Yamaha YFM90RA User Manual

2011

SERVICE MANUAL

YFM90RA

43D-F8197-12LIT-11616-24-16

EBS00001

YFM90RA

SERVICE MANUAL

First edition, July 2010

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-11616-24-16

EBS00002

IMPORTANT

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

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

TIP

Designs and specifications are subject to change without notice.

EBS00003

IMPORTANT INFORMATION

Particularlyimportant information is distinguished in this manual by the following notations:

This is the safety alert symbol. It is used to alert you to potential

personal injury hazards. Obey all safety messages that follow this

symbol to avoid possible injury or death.

WARNING

NOTICE

TIP

* Product and specifications are subject to change withoutnotice.

A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property.

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

EBS00004

HOW TO USE THIS MANUAL

MANUAL ORGANIZATION

This manual consists of chapters for the main categories of subjects. (See “symbols”) 1st title : This is the title of the chapter with its symbol in the upper right corner of each page. 2nd title : 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 : 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 is provided for removal and disassembly jobs.

2. Numbers 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

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

4. A job instruction chart 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 are given in addition to the exploded diagram and the job instruction chart.

EAS00338

KICKSTARTER

Removing the kickstarter

Crankcase, cover Kick pinion gear clip

Kick pinion gear

Washer

Circlip

Washer

Kick shaft assembly

Torsion spring

Spacer

Solid bush

BELT DRIVE

Remove the parts in the order listed. Refer to “CRANKCASE COVER “.

Refer to “INSTALLING THE KICKSTARTER“.

1 1 1 1 1 1 1 1 1

For installation, reverse the removal procedure.

4 - 32

ENG

New

RemarksOrder Job/Part Q’ty

BELT DRIVE

EAS00340

INSTALLING THE KICKSTARTER

1. Install: solid bush kickstarter shaft kickstarter spring

2. Hook: kickstarter spring

TIP

Hook the spring end on the kickstarter shaft

as shown, and hook the other end on the

projection .

3. Install: plain washer circlip

4. Install: kick pinion gear kick pinion gear clip

TIP

Install the clip at the position shown.

4 - 33

ENG

New

GEN

INFO

CHK

ADJ

CARB

SPEC

ENG

CHAS

EBS00005

SYMBOLS

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

General information Specifications Periodic checks and adjustments Engine Carburetor Chassis Electrical Troubleshooting

ELEC

– +

TRBL

SHTG

Symbols to indicate the following.

Serviceable with engine mounted Filling fluid Lubricant Special tool Torque Wear limit, clearance Engine speed Electrical data (Ω, V, A)

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

Apply engine oil Apply gear oil Apply molybdenum disulfide oil Apply wheel bearing grease Apply lithium-soap-based grease Apply molybdenum disulfide grease

New

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

Apply the locking agent (LOCTITE Replace

)

EBS00007

TABLE OF CONTENTS

GENERAL INFORMATION

SPECIFICATIONS

PERIODIC CHECKS AND ADJUSTMENTS

ENGINE

GEN

INFO

SPEC

CHK

ADJ

ENG

1 2 3 4

CARBURETOR

CHASSIS

ELECTRICAL

TROUBLESHOOTING

CARB

CHAS

– +

ELEC

TRBL SHTG

5 6

7 8

CONTENTS

CHAPTER 1

GENERAL INFORMATION

MACHINE IDENTIFICATION

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

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

IMPORTANT INFORMATION

PREPARATION FOR REMOVAL AND DISASSEMBLY...........................1-2

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

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

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

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

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

CHECKING THE CONNECTIONS............................................................1-4

SPECIAL TOOLS

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

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

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

CHAPTER 2

SPECIFICATIONS

GENERAL SPECIFICATIONS

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

ENGINE SPECIFICATIONS

CHASSIS SPECIFICATIONS

ELECTRICAL SPECIFICATIONS

TIGHTENING TORQUES

ENGINE TIGHTENING TORQUES.........................................................2-15

CHASSIS TIGHTENING TORQUES.......................................................2-16

HOW TO USE THE CONVERSION TABLE

GENERAL TIGHTENING TORQUE SPECIFICATIONS

LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE...................................................................................................2-19

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

........................................................................2-11

.................................................................2-13

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

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

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

....................................2-19

OIL FLOW DIAGRAMS.................................................................................2-21

CABLE ROUTING.........................................................................................2-22

CHAPTER 3

PERIODIC CHECKS AND ADJUSTMENTS

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

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

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

SEAT AND FRONT PANEL ......................................................................3-3

FRONT FENDER ......................................................................................3-4

REAR FENDER AND FOOTREST BOARDS ...........................................3-5

FUEL TANK...............................................................................................3-7

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

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

ADJUSTING THE ENGINE IDLING SPEED...........................................3-10

ADJUSTING THE THROTTLE LEVER FREE PLAY ..............................3-11

ADJUSTING THE SPEED LIMITER........................................................3-12

CHECKING THE SPARK PLUG .............................................................3-13

CHECKING THE IGNITION TIMING.......................................................3-14

MEASURING THE COMPRESSION PRESSURE..................................3-15

CHECKING THE ENGINE OIL LEVEL....................................................3-17

CHANGING THE ENGINE OIL ...............................................................3-18

CLEANING THE AIR FILTER ELEMENT................................................3-19

CLEANING THE SPARK ARRESTER....................................................3-20

CHASSIS.......................................................................................................3-22

CHECKING THE FRONT BRAKE SHOES..............................................3-22

ADJUSTING THE FRONT BRAKE..........................................................3-22

ADJUSTING THE PARKING BRAKE.......................................................3-23

CHECKING THE REAR BRAKE FLUID LEVEL......................................3-24

CHECKING THE REAR BRAKE PADS...................................................3-25

CHECKING THE BRAKE HOSE..............................................................3-25

BLEEDING THE HYDRAULIC BRAKE SYSTEM....................................3-25

CHANGING THE FINAL TRANSMISSION OIL.......................................3-27

ADJUSTING THE DRIVE CHAIN SLACK................................................3-27

CHECKING THE STEERING SYSTEM...................................................3-29

ADJUSTING THE TOE-IN.......................................................................3-30

CHECKING THE FRONT AND REAR SHOCK ABSORBERS...............3-31

ADJUSTING THE SHOCK ABSORBERS...............................................3-32

CHECKING THE TIRES..........................................................................3-33

CHECKING THE WHEELS.....................................................................3-35

CHECKING AND LUBRICATING THE CABLES ....................................3-36

LUBRICATING THE LEVERS, STEERING SHAFT

AND STEERING KNUCKLES ................................................................3-36

ELECTRICAL SYSTEM.................................................................................3-37

CHECKING AND CHARGING THE BATTERY.......................................3-37

CHECKING THE FUSES.........................................................................3-44

CHAPTER 4

ENGINE

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

EXHAUST PIPE/MUFFLER, BREATHER HOSE AND LEADS................4-1

ENGINE MOUNTING BOLTS ...................................................................4-2

REMOVING THE ENGINE........................................................................4-3

INSTALLING THE ENGINE.......................................................................4-3

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

REMOVING THE CYLINDER HEAD.........................................................4-6

CHECKING THE CAMSHAFT SPROCKET..............................................4-7

CHECKING THE CYL. HEAD COVER ASSY............................................4-7

CHECKING THE TIMING CHAIN GUIDES...............................................4-7

CHECKING THE TIMING CHAIN TENSIONER ASSEMBLY...................4-7

CHECKING THE CYLINDER HEAD.........................................................4-8

INSTALLING THE CYLINDER HEAD.......................................................4-9

CAMSHAFT, ROCKER ARMS AND VALVES..............................................4-11

REMOVING THE ROCKER ARMS AND CAMSHAFT............................4-12

REMOVING THE VALVES AND VALVE SPRINGS ...............................4-12

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

CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........4-13

CHECKING THE VALVES AND VALVE SPRINGS................................4-15

INSTALLING THE VALVES AND VALVE SPRINGS..............................4-19

INSTALLING THE CAMSHAFT AND ROCKER ARMS..........................4-20

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

REMOVING THE PISTON ......................................................................4-22

CHECKING THE CYLINDER AND PISTON...........................................4-22

CHECKING THE PISTON RINGS...........................................................4-24

CHECKING THE PISTON PIN................................................................4-25

INSTALLING THE PISTON.....................................................................4-26

INSTALLING THE CYLINDER................................................................4-27

C.D.I. MAGNETO...........................................................................................4-28

REMOVING THE C.D.I. MAGNETO ROTOR .........................................4-29

CHECKING THE PICKUP COIL/STATOR ASSEMBLY..........................4-29

INSTALLING STATOR COIL ASSEMBLY ............................................4-30

INSTALLING THE C.D.I. MAGNETO ROTOR........................................4-30

BELT DRIVE ................................................................................................4-31

CRANKCASE COVER.............................................................................4-31

KICKSTARTER........................................................................................4-32

INSTALLING THE KICKSTARTER..........................................................4-33

V-BELT, CLUTCH, PRIMARY AND SECONDARY SHEAVE..................4-34

DISASSEMBLING THE SECONDARY SHEAVE....................................4-35

REMOVING THE PRIMARY SHEAVE....................................................4-36

REMOVING THE SECONDARY SHEAVE AND V-BELT........................4-36

DISASSEMBLING THE SECONDARY SHEAVE....................................4-37

CHECKING THE CLUTCH SHOE...........................................................4-37

CHECKING THE V-BELT........................................................................4-38

CHECKING THE PRIMARY SHEAVE.....................................................4-38

CHECKING THE PRIMARY SHEAVE WEIGHTS...................................4-38

CHECKING THE SLIDER........................................................................4-39

CHECKING THE SECONDARY SHEAVE..............................................4-39

ASSEMBLING THE PRIMARY SHEAVE................................................4-40

ASSEMBLING THE SECONDARY SHEAVE..........................................4-41

INSTALLING THE BELT DRIVE..............................................................4-42

STARTER CLUTCH AND STARTER MOTOR ............................................4-44

CHECKING THE STARTER WHEEL GEAR...........................................4-45

OIL PUMP .....................................................................................................4-46

CHECKING THE OIL PUMP....................................................................4-47

INSTALLING THE OIL PUMP..................................................................4-48

CRANKCASE AND CRANKSHAFT ............................................................4-49

SEPARATING THE CRANKCASE..........................................................4-50

REMOVING THE CRANKSHAFT ASSEMBLY........................................4-51

CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDES...........4-51

CHECKING THE CRANKSHAFT AND CONNECTING ROD..................4-52

INSTALLING THE CRANKSHAFT..........................................................4-53

ASSEMBLING THE CRANKCASE..........................................................4-54

TRANSMISSION ..........................................................................................4-55

CHECKING THE TRANSMISSION.........................................................4-56

CHAPTER 5

CARBURETOR

DISASSEMBLING THE CARBURETOR...................................................5-4

CHECKING THE CARBURETOR.............................................................5-4

ASSEMBLING THE CARBURETOR.........................................................5-6

INSTALLING THE CARBURETOR...........................................................5-7

MEASURING AND ADJUSTING THE FUEL LEVEL................................5-8

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

CHAPTER 6

CHASSIS

FRONT AND REAR WHEELS

FRONT WHEELS......................................................................................6-1

REAR WHEELS ........................................................................................6-2

CHECKING THE WHEELS.......................................................................6-3

CHECKING THE FRONT WHEEL HUBS.................................................6-3

CHECKING THE REAR WHEEL HUBS....................................................6-4

INSTALLING THE WHEEL HUBS.............................................................6-4

INSTALLING THE FRONT WHEELS........................................................6-5

INSTALLING THE REAR WHEELS..........................................................6-5

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

FRONT BRAKES ............................................................................................6-6

FRONT BRAKES......................................................................................6-6

REMOVING THE FRONT BRAKES .........................................................6-7

CHECKING THE FRONT BRAKE SHOE PLATES..................................6-7

CHECKING THE FRONT BRAKE SHOES................................................6-7

CHECKING THE FRONT BRAKE DRUMS...............................................6-8

INSTALLING THE FRONT BRAKES ........................................................6-9

...........................................................6-11

REAR AXLE AND REAR AXLE HUB

REAR AXLE AND REAR AXLE HUB......................................................6-11

REMOVING THE REAR AXLE...............................................................6-13

CHECKING THE REAR AXLE...............................................................6-14

CHECKING THE DRIVEN SPROCKET..................................................6-14

CHECKING THE BRAKE DISC................................................................6-14

INSTALLING THE DRIVEN SPROCKET.................................................6-14

INSTALLING THE REAR AXLE...............................................................6-15

REAR BRAKES ............................................................................................6-16

REAR BRAKE PADS...............................................................................6-16

REPLACING THE REAR BRAKE PADS.................................................6-17

REAR BRAKE MASTER CYLINDER......................................................6-19

CHECKING THE MASTER CYLINDER...................................................6-20

ASSEMBLING THE REAR BRAKE MASTER CYLINDER......................6-20

INSTALLING THE REAR BRAKE MASTER CYLINDER.........................6-21

REAR BRAKE CALIPER..........................................................................6-23

REMOVING THE PARKING BRAKE CABLE..........................................6-25

CHECKING THE REAR BRAKE CALIPER.............................................6-25

INSTALLING THE REAR BRAKE CALIPER............................................6-26

STEERING SYSTEM.....................................................................................6-28

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

REMOVING THE HANDLEBAR GRIPS..................................................6-30

REMOVING THE REAR BRAKE SWITCH .............................................6-30

CHECKING THE HANDLEBAR ..............................................................6-30

INSTALLING THE HANDLEBAR ............................................................6-31

INSTALLING THE HANDLEBAR GRIPS................................................6-31

INSTALLING THE REAR BRAKE MASTER CYLINDER........................6-32

INSTALLING THE FRONT BRAKE LEVER ASSEMBLY........................6-32

INSTALLING THE PARKING BRAKE LEVER.........................................6-33

STEERING STEM...................................................................................6-34

REMOVING THE STEERING STEM ......................................................6-35

CHECKING THE STEERING STEM.......................................................6-35

INSTALLING THE LOWER HANDLEBAR HOLDER...............................6-36

INSTALLING THE STEERING STEM.....................................................6-36

INSTALLING THE LOCK WASHER........................................................6-36

TIE-RODS AND STEERING KNUCKLES...............................................6-37

REMOVING THE TIE-RODS...................................................................6-38

REMOVING THE STEERING KNUCKLES..............................................6-38

CHECKING THE TIE-RODS...................................................................6-38

CHECKING THE STEERING KNUCKLES..............................................6-38

INSTALLING THE TIE-RODS.................................................................6-39

FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES

FRONT ARMS AND FRONT SHOCK ABSORBER

ASSEMBLIES..........................................................................................6-40

REMOVING THE FRONT ARMS.............................................................6-41

CHECKING THE FRONT ARMS.............................................................6-41

CHECKING THE FRONT SHOCK ABSORBERS...................................6-41

CHECKING THE BALL JOINTS..............................................................6-42

INSTALLING THE FRONT ARMS............................................................6-42

.............6-40

REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN..................6-43

REAR SHOCK ABSORBER, SWINGARM AND DRIVE CHAIN.............6-43

REMOVING THE REAR SHOCK ABSORBER........................................6-45

CHECKING THE REAR SHOCK ABSORBER........................................6-45

REMOVING THE SWINGARM................................................................6-45

CHECKING THE SWINGARM.................................................................6-46

CHECKING THE DRIVE CHAIN..............................................................6-47

INSTALLING THE DRIVE SPROCKET...................................................6-48

INSTALLING THE DRIVE CHAIN............................................................6-48

CHAPTER 7

ELECTRICAL

ELECTRICAL COMPONENTS

CHECKING SWITCH CONTINUITY

CHECKING THE SWITCHES

IGNITION SYSTEM

CIRCUIT DIAGRAM..................................................................................7-4

TROUBLESHOOTING ..............................................................................7-5

ELECTRIC STARTING SYSTEM

CIRCUIT DIAGRAM..................................................................................7-9

STARTING CIRCUIT OPERATION.........................................................7-10

TROUBLESHOOTING ............................................................................7-11

STARTER MOTOR

CHECKING THE STARTER MOTOR.....................................................7-14

ASSEMBLING THE STARTER MOTOR.................................................7-15

CHARGING SYSTEM

CIRCUIT DIAGRAM................................................................................7-16

TROUBLESHOOTING ............................................................................7-17

.........................................................................................7-4

........................................................................................7-13

....................................................................................7-16

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

................................................................7-2

..........................................................................7-3

....................................................................7-9

CHAPTER 8

TROUBLESHOOTING

STARTING FAILURE/HARD STARTING

FUEL SYSTEM..........................................................................................8-1

ELECTRICAL SYSTEM.............................................................................8-1

COMPRESSION SYSTEM........................................................................8-2

POOR IDLE SPEED PERFORMANCE...........................................................8-2

POOR IDLE SPEED PERFORMANCE.....................................................8-2

POOR MEDIUM AND HIGH-SPEED PERFORMANCE..................................8-2

POOR MEDIUM AND HIGH-SPEED PERFORMANCE ...........................8-2

FAULTY CLUTCH ...........................................................................................8-3

ENGINE OPERATES BUT VEHICLE WILL NOT MOVE..........................8-3

POOR STARTING PERFORMANCE........................................................8-3

POOR SPEED PERFORMANCE..............................................................8-3

OVERHEATING...............................................................................................8-3

OVERHEATING ........................................................................................8-3

FAULTY BRAKE.............................................................................................8-4

POOR BRAKING EFFECT........................................................................8-4

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

SHOCK ABSORBER MALFUNCTION...........................................................8-4

MALFUNCTION.........................................................................................8-4

UNSTABLE HANDLING..................................................................................8-4

UNSTABLE HANDLING............................................................................8-4

MACHINE IDENTIFICATION

EBS00009

GENERAL INFORMATION

MACHINE IDENTIFICATION

EBS00010

VEHICLE IDENTIFICATION NUMBER

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

EBS00011

MODEL LABEL

The model label is affixed to the frame. This information will be needed to order spare parts.

GEN

INFO

1 - 1

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 - 2

IMPORTANT INFORMATION

EBS00016

LOCK WASHERS/PLATES AND COTTER PINS

After removal, replace all lock washers/plates

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

GEN

INFO

NOTICE

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

Bearing

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 , make sure the sharp-edged corner is positioned opposite the thrust that the circlip receives.

Shaft

1 - 3

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.

GEN

INFO

3. Check:

• all connections Loose connection → Connect properly.

TIP

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

4. Connect:

• lead

• coupler

• connector

TIP

Make sure all connections are tight.

5. Check:

• continuity (with the pocket tester)

Pocket tester

P/N. YU-03112-C, 90890-03112

TIP

• 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 - 4

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

Bolt

90890-04158

YM-04158

Weight

90890-01084

Set

YU-01083-A

Slide hammer bolt (M5)/weight/set

These tools are used to remove the rocker arm shaft.

INFO

90890-01189

YM-01189

90890-01304

YU-01304

90890-01311

YM-08035

90890-01312

YM-01312-A

Flywheel puller

This tool is needed to remove the rotor. Piston pin puller set

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

This tool is necessary for adjusting the valve clearance.

Fuel level gauge

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

Sheave holder

90890-01701

YS-01880-A

90890-01268

YU-01268

This tool is needed to hold the rotor when

removing or installing the rotor nut.

Ring nut wrench Spanner wrench

This tool is used to adjusting the front and rear shock absorbers.

1 - 5

GEN

SPECIAL TOOLS

Tool No. Tool name/Function Illustration

INFO

Gauge

90890-03081

YU-33223

Adapter

90890-04082

90890-03112

YU-03112-C

90890-03113

YU-8036-B

90890-03141

YM-33277-A

Compression gauge Adapter

These tools are needed to measure engine compression.

Pocket tester

This instrument is needed for checking the electrical system.

Engine tachometer

This tool is needed for observing engine rpm.

Timing light

This tool is necessary for checking ignition timing.

Compressor

90890-04019

YM-04019

Attachment

90890-04108

YM-04108

90890-01235 YU-01235

90890-03079 YM-34483

Bond

90890-85505

Sealant

ACC-11001-05-01

Valve spring compressor Valve spring compressor attachment

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

Rotor holding tool

This tool is used to remove the flywheel magneto.

Thickness gauge

This tool is used to measure the valve cleanance.

Yamaha bond No. 1215 Sealant (Quick Gasket

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

)

1 - 6

SPECIAL TOOLS

INFO

Tool No. Tool name/Function Illustration

Ignition checker

90890-06754

This instrument is necessary for checking the ignition system components.

Dynamic spark tester

YM-34487

This instrument is necessary for checking the ignition system components.

Oil seal guide

90890-01384 YM-33299

90890-01348 YM-01348

This tool is used for protecting the oil seal lip when installing the secondary sliding sheave.

Lock nut wrench

This tool is used for removing the A.C. magneto rotor.

GEN

90890-01337 YM-33285 YM-33285-6

90890-01493

YM-01493

90890-01422

YM-37132

Clutch spring holder

These tool are used for removing the nut with holding the compression spring.

Socket wrench 39 mm

This tool is used when removing or installing the secondary sheave nut.

Axle nut wrench (36mm)

This tool is neededto loosen or tighten the rear axle nut.

1 - 7

GENERAL SPECIFICATIONS

EBS01001

SPECIFICATIONS

GENERAL SPECIFICATIONS

Item Standard

SPEC

Model code

43D7

Dimensions

Overall length 1,490 mm (58.7 in) Overall width 885 mm (34.8 in) Overall height 910 mm (35.8 in) Seat height 654 mm (25.7 in) Wheelbase 1,010 mm (39.8 in) Minimum ground clearance 100 mm (3.9 in) Minimum turning radius 2,900 mm (114in)

Basic weight

With oil and full fuel tank 120 kg (264 lb)

Engine

Engine type Air cooled 4-stroke, SOHC Cylinder arrangement Single cylinder Displacement 88.0 cm (5.37 cu.in)

Bore

47.0 × 51.0 mm (1.85 × 2.01 in)stroke

Compression ratio 10.2 : 1 Standard compression pressure (at sea level) 1,250 kPa

(12.5 kg/cm

, 177.8 psi) at 1,000 r/min

Electric starter & kickstarterStarting system

Lubrication system

Wet sump

Oil type or grade

Engine oil

0˚

10˚ 30˚

50˚

70˚

90˚

110˚

130˚F

YAMALUBE 4, SAE5W-30 or SAE10W-40 or SAE20W-50

YAMALUBE 4 (20W-50) or SAE 20W-50

YAMALUBE 4 (10W-40) or SAE 10W-40

SAE 5W-30

-20˚

-10˚ 0˚

10˚

30˚ 40˚ 50˚C

20˚

Final transmission oil SAE 80API “GL-4” Hypoid gear oil

Oil capacity

Engine oil

Periodic oil change 0.75 L (0.66 Imp qt, 0.80 US qt) Total amount 0.80 L (0.70 Imp qt, 0.85 US qt)

Final transmission oil

Total amount 0.30 L (0.27 Imp qt, 0.32 US qt)

Air filter

Wet type element

2 - 1

GENERAL SPECIFICATIONS

Item Standard

Fuel

Type Unleaded gasoline only Fuel tank capacity 4.8 L (1.06 lmp gal, 1.27 US gal)

Fuel reserve amount 1.0 L (0.22 Imp gal, 0.26 US gal)

Carburetor

Type/quantity SVR 22-1G x 1 Manufacturer TK

Spark plug

Type/manufacturer NGK/CR7HSA Spark plug gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in)

Clutch type Dry, centrifugal automatic Transmission

Primary reduction system V-belt Primary reduction ratio 2.47-0.61:1 Secondary reduction system Spur Secondary reduction ratio 41/15 × 45/13 (9.462) Third reduction system Chain drive Third reduction ratio 28/13(2.154) Transmission type V-belt automatic

Chassis

Frame type Steel tube frame Caster angle 4°00’ Camber angle –0°30’ Kingpin angle 18°00’ Trail 16 mm (0.63 in) Tread (STD) front 710 mm (27.95 in)

rear 655 mm (25.79 in)

Toe-in (with tires touching the ground) 15 mm (0.59 in)

Tire

Type Tubeless Size front AT18 × 7-8

rear AT18 × 9-8

Manufacturer front MAXXIS

rear MAXXIS

Type front M939

rear M940

Tire pressure (cold tire)

Maximum load* 70.0 kg (154 lb) Off-road riding front 22 ~ 25 kPa (0.22 ~ 0.25 kgf/cm, 3.2 ~ 3.6 psi)

rear 22 ~ 25 kPa (0.22 ~ 0.25 kgf/cm, 3.2 ~ 3.6 psi) *Load in total weight of rider and accessories

SPEC

2 - 2

GENERAL SPECIFICATIONS

Item Standard

Brake

Front brake type Drum brake

operation Right hand operation Rear brake type Single disc brake

operation Left hand operation

Suspension

Front suspension Double wishbone / Independent Rear suspension Swingarm

Shock absorber

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

Wheel travel

Front wheel travel 111 mm (4.4 in) Rear wheel travel 83 mm (3.3 in)

Electrical

Ignition system AC-CDI Generator system AC magneto Battery type GTX5L-BS Battery capacity 12 V 4.0 Ah

SPEC

2 - 3

ENGINE SPECIFICATIONS

EBS01002

SPEC

ENGINE SPECIFICATIONS

Item Standard Limit

Cylinder head

Warp limit 0.05 mm

Cylinder

Bore size 47.000 ~ 47.010 mm

Taper limit ---- 0.05 mm

Maximum out-of-round ---- 0.01 mm

Camshaft

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

7.00 ~ 7.40 cm (0.43 ~ 0.45 cu.in)

(1.8504 ~ 1.8508 in)

(0.002 in)

47.10 mm (1.8543 in)

(0.002 in)

(0.0004 in)

Intake “A” 25.683 ~ 25.843 mm

(1.0111 ~ 1.0174 in)

“B” 20.985 ~ 21.015 mm

(0.8262 ~ 0.8274 in)

Exhaust “A” 25.525 ~ 25.685 mm

(1.0049 ~ 1.0112 in)

“B” 20.985 ~ 21.015 mm

(0.8262 ~ 0.8274 in)

Camshaft runout limit ---- 0.03 mm

Timing chain

Timing chain type/No. of links KMC 92 RH 2005 / 86 ---Timing chain adjustment method Automatic ----

25.583 mm (1.0072 in)

20.886 mm (0.8223 in)

25.425 mm (1.0010 in)

20.886 mm (0.8223 in)

(0.0012 in)

2 - 4

ENGINE SPECIFICATIONS

Item Standard Limit

Rocker arm/rocker arm shaft

Rocker arm inside diameter 10.000 ~ 10.015 mm

(0.3937 ~ 0.3943 in)

Rocker arm shaft outside diameter 9.972 ~ 9.987 mm

(0.3926 ~ 0.3932 in)

Rocker-arm-to-rocker-arm-shaft clearance 0.013 ~ 0.043 mm

(0.0005 ~ 0.0017 in)

Valve, valve seat, valve guide

Valve clearance (cold) IN 0.07 ~ 0.10 mm

(0.0027 ~ 0.0039 in)

EX 0.07 ~ 0.10 mm

(0.0027 ~ 0.0039 in)

Valve dimensions

SPEC

10.100 mm (0.3976 in)

9.910 mm (0.3902 in)

----

Head Diameter Face Width Seat Width Margin Thickness

“A” head diameter ----

“B” face width ----

“C” seat width

“D” margin thickness

Stem outside diameter

Guide inside diameter

IN 20.9 ~ 21.1 mm

(0.8228~ 0.8307 in)

EX 18.9 ~ 19.1 mm

(0.7441~ 0.7520 in)

IN 1.50 ~ 1.80 mm

(0.0591~ 0.07.9 in)

EX 1.50 ~ 1.80 mm

(0.0591~ 0.0709 in)

IN 0.8 ~ 1.1 mm

(0.0315 ~ 0.0433 in)

EX 0.8 ~ 1.1 mm

(0.0315 ~ 0.0433 in)

IN 0.5 ~ 0.9 mm

(0.0197 ~ 0.0354 in)

EX 0.6 ~ 1.0 mm

(0.0236 ~ 0.0394 in)

IN 4.975 ~ 4.990 mm

(0.1959 ~ 0.1965 in)

EX 4.955 ~ 4.970 mm

(0.1951~ 0.1957 in)

IN 5.000 ~ 5.012 mm

(0.1969 ~ 0.1973 in)

EX 5.000 ~ 5.012 mm

(0.1969 ~ 0.1973 in)

1.6 mm (0.0630 in)

4.900 mm (0.1930 in)

5.030 mm (0.1980 in)

----

2 - 5

ENGINE SPECIFICATIONS

Item Standard Limit

SPEC

Stem-to-guide clearance IN 0.010 ~ 0.037 mm

(0.0004 ~ 0.0015 in)

EX 0.025 ~ 0.052 mm

(0.0010 ~ 0.0020 in)

Stem runout limit ---- 0.02 mm

Valve seat width IN 0.8 ~ 1.1 mm

(0.0315 ~ 0.0433 in)

EX 0.8 ~ 1.1 mm

(0.0315 ~ 0.0433 in)

Valve spring

Inner spring

Free length IN 30.00 mm (1.18 in) 27.00 mm

EX 30.00 mm (1.18 in) 27.00 mm

Compressed pressure (installed) IN 39.14 ~ 47.77 N at 22.45 mm

(3.99 ~ 4.87 kg,

8.80 ~ 10.74 lb at 0.898 in)

EX 39.14 ~ 47.77 N at 22.45 mm

(3.99 ~ 4.87 kg,

8.80 ~ 10.74 lb at 0.898 in)

Tilt limit IN

0.08 mm (0.0031 in)

0.10 mm (0.0039 in)

(0.0008 in)

1.6 mm (0.0630 in)

(1.06 in)

°/1.1 mm

2.0 (2.0°/0.04 in)

°/1.1 mm

2.0 (2.0°/0.04 in)

----

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

EX Counterclockwise ----

Outer spring

Free length

IN 33.50 mm (1.32 in) 30.50 mm

(1.20 in)

EX 33.50 mm (1.32in) 30.50 mm

(1.20 in)

2 - 6

ENGINE SPECIFICATIONS

SPEC

LimitStandardItem

Compressed pressure

installed)

Tilt limit

Direction of winding

Piston

Piston to cylinder clearance 0.010 ~ 0.040 mm

Piston size “D”

IN(top view)

73.87 ~ 90.06 N at 25.45 mm

7.52 ~ 9.18 kg,

16.59 ~ 20.24 lb at 1.00 in)

73.87 ~ 90.06 N at 25.45 mm

7.52 ~ 9.18 kg,

16.59 ~ 20.24 lb at 1.00 in)

Counterclockwise

46.970 ~ 46.990 mm (1.8492 ~ 1.8500 in)

----

2.0

°/1.2 mm

(

2.0

°/0.05 in)

2.0°/1.2 mm

(

2.0

°/0.05 in)

----Counterclockwise

----EX

0.10 mm (0.0039 in)(0.0004 ~ 0.0016 in)

Measuring point “H” Piston off-set

Piston pin bore inside diameter 13.002 ~ 13.008 mm

Piston pin outside diameter 12.996 ~ 13.000 mm

5.0 mm (0.20 in)

(0.5119 ~ 0.5121 in)

(0.5117 ~ 0.5118 in)

2 - 7

----0.5 mm (0.02 in)

----Intake sidePiston off-set direction

13.040 mm (0.5134 in)

12.960 mm (0.5102 in)

Piston rings

Top ring

ENGINE SPECIFICATIONS

SPEC

LimitStandardItem

Type Dimensions (B × T)

End gap (installed)

Side clearance (installed)

2nd ring

Type Dimensions (B × T)

End gap (installed)

Side clearance

Oil ring

Dimensions (B × T)

End gap (installed)

Crankshaft

Barrel

1.0 × 2.1 mm

----

(0.0394 × 0.0827 in)

0.10 ~ 0.25 mm (0.0039~0.0098in)

0.015 ~0.055 mm (0.0006~0.0022in)

0.45 mm (0.0177in)

0.09 mm (0.0035in)

----Taper

1.0 × 2.0 mm

----

0.0394 × 0.0787 in)

0.25 ~ 0.40 mm

(0.0098~0.0157in)

0.015 ~ 0.055 mm

(0.0006~0.0022in)

2.0 × 1.9 mm

0.55mm (0.0217in)

0.09mm (0.0035in)

----

(0.0787 × 0.0748 in)

0.20 ~ 0.70 mm

----

(0.0079~0.0276in)

Crankwidth 44.10~44.15mm

”

“

(1.7362~1.7382in)

Big end side clearance “D” 0.10~0.30mm

(0.0039~0.0118in)

Big end radial clearance “E” 0.007~0.015mm

(0.0003~0.0006in)

Small end free play “F” 0.80~1.00mm

(0.0315~0.0394in)

2 - 8

----

0.04 mm----Runout limit C1 (0.0016in)

0.04 mm----C2 (0.0016in)

0.50 mm (0.0197in)

----

1.50mm (0.0591in)

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