Yamaha YFM700RV Raptor Service Manual

YFM700RV

SERVICE MANUAL

LIT-11616-19-13 1S3-28197-10

EBS00001

YFM700RV

SERVICE MANUAL

©2005 by Yamaha Motor Corporation, U.S.A.

First Edition, May 2005

All rights reserved.

Any reproduction or unauthorized use

without the written permission of

Yamaha Motor Corporation, U.S.A.

is expressly prohibited.

Printed in U.S.A.

LIT-11616-19-13

EBS00002

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 vehicle has a basic understanding of the mechanical ideas and the procedures of vehicle
repair. Repairs attempted by anyone without this knowledge are likely to render the vehicle 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.

EBS00003

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
the vehicle operator, a bystander or a person checking or repairing the vehicle.

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

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

to

EBS00004

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “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 accompa­nied 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

SPEC

INFO

34

CHK

ENG

ADJ

56

COOL

78

FI

EBS00006

SYMBOLS

The following symbols are not relevant to
every vehicle.
Symbols 1 to 9 indicate the subject of each
chapter.

General information

1

Specifications

2

Periodic checks and adjustments

3

Engine

4

Cooling system

5

Fuel injection system

6

Chassis

7

Electrical

8

Troubleshooting

9

CHAS

90

ELEC

–+

TRBL
SHTG

AB

CD

T

.

R

.

EFG

HIJ

LS

G

M

M

E

KLM

B

Symbols 0 to G indicate the following.

Serviceable with engine mounted

0

Filling fluid

A

Lubricant

B

Special tool

C

Tightening torque

D

Wear limit, clearance

E

Engine speed

F

Electrical data (Ω, V, A)

G

Symbols H to M in the exploded diagrams
indicate the types of lubricants and lubrication
points.

Apply engine oil

H

Apply gear oil

I

Apply molybdenum disulfide oil

J

Apply wheel bearing grease

K

Apply lithium-soap-based grease

L

Apply molybdenum disulfide grease

M

NO

LT

New

Symbols N to O in the exploded diagrams
indicate where to apply a locking agent N and
when to install a new part O.

Apply the locking agent (LOCTITE

N

Replace

O

®

)

EBS00008

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND
ADJUSTMENTS

ENGINE

COOLING SYSTEM

GEN

INFO

SPEC

CHK

ADJ

ENG

COOL

1

2

3

4

5

FUEL INJECTION SYSTEM

CHASSIS

ELECTRICAL

TROUBLESHOOTING

FI

CHAS

– +

ELEC

TRBL
SHTG

6

7

8

9

CONTENTS

CHAPTER 1

GENERAL INFORMATION

VEHICLE IDENTIFICATION

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

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

FEATURES

OUTLINE OF THE FI SYSTEM.................................................................1-2

FI SYSTEM................................................................................................ 1-3

SELF-ADJUSTING PARKING BRAKE MECHANISM...............................1-4

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-7

REPLACEMENT PARTS...........................................................................1-7

GASKETS, OIL SEALS AND O-RINGS .................................................... 1-7

LOCK WASHERS/PLATES AND COTTER PINS .....................................1-8

BEARINGS AND OIL SEALS ....................................................................1-8

CIRCLIPS ..................................................................................................1-8

CHECKING THE CONNECTIONS............................................................1-9

SPECIAL TOOLS

......................................................................................................1-2

..........................................................................................1-10

............................................................................1-1

.........................................................................1-7

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS

ENGINE SPECIFICATIONS

CHASSIS SPECIFICATIONS

ELECTRICAL SPECIFICATIONS

TIGHTENING TORQUES

ENGINE TIGHTENING TORQUES ........................................................2-16

CHASSIS TIGHTENING TORQUES ......................................................2-19

HOW TO USE THE CONVERSION TABLE

GENERAL TIGHTENING TORQUE SPECIFICATIONS

........................................................................2-1

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

........................................................................2-12

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

..............................................................................2-16

..................................................2-22

...............................2-22

LUBRICATION POINTS AND LUBRICANT TYPES ....................................2-23

ENGINE...................................................................................................2-23

COOLANT FLOW DIAGRAMS .....................................................................2-24

OIL FLOW DIAGRAMS.................................................................................2-28

CABLE ROUTING .........................................................................................2-33

CHAPTER 3

PERIODIC CHECKS AND ADJUSTMENTS

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

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL

SYSTEM .........................................................................................................3-1

GENERAL MAINTENANCE AND LUBRICATION CHART ............................ 3-2

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

REMOVING THE FUEL TANK ..................................................................3-9

REMOVING THE FUEL PUMP .................................................................3-9

INSTALLING THE FUEL PUMP..............................................................3-10

INSTALLING THE FUEL HOSE ..............................................................3-10

ENGINE .........................................................................................................3-11

ADJUSTING THE VALVE CLEARANCE ................................................3-11

ADJUSTING THE ENGINE IDLING SPEED ...........................................3-13

ADJUSTING THE THROTTLE LEVER FREE PLAY ..............................3-14

ADJUSTING THE SPEED LIMITER........................................................ 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.................................................... 3-20

CHANGING THE ENGINE OIL ...............................................................3-22

ADJUSTING THE CLUTCH CABLE........................................................3-25

CLEANING THE AIR FILTER ELEMENT................................................3-25

CHECKING THE THROTTLE BODY JOINT...........................................3-27

CHECKING THE FUEL HOSE ................................................................3-28

CHECKING THE BREATHER HOSES ................................................... 3-28

CHECKING THE COOLANT LEVEL.......................................................3-29

CHANGING THE COOLANT...................................................................3-29

CHECKING THE COOLING SYSTEM ....................................................3-32

CHECKING THE COOLANT TEMPERATURE WARNING LIGHT.........3-33

CHECKING THE EXHAUST SYSTEM.................................................... 3-34

CLEANING THE SPARK ARRESTER ....................................................3-34

CHASSIS .......................................................................................................3-36

ADJUSTING THE FRONT BRAKE .........................................................3-36

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

ADJUSTING THE PARKING BRAKE......................................................3-37

CHECKING THE BRAKE FLUID LEVEL.................................................3-38

CHECKING THE FRONT BRAKE PADS ................................................3-39

CHECKING THE REAR BRAKE PADS ..................................................3-39

ADJUSTING THE REAR BRAKE LIGHT SWITCH .................................3-40

CHECKING THE BRAKE HOSES...........................................................3-40

BLEEDING THE HYDRAULIC BRAKE SYSTEM ...................................3-41

ADJUSTING THE SHIFT PEDAL............................................................3-43

ADJUSTING THE REVERSE CONTROL CABLE ..................................3-43

ADJUSTING THE DRIVE CHAIN SLACK ...............................................3-44

CHECKING THE STEERING SYSTEM .................................................. 3-46

ADJUSTING THE TOE-IN.......................................................................3-46

CHECKING THE FRONT AND REAR SHOCK ABSORBERS ............... 3-48

ADJUSTING THE FRONT SHOCK ABSORBERS .................................3-48

ADJUSTING THE REAR SHOCK ABSORBER ...................................... 3-49

CHECKING THE TIRES..........................................................................3-52

CHECKING THE WHEELS .....................................................................3-54

CHECKING AND LUBRICATING THE CABLES ....................................3-54

LUBRICATING THE LEVERS AND PEDALS ......................................... 3-55

ELECTRICAL SYSTEM.................................................................................3-56

CHECKING AND CHARGING THE BATTERY.......................................3-56

CHECKING THE FUSES ........................................................................3-62

ADJUSTING THE HEADLIGHT BEAMS.................................................3-64

REPLACING A HEADLIGHT BULB ........................................................3-64

CHAPTER 4

ENGINE

ENGINE REMOVAL ........................................................................................4-1

MUFFLER AND EXHAUST PIPES ...........................................................4-1

INSTALLING THE EXHAUST PIPES AND MUFFLER ............................. 4-2

OIL TANK ..................................................................................................4-3

LEADS, CABLES AND HOSES ................................................................4-4

ENGINE MOUNTING BOLTS ...................................................................4-6

INSTALLING THE ENGINE.......................................................................4-8

CYLINDER HEAD............................................................................................4-9

REMOVING THE CYLINDER HEAD.......................................................4-11

CHECKING THE CYLINDER HEAD ....................................................... 4-12

CHECKING THE TAPPET COVERS AND CAMSHAFT SPROCKET

COVER...................................................................................................4-13

CHECKING THE TIMING CHAIN TENSIONER......................................4-13

CHECKING THE CAMSHAFT SPROCKET............................................4-13

INSTALLING THE CYLINDER HEAD .....................................................4-13

ROCKER ARMS AND CAMSHAFT ..............................................................4-17

REMOVING THE ROCKER ARMS AND CAMSHAFT............................4-19

CHECKING THE CAMSHAFT.................................................................4-19

CHECKING THE DECOMPRESSION SYSTEM..................................... 4-20

CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........4-21

INSTALLING THE CAMSHAFT AND ROCKER ARMS .......................... 4-22

VALVES AND VALVE SPRINGS..................................................................4-24

REMOVING THE VALVES AND VALVE SPRINGS ...............................4-25

CHECKING THE VALVES AND VALVE SPRINGS ................................4-26

INSTALLING THE VALVES AND VALVE SPRINGS ..............................4-31

CYLINDER AND PISTON..............................................................................4-33

REMOVING THE PISTON ......................................................................4-34

CHECKING THE CYLINDER AND PISTON ........................................... 4-34

CHECKING THE PISTON RINGS...........................................................4-36

CHECKING THE PISTON PIN ................................................................4-37

INSTALLING THE PISTON AND CYLINDER .........................................4-38

A.C. MAGNETO.............................................................................................4-41

REMOVING THE A.C. MAGNETO ROTOR............................................4-43

CHECKING THE STATOR COIL

AND CRANKSHAFT POSITION SENSOR ............................................4-43

CHECKING THE STARTER CLUTCH ....................................................4-44

CHECKING THE TORQUE LIMITER......................................................4-45

INSTALLING THE A.C. MAGNETO ROTOR .......................................... 4-45

CLUTCH ........................................................................................................4-47

REMOVING THE CLUTCH .....................................................................4-51

REMOVING THE PRIMARY DRIVE GEAR

AND BALANCER DRIVEN GEAR..........................................................4-52

CHECKING THE FRICTION PLATES.....................................................4-52

CHECKING THE CLUTCH PLATES .......................................................4-53

CHECKING THE CLUTCH SPRINGS.....................................................4-53

CHECKING THE CLUTCH HOUSING ....................................................4-54

CHECKING THE CLUTCH BOSS...........................................................4-54

CHECKING THE PRESSURE PLATE .................................................... 4-54

CHECKING THE PULL LEVER SHAFT AND PULL ROD ...................... 4-54

CHECKING THE PRIMARY DRIVE GEARS ..........................................4-55

CHECKING THE BALANCER DRIVE GEARS .......................................4-55

INSTALLING THE PRIMARY DRIVE GEAR

AND BALANCER DRIVEN GEARS .......................................................4-55

INSTALLING THE CLUTCH....................................................................4-56

OIL PUMP......................................................................................................4-59

CHECKING THE OIL PUMP ...................................................................4-61

ASSEMBLING THE OIL PUMP...............................................................4-62

SHIFT SHAFT................................................................................................4-63

CHECKING THE SHIFT SHAFT ............................................................. 4-65

CHECKING THE STOPPER LEVER ......................................................4-65

CHECKING THE SHIFT GUIDE..............................................................4-65

CHECKING THE SHIFT DRUM SEGMENT ...........................................4-65

INSTALLING THE SHIFT LEVER ........................................................... 4-65

INSTALLING THE SHIFT SHAFT ...........................................................4-66

CRANKCASE ................................................................................................4-67

CRANKCASE BEARINGS....................................................................... 4-69

SEPARATING THE CRANKCASE..........................................................4-70

CHECKING THE OIL STRAINER ...........................................................4-70

CHECKING THE TIMING CHAIN AND GUIDE.......................................4-71

CHECKING THE BEARINGS AND OIL SEALS......................................4-71

CHECKING THE CRANKCASE ..............................................................4-71

ASSEMBLING THE CRANKCASE..........................................................4-72

CRANKSHAFT ..............................................................................................4-74

CRANKSHAFT AND BALANCER ...........................................................4-74

REMOVING THE CRANKSHAFT ...........................................................4-75

CHECKING THE CRANKSHAFT ............................................................4-75

INSTALLING THE CRANKSHAFT ..........................................................4-76

TRANSMISSION............................................................................................4-77

MAIN AXLE .............................................................................................4-79

DRIVE AXLE ...........................................................................................4-80

COUNTER AXLE.....................................................................................4-82

CHECKING THE SHIFT FORKS.............................................................4-83

CHECKING THE SHIFT DRUM ASSEMBLY..........................................4-83

CHECKING THE TRANSMISSION .........................................................4-83

ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ..............................4-84

INSTALLING THE TRANSMISSION .......................................................4-85

CHAPTER 5

COOLING SYSTEM

RADIATOR ......................................................................................................5-1

CHECKING THE RADIATOR....................................................................5-3

INSTALLING THE RADIATOR..................................................................5-4

THERMOSTAT ................................................................................................5-5

CHECKING THE THERMOSTAT..............................................................5-6

INSTALLING THE THERMOSTAT............................................................5-6

WATER PUMP.................................................................................................5-7

DISASSEMBLING THE WATER PUMP.................................................... 5-9

CHECKING THE WATER PUMP ..............................................................5-9

ASSEMBLING THE WATER PUMP........................................................5-10

CHAPTER 6

FUEL INJECTION SYSTEM

FUEL INJECTION SYSTEM

CIRCUIT DIAGRAM ..................................................................................6-2

ECU’S SELF-DIAGNOSTIC FUNCTION................................................... 6-4

SELF-DIAGNOSTIC FUNCTION TABLE ..................................................6-5

TROUBLESHOOTING CHART .................................................................6-6

DIAGNOSTIC MODE ................................................................................6-7

TROUBLESHOOTING DETAILS ............................................................6-11

CHECKING THE SPEED SENSOR ........................................................6-25

CHECKING THE INTAKE AIR PRESSURE SENSOR ...........................6-26

CHECKING THE INTAKE AIR TEMPERATURE SENSOR ....................6-27

THROTTLE BODY

CHECKING THE INJECTOR ..................................................................6-31

CHECKING THE THROTTLE BODY ...................................................... 6-31

INSTALLING THE THROTTLE BODY ASSEMBLY................................6-31

CHECKING THE FUEL PUMP

AND PRESSURE REGULATOR OPERATION...................................... 6-32

CHECKING AND ADJUSTING THE THROTTLE POSITION

SENSOR ................................................................................................6-33

.........................................................................................6-28

............................................................................6-1

CHAPTER 7

CHASSIS

FRONT AND REAR WHEELS

FRONT WHEELS ......................................................................................7-1

REAR WHEELS ........................................................................................7-3

CHECKING THE WHEELS .......................................................................7-4

CHECKING THE WHEEL HUBS...............................................................7-4

CHECKING THE BRAKE DISCS ..............................................................7-5

INSTALLING THE FRONT WHEEL HUB BEARINGS ..............................7-6

INSTALLING THE FRONT BRAKE DISCS...............................................7-6

INSTALLING THE FRONT WHEELS........................................................7-6

INSTALLING THE FRONT WHEEL HUBS ...............................................7-7

INSTALLING THE REAR WHEEL HUBS..................................................7-7

REAR AXLE AND REAR AXLE HUB

REMOVING THE REAR BRAKE CALIPER ............................................ 7-10

REMOVING THE REAR AXLE................................................................7-10

CHECKING THE REAR AXLE ................................................................7-11

CHECKING THE DRIVEN SPROCKET ..................................................7-11

CHECKING THE BRAKE DISC...............................................................7-12

INSTALLING THE DRIVEN SPROCKET ................................................7-12

INSTALLING THE REAR AXLE ..............................................................7-12

........................................................................7-1

.............................................................7-8

FRONT AND REAR BRAKES.......................................................................7-14

FRONT BRAKE PADS ............................................................................7-14

REAR BRAKE PADS...............................................................................7-15

REPLACING THE FRONT BRAKE PADS .............................................. 7-16

REPLACING THE REAR BRAKE PADS................................................. 7-18

FRONT BRAKE MASTER CYLINDER....................................................7-20

REAR BRAKE MASTER CYLINDER ...................................................... 7-22

REMOVING THE FRONT BRAKE LIGHT SWITCH ...............................7-25

CHECKING THE MASTER CYLINDERS................................................7-25

ASSEMBLING THE FRONT BRAKE MASTER CYLINDER ................... 7-26

ASSEMBLING THE REAR BRAKE MASTER CYLINDER...................... 7-26

INSTALLING THE FRONT BRAKE MASTER CYLINDER...................... 7-27

INSTALLING THE REAR BRAKE MASTER CYLINDER ........................7-29

FRONT BRAKE CALIPERS ....................................................................7-31

REAR BRAKE CALIPER .........................................................................7-33

REMOVING THE REAR BRAKE CALIPER ............................................ 7-36

DISASSEMBLING THE FRONT BRAKE CALIPERS.............................. 7-36

DISASSEMBLING THE REAR BRAKE CALIPER ..................................7-37

CHECKING THE FRONT AND REAR BRAKE CALIPERS ....................7-37

ASSEMBLING THE FRONT BRAKE CALIPERS.................................... 7-38

ASSEMBLING THE REAR BRAKE CALIPER ........................................7-39

INSTALLING THE FRONT BRAKE CALIPERS ......................................7-40

INSTALLING THE REAR BRAKE CALIPER...........................................7-41

STEERING SYSTEM.....................................................................................7-44

HANDLEBAR........................................................................................... 7-44

REMOVING THE FRONT BRAKE LIGHT SWITCH

AND CLUTCH SWITCH .........................................................................7-46

REMOVING THE HANDLEBAR GRIPS.................................................. 7-46

CHECKING THE HANDLEBAR ..............................................................7-46

INSTALLING THE HANDLEBAR ............................................................7-47

INSTALLING THE HANDLEBAR GRIPS ................................................7-47

INSTALLING THE CLUTCH LEVER .......................................................7-48

INSTALLING THE BRAKE MASTER CYLINDER ................................... 7-48

STEERING STEM ...................................................................................7-49

REMOVING THE BEARING RETAINER ................................................7-51

CHECKING THE STEERING STEM .......................................................7-51

INSTALLING THE BEARING RETAINER ...............................................7-51

INSTALLING THE LOCK WASHER........................................................7-51

INSTALLING THE PITMAN ARM............................................................7-52

TIE-RODS AND STEERING KNUCKLES ...............................................7-53

REMOVING THE STEERING KNUCKLES .............................................7-54

CHECKING THE TIE-RODS ...................................................................7-54

CHECKING THE STEERING KNUCKLES..............................................7-54

INSTALLING THE TIE-RODS .................................................................7-54

FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES ............. 7-55

REMOVING THE FRONT ARMS ............................................................7-57

CHECKING THE FRONT ARMS.............................................................7-57

CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES .............7-57

CHECKING THE BALL JOINTS..............................................................7-58

INSTALLING THE FRONT ARMS...........................................................7-59

REAR SHOCK ABSORBER AND RELAY ARM ..........................................7-60

HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER....7-62

DISPOSING OF A REAR SHOCK ABSORBER

AND GAS CYLINDER ............................................................................7-62

REMOVING THE REAR SHOCK ABSORBER .......................................7-63

CHECKING THE REAR SHOCK ABSORBER........................................7-63

CHECKING THE RELAY ARM AND CONNECTING ARM.....................7-63

INSTALLING THE RELAY ARM AND CONNECTING ARM...................7-64

INSTALLING THE REAR SHOCK ABSORBER......................................7-64

SWINGARM AND DRIVE CHAIN..................................................................7-65

REMOVING THE SWINGARM................................................................7-67

CHECKING THE SWINGARM ................................................................7-67

CHECKING THE DRIVE CHAIN .............................................................7-68

INSTALLING THE SWINGARM ..............................................................7-70

INSTALLING THE DRIVE SPROCKET...................................................7-70

CHAPTER 8

ELECTRICAL

ELECTRICAL COMPONENTS........................................................................8-1

CHECKING SWITCH CONTINUITY................................................................8-2

CHECKING THE SWITCHES..........................................................................8-3

CHECKING THE BULBS AND BULB SOCKETS ..........................................8-5

TYPES OF BULBS ....................................................................................8-5

CHECKING THE CONDITION OF THE BULBS ....................................... 8-5

CHECKING THE CONDITION OF THE BULB SOCKETS .......................8-7

IGNITION SYSTEM .........................................................................................8-8

CIRCUIT DIAGRAM ..................................................................................8-8

TROUBLESHOOTING ..............................................................................8-9

ELECTRIC STARTING SYSTEM .................................................................. 8-14

CIRCUIT DIAGRAM ................................................................................8-14

STARTING CIRCUIT CUT-OFF SYSTEM OPERATION ........................8-15

TROUBLESHOOTING ............................................................................8-16

STARTER MOTOR........................................................................................8-20

CHECKING THE STARTER MOTOR ..................................................... 8-22

ASSEMBLING THE STARTER MOTOR.................................................8-23

CHARGING SYSTEM....................................................................................8-25

CIRCUIT DIAGRAM ................................................................................8-25

TROUBLESHOOTING ............................................................................8-26

LIGHTING SYSTEM ......................................................................................8-28

CIRCUIT DIAGRAM ................................................................................8-28

TROUBLESHOOTING ............................................................................8-29

CHECKING THE LIGHTING SYSTEM.................................................... 8-30

SIGNALING SYSTEM ...................................................................................8-33

CIRCUIT DIAGRAM ................................................................................8-33

TROUBLESHOOTING ............................................................................8-34

CHECKING THE SIGNALING SYSTEM .................................................8-35

COOLING SYSTEM.......................................................................................8-42

CIRCUIT DIAGRAM ................................................................................8-42

TROUBLESHOOTING ............................................................................8-43

CHAPTER 9

TROUBLESHOOTING

STARTING FAILURE/HARD STARTING .......................................................9-1

FUEL SYSTEM..........................................................................................9-1

ELECTRICAL SYSTEM............................................................................. 9-1

COMPRESSION SYSTEM........................................................................9-1

POOR IDLE SPEED PERFORMANCE ...........................................................9-2

POOR IDLE SPEED PERFORMANCE.....................................................9-2

POOR MEDIUM AND HIGH-SPEED PERFORMANCE.................................. 9-2

POOR MEDIUM AND HIGH-SPEED PERFORMANCE ...........................9-2

FAULTY GEAR SHIFTING..............................................................................9-2

HARD SHIFTING.......................................................................................9-2

SHIFT PEDAL DOES NOT MOVE ............................................................ 9-2

JUMPS OUT GEAR...................................................................................9-2

CLUTCH SLIPPING/DRAGGING....................................................................9-3

CLUTCH SLIPPING ..................................................................................9-3

CLUTCH DRAGGING ...............................................................................9-3

OVERHEATING...............................................................................................9-3

OVERHEATING ........................................................................................9-3

OVERCOOLING ..............................................................................................9-3

COOLING SYSTEM .................................................................................. 9-3

FAULTY BRAKE .............................................................................................9-4

POOR BRAKING EFFECT........................................................................9-4

SHOCK ABSORBER MALFUNCTION ...........................................................9-4

MALFUNCTION......................................................................................... 9-4

UNSTABLE HANDLING..................................................................................9-4

UNSTABLE HANDLING ............................................................................9-4

LIGHTING SYSTEM ........................................................................................9-5

HEADLIGHT DOES NOT COME ON ........................................................9-5

TAIL/BRAKE LIGHT DOES NOT COME ON ............................................ 9-5

HEADLIGHT BULB BURNT OUT.............................................................. 9-5

1

VEHICLE IDENTIFICATION

EBS00009

GENERAL INFORMATION

VEHICLE IDENTIFICATION

EBS00010

VEHICLE IDENTIFICATION NUMBER

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

EBS00011

1

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

GEN

FEATURES

EAS20170

FEATURES

OUTLINE OF THE FI SYSTEM

The main function of a fuel supply system is to provide fuel to the combustion chamber at the opti­mum air-fuel ratio in accordance with the engine operating conditions and the atmospheric tempera­ture. In the conventional carburetor system, the air-fuel ratio of the mixture that is supplied to the
combustion chamber is created by the volume of the intake air and the fuel that is metered by the jet
used in the respective carburetor.
Despite the same volume of intake air, the fuel volume requirement varies with the engine operating
conditions, such as acceleration, deceleration, or operating under a heavy load. Carburetors that
meter the fuel through the use of jets have been provided with various auxiliary devices, so that an
optimum air-fuel ratio can be achieved to accommodate the constant changes in the operating con­ditions of the engine.
As the requirements for the engine to deliver more performance and cleaner exhaust gases
increase, it becomes necessary to control the air-fuel ratio in a more precise and finely tuned man­ner. To accommodate this need, this model has adopted an electronically controlled fuel injection
(FI) system, in place of the conventional carburetor system. This system can achieve an optimum
air-fuel ratio required by the engine at all times by using a microprocessor that regulates the fuel
injection volume according to the engine operating conditions detected by various sensors.
The adoption of the FI system has resulted in a highly precise fuel supply, improved engine
response, better fuel economy, and reduced exhaust emissions.

INFO

1

Engine trouble warning light

1

Ignition coil

2

Fuel tank

3
4

Fuel hose

5

Fuel pump

6

Intake air pressure sensor

7

Lean angle sensor

8

Battery

9

Intake air temperature sensor

12

345 6 78

D

EFGH

C

ECU (electronic control unit)

0
A

Air filter case

B

Relay unit (fuel pump relay)

C

Speed sensor

D

Throttle position sensor

E

Crankshaft position sensor

F

Fuel injector

G

Coolant temperature sensor

H

Spark plug

9

0A B

1 - 2

GEN

FEATURES

FI SYSTEM

The fuel pump delivers fuel to the fuel injector via the fuel filter. The pressure regulator maintains
the fuel pressure that is applied to the fuel injector at only 324 kPa (3.24 kg/cm
ingly, when the energizing signal from the ECU energizes the fuel injector, the fuel passage opens,
causing the fuel to be injected into the intake manifold only during the time the passage remains
open. Therefore, the longer the length of time the fuel injector is energized (injection duration), the
greater the volume of fuel that is supplied. Conversely, the shorter the length of time the fuel injector
is energized (injection duration), the lesser the volume of fuel that is supplied.
The injection duration and the injection timing are controlled by the ECU. Signals that are input from
the throttle position sensor, crankshaft position sensor, intake air pressure sensor, intake air tem­perature sensor, coolant temperature sensor and speed sensor enable the ECU to determine the
injection duration. The injection timing is determined through the signals from the crankshaft posi­tion sensor. As a result, the volume of fuel that is required by the engine can be supplied at all times
in accordance with the driving conditions.

Illustration is for reference only.

INFO

2

, 46.1 psi). Accord-

0

Fuel pump

1

Fuel injector

2

Ignition coil

3

ECU (electronic control unit)

4

Coolant temperature sensor

5

Crankshaft position sensor

6

Intake air pressure sensor

7

Throttle body

8

1

9

É

A

7

È

8

2

Ê

4

B

3

5

6

Intake air temperature sensor

9

Air filter case

0

Throttle position sensor

A

Speed sensor

B

Fuel system

È

Air system

É

Control system

Ê

1 - 3

GEN

FEATURES

SELF-ADJUSTING PARKING BRAKE MECHANISM

Usually, for vehicles equipped with a parking brake that must be adjusted manually, it is necessary
to adjust the adjusting bolt 5 to achieve the proper clearance between the brake caliper piston 7
and the adjusting bolt 5.
This adjustment procedure is unnecessary for vehicles equipped with a self-adjusting parking brake
mechanism. The proper clearance is automatically maintained at all times, ensuring stable braking
performance when parking the vehicle.

INFO

1

2

Parking brake arm

1

Parking brake shaft

2

Adjusting bolt

3

Adjusting bolt sleeve

4

4567

Adjusting bolt

5

Nut

6

Brake caliper piston

7

3

1 - 4

Parking Brake Operation

FEATURES

GEN

INFO

1

2

3

456

1 Parking brake arm
2 Parking brake shaft
3 Adjusting bolt

When the parking brake is operated, the parking brake cable turns the parking brake arm 1. The
rotation of the parking brake arm is changed to axial thrust in the parking brake shaft 2 and the
adjusting bolt 3 is pushed against the adjusting bolt sleeve 4.
When the adjusting bolt sleeve receives the force, the dark shaded area in the above illustration is
pushed and the brake pad 6 is pushed against the brake disc.
When the brake pad wears, the clearance between the brake caliper piston 5 and the brake pad
becomes larger and the force applied to the brake pad becomes weaker.
If this occurs, the self-adjusting parking brake mechanism adjusts automatically to achieve the
proper clearance.

4 Adjusting bolt sleeve
5 Brake caliper piston
6 Brake pad

1 - 5

Parking Brake Operation

FEATURES

GEN

INFO

12

È

É

4

3

Ê

1 Brake caliper piston
2 Nut

When the brake pedal is operated, the brake fluid pressure in the master cylinder increases and the
brake caliper piston 1 and the nut 2 are pushed.
When there is proper clearance between the brake caliper piston and the brake pad, no other parts
move because the movement of the brake caliper piston and the nut is absorbed by the backlash of
the threads of the nut and the adjusting bolt 3.
When the movement of the nut is greater than the backlash between the nut and the adjusting bolt,
the parking brake adjusts automatically.
The amount of the adjustment varies with brake fluid pressure. Operating the parking brake makes
no adjustment.
The adjustment operation is as follows.

1. When the brake pedal is operated, the brake fluid pressure increases and the brake caliper pis­ton and the nut move.

2. When the movement of the brake caliper piston and the nut is greater than the backlash of the
threads of the nut and the adjusting bolt, the force È will be required to pull the adjusting bolt.
The force to pull the adjusting bolt will be turned into the rotation torque É by the shape of the
threads of the nut and the adjusting bolt.

3. At this time, the clutch torque Ê between the adjusting bolt and the adjusting bolt sleeve 4 will
decrease depending on the force required to pull the adjusting bolt.
When the rotation torque exceeds the clutch torque, the adjusting bolt rotates and the clearance
between the brake caliper piston and the brake pad decreases by the movement of the threads of
the nut and the adjusting bolt.

3 Adjusting bolt
4 Adjusting bolt sleeve

1 - 6

IMPORTANT INFORMATION

EBS00013

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND
DISASSEMBLY

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

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

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

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

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

GEN

INFO

EBS00014

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.

EBS00015

GASKETS, OIL SEALS AND O-RINGS

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

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

1 - 7

IMPORTANT INFORMATION

EBS00016

LOCK WASHERS/PLATES AND COTTER
PINS

After removal, replace all lock washers/plates

1

and cotter pins. After the bolt or nut has
been tightened to specification, bend the lock
tabs along a flat of the bolt or nut.

EBS00017

BEARINGS AND OIL SEALS

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

Oil seal

1

GEN

INFO

CAUTION:

_

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

Bearing

1

EBS00018

CIRCLIPS

Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip 1, make sure the
sharp-edged corner 2 is positioned opposite
the thrust 3 that the circlip receives.

Shaft

4

1 - 8

IMPORTANT INFORMATION

EBS00019

CHECKING THE CONNECTIONS

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

1. Disconnect:

• lead

• coupler

• connector

2. Check:

• lead

• coupler

• connector

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

3. Check:

• all connections
Loose connection → Connect properly.

NOTE:

_

If the pin 1 on the terminal is flattened, bend it
up.

GEN

INFO

4. Connect:

• lead

• coupler

• connector

NOTE:

_

Make sure all connections are tight.

5. Check:

• continuity (with the pocket tester)

Pocket tester

90890-03112

Analog pocket tester

YU-03112-C

NOTE:

_

• If there is no continuity, clean the terminals.

• When checking the wire harness, perform

steps (1) to (3).

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

1 - 9

GEN

SPECIAL TOOLS

EBS00021

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/Function Illustration

Slide hammer bolt
Slide hammer bolt (6 mm)

90890-01083

YU-01083-1

This tool is used to remove the rocker arm
shaft.

INFO

90890-01084

YU-01083-3

90890-01135

YU-01135-B

90890-01268

YU-01268

90890-01274

YU-90058
YU-90059

Weight

This tool is used to remove the rocker arm
shaft.

Crankcase separating tool
Crankcase separator

This tool is used to separate the crank­case.

Ring nut wrench
Spanner wrench

This tool is used to loosen or tighten the
rear shock absorber locknuts.

Crankshaft installer pot
Installer pot
Pot installer

90890-01275

YU-90060

This tool is used to install the crankshaft.

Crankshaft installer bolt
Bolt

This tool is used to install the crankshaft.

1 - 10

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

Adapter (M16)
Adapter #13

90890-04130

YM-04059

This tool is used to install the crankshaft.

Spacer (crankshaft installer)
Pot spacer

90890-04081

YM-91044

This tool is used to install the crankshaft.

Piston pin puller set
Piston pin puller

90890-01304

YU-01304

This tool is used to remove the piston pin.

INFO

90890-01311

YM-08035-A

90890-01325
YU-24460-01

90890-01352

YU-33984

90890-01327

YM-01327

Tappet adjusting tool
Valve adjuster (3 mm & 4 mm)

This tool is necessary for adjusting the
valve clearance.

Radiator cap tester
Radiator pressure tester

This tool is used to check the cooling sys­tem.

Radiator cap tester adapter
Radiator pressure tester 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.

90890-01404

YM-01404

Flywheel puller

This tool is used to remove the A.C.mag­neto rotor.

1 - 11

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

Steering nut wrench
Spanner wrench

90890-01443

YU-33975

90890-01474

YM-01474

90890-01480

YM-01480

This tool is needed to loosen and tighten
the front shock absorber and rear shock
absorber locknuts.

Ball joint remover

This tool is used to remove or install the
ball joints.

Ball joint remover attachment set
Ball joint adapter set

These tools are used to remove or install
the ball joints.

INFO

90890-01498

YM-37134

90890-01701

YS-01880-A

90890-03079

YM-34483

90890-03081

YU-33223

Rear axle nut wrench (46 mm)
Axle nut wrench (46 mm)

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

Sheave holder
Primary clutch holder

This tool is used to hold the A.C. magneto
rotor when loosen or tighten the A.C. mag­neto rotor nut.

Thickness gauge
Narrow gauge set

This tool is used to measure the valve
clearance.

Compression gauge
Engine compression tester

This tool is used to measure engine com­pression.

90890-04082

Extension

This tool is used to measure engine com­pression.

1 - 12

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

Pocket tester
Analog pocket tester

90890-03112

YU-03112-C

This instrument is needed for checking the
electrical system.

Timing light
Inductive clamp timing light

90890-03141

YU-03141

This tool is necessary for checking ignition
timing.

Pressure gauge

90890-03153

YU-03153

This tool is used to measure fuel pressure.

INFO

90890-03176

YM-03176

90890-03174

YU-A1927

90890-03182

YU-03182

90890-04019

YM-04019

Fuel pressure adapter

This tool is used to measure fuel pressure.

Digital circuit tester
Model 88 Multimeter with tachometer

This tool is used to check the electrical
system.

FI diagnostic tool

This tool is used to check the diagnosis.

Valve spring compressor

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

90890-01243

YM-01253-1

Valve spring compressor attachment
Valve spring compressor adapter (26 mm)

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

1 - 13

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

Middle driven shaft bearing driver
Bearing driver (40 mm)

90890-04058

YM-04058

This tool is used to install the water pump
seal.

Mechanical seal installer
Water pump seal installer

90890-04132

YM-33221-A

This tool is used to install the water pump
seal.

Valve guide remover (ø6)
Valve guide remover (6.0 mm)

90890-04064

YM-4064-A

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

INFO

90890-04065

YM-4065-A

90890-04066

YM-04066

90890-04086

YM-91042

90890-06754

YM-34487

Valve guide installer (ø6)
Valve guide installer (6.0 mm)

This tool is needed to install the valve
guides.

Valve guide reamer (ø6)
Valve guide reamer (6.0 mm)

This tool is needed to rebore the new
valve guides.

Universal clutch holder

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

Ignition checker
Opama pet-4000 spark checker

This tool is used to check the ignition sys­tem components.

90890-06760

YU-39951-B

Digital tachometer

This tool is needed to observe engine rpm.

1 - 14

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

Yamaha bond No. 1215
(Three bond No. 1215)

90890-85505

This bond is used on crankcase mating
surfaces, etc.

INFO

1 - 15

GENERAL SPECIFICATIONS

EBS01001

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard

SPEC

Model code
Dimensions

Overall length 1,845 mm (72.6 in)
Overall width 1,170 mm (46.1 in)
Overall height 1,130 mm (44.5 in)
Seat height 815 mm (32.1 in)
Wheelbase 1,280 mm (50.4 in)
Minimum ground clearance 240 mm (9.45 in)
Minimum turning radius 3,500 mm (137.8 in)

Basic weight

With oil and full fuel tank 192 kg (423 lb)

Engine

Engine type Liquid-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 686 cm
Bore × stroke 102.0 × 84.0 mm (4.02 × 3.31 in)
Compression ratio 9.20:1
Standard compression pressure (at sea level) 450 kPa (4.5 kg/cm
Starting system Electric starter

Lubrication system
Oil type or grade

Engine oil

0° 10° 30° 50° 70° 90° 110°

130°F

1S31

3

(41.86 cu in)

2

, 64.0 psi)

Dry sump

API service SE, SF, SG type or higher

2

YAMALUBE4 (20W40) or SAE 20W40

YAMALUBE4 (10W30) or SAE 10W30

SAE 5W30

-20° -10° 0° 10° 20° 30° 40°

50°C

2 - 1

GENERAL SPECIFICATIONS

Item Standard

Oil capacity

Engine oil

Periodic oil change 1.75 L (1.54 Imp qt, 1.85 US qt)
With oil filter replacement 1.85 L (1.63 Imp qt, 1.96 US qt)
Total amount 2.30 L (2.02 Imp qt, 2.43 US qt)

Radiator capacity (including all routes)
Air filter
Fuel

Type Regular unleaded gasoline only (For CDN,

Fuel tank capacity 11.0 L (2.42 Imp gal, 2.91 US gal)
Fuel reserve amount 2.6 L (0.57 Imp gal, 0.69 US gal)

Fuel injector

Type/quantity 297500-0390/1
Manufacturer DENSO

Spark plug

Type/manufacturer CR8E/NGK
Spark plug gap 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)

Clutch type
Transmission

Primary reduction system Spur gear
Primary reduction ratio 77/34 (2.265)
Secondary reduction system Chain drive
Secondary reduction ratio 38/14 (2.714)
Transmission type Constant mesh, 5-speed/forward, 1 speed/

Operation Left foot operation
Gear ratio

1st gear 38/13 (2.923)
2nd gear 28/14 (2.000)
3rd gear 25/17 (1.471)
4th gear 25/22 (1.136)
5th gear 22/24 (0.917)
Reverse gear 24/13 × 29/12 (4.462)

Chassis

Frame type Aluminum die-cast and steel tube frame
Caster angle 5°
Camber angle –1.0°
Kingpin angle 14.8°
Kingpin offset 2.8 mm (0.11 in)
Trail 21.0 mm (0.83 in)
Tread front (STD) 940 mm (37.01 in)
Tread rear (STD) 900 mm (35.43 in)
Toe-in (with tires touching the ground) 2 ~ 12 mm (0.08 ~ 0.47 in)

1.61 L (1.42 Imp qt, 1.70 US qt)
Wet type element

Europe)
Unleaded gasoline only (For Oceania)

Wet, multiple disc

reverse

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 KT341 Radial

rear KT345 Radial

Tire pressure (cold tire)

Maximum load* 100 kg (220 lb)
Off-road riding front 27.5 kPa (0.28 kg/cm

rear 27.5 kPa (0.28 kg/cm

*Load is 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 256 mm (10.08 in)

Electrical system

Ignition system Transistorized coil ignition (digital)
Generator system A.C. magneto
Battery type GT9B-4
Battery capacity 12 V 8.0 Ah

Bulb type
Bulb voltage/wattage × quantity

Headlight 12 V 30 W/30 W × 2
Tail/brake light LED
Indicator light

Neutral indicator light LED
Fuel level warning light LED
Reverse indicator light LED
Coolant temperature warning light LED
Engine trouble warning light LED

Krypton bulb

2

2

SPEC

, 4.0 psi)
, 4.0 psi)

2 - 3

ENGINE SPECIFICATIONS

EBS01002

SPEC

ENGINE SPECIFICATIONS

Item Standard Limit

Cylinder head

Maximum warpage ---- 0.03 mm

(0.0012 in)

Cylinder

Bore 102.000 ~ 102.010 mm (4.0157 ~ 4.0161 in) 102.080 mm

(4.0189 in)

Measuring point 50.0 mm (1.97 in) ----

Out of round 0.05 mm

(0.002 in)

Camshaft

Drive system Chain drive (left) ---­Camshaft lobe dimensions

A

B

Intake measurement “A” 43.300 ~ 43.400 mm (1.7047 ~ 1.7087 in) 43.200 mm

(1.7008 in)

“B” 37.026 ~ 37.126 mm (1.4577 ~ 1.4617 in) 36.926 mm

(1.4538 in)

Exhaust measurement “A” 43.129 ~ 43.229 mm (1.6980 ~ 1.7019 in) 43.029 mm

(1.6941 in)

“B” 37.057 ~ 37.157 mm (1.4589 ~ 1.4629 in) 36.957 mm

(1.4550 in)

Maximum camshaft runout ---- 0.03 mm

(0.0012 in)

Timing chain

Model/number of links 98XRH2010/126 ---­Tensioning system Automatic ----

2 - 4

ENGINE SPECIFICATIONS

Item Standard Limit

Rocker arm/rocker arm shaft

Rocker arm inside diameter 12.000 ~ 12.018 mm (0.4724 ~ 0.4731 in) ---­Shaft outside diameter 11.981 ~ 11.991 mm (0.4717 ~ 0.4721 in) ---­Arm-to-shaft clearance 0.009 ~ 0.037 mm (0.0004 ~ 0.0015 in) ----

Valve, valve seat, valve guide

Valve clearance–intake (cold) 0.09 ~ 0.13 mm (0.0035 ~ 0.0051 in) ---­Valve clearance–exhaust (cold) 0.16 ~ 0.20 mm (0.0063 ~ 0.0079 in) ---­Valve dimensions

SPEC

B

A

Head Diameter Face Width Seat Width Margin Thickness

Valve head diameter “A”

Intake 37.9 ~ 38.1 mm (1.4921 ~ 1.5000 in) ---­Exhaust 31.9 ~ 32.1 mm (1.2559 ~ 1.2638 in) ----

Valve face width “B”

Intake 2.26 mm (0.0890 in) ---­Exhaust 2.26 mm (0.0890 in) ----

Valve seat width “C”

Intake 1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in) 1.6 mm

Exhaust 1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in) 1.6 mm

Valve margin thickness “D”

Intake 0.8 ~ 1.2 mm (0.0315 ~ 0.0472 in) ---­Exhaust 0.8 ~ 1.2 mm (0.0315 ~ 0.0472 in) ----

Valve stem diameter

Intake 5.975 ~ 5.990 mm (0.2352 ~ 0.2358 in) 5.945 mm

Exhaust 5.960 ~ 5.975 mm (0.2346 ~ 0.2352 in) 5.930 mm

Valve guide inside diameter

Intake 6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in) 6.050 mm

Exhaust 6.000 ~ 6.012 mm (0.2362 ~ 0.2367 in) 6.050 mm

Valve-stem-to-valve-guide clearance

Intake 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.080 mm

Exhaust 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) 0.100 mm

C

(0.063 in)

(0.063 in)

(0.2341 in)

(0.2335 in)

(0.2382 in)

(0.2382 in)

(0.0031 in)

(0.0039 in)

D

2 - 5

ENGINE SPECIFICATIONS

Item Standard Limit

Valve stem runout ---- 0.01 mm

Valve seat width

Intake 1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in) 1.6 mm

Exhaust 1.0 ~ 1.2 mm (0.0394 ~ 0.0472 in) 1.6 mm

Valve spring

Free length

Intake 38.79 mm (1.53 in) 36.85 mm

Exhaust 38.79 mm (1.53 in) 36.85 mm

Installed length (valve closed)

Intake 35.00 mm (1.38 in) ---­Exhaust 35.00 mm (1.38 in) ----

Compressed spring force (installed)

Intake 169.0 ~ 199.0 N

(17.23 ~ 20.29 kg, 37.99 ~ 44.73 lb)

Exhaust 169.0 ~ 199.0 N

(17.23 ~ 20.29 kg, 37.99 ~ 44.73 lb)

Spring tilt

SPEC

(0.0004 in)

(0.0630 in)

(0.0630 in)

(1.45 in)

(1.45 in)

----

----

Intake ---- 2.5°/1.70 mm

(2.5°/0.067 in)

Exhaust ---- 2.5°/1.70 mm

(2.5°/0.067 in)

Winding direction (top view)

Intake Clockwise ---­Exhaust Clockwise ----

2 - 6

ENGINE SPECIFICATIONS

Item Standard Limit

Piston

Piston-to-cylinder clearance 0.030 ~ 0.055 mm (0.0012 ~ 0.0022 in) 0.13 mm

Diameter “D” 101.955 ~ 101.970 mm

(4.0140 ~ 4.0146 in)

H

D

Height “H” 10 mm (0.39 in) ---­Offset 0.5 mm (0.0197 in) ---­Offset direction Intake side ---­Piston pin bore inside diameter 23.004 ~ 23.015 mm (0.9057 ~ 0.9061 in) 23.045 mm

Piston pin outside diameter 22.991 ~ 23.000 mm (0.9052 ~ 0.9055 in) 22.971 mm

Piston-pin-to-piston-pin-bore clear­ance

Piston rings

Top ring

0.004 ~ 0.024 mm (0.0002 ~ 0.0009 in) 0.074 mm

SPEC

(0.0051 in)

----

(0.9073 in)

(0.9044 in)

(0.0029 in)

B

T

Ring type Barrel ---­Dimensions (B × T) 1.20 × 3.80 mm (0.05 × 0.15 in) ---­End gap (installed) 0.20 ~ 0.35 mm (0.008 ~ 0.014 in) 0.60 mm

(0.024 in)

Ring side clearance 0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in) 0.12 mm

(0.0047 in)

2nd ring

B

T

Ring type Taper ---­Dimensions (B × T) 1.20 × 4.00 mm (0.05 × 0.16 in) ---­End gap (installed) 0.35 ~ 0.50 mm (0.014 ~ 0.020 in) 0.85 mm

(0.033 in)

Ring side clearance 0.030 ~ 0.070 mm (0.0012 ~ 0.0028 in) 0.13 mm

(0.0051 in)

2 - 7

ENGINE SPECIFICATIONS

Item Standard Limit

Oil ring

B

T

Dimensions (B × T) 2.50 × 3.40 mm (0.10 × 0.13 in) ---­End gap (installed) 0.20 ~ 0.70 mm (0.008 ~ 0.028 in) ---­Ring side clearance 0.060 ~ 0.150 mm (0.0024 ~ 0.0059 in) ----

Crankshaft

F

SPEC

C

Crank width “A” 74.95 ~ 75.00 mm (2.951 ~ 2.953 in) ---­Maximum runout “C” ---- 0.03 mm

Big end side clearance “D” 0.350 ~ 0.650 mm (0.0138 ~ 0.0256 in) 1.00 mm

Big end radial clearance “E” 0.010 ~ 0.025 mm (0.0004 ~ 0.0010 in) ---­Small end free play “F” 0.16 ~ 0.40 mm (0.0063 ~ 0.0157 in) ----

Balancer

Balancer drive method Gear ----

Clutch

Friction plate 1 (inside dia.: 121 mm)

Thickness 2.92 ~ 3.08 mm (0.115 ~ 0.121 in) 2.82 mm

Quantity 7 ----

Friction plate 2 (inside dia.: 128 mm)

Thickness 2.90 ~ 3.10 mm (0.114 ~ 0.122 in) 2.80 mm

Quantity 1 ----

Clutch plate

Thickness 1.50 ~ 1.60 mm (0.059 ~ 0.063 in) ---­Quantity 7 ---­Maximum warpage ---- 0.20 mm

Clutch spring

Free length 50.0 mm (1.97 in) 48.0 mm

Quantity 6 ----

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

C

E

D

A

(0.0012 in)

(0.040 in)

(0.111 in)

(0.110 in)

(0.0079 in)

(1.89 in)

2 - 8

ENGINE SPECIFICATIONS

SPEC

Item Standard Limit

Transmission

Maximum main axle runout ---- 0.08 mm

(0.0031 in)

Maximum drive axle runout ---- 0.08 mm

(0.0031 in)

Shifting mechanism

Shift mechanism type Shift drum and guide bar ----

Decompression device

Device type Auto decomp ----

Air filter oil grade

Air-cooled 2-stroke engine oil ----

Throttle body

Model/manufacturer × quantity 44EHS/MIKUNI × 1 ---­Engine idle speed 1,500 ~ 1,700 r/min ---­Intake vacuum 37.8 kPa (284 mmHg, 11.2 inHg) ----

Fuel pump

Pump type Electrical ---­Model/manufacturer 1S3/DENSO ---­Maximum consumption amperage 4.8 A ---­Output pressure 324 kPa (3.24 kg/cm

Oil filter type

Paper ----

2

, 46.1 psi) ----

Oil pump

Oil pump type Trochoid ---­Inner-rotor-to-outer-rotor-tip clear-

ance
Outer-rotor-to-oil-pump-housing

clearance

Less than 0.12 mm (0.0047 in) 0.20 mm

(0.0079 in)

0.09 ~ 0.15 mm (0.0035 ~ 0.0059 in) 0.22 mm
(0.0087 in)

Bypass valve opening pressure 40.0 ~ 80.0 kPa

(0.40 ~ 0.80 kg/cm

Oil pressure (hot) 40.0 kPa at 1,600 r/min (0.40 kg/cm

2

, 5.70 ~ 11.4 psi)

2

at

1,600 r/min, 5.70 psi at 1,600 r/min)

Pressure check location Element cover ----

Cooling system

Radiator core

Width 197 mm (7.76 in) ---­Height 300 mm (11.81 in) ---­Depth 22 mm (0.87 in) ----

Radiator cap opening pressure 93.3 ~ 122.7 kPa

(0.933 ~ 1.227 kg/cm

2

, 13.27 ~ 17.45 psi)

Coolant reservoir capacity

Up to the maximum level mark 0.25 L (0.22 Imp qt, 0.26 US qt) ---­From low to full level 0.15 L (0.13 Imp qt, 0.16 US qt) ----

Water pump

Water pump type Single-suction centrifugal pump ---­Reduction ratio 27/28 (0.964) ----

----

----

----

2 - 9

Lubrication chart

ENGINE SPECIFICATIONS

SPEC

To oil tank

Oil tank inlet pipe

A.C. magneto
cover

Left
crankcase

Counter axle

From oil tank

Oil tank outlet
hose joint

Main axle

Drive axle

Decompression

Oil filter

element

Drain bolt

Cylinder head

Camshaft

Oil delivery pipe

Right crankcase

Right
crankcase

Oil
strainer

Oil pump

Right crankcase Clutch cover

Crankshaft

To clutch cover

2 - 10

Cylinder head tightening sequence

7

2

8

4

ENGINE SPECIFICATIONS

5

6

SPEC

3

1

2 - 11

CHASSIS SPECIFICATIONS

EBS01003

SPEC

CHASSIS SPECIFICATIONS

Item Standard Limit

Steering system

Steering bearing type Ball and race bearing ----

Front suspension

Shock absorber travel 115.0 mm (4.53 in) ---­Spring free length 269.0 mm (10.59 in) ---­Installed length 260.5 mm (10.26 in) ---­Spring rate (K1) 21.60 N/mm (2.20 kg/mm, 123.33 lb/in) ---­Spring rate (K2) 29.40 N/mm (3.00 kg/mm, 167.87 lb/in) ---­Optional spring available No ----

Rear suspension

Shock absorber travel 110.0 mm (4.33 in) ---­Spring free length 255.0 mm (10.04 in) ---­Installed length 236.0 mm (9.29 in) ---­Spring rate (K1) 46.00 N/mm (4.69 kg/mm, 262.66 lb/in) ---­Spring stroke (K1) 0 ~ 110.0 mm (0 ~ 4.33 in) ---­Optional spring available No ----

Swingarm

Free play limit (radial) ---- 1.0 mm

(0.04 in)

Free play limit (axial) ---- 1.0 mm

(0.04 in)

Front wheel

Type Panel wheel ---­Rim size 10 × 5.5 AT ---­Rim material Aluminum ---­Maximum radial wheel runout ---- 2.0 mm

(0.08 in)

Maximum lateral wheel runout ---- 2.0 mm

(0.08 in)

Rear wheel

Type Panel wheel ---­Rim size 9 × 8.5 AT ---­Rim material Aluminum ---­Maximum radial wheel runout ---- 2.0 mm

(0.08 in)

Maximum lateral wheel runout ---- 2.0 mm

(0.08 in)

Drive chain

Type/manufacturer 520MXV/DAIDO ---­Link quantity 98 ---­Drive chain slack 25 ~ 35 mm (0.98 ~ 1.38 in) ----

2 - 12

CHASSIS 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 4.3 mm (0.17 in) 1.0 mm

Pad thickness outer 4.3 mm (0.17 in) 1.0 mm

Master cylinder inside diameter 12.70 mm (0.50 in) ---­Caliper cylinder inside diameter 25.40 mm (1.00 in) ---­Brake fluid type DOT 4 ----

Rear disc brake

Type Single ---­Disc outside diameter × thickness 200.0 × 3.6 mm (7.87 × 0.14 in) ---­Pad thickness inner 5.6 mm (0.22 in) 1.0 mm

Pad thickness outer 5.6 mm (0.22 in) 1.0 mm

Master cylinder inside diameter 12.70 mm (0.50 in) ---­Caliper cylinder inside diameter 32.03 mm (1.26 in) ---­Brake fluid type DOT 4 ----

Brake lever and brake pedal

Brake pedal position 15.3 mm (0.60 in) ---­Parking brake cable end length 58 ~ 60 mm (2.28 ~ 2.36 in) ---­Clutch lever free play (lever end) 5 ~ 10 mm (0.20 ~ 0.39 in) ---­Throttle lever free play 2 ~ 4 mm (0.08 ~ 0.16 in) ---­Speed limiter length Less than 12 mm (0.47 in) ---­Shift pedal height 48 mm (1.89 in) ----

SPEC

(0.04 in)

(0.04 in)

(0.04 in)

(0.04 in)

2 - 13

ELECTRICAL SPECIFICATIONS

EBS01004

SPEC

ELECTRICAL SPECIFICATIONS

Item Standard Limit

System voltage
Ignition system

Ignition timing (B.T.D.C.) 9.0°/1,600 r/min ---­Advancer type Digital type ----

Transistorized coil ignition

Crankshaft position sensor resis­tance/color

ECU

Model/manufacturer TBDF18/DENSO ----

Ignition coil

Model/manufacturer JO267/DENSO ---­Minimum ignition spark gap 6.0 mm (0.24 in) ---­Primary winding resistance 3.4 ~ 4.6 Ω at 20 °C (68 °F) ----
Secondary winding resistance 10.4 ~ 15.6 kΩ at 20 °C (68 °F) ----

Spark plug cap

Material Resin ---­Resistance 10.0 k

A.C. magneto

Model/manufacturer LMX58/DENSO ---­Standard output 14 V 17.2 A at 5,000 r/min ---­Stator coil resistance/color 0.248 ~ 0.372 Ω at 20 °C (68 °F)/

Rectifier/regulator

Type Semiconductor, short-circuit type ---­Model/manufacturer SH650D-11/SHINDENGEN ---­No load regulated voltage (DC) 14.1 ~ 14.9 V ---­Rectifier capacity 18.0 A ---­Withstand voltage 200.0 V ----

Electric starting system

Type Constant mesh type ----

Starter motor

Model/manufacturer SM-13/MITSUBA ---­Power output 0.80 kW ---­Armature coil resistance 0.0250 ~ 0.0350 Ω at 20 °C (68 °F) ----
Brush overall length 12.5 mm (0.49 in) 5.00 mm

Spring force 7.65 ~ 10.01 N

Commutator diameter 28.0 mm (1.10 in) 27.0 mm

Mica undercut 0.70 mm (0.03 in) ----

12 V ----

192 ~ 288 Ω at 20 °C (68 °F)/
blue/yellow-green/white

Ω

white-white

(0.20 in)

(780 ~ 1,021 gf, 27.54 ~ 36.03 oz)

(1.06 in)

----

----

----

----

2 - 14

ELECTRICAL SPECIFICATIONS

Item Standard Limit

Starter relay

Model/manufacturer 2768106-A/JIDECO ---­Amperage rating 180.0 A ---­Coil winding resistance 4.18 ~ 4.62 Ω at 20 °C (68 °F) ----

Circuit breaker

Circuit breaker type Fuse ---­Fuses

Main fuse 20 A ---­Headlight fuse 15 A ---­Signaling system fuse 10 A ---­Ignition fuse 10 A ---­Fuel injection system fuse 10 A ---­Spare fuse 20 A

15 A
10 A

SPEC

----

----

----

2 - 15

EBS01005

TIGHTENING TORQUES

ENGINE TIGHTENING TORQUES

TIGHTENING TORQUES

SPEC

Part to be tightened Part name

Thread

size

Q’ty

Tightening torque

Nm m · kg ft · lb

Cylinder head (exhaust pipe) Stud bolt M8 4 15 1.5 11
Cylinder head Bolt M9 4 35 3.5 25
Cylinder head Bolt M9 2 38 3.8 27
Cylinder head Bolt M6 2 10 1.0 7.2
Spark plug — M101 13 1.39.4
Oil gallery bolt Union bolt M8 1 10 1.0 7.2
Tappet cover Bolt M6 8 10 1.0 7.2
Camshaft sprocket cover Bolt M6 2 10 1.0 7.2
Camshaft sprocket Bolt M7 2 20 2.0 14
Decompressor assembly Bolt M7 2 20 2.0 14

Cylinder Bolt M10 4 50 5.0 36

Cylinder Bolt M6 2 10 1.0 7.2
Cable guide Bolt M6 1 7 0.7 5.1
Water jacket joint Bolt M6 2 10 1.0 7.2
A.C. magneto rotor Nut M16 1 60 6.0 43
A.C. magneto cover Bolt M6 14 10 1.0 7.2

Balancer driven gear Nut M16 2 60 6.0 43

Breather plate Bolt M6 3 10 1.0 7.2

Primary drive gear Nut M20 1 110 11.0 80

Remarks

M

E

See NOTE.

E

E

Use a lock
washer.

Use a lock
washer.

M

Valve adjusting screw Nut M6 4 14 1.4 10
Camshaft bearing retainer Bolt M6 2 10 1.0 7.2
Timing chain guide (intake side) Bolt M6 2 10 1.0 7.2
Timing chain tensioner cap bolt Bolt M16 1 20 2.0 14
Timing chain tensioner Bolt M6 2 10 1.0 7.2
Water pump outlet hose clamp Screw M4 2 2 0.2 1.4
Water pump Bolt M6 3 10 1.0 7.2
Water pump housing cover Bolt M6 3 11 1.1 8.0
Thermostat cover Bolt M6 2 10 1.0 7.2
Radiator Bolt M6 2 7 0.7 5.1
Engine oil drain bolt (crankcase) Bolt M14 1 23 2.3 17
Engine oil drain bolt (oil tank) Bolt M8 1 19 1.9 13
Oil baffle plate 1 Bolt M5 2 4 0.4 2.9
Oil baffle plate 2 Bolt M6 2 10 1.0 7.2
Oil pump Bolt M6 1 10 1.0 7.2
Oil pump housing 2 Screw M6 1 7 0.7 5.1
Oil strainer Bolt M6 2 10 1.0 7.2

2 - 16

LT

LT

LT

TIGHTENING TORQUES

SPEC

Part to be tightened Part name

Thread

size

Q’ty

Tightening torque

Remarks

Nm m · kg ft · lb

Oil filter cover drain bolt Bolt M6 1 10 1.0 7.2
Oil filter cover Bolt M6 2 10 1.0 7.2
Check screw (oil filter cover) Screw M5 1 5 0.5 3.6
Oil delivery pipe Union bolt M10 2 20 2.0 14
Oil delivery pipe Bolt M6 1 10 1.0 7.2
Oil pipe joint Bolt M14 1 50 5.0 36
Oil tank inlet hose (oil tank side) Bolt M6 1 10 1.0 7.2
Oil tank inlet hose (engine side) Bolt M6 1 10 1.0 7.2
Oil tank outlet hose Nut M16 1 35 3.5 25
Oil tank outlet hose Bolt M6 2 10 1.0 7.2
Intake manifold clamp Screw M4 2 3 0.3 2.2
Air filter case joint clamp Screw M5 1 4 0.4 2.9
ECU bracket Bolt M6 2 7 0.7 5.1
Exhaust pipe 2 and exhaust pipe 1 Bolt M8 1 16 1.6 11
Spark arrester Bolt M6 1 8 0.8 5.8
Muffler and exhaust pipe 2 Bolt M8 1 18 1.8 13
Muffler Bolt M8 2 38 3.8 27
Exhaust pipes Nut M8 4 20 2.0 14
Muffler protector Screw M6 2 8 0.8 5.8
Exhaust pipe protector Bolt M6 4 8 0.8 5.8
Oil seal retainer (clutch cover) Bolt M6 2 10 1.0 7.2
Timing mark accessing screw Screw M14 1 6 0.6 4.3
Crankshaft end accessing screw Screw M36 1 10 1.0 7.2
Crankcase bearing retainer Screw M6 2 10 1.0 7.2
Crankcase bearing retainer Bolt M6 2 10 1.0 7.2
Crankcase Bolt M6 17 10 1.0 7.2
Engine oil filler bolt Bolt M20 1 12 1.2 8.7
Starter clutch Bolt M8 3 30 3.0 22
Clutch spring Bolt M6 6 8 0.8 5.8
Clutch boss Nut M20 1 95 9.5 68 Stake
Clutch cover Bolt M6 14 10 1.0 7.2

Drive sprocket Nut M22 1 85 8.5 61

Use a lock

washer.
Oil seal retainer (left crankcase) 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
Reverse shift lever Bolt M6 1 13 1.3 9.4
Shift pedal Bolt M6 1 16 1.6 11
Stator coil Bolt M6 3 7 0.7 5.1
Crankshaft position sensor Bolt M5 2 7 0.7 5.1
A.C. magneto lead holder Bolt M5 1 7 0.7 5.1
Coolant temperature sensor — M12 1 18 1.8 13
Starter motor Bolt M6 2 10 1.0 7.2

LT

LT

LT

LT

LT

LT

LT

LT

LT

LT

2 - 17

TIGHTENING TORQUES

SPEC

Part to be tightened Part name

Reverse switch — M10 1 17 1.7 12
Neutral switch — M10 1 17 1.7 12

NOTE:

Temporarily tighten the cylinder bolts to 15 Nm (1.5 m · kg, 11 ft · lb), and then tighten them to
50 Nm (5.0 m · kg, 36 ft · lb).

Thread

size

Q’ty

Tightening torque

Remarks

Nm m · kg ft · lb

2 - 18

EBS01006

CHASSIS TIGHTENING TORQUES

TIGHTENING TORQUES

SPEC

Part to be tightened Thread size

Remarks

Nm m · kg ft · lb

Engine upper bracket M8 33 3.3 24
Engine mounting bolt (upper) M10 40 4.0 29
Engine lower bracket M8 41 4.1 30
Engine mounting bolt (middle) M10 66 6.6 48
Engine mounting bolt (lower) M10 66 6.6 48
Swingarm pivot shaft, engine, and frame M16 100 10.0 72
Middle frame and rear frame M10 54 5.4 39
Frame and oil tank M6 7 0.7 5.1
Frame and coolant reservoir M6 7 0.7 5.1
Rear shock absorber and frame M12 55 5.5 40
Relay arm and swingarm M10 43 4.3 31
Connecting arm and frame M12 55 5.5 40
Relay arm and rear shock absorber M10 43 4.3 31
Relay arm and connecting arm M10 43 4.3 31
Rear axle pinch bolt M8 21 2.1 15

Tightening torque

Swingarm and guide pin M12 55 5.5 40

LT

Swingarm skid plate and swingarm M6 7 0.7 5.1
Drive chain guide 1 and swingarm M6 7 0.7 5.1
Drive sprocket cover and engine M6 10 1.0 7.2
Upper front arm and frame M10 38 3.8 27
Lower front arm and frame M10 55 5.5 40
Front shock absorber and frame M10 48 4.8 35
Front shock absorber and lower front arm M10 48 4.8 35
Steering stem, pitman arm, and frame M14 180 18.0 130

Steering stem bushing and frame M8 23 2.3 17

Use a lock

washer.
Steering stem and handlebar holder M8 23 2.3 17
Tie-rod end and locknut M12 18 1.8 13
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 65 6.5 47
Fuel tank and fuel pump M6 7 0.7 5.1
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 bracket M8 28 2.8 20
Front brake disc and front wheel hub M8 28 2.8 20

LT

Rear brake caliper and brake caliper bracket M8 34 3.4 24
Rear axle and rear wheel hub M16 200 20.0 145 See NOTE.
Rear wheel and rear wheel hub M10 45 4.5 32

2 - 19

TIGHTENING TORQUES

SPEC

Part to be tightened Thread size

Tightening torque

Nm m · kg ft · lb

Driven sprocket and sprocket bracket M10 72 7.2 52
Front brake caliper and brake hose M10 27 2.7 19
Front brake pad retaining bolt M10 17 1.7 12
Brake caliper bleed screw M8 6 0.6 4.3
Front brake master cylinder and handlebar M6 7 0.7 5.1
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
Throttle lever assembly and handlebar M5 4 0.4 2.9
Clutch lever and handlebar M5 4 0.4 2.9
Parking brake lever and clutch lever M6 7 0.7 5.1
Front brake pipe nut M10 19 1.9 13
Brake hose joint and frame M6 10 1.0 7.2
Brake hose holder and front upper arm M6 7 0.7 5.1
Footrest and frame M10 78 7.8 56
Foot protector and footrest M6 13 1.3 9.4
Foot protector and footrest M8 16 1.6 11
Foot protector and bracket M6 12 1.2 8.7
Engine skid plate and frame M6 7 0.7 5.1
Rear axle ring nut M36 240 24.0 175
Rear axle ring nut set bolt M6 7 0.7 5.1
Rear brake pad retaining bolt M10 17 1.7 12
Rear brake caliper and brake hose M10 30 3.0 22
Parking brake case bracket and parking brake

case

M8 22 2.2 16

Rear brake master cylinder and frame M6 20 2.0 14
Rear brake master cylinder and brake hose M10 30 3.0 22
Rear brake master cylinder adjusting bolt and

locknut

M8 17 1.7 12

Parking brake adjusting bolt and locknut M6 10 1.0 7.2
Rear brake disc and brake disc bracket M8 33 3.3 24
Brake hose holder and swingarm M6 7 0.7 5.1
Front guard and frame M8 12 1.2 8.7
Front fender and frame M6 7 0.7 5.1
Headlight and frame M6 7 0.7 5.1
Rear fender and frame M6 7 0.7 5.1
Rear fender and bracket 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
Rear guard and frame M8 32 3.2 23
Battery box and lean angle sensor M4 2 0.2 1.4

Remarks

LT

LS

LT

LT

LT

LT

LT

2 - 20

TIGHTENING TORQUES

NOTE:

1. Apply a rust preventive lubricant to the threads on both sides of the rear axle and to the wheel
hub surfaces that contact the rear axle washers.

2. Tighten the rear axle nuts 200 Nm (20.0 m · kg, 145 ft · lb).

3. Loosen the rear axle nuts completely.

4. Retighten the rear axle nuts 200 Nm (20.0 m · kg, 145 ft · lb). Do not loosen the axle nuts after
tightening them. If an axle nut slot is not aligned with the cotter pin hole on either side of the axle,
further tighten the axle nut until a slot is aligned with the hole.

SPEC

2 - 21

HOW TO USE THE CONVERSION TABLE/

GENERAL TIGHTENING TORQUE SPECIFICATIONS

SPEC

EBS00022

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

3

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

kg/mm

2

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

)

0.03527

0.06102

0.8799

0.2199

55.997

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/in2)
Fahrenheit
(°F)

EBS00023

GENERAL TIGHTENING TORQUE
SPECIFICATIONS

This chart specifies tightening torques for stan­dard fasteners with a standard ISO thread
pitch. Tightening torque specifications for spe­cial components or assemblies are provided
for each chapter of this manual. To avoid
warpage, tighten multi-fastener assemblies in
a crisscross pattern and progressive stages
until the specified tightening torque is reached.
Unless otherwise specified, tightening torque
specifications require clean, dry threads. Com­ponents should be at room temperature.
A: Distance between flats
B: Outside thread diameter

General tightening

A

(nut)

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

19 mm 14 mm 85 8.5 61

22 mm 16 mm 130 13.0 94

B

(bolt)

torques

Nm m · kg ft · lb

2 - 22

LUBRICATION POINTS AND LUBRICANT TYPES

EBS00024

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE

Lubrication point Lubricant

SPEC

Oil seal lips

O-rings

Bearings

Crankshaft pins

Timing chain sprocket inner surface

Connecting rod big end thrust surface

Piston pin

Piston surface

Valve stems (intake and exhaust)

Valve stem ends (intake and exhaust)

Rocker arm shaft

Camshaft lobes

Decompressor lever pin

Decompressor lever spring

Water pump impeller shaft

Oil pump rotors (inner rotor 2 and outer rotor 2) and pump

Oil pump rotors (inner rotor 1 and outer rotor 1) and pump

Torque limiter

Starter idle gear and starter wheel gear inner surface

Primary driven gear

Clutch pull rod

Transmission gears (wheel and pinion)

Shift drum

Shift forks

Shift lever assembly

Shift shaft

Reverse shift shaft

LS

LS

E

E

M

E

E

E

M

M

E

M

E

E

E

E

LS

E

E

E

LS

M

E

E

E

E

E

Crankcase mating surface

A.C. magneto lead grommet (A.C. magneto cover)

2 - 23

Yamaha bond

No. 1215

(Three bond

No. 1215)

Yamaha bond

No. 1215

(Three bond

No. 1215)

COOLANT FLOW DIAGRAMS

EBS00025

COOLANT FLOW DIAGRAMS

Thermostat cover

1

Fast idle plunger outlet hose

2

Radiator inlet hose

3

Radiator

4

Radiator outlet hose

5

Water pump breather hose

6

Water pump

7

SPEC

Install the radiator inlet hose onto the thermostat

È

cover pipe, making sure that it contacts the
cover and its yellow paint mark is facing out­ward.
Fasten the fast idle plunger outlet hose and the

É

radiator inlet hose with the plastic band.
Install the radiator inlet hose with its white paint

Ê

mark facing outward.

Ë

4

2

7

Î

6

È

3

É

Ê

A

A

Ë

1

Ì

B

B

Í

A-A

5

Ð

Ï

B-B

2 - 24

COOLANT FLOW DIAGRAMS

SPEC

Ë Position the screw clamp so that its screw can

be tightened from the right side of the vehicle.

Ì Install the radiator outlet hose with its white paint

mark facing outward.

Í Install the radiator outlet hose with its yellow

paint mark facing outward.

Î From fast idle plunger
Ï Make sure that the end of the screw clamp does

not protrude past the side of the radiator inlet
hose.

È

2

3

É

A

A

Ð Make sure that the end of the screw clamp does

not protrude past the side of the radiator outlet
hose.

Ë

4

Ê

7

Î

6

Í

1

Ë

Ì

B

B

5

Ð

A-A

Ï

B-B

2 - 25

COOLANT FLOW DIAGRAMS

SPEC

1 Radiator
2 Radiator fan breather hose
3 Fuel tank shield
4 Coolant reservoir breather hose
5 Coolant reservoir
6 Coolant reservoir hose
7 Drain hose

È Pass the radiator fan breather hose through the

guide.

É

1

6

Ê

2

6

É Install the coolant reservoir hose onto the radia-

tor pipe, making sure that it contacts the radia­tor.

Ê Pass the coolant reservoir hose and radiator fan

breather hose through the guide on the fuel tank
shield.

Ë 60 mm (2.36 in)
Ì Pass the clamp through the hole in the stay on

the frame, and then fasten the coolant reservoir
hose and drain hose with the clamp.

3

C

4

Ë

6

7

C

BA

C-C D-D

Ì

1

A

2

È

B

3

D

4

5

D

6

2 - 26

COOLANT FLOW DIAGRAMS

SPEC

1 Water pump outlet hose
2 Water pump
3 Water pump breather hose
4 Water jacket inlet housing

È From radiator
É Install the water pump outlet hose onto the water

jacket inlet housing, making sure to align the yel­low paint mark on the hose with the projection
on the water jacket inlet housing.

A

1

B

2

3

È

B

2

4

1

É

A

È

B-B

2 - 27

EBS00026

OIL FLOW DIAGRAMS

Oil tank breather hose

1

Oil tank outlet hose

2

Oil tank inlet hose

3

Oil tank

4

OIL FLOW DIAGRAMS

1

SPEC

1

4

3

34

2

2 - 28

1 Oil delivery pipe
2 Oil filter
3 Oil pump

OIL FLOW DIAGRAMS

2

SPEC

A-A

1

A

2

A

3

2 - 29

1 Oil filter
2 Oil pump driven gear
3 Oil pump rotor 1
4 Oil pump rotor 2
5 Oil pipe joint
6 Main axle
7 Counter axle

OIL FLOW DIAGRAMS

SPEC

1

6

7

345

2

2 - 30

1 Oil strainer
2 Oil pump rotor 2
3 Oil pump rotor 1
4 Oil pump driven gear

È To oil tank

OIL FLOW DIAGRAMS

SPEC

1

È

A-A

A

A

23

4

1

2 - 31

1 Balancer 1
2 Crankshaft

OIL FLOW DIAGRAMS

1

SPEC

2 - 32

2

EBS00028

CABLE ROUTING

Handlebar switch lead

1

Clutch switch lead

2

Parking brake cable

3

Clutch cable

4

Front brake hose

5

Front brake light switch lead

6

Throttle cable

7

Indicator light assembly lead

8

Radiator fan breather hose

9

3

4

CABLE ROUTING

Coolant reservoir breather hose

0

Coolant reservoir hose

A

Radiator fan motor lead

B

Main switch lead

C

A

5

SPEC

Ø

×

Ù

B

C

Ö

Ô

Û

1

6

Õ

2

5

Ú

È

7

Ê

Ò

4

É

3

7

Ë

Ì

2

6

8

9

È

Î

Ï

0

1

Í

A

Ó

Ð

Ñ

A

2 - 33

CABLE ROUTING

SPEC

È Fasten the handlebar switch lead and clutch

switch lead with the plastic bands at the bends in
the handlebar.

É Fasten the front brake light switch lead with the

plastic band at the bend in the handlebar.

Ê To main switch
Ë Route the parking brake cable and clutch cable

in front of the front brake light switch and main
switch lead.

Ì To radiator

4

3

È

2

1

7

5

Í Route the coolant reservoir breather hose under

the wire harness and over the handlebar switch
lead, clutch switch lead, front brake light switch
lead, main switch lead and indicator light assem­bly lead and then fasten the hose with the holder
on the fuel tank shield.

Î To resistor
Ï To left headlight

A

5

É

6

7

3

4

1

Ø

×

Ù

B

C

Ö

Ô

Û

6

Õ

Ú

Ê

Ò

Ë

Ì

2

8

9

È

Ð

Î

Ï

0

Í

A

Ó

Ñ

A

2 - 34

CABLE ROUTING

SPEC

Ð Route the radiator fan breather hose and coolant

reservoir hose in front of the front brake light
switch lead, main switch lead, handlebar switch
lead, clutch switch lead and indicator light assem­bly lead.

Ñ Secure the plastic band by inserting the projection

on the band into the hole in the frame, and then
fasten the wire harness with the band, making
sure to face the end of the band backward.

Ò To radiator fan

4

3

È

2

1

7

5

Ó Secure the plastic band by inserting the projection

on the band into the hole in the frame, and then
fasten the wire harness and radiator fan motor
lead with the band, making sure to face the end of
the band backward.

Ô To rectifier/regulator
Õ To ignition coil
Ö To right headlight
× Pass the clutch cable and parking brake cable

through the wire guide.

A

5

É

6

7

3

4

1

Ø

×

Ù

B

C

Ö

Ô

Û

6

Õ

Ú

Ê

Ò

Ë

Ì

2

8

9

È

Ð

Î

Ï

0

Í

A

Ó

Ñ

A

2 - 35

CABLE ROUTING

SPEC

Ø Pass the radiator fan breather hose, coolant res-

ervoir hose, front brake light switch lead, main
switch lead, handlebar switch lead, clutch switch
lead, and indicator light assembly lead through
the guide on the fuel tank shield, and then con­nect the leads below the guide.

Ù Route the throttle cable in front of the clutch

cable and parking brake cable.

4

3

È

2

1

7

5

Ú Pass the throttle cable, clutch cable, parking

brake cable, front brake light switch lead, main
switch lead, handlebar switch lead, clutch switch
lead, indicator light assembly lead and radiator
fan breather hose through the wire guide.

Û Route the front brake light switch lead behind

the front brake hose and throttle cable.

A

5

É

6

7

3

4

1

Ø

×

Ù

B

C

Ö

Ô

Û

6

Õ

Ú

Ê

Ò

Ë

Ì

2

8

9

È

Ð

Î

Ï

0

Í

A

Ó

Ñ

A

2 - 36

CABLE ROUTING

SPEC

1 Coolant reservoir hose
2 Radiator fan breather hose
3 Throttle cable
4 Fuel tank breather hose
5 Fuel hose
6 Oil tank inlet hose
7 Reverse control cable
8 Oil tank outlet hose
9 Drain hose
0 Coolant reservoir breather hose
A Resistor lead

A

Ñ

B

C

1

9

A

Ò

9

0

Ð

È

1

B Resistor
C Headlight lead
D Main switch lead
E Handlebar switch lead
F Clutch switch lead
G Front brake light switch lead
H Wire harness
I Indicator assembly lead
J Fuel tank shield
K Fuel tank
L Rubber damper

3

Ê

2

É

B

4

Ë

5

Ì

Í

D

D

E

E

Ó

2

D

1

E

I

F

H

F

A

F

F

F

3

K

H

Ô

L

G

C

C

B

0

J

C-C

0

H

D-D

J

Õ

8

5

Ï

H

J

Ö

K

Î

E-E

7

6

1

×

9

F-F

2 - 37

CABLE ROUTING

SPEC

È Route the coolant reservoir hose in front of the

radiator fan breather hose, and then connect it to
the radiator.

É Pass the radiator fan breather hose through the

wire guide.

Ê Route the throttle cable on top of the fuel tank

shield.

Ë Pass the fuel tank breather hose through the

hole in the handlebar cover, and then insert the
end of the hose into the steering stem.

A

Ñ

1

9

B

C

Ò

È

Ð

0

9

A

1

Ì Route the wire harness to the inside of the

frame.

Í Connect the A.C. magneto lead, wire sub lead,

rear brake switch lead, and speed sensor lead,
and then fasten the leads with the plastic band.
Face the end of the plastic band inward.

Î Fasten the oil tank outlet hose and reverse con-

trol cable with the clamp, making sure that the
reverse control cable does not contact the edge
of the engine stay.

4

Ë

5

D

D

E

E

É

2

Ê

3

B

Ì

Í

Ó

2

D

1

E

I

F

H

F

A

F

F

F

3

K

H

Ô

L

G

C

C

B

0

J

C-C

0

H

D-D

J

Õ

8

5

Ï

H

J

Ö

K

Î

E-E

7

6

1

×

9

F-F

2 - 38

CABLE ROUTING

SPEC

Ï Route the reverse control cable under the oil

tank outlet hose.

Ð Pass the plastic band through the space

between the frame and the frame support, and
then fasten the wire harness to the frame with
the band, making sure to face the end of the
band inward.

A

Ñ

1

9

B

C

Ò

È

Ð

0

9

A

1

Ñ Route the resistor lead over the frame, making

sure that its coupler is positioned to the inside of
the frame.

Ò Route the headlight lead over the frame, con-

nect the headlight coupler, and then insert the
projection on the coupler into the hole in the stay
on the front fender bracket.

4

Ë

5

D

D

E

E

É

2

Ê

3

B

Ì

Í

Ó

2

D

1

E

I

F

H

F

A

F

F

F

3

K

H

Ô

L

G

C

C

B

0

J

C-C

0

H

D-D

J

Õ

8

5

Ï

H

J

Ö

K

Î

E-E

7

6

1

×

9

F-F

2 - 39

CABLE ROUTING

SPEC

Ó Pass the radiator fan breather hose and coolant

reservoir hose, then the front brake light switch
lead, main switch lead, handlebar switch lead,
clutch switch lead, and indicator light assembly
lead through the guide on the fuel tank shield,
making sure to route the hoses in front of leads.
Do not pinch or crush the radiator fan breather
hose or coolant reservoir hose. Route the indica­tor light assembly lead to the left of the other
leads.

A

Ñ

1

9

B

C

Ò

È

Ð

0

9

A

1

Ô Pass the wire harness through the rubber

damper.

Õ Route the fuel hose to the outside of the wire

harness.

Ö Route the wire harness above the fuel tank

shield.

× Pass the clamp through the hole in the stay on

the frame, and then fasten the coolant reservoir
hose and drain hose with the clamp.

4

Ë

5

D

D

E

E

É

2

Ê

3

B

Ì

Í

Ó

2

D

1

E

I

F

H

F

A

F

F

F

3

K

H

Ô

L

G

C

C

B

0

J

C-C

0

H

D-D

J

Õ

8

5

Ï

H

J

Ö

K

Î

E-E

7

6

1

×

9

F-F

2 - 40

CABLE ROUTING

SPEC

1 A.C. magneto lead
2 Lean angle sensor lead
3 Negative battery lead
4 Crankcase breather hose
5 Starter relay lead
6 Relay unit
7 Self-diagnosis signal lead
8 Tail/brake light
9 Tail/brake light lead
0 ECU
A ECU lead

1

E

A-A

3

F

D

×

B Battery box
C Starter motor lead
D Speed sensor lead
E Rear brake light switch lead
F Wire sub lead
G Reverse switch lead
H Neutral switch lead
I Speed sensor
J Wire harness

Ø

E

F

D

I

B

Ù

J

C

C-C

É

È

1

Ö

2

H

3

Ê

Ë

4

5

Ì

6

7

D

C

Î

8

9

Í

C

Ï

Ð

A

C

B

Ó

Ò

A

B

A

D

E

G

F

F

F

Õ

Ô

0

Ñ

E

F

F-F

9

9

E E

D

2 - 41

8

Ú

8

E-E

CABLE ROUTING

SPEC

È Route the leads that branch off from the wire

harness over the crankcase breather hose, then
towards the right side of the vehicle, making
sure that they do not contact the frame.

É Route the lean angle sensor lead to the outside

of the A.C. magneto lead, negative battery lead,
wire sub lead, rear brake light switch lead, and
speed sensor lead.

Ê Connect the negative battery lead to the nega-

tive battery terminal.

3

1

F

D

E

×

A-A

Ë Secure the plastic band by inserting the projec-

tion on the band into the hole in the frame, and
then fasten the wire harness at the center of its
positioning tape with the band, making sure that
the end of the band faces rearward and the
leads that branch off from the wire harness do
not contact the frame.

Ì Make sure that there is no slack in the wire har-

ness in the area shown in the illustration.

Ø

E

J

F

D

I

B

C-C

Ù

C

É

È

1

Ö

2

H

3

Ê

Ë

4

5

Ì

6

7

D

C

Î

8

9

Í

C

Ï

Ð

A

C

B

Ó

Ò

A

B

A

D
E

G

F

F

F

Õ

Ô

0

Ñ

E

F

F-F

9

9

E E

D

2 - 42

8

Ú

8

E-E

CABLE ROUTING

SPEC

Í When installing the tail/brake light cover and

rear fender, be sure not to pinch the tail/brake
light lead between the frame and the cover.

Î To fuse box
Ï Make sure that the tail/brake light lead is not

pulled taut when installing the rear fender.

3

1

F

D

E

×

A-A

Ð Fasten the radiator fan motor relay lead and tail/

brake light lead with the plastic band, making
sure to face the end of the band downward. Fas­ten the leads near the tail/brake light coupler and
after the split in the wire harness, making sure to
install the plastic band around the protective
sleeve of the tail/brake light lead, not the lead
itself.

Ø

E

J

F

D

I

B

C-C

Ù

C

É

È

1

Ö

2

H

3

Ê

Ë

4

5

Ì

6

7

D

C

Î

8

9

Í

C

Ï

Ð

A

C

B

Ó

Ò

A

B

A

D
E

G

F

F

F

Õ

Ô

0

Ñ

E

F

F-F

9

9

E E

D

2 - 43

8

Ú

8

E-E

CABLE ROUTING

SPEC

Ñ Secure the plastic band by inserting the projec-

tion on the band into the hole in the frame.

Ò Fasten the wire harness with the plastic band so

that the ECU lead is routed downward.

Ó Route the starter motor lead between the frame

and the battery box, then under the crankcase
breather hose.

Ô Make sure that there is not excessive slack in

the wire sub lead in the area shown in the illus­tration.

3

1

F

D

E

×

A-A

Õ Route the wire sub lead as shown in the illustra-

tion. The longer lead past the end of the protec­tive sleeve is the neutral switch lead and the
shorter lead is the reverse switch lead.

Ö Route the A.C. magneto lead, negative battery

lead, wire sub lead, rear brake light switch lead,
and speed sensor lead between the crankcase
breather hose and the starter motor lead, and to
the rear of the leads that branch off from the wire
harness.

Ø

E

J

F

D

I

B

C-C

Ù

C

É

È

1

Ö

2

H

3

Ê

Ë

4

5

Ì

6

7

D

C

Î

8

9

Í

C

Ï

Ð

A

C

B

Ó

Ò

A

B

A

D
E

G

F

F

F

Õ

Ô

0

Ñ

E

F

F-F

9

9

E E

D

2 - 44

8

Ú

8

E-E

CABLE ROUTING

SPEC

× Fasten the speed sensor lead, rear brake light

switch lead, A.C. magneto lead, negative battery
lead and wire sub lead with the plastic band.
Face the end of the plastic band inward.

Ø Fasten the rear brake light switch lead and wire

sub lead with the holder.

3

1

F

D

E

×

A-A

Ù Secure the plastic band by inserting the projec-

tion on the band into the hole in the frame, and
then fasten the wire harness and starter motor
lead with the band, making sure to face the end
of the band upward and to fasten the wire har­ness between the sections where the starter
relay lead and ECU lead branch off from the wire
harness.

Ú Fasten the tail/brake light lead with the plastic

band.

Ø

E

J

F

D

I

B

C-C

Ù

C

É

È

1

Ö

2

H

3

Ê

Ë

4

5

Ì

6

7

D

C

Î

8

9

Í

C

Ï

Ð

A

C

B

Ó

Ò

A

B

A

D
E

G

F

F

F

Õ

Ô

0

Ñ

E

F

F-F

9

9

E E

D

2 - 45

8

Ú

8

E-E

CABLE ROUTING

SPEC

1 Intake air pressure sensor lead
2 Fuel injector lead
3 Intake air pressure sensor
4 Throttle position sensor
5 Throttle position sensor lead
6 Intake air temperature sensor lead
7 Intake air temperature sensor
8 Crankcase breather hose
9 Negative battery lead
0 Lean angle sensor
A Fuel injector

G

B Fuel pump
C Fuel hose
D Fuel pump lead
E Front brake light switch lead
F Radiator fan breather hose
G Indicator light assembly lead
H Clutch cable
I Parking brake cable
J Indicator light assembly
K Throttle cable
L Handlebar switch lead

H

Ò

Ñ

A

I

J

8

A-A

Ó

B-B

8

7

Î

Ë

Ê

G

Ð

F

E

D

C

B

A

0

9

8

Í
Ì

Ï

A

K

M

N

L

1

È

2

3

B

B

4
5

6

É

7

2 - 46

CABLE ROUTING

SPEC

M Clutch switch lead
N Main switch lead

È To coolant temperature sensor
É Leave some slack in the intake air temperature

sensor lead in the area shown in the illustration.

Ê Route the crankcase breather hose between the

battery box and the air filter joint, and under the
wire harness.

Ë Route the negative battery lead between the

lean angle sensor and the wire harness.

G

Ì Route the negative battery lead connector as

shown.

Í Connect the A.C. magneto lead, wire sub lead,

rear brake switch lead, and speed sensor lead in
front of the lean angle sensor.

Î Route the fuel pump lead under the fuel hose.
Ï 10 mm (0.39 in)
³ Pass the indicator light assembly lead through

the guide on the front fender.

Ñ Insert the projection on the indicator light assem-

bly coupler into the hole in the front fender.

H

I

Ò

J

Ñ

A

8

A-A

Ó

B-B

8

7

Î

Ë

Ê

G

Ð

F

E

D

C

B

A

0

9

8

Í
Ì

Ï

A

K

M

N

L

1

È

2

3

B

B

4
5

6

É

7

2 - 47

Ò Pass the indicator light assembly lead through

the guide on the radiator cover.

Ó Fasten the leads with the holder at the section

before the intake air temperature sensor lead
branches off from the other leads.

CABLE ROUTING

H

SPEC

8

A-A

Ó

B-B

G

8

7

Î

Ë

Ê

G

Ð

F

E

D

C

B

A

0

9

8

Ñ

Í
Ì

Ò

Ï

I

A

A

M

N

L

È

B

B

J

K

1

2

3
4
5

6

7

É

2 - 48

CABLE ROUTING

SPEC

1 Radiator fan motor relay
2 Headlight relay
3 Fuse box
4 Relay unit
5 Relay unit lead
6 Self-diagnosis signal lead
7 Starter motor lead
8 Starter relay lead
9 Starter relay
0 Fuse box lead
A Headlight relay lead
B Radiator fan motor relay lead

4

6

É

C Tail/brake light lead

È Route the starter motor lead under the starter

relay lead.

É Make sure that the self-diagnosis signal coupler

is positioned above the relay unit lead, fuse box
lead, headlight relay lead, and radiator fan motor
relay lead.

Ê Install the headlight relay, then the radiator fan

motor relay, onto the tab on the rear fender. The
headlight relay is identified by the presence of
white tape wrapped around its lead.

5

0

A

1

A-A

Ê

2

B

B

C

È

9

8

7

6

AA

BB

B-B

5

2 - 49

4

3

1

2

CABLE ROUTING

SPEC

1 Radiator inlet hose
2 Fast idle plunger outlet hose
3 Reverse control cable
4 Ignition coil lead (red/black)
5 Rectifier/regulator lead
6 Ignition coil lead (orange)
7 Radiator outlet hose
8 Brake pipe
9 Rear brake light switch holder
0 Rear brake light switch lead
A Rear brake light switch

A

0

A-A

B

I

J

Ô

N

F

G

Ñ

F

E

Ð

D

Ï

H

I

O

5

1

B Throttle position sensor lead
C Coolant temperature sensor
D Hose (air-filter-joint-to-throttle-body-right-side)
E Coolant temperature sensor lead
F Intake air pressure sensor
G Fuel injector lead
H Intake air pressure sensor lead
I Parking brake cable
J Clutch cable
K Headlight lead
L Radiator fan motor lead

I

J

I

K

H

C

Ò

4

3

I

I

3

6

Ó

M

L

O

G

D

J

L

E

Õ

P

4

6

K

5

H

I-I

7

2

È

Ö

3

J

Ì

Ë

B

Í

A

0

C

3

É

F

4

5

Î

E

D

C

B

A

A

Ê

9

6

7

J

G

8

2 - 50

CABLE ROUTING

SPEC

M Wire harness
N Spark plug lead
O Rectifier/regulator
P Ignition coil

È Fasten the fast idle plunger outlet hose and radi-

ator inlet hose with the plastic band, making sure
not to pinch or crush the hoses.

É Route the reverse control cable to the inside of

the frame.

I

A

O

0

A-A

I

J

Ô

B

I

N

F

5

Ó

G

Ñ

G

H

1

2

F

E

Ð

D

Ï

6

Ê Make sure that the rear brake light switch lead

does not contact the swingarm. There should be
no slack in the rear brake light switch lead
between the holder shown in the illustration and
the holder on the left side of the vehicle.

Ë Route the rear brake light switch lead behind the

spring.

Ì Route the rear brake light switch lead to the right

of the rear brake light switch holder.

I

J

I

K

H

C

Ò

4

3

M

L

O

I

3

L

5

D

E

Õ

4

6

K

H

È

Ö

3

J

J

P

I-I

7

Ì

Ë

B

Í

A

0

C

3

É

F

4

5

Î

E

D

C

B

A

A

Ê

9

6

7

J

G

8

2 - 51

CABLE ROUTING

SPEC

Í Secure the plastic band by inserting the projec-

tion on the band into the hole in the frame, and
then fasten the leads where the throttle position
sensor lead branches off from the other leads,
making sure to face the end of the band rear­ward.

Î From the left side of the vehicle
Ï Install the hose (air filter joint to right side of

throttle body) onto the pipe on the air filter joint.

I

A

O

0

A-A

I

J

Ô

B

I

N

F

5

Ó

G

Ñ

G

H

1

2

F

E

Ð

D

Ï

6

Ð Route the leads that branch off from the wire

harness over the fast idle plunger outlet hose
and to the right of the hose (air filter joint to right
side of throttle body).

Ñ Route the fuel injector lead over the intake air

pressure sensor.

Ò Route the headlight lead over the frame, con-

nect the headlight coupler, and then insert the
projection on the coupler into the hole in the stay
on the front fender bracket.

I

J

I

K

H

C

Ò

4

3

M

L

O

I

3

L

5

D

E

Õ

4

6

K

H

È

Ö

3

J

‘

J

P

I-I

7

Ì

Ë

B

Í

A

0

C

3

É

F

4

5

Î

E

D

C

B

A

A

Ê

9

6

7

J

G

8

2 - 52

CABLE ROUTING

SPEC

Ó Fasten the rectifier/regulator lead with the plastic

band. Face the end of the plastic band down­ward.

Ô Route the spark plug lead to the right of the

clutch cable and parking brake cable, making
sure that the lead does not contact the cylinder
head.

Õ Route the reverse control cable in front of the

wire harness.

I

A

O

0

A-A

I

J

Ô

B

I

N

F

5

Ó

G

Ñ

G

H

1

2

F

E

Ð

D

Ï

6

Ö Fasten the reverse control cable to the frame

with the plastic band, making sure to face the
end of the band downward.

I

J

I

K

H

C

Ò

4

3

M

L

O

I

3

L

5

D

E

Õ

4

6

K

H

È

Ö

3

J

J

P

I-I

7

Ì

Ë

B

Í

A

0

C

3

É

F

4

5

Î

E

D

C

B

A

A

Ê

9

6

7

J

G

8

2 - 53

INTRODUCTION/PERIODIC MAINTENANCE CHART

FOR THE EMISSION CONTROL SYSTEM

EBS00029

CHK

ADJ

PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION

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

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

NOTE:

• For ATVs not equipped with an odometer or an hour meter, follow the month maintenance inter-

vals.

• For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance

intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month
maintenance intervals should be followed.

• Items marked with an asterisk should be performed by a Yamaha dealer as they require special

tools, data and technical skills.

ITEM ROUTINE

Fuel line*

Spark plug

Valves*

Fuel injection*

Crankcase breather
system*

Exhaust system*

Spark arrester

Whichever

comes first

• Check fuel hose for cracks or damage.

• Replace if necessary.

• Check condition.

• Adjust gap and clean.

• Replace if necessary.

• Check valve clearance.

• Adjust if necessary.

• Check and adjust engine idle speed.

• Check breather hose for cracks or damage.

• Replace if necessary.

• Check for leakage.

• Tighten if necessary.

• Replace gasket if necessary.

• Clean.

INITIAL EVERY

month136612

km

(mi)

hours 20 80 160 160 320

320

(200)

1300

(800)

2500

(1600)

2500

(1600)

5000

(3200)

3 - 1

GENERAL MAINTENANCE AND LUBRICATION CHART

GENERAL MAINTENANCE AND LUBRICATION CHART

INITIAL EVERY

month136612

km

(mi)

hours 20 80 160 160 320

320

(200)

1300

(800)

Every 20 ~ 40 hours

(more often in wet or dusty areas)

ITEM ROUTINE

Air filter element

Clutch*

Front brake*

Rear brake*

Wheels*

Wheel bearings*

Rear arm pivots*

Upper and lower arm
pivot and steering
shaft*

Drive chain

Fittings and fasten­ers*

Front and rear sus­pension*

Steering system*

Engine oil

Engine oil filter ele­ment

Cooling system

Lights and switches*

Whichever

comes first

• Clean.

• Replace if necessary.

• Check operation.

• Adjust if necessary.

• Check free play/operation/fluid leakage/See NOTE.

• Correct if necessary.

• Check operation/fluid leakage/See NOTE.

• Correct if necessary.

• Check balance/damage/runout.

• Replace if necessary.

• Check bearing assemblies for looseness/damage.

• Replace if damaged.

• Lubricate every 6 months with lithium-soap-based

grease.

• Lubricate every 6 months with lithium-soap-based
grease.

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

• Check all chassis fittings and fasteners.

• Correct if necessary.

• Check operation.

• Correct if necessary.

• Check operation.

• Repair if damaged.

• Check toe-in.

• Adjust if necessary.

• Replace (Warm engine before draining).

• Replace.

• Check coolant leakage.

• Repair if necessary.

• Replace coolant every 24 months.

• Check operation.

• Adjust headlight beams.

CHK

ADJ

2500

(1600)

2500

(1600)

5000

(3200)

3

NOTE:

_

• Recommended brake fluid: DOT 4

• Brake fluid replacement:

• When disassembling the master cylinder or caliper cylinder, replace the brake fluid. Normally

check the brake fluid level and add the fluid as required.

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

• 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.

3 - 2

SEAT, FENDERS AND FUEL TANK

EBS00033

SEAT, FENDERS AND FUEL TANK

CHK

ADJ

T

4 Nm (0.4 m

.

R

.

2

•

kg, 2.9 ft

T

16 Nm (1.6 m

.

R

.

T

13 Nm (1.3 m

.

R

.

4

•

Ib)

•

kg, 11 ft

•

Ib)

•

kg, 9.4 ft

•

Ib)

1

T

13 Nm (1.3 m

.

R

.

•

kg, 9.4 ft

•

Ib)

3

5

(4)

T

16 Nm (1.6 m

.

R

.

•

kg, 11 ft

•

Ib)

LT

T

7 Nm (0.7 m

.

R

.

Order Job/Part Q’ty Remarks

Removing the seat, front panel, foot

Remove the parts in the order listed.

protectors and engine skid plate

1 Seat 1

NOTE:

_

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

2 Front panel 1
3 Left foot protector 1
4 Right foot protector 1
5 Engine skid plate 1

For installation, reverse the removal pro­cedure.

•

kg, 5.1 ft

•

Ib)

3 - 3

EBS00036

SEAT, FENDERS AND FUEL TANK

CHK

ADJ

T

10 Nm (1.0 m

.

R

.

T

7 Nm (0.7 m

.

R

.

•

kg, 7.2 ft

•

kg, 5.1 ft

3

•

Ib)

•

Ib)

4

T

7 Nm (0.7 m

.

R

.

•

kg, 5.1 ft

•

Ib)

5

6

T

10 Nm (1.0 m

.

R

.

T

7 Nm (0.7 m

.

R

.

•

kg, 7.2 ft

•

kg, 5.1 ft

•

Ib)

•

Ib)

1

2

T

7 Nm (0.7 m

.

R

.

•

kg, 5.1 ft

•

Ib)

1

T

7 Nm (0.7 m

.

R

.

Order Job/Part Q’ty Remarks

Removing the headlights and front

Remove the parts in the order listed.

fender

Seat/front panel Refer to “SEAT, FENDERS AND FUEL

TANK”.
1 Headlight coupler 2 Disconnect.
2 Left headlight 1
3 Right headlight 1
4 Fuel tank top panel 1
5 Indicator light assembly coupler 1 Disconnect.
6 Front fender 1

For installation, reverse the removal pro-

cedure.

•

kg, 5.1 ft

•

Ib)

3 - 4

EBS00039

SEAT, FENDERS AND FUEL TANK

CHK

ADJ

T

.

R

.

2

3

4

7 Nm (0.7 m

3

T

7 Nm (0.7 m

.

R

.

•

kg, 5.1 ft

•

Ib)

•

kg, 5.1 ft

•

Ib)

10

12

8

T

9 Nm (0.9 m

.

R

.

6

(4)

•

kg, 6.5 ft

9

7

•

11

Ib)

1

5

T

4 Nm (0.4 m

.

R

T

7 Nm (0.7 m

.

R

.

•

kg, 5.1 ft

•

Ib)

.

Order Job/Part Q’ty Remarks

Removing the rear fender

Seat/front panel/fuel tank top panel/
front fender

Remove the parts in the order listed.

Refer to “SEAT, FENDERS AND FUEL

TANK”.
1 Air filter case cover 1
2 Battery holding bracket 1
3 Battery lead 2 Disconnect.

CAUTION:

_

First disconnect the negative lead,

then disconnect the positive lead.

4 Battery 1
5ECU 1
6 Intake air temperature sensor coupler 1

•

kg, 2.9 ft

•

Ib)

3 - 5

SEAT, FENDERS AND FUEL TANK

CHK

ADJ

T

.

R

.

2

3

4

7 Nm (0.7 m

3

T

7 Nm (0.7 m

.

R

.

•

kg, 5.1 ft

•

Ib)

•

kg, 5.1 ft

•

Ib)

10

12

8

T

9 Nm (0.9 m

.

R

.

6

(4)

•

kg, 6.5 ft

9

7

•

11

Ib)

1

5

T

4 Nm (0.4 m

.

R

T

7 Nm (0.7 m

.

R

.

•

kg, 5.1 ft

•

Ib)

.

Order Job/Part Q’ty Remarks

7 Hose (throttle-body-joint-to-throttle-

1

body-left side)

8 Hose (throttle-body-joint-to-throttle-

1

body-right side)

9 Crankcase breather hose 1

10 Clamp (throttle body joint) 1 Loosen
11 Air filter case 1
12 Rear fender 1

For installation, reverse the removal pro-

cedure.

•

kg, 2.9 ft

•

Ib)

3 - 6

EBS00042

SEAT, FENDERS AND FUEL TANK

CHK

ADJ

T

7 Nm (0.7 m

.

R

.

T

7 Nm (0.7 m

.

R

.

•

•

kg, 5.1 ft

kg, 5.1 ft

•

Ib)

4

•

Ib)

(6)

New

1

7

2

3

T

7 Nm (0.7 m

.

R

.

•

kg, 5.1 ft

•

Ib)

6

5

Order Job/Part Q’ty Remarks

Removing the fuel tank

Seat/front panel/fuel tank top panel/
front fender

Remove the parts in the order listed.

Refer to “SEAT, FENDERS AND FUEL

TANK”.
1 Fuel pump coupler 1 Disconnect.
2 Fuel hose connector holder 1 Refer to “REMOVING THE FUEL TANK”
3 Fuel hose 1
4 Fuel tank 1

and “INSTALLING THE FUEL HOSE”.

NOTE:

_

When installing the fuel tank, pass the

fuel tank breather hose through the hole

in the handlebar cover, and then insert

the end of the hose into the steering

stem.

5 Drain hose 1
6 Fuel tank shield 1

3 - 7

SEAT, FENDERS AND FUEL TANK

CHK

ADJ

T

7 Nm (0.7 m

.

R

.

T

7 Nm (0.7 m

.

R

.

•

•

kg, 5.1 ft

kg, 5.1 ft

•

Ib)

4

•

Ib)

(6)

New

1

7

2

3

T

7 Nm (0.7 m

.

R

.

•

kg, 5.1 ft

•

Ib)

6

5

Order Job/Part Q’ty Remarks

7 Fuel pump 1 Refer to “REMOVING THE FUEL PUMP”

and “INSTALLING THE FUEL PUMP”.

For installation, reverse the removal pro-

cedure.

3 - 8

a

2

1

SEAT, FENDERS AND FUEL TANK

REMOVING THE FUEL TANK

1

3

1. Extract the fuel in the fuel tank through the
fuel tank cap with a pump.

2. Remove:

• fuel hose connector holder

• fuel hose

CAUTION:

• Be sure to disconnect the fuel hose by

hand. Do not forcefully disconnect the
hose with tools.

• Although the fuel has been removed from

the fuel tank be careful when removing
the fuel hose, since there may be fuel
remaining in it.

NOTE:

• When removing the fuel hose from the fuel

pump, remove the fuel hose connector
holder first, and next, insert a slotted head
screwdriver etc. in the slot part a of the fuel
hose connector cover 1, then slide the
screwdriver in the direction of the arrow, and
remove the fuel hose.

• To remove the fuel hose from the throttle

body, slide the fuel hose connector cover 2
on the end of the hose in direction of the
arrow shown, press the two buttons 3 on the
sides of the connector, and then remove the
hose.

• Before removing the hose, place a few rags

in the area under where it will be removed.

CHK

ADJ

3. Remove:

• fuel tank

NOTE:

Do not set the fuel tank down on the installa­tion surface of the fuel pump. Be sure to lean
the fuel tank against a wall or like.

REMOVING THE FUEL PUMP

1. Remove:

• fuel pump bracket

• fuel pump

• fuel pump gasket

3 - 9

SEAT, FENDERS AND FUEL TANK

CAUTION:

• Do not drop the fuel pump or give it a

strong shock.

• Do not touch the base section of the fuel

sender.

CHK

ADJ

a

6

4

a

1

INSTALLING THE FUEL PUMP

1. Install:

• fuel pump gasket

• fuel pump

New

T

7 Nm (0.7 m · kg, 5.1 ft · lb)

.

R

.

• fuel pump bracket

NOTE:

2

5

3

• Do not damage the installation surface of the

fuel tank when installing the fuel pump.

• Always use a new fuel pump gasket.

• Install the fuel pump bracket by aligning the

projection a on the fuel pump with the pro­jection on the fuel tank.

• Tighten the bolts to the specified torque in

the proper tightening sequence as shown.

• Install the fuel pump in the direction shown in

the illustration.

INSTALLING THE FUEL HOSE

11

1. Install:

• fuel hose

• fuel hose holder

• fuel pump coupler

3 - 10

CAUTION:

When installing the fuel hose, make sure
that it is securely connected, and that the
fuel hose holder is in the correct position,
otherwise the fuel hose will not be properly
installed.

NOTE:

Install the fuel hose connector cover 1
securely onto the fuel tank until a distinct
“click” is heard, and then make sure that it
does not come loose.

ADJUSTING THE VALVE CLEARANCE

EAS00049

ENGINE

ADJUSTING THE VALVE CLEARANCE

The following procedure applies to all of the
valves.

NOTE:

• Valve clearance adjustment should be made

on a cold engine, at room temperature.

• When the valve clearance is to be measured

or adjusted, the piston must be at top dead
center (TDC) on the compression stroke.

1. Remove:

• seat

• front fender

• fuel tank

Refer to “SEAT, FENDERS AND FUEL
TANK”.

CHK

ADJ

2

1

1

2

2. Remove:

• intake tappet cover

• exhaust tappet cover

• camshaft sprocket cover

3. Disconnect:

• spark plug cap

4. Remove:

• spark plug

5. Remove:

• timing mark accessing screw

• crankshaft end accessing screw

1

2

1

2

1

2

2

1

3 - 11

ADJUSTING THE VALVE CLEARANCE

6. Measure:

• valve clearance

a

Out of specification → Adjust.

CHK

ADJ

d

c

b

Valve clearance (cold)

Intake valve

0.09 ~ 0.13 mm
(0.0035 ~ 0.0051 in)

Exhaust valve

0.16 ~ 0.20 mm
(0.0063 ~ 0.0079 in)

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

a. Turn the crankshaft counterclockwise.
b. When the piston is at the top dead center

(TDC) on the compression stroke, align the
“I” mark a on the A.C. magneto rotor with
the stationary pointer b on the A.C. mag­neto cover.

NOTE:

To position the piston at top dead center (TDC)
on the compression stroke, align the “I” mark
c on the camshaft sprocket with the stationary
pointer d on the cylinder head, as shown in
the illustration.

4

1

2

1

3

c. Measure the valve clearance with a thick-

ness gauge 1.

Thickness gauge

90890-03079

Narrow gauge set

YM-34483

Out of specification → Adjust.

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

7. Adjust:

• valve clearance

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

a. Loosen the locknut 1.
b. Insert a thickness gauge 2 between the

end of the adjusting screw and the valve tip.

c. Turn the adjusting screw 3 with the tappet

adjusting tool 4 until the specified valve
clearance is obtained.

Tappet adjusting tool

90890-01311

Valve adjuster (3 mm & 4 mm)

YM-08035-A

3 - 12

1

New

ADJUSTING THE VALVE CLEARANCE/

ADJUSTING THE ENGINE IDLING SPEED

d. Hold the adjusting screw to prevent it from

moving and tighten the locknut to the speci­fied torque.

Locknut

14 Nm (1.4 m · kg, 10 ft · lb)

T

.

R

.

e. Measure the valve clearance again.
f. If the valve clearance is still out of specifica-

tion, repeat all of the valve clearance adjust­ment steps until the specified clearance is
obtained.

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

8. Install:

• timing mark accessing screw

T

6 Nm (0.6 m · kg, 4.3 ft · lb)

.

R

.

• crankshaft end accessing screw

T

10 Nm (1.0 m · kg, 7.2 ft · lb)

.

R

.

9. Install:

• spark plug

10.Connect:

• spark plug cap

11.Install:

• O-ring

New

• camshaft sprocket cover

• O-ring 1

• intake tappet cover

• O-ring

New

• exhaust tappet cover

12.Install:

• fuel tank

• front fender

• seat

Refer to “SEAT, FENDERS AND FUEL
TANK”.

New

T

13 Nm (1.3 m · kg, 9.4 ft · lb)

.

R

.

T

10 Nm (1.0 m · kg, 7.2 ft · lb)

.

R

.

T

10 Nm (1.0 m · kg, 7.2 ft · lb)

.

R

.

T

10 Nm (1.0 m · kg, 7.2 ft · lb)

.

R

.

CHK

ADJ

3 - 13

EBS00051

ADJUSTING THE ENGINE IDLING SPEED

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

2. Attach:

• tachometer
(to the spark plug lead)

Digital tachometer

90890-06760, YU-39951-B

ADJUSTING THE ENGINE IDLING SPEED/

ADJUSTING THE THROTTLE LEVER FREE PLAY

3. Measure:

• idling speed
Out of specification → Adjust.

Engine idling speed

1,500 ~ 1,700 r/min

4. Adjust:

• engine idling speed

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

a. Turn the throttle stop screw 1 in direction

a or b until the specified idling speed is
obtained.

CHK

ADJ

b

a

1

Direction

Direction

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

5. Detach:

• tachometer

6. Adjust:

• throttle lever free play
Refer to “ADJUSTING THE THROTTLE
LEVER FREE PLAY”.

EBS00052

ADJUSTING THE THROTTLE LEVER FREE
PLAY

NOTE:

_

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

a

b

Throttle lever free play

2 ~ 4 mm (0.08 ~ 0.16 in)

Idling speed becomes
higher.

Idling speed becomes
lower.

a

1. Measure:

• throttle lever free play a
Out of specification → Adjust.

Throttle lever free play

2 ~ 4 mm (0.08 ~ 0.16 in)

3 - 14

ADJUSTING THE THROTTLE LEVER FREE PLAY/

ADJUSTING THE SPEED LIMITER

CHK

ADJ

1

d

b

3

a

2

2. Adjust:

• throttle lever free play

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

First step:

a. Slide back the rubber cover 1.
b. Loosen the locknut 2 on the throttle body

side.

c. Turn the adjusting nut 3 in direction a or

b until the correct free play is obtained.

Direction

Direction

a

b

Free play is increased.

Free play is decreased.

d. Tighten the locknut.
e. Slide the rubber cover to its original posi-

tion.

NOTE:

_

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

Second step:

f. Slide back the rubber cover 4.
g. Loosen the locknut 5.
h. Turn the adjusting bolt 6 in direction c or

d until the correct free play is obtained.

4

c

6

5

Direction c Free play is increased.

Direction d Free play is decreased.

i. Tighten the locknut.
j. Slide the rubber cover to its original posi-

tion.

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.

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

EBS00053

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 adjusting screw stops the
engine speed from increasing.

1. Measure:

• speed limiter length a
Out of specification → Adjust.

3 - 15

Speed limiter length

Less than 12 mm (0.47 in)

ADJUSTING THE SPEED LIMITER/

CHECKING THE SPARK PLUG

2. Adjust:

• speed limiter length

▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼ ▼▼▼▼ ▼▼▼

a. Loosen the locknut 1.
b. Turn the adjusting screw 2 in or out until

the specified speed limiter length is
obtained.

CHK

ADJ

Turning in

Turning out

c. Tighten the locknut.

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 adjusting screw more than
12 mm (0.47 in). Also, always adjust the
throttle lever free play to 2 ~ 4 mm (0.08 ~

0.16 in).

▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲ ▲▲▲▲ ▲▲▲

Speed limiter length is
decreased.

Speed limiter length is
increased.

3 - 16

EBS00057

CHECKING THE SPARK PLUG

1. Remove:

• spark plug

2. Check:

• spark plug type
Incorrect → Change.

Standard spark plug

CR8E/NGK

3. Check:

• electrode 1
Wear/damage → Replace.

• insulator 2
Abnormal color → Replace.
Normal color is a medium-to-light tan color.

4. Clean:

• spark plug
(with a spark plug cleaner or wire brush)