At115 2002 (Nouvo) 5mx-F8197-E0

AT115
SERVICEMANUAL
5MX-F8197-E0
EAS00000
AT115
SERVICE MANUAL
©2002 by Yamaha Motor Co., Ltd.
First edition, January 2002
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS00002
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal-
ers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in
one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles. Repair and maintenance work attempted by anyone without this knowledge is likely to
render the vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha deal-
ers and will appear in future editions of this manual where applicable.
NOTE:
_
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person checking or repairing the
motorcycle.
CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.
EASF0007
HOW TO USE THIS MANUAL

CONSTRUCTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title 1: This is a chapter with its symbol on the upper right of each page.
2nd title 2: This title appears on the upper of each page on the left of the chapter sym-
bol. (For the chapter “Periodic checks and adjustments” the 3rd title
appears.)
3rd title 3: This is a final title.
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-
tion has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspections.
A set of particularly important procedure 4 is placed between a line of triangle “▲” with each proce-
dure preceded by “●”.
IMPROTANT FEATURES
● Data and a special tool are framed in a box preceded by a relevant symbol 5.
● An encircled numeral 6 indicates a part name, and an encircled alphabetical letter data or an
alignment mark 7, the others being indicated by an alphabetical letter in a box 8.

● A condition of a faulty component will precede an arrow symbol and the course of action required
the symbol 9.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying
correct disassembly and assembly procedures.
EASF0009
1 2
SYMBOLS
GEN The following symbols are not relevant to
INFO SPEC every vehicle.
Symbols 1 to 8 indicate the subject of each
3 4 chapter.
CHK ENG
1 General information
2 Specifications
ADJ 3 Periodic checks and adjustments
5 6 4 Engine
5 Carburetor
6 Chassis
CARB CHAS 7 Electrical system
8 Troubleshooting
7 8
– + TRBL
ELEC SHTG
9 0 Symbols 9 to F indicate the following.
9 Serviceable with engine mounted
0 Filling fluid
A Lubricant
B Special tool
A B C Tightening torque
D Wear limit, clearance
E Engine speed
F Electrical data
C D
T.
R.
E F
G H I Symbols G to L in the exploded diagrams

indicate the types of lubricants and lubrication
points.
E G M G Engine oil
H Gear oil
J K L
I Molybdenum-disulfide oil
J Wheel-bearing grease
B LS M K Lithium-soap-based grease
L Molybdenum-disulfide grease
M N Symbols M to N in the exploded diagrams
indicate the following.
LT
New M Apply locking agent (LOCTITE®)
N Replace the part
EASF0011
TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC 2
PERIODIC CHECKS AND
ADJUSTMENTS CHK
ADJ 3
ENGINE ENG 4
CARBURETOR CARB 5
CHASSIS CHAS 6
– +
ELECTRICAL SYSTEM ELEC 7

TROUBLESHOOTING TRBL
SHTG 8
GEN
INFO
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION..................................................................1-1
VEHICLE IDENTIFICATION NUMBER .....................................................1-1
ENGINE SERIAL NUMBER ...................................................................... 1-1
FEATURES...................................................................................................... 1-2
V-BELT POWERMATIC ............................................................................1-2
TORQUE CAM .......................................................................................... 1-5
IMPORTANT INFORMATION ......................................................................... 1-6

PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-6
REPLACEMENT PARTS...........................................................................1-6
GASKETS, OIL SEALS AND O-RINGS .................................................... 1-6
LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-7
BEARINGS AND OIL SEALS .................................................................... 1-7
CIRCLIPS ..................................................................................................1-7
CHECKING THE CONNECTIONS ..................................................................1-8
SPECIAL TOOLS ............................................................................................ 1-9

GEN
INFO
GEN
MOTORCYCLE IDENTIFICATION INFO
EAS00014
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
1 EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification 1 is stamped into
the frame.
EASF0016
ENGINE SERIAL NUMBER
1 The engine serial number 1 is stamped into
the crankcase.
NOTE:
Designs and specifications are subject to
change without notice.
1-1
GEN
FEATURES INFO
EAS00019
FEATURES
V-BELT POWERMATIC
Mechanism
A variable ratio V-belt transmission, which is fully automatic, has been adopted.
To accommodate the engine speed, the optimum transmission ratio is automatically established. In
addition, shocks cannot be felt when changing speeds, and smooth acceleration and an excellent
climbing power can be achieved.
This transmission mechanism consists of a primary pulley and a secondary pulley, which are con-
nected by a V-belt. Also, the reduction ratio changes according to the movement of the V-belt.
1 2 3 4 5
C B A 0 9 8
1 Crankshaft 6 Secondary fixed sheave A Clutch carrier

2 Primary sliding sheave 7 Secondary sliding sheave B V-belt
3 Primary pulley weight 8 Spring C Primary fixed sheave
4 Main axle 9 Primary drive gear
5 Drive axle 0 Clutch housing
1-2
GEN
FEATURES INFO
Operation
1. Idle speed operation
When the engine speed is at idle, power is transmitted from the primary pulley, V-belt, and sec-
ondary pulley to the clutch carrier. However, power is not transmitted to the clutch housing
because the centrifugal force of the clutch carrier is weaker than the tension of the clutch springs,
thus the clutch carrier (shoe) does not come into contact with the clutch housing.
2. Starting out
When engine speed reaches approximately 3,000 r/min, the centrifugal force of the clutch carrier
becomes stronger than the tension of the clutch springs. This causes the clutch carrier (shoe) to
come into contact with the clutch housing and to initiate frictional force (transmission torque).
When this occurs, the V-belt moves inward toward the inner diameter of the primary pulley and
outward toward the perimeter of the secondary pulley. Also, the reduction ratio is maximized and
sufficient driving force is transmitted to the rear wheel.
1 2 Clutch-in revolution 2,550 ~ 2,950 rpm

Clutch-stall revolution 4,700 ~ 5,300 rpm
1 V-belt
2 Secondary pulley
3 Primary pulley
1-3
GEN
FEATURES INFO
3. Medium-speed operation
As engine speed increases, the primary pulley weight is moved outward by centrifugal force.
The primary pulley weight pushes the primary sliding sheave towards the primary fixed sheave,
which forces the V-belt toward the outer perimeter of the primary pulley. When this occurs, the
diameter of the V-belt is increased at the primary pulley. As the diameter of the V-belt increases,
the belt is pulled at the secondary pulley because the length of the belt is constant. As a result,
the belt is pushed toward the inner diameter of the secondary pulley until the tension of the V-belt
and clutch springs is balanced. When this occurs, the diameter of the V-belt is decreased at the
secondary pulley and the reduction ratio gradually decreases and the speed of the secondary
pulley gradually increases.
4. High-speed operation
As engine speed increases from medium-speed operation, the primary pulley weight moves fur-
ther outward, the primary sliding sheave is pushed closer toward the primary fixed sheave, and
the V-belt is forced further outward toward the perimeter of the primary pulley.
At the secondary pulley the V-belt is forced further inward and, as a result, the reduction ratio is
minimized.
1-4
GEN
FEATURES INFO
TORQUE CAM
When a powerful torque is needed to climb hills, powerful climbing power is delivered from the oper-
ation of the torque cam, not from driving skill of the rider.
Operation
When the motorcycle approaches a hill, the load of the rear wheel increases and traveling speed is
reduced. As the throttle is opened to increase speed, the torque of the engine increases and the
secondary sliding sheave forces the V-belt outward toward the perimeter of the secondary pulley.
As a result, the diameter of the V-belt increases at the secondary pulley, and at the same time a
large driving force, excellent operation, excellent acceleration ability, and powerful climbing capabil-
ities are achieved because the transmission ratio is also increased.
Normal operation Climbing hills or quick acceleration
1 2
1 2
3
È
É 3
1 Secondary fixed sheave È Small load on rear wheel

2 Secondary sliding sheave É Large load on rear wheel
3 V-belt
4 Torque cam
1-5
GEN
IMPORTANT INFORMATION INFO
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to the “SPECIAL TOOLS”.
3. When disassembling, always keep mated
parts together. This includes gears, cylin-
ders, pistons and other parts that have been
“mated” through normal wear. Mated parts
must always be reused or replaced as an
assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of dis-
assembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS00021
REPLACEMENT PARTS
Use only genuine Yamaha parts for all
replacements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EAS00022
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket sur-
faces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
1-6
GEN
IMPORTANT INFORMATION INFO
EAS00023
LOCK WASHERS/PLATES AND COTTER
PINS
After removal, replace all lock washers/plates
1 and cotter pins. After the bolt or nut has
been tightened to specification, bend the lock
tabs along a flat of the bolt or nut.
EAS00024
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manu-
facturer’s marks or numbers are visible. When
installing oil seals, lubricate the oil seal lips
with a light coat of lithium-soap-based grease.
Oil bearings liberally when installing, if appro-
priate.
1 Oil seal
CAUTION:
_
Do not spin the bearing with compressed

air because this will damage the bearing
surfaces.
1 Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip 1, make sure the
sharp-edged corner 2 is positioned opposite
the thrust 3 that the circlip receives.
4 Shaft
1-7
GEN
CHECKING THE CONNECTIONS INFO
EAS00026
CHECKING THE CONNECTIONS

Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• lead
• coupler
• connector
2. Check:
• lead
• coupler
• connector
Moisture → Dry with an air blower.
Rust/stains → Connect and disconnect sev-
eral times.
3. Check:
• all connections
Loose connection → Connect properly.
NOTE:
_
If the pin 1 on the terminal is flattened, bend it

up.
4. Connect:
• lead
• coupler
• connector
NOTE:
_
Make sure all connections are tight.
5. Check:
• continuity
(with the pocket tester)
Pocket tester
90890-03112
NOTE:
_
• If there is no continuity, clean the terminals.

• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
1-8
GEN
SPECIAL TOOLS INFO
EAS00027
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of inappropri-
ate tools or improvised techniques. Special tools, part numbers or both may differ depending on the
country.
When placing an order, refer to the list provided below to avoid any mistakes.
Tool No. Tool name/Usage Illustration
Weight
Weight Slide hammer bolt
90890-01084
Slide hammer bolt
90890-01085 These tools are used when removing or
installing the rocker arm shafts.
Fork seal driver weight
90890-01184
This tool is used to installing the oil seal.

Fork seal driver attachment
90890-01186
This tool is used to installing the oil seal.

Flywheel puller
90890-01189
This tool is used for removing the rotor.

Rotor holding tool
90890-01235
This tool is used to hold the generator
rotor when removing or installing the
generator rotor bolt.
Valve spring compressor
90890-01253
These tools are used when removing or
installing the valve and the valve spring.
Ring nut wrench
90890-01268
This tool is used to loosen and tighten
the steering ring nut.
1-9
GEN
SPECIAL TOOLS INFO
Tappet adjusting tool
90890-01311
This tool is necessary for adjusting
valve clearance.
Fuel level gauge
90890-01312
This gauge is used to measure the fuel
level in the float chamber.
T-handle
90890-01326
This tool is used for holding the damper
rod holder when removing or installing
the damper rod holder.
Clutch spring holder
90890-01337
This tool is used to disassembly and
assembly the secondary pulley.
Locknut wrench
90890-01348
the clutch carrier locknut of the second-
ary pulley.
Steering nut wrench
90890-01403
the steering ring nut.
Oil seal guide
90890-01384
This tool is used to install oil seals.

Sheave holder
90890-01701
This tool is used for holding the second-
ary pulley.
1 - 10
GEN
SPECIAL TOOLS INFO
Thickness gauge
90890-03079
This tool is used to measure the valve
clearance.
Compression gauge
90890-03081
These tools are used to measure the
engine compression.
Pocket tester
90890-03112
These instruments are invaluable for
checking the electrical system.
Engine tachometer
90890-03113
This tool is needed for detecting engine
rpm.
Valve guide remover (5 mm)
90890-04097
This tool is needed to remove and
install the valve guide.
Valve guide installer (5 mm)
90890-04098
This tool is needed to install the valve
guide.
Valve guide reamer (5 mm)
90890-04099
This tool is needed to rebore the new
valve guide.
Valve lapper
90890-04101
This tool is used for removing and
installing the lifter and for lapping the
valve.
1 - 11
GEN
SPECIAL TOOLS INFO
Ignition checker
90890-06754
This instrument is necessary for check-
ing the ignition system components.
Yamaha bond No. 1215
90890-85505
This sealant (bond) is used for crank-
case mating surface, etc.
1 - 12
SPEC
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
MAINTENANCE SPECIFICATIONS ............................................................... 2-4

ENGINE..................................................................................................... 2-4
TIGHTENING TORQUES..........................................................................2-8
CHASSIS.................................................................................................2-10
TIGHTENING TORQUES........................................................................2-12
ELECTRICAL .......................................................................................... 2-14
GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................2-16
LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-17

ENGINE .................................................................................................. 2-17
CHASSIS ................................................................................................2-18
CABLE ROUTING ......................................................................................... 2-19

SPEC
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model AT115
Model code 5MX1
Dimensions
Overall length 1,935 mm
Overall width 675 mm
Overall height 1,070 mm
Seat height 755 mm
Wheelbase 1,280 mm
Minimum ground clearance 135 mm
Minimum turning radius 1,900 mm
Weight
Wet (with oil and full fuel tank) 103 kg
Engine
Engine type Forced-air-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 0.1137 L
Bore × stroke 50.0 × 57.9 mm
Compression ratio 8.8 : 1
Compression pressure (STD) 1,100 kPa (11 kgf/cm2) at 510 r/min
Starting system Kick and electric starter
Lubrication system Wet sump
Engine idling speed 1,500 ~ 1,700 r/min
Oil type or grade
Engine oil YAMALUBE 4, SAE 10W30 SE/F or
SAE 20W40 SE/F
Periodic oil change 0.8 L
Total amount 0.9 L
Transmission oil
Recommended oil Engine oil
Periodic oil change 0.1 L
Total amount 0.12 L
Air filter Dry type element
Fuel
Recommended fuel Regular gasoline
Fuel tank capacity 4.9 L
2-1
Model AT115
Carburetor
Type/quantity BS25/1
Manufacturer MIKUNI
Spark plug
Type CR7HSA
Manufacturer NGK
Spark plug gap 0.6 ~ 0.7 mm
Clutch type V-belt automatic
Transmission
Primary reduction system Helical gear
Primary reduction ratio 47/15 (3.133)
Secondary reduction system Spur gear
Secondary reduction ratio 43/12 (3.538)
Transmission type V-belt automatic
Operation Centrifugal automatic type
Chassis
Frame type Steel tube underbone
Caster angle 25°
Trail 112 mm
Tire
Type With tube
Size front 70/90-16 36P
rear 80/90-16 43P
Model (manufacturer) front D110 (DUNLOP)
rear D110 (DUNLOP)
Min. tire tread depth front 0.8 mm
rear 0.8 mm
Tire pressure (cold tire)
Maximum load*-except motorcycle 116 kg
front 200 kPa (2.00 kg/cm2)
rear 225 kPa (2.25 kg/cm2)
*Load is the total weight of cargo, rider, passenger, and accessories.
2-2
Model AT115
Brake
Front brake type Single disc brake
operation Right hand operation
Rear brake type Drum brake
operation Left hand operation
Suspension
Front suspension Telescopic fork
Rear suspension Unit swing
Shock absorber
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/oil damper
Wheel travel
Front wheel travel 90 mm
Rear wheel travel 50 mm
Electrical
Ignition system DC. C.D.I.
Generator system A.C. magneto
Battery type/manufacturer YB7B-B/YUASA
Battery capacity 12 V 7 AH
Headlight type Incandescence bulb
Bulbs (voltage/wattage × quantity)
Headlight 12 V 25 W/25 W × 2
Tail/brake light 12 V 5 W/21 W × 1
Front turn signal light 12 V 10 W × 2
Rear turn signal light 12 V 10 W × 2
Meter light 12 V 3.4 W × 1
12 V 1.7 W × 1
High beam indicator light 12 V 1.7 W × 1
Turn indicator light 12 V 3.4 W × 2
2-3
MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Cylinder head
Max. warpage “*” ---- 0.05 mm
Cylinder
Bore 50.000 ~ 50.010 mm 50.1 mm
Warp limit ---- 0.05 mm
Camshaft
Drive method Chain drive (left)
Cam dimensions
Intake “A” A 25.881 ~ 25.981 mm 25.780 mm
“B” 21.195 ~ 21.295 mm 21.095 mm
Exhaust “A” 25.841 ~ 25.941 mm 25.740 mm
“B” 21.050 ~ 21.150 mm 20.950 mm
B
Camshaft runout limit ---- 0.03 mm
Cam chain
Cam chain type/No. of links DID SCR-0404 SDH/90
Rocker arm/rocker armshaft
Rocker arm inside diameter 10.000 ~ 10.015 mm 10.030 mm
Rocker shaft outside diameter 9.981 ~ 9.991 mm 9.950 mm
Rocker arm-to-rocker arm shaft 0.009 ~ 0.034 mm 0.08 mm
clearance
Valve, valve seat, valve guide
Valve clearance (cold) IN 0.08 ~ 0.12 mm ----
EX 0.08 ~ 0.12 mm ----
Valve dimensions
B C
D
A
Head Diameter Face Width Seat Width Margin Thickness
“A” head diameter IN 22.9 ~ 23.1 mm ----
EX 19.9 ~ 20.1 mm ----
“B” face width IN 1.20 ~ 2.50 mm ----
EX 1.30 ~ 2.40 mm ----
“C” seat width IN 0.9 ~ 1.1 mm 1.6 mm
EX 0.9 ~ 1.1 mm 1.6 mm
“D” margin thickness IN 0.7 mm ----
EX 1.0 mm ----
2-4
Item Standard Limit
Stem outside diameter IN 4.970 ~ 4.985 mm 4.930 mm
EX 4.955 ~ 4.970 mm 4.920 mm
Guide inside diameter IN 5.000 ~ 5.012 mm 5.050 mm
EX 5.000 ~ 5.012 mm 5.050 mm
Valve stem-to-guide clearance IN 0.015 ~ 0.042 mm 0.080 mm
EX 0.030 ~ 0.057 mm 0.110 mm
Valve stem runout limit ---- 0.01 mm
Valve spring
Free length IN/EX 35.44 mm 34.00 mm
Tilt limit “*” IN/EX ---- 2.5°/1.5 mm
Winding direction IN/EX Clockwise ----

Piston
Piston to cylinder clearance 0.020 ~ 0.035 mm 0.150 mm
Piston size “D” 49.970 ~ 49.985 mm ----
Measuring point “H” 5.0 mm ----
Offset 0.5 mm ----
H
Offset direction D Intake side ----
Piston pin bore inside diameter 15.002 ~ 15.013 mm 15.043 mm
Piston pin outside diameter 14.995 ~ 15.000 mm 14.975 mm
Piston rings
Top ring
Ring type Barrel ----
Dimensions (B × T) B 1.00 × 1.85 mm ----
End gap (installed) T 0.10 ~ 0.25 mm 0.50 mm
Ring side clearance (installed) 0.03 ~ 0.07 mm 0.12 mm
2nd ring
Ring type Taper ----
Dimensions (B × T) B 1.0 × 2.0 mm ----
End gap (installed) T 0.10 ~ 0.25 mm 0.60 mm
Ring side clearance 0.02 ~ 0.06 mm 0.12 mm
Oil ring
B
Dimensions (B × T) 2.0 × 2.2 mm ----
End gap (installed) T 0.20 ~ 0.70 mm ----
2-5
Item Standard Limit
Crankshaft
C C
E
D
A
Crank width “A” 45.45 ~ 45.50 mm ----
Max. runout limit “C” ---- 0.03 mm
Big end side clearance “D” 0.15 ~ 0.45 mm ----
Big end radial clearance “E” 0.004 ~ 0.014 mm ----
Clutch
Clutch shoe thickness 2.0 mm 1.0 mm
Clutch shoe spring free length 28.8 mm
Clutch housing inside diameter 112 mm 112.5 mm
Compression spring free length 76 mm 73 mm
Weight outside diameter 15 mm 14.5 mm
Clutch - in revolution 2,550 ~ 2,950 r/min ----
Clutch - stall revolution 4,700 ~ 5,300 r/min ----
V-belt
V-belt width 18.2 mm 17.2 mm
Kick starter
Kick starter type Ratchet type ----
Kick clip friction force 1.5 ~ 2.5 N (0.15 ~ 0.25 kgf) ----
Carburetor
Type BS25
I.D. mark 5MX1 00 ----
Main jet (M.J) #100 ----
Main air jet (M.A.J) ø0.8 ----
Jet needle (J.N) 4DFZ03-2 ----
Needle jet (N.J) E-3M (906) ----
Pilot air jet 1 #90 ----
Pilot air jet 2 #90 ----
Pilot outlet (P.O) ø0.8 ----
Pilot jet (P.J) #17.5 ----
Bypass 1 0.7 ----
Bypass 2 0.7 ----
Bypass 3 0.7 ----
Bypass 4 0.7 ----
Pilot screw turns out 1-1/2 ----
Valve seat size ø1.8 ----
Starter jet 1 #30 ----
Starter jet 2 ø0.6 ----
Throttle valve size #115 ----
2-6
Item Standard Limit
Oil filter type Wire mesh ----
Oil pump
Oil pump type Trochoid type ----
Inner rotor to outer rotor tip clearance 0.15 mm 0.23 mm
Outer rotor to pump housing 0.13 ~ 0.18 mm 0.25 mm
clearance
Housing and rotor clearance 0.06 ~ 0.10 mm 0.17 mm
Rotor thickness 7.96 ~ 7.98 mm ----
Model AT115
Lubrication chart
OIL RING PISTON CYLINDER HEAD CAMSHAFT
CONNECTING
ROD BIG END
CRANKSHAFT
OIL PUMP
OIL STRAINER
OIL PAN
2-7
TIGHTENING TORQUES
ENGINE
Tightening
Thread torque
Part to be tightened Part name Q’ty Remarks
size
Nm m·kg
Spark plug — M10 1 13 1.3
Cylinder head Nut M8 4 22 2.2 E
Cylinder head (timing chain side) Bolt M6 2 10 1.0

Cylinder head stud bolt Bolt M8 2 13 1.3
Oil gallery bolt Bolt M6 1 7 0.7
Tappet cover (intake and exhaust side) — M45 2 18 1.8
Camshaft sprocket cover Bolt M6 2 12 1.2
Camshaft retainer Bolt M6 1 12 1.2
Camshaft sprocket cover breather plate Bolt M6 2 10 1.0
Camshaft sprocket Bolt M8 1 30 3.0
Valve adjusting locknut Nut M5 2 7 0.7
Chain guide retainer (intake side) Bolt M6 1 7 0.7
Timing chain tensioner Bolt M6 2 9 0.9
Timing chain tensioner cap bolt Bolt M8 1 8 0.8
Engine cooling fan cover Screw M6 3 7 0.7
Engine cooling fan Bolt M6 3 10 1.0
Generator rotor Nut M12 1 70 7.0
Oil pump cover Bolt M6 3 10 1.0
Oil pump Screw M5 2 4 0.4
Engine oil drain plug Plug M30 1 20 2.0
Engine oil drain bolt Bolt M12 1 20 2.0
Transmission oil drain bolt Bolt M8 1 22 2.2
Muffler and cylinder head Nut M8 2 20 2.0
Muffler and rear suspension arm Bolt M8 2 35 3.5
Muffler protector 1 Bolt M6 3 11 1.1 LT
Exhaust pipe protector Bolt M6 2 11 1.1

Muffler cap Bolt M6 3 11 1.1 LT
Muffler protector 2 Bolt M6 2 11 1.1 LT
Intake manifold Bolt M6 2 10 1.0

Air filter case Bolt M6 2 10 1.0
Kickstarter crank Bolt M6 1 11 1.1
V-belt case cover protector 1 Bolt M8 2 23 2.3
V-belt case air filter cover Bolt M6 3 10 1.0
V-belt case cover Bolt M6 13 10 1.0
V-belt case cover protector 2 Bolt M6 2 10 1.0
Kickstarter shaft plate Screw M6 4 9 0.9
Secondary pulley nut Nut M10 1 40 4.0
Clutch carrier nut Nut M28 1 75 7.5
Transmission case cover Bolt M6 6 13 1.3
Bearing retainer (primary drive gear) Bolt M6 1 10 1.0 LT
2-8
Tightening
Thread torque
Part to be tightened Part name Q’ty Remarks
size
Nm m·kg
Primary pulley nut Nut M12 1 55 5.5
Idle gear plate Bolt M6 2 10 1.0
Starter wheel gear holder Bolt M6 1 10 1.0
Crankcase (left and right) Bolt M6 9 10 1.0
Crankcase stud bolt Bolt M8 4 13 1.3
Stator coil Bolt M6 3 11 1.1
Pickup coil bracket Screw M6 2 7 0.7
Starter motor Bolt M6 2 7 0.7
2-9
CHASSIS
Item Standard Limit

Steering system
Steering bearing type Angular bearing ----
Lock to lock angle left 50° ----
Lock to lock angle right 50° ----
Front suspension
Front fork travel 90 mm ----
Front absorber travel 50 mm ----
Fork spring free length 307.7 mm 301.5 mm
Installed length 287.7 mm ----
Spring rate (K1) 7.8 N/mm (0.8 kgf/mm) ----
(K2) 15.6 N/mm (1.59 kgf/mm) ----
Stroke (K1) 0 ~ 50 mm ----
(K2) 50 ~ 90 mm ----
Optional spring available No ----
Oil capacity 0.063 L (63.0 cm3) ----
Oil level 106 mm ----
Recommended oil Fork oil 10 W or equivalent ----
Inner tube outer diameter 26 mm ----
Inner tube vend limit ---- 0.2 mm
Rear suspension
Shock absorber stroke 50 mm ----
Spring free length 203.6 mm 199.5 mm
Installed length 198.6 mm ----
Spring rate (K1) 30 N/mm (3.06 kgf/mm) ----
(K2) 74.3 N/mm (7.58 kgf/mm) ----
Stroke (K1) 0 ~ 15 mm ----
(K2) 15 ~ 50 mm ----
Optional spring available No
Front wheel
Type Spoke wheel ----
Rim size 16 × 1.40 ----
Rim material Steel ----
Max. radial wheel runout ---- 2.0 mm
Max. lateral wheel runout ---- 2.0 mm
Rear wheel
Type Spoke wheel ----
Rim size 16 × 1.60 ----
Rim material Steel ----
Max. radial wheel runout ---- 2.0 mm
Max. lateral wheel runout ---- 2.0 mm
2 - 10
Item Standard Limit
Front brake
Disk brake type Single ----
Disc outside diameter × thickness 220.0 × 3.5 mm 3.0 mm
Pad thickness inner 5.3 mm 0.8 mm
Pad thickness outer 5.3 mm 0.8 mm
Master cylinder inside diameter 11 mm ----

Caliper cylinder inside diameter 22.22 mm × 2 ----
Brake fluid type DOT 4 ----
Rear brake
Drum brake type Leading, trailing ----
Rear brake lever free play (lever end) 10 ~ 20 mm ----
Drum inside diameter 130 mm 131 mm
Lining thickness 4 mm 2 mm
Shoe spring free length 52 mm ----
(camshaft side)
Shoe spring free length (pivot side) 48 mm ----
Throttle cable free play 3 ~ 7 mm ----
2 - 11
TIGHTENING TORQUES
CHASSIS
Tightening
Part to be tightened Thread size torque Remarks
Nm m·kg
Brake master cylinder M6 11 1.1
Rear bake lever holder M6 7 0.7
Handlebar nut M10 43 4.3
Steering ring nut (upper) M25 75 7.5 See NOTE
Steering ring nut (lower) M25 30 3.0 See NOTE
Engine mounting nut M12 59 5.9
Engine mounting rubber damper and engine
M8 16 1.6
bracket
Engine bracket and engine assembly M10 32 3.2
Rear shock absorber nut M10 30 3.0
Rear shock absorber lower bolt M8 16 1.6
Rear suspension arm and engine M8 30 3.0
Front wheel axle nut M10 40 4.0
Rear wheel axle nut M14 104 10.4
Disk brake and hub M8 23 2.3 LT
Front fork and brake hose holder M6 7 0.7

Brake hose holder and lower bracket M6 10 1.0
Brake hose/speed meter cable holder and lower
M6 10 1.0
bracket
Brake caliper bolt M10 35 3.5
Brake pad retaining bolt M10 27 2.7
Bleed screw M7 6 0.6
Brake hose union bolt M10 26 2.6
Brake camshaft lever pinch bolt M6 7 0.7
Front fender M6 7 0.7
Lower bracket pinch bolt M10 50 5.0
Front fork cap bolt M20 50 5.0
Damper rod bolt M10 23 2.3 LT
Rear view mirror M10 32 3.2

Sidestand (bracket and frame) M10 32 3.2
Sidestand bolt M8 26 2.6 LS
Sidestand nut M8 16 1.6

Rear brake cable holder M6 7 0.7
Storage compartment M6 8 0.8
Fuel tank M6 7 0.7
Fuel tank and fuel cock M6 7 0.7
Fuel sender M5 4 0.4
Seat M6 7 0.7
Side panel M6 4 0.4
Side panel/side cover and frame M6 7 0.7
2 - 12
Tightening
Part to be tightened Thread size torque Remarks
Nm m·kg
Under cover M6 7 0.7
Ignition coil M6 7 0.7
Rectifier regulator M6 7 0.7
Battery box M6 7 0.7
NOTE:
1. First tighten the ring nut (lower) 30 Nm (3.0 m • kg) by using the torque wrench, then loosen the
ring nut quarter turn.
2. Then, hold the ring nuts (lower) and tighten the ring nut (upper) 70 Nm (7.0 m • kg) by using the
torque wrench.
2 - 13
ELECTRICAL
Item Standard Limit

System voltage 12 V ----
Ignition system
Ignition timing (B.T.D.C.) 5° ----
Advanced type Digital ----
DC.C.D.I.
Pickup coil resistance/color 248 ~ 372 Ω at 20 °C/W/L–W/R ----
C.D.I. unit model/manufacturer 5LW/YIMM ----
Ignition coil
Model/manufacturer 5LW/YIMM ----
Minimum ignition spark gap 6 mm ----
Primary coil resistance 0.32 ~ 0.48 Ω at 20 °C ----
Secondary coil resistance 5.68 ~ 8.52 kΩ at 20 °C ----
Spark plug cap
Material Resin ----
Resistance 5 kΩ ----
Charging system
Type A.C. magneto ----
Model/manufacturer F5LW/YIMM ----
Nominal output 14 V 105 W at 5,000 r/min ----
Lighting coil resistance/color 0.24 ~ 0.36 Ω at 20 °C/Y/R–B ----
Charging coil resistance/color 0.32 ~ 0.48 Ω at 20 °C/W–B ----
Rectifier/regulator
Regulator type Semi conductor-short circuit ----
Model/manufacturer SH656-12/SHINDENGEN ----
No load regulated voltage (DC) 14.1 ~ 14.9 V ----
(AC) 13.0 ~ 14.0 V ----
Rectifier capacity (DC) 8A ----
(AC) 12 A ----
2 - 14
Item Standard Limit
Battery
Type/manufacturer YB7B-B/YUASA
Voltage/capacity 12 V 7 AH ----
Specific gravity 1.280 ----
Electric starting system
Type Constant mesh
Starter motor
Model/manufacturer 5LW/YIMM ----
Power output 0.3 kW ----
Armature coil resistance 0.031 ~ 0.037 Ω at 20 °C ----
Brush overall length 10 mm 3.5 mm
Spring force 5.52 ~ 8.28 N (563 ~ 844 gf) 5.52 N
(563 gf)
Commutator diameter 22 mm 21 mm
Mica undercut (depth) 1.5 mm ----
Starter relay
Model/manufacturer 2768081-A/JIDECO ----
Amperage rating 180 A ----
Coil resistance 4.2 ~ 4.6 Ω at 20 °C ----
Horn
Type Plane ----
Quantity 1 pcs ----
Model/manufacturer LOCAL MADE ----
Max. amperage 1.5 A ----
Performance 95 ~ 105 db (2 m) ----
Coil resistance 4.30 ~ 4.80 Ω at 20 °C ----
Turn signal relay
Relay type Condenser ----
Model/manufacturer LOCAL MADE ----
Self-canceling device built-in No
Hazard flasher device No
Flasher frequency 75 ~ 95 cycle/min ----
Wattage 10 W × 2 + 3.4 W ----
Fuel gauge
Model/manufacturer 5LW/CHAO LONG ----
Sender unit resistance- full 4 ~ 10 Ω at 20 °C ----
- empty 90 ~ 100 Ω at 20 °C ----
Circuit breaker
Circuit breaker type Fuse ----
Main 10 A ----
Reserve 10 A ----
2 - 15
GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC
EAS00029
GENERAL TIGHTENING TORQUE

SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread
pitch. Tightening torque specifications for spe-
cial components or assemblies are provided
for each chapter of this manual. To avoid
warpage, tighten multi-fastener assemblies in
a crisscross pattern and progressive stages
until the specified tightening torque is reached.
Unless otherwise specified, tightening torque
specifications require clean, dry threads. Com-
ponents should be at room temperature.
A: Width across flats
B: Thread diameter
General tightening
A B torques
(nut) (bolt)
Nm m•kg
10 mm 6 mm 6 0.6
12 mm 8 mm 15 1.5
14 mm 10 mm 30 3.0
17 mm 12 mm 55 5.5
19 mm 14 mm 85 8.5
22 mm 16 mm 130 13.0
2 - 16
LUBRICATION POINTS AND LUBRICANT TYPES SPEC
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication point Lubricant

Oil seal lips LS
O-rings LS
Bearings E
Piston outside and ring groove E
Piston ring E
Piston pin E
Cylinder inner surface E
Timing chain E
Rocker arm shaft M
Rocker arm inner surfaces M
Camshaft lobes and camshaft journals E
Valve stem M
Valve stem seal M
Kickstarter pinion gear shaft LS
Idle gear shaft LS
Centerstand pivot LS
Sidestand pivot LS
Crankcase mating surfaces Yamaha bond No.1215
2 - 17
LUBRICATION POINTS AND LUBRICANT TYPES SPEC
CHASSIS
Lubrication point Lubricant

Front wheel oil seal lips LS
Rear wheel oil seal lips LS
Front wheel axle LS
Speedometer gear fitting area LS
Brake pad retaining bolt and boot LS
Brake cam pivot shaft and cam surface LS
Brake cable (brake lever) LS
Tube guide (throttle grip) inner surface LS
Throttle cable (throttle grip) LS
Starter cable (starter lever) LS
Steering head pipe bearing (upper/lower) LS
2 - 18
CABLE ROUTING SPEC
EAS00035
CABLE ROUTING
1 Right handlebar switch lead È Pass the left handlebar switch Ë Fasten the starter cable, speed-
2 Left handlebar switch lead lead behind the handlebar and ometer cable, rear brake cable,
3 Starter cable over the rear brake cable, and and throttle cable to the handle-
4 Rear brake cable then connect it in front of the bar with a plastic locking tie. Be
5 Rear brake light switch lead meter assembly. sure to position the plastic lock-
6 Speedometer cable É Connect the brake light switch ing tie over the handlebar pro-
7 Wire harness coupler in front of the rear brake jection and to position the lock
8 Front brake hose cable. of the tie in the handlebar slit.
9 Throttle cable Ê Pass the right handlebar switch Ì Less than 1 mm
0 Front brake light switch lead lead behind the handlebar, and
then connect it in front of the
meter assembly.
2
1
A A 4 3
Ê È
5
0 9 8 É
6
7
Ë
Ì
7 6
9 4 8
A-A
2 - 19
CABLE ROUTING SPEC
1 Rear brake cable 0 Horn lead
2 Throttle cable A Turn signal relay
3 Starter cable B Main switch lead
4 Air vent hose C Front brake hose
5 Fuel overflow hose
6 Battery È Do not pass the starter cable over the frame.
7 Speedometer cable É Fasten the wire harness with a plastic locking tie
8 Turn signal relay lead as shown.
9 Headlight unit assembly lead Ê Route the horn lead as shown.
C
Ê
0
B
A
8
0 É
A 7
9
1 3
B-B 2
B
B
8
A
C 1
2
C 3 4
È
3
1
C-C 2
2 - 20
CABLE ROUTING SPEC
1 Cylinder head breather hose È Use the holder to hold the vacuum hose and fuel
2 Fuel hose hose as shown.
3 Vacuum hose É Make sure that the metal clip does not interfere
4 Drain hose with the fuel hose, when clamping it to the vac-
5 A.C. magneto lead uum hose.
6 Rectifier/regulator lead Ê Make sure that the metal clip does not interfere
7 Rear brake cable with the vacuum hose, when clamping it to the
fuel hose.
3
2
Ê
A-A 2
3
É B
4
2 3
È
1
A B
6
5 É Ê
A
D C
E
E
D 7
C
7
7 7
E-E D-D C-C
2 - 21
CABLE ROUTING SPEC
1 Negative battery lead A Starter relay lead
2 Ground lead B Starter motor lead
3 Seat lock cable C Positive battery lead
4 Wire harness D Battery breather hose
5 Horn lead
6 Headlight unit assembly lead È Align the white tape of the wire harness with the
7 Main switch lead clamp.
8 Front brake hose
9 Starter relay
0 Main fuse
5
3
6
4 3 4
A-A B-B
4 A
7
3 8
2
1 B
E
D È
B
9
D
C C
0
A
B
C
D
1
4
1
D 4
B
B C B
E-E 4 D-D C-C
2 - 22
CABLE ROUTING SPEC
1 Fuel sender lead A Starter motor
2 Seat lock cable B C.D.I. unit
3 Wire harness C Tail/brake light unit assembly lead
4 Rectifier/regulator
5 Ignition coil
6 Rectifier/regulator lead
7 Spark plug lead
8 A.C. magneto lead
9 Negative battery lead
0 Starter motor lead
2
9
7
6
0
3 C-C
A-A
È 8
B-B
1
23
4 É
C
A
5 6
Ì Ê
7
8 9
B B 0
A
Ë
B
2 - 23
CABLE ROUTING SPEC
È Make sure that the rubber cover does not pinch Ë When installing the side cover (right), make sure
the seat lock cable and the fuel sender lead. that it does not pinch the wire harness.
É Pass the plastic locking tie between the rectifier/ Ì Place the tail/brake light unit assembly coupler
regulator bracket and ignition coil bracket, and between the frame and C.D.I. unit.
then fasten the wire harness and seat lock cable
with the tie.
Ê Make sure that the A.C. magneto coupler and
A.C. magneto lead are not pinched between the
rear fender and storage compartment.
2
9
7
6
0
3 C-C
A-A
È 8
B-B
1
23
4 É
C
A
5 6
Ì Ê
7
8 9
B B 0
A
Ë
B
2 - 24
CABLE ROUTING SPEC
1 Air vent hose A Throttle cable
2 Wire harness B Starter cable
3 Seat lock cable
4 Starter motor lead
6 Starter motor
7 Fuel hose
8 Vacuum hose
9 Drain hose
0 Cylinder head breather hose
4 5
A-A
B
9
2
8
7
A A
3
5
6
2 - 25
CABLE ROUTING SPEC
1 Starter motor lead È Install the plastic clip in the direction shown.
3 A.C. magneto lead
4 Rectifier/regulator lead
5 Wire harness
6 Fuel sender lead
7 Seat lock cable
8 Rear turn signal light lead
9 Tail/brake light lead
0 Fuel sender
È 1 2
8 8
2 - 26
CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION.............................................................................................. 3-1
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS .................... 3-1
SIDE COVER ...................................................................................................3-3

REMOVING THE SIDE COVER................................................................3-3
INSTALLING THE SIDE COVER .............................................................. 3-3
LEG SHIELD.................................................................................................... 3-4

REMOVING THE LEG SHIELD.................................................................3-4
INSTALLING THE LEG SHIELD ............................................................... 3-5
AIR FILTER CASE .......................................................................................... 3-6

REMOVING THE AIR FILTER CASE........................................................3-6
INSTALLING THE AIR FILTER CASE ......................................................3-6
ENGINE ...........................................................................................................3-7
ADJUSTING THE VALVE CLEARANCE .................................................. 3-7
ADJUSTING THE ENGINE IDLING SPEED .............................................3-9
ADJUSTING THE THROTTLE CABLE FREE PLAY ..............................3-11
CHECKING THE SPARK PLUG ............................................................. 3-13
MEASURING THE COMPRESSION PRESSURE..................................3-14
CHECKING THE ENGINE OIL LEVEL....................................................3-16
CHANGING THE ENGINE OIL ...............................................................3-17
CHANGING THE TRANSMISSION OIL.................................................. 3-18
CLEANING THE AIR FILTER ELEMENT................................................ 3-19
CHECKING THE V-BELT........................................................................3-20
CLEANING THE V-BELT CASE AIR FILTER ELEMENT .......................3-21
CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD...... 3-22
CHECKING THE FUEL AND VACUUM HOSE....................................... 3-23
CHECKING THE CYLINDERHEAD BREATHER HOSE ........................ 3-23
CHECKING THE EXHAUST SYSTEM....................................................3-24
CHK
ADJ
CHASSIS ....................................................................................................... 3-25
ADJUSTING THE REAR BRAKE............................................................ 3-25
CHECKING THE BRAKE FLUID LEVEL................................................. 3-25
CHECKING THE FRONT BRAKE PADS ................................................ 3-26
CHECKING THE REAR BRAKE SHOES................................................ 3-26
CHECKING THE FRONT BRAKE HOSE................................................ 3-27
BLEEDING THE HYDRAULIC BRAKE SYSTEM ................................... 3-27
CHECKING AND ADJUSTING THE STEERING HEAD ......................... 3-29
CHECKING THE FRONT FORK ............................................................. 3-30
CHECKING THE TIRES..........................................................................3-31
CHECKING AND TIGHTENING THE SPOKES...................................... 3-33
CHECKING AND LUBRICATING THE CABLES .................................... 3-34
LUBRICATING THE LEVERS .................................................................3-34
LUBRICATING THE SIDESTAND........................................................... 3-34
LUBRICATING THE CENTERSTAND ....................................................3-34
ELECTRICAL SYSTEM................................................................................. 3-35

CHECKING AND CHARGING THE BATTERY....................................... 3-35
CHECKING THE FUSE...........................................................................3-39
REPLACING THE HEADLIGHT BULBS ................................................. 3-41
ADJUSTING THE HEADLIGHT BEAMS................................................. 3-42
INTRODUCTION/PERIODIC MAINTENANCE AND CHK
LUBRICATION INTERVALS ADJ
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAS00037
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS

ODOMETER READING (× 1,000 km)
NO. ITEM CHECK OR MAINTENANCE JOB
0.5 2 4 8 12
• Check fuel hoses and vacuum hose for cracks or
1 * Fuel line
damage.
• Check condition.
2 Spark plug • Clean and regap.
• Replace if necessary.
• Check valve clearance.
3 * Valves
• Adjust.
4 Air filter element • Clean. Replace if necessary.
V-belt case air filter
5 • Clean. Replace if necessary.
elements
• Check electrolyte level and specific gravity.
6 * Battery • Make sure that the breather hose is properly
routed.
• Check operation, fluid level and vehicle for fluid
7 * Front brake leakage. (See NOTE on page 3-2.)
• Replace brake pads if necessary.
• Check operation and adjust brake lever free play.
8 * Rear brake
• Replace brake shoes if necessary.
• Check runout, spoke tightness and for damage.
9 * Wheels
• Tighten spokes if necessary.
10 * Wheel bearings • Check bearing for looseness or damage.
• Check operation and for excessive play.
11 * Swingarm • Lubricate with lithium-soap based grease, every
24,000 km.
• Check bearing play and steering for roughness.
12 * Steering bearings • Lubricate with lithium-soap-based grease, every
12,000 km.
• Make sure that all nuts, bolts and screws are
13 * Chassis fasteners
properly tightened.
Sidestand/ • Check operation.
14
centerstand • Lubricate.
15 * Sidestand switch • Check operation.
16 * Front fork • Check operation and for oil leakage.
Shock absorber • Check operation and shock absorbers for oil
17 *
assemblies leakage.
• Check starter (choke) operation.
18 * Carburetor
• Adjust engine idling speed.
• Change.
19 Engine oil Every 2,000 km
• Check oil level and vehicle for oil leakage.
20 * Engine oil strainer • Clean.
Final transmission • Check vehicle for oil leakage.

21
oil • Change. Every 10,000 km
3-1
PERIODIC MAINTENANCE AND LUBRICATION CHK
INTERVALS ADJ
ODOMETER READING (× 1,000 km)
NO. ITEM CHECK OR MAINTENANCE JOB
0.5 2 4 8 12
• Check the damage and wear.
22 * V-belt
• Replace. Every 25,000 km
Front and rear brake
23 * • Check operation.
switches
Moving parts and
24 • Lubricate.
cables
Lights, signals and • Check operation.
25 *
switches • Adjust headlight beam.
*Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.
NOTE:
_
• From 16,000 km, repeat the maintenance intervals starting from 4,000 km.
• Depending on riding conditions, the V-belt replacement interval may vary.
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake system
• After disassembling the brake master cylinder, and caliper cylinder, always change the fluid.
Regularly check the brake fluid level and fill reservoir as required.
• Replace the oil seals on the inner parts of the brake master cylinder and caliper cylinder every
two years.
• Replace the brake hose every four years or if cracked or damaged.
3-2
CHK
SIDE COVER ADJ
SIDE COVER
1
REMOVING THE SIDE COVER
1. Remove:
• side panel (left and right) 1
2. Open the seat.
3. Remove:
• rear panel 1
1
NOTE:
Remove the rear panel by sliding it in the
direction of the arrow shown.
4. Remove:
1 • side cover (left and right) 1
INSTALLING THE SIDE COVER

1 1. Install:
• side cover (left and right) 1
NOTE:
Before tightening the side cover screw and
bolts make sure that all hooks are securely fit-
ted.
2. Install:
• rear panel 1
1
3-3
CHK
SIDE COVER/LEG SHIELD ADJ
3. Install:
• side panel (left and right) 1
• side panel screws
NOTE:
Before tightening the side panel screws make
sure that all hooks are securely fitted.
LEG SHIELD
REMOVING THE LEG SHIELD
3 1. Remove:
• side cover (left and right)
Refer to “SIDE COVER”.
2. Remove:
2 • footboard mat (left and right) 1
• footboard (left and right) 2
1
NOTE:
Remove the battery breather hose 3 that
passes through the hole in the right footboard.
3. Remove:
• front cover 1
NOTE:
Disconnect the headlight unit assembly cou-
pler 2.
2
1
3-4
CHK
LEG SHIELD ADJ
4. Remove:
• seat 1
1
5. Remove:
1 • center cover 1
6. Remove:
• hook 1
• main switch cover 2
2
7. Remove:
• leg shield 1
INSTALLING THE LEG SHIELD

1. Install:
• leg shield
• main switch cover
• hook
• front cover 1
NOTE:
2 Connect the headlight unit assembly coupler
2.
1
2. Install:
• seat
• seat nuts 7 Nm (0.7 m • kg)
T.
R.
3-5
CHK
LEG SHIELD/AIR FILTER CASE ADJ
3.Install:
• footboard (left and right) 1
• footboard mat (left and right) 2
3
NOTE:
Pass the battery breather hose 3 through the
hole in the right footboard.
1
EASF0043
AIR FILTER CASE

REMOVING THE AIR FILTER CASE
1. Remove:
• side panel (left and right)
• footboard (left and right)
Refer to “LEG SHIELD”.
2. Loosen:
1
• screw (carburetor joint) 1
NOTE:
2 Remove the fuel overflow hose 2 and cylinder
head breather hose 3 that pass through the
hole in the air filter case.
3
3. Remove:
• air filter case 1
INSTALLING THE AIR FILTER CASE

1. Install:
• air filter case
• air filter case bolts 10 Nm (1.0 m • kg)
T.
R.
3-6
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
EAS00049
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
NOTE:
_
• Valve clearance adjustment should be made

on a cold engine, at room temperature.
• When the valve clearance is to be measured
or adjusted, the piston must be at top dead
center (TDC) on the compression stroke.
1. Remove:
• air filter case
Refer to “AIR FILTER CASE”.
2. Remove:
1 • tappet cover (intake side) 1
• tappet cover (exhaust side) 2
• cam sprocket cover 3
3
3. Remove:
• engine cooling fan cover 1
1
3-7
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
4. Measure:
• valve clearance
Out of specification → Adjust.
b
Valve clearance (cold)
Intake valve
0.08 ~ 0.12 mm
Exhaust valve
0.08 ~ 0.12 mm
a
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.
b. When the piston is at TDC on the compres-
d sion stroke, align the “I” mark a in the cam-
shaft sprocket with the stationary pointer b
on the cylinder head.
c. Align the TDC mark c on the generator
c
rotor with the stationary pointer d on the
crankcase.
d. Measure the valve clearance with a thick-
ness gauge 1.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Adjust:
• valve clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
12 a. Loosen the locknut 1.
b. Insert a thickness gauge 2 between the
end of the adjusting screw and the valve tip.
c. Turn the adjusting screw 3 in direction a
or b until the specified valve clearance is
obtained.
Valve clearance is
Direction a
increased.
Valve clearance is
Direction b
b decreased.
Tappet adjusting tool

90890-01311
a
3
3-8
ADJUSTING THE VALVE CLEARANCE/ CHK
ADJUSTING THE ENGINE IDLING SPEED ADJ
• Hold the adjusting screw to prevent it from
moving and tighten the locknut to specifica-
tion.
Locknut
7 Nm (0.7 m • kg)
T.
R.
d. Measure the valve clearance again.
e. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance adjust-
ment steps until the specified clearance is
obtained.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
• engine cooling fan cover
• engine cooling fan cover screws
7 Nm (0.7 m • kg)
T.
R.
7. Install:
1 New • cam sprocket cover
• cam sprocket cover bolts
12 Nm (1.2 m • kg)
T.
R.
• tappet cover (exhaust side)
• tappet cover (intake side)
18 Nm (1.8 m • kg)
T.
R.
• O-ring 1 New
8. Install:
• air filter case
Refer to “AIR FILTER CASE”.
EAS00054
ADJUSTING THE ENGINE IDLING SPEED
NOTE:
_
Prior to adjusting the engine idling speed, the

air filter element should be clean, and the
engine should have adequate compression.
1. Start the engine and let it warm up for sev-

eral minutes.
3-9
CHK
ADJUSTING THE ENGINE IDLING SPEED ADJ
2. Remove:
• side panel (right)
3. Connect:
• engine tachometer
(onto the spark plug lead)
Engine tachometer
90890-03113
4. Check:
• engine idling speed
Engine idling speed

1,500 ~ 1,700 r/min
5. Adjust:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the pilot screw 1 in or out until it is
lightly seated.
1 b. Turn the pilot screw out the specified num-
ber of turns.
Pilot screw setting

1-1/2 turns out
c. Remove the cap 2.

d. Turn the throttle stop screw 3 in direction
2 a or b until the specified engine idling
speed is obtained.
3 b Engine idling speed is

Direction a
increased.
a Engine idling speed is
Direction b
decreased.
e. Install the cap 2.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 10
ADJUSTING THE ENGINE IDLING SPEED/ CHK
ADJUSTING THE THROTTLE CABLE FREE PLAY ADJ
6. Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play (at the

flange of the throttle grip)
3 ~ 7 mm
7. Install:
EAS00058
ADJUSTING THE THROTTLE CABLE FREE
PLAY
NOTE:
_
Prior to adjusting the throttle cable free play,

the engine idling speed should be adjusted.
1. Check:
• throttle cable free play a
a Out of specification → Adjust.

3 ~ 7 mm
2. Remove:
• side panel (left)
3 - 11
CHK
ADJUSTING THE THROTTLE CABLE FREE PLAY ADJ
3. Adjust:
a2 1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Carburetor side
a. Loosen the locknut 1.
b b. Turn the adjusting nut 2 in direction a or
b until the specified throttle cable free play
is obtained.
Throttle cable free play

Direction a
is increased.
Direction b
is decreased.
c. Tighten the locknut.

NOTE:
_
If the specified throttle cable free play cannot

be obtained on the carburetor side of the
cable, use the adjusting nut on the handlebar
side.
Handlebar side
a. Pull the boot 1 off.
b b. Loosen the locknut 2.
c. Turn the adjusting nut 3 in direction a or
b until the specified throttle cable free play
1 2 is obtained.
3
a
Direction a
is increased.
Direction b
is decreased.
d. Tighten the locknut.

WARNING
_
After adjusting the throttle cable free play,

start the engine and turn the handlebar to
the right or left to ensure that this does not
cause the engine idling speed to change.
e. Pull the boot 1 in.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Install:
3 - 12
CHK
CHECKING THE SPARK PLUG ADJ
EAS00060
CHECKING THE SPARK PLUG
1. Remove:
2. Disconnect:
• spark plug cap
3. Remove:
• spark plug
CAUTION:
_
Before removing the spark plug, blow away

any dirt accumulated in the spark plug well
with compressed air to prevent it from fall-
ing into the cylinder.
4. Check:
• spark plug type
Incorrect → Replace.
Spark plug type (manufacturer)

CR7HSA (NGK)
5. Check:
• electrode 1
Damage/wear → Replace the spark plug.
• insulator 2
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
6. Clean:
• spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
• spark plug gap a
(with a wire thickness gauge)
Out of specification → Regap.
Spark plug gap

0.6 ~ 0.7 mm
3 - 13
CHECKING THE SPARK PLUG/ CHK
MEASURING THE COMPRESSION PRESSURE ADJ
8. Install:
• spark plug 13 Nm (1.3 m • kg)
T.
R.
NOTE:
_
Before installing the spark plug, clean the

spark plug and gasket surface.
9. Connect:
• spark plug cap
10.Install:
EAS00067
MEASURING THE COMPRESSION
PRESSURE
NOTE:
_
Insufficient compression pressure will result in

a loss of performance.
1. Measure:
• valve clearance
Refer to “ADJUSTING THE VALVE
CLEARANCE”.
2. Start the engine, warm it up for several min-
utes, and then turn it off.
3. Disconnect:
• spark plug cap
4. Remove:
• spark plug
CAUTION:
_
Before removing the spark plug, use com-

pressed air to blow away any dirt accumu-
lated in the spark plug well to prevent it
from falling into the cylinder.
3 - 14
CHK
MEASURING THE COMPRESSION PRESSURE ADJ
5. Install:
• compression gauge 1
1
Compression gauge
90890-03081
6. Measure:
• compression pressure
Out of specification → Refer to steps (c)
and (d).
Compression pressure (at sea

level)
Minimum
900 kPa (9.0 kg/cm2)
Standard
1,100 kPa (11.0 kg/cm2)
Maximum
1,230 kPa (13.0 kg/cm2)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “ON”.
b. With the throttle wide open, crank the
engine until the reading on the compression
gauge stabilizes.
WARNING
_
To prevent sparking, ground the spark plug

lead before cranking the engine.
c. If the compression pressure is above the

maximum specification, check the cylinder
head, valve surfaces, and piston crown for
carbon deposits.
Carbon deposits → Eliminate.
3 - 15
MEASURING THE COMPRESSION PRESSURE/ CHK
CHECKING THE ENGINE OIL LEVEL ADJ
d. If the compression pressure is below the
minimum specification, pour a teaspoonful
engine of oil into the spark plug bore and
measure again.
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
Reading Diagnosis
Piston ring(s) wear
Higher than with-
or damage →
out oil
Repair.
Piston, valves, cyl-
Same as without inder head gasket
oil or piston possibly
defective → Repair.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Install:
T.
R.
8. Connect:
• spark plug cap
9. Install:
EASF0070
CHECKING THE ENGINE OIL LEVEL
1. Stand the motorcycle on a level surface.
NOTE:
_
Make sure the motorcycle is upright.

3. Remove:
• dipstick 1
4. Check:
• engine oil level
The engine oil level should be between the
b minimum level mark a and maximum level
a mark b.
NOTE:
_
1 Before checking the engine oil level, wait a few

minutes until the oil has settled.
3 - 16
CHECKING THE ENGINE OIL LEVEL/ CHK
CHANGING THE ENGINE OIL ADJ
Below the minimum level mark → Add the
-20 -10 0 10 20 30 40 50 ˚C
recommended engine oil to the proper level.
SAE 10W-30 Recommended oil
Refer to the chart for the engine
SAE 10W-40
oil grade which is best suited
SAE 20W-40
for certain atmospheric temper-
atures.
SAE 20W-50
API standard
SE or higher grade
CAUTION:
_
Do not allow foreign materials to enter the

crankcase.

6. Check the engine oil level again.
EAS00075
CHANGING THE ENGINE OIL
1
2. Place a container under the engine oil drain
bolt.
3. Remove:
• dipstick 1
• engine oil drain bolt 2
(along with the gasket)
• engine oil drain plug 3
• O-ring
• spring 4
• engine oil strainer 5
NOTE:
2 3 When only changing the engine oil, remove
engine oil drain bolt only.
3 - 17
CHANGING THE ENGINE OIL/ CHK
CHANGING THE TRANSMISSION OIL ADJ
4. Drain:
• engine oil
(completely from the crankcase)
5. Check:
• engine oil strainer
Dirt → clean.
Damage → Replace.
6. Check:
• engine oil drain bolt gasket
Damage → Replace.
7. Install:
• engine oil drain bolt
20 Nm (2.0 m • kg)
T.
R.
• spring
• engine oil strainer
• engine oil drain plug
20 Nm (2.0 m • kg)
T.
R.
• O-ring
8. Fill:
• crankcase
(with the specified amount of the recom-
mended engine oil)
Quantity
Total amount
0.9 L
Periodic replacement
0.8 L
9. Install:
• dipstick
10.Start the engine, warm it up for several min-
11.Check:
• engine
(for engine oil leaks)
12.Check:
• engine oil level
Refer to “CHECKING THE ENGINE OIL
LEVEL”.
CHANGING THE TRANSMISSION OIL
2. Place a container under the transmission oil
drain bolt.
3 - 18
CHANGING THE TRANSMISSION OIL/ CHK
CLEANING THE AIR FILTER ELEMENT ADJ
3. Remove:
• transmission oil filler plug 1
• transmission oil drain bolt 2
4. Drain:
1 • transmission oil
(completely from the transmission case)
5. Check:
• transmission oil drain bolt gasket
Damage → Replace.
6. Install:
• transmission oil drain bolt
2 (along with the gasket)
22 Nm (2.2 m • kg)
T.
R.
7. Fill:
• transmission case
mended transmission oil)
Transmission oil
Engine oil
Quantity
Total amount
0.12 L
Periodic replacement
0.1 L
8. Install:
• transmission oil filler plug
EAS00086
CLEANING THE AIR FILTER ELEMENT
NOTE:
On the bottom of the air filter case is a check
hose 1. If dust or water or both collects in this
hose, clean the air filter element and air filter
1
case.
1. Remove:
2 2. Remove:
• air filter case cover 1
• air filter element
3 - 19
CLEANING THE AIR FILTER ELEMENT/ CHK
CHECKING THE V-BELT ADJ
3. Clean:
Apply compressed air to the outer surface
of the air filter element.
4. Check:
Damage → Replace.
5. Install:
• air filter case cover
CAUTION:
_
Never operate the engine without the air fil-

ter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the carburetor tuning, leading to poor
engine performance and possible overheat-
ing.
NOTE:
_
When installing the air filter element into the air

filter case cover, make sure their sealing sur-
faces are aligned to prevent any air leaks.
6. Install:
EAS00320
CHECKING THE V-BELT
1 1. Remove:
• V-belt case cover
Refer to “KICKSTARTER” in chapter 4.
2. Check:
a • V-belt 1
Cranks/damage/wear → Replace.
Grease/oil → Clean the primary and sec-
ondary pulleys.
Refer to “BELT DRIVE” in chapter 4.
3. Measure:
• V-belt width a
Out of specification → Replace.
Refer to “BELT DRIVE” in chapter 4.
V-belt width
18.2 mm
<Limit>: 17.2 mm
3 - 20
CHK
CLEANING THE V-BELT CASE AIR FILTER ELEMENT ADJ
EAS00091
CLEANING THE V-BELT CASE AIR FILTER
1
ELEMENT
NOTE:
On the bottom of the V-belt case cover is a
check hose 1. If dust or water or both collects
in this hose, clean the V-belt air filter elements.
1. Remove:
1
• V-belt case cover protector 1 1
• V-belt case air filter cover 2
• V-belt case air filter element 1 3

4 • V-belt case air filter element 2 4
3
2. Clean:
• V-belt case air filter element 1
Blow the compressed air to the outer sur-
face of the V-belt case air filter element.
3 - 21
CLEANING THE V-BELT CASE AIR FILTER ELEMENT/ CHK
CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD
ADJ
3. Check:
Damage → Replace.
CAUTION:
_
Since the V-belt case air filter element is a

dry type, do not let grease or water contact
it.
4. Install:
1 • V-belt case air filter element 1
• V-belt case air filter cover
• V-belt case air filter cover bolts
10 Nm (1.0 m • kg)
T.
R.
• V-belt case cover protector 1
• V-belt case cover protector 1 bolts
23 Nm (2.3 m • kg)
T.
R.
NOTE:
When installing the V-belt case cover protector
1, be sure to pass the V-belt case breather
hose 1 through the hole in the V-belt case
cover protector 1.
EAS00094
CHECKING THE CARBURETOR JOINT AND
INTAKE MANIFOLD
1. Remove:
2. Check:
1 • carburetor joint 1
2 • intake manifold 2
Cracks/damage → Replace.
Refer to “REMOVING THE ENGINE” in
chapter 4.
3 - 22
CHECKING THE CARBURETOR JOINT AND INTAKE MANIFOLD/
CHECKING THE FUEL AND VACUUM HOSE/ CHK
CHECKING THE CYLINDERHEAD BREATHER HOSE
ADJ
3. Install:
EAS00096
CHECKING THE FUEL AND VACUUM HOSE
1. Remove:
• side cover (left)
2. Check:
1 2 • vacuum hose 1
• fuel hose 2
3. Install:
• side cover (left)
EAS00098
CHECKING THE CYLINDERHEAD
BREATHER HOSE
1. Remove:
3 - 23
CHECKING THE CYLINDERHEAD BREATHER HOSE/ CHK
CHECKING THE EXHAUST SYSTEM ADJ
2. Check:
• cylinder head breather hose 1
1
CAUTION:
_
Make sure the cylinder head breather hose

is routed correctly.
3. Install:
EAS00100
CHECKING THE EXHAUST SYSTEM
1. Remove:
• footboard (right)
2. Check:
• muffler 1
Exhaust gas leaks → Replace the gasket.
3. Check:
• tightening torque
Muffler nut 3
3 1 20 Nm (2.0 m • kg)
T.
Muffler bolt 4
R.
35 Nm (3.5 m • kg)
4. Install:
3 • footboard (right)
3 - 24
ADJUSTING THE REAR BRAKE/ CHK
CHECKING THE BRAKE FLUID LEVEL ADJ
EAS00108
CHASSIS
EAS00114
ADJUSTING THE REAR BRAKE
1. Check:
• rear brake lever free play a
Rear brake lever free play

10 ~ 20 mm
2. Adjust:
• rear brake lever free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjusting nut 1 in direction a or
b until the specified brake lever free play is
obtained.
Brake lever free play is

Direction a
increased.
Brake lever free play is
Direction b
decreased.
CAUTION:
_
After adjusting the brake lever free play,

make sure there is no brake drag.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EASF0115
CHECKING THE BRAKE FLUID LEVEL
NOTE:
_
2. Check:
LOWER • brake fluid level
a Below the minimum level mark a → Add
the recommended brake fluid to the proper
level.
Recommended brake fluid

DOT 4
3 - 25
CHECKING THE BRAKE FLUID LEVEL/
CHECKING THE FRONT BRAKE PADS/ CHK
CHECKING THE REAR BRAKE SHOES
ADJ
WARNING
_
• Use only the designated brake fluid.

Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid
that is already in the system. Mixing
brake fluids may result in a harmful
chemical reaction, leading to poor brake
performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
CAUTION:
_
Brake fluid may damage painted surfaces

and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
NOTE:
_
In order to ensure a correct reading of the

brake fluid level, make sure the top of the
brake fluid reservoir is horizontal.
EASF0117
CHECKING THE FRONT BRAKE PADS
1. Operate the brake.
2. Check:
• front brake pad
Wear indicators 1 almost touch the brake
disc → Replace the brake pads as a set.
1 Refer to “REPLACING THE FRONT
BRAKE PADS” in chapter 6.
EASF0126
CHECKING THE REAR BRAKE SHOES
1. Operate the brake.
2. Check:
• wear indicator 1
Reaches the wear limit line 2 → Replace
the brake shoes as a set.
Refer to “CHECKING THE BRAKE” in
chapter 6.
1 2
3 - 26
CHECKING THE FRONT BRAKE HOSE/ CHK
BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ
EAS00129
CHECKING THE FRONT BRAKE HOSE
1. Check:
• brake hose
Cracks/damage/wear → Replace.
2. Check:
• brake hose clamp
Loose Connection → Tighten the clamp
bolt.
3. Hold the motorcycle upright and apply the
front brake several times.
4. Check:
• brake hose
Brake fluid leakage → Replace the dam-
aged hose.
Refer to “FRONT BRAKE” in chapter 6.
EAS00133
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNING
_
Bleed the hydraulic brake system when-

ever:
• the system is disassembled.
• a brake hose is loosened, disconnected
or replaced.
• the brake fluid level is very low.
• brake operation is faulty.
NOTE:
_
• Be careful not to spill any brake fluid or allow

the brake master cylinder reservoir to over-
flow.
• When bleeding the hydraulic brake system,
make sure there is always enough brake
fluid before applying the brake. Ignoring this
precaution could allow air to enter the
hydraulic brake system, considerably length-
ening the bleeding procedure.
• If bleeding is difficult, it may be necessary to
let the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the hose have disappeared.
3 - 27
CHK
BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ
1. Bleed:
• hydraulic brake system
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 2 a. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
b. Install the brake master cylinder reservoir
diaphragm.
c. Connect a clear plastic hose 1 tightly to the
bleed screw 2.
d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake lever several times.
f. Fully pull the brake lever without releasing
it.
g. Loosen the bleed screw.
NOTE:
_
Loosening the bleed screw will release the

pressure and cause the brake lever to contact
the throttle grip.
h. Tighten the bleed screw and then release

the brake lever.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
Bleed screw
6 Nm (0.6 m • kg)
T.
R.
k. Fill the brake fluid reservoir to the proper

level with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.
WARNING
_
After bleeding the hydraulic brake system,

check the brake operation.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3 - 28
CHK
CHECKING AND ADJUSTING THE STEERING HEAD ADJ
EASF0146
CHECKING AND ADJUSTING THE
STEERING HEAD
NOTE:
_
• Place the motorcycle on a suitable stand so

that the front wheel is elevated.
• Make sure the motorcycle is upright.
2. Check:
• steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding/looseness → Adjust the steering
head.
3. Remove:
• front cover
• leg shield
4. Adjust:
1 • steering head
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the upper ring nut 1.
b. Loosen the lower ring nut 2 and then
tighten it to specification with a steering nut
wrench 3.
NOTE:
_
Set the torque wrench at a right angle to the

steering nut wrench.
3
Steering nut wrench
2 90890-01403
Lower ring nut

30 Nm (3.0 m • kg)
T.
R.
3 - 29
CHECKING AND ADJUSTING THE STEERING HEAD/ CHK
CHECKING THE FRONT FORK ADJ
c. Loosen the lower ring nut a quarter turn.
5 d. Hold the lower ring nut with a ring nut
4 wrench 4 and tighten the upper ring nut 5
with a steering nut wrench.
Ring nut wrench

90890-01268
Upper ring nut

75 Nm (7.5 m • kg)
T.
R.
e. Check the steering head for looseness or
binding by turning the front fork all the way
in both directions. If any binding is felt,
remove the lower bracket and check the
upper and lower bearings.
Refer to “STEERING HEAD” in chapter 6.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Install:
• leg shield
• front cover
EASF0149
CHECKING THE FRONT FORK
NOTE:
_
2. Check:
• inner tube
Damage/scratches → Replace.
• oil seal
Oil leakage → Replace.
3. Hold the motorcycle upright and apply the
front brake.
4. Check:
• front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Rough movement → Repair.
Refer to “FRONT FORK” in chapter 6.
3 - 30
CHK
CHECKING THE TIRES ADJ
EASF0166
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Check:
• tire pressure
Out of specification → Regulate.
WARNING
_
• The tire pressure should only be checked

and regulated when the tire temperature
equals the ambient air temperature.
• The tire pressure and the suspension
must be adjusted according to the total
weight (including cargo, rider, passenger
and accessories) and the anticipated
riding speed.
• Operation of an overloaded motorcycle
could cause tire damage, an accident or
an injury.
NEVER OVERLOAD THE MOTORCYCLE.
Basic weight
(with oil and
103 kg
a full fuel
tank)
Maximum
116 kg
load*
Front Rear
Cold tire
200 kPa 225 kPa
pressure
(2.00 kgf/cm2) (2.25 kgf/cm2)
* Total weight of rider, passenger, cargo and
accessories
WARNING
_
It is dangerous to ride with a worn-out tire.

When the tire tread reaches the wear limit,
replace the tire immediately.
3 - 31
CHK
CHECKING THE TIRES ADJ
2. Check:
• tire surfaces
Damage/wear → Replace the tire.
Minimum tire tread depth

0.8 mm
1 Tire tread depth

2 Sidewall
3 Wear indicator
WARNING
_
• Do not use a tubeless tire on a wheel

designed only for tube tires to avoid tire
failure and personal injury from sudden
deflation.
• When using tube tires, be sure to install
the correct tube.
• Always replace a new tube tire and a new
tube as a set.
• To avoid pinching the tube, make sure the
wheel rim band and tube are centered in
the wheel groove.
• Patching a punctured tube is not recom-
mended. If it is absolutely necessary to
do so, use great care and replace the tube
as soon as possible with a good quality
replacement.
Tube wheel Tube tire only

Tube or tubeless
Tubeless wheel
tire
• After extensive tests, the tires listed
below have been approved by Yamaha
Motor Co., Ltd. for this model. The front
and rear tires should always be by the
same manufacturer and of the same
design. No guarantee concerning han-
dling characteristics can be given if a tire
combination other than one approved by
Yamaha is used on this motorcycle.
3 - 32
CHECKING THE TIRES/ CHK
CHECKING AND TIGHTENING THE SPOKES ADJ
WARNING
_
• New tires have a relatively low grip on the

road surface until they have been slightly
worn. Therefore, approximately 100 km
should be traveled at normal speed
before any high-speed riding is done.
• After a tire has been repaired or replaced,
be sure to tighten the tire air valve stem
locknut 1 to specification.
NOTE:
_
For tires with a direction of rotation mark 2:

• Install the tire with the mark pointing in the
direction of wheel rotation.
• Align the mark 3 with the valve installation
point.
EAS00169
CHECKING AND TIGHTENING THE
SPOKES
spokes.
1. Check:
• spoke 1
Bends/damage → Replace.
Loose → Tighten.
Tap the spokes with a screwdriver.
NOTE:
_
A tight spoke will emit a clear, ringing tone, a

loose spoke will sound flat.
2. Tighten:
• spoke
(with a spoke wrench 1)
3 Nm (0.3 m • kg)
T.
R.
NOTE:
_
Be sure to tighten the spokes before and after

break-in.
3 - 33
CHECKING AND LUBRICATING THE CABLES/
LUBRICATING THE LEVERS/LUBRICATING THE SIDESTAND/ CHK
LUBRICATING THE CENTERSTAND ADJ
EAS00170
CHECKING AND LUBRICATING THE
CABLES
inner and outer cables.
WARNING
_
Damaged outer cable may cause the cable

to corrode and interfere with its movement.
Replace damaged outer cable and inner
cables as soon as possible.
1. Check:
• outer cable
Damage → Replace.
2. Check:
• cable operation
Rough movement → Lubricate.
Recommended lubricant
Engine oil or a suitable cable
lubricant
NOTE:
_
Hold the cable end upright and pour a few

drops of lubricant into the cable sheath or use
a suitable lubricating device.
EAS00171
LUBRICATING THE LEVERS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers.
Lithium-soap-based grease
EAS00172
LUBRICATING THE SIDESTAND
moving parts of the sidestand.
EAS00173
LUBRICATING THE CENTERSTAND
moving parts of the centerstand.
3 - 34
CHK
CHECKING AND CHARGING THE BATTERY ADJ
EAS00176
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE
BATTERY
WARNING
_
Batteries generate explosive hydrogen gas

and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
• Wear protective eye gear when handling
or working near batteries.
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
• DO NOT SMOKE when charging or han-
dling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
3 - 35
CHK
1. Remove:
2 Refer to “SIDE COVER”.
• battery band 1
2. Disconnect:
3 • battery leads
(from the battery terminals)
1
CAUTION:
UPPER LEVEL
LOWER LEVEL
First, disconnect the negative battery lead

2, and then the positive lead 3.
3. Remove:
• battery
4. Check:
• electrolyte level
The electrolyte level should be between the
minimum level mark a and the maximum
level mark b.
Below the minimum level mark → Add dis-
tilled water to the proper level.
CAUTION:
_
Add only distilled water. Tap water con-

tains minerals which are harmful to the bat-
tery.
5. Check:
• specific gravity
Less than 1.280 → Recharge the battery.
Specific gravity
1.280 at 20°C
3 - 36
CHK
6. Charge:
• battery
Battery charging amperage and time

0.7 amps/10 hrs
WARNING
_
Do not quick charge a battery.
CAUTION:
_
• Loosen the battery sealing caps.

• Make sure the battery breather hose and
battery vent are free of obstructions.
• To ensure maximum performance, always
charge a new battery before using it.
• Do not use a high-rate battery charger.
They force a high-amperage current into
the battery quickly and can cause battery
overheating and battery plate damage.
• If it is impossible to regulate the charging
current on the battery charger, be careful
not to overcharge the battery.
• When charging a battery, be sure to
remove it from the motorcycle. (If charg-
ing has to be done with the battery
mounted on the motorcycle, disconnect
the negative lead from the battery termi-
nal.)
• To reduce the chance of sparks, do not
plug in the battery charger until the bat-
tery charger leads are connected to the
battery.
• Before removing the battery charger lead
clips from the battery terminals, be sure
to turn off the battery charger.
• Make sure the battery charger lead clips
are in full contact with the battery termi-
nal and that they are not shorted. A cor-
roded battery charger lead clip may
generate heat in the contact area and a
weak clip spring may cause sparks.
• If the battery becomes hot to the touch at
any time during the charging process,
disconnect the battery charger and let the
battery cool before reconnecting it. Hot
batteries can explode!
3 - 37
CHK
NOTE:
_
Replace the battery whenever:

• battery voltage does not rise to specification
or bubbles fail to rise during charging.
• sulphation of one or more battery cells
occurs (as indicated by the battery plates
turning white or material accumulating in the
bottom of the battery cell).
• specific gravity readings after a long, slow
charge indicate that one battery cell’s charge
is lower than the rest.
• warpage or buckling of the battery plates or
insulators is evident.
7. Check:
• battery breather hose and battery vent
Obstruction → Clean.
Damage → Replace.
8. Connect:
• battery breather hose 1
1 CAUTION:
UPPER LEVEL _
LOWER LEVEL
When checking the battery, make sure the
battery breather hose is properly installed
and routed correctly. If the battery breather
hose is positioned so as to allow electro-
lyte or hydrogen gas from the battery to
contact the frame, the motorcycle and its
finish may be damaged.
9. Check:
• battery terminals
Dirt → Clean with a wire brush.
3 - 38
CHECKING AND CHARGING THE BATTERY/ CHK
CHECKING THE FUSE ADJ
10.Connect:
1 • battery leads
(to the battery terminals)
1
CAUTION:
UPPER LEVEL
LOWER LEVEL
First, connect the positive battery lead 1,

install the battery, and then connect the
negative battery lead 2.
NOTE:
Pass the battery breather hose 3 through the
hole in the footboard (right).
2
3
1
11.Lubricate:
• battery terminals
Dielectric grease
12.Install:
• battery band
EASF0181
CHECKING THE FUSE
CAUTION:
_
To avoid a short circuit, always set the

main switch to “OFF” when checking or
replacing a fuse.
1. Remove:
• battery (without disconnect the battery
leads)
Refer to “CHECKING AND CHARGING
THE BATTERY”.
3 - 39
CHK
CHECKING THE FUSE ADJ
2. Check:
• fuse
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and
check the continuity.
NOTE:
_
Set the pocket tester selector to “Ω × 1”.
Pocket tester
90890-03112
b. If the pocket tester indicates “∞”, replace

the fuse.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Replace:
• blown fuse
WARNING
_
Never use a fuse with an amperage rating

other than that specified. Improvising or
using a fuse with the wrong amperage rat-
ing may cause extensive damage to the
electrical system, cause the lighting and
ignition systems to malfunction and could
possibly cause a fire.
4. Install:
• battery
THE BATTERY”.
3 - 40
CHK
REPLACING THE HEADLIGHT BULBS ADJ
EAS00183
REPLACING THE HEADLIGHT BULBS
1 The following procedure applies to both of the
headlight bulbs.
1.Remove:
• front cover
2. Remove:
• headlight bulb holder 1
3. Remove:
• headlight bulb 2
2 WARNING
_
Since the headlight bulb gets extremely

hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
4. Install:
• headlight bulb New
Secure the new headlight bulb with the
headlight bulb holder.
CAUTION:
_
Avoid touching the glass part of the head-

light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb and the luminous flux will be
adversely affected. If the headlight bulb
gets soiled, thoroughly clean it with a cloth
moistened with alcohol or lacquer thinner.
5. Install:
• headlight bulb holder
6. Install:
• front cover
3 - 41
CHK
ADJUSTING THE HEADLIGHT BEAMS ADJ
EAS00185
ADJUSTING THE HEADLIGHT BEAMS
1. Adjust:
1
• headlight beam (vertically)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the adjuster 1 in direction a or b.
Headlight beam is
Direction a
raised.
Headlight beam is low-
Direction b
ered.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
b
3 - 42
ENG
CHAPTER 4
OVERHAULING THE ENGINE
REMOVING THE ENGINE............................................................................... 4-1

ENGINE OIL .............................................................................................. 4-1
CARBURETOR ......................................................................................... 4-2
MUFFLER..................................................................................................4-2
REAR SHOCK ABSORBER BOLTS .........................................................4-2
WIRE, CABLE AND HOSE........................................................................ 4-3
SIDESTAND .............................................................................................. 4-3
ENGINE ASSEMBLY ................................................................................ 4-4
ENGINE INSTALLATION ................................................................................ 4-4

ENGINE ASSEMBLY ................................................................................ 4-4
SIDESTAND .............................................................................................. 4-4
WIRE, CABLE AND HOSE........................................................................ 4-4
REAR SHOCK ABSORBER BOLTS .........................................................4-5
MUFFLER..................................................................................................4-5
CARBURETOR ......................................................................................... 4-5
UNDER COVER ........................................................................................4-5
CYLINDER HEAD............................................................................................ 4-6

REMOVING THE CYLINDER HEAD.........................................................4-7
CHECKING THE CYLINDER HEAD .......................................................4-10
CHECKING TIMING CHAIN GUIDE .......................................................4-11
CHECKING THE TIMING CHAIN TENSIONER...................................... 4-12
INSTALLING THE CYLINDER HEAD .....................................................4-12
CAMSHAFT ................................................................................................... 4-16

REMOVING THE ROCKER ARMS AND CAMSHAFT............................ 4-17
CHECKING THE CAMSHAFTS ..............................................................4-18
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 4-18
CHECKING THE CAMSHAFT SPROCKET............................................4-20
CHECKING THE TAPPET COVERS AND
CAMSHAFT SPROCKET COVER ......................................................... 4-20
INSTALLING THE CAMSHAFTS AND ROCKER ARMS........................ 4-20
VALVES AND VALVE SPRINGS .................................................................4-22

REMOVING THE VALVES...................................................................... 4-23
CHECKING THE VALVES AND VALVE GUIDES ..................................4-24
CHECKING THE VALVE SEATS ............................................................ 4-26
CHECKING THE VALVE SPRINGS........................................................ 4-28
INSTALLING THE VALVES .................................................................... 4-29
ENG
CYLINDER AND PISTON.............................................................................. 4-31
REMOVING THE CYLINDER AND PISTON...........................................4-32
CHECKING THE PISTON PIN ................................................................4-33
CHECKING THE CYLINDER AND PISTON ...........................................4-34
CHECKING THE PISTON RINGS........................................................... 4-35
INSTALLING THE PISTON AND CYLINDER .........................................4-36
KICKSTARTER ............................................................................................. 4-38

REMOVING THE KICKSTARTER........................................................... 4-39
DISASSEMBLING THE KICKSTARTER SHAFT .................................... 4-39
CHECKING THE KICKSTARTER ........................................................... 4-40
ASSEMBLING THE KICKSTARTER.......................................................4-41
INSTALLING THE KICKSTARTER ......................................................... 4-41
BELT DRIVE.................................................................................................. 4-42

V-BELT, PRIMARY AND SECONDARY PULLEY ..................................4-42
REMOVING THE SECONDARY PULLEY AND V-BELT ........................ 4-44
REMOVING THE PRIMARY PULLEY.....................................................4-45
DISASSEMBLING THE SECONDARY PULLEY .................................... 4-46
CHECKING THE CLUTCH HOUSING ....................................................4-46
CHECKING THE CLUTCH SHOES ........................................................ 4-47
CHECKING THE V-BELT........................................................................4-47
CHECKING THE PRIMARY PULLEY WEIGHTS ................................... 4-48
CHECKING THE SECONDARY PULLEY............................................... 4-48
ASSEMBLING THE SECONDARY PULLEY ..........................................4-49
ASSEMBLING THE PRIMARY PULLEY................................................. 4-50
INSTALLING THE BELT DRIVE ............................................................. 4-52
STARTER CLUTCH ......................................................................................4-54

CHECKING THE STARTER CLUTCH ....................................................4-55
INSTALLING THE STARTER CLUTCH .................................................. 4-56
GENERATOR ................................................................................................4-57
REMOVING THE GENERATOR ............................................................. 4-58
INSTALLING THE GENERATOR............................................................ 4-60
OIL PUMP...................................................................................................... 4-62

REMOVING THE OIL PUMP................................................................... 4-63
DISASSEMBLING THE OIL PUMP......................................................... 4-63
CHECKING THE OIL PUMP ................................................................... 4-64
ASSEMBLING THE OIL PUMP...............................................................4-65
INSTALLING THE OIL PUMP .................................................................4-65
TRANSMISSION............................................................................................ 4-66
REMOVING THE TRANSMISSION ........................................................ 4-67
CHECKING THE TRANSMISSION ......................................................... 4-68
INSTALLING THE TRANSMISSION .......................................................4-68
ENG
CRANKSHAFT ..............................................................................................4-70
DISASSEMBLING THE CRANKCASE....................................................4-71
REMOVING THE CRANKSHAFT ASSEMBLY ....................................... 4-73
CHECKING THE CRANKCASE ..............................................................4-73
CHECKING THE BEARINGS.................................................................. 4-73
TIMING CHAIN GUIDE ...........................................................................4-74
CHECKING THE TIMING CHAIN............................................................ 4-74
CHECKING THE CRANKSHAFT AND CONNECTING ROD ................. 4-74
INSTALLING THE CRANKSHAFT .......................................................... 4-75
ASSEMBLING THE CRANKCASE.......................................................... 4-75
ENG
REMOVING THE ENGINE ENG
EASF0188
OVERHAULING THE ENGINE

REMOVING THE ENGINE
NOTE:
It is not necessary to remove the engine in
order to remove the following components.
• Cylinder head
• Cylinder
• Piston
• Starter clutch
• Starter motor
• Kickstarter shaft
• V-belt
• Primary pulley
• Secondary pulley
• Transmission
• Rear wheel assembly
• Oil pump
• Generator
1. Remove:
Refer to “SIDE COVER” in chapter 3.
• leg shield
Refer to “LEG SHIELD” in chapter 3.
2. Remove:
• under cover 1
1 WARNING
Securely support the motorcycle so there
is no danger of it falling over.
ENGINE OIL
1. Drain:
• engine oil
Refer to “CHANGING THE ENGINE OIL” in
chapter 3.
4-1
CARBURETOR
1. Remove:
• carburetor assembly
Refer to “CARBURETOR” in chapter 5.
MUFFLER
1 1. Remove:
• muffler nuts 1
2. Remove:
• muffler bolts 1
• muffler 2
1 2
REAR SHOCK ABSORBER BOLTS

1. Remove:
2. Remove:
• rear shock absorber lower bolts 1
1 1
4-2
WIRE, CABLE AND HOSE
1. Remove:
• spark plug cap 1
2. Disconnect:
• A.C. magneto couplers 1
• starter motor lead 2
• negative battery lead 3
1
3. Remove:
3 • plastic clip 4
2 4
4. Disconnect:
2 • vacuum hose 2
5. Remove:
• rear brake cable 1
• rear brake cable holder 2
2 1
SIDESTAND
1. Remove:
• sidestand 1
4-3
ENGINE INSTALLATION ENG
ENGINE ASSEMBLY
1. Remove:
• nut 1
• mounting bolt 2
• washer
1 • engine assembly
2
ENGINE INSTALLATION
ENGINE ASSEMBLY
WARNING
Securely support the motorcycle so there
is no danger of it falling over when install-
ing engine.
1. Install:
• engine assembly
• washer
• mounting bolt
• nut 59 Nm (5.9 m • kg)
T.
R.
SIDESTAND
1. Install:
• sidestand 32 Nm (3.2 m • kg)
T.
R.
WIRE, CABLE AND HOSE

1. Install:
• rear brake cable holder
• rear brake cable holder screws
7 Nm (0.7 m • kg)
T.
R.
• rear brake cable

2. Connect:
• vacuum hose
• cylinder head breather hose
3. Connect:
• negative battery lead
• starter motor lead
• A.C. magneto couplers
4. Install:
• plastic clip
5. Install:
• spark plug cap
4-4
ENGINE INSTALLATION ENG
REAR SHOCK ABSORBER BOLTS
1. Install:
• rear shock absorber lower bolts
16 Nm (1.6 m • kg)
T.
R.
2. Install:
23 Nm (2.3 m • kg)
T.
R.
MUFFLER
1. Install:
• muffler
• muffler bolts 35 Nm (3.5 m • kg)
T.
R.
• muffler nuts 20 Nm (2.0 m • kg)
T.
R.
CARBURETOR
1. Install:
UNDER COVER
1. Install:
• under cover
2. Install:
• leg shield
3. Fill:
• engine oil
chapter 3.
4. Adjust:
• rear brake cable free play
CABLE FREE PLAY” and “ADJUSTING
THE REAR BRAKE” in chapter 3.

(at the flange of the throttle grip)
3 ~ 7 mm
10 ~ 20 mm
4-5
CYLINDER HEAD ENG
EASF0221
CYLINDER HEAD
1 Cylinder head 7 Timing chain guide C O-ring

2 Spark plug (exhaust side) D Intake manifold
3 O-ring 8 O-ring E Air shroud
4 Tappet cover 9 Camshaft sprocket cover F Rubber cover
5 Camshaft sprocket 0 Dowel pin G Air duct
6 Plate A Gasket H Timing chain tensioner
B Gasket I Gasket
G 8 Nm (0.8 m • kg)
T.
R.
9 Nm (0.9 m • kg)
T.
R.
10 Nm (1.0 m • kg)
T.
R.
H
I
E
New
F
D
LS C
New E
B
13 Nm (1.3 m • kg)
T.
R.
18 Nm (1.8 m • kg)
4
T.
R.
3 New
2 A
1 0
30 Nm (3.0 m • kg)
T.
R.
3 5
4 6
10 Nm (1.0 m • kg) 7
T.
R.
22 Nm (2.2 m • kg)
T.
R.
10 Nm (1.0 m • kg)
T.
R.
LS 8
9
12 Nm (1.2 m • kg)
T.
R.
4-6
CYLINDER HEAD ENG
EASF0225
REMOVING THE CYLINDER HEAD

1. Remove:
• side cover
• center cover
2. Remove:
1 • fuel tank cap 1
2
• fuel tank cover 2
3
• storage compartment 3
NOTE:
• After removing the fuel tank cover, immedi-
ately install the fuel tank cap on fuel tank.
• Unfasten the A.C. magneto lead 4.
3. Remove:
4. Remove:
• muffler
Refer to “REMOVING THE ENGINE”.
5. Remove:
• engine cooling fan
Refer to “GENERATOR”.
6. Remove:
• spark plug cap 1
• spark plug 2
1
2
4-7
CYLINDER HEAD ENG
7. Remove:
• tappet cover (intake side) 1
1
• tappet cover (exhaust side) 2
• camshaft sprocket cover 3
3
8. Remove:
• air duct 1
• rubber cover 2
1
2
9. Remove:
• intake manifold 1
10.Remove:
• air shroud (left) 1
• air shroud (right) 2
2
4-8
CYLINDER HEAD ENG
11.Align:
• “I” mark a on the generator rotor
b
(with the stationary pointer b on the crank-
case)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
b. When the piston is at TDC on the compres-
sion stroke, align the “I” mark c on the
a camshaft sprocket with the stationary
pointer d on the cylinder head.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
12.Loosen:
• bolt 1
NOTE:
_
While holding the generator rotor with the rotor

holding tool 2, loosen the bolt 1.
2
1
Rotor holding tool
90890-01235
13.Remove:
• timing chain tensioner 1
1
• bolt 2
• camshaft sprocket plate 3
• camshaft sprocket 4
• timing chain 5
NOTE:
_
To prevent the timing chain from falling into the

crankcase, fasten it with a wire.
4
5
4-9
CYLINDER HEAD ENG
14.Remove:
• cylinder head
2
NOTE:
_
6 4 • Loosen the bolts and nuts in the proper

sequence as shown.
• Loosen each bolt and nut a 1/2 turn at a time.
3 After all of the bolts and nuts are fully loos-
5 1
ened, remove them.
15.Remove:
1 • dowel pins 1
• gasket 2
• timing chain guide (exhaust side) 3
2
EAS00227
CHECKING THE CYLINDER HEAD

1. Eliminate:
• combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
_
Do not use a sharp instrument to avoid damag-

ing or scratching:
• spark plug bore threads
• valve seats
2. Check:
• cylinder head
Damage/scratches → Replace.
4 - 10
CYLINDER HEAD ENG
3. Measure:
• cylinder head warpage
Out of specification → Resurface the cylin-
der head.
Maximum cylinder head warpage

0.05 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge 1 and a thickness
gauge 2 across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylin-
der head as follows.
d. Place a 400 ~ 600 grit wet sandpaper on
the surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
NOTE:
_
To ensure an even surface, rotate the cylinder

head several times.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING TIMING CHAIN GUIDE

1. Check:
• timing chain guide (exhaust side)
Damage/wear → Replace.
4 - 11
CYLINDER HEAD ENG
EAS00210
CHECKING THE TIMING CHAIN

TENSIONER
1. Check:
• timing chain tensioner
2. Check:
• one-way cam operation
Rough movement → Replace the timing
chain tensioner housing.
3. Check:
• cap bolt
• spring
• one-way cam
• timing chain tensioner rod
Damage/wear → Replace the defective
part(s).
EAS00231
INSTALLING THE CYLINDER HEAD

2 1. Install:
• timing chain guide (exhaust side) 1
• dowel pins 2
New 3 • gasket 3 New
2. Install:
• cylinder head
3. Tighten:
1 5
3 • cylinder head nuts 22 Nm (2.2 m • kg)
T.
R.
• cylinder head bolts 10 Nm (1.0 m • kg)

T.
R.
NOTE:
4
_
6 • Lubricate the cylinder head nuts with engine

2
oil.
• Tighten the cylinder head nuts and bolts in
the proper tightening sequence as shown
and torque them in two stages.
4 - 12
CYLINDER HEAD ENG
4. Install:
1 • camshaft sprocket 1
• timing chain 2
d
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
c b. Align the “I” mark a on the generator rotor
with the stationary pointer b on the crank-
2
case.
c. Align the “I” mark c on the camshaft
sprocket with the stationary pointer d on
the cylinder head.
d. Install the timing chain onto the camshaft
b sprocket, and then install the camshaft
sprocket onto the camshaft.
NOTE:
_
• When installing the camshaft sprocket, be

sure to keep the timing chain as tight as pos-
sible on the exhaust side.
a • Align the projection e on the camshaft
sprocket with the slot in the camshaft.
e CAUTION:
_
Do not turn the crankshaft when installing

the camshaft to avoid damage or improper
valve timing.
e. While holding the camshaft, temporarily

tighten the camshaft sprocket bolt.
f. Remove the wire from the timing chain.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4 - 13
CYLINDER HEAD ENG
5. Install
• timing chain tensioner
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the cap bolt 1 and spring 2.
b. Release the timing chain tensioner one-way
cam 3 and push the timing chain tensioner
rod 4 all the way into the timing chain ten-
sioner housing.
c. Install the timing chain tensioner and gasket
5 onto the cylinder.
Timing chain tensioner bolt

9 Nm (0.9 m • kg)
T.
R.
d. Install the spring 2 and cap bolt 1.
Cap bolt
8 Nm (0.8 m • kg)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Tighten:
• camshaft sprocket bolt
30 Nm (3.0 m • kg)
T.
R.
CAUTION:
_
Be sure to tighten the camshaft sprocket

bolt to the specified torque to avoid the
possibility of the bolts coming loose and
damaging the engine.
7. Turn:
• crankshaft
(several turns clockwise)
4 - 14
CYLINDER HEAD ENG
8. Check:
• “I” mark a
b
Align the “I” mark on the generator rotor
with the stationary pointer b on the crank-
case.
• “I” mark c
Align the “I” mark on the camshaft sprocket
with the stationary pointer d on the cylinder
a head.
Out of alignment → Correct.
Refer to the installation steps above.
9. Measure:
• valve clearance
Refer to “ADJUSTING THE VALVE
CLEARANCE” in chapter 3.
10.Install:
• intake manifold
• intake manifold bolts
10 Nm (1.0 m • kg)
T.
R.
11.Install:
• tappet cover (exhaust side)
• tappet cover (intake side)
18 Nm (1.8 m • kg)
T.
R.
• camshaft sprocket cover

• camshaft sprocket cover bolts
12 Nm (1.2 m • kg)
T.
R.
12.Install:
T.
R.
4 - 15
CAMSHAFT ENG
EASF0193
CAMSHAFT
1 Locknut 5 Rocker arm shaft (intake side)

2 Adjusting screw 6 Rocker arm shaft (exhaust side)
3 Rocker arm (intake side) 7 Camshaft
4 Rocker arm (exhaust side) 8 Camshaft retainer
1 2
3
7 Nm (0.7 m • kg)
T.
R.
8
4
E 12 Nm (1.2 m • kg)
2
T.
R.
6
1
M
4 - 16
CAMSHAFT ENG
EASF0202
REMOVING THE ROCKER ARMS AND

2 CAMSHAFT
1 NOTE:
Prior to remove the rocker arms and camshaft,
remove the cylinder head.
1. Loosen:
• locknuts 1
• adjusting screws 2
2. Remove:
• camshaft retainer 1
1
3. Remove:
• camshaft assembly 1
1 NOTE:
_
Screw 8 mm bolt 2 into the threaded end of

2 the camshaft and then pull out the camshaft.
4. Remove:
• rocker arm shaft (intake side)
1 • rocker arm shaft (exhaust side)
• rocker arm (intake side)
• rocker arm(exhaust side)
NOTE:
_
Remove the rocker arm shafts with the slide

hammer 1.
Slide hammer bolt

90890-01085
Weight
90890-01084
4 - 17
CAMSHAFT ENG
EAS00205
CHECKING THE CAMSHAFTS

1. Check:
• camshaft lobes
Blue discoloration/pitting/scratches →
Replace the camshaft.
2. Measure:
• cam lobe dimensions a and b
Out of specification → Replace the cam-
shaft.
Cam lobe dimension

Intake
a 25.881 ~ 25.981 mm
<Limit>: 25.780 mm
b 21.195 ~ 21.295 mm
<Limit>: 21.095 mm
Exhaust
a 25.841 ~ 25.941 mm
<Limit>: 25.740 mm
b 21.050 ~ 21.150 mm
<Limit>: 20.950 mm
3. Check:
• camshaft oil passage
Obstruction → Blow out with compressed
air.
EAS00206
CHECKING THE ROCKER ARMS AND

ROCKER ARM SHAFTS
rocker arms and rocker arm shafts.
1. Check:
• rocker arm
4 - 18
CAMSHAFT ENG
2. Check:
• rocker arm shaft
Blue discoloration/excessive wear/pitting/
scratches → Replace or check the lubrica-
tion system.
3. Measure:
• rocker arm inside diameter
Rocker arm inside diameter

10.000 ~ 10.015 mm
<Limit>: 10.030 mm
4. Measure:
• rocker arm shaft outside diameter
Rocker arm shaft outside diame-

ter
9.981 ~ 9.991 mm
<Limit>: 9.950 mm
5. Calculate:
• rocker-arm-to-rocker-arm-shaft clearance
NOTE:
_
Calculate the clearance by subtracting the

rocker arm shaft outside diameter from the
rocker arm inside diameter.
Above 0.08 mm → Replace the defective

part(s).
Rocker-arm-to-rocker-arm-shaft
clearance
0.009 ~ 0.034 mm
<Limit>: 0.08 mm
4 - 19
CAMSHAFT ENG
EAS00207
CHECKING THE CAMSHAFT SPROCKET

1. Check:
• camshaft sprocket
More than 1/4 tooth wear a → Replace the
camshaft sprocket and the timing chain as a
set.
a 1/4 tooth
b Correct
1 Timing chain roller
2 Camshaft sprocket
EAS00212
CHECKING THE TAPPET COVERS AND

CAMSHAFT SPROCKET COVER
tappet covers and O-rings.
1. Check:
• tappet cover
• camshaft sprocket cover
• O-ring
part(s).
EAS00219
INSTALLING THE CAMSHAFTS AND

ROCKER ARMS
1. Lubricate:
• camshaft journals
Engine oil
4 - 20
CAMSHAFT ENG
2. Install:
• camshaft assembly 1
1
3. Lubricate:
• rocker arm shafts
Molybdenum disulfide oil
4. Install:
• rocker arm (exhaust side)
• rocker arm (intake side)
M • rocker arm shaft (exhaust side)
• rocker arm shaft (intake side)
5. Install:
• camshaft retainer 1
1 • camshaft retainer bolt
12 Nm (1.2 m • kg)
T.
R.
NOTE:
_
Install the camshaft retainer with the folded

side facing inward.
4 - 21
VALVES AND VALVE SPRINGS ENG
EASF0236
VALVES AND VALVE SPRINGS
1 Valve cotter
2 Upper spring seat
3 Valve spring
4 Valve stem seal
5 Lower spring seat
6 Valve (intake side)
7 Valve (exhaust side)
1
2
4
New
5
M
7
New
5
4
3
2
1
4 - 22
EASF0237
REMOVING THE VALVES

NOTE:
Prior to remove the valves, remove the cylin-
der head, rocker arm and camshaft.

valves and related components.
NOTE:
_
Before removing the internal parts of the cylin-

der head (e.g., valves, valve springs, valve
seats), make sure the valves properly seal.
1. Check:
• valve sealing
Leakage at the valve seat → Check the
valve face, valve seat, and valve seat width.
Refer to “CHECKING THE VALVE SEATS”.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Pour a clean solvent a into the intake and
exhaust ports.
b. Check that the valves properly seal.
NOTE:
_
There should be no leakage at the valve seat

1.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Remove:
• valve cotters 1
NOTE:
_
Remove the valve cotters by compressing the

valve spring with the valve spring compressor
2.

90890-01253
4 - 23
4. Remove:
• upper spring seat 1
• valve spring 2
• valve stem seal 3
• lower spring seat 4
• valve 5
NOTE:
_
Identify the position of each part very carefully

so that it can be reinstalled in its original place.
EAS00239
CHECKING THE VALVES AND VALVE

GUIDES
valves and valve guides.
1. Measure:
• valve-stem-to-valve-guide clearance
Valve-stem-to-valve-guide clearance =
Valve guide inside diameter a –
Valve stem diameter b
Out of specification → Replace the valve

guide.
Valve-stem-to-valve-guide
clearance
Intake
0.015 ~ 0.042 mm
<Limit>: 0.080 mm
Exhaust
0.030 ~ 0.057 mm
<Limit>: 0.110 mm
4 - 24
2. Replace:
• valve guide
NOTE:
_
To ease valve guide removal and installation,

and to maintain the correct fit, heat the cylinder
head to 100°C in an oven.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve guide with the valve
guide remover 1.
b. Install the new valve guide with the valve
guide installer 2 and valve guide remover
1.
c. After installing the valve guide, bore the
valve guide with the valve guide reamer 3
to obtain the proper valve-stem-to-valve-
guide clearance.
NOTE:
_
After replacing the valve guide, reface the

valve seat.
Valve guide remover (5 mm)

90890-04097
Valve guide installer (5 mm)
90890-04098
Valve guide reamer (5 mm)
90890-04099
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
• carbon deposits
(from the valve face and valve seat)
4. Check:
• valve face
Pitting/wear → Grind the valve face.
• valve stem end
Mushroom shape or diameter larger than
the body of the valve stem → Replace the
valve.
5. Measure:
• valve margin thickness a
Out of specification → Replace the valve.
Valve margin thickness

Intake: 0.7 mm
Exhaust: 1.0 mm
4 - 25
6. Measure:
• valve stem runout
Out of specification → Replace the valve.
NOTE:
_
• When installing a new valve, always replace

the valve guide.
• If the valve is removed or replaced, always
replace the oil seal.
Valve stem runout

0.01 mm
EAS00240
CHECKING THE VALVE SEATS

valves and valve seats.
1. Eliminate:
• carbon deposits
(from the valve face and valve seat)
2. Check:
• valve seat
Pitting/wear → Replace the cylinder head.
3. Measure:
• valve seat width a
Out of specification → Replace the cylinder
head.
Valve seat width

Intake: 0.9 ~ 1.1 mm
Exhaust: 0.9 ~ 1.1 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply Mechanic’s blueing dye (Dykem) b
onto the valve face.
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 impres-
sion.
d. Measure the valve seat width.
4 - 26
NOTE:
_
Where the valve seat and valve face contacted

one another, the blueing will have been
removed.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Lap:
• valve face
• valve seat
NOTE:
_
After replacing the cylinder head or replacing

the valve and valve guide, the valve seat and
valve face should be lapped.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound a to the
valve face.
CAUTION:
_
Do not let the lapping compound enter the

gap between the valve stem and the valve
guide.
b. Apply molybdenum disulfide oil onto the

valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all
of the lapping compound.
NOTE:
_
For the best lapping results, lightly tap the

valve seat while rotating the valve back and
forth between your hands.
e. Apply a fine lapping compound to the valve

face and repeat the above steps.
f. After every lapping procedure, be sure to
clean off all of the lapping compound from
the valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) b
onto the valve face.
4 - 27
h. Install the valve into the cylinder head.
i. Press the valve through the valve guide and
onto the valve seat to make a clear impres-
sion.
j. Measure the valve seat width c again. If
the valve seat width is out of specification,
reface and lap the valve seat.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00241
CHECKING THE VALVE SPRINGS

valve springs.
1. Measure:
• valve spring free length a
spring.
Valve spring free length

Intake valve spring
35.44 mm
<Limit>: 34.00 mm
Exhaust valve spring
35.44 mm
<Limit>: 34.00 mm
2. Measure:
• compressed valve spring force a
spring.
b Installed length
Compressed valve spring force

(installed)
Intake and exhaust valve spring
14.9 ~ 17.1 kg at 24.10 mm
3. Measure:
• valve spring tilt a
spring.
Spring tilt limit

Intake and exhaust valve spring
2.5°/1.5 mm
4 - 28
EAS00245
INSTALLING THE VALVES

valves and related components.
1. Deburr:
• valve stem end
(with an oil stone)
2. Lubricate:
• valve stem 1
• valve stem seal 2
(with the recommended lubricant)
Molybdenum disulfide oil
3. Install:
• valve 1
• lower spring seat 2
• valve stem seal 3 New
• valve spring 4
• upper spring seat 5
(into the cylinder head)
NOTE:
_
Install the valve spring with the larger pitch a

facing up.
a Larger pitch
b Smaller pitch
4. Install:
• valve cotters 1
NOTE:
_
Install the valve cotters by compressing the

valve spring with the valve spring compressor
2.

90890-01253
4 - 29
5. To secure the valve cotters onto the valve
stem, lightly tap the valve tip with a soft-face
hammer.
CAUTION:
_
Hitting the valve tip with excessive force

could damage the valve.
4 - 30
CYLINDER AND PISTON ENG
EASF0251
CYLINDER AND PISTON
1 Top ring 6 Piston pin circlip

2 2nd ring 7 Cylinder
3 Oil ring 8 Cylinder gasket
4 Piston 9 Dowel pin
5 Piston pin
New
8
E
6
New 7
3
2 6
1
4 5
New
4 - 31
EASF0253
REMOVING THE CYLINDER AND PISTON

NOTE:
Prior to remove the cylinder and piston,
1 remove the cylinder head.
1. Remove:
• cylinder 1
2. Remove:
1 • dowel pins 1
• gasket 2
3. Remove:
• piston pin clip 1
• piston pin 2
• piston 3
CAUTION:
_
Do not use a hammer to drive the piston

2 3
pin out.
1
NOTE:
_
• Before removing the piston pin clip, cover the

crankcase opening with a clean rag to pre-
vent the piston pin clip from falling into the
crankcase.
• Before removing the piston pin, deburr the
piston pin clip’s groove and the piston’s pin
bore area. If both areas are deburred and the
piston pin is still difficult to remove, remove it
with the piston pin puller set.
4. Remove:
• top ring
• 2nd ring
• oil ring
NOTE:
_
When removing a piston ring, open the end

gap with your fingers and lift the other side of
the ring over the piston crown.
4 - 32
EAS00265
CHECKING THE PISTON PIN

1. Check:
• piston pin
Blue discoloration/grooves → Replace the
piston pin and then check the lubrication
system.
2. Measure:
• piston pin bore inside diameter
Out of specification → Replace the piston.
Piston pin bore inside diameter

15.002 ~ 15.013 mm
<Limit>: 15.043 mm
3. Measure:
• piston pin outside diameter
Out of specification → Replace the piston
pin.
Piston pin outside diameter

14.995 ~ 15.000 mm
<Limit>: 14.975 mm
4. Calculate:
• piston-pin-to-piston-pin-bore clearance
pin and piston as a set.
Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter –
Piston pin outside diameter
Piston-pin-to-piston clearance
0.002 ~ 0.018 mm
<Limit>: 0.068 mm
4 - 33
EAS00255
CHECKING THE CYLINDER AND PISTON

1. Check:
• piston wall
• cylinder wall
Vertical scratches → Rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
2. Measure:
• piston-to-cylinder clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure cylinder bore “C” with the cylinder
bore gauge.
NOTE:
_
Measure cylinder bore “C” by taking side-to-

side and front-to-back measurements of the
cylinder. Then, find the average of the mea-
surements.
Cylinder bore “C” 50.000 ~ 50.010 mm

Taper limit “T” 0.05 mm
Out-of-round “R” 0.05 mm
“C” = maximum of D1 ~ D2
“T” = maximum of D1 or D2 - maximum of
D5 or D6
“R” = maximum of D1, D3 or D5 - minimum
of D2, D4 or D6
b. If out of specification, rebore or replace the
rings as a set.
c. Measure piston skirt diameter “P” with the
micrometer.
a 5 mm from the bottom edge of the piston
Piston size “P”

Standard 49.970 ~ 49.985 mm
d. If out of specification, replace the piston and
piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” -
Piston skirt diameter “P”
4 - 34
Piston-to-cylinder clearance
0.015 ~ 0.040 mm
<Limit>: 0.15 mm
f. If out of specification, rebore or replace the

rings as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00263
CHECKING THE PISTON RINGS

1. Measure:
• piston ring side clearance
and piston rings as a set.
NOTE:
_
Before measuring the piston ring side clear-

ance, eliminate any carbon deposits from the
piston ring grooves and piston rings.
Piston ring side clearance

Top ring
0.03 ~ 0.07 mm
<Limit>: 0.12 mm
2nd ring
0.02 ~ 0.06 mm
<Limit>: 0.12 mm
2. Install:
• piston ring
(into the cylinder)
a NOTE:
_
Level the piston ring into the cylinder with the

piston crown.
a 5.0 mm
3. Measure:
• piston ring end gap
ring.
NOTE:
_
The oil ring expander spacer’s end gap cannot

be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings.
4 - 35
Piston ring end gap
Top ring
0.10 ~ 0.25 mm
<Limit>: 0.50 mm
2nd ring
0.10 ~ 0.25 mm
<Limit>: 0.60 mm
Oil ring
0.20 ~ 0.70 mm
EAS00267
INSTALLING THE PISTON AND CYLINDER

1. Install:
• top ring 1
• 2nd ring 2
• oil ring 3
NOTE:
_
• Be sure to install the piston rings so that the

manufacturer’s marks or numbers face up.
• The piston rings that have and “R” mark must
be installed into the top ring groove.
• The piston rings that have and “RN” mark
must be installed into the 2nd ring groove.
2. Install:
• piston 1
• piston pin 2
• piston pin clip 3 New
NOTE:
_
a • Apply engine oil the piston pin.

2 1 • Make sure the arrow mark a on the piston
points towards the exhaust side of the cylin-
3 New der.
• Before installing the piston pin clip, cover the
crankcase opening with a clean rag to pre-
vent the clip from falling into the crankcase.
4 - 36
3. Install:
2 • gasket 1 New
• dowel pins 2
4. Lubricate:
New 1 • piston
• piston rings
• cylinder
Engine oil
5. Offset:
• piston ring end gaps
a Top ring
b Lower oil ring rail
c Upper oil ring rail
d 2nd ring
È exhaust
6. Install:
• cylinder 1
NOTE:
_
• While compressing the piston rings with one

1 hand, install the cylinder with the other hand.
• Pass the timing chain and timing chain guide
(intake side) through the timing chain cavity.
4 - 37
KICKSTARTER ENG
EASF0338
KICKSTARTER
1 V-belt case cover protector 1 8 V-belt case air filter cover E Washer
2 Dowel pin 9 Kickstarter pinion gear
3 V-belt case cover 0 Kickstarter pinion gear clip
4 V-belt case cover protector 2 A Spacer
5 Kickstarter crank B Kickstarter spring
6 Oil seal C Kickstarter shaft
7 Circlip D Kickstarter shaft plate
9 Nm (0.9 m • kg)
T.
R.
1
23 Nm (2.3 m • kg)
T.
R.
D
10 Nm (1.0 m • kg)
T.
A
R.
2
E 3
C T.
R.
10 Nm (1.0 m • kg)
4
B
0
9
LS
M 7
6
New 5
LS
11 Nm (1.1 m • kg)
T.
R.
10 Nm (1.0 m • kg)
T.
R.
4 - 38
KICKSTARTER ENG
REMOVING THE KICKSTARTER
1
1. Remove:
• V-belt case air filter cover 2
2. Remove:
2 • kickstarter crank bolt
3 • kickstarter crank 1
• V-belt case cover 3
• dowel pins
1
DISASSEMBLING THE KICKSTARTER

SHAFT
1. Remove:
• kickstarter shaft plate 1
2. Remove:
1 • kickstarter pinion gear 1
• kickstarter pinion gear clip 2
4 - 39
KICKSTARTER ENG
3. Remove:
• oil seal 1
• circlip 2
1
4. Remove:
• kickstarter shaft 1
1 • kickstarter spring 2
• spacer
• washer
EAS00339
CHECKING THE KICKSTARTER

1. Check:
• kickstarter shaft
• kickstarter pinion gear
2. Check:
• kickstarter spring
3. Measure:
• kickstarter pinion gear clip force
(with the spring gauge)
Out of specification → Replace the kick-
starter pinion gear clip.
Kickstarter pinion gear clip force

0.7 ~ 2.0 N (0.07 ~ 0.20 kgf)
4 - 40
KICKSTARTER ENG
EAS00340
ASSEMBLING THE KICKSTARTER

1. Install:
1 • washer
• spacer
• kickstarter spring
2 • kickstarter shaft
• circlip
• oil seal New
NOTE:
_
Install the kickstarter spring straight end on the

kickstarer shaft notch 1 and hook the spring
hooked end on the projection 2 as shown.
2. Install:
• kickstarter pinion gear clip
• kickstarter pinion gear
• kickstarter shaft plate
• kickstarter shaft plate screws
9 Nm (0.9 m • kg)
T.
R.
INSTALLING THE KICKSTARTER
1. Install:
• dowel pins
• V-belt case cover bolts
10 Nm (1.0 m • kg)
T.
R.

10 Nm (1.0 m • kg)
T.
R.
• kickstarter crank
• kickstarter crank bolt
11 Nm (1.1 m • kg)
T.
R.
2. Install:
• V-belt case air filter cover
• V-belt case air filter cover bolts
10 Nm (1.0 m • kg)
T.
R.

23 Nm (2.3 m • kg)
T.
R.
4 - 41
BELT DRIVE ENG
EASF0316
BELT DRIVE
V-BELT, PRIMARY AND SECONDARY PULLEY

1 O-ring 6 Spring seat A V-belt
2 Clutch housing 7 Oil seal B Conical spring washer
3 Clutch carrier 8 O-ring C Kickstarter one-way clutch
4 Clutch shoe 9 Secondary sliding sheave D Claw washer
5 Spring 0 Secondary fixed sheave E Primary fixed sheave
®
* Shell Dolium grease R
4
3
75 Nm (7.5 m • kg)
T.
R.
7 New 9 2
*
1
New
8
7 40 Nm (4.0 m • kg)
T.
R.
New 6
5
0
K
*
J
I
L New
G A
New H 55 Nm (5.5 m • kg)
T.
R.
G D
C
New F B
4 - 42
BELT DRIVE ENG
F Collar
G Oil seal
H Primary sliding sheave
I Primary pulley weight
J Slider
K Cam
L Gasket
M Guide pin
®
* Shell Dolium grease R
4
3
75 Nm (7.5 m • kg)
T.
R.
7 New 9 2
*
1
New
8
7 40 Nm (4.0 m • kg)
T.
R.
New 6
5
0
K
*
J
I
L New
G A
New H 55 Nm (5.5 m • kg)
T.
R.
G D
C
New F B
4 - 43
BELT DRIVE ENG
EASF0318
REMOVING THE SECONDARY PULLEY

3 AND V-BELT
4 1. Remove:
2
1 Refer to “KICKSTARTER”.
2. Remove:
• O-ring 1
• secondary pulley nut 2
• clutch housing 3
NOTE:
_
While holding the clutch housing with the

sheave holder 4, loosen the secondary pulley
nut.
Sheave holder
90890-01701
3. Loosen:
• clutch carrier nut 1
CAUTION:
1
_
Do not remove the clutch carrier nut at this

3 stage.
2
NOTE:
_
While holding the clutch carrier with the rotor

holding tool 2, loosen the clutch carrier nut
one full turn with the locknut wrench 3.
Rotor holding tool

90890-01235
Locknut wrench
90890-01348
4. Remove:
2 • secondary pulley 1
• V-belt 2
NOTE:
_
Pull the secondary sliding sheave out as

shown, remove the V-belt along with the sec-
ondary pulley 1, and then remove the V-belt
1 2 from the primary pulley.
4 - 44
BELT DRIVE ENG
5. Remove:
1 • gasket 1
EASF0317
REMOVING THE PRIMARY PULLEY

3 1. Remove:
2 Refer to “GENERATOR”.
2. Remove:
• primary pulley nut 1
• conical spring washer
1 • kickstarter one-way clutch
• claw washer
• primary fixed sheave 2
• washer
• primary sliding sheave
NOTE:
_
While holding the generator rotor with the rotor

holding tool 3, loosen the primary pulley nut.
Rotor holding tool

90890-01235
3. Remove:
3 3 1
2 • cams 1
• slider 2
• primary pulley weight 3
1 1
3
4 - 45
BELT DRIVE ENG
EAS00319
DISASSEMBLING THE SECONDARY
PULLEY
1. Remove:
1 • clutch carrier nut 1
NOTE:
_
Install the clutch spring holder 2 onto the sec-

2 ondary pulley as shown. Then, compress the
spring, and remove the clutch carrier nut 1.

90890-01337
2. Remove:
1 • spring seat
3. Remove:
• guide pins 1
EAS00290
CHECKING THE CLUTCH HOUSING

1. Check:
• clutch housing
2. Measure:
a • clutch housing inside diameter a
Out of specification → Replace the clutch
housing.
Clutch housing inside diameter

112 mm
<Limit>: 112.5 mm
4 - 46
BELT DRIVE ENG
EAS00291
CHECKING THE CLUTCH SHOES

clutch shoes.
1. Check:
• clutch shoe
Damage/wear → Replace the clutch shoes
and springs as a set.
Glazed areas → Sand with course sandpa-
per.
NOTE:
_
After sanding the glazed areas, clean the

clutch with a cloth.
2. Measure:
• clutch shoe thickness a
Out of specification → Replace the clutch
shoes and springs as a set.
Clutch shoe thickness

2.0 mm
<Limit>: 1.0 mm
EAS00320
CHECKING THE V-BELT

1 1. Check:
• V-belt 1
Grease/oil → Clean the primary and sec-
a ondary pulley.
2. Measure:
• V-belt width a
V-belt width
18.2 mm
<Limit>: 17.2 mm
4 - 47
BELT DRIVE ENG
EAS00321
CHECKING THE PRIMARY PULLEY

WEIGHTS
primary pulley weights.
1. Check:
• primary pulley weight
2. Measure:
• primary pulley weight outside diameter a
Primary pulley weight outside

diameter
15 mm
<Limit>: 14.5 mm
a
EAS00322
CHECKING THE SECONDARY PULLEY

1. Check:
• secondary fixed sheave
• secondary sliding sheave
Cracks/damage/wear → Replace the sec-
ondary fixed and sliding sheaves as a set.
2. Check:
• torque cam groove 1
2 Damage/wear → Replace the secondary
fixed and sliding sheaves as a set.
3. Check:
• guide pin 2
Damage/wear → Replace the secondary
fixed and sliding sheaves as a set.
1
4. Check:
• spring free length
Out of specification → Replace the spring.
Spring free length

76 mm
<Limit>: 73 mm
4 - 48
BELT DRIVE ENG
EAS00324
ASSEMBLING THE SECONDARY PULLEY

1
1. Lubricate:
• secondary fixed sheave 1
2
• secondary sliding sheave 2
• bearing
NOTE:
_
Do not get any grease on the surfaces of the

pulley. If any grease gets on the pulley, be
sure to wipe it off with alcohol, etc.
Shell Dolium grease R®
2. Install:
3 • oil seals New
• secondary sliding sheave 1
• secondary fixed sheave 2
NOTE:
1 _
2 Install the secondary sliding sheave onto the

secondary fixed sheave 2 with the oil seal
guide 3.
Oil seal guide

90890-01384
3. Install:
1 • guide pin 1
4 - 49
BELT DRIVE ENG
4. Lubricate:
• guide pin groove 1
• O-rings 2 New
2
New Recommended lubricant
5. Install:
a
• spring seat 1
NOTE:
_
Do not get any grease on the surfaces a and

b of the pulley. If any grease gets on the pul-
ley, be sure to wipe it off with alcohol, etc.
1
b
6. Install:
2
• spring
• clutch carrier 1 75 Nm (7.5 m • kg)
1
T.
R.
NOTE:
_
Attach the clutch spring holder 2 onto the sec-

3
ondary pulley as shown. Then, compress the
spring, and tighten the clutch carrier nut 3.

90890-01337
EAS00323
ASSEMBLING THE PRIMARY PULLEY

1. Clean:
• primary fixed sheave
• collar
• primary pulley weights
4 - 50
BELT DRIVE ENG
2. Install:
• oil seal
3. Lubricate:
• collar
NOTE:
_
Fill the notch of the primary sliding sheave with

grease. Apply grease to the inside diameter of
the primary sliding sheave.
CAUTION:
_
Do not get any grease on the surfaces of

the pulley. If any grease gets on the pulley,
be sure to wipe it off with alcohol, etc.
4. Install:
1 1 3
2 • primary pulley weights 1
• slider 2
• cams 3
3 3
1
5. Install:
• primary sliding sheave 1
4 - 51
BELT DRIVE ENG
6. Install:
• washer 1
• primary fixed sheave 2
4 5 • claw washer 3
• kickstarter one-way clutch 4
1
• conical spring washer 5
3 • primary pulley nut 6
2 4 5
55 Nm (5.5 m • kg)
6
T.
R.
NOTE:
_
• Install the conical spring washer 5 as shown

in the illustration.
• While holding the generator rotor with the
rotor holding tool, tighten the primary pulley
nut.
Rotor holding tool

90890-01235
EAS00325
INSTALLING THE BELT DRIVE

2 a
1. Install:
• gasket 1 New
1 • V-belt 2
• secondary pulley 3
CAUTION:
_
3 Do not allow grease to contact the V-belt,

secondary pulley assembly.
NOTE:
_
• The V-belt must be installed, with the arrow

a forward.
• Install the V-belt on the primary pulley, then
install the secondary pulley 3 along with the
V-belt 2.
4 - 52
BELT DRIVE ENG
2. Install:
• clutch carrier nut 1
50 Nm (5.0 m • kg)
T.
R.
1 NOTE:
_
3 While holding the clutch carrier with the rotor

holding tool 2, tighten the clutch carrier nut
2 with the locknut wrench 3.
Rotor holding tool

90890-01235
Locknut wrench
90890-01348
3. Position:
• V-belt 1
1
2 NOTE:
_
3 Position the V-belt in the primary pulley 2

(when the pulley is at its widest position) and in
the secondary pulley 3 (when the pulley is at
its narrowest position), and make sure the V-
belt is tight.
4. Install:
• clutch housing 1
1
• secondary pulley nut 2
3 40 Nm (4.0 m • kg)
T.
R.
2 • O-ring
NOTE:
_
Tighten the secondary pulley nut with the

sheave holder 3.
Sheave holder
90890-01701
5. Install:
Refer to “KICKSTARTER”.
4 - 53
STARTER CLUTCH ENG
EASF0341
STARTER CLUTCH
1 Idle gear plate

2 Idle gear
3 Starter clutch assembly
4 Starter wheel gear holder
5 Starter wheel gear
6 Bearing
2
1
LS
10 Nm (1.0 m • kg)
T.
R.
10 Nm (1.0 m • kg)
T.
R.
6
4
10 Nm (1.0 m • kg)
T.
R.
LT
4 - 54
STARTER CLUTCH ENG
1. Remove:
Refer to “BELT DRIVE”.
2. Remove:
1
• idle gear plate 1
• washer
• idle gear 2
2 • washer
3 • starter clutch assembly 3
3. Remove:
• starter wheel gear holder 1
• starter wheel gear 2
2
• bearing 3
3
1
EAS00348
CHECKING THE STARTER CLUTCH

1. Check:
• idle gear
• starter wheel gear
• starter clutch assembly
Burrs/chips/roughness/wear → Replace the
defective part(s).
2. Check:
• starter wheel gear contacting surface
Damage/pitting/wear → Replace the starter
wheel gear.
4 - 55
STARTER CLUTCH ENG
3. Check:
É È
• starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter wheel gear onto the
starter clutch and hold the starter clutch.
b. When turning the starter wheel gear clock-
wise È, the starter clutch and the starter
wheel gear should engage, otherwise the
starter clutch is faulty and must be
replaced.
c. When turning the starter wheel gear coun-
terclockwise É, it should turn freely, other-
wise the starter clutch is faulty and must be
replaced.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00355
2 INSTALLING THE STARTER CLUTCH

1. Install:
• starter wheel gear 1
• starter clutch assembly 2
1
NOTE:
_
• Install the starter wheel gear 1 while turning

the starter clutch assembly 2 counterclock-
wise.
• Apply a thin coat of grease to the needle
bearing.
2. Install:
• starter wheel gear holder
• starter wheel gear holder bolt
10 Nm (1.0 m • kg)
T.
R.
3. Install:
• idle gear plate
• idle gear plate bolts 10 Nm (1.0 m • kg)
T.
R.
4 - 56
GENERATOR ENG
GENERATOR
1 Stator coil assembly
2 Generator rotor
3 Engine cooling fan
4 Engine cooling fan cover
7 Nm (0.7 m • kg)
T.
R.
10 Nm (1.0 m • kg)
T.
R.
70 Nm (7.0 m • kg)
T.
R.
7 Nm (0.7 m • kg)
T.
R.
11 Nm (1.1 m • kg)
T.
R.
4 - 57
GENERATOR ENG
EASF0346
REMOVING THE GENERATOR

1. Remove:
• side cover (right)
2. Disconnect:
• A.C. magnet couplers 1
1 3. Remove:
2 • plastic clip 2
4. Remove:
• engine cooling fan cover 1
1
5. Remove:
• engine cooling fan 1
4 - 58
GENERATOR ENG
6. Remove:
• generator rotor nut 1
2 • washer
NOTE:
_
1 While holding the generator rotor 2 with the

rotor holding tool 3, loosen the generator rotor
nut.
3
Rotor holding tool
90890-01235
7. Remove:
• generator rotor 1
(with the flywheel puller 2)
1
• woodruff key
Flywheel puller
90890-01189
8. Remove:
4
3 • stator coil 1
2 9. Disconnect:
• stator coil coupler 2
10.Remove:
• pickup coil bracket 3
• pickup coil 4
1
4 - 59
GENERATOR ENG
EAS00354
INSTALLING THE GENERATOR

1
1. Install:
• pickup coil
• pickup coil bracket 1
• pickup coil bracket screws
7 Nm (0.7 m • kg)
T.
R.
NOTE:
2
_
Pass the starter coil lead under the pickup coil

bracket.
2. Connect:
• stator coil coupler
3. Install:
• stator coil 2
• stator coil bolts 11 Nm (1.1 m • kg)
T.
R.
4. Install:
• woodruff key
• generator rotor 1
1 • washer
• generator rotor nut
NOTE:
_
• Clean the tapered portion of the crankshaft

and the generator rotor hub.
• When installing the generator rotor, make
sure the woodruff key is properly seated in
the keyway of the crankshaft.
2 5. Tighten:
• generator rotor nut 1
1 70 Nm (7.0 m • kg)
T.
R.
NOTE:
_
While holding the generator rotor 2 with the

rotor holding tool 3, tighten the generator
3 rotor nut.
Rotor holding tool

90890-01235
4 - 60
GENERATOR ENG
5. Install:
• engine cooling fan bolts
10 Nm (1.0 m • kg)
T.
R.
6. Install:
• engine cooling fan cover
• engine cooling fan cover screws
7 Nm (0.7 m • kg)
T.
R.
4 - 61
OIL PUMP ENG
EASF0357
OIL PUMP
1 Oil pump cover 7 Engine oil strainer

2 Oil seal 8 Spring
3 O-ring 9 O-ring
4 Gasket 0 Engine oil drain plug
5 Oil pump assembly
6 Gasket
10 Nm (1.0 m • kg)
T.
R.
2 New
LS
4 Nm (0.4 m • kg)
T.
R.
10 Nm (1.0 m • kg)
T.
R.
1
3 New
4 New
6
New
7
8
LS
9 New
0
20 Nm (2.0 m • kg)
T.
R.
4 - 62
OIL PUMP ENG
REMOVING THE OIL PUMP
1. Drain:
• engine oil
(completely from the crankcase)
chapter 3.
2. Remove:
• stator coil
3. Remove:
• oil pump cover 1
• O-ring
1 • gasket
4. Remove:
• circlip 1
• plate washer 2
3 • driven gear 3
1
2
5. Remove:
• oil pump assembly 1
• gasket
DISASSEMBLING THE OIL PUMP

5 4
1. Remove:
• pin
3 • oil pump housing cover 1
• pin
1
• oil pump shaft 2
• inner rotor 3
2 • outer rotor 4
• oil pump housing 5
4 - 63
OIL PUMP ENG
EAS00364
CHECKING THE OIL PUMP

1. Check:
• oil pump drive gear
• oil pump driven gear 1
• oil pump housing 2
• oil pump housing cover 3
3 2 Cracks/damage/wear → Replace the defec-
1 tive part(s).
2. Measure:
• inner-rotor-to-outer-rotor-tip clearance a
• outer-rotor-to-oil-pump-housing clearance
b
• oil-pump-housing-to-inner-rotor-and-outer-
rotor clearance c
Out of specification → Replace the oil
pump.
1 Inner rotor
2 Outer rotor
3 Oil pump housing
Inner-rotor-to-outer-rotor-tip
clearance
0.15 mm
<Limit>: 0.23 mm
Outer-rotor-to-oil-pump-housing
clearance
0.13 ~ 0.18 mm
<Limit>: 0.25 mm
Oil-pump-housing-to-inner-rotor-
and-outer-rotor clearance
0.06 ~ 0.10 mm
<Limit>: 0.17 mm
3. Check:
• oil pump operation
Rough movement → Repeat steps (1) and
(2) or replace the defective part(s).
4 - 64
OIL PUMP ENG
EAS00375
ASSEMBLING THE OIL PUMP

1. Lubricate:
• inner rotor
• outer rotor
• oil pump shaft
Engine oil
2. Install:
1 • oil pump shaft
a • oil pump housing cover
• pin 1
• inner rotor 2
• outer rotor
• pin
• oil pump housing
2
NOTE:
_
When installing the inner rotor, align the pin 1

in the oil pump shaft with the groove a in the
inner rotor 2.
3. Check:
• oil pump operation
Refer to “CHECKING THE OIL PUMP”.
EAS00376
INSTALLING THE OIL PUMP

1. Install:
• gasket New
• oil pump assembly
• oil pump assembly screws
4 Nm (0.4 m • kg)
T.
R.
2. Install:
• gasket New
• O-ring New
• oil pump cover
• oil pump cover bolts
10 Nm (1.0 m • kg)
T.
R.
4 - 65
TRANSMISSION ENG
EASF0419
TRANSMISSION
1 Drive axle 8 Oil seal

2 Oil seal 9 Transmission case cover
3 Conical spring washer 0 Gasket
4 Drive axle gear A Primary drive gear
5 Main axle
6 Conical spring washer
7 Dowel pin
2 New
3
4
10 Nm (1.0 m • kg) 7
T.
R.
13 Nm (1.3 m • kg)
T.
R.
0 New
LS
8 New
4 - 66
TRANSMISSION ENG
EASF0420
REMOVING THE TRANSMISSION

NOTE:
Prior to remove the transmission, remove the
muffler, rear wheel and secondary pulley.
1. Drain:
• transmission oil
(completely from the transmission case)
Refer to “CHANGING THE TRANSMIS-
SION OIL” in chapter 3.
2. Remove:
• transmission case cover 1
1 (with primary drive gear, bearings)
• gasket
• dowel pins
3. Remove:
1 • oil seal 1
• circlip 2
4. Remove:
• primary drive gear 1
5. Remove:
• washer 1
2 • drive axle gear 2
• main axle 3
3
4 - 67
TRANSMISSION ENG
6. Remove:
• drive axle 1
(with circlip)
1
EAS00425
CHECKING THE TRANSMISSION

1. Check:
• drive axle
• main axle
• primary drive gear
2. Check:
• bearings
Rough movement → Replace.
3. Check:
• circlips
Bends/damage/looseness → Replace.
EAS00428
INSTALLING THE TRANSMISSION

1. Install:
• drive axle
a • circlip 1
1
NOTE:
_
• Make sure the circlip 1 is inserted into the

groove a in the drive axle.
• Always use a new gasket and O-ring.
4 2. Install:
5 • main axle 1
• conical spring washer 2
3 • drive axle gear 3
3 2 • conical spring washer 4
• washer 5
1 NOTE:
_
Install the conical spring washers as shown in

5 the illustration.
4 - 68
TRANSMISSION ENG
3. Install:
• primary drive gear bearing
• retainer bolt 10 Nm (1.0 m • kg)
T.
R.
4. Install:
• circlip
• oil seal New
• dowel pins
• gasket New
• transmission case cover
(with primary drive gear, bearings)
• transmission case cover bolts
13 Nm (1.3 m • kg)
T.
R.
5. Check:
• transmission
Rough movement → Repair.
NOTE:
_
Oil each gear, shaft, and bearing thoroughly.
4 - 69
CRANKSHAFT ENG
EASF0381
CRANKSHAFT
1 Crankcase (right) 9 Rubber damper
2 Crankshaft assembly 0 Collar
3 Timing chain A Engine bracket
4 Timing chain guide (intake side) B Spacer
5 Dowel pin C Center stand shaft
6 Crankcase (left) D Center stand spring
7 Oil seal E Center stand
8 Engine drain bolt
10 Nm (1.0 m • kg) 1
T.
R.
New
3
6
LS
E
2
09 7 New
LS
7 Nm (0.7 m • kg)
T.
R.
9 8
0 20 Nm (2.0 m • kg)
T.
R.
B 16 Nm (1.6 m • kg)
A
T.
R.
E C
32 Nm (3.2 m • kg)
T.
R.
LS
4 - 70
CRANKSHAFT ENG
EAS00385
DISASSEMBLING THE CRANKCASE

1. Remove:
• engine assembly
Refer to “REMOVING THE ENGINE”.
2. Remove:
• cylinder head
• cylinder
• piston
Refer to “CYLINDER HEAD” and “CYLIN-
DER AND PISTON”.
3. Remove:
Refer to “KICKSTARTER”.
4. Remove:
• secondary pulley
• V-belt
• primary pulley
Refer to “BELT DRIVE”.
5. Remove:
• starter clutch
Refer to “STARTER CLUTCH”.
6. Remove:
• starter motor
Refer to “STARTER MOTOR” in chapter 7.
7. Remove:
• generator
8. Remove:
• oil pump
Refer to “OIL PUMP”.
9. Remove:
• rear wheel assembly
Refer to “REAR WHEEL AND BRAKE” in
chapter 6.
10.Remove:
• rubber dampers 1
• collars
• engine bracket 2
4 - 71
CRANKSHAFT ENG
11.Remove:
2 3 • centerstand spring 1
• circlip 2
• washer
• centerstand shaft 3
4 1
• centerstand 4
12.Remove:
• timing chain guide (intake side) 1
1
13.Remove:
• crankcase bolts
NOTE:
_
Loosen each bolt 1/4 of a turn at a time, in

stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
14.Remove:
• right crankcase
CAUTION:
_
Tap on one side of the crankcase with a

soft-face hammer. Tap only on reinforced
portions of the crankcase, not on the
crankcase mating surfaces. Work slowly
and carefully and make sure the crankcase
halves separate evenly.
4 - 72
CRANKSHAFT ENG
EASF0389
REMOVING THE CRANKSHAFT

ASSEMBLY
1 1. Remove:
• crankshaft assembly 1
2 • timing chain 2
NOTE:
_
• Before removing the crankshaft assembly,

remove the timing chain from the crankshaft
sprocket.
• The crankshaft assembly cannot be removed
if the timing chain is attached onto the crank-
shaft sprocket.
EAS00399
CHECKING THE CRANKCASE

1. Thoroughly wash the crankcase halves in a
mild solvent.
2. Thoroughly clean all the gasket surfaces
and crankcase mating surfaces.
3. Check:
• crankcase
• oil delivery passages
air.
EAS00401
CHECKING THE BEARINGS

1. Check:
• bearings
Clean and lubricate the bearings, then
rotate the inner race with your finger.
Rough movement → Replace.
4 - 73
CRANKSHAFT ENG
TIMING CHAIN GUIDE
1. Check:
• timing chain guide (intake side)
EAS00207
CHECKING THE TIMING CHAIN

1. Check:
• timing chain
Damage/stiffness → Replace the timing
chain and camshaft sprocket as a set.
EAS00394
CHECKING THE CRANKSHAFT AND

CONNECTING ROD
1. Measure:
• crankshaft runout 1
Out of specification → Replace the crank-
shaft, bearing or both.
NOTE:
_
Turn the crankshaft slowly.
Maximum crankshaft runout

0.03 mm
2. Measure:
• big end side clearance 2
Out of specification → Replace the big end
bearing, crankshaft pin, or connecting rod.
Big end side clearance

0.15 ~ 0.45 mm
3. Measure:
• crankshaft width 3
Out of specification → Replace the crank-
shaft.
Crankshaft width
45.45 ~ 45.50 mm
4 - 74
CRANKSHAFT ENG
4. Check:
• crankshaft sprocket 1
Damage/wear → Replace the crankshaft.
• bearing 2
Rough movement → Replace the crank-
shaft.
5. Check:
• crankshaft journal
Scratches/wear → Replace the crankshaft.
• crankshaft journal oil passage
air.
EAS00408
INSTALLING THE CRANKSHAFT

1. Install:
• timing chain
• crankshaft assembly
CAUTION:
_
To avoid scratching the crankshaft and to

ease the installation procedure, lubricate
the oil seal lips with lithium-soap-based
grease and each bearing with engine oil.
EAS00416
ASSEMBLING THE CRANKCASE

1. Apply:
• sealant
(onto the crankcase mating surfaces)
Yamaha bond No. 1215

90890-85505
NOTE:
_
Do not allow any sealant to come into contact

with the oil gallery.
4 - 75
CRANKSHAFT ENG
2. Install:
• dowel pins 1
1 3. Install:
• right crankcase
(onto the left crankcase)
NOTE:
_
1 Tap lightly on the right crankcase with a soft-

face hammer.
4. Install:
• crankcase bolts 10 Nm (1.0 m • kg)
T.
R.
5. Install:
• timing chain guide (intake side)
• timing chain guide retainer bolt
7 Nm (0.7 m • kg)
T.
R.
6. Install:
• engine bracket
• engine bracket bolts
• engine bracket nuts
32 Nm (3.2 m • kg)
T.
R.
• collars
• rubber dampers
• rubber damper bolts
• rubber damper nuts
T.
R.
16 Nm (1.6 m • kg)
4 - 76
CARB
CHAPTER 5
CARBURETOR
CARBURETOR................................................................................................5-1
REMOVING THE CARBURETOR............................................................. 5-2
DISASSEMBLING THE CARBURETOR................................................... 5-3
CHECKING THE CARBURETOR ............................................................. 5-5
ASSEMBLING THE CARBURETOR.........................................................5-7
INSTALLING THE CARBURETOR ........................................................... 5-9
MEASURING AND ADJUSTING THE FUEL LEVEL ................................5-9
CHECKING THE FUEL COCK OPERATION..........................................5-11
CARB
CARBURETOR CARB
EASF0480
CARBURETOR
CARBURETOR
1 Vacuum chamber cover 9 Throttle stop screw set G Needle valve
2 Piston valve spring 0 Coasting enricher spring H Float
3 Jet needle set A Coasting enricher I Float pivot pin
4 Piston valve B Pilot jet J Accelerator plunger set
5 Air vent hose C Cap K Gasket
6 Pilot screw set D O-ring L Fuel drain screw
7 Starter plunger assembly E Needle jet M Float chamber
8 Gasket F Main jet N Fuel overflow hose
1
5
4 9
6
New
New D B
G E
C
K New F
H
J A
0
L I
M
N
5-1
CARBURETOR CARB
EASF0481
REMOVING THE CARBURETOR

WARNING
Gasoline is highly flammable.
Avoid spilling fuel on the hot engine.
1. Remove:
• side panel (left and right)
2. Remove:
• air filter case
Refer to “AIR FILTER CASE” in chapter 3.
3. Loosen:
• fuel drain screw 1
4. Drain:
• fuel (float chamber)
5. Loosen:
• locknut (throttle cable) 1
• adjusting nut 2
6. Disconnect:
• throttle cable 3
3 4 7. Loosen:
2 • screw (intake manifold) 4
1
8. Remove:
• carburetor assembly 1
5-2
CARBURETOR CARB
9. Remove:
10.Disconnect:
• fuel hose 2
1 • starter cable 3
• air vent hose 4
4 • fuel overflow hose 5
2
5
11.Disconnect:
• starter plunger assembly 1
EASF0483
DISASSEMBLING THE CARBURETOR

NOTE:
The following parts can be cleaned and
inspected without disassembly.
• Starter plunger
• Throttle stop screw
• Pilot screw
1 1. Remove:
• float chamber 1
• float chamber rubber gascket
5-3
CARBURETOR CARB
2. Remove:
• accelerator plunger assembly 1
3. Remove:
• float pivot pin 1
• float 2
• needle valve 3
3 2 • float pin screw 4
1
4
4. Remove:
• main jet 1
• needle jet 2
4
• pilot jet 3
2 3 • O-ring 4
• cap 5
1
5
5. Remove:
3
1 • vacuum chamber cover 1
6. Remove:
2 • piston valve spring 2
• piston valve 3
1
7. Remove:
• jet needle set 1
5-4
CARBURETOR CARB
8. Remove:
• pilot screw set 1
9. Remove:
• fuel strainer 1
EAS00485
CHECKING THE CARBURETOR

1. Check:
• carburetor body
• float chamber
• jet housing
2. Check:
• fuel passages
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the carburetor in a petroleum-based
solvent. Do not use any caustic carburetor
cleaning solution.
b. Blow out all of the passages and jets with
compressed air.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Check:
• float chamber body
Dirt → Clean.
4. Check:
• fuel passages
5. Check:
• float chamber rubber gasket
5-5
CARBURETOR CARB
6. Check:
• float
Damage → Replace.
7. Check:
• needle valve 1
• needle valve seat 2
Damage/obstruction/wear → Replace the
2 needle valve.
1
8. Check:
• piston valve 1
Damage/scratches/wear → Replace.
• piston valve diaphragm 2
Cracks/tears → Replace.
9. Check:
2 • vacuum chamber cover 1
1 • piston valve spring 2
10.Check:
• jet needle set 1
2 3 4 5 6 • needle jet 2
• main jet 3
• pilot jet 4
1 • pilot screw 5
• fuel strainer 6
Bends/damage/wear → Replace.
Blow out the jets with compressed air.
5-6
CARBURETOR CARB
11.Check:
• piston valve movement
Insert the piston valve into the carburetor
body and move it up and down.
Tightness → Replace the piston valve.
12.Check:
• starter plunger 1
• starter plunger spring 2
Bends/cracks/damage → Replace.
1 2
13.Check:
• accelerator plunger 1
3
• O-ring 2
2 • accelerator plunger spring 3
1 14.Check:
• hose joints
15.Check:
• vacuum hose
• fuel hose
Blow out the hoses with compressed air.
EAS00487
ASSEMBLING THE CARBURETOR
CAUTION:
_
• Before assembling the carburetor, wash

all of the parts in a petroleum-based sol-
vent.
• Always use new gasket and o-ring.
5-7
CARBURETOR CARB
1. Install:
• jet needle set
NOTE:
Push the jet needle holder 1 with a Phillips
screwdriver, and then turn it to secure it in
1 place.
2. Install:
1 • piston valve 1
b NOTE:
1 a • Install the piston valve into the carburetor
body as shown.
• Match the tab a on the piston diaphragm to
the matching recess b in the carburetor
body.
• To install the piston valve spring and vacuum
chamber cover, push the piston valve as
shown and make sure that the diaphragm is
not inserted into the carburetor body.
3. Install:
• pilot screw 1
NOTE:
1
• Screw in the pilot screw 1 until it is lightly
seated.
• Back out by the specified number of turns.
4. Connect:
• fuel overflow hose 1
• air vent hose 2
3 • starter cable 3
• fuel hose 4
5. Install:
4
1
WARNING
Proper hose and cable routing are essential
to insure safe motorcycle operation. Refer
to “CABLE ROUTING” in chapter 2.
5-8
CARBURETOR CARB
EAS00492
INSTALLING THE CARBURETOR

a b 1. Install:
NOTE:
Be sure to insert the projection a into the slot
b of intake manifold.
2. Adjust:
Engine idling speed

1,500 ~ 1,700 r/min
Refer to “ADJUSTING THE ENGINE

IDLING SPEED” in chapter 3.
3. Adjust:

3 ~ 7 mm

CABLE FREE PLAY” in chapter 3.
EAS00498
1 MEASURING AND ADJUSTING THE FUEL

LEVEL
1. Remove:
• vacuum hose 1
NOTE:
Remove the vacuum hose from the intake
manifold.
5-9
CARBURETOR CARB
2. Measure:
• fuel level a
Fuel level (above the float cham-

ber mating surface)
7 ~ 8 mm
1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Stand the motorcycle on a level surface.
a b. Place the motorcycle on a suitable stand to
ensure that the motorcycle is standing
4
straight up.
2 c. Install the fuel level gauge 1 onto the fuel
overflow pipe 2.
Fuel level gauge

90890-01312
d. Suck on the end of the vacuum hose.

e. Loosen the fuel drain screw 3.
f. Hold the fuel level gauge vertically next to
the float chamber 4.
g. Measure the fuel level a.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Adjust:
• fuel level
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the carburetor.
b. Check the needle valve seat and needle
1 valve.
c. If either is worn, replace the carburetor
body and needle valve.
d. If both are fine, adjust the float level by
slightly bending the float tang 1.
e. Install the carburetor.
f. Measure the fuel level again.
g. Repeat steps (a) to (g) until the fuel level is
within specification.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 10
CARBURETOR CARB
EAS00506
CHECKING THE FUEL COCK OPERATION

1. Place a container under the end of the fuel
hose 1.
2. Check:
• fuel cock operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 a. Suck on the end of the vacuum hose 1.
Fuel flows. Fuel cock is OK.

Replace the fuel
Fuel does not flow.
cock.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5 - 11
CHAS
CHAPTER 6
CHASSIS
FRONT WHEEL AND BRAKE DISC............................................................... 6-1

REMOVING THE FRONT WHEEL............................................................ 6-2
CHECKING THE FRONT WHEEL ............................................................ 6-3
CHECKING THE BRAKE DISC.................................................................6-5
ASSEMBLING THE FRONT WHEEL........................................................6-7
INSTALLING THE FRONT WHEEL .......................................................... 6-7
REAR WHEEL AND BRAKE ..........................................................................6-9

REMOVING THE REAR WHEEL ............................................................ 6-10
CHECKING THE REAR WHEEL............................................................. 6-10
REMOVING THE REAR BRAKE............................................................. 6-11
CHECKING THE BRAKE ........................................................................6-12
ASSEMBLING THE BRAKE SHOE PLATE ............................................6-13
INSTALLING THE REAR WHEEL........................................................... 6-13
FRONT BRAKE ............................................................................................. 6-15

FRONT BRAKE CALIPER....................................................................... 6-15
REPLACING THE FRONT BRAKE PADS .............................................. 6-16
DISASSEMBLING THE FRONT BRAKE CALIPER ................................6-19
CHECKING THE FRONT BRAKE CALIPER ..........................................6-20
ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER ....... 6-21
FRONT BRAKE MASTER CYLINDER....................................................6-24
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER ............. 6-25
CHECKING THE FRONT BRAKE MASTER CYLINDER........................ 6-26
ASSEMBLING AND INSTALLING THE FRONT BRAKE
MASTER CYLINDER ............................................................................. 6-27
FRONT FORK................................................................................................6-30
REMOVING THE FRONT FORK LEGS.................................................. 6-31
DISASSEMBLING THE FRONT FORK LEGS ........................................ 6-32
CHECKING THE FRONT FORK LEGS .................................................. 6-33
ASSEMBLING THE FRONT FORK LEGS .............................................. 6-34
INSTALLING THE FRONT FORK LEGS ................................................ 6-37
HANDLEBAR ................................................................................................6-38
REMOVING THE HANDLEBAR..............................................................6-39
CHECKING THE HANDLEBAR ..............................................................6-41
INSTALLING THE HANDLEBAR ............................................................ 6-41
CHAS
STEERING HEAD.......................................................................................... 6-45
REMOVING THE LOWER BRACKET.....................................................6-46
CHECKING THE STEERING HEAD .......................................................6-47
INSTALLING THE STEERING HEAD .....................................................6-48
REAR SHOCK ABSORBER ASSEMBLY AND

REAR SUSPENSION ARM ..........................................................................6-50
REMOVING THE REAR SHOCK ABSORBER ASSEMBLIES ............... 6-51
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 6-52
CHECKING THE REAR SUSPENSION ARM.........................................6-52
CHECKING THE CRANKCASE (LEFT).................................................. 6-53
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLIES.............. 6-53
FRONT WHEEL AND BRAKE DISC CHAS
EASF0512
CHASSIS
FRONT WHEEL AND BRAKE DISC
1 Front wheel axle
2 Brake disc
3 Collar
4 Oil seal
5 Bearing
6 Spacer
7 Speedometer gear unit
1 LS 2
3 4 New
5
6
LT
23 Nm (2.3 m • kg) LS
T.
R.
5
7
LS
40 Nm (4.0 m • kg)
T.
R.
6-1
EAS00519
REMOVING THE FRONT WHEEL

WARNING
_
Securely support the motorcycle so that

there is no danger of it falling over.
NOTE:
_
Place the motorcycle on a suitable stand so

2. Remove:
• speedometer cable 1
• axle nut 2
• washer 3
1
2 3
3. Remove:
• front wheel axle 1
• spacer 2
• speedometer gear unit 3
• front wheel 4
3
1 2 4
4. Remove:
• brake disc 1
6-2
EAS00526
CHECKING THE FRONT WHEEL

1. Check:
• wheel axle
Roll the wheel axle on a flat surface.
Bends → Replace.
WARNING
_
Do not attempt to straighten a bent wheel

axle.
Wheel axle bending limit

0.25 mm
2. Check:
• tire
• front wheel
Refer to “CHECKING THE TIRES” in chap-
ter 3.
3. Check:
• spokes
Bends/damage → Replace.
Loose → Tighten.
Tap the spokes with a screwdriver.
NOTE:
_
A tight spoke will emit a clear, ringing tone, a

loose spoke will sound flat.
4. Tighten:
• spokes 3 Nm (0.3 m • kg)
T.
R.
NOTE:
_
After tightening the spokes, measure the front

wheel runout.
5. Measure:
• front wheel radial runout a
• front wheel lateral runout b
Over the specified limits → Replace.
Front wheel radial runout limit

2.0 mm
Front wheel lateral runout limit
2.0 mm
6-3
6. Check:
• collar
WARNING
_
• After mounting a new tire, ride conserva-

tively for a while to become accustomed
to the “feel” of the new tire and to allow
the tire to seat itself properly in the rim.
Failure to do so could lead to an accident
with possible injury to the rider or dam-
age to the motorcycle.
• After a tire has been repaired or replaced,
be sure to tighten the tire air valve stem
locknut 1 to specification.
7. Check:
• wheel bearings
Front wheel turns roughly or is loose →
Replace the wheel bearings.
• oil seal
6-4
8. Replace:
2
• wheel bearings New
• oil seal New
1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
New a. Clean the outside of the front wheel hub.
b. Remove the oil seal 1 with a flat-head
screwdriver.
NOTE:
_
To prevent damaging the wheel, place a rag 2

between the screwdriver and the wheel sur-
face.
c. Remove the wheel bearings 3 with a gen-

eral bearing puller.
d. Install the new wheel bearings and oil seal
in the reverse order of disassembly.
CAUTION:
_
Do not contact the wheel bearing inner race

4 or balls 5. Contact should be made only
with the outer race 6.
NOTE:
_
Use a socket 7 that matches the diameter of

the wheel bearing outer race and oil seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00527
CHECKING THE BRAKE DISC

1. Check:
• brake disc
Damage/galling → Replace.
2. Measure:
• brake disc deflection
Out of specification → Correct the brake
disc deflection or replace the brake disc.
Brake disc deflection limit

(maximum)
0.15 mm
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the motorcycle on a suitable stand so
6-5
b. Before measuring the front brake disc
deflection, turn the handlebar to the left or
right to ensure that the front wheel is sta-
tionary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 14 mm below the
edge of the brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Measure:
• brake disc thickness
Measure the brake disc thickness at a few
different locations.
Brake disc thickness limit

(minimum)
3.0 mm
4. Adjust:
• brake disc deflection
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
_
Tighten the brake disc bolts in stages and in a

crisscross pattern.
Brake disc bolt

23 Nm (2.3 m • kg)
T.
LOCTITE®
R.
d. Measure the brake disc deflection.

e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be
brought within specification, replace the
brake disc.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-6
EAS00539
ASSEMBLING THE FRONT WHEEL

1. Install:
• wheel bearings
• oil seal New
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the new wheel bearings and oil seal
in the reverse order of disassembly.
CAUTION:
_
Do not contact the wheel bearing inner race

1 or balls 2. Contact should be made only
with the outer race 3.
NOTE:
_
Use a socket 4 that matches the diameter of

the wheel bearing outer race and oil seal.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00542
INSTALLING THE FRONT WHEEL

1. Lubricate:
• wheel axle
• wheel bearings
• oil seal lips
• speedometer gear unit
2. Install:
• speedometer gear unit 1
NOTE:
_
Make sure the speedometer gear unit and the

wheel hub are installed with the two slots a
meshed into the two projections b respec-
tively.
6-7
3. Install:
• speedometer gear unit
a • spacer
• front wheel
• wheel axle
• washer
NOTE:
_
Make sure the projection a in the speedome-

ter gear unit fits over the stopper on the outer
tube.
4. Tighten:
• axle nut 40 Nm (4.0 m • kg)
T.
R.
WARNING
_
Make sure the brake hose is routed prop-

erly.
CAUTION:
_
Before tightening the axle nut, push down

hard on the handlebar several times and
check if the front fork rebounds smoothly.
5. Connect:
NOTE:
_
Be sure that slit a on the speedometer cable

mesh with the projection b in the speedome-
ter gear unit 2.
6-8
REAR WHEEL AND BRAKE CHAS
EASF0554
REAR WHEEL AND BRAKE

1 Axle nut 9 Wave washer
2 Rear wheel 0 Adjusting nut
3 Brake shoe A Pin
4 Brake shoe spring (brake camshaft side) B Rear brake cable
5 Brake shoe spring (pivot side)
6 Brake camshaft
7 O-ring
8 Brake shoe wear indicator
104 Nm (10.4 m • kg)

T.
R.
4 New
LS
T.
R.
7 Nm (0.7 m • kg)
6
7 New
New 5
7 8
LS 9
New
0
A
B
7 Nm (0.7 m • kg)
T.
R.
6-9
EASF0563
REMOVING THE REAR WHEEL

NOTE:
_

that the rear wheel is elevated.
2. Remove:
• muffler
chapter 4.
3. Remove:
• rear suspension arm
Refer to “REAR SHOCK ABSORBER
1 ASSEMBLY AND REAR SUSPENSION
ARM”.
4. Remove:
• rear wheel 1
• washer
EAS00566
CHECKING THE REAR WHEEL

1. Check:
• rear wheel
Refer to “CHECKING THE FRONT
WHEEL”.
2. Check:
• tire
• rear wheel
Refer to “CHECKING THE TIRES” in chap-
ter 3.
3. Check:
• spokes
WHEEL”.
4. Measure:
• radial wheel runout
• lateral wheel runout
WHEEL”.
6 - 10
REMOVING THE REAR BRAKE
1. Remove:
4 • adjusting nut 1
• rear brake cable 2
• pin 3
5 • brake camshaft lever bolt 4
• brake camshaft lever 5
2
3 1
2. Remove:
• wave washer 1
• brake shoe wear indicator 2
12
3. Remove:
• brake shoes 1
• brake shoe spring (brake camshaft side) 2
3 • brake shoe spring (pivot side) 3
1 2
4. Remove:
• brake camshaft 1
6 - 11
EAS00569
CHECKING THE BRAKE

brake shoes.
1. Check:
• brake shoe lining
Glazed areas → Repair.
Sand the glazed areas with course sandpa-
per.
NOTE:
_
After sanding the glazed areas, clean the

brake shoe with a cloth.
2. Measure:
• brake shoe lining thickness a
Brake shoe lining thickness limit

2 mm
WARNING
_
Do not allow oil or grease to contact the

brake shoes.
NOTE:
_
Replace the brake shoes as a set, if either is

worn to the wear limit.
3. Check:
• brake drum inner surface
Oil deposits → Clean.
Remove the oil with a rag soaked in lacquer
thinner or solvent.
Scratches → Repair.
Lightly and evenly polish the scratches with
an emery cloth.
4. Measure:
• brake drum inside diameter a
Out of specification → Replace the wheel.
Brake drum inside diameter limit

(maximum)
a
131 mm
5. Check:
• brake camshaft
6 - 12
EAS00570
ASSEMBLING THE BRAKE SHOE PLATE

1. Install:
a b • brake camshaft 1
• brake shoe wear indicator 2
• wave washer
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1 a. Install the brake camshaft so its punch mark
2 a is positioned as shown.
b. Align the projection b on the brake shoe
wear indicator with the notch in the brake
camshaft.
c. Check that the brake shoes are properly
positioned.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EAS00573
INSTALLING THE REAR WHEEL

1 1. Install:
• brake camshaft lever
a WARNING
_
After installing the rear brake camshaft,

remove any excess grease.
2
NOTE:
_
• Align the punch mark on the brake camshaft

with the mark on the brake camshaft lever
positioned as shown a.
• Lubricate the brake camshaft 1 and pin 2
with lithium-soap-based grease.
A B 2. Install:
• brake shoes
• brake shoe spring (pivot side)
• brake shoe spring (brake camshaft side)
NOTE:
_
• Do not to damage the springs during installa-

tion.
• Install the brake shoe spring as shown.
A B A A B B
6 - 13
3. Tighten:
• brake camshaft lever pinch bolt
7 Nm (0.7 m • kg)
T.
R.
• axle nut 104 Nm (10.4 m • kg)
T.
R.
4. Adjust:
• brake lever free play
Refer to “ADJUSTING THE REAR BRAKE”
in chapter 3.

10 ~ 20 mm
6 - 14
FRONT BRAKE CHAS
FRONT BRAKE
EASF0612
FRONT BRAKE CALIPER

1 Brake hose holder 6 Brake caliper seal
2 Brake caliper bolt 7 Brake caliper piston
3 Retaining bolt 8 Brake pad spring
4 Brake caliper 9 Brake pad
5 Bleed screw kit
7 Nm (0.7 m • kg)
T.
R.
35 Nm (3.5 m • kg)
T.
R.
27 Nm (2.7 m • kg)
2
T.
R.
LS 5
4
LS
9 6
6 - 15
FRONT BRAKE CHAS
EAS00579
CAUTION:
_
Disc brake components rarely require dis-

assembly.
Therefore, always follow these preventive
measures:
• Never disassemble brake components
unless absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly.
• Never use solvents on internal brake
components.
• Use only clean or new brake fluid for
cleaning brake components.
• Brake fluid may damage painted surfaces
• Avoid brake fluid coming into contact
with the eyes as it can cause serious
injury.
FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.
EAS00581
REPLACING THE FRONT BRAKE PADS

NOTE:
_
When replacing the brake pads, it is not neces-

1 sary to disconnect the brake hose or disas-
semble the brake caliper.
1. Loosen:
• retaining bolts 1
2. Remove:
• brake caliper bolts
• washer
• brake caliper 1
1
6 - 16
FRONT BRAKE CHAS
3. Remove:
• retaining bolts
• brake pads 1
4. Measure:
• brake pad wear limit a
Out of specification → Replace the brake
pads as a set.
Brake pad wear limit

0.8 mm
5. Install:
• brake pads
• brake pad spring
NOTE:
_
Always install new brake pads and a new

brake pad spring as a set.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a clear plastic hose 1 tightly to the
bleed screw 2. Put the other end of the
hose into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
Bleed screw
6 Nm (0.6 m • kg)
T.
R.
d. Install new brake pads and a new brake pad

spring.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 17
FRONT BRAKE CHAS
6. Lubricate:
• retaining bolts
CAUTION:
_
• Do not allow grease to contact the brake

pads.
• Remove any excess grease.
7. Install:
• brake caliper
• brake caliper bolt 35 Nm (3.5 m • kg)
T.
R.
• retaining bolts 27 Nm (2.7 m • kg)
T.
R.
8. Check:
level.
LEVEL” in chapter 3.
9. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
6 - 18
FRONT BRAKE CHAS
EAS00619
DISASSEMBLING THE FRONT BRAKE

CALIPER
NOTE:
_
Before disassembling the brake caliper, drain

the brake fluid from the entire brake system.
1. Remove:
• union bolt 1
• copper washers 2
• brake hose
NOTE:
_
Put the end of the brake hose into a container

1 and pump out the brake fluid carefully.
2
2. Remove:
• retaining bolts 1
• brake caliper 2
1
3. Remove:
• brake caliper pistons 1
• brake caliper seals 2
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Blow compressed air into the brake hose
joint opening to force out the pistons from
the brake caliper.
WARNING
_
• Cover the brake caliper pistons with a

rag. Be careful not to get injured when the
pistons are expelled from the brake cali-
per.
• Never try to pry out the brake caliper pis-
tons.
b. Remove the brake caliper seals.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6 - 19
FRONT BRAKE CHAS
EAS00631
CHECKING THE FRONT BRAKE CALIPER
Recommended brake component

replacement schedule
Brake pads If necessary
Piston seals Every two years
Brake hoses Every four years
Every two years
and whenever the
Brake fluid
brake is disassem-
bled
1. Check:
Rust/scratches/wear → Replace the brake
caliper pistons.
• brake caliper cylinders 2
Scratches/wear → Replace the brake cali-
per assembly.
• brake caliper body 3
Cracks/damage → Replace the brake cali-
per assembly.
• brake fluid delivery passages
(brake caliper body)
air.
WARNING
_
Whenever a brake caliper is disassembled,

replace the piston seals.
6 - 20
FRONT BRAKE CHAS
EAS00634
ASSEMBLING AND INSTALLING THE

FRONT BRAKE CALIPER
WARNING
_
• Before installation, all internal brake com-

ponents should be cleaned and lubricated
with clean or new brake fluid.
components as they will cause the piston
seals to swell and distort.
• Whenever a brake caliper is disassem-
bled, replace the brake caliper piston
seals.

DOT 4
1. Install:
• brake caliper seals 1 New
2. Install:
• brake caliper 1
3 (temporarily)
• copper washers 2 New
• brake hose 3
• union bolt 4 26 Nm (2.6 m • kg)
T.
R.
4 WARNING
2
1
_
Proper brake hose routing is essential to

New
insure safe motorcycle operation. Refer to
“CABLE ROUTING” in chapter 2.
CAUTION:
_
b When installing the brake hose onto the

a
brake caliper 1, make sure the brake pipe
a touches the projection b on the brake
caliper.
1
6 - 21
FRONT BRAKE CHAS
3. Remove:
• brake caliper
4. Install:
• brake pad springs
• brake pads
• brake caliper
• brake caliper bolts (with washer)
35 Nm (3.5 m • kg)
T.
R.
• retaining bolts 27 Nm (2.7 m • kg)
T.
R.
5. Fill:
• brake master cylinder reservoir
mended brake fluid)

DOT 4
WARNING
_

performance.
not enter the brake master cylinder reser-
voir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
CAUTION:
_

6. Bleed:
• brake system
6 - 22
FRONT BRAKE CHAS
7. Check:
level.
8. Check:
system.
6 - 23
FRONT BRAKE CHAS
EASF0584
FRONT BRAKE MASTER CYLINDER

1 Brake master cylinder 6 Brake master cylinder holder
2 Brake lever 7 Front brake light switch
3 Brake master cylinder kit 8 Copper washer
4 Brake master cylinder reservoir cap 9 Union bolt
5 Brake master cylinder reservoir diaphragm 0 Brake hose
11 Nm (1.1 m • kg)
T.
R.
4
3
6
2
1
7
New 8
9
26 Nm (2.6 m • kg)
T.
R.
0
26 Nm (2.6 m • kg)
T.
R.
8 New
6 - 24
FRONT BRAKE CHAS
EAS00588
DISASSEMBLING THE FRONT BRAKE

MASTER CYLINDER
NOTE:
_
Before disassembling the front brake master

cylinder, drain the brake fluid from the entire
brake system.
1. Remove:
• rear view mirror (left and right)
2. Remove:
• handlebar cover (front) 1
1
3. Remove:
• handlebar cover (rear) screws
4. Remove:
• meter assembly screw
• handlebar cover (rear) 1
1
5. Disconnect:
• front brake light switch connectors 1
1
6 - 25
FRONT BRAKE CHAS
6. Remove:
• union bolt 1
• copper washers 2
• brake hose 3
NOTE:
_
To collect any remaining brake fluid, place a

container under the master cylinder and the
2
1 end of the brake hose.
3
7. Remove:
• brake master cylinder holder
• brake master cylinder
EAS00590
CHECKING THE FRONT BRAKE MASTER

CYLINDER
1. Check:
1
• brake master cylinder 1
• brake fluid delivery passages 2
2
(brake master cylinder body)
air.
2. Check:
• brake master cylinder kit
3. Check:
• brake master cylinder reservoir diaphragm
1
6 - 26
FRONT BRAKE CHAS
4. Check:
• brake hose 1
EAS00598
ASSEMBLING AND INSTALLING THE

FRONT BRAKE MASTER CYLINDER
WARNING
_
• Before installation, all internal brake com-

ponents should be cleaned and lubricated
with clean or new brake fluid.
components.

DOT 4
1. Install:
• brake master cylinder 1
• brake master cylinder holder
• brake master cylinder holder bolts
11 Nm (1.1 m • kg)
T.
R.
NOTE:
_
• Install the brake master cylinder holder with

the “UP” mark facing up.
• Adjust the brake master cylinder to the
proper angle.
• First, tighten the upper bolt, then the lower
bolt.
6 - 27
FRONT BRAKE CHAS
2. Install:
• copper washers 1 New
• brake hose 2
• union bolt 3 26 Nm (2.6 m • kg)
T.
R.
WARNING
_
Proper brake hose routing is essential to

New 1 insure safe motorcycle operation. Refer to
3 “CABLE ROUTING” in chapter 2.
2
NOTE:
_
• While holding the brake hose, tighten the

union bolt as shown.
• Turn the handlebar to the left and right to
make sure the brake hose does not touch
other parts (e.g., wire harness, cables,
leads). Correct if necessary.
3. Connect:
• front brake light switch connectors
4. Install:
• rear view mirror (left and right)
T.
R.
32 Nm (3.2 m • kg)
5. Fill:
• brake master cylinder reservoir
mended brake fluid)

DOT 4
WARNING
_

performance.
not enter the brake master cylinder reser-
voir. Water will significantly lower the
boiling point of the brake fluid and could
cause vapor lock.
6 - 28
FRONT BRAKE CHAS
CAUTION:
_

6. Bleed:
• brake system
7. Check:
level.
8. Check:
system.
6 - 29
FRONT FORK CHAS
FRONT FORK
1 Front fork cap bolt 7 Dust seal
2 O-ring 8 Oil seal clip
3 Fork spring 9 Oil seal
4 Damper rod 0 Outer tube
5 Rebound spring A Front fender
6 Inner tube
50 Nm (5.0 m • kg)
T.
R.
1
2
New
4
7 New
5 8 New
9 New
50 Nm (5.0 m • kg)
T.
R.
6 0
New
LT 23 Nm (2.3 m • kg)
T.
R.
7 Nm (0.7 m • kg)
T.
R.
6 - 30
FRONT FORK CHAS
EASF0651
REMOVING THE FRONT FORK LEGS

front fork legs.
NOTE:
_

2. Remove:
• front cover
3. Remove:
• brake hose holder
• brake caliper
Refer to “FRONT BRAKE”.
4. Remove:
• front wheel
Refer to “FRONT WHEEL AND BRAKE
DISC”.
5. Remove:
2 • front fender bolts 1
• washers
• front fender 2
1
6. Remove:
• front fork cap bolt 1
(with a 10-mm hexagonal wrench)
7. Loosen:
• lower bracket pinch bolt 1
WARNING
_
Before loosening the lower bracket pinch

bolt, support the front fork leg.
6 - 31
FRONT FORK CHAS
8. Remove:
• front fork leg 1
EAS00652
DISASSEMBLING THE FRONT FORK LEGS

front fork legs.
1. Remove:
• fork spring
2. Drain:
• fork oil
3. Remove:
• dust seal 1
• oil seal clip 2
(with a flat-head screwdriver)
CAUTION:
_
Do not scratch the inner tube.
4. Remove:
• damper rod assembly bolt
NOTE:
_
While holding the damper rod assembly with

the 10 mm hexagon nut/socket wrench 1 and
T-handle 2, loosen the damper rod assembly
bolt 3.
T-handle
90890-01326
6 - 32
FRONT FORK CHAS
5. Remove:
• inner tube
• damper rod
Pull out the inner tube with damper rod.
6. Remove:
• oil seal 1
CAUTION:
_
Never reuse the oil seal.
2 Rag
EAS00657
CHECKING THE FRONT FORK LEGS

1
front fork legs.
1. Check:
• inner tube 1
• outer tube 2
Bends/damage/scratches → Replace.
2
WARNING
_
Do not attempt to straighten a bent inner

tube as this may dangerously weaken it.
2. Measure:
• spring free length a
Spring free length

307.7 mm
<Limit>: 301.5 mm
3. Check:
• damper rod 1
1 Damage/wear → Replace.
Obstruction → Blow out all of the oil pas-
sages with compressed air.
6 - 33
FRONT FORK CHAS
EAS00659
ASSEMBLING THE FRONT FORK LEGS

front fork legs.
WARNING
_
• Make sure the oil levels in both front fork

legs are equal.
• Uneven oil levels can result in poor han-
dling and a loss of stability.
NOTE:
_
• When assembling the front fork leg, be sure

to replace the following parts:
- oil seal
- dust seal
• Before assembling the front fork leg, make
sure all of the components are clean.
1. Install:
• damper rod assembly 1
2
• rebound spring
• inner tube 2
1 CAUTION:
_
Allow the damper rod assembly to slide

slowly down the inner tube 2 until it pro-
trudes from the bottom of the inner tube.
Be careful not to damage the inner tube.
6 - 34
FRONT FORK CHAS
2. Lubricate:
• inner tube’s outer surface
Fork oil 10W or equivalent
3. Tighten:
• damper rod assembly bolt 1
23 Nm (2.3 m • kg)
LOCTITE®
T.
R.
NOTE:
_
While holding the damper rod assembly with

the 10 mm hexagon nut/socket wrench 2 and
T-handle 3, tighten the damper rod assembly
bolt.
T-handle
90890-01326
4. Install:
• oil seal 1 New
(with the fork seal driver weight and fork
seal driver attachment)
Fork seal driver attachment 2

90890-01186
Fork seal driver weight 3
90890-01184
CAUTION:
_
Make sure the numbered side of the oil seal

faces up.
NOTE:
_
• Before installing the oil seal, lubricate its lips

with lithium-soap-based grease.
• Lubricate the outer surface of the inner tube
with fork oil.
• Before installing the oil seal, cover the top of
the front fork leg with a plastic bag 4 to pro-
tect the oil seal during installation.
6 - 35
FRONT FORK CHAS
5. Install:
• oil seal clip 1 New
NOTE:
_
Adjust the oil seal clip so that it fits into the

outer tube’s groove.
6. Fill:
• front fork leg
mended fork oil)
Quantity (each front fork leg)

0.063 L (63.0 cm3)
Recommended oil
Yamaha fork and shock oil 10W
or equivalent
Front fork leg oil level a (from

the top of the inner tube, with the
inner tube fully compressed and
without the fork spring)
106 mm
NOTE:
_
• While filling the front fork leg, keep it upright.

• After filling, slowly pump the front fork leg up
and down to distribute the fork oil.
7. Install:
• spring 1
NOTE:
_
Install the spring with the smaller pitch facing

up.
6 - 36
FRONT FORK CHAS
EAS00663
INSTALLING THE FRONT FORK LEGS

front fork legs.
1. Install:
• front fork leg 1
• O-ring New
NOTE:
_
Pull up the inner tube until it stops, then install

the cap bolt.
1
2. Tighten:
50 Nm (5.0 m • kg)
T.
R.
• lower bracket pinch bolt 2
50 Nm (5.0 m • kg)
T.
R.
2
3. Install:
• front fender
• washers
• front fender bolts 7 Nm (0.7 m • kg)
T.
R.
4. Install:
• front wheel
Refer to “FRONT WHEEL AND BRAKE
DISC”.
5. Install:
• brake caliper
• brake hose holder
6. Install:
• front cover
6 - 37
HANDLEBAR CHAS
EASF0664
HANDLEBAR
1 Rear view mirror
2 Throttle grip
3 Handlebar
4 Throttle cable
5 Rear brake cable
6 Starter cable
7 Rear brake lever
8 Handlebar grip
32 Nm (3.2 m • kg)
1
T.
R.
2
LS
3
LS 7 Nm (0.7 m • kg)
T.
R.
4 8
LS
43 Nm (4.3 m • kg)
T.
R.
5
6
LS
6 - 38
HANDLEBAR CHAS
EASF0666
REMOVING THE HANDLEBAR

NOTE:
_
1. Remove:
• handlebar cover (left and right)
NOTE:
_
It is not necessary to disconnect the brake

hose when the brake fluid has been removed.
2. Remove:
1 • meter assembly 1
3. Disconnect:
• meter assembly couplers 2
• right handlebar switch coupler 3
3 • left handlebar switch couplers 4
• rear brake light switch coupler 5
2 5
4
4. Remove:
1 • plastic locking tie 1
• wire harness 2
5. Remove:
• right handlebar switch screws 1
2
• right handlebar switch 2
6 - 39
HANDLEBAR CHAS
6. Remove:
• throttle grip 2
2
7. Remove:
• starter lever screw 1
• starter lever washer
• starter lever 2
• starter cable 3
• spring washer
3
1 2
8. Remove:
2 1 • left handlebar switch screw 1
• left handlebar switch 2
9. Remove:
• rear brake light switch 1
10.Remove:
1 • handlebar grip 1
NOTE:
_
Blow compressed air between the handlebar

and the handlebar grip, and gradually push the
grip off the handlebar.
6 - 40
HANDLEBAR CHAS
11.Remove:
1 • rear brake cable 1
• rear brake lever bolt 2
• rear brake lever holder 3
2 3
12.Remove:
• handlebar nut 1
• handlebar bolt 2
3 • handlebar 3
EAS00668
CHECKING THE HANDLEBAR

1. Check:
• handlebar 1
1 WARNING
_
Do not attempt to straighten a bent handle-

bar as this may dangerously weaken it.
EASF0673
INSTALLING THE HANDLEBAR

NOTE:
_
2. Install:
• handlebar 1
NOTE:
_
Align the projection a on the handlebar with

1 a
the slit on the under bracket b.
b
6 - 41
HANDLEBAR CHAS
3. Tighten:
• handlebar bolt
• handlebar nut 43 Nm (4.3 m • kg)
T.
R.
4. Install:
• rear brake lever holder
• rear brake lever holder bolt
7 Nm (0.7 m • kg)
T.
R.
• rear brake cable
5. Install:
• handlebar grip
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a thin coat of rubber adhesive onto
the left end of the handlebar.
b. Slide the handlebar grip over the left end of
the handlebar.
c. Wipe off any excess rubber adhesive with a
clean reg.
WARNING
_
Do not touch the handlebar grip until the

rubber adhesive has fully dried.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
• rear brake light switch
7. Install:
1
a • left handlebar switch 1
• left handlebar switch screws
NOTE:
_
• Align the projection a on the left handlebar

b switch with the hole b on the handlebar.
• Make sure that the left handlebar switch is in
full contact with the handlebar grip.
8. Install:
0mm • spring washer
• starter cable
• starter lever
• starter lever washer
• starter lever screw
6 - 42
HANDLEBAR CHAS
9. Install:
• throttle grip 2
NOTE:
_
Lubricate the inside of the throttle grip with a

thin coat of lithium-soap-based grease and
install it onto the handlebar.
1 2
10.Install:
b • right handlebar switch 1
• right handlebar switch screws
a
1 WARNING
_
Make sure the throttle grip operates

smoothly.
NOTE:
_
Align the projection a on the right handlebar

switch with the hole b on the handlebar.
11.Install:
12.Connect:
• rear brake light switch coupler
• left handlebar switch couplers
• right handlebar switch coupler
• meter assembly couplers
13.Install:
• meter assembly
14.Install:
• wire harness
• plastic locking tie
15.Install:
• handlebar cover (front and rear)
16.Adjust:
CABLE FREE PLAY” in chapter 3.

3 ~ 7 mm
6 - 43
HANDLEBAR CHAS
18.Adjust:
• brake lever free play
Refer to “ADJUSTING THE REAR BRAKE”
in chapter 3.
Brake lever free play

10 ~ 20 mm
6 - 44
STEERING HEAD CHAS
STEERING HEAD
1 Upper ring nut 6 Bearing inner race
2 Lower ring nut 7 Lower bearing
3 Ball race cover 8 Lower bracket
4 Bearing outer race 9 Inner fender
5 Upper bearing
LS 4
5
6
LS 4
7
10 Nm (1.0 m • kg) 6
T.
R.
10 Nm (1.0 m • kg) 9
T.
R.
6 - 45
STEERING HEAD CHAS
EASF0679
REMOVING THE LOWER BRACKET

NOTE:
_
2. Remove:
• front fork
Refer to “FRONT FORK”.
• handlebar
Refer to “HANDLEBAR”.
3. Remove:
• brake hose/speedometer cable bracket 1
4. Remove:
• brake hose bracket 1
5. Remove:
• inner fender 1
6 - 46
STEERING HEAD CHAS
6. Remove:
• upper ring nut 1
• lower ring nut 2
• lower bracket
NOTE:
1 _
Hold the lower ring nut with the ring and steer-
ing nut wrench, and then remove the upper
2 ring nut with the ring nut wrench.
Ring nut wrench

90890-01268
Steering nut wrench
90890-01403
WARNING
_
Securely support the lower bracket so that

there is no danger of it falling.
EAS00681
CHECKING THE STEERING HEAD

1. Clean:
• bearings
• bearing races
Recommended cleaning solvent

Kerosene
2. Check:
2 • bearings 1
1
• bearing races 2
Damage/pitting → Replace.
6 - 47
STEERING HEAD CHAS
3. Replace:
• bearings
• bearing races
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bearing races from the steering
head pipe with a long rod 1 and hammer.
b. Remove the bearing race from the lower
bracket with a floor chisel 2 and hammer.
c. Install the new bearing races.
CAUTION:
_
If the bearing race is not installed properly,

the steering head pipe could be damaged.
NOTE:
_
Always replace the bearings and bearing races

as a set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check:
• lower bracket 1
(along with the steering stem)
1
EAS00683
INSTALLING THE STEERING HEAD

1. Lubricate:
• upper bearing
• lower bearing
• bearing races
2. Tighten:
• lower ring nut
• upper ring nut
Refer to “CHECKING AND ADJUSTING
THE STEERING HEAD” in chapter 3.
6 - 48
STEERING HEAD CHAS
3. Install:
• brake hose bracket
• brake hose bracket bolts
10 Nm (1.0 m • kg)
T.
R.
4. Install:
• brake hose/speedometer cable bracket
• brake hose/speedometer cable bracket
bolts 10 Nm (1.0 m • kg)
T.
R.
6 - 49
REAR SUSPENSION ARM CHAS
EASF0685
REAR SHOCK ABSORBER ASSEMBLY AND REAR SUSPENSION ARM

1 Rear shock absorber (right)
2 Rear shock absorber (left)
3 Axle nut
4 Collar
5 Oil seal
6 Bearing
7 Collar
8 Rear suspension arm
30 Nm (3.0 m • kg)
T.
R.
16 Nm (1.6 m • kg)
T.
R.
104 Nm (10.4 m • kg)

T.
R.
3
4
5
LS 2
30 Nm (3.0 m • kg)
9
T.
R.
6
5
7
LS
16 Nm (1.6 m • kg)
T.
R.
6 - 50
EASF0691
REMOVING THE REAR SHOCK ABSORBER

ASSEMBLIES
NOTE:
_

that the rear wheel is elevated.
2. Remove:
3. Remove:
• storage compartment
Refer to “CYLINDER HEAD” in chapter 4.
4. Remove:
Refer to “KICKSTARTER” in chapter 4.
5. Remove:
• muffler
chapter 4.
6. Remove:
• axle nut 1
• rear shock absorber lower bolt (right) 2
1
2 • rear suspension arm bolts 3
• rear suspension arm 4
3 • collar
7. Remove:
2 • rear shock absorber nut (right) 1
1
• rear shock absorber upper bolt (right) 2
• rear shock absorber (right) 3
6 - 51
8. Remove:
• rear shock absorber nut (left) 1
2 1 • rear shock absorber upper bolt (left) 2
• rear shock absorber lower bolt (left) 3
4 • rear shock absorber (left) 4
EAS00695
CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY
1. Check:
• rear shock absorber rod
Bends/damage → Replace the rear shock
absorber assembly.
• rear shock absorber
Oil leaks → Replace the rear shock
absorber assembly.
• spring
Damage/wear → Replace the rear shock
absorber assembly.
• bushings
Damage/wear → Replace the rear shock
absorber assembly.
• bolts
Bends/damage/wear → Replace.
CHECKING THE REAR SUSPENSION ARM

1. Check:
• bushing (rear shock absorber assembly)
2. Check:
• oil seals
• collar
6 - 52
CHECKING THE CRANKCASE (LEFT)
1. Check:
• bushing (rear shock absorber assembly)
EAS00699
INSTALLING THE REAR SHOCK

ABSORBER ASSEMBLIES
1. Install:
• rear shock absorber (left and right)
• rear shock absorber nut (left and right)
30 Nm (3.0 m • kg)
T.
R.
• rear shock absorber lower bolt (left)
16 Nm (1.6 m • kg)
T.
R.
2. Install:
• collar
• rear suspension arm
• rear suspension arm bolts
30 Nm (3.0 m • kg)
T.
R.
• rear shock absorber lower bolt
(right) 16 Nm (1.6 m • kg)
T.
R.
• axle nut 104 Nm (10.4 m • kg)

T.
R.
6 - 53
– +
ELEC
CHAPTER 7
ELECTRICAL
ELECTRICAL COMPONENTS........................................................................ 7-1
CHECKING SWITCH CONTINUITY................................................................7-3
CHECKING THE SWITCHES..........................................................................7-5
CHECKING THE BULBS AND BULB SOCKETS .......................................... 7-7

TYPES OF BULBS .................................................................................... 7-7
CHECKING THE CONDITION OF THE BULBS ....................................... 7-8
CHECKING THE CONDITION OF THE BULB SOCKETS .......................7-9
IGNITION SYSTEM ....................................................................................... 7-10

CIRCUIT DIAGRAM ................................................................................ 7-10
TROUBLESHOOTING ............................................................................7-11
ELECTRIC STARTING SYSTEM .................................................................. 7-15

CIRCUIT DIAGRAM ................................................................................ 7-15
STARTER MOTOR........................................................................................ 7-18

REMOVING THE STARTER MOTOR.....................................................7-19
DISASSEMBLING THE STARTER MOTOR...........................................7-19
CHECKING THE STARTER MOTOR .....................................................7-20
ASSEMBLING THE STARTER MOTOR................................................. 7-22
INSTALLING THE STARTER MOTOR ...................................................7-22
CHARGING SYSTEM....................................................................................7-23
CIRCUIT DIAGRAM ................................................................................ 7-23
LIGHTING SYSTEM ......................................................................................7-26

CIRCUIT DIAGRAM ................................................................................ 7-26
CHECKING THE LIGHTING SYSTEM....................................................7-28
SIGNALING SYSTEM ...................................................................................7-32

CIRCUIT DIAGRAM ................................................................................ 7-32
CHECKING THE SIGNALING SYSTEM ................................................. 7-34
– +
ELEC
– +
ELECTRICAL COMPONENTS ELEC
EAS00729
ELECTRICAL
ELECTRICAL COMPONENTS
1 Main switch
2 Wire harness
3 Battery
7-1
– +
ELECTRICAL COMPONENTS ELEC
1 Horn
2 Ignition coil
3 Rectifier/regulator
4 C.D.I. unit
5 Fuel sender
6 Starter relay
7 Turn signal relay
7 5
7-2
– +
CHECKING SWITCH CONTINUITY ELEC
EAS00730
“∞” “0”
CHECKING SWITCH CONTINUITY
Check each switch for continuity with the
pocket tester. If the continuity reading is incor-
rect, check the wiring connections and if nec-
essary, replace the switch.
“Ω×1”
CAUTION:
_
Never insert the tester probes into the cou-

pler terminal slots 1. Always insert the
probes from the opposite end of the cou-
pler, taking care not to loosen or damage
1
the leads.
Pocket tester
90890-03112
NOTE:
_
• Before checking for continuity, set the

pocket tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back
b and forth between the switch positions a
few times.
Br R
OFF The terminal connections for switches (e.g.,
a
ON
main switch, engine stop switch) are shown in
an illustration similar to the one on the left.
Br R
The switch positions a are shown in the far
left column and the switch lead colors b are
shown in the top row in the switch illustration.
NOTE:
_
“ ” indicates a continuity of electricity

between switch terminals (i.e., a closed circuit
at the respective switch position).
The example illustration on the left shows

that:
There is continuity between red and brown
when the switch is set to “ON”.
7-3
– +
CHECKING SWITCH CONTINUITY ELEC
7-4
– +
CHECKING THE SWITCHES ELEC
EAS00731
CHECKING THE SWITCHES

Check each switch for damage or wear, proper connections, and also for continuity between the ter-
minals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear → Repair or replace.
Improperly connected → Properly connect.
Incorrect continuity reading → Replace the switch.
1 2 3 4 5
Y P
P B Y/R L Y L G Ch Br/W Dg L Y/R
OFF OFF HI L
G B
B PUSH ON LO N
B R
Dg
(BLACK) Br/W
Ch
6 7
L/W B
OFF
START L/W Br
B G/Y
8
Br R
R
OFF
Br
ON
7-5
– +
CHECKING THE SWITCHES ELEC
1 Rear brake light switch
2 Horn switch
3 Light switch
4 Dimmer switch
5 Turn signal switch
6 Start switch
7 Front brake light switch
8 Main switch
9 Main fuse
7-6
– +
CHECKING THE BULBS AND BULB SOCKETS ELEC
EAS00732
CHECKING THE BULBS AND

BULB SOCKETS
Check each bulb and bulb socket for damage
or wear, proper connections, and also for con-
tinuity between the terminals.
Damage/wear → Repair or replace the
bulb, bulb socket or both.
Improperly connected → Properly connect.
No continuity → Repair or replace the bulb,
bulb socket or both.
TYPES OF BULBS
The bulbs used on this motorcycle are shown
in the illustration on the left.
• Bulbs A and B are used for the headlights
and usually use a bulb holder that must be
detached before removing the bulb. The
majority of these types of bulbs can be
removed from their respective socket by
turning them counterclockwise.
• Bulbs C is used for turn signal and tail/
brake lights and can be removed from the
socket by pushing and turning the bulb
counterclockwise.
• Bulbs D and E are used for meter and indi-
cator lights and can be removed from their
respective socket by carefully pulling them
out.
7-7
– +
CHECKING THE CONDITION OF THE
BULBS
bulbs.
1. Remove:
• bulb
WARNING
_
Since the headlight bulb gets extremely

hot, keep flammable products and your
hands away from the bulb until it has
cooled down.
CAUTION:
_
• Be sure to hold the socket firmly when

removing the bulb. Never pull the lead,
otherwise it may be pulled out of the ter-
minal in the coupler.
• Avoid touching the glass part of the head-
light bulb to keep it free from oil, other-
wise the transparency of the glass, the
life of the bulb, and the luminous flux will
be adversely affected. If the headlight
bulb gets soiled, thoroughly clean it with
a cloth moistened with alcohol or lacquer
thinner.
2. Check:
• bulb (for continuity)
No continuity → Replace.
Pocket tester
90890-03112
NOTE:
_
Before checking for continuity, set the pocket

tester to “0” and to the “Ω × 1” range.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the positive tester probe to termi-
nal 1 and the negative tester probe to ter-
minal 2, and check the continuity.
b. Connect the positive tester probe to termi-
nal 1 and the negative tester probe to ter-
minal 3, and check the continuity.
c. If either of the readings indicate no continu-
ity, replace the bulb.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-8
– +
CHECKING THE CONDITION OF THE BULB
SOCKETS
bulb sockets.
1. Check:
• bulb socket (for continuity)
No continuity → Replace.
Pocket tester
90890-03112
NOTE:
_
Check each bulb socket for continuity in the

same manner as described in the bulb section;
however, note the following.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install a good bulb into the bulb socket.
b. Connect the pocket tester probes to the
respective leads of the bulb socket.
c. Check the bulb socket for continuity. If any
of the readings indicate no continuity,
replace the bulb socket.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7-9
1
EAS00734
Br B O
OFF R R W B W/R W/L B
ON Br Br R Y
(BLACK)
Br R W W W/L W/L O O
R 6 Y Y/R 7 W/R W/R A B B
Br
W W
B
Y/R Y/R
B B C
CIRCUIT DIAGRAM
B B
R W/L W/R W/R W/L
R
IGNITION SYSTEM
3 L/W Br/Y B
(BLACK)
Br/Y
R 8
4
R L/W L/W
B 9
OFF 0
B
START
B2
5 Br L/W L/W Br
B G/Y B B G/Y
B
B B Br G/Y
7 - 10
Br Br
D
F Br/W Br B
Br
E G/Y B
(BLACK) (BLACK)
Br
P Br/W G/Y
R Br Ch Dg Y
G P Y/R Br/W
Ch Ch
P Y Y P H I J K
Y Dg Dg Y
Y/R L L Y/R
OFF OFF HI L
(BLACK) (BLACK) UU T T S B G G B
PUSH PUSH LO N
V R
Br Br Dg Dg
IGNITION SYSTEM
G G Br/W Br/W
B B Ch Ch
(BLACK) (BLACK) B L Y G Ch Dg
G B
1 Main switch
2 Battery
3 Main fuse
G Ch Dg L G/Y
ELEC
7 A.C. magneto O Ch Y G Dg L
A C.D.I. unit G G
–
B B M M N
B L L B
B Ignition coil G Y Y G P Q Q P
W (GREEN) Y G/Y
B B
C Spark plug Ch Dg Dg Ch
+
Dg Ch Ch Dg
B
– +
IGNITION SYSTEM ELEC
EAS00736 EAS00739
TROUBLESHOOTING
2. Battery
The ignition system fails to operate (no • Check the condition of the battery.
spark or intermittent spark). Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check:
1. main fuse Minimum open-circuit voltage
2. battery 12.8 V or more at 20°C
3. spark plug
• Is the battery OK?
4. ignition spark gap
5. spark plug cap resistance YES NO
6. ignition coil resistance
7. pickup coil resistance
8. main switch • Clean the battery
9. wiring connections terminals.
(of the entire ignition system) • Recharge or
replace the battery.
NOTE:
• Before troubleshooting, remove the following EAS00740
part(s): 3. Spark plug

1. rear panel
• Check the condition of the spark plug.
2. side panel (right)
• Check the spark plug type.
3. side panel (left)
• Measure the spark plug gap.
4. side cover (right)
Refer to “CHECKING THE SPARK PLUG”
5. front cover
in chapter 3.
• Troubleshoot with the following special
tool(s). Standard spark plug
CR7HSA (NGK)
Spark plug gap
Ignition checker 0.6 ~ 0.7 mm
90890-06754
Pocket tester • Is the spark plug in good condition, is it of
90890-03112 the correct type, and is its gap within spec-
ification?
EAS00738
1. Main fuse YES NO

• Check the main fuse for continuity.
Refer to “CHECKING THE FUSE” in chap- Re-gap or replace
ter 3. the spark plug.
• Is the main fuse OK?
YES NO
Replace the fuse.
7 - 11
– +
EAS00742 EAS00744
4. Ignition spark gap 5. Spark plug cap resistance

• Disconnect the spark plug cap from the • Remove the spark plug cap from the spark
spark plug. plug lead.
• Connect the ignition checker 1 as shown. • Connect the pocket tester (“Ω × 1k” range)
2 Spark plug cap to the spark plug cap as shown.
• Set the main switch to “ON”. • Measure the spark plug cap resistance.
• Crank the engine by pushing the starter
switch and gradually increase the spark
gap until a misfire occurs.
• Measure the ignition spark gap a. Ω×1k
Spark plug cap resistance

5 kΩ at 20°C
• Is the spark plug cap OK?

Minimum ignition spark gap YES NO
6 mm
• Is there a spark and is the spark gap within

Replace the spark
specification?
plug cap.
NO YES
The ignition system

is OK.
7 - 12
– +
EAS00746 EAS00748
6. Ignition coil resistance 7. Pickup coil resistance

• Disconnect the ignition coil connector from • Disconnect the pickup coil coupler from
the ignition coil terminal. the wire harness.
• Connect the pocket tester (Ω × 1) to the • Connect the pocket tester (Ω × 100) to the
ignition coil as shown. pickup coil terminal as shown.
Positive tester probe → terminal 1 Positive tester probe → white/blue 1
Negative tester probe → Negative tester probe → white/red 2
ignition coil base 2
2
B Y/R W W/R W/L
1 2 1
• Measure the pickup coil resistance.
• Measure the primary coil resistance.
Pickup coil resistance
Primary coil resistance 248 ~ 372 Ω at 20°C
0.32 ~ 0.48 Ω at 20°C (between white/blue and white/
red)
• Connect the pocket tester (Ω × 1k) to the
ignition coil as shown. • Is the pickup coil OK?
Negative tester probe → terminal 1 YES NO

Positive tester probe → spark plug lead 2
Replace the pickup

coil.
EAS00749
8. Main switch
• Check the main switch for continuity.
1
2 Refer to “CHECKING THE SWITCHES”.
• Is the main switch OK?
• Measure the secondary coil resistance. YES NO
Secondary coil resistance

5.68 ~ 8.52 kΩ at 20°C Replace the main
switch.
• Is the ignition coil OK?
YES NO
Replace the ignition

coil.
7 - 13
– +
EAS00754
9. Wiring
• Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the ignition system’s wiring properly
connected and without defects?
YES NO
Replace the C.D.I. Properly connect or

unit. repair the ignition
system’s wiring.
7 - 14
1 Br B O
EAS00755
ON Br Br R Y
(BLACK)
Br
W W
B
Y/R Y/R
B B C
B B
CIRCUIT DIAGRAM
R W/L W/R W/R W/L
R
3 L/W Br/Y B
(BLACK)
Br/Y
R 8
4
R L/W L/W
B 9
OFF 0
B
START
B2
5 Br L/W L/W Br
B G/Y B B G/Y
ELECTRIC STARTING SYSTEM
B B Br G/Y
Br Br
7 - 15
D
F Br/W Br B
Br
E G/Y B
(BLACK) (BLACK)
Br
P Br/W G/Y
R Br Ch Dg Y
G P Y/R Br/W
Ch Ch
P Y Y P H I J K
Y Dg Dg Y
Y/R L L Y/R
OFF OFF HI L
PUSH PUSH LO N
V R
Br Br Dg Dg
G G Br/W Br/W
B B Ch Ch
ELECTRIC STARTING SYSTEM
1 Main switch G B
2 Battery
3 Main fuse
G Ch Dg L G/Y
4 Starter relay O Ch Y G Dg L
ELEC
5 Starter motor G G
B B M M N
9 Start switch G Y Y G P Q Q P B L L B
–
W (GREEN) Y G/Y
0 Front brake light switch B B
Dg Ch Ch Dg Ch Dg Dg Ch
B
D Rear brake light switch
+
B B
– +
ELECTRIC STARTING SYSTEM ELEC
EAS00757 EAS00739
TROUBLESHOOTING
2. Battery
The starter motor fails to turn. • Check the condition of the battery.
Check:
1. main fuse
2. battery Minimum open-circuit voltage
3. starter motor 12.8 V or more at 20°C
4. starter relay
5. main switch
6. start switch YES NO
7. front brake light switch
8. rear brake light switch
9. wiring connections • Clean the battery
(of the entire starting system) terminals.
• Recharge or
NOTE:
• Before troubleshooting, remove the following replace the battery.
part(s): EAS00758
1. rear panel 3. Starter motor

2. side panel (right)
• Connect the positive battery terminal 1
3. side panel (left)
and starter motor lead 2 with a jumper
lead 3.
5. front cover
6. handlebar cover
tool(s).
Pocket tester
90890-03112
EAS00738
1. Main fuse
• Check the main fuse for continuity. WARNING
_
Refer to “CHECKING THE FUSE” in chap- • A wire that is used as a jumper lead
ter 3. must have at least the same capacity or
• Is the main fuse OK? more as that of the battery lead, other-
wise the jumper lead may burn.
YES NO • This check is likely to produce sparks,
therefore make sure nothing flammable
is in the vicinity.
Replace the fuse.
• Does the starter motor turn?
YES NO
Repair or replace the

starter motor.
7 - 16
– +
ELECTRIC STARTING SYSTEM ELEC
EAS00761 EAS00764
4. Starter relay 6. Start switch

• Disconnect the starter relay coupler from • Check the start switch for continuity.
the coupler. Refer to “CHECKING THE SWITCHES”.
• Connect the pocket tester (Ω × 1) and bat- • Is the start switch OK?
tery (DC 12 V) to the starter relay coupler
as shown. YES NO
Positive battery terminal →

brown/yellow 1 Replace the right
Negative battery terminal → blue/white 2 handlebar switch.
Positive tester probe → red 3
Negative tester probe → red 4 7. Front brake light switch
• Check the front brake light switch for conti-
3
nuity.
R
Refer to “CHECKING THE SWITCHES”.
• Is the front brake light switch OK?
R
L/W Br/Y YES NO

R
1 2
Replace the front
4 brake light switch.
• Does the starter relay have continuity
between red and red? 8. Rear brake light switch
• Check the rear brake light switch for conti-
YES NO
nuity.
Replace the starter • Is the rear brake light switch OK?
relay.
YES NO
EAS00749
5. Main switch
Replace the rear
brake light switch.
EAS00766
9. Wiring
YES NO
• Check the entire starting system’s wiring.
Replace the main • Is the starting system’s wiring properly
switch. connected and without defects?
YES NO
The starting system Properly connect or

circuit is OK. repair the starting
system’s wiring.
7 - 17
– +
STARTER MOTOR ELEC
EASF0767
STARTER MOTOR
1 Starter motor side cover
2 Starter motor yoke
3 Armature
4 Bush holder
5 Starter motor front cover
7 Nm (0.7 m • kg)
T.
R.
New
2
New
3
New
BRUSH LENGTH LIMIT:

A New
3.5 mm
COMMUTATOR WEAR LIMIT: 4
B LS
21 mm
MICA UNDER CUT: 5
C
1.5 mm
ARMATURE COIL RESISTANCE:
D
0.031 ~ 0.037 Ω at 20°C
7 - 18
– +
STARTER MOTOR ELEC
REMOVING THE STARTER MOTOR
2 1. Disconnect:
2. Remove:
• starter motor 2
1
DISASSEMBLING THE STARTER MOTOR

1 1. Remove:
2 • starter motor front cover bolts
(with washer and O-ring)
2. Remove:
• starter motor front cover 1
• washer 2
3. Remove:
1
• starter motor yoke 1
• O-rings 2 New
2
New
2
New
4. Remove:
• armature 1
1
7 - 19
– +
STARTER MOTOR ELEC
EAS00770
CHECKING THE STARTER MOTOR

1. Check:
• commutator
Dirt → Clean with 600 grit sandpaper.
2. Measure:
• commutator diameter a
Out of specification → Replace the starter
motor.
Commutator wear limit

21 mm
3. Measure:
• mica undercut a
Out of specification → Scrape the mica to
the proper measurement with a hacksaw
blade that has been grounded to fit the
commutator.
Mica undercut
1.5 mm
NOTE:
_
The mica of the commutator must be undercut

to ensure proper operation of the commutator.
7 - 20
– +
STARTER MOTOR ELEC
4. Measure:
• armature assembly resistances (commuta-
tor and insulation)
Out of specification → Replace the starter
motor.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the armature assembly resis-
tances with the pocket tester.
Pocket tester
90890-03112
Armature coil
Commutator resistance 1
0.031 ~ 0.037 Ω at 20°C
Insulation resistance 2
Above 1 MΩ at 20°C
b. If any resistance is out of specification,

replace the starter motor.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
• brush length a
Out of specification → Replace the brushes
as a set.
Brush length wear limit

3.5 mm
6. Measure:
• brush spring force
Out of specification → Replace the brush
springs as a set.
Brush spring force

5.52 ~ 8.28 N (563 ~ 844 gf)
7. Check:
• gear teeth
Damage/wear → Replace the gear.
8. Check:
• bearing
• oil seal
part(s).
7 - 21
– +
STARTER MOTOR ELEC
ASSEMBLING THE STARTER MOTOR
b a b
WARNING
_
Always use a new O-ring.
1. Install:
• starter motor assembly
NOTE:
_
Align the groove a on the starter motor

assembly with the groove b on the covers.
INSTALLING THE STARTER MOTOR

1 1. Install:
• starter motor 1
• starter motor bolts 7 Nm (0.7 m • kg)
T.
R.
2. Connect:
2
7 - 22
EAS00773
1 Br B O
ON Br Br R Y
(BLACK)
R 6 Y Y/R 7 W/R W/R A B
CIRCUIT DIAGRAM
Br
W W
B
Y/R Y/R
B B
CHARGING SYSTEM
B B
R W/L W/R W/R W/L
R
3 L/W Br/Y B
(BLACK)
Br/Y
R 8
4
R L/W L/W
B 9
OFF 0
B
START
B2
7 - 23
5 Br L/W L/W Br
B G/Y B B G/Y
B
B B Br G/Y
Br Br
D
F Br B
CHARGING SYSTEM
Br/W
Br
E G/Y B
(BLACK) (BLACK)
Br
P Br/W G/Y
R Br Ch Dg Y
G P Y/R Br/W
Ch
ELEC
2Ch Battery
P Y Y P H I J K
Y Dg Dg Y
3 Main fuse Y/R L L Y/R
OFF OFF HI L
–
6 Rectifier/regulator PUSH PUSH LO N
V R
Br
7 A.C.Brmagneto Dg Dg
+
G G Br/W Br/W
B B Ch Ch
– +
CHARGING SYSTEM ELEC
EAS00774 EAS00739
TROUBLESHOOTING
2. Battery
The battery is not being charged. • Check the condition of the battery.
Check:
1. main fuse
2. battery Minimum open-circuit voltage
3. charging voltage 12.8 V or more at 20°C
4. charging coil resistance
5. wiring connections
(of the entire charging system) YES NO
NOTE:
_
• Before troubleshooting, remove the follow-

ing part(s): • Clean the battery
1. seat terminals.
2. rear panel • Recharge or
3. side panel (right) replace the battery.
tool(s).
Engine tachometer
90890-03113
Pocket tester
90890-03112
EAS00738
1. Main fuse
• Check the main fuse for continuity.
Refer to “CHECKING THE FUSE” in chap-
ter 3.
YES NO
Replace the fuse.
7 - 24
– +
CHARGING SYSTEM ELEC
EAS00775 EAS00776
3. Charging voltage 4. Charging coil resistance

• Connect the engine tachometer to the • Connect the pocket tester (Ω × 1) to the
spark plug lead. charging coils as shown.
• Connect the pocket tester (DC 20 V) to the Positive tester probe → white 1
battery as shown. Negative tester probe → black 2
Positive tester probe →
positive battery terminal 1
Negative tester probe →
negative battery terminal 2
B Y/R W W/R W/L
2 1
• Measure the charging coil resistances.
Charging coil resistance (W – B)
0.32 ~ 0.48 Ω at 20°C
• Start the engine and let it run at approxi- • Is the charging coil OK?
mately 5,000 r/min.
• Measure the charging voltage. YES NO
Charging voltage
14 V at 5,000 r/min Replace the stator
coil assembly.
NOTE:
_
EAS00779
Make sure the battery is fully charged.
5. Wiring
• Is the charging voltage within specifica- • Check the wiring connections of the entire
tion? charging system.
NO YES • Is the charging system’s wiring properly
The charging circuit
YES NO
is OK.
Replace the rectifier/ Properly connect or

regulator. repair the charging
system’s wiring.
7 - 25
1 Br B O
1 Main switch
EAS00780
ON Br Br R Y
(BLACK)
2 Battery
3 Main fuse
Br R W W W/L W/L O
R 6 Y Y/R 7 W/R W/R A
6 OBRectifier/regulator
B
Br
W W
7 A.C. magneto
B
Y/R Y/R
B B
I Light switch
C
B B J Dimmer switch
CIRCUIT DIAGRAM
R W/L W/R W/R W/L N Tail/brake light

R
3 L/W Br/Y B Q Headlight
(BLACK)
LIGHTING SYSTEM
S High beam indicator light

Br/Y
R
U Meter light
8
4
R L/W L/W
B 9
OFF 0
B
START
B2
5 Br L/W L/W Br
B G/Y B B G/Y
B
B B Br G/Y
Br Br
7 - 26
F Br/W Br B
Br
E G/Y B
(BLACK) (BLACK)
Br
P Br/W G/Y
R Br Ch Dg Y
G P Y/R Br/W
Ch Ch
P Y Y P H I J K
Y Dg Dg Y
Y/R L L Y/R
OFF OFF HI L
PUSH PUSH LO N
V R
Br Br Dg Dg
G G Br/W Br/W
B B Ch Ch
LIGHTING SYSTEM
G B
G Ch Dg L G/Y
O Ch Y G Dg L
G G
ELEC
B B M M N
G Y Y G P Q Q P B L L B
W (GREEN) Y G/Y
B B
–
B
+
B B
– +
LIGHTING SYSTEM ELEC
EAS00781 EAS00739
TROUBLESHOOTING
2. Battery
Any of the following fail to light: head- • Check the condition of the battery.
light, high beam indicator light, taillight or Refer to “CHECKING AND CHARGING
meter light. THE BATTERY” in chapter 3.
Check: Minimum open-circuit voltage
1. main fuse 12.8 V or more at 20°C
2. battery
3. main switch
4. light switch YES NO
(of the entire lighting system)
• Clean the battery
NOTE:
_
• Before troubleshooting, remove the follow- terminals.

ing part(s): • Recharge or
1. rear panel replace the battery.
2. side panel (right) EAS00783
3. side panel (left) 3. Main switch

5. side cover (left)
6. front cover
7. handlebar cover
• Troubleshoot with the following special YES NO
tool(s).
Replace the main

Pocket tester switch.
90890-03112
EAS00738 4. Light switch
1. Main fuse • Check the light switch for continuity.
• Check the main fuse for continuity. Refer to “CHECKING THE SWITCHES”.
Refer to “CHECKING THE FUSE” in chap- • Is the light switch OK?
ter 3. YES NO
YES NO Replace the light

switch.
Replace the fuse.
7 - 27
– +
EAS00787 EAS00788
CHECKING THE LIGHTING SYSTEM
5. Wiring
1. The headlight and the high beam indicator
• Check the entire lighting system’s wiring. light fail to come on.
Refer to “CIRCUIT DIAGRAM”. EAS00784
• Is the lighting system’s wiring properly 1. Dimmer switch

• Check the dimmer switch for continuity.
YES NO Refer to “CHECKING THE SWITCHES”.
• Is the dimmer switch OK?
Check the condition Properly connect or YES NO

of each of the light- repair the lighting
ing system’s circuits. system’s wiring.
Refer to “CHECK- The dimmer switch is
ING THE LIGHTING faulty. Replace the
SYSTEM”. left handlebar
switch.
2. Headlight bulb and socket

• Check the headlight bulb and socket for
continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
• Are the headlight bulb and socket OK?
YES NO
Replace the head-

light bulb, socket or
both.
7 - 28
– +
3. Voltage • Set the main switch to “ON”.
• Start the engine.
• Connect the pocket tester (AC 20 V) to the
• Set the dimmer switch to “ ” or “ ”.
headlight and high beam indicator light
• Measure the voltage (AC 12 V) of green 1
couplers as shown.
(yellow 2) on the headlight coupler (wire
È When the dimmer switch is set to “ ”. harness side) and yellow 4 on the meter
É When the dimmer switch is set to “ ”. assembly coupler (wire harness side).
Headlight coupler (wire harness side) • Is the voltage within specification?
YES NO
É
AC20V 1 2 The wiring circuit
from the main switch
G Y to the headlight cou-
È B pler is faulty and
Dg Ch must be repaired.
3
Headlight
Positive tester probe →
green 1 or yellow 2
Negative tester probe → black 3
Meter light coupler (wire harness side)
Ch Ch
Dg Y Y Dg
4
Br Br
G G
B B
5
High beam indicator light
Positive tester probe → yellow 4
7 - 29
– +
EAS00776 EAS00789
2. The meter light fails to come on.

4. Lighting coil resistance
• Connect the pocket tester (Ω × 1) to the 1. Meter light bulb and socket
lighting coils as shown. • Check the meter light bulb and socket for
Positive tester probe → yellow/red 1 continuity.
Negative tester probe → black 2 Refer to “CHECKING THE BULBS AND
BULB SOCKETS”
• Are the meter light bulb and socket OK?
YES NO
Replace the meter

B Y/R W W/R W/L light bulb, socket or
both.
2 1
2. Voltage
• Measure the lighting coil resistances.
• Connect the pocket tester (DC 20 V) to the
Lighting coil resistance (Y/R – B)
meter light coupler (wire harness side) as
0.24 ~ 0.36 Ω at 20°C
shown.
• Is the lighting coil OK? Positive tester probe → brown 1
YES NO
This circuit is OK. Replace the stator 1

coil assembly.
Br Br
G G
B B
• Set the main switch to “ON”.

• Measure the voltage (DC 12 V) of brown
1 on the meter light coupler (wire harness
side).
• Is the voltage within specification?
YES NO
This circuit is OK. The wiring circuit

to the meter light
coupler is faulty and
must be repaired.
7 - 30
– +
EAS00790 EAS00776
3. The tail/brake light fails to come on.

3. Lighting coil resistance
1. Tail/brake light bulb and socket • Connect the pocket tester (Ω × 1) to the
• Check the tail/brake light bulb and socket lighting coils as shown.
for continuity. Positive tester probe → yellow/red 1
Refer to “CHECKING THE BULBS AND Negative tester probe → black 2
BULB SOCKETS”
• Are the tail/brake light bulb and socket
OK?
YES NO
Replace the tail/ B Y/R W W/R W/L

brake light bulb,
socket or both. 2 1
• Measure the lighting coil resistances.
2. Voltage
Lighting coil resistance (Y/R – B)
• Connect the pocket tester (AC 20 V) to the
0.24 ~ 0.36 Ω at 20°C
tail/brake light coupler (wire harness side)
as shown. • Is the lighting coil OK?
Positive tester probe → blue 1
YES NO
This circuit is OK. Replace the stator

1 2 coil assembly.
B L L B
Y G/Y
Ch Dg Dg Ch

• Start the engine.
• Measure the voltage (AC 12 V) of blue 1
on the tail/brake light coupler (wire har-
ness side).
YES NO
wiring circuit from

the main switch to
the tail/brake light
must be repaired.
7 - 31
1 Br B O
1 Main switch
EAS00793
ON Br Br R Y
(BLACK)
2 Battery
3 Main fuse
Br R W W W/L W/L
R 6 Y Y/R 7 W/R W/R A
0 OBFrontO brake light switch
B
Br
W W
D Rear brake light switch
B
Y/R Y/R
B B
E Turn signal relay
C
B B F Horn
CIRCUIT DIAGRAM
R W/L W/R W/R W/L H Horn switch

R
3 L/W Br/Y B K Turn signal switch
(BLACK) M Rear turn signal light
Br/Y
SIGNALING SYSTEM
R
N Tail/brake light
8
4 P Front turn signal light
R L/W L/W
B 9 T Turn signal indicator light
OFF 0 V Fuel gauge
B
START
B2
W Fuel sender
5 Br L/W L/W Br
B G/Y B B G/Y
B
B B Br G/Y
Br Br
7 - 32
F Br/W Br B
Br
E G/Y B
(BLACK) (BLACK)
Br
P Br/W G/Y
R Br Ch Dg Y
G P Y/R Br/W
Ch Ch
P Y Y P H I J K
Y Dg Dg Y
Y/R L L Y/R
OFF OFF HI L
PUSH PUSH LO N
V R
Br Br Dg Dg
G G Br/W Br/W
B B Ch Ch
SIGNALING SYSTEM
G B
G Ch Dg L G/Y
O Ch Y G Dg L
G G
ELEC
B B M M N
W (GREEN) Y G/Y
–
B B
B
+
B B
– +
SIGNALING SYSTEM ELEC
EAS00794 EAS00739
TROUBLESHOOTING
2. Battery
• Any of the following fail to light: turn • Check the condition of the battery.
signal light, brake light or an indicator Refer to “CHECKING AND CHARGING
light. THE BATTERY” in chapter 3.
• The horn fails to sound.
Minimum open-circuit voltage
Check: 12.8 V or more at 20°C
1. main fuse
2. battery
3. main switch YES NO
(of the entire signaling system)
• Clean the battery
NOTE:
_
• Before troubleshooting, remove the follow- terminals.

ing part(s): • Recharge or
1. rear panel replace the battery.
2. side panel (right) EAS00783
3. side panel (left) 3. Main switch

5. side cover (left)
6. front cover
7. handlebar cover
8. rubber cover YES NO
tool(s).
Replace the main
switch.
Pocket tester
EAS00795
90890-03112
4. Wiring
EAS00738
• Check the entire signal system’s wiring.

1. Main fuse
• Check the main fuse for continuity. • Is the signaling system’s wiring properly
Refer to “CHECKING THE FUSE” in chap- connected and without defects?
ter 3.
• Is the main fuse OK? YES NO
YES NO
Check the condition Properly connect or
of each of the signal- repair the signaling
Replace the fuse. ing system’s circuits. system’s wiring.
Refer to “CHECK-
ING THE SIGNAL-
ING SYSTEM”.
7 - 33
– +
EAS00796
CHECKING THE SIGNALING SYSTEM 3. Horn

1. The horn fails to sound. • Disconnect the pink connector at the horn
1. Horn switch terminal.
• Connect a jumper lead 1 to the horn ter-
• Check the horn switch for continuity.
minal and ground the jumper lead.
• Is the horn switch OK?
• Does the horn sound?
YES NO
Br
Replace the left han-

dlebar switch. 1
2. Voltage
horn connector at the horn terminal as
shown.
NO YES
Positive tester probe → brown 1
Negative tester probe → ground
The horn is OK.
Br P
4. Voltage
horn connector at the pink terminal as
1
shown.
Positive tester probe → pink 1

Br P
• Push the horn switch.
• Measure the voltage (DC 12 V) of brown at
the horn terminal.
• Is the voltage within specification? 1
YES NO
The wiring circuit • Set the main switch to “ON”.

from the main switch • Measure the voltage (DC 12 V) of pink 1
to the horn connec- at the horn terminal.
tor is faulty and must • Is the voltage within specification?
be repaired.
YES NO
Repair or replace the Replace the horn.

horn.
7 - 34
– +
EAS00797
2. The tail/brake light fails to come on. 3. Voltage

1. Tail/brake light bulb and socket • Connect the pocket tester (DC 20 V) to the
tail/brake light coupler (wire harness side)
• Check the tail/brake light bulb and socket
as shown.
for continuity.
Refer to “CHECKING THE BULBS AND Positive tester probe → green/yellow 1
BULB SOCKETS” Negative tester probe → black 2
• Are the tail/brake light bulb and socket
OK?
1 2
YES NO
B L L B
Y G/Y
Ch Dg Dg Ch
Replace the tail/
brake light bulb,
socket or both.
2. Brake light switches • Set the main switch to “ON”.

• Pull in the brake levers.
• Check the brake light switches for continu-
• Measure the voltage (DC 12 V) of green/
ity.
yellow 1 on the tail/brake light coupler
(wire harness side).
• Is the brake light switch OK?
YES NO
YES NO
Replace the brake

This circuit is OK. The wiring circuit
light switch.
to the tail/brake light
must be repaired.
7 - 35
– +
EAS00799
3. The turn signal light, turn signal indicator 3. Voltage

light or both fail to blink. • Connect the pocket tester (DC 20 V) to the
1. Turn signal indicator light bulb and socket turn signal relay coupler (wire harness
side) as shown.
• Check the turn signal light bulb and socket
for continuity. Positive tester probe → brown 1
Refer to “CHECKING THE BULBS AND Negative tester probe → ground
BULB SOCKETS”
• Are the turn signal light bulb and socket
OK?
Br/W
YES NO 1 Br
Replace the turn sig-

nal light bulb, socket
or both.
2. Turn signal switch • Measure the voltage (DC 12 V) on brown
1 at the turn signal relay coupler (wire
• Check the turn signal switch for continuity.
harness side).
• Is the turn signal switch OK?
YES NO
YES NO
The wiring circuit

Replace the left han-
dlebar switch.
to the turn signal
relay coupler is faulty
and must be
repaired.
7 - 36
– +
4. Voltage 5. Voltage
• Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (DC 20 V) to the
turn signal relay coupler (wire harness turn signal light connector (wire harness
side) as shown. side) as shown.
Positive tester probe → brown/white 1 È Rear turn signal light
Negative tester probe → ground Left turn signal light
Positive tester probe → chocolate 1
Right turn signal light
1 Br/W Positive tester probe → dark green 2
Br Negative tester probe → ground
É Front turn signal light
Left turn signal light
Positive tester probe → chocolate 3
• Set the main switch to “ON”. Right turn signal light
• Measure the voltage (DC 12 V) on brown/ Positive tester probe → dark green 4
white 1 at the turn signal relay coupler Negative tester probe → ground
(wire harness side). Ê Turn signal indicator light
• Is the voltage within specification? Positive tester probe → chocolate 5
YES NO
Positive tester probe → dark green 7
The turn signal relay È
is faulty and must be
replaced.
B L L B
Y G/Y
Ch Dg Dg Ch
2 1
Y G G Y
B B
Ch Dg Dg Ch
4 3
7 - 37
– +
EAS00804
Ê
5 4. The fuel level gauge fails to operate.
Ch Ch 1. Fuel sender
Dg Y Y Dg • Remove the fuel sender from the fuel tank.
7 • Connect the pocket tester to the fuel
Br Br sender coupler (fuel sender side) as
G G shown.
B B
Positive tester probe → green 1
6
• Set the turn signal switch to “ ” or “ ”. 2 1
• Measure the voltage (DC 12 V) of the
chocolate 1 or dark green 2 at the turn B G
signal light connector (wire harness side)
and chocolate 5 or dark green 7 at the
turn signal indicator light coupler (wire har- È
ness side).
• Is the voltage within specification? É
YES NO • Measure the fuel sender resistances.

Fuel sender resistance
This circuit is OK. The wiring circuit (up position È)
from the turn signal (Ω × 1)
4 ~ 10 Ω at 20°C
switch to the turn Fuel sender resistance
signal light connec- (down position É)
tor is faulty and must (Ω × 10)
be repaired. 90 ~ 100 Ω at 20°C
• Is the fuel sender OK?
YES NO
Replace the fuel

sender.
7 - 38
– +
2. Voltage 3. Fuel level gauge
• Connect the pocket tester (DC 20 V) to the • Set the main switch to “ON”.
meter coupler (wire harness side) as • Move the float up 1 or down 2.
shown. • Check that the fuel level gauge needle
Fuel level gauge moves to “F” or “E”.
Positive tester probe → brown 1 NOTE:
Negative tester probe → green 2
_
Before reading the fuel level gauge, leave the

float in one position (either up or down) for at
least three minutes.
E F
Br Br
G G
B B
2 1

• Measure the voltage (DC 12 V) of brown 2
1 on the meter coupler (wire harness
side). • Does the fuel level gauge needle move
• Is the voltage within specification? appropriately?
YES NO YES NO
Check the wiring This circuit is OK. Replace the fuel

connections of the level gauge.
entire signaling sys-
tem.
7 - 39
TRBL
SHTG
CHAPTER 8
TROUBLESHOOTING
TROUBLESHOOTING.....................................................................................8-1
ELECTRICAL SYSTEM.............................................................................8-1
COMPRESSION SYSTEMS ..................................................................... 8-2
INTAKE AND EXHAUST SYSTEM ........................................................... 8-3
TRBL
SHTG
TRBL
TROUBLESHOOTING SHTG
EASF0844
TROUBLESHOOTING
TROUBLESHOOTING
ELECTRICAL SYSTEM
CHECK ALL WIRE CONNECTIONS
IGNITION COIL (see page 7-12)

• Primary or secondary windings
are broken or faulty
• High tension lead is faulty
• Plug cap is faulty
C.D.I. unit
MAIN SWITCH (see page 7-5)
• C.D.I. unit is broken
• Main switch is shorted
SPARK PLUG
• Many carbon deposits
STARTER MOTOR (see page 7-18) • Electrodes are wet
• Starter motor is broken or faulty • Improper gap
• Starter relay is broken • Broken
• Starter switch is broken
CHARGING COIL (see page 7-25) /
PICKUP COIL (see page 7-13)
• Windings are broken
8-1
TRBL
COMPRESSION SYSTEMS
WEAR/SCRATCH/DAMAGE
WEAR/STICK/BROKEN
INSUFFICIENT TIGHTENING TORQUE
WEAR/SCRATCH
WEAR/CARBON DEPOSITS DAMAGE
DAMAGE
INSUFFICIENT TIGHTENING TORQUE
8-2
TRBL
INTAKE AND EXHAUST SYSTEM
FUEL TANK CAP

• Clogged
SILENCER
• Clogged EXHAUST PIPE AIR CLEANER ELEMENT
• Cracked or broken • Dirty or clogged
• Carbon deposits
JET NEEDLE
• Improperly adjusted
(medium speed)
THROTTLE STOP SCREW

PILOT SCREW • Improperly adjusted
• Improperly adjusted (idling and starting)
(idling and starting)
STARTER
• Improperly adjusted
(starting)
NEEDLE VALVE
• Wear
PILOT JET
MAIN JET • Clogged (low speed)
• Incorrect size
• Clogged (high speed) FLOAT
• Incorrect fuel level adjustment
• Puncture
FLOAT CHAMBER
• Accumulated dust and/or water
8-3
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
AT115 WIRING DIAGRAM
1
OFF R R W B
Br B O
1 Main switch
W/R W/L B
ON Br Br R Y 2 Battery
(BLACK) 3 Main fuse
Br R
4 Starter relay
O O
5 Starter motor
W W W/L W/L
W W
Br 6 Rectifier/regulator
Y/R Y/R
B
7 A.C. magneto
B B C 8 Right handlebar switch
B B
9 Start switch
R W/L W/R W/R W/L
0 Front brake light switch
3
R
L/W Br/Y B
A C.D.I. unit
(BLACK) B Ignition coil
Br/Y C Spark plug
R 8 D Rear brake light switch
4 E Turn signal relay
L/W L/W
F Horn
R
B 9
OFF 0 G Left handlebar switch
B2
B
START H Horn switch
5 Br L/W L/W Br
I Light switch
B G/Y B B G/Y J Dimmer switch
K Turn signal switch
B
B B Br G/Y
L Tail/brake light unit assembly
B M Rear turn signal light
N Tail/brake light
O Headlight unit assembly
Br Br
P Front turn signal light
D Q Headlight
F Br/W
E
Br B
R Meter assembly
G/Y B
Br
S High beam indicator light
(BLACK) (BLACK)
Br
T Turn signal indicator light
R
P Br/W G/Y U Meter light
Br Ch Dg Y
G P Y/R Br/W V Fuel gauge
Ch Ch
P Y Y P H I J K W Fuel sender
Y Dg Dg Y
Y/R L L Y/R
OFF OFF HI L
PUSH PUSH LO N
V R
Br Br Dg Dg
G G Br/W Br/W
B B Ch Ch
G B
G Ch Dg L G/Y
O Ch Y G Dg L
G G
B B M M N
W (GREEN)
B B Y G/Y
B
B B
COLOR CODE
B .............Black P ............ Pink L/W .........Blue/White
Br............Brown R ............ Red W/L .........White/Blue
Ch...........Chocolate W ........... White W/R ........White/Red
Dg...........Dark green Y ............ Yellow Y/R .........Yellow/Red
G ............Green Br/W....... Brown/White
L .............Blue Br/Y........ Brown/Yellow
Or ...........Orange G/Y ........ Green/Yellow

At115 2002 (Nouvo) 5mx-F8197-E0

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

At115 2002 (Nouvo) 5mx-F8197-E0

Загружено:

Авторское право:

Доступные форматы

AT115

Designs and specifications are subject to change without notice.

IMPORTANT MANUAL INFORMATION

HOW TO USE THIS MANUAL

3rd title 3: This is a final title.

alignment mark 7, the others being indicated by an alphabetical letter in a box 8.

G H I Symbols G to L in the exploded diagrams

ELECTRICAL SYSTEM ELEC 7

IMPORTANT INFORMATION ......................................................................... 1-6

CHECKING THE CONNECTIONS ..................................................................1-8

SPECIAL TOOLS ............................................................................................ 1-9

1 Crankshaft 6 Secondary fixed sheave A Clutch carrier

1 2 Clutch-in revolution 2,550 ~ 2,950 rpm

Normal operation Climbing hills or quick acceleration

1 Secondary fixed sheave È Small load on rear wheel

Do not spin the bearing with compressed

CHECKING THE CONNECTIONS

If the pin 1 on the terminal is flattened, bend it

Make sure all connections are tight.

• If there is no continuity, clean the terminals.

This tool is used to installing the oil seal.

This tool is used to installing the oil seal.

This tool is used for removing the rotor.

This tool is used to install oil seals.

GENERAL SPECIFICATIONS ........................................................................ 2-1

MAINTENANCE SPECIFICATIONS ............................................................... 2-4

GENERAL TIGHTENING TORQUE SPECIFICATIONS...............................2-16

LUBRICATION POINTS AND LUBRICANT TYPES .................................... 2-17

CABLE ROUTING ......................................................................................... 2-19

Winding direction IN/EX Clockwise ----

Cylinder head (timing chain side) Bolt M6 2 10 1.0

Exhaust pipe protector Bolt M6 2 11 1.1

Muffler protector 2 Bolt M6 2 11 1.1 LT

Intake manifold Bolt M6 2 10 1.0

Item Standard Limit

Master cylinder inside diameter 11 mm ----

Front fork and brake hose holder M6 7 0.7

Rear view mirror M10 32 3.2

Sidestand nut M8 16 1.6

Item Standard Limit

GENERAL TIGHTENING TORQUE

Lubrication point Lubricant

Piston outside and ring groove E

Cylinder inner surface E

Rocker arm shaft M

Rocker arm inner surfaces M

Camshaft lobes and camshaft journals E

Valve stem seal M

Kickstarter pinion gear shaft LS

Idle gear shaft LS

Crankcase mating surfaces Yamaha bond No.1215

Lubrication point Lubricant

Rear wheel oil seal lips LS

Front wheel axle LS

Speedometer gear fitting area LS

Brake pad retaining bolt and boot LS

Brake cam pivot shaft and cam surface LS

Brake cable (brake lever) LS

Tube guide (throttle grip) inner surface LS

Throttle cable (throttle grip) LS

Starter cable (starter lever) LS

Steering head pipe bearing (upper/lower) LS

PERIODIC MAINTENANCE AND LUBRICATION INTERVALS .................... 3-1