Yamaha YFM660R User Manual

2001

YFM660R

(

N

)

5LP2-AE1

SERVICEMANUAL

YFM660R(N) 2001

SERVICE MANUAL

 2000 by Yamaha Motor Co., Ltd.

First Edition, July 2000

All rights reserved. Any reproduction or

unauthorized use without the written

permission of Yamaha Motor Co., Ltd.

is expressly prohibited.

EB001000

NOTICE

This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on
Yamaha machine has a basic understanding of the mechanical ideas and the procedures of
machine repair. Repairs attempted by anyone without this knowledge are likely to render the
machine unsafe and unfit for use.

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

NOTE:

Designs and specifications are subject to change without notice.

IMPORTANT INFORMATION

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

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

WARNING

CAUTION:

NOTE:

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

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

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

EB002000

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.
2nd title 2: This title indicates the section of the chapter and only appears on the first page of each

section. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa-

nied by corresponding illustrations.

EXPLODED DIAGRAMS

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

1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.

2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed
by a circle indicates a disassembly step.

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

6

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

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

5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition
to the exploded diagram and the job instruction chart.

12

GEN

INFO

34

SPEC

CHK

CHAS

ADJ

56

ENG

78

COOL

EB003000

ILLUSTRATED SYMBOLS

Illustrated symbols 1 to 9 are printed on the
top right of each page and indicate the subject
of each chapter.

General information

1

Specifications

2

Periodic checks and adjustments

3

Chassis

4

Engine

5

Cooling system

6

Carburetion

7

Electrical

8

Troubleshooting

9

CARB

90

ELEC

–+

TRBL
SHTG

AB

CD

T

.

R

.

EFG

HIJ

Illustrated symbols 0 to G are used to identify
the specifications appearing in the text.

Can be serviced with engine mounted

0

Filling fluid

A

Lubricant

B

Special tool

C

Torque

D

Wear limit, clearance

E

Engine speed

F

, V, A

Ω

G

Illustrated symbols H to N in the exploded
diagrams indicate the types of lubricants and
lubrication points.

LS

G

M

M

S

New

E

K

OP

LMN

B

LT

Apply engine oil

H

Apply gear oil

I

Apply molybdenum disulfide oil

J

Apply wheel bearing grease

K

Apply lightweight lithium soap base grease

L

Apply molybdenum disulfide grease

M

Apply silicon grease

N

Illustrated symbols O to P in the exploded
diagrams indicate where to apply a locking
agent O and when to install a new part P.



Apply the locking agent (LOCTITE

O

Replace

P

)

TABLE OF CONTENTS

–+

GENERAL INFORMATION

SPECIFICATIONS
PERIODIC CHECKS AND

ADJUSTMENTS
CHASSIS

ENGINE

GEN

INFO

SPEC

CHK

ADJ

CHAS

ENG

1
2
3
4
5

COOLING SYSTEM

CARBURETION

ELECTRICAL

TROUBLESHOOTING

COOL

CARB

ELEC

TRBL

SHTG

6
7
8
9

GEN

INFO

1

GEN

INFO

CHAPTER 1.

GENERAL INFORMATION

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

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

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

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

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

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

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

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

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

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

CHECKING OF CONNECTIONS ...................................................................1-4

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

GEN

INFO

MACHINE IDENTIFICATION

GENERAL INFORMATION

MACHINE IDENTIFICATION

VEHICLE IDENTIFICATION NUMBER

The vehicle identification number 1 is
stamped into the left side of the frame.

MODEL LABEL

The model label 1 is affixed to the air filter
case cover. This information will be needed to
order spare parts.

GEN

INFO

1 - 1

IMPORTANT INFORMATION

EB101000

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL
PROCEDURES

1.Remove all dirt, mud, dust and foreign mate­rial before removal and disassembly.

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

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

4.During machine disassembly, clean all parts
and place them in trays in the order of 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

EB101010

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.

EB101020

GASKETS, OIL SEALS AND O-RINGS

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

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

1 - 2

IMPORTANT INFORMATION

EB101030

LOCK WASHERS/PLATES AND COTTER
PINS

1.Replace all lock washers/plates 1 and cotter
pins after removal. Bend lock tabs along the
bolt or nut flats after the bolt or nut has been
tightened to specification.

EB101040

BEARINGS AND OIL SEALS

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

Oil seal

1

GEN

INFO

CAUTION:

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

Bearing

1

EB101050

CIRCLIPS

1.Check all circlips carefully before reassem­bly. Always replace piston pin clips after one
use. Replace distorted circlips. When install­ing a circlip 1, make sure that the sharp­edged corner 2 is positioned opposite the
thrust 3 it receives. See sectional view.

Shaft

4

1 - 3

CHECKING OF CONNECTIONS

EB801000

CHECKING OF CONNECTIONS

Check the connectors for stains, rust, mois­ture, etc.

1.Disconnect:

●

Connector

2.Check:

●

Connector
Moisture → Dry each terminal with an air
blower.
Stains/rust → Connect and disconnect the
terminals several times.

3.Check:

●

Connector leads
Looseness → Bend up the pin 1 and con­nect the terminals.

GEN

INFO

4.Connect:

●

Connector terminals

NOTE:

The two terminals “click” together.

5.Check:

●

Continuity (using a pocket tester)

NOTE:

●

If there is no continuity, clean the terminals.

●

When checking the wire harness be sure to
perform steps 1 to 3.

●

As a quick remedy, use a contact revitalizer
available at most part stores.

●

Check the connector with a pocket tester as
shown.

1 - 4

GEN

SPECIAL TOOLS

EB102001

SPECIAL TOOLS

The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools; this will help prevent damage caused by the use of inappropriate
tools or improvised techniques. Special tools may differ by shape and part number from country to
country. In such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.

For US and CDN

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

Except for US and CDN

P/N. 90890-

Tool No. Tool name/How to use Illustration

INFO

Bolt

90890-01083

Weight

90890-01084

Set

YU-01083-A

90890-01135

YU-01135-A

Pot

90890-01274

Bolt

90890-01275

YU-90050

Slide hammer bolt (M6)/weight/set

These tools are used to remove the rocker
arm shaft.

Crankcase separating tool

This tool is used to separate the crank­case.

Crankshaft installer pot
Crankshaft installer bolt

These tools are used to install the crank­shaft.

Crankshaft installer set

These tools are used to install the crank­shaft.

Adapter

90890-04059

YM-90069

Spacer

90890-04081

YM-91044

90890-01016

Adapter
Spacer (crankshaft installer)

These tools are used to install the crank­shaft.

Spacer

This tool is used to install the crankshaft.

1 - 5

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

Piston pin puller

90890-01304

YU-01304

This tool is used to remove the piston pin.
Tappet adjusting tool (3 mm)

90890-01311

YM-08035

This tool is necessary for adjusting the
valve clearance.

Fuel level gauge

90890-01312

YM-01312-A

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

INFO

90890-01325
YU-24460-01

90890-01352

YU-33984

90890-01327

YM-01327

90890-01362

YU-33270

Radiator cap tester

This tool is used to check the cooling sys­tem.

Adapter

This tool is used to check the cooling sys­tem.

Damper rod holder (30 mm)

This tool is needed to loosen and tighten
the steering stem bearing retainer.

Flywheel puller

These tools are needed to remove the
rotor.

90890-01419

YM-37132

Axle nut wrench (50 mm)

This tool is needed to loosen or tighten the
rear axle nut.

1 - 6

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

Oil filter wrench

90890-01469

YM-01469

This tool is needed to loosen or tighten
the oil filter cartridge.

Ball joint remover/installer set

90890-01474

YM-01474

These tools are used to removing or
installing the ball joint.

Ball joint remover/installer attachment set

90890-01480

YM-01480

These tools are used to removing or
installing the ball joint.

INFO

90890-01701

YS-01880

Set

90890-03081

YU-33223

Adapter

90890-04082

YU-33223-3

90890-03112

YU-03112

90890-03141

YM-33277-A

Sheave holder

This tool is needed to hold the AC mag­neto rotor when removing or installing the
AC magneto rotor bolts.

Compression gauge set
Adapter

These tools are needed to measure
engine compression.

Pocket tester

This instrument is needed for checking the
electrical system.

Timing light

This tool is necessary for checking ignition
timing.

90890-03158

Carburetor angle driver

This tool is used to turn the pilot screw
when adjusting the engine idling speed.

1 - 7

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

INFO

Compressor

90890-04019

YM-04019

Attachment

90890-01243

Middle driven shaft

bearing driver

90890-04058

YM-04058-1

Mechanical seal

installer

90890-04078

YM-33221

90890-04064

YM-4064-A

90890-04065

YM-04065-A

Valve spring compressor
Valve spring compressor attachment

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

Middle driven shaft bearing driver
Mechanical seal installer

These tools are used to install the water
pump seal.

Valve guide remover (ø 6)

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

Valve guide installer (ø 6)

This tool is needed to install the valve
guide.

90890-04066

YM-04066

90890-04086

YM-91042

90890-06754

YM-34487

Valve guide reamer (ø 6)

This tool is needed to rebore the new
valve guide.

Clutch holding tool

This tool is needed to hold the clutch car­rier when removing or installing the carrier
nut.

Ignition checker

This instrument is necessary for checking
the ignition system components.

Dynamic spark tester

This instrument is necessary for checking
the ignition system components.

1 - 8

GEN

SPECIAL TOOLS

Tool No. Tool name/How to use Illustration

INFO

Bond

90890-85505

Sealant

ACC-11001-05-01

Yamaha bond No. 1215
Sealant (Quick Gasket

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

®

)

1 - 9

GEN

INFO

1 - 10

SPEC

2

SPEC

CHAPTER 2.

SPECIFICATIONS

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

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

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

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

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

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

GENERAL TORQUE SPECIFICATIONS .....................................................2-20

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

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

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

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

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

SPEC

GENERAL SPECIFICATIONS

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard

Model code: 5LP2 : (For CDN)

5LP4 : (For Europe)

Dimensions:

Overall length 1,830 mm (72.0 in)
Overall width 1,100 mm (43.3 in)
Overall height 1,150 mm (45.3 in)
Seat height 860 mm (33.9 in)
Wheelbase 1,245 mm (49.0 in)
Minimum ground clearance 265 mm (10.4 in)
Minimum turning radius 3,300 mm (129.9 in)

Basic weight:

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

Engine:

Engine type Liquid-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 660 cm
Bore × stroke 100.0 × 84.0 mm (3.94 × 3.31 in)
Compression ratio 9.2 : 1
Standard compression pressure (at sea level) 1,250 kPa (12.5 kg/cm

Starting system Electric starter
Lubrication system: Dry sump
Oil type or grade:

Engine oil

For CDN

3

2

, 181 psi)

SPEC

0 ° 10 ° 30 ° 50 ° 70 ° 90 ° 110 °

YAMALUBE 4 (20W40) or SAE 20W40

YAMALUBE 4 (10W30) or SAE 10W30

SAE 5W30

-20 ° -10 ° 0 ° 10 ° 20 ° 30 ° 40 °

For Europe

Temp.

-20 ° -10 ° 0 ° 10 ° 20 ° 30 ° 40 ° 50 ° C

5W/30

10W/30

10W/40

15W/40

20W/40

20W/50

130°F

50 °C

API service SE, SF, SG type or higher

2 - 1

GENERAL SPECIFICATIONS

Item Standard

Oil capacity:

Engine oil

Periodic oil change 1.9 L (1.67 lmp qt, 2.01 US qt)
With oil filter replacement 1.95 L (1.72 lmp qt, 2.06 US qt)
Total amount 2.3 L (2.02 lmp qt, 2.43 US qt)

Radiator capacity (including all routes) 1.3 L (1.14 lmp qt, 1.37 US qt)
Air filter: Wet type element
Fuel:

Type Regular unleaded fuel

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

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

Type/quantity BSR33/2

Manufacturer MIKUNI
Spark plug:

Type/manufacturer DPR8EA-9/NGK

Spark plug gap 0.8 ~ 0.9 mm (0.031 ~ 0.035 in)
Clutch type: Wet, multiple disc
Transmission:

Primary reduction system Spur gear

Primary reduction ratio 71/34 (2.088)

Secondary reduction system Chain drive

Secondary reduction ratio 40/13 (3.076)

Transmission type Constant mesh, 5-speed/forward.

1-speed/reverse
Operation Left foot operation
Gear ratio

1st gear 34/14 (2.428)
2nd gear 29/19 (1.526)
3rd gear 26/21 (1.238)
4th gear 22/21 (1.047)
5th gear 19/21 (0.904)

Reverse gear 28/23 × 23 × 16 (1.750)

Chassis:

Frame type Steel tube frame
Caster angle 8°
Camber angle –1°
Kingpin angle 14.5°
Kingpin offset 5 mm (0.20 in)
Trail 47 mm (1.85 in)
Tread (STD) front 925 mm (36.42 in)

rear 840 mm (33.07 in)

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

SPEC

2 - 2

GENERAL SPECIFICATIONS

Item Standard

Tire:

Type Tubeless
Size front AT21 × 7–10

rear AT20 × 10–9

Manufacturer front DUNLOP

rear DUNLOP

Type front KT331 Radial

rear KT335 Radial

Tire pressure (cold tire):

Maximum load* 100 kg (220 lb)
Off-road riding front 27.5 kPa (0.275 kg/cm

rear 27.5 kPa (0.275 kg/cm

*Load in total weight of cargo, rider and acces­sories

Brake:

Front brake type Dual disc brake

operation Right hand operation

Rear brake type Single disc brake

operation Right foot operation

Suspension:

Front suspension Double wishbone
Rear suspension Swingarm (link suspension)

Shock absorber:

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

Wheel travel:

Front wheel travel 230 mm (9.06 in)
Rear wheel travel 220 mm (8.66 in)

Electrical:

Ignition system DC-C.D.I.
Generator system A.C. magneto
Battery type YTX14-BS
Battery capacity 12 V 12 Ah

Headlight type: Krypton bulb
Bulb voltage/wattage × quantity:

Headlight 12 V 30 W/30 W × 2
Tail/brake light 12 V 5 W/21 W × 1
Indicator and warning lights

Neutral 12 V 1.7 W × 1
Reverse 12 V 1.7 W × 1
Coolant temperature 12 V 1.7 W × 1

SPEC

2

, 4.0 psi)

2

, 4.0 psi)

2 - 3

MAINTENANCE SPECIFICATIONS

SPEC

MAINTENANCE SPECIFICATIONS

ENGINE

Item Standard Limit

Cylinder head:

Warp limit ---- 0.05 mm

(0.002 in)

Cylinder:

Bore size 100.005 ~ 100.045 mm

(3.9372 ~ 3.9388 in)
Measuring point

*

50 mm (2.0 in) ----

100.1 mm
(3.94 in)

Camshaft:

Drive method Chain drive (Left) ---­Camshaft cap inside diameter 23.000 ~ 23.021 mm

(0.9055 ~ 0.9063 in)
Camshaft journal diameter 22.967 ~ 22.980 mm

(0.9042 ~ 0.9047 in)
Camshaft journal-to-camshaft cap clearance 0.020 ~ 0.054 mm

(0.0008 ~ 0.0021 in)
Cam dimensions

C

A

B

Intake “A” 35.69 ~ 35.79 mm

(1.4051 ~ 1.4091 in)

“B” 30.15 ~ 30.25 mm

(1.1870 ~ 1.1909 in)

“C” 5.74 mm (0.2260 in) ----

Exhaust “A” 36.50 ~ 36.60 mm

(1.437 ~ 1.441 in)

“B” 30.15 ~ 30.25 mm

(1.187 ~ 1.191 in)

“C” 6.55 mm (0.2579 in) ----

----

----

----

35.59 mm
(1.4012 in)

30.05 mm
(1.1831 in)

36.40 mm
(1.4331 in)

30.05 mm
(1.1831 in)

2 - 4

MAINTENANCE SPECIFICATIONS

SPEC

Item Standard Limit

Camshaft runout limit ---- 0.03 mm

(0.0012 in)

Timing chain:

Timing chain type/No. of links 75-RH2015/126 ---­Timing chain adjustment method Automatic ----

Rocker arm/rocker arm shaft:

Shaft outside diameter 11.976 ~ 11.991 mm

----

(0.4715 ~ 0.4721 in)
Arm-to-shaft clearance 0.009 ~ 0.042 mm

----

(0.0004 ~ 0.0017 in)

Valve, valve seat, valve guide:

Valve clearance (cold) IN 0.10 ~ 0.15 mm

----

(0.0039 ~ 0.0059 in)

EX 0.15 ~ 0.20 mm

----

(0.0059 ~ 0.0079 in)
Valve dimensions

A

Head Diameter

Face Width

B

Seat Width

C

Margin Thickness

“A” head diameter IN 29.9 ~ 30.1 mm

(1.1772 ~ 1.1850 in)

EX 31.9 ~ 32.1 mm

(1.2559 ~ 1.2638 in)

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

EX 2.26 mm (0.0890 in) ----

“C” seat width IN 0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in)

EX 0.9 ~ 1.1 mm

(0.0354 ~ 0.0433 in)

“D” margin thickness IN 0.85 ~ 1.15 mm

(0.0335 ~ 0.0453 in)

EX 0.85 ~ 1.15 mm

(0.0335 ~ 0.0453 in)
Stem outside diameter IN 5.975 ~ 5.990 mm

(0.2352 ~ 0.2358 in)

EX 5.960 ~ 5.975 mm

(0.2346 ~ 0.2352 in)
Guide inside diameter IN 6.000 ~ 6.012 mm

(0.2362 ~ 0.2367 in)

EX 6.000 ~ 6.012 mm

(0.2362 ~ 0.2367 in)

D

----

----

1.6 mm
(0.0630 in)

1.6 mm
(0.0630 in)

----

----

5.945 mm
(0.2341 in)

5.930 mm
(0.2335 in)

6.040 mm
(0.2378 in)

6.040 mm
(0.2378 in)

2 - 5

MAINTENANCE SPECIFICATIONS

Item Standard Limit

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)
Stem runout limit ---- 0.01 mm

SPEC

0.08 mm
(0.0031 in)

0.10 mm
(0.0039 in)

(0.0004 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 35.95 mm (1.42 in) 34.15 mm

EX 37.75 mm (1.49 in) 35.86 mm

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

EX 30.7 mm (1.21 in) ----

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

33.50 ~ 38.89 lb)

EX 165 ~ 191 N (16.83 ~ 19.49 kg,

37.09 ~ 42.94 lb)

Tilt limit IN ---- 2.5°/1.6 mm

*

EX ---- 2. 5 ° / 1 . 6 m m

1.6 mm
(0.0630 in)

1.6 mm
(0.0630 in)

(1.34 in)

(1.41 in)

----

----

(2.5°/0.06 in)

(2.5°/0.06 in)

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

EX Clockwise ----

2 - 6

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Piston:

Piston to cylinder clearance 0.05 ~ 0.07 mm

(0.0020 ~ 0.0028 in)
Piston size “D” 99.945 ~ 99.995 mm

(3.9348 ~ 3.9368 in)

H

D

Measuring point “H” 2.5 mm (0.10 in) ---­Piston off-set 1.0 mm (0.04 in) ---­Piston pin bore inside diameter 22.004 ~ 22.015 mm

(0.8663 ~ 0.8667 in)
Piston pin outside diameter 21.991 ~ 22.000 mm

(0.8658 ~ 0.8661 in)

Piston rings:

Top ring

SPEC

0.15 mm
(0.0059 in)

----

22.045 mm
(0.8679 in)

21.971 mm
(0.8650 in)

B

T

Type Barrel ---­Dimensions (B × T) 1.2 × 3.8 mm

(0.0472 × 0.1496 in)

End gap (installed) 0.30 ~ 0.45 mm

(0.0118 ~ 0.0177 in)

Side clearance (installed) 0.04 ~ 0.08 mm

(0.0016 ~ 0.0031 in)
2nd ring

B

T

Type Taper ---­Dimensions (B × T) 1.2 × 4.0 mm

(0.0472 × 0.1575 in)

End gap (installed) 0.30 ~ 0.45 mm

(0.0118 ~ 0.0177 in)

Side clearance 0.03 ~ 0.07 mm

(0.0012 ~ 0.0028 in)
Oil ring

----

0.70 mm
(0.0276 in)

0.13 mm
(0.0051 in)

----

0.80 mm
(0.0315 in)

0.13 mm
(0.0051 in)

B

T

Dimensions (B × T) 2.5 × 3.4 mm

(0.0984 × 0.1339 in)

End gap (installed) 0.2 ~ 0.7 mm

(0.0079 ~ 0.0276 in)

2 - 7

----

----

Crankshaft:

MAINTENANCE SPECIFICATIONS

Item Standard Limit

SPEC

Crank width “A” 74.95 ~ 75.00 mm

(2.9508 ~ 2.9528 in)
Runout limitC1 ---- 0.03 mm

C2 ---- 0.03 mm

Big end side clearance “D” 0.32 ~ 0.64 mm

(0.0126 ~ 0.0252 in)
Big end radial clearance “E” 0.010 ~ 0.025 mm

(0.0004 ~ 0.0010 in)
Small end free play “F” 0.8 mm (0.0315 in) ----

Balancer:

Balancer drive method Gear ----

Clutch:

Friction plate 1

Thickness 2.74 ~ 2.86 mm

(0.108 ~ 0.113 in)

Quantity 6 ----

Friction plate 2

Thickness 2.94 ~ 3.06 mm

(0.116 ~ 0.120 in)

Quantity 2 ----

Clutch plate

Thickness 1.1 ~ 1.3 mm

(0.043 ~ 0.051 in)

Quantity 7 ---­Max. warpage ---- 0.2 mm

Clutch spring

Free length 42.8 mm (1.69 in) 40.7 mm

Quantity 5 ---­Min. length ---- 40.8 mm

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

----

(0.0012 in)

(0.0012 in)

1.0 mm
(0.0394 in)

----

2.6 mm
(0.102 in)

2.8 mm
(0.110 in)

----

(0.008 in)

(1.60 in)

(1.61 in)

2 - 8

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Transmission:

Main axle deflection limit ---- 0.08 mm

Drive axle deflection limit ---- 0.08 mm

Shifter:

Shifter type Shift drum and guide bar ----

Decompression device:

Device type Auto decomp ----

Air filter oil grade: Engine oil ---­Carburetors:

I. D. mark 5LP1 00 ---­Main jet (M.J) Carburetor #1 : #140

Carburetor #2 : #145
Main air jet (M.A.J) #130 ---­Jet needle (J.N) 5ND16-56-3 ---­Needle jet (N.J) P-6M (#826) ---­Pilot air jet (P.A.J.1) Carburetor #1 : #80

Carburetor #2 : #150
Pilot air jet (P.A.J.2) 1.3 ---­Pilot outlet (P.O) Carburetor #1 : 1.0

Carburetor #2 : 0.9
Pilot jet (P.J) #22.5 ---­Bypass 1 (B.P.1) 0.8 ---­Bypass 2 (B.P.2) 0.8 ---­Pilot screw turns out Carburetor #1: 2-1/2

Carburetor #2: 1-1/2
Valve seat size (V.S) 2.0 ---­Starter jet (G.S.1) #95 ---­Starter jet (G.S.2) 0.5 ---­Throttle valve size (Th.V) #80 ---­Float height (F.H) 13 mm (0.51 in) ---­Fuel level (F.L) 3 ~ 4 mm (0.12 ~ 0.16 in) ---­Engine idle speed 1,450 ~ 1,550 r/min ---­Intake vacuum 32. 0 ~ 33 .3 k Pa (240 ~ 250mmHg,

9.45 ~ 9.83 inHg)

Oil pump:

Oil filter type Paper ---­Oil pump type Trochoid ---­Tip clearance “A” or “B” 0.12 mm (0.005 in) 0.2 mm

Side clearance 0.03 ~ 0.08 mm

(0.001 ~ 0.003 in)
Bypass valve setting pressure 80 ~ 120 kPa (0.8 ~ 1.2 kg/cm

11.6 ~ 17.4 psi)

2

Oil pressure (hot) 65 kPa (0.65 kg/cm

1,500 r/min
Pressure check location Cylinder head ----

, 9.4 psi) at

SPEC

(0.0031 in)

(0.0031 in)

----

----

----

----

----

(0.008 in)

----

2

,

----

----

2 - 9

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Cooling system:

Radiator core

Width 219 mm (8.62 in) ---­Height 300 mm (11.8 in) ---­Depth 16 mm (0.63 in) ----

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

13.8 ~ 18.1 psi)
Radiator capacity 0.55 L (0.48 Imp qt, 0.58 US qt) ---­Coolant reservoir

Capacity 0.29 L (0.26 Imp qt, 0.31 US qt) ---­From low to full level 0.165 L (0.15 Imp qt, 0.17 US qt) ----

Water pump:

Type Single suction centrifugal pump ---­Reduction ratio 33/34 (0.971)

Lubrication chart:

SPEC

2

,

----

2 - 10

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Cylinder head tightening sequence:

SPEC

2 - 11

Tightening torques

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened

Cylinder head (exhaust pipe)

Part

name

Stud bolt

Thread

size

Q’ty

M6 4 7 0.7 5.1

Tightening torque
Nm m·kg ft·lb

Cylinder head Bolt M9 4 38 3.8 27

Bolt M9 2 38 3.8 27

Bolt M6 1 10 1.0 7.2
Spark plug — M12 1 18 1.8 13
Cylinder head cover Bolt M6 17 10 1.0 7.2
Camshaft end cap Bolt M6 1 10 1.0 7.2
Oil check bolt — M6 1 7 0.7 5.1
Tappet cover (exhaust) — M32 2 12 1.2 8.7
Tappet cover (intake) Bolt M6 4 10 1.0 7.2
Cylinder Bolt M10 2 42 4.2 30

Bolt M10 2 42 4.2 30

Bolt M6 2 10 1.0 7.2
Timing chain tensioner Bolt M6 2 10 1.0 7.2
Timing chain tensioner cap Bolt M16 1 22 2.2 16
Timing chain guide (intake) Bolt M6 2 8 0.8 5.8
Camshaft sprocket Bolt M7 2 20 2.0 14
Rocker arm shaft Bolt M6 2 10 1.0 7.2
Valve adjusting screw Nut M6 5 14 1.4 10
Radiator Bolt M6 2 7 0.7 5.1
Coolant drain bolt — M6 1 10 1.0 7.2
Engine oil drain bolt (oil tank) — M10 1 25 2.5 18
Engine oil drain bolt (engine) — M14 1 30 3.0 22
Oil filter bolt

Union bolt

M20 1 63 6.3 45
Oil filter cartridge — M20 1 17 1.7 12
Oil delivery pipe 1
Oil delivery pipe 2

Union bolt
Union bolt

M10 2 20 2.0 14

M8 2 18 1.8 13
Oil pipe joint — M14 1 50 5.0 36
Oil pipe 1 and oil pipe joint Nut M16 1 35 3.5 25
Oil pipe 2 and oil tank Nut M16 1 35 3.5 25
Air filter case Bolt M6 2 7 0.7 5.1
Carburetor clamp Bolt M4 4 5 0.5 3.6
Exhaust pipe 1 and exhaust pipe 2 Bolt M8 1 16 1.6 12
Exhaust pipe protector Bolt M6 4 10 1.0 7.2
Spark arrester Bolt M6 1 8 0.8 5.8
Muffler and exhaust pipe 2 Bolt M8 1 20 2.0 14
Muffler Bolt M8 2 26 2.6 19
Silencer cap Bolt M6 3 10 1.0 7.2
Exhaust pipe Nut M6 4 10 1.0 7.2

Remarks

E

LT

LT

2 - 12

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened

Part

name

Thread

size

Q’ty

Tightening torque
Nm m·kg ft·lb

Bearing retainer Screw M6 4 7 0.7 5.1
AC magneto rotor Nut M14 1 150 15.0 110
Starter clutch Bolt M6 6 16 1.6 11
Balancer driven gear Nut M18 1 140 14.0 100

Primary drive gear Nut M20 1 150 15.0 110

Clutch spring Bolt M6 5 8 0.8 5.8
Clutch boss Nut M20 1 90 9.0 65

Pull lever shaft Bolt M6 1 7 0.7 5.1
Drive sprocket Nut M18 1 70 7.0 50

Oil seal retainer Bolt M6 2 10 1.0 7.2
Shift drum segment Bolt M8 1 30 3.0 22
Shift guide Bolt M6 2 10 1.0 7.2
Stopper lever Bolt M6 1 10 1.0 7.2
Reverse shift lever Bolt M6 1 13 1.3 9.4
Shift arm Bolt M6 1 10 1.0 7.2
Shift pedal adjusting rod Nut M6 1 8 0.8 5.8

Nut M6 1 8 0.8 5.8
Stator assembly Bolt M5 3 7 0.7 5.1
Pick up coil Bolt M5 2 7 0.7 5.1
AC magneto lead holder Bolt M6 2 10 1.0 7.2
Ignition coil Bolt M6 2 7 0.7 5.1
Starter motor Bolt M6 2 10 1.0 7.2
Neutral switch — M10 1 20 2.0 14
Reverse switch — M10 1 20 2.0 14
Thermo switch 1 — M18 1 28 2.8 20
Thermo switch 2 — M18 1 28 2.8 20

Remarks

LT

LT

M

Use a lock
washer.

M

Use a lock
washer.

Use a lock
washer.

Use a lock
washer.

LT

Left-hand
threads

LT

LT

LT

2 - 13

MAINTENANCE SPECIFICATIONS

CHASSIS

Item Standard Limit

Steering system:

Steering bearing type Ball and race bearing ----

Front suspension:

Shock absorber travel 110 mm (4.33 in) ---­Fork spring free length 316.5 mm (12.46 in) ---­Spring fitting length 293.5 mm (11.56 in) ---­Spring rate (K1) 19.6 N/mm

(2.00 kg/mm, 111.92 lb/in)

Spring rate (K2) 29.4 N/mm

(3.00 kg/mm, 167.87 lb/in)

Optional spring No ----

Rear suspension:

Shock absorber travel 100 mm (3.94 in) ---­Spring free length 273 mm (10.75 in) ---­Spring fitting length 253 mm (9.96 in) ---­Spring rate (K1) 55 N/mm

(5.61 kg/mm, 314.05 lb/in)
Stroke (K1) 0 ~ 100 mm (0 ~ 3.94 in) ---­Optional spring No ----

Swingarm:

Free play limit end ---- 1 mm

side ---- 1 mm

Front wheel:

Type Panel wheel ---­Rim size 10 × 5.5 AT ---­Rim material Aluminum ---­Rim runout limit radial ---- 2 mm

lateral ---- 2 mm

Rear wheel:

Type Panel wheel ---­Rim size 9 × 8.5 AT ---­Rim material Aluminum ---­Rim runout limit radial ---- 2 mm

lateral ---- 2 mm

SPEC

----

----

----

(0.04 in)

(0.04 in)

(0.08 in)

(0.08 in)

(0.08 in)

(0.08 in)

2 - 14

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Front disc brake:

Type Dual ---­Disc outside diameter × thickness 161.0 × 3.5 mm (6.34 × 0.14 in) ---­Pad thickness inner 4.2 mm (0.17 in) 1 mm

Pad thickness outer 4.2 mm (0.17 in) 1 mm

Master cylinder inside diameter 12.7 mm (0.50 in) ---­Caliper cylinder inside diameter 32.03 mm (1.26 in) ---­Brake fluid type DOT 4 ----

Rear disc brake:

Type Single ---­Disc outside diameter × thickness 220.0 × 3.6 mm (8.66 × 0.14 in) ---­Pad thickness inner 4.5 mm (0.18 in) 1 mm

Pad thickness outer 4.5 mm (0.18 in) 1 mm

Master cylinder inside diameter 12.7 mm (0.50 in) ---­Caliper cylinder inside diameter 33.96 mm (1.34 in) ---­Brake fluid type DOT 4 ----

Brake lever and brake pedal:

Brake lever free play (at lever end) 0 mm (0 in) ---­Brake pedal position 4 mm (0.16 in)

(Below the top of footrest)
Throttle lever free play 3 ~ 5 mm (0.12 ~ 0.20 in) ----

SPEC

(0.04 in)

(0.04 in)

(0.04 in)

(0.04 in)

----

2 - 15

Tightening torques

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened Thread size

Tightening torque
Nm m·kg ft·lb

Engine bracket (upper) and frame M8 33 3.3 24
Engine bracket (upper) and engine M10 40 4.0 29
Engine bracket (lower) and frame M10 56 5.6 40
Engine bracket (lower) and engine M10 56 5.6 40
Engine bracket (middle and lower) and engine M10 56 5.6 40
Swingarm pivot shaft, engine and frame M16 95 9.5 68
Rear shock absorber and frame M10 32 3.2 23
Relay arm and swingarm M10 32 3.2 23
Connecting arm and frame M10 32 3.2 23
Relay arm and rear shock absorber M10 32 3.2 23
Relay arm and connecting arm M10 32 3.2 23
Drive chain guide and swingarm M6 7 0.7 5.1
Hub, brake caliper bracket and swingarm M12 90 9.0 65
Drive chain adjusting bolt and locknut M8 16 1.6 11
Front shock absorber and frame M10 45 4.5 32
Front shock absorber and front arm (lower) M10 45 4.5 32
Front arm (upper) and frame M10 38 3.8 27
Front arm (lower) and frame M10 32 3.2 23
Brake hose holder and front arm (upper) M6 7 0.7 5.1
Steering stem, pitman arm and frame M14 110 11 80
Steering stem bushing and frame M8 23 2.3 17

Steering stem and handlebar holder M8 23 2.3 17
Tie-rod end and locknut M10 15 1.5 11
Steering knuckle and front wheel hub M14 70 7.0 50
Steering knuckle and front arm (upper and lower) M10 25 2.5 18
Steering knuckle and tie-rod ball joint M10 25 2.5 18
Pitman arm and tie-rod ball joint M10 25 2.5 18
Frame and bearing retainer M42 40 4.0 29
Fuel tank and fuel cock M6 4 0.4 2.9
Fuel tank and frame M6 7 0.7 5.1
Front wheel and front wheel hub M10 45 4.5 32
Steering knuckle and front brake caliper M8 28 2.8 20
Front brake disc and front wheel hub M8 28 2.8 20
Rear axle and rear wheel hub M14 120 12 85
Rear brake caliper and brake caliper bracket M8 28 2.8 20
Rear wheel and rear wheel hub M10 45 4.5 32
Driven sprocket and sprocket bracket M8 24 2.4 17
Front brake pipe nut M10 19 1.9 13
Front brake master cylinder and handlebar M6 7 0.7 5.1

Remarks

Use a lock
washer.

LT

2 - 16

MAINTENANCE SPECIFICATIONS

SPEC

Part to be tightened Thread size

Tightening torque
Nm m·kg ft·lb

Front brake master cylinder and brake lever M6 6 0.6 4.3
Front brake master cylinder and brake hose M10 27 2.7 19
Brake hose joint and frame M6 10 1.0 7.2
Bleed screw M8 6 0.6 4.3
Front brake pad holding bolt M10 18 1.8 13
Front brake caliper and brake hose M10 27 2.7 19
Front brake caliper retaining bolt M8 23 2.3 17
Rear axle ring nut M38 SEE NOTE
Rear brake pad holding bolt M10 18 1.8 13

Rear brake caliper and brake hose M10 30 3.0 22
Rear brake master cylinder and frame M8 20 2.0 14
Rear brake master cylinder and brake hose M10 30 3.0 22
Parking brake adjusting bolt and locknut M8 16 1.6 11
Rear brake disc and brake disc bracket M8 28 2.8 20
Rear brake fluid reservoir cover and bracket M6 4 0.4 2.9
Rear brake fluid reservoir and bracket M6 4 0.4 2.9
Brake hose holder and swingarm M6 7 0.7 5.1
Front bumper and frame M8 31 3.1 22
Front fender bracket and frame M8 16 1.6 11
Rear carrier bar and frame M8 23 2.3 17
Footrest and frame M10 65 6.5 48
Footrest guard bracket and frame M 8 33 3.3 24
Footrest and footrest guard bracket M8 16 1.6 11
Footrest guard bracket and rear fender M6 7 0.7 5.1
Battery holding bracket and frame M6 7 0.7 5.1
Air filter case and frame M6 7 0.7 5.1
Carburetor clamp screw M4 5 0.5 3.6
Tail/brake light bracket and frame M6 7 0.7 5.1
Tail/brake light bracket and tail/brake light M6 7 0.7 5.1
Swingarm skid plate and swingarm M6 7 0.7 5.1
Swingarm skid plate and swingarm M8 16 1.6 11
Drive chain tensioner and frame M8 32 3.2 23
Engine skid plate and frame M6 7 0.7 5.1
Main frame and rear frame M10 53 5.3 38

Remarks

Use a lock
washer.

HINWEIS:

NOTE:

Apply locking agent (LOCTITE®) to ring nuts threads.
1st: Tighten the inside ring nut 55 Nm (5.5 m • kg, 40 ft • lb).
2nd: Tighten the outside ring nut while holding the inside ring nut 190 Nm (19 m • kg, 140 ft • lb).
3rd: Loosen the inside ring nut while holding the outside ring nut 240 Nm (24 m • kg, 170 ft • lb).

2 - 17

MAINTENANCE SPECIFICATIONS

ELECTRICAL

Item Standard Limit

Voltage: 12 V ---­Ignition system:

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

C.D.I.:

Magneto model/manufacturer F4T260/MITSUBISHI ---­Pickup coil resistance/color 445 ~ 545 Ω at 20 °C (68 °F)/

White/Red – White/Green
Rotor rotation direction detection coil resis-

tance/color
C.D.I. unit model/manufacturer F8T37971/MITSUBISHI ----

Ignition coil:

Model/manufacturer 2JN/YAMAHA ---­Minimum spark gap 6 mm (0.24 in) ---­Primary winding resistance 0.18 ~ 0.28 Ω at 20 °C (68 °F) ---­Secondary winding resistance 6.32 ~ 9.48 kΩ at 20 °C (68 °F) ----

Spark plug cap:

Type Resin type ---­Resistance 10 kΩ ----

Charging system:

Type A.C. magneto generator ---­Model/manufacturer F4T260/MITSUBISHI ---­Nominal output 14 V 16 A at 5,000 r/min ---­Charging coil resistance/color 0.43 ~ 0.65 Ω at 20 °C (68 °F)/

Rectifier:

Type Semi conductor-short circuit ---­Model/manufacturer SH640E-11/SHINDENGEN ---­No load voltage (DC) 14.1 ~ 14.9 V ---­Capacity 14 A ---­Withstand voltage 200 V ----

Electric starter system:

Type Constantmesh type ---­Starter motor

Model/manufacturer SM-13/MITSUBA ---­Output 0.8 kW ---­Armature coil resistance 0.025 ~ 0.035 Ω at 20 °C (68 °F) ---­Brush overall length 12.5 mm (0.49 in) 5 mm

Spring force 7.65 ~ 10.01 N (27.54 ~ 36.03 oz) ---­Commutator diameter 28 mm (1.10 in) 27 mm

Mica undercut 0.7 mm (0.03 in) ----

0.069 ~ 0.085 Ω at 20 °C (68 °F)/

Red – White/Blue

White – White

SPEC

----

----

----

(0.20 in)

(1.06 in)

2 - 18

MAINTENANCE SPECIFICATIONS

Item Standard Limit

Starter relay

Model/manufacturer MS5F-721/JIDECO ---­Amperage rating 180 A ---­Coil winding resistance 4.18 ~ 4.62 Ω at 20 °C (68 °F) ----

Thermostat switch:

Thermostat switch 1

Model/manufacturer 5GH/NIPPON THERMOSTAT ----

Thermostat switch 2

Model/manufacturer 5LP/NIPPON THERMOSTAT ----

Circuit breaker:

Type Fuse ---­Amperage for individual circuit

Fuse 20 A × 1 ---­Reserve 20 A × 1 ----

SPEC

2 - 19

HOW TO USE THE CONVERSION TABLE/

GENERAL TORQUE SPECIFICATIONS

SPEC

EB201000

HOW TO USE THE CONVERSION
TABLE

All specification data in this manual are listed
in SI and METRIC UNITS.
Use this table to convert METRIC unit data to
IMPERIAL unit data.

Ex.

METRIC MULTIPLIER IMPERIAL

** mm

2 mm

CONVERSION TABLE

Torque

Weight
Speed km/hr 0.6214 mph

Distance

Volume/
Capacity

Misc.

×

0.03937 = ** in

×

0.03937 = 0.08 in

METRIC TO IMPERIAL

Metric unit Multiplier Imperial unit

m·kg
m·kg
cm·kg
cm·kg

kg
g

km
m
m
cm
mm

cc (cm
cc (cm3)
lt (liter)
lt (liter)

kg/mm
kg/cm
Centigrade
(°C)

7.233

86.794

0.0723

0.8679

2.205

0.03527

0.6214

3.281

1.094

0.3937

0.03937

3

)

0.03527

0.06102

0.8799

0.2199

55.997

2

14.2234
9/5+32

ft·lb
in·lb
ft·lb
in·lb

lb
oz

mi
ft
yd
in
in

oz (IMP liq.)
cu·in
qt (IMP liq.)
gal (IMP liq.)

lb/in
psi (lb/in
Fahrenheit (°F)

2

)

EB202001

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 provided for each chapter of
this manual. To avoid warpage, tighten multi­fastener assemblies in a crisscross fashion, in
progressive stages, until the specified torque is
reached. Unless otherwise specified, torque
specifications require clean, dry threads. Com­ponents should be at room temperature.

A: Distance between flats
B: Outside thread diameter

A

(nut)

B

(bolt)

10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40

General torque

specifications

Nm m•kg ft•lb

2 - 20

19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94

LUBRICATION POINTS AND LUBRICANT TYPES

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE

Lubrication points Lubricant type
Oil seal lips (all)
O-ring (all)

SPEC

LS

LS

Bearings (all)
Crank pin
Connecting rod (bearing)
Camshaft sprocket
Crankshaft
Piston surface/piston rings
Piston pin
Primary drive gear/primary driven gear
Valve stem/valve stem end
Rocker arm shaft
Rocker arm
Camshaft lobe/journal
Oil pump shaft, rotor, housing
Oil filter O-ring
Starter idle gear/shaft
Transmission gear (wheel/pinion)

E

E

E

M

E

E

E

E

M

E

M
M

E

E

E

M

Axle (main/drive)
Shift fork/guide bar
Shift drum/shift shaft/shift cam stopper ball
Shift lever/shift guide

Crankcase mating surfaces

Cylinder head and cylinder head cover mating surfaces
AC magneto lead grommet

(AC magneto cover)

M

E

E

LS

Sealant (Quick Gasket
Yamaha bond No.1215

Sealant (Quick Gasket
Yamaha bond No.1215

Sealant (Quick Gasket
Yamaha bond No.1215



)



)



)

2 - 21

COOLANT FLOW DIAGRAMS

COOLANT FLOW DIAGRAMS

1 Radiator
2 Radiator fan
3 Radiator outlet hose
4 Water pump inlet hose
5 Water pump
6 Water jacket outlet pipe
7 Thermostat inlet hose
8 Thermostat

9 Radiator inlet hose
0 Thermo switch 2
A Thermo switch 1

SPEC

2 - 22

OIL FLOW DIAGRAMS

1 Oil tank
2 Oil pipe 2
3 Oil pipe 1

OIL FLOW DIAGRAMS

SPEC

2 - 23

1 Oil delivery pipe 2
2 Oil delivery pipe 1
3 Oil filter
4 Crankshaft
5 Oil pump

OIL FLOW DIAGRAMS

SPEC

2 - 24

1 Oil pipe 2
2 Drive axle
3 Main axle
4 Engine oil drain bolt (engine)
5 Oil pipe 1
6 Oil strainer
7 Shift drum

OIL FLOW DIAGRAMS

SPEC

2 - 25

1 Oil delivery pipe 2
2 Oil filter cartridge
3 Oil pump rotor 1
4 Oil pump rotor 2
5 Oil pipe 1
6 Main axle

OIL FLOW DIAGRAMS

SPEC

2 - 26

CABLE ROUTING

1 Parking brake cable
2 Starter cable
3 Clutch cable
4 Throttle cable
5 Front brake hose
6 Front brake switch
7 Park switch

CABLE ROUTING

È Fasten the handlebar switch lead, park switch

lead and clutch switch lead to the handlebar with
the plastic band.

É Fasten the front brake switch lead to the handle-

bar with the plastic band.

SPEC

2 - 27

CABLE ROUTING

SPEC

1 Front brake hose
2 Throttle cable
3 Main switch lead
4 Indicator light lead
5 Clutch cable
6 Parking brake cable
7 Starter cable
8 Coolant reservoir hose
9 Wire harness
0 Ignition coil lead
A Headlight lead coupler (left)

B Brake pipe
C Headlight lead coupler (right)
D Radiator fan breather hose
E Headlight lead (right)

È Pass the throttle cable through the cable guide.
É Pass the clutch cable, parking brake cable and

starter cable through the cable guide.

Ê Fasten the left and right headlight lead, radiator

fan lead and thermo switch 1 lead to the frame
with the plastic band.

2 - 28

CABLE ROUTING

SPEC

1 Throttle cable
2 Fuel tank breather hose
3 Fuel hose
4 Carburetor air vent hose
5 Negative battery lead
6 AC magneto lead
7 Thermo switch 1
8 Coolant reservoir hose
9 Starter cable

È Put the wire harness and coolant reservoir hose

with the plastic holder.

É Fasten the wire harness, AC magneto lead,

speed sensor lead, negative battery lead and
rear brake switch lead with the plastic band.

Ê 70 mm (2.76 in)
Ë 25 ~ 35 mm (0.98 ~ 1.38 in)
Ì 60 mm (2.36 in)
Í 0 ~ 5 mm (0 ~ 0.20 in)
Î 80 ~ 90 mm (3.15 ~ 3.54 in)

2 - 29

CABLE ROUTING

SPEC

1 Coolant reservoir hose
2 Carburetor air vent hose
3 Reservoir tank breather hose
4 Rectifier/regulator
5 CDI unit
6 Negative battery lead
7 AC magneto lead
8 Wire harness
9 Starter motor lead
0 Tail/brake light lead
A Rectifier/regulator lead

È Pass the negative battery lead between th e wire

harness and frame.

2 - 30

CABLE ROUTING

SPEC

1 Radiator fan breather hose
2 Reverse control cable
3 Parking brake cable
4 Clutch cable

È Fasten the reverse control cable to the frame

with the plastic band.

É 15 ~ 25 mm (0.59 ~ 0.98 in)

2 - 31

1 Rear brake hose
2 Parking brake cable
3 Negative battery lead
4 AC magneto lead
5 Crankcase breather hose
6 Carburetor drain hose
7 Rear brake switch
8 Speed sensor
9 Speed sensor lead
0 Rear brake switch lead

CABLE ROUTING

SPEC

2 - 32

CABLE ROUTING

SPEC

1 Thermo switch 1 lead
2 Headlight lead (right)
3 Radiator fan breather hose
4 Thermo switch 2 lead
5 Carburetor breather hose
6 Headlight lead (left)
7 Wire harness
8 Coolant reservoir hose

È Fasten the fan motor lead, headlight lead (right)

and thermo switch 1 lead to the frame with the
plastic band.

2 - 33

CABLE ROUTING

SPEC

1 Positive battery lead
2 Tail/brake light lead
3 Coolant reservoir breather hose
4 Negative battery lead
5 Coolant reservoir hose
6 Starter motor lead
7 Wire harness
8 Rectifier/regulator lead

È Fasten the wire harness with the plastic clamp.
É Fasten the starter motor lead and starter relay

lead with the plastic clamp.

2 - 34

CHK

ADJ

3

CHK

ADJ

CHAPTER 3.

PERIODIC CHECKS AND ADJUSTMENTS

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

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

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

SEAT, FRONT PANEL, FOOTREST GUARDS

AND ENGINE SKID PLATE ....................................................................3-3

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

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

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

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

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

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

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

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

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

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

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

CHECKING THE IGNITION TIMING ......................................................3-17

MEASURING THE COMPRESSION PRESSURE .................................3-18

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

CHANGING THE ENGINE OIL ..............................................................3-21

ADJUSTING THE CLUTCH CABLE .......................................................3-24

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

CHECKING THE COOLANT LEVEL ......................................................3-27

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

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

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

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

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

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

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

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

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

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

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

CHECKING THE BRAKE HOSE ............................................................3-37

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

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

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

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

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

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

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

CHK

ADJ

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

CHECKING THE TIRE ...........................................................................3-47

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

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

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

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

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

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

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

REPLACING THE HEADLIGHT BULB ...................................................3-58

INTRODUCTION/PERIODIC MAINTENANCE/

LUBRICATION INTERVALS

EB300000

CHK

ADJ

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION

This chapter includes all information necessary to perform recommended inspections and adjust­ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle
operation and a longer service life. The need for costly overhaul work will be greatly reduced. This
information applies to vehicles already in service as well as to new vehicles that are being prepared
for sale. All service technicians should be familiar with this entire chapter.

EB301000

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

ITEM ROUTINE

Valves*
(See page 3-8.)

Cooling system
(See page 3-27.)

Spark plug
(See page 3-16.)

Air filter element
(See page 3-24.)

Carburetor*
(See page 3-11.)

Crankcase breather
system*

Exhaust system*

Spark arrester
(See page 3-31.)

Fuel line*
Engine oil

(See page 3-19.)
Engine oil filter car-

tridge
Drive chain

(See page 3-40.)
Brake*

(See page 3-33.)
Clutch*

(See page 3-24.)
Wheels*

(See page 4-3.)
Wheel bearings*

Steering system*
(See page 3-42.)

Upper and lower arm
pivot and steering
shaft*

Rear arm pivot*
Fittings and fasten-

ers*

• Check valve clearance.

• Adjust if necessary.

• Check coolant leakage.

• Repair if necessary.

• Replace coolant every 24 months.

• Check condition.

• Adjust gap and clean.

• Replace if necessary.

• Clean.

• Replace if necessary.

• Check and adjust idle speed/starter operation.

• Adjust if necessary.

• Check breather hose for cracks or damage.

• Replace if necessary.

• Check for leakage.

• Retighten if necessary.

• Replace gasket if necessary.

•Clean.

• Check fuel hose for cracks or damage.

• Replace if necessary.

• Replace (Warm engine before draining).

• Replace if necessary.

• Check and adjust slack/alignment/clean/lube.

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

• Correct if necessary.

• Check operation.

• Adjust if necessary.

• Check balance/damage/runout.

• Replace if necessary.

• Check bearing assembly for looseness/damage.

• Replace if damaged.

• Check operation.

• Replace if damaged.

• Check toe-in.

• Adjust if necessary.

• Lubricate every 6 months.**

• Lubricate every 6 months.**

• Check all chassis fittings and fasteners.

• Correct if necessary.

INITIAL EVERY

1

month3months6months6months1year

Every 20 ~ 40 hours

(More often in wet or dusty areas.)

* It is recommended that these items be serviced by a Yamaha dealer.
** Lithium soap base grease

3 - 1

CHK

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

NOTE:

● Recommended brake fluid: DOT 4

● Brake fluid replacement:

1.When disassembling the master cylinder or caliper cylinder, replace the brake fluid.
Normally check the brake fluid level and add fluid as required.

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

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

WARNING

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

ADJ

3 - 2

SEAT, FENDERS AND FUEL TANK

SEAT, FENDERS AND FUEL TANK

SEAT, FRONT PANEL, FOOTREST GUARDS AND ENGINE SKID PLATE

CHK

ADJ

Order Job name/Part name Q’ty Remarks

Removing the seat, front panel, foot­rest guard and engine skid plate

1 Seat 1

2 Front panel 1
3 Left footrest guard 1
4 Right footrest guard 1
5 Engine skid plate 1

Remove the parts in the order below.

NOTE:

Pull back the seat lock lever, than pull up
on the rear of the seat.

For installation, reverse the removal pro­cedure.

3 - 3

SEAT, FENDERS AND FUEL TANK

HEADLIGHTS AND FRONT FENDER

CHK

ADJ

Order Job name/Part name Q’ty Remarks

Removing the headlight and front
fender

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

1 Headlight coupler 2 Disconnect.
2 Left headlight 1
3 Right headlight 1
4 Fuel tank top panel 1
5 Front fender 1

Remove the parts in the order below.

REST GUARDS AND ENGINE SKID
PLATE”.

For installation, reverse the removal pro­cedure.

3 - 4

REAR FENDER

SEAT, FENDERS AND FUEL TANK

CHK

ADJ

Order Job name/Part name Q’ty Remarks

Removing the rear fender Remove the parts in the order below.
Seat Refer to “SEAT, FRONT PANEL, FOOT-

REST GUARDS AND ENGINE SKID
PLATE”.

Front fender Refer to “HEADLIGHTS AND FRONT

FENDER”.
1 Battery holding bracket 1
2 Battery lead 2 Disconnect.

CAUTION:

First disconnect the negative lead,

then disconnect the positive lead.

3 Battery 1
4 Rear fender 1

For installation, reverse the removal pro-

cedure.

3 - 5

FUEL TANK

SEAT, FENDERS AND FUEL TANK

CHK

ADJ

Order Job name/Part name Q’ty Remarks

Removing the fuel tank Remove the parts in the order below.
Seat and front panel Refer to “SEAT, FRONT PANEL, FOOT-

REST GUARDS AND ENGINE SKID

PLATE”.

Front fender Refer to “HEADLIGHTS AND FRONT

FENDER”.
1 Fuel hose 1

2 Fuel tank 1

3 Plastic band 2

NOTE:

Before disconnecting the fuel hose, turn

the fuel cock to “OFF”.

NOTE:

When installing the fuel tank, pass the

fuel tank breather hose through the hole

in the handlebar protector.

3 - 6

SEAT, FENDERS AND FUEL TANK

CHK

ADJ

Order Job name/Part name Q’ty Remarks

4 Rubber cover 1 1
5 Rubber cover 2 1
6 Hose holder 2

For installation, reverse the removal pro-

cedure.

3 - 7

ADJUSTING THE VALVE CLEARANCE

ENGINE

ADJUSTING THE VALVE CLEARANCE
NOTE:

● The valve clearance must be adjusted when

the engine is cool to the touch.

● Adjust the valve clearance when the piston is

at the Top Dead Center (T.D.C.) on the com­pression stroke.

1.Remove:

● Seat

● Front fender

● Fuel tank

Refer to “SEAT, FENDERS AND FUEL
TANK”.

CHK

ADJ

2.Remove:

● Tappet cover (intake) 1

● Tappet covers (exhaust) 2

3.Disconnect:

● Spark plug cap 3

4.Remove:

● Spark plug

5.Remove:

● Crankshaft end accessing screw 1

● Timing mark accessing screw 2

3 - 8

ADJUSTING THE VALVE CLEARANCE

6.Check:

● Valve clearance

Out of specification → Adjust.

Valve clearance (cold):

Intake:

0.10 ~ 0.15 mm
(0.0039 ~ 0.0059 in)

Exhaust:

0.15 ~ 0.20 mm
(0.0059 ~ 0.0079 in)

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

Checking steps:

●Turn the crankshaft counterclockwise with a

wrench.

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

tionary pointer 2 on the crankcase cover.
When the “I” mark is aligned with the station­ary pointer, the piston is at the Top Dead
Center (T.D.C.).

CHK

ADJ

NOTE:

● When the piston is at the Top Dead Center

(T.D.C.) on the compression stroke, there
should be clearance between the valve stem
tips and their respective rocker arm adjusting
screws.

● If there is no clearance, rotate the crankshaft

counterclockwise one turn.

●Measure the valve clearance using a feeler

gauge 3.

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

3 - 9

ADJUSTING THE VALVE CLEARANCE

7.Adjust:

● Valve clearance

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

Adjustment steps:

●Loosen the locknut 1.

●Insert a feeler gauge 2 between the adjuster

end and the valve end.

●Turn the adjuster 3 clockwise or counter-

clockwise with the tappet adjusting tool 4
until the proper clearance is obtained.

Tappet adjusting tool:

P/N. YM-08035, 90890-01311

●Hold the adjuster to prevent it from moving

and then tighten the locknut.

Locknut:

T

14 Nm (1.4 m • kg, 10 ft • lb)

.

R

.

CHK

ADJ

●Measure the valve clearance.

●If the clearance is incorrect, repeat the above

steps until the proper clearance is obtained.

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

8.Install:

● All removed parts

NOTE:

Install all removed parts in the reverse order of
their disassembly. Note the following points.

3 - 10

9.Install:

T

18 Nm (1.8 m • kg, 13 ft • lb)

.

● Spark plug

● Tappet cover (intake)

● Tappet covers (exhaust)

R

.

T

10 Nm (1.0 m • kg, 7.2 ft • lb)

.

R

.

T

12 Nm (1.2 m • kg, 8.7 ft • lb)

.

R

.

ADJUSTING THE VALVE CLEARANCE/ADJUSTING THE

TIMING CHAIN/ADJUSTING THE IDLING SPEED

10.Install:

● Fuel tank

● Front fender

●

Seat
Refer to “SEAT, FENDERS AND FUEL
TANK”.

ADJUSTING THE TIMING CHAIN

Adjustment free.

CHK

ADJ

ADJUSTING THE IDLING SPEED

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

2.Attach:

● Tachometer

(to the spark plug lead)

3.Check:

● Engine idling speed

Out of specification → Adjust.

Engine idling speed:

1,450 ~ 1,550 r/min

3 - 11

ADJUSTING THE IDLING SPEED/

ADJUSTING THE THROTTLE LEVER FREE PLAY

4.Adjust:

● Engine idling speed

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

Adjustment steps:

●Turn the pilot screw 1 in until it is lightly

seated.

●

Turn the pilot screw out the specified number
of turns.

Carburetor angle driver:

P/N. 90890-03158

Pilot screw setting:

Carburetor #1 : 2-1/2 turns out
Carburetor #2 : 1-1/2 turns out

●Turn the throttle stop screw 2 in or out until

the specified idling speed is obtained.

CHK

ADJ

Turning in

Turning out

Idling speed becomes
higher.

Idling speed becomes
lower.

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

5.Detach:

● Tachometer

6.Adjust:

● Throttle lever free play

Refer to “ADJUSTING THE THROTTLE
LEVER FREE PLAY”.

3 - 12

ADJUSTING THE THROTTLE LEVER FREE
PLAY

NOTE:

Engine idling speed should be adjusted prop­erly before adjusting the throttle lever free
play.

ADJUSTING THE THROTTLE LEVER FREE PLAY

1.Check:

● Throttle lever free play a

Out of specification → Adjust.

Throttle lever free play:

3 ~ 5 mm (0.12 ~ 0.20 in)

2.Adjust:

● Throttle lever free play

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

Adjustment steps:
First step:

●Pull back the adjuster cover 1.

●Loosen the locknut 2 on the carburetor side.

●Turn the adjuster 3 in or out until the correct

free play is obtained.

CHK

ADJ

Turning in Free play is increased.
Turning out Free play is decreased.

●Tighten the locknut 2.

●Push in the adjuster cover 1.

NOTE:

If the free play cannot be adjusted here, adjust
it at the throttle lever side of the cable.

Second step:

●Pull back the adjuster cover 4.

●Loosen the locknut 5.

●Turn the adjuster 6 in or out until the correct

free play is obtained.

Turning in Free play is increased.
Turning out Free play is decreased.

●Tighten the locknut 5.

●Push in the adjuster cover 4.

WARNING

After adjusting the free play, turn the handle­bar to the right and left to make sure that the
engine idling speed does not increase.

3 - 13

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

ADJUSTING THE SPEED LIMITER

ADJUSTING THE SPEED LIMITER

The speed limiter keeps the carburetor throttle
from becoming fully-opened even when the
throttle lever is applied to the maximum posi­tion. Screwing in the adjuster stops the engine
speed from increasing.

1.Check:

● Speed limiter length a

Out of specification → Adjust.

Speed limiter length:

12 mm (0.47 in)

CHK

ADJ

2.Adjust:

● Speed limiter length

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

Speed limiter length adjustment steps:

●Loosen the locknut 1.

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

fied speed limiter length is obtained.

Turning in

Turning out

●Tighten the locknut.

Speed limiter length is
decreased.

Speed limiter length is
increased.

WARNING

Particularly for a beginner rider, the

●

speed limiter should be screwed in com­pletely. Screw it out little by little as their
riding technique improves. Never remove
the speed limiter for a beginning rider.
For proper throttle lever operation do not

●

turn out the adjuster more than 12 mm
(0.47 in). Also, always adjust the throttle
lever free play to 3 ~ 5 mm (0.12 ~ 0.20 in).

3 - 14

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

ADJUSTING THE STARTER CABLE

ADJUSTING THE STARTER CABLE

1.Adjust:

● Starter cable

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

Adjustment steps:

●Disconnect the starter cable 1 from the car-

buretor body.

NOTE:

Do not remove the starter plunger 2 from the
starter cable.

●Measure the starter plunger stroke distance

a of the starter lever 3 fully close-to-fully
open position.
If the distance is out of specification adjust it
as described below.

Starter plunger stroke distance a:

15 mm (0.59 in)

CHK

ADJ

Fully closed position

È

Fully open position

É

●Pull back the boot 4.

●Loosen the locknut 5.

●Turn the adjuster 6 in or out until the correct

distance is obtained.

Turning in Distance increased.
Turning out Distance decreased.

●Tighten the locknut 5.

●Push in the boot 4.

●Connect the starter cable.

WARNING

After adjusting the cable, turn the handle­bar to right to left, and make sure that the
engine idling speed does not increase.

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

3 - 15

CHECKING THE SPARK PLUG

CHECKING THE SPARK PLUG

1.Remove:

● Spark plug

2.Check:

● Spark plug type

Incorrect → Replace.

Standard spark plug:

DPR8EA-9/NGK

3.Check:

● Electrode 1

Wear/damage → Replace.

● Insulator 2

Abnormal color → Replace.
Normal color is a medium-to-light tan color.

4.Clean the spark plug with a spark plug
cleaner or wire brush.

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ADJ

5.Measure:

● Plug gap a

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

Spark plug gap:

0.8 ~ 0.9 mm (0.031 ~ 0.035 in)

6.Tighten:

● Spark plug

T

18 Nm (1.8 m • kg, 13 ft • lb)

.

R

.

NOTE:

Before installing a spark plug, clean the gasket
surface and plug surface.

3 - 16

CHECKING THE IGNITION TIMING

CHECKING THE IGNITION TIMING
NOTE:

Engine idling speed and throttle cable free play
should be adjusted properly before checking
the ignition timing.

1.Attach:

● Tachometer

● Timing light

(to spark plug lead)

Timing light:

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

CHK

ADJ

2.Check:

● Ignition timing

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

Checking steps:

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

fied speed.

Engine speed:

1,450 ~ 1,550 r/min

●Remove the timing mark accessing screw 1.

●Visually check the stationary pointer 2 to

verify it is within the required firing range 3
indicated on the flywheel.
Incorrect firing range → Check the pulser coil
assembly.

●Install the timing mark accessing screw.

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

3.Detach:

● Timing light

● Tachometer

3 - 17

MEASURING THE COMPRESSION PRESSURE

MEASURING THE COMPRESSION
PRESSURE

NOTE:

Insufficient compression pressure will result in
a loss of performance.

1.Check:

● Valve clearance

Out of specification → Adjust.
Refer to “ADJUSTING THE VALVE CLEAR­ANCE”.

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

3.Stop the engine.

4.Remove:

● Spark plug

CHK

ADJ

5.Attach:

● Adapter

● Compression gauge 1

Compression gauge:

P/N. YU-33223, 90890-03081

Adapter:

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

6.Measure:

● Compression pressure

Above the maximum pressure:
Inspect the cylinder head, valve surfaces,
and piston crown for carbon deposits.
Below the minimum pressure:
Squirt a few drops of oil into the affected cyl­inder and measure again.

● Refer to the table below.

Compression pressure

(with oil introduced into cylinder)

3 - 18

Reading Diagnosis

Higher than
without oil

Same as
without oil

Worn or damaged piston,
rings or cylinder wall.

Defective valves or
cylinder head gasket.

MEASURING THE COMPRESSION PRESSURE/

CHECKING THE ENGINE OIL LEVEL

Compression pressure (at sea level):

Standard:

1,250 kPa (12.5 kg/cm

Minimum:

1,050 kPa (10.5 kg/cm

Maximum:

1,350 kPa (13.5 kg/cm

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

Measurement steps:

●

Crank over the engine with the electric
starter (be sure the battery is fully charged)
with the throttle fully-open until the compres­sion reading on the gauge stabilizes.

WARNING

When cranking the engine, ground the
spark plug lead to prevent sparking.

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

7.Install:

●

Spark plug

T

18 Nm (1.8 m • kg, 13 ft • lb)

.

R

.

CHK

ADJ

2

, 181 psi)

2

, 149 psi)

2

, 192 psi)

3 - 19

CHECKING THE ENGINE OIL LEVEL

1.Place the machine on a level surface.

2.Start the engine, warm it up until the engine
oil has reached a normal temperature of
60 °C (140 °F), let it continue to idle for ten
seconds, and then turn the engine off.

NOTE:

To achieve the proper engine oil temperature
for an accurate oil level reading, the engine
must have first completely cooled down, and
then warmed up again for several minutes to
normal operating temperature.

È

CHECKING THE ENGINE OIL LEVEL

3.Check:

● Engine oil level

Oil level should be between the minimum
level mark a and the maximum level mark
b.
Low oil level → Add oil to the proper level.

NOTE:

● Wait a few minutes until the oil settles before

inspecting the oil level.

● Do not screw the dipstick 1 in when inspect-

ing the oil level.

Recommended oil:

Follow the left chart.

NOTE:

Recommended oil classification:
API Service “SE”, “SF”, “SG” type or equiva­lent (e.g. “SF–SE–CC”, “SF–SE–SD” etc.)

CHK

ADJ

É

É

CAUTION:

Engine oil also lubricates the clutch and

●

the wrong oil types or additives could
cause clutch slippage. There-fore, do not
add any chemical additives or use engine
oils with a grade of CD c or higher and
do not use oils labeled “ENERGY CON­SERVING II” d or higher.
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.

For CDN

È

For Europe

É

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

5.Stop the engine and inspect the oil level
again.

NOTE:

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

3 - 20

CHANGING THE ENGINE OIL

CHANGING THE ENGINE OIL

1.Remove:

● Engine skid plate

Refer to “SEAT, FENDERS AND FUEL
TANK”.

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

3.Stop the engine and place a container under
the engine oil drain bolt.

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ADJ

4.Remove:

● Dipstick 1

● Engine oil drain bolt (oil tank) 2

● Engine oil drain bolt (crankcase) 3

Drain the engine oil from the oil tank and
crankcase.

3 - 21

CHANGING THE ENGINE OIL

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

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

Replacement steps:

●Remove the oil filter cartridge 1 with an oil

filter wrench 2.

Oil filter wrench:

P/N. YM-01469, 90890-01469

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

3 of the new oil filter cartridge.

CAUTION:

Make sure that the O-ring 3 is properly
seated in the groove of the oil filter car­tridge.

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ADJ

●Tighten the new oil filter cartridge to specifi-

cation with an oil filter wrench.

Oil filter cartridge:

T

17 Nm (1.7 m • kg, 12 ft • lb)

.

R

.

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

6.Install:

● Engine oil drain bolt (crankcase)

T

30 Nm (3.0 m • kg, 22 ft • lb)

.

R

.

● Engine oil drain bolt (oil tank)

T

25 Nm (2.5 m • kg, 18 ft • lb)

.

R

.

7.Fill:

● Oil tank

(with the specified amount of the recom­mended engine oil)

Quantity:

Total amount:

2.3 L (2.02 Imp qt, 2.43 US qt)

Periodic oil replacement:

1.9 L (1.67 Imp qt, 2.01 US qt)
With oil filter cartridge replace­ment:

1.95 L (1.72 Imp qt, 2.06 US qt)

3 - 22

NOTE:

● Pour the engine oil in several stages.

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

of oil, and then start the engine and rev it 3 to
5 times. Stop the engine, and then pour in
the remainder of the specified amount.

CHANGING THE ENGINE OIL

CAUTION:

When starting the engine make sure the
dipstick is securely fitted into the oil tank.

8.Install:

● Dipstick

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

10.Check:

● Engine

(for engine oil leaks)

● Oil level

Refer to “CHECKING THE ENGINE OIL
LEVEL”.

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ADJ

11.Check:

● Engine oil pressure

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

●Slightly loosen the oil gallery bolt 1.

●Start the engine and keep it idling until

engine oil starts to seep from the oil gallery
bolt. If no engine oil comes out after one
minute, turn the engine off so that it will not
seize.

● Check the engine oil passages, the oil filter

cartridge and the oil pump for damage or
leakage.
Refer to “OIL PUMP” in CHAPTER 5.

●Start the engine after solving the problem(s)

and check the engine oil pressure again.

●Tighten the oil gallery bolt to specification.

Oil gallery bolt:

T

7 Nm (0.7 m • kg, 5.1 ft • lb)

.

R

.

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

12.Install:

● Engine skid plate

Refer to “SEAT, FENDERS AND FUEL
TANK”.

3 - 23

ADJUSTING THE CLUTCH CABLE/

CLEANING THE AIR FILTER

ADJUSTING THE CLUTCH CABLE

1.Check:

● Clutch lever free play a

Out of specification → Adjust.

Clutch lever free play
(at the clutch lever end):

5 ~ 10 mm (0.20 ~ 0.39 in)

2.Adjust:

● Clutch lever free play

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

Adjustment steps:

●Pull the rubber cover 1 off.

●Loosen the locknut 2 and finger tighten the

adjusting bolt 3.

●Loosen the locknut 4.

●Turn the adjusting nut 5 until the clutch lever

free play is within the specified limits.

CHK

ADJ

Clutch lever free play
(at the clutch lever end):

5 ~ 10 mm (0.20 ~ 0.39 in)

●Tighten the locknut 4.

NOTE:

If the specified clutch lever free play cannot be
obtained on it, use the adjusting bolt 3.

●Turn the adjusting bolt 3 until the clutch

lever free play is within the specified limits.

●Tighten the locknut 2.

●Pull the rubber cover 1 in.

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

CLEANING THE AIR FILTER

3 - 24

NOTE:

There is a check hose 1 at the bottom of the
air filter case. If dust and/or water collects in
this hose, clean the air filter element and air fil­ter case.

CLEANING THE AIR FILTER

1.Remove:

● Seat

Refer to “SEAT, FENDERS AND FUEL
TANK”.

2.Disconnect:

● Crankcase breather hose 1

3.Remove:

● Air filter case cover 2

4.Remove:

● Air filter element assembly 1

● Air filter element cap 2

● Air filter element 3

NOTE:

When removing the air filter element, rotate
the air filter element cap 1/4 of a turn and
remove the element.

CHK

ADJ

CAUTION:

Never operate the engine with the air filter
element removed. This will allow unfiltered
air to enter, causing rapid wear and possible
engine damage. Additionally, operation
without the filter element will affect carbure­tor tuning with subsequent poor perfor­mance and possible engine overheating.

5.Check:

● Air filter element

Damaged → Replace.

3 - 25

CLEANING THE AIR FILTER

6.Clean:

● Air filter element

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

Cleaning steps:

●Wash the element gently, but thoroughly in

solvent.

WARNING

Use a cleaning solvent which is designed
to clean parts only. Never use gasoline or
low flash point solvents as they may cause
a fire or explosion.

●Squeeze the excess solvent out of the ele-

ment and let it dry.

CAUTION:

Do not twist or wring out the element. This
could damage the foam material.

CHK

ADJ

●Apply engine oil to the element.

●Squeeze out the excess oil.

NOTE:

The element should be wet but not dripping.

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

7.Install:

● Air filter element

● Air filter case cover

NOTE:

● Insert the lobes 1 on the filter element into

the receptacles 2 on the filter case.

● To prevent air leaks make sure that the seal-

ing surface of the element matches the seal­ing surface of the case.

3 - 26

8.Connect:

● Crankcase breather hose 1

9.Install:

● Seat

Refer to “SEAT, FENDERS AND FUEL
TANK”.

CHECKING THE COOLANT LEVEL/

CHANGING THE COOLANT

CHECKING THE COOLANT LEVEL

1.Place the machine on a level surface.

2.Check:

●

Coolant level
The coolant level should be between the
minimum level mark a and maximum level
mark b.
Below the minimum level mark → Add the
recommended coolant to the proper level.

CAUTION:

Adding water instead of coolant lowers

●

the antifreeze content of the coolant. If
water is used instead of coolant, check
and if necessary, correct the antifreeze
concentration of the coolant.
Use only distilled water. However, soft

●

water may be used if distilled water is not
available.

CHK

ADJ

3.Start the engine, warm it up for several min­utes, and then turn it off.

4.Check:

● Coolant level

NOTE:

Before inspecting the coolant level, wait a few
minutes until the coolant has settled.

CHANGING THE COOLANT

1.Remove:

● Front panel

Refer to “SEAT, FENDERS AND FUEL
TANK”.

3 - 27

2.Remove:

● Coolant reservoir cap 1

3.Disconnect:

● Coolant reservoir hose 2

CHANGING THE COOLANT

4.Drain:

● Coolant

(from the coolant reservoir)

5.Connect:

● Coolant reservoir hose

6.Remove:

● Radiator cap 1

WARNING

A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the
engine is hot. Scalding hot fluid and steam
may be blown out, which could cause seri­ous injury. When the engine has cooled,
open the radiator cap as follows:
Place a thick rag or a towel over the radia­tor cap and slowly turn the radiator cap
counterclockwise toward the detent to
allow any residual pressure to escape.
When the hissing sound has stopped, turn
the radiator cap counterclockwise while
pressing down on it and then remove it.

CHK

ADJ

3 - 28

7.Remove:

● Coolant drain bolt 1

(along with the copper washer)

8.Drain:

● Coolant

9.Check:

● Copper washer 1

● Coolant drain bolt 2

New

Damage → Replace.

10.Install:

● Coolant drain bolt

T

10 Nm (1.0 m • kg, 7.2 ft • lb)

.

R

.

CHANGING THE COOLANT

11.Fill:

● Cooling system

(with the specified amount of the recom­mended coolant)

Recommended antifreeze:

High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines

Mixing ratio:

1:1 (antifreeze:water)

Quantity:

Total amount:

1.3 L
(1.14 lmp qt, 1.37 US qt)

Coolant reservoir capacity:

0.29 L
(0.26 lmp qt, 0.31 US qt)

Handling notes for coolant

Coolant is potentially harmful and should be
handled with special care.

CHK

ADJ

WARNING

If coolant splashes in your eyes, thor-

●

oughly wash them with water and consult
a doctor.
If coolant splashes on your clothes,

●

quickly wash it away with water and then
with soap and water.
If coolant is swallowed, induce vomiting

●

and get immediate medical attention.

CAUTION:

Adding water instead of coolant lowers

●

the antifreeze content of the coolant. If
water is used instead of coolant, check,
and if necessary, correct the antifreeze
concentration of the coolant.
Use only distilled water. However, soft

●

water may be used if distilled water is not
available.
If coolant comes into contact with painted

●

surfaces, immediately wash them with
water.
Do not mix different types of antifreeze.

●

3 - 29

12.Install:

● Radiator cap

CHANGING THE COOLANT

13.Fill:

● Coolant reservoir

(with the recommended coolant to the proper
level)

14.Install:

● Coolant reservoir cap

15.Start the engine, warm it up for several min­utes, and then turn it off.

16.Check:

● Coolant level

Refer to “CHECKING THE COOLANT
LEVEL”.

NOTE:

Before inspecting the coolant level, wait a few
minutes until the coolant has settled.

17.Install:

● Front panel

Refer to “SEAT, FENDERS AND FUEL
TANK”.

CHK

ADJ

3 - 30

CHECKING THE COOLANT TEMPERATURE WARNING

LIGHT/CLEANING THE SPARK ARRESTER

CHECKING THE COOLANT TEMPERATURE
WARNING LIGHT

1 Coolant temperature warning light

CHK

ADJ

3 - 31

CLEANING THE SPARK ARRESTER

1.Clean:

●

Spark arrester

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

Cleaning steps:

WARNING

Select a well-ventilated area free of com-

●

bustible materials.
Always let the exhaust system cool

●

before performing this operation.
Do not start the engine when removing

●

the tailpipe from the muffler.

●

Remove the bolt 1.

●

Remove the tailpipe 2 by pulling it out of the
muffler.

CLEANING THE SPARK ARRESTER

●

Tap the tailpipe lightly with a soft-face ham­mer or suitable tool, then use a wire brush to
remove any carbon deposits from the spark
arrester portion of the tailpipe and the inner
contact surfaces of the muffler.

●Insert the tailpipe into the muffler and align

the bolt holes.

●Insert the bolt and tighten it.

●Remove the purging bolt 3.

●Start the engine and rev it up approximately

twenty times while momentarily creating
exhaust system back pressure by blocking
the end of the muffler with a shop towel.

●Stop the engine and allow the exhaust pipe

to cool.

●Install the purging bolt 3 and tighten it.

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

CHK

ADJ

3 - 32

ADJUSTING THE FRONT BRAKE/

ADJUSTING THE REAR BRAKE

CHASSIS

ADJUSTING THE FRONT BRAKE

1.Check:

● Brake lever free play a

Out of specification → Bleed the front brake
system.
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)”.

Brake lever free play (at the brake
lever end):

0 mm (0 in)

CHK

ADJ

ADJUSTING THE REAR BRAKE

1.Check:

● Rear brake pedal height a

Out of specification → Adjust.

Rear brake pedal height:

4 mm (0.16 in)

2.Adjust:

● Rear brake pedal height

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

Adjustment steps:

●Loosen the locknut 1.

●Turn the adjusting bolt 2 until the brake

pedal height is within the specified limits.

Brake pedal height:

4 mm (0.16 in)

●Tighten the locknut 1.

NOTE:

When adjusting the brake pedal height make
sure the locknut-to-adjusting bolt clearance a
does not exceed 2.2 ~ 3.2 mm (0.09 ~ 0.13 in).

3 - 33

ADJUSTING THE REAR BRAKE/

ADJUSTING THE PARKING BRAKE

WARNING

After this adjustment is performed, lift the
rear wheels off the ground by placing a
block under the engine, and spin the rear
wheels to ensure there is no brake drag. If
any brake drag is noticed perform the
above steps again.

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

ADJUSTING THE PARKING BRAKE

1.Check:

●

Parking brake cable end length a
Out of specification → Adjust.

Parking brake cable end length:

64 ~ 68 mm (2.5 ~ 2.7 in)

CHK

ADJ

2.Adjust:

●

Parking brake cable end length

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

Adjustment steps:

●

Loosen the locknut 1 and adjusting bolt 2.

●

Pull the rubber cover 3 off.

●

Loosen the locknut 4.

●

Turn the adjuster 5 in or out until the speci­fied brake cable end length is obtained.

●

Tighten the locknut 4.

●

Slowly turn the adjusting bolt 2 clockwise
until resistance is felt.

●

Turn it 1/8 counterclockwise.

●

Tighten the locknut 1.

Locknut:

T

●

Check the parking brake cable free play a.

16 Nm (1.6 m • kg, 11 ft • lb)

.

R

.

Free play (parking brake cable):

0 mm (0 in)
at parking brake lever pivot

3 - 34

●

If the free play is incorrect, adjust the free
play by adjuster 5.

●

Pull the rubber cover 3 in.

ADJUSTING THE PARKING BRAKE/

CHECKING THE BRAKE FLUID LEVEL

WARNING

After this adjustment is performed, lift the
rear wheels off the ground by placing a
block under the engine, and spin the rear
wheels to ensure there is no brake drag. If
any brake drag is noticed perform the
above steps again.

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

CHECKING THE BRAKE FLUID LEVEL

1.Place the machine on a level surface.

NOTE:

When inspecting the brake fluid level, make
sure that the top of the brake fluid reservoir top
is horizontal.

CHK

ADJ

È

É



2.Check:

●

Brake fluid level
Fluid level is below the “LOWER” level line

1

→ Add the recommended brake fluid to

the proper level.

Recommended brake fluid:

DOT 4

Front brake

È

Rear brake

É

CAUTION:

Brake fluid may erode painted surfaces or
plastic parts. Always clean up spilled fluid
immediately.

WARNING

Use only the designated quality brake

●

fluid: Otherwise, the rubber seals may
deteriorate, causing leakage and poor
brake performance.
Refill with the same type of brake fluid:

●

Mixing fluids may result in a harmful
chemical reaction and lead to poor perfor­mance.
Be careful that water does not enter the

●

master cylinder when refilling. Water will
significantly lower the boiling point of the
fluid and may result in a vapor lock.

3 - 35

CHECKING THE FRONT BRAKE PAD/

CHECKING THE REAR BRAKE PAD/

ADJUSTING THE REAR BRAKE LIGHT SWITCH

CHECKING THE FRONT BRAKE PAD

1.Remove:

● Front wheels

2.Check:

● Brake pad

Wear indicators 1 almost in contact with the
brake disc → Replace the brake pads as a
set.
Refer to “FRONT AND REAR BRAKES” in
CHAPTER 4.

Brake pad wear limit a:

1 mm (0.04 in)

3.Operate the brake lever.

4.Install:

● Front wheels

CHK

ADJ

CHECKING THE REAR BRAKE PAD

1.Check:

● Brake pad

Wear indicators 1 almost in contact with the
brake disc → Replace the brake pads as a
set.
Refer to “FRONT AND REAR BRAKES” in
CHAPTER 4.

Brake pad wear limit a:

1 mm (0.04 in)

2.Operate the brake pedal.

ADJUSTING THE REAR BRAKE LIGHT
SWITCH

3 - 36

NOTE:

The rear brake light switch is operated by
movement of the brake pedal.
The rear brake light switch is properly adjusted
when the brake light comes on just before the
braking effect starts.

ADJUSTING THE REAR BRAKE LIGHT SWITCH/

CHECKING THE BRAKE HOSE

1.Check:

● Rear brake light operation timing

Incorrect → Adjust.

2.Adjust:

● Rear brake light operation timing

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

●

Hold the main body 1 of the rear brake light
switch so that it does not rotate and turn the
adjusting nut 2 in direction a or b until the
rear brake light comes on at the proper time.

CHK

ADJ

Direction a

Direction b

Brake light comes on
sooner.

Brake light comes on
later.

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

CHECKING THE BRAKE HOSE

1.Remove:

● Seat

● Front fender

Refer to “SEAT, FENDERS AND FUEL
TANK”.

2.Check:

● Front brake hoses 1

● Rear brake hoses 2

Cracks/wear/damage → Replace.

3.Check:

● Brake hose clamp

Loosen → Tighten.

4.Hold the machine in an upright position and
apply the front or rear brake.

5.Check:

● Brake hoses

Apply the brake lever several times.
Fluid leakage → Replace the hose.
Refer to “FRONT AND REAR BRAKE” in
CHAPTER 4.

3 - 37

CHECKING THE BRAKE HOSE/

BLEEDING THE HYDRAULIC BRAKE SYSTEM

6.Install:

● Front fender

● Seat

Refer to “SEAT, FENDERS AND FUEL
TANK”.

BLEEDING THE HYDRAULIC BRAKE
SYSTEM

WARNING

Bleed the brake system if:

The system has been disassembled.

●

A brake hose or brake pipe have been

●

loosened or removed.
The brake fluid has been very low.

●

The brake operation has been faulty.

●

A loss of braking performance may occur if
the brake system is not properly bled.

CHK

ADJ

È



É

1.Bleed:

● Brake system

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

Air bleeding steps:

a. Add the proper brake fluid to the reservoir.
b. Install the diaphragm. Be careful not to spill

any fluid or allow the reservoir to overflow.

c. Connect the clear plastic hose 1 tightly to

the caliper bleed screw 2.

Front

È

Rear

É

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

tainer.

e. Slowly apply the brake lever or pedal sev-

eral times.

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

and hold it.

g. Loosen the bleed screw and allow the lever

or pedal to travel towards its limit.

h. Tighten the bleed screw when the lever or

pedal limit has been reached, then release
the lever or pedal.

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

bles have disappeared from the fluid.

3 - 38

BLEEDING THE HYDRAULIC BRAKE SYSTEM/

ADJUSTING THE SHIFT PEDAL

j. Tighten the bleed screw.

Bleed screw:

T

NOTE:

If bleeding is difficult, it may be necessary to
let the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the system have disappeared.

k. Add brake fluid to the proper level.

Refer to “CHECKING THE BRAKE FLUID
LEVEL”.

WARNING

Check the operation of the brake after
bleeding the brake system.

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

6 Nm (0.6 m • kg, 4.3 ft • lb)

.

R

.

CHK

ADJ

ADJUSTING THE SHIFT PEDAL

1.Check:

● Shift pedal height a

Out of specification → Adjust.

Shift pedal height:

22 mm (0.89 in)

2.Adjust:

● Shift pedal height

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

Adjustment steps:

●Loosen the locknuts 1.

●Turn the adjusting rod 2 in direction a or b

until the specified shift pedal position
obtained.

Direction a

Shift pedal position is
down.

3 - 39

Direction b

●Tighten the locknuts.

Shift pedal position is
up.

Locknut:

T

8 Nm (0.8 m • kg, 5.8 ft • lb)

.

R

.

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

ADJUSTING THE REVERSE CONTROL CABLE/

ADJUSTING THE DRIVE CHAIN SLACK

ADJUSTING THE REVERSE CONTROL
CABLE

1.Check:

●

Reverse knob free play a
Out of specification → Adjust.

Reverse knob free play:

0 mm (0 in)

2.Adjust:

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

Adjustment steps:

●Pull the boots 1 and 2 off.

●Loosen the locknut 3.

●Turn the adjusting nut 4 until the reverse

control cable 5 is taut or the length a is
135 mm (5.31 in).

CHK

ADJ

NOTE:

Be sure to hold the reverse shift lever 6 when
make this adjustment so that it does not move.

●Tighten the locknut 3.

●Pull the boots 1 and 2 in.

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

ADJUSTING THE DRIVE CHAIN SLACK
NOTE:

The drive chain slack must be checked at the
tightest point on the chain.

CAUTION:

A drive chain that is too tight will overload
the engine and other vital parts, and one
that is too loose can skip and damage the
swingarm or cause an accident. Therefore,
keep the drive chain slack within the speci­fied limits.

3 - 40

1.Elevate the rear wheels by placing the suit­able stand under the frame.

2.Rotate the rear wheel several times and
check the drive chain to locate its tightest
point.