q Read this manual carefully before operating this vehicle.
2009
OWNER’S SERVICE MANUAL
LIT-11626-22-54
YZ125Y
1C3-28199-14
Q
Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
©2008 by Yamaha Motor Corporation, U.S.A.
YZ125Y
OWNER'S SERVICE MANUAL
1st Edition, April 2008
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation U.S.A.
is expressly prohibited.
Printed in Japan
P/N. LIT-11626-22-54
INTRODUCTION
Congratulations on your purchase of a Yamaha
YZ series. This model is the culmination of
Yamaha's vast experience in the production of
pacesetting racing machines. It represents the
highest grade of craftsmanship and reliability
that have made Yamaha a leader.
This manual explains operation, inspection, basic maintenance and tuning of your machine. If
you have any questions about this manual or
your machine, please contact your Yamaha
dealer.
Yamaha continually seeks advancements in
product design and quality. Therefore, while
this manual contains the most current product
information available at the time of printing,
there may be minor discrepancies between
your machine and this manual. If you have any
questions concerning this manual, please consult your Yamaha dealer.
IMPORTANT MANUAL
INFORMATION
Particularly important 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.
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.
PLEASE READ THIS MANUAL CAREFULLY
AND COMPLETELY BEFORE OPERATING
THIS MACHINE. DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE
ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING
FEATURES AND UNTIL YOU HAVE BEEN
TRAINED IN SAFE AND PROPER RIDING
TECHNIQUES. REGULAR INSPECTIONS
AND CAREFUL MAINTENANCE, ALONG
WITH GOOD RIDING SKILLS, WILL ENSURE
THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE.
A TIP provides key information to make procedures easier or clearer.
SAFETY INFORMATION
THIS MACHINE IS DESIGNED STRICTLY
FOR COMPETITION USE, ONLY ON A
CLOSED COURSE. It is illegal for this machine
to be operated on any public street, road, or
highway. Off-road use on public lands may also
be illegal. Please check local regulations before riding.
• THIS MACHINE IS TO BE OPERATED BY
AN EXPERIENCED RIDER ONLY.
Do not attempt to operate this machine at
maximum power until you are totally familiar
with its characteristics.
• THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY.
Do not carry passengers on this machine.
• ALWAYS WEAR PROTECTIVE APPAREL.
When operating this machine, always wear an
approved helmet with goggles or a face
shield. Also wear heavy boots, gloves, and
protective clothing. Always wear proper fitting
clothing that will not be caught in any of the
moving parts or controls of the machine.
• ALWAYS MAINTAIN YOUR MACHINE IN
PROPER WORKING ORDER.
For safety and reliability, the machine must be
properly maintained. Always perform the preoperation checks indicated in this manual.
Correcting a mechanical problem before you
ride may prevent an accident.
• GASOLINE IS HIGHLY FLAMMABLE.
Always turn off the engine while refueling.
Take care to not spill any gasoline on the engine or exhaust system. Never refuel in the vicinity of an open flame, or while smoking.
• GASOLINE CAN CAUSE INJURY.
If you should swallow some gasoline, inhale
excess gasoline vapors, or allow any gasoline
to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or
clothing, immediately wash skin areas with
soap and water, and change your clothes.
• ONLY OPERATE THE MACHINE IN AN
AREA WITH ADEQUATE VENTILATION.
Never start the engine or let it run for any
length of time in an enclosed area. Exhaust
fumes are poisonous. These fumes contain
carbon monoxide, which by itself is odorless
and colorless. Carbon monoxide is a dangerous gas which can cause unconsciousness or
can be lethal.
• PARK THE MACHINE CAREFULLY; TURN
OFF THE ENGINE.
Always turn off the engine if you are going to
leave the machine. Do not park the machine
on a slope or soft ground as it may fall over.
• THE ENGINE, EXHAUST PIPE, MUFFLER,
AND OIL TANK WILL BE VERY HOT AFTER
THE ENGINE HAS BEEN RUN.
Be careful not to touch them or to allow any
clothing item to contact them during inspection or repair.
• PROPERLY SECURE THE MACHINE BEFORE TRANSPORTING IT.
When transporting the machine in another vehicle, always be sure it is properly secured
and in an upright position and that the fuel
cock is in the "OFF" position. Otherwise, fuel
may leak out of the carburetor or fuel tank.
YAMAHA MOTOR CORPORATION, U.S.A. YZ MOTORCYCLE
LIMITED WARRANTY
F.I.M. MACHINE WEIGHTS
Weights of machines without fuel
The minimum weights for motocross machines
are:
for the class 125 cc: minimum 88 kg (194 lb)
for the class 250 cc: minimum 98 kg (216 lb)
for the class 500 cc: minimum 102 kg (225 lb)
In modifying your machine (e.g., for weight reduction), take note of the above limits of weight.
HOW TO USE THIS MANUAL
FINDING THE REQUIRED PAGE
1. This manual consists of seven chapters; "General Information", "Specifications", "Regular inspection and adjustments", "Engine", "Chassis", "Electrical" and "Tuning"
2. The table of contents is at the beginning of the manual. Look over the general layout of the book
before finding then required chapter and item.
Bend the book at its edge, as shown, to find the required fore edge symbol mark and go to a page
for required item and description.
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the
course of action required will follow the symbol, e.g.,
• Bearings
Pitting/damage → Replace.
HOW TO READ DESCRIPTIONS
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 "1" is provided for removal and disassembly jobs.
2. Numbers "2" 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
"3". The meanings of the symbol marks are given on the next page.
4. A job instruction chart "4" 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 "5" are given in addition
to the exploded diagram and job instruction chart.
ILLUSTRATED SYMBOLS (Refer
to the illustration)
Illustrated symbols "1" to "7" are used to identify the specifications appearing in the text.
1. With engine mounted
2. Filling fluid
3. Lubricant
4. Special tool
5. Tightening
6. Specified value, Service limit
7. Resistance (Ω), Voltage (V), Electric cur-
rent (A)
Illustrated symbols "8" to "14" in the exploded
diagrams indicate grade of lubricant and location of lubrication point.
8. Apply engine mixing oil
9. Apply transmission oil
10. Apply molybdenum disulfide oil
11. Apply brake fluid
12. Apply lightweight lithium-soap base grease
13. Apply molybdenum disulfide grease
14. Apply silicone grease
Illustrated symbols "15" to "16" in the exploded
diagrams indicate where to apply a locking
agent and where to install new parts.
15. Apply locking agent (LOCTITE
16. Use new one
®
)
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
REGULAR INSPECTION AND
ADJUSTMENTS
ENGINE
CHASSIS
1
2
3
4
5
ELECTRICAL
TUNING
6
7
CONTENTS
CHAPTER 1
GENERAL INFORMATION
LOCATION OF IMPORTANT LABELS ..... 1-1
DESCRIPTION ........................................... 1-2
MACHINE IDENTIFICATION ..................... 1-3
INCLUDED PARTS.................................... 1-4
IMPORTANT INFORMATION .................... 1-5
CHECKING OF CONNECTION ................. 1-7
SPECIAL TOOLS....................................... 1-8
CONTROL FUNCTIONS .......................... 1-11
STARTING AND BREAK-IN .................... 1-13
TORQUE-CHECK POINTS ...................... 1-15
CLEANING AND STORAGE ................... 1-16
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS................... 2-1
MAINTENANCE SPECIFICATIONS.......... 2-3
TIGHTENING TORQUES........................... 2-9
CABLE ROUTING DIAGRAM.................. 2-15
CHAPTER 3
REGULAR INSPECTION AND
ADJUSTMENTS
MAINTENANCE INTERVALS.................... 3-1
PRE-OPERATION INSPECTION AND
MAINTENANCE ......................................... 3-5
ENGINE ...................................................... 3-6
CHASSIS.................................................. 3-13
ELECTRICAL........................................... 3-29
CHAPTER 4
ENGINE
SEAT, FUEL TANK AND SIDE COVERS . 4-2
EXHAUST PIPE AND SILENCER ............. 4-4
RADIATOR................................................. 4-6
CARBURETOR AND REED VALVE ......... 4-9
CYLINDER HEAD, CYLINDER AND
PISTON .................................................... 4-17
CLUTCH ................................................... 4-28
KICK SHAFT AND SHIFT SHAFT........... 4-34
YPVS GOVERNOR .................................. 4-42
WATER PUMP ......................................... 4-45
CDI MAGNETO ........................................ 4-48
ENGINE REMOVAL................................. 4-51
CRANKCASE AND CRANKSHAFT ........ 4-55
TRANSMISSION, SHIFT CAM AND
SHIFT FORK ............................................ 4-62
CHAPTER 5
CHASSIS
FRONT WHEEL AND REAR WHEEL ....... 5-2
FRONT BRAKE AND REAR BRAKE........ 5-9
FRONT FORK .......................................... 5-23
HANDLEBAR........................................... 5-36
STEERING ............................................... 5-43
SWINGARM ............................................. 5-48
REAR SHOCK ABSORBER .................... 5-55
CHAPTER 6
ELECTRICAL
ELECTRICAL COMPONENTS AND
WIRING DIAGRAM .................................... 6-2
IGNITION SYSTEM.................................... 6-4
CHAPTER 7
TUNING
ENGINE ...................................................... 7-1
CHASSIS.................................................. 7-10
LOCATION OF IMPORTANT LABELS
GENERAL INFORMATION
LOCATION OF IMPORTANT LABELS
Please read the following important labels carefully before operating this vehicle.
1
1-1
DESCRIPTION
DESCRIPTION
1. Clutch lever
2. Engine stop switch
3. Front brake lever
4. Throttle grip
5. Radiator cap
6. Fuel tank cap
7. Kickstarter crank
8. Fuel tank
9. Radiator
10. Coolant drain bolt
11. Check bolt (Transmission oil level)
12. Rear brake pedal
13. Valve joint
• The machine you have purchased may differ slightly from those shown in the following.
• Designs and specifications are subject to change without notice.
14. Fuel cock
15. Air filter
16. Drive chain
17. Shift pedal
18. Starter knob
19. Front fork
1-2
MACHINE IDENTIFICATION
There are two significant reasons for knowing
the serial number of your machine:
1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own.
2. If your machine is stolen, the authorities will
need the number to search for and identify
your machine.
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number "1" is
stamped on the right of the steering head pipe.
MACHINE IDENTIFICATION
ENGINE SERIAL NUMBER
The engine serial number "1" is stamped into
the elevated part of the right-side of the engine.
MODEL LABEL
The model label "1" is affixed to the frame under the rider's seat. This information will be
needed to order spare parts.
1-3
INCLUDED PARTS
INCLUDED PARTS
DETACHABLE SIDESTAND
This sidestand "1" is used to support only the
machine when standing or transporting it.
• Never apply additional force to the side-
stand.
• Remove this sidestand before starting out.
VALVE JOINT
This valve joint "1" prevents fuel from flowing
out and is installed to the fuel tank breather
hose.
NIPPLE WRENCH
This nipple wrench "1" is used to tighten the
spoke.
In this installation, make sure the arrow faces the fuel tank and also downward.
COLLAR (tool for YPVS)
This collar "1" is used to remove and install the
push rod of the engine.
1-4
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Remove all dirt, mud, dust, and foreign material before removal and disassembly.
• When washing the machine with high pressured water, cover the parts follows.
Silencer exhaust port
Side cover air intake port
Crankcase cover hole at the bottom
Water pump housing hole at the bottom
End of each hose
IMPORTANT INFORMATION
4. During the machine disassembly, clean all
parts and place them in trays in the order of
disassembly. This will speed up assembly
time and help assure that all parts are correctly reinstalled.
2. Use proper tools and cleaning equipment.
Refer to "SPECIAL TOOLS" section.
3. When disassembling the machine, keep
mated parts together. They include gears,
cylinders, pistons, and other mated parts
that have been "mated" through normal
wear. Mated parts must be reused as an assembly or replaced.
5. Keep away from fire.
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha genuine
parts for all replacements. Use oil and/or
grease recommended by Yamaha for assembly and adjustment.
GASKETS, OIL SEALS AND O-RINGS
1. All gaskets, oil seals, and O-rings should be
replaced when an engine is overhauled. All
gasket surfaces, oil seal lips, and O-rings
must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
LOCK WASHERS/PLATES AND COTTER
PINS
1. All lock washers/plates "1" and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt or
nut flat(s) after the bolt or nut has been properly tightened.
1-5
BEARINGS AND OIL SEALS
1. Install the bearing(s) "1" and oil seal(s) "2"
with their manufacturer's marks or numbers
facing outward. (In other words, the
stamped letters must be on the side exposed to view.) When installing oil seal(s),
apply a light coating of lightweight lithium
base grease to the seal lip(s). Oil the bearings liberally when installing.
IMPORTANT INFORMATION
Do not use compressed air to spin the bearings dry. This causes damage to the bearing
surfaces.
CIRCLIPS
1. All circlips should be inspected carefully before reassembly. Always replace piston pin
clips after one use. Replace distorted circlips. When installing a circlip "1", make sure
that the sharp-edged corner "2" is positioned
opposite to the thrust "3" it receives. See the
sectional view.
1-6
CHECKING OF CONNECTION
Dealing with stains, rust, moisture, etc. on the
connector.
1. Disconnect:
• Connector
2. Dry each terminal with an air blower.
3. Connect and disconnect the connector two
or three times.
4. Pull the lead to check that it will not come off.
5. If the terminal comes off, bend up the pin "1"
and reinsert the terminal into the connector.
CHECKING OF CONNECTION
6. Connect:
• Connector
The two connectors "click" together.
7. Check for continuity with a tester.
• If there in no continuity, clean the terminals.
• Be sure to perform the steps 1 to 7 listed
above when checking the wire harness.
• For a field remedy, use a contact revitalizer
available on the market.
• Use the tester on the connector as shown.
1-7
SPECIAL TOOLS
SPECIAL TOOLS
The proper special tools are necessary for
complete and accurate tune-up and assembly.
Using the correct special tool will help prevent
damage caused by the use of improper tools or
improvised techniques. The shape and part
number used for the special tool differ by country, so two types are provided. Refer to the list
provided to avoid errors when placing an order.
Tool name/Part number How to use Illustration
Crankcase separating tool
YU-1135-A, 90890-01135
These tool is used to remove
the crankshaft from either
case.
• For U.S.A. and Canada, use part number
starting with "YM-", "YU-" or "ACC-".
• For others, use part number starting with
"90890-".
Flywheel puller
YM-1189, 90890-01189
Rotor holding tool
YU-1235, 90890-01235
Dial gauge and stand
YU-3097, 90890-01252
Stand
YU-1256
Crankshaft installing tool
Crankshaft installing pot
YU-90050, 90890-01274
Crankshaft installing bolt
YU-90050, 90890-01275
Adapter
YU-90063, 90890-01278
Adapter
YU-01499, 90890-01499
This tool is used to remove
the flywheel magneto.
This tool is used when loosening or tightening the flywheel magneto securing nut.
These tools are used to check
each part for runout or bent.
These tools are used to install
the crankshaft.
1-8
SPECIAL TOOLS
Tool name/Part number How to use Illustration
Piston pin puller set
YU-1304, 90890-01304
Fuel level gauge "1"
YM-1312-A, 90890-01312
Fuel level gauge adaptor "2"
YM-01470, 90890-01470
Radiator cap tester
YU-24460-01, 90890-01325
Radiator cap tester adapter
YU-33984, 90890-01352
Flywheel puller
YU-33270-B, 90890-01362
This tool is used to remove
the piston pin.
This gauge is used to measure the fuel level in the float
chamber.
These tools are used for
checking the cooling system.
These tool is used to split the
crankcase.
Steering nut wrench
YU-33975, 90890-01403
Cap bolt wrench
YM-01500, 90890-01500
Cap bolt ring wrench
YM-01501, 90890-01501
This tool is used when tighten
the steering ring nut to specification.
This tool is used to loosen or
tighten the base valve.
This tool is used to loosen or
tighten the damper assembly.
1-9
SPECIAL TOOLS
Tool name/Part number How to use Illustration
Fork seal driver
YM-A0948, 90890-01502
Spoke nipple wrench
YM-01521, 90890-01521
Pocket tester
YU-3112-C, 90890-03112
Clutch holding tool
YM-91042, 90890-04086
This tool is used when install
the fork oil seal.
This tool is used to tighten the
spoke.
Use this tool to inspect the
coil resistance, output voltage
and amperage.
This tool is used to hold the
clutch when removing or installing the clutch boss securing nut.
Dynamic spark tester
YM-34487
Ignition checker
90890-06754
YAMAHA Bond No. 1215
(ThreeBond
90890-85505
®
No. 1215)
This instrument is necessary
for checking the ignition system components.
This sealant (Bond) is used
for crankcase mating surface,
etc.
1-10
CONTROL FUNCTIONS
CONTROL FUNCTIONS
ENGINE STOP SWITCH
The engine stop switch "1" is located on the left
handlebar. Continue pushing the engine stop
switch till the engine comes to a stop.
CLUTCH LEVER
The clutch lever "1" is located on the left handlebar; it disengages or engages the clutch.
Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch. The lever should be pulled
rapidly and released slowly for smooth starts.
KICKSTARTER CRANK
Rotate the kickstarter crank "1" away from the
engine. Push the starter down lightly with your
foot until the gears engage, then kick smoothly
and forcefully to start the engine. This model
has a primary kickstarter crank so the engine
can be started in any gear if the clutch is disengaged. In normal practices, however, shift to
neutral before starting.
THROTTLE GRIP
The throttle grip "1" is located on the right handlebar; it accelerates or decelerates the engine. For acceleration, turn the grip toward you;
for deceleration, turn it away from you.
SHIFT PEDAL
The gear ratios of the constant-mesh 6 speed
transmission are ideally spaced. The gears can
be shifted by using the shift pedal "1" on the left
side of the engine.
FRONT BRAKE LEVER
The front brake lever "1" is located on the right
handlebar. Pull it toward the handlebar to activate the front brake.
1-11
REAR BRAKE PEDAL
The rear brake pedal "1" is located on the right
side of the machine. Press down on the brake
pedal to activate the rear brake.
FUEL COCK
The fuel cock supplies fuel from the tank to carburetor and also filters the fuel. The fuel cock
has the two positions:
OFF:
With the lever in this position, fuel will not flow.
Always return the lever to this position when the
engine is not running.
ON:
With the lever in this position, fuel flows to the
carburetor. Normal riding is done with the lever
in this position.
CONTROL FUNCTIONS
STARTER KNOB (CHOKE)
When cold, the engine requires a richer air-fuel
mixture for starting. A separate starter circuit,
which is controlled by the starter knob "1", supplies this mixture. Pull the starter knob out to
open the circuit for starting. When the engine
has warmed up, push it in to close the circuit.
1-12
STARTING AND BREAK-IN
STARTING AND BREAK-IN
FUEL
Mix oil with the gas at the ratio specified below.
Always use fresh, name-brand gasoline, and
mix the oil and gas the day of the race. Do not
use premix that is more than a few hours old.
Recommended fuel:
Premium unleaded gasoline only
with a research octane number of
95 or higher.
If knocking or pinging occurs, use a different
brand of gasoline or higher octane grade.
Never mix two types of oil in the same
batch; clotting of the oil could result. If you
wish to change oil types, be sure to drain
the fuel tank and the carburetor float bowl of
old premix prior to filling with the new type.
chine in a well-ventilated area.
AIR FILTER MAINTENANCE
According to "CLEANING THE AIR FILTER
ELEMENT" section in the CHAPTER 3, apply
the foam-air-filter oil or its equivalent to the element. (Excess oil in the element may adversely
affect engine starting.)
STARTING A COLD ENGINE
1. Shift the transmission into neutral.
2. Turn the fuel cock to "ON" and full open the
starter knob (CHOKE).
3. With the throttle completely closed start the
engine by kicking the kick starter forcefully
with firm stroke.
4. Run the engine at idle or slightly higher until
it warms up: this usually takes about one or
two minutes.
5. The engine is warmed up when it responds
normally to the throttle with the starter knob
(CHOKE) turned off.
Fuel tank capacity:
8.0 L (1.76 Imp gal, 2.11 US gal)
Mixing oil:
Recommended oil:
Yamalube "2-R"
(Yamalube racing 2-cycle oil)
Mixing ratio: 30:1
If unavailable, use an equivalent
type of oil.
HANDLING NOTE
Before starting the machine, perform the
checks in the pre-operation check list.
Never start or run the engine in a closed area. The exhaust fumes are poisonous; they
can cause loss of consciousness and death
in a very short time. Always operate the ma-
Do not warm up the engine for extended periods of time.
STARTING A WARM ENGINE
Do not operate the starter knob (CHOKE).
Open the throttle slightly and start the engine
by kicking the kick starter forcefully with firm
stroke.
Observe the following break-in procedures
during initial operation to ensure optimum
performance and avoid engine damage.
BREAK-IN PROCEDURES
1. Before starting the engine, fill the fuel tank
with a break-in oil-fuel mixture as follows.
Mixing oil:
Yamalube "2-R"
Mixing ratio:
15:1
2. Perform the pre-operation checks on the
machine.
3. Start and warm up the engine. Check the
idle speed, and check the operation of the
controls and the "ENGINE STOP" button.
4. Operate the machine in the lower gears at
moderate throttle openings for five to eight
minutes. Stop and check the spark plug condition; it will show a rich condition during
break-in.
1-13
5. Allow the engine to cool. Restart the engine
and operate the machine as in the step
above for five minutes. Then, very briefly
shift to the higher gears and check full-throttle response. Stop and check the spark plug.
6. After again allowing the engine to cool, restart and run the machine for five more minutes. Full throttle and the higher gears may
be used, but sustained full-throttle operation
should be avoided. Check the spark plug
condition.
7. Allow the engine to cool, remove the top
end, and inspect the piston and cylinder. Remove any high spots on the piston with #600
grit wet sandpaper. Clean all components
and carefully reassemble the top end.
8. Drain the break-in oil-fuel mixture from the
fuel tank and refill with the specified mix.
9. Restart the engine and check the operation
of the machine throughout its entire operating range. Stop and check the spark plug
condition. Restart the machine and operate
it for about 10 to 15 more minutes. The machine will now be ready to race.
STARTING AND BREAK-IN
• After the break-in or before each race, you
must check the entire machine for loose
fittings and fasteners as per "TORQUECHECK POINTS". Tighten all such fasteners as required.
• When any of the following parts have been
replaced, they must be broken in.
CYLINDER AND CRANKSHAFT:
About one hour of break-in operation is
necessary.
PISTON, RING AND GEARS:
These parts require about 30 minutes of
break-in operation at half-throttle or less.
Observe the condition of the engine carefully during operation.
1-14
TORQUE-CHECK POINTS
TORQUE-CHECK POINTS
Frame construction Frame to rear frame
Combined seat and fuel tank Fuel tank to frame
Exhaust system Silencer to rear frame
Engine mounting Frame to engine
Engine bracket to engine
Engine bracket to frame
Steering Steering stem to handlebar Steering stem to frame
Steering stem to upper bracket
Upper bracket to handlebar
Suspension Front Steering stem to front fork Front fork to upper bracket
Front fork to lower bracket
Rear For link type Assembly of links
Link to frame
Link to rear shock absorber
Link to swingarm
Installation of rear shock absorber Rear shock absorber to frame
Installation of swingarm Tightening of pivot shaft
Wheel Installation of wheel Front Tightening of wheel axle
Tightening of axle holder
Rear Tightening of wheel axle
Wheel to rear wheel sprocket
Brake Front Brake caliper to front fork
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to handlebar
Tightening of bleed screw
Tightening of brake hose holder
Rear Brake pedal to frame
Brake disc to wheel
Tightening of union bolt
Brake master cylinder to frame
Tightening of bleed screw
Fuel system Fuel tank to fuel cock
Concerning the tightening torque, refer to "TIGHTENING TORQUES" section in the CHAPTER 2.
Tightening of brake hose holder
1-15
CLEANING AND STORAGE
CLEANING AND STORAGE
CLEANING
Frequent cleaning of your machine will enhance its appearance, maintain good overall
performance, and extend the life of many components.
1. Before washing the machine, block off the
end of the exhaust pipe to prevent water
from entering. A plastic bag secured with a
rubber band may be used for this purpose.
2. If the engine is excessively greasy, apply
some degreaser to it with a paint brush. Do
not apply degreaser to the chain, sprockets,
or wheel axles.
3. Rinse the dirt and degreaser off with a garden hose; use only enough pressure to do
the job.
Excessive hose pressure may cause water
seepage and contamination of wheel bearings, front forks, brakes and transmission
seals. Many expensive repair bills have resulted from improper high pressure detergent applications such as those available in
coin-operated car washers.
4. After the majority of the dirt has been hosed
off, wash all surfaces with warm water and a
mild detergent. Use an old toothbrush to
clean hard-to-reach places.
5. Rinse the machine off immediately with
clean water, and dry all surfaces with a soft
towel or cloth.
6. Immediately after washing, remove excess
water from the chain with a paper towel and
lubricate the chain to prevent rust.
7. Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy.
8. Automotive wax may be applied to all painted or chromed surfaces. Avoid combination
cleaner-waxes, as they may contain abrasives.
9. After completing the above, start the engine
and allow it to idle for several minutes.
STORAGE
If your machine is to be stored for 60 days or
more, some preventive measures must be taken to avoid deterioration. After cleaning the machine thoroughly, prepare it for storage as
follows:
1. Drain the fuel tank, fuel lines, and the carburetor float bowl.
2. Remove the spark plug, pour a tablespoon
of SAE 10W-40 motor oil in the spark plug
hole, and reinstall the plug. With the engine
stop switch pushed in, kick the engine over
several times to coat the cylinder walls with
oil.
3. Remove the drive chain, clean it thoroughly
with solvent, and lubricate it. Reinstall the
chain or store it in a plastic bag tied to the
frame.
4. Lubricate all control cables.
5. Block the frame up to raise the wheels off
the ground.
6. Tie a plastic bag over the exhaust pipe outlet
to prevent moisture from entering.
7. If the machine is to be stored in a humid or
salt-air environment, coat all exposed metal
surfaces with a film of light oil. Do not apply
oil to rubber parts or the seat cover.
Make any necessary repairs before the machine is stored.
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