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.
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 useIllustration
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 useIllustration
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 useIllustration
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 useIllustration
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 useIllustration
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
Overall length1,830 mm (72.0 in)
Overall width1,100 mm (43.3 in)
Overall height1,150 mm (45.3 in)
Seat height860 mm (33.9 in)
Wheelbase1,245 mm (49.0 in)
Minimum ground clearance265 mm (10.4 in)
Minimum turning radius3,300 mm (129.9 in)
Basic weight:
With oil and full fuel tank193 kg (426 lb)
Engine:
Engine typeLiquid-cooled 4-stroke, SOHC
Cylinder arrangementForward-inclined single cylinder
Displacement660 cm
Bore × stroke100.0 × 84.0 mm (3.94 × 3.31 in)
Compression ratio9.2 : 1
Standard compression pressure (at sea level) 1,250 kPa (12.5 kg/cm
Starting systemElectric 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
ItemStandard
Oil capacity:
Engine oil
Periodic oil change1.9 L (1.67 lmp qt, 2.01 US qt)
With oil filter replacement1.95 L (1.72 lmp qt, 2.06 US qt)
Total amount2.3 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:
TypeRegular unleaded fuel
Fuel tank capacity12 L (2.64 lmp gal, 3.17 US gal)
Fuel reserve amount2.6 L (0.57 lmp gal, 0.69 US gal)
Carburetor: