Yz 450 FX

2008
YZ450F(X)
OWNER’S SERVICE MANUAL
MANUEL D’ATELIER DU
PROPRIETAIRE
FAHRER- UND
WARTUNGSHANDBUCH
2008
YZ450F(X)
PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN 2S2-28199-82
2007.05-2.1×1 CR
2500 SHINGAI IWATA SHIZUOKA JAPAN
(E,F,G)
2008
OWNER’S SERVICE MANUAL
YZ450F(X)
2S2-28199-82-E0
YZ450F(X)
OWNER'S SERVICE MANUAL
©2007 by Yamaha Motor Co., Ltd.
1st Edition, May 2007
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
FOREWORD 5. GASOLINE IS HIGHLY FLAM-
A CAUTION indicates special pre- MABLE.
INTRODUCTION cautions that must be taken to avoid
Congratulations on your purchase of Always turn off the engine
damage to the machine. while refueling. Take care to
a Yamaha YZ series. This model is
the culmination of Yamaha's vast ex- not spill any gasoline on the
perience in the production of paceset- engine or exhaust system.
A NOTE provides key information to Never refuel in the vicinity of
ting racing machines. It represents make procedures easier or clearer.
the highest grade of craftsmanship an open flame, or while
IMPORTANT NOTICE smoking.
and reliability that have made
THIS MACHINE IS DESIGNED
Yamaha a leader. 6. GASOLINE CAN CAUSE IN-
STRICTLY FOR COMPETITION
This manual explains operation, in- JURY.
USE, ONLY ON A CLOSED
spection, basic maintenance and tun- If you should swallow some
COURSE. It is illegal for this machine
ing of your machine. If you have any gasoline, inhale excess gaso-
to be operated on any public street,
questions about this manual or your line vapors, or allow any gas-
road, or highway. Off-road use on
machine, please contact your oline to get into your eyes,
public lands may be illegal. Please
Yamaha dealer. contact a doctor immediately.
check local regulations before riding.
If any gasoline spills onto
Yamaha continually seeks advance- your skin or clothing, imme-
ments in product design and quality. diately wash skin areas with
Therefore, while this manual contains soap and water, and change
the most current product information 1. THIS MACHINE IS TO BE OP- your clothes.
available at the time of printing, there ERATED BY AN EXPERI-
7. ONLY OPERATE THE MA-
may be minor discrepancies between ENCED RIDER ONLY.
CHINE IN AN AREA WITH AD-
your machine and this manual. If you Do not attempt to operate this
EQUATE VENTILATION.
have any questions concerning this machine at maximum power
Never start the engine or let it
manual, please consult your Yamaha until you are totally familiar
run for any length of time in
dealer. with its characteristics.
an enclosed area. Exhaust
2. THIS MACHINE IS DESIGNED fumes are poisonous. These
TO BE RIDDEN BY THE OP- fumes contain carbon mon-
PLEASE READ THIS MANUAL ERATOR ONLY. oxide, which by itself is odor-
CAREFULLY AND COMPLETELY Do not carry passengers on less and colorless. Carbon
BEFORE OPERATING THIS MA- this machine. monoxide is a dangerous gas
CHINE. DO NOT ATTEMPT TO OP- which can cause uncon-
ERATE THIS MACHINE UNTIL YOU 3. ALWAYS WEAR PROTEC- sciousness or can be lethal.
HAVE ATTAINED A SATISFACTO- TIVE APPAREL.
RY KNOWLEDGE OF ITS CON- When operating this ma- 8. PARK THE MACHINE CARE-
TROLS AND OPERATING chine, always wear an ap- FULLY; TURN OFF THE EN-
FEATURES AND UNTIL YOU HAVE proved helmet with goggles GINE.
BEEN TRAINED IN SAFE AND or a face shield. Also wear Always turn off the engine if
PROPER RIDING TECHNIQUES. heavy boots, gloves, and pro- you are going to leave the
REGULAR INSPECTIONS AND tective clothing. Always wear machine. Do not park the ma-
CAREFUL MAINTENANCE, proper fitting clothing that chine on a slope or soft
ALONG WITH GOOD RIDING will not be caught in any of ground as it may fall over.
SKILLS, WILL ENSURE THAT YOU the moving parts or controls
9. THE ENGINE, EXHAUST
SAFETY ENJOY THE CAPABILI- of the machine.
PIPE, MUFFLER, AND OIL
TIES AND THE RELIABILITY OF TANK WILL BE VERY HOT
4. ALWAYS MAINTAIN YOUR
THIS MACHINE. AFTER THE ENGINE HAS
MACHINE IN PROPER
WORKING ORDER. BEEN RUN.
PARTICULARLY IMPORTANT
For safety and reliability, the Be careful not to touch them
INFORMATION
machine must be properly or to allow any clothing item
maintained. Always perform to contact them during in-
The Safety Alert Symbol means AT-
the pre-operation checks inspection or repair.
TENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED! dicated in this manual. Cor-
recting a mechanical problem
before you ride may prevent
Failure to follow WARNING instruc- an accident.
tions could result in severe injury or
death to the machine operator, a by-
stander, or a person inspecting or re-
pairing the machine.
10. PROPERLY SECURE THE fore finding then required chapter
MACHINE BEFORE TRANS- and item.
PORTING IT. Bend the book at its edge, as
When transporting the ma- shown, to find the required fore
chine in another vehicle, al- edge symbol mark and go to a
ways be sure it is properly page for required item and de-
secured and in an upright po- scription.
sition and that the fuel cock is
in the "OFF" position. Other-
wise, fuel may leak out of the
carburetor or fuel tank.
TO THE NEW OWNER

This manual will provide you with a
good basic understanding of fea-
tures, operation, and basic mainte- MANUAL FORMAT
nance and inspection items of this All of the procedures in this manual
machine. Please read this manual are organized in a sequential, step-
carefully and completely before oper- by-step format. The information has
ating your new machine. If you have been complied to provide the me-
any questions regarding the opera- chanic with an easy to read, handy
tion or maintenance of your machine, reference that contains comprehen-
please consult your Yamaha dealer. sive explanations of all disassembly,
repair, assembly, and inspection op-
erations.
This manual should be considered a
In this revised format, the condition of
permanent part of this machine and
a faulty component will precede an
should remain with it even if the ma-
arrow symbol and the course of ac-
chine is subsequently sold.
tion required will follow the symbol,
NOTICE e.g.,
Some data in this manual may be- • Bearings
come outdated due to improve- Pitting/damage → Replace.
ments made to this model in the
future. If there is any question you
have regarding this manual or your
machine, please consult your
Yamaha dealer.
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)
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 inspec-
tion and adjustments", "Engine",
"Chassis", "Electrical" and "Tun-
ing"
2. The table of contents is at the be-
ginning of the manual. Look over
the general layout of the book be-
der of the jobs in the exploded di- 4. A job instruction chart "4" accom-
HOW TO READ DESCRIPTIONS
agram. A number that is enclosed panies the exploded diagram,
To help identify parts and clarify pro-
by a circle indicates a disassem- providing the order of jobs, names
cedure steps, there are exploded dia-
bly step. of parts, notes in jobs, etc.
grams at the start of each removal
3. An explanation of jobs and notes 5. For jobs requiring more informa-
and disassembly section.
is presented in an easy-to-read tion, the step-by-step format sup-
1. An easy-to-see exploded diagram
way by the use of symbol marks plements "5" are given in addition
"1" is provided for removal and
"3". The meanings of the symbol to the exploded diagram and job
disassembly jobs.
marks are given on the next page. instruction chart.
2. Numbers "2" are given in the or-
3 5
ILLUSTRATED SYMBOLS (Refer to Illustrated symbols "1" to "7" are used 14. Apply locking agent (LOC-
the illustration) to identify the specifications appear- TITE®)
ing in the text. 15. Use new one
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 current (A)
Illustrated symbols "8" to "13" in the
exploded diagrams indicate grade of
lubricant and location of lubrication
point.
8. Apply engine oil
9. Apply molybdenum disulfide oil
10. Apply brake fluid
11. Apply lightweight lithium-soap
base grease
12. Apply molybdenum disulfide
grease
13. Apply silicone grease
Illustrated symbols "14" to "15" in the
exploded diagrams indicate where to
apply a locking agent and where to in-
stall new parts.
TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
REGULAR INSPECTION AND
ADJUSTMENTS 3
ENGINE 4
CHASSIS 5
ELECTRICAL 6
TUNING 7
CONTENTS
CHAPTER 1 PRE-OPERATION STEERING ......................5-28

INSPECTION AND MAINTE- SWINGARM ....................5-32
GENERAL INFOR- NANCE ............................. 3-4 REAR SHOCK
MATION ENGINE ............................ 3-5 ABSORBER....................5-37
CHASSIS ........................ 3-13
ELECTRICAL ................. 3-22
DESCRIPTION ................. 1-1 CHAPTER 6
MACHINE
CHAPTER 4 ELECTRICAL
IDENTIFICATION ............ 1-2
INCLUDED PARTS .......... 1-2 ENGINE
IMPORTANT ELECTRICAL COMPO-
INFORMATION................. 1-2 NENTS AND WIRING DIA-
CHECKING OF CONNEC- SEAT, FUEL TANK AND GRAM ...............................6-1
TION ................................. 1-3 SIDE COVERS.................. 4-1 IGNITION SYSTEM...........6-2
SPECIAL TOOLS ............. 1-4 EXHAUST PIPE AND THROTTLE POSITION SEN-
CONTROL FUNCTIONS .. 1-8 SILENCER ........................ 4-3 SOR SYSTEM...................6-5
STARTING AND RADIATOR ....................... 4-5
BREAK-IN ........................ 1-8 CARBURETOR................. 4-7
TORQUE-CHECK CAMSHAFTS.................. 4-14 CHAPTER 7
POINTS........................... 1-11 CYLINDER HEAD........... 4-19 TUNING
CLEANING AND VALVES AND VALVE
STORAGE ...................... 1-12 SPRINGS ........................ 4-22
CYLINDER AND ENGINE.............................7-1
PISTON........................... 4-26 CHASSIS ..........................7-6
CHAPTER 2 CLUTCH ......................... 4-29
SPECIFICATIONS OIL FILTER ELEMENT
AND WATER PUMP....... 4-33
BALANCER .................... 4-37
GENERAL SPECIFICA- OIL PUMP....................... 4-39
TIONS ............................... 2-1 KICK SHAFT AND SHIFT
MAINTENANCE SPECIFICA- SHAFT ............................ 4-42
TIONS ............................... 2-3 CDI MAGNETO............... 4-47
TIGHTENING ENGINE REMOVAL ....... 4-49
TORQUES ...................... 2-10 CRANKCASE AND CRANK-
LUBRICATION SHAFT ............................ 4-53
DIAGRAMS .................... 2-16 TRANSMISSION, SHIFT
CABLE ROUTING CAM AND SHIFT FORK. 4-59
DIAGRAM....................... 2-18
CHAPTER 5
CHAPTER 3
CHASSIS
REGULAR INSPEC-
TION AND AD- FRONT WHEEL AND REAR
JUSTMENTS WHEEL ............................. 5-1
FRONT BRAKE AND REAR
BRAKE ............................. 5-6
MAINTENANCE FRONT FORK................. 5-16
INTERVALS...................... 3-1 HANDLEBAR ................. 5-24
DESCRIPTION
GENERAL INFORMATION
DESCRIPTION
1. Clutch lever 11. Coolant drain bolt

2. Hot starter lever 12. Rear brake pedal
3. Front brake lever 13. Valve joint
4. Throttle grip 14. Fuel cock
5. Radiator cap 15. Cold starter knob
6. Fuel tank cap 16. Drive chain
7. Engine stop switch 17. Air cleaner
8. Kickstarter crank 18. Shift pedal
9. Fuel tank 19. Oil dipstick
10. Radiator 20. Front fork
• The machine you have purchased may differ slightly from those shown in the following.
• Designs and specifications are subject to change without notice.
1-1
MACHINE IDENTIFICATION
MACHINE IDENTIFICATION IMPORTANT INFORMATION

There are two significant reasons for PREPARATION FOR REMOVAL
knowing the serial number of your AND DISASSEMBLY
machine: 1. Remove all dirt, mud, dust, and
1. When ordering parts, you can foreign material before removal
give the number to your Yamaha and disassembly.
dealer for positive identification of • When washing the machine with
the model you own. high pressured water, cover the
2. If your machine is stolen, the au- VALVE JOINT parts follows.
thorities will need the number to This valve joint "1" prevents fuel from Silencer exhaust port
search for and identify your ma- flowing out and is installed to the fuel Side cover air intake port
chine. tank breather hose. Water pump housing hole at the
VEHICLE IDENTIFICATION bottom
NUMBER In this installation, make sure the Drain hole on the cylinder head
The vehicle identification number "1" arrow faces the fuel tank and also (right side)
is stamped on the right of the steering downward.
head pipe.
ENGINE SERIAL NUMBER SPARK PLUG WRENCH

The engine serial number "1" is This spark plug wrench "1" is used to
stamped into the elevated part of the remove and install the spark plug.
right-side of the engine.
2. Use proper tools and cleaning

equipment. Refer to "SPECIAL
TOOLS" section.
NIPPLE WRENCH
MODEL LABEL This nipple wrench "1" is used to
The model label "1" is affixed to the tighten the spoke.
frame under the rider's seat. This in-
formation will be needed to order
spare parts.
3. When disassembling the ma-
chine, keep mated parts together.
They include gears, cylinders,
pistons, and other mated parts
that have been "mated" through
JET NEEDLE PULL-UP TOOL normal wear. Mated parts must
The jet needle pull-up tool "1" is used be reused as an assembly or re-
to pull the jet needle out of the carbu- placed.
INCLUDED PARTS retor.
DETACHABLE SIDESTAND
This sidestand "1" is used to support
only the machine when standing or
transporting it.
• Never apply additional force to

the sidestand. 4. During the machine disassembly,
• Remove this sidestand before clean all parts and place them in
starting out. trays in the order of disassembly.
This will speed up assembly time
1-2
CHECKING OF CONNECTION
and help assure that all parts are

correctly reinstalled.
6. Connect:
• Connector
5. Keep away from fire.
ALL REPLACEMENT PARTS The two connectors "click" together.
1. We recommend to use Yamaha
genuine parts for all replace- 7. Check for continuity with a tester.
ments. Use oil and/or grease rec-
ommended by Yamaha for • If there in no continuity, clean the
assembly and adjustment. CIRCLIPS terminals.
GASKETS, OIL SEALS AND O- 1. All circlips should be inspected • Be sure to perform the steps 1 to 7
RINGS carefully before reassembly. Al- listed above when checking the
1. All gaskets, oil seals, and O-rings ways replace piston pin clips after wire harness.
should be replaced when an en- one use. Replace distorted cir- • For a field remedy, use a contact re-
gine is overhauled. All gasket sur- clips. When installing a circlip "1", vitalizer available on the market.
faces, oil seal lips, and O-rings make sure that the sharp-edged • Use the tester on the connector as
must be cleaned. corner "2" is positioned opposite shown.
2. Properly oil all mating parts and to the thrust "3" it receives. See
bearings during reassembly. Ap- the sectional view.
ply 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.
CHECKING OF
CONNECTION
Dealing with stains, rust, moisture,
etc. on the connector.
1. Disconnect:
• Connector
2. Dry each terminal with an air
blower.
BEARINGS AND OIL SEALS

1. Install the bearing(s) "1" and oil
seal(s) "2" with their manufactur-
er's marks or numbers facing out-
ward. (In other words, the
stamped letters must be on the
side exposed to view.) When in-
stalling oil seal(s), apply a light 3. Connect and disconnect the con-
coating of lightweight lithium base nector two or three times.
grease to the seal lip(s). Oil the 4. Pull the lead to check that it will
bearings liberally when installing. not come off.
5. If the terminal comes off, bend up
the pin "1" and reinsert the termi-
Do not use compressed air to spin nal into the connector.
the bearings dry. This causes dam-
age to the bearing surfaces.
1-3
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.
• For U.S.A. and Canada, use part number starting with "YM-", "YU-" or "ACC-".
• For others, use part number starting with "90890-".
Tool name/Part number How to use Illustration

Dial gauge and stand These tools are used to check each
YU-3097, 90890-01252 part for runout or bend.
Stand
YU-1256
Crankshaft installing tool These tools are used to install the

Crankshaft installing pot crankshaft.
YU-90050, 90890-01274
Crankshaft installing bolt
YU-90050, 90890-01275
Spacer (crankshaft installer)
YM-91044, 90890-04081
Adapter (M12)
YU-90063, 90890-01278
Piston pin puller set This tool is used to remove the pis-
YU-1304, 90890-01304 ton pin.
Radiator cap tester These tools are used for checking

YU-24460-01, 90890-01325 the cooling system.
Radiator cap tester adapter
YU-33984, 90890-01352
Rotor puller This tool is used to remove the fly-

YM-04151, 90890-04151 wheel magneto.
1-4
SPECIAL TOOLS

Steering nut wrench This tool is used when tighten the
YU-33975, 90890-01403 steering ring nut to specification.
Cap bolt wrench This tool is used to loosen or tighten

YM-01500, 90890-01500 the base valve.
Cap bolt ring wrench This tool is used to loosen or tighten

YM-01501, 90890-01501 the damper assembly.
Fork seal driver This tool is used when install the fork
YM-A0948, 90890-01502 oil seal.
Pocket tester Use this tool to inspect the coil resis-

YU-3112-C, 90890-03112 tance, output voltage and amper-
age.
Timing light This tool is necessary for checking

YM-33277-A, 90890-03141 ignition timing.
Valve spring compressor This tool is needed to remove and

YM-4019, 90890-04019 install the valve assemblies.
1-5
SPECIAL TOOLS

Clutch holding tool This tool is used to hold the clutch
YM-91042, 90890-04086 when removing or installing the
clutch boss securing nut.
Valve guide remover This tool is needed to remove and

Intake 4.5 mm (0.18 in) install the valve guide.
Exhaust 5.0 mm (0.20 in)
YM-4116, 90890-04116
YM-4097, 90890-04097
Valve guide installer This tool is needed to install the

Intake 4.5 mm (0.18 in) valve guide.
YM-4117, 90890-04117
YM-4098, 90890-04098
Valve guide reamer This tool is needed to rebore the

Intake 4.5 mm (0.18 in) new valve guide.
YM-4118, 90890-04118
YM-4099, 90890-04099
Crankcase separating tool These tool is used to remove the

YU-A9642 crankshaft from either case.
90890-04152
Dynamic spark tester This instrument is necessary for

YM-34487 checking the ignition system compo-
Ignition checker nents.
90890-06754
1-6
SPECIAL TOOLS

Digital tachometer This tool is needed for observing en-
YU-39951-B, 90890-06760 gine rpm.
YAMAHA Bond No. 1215 (ThreeB- This sealant (Bond) is used for
ond® No. 1215) crankcase mating surface, etc.
90890-85505
1-7
CONTROL FUNCTIONS
CONTROL FUNCTIONS
ENGINE STOP SWITCH
The engine stop switch "1" is located
on the left handlebar. Continue push-
ing the engine stop switch till the en-
gine comes to a stop.
THROTTLE GRIP COLD STARTER KNOB

The throttle grip "1" is located on the When cold, the engine requires a
right handlebar; it accelerates or de- richer air-fuel mixture for starting. A
celerates the engine. For accelera- separate starter circuit, which is con-
tion, turn the grip toward you; for trolled by the cold starter knob "1",
deceleration, turn it away from you. supplies this mixture. Pull the cold
CLUTCH LEVER starter knob out to open the circuit for
The clutch lever "1" is located on the starting. When the engine has
left handlebar; it disengages or en- warmed up, push it in to close the cir-
gages the clutch. Pull the clutch lever cuit.
to the handlebar to disengage the
clutch, and release the lever to en-
gage the clutch. The lever should be
pulled rapidly and released slowly for
smooth starts. FRONT BRAKE LEVER
The front brake lever "1" is located on
the right handlebar. Pull it toward the
handlebar to activate the front brake.
HOT STARTER LEVER
The hot starter lever "1" is used when
starting a warm engine. Use the hot
starter lever when starting the engine
again immediately after it was
SHIFT PEDAL stopped (the engine is still warm).
The gear ratios of the constant-mesh Pulling the hot starter lever injects
5 speed transmission are ideally secondary air to thin the air-fuel mix-
spaced. The gears can be shifted by REAR BRAKE PEDAL ture temporarily, allowing the engine
using the shift pedal "1" on the left The rear brake pedal "1" is located on to be started more easily.
side of the engine. the right side of the machine. Press
down on the brake pedal to activate
the rear brake.
STARTING AND BREAK-IN

KICKSTARTER CRANK FUEL
Rotate the kickstarter crank "1" away Always use the recommended fuel as
from the engine. Push the starter FUEL COCK stated below. Also, be sure to use
down lightly with your foot until the The fuel cock supplies fuel from the new gasoline the day of a race.
gears engage, then kick smoothly tank to carburetor and also filters the
fuel. The fuel cock has the two posi- Recommended fuel:
and forcefully to start the engine. This Premium unleaded
model has a primary kickstarter crank tions:
OFF: gasoline only with a re-
so the engine can be started in any search octane number
gear if the clutch is disengaged. In With the lever in this position, fuel will
not flow. Always return the lever to of 95 or higher.
normal practices, however, shift to
neutral before starting. this position when the engine is not
running.
ON: Use only unleaded gasoline. The
With the lever in this position, fuel use of leaded gasoline will cause
flows to the carburetor. Normal riding severe damage to the engine inter-
is done with the lever in this position. nal parts such as valves, piston
rings, and exhaust system, etc.
1-8
6. Return the cold starter knob to its The engine fails to start
If knocking or pinging occurs, use a original position and run the en- Pull the hot starter lever all the way
different brand of gasoline or higher gine at 3,000–5,000 r/min for 1 or out and while holding the lever, kick
octane grade. 2 minutes. the kickstarter crank 10 to 20 times to
clear the engine. Then, restart the en-
Since this model is equipped with an gine. Refer to "Restarting an engine
accelerator pump, if the engine is after a fall".
• For refueling, be sure to stop the
engine and use enough care not raced (the throttle opened and Thrott
closed), the air/fuel mixture will be too Cold Hot
to spill any fuel. Also be sure to le
start- start-
avoid refueling close to a fire. rich and the engine may stall. Also grip
er er le-
• Refuel after the engine, exhaust unlike a two-stroke engine, this model oper-
knob ver
pipe, etc. have cooled off. can idle. ation*
Air tem-
HANDLING NOTE perature = Open
Do not warm up the engine for ex- less than 3 or 4 ON OFF
tended periods of time. 5 °C (41 times
Never start or run the engine in a °F)
closed area. The exhaust fumes STARTING A WARM ENGINE Air tem-
are poisonous; they can cause Do not operate the cold starter knob perature =
loss of consciousness and death and throttle. Pull the hot starter lever more than None ON OFF
in a very short time. Always oper- "1" and start the engine by kicking 5 °C (41
ate the machine in a well-ventilated the kickstarter crank forcefully with a Star °F)
area. firm stroke. As soon as the engine ting Air tem-
starts, release the hot starter lever to a perature
close the air passage. cold (normal
• The carburetor on this machine en- tempera-
has a built-in accelerator pump. gine ture) = be- None ON/ OFF
Therefore, when starting the en- OFF
tween 5
gine, do not operate the throttle °C (41 °F)
or the spark plug will foul. and 25 °C
• Unlike a two-stroke engine, this (77 °F)
engine cannot be kick started Air tem-
when the throttle is open be- perature =
cause the kickstarter may kick Restarting an engine after a fall more than None OFF OFF
back. Also, if the throttle is open Pull the hot starter lever and start the 25 °C (77
the air/fuel mixture may be too engine. As soon as the engine starts, °F)
lean for the engine to start. release the hot starter lever to close
Starting an en-
• Before starting the machine, per- the air passage.
gine after a long None ON OFF
form the checks in the pre-opera-
period of time
tion check list.
Restarting a
None OFF ON
STARTING A COLD ENGINE warm engine
1. Inspect the coolant level. Restarting an
2. Turn the fuel cock to "ON". engine after a None OFF ON
3. Shift the transmission into neutral. fall
4. Fully open the cold starter knob
* Operate the throttle grip before kick
"1". starting.
5. Kick the kickstarter crank.
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 the fuel.
Do not open the throttle while kick- 2. Perform the pre-operation checks
ing the kickstarter crank. Other- on the machine.
wise, the kickstarter crank may 3. Start and warm up the engine.
kick back. Check the idle speed, and check
the operation of the controls and
1-9
the engine stop switch. Then, re-

start the engine and check its op-
eration within no more than 5
minutes after it is restarted.
4. Operate the machine in the lower
gears at moderate throttle open-
ings for five to eight minutes.
5. Check how the engine runs when
the machine is ridden with the
throttle 1/4 to 1/2 open (low to me-
dium speed) for about one hour.
6. Restart the engine and check the
operation of the machine through-
out its entire operating range. Re-
start the machine and operate it
for about 10 to 15 more minutes.
The machine will now be ready to
race.
• After the break-in or before each

race, you must check the entire
machine for loose fittings and
fasteners as per "TORQUE-
CHECK 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 oper-
ation is necessary.
PISTON, RING, VALVES, CAM-
SHAFTS 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.
1-10
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
Tightening of brake hose holder
Fuel system Fuel tank to fuel cock
Lubrication system Tightening of oil hose clamp
Concerning the tightening torque, refer to "TIGHTENING TORQUES" section in the CHAPTER 2.
1-11
CLEANING AND STORAGE
CLEANING AND STORAGE the carburetor float bowl.

CLEANING 2. Remove the spark plug, pour a ta-
Frequent cleaning of your machine blespoon of SAE 10W-30 motor
will enhance its appearance, maintain oil in the spark plug hole, and re-
good overall performance, and ex- install the plug. With the engine
tend the life of many components. stop switch pushed in, kick the en-
1. Before washing the machine, gine over several times to coat the
block off the end of the exhaust cylinder walls with oil.
pipe to prevent water from enter- 3. Remove the drive chain, clean it
ing. A plastic bag secured with a thoroughly with solvent, and lubri-
rubber band may be used for this cate it. Reinstall the chain or store
purpose. it in a plastic bag tied to the frame.
2. If the engine is excessively 4. Lubricate all control cables.
greasy, apply some degreaser to 5. Block the frame up to raise the
it with a paint brush. Do not apply wheels off the ground.
degreaser to the chain, sprockets, 6. Tie a plastic bag over the exhaust
or wheel axles. pipe outlet to prevent moisture
3. Rinse the dirt and degreaser off from entering.
with a garden hose; use only 7. If the machine is to be stored in a
enough pressure to do the job. humid or salt-air environment,
coat all exposed metal surfaces
with a film of light oil. Do not apply
Excessive hose pressure may oil to rubber parts or the seat cov-
cause water seepage and contami- er.
nation of wheel bearings, front
forks, brakes and transmission Make any necessary repairs before
seals. Many expensive repair bills the machine is stored.
have resulted from improper high
pressure detergent applications
such as those available in coin-op-
erated car washers.
4. After the majority of the dirt has

been hosed off, wash all surfaces
with warm water and a mild deter-
gent. Use an old toothbrush to
clean hard-to-reach places.
5. Rinse the machine off immediate-
ly with clean water, and dry all
surfaces with a soft towel or cloth.
6. Immediately after washing, re-
move excess water from the
chain with a paper towel and lubri-
cate the chain to prevent rust.
7. Clean the seat with a vinyl uphol-
stery cleaner to keep the cover
pliable and glossy.
8. Automotive wax may be applied
to all painted or chromed surfac-
es. Avoid combination cleaner-
waxes, as they may contain abra-
sives.
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 mea-
sures must be taken to avoid deterio-
ration. After cleaning the machine
thoroughly, prepare it for storage as
follows:
1. Drain the fuel tank, fuel lines, and
1-12
GENERAL SPECIFICATIONS
SPECIFICATIONS
Model name: YZ450FX (USA, CDN, AUS, NZ)
YZ450F (EUROPE, ZA)
Model code number: 2S2B (USA,CDN)
2S2C (EUROPE)
2S2E (AUS, NZ, ZA)
Dimensions: USA, CDN, AUS, NZ, ZA EUROPE
2
Overall length 2,194 mm (86.38 in) 2,195 mm (86.42 in)
Overall width 825 mm (32.48 in) ←
Overall height 1,306 mm (51.42 in) ←
Seat height 990 mm (38.98 in) 1,001 mm (39.41 in)
Wheelbase 1,495 mm (58.86 in) ←
Minimum ground clearance 374 mm (14.72 in) 375 mm (14.76 in)
Dry weight:
Without oil and fuel 99.5 kg (219 lb)
Engine:
Engine type Liquid cooled 4-stroke, DOHC
Cylinder arrangement Single cylinder, forward inclined
Displacement 449 cm3 (15.8 Imp oz, 15.2 US oz)
Bore × stroke 95.0 × 63.4 mm (3.74 × 2.50 in)
Compression ratio 12.3 : 1
Starting system Kickstarter
Lubrication system: Dry sump
Oil type or grade:
Engine oil (For USA and CDN)
Yamalube 4, SAE10W30 or SAE20W40
Yamalube 4-R, SAE10W50
API service SG type or higher,
JASO standard MA
(Except for USA and CDN)

SAE10W30, SAE10W40, SAE15W40,
SAE20W40 or SAE20W50
API service SG type or higher,
JASO standard MA
Oil capacity:
Engine oil
Periodic oil change 0.95 L (0.84 Imp qt, 1.00 US qt)
With oil filter replacement 1.0 L (0.88 Imp qt, 1.06 US qt)
Total amount 1.2 L (1.06 Imp qt, 1.27 US qt)
Coolant capacity (including all routes): 0.99 L (0.87 Imp qt, 1.05 US qt)
Air filter: Wet type element
2-1
Fuel:
Type Premium unleaded gasoline only with a research octane
number of 95 or higher.
Tank capacity 7.0 L (1.54 Imp gal, 1.85 US gal)
Carburetor:
Type FCR-MX39
Manufacturer KEIHIN
Spark plug:
Type/manufacturer CR8E/NGK (resistance type)
Gap 0.7–0.8 mm (0.028–0.031 in)
Clutch type: Wet, multiple-disc
Transmission:
Primary reduction system Gear
Primary reduction ratio 61/23 (2.652)
Secondary reduction system Chain drive
Secondary reduction ratio 49/13 (3.769)
Transmission type Constant mesh, 5-speed
Operation Left foot operation
Gear ratio:
1st 27/14 (1.929)
2nd 23/15 (1.533)
3rd 23/18 (1.278)
4th 24/22 (1.091)
5th 20/21 (0.952)
Chassis: USA, CDN, AUS, NZ, ZA EUROPE
Frame type Semi double cradle ←
Caster angle 26.9° 26.7°
Trail 115.2 mm (4.54 in) 113.8 mm (4.48 in)
Tire:
Type With tube
Size (front) 80/100-21 51M
Size (rear) 120/80-19 63M (For USA, CDN, ZA, AUS, NZ)
110/90-19 62M (For EUROPE)
Tire pressure (front and rear) 100 kPa (1.0 kgf/cm2, 15 psi)
Brake:
Front brake type Single disc brake
Operation Right hand operation
Rear brake type Single disc brake
Operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm (link type monocross suspension)
Shock absorber:
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/gas, oil damper
2-2
MAINTENANCE SPECIFICATIONS
Wheel travel:
Front wheel travel 300 mm (11.8 in)
Rear wheel travel 313 mm (12.3 in)
Electrical:
Ignition system CDI magneto
ENGINE
Item Standard Limit

Cylinder head:
Warp limit ---- 0.05 mm (0.002
in)
Cylinder:
Bore size 95.00–95.01 mm (3.7402–3.7406 in) ----
Out of round limit ---- 0.05 mm (0.002
in)
Camshaft:
Drive method Chain drive (Left) ----
Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in) ----
Camshaft outside diameter 21.959–21.972 mm (0.8645–0.8650 in) ----
Shaft-to-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) 0.08 mm (0.003
in)
Cam dimensions
Intake "A" 31.200–31.300 mm (1.2283–1.2323 in) 31.100 mm

(1.2244 in)
Intake "B" 22.550–22.650 mm (0.8878–0.8917 in) 22.450 mm
(0.8839 in)
Exhaust "A" 30.900–31.000 mm (1.2165–1.2205 in) 30.800 mm
(1.2126 in)
Exhaust "B" 22.468–22.568 mm (0.8846–0.8885 in) 22.368 mm
(0.8806 in)
Camshaft runout limit ---- 0.03 mm
(0.0012 in)
2-3
Item Standard Limit

Timing chain:
Timing chain type/No. of links 98XRH2010-118M/118 ----
Timing chain adjustment method Automatic ----
Valve, valve seat, valve guide:
Valve clearance (cold)
IN 0.10–0.15 mm (0.0039–0.0059 in) ----
EX 0.20–0.25 mm (0.0079–0.0098 in) ----
Valve dimensions:
"A" head diameter (IN) 26.9–27.1 mm (1.0591–1.0669 in) ----
"A" head diameter (EX) 27.9–28.1 mm (1.0984–1.1063 in) ----
"B" face width (IN) 2.26 mm (0.089 in) ----

"B" face width (EX) 2.26 mm (0.089 in) ----
"C" seat width (IN) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630

in)
"C" seat width (EX) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630
in)
"D" margin thickness (IN) 1 mm (0.0394 in) 0.85 mm (0.033

in)
"D" margin thickness (EX) 1 mm (0.0394 in) 0.85 mm (0.033
in)
Stem outside diameter (IN) 4.475–4.490 mm (0.1762–0.1768 in) 4.445 mm

(0.1750 in)
Stem outside diameter (EX) 4.965–4.980 mm (0.1955–0.1961 in) 4.935 mm
(0.1943 in)
Guide inside diameter (IN) 4.500–4.512 mm (0.1772–0.1776 in) 4.550 mm
(0.1791 in)
Guide inside diameter (EX) 5.000–5.012 mm (0.1969–0.1973 in) 5.050 mm
(0.1988 in)
2-4
Item Standard Limit

Stem-to-guide clearance (IN) 0.010–0.037 mm (0.0004–0.0015 in) 0.08 mm (0.003
in)
Stem-to-guide clearance (EX) 0.020–0.047 mm (0.0008–0.0019 in) 0.10 mm (0.004
in)
Stem runout limit ---- 0.01 mm
(0.0004 in)
Valve seat width (IN) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630

in)
Valve seat width (EX) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630
in)
Valve spring:
Free length (IN) 37.03 mm (1.46 in) 36.03 mm (1.42
in)
Free length (EX) 37.68 mm (1.48 in) 36.68 mm (1.44
in)
Set length (valve closed) (IN) 27.87 mm (1.10 in) ----
Set length (valve closed) (EX) 27.38 mm (1.08 in) ----
Compressed force (installed) (IN) 111.3–127.9 N at 27.87 mm (11.3–13.0 kg ----
at 27.87 mm, 24.91–28.66 lb at 1.10 in)
Compressed force (installed) (EX) 127.4–146.4 N at 27.38 mm (13.0–14.9 kg ----
at 27.38 mm, 28.66–32.85 lb at 1.08 in)
Tilt limit* (IN) ---- 2.5°/1.61 mm
(2.5°/0.063 in)
Tilt limit* (EX) ---- 2.5°/1.65 mm
(2.5°/0.065 in)
Direction of winding (top view) (IN) Clockwise ----

Direction of winding (top view) (EX) Clockwise ----
Piston:
Piston to cylinder clearance 0.020–0.045 mm (0.0008–0.0018 in) 0.1 mm (0.004
in)
Piston size "D" 94.965–94.980 mm (3.7388–3.7394 in) ----
Measuring point "H" 8 mm (0.315 in) ----
2-5
Item Standard Limit

Piston off-set 1 mm (0.0394 in) ----
Piston pin bore inside diameter 18.004–18.015 mm (0.7088–0.7093 in) 18.045 mm
(0.7104 in)
Piston pin outside diameter 17.991–18.000 mm (0.7083–0.7087 in) 17.971 mm
(0.7075 in)
Piston rings:
Top ring:
Type Barrel ----

Dimensions (B × T) 1.2 × 3.5 mm (0.05 × 0.14 in) ----
End gap (installed) 0.20–0.30 mm (0.008–0.012 in) 0.55 mm (0.022
in)
Side clearance (installed) 0.030–0.065 mm (0.0012–0.0026 in) 0.12 mm (0.005
in)
2nd ring:
Type Taper ----

End gap (installed) 0.35–0.50 mm (0.014–0.020 in) 0.85 mm (0.033
in)
Side clearance 0.020–0.055 mm (0.0008–0.0022 in) 0.12 mm (0.005
in)
Oil ring:

End gap (installed) 0.2–0.5 mm (0.01–0.02 in) ----
Crankshaft:
Crank width "A" 61.95–62.00 mm (2.439–2.441 in) ----
Runout limit "C" 0.03 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 (0.02
in)
Small end free play "F" 0.4–1.0 mm (0.02–0.04 in) 2.0 mm (0.08
in)
Balancer:
Balancer drive method Gear ----
2-6
Item Standard Limit

Air filter oil grade: Foam-air-filter oil or equivalent oil ----
Clutch:
Friction plate thickness 2.92–3.08 mm (0.115–0.121 in) 2.8 mm (0.110
in)
Quantity 8 ----
Clutch plate thickness 1.5–1.7 mm (0.059–0.067 in) ----
Quantity 7 ----
Warp limit ---- 0.1 mm (0.004
in)
Clutch spring free length 50.0 mm (1.97 in) 49.0 mm (1.93
in)
Quantity 6 ----
Clutch housing thrust clearance 0.10–0.35 mm (0.0039–0.0138 in) ----
Clutch housing radial clearance 0.010–0.044 mm (0.0004–0.0017 in) ----
Clutch release method Inner push, cam push ----
Shifter:
Shifter type Cam drum and guide bar ----
Guide bar bending limit ---- 0.05 mm (0.002
in)
Kickstarter:
Type Kick and ratchet type ----
Carburetor:
Type/manufacturer FCR-MX39/KEIHIN ----
I. D. mark 2S2B B0 ----
Main jet (M.J) #160 ----
Main air jet (M.A.J) ø2.0 ----
Jet needle - clip position (J.N) NFLR-3 ----
Cutaway (C.A) 1.5 ----
Pilot jet (P.J) #45 ----
Pilot air jet (P.A.J) #100 ----
Pilot outlet (P.O) ø0.9 ----
Pilot screw (example) (P.S) 1-1/2 ----
Bypass (B.P) ø1.0 ----
Valve seat size (V.S) ø3.8 ----
Starter jet (G.S) #72 ----
Leak jet (Acc.P) #55 ----
Float height (F.H) 8 mm (0.31 in) ----
Engine idle speed 1,900–2,100 r/min ----
Intake vacuum 28.0–33.3 kPa (210–250 mmHg, 8.27– ----
9.84 inHg)
Hot starter lever free play 3–6 mm (0.12–0.24 in) ----
Lubrication system:
Oil filter type Paper type ----
Oil pump type Trochoid type ----
Tip clearance 0.12 mm or less (0.0047 in or less) 0.20 mm (0.008
in)
2-7
Item Standard Limit

Side clearance 0.09–0.17 mm (0.0035–0.0067 in) 0.24 mm (0.009
in)
Housing and rotor clearance 0.03–0.10 mm (0.0012–0.0039 in) 0.17 mm (0.007
in)
Bypass valve setting pressure 40–80 kPa (0.4–0.8 kg/cm2, 5.69–11.38 ----
psi)
Cooling:
Radiator core size
Width 120.2 mm (4.73 in) ----
Height 240 mm (9.45 in) ----
Thickness 22 mm (0.87 in) ----
2,
Radiator cap opening pressure 110 kPa (1.1 kg/cm 15.6 psi) ----
Radiator capacity (total) 0.56 L (0.49 Imp qt, 0.59 US qt) ----
Water pump
Type Single-suction centrifugal pump ----
CHASSIS
Item Standard Limit

Steering system:
Steering bearing type Taper roller bearing ----
Front suspension:
Front fork travel 300 mm (11.8 in) ----
Fork spring free length 454 mm (17.9 in) 449 mm (17.7
in)
Spring rate, STD K = 4.6 N/mm (0.469 kg/mm, 26.3 lb/in) ----
Optional spring Yes ----
Oil capacity 541 cm3 (19.0 lmp oz, 18.3 US oz) ----
Oil grade Suspension oil "S1" ----
Inner tube outer diameter 48 mm (1.89 in) ----
Front fork top end 5 mm (0.20 in) ----
Rear suspension: USA, CDN, AUS, NZ,
EUROPE
ZA
Shock absorber travel 131.5 mm (5.18 in) ← ----
Spring free length Approx.275 mm (10.83 ← ----
in)
Fitting length
One I.D. mark 267 mm (10.51 in) 262 mm (10.31 in) ----
Two I.D. marks 273 mm (10.75 in) 268 mm (10.55 in) ----
Three I.D. marks 264.5 mm (10.41 in) 259.5 mm (10.22 in) ----
<Min.–Max.>
One I.D. mark 255.5–273.5 mm ← ----
(10.06–10.77 in)
Two I.D. marks 261.5–279.5 mm ← ----
(10.30–11.00 in)
Three I.D. marks 253.0–271.0 mm (9.96– ← ----
10.67 in)
Spring rate, STD K = 54.0 N/mm (5.50 kg/ ← ----
mm, 308.0 lb/in)
2-8
Item Standard Limit

Optional spring Yes ← ----
Enclosed gas pressure 1,000 kPa (10 kg/cm2, ← ----
142 psi)
Swingarm:
Swingarm free play limit
End ---- 1.0 mm (0.04
in)
Wheel:
Front wheel type Spoke wheel ----
Rear wheel type Spoke wheel ----
Front rim size/material 21 × 1.60/Aluminum ----
Rear rim size/material 19 × 2.15/Aluminum ----
Rim runout limit:
Radial ---- 2.0 mm (0.08
in)
Lateral ---- 2.0 mm (0.08
in)
Drive chain:
Type/manufacturer DID520DMA2 SDH/DAIDO ----
Number of links 113 links + joint ----
Chain slack 48–58 mm (1.9–2.3 in) ----
Chain length (15 links) ---- 242.9 mm
(9.563 in)
Front disc brake:
Disc outside dia.×Thickness 250 × 3.0 mm (9.84 × 0.12 in) 250 × 2.5 mm
(9.84 × 0.10 in)
Pad thickness 4.4 mm (0.17 in) 1.0 mm (0.04
in)
Master cylinder inside dia. 9.52 mm (0.375 in) ----
Caliper cylinder inside dia. 22.65 mm (0.892 in) × 2 ----
Brake fluid type DOT #4 ----
Rear disc brake:
Disc outside dia.×Thickness 245 × 4.0 mm (9.65 × 0.16 in) 245 × 3.5 mm
(9.65 × 0.14 in)
Deflection limit ---- 0.15 mm
(0.006 in)
Pad thickness 6.4 mm (0.25 in) 1.0 mm (0.04
in)
Master cylinder inside dia. 11.0 mm (0.433 in) ----
Caliper cylinder inside dia. 25.4 mm (1.000 in) × 1 ----
Brake fluid type DOT #4 ----
Brake lever and brake pedal:
Brake lever position 95 mm (3.74 in) ----
Brake pedal height (vertical height above footrest 5 mm (0.20 in) ----
top)
Clutch lever free play (lever end) 8–13 mm (0.31–0.51 in) ----
Throttle grip free play 3–5 mm (0.12–0.20 in) ----
2-9
TIGHTENING TORQUES
ELECTRICAL
Item Standard Limit

Ignition system:
Advancer type Electrical ----
CDI:
Magneto-model (stator)/manufacturer 2S200/YAMAHA ----
Charging coil 1 resistance (color) 720–1,080 Ωat 20 °C (68 °F) (Green– ----
Brown)
Charging coil 2 resistance (color) 44–66 Ωat 20 °C (68 °F) (Black–Pink) ----
Pickup coil resistance (color) 248–372 Ωat 20 °C (68 °F) (White–Red) ----
CDI unit-model/manufacturer 2S2-B0/YAMAHA (Except for EUROPE) ----
2S2-C0/YAMAHA (For EUROPE) ----
Ignition coil:
Model/manufacturer 5TA-10/DENSO ----
Minimum spark gap 6 mm (0.24 in) ----
Primary coil resistance 0.08–0.10 Ωat 20 °C (68 °F) ----
Secondary coil resistance 4.6–6.8 kΩat 20 °C (68 °F) ----
TIGHTENING TORQUES
ENGINE
△ - marked portion shall be checked for torque tightening after break-in or before each race.
Tightening torque
Part to be tightened Thread size Q'ty
Nm m•kg ft•lb
Spark plug M10S × 1.0 1 13 1.3 9.4
Camshaft cap M6 × 1.0 10 10 1.0 7.2
Cylinder head blind plug screw M12 × 1.0 1 28 2.8 20
Cylinder head (stud bolt) M8 × 1.25 1 15 1.5 11
*1
Cylinder head (bolt) M10 × 1.25 4 Refer to NOTE.
Cylinder head (bolt) M6 × 1.0 2 10 1.0 7.2
Cylinder head cover M6 × 1.0 2 10 1.0 7.2
Cylinder M6 × 1.0 1 10 1.0 7.2
Timing chain tensioner M6 × 1.0 2 10 1.0 7.2
Timing chain tensioner cap bolt M6 × 1.0 1 7 0.7 5.1
Timing chain guide (intake side) M6 × 1.0 2 10 1.0 7.2
Exhaust pipe (nut) M8 × 1.25 1 20 2.0 14
Exhaust pipe (bolt) M8 × 1.25 1 20 2.0 14
△ Silencer M8 × 1.25 2 30 3.0 22
Silencer clamp M8 × 1.25 1 14 1.4 10
Exhaust pipe protector M6 × 1.0 3 10 1.0 7.2
Carburetor joint M6 × 1.0 3 10 1.0 7.2
Carburetor joint clamp M4 × 0.7 1 3 0.3 2.2
△ Air filter case M6 × 1.0 2 8 0.8 5.8
Air filter joint clamp M6 × 1.0 1 3 0.3 2.2
Air filter joint and air filter case M5 × 0.8 1 4 0.4 2.9
Throttle cable adjust bolt and locknut M6 × 0.75 1 4 0.4 2.9
Throttle cable (pull) M6 × 1.0 1 4 0.4 2.9
2-10
TIGHTENING TORQUES
Tightening torque
Nm m•kg ft•lb
Throttle cable (return) M12 × 1.0 1 11 1.1 8.0
Throttle cable cover M5 × 0.8 2 4 0.4 2.9
Hot starter plunger M12 × 1.0 1 2 0.2 1.4
Hot starter cable adjust bolt and locknut M6 × 0.75 1 4 0.4 2.9
Air filter element M6 × 1.0 1 2 0.2 1.4
Radiator stay M6 × 1.0 6 7 0.7 5.1
Radiator M6 × 1.0 4 10 1.0 7.2
Radiator hose clamp M6 × 1.0 8 2 0.2 1.4
Radiator pipe 1, 2 M6 × 1.0 2 10 1.0 7.2
Impeller M8 × 1.25 1 14 1.4 10
Water pump housing cover M6 × 1.0 3 10 1.0 7.2
Coolant drain bolt M6 × 1.0 1 10 1.0 7.2
Oil pump cover M4 × 0.7 1 2 0.2 1.4
Oil pump M6 × 1.0 2 10 1.0 7.2
Oil pump drive gear shaft M6 × 1.0 1 10 1.0 7.2
Oil filter element drain bolt M6 × 1.0 1 10 1.0 7.2
Oil filter element cover M6 × 1.0 2 10 1.0 7.2
Oil pressure check bolt M6 × 1.0 1 10 1.0 7.2
△ Oil hose clamp — 2 2 0.2 1.4
Crankshaft end accessing screw M27 × 1.5 1 10 1.0 7.2
Timing mark accessing screw M14 × 1.5 1 6 0.6 4.3
Clutch cover M6 × 1.0 7 10 1.0 7.2
Right crankcase cover M6 × 1.0 8 10 1.0 7.2
Right crankcase cover M6 × 1.0 2 12 1.2 8.7
Left crankcase cover M6 × 1.0 8 10 1.0 7.2
Crankcase M6 × 1.0 12 12 1.2 8.7
Clutch cable holder M6 × 1.0 2 10 1.0 7.2
Oil drain bolt (right crankcase) M10 × 1.25 1 20 2.0 14
Oil drain bolt (left crankcase) M8 × 1.25 1 20 2.0 14
Oil check bolt (crankcase) M6 × 1.0 1 10 1.0 7.2
Oil strainer M6 × 1.0 1 10 1.0 7.2
Crankcase bearing stopper M6 × 1.0 8 10 1.0 7.2
Crankcase bearing stopper (crankshaft) M6 × 1.0 4 14 1.4 10
Drive axle oil seal stopper M6 × 1.0 2 10 1.0 7.2
Kick shaft ratchet wheel guide M6 × 1.0 2 12 1.2 8.7
Kickstarter crank M8 × 1.25 1 33 3.3 24
Screw (kickstarter crank) M6 × 1.0 1 7 0.7 5.1
Primary drive gear M20 × 1.0 1 110 11.0 80
Clutch boss M20 × 1.0 1 75 7.5 54
Clutch cable adjust bolt and locknut M6 × 0.75 1 4 0.4 2.9
Clutch spring M6 × 1.0 6 10 1.0 7.2
Balancer M10 × 1.0 1 45 4.5 32
Balancer shaft driven gear M14 × 1.0 1 50 5.0 36
Balancer weight M6 × 1.0 3 10 1.0 7.2
2-11
TIGHTENING TORQUES
Tightening torque
Nm m•kg ft•lb
Drive sprocket M20 × 1.0 1 75 7.5 54
Drive chain sprocket cover M6 × 1.0 2 8 0.8 5.8
Shift pedal M6 × 1.0 1 12 1.2 8.7
Shift guide M6 × 1.0 2 10 1.0 7.2
Stopper lever M6 × 1.0 1 10 1.0 7.2
Segment M8 × 1.25 1 30 3.0 22
*1: Tighten the cylinder head bolts to 30 Nm (3.0 m • kg, 22 ft • lb) in the proper tightening sequence, remove and retighten
the cylinder head bolts to 20 Nm (2.0 m • kg, 14 ft • lb) in the proper tightening sequence, and then tighten the cylinder head
bolts further to reach the specified angle 180° in the proper tightening sequence.
CHASSIS
△ - marked portion shall be checked for torque tightening after break-in or before each race.
Tightening torque
Nm m•kg ft•lb
△ Upper bracket and outer tube M8 × 1.25 4 21 2.1 15
△ Lower bracket and outer tube M8 × 1.25 4 21 2.1 15
△ Upper bracket and steering stem M24 × 1.0 1 145 14.5 105
△ Handlebar upper holder M8 × 1.25 4 28 2.8 20
△ Handlebar lower holder M10 × 1.25 2 34 3.4 24
△ Steering ring nut M28 × 1.0 1 Refer to NOTE.
Front fork and damper assembly M51 × 1.5 2 30 3.0 22
Front fork and adjuster M22 × 1.25 2 55 5.5 40
Damper assembly and base valve M42 × 1.5 2 29 2.9 21
Adjuster and damper assembly M12 × 1.25 2 29 2.9 21
Bleed screw (front fork) and base valve M5 × 0.8 2 1 0.1 0.7
△ Front fork and front fork protector M6 × 1.0 6 5 0.5 3.6
△ Front fork protector and brake hose holder M6 × 1.0 2 7 0.7 5.1
Throttle grip cap M5 × 0.8 2 4 0.4 2.9
Clutch lever holder M5 × 0.8 2 4 0.4 2.9
Clutch lever mounting nut M6 × 1.0 1 4 0.4 2.9
Hot starter lever holder M5 × 0.8 2 4 0.4 2.9
△ Front brake master cylinder and bracket M6 × 1.0 2 9 0.9 6.5
Front brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
Brake lever mounting bolt M6 × 1.0 1 6 0.6 4.3
Brake lever mounting nut M6 × 1.0 1 6 0.6 4.3
Brake lever position locknut M6 × 1.0 1 5 0.5 3.6
△ Cable guide (front brake hose) and under bracket M6 × 1.0 1 4 0.4 2.9
△ Front brake hose union bolt (brake master cylinder) M10 × 1.25 1 30 3.0 22
△ Front brake hose union bolt (brake caliper) M10 × 1.25 1 30 3.0 22
△ Front brake caliper and front fork M8 × 1.25 2 28 2.8 20
△ Brake caliper (front and rear) and pad pin plug M10 × 1.0 2 3 0.3 2.2
△ Brake caliper (front and rear) and pad pin M10 × 1.0 2 18 1.8 13
△ Brake caliper (front and rear) and bleed screw M8 × 1.25 2 6 0.6 4.3
2-12
TIGHTENING TORQUES
Tightening torque
Nm m•kg ft•lb
△ Front wheel axle and axle nut M16 × 1.5 1 105 10.5 75
△ Front wheel axle holder M8 × 1.25 4 21 2.1 15
△ Front brake disc and wheel hub M6 × 1.0 6 12 1.2 8.7
△ Rear brake disc and wheel hub M6 × 1.0 6 14 1.4 10
△ Footrest bracket and frame M10 × 1.25 4 55 5.5 40
△ Brake pedal mounting M8 × 1.25 1 26 2.6 19
△ Rear brake master cylinder and frame M6 × 1.0 2 10 1.0 7.2
Rear brake master cylinder cap M4 × 0.7 2 2 0.2 1.4
△ Rear brake hose union bolt (brake caliper) M10 × 1.25 1 30 3.0 22
△ Rear brake hose union bolt (brake master cylinder) M10 × 1.25 1 30 3.0 22
△ Rear wheel axle and axle nut M20 × 1.5 1 125 12.5 90
△ Driven sprocket and wheel hub M8 × 1.25 6 42 4.2 30
△ Nipple (spoke) — 72 3 0.3 2.2
△ Disc cover and rear brake caliper M6 × 1.0 2 10 1.0 7.2
△ Protector and rear brake caliper M6 × 1.0 2 7 0.7 5.1
Drive chain puller adjust bolt and locknut M8 × 1.25 2 19 1.9 13
Engine mounting:
△ Upper engine bracket and frame M10 × 1.25 4 55 5.5 40
△ Lower engine bracket and frame M8 × 1.25 4 34 3.4 24
△ Engine and engine bracket (front) M10 × 1.25 1 53 5.3 38
△ Engine and engine bracket (upper) M10 × 1.25 1 55 5.5 40
△ Engine and frame (lower) M10 × 1.25 1 53 5.3 38
△ Engine guard M6 × 1.0 1 10 1.0 7.2
Lower engine guard M6 × 1.0 3 10 1.0 7.2
CDI unit bracket M6 × 1.0 2 7 0.7 5.1
Cable guide and CDI unit bracket M5 × 0.8 2 4 0.4 2.9
Cable guide and frame M5 × 0.8 1 5 0.5 3.6
△ Pivot shaft and nut M16 × 1.5 1 85 8.5 61
△ Relay arm and swingarm M14 × 1.5 1 70 7.0 50
△ Relay arm and connecting rod M14 × 1.5 1 80 8.0 58
△ Connecting rod and frame M14 × 1.5 1 80 8.0 58
△ Rear shock absorber and frame M10 × 1.25 1 56 5.6 40
△ Rear shock absorber and relay arm M10 × 1.25 1 53 5.3 38
△ Rear frame and frame (upper) M8 × 1.25 1 38 3.8 27
△ Rear frame and frame (lower) M8 × 1.25 2 32 3.2 23
△ Swingarm and brake hose holder M5 × 0.8 4 2 0.2 1.4
Swingarm and patch M4 × 0.7 4 2 0.2 1.4
Upper drive chain tensioner M8 × 1.25 1 16 1.6 11
Lower drive chain tensioner M8 × 1.25 1 16 1.6 11
Drive chain support and swingarm M6 × 1.0 3 7 0.7 5.1
△ Seal guard and swingarm M5 × 0.8 4 6 0.6 4.3
△ Fuel tank mounting boss and frame M10 × 1.25 1 20 2.0 14
△ Fuel tank mounting M6 × 1.0 2 9 0.9 6.5
△ Fuel tank and fuel cock M6 × 1.0 2 4 0.4 2.9
2-13
TIGHTENING TORQUES
Tightening torque
Nm m•kg ft•lb
Fuel tank and seat set bracket M6 × 1.0 1 7 0.7 5.1
Fuel tank and fuel tank bracket M6 × 1.0 4 7 0.7 5.1
Seat M8 × 1.25 2 23 2.3 17
△ Side cover M6 × 1.0 2 7 0.7 5.1
△ Air scoop and fuel tank M6 × 1.0 6 7 0.7 5.1
△ Air scoop and radiator guard (lower) M6 × 1.0 2 7 0.7 5.1
△ Front fender M6 × 1.0 4 7 0.7 5.1
△ Rear fender (front) M6 × 1.0 2 7 0.7 5.1
△ Rear fender (rear) M6 × 1.0 2 16 1.6 11
△ Number plate M6 × 1.0 1 7 0.7 5.1
1. First, tighten the steering ring nut approximately 38 Nm (3.8 m•kg, 27 ft•lb) by using the steering nut wrench, then loosen
the steering ring nut one turn.
2. Retighten the steering ring nut 7 Nm (0.7 m•kg, 5.1 ft•lb).
ELECTRICAL
Tightening torque
Nm m•kg ft•lb
Stator M6 × 1.0 3 10 1.0 7.2
Rotor M12 × 1.25 1 56 5.6 40
Neutral switch M5 × 0.8 2 4 0.4 2.9
2-14
TIGHTENING TORQUES
GENERAL TORQUE
SPECIFICATIONS B TORQUE SPECIFI-
A CATION
This chart specifies torque for stan- (Bolt
(Nut)
dard fasteners with standard I.S.O. ) Nm m•kg ft•lb
pitch threads. Torque specifications
10
for special components or assem- 6 mm 6 0.6 4.3
mm
blies are included in the applicable
sections of this book. To avoid 12
8 mm 15 1.5 11
warpage, tighten multi-fastener as- A. Distance between flats mm
semblies in a crisscross fashion, in B. Outside thread diameter 14 10
progressive stages, until full torque is 30 3.0 22
mm mm
reached. Unless otherwise specified,
17 12
torque specifications call for clean, 55 5.5 40
mm mm
dry threads. Components should be
at room temperature. 19 14
85 8.5 61
mm mm
22 16
130 13 94
mm mm
DEFINITION OF UNITS
Unit Read Definition Measure

-3
mm millimeter 10 meter Length
cm centimeter 10-2 meter Length
kg kilogram 103 gram Weight
2
N Newton 1 kg × m/sec Force
Nm Newton meter N×m Torque
m•kg Meter kilogram m × kg Torque
2
Pa Pascal N/m Pressure
N/mm Newton per millimeter N/mm Spring rate
L Liter — Volume or capacity
cm3 Cubic centimeter — Volume or capacity
r/min Revolution per minute — Engine speed
2-15
LUBRICATION DIAGRAMS
1. Oil filter element

2. Oil pump
3. Drive axle
4. Main axle
5. Crankshaft
6. Connecting rod
A. From cylinder
B. To oil tank
2-16
1. Intake camshaft
2. Exhaust camshaft
A. To main axle
B. From oil pump
2-17
CABLE ROUTING DIAGRAM
1. Fuel tank breather hose 10. Hot starter cable B. Pass the cylinder head breather
2. Radiator hose 1 11. Carburetor breather hose hose on the outside of the radia-
3. Cylinder head breather hose 12. Carburetor overflow hose tor hose 1 and between the radi-
4. Hose holder A. Insert the end of the fuel tank ator hose 4 and frame.
5. Radiator hose 4 breather hose into the hole in C. Align the paint on the cylinder
6. Clutch cable the steering stem. head breather hose with the
7. Connector cover front edge of the hose holder.
8. Fuel hose D. Pass the clutch cable through
9. Throttle position sensor lead the cable guide.
2-18
E. Pass the clutch cable in front of

the radiator mounting boss.
F. Install the connector cover so
that it does not come in between
the radiator hose 1 and radiator.
G. Pass the fuel hose between the
hot starter cable and throttle po-
sition sensor lead.
H. Pass the carburetor breather
hoses and overflow hose so that
all there hoses do not contact
the rear shock absorber.
2-19
1. Hot starter cable 12. Engine stop switch lead A. Fasten the hot starter cable and
2. Clamp 13. Sub-wire harness throttle cables onto the frame.
3. Throttle position sensor lead 14. Ground lead Locate the clamp ends under
4. Hump (frame) 15. CDI unit bracket the hot starter cable.
5. Neutral switch lead 16. CDI unit B. Fasten the hot starter cable,
6. Engine bracket 17. Cable guide throttle cables, throttle position
7. Lower engine guard stay 18. Ignition coil lead sensor lead and ignition coil lead
8. CDI magneto lead 19. Throttle cable to the frame.
9. Clutch cable C. Pass the throttle position sensor
10. Radiator breather hose lead over the hot starter cable.
11. Radiator hose 2
2-20
D. Fasten the throttle position sen-

sor lead to the frame behind its
hump.
E. Pass the neutral switch lead on
the inside of the engine bracket.
F. Pass the neutral switch lead
over the lower engine guard
stay.
G. Fasten the neutral switch lead
and radiator breather hose to
the frame.
H. Fasten the neutral switch lead,
CDI magneto lead and radiator
breather hose to the frame.
I. Fasten the neutral switch lead,
CDI magneto lead, radiator
breather hose and clutch cable
to the frame over the radiator
mounting boss.
J. Pass the radiator breather hose
in front of the radiator hose 2, on
the left of the chassis, and then
between the frame and radiator
hose 4.
K. Fasten the sub-wire harness,
engine stop switch lead and
ground lead to the CDI unit
bracket at the position-taped
portion of the sub-wire harness
and with the clamp ends facing
downward.
L. Fasten the ground lead and ca-
ble guide together to the CDI
unit bracket.
M. Locate the clamp ends in the ar-
rowed range.
N. Fasten the neutral switch lead
and CDI magneto lead to the
frame over its hump.
2-21
1. Throttle cable (pull) C. Fasten the throttle cables with

2. Throttle cable (return) the clamp so that the cables are
3. Radiator hose 2 not bent, and pass them under
4. Ignition coil the rear arm bracket.
5. Rear arm bracket D. Pass the cylinder head breather
6. Cylinder head breather hose hose so that it does not contact
A. Pass the throttle cables over the the ignition coil.
radiator hose 2.
B. Pass the throttle cables on the
outside of the ignition coil.
2-22
1. Brake master cylinder C. If the brake hose contacts the

2. Brake hose holder spring (rear shock absorber),
3. Brake hose correct its twist.
A. Install the brake hose so that its D. Install the brake hose so that its
pipe portion directs as shown pipe portion directs as shown
and lightly touches the projec- and lightly touches the projec-
tion on the brake caliper. tion on the brake master cylin-
B. Pass the brake hose into the der.
brake hose holders.
2-23
1. Throttle cable B. Pass the clutch cable and hot

2. Clamp starter cable through the cable
3. Hot starter cable guide.
4. Clutch cable C. Pass the brake hose in front of
5. Engine stop switch lead the number plate.
6. Cable guide D. Pass the throttle cables through
7. Brake hose the cable guide.
8. Hose guide E. Pass the clutch cable and hot
A. Fasten the engine stop switch starter cable through the cable
lead to the handlebar. guide on the number plate.
2-24
MAINTENANCE INTERVALS
REGULAR INSPECTION AND ADJUSTMENTS

The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as
weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If
you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.
Every Every
After
Every third fifth (or As re-
Item break- Remarks
race (or 500 1,000 quired
in
km) km)
ENGINE OIL
Replace ● ●
VALVES
Check the valve clearances ● ● The engine must be cold.
Inspect ● Check the valve seats and valve
stems for wear.
Replace
VALVE SPRINGS
Inspect ●
●
Check the free length and the tilt.

3
Replace ●
VALVE LIFTERS
Inspect ● Check for scratches and wear.
Replace ●
CAMSHAFTS Inspect the camshaft surface.
Inspect ● Inspect the decompression system.
Replace ●
CAMSHAFT SPROCKETS
Inspect ● Check for wear on the teeth and for
damage.
Replace ●
PISTON
Inspect ● ● Inspect crack.
Clean ● Inspect carbon deposits and eliminate
them.
Replace ●
PISTON RING
Inspect ● Check ring end gap.
Replace ● ●
PISTON PIN
Inspect ●
Replace ●
CYLINDER HEAD Inspect carbon deposits and eliminate
them.
Inspect and clean ● Change gasket.
CYLINDER
Inspect and clean ● Inspect score marks.
Replace ● Inspect wear.
CLUTCH
Inspect and adjust ● ● Inspect housing, friction plate, clutch
plate and spring.
3-1
Every Every
After
Item break- Remarks
in
km) km)
Replace ●
TRANSMISSION
Inspect ●
Replace bearing ●
SHIFT FORK, SHIFT CAM,
GUIDE BAR
Inspect ● Inspect wear.
ROTOR NUT
Retighten ● ●
EXHAUST PIPE, SILENCER,
PROTECTOR
Inspect and retighten ● ●
Clean ●
Replace ● * Whichever comes first
CRANK
Inspect and clean ● ●
CARBURETOR
Inspect, adjust and clean ● ●
SPARK PLUG
Inspect and clean ● ●
Replace ●
DRIVE CHAIN Use chain lube.
Lubricate, slack, alignment ● ● Chain slack: 48–58 mm (1.9–2.3 in)
Replace ●
COOLING SYSTEM
Check coolant level and leakage ● ●
Check radiator cap operation ●
Replace coolant ● Every two years
Inspect hoses ●
OUTSIDE NUTS AND BOLTS
Retighten ● ● Refer to "STARTING AND BREAK-
IN" section in the CHAPTER 1.
AIR FILTER
Clean and lubricate ● ● Use foam air-filter oil or equivalent oil.
Replace ●
OIL FILTER
Replace ● ●
FRAME
Clean and inspect ● ●
FUEL TANK, COCK
Clean and inspect ● ●
BRAKES
Adjust lever position and pedal ● ●
height
3-2
Every Every
After
Item break- Remarks
in
km) km)
Lubricate pivot point ● ●
Check brake disc surface ● ●
Check fluid level and leakage ● ●
Retighten brake disc bolts, cali- ● ●
per bolts, master cylinder bolts
and union bolts
Replace pads ●
Replace brake fluid ● Every one year
FRONT FORKS
Inspect and adjust ● ●
Replace oil ● ● Suspension oil "S1"
Replace oil seal ●
FRONT FORK OIL SEAL AND
DUST SEAL
Clean and lube ● ● Lithium base grease
PROTECTOR GUIDE
Replace ●
REAR SHOCK ABSORBER
Inspect and adjust ● ●
(After
rain
Lube ● ride) ● Molybdenum disulfide grease
Replace spring seat ● Every one year
Retighten ● ●
DRIVE CHAIN GUIDE AND
ROLLERS
Inspect ● ●
SWINGARM
Inspect, lube and retighten ● ● Molybdenum disulfide grease
RELAY ARM, CONNECTING
ROD
Inspect, lube and retighten ● ● Molybdenum disulfide grease
STEERING HEAD
Inspect free play and retighten ● ●
Clean and lube ● Lithium base grease
Replace bearing ●
TIRE, WHEELS
Inspect air pressure, wheel run- ● ●
out, tire wear and spoke loose-
ness
Retighten sprocket bolt ● ●
Inspect bearings ●
Replace bearings ●
Lubricate ● Lithium base grease
3-3
PRE-OPERATION INSPECTION AND MAINTENANCE
Every Every
After
Item break- Remarks
in
km) km)
THROTTLE, CONTROL CABLE
Check routing and connection ● ● Yamaha cable lube or SAE 10W-30
motor oil
Lubricate ● ●
HOT STARTER, CLUTCH LEVER
Inspect free play ●
PRE-OPERATION INSPECTION AND MAINTENANCE
Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition.
Before using this machine, check the following points.
GENERAL INSPECTION AND MAINTENANCE
Item Routine Page

Check that coolant is filled up to the radiator cap. Check the cool-
Coolant P.3-5 – 6
ing system for leakage.
Check that a fresh gasoline is filled in the fuel tank. Check the fuel
Fuel P.1-8
line for leakage.
Check that the oil level is correct. Check the crankcase and oil line
Engine oil P.3-8 – 9
for leakage.
Check that gears can be shifted correctly in order and that the
Gear shifter and clutch P.3-6
clutch operates smoothly.
Check that the throttle grip operation and free play are correctly
Throttle grip/Housing P.3-6 – 7
adjusted. Lubricate the throttle grip and housing, if necessary.
Brakes Check the play of front brake and effect of front and rear brake. P.3-13 – 15
Check drive chain slack and alignment. Check that the drive chain
Drive chain P.3-16
is lubricated properly.
Check for excessive wear and tire pressure. Check for loose
Wheels P.3-19
spokes and have no excessive play.
Check that the handlebar can be turned smoothly and have no ex-
Steering P.3-19 – 20
cessive play.
Front forks and rear shock Check that they operate smoothly and there is no oil leakage.
P.3-17 – 19
absorber
Check that the clutch and throttle cables move smoothly. Check
Cables (wires) that they are not caught when the handlebars are turned or when —
the front forks travel up and down.
Exhaust pipe Check that the exhaust pipe is tightly mounted and has no cracks. P.4-3 – 4
Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose. P.3-15 – 16
Lubrication Check for smooth operation. Lubricate if necessary. P.3-21
Bolts and nuts Check the chassis and engine for loose bolts and nuts. P.1-11
Check that the CDI magneto, CDI unit, and ignition coil are con-
Lead connectors P.1-3
nected tightly.
Is the machine set suitably for the condition of the racing course
Settings and weather or by taking into account the results of test runs be- P.7-1 – 10
fore racing? Are inspection and maintenance completely done?
3-4
ENGINE
ENGINE gine.
CHECKING THE COOLANT LEVEL 2. Remove:
• Engine guard "1"
• Coolant drain bolt "2"
Do not remove the radiator cap
"1", drain bolt and hoses when the
engine and radiator are hot. Scald-
ing hot fluid and steam may be
blown out under pressure, which
could cause serious injury. When Handling notes of coolant:
the engine has cooled, place a The coolant is harmful so it should be
thick towel over the radiator cap, handled with special care.
slowly rotate the cap counter- 3. Remove:
clockwise to the detent. This pro- • Radiator cap
cedure allows any residual Drain the coolant completely. • When coolant splashes to your
pressure to escape. When the 4. Clean: eye.
hissing sound has stopped, press • Cooling system Thoroughly wash your eye with
down on the cap while turning Thoroughly flush the cooling sys- water and see your doctor.
counterclockwise and remove it. tem with clean tap water. • When coolant splashes to your
5. Install: clothes.
• Copper washer Quickly wash it away with water
Hard water or salt water is harmful • Coolant drain bolt and then with soap.
to the engine parts. You may use Coolant drain bolt: • When coolant is swallowed.
distilled water, if you can't get soft 10 Nm (1.0 m•kg, 7.2 Quickly make him vomit and take
water. ft•lb) him to a doctor.
• Engine guard
• Bolt (engine guard) 7. Install:
Bolt (engine guard): • Radiator cap
10 Nm (1.0 m•kg, 7.2 Start the engine and warm it up
ft•lb) for a several minutes.
8. Check:
6. Fill: • Coolant level
• Radiator Coolant level low → Add coolant.
1. Place the machine on a level • Engine CHECKING THE RADIATOR CAP
place, and hold it in an upright po- To specified level. 1. Inspect:
sition. Recommended coolant: • Seal (radiator cap) "1"
2. Remove: High quality ethylene • Valve and valve seat "2"
• Radiator cap glycol anti-freeze con- Crack/damage → Replace.
3. Check: taining anti-corrosion Exist fur deposits "3" → Clean or
• Coolant level "a" for aluminum engine replace.
Coolant level low → Add coolant. Coolant "1" and water
(soft water) "2" mixing ra-
tio:
50%/50%
Coolant capacity:
0.99 L (0.87 Imp qt, 1.05
US qt)
CHECKING THE RADIATOR CAP

1. Radiator OPENING PRESSURE
• Do not mix more than one type of
CHANGING THE COOLANT ethylene glycol antifreeze con- 1. Attach:
taining corrosion inhibitors for • Radiator cap tester "1" and adapt-
aluminum engine. er "2"
• Do not use water containing im- Radiator cap tester:
when the engine is hot.
purities or oil. YU-24460-01/90890-
01325
Radiator cap tester
Take care so that coolant does not adapter:
splash on painted surfaces. If it YU-33984/90890-01352
splashes, wash it away with water.
1. Place a container under the en-
3-5
ENGINE
place.
Apply water on the radiator cap seal. • Radiator hose
Swelling → Replace.
ADJUSTING THE CLUTCH CABLE
FREE PLAY
1. Check:
• Clutch lever free play "a"
Out of specification → Adjust.
ADJUSTING THE THROTTLE
Clutch lever free play "a"
CABLE FREE PLAY
:
1. Check:
3. Radiator cap 8–13 mm (0.31–0.51 in)
• Throttle grip free play "a"
2. Apply the specified pressure. Out of specification → Adjust.
Radiator cap opening Throttle grip free play
pressure: "a":
110 kPa (1.1 kg/cm2, 3–5 mm (0.12–0.20 in)
15.6 psi)
3. Inspect:
• Pressure
Impossible to maintain the speci- 2. Adjust:
fied pressure for 10 seconds → • Clutch lever free play
Replace.
CHECKING THE COOLING
Clutch lever free play adjustment
SYSTEM
steps:
1. Inspect: 2. Adjust:
a. Loosen the locknuts "1".
• Coolant level • Throttle grip free play
b. Turn the adjuster "2" until free
2. Attach:
play "a" is within the specified lim-
• Radiator cap tester "1" and adapt- Throttle grip free play adjustment
its.
er "2" steps:
c. Tighten the locknuts.
Radiator cap tester: a. Slide the adjuster cover.
Locknut:
YU-24460-01/90890- b. Loosen the locknut "1".
4 Nm (0.4 m•kg, 2.9
01325 c. Turn the adjuster "2" until the
ft•lb)
Radiator cap tester specified free play is obtained.
adapter: d. Tighten the locknut.
YU-33984/90890-01352 Locknut:
• Before adjustment, expose the ad- 4 Nm (0.4 m•kg, 2.9
juster by moving the boot "3" and ft•lb)
cap "4" away.
• Make minute adjustment on the le-
Before adjusting the throttle cable
ver side using the adjuster "5".
free play, the engine idle speed
• After adjustment, check proper op-
should be adjusted.
eration of clutch lever.
3. Apply the specified pressure.

After adjusting the throttle cable
Standard pressure:
free play, start the engine and turn
180 kPa (1.8 kg/cm2,
the handlebar to right and left and
25.6 psi)
make sure that the engine idling
does not run faster.
• Do not apply pressure more than
specified pressure.
3. Install:
• Radiator should be filled fully.
• Cap "1"
4. Inspect: • Boot "2"
• Pressure
Impossible to maintain the speci- Place the tip "a" of the cap in the boot.
fied pressure for 10 seconds →
Repair.
• Radiator
• Radiator hose joint
Coolant leakage → Repair or re-
3-6
ENGINE
LUBRICATING THE THROTTLE

1. Remove:
• Cover (throttle cable cap) "1"
• Cover (grip cap) "2"
• Throttle grip cap "3"
5. Install:
• Air filter guide "1"
CLEANING THE AIR FILTER
ELEMENT
Align the projection "a" on filter guide
with the hole "b" in air filter element.
Proper air filter maintenance is the
2. Apply: biggest key to preventing premature
• Lithium soap base grease engine wear and damage.
On the throttle cable end "a".
Never run the engine without the

air filter element in place; this
would allow dirt and dust to enter
the engine and cause rapid wear
and possible engine damage. 6. Apply:
• Lithium soap base grease
1. Remove: On the matching surface "a" on air
3. Install: • Seat filter element.
• Throttle grip cap • Fitting bolt "1"
• Screw (throttle grip cap) • Washer "2"
Screw (throttle grip cap): • Air filter element "3"
4 Nm (0.4 m•kg, 2.9 • Air filter guide "4"
ft•lb)
• Cover (grip cap)
• Cover (throttle cable cap)
ADJUSTING THE HOT STARTER 7. Install:
LEVER FREE PLAY • Air filter element "1"
1. Check: • Washer
• Hot starter lever free play "a" • Fitting bolt
Out of specification → Adjust. 2. Clean:
Fitting bolt:
Hot starter lever free play • Air filter element
2 Nm (0.2 m•kg, 1.4
"a": Clean them with solvent.
ft•lb)
3–6 mm (0.12–0.24 in)
After cleaning, remove the remaining
2. Adjust: solvent by squeezing the element. Align the projection "a" on filter guide
• Hot starter lever free play
with the hole "b" in air filter case.
Hot starter lever free play adjust- • Do not twist the element when
ment steps: squeezing the element.
a. Loosen the locknut "1". • Leaving too much of solvent in
b. Turn the adjuster "2" until free the element may result in poor
play "a" is within the specified lim- starting.
its.
c. Tighten the locknut. 3. Inspect:
Locknut: • Air filter element
4 Nm (0.4 m•kg, 2.9 Damage → Replace.
ft•lb) 4. Apply:
• Foam-air-filter oil or equivalent oil
to the element
After adjustment, check proper oper-
ation of hot starter. Squeeze out the excess oil. Element
should be wet but not dripping.
3-7
ENGINE
• Do not allow foreign material to

CHECKING THE ENGINE OIL
enter the crankcase.
LEVEL
1. Stand the machine on a level sur-
face.
• When checking the oil level make

sure that the machine is upright.
• Place the machine on a suitable (For USA and CDN)
stand.
Recommended oil:
Yamalube 4, 5. Start the engine and let it warm up
SAE10W30 or for several minutes.
Never remove the oil tank cap just SAE20W40
after high speed operation. The Yamalube 4-R,
heated oil could spurt out. causing SAE10W50 When the oil tank is empty, never
danger. Wait until the oil cools API service SG type or start the engine.
down to approximately 70°C higher, JASO standard
(158°F). 6. Idle the engine more than 10 sec-
MA
onds while keeping the machine
2. Idle the engine more than 3 min- upright. Then stop the engine and
utes while keeping the machine add the oil to the maximum level.
upright. Then stop the engine and • Do not add any chemical addi- 7. Install:
inspect the oil level. tives. Engine oil also lubricates • Oil tank cap
3. Remove: the clutch and additives could
CHANGING THE ENGINE OIL
• Oil tank cap 1 cause clutch slippage.
1. Start the engine and let it warm up
• Do not allow foreign material to
for several minutes.
enter the crankcase.
2. Stop the engine and place an oil
pan under the drain bolt.
3. Remove:
• Oil tank plug "1"
• Oil filler cap "2"
• Drain bolt (with gasket) "3"
• Oil filter drain bolt (O-ring) "4"
4. Inspect:
• Drain bolt (with gasket) "5"
• Oil level
Drain the crankcase and oil tank
Check that the engine oil is above
of its oil.
the level mark "a" and that the oil
does not come out when the
check bolt "1" is removed.
Below the level mark "a"→Add oil
through the filler cap hole until it is
above the level mark "a".
Oil comes out at the check bolt →
Drain the oil until it stops coming
out. (Except for USA and CDN)
Recommended oil:
When inspecting the oil level, do not SAE10W30,
screw the oil level gauge into the oil SAE10W40,
tank. Insert the gauge lightly. SAE15W40, SAE20W40
or SAE20W50
API service SG type or
higher, JASO standard
MA
• Do not add any chemical addi-

tives or use oils with a grade of
CD "a" or higher.
• Do not use oils labeled "ENERGY
CONSERVING II" "b" or higher.
Engine oil also lubricates the 4. If the oil filter is to be replaced dur-
clutch and additives could cause ing this oil change, remove the fol-
clutch slippage. lowing parts and reinstall them.
3-8
ENGINE
7. Install:
Replacement steps: • Oil filler cap
a. Remove the oil filter element cov- 8. Inspect:
er "1" and oil filter element "2". • Engine (for oil leaks)
b. Check the O-rings "3", if cracked • Oil level
or damaged, replace them with a Refer to "ENGINE OIL LEVEL IN-
new one. SPECTION".
c. Install the oil filter element and oil CHECKING THE OIL PRESSURE
filter element cover. 1. Check:
• Oil pressure ADJUSTING THE ENGINE IDLING
Oil filter element cover:
10 Nm (1.0 m•kg, 7.2 SPEED
ft•lb) Checking steps: 1. Start the engine and thoroughly
a. Slightly loosen the oil pressure warm it up.
check bolt "1". 2. Adjust:
b. Start the engine and keep it idling • Engine idling speed
until oil starts to seep from the oil
pressure check bolt. If no oil Adjustment steps:
comes out after one minute, turn a. Adjust the pilot screw.
the engine off so it will not seize. Refer to "ADJUSTING THE PI-
c. Check oil passages and oil pump LOT SCREW" section.
for damage or leakage. b. Turn the throttle stop screw "1"
d. Start the engine after solving the until the specified engine idling
5. Install: problem(s) and recheck the oil speed.
• Gaskets pressure.
• Oil filter drain bolt e. Tighten the oil pressure check Using a digital engine tachometer for
Oil filter drain bolt: bolt. idle speed adjustment, detect the en-
10 Nm (1.0 m•kg, 7.2 Oil pressure check bolt: gine idling speed by bringing the
ft•lb) 10 Nm (1.0 m•kg, 7.2 sensing element "c" of the engine ta-
ft•lb) chometer close to the ignition coil "2".
• Drain bolt (right crankcase)
Drain bolt (right crank- Digital tachometer:
case): YU-39951-B/90890-
20 Nm (2.0 m•kg, 14 06760
ft•lb)
To increase idle speed→Turn the
• Drain bolt (left crankcase) throttle stop screw "1" in "a".
Drain bolt (left crank- To decrease idle speed → Turn
case): the throttle stop screw "1" out
20 Nm (2.0 m•kg, 14 "b".
ft•lb) ADJUSTING THE PILOT SCREW Engine idling speed:
6. Fill: 1. Adjust: 1,900–2,100 r/min
• Engine oil • Pilot screw "1"
Oil quantity:
Periodic oil change: Adjustment steps:
0.95 L (0.84 Imp qt,
1.00 US qt) To optimize the fuel flow at a smaller
With oil filter replace- throttle opening, each machine's pilot
ment: screw has been individually set at the
1.0 L (0.88 Imp qt, 1.06 factory. Before adjusting the pilot
US qt) screw, turn it in fully and count the
Total amount: number of turns. Record this number
1.2 L (1.06 Imp qt, 1.27 as the factory-set number of turns
US qt) out.
a. Turn in the pilot screw until it is

lightly seated.
b. Turn out the pilot screw by the
factory-set number of turns.
Pilot screw (example):
1-1/2 turns out
3-9
ENGINE
ADJUSTING THE VALVE • Identity each valve lifter and pad

CLEARANCE position very carefully so that they
can be reinstalled in their original
• The valve clearance should be ad- place.
justed when the engine is cool to
the touch.
• The piston must be at Top Dead
Center (T.D.C.) on compression
stroke to check or adjust the valve
clearance. In order to be sure that the piston is at
Top Dead Center, the punch mark "c"
1. Remove: on the exhaust camshaft and the
• Seat punch mark "d" on the intake cam-
• Fuel tank shaft must align with the cylinder
Refer to "SEAT, FUEL TANK head surface, as shown in the illustra-
AND SIDE COVERS" section in tion.
the CHAPTER 4.
2. Remove:
• Spark plug
• Engine upper bracket
• Hot starter plunger
Refer to "CARBURETOR" section c. Select the proper pad using the
in the CHAPTER 4. pad selecting table.
• Cylinder head cover Pad Availability:
Refer to "CAMSHAFTS" section Pad range
25 increments
in the CHAPTER 4. c. Measure the valve clearance "e"
No. 1.20
3. Remove: using a feeler gauge "1". Pads are avail-
120– mm–
• Timing mark accessing screw "1" able in 0.05 mm
No. 2.40
• Crankshaft end accessing screw Record the measured reading if the increments
240 mm
"2" clearance is incorrect.
• O-ring
The thickness "a" of each pad is indi-
cated in hundredths of millimeters on
the pad upper surface.
4. Check:
• Valve clearance
Valve clearance (cold):
d. Round off the last digit of the in-
Intake valve:
stalled pad number to the nearest
0.10–0.15 mm
increment.
(0.0039–0.0059 in)
Exhaust valve: Last digit of pad
Rounded valve
0.20–0.25 mm number
(0.0079–0.0098 in) 5. Adjust:
0, 1 or 2 0
• Valve clearance
4, 5 or 6 5
Checking steps: Adjustment steps: 8 or 9 10
a. Turn the crankshaft counterclock- a. Remove the camshaft (intake and
wise with a wrench. EXAMPLE:
exhaust).
b. Align the T.D.C. mark "a" on the Installed pad number = 148
Refer to "CAMSHAFTS" section
rotor with the align mark "b" on the Rounded off value = 150
in the CHAPTER 4.
crankcase cover when piston is at b. Remove the valve lifters "1" and
T.D.C. on compression stroke. the pads "2". Pads can only be selected in 0.05
mm increments.
• Place a rag in the timing chain e. Locate the rounded-off value and
space to prevent pads from falling the measured valve clearance in
into the crankcase. the chart "PAD SELECTION TA-
3-10
ENGINE
BLE". The field where these two

coordinates intersect shows the
new pad number to use.
Use the new pad number only as a

guide when verifying the valve clear-
ance adjustment.
f. Install the new pads "3" and the

valve lifters "4".
• Apply the engine oil on the valve lift-

ers.
• Apply the molybdenum disulfide oil
on the valve stem ends.
• Valve lifter must turn smoothly
when rotated with a finger.
• Be careful to reinstall valve lifters
and pads in their original place.
g. Install the camshafts (exhaust

and intake).
Refer to "CAMSHAFTS" section
in the CHAPTER 4.
3-11
ENGINE
INTAKE
EXHAUST
3-12
CHASSIS
CHASSIS reached; then release the lever or

BLEEDING THE HYDRAULIC pedal.
BRAKE SYSTEM Bleed screw:
6 Nm (0.6 m•kg, 4.3
ft•lb)
Bleed the brake system if:
• The system has been disassem- i. Repeat steps (e) to (h) until of the
bled. air bubbles have been removed
• A brake hose has been loosened from the system. c. Tighten the locknut.
or removed. Locknut:
• The brake fluid is very low. If bleeding is difficult, it may be nec- 5 Nm (0.5 m •kg, 3.6
• The brake operation is faulty. essary to let the brake fluid system ft•lb)
A dangerous loss of braking per- stabilize for a few hours. Repeat the
formance may occur if the brake bleeding procedure when the tiny
system is not properly bled. bubbles in the system have disap-
Be sure to tighten the locknut, as it
peared.
1. Remove: will cause poor brake perfor-
• Brake master cylinder cap j. Add brake fluid to the level line on mance.
• Diaphragm the reservoir.
• Reservoir float (front brake)
• Protector (rear brake) 4. Install:
2. Bleed: Check the operation of the brake • Brake lever cover
• Brake fluid after bleeding the brake system. ADJUSTING THE REAR BRAKE
1. Check:
Air bleeding steps: • Brake pedal height "a"
3. Install: Out of specification → Adjust.
a. Add proper brake fluid to the res- • Protector (rear brake)
ervoir. • Reservoir float (front brake) Brake pedal height "a":
b. Install the diaphragm. Be careful • Diaphragm 5 mm (0.20 in)
not to spill any fluid or allow the • Brake master cylinder cap
reservoir to overflow.
ADJUSTING THE FRONT BRAKE
c. Connect the clear plastic tube "2"
1. Check:
tightly to the caliper bleed screw
• Brake lever position "a"
"1".
Brake lever position "a":
Standard posi- Extent of ad-

tion justment 2. Adjust:
86–105 mm • Brake pedal height
95 mm (3.74 in)
(3.39–4.13 in)
Pedal height adjustment steps:
a. Loosen the locknut "1".
b. Turn the adjusting nut "2" until the
pedal height "a" is within specified
height.
c. Tighten the locknut.
• Adjust the pedal height between

2. Remove:
A. Front the maximum "A" and the mini-
• Brake lever cover
B. Rear mum "B" as shown. (In this ad-
3. Adjust:
d. Place the other end of the tube justment, the bolt "3" end "b"
• Brake lever position
into a container. should protrude out of the
e. Slowly apply the brake lever or threaded portion "4" but not be
pedal several times. Brake lever position adjustment less than 2 mm (0.08 in) "c" away
f. Pull the lever in or push down on steps: from the brake pedal "5").
the pedal. Hold the lever or pedal a. Loosen the locknut "1". • After the pedal height adjust-
in position. b. Turn the adjusting bolt "2" until the ment, make sure that the rear
g. Loosen the bleed screw and allow lever position "a" is within speci- brake does not drag.
the lever or pedal to travel to- fied position.
wards its limit.
h. Tighten the bleed screw when the
lever or pedal limit has been
3-13
CHASSIS
e. Connect the transparent hose "5" j. Install the pad pin plug "10".
to the bleed screw "6" and place Pad pin plug:
the suitable container under its 3 Nm (0.3 m•kg, 2.2
end. ft•lb)
CHECKING AND REPLACING THE

FRONT BRAKE PADS
1. Inspect:
f. Loosen the bleed screw and push
• Brake pad thickness "a"
the brake caliper piston in.
Out of specification → Replace as
a set. 3. Inspect:
• Brake fluid level
Brake pad thickness: Do not reuse the drained brake flu-
Refer to "CHECKING THE
4.4 mm (0.17 in) id.
BRAKE FLUID LEVEL" section.
<Limit>: 1.0 mm (0.04 4. Check:
g. Tighten the bleed screw.
in) • Brake lever operation
Bleed screw:
A softy or spongy feeling → Bleed
6 Nm (0.6 m•kg, 4.3
brake system.
ft•lb)
Refer to "BLEEDING THE HY-
h. Install the brake pads "7" and pad DRAULIC BRAKE SYSTEM" sec-
pin. tion.
CHECKING AND REPLACING THE
• Install the brake pads with their pro- REAR BRAKE PADS
jections "a" into the brake caliper re- 1. Inspect:
2. Replace: cesses "b". • Brake pad thickness "a"
• Brake pad • Temporarily tighten the pad pin at Out of specification → Replace as
this point. a set.
Brake pad replacement steps: Brake pad thickness:
a. Remove the pad pin plug "1". 6.4 mm (0.25 in)
<Limit>: 1.0 mm (0.04
in)
i. Install the brake caliper "8" and

tighten the pad pin "9".
b. Loosen the pad pin "2".
c. Remove the brake caliper "3" Bolt (brake caliper):
from the front fork. 28 Nm (2.8 m•kg, 20
ft•lb) 2. Replace:
Pad pin: • Brake pad
18 Nm (1.8 m•kg, 13
ft•lb) Brake pad replacement steps:
a. Remove the protector "1" and pad
pin plug "2".
d. Remove the pad pin and brake

pads "4".
3-14
CHASSIS
this point. PADS" section.

2. Inspect:
• Rear brake pad insulator "1"
Damage → Replace.
b. Loosen the pad pin "3".

c. Remove the rear wheel "4" and
brake caliper "5". i. Install the brake caliper "12" and
Refer to "FRONT WHEEL AND rear wheel "13".
REAR WHEEL" section in the Refer to "FRONT WHEEL AND CHECKING THE BRAKE FLUID
CHAPTER 5. REAR WHEEL" section in the LEVEL
CHAPTER 5. 1. Place the brake master cylinder
j. Tighten the pad pin "14". so that its top is in a horizontal po-
Pad pin: sition.
18 Nm (1.8 m•kg, 13 2. Inspect:
ft•lb) • Brake fluid level
Fluid at lower level → Fill up.
Recommended brake flu-
id:
d. Remove the pad pin "6" and brake DOT #4
pads "7".
• Use only designated quality

brake fluid to avoid poor brake
k. Install the pad pin plug "15" and performance.
protector "16". • Refill with same type and brand
Pad pin plug: of brake fluid; mixing fluids
3 Nm (0.3 m•kg, 2.2 could result in poor brake perfor-
ft•lb) mance.
e. Connect the transparent hose "8"
Bolt (protector): • Be sure that water or other con-
to the bleed screw "9" and place
7 Nm (0.7 m•kg, 5.1 taminants do not enter master
the suitable container under its
ft•lb) cylinder when refilling.
end.
• Clean up spilled fluid immediate-
ly to avoid erosion of painted
surfaces or plastic parts.
f. Loosen the bleed screw and push

the brake caliper piston in.
3. Inspect:
a. Lower level
Do not reuse the drained brake flu- Refer to "CHECKING THE
A. Front
id. BRAKE FLUID LEVEL" section.
B. Rear
4. Check:
g. Tighten the bleed screw. CHECKING THE SPROCKET
• Brake pedal operation
Bleed screw: A softy or spongy feeling → Bleed 1. Inspect:
6 Nm (0.6 m•kg, 4.3 brake system. • Sprocket teeth "a"
ft•lb) Refer to "BLEEDING THE HY- Excessive wear → Replace.
DRAULIC BRAKE SYSTEM" sec-
h. Install the brake pad "10" and pad Replace the drive sprocket, rear
tion.
pin "11". wheel sprocket and drive chain as a
CHECKING THE REAR BRAKE
PAD INSULATOR set.
• Install the brake pads with their pro-
1. Remove:
jections "a" into the brake caliper re-
• Brake pad
cesses "b".
Refer to "CHECKING AND RE-
• Temporarily tighten the pad pin at
PLACING THE REAR BRAKE
3-15
CHASSIS
hold as illustrated. chain" position.

Stiff → Replace the drive chain.
CHECKING THE DRIVE CHAIN

1. Measure:
• Drive chain length (15 links) "a" 5. Install: 3. Adjust:
Out of specification → Replace. • Drive chain "1" • Drive chain slack
Drive chain length (15 • Joint "2"

links): • Master link clip "3" Drive chain slack adjustment
<Limit>: 242.9 mm steps:
(9.563 in) a. Loosen the axle nut "1" and lock-
Be sure to install the master link nuts "2".
clip to the direction as shown. b. Adjust the drive chain slack by
• While measuring the drive chain turning the adjusters "3".
length, push down on the drive To tighten→Turn the adjuster "3"
chain to increase its tension. counterclockwise.
• Measure the length between drive To loosen→Turn the adjuster "3"
chain roller "1" and "16" as shown. clockwise and push wheel for-
• Perform this measurement at two or ward.
three different places.
c. Turn each adjuster exactly the
same amount to maintain correct
a. Turning direction
axle alignment. (There are marks
6. Lubricate:
"a" on each side of the drive chain
• Drive chain
puller alignment.)
Drive chain lubricant:
SAE 10W-30 motor oil
or suitable chain lubri-
cants
2. Remove:
• Master link clip
• Joint "1"
• Drive chain "2"
Turn the adjuster so that the drive

chain is in line with the sprocket, as
viewed from the rear.
ADJUSTING THE DRIVE CHAIN
SLACK
1. Elevate the rear wheel by placing Too small drive chain slack will
the suitable stand under the en- overload the engine and other vital
3. Clean:
gine. parts; keep the slack within the
• Drive chain
2. Check: specified limits.
Place it in kerosene, and brush off
• Drive chain slack "a"
as much dirt as possible. Then re- d. Tighten the axle nut while pushing
Above the seal guard installation
move the drive chain from the ker- down the drive chain.
bolt.
osene and dry the drive chain.
Out of specification → Adjust. Axle nut:
Drive chain slack: 125 Nm (12.5 m•kg, 90
48–58 mm (1.9–2.3 in) ft•lb)
e. Tighten the locknuts.
Before checking and/or adjusting, ro- Locknut:

tate the rear wheel through several 19 Nm (1.9 m•kg, 13
revolutions and check the slack sev- ft•lb)
4. Check: eral times to find the tightest point.
• Drive chain stiffness "a" Check and/or adjust the drive chain
Clean and oil the drive chain and slack with the rear wheel in this "tight
3-16
CHASSIS
CHECKING THE FRONT FORK • Air bleed screw ADJUSTING THE FRONT FORK
1. Inspect: Air bleed screw: COMPRESSION DAMPING FORCE
• Front fork smooth action 1 Nm (0.1 m•kg, 0.7 1. Adjust:
Operate the front brake and ft•lb) • Compression damping force
stroke the front fork. By turning the adjuster "1".
Unsmooth action/oil leakage → Stiffer "a" → Increase the com-
Repair or replace. pression damping force. (Turn
the adjuster "1" in.)
Softer "b" → Decrease the com-
pression damping force. (Turn
the adjuster "1" out.)
ADJUSTING THE FRONT FORK Extent of adjustment:

REBOUND DAMPING FORCE
CLEANING THE FRONT FORK OIL 1. Adjust: Maximum Minimum
SEAL AND DUST SEAL • Rebound damping force 20 clicks out
By turning the adjuster "1". Fully turned in
1. Remove: (from maximum
position
• Protector Stiffer "a" → Increase the re- position)
• Dust seal "1" bound damping force. (Turn
Use a thin screw driver, and be care- Softer "b" → Decrease the re-
ful not to damage the inner fork tube bound damping force. (Turn
and dust seal. the adjuster "1" out.)
Extent of adjustment:
Maximum Minimum • STANDARD POSITION:

20 clicks out This is the position which is back
Fully turned in by the specific number of clicks
(from maximum
position from the fully turned-in position.
position)
Standard position:
2. Clean: 12 clicks out
• Dust seal "a" * 7 clicks out
• Oil seal "b"
* For EUROPE
• Clean the dust seal and oil seal af-

ter every run.
Do not force the adjuster past the
• Apply the lithium soap base grease
minimum or maximum extent of
on the inner tube.
• STANDARD POSITION: adjustment. The adjuster may be
This is the position which is back damaged.
by the specific number of clicks
from the fully turned-in position.
Standard position: Always adjust each front fork to
12 clicks out the same setting. Uneven adjust-
* 11 clicks out ment can cause poor handling and
* For EUROPE loss of stability.
RELIEVING THE FRONT FORK CHECKING THE REAR SHOCK

INTERNAL PRESSURE ABSORBER
Do not force the adjuster past the 1. Inspect:
If the front fork initial movement feels minimum or maximum extent of • Swingarm smooth action
adjustment. The adjuster may be Abnormal noise/unsmooth action
stiff during a run, relieve the front fork
damaged. → Grease the pivoting points or
internal pressure.
repair the pivoting points.
1. Elevate the front wheel by placing Damage/oil leakage → Replace.
a suitable stand under the engine. Always adjust each front fork to
2. Remove the air bleed screw "1" the same setting. Uneven adjust-
and release the internal pressure ment can cause poor handling and
from the front fork. loss of stability.
3. Install:
3-17
CHASSIS
of the adjuster.
• The I.D. mark "b" is marked at the Extent of adjustment:
end of the spring.
• The standard length and extent of Maximum Minimum
adjustment vary according to the 20 clicks out
quantity of I.D. marks. Fully turned in
(from maximum
position
position)
ADJUSTING THE REAR SHOCK Never attempt to turn the adjuster

ABSORBER SPRING PRELOAD beyond the maximum or minimum
1. Elevate the rear wheel by placing setting.
the suitable stand under the en-
gine.
2. Remove:
• Rear frame
3. Loosen:
• Locknut "1" • STANDARD POSITION:
4. Adjust: This is the position which is back
• Spring preload by the specific number of clicks
By turning the adjuster "2". from the fully turned-in position.
(Which align the punch mark "a"
Stiffer → Increase the spring pre- on the adjuster with the punch
load. (Turn the adjuster "2" in.) mark "b" on the bracket.)
Softer → Decrease the spring pre-
load. (Turn the adjuster "2" Standard position:
out.) About 12 clicks out
* About 6 clicks out
* For EUROPE

minimum or maximum extent of
adjustment. The adjuster may be
damaged.
Spring length (installed)

"a":
5. Tighten:
Standard Extent of ad-
• Locknut
length justment
6. Install:
One I.D. mark • Rear frame (upper)
267 mm 255.5–273.5
Rear frame (upper):
(10.51 in) mm (10.06–
38 Nm (3.8 m•kg, 27
*262 mm 10.77 in) ADJUSTING THE REAR SHOCK
ft•lb)
(10.31 in) ABSORBER LOW COMPRESSION
Two I.D. marks • Rear frame (lower) DAMPING FORCE
273 mm 261.5–279.5 1. Adjust:
Rear frame (lower):
(10.75 in) mm (10.30– • Low compression damping force
32 Nm (3.2 m•kg, 23
*268 mm 11.00 in) By turning the adjuster "1".
ft•lb)
(10.55 in) Stiffer "a" → Increase the low
Three I.D. ADJUSTING THE REAR SHOCK
compression damping force.
marks ABSORBER REBOUND DAMPING
(Turn the adjuster "1" in.)
264.5 mm 253.0–271.0 FORCE
Softer "b" → Decrease the low
(10.41 in) mm (9.96–10.67 1. Adjust:
*259.5 mm in) • Rebound damping force
(Turn the adjuster "1" out.)
(10.22 in) By turning the adjuster "1".
* For EUROPE Stiffer "a" → Increase the re- Extent of adjustment:
bound damping force. (Turn
• Be sure to remove all dirt and mud Maximum Minimum
Softer "b" → Decrease the re-
from around the locknut and adjust- bound damping force. (Turn 20 clicks out
er before adjustment. Fully turned in
the adjuster "1" out.) (from maximum
• The length of the spring (installed) position
position)
changes 1.5 mm (0.06 in) per turn
3-18
CHASSIS
CHECKING AND TIGHTENING THE

SPOKES
1. Inspect:
• Spokes "1"
Bend/damage → Replace.
Loose spoke → Retighten.
2. Tighten:
• Spokes
• STANDARD POSITION: • STANDARD POSITION: Spokes:
This is the position which is back This is the position which is back 3 Nm (0.3 m•kg, 2.2
by the specific number of clicks by the specific number of turns ft•lb)
from the fully turned-in position. from the fully turned-in position.
(Which align the punch mark "a" (Which align the punch mark "a"
on the adjuster with the punch on the adjuster with the punch Be sure to retighten these spokes be-
mark "b" on the high compression mark "b" on the adjuster body.) fore and after break-in. After a prac-
damping adjuster.) Standard position: tice or a race check spokes for
Standard position: About 1-1/2 turns out looseness.
About 11 clicks out * About 2 turns out
* About 10 clicks out * For EUROPE
* For EUROPE

Do not force the adjuster past the minimum or maximum extent of
minimum or maximum extent of adjustment. The adjuster may be
adjustment. The adjuster may be damaged.
damaged. CHECKING THE WHEELS
1. Inspect:
• Wheel runout
Elevate the wheel and turn it.
Abnormal runout → Replace.
CHECKING THE TIRE PRESSURE

ADJUSTING THE REAR SHOCK 1. Measure:
ABSORBER HIGH COMPRESSION • Tire pressure
DAMPING FORCE Out of specification → Adjust.
1. Adjust: Standard tire pressure: 2. Inspect:
• High compression damping force 100 kPa (1.0 kgf/cm2, • Bearing free play
By turning the adjuster "1". 15 psi) Exist play → Replace.
Stiffer "a" → Increase the high
(Turn the adjuster "1" in.) • Check the tire while it is cold.
Softer "b" → Decrease the high • Loose bead stoppers allow the tire
compression damping force. to slip off its position on the rim
(Turn the adjuster "1" out.) when the tire pressure is low.
• A tilted tire valve stem indicates that
the tire slips off its position on the
rim. CHECKING AND ADJUSTING THE
• If the tire valve stem is found tilted, STEERING HEAD
Maximum Minimum the tire is considered to be slipping 1. Elevate the front wheel by placing
2 turns out off its position. Correct the tire posi- a suitable stand under the engine.
Fully turned in
(from maximum tion. 2. Check:
position
position) • Steering stem
Grasp the bottom of the forks and
gently rock the fork assembly
back and forth.
Free play → Adjust steering head.
3-19
CHASSIS
Steering stem nut:

145 Nm (14.5 m•kg, 105
ft•lb)
Handlebar upper holder:
28 Nm (2.8 m•kg, 20
ft•lb)
Pinch bolt (upper brack-
3. Check: e. Loosen the steering ring nut one et):
• Steering smooth action turn. 21 Nm (2.1 m•kg, 15
Turn the handlebar lock to lock. f. Retighten the steering ring nut us- ft•lb)
Unsmooth action → Adjust steering the steering nut wrench. Number plate:
ing ring nut. 7 Nm (0.7 m•kg, 5.1
ft•lb)
Avoid over-tightening.
Steering ring nut (final

tightening):
7 Nm (0.7 m•kg, 5.1
ft•lb)
g. Check the steering stem by turn-
4. Adjust:
ing it lock to lock. If there is any
• Steering ring nut
binding, remove the steering stem
assembly and inspect the steer-
Steering ring nut adjustment ing bearings.
steps: h. Install the washer "5", upper
a. Remove the number plate. bracket "6", washer "7", steering
b. Remove the handlebar and upper stem nut "8", handlebar "9", han-
bracket. dlebar upper holder "10" and
c. Loosen the steering ring nut "1" number plate "11".
using the steering nut wrench "2".
Steering nut wrench: • The handlebar upper holder should
YU-33975/90890-01403 be installed with the punched mark
"a" forward.
• Install the handlebar so that the
marks "b" are in place on both
sides.
• Install the handlebar so that the pro-
jection "c" of the handlebar upper
holder is positioned at the mark on
the handlebar as shown.
• Insert the end of the fuel breather
d. Tighten the steering ring nut "3" hose "12" into the hole in the steer-
using steering nut wrench "4". ing stem.

on the thread of the steering stem. First tighten the bolts on the front
• Set the torque wrench to the steer- side of the handlebar upper holder,
ing nut wrench so that they form a and then tighten the bolts on the
right angle. rear side.
Steering nut wrench:

YU-33975/90890-01403
Steering ring nut (initial

tightening):
38 Nm (3.8 m•kg, 27
ft•lb)
3-20
CHASSIS
LUBRICATION
To ensure smooth operation of all B. Use SAE 10W-30 motor oil or

components, lubricate your machine suitable chain lubricants.
during setup, after break-in, and after C. Lubricate the following areas
every race. with high quality, lightweight lith-
1. All control cable ium-soap base grease.
2. Clutch lever pivot
3. Shift pedal pivot
4. Footrest pivot Wipe off any excess grease, and
5. Throttle-to-handlebar contact avoid getting grease on the brake
6. Drive chain discs.
7. Tube guide cable winding por-
tion
8. Throttle cable end
9. Clutch cable end
10. Hot starter cable end
A. Use Yamaha cable lube or
equivalent on these areas.
3-21
ELECTRICAL
ELECTRICAL
CHECKING THE SPARK PLUG
1. Remove:
• Spark plug
2. Inspect:
• Electrode "1"
Wear/damage → Replace.
• Insulator color "2" 2. Attach:
Normal condition is a medium to • Timing light
light tan color. • Inductive tachometer
Distinctly different color → Check To the ignition coil lead (orange
the engine condition. lead"1").
Timing light:
When the engine runs for many hours
YM-33277-A/90890-
at low speeds, the spark plug insula-
03141
tor will become sooty, even if the en-
gine and carburetor are in good
operating condition.
3. Adjust:
• Engine idling speed
Refer to "ADJUSTING THE EN-
3. Measure:
GINE IDLING SPEED" section.
• Plug gap "a"
4. Check:
Use a wire gauge or thickness
• Ignition timing
gauge.
Visually check the stationary
Out of specification → Regap.
pointer "a" is within the firing
Spark plug gap: range "b" on the rotor.
0.7–0.8 mm (0.028– Incorrect firing range → Check ro-
0.031 in) tor and pickup assembly.
4. Clean the plug with a spark plug
cleaner if necessary.
5. Tighten:
• Spark plug
Spark plug:
13 Nm (1.3 m•kg, 9.4
ft•lb)
5. Install:
• Timing mark accessing screw
• Before installing a spark plug, clean
the gasket surface and plug sur-
face.
• Finger-tighten "a" the spark plug
before torquing to specification "b".
CHECKING THE IGNITION TIMING

1. Remove:
• Timing mark accessing screw "1"
3-22
SEAT, FUEL TANK AND SIDE COVERS
ENGINE
REMOVING THE SEAT, FUEL TANK AND SIDE COVERS
Order Part name Q'ty Remarks

Turn the fuel cock to "OFF".
Disconnect the fuel hose.
1 Seat 1
2 Air scoop (left and right) 2
3 Bolt (fuel tank) 2
4 Fuel tank 1
5 Left side cover 1 Refer to removal section.
6 Right side cover 1 Refer to removal section.
7 Number plate 1 Refer to removal section.
4-1
REMOVING THE SIDE COVER

1. Remove:
Put the portion "a" of the flap of the air
• Bolt (side cover)
filter case on the inside of the air
• Left side cover "1"
scoop.
• Right side cover "2"
Draw the side cover downward to re-

move it because its claws "a" are in-
serted in the air filter case.
REMOVING THE NUMBER PLATE

1. Remove:
• Bolt (number plate)
• Number plate "1"
• The projection "a" is inserted into

the band of the number plate. Pull
the band off the projection before
removal.
• Remove the hot starter cable "2"
and clutch cable "3" from the cable
guide "b" on the number plate.
• The projection "c" on the lower
bracket is inserted into the number
plate. Remove the number plate by
pulling it off the projection.
INSTALLING THE AIR SCOOP

1. Install
• Air scoop "1"
• Bolt (air scoop)
Bolt (air scoop):
7 Nm (0.7 m•kg, 5.1
ft•lb)
4-2
EXHAUST PIPE AND SILENCER

REMOVING THE EXHAUST PIPE AND SILENCER

Refer to "SEAT, FUEL TANK AND SIDE
Right side cover
COVERS" section.
1 Bolt (silencer clamp) 1 Only loosening.
2 Bolt [silencer (front)] 1
3 Bolt [silencer (rear)] 1
4 Collar 1
5 Silencer 1
6 Silencer clamp 1
7 Nut (exhaust pipe) 1
8 Bolt (exhaust pipe) 1
9 Exhaust pipe 1
10 Gasket 2
4-3
CHECKING THE SILENCER AND

EXHAUST PIPE First, temporarily tighten the nut (ex-
1. Inspect: haust pipe), then tighten the bolt (ex-
• Gasket "1" haust pipe) 13 Nm (1.3 m•kg, 9.4
Damage → Replace. ft•lb). After that, retighten the nut (ex-
haust pipe) 20 Nm (2.0 m•kg, 14 ft•lb)
and then the bolt (exhaust pipe) 20
Nm (2.0 m•kg, 14 ft•lb).
4. Install:
• Inner pipe "1"
• Rivet (front) "2"
• Band "3"
CHANGING THE SILENCER FIBER • Apply heat resistant sealant along

1. Remove: the plate edge "a" on the inside of
• Rivet (front) "1" the silencer and also along the si-
• Inner pipe "2" lencer edge "b" as shown.
• Take care not to allow the fiber out 2. Install:
of place when installing the inner • Silencer clamp "1"
Take care not to damage the rivet
pipe. Silencer clamp:
fitting holes (ø4.9 mm) "a" in re-
• Install the band "3" with the mating 14 Nm (1.4 m•kg, 10
moval.
ends "c" positioned as shown. ft•lb)
• Gasket "2"
Pull out the inner pipe while lightly • Silencer "3"
tapping the stay "b" on the silencer • Washer "4"
using a soft hammer. • Bolt (silencer) "5"
Bolt (silencer):
30 Nm (3.0 m•kg, 22
ft•lb)
• Install the gasket with its meshed

area "a" toward the exhaust pipe
side.
2. Replace: • The gasket should be installed ac-
• Fiber "1" (for EUROPE) cording to the dimension shown.
New
3. Replace:
• Fiber "1" (except for EUROPE)
INSTALLING THE SILENCER AND
EXHAUST PIPE
Wrap around the inner pipe the fiber
1. Install:
as is vinyl packaged, then secure it
• Gasket
with pieces of tape "2".
• Exhaust pipe "1"
• Nut (exhaust pipe) "2"
Nut (exhaust pipe):
20 Nm (2.0 m•kg, 14
ft•lb)
• Bolt (exhaust pipe) "3"
Bolt (exhaust pipe):
20 Nm (2.0 m•kg, 14
ft•lb)
4-4
RADIATOR
RADIATOR
REMOVING THE RADIATOR

Refer to "CHANGING THE COOLANT" sec-
Drain the coolant.
tion in the CHAPTER 3.
Seat and fuel tank
COVERS" section.
Refer to "EXHAUST PIPE AND SILENCER"
Exhaust pipe
section.
1 Radiator guard 2
2 Radiator hose clamp 8 Only loosening.
3 Right radiator 1
4 Radiator hose 2 1
5 Radiator hose 3 1
6 Radiator hose 4 1
7 Pipe 2/O-ring 1/1
8 Radiator breather hose 1
9 Left radiator 1
10 Radiator hose 1 1
11 Pipe 1/O-ring 1/1
4-5
RADIATOR
HANDLING NOTE

when the engine and radiator are
hot. Scalding hot fluid and steam
may be blown out under pressure,
which could cause serious injury.
When the engine has cooled, open 2. Install:
the radiator cap by the following • Radiator hose 2 "1"
procedure:
Place a thick rag, like a towel, over Radiator hose 2:
the radiator cap, slowly rotate the 2 Nm (0.2 m•kg, 1.4
cap counterclockwise to the de- ft•lb)
tent. This procedure allows any re- • Left radiator "2"
sidual pressure to escape. When
the hissing sound has stopped, Left radiator:
press down on the cap while turn- 10 Nm (1.0 m•kg, 7.2
ing counterclockwise and remove ft•lb)
it.
CHECKING THE RADIATOR

1. Inspect:
• Radiator core "1"
Obstruction → Blow out with com-
pressed air through rear of the ra-
diator.
Bent fin → Repair/replace. 3. Install:
• Radiator breather hose "1"
• Right radiator "2"
Right radiator:
10 Nm (1.0 m•kg, 7.2
ft•lb)
Refer to "CABLE ROUTING DIA-
GRAM" section in the CHAPTER
INSTALLING THE RADIATOR 2.
1. Install:
• Pipe 1 "1"
Pipe 1:
10 Nm (1.0 m•kg, 7.2
ft•lb)
• Radiator hose 1 "2"
Radiator hose 1:
2 Nm (0.2 m•kg, 1.4 4. Install:
ft•lb) • Radiator guard "1"
• Pipe 2 "3"
First fit the inner hook portion "a" and
Pipe 2: then the outer one "b" onto the radia-
10 Nm (1.0 m•kg, 7.2 tor.
ft•lb)
Radiator hose 3:
2 Nm (0.2 m•kg, 1.4
ft•lb)
Radiator hose 4:
2 Nm (0.2 m•kg, 1.4
ft•lb)
4-6
CARBURETOR
CARBURETOR
REMOVING THE CARBURETOR

Seat and fuel tank
COVERS" section.
Refer to "REAR SHOCK ABSORBER" sec-
Rear shock absorber
1 Clamp 1
2 Throttle position sensor lead coupler 1
3 Throttle cable cover 1
4 Throttle cable 2
5 Clamp (air filter joint) 1 Loosen the screw (air filter joint).
6 Clamp (carburetor joint) 1 Loosen the screws (carburetor joint).
7 Hot starter plunger 1
8 Carburetor assembly 1
9 Carburetor joint 1
4-7
CARBURETOR
DISASSEMBLING THE CARBURETOR

1 Carburetor breather hose 4
2 Valve lever housing cover 1
3 Screw (throttle shaft) 1
4 Throttle valve 1
5 Needle holder 1
6 Jet needle 1
7 Accelerator pump cover 1
8 Spring 1
9 Diaphragm (accelerator pump) 1
10 Float chamber 1
11 Leak jet 1
12 Pilot screw 1 Refer to removal section.
13 Float pin 1
14 Float 1
15 Needle valve 1
16 Main jet 1
17 Needle jet 1
18 Spacer 1
4-8
CARBURETOR

19 Pilot jet 1
20 Starter jet 1
21 Push rod 1 Pull the push rod.
22 Throttle shaft assembly 1
23 Push rod link lever assembly 1
24 Pilot air jet 1
25 Cold starter plunger 1
4-9
CARBURETOR
HANDLING NOTE Damage → Replace.

Contamination → Clean.
Do not loosen the screw (throttle

• Use a petroleum based solvent for
position sensor) "1" except when
cleaning. Blow out all passages and
changing the throttle position sen-
jets with compressed air.
sor due to failure because it will
• Never use a wire.
cause a drop in engine perfor-
mance. MEASURING AND ADJUSTING
THE FLOAT HEIGHT
1. Measure:
• Float height "a"
Float height:
8.0 mm (0.31 in)
CHECKING THE NEEDLE VALVE
1. Inspect:
REMOVING THE PILOT SCREW
• Needle valve "1"
1. Remove:
• Valve seat "2"
• Pilot screw "1"
Grooved wear "a" → Replace.
Dust "b" → Clean.
To optimize the fuel flow at a small • Filter "c"
throttle opening, each machine's pilot Clogged → Clean.
screw has been individually set at the
factory. Before removing the pilot
screw, turn it in fully and count the Measurement and adjustment
number of turns. Record this number steps:
as the factory-set number of turns a. Hold the carburetor in an upside
out. down position.
• Slowly tilt the carburetor in the op-

CHECKING THE THROTTLE posite direction, then take the mea-
VALVE surement when the needle valve
1. Check: aligns with the float arm.
• Free movement • If the carburetor is level, the weight
Stick → Repair or replace. of the float will push in the needle
valve, resulting in an incorrect mea-
CHECKING THE CARBURETOR Insert the throttle valve "1" into the surement.
1. Inspect: carburetor body, and check for free b. Measure the distance between
• Carburetor body movement. the mating surface of the float
Contamination → Clean. chamber and top of the float using
a vernier calipers.
• Use a petroleum based solvent for
cleaning. Blow out all passages and The float arm should be resting on the
jets with compressed air. needle valve, but not compressing
• Never use a wire. the needle valve.
c. If the float height is not within

specification, inspect the valve
CHECKING THE JET NEEDLE
seat and needle valve.
1. Inspect:
d. If either is worn, replace them
• Jet needle "1"
both.
Bends/wear → Replace.
e. If both are fine, adjust the float
• Clip groove
height by bending the float tab "b"
Free play exists/wear → Replace.
on the float.
2. Inspect: • Clip position
• Main jet "1" Standard clip position:
• Pilot jet "2" No.3 Groove
• Needle jet "3"
• Starter jet "4"
• Pilot air jet "5"
• Leak jet "6"
4-10
CARBURETOR
• Spring 2 "6" carburetor.

Dirt → Clean.
f. Recheck the float height.
ASSEMBLING THE CARBURETOR 6. Install:

CHECKING THE FLOAT • Washer "1"
1. Install:
1. Inspect: • Circlip "2"
• Cold starter plunger "1"
• Float "1"
Damage → Replace.
2. Install: 7. Install:
• Pilot air jet "1" • Spring "1"
CHECKING THE STARTER To throttle shaft "2".
PLUNGER
1. Inspect: Install the bigger hook "a" of the
• Cold starter plunger "1" spring fits on the stopper "b" of the
• Hot starter plunger "2" throttle shaft pulley.
3. Install:
• Spring 1 "1"
• Lever 1 "2"
To lever 2 "3".
CHECKING THE ACCELERATOR Make sure the spring 1 fits on the 8. Install:
PUMP stopper "a" of the lever 2. • Throttle shaft assembly "1"
1. Inspect: • Washer (metal) "2"
• Diaphragm (accelerator pump) • Washer (resin) "3"
"1" • Valve lever "4"
• Spring (accelerator pump) "2"
• Accelerator pump cover "3" • Apply the fluorochemical grease on
• O-ring "4" the bearings.
• Push rod "5" • Fit the projection "a" on the throttle
Tears (diaphragm)/damage → shaft assembly into the slot "b" in
Replace. 4. Install: the throttle position sensor.
Dirt → Clean. • Spring 2 "1" • Make sure the stopper "c" of the
To lever 2 "2". spring fits into the recess in the car-
buretor.
• Turn the throttle shaft assembly left
while holding down the lever 1 "5"
and fit the throttle stop screw tip "d"
to the stopper "e" of the throttle
shaft assembly pulley.
2. Inspect:
• Throttle shaft "1" 5. Install:
• Spring "2" • Push rod link lever assembly "1"
• Lever 1 "3"
• Spring 1 "4"
Make sure the stopper "a" of the
• Lever 2 "5"
spring 2 fits into the recess "b" in the
4-11
CARBURETOR
• Check the float for smooth move-

ment. Install the diaphragm (accelerator
pump) with its mark "a" facing the
spring.
12. Install:
• Pilot screw "1"
• Spring "2" 15. Install:
• Washer "3" • Jet needle "1"
• O-ring "4" • Collar "2"
• Spring "3"
• Needle holder "4"
• Throttle valve plate "5"
To throttle valve "6".
9. Install: Note the following installation

• Push rod "1" points:
a. Turn in the pilot screw until it is
While holding down the lever 1 "2", in- lightly seated. 16. Install:
sert the push rod farthest into the car- b. Turn out the pilot screw by the • Throttle valve assembly "1"
buretor. number of turns recorded before • Screw (throttle shaft) "2"
removing.
Pilot screw (example): Install the valve lever rollers "3" into
1-1/2 turns out the slits "a" of the throttle valve.
13. Install:
• O-ring
• Leak jet "1"
• Float chamber "2"
10. Install: • Bolt (float chamber) "3"
• Starter jet "1" • Cable holder (throttle stop screw
• Pilot jet "2" cable) "4" 17. Install:
• Spacer "3" • Hose holder (carburetor breather • O-ring "1"
• Needle jet "4" hose) "5" • Valve lever housing cover "2"
• Main jet "5" • Bolt (valve lever housing cover)
"3"
14. Install:
11. Install: • Diaphragm (accelerator pump)
• Needle valve "1" "1" 18. Install:
• Float "2" • Spring "2" • Carburetor breather hose "1"
• Float pin "3" • O-ring "3" Refer to "CABLE ROUTING DIA-
• Accelerator pump cover "4" GRAM"section in the CHAPTER
• Hose holder (drain hose) "5" 2.
• After installing the needle valve to
• Screw (accelerator pump cover)
the float, install them to the carbure-
"6"
tor.
4-12
CARBURETOR
2. Install:
• Carburetor "1"
Install the projection "a" between the

carburetor joint slots.
ADJUSTING THE ACCELERATOR 6. Adjust:

PUMP TIMING • Throttle grip free play
Refer to "ADJUSTING THE
Adjustment steps: THROTTLE CABLE FREE PLAY"
section in the CHAPTER 3.
7. Install:
In order for the throttle valve height 3. Install: • Throttle cable cover "1"
"a" to achieve the specified value, • Hot starter plunger "1" • Bolt (throttle cable cover) "2"
tuck under the throttle valve plate "1"
the rod "2" etc. with the same outer di- Hot starter plunger: Bolt (throttle cable cov-
ameter as the specified value. 2 Nm (0.2 m•kg, 1.4 er):
ft•lb) 4 Nm (0.4 m•kg, 2.9
Throttle valve height: ft•lb)
1.25 mm (0.049 in)
4. Tighten:
• Bolt (carburetor joint) "1" 8. Install:
Bolt (carburetor joint): • Throttle position sensor lead cou-
a. Fully turn in the accelerator pump
3 Nm (0.3 m•kg, 2.2 pler "1"
adjusting screw "3".
ft•lb) • Clamp "2"
b. Check that the link lever "4" has
Refer to "CABLE ROUTING DIA-
free play "b" by pushing lightly on • Bolt (air filter joint) "2" GRAM" section in the CHAPTER
it.
Bolt (air filter joint): 2.
3 Nm (0.3 m•kg, 2.2
ft•lb)
c. Gradually turn out the adjusting

screw while moving the link lever
until it has no more free play.
5. Install:
INSTALLING THE CARBURETOR • Throttle cable (pull) "1"
1. Install: Throttle cable (pull):
• Carburetor joint "1" 4 Nm (0.4 m•kg, 2.9
Carburetor joint: ft•lb)
10 Nm (1.0 m•kg, 7.2 • Throttle cable (return) "2"
ft•lb)
Throttle cable (return):
11 Nm (1.1 m•kg, 8.0
ft•lb)
4-13
CAMSHAFTS
CAMSHAFTS
REMOVING THE CYLINDER HEAD COVER

Seat and fuel tank
COVERS" section.
Hot starter plunger Refer to "CARBURETOR" section.
Engine upper bracket (right) Refer to "ENGINE REMOVAL" section.
Engine upper bracket (left)
1 Spark plug 1
2 Cylinder head breather hose 1
3 Bolt (cylinder head cover) 2
4 Cylinder head cover 1
5 Cylinder head cover gasket 1
6 Timing chain guide (top side) 1
4-14
CAMSHAFTS
REMOVING THE CAMSHAFTS

1 Timing mark accessing screw 1 Refer to removal section.
2 Crankshaft end accessing screw 1 Refer to removal section.
3 Timing chain tensioner cap bolt 1 Refer to removal section.
4 Timing chain tensioner 1 Refer to removal section.
5 Gasket 1 Refer to removal section.
6 Bolt (camshaft cap) 10 Refer to removal section.
7 Camshaft cap 2 Refer to removal section.
8 Clip 2 Refer to removal section.
9 Exhaust camshaft 1 Refer to removal section.
10 Intake camshaft 1 Refer to removal section.
4-15
CAMSHAFTS
REMOVING THE CAMSHAFT

1. Remove: Cam lobes length:
• Timing mark accessing screw "1" Intake "a":
• Crankshaft end accessing screw 31.200–31.300 mm
"2" (1.2283–1.2323 in)
<Limit>:
31.100 mm (1.2244 in)
Intake "b":
4. Remove: 22.550–22.650 mm
• Bolt (camshaft cap) "1" (0.8878–0.8917 in)
• Camshaft cap "2" <Limit>:
• Clip 22.450 mm (0.8839 in)
Exhaust "a":
2. Align: 30.900–31.000 mm
Remove the bolts (camshaft cap) in a
• T.D.C. mark (1.2165–1.2205 in)
crisscross pattern, working from the
With align mark. <Limit>:
outside in.
30.800 mm (1.2126 in)
Exhaust "b":
Checking steps:
22.468–22.568 mm
a. Turn the crankshaft counterclock- The bolts (camshaft cap) must be (0.8846–0.8885 in)
wise with a wrench. removed evenly to prevent dam- <Limit>:
b. Align the T.D.C. mark "a" on the age to the cylinder head, cam- 22.368 mm (0.8806 in)
rotor with the align mark "b" on the shafts or camshaft caps.
crankcase cover when piston is at
T.D.C. on compression stroke.
In order to be sure that the piston is at

Top Dead Center, the punch mark "c"
on the exhaust camshaft and the
punch mark "d" on the intake cam-
shaft must align with the cylinder
head surface, as shown in the illustra-
tion. 5. Remove:
• Exhaust camshaft "1"
• Intake camshaft "2"
Attach a wire "3" to the timing chain to

prevent it from falling into the crank-
case.
3. Measure:
• Runout (camshaft)
Out of specification → Replace.
Runout (camshaft):
Less than 0.03 mm
(0.0012 in)
CHECKING THE CAMSHAFT

1. Inspect:
• Cam lobe
Pitting/scratches/blue discolora-
3. Remove:
tion → Replace.
• Timing chain tensioner cap bolt
2. Measure:
"1"
• Cam lobe length "a" and "b" 4. Measure:
• Timing chain tensioner "2"
Out of specification → Replace. • Camshaft-to-cap clearance
• Gasket
Out of specification → Measure
camshaft outside diameter.
4-16
CAMSHAFTS
Camshaft-to-cap clear-
ance:
0.028–0.062 mm
(0.0011–0.0024 in)
<Limit>:0.08 mm (0.003
in)
CHECKING THE CAMSHAFT

Measurement steps:
SPROCKET
a. Install the camshaft onto the cylin-
1. Inspect:
der head.
• Camshaft sprocket "1"
b. Position a strip of Plastigauge®
Wear/damage → Replace the
"1" onto the camshaft.
camshaft assembly and timing
chain as a set.
INSTALLING THE CAMSHAFT

1. Install:
• Exhaust camshaft "1"
• Intake camshaft "2"
c. Install the clip, dowel pins and

camshaft caps.
CHECKING THE
Bolt (camshaft cap): DECOMPRESSION SYSTEM
10 Nm (1.0 m•kg, 7.2 1. Check:
ft•lb) • Decompression system
• Tighten the bolts (camshaft cap) in Checking steps:

a crisscross pattern from innermost a. Check that the decompression Installation steps:
to outer caps. mechanism cam "1" moves a. Turn the crankshaft counterclock-
• Do not turn the camshaft when smoothly. wise with a wrench.
measuring clearance with the Plas- b. Check that the decompression
tigauge®. mechanism cam lever pin "2" • Apply the molybdenum disulfide oil
projects from the camshaft. on the camshafts.
d. Remove the camshaft caps and • Apply the engine oil on the decom-
measure the width of the Plasti- pression system.
gauge® "1".
b. Align the T.D.C. mark "a" on the
rotor with the align mark "b" on the
crankcase cover when piston is at
T.D.C. on compression stroke.
CHECKING THE TIMING CHAIN

TENSIONER
1. Check:
5. Measure: • While pressing the tensioner rod
• Camshaft outside diameter "a" lightly with fingers, use a thin
Out of specification → Replace screwdriver "1" and wind the ten- c. Fit the timing chain "3" onto both
the camshaft. sioner rod up fully clockwise. camshaft sprockets and install the
Within specification → Replace • When releasing the screwdriver camshafts on the cylinder head.
camshaft case and camshaft by pressing lightly with fingers,
caps as a set. make sure that the tensioner rod
The camshafts should be installed
Camshaft outside diame- will come out smoothly.
onto the cylinder head so that the
ter: • If not, replace the tensioner as-
punch mark "c" on the exhaust cam-
21.959–21.972 mm sembly.
shaft and the punch mark "d" on the
(0.8645–0.8650 in) intake camshaft must align with the
cylinder head surface, as shown in
the illustration.
4-17
CAMSHAFTS
b. With the rod fully wound and the

chain tensioner UP mark "a" fac-
Do not turn the crankshaft during ing upward, install the gasket "1",
the camshaft installation. Damage the timing chain tensioner "2", and
or improper valve timing will re- the gasket "3", and tighten the bolt
sult. "4" to the specified torque.
d. Install the clips, camshaft caps "4" Bolt (timing chain ten-
and bolts (camshaft cap) "5". sioner):
Bolt (camshaft cap): 10 Nm (1.0 m•kg, 7.2
10 Nm (1.0 m•kg, 7.2 ft•lb)
ft•lb)
c. Release the screwdriver, check

the tensioner rod to come out and
tighten the gasket "5" and the cap
• Before removing the clips, cover the
bolt "6" to the specified torque.
cylinder head with a clean rag to
prevent the clips from into the cylin- Tensioner cap bolt:
der head cavity. 7 Nm (0.7 m•kg, 5.1
• Apply the molybdenum disulfide oil ft•lb)
on the thread of the bolts (camshaft
cap).
• Tighten the bolts to the specified
torque in two or three steps in the
proper tightening sequence as
shown.
The bolts (camshaft cap) must be

tightened evenly, or damage to the
3. Turn:
cylinder head, camshaft caps, and
• Crankshaft
camshaft will result.
Counterclockwise several turns.
4. Check:
• Rotor T.D.C. mark
2. Install:
Align with the crankcase align
• Timing chain tensioner
mark.
• Camshaft match marks
Installation steps: Align with the cylinder head sur-
a. While pressing the tensioner rod face.
lightly with fingers, use a thin Out of alignment → Adjust.
screwdriver and wind the tension-
er rod up fully clockwise.
4-18
CYLINDER HEAD
CYLINDER HEAD
REMOVING THE CYLINDER HEAD

Seat and fuel tank
COVERS" section.
Exhaust pipe and silencer
section.
Radiator Refer to "RADIATOR" section
Carburetor Refer to "CARBURETOR" section.
Camshaft Refer to "CAMSHAFTS" section.
1 Bolt 2
2* Bolt 4 Refer to NOTE.
3 Cylinder head 1
4 Gasket 1
5 Timing chain guard (exhaust side) 1
Tighten the cylinder head bolts to 30 Nm (3.0 m•kg, 22 ft•lb) in the proper tightening sequence, remove and retighten the
cylinder head bolts to 20 Nm (2.0 m•kg, 14 ft•lb) in the proper tightening sequence, and then tighten the cylinder head bolts
further to reach the specified angle 180° in the proper tightening sequence.
4-19
CYLINDER HEAD
CHECKING THE CYLINDER HEAD • Cylinder head gasket "3" e. Remove the bolts.
1. Eliminate: • Cylinder head "4" f. Again apply the molybdenum dis-
• Carbon deposits (from the com- ulfide grease on the threads and
bustion chambers) While pulling up the timing chain, in- contact surfaces of the bolts and
Use a rounded scraper. stall the timing chain guide (exhaust on both contact surfaces of the
side) and cylinder head. plain washers.
Do not use a sharp instrument to g. Retighten the bolts.
avoid damaging or scratching:
• Spark plug threads Tighten the bolts to the specified
• Valve seats torque in two or three steps in the
shown.
Bolts (cylinder head):

2nd:
2. Install:
20 Nm (2.0 m•kg, 14
• Washer "1"
ft•lb)
• Bolts "2"
2. Inspect:
• Cylinder head
Scratches/damage → Replace.
3. Measure:
• Cylinder head warpage
Out of specification → Resurface.
Cylinder head warpage:
h. Put a mark on the corner "1" of the
Less than 0.05 mm
bolt (cylinder head) and the cylin-
(0.002 in) Installation steps:
der head "2" as shown.
Warpage measurement and resur- Tighten the cylinder head using

facing steps: the rotation angle procedure to ob-
a. Place a straightedge and a feeler tain uniform tightening torque.
gauge across the cylinder head. a. Wash the threads and contact
b. Use a feeler gauge to measure surfaces of the bolts, the contact
the warpage. surfaces of the plain washers, the
c. If the warpage is out of specifica- contact surface of the cylinder
tion, resurface the cylinder head. head, and the threads of the
d. Place a 400–600 grit wet sandpa- Tighten the bolts 90° in each of the
crankcase.
per on the surface plate, and re- two steps to reach the specified angle
b. Apply the molybdenum disulfide
surface the head using a figure- of 180° in the proper tightening se-
grease on the threads and con-
eight sanding pattern. quence as shown.
tact surfaces of the bolts and on
both contact surfaces of the plain
To ensure an even surface rotate the washers. Bolts (cylinder head):
cylinder head several times. c. Install the plain washers and Final:
bolts. Specified angle 180°
d. Tighten the bolts to the specified
torque in two or three steps in the
shown.
Bolts (cylinder head):
1st:
30 Nm (3.0 m•kg, 22
ft•lb)
INSTALLING THE CYLINDER 3. Install:
HEAD • Bolt (cylinder head) "1"
1. Install:
• Timing chain guide (exhaust side) Bolt (cylinder head):
"1" 10 Nm (1.0 m•kg, 7.2
• Dowel pin "2" ft•lb)
4-20
CYLINDER HEAD
4-21
VALVES AND VALVE SPRINGS

REMOVING THE VALVES AND VALVE SPRINGS

Cylinder head Refer to "CYLINDER HEAD" section.
1 Valve lifter 5 Refer to removal section.
2 Adjusting pad 5 Refer to removal section.
3 Valve cotter 10 Refer to removal section.
4 Valve spring retainer 5
5 Valve spring 5
6 Valve stem seal 5
7 Valve spring seat 5
8 Exhaust valve 2
9 Intake valve 3
4-22
REMOVING THE VALVE LIFTER

AND VALVE COTTER
1. Remove:
• Valve lifter "1"
• Pad "2"
Identify each lifter "1" and pad "2" po-

sition very carefully so that they can
be reinstalled in their original place. CHECKING THE VALVE b. Install the new valve guide using a
1. Measure: valve guide remover "1" and valve
• Stem-to-guide clearance guide installer "2".
Stem-to-guide clearance = valve
guide inside diameter "a" -
valve stem diameter "b"
Out of specification → Replace
the valve guide.
Clearance (stem to
2. Check:
guide):
• Valve sealing c. After installing the valve guide,
Intake:
Leakage at the valve seat → In- bore the valve guide using a valve
0.010–0.037 mm
spect the valve face, valve seat guide reamer "3" to obtain proper
(0.0004–0.0015 in)
and valve seat width. stem-to-guide clearance.
<Limit>:0.08 mm
(0.003 in)
Checking steps: Exhaust:
a. Pour a clean solvent "1" into the 0.020–0.047 mm
intake and exhaust ports. (0.0008–0.0019 in)
b. Check that the valve seals prop- <Limit>:0.10 mm
erly. (0.004 in)
There should be no leakage at the
valve seat "2".
Valve guide remover:
Intake:4.5 mm (0.18 in)
YM-4116/90890-04116
Exhaust:5.0 mm (0.20
in)
YM-4097/90890-04097
Valve guide installer:
Intake:
YM-4117/90890-04117
Exhaust:
YM-4098/90890-04098
Valve guide reamer:
Intake:4.5 mm (0.18 in)
YM-4118/90890-04118
Exhaust:5.0 mm (0.20
2. Replace:
in)
• Valve guide
YM-4099/90890-04099
3. Remove:
• Valve cotter Replacement steps:
After replacing the valve guide reface
Attach a valve spring compressor "1" the valve seat.
To ease guide removal, installation
between the valve spring retainer and and to maintain correct fit heat the
the cylinder head to remove the valve cylinder head in an over to 100 °C
3. Inspect:
cotters. (212 °F).
• Valve face
a. Remove the valve guide using a Pitting/wear → Grind the face.
Valve spring compres- • Valve stem end
valve guide remover "1".
sor: Mushroom shape or diameter
YM-4019/90890-04019 larger than the body of the stem
→ Replace.
4-23
4. Measure: gap between the valve stem and

Valve seat width: the guide.
• Margin thickness "a"
Intake:
0.9–1.1 mm (0.0354–
Margin thickness: 0.0433 in)
Intake: <Limit>:1.6 mm
1.0 mm (0.039 in) (0.0630 in)
<Limit>:0.85 mm Exhaust:
(0.033 in) 0.9–1.1 mm (0.0354–
Exhaust: 0.0433 in)
1.0 mm (0.039 in) <Limit>:1.6 mm
<Limit>:0.85 mm (0.0630 in) b. Apply molybdenum disulfide oil to
(0.033 in) the valve stem.
c. Install the valve into the cylinder

5. Measure: Measurement steps: head.
• Runout (valve stem) a. Apply Mechanic's blueing dye d. Turn the valve until the valve face
Out of specification → Replace. (Dykem) "b" to the valve face. and valve seat are evenly pol-
Runout limit: ished, then clean off all of the
0.01 mm (0.0004 in) compound.
For best lapping results, lightly tap

• When installing a new valve always the valve seat while rotating the valve
replace the guide. back and forth between your hands.
• If the valve is removed or replaced
always replace the oil seal.
b. Install the valve into the cylinder
head.
c. Press the valve through the valve
guide and onto the valve seat to
make a clear pattern.
d. Measure the valve seat width.
Where the valve seat and valve
face made contact, blueing will e. Apply a fine lapping compound to
have been removed. the valve face and repeat the
6. Eliminate: e. If the valve seat is too wide, too above steps.
• Carbon deposits narrow, or the seat is not cen-
(from the valve face and valve tered, the valve seat must be re- After every lapping operation be sure
seat) faced. to clean off all of the compound from
7. Inspect: the valve face and valve seat.
• Valve seat
9. Lap:
Pitting/wear → Reface the valve f. Apply Mechanic's blueing dye
• Valve face
seat. (Dykem) to the valve face.
• Valve seat
8. Measure: g. Install the valve into the cylinder
• Valve seat width "a" head.
Out of specification → Reface the After refacing the valve seat or re- h. Press the valve through the valve
valve seat. placing the valve and valve guide, the guide and onto the valve seat to
valve seat and valve face should be make a clear pattern.
lapped. i. Measure the valve seat width
again. If the valve seat width is out
of specification, reface and relap
Lapping steps: the valve seat.
a. Apply a coarse lapping compound
to the valve face.
Do not let the compound enter the
4-24
CHECKING THE VALVE SPRINGS 3. Install:

1. Measure: • Valve cotters
• Valve spring free length "a"
Out of specification → Replace. While compressing the valve spring
Free length (valve with a valve spring compressor "1" in-
spring): stall the valve cotters.
Intake:
37.03 mm (1.46 in) CHECKING THE VALVE LIFTERS Valve spring compres-
<Limit>: 36.03 mm 1. Inspect: sor:
(1.42 in) • Valve lifter YM-4019/90890-04019
Exhaust: Scratches/damage → Replace
37.68 mm (1.48 in) both lifters and cylinder head.
<Limit>: 36.68 mm
(1.44 in)
4. To secure the valve cotters onto

the valve stem, lightly tap the
INSTALLING THE VALVES valve tip with a piece of wood.
1. Apply:
2. Measure: • Molybdenum disulfide oil
Onto the valve stem and valve Hitting the valve tip with excessive
• Compressed spring force "a" force could damage the valve.
Out of specification → Replace. stem seal.
2. Install:
Compressed spring • Valves "1"
force: • Valve spring seats "2"
Intake: • Valve stem seals "3"
111.3–127.9 N at 27.87 • Valve springs "4"
mm (11.3–13.0 kg at • Valve spring retainers "5"
27.87 mm, 24.91–
28.66 lb at 1.10 in)
• Make sure that each valve is in-
Exhaust:
stalled in its original place, also re- 5. Install:
127.4–146.4 N at 27.38
ferring to the painted color as • Adjusting pad "1"
mm (13.0–14.9 kg at
follows. • Valve lifter "2"
27.38 mm, 28.66–
Intake (middle) "a": blue
32.85 lb at 1.08 in)
Intake (right/left) "b": gray • Apply the molybdenum disulfide oil
Exhaust "c": brown on the valve stem end.
• Install the valve springs with the • Apply the engine oil on the valve lift-
larger pitch "d" facing upward. ers.
• Valve lifter must turn smoothly
when rotated with a finger.
• Be careful to reinstall valve lifters
and pads in their original place.
b. Installed length
3. Measure:
• Spring tilt "a"
Spring tilt limit:
Intake:
2.5°/1.61 mm (0.063
in)
Exhaust:
2.5°/1.65 mm (0.065
in)
e. Smaller pitch
4-25
CYLINDER AND PISTON
CYLINDER AND PISTON

REMOVING THE CYLINDER AND PISTON

Cylinder head Refer to "CYLINDER HEAD" section.
1 Bolt (cylinder) 1
2 Cylinder 1
3 Gasket 1
4 Dowel pin 2
5 Piston pin clip 2 Refer to removal section.
6 Piston pin 1 Refer to removal section.
7 Piston 1 Refer to removal section.
8 Piston ring set 1 Refer to removal section.
4-26
CYLINDER AND PISTON
REMOVING THE PISTON AND 2. Measure: Piston-to-cylinder clear-

PISTON RING • Piston-to-cylinder clearance ance:
1. Remove: 0.020–0.045 mm
• Piston pin clip "1" Measurement steps: (0.0008–0.0018 in)
• Piston pin "2" a. Measure the cylinder bore "C" <Limit>:0.1 mm (0.004
• Piston "3" with a cylinder bore gauge. in)
f. If out of specification, replace the
• Put identification marks on each Measure the cylinder bore "C" in par- cylinder, and replace the piston
piston head for reference during re- allel to and at right angles to the and piston rings as set.
installation. crankshaft. Then, find the average of
• Before removing each piston pin, the measurements.
deburr the clip groove and pin hole CHECKING THE PISTON RING
area. If the piston pin groove is de- 1. Measure:
Cylinder 95.00–95.01 mm
burred and the piston pin is still dif- • Ring side clearance
bore "C" (3.7402–3.7406 in)
ficult to remove, use the piston pin Use a feeler gauge "1".
puller set "4". Taper limit Out of specification → Replace
0.05 mm (0.002 in)
"T" the piston and rings as a set.
Piston pin puller set: Out of
0.05 mm (0.002 in) Clean carbon from the piston ring
YU-1304/90890-01304 round "R"
grooves and rings before measuring
"C" = Maximum D the side clearance.
Do not use a hammer to drive the "T" = (Maximum D1 or D2) - (Max-
piston pin out. imum D5 or D6) Side clearance:
"R" = (Maximum D1, D3 or D5) - Standard <Limit>
(Minimum D2, D4 or D6)
0.030–0.065
Top mm 0.12 mm
ring (0.0012– (0.005 in)
0.0026 in)
0.020–0.055
2nd mm 0.12 mm
ring (0.0008– (0.005 in)
0.0022 in)
b. If out of specification, replace the
cylinder, and replace the piston
and piston rings as set.
c. Measure the piston skirt diameter
"P" with a micrometer.
2. Remove:
• Piston ring "1" 2. Position:
• Piston ring
(in cylinder)
Spread the end gaps apart while at
the same time lifting the piston ring
Insert a ring into the cylinder and
over the top of the piston crown, as
a. 8 mm (0.31 in) from the piston push it approximately 10 mm (0.39 in)
shown in the illustration.
bottom edge into the cylinder. Push the ring with
Piston size "P" the piston crown so that the ring will
be at a right angle to the cylinder
94.965–94.980 mm bore.
Standard
(3.7388–3.7394 in)
d. If out of specification, replace the
piston and piston rings as a set.
e. Calculate the piston-to-cylinder
clearance with following formula:
CHECKING THE CYLINDER AND
Piston-to-cylinder clearance =
PISTON
Cylinder bore "C" - Piston skirt
1. Inspect:
diameter "P"
• Cylinder and piston walls
a. 10 mm (0.39 in)
Vertical scratches → Replace cyl-
inder and piston.
4-27
CYLINDER AND PISTON
3. Measure: c. Calculate the piston pin-to-piston

• Ring end gap clearance with the following for- • Apply engine oil onto the piston pin
Out of specification → Replace. mula. and piston.
Piston pin-to-piston clearance = • Be sure that the arrow mark "a" on
You cannot measure the end gap on Inside diameter (piston) "b" - the piston points to the exhaust side
the expander spacer of the oil control Outside diameter (piston pin) of the engine.
ring. If the oil control ring rails show "a" • Before installing the piston pin clip,
excessive gap, replace all three rings. cover the crankcase with a clean
d. If out of specification, replace the rag to prevent the piston pin clip
piston. from falling into the crankcase.
End gap:
Piston pin-to-piston • Install the piston pin clips with their
Standard <Limit>
clearance: ends facing downward.
0.20–0.30 0.004–0.024 mm
Top 0.55 mm
mm (0.008– (0.00016–0.00094 in)
ring (0.022 in)
0.012 in) <Limit>:0.07 mm (0.003
0.35–0.50 in)
2nd 0.85 mm
mm (0.014–
ring (0.033 in)
0.020 in)
INSTALLING THE PISTON RING
0.20–0.50
Oil AND PISTON
mm (0.01– —
ring 1. Install:
0.02 in)
• Piston ring
CHECKING THE PISTON PIN Onto the piston.
1. Inspect:
• Piston pin • Be sure to install the piston rings so
Blue discoloration/grooves → Re- that the manufacturer's marks or
place, then inspect the lubrication numbers are located on the upper New
system. side of the rings.
2. Measure: • Lubricate the piston and piston
• Piston pin-to-piston clearance INSTALLING THE CYLINDER
rings liberally with engine oil. 1. Install:
• Dowel pins
Measurement steps: • Cylinder gasket "1"
a. Measure the outside diameter • Cylinder "2"
(piston pin) "a".
If out of specification, replace the
Install the cylinder with one hand
piston pin.
while compressing the piston rings
Outside diameter (piston with the other hand.
pin):
17.991–18.000 mm 2. Position:
(0.7083–0.7087 in) • Top ring • Pass the timing chain "3"
• 2nd ring through the timing chain cavity.
• Oil ring • Be careful not to damage the tim-
Offset the piston ring end gaps as ing chain guide "4" during instal-
shown. lation.
2. Install:
• Bolt (cylinder)
Bolt (cylinder):
b. Measure the inside diameter (pis- 10 Nm (1.0 m•kg, 7.2
ton) "b". ft•lb)
Inside diameter (piston):
18.004–18.015 mm a. Top ring end
(0.7088–0.7093 in) b. 2nd ring end
c. Oil ring end (upper)
d. Oil ring
e. Oil ring end (lower)
3. Install:
• Piston "1"
• Piston pin "2"
• Piston pin clip "3"
4-28
CLUTCH
CLUTCH
REMOVING THE CLUTCH

Refer to "CHANGING THE ENGINE OIL"
Drain the engine oil.
Brake pedal Refer to "ENGINE REMOVAL" section.
Clutch cable Disconnect at engine side.
1 Clutch cover 1
2 Gasket 1
3 Dowel pin 2
4 Clutch spring 6
5 Pressure plate 1
6 Push rod 1 1
7 Circlip 1
8 Washer 1
9 Bearing 1
10 Ball 1
11 Push rod 2 1
12 Clutch plate 7
13 Friction plate 8
4-29
CLUTCH

14 Nut (clutch boss) 1 Refer to removal section.
15 Lock washer 1 Refer to removal section.
16 Clutch boss 1 Refer to removal section.
17 Thrust washer 1
18 Primary driven gear 1
19 Push lever shaft 1
4-30
CLUTCH
REMOVING THE CLUTCH BOSS CHECKING THE CLUTCH Wear/damage → Replace.

1. Remove: SPRINGS
• Nut "1" 1. Measure:
• Lock washer "2" • Clutch spring free length "a"
• Clutch boss "3" Out of specification → Replace
springs as a set.
Straighten the lock washer tab and Clutch spring free
use the clutch holding tool "4" to hold length:
the clutch boss. 50.0 mm (1.97 in)
<Limit>: 49.0 mm (1.93 CHECKING THE PUSH ROD
Clutch holding tool: in) 1. Inspect:
YM-91042/90890-04086 • Push rod 1 "1"
• Bearing "2"
• Washer "3"
• Push rod 2 "4"
• Ball "5"
Wear/damage/bend → Replace.
CHECKING THE FRICTION

PLATES
1. Measure:
• Friction plate thickness
friction plate as a set. INSTALLING THE PUSH LEVER
Measure at all four points. SHAFT
Friction plate thickness: 1. Install:
2.92–3.08 mm (0.115– • Push lever shaft "1"
A. For USA and CDN 0.121 in)
B. Except for USA and CDN <Limit>: 2.8 mm (0.110 • Apply the lithium soap base grease
CHECKING THE CLUTCH in) on the oil seal lip.
HOUSING AND BOSS • Apply the engine oil on the push le-
1. Inspect: ver shaft.
• Clutch housing "1"
Cracks/wear/damage → Replace.
• Clutch boss "2"
Scoring/wear/damage → Re-
place.
CHECKING THE CLUTCH PLATES

1. Measure:
• Clutch plate warpage INSTALLING THE CLUTCH
Out of specification → Replace 1. Install:
clutch plate as a set. • Primary driven gear "1"
Use a surface plate "1" and thick- • Thrust washer "2"
ness gauge "2". • Clutch boss "3"
CHECKING THE PRIMARY DRIVEN
GEAR Warp limit:
1. Check: 0.1 mm (0.004 in) Apply the engine oil on the primary
• Circumferential play driven gear inner circumference.
Free play exists → Replace.
• Gear teeth "a"
CHECKING THE PUSH LEVER

SHAFT 2. Install:
1. Inspect: • Lock washer "1"
• Push lever shaft "1"
4-31
CLUTCH
• Nut (clutch boss) "2"

Nut (clutch boss):
75 Nm (7.5 m•kg, 54
ft•lb)
Make sure to tighten to specifica-

tion; otherwise, it may damage the
other part that is fastened togeth-
• Bearing "1" • Gasket (clutch cover) "1"
er.
• Washer "2" • Dowel pin "2"
• Circlip "3"
To push rod 1 "4".
• Install the lock washer with its con-
caves fitted over the convexes of
the clutch boss. Apply the engine oil on the bearing
• Use the clutch holding tool "3" to and washer.
hold the clutch boss.
Clutch holding tool: 10. Install:

YM-91042/90890-04086 • Clutch cover "1"
• Bolt (clutch cover)
Bolt (clutch cover):
10 Nm (1.0 m•kg, 7.2
ft•lb)
6. Install:
• Push rod 2 "1"
• Ball "2" Tighten the bolts in stage, using a
• Push rod 1 "3" crisscross pattern.
Apply the engine oil on the push rod

1, 2 and ball.
A. For USA and CDN

B. Except for USA and CDN
3. Bend the lock washer "1" tab.
7. Install:
• Pressure plate "1"
4. Install:
• Friction plate "1"
• Clutch plate "2" 8. Install:
• Clutch spring
• Install the clutch plates and friction • Bolt (clutch spring)
plates alternately on the clutch
Bolt (clutch spring):
boss, starting with a friction plate
10 Nm (1.0 m•kg, 7.2
and ending with a friction plate.
ft•lb)
• Apply the engine oil on the friction
plates and clutch plates.
Tighten the bolts in stage, using a
crisscross pattern.
4-32
OIL FILTER ELEMENT AND WATER PUMP

REMOVING THE OIL FILTER ELEMENT AND WATER PUMP
10 Nm (1.0 m kg, 7.2 ft lb)
33 Nm (3.3 m kg, 24 ft lb)
10 Nm (1.0 m kg, 7.2 ft lb)
12 Nm (1.2 m kg, 8.7 ft lb)

10 Nm (1.0 m kg, 7.2 ft lb)
10 Nm (1.0 m kg, 7.2 ft lb)
10 Nm (1.0 m kg, 7.2 ft lb)

14 Nm (1.4 m kg, 10 ft lb)

Right engine guard Refer to "ENGINE REMOVAL" section.
Refer to "CHANGING THE COOLANT" sec-
Drain the coolant.
tion.
Exhaust pipe
section.
Brake pedal Refer to "ENGINE REMOVAL" section.
Clutch cover Refer to "CLUTCH" section.
1 Oil filter element cover 1
2 Oil filter element 1
3 Coolant pipe 2 1
4 Water pump housing 1
5 Pin 2
6 Oil tank breather hose 1
7 Kickstarter crank 1
8 Right crankcase cover 1
4-33
10 Nm (1.0 m kg, 7.2 ft lb)
33 Nm (3.3 m kg, 24 ft lb)
10 Nm (1.0 m kg, 7.2 ft lb)
12 Nm (1.2 m kg, 8.7 ft lb)

10 Nm (1.0 m kg, 7.2 ft lb)
10 Nm (1.0 m kg, 7.2 ft lb)
10 Nm (1.0 m kg, 7.2 ft lb)

14 Nm (1.4 m kg, 10 ft lb)

9 Gasket 1
10 Dowel pin/O-ring 3/1
11 Impeller 1 Refer to removal section.
12 Washer 1 Refer to removal section.
13 Impeller shaft 1 Refer to removal section.
14 Oil seal 1 1 Refer to removal section.
15 Oil seal 2 1 Refer to removal section.
16 Bearing 1 Refer to removal section.
4-34
REMOVING THE IMPELLER

SHAFT
1. Remove:
• Impeller "1"
• Washer "2"
• Impeller shaft "3"
Hold the impeller shaft on its width

across the flats "a" with spanners, CHECKING THE BEARING INSTALLING THE IMPELLER
etc. and remove the impeller. 1. Inspect: SHAFT
• Bearing 1. Install:
Rotate inner race with a finger. • Impeller shaft "1"
Rough spot/seizure → Replace. • Washer "2"
• Impeller "3"
Impeller:
14 Nm (1.4 m•kg, 10
ft•lb)
• Take care so that the oil seal lip is

not damaged or the spring does not
CHECKING THE OIL SEAL slip off its position.
1. Inspect: • When installing the impeller shaft,
• Oil seal "1" apply the engine oil on the oil seal
Wear/damage → Replace. lip, bearing and impeller shaft. And
install the shaft while turning it.
• Hold the impeller shaft on its width
REMOVING THE OIL SEAL across the flats "a" with spanners,
etc. and install the impeller.
It is not necessary to disassemble the
water pump, unless there is an abnor-
mality such as excessive change in
coolant level, discoloration of coolant,
or milky transmission oil. INSTALLING THE OIL SEAL
1. Install:
1. Remove: • Oil seal "1"
• Bearing "1"
• Oil seal "2"
on the oil seal lip.
• Install the oil seal with its manufac-
ture's marks or numbers facing the
right crankcase cover "2".
INSTALLING THE RIGHT

CRANKCASE COVER
1. Install:
• Dowel pin "1"
• O-ring "2"
2. Install: • Collar "3"
• Bearing "1" • Gasket "4"
CHECKING THE IMPELLER SHAFT Install the bearing by pressing its out- Apply the lithium soap base grease
1. Inspect: er race parallel. on the O-ring.
• Impeller shaft "1"
Bend/wear/damage → Replace.
Fur deposits → Clean.
4-35
3. Install:
• O-ring "3"
• Coolant pipe "1"
• Bolt (coolant pipe) "2"
Bolt (coolant pipe):
10 Nm (1.0 m•kg, 7.2
ft•lb)
• Right crankcase cover "1" • Oil tank breather hose "1" Apply the lithium soap base grease
• Bolt "2" • Clamp "2" on the O-ring.
Bolt: Clamp:
12 Nm (1.2 m•kg, 8.7 2 Nm (0.2 m•kg, 1.4
ft•lb) ft•lb)
• Bolt
Bolt:
10 Nm (1.0 m•kg, 7.2
ft•lb)
INSTALLING THE OIL FILTER
• Apply the engine oil on the impeller ELEMENT
shaft end. 1. Install:
• When installing the crankcase cov- INSTALLING THE WATER PUMP • Oil filter element "1"
er onto the crankcase, be sure that HOUSING • O-ring "2"
the impeller shaft end "2" aligns 1. Install: • Oil filter element cover "3"
with the balancer end slot "3". • Dowel pin "1" • Bolt (oil filter element cover)
• Tighten the bolts in stage, using a • O-ring "2" Bolt (oil filter element
crisscross pattern. cover):
Apply the lithium soap base grease 10 Nm (1.0 m•kg, 7.2
on the O-ring. ft•lb)
Apply the lithium soap base grease

on the O-ring.
2. Install:
• Water pump housing "1"
• Bolt (water pump housing) "2"
Bolt (water pump hous-
ing):
INSTALLING THE KICKSTARTER
10 Nm (1.0 m•kg, 7.2
CRANK
ft•lb)
1. Install:
• Kickstarter crank "1" • Washer "3"
• Washer • Coolant drain bolt "4"
• Bolt (kickstarter crank) Coolant drain bolt:
Bolt (kickstarter crank): 10 Nm (1.0 m•kg, 7.2
33 Nm (3.3 m•kg, 24 ft•lb)
ft•lb)
Install so that there is a clearance "a"

of 8 mm (0.31 in) or more between
the kickstarter and frame and that the
kickstarter does not contact the
crankcase cover when it is pulled.
4-36
BALANCER
BALANCER
REMOVING THE BALANCER

Primary driven gear Refer to "CLUTCH" section.
Refer to "OIL FILTER ELEMENT AND WA-
Right crankcase cover
TER PUMP" section.
Stator Refer to "CDI MAGNETO" section.
1 Nut (balancer) 1 Refer to removal section.
2 Nut (primary drive gear) 1 Refer to removal section.
3 Nut (balancer shaft driven gear) 1 Refer to removal section.
4 Lock washer 1
5 Balancer 1
6 Straight key 1
7 Conical washer 1
8 Primary drive gear 1
9 Balancer shaft drive gear 1
10 Lock washer 1
11 Balancer shaft driven gear 1
4-37
BALANCER
REMOVING THE BALANCER • Nut (balancer) "9"

1. Straighten the lock washer tab. Nut (balancer):
2. Loosen: 45 Nm (4.5 m•kg, 33
• Nut (balancer) "1" ft•lb)
• Nut (primary drive gear) "2"
• Nut (balancer shaft driven gear)
"3" • Apply engine oil to the contact sur-
face and threaded portion of the nut
Place an aluminum plate "a" between INSTALLING THE BALANCER (primary drive gear).
the teeth of the balancer shaft drive 1. Install: • Place an aluminum plate "a" be-
gear "4" and driven gear "5". • Balancer shaft driven gear "1" tween the teeth of the balancer
shaft drive gear "10" and balancer
Install the balancer shaft driven gear shaft driven gear "11".
and balancer shaft with their lower • Install the conical washer with its
splines "a" aligning with each other. convex surface "b" outward.
2. Install:
• Balancer shaft driven gear "1"
• Align the punched mark "a" on the

balancer shaft drive gear with the
punched mark "b" on the balancer
shaft driven gear.
• Install the balancer shaft driven
gear and crankshaft with the lower 4. Bend the lock washer tab.
splines "c" aligning with each other.
CHECKING THE PRIMARY DRIVE

GEAR, BALANCER SHAFT DRIVE
GEAR AND BALANCER SHAFT
DRIVEN GEAR
1. Inspect:
• Primary drive gear "1"
• Balancer shaft drive gear "2"
• Balancer shaft driven gear "3" 3. Install:
Wear/damage → Replace. • Lock washer "1"
• Nut (balancer shaft driven gear)
"2"
Nut (balancer shaft driv-
en gear):
50 Nm (5.0 m•kg, 36
ft•lb)
• Primary drive gear "3"
CHECKING THE BALANCER • Conical washer "4"
1. Inspect: • Nut (primary drive gear) "5"
• Balancer Nut (primary drive gear):
Cracks/damage → Replace. 110 Nm (11.0 m•kg, 80
ft•lb)
• Straight key "6"
• Balancer "7"
• Lock washer "8"
4-38
OIL PUMP
OIL PUMP
REMOVING THE OIL PUMP

Primary driven gear Refer to "CLUTCH" section.
Refer to "OIL FILTER ELEMENT AND WA-
Right crankcase cover
TER PUMP" section.
1 Circlip 1
2 Washer 1
3 Oil pump drive gear 1
4 Oil pump assembly 1
5 Dowel pin 2
6 Outer rotor 2 1
7 Circlip 1
8 Inner rotor 2 1
9 Dowel pin 1
10 Oil pump cover 1
11 Outer rotor 1 1
12 Inner rotor 1 1
13 Dowel pin 1
14 Washer 1
4-39
OIL PUMP

15 Oil pump drive shaft 1
16 Rotor housing 1
4-40
OIL PUMP
CHECKING THE OIL PUMP INSTALLING THE OIL PUMP • Bolt (oil pump assembly) "4"
1. Inspect: 1. Install: Bolt (oil pump assem-
• Oil pump drive gear • Oil pump drive shaft "1" bly):
• Oil pump drive shaft • Washer "2" 10 Nm (1.0 m•kg, 7.2
• Rotor housing • Dowel pin "3" ft•lb)
• Oil pump cover • Inner rotor 1 "4"
Cracks/wear/damage → Replace.
2. Measure: • Apply the engine oil on the oil pump Apply the engine oil on the outer rotor
• Tip clearance "a" drive shaft and inner rotor 1. 2.
(between the inner rotor "1" and • Fit the dowel pin into the groove in
outer rotor "2") the inner rotor 1.
• Side clearance "b"
(between the outer rotor "2" and
rotor housing "3")
• Housing and rotor clearance "c"
(between the rotor housing "3"
and rotors "1" "2")
the oil pump assembly. 5. Install:
• Oil pump drive gear "1"
Tip clearance "a": • Washer "2"
2. Install:
0.12 mm or less (0.0047 • Circlip"3"
• Outer rotor 1 "1"
in or less)
<Limit>: 0.20 mm
Apply the engine oil on the outer rotor Apply the engine oil on the oil pump
(0.008 in)
1. drive gear inner circumference.
Side clearance "b":
0.09–0.17 mm (0.0035–
0.0067 in)
<Limit>: 0.24 mm
(0.009 in)
Housing and rotor clear-
ance "c":
0.03–0.10 mm (0.0012–
0.0039 in)
<Limit>: 0.17 mm 3. Install:
(0.0067 in) • Oil pump cover "1"
• Screw (oil pump cover) "2"
Screw (oil pump cover):
2 Nm (0.2 m•kg, 1.4
ft•lb)
• Dowel pin "3"
• Inner rotor 2 "4"
• Circlip "5"
• Apply the engine oil on the oil pump

drive shaft end and inner rotor 2.
• Fit the dowel pin into the groove in
the inner rotor 2.
3. Check:
• Unsmooth→Repeat steps #1 and
#2 or replace the defective parts.
4. Install:
• Outer rotor 2 "1"
• Dowel pin "2"
• Oil pump assembly "3"
4-41
KICK SHAFT AND SHIFT SHAFT

REMOVING THE KICK SHAFT AND SHIFT SHAFT

Oil pump Refer to "OIL PUMP" section.
1 Kick idle gear 1
2 Kick shaft assembly 1 Refer to removal section.
3 Spring guide 1
4 Torsion spring 1
5 Ratchet wheel 1
6 Kick gear 1
7 Kick shaft 1
8 Washer 1
9 Shift pedal 1
10 Shift shaft 1
11 Collar 1
12 Torsion spring 1
13 Roller 1
14 Shift guide 1 Refer to removal section.
15 Shift lever assembly 1 Refer to removal section.
16 Shift lever 1
4-42

17 Pawl 2
18 Pawl pin 2
19 Spring 2
20 Bolt (stopper lever) 1
21 Stopper lever 1
22 Torsion spring 1
23 Segment 1 Refer to removal section.
4-43
REMOVING THE KICK SHAFT • Kick shaft "2"

CHECKING THE STOPPER LEVER
ASSEMBLY Wear/damage → Replace.
1. Inspect:
1. Remove: • Spring "3"
• Stopper lever "1"
• Kick shaft assembly "1" Broken → Replace.
• Torsion spring "2"
Unhook the torsion spring "2" from Broken → Replace.
the hole "a" in the crankcase.
CHECKING THE KICK GEAR, KICK

IDLE GEAR AND RATCHET
WHEEL
INSTALLING THE SEGMENT
1. Inspect:
REMOVING THE SHIFT GUIDE 1. Install:
• Kick gear "1"
AND SHIFT LEVER ASSEMBLY • Segment "1"
• Kick idle gear "2"
1. Remove: • Bolt (segment)
• Ratchet wheel "3"
• Bolt (shift guide) • Gear teeth "a" Bolt (segment):
• Shift guide "1" • Ratchet teeth "b" 30 Nm (3.0 m•kg, 22
• Shift lever assembly "2" Wear/damage → Replace. ft•lb)
The shift lever assembly is disassem-

Align the notch "a" on the segment
bled at the same time as the shift
with the pin "b" on the shift cam.
guide.
If the segment gets an impact, it

may be damaged. Take care not to
CHECKING THE SHIFT SHAFT give an impact to the segment
1. Inspect: when tightening the bolt.
• Shift shaft "1"
• Spring "2"
REMOVING THE SEGMENT Broken → Replace.
1. Remove:
• Bolt (segment) "1"
• Segment "2"
Turn the segment counterclockwise

until it stops and loosen the bolt. INSTALLING THE STOPPER
LEVER
1. Install:
If the segment gets an impact, it CHECKING THE SHIFT GUIDE AND
• Washer "2"
may be damaged. Take care not to SHIFT LEVER ASSEMBLY
• Stopper lever "3"
give an impact to the segment 1. Inspect:
• Bolt (stopper lever) "4"
when removing the bolt. • Shift guide "1"
• Shift lever "2" Bolt (stopper lever):
• Pawl "3" 10 Nm (1.0 m•kg, 7.2
• Pawl pin "4" ft•lb)
• Spring "5"
Align the stopper lever roller with the
slot on segment.
CHECKING THE KICK SHAFT AND

RATCHET WHEEL
1. Check:
• Ratchet wheel "1" smooth move-
ment
Unsmooth movement → Replace.
4-44
INSTALLING THE SHIFT GUIDE

INSTALLING THE SHIFT SHAFT
AND SHIFT LEVER ASSEMBLY
1. Install:
1. Install:
• Roller "1"
• Spring "1"
• Collar "2"
• Pawl pin "2"
• Pawl "3"
• Washer "4"
To shift lever "4".
• Shift shaft "5"
Apply the engine oil on the spring, 2. Install:

Apply the engine oil on the roller and • Torsion spring "1"
pawl pin and pawl.
shift shaft. To kick shaft "2".
Make sure the stopper "a" of the tor-

sion spring fits into the hole "b" on the
kick shaft.
2. Install:
2. Install:
• Shift lever assembly "1"
• Shift pedal "1"
To shift guide "2".
• Bolt (shift pedal) "2"
Bolt (shift pedal):
12 Nm (1.2 m•kg, 8.7 3. Install:
ft•lb) • Spring guide "1"
When installing the shift pedal onto Slide the spring guide into the kick
the shift shaft, be sure that the center shaft, make sure the groove "a" in the
of the shift pedal is about 4.4 mm spring guide fits on the stopper of the
3. Install: torsion spring.
(0.17 in) "a" above the top of the foot-
• Shift lever assembly "1"
rest.
• Shift guide "2"
• The shift lever assembly is installed

at the same time as the shift guide.
• Apply the engine oil on the bolt
(segment) shaft.
4. Install:
INSTALLING THE KICK SHAFT • Kick shaft assembly "1"
ASSEMBLY • Washer "2"
1. Install:
• Kick gear "1" • Apply the molybdenum disulfide
• Washer "2" grease on the contacting surfaces
• Circlip "3" of the kick shaft stopper "a" and kick
4. Install: • Ratchet wheel "4" shaft ratchet wheel guide "3".
• Bolt (shift guide) "1" • Spring "5" • Apply the engine oil on the kick
Bolt (shift guide): • Washer "6" shaft.
10 Nm (1.0 m•kg, 7.2 • Circlip "7" • Slide the kick shaft assembly into
ft•lb) To kick shaft "8". the crankcase and make sure the
kick shaft stopper "a" fits into the
• Apply the molybdenum disulfide oil kick shaft ratchet wheel guide.
on the inner circumferences of the
kick gear and ratchet wheel.
• Align the punch mark "a" on the
ratchet wheel with the punch mark
"b" on the kick shaft.
4-45
5. Hook:
Turn the torsion spring clockwise and

hook into the proper hole "a" in the
crankcase.
INSTALLING THE KICK IDLE

GEAR
1. Install:
• Kick idle gear "1"
• Washer "2"
• Circlip "3"
• Apply the engine oil on the kick idle

gear inner circumference.
• Install the kick idle gear with its de-
pressed side "a" toward you.
4-46
CDI MAGNETO
CDI MAGNETO
REMOVING THE CDI MAGNETO

Seat and fuel tank Refer to "SEAT, FUEL TANK AND SIDE
COVERS" section.
Disconnect the CDI magneto lead.
1 Left crankcase cover 1
2 Gasket 1
3 Dowel pin 2
4 Nut (rotor) 1 Refer to removal section.
5 Rotor 1 Refer to removal section.
6 Stator 1
7 Woodruff key 1
4-47
CDI MAGNETO
REMOVING THE ROTOR

1. Remove: • Apply the sealant on the grommet
• Nut (rotor) "1" of the CDI magneto lead.
• Washer • Tighten the screws using the T30
bit.
YAMAHA Bond No. 1215

(ThreeBond® No. 1215):
90890-85505 5. Install:
• Dowel pin
• O-ring
• Gasket (left crankcase cover)
2. Remove:
• Rotor "1" • Left crankcase cover "1"
Use the rotor puller 2. • Hose guide (cylinder head breath-
Rotor puller: er hose) "2"
YM-04151/90890-04151 • Bolt (left crankcase cover)
2. Install: Bolt (left crankcase cov-

• Woodruff key "1" er):
• Rotor "2" 10 Nm (1.0 m•kg, 7.2
ft•lb)
• Degrease the contact surfaces of
the tapered portions of the crank- • Apply the lithium soap base grease
shaft and rotor. on the O-ring.
• When installing the woodruff key, • Tighten the bolts in stage, using a
CHECKING THE CDI MAGNETO make sure that its flat surface "a" is crisscross pattern.
1. Inspect: in parallel with the crankshaft center
• Rotor inner surface "a" line "b".
• Stator outer surface "b" • When installing the rotor, align the
Damage→Inspect the crankshaft keyway "c" of the rotor with the
runout and crankshaft bearing. woodruff key.
If necessary, replace CDI magne-
to and/or stator.
3. Install:
• Washer
CHECKING THE WOODRUFF KEY • Nut (rotor) "1"
1. Inspect:
• Woodruff key "1" Nut (rotor):
Damage → Replace. 56 Nm (5.6 m•kg, 40
ft•lb)
INSTALLING THE CDI MAGNETO

1. Install: 4. Connect:
• Stator "1" • CDI magneto lead
• Screw (stator) "2" Refer to "CABLE ROUTING DIA-
Screw (stator): GRAM" section in the CHAPTER
10 Nm (1.0 m•kg, 2.
7.2ft•lb)
4-48
ENGINE REMOVAL
ENGINE REMOVAL
REMOVING THE ENGINE

Hold the machine by placing the suitable stand
Refer to "HANDLING NOTE".
under the frame.
Seat and fuel tank
COVERS" section.
Refer to "REAR SHOCK ABSORBER" sec-
Rear shock absorber
Carburetor Refer to "CARBURETOR" section.
Exhaust pipe and silencer
section.
Clutch cable Disconnect at the engine side.
Radiator Refer to "RADIATOR" section.
Refer to "KICK SHAFT AND SHIFT SHAFT"
Shift pedal
section.
Cylinder head breather hose Refer to "CAMSHAFTS" section.
Ignition coil
Disconnect the CDI magneto lead.
4-49
ENGINE REMOVAL

Engine guard
1 Neutral switch 1
2 Drive chain sprocket cover 1
3 Nut (drive sprocket) 1 Refer to removal section.
4 Lock washer 1 Refer to removal section.
5 Drive sprocket 1 Refer to removal section.
6 Clip 1
7 Bolt (brake pedal) 1
8 Brake pedal 1
9 Upper engine bracket 2
10 Lower engine bracket 2
11 Engine mounting bolt 3
12 Pivot shaft 1 Refer to removal section.
13 Engine 1 Refer to removal section.
4-50
ENGINE REMOVAL
HANDLING NOTE
Support the machine securely so

there is no danger of it falling over.
REMOVING THE DRIVE

SPROCKET
1. Remove:
INSTALLING THE ENGINE
• Nut (drive sprocket) "1"
1. Install:
• Lock washer "2"
• Engine "1"
Install the engine from right side.
• Straighten the lock washer tab. • Pivot shaft "2"
• Loosen the nut while applying the
rear brake. Pivot shaft:
85 Nm (8.5 m•kg, 61
ft•lb)
INSTALLING THE BRAKE PEDAL
• Engine mounting bolt (lower) "3"
1. Install:
Engine mounting bolt • Spring "1"
(lower): • Brake pedal "2"
53Nm (5.3 m•kg, 38 • O-ring "3"
ft•lb) • Bolt (brake pedal) "4"
• Lower engine bracket "4" Bolt (brake pedal):
2. Remove:
• Bolt (lower engine bracket) "5" 26 Nm (2.6 m•kg, 19
• Drive sprocket "1"
Bolt (lower engine brack- ft•lb)
• Drive chain "2"
et): • Clip "5"
Remove the drive sprocket together 34 Nm (3.4 m•kg, 24
with the drive chain. ft•lb) Apply the lithium soap base grease
• Patch "6" on the bolt, O-rings and brake pedal
• Engine mounting bolt (front) "7" bracket.
Engine mounting bolt
(front):
53 Nm (5.3 m•kg, 38
ft•lb)
• Upper engine bracket "8"
• Bolt (upper engine bracket) "9"
REMOVING THE ENGINE
1. Remove: Bolt (upper engine brack-
• Pivot shaft "1" et): INSTALLING THE DRIVE
55 Nm (5.5 m•kg, 40 SPROCKET
If the pivot shaft is pulled all the way ft•lb) 1. Install:
out, the swingarm will come loose. If • Engine mounting bolt (upper) "10" • Drive sprocket "1"
possible, insert a shaft of similar di- • Drive chain "2"
Engine mounting bolt
ameter into the other side of the swin-
(upper):
garm to support it. Install the drive sprocket together
55 Nm (5.5 m•kg, 40
with the drive chain.
ft•lb)
• Apply the molybdenum disulfide

grease on the pivot shaft.
• Install the patch with the claw "a"
facing outside the chassis.
2. Remove:
• Engine "1"
From right side.
Make sure that the couplers, hoses

and cables are disconnected.
4-51
ENGINE REMOVAL
2. Install:
• Lock washer "1"
• Nut (drive sprocket) "2"
Nut (drive sprocket):
75 Nm (7.5 m•kg, 54
ft•lb)
Tighten the nut while applying the

rear brake.
Make sure to tighten to specifica-

tion; otherwise, it may damage the
other part that is fastened togeth-
er.
3. Bend the lock washer tab to lock

the nut.
4. Install:
• Drive chain sprocket guide
• Drive chain sprocket cover "1"
• Screw (drive chain sprocket cov-
er) "2"
Screw (drive chain
sprocket cover):
8 Nm (0.8 m•kg, 5.8
ft•lb)
INSTALLING THE NEUTRAL

SWITCH
1. Install:
• Spring "1"
• Pin "2"
• O-ring "3"
• Neutral switch "4"
• Screw (neutral switch) "5"
Screw (neutral switch):
4 Nm (0.4 m•kg, 2.9
ft•lb)

on the O-ring.
4-52
CRANKCASE AND CRANKSHAFT

REMOVING THE CRANKSHAFT

Engine Refer to "ENGINE REMOVAL" section.
Piston Refer to "CYLINDER AND PISTON" section.
Balancer Refer to "BALANCER" section.
Kick shaft assembly
section.
Segment
section.
Stator Refer to "CDI MAGNETO" section.
1 Timing chain guide (intake side) 1
2 Timing chain 1
3 Bolt [L = 50 mm (1.97 in)] 7 Refer to removal section.
6 Hose guide 1 Refer to removal section.
7 Right crankcase 1 Refer to removal section.
8 Left crankcase 1 Refer to removal section.
9 Oil strainer 1
4-53

10 Balancer shaft 1 Refer to removal section.
11 Crankshaft 1 Refer to removal section.
4-54
REMOVING THE CRANKCASE BEARING

Refer to "TRANSMISSION, SHIFT CAM AND
Transmission
SHIFT FORK" section.
Refer to "TRANSMISSION, SHIFT CAM AND
Shift cam and shift fork
SHIFT FORK" section.
1 Oil seal 3
4-55
DISASSEMBLING THE c. Remove the dowel pins and O-

CRANKCASE ring.
1. Separate:
• Right crankcase
REMOVING THE BALANCER
• Left crankcase
SHAFT
1. Remove:
Separation steps: • Balancer shaft "1"
a. Remove the crankcase bolts,
hose guide and clutch cable hold- CHECKING THE TIMING CHAIN
Remove the balancer shaft with its AND TIMING CHAIN GUIDE
er. flat side "a" facing the crankshaft. 1. Inspect:
• Timing chain
Cracks/stiff → Replace the timing
chain and camshaft sprocket as a
set.
Loosen each bolt 1/4 of a turn at a REMOVING THE CRANKSHAFT

time and after all the bolts are loos- 1. Remove:
ened, remove them. • Crankshaft "1"
Use the crankcase separating
b. Remove the right crankcase "1". tool "2". 2. Inspect:
• Timing chain guide
Crankcase separating Wear/damage → Replace.
• Place the crankcase with its left tool:
side downward and split it by insert- CHECKING THE CRANKCASE
YU-A9642/90890-04152
ing a screwdriver tip into the split- 1. Inspect:
ting slit "a" in the crankcase. • Contacting surface "a"
• Lift the right crankcase horizontally Install the crankcase separating tool Scratches → Replace.
while lightly patting the case split- as shown. • Engine mounting boss "b", crank-
ting slit and engine mounting boss case
using a soft hammer, and leave the Cracks/damage → Replace.
crankshaft and transmission with Do not use a hammer to drive out
the left crankcase. the crankshaft.
Use soft hammer to tap on the

case half. Tap only on reinforced
portions of case. Do not tap on
gasket mating surface. Work slow-
2. Inspect:
ly and carefully. Make sure the
• Bearing
case halves separate evenly. If the
Rotate inner race with a finger.
cases do not separate, check for a
Rough spot/seizure → Replace.
remaining case bolt or fitting. Do
not force.
REMOVING THE CRANKCASE

BEARING 3. Inspect:
1. Remove: • Oil seal
• Bearing "1" Damage → Replace.
CHECKING THE CRANKSHAFT
• Remove the bearing from the 1. Measure:
crankcase by pressing its inner • Runout limit "a"
race. • Small end free play limit "b"
• Do not use the removed bearing. • Connecting rod big end side
clearance "c"
4-56
• Crank width "d" • Screw (bearing stopper)

Out of specification → Replace. Screw (bearing stopper):
Use the dial gauge and a thick- Do not use a hammer to drive in
10 Nm (1.0 m•kg, 7.2
ness gauge. the crankshaft.
ft•lb)
Dial gauge and stand:
• Screw [bearing stopper (crank-
YU-3097/90890-01252
shaft)] "1"
Screw [bearing stopper
Standard <Limit> (crankshaft)]:
14 Nm (1.4 m•kg, 1.0
Runout 0.03 mm 0.05 mm ft•lb)
limit: (0.0012 in) (0.002 in)
To left and right crankcase.
Small
0.4–1.0 mm
end 2.0 mm
(0.016–0.039 • Install the bearing by pressing its
free (0.08 in)
in) outer race parallel.
play:
• To prevent the screw [bearing stop-
Side 0.15–0.45 per (crankshaft)] from becoming
0.50 mm
clear- mm (0.0059– loose, crush the screw head periph-
(0.02 in)
ance: 0.0177 in) ery "a" into the concave "b" using a
61.95–62.00 punch etc. In so doing, take care
Crack A. For USA and CDN
mm (2.439– — not to damage the screwdriver re-
width: B. Except for USA and CDN
2.441 in) ceiving hole in the screw head.
2. Check:
• Shifter operation
• Transmission operation
Unsmooth operation → Repair.
INSTALLING THE CRANKSHAFT

1. Install:
• Crankshaft "1"
Use the crankshaft installing tool 3. Install:
"2", "3", "4" and "5". • Oil strainer "1"
• Bolt (oil strainer) "2"
Crankshaft installing pot
"2": Bolt (oil strainer):
YU-90050/90890-01274 10 Nm (1.0 m•kg, 7.2
CHECKING THE OIL STRAINER Crankshaft installing bolt ft•lb)
1. Inspect: "3":
• Oil strainer YU-90050/90890-01275
Damage → Replace. Adapter (M12) "4":
YU-90063/90890-01278
Spacer (crankshaft in-
staller) "5":
YM-91044/90890-04081
• Hold the connecting rod at top dead 4. Apply:

center with one hand while turning • Sealant
INSTALLING THE CRANKCASE the nut of the installing tool with the On the right crankcase.
BEARING other. Operate the installing tool un- YAMAHA Bond No. 1215
1. Install: til the crankshaft bottoms against (ThreeBond® No.1215):
• Bearing the bearing. 90890-85505
• Bearing stopper • Before installing the crankshaft,
• Bolt (bearing stopper) clean the contacting surface of
crankcase. Clean the contacting surface of left
Bolt (bearing stopper):
and right crankcase before applying
10 Nm (1.0 m•kg, 7.2
the sealant.
ft•lb)
4-57
9. Apply:
• Engine oil
To the crank pin, bearing and oil
delivery hole.
10. Check:
• Crankshaft and transmission op-
eration.
5. Install:
• Dowel pin "1"
• O-ring "2"
• Right crankcase
To left crankcase.

on the O-ring.
• Fit the right crankcase onto the left
crankcase. Tap lightly on the case
with soft hammer.
• When installing the crankcase, the
connecting rod should be posi-
tioned at TDC (top dead center).
6. Tighten:
• Bolt (hose guide) "1"
• Bolt (crankcase)
Bolt (crankcase):
12 Nm (1.2 m•kg, 8.7
ft•lb)
Tighten the crankcase tightening

bolts in stage, using a crisscross pat-
tern.
7. Install:
• Timing chain
• Timing chain guide (intake side)
• Bolt (timing chain guide)
Bolt (timing chain guide):
10 Nm (1.0 m•kg, 7.2
ft•lb)
8. Remove:
• Sealant
Forced out on the cylinder mating
surface.
4-58
TRANSMISSION, SHIFT CAM AND SHIFT FORK

REMOVING THE TRANSMISSION, SHIFT CAM AND SHIFT FORK

Engine Refer to "ENGINE REMOVAL" section.
Refer to "CRANKCASE AND CRANK-
Separate the crankcase.
SHAFT" section.
1 Main axle 1 Refer to removal section.
2 Drive axle 1 Refer to removal section.
3 Shift cam 1 Refer to removal section.
4 Shift fork 3 1 Refer to removal section.
7 Collar 1
4-59
REMOVING THE TRANSMISSION idler gear and on the inner surface of

1. Remove: the sliding gear, then install.
• Main axle "1"
• Drive axle "2"
• Shift cam
• Shift fork 3
• Shift fork 2
• Shift fork 1
CHECKING THE SHIFT FORK,
• Remove assembly with the collar SHIFT CAM AND SEGMENT
"3" installed to the crankcase. 1. Inspect:
• Remove assembly carefully. Note • Shift fork "1"
the position of each part. Pay partic- Wear/damage/scratches → Re-
ular attention to the location and di- place.
rection of shift forks.
• Remove the main axle, drive axle,
shift cam and shift fork all together
by tapping lightly on the transmis-
sion drive axle with a soft hammer.
2. Install:
• Collar "1"
• 2nd wheel gear (23T) "2"
2. Inspect: • 4th wheel gear (24T) "3"
• Shift cam "1" • 3rd wheel gear (23T) "4"
• Segment "2" • 5th wheel gear (20T) "5"
Wear/damage → Replace. • Collar "6"
• 1st wheel gear (27T) "7"
• O-ring "8"
CHECKING THE GEARS To drive axle "9".
1. Inspect:
• Matching dog "a"
• Gear teeth "b"
on the inner and end surface of the
• Shift fork groove "c"
idler gear and on the inner surface
of the sliding gear, then install.
3. Check: • Apply the lithium soap base grease
• Shift fork movement on the O-ring.
Unsmooth operation → Replace
shift fork.
2. Inspect:
• O-ring "1"
Damage → Replace.
For a malfunctioning shift fork, re-

place not only the shift fork itself but
the two gears each adjacent to the
shift fork.
INSTALLING THE TRANSMISSION

3. Check: 1. Install:
• Gears movement • 5th pinion gear (21T) "1"
Unsmooth movement→Repair or • 3rd pinion gear (18T) "2"
replace. • Collar "3"
CHECKING THE BEARING • 4th pinion gear (22T) "4"
1. Inspect: • 2nd pinion gear (15T) "5"
• Bearing "1" To main axle "6".
Rotate inner race with a finger.
Rough spot/seizure → Replace. Apply the molybdenum disulfide oil
on the inner and end surface of the
4-60
3. Install:
• Washer "1"
• Circlip "2"
• Be sure the circlip sharp-edged cor-

ner "a" is positioned opposite side
to the washer and gear "b".
• Install the circlip with its ends "c"
settled evenly on the spline crests.
6. Install:
• Transmission assembly "1"
To left crankcase "2".
Apply the engine oil on the bearings

and guide bars.
4. Install:
• Collar "1"

• When installing the collar into the 7. Check:
crankcase, pay careful attention to • Shifter operation
the crankcase oil seal lip. • Transmission operation
5. Install:
• Shift fork 1 (L) "1"
• Shift fork 2 (C) "2"
• Shift fork 3 (R) "3"
• Shift cam "4"
To main axle and drive axle.

on the shift fork grooves.
• Apply engine oil to the shift cam
groove, bearing contact surface
and shift fork shaft.
• Mesh the shift fork #1 (L) with the
4th wheel gear "5" and #3 (R) with
the 5th wheel gear "7" on the drive
axle.
• Mesh the shift fork #2 (C) with the
3rd pinion gear "6" on the main ax-
le.
4-61
FRONT WHEEL AND REAR WHEEL
CHASSIS
REMOVING THE FRONT WHEEL

under the engine.
1 Bolt (axle holder) 4 Only loosening.
2 Nut (front wheel axle) 1
3 Front wheel axle 1
4 Front wheel 1
5 Collar 2
6 Oil seal 2
8 Brake disc 1
5-1
REMOVING THE REAR WHEEL
5
under the engine.
1 Nut (rear wheel axle) 1
2 Rear wheel axle 1
3 Drive chain puller 2
4 Rear wheel 1 Refer to removal section.
5 Collar 2
6 Rear wheel sprocket 1
7 Oil seal 2
8 Circlip 1
10 Brake disc 1
5-2
HANDLING NOTE

REMOVING THE REAR WHEEL

1. Remove:
• Wheel "1"
CHECKING THE WHEEL AXLE
1. Measure:
Push the wheel forward and remove • Wheel axle bends
the drive chain "2". Out of specification → Replace.
Use the dial gauge "1".
Wheel axle bending limit:
0.5 mm (0.020 in)
INSTALLING THE FRONT WHEEL

The bending value is shown by one 1. Install:
half of the dial gauge reading. • Bearing (left) "1"
• Spacer "2"
REMOVING THE WHEEL BEARING • Bearing (right) "3"
1. Remove: • Oil seal "4"
Do not attempt to straighten a bent
• Bearing "1"
axle.
Remove the bearing using a general on the bearing and oil seal lip when
bearing puller "2". installing.
• Use a socket that matches the out-
side diameter of the race of the
bearing.
• Left side of bearing shall be in-
stalled first.
CHECKING THE BRAKE DISC ture's marks or numbers facing out-
1. Measure: ward.
• Brake disc deflection (only rear
CHECKING THE WHEEL brake disc)
1. Measure: Use the dial gauge "1".
• Wheel runout Do not strike the inner race of the
Out of specification → Inspect
Out of limit → Repair/replace. bearing. Contact should be made
wheel runout.
only with the outer race.
Wheel runout limit: If wheel runout is in good condi-
Radial "1": 2.0 mm tion, replace the brake disc.
(0.08 in) Brake disc deflection lim-
Lateral "2": 2.0 mm it:
(0.08 in) Rear:
<Limit>: 0.15 mm
(0.006 in)
2. Measure:
• Brake disc thickness "a"
Out of limit → Replace.
Brake disc thickness:
Front:
2. Inspect: 3.0 mm (0.12 in)
• Bearing <Limit>: 2.5 mm (0.10
Rotate inner race with a finger. in)
Rough spot/seizure → Replace. Rear:
4.0 mm (0.16 in)
<Limit>: 3.5 mm (0.14
Replace the bearings, oil seal and in)
wheel collar as a set.
5-3
• Brake disc "1" • Nut (wheel axle) "1"
Do not strike the inner race of the
• Bolt (brake disc) "2" Nut (wheel axle): bearing. Contact should be made
Bolt (brake disc): 105 Nm (10.5 m•kg, 75 only with the outer race.
12 Nm (1.2 m•kg, 8.7 ft•lb)
ft•lb)

crisscross pattern.
7. Tighten:
• Bolt (axle holder) "1"
Bolt (axle holder):
21 Nm (2.1 m•kg, 15
ft•lb)
3. Install:
• Collar "1"
Before tightening the bolt, fit the
wheel axle to the axle holder by strok- 2. Install:
ing the front fork several times with • Brake disc "1"
the front brake applied. • Bolt (brake disc) "2"
• Install the collars with their projec-
tions "a" facing the wheel. Bolt (brake disc):
14 Nm (1.4 m•kg, 10
ft•lb)

crisscross pattern.
4. Install:
• Wheel
Install the brake disc "1" between the

brake pads "2" correctly.
3. Install:
INSTALLING THE REAR WHEEL • Rear wheel sprocket "1"
1. Install: • Bolt (rear wheel sprocket) "2"
• Bearing (right) "1" • Washer (rear wheel sprocket) "3"
• Circlip "2" • Nut (rear wheel sprocket) "4"
• Spacer "3" Nut (rear wheel sprock-
• Bearing (left) "4" et):
• Oil seal "5" 42 Nm (4.2 m•kg, 30
5. Install: ft•lb)
• Wheel axle "1" • Apply the lithium soap base grease
on the bearing and oil seal lip when
Apply the lithium soap base grease installing. Tighten the nuts in stage, using a
on the wheel axle. • Install the bearing with seal facing crisscross pattern.
outward.
• Use a socket that matches the out-
side diameter of the race of the
bearing.
• Right side of bearing shall be in-
stalled first.
ture's marks or numbers facing out-
ward.
5-4
4. Install:
• Collar "1" Temporarily tighten the nut (wheel
axle) at this point.
9. Adjust:
• Drive chain slack "a"
5. Install: Drive chain slack:
• Wheel 48–58 mm (1.9–2.3 in)
Install the brake disc "1" between the Refer to "ADJUSTING THE
brake pads "2" correctly. DRIVE CHAIN SLACK" section in
the CHAPTER 3.
6. Install: 10. Tighten:

• Drive chain "1" • Nut (wheel axle) "1"
Nut (wheel axle):
Push the wheel "2" forward and install 125 Nm (12.5 m•kg, 90
the drive chain. ft•lb)
• Locknut "2"
Locknut:
19 Nm (1.9 m•kg, 13
ft•lb)
7. Install:
• Left drive chain puller "1"
• Wheel axle "2"
• Install the left drive chain puller, and

insert the wheel axle from left side.
on the wheel axle.
8. Install:
• Right drive chain puller "1"
• Washer "2"
• Nut (wheel axle) "3"
5-5
FRONT BRAKE AND REAR BRAKE

REMOVING THE FRONT BRAKE

under the engine.
Drain the brake fluid. Refer to removal section.
1 Brake hose holder (protector) 2
2 Union bolt 2
3 Brake hose 1
4 Pad pin plug 1 Remove when loosening the pad pin.
Loosen when disassembling the brake cali-
5 Pad pin 1
per.
6 Brake caliper 1
7 Brake lever 1
8 Brake master cylinder bracket 1
9 Brake master cylinder 1
5-6
REMOVING THE REAR BRAKE

under the engine.
Refer to "FRONT WHEEL AND REAR
Rear wheel
WHEEL" section.
Drain the brake fluid. Refer to removal section.
1 Brake pedal 1
2 Brake master cylinder 1
3 Brake hose holder 2
4 Union bolt 2
5 Brake hose 1
6 Pad pin plug 1 Remove when loosening the pad pin.
Loosen when disassembling the brake cali-
7 Pad pin 1
per.
8 Brake caliper 1
5-7
DISASSEMBLING THE BRAKE CALIPER

A. Front
B. Rear
A B
1 Pad pin 1 1
2 Brake pad 2 2
3 Pad support 1 1
4 Brake caliper piston 2 1 Refer to removal section.
5 Brake caliper piston dust seal 2 1 Refer to removal section.
6 Brake caliper piston seal 2 1 Refer to removal section.
5-8
DISASSEMBLING THE BRAKE MASTER CYLINDER

A. Front
B. Rear
1 Brake master cylinder cap 1
2 Diaphragm 1
3 Reservoir float 1
4 Push rod (Front) 1
5 Brake master cylinder boot 1
6 Circlip 1 Use a long nose circlip pliers.
7 Washer 1
8 Push rod (Rear) 1
9 Brake master cylinder kit 1
5-9
HANDLING NOTE
• Cover piston with rag and use ex-

Support the machine securely so treme caution when expelling
there is no danger of it falling over. piston from cylinder.
• Never attempt to pry out piston.
DRAINING THE BRAKE FLUID
1. Remove:
• Brake master cylinder cap "1" Caliper piston removal steps: A. Front
• Protector (rear brake) a. Insert a piece of rag into the brake B. Rear
caliper to lock one brake caliper.
CHECKING THE BRAKE MASTER
Do not remove the diaphragm. b. Carefully force the piston out of
CYLINDER
the brake caliper cylinder with
1. Inspect:
compressed air.
• Brake master cylinder inner sur-
face "a"
Wear/scratches → Replace mas-
ter cylinder assembly.
Stains → Clean.
Use only new brake fluid.
A. Front
B. Rear A. Front A. Front
2. Connect the transparent hose "2" B. Rear B. Rear
to the bleed screw "1" and place a 2. Inspect:
suitable container under its end. • Diaphragm "1"
REMOVING THE BRAKE CALIPER Crack/damage → Replace.
PISTON SEAL KIT
1. Remove:
• Brake caliper piston dust seal "1"
• Brake caliper piston seal "2"
Remove the brake caliper piston

seals and brake caliper piston dust
A. Front seals by pushing them with a finger.
B. Rear A. Front
3. Loosen the bleed screw and drain B. Rear
the brake fluid while pulling the le- Never attempt to pry out brake cal- 3. Inspect: (front brake only)
ver in or pushing down on the iper piston seals and brake caliper • Reservoir float "1"
pedal. piston dust seals. Damage → Replace.
• Do not reuse the drained brake

fluid. Replace the brake caliper piston
• Brake fluid may erode painted seals and brake caliper piston dust
surfaces or plastic parts. Always seals whenever a caliper is disas-
clean up spilled fluid immediate- sembled.
ly.
REMOVING THE BRAKE CALIPER 4. Inspect:

PISTON • Brake master cylinder piston "1"
1. Remove: • Brake master cylinder cup "2"
• Brake caliper piston Wear/damage/score marks →Re-
Use compressed air and proceed place brake master cylinder kit.
carefully.
5-10
seals and brake caliper piston

dust seals whenever a caliper is
disassembled.
INSTALLING THE BRAKE

CALIPER PISTON
1. Clean:
• Brake caliper
CHECKING THE BRAKE CALIPER • Brake caliper piston seal
1. Inspect: • Brake caliper piston dust seal
• Brake caliper cylinder inner sur- • Brake caliper piston
face "a" Clean them with brake fluid.
Wear/score marks → Replace 2. Install:
brake caliper assembly. • Brake caliper piston seal "1"
• Brake caliper piston dust seal "2"

A. Front
B. Rear
Always use new brake caliper pis- INSTALLING THE FRONT BRAKE
ton seals and brake caliper piston CALIPER
dust seals. 1. Install:
• Pad support "1"
A. Front • Brake pad "2"
B. Rear • Apply the brake fluid on the brake • Pad pin "3"
2. Inspect: caliper piston seal.
• Brake caliper piston "1" • Apply the silicone grease on the • Install the brake pads with their pro-
Wear/score marks → Replace brake caliper piston dust seal. jections "a" into the brake caliper re-
brake caliper piston assembly. • Fit the brake caliper piston seals cesses "b".
and brake caliper piston dust seals • Temporarily tighten the pad pin at
Replace the brake caliper piston onto the slot on brake caliper cor- this point.
seals and brake caliper piston dust rectly.
seals "2" whenever a caliper is dis-
assembled.
2. Install:
• Brake caliper "1"
• Bolt (brake caliper) "2"
CHECKING THE BRAKE HOSE Bolt (brake caliper):
1. Inspect: 28 Nm (2.8 m•kg, 20
• Brake hose "1" ft•lb)
Crack/damage → Replace.
3. Tighten:
• Pad pin "3"
A. Front Pad pin:
B. Rear 18 Nm (1.8 m•kg, 13
• Brake caliper piston "1"
4. Install:
Apply the brake fluid on the piston • Pad pin plug "4"
HANDLING NOTE wall. Pad pin plug:
3 Nm (0.3 m•kg, 2.2
ft•lb)
• All internal parts should be
• Install the piston with its shallow
cleaned in new brake fluid only.
depressed side "a" facing the
• Internal parts should be lubricat-
brake caliper.
ed with brake fluid when in-
• Never force to insert.
stalled.
• Replace the brake caliper piston
5-11
4. Install:
• Brake master cylinder kit "1"
• Washer (front brake) "2"
• Push rod (rear brake) "2"
• Circlip "3"
• Brake master cylinder boot "4"
• Push rod (front brake) "5"
To brake master cylinder.
INSTALLING THE REAR BRAKE INSTALLING THE BRAKE
CALIPER MASTER CYLINDER KIT • Apply the brake fluid on the brake
1. Install: 1. Clean: master cylinder kit.
• Pad support "1" • Brake master cylinder • Apply the silicone grease on the tip
• Brake pad "2" • Brake master cylinder kit of the push rod.
• Pad pin "3" Clean them with brake fluid. • When installing the circlip, use a
2. Install: long nose circlip pliers.
• Install the brake pads with their pro- • Brake master cylinder cup (prima-
jections "a" into the brake caliper re- ry) "1"
cesses "b". • Brake master cylinder cup (sec-
• Temporarily tighten the pad pin at ondary) "2"
this point. To brake master cylinder piston
"3".
Apply the brake fluid on the brake

master cylinder cup.
After installing, cylinder cup

should be installed as shown di-
2. Install: rection. Wrong installation cause
• Brake disc cover "1" improper brake performance.
• Bolt (brake disc cover) "2"
Bolt (brake disc cover): A. Front
10 Nm (1.0 m•kg, 7.2 B. Rear
ft•lb)
INSTALLING THE FRONT BRAKE
MASTER CYLINDER
1. Install:
• Brake master cylinder "1"
• Brake master cylinder bracket "2"
• Bolt (brake master cylinder brack-
et) "3"
Bolt (brake master cylin-
3. Install: der bracket):
• Brake caliper "1" 9 Nm (0.9 m•kg, 6.5
• Rear wheel "2" ft•lb)
Refer to "FRONT WHEEL AND 3. Install:
REAR WHEEL" section. • Spring "1" • Install the bracket so that the arrow
4. Tighten: To brake master cylinder piston mark "a" face upward.
• Pad pin "3" "2". • First tighten the bolts on the upper
Pad pin: side of the brake master cylinder
18 Nm (1.8 m•kg, 13 Install the spring at the smaller dia. bracket, and then tighten the bolts
ft•lb) side. on the lower side.
5. Install:
• Pad pin plug "4"
Pad pin plug:
3 Nm (0.3 m•kg, 2.2
ft•lb)
5-12
2. Install: 2. Install: • Union bolt "3"

• Brake lever "1" • Brake master cylinder "1" Union bolt:
• Bolt (brake lever) "2" • Bolt (brake master cylinder) "2" 30 Nm (3.0 m•kg, 22
Bolt (brake lever): Bolt (brake master cylin- ft•lb)
6 Nm (0.6 m•kg, 4.3 der):
ft•lb) 10 Nm (1.0 m•kg, 7.2
ft•lb) Always use new copper washers.
• Nut (brake lever) "3"
Nut (brake lever):
6 Nm (0.6 m•kg, 4.3
ft•lb)
Apply the silicone grease on the

brake lever sliding surface, bolt and
tip of the push rod.
3. Install:
• Spring "1"
• Brake pedal "2" Install the brake hose so that its
• O-ring "3" pipe portion "a" directs as shown
• Bolt (brake pedal) "4" and lightly touches the projection
Bolt (brake pedal): "b" on the brake caliper.
26 Nm (2.6 m•kg, 19
ft•lb)
• Clip "5"
INSTALLING THE REAR BRAKE
MASTER CYLINDER Apply the lithium soap base grease
1. Install: on the bolt, O-ring and brake pedal
• Copper washer "1" bracket.
• Brake hose "2"
• Union bolt "3" 2. Install:
• Brake hose holder "1"
Union bolt: • Nut (brake hose holder) "2"
30 Nm (3.0 m•kg, 22
ft•lb) Nut (brake hose holder):
7 Nm (0.7 m•kg, 5.1 ft
•lb)
Always use new copper washers.
4. Install: Align the top "a" of the brake hose
• Pin "1" holder with the paint "b" of the brake
• Washer "2" hose.
• Cotter pin "3"
After installing, check the brake pedal

height. Refer to "ADJUSTING THE
REAR BRAKE" section in the CHAP-
TER 3.
Install the brake hose so that its

pipe portion "a" directs as shown
3. Pass the brake hose through the
and lightly touches the projection
cable guide "1".
"b" on the brake master cylinder.
INSTALLING THE FRONT BRAKE

HOSE
1. Install:
• Copper washer "1"
• Brake hose "2"
5-13
4. Install: lower the boiling point of the flu-

• Copper washer "1" id and may result in vapor lock.
• Brake hose "2"
• Union bolt "3"
Union bolt: Brake fluid may erode painted sur-
30 Nm (3.0 m•kg, 22 faces or plastic parts. Always
ft•lb) clean up spilled fluid immediately.
2. Install:
• Brake hose holder "1"
Always use new copper washers. • Screw (brake hose holder) "2"
Screw (brake hose hold-
er):
2 Nm (0.2 m•kg, 1.4
ft•lb)
After installing the brake hose

holders, make sure the brake hose
does not contact the spring (rear
shock absorber). If it does, correct
Install the brake hose so that its
its twist.
pipe portion "a" directs as shown
and lightly touches the projection
"b" on the brake master cylinder. A. Front
B. Rear
2. Air bleed:
• Brake system
Refer to "BLEEDING THE HY-
DRAULIC BRAKE SYSTEM" sec-
3. Inspect:
Fluid at lower level → Fill up.
INSTALLING THE REAR BRAKE Refer to "CHECKING THE
HOSE BRAKE FLUID LEVEL" section in
1. Install: the CHAPTER 3.
• Copper washer "1" 4. Install:
• Brake hose "2" • Reservoir float (front brake)
• Union bolt "3" • Diaphragm
FILLING THE BRAKE FLUID
Union bolt: 1. Fill: • Brake master cylinder cap "1"
30 Nm (3.0 m•kg, 22 • Brake fluid • Screw (brake master cylinder
ft•lb) Until the fluid level reaches cap) "2"
"LOWER" level line "a". Screw (bolt) {brake mas-
Recommended brake flu- ter cylinder cap}:
Always use new copper washers. id: 2 Nm (0.2 m•kg, 1.4
DOT #4 ft•lb)
• Use only the designated quality After installation, while pulling the
brake fluid: brake lever in or pushing down on
otherwise, the rubber seals may the brake pedal, check whether
deteriorate, causing leakage and there is any brake fluid leaking
poor brake performance. where the union bolts are installed
• Refill with the same type of brake respectively at the brake master
fluid; cylinder and brake caliper.
Install the brake hose so that its mixing fluids may result in a
pipe portion "a" directs as shown harmful chemical reaction and
and lightly touches the projection lead to poor performance.
"b" on the brake caliper. • Be careful that water does not
enter the master cylinder when
refilling. Water will significantly
5-14
A. Front
B. Rear
5. Install: (rear brake only)
• Protector "1"
• Bolt (protector) "2"
Bolt (protector):
7 Nm (0.7 m•kg, 5.1
ft•lb)
5-15
FRONT FORK
FRONT FORK
REMOVING THE FRONT FORK
21 Nm (2.1 m kg, 15 ft lb)
21 Nm (2.1 m kg, 15 ft lb)
7 Nm (0.7 m kg, 5.1 ft lb)
5 Nm (0.5 m kg, 3.6 ft lb)

5 Nm (0.5 m kg, 3.6 ft lb)

under the engine.
Refer to "FRONT WHEEL AND REAR
Front wheel
WHEEL" section.
Refer to "FRONT BRAKE AND REAR
Front brake caliper
BRAKE" section.
Number plate
COVERS" section in the CHAPTER 4.
1 Protector 1
2 Pinch bolt (upper bracket) 2 Only loosening.
Loosen when disassembling the front fork.
3 Damper assembly 1
Refer to removal section.
4 Pinch bolt (lower bracket) 2 Only loosening.
5 Front fork 1
5-16
FRONT FORK
DISASSEMBLING THE FRONT FORK
30 Nm (3.0 m kg, 22 ft lb)
29 Nm (2.9 m kg, 21 ft lb)
1 Nm (0.1 m kg, 0.7 ft lb)
55 Nm (5.5 m kg, 40 ft lb) 29 Nm (2.9 m kg, 21 ft lb)

1 Adjuster 1 Drain the fork oil. Refer to removal section.
2 Fork spring 1 Drain the fork oil.
3 Dust seal 1 Refer to removal section.
4 Stopper ring 1 Refer to removal section.
5 Inner tube 1 Refer to removal section.
6 Outer tube 1
7 Piston metal 1
8 Slide metal 1
9 Oil seal washer 1
10 Oil seal 1
11 Base valve 1 Drain the fork oil. Refer to removal section.
12 Damper assembly 1 Drain the fork oil. Refer to removal section.
5-17
FRONT FORK
HANDLING NOTE

The front fork requires careful atten-

tion. So it is recommended that the
3. Remove:
front fork be maintained at the deal-
• Adjuster "1"
ers. REMOVING THE BASE VALVE
1. Remove:
• While compressing the inner tube • Base valve "1"
"2", set the cap bolt ring wrench "4" From damper assembly "2".
To prevent an accidental explosion between the inner tube and locknut
of air, the following instructions "3".
should be observed: Hold the damper assembly with the
• Hold the locknut and remove the
cap bolt ring wrench "3" and use the
adjuster.
• The front fork with a built-in pis- cap bolt wrench "4" to remove the
ton rod has a very sophisticated base valve.
internal construction and is par-
Do not remove the locknut as the Cap bolt wrench:
ticularly sensitive to foreign ma-
damper rod may go into the damp- YM-01500/90890-01500
terial. Use enough care not to
er assembly and not be taken out. Cap bolt ring wrench:
allow any foreign material to
come in when the oil is replaced YM-01501/90890-01501
or when the front fork is disas- Cap bolt ring wrench:
sembled and reassembled. YM-01501/90890-01501
• Before removing the base valves
or front forks, be sure to extract
the air from the air chamber com-
pletely.
REMOVING THE DAMPER

ASSEMBLY CHECKING THE DAMPER
1. Loosen:
ASSEMBLY
• Damper assembly "1"
REMOVING THE INNER TUBE 1. Inspect:
1. Remove: • Damper assembly "1"
Before removing the front fork from • Dust seal "1" Bend/damage → Replace.
the machine, loosen the damper as- • Stopper ring "2" • O-ring "2"
sembly with the cap bolt ring wrench Using slotted-head screwdriver. Wear/damage → Replace.
"2".
Cap bolt ring wrench: Take care not to scratch the inner The front fork with a built-in piston
YM-01501/90890-01501 tube. rod has a very sophisticated inter-
nal construction and is particularly
sensitive to foreign material.
Use enough care not to allow any
foreign material to come in when
the oil is replaced or when the
front fork is disassembled and re-
assembled.
REMOVING THE ADJUSTER 2. Remove:

1. Drain the outer tube of its front • Inner tube "1"
fork oil at its top.
2. Loosen: Oil seal removal steps:
• Adjuster "1" a. Push in slowly "a" the inner tube
just before it bottoms out and then
pull it back quickly "b".
CHECKING THE BASE VALVE
b. Repeat this step until the inner
1. Inspect:
tube can be pulled out from the
• Base valve "1"
outer tube.
5-18
FRONT FORK
Contamination → Clean. half of the dial gauge reading. enter the front fork.
• O-ring "2"
• Piston metal "3" Do not attempt to straighten a bent
Wear/damage → Replace. inner tube as this may dangerous-
• Spring "4" ly weaken the tube.
Damage/fatigue → Replace base
valve.
• Air bleed screw "5"
4. After filling, pump the damper as-
sembly "1" slowly up and down
(about 200 mm (7.9 in) stroke)
several times to bleed the damper
assembly of air.
CHECKING THE OUTER TUBE
1. Inspect: Be careful not to excessive full stroke.
• Outer tube "1" A stroke of 200 mm (7.9 in) or more
CHECKING THE COLLAR Score marks/wear/damage → Re- will cause air to enter. In this case, re-
1. Inspect: place. peat the steps 2 to 4.
• Piston metal "1"
CHECKING THE ADJUSTER

5. Measure:
1. Inspect:
• Oil level (left and right) "a"
CHECKING THE FORK SPRING • Adjuster "1"
1. Measure: • O-ring "2"
• Fork spring free length "a" Wear/damage → Replace. Standard oil level:
Out of specification → Replace. 145-148 mm (5.71-5.83
in)
Fork spring free length:
From top of fully
454 mm (17.9 in)
stretched damper as-
<Limit>: 449 mm (17.7
sembly.
in)
ASSEMBLING THE FRONT FORK

1. Wash the all parts in a clean sol-
vent.
2. Stretch the damper assembly ful-
ly.
3. Fill:
CHECKING THE INNER TUBE • Front fork oil "1"
1. Inspect: To damper assembly.
• Inner tube surface "a"
Recommended oil:
Score marks → Repair or replace.
Suspension oil "S1"
Use #1,000 grit wet sandpaper.
Oil capacity:
Damaged oil lock piece → Re-
199 cm3 (7.00 Imp oz,
place. 6.73 US oz)
• Inner tube bends
6. Tighten:
• Locknut "1"
Use the dial gauge "1".
• Be sure to use recommended
Inner tube bending limit: fork oil. If other oils are used, Fully finger tighten the locknut onto
0.2 mm (0.008 in) they may have an excessively ad- the damper assembly.
verse effect on the front fork per-
formance.
The bending value is shown by one • Never allow foreign materials to
5-19
FRONT FORK
15. Install:
• Dust seal "1"
• Stopper ring "2"
• Oil seal "3"
• Oil seal washer "4"
• Slide metal "5"
To inner tube "6".
7. Loosen: 11. After filling, pump the damper as-

• Apply the fork oil on the inner tube.
• Compression damping adjuster sembly "1" slowly up and down
• When installing the oil seal, use vi-
"1" more than 10 times to distribute
nyl seat "a" with fork oil applied to
the fork oil.
protect the oil seal lip.
• Loosen the compression damping • Install the oil seal with its manufac-
adjuster finger tight. ture's marks or number facing the
• Record the set position of the ad- axle holder side.
juster (the amount of turning out the
fully turned in position).
12. While protecting the damper as-

sembly "1" with a rag and com-
pressing fully, allow excessive oil
to overflow on the base valve
side.
8. Install:
• Base valve "1" Take care not to damage the damp-
To damper assembly "2". er assembly.
First bring the damper rod pressure to

a maximum. Then install the base
valve while releasing the damper rod 16. Install:
pressure. • Piston metal "1"
Install the piston metal onto the slot

on inner tube.
13. Allow the overflowing oil to es-
cape at the hole "a" in the damper
assembly.
9. Check:
• Damper assembly
Not fully stretched → Repeat the
steps 2 to 8. 17. Install:
10. Tighten: • Outer tube "1"
• Base valve "1" To inner tube "2".
14. Check:
Base valve: • Damper assembly smooth move-
29 Nm (2.9 m•kg, 21 ft• ment
lb) Tightness/binding/rough spots
→ Repeat the steps 2 to 13.
Hold the damper assembly with the
cap bolt ring wrench "2" and use the
cap bolt wrench "3" to tighten the
base valve with specified torque. 18. Install:
• Slide metal "1"
Cap bolt wrench: • Oil seal washer "2"
YM-01500/90890-01500 To outer tube slot.
Cap bolt ring wrench:
YM-01501/90890-01501 Press the slide metal into the outer
5-20
FRONT FORK
tube with fork seal driver "3". vertically, the damper assembly
may fall into it, damaging the valve
Fork seal driver: inside.
YM-A0948/90890-01502
22. Check:
• Inner tube smooth movement
Tightness/binding/rough spots
→ Repeat the steps 15 to 21.
26. Loosen:
• Rebound damping adjuster "1"
• Loosen the rebound damping ad-

juster finger tight.
• Record the set position of the ad-
juster (the amount of turning out the
fully turned in position).
23. Measure:
19. Install: • Distance "a"
• Oil seal "1" Out of specification → Turn into
the locknut.
Press the oil seal into the outer tube Distance "a":
with fork seal driver "2". 16 mm (0.63 in) or more
Between the damper
Fork seal driver: assembly "1" bottom
YM-A0948/90890-01502 and locknut "2" bot- 27. Install:
tom. • Push rod "1"
• Copper washer "2"
• Adjuster "3"
To damper assembly "4".
• While compressing the inner tube

"5", set the cap bolt ring wrench "7"
between the inner tube and locknut
20. Install: "6".
• Stopper ring "1" 24. Install: • Fully finger tighten the adjuster onto
• Collar "1" the damper assembly.
Fit the stopper ring correctly in the • Fork spring "2"
groove in the outer tube. To damper assembly "3". Cap bolt ring wrench:
YM-01501/90890-01501
Install the collar with its larger dia.
end "a" facing the fork spring.
21. Install:
• Dust seal "1" 28. Inspect:
• Gap "a" between the adjuster "1"
25. Install: and locknut "2".
• Damper assembly "1" Out of specification → Retighten
on the inner tube.
To inner tube "2". and readjust the locknut.
Gap "a" between the ad-
juster and locknut:
To install the damper assembly
0.5–1.0 mm (0.02–0.04
into the inner tube, hold the inner
in)
tube aslant. If the inner tube is held
5-21
FRONT FORK
adjust each front fork to the same

If the adjuster is installed out of spec- setting. Uneven adjustment can
ification, proper damping force can- cause poor handling and loss of
not be obtained. stability.
• Be sure to use recommended

fork oil. If other oils are used,
they may have an excessively ad- 2. Tighten:
verse effect on the front fork per- • Damper assembly "1"
formance. Damper assembly:
• Never allow foreign materials to 30 Nm (3.0 m•kg, 22
enter the front fork. ft•lb)
29. Tighten:
• Adjuster (locknut) "1"
Adjuster (locknut): Use the cap bolt ring wrench "2" to
29 Nm (2.9 m•kg, 21 tighten the damper assembly with
ft•lb) specified torque.
Cap bolt ring wrench:

Hold the locknut "2" and tighten the YM-01501/90890-01501
adjuster with specified torque.
32. Install:
• Damper assembly "1"
To outer tube.
Temporarily tighten the damper as-

sembly.
3. Adjust:
30. Install:
• Front fork top end "a"
• Adjuster "1"
Front fork top end (stan-
Adjuster:
dard) "a":
55 Nm (5.5 m•kg, 40
5 mm (0.20 in)
ft•lb)
To inner tube. 33. Install:
• Protector guide "1"
4. Tighten:
• Pinch bolt (upper bracket) "1"
31. Fill:
• Front fork oil "1" Pinch bolt (upper brack-
INSTALLING THE FRONT FORK
From outer tube top. et):
1. Install:
21 Nm (2.1 m•kg, 15
Recommended oil: • Front fork "1"
ft•lb)
Suspension oil "S1"
Standard oil amount: • Temporarily tighten the pinch bolts • Pinch bolt (lower bracket) "2"
350 cm3 (12.3 Imp oz, (lower bracket). Pinch bolt (lower brack-
11.8 US oz) • Do not tighten the pinch bolts (up- et):
Extent of adjustment: per bracket) yet. 21 Nm (2.1 m•kg, 15
300–375 cm3 ft•lb)
(10.6–13.2 Imp oz,10.1–
12.7 US oz)
Tighten the lower bracket to speci-
fied torque. If torqued too much, it
Never fail to make the oil amount may cause the front fork to mal-
adjustment between the maximum function.
and minimum amount and always
5-22
FRONT FORK
5. Install:
• Protector "1"
• Bolt (protector) "2"
Bolt (protector):
5 Nm (0.5 m•kg, 3.6
ft•lb)
6. Adjust:
• Rebound damping force
Turn in the damping adjuster "1" fin-

ger-tight and then turn out to the orig-
inally set position.
7. Adjust:
• Compression damping force
Turn in the damping adjuster "1" fin-

ger-tight and then turn out to the orig-
inally set position.
5-23
HANDLEBAR
HANDLEBAR
REMOVING THE HANDLEBAR

Number plate Remove the band only.
1 Hot starter cable 1 Disconnect at the lever side.
2 Hot starter lever holder 1
3 Clutch cable 1 Disconnect at the lever side.
4 Clutch lever holder 1
5 Engine stop switch 1
6 Brake master cylinder 1 Refer to removal section.
7 Throttle cable cap 1
8 Throttle cable #1 (pulled) 1 Disconnect at the throttle side.
9 Throttle cable #2 (pushed) 1 Disconnect at the throttle side.
10 Right grip 1 Refer to removal section.
11 Tube guide 1
12 Collar 1
13 Left grip 1 Refer to removal section.
14 Handlebar upper holder 2
15 Handlebar 1
16 Handlebar lower holder 2
5-24
HANDLEBAR
REMOVING THE BRAKE MASTER tance "a" from the mounting bolt
CYLINDER center facing forward.
1. Remove: • Apply the lithium soap base grease
• Brake master cylinder bracket "1" on the thread of the handlebar low-
• Brake master cylinder "2" er holder.
• Installing the handlebar lower hold-
er in the reverse direction allows the
• Do not let the brake master cylin- front-to-rear offset amount of the
der hang on the brake hose. handlebar position to be changed.
• Keep the brake master cylinder • Do not tighten the nut yet.
cap side horizontal to prevent air
from coming in.
REMOVING THE GRIP

1. Remove:
• Grip "1"
3. Tighten:
Blow in air between the handlebar or
• Nut (handlebar lower holder) "1"
tube guide and the grip. Then remove
the grip which has become loose. 2. Install: Nut (handlebar lower
• Handlebar "1" holder):
• Handlebar upper holder "2" 34 Nm (3.4 m•kg, 24
• Bolt (handlebar upper holder) "3" ft•lb)
Bolt (handlebar upper

holder):
28 Nm (2.8 m•kg, 20
ft•lb)
CHECKING THE HANDLEBAR

1. Inspect: • The handlebar upper holder should
• Handlebar "1" be installed with the punched mark
Bends/cracks/damage → Re- "a" forward. 4. Install:
place. • Install the handlebar so that the • Left grip "1"
marks "b" are in place on both Apply the adhesive to the handle-
sides. bar "2".
Do not attempt to straighten a bent • Install the handlebar so that the pro-
handlebar as this may dangerous- jection "c" of the handlebar upper • Before applying the adhesive, wipe
ly weaken the handlebar. holder is positioned at the mark on off grease or oil on the handlebar
the handlebar as shown. surface "a" with a lacquer thinner.
• First tighten the bolts on the front • Install the left grip to the handlebar
side of the handlebar upper holder, so that the line "b" between the two
and then tighten the bolts on the arrow marks faces straight upward.
rear side.
INSTALLING THE HANDLEBAR

1. Install:
• Handlebar lower holder "1"
• Washer "2"
• Nut (handlebar lower holder) "3"
• Install the handlebar lower holder

with its side having the greater dis-
5-25
HANDLEBAR
• Right grip "1" • Throttle cable cap "1"
• Collar "2" • Screw (throttle cable cap) "2"
Apply the adhesive on the tube Screw (throttle cable
guide "3". cap):
4 Nm (0.4 m•kg, 2.9
• Before applying the adhesive, wipe ft•lb)
off grease or oil on the tube guide
11. Install:
surface "a" with a lacquer thinner.
• Engine stop switch "1"
• Install the grip to the tube guide so After tightening the screws, check • Clutch lever holder "2"
that the grip match mark "b" and that the throttle grip "3" moves • Bolt (clutch lever holder) "3"
tube guide slot "c" form the angle as smoothly. If it does not, retighten
shown. Bolt (clutch lever holder):
the bolts for adjustment.
4 Nm (0.4 m•kg, 2.9
ft•lb)
• Hot starter lever holder "4"
• Bolt (hot starter lever holder) "5"
Bolt (hot starter lever
holder):
4 Nm (0.4 m•kg, 2.9
ft•lb)
• Clamp "6"
• The engine stop switch, clutch lever

holder and clamp should be in-
stalled according to the dimensions
shown.
• Pass the engine stop switch lead in
6. Install: the middle of the clutch lever hold-
9. Install:
• Collar "1" er.
• Grip cap cover "1"
• Grip cap cover "2" • Cover (throttle cable cap) "2"
• Throttle grip "3"

on the throttle grip sliding surface.
10. Install:
• Brake master cylinder "1"
• Brake master cylinder bracket "2"
• Bolt (brake master cylinder brack-
et) "3"
7. Install:
• Throttle cables "1" Bolt (brake master cylin-
To tube guide "2". der bracket):
9 Nm (0.9 m•kg, 6.5 12. Install:
ft•lb) • Clutch cable "1"
• Hot starter cable "2"
on the throttle cable end and tube
guide cable winding portion.
• Install the bracket so that the arrow Apply the lithium soap base grease
mark "a" faces upward. on the clutch cable end and hot start-
• First tighten the bolt on the upper er cable end.
side of the brake master cylinder
bracket, and then tighten the bolt on
the lower side.
5-26
HANDLEBAR
13. Adjust:
• Clutch lever free play
Refer to "ADJUSTING THE
CLUTCH CABLE FREE PLAY"
• Hot starter lever free play
Refer to "ADJUSTING THE HOT
STARTER LEVER FREE PLAY"
5-27
STEERING
STEERING
REMOVING THE STEERING

TIGHTENING STEPS:
• Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb)
• Loosen it one turn.
• Retighten it. 7 Nm (0.7 m•kg, 5.1 ft•lb)
under the engine.
Number plate
Handlebar Refer to "HANDLEBAR" section.
Front fender
1 Steering stem nut 1
2 Front fork 2 Refer to "FRONT FORK" section.
3 Upper bracket 1
4 Steering ring nut 1 Refer to removal section.
5 Lower bracket 1
6 Bearing race cover 1
7 Upper bearing 1
8 Lower bearing 1 Refer to removal section.
5-28
STEERING

9 Bearing race 2 Refer to removal section.
5-29
STEERING
HANDLING NOTE

REMOVING THE STEERING RING

NUT
1. Remove:
CHECKING THE BEARING AND 3. Install:
• Steering ring nut "1"
BEARING RACE • Lower bracket "1"
Use the steering nut wrench "2".
1. Wash the bearings and bearing
Steering nut wrench: races with a solvent. Apply the lithium soap base grease
YU-33975/90890-01403 2. Inspect: on the bearing, the portion "a" and
• Bearing "1" thread of the steering stem.
• Bearing race
Support the steering stem so that Pitting/damage → Replace bear-
it may not fall down. ings and bearing races as a set.
Install the bearing in the bearing
races. Spin the bearings by hand.
If the bearings hang up or are not
smooth in their operation in the
bearing races, replace bearings
and bearing races as a set.
4. Install:
• Steering ring nut "1"
Steering ring nut:
REMOVING THE LOWER 7 Nm (0.7 m•kg, 5.1 ft•
BEARING lb)
1. Remove:
• Lower bearing "1" Tighten the steering ring nut using
Use the floor chisel "2". the steering nut wrench "2".
INSTALLING THE LOWER Refer to "CHECKING AND AD-
BRACKET JUSTING THE STEERING
Take care not to damage the steer- 1. Install: HEAD" section in the CHAPTER
ing shaft thread. • Lower bearing "1" 3.

on the dust seal lip and bearing inner
circumference.
5. Check the steering stem by turn-

REMOVING THE BEARING RACE ing it lock to lock. If there is any
1. Remove: binding, remove the steering stem
• Bearing race "1" assembly and inspect the steer-
Remove the bearing race using ing bearings.
long rod "2" and the hammer.
2. Install:
• Bearing race
• Upper bearing "1"
• Bearing race cover "2"

on the bearing and bearing race cov-
er lip.
CHECKING THE STEERING STEM
1. Inspect:
• Steering stem "1"
5-30
STEERING
6. Install: 11. Tighten:

• Washer "1" • Pinch bolt (upper bracket) "1"
Pinch bolt (upper brack-
et):
21 Nm (2.1 m•kg, 15
ft•lb)
• Pinch bolt (lower bracket) "2"
Pinch bolt (lower brack-
et):
21 Nm (2.1 m•kg, 15
• Front fork "1"
• Upper bracket "2"
Tighten the lower bracket to speci-
• Temporarily tighten the pinch bolts fied torque. If torqued too much, it
(lower bracket). may cause the front fork to mal-
• Do not tighten the pinch bolts (up- function.
per bracket) yet.
8. Install:
• Washer "1"
• Steering stem nut "2"
Steering stem nut:
145 Nm (14.5 m•kg, 105
ft•lb)
9. After tightening the nut, check the

steering for smooth movement. If
not, adjust the steering by loosen-
ing the steering ring nut little by lit-
tle.
10. Adjust:
• Front fork top end "a"
Front fork top end (stan-
dard) "a":
5 mm (0.20 in)
5-31
SWINGARM
SWINGARM
REMOVING THE SWINGARM

under the engine.
Brake hose holder
BRAKE" section.
Rear brake caliper
BRAKE" section.
Bolt (brake pedal) Shift the brake pedal backward.
Drive chain
1 Drive chain support 1
2 Lower chain tensioner 1
3 Bolt (rear shock absorber-relay arm) 1 Hold the swingarm.
4 Bolt (connecting rod) 1
5 Pivot shaft 1
6 Swingarm 1
5-32
SWINGARM
DISASSEMBLING THE SWINGARM

1 Cap 2 Refer to removal section.
2 Relay arm 1
3 Connecting rod 1
4 Collar 2
5 Oil seal 2
6 Thrust bearing 2
7 Bushing 2
8 Oil seal 8
5-33
SWINGARM
HANDLING NOTE 2. Inspect:

• Oil seal "3"
Damage → Replace.
REMOVING THE CAP

1. Remove:
• Left cap "1"
2. Install:
• Bearing "1"
Remove with a slotted-head screw- • Washer "2"
driver inserted under the mark "a" on CHECKING THE CONNECTING • Oil seal "3"
the left cap. ROD To relay arm.
1. Inspect:
• Bearing "1" • Apply the molybdenum disulfide
• Collar "2" grease on the bearing when install-
Free play exists/unsmooth revolu- ing.
tion/rust → Replace bearing and • Install the bearing by pressing it on
collar as a set. the side having the manufacture's
2. Inspect: marks or numbers.
• Oil seal "3" • Apply the molybdenum disulfide
Damage → Replace. grease on the washer.
REMOVING THE BEARING
1. Remove: Installed depth of bear-
• Bearing "1" ings "a":
Zero mm (Zero in)
Remove the bearing by pressing its
outer race.
INSTALLING THE BEARING AND

OIL SEAL
1. Install:
• Bearing "1"
• Oil seal "2"
To swingarm.
CHECKING THE SWINGARM • Apply the molybdenum disulfide

1. Inspect: grease on the bearing when install-
• Bearing "1" ing.
• Bushing "2" • Install the bearing by pressing it on
Free play exists/unsmooth revolu- the side having the manufacture's
tion/rust → Replace bearing and marks or numbers.
bushing as a set. • First install the outer and then the 3. Install:
2. Inspect: inner bearings to a specified depth • Bearing "1"
• Oil seal "3" from inside. • Oil seal "2"
Damage → Replace. To connecting rod.
Installed depth of bear-
ings: • Apply the molybdenum disulfide
Outer "a": Zero mm grease on the bearing when install-
(Zero in) ing.
Inner "b": 6.5 mm (0.26 • Install the bearing by pressing it on
in) the side having the manufacture's
marks or numbers.
CHECKING THE RELAY ARM Installed depth of bear-

1. Inspect: ings "a":
• Bearing "1" Zero mm (Zero in)
• Collar "2"
Free play exists/unsmooth revolu-
tion/rust → Replace bearing and
collar as a set.
5-34
SWINGARM
• Washer "3" • Swingarm up and down move-

• Nut (connecting rod) "4" ment "b"
Nut (connecting rod): Unsmooth movement/binding/
80 Nm (8.0 m•kg, 58 rough spots → Grease or replace
ft•lb) bearings, bushings and collars.
To relay arm "5".
INSTALLING THE SWINGARM Apply the molybdenum disulfide

1. Install: grease on the bolt.
• Bushing "1"
• Thrust bearing "2"
• Oil seal "3"
• Collar "4" 8. Install:
To swingarm "5". • Bolt (connecting rod) "1"
• Washer "2"
Apply the molybdenum disulfide • Nut (connecting rod) "3"
grease on the bushings, thrust bear-
ings, oil seal lips and contact surfaces • Apply the molybdenum disulfide
5. Install:
of the collar and thrust bearing. grease on the bolt.
• Relay arm "1"
• Do not tighten the nut yet.
• Bolt (relay arm) "2"
• Washer "3"
• Nut (relay arm) "4"
To swingarm.

grease on the bolt circumference
and threaded portion.
2. Install: • Do not tighten the nut yet.
• Collar "1" 9. Install:
• Washer "2" • Bolt (rear shock absorber-relay
To relay arm "3". arm) "1"
• Nut (rear shock absorber-relay
Apply the molybdenum disulfide arm) "2"
grease on the collars and oil seal lips. Nut (rear shock absorb-
er-relay arm):
53 Nm (5.3 m•kg, 38
• Swingarm "1"
• Pivot shaft "2" Apply the molybdenum disulfide
Pivot shaft: grease on the bolt.
85 Nm (8.5 m•kg, 61
ft•lb)
3. Install:
• Collar "1"
To connecting rod "2". • Apply the molybdenum disulfide
grease on the pivot shaft.
Apply the molybdenum disulfide • Insert the pivot shaft from right side.
grease on the collar and oil seal lips.
10. Tighten:
• Nut (connecting rod) "1"
Nut (connecting rod):
80 Nm (8.0 m•kg, 58
ft•lb)
7. Check:
4. Install: • Swingarm side play "a"
• Connecting rod "1" Free play exists → Replace thrust
• Bolt (connecting rod) "2" bearing.
5-35
SWINGARM
• Nut (drive chain support) "4"

Nut (drive chain sup-
port):
7 Nm (0.7 m•kg, 5.1
ft•lb)
• Bolt {drive chain support cover [L
= 10 mm (0.39 in)]} "5"
11. Tighten: Bolt (drive chain support
• Nut (relay arm) "1" cover):
Nut (relay arm): 7 Nm (0.7 m•kg, 5.1
70 Nm (7.0 m•kg, 50 ft•lb)
ft•lb)
12. Install:
• Cap "1"
Install the right cap with its mark "a"

facing forward.
13. Install:
• Bolt (lower chain tensioner) "1"
• Washer "2"
• Collar "3"
• Lower chain tensioner "4"
• Nut (lower chain tensioner) "5"
Nut (lower chain tension-
er):
16 Nm (1.6 m•kg, 11
ft•lb)
14. Install:
• Drive chain support "1"
• Drive chain support cover "2"
• Bolt {drive chain support [L = 50
mm (1.97 in)]} "3"
5-36
REAR SHOCK ABSORBER
REAR SHOCK ABSORBER

REMOVING THE REAR SHOCK ABSORBER

under the engine.
Seat
Silencer
1 Clamp (air filter joint) 1 Only loosening.
2 Rear frame 1
3 Bolt (rear shock absorber-relay arm) 1 Hold the swingarm.
4 Bolt (rear shock absorber-frame) 1
5 Rear shock absorber 1
6 Locknut 1 Only loosening.
7 Adjuster 1 Only loosening.
8 Spring seat 2
9 Lower spring guide 1
10 Upper spring guide 1
11 Spring (rear shock absorber) 1
5-37
REAR SHOCK ABSORBER

5-38
REAR SHOCK ABSORBER
HANDLING NOTE • Spring "3"

Damage → Replace spring.
Fatigue → Replace spring.
• Support the machine securely so Move spring up and down.
there is no danger of it falling • Spring guide "4"
over. Wear/damage → Replace spring
• This rear shock absorber is pro- guide.
vided with a separate type tank • Spring seat "5"
filled with high-pressure nitro- REMOVING THE BEARING Cracks/damage → Replace.
gen gas. To prevent the danger 1. Remove: • Bearing "6"
of explosion, read and under- • Stopper ring (upper bearing) "1" Free play exists/unsmooth revolu-
stand the following information tion/rust → Replace.
before handling the shock ab-
Press in the bearing while pressing its
sorber. The manufacturer can
outer race and remove the stopper
not be held responsible for prop-
ring.
erty damage or personal injury
that may result from improper
handling.
• Never tamper or attempt to dis-
assemble the cylinder or the
tank.
• Never throw the rear shock ab-
sorber into an open flame or
other high heat. The rear shock
absorber may explode as a re- 2. Remove:
sult of nitrogen gas expansion • Upper bearing "1"
and/ or damage to the hose.
• Be careful not to damage any Remove the bearing by pressing its
part of the gas tank. A damaged outer race. INSTALLING THE BEARING
gas tank will impair the damp- 1. Install:
ing performance or cause a • Upper bearing "1"
malfunction.
• Take care not to scratch the
Install the bearing parallel until the
contact surface of the piston
stopper ring groove appears by
rod with the cylinder; or oil
pressing its outer race.
could leak out.
• Never attempt to remove the
plug at the bottom of the nitro-
gen gas tank. It is very danger- 3. Remove: Do not apply the grease on the
ous to remove the plug. • Lower bearing "1" bearing outer race because it will
• When scrapping the rear shock wear the rear shock absorber sur-
absorber, follow the instruc- Remove the bearing by pressing its face on which the bearing is press
tions on disposal. outer race. fitted.
NOTES ON DISPOSAL (YAMAHA

DEALERS ONLY)
Before disposing the rear shock ab-
sorber, be sure to extract the nitrogen
gas from valve "1". Wear eye protec-
tion to prevent eye damage from es-
caping gas and/or metal chips.
CHECKING THE REAR SHOCK 2. Install:

To dispose of a damaged or worn- ABSORBER • Stopper ring (upper bearing) "1"
out rear shock absorber, take the 1. Inspect:
unit to your Yamaha dealer for this • Damper rod "1"
disposal procedure. Bends/damage → Replace rear After installing the stopper ring, push
shock absorber assembly. back the bearing until it contacts the
• Shock absorber "2" stopper ring.
Oil leaks → Replace rear shock
absorber assembly.
Gas leaks → Replace rear shock
absorber assembly.
5-39
REAR SHOCK ABSORBER
3. Tighten:
• Adjuster "1"
• Lower bearing "1" • Rear shock absorber
4. Adjust: 4. Install:
Install the bearing by pressing it on • Spring length (installed) • Bolt (rear shock absorber-frame)
the side having the manufacture's Refer to "ADJUSTING THE "1"
marks or numbers. REAR SHOCK ABSORBER • Washer "2"
SPRING PRELOAD" section in • Nut (rear shock absorber-frame)
Installed depth of the the CHAPTER 3. "3"
bearing "a": 5. Tighten: Nut (rear shock absorb-
4 mm (0.16 in) • Locknut "1" er-frame):
56 Nm (5.6 m•kg, 40
ft•lb)
Apply the molybdenum disulfide

grease on the bolt.
INSTALLING THE REAR SHOCK

INSTALLING THE SPRING (REAR
ABSORBER
SHOCK ABSORBER)
1. Install:
1. Install:
• Dust seal "1"
• Spring "1"
• O-ring "2"
• Upper spring guide "2"
• Collar "3"
• Lower spring guide "3"
5. Install:
• Apply the molybdenum disulfide • Bolt (rear shock absorber-relay
grease on the dust seal lips and col- arm) "1"
lars. • Nut (rear shock absorber-relay
• Apply the lithium soap base grease arm) "2"
on the O-rings.
Nut (rear shock absorb-
er-relay arm):
53 Nm (5.3 m•kg, 38
• Spring seat "1"
Install the spring seat with the projec- Apply the molybdenum disulfide
tion "a" brought into contact with the grease on the bolt.
spring end, as shown.
2. Install:
• Bushing "1"
• Collar "2"
• Dust seal "3"

grease on the bearing and dust seal
lips. 6. Install:
• Install the dust seals with their lips • Rear frame "1"
facing outward. • Bolt [rear frame (upper)] "2"
Bolt [rear frame (upper)]:
38 Nm (3.8 m•kg, 27
ft•lb)
5-40
REAR SHOCK ABSORBER
• Bolt [rear frame (lower)] "3"

Bolt [rear frame (lower)]:
32 Nm (3.2 m•kg, 23
ft•lb)
7. Tighten:
• Bolt (air filter joint) "1"
Bolt (air filter joint):
3 Nm (0.3 m•kg, 2.2
ft•lb)
5-41
ELECTRICAL COMPONENTS AND WIRING DIAGRAM
ELECTRICAL
ELECTRICAL
COMPONENTS AND
WIRING DIAGRAM
ELECTRICAL COMPONENTS
1. Engine stop switch 4. CDI magneto 7. CDI unit

2. Throttle position sensor 5. Ignition coil
3. Neutral switch 6. Spark plug
WIRING DIAGRAM
B/W B/W
B/W G/B B B/W
G/B B
L Y L L Y L
Y Y
B/L B/L B B
Y Sb Sb Y
6
Sb Sb Sb Sb
W L L W
G B/L B/L G
B B P P
Br Br
P B/Y B/Y P
G P Br W W Br P G
W B/Y G R R G B W
Br R R Br
R
B/W G/B G/B B/W B/Y
O R
O O B B
O B
1. Engine stop switch COLOR CODE Y Yellow

2. Throttle position sensor B Black B/L Black/Blue
3. Neutral switch Br Brown B/W Black/White
4. CDI magneto G Green B/Y Black/Yellow
5. Ignition coil L Blue G/B Green/Black
6. Spark plug O Orange L/W Blue/White
7. CDI unit P Pink R/W Red/White
R Red
Sb Sky blue
W White
6-1
IGNITION SYSTEM
IGNITION SYSTEM
INSPECTION STEPS
Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure
and for checking the spark plug which will not spark.
Spark gap test Spark → *Clean or replace spark plug.
No spark ↓
Check entire ignition system for connection. No good →
Repair or replace.
(couplers, leads and ignition coil)
OK ↓
Check engine stop switch. No good → Replace.
OK ↓
Check ignition coil. (primary coil and secondary No good →
Replace.
coil)
OK ↓
Check CDI magneto. (pickup coil and charging No good → Replace.
coil)
OK ↓
Check neutral switch. No good → Repair or replace.
OK ↓
Replace CDI unit.
*marked: Only when the ignition checker is used.
• Remove the following parts before inspection.

1. Seat
2. Fuel tank
• Use the following special tools in this inspection.
Dynamic spark tester:

YM-34487
Ignition checker:
90890-06754
Pocket tester:
YU-3112-C/90890-03112
6-2
IGNITION SYSTEM
SPARK GAP TEST Result

1. Disconnect the ignition coil from Conductive (while the
spark plug. engine stop switch is
2. Remove the ignition coil cap. pushed)
3. Connect the dynamic spark tester
"1" (ignition checker "2") as Not conductive while it is pushed →
shown. Replace.
• Ignition coil "3" Conductive while it is freed → Re-
• Spark plug "4" place. 4. Inspect:
• Sealed portion of ignition coil "a"
Set the tester selection position to • Spark plug terminal pin "b"
"Ω × 1". • Threaded portion of spark plug "c"
Wear → Replace.
CHECKING THE IGNITION COIL

CHECKING THE CDI MAGNETO
1. Remove the ignition coil cap.
1. Inspect:
2. Inspect:
• Pickup coil resistance
• Primary coil resistance
A. For USA and CDN Tester (+) lead → Red lead "1"
B. Except for USA and CDN Tester (+) lead → Orange lead "1"
Tester (-) lead → White lead "2"
4. Kick the kickstarter crank. Tester (-) lead → Black lead "2"
5. Check the ignition spark gap. Tester se-
Primary Tester se- Pickup coil
6. Start engine, and increase spark lector posi-
coil resis- lector posi- resistance
gap until misfire occurs. (for USA tion
tance tion
and CDN only) 248-372 Ω
0.08–0.10
Minimum spark gap:
Ω at 20 °C Ω×1 at 20 °C (68 Ω ×100
6.0 mm (0.24 in) °F)
(68 °F)
CHECKING THE COUPLERS,
LEADS AND IGNITION COIL
CONNECTION
1. Check:
• Couplers and leads connection
Rust/dust/looseness/short-circuit
→ Repair or replace.
• Ignition coil and spark plug as
they are fitted 2. Inspect:
3. Inspect:
Push in the ignition coil until it • Charging coil 1 resistance
• Secondary coil resistance
closely contacts the spark plug Out of specification → Replace.
hole in the cylinder head cover. Tester (+) lead → Brown lead "1"
Tester (+) lead → Orange lead "1"
Tester (-) lead → Green lead "2"
Tester (-) lead→Spark plug termi-
nal "2" Charging Tester se-
coil 1 resis- lector posi-
Secondary Tester se-
tance tion
coil resis- lector posi-
tance tion 720-1,080
4.6–6.8
Ω at 20 °C Ω ×100
(68 °F)
kΩat 20 °C kΩ × 1
CHECKING THE ENGINE STOP
(68 °F)
SWITCH
1. Inspect:
• Engine stop switch conduction
Tester (+) lead → Black/White
lead "1"
Tester (-) lead → Black lead "2"
6-3
IGNITION SYSTEM
3. Inspect:
• Charging coil 2 resistance
Tester (+) lead → Pink lead "1"
Charging Tester se-

coil 2 resis- lector posi-
tance tion
44-66 Ω at
20 °C (68 Ω ×10
°F)
CHECKING THE NEUTRAL

SWITCH
1. Inspect:
• Neutral switch conduction
Tester (+) lead → Sky blue lead
"1"
Tester (-) lead → Ground "2"
Result
Conductive (while gear
is in neutral)
Not conductive while it is in neutral →
Replace.
Conductive while it is engaged → Re-
place.
Set the tester selection position to

"Ω × 1".
CHECKING THE CDI UNIT

Check all electrical components. If no
fault is found, replace the CDI unit.
Then check the electrical compo-
nents again.
6-4
THROTTLE POSITION SENSOR SYSTEM

INSPECTION STEPS
If the throttle position sensor will not operate, use the following inspection steps.
Check entire ignition system for connection. No good → Repair or replace.
OK ↓
Check throttle position sensor. (Throttle position No good → Replace.
sensor coil)
OK ↓
*Check CDI magneto. (Charging coil) No good → Replace.
OK ↓
Check CDI unit. (Throttle position sensor input No good →
Replace.
voltage)
*marked: Refer to "IGNITION SYSTEM" section.
Use the following special tools in this inspection.
Pocket tester:
YU-3112-C/90890-03112
6-5
HANDLING NOTE 3. Inspect: • Temporarily tighten the screw

• Throttle position sensor coil vari- (throttle position sensor).
able resistance
Do not loosen the screw (throttle Check that the resistance in in-
position sensor) "1" except when creased as the throttle grip is
changing the throttle position sen- moved from the full close position
sor due to failure because it will to the full open position.
cause a drop in engine perfor- Out of specification → Replace.
mance.
Tester (+) lead → Yellow lead "1"
Tester 5. Install:
Throttle position •Carburetor
selec-
sensor coil vari- •Throttle position sensor coupler
tor po-
able resistance 6. Adjust:
sition
•Engine idling speed
Full Full Refer to "ADJUSTING THE EN-
closed opened GINE IDLING SPEED" section in
CHECKING THE COUPLERS AND the CHAPTER 3.
Zero –2 4–6 kΩ×1
LEADS CONNECTION
kΩat kΩat 7. Insert the thin electric conductors
1. Check: "2" (lead) into the throttle position
20°C 20 °C
• Couplers and leads connection sensor coupler "1", as shown, and
(68 °F) (68 °F)
Rust/dust/looseness/short-circuit connect the tester to them.
→ Repair or replace.
Tester (+) lead → Yellow lead "3"
CHECKING THE THROTTLE
POSITION SENSOR COIL
1. Inspect:
• Throttle position sensor coil resis-
tance • Do not insert the electric conduc-
Out of specification → Replace. tors more than required because
it may reduce the waterproof
Tester (+) lead → Blue lead "1" function of the coupler.
Tester (-) lead → Black lead "2" Make sure that a short-circuit
CHANGING AND ADJUSTING THE
Throttle po- THROTTLE POSITION SENSOR does not develop between the
Tester se- terminals because it may cause
sition sen- 1. Remove:
lector posi- damage to electrical compo-
sor coil • Throttle position sensor coupler
tion nents.
resistance • Carburetor
4–6 kΩ at 2. Remove:
kΩ×1 • Screw (throttle position sensor)
20°C (68 °F)
"1"
• Throttle position sensor "2"
Loosen the screw (throttle position

sensor) using the T25 bit.
8. Start the engine.

9. Adjust:
• Throttle position sensor output
2. Loosen:
voltage
• Throttle stop screw "1"
Turn out the throttle stop screw until Adjustment steps:

the throttle shaft is in the full close po- a. Adjust the installation angle of the
sition. 3. Replace: throttle position sensor "1" to ob-
• Throttle position sensor tain the specified output voltage.
4. Install:
• Throttle position sensor "1" Measure the output voltage accurate-
• Screw (throttle position sensor) ly with a digital electronic voltmeter
"2" that gives an easy reading of a small
voltage.
• Align the slot "a" in the throttle posi-
tion sensor with the projection "b"
on the carburetor.
6-6
Throttle po-
Throttle po- Tester se-
Tester se- sition sen-
sition sen- lector posi-
lector posi- sor input
sor output tion
tion voltage
voltage
4–6 V DCV-20
0.58–0.78 V DCV
10. Put the aligning marks "a" on the

throttle position sensor and car-
buretor.
11. Stop the engine.

12. Remove the carburetor.
13. Tighten:
• Screw (throttle position sensor)
"1"
Tighten the screw (throttle position

sensor) using the T25 bit.
14. Install the carburetor.

CHECKING THE THROTTLE
POSITION SENSOR INPUT
VOLTAGE
1. Disconnect the throttle position
sensor coupler.
2. Start the engine.
3. Inspect:
• Throttle position sensor input volt-
age
the CDI unit.
Tester (+) lead → Blue lead "1"
Tester (-) lead → Black/Blue lead
"2"
6-7
ENGINE
TUNING correctly and opens and closes CONSTRUCTION OF

smoothly. CARBURETOR AND SETTING
ENGINE PARTS
CARBURETOR SETTING ATMOSPHERIC CONDITIONS AND The FLATCR carburetor has a prima-
• The air/fuel mixture will vary de- CARBURETOR SETTINGS ry main jet. This type of main jet is
pending on atmospheric conditions. perfect for racing machines since it
Therefore, it is necessary to take Air
supplies an even flow of fuel, even at
into consideration the air pressure, Air Hu- pres-
Mix- Set- full load. Use the main jet and the jet
ambient temperature, humidity, tem midi- sure
ture ting needle to set the carburetor.
etc., when adjusting the carburetor. p. ty (alti-
The FLATCR carburetor is manufac-
• Perform a test run to check for prop- tude)
tured with a pilot screw. The pilot
er engine performance (e.g., throt- Low Rich- Lean- screw adjustment ranges from fully
High High
tle response) and spark plug(-s) (high) er er closed throttle to 1/4 open throttle.
discoloration or fouling. Use these High Lean- Rich-
readings to determine the best pos- Low Low
(low) er er
sible carburetor setting.
It is recommended to keep a record of The air density (i.e., concentration of

all carburetor settings and external oxygen in the air) determines the rich-
conditions (e.g., atmospheric condi- ness or leanness of the air/fuel mix-
tions, track/surface conditions, lap ture.
times) to make future carburetor set- • Higher temperature expands the air
ting easier. with its resultant reduced density.
• Higher humidity reduces the
amount of oxygen in the air by so
much of the water vapor in the
• The carburetor is a part of the
same air.
fuel line. Therefore, be sure to in-
• Lower atmospheric pressure (at a
stall it in a wellventilated area,
high altitude) reduces the density of
away from flammable objects
the air.
and any sources of fire. 1. Jet needle
• Never look into the carburetor in- EFFECT OF SETTING PARTS IN 2. Pilot air jet
take. Flames may shoot out from RELATION TO THROTTLE VALVE 3. Needle jet
the pipe if the engine backfires OPENING 4. Main jet
while it is being started. Gasoline 5. Pilot jet
may be discharged from the ac- 6. Pilot screw
celerator pump nozzle when the ADJUSTING THE MAIN JET
carburetor has been removed. The richness of the air-fuel mixture at
full throttle can be set by changing the
main jet "1".
• The carburetor is extremely sen- Standard main jet #160
sitive to foreign matter (dirt,
sand, water, etc.). During instal- If the air-fuel mixture is too rich or too
lation, do not allow foreign mat- lean, the engine power will drop, re-
ter to get into the carburetor. sulting in poor acceleration.
• Always handle the carburetor
and its components carefully.
Even slight scratches, bends or
damage to carburetor parts may
prevent the carburetor from
functioning correctly. Carefully A. Closed
perform all servicing with the ap- B. Fully open
propriate tools and without ap- 1. Pilot screw/pilot jet
plying excessive force. 2. Throttle valve cutaway Effects of changing the main jet
• When the engine is stopped or 3. Jet needle (reference)
when riding at no load, do not 4. Main jet
open and close the throttle un-
necessarily. Otherwise, too
much fuel may be discharged,
starting may become difficult or A. Idle
the engine may not run well. B. Fully open
• After installing the carburetor, 1. #162
check that the throttle operates 2. #158
7-1
ENGINE
3. #160 Effects of adjusting the pilot jet a. Diameter of the straight por-
ADJUSTING THE PILOT SCREW (reference) tion
The richness of the air-fuel mixture b. Reference needle
with the throttle fully closed to 1/4 c. 0.5 richer
open can be set by turning the pilot
screw "1". Turning in the pilot screw
will make the mixture lean at low A. Idle
speeds, and turning it out will enrich B. Fully open
it. 1. #48
Standard pilot screw 2. #42
1-1/2 3. #45
position (example)
ADJUSTING THE JET NEEDLE
GROOVE POSITION
• If the engine idling speed fluctuates, Adjusting the jet needle "1" position
turn the pilot screw only 1/2 of a turn affects the acceleration when the
in either direction. throttle is 1/8 to 3/4 open.
• To optimize the fuel flow at a small- 1. Too rich at intermediate speeds
er throttle opening, each machine's • Rough engine operation is felt
pilot screw has been individually set and the engine will not pick up
at the factory. Before adjusting the speed smoothly.
pilot screw, turn it in fully and count Changing from NFLR-3 to NFPR-3
Step up the jet needle clip by one
the number of turns. Record this has the same effect as a rising of 0.5
groove and move down the nee-
number as the factory-set number clip position.
dle to lean out the mixture.
of turns out. Effects of changing the jet needle
2. Too lean at intermediate speeds
(reference)
• The engine breathes hard and will
(Diameter of the straight portion)
not pick up speed quickly.
Changing the diameter of the straight
Step down the jet needle clip by
portion adjusts the air-fuel mixture
one groove and move up the nee-
when the throttle is 1/8 to 1/4 open.
dle to enrich the mixture.
Standard clip posi- No.3
tion groove
Effects of adjusting the pilot screw A. Idle

(reference) B. Fully open
RELATIONSHIP WITH THROTTLE
OPENING
The flow of the fuel through the car-
buretor main system is controlled by
A. Idle the main jet and then, it is further reg-
B. Fully open ulated by the area between the main
Effects of changing the jet needle
1. 2 turns out nozzle and the jet needle.
groove position (reference)
2. 1 turn out The fuel flow relates to the diameter
7
3. 1-1/2 turns out of the straight portion of the jet needle
ADJUSTING THE PILOT JET with the throttle 1/8 to 1/4 open and
The richness of the air-fuel mixture relates to the clip position with the
with the throttle open 1/4 or less can A. Idle throttle 1/8 to 3/4 open.
be set by adjusting the pilot jet "1". B. Fully open Therefore, the fuel flow is balanced at
Standard pilot jet #45 1. No.4 groove each stage of throttle opening by the
2. No.2 groove combination of the jet needle straight
3. No.3 groove portion diameter and clip position.
ADJUSTING THE JET NEEDLE
The jet needle is adjusted by chang-
ing it.
Standard jet needle NFLR
The jet needle setting parts, having
the same taper angle, are available in
different straight portion diameters
and in different taper starting posi-
tions.
7-2
ENGINE
ADJUSTING THE LEAK JET

CARBURETOR SETTING PARTS
(ADJUSTING THE ACCELERATOR
PUMP) Main jet Size Part number
The leak jet "1" is a setting part that
Rich #172 4MX-14943-92
adjusts the flow of fuel discharged by
the accelerator pump. Since the ac- #170 4MX-14943-41
celerator pump operates only when #168 4MX-14943-91
throttle is open, the leak jet is used to
adjust a fuel mixture ratio for quick #165 4MX-14943-40
throttle opening and is therefore dif- #162 4MX-14943-90
ferent from other setting parts that ad- (STD) #160 4MX-14943-39
just a fuel mixture for each throttle
opening (each engine speed). #158 4MX-14943-89
1. When the engine breathes hard in #155 4MX-14943-38
quick throttle opening, select a
#152 4MX-14943-88
leak jet having lower calibrating
No. than standard to enrich the #150 4MX-14943-37
mixture. <Example> #70 → #60 Lean #148 4MX-14943-87
2. When rough engine operation is
Pilot jet Size Part number
felt in quick throttle opening, se-
lect a leak jet having higher cali- Rich #52 4MX-14948-08
brating No. than standard to lean #50 4MX-14948-07
out the mixture. <Example> #55
→ #50 #48 4MX-14948-06
Standard leak jet #55 (STD) #45 4MX-14948-05

#42 4MX-14948-04
#40 4MX-14948-03
Lean #38 4MX-14948-02
Jet needle Size Part number
Rich NFPN 5TA-14916-PN
NFPP 5TA-14916-PP
NFPQ 5TA-14916-P1
NFPR 5TA-14916-PR
NFPS 5TA-14916-PS
NFPT 5TA-14916-PT
Lean NFPU 5TA-14916-PU
Rich NFLN 5TA-14916-LN
NFLP 5TA-14916-LP
NFLQ 5TA-14916-L1
(STD) NFLR 5TA-14916-LR
NFLS 5TA-14916-LS
NFLT 5TA-14916-LT
Lean NFLU 5TA-14916-LU
Leak jet Size Part number
Rich #45 4JT-1494F-05
#50 4JT-1494F-07
(STD) #55 4JT-1494F-09
#60 4JT-1494F-11
Lean #65 4JT-1494F-13
7-3
ENGINE
SPECIFICATIONS OF JET NEEDLE
Diameter of straight portion

Rich Lean
N P Q R S T U
Rich 1 richer NFLN-4 NFLP-4 NFLQ-4 NFLR-4 NFLS-4 NFLT-4 NFLU-4
0.5 richer NFPN-3 NFPP-3 NFPQ-3 NFPR-3 NFPS-3 NFPT-3 NFPU-3
STD NFLN-3 NFLP-3 NFLQ-3 NFLR-3 NFLS-3 NFLT-3 NFLU-3
0.5 leaner NFPN-2 NFPP-2 NFPQ-2 NFPR-2 NFPS-2 NFPT-2 NFPU-2
Lean 1 leaner NFLN-2 NFLP-2 NFLQ-2 NFLR-2 NFLS-2 NFLT-2 NFLU-2
EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM
Symptom Setting Checking

At full throttle Increase main jet calibration no. (Gradual- Discoloration of spark plug → If tan color, it
Hard breathing ly) is in good condition.
Shearing noise If cannot be corrected:
Whitish spark plug Clogged float valve seat
↓ Clogged fuel hose
Lean mixture Clogged fuel cock
Check that the accelerator pump operates
smoothly.
At full throttle Decrease main jet calibration no. (Gradual- Discoloration of spark plug → If tan color, it
Speed pick-up stops ly) is in good condition.
Slow speed pick-up If cannot be corrected:
Slow response Clogged air filter
Sooty spark plug Fuel overflow from carburetor
↓
Rich mixture
Lean mixture Lower jet needle clip position. (1 groove
Groove 1
down) Groove 2
Clip
Groove 3
Groove 4 Leaner
Rich mixture Raise jet needle clip position. (1 groove up) Groove 5
Groove 6
1/4–3/4 throttle Lower jet needle clip position. (1 groove Groove 7
(Standard)
Hard breathing down)
Lack of speed
Jet needle
Richer
1/4–1/2 throttle Raise jet needle clip position. (1 groove up)
Slow speed pick-up
Poor acceleration The clip position is the jet needle groove on
which the clip is installed.
The positions are numbered from the top.
Check that the accelerator pump operates
smoothly. (except for rich mixture symp-
tom).
Closed to 1/4 throttle Use jet needle with a smaller diameter. Slow-speed-circuit passage
Hard breathing Clogged → Clean.
Speed down Overflow from carburetor
Closed to 1/4 throttle Use jet needle with a larger diameter.
Poor acceleration Raise jet needle clip position. (1 groove up)
Poor response in the low to in- Raise jet needle clip position.
termediate speeds If this has no effect, lower the jet needle clip
position.
Poor response when throttle is Check overall settings. Check air filter for fouling.
opened quickly Use main jet with a lower calibration no. Check that the accelerator pump operates
Raise jet needle clip position. (1 groove up) smoothly.
If these have no effect, use a main jet with
a higher calibration no. and lower the jet
needle clip position.
7-4
ENGINE
* This should be taken simply for an example. It is necessary to set the carburetor while checking the operating conditions
of the engine.
7-5
CHASSIS
CHASSIS DRIVE AND REAR WHEEL The front fork setting includes the fol-
SELECTION OF THE SECONDARY SPROCKETS SETTING PARTS lowing three factors:
REDUCTION RATIO (SPROCKET) 1. Setting of air spring characteris-
Part name Size Part number tics
Secondary reduction ratio = Drive • Change the fork oil amount.
Number of rear wheel sprocket sprocket "1" 2. Setting of spring preload
teeth/Number of drive sprocket • Change the spring.
(STD) 13T 9383B-13233
teeth 3. Setting of damping force
Rear wheel • Change the compression damp-
Standard secondary 49/13 sprocket "2" ing.
reduction ratio (3.769) • Change the rebound damping.
47T 1C3-25447-00
<Requirement for selection of sec- The spring acts on the load and
48T 1C3-25448-00
ondary gear reduction ratio> the damping force acts on the
• It is generally said that the second- (STD) 49T 1C3-25449-00 cushion travel speed.
ary gear ratio should be reduced for 50T 1C3-25450-00 CHANGE IN AMOUNT AND
a longer straight portion of a speed CHARACTERISTICS OF FORK OIL
51T 1C3-25451-00
course and should be increased for Damping characteristic near the final
a course with many corners. Actual- 52T 1C3-25452-00 stroke can be changed by changing
ly, however, as the speed depends the fork oil amount.
on the ground condition of the day
of the race, be sure to run through
the circuit to set the machine suit- Adjust the oil amount in 5 cm3 (0.2
able for the entire course. Imp oz, 0.2 US oz) increments or
• In actuality, it is very difficult to decrements. Too small oil amount
achieve settings suitable for the en- causes the front fork to produce a
tire course and some settings may noise at full rebound or the rider to
be sacrificed. Thus, the settings feel some pressure on his hands
should be matched to the portion of or body. Alternatively, too large oil
the course that has the greatest ef- amount will cause the air spring
fect on the race result. In such a characteristics to have a tendency
case, run through the entire course to be stiffer with the consequent
while making notes of lap times to deteriorated performance and
find the best balance; then, deter- characteristics. Therefore, adjust
mine the secondary reduction ratio. the front fork within the specified
• If a course has a long straight por- range.
tion where a machine can run at TIRE PRESSURE
maximum speed, the machine is Tire pressure should be adjust to suit Standard oil amount:
generally set such that it can devel- the road surface condition of the cir- 350 cm3 (12.3 Imp oz,
op its maximum revolutions toward cuit. 11.8 US oz)
the end of the straight line, with care Standard tire pressure: Extent of adjustment:
taken to avoid the engine over-rev- 100 kPa (1.0 kgf/cm2, 300–375 cm3(10.6–13.2
ving. 15 psi) Imp oz, 10.1–12.7 US
oz)
• Under a rainy, muddy, sandy, or
Riding technique varies from rider to slippery condition, the tire pressure
rider and the performance of a ma- should be lower for a larger area of
chine also vary from machine to ma- contact with the road surface.
chine. Therefore, do not imitate other
rider's settings from the beginning but Extent of adjustment:
choose your own setting according to 60–80 kPa (0.6–0.8 kgf/
the level of your riding technique. cm2, 9.0–12 psi)
• Under a stony or hard road condi-
tion, the tire pressure should be
higher to prevent a flat tire.
100–120 kPa (1.0–1.2
kgf/cm2, 15–18 psi)
FRONT FORK SETTING
The front fork setting should be made
depending on the rider's feeling of an A. Air spring characteristics in
actual run and the circuit conditions. relation to oil amount change
B. Load
7-6
CHASSIS
C. Stroke the end of the spring. adjustment by turning the spring

1. Max. oil amount adjuster "2" to achieve the stan-
2. Standard oil amount dard figure from the subtraction of
3. Min. oil amount the length "b" from the length "a".
SETTING OF SPRING AFTER Standard figure:
REPLACEMENT 90–100 mm (3.5–3.9 in)
As the front fork setting can be easily
affected by rear suspension, take
care so that the machine front and • If the machine is new and after it is
rear are balanced (in position, etc.) broken in, the same set length of
when setting the front fork. the spring may change because of
1. Use of soft spring the initial fatigue, etc. of the spring.
• Change the rebound damping. Therefore, be sure to make reeval-
Turn out one or two clicks. uation.
• Change the compression damp- • If the standard figure cannot be
ing. achieved by adjusting the spring
Turn in one or two clicks. adjuster and changing the spring
set length, replace the spring with
Generally a soft spring gives a soft REAR SUSPENSION SETTING an optional one and make readjust-
riding feeling. Rebound damping The rear suspension setting should ment.
tends to become stronger and the be made depending on the rider's
front fork may sink deeply over a se- feeling of an actual run and the circuit
ries of gaps. conditions.
The rear suspension setting includes
2. Use of stiff spring the following two factors:
• Change the rebound damping. 1. Setting of spring preload
Turn in one or two clicks. • Change the set length of the
• Change the compression damp- spring.
ing. • Change the spring.
Turn out one or two clicks. 2. Setting of damping force SETTING OF SPRING AFTER
• Change the rebound damping. REPLACEMENT
Generally a stiff spring gives a stiff • Change the compression damp- After replacement, be sure to adjust
riding feeling. Rebound damping ing. the spring to the set length [sunken
tends to become weaker, resulting in CHOOSING SET LENGTH length 90–100 mm (3.5–3.9 in)] and
lack of a sense of contact with the 1. Place a stand or block under the set it.
road surface or in a vibrating handle- engine to put the rear wheel 1. Use of soft spring
bar. above the floor, and measure the • Set the soft spring for less re-
length "a" between the rear wheel bound damping to compensate
FRONT FORK SETTING PARTS axle center and the rear fender for its less spring load. Run with
• Front fork spring "1" holding bolt. the rebound damping adjuster
I.D. one or two clicks on the softer
SPRIN MA side and readjust it to suit your
TY SPRING PART preference.
G RK
PE NUMBER 2. Use of stiff spring
RATE (slit
s) • Set the soft spring for more re-
bound damping to compensate
0.398 1C3-23141-A1 | for its greater spring load. Run
0.408 1C3-23141-B1 || with the rebound damping adjust-
2. Remove the stand or block from er one or two clicks on the stiffer
0.418 1C3-23141-C1 |||
SO the engine and with a rider astride side and readjust it to suit your
0.428 1C3-23141-D1 |||| the seat, measure the sunken preference.
FT
0.438 1C3-23141-E1 ||||| length "b" between the rear wheel
0.449 1C3-23141-F1 |-| axle center and the rear fender Adjusting the rebound damping will
holding bolt. be followed more or less by a change
0.459 1C3-23141-G1 |-|| in the compression damping. For cor-
ST rection, turn the low compression
0.469 2S2-23141-L1 —
D damping adjuster on the softer side.
STI
0.479 1C3-23141-J1 |-||||
FF
When using a rear shock absorber
other than currently installed, use
The I.D. mark (slits) "a" is proved on the one whose overall length "a"
3. Loosen the locknut "1" and make
7-7
CHASSIS
does not exceed the standard as it [Unequal-pitch steel spring] [Titanium spring]
may result in faulty performance. SPRI SPRING
Never use one whose overall SPR EXTENT OF AD-
NG SPRING FREE
length is greater than standard. T ING JUSTMENT "b"
RAT PART I.D. LENGTH
Y FRE
E NUM- MARK/
P E One I.D. mark
Length "a" of standard (ap- BER Q'TY
E LEN
shock: prox. (-22212-) 245.5–263.5 mm
GTH
490 mm (19.29 in) ) (9.67–10.37 in)
S Approx. Two I.D. marks
O 265 mm
4.5 5UN-A0 Green/2 275 251.5–269.5 mm
F (10.43 in) (9.90–10.61 in)
T
4.7 5UN-B0 Red/2 275
Three I.D. marks
4.9 5UN-C0 Black/2 275 243.0–261.0 mm

(9.57–10.28 in)
5.1 5UN-D0 Blue/2 275
One I.D. mark
REAR SHOCK ABSORBER Yellow/
5.3 5UN-E0 275 255.5–273.5 mm
SETTING PARTS 2
• Rear shock spring "1" (10.06–10.77 in)
5.5 5UN-F0 Pink/2 275
[Equal-pitch titanium spring] Approx. Two I.D. marks
S
SPR TI 275 mm 261.5–279.5 mm
ING 5.7 5UN-G0 White/2 275 (10.83 in) (10.30–11.00 in)
F
SPRING FRE F
T SPRI Three I.D. marks
PART E
Y NG I.D.
NUM- LEN 253.0–271.0 mm
P RAT MARK
BER GTH (9.96–10.67 in)
E E Install the spring seat "2" to the ti-
(-22212-) (ap-
prox tanium spring. [Steel spring]
.) SPRING
EXTENT OF AD-
4.5 1C3-00 Green 265 FREE
• The unequal-pitch spring is softer in JUSTMENT "b"
S
LENGTH
4.7 1C3-10 Red 265 initial characteristic than the equal-
O pitch spring and is difficult to bottom 260 mm 240.5–258.5 mm
4.9 1C3-20 Black 265
F out under full compression. (10.24 in) (9.47–10.18 in)
T 5.1 1C3-30 Blue 265 • The I.D. mark "a" is marked at the 275 mm 255.5–273.5 mm
5.3 1C3-40 Yellow 275 end of the spring. (10.83 in) (10.06–10.77 in)
S • Spring specification varies accord-
1C3-50 ing to the color and quantity of I.D.
T 5.5 Pink 275
(1C3-B0) marks.
D
S
TI
5.7 1C3-60 White 275
F
F
[Equal-pitch steel spring]
SPR
SPRING
T SPRI ING
PART I.D.
Y NG FRE
NUM- MARK/
P RAT E
BER Q'TY
E E LEN
(-22212-)
GTH
4.3 5UN-00 Brown/1 260
• Extent of adjustment (spring length)
7-8
CHASSIS
SUSPENSION SETTING (FRONT FORK)
• If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to
the adjustment procedure given in the same chart.
• Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in).
Section
Symptom Medi- Check Adjust

Large Small
Jump um
gap gap
gap
Compression damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Stiff over entire
○ ○ ○ Oil amount Decrease oil amount by about 5–10 cm3 (0.2–0.4
range
Imp oz, 0.2–0.3 US oz).
Spring Replace with soft spring.
Outer tube Check for any bends, dents, and other noticeable
Inner tube scars, etc. If any, replace affected parts.
Unsmooth move-
Slide metal Replace with a new one for extended use.
ment over entire ○ ○ ○ ○
range Piston metal Replace with a new one for extended use.
Under bracket tighten- Retighten to specified torque.
ing torque
Rebound damping Turn adjuster counterclockwise (about 2 clicks) to
Poor initial move- decrease damping.
ment
○
Oil seal Apply grease in oil seal wall.
Compression damping Turn adjuster clockwise (about 2 clicks) to in-
Soft over entire crease damping.
range, bottoming ○ ○ Oil amount Increase oil amount by about 5–10 cm3 (0.2–0.4
out Imp oz, 0.2–0.3 US oz).
Spring Replace with stiff spring.
Stiff toward stroke Decrease oil amount by about 5 cm3 (0.2 Imp
end
○ Oil amount
oz,0.2 US oz).
Soft toward stroke Increase oil amount by about 5 cm3 (0.2 Imp
end, bottoming out
○ Oil amount
oz,0.2 US oz).
Stiff initial move- Turn adjuster counterclockwise (about 2 clicks) to
ment
○ ○ ○ ○ Compression damping
decrease damping.
Compression damping Turn adjuster clockwise (about 2 clicks) to in-
crease damping.
decrease damping.
Low front, tending to
lower front posture
○ ○ Balance with rear end Set sunken length for 95–100 mm (3.7–3.9 in)
when one passenger is astride seat (lower rear
posture).
Oil amount Increase oil amount by about 5 cm3 (0.2 Imp oz,
0.2 US oz).
Compression damping Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Balance with rear end Set sunken length for 90–95 mm (3.5–3.7 in)
"Obtrusive" front, when one passenger is astride seat (upper rear
tending to upper ○ ○ posture).
front posture
Oil amount Decrease oil amount by about 5–10 cm3 (0.2–0.4
Imp oz, 0.2–0.3 US oz).
7-9
CHASSIS
SUSPENSION SETTING (REAR SHOCK ABSORBER)
• If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to
the adjustment procedure given in the same chart.
• Adjust the rebound damping in 2-click increments or decrements.
• Adjust the low compression damping in 1-click increments or decrements.
• Adjust the high compression damping in 1/6 turn increments or decrements.
Section
Symptom Medi- Check Adjust

Large Small
Jump um
gap gap
gap
decrease damping.
Stiff, tending to sink ○ ○
Spring set length Set sunken length for 90–100 mm (3.5–3.9 in)
when one passenger is astride seat.
Rebound damping Turn adjuster clockwise (about 2 clicks) to in-
crease damping.
Spongy and unsta-
ble
○ ○ Low compression Turn adjuster clockwise (about 1 click) to increase
damping damping.
Heavy and dragging ○ ○ decrease damping.
decrease damping.
Low compression Turn adjuster clockwise (about 1 clicks) to in-
damping crease damping.
Poor road gripping ○ High compression Turn adjuster clockwise (about 1/6 turn) to in-
Spring set length Set sunken length for 90–100 mm (3.5–3.9 in)
High compression Turn adjuster clockwise (about 1/6 turn) to in-
Bottoming out ○ ○ Spring set length Set sunken length for 90–100 mm (3.5–3.9 in)
Rebound damping Turn adjuster clockwise (about 2 clicks) to in-
Bouncing ○ ○ crease damping.
High compression Turn adjuster counterclockwise (about 1/6 turn) to
damping decrease damping.
Stiff travel ○ ○ Spring set length Set sunken length for 90–100 mm (3.5–3.9 in)
7-10
PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO., LTD. PRINTED IN JAPAN
(E)
2500 SHINGAI IWATA SHIZUOKA JAPAN

Yz 450 FX

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2008

OWNER’S SERVICE MANUAL

TO THE NEW OWNER

CHAPTER 1 PRE-OPERATION STEERING ......................5-28

1. Clutch lever 11. Coolant drain bolt

MACHINE IDENTIFICATION IMPORTANT INFORMATION

ENGINE SERIAL NUMBER SPARK PLUG WRENCH

2. Use proper tools and cleaning

• Never apply additional force to

and help assure that all parts are

BEARINGS AND OIL SEALS

Tool name/Part number How to use Illustration

Crankshaft installing tool These tools are used to install the

Radiator cap tester These tools are used for checking

Rotor puller This tool is used to remove the fly-

Tool name/Part number How to use Illustration

Cap bolt wrench This tool is used to loosen or tighten

Cap bolt ring wrench This tool is used to loosen or tighten

Pocket tester Use this tool to inspect the coil resis-

Timing light This tool is necessary for checking

Valve spring compressor This tool is needed to remove and

Tool name/Part number How to use Illustration

Valve guide remover This tool is needed to remove and

Valve guide installer This tool is needed to install the

Valve guide reamer This tool is needed to rebore the

Crankcase separating tool These tool is used to remove the

Dynamic spark tester This instrument is necessary for

Tool name/Part number How to use Illustration

THROTTLE GRIP COLD STARTER KNOB

STARTING AND BREAK-IN

Observe the following break-in

the engine stop switch. Then, re-

• After the break-in or before each

CLEANING AND STORAGE the carburetor float bowl.

4. After the majority of the dirt has

(Except for USA and CDN)

Item Standard Limit

Intake "A" 31.200–31.300 mm (1.2283–1.2323 in) 31.100 mm

Item Standard Limit

"B" face width (IN) 2.26 mm (0.089 in) ----

"C" seat width (IN) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630

"D" margin thickness (IN) 1 mm (0.0394 in) 0.85 mm (0.033

Stem outside diameter (IN) 4.475–4.490 mm (0.1762–0.1768 in) 4.445 mm

Item Standard Limit

Valve seat width (IN) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630

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

Measuring point "H" 8 mm (0.315 in) ----

Item Standard Limit

Type Barrel ----

Type Taper ----

Dimensions (B × T) 2.0 × 2.9 mm (0.08 × 0.11 in) ----

Item Standard Limit

Item Standard Limit

Item Standard Limit

Item Standard Limit

Item Standard Limit

Unit Read Definition Measure

1. Oil filter element

CABLE ROUTING DIAGRAM