YAMAHA XVZ13TF(L) 1999 SERVICE MANUALS

EAS00001

XVZ13TF (L)

SERVICE MANUAL

1999 by Yamaha Motor Co., Ltd.

First edition, January 1999

unauthorized use without the written

permission of Yamaha Motor Co., Ltd

is expressly prohibited.

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NOTICE

This manual was produced by the Y amaha Motor Company , Ltd. primarily for use by Y amaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to render the vehicle unsafe and unfit for use.

This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools in necessary to ensure that the vehicle will operate as designed. If there is any question about a service procedure, it is imperative that you contact a Y amaha dealer for any service information changes that apply to this model. This policy is intended to provide the customer with the most satisfaction from his vehicle and to conform with federal environmental quality objectives.

Y amaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Y amaha dealers and will appear in future editions of this manual where applicable.

NOTE:

 This Service Manual contains information regarding periodic maintenance to the emission control

system. Please read this material carefully.

 Designs and specifications are subject to change without notice.

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IMPORTANT INFORMATION

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

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

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

CAUTION:

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

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

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HOW TO USE THIS MANUAL

This manual is intended as a handy , easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly , assembly , repair and inspection procedures are laid out with the individual steps in sequential order.

The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each

page indicate the current chapter. Refer to “SYMBOLS” on the following page.

Each chapter is divided into sections. The current section title is shown at the top of each page,

except in Chapter 3 (“Periodic Inspections and Adjustments”), where the sub-section title(-s) appear. (In Chapter 3, “Periodic Inspection and Adjustments”, the sub-section title appears at the top of each

page, instead of the section title.)

Sub-section titles appear in smaller print than the section title.

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

removal and disassembly section.

Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a

disassembly step.

Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).

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

parts, notes in jobs, etc.

Jobs requiring more information (such as special tools and technical data) are described sequen-

tially .

GEN

INFO

CHK

ADJ

COOL

SPEC

ENG

CARB

ELECCHAS

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SYMBOLS

The following symbols are not relevant to every vehicle. Symbols chapter.

General information

Specifications

Periodic inspections and adjustments

Engine

Cooling system

Carburetor(-s)

Chassis

Electrical system

Troubleshooting

to 9 indicate the subject of each

TRBL

SHTG

11 12

1413

16 1715

19 2018

Symbols 10 to 17 indicate the following.

Serviceable with engine mounted

Filling fluid

Lubricant

Special tool

Tightening torque

Wear limit, clearance

Engine speed

Electrical data

Symbols 18 to 23 in the exploded diagrams indicate the types of lubricants and lubrication points.

Engine oil

Gear oil

2321

Molybdenum disulfide oil

Wheel bearing grease

Lithium soap base grease

Molybdenum disulfide grease

24 25

Symbols 24 to 25 in the exploded diagrams indicate the following:

Apply locking agent (LOCTITER)

Replace the part

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TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC INSPECTIONS AND ADJUSTMENTS

ENGINE

COOLING SYSTEM

GEN

INFO

SPEC

CHK

ADJ

ENG

COOL

1 2 3 4 5

CARBURETORS

CHASSIS

ELECTRICAL SYSTEM

TROUBLESHOOTING

CARB

CHAS

ELEC

TRBL SHTG

6 7 8 9

GEN

INFO

GEN

INFO

CONTENTS

GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

MODEL CODE 1-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FEA TURES 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CRUISE CONTROL 1-2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DIGITAL SPEEDOMETER 1-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUDIO SYSTEM 1-5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IMPORTANT INFORMATION 1-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PREPARATION FOR REMOVAL AND DISASSEMBLY 1-13. . . . . . . . . .

REPLACEMENT PARTS 1-13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GASKETS, OIL SEALS AND O-RINGS 1-13. . . . . . . . . . . . . . . . . . . . . . . .

LOCK WASHERS/PLATES AND COTTER PINS 1-14. . . . . . . . . . . . . . . .

BEARINGS AND OIL SEALS 1-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCLIPS 1-14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHECKING THE CONNECTIONS 1-15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIAL TOOLS 1-16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEN

INFO

MOTORCYCLE IDENTIFICATION

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GENERAL INFORMATION

MOTORCYCLE IDENTIFICATION

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VEHICLE IDENTIFICATION NUMBER

The vehicle identification number into the right side of the steering head.

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MODEL CODE

The model code label This information will be needed to order spare parts.

GEN

INFO

is stamped

is affixed to the frame.

1-1

GEN

FEATURES

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FEATURES

CRUISE CONTROL

This motorcycle is equipped with cruise control which designed to maintain a set speed.

CAUTION:

 Giving a severe load like using as a trailer/tractor or driving on a steep slope could remove the

cruise control.

 Do not set the cruise control while idling the rear tires for the preparation.  Do not disassemble the vacuum pump.  Never remove the cruise control actuator rubber cover. When putting it back, bolts or other

parts will be caught and the cruise control wire can be locked.

 Do not remove the air cleaner cover of the vacuum pump in order not to cause a malfunction in

cancellation of the cruise control by dirt, trash etc.

 Do not drive without holding the steering wheel whether the cruise control is ON or OFF.

INFO

“CRUISE” switch

“ON” indicator light

Cruise control switch functions

“CRUISE” switch Push this switch to “ON” when the cruise control system is preset. The “ON” indicator light will come on. Once the switch is released it will return to the center (Hold) position. To cancel the cruise control system, push the switch to “OFF” or main switch to the “OFF” position.

“ON” indicator light This indicator light comes on when the cruise control systems preset (when “ON” is selected by the “CRUISE” switch).

“SET” indicator light This indicator light comes on when the motorcycle is operating at a set speed.

“RES” indicator light This light comes on when the set speed, which is cancelled by any steps, is memorized and when the operating speed is in the range of approx. 50-130 km/h. If the resume system is operated while this light is on, it continues flashing until the speed returns to that memorized.

Cruise control switch This switch is capable of the following controls. Refer to the “Operation chart” for details. Set speed ride Minute adjustment of set speed Consecutive adjustment of set speed “RESUME” system

“CANCEL” switch Push this switch to cancel the set speed ride in the cruise control system.

3 “SET” indicator light 4 “RES” indicator light

5 Cruise control switch 6 “CANCEL” switch

1-2

Operation chart

FEATURES

GEN

INFO

Opera-

tion

Speed

Indica-

tor

Cruise SW

CRUISE

SET RES ON

SET

(After1.4sec)

Out of range

SET RES ON

Mannual acceleration

cancel

Clutch

SET Front brake

Out of range

SET RES ON

Rear brake

Resume

Flash

Cruise control function

1) The cruise control can only be activated when riding in 4th, 5th gear and traveling between the

speed of 50 and 130 km/h.

2) To operate the system, the “CRUISE” switch should be turned “ON”.

3) When push the cruise control switch to “SET”, the cruise control system will be set the set speed.

4) By pushing (in shorter than 0.5 seconds), the control switch in the direction of either “ACC” or “DEC”,

the set speed can be changed in increments or decrements of approximately 1.6 km/h.

5) If the control switch is held in the “ACC” or “DEC” position (longer than 0.5 seconds), the speed can

be successively increased or decreased slowly.

6) The cruise control will be deactivated if the front or rear brake is applied or if the clutch is disengaged

or if the “CANCEL” switch is pushed.

7) After canceling, the speed is returned to the one set before the cancellation by pushing the control

switch once in the “RES” direction.

8) Auto cruise function is canceled;

a. In case of current speed drops 8 km/h less than the originally set speed.

b. In case of gear position is moved to gears other than of 4th, 5th.

c. In case of systems fines any faulty signal in the following systems.

 Control unit

 Actuator cable

 Logical error in cut off signal

 Error signal in speed sensor signal

 Error signal in engine revolution

 Cruise control switch lead (“SET”/“RES”)

9) When main switch is cut off once, “resume” is canceled.

1-3

DIGITAL SPEEDOMETER

This speedometer is equipped with:

 An odometer  Two trip odometers  A fuel reserve trip meter  A clock

FEATURES

GEN

INFO

Odometer and trip meter modes

1) Selecting a mode Push the “SELECT” button to change between the odometer mode “ODO” and the trip odometer modes “TRIP 1” and “TRIP 2” in the following order. “ODO”  “TRIP 1”  “TRIP 2”  “ODO” If the fuel level indicator light comes on, the odometer display will automatically change to the fuel reserve trip meter mode “TRIP F” and start counting the distance traveled from that point. Push the “SELECT” button to change between the fuel reserve tripmeter, trip odometer and odometer modes in the following order: “TRIP F”  “TRIP 1”  “TRIP 2”  “ODO”  “TRIP F”

2) Resetting a meter T o reset a trip odometer to 0.0, select it by pushing the “SELECT” button and push the “RESET” button. To reset the fuel reserve trip meter, select it by pushing the “SELECT” button and push the “RESET” button. The display will return to prior mode (“ODO”, “TRIP 1” or “TRIP 2”). If you do not reset the fuel reserve trip meter manually , it will automatically reset and retum to “TRIP 1” after refueling and the motorcycle has traveled both 5km.

NOTE:

 If the fuel reserve trip meter appears, and a different mode was NOT selected prior to resetting the fuel

reserve trip meter, the display always returns to the “TRIP 1” mode.

 If the fuel reserve trip meter appears, and a different mode was selected prior to resetting the fuel

reserve trip meter, the display automatically returns to the prior mode.

1-4

GEN

FEATURES

Clock mode

To change the display to the clock mode, push both the “SELECT” and “RESET” buttons. To change the display back to odometer mode, push the “RESET” button.

1) To set the clock a. Push both the “SELECT” and “RESET” buttons for at least two seconds. b. When the hour digits start flashing, push the “RESET” button to set the hours. c. Push the “SELECT” button and the minute digits will start flashing. d. Push the “RESET” button to set the minutes. e. Push the “SELECT” button to start the clock.

NOTE:

After setting the clock, be sure to push the “SELECT” button before turning the main switch to “OFF”, otherwise the clock will not be set.

INFO

AUDIO SYSTEM

1. POWERING ON/OFF THE AUDIO SYSTEM

Turning on/off the audio system

Turn the main switch to the “ACC” or “ON” position.  To turn on the power for the audio system,

push the audio button “AUDIO”.

 To turn off the audio system, push the audio

button “AUDIO” continuously for 1 second or more.

1-5

GEN

FEATURES

2. CASSETTE DESK OPERATION

The cassette tape deck has the following functions.

 Song search  Change tape play direction  Dolby noise reduction  Blank tape skip

a. Turn the main switch to the “ACC” or “ON”

position and push the “AUDIO”button to turn on the power.

b. Insert a cassette tape into the cassette deck. c. If a tape is aleady loaded in the cassette

deck, push the “AUDIO” button until “PLAY” appears. The tape will start playing.

d. Turn the volume control knob to set the vol-

ume level. The volume level can be set from 0 to 30.

INFO

Track searching

To search for a song on the tape, push the updown switch “APC” (auto program control) indicator will appear in the display. Push the witch once for each song to be skipped. Pushing the switch in direction “n” will search in the forward direction. Pushing the switch in direction “o” will search in the reserve direction. When searching in the forward direction, the number of song that are being skipped will appear. (i.e., “1”, meaning one track is being skipped) When searching the reverse direction, the number of song that are being skipped will appear along with a minus sign before the number. (i.e., “-1”, meaning one song is being skipped) The maxmum number of songs that can be skipped in either direction is 9. To stop a searching operation, push the updown button in the opposite direction that it was originally pushed.

1-6

for less than one second. The

GEN

FEATURES

Reserving tape play direction

Push the up-down button for more than one second to reverse tape play . When the tape is playing the forward direction, the “F” indicator will appear. When the tape is playing in the reverse direction, the “R” indicator will appear.

Dolby noise reduction

The Dolby noise reduction can be turned on or off by pushing the “EJECT” button for at least two seconds. When the noise reduction is on, the “BNR” indicator appears in the display.

INFO

in either direction

Ejecting the cassette tape

Push the “EJECT” button to eject the tape from the cassette dack.

Blank skipping

When there is a blank portion on the cassette tape the “BLS” indicator light will come on and the cassette deck automatically fast forwards the tape to the next track.

1-7

GEN

FEATURES

3. RADIO OPERATION

The radio has the following functions.

 Switching the receiving band  Switching the receiving station  Automatic tuning (Seek)  Manual tuning  Programing preset stations in memory  Automatic writing of stations in memory (Auto

store operation)

Switching the receiving bands

This radio system has 3 bands for FM and 1 band for AM. Select a band by pushing the “AUDIO” button for less than 1 second. The display will change as follows.



TAPE  FM1  FM2  FM3 AUX.  CD(option)  AM

INFO



Automatic tuning (Seek operation)

Push the up-down switch and hold it for as least 1 second. The tuner will automatically stop at the first station that has a strong enough radio wave.

Manually turning

When a radio wave is too weak to be picked up automatically, it can be selected manually as follows. Push the “SELECT” button until “RADIO” station appears. Push the up-down switch cond in either direction and the ferequency will change in 0.1 MHz steps for FM and in 9 kHz for AM.

Presetting station in memory

Station can be preset either automatically or manually. 6 stations can be set for each band. Preset station either manually or automatically by the following procedure. a. Select the station desired to be preset. b. Push the “SELECT” button for as least 2 se-

conds unitl the radio frequency and the channel “Ch” start flashing.

in either direction

for less than 1 se-

1-8

FEATURES

GEN

INFO

c. Push the up-down switch

tion to select the channel number to be set for the current station. (Ch1, Ch2, Ch3, Ch4, Ch5 and Ch6)

d. Press the “SELECT” button to programing

the channel in memory.

Repeat this procedure for the remaining stations desired to be preset in the memory. Stations can be also be automatically preset by the following procedure. a. Push the “SELECT” button until the radio fre-

quency and the channel “Ch” start flashing.

b. Push the up-down button in either direction

for at least 1 second to automatically tune in a station.

c. When the desired station is found, push the

up-down switch for less than one second to select the channel number to be set for that station.

d. Push the “SELECT” button to programing the

channels in memory.

e. Repeat this procedure for the remaining sta-

tions desived to be preset in memory.

in either direc-

Programing preset stations in memory automatically

Setting up to 6 channels can be made by the following procedure.

NOTE:

Stations will be starting from the station preset at chanel 6. It is recommended to use this function only in areas with strong radio frequencies.

a. Push the “SELECT” button until the radio fre-

quency and the channel “Ch” start flashing.

b. Push the up-down switch

tion to select channel “A”.

c. Press the “SELECT” button to start the ran-

dom channel selection and the tuner will automatically write the channels in memory.

1-9

in either direc-

GEN

FEATURES

“AUX” (Auxiliary) operation

Auxiliary audio equipment can be used to play through the audio system. a. Insert the output plug of the auxiliary equip-

ment into the jack located at the right side of the dassette deck.

b. Push the “AUDIO” button until “AUX” ap-

pears and the auxiliary equipment can be used to play through the audio system.



TAPE  FM1  FM2  FM3 AUX.  CD(option)  AM

INFO



5. BASIC SETTINGS

AUDIO system

The following settings can be made in the audio system. Selecting output between speakers and a headset assembly Controlling bass level Controlling treble level Controlling fader (balance between the front and the rear speakers) Controlling intercom volume level Changing auto volume level

Setting procedure

The following setting procedures apply to the audio system, auxiliary mode and CD Changer. a. Select the desired setting mode by pushing

the “SELECT” button. On each press of the button, the mode changes as follows. Audio system



OUTPUT  BASS  TREB  FADE RADIO station  AVC  INT.VOL

b. Push the up-down switch

tion to change the setting for any mode.



in either direc-

1-10

GEN

FEATURES

Selecting the output for speaker or headset (optional)

To select the output for speaker or headset, push the “SELECT” button and the “SP” (speaker) or “HS” (headset) indicator will appear. To change between speaker and headset, push the up-down switch

NOTE:

The speaker and headset cannot be used the same time.

Controlling the bass level

a. To control the bass level, push the “SELECT”

button until the “BASS” indicator appears.

b. Push the up-down switch

tion to change the level.

INFO

in either direction.

in either direc-

Controllingthe treble level

a. To control the treble level, push the “SE-

LECT” button until the “TREB” indicator appears.

b. Push the up-down switch

tion to change the level. The treble level can be set from –6 to +6.

Controlling the fader (balance between front and rear speakers)

a. To control the fader , push the “SELECT” but-

ton until the “FAD” indicator appears.

b. Push the up-down switch

tion to change the balance. The fader level can be adjusted from F9 to R9.

Controlling the intercom volume level

a. To control the intercom volume level, push

the “SELECT” button until the “IC:” indicator appears.

b. Push the up-down switch

tion to change the volume level. The intercom volume level can be set from 0 to 20.

in either direc-

1-11

GEN

FEATURES

Changing the level for auto volume control system

a. To control the level for the auto volume con-

trol system, push the “SELECT” button untill the “AV:” indicator appears.

b. Push the up-down switch

tion to change the volume level. The auto volume control rate of compensation can be adjusted from 0 to 5.

INFO

in either direc-

1-12

IMPORTANT INFORMATION

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IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND DISASSEMBLY

1. Before removal and disassembly, remove all dirt, mud, dust and foreign material.

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

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

4. During disassembly, clean all of the parts and place them in trays in the order of disassembly . This will speed up assembly and allow for the correct installation of all parts.

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

GEN

INFO

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REPLACEMENT PARTS

1. Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by Yamaha for all lubrication jobs. Other brands may be similar in-function and appearance, but inferior in quality.

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GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be cleaned.

2. During reassembly, properly oil all mating parts and bearings and apply grease onto the oil seal lips.

1-13

IMPORTANT INFORMATION

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LOCK WASHERS/PLATES AND COTTER PINS

1. After removal, replace all lock washers/plates nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut.

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BEARINGS AND OIL SEALS

1. Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, apply a light coat of lithium soap base grease onto the oil seal lips. Oil bearings liberally when installing, if appropriate.

Oil seal

and cotter pins. After the bolt or

GEN

INFO

CAUTION:

Do not spin the bearing with compressed air because this will damage the bearing surfaces.

Bearing

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CIRCLIPS

1. Before reassembly , check all circlips carefully and replace damaged or distorted circlips. Always replace piston pin clips after one use. When installing a circlip the sharp-edged corner posite the thrust

Shaft

, make sure that

is positioned op-

that the circlip receives.

1-14

CHECKING THE CONNECTIONS

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CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for stains, rust, moisture, etc.

1. Disconnect:

 lead  coupler  connector

2. Check:

 lead  coupler  connector

Moisture  Dry with an air blower. Rust/stains  Connect and disconnect several times.

3. Check:

 all connections

Loose connection  Connect properly.

NOTE:

If the pin up.

on the terminal is flattened, bend it

GEN

INFO

4. Connect:

 lead  coupler  connector

NOTE:

Make sure that all connections are tight.

5. Check:

 continuity

(with a pocket tester)

Pocket tester

YU-03112,90890-03112

NOTE:

 If there is no continuity, clean the terminals.  When checking the wire harness, perform

steps 1 to 3.

 As a quick remedy, use a contact revitalizer

available at most part stores.

1-15

GEN

SPECIAL TOOLS

EAS00027

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly . Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part umbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes.

P/N.YM-, YUFOr US, CDN YS-, YK- ACCP/N.90890Except for US, CDN

INFO

Tool No.

YM-33961

90890-04105

YU-08030-A

90890-03094

YU-08036-A

90890-031 13

YU-33277-A

90890-03141

Tool name/Usage Illustration

Tappet adjusting tool This tool is needed to rotate the

camshaft for access to the valve lifter and valve pad

Vacuum gauge

This gauge is needed for carburetor synchronization.

Engine tachometer

This tool is needed for observing engine rpm.

Timing light

This tool is necessary for checking ignition timing.

YU-33223

90890-03081

YU-38411

90890-01426

Gauge

90890-03153

Adapter

90890-03124

Compression gauge/Set

These tools are needed to measure engine compression.

Oil filter wrench

This tool is needed to remove and install the oil filter.

Pressure gauge/adapter

These tools are needed to measure engine oil pressure.

1-16

GEN

SPECIAL TOOLS

Tool No. Tool name/Usage Illustration

INFO

YU-01268

90890-01268

YU-33975

90890-01403

YU-03112

90890-03112

Compressor

YM-04019

90890-04019

Adapter

YM-01253-1

90890-04114

YM-4064-A

90890-04064

Ring nut wrench

This tool is needed to loosen and tighten the steering stem ring nut.

Pocket tester

This instrument is needed for checking the electrical system.

Valve spring compressor/adapter

These tools are needed to remove and install the valve assemblies.

Valve guide remover (6.0 mm)

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

Vale guide installer (6.0 mm)

YM-04065-A

90890-04065

YM-04066

90890-04066

YM-91042

90890-04085

YS-01880

90890-01701

Puller

YU-33270

90890-01362

Adapter

YM-33282

90890-04089

This tool is needed to install the valve guide.

Valve guide reamer (6.0 mm)

This tool is needed to rebore the new valve guide.

Universal clutch holder This tool is needed to hold the clutch

when removing or installing the clutch boss nut.

Sheave holder This tool is needed to hold the rotor

when removing or installing the rotor bolt.

Flywheel puller/adapter

These tools are needed to remove the rotor.

1-17

SPECIAL TOOLS

Tool No. Tool name/Usage Illustration



ACC-1100-15-01

90890-85505

YU-01304

90890-01304

Quick gasket Yamaha Bond No.1215

This sealant (bond) is used on crankcase mating surfaces, etc.

Piston pin puller

This tool is used to remove the piston pin.

Piston ring compressor

GEN

INFO

YM-8037

90890-05158

YM-33286

90890-04090

YM-33222

90890-04080

YM-04054

90890-04054

This tool is used to compress the piston rings when installing the piston into the cylinder.

Damper spring compressor

This tool is needed when removing or installing the damper spring.

Middle drive gear holder This tool is needed to remove and install the middle drive pinion gear. This tool is also used for the gear backlash adjustment.

Middle drive gear holder

This tool is needed for the gear backlash adjustment.

Offset wrench (55 mm) This tool is needed when removing

or installing the middle drive gear nut.

YM-04062

90890-04062

YU-03097

90890-03097

Universal joint holder This tool is needed when removing

or installing the driven pinion gear nut.

Dial gauge

This tool is used to measure the middle gear backlash.

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GEN

These tools are needed to loosen

SPECIAL TOOLS

Tool No. Tool name/Usage Illustration

INFO

Tester

YU-24460-01

90890-01325

Adapter

YU-33984

YM-01312-A

90890-01312

Rod holder

YM-01300-1

90890-01294

T-handle

YM-01326

90890-01326

Weight

YM-33963

90890-01367

Adapter

YM-8020

90890-01374

Radiator cap tester/adapter

This tester and its adapter are needed for checking the cooling system.

Fuel level gauge

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

Damper rod holder/T-handle

and tighten the damper rod holding bolt.

Fork seal driver weight/adapter These tools are needed when instal-

ling the slide metal, oil seal and dust seal into the fork.

Final gear backlash band

YM-01230

90890-01230

YM-01229

90890-01229

YM-04050

90890-04050

YM-34487

90890-06754

This tool is needed when measuring final gear backlash.

Coupling gear/middle shaft tool

This tool is needed when removing or installing the coupling gear nut.

Bearing retainer wrench This tool is needed when removing

or installing the final drive shaft bearing.

Dynamic spark tester Ignition checker

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