• 6th wheel gear 3• Shift fork groove aOut of specification ≥ Replace.Shift fork groove a:Standard]5.05~5.18 mm 5.35 mm(0.199~0.204 in) (0.211 in)EC4H4400Thrust clearance1. Check:• After assembling the transmission, checkwhether the idle gear turns smoothly withouta thrust.If the thrust clearance is too large or theidle gear moves with difficulty ≥ Replacethe shim 1, 2 and 3.Choose the shims by the following chart.Part name Size (thickness) Part numberShim 1 STD t=1.0 mm 90201-253K0(0.039 in)t=0.9 mm 90201-256E6(0.035 in)Shim 2 STD t=1.0 mm 90201-20276(0.039 in)t=0.9 mm 90201-206E5(0.035 in)Shim 3 STD t=0.7 mm 5F7-17136-00(0.028 in)Nt=0.5 mm 90209-22082(0.020 in)NOTE:It is necessary to adjust the thrust clearancewhen the transmission gear, axle, washer, circlip,bearing or crankcase is replaced.4-58

TRANSMISSION, SHIFT CAM AND SHIFT FORKENGEC4H4501Dog clearanceNOTE:• It is necessary to adjust the dog clearancewhen the transmission gear, axle, washer,circlip, bearing or crankcase is replaced.• If there is any shifting trouble, it is necessaryto check the shift fork, shift cam, shift leverand gears. But if there are in good condition,the dog clearance should be inspected.1. Install the transmission, shift cam and shiftfork into the transmission housing.2. Position the transmission is neutral.3. Pull the main axle toward the clutch side.4. Bring the 3rd/4th pinion gear 1 into lightcontact with the 6th pinion gear 2 to theextent that they are not engaged, and measurethe clearance a between 3rd/4th piniongear and 6th pinion gear.Bring the 3rd/4th pinion gear into light contactwith the 5th pinion gear 3 to theextent that they are not engaged and measurethe clearance b between 3rd/4th piniongear and 5th pinion gear.aDog clearance a, b:0.5 mm (0.020 in) or moreOut of specification or clearance a and bare not equal ≥ Replace the shim 4.Choose the shim by the following chart.Part name Size (thickness) Part numberShim 4 STD t=1.0 mm 90201-253K0(0.039 in)Mt=0.9 mm 90201-256E6(0.035 in)EC4H4600Bearing1. Inspect:• Bearing 1Rotate inner race with a finger.Rough spot/Seizure ≥ Replace.4-59

TRANSMISSION, SHIFT CAM AND SHIFT FORKENGEC4H4801Shift fork, shift cam and segment1. Inspect:• Shift fork 1Wear/Damage/Scratches ≥ Replace.2. Inspect:• Shift cam 1• Segment 2• Guide bar 3Bend/Wear/Damage ≥ Replace.3. Check:• Shift fork movementOn its guide bar.Unsmooth operation ≥ Replace shift forkand/or guide bar.NOTE:For a malfunctioning shift fork, replace notonly the shift fork itself but the two gears eachadjacent to the shift fork.EC4H5000ASSEMBLY AND INSTALLATIONEC4H5112Shift cam1. Install:• Shift cam 1NOTE:Apply the transmission oil on the shift cambearing.4-60

TRANSMISSION, SHIFT CAM AND SHIFT FORKENG2. Install:• Segment 1• Bolt (segment) 2GT23 Nm (2.3 mdkg, 17 ftdlb)NOTE:• When installing the segment onto the shiftcam, align the punch mark a with the dowelpin b.• Clamp the shift cam 3 securely in a vise,using soft protecting material 4 to tightenthe bolt (segment).EC4H5232Transmission1. Install:• 6th pinion gear (22T) 1• 3rd/4th pinion gear (23T/25T) 2• 5th pinion gear (27T) 3• 2nd pinion gear (21T) 4To main axle 5.NOTE:Apply the molybdenum disulfide oil on thegears inner circumference.2. Install:• 2nd wheel gear (31T) 1• 5th wheel gear (26T) 2• 3rd wheel gear (29T) 3• 4th wheel gear (27T) 4• 6th wheel gear (20T) 5• 1st wheel gear (34T) 6To drive axle 7.NOTE:Apply the molybdenum disulfide oil on thegears inner circumference.4-61

TRANSMISSION, SHIFT CAM AND SHIFT FORKENG3. Install:• Plain washer 1• Circlip 2NNOTE:• Be sure the circlip sharp-edged corner a ispositioned opposite to the plain washer andgear b.• Be sure the circlip end c is positioned ataxle spline groove d.4-62

TRANSMISSION, SHIFT CAM AND SHIFT FORKENG4. Install:• Main axle 1• Drive axle 2NOTE:• Apply the transmission oil on the main axleand drive axle bearings.• Install the main axle together with the driveaxle into the transmission housing 3.5. Install:• Shift fork 1 1• Shift fork 2 2• Shift fork 3 3NOTE:• Mesh the shift fork #1 with the 5th wheelgear 4 and #3 with the 6th gear 6 on thedrive axle.• Mesh the shift fork #2 with the 3rd/4th piniongear 5 on the main axle.6. Install:• Guide bar 1 (short) 1• Guide bar 2 (long) 2NOTE:• Apply the transmission oil on the guide bars.• Be sure the short bar is inserted into the shiftfork #2 and the long one into #1 and #3.7. Check:• Shift operation• Transmission operationUnsmooth operation ≥ Repair.8. Install:• Thrust plate 1• Spacer 1 2• O-ring 3NNOTE:Apply the lithium soap base grease on the O-ring.4-63

OIL PUMPENGEC4J0000OIL PUMPT8 Nm (0.8 mdkg, 5.8 ftdlb)T7 Nm (0.7 mdkg, 5.1 ftdlb)Extend of removal:1 Oil pump removal and disassemblyExtend of removal Order Part name Q’ty RemarksOIL PUMP REMOVALPreparation forTransmission housingremovalShift shaft and Stopper leverRefer to “SHIFT SHAFT” section.Transmission and shift forkRefer to “TRANSMISSION, SHIFTCAM AND SHIFT FORK” section.1 Strainer 12 Oil pump cover 13 Outer rotor 14 Inner rotor 15 Dowel pin 116 Plain washer 1[D=ø15 mm (0.59 in)]7 Plain washer 1[D=ø22 mm (0.87 in)]8 Oil pump gear shaft 19 Oil delivery pipe 14-64

OIL PUMPENGEC4J4000INSPECTIONEC4J4100Oil pump1. Measure:• Tip clearanceMeasure the clearance between the innerrotor 1 and outer rotor 2.Out of limit ≥ Replace the inner rotor andouter rotor as a set.aTip clearance limit:0.15 mm (0.0059 in)EC4E4310Strainer1. Clean:• Strainer 1Use compressed air.NOTE:• Clean the strainer every 500 km (300 miles).• If a lot of metallic dust in noticed, disassemblethe engine and check.EC4J4200Oil pump gear shaft1. Inspect:• Oil pump gear shaft 1Wear/Damage ≥ Replace.EC4H4100Oil delivery pipe1. Inspect:• Oil delivery pipe 1• O-ring 2Damage ≥ Replace.• Oil orifice aClogged ≥ Blow.EC4J5000ASSEMBLY AND INSTALLATIONEC4J5102Oil pump1. Install:• O-ring 1NTo oil delivery pipe 2.NOTE:Apply the lithium soap base grease on the O-rings.4-65

OIL PUMPENG2. Install:• Oil delivery pipe 1NOTE:When installing the oil delivery pipe, fit theprojection a of the oil delivery pipe into thehole b on the crankcase.3. Install:• Plain washer [D=ø22 mm (0.87 in)] 1• Oil pump gear shaft 2To transmission housing 3.4. Install:• Plain washer [D=ø15 mm (0.87 in)] 1• Dowel pin 2• Inner rotor 3• Outer rotor 4To oil pump gear shaft 5.NOTE:• Apply the transmission oil on the inner rotorand outer rotor.• Make sure the dowel pin fits into the groovea in the inner rotor.• When installing the outer rotor, make surethe punch mark b on the outer rotor face thetransmission housing side.5. Install:• Dowel pin 14-66

OIL PUMPENG6. Install:• Oil pump cover 1• Plain washer 2• Bolt (oil pump cover) 3T8 Nm (0.8 mdkg, 5.8 ftdlb)NOTE:While turning the oil pump gear shaft, installthe oil pump cover.7. Install:• Strainer 1• Screw (strainer) 2T7 Nm (0.7 mdkg, 5.1 ftdlb)NOTE:Strainer is installed with the mesh a facingoutward.4-67

CDI MAGNETOENGEC4L0000CDI MAGNETOT 7 Nm (0.7 mdkg, 5.1 ftdlb)T 53 Nm (5.3 mdkg, 38 ftdlb)Extend of removal:1 CDI magneto removalExtend of removal Order Part name Q’ty RemarksCDI MAGNETO REMOVALPreparation for Cowling and fuel tank Refer to “COWLING, INDUCTIONremovalGUIDE, SEAT AND FUEL TANK”section.Disconnect the CDI magneto lead.1 Nut (rotor) 1 Use special tool.12 Rotor 1 Refer to “REMOVAL POINTS”.3 Stator 14 Woodruff key 14-68

CDI MAGNETOENGEC4L3000REMOVAL POINTSEC4L3102Rotor1. Remove:• Nut (rotor) 1• Plain washer 2Use the rotor holding tool 3.ARotor holding tool:YU-1235/90890-012352. Remove:• Rotor 1Use the flywheel puller 2.AFlywheel puller:YM-1189/90890-01189NOTE:When installing the flywheel puller, turn itcounterclockwise.EC4L4000INSPECTIONEC4L4101CDI magneto1. Inspect:• Rotor inner surface a• Stator outer surface bDamage ≥ Inspect the crankshaft runoutand crankshaft bearing.If necessary, replace CDI magneto and/orstator.EC4L4200Woodruff key1. Inspect:• Woodruff key 1Damage ≥ Replace.EC4L5000ASSEMBLY AND INSTALLATIOEC4L5191CDI magneto1. Install:• Stator 1• Screw (stator) 2NOTE:Temporarily tighten the screw (stator) at thispoint.4-69

CDI MAGNETOENG2. Install:• Woodruff key 1• Rotor 2NOTE:• Clean the tapered portions of the crankshaftand rotor.• When installing the woodruff key, make surethat its flat surface a is in parallel with thecrankshaft center line b.• When installing the rotor, align the keyway cof the rotor with the woodruff key.3. Install:• Plain washer 1• Nut (rotor) 2 T53 Nm (5.3 mdkg, 38 ftdlb)Use the rotor holding tool 3.ARotor holding tool:YU-1235/90890-012354. Adjust:• Ignition timingaIgnition timing:2.4 mm (0.094 in)Refer to “IGNITION TIMING CHECK” sectionin the CHAPTER 3.5. Connect:• CDI magneto lead 1Refer to “CABLE ROUTING DIAGRAM”section in the CHAPTER 2.4-70

ENGINE REMOVALENGEC4M0000ENGINE REMOVALT 30 Nm (3.0 mdkg, 22 ftdlb)T 8 Nm (0.8 mdkg, 5.8 ftdlb)T11 Nm (1.1 mdkg, 8.0 ftdlb)T 23 Nm (2.3 mdkg, 17 ftdlb)T11 Nm (1.1 mdkg, 8.0 ftdlb)T 30 Nm (3.0 mdkg, 22 ftdlb)T 23 Nm (2.3 mdkg, 17 ftdlb)Extend of removal Order Part name Q’ty RemarksENGINE REMOVALPreparation forHold the machine by placingremovalthe suitable stand.Cowling and fuel tankCarburetor and carburetor boxExhaust pipeClutch cableRadiator hose 2Radiator hose 3, 4Drive sprocketShift armSpark plug capYPVS cableDisconnect the CDI magneto lead.WSupport the machine securely so thereis no danger of it falling over.Refer to “COWLING, INDUCTIONGUIDE, SEAT AND FUEL TANK” section.Refer to “CARBURETOR AND REEDVALVE” section.Refer to “EXHAUST PIPE ANDSILENCER” section.Disconnect at engine side.Disconnect at water pump side.Disconnect at cylinder head side.Refer to “SHIFT SHAFT” section.4-71

ENGINE REMOVALENGT 30 Nm (3.0 mdkg, 22 ftdlb)T 8 Nm (0.8 mdkg, 5.8 ftdlb)T11 Nm (1.1 mdkg, 8.0 ftdlb)T 23 Nm (2.3 mdkg, 17 ftdlb)T11 Nm (1.1 mdkg, 8.0 ftdlb)T 30 Nm (3.0 mdkg, 22 ftdlb)T 23 Nm (2.3 mdkg, 17 ftdlb)Extend of removal:1 Engine removalExtend of removal Order Part name Q’ty Remarks1 Pinch bolt (engine mounting collar) 2 Only loosening.2 Nut (engine mounting bolt) 413 Engine mounting adjust bolt 24 Engine mounting bolt 4 Refer to “REMOVAL POINTS.”5 Engine 16 Engine bracket 24-72

ENGINE REMOVALENGEC4M6000HANDLING NOTEWhen the frame alone is stored, insert theengine mounting collars 1 into the bracketsand tighten them with the pinch bolts 2 to6 Nm (0.6 m•kg, 4.3 ft•lb) in order to preventthe brackets a from damage.EC4M3000REMOVAL POINTSEC4M3331Engine removal1. Loosen:• Engine mounting adjust bolt 1NOTE:Use the adjust bolt wrench 2 to loosen theengine mounting adjust bolt.2. Remove:• Engine mounting bolt 1• Engine 2NOTE:• Before removing the engine, make sure thatthe couplers, hoses and cables are disconnected.• Remove the engine by lowering it with a jack3.EC4M5000ASSEMBLY AND INSTALLATIONEC4M5190Engine installation1. Install:• Engine bracket 1• Bolt (engine bracket) 2NOTE:• Install the engine brackets with their “OUT-SIDE” marks a facing outward.• Tighten the bolts (engine brackets) to 23 Nm(2.3 m•kg, 17 ft•lb), then loosen them by 1/4turn, for temporary fitting.4-73

ENGINE REMOVALENG2. Install:• Engine 1NOTE:Install the engine by raising it into the framewith a jack 2.3. Install:• Engine mounting bolt (upper) 1• Engine mounting bolt (lower) 24. Tighten:• Engine mounting adjust bolt 1T8 Nm (0.8 mdkg, 5.8 ftdlb)NOTE:• Use the adjust bolt wrench 2 to tighten theengine mounting adjust bolts.• Tighten the adjust bolts to specified torquealternately two times.5. Install:• Nut (engine mounting bolt) (upper) 1T30 Nm (3.0 mdkg, 22 ftdlb)• Nut (engine mounting bolt) (lower) 2T30 Nm (3.0 mdkg, 22 ftdlb)4-74

ENGINE REMOVALENG6. Install:• Engine mounting collar (left) 1• Engine mounting bolt (left) 2• Engine mounting nut (left) 3T30 Nm (3.0 mdkg, 22 ftdlb)7. Tighten:• Bolt (engine bracket) (left) 4T23 Nm (2.3 mdkg, 17 ftdlb)8. Tighten:• Pinch bolt (engine mounting collar) (left) 5T11 Nm (1.1 mdkg, 8.0 ftdlb)9. Install:• Engine mounting collar (right) 1• Engine mounting bolt (right) 2• Engine mounting nut (right) 3T30 Nm (3.0 mdkg, 22 ftdlb)10.Tighten:• Bolt (engine bracket) (right) 4T23 Nm (2.3 mdkg, 17 ftdlb)11.Tighten:• Pinch bolt (engine mounting collar) (right) 5T11 Nm (1.1 mdkg, 8.0 ftdlb)4-75

CRANKCASE AND CRANKSHAFTENGEC4N0000CRANKCASE AND CRANKSHAFTT 11 Nm (1.1 mdkg, 8.0 ftdlb)T 8 Nm (0.8 mdkg, 5.8 ftdlb)T 7 Nm (0.7 mdkg, 5.1 ftdlb)T 11 Nm (1.1 mdkg, 8.0 ftdlb)T 50 Nm (5.0 mdkg, 36 ftdlb)T 26 Nm (2.6 mdkg, 19 ftdlb)Extend of removal Order Part name Q’ty RemarksCRANKCASE ANDCRANK SHAFT REMOVALPreparation for Engine Refer to “ENGINE REMOVAL”removalsection.Reed valveRefer to “CARBURETOR AND REEDVALVE” section.PistonRefer to “CYLINDER HEAD, CYLIN-DER AND PISTON” section.Primary drive gearRefer to “PRIMARY DRIVEN GEAR,PRIMARY DRIVE GEAR ANDBALANCER SHAFT” section.Rotor and statorRefer to “CDI MAGNETO” section.Engine bracket4-76

CRANKCASE AND CRANKSHAFTENGT 11 Nm (1.1 mdkg, 8.0 ftdlb)T 8 Nm (0.8 mdkg, 5.8 ftdlb)T 7 Nm (0.7 mdkg, 5.1 ftdlb)T 11 Nm (1.1 mdkg, 8.0 ftdlb)T 50 Nm (5.0 mdkg, 36 ftdlb)T 26 Nm (2.6 mdkg, 19 ftdlb)Extend of removal: 1 Crankcase separation 2 Crankshaft removal3 Oil seal removal 4 Push lever axle removalExtend of removal Order Part name Q’ty Remarks1 Bolt [crankcase (M6)] 6[L=30 mm (1.18 in)]2 Bolt [crankcase (M6)] 31 2[L=35 mm (1.38 in)]33 Bolt [crankcase (M8)] 6Refer to “REMOVAL POINTS”.[L=45 mm (1.77 in)]4 Crankcase (upper) 15 Crankcase (lower) 16 Crankshaft 17 Oil seal (crankshaft) 28 Bolt (seat plate) 14 9 Seat plate 110 Push lever axle 14-77

CRANKCASE AND CRANKSHAFTENGEC4N3000REMOVAL POINTSEC4N3230Crankcase1. Remove:• Bolt [crankcase (M6)] 1• Bolt [crankcase (M8)] 2NOTE:• The M6 size bolts should be removed first.• Loosen the bolts from the outer sides inward.2. Remove:• Crankcase (upper) 1From crankcase (lower) 2.CCAUTION:Use soft hammer to tap on the case half.Tap only on reinforced portions of case. Donot tap on gasket mating surface. Workslowly and carefully. If the cases do notseparate, check for a remaining case screwor fitting. Do not force.EC4N4000INSPECTIONEC4N4112Crankcase1. Inspect:• Contacting surface aScratches ≥ Replace crankcase assembly.• Engine mounting boss b, crankcaseCracks/Damage ≥ Replace crankcaseassembly.EC4N4214Crankshaft1. Inspect:• Bearing 1Rotate outer race with a finger.Rough spot/Seizure ≥ Replace crankshaftassembly.4-78

CRANKCASE AND CRANKSHAFTENG2. Inspect:• Oil seal 1Wear/Damage ≥ Replace.3. Measure:• Runout limit a• Small end free play limit b• Connecting rod big end side clearance c• Crank width (crank pin side) dOut of specification ≥ Replace.Use the dial gauge and thickness gauge.ADial gauge:YU-3097/90890-01252StandardRunout 0.03 mm 0.05 mmlimit (0.0012 in) (0.0020 in)Small end 0.8~1.0 mm 2.0 mmfree play (0.031~0.039 in) (0.08 in)Side 0.45~0.95 mm–clearance (0.018~0.037 in)sCrank 49.975~50.025 mm–width (1.968~1.969 in)EC4A4200Push lever axle1. Inspect:• Push lever axle 1Wear/Damage ≥ Replace.• Torsion spring 2Broken/Damage ≥ Replace.EC4N5000ASSEMBLY AND INSTALLATIONEC4N5291Crankshaft1. Install:• Oil seal 1To crankshaft 2.NOTE:Apply the lithium soap base grease on the oilseal lip.4-79

CRANKCASE AND CRANKSHAFTENG2. Install:• Circlip 1To crankcase (lower) 2.3. Install:• Crankshaft 1To crankcase (lower) 2.NOTE:• When installing the crankshaft into thecrankcase (lower), apply the transmission oilon the oil seal 3 outer circumference.• Align the bearing knock pin with the pin slota in the crankcase (lower) and the projectionof oil seal with the groove b in thecrankcase (lower).• After installing the crankshaft, push the oilseal to the crankcase (lower).4. Install:• Dowel pin 1• O-ring 2To crankcase (lower) 3.5. Apply:• SealantOn the crankcase (upper) 1.Quick gasket®:ACC-YAMAB-ON-D4YAMAHA Bond No.490890-05143CNOTE:Clean the contacting surface of crankcase(upper and lower) before applying the sealant.4-80

CRANKCASE AND CRANKSHAFTENG6. Install:• Crankcase (upper) 1To crankcase (lower).NOTE:After installation, tap the crankcase (upper)with a soft hammar to settle it.7. Tighten:• Bolt [crankcase (M8)] 1~6• Bolt [crankcase (M6)] 7~∞CCAUTION:The M6 bolt comes in two lengths. Use thecorrect one for installation.L=30 mm (1.18 in) (green) 7 0 ¡ £ ¢ ∞Mark $:L=35 mm (1.38 in) (silver) 8 9 NOTE:Tighten all bolts in 2 steps as follows and besure to tighten in numbered order as shown.•First: 1~6 (M8) 11 Nm (1.1 m•kg, 8.0 ft•lb)7~∞ (M6) 6 Nm (0.6 m•kg, 4.3 ft•lb)•Final: 1~6 (M8) 26 Nm (2.6 m•kg, 19 ft•lb)7~∞ (M6) 11 Nm (1.1 m•kg, 8.0 ft•lb)8. Remove:• SealantForced out on the crankcase mating surface.CCAUTION:If any sealant remains, especially wherethe stator is installed, it may cause the statorto be installed improperly, resulting inan electrical problem.9. Apply:• Engine oilTo the crank pin, bearing and oil deliveryhole.10.Check:• Crankshaft operationUnsmooth operation ≥ Repair.4-81

CRANKCASE AND CRANKSHAFTENGEC4A5101Push lever axle1. Install:• Seat plate 1• Torsion spring 2• Push lever axle 3NOTE:Apply the lithium soap base grease on thepush lever axle, oil seal lip and bearing.2. Install:• Bolt (seat plate) 1T7 Nm (0.7 mdkg, 5.1 ftdlb)NOTE:Fit the seat plate 2 in the groove a of thepush lever axle 3 and tighten the bolt (seatplate).4-82

FRONT WHEEL AND REAR WHEELCHASEC500000CHASSISEC590000FRONT WHEEL AND REAR WHEELEC598000FRONT WHEELT 35 Nm (3.5 mdkg, 25 ftdlb)T 11 Nm (1.1 mdkg, 8.0 ftdlb)T 35 Nm (3.5 mdkg, 25 ftdlb)T 80 Nm (8.0 mdkg, 58 ftdlb)T 11 Nm (1.1 mdkg, 8.0 ftdlb)T 20 Nm (2.0 mdkg, 14 ftdlb)5T 20 Nm (2.0 mdkg, 14 ftdlb)Extend of removal: 1 Front wheel removal 2 Wheel bearing removal3 Brake disc removalExtend of removal Order Part name Q’ty RemarksFRONT WHEEL REMOVAL WPreparation forHold the machine by placingSupport the machine securely so thereremovalthe suitable stand.is no danger of it falling over.1 3231 Bolt (axle holder) 4 Only loosening.2 Nut (front wheel axle) 13 Front wheel axle 14 Caliper 25 Front wheel 16 Collar 2 Refer to “REMOVAL POINTS”.7 Bearing 2 Refer to “REMOVAL POINTS”.8 Brake disk 25-1

FRONT WHEEL AND REAR WHEELCHASEC598100REAR WHEELT 80 Nm (8.0 mdkg, 58 ftdlb)T 16 Nm (1.6 mdkg, 11 ftdlb)T 2 Nm (0.2 mdkg, 1.4 ftdlb)T 23 Nm (2.3 mdkg, 17 ftdlb)T 32 Nm (3.2 mdkg, 23 ftdlb)T 16 Nm (1.6 mdkg, 11 ftdlb)5T 2 Nm (0.2 mdkg, 1.4 ftdlb)Extend of removal: 1 Rear wheel removal 2 Wheel bearing removal3 Brake disc removalExtend of removal Order Part name Q’ty RemarksREAR WHEEL REMOVALWPreparation forHold the machine by placingSupport the machine securely so thereremovalthe suitable stand.is no danger of it falling over.1 Nut (rear wheel axle) 11 3 2 Rear wheel axle 13 Rear wheel 1 Refer to “REMOVAL POINTS”.4 Collar 125 Clutch hub 16 Shim 17 Driven sprocket 18 Sprocket damper 59 Collar 1 Refer to “REMOVAL POINTS”.10 Bearing 2 Refer to “REMOVAL POINTS”.3 11 Brake disc 15-2

FRONT WHEEL AND REAR WHEELCHASEC593000REMOVAL POINTSEC523101Rear wheel1. Remove:• Wheel 1NOTE:Push the wheel forward and remove the drivechain 2.EC513300Collar1. Remove:• Collar 1Knock out of wheel on inside.NOTE:Knock the collar out of the wheel gradually notto deform it.EC513201Wheel bearing (if necessary)1. Remove:• Bearing 1NOTE:Remove the bearing using a general bearingpuller 2.EC594000INSPECTIONEC514110Wheel1. Measure:• Wheel runoutOut of limit ≥ Replace.Wheel runout limit:Radial: 1.0 mm (0.04 in)Lateral: 0.5 mm (0.02 in)b2. Inspect:• BearingRotate inner race with a finger.Rough spot/Seizure ≥ Replace.NOTE:Replace the bearings and wheel collar as aset.5-3

FRONT WHEEL AND REAR WHEELCHASEC514200Wheel axle1. Measure:• Wheel axle bendsOut of specification ≥ Replace.Use the dial gauge 1.aWheel axle bending limit:0.25 mm (0.010 in)NOTE:The bending value is shown by one half of thedial gauge reading.WDo not attempt to straighten a bent axle.EC594100Brake disc1. Measure:• Brake disc deflection (only rear brake disc)Use the dial gauge 1.Out of specification ≥ Inspect wheelrunout.If wheel runout is in good condition,replace the brake disc.Disc deflection limit:≈Standard Rear – 0.15 mm (0.006 in)2. Measure:• Brake disc thicknessUse the micrometer 1.Out of limit ≥ Replace.Disc wear limit:Standard∆Front 5.0 mm (0.20 in) 4.5 mm (0.18 in)Rear 4.0 mm (0.16 in) 3.5 mm (0.14 in)3. Inspect:• Brake disc surfaceScore marks/Damege≥Replace.5-4

FRONT WHEEL AND REAR WHEELCHASEC524100Clutch hub1. Inspect:• Bearing 1Rotate inner race with a finger.Rough spot/Seizure ≥ Replace.EC594300Clucth hub clearance1. Inspect:• Clucth hub clearance aOut of specification ≥ Adjust by addingthe supplyed shim [0.3 mm (0.012 in)].aClucth hub clearance:Zero~0.3 mm (Zero~0.012 in)NOTE:• When inspecting the clutch hub clearance,measure it as it is assembled to the body atspecified torque.• Measurement may be made of the clearanceeither between the shim 1 and clutch hub 2or between the shim and sprocket 3.EC595000ASSEMBLY AND INSTALLATIONEC515172Front wheel1. Install:• Bearing (right) 1• Spacer 2• Bearing (left) 3NOTE:• Apply the lithium soap base grease on thebearing when installing.• Use a socket that matches the outside diameterof the race of the bearing.• Right side of bearing shall be installed first.CCAUTION:Do not strike the inner race of the bearing.Contact should be made only with theouter race.5-5

FRONT WHEEL AND REAR WHEELCHAS2. Install:• Brake disc 1• Bolt (brake disc) 2GT20 Nm (2.0 mdkg, 14 ftdlb)NOTE:Tighten the bolts in stage, using a crisscrosspattern.3. Install:• Collar 1NOTE:If the collar is hard to install, apply the lithiumsoap base grease on the collar and press it in.4. Install:• Wheel 1• Caliper 2• Bolt (caliper)T35 Nm (3.5 mdkg, 25 ftdlb)NOTE:Before installing the wheel axle, install thecaliper.5. Install:• Wheel axle 1NOTE:• Apply the lithium soap base grease on thewheel axle.• Insert the wheel axle from right side.6. Install:• Plain washer 1• Nut (wheel axle) 2T80 Nm (8.0 mdkg, 58 ftdlb)NOTE:Apply the lithium soap base grease on thewheel axle thread.5-6

FRONT WHEEL AND REAR WHEELCHAS7. Tighten:• Bolt (axle holder) 1T11 Nm (1.1 mdkg, 8.0 ftdlb)EC5251C0Rear wheel1. Install:• Fitting plate (right) 1• Bearing (right) 2• Spacer 3• Fitting plate (left) 4• Bearing (left) 5NOTE:• Apply the lithium soap base grease on thebearing when installing.• Use a socket that matches the outside diameterof the race of the bearing.• Right side of bearing shall be installed first.CCAUTION:Do not strike the inner race of the bearing.Contact should be made only with theouter race.2. Install:• Brake disc 1• Bolt (brake disc) 2GT23 Nm (2.3 mdkg, 17 ftdlb)NOTE:Tighten the bolts in stage, using a crisscrosspattern.3. Install:• Collar 1NOTE:If the collar is hard to install, apply the lithiumsoap base grease on the collar and press it in.5-7

FRONT WHEEL AND REAR WHEELCHAS4. Install:• Sprocket damper 1• Nut (sprocket damper) 2T32 Nm (3.2 mdkg, 23 ftdlb)To driven sprocket 3.NOTE:Make sure that the nut is on the side of thesprocket bearing the manufacturer’s mark a.5. Install:• Driven sprocket 1To wheel.NOTE:Apply the lithium soap base grease on thesprocket damper.6. Install:• Shim 1• Clutch hub 2• Collar 3NOTE:Apply the lithium soap base grease on theshim and clutch hub outer circumference.7. Install:• WheelNOTE:Install the brake disc 1 between the brakepads 2 correctly.8. Install:• Drive chain 1NOTE:Push the wheel 2 forward and install the drivechain.5-8

FRONT WHEEL AND REAR WHEELCHAS9. Install:• Wheel axle 1NOTE:• Apply the lithium soap base grease on thewheel axle.• Insert the wheel axle from left side.10.Install:• Plain washer 1• Nut (wheel axle) 2NOTE:• Apply the lithium soap base grease on thewheel axle thread.• Temporarily tighten the nut (wheel axle) atthis point.11.Adjust:• Drive chain slack aaDrive chain slack:40~50 mm (1.6~2.0 in)Refer to “DRIVE CHAIN SLACK ADJUST-MENT” section in the CHAPTER 3.12.Tighten:• Nut (wheel axle) 1• Adjuster 2• Locknut 3T80 Nm (8.0 mdkg, 58 ftdlb)T2 Nm (0.2 mdkg, 1.4 ftdlb)T16 Nm (1.6 mdkg, 11 ftdlb)NOTE:• Tighten the axle nut while pushing down thedrive chain.• After tightening the axle nut, tighten the locknutwith the turned out the adjuster.13.Adjust:• Wheel alignmentRefer to “WHEEL ALIGNMENT ADJUST-MENT” section in the CHAPTER 3.5-9

FRONT BRAKE AND REAR BRAKECHASEC5A0000FRONT BRAKE AND REAR BRAKEEC5A8000FRONT BRAKET 1 Nm (0.1 mdkg, 0.7 ftdlb)T 5 Nm (0.5 mdkg, 3.6 ftdlb)T 8 Nm (0.8 mdkg, 5.8 ftdlb)T 6 Nm (0.6 mdkg, 4.3 ftdlb)T 30 Nm (3.0 mdkg, 22 ftdlb)T 14 Nm (1.4 mdkg, 10 ftdlb)T 26 Nm (2.6 mdkg, 19 ftdlb)T 18 Nm (1.8 mdkg, 13 ftdlb)T 14 Nm (1.4 mdkg, 10 ftdlb)T 26 Nm (2.6 mdkg, 19 ftdlb)T 35 Nm (3.5 mdkg, 25 ftdlb)T 6 Nm (0.6 mdkg, 4.3 ftdlb)T 35 Nm (3.5 mdkg, 25 ftdlb)Extend of removal: 1 Brake hose removal 2 Caliper removal3 Master cylinder removalExtend of removal Order Part name Q’ty RemarksFRONT BRAKE REMOVAL WPreparation forHold the machine by placingSupport the machine securely so thereremovalthe suitable stand.Cowlingis no danger of it falling over.Refer to “COWLING, INDUCTIONInduction guide (left cylinder)GUIDE, SEAT AND FUEL TANK”section in the CHAPTER 4.Drain the brake fluid.Refer to “REMOVAL POINTS”.21 Adapter 1ea.13 2 Union bolt 1 Loosen by moving the master cylindermounting position either way.3 Brake hose 1ea.24 Pad pin 1ea. Loosen when disassembling the caliper.5 Caliper 1ea.6 Brake lever 17 Reservoir tank 13 8 Reservoir hose 19 Master cylinder bracket 110 Master cylinder 15-10

FRONT BRAKE AND REAR BRAKECHASEC5A8100REAR BRAKET 7 Nm (0.7 mdkg, 5.1 ftdlb)T 8 Nm (0.8 mdkg, 5.8 ftdlb)T 14 Nm (1.4 mdkg, 10 ftdlb)T 26 Nm (2.6 mdkg, 19 ftdlb)T 30 Nm (3.0 mdkg, 22 ftdlb)T 23 Nm (2.3 mdkg, 17 ftdlb)T 2 Nm (0.2 mdkg, 1.4 ftdlb)T 12 Nm (1.2 mdkg, 8.7 ftdlb)T 18 Nm (1.8 mdkg, 13 ftdlb)T 20 Nm (2.0 mdkg, 14 ftdlb)T 6 Nm (0.6 mdkg, 4.3 ftdlb)Extend of removal: 1 Brake hose removal 2 Caliper removal3 Master cylinder removalExtend of removal Order Part name Q’ty RemarksREAR BRAKE REMOVALWPreparation forHold the machine by placingSupport the machine securely so thereremovalthe suitable stand.Drain the brake fluid.is no danger of it falling over.Refer to “REMOVAL POINTS”.1 Brake hose holder 21 22 Adapter 13 3 Union bolt 14 Brake hose 125 Pad pin 1 Loosen when disassembling the caliper.6 Caliper 17 Brake pedal connecting bolt 138 Reservoir tank 19 Reservoir hose 110 Master cylinder 15-11

FRONT BRAKE AND REAR BRAKECHASEC5A8200CALIPER DISASSEMBLYAT 6 Nm (0.6 mdkg, 4.3 ftdlb)T 18 Nm (1.8 mdkg, 13 ftdlb)BT 6 Nm (0.6 mdkg, 4.3 ftdlb)T 18 Nm (1.8 mdkg, 13 ftdlb)A FrontB RearExtend of removal: 1 Front caliper disassembly 2 Rear caliper disassemblyExtend of removal Order Part name Q’ty RemarksCALIPER DISASSEMBLY A B1 Cotter pin 1ea. 12 Pad pin 1ea. 13 Pad support 1ea. 11 2 4 Brake pad 2ea. 25 Caliper piston 4ea. 2 Refer to “REMOVAL POINTS”.6 Dust seal 4ea. 27 Piston seal 4ea. 2Refer to “REMOVAL POINTS”.5-12

FRONT BRAKE AND REAR BRAKECHASEC5A8300MASTER CYLINDER DISASSEMBLYAT 6 Nm (0.6 mdkg, 4.3 ftdlb)BT 2 Nm (0.2 mdkg, 1.4 ftdlb)A FrontB RearExtend of removal: 1 Front master cylinder disassembly 2 Rear master cylinder disassemblyExtend of removal Order Part name Q’ty Remarks1 2MASTER CYLINDER DISASSEMBLY1 Master cylinder boot 12 Circlip 13 Master cylinder kit 15-13

FRONT BRAKE AND REAR BRAKECHASEC536000HANDLING NOTEWThe brake components of this machine aresuit for closed circuit use only. Never useon any public road.EC5A3000REMOVAL POINTSEC5A3200Brake fluid1. Remove:• Reservoir tank cap 1NOTE:Do not remove the diaphragm.A FrontB Rear2. Connect the transparent hose 2 to thebleed screw 1 and place a suitable containerunder its end.A FrontB Rear3. Loosen the bleed screw and drain thebrake fluid while pulling the lever in orpushing down on the pedal.CCAUTION:• Do not reuse the drained brake fluid.• Brake fluid may erode painted surfaces orplastic parts. Always clean up spilled fluidimmediately.5-14

FRONT BRAKE AND REAR BRAKECHASEC533301Caliper piston1. Remove:• Caliper pistonUse compressed air and proceed carefully.W• Cover piston with rag and use extremecaution when expelling piston from cylinder.• Never attempt to pry out piston.Caliper piston removal steps:• Insert a piece of rag into the caliper to lockone caliper.• Carefully force the piston out of the calipercylinder with compressed air.A FrontB RearEC543411Piston seal kit1. Remove:• Dust seal 1• Piston seal 2NOTE:Remove the piston seals and dust seals bypushing them with a finger.CCAUTION:• Never attempt to pry out piston seals anddust seals.• Do not loosen the bolts 3 and nuts 4.WReplace the piston seals and dust sealswhenever a caliper is disassembled.A FrontB Rear5-15

FRONT BRAKE AND REAR BRAKECHASEC5A4000INSPECTIONEC534112Master cylinder1. Inspect:• Master cylinder inner surface aWear/Scratches ≥ Replace master cylinderassembly.Stains ≥ Clean.WUse only new brake fluid.A FrontB Rear2. Inspect:• Diaphragm 1Crack/Damage ≥ Replace.A FrontB Rear3. Inspect:• Master cylinder piston 1• Master cylinder cup 2Wear/Damage/Score marks ≥master cylinder kit.A FrontB RearReplaceEC534214Caliper1. Inspect:• Caliper cylinder inner surface aWear/Score marks ≥ Replace caliperassembly.A FrontB Rear5-16

FRONT BRAKE AND REAR BRAKECHAS2. Inspect:• Caliper piston 1Wear/Score marks ≥ Replace caliper pistonassembly.WReplace the piston seals and dust seals 2whenever a caliper is disassembled.EC534301Brake hose1. Inspect:• Brake hose 1Crack/Damage ≥ Replace.EC5A5000ASSEMBLY AND INSTALLATIONW• All internal parts should be cleaned innew brake fluid only.• Internal parts should be lubricated withbrake fluid when installed.• Replace the piston seals and dust sealswhenever a caliper is disassembled.EC535113Caliper piston1. Clean:• Caliper• Piston seal• Dust seal• Caliper pistonClean them with brake fluid.2. Install:• Piston seal 1N• Dust seal 2NWAlways use new piston seals and dustseals.NOTE:Fit the piston seals and dust seals onto theslot on caliper correctly.A FrontB Rear5-17

FRONT BRAKE AND REAR BRAKECHAS3. Install:• Caliper piston 1NOTE:Apply the brake fluid on the piston wall.CCAUTION:• Install the piston with its shallowdepressed side a facing the caliper.• Never force to insert.A FrontB RearEC535241Front caliper1. Install:• Brake pad 1• Pad support 2• Pad pin 3• Cotter pin 4NNOTE:Temporarily tighten the pad pin at this point.2. Install:• Caliper 1• Bolt (caliper) 23. Tighten:• Pad pin 3T35 Nm (3.5 mdkg, 25 ftdlb)T18 Nm (1.8 mdkg, 13 ftdlb)EC545141Rear caliper1. Install:• Brake pad 1• Pad support 2• Pad pin 3• Cotter pin 4NNOTE:Temporarily tighten the pad pin at this point.5-18

FRONT BRAKE AND REAR BRAKECHAS2. Install:• Caliper 1• Bolt (caliper) 23. Tighten:• Pad pin 3T23 Nm (2.3 mdkg, 17 ftdlb)T18 Nm (1.8 mdkg, 13 ftdlb)EC5A5230Master cylinder kit1. Clean:• Master cylinder• Master cylinder kitClean them with brake fluid.2. Install:• Master cylinder cup (primary) 1• Master cylinder cup (secondary) 2To master cylinder piston 3.NOTE:Apply the brake fluid on the master cylindercup.WAfter installing, cylinder cup should beinstalled as shown direction. Wrong installationcause improper brake performance.A FrontB Rear3. Install:• Spring 1To master cylinder piston 2.NOTE:Install the spring at the smaller dia. side.A FrontB Rear5-19

FRONT BRAKE AND REAR BRAKECHAS4. Install:• Spring guide 1• Master cylinder kit 2• Circlip 3• Master cylinder boot 4To master cylinder 5.NOTE:• Apply the brake fluid on the master cylinderkit.• Install the spring guide with the projection aaligning with the master cylinder hole b.• Apply the lithium soap base grease on the tipc of the push rod.• When installing the circlip, use a long nosecirclip pliers.A FrontB RearEC545270Rear master cylinder1. Install:• Reservoir hose 1• Reservoir tank 2• Nut (reservoir tank) 3GT7 Nm (0.7 mdkg, 5.1 ftdlb)2. Install:• Master cylinder 1• Bolt (master cylinder) 2T20 Nm (2.0 mdkg, 14 ftdlb)3. Install:• Brake pedal 1• Brake pedal connecting bolt 2• Nut (brake pedal connecting bolt) 3T12 Nm (1.2 mdkg, 8.7 ftdlb)NOTE:After installing, check the brake pedal height.Refer to “REAR BRAKE ADJUSTMENT” sectionin the CHAPTER 3.5-20

FRONT BRAKE AND REAR BRAKECHASEC5A5A00Front brake hose and master cylinder1. Install:• Copper washer 1N• Brake hose 2• Union bolt 3WAlways use new copper washers.NOTE:• Position the brake hoses with their paintmarks a downward.• Temporarily tighten the union bolt.2. Install:• Master cylinder 1• Master cylinder bracket 2• Bolt (master cylinder bracket) 3NOTE:• Install the bracket so that the arrow mark aface upward.• Temporarily tighten the bolt (master cylinderbracket).CCAUTION:• Take care not to allow the brake hosemetal fittings and union bolts to contactwith other parts. If they are installed incontact with other parts, it will result inbrake failure.• Install the brake hoses with a clearance bof 2 mm (0.008 in) provided between theirmetal fittings.• Install the brake hoses with a clearance cof 3 mm (0.012 in) between the union boltand steering damper stay and a clearanced of 3 mm (0.012 in) between the brakehose (for the left caliper) and front fork.3. Tighten:• Union bolt T30 Nm (3.0 mdkg, 22 ftdlb)• Bolt (master cylinder bracket)T8 Nm (0.8 mdkg, 5.8 ftdlb)5-21

FRONT BRAKE AND REAR BRAKECHASEC545451Rear brake hose1. Install:• Copper washer 1N• Brake hose 2• Union bolt 3 T30 Nm (3.0 mdkg, 22 ftdlb)WAlways use new copper washers.CCAUTION:When installing the brake hose to the mastercylinder, lightly touch the brake pipe awith the projection b on the master cylinder.2. Install:• Copper washer 1N• Adapter 2 T26 Nm (2.6 mdkg, 19 ftdlb)• Brake hose 3 T14 Nm (1.4 mdkg, 10 ftdlb)WAlways use a new copper washer.NOTE:When turning the adapter over the brake hose,hold the brake hose so that it may not be twisted.3. Install:• Brake hose holder 1• Bolt (brake hose holder) 2T 8Nm (0.8 mdkg,5.8 ftdlb)4. Install:• Brake hose 1Refer to “CABLE ROUTING DIAGRAM”section in the CHAPTER 2.5-23

FRONT BRAKE AND REAR BRAKECHASEC5A5610Brake fluid1. Fill:• Brake fluidUntil the fluid level reaches “LOWER” levelline a.Recommended brake fluid:DOT #40W• Use only the designated quality brakefluid: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 harmfulchemical reaction and lead to poor performance.• Be careful that water does not enter themaster cylinder when refilling. Water willsignificantly lower the boiling point of thefluid and may result in vapor lock.CCAUTION:Brake fluid may erode painted surfaces orplastic parts. Always clean up spilled fluidimmediately.A FrontB Rear2. Air bleed:• Brake systemRefer to “BRAKE SYSTEM AIR BLEED-ING” section in the CHAPTER 3.3. Inspect:• Brake fluid levelFluid at lower level ≥ Fill up.Refer to “BRAKE FLUID LEVEL INSPEC-TION” section in the CHAPTER 3.5-24

FRONT BRAKE AND REAR BRAKECHAS4. Install:• Diaphragm• Reservoir tank cap 1CCAUTION:After installation, while pulling the lever inor pushing down on the pedal, checkwhether there is any brake fluid leakingwhere the union bolts are installed respectivelyat the master cylinder and caliper.A FrontB Rear5-25

FRONT FORKCHASEC550000FRONT FORKT 20 Nm (2.0 mdkg, 14 ftdlb)T 7 Nm (0.7 mdkg, 5.1 ftdlb)T 10 Nm (1.0 mdkg, 7.2 ftdlb)T 23 Nm (2.3 mdkg, 17 ftdlb)T 8 Nm (0.8 mdkg, 5.8 ftdlb)Extend of removal:1 Front fork removalExtend of removal Order Part name Q’ty RemarksFRONT FORK REMOVALWPreparation forHold the machine by placingSupport the machine securely so thereremovalthe suitable stand.Cowlingis no danger of it falling over.Refer to “COWLING, INDUCTIONInduction guide (left cylinder)GUIDE, SEAT AND FUEL TANK”section in the CHAPTER 4.Front caliperRefer to “FRONT BRAKE ANDREAR BRAKE” section.Front wheelRefer to “FRONT WHEEL ANDREAR WHEEL” section.1 Front fender 12 Pinch bolt (steering damper stay) 1 Only loosening. (right side only)3 Pinch bolt (handlebar) 2 Only loosening.14 Pinch bolt (handle crown) 1 Only loosening.5 Cap bolt 1 Loosen when disassembling the front fork.6 Pinch bolt (under bracket) 2 Only loosening.7 Front fork 15-26

FRONT FORKCHASEC558000FRONT FORK DISASSEMBLYT 23 Nm (2.3 mdkg, 17 ftdlb)T 29 Nm (2.9 mdkg, 21 ftdlb)T 40 Nm (4.0 mdkg, 29 ftdlb)Extend of removal: 1 Oil seal removal 2 Damper rod removalExtend of removal Order Part name Q’ty RemarksFRONT FORK DISASSEMBLY1 Cap bolt 1 Use special tool.Refer to “REMOVAL POINTS”.2 Spacer 13 Spacer guide 114 Fork spring 1 Drain the fork oil.2 5 Inner tube 16 Stopper ring 17 Oil seal 1Refer to “REMOVAL POINTS”.8 Oil seal washer 19 Bolt (damper rod) 1 Use special tool.0 Damper rod 1 Refer to “REMOVAL POINTS”.5-27

FRONT FORKCHASEC556010HANDLING NOTENOTE:• With the 97 or later models, the dampar roddiameter is 12.5 mm (0.49 in). If the dimensiona of your dampar rod holders is 12 mm(0.47 in), drill it to expand its diameter to 14mm (0.55 in).• The front fork requires careful attention. So itis recommended that the front fork be maintainedat the dealers.CCAUTION:To prevent an accidental explosion of air,the following instructions should beobserved:• The front fork with a built-in piston rodhas a very sophisticated internal constructionand is particularly sensitive toforeign material.Use enough care not to allow any foreignmaterial to come in when the oil isreplaced or when the front fork is disassembledand reassembled.• Before removing the cap bolts or frontforks, be sure to extract the air from theair chamber completely.EC553000REMOVAL POINTSEC553144Cap bolt1. Remove:• Cap bolt 1From the outer tube.NOTE:Before removing the front fork from themachine, loosen the cap bolt.2. Loosen:• Spring preload adjuster 1NOTE:Record the set position of the adjuster (theamount of turning out the adjuster to the fullyturned out position) before loosening it.5-28

FRONT FORKCHAS3. Remove:• Cap bolt 1NOTE:• While pressing down the spacer 3 with thefork spring compressor 2, set the rod holder5 between the locknut 4 and spacer.• Hold the locknut and remove the cap bolt byturning the spring preload adjuster 6.Fork spring compressor:YM-1441/90890-01441Rod holder:YM-1434/90890-01434CEC553212Oil seal1. Remove:• Inner tube 1Pull out the inner tube from the outer tube2.2. Remove:• Stopper ring 1Using slotted-head screwdriver.3. Remove:• Oil seal 1• Oil seal washerUsing slotted-head screwdriver.CCAUTION:• Take care not to scratch the outer tubeinner surface.• Replace the oil seal whenever removed.5-29

FRONT FORKCHASEC553322Damper rod1. Remove:• Locknut 12. Remove:• Bolt (damper rod) 1• Damper rod 2NOTE:Use a damper rod holder 3 to lock thedamper rod.Damper rod holder:YM-1425/90890-01425AEC554000INSPECTIONEC554100Damper rod1. Inspect:• Damper rod 1Bend/Damage ≥ Replace damper rod.CCAUTION:The front fork with a built-in piston rod hasa very sophisticated internal constructionand is particularly sensitive to foreignmaterial.Use enough care not to allow any foreignmaterial to come in when the oil isreplaced or when the front fork is disassembledand reassembled.EC554400Fork spring1. Measure:• Fork spring free length aOut of specification ≥ Replace.5-30Fork spring free length:Standard]212.5 mm 210.5 mm(8.37 in) (8.29 in)

FRONT FORKCHASEC554502Inner tube1. Inspect:• Inner tube surface aScore marks ≥ Repair or replace.Use #1,000 grit wet sandpaper.Damaged oil lock piece ≥ Replace.• Inner tube bendsOut of specification ≥ Replace.Use the dial gauge 1.aInner tube bending limit:0.2 mm (0.008 in)NOTE:The bending value is shown by one half of thedial gauge reading.WDo not attempt to straighten a bent innertube as this may dangerously weaken thetube.EC554611Outer tube1. Inspect:• Outer tube 1• Piston metal 2• Slide metal 3Damage/Score marks/Wear ≥outer tube assembly.ReplaceEC554710Cap bolt1. Inspect:• Cap bolt 1• O-ring 2Wear/Damage ≥ Replace.5-31

FRONT FORKCHASEC555000ASSEMBLY AND INSTALLATIONEC555191Front fork assembly1. Wash the all parts in a clear solvent.2. Install:• Damper rod 1To inner tube 2.CCAUTION:To install the damper rod into the innertube, hold the inner tube aslant. If the innertube is held vertically, the damper rod mayfall into it, damaging the valve inside.3. Install:• Copper washer 1N• Bolt (damper rod) 2To inner tube 3.4. Tighten:• Bolt (damper rod) 1GT40 Nm (4.0 mdkg, 29 ftdlb)NOTE:Use a damper rod holder 3 to lock thedamper rod 2.ADamper rod holder:YM-1425/90890-014255. Install:• Locknut 1To damper rod 2.NOTE:Install the locknut with its width across flat afacing upward.5-32

FRONT FORKCHAS6. Install:• Stopper ring 1• Oil seal 2N• Oil seal washer 3To inner tube 4.NOTE:• Apply the fork oil on the inner tube.• When installing the oil seal, use vinyl seat awith fork oil applied to protect the oil seal lip.• Install the oil seal with its manufacture’smarks or number facing the axle holder side.7. Install:• Inner tube 1To outer tube 2.CCAUTION:When installing the inner tube, slowly andtake care to insert it carefully so that theslide metal 3 and piston metal 4 will notbe scratched.8. Install:• Oil seal washer 1To outer tube slot.9. Install:• Oil seal 1NOTE:Press the oil seal into the outer tube with forkseal driver 2.AFork seal driver:YM-1442/90890-014425-33

FRONT FORKCHAS10.Install:• Stopper ring 1NOTE:Fit the stopper ring correctly in the groove inthe outer tube.11.Check:• Inner tube smooth movementTightness/Binding/Rough spots ≥ Repeatthe steps 2 to 10.12.Compress the front fork fully.13.Fill:• Front fork oilUntil outer tube top surface with recommendedfork oil 1.0Recommended oil:Suspension oil “01”CCAUTION:• Be sure to use recommended fork oil. Ifother oils are used, they may have anexcessively adverse effect on the frontfork performance.• Never allow foreign materials to enter thefront fork.14.After filling, pump the damper rod 1 slowlyup and down more than 10 times to distributethe fork oil.NOTE:Use the rod puller 2 and rod puller attachment3 to pull up and down the damper rod.Rod puller 2:YM-1437/90890-01437Rod puller attachment 3:90890-01435C5-34

FRONT FORKCHAS15.Fill:• Front fork oilUntil outer tube top surface with recommendedfork oil once more.16.After filling, pump the outer tube 1 slowlyup and down (about 60 mm (2.4 in) stroke)to distribute the fork oil once more.NOTE:Be careful not to excessive full stroke. A strokeof 60 mm (2.4 in) or more will cause air toenter. In this case, repeat the steps 13 to 16.17.Wait ten minutes until the air bubbles havebeen removed from the front fork, and theoil has dispense evenly in system beforesetting recommended oil level.NOTE:Fill with the fork oil up to the top end of theouter tube, or the fork oil will not spread overto every part of the front forks, thus making itimpossible to obtain the correct level. Be sureto fill with the fork oil up to the top of the outertube and bleed the front forks.18.Measure:• Oil level (left and right) aOut of specification ≥ Adjust.Standard oil level:135 mm (5.31 in)Extent of adjustment:97~157 mm (3.82~6.18 in)From top of outer tube with innertube and damper rod 1 fullycompressed without spring.fWNever fail to make the oil level adjustmentbetween the maximum and minimum leveland always adjust each front fork to thesame setting. Uneven adjustment cancause poor handling and loss of stability.5-35

FRONT FORKCHAS19.Install:• Fork spring 1• Spacer guide 2• Spacer 3NOTE:Install the fork spring with its smaller dia. portionupward.20.Attach:• Rod puller 1• Rod puller attachment 2• Fork spring compressor 3• Rod holder 4NOTE:• Pull up the damper rod with the rod pullerand rod puller attachment.• While pressing down the spacer 5 with thefork spring compressor, set the rod holderbetween the locknut 6 and spacer.Rod puller 1:YM-1437/90890-01437Rod puller attachment 2:90890-01435Fork spring compressor 3:YM-1441/90890-01441Rod holder 4:YM-1434/90890-01434g21.Adjust:• Distance aOut of specification ≥ Turn the locknut 2until the specified distance is obtained.Distance a:13 mm (0.51 in)Between damper rod 1 top andlocknut 2 top.c22.Adjust:• Rebound damping adjuster position aOut of specification ≥ Turn the adjuster 1until the specified position is obtained.Rebound damping adjuster positiona:Zero mm (Zero in)b5-36

FRONT FORKCHASNOTE:Record the set position of the adjuster (theamount of turning in the adjuster to the fullyturned in position) before adjusting it.CCAUTION:If the rebound damping adjuster position isout of specification, proper damping forcecannot be obtained.23.Install:• Push rod 1• Cap bolt 2NOTE:Turn in the cap bolt fully by holding the springpreload adjuster 4 with your hand until therebound damping adjuster 3 hits the push rodtip.24.Check:• Cap bolt clearance aOut of specification ≥ Repeat the steps 21to 23.aCap bolt clearance a:Zero~2 mm (Zero~0.08 in)CCAUTION:If the cap bolt is installed out of specification,proper damping force cannot beobtained.25.Install:• Cap bolt (locknut) 1T29 Nm (2.9 mdkg, 21 ftdlb)NOTE:Hold the locknut 2 and tighten the cap bolt byturning the spring preload adjuster 3 withspecified torque.CCAUTION:Do not tighten the cap bolt. It may causedamage to the spring preload adjuster.5-37

FRONT FORKCHAS26.Install:• Cap bolt 1To outer tube.NOTE:Temporarily tighten the cap bolt.EC555290Installation1. Install:• Front fork 1• Steering damper stay 2 (right side only)• Handlebar 3NOTE:• Temporarily tighten the pinch bolt (underbracket).• Do not tighten the pinch bolts (handle crown,steering damper stay and handlebar) yet.2. Tighten:• Cap bolt 1T23 Nm (2.3 mdkg, 17 ftdlb)3. Adjust:• Front fork top end a• Handlebar position b• Steering damper stay position c (left sideonly)Front fork top end:13 mm (0.51 in)Handlebar position:9 mm (0.35 in)Steering damper stay position:73 mm (2.87 in)eRefer to “FRONT FORK TOP ENDADJUSTMENT” in the CHAPTER 3.5-38

FRONT FORKCHAS4. Tighten:• Pinch bolt (handle crown) 1T20 Nm (2.0 mdkg, 14 ftdlb)• Pinch bolt (under bracket) 2T23 Nm (2.3 mdkg, 17 ftdlb)• Pinch bolt (handlebar) 3T7 Nm (0.7 mdkg, 5.1 ftdlb)• Pinch bolt (steering damper stay) 4 (rightside only) T10 Nm (1.0 mdkg, 7.2 ftdlb)Refer to “FRONT FORK TOP ENDADJUSTMENT” in the CHAPTER 3.5. Check:• Steering smooth actionTurn the handlebar to make sure no partsare being contacted with others.Contact ≥ Repair.6. Adjust:• Rebound damping force• Spring preloadNOTE:• Turn in the rebound damping adjuster 1fully, then turn out it to the originally set position.• Turn in the spring preload adjuster 2 to theoriginally set position.7. Install:• Front fender 1• Bolt (front fender) 2T8 Nm (0.8 mdkg, 5.8 ftdlb)5-39

HANDLEBARCHASEC5B0000HANDLEBART 7 Nm (0.7 mdkg, 5.1 ftdlb)T 7 Nm (0.7 mdkg, 5.1 ftdlb)T 2 Nm (0.2 mdkg, 1.4 ftdlb)T 8 Nm (0.8 mdkg, 5.8 ftdlb)Extend of removal: 1 Handlebar removal 2 Throttle disassemblyExtend of removal Order Part name Q’ty RemarksHANDLEBAR REMOVALPreparation for Cowling Refer to “COWLING, INDUCTIONremoval Induction guide (left cylinder) GUIDE, SEAT AND FUEL TANK”section in the CHAPTER 4.Handle crownRefer to “STEERING” section.1 Clutch cable 1 Disconnect at the lever side.2 Clutch lever holder 13 Main switch 14 Grip (left) 1 Refer to “REMOVAL POINTS”.5 Starter cable 2 Disconnect at the lever side.6 Starter lever 117 Master cylinder 18 Grip cap (upper) 12 9 Throttle cable 210 Throttle 111 Grip cap (lower) 112 Grip end 213 Handlebar 2214 Grip (right) 1 Refer to “REMOVAL POINTS”.15 Tube guide 15-40

HANDLEBARCHASEC5B3000REMOVAL POINTSEC5B3200Grip1. Remove:• Grip 1NOTE:Blow in air between the handlebar or tubeguide and the grip. Then remove the gripwhich has become loose.EC5B4000INSPECTIONEC5B4100Handlebar1. Inspect:• Handlebar 1Bends/Cracks /Damage ≥ Replace.WDo not attempt to straighten a bent handlebaras this may dangerously weaken thehandlebar.EC5B5000ASSEMBLY AND INSTALLATIONEC5B5110Throttle assembly1. Install:• Ring plate 1• Grip (right) 2Apply the adhesive on the tube guide 3.NOTE:Before applying the adhesive, wipe off greaseor oil on the tube guide surface a with a lacquerthinner.EC5B5230Handlebar1. Install:• Handlebar 1• Grip end 2NOTE:Temporarily tighten the bolts (handlebar).5-41

HANDLEBARCHAS2. Install:• Throttle cable [carburetor (left cylinder)] 1• Throttle cable [carburetor (right cylinder)]2To grip cap (lower) 3.NOTE:Install the throttle cable [carburetor (left cylinder)]in the grip side slit a in the grip cap(lower).3. Install:• Throttle 1NOTE:Apply the lithium soap base grease on thethrottle grip sliding surface.4. Install:• Throttle cable [carburetor (left cylinder)] 1• Throttle cable [carburetor (right cylinder)] 2To tube guide 3.NOTE:• Apply the lithium soap base grease on thethrottle cable ends and tube guide cable widingportions.• Install the throttle cable [carburetor (left cylinder)]in the grip side slit a in the tube guide.5. Install:• Grip cap (upper) 1• Bolt (grip cap) 2NOTE:• Align the contacting surface a of the gripcap (upper) with the punch mark b on thehandlebar.• Tighten the bolts so that the upper side contactingsurface c is closed.6. Adjust:• Throttle grip free playRefer to “THROTTLE CABLE ADJUST-MENT” section in the CHAPTER 3.5-42

HANDLEBARCHAS7. Install:• Master cylinder 1• Master cylinder bracket 2• Bolt (master cylinder bracket) 3T8 Nm (0.8 mdkg, 5.8 ftdlb)NOTE:Install the bracket so that the arrow mark afaces upward.8. Install:• Starter lever 1• Screw (starter lever) 2NOTE:The starter lever should be installed accordingto the dimension shown.9. Install:• Starter cable [carburetor (left cylinder)] 1• Starter cable [carburetor (right cylinder)] 2To starter lever 3.NOTE:• Apply the lithium soap base grease on thestarter lever ends.• Install the starter cable [carburetor (left cylinder)]in the upper side slit a in the starterlever.10.Install:• Grip (left) 1Apply the adhesive to the handlebar 2.NOTE:Before applying the adhesive, wipe off greaseor oil on the handlebar surface a with a lacquerthinner.5-43

HANDLEBARCHAS11.Install:• Main switch 1• Main switch holder 2• Screw (main switch holder) 3T2 Nm (0.2 mdkg, 1.4 ftdlb)• Clutch lever holder 4• Bolt (clutch lever holder) 5T5 Nm (0.5 mdkg, 3.6 ftdlb)NOTE:The main switch and clutch lever holdershould be installed according to the dimensionsshown.12.Install:• Clutch cable 1NOTE:Apply the lithium soap base grease on theclutch cable end.13.Install:• Handle crown 1Refer to “STEERING” section.14.Adjust:• Handlebar position aaHandlebar position:9 mm (0.35 in)5-44

HANDLEBARCHAS15.Tighten:• Pinch bolt (handlebar) 1CCAUTION:T7 Nm (0.7 mdkg, 5.1 ftdlb)Tighten the pinch bolts to specified torpue.If torpue too much, it may cause the frontfork to malfunction.16.Adjust:• Clutch lever free playRefer to “CLUTCH ADJUSTMENT” sectionin the CHAPTER 3.17.Lock the throttle cables and starter cablesusing a locking wire.Refer to “LOCKING WIRE INSTALLATIONGUIDE” section in the CHAPTER 3.5-45

STEERINGCHASEC560000STEERINGEC568000HANDLE CROWN AND STEERING DAMPERT 80 Nm (8.0 mdkg, 58 ftdlb)T 5 Nm (0.5 mdkg, 3.6 ftdlb)T 20 Nm (2.0 mdkg, 14 ftdlb)T 23 Nm (2.3 mdkg, 17 ftdlb)Extend of removal: 1 Handle crown removal 2 Steering damper removalExtend of removal Order Part name Q’ty RemarksPreparation forremoval12HANDLE CROWN ANDSTEERING DAMPER REMOVALHold the machine by placingthe suitable stand.CowlingInduction guide (left cylinder)Bolt (Front brake reservoir tank)Front brake caliperFront wheelFront fender5-46Refer to “COWLING, INDUCTIONGUIDE, SEAT AND FUEL TANK”section in the CHAPTER 4.Refer to “FRONT BRAKE ANDREAR BRAKE” section.Refer to “FRONT WHEEL ANDREAR WHEEL” section.1 Steering shaft nut 12 Pinch bolt (handle crown) 2 Only loosening.3 Handle crown 14 Clip 15 Bolt (steering damper) 16 Steering damper 17 Steering damper bracket 1WSupport the machine securely so thereis no danger of it falling over.

STEERINGCHASEC568100UNDER BRACKETT 7 Nm (0.7 mdkg, 5.1 ftdlb)t TIGHTENING STEPS:• Tighten ring nut.46 Nm (4.6 mdkg, 33 ftdlb)• Loosen it one turn.• Retighten it.1 Nm (0.1 mdkg, 0.7 ftdlb)T 10 Nm (1.0 mdkg, 7.2 ftdlb)T 23 Nm (2.3 mdkg, 17 ftdlb)Extend of removal: 1 Under bracket removal 2 Bearing removalExtend of removal Order Part name Q’ty RemarksUNDER BRACKET REMOVAL1 Pinch bolt (steering damper stay) 1 Only loosening.2 Pin 13 Pinch bolt (handlebar) 4 Only loosening.4 Pinch bolt (under bracket) 4 Only loosening.15 Front fork 2 Refer to “FRONT FORK” section.26 Ring nut 1 Use special tool.Refer to “REMOVAL POINTS”.7 Under bracket 18 Inner fender 19 Ball race cover 110 Bearing (upper) 111 Bearing (lower) 1 Refer to “REMOVAL POINTS”.12 Ball race 2 Refer to “REMOVAL POINTS”.5-47

STEERINGCHASEC563000REMOVAL POINTSEC563202Ring nut1. Remove:• Ring nut 1Use the ring nut wrench 2.ARing nut wrench:YU-33975/90890-01403WSupport the steering shaft so that it maynot fall down.EC563300Bearing (lower)1. Remove:• Bearing (lower) 1Use the floor chisel 2.CCAUTION:Take care not to damage the steering shaftthread.EC563400Ball race1. Remove:• Ball race 1Remove the ball race using long rod 2 andthe hammer.EC564000INSPECTIONEC564200Steering shaft1. Inspect:• Steering shaft 1Bend/Damage ≥ Replace.5-48

STEERINGCHASEC564101Bearing and ball race1. Wash the bearings and ball races with asolvent.2. Inspect:• Bearing 1• Ball racePitting/Damage ≥ Replace bearings andball races as a set.Install the bearing in the ball races. Spinthe bearings by hand. If the bearings hangup or are not smooth in their operation inthe ball races, replace bearings and ballraces as a set.EC564300Steering damper1. Inspect:• Steering damper 1Bend/Damage ≥ Replace.Oil leaks/Unsmooth movement ≥ Replace.EC565000ASSEMBLY AND INSTALLATIONEC565190Under bracket1. Install:• Bearing (lower) 1NOTE:Apply the lithium soap base grease on thedust seal lip and bearing inner circumference.2. Install:• Inner fender 1• Screw (inner fender) 2To under bracket 3.NOTE:Install the inner fender with its brake hosethrough hole a facing to the right.3. Install:• Ball race• Bearing 1• Ball race cover 2NOTE:Apply the lithium soap base grease on thebearing.5-49

STEERINGCHAS4. Install:• Under bracket 1NOTE:Apply the lithium soap base grease on thebearing.5. Install:• Ring nut 1 T1 Nm (0.1 mdkg, 0.7 ftdlb)Tighten the ring nut using the ring nutwrench 2.Refer to “STEERING HEAD INSPECTIONAND ADJUSTMENT” section in the CHAP-TER 3.6. Check the steering shaft by turning it lockto lock. If there is any binding, remove thesteering shaft assembly and inspect thesteering bearings.7. Install:• Plain washer 18. Install:• Front fork 1• Steering damper stay 2 (right side only)• Handlebar 3• Handle crown 4NOTE:• Temporarily tighten the pinch bolts (underbracket).• Do not tighten the pinch bolts (handle crown,steering damper stay and handlebar) yet.5-50

STEERINGCHAS9. Install:• Plain washer 1• Steering shaft nut 2T80 Nm (8.0 mdkg, 58 ftdlb)NOTE:Apply the lithium soap base grease on thesteering shaft nut thread.10.After tightening the nut, check the steeringfor smooth movement. If not, adjust thesteering by loosening the ring nut little bylittle.11.Install:• Steering damper bracket 1• Pinch bolt (steering damper bracket) 2T5 Nm (0.5 mdkg, 3.6 ftdlb)To steering damper 3.NOTE:When installing the steering damper bracket,provide a distance a of 9 mm (0.35 in) fromits edge.CCAUTION:Tighten the pinch bolt to specified torque.If torqued too much, it may cause the steeringdamper to malfunction.12.Install:• Pin 1• Plain washer 2• Steering damper 3• Clip 4• Bolt (steering damper) 5T23 Nm (2.3 mdkg, 17 ftdlb)5-51

STEERINGCHAS13.Adjust:• Front fork top end a• Handlebar position b• Steering damper stay position c (right sideonly)Front fork top end:13 mm (0.51 in)Handlebar position:9 mm (0.35 in)Steering damper stay position:73 mm (2.87 in)eRefer to “FRONT FORK TOP ENDADJUSTMENT” in the CHAPTER 3.14.Tighten:• Pinch bolt (handle crown) 1T20 Nm (2.0 mdkg, 14 ftdlb)• Pinch bolt (under bracket) 2T23 Nm (2.3 mdkg, 17 ftdlb)• Pinch bolt (handlebar) 3T7 Nm (0.7 mdkg, 5.1 ftdlb)• Pinch bolt (steering damper stay) 4 (rightside only) T10 Nm (1.0 mdkg, 7.2 ftdlb)Refer to “FRONT FORK TOP ENDADJUSTMENT” in the CHAPTER 3.15.Check:• Steering smooth actionTurn the handlebar to make sure no partsare being contacted with others.Contact ≥ Repair.5-52

SWINGARMCHASEC570000SWINGARMT 10 Nm (1.0 mdkg, 7.2 ftdlb)T115 Nm (11.5 mdkg, 85 ftdlb)T 5 Nm (0.5 mdkg, 3.6 ftdlb)T 8 Nm (0.8 mdkg, 5.8 ftdlb)T 34 Nm (3.4 mdkg, 24 ftdlb)T 8 Nm (0.8 mdkg, 5.8 ftdlb)Extend of removal: 1 Swingarm removal 2 Swingarm disassemblyExtend of removal Order Part name Q’ty RemarksSWINGARM REMOVALPreparation forHold the machine by placingremovalthe suitable stand.Lower cowl and fuel tank12Exhaust pipeBrake hose holderDrive chainRear wheel5-53WSupport the machine securely so thereis no danger of it falling over.Refer to “COWLING, INDUCTIONGUIDE, SEAT AND FUEL TANK” sectionin the CHAPTER 4.Refer to “EXHAUST PIPE ANDSILENCER” section.Refer to “FRONT BRAKE ANDREAR BRAKE” section.Refer to “FRONT WHEEL ANDREAR WHEEL” section.1 Connecting rod 2 Hold the swingarm.2 Bolt (rear shock absorber 1– relay arm)3 Pivot shaft adjust bolt 1Use special tool.4 Pivot shaft 1Refer to “REMOVAL POINTS”.5 Swingarm 16 Relay arm 17 Cover 28 Thrust bearing 29 Bush 110 Bearing 5 Refer to “REMOVAL POINTS”.

SWINGARMCHASEC573000REMOVAL POINTSEC573153Swingarm1. Loosen:• Pivot shaft adjust bolt 1NOTE:Loosen the pivot shaft adjust bolt using thepivot shaft wrench 2 and pivot shaft wrenchadapter 3.Pivot shaft wrench:YM-1455/90890-01455Pivot shaft wrench adapter:YM-1476/90890-01476C2. Remove:• Pivot shaft 1• Swingarm 2EC573210Bearing1. Remove:• Bearing 1Use a general bearing puller 2.EC574010INSPECTIONWash the bearings, bushes, collars, and coversin a solvent.EC574131Swingarm1. Inspect:• Bearing 1• Bush 2Free play exists/Unsmooth revolution/Rust≥ Replace bearing and bush as a set.2. Inspect:• Bearing 1• Collar 2Free play exists/Unsmooth revolution/Rust≥ Replace bearing and collar as a set.5-54

SWINGARMCHASEC574220Relay arm1. Inspect:• Bearing 1• Collar 2Free play exists/Unsmooth revolution/Rust≥ Replace bearing and collar as a set.EC574320Connecting rod1. Inspect:• Connecting rod 1Wear/Damage ≥ Replace.EC574520Swingarm side clearance1. Measure:• Bush length a2. Measure:• Thrust bearing (right) thickness b• Thrust bearing (left) thickness c3. Measure:• Swingarm head pipe length d5-55

SWINGARMCHAS4. Calculate:• Swingarm side clearance “A + B”Out of specification ≥ Adjust side clearanceusing shim.By using formula given below.%“A + B” = a – ( b + c + d )aSide clearance “A + B”:0.05~0.35 mm (0.002~0.014 in)If the side clearance is out of specification,adjust it to specification by installing the adjustshim 1 at position, A and B.NOTE:• The adjust shim is available only in the 0.3mm (0.012 in)-thick type.• When only one shim is required, install it onthe left side, and when two shims are necessary,install them on both right and left sides.EC575000ASSEMBLY AND INSTALLATIONEC575300Bearing1. Install:• Bearing 1To swingarm.NOTE:• Apply the lithium soap base grease on thebearing when installing.• Install the bearing by pressing it on the sidehaving the manufacture’s marks or numbers.Installed depth of bearings:For head pipe a:1.0 mm (0.04 in)For connecting rod bracket b:0.5 mm (0.02 in)d5-56

SWINGARMCHAS2. Install:• Bearing 1To relay arm.NOTE:• Apply the lithium soap base grease on thebearing when installing.• Install the bearing by pressing it on the sidehaving the manufacture’s marks or numbers.aInstalled depth of bearings a:Zero mm (Zero in)EC575142Swingarm1. Install:• Collar 1To relay arm 2.NOTE:Apply the molybdenum disulfide grease on thecollars and bearings.2. Install:• Relay arm 1• Bolt (relay arm) 2• Nut (relay arm) 3T34 Nm (3.4 mdkg, 24 ftdlb)NOTE:Apply the molybdenum disulfide grease on thebolt.3. Install:• Bush 1• Thrust bearing 2• Cover 3To swingarm 4.NOTE:Apply the molybdenum disulfide grease on thebush, bearings and cover lips.5-57

SWINGARMCHAS4. Install:• Swingarm 1• Pivot shaft 2NOTE:• Apply the molybdenum disulfide grease onthe pivot shaft.• Insert the pivot shaft from left side.5. Tighten:• Pivot adjust bolt 1T5 Nm (0.5 mdkg, 3.6 ftdlb)NOTE:Use the pivot shaft wrench 2 and pivot shaftwrench adapter 3 to tighten the pivot adjustbolt.Pivot shaft wrench:YM-1455/90890-01455Pivot shaft wrench adapter:YM-1476/90890-01476C6. Install:• Plain washer 1• Nut (pivot shaft) 2T115 Nm (11.5 mdkg, 85 ftdlb)7. Check:• Swingarm side play aFree play exists ≥ Check side clearance.• Swingarm up and down movement bUnsmooth movement/Binding/Rough spots≥ Grease or replace bearings, bushesand collars.8. Install:• Bolt (rear shock absorber – relay arm) 1• Nut (rear shock absorber – relay arm) 2T34 Nm (3.4 mdkg, 24 ftdlb)NOTE:Apply the molybdenum disulfide grease on thebolt.5-58

SWINGARMCHAS9. Install:• Collar (swingarm) 1NOTE:Apply the molybdenum disulfide grease on thecollars and bearings.10.Install:• Connecting rod 1• Bolt (connecting rod) 2• Nut (connecting rod) 3T34 Nm (3.4 mdkg, 24 ftdlb)NOTE:• Install the connecting rods with the mark aoutward of the chassis.• Apply the molybdenum disulfide grease onthe bolts.5-59

REAR SHOCK ABSORBERCHASEC580000REAR SHOCK ABSORBERT 38 Nm (3.8 mdkg, 27 ftdlb)T 40 Nm (4.0 mdkg, 29 ftdlb)T 34 Nm (3.4 mdkg, 24 ftdlb)T 20 Nm (2.0 mdkg, 14 ftdlb)T 34 Nm (3.4 mdkg, 24 ftdlb)Extend of removal: 1 Rear shock absorber removal 2 Rear shock absorber disassemblyExtend of removal Order Part name Q’ty RemarksREAR SHOCK ABSORBERREMOVALPreparation forHold the machine by placingremovalthe suitable stand.Lower cowl, seat and fuel tank12Exhaust pipeWSupport the machine securely so thereis no danger of it falling over.Refer to “COWLING, INDUCTIONGUIDE SEAT AND FUEL TANK”section in the CHAPTER 4.Refer to “EXHAUST PIPE ANDSILENCER” section in theCHAPTER 4.1 Bolt (rear shock absober 1 Hold the swingarm.– relay arm)2 Cap 13 Bolt (Upper bracket) 14 Rear shock absober 1 Refer to “REMOVAL POINTS”.5 Bolt (rea shock absober 1– upper bracket)6 Upper bracket 17 Locknut 1 Loosen.8 Adjuster 1 Loosen.9 Spring guide 110 Spring (rear shock absober) 15-60

REAR SHOCK ABSORBERCHASEC586000HANDLING NOTEWThis shock absorber is provided with aseparate type tank filled with high-pressurenitrogen gas. To prevent the danger ofexplosion, read and understand the followinginformation before handling the shockabsorber.The manufacturer can not be held responsiblefor property damage or personalinjury that may result from improper handling.1. Never tamper or attempt to disassemblethe cylinder or the tank.2. Never throw the shock absorber into anopen flame or other high heat. Theshock absorber may explode as a resultof nitrogen gas expansion and/or damageto the hose.3. Be careful not to damage any part of thegas tank. A damaged gas tank willimpair the damping performance orcause a malfunction.4. Take care not to scratch the contact surfaceof the piston rod with the cylinder;or oil could leak out.5. Never attempt to remove the plug at thebottom of the nitrogen gas tank. It isvery dangerous to remove the plug.6. When scrapping the shock absorber,follow the instructions on disposal.EC587011NOTES ON DISPOSAL (YAMAHA DEALERSONLY)Before disposing of the shock absorber, besure to extract the nitrogen gas. To do so, drilla 2 or 3 mm (0.08~0.12 in) hole through thetank at a position 30 mm (1.2 in) from the bottomend of the tank. At this time, wear eye protectionto prevent eye damage from escapinggas and/or metal chips.WTo dispose of a damaged or worn-outshock absorber, take the unit to yourYamaha dealer for this disposal procedure.5-61

REAR SHOCK ABSORBERCHASEC583000REMOVAL POINTSEC583160Rear shock absorber1. Remove:• Rear shock absorber 1NOTE:Remove the rear shock absorber between therear frame and swingarm.EC583221Spring (rear shock absorber)1. Remove:•Spring guide 1•Spring 2NOTE:Remove the spring guide while compressingthe spring by using the spring compressor 3.EC584000INSPECTIONEC584130Rear shock absorber1. Inspect:• Damper rod 1Bends/Damage ≥ Replace absorberassembly.• Shock absorber 2Oil leaks ≥ Replace absorber assembly.Gas leaks ≥ Replace absorber assembly.• Spring 3Damage ≥ Replace spring.Fatigue ≥ Replace spring.Move spring up and down.• Spring guide 4Wear/Damage ≥ Replace spring guide.• Plate 5Wear/Damage ≥ Replace plate.5-62

REAR SHOCK ABSORBERCHASEC585000ASSEMBLY AND INSTALLATIONEC585143Spring (rear shock absorber)1. Install:• Plate 1• Spring 2• Spring guide 3NOTE:Install the spring guide while compressing thespring by using the spring compressor 4.2. Tighten:• Adjuster 13. Adjust:• Spring length (installed) aSpring length (installed) a:Standard length Extent of adjustment]133~142 mm137 mm (5.39 in)(5.24~5.59 in)NOTE:The length of the spring (installed) changes1.5 mm (0.06 in) per turn of the adjuster.CCAUTION:Never attempt to turn the adjuster beyondthe maximum or minimum setting.5-63

REAR SHOCK ABSORBERCHAS4. Tighten:• Locknut 1T20 Nm (2.0 mdkg, 14 ftdlb)EC5852A1Rear shock absorber1. Install:• Upper bracket 1• Bolt (rear shock absorber – upper bracket)2• Plain washer (rear shock absorber – upperbracket) 3• Nut (rear shock absorber – upper bracket) 4T34 Nm (3.4 mdkg, 24 ftdlb)NOTE:Apply the molybdenum disulfide grease on thebolt.2. Install:• Rear shock absorber3. Install:• Bolt (upper bracket) 1• Cap 2T40 Nm (4.0 mdkg, 29 ftdlb)4. Install:• Bolt (rear shock absorber – relay arm) 1• Nut (rear shock absorber – relay arm) 2T34 Nm (3.4 mdkg, 24 ftdlb)NOTE:Apply the molybdenum disulfide grease on thebolt.5-64

ELECTRICAL COMPONENTS AND WIRING DIAGRAMELECEC600000ELECTRICALEC610000ELECTRICAL COMPONENTS AND WIRING DIAGRAMEC611000ELECTRICAL COMPONENTS1 CDI unit9 Fuel pump relay2 Voltage regulator 0 Fuel pump stop switch3 Tachometer assembly ¡ Battery4 Fuse CDI magneto5 Main switch£ Spark pulg6 Ignition coil¢ Thermo unit7 Solenoid valve ∞ Servomotor8 Fuel pumpCOLOR CODEB . . . . . .BlackBr . . . . . .BrownG . . . . . .GreenGy . . . . .GrayO . . . . . .OrangeP . . . . . .PinkR . . . . . .RedY . . . . . .YellowW . . . . . .WhiteB/Br . . . .Black/BrownB/L . . . . .Black/BlueB/R . . . . .Black/RedB/W . . . .Black/WhiteG/W . . . .Green/WhiteW/B . . . .White/BlackW/G . . . .White/GreenW/L . . . .White/BlueW/R . . . .White/RedY/L . . . . .Yellow/BlueEC612000WIRING DIAGRAM66-1

IGNITION SYSTEMELECEC620000IGNITION SYSTEMEC621031INSPECTION STEPSUse the following steps for checking the possibility of the malfunctioning engine being attributableto ignition system failure and for checking the spark plug which will not spark.Check fuse.No goodReplace fuse andcheck wireharness.OK*1 Check batteryNo goodRecharge or replace.OKSpark gap testCheck entire ignitionsystem for connection.OKCheck ignition coil.No sparkCheck spark plug cap.OKCheck main switch.OKOKSparkNo goodNo goodNo goodPrimary coilSecondary coilNo goodNo good*2 Clean or replacespark plug.Replace.Repair or replace.Replace.Replace.Replace.6Check CDI magneto.OKPick-up coilSource coilNo goodNo goodReplace.Replace.Replace CDI unit.*1 marked : Refer to “BATTERY INSPECTION” section in the CHAPTER 3.*2 marked : Only when the ignition checker is used.NOTE:• Remove the following parts before inspection.1) Cowling 3) Seat2) Fuel tank• Use the following special tools in this inspection.Dynamic spark tester:YM-34487Ignition checker:90890-06754CAPocket tester:YU-3112-C/90890-031126-2

IGNITION SYSTEMELECEC629000FUSE INSPECTION1. Remove:• Fuse 12. Check:• Fuse conductUse pocket tester (tester selector positionΩ X 1).Not continuous ≥ Replace fuse and checkthat the wireharness is not shorted.EC622020SPARK GAP TEST1. Disconnect the fuel pump coupler to preventthe fuel pump operating.2. Disconnect the spark plug cap from sparkplug.3. Connect the dynamic spark tester 1 (ignitionchecker 2) as shown.• Spark plug cap 3• Spark plug 4A For USA and CDNB Except for USA and CDN4. Start the engine and increase the sparkgap until misfire occurs. (for USA and CDN)5. Move the main switch to “RUN” and rotatethe rear wheel with gear in 3rd and checkthe spark gap. (except for USA and CDN)aMinimum spark gap:5.0 mm(0.20 in)EC623001SPARK PLUG CAP INSPECTION1. Remove:• Spark plug capCCAUTION:Do not pull the spark plug lead out of thespark plug cap. Turn the spark plug capcounterclockwise to remove it and clockwiseto install it.2. Check:• Spark plug cap resistanceOut of specification ≥ Replace.Spark plug cap Tester selectorresistance position4~6 kΩ atkΩ X 120˚C (68˚F)?6-3

IGNITION SYSTEMELECEC624000COUPLERS AND LEADS CONNECTIONINSPECTION1. Check:• Couplers and leads connectionRust/ Dust/ Looseness/Short-circuit ≥Repair or replace.EC62A000MAIN SWITCH INSPECTION1. Inspect:• Main switch conduct%Tester (+) lead ≥ Red lead 1Tester (-) lead ≥ Brown lead 2R Br Tester selector1 2 positionRUNΩ X 1OFFuContinuous while the main switch is moved to“OFF” ≥ Replace.Not continuous while the main switch is movedto “RUN” ≥ Replace.EC626002IGNITION COIL INSPECTION1. Inspect:• Primary coil resistanceOut of specification ≥ Replace.%Tester (+) lead ≥ Orange (Gray) lead 1Tester (–) lead ≥ Black lead 2Primary coil Tester selectorresistance position0.14~0.18 Ω atΩ X 120˚C (68˚F)?6-4

IGNITION SYSTEMELEC2. Inspect:• Secondary coil resistanceOut of specification ≥ Replace.%Tester (+) lead ≥ Spark plug lead 1Tester (–) lead ≥ Orange (Gray) lead 2Secondary coil Tester selectorresistance position5.0~7.4 kΩ atkΩ X 120˚C (68˚F)?NOTE:When inspecting the secondary coil resistance,remove the spark plug cap.EC627031CDI MAGNETO INSPECTION1. Inspect:• Pick-up coil resistance (left cylinder)Out of specification ≥ Replace.%Tester (+) lead ≥ White/Blue lead 1Tester (-) lead ≥ White/Black lead 2Pick-up coil Tester selectorresistance position94~140 Ω atΩ X 10020˚C (68˚F)?2. Inspect:• Pick-up coil resistance (right cylinder)Out of specification ≥ Replace.%Tester (+) lead ≥ White/Green lead 1Tester (-) lead ≥ White/Black lead 2Pick-up coil Tester selectorresistance position94~140 Ω atΩ X 10020˚C (68˚F)?6-5

IGNITION SYSTEMELEC3. Inspect:• Source coil resistanceOut of specification ≥ Replace.%Tester (+) lead ≥ White lead 1Tester (-) lead ≥ White lead 2Source coil Tester selectorresistance position2.3~3.5 Ω atΩ X 120˚C (68˚F)?EC628000CDI UNIT INSPECTIONCheck all electrical components. If no fault isfound, replace the CDI unit. Then check theelectrical components again.6-6

CHARGING SYSTEMELECEC680000CHARGING SYSTEMEC681001INSPECTION STEPSIf the battery is not charged, use the following inspection steps.*1 Check fuse.No goodReplace fuse andcheck wireharness.OK*2 Check batteryNo goodRecharge or replace.OKCheck each coupler andwire connection.OKCheck charging voltage.No good*1 Check CDI magneto.OKCheck voltage regulator.*1 marked : Refer to “IGNITION SYSTEM” section.*2 marked : Refer to “BATTERY INSPECTION” section in the CHAPTER 3.NOTE:• Remove the following parts before inspection.1) Cowling2) Fuel tank• Use the following special tool in this inspection.APocket tester:YU-3112-C/90890-03112No goodOKSource coilNo goodNo goodRepair or replace.Charging system isgood.Replace.Replace.6-7

CHARGING SYSTEMELECEC624000COUPLERS AND LEADS CONNECTIONINSPECTION1. Check:• Couplers and leads connectionRust/ Dust/ Looseness/Short-circuit ≥Repair or replace.EC682000CHARGING VOLTAGE INSPECTION1. Start the engine.2. Inspect:• Charging voltageOut of specification ≥ If no failure is foundin checking the source coil resistance,check the voltage regulator.%Tester (+) lead ≥ Red lead 1Tester (-) lead ≥ Black lead 2Charging Tester selectorvoltageposition14.2~15.2 VDCV-20at 5,000 r/min?EC683000VOLTAGE REGULATOR INSPECTION1. Check:• Voltage regulator conductUse pocket tester (tester selection positionΩ X 1).Tester (+)leadTester(-) leadW1 W2 R B1 2 3 4W1 1 X D XW2 2 X D XR 3 X X XB 4 D D D“D” indicates continuity and “X” non-continuity.In case of continuity for “X” ≥ Replace.In case of non-continuity for “D” ≥ Replace.6-8

CHARGING SYSTEMELECNOTE:If nothing is wrong with the continuity of thevoltage regulator and with all the others in thecharging system, replace the voltage regulator.6-9

YPVS SYSTEMELECEC640000YPVS SYSTEMEC641021INSPECTION STEPSIf the servomotor will not turn, use the following inspection steps.*1 Check fuse.No goodReplace fuse andcheck wireharness.OK*2 Check batteryNo goodRecharge or replace.OKCheck each coupler andwire connection.*1 marked : Refer to “IGNITION SYSTEM” section.*2 marked : Refer to “BATTERY INSPECTION” section in the CHAPTER 3.NOTE:• Remove the following parts before inspection.1) Cowling2) Fuel tank• Use 12V battery in this inspection.• Use the following special tool in this inspection.APocket tester:YU-3112-C/90890-03112No goodRepair or replace.OK*1 Check main switch.No goodReplace.OKCheck servomotoroperation.No goodCheck servomotor.OKReplace CDI unit.No goodReplace.6-10

YPVS SYSTEMELECEC624000COUPLERS AND LEADS CONNECTIONINSPECTION1. Check:• Couplers and leads connectionRust/ Dust/ Looseness/Short-circuit ≥Repair or replace.EC642020SERVOMOTOR OPERATION1. Disconnect the fuel pump coupler to preventthe fuel pump operating.2. Inspect:• Servomotor 1Operative when the main switch is movedto “RUN” ≥ OKEC643001SERVOMOTOR INSPECTION1. Disconnect the YPVS cable from the servomotor.2. Disconnect the servomotor lead.3. Connect 12V battery to the servomotorlead.%Battery (+) lead ≥ Black/Red lead 1Battery (-) lead ≥ Black/Brown lead 24. Inspect:• Servomotor 1Not operate ≥ Replace servomotor.6-11

SOLENOID VALVE SYSTEMELECEC650001SOLENOID VALVE SYSTEMEC651021INSPECTION STEPSIf the solenoid valve will not operate, use the following inspection steps.*1 Check fuse.No goodReplace fuse andcheck wireharness.OK*2 Check batteryNo goodRecharge or replace.OKCheck each coupler andwire connection.No good*1 marked : Refer to “IGNITION SYSTEM” section.*2 marked : Refer to “BATTERY INSPECTION” section in the CHAPTER 3.NOTE:• Remove the following parts before inspection.1) Cowling 4) Induction guide (right cylinder)2) Fuel tank 5) Seat3) Induction cap (left cylinder)• Use l2V battery in this inspection.• Use the following special tools in this inspection.APocket tester:YU-3112-C/90890-03112Repair or replace.OK*1 Check main switch.No goodReplace.OKCheck solenoid valveoperation.No goodCheck solenoid valve coil.OKReplace CDI unit.No goodReplace.6-12

SOLENOID VALVE SYSTEMELECEC624000COUPLERS AND LEADS CONNECTIONINSPECTION1. Check:• Couplers and leads connectionRust/ Dust/ Looseness/Short-circuit ≥Repair or replace.EC652020SOLENOID VALVE OPERATION1. Disconnect the fuel pump and servomotorcoupler to prevent the fuel pump and servomotoroperating.2. Inspect:• Solenoid valve 1Click when the main switch is moved to“RUN” ≥ OKNOTE:Before checking the solenoid valve, disconnectthe other solenoid valve lead.EC653002SOLENOID VALVE COIL INSPECTION1. Inspect:• Solenoid valve coil resistanceOut of specification ≥ Replace.%Tester (+) lead ≥ Yellow lead 1Tester (–) lead ≥ White lead 2Solenoid Tester selectorresistance position52.0~63.6 Ω atΩ X 1020˚C (68˚F)?6-13

THERMO UNIT SYSTEMELECEC6A0000THERMO UNIT SYSTEMEC6A1011INSPECTION STEPSIf the water temperature gauge (thermo unit) will not operate, use the following inspection steps.*1 Check fuse.No goodReplace fuse andcheck wireharness.OK*2 Check batteryNo goodRecharge or replace.OKCheck each coupler andwire connection.*1 marked : Refer to “IGNITION SYSTEM” section.*2 marked : Refer to “BATTERY INSPECTION” section in the CHAPTER 3.NOTE:• Remove the following parts before inspection.1) Cowling• Use the following special tools in this inspection.APocket tester:YU-3112-C/90890-03112No goodRepair or replace.OK*1 Check main switch.No goodReplace.OKCheck thermo unit.OKReplace tachometer assembly.No goodReplace.6-14

THERMO UNIT SYSTEMELECEC624000COUPLERS AND LEADS CONNECTIONINSPECTION1. Check:• Couplers and leads connectionRust/ Dust/ Looseness/Short-circuit ≥Repair or replace.EC6A2000THERMO UNIT INSPECTION1. Drain the cooling water.2. Remove:• Thermo unit 13. Immerse the thermo unit with a tester leadconnected in a container containing cooling(tap) water 1 down to the upper threadedportion a.2 Water temperature gauge3 Poket tester4. Inspect:• Thermo unit resistanceMeasure the resistance while graduallyheating the cooling water.Out of specification ≥ Replace .Cooling Thermo Testerwater unit selectortemperature resistance position50˚C (122˚F) 9.72~11.4 kΩ80˚C (176˚F) 3.41~4.01 kΩ kΩ X 1NOTE:Do not allow the thermo unit to contact thetest container bottom.6-15

FUEL PUMP SYSTEMELECEC670000FUEL PUMP SYSTEMEC671001INSPECTION STEPSIf the fuel pump will not operate, use the following inspection steps.*1 Check fuse.No goodReplace fuse andcheck wireharness.OK*2 Check batteryNo goodRecharge or replace.OKCheck each coupler andwire connection.No good*1 marked : Refer to “IGNITION SYSTEM” section.*2 marked : Refer to “BATTERY INSPECTION” section in the CHAPTER 3.NOTE:• Remove the following parts before inspection.1) Cowling 3) Seat2) Fuel tank 4) Induction cap (left cylinder)• Use 12V battery in this inspection.• Use the following special tool in this inspection.APocket tester:YU-3112-C/90890-03112Repair or replace.OK*1 Check main switch.No goodReplace.OKCheck fuel pump stopswitch.OKCheck fuel pump relay.OKCheck fuel pump operation.No goodNo goodNo goodFuel pump coilOKCheck fuel pump.No goodNo goodReplace.Replace.Replace.Replace.6-16

FUEL PUMP SYSTEMELECEC624000COUPLERS AND LEADS CONNECTIONINSPECTION1. Check:• Couplers and leads connectionRust/ Dust/ Looseness/Short-circuit ≥Repair or replace.EC672000FUEL PUMP STOP SWITCH INSPECTION1. Remove:• Fuel pump stop switch 12. Inspect:• Fuel pump stop switch conductTo inspect, tilt the fuel pump stop switch tothe right and left.%Tester (+) lead ≥ Black lead 1Tester (-) lead ≥ Black lead 2B B Tester selector1 2 positionTilted 90˚Ω X 1NormaluContinuous if normal ≥ Replace.Not continuous if tilted 90˚ ≥ Replace.EC673000FUEL PUMP RELAY INSPECTION1. Remove:• Fuel pump relay 16-17

FUEL PUMP SYSTEMELEC2. Inspect:• Fuel pump relay conductUse 12V battery.Battery (+) lead ≥ Black lead 1Battery (-) lead ≥ Green lead 2Tester (+) lead ≥ Black/Blue lead 3Tester (-) lead ≥ Brown lead 4&B/L Br Tester selector3 4 positionConnectedto batteryNot Ω X 1connectedto batteryvContinuous while connected to the battery ≥Replace.Not continuous while not connected to the battery≥ Replace.3. Inspect:• Fuel pump relay resistanceOut of specification ≥ Replace.%Tester (+) lead ≥ Green lead 1Tester (-) lead ≥ Black lead 2Fuel pump relay Tester selectorresistance position72~80 Ω atΩ X 1020˚C (68˚F)?EC674000FUEL PUMP OPERATIONCCAUTION:Do not operate the fuel pump on an emptyfuel tank because it may damage thepump.1. Loosen the drain plug (carburetor) anddrain the fuel from the float chamber.6-18

FUEL PUMP SYSTEMELEC2. Install:• Drain plug3. Turn the fuel cock to “ON”.4. Inspect:• Fuel pump 1Operation sound when the main switch ismoved to “RUN” ≥ OKEC675000FUEL PUMP COIL INSPECTION1. Disconnect the fuel pump coupler.2. Inspect:• Fuel pump coil resistanceOut of specification ≥ Replace.%Tester (+) lead ≥ Black/Blue lead 1Tester (-) lead ≥ Black lead 2Fuel pump coil Tester selectorresistance position1~3 Ω atΩ X 120˚C (68˚F)?EC676000FUEL PUMP INSPECTIONCCAUTION:Do not operate the fuel pump on an emptyfuel tank because it may damage thepump.1. Remove the fuel outlet hose from the fuelpump.2. Connect another plastic hose 1 to the fuelpump and place its other end into a container.6-19

FUEL PUMP SYSTEMELEC3. Turn the fuel cock to “ON”.4. Disconnect the fuel pump coupler.5. Connect 12V battery to the fuel pump coupler.%Battery (+) lead ≥ Black/Blue lead 1Battery (-) lead ≥ Black lead 26. Inspect:• Fuel pump 1No fuel flows from the plastic hose 2 ≥Replace.6-20

SETTINGTUNEC700000TUNINGEC710000ENGINEEC711011Carburetor setting• The role of fuel is not only to produce motivepower but also to cool the engine and, in thecase of a 2-stroke engine, to lubricate it.Therefore, too lean a mixture (of air and fuel)tends to cause an abnormal combustion (i.e.,detonation), whereas too rich a mixturemakes it difficult for the engine to develop itsfull performance, with the result that in somecases the spark plug may be fouled, causingthe engine to stop running.• The richness of the air-fuel mixture requiredfor the engine will vary with atmospheric conditionsof the day and therefore, the settingsof the carburetor must be properly suited tothe atmospheric conditions (air pressure,humidity and temperature).• As a basic setting method, only the factoryset main jet is first changed to check for thediscoloration of the spark plug(s) and piston(s)at full throttle in 6th and then the settingis determined at mid-open throttle.$ Recording and storing the data on the settings,weather conditions, road surface conditionsof the circuit, lap times, etc. willenable quick setting under different conditionsat a later time.EC712000Atmospheric conditions and carburetorsettingAirAir temp. Humidity pressure Mixture Setting(altitude)HighLowHighLowLow(high)High(low)RicherLeanerLeanerRicher7The reason for the above tendency is that therichness or leanness of a fuel mixturedepends on the density of the air (i.e. the concentrationof oxygen in it).7-1

SETTINGTUNThat is:• Higher temperature expands the air with itsresultant reduced density.• Higher humidity reduces the amount of oxygenin the air by so much of the water vaporin the same air.• Lower atmospheric pressure (at a high altitude)reduces the density of the air.EC714000Effects of setting parts in relation to throttlevalve opening1 Throttle valve opening2 Full-open3 Full-closed7EC71E003Basic process of carburetor settingEx-factory setting is on the richer side, whichshould basically have no problems with thebrake-in procedure.Refer to “STARTING AND BREAK-IN” sectionin the CHAPTER 1.1. Adjustment of main jetUse a main jet 1 with a smaller calibrationnumber if the engine does not developmore than 12,000 rpm after a few laps ofthe circuit when the water temperaturebecomes stable [55°C (131°F) or more].Example:#560 ≥ #5407-2

SETTINGTUNNext run a few laps of the circuit with thissetting and check for any difference inengine revolutions. If no difference isnoticed, use a main jet with a much smallercalibration number.Example: #540 ≥ #500ABCwFactory-set main jet #5602. Checking of spark plug and piston for discolorationRepeat the adjustment in the above “1”several times. If the engine begins to run atmore than 12,000 rpm at full throttle, proceedto the “spark plug chopping” step(refer to P7-9) to check for the discolorationof the spark plug(s) and piston(s).Refer to the photo for judgment on the discoloration.As a novice will find it difficult to determinehow much smaller number main jet can beused just by looking at discoloration, heshould consult an experienced person forhis own experience, too.Whether the setting is proper or not can bejudged by engine revolutions.Approximate criteria for such judgment aregiven below, on condition that the secondaryreduction ratio is fit for conditions ofthe circuit.•13,000 rpm in 1st and 2nd•12,500 rpm in 5th and 6thA NormalB Over burned (too lean)C Oil fouled (too rich)3. Adjustment of main nozzleThe main nozzle 1 adjustment follows thecompletion of the adjustment of the mainjet. Check that engine revolutions smoothlyrespond to throttle opening from wherethrottle is about to be opened to 1/2 throttleopening. Use a main nozzle of a smallersize if engine revolutions appear to falter atthe beginning of throttle opening and thensuddenly respond to further throttle opening.Example:S-4 ≥ S-37-3

SETTINGTUNIf the main jet is fully adjusted with notmuch allowance for discoloration, use amain jet which is approximately #20 lager.Run a few laps of the circuit to check theengine for response to revolutions. Alsocheck for the discoloration of the sparkplug(s) and piston(s).Use a main jet of a smaller size if goodresponse to engine revolutions is achievedwith an allowance for the discoloration ofthe spark plug(s) and piston(s).On the other hand, if the use of a differentmain nozzle appears to produce lesspower, change to a main nozzle of a largersize.Example:S-1 ≥ S-2wFactory-set main nozzle S-4NOTE:Difference between individual riders or differencebetween circuit layouts greatly affect themain nozzle setting.1. Rider who frequently uses mid-open throttle2. Circuit that requires frequent throttle openingand closing3. Wet environmentConditions as mentioned above require alonger period of throttle closing, resulting inthe drawn in mixture staying longer in thecrankcase. Such setting in turn will inevitablycause the mixture to be richer at the nextthrottle opening, a main nozzle of a smallersize has to be used.7-4

SETTINGTUNEC71F002Carburetor settings by correction coefficientNow you should be able to understand theessentials of basic carburetor setting from anexplanation given under “Basic process of carburetorsetting” (P7-2).Next is an explanation of how to select a mainjet to deal with changes in weather conditionsby means of a correction coefficient.NOTE:• Before this correction coefficient can beused, satisfactory carburetor setting musthave been made.• This correction coefficient can not be used ifthere is a change in specification (e.g., ignitiontiming, compression ratio, etc.).Illustration:Suppose the best setting was represented bya #450 main jet at an air pressure of 1013 hPa(760 mmHg) and an air temperature of 20°C(68°F) in the previous riding.In this riding, there has been a substantialchange in conditions; namely, an air pressureof 1007 hPa (755 mmHg) and an air temperatureof 30°C (86°F).1. Refer to a table of correction coefficients(P7-6) to find the correction coefficient forthe previous riding.The correction coefficient A=100.02. Find the correction coefficient for this time.The correction coefficient B=96.13. Use the following equation to calculate thesize of a main jet needed in this particularcase.%Previous main jet size X B/A= Currently required main jet size450 X 96.1/100 = 432.5Thus, a #430 main jet can be selected.7-5

SETTINGTUNCCAUTION:If a change in conditions require a main jetof a larger size, use the size to which #20 isadded for safety.NOTE:• Since this correction coefficient table lacks acolumn for humidity, it is advisable to checkthe degree of discoloration of the sparkplug(s) for final selection according to anexplanation under “Atmospheric conditionsand carburetor setting’’ (P7-1).• As the main nozzle is more susceptible toother than atmospheric conditions, no correctioncoefficient is used for main nozzle setting.EC71G002Table of correction coefficients for carburetor settingAirAir temperature °C (°F)AltitudepressurehPa (mmHg) -5 (23) Zero (32) 5 (41) 10 (50) 15 (59) 20 (68) 25 (77) 30 (86) 35 (95) 40(104) m (ft)1040 (780) 112.2 110.2 108.2 106.3 104.4 102.6 100.9 99.3 97.7 96.1 -220 (-722)1033 (775) 111.5 109.4 107.5 105.6 103.7 102.0 100.3 98.6 97.0 95.5 -165 (-541)1027 (770) 110.8 108.7 106.8 104.9 103.1 101.3 99.6 98.0 96.4 94.8 -110 (-361)1020 (765) 110.0 108.0 106.1 104.2 102.4 100.7 99.0 97.3 95.8 94.2 -55 (-180)1013 (760) 109.3 107.3 105.4 103.5 101.7 100.0 98.3 96.7 95.1 93.6 Zero (Zero)1007 (755) 108.6 106.6 104.7 102.9 101.1 99.3 97.7 96.1 94.5 93.0 56 (184)1000 (750) 107.9 105.9 104.0 102.2 100.4 98.7 97.0 95.4 93.9 92.4 112 (367)993 (745) 107.2 105.2 103.3 101.5 99.7 98.0 96.4 94.8 93.3 91.8 168 (551)987 (740) 106.5 104.5 102.6 100.8 99.1 97.4 95.7 94.2 92.6 91.1 224 (735)980 (735) 105.7 103.8 101.9 100.1 98.4 96.7 95.1 93.5 92.0 90.5 281 (922)973 (730) 105.0 103.1 101.2 99.4 97.7 96.1 94.4 92.9 91.4 89.9 338 (1,109)967 (725) 104.3 102.4 100.5 98.8 97.1 95.4 93.8 92.2 90.7 89.3 396 (1,299)960 (720) 103.6 101.7 99.8 98.1 96.4 94.7 93.1 91.6 90.1 88.7 453 (1,486)953 (715) 102.9 101.0 99.2 97.4 95.7 94.1 92.5 91.0 89.5 88.1 512 (1,680)947 (710) 102.1 100.3 98.5 96.7 95.0 93.4 91.9 90.3 88.9 87.5 570 (1,870)940 (705) 101.4 99.6 97.8 96.0 94.4 92.8 91.2 89.7 88.2 86.8 629 (2,064)933 (700) 100.7 98.9 97.1 95.4 93.7 92.1 90.6 89.1 87.6 86.2 688 (2,257)927 (695) 100.0 98.1 96.4 94.7 93.0 91.4 89.9 88.4 87.0 85.6 747 (2,451)920 (690) 99.3 97.4 95.7 94.0 92.4 90.8 89.3 87.8 86.4 85.0 807 (2,648)913 (685) 98.5 96.7 95.0 93.3 91.7 90.1 88.6 87.2 85.7 84.4 867 (2,845)907 (680) 97.8 96.0 94.3 92.6 91.0 89.5 88.0 86.5 85.1 83.8 928 (3,045)900 (675) 97.1 95.3 93.6 92.0 90.4 88.8 87.3 85.9 84.5 83.1 989 (3,245)893 (670) 96.4 94.6 92.9 91.3 89.7 88.2 86.7 85.2 83.9 82.5 1,050 (3,445)887 (665) 95.7 93.9 92.2 90.6 89.0 87.5 86.0 84.6 83.2 81.9 1,111 (3,645)880 (660) 94.9 93.2 91.5 89.9 88.3 86.8 85.4 84.0 82.6 81.3 1,173 (3,848)873 (655) 94.2 92.5 90.8 89.2 87.7 86.2 84.7 83.2 82.0 80.7 1,236 (4,055)867 (650) 93.5 91.8 90.1 88.5 87.0 85.5 84.1 82.7 81.4 80.1 1,299 (4,262)860 (645) 92.8 91.1 89.4 87.9 86.3 84.9 83.4 82.1 80.7 79.4 1,362 (4,469)853 (640) 92.1 90.4 88.8 87.2 85.7 84.2 82.8 81.4 80.1 78.8 1,425 (4,675)847 (635) 91.3 89.7 88.1 86.5 85.0 83.6 82.2 80.8 79.5 78.2 1,489 (4,885)840 (630) 90.6 89.0 87.4 85.8 84.3 82.9 81.5 80.2 78.9 77.6 1,554 (5,099)7-6

SETTINGTUNEC71H040Other setting parts1. Power jet 1Power jet is not basically changed. Sincethe areas of the main jet and main nozzleoverlap each other, special knowledge isrequired for a setting change.A larger size results in a richer mixture anda smaller size in a leaner mixture.wFactory-set power jet #552. Pilot jet 1The pilot jet is used in relation to theengine response at small throttle opening.This is changed when the main nozzle settingis not enough.A larger size results in a richer mixture anda smaller size in a leaner mixture.wFactory-set pilot jet #403. Pilot air screw 1The pilot air screw relates to the engineresponse at a smaller opening than for thepilot jet.This setting may be changed for want oftime or in emergency, but it is basically setat the factory-set pilot air screw position.Factory-set pilot air1-1/2 turns outscrew positionw4. Spark plugThe spark plug heat range is not basicallychanged.Constant attention to the discoloration ofthe spark plug and piston head will enableyou to tell to some extent whether the settingis good or bad.wStandard spark plug R6179A-105P/NGKNOTE:For the effects each setting part has, refer to“Effects of setting parts in relation to throttlevalve opening” (P7-2).7-7

SETTINGTUNEC71Q021Carburetor setting partsPart name Size Part numberMain jet 1 Lean #350 137-14143-70#360 137-14143-72#370 137-14143-74#380 137-14143-76#390 137-14143-78#400 137-14143-80#410 137-14143-82#420 137-14143-84#430 137-14143-86#440 137-14143-88#450 137-14143-90#460 137-14143-92#470 137-14143-94#480 137-14143-96#490 137-14143-98#500 137-1414K-00#540 137-1414K-08* Rich #560 137-1414K-12Pilot jet 2 Lean #25 4KM-14142-25#30 4KM-14142-30#35 4KM-14142-35* Rich #40 4KM-14142-40Main nozzle Lean R-7 5KE-14141-R73 R-8 5KE-14141-R8R-9 5KE-14141-R9S-0 5KE-14141-S0S-1 5KE-14141-S1S-2 5KE-14141-S2S-3 5KE-14141-S3* Rich S-4 5KE-14141-S4Jet needle 4 * 6DGJ1-63 275-14116-R0Power jet 5 Lean #50 830-14231-10* Rich #55 830-14231-11* Factory installedNOTE:Use a #500 main jet when selecting a nextsmaller size jet than a #540.7-8

SETTINGTUNEC71J010Plug chopWhen checking the discoloration of the sparkplug and piston head, move the main switch to“OFF” while running along a straight lane atfull throttle, disengage the clutch at the sametime and stop the engine. Then let yourmachine go back to the pit by inertia. This iscalled a “plug chop”.CCAUTION:• When you do a “plug chop”, pay attentionto your surrounding environment to avoidinterference with other riders.• Do not shift down while riding yourmachine by inertia (as it may cause aseizure of the clutch push rod and ball).EC71K010Setting of cylinder gasketThe use of the supplied gaskets of differentthicknesses makes it possible to change thecombustion chamber volume.Not much torque is felt with slow engine acceleration≥ Reduce the combustion chambervolume.Torque is felt with no higher revolutions ≥Expand the combustion chamber volume.ThicknessActual combustionchamber volumeType0.6 mm Approx. 9.66 cm 3(0.024 in) (0.340 lmp oz, 0.327 US oz)STD0.5 mm Approx. 9.43 cm 3(0.020 in) (0.332 lmp oz, 0.319 US oz)0.38 mm Approx. 9.20 cm 3(0.015 in) (0.324 lmp oz, 0.311 US oz) Supplying0.3 mm Approx. 8.98 cm 3 parts(0.012 in) (0.316 lmp oz, 0.304 US oz)0.2 mm Approx. 8.75 cm 3(0.008 in) (0.308 lmp oz, 0.296 US oz)7-9

SETTINGTUNNOTE:• Finish the break-in before changing the gasket.• A change of 0.1 mm (0.004 in) for the gasketcauses a change of approximately 0.23 cm 3(0.008 lmp oz, 0.008 US oz) of the combustionchamber volume.• After break-in, change to an appropriate gasketto allow the piston protrusion to be -0.15mm (-0.006 in) to 0.05 mm (0.002 in).CCAUTION:• Piston protruding amount must be a maximum0.15 mm (0.006 in). Above this value,the piston and cylinder head may contacteach other.• Too much random piston protrusion atlow temperature may develop an abnormalcombustion (detonation), which mayadversely affect the intended performanceof the engine.A Air temperatureB Piston protruding amountEC71T000Cylinder gasket setting partsPart number Size (thickness)5KE-11351-60 * t=0.6 mm (0.024 in)5KE-11351-50 t=0.5 mm (0.020 in)5KE-11351-40 t=0.38 mm (0.015 in)5KE-11351-30 t=0.3 mm (0.012 in)5KE-11351-20 t=0.2 mm (0.008 in)* Factory installedEC71L003Measuring piston protrusion1. Install the dial gauge 1 and dial gaugestand 2 to the cylinder contact surface andset the scale of the dial gauge to zero.Dial gauge and stand:YU-3097/90890-01252Offset dial stand:YU-1037C7-10

SETTINGTUN2. Loosen the stand installation bolt 1, thenrotate the dial gauge stand and set it closeto the center of the piston. Tighten thestand installation bolt again.NOTE:Do not loosen the dial gauge installation bolt2 while doing the above.3. Set the piston at top dead center (TDC),then measure the piston protrusion.NOTE:For measurement, avoid the top center projectedarea a on the piston head but measureseveral positions above the piston pin as closeto the center as possible. The average ofthese measurements indicates the piston protrusion.EC71N001Selection of transmission gear ratioThe following gear sets are contained in thepacking (or optional) to allow the rider tochange the gear ratios according to the circuitcondition or rider’s preference.CCAUTION:Select the transmission gears so that thenumber of grooves in the wheel gearmatch that of the pinion gear as shownbelow. Trouble may be occurred if theselection is different than that listed below.a Groove1st gearGear ratioPart numberNumber ofgrooveFactory installed 34/18 (1.889) 5KE-17211-20/5KE-17411-20 2Supplying part 28/14 (2.000) 5KE-17211-10/5KE-17411-10 12nd gearGear ratioPart numberNumber ofgrooveFactory installed 31/21 (1.476) 4DP-17221-11/4DP-17121-11 1Optional part 27/19 (1.421) 5F7-17221-21/5F7-17121-21 2Optional part 28/18 (1.556) 5F7-17221-00/5F7-17121-00 –7-11

SETTINGTUN3rd gearGear ratioPart numberNumber ofgrooveFactory installed 29/23 (1.261) 5KE-17231-00/5KE-17131-00 –Optional part/Supplying part25/21 (1.190) 5KE-17231-20/5KE-17131-10 2/1Supplying part 26/21 (1.238) 5KE-17231-10/5KE-17131-10 16th gearGear ratioPart numberNumber ofgrooveFactory installed 20/22 (0.909) 5KE-17261-00/5KE-17191-00 1Supplying part 22/25 (0.880) 5KE-17261-10/5KE-17161-10 27-12

SETTINGTUNEC71U011Transmission setting partsPart name Size Part numberMain axle 1 14T 5KE-17411-10* 18T 5KE-17411-202nd pinion gear 2 ∆ 18T 5F7-17121-00∆ 19T 5F7-17121-21* 21T 4DP-17121-113rd/4th pinion 21T/25T 5KE-17131-10gear 3 * 23T/25T 5KE-17131-005th pinion gear 4 * 27T 5F7-17151-016th pinion gear 5 * 22T 5KE-17161-0025T 5KE-17161-101st wheel gear 6 28T 5KE-17211-10* 34T 5KE-17211-202nd wheel gear 7 ∆ 27T 5F7-17221-21∆ 28T 5F7-17221-00* 31T 4DP-17221-113rd wheel gear 8 ∆ 25T 5KE-17231-2026T 5KE-17231-10* 29T 5KE-17231-004th wheel gear 9 * 27T 5KE-17241-005th wheel gear 0 * 26T 3YL-17251-006th wheel gear ¡ * 20T 5KE-17261-0022T 5KE-17261-10* Factory installedNOTE:• The mark ∆ shows that this part is not suppliedtogether and that it is available on orderas a YAMAHA genuine part.• 3rd/4th pinion gear 5KE-17131-10 allows fora combination of 3rd wheel gear 5KE-17231-10 or 5KE-17231-20. No combination can beselected for the factory installed 5KE-17231-00.7-13

SETTINGTUNEC720000CHASSISEC72J001Chassis settingHow to go about setting the chassis• Measure the stroke of the front and rear suspensionto get an idea of the operation.• If the time increases, the stroke increases.• If the tire grip becomes firmer, the strokeincreases.(On the other hand, the stroke decreases onrainy weather.)• Rider’s position and posture affect the stroke.• Be careful not to allow the suspension to bottomout.• Start the setting with the preload.Next, go to the damping force adjustment,and if this not enough, then adjust themachine height.(On the side where the machine height isgreater the stroke increases; whereas itdecreases on the side with a smallermachine height.)• If the damping force is increased either onthe compression or the expansion side, itresults in less smooth movement, so do notdepart too far from the standard settings.• Adjust the machine height in an increment ofmm (in).• If you lose your way while doing the setting,go back to the standard settings.• Oil level adjustment in the front fork producesa greater effect in further stroke than in midstroke.(Increase or decrease the oil level in anapproximately 5~10 mm (0.20~0.39 in) interval.)7-14

SETTINGTUNEC72M001Tire and machine’s postureIf a non-designated tire is used, the differencein radius between the front and the rear tiremay affect the machine’s posture.To keep the machine in a proper posture,adjust the front fork top end or seat height.Basically, with a larger radius tire, lower themachine’s posture and vice versa.[Front]Tirebrand*3.10/4.80 R17DUNLOP KR106120/70 R17DUNLOP MR977*Designated tireTire circumference Tire radius Front fork top endAbout 1,875 mm (73.8 in) About 298.5 mm (11.8 in) 13 mm (0.51 in)About 1,885 mm (74.2 in) About 300 mm (11.8 in) 11.5 mm (0.45 in)[Rear]Tirebrand*165/55 R17DUNLOP KR108165/50 R17DUNLOP KR244*Designated tireTire circumference Tire radius Seat heightAbout 1,975 mm (77.8 in) About 314.5 mm (12.4 in) 24 mm (0.94 in)About 1,957 mm (77.0 in) About 311.5 mm (12.3 in) 25.5 mm (1.00 in)Example:If the front tire radius is 1 mm (0.04 in) larger,lower the front posture by 1 mm (0.04 in) byincreasiry the front fork top end a by 1 mm(0.04 in). If the rear tire radius is 2 mm (0.08in) smaller, raise the rear posture by 2 mm(0.08 in) by decreasiry the adjuster set lengthb by 1 mm (0.04 in).NOTE:• Find the tire radius by calculating the measuredcircumference of the tire.• A change of 1 mm (0.04 in) in the front forktop end results in a change of about 1 mm(0.04 in) in the front posture. A change of 1mm (0.04 in) in the adjuster set length resultsin a change of about 2 mm (0.08 in) in therear posture.7-15

SETTINGTUNEC72K014SettingsFor full use of engine performance and saferiding, set the suspension as follows. (Ex-factorysettings are intended for a rider approximately170 cm (66.9 in) in height and approximately60 kg (132 lb) in weight.)1. PreparationsTo check for the remaining stroke in thefront and rear suspension, either install athin insu-lock tie or apply a small amount ofgrease at the front fork inner tube and atthe rear shock absorber rod.2. SettingsAt the beginning of the break-in period,always record the remaining stroke asdata.To judge front and rear balance in relationto the machine height, the usual way is toshift from full braking to turning and get thefeel when the clipper riding.After making an actual run, proceed to thesettings for a target of a 5~10 mm(0.20~0.39 in) remaining stroke for frontand a 10 ~ 20 mm (0.39~0.79 in) remainingstroke for rear.Basically, the best settings can be obtainedby repeating the following steps.NOTE:The figures show the bottom-out positions ofthe front and rear suspension.A FrontB Rear7-16

SETTINGTUNSETTING CHARTACTUAL RUNCheck strokeNOTE:The remaining stroke value is providedjust as a guide and may changeaccording to the riding style.Front remaining strokeRear remaining stroke5 to 10 mm (0.20 ~ 0.39 in)10 to 20 mm (0.39 ~ 0.79 in)NOYESNOPoor strokeDecrease the springpreload.•FrontEvery two clicks[1 mm (0.04 in)]•RearEvery one turn[1.5 mm (0.06 in)]Too much strokeIncrease the springpreload.•FrontEvery two clicks[1 mm (0.04 in)]•RearEvery one turn[1.5 mm (0.06 in)]NOTE:Preload increase results in relativelack of damping force. If the preloadis increased two times, increase thedamping force a little.Too stiff from thebeginning and notsmooth in mid rangeas well.Decrease damping forceon compression side.•FrontEvery one turn•RearEvery two clicksUnstable and spongyIncrease damping forceboth on compressionand rebound.•FrontEvery one turn•RearEvery two clicksOK7-17

SETTINGTUNEC71P011Selection of the secondary reduction ratio(Sprocket)Secondaryreduction =ratioNumber of driven sprocket teethNumber of drive sprocket teethFactory-set secondary36/14 (2.571)reduction ratiowDriven sprocketDrive sprocket35T 36T 37T 38T 39T 40T14T 2.500 2.571 2.643 2.714 2.786 2.85715T 2.333 2.400 2.467 2.534 2.600 2.66616T 2.188 2.250 2.313 2.375 2.438 2.500The larger value, the higher speed ratioThe smaller value, the lower speed ratioEC72N000Drive and driven sprockets setting partsPart name Size Part numberDrive sprocket 1 * 14T 93834-1417815T 93834-1507916T 93834-16104Driven sprocket 2 35T 5KE-25435-10* 36T 5KE-25436-1037T 5KE-25437-1038T 5KE-25438-1039T 5KE-25439-1040T 5KE-25440-10* Factory installed7-18

SETTINGTUNEC72L003Chassis setting troubleshooting Chattering(Smallrebounds, Bottoming (full stroke) • Increase spring preload.up-and-down• Increase damping force for compression.movements)Further in stroke• Increase damping force for compression, ordecrease damping force for rebound.Too stiff (poor stroke)Looseness in partsTire/Rim• Decrease spring preload.• Decrease damping force for compression.• Down the oil level (for front fork only).• Check bolts, bearings, etc. as well as theirinstallation.• Recheck balance.• Check deformation (runout).Too stifffeelingPoor operationToo stiff (poor stroke)Bottoming (full stroke)• Check the shock absorber.(Check rod, inner tube, etc. for bending. Ifbent, replace.)• Check for any deviation from center aftertightening front wheel axle.(Replace if deviated in any way.)• Too much tightened bolts for frontfork outer tube ≥ Retorque the bolts tospecification (handle crown, under bracket,steering damper stay, handlebar).• Decrease spring preload.• Decrease damping force (for both compressionand rebound).• Increase spring preload.• Increase oil level (for front fork only).• Increase damping force for compression, ordecrease damping force for rebound.Spongy feeling Poor of damping force • Increase damping force (for both compressionand rebound).Too soft• Increase spring preload.7-19

SETTINGTUN HandlebarfluctuatingPoor of front loadToo soft of front• Decrease spring preload (for front).• Increase front fork top end.• Increase rear height.• Increase spring preload (for rear).• Increase spring preload (for front).• Increase damping force (for front).Poor cornermaneuveringMachine tends to inclinetoo much backward.(Too big caster angle)• Increase rear height.• Increase spring preload (for rear).• Decrease damping force for rebound (forrear).• Increase front fork top end.• Decrease spring preload (for front).Too much knifingat corneringMachine tend to inclinetoo much forward.(Too small caster angle)Front dives in too early• Decrease front fork top end.• Decrease rear height.• Increase spring preload (for front).• Increase damping force for compression (forfront).• Increase damping force for compression (forfront).Swinging on(bounding) Too much damping force • Decrease damping force for rebound.over gapsfor reboundBottoming• Increase spring preload.7-20

SETTINGTUNEC740002Setting record tableThe data shown here is an example of entry. For your actual use, copy the necessary data.Event nameDateWeatherPlaceSetting specs:Ignition timingSpark plugCarburetorMain jetPower jetJet needleMain nozzlePilot jetPilot air screwFloat heightGearing1st2nd3rd4th5th6thSecondaryFront forkSpring rateSpring preloadRebound dampingCompression dampingTop endOil capacityOil levelRear shockSpring fitting lengthSpring rateRebound dampingCompression dampingSeat heightFront tire (pressure)Rear tire (pressure)Fuel consumption7-21

SETTINGTUNEvent nameDateWeatherPlaceSetting specs:Ignition timingSpark plugCarburetorMain jetPower jetJet needleMain nozzlePilot jetPilot air screwFloat heightGearing1st2nd3rd4th5th6thSecondaryFront forkSpring rateSpring preloadRebound dampingCompression dampingTop endOil capacityOil levelRear shockSpring fitting lengthSpring rateRebound dampingCompression dampingSeat heightFront tire (pressure)Rear tire (pressure)Fuel consumptionNOTE:1. Make setting changes in small increments.2. When the proper settings have been determined for a particular track, they should be writtendown for reference upon returning to that track.3. Always make adjustment in cold state.7-22

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