Measure: S long clutch push rod bending limit Out of specification! Replace the long clutch push rod. Install: S friction plates S clutch plates NOTE: First, install a friction plate and then alternate between a clutch plate and a friction plate.
Install: S long clutch push rod S ball 7. Push lever lock nut 8Nm 0. Install: S clutch cover 1 7 Nm 0. Dowel pins short length Dowel pins long length For installation, reverse the removal pro- cedure. Install: S shift shaft assembly a. Set the stopper lever and return spring to the shift shaft. Mesh the stopper lever 1 with the shift cam segment.
Install the shift lever 2 to the shift cam seg- ment. Primary drive gear Oil pump drive gear Oil pump cover Straighten the lock washer tab. Remove: S nut primary drive gear 1 S lock washer 2 S primary drive gear 3 NOTE: Place a folded aluminium plate or copper wash- er a between the teeth of the balancer drive gear 4 and balancer driven gear 5. Lubricate: S inner rotor S outer rotor S oil pump shaft with the recommended lubricant Recommended lubricant Engine oil 2.
Install: S oil pump shaft 1 to the oil pump cover 2 S pin 3 S inner rotor 4 S outer rotor Install: S primary drive gear 1 S lock washer 2 S primary drive gear nut 3 50 Nm 5. Balancer driven gear Woodruff key Claw washer Remove: S nut balancer driven gear 1 S lock washer 2 S balancer driven gear 3 NOTE: Place a folded aluminium plate or copper wash- er a between the teeth of the balancer drive gear 4 and balancer driven gear 3.
Install: S balancer driven gear 1 NOTE: Install the balancer driven gear, then mesh the balancer driven gear match mark a and ba- lancer drive gear assembly match mark b. Install: S lock washer 1 S nut balancer drive gear 2 50 Nm 5. Clamp stator coil Clamp pickup coil Pickup coil Stator coil For installation, reverse the removal pro- cedure. S Do not allow the sheave holder to touch the projection on the rotor.
When turning the starter clutch gear clock- wise a , the starter clutch and the starter clutch gear should engage. If the starter clutch gear and starter clutch do not engage, the starter clutch is faulty and must be replaced.
Install: S shim 1 S starter wheel gear 2 S woodruff key 3 2. S When installing the rotor, make sure the wood- ruff key is properly seated in the key way of the crankshaft and turning the starter wheel gear For installation, reverse the removal pro- cedure. After all of the bolts are fully loosened, remove them.
S Loosen the bolts in decreasing numerical or- der refer to the numbers in the illustration. Measure: S crankshaft runout Out of specification! Replace the crank- shaft, bearing or both. NOTE: Turn the crankshaft slowly. Crankshaft runout Less than 0. Measure: S big end axial clearance Out of specification! Replace the big end bearing, crankshaft pin, or connecting rod. Check: S bearings Clean and lubricate the bearings, then rotate the inner race with your finger.
Rough movement! Page Installing The Crankshaft 1. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. Apply: S sealant onto the crankcase mating surfaces Yamaha bond No.
Measure: S main axle runout with a centering device and dial gauge 1 Out of specification! Replace the main axle. Main axle runout limit 0. Measure: S drive axle runout with a centering device and dial gauge 1 Out of specification! Replace the drive axle. Page CARB Check: S fuel passages Obstruction! Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution.
Check: S piston valve movement Insert the piston valve into the carburetor body and move it up and down. Replace the piston valve.
Install: S needle valve seat 1 3. Install: S float chamber 1 S pilot screw 2 5. Adjust: S fuel level a. Remove the carburetor. Check the needle valve seat and needle valve. If either is worn, replace them as a set. If both are fine, adjust the float level by slight- ly bending the float tang 1.
Page CHAS Page Chapter 6. Bearing For assembly, reverse the disassembly procedure. NOTE: Place the motorcycle on a suitable stand so that the front wheel is elevated. NOTE: A tight spoke will emit a clear, ringing tone, a loose spoke will sound flat.
Tighten: S spokes 2 Nm 0. Check: S wheel bearings Front wheel turns roughly or is loose! Re- place the wheel bearings. Replace: S wheel bearings New S oil seals New a. Measure: S brake disc deflection 1 Out of specification! Correct the brake disc deflection or replace the brake disc.
Brake disc deflection limit maxi- mum 0. Measure the brake disc deflection. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. If the brake disc deflection cannot be brought within specification, replace the brake disc.
S Adjust the front wheel static balance with the brake disc installed. If the heavy spot does not stay in that posi- tion, install a heavier weight. Repeat steps b and c until the front wheel is balanced. Replace the rear wheel sprocket. Bent teeth! Replace the rear wheel sprock- b Correct 1 Drive chain roller 2 Rear wheel sprocket NOTE: Replace the brake shoes as a set, if either is worn to the wear limit. Measure: S brake drum inside diameter a Out of specification! Replace the wheel.
Lubricate: S wheel axle S wheel bearings S oil seal lips Recommended lubricant Lithium soap base grease 2. Pad springs For installation, reverse the removal procedure. Therefore, always follow these preventive measures: S Never disassemble brake components un- less absolutely necessary. S If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. Measure: S brake pad wear limit a Out of specification!
Brake pad wear limit 0. Install: S brake caliper S brake pad bolt 27 Nm 2. Disconnect: S brake switch 1 2. S Never use solvents on internal brake com- ponents. Correct if necessary. Fill: S brake master cylinder reservoir with the specified amount of the recom- mended brake fluid Recommended brake fluid Replace the brake caliper. Replace the brake cali- per. S brake fluid delivery passages brake caliper body Obstruction! CAUTION: When installing the brake hose onto the brake caliper 1 , make sure that the brake pipe a touches the projection b on the brake caliper.
Therefore, always clean up any spilt brake fluid immediately. Damper rod holder T-handle 4. S When disassembling and assembling the front fork leg, do not allow any foreign ma- terial to enter the front fork. Tighten: S damper rod bolt 27 Nm 2. Page with the specified amount of the recom- mended fork oil Quantity each front fork leg 0. Front fork leg oil level a from the top of the inner tube, with the Install: S front fork leg Temporarily tighten the upper and lower bracket pinch bolts.
NOTE: Make sure that the inner fork tube is flush with the top of the handlebar holder. Handlebar switch right Clutch switch Clutch cable For installation, reverse the removal procedure. Remove: S throttle cable housing 1 S throttle grip 2 3.
Install: S clutch cable 7. Ball race center Ball race lower For installation, reverse the removal pro- cedure. Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. Install a new dust seal and new bearing races. Before handling the rear shock absorber, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber.
Tap water contains minerals which are harmful to the battery. Check: S specific gravity Less than 1. S Make sure that the battery breather hose and battery vent are free of obstructions. S To ensure maximum performance, always charge a new battery before using it. S Do not use a high-rate battery charger. They force a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage.
S If it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery. S When charging a battery, be sure to re- move it from the motorcycle. If charging has to be done with the battery mounted on the motorcycle, disconnect the negative lead from the battery terminal. S To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery.
A cor- roded battery charger lead clip may gener- ate heat in the contact area and a weak clip spring may cause sparks. Hot batter- ies can explode! If the battery breather hose is positioned so as to allow electrolyte or hydrogen gas from the bat- tery to contact the frame, the motorcycle and its finish may be damaged. Recommended lubricant Dielectric grease. Connect the pocket tester to the fuse and check it for continuity.
Pocket tester Replace: blown fuse. Turn off the ignition. Install a new fuse of the correct amperage rating. Turn on the switches to verify if the electrical circuit is operational.
If the fuse immediately blows again, check the electrical circuit. Improvising or us- ing a fuse with the wrong amperage rating may cause extensive damage to the electri- cal system, cause the lighting and ignition systems to malfunction and could possibly cause a fire. CAUTION: Avoid touching the glass part of the head- light bulb to keep it free from oil, otherwise the transparency of the glass, the life of the bulb and the luminous flux will be adversely affected.
If the headlight bulb gets soiled, thoroughly clean it with a cloth moistened with alcohol or lacquer thinner. Turn the adjusting screw 1 in direction a or b. Headlight beam is raised. Headlight beam is lowered.
Turn the adjusting knob 2 in direction a or b. Securely support the motorcycle so there is no danger of it falling over. Pivot shaft 1 80 Nm 8. Turn the primary pulley counterclockwise. After all of the nuts are fully loosened, remove them. Place a straightedge 1 and a thickness gauge 2 across the cylinder head. Measure the warpage. If the limited is exceeded, resurface the cylin- der head as follows. NOTE: To ensure an even surface, rotate the cylinder head several times.
NOTE: Be sure to keep the timing chain as tight as pos- sible. Align the camshaft marks a with the edge of the cylinder head as shown. While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod ful- ly clockwise with a thin screwdriver 1. Tighten the timing chain tensioner bolts to the specified torque.
Remove the screwdriver, make sure that the timing chain tensioner rod releases, and then tighten the cap bolt 3 to the specified torque. Rocker arm shaft puller bolt Weight EAS Camshaft lobe dimension limit Intake A Rocker arm inside diameter Rocker arm shaft outside diameter Rocker-arm-to-rocker-arm-shaft clearance 0.
Recommended lubricant Camshaft Molybdenum disulfide oil Camshaft bearing Engine oil. NOTE: Before removing the internal parts of the cylin- der head e. Pour a clean solvent a into the intake and exhaust ports. Check that the valves properly seal.
There should be no leakage at the valve seat 1. Valve spring compressor Attachment Measure: S valve-stem-to-valve-guide clearance. Valve-stem-to-valve-guide clear- ance Intake 0. Remove the valve guide with a valve guide remover 1.
Install the new valve guide with a valve guide installer 2 and valve guide remover 1. After installing the valve guide, bore the valve guide with a valve guide reamer 3 to obtain the proper valve-stem-to-valve-guide clearance. NOTE: After replacing the valve guide, reface the valve seat. Valve guide remover 6 mm Valve guide installer 6 mm Valve guide reamer 6 mm Valve margin thickness 0.
Valve stem runout Limit: 0. Valve seat width Intake: 0. Install the valve into the cylinder head. Press the valve through the valve guide and onto the valve seat to make a clear pattern. Measure the valve seat width. Where the valve seat and valve face contacted one another, the blueing will have been removed.
Apply a coarse lapping compound a to the valve face. Apply molybdenum disulfide oil onto the valve stem. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound. NOTE: For the best lapping results, lightly tap the valve seat while rotating the valve back and forth be- tween your hand.
Apply a fine lapping compound to the valve face and repeat the above steps. After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat.
Press the valve through the valve guide and onto the valve seat to make a clear impres- sion. Measure the valve seat width c again. If the valve seat width is out of specification, reface and lap the valve seat. Valve spring free length intake and exhaust Inner spring Compressed spring force Intake and exhaust inner spring 8.
Spring tilt limit Intake and exhaust inner spring 2. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a soft-face hammer. For installation, reverse the removal procedure. Then, find the average of the measure- ments. If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set.
If out of specification, replace the piston and piston rings as a set. Calculate the piston-to-cylinder clearance with the following formula. Piston-to-cylinder clearance 0.
NOTE: Before measuring the piston ring side clear- ance, eliminate any carbon deposits from the piston ring grooves and piston rings. Piston ring side clearance Top ring 0.
Piston ring end gap Top ring 0. Piston pin outside diameter Piston-pin-to-piston clearance 0. Straighten the lock washer tab 1. NOTE: Measure the friction plate at four places. Friction plate thickness 2. Clutch plate warpage limit Less than 0. Clutch spring free length NOTE: Pitting on the clutch housing dogs will cause er- ratic clutch operation. NOTE: Pitting on the clutch boss splines will cause er- ratic clutch operation. Bend the lock washer tab along a flat side of the nut.
NOTE: Push the push lever in direction c and make sure that the marks are aligned. Turn the adjusting screw 2 in or out until the marks are aligned. Hold the adjusting screw to prevent it from moving and then tighten the locknut to speci- fication. Set the stopper lever and return spring to the shift shaft. Mesh the stopper lever 1 with the shift cam segment. Install the shift lever 2 to the shift cam seg- ment.
After installing the shift shaft, check the shift cam for smooth operation by turning the shift shaft with your hand. Straighten the lock washer tab. Inner-rotor-to-outer-rotor-tip cle- arance 0. NOTE: When installing the inner rotor, align the pin 3 in the oil pump shaft with the groove a on the inner rotor 4.
Rotor puller: Rotor puller attachment: When turning the starter clutch gear clock- wise a , the starter clutch and the starter clutch gear should engage.
If the starter clutch gear and starter clutch do not engage, the starter clutch is faulty and must be replaced. When turning the starter clutch gear counter- clockwise b , it should turn freely. If the starter clutch gear does not turn freely, the starter clutch is faulty and must be re- placed. Unloosen the starter clutch assembly by us- ing the center punch. For installation, reverse the removal pro- cedure. After all of the bolts are fully loosened, remove them. NOTE: Turn the crankshaft slowly.
Big end axial clearance 0. Check the plunger seal smooth operation pushing the plunger seal by your finger. Thoroughly clean all the gasket mating sur- faces and crankcase mating surfaces. NOTE: Do not allow any sealant to come into contact with the oil gallery a. Main axle runout limit 0. Drive axle runout limit 0. NOTE: When reassembling the main axle, press the 2nd pinion gear 1 onto it 2 as shown. Check: NOTE: Check the transmission and shift forks for smooth operation by turning the shift cam with your hand.
Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution. Blow out all of the passages and jets with compressed air. Blow out the hoses with compressed air.
Place the motorcycle on a suitable stand to ensure that the motorcycle is standing straight up. Install the fuel level gauge 1 to the fuel drain pipe 2. Loosen the fuel drain screw 3. Hold the fuel level gauge vertically next to the float chamber. Measure the fuel level a. Remove the carburetor. Check the needle valve seat and needle valve. If either is worn, replace them as a set. If both are fine, adjust the float level by slight- ly bending the float tang 1.
Install the carburetor. Measure the fuel level again. Repeat steps a to f until the fuel level is within specification. Place a container under the end of the fuel hose. Fuel flows. Fuel cock is OK. Fuel does not flow. Replace the fuel cock. For assembly, reverse the disassembly procedure. NOTE: A tight spoke will emit a clear, ringing tone, a loose spoke will sound flat.
NOTE: After tightening the spokes, measure the front wheel runout. Front wheel radial runout limit 2 mm Front wheel lateral runout limit 2 mm. Clean the outside of the front wheel hub. Remove the oil seals 1 with a flat-head screwdriver. NOTE: To prevent damaging the wheel, place a rag 2 between the screwdriver and the wheel surface.
Remove the wheel bearings 1 with a gener- al bearing puller 2. Install the new wheel bearings and oil seals in the reverse order of disassembly. Contact should be made only with the outer race 3. NOTE: Use a socket 4 that matches the diameter of the wheel bearing outer race and oil seal. Brake disc deflection limit maxi- mum 0. Place the motorcycle on a suitable stand so that the front wheel is elevated.
Before measuring the front brake disc deflection, turn the handlebar to the left or right to ensure that the front wheel is station- ary. Remove the brake caliper. Hold the dial gauge at a right angle against the brake disc surface. Brake disc thickness limit mini- mum 3 mm. Remove the brake disc. Rotate the brake disc by one bolt hole.
Install the brake disc. NOTE: Tighten the brake disc bolts in stages and in a crisscross pattern. Brake disc bolt 13 Nm 1. Measure the brake disc deflection. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification.
If the brake disc deflection cannot be brought within specification, replace the brake disc. Recommended lubricant Lithium soap base grease.
CAUTION: Before tightening the wheel axle nut, push down hard on the handlebar several times and check if the front fork rebounds smoothly. S Adjust the front wheel static balance with the brake disc installed.
Spin the front wheel. Release the front wheel. Repeat steps b through d several times until all the marks come to rest at the same spot. NOTE: Start with the lightest weight. If the heavy spot does not stay in that posi- tion, install a heavier weight. Repeat steps b and c until the front wheel is balanced. Turn the front wheel and make sure that it stays at each position shown.
If the front wheel does not remain stationary at all of the positions, rebalance it. Remove the self-locking nuts and the rear wheel sprocket. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the sprocket. Install the new rear wheel sprocket. Rear wheel sprocket self-locking nut 35 Nm 3. NOTE: Tighten the self-locking nuts in stages and in a crisscross pattern.
Sand the glazed areas with course sandpa- per. NOTE: After sanding the glazed areas, clean the brake shoe with a cloth. NOTE: Replace the brake shoes as a set, if either is worn to the wear limit.
Brake drum inside diameter limit maximum mm. Remove the oil with a rag soaked in lacquer thinner or solvent. Lightly and evenly polish the scratches with an emery cloth. Align the projection a on the brake shoe wear indicator with the notch b in the brake shoe camshaft. Check that the brake shoes are properly positioned. Therefore, always clean up any spilt fluid immediately.
Put the other end of the hose into an open container. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. Tighten the bleed screw. Install new brake pads and brake pad spring. CAUTION: When installing the brake hose onto the master cylinder,make sure that the brake pipe a touches the projection b on the master cylinder. NOTE: Turn the handlebar to the left and to the right to make sure that the brake hose does not touch other parts e. Correct if necessary.
Blow compressed air into the brake hose joint opening a to force out the pistons from the brake caliper. Be careful not to get injured when the pis- tons are expelled from the brake caliper. Recommended brake fluid DOT 4 1. CAUTION: When installing the brake hose onto the brake caliper 1 , make sure that the brake pipe a touches the projection b on the brake caliper. Damper rod holder T-handle Be careful not to dam- age the inner tube. Fork seal driver weight Adapter NOTE: Make sure that the inner fork tube is flush with the top of the handlebar holder.
Do not attempt to straighten a bent handle- bar as this may dangerously weaken it. Apply a light coat of rubber adhesive onto the left end of the handlebar. Slide the handlebar grip over the left end of the handlebar. Wipe off any excess rubber adhesive with a clean rag. If there is any contact with the fuel tank, adjust the handlebar position. Exhaust and steering nut wrench 2 Remove the bearing races from the steering head pipe with a long rod 1 and hammer.
Remove the bearing race from the lower bracket with a floor chisel 2 and hammer. Install a new dust seal and new bearing races. NOTE: Temporarily tighten the upper and lower bracket pinch bolts. Before handling the rear shock absorber, read and make sure you understand the following information.
The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber. High heat can cause an explosion due to excessive gas pressure. If the rear shock ab- sorber or both are damaged, damping per- formance will suffer. Gas pressure must be released before dis- posing of a rear shock absorber. Check the tightening torque of the pivot shaft nut. Pivot shaft nut 80 Nm 8. Check the swingarm side play A by moving the swingarm from side to side.
If the swingarm side play is out of specifica- tion, check the spacers, bearings, washers, and dust covers. Swingarm side play at the end of the swingarm 1. Check the swingarm vertical movement B by moving the swingarm up and down. If swingarm vertical movement is not smooth or if there is binding, check the spacers, bearings, washers, and dust covers.
Recommended cleaning solvent Kerosine. Wipe the drive chain with a clean cloth. Put the drive chain in kerosine and remove any remaining dirt. Free play c. Have a Yamaha dealer inspect and It is advisable to have a Yamaha bleed the system if necessary. Pedal height The brake pedal should be posi Page Brake Light Switch Adjustment Brake light switch proper adjustment, consult a The rear brake pedal free play adjustment Yamaha dealer. Turn the vated by the brake pedal and is These indi Page Brake Fluid Replacement Yamaha service causing leakage poor fluid immediately.
Have the Yamaha deal- 8 Have a Yamaha dealer check brake performance. Check the slack at the position shown in the illustra- tion. If the the engine and other vital parts. If a cable does not operate lubrication smoothly, ask a Yamaha dealer to The throttle twist grip assembly replace it. Check that the sidestand Recommended lubricant: Recommended lubricant: moves up and down smoothly. Page Rear Suspension Lubrication 3.
Push down hard on the han- dlebars several times check if the fork rebounds smoothly. EC If any damage or unsmooth move- ment is found with the front fork, consult a Yamaha dealer. Page Steering Inspection Hold the lower end of the front forks and try to move them forward and backward. If any free play can be felt, ask a Yamaha dealer to inspect and adjust the steering. Inspection is easier if the front wheel is removed. It contains sulfuric acid.
Avoid contact with skin, eyes or clothing. Battery 1. Page Fuse Replacement Yamaha dealer. Completely recharge the battery before reinstalla- tion. Substitution of a fuse of improper rating can cause exten- sive electrical system damage and possibly a fire. Bolt 2 1. If the headlight beam adjust- lens. Do not touch a bulb until it cools down. Check that Page Front Wheel Installation Make sure the projections are meshed into the slots. Lift up the wheel between the Yamaha dealer service the front fork legs.
Make sure that wheel. Turn the chain adjusting plates 4. Tighten the axle nut to the on each side fully in direction specified torque. Tightening torque: 4. Elevate the rear wheel. Axle nut: 5.
Remove the axle nut. Page Troubleshooting If your motorcycle requires any repair, bring it to a Yamaha dealer. Page Troubleshooting Chart 2. Compression There is compression. Go to ignition check. Use the electric starter. No compression. Ask a Yamaha dealer to inspect. Ignition Wipe clean with dry cloth and Open throttle half-way and start Wet.
Remove spark correct spark gap or replace plug. Cover up the muffler outlet After normal use The exposure of its technology with a plastic bag. Remove dirt with warm water, a makes a motorcycle charming but 2. Make sure that all caps and neutral detergent and a soft clean also vulnerable. Use since they cause water seep- Since sea salt or salt sprayed on only a soft, clean cloth or age and deterioration in the Page 74 After cleaning 8.
Let the motorcycle dry com- NOTE: 1. Dry the motorcycle with a pletely before storing it or cov- Consult Yamaha dealer chamois or an absorbing cloth. Immediately drive Pour a teaspoonful of engine Storage Before storing your motorcycle for oil into the spark plug bore. Short-term several months: c. Install the spark plug cap onto Always store your motorcycle in a 1. Check and, if necessary, cor- NOTE: rect the tire air pressure, then Make any necessary repairs before raise the motorcycle so that storing the motorcycle.
Alternatively, turn the wheels a little every month in order to prevent the tires from becoming degraded in one Page Consumer Information Yamaha dealer or for reference in case the vehicle is stolen. Key identification number 1. Vehicle identification number EAU Record the information on this label in the space provided. This information will be needed to order spare parts from your Yamaha dealer. Print page 1 Print document 86 pages.
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