Yamaha 5HN-28199-13, LIT-11626-16-27 User Manual

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OWNER’S SERVICE MANUAL

TT-R90R

LIT-11626-16-27

5HN-28199-13

EC010000

TT-R90R

OWNER’S SERVICE MANUAL

permission of Yamaha Motor Corporation

U.S.A. is expressly prohibited.

Printed in Japan

P/N. LIT-11626-16-27

INTRODUCTION

Congratulations on your purchase of a Yamaha TT-R90R. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.

This manual explains operation, inspection, basic maintenance and tuning of your machine. If you have any questions about this manual or your machine, please contact your Yamaha dealer.

OTE:

As improvements are made on this model, some data in this manual may become outdated. If you have any questions, please consult your Yamaha dealer.

WARNING

READ THIS MANUAL CAREFULLY FOR

●

INSTRUCTIONS ON HOW TO PROPERLY OPERATE THIS MACHINE. ADULT INSTRUCTION AND SUPERVI-

●

SION ARE REQUIRED.

●

WEIGHT OF THE RIDER SHOULD NOT EXCEED 40 kg (88 lb). ALWAYS WEAR A HELMET AND SUIT-

●

ABLE PROTECTIVE CLOTHING WHEN RIDING. DO NOT TOUCH ANY MOVING PARTS OR

●

HEATED AREAS.

●

ALWAYS PERFORM PRE-OPERATION CHECKS. REFER TO PAGE 15. THIS MACHINE IS DESIGNED TO CARRY

●

THE OPERATOR ONLY. NO PASSENGERS. THIS MACHINE IS DESIGNED OFF-ROAD

●

USE ONLY. IT IS NOT SUITABLE FOR ON-ROAD USE.

IMPORTANT NOTICE

This machine is designed for off-road use only by young operators under adult instruction and supervision. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may be illegal. Please check local regulations before riding.

SAFETY INFORMATION

1. GASOLINE IS HIGHLY FLAMMABLE: * Always turn off the engine when

refueling.

* Take care not to spill on the engine

or exhaust pipe/muffler, when refueling.

* Never refuel while smoking or in

the vicinity of an open flame.

2. If you should swallow some gasoline or inhale a lot of gasoline vapor, or allow some gasoline to get in your eye(s), see your doctor immediately. If any gasoline spills on your skin or clothing, immediately wash it with soap and water, and change your clothes.

3. Always turn off the engine before leaving the machine unattended. When parking the machine, note the following: * The engine and exhaust pipe(s)/

muffler(s) may be hot. Park the machine in a place where pedestrians or children are not likely to touch the machine.

* Do not park the machine on a slope

or soft ground; the machine may overturn.

4. When transporting the machine in another vehicle, be sure is kept upright and that the fuel cock is turned to the “OFF”. If it should lean over, gasoline may leak out of the carburetor or fuel tank.

5. Never start your engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of consciousness and death within a short time. Always operate your machine in an area with adequate ventilation.

6. Always wear a helmet, gloves, boots, trousers, and jacket for motocross riding.

SAFETY INFORMATION

1. Don’t ride it on the street.

2. Don’t run the engine inside a building.

3. This is a one-seater motorbike. Don’t give any person a ride.

4. Let’s learn how to ride properly. Ask your parents for any question.

5. When riding the machine, be sure to wear the protective apparel as illustrated.

Helmet Goggles Mouth guard Gloves Boots Motocross pants Long sleeved trainer

6. When going for riding, be sure to be with your family. Never go alone.

7. Before riding the machine, ask your parents to check the machine very carefully.

8. Don’t touch the areas shown, or you’ll get burnt in the hand.

9. Don’t touch rotating or moving parts.

10. Before starting the engine, be sure to shift the transmission into neutral.

EC080000

HOW TO USE

THIS MANUAL

EC081000

PARTICULARLY IMPORTANT INFORMATION

The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

WARNING

Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage to the machine.

NOTE:

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

EC082000

FINDING THE REQUIRED PAGE

1. This manual consists of six chapters;

“General Information”, “Specifications”, “Regular inspection and adjustments”, “Engine”, “Chassis” and “Electrical”.

2. The table of contents is at the beginning of the manual. Look over the general layout of the book before finding then required chapter and item. Bend the book at its edge, as shown, to find the required fore edge symbol mark and go to a page for required item and description.

EC083000

MANUAL FORMAT

All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g.

●

Bearings Pitting/damage → Replace.

EC084002

HOW TO READ DESCRIPTIONS

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

1. An easy-to-see exploded diagram 1 is provided for removal and disassembly jobs.

2. Numbers 2 are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step.

3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks 3. The meanings of the symbol marks are given on the next page.

4. A job instruction chart 4 accompanies the exploded diagram, providing the order of jobs, names of parts, notes in jobs, etc.

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

6. For jobs requiring more information, the step-by-step format supplements 6 are given in addition to the exploded diagram and job instruction chart.

GEN

INFO

SPEC

INSP

ADJ

CHAS

ENG

– +

ELEC

ILLUSTRATED SYMBOLS (Refer to the illustration)

Illustrated symbols 1 to 6 are designed as thumb tabs to indicate the chapter’s number and content.

General information Specifications Regular inspection and adjustments Engine Chassis Electrical

Illustrated symbols 7 to D are used to identify the specifications appearing in the text.

With engine mounted Special tool Filling fluid Lubricant Tightening Specified value, Service limit Engine speed Resistance ( Ω ), Voltage (V), Electric current (A)

E F

G H

New

Illustrated symbols E to H in the exploded diagram indicate grade of lubricant and location of lubrication point.

E Apply engine oil F Apply molybdenum disulfide oil G Apply lightweight lithium-soap base grease H Apply molybdenum disulfide grease

Illustrated symbols I to J in the exploded diagrams indicate where to apply a locking agent and when to install new parts.

I Apply locking agent (LOCTITE®) J Use new one

INDEX

– +

GENERAL INFORMATION

SPECIFICATIONS

REGULAR INSPECTION AND ADJUSTMENTS

ENGINE

CHASSIS

GEN

INFO

SPEC

INSP

ADJ

ENG

CHAS

ELECTRICAL

ELEC

CONTENTS

CHAPTER 1

GENERAL INFORMATION

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

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

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

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

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

CONTROL FUNCTIONS ........................... 1-9

FUEL ....................................................... 1-11

STARTING AND OPERATION ...............1-12

CHAPTER 2

SPECIFICATIONS

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

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

GENERAL TORQUE

SPECIFICATIONS ................................... 2-15

DEFINITION OF UNITS ........................... 2-15

CABLE ROUTING DIAGRAM ................. 2-16

CHAPTER 3

REGULAR INSPECTION AND

ADJUSTMENTS

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

PERIODIC MAINTENANCE AND

LUBRICATION .......................................... 3-1

PRE-OPERATION INSPECTION AND

MAINTENANCE ........................................3-2

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

CHASSIS ................................................. 3-11

ELECTRICAL .......................................... 3-19

CHAPTER 4

ENGINE

CARBURETOR .........................................4-1

CYLINDER HEAD .....................................4-8

CAMSHAFT AND ROCKER ARMS ........ 4-13

VALVES AND VALVE SPRINGS ........... 4-16

CYLINDER AND PISTON .......................4-21

CLUTCH .................................................. 4-27

KICK AXLE ............................................. 4-33

SHIFT SHAFT ......................................... 4-34

OIL PUMP ............................................... 4-36

CDI MAGNETO .......................................4-39

CRANKCASE AND CRANKSHAFT ....... 4-41

SHIFT FORK, SHIFT CAM AND

TRANSMISSION .....................................4-44

CHAPTER 5

CHASSIS

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

FRONT FORK ...........................................5-6

HANDLEBAR ............................................ 5-9

STEERING .............................................. 5-10

SWINGARM ............................................ 5-11

CHAPTER 6

ELECTRICAL

ELECTRICAL COMPONENTS AND

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

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

CARBURETOR HEATING SYSTEM ........6-6

NOISE REGULATION ............................... 6-9

MAINTENANCE RECORD ........................ 6-9

GEN

DESCRIPTION

EC100000

GENERAL INFORMATION

EC110000

DESCRIPTION

1 “ENGINE STOP” button 2 Front brake lever 3 Throttle grip 4 Fuel tank cap 5 Kick starter 6 Fuel tank 7 Air cleaner 8 Rear brake pedal 9 Fuel cock 0 Starter lever (choke) A Drive chain B Shift pedal C Front fork

OTE:

● The machine you have purchased may differ

slightly from those shown in the following.

● Designs and specifications are subject to

change without notice.

INFO

1 - 1

MACHINE IDENTIFICATION

EC120001

MACHINE IDENTIFICATION

There are two significant reasons for knowing the serial number of your machine:

1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own.

2. If your machine is stolen, the authorities will need the number to search for and identify your machine.

EC121001

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is stamped on the right of the steering head pipe.

GEN

INFO

ENGINE SERIAL NUMBER

The engine serial number 1 is stamped into the elevated part of the left-side of the engine.

EC124000

MODEL LABEL

The model label 1 is affixed to the frame under the rider’s seat. This information will be needed to order spare parts.

1 - 2

IMPORTANT INFORMATION

EC130000

IMPORTANT INFORMATION

EC131002

PREPARATION FOR REMOVAL AND DISASSEMBLY

1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. When washing the machine with high pressured water, cover the parts as follows.

● Silencer exhaust port

GEN

INFO

2. Use proper tools and cleaning equipment. Refer to “SPECIAL TOOLS” section.

3. When disassembling the machine, keep mated parts together. They include gears, cylinders, pistons, and other mated parts that have been “mated” through normal wear. Mated parts must be reused as an assembly or replaced.

4. During the machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled.

1 - 3

5. Keep away from fire.

IMPORTANT INFORMATION

EC132000

ALL REPLACEMENT PARTS

1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment.

EC133000

GASKETS, OIL SEALS AND O-RINGS

1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned.

2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.

GEN

INFO

EC134000

LOCK WASHERS/PLATES AND COTTER PINS

1. All lock washers/plates 1 and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been properly tightened.

EC135001

BEARINGS AND OIL SEALS

1. Install the bearing(s) 1 and oil seal(s) 2 with their manufacturer’s marks or numbers facing outward. (In other words, the stamped letters must be on the side exposed to view.) When installing oil seal(s), apply a light coating of lightweight lithium base grease to the seal lip(s). Oil the bearings liberally when installing.

CAUTION:

Do not use compressed air to spin the bearings dry. This causes damage to the bearing surfaces.

1 - 4

IMPORTANT INFORMATION/

CHECKING OF CONNECTION

EC136000

CIRCLIPS

1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1, make sure that the sharp-edged corner 2 is positioned opposite to the thrust

3 it receives. See the sectional view.

4 Shaft

CHECKING OF CONNECTION

Dealing with stains, rust, moisture, etc. on the connector.

1. Disconnect:

● Connector

2. Dry each terminal with an air bower.

GEN

INFO

3. Connect and disconnect the connector two or three times.

4. Pull the lead to check that it will not come off.

5. If the terminal comes off, bend up the pin 1 and reinsert the terminal into the connector.

6. Connect:

● Connector

OTE:

The two connectors “click” together.

7. Check for continuity with a tester.

OTE:

● If there in no continuity, clean the terminals.

● Be sure to perform the steps 1 to 7 listed

above when checking the wireharness.

● For a field remedy, use a contact revitalizer

available on the market.

● Use the tester on the connector as shown.

1 - 5

GEN

SPECIAL TOOLS

The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order.

OTE:

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

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

Part number Tool name/How to use Illustration

YU-1083-A

90890-01084 90890-01085

YU-1268, 90890-01268 Ring nut wrench

Slide hammer set Weight Slide hammer bolt

These tools are used when removing or installing the rocker arm shafts.

YU-1083-A 90890-01084

YU-1268 90890-01268

INFO

90890-01085

This tool is used when loosen the steering ring nut to specification.

YU-3112-C, 90890-03112 Pocket tester

Use this tool to inspect the coil resistance, output voltage and amperage.

YU-8036-B

90890-03113

YM-4019, 90890-04019 Valve spring compressor

YM-1300

90890-01294

Inductive tachometer Engine tachometer

This tool is needed for observing engine rpm.

This tool is needed to remove and install the valve assemblies.

Damper rod holder set Damper rod holder

YU-3112-C 90890-03112

YU-8036-B 90890-03113

YM-4019 90890-04019

YM-1300 90890-01294

Use this tool to remove and install the damper rod.

YU-1304, 90890-01304 Piston pin puller set

This tool is used to remove the piston pin.

YU-1304 90890-01304

1 - 6

SPECIAL TOOLS

Part number Tool name/How to use Illustration

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

This gauge is used to measure the fuel level in the float chamber.

YM-1326, 90890-01326 T-handle

This tool is used for holding the damper rod holder when removing or installing the damper rod holder.

90890-01186 Fork seal driver attachment

This tool is used to installing the oil seal.

YM-8035, 90890-01311 Valve adjusting tool

YM-1312-A 90890-01312

YM-1326 90890-01326

YM-8035 90890-01311

GEN

INFO

90890-01186

This tool is necessary for adjusting valve clearance.

YM-33963, 90890-01184 Fork seal driver weight

This tool is used to installing the oil seal.

YM-34487

90890-06754

YM-33975, 90890-01403 Ring nut wrench

YM-91042, 90890-04086 Clutch holding tool

YS-1880-A, 90890-01701 Sheave holder

Dynamic spark tester Ignition checker

This instrument is necessary for checking the ignition system components.

This tool is used when tighten the steering ring nut to specification.

This tool is used to hold the clutch when removing or installing the clutch boss securing nut.

YM-33963 90890-01184

YM-34487 90890-06754

YM-33975 90890-01403

YM-91042 90890-04086

YS-1880-A 90890-01701

This tool is used for when loosening or tightening the flywheel magneto securing nut.

1 - 7

SPECIAL TOOLS

Part number Tool name/How to use Illustration

YU-33270-B, 90890-01362 Flywheel puller

This tool is used to remove the rotor.

ACC-QUICK-GS-KT

90890-85505

Quick gasket® YAMAHA Bond No. 1215

This sealant (Bond) is used for crankcase mating surface, etc.

YU-33270-B 90890-01362

ACC-QUICK-GS-KT 90890-85505

GEN

INFO

1 - 8

CONTROL FUNCTIONS

EC150000

CONTROL FUNCTIONS

“ENGINE STOP” SWITCH

Make sure that the engine stop switch 1 is positioned to “”. The engine stop switch has been equipped to ensure safety in an emergency such when the machine is up set or trouble takes place in the throttle system. The engine will not start or run when the engine stop switch is turned to “”.

SHIFT PEDAL

The gear ratios of the constant-mesh 3 speed transmission are ideally spaced. The gears can be shifted by using the shift pedal 1 on the left side of the engine.

WARNING

When starting out on the machine, shift the transmission into 1st after pulling in the front brake lever and closing the throttle grip.

GEN

INFO

KICK STARTER

WARNING

Before starting the engine, be sure to shift the transmission into neutral.

Rotate the kick starter 1 away from the engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine.

EC155001

THROTTLE GRIP

The throttle grip 1 is located on the right handlebar; it accelerates or decelerates the engine. For acceleration, turn the grip toward you; for deceleration, turn it away from you.

1 - 9

CONTROL FUNCTIONS

EC156000

FRONT BRAKE LEVER

The front brake lever 1 is located on the right handlebar. Pull it toward the handlebar to activate the front brake.

EC157000

REAR BRAKE PEDAL

The rear brake pedal 1 is located on the right side of the machine. Press down on the brake pedal to activate the rear brake.

GEN

INFO

FUEL COCK

The fuel cock supplies fuel from the tank to carburetor while filtering the fuel. The fuel cock has the three positions: OFF: With the lever in this position, fuel will

not flow. Always return the lever to this position when the engine is not running.

ON: With the lever in this position, fuel flows

to the carburetor. Normal riding is done with the lever in this position.

RES: This indicates reserve. If you run out of

fuel while riding, move the lever to this position. FILL THE TANK AT THE FIRST OPPORTUNITY. BE SURE TO SET THE LEVER TO “ON” AFTER REFUELING.

STARTER LEVER (CHOKE)

When cold, the engine requires a richer air/fuel mixture for starting. A separate starter circuit, which is controlled by the starter lever 1, supplies this mixture. Pull the lever out to open the circuit (for starting) and push the lever in to close the circuit.

1 - 10

CONTROL FUNCTIONS/FUEL

FUEL TANK CAP

Remove the fuel tank cap 1 by turning counter-clockwise.

WARNING

Do not overfill the fuel tank. Avoid spilling fuel on the hot engine.

FUEL

Use regular gasoline. Always use fresh, name brand gasoline.

WARNING

Do not overfill the fuel tank. Avoid spilling fuel on the hot engine. Do not fill the fuel tank above the bottom of the filler tube 1 as shown in the illustration or it may overflow when the fuel heats up later and expands.

GEN

INFO

a Fuel level

Recommended fuel:

For USA, AUS and NZ:

Unleaded gasoline only

For CDN and EUROPE:

Regular unleaded gasoline only

For ZA:

Regular gasoline

Fuel tank capacity:

Total:

4.1 L (0.90 lmp gal, 1.08 US gal)

Reserve:

0.5 L (0.11 lmp gal, 0.13 US gal)

CAUTION:

Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine internal parts such as valves, piston rings, and exhaust system, etc.

1 - 11

STARTING AND OPERATION

GEN

INFO

STARTING AND OPERATION

CAUTION:

Prior to operating the machine, perform steps listed in pre-operation check list.

WARNING

Never start your engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and can cause loss of consciousness and death within a short time. Always operate your machine in an area with adequate ventilation.

STARTING A COLD ENGINE

WARNING

Before starting the engine, be sure to shift the transmission into neutral.

1. Turn the fuel cock to “ON”.

2. Operate the starter (choke) and completely close the throttle grip.

3. Slide the “ENGINE STOP” switch to the “”.

4. Kick the kick starter with full strength to start the engine.

5. After the engine starts, warm up for one or two minutes. Make sure the stater (choke) is returned to the original position before riding.

STARTING A WARM ENGINE

To start a warm engine, refer to the “Starting a cold engine” section. The starter (choke) should not be used. The throttle should be opened slightly.

WARMING UP

To get maximum engine life, always “warm-up” the engine before starting off. Never accelerate hard with a cold engine! To see whether or not the engine is warm, see if it responds to throttle normally with the stater (choke) turned off.

WARNING

Before starting off, be sure to turn up or remove the side stand. Failure to retract the side stand completely can result in a serious accident when you try to turn a corner.

ENGINE BREAK-IN

Brake-in is important to better fit the moving and sliding parts as well as the installed parts. It is also important to accustom the rider to the machine better. Avoid full-throttle run on a new machine for the first 5 hours. After the trial run, check for loose parts, oil leakage and other problems. Make full inspection and adjustment especially of slack cables and drive chain and loose spokes.

CAUTION:

After the break-in period, check every fitting and fastener for looseness. If any loose is found, retighten it securely.

CAUTION:

See “Engine break-in Section” prior to operating engine for the first time.

1 - 12

GENERAL SPECIFICATIONS

EC200000

SPECIFICATIONS

EC211000

GENERAL SPECIFICATIONS

Model name: TT-R90R (USA, CDN, AUS, NZ)

TT-R90 (Europe, ZA)

Model code number: 5HNB (USA)

5HNC (Europe, AUS, NZ, ZA) 5HND (CDN)

Dimensions:

Overall length 1,525 mm (57.0 in) Overall width 605 mm (23.8 in) Overall height 865 mm (34.1 in) Seat height 625 mm (24.6 in) Wheelbase 1,040 mm (40.9 in) Minimum ground clearance 160 mm (6.3 in)

Basic weight:

With oil and full fuel tank 64 kg (141 lb)

Engine:

Engine type Air cooled 4-stroke, SOHC Cylinder arrangement Single cylinder, forward inclined Displacement 89 cm Bore × stroke 47.0 × 51.8 mm (1.85 × 2.04 in) Compression ratio 8.5 : 1 Compression pressure (STD) 1,000 kPa (10 kg/cm

Starting system Kick starter Lubrication system: Wet sump Oil type or grade:

Engine oil

0 10 30 50 70 90 110 130

˚F

(For USA and CDN) At –10 ˚C (10 ˚F) or higher Å Yamalube 4 (10W-30) or SAE 10W-30 type SE/SF motor oil

At 5 ˚C (40 ˚F) or higher ı Yamalube 4 (20W-40) or SAE 20W-40 type

SE/SF motor oil

(5.43 cu.in)

, 145 psi) at 1,000 r/min

SPEC

-20 -10 0

30 40 50

˚C

(Except for USA and CDN) API “SE/SF” or higher grade

2 - 1

GENERAL SPECIFICATIONS

Oil capacity:

Engine oil

Periodic oil change 0.8 L (0.70 Imp qt, 0.85 US qt)

Total amount 1.0 L (0.88 Imp qt, 1.06 US qt) Air ﬁlter: Wet type element Fuel:

Type Unleaded gasoline only (USA, AUS and NZ)

Regular unleaded gasoline only (CDN, Europe)

Regular gasoline (ZA) Tank capacity 4.1 L (0.90 lmp gal, 1.08 US gal) Reserve amount 0.5 L (0.11 Imp gal, 0.13 US gal)

Carburetor:

Type VM16SH Manufacturer MIKUNI

Spark plug:

Type CR6HSA/U20FSR-U Manufacturer NGK/DENSO Gap 0.6 ~ 0.7 mm (0.02 ~ 0.03 in)

Clutch type: Wet, multiple-disc and centrifugal automatic Transmission:

Primary reduction system Spur gear Primary reduction ratio 67/18 (3.722) Secondary reduction system Chain drive Secondary reduction ratio 35/14 (2.500) Transmission type Constant mesh, 3-speed Operation Left foot operation Gear ratio: 1st 37/13 (2.846)

2nd 33/19 (1.736) 3rd 28/23 (1.217)

Chassis:

Frame type Double cradle Caster angle 24.83˚ Trail 56.0 mm (2.2 in)

Tire:

Type With tube Size (front) 2.50-14 4PR Size (rear) 3.00-12 4PR Manufacturer (front and rear) CHENG SHIN Type (front and rear) KNOBBY Tire pressure (front and rear) 100 kPa (1.00 kgf/cm

, 14.5 psi)

SPEC

2 - 2

GENERAL SPECIFICATIONS

Brake:

Front brake type Drum brake Operation Right hand operation Rear brake type Drum brake Operation Right foot operation

Suspension:

Front suspension Telescopic fork Rear suspension Swingarm (monocross suspension)

Shock absorber:

Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/gas, oil damper

Wheel travel:

Front wheel travel 110 mm (4.33 in) Rear wheel travel 93 mm (3.66 in)

Electrical:

Ignition system CDI magneto

SPEC

2 - 3

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Item Standard Limit

Cylinder head:

Warp limit ---- 0.03 mm

(0.0012 in)

Cylinder:

Bore size 47.000 ~ 47.005 mm

(1.8504 ~ 1.8506 in) Out of round limit ---- 0.05 mm

Camshaft:

Drive method Chain drive (left) ---Cam dimensions

47.05 mm (1.8524 in)

(0.0020 in)

Intake “A” 25.428 ~ 25.528 mm

(1.0011 ~ 1.0050 in)

“B” 21.034 ~ 21.134 mm

(0.8281 ~ 0.8320 in)

Exhaust “A” 25.286 ~ 25.386 mm

(0.9955 ~ 0.9994 in)

“B” 21.047 ~ 21.147 mm

(0.8286 ~ 0.8326 in) Camshaft runout limit ---- 0.03 mm

25.398 mm (0.9999 in)

21.004 mm (0.8269 in)

25.256 mm (0.9943 in)

21.017 mm (0.8274 in)

(0.0012 in)

2 - 4

MAINTENANCE SPECIFICATIONS

SPEC

Item Standard Limit

Cam chain:

Cam chain type/No. of links 92RH2005-84M/84 ---Cam chain adjustment method Automatic ----

Rocker arm/rocker arm shaft:

Shaft outside diameter 9.981 ~ 9.991 mm

(0.3930 ~ 0.3933 in) Rocker arm inside diameter 10.000 ~ 10.015 mm

(0.3937 ~ 0.3943 in)

Valve, valve seat, valve guide:

Valve clearance (cold) IN 0.05 ~ 0.09 mm

(0.0020 ~ 0.0035 in)

EX 0.08 ~ 0.12 mm

(0.0031 ~ 0.0047 in) Valve dimensions:

9.95 mm (0.3917 in)

10.03 mm (0.3949 in)

----

Head Diameter

Face Width

Seat Width

“A” head diameter IN 22.9 ~ 23.1 mm

(0.9016 ~ 0.9094 in)

EX 19.9 ~ 20.1 mm

(0.7835 ~ 0.7913 in)

“B” face width IN 1.19 ~ 2.51 mm

(0.0469 ~ 0.0989 in)

EX 1.49 ~ 3.07 mm

(0.0587 ~ 0.1209 in)

“C” seat width IN 0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in)

EX 0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in)

“D” margin thickness IN 0.5 ~ 0.9 mm

(0.0197 ~ 0.354 in)

EX 0.8 ~ 1.2 mm

(0.0315 ~ 0.0472 in) Stem outside diameter IN 4.475 ~ 4.490 mm

(0.1762 ~ 0.1768 in)

EX 4.460 ~ 4.475 mm

(0.1756 ~ 0.1762 in) Guide inside diameter IN 4.500 ~ 4.512 mm

(0.1772 ~ 0.1776 in)

EX 4.500 ~ 4.512 mm

(0.1772 ~ 0.1776 in) Stem-to-guide clearance IN 0.010 ~ 0.037 mm

(0.0004 ~ 0.0015 in)

EX 0.025 ~ 0.052 mm

(0.0010 ~ 0.0020 in)

Margin Thickness

----

1.6 mm (0.0630 in)

----

4.450 mm (0.1752 in)

4.435 mm (0.1746 in)

4.542 mm (0.1788 in)

0.08 mm (0.003 in)

0.10 mm (0.004 in)

2 - 5

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Stem runout limit ---- 0.02 mm

SPEC

(0.0008 in)

Valve seat width IN 0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in)

EX 0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in)

Valve spring:

Free length IN 28.32 mm (1.11 in) 26.9 mm

EX 28.32 mm (1.11 in) 26.9 mm

Set length (valve closed) IN 24.2 mm (0.95 in) ----

EX 24.2 mm (0.95 in) ----

Compressed pressure (installed) IN 90.4 ~ 104.1 N

(9.22 ~ 10.62 kg, 20.33 ~ 23.41 lb)

EX 90.4 ~ 104.1 N

(9.22 ~ 10.62 kg, 20.33 ~ 23.41 lb)

Tilt limit IN ---- 2.5˚/1.2 mm

EX ---- 2.5˚/1.2 mm

1.6 mm (0.0630 in)

(1.06 in)

----

(2.5˚/0.05 in)

Direction of winding (top view) IN Clockwise ----

EX Clockwise ----

2 - 6

MAINTENANCE SPECIFICATIONS

SPEC

Item Standard Limit

Piston:

Piston to cylinder clearance 0.025 ~ 0.045 mm

(0.0010 ~ 0.0018 in) Piston size “D” 46.960 ~ 46.975 mm

(1.8488 ~ 1.8494 in)

Piston over size (2nd) 47.5 mm (1.8701 in) ----

(4th) 48.0 mm (1.8898 in) ---Measuring point “H” 4 mm (0.16 in) ---Piston off-set 0.75 mm (0.0295 in) ---Piston pin bore inside diameter 13.002 ~ 13.013 mm

(0.5119 ~ 0.5123 in)

Piston pin outside diameter 12.996 ~ 13.000 mm

(0.5117 ~ 0.5118 in)

Piston rings:

Top ring

0.15 mm (0.0059 in)

----

13.045 mm (0.5136 in)

12.976 mm (0.5109 in)

Type Barrel ---Dimensions (B × T) 1.0 × 2.0 mm (0.04 × 0.08 in) ---End gap (installed) 0.10 ~ 0.25 mm

(0.004 ~ 0.010 in)

Side clearance (installed) 0.030 ~ 0.065 mm

(0.0012 ~ 0.0026 in)

2nd ring

Type Taper ---Dimensions (B × T) 1.0 × 2.0 mm (0.04 × 0.08 in) ---End gap (installed) 0.10 ~ 0.25 mm

(0.004 ~ 0.010 in)

Side clearance 0.020 ~ 0.055 mm

(0.0008 ~ 0.0022 in)

Oil ring

0.4 mm (0.016 in)

0.12 mm (0.005 in)

0.4 mm (0.016 in)

0.12 mm (0.005 in)

Dimensions (B × T) 2.0 × 2.3 mm (0.08 × 0.09 in) ---End gap (installed) 0.2 ~ 0.7 mm (0.01 ~ 0.03 in) ----

2 - 7

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Crankshaft:

Crank width “A” 42.95 ~ 43.00 mm

Runout limit C ---- 0.03 mm

Big end side clearance “D” 0.10 ~ 0.40 mm

Big end radial clearance “E” 0.010 ~ 0.025 mm

Clutch:

Friction plate thickness 2.7 ~ 2.9 mm

Quantity 5 ----

Clutch plate thickness 1.1 ~ 1.3 mm (0.043 ~ 0.051 in) ----

Quantity 4 ---Warp limit ---- 0.2 mm

Clutch spring free length 26.2 mm (1.03 in) 24.2 mm

Quantity 4 ---Clutch release method Inner push, cam push ---Push rod bending limit ---- 0.5 mm

Automatic centrifugal clutch:

Clutch-in revolution 2,160 ~ 2,560 r/min ---Clutch-stall revolution 3,300 ~ 3,800 r/min ----

Shifter:

Shifter type Cam drum and guide bar ----

Kick starter:

Type Ratchet type ---Kick clip friction force 5.8 ~ 14.7 N

Carburetor:

I. D. mark 5HN1 01 ---Main jet (M.J) #90 ---Main air jet (M.A.J) ø 1.1 ---Jet needle (J.N) 4E9-2 ---Cutaway (C.A) 2.5 ---Pilot outlet (P.O) ø 1.0 × 2.0 ---Pilot jet (P.J) #12.5 ---Valve seat size (V.S) ø 1.5 ---Starter jet 1 (G.S.1) #37.5 ---Pilot air screw 1-3/4 turns out ---Float height (F.H) 15.5 ~ 16.5 mm (0.61 ~ 0.65 in) ---Fuel level (F.L) 2 ~ 3 mm (0.08 ~ 0.1 in) ---Engine idle speed 1,400 ~ 1,600 r/min ----

(1.691 ~ 1.693 in)

(0.0039 ~ 0.0157 in)

(0.0004 ~ 0.0010 in)

(0.106 ~ 0.114 in)

(0.59 ~ 1.50 kg, 1.3 ~ 3.3 lb)

SPEC

----

(0.0012 in)

0.50 mm (0.02 in)

0.05 mm (0.002 in)

2.6 mm (0.102 in)

(0.008 in)

(0.95 in)

(0.02 in)

----

2 - 8

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Lubrication system:

Oil ﬁlter type Wire mesh type ---Oil pump type Trochoid type ---Tip clearance “A” or “B” 0.15 mm

(0.0059 in)

Side clearance 0.13 ~ 0.18 mm

(0.0051 ~ 0.0071 in)

Housing and rotor clearance 0.06 ~ 0.10 mm

(0.0024 ~ 0.0039 in)

SPEC

0.2 mm (0.0079 in)

0.23 mm (0.0091 in)

0.15 mm (0.0059 in)

2 - 9

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened Thread size Q’ty

Cylinder head nut M8 × 1.25 4 22 2.2 16 Cylinder head bolt M6 × 1.0 2 10 1.0 7.2 Spark plug M10 × 1.0 1 13 1.3 9.4 Camshaft sprocket cover bolt M6 × 1.0 2 7 0.7 5.1 Tappet cover M45 × 1.5 2 18 1.8 13 Exhaust pipe stud bolt M6 × 1.0 2 7 0.7 5.1 Rotor nut M12 × 1.25 1 48 4.8 35 Timing chain guide (rear) M6 × 1.0 2 10 1.0 7.2 Valve clearance adjust screw locknut M5 × 0.5 2 7 0.7 5.1 Camshaft sprocket M8 × 1.25 1 20 2.0 14 Camshaft bearing retainer M6 × 1.0 1 10 1.0 7.2 Timing chain tensioner cap bolt M8 × 1.25 1 8 0.8 5.8 Timing chain tensioner M6 × 1.0 2 10 1.0 7.2 Oil pump M6 × 1.0 2 7 0.7 5.1 Drain bolt M12 × 1.5 1 20 2.0 14 Carburetor joint (cylinder head side) M6 × 1.0 2 7 0.7 5.1 Carburetor joint (carburetor side) M6 × 1.0 2 7 0.7 5.1 Air ﬁlter case M6 × 1.0 2 7 0.7 5.1 Exhaust pipe M6 × 1.0 2 7 0.7 5.1 Exhaust pipe protector M6 × 1.0 7 7 0.7 5.1 Silencer M8 × 1.25 1 24 2.4 17 Silencer protector M5 × 0.8 2 4 0.4 2.9 Crankcase M6 × 1.0 9 10 1.0 7.2 Crankcase cover (left) M6 × 1.0 8 7 0.7 5.1 Drive sprocket cover M6 × 1.0 2 7 0.7 5.1 Crankcase cover (right) M6 × 1.0 9 7 0.7 5.1 Timing plug M14 × 1.5 1 7 0.7 5.1 Crankshaft end cover M32 × 1.5 1 7 0.7 5.1 Cylinder head stud bolt M8 × 1.25 4 13 1.3 9.4 Kick crank M6 × 1.0 1 10 1.0 7.2 Primary drive gear M12 × 1.0 1 50 5.0 36 Pressure plate M5 × 0.8 4 6 0.6 4.3 Clutch boss M14 × 1.0 1 70 7.0 50 Main axle bearing retainer M6 × 1.0 1 10 1.0 7.2 Shift pedal M6 × 1.0 1 8 0.8 5.8 Clutch adjust screw locknut M6 × 1.0 1 8 0.8 5.8 Pickup coil M6 × 1.0 2 10 1.0 7.2 Stator assembly M6 × 1.0 3 10 1.0 7.2

Tightening torque

Nm m•kg ft•lb

2 - 10

MAINTENANCE SPECIFICATIONS

SPEC

CHASSIS

Item Standard Limit

Steering system:

Steering bearing type Angular bearing ----

Front suspension:

Front fork travel 110 mm (4.33 in) ---Fork spring free length 425.1 mm (16.74 in) 417 mm (16.4 in) Fork spring ﬁtting length 415.1 mm (16.34 in) ---Spring rate, STD K = 3.4 N/mm

----

(0.35 kg/mm, 19.41 lb/in) Optional spring/spacer No ---Oil capacity 64 cm

----

(2.26 lmp oz, 2.16 US oz) Oil level 185 mm (7.28 in) ---Oil grade Fork oil 15W or equivalent ----

Rear suspension:

Shock absorber travel 48 mm (1.89 in) ---Spring free length 169 mm (6.65 in) ---Fitting length 165 mm (6.5 in) ---Spring rate, STD K = 45.6 N/mm

----

(4.65 kg/mm, 260 lb/in) Optional spring No ---Enclosed gas pressure 2,000 kPa

(20 kg/cm

, 290 psi)

----

Swingarm:

Swingarm free play limit

End ---- 1.0 mm (0.04 in) Side clearance ---- 0.3 mm (0.01 in)

Wheel:

Front wheel type Spoke wheel ---Rear wheel type Spoke wheel ---Front rim size/material 14 × 1.40/steel ---Rear rim size/material 12 × 1.60/steel ---Rim runout limit:

Radial ---- 2.0 mm (0.08 in) Lateral ---- 2.0 mm (0.08 in)

Drive chain:

Type/manufacturer DID420(I)/DAIDO ---Number of links 86 links ---Chain slack 40 ~ 53 mm (1.6 ~ 2.1 in) ---Chain length (10 links) ---- 121.9 mm

(4.80 in)

2 - 11

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Drum brake:

Front drum brake type Leading, trailing ---Rear drum brake type Leading, trailing ---Front drum inside diameter 95 mm (3.74 in) 96 mm (3.78 in) Rear drum inside diameter 110 mm (4.33 in) 111 mm (4.37 in) Front lining thickness 3 mm (0.12 in) 2 mm (0.08 in) Rear lining thickness 4 mm (0.16 in) 2 mm (0.08 in) Front shoe spring free length 32.7 mm (1.29 in) ---Rear shoe spring free length 50.5 mm (1.99 in) ----

Brake lever and brake pedal:

Brake lever free play (lever end) 10 ~ 20 mm (0.39 ~ 0.79 in) ---Brake pedal free play 10 ~ 20 mm (0.39 ~ 0.79 in) ---Throttle grip free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----

SPEC

2 - 12

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened Thread size Q’ty

Tightening torque

Nm m•kg ft•lb

Engine mounting:

Engine and frame (front-upper) M8 × 1.25 1 30 3.0 22 Engine and frame (rear-upper) M8 × 1.25 1 26 2.6 19

Engine and frame (rear-lower) M10 × 1.25 1 40 4.0 29 Starter cable and frame M11 × 1.25 1 1 0.1 0.7 Pivot shaft and nut M10 × 1.25 1 30 3.0 22 Handle crown and steering shaft M10 × 1.25 1 40 4.0 29 Front fork cap bolt M20 × 1.0 2 40 4.0 29 Under bracket and front fork M10 × 1.25 2 33 3.3 24 Damper rod bolt M8 × 1.25 2 20 2.0 14 Handle crown and handlebar holder (lower) M10 × 1.25 2 40 4.0 29 Handlebar holder (upper) M6 × 1.0 4 13 1.3 9.4 Front brake cable holder and front fork M6 × 1.0 2 7 0.7 5.1 Steering ring nut M25 1 Refer to NOTE. Fuel tank and fuel cock M6 × 1.0 2 7 0.7 5.1 Fuel tank and frame M6 × 1.0 2 7 0.7 5.1 Grab bar and frame M6 × 1.0 4 13 1.3 9.4 Front brake camshaft lever and camshaft M6 × 1.0 1 7 0.7 5.1 Rear brake camshaft lever and camshaft M6 × 1.0 1 7 0.7 5.1 Front wheel axle nut M10 × 1.25 1 35 3.5 25 Rear brake shoe plate tension bar M8 × 1.25 2 26 2.6 19 Wheel drive hub and driven sprocket M8 × 1.25 4 25 2.5 18 Rear wheel axle nut M12 × 1.25 1 60 6.0 43 Wheel nipple (spoke) — 64 2 0.2 1.4 Drive chain guard M5 × 0.8 2 4 0.4 2.9 Drive chain support M5 × 0.8 3 4 0.4 2.9 Chain puller locknut M6 × 1.0 2 3 0.3 2.2 Footrest and frame M8 × 1.25 2 30 3.0 22

NOTE:

● 1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut

wrench and turn the steering right and left a few times; then loosen the ring nut one turn.

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

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

2 - 13

MAINTENANCE SPECIFICATIONS

EC212300

ELECTRICAL

Item Standard Limit

CDI:

Magneto-model/manufacturer F5HN 00/YAMAHA ---Source coil resistance (color) 688 ~ 1,032 Ω at 20 ˚C (68 ˚F)

(Brown – Green)

Pickup coil resistance (color) 248 ~ 372 Ω at 20 ˚C (68 ˚F)

(Red – White)

CDI unit-model/manufacturer 4GL-20/YAMAHA ----

Ignition coil:

Model/manufacturer 2JN-00/YAMAHA ---Minimum spark gap 6 mm (0.24 in) ---Primary winding resistance 0.18 ~ 0.28 Ω at 20 ˚C (68 ˚F) ---Secondary winding resistance 6.3 ~ 9.5 kΩ at 20 ˚C (68 ˚F) ----

Spark plug cap:

Type Resin ---Resistance 10 kΩ at 20 ˚C (68 ˚F) ----

SPEC

----

2 - 14

GENERAL TORQUE SPECIFICATIONS/

DEFINITION OF UNITS

EC220001

GENERAL TORQUE SPECIFICATIONS

This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature.

(Nut)

(Bolt)

Nm m•kg ft•lb

TORQUE

SPECIFICATION

SPEC

A: Distance between flats B: Outside thread diameter

10 mm 12 mm 14 mm 17 mm 19 mm 22 mm

EC230000

6 mm

8 mm 10 mm 12 mm 14 mm 16 mm

6 15 30 55 85

130

0.6

1.5

3.0

5.5

8.5 13

4.3 11 22 40 61 94

DEFINITION OF UNITS

Unit Read Definition Measure

-3

mm cm

millimeter

centimeter kg kilogram 10 N Newton 1 kg × m/sec Nm

m • kg

Newton meter

Meter kilogram Pa Pascal N/m

meter

-2

meter

gram Weight

Force

N × m m × kg

N/mm Newton per millimeter N/mm Spring rate L

Liter

Cubic centimeter

— —

r/min Revolution per minute — Engine speed

Length Length

Torque Torque

Pressure

Volume or capacity Volume or capacity

2 - 15

CABLE ROUTING DIAGRAM

1 Crankcase breather hose 2 Wire harness 3 CDI magneto lead 4 Starter cable 5 Carburetor heating lead 6 Engine stop switch lead 7 Thermo switch 8 Thermo switch lead 9 Spark plug lead 0 Throttle cable

A Cable holder B Fuel tank breather hose C Brake cable

Å After fastening the starter cable, CDI magneto lead, wire harness and

thermo switch lead, cut off any excess from the plastic locking tie end.

ı Pass the ignition coil lead through the lead guide. Ç Fasten the engine stop switch lead with the plastic bands. Î Pass the brake cable through the cable guides.

CABLE ROUTING DIAGRAM

SPEC

20 ~ 30 mm (0.79 ~ 1.18 in)

2 - 16

CABLE ROUTING DIAGRAM

SPEC

1 Cable guide 2 Brake cable 3 Throttle cable 4 Fuel tank breather hose 5 Engine stop switch lead 6 Air vent hose 7 Air intake duct 8 Ignition coil 9 Cable guide 0 Wire harness A Damper

B CDI unit lead C CDI unit D Rectifier/regulator lead E Rectifier/regulator F Crankcase breather hose G Carburetor breather hose H Spark plug lead I Fuel hose J Starter cable K CDI magneto lead L Thermo switch

BBB

CCC

‰

B - B C - C

D - D F - F

2 - 17

CABLE ROUTING DIAGRAM

SPEC

Å Pass the fuel tank breather hose through the

cable guide.

ı Pass the throttle cable and engine stop switch

lead through the cable guide.

Ç Pass the air vent hose through the hose guide. Î Fasten the CDI unit lead and rectifier/regulator

lead with the plastic clamp.

‰ Align the tape on the rectifier/regulator lead with

the plastic clamp.

Ï After fastening the engine stop switch lead, cut

off any excess from the plastic locking tie end.

Ì Pass the CDI unit lead through the lead guide.

‰

BBB

CCC

B - B C - C

D - D F - F

2 - 18

MAINTENANCE INTERVALS/

PERIODIC MAINTENANCE AND LUBRICATION

EC300000

INSP

ADJ

REGULAR INSPECTION AND ADJUSTMENTS

MAINTENANCE INTERVALS

The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.

PERIODIC MAINTENANCE AND LUBRICATION

Dealer

Note

* Fuel line

Spark plug

* Valves

Air filter Clean or replace if necessary.

* Carburetor

Exhaust systems

Engine oil

Clutch

* Front brake

* Rear brake

* Wheels

* Tires

* Wheel bearings

* Swingarm

Drive chain

* Steering bearings

Item Checks and maintenance jobs

Check fuel hoses for cracks or damage. Replace if necessary.

Check condition. Clean, regap or replace if necessary.

Check valve clearance. Adjust if necessary.

Check engine idling speed and starter operation. Adjust if necessary.

Check for leakage. Retighten if necessary. Replace gasket if necessary.

Check oil level and vehicle for oil leakage. Correct if necessary. Change. (Warm engine before draining.)

Check operation. Adjust or replace cable.

Check operation. Adjust brake lever free play and replace brake shoes if necessary.

Check operation. Adjust brake pedal free play and replace brake shoes if necessary.

Check balance, runout, spoke tightness and for damage. Tighten spokes and rebalance, replace if necessary.

Check tread depth and for damage. Replace if necessary. Check air pressure. Correct if necessary.

Check bearing for looseness or damage. Replace if necessary.

Check swingarm pivoting point for play. Correct if necessary. Lubricate with lithium soap base grease.

Check chain slack. Adjust if necessary. Make sure that the rear wheel is properly aligned. Clean and lubricate.

Check bearing play and steering for roughness. Correct accordingly. Lubricate with lithium soap base grease every 120 hours.

Initial Every

10 hours

(1 month)

60 hours

(6 months)

Every ride

120 hours

(12 months)

3 - 1

PRE-OPERATION INSPECTION AND MAINTENANCE

INSP

ADJ

Dealer

Note

* Chassis fasteners

Sidestand

* Spark arrester*

* Front fork

Rear shock

absorber assembly

*: Since these items requires special tools data and technical skills, they should be serviced. *1: For USA

Item Checks and maintenance jobs

Make sure that all nuts, bolts and screws are properly tightened. Tighten if necessary.

Check operation. Lubricate and repair if necessary.

Clean. Check operation and for oil leakage.

Correct accordingly. Check operation and shock absorber for oil

leakage. Replace shock absorber assembly if necessary.

Initial Every

10 hours

(1 month)

60 hours

(6 months)

120 hours

(12 months)

SERVICE NOTES:

No. 1. DRIVE CHAIN: In addition to tension and alignment, chain must be lubricated every

0.5 ~ 1.0 hour. If unit is subjected to extremely hard usage and wet weather riding, chain must be checked constantly. See “Lubrication Intervals” for additional details.

No. 2. AIR FILTER: Remove and clean filter every 20 ~ 40 hours.

PRE-OPERATION INSPECTION AND MAINTENANCE

Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points.

GENERAL INSPECTION AND MAINTENANCE

Item Routine Page Brake Check operation/adjustment. P3-11 Engine oil Change oil as required. P3-5 ~ 7 Drive chain Check alignment/adjustment/lubrication. P3-12 ~ 13 Spark plug Check color/condition. P3-19 Throttle Check for proper throttle cable operation. P3-3 Air filter Foam type – must be clean and damp oil always P3-3 ~ 4 Wheels and tires Check pressure/runout/spoke tightness/bead stopper/axle nuts. P3-14 ~ 17 Fittings/fasteners Check all – tighten as necessary. P2-13

3 - 2

ENGINE/THROTTLE CABLE ADJUSTMENT/

AIR FILTER CLEANING

EC350000

ENGINE

THROTTLE CABLE ADJUSTMENT

1. Check:

● Throttle grip free play a

Out of specification → Adjust.

Throttle grip free play a:

3 ~ 5 mm (0.12 ~ 0.20 in)

2. Adjust:

● Throttle grip free play

Throttle grip free play adjustment steps:

OTE:

Before adjusting the throttle cable free play, the engine idle speed should be adjusted.

● Loosen the locknut 1 on throttle cable.

● Turn the adjuster 2 in or out until the

specified free play is obtained.

INSP

ADJ

Turning in: Free play is increased.

Turning out: Free play is decreased.

● Tighten the locknut.

WARNING

After adjusting, turn the handlebar to right and left and make sure that the engine idling does not run faster.

AIR FILTER CLEANING

OTE:

Proper air filter maintenance is the biggest key to preventing premature engine wear and damage.

CAUTION:

Never run the engine without the air filter element in place; this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage.

3 - 3

AIR FILTER CLEANING

1. Install:

● Air scoop (right) 1

2. Install:

● Air filter case cover 1

3. Clean:

● Air filter element

Clean them with solvent.

INSP

ADJ

OTE:

After cleaning, remove the remaining solvent by squeezing the element.

CAUTION:

● Do not twist the element when squeezing

the element.

● Leaving too much of solvent in the ele-

ment may result in poor starting.

4. Inspect:

● Air filter element

Damage → Replace.

5. Apply:

● Foam-air-filter oil or engine mixing oil

To the element.

OTE:

Squeeze out the excess oil. Element should be wet but not dripping.

6. Install:

● Air filter element 1

OTE:

Align the projection a on the air filter case with the hole b in the air filter element.

7. Install:

● Air filter case cover

8. Install:

● Air scoop (right)

3 - 4

ENGINE OIL LEVEL INSPECTION

1. Start the engine, warm it up for several minutes and wait for five minutes.

2. Place the machine on a level place and hold it up on upright position by placing the suitable stand under the engine.

3. Remove:

● Dipstick 1

INSP

ADJ

10 30 50 70

-20

-10

4. Check:

● Oil level

Oil level should be between maximum a and minimum b marks. Oil level is low → Add oil to proper level.

OTE:

When inspecting the oil level, do not screw the dipstick into the oil tank. Insert the gauge lightly.

130

˚F

110

(For USA and CDN)

Recommended oil:

At –10 ˚C (10 ˚F) or higher Å:

Yamalube 4 (10W-30) or SAE

10W-30 type SE/SF motor oil

At 5 ˚C (40 ˚F) or higher ı:

20 30 40

˚C

Yamalube 4 (20W-40) or SAE 20W-40 type SE/SF motor oil

CAUTION:

● Do not add any chemical additives.

Engine oil also lubricates the clutch and additives could cause clutch slippage.

● Do not allow foreign material to enter the

crankcase.

3 - 5

ENGINE OIL REPLACEMENT

(Except for USA and CDN)

Recommended oil:

Refer to the following chart for selection of oils which are suited

to the atmospheric temperatures. Recommended engine oil classification: API STANDARD:

API “SE/SF” or higher grade

(Designed primarily for motor-

cycles)

CAUTION:

● Do not add any chemical additives or use

oils with a grade of CD a or higher.

● Do not use oils labeled “ENERGY CON-

SERVING II” b or higher. Engine oil also lubricates the clutch and additives could cause clutch slippage.

● Do not allow foreign materials to enter the

crankcase.

INSP

ADJ

5. Install:

● Dipstick

6. Start the engine and let it warm up for several minutes.

7. Turn off the engine and inspect the oil level once again.

OTE:

Wait a few minutes until the oil settles before inspecting the oil level.

ENGINE OIL REPLACEMENT

1. Start the engine and warm it up for several minutes and wait for five minutes.

2. Place the machine on a level place and hold it on upright position by placing the suitable stand under the engine.

3. Place a suitable container under the engine.

4. Remove:

● Dipstick 1

● Drain bolt (with gasket) 2

Drain the crankcase of its oil.

3 - 6

PILOT AIR SCREW ADJUSTMENT

5. Install:

● Gasket

● Drain bolt

6. Fill:

● Crankcase

Oil quantity:

New

20 Nm (2.0 m · kg, 14 ft · lb)

Periodic oil change:

0.8 L (0.70 Imp qt, 0.85 US qt)

INSP

ADJ

7. Install:

● Dipstick

8. Inspect:

● Engine (for oil leaks)

● Oil level

Refer to “ENGINE OIL LEVEL INSPECTION”.

PILOT AIR SCREW ADJUSTMENT

1. Adjust:

● Pilot air screw 1

Adjusting steps:

● Screw in the pilot air screw until it is lightly

seated.

● Back out by the specified number of turns.

Pilot air screw:

1-3/4 turns out

3 - 7

IDLE SPEED ADJUSTMENT/

VALVE CLEARANCE ADJUSTMENT

IDLE SPEED ADJUSTMENT

1. Start the engine and thoroughly warm it up.

2. Attach:

● Inductive tachometer

To spark plug lead.

3. Adjust:

● Idle speed

Adjustment steps:

● Adjust the pilot screw.

Refer to “PILOT AIR SCREW ADJUSTMENT” section.

● Turn the throttle stop screw 1 until the

engine runs at the lowest possible speed.

To increase idle speed →

Turn the throttle stop screw 1 in a.

To decrease idle speed →

Turn the throttle stop screw 1 out b.

INSP

ADJ

Inductive tachometer:

YU-8036-B/90890-03113

Engine idling speed:

1,400 ~ 1,600 r/min

VALVE CLEARANCE ADJUSTMENT

OTE:

● The valve clearance should be adjusted

when the engine is cool to the touch.

● The piston must be at Top Dead Center

(T.D.C.) on compression stroke to check or adjust the valve clearance.

1. Remove:

● Air scoop (right) 1

● Air filter case 2

2. Remove:

● Spark plug

● Tappet cover (intake side) 1

● Tappet cover (exhaust side) 2

3 - 8

3. Remove:

● Timing plug 1

● Crankshaft end cover 2

● O-rings

VALVE CLEARANCE ADJUSTMENT

4. Check:

● Valve clearance

Out of specification → Adjust.

Valve clearance (cold):

Intake valve:

0.05 ~ 0.09 mm (0.0020 ~ 0.0035 in)

Exhaust valve:

0.08 ~ 0.12 mm (0.031 ~ 0.047 in)

Checking steps:

● Turn the crankshaft counterclockwise with

a wrench.

● Align the T.D.C. mark a on the rotor with

the align mark b on the crankcase cover when piston is at T.D.C. on compression stroke.

● Measure the valve clearance using a

feeler gauge 1. Out of specification → Adjust clearance.

INSP

ADJ

5. Adjust:

● Valve clearance

Adjustment steps:

● Loosen the locknut 1.

● Turn the adjuster 3 in or out with the

valve adjusting tool 2 until specified clearance is obtained.

Turning in →

Valve clearance is decreased.

Turning out →

Valve clearance is increased.

Valve adjusting tool:

YM-8035/90890-01311

● Hold the adjuster to prevent it from moving

and tighten the locknut.

7 Nm (0.7 m · kg, 5.1 ft · lb)

● Measure the valve clearance.

● If the clearance is incorrect, repeat above

steps until specified clearance is obtained.

3 - 9

SPARK ARRESTER CLEANING (For USA)

6. Install:

● Tappet cover (intake side) 1

18 Nm (1.8 m · kg, 13 ft · lb)

● O-ring 2

OTE:

Apply the lithium soap base grease on the O-ring.

7. Install:

● Tappet cover (exhaust side)

● O-ring

● Spark plug

● Timing plug

● Crankshaft end cover

OTE:

Apply the lithium soap base grease on the O-ring.

New

18 Nm (1.8 m · kg, 13 ft · lb)

New

13 Nm (1.3 m · kg, 9.4 ft · lb)

7 Nm (0.7 m · kg, 5.1 ft · lb)

INSP

ADJ

8. Install:

● Air filter case

● Air scoop (right)

SPARK ARRESTER CLEANING (For USA)

WARNING

● Be sure the exhaust pipe and muffler are

cool before cleaning the spark arrester.

● Do not start the engine when cleaning the

exhaust system.

1. Remove:

● Bolt (tailpipe) 1

2. Remove:

● Tailpipe 2

Pull the tailpipe out of the muffler.

3. Clean:

● Spark arrester

Use a wire brush to remove any carbon deposits from the spark arrester portion of the muffler body 3 inner surface. Tap the tailpipe lightly and remove the carbon deposits from the outside portion a of the tailpipe.

4. Install:

● Tailpipe

Insert the tailpipe into the muffler and align the bolt hole.

● Bolt (tailpipe)

7 Nm (0.7 m · kg, 5.1 ft · lb)

3 - 10

CHASSIS/FRONT BRAKE ADJUSTMENT/

REAR BRAKE ADJUSTMENT

CHASSIS

FRONT BRAKE ADJUSTMENT

1. Check:

● Brake lever free play a

Out of specification → Adjust.

INSP

ADJ

Free play (brake lever):

10 ~ 20 mm (0.39 ~ 0.79 in) (at brake lever end)

2. Adjust:

● Brake lever free play

Adjustment steps:

● Loosen the locknuts 1.

● Turn the adjusters 2 in or out until the

specified free play is obtained.

Turning in: Free play is increased.

Turning out: Free play is decreased.

● Tighten the locknuts.

CAUTION:

Make sure that there is no brake drag after adjusting the front brake lever free play.

REAR BRAKE ADJUSTMENT

1. Check:

● Brake pedal free play a

Out of specification → Adjust.

Free play:

10 ~ 20 mm (0.39 ~ 0.79 in)

2. Adjust:

● Brake pedal free play

Adjustment steps:

● Turn the adjuster 1 in or out until the

specified free play is obtained.

Turning in: Free play is decreased.

Turning out: Free play is increased.

CAUTION:

Make sure that the brake does not drag after adjusting it.

3 - 11

DRIVE CHAIN SLACK ADJUSTMENT

1. Elevate the rear wheel by placing the suitable stand under the engine.

2. Check:

● Drive chain slack a

In the center between the drive axle and rear wheel axle. Out of specification → Adjust.

Drive chain slack:

40 ~ 53 mm (1.6 ~ 2.1 in)

OTE:

Before checking and/or adjusting, rotate the rear wheel through several revolutions and check the slack several times to find the tightest point. Check and/or adjust chain slack with rear wheel in this “tight chain” position.

INSP

ADJ

3. Adjust:

● Drive chain slack

Drive chain slack adjustment steps:

● Loosen the wheel axle nut 1.

● Adjust chain slack by turning the adjusters

To tighten → Turn adjuster 2 clockwise. To loosen → Turn adjuster 2 counter-

clockwise and push wheel forward.

● Turn each adjuster exactly the same

amount to maintain correct axle alignment. (There are marks a on each side of chain puller alignment.)

OTE:

Turn the adjuster so that the chain is in line with the sprocket, as viewed from the rear.

CAUTION:

Too small chain slack will overload the engine and other vital parts; keep the slack within the specified limits.

3 - 12

FRONT FORK INSPECTION/REAR SHOCK ABSORBER INSPECTION/

REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT

● Tighten the wheel axle nut while pushing

down the drive chain.

Axle nut:

60 Nm (6.0 m • kg, 43 ft • lb)

EC36C000

FRONT FORK INSPECTION

1. Inspect:

● Front fork smooth action

Operate the front brake and stroke the front fork. Unsmooth action/oil leakage → Repair or replace.

INSP

ADJ

EC36K000

REAR SHOCK ABSORBER INSPECTION

1. Inspect:

● Swingarm smooth action

Abnormal noise/unsmooth action → Grease the pivoting points or repair the pivoting points. Damage/oil leakage → Replace.

REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT

1. Elevate the rear wheel by placing the suitable stand under the engine.

2. Remove:

● Rear shock absorber

Refer to “SWINGARM” section in the CHAPTER 5.

3. Remove:

● Spring guide 1

OTE:

While compressing the spring, remove the spring guide.

3 - 13

TIRE PRESSURE CHECK

4. To stiffen the spring preload, install the circlip 1 into the groove a. To soften the spring preload, install the circlip into the groove b.

OTE:

Do not spread the circlip too much.

Standard installation position:

Groove b

5. Install:

● Spring guide 1

OTE:

While compressing the spring, install the spring guide.

INSP

ADJ

6. Install:

● Rear shock absorber

Refer to “SWINGARM” section in the CHAPTER 5.

EC36Q000

TIRE PRESSURE CHECK

1. Measure:

● Tire pressure

Out of specification → Adjust.

Standard tire pressure:

100 kPa (1.00 kgf/cm

, 14.5 psi)

OTE:

● Check the tire while it is cold.

● Loose bead stoppers allow the tire to slip off

its position on the rim when the tire pressure is low.

● A tilted tire valve stem indicates that the tire

slips off its position on the rim.

● If the tire valve stem is found tilted, the tire is

considered to be slipping off its position. Correct the tire position.

3 - 14

SPOKES INSPECTION AND TIGHTENING/WHEEL INSPECTION/

STEERING HEAD INSPECTION AND ADJUSTMENT

SPOKES INSPECTION AND TIGHTENING

1. Inspect:

● Spokes 1

Bend/damage → Replace. Loose spoke → Retighten.

2. Tighten:

2 Nm (0.2 m · kg, 1.4 ft · lb)

● Spokes

OTE:

Be sure to retighten these spokes before and after break-in. After a practice or a race check spokes for looseness.

INSP

ADJ

EC36T000

WHEEL INSPECTION

1. Inspect:

● Wheel runout

Elevate the wheel and turn it. Abnormal runout → Replace.

2. Inspect:

● Bearing free play

Exist play → Replace.

STEERING HEAD INSPECTION AND ADJUSTMENT

1. Elevate the front wheel by placing a suitable stand under the engine.

2. Check:

● Steering shaft

Grasp the bottom of the forks and gently rock the fork assembly back and forth. Free play → Adjust steering head.

3 - 15

STEERING HEAD INSPECTION AND ADJUSTMENT

3. Check:

● Steering smooth action

Turn the handlebar lock to lock. Unsmooth action → Adjust steering ring nut.

4. Adjust:

● Steering ring nut

Steering ring nut adjustment steps:

● Remove the front fender 1.

● Remove the handlebar and handle crown.

● Loosen the ring nut 2 using the ring nut

wrench 3.

INSP

ADJ

Ring nut wrench:

YU-1268/90890-01268

● Tighten the ring nut 4 using ring nut

wrench 5 and turn the steering right and left a few times.

OTE:

Set the torque wrench to the ring nut wrench so that they form a right angle.

Ring nut wrench:

YM-33975/90890-01403

Ring nut (initial tightening):

38 Nm (3.8 m • kg, 27 ft • lb)

● Loosen the ring nut one turn.

● Retighten the ring nut using the ring nut

wrench.

WARNING

Avoid over-tightening.

3 - 16

Ring nut (final tightening):

1 Nm (0.1 m • kg, 0.7 ft • lb)

● Check the steering shaft by turning it lock

to lock. If there is any binding, remove the steering shaft assembly and inspect the steering bearings.

● Install the handle crown 6, handlebar 7,

and front fender.

STEERING HEAD INSPECTION AND ADJUSTMENT

INSP

ADJ

CAUTION:

Install the handlebar holder with its groove a facing outward, and tighten the bolts so that the gaps b are equal.

Steering stem bolt:

40 Nm (4.0 m • kg, 2.9 ft • lb)

Front fork cap bolt:

40 Nm (4.0 m • kg, 2.9 ft • lb)

Handlebar upper holder:

13 Nm (1.3 m • kg, 9.4 ft • lb)

3 - 17

LUBRICATION

INSP

ADJ

LUBRICATION

To ensure smooth operation of all components, lubricate your machine during setup, after break-in, and after every race.

1 All control cable 2 Brake lever pivot 3 Shift pedal pivot 4 Footrest pivot 5 Throttle-to-handlebar contact 6 Drive chain 7 Tube guide cable winding portion 8 Throttle cable end 9 Brake cable end

Å Use Yamaha cable lube or equivalent on these

areas.

ı Use SAE 10W-30 motor oil or suitable chain

lubricants.

Ç Lubricate the following areas with high quality,

lightweight lithium-soap base grease.

AAA

AAB

3 - 18

ELECTRICAL/SPARK PLUG INSPECTION

EC370000

ELECTRICAL

EC371001

SPARK PLUG INSPECTION

1. Remove:

● Spark plug

2. Inspect:

● Electrode 1

Wear/damage → Replace.

● Insulator color 2

Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition.

OTE:

When the engine runs for many hours at low speeds, the spark plug insulator will become sooty, even if the engine and carburetor are in good operating condition.

INSP

ADJ

3. Measure:

● Plug gap a

Use a wire gauge or thickness gauge. Out of specification → Regap.

Spark plug gap:

0.6 ~ 0.7 mm (0.02 ~ 0.03 in)

Standard spark plug:

CR6HSA (NGK) U20FSR-U (DENSO)

4. Clean the plug with a spark plug cleaner if necessary.

5. Tighten:

● Spark plug

13 Nm (1.3 m · kg, 9.4 ft · lb)

OTE:

● Before installing a spark plug, clean the gas-

ket surface and plug surface.

● Finger-tighten a the spark plug before

torquing to specification b.

3 - 19

ENGINE

CARBURETOR

ENG

Extent of removal:

Extent of removal Order Part name Q’ty Remarks

Preparation for removal Fuel tank

1 Clamp (air filter joint) 1 Loosen the screw (air filter joint). 2 Carburetor heater lead 1 3 Air vent hose 1 4 Fuel hose 1

5 Bolt 2 6 Carburetor assembly 1 7 O-ring 1 8 Spacer 1 9 Carburetor top 1

10 Starter plunger assembly 1

Carburetor removal

CARBURETOR REMOVAL

4 - 1

EC468000

CARBURETOR DISASSEMBLY

CARBURETOR

ENG

Extent of removal:

Extent of removal Order Part name Q’ty Remarks

Carburetor disassembly

CARBURETOR DISASSEMBLY

Throttle valve 1 Throttle cable 1 Spring 1 Gasket 1 Carburetor top cover 1 Jet needle stopper 1 Jet needle assembly 1 Starter plunger assembly 1 Starter cable 1 Float chamber 1

4 - 2

CARBURETOR

ENG

Extent of removal Order Part name Q’ty Remarks

Float pin 1 Float 1 Needle valve 1

Main jet 1 Pilot jet 1 Needle jet 1 Throttle stop screw assembly 1 Pilot air screw assembly 1 Carburetor heater

4 - 3

CARBURETOR

EC464000

ENG

INSPECTION Carburetor

1. Inspect:

●

Carburetor body Contamination → Clean.

NOTE:

Use a petroleum based solvent for cleaning.

●

Blow out all passages and jets with compressed air. Never use a wire.

●

2. Inspect:

●

Main jet 1 Pilot jet 2

●

Needle jet 3 Damage → Replace. Contamination → Clean.

NOTE:

●

Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air. Never use a wire.

●

Needle valve

1. Inspect:

Needle valve 1

●

Valve seat 2 Grooved wear a → Replace. Dust b → Clean.

EC464301

Throttle valve

1. Check:

Free movement

●

Stick → Repair or replace.

NOTE:

Insert the throttle valve 1 into the carburetor body, and check for free movement.

4 - 4

CARBURETOR

EC464401

ENG

Jet needle

1. Inspect:

Jet needle 1

●

Bends/wear → Replace.

● Clip groove

Free play exists/wear → Replace.

● Clip position

Standard clip position:

No.2 Groove

Float height

1. Measure:

● Float height a

Out of specification → Adjust.

Float height:

15.5 ~ 16.5 mm (0.61 ~ 0.65 in)

Measurement and adjustment steps:

● Hold the carburetor in an upside down

position.

NOTE:

● Slowly tilt the carburetor in the opposite

direction, then take the measurement when the needle valve aligns with the float arm.

● If the carburetor is level, the weight of the

float will push in the needle valve, resulting in an incorrect measurement.

● Measure the distance between the mating

surface of the float chamber and top of the float using a vernier calipers.

NOTE:

The float arm should be resting on the needle valve, but not compressing the needle valve.

● If the float height is not within specifica-

tion, inspect the valve seat and needle valve.

● If either is worn, replace them both.

● If both are fine, adjust the float height by

bending the float tab 1 on the float.

● Recheck the float height.

4 - 5

CARBURETOR

EC464600

ENG

Float

1. Inspect:

● Float 1

Damage → Replace.

ASSEMBLY AND INSTALLATION Carburetor

1. Install:

● Pilot air screw 1

Note the following installation points:

● Screw in the pilot air screw until it is lightly

seated.

● Back out it by the specified number of

turns.

Pilot air screw:

1-3/4 turns out

2. Install:

● Throttle valve 1

● Starter plunger 2

NOTE:

Align the slit a of the throttle valve with the tab b of the carburetor top.

FUEL LEVEL ADJUSTMENT

WARNING

Gasoline (fuel) and its vapors are highly flammable and explosive. Keep away from sparks, cigarettes, flames or other sources of ignition.

4 - 6

CARBURETOR

1. Measure:

● Fuel level a

Use a fuel level gauge 1. Out of specification → Adjust.

Fuel level gauge:

YM-1312-A/90890-01312

Fuel level:

2 ~ 3 mm (0.08 ~ 0.12 in) below the float chamber line

ENG

4 - 7

CYLINDER HEAD

ENG

Extent of removal: 1 Cylinder head removal

Extent of removal Order Part name Q’ty Remarks

CYLINDER HEAD REMOVAL

Preparation for removal Seat, fuel tank and rear fender

Exhaust pipe Carburetor Refer to “CARBURETOR” section.

Air filter case and starter lever 1 Plug cap/spark plug 1/1 2 Crankshaft end cover/O-ring 1/1 3 Timing plug/O-ring 1/1 4 Camshaft sprocket cover/O-ring 1/1

5 Tappet cover (intake)/O-ring 1/1 6 Tappet cover (exhaust)/O-ring 1/1 7 Camshaft sprocket bolt/washer 1/1

Refer to “REMOVAL POINTS”.8 Timing chain tensioner 1

9 Gasket 1

4 - 8

CYLINDER HEAD

ENG

Extent of removal Order Part name Q’ty Remarks

10 Camshaft sprocket 1

Refer to “REMOVAL POINTS”.11 Timing chain 1

12 Cylinder head 1 13 Gasket 1 14 Dowel pin 2

4 - 9

CYLINDER HEAD

ENG

REMOVAL POINTS Cylinder head

1. Align:

● “I” mark

(with stationary pointer)

Checking steps:

● Turn the crankshaft counterclockwise with

a wrench.

● Align the “I” mark a on the rotor with the

stationary pointer b on the crankcase cover. When the “I” mark is aligned with the stationary pointer, the piston is at the Top Dead Center (T.D.C.).

NOTE:

● In order to be sure that the piston is at Top

Dead Center, the match mark c on the camshaft sprocket must align with the stationary pointer d on the cylinder head as shown in the illustration.

● If there is no valve clearance, rotate the

crankshaft counterclockwise one turn.

2. Loosen:

● Camshaft sprocket bolt 1

3. Remove:

● Timing chain tensioner

● Camshaft sprocket 2

NOTE:

● Fasten a safety wire to the timing chain 3 to

prevent it from falling into the crankcase.

● Remove the bolt 1 while holding the rotor

nut with a wrench.

4 - 10

CYLINDER HEAD

ENG

4. Remove:

● Cylinder head

NOTE:

● Loosen the bolts and nuts in their proper

loosening sequence.

● Start by loosening each bolt and nut 1/2 turn

until all are loose.

ASSEMBLY AND INSTALLATION

1. Install:

● Cylinder head

2. Tighten:

22 Nm (2.2 m · kg, 16 ft · lb)

● Nuts

● Bolts

10 Nm (1.0 m · kg, 7.2 ft · lb)

NOTE:

● Apply the engine oil on the contact surfaces

of the nuts, bolts and copper washers.

● Follow the numerical order shown in the illus-

tration. Tighten the bolts and nuts in two stages.

4 - 11

3. Install:

● Camshaft sprocket 1

Installation steps:

● Turn the crankshaft counterclockwise until

the “I” mark a on the rotor is aligned with the stationary pointer b on the crankcase cover.

● Align the “I” mark c on the camshaft

sprocket with the stationary pointer d on the cylinder head.

● Fit the timing chain 2 onto camshaft

sprocket and install the camshaft sprocket on the camshaft.

NOTE:

When installing the camshaft sprocket, keep the timing chain as tense as possible on the exhaust side.

CYLINDER HEAD

ENG

CAUTION:

.Do not turn the crankshaft during instal-

lation of the camshaft. Damage or improper valve timing will result.

● Remove the safety wire from the timing

chain.

4. Install:

● Washer

20 Nm (2.0 m · kg, 14 ft · lb)

● Bolt 1

NOTE:

Install the bolt 1 while holding the rotor nut with a wrench.

5. Install:

● Timing chain tensioner

Installation steps:

● Remove the tensioner cap bolt 1 and

spring 2.

● Release the timing chain tensioner one-

way cam 3 and push the tensioner rod 4 all the way in.

● Install the tensioner with a new gasket 5

onto the cylinder.

Timing chain tensioner bolt:

10 Nm (1.0 m • kg, 7.2 ft • lb)

● Install the spring 2 and cap bolt 1.

● Tighten the bolt (with gasket) to the speci-

fied torque.

Cap bolt:

8 Nm (0.8 m • kg, 5.8 ft • lb)

6. Check:

● Rotor “I” mark

Align with the crankcase stationary pointer.

● Valve clearance

Out of specification → Adjust. Refer to the “VALVE CLEARANCE ADJUSTMENT” section in CHAPTER

4 - 12

CAMSHAFT AND ROCKER ARMS

ENG

Extent of removal: 1 Rocker arm 2 Camshaft removal

Extent of removal Order Part name Q’ty Remarks

CAMSHAFT AND ROCKER

ARMS

Preparation for removal Cylinder head Refer to “CYLINDER HEAD” section.

1 Rocker arm shaft (intake) 1 Use special tool.

2 Rocker arm shaft (exhaust) 1 Refer to “REMOVAL POINTS”. 3 Rocker arm 2 4 Camshaft bearing retainer 1 5 Camshaft 1 6 Valve clearance adjust screw

locknut 7 Valve clearance adjust screw 2

4 - 13

CAMSHAFT AND ROCKER ARMS

REMOVAL POINTS Rocker arm shaft

1. Remove:

● Rocker arm shafts

NOTE:

Use a slide hammer bolt 1 and weight 2 to slide out the rocker arm shafts.

Slide hammer set:

YU-1083-A

Slide hammer bolt:

90890-01085

Weight:

90890-01084

ENG

INSPECTION Camshaft

1. Measure:

● Cam lobes length a and b

Out of specification → Replace.

Cam lobes length limit:

Intake:

a 25.398 mm (0.9999 in) b 21.004 mm (0.8269 in)

Exhaust:

a 25.256 mm (0.9943 in) b 21.017 mm (0.8274 in)

ASSEMBLY AND INSTALLATION

1. Apply:

● Molybdenum disulfide oil

(onto the camshaft cam lobe)

● Engine oil

(onto the camshaft bearing)

2. Install:

● Camshaft 1

4 - 14

CAMSHAFT AND ROCKER ARMS

3. Apply:

● Molybdenum disulfide oil

(onto the rocker arm and rocker arm shaft)

4. Install:

● Rocker arm 1

● Rocker arm shaft 2

ENG

4 - 15

VALVES AND VALVE SPRINGS

ENG

Extent of removal: 1 Valves removal

Extent of removal Order Part name Q’ty Remarks

VALVES AND VALVE SPRINGS

REMOVAL

Preparation for removal Cylinder head Refer to “CYLINDER HEAD” section.

Rocker arm and camshaft Refer to “CAMSHAFT AND ROCKER

ARMS” section.

1 Valve cotter 4 Use special tool.

Refer to “REMOVAL POINTS”.

2 Spring retainer 2

3 Valve spring 2 4 Intake valve 1 5 Exhaust valve 1 6 Valve stem seal 2

4 - 16

VALVES AND VALVE SPRINGS

REMOVAL POINTS Valve removal

1. Remove:

● Valve cotters 1

NOTE:

Attach a valve spring compressor 2 between the valve spring retainer and the cylinder head to remove the valve cotters.

Valve spring compressor:

YM-4019/90890-04019

ENG

INSPECTION Valve

1. Measure:

● Stem-to-guide clearance

Stem-to-guide clearance =

valve guide inside diameter a – valve stem diameter b

Out of specification → Replace the valve guide.

Clearance (stem to guide):

Intake:

0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) <Limit>: 0.08 mm (0.003 in)

Exhaust:

0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) <Limit>: 0.10 mm (0.004 in)

2. Measure:

● Runout (valve stem)

Out of specification → Replace.

4 - 17

Runout limit:

0.02 mm (0.0008 in)

VALVES AND VALVE SPRINGS

Valve spring

1. Measure:

● Valve spring free length a

Out of specification → Replace.

Free length (valve spring):

Intake:

28.32 mm (1.11 in) <Limit>: 26.9 mm (1.06 in)

Exhaust:

28.32 mm (1.11 in) <Limit>: 26.9 mm (1.06 in)

2. Measure:

● Spring tilt a

Out of specification → Replace.

Spring tilt limit:

Intake:

2.5˚/1.2 mm (0.05 in)

Exhaust:

2.5˚/1.2 mm (0.05 in)

ENG

Valve seat

1. Measure:

● Valve seat width a

Out of specification → Reface the valve seat.

Valve seat width:

Intake:

0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) <Limit>: 1.6 mm (0.0630 in)

Exhaust:

0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) <Limit>: 1.6 mm (0.0630 in)

Measurement steps:

● Apply Mechanic’s blueing dye (Dykem) b

to the valve face.

● Install the valve into the cylinder head.

● Press the valve through the valve guide

and onto the valve seat to make a clear pattern.

● Measure the valve seat width. Where the

valve seat and valve face made contact, blueing will have been removed.

● If the valve seat is too wide, too narrow, or

the seat is not centered, the valve seat must be refaced.

4 - 18

VALVES AND VALVE SPRINGS

2. Lap:

● Valve face

● Valve seat

NOTE:

After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped.

Lapping steps:

● Apply a coarse lapping compound to the

valve face.

CAUTION:

Do not let the compound enter the gap between the valve stem and the guide.

● Apply molybdenum disulfide oil to the

valve stem.

● Install the valve into the cylinder head.

● Turn the valve until the valve face and

valve seat are evenly polished, then clean off all of the compound.

ENG

NOTE:

For best lapping results, lightly tap the valve seat while rotating the valve back and forth between your hands.

● Apply a fine lapping compound to the

valve face and repeat the above steps.

NOTE:

After every lapping operation be sure to clean off all of the compound from the valve face and valve seat.

● Apply Mechanic’s blueing dye (Dykem) to

the valve face.

● Install the valve into the cylinder head.

● Press the valve through the valve guide

and onto the valve seat to make a clear pattern.

● Measure the valve seat width again. If the

valve seat width is out of specification, reface and relap the valve seat.

4 - 19

VALVES AND VALVE SPRINGS

ASSEMBLY AND INSTALLATION

1. Apply:

● Molybdenum disulfide oil

(onto the valve stem and valve stem seal)

2. Install:

● Valve stem seats

● Valves

● Valve springs

● Valve spring retainers

NOTE:

● Make sure that each valve is installed in its

original place, also referring to the embossed mark as follows.

Intake: “G” Exhaust: “L”

● Install the valve springs with the larger pitch

a facing upwards.

b Smaller pitch

ENG

New

3. Install:

● Valve cotters

NOTE:

While compressing the valve spring with a valve spring compressor and attachment 1 install the valve cotters.

Valve spring compressor:

YM-4019/90890-04019

4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood.

CAUTION:

Hitting the valve tip with excessive force could damage the valve.

4 - 20

CYLINDER AND PISTON

ENG

Extent of removal: 1 Cylinder removal 2 Piston removal

Extent of removal Order Part name Q’ty Remarks

CYLINDER AND PISTON REMOVAL

Preparation for removal Cylinder head Refer to “CYLINDER HEAD” section.

1 Timing chain guide (exhaust) 1 2 Cylinder 1 3 Dowel pin 2 4 Gasket 1 5 Piston pin clip 2 6 Piston pin 1 7 Piston 1 8 Piston ring (top) 1

10 Side rail/spacer 2/1

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Use special tool. Refer to “REMOVE POINTS”.

Refer to “REMOVAL POINTS”.9 Piston ring (2nd) 1

CYLINDER AND PISTON

REMOVAL POINTS Piston

1. Remove:

● Piston pin clips 1

● Piston pin 2

● Piston 3

NOTE:

● Before removing the piston pin clip, cover the

crankcase opening with a clean towel or rag to prevent the clip from falling into the crankcase cavity.

● Before removing each piston pin, deburr the

clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller set 4.

Piston pin puller set:

YU-1304/90890-01304

ENG

Piston ring

1. Remove:

● Piston rings

NOTE:

Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown, as shown in the illustration.

INSPECTION Cylinder and piston

1. Inspect:

● Cylinder and piston walls

Vertical scratches → Replace cylinder and piston.

2. Measure:

● Piston-to-cylinder clearance

Measurement steps: 1st step:

● Measure the cylinder bore “C” with a cylin-

der bore gauge.

4 - 22

NOTE:

Measure the cylinder bore “C” in parallel to and at right angles to the crankshaft. Then, find the average of the measurements.

CYLINDER AND PISTON

ENG

Cylinder bore “C”

47.000 ~ 47.005 mm

(1.8504 ~ 1.8506 in)

Taper limit “T” 0.05 mm (0.002 in)

Out of round “R” 0.05 mm (0.002 in)

“C” = Maximum D

“T” = (Maximum D

– (Maximum D

“R” = (Maximum D

1 or D2)

5 or D6)

1, D3 or D5)

– (Minimum D2, D4 or D6)

● If out of specification, replace the cylinder,

and replace the piston and piston rings as set.

2nd step:

● Measure the piston skirt diameter “P” with

a micrometer.

a 4 mm (0.16 in) from the piston bottom edge.

Piston size P

Standard

46.960 ~ 46.975 mm (1.8488 ~ 1.8494 in)

● If out of specification, replace the piston

and piston rings as a set.

3rd step:

● Calculate the piston-to-cylinder clearance

with following formula:

Piston-to-cylinder clearance =

Cylinder bore “C” – Piston skirt diameter “P”

Piston-to-cylinder clearance:

0.025 ~ 0.045 mm (0.0010 ~ 0.0018 in) <Limit>: 0.15 mm (0.0059 in)

● If out of specification, replace the cylinder,

and replace the piston and piston rings as set.

4 - 23

CYLINDER AND PISTON

Piston ring

1. Measure:

● Ring side clearance

Use a feeler gauge. Out of specification → Replace the piston and rings as a set.

NOTE:

Clean carbon from the piston ring grooves and rings before measuring the side clearance.

Side clearance

Standard Limit

ENG

Top ring

2nd ring

0.030 ~ 0.065 mm

(0.0012 ~ 0.0026 in)

0.020 ~ 0.055 mm

(0.0008 ~ 0.0022 in)

0.12 mm (0.005 in)

0.12 mm

(0.005 in)

2. Position:

● Piston ring

(in cylinder)

NOTE:

Insert a ring into the cylinder and push it approximately 5 mm (0.20 in) into the cylinder. Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore.

a 5 mm (0.20 in)

3. Measure:

● Ring end gap

Out of specification → Replace.

NOTE:

You cannot measure the end gap on the expander spacer of the oil control ring. If the oil control ring rails show excessive gap, replace all three rings.

4 - 24

Top ring

2nd ring

Oil ring

End gap

Standard Limit

0.10 ~ 0.25 mm

(0.004 ~ 0.010 in)

0.10 ~ 0.25 mm

(0.004 ~ 0.010 in)

0.2 ~ 0.7 mm

(0.01 ~ 0.03 in)

0.4 mm

(0.016 in)

0.4 mm

(0.016 in)

—

CYLINDER AND PISTON

Piston pin

1. Inspect:

● Piston pin

Blue discoloration/grooves → Replace, then inspect the lubrication system.

2. Measure:

● Piston pin outside diameter

● Piston pin bore inside diameter

Measurement steps:

● Measure the piston pin outside diameter

a. If out of specification, replace the piston pin

ENG

Outside diameter (piston pin):

12.996 ~ 13.000 mm (0.5117 ~ 0.5118 in) <Limit>:12.976 mm (0.5109 in)

● Measure the piston inside diameter b.

If out of specification, replace the piston.

Inside diameter (piston):

13.002 ~ 13.013 mm (0.5119 ~ 0.5123 in) <Limit>: 13.045 mm (0.5136 in)

ASSEMBLY AND INSTALLATION Piston

1. Install:

● Piston rings

(onto the piston)

NOTE:

● Be sure to install the piston rings so that the

manufacturer’s marks or numbers are located on the upper side of the rings.

● Lubricate the piston and piston rings liberally

with engine oil.

4 - 25

CYLINDER AND PISTON

2. Position:

● Top ring

● 2nd ring

● Oil ring

Offset the piston ring end gaps as shown.

a Top ring end b Oil ring end (lower) c Oil ring end (upper) d 2nd ring end

3. Install:

● Piston 1

● Piston pin 2

● Piston pin clips 3

NOTE:

● Apply engine oil onto the piston pin, piston

ring and piston.

● Be sure that the arrow mark a on the piston

points to the exhaust side of the engine.

● Before installing the piston pin clip, cover the

crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase.

ENG

New

4. Lubricate:

● Piston

● Piston rings

● Cylinder

NOTE:

Apply a liberal coating of engine oil.

Cylinder

1. Install:

● Dowel pins

● Gasket

● Cylinder 1

New

NOTE:

Install the cylinder with one hand while compressing the piston rings with the other hand.

CAUTION:

● Be careful not to damage the timing chain

damper during installation.

● Pass the timing chain through the timing

chain cavity.

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CLUTCH

CRANKCASE COVER (LEFT AND RIGHT)

CLUTCH

ENG

Extent of removal: 1 Crankcase cover (left) removal 2 Crankcase cover (right) removal

Extent of removal Order Part name Q’ty Remarks

CRANKCASE COVER (LEFT AND RIGHT) REMOVAL

Preparation for removal Drain the engine oil. Refer to “ENGINE OIL REPLACEMENT”

section in the CHAPTER 3. 1 Shift pedal 1 2 Drive sprocket cover 1

3 Crankcase cover (left) 1 4 Gasket 1 5 Dowel pin 2 6 Clutch adjusting screw 1 7 Kick crank 1 8 Crankcase cover (right) 1 9 Gasket 1

10 Dowel pin 2

4 - 27

CLUTCH

ENG

Extent of removal: 1 Friction plate and clutch plate removal 2 Clutch housing removal

3 Primary clutch removal

Extent of removal Order Part name Q’ty Remarks

CLUTCH REMOVAL

1 Bolt/clutch spring 4/4 2 Pressure plate 1

2 3

3 Washer 1 4 Push rod #1 1 5 Friction plate 5 6 Clutch plate 4 7 Push rod #2 1 8 Clutch boss nut 1 Use special tool. 9 Lock washer 1 Refer to “REMOVAL POINTS”.

10 Clutch boss 1 11 Washer 1 12 Clutch housing 1

4 - 28

CLUTCH

ENG

Extent of removal Order Part name Q’ty Remarks

13 Spacer 1 14 Spacer 1 15 Primary clutch nut 1 Use special tool.

Refer to “REMOVAL POINTS”.

16 Washer 1 17 Spacer 1 18 Primary clutch housing 1 19 Primary clutch boss 1 20 Clutch carrier 1 21 One-way clutch assembly 1 22 Washer 1

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CLUTCH

ENG

REMOVAL POINTS Clutch boss

1. Remove:

● Clutch boss nut 1

● Lock washer 2

● Clutch boss

NOTE:

Straighten the lock washer tab and use the clutch holding tool 3 to hold the clutch boss.

Clutch holding tool:

YM-91042/90890-04086

Å For USA and CDN ı Except for USA and CDN

Primary clutch

1. Remove:

● Primary clutch nut 1

NOTE:

Loosen the nut while holding the magnet rotor with the sheave holder 2.

Sheave holder:

YS-1880-A/90890-01701

INSPECTION

EC484500

Friction plate

1. Measure:

● Friction plate thickness

Out of specification → Replace friction plate as a set. Measure at all four points.

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Friction plate thickness

Standard Limit

2.7 ~ 2.9 mm

(0.106 ~ 0.114 in)

2.6 mm

(0.102 in)

CLUTCH

EC484600

Clutch plate

1. Measure:

● Clutch plate warpage

Out of specification → Replace clutch plate as a set. Use a surface plate 1 and thickness gauge 2.

Warp limit:

0.2 mm (0.008 in)

EC484400

Clutch spring

1. Measure:

● Clutch spring free length a

Out of specification → Replace springs as a set.

Clutch spring free length

ENG

Standard Limit

26.2 mm (1.03 in)

24.2 mm (0.95 in)

Push rod

1. Measure:

● Push rod #2 bend

Out of specification → Replace.

Bending limit:

0.5 mm (0.02 in)

Primary clutch

1. Measure:

● Primary clutch housing inside diameter

Out of specification → Replace.

Primary clutch housing inside diameter:

105 mm (4.13 in) <Limit>: 106 mm (4.17 in)

4 - 31

2. Measure:

● Clutch shoe groove depth a

Out of specification → Replace.

Clutch shoe groove depth:

1.0 ~ 1.3 mm (0.039 ~ 0.051 in) <Limit>: 0.1 mm (0.004 in)

Åı

CLUTCH

ENG

ASSEMBLY AND INSTALLATION Primary clutch

1. Install:

● Washer 1

● Nut (primary clutch) 2

50 Nm (5.0 m · kg, 36 ft · lb)

NOTE:

Tighten the nut while holding the magneto rotor with the sheave holder 3.

Sheave holder:

YS-1880-A/90890-01701

Clutch

1. Install:

● Lock washer 1

● Nut (clutch boss) 2

New

70 Nm (7.0 m · kg, 50 ft · lb)

NOTE:

Use the clutch holding tool 3 to hold the clutch boss.

Clutch holding tool:

YM-91042/90890-04086

Å For USA and CDN ı Except for USA and CDN

2. Bend:

● Lock washer tab

Clutch release adjustment

1. Adjust:

● Clutch release

Adjustment steps:

● Loosen the locknut 1.

● Turn in the adjuster 2 until it is lightly

seated.

● Turn out by 1/8 turn.

● Tighten the locknut.

Locknut:

8 Nm (0.8 m • kg, 5.8 ft • lb)

4 - 32

KICK AXLE

ENG

Extent of removal: 1 Kick axle removal 2 Kick axle disassembly

Extent of removal Order Part name Q’ty Remarks

KICK AXLE REMOVAL AND DISASSEMBLY

Preparation for removal Crankcase cover (right) Refer to “CLUTCH” section.

1 Kick axle assembly 1 2 Circlip 2 3 Spring cover 1 4 Torsion spring 1 5 Spring guide 1 6 Circlip 1 7 Ratchet wheel 1 8 Clip 1

9 Circlip 1 10 Washer/wave washer 1/1 11 Kick gear 1

Kick axle

4 - 33

SHIFT SHAFT

ENG

Extent of removal: 1 Shift shaft removal

Extent of removal Order Part name Q’ty Remarks

SHIFT SHAFT REMOVAL

Preparation for removal Clutch housing and clutch carrier Refer to “CLUTCH” section.

1 Shift fork guide bar 1

2 Shift arm 3 1

3 Plate washer 1

4 Compression spring 1

5 Shift guide 1

6 Ball holder 1

7 Guide 1

8 Dowel pin 1

9 Plate washer 1 10 Thrust bearing 1 11 Circlip 1 12 Shift lever assembly 1 13 Shift shaft 1

4 - 34

SHIFT SHAFT

ENG

Extent of removal Order Part name Q’ty Remarks

14 Stopper lever 1 15 Torsion spring 1

16 Circlip 1 17 Plate washer 1 18 Torsion spring 1 19 Shift lever 1

4 - 35

OIL PUMP

ENG

Extent of removal: 1 Oil pump removal 2 Oil strainer removal

3 Oil pump disassembly

Extent of removal Order Part name Q’ty Remarks

OIL PUMP REMOVAL AND DISASSEMBLY

Preparation for removal Clutch housing and clutch carrier Refer to “CLUTCH” section.

Shift shaft Refer to “SHIFT SHAFT” section.

1 Rotary filter 1

2 Oil pump assembly 1

3 Gasket 1

4 Oil pump drive gear 1

5 Oil strainer 1

6 Circlip 1

7 Oil pump driven gear 1

8 Spring washer 1

9 Circlip 1 10 Washer 1

4 - 36

Yamaha 5HN-28199-13, LIT-11626-16-27 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

INTRODUCTION

SAFETY INFORMATION

INDEX

DESCRIPTION

GENERAL INFORMATION

MACHINE IDENTIFICATION

IMPORTANT INFORMATION

CHECKING OF CONNECTION

SPECIAL TOOLS

CONTROL FUNCTIONS

STARTING AND OPERATION

GENERAL SPECIFICATIONS

MAINTENANCE SPECIFICATIONS

GENERAL TORQUE SPECIFICATIONS

CABLE ROUTING DIAGRAM

PERIODIC MAINTENANCE AND LUBRICATION

MAINTENANCE INTERVALS

PRE-OPERATION INSPECTION AND MAINTENANCE

ENGINE

CHASSIS

ELECTRICAL

CARBURETOR

CYLINDER HEAD

CAMSHAFT AND ROCKER ARMS

VALVES AND VALVE SPRINGS

CYLINDER AND PISTON

CLUTCH

KICK AXLE

SHIFT SHAFT

OIL PUMP