This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual, so it is assumed that anyone who uses this book to perform maintenance and repairs on
Yamaha machine has a basic understanding of the mechanical ideas and the procedures of
machine repair. Repairs attempted by anyone without this knowledge are likely to render the
machine unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
NOTE:
_
Designs and specifications are subject to change without notice.
EBS00003
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
WARNING
CAUTION:
NOTE:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
Failure to follow WARNING instructions could result in severe injury or death
to
the machine operator, a bystander or a person checking or repairing the
machine.
A CAUTION indicates special precautions that must be taken to avoid damage
to the machine.
A NOTE provides key information to make procedures easier or clearer.
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
CARB
EBS00006
SYMBOLS
The following symbols are not relevant to
every machine.
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
Carburetor
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
Torque
D
Wear limit, clearance
E
Engine speed
F
Electrical data (Ω, V, A)
G
Symbols H to N 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
CARBURETOR
CHASSIS
ELECTRICAL
TROUBLESHOOTING
CARB
CHAS
ELEC
TRBL
SHTG
6
7
8
9
GEN
INFO
1
CHAPTER 1
GENERAL INFORMATION
GEN
INFO
MACHINE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL..........................................................................................1-1
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-2
The vehicle identification number 1 is
stamped into the left side of the frame.
EBS00011
MODEL LABEL
The model label 1 is affixed to the air filter
case cover. This information will be needed to
order spare parts.
GEN
INFO
1 - 1
IMPORTANT INFORMATION
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
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 - 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.
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
P/N. YU-03112-C, 90890-03112
NOTE:
_
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
1 - 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/FunctionIllustration
Crankcase separating tool
90890-01135
YU-01135-A
This tool is used to separate the crankcase.
INFO
Pot
90890-01274
Bolt
90890-01275
YU-90050
Adapter
90890-01278
YM-90063
Spacer
90890-04081
YM-91044
90890-01304
YU-01304
Crankshaft installer pot
Crankshaft installer bolt
These tools are used to install the crankshaft.
Crankshaft installer set
These tools are used to install the crankshaft.
Adapter
Spacer (crankshaft installer)
These tools are used to install the crankshaft.
Piston pin puller
90890-01325
YU-24460-01
This tool is used to remove the piston pin.
Radiator cap tester
This tool is used to check the cooling system.
1 - 5
GEN
SPECIAL TOOLS
Tool No.Tool name/FunctionIllustration
Radiator cap tester adapter
90890-01352
YU-33984
This tool is used to check the cooling system.
Damper rod holder (30 mm)
90890-01327
YM-01327
This tool is needed to loosen and tighten
the steering stem bearing retainer.
Steering nut wrench
90890-01443
YU-33975
This tool is needed to loosen and tighten
the front shock absorber and rear shock
absorber locknuts.
INFO
90890-01474
YM-01474
90890-01480
YM-01480
90890-01701
YS-01880-A
90890-03112
YU-03112-C
Ball joint remover/installer set
These tools are used to removing or
installing the ball joints.
Ball joint remover/installer attachment set
These tools are used to removing or
installing the ball joints.
Sheave holder
This tool is needed to hold the A.C. magneto rotor when loosen or tighten the A.C.
magneto rotor nut.
Pocket tester
This instrument is needed for checking the
electrical system.
90890-03141
YM-33277-A
Timing light
This tool is necessary for checking ignition
timing.
1 - 6
GEN
SPECIAL TOOLS
Tool No.Tool name/FunctionIllustration
INFO
Compressor
90890-04019
YM-04019
Attachment
90890-04114
YM-04114
90890-04086
YM-91042
90890-04097
YM-04097
90890-04116
YM-04116
90890-04098
YM-04098
90890-04117
YM-04117
Valve spring compressor
Valve spring compressor attachment
This tool is needed to remove and install
the valve assemblies.
Universal clutch holder
This tool is needed to hold the clutch carrier when removing or installing the carrier
nut.
Periodic oil change1.75 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 amount1.95 L (1.72 Imp qt, 2.06 US qt)
Radiator capacity (including all routes)
Air filter
Fuel
TypePremium unleaded gasoline only
Fuel tank capacity 10.0 L (2.20 Imp gal, 2.64 US gal)
Fuel reserve amount1.9 L (0.42 Imp gal, 0.50 US gal)
Headlight 12 V 30 W/30 W × 2
Tail/brake light 12 V 5 W/21 W × 1
Indicator and warning lights
Neutral12 V 1.7 W × 1
Coolant temperature12 V 1.7 W × 1
Krypton bulb
2
, 4.4 psi)
2
, 5.0 psi)
SPEC
2 - 3
ENGINE SPECIFICATIONS
EBS01002
SPEC
ENGINE SPECIFICATIONS
ItemStandardLimit
Cylinder head
Warp limit----0.05 mm
(0.002 in)
Cylinder
Bore size95.00 ~ 95.01 mm (3.7402 ~ 3.7406 in)----
Camshaft
Drive methodChain drive (Left)
Camshaft cap inside diameter22.000 ~ 22.021 mm (0.8661 ~ 0.8670 in)---Camshaft journal diameter21.967 ~ 21.980 mm (0.8648 ~ 0.8654 in)---Camshaft-journal-to-camshaft-cap
clearance
Camshaft lobe dimensions
0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in)0.080 mm
(0.0032 in)
A
B
Intake“A”31.200 ~ 31.300 mm (1.2283 ~ 1.2323 in) 31.100 mm
(1.2244 in)
“B”22.550 ~ 22.650 mm (0.8878 ~ 0.8917 in) 22.450 mm
(0.8839 in)
Exhaust“A”30.950 ~ 31.050 mm (1.2185 ~ 1.2224 in) 30.850 mm
(1.2146 in)
“B”22.494 ~ 22.594 mm (0.8856 ~ 0.8895 in) 22.394 mm
(0.8817 in)
Camshaft runout limit----0.03 mm
(0.0012 in)
Timing chain
Timing chain type/No. of links98XRH2010-118M---Timing chain adjustment methodAutomatic----
2 - 4
ENGINE SPECIFICATIONS
ItemStandardLimit
Valve, valve seat, valve guide
Valve clearance (cold)IN0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in)----
EX0.20 ~ 0.25 mm (0.0079 ~ 0.0098 in)----
Valve dimensions
SPEC
B
A
Head DiameterFace WidthSeat WidthMargin Thickness
“A” head diameterIN26.9 ~ 27.1 mm (1.0591 ~ 1.0669 in)----
EX27.9 ~ 28.1 mm (1.0984 ~ 1.1063 in)----
“B” face widthIN2.26 mm (0.0890 in)----
EX2.26 mm (0.0890 in)----
“C” seat widthIN0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)1.6 mm
EX0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)1.6 mm
“D” margin thicknessIN1.0 mm (0.0394 in)0.85 mm
EX1.0 mm (0.0394 in)0.85 mm
Stem outside diameter IN4.475 ~ 4.490 mm (0.1762 ~ 0.1768 in)4.445 mm
EX4.965 ~ 4.980 mm (0.1955 ~ 0.1961 in)4.935 mm
Guide inside diameterIN4.500 ~ 4.512 mm (0.1772 ~ 0.1776 in)4.550 mm
EX5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in)5.050 mm
Stem-to-guide clearance IN0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in)0.080 mm
EX0.020 ~ 0.047 mm (0.0008 ~ 0.0019 in)0.100 mm
Valve stem runout----0.01 mm
Valve seat widthIN0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)1.6 mm
EX0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)1.6 mm
C
D
(0.06 in)
(0.06 in)
(0.033 in)
(0.033 in)
(0.175 in)
(0.194 in)
(0.179 in)
(0.199 in)
(0.003 in)
(0.004 in)
(0.0004 in)
(0.06 in)
(0.06 in)
2 - 5
ENGINE SPECIFICATIONS
ItemStandardLimit
Valve spring
Free lengthIN37.03 mm (1.46 in)35.17 mm
EX37.68 mm (1.48 in)35.79 mm
Set length (valve closed) IN27.87 mm (1.10 in)----
EX27.38 mm (1.08 in)----
Compressed pressure
(installed)IN111.3 ~ 127.9 N
(11.35 ~ 13.04 kg, 25.02 ~ 28.75 lb)
EX127.4 ~ 146.4 N
(12.99 ~ 14.93 kg, 28.64 ~ 32.91 lb)
Tilt limitIN----2.5°/1.61 mm
EX----2.5°/1.65 mm
SPEC
(1.38 in)
(1.41 in)
----
----
(2.5°/0.063 in)
(2.5°/0.065 in)
Direction of winding
(top view)INClockwise----
EXClockwise----
Piston
Piston to cylinder clearance0.040 ~ 0.065 mm (0.0016 ~ 0.0026 in)0.10 mm
(0.004 in)
Piston size “D”94.945 ~ 94.960 mm (3.7380 ~ 3.7386 in)----
H
D
Measuring point “H”10 mm (0.39 in)---Piston off set1.0 mm (0.0394 in)---Offset directionIntake side---Piston pin bore inside diameter20.004 ~ 20.015 mm (0.7876 ~ 0.7880 in) 20.045 mm
(0.789 in)
Piston pin outside diameter19.991 ~ 20.000 mm (0.7870 ~ 0.7874 in) 19.971 mm
(0.786 in)
Piston-pin-to-piston-pin-bore clearance
0.004 ~ 0.024 mm (0.0002 ~ 0.0009 in)0.074 mm
(0.0029 in)
2 - 6
ENGINE SPECIFICATIONS
SPEC
ItemStandardLimit
Piston rings
Top ring
B
T
Type Barrel---Dimensions (B × T)1.2 × 3.5 mm (0.047 × 0.138 in)----
End gap (installed)0.20 ~ 0.30 mm (0.008 ~ 0.012 in)0.55 mm
(0.022 in)
Side clearance 0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in)0.12 mm
(0.0047 in)
2nd ring
B
T
TypeTaper---Dimensions (B × T)1.00 × 3.35 mm (0.039 × 0.132 in)---End gap (installed)0.35 ~ 0.50 mm (0.014 ~ 0.020 in)0.85 mm
(0.034 in)
Side clearance 0.020 ~ 0.055 mm (0.0008 ~ 0.0022 in)0.12 mm
(0.0047 in)
Oil ring
B
T
Dimensions (B × T)2.0 × 2.9 mm (0.079 × 0.114 in)---End gap (installed)0.20 ~ 0.50 mm (0.008 ~ 0.020 in)----
Crankshaft
C1
C2
E
D
A
Crank width “A”61.95 ~ 62.00 mm (2.439 ~ 2.441 in)---Runout limit C10.03 mm (0.0012 in)0.05 mm
(0.002 in)
C20.03 mm (0.0012 in)0.05 mm
(0.002 in)
Big end side clearance “D”0.15 ~ 0.45 mm (0.0059 ~ 0.0177 in)0.50 mm
(0.0197 in)
Big end radial clearance “E”0.010 ~ 0.025 mm (0.0004 ~ 0.0010 in)----
2 - 7
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