Yfm90r 2016 Bd3-F8197-E0

2016
SERVICE MANUAL
YF09RG
YFM09RYXG
BD3-F8197-E0
EBS20002
YF09RG/YFM09RYXG
SERVICE MANUAL
©2015 by Yamaha Motor Co., Ltd.
First edition, June 2015
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EBS20003
IMPORTANT
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers
and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual. 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 vehi-
cle unsafe and unfit for use.
This model has been designed and manufactured to perform within certain specifications in regard to
performance and emissions. Proper service with the correct tools is necessary to ensure that the vehi-
cle will operate as designed. If there is any question about a service procedure, it is imperative that you
contact a Yamaha dealer for any service information changes that apply to this model. This policy is
intended to provide the customer with the most satisfaction from his vehicle and to conform to federal
environmental quality objectives.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and
will appear in future editions of this manual where applicable.
TIP
Designs and specifications are subject to change without notice.
EBS30001
IMPORTANT MANUAL INFORMATION

Particularly important information is distinguished in this manual by the following notations.
This is the safety alert symbol. It is used to alert you to potential personal inju-
ry hazards. Obey all safety messages that follow this symbol to avoid possible
injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could result

WARNING in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to

NOTICE the vehicle or other property.
TIP A TIP provides key information to make procedures easier or clearer.

EBS20004
HOW TO USE THIS MANUAL

This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive
explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid
out with the individual steps in sequential order.
• The manual is divided into chapters and each chapter is divided into sections. The current section title
“1” is shown at the top of each page.
• Sub-section titles “2” appear in smaller print than the section title.
• To help identify parts and clarify procedure steps, there are exploded diagrams “3” at the start of each
removal and disassembly section.
• Numbers “4” are given in the order of the jobs in the exploded diagram. A number indicates a disas-
sembly step.
• Symbols “5” indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
• A job instruction chart “6” accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc. This step explains removal and disassembly procedure only. For installation
and assembly procedure, reverse the steps.
• Jobs “7” requiring more information (such as special tools and technical data) are described sequen-
tially.
4
5
7
EBS20005
SYMBOLS
The following symbols are used in this manual for easier understanding.
TIP
The following symbols are not relevant to every vehicle.
SYMBOL DEFINITION SYMBOL DEFINITION
Serviceable with engine mounted Gear oil

G
Filling fluid Molybdenum disulfide oil

M
Lubricant Brake fluid

BF
Special tool B Wheel bearing grease
Tightening torque LS Lithium-soap-based grease

T.
R.
Wear limit, clearance M Molybdenum disulfide grease
Engine speed S Silicone grease
Electrical data Apply locking agent (LOCTITE®).

LT
Engine oil New Replace the part with a new one.

E
EBS10003
TABLE OF CONTENTS
GENERAL INFORMATION 1
SPECIFICATIONS 2
PERIODIC CHECKS AND
ADJUSTMENTS 3
CHASSIS 4
ENGINE 5
FUEL SYSTEM 6
ELECTRICAL SYSTEM 7
TROUBLESHOOTING 8
GENERAL INFORMATION
IDENTIFICATION ............................................................................................ 1-1

VEHICLE IDENTIFICATION NUMBER .....................................................1-1
MODEL LABEL.......................................................................................... 1-1
IMPORTANT INFORMATION ......................................................................... 1-2

1
PREPARATION FOR REMOVAL AND DISASSEMBLY........................... 1-2
REPLACEMENT PARTS...........................................................................1-2
GASKETS, OIL SEALS AND O-RINGS .................................................... 1-2
LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-2
BEARINGS AND OIL SEALS .................................................................... 1-3
CIRCLIPS ..................................................................................................1-3
RUBBER PARTS.......................................................................................1-3
BASIC SERVICE INFORMATION...................................................................1-4

QUICK FASTENERS................................................................................. 1-4
ELECTRICAL SYSTEM.............................................................................1-5
SPECIAL TOOLS ............................................................................................ 1-9

IDENTIFICATION
EBS20009
IDENTIFICATION
EBS30003
VEHICLE IDENTIFICATION NUMBER

The vehicle identification number “1” is stamped
into the frame.
EBS30004
MODEL LABEL
The model label “1” is affixed to the rear fender
under the seat. This information will be needed
to order spare parts.
1-1
IMPORTANT INFORMATION
EBS20011
EBS30009
PREPARATION FOR REMOVAL AND

DISASSEMBLY
1. Before removal and disassembly, remove all
dirt, mud, dust and foreign material.
EBS30011
GASKETS, OIL SEALS AND O-RINGS

1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfac-
es, oil seal lips and O-rings must be cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
2. Use only the proper tools and cleaning equip- lips with grease.
ment.
Refer to “SPECIAL TOOLS” on page 1-9.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders,
pistons and other parts that have been “mat-
ed” through normal wear. Mated parts must
always be reused or replaced as an assem-
bly.
1. Oil
2. Lip
3. Spring
4. Grease
EBS30012
LOCK WASHERS/PLATES AND COTTER

PINS
After removal, replace all lock washers/plates
4. During disassembly, clean all of the parts and “1” and cotter pins. After the bolt or nut has been
place them in trays in the order of disassem- tightened to specification, bend the lock tabs
bly. This will speed up assembly and allow for along a flat of the bolt or nut.
the correct installation of all parts.
5. Keep all parts away from any source of fire.
EBS30010
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replace-
ments. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
1-2
EBS30013 EBS30015
BEARINGS AND OIL SEALS RUBBER PARTS

Install bearings “1” and oil seals “2” so that the Check rubber parts for deterioration during in-
manufacturer’s marks or numbers are visible. spection. Some of the rubber parts are sensitive
When installing oil seals, lubricate the oil seal to gasoline, flammable oil, grease, etc. Do not al-
lips with a light coat of lithium-soap-based low any items other than the specified one to
grease. Oil bearings liberally when installing, if contact the parts.
appropriate.
ECB01260
NOTICE
Do not spin the bearing with compressed air
because this will damage the bearing surfac-
es.
EBS30014
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips. Al-
ways 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.
1-3
BASIC SERVICE INFORMATION
EBS20012

EBS30016
QUICK FASTENERS
Rivet type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, push its pin with a
screwdriver, then pull the fastener out. Screw type
1. Remove:
• Quick fastener
TIP
To remove the quick fastener, loosen the screw
with a screwdriver, then pull the fastener out.
2. Install:
• Quick fastener
TIP
To install the quick fastener, push its pin so that
it protrudes from the fastener head, then insert
the fastener into the part to be secured and push 2. Install:
the pin in with a screwdriver. Make sure that the • Quick fastener
pin is flush with the fastener’s head.
TIP
To install the quick fastener, insert the fastener
into the part to be secured and tighten the screw.
1-4
ECB01520
EBS30017
NOTICE
ELECTRICAL SYSTEM
Be sure to connect the battery leads to the
Electrical parts handling correct battery terminals. Reversing the bat-
ECB01460 tery lead connections could damage the
NOTICE electrical components.
Never disconnect a battery lead while the en-
gine is running; otherwise, the electrical
components could be damaged.
ECB01530
NOTICE
When connecting the battery leads to the
ECB01510 battery, be sure to connect the positive bat-
NOTICE tery lead first, then the negative battery lead.
When disconnecting the battery leads from If the negative battery lead is connected first
the battery, be sure to disconnect the nega- and a tool or similar item contacts the vehi-
tive battery lead first, then the positive bat- cle while the positive battery lead is being
tery lead. If the positive battery lead is connected, a spark could be generated,
disconnected first and a tool or similar item which is extremely dangerous.
contacts the vehicle, a spark could be gener-
ated, which is extremely dangerous.
ECB01470
NOTICE
TIP Turn the main switch to “OFF” before dis-

connecting or connecting an electrical com-
If a battery lead is difficult to disconnect due to
ponent.
rust on the battery terminal, remove the rust us-
ing hot water.
1-5
ECB01480
NOTICE Checking the electrical system

Handle electrical components with special TIP
care, and do not subject them to strong Before checking the electrical system, make
shocks. sure that the battery voltage is at least 12 V.
ECB01490 ECB01440
NOTICE NOTICE
Electrical components are very sensitive to Never insert the tester probes into the cou-
and can be damaged by static electricity. pler terminal slots. Always insert the probes
Therefore, never touch the terminals and be from the opposite end “a” of the coupler, tak-
sure to keep the contacts clean. ing care not to loosen or damage the leads.
ECB01500
TIP
NOTICE
When resetting the ECU by turning the main
switch to “OFF”, be sure to wait approximately 5 For waterproof couplers, never insert the
seconds before turning the main switch back to tester probes directly into the coupler. When
“ON”. performing any checks using a waterproof
coupler, use the specified test harness or a
suitable commercially available test har-
ness.
1-6
2. Check:
Checking the connections
• Lead
Check the leads, couplers, and connectors for
• Coupler
stains, rust, moisture, etc.
• Connector
1. Disconnect:
Moisture → Dry with an air blower.
• Lead
Rust/stains → Connect and disconnect sev-
• Coupler
eral times.
• Connector
ECB01540
NOTICE
• When disconnecting a coupler, release the
coupler lock, hold both sections of the cou-
pler securely, and then disconnect the cou-
pler.
• There are many types of coupler locks;
therefore, be sure to check the type of cou-
pler lock before disconnecting the coupler.
3. Connect:
• Lead
• Coupler
• Connector
TIP
• When connecting a coupler or connector, push
both sections of the coupler or connector to-
gether until they are connected securely.
• Make sure all connections are tight.
ECB01550
NOTICE
When disconnecting a connector, do not pull
the leads. Hold both sections of the connec-
tor securely, and then disconnect the con-
nector.
1-7
4. Check:
• Continuity
(with the pocket tester)
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
TIP
• 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
SPECIAL TOOLS
EBS20013
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 inappropriate 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.
TIP
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, “YS-”, “YK-”, or “ACC-”.
• For others, use part number starting with “90890-”.
Reference
Tool name/Tool No. Illustration
pages
Pocket tester 1-8, 7-23, 7-24,
90890-03112 7-27, 7-28, 7-28,
Analog pocket tester 7-28, 7-29, 7-30,
YU-03112-C 7-30
Thickness gauge 3-5

90890-03079
Narrow gauge set
YM-34483
Tappet adjusting tool 3-5

90890-01311
Six piece tappet set
YM-A5970
YM-A5970
ø8 ø9 ø10
ø3 ø4
Ring nut wrench 3-15, 3-16
90890-01268
Spanner wrench
YU-01268
Axle nut wrench (36 mm) 4-18, 4-20

90890-01422
Rear axle retaining nut wrench
YM-37132
YM-37132
1-9
SPECIAL TOOLS
Reference
pages
Yamaha bond No. 1215 4-19, 5-30, 5-54
90890-85505
(Three bond No.1215®)
Extension 5-1
90890-04082
Compression gauge 90890-03081 5-1

90890-03081
Engine compression tester
YU-33223
YU-33223
Valve spring compressor 5-17, 5-22

90890-04019
Valve spring compressor
YM-04019
Valve spring compressor attachment 5-17, 5-22

90890-01243
Valve spring compressor adapter (26 mm)
YM-01253-1
Valve guide remover (ø5) 5-19

90890-04097
Valve guide remover (5.0 mm)
YM-04097
Valve guide installer (ø5) 5-19

90890-04098
Valve guide installer (5.0 mm)
YM-04098
Valve guide reamer (ø5) 5-19

90890-04099
Valve guide reamer (5.0 mm)
YM-04099
1-10
SPECIAL TOOLS
Reference
pages
Piston pin puller set 5-24
90890-01304
Piston pin puller
YU-01304
YU-01304
Rotor holding tool 5-29, 5-30, 5-46,

90890-01235 5-46, 5-49, 5-50
Universal magneto and rotor holder
YU-01235
Flywheel puller 5-29

90890-01189
Flywheel puller
YM-01189
Digital circuit tester 5-37

90890-03174
Model 88 Multimeter with tachometer
YU-A1927
Rotor holding tool 5-46, 5-49

90890-04166
YM-04166
Socket wrench (39 mm) 5-46, 5-49

90890-01493
Clutch spring holder 5-47, 5-48

90890-01337
Universal clutch compressor holder
YM-33285
Fuel level gauge 6-10

90890-01312
Fuel level gauge
YM-01312-A
1-11
SPECIAL TOOLS
Reference
pages
Ignition checker 7-29
90890-06754
Oppama pet–4000 spark checker
YM-34487
Digital tachometer 7-30

90890-06760
Digital tachometer
YU-39951-B
1-12
SPECIAL TOOLS
1-13
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
ENGINE SPECIFICATIONS ............................................................................2-2
CHASSIS SPECIFICATIONS ..........................................................................2-6
ELECTRICAL SPECIFICATIONS ...................................................................2-8
TIGHTENING TORQUES ................................................................................ 2-9

2
GENERAL TIGHTENING TORQUE SPECIFICATIONS........................... 2-9
ENGINE TIGHTENING TORQUES......................................................... 2-10
CHASSIS TIGHTENING TORQUES.......................................................2-12
LUBRICATION AND SEALING POINTS ......................................................2-14

ENGINE................................................................................................... 2-14
LUBRICATION SYSTEM CHART AND DIAGRAMS.................................... 2-15

LUBRICATION DIAGRAMS .................................................................... 2-15
CABLE ROUTING ......................................................................................... 2-17

GENERAL SPECIFICATIONS
EBS20014
GENERAL SPECIFICATIONS
Model
Model BD31 (for Oceania and Mexico)
BD32 (for CDN)
BD33 (for Europe)
Dimensions
Overall length 1485 mm (58.5 in)
Overall width 1020 mm (40.2 in)
Overall height 955 mm (37.6 in)
Seat height 750 mm (29.5 in)
Wheelbase 1030 mm (40.6 in)
Ground clearance 100 mm (3.9 in)
Minimum turning radius 3000 mm (118 in)
Maximum water depth 20 cm (8 in)
Weight
Curb weight 126.5 kg (279 lb)
Maximum loading limit 82.0 kg (181 lb)
2-1
ENGINE SPECIFICATIONS
EBS20015
Engine
Engine type Air cooled 4-stroke, SOHC
Cylinder arrangement Single cylinder
Displacement 89 cm³
Bore × stroke 47.0 × 51.8 mm (1.85 × 2.04 in)
Compression ratio 9.2 : 1
Standard compression pressure (at sea level) 790–1080 kPa (7.9–10.8 kgf/cm², 112.4–153.6
psi)
Starting system Electric starter and kickstarter
Fuel
Recommended fuel Regular unleaded gasoline only
Fuel tank capacity 6.6 L (1.74 US gal, 1.45 Imp.gal)
Fuel reserve amount 0.9 L (0.24 US gal, 0.20 Imp.gal)
Engine oil
Lubrication system Wet sump
Recommended brand YAMALUBE
Type SAE 10W-50
Recommended engine oil grade API service SG type or higher, JASO standard
MA
Periodic oil change 0.90 L (0.95 US qt, 0.79 Imp.qt)
Quantity (disassembled) 0.90 L (0.95 US qt, 0.79 Imp.qt)
Engine oil quantity
Periodic oil change 0.90 L (0.95 US qt, 0.79 Imp.qt)
Quantity (disassembled) 0.90 L (0.95 US qt, 0.79 Imp.qt)
Transmission oil
Type SAE 80W-90
Quantity 0.35 L (0.37 US qt, 0.31 Imp.qt)
Oil pump
Inner-rotor-to-outer-rotor-tip clearance limit 0.15 mm (0.0059 in)
Outer-rotor-to-oil-pump-housing clearance limit 0.240 mm (0.0094 in)
Spark plug (s)

Manufacturer/model NGK/CR6HSA
Spark plug gap 0.6–0.7 mm (0.024–0.028 in)
Cylinder head
Warpage limit 0.05 mm (0.0020 in)
Camshaft
Drive system Chain drive (left)
Camshaft lobe dimensions
Lobe height (Intake) limit 26.200 mm (1.0315 in)
Base circle diameter (Intake) limit 20.650 mm (0.8130 in)
Lobe height (Exhaust) limit 26.000 mm (1.0236 in)
Base circle diameter (Exhaust) limit 20.650 mm (0.8130 in)
2-2
Rocker arm/rocker arm shaft

Rocker arm inside diameter limit 10.100 mm (0.3976 in)
Rocker arm shaft outside diameter limit 9.910 mm (0.3902 in)
Rocker-arm-to-rocker-arm-shaft clearance limit 0.190 mm (0.0075 in)
Valve, valve seat, valve guide

Valve clearance (cold)
Intake 0.06–0.09 mm (0.0024–0.0035 in)
Exhaust 0.06–0.09 mm (0.0024–0.0035 in)
Valve dimensions
Valve head diameter (intake) 22.90–23.10 mm (0.9016–0.9094 in)
Valve head diameter (exhaust) 19.90–20.10 mm (0.7835–0.7913 in)
Valve seat contact width (intake) limit 1.6 mm (0.06 in)
Valve seat contact width (exhaust) limit 1.6 mm (0.06 in)
Valve stem diameter (intake) limit 4.900 mm (0.1929 in)
Valve stem diameter (exhaust) limit 4.900 mm (0.1929 in)
Valve guide inside diameter (intake) limit 5.030 mm (0.1980 in)
Valve guide inside diameter (exhaust) limit 5.030 mm (0.1980 in)
Valve-stem-to-valve-guide clearance (intake)
limit 0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clearance
(exhaust) limit 0.100 mm (0.0039 in)
Valve stem runout 0.020 mm (0.0008 in)
Valve spring
Inner spring
Free length (intake) 32.41 mm (1.28 in)
Free length (exhaust) 32.41 mm (1.28 in)
Spring tilt (intake) 2.0 mm (0.08 in)
Spring tilt (exhaust) 2.0 mm (0.08 in)
Winding direction (intake) Counterclockwise
Winding direction (exhaust) Counterclockwise
Outer spring
Free length (intake) 35.25 mm (1.39 in)
Free length (exhaust) 35.25 mm (1.39 in)
Spring tilt (intake) 2.0 mm (0.08 in)
Spring tilt (exhaust) 2.0 mm (0.08 in)
Winding direction (intake) Clockwise
Winding direction (exhaust) Clockwise
Cylinder
Bore 47.000–47.010 mm (1.8504–1.8508 in)
Taper limit 0.050 mm (0.0020 in)
Out of round limit 0.050 mm (0.0020 in)
Wear limit 47.100 mm (1.8543 in)
Piston
Piston-to-cylinder clearance 0.010–0.040 mm (0.0004–0.0016 in)
Diameter 46.970–46.990 mm (1.8492–1.8500 in)
Measuring point (from piston skirt bottom) 5.0 mm (0.20 in)
Offset 0.50 mm (0.0197 in)
Offset direction Intake side
2-3
Piston pin bore inside diameter limit 13.040 mm (0.5134 in)

Piston pin outside diameter limit 12.960 mm (0.5102 in)
Piston ring
Top ring
Ring type Barrel
End gap (installed) limit 0.45 mm (0.0177 in)
Ring side clearance limit 0.09 mm (0.0035 in)
2nd ring
Ring type Taper
Ring side clearance limit 0.09 mm (0.0035 in)
Oil ring
Crankshaft
Crank assembly width 75.00–75.10 mm (2.953–2.957 in)
Runout limit 0.040 mm (0.0016 in)
Big end side clearance 0.100–0.300 mm (0.0039–0.0118 in)
Clutch
Clutch type Dry, centrifugal automatic
Clutch shoe thickness limit 1.0 mm (0.04 in)
Clutch housing inside diameter 112.0 mm (4.41 in)
Clutch housing inside diameter limit 112.3 mm (4.42 in)
Weight outside diameter 15.1 mm (0.59 in)
Weight outside diameter limit 14.6 mm (0.57 in)
Compression spring free length limit 70.0 mm (2.76 in)
Clutch-in revolution 1600–1800 r/min
Clutch-stall revolution 1920–2320 r/min
V-belt
V-belt width limit 15.5 mm (0.61 in)
Transmission type V-belt automatic
Operation Centrifugal automatic type
Gear ratio 2.570–0.851 : 1
Secondary reduction ratio 35/14 (2.500)
Secondary reduction system Chain drive
Main axle runout limit 0.04 mm (0.0016 in)
Shaft drive
Middle gear backlash 0.08–0.16 mm (0.003–0.006 in)
Final gear backlash 0.08–0.16 mm (0.003–0.006 in)
Air filter
Air filter element Wet element
Air filter oil grade Foam air-filter oil
Carburetor
Type × quantity H66D × 1
ID mark AT88
Float height 10.0 mm (0.39 in)
Fuel level A (using fuel level gauge) 2.0–3.0 mm (0.08–0.12 in)
2-4
Idling condition
Engine idling speed 1600–1800 r/min
Throttle lever free play 1.5–4.0 mm (0.06–0.16 in)
Speed limiter length 10 mm (0.4 in)
2-5
CHASSIS SPECIFICATIONS
EBS20016
Chassis
Frame type Steel tube frame
Caster angle 3.40°
Camber angle -0.2°
Kingpin angle 8.8°
Kingpin offset 39.7 mm (1.56 in)
Trail 19.8 mm (0.78 in)
Tread front (STD) 860.0 mm (33.86 in)
Tread rear (STD) 760.0 mm (29.92 in)
Toe-in (with tires touching the ground) 16.0 mm (0.63 in)
Front wheel
Wheel type Panel wheel
Rim size 8 × 5.5AT
Wheel material Steel
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Rear wheel
Wheel type Panel wheel
Rim size 8 × 5.5AT
Wheel material Steel
Radial wheel runout limit 2.0 mm (0.08 in)
Lateral wheel runout limit 2.0 mm (0.08 in)
Front tire
Type Tubeless
Size AT18 × 7–8
Manufacturer/model MAXXIS/M939
Manufacturer/model DURO/DI2017
Wear limit (front) 3.0 mm (0.12 in)
Rear tire
Type Tubeless
Size AT18 × 9–8
Manufacturer/model MAXXIS/M940
Manufacturer/model DURO/DI2016
Wear limit (rear) 3.0 mm (0.12 in)
Tire air pressure (measured on cold tires)

Recommended
Front 24.0 kPa (0.240 kgf/cm², 3.5 psi)
Rear 24.0 kPa (0.240 kgf/cm², 3.5 psi)
Minimum
Front 20.7 kPa (0.207 kgf/cm², 3.0 psi)
Rear 20.7 kPa (0.207 kgf/cm², 3.0 psi)
Front brake
Type Mechanical leading, trailing drum brake
Operation Right hand operation
2-6
Brake drum inside diameter limit 86.0 mm (3.39 in)

Lining thickness limit 1.3 mm (0.05 in)
Shoe spring free length 36.0 mm (1.42 in)
Rear brake
Operation Left hand operation
Brake drum inside diameter limit 131.0 mm (5.16 in)
Lining thickness limit 2.0 mm (0.08 in)
Shoe spring free length 36.0 mm (1.42 in)
Brake lever and brake pedal

Front brake lever free play 20.0–25.0 mm (0.79–0.98 in)
Rear brake lever free play 30.0–40.0 mm (1.18–1.57 in)
Parking brake
Front suspension
Type Swing axle
Spring/shock absorber type Coil spring/oil damper
Shock absorber travel 69.0 mm (2.72 in)
Wheel travel 126 mm (5.0 in)
Spring preload adjusting positions
Minimum 1
Standard 3
Maximum 5
Rear suspension
Type Swingarm
Spring/shock absorber type Coil spring/oil damper
Wheel travel 145 mm (5.7 in)
Rear shock absorber assembly travel 89.0 mm (3.50 in)
Spring preload adjusting positions
Minimum 1
Standard 2
Maximum 5
Drive chain
Link quantity 82
Drive chain slack 24.0–32.0 mm (0.94–1.26 in)
15-link length limit 195.6 mm (7.70 in)
Rear axle
Runout limit 1.5 mm (0.06 in)
2-7
ELECTRICAL SPECIFICATIONS
EBS20017
ELECTRICAL SPECIFICATIONS
Voltage
System voltage 12 V
Ignition system
Ignition system CDI
Advancer type Electrical (Analogue)
Ignition timing (B.T.D.C.) 17.5°/2000 r/min
Pickup coil resistance 96.0–144.0 Ω
Source coil resistance 0.2–0.4 Ω (Y/B)
Ignition coil
Minimum ignition spark gap 6.0 mm (0.24 in)
Primary coil resistance 0.18–0.23 Ω
Secondary coil resistance 2.79–3.41 kΩ
Spark plug cap

Resistance 5.0 kΩ
Charging system
Charging system AC magneto
Standard output 14.0 V, 57 W at 5000 r/min
Stator coil resistance 0.50–0.77 Ω (R/B)
Lighting coil resistance 0.17–0.25 Ω
Rectifier/regulator
Regulator type Semi conductor-short circuit
Regulated voltage (DC) 14.0–15.0 V
Rectifier capacity (DC) 7.0 A
Battery
Model GTX5L-BS
Voltage, capacity 12 V, 4.0 Ah
Bulb voltage, wattage × quantity

Neutral indicator light 12 V, 3.5 W × 1
Reverse indicator light 12 V, 3.5 W × 1
Starter motor
Power output 0.30 kW
Armature coil resistance 0.036–0.048 Ω
Brush overall length limit 4.00 mm (0.16 in)
Commutator diameter limit 20.0 mm (0.79 in)
Mica undercut (depth) 1.60 mm (0.06 in)
Starter relay
Amperage 80.0 A
Coil resistance 85.50–104.50 Ω
Fuse
Fuse 7.5 A
2-8
TIGHTENING TORQUES
EBS20018
TIGHTENING TORQUES
EBS30018
GENERAL TIGHTENING TORQUE

SPECIFICATIONS
This chart specifies tightening torques for stan-
dard fasteners with a standard ISO thread pitch.
Tightening torque specifications for special com-
ponents or assemblies are provided for each
chapter of this manual. To avoid warpage, tight-
en multi-fastener assemblies in a crisscross pat-
tern and progressive stages until the specified
tightening torque is reached. Unless otherwise
specified, tightening torque specifications re-
quire clean, dry threads. Components should be
at room temperature.
A. Distance between flats

B. Outside thread diameter
General tightening torques

A (nut) B (bolt)
Nm m·kgf ft·lbf
10 mm 6 mm 6 0.6 4.3
12 mm 8 mm 15 1.5 11
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
2-9
TIGHTENING TORQUES
EBS30019
ENGINE TIGHTENING TORQUES

Thread
Item Q’ty Tightening torque Remarks
size
Spark arrester nut M5 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Muffler bolt (rear side) M8 1 22 Nm (2.2 m·kgf, 16 ft·lbf) LT
Muffler bolt (front side) M8 1 22 Nm (2.2 m·kgf, 16 ft·lbf)

Exhaust pipe to muffler bolt M8 2 25 Nm (2.5 m·kgf, 18 ft·lbf)
Exhaust pipe nut M6 2 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Exhaust pipe protector bolt M6 2 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Engine mounting bolt (front) M10 2 45 Nm (4.5 m·kgf, 33 ft·lbf)
Engine mounting bolt (rear) M8 1 22 Nm (2.2 m·kgf, 16 ft·lbf)
Camshaft sprocket cover bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Camshaft sprocket bolt M5 3 8 Nm (0.8 m·kgf, 5.8 ft·lbf) LT
Cylinder head side cover bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Cylinder head bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head nut M6 4 16 Nm (1.6 m·kgf, 12 ft·lbf)
Cylinder bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Tappet cover M30 2 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Cylinder head stud bolt (intake) M6 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Cylinder head stud bolt (exhaust) M6 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Valve adjusting screw locknut M5 2 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Spark plug M10 1 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
CDI magneto rotor cover bolt M6 7 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing mark accessing screw M14 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
CDI magneto rotor nut M12 1 60 Nm (6.0 m·kgf, 43 ft·lbf)
Pickup coil bolt M5 2 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Stator coil bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pump screw M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Oil pump housing cover screw M3 1 1.1 Nm (0.11 m·kgf, 0.80 ft·lbf)
Starter motor front cover bolt M5 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Starter motor brush screw M4 2 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Starter motor bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Starter motor lead screw M5 1 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
V-belt case bolt M6 9 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Air duct bolt (rear side) M8 1 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Air duct screw (front side) M5 2 1.0 Nm (0.10 m·kgf, 0.72 ft·lbf)
Air duct clamp screw M4 4 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Primary fixed sheave nut M10 1 40 Nm (4.0 m·kgf, 29 ft·lbf)
Clutch housing nut M10 1 40 Nm (4.0 m·kgf, 29 ft·lbf)
Secondary sheave nut M28 1 40 Nm (4.0 m·kgf, 29 ft·lbf)
Gear position switch bolt M5 2 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
Crankcase bolt (95 mm) M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Crankcase bolt (60 mm) M6 5 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
2-10
TIGHTENING TORQUES
Thread
size
Timing chain guide bolt M6 1 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Engine oil drain bolt M30 1 15 Nm (1.5 m·kgf, 11 ft·lbf)
Crankcase drain bolt M12 1 30 Nm (3.0 m·kgf, 22 ft·lbf)
Crankcase stud bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Engine oil filler neck bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
V-belt case drain bolt M8 1 20 Nm (2.0 m·kgf, 14 ft·lbf)
Timing chain tensioner bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Timing chain tensioner cap bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Transmission case cover bolt M6 8 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Shift lever holder bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Shift lever guide bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Shift knob bolt M6 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Transmission oil filler cap M14 1 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Transmission oil drain bolt M12 1 22 Nm (2.2 m·kgf, 16 ft·lbf)
Fuel tank bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Fuel cock nut M16 1 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
Air filter case bolt M6 3 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Air filter case stay bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf) LT
Breather hose holder bolt M6 1 6 Nm (0.6 m·kgf, 4.3 ft·lbf) LT
Oil catch tank bolt (upper side) M6 1 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf) LT
Oil catch tank bolt (lower side) M6 1 3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
Carburetor top cover M20 1 8 Nm (0.8 m·kgf, 5.8 ft·lbf)
Intake manifold bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Intake manifold nut M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Air filter case joint clamp screw M4 1 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Float chamber bolt M4 2 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Float chamber drain screw M4 1 1.0 Nm (0.10 m·kgf, 0.72 ft·lbf)
TIP
Cylinder head nut, cylinder bolt and cylinder head bolt
1. Temporarily tighten the cylinder head bolts (M6), cylinder bolts (M6) and cylinder head nuts (M6).
2. Tighten the cylinder head nuts (M6) to 16 Nm (1.6 m·kgf, 12 ft·lbf) in the proper tightening sequence.
3. Tighten the cylinder bolts (M6) to 10 Nm (1.0 m·kgf, 7.2 ft·lbf) in the proper tightening sequence.
4. Tighten the cylinder head bolt (M6) to 10 Nm (1.0 m·kgf, 7.2 ft·lbf) in the proper tightening sequence.
3 2 5
7
1 4 6
3
2-11
TIGHTENING TORQUES
EBS30020
CHASSIS TIGHTENING TORQUES

Thread
size
Front bumper bolt M8 4 20 Nm (2.0 m·kgf, 14 ft·lbf)
Front outer panel bolt M6 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Front inner panel screw M5 1 1.0 Nm (0.10 m·kgf, 0.72 ft·lbf)
Dummy headlight bolt M6 4 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Reverse indicator light nut M10 1 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Neutral indicator light nut M10 1 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Front fender bolt M6 5 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Front fender bolt (footrest board) M6 4 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Rear fender bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Rear fender bolt (footrest board) M6 6 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
Side cover bolt M6 2 5 Nm (0.5 m·kgf, 3.6 ft·lbf)
Footrest board bolt M6 8 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Battery terminal bolt M5 2 2.0 Nm (0.20 m·kgf, 1.4 ft·lbf)
Front wheel axle nut M12 2 50 Nm (5.0 m·kgf, 36 ft·lbf)
Front wheel bolt M10 8 45 Nm (4.5 m·kgf, 33 ft·lbf)
Rear wheel axle nut M14 2 50 Nm (5.0 m·kgf, 36 ft·lbf)
Rear wheel bolt M10 8 45 Nm (4.5 m·kgf, 33 ft·lbf)
Front brake camshaft lever bolt M5 2 4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
Rear brake camshaft lever bolt M6 1 7 Nm (0.7 m·kgf, 5.1 ft·lbf)
Rear lower guard bolt M8 4 2.5 Nm (0.25 m·kgf, 1.8 ft·lbf) LT
Chain puller nut M8 1 22 Nm (2.2 m·kgf, 16 ft·lbf)

Chain puller locknut M8 1 22 Nm (2.2 m·kgf, 16 ft·lbf)
Drive chain guard bolt M8 2 9 Nm (0.9 m·kgf, 6.5 ft·lbf) LT
Sprocket bracket bolt M8 3 25 Nm (2.5 m·kgf, 18 ft·lbf)

Rear brake shoe shaft nut M8 1 22 Nm (2.2 m·kgf, 16 ft·lbf)
Rear axle nut M28 1 100 Nm (10 m·kgf, 72 ft·lbf)
Yamaha
Rear axle locknut M28 1 100 Nm (10 m·kgf, 72 ft·lbf) bond No.
1215
Rear axle hub bolt M12 2 45 Nm (4.5 m·kgf, 33 ft·lbf) LT
Rear axle hub nut (rear brake shoe

M12 2 54 Nm (5.4 m·kgf, 39 ft·lbf)
plate)
Front brake lever/throttle lever as-
M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
sembly bolt
Front brake lever/throttle lever as-
M4 2 1.0 Nm (0.10 m·kgf, 0.72 ft·lbf)
sembly cover bolt
Rear brake lever assembly bolt M6 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Choke lever lock bolt M3 1 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
Handlebar switch assembly/choke
M5 1 1.2 Nm (0.12 m·kgf, 0.87 ft·lbf)
lever bolt (front)
Handlebar switch assembly/choke
M5 1 1.2 Nm (0.12 m·kgf, 0.87 ft·lbf)
lever bolt (rear)
2-12
TIGHTENING TORQUES
Thread
size
Upper handlebar holder bolt M6 4 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Lower handlebar holder nut M10 2 50 Nm (5.0 m·kgf, 36 ft·lbf)
Steering stem cable holder bolt M8 2 20 Nm (2.0 m·kgf, 14 ft·lbf)
Steering stem nut M14 1 50 Nm (5.0 m·kgf, 36 ft·lbf)
Tie-rod end locknut M10 4 40 Nm (4.0 m·kgf, 29 ft·lbf)
Steering knuckle nut M10 2 45 Nm (4.5 m·kgf, 33 ft·lbf)
Front shock absorber upper nut M10 2 45 Nm (4.5 m·kgf, 33 ft·lbf) LT
Front shock absorber lower nut M10 2 45 Nm (4.5 m·kgf, 33 ft·lbf) LT
Front arm nut M10 4 40 Nm (4.0 m·kgf, 29 ft·lbf) LT
Rear shock absorber upper nut M10 1 45 Nm (4.5 m·kgf, 33 ft·lbf) LT
Rear shock absorber lower nut M10 1 50 Nm (5.0 m·kgf, 36 ft·lbf) LT
Pivot shaft nut M14 1 85 Nm (8.5 m·kgf, 61 ft·lbf)

Drive chain tensioner bolt M8 1 20 Nm (2.0 m·kgf, 14 ft·lbf) LT
Drive sprocket cover screw M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)

Drive sprocket retainer bolt M6 2 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
2-13
LUBRICATION AND SEALING POINTS
EBS20019
LUBRICATION AND SEALING POINTS

EBS30021
ENGINE
Lubrication point Lubricant/Sealant
Oil seal lips LS
Bearings E
Camshaft sprocket cover O-ring LS
Camshaft sprocket cover bolt E
Tappet cover O-rings LS
Camshaft lobes M
Rocker arm shafts outer surface E
Rocker arm inner surface M
Valve stems, valve guides, and valve stem seals M
Valve stem ends M
Piston pin E
Cylinder inner surface, piston ring grooves, and piston rings E
Oil pump rotors (inner and outer) and oil pump housing and shaft E
Starter motor O-ring E
Starter clutch idle gear inner surface M
Starter clutch idle gear shaft outer surface M
Starter wheel inner surface E
Crankshaft threads LS
Crankcase stud bolt thread E
Drive axle gear M
Shift fork guide bar and shift fork E
Drive axle gear, counter axle gear and primary drive gear M
Main axle and pinion gears M
Yamaha bond No.1215

Pickup coil/stator coil assembly lead grommet (Three Bond
No.1215®)
Yamaha bond No.1215
Pickup coil bolt (Three Bond
No.1215®)
2-14
LUBRICATION SYSTEM CHART AND DIAGRAMS
EBS20020

EBS30023
LUBRICATION DIAGRAMS
3
A
2-15
1. Camshaft
2. Crankshaft
3. Oil pump
4. Oil strainer
A. To the cylinder from oil pump
2-16
CABLE ROUTING
EBS20022
CABLE ROUTING
Frame (front view)
2 3 1 6 7 8
D E F
1 2 3 4 5 6 7 8 9
16
10
B
16 11
15 12
14 C
13
3 7 2
2-17
CABLE ROUTING
1. Throttle cable
2. Front brake cable (left)
3. Front brake cable (right)
4. Neutral indicator light lead
5. Reverse indicator light lead
6. Brake switch lead
7. Rear brake cable
8. Handlebar switch lead
9. Choke cable
10. Air filter case breather hose
11. Cylinder head breather hose
12. Crankcase breather hose
13. Carburetor air vent hose
14. Ground lead
15. Ignition coil lead
16. Fuel drain hose
A. Position the connectors above the cable holder.
B. Route the handlebar switch lead and choke cable
so that they are positioned near the brake switch
lead and rear brake cable, and then fasten the
throttle cable, front brake cables, neutral indicator
light lead, reverse indicator light lead, brake switch
lead, rear brake cable, handlebar switch lead, and
choke cable with the plastic band.
C. Fasten the carburetor air vent hose to the frame
with the plastic band.
D. Route the front brake cables through the right
opening in the cable holder.
E. Route the neutral indicator light lead, reverse
indicator light lead, brake switch lead, rear brake
cable, and handlebar switch lead through the
center opening in the cable holder.
F. Route the choke cable through the left opening in
the cable holder.
2-18
CABLE ROUTING
Frame (Right view)
6 B 1 2 3 4 5 A 6 B
9
C
F 6 E 13 14 13 12 D 11 10 D
2-19
CABLE ROUTING
1. Fuel drain hose

3. Front brake cable (left)
4. Front brake cable (right)
5. Main switch coupler
6. Wire harness
7. Ignition coil lead
9. Spark plug lead
10. Throttle cable
12. Choke cable
13. Fuel hose
14. Fuel filter
A. Route the main switch lead between the steering
bracket and the fuel tank stay.
B. Fasten the wire harness with the holder.
C. Fasten the spark plug lead to the frame with the
plastic band.
D. Make sure that the throttle cable and choke cable
do not cross.
E. Fasten the wire harness to the frame with the
plastic band.
F. Pass the plastic band through the hole in the
frame, and then fasten the wire harness to the
frame with the band.
2-20
CABLE ROUTING
Frame (left view)
6 F 15 1 2 3 4 5 A 6 7 8 4 B C 9
15 3 E 1 D 14 E 13 5 12 11 10 1 D 4
2-21
CABLE ROUTING
1. Rear brake cable

2. Handlebar switch lead
3. Choke cable
4. Air filter case breather hose
7. Fuel drain hose
8. Fuel filter
9. Rectifier/regulator lead
10. Gear position switch lead
11. Pickup coil/stator coil assembly lead
12. Starter motor lead
13. Fuel hose
14. Throttle cable
A. Fasten the crankcase breather hose with the
holder.
B. Fasten the starter motor lead, starter motor ground
lead, pickup coil/stator coil assembly lead, gear
position switch lead, and air filter case breather
hose to the frame with the plastic band.
C. Fasten the starter motor lead, starter motor ground
lead, pickup coil/stator coil assembly lead, and
gear position switch lead with the plastic band.
D. Route the rear brake cable through the guide.
E. Make sure that the throttle cable and choke cable
do not cross.
F. Fasten the carburetor air vent hose to the frame
with the plastic band.
2-22
CABLE ROUTING
Frame (rear top view)
FWD
6 5 4
2-23
CABLE ROUTING
1. Main fuse lead

2. Starter relay lead
3. Wire harness
4. CDI unit lead
5. Positive battery lead
6. Negative battery lead
2-24
CABLE ROUTING
2-25
PERIODIC CHECKS AND ADJUSTMENTS
PERIODIC MAINTENANCE ............................................................................3-1

INTRODUCTION .......................................................................................3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM ...................................................................................................3-1
GENERAL MAINTENANCE AND LUBRICATION CHART .......................3-1
CHECKING THE FUEL LINE .................................................................... 3-3
CHECKING THE SPARK PLUG ............................................................... 3-3
ADJUSTING THE VALVE CLEARANCE .................................................. 3-4
CHECKING THE STARTER (CHOKE) OPERATION ............................... 3-6
ADJUSTING THE ENGINE IDLING SPEED .............................................3-6
CHECKING THE CRANKCASE BREATHER HOSE AND
CYLINDER HEAD BREATHER HOSE.....................................................3-7
CHECKING THE EXHAUST SYSTEM......................................................3-7
CLEANING THE SPARK ARRESTER ......................................................3-7
CLEANING THE AIR FILTER ELEMENT.................................................. 3-8
ADJUSTING THE FRONT BRAKE LEVER FREE PLAY........................ 3-10
3
CHECKING THE FRONT BRAKE SHOES ............................................. 3-10
ADJUSTING THE REAR BRAKE LEVER FREE PLAY .......................... 3-10
CHECKING THE REAR BRAKE SHOES................................................ 3-11
CHECKING THE WHEELS ..................................................................... 3-11
CHECKING THE TIRES..........................................................................3-11
CHECKING THE WHEEL HUB BEARINGS ...........................................3-13
ADJUSTING THE DRIVE CHAIN SLACK ............................................... 3-13
LUBRICATING THE DRIVE CHAIN ........................................................ 3-14
REPLACING THE V-BELT ...................................................................... 3-14
CHECKING THE CHASSIS FASTENERS .............................................. 3-14
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES ............. 3-15
ADJUSTING THE FRONT SHOCK ABSORBER ASSEMBLIES ............3-15
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 3-15
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY.................. 3-15
LUBRICATING THE FRONT KNUCKLE PIVOTS................................... 3-16
LUBRICATING THE FRONT ARM.......................................................... 3-16
CHECKING THE STEERING SYSTEM .................................................. 3-16
ADJUSTING THE TOE-IN....................................................................... 3-17
CHECKING THE ENGINE OIL LEVEL....................................................3-18
CHANGING THE ENGINE OIL ...............................................................3-19
CHECKING THE TRANSMISSION OIL LEVEL ...................................... 3-20
CHANGING THE TRANSMISSION OIL LEVEL...................................... 3-20
CHECKING AND LUBRICATING THE CABLES .................................... 3-20
LUBRICATING THE LEVERS .................................................................3-21
ADJUSTING THE THROTTLE LEVER FREE PLAY ..............................3-21
ADJUSTING THE SPEED LIMITER........................................................ 3-21
PERIODIC MAINTENANCE
EBS20023
EBS30024
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 lon-
ger service life and reduce the need for costly overhaul work. This information applies to vehicles al-
ready in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EBS30025
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM

TIP
• For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
• For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance in-
tervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month mainte-
nance intervals should still be followed.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
INITIAL EVERY
month 1 3 6 6 12
NO. ITEM CHECK OR MAINTENANCE Whichever
JOB comes first km (mi) 320 1300 2500 2500 5000
(200) (800) (1600) (1600) (3200)
hours 20 80 160 160 320
1 * Fuel line • Check fuel hoses for cracks or other damage, and re- √ √ √
place if necessary.
• Check condition and clean, regap, or replace if nec-
2 Spark plug √ √ √ √ √
essary.
3 * Valves • Check valve clearance and adjust if necessary. √ √ √ √
• Check starter (choke) operation and correct if neces-
4 * Carburetor sary. √ √ √ √
• Check engine idling speed and adjust if necessary.
Crankcase breather • Check breather hose for cracks or other damage, and
5 * √ √ √
system replace if necessary.
• Check for leakage and replace gasket(s) if neces-
sary.
6 * Exhaust system √ √ √
• Check for looseness and tighten all screw clamps
and joints if necessary.
7 Spark arrester • Clean. √ √ √
EBS30026
GENERAL MAINTENANCE AND LUBRICATION CHART

TIP
• For ATVs not equipped with an odometer or an hour meter, follow the month maintenance intervals.
• For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance in-
tervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month mainte-
nance intervals should still be followed.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools,
data and technical skills.
3-1
INITIAL EVERY
month 1 3 6 6 12
CHECK OR MAINTENANCE Whichever
NO. ITEM
JOB comes first km (mi) 320 1300 2500 2500 5000
(200) (800) (1600) (1600) (3200)
hours 20 80 160 160 320
1 Air filter element • Clean and replace if necessary. Every 20–40 hours (more often in wet or
dusty areas)
2 Air filter check hose • Clean. √ √ √ √ √
• Check operation and correct if necessary. √ √ √ √ √
3 * Front brake • Check brake lever free play and adjust if necessary.
• Replace brake shoes. Whenever worn to the limit
• Check operation and correct if necessary. √ √ √ √ √
4 * Rear brake • Check brake lever free play and adjust if necessary.
• Replace brake shoes. Whenever worn to the limit
5 * Wheels • Check runout and for damage, and replace if neces- √ √ √ √

sary.
• Check tread depth and for damage, and replace if
6 * Tires necessary. √ √ √ √
• Check air pressure and balance, and correct if neces-
sary.
7 * Wheel hub bearings • Check for looseness or damage, and replace if nec- √ √ √ √
essary.
• Check chain slack and adjust if necessary.
8 Drive chain • Check rear wheel alignment and correct if necessary. √ √ √ √ √
• Clean and lubricate.
9 * Drive chain rollers • Check for wear and replace if necessary. √ √ √
10 * V-belt • Check for wear, cracks or other damage, and replace √ √ √ √

if necessary.
• Make sure that all nuts, bolts, and screws are proper-
11 * Chassis fasteners √ √ √ √ √
ly tightened.
Shock absorber as- • Check operation and correct if necessary.
12 * semblies • Check for oil leakage and replace if necessary. √ √ √
13 * Front knuckle pivots • Lubricate with lithium-soap-based grease. √ √ √

14 * Steering shaft • Lubricate with lithium-soap-based grease. √ √ √
• Check operation and repair or replace if damaged.
15 * Steering system √ √ √ √ √
• Check toe-in and adjust if necessary.
• Change.
16 Engine oil • Check ATV for oil leakage, and correct if necessary. √ √ √ √
17 Engine oil strainer • Clean. √ √ √

• Change.
18 Transmission oil • Check ATV for oil leakage, and correct if necessary. √ √
19 * Moving parts and ca- • Lubricate. √ √ √ √

bles
• Check operation.
20 * Throttle lever • Check throttle lever free play, and adjust if necessary. √ √ √ √ √
• Lubricate cable and lever housing.
21 * Front brake switch • Check operation and correct if necessary. √ √ √ √ √
22 * Switches • Check operation and correct if necessary. √ √ √ √ √
TIP
Some maintenance items need more frequent service if you are riding in unusually wet, dusty, sandy
or muddy areas, or at full-throttle.
3-2
EBS30027 ECB01270
CHECKING THE FUEL LINE NOTICE

1. Check: Before removing the spark plug, blow away
• Fuel hose “1” any dirt accumulated in the spark plug well
• Fuel filter “2” with compressed air to prevent it from falling
Cracks/damage → Replace. into the cylinder.
Loose connections → Connect properly.
3. Check:
• Spark plug type
1
Incorrect → Change.
Manufacturer/model
NGK/CR6HSA
4. Check:
2 • Electrodes “1”
Damage/wear → Replace the spark plug.
• Insulator “2”
2. Remove: Abnormal color → Replace the spark plug.
• Fuel tank top cover Normal color is medium-to-light tan.
• Front fender 5. Clean:
Refer to “GENERAL CHASSIS (2)” on page • Spark plug
4-4. (with a spark plug cleaner or wire brush)
3. Check: 6. Measure:
• Fuel tank breather hose “3” • Spark plug gap “a”
Cracks/damage → Replace. (with a wire thickness gauge)
Loose connections → Connect properly. Out of specification → Regap.
ECB02750
NOTICE
Spark plug gap
Make sure the fuel tank breather hose is rout- 0.6–0.7 mm (0.024–0.028 in)
ed correctly.
3
7. Install:
4. Install:
• Spark plug
• Front fender
• Fuel tank top cover Spark plug
Refer to “GENERAL CHASSIS (2)” on page 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
T.
R.
4-4.
EBS30029
TIP
CHECKING THE SPARK PLUG Before installing the spark plug, clean the spark
1. Disconnect: plug and gasket surface.
• Spark plug cap
8. Connect:
2. Remove:
• Spark plug cap
• Spark plug
3-3
EBS30028
ADJUSTING THE VALVE CLEARANCE

The following procedure applies to all of the
valves.
TIP
• Valve clearance adjustment should be made
on a cold engine, at room temperature. 1
• When the valve clearance is to be measured or
adjusted, the piston must be at top dead center
(TDC) on the compression stroke.
1. Install: 7. Measure:
• Kickstarter lever “1” • Valve clearance
Out of specification → Adjust.
Valve clearance (cold)

Intake
1 0.06–0.09 mm (0.0024–0.0035 in)
Exhaust
0.06–0.09 mm (0.0024–0.0035 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Move the kickstarter lever down lightly.
b. When the piston is at TDC on the compres-
2. Disconnect: sion stroke, align the “I” mark “a” on the CDI
• Cylinder head breather hose “1” magneto rotor with the stationary pointer “b”
3. Remove: on the CDI magneto rotor cover.
• Exhaust tappet cover “2” a
• Intake tappet cover “3”
• Camshaft sprocket cover “4”
2 1 b
4 TIP
To position the piston at TDC on the compres-
3
sion stroke, align the punch mark “c” on the cam-
4. Disconnect: shaft sprocket with the mark “d” on the cylinder
• Spark plug cap head, as shown in the illustration.
5. Remove:
• Spark plug
ECB01270 c
NOTICE
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
d
with compressed air to prevent it from falling
into the cylinder.
6. Remove:
• Timing mark accessing screw “1”
c. Measure the valve clearance with the thick-
ness gauge “1”.
3-4
Out of specification → Adjust. d. Measure the valve clearance again.

e. If the valve clearance is still out of specifica-
Thickness gauge tion, repeat all of the valve clearance adjust-
90890-03079 ment steps until the specified clearance is
Narrow gauge set obtained.
YM-34483
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
9. Remove:
• Kickstarter lever
10.Install:
1 • Kickstarter cap
• O-ring New
• Timing mark accessing screw
Timing mark accessing screw

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
T.
R.
11.Install:
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Spark plug
8. Adjust:
TIP
• Valve clearance
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Before installing the spark plug, clean the spark
a. Loosen the locknut “1”. plug and gasket surface.
b. Insert the thickness gauge “2” between the
end of the adjusting screw and the valve tip. Spark plug
c. Turn the adjusting screw “3” in direction “a” or 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
T.
R.
“b” with the tappet adjusting tool “4” until the

specified valve clearance is obtained. 12.Connect:
• Spark plug cap
Tappet adjusting tool 13.Install:
90890-01311
• Gasket New
Six piece tappet set
YM-A5970 • Camshaft sprocket cover
• O-ring “1” New
• Exhaust tappet cover
Direction “a” • O-ring New
Valve clearance is increased.
• Intake tappet cover
Direction “b”
Valve clearance is decreased. Camshaft sprocket cover bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
b Tappet cover
2.5 Nm (0.25 m·kgf, 1.8 ft·lbf)
4 3
a
1
2
• Hold the adjusting screw to prevent it from
moving and tighten the locknut to specifica- 1 New
tion.
14.Connect:
Valve adjusting screw locknut • Cylinder head breather hose
8 Nm (0.8 m·kgf, 5.8 ft·lbf)
T.
R.
3-5
EBS30559
c. Loosen the locknut “3”
CHECKING THE STARTER (CHOKE)
d. Turn the adjusting nut “4” in direction “d” or “e”
OPERATION
1. Check: Direction “d”
• Starter (choke) lever “1” operation Choke cable is decreased.
Unsmooth operation → Replace. Direction “e”
Refer to “CHECKING THE CARBURETOR” Choke cable is increased.
on page 6-8.
2
3
d
4
2
e
1
a b
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Direction “a”
3. Adjust:
Turn on the starter (choke).
Direction “b” • Engine idling speed
Turn off the starter (choke). Refer to “ADJUSTING THE ENGINE IDLING
SPEED” on page 3-6.
2. Adjust: EBS30527
• Distance “a” (between the projection “b” on ADJUSTING THE ENGINE IDLING SPEED
the butterfly valve spring lever and projection TIP
“c” on the choke cable holder) Prior to adjusting the engine idling speed, the air
filter element should be clean, and the engine
Distance “a”
1.5 mm (0.059 in) should have adequate compression.
1. Start the engine and let it warm up for several
minutes.
2. Connect:
b
• Digital tachometer
a (onto the spark plug lead)
3. Check:
c • Engine idling speed
Engine idling speed

1600–1800 r/min
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn on the starter (choke) lever “1” 4. Adjust:
• Engine idling speed
Turn the throttle stop screw “1” in direction “a”
or “b” until the specified engine idling speed is
obtained.
b. Slide back lubber cover “2”.
3-6
1. Check:
• Muffler “1”
• Exhaust pipe “2”
a 1 Cracks/damage → Replace.
• Muffler gasket “3”
b • Gaskets “4”
Exhaust gas leaks → Replace.
2. Check:
Tightening torque
• Muffler bolt (rear side) “5”
• Muffler bolt (front side) “6”
Direction “a” • Exhaust pipe to muffler bolt “7”
Engine idling speed is increased. • Exhaust pipe nut “8”
Direction “b” • Exhaust pipe protector bolt “9”
Engine idling speed is decreased.
Muffler bolt (rear side)
5. Disconnect: 22 Nm (2.2 m·kgf, 16 ft·lbf)
T.
R.
• Digital tachometer LOCTITE®
6. Adjust: Muffler bolt (front side)
• Throttle lever free play 22 Nm (2.2 m·kgf, 16 ft·lbf)
Refer to “ADJUSTING THE THROTTLE LE- Exhaust pipe to muffler bolt
VER FREE PLAY” on page 3-21. 25 Nm (2.5 m·kgf, 18 ft·lbf)
Exhaust pipe nut
Throttle lever free play 12 Nm (1.2 m·kgf, 8.7 ft·lbf)
1.5–4.0 mm (0.06–0.16 in) Exhaust pipe protector bolt
8 Nm (0.8 m·kgf, 5.8 ft·lbf)
EBS30556
CHECKING THE CRANKCASE BREATHER

HOSE AND CYLINDER HEAD BREATHER 3
5 2
HOSE
1. Check: 9
• Crankcase breather hose “1” 7
4
• Cylinder head breather hose “2”
Cracks/damage → Replace.
Loose connection → Connect properly. 6
ECB02760 1
NOTICE 8
Make sure the crankcase breather hose and EBS30032
cylinder head breather hose are routed cor- CLEANING THE SPARK ARRESTER
rectly. 1. Clean:
• Spark arrester
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
EWB03080
1 WARNING
• Select a well-ventilated area free of com-
bustible materials.
2 • Always let the exhaust system cool before
performing this operation.
• Do not start the engine when removing the
tailpipe from the muffler.
a. Remove the bolts “1” and nut “2”.
EBS30031
CHECKING THE EXHAUST SYSTEM b. Remove the spark arrester “3” by pulling it out
The following procedure applies to all of the ex- of the muffler.
haust pipe and gaskets.
3-7
1
2
1
2
c. Tap the spark arrester lightly with a soft-face ECB01800
hammer or suitable tool, then use a wire NOTICE

brush to remove any carbon deposits from The engine should never be run without the
the spark arrester and the inner contact sur- air filter; excessive piston and/or cylinder
faces of the muffler. wear may result.
d. Install the spark arrester into the muffler and 4. Remove:
align the bolt holes. • Air filter element “1”
e. Install the bolts “1” and tighten them.
Spark arrester nut

1
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30037
CLEANING THE AIR FILTER ELEMENT

1. Check:
• Check hose “1”
TIP
5. Check:
There is a check hose at the bottom of the air fil- • Air filter case cover “1”
ter case. If dust or water collects in this hose, • Air filter element “2”
empty the hose and clean the air filter element • Air filter element guide “3”
and air filter case. Damage → Replace.
3
1
2. Remove: 6. Clean:
• Seat • Air filter element
Refer to “GENERAL CHASSIS (1)” on page ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
4-1. a. Carefully wash the air filter element in sol-
3. Remove: vent.
EWB02760
• Air filter case cover holder “1” WARNING
• Air filter case cover “2”
Never use low flash point solvents, such as
gasoline, to clean the air filter element. Such
solvents may cause a fire or an explosion.
3-8
g. Place the air filter element into the storage

bag and repeatedly squeeze the element un-
til the air filter element is saturated with oil.
TIP
The air filter element should be wet but not drip-
ping.
b. After cleaning, squeeze the air filter element

to remove the excess solvent.
ECB01290
NOTICE
Do not twist the air filter element when
squeezing it.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Install:
• Air filter element guide
• Air filter element
• O-ring New
TIP
• Insert the projection “a” of the air filter cover.
• Hold the air filter case cover in holder “b”.
c. Properly dispose of the used solvent.
d. Carefully wash the air filter element in soap
1
water.
a
1
e. Thoroughly rinse the air filter element with
water, and then let it dry.
ECB01290
NOTICE
Do not twist the air filter element when
squeezing it. b
f. Pour the recommended oil into a storage bag

large enough for the air filter element.
8. Install:
Air filter oil grade • Seat
Foam air-filter oil Refer to “GENERAL CHASSIS (1)” on page
4-1.
3-9
EBS30534 ECB02860
ADJUSTING THE FRONT BRAKE LEVER NOTICE

FREE PLAY After adjusting the brake lever free play,
1. Check: make sure there is no brake drag.
• Front brake lever free play “a”
Out of specification → Adjust. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30561
Front brake lever free play CHECKING THE FRONT BRAKE SHOES
20.0–25.0 mm (0.79–0.98 in) 1. Operate the brake.
2. Check:
• Distance “a”
a (between the upper locknut “1” and the upper
adjusting bolt “2” and between the lower lock-
nut “3” and the lower adjusting bolt “4”.)
Distance “a” is more than 12 mm (0.47 in) →
Replace the brake shoes as a set.
Refer to “FRONT BRAKE” on page 4-14.
1 a 2
2. Adjust:
• Front brake lever free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the upper locknut “1” and fully turn in
the upper adjusting bolt “2”.
b. Loosen the lower locknut “3”.
c. Turn the lower adjusting bolt “4” in direction 3 4
“a” or “c” until the specified front brake lever
EBS30562
free play is obtained.
ADJUSTING THE REAR BRAKE LEVER
Direction “a” FREE PLAY
Free play is increased. 1. Check:
Direction “b” • Rear brake lever free play “a”
Free play is decreased. Out of specification → Adjust.
Rear brake lever free play

d. Tighten the lower locknut “3”.
30.0–40.0 mm (1.18–1.57 in)
e. While applying the front brake, turn out the
upper adjusting bolt “2” until the upper and
lower cable lengths are equal. The cable joint
“5” will become vertical. a
c c=d´ 1 2
d´ a
2. Adjust:
34 b • Rear brake lever free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
f. Tighten the upper locknut. a. Turn the rear brake lever adjusting nut “1” in
or out until the specified rear brake lever free
play is obtained.
3-10
• Ride conservatively after installing a tire to

Direction “a” allow it to seat itself properly on the rim.
Free play is increased.
Direction “b”
Free play is decreased. 1
a
b 2. Measure:
• Radial wheel runout
• Lateral wheel runout
ECB02860 Refer to “CHECKING THE FRONT
NOTICE WHEELS” on page 4-9 and “CHECKING
After adjusting the brake lever free play, THE REAR WHEELS” on page 4-13.
make sure there is no brake drag. 3. Check:
• Wheel bearings (front wheel)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Refer to “CHECKING THE FRONT WHEEL
EBS30563
HUBS” on page 4-9.
CHECKING THE REAR BRAKE SHOES
1. Operate the brake. EBS30058
2. Check: CHECKING THE TIRES

• Distance “a” The following procedure applies to all of the
(from the end of the bolt “1” to the rear brake tires.
EWB02960
lever adjusting nut “2”.) WARNING
Distance “a” is more than 18 mm (0.71 in) →
Replace the brake shoes as a set. This model is equipped with low-pressure
Refer to “REAR BRAKE” on page 4-17. tires. It is important that they be inflated cor-
rectly and maintained at the proper pres-
sures.
2
Tire characteristics
1 EWB02970
WARNING
a Tire characteristics influence the handling of
vehicles. The tires listed below have been
approved by Yamaha Motor Co., Ltd. for this
model. If other tire combinations are used,
EBS30057
they can adversely affect your vehicle’s han-
CHECKING THE WHEELS dling characteristics and are therefore not
The following procedure applies to all of the recommended.
wheels.
1. Check:
• Wheel “1”
Damage/bends → Replace.
EWB03010
WARNING
• Never attempt even small repairs to the
wheel.
3-11
Maximum loading limit

Front tire EWB02990
Type WARNING
Tubeless Be extra careful of the vehicle balance and
Size stability when towing a trailer.
AT18 × 7–8
Manufacturer/model
MAXXIS/M939 Maximum loading limit
Manufacturer/model 82.0 kg (181 lb)
DURO/DI2017 (Total weight of rider, cargo, ac-
Rear tire cessories, and tongue)
Type
Tubeless 1. Measure:
Size • Tire pressure
AT18 × 9–8 Out of specification → Adjust.
Manufacturer/model TIP
MAXXIS/M940 • The tire pressure gauge “1” is included as stan-
Manufacturer/model
dard equipment.
DURO/DI2016
• In order to insure an accurate reading, make
sure that the gauge is clean before use.
Tire pressure
EWB02980
WARNING
• Tire pressure below the minimum specifi-
cation could cause the tire to dislodge from
the rim under severe riding conditions.
• Use no more than the following pressures
when seating the tire beads. 1
Front
250 kPa (2.5 kgf/cm²) (36 psi)
Rear
EWB03000
250 kPa (2.5 kgf/cm²) (36 psi)
WARNING
Higher pressures and fast inflation may
cause a tire to burst. Inflate the tires very Uneven or improper tire pressure may ad-
slowly and carefully. versely affect the handling of this vehicle
and may cause loss of control.
• Maintain proper tire pressures.
Tire air pressure (measured on
cold tires) • Set tire pressures when the tires are cold.
Recommended • Tire pressures must be equal in both front
Front tires and equal in both rear tires.
24.0 kPa (0.240 kgf/cm², 3.5 2. Check:
psi) • Tire surfaces
Rear Wear/damage → Replace.
24.0 kPa (0.240 kgf/cm², 3.5
psi) Wear limit (front)
Minimum 3.0 mm (0.12 in)
Front Wear limit (rear)
20.7 kPa (0.207 kgf/cm², 3.0 3.0 mm (0.12 in)
psi)
Rear EWB03100
20.7 kPa (0.207 kgf/cm², 3.0 WARNING

psi) It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit, re-
place the tire immediately.
3-12
ECB02520
NOTICE
Improper drive chain slack will overload the
engine as well as other vital parts of the ATV
and can lead to chain slippage or breakage.
If the drive chain slack is more than the spec-
ified limit, the chain can damage the frame,
swingarm, and other parts. To prevent this
from occurring, keep the drive chain slack
within the specified limits.
a. Wear limit 2. Adjust:
EBS30564
• Drive chain slack
CHECKING THE WHEEL HUB BEARINGS ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Refer to “CHECKING THE FRONT WHEEL a. Loosen the rear axle hub bolts “1” and rear
HUBS” on page 4-9. axle hub nuts “2”.
EBS30538
ADJUSTING THE DRIVE CHAIN SLACK

ECB02740
NOTICE
A drive chain that is too tight will overload
1
the engine and other vital parts, and one that
is too loose can skip and damage the swing-
arm or cause an accident. Therefore, keep
the drive chain slack within the specified lim-
its.
TIP
• Before checking the drive chain slack, rotate
the rear wheels several turns and check the
slack at several points to find the tightest point.
Check the chain slack with the rear wheels in 2
this “tightest” position.
• When checking and adjusting the drive chain
slack, there should be no weight on the vehicle
and all tires must be touching the ground.
b. Loosen the rear brake lever adjusting nut “3”.
1. Check:
• Drive chain slack “a”
3
c. Loosen the locknuts “4”.

d. Turn the chain puller nuts “5” in direction “a”
or “b” until the specified drive chain slack is
Drive chain slack obtained.
24.0–32.0 mm (0.94–1.26 in)
3-13
Direction “a” Recommended lubricant

Drive chain is tightened. Engine oil or chain lubricant
Direction “b” suitable for O-ring chains
Drive chain is loosened.
EBS30056
REPLACING THE V-BELT

1. Remove:
5 • Front inner panel
Refer to “GENERAL CHASSIS (1)” on page
4-1.
4 • Footrest board (left side)
a Refer to “GENERAL CHASSIS (3)” on page
4-7.
b • V-belt case cover
Refer to “KICKSTARTER” on page 5-39.
e. Tighten the locknut, and then rear axle bolts 2. Check:
and nuts to specification. • V-belt “1”
Cracks/damage/wear → Replace.
Chain puller locknut Grease/oil → Clean the primary and second-
22 Nm (2.2 m·kgf, 16 ft·lbf) ary sheaves.
T.
R.
Rear axle hub bolt Refer to “BELT DRIVE” on page 5-43.

45 Nm (4.5 m·kgf, 33 ft·lbf) 3. Measure:
LOCTITE® • V-belt width “a”
Rear axle hub nut (rear brake Out of specification → Raplace.
shoe plate) Refer to “BELT DRIVE” on page 5-43.
54 Nm (5.4 m·kgf, 39 ft·lbf)
V-belt width limit
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 15.5 mm (0.61 in)
3. Adjust:
• Rear brake lever free play
Refer to “ADJUSTING THE REAR BRAKE
LEVER FREE PLAY” on page 3-10.
EBS30565
LUBRICATING THE DRIVE CHAIN

The drive chain consists of many interacting
parts. If the drive chain is not maintained proper-
ly, it will wear out quickly. Therefore, the drive
chain should be serviced, especially when the
vehicle is used in dusty areas.
This vehicle has a drive chain with small rubber 4. Install:
O-rings between each side plate. Steam clean- • V-belt case cover
ing, high-pressure washing, certain solvents, Refer to “KICKSTARTER” on page 5-39.
and the use of a coarse brush can damage • Footrest board (left side)
these O-rings. Therefore, use only kerosene to Refer to “GENERAL CHASSIS (3)” on page
clean the drive chain. Wipe the drive chain dry 4-7.
and thoroughly lubricate it with engine oil or • Front inner panel
chain lubricant that is suitable for O-ring chains. Refer to “GENERAL CHASSIS (1)” on page
Do not use any other lubricants on the drive 4-1.
chain since they may contain solvents that could EBS30566
damage the O-rings. CHECKING THE CHASSIS FASTENERS

Make sure that all nuts, bolts, and screws are
properly tightened.
3-14
Refer to “CHASSIS TIGHTENING TORQUES”

on page 2-12. Direction “a”
Spring preload is increased (suspen-
EBS30059
sion is harder).
CHECKING THE FRONT SHOCK ABSORBER Direction “b”
ASSEMBLIES Spring preload is decreased (suspen-
The following procedure applies to both of the sion is softer).
front shock absorber assemblies.
1. Place the vehicle on a level place.
2. Check: Spring preload adjusting positions
• Front shock absorber assembly Minimum
Refer to “CHECKING THE FRONT SHOCK 1
ABSORBER ASSEMBLIES” on page 4-31. Standard
3. Check: 3
Maximum
• Operation
5
Pump the front shock absorber assembly up
and down several times.
Unsmooth operation → Replace front shock 1 2
absorber assembly. 3 4
5
Refer to “FRONT ARMS AND FRONT
SHOCK ABSORBER ASSEMBLIES” on
page 4-29.
EBS30430 1
ADJUSTING THE FRONT SHOCK
ABSORBER ASSEMBLIES b 2
a
The following the procedure applies to both of
the front shock absorber assemblies. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EWB03760
EBS30060
WARNING
CHECKING THE REAR SHOCK ABSORBER
Always adjust the spring preload for both ASSEMBLY
front shock absorber assemblies to the The following procedure applies to both of the
same setting. Uneven adjustment can cause rear shock absorber assemblies.
poor handling and loss of stability. 1. Place the vehicle on a level place.
ECB02470 2. Check:
NOTICE • Rear shock absorber assembly
Never attempt to turn the adjusting ring be- Refer to “CHECKING THE REAR SHOCK
yond the maximum or minimum setting. ABSORBER ASSEMBLY” on page 4-34.
3. Check:
1. Adjust:
• Operation
• Spring preload
Pump the rear shock absorber assembly up
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a. Turn the adjusting ring “1” in direction “a” or and down several times.
“b” with the ring nut wrench “2”. Unsmooth operation → Replace rear shock
absorber assembly.
Ring nut wrench Refer to “REAR SHOCK ABSORBER AS-
90890-01268 SEMBLY AND SWINGARM” on page 4-33.
Spanner wrench
YU-01268 EBS30431
ADJUSTING THE REAR SHOCK ABSORBER

ASSEMBLY
1. Adjust:
• Spring preload
3-15
ECB02470
NOTICE
Never attempt to turn the adjusting ring be-
yond the maximum or minimum setting.
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a. Turn the adjusting ring “1” in direction “a” or
“b” with the ring nut wrench “2”.
Ring nut wrench

90890-01268 1
Spanner wrench
EBS30568
YU-01268 LUBRICATING THE FRONT ARM
1. Lubricate:
Direction “a” • Grease nipples “1”
Spring preload is increased (suspen-
Recommended lubricant
sion is harder).
Lithium-soap-based grease
Direction “b”
Spring preload is decreased (suspen-
sion is softer).
Spring preload adjusting positions 1

Minimum 1
1
Standard
2
Maximum
5
EBS30061
CHECKING THE STEERING SYSTEM

1 2
3 4
2 1. Place the vehicle on a level surface.
5 2. Check:
• Steering assembly bushings
Move the handlebar up and down, and back
and forth.
b Excessive play → Replace the steering stem
1 a bushings.
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EBS30567
LUBRICATING THE FRONT KNUCKLE

PIVOTS
1. Lubricate:
• Grease nipples “1”
3. Check:
• Tie-rod ends “1”
Free play → Replace the tie-rod end.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the handlebar left until it stops.
b. Move the handlebar slightly to the right and
left.
3-16
c. Check for play in the tie-rod ends. d. Rotate the front tires 180° until the marks are
d. Turn the handlebar right until it stops. exactly opposite one another.
e. Move the handlebar slightly to the left and e. Measure the width “B” between the marks.
right. f. Calculate the toe-in using the formula given
f. Check for play in the tie-rod ends. below.
Toe-in = “B” – “A”
g. If the toe-in is incorrect, adjust it.
1 1
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4. Raise the front end of the vehicle so that
there is no weight on the front wheels.
5. Check:
• Ball joints and wheel bearings
Move the wheels laterally back and forth.
Excessive free play → Replace the front
arms (upper and lower) and/or wheel bear-
ings.
C. Forward
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3. Adjust:
• Toe-in
EWB03750
EBS30062
WARNING
ADJUSTING THE TOE-IN
1. Place the vehicle on a level surface. • Be sure that both tie-rods are turned the
2. Measure: same amount. If not, the vehicle will drift
• Toe-in right or left even though the handlebar is
Out of specification → Adjust. positioned straight. This may lead to mis-
handling and an accident.
Toe-in (with tires touching the • After setting the toe-in to specification, run
ground) the vehicle slowly for some distance with
16.0 mm (0.63 in) both hands lightly holding the handlebar
and check that the handlebar responds cor-
TIP rectly. If not, turn either the right or left tie-
Before measuring the toe-in, make sure that the rod within the toe-in specification.
tire pressure is correct. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
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a. Mark both tie-rods ends.
a. Mark both front tire tread centers. This reference point will be needed during
b. Face the handlebar straight ahead. adjustment.
c. Measure the width “A” between the marks. b. Loosen the tie-rod end locknuts “1” of both
tie-rods.
3-17
c. The same number of turns should be given to EBS30038
CHECKING THE ENGINE OIL LEVEL

both the right and left tie-rods “2” until the
1. Place the vehicle on a level surface.
specified toe-in is obtained. This is to keep
2. Start the engine, warm it up until the engine
the length of the tie-rods the same.
oil has reached a normal temperature of 60
°C (140 °F), let it continue to idle for ten sec-
2 2 onds, and then turn the engine off.
TIP
To achieve the proper engine oil temperature for
an accurate oil level reading, the engine must
have first completely cooled down, and then
warmed up again for several minutes to normal
operating temperature.
1 1
3. Check:
d. Tighten the tie-rod end locknuts to specifica- • Engine oil level
tion. The engine oil level should be between the
minimum level mark “a” and maximum level
Tie-rod end locknut
40 Nm (4.0 m·kgf, 29 ft·lbf) mark “b”.
T.
Below the minimum level mark → Add the

R.
TIP recommended engine oil to the proper level.

Adjust the rod ends so that “A” and “B” are equal. TIP
• Before checking the engine oil level, wait a few
minutes until the oil has set.
A B • Do not screw the dipstick “1” in when checking
the oil level.
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b
a
4. Check:
• Handlebar
TIP
After adjusting the toe-in, the handlebar should Recommended brand
be centered. YAMALUBE
Type
Refer to “HANDLEBAR” on page 4-24. SAE 10W-50
Recommended engine oil grade
API service SG type or higher,
JASO standard MA
ECB02800
NOTICE
• Do not use engine oils with a grade of “CD”
or higher and do not use oils labeled “EN-
ERGY CONSERVING II” or higher.
• Do not allow foreign materials to enter the
crankcase.
3-18
4. Start the engine, warm it up for several min- 8. Fill:

utes, and then turn it off. • Crankcase
5. Check the engine oil level again. (with the specified amount of the recom-
TIP mended engine oil)
Before checking the engine oil level, wait a few
Engine oil quantity
minutes until the oil has settled. Quantity (disassembled)
0.90 L (0.95 US qt, 0.79 Imp.qt)
EBS30039
CHANGING THE ENGINE OIL 9. Install:

1. Place the vehicle on a level surface. • Dipstick
2. Start the engine, warm it up for several min-
utes, and then turn it off. (along with the O-ring New )
3. Place a container under the engine oil drain 10.Start the engine, warm it up for several min-
bolt. utes, and then turn it off.
4. Remove: 11.Check:
• Dipstick “1” • Engine
• Engine oil drain bolt “2” (for engine oil leaks)
• O-ring “3” 12.Check:
• Compression spring “4” • Engine oil level
• Oil strainer “5” Refer to “CHECKING THE ENGINE OIL
LEVEL” on page 3-18.
13.Check:
• Engine oil pressure
1 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Slightly loosen the oil check bolt “1”.
4 b. Start the engine and keep it idling until engine

oil starts to seep from the oil check bolt. If no
3 engine oil comes out after one minute, turn
the engine off so that it will not seize.
2 c. Check the engine oil passages, the oil pump
for damage or leakage. Refer to “OIL PUMP”
5. Drain: on page 5-31.
• Engine oil d. Start the engine after solving the problems
(completely from the crankcase) and check the engine oil pressure again.
6. Clean: e. Tighten the oil check bolt to specification.
• Oil strainer (with solvent)
7. Install: Oil check bolt (camshaft sprocket
• Engine oil drain bolt cover bolt)
T.
R.
10 Nm (1.0 m·kgf, 7.2 ft·lbf)

(along with the gasket New )
Engine oil drain bolt ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

15 Nm (1.5 m·kgf, 11 ft·lbf)
T.
R.
3-19
EBS30557
CHECKING THE TRANSMISSION OIL LEVEL 1 2

2. Remove:
• Transmission oil filler cap “1”
(along with the O-ring) 4
3. Check:
• Transmission oil level
The transmission oil level “2” should be at the 3
bottom of filler cap.
Below the brim → Add the recommended
5. Install:
transmission oil to the proper level.
• Transmission oil drain bolt
Transmission oil • Gasket New
Type
SAE 80W-90 Transmission oil drain bolt
22 Nm (2.2 m·kgf, 16 ft·lbf)
T.
R.
ECB02810
NOTICE 6. Fill:
Take care not to allow foreign material to en- • Transmission case
ter the transmission case. (with the specified amount of the recom-
mended transmission oil)
2 Transmission oil
Type
SAE 80W-90
1 Quantity
0.35 L (0.37 US qt, 0.31 Imp.qt)
7. Check:
• Oil level
Refer to “CHECKING THE TRANSMISSION
4. Check: OIL LEVEL” on page 3-20.
• Transmission oil filler cap 8. Install:
Damage → Replace. • Transmission oil filler cap
5. Install: (along with the O-ring New )
• Transmission oil filler cap
EBS30053
(along with the O-ring New ) CHECKING AND LUBRICATING THE
EBS30558
CABLES
CHANGING THE TRANSMISSION OIL LEVEL The following procedure applies to all of the in-
1. Place the vehicle on a level surface. ner and outer cables.
EWB02820
2. Place a container under the transmission
WARNING
case.
3. Remove: Damaged outer cable may cause the cable to
• Transmission oil filler cap “1” corrode and interfere with its movement. Re-
• O-ring “2” place damaged outer cable and inner cables
• Transmission oil drain bolt “3” as soon as possible.
• Gasket “4” 1. Check:
4. Drain: • Outer cable
• Transmission oil Damage → Replace.
2. Check:
• Cable operation
Rough movement → Lubricate.
3-20
Recommended lubricant Direction “a”

Engine oil or a suitable cable lu- Throttle lever free play is increased.
bricant Direction “b”
Throttle lever free play is decreased.
TIP
Hold the cable end upright and pour a few drops d. Tighten the locknut.
of lubricant into the cable sheath or use a suit- e. Slide the rubber cover to its original position.
able lubricating device.
1
3. Apply: 2
• Lithium-soap-based grease 3
(onto end of the cable)
1 a
EBS30464
LUBRICATING THE LEVERS

Lubricate the pivoting point and metal-to-metal b
moving parts of the levers.
Recommended lubricant EWB03810
Silicone grease WARNING

After adjusting the throttle cable free play,
EBS30446
start the engine and turn the handlebar to the
ADJUSTING THE THROTTLE LEVER FREE
right and to the left to ensure that this does
PLAY
not cause the engine idling speed to change.
TIP
Prior to adjusting the throttle lever free play, the ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
engine idling speed should be adjusted. EBS30463
ADJUSTING THE SPEED LIMITER

1. Check: 1. Measure:
• Throttle lever free play “a” • Speed limiter length “a”
Out of specification → Adjust. Out of specification → Adjust.
Speed limiter length

10 mm (0.4 in)
2. Adjust:
• Speed limiter length
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a a. Loosen the locknut “1”.
b. Turn the adjusting screw “2” in or out until the
specified speed limiter length is obtained.
Throttle lever free play Direction “b”

1.5–4.0 mm (0.06–0.16 in) Speed limiter is decreased.
Direction “c”
2. Adjust: Speed limiter is increased.
• Throttle lever free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
c. Tighten the locknut.
a. Slide back the rubber cover “1”.
b. Loosen the locknut “2”.
c. Turn the adjusting nut “3” in direction “a” or “b”
until the specified throttle lever free play is ob-
tained.
3-21
a 1
2
c
b
EWB03830
WARNING
• Particularly for a beginner rider, the speed
limiter should be screwed in completely.
Screw it out little by little as their riding
technique improves. Never remove the
speed limiter for a beginning rider.
• For proper throttle lever operation, do not
turn out the adjuster more than the speci-
fied length. Also, always adjust the throttle
cable free play to within specification.
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3-22
3-23
CHASSIS
GENERAL CHASSIS (1) ................................................................................. 4-1

REMOVING THE FRONT OUTER PANEL ............................................... 4-2
INSTALLING THE FRONT OUTER PANEL..............................................4-2
REMOVING THE FRONT INNER PANEL ................................................ 4-2
INSTALLING THE FRONT INNER PANEL ............................................... 4-2
GENERAL CHASSIS (2) ................................................................................. 4-4

REMOVING THE FUEL TANK TOP COVER............................................4-5
INSTALLING THE FUEL TANK TOP COVER .......................................... 4-5
REMOVING THE FRONT FENDER.......................................................... 4-5
INSTALLING THE FRONT FENDER ........................................................4-5
GENERAL CHASSIS (3) ................................................................................. 4-7
FRONT WHEEL............................................................................................... 4-8

REMOVING THE FRONT WHEELS .........................................................4-9
CHECKING THE FRONT WHEELS.......................................................... 4-9
CHECKING THE FRONT WHEEL HUBS ................................................. 4-9
ASSEMBLING THE FRONT WHEEL HUB ............................................. 4-10
INSTALLING THE FRONT WHEEL HUBS ............................................. 4-10
4
INSTALLING THE FRONT WHEELS......................................................4-10
REAR WHEEL ...............................................................................................4-12

REMOVING THE REAR WHEELS.......................................................... 4-13
CHECKING THE REAR WHEELS .......................................................... 4-13
CHECKING THE REAR WHEEL HUBS.................................................. 4-13
INSTALLING THE REAR WHEEL HUBS................................................ 4-13
INSTALLING THE REAR WHEELS ........................................................ 4-13
FRONT BRAKE ............................................................................................. 4-14

CHECKING THE FRONT BRAKE SHOES ............................................. 4-15
ASSEMBLING THE FRONT BRAKE SHOE PLATE...............................4-15
INSTALLING THE FRONT BRAKE......................................................... 4-16
REAR BRAKE ...............................................................................................4-17

REMOVING THE REAR BRAKE............................................................. 4-18
CHECKING THE REAR BRAKE SHOES................................................ 4-18
ASSEMBLING THE REAR BRAKE SHOE PLATE .................................4-19
INSTALLING THE REAR BRAKE DRUM ............................................... 4-19
CHECKING THE REAR BRAKE DRUM WEAR LIMIT ........................... 4-20
REAR AXLE AND REAR AXLE HUB ........................................................... 4-21
REMOVING THE REAR AXLE................................................................4-22
CHECKING THE REAR AXLE ................................................................4-22
CHECKING THE REAR AXLE HUB........................................................ 4-22
CHECKING THE REAR WHEEL SPROCKET........................................ 4-23
CHECKING THE SPROCKET BRACKET............................................... 4-23
INSTALLING THE REAR AXLE HUB......................................................4-23
HANDLEBAR ................................................................................................4-24
REMOVING THE HANDLEBAR..............................................................4-25
CHECKING THE HANDLEBAR ..............................................................4-25
INSTALLING THE HANDLEBAR ............................................................ 4-25
STEERING STEM.......................................................................................... 4-27

CHECKING THE STEERING STEM .......................................................4-28
INSTALLING THE CABLE HOLDER.......................................................4-28
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES ............. 4-29

REMOVING THE STEERING KNUCKLES ............................................. 4-30
CHECKING THE TIE-RODS ................................................................... 4-30
CHECKING THE STEERING KNUCKLES.............................................. 4-30
REMOVING THE FRONT ARMS ............................................................ 4-30
CHECKING THE FRONT ARMS............................................................. 4-30
CHECKING THE FRONT SHOCK ABSORBER ASSEMBLIES ............. 4-31
INSTALLING THE TIE-RODS .................................................................4-31
INSTALLING THE FRONT ARMS AND
FRONT SHOCK ABSORBER ASSEMBLIES.........................................4-31
REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM ......................4-33

CHECKING THE REAR SHOCK ABSORBER ASSEMBLY ................... 4-34
CHECKING THE SWINGARM ................................................................4-34
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY ................. 4-34
INSTALLING THE SWINGARM ..............................................................4-34
CHAIN DRIVE................................................................................................4-36
REMOVING THE DRIVE CHAIN............................................................. 4-37
CHECKING THE DRIVE CHAIN ............................................................. 4-37
CHECKING THE DRIVE SPROCKET.....................................................4-38
INSTALLING THE DRIVE CHAIN ........................................................... 4-38
GENERAL CHASSIS (1)
EBS20024
GENERAL CHASSIS (1)

Removing the front bumper, seat and front panel
5 Nm (0.5 m•kgf, 3.6 ft•Ibf)
6
T.R
.
7
4
3
0.5 Nm (0.05 m•kgf, 0.36 ft•Ibf)
T.R
.
2
1.0 Nm (0.10 m•kgf, 0.72 ft•Ibf)

T.R
.
20 Nm (2.0 m•kgf, 14 ft•Ibf)

T.R
.
Order Job/Parts to remove Q’ty Remarks

1 Front bumper 1
TIP
2 Seat 1 Pull back the seat lock lever, then pull up on
the rear of the seat.
3 Handlebar cover 1
4 Front outer panel 1
5 Front inner panel 1
6 Reverse indicator light 1 Disconnect.
7 Neutral indicator light 1 Disconnect.
4-1
GENERAL CHASSIS (1)
EBS30489
REMOVING THE FRONT OUTER PANEL 1

a
1. Remove:
• Front outer panel “1”
a
a b
a
1 b
b
c. Install the bolts.
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EBS30491
REMOVING THE FRONT INNER PANEL

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bolts. 1. Remove:
b. Slide the front outer panel rearward to re- • Front inner panel “1”
move the projections “a” on the front outer
panel from the holes “b” in the front fender.
c. Remove the projections “a” on the front outer 1
panel from the holes “b” in the front inner pan-
el.
a 1
a
a b ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a a. Remove the quick fasteners and screw.
b b. Remove the projections “a” on the front inner
panel from the holes “b” in the front fender.
b
1
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EBS30490
a
INSTALLING THE FRONT OUTER PANEL a
1. Install: b
• Front outer panel “1”
b
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30492
INSTALLING THE FRONT INNER PANEL

1. Install:
• Front inner panel “1”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the projections “a” on the front outer panel
from the holes “b” in the front fender.
b. Slide the front outer panel forward, fit the pro-
jection “a” on the front fender into the hole “b”.
4-2
GENERAL CHASSIS (1)
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a. Fit the projections “a” on the front inner panel
from the holes “b” in the front fender.
1
a
a
b
b
b. Install the quick fasteners and screw.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-3
GENERAL CHASSIS (2)
EBS20087
GENERAL CHASSIS (2)

Removing the front fender
1
1.0 Nm (0.10 m•kgf, 0.72 ft•Ibf) 2
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
5
(2)
2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)
T.R
.
4
(4)
5 Nm (0.5 m•kgf, 3.6 ft•Ibf)

T.R
.
5 Nm (0.5 m•kgf, 3.6 ft•Ibf)

T.R
.

Front inner panel 4-1.
1 Fuel tank cap 1
2 Fuel tank top cover 1
3 Dummy headlight 2
4 Main switch coupler 1 Disconnect.
5 Front fender 1
6 Front reflector 1 For CDN
4-4
GENERAL CHASSIS (2)
EBS30576
REMOVING THE FUEL TANK TOP COVER a

1. Remove: a 1
• Fuel tank top cover “1”
1
b
b
c. Install the quick fasteners.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30584
REMOVING THE FRONT FENDER

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the quick fasteners. 1. Removing:
b. Slide the fuel tank top cover rearward to re- • Front fender “1”
move the projections “a” on the fuel tank top
cover from the holes “b” in the front fender.
c. Remove the projections “a” on the fuel tank
top cover from the holes “b” in the front fend-
er. 1
a
a 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the bolts and screws.
b b. Slide the front fender rearward to remove the
projections “a” on the front fender from the
b holes “b” in the side cover and rear fender.
c. Remove the projection “a” on the front fender
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
from the hole “b” in the side cover and rear
EBS30577
fender.
INSTALLING THE FUEL TANK TOP COVER
1. Install:
• Fuel tank top cover “1”
b
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30585
INSTALLING THE FRONT FENDER

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the projections “a” on the fuel tank top cov- 1. Install:
er from the holes “b” in the front fender. • Front fender “1”
b. Slide the fuel tank top cover forward, fit the
projection “a” on the fuel tank top cover into
the hole “b” in the front fender.
4-5
GENERAL CHASSIS (2)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Fit the projection “a” on the front fender from
the holes “b” in the side cover and rear fend-
er.
b. Slide the front fender forward, fit the projec-
tion “a” on the front fender into the hole “b” in
the side cover and rear fender.
b
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-6
GENERAL CHASSIS (3)
EBS20088
GENERAL CHASSIS (3)

Removing the rear fender and footrest board
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
T.R
.
.
T.R
T.R
.
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
1
T.R
.
2
4
3
5
8
6 7 (4)
10
(4)
10
9
2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf) 9

T.R
.

T.R
T.R
.

Seat 4-1.
Front fender 4-4.
1 Negative battery lead 1 Disconnect.
2 Positive battery lead 1 Disconnect.
3 Battery 1
4 Kickstarter 1
5 CDI unit 1 Disconnect.
6 Relay unit 1 Disconnect.
7 Fuse box 1
8 Rear fender 1
9 Side cover 2
10 Footrest board 2
4-7
FRONT WHEEL
EBS20095
FRONT WHEEL
Removing the front wheel
D
FW 12 New
11
10 9
LS
2 8
7 New
6
LS
45 Nm (4.5 m•kgf, 33 ft•Ibf)
T.R
.
(4)
5
4 New
3
50 Nm (5.0 m•kgf, 36 ft•Ibf)

T.R
.

The following procedure applies to both of
the front wheels.
1 Front wheel bolt 4
2 Front wheel 1
3 Front wheel cap 1
4 Cotter pin 1
5 Axle nut 1
6 Collar 1
7 Oil seal 1
8 Bearing 1
9 Front wheel hub 1
10 Collar 1
11 Bearing 1
12 Oil seal 1
4-8
FRONT WHEEL
EBS30358
REMOVING THE FRONT WHEELS

The following procedure applies to both of the
front wheels.
2. Elevate:
• Front wheels
TIP 2
Place the vehicle on a suitable stand so that the
front wheel is elevated.
3. Remove:
• Front wheel
1
EBS30360
CHECKING THE FRONT WHEELS 3 3

front wheels.
1. Check:
• Tire
• Wheel
Refer to “CHECKING THE TIRES” on page
3-11 and “CHECKING THE WHEELS” on 3. Check:
page 3-11. • Wheel balance
2. Measure: Out of balance → Adjust.
• Radial wheel runout “1” EWB03020
• Lateral wheel runout “2” WARNING

Over the specified limit → Replace the wheel After replacing the tire, ride conservatively to
or check the wheel bearing play “3”. allow the tire to be properly seated in the rim.
Failure to do so may cause an accident re-
Front wheel sulting in vehicle damage and possible inju-
Radial wheel runout limit
ry.
2.0 mm (0.08 in)
Lateral wheel runout limit
2.0 mm (0.08 in)
EBS30361
CHECKING THE FRONT WHEEL HUBS

front wheel hubs.
1. Check:
• Wheel hub “1”
4-9
FRONT WHEEL
2. Install:
• Collar “1”
1 TIP
Install the collar with the tapered end “a” facing
toward the front wheel hub.
1
2. Check:
• Wheel bearings
Wheel hub play/wheel turns roughly → Re-
place.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ a
a. Clean wheel hub exterior.
b. Drive bearing out by pushing spacer aside EBS30363
and tapping around perimeter of bearing in- INSTALLING THE FRONT WHEEL HUBS
ner race. Use soft metal drift punch and ham- The following procedure applies to both of the
mer. The spacer “1” “floats” between front hubs.
bearings. Remove both bearings as de- 1. Install:
scribed. • Front wheel hub
EWB03030
• Washer (43 mm)
WARNING • Washer (24 mm)
Eye protection is recommended when using • Front wheel axle nut “1”
striking tools. • Cotter pin “2” New
c. To install the wheel bearings, reverse the
above sequence. Use a socket that matches Front wheel axle nut
outside diameter of bearing outer race to 50 Nm (5.0 m·kgf, 36 ft·lbf)
T.
R.
drive in bearing.
ECB02650 TIP
NOTICE • Do not loosen the axle nut after torquing it. If
Do not strike the center race or balls of the the axle nut groove is not aligned with the cot-
bearing. Contact should be made only with ter pin hole, align the groove with the hole by
the outer race. tightening the axle nut.
• Bend the longer cotter pin up.
1
2 New
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30364
EBS30495
ASSEMBLING THE FRONT WHEEL HUB INSTALLING THE FRONT WHEELS

1. Assembling: The following procedure applies to both of the
• Bearing front wheels.
• Collar 1. Install:
• Oil seal • Front wheel
4-10
FRONT WHEEL
Front wheel bolt

45 Nm (4.5 m·kgf, 33 ft·lbf)
T.
R.
4-11
REAR WHEEL
EBS20096
REAR WHEEL
Removing the rear wheel
6
2
50 Nm (5.0 m•kgf, 36 ft•Ibf)
T.R
.
5
(4) 4
3
1
45 Nm (4.5 m•kgf, 33 ft•Ibf)

T.R
.

1 Rear wheel bolt 4
2 Rear wheel 1
3 Rear wheel cap 1
4 Cotter pin 1
5 Rear wheel axle nut 1
6 Rear wheel hub 1
4-12
REAR WHEEL
EBS30365
REMOVING THE REAR WHEELS

1. Place the vehicle on a level surface. 1
2. Elevate:
• Front wheel
TIP
2
Place the vehicle on a suitable stand so that the
rear wheel is elevated.
3. Remove:
• Rear wheels
EBS30370
EBS30367 INSTALLING THE REAR WHEEL HUBS
CHECKING THE REAR WHEELS The following procedure applies to both of the
The following procedure applies to both of the rear wheel hubs.
rear wheels. 1. Install:
1. Check: • Rear wheel hub
• Tire • Washer (43 mm)
• Wheel • Washer (26 mm)
Refer to “CHECKING THE TIRES” on page • Rear wheel axle nut
3-11 and “CHECKING THE WHEELS” on
page 3-11. Rear wheel axle nut
2. Measure: 50 Nm (5.0 m·kgf, 36 ft·lbf)
T.
R.
• Wheel runout
Refer to “CHECKING THE FRONT • Cotter pin New
WHEELS” on page 4-9. Refer to “INSTALLING THE FRONT WHEEL
Over the specified limit → Replace. HUBS” on page 4-10.
Rear wheel EBS30371
Radial wheel runout limit INSTALLING THE REAR WHEELS

2.0 mm (0.08 in) The following procedure applies to both of the
Lateral wheel runout limit rear wheels.
2.0 mm (0.08 in) 1. Install:
• Rear wheel
3. Check:
• Wheel balance Rear wheel bolt
Out of balance → Adjust. 45 Nm (4.5 m·kgf, 33 ft·lbf)
T.
R.
EBS30368
CHECKING THE REAR WHEEL HUBS

rear wheel hubs.
1. Check:
• Wheel hub “1”
• Spline (wheel hub) “2”
Wear/damage → Replace.
4-13
FRONT BRAKE
EBS20097
FRONT BRAKE
Removing the front brakes
New
1 New
7
3
4
LS 6
D
FW 4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
5
T.R
.

Refer to “FRONT WHEEL” on page 4-8 and
Front wheel “REAR WHEEL” on page 4-12.
1 Cotter pin 1
2 Front brake cable (drum side) 1
3 Front brake shoe plate 1
4 Front brake shoe spring 1
5 Front brake shoe 2
6 Front brake camshaft 1
7 Front brake camshaft lever bolt 1
8 Front brake camshaft lever 1
4-14
FRONT BRAKE
EBS30496
CHECKING THE FRONT BRAKE SHOES a

1. Check:
• Front brake shoe
Cracks/damage → Replace as a set.
2. Check:
• Brake shoe lining
Glazed areas → Repair.
Sand the glazed areas with coarse sandpa-
per.
TIP 5. Check:
After sanding the glazed areas, clean the brake • Brake drum inner surface
shoe with a cloth. Oil deposits → Clean.
3. Measure: Remove the oil with a rag soaked in lacquer
• Brake shoe lining thickness “a” thinner or solvent.
Out of specification → Replace. Scratches → Repair.
Lightly and evenly polish the scratches with
Lining thickness limit an emery cloth.
1.3 mm (0.05 in) 6. Check:
• Front brake camshaft
Damage/wear → Replace.
EBS30497
ASSEMBLING THE FRONT BRAKE SHOE

PLATE
front brakes.
1. Lubricate:
a
EWB03840
WARNING
Do not allow oil or grease on the brake 2. Install:
shoes. • Front brake camshaft “1”
• Front brake camshaft lever “2”
TIP
Replace the brake shoes as a set, if either is • Brake camshaft lever spring “3” New
worn to the wear limit. • Brake camshaft lever bolt “4”
TIP
4. Measure:
Align the punch mark “a” on the front brake cam-
• Brake drum inside diameter “a”
shaft with the punch mark “b” on the front brake
Out of specification → Replace the wheel.
camshaft lever.
Brake drum inside diameter limit EWB03850
86.0 mm (3.39 in) WARNING

After installing the brake camshaft, remove
any excess grease.
Front brake camshaft lever bolt

4.0 Nm (0.40 m·kgf, 2.9 ft·lbf)
T.
R.
4-15
FRONT BRAKE
a
2
b
4
New 3 1
3. Install:
• Front brake shoe
• Front brake shoe spring
EWB03860
WARNING
Do not apply grease to the brake shoe lin-
ings.
TIP
Check that the front brake shoe are properly po-
sitioned.
EBS30498
INSTALLING THE FRONT BRAKE

1. Install:
• Brake shoe plate “1”
TIP
When installing the brake shoe plate, align the
groove “a” of the brake shoe plate with the pro-
jection “b” of the steering knuckle.
b
a
2. Install:
• Front brake cable (drum side)
• Cotter pin New
3. Check:
• Brake camshaft operation
Unsmooth operation → Repair.
4. Adjust:
• Front brake free play
Refer to “ADJUSTING THE FRONT BRAKE
4-16
REAR BRAKE
EBS20098
REAR BRAKE
Disassembling the rear brake
100 Nm (10 m•kgf, 72 ft•lbf)

T.R
.
New 2 4
11
13 1
9 LS
10
New
12
9
T.R
.
7 Nm (0.7 m•kgf, 5.1 ft•Ibf)
6 New
8
7
*
* Apply Yamaha bond No. 1215 (90890-85505)

Refer to “FRONT WHEEL” on page 4-8 and
Rear wheel (left) “REAR WHEEL” on page 4-12.
1 Rear brake lever adjusting nut 1
2 Compression spring 1
3 Rear brake cable 1
4 Pin 1
5 Rear brake axle locknut 1
6 Rear brake axle nut 1
7 Conical washer 1
8 Rear brake drum 1
9 Rear brake shoe 2
10 Rear brake camshaft lever bolt 1
11 Rear brake camshaft lever 1
12 Spring 1
13 Rear brake camshaft 1
4-17
REAR BRAKE
EBS30499
2. Check:
REMOVING THE REAR BRAKE
• Rear brake shoe lining
Glazed areas → Repair.
2. Remove:
Sand the glazed areas with coarse sandpa-
• Rear axle locknut “1”
per.
3. Loosen:
• Rear axle nut “2” TIP
TIP
After sanding the glazed areas, clean the brake
shoe with a cloth.
• Apply the rear brake lever so that the rear axle
does not turn when loosening the nut. 3. Measure:
• Use the axle nut wrench (36 mm) (rear axle nut • Rear brake shoe lining thickness “a”
wrench 36 mm) “3”. Out of specification → Replace.
Lining thickness limit

Axle nut wrench (36 mm) 2.0 mm (0.08 in)
90890-01422
Rear axle retaining nut wrench
YM-37132
2
1
a
EWB03840
WARNING
Do not allow oil or grease on the brake
shoes.
TIP
Replace the brake shoes as a set, if either is
3 worn to the wear limit.
4. Measure:
• Brake drum inside diameter “a”
Out of specification → Replace the wheel.
Brake drum inside diameter limit

4. Elevate the rear wheels by placing a suitable 131.0 mm (5.16 in)
stand under the frame.
5. Remove: a
• Rear wheel (left)
• Rear wheel hub (left)
Refer to “REAR WHEEL” on page 4-12.
• Rear axle nut
• Conical washer
6. Remove:
• Rear brake drum
EBS30500
CHECKING THE REAR BRAKE SHOES

1. Check: 5. Check:
• Rear brake shoe • Splines
Cracks/damage → Replace as a set. Cracks/damage/wear → Replace.
4-18
REAR BRAKE
• Rear brake drum inner surface

Oil deposits → Clean. b
Remove the oil with a rag soaked in lacquer 3
3
thinner or solvent.
Scratches → Repair. 1
Lightly and evenly polish the scratches with
an emery cloth. 2 a
6. Check:
• Rear brake camshaft 1
• Rear brake shoe lining stud bolt “1” 4
Damage/wear → Replace. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Install:
• Rear brake shoe spring “1” New
• Rear brake shoe
1 TIP
• Lubricate the pivot pin with a thin coat of lithi-
um-soap-based grease.
• Do not to damage the springs during installa-
tion.
• Install the brake shoe springs as shown.
EBS30501 EWB03860
ASSEMBLING THE REAR BRAKE SHOE WARNING

PLATE Do not apply grease to the brake shoe lin-
1. Lubricate: ings.
• Rear brake camshaft lever
New 1 1 New
2. Install:
• Rear brake camshaft “1”
• Spring “2”
• Rear brake camshaft lever “3”
LS LS
• Rear brake camshaft lever bolt “4”
Rear brake camshaft lever bolt EBS30503

7 Nm (0.7 m·kgf, 5.1 ft·lbf) INSTALLING THE REAR BRAKE DRUM
T.
R.
1. Apply:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the rear brake camshaft “1” so its • Sealant
punch mark “a” is positioned as shown. (to the threads of rear axle nut and rear axle
b. Align the projection “b” on the rear brake locknut)
camshaft lever “3” with the projection “a” on
Yamaha bond No. 1215
the rear brake camshaft “1”. 90890-85505
c. Check that the brake shoes are properly po- (Three bond No.1215®)
sitioned.
EWB03850
2. Install:
WARNING
• Rear brake drum “1”
After installing the brake camshaft, remove 3. Install:
any excess grease. • Conical washer “2”
• Rear axle nut “3”
4-19
REAR BRAKE
EBS30502
TIP CHECKING THE REAR BRAKE DRUM WEAR
Install the conical washer with the convex side of LIMIT
the washer facing outward as shown. TIP
Perform this check with new brake shoes in-
stalled.
1. Check:
• Rear brake camshaft lever
3 2 1 • Rear brake camshaft
Incorrect installation → Reinstall.
2. Check:
• Position of the adjusting nut “1”.
(distance “a” from the end of the bolt to the
adjusting nut)
4. Tighten:
Less than 18 mm → Still usable.
• Rear axle nut “1”
18 mm or more → Replace the rear brake
• Rear axle locknut “2”
shoe.
Rear axle nut
100 Nm (10 m·kgf, 72 ft·lbf)
T.
1
R.
Rear axle locknut

100 Nm (10 m·kgf, 72 ft·lbf)
TIP
a
• Apply the brake lever so that the rear axle does
not turn when tightening the nut.
• Use the axle nut wrench (36 mm) (rear axle nut
wrench 36 mm) “3”.
3. Check:
Axle nut wrench (36 mm) • Brake lever free play
90890-01422 Refer to “ADJUSTING THE REAR BRAKE
Rear axle retaining nut wrench LEVER FREE PLAY” on page 3-10.
YM-37132
1
2
4-20
REAR AXLE AND REAR AXLE HUB
EBS20110

Removing the rear axle and axle hub
LT 25 Nm (2.5 m•kgf, 18 ft•Ibf)

9 Nm (0.9 m•kgf, 6.5 ft•Ibf)
T.R
.
T.R
.
T.R
. 54 Nm (5.4 m•kgf, 39 ft•Ibf) 1
45 Nm (4.5 m•kgf, 33 ft•Ibf)
T.R
.
22 Nm (2.2 m•kgf, 16 ft•Ibf)

3 (3)
T.R
.
LT
LS
8
5 New
6
7
LT
LT
LT 9 4
2
6
LS
5 New
54 Nm (5.4 m•kgf, 39 ft•Ibf)
T.R
.
LT
LT 10
2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)

T.R
.

Rear wheel Refer to “REAR WHEEL” on page 4-12.
Rear brake Refer to “REAR BRAKE” on page 4-17.
1 Drive chain guard 1
2 Rear axle 1
3 Rear wheel sprocket/sprocket bracket 1
4 Rear axle hub 1
5 Oil seal 2
6 Bearing 2
7 Spacer 1
8 Chain puller 1
9 Rear brake shoe plate 1
10 Rear lower guard 1
4-21
EBS30504 EBS30505
REMOVING THE REAR AXLE CHECKING THE REAR AXLE

1. Place the vehicle on a level surface. 1. Check:
2. Elevate the rear wheels by placing a suitable • Rear axle runout “a”
stand under the frame. Out of specification → Replace.
3. Remove: EWB03870
• Rear wheel WARNING

• Rear wheel hub Do not attempt to straighten a bent axle.
Refer to “REAR WHEEL” on page 4-12.
• Rear axle locknut Runout limit
• Rear axle nut 1.5 mm (0.06 in)
• Conical washer
• Rear brake drum
• Rear brake shoe
Refer to “REAR BRAKE” on page 4-17. a a
4. Loosen:
• Drive chain
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” on page 3-13.
5. Remove:
• Drive chain guard
• Rear axle “1”
ECB02720 EBS30506
NOTICE CHECKING THE REAR AXLE HUB

• Never directly tap the axle end with a ham- 1. Check:
mer, since this will result in damage to the • Rear axle hub
axle thread and spline. Cracks/damage → Replace.
• Attach a suitable socket on the axle end 2. Check:
and tap it with a soft hammer, then pull out • Rear axle hub bearings
the rear axle to the right. Rear axle hub play/wheel turns roughly →
Replace.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Clean rear axle hub exterior.
b. Drive bearing out by pushing spacer aside
and tapping around perimeter of bearing in-
ner race. Use soft metal drift punch and ham-
1
mer. The spacer “1” “floats” between
bearings. Remove both bearings as de-
scribed.
EWB03030
WARNING
Eye protection is recommended when using
striking tools.
c. To install the rear axle hub bearings, reverse
2 the above sequence. Use a socket that
matches outside diameter of bearing outer
race to drive in bearing.
ECB02650
NOTICE
Do not strike the center race or balls of the
bearing. Contact should be made only with
2. Suitable socket the outer race.
4-22
5
1
4
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ 2. Install:
EBS30507 • Rear wheel sprocket/sprocket bracket
CHECKING THE REAR WHEEL SPROCKET • Drive chain
1. Check: • Rear axle
• Rear wheel sprocket
Refer to “CHECKING THE DRIVE SPROCK- Sprocket bracket bolt
ET” on page 4-38. 25 Nm (2.5 m·kgf, 18 ft·lbf)
T.
R.
EBS30508
3. Adjust:
CHECKING THE SPROCKET BRACKET • Drive chain slack
1. Check: Refer to “ADJUSTING THE DRIVE CHAIN
• Sprocket bracket SLACK” on page 3-13.
Cracks/damage → Replace. 4. Tighten:
EBS30509 • Rear axle hub bolt
INSTALLING THE REAR AXLE HUB • Rear axle hub nut
1. Install:
• Rear axle hub “1” Rear axle hub bolt
• Chain puller “2” 45 Nm (4.5 m·kgf, 33 ft·lbf)
T.
R.
• Rear axle hub bolt “3” LOCTITE®

• Rear brake shoe plate “4” Rear axle hub nut (rear brake
shoe plate)
• Rear axle hub nut “5”
54 Nm (5.4 m·kgf, 39 ft·lbf)
TIP
Temporarily tighten the rear axle hub bolt “3” and
rear axle hub nut “5”.
1
4 3
2
4-23
HANDLEBAR
EBS20099
HANDLEBAR
Removing the handlebar
3 1.0 Nm (0.10 m•kgf, 0.72 ft•Ibf)
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
1 LS 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
7
5 12
11
4
2
LS
9
10 7
50 Nm (5.0 m•kgf, 36 ft•Ibf) 1
T.R
.
8
13 6
13
LS
0.5 Nm (0.05 m•kgf, 0.36 ft•Ibf)
T.R
.
1.2 Nm (0.12 m•kgf, 0.87 ft•Ibf)

T.R
.
50 Nm (5.0 m•kgf, 36 ft•Ibf)

T.R
.

Handlebar cover 4-1.
1 Handlebar grip 2
2 Front brake cable 2 Disconnect.
3 Throttle lever assembly cover 1
4 Throttle cable 1
5 Front brake lever/throttle lever assembly 1
6 Choke cable 1 Disconnect.
7 Handlebar switch/choke lever assembly 1
8 Rear brake cable 1 Disconnect.
9 Brake switch lead 1 Disconnect.
10 Rear brake lever assembly 1
11 Upper handlebar holder 2
12 Handlebar 1
13 Lower handlebar holder 2
4-24
HANDLEBAR
EBS30393 EBS30395
REMOVING THE HANDLEBAR INSTALLING THE HANDLEBAR

1. Remove: 1. Install
• Brake switch “1” • Handlebar “1”
TIP • Upper handlebar holder “2”
Push the fastener when removing the brake • Lower handlebar holder “3”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
switch out of the rear brake lever holder.
a. Install the lower handlebar holders “3” to the
steering stem “4” and temporarily tighten the
lower handlebar holder nuts “5”.
2. Remove: 5
• Handlebar grip “1”
TIP b. Install the handlebar “1” and the upper han-
Blow compressed air between the left handlebar dlebar holders “2” so that the punch marks “a”
and the handlebar grip, and gradually push the on the handlebar are positioned to the out-
grip off the handlebar. side of the upper and lower handlebar hold-
ers. Align the punch marks on the handlebar
with the top of the lower handlebar holders.
TIP
First tighten the bolts on the rear side, and then
tighten the bolts on the front side.
Upper handlebar holder bolt

1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
1 2
EBS30394
CHECKING THE HANDLEBAR

1. Check: a
a
• Handlebar “1”
Bends/cracks/damage → Replace.
EWB03680
WARNING
3
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken it.
c. Tighten the lower handlebar holder nuts to
specification.
Lower handlebar holder nut

50 Nm (5.0 m·kgf, 36 ft·lbf)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Install
• Rear brake lever assembly “1”
4-25
HANDLEBAR
TIP TIP
Align the slit of the rear brake lever assembly ”1” Before applying the adhesive, wipe off grease or
with the match mark “a” on the handlebar. oil on the handlebar surface “a” with a lacquer
thinner.
1
1
3. Install
• Handlebar switch/choke lever assembly “1” 6. Adjust:
TIP • Throttle lever free play
Align the projection “a” on the handlebar Refer to “ADJUSTING THE THROTTLE LE-
switch/choke lever assembly with the holes “b” VER FREE PLAY” on page 3-21.
in the handlebar.
Throttle lever free play
1.5–4.0 mm (0.06–0.16 in)
1 a
b 7. Adjust:
• Front brake lever free play
Refer to “ADJUSTING THE FRONT BRAKE
Front brake lever free play

20.0–25.0 mm (0.79–0.98 in)
8. Adjust:
4. Install • Rear brake lever free play
• Front brake lever/throttle lever assembly “1” Refer to “ADJUSTING THE REAR BRAKE
TIP LEVER FREE PLAY” on page 3-10.
Align the slit of the front brake lever/throttle lever
assembly “1” with the match mark “a” on the Rear brake lever free play
handlebar. 30.0–40.0 mm (1.18–1.57 in)
5. Install
• Handlebar grips “1”
4-26
STEERING STEM
EBS20101
STEERING STEM
Removing the steering stem
20 Nm (2.0 m•kgf, 14 ft •Ibf)
T.
R.
LS
2 3 New
3
New 1
10
LS
11
9
New
4
8 5 New
6 4
7
New
50 Nm (5.0 m•kgf, 36 ft •Ibf)

T.
R.
40 Nm (4.0 m•kgf, 29 ft •Ibf)

T.
R.

Front fender 4-4.
1 Handlebar switch lead coupler 1 Disconnect.
2 Steering stem cable holder 1
3 Steering stem bushing holder 2
4 Tie-rod end locknut 2
5 Tie-rod 2
6 Steering stem nut 1
7 Washer 2
8 Collar 1
9 Steering stem 1
10 Oil seal 1
11 Bearing 1
4-27
STEERING STEM
EBS30397
CHECKING THE STEERING STEM FWD

1. Check:
• Steering stem “1” 1
Bends → Replace.
EWB03780
2
WARNING 3
Do not attempt to straighten a bent stem; this
may dangerously weaken the stem.
a
2. Check:
• Steering stem bushing holders “1”
• Steering stem bushing “2”
1 2 1
EBS30578
INSTALLING THE CABLE HOLDER

1. Install
• Steering stem “1”
• Steering stem bushing “2”
• Steering stem bushing holder “3”
• Steering stem cable holder
Steering stem cable holder bolt

20 Nm (2.0 m·kgf, 14 ft·lbf)
T.
R.
TIP
• Install the steering stem bushing with its slit “a”
facing rearward.
• Route the cables through the steering stem ca-
ble holder.
Refer to “CABLE ROUTING” on page 2-17.
4-28
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES
EBS20031

Removing the tie-rods, steering knuckles, front arms and front shock absorber assemblies
45 Nm (4.5 m•kgf, 33 ft •Ibf) 40 Nm (4.0 m•kgf, 29 ft •Ibf)
T.
T.
R.
R.
LT New
3
40 Nm (4.0 m•kgf, 29 ft•Ibf)

T.R
.
LT
LS
LS LT
LS
1
5 6 7
6 5
5 67
6 5
New
LS 4
LS
LT
2
45 Nm (4.5 m•kgf, 33 ft •Ibf)
T.
R.
40 Nm (4.0 m•kgf, 29 ft •Ibf) New

T.
R.

The following procedure applies to both of
the tie-rods, steering knuckles, front arms
and front shock absorber assemblies.
Front bumper 4-1.
Front wheel Refer to “FRONT WHEEL” on page 4-8.
Front wheel hub Refer to “FRONT WHEEL” on page 4-8.
Front brake shoe plate Refer to “FRONT BRAKE” on page 4-14.
1 Tie-rod 1
2 Steering knuckle 1
3 Front shock absorber assembly 1
4 Front arm 1
5 Dust cover 4
6 Bushing 4
7 Spacer 2
4-29
EBS30401
REMOVING THE STEERING KNUCKLES

steering knuckles. 1
1. Remove:
• Steering knuckle “1”
TIP
Use a general puller to separate the ball joints
“2” from the steering knuckle “1”.
EBS30511
REMOVING THE FRONT ARMS

2 The following procedure applies to both of the
front upper arms and front lower arms.
1 1. Check:
• Front arm free play
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Check the front arm side play “A” by moving
it from side to side.
If side play is noticeable, check the bushings.
EBS30402
CHECKING THE TIE-RODS

tie-rods.
1. Check:
• Tie-rod free play and movement
Free play → Replace the tie-rod end.
Turns roughly → Replace the tie-rod end. A
b. Check the front arm vertical movement “B” by

moving it up and down.
If the vertical movement is tight or rough, or if
there is binding, check the bushings.
2. Check:
• Tie-rod
Bends/damage → Replace. B
Rubber boot damage → Replace the tie-rod
end.
EBS30510
CHECKING THE STEERING KNUCKLES ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

The following procedure applies to both of the 2. Remove:
steering knuckles. • Front arm
1. Check:
• Steering knuckle “1” EBS30113
Damage/pitting → Replace. CHECKING THE FRONT ARMS

front upper arms and front lower arms.
4-30
1. Check: TIP
• Front arm “1” Install the tie-rod so that the groove “1” is on the
Bends/damage → Replace. wheel side.
2. Check:
• Bushings “2”
2 2 1
2. Adjust:
• Toe-in
EBS30514
Refer to “ADJUSTING THE TOE-IN” on page
CHECKING THE FRONT SHOCK ABSORBER 3-17.
ASSEMBLIES EBS30118
The following procedure applies to both of the INSTALLING THE FRONT ARMS AND
front shock absorber assemblies. FRONT SHOCK ABSORBER ASSEMBLIES
1. Check: The following procedure applies to both of the
• Front shock absorber assembly front upper arms, front lower arms, and front
Gas leaks/oil leaks → Replace the front shock absorber assemblies.
shock absorber assembly. 1. Install:
• Front shock absorber rod • Front arm
Bends/damage → Replace the front shock • Front shock absorber assembly
absorber assembly. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Spring a. Install the front arm.
Move the spring up and down. TIP
Fatigue → Replace the front shock absorber Temporarily tighten the front arm nuts.
assembly.
b. Install the front shock absorber assembly.
Front shock absorber upper nut

45 Nm (4.5 m·kgf, 33 ft·lbf)
T.
R.
LOCTITE®
Front shock absorber lower nut
45 Nm (4.5 m·kgf, 33 ft·lbf)
LOCTITE®
c. Install the steering knuckle.
EBS30405
Steering knuckle nut
INSTALLING THE TIE-RODS 45 Nm (4.5 m·kgf, 33 ft·lbf)
T.
R.

d. Install the new cotter pins.
tie-rods.
e. Tighten the front nuts to specification.
1. Install:
• Tie-rod Front arm nut
40 Nm (4.0 m·kgf, 29 ft·lbf)
T.
Tie-rod end locknut

R.
LOCTITE®
40 Nm (4.0 m·kgf, 29 ft·lbf)
T.
R.
4-31
TIP
Apply lithium-soap-based grease to the grease
nipples “1”.
1
1
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4-32
REAR SHOCK ABSORBER ASSEMBLY AND SWINGARM
EBS20112

Removing the rear shock absorber assembly and swingarm
45 Nm (4.5 m•kgf, 33 ft•Ibf)
T.R
.
LT
85 Nm (8.5 m•kgf, 61 ft •Ibf)
T.
R.
LS
2
5
LS
6
7
8 9
4
LS
7
5
3
LS
LT
1 T.R
.
20 Nm (2.0 m•kgf, 14 ft•Ibf)
50 Nm (5.0 m•kgf, 36 ft•Ibf)

T.R
.

Rear wheel Refer to “REAR WHEEL” on page 4-12.
Rear brake Refer to “REAR BRAKE” on page 4-17.
Refer to “REAR AXLE AND REAR AXLE
Rear axle hub HUB” on page 4-21.
1 Rear shock absorber assembly 1
2 Swingarm pivot shaft nut 1
3 Swingarm pivot shaft 1
4 Swingarm 1
5 Dust cover 2
6 Collar 1
7 Bushing 2
8 Spacer 1
9 Drive chain tensioner assembly 1
4-33
EBS30125
CHECKING THE REAR SHOCK ABSORBER

ASSEMBLY
1. Check:
• Rear shock absorber assembly
Gas leaks/oil leaks → Replace the rear shock
absorber assembly.
• Rear shock absorber rod
Bends/damage → Replace the rear shock
absorber assembly.
• Spring
3. Check:
Move the spring up and down.
• Drive chain tensioner assembly
Fatigue → Replace the front shock absorber
assembly.
4. Wash:
• Pivot shaft
• Dust covers
• Collar
• Spacer
• Bushings
Recommended cleaning solvent

Kerosene
EBS30517 5. Check:
CHECKING THE SWINGARM • Dust covers
1. Check: • Collar
• Swingarm • Spacer
Bends/cracks/damage → Replace. • Bushings
Damage/pitting → Replace.
Damage/pitting → Replace.
EBS30518
INSTALLING THE REAR SHOCK

ABSORBER ASSEMBLY
1. Install:
TIP
2. Check: When installing the rear shock absorber assem-
• Pivot shaft bly lower bolt, lift up the swingarm.
Roll the pivot shaft on a flat surface.
Bends → Replace. Rear shock absorber upper nut
EWB03880 45 Nm (4.5 m·kgf, 33 ft·lbf)
T.
R.
WARNING LOCTITE®
Do not attempt to straighten a bent pivot Rear shock absorber lower nut
shaft. 50 Nm (5.0 m·kgf, 36 ft·lbf)
LOCTITE®
EBS30519
INSTALLING THE SWINGARM

1. Lubricate:
• Pivot shaft
4-34
2. Install:
• Spacer
• Bushing
• Collar
• Dust covers
3. Install:
• Pivot shaft
Pivot shaft nut

85 Nm (8.5 m·kgf, 61 ft·lbf)
T.
R.
4. Install:
• Rear axle hub
• Rear axle
• Rear wheel
Refer to “REAR WHEEL” on page 4-12 and
“REAR AXLE AND REAR AXLE HUB” on
page 4-21.
5. Adjust:
• Drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” on page 3-13.
Drive chain slack

24.0–32.0 mm (0.94–1.26 in)
4-35
CHAIN DRIVE
EBS20113
CHAIN DRIVE
Removing the drive chain
D
FW
7
5
6
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)

T.
R.
2 New
3
4

Footrest board (right side) 4-7.
1 Drive sprocket cover 1
2 Master link clip 1
3 Master link 1
4 Master link plate 1
5 Drive chain 1
6 Drive sprocket retainer 1
7 Drive sprocket 1
4-36
CHAIN DRIVE
EBS30520
REMOVING THE DRIVE CHAIN 15-link length limit

1. Place the vehicle on a level surface. 195.6 mm (7.70 in)
2. Loosen:
• Rear axle hub bolt “1” ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Rear axle hub nut (rear brake shoe plate) “2” a. Measure the length “b” between the inner
sides of the pins and the length “c” between
the outer sides of the pins on a 15-link section
of the drive chain as shown in the illustration.
b. Calculate the length “a” of the 15-link section
of the drive chain using the following formula.
1 Drive chain 15-link section length “a” =
(length “b” between pin inner sides + length
“c” between pin outer sides)/2
TIP
• When measuring a 15-link section of the drive
chain, make sure that the drive chain is taut.
• Perform this procedure 2–3 times, at a different
location each time.
3. Move:
• Rear axle hub
Move the rear axle hub forward to loosen the
drive chain.
HUB” on page 4-21.
4. Remove:
• Master link clip
• Master link “1”
• Master link plate “2”
• Drive chain “3”
1
3
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
• Drive chain
2 Stiffness → Clean and lubricate or replace.
EBS30521
CHECKING THE DRIVE CHAIN

1. Measure:
• 15-link section “a” of the drive chain
Out of specification → Replace the drive
chain.
4-37
CHAIN DRIVE
3. Clean:
• Drive chain
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
ECB02730
NOTICE
• This ATV has a drive chain with small rub- 5. Lubricate:
ber O-rings “1” between the drive chain • Drive chain
side plates. Never use high-pressure water
or air, steam, gasoline, certain solvents Recommended lubricant
(e.g., benzine), or a coarse brush to clean Chain lubricant suitable for O-
the drive chain. High-pressure methods ring chains
could force dirt or water into the drive
chain’s internals, and solvents will deterio- EBS30522
rate the O-rings. A coarse brush can also CHECKING THE DRIVE SPROCKET
damage the O-rings. Therefore, use only 1. Check:
kerosene to clean the drive chain. • Drive sprocket
• Do not soak the drive chain in kerosene for More than 1/4 tooth “a” wear → Replace the
more than ten minutes, otherwise the O- drive chain sprocket, drive chain, and rear
rings can be damaged. wheel sprocket as a set.
Bent teeth → Replace the drive chain sprock-
et, drive chain, and rear wheel sprocket as a
set.
b. Correct
1. Drive chain roller
2. Drive sprocket
EBS30523
INSTALLING THE DRIVE CHAIN

1. Lubricate:
• Drive chain
• Master link
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Check: Recommended lubricant
• O-rings “1” Engine oil or chain lubricant
Damage → Replace the drive chain. suitable for non-O-ring chains
• Drive chain rollers “2”
Damage/wear → Replace the drive chain. 2. Install:
• Drive chain side plates “3” • Drive sprocket
Damage/wear/cracks → Replace the drive • Drive sprocket retainer
chain.
4-38
CHAIN DRIVE
Drive sprocket retainer bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
3. Install:
• Master link “1” 1
• Master link plate “2”
2 2
4. Install:
• Master link clip “3” New
ECB02830
NOTICE
• The closed end of the master link clip must 7. Adjust:
face in the direction of drive chain rotation. • Drive chain slack
• Never install a new drive chain onto worn Refer to “ADJUSTING THE DRIVE CHAIN
drive chain sprockets; this will dramatically SLACK” on page 3-13.
shorten the drive chain’s life. Drive chain slack
24.0–32.0 mm (0.94–1.26 in)
ECB02740
NOTICE
3 New A drive chain that is too tight will overload
the engine and other vital parts, and one that
is too loose can skip and damage the swing-
arm or cause an accident. Therefore, keep
the drive chain slack within the specified lim-
its.
5. Move:
• Rear axle hub
Move the rear axle hub rearward to tighten
the drive chain.
HUB” on page 4-21.
6. Tighten:
• Rear axle hub nut (rear brake shoe plate) “1”
• Rear axle hub bolt “2”
Rear axle hub nut (rear brake

shoe plate)
T.
R.
54 Nm (5.4 m·kgf, 39 ft·lbf)

Rear axle hub bolt
45 Nm (4.5 m·kgf, 33 ft·lbf)
LOCTITE®
4-39
ENGINE
ENGINE INSPECTION .................................................................................... 5-1

MEASURE THE COMPRESSION PRESSURE........................................ 5-1
ENGINE REMOVAL ........................................................................................5-2

INSTALLING THE ENGINE....................................................................... 5-6
CYLINDER HEAD............................................................................................ 5-7

REMOVING THE CYLINDER HEAD.........................................................5-8
CHECKING THE CYLINDER HEAD .........................................................5-8
CHECKING THE TAPPET COVERS AND
CAMSHAFT SPROCKET COVER ........................................................... 5-9
CHECKING THE CAMSHAFT SPROCKET..............................................5-9
CHECKING THE TIMING CHAIN TENSIONER........................................ 5-9
INSTALLING THE CYLINDER HEAD .....................................................5-10
CAMSHAFT ................................................................................................... 5-13

REMOVING THE ROCKER ARMS AND CAMSHAFT............................ 5-14
CHECKING THE CAMSHAFT.................................................................5-14
CHECKING THE ROCKER ARMS AND ROCKER ARM SHAFTS ........ 5-14
INSTALLING THE CAMSHAFT AND ROCKER ARMS .......................... 5-15
VALVES AND VALVE SPRINGS.................................................................. 5-16

REMOVING THE VALVES...................................................................... 5-17
CHECKING THE VALVES AND VALVE GUIDES ..................................5-17
5
CHECKING THE VALVE SEATS ............................................................ 5-19
CHECKING THE VALVE SPRINGS........................................................ 5-20
INSTALLING THE VALVES .................................................................... 5-21
CYLINDER AND PISTON.............................................................................. 5-23

REMOVING THE PISTON ...................................................................... 5-24
CHECKING THE TIMING CHAIN GUIDE ............................................... 5-24
CHECKING THE CYLINDER AND PISTON ...........................................5-24
CHECKING THE PISTON RINGS........................................................... 5-25
CHECKING THE PISTON PIN ................................................................5-26
INSTALLING THE PISTON AND CYLINDER .........................................5-26
CDI MAGNETO..............................................................................................5-28
REMOVING THE CDI MAGNETO ROTOR ............................................5-29
INSTALLING THE CDI MAGNETO ROTOR ...........................................5-29
OIL PUMP...................................................................................................... 5-31

CHECKING THE OIL PUMP ................................................................... 5-33
ASSEMBLING THE OIL PUMP...............................................................5-33
INSTALLING THE OIL PUMP .................................................................5-34
ELECTRIC STARTER ...................................................................................5-35
CHECKING THE STARTER MOTOR .....................................................5-37
ASSEMBLING THE STARTER MOTOR................................................. 5-38
KICKSTARTER ............................................................................................. 5-39

CHECKING THE KICKSTARTER ........................................................... 5-40
ASSEMBLING THE KICKSTARTER.......................................................5-40
INSTALLING THE AIR DUCTS ...............................................................5-40
STARTER CLUTCH ......................................................................................5-41

CHECKING THE STARTER WHEEL......................................................5-42
CHECKING THE STARTER CLUTCH ....................................................5-42
INSTALLING THE GEAR POSITION SWITCH....................................... 5-42
BELT DRIVE.................................................................................................. 5-43

REMOVING THE PRIMARY SHEAVE....................................................5-46
REMOVING THE SECONDARY SHEAVE ............................................. 5-46
DISASSEMBLING THE SECONDARY SHEAVE.................................... 5-46
CHECKING THE CLUTCH HOUSING ....................................................5-47
CHECKING THE CLUTCH SHOE........................................................... 5-47
CHECKING THE V-BELT........................................................................5-47
CHECKING THE PRIMARY SHEAVE ....................................................5-47
CHECKING THE PRIMARY SHEAVE WEIGHTS................................... 5-48
CHECKING THE PRIMARY SHEAVE SLIDERS .................................... 5-48
CHECKING THE SECONDARY SHEAVE .............................................. 5-48
ASSEMBLING THE PRIMARY SHEAVE ................................................ 5-48
ASSEMBLING THE SECONDARY SHEAVE..........................................5-48
INSTALLING THE PRIMARY AND SECONDARY SHEAVES................ 5-48
CRANKCASE ................................................................................................5-51
SEPARATING THE CRANKCASE.......................................................... 5-53
CHECKING THE CRANKCASE ..............................................................5-53
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE............. 5-53
CHECKING THE CRANKSHAFT ............................................................ 5-53
CHECKING THE BEARINGS.................................................................. 5-54
ASSEMBLING THE CRANKCASE.......................................................... 5-54
TRANSMISSION............................................................................................ 5-56
REMOVING THE TRANSMISSION ........................................................ 5-59
CHECKING THE SHIFT FORK ...............................................................5-59
CHECKING THE SHIFT DRUM ..............................................................5-59
CHECKING THE TRANSMISSION ......................................................... 5-59
ASSEMBLING THE MAIN AXLE............................................................. 5-60
INSTALLING THE SHIFT FORK AND SHIFT DRUM ............................. 5-61
INSTALLING THE SHIFT LEVER ........................................................... 5-61
ENGINE INSPECTION
EBS20105
ENGINE INSPECTION Standard compression pressure

(at sea level)
EBS30539
790–1080 kPa (7.9–10.8 kgf/cm²,
MEASURE THE COMPRESSION PRESSURE 112.4–153.6 psi)
TIP
Insufficient compression pressure will result in a ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
loss of performance. a. Set the main switch to “ON”.
b. With the throttle wide open, crank the engine
1. Measure: until the reading on the compression gauge
• Valve clearance stabilizes.
Out of specification → Adjust. EWB03200
Refer to “ADJUSTING THE VALVE CLEAR- WARNING

ANCE” on page 3-4. To prevent sparking, ground the spark plug
2. Start the engine, warm it up for several min- lead before cranking the engine.
utes, and then turn it off.
c. If the compression pressure is above the
3. Disconnect:
maximum specification, check the cylinder
• Spark plug cap
head, valve surfaces, and piston crown for
4. Remove:
carbon deposits.
• Spark plug
ECB01870
Carbon deposits → Eliminate.
NOTICE d. If the compression pressure is below the min-
Before removing the spark plug, use com- imum specification, pour a teaspoonful of en-
pressed air to blow away any dirt accumulat- gine oil into the spark plug bore and measure
ed in the spark plug well to prevent it from again.
falling into the cylinder. Refer to the following table.
Compression pressure (with oil applied into the
5. Install: cylinder)
• Extension “1”
Reading Diagnosis
• Compression gauge “2”
Piston ring(s) wear or
Higher than without oil
Extension damage → Repair.
90890-04082 Piston, valves, cylinder
Compression gauge Same as without oil
head gasket or piston
90890-03081 ring(s) possibly defec-
Engine compression tester tive → Repair.
YU-33223
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Remove:
• Compression gauge
2 8. Install:
• Spark plug
1 Spark plug
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
T.
R.
9. Connect:
• Spark plug cap
6. Measure:
• Compression pressure
Out of specification → Refer to steps (c) and
(d).
5-1
ENGINE REMOVAL
EBS20034
ENGINE REMOVAL
Removing the exhaust pipe and muffler
3
LT
LT
22 Nm (2.2 m•kgf, 16 ft•Ibf)

T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
New
.
22 Nm (2.2 m•kgf, 16 ft•Ibf)

T.R
.
6 4
New
8 Nm (0.8 m•kgf, 5.8 ft•Ibf)
5
T.R
.
25 Nm (2.5 m•kgf, 18 ft•Ibf)

T.R
.
12 Nm (1.2 m•kgf, 8.7 ft•Ibf)

T.R
.

1 Muffler 1
2 Muffler gasket 1
3 Spark arrester 1
4 Exhaust pipe 1
5 Gasket 1
6 Exhaust pipe protector 1
5-2
ENGINE REMOVAL
Disconnecting the couplers and leads

Front fender 4-4.
Fuel tank Refer to “FUEL TANK” on page 6-1.
Air filter case Refer to “AIR FILTER CASE” on page 6-3.
Air duct Refer to “KICKSTARTER” on page 5-39.
Carburetor Refer to “CARBURETOR” on page 6-5.
Drive sprocket Refer to “CHAIN DRIVE” on page 4-36.
Air filter case breather hose Refer to “AIR FILTER CASE” on page 6-3.
Cylinder head breather hose Refer to “AIR FILTER CASE” on page 6-3.
Crankcase breather hose Refer to “AIR FILTER CASE” on page 6-3.
5-3
ENGINE REMOVAL
Disconnecting the couplers and leads
4
2

1 Spark plug cap 1 Disconnect.
2 Pickup coil/stator coil assembly coupler 1 Disconnect.
3 Gear position switch coupler 1 Disconnect.
4 Starter motor lead coupler 1 Disconnect.
5-4
ENGINE REMOVAL
Removing the engine
45 Nm (4.5 m•kgf, 33 ft•Ibf)
T.R
.
1
4
22 Nm (2.2 m•kgf, 16 ft•Ibf)

T.R
.

1 Engine mounting bolt (front left side) 1
2 Engine mounting bolt (front right side) 1
3 Engine mounting bolt (rear side) 1
4 Engine 1
5-5
ENGINE REMOVAL
EBS30128
INSTALLING THE ENGINE

1. Install:
• Engine mounting bolt (front left side) “1”
• Engine mounting bolt (front right side) “2”
• Engine mounting bolt (rear side) “3”
TIP
Do not fully tighten the bolts.
2. Tighten:
• Engine mounting bolt (front left side) “1”
• Engine mounting bolt (front right side) “2”
• Engine mounting bolt (rear side) “3”
Engine mounting bolt (front)

45 Nm (4.5 m·kgf, 33 ft·lbf)
T.
R.
Engine mounting bolt (rear)

22 Nm (2.2 m·kgf, 16 ft·lbf)
1,2 3
5-6
CYLINDER HEAD
EBS20035
CYLINDER HEAD
Removing the cylinder head
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 16 Nm (1.6 m•kgf, 12 ft•Ibf)
T.R
T.R
.
.
7
11 New
New New
(4)
8 9 2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)

T.R
.
2
New
New
LS 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
8 Nm (0.8 m•kgf, 5.8 ft•Ibf)
T.R
.
12 (3)
6 New
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
5
10 LT New
E 4
New LS
1
3
New
LS
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) 12 Nm (1.2 m•kgf, 8.7 ft•Ibf) 2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)
T.R
T.R
T.R
.

Spark plug cap Refer to “ENGINE REMOVAL” on page 5-2.
Carburetor Refer to “CARBURETOR” on page 6-5.
1 Spark plug 1
2 Intake tappet cover 1
3 Exhaust tappet cover 1
4 Camshaft sprocket cover bolt 1
5 Camshaft sprocket cover 1
6 Cylinder head side cover 1
7 Timing chain tensioner cap bolt 1
8 Breather hose holder 1
9 Timing chain tensioner assembly 1
10 Camshaft sprocket 1
11 Cylinder head top cover 1
12 Cylinder head 1
5-7
CYLINDER HEAD
EBS30129
REMOVING THE CYLINDER HEAD

1. Align:
• “I” mark “a” on the CDI magneto rotor
(with the stationary pointer “b” on the CDI 1
magneto rotor cover)
a
b TIP
While holding the CDI magneto rotor nut with a
wrench, remove the bolt.
3. Loosen:
• Timing chain tensioner cap bolt
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 4. Remove:
a. Install the kickstarter lever “1”.
• Timing chain tensioner
(along with the gasket)
• Camshaft sprocket
• Timing chain
1 TIP
To prevent the timing chain from falling into the
crankcase, fasten it with a wire.
5. Remove:
• Cylinder head
TIP
b. Move the kickstarter lever down lightly.
c. When the piston is at TDC on the compres- • Loosen the bolts and nuts in the proper se-
sion stroke, align the punch mark “c” on the quence as shown.
camshaft sprocket with the mark “d” on the • Loosen each bolt and nut 1/2 of a turn at a
cylinder head. time. After bolt No. 1 and nuts No. 4–7 are fully
loosened, remove them.
c
5 6 3
d
1
7 4 2
3
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4
2. Loosen: EBS30130
• Camshaft sprocket bolt “1” CHECKING THE CYLINDER HEAD

1. Eliminate:
• Combustion chamber carbon deposits
(with a rounded scraper)
TIP
Do not use a sharp instrument to avoid damag-
ing or scratching:
• Spark plug bore threads
5-8
CYLINDER HEAD
• Valve seats TIP

To ensure an even surface, rotate the cylinder
head several times.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30132
CHECKING THE TAPPET COVERS AND

CAMSHAFT SPROCKET COVER
tappet covers.
1. Check:
• Tappet covers
2. Check: • Camshaft sprocket cover
• Cylinder head Damage/wear → Replace the defective
Damage/scratches → Replace. part(s).
3. Measure:
• Cylinder head warpage EBS30131
Out of specification → Resurface the cylinder CHECKING THE CAMSHAFT SPROCKET

head. 1. Check:
• Camshaft sprocket
Warpage limit More than 1/4 tooth wear “a” → Replace the
0.05 mm (0.0020 in) camshaft sprocket and the timing chain as a
set.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place a straightedge “1” and a thickness
gauge “2” across the cylinder head.
a. 1/4 tooth
b. Correct
1. Timing chain roller
2. Camshaft sprocket
1
EBS30133
CHECKING THE TIMING CHAIN TENSIONER

1. Check:
• Timing chain tensioner
2. Check:
2 • One-way cam operation
Rough movement → Replace the timing
b. Measure the warpage. chain tensioner assembly.
c. If the limit is exceeded, resurface the cylinder 3. Check:
head as follows. • Timing chain tensioner cap bolt “1”
d. Place a 400–600 grit wet sandpaper on the • O-ring “2”
surface plate and resurface the cylinder head • Timing chain tensioner spring “3”
using a figure-eight sanding pattern. • One-way cam “4”
• Timing chain tensioner gasket “5”
5-9
CYLINDER HEAD
• Timing chain tensioner rod “6”

Damage/wear → Replace the defective Cylinder head nut “1”–“4”
part(s). 16 Nm (1.6 m·kgf, 12 ft·lbf)
T.
R.
Cylinder bolt “5”, “6”
5 3 2 1 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
Cylinder head nut “7”
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
TIP
Tighten the cylinder head bolt, nuts and cylinder
bolts in the proper tightening sequence as
4
6 shown and torque them in two stages.
EBS30134
INSTALLING THE CYLINDER HEAD

1. Install: 3 2 5
• Dowel pins
7
• Cylinder head gasket New
2. Install: 1 4 6
• Cylinder head 3
3. Install:
4
• Cylinder head top cover gasket “1” New
• Cylinder head top cover “2” 5. Install:
• Washers New • Camshaft sprocket “1”
• Cylinder head nuts • Timing chain “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Cylinder head bolts a. Move the kickstarter lever down lightly.
• Cylinder bolt b. Align the “I” mark “a” on the CDI magneto ro-
TIP tor with the stationary pointer “b” on the CDI
• Make sure that the cutout “a” in the cylinder magneto rotor cover.
head top cover gasket “1” New faces down-
a
ward.
• Make sure that the arrow mark “b” on the cylin-
der head top cover “2” points downward.
• Lubricate the contact surfaces of the cylinder b
head bolts, and nuts and on both contact sur-
faces of washers with engine oil.
1 New
b
c. Align the punch mark “c” on the camshaft
2 sprocket with the mark “d” on the cylinder
head.
d. Install the timing chain onto the camshaft
sprocket, and then install the camshaft
sprocket onto the camshaft.
a ECB02540
NOTICE
4. Tighten: Do not turn the crankshaft when installing
• Cylinder bolt the camshaft sprocket to avoid damage or
• Cylinder head bolts improper valve timing.
• Cylinder head nuts
5-10
CYLINDER HEAD
8. Move:
c • Kickstarter lever
(down lightly)
1 9. Check:
• “I” mark “a”
d Align the “I” mark on the CDI magneto rotor
with the stationary pointer “b” on the CDI
2 magneto rotor cover.
a
e. While holding the camshaft, temporarily tight-
en the camshaft sprocket bolt.
f. Remove the wire from the timing chain. b
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6. Install:
• Timing chain tensioner gasket “1” New
• Timing chain tensioner “2”
TIP
• Punch mark “c”
To push in the timing chain tensioner rod, re- Align the “I” mark on the camshaft sprocket
lease the lock by pushing in the one-way cam with the mark “d” on the cylinder head.
“6”. Out of alignment → Correct.
Refer to the installation steps above.
Timing chain tensioner bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf) c
T.
R.
7. Install:
• Timing chain tensioner spring “3”
• O-ring “4” New d
• Timing chain tensioner cap bolt “5”
Timing chain tensioner cap bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
10.Tighten:
• Camshaft sprocket bolts
1 New 2 3 4 New 5
Camshaft sprocket bolt
8 Nm (0.8 m·kgf, 5.8 ft·lbf)
T.
R.
LOCTITE®
ECB01780
NOTICE
6
Be sure to tighten the camshaft sprocket
bolts to the specified torque to avoid the
possibility of the bolts coming loose and
5 damaging the engine.
11.Measure:
2 • Valve clearance
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE” on page 3-4.
12.Install:
• Cylinder head side cover
5-11
CYLINDER HEAD
• Cylinder head side cover gasket

• Camshaft sprocket cover “1”
• Camshaft sprocket cover gasket New
Camshaft sprocket cover bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
Cylinder head side cover bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
TIP
Fit the projection “a” on the camshaft sprocket
cover “1” between the projections “b” on the cyl-
inder head. Also, make sure that the hole “c” in
the camshaft sprocket cover “1” fits over the pro-
jection “d” on the cylinder head.
a
b
1
d c
5-12
CAMSHAFT
EBS20106
CAMSHAFT
Removing the rocker arms and camshaft
8 Nm (0.8 m•kgf, 5.8 ft•Ibf)
T.R
.
1
2 4
M
3
M
5
6 M 7
E
2 1
8 Nm (0.8 m•kgf, 5.8 ft•Ibf)

T.R
.

Cylinder head Refer to “CYLINDER HEAD” on page 5-7.
1 Locknut 2 Loosen.
2 Adjusting screw 2 Loosen.
3 Intake rocker arm shaft 1
4 Intake rocker arm 1
5 Exhaust rocker arm shaft 1
6 Exhaust rocker arm 1
7 Camshaft assembly 1
5-13
CAMSHAFT
EBS30136
REMOVING THE ROCKER ARMS AND Camshaft lobe dimensions

CAMSHAFT Lobe height (Intake) limit
1. Loosen: 26.200 mm (1.0315 in)
• Locknuts “1” Base circle diameter (Intake) limit
• Valve clearance adjusting screws “2” 20.650 mm (0.8130 in)
Lobe height (Exhaust) limit
26.000 mm (1.0236 in)
Base circle diameter (Exhaust)
limit
2 20.650 mm (0.8130 in)
1
2. Remove:
• Intake rocker arm shaft
• Intake rocker arm
• Exhaust rocker arm shaft
• Exhaust rocker arm
TIP
Screw an 8 mm (0.31 in) bolt “1” into the thread-
ed end of the rocker arm shaft, and then pull out
the shaft.
EBS30139
CHECKING THE ROCKER ARMS AND

1 ROCKER ARM SHAFTS
3. Remove: rocker arms and rocker arm shafts.
• Camshaft 1. Check:
• Rocker arms
EBS30137
CHECKING THE CAMSHAFT
2. Check:
1. Check:
• Rocker arm shafts
• Camshaft lobes
Blue discoloration/excessive wear/pit-
Blue discoloration/pitting/scratches → Re-
ting/scratches → Replace or check the lubri-
place the camshaft.
cation system.
2. Measure:
3. Check:
• Camshaft lobe dimensions “a” and “b”
• Camshaft lobe
Out of specification → Replace the camshaft.
Excessive wear → Replace the camshaft.
4. Measure:
• Rocker arm inside diameter “a”
Out of specification → Replace.
Rocker arm inside diameter limit

10.100 mm (0.3976 in)
5-14
CAMSHAFT
2. Install:
• Camshaft
3. Lubricate:
• Rocker arm shafts
a
Rocker arm inner surface
Molybdenum disulfide grease
Rocker arm shaft outer surface
Engine oil
5. Measure: 4. Install:
• Rocker arm shaft outside diameter “a” • Exhaust rocker arm “1”
Out of specification → Replace. • Exhaust rocker arm shaft “2”
• Intake rocker arm
Rocker arm shaft outside diame-
ter limit • Intake rocker arm shaft
ECB02840
9.910 mm (0.3902 in) NOTICE
Install each rocker arm shaft so that the
a threaded end of the shaft points outward.
TIP
Screw an 8 mm (0.31 in) bolt “3” into the thread-
ed end of the rocker arm shaft, and then install
the shaft.
1 2
6. Calculate:
• Rocker-arm-to-rocker-arm-shaft clearance
Out of specification → Replace the defective
part(s).
TIP
Calculate the clearance by subtracting the rock- 3
er arm shaft outside diameter from the rocker
arm inside diameter.
Rocker-arm-to-rocker-arm-shaft
clearance limit
0.190 mm (0.0075 in)
EBS30140
INSTALLING THE CAMSHAFT AND ROCKER

ARMS
1. Lubricate:
• Camshaft
• Camshaft bearings
Camshaft
Molybdenum disulfide grease
Camshaft bearing
Engine oil
5-15
VALVES AND VALVE SPRINGS
EBS20037

Removing the valves and valve springs
3
M
4 M
9 1
5 9
M 10 New
10 New 2
New 8
3
4
5
M
8 New
M
M
6

Camshaft Refer to “CAMSHAFT” on page 5-13.
1 Valve cotter 4
2 Valve spring retainer 2
3 Outer valve spring 2
4 Inner valve spring 2
5 Valve spring seat 2
6 Intake valve 1
7 Exhaust valve 1
8 Valve stem seal 2
9 Valve guide 2
10 O-ring 2
5-16
EBS30141
REMOVING THE VALVES

valves and related components.
TIP
Before removing the internal parts of the cylinder
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 3. Remove:
face, valve seat, and valve seat contact • Valve spring retainer “1”
width. • Outer valve spring “2”
Refer to “CHECKING THE VALVE SEATS” • Inner valve spring “3”
on page 5-19. • Valve “4”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Valve spring seat “5”
a. Pour a clean solvent “a” into the intake and • Valve stem seal “6”
exhaust ports. TIP
b. Check that the valves properly seal. Identify the position of each part very carefully so
TIP that it can be reinstalled in its original place.
There should be no leakage at the valve seat “1”.
1
4
2
6
5
EBS30142
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE VALVES AND VALVE
2. Remove: GUIDES
• Valve cotters The following procedure applies to all of the
valves and valve guides.
TIP
1. Measure:
Remove the valve cotters by compressing the • Valve-stem-to-valve-guide clearance
valve spring with the valve spring compressor Out of specification → Replace the valve
“1” and the valve spring compressor attachment guide.
“2”.
• Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” -
Valve spring compressor Valve stem diameter “b”
90890-04019
YM-04019
Valve spring compressor attach-
ment
90890-01243
Valve spring compressor adapt-
er (26 mm)
YM-01253-1
5-17
Valve stem diameter (intake) limit

4.900 mm (0.1929 in)
Valve stem diameter (exhaust)
limit
4.900 mm (0.1929 in)
Valve guide inside diameter (in-
take) limit
5.030 mm (0.1980 in)
Valve guide inside diameter (ex-
haust) limit
5.030 mm (0.1980 in) b. Install a new valve guide with the valve guide
Valve-stem-to-valve-guide clear- installer “2” and valve guide remover “1”.
ance (intake) limit
0.080 mm (0.0032 in) 2
Valve-stem-to-valve-guide clear-
ance (exhaust) limit
0.100 mm (0.0039 in)
c. After installing the valve guide, bore the valve

guide with the valve guide reamer “3” to ob-
tain the proper valve-stem-to-valve-guide
clearance.
TIP
2. Replace: After replacing the valve guide, reface the valve
seat.
• Valve guide New
TIP
To ease valve guide removal and installation,
and to maintain the correct fit, heat the cylinder
head to 100 °C (212 °F) in an oven.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve guide with the valve guide
remover “1”.
5-18
2. Check:
Valve guide remover (ø5) • Valve seat
90890-04097 Pitting/wear → Replace the cylinder head.
Valve guide remover (5.0 mm) 3. Measure:
YM-04097
• Valve seat contact width “a”
Valve guide installer (ø5)
90890-04098 Out of specification → Replace the cylinder
Valve guide installer (5.0 mm) head.
YM-04098
Valve guide reamer (ø5) Valve seat contact width (intake)
90890-04099 limit
Valve guide reamer (5.0 mm) 1.6 mm (0.06 in)
YM-04099 Valve seat contact width (ex-
haust) limit
1.6 mm (0.06 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
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 stem runout ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Out of specification → Replace the valve. a. Apply blue layout fluid “b” onto the valve face.
TIP
• When installing a new valve, always replace
the valve guide.
• If the valve is removed or replaced, always re-
place the valve stem seal.
Valve stem runout

0.020 mm (0.0008 in)
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 contact width.
TIP
Where the valve seat and valve face contacted
one another, the blue layout fluid will have been
removed.
EBS30143
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
CHECKING THE VALVE SEATS
The following procedure applies to all of the 4. Lap:
valves and valve seats. • Valve face
1. Eliminate: • Valve seat
• Carbon deposits
(from the valve face and valve seat)
5-19
TIP e. Apply a fine lapping compound to the valve

After replacing the cylinder head or replacing the face and repeat the above steps.
valve and valve guide, the valve seat and valve f. After every lapping procedure, be sure to
face should be lapped. clean off all of the lapping compound from the
valve face and valve seat.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ g. Apply blue layout fluid “b” onto the valve face.
a. Apply a coarse lapping compound “a” to the
valve face.
ECB01360
NOTICE
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.
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 contact width “c”
again. If the valve seat contact width is out of
specification, reface and lap the valve seat.
b. Apply molybdenum disulfide oil onto the
valve stem.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30144
c. Install the valve into the cylinder head. CHECKING THE VALVE SPRINGS
d. Turn the valve until the valve face and valve The following procedure applies to all of the
seat are evenly polished, then clean off all of valve springs.
the lapping compound. 1. Measure:
TIP • Valve spring free length “a”
For the best lapping results, lightly tap the valve Out of specification → Replace the valve
seat while rotating the valve back and forth be- spring.
tween your hands.
Inner spring
Free length (intake)
32.41 mm (1.28 in)
Free length (exhaust)
32.41 mm (1.28 in)
Outer spring
Free length (intake)
35.25 mm (1.39 in)
Free length (exhaust)
35.25 mm (1.39 in)
5-20
2. Lubricate:
• Valve stem “1”
• Valve stem seal “2” New
(with the recommended lubricant)
Molybdenum disulfide oil
b. Installed length
2. Measure:
• Valve spring tilt “a”
Out of specification → Replace the valve
M
spring.
Inner spring
Spring tilt (intake)
3. Install:
2.0 mm (0.08 in)
Spring tilt (exhaust) • Valve spring seat “1”
2.0 mm (0.08 in) • Valve stem seal “2” New
Outer spring • Valve “3”
Spring tilt (intake) • Inner valve spring “4”
2.0 mm (0.08 in) • Outer valve spring “5”
Spring tilt (exhaust) • Valve spring retainer “6”
2.0 mm (0.08 in) (into the cylinder head)
TIP
a • Make sure each valve is installed in its original
place.
• Install the valve springs with the larger pitch “a”
facing up.
1
3
6
EBS30145 2 New
INSTALLING THE VALVES
5
valves and related components.
1. Deburr: 4
• Valve stem end
(with an oil stone)
a. Large pitch
5-21
b. Smaller pitch
4. Install:
• Valve cotters
TIP
Install the valve cotters by compressing the
valve spring with the valve spring compressor
“1” and the valve spring compressor attachment
“2”.

90890-04019
YM-04019
Valve spring compressor attach-
ment
90890-01243
Valve spring compressor adapt-
er (26 mm)
YM-01253-1
5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-face
hammer.
ECB01370
NOTICE
Hitting the valve tip with excessive force
could damage the valve.
5-22
CYLINDER AND PISTON
EBS20038
CYLINDER AND PISTON

Removing the cylinder and piston
1
3 New
E
2
6 E
7
5 New 10
9
8
1 Timing chain guide (exhaust side) 1
2 Cylinder 1
3 Cylinder gasket 1
4 Dowel pin 2
5 Piston pin clip 2
6 Piston pin 1
7 Piston 1
8 Top ring 1
9 2nd ring 1
10 Oil ring 1
5-23
CYLINDER AND PISTON
EBS30146
REMOVING THE PISTON TIP

1. Remove: When removing a piston ring, open the end gap
• Piston pin clips “1” with your fingers and lift the other side of the ring
• Piston pin “2” over the piston crown.
• Piston “3”
ECB01380
NOTICE
Do not use a hammer to drive the piston pin
out.
TIP
• Before removing the piston pin clips, cover the
crankcase opening with a clean rag to prevent
the piston pin clips from falling into the crank-
case.
• Before removing the piston pin, deburr the pis- EBS30579
ton pin clip grooves and the piston pin bore ar- CHECKING THE TIMING CHAIN GUIDE
ea. If both areas are deburred and the piston 1. Check:
• Timing chain guide (exhaust side)
pin is still difficult to remove, remove it with the
piston pin puller set “4”. Damage/wear → Replace.
EBS30147
Piston pin puller set CHECKING THE CYLINDER AND PISTON

90890-01304 1. Check:
Piston pin puller • Piston wall
YU-01304 • Cylinder wall
Vertical scratches → Replace the cylinder,
and replace the piston and piston rings as a
set.
1
2. Measure:
• Piston-to-cylinder clearance
2 ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the cylinder bore “C” with the cylin-
der bore gauge.
TIP
Measure the cylinder bore “C” by taking side-to-
side and front-to-back measurements of the cyl-
2. Remove: inder.
• Top ring
• 2nd ring
• Oil ring
5-24
CYLINDER AND PISTON
Bore Piston-to-cylinder clearance

47.000–47.010 mm (1.8504– 0.010–0.040 mm (0.0004–0.0016
1.8508 in) in)
Taper limit
0.050 mm (0.0020 in) f. If out of specification, replace the cylinder,
Out of round limit and replace the piston and piston rings as a
0.050 mm (0.0020 in) set.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
“C” = maximum of D1, D2, D3, D4, D5, D6 EBS30148
Taper (front-to-back) = maximum difference be- CHECKING THE PISTON RINGS

tween D1, D3, D5 1. Measure:
Taper (side-to-side) = maximum difference be- • Piston ring side clearance
tween D2, D4, D6 Out of specification → Replace the piston
Out of round (top) = difference between D1, D2 and piston rings as a set.
Out of round (middle) = difference between D3, TIP
D4 Before measuring the piston ring side clearance,
Out of round (bottom) = difference between D5, eliminate any carbon deposits from the piston
D6 ring grooves and piston rings.
b. If out of specification, replace the cylinder,
Piston ring
and replace the piston and piston rings as a
Ring side clearance limit
set. 0.09 mm (0.0035 in)
c. Measure piston skirt diameter “P” with a mi- 2nd ring
crometer. Ring side clearance limit
0.09 mm (0.0035 in)
Piston
Diameter
46.970–46.990 mm (1.8492–
1.8500 in)
a
P
2. Install:
• Piston ring
(into the cylinder)
a. 5 mm (0.2 in) from the bottom edge of the TIP
piston Use the piston crown to level the piston ring near
bottom of cylinder “a”, where cylinder wear is
d. If out of specification, replace the piston and
lowest.
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”
5-25
CYLINDER AND PISTON
3. Measure:
a • Piston pin bore diameter “b”
Out of specification → Replace the piston.
Piston pin bore inside diameter

limit
13.040 mm (0.5134 in)
b
b. Upper of cylinder
3. Measure:
• Piston ring end gap
Out of specification → Replace the piston
ring.
b
TIP
The oil ring expander end gap cannot be mea-
EBS30150
sured. If the oil ring rail gap is excessive, replace
INSTALLING THE PISTON AND CYLINDER
all three piston rings.
1. Install:
• Lower oil ring rail “1”
Top ring • Oil ring expander “2”
End gap (installed) limit • Upper oil ring rail “3”
0.45 mm (0.0177 in) • 2nd ring “4”
2nd ring
• Top ring “5”
End gap (installed) limit
0.55 mm (0.0217 in) TIP
Oil ring Be sure to install the piston rings so that the
End gap (installed) limit manufacturer marks or numbers face up.
0.9 mm (0.04 in)
EBS30149
CHECKING THE PISTON PIN

1. Check:
• Piston pin
Blue discoloration/grooves → Replace the
piston pin, and then check the lubrication sys-
tem.
2. Measure:
• Piston pin outside diameter “a”
Out of specification → Replace the piston pin. 2. Install:
• Piston “1”
Piston pin outside diameter limit • Piston pin “2”
12.960 mm (0.5102 in)
• Piston pin clips “3” New
TIP
• Apply engine oil to the piston pin.
• Make sure the mark “a” on the piston points to-
wards the intake side of the cylinder.
• Before installing the piston pin clips, cover the
crankcase opening with a clean rag to prevent
the clips from falling into the crankcase.
5-26
CYLINDER AND PISTON
• When installing a piston pin clip, make sure

a
that the clip ends “b” are positioned away from
the cutout “c” in the piston as shown in the illus-
tration.
120˚ 120˚
b
f
1 d 120˚ e
f
a c
A
a. Top ring
2 b. Upper oil ring rail
c. Lower oil ring rail
3 New
d. 2nd ring
e. Oil ring expander
f. 20 mm or more
3 New 2
A. Exhaust side
1
b
6. Install:
• Dowel pins
• Cylinder gasket New
c • Cylinder “1”
TIP
• While holding the piston “2” with one hand, in-
stall the cylinder with the other hand.
3. Install:
• Pass the timing chain and timing chain guide
• Cylinder gasket New (intake side) through the timing chain cavity.
• Dowel pins
4. Lubricate: 1
• Piston 2
• Piston rings
• Cylinder
Engine oil
5. Offset:
• Piston ring end gaps
5-27
CDI MAGNETO
EBS20115
CDI MAGNETO
Removing the CDI magneto
1
D
FW
*
5 7**
*
5
6 Nm (0.6 m•kgf, 4.3 ft•Ibf)
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
8** LT
LT
4 2 6
LT
LT
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
LT
LT 60 Nm (6.0 m•kgf, 43 ft•Ibf)
New
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

3
T.R
.
New (5) LT
LS
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
* Apply Yamaha bond No. 1215 (90890-85505)

** When replacing any of parts, replace the pickup coil/stator coil assembly.

Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-19.
Footrest board (right) 4-7.
1 Pickup coil/stator coil assembly coupler 1/1 Disconnect.
2 CDI magneto rotor cover 1
3 Timing mark accessing screw 1
4 CDI magneto rotor cover gasket 1
5 Dowel pin 2
6 CDI magneto rotor 1
7 Pickup coil 1
8 Pickup coil/stator coil assembly 1
5-28
CDI MAGNETO
EBS30540
REMOVING THE CDI MAGNETO ROTOR TIP

1. Remove: • Use the flywheel puller “2”.
• CDI magneto rotor cover • Make sure the flywheel puller is centered over
TIP
the CDI magneto rotor.
Loosen each bolt 1/4 of a turn at a time, in stag-
es and in a crisscross pattern. After all of the Flywheel puller
bolts are fully loosened, remove them. 90890-01189
Flywheel puller
YM-01189
1
2
2. Remove:
• CDI magneto rotor nut “1”
• Washer EBS30541
TIP
INSTALLING THE CDI MAGNETO ROTOR
1. Install:
Hold the CDI magneto rotor “2” with the rotor
• Woodruff key
holding tool “3” while loosening the CDI magneto
• CDI magneto rotor
rotor nut.
• Washer
• CDI magneto rotor nut
Rotor holding tool TIP
90890-01235
Universal magneto and rotor • Clean the tapered portion of the crankshaft and
holder the CDI magneto rotor hub.
YU-01235 • When installing the CDI magneto rotor, make
sure the woodruff key is properly seated in the
keyway of the crankshaft.
2 3 • Lubricate the threads of the crankshaft with en-
gine oil.
• After installing the CDI magneto rotor, check
1 that the CDI magneto rotor rotates smoothly. If
not, reinstall the woodruff key and CDI magne-
to rotor.
2. Tighten:
• CDI magneto rotor nut “1”
• Pickup coil bolt
3. Remove:
• Stator coil bolt
• CDI magneto rotor “1”
• Woodruff key CDI magneto rotor nut
ECB01390
60 Nm (6.0 m·kgf, 43 ft·lbf)
T.
NOTICE
R.
Pickup coil bolt

To protect the end of the crankshaft, place an 6 Nm (0.6 m·kgf, 4.3 ft·lbf)
appropriate sized socket between the fly- Stator coil bolt
wheel puller set center bolt and the crank- 10 Nm (1.0 m·kgf, 7.2 ft·lbf)
shaft.
5-29
CDI MAGNETO
TIP • M6 × 25 mm bolt: “3”–“7”

While holding the CDI magneto rotor “2” with the 7
rotor holding tool “3”, tighten the CDI magneto
rotor nut “1”. 6 1
Rotor holding tool

90890-01235
Universal magneto and rotor 2
holder 5
YU-01235 4 3
2 3
3. Apply:
• Sealant
(onto the pickup coil/stator coil assembly lead
grommet “1”)

90890-85505
4. Install:
• CDI magneto rotor cover
5. Tighten:
• CDI magneto rotor cover bolt
CDI magneto rotor cover bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
TIP
Tighten the CDI magneto cover bolts in stages
and in a crisscross pattern.
• M6 × 127 mm bolt: “1”
• M6 × 120 mm bolt: “2”
5-30
OIL PUMP
EBS20116
OIL PUMP
Removing the oil pump
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

Pickup coil/stator coil assembly Refer to “CDI MAGNETO” on page 5-28.
1 Oil pump assembly 1
5-31
OIL PUMP
Disassembling the oil pump
1.1 Nm (0.11 m•kgf, 0.80 ft•Ibf)
T.R
6*
.
5*
7*
4*
10*
3*
8*
9*
E
2*
1
New
* When replacing any of parts, replace the oil pump assembly.

1 Circlip 1
2 Washer 1
3 Oil pump driven gear 1
4 Pin 1
5 Oil pump housing cover 1
6 Oil pump shaft 1
7 Pin 1
8 Oil pump inner rotor 1
9 Oil pump outer rotor 1
10 Oil pump housing 1
5-32
OIL PUMP
EBS30189
• Oil pump shaft
CHECKING THE OIL PUMP
1. Check:
• Oil pump drive gear Recommended lubricant
• Oil pump driven gear Engine oil
• Oil pump housing
• Oil pump housing cover 2. Install:
Cracks/damage/wear → Replace the defec- • Oil pump housing “1”
tive part(s). • Oil pump outer rotor “2”
2. Measure: • Oil pump inner rotor “3”
• Inner-rotor-to-outer-rotor-tip clearance “a” • Oil pump shaft “4”
• Outer-rotor-to-oil-pump-housing clearance • Pin “5”
“b” • Oil pump housing cover
Inner-rotor-to-outer-rotor-tip Oil pump housing cover screw

clearance limit 1.1 Nm (0.11 m·kgf, 0.80 ft·lbf)
T.
R.
0.15 mm (0.0059 in)
Outer-rotor-to-oil-pump-housing TIP
clearance limit When installing the inner rotor, align the pin in
0.240 mm (0.0094 in)
the oil pump shaft with the groove “a” in the inner
rotor.
1 4
a 5 3
2 a
3 2
1
b
1. Inner rotor
2. Outer rotor 3. Install:
3. Oil pump housing • Pin “1”
• Oil pump driven gear “2”
3. Check:
• Washer
• Oil pump operation
Rough movement → Repeat steps (1) and • Circlip New
(2) or replace the defective part(s). TIP
When installing the oil pump driven gear, align
the pin in the oil pump shaft with groove “a” in the
oil pump driven gear.
EBS30192
1
ASSEMBLING THE OIL PUMP
1. Lubricate: a
• Oil pump inner rotor
• Oil pump outer rotor
5-33
OIL PUMP
4. Check:
• Oil pump operation
Refer to “CHECKING THE OIL PUMP” on
page 5-33.
EBS30445
INSTALLING THE OIL PUMP

1. Install:
• Oil pump assembly
Oil pump screw

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
ECB02660
NOTICE
After tightening the screws, make sure the
oil pump turns smoothly.
5-34
ELECTRIC STARTER
EBS20040
ELECTRIC STARTER
Removing the starter motor
D
FW
New
LS
3
2
1
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.

Exhaust pipe Refer to “ENGINE REMOVAL” on page 5-2.
1 Starter motor lead 1 Disconnect.
2 Ground lead 1 Disconnect.
3 Starter motor 1
5-35
ELECTRIC STARTER
Disassembling the starter motor
4
2.0 Nm (0.20 m•kgf, 1.4 ft•Ibf)
6
T.R
.
5
New
New
2
New
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

T.R
.

1 Starter motor rear cover 1
2 Gasket 1
3 Armature assembly 1
4 Brush holder set 1
5 Bearing 1
6 Starter motor front cover 1
5-36
ELECTRIC STARTER
EBS30157
CHECKING THE STARTER MOTOR Digital circuit tester

1. Check: 90890-03174
• Commutator Model 88 Multimeter with ta-
Dirt → Clean with 600 grit sandpaper. chometer
2. Measure: YU-A1927
• Commutator diameter “a”
Out of specification → Replace the starter
Armature coil resistance
motor.
0.036–0.048 Ω
Commutator diameter limit Insulation resistance “2”
20.0 mm (0.79 in) No continuity (Above 1 MΩ at 20
°C (68 °F))
a
2
3. Measure:
• Mica undercut “a” b. If any resistance is out of specification, re-
Out of specification → Scrape the mica to the place the starter motor.
proper measurement with a hacksaw blade ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
that has been grounded to fit the commutator. 5. Measure:

• Brush length “a”
Mica undercut (depth) Out of specification → Replace the brushes
1.60 mm (0.06 in) as a set.
TIP Brush overall length limit

The mica of the commutator must be undercut to 4.00 mm (0.16 in)
ensure proper operation of the commutator.
6. Check:
4. Measure: • Gear teeth
• Armature assembly resistances (commutator Damage/wear → Replace the gear.
and insulation) “1” 7. Check:
Out of specification → Replace the starter • Bearing
motor. • Oil seal
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Damage/wear → Replace the defective
a. Measure the armature assembly resistances part(s).
with the digital circuit tester.
5-37
ELECTRIC STARTER
EBS30158
ASSEMBLING THE STARTER MOTOR

1. Assemble:
• Starter motor front cover “1”
• Starter motor rear cover “2”
TIP
Align the match mark “a” on the starter motor
rear cover with the match mark “b” in the starter
motor front cover.
2 1
a b
5-38
KICKSTARTER
EBS20117
KICKSTARTER
Removing the v-belt case and kickstarter
1.0 Nm (0.10 m•kgf, 0.72 ft•Ibf)

T.R
.
LT
5 Nm (0.5 m•kgf, 3.6 ft•Ibf)
T.R
.
0.5 Nm (0.05 m•kgf, 0.36 ft•Ibf)
T.R
.
3
6
New
6
5
New
New 10
11 (9)
12
7
8
9
2
4 New
1
0.5 Nm (0.05 m•kgf, 0.36 ft•Ibf) 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
T.R
.

Footrest board (left) 4-4.
1 Kickstarter lever/cap 1/1
2 Air duct (front side) 1
3 Air duct (rear side) 1
4 V-belt case cover 1
5 V-belt case gasket 1
6 Dowel pin 1
7 Kickstarter pinion gear assembly 1
8 Circlip 1
9 Washer 1
10 Kickstarter shaft 1
11 Kickstarter spring 1
12 Collar 1
5-39
KICKSTARTER
EBS30572
CHECKING THE KICKSTARTER 4

1. Check: c
• Kickstarter pinion gear assembly
• Kickstarter shaft 2 4
Cracks/damage/wear → Replace. a
2. Check: 1
3
• Kickstarter spring
b
EBS30571
a
ASSEMBLING THE KICKSTARTER b. Install the screw clamps on the grommet, and
1. Install: then tighten the air duct clamp screws “4”.
• O-ring
• Collar Air duct clamp screw
• Kickstarter spring “1” 0.5 Nm (0.05 m·kgf, 0.36 ft·lbf)
T.
R.
• Kickstarter shaft “2”
• Washer ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Circlip
• Kickstarter pinion gear assembly “3”
TIP
Install the parts as shown in the illustration.
• Kickstarter spring straight end “a”
• Kickstarter spring hooked end “b” (Hook the
kickstarter spring hooked end onto the projec-
tion on the V-belt case.)
1
a
b 3
EBS30546
INSTALLING THE AIR DUCTS

1. Install:
• Air duct (front side)
• Air duct (rear side)
• Grommet
• Screw clamps
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the V-belt case air duct “1” and air
duct “2” using the grommet “3”.
TIP
• Fit the flanges “a” on the ends of the V-belt
case air duct “1” and air duct “2” into the slot “b”
inside the grommet “3”.
• Point the arrow mark “c” on the grommet to-
ward the air duct.
5-40
STARTER CLUTCH
EBS20118
STARTER CLUTCH
Removing the starter clutch
8
M
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
M
2
1
6
7
5
3 4
E
9
E LT
LT
LT
6 Nm (0.6 m•kgf, 4.3 ft•Ibf)

T.R
.

V-belt case cover Refer to “KICKSTARTER” on page 5-39.
Primary sliding sheave Refer to “BELT DRIVE” on page 5-43.
1 Starter clutch idle gear plate 1
2 Starter clutch idle gear 1
3 Starter clutch 1
4 Collar 1
5 Starter wheel 1
6 Circlip 1
7 Bearing 1
8 Gear position switch coupler 1
9 Gear position switch 1
5-41
STARTER CLUTCH
EBS30547
CHECKING THE STARTER WHEEL TIP

1. Check: Install the gear position switch so that the gear
• Bearing position switch lead “a” is routed upward.
2. Check: a
• Starter clutch idle gear
• Starter wheel “1”
Burrs/chips/roughness/wear → Replace the 1
defective part(s).
3. Check:
• Starter wheel’s contacting surfaces
Damage/pitting/wear → Replace the starter
wheel.
2. Tighten:
1 • Gear position switch bolt
Gear position switch bolt

6 Nm (0.6 m·kgf, 4.3 ft·lbf)
T.
R.
EBS30153
CHECKING THE STARTER CLUTCH

1. Check:
• Starter clutch operation
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the starter wheel “1” onto the starter
clutch “2” and hold the starter clutch.
b. When turning the starter wheel counterclock-
wise “A”, the starter clutch and the starter
wheel should engage, otherwise the starter
clutch is faulty and must be replaced.
c. When turning the starter wheel clockwise “B”,
it should turn freely, otherwise the starter
clutch is faulty and must be replaced.
1
2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30573
INSTALLING THE GEAR POSITION SWITCH

1. Install:
• Gear position switch “1”
5-42
BELT DRIVE
EBS20119
BELT DRIVE
Removing the V-belt, primary sheave and secondary sheave
40 Nm (4.0 m•kgf, 29 ft•Ibf)
T.R
.
LS
9
6
8
5 7
4
3
2
D 1
FW
40 Nm (4.0 m•kgf, 29 ft•Ibf)
T.R
.

V-belt case cover Refer to “KICKSTARTER” on page 5-39.
1 Primary fixed sheave nut 1
2 Washer 1
3 One-way clutch 1
4 Lock washer 1
5 Primary fixed sheave 1
6 V-belt 1
7 Collar 1
8 Primary sliding sheave 1
9 Primary sheave weight 6
5-43
BELT DRIVE
Removing the V-belt, primary sheave and secondary sheave
14
40 Nm (4.0 m•kgf, 29 ft•Ibf)
T.R
.
13
11
10
LS 12
11
D
FW
40 Nm (4.0 m•kgf, 29 ft•Ibf)
T.R
.

10 Cam 1
11 Slider 3
12 Clutch housing nut 1
13 Clutch housing 1
14 Secondary sheave assembly 1
5-44
BELT DRIVE
Disassembling the secondary sheave
9
2
8
3 New 4
5
6 7
40 Nm (4.0 m•kgf, 29 ft•Ibf)

T.R
.

1 Secondary sheave nut 1
2 Clutch carrier assembly 1
3 Clip 3
4 Clutch shoe spring 3
5 Clutch shoe 3
6 Damper 3
7 Clutch carrier 1
8 Compression spring 1
9 Secondary sliding sheave assembly 1
5-45
BELT DRIVE
EBS30549
REMOVING THE PRIMARY SHEAVE 2 1

1. Remove:
• Primary fixed sheave nut “1”
• Washer 3
• Primary fixed sheave “2”
• CDI magneto rotor cover
Refer to “CDI MAGNETO” on page 5-28.
TIP
While holding the CDI magneto rotor “3” with the
rotor holding tool “4”, loosen the primary fixed 2. Loosen:
sheave nut “1”. • Secondary sheave nut “1”
ECB02670
NOTICE
Rotor holding tool
90890-01235 Do not remove the secondary sheave nut at
Universal magneto and rotor this stage.
holder
YU-01235 TIP
While holding the secondary sheave with the ro-
tor holding tool “2”, loosen the secondary
sheave nut one full turn with the socket wrench
“3”.
2 Rotor holding tool

1 90890-01235
Universal magneto and rotor
holder
YU-01235
Socket wrench (39 mm)
90890-01493
3 4
1
3
EBS30550
REMOVING THE SECONDARY SHEAVE

EBS30168
1. Remove: DISASSEMBLING THE SECONDARY
• Clutch housing nut “1” SHEAVE
• Clutch housing “2” 1. Remove:
TIP • Secondary sheave nut “1”
While holding the clutch housing with the rotor TIP
holding tool “3”, loosen the clutch housing nut. While compressing the compression spring with
the clutch spring holder “2” remove the second-
Rotor holding tool ary sheave nut.
90890-04166
YM-04166
5-46
BELT DRIVE
Glazed areas → Sand with coarse sandpa-

Clutch spring holder per.
90890-01337
TIP
Universal clutch compressor
holder After sanding the glazed areas, clean the clutch
YM-33285 with a cloth.
2. Measure:
• Clutch shoe thickness “a”
Out of specification → Replace the clutch
shoes and springs as a set.
Clutch shoe thickness limit

1.0 mm (0.04 in)
1
2
EBS30551
CHECKING THE CLUTCH HOUSING

1. Check:
• Clutch housing
Damage/wear → Replace. a
• Clutch housing splines
Cracks/damage/wear → Replace the clutch
housing. EBS30169
2. Measure: CHECKING THE V-BELT

• Clutch housing inside diameter “a” 1. Check:
Out of specification → Replace the clutch • V-belt “1”
housing. Cracks/damage/wear → Replace.
Grease/oil → Clean the primary and second-
Clutch housing inside diameter ary sheave.
112.0 mm (4.41 in) 2. Measure:
Clutch housing inside diameter • V-belt width “a”
limit
112.3 mm (4.42 in)
V-belt width limit
15.5 mm (0.61 in)
EBS30179
CHECKING THE CLUTCH SHOE

The following procedure applies to all of the EBS30170
clutch shoes. CHECKING THE PRIMARY SHEAVE
1. Check: 1. Check:
• Clutch shoe • Primary sliding sheave
Damage/wear → Replace the clutch shoes • Primary fixed sheave
and springs as a set.
5-47
BELT DRIVE
• Collar
Cracks/damage/wear → Replace the primary
sliding sheave, primary fixed sheave, and
collar as a set.
EBS30171
CHECKING THE PRIMARY SHEAVE

WEIGHTS
The following procedure applies to all of the pri-
mary sheave weights.
1. Check:
• Primary sheave weight EBS30174
Cracks/damage/wear → Replace. ASSEMBLING THE PRIMARY SHEAVE

2. Measure: 1. Clean:
• Primary sheave weight outside diameter “a” • Primary fixed sheave
Out of specification → Replace. • Primary sliding sheave
• Primary sheave weights
Weight outside diameter limit • Cam
14.6 mm (0.57 in) EBS30175
ASSEMBLING THE SECONDARY SHEAVE

1. Install:
• Compression spring
• Clutch carrier assembly “1”
• Secondary sheave nut “2”
TIP
• While compressing the compression spring
with the clutch spring holder “3” remove the
secondary sheave nut “2”.
• Install the secondary sheave nut “2” with its ta-
EBS30172
pered side facing the clutch carrier.
CHECKING THE PRIMARY SHEAVE
SLIDERS Clutch spring holder
1. Check: 90890-01337
• Primary sheave slider Universal clutch compressor
Cracks/damage/wear → Replace. holder
YM-33285
EBS30173
CHECKING THE SECONDARY SHEAVE

1. Check:
• Secondary fixed sheave
• Secondary sliding sheave
Cracks/damage/wear → Replace the sec-
ondary fixed and sliding sheaves as a set.
2. Check: 2
• Spring free length 3
Out of specification → Replace the spring.
1
Compression spring free length
EBS30176
limit
INSTALLING THE PRIMARY AND
70.0 mm (2.76 in)
SECONDARY SHEAVES
1. Install:
• Secondary sheave assembly
5-48
BELT DRIVE
TIP TIP
Before installing the secondary sheave assem- While holding the clutch housing with the rotor
bly, check that there is no grease on the splines holding tool “3”, tighten the clutch housing nut.
“a” of the primary drive gear. If there is any
grease on the splines, be sure to wipe it off thor- Rotor holding tool
oughly. 90890-04166
YM-04166
a
3
2. Tighten: 2
• Secondary sheave nut “1”
4. Install:
Secondary sheave nut • Primary sliding sheave assembly “1”
40 Nm (4.0 m·kgf, 29 ft·lbf) TIP
T.
R.
When installing the primary sliding sheave as-

TIP sembly, hold the cam to prevent the primary
While holding the secondary sheave with the ro- sheave weights from falling out of the primary
tor holding tool “2”, tighten the secondary sliding sheave.
sheave nut with the socket wrench “3”.
Rotor holding tool

1
90890-01235
holder
YU-01235
Socket wrench (39 mm)
90890-01493
5. Install:
1 • V-belt “1”
ECB02680
NOTICE
Do not allow grease to come in contact with
the V-belt.
TIP
2 • Install the V-belt with the printed mark on the V-
3
belt facing in the direction shown in the illustra-
3. Install: tion.
• Clutch housing “1” • Install the V-belt onto the primary sheave side.
• Clutch housing nut “2”
Clutch housing nut

40 Nm (4.0 m·kgf, 29 ft·lbf)
T.
R.
5-49
BELT DRIVE
BANDO VS BELT
BANDO VS BELT
BANDO
BANDO
VS
VS
BELT
BELT
2 3
BANDO VS BELT
6. Install:
• Primary fixed sheave
• Lock washer
• One-way clutch
• Washer
• Primary fixed sheave nut
ECB02690
NOTICE
Do not allow grease to contact the primary
sheave assembly.
TIP
Install the V-belt in the primary sheave (when the
pulley is at its widest position) and in the second-
ary sheave (when the pulley is at its narrowest
position), and make sure the V-belt is tight.
7. Tighten:
• Primary fixed sheave nut “1”
Primary fixed sheave nut

40 Nm (4.0 m·kgf, 29 ft·lbf)
T.
R.
TIP
While holding the CDI magneto rotor “2” with the
rotor holding tool “3”, tighten the primary fixed
sheave nut “1”.
Rotor holding tool

90890-01235
holder
YU-01235
5-50
CRANKCASE
EBS20045
CRANKCASE
Separating the crankcase
T.R
T.R
.
.
LT
LT
E
(5) E
New
LT E
LS
LT
E
New
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
30 Nm (3.0 m•kgf, 22 ft•Ibf)

T.R
.
15 Nm (1.5 m•kgf, 11 ft•Ibf) E

T.R
New
.
LS
E
20 Nm (2.0 m•kgf, 14 ft•Ibf)
T.R
.
E 12 Nm (1.2 m•kgf, 8.7 ft•Ibf)

T.R
.
* Yamaha bond No.1215 (90890-85505)

Engine Refer to “ENGINE REMOVAL” on page 5-2.
Refer to “CYLINDER AND PISTON” on page
Cylinder/Piston 5-23.
CDI magneto rotor Refer to “CDI MAGNETO” on page 5-28.
Oil pump Refer to “OIL PUMP” on page 5-31.
V-belt case Refer to “KICKSTARTER” on page 5-39.
Primary sheave/secondary sheave Refer to “BELT DRIVE” on page 5-43.
Refer to “ELECTRIC STARTER” on page
Starter motor 5-35.
Starter clutch/Gear position switch Refer to “STARTER CLUTCH” on page 5-41.
Transmission Refer to “TRANSMISSION” on page 5-56.
5-51
CRANKCASE
Separating the crankcase

T.R
T.R
.
.
LT
LT 9
2 E
(5) 6 E
New
LT E
LS
9
LT 10
E
3 New
13 4 7
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
13
T.R
.
30 Nm (3.0 m•kgf, 22 ft•Ibf)

T.R
.
15 Nm (1.5 m•kgf, 11 ft•Ibf) E

T.R
New 8*
.
E
14
13
1
12
11 13 LS
5
E
20 Nm (2.0 m•kgf, 14 ft•Ibf)
T.R
.
E 12 Nm (1.2 m•kgf, 8.7 ft•Ibf)

T.R
.
* Yamaha bond No.1215 (90890-85505)

1 Timing chain guide (intake side) 1
2 Engine oil filler neck 1
3 Engine oil drain bolt 1
4 Engine oil drain bolt (with strainer) 1
5 V-belt case drain bolt 1
6 Crankcase (right) 1
7 Crankcase (left) 1
8 Gasket 1
9 Dowel pin 2
10 Crankshaft 1
11 Timing chain 1
12 Oil seal 1
13 Crankcase bushing 2
14 Collar 1
5-52
CRANKCASE
EBS30182 EBS30183
SEPARATING THE CRANKCASE CHECKING THE TIMING CHAIN AND TIMING

1. Remove: CHAIN GUIDE
• Crankcase bolts 1. Check:
TIP • Timing chain
Loosen each bolt 1/4 of a turn at a time, in stag- Damage/stiffness → Replace the timing
es and in a crisscross pattern. After all of the chain and camshaft sprocket as a set.
bolts are fully loosened, remove them.
• M6 × 60 mm bolts “1–5”
• M6 × 95 mm bolt “6”
×5 ×1
2. Check:
1 • Timing chain guide (intake side)
EBS30191
2
CHECKING THE CRANKSHAFT
1. Measure:
• Crankshaft runout
Out of specification → Replace the crank-
3 shaft assembly.
TIP
Turn the crankshaft slowly.
Runout limit
4 5 6
0.040 mm (0.0016 in)
2. Remove:
• Crankcase (right)
ECB01400
NOTICE
Tap on one side of the crankcase with a soft-
face hammer. Tap only on reinforced por-
tions of the crankcase, not on the crankcase
mating surfaces. Work slowly and carefully
and make sure the crankcase halves sepa-
rate evenly.
EBS30186 2. Measure:
CHECKING THE CRANKCASE • Crankshaft width
1. Thoroughly wash the crankcase halves in a Out of specification → Replace the crank-
mild solvent. shaft.
2. Thoroughly clean all the gasket surfaces and
crankcase mating surfaces. Crank assembly width
3. Check: 75.00–75.10 mm (2.953–2.957 in)
• Crankcase
• Oil delivery passages
Obstruction → Blow out with compressed air.
5-53
CRANKCASE
3. Thoroughly clean all the gasket mating sur-

faces and crankcase mating surfaces.
4. Apply:
• Sealant
(onto the crankcase mating surfaces)

90890-85505
3. Check: TIP
• Crankshaft sprocket Do not allow any sealant to come into contact
Damage/wear → Replace the crankshaft. with the oil gallery.
• Bearing
Cracks/damage/wear → Replace the crank-
shaft.
4. Check:
• Crankshaft journal
Scratches/wear → Replace the crankshaft.
• Crankshaft journal oil passage
Obstruction → Blow out with compressed air.
EBS30185
CHECKING THE BEARINGS

1. Check: 5. Install:
• Bearings • Crankcase gasket
Clean and lubricate the bearings, then rotate (onto the crankcase mating surfaces)
the inner race with your finger. 6. Install:
Rough movement → Replace. • Dowel pin
• Timing chain “1”
EBS30187
ASSEMBLING THE CRANKCASE • Crankshaft

1. Install: • Crankcase (right)
• Timing chain guide (intake side) (onto the crankcase (left) “2”)
ECB02870
NOTICE
Timing chain guide bolt
12 Nm (1.2 m·kgf, 8.7 ft·lbf) To prevent the timing chain from becoming
T.
R.
caught in the crankcase when turning the

2. Cut: crankshaft, pull the timing chain using a
• Gasket “1” New wire.
TIP TIP
Cut the gasket as shown in the illustration to re- After installing the left crankcase, make sure that
move the gasket portion that covers the crank- the timing chain is securely meshed with the
case opening “a”. crankshaft sprocket.
1 New
1 2
5-54
CRANKCASE
7. Tighten:
• Crankcase bolts
Crankcase bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
TIP
• Thoroughly wipe off any sealant that protrudes
from between the left crankcase and the right
crankcase.
• Tighten the crankcase bolts in stages and in a
crisscross pattern.
• M6 × 95 mm bolt: “1”
• M6 × 60 mm bolts: “2”–“6”
×5 ×1
1
4 5 6
5-55
TRANSMISSION
EBS20047
TRANSMISSION
Removing the shift lever and transmission
M
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)
T.R
.
E
New
E LT
LT
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
M
E E
2 New 3 4
9
E
New 35 Nm (3.5 m•kgf, 25 ft•Ibf)
T.R
.
M New 6
1
7
22 Nm (2.2 m•kgf, 16 ft•Ibf)
5
T.R
.
E
8
New New
E (7)
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) D
New FW
T.R
.

T.R
.
T.R
.

Footrest board (right side) 4-7.
Drive sprocket Refer to “CHAIN DRIVE” on page 4-36.
1 Transmission oil drain bolt 1
2 Shift drum stopper bolt assembly 1
3 Shift knob 1
4 Shift lever guide 1
5 Shift lever shaft 1
6 Shift lever 1
7 Shift lever spring 1
8 Shift lever holder 1
9 Transmission case breather hose 1
5-56
TRANSMISSION
Removing the shift lever and transmission

M
4.0 Nm (0.40 m•kgf, 2.9 ft•Ibf)

19
T.R
.
E
New
E LT
LT
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
20
M
13
17 16
E
15 E
18 New
12
E 11
New T.R
. 35 Nm (3.5 m•kgf, 25 ft•Ibf)
M New
14
22 Nm (2.2 m•kgf, 16 ft•Ibf)
T.R
.
E
10
New New
E (7)
10 Nm (1.0 m•kgf, 7.2 ft•Ibf) D
New FW
T.R
.

T.R
.
T.R
.

10 Transmission oil filler cap 1
11 Transmission case cover 1
12 Transmission case gasket 1
13 Shift shaft 1
14 Drive axle assembly 1
15 Shift fork guide bar 1
16 Shift drum 1
17 Shift fork 1
18 Main axle assembly 1
19 Counter axle assembly 1
20 Primary drive gear 1
5-57
TRANSMISSION
Removing the main axle assembly
New
M

1 Reverse wheel gear 1
2 Clutch dog 1
3 Primary driven gear 1
4 Main axle/1st pinion gear 1
5-58
TRANSMISSION
EBS30194
3. Check:
REMOVING THE TRANSMISSION
• Shift fork movement
1. Remove:
(along the shift fork guide bar)
• Shift fork guide bar “1”
Rough movement → Replace the shift forks
• Shift drum “2”
and shift fork guide bar as a set.
• Shift fork “3”
• Transmission “4”
4
1 2 EBS30197
CHECKING THE SHIFT DRUM

EBS30196
1. Check:
CHECKING THE SHIFT FORK
• Shift drum groove
The following procedure applies to all of the shift
Damage/scratches/wear → Replace the shift
forks.
drum assembly.
1. Check:
• Shift fork cam follower “1”
• Shift fork pawl “2”
Bends/damage/scoring/wear → Replace the
shift fork.
2
EBS30198
CHECKING THE TRANSMISSION

1. Measure:
1
• Main axle runout
(with a centering device and dial gauge “1”)
2. Check: Out of specification → Replace the main axle.
• Shift fork guide bar
Roll the shift fork guide bar on a flat surface. Main axle runout limit
Bends → Replace. 0.04 mm (0.0016 in)
EWB02750
WARNING
Do not attempt to straighten a bent shift fork
guide bar.
1
2. Measure:
• Primary drive gear
(with a centering device and dial gauge “1”)
5-59
TRANSMISSION
Out of specification → Replace the primary

drive gear.
Primary drive gear runout limit

0.06 mm (0.0023 in)
1
2. Install:
• Clutch dog
TIP
Install the clutch dog “1” so that the recessed
portion “a” of the clutch dog faces the recesses
3. Check: “b” in the primary driven gear “2“.
• Transmission gears
Blue discoloration/pitting/wear → Replace 1 a 2 b
the defective gear(s).
• Transmission gear dogs
Cracks/damage/rounded edges → Replace
the defective gear(s).
3. Install:
• Reverse wheel gear
• Washer
• Collar “1”
TIP
• Face the cutouts “a” in the collar inward.
4. Check:
• Press the collar into the main axle/1st pinion
• Transmission gear engagement
gear “2”, as shown in the illustration.
(each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission 1
axle assemblies.
5. Check:
• Transmission gear movement
Rough movement → Replace the defective
part(s). a
EBS30552
ASSEMBLING THE MAIN AXLE

1. Install:
• Primary driven gear
• Washer “1”
• Circlip “2” New
TIP
Be sure the circlip sharp-edged corner “a” is po-
sitioned opposite side to the washer and gear.
5-60
TRANSMISSION
TIP
1 2 Position the center tooth “a” on the cam portion
of the shift shaft “1” between the teeth identified
with punch marks “b” on the shift drum “2”.
2 1
b
EBS30202
INSTALLING THE SHIFT FORK AND SHIFT

DRUM
1. Install: a
• Transmission “1”
• Shift fork “2” 2. Install:
• Shift drum “3” • Transmission case gasket New
• Shift fork guide bar “4” • Transmission case cover
• Transmission case cover bolt
1
Transmission case cover bolt
10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
2
TIP
Tighten the transmission case cover bolts in
stages and in a crisscross pattern.
4 3 3. Install:
• Shift lever guide
2. Check: 4. Install:
• Shift cam operation • Shift lever holder “1”
Rough movement → Repair. • Shift lever shaft
TIP • Shift lever spring
• Apply engine oil to each gear, shaft, and bear- • Shift lever
ing thoroughly. • Washer
• Check the transmission and shift fork for • Cotter pin New
smooth operation by turning the shift cam with TIP
your hand. Align the punch mark “a” on the shift lever holder
“1” with the cutout “b” in the shift shaft “2”.
Shift lever holder bolt

10 Nm (1.0 m·kgf, 7.2 ft·lbf)
T.
R.
a
b
1
EBS30165
INSTALLING THE SHIFT LEVER

2
1. Install:
• Shift shaft “1”
5-61
FUEL SYSTEM
FUEL TANK..................................................................................................... 6-1

REMOVING THE FUEL TANK ..................................................................6-2
CHECKING THE FUEL COCK..................................................................6-2
CHECKING THE FUEL FILTER................................................................6-2
AIR FILTER CASE .......................................................................................... 6-3

INSTALLING THE AIR FILTER CASE COVER ........................................ 6-4
INSTALLING THE OIL CATCH TANK.......................................................6-4
CARBURETOR................................................................................................6-5
CHECKING THE CARBURETOR ............................................................. 6-8
CHECKING THE INTAKE MANIFOLD......................................................6-9
ASSEMBLING THE CARBURETOR.........................................................6-9
INSTALLING THE CARBURETOR ......................................................... 6-10
MEASURING AND ADJUSTING THE FUEL LEVEL ..............................6-10
6
FUEL TANK
EBS20054
FUEL TANK
Removing the fuel tank
New
10 Nm (1.0 m•kgf, 7.2 ft•Ibf)
T.R
.
4 1
3
2 New
12 Nm (1.2 m•kgf, 8.7 ft•Ibf)

T.R
.

Seat 4-1.
Front fender 4-4.
1 Fuel drain hose 1 Disconnect.
2 Fuel hose 2 Disconnect.
3 Fuel filter 1
4 Fuel tank 1
5 Fuel cock 1
6-1
FUEL TANK
EBS30221
REMOVING THE FUEL TANK

1. Extract the fuel in the fuel tank through the
1
fuel tank cap with a pump.
2. Remove:
• Fuel hose
• Fuel filter
ECB01560
NOTICE
Although the fuel has been removed from
the fuel tank, be careful when removing the
fuel hose, since there may be fuel remaining
in it.
TIP
Before removing the hoses, place a few rags in
the area under where it will be removed.
3. Remove:
• Fuel tank
EBS30479
CHECKING THE FUEL COCK

1. Check:
• Fuel cock
2. Check:
• Fuel cock strainer “1”
Obstruction → clean.
Blow out the jets with compressed air.
Damage → Replace the fuel cock.
EBS30480
CHECKING THE FUEL FILTER

1. Check:
• Fuel filter “1”
Obstruction → clean.
6-2
AIR FILTER CASE
EBS20055
AIR FILTER CASE

Removing the air filter case
3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)

T.R
.
5 2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)
T.R
.
LT
0.5 Nm (0.05 m•kgf, 0.36 ft•Ibf)
T.R
.
New
6
4
7
1
9
2
3
10
8 LT
3.0 Nm (0.30 m•kgf, 2.2 ft•Ibf)

T.R
.
11
LT 10 Nm (1.0 m•kgf, 7.2 ft•Ibf)

T.R
.
6 Nm (0.6 m•kgf, 4.3 ft•Ibf)

T.R
.

Seat 4-1.
Front fender 4-4.
1 Air filter case breather hose 1 Disconnect.
2 Crankcase breather hose 1 Disconnect.
3 Cylinder head breather hose 1 Disconnect.
4 Oil catch tank 1
5 Air filter case cover 1
6 Air filter element 1
7 Air filter element guide 1
8 Air filter case stay 1
9 Air filter case joint clamp screw 1 Loosen.
10 Air filter case 1
11 Breather hose holder 1
6-3
AIR FILTER CASE
EBS30481
INSTALLING THE AIR FILTER CASE COVER

1. Install:
TIP
• Insert the projection “a” of the air filter cover.
• Hold the air filter case cover in holder “b”.
1
a
EBS30482
INSTALLING THE OIL CATCH TANK

1. Install:
• Oil catch tank “1”
TIP
Fit the projection “a” of the oil catch tank holder.
1
a
Oil catch tank bolt (upper side)

3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
T.
R.
LOCTITE®
Oil catch tank bolt (lower side)
3.0 Nm (0.30 m·kgf, 2.2 ft·lbf)
6-4
CARBURETOR
EBS20109
CARBURETOR
Removing the carburetor
8 Nm (0.8 m•kgf, 5.8 ft •Ibf)
T.
R.
LS
3
5 2 New
6
7 4
9
LS
8
1
1.2 Nm (0.12 m•kgf, 0.87 ft•Ibf)

T.R
.
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)

T.
R.
New
New
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)

T.
R.
New 0.5 Nm (0.05 m•kgf, 0.36 ft•Ibf)

T.R
.

Front fender 4-4.
Fuel tank Refer to “FUEL TANK” on page 6-1.
1 Fuel hose 1 Disconnect.
2 Carburetor top cover 1
3 Throttle cable 1 Disconnect.
4 Spring 1
5 Jet needle holder 1
6 Jet needle set 1
7 Piston valve 1
8 Choke cable guide 1
9 Choke cable 1
6-5
CARBURETOR
Removing the carburetor

8 Nm (0.8 m•kgf, 5.8 ft •Ibf)
T.
R.
LS
10
New
LS
10 12
1.2 Nm (0.12 m•kgf, 0.87 ft•Ibf)
T.R
.
10 Nm (1.0 m•kgf, 7.2 ft •Ibf) 15

T.
R.
New
13
New
11
14
10 Nm (1.0 m•kgf, 7.2 ft •Ibf)
T.
R.
New 0.5 Nm (0.05 m•kgf, 0.36 ft•Ibf)

T.R
.

10 Carburetor air vent hose 1 Disconnect.
11 Drain hose 1 Disconnect.
12 Air filter case joint clamp screw 1 Loosen.
13 Intake manifold 1
14 Intake manifold joint 1
15 Carburetor 1
6-6
CARBURETOR
Disassembling the carburetor
1.5 Nm (0.15 m•kgf, 1.1 ft•Ibf)

T.R
.
4 New 1
2 7 6
New
5
10
3
9
8
2.5 Nm (0.25 m•kgf, 1.8 ft•Ibf)
T.R
.

1 Throttle stop screw 1
2 Float chamber drain screw 1
3 Float chamber 1
4 Gasket 1
5 Main jet 1
6 Main nozzle 1
7 Pilot jet 1
8 Float pin 1
9 Float 1
10 Needle valve 1
6-7
CARBURETOR
EBS30483
CHECKING THE CARBURETOR

1. Check: 1
• Carburetor body
• Float chamber
2. Check:
• Fuel passages
Obstruction → Clean.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the carburetor in a petroleum-based
solvent. Do not use any caustic carburetor 6. Check:
cleaning solution. • Piston valve “1”
b. Blow out all of the passages and jets with Damage/scratches/wear → Replace.
compressed air. • Piston valve spring “2”
1 2
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Check:
3. Check:
• Jet needle “1”
• Float chamber body
Bends/wear/damage → Replace.
Dirt → Clean.
4. Check:
• Float “1”
• Float tang “2”
Damage → Replace.
2 8. Check:
1 • Main jet “1”
• Main nozzle “2”
• Pilot jet “3”
• Bends/damage/wear → Replace.
5. Check:
• Needle valve “1”
Contamination → Clean.
Damage/obstruction/wear → Replace the
needle valve.
6-8
CARBURETOR
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Hold the carburetor in an upside down posi-
tion.
b. Measure the distance from the front mating
surface of the float chamber (gasket re-
moved) to the top of the float.
TIP
The float arm should be resting on the needle
1 2 3 valve, but not compressing it.
c. If the float height is not within the specifica-
9. Check:
tion, check the needle valve.
• Air vent hose joint
d. If either is worn, replace the needle valve.
e. If both are fine, adjust the float height by
10.Check:
bending the float tang “1” on the float.
• Air vent hoses
• Fuel hose
• Drain hose
Blow out the hoses with compressed air.
1
EBS30484
CHECKING THE INTAKE MANIFOLD

1. Check:
• Intake manifold
Cracks/damage → Replace. f. Recheck the float height.
EBS30485 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
ASSEMBLING THE CARBURETOR 3. Install:
ECB02820
• Pilot jet “1”
NOTICE
• Main nozzle “2”
• Before assembling the carburetor, wash all • Main jet “3”
of the parts in a petroleum-based solvent.
• Always use a new gasket. 3
2
1. Install: 1
• Needle valve
• Float
• Float pin
2. Measure:
• Float height “a”
Float height 4. Install:

10.0 mm (0.39 in) • Float chamber
• Gasket New
5. Install:
a • Throttle stop screw “1”
Throttle stop screw turns out

4–1/2
6-9
CARBURETOR
TIP
Before disassembling the carburetor, make sure
to turn out the throttle stop screw the same num-
ber of times, as noted before disassembly, from a
the seated position to set position.
4
1 2
3 1
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Place the vehicle on a level surface.
b. Install the fuel level gauge “1” onto the fuel
drain pipe “2”.
Fuel level gauge

EBS30486
90890-01312
INSTALLING THE CARBURETOR Fuel level gauge
1. Install: YM-01312-A
• Carburetor
c. Loosen the fuel drain screw “3”.
2. Adjust:
d. Hold the fuel level gauge vertically next to the
• Engine idling speed
float chamber “4”.
Refer to “ADJUSTING THE ENGINE IDLING
e. Start the engine.
SPEED” on page 3-6.
f. Measure the fuel level “a”.
Engine idling speed ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
1600–1800 r/min 2. Adjust:
• Fuel level
3. Adjust: ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
• Throttle cable free play a. Remove the carburetor.
Refer to “ADJUSTING THE THROTTLE LE- b. Check the needle valve.
VER FREE PLAY” on page 3-21. c. If either is worn, replace the needle valve and
gasket as a set.
Throttle lever free play d. If both are fine, adjust the float level by slightly
1.5–4.0 mm (0.06–0.16 in) bending the float tang “1”.
EBS30487
MEASURING AND ADJUSTING THE FUEL

LEVEL
1. Measure:
• Fuel level “a”
Out of specification → Adjust. 1
Fuel level A (using fuel level

gauge)
2.0–3.0 mm (0.08–0.12 in)
e. Install the carburetor.
f. Measure the fuel level again.
g. Repeat steps (a) to (f) until the fuel level is
within specification.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
6-10
CARBURETOR
6-11
ELECTRICAL SYSTEM
IGNITION SYSTEM ......................................................................................... 7-1

CIRCUIT DIAGRAM .................................................................................. 7-1
TROUBLESHOOTING ..............................................................................7-3
ELECTRIC STARTING SYSTEM .................................................................... 7-5

CIRCUIT DIAGRAM .................................................................................. 7-5
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION .......................... 7-7
TROUBLESHOOTING ..............................................................................7-8
CHARGING SYSTEM....................................................................................7-11
CIRCUIT DIAGRAM ................................................................................ 7-11
TROUBLESHOOTING ............................................................................7-13
SIGNALING SYSTEM ...................................................................................7-15

CIRCUIT DIAGRAM ................................................................................ 7-15
TROUBLESHOOTING ............................................................................7-17
ELECTRICAL COMPONENTS...................................................................... 7-19

CHECKING THE SWITCHES .................................................................7-21
CHECKING THE FUSES ........................................................................7-24
CHECKING AND CHARGING THE BATTERY....................................... 7-24
CHECKING THE RELAY.........................................................................7-27
CHECKING THE SPARK PLUG CAP .....................................................7-28
CHECKING THE IGNITION COIL ........................................................... 7-28
CHECKING THE PICKUP COIL..............................................................7-29
CHECKING THE STARTER MOTOR OPERATION ...............................7-29
CHECKING THE STATOR COIL ............................................................ 7-30
CHECKING THE RECTIFIER/REGULATOR ..........................................7-30
7
EBS30264
EBS20074
3
4 5
CIRCUIT DIAGRAM
2 6
1
7
IGNITION SYSTEM
R R B
G L R B
G L R R B
W/L B
R/W L/W
Y B
G/W L
8 R/W B
R Y/R G/Y
R
R B Y/R Y L/W G/Y G/W L R R/W B
R R/W
G/W G/W G/W

17 Br Br Br
L L L
16 Br Br Br
7-1
Br/W R Br B L/W Br/W G/Y Br Y Y/R B L/B L/B B W/L Br L
Br/W Br L/W B Br
Y L/B
R B Br/W
L/B W/L L
Y/R B
G/Y Br
R B B/Y
Br Br L/W Y B
B L/W B/Y Br R L
Br R
Y R B L
ON
OFF
12 9
L/W B B/Y Br
13 14 10
15
11
IGNITION SYSTEM
IGNITION SYSTEM
1. Ignition coil
2. Spark plug
6. Battery
8. Fuse
9. CDI unit
10.Pickup coil/stator coil assembly
12.Handlebar switch (left)
14.Engine stop switch
15.Main switch
7-2
IGNITION SYSTEM
EBS30265
TROUBLESHOOTING
The ignition system fails to operate (no spark or intermittent spark).
TIP
• Before troubleshooting, remove the following part(s):
1. Seat
2. Front fender
3. Footrest board (right)
4. CDI magneto
1. Check the fuse. NG →

Refer to “CHECKING THE FUS- Replace the fuse.
ES” on page 7-24.
OK ↓
2. Check the battery. NG →
Refer to “CHECKING AND • Clean the battery terminals.
CHARGING THE BATTERY” on • Recharge or replace the battery.
page 7-24.
OK ↓
3. Check the spark plug. NG →
Refer to “CHECKING THE SPARK Re-gap or replace the spark plug.
PLUG” on page 3-3.
OK ↓
4. Check the ignition spark gap. OK →
Refer to “CHECKING THE IGNI- Ignition system is OK.
TION COIL” on page 7-28.
NG ↓
5. Check the spark plug cap. NG →
Refer to “CHECKING THE SPARK Replace the spark plug cap.
PLUG CAP” on page 7-28.
OK ↓
6. Check the ignition coil. NG →
Refer to “CHECKING THE IGNI- Replace the ignition coil.
TION COIL” on page 7-28.
OK ↓
7. Check the pickup coil. NG →
Replace the pickup coil/stator coil assem-
Refer to “CHECKING THE PICKUP
bly.
COIL” on page 7-29.
OK ↓
8. Check the main switch. NG →
Refer to “CHECKING THE Replace the main switch.
SWITCHES” on page 7-21.
OK ↓
7-3
IGNITION SYSTEM
9. Check the engine stop switch. NG →

Refer to “CHECKING THE Replace the left handlebar switch.
OK ↓
10.Check the entire ignition system’s NG →
wiring. Properly connect or repair the ignition sys-
Refer to “CIRCUIT DIAGRAM” on tem’s wiring
page 7-1.
OK ↓
Replace the CDI unit.
7-4
EBS30266
EBS20075
3
4 5
CIRCUIT DIAGRAM
2 6
1
7
R R B
G L R B
G L R R B
W/L B
R/W L/W
Y B
G/W L
8 R/W B
R Y/R G/Y
R
R R/W
ELECTRIC STARTING SYSTEM
G/W G/W G/W

17 Br Br Br
L L L
16 Br Br Br
7-5
Br/W Br L/W B Br
Y L/B
R B Br/W
L/B W/L L
Y/R B
G/Y Br
R B B/Y
Br Br L/W Y B
B L/W B/Y Br R L
Br R
Y R B L
ON
OFF
12 9
L/W B B/Y Br
13 14 10
15
11
4. Starter relay
6. Battery
7. Starter motor
8. Fuse
11.Brake switch
13.Start switch
15.Main switch
7-6
EBS30267
STARTING CIRCUIT CUT-OFF SYSTEM OPERATION

If the engine stop switch is set to “ ” and the main switch is set to “ON” (both switches are closed), the
starter motor can only operate if at least one of the following conditions is met:
• The rear brake lever is pulled to the handlebar (the brake switch is closed).
6
2
7 5 4
1. Battery
2. Fuse
3. Main switch
4. Engine stop switch
5. Brake switch
6. Starter relay
7. Start switch
8. Starter motor
7-7
EBS30268
TROUBLESHOOTING
The starter motor fails to turn.
TIP
1. Seat
2. Exhaust pipe
3. Front fender

ES” on page 7-24.
OK ↓
page 7-24.
OK ↓
3. Check the starter motor operation. OK →
Starter motor is OK. Perform the electric
Refer to “CHECKING THE START-
starting system troubleshooting, starting
ER MOTOR OPERATION” on page
with step 5.
7-29.
NG ↓
4. Check the starter motor. NG →
Refer to “CHECKING THE START- Repair or replace the starter motor.
ER MOTOR” on page 5-37.
OK ↓
5. Check the starter relay. NG →
Refer to “CHECKING THE RELAY” Replace the starter relay.
on page 7-27.
OK ↓
OK ↓
7. Check the engine stop switch. NG →
OK ↓
8. Check the brake switch. NG →
Refer to “CHECKING THE Replace the brake switch.
OK ↓
7-8
9. Check the start switch. NG →

OK ↓
10.Check the entire starting system’s NG →
wiring. Properly connect or repair the starting sys-
Refer to “CIRCUIT DIAGRAM” on tem’s wiring.
page 7-5.
OK ↓
The starting system circuit is OK.
7-9
7-10
EBS30269
EBS20076
3
4 5
CIRCUIT DIAGRAM
2 6
1
7
R R B
CHARGING SYSTEM
G L R B
G L R R B
W/L B
R/W L/W
Y B
G/W L
8 R/W B
R Y/R G/Y
R
R R/W
G/W G/W G/W

17 Br Br Br
L L L
16 Br Br Br
7-11
Br/W Br L/W B Br
Y L/B
R B Br/W
L/B W/L L
Y/R B
G/Y Br
R B B/Y
Br Br L/W Y B
B L/W B/Y Br R L
Br R
Y R B L
ON
OFF
12 9
L/W B B/Y Br
13 14 10
15
11
CHARGING SYSTEM
CHARGING SYSTEM
3. Rectifier/regulator
6. Battery
8. Fuse
10.Pickup coil/stator coil assembly
7-12
CHARGING SYSTEM
EBS30270
TROUBLESHOOTING
The battery is not being charged.
TIP
1. Seat
2. Footrest board (right)
3. CDI magneto

ES” on page 7-24.
OK ↓
page 7-24.
OK ↓
3. Check the stator coil. NG →
Replace the pickup coil/stator coil assem-
Refer to “CHECKING THE STATOR
bly.
COIL” on page 7-30.
OK ↓
4. Check the rectifier/regulator. NG →
Refer to “CHECKING THE RECTI- Replace the rectifier/regulator.
FIER/REGULATOR” on page 7-30.
OK ↓
5. Check the entire charging system’s NG →
wiring. Properly connect or repair the charging
Refer to “CIRCUIT DIAGRAM” on system’s wiring.
page 7-11.
OK ↓
The charging system circuit is OK.
7-13
CHARGING SYSTEM
7-14
EBS30273
EBS20078
3
4 5
CIRCUIT DIAGRAM
2 6
1
7
R R B
SIGNALING SYSTEM
G L R B
G L R R B
W/L B
R/W L/W
Y B
G/W L
8 R/W B
R Y/R G/Y
R
R R/W
G/W G/W G/W

17 Br Br Br
L L L
16 Br Br Br
7-15
Br/W Br L/W B Br
Y L/B
R B Br/W
L/B W/L L
Y/R B
G/Y Br
R B B/Y
Br Br L/W Y B
B L/W B/Y Br R L
Br R
Y R B L
ON
OFF
12 9
L/W B B/Y Br
13 14 10
15
11
SIGNALING SYSTEM
SIGNALING SYSTEM
5. Gear position switch

6. Battery
8. Fuse
15.Main switch
16.Reverse indicator light
17.Neutral indicator light
7-16
SIGNALING SYSTEM
EBS30274
TROUBLESHOOTING
Any of the following fail to light: indicator light.
TIP
1. Seat
2. Front fender
3. Handlebar cover
4. Footrest board (left)
5. Front inner panel
6. V-belt case cover
7. Primary sliding sheave

ES” on page 7-24.
OK ↓
page 7-24.
OK ↓
OK ↓
4. Check the entire signaling sys- NG →
tem’s wiring. Properly connect or repair the signaling
page 7-15.
OK ↓
Check the condition of each of the sig-
naling system circuits. Refer to
“Checking the signaling system”.
Checking the signaling system

The neutral indicator light fails to come on.
1. Check the neutral indicator light as- NG →
sembly. Replace the neutral indicator light assem-
Refer to “GENERAL CHASSIS (1)” bly.
on page 4-1.
OK ↓
2. Check the gear position switch. NG →
Refer to “CHECKING THE Replace the gear position switch.
OK ↓
7-17
SIGNALING SYSTEM

page 7-15.
OK ↓
This circuit is OK.
The reverse indicator light fails to come on.

1. Check the reverse indicator light as- NG →
sembly. Replace the reverse indicator light assem-
Refer to “GENERAL CHASSIS (1)” bly.
on page 4-1.
OK ↓
2. Check the gear position switch. NG →
Refer to “CHECKING THE Replace the gear position switch.
OK ↓
page 7-15.
OK ↓
This circuit is OK.
7-18
ELECTRICAL COMPONENTS
EBS20084
3
7 8
5 6
4
2
1
9
10
15
11
14 12
13
7-19
1. Battery
2. CDI unit
3. Fuse
4. Starter relay
5. Brake switch
6. Handlebar switch (left)
7. Neutral indicator light
8. Reverse indicator light
9. Main switch
10. Ignition coil
11. Spark plug
12. Pickup coil/stator coil assembly
14. Starter motor
15. Rectifier/regulator
7-20
EBS30292
CHECKING THE SWITCHES
1 2 3
L/W B B/Y Br
B B/Y
Br L/W
5 4
Br R
G L R
ON
Br
OFF
7-21
1. Start switch
3. Brake switch
4. Main switch
7-22
Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the
wiring connections and if necessary, replace the switch.
ECB01430
NOTICE
Never insert the tester probes into the coupler terminal slots “a”. Always insert the probes from
the opposite end of the coupler, taking care not to loosen or damage the leads.
Pocket tester
90890-03112
YU-03112-C
TIP
• Before checking for continuity, set the pocket tester to “0” and to the “Ω × 1” range.
• When checking for continuity, switch back and forth between the switch positions a few times.
The switches and their terminal connections are illustrated as in the following example of the main
switch.
The switch positions “a” are shown in the far left column and the switch lead colors “b” are shown in the
top row.
The continuity (i. e., a closed circuit) between switch terminals at a given switch position is indicated by
“ ”.
There is continuity between brown and red when the switch is set to “ON”.
b
Br R
R
ON
a Br
OFF
7-23
EBS30296
cal system, cause the lighting and ignition
CHECKING THE FUSES
systems to malfunction and could possibly
The following procedure applies to all of the fus-
cause a fire.
es.
ECB02590
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
NOTICE
4. Install:
To avoid a short circuit, always set the main • Seat
switch to “OFF” when checking or replacing Refer to “GENERAL CHASSIS (1)” on page
a fuse. 4-1.
1. Remove: EBS30297
• Seat CHECKING AND CHARGING THE BATTERY
Refer to “GENERAL CHASSIS (1)” on page EWB02830
4-1. WARNING
2. Check: Batteries generate explosive hydrogen gas
• Fuse and contain electrolyte which is made of poi-
Amperage sonous and highly caustic sulfuric acid.
Fuses Q’ty Therefore, always follow these preventive
rating
measures:
Main 7.5 A 1
• Wear protective eye gear when handling or
Spare 7.5 A 1 working near batteries.
• Charge batteries in a well-ventilated area.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect the pocket tester to the fuse and • Keep batteries away from fire, sparks or
check the continuity. open flames (e.g., welding equipment,
TIP
lighted cigarettes).
• DO NOT SMOKE when charging or han-
Set the pocket tester selector to “Ω × 1”.
dling batteries.
• KEEP BATTERIES AND ELECTROLYTE
Pocket tester OUT OF REACH OF CHILDREN.
90890-03112 • Avoid bodily contact with electrolyte as it
Analog pocket tester can cause severe burns or permanent eye
YU-03112-C
injury.
b. If the pocket tester indicates “∞”, replace the FIRST AID IN CASE OF BODILY CONTACT:
fuse. EXTERNAL
• Skin — Wash with water.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• Eyes — Flush with water for 15 minutes and
3. Replace: get immediate medical attention.
• Blown fuse INTERNAL
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the main switch to “OFF”. • Drink large quantities of water or milk fol-
b. Install a new fuse of the correct amperage lowed with milk of magnesia, beaten egg or
rating. vegetable oil. Get immediate medical atten-
c. Set on the switches to verify if the electrical tion.
circuit is operational. ECB01990
d. If the fuse immediately blows again, check NOTICE

the electrical circuit. • This is a VRLA (Valve Regulated Lead Acid)
EWB02850 battery. Never remove the sealing caps be-
WARNING cause the balance between cells will not be
Never use a fuse with an amperage rating maintained and battery performance will
other than that specified. Improvising or us- deteriorate.
ing a fuse with the wrong amperage rating • Charging time, charging amperage and
may cause extensive damage to the electri- charging voltage for a VRLA (Valve Regu-
lated Lead Acid) battery are different from
those of conventional batteries. The VRLA
(Valve Regulated Lead Acid) battery should
7-24
be charged according to the appropriate TIP

charging method. If the battery is over- • The charge state of a VRLA (Valve Regulated
charged, the electrolyte level will drop con- Lead Acid) battery can be checked by measur-
siderably. Therefore, take special care ing its open-circuit voltage (i.e., the voltage
when charging the battery. when the positive battery terminal is discon-
TIP nected).
Since VRLA (Valve Regulated Lead Acid) bat- • No charging is necessary when the open-cir-
teries are sealed, it is not possible to check the cuit voltage equals or exceeds 12.8 V.
charge state of the battery by measuring the b. Check the charge of the battery, as shown in
specific gravity of the electrolyte. Therefore, the the charts and the following example.
charge of the battery has to be checked by mea- Example
suring the voltage at the battery terminals. Open-circuit voltage=12.0 V
Charging time=6.5 hours
1. Remove: Charge of the battery=20–30%
• Seat
4-1.
2. Disconnect:
• Battery leads
(from the battery terminals)
ECB01340
NOTICE
First, disconnect the negative battery lead
“1”, and then positive battery lead “2”.
A. Open-circuit voltage (V)

1
2 B. Charging time (hours)
C. Relationship between the open-circuit voltage
and the charging time at 20 °C (68 °F)
D. These values vary with the temperature, the
condition of the battery plates, and the
electrolyte level.
3. Remove:
• Battery band
• Battery
4-1.
4. Check:
• Battery charge
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Connect a pocket tester to the battery termi- A. Open-circuit voltage (V)
nals. B. Charging condition of the battery (%)
• Positive tester probe → C. Ambient temperature 20 °C (68 °F)
positive battery terminal
• Negative tester probe → ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
negative battery terminal
5. Charge:
• Battery
(refer to the appropriate charging method)
7-25
EWB02840
B. Time (minutes)
WARNING
C. Charging
Do not quick charge a battery. D. Ambient temperature 20 °C (68 °F)
ECB02000 E. Check the open-circuit voltage.
NOTICE
• Do not use a high-rate battery charger ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Charging method using a variable-current
since it forces a high-amperage current
(voltage) charger
into the battery quickly and can cause bat-
a. Measure the open-circuit voltage prior to
tery overheating and battery plate damage.
charging.
• If it is impossible to regulate the charging
current on the battery charger, be careful TIP
not to overcharge the battery. Voltage should be measured 30 minutes after
• When charging a battery, be sure to remove the engine is stopped.
it from the vehicle. (If charging has to be b. Connect a charger and ammeter to the bat-
done with the battery mounted on the vehi- tery and start charging.
cle, disconnect the negative battery lead
TIP
from the battery terminal.)
• To reduce the chance of sparks, do not Set the charging voltage to 16–17 V. If the set-
plug in the battery charger until the battery ting is lower, charging will be insufficient. If too
charger leads are connected to the battery. high, the battery will be over-charged.
• Before removing the battery charger lead c. Make sure that the current is higher than the
clips from the battery terminals, be sure to standard charging current written on the bat-
turn off the battery charger. tery.
• Make sure the battery charger lead clips are TIP
in full contact with the battery terminal and
If the current is lower than the standard charging
that they are not shorted. A corroded bat-
current written on the battery, set the charging
tery charger lead clip may generate heat in
voltage adjust dial at 20–24 V and monitor the
the contact area and a weak clip spring may
amperage for 3–5 minutes to check the battery.
cause sparks.
• If the battery becomes hot to the touch at • Standard charging current is reached
any time during the charging process, dis- Battery is good.
connect the battery charger and let the bat- • Standard charging current is not reached
tery cool before reconnecting it. Hot Replace the battery.
batteries can explode! d. Adjust the voltage so that the current is at the
• As shown in the following illustration, the standard charging level.
open-circuit voltage of a VRLA (Valve Reg- e. Set the time according to the charging time
ulated Lead Acid) battery stabilizes about suitable for the open-circuit voltage.
30 minutes after charging has been com- f. If charging requires more than 5 hours, it is
pleted. Therefore, wait 30 minutes after advisable to check the charging current after
charging is completed before measuring a lapse of 5 hours. If there is any change in
the open-circuit voltage. the amperage, readjust the voltage to obtain
the standard charging current.
g. Measure the battery open-circuit voltage after
leaving the battery unused for more than 30
minutes.
12.8 V or more --- Charging is complete.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
A. Open-circuit voltage (V)
7-26
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
Charging method using a constant volt-
2
age charger 1
a. Measure the open-circuit voltage prior to
charging.
TIP
Voltage should be measured 30 minutes after
the engine is stopped.
b. Connect a charger and ammeter to the bat-
tery and start charging.
8. Check:
c. Make sure that the current is higher than the
• Battery terminals
standard charging current written on the bat-
Dirt → Clean with a wire brush.
tery.
Loose connection → Connect properly.
TIP 9. Install:
If the current is lower than the standard charging • Seat
current written on the battery, this type of battery Refer to “GENERAL CHASSIS (1)” on page
charger cannot charge the VRLA (Valve Regu- 4-1.
lated Lead Acid) battery. A variable voltage
EBS30298
charger is recommended.
CHECKING THE RELAY
d. Charge the battery until the battery’s Check each switch for continuity with the pocket
charging voltage is 15 V. tester. If the continuity reading is incorrect, re-
TIP place the relay.
Set the charging time at 20 hours (maximum). Pocket tester
e. Measure the battery open-circuit voltage after 90890-03112
leaving the battery unused for more than 30 Analog pocket tester
minutes. YU-03112-C
12.8 V or more --- Charging is complete. 1. Disconnect the relay from the wire harness.
12.7 V or less --- Recharging is required.
Under 12.0 V --- Replace the battery. 2. Connect the pocket tester (Ω × 1) and battery
(12 V) to the relay terminal as shown.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Check the relay operation.
6. Install: Out of specification → Replace.
• Battery
• Battery band Starter relay
Refer to “GENERAL CHASSIS (1)” on page 3 1
4-1.
1 2
7. Connect:
• Battery leads L/W G/Y
(to the battery terminals)
ECB01330 R/W R
NOTICE
First, connect the positive battery lead “1”, 3 4
and then the negative battery lead “2”. 4 2
1. Positive battery terminal

2. Negative battery terminal
3. Positive tester probe
4. Negative tester probe
7-27
• Positive tester probe

Result White/blue “1”
Continuity • Negative tester probe
(between “3” and “4”) Black “2”
EBS30299
CHECKING THE SPARK PLUG CAP

1. Check: 2
• Spark plug cap resistance 1
Resistance
5.0 kΩ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the spark plug cap from the spark
plug lead. c. Measure the primary coil resistance.
b. Connect the pocket tester (Ω × 1 k) to the ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
spark plug cap as shown. 2. Check:
• Secondary coil resistance
Pocket tester Out of specification → Replace.
90890-03112
Analog pocket tester Secondary coil resistance
YU-03112-C 2.79–3.41 kΩ
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the igni-
tion coil.
b. Connect the pocket tester (Ω × 1 k) to the ig-
nition coil as shown.
Pocket tester
90890-03112
YU-03112-C
c. Measure the spark plug cap resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ White/blue “1”
EBS30300 • Negative tester probe
CHECKING THE IGNITION COIL Spark plug lead “2”
1. Check:
• Primary coil resistance
Out of specification → Replace. 1
Primary coil resistance
0.18–0.23 Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the ignition coil connector from
2
the ignition coil terminal.
b. Connect the pocket tester (Ω × 1) to the igni-
tion coil as shown. c. Measure the secondary coil resistance.
Pocket tester ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
90890-03112 3. Check:
Analog pocket tester • Ignition spark gap
YU-03112-C Out of specification → Replace.
7-28

Minimum ignition spark gap Blue “1”
6.0 mm (0.24 in) • Negative tester probe
Pickup coil base “2”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Disconnect the spark plug cap from the spark
plug.
b. Connect the Ignition checker/Oppama pet–
2
4000 spark checker “1” as shown.
Ignition checker
90890-06754
Oppama pet–4000 spark checker
YM-34487 Y B
R L 1
b. Measure the pickup coil resistance.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30304
CHECKING THE STARTER MOTOR

OPERATION
1. Check:
• Starter motor operation
Does not operate → Perform the electric
starting system troubleshooting, starting with
2. Spark plug cap step 4.
Refer to “TROUBLESHOOTING” on page
c. Set the main switch to “ON”. 7-8.
d. Crank the engine by pushing the starter ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
switch and gradually increase the spark gap a. Connect the positive battery terminal “1” and
until a misfire occurs. starter motor lead “2” with a jumper lead “3”.
EWB02920
e. Measure the ignition spark gap “a”.
WARNING
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
• A wire that is used as a jumper lead must
EBS30570
CHECKING THE PICKUP COIL have at least the same capacity of the bat-
1. Disconnect: tery lead, otherwise the jumper lead may
• Pickup coil/stator coil assembly coupler burn.
(from the wire harness) • This check is likely to produce sparks,
2. Check: therefore, make sure no flammable gas or
• Pickup coil resistance fluid is in the vicinity.
Out of specification → Replace the pickup
coil/stator coil assembly. 3
Pickup coil resistance 2
96.0–144.0 Ω
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
a. Connect the pocket tester (Ω × 100) to the R/W L/W
pickup coil/stator coil assembly coupler as R

G/Y
shown.
Pocket tester b. Check the starter motor operation.

90890-03112 ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
YU-03112-C
7-29
EBS30305
CHECKING THE STATOR COIL Digital tachometer

1. Disconnect: 90890-06760
• Pickup coil/stator coil assembly coupler Digital tachometer
(from the wire harness) YU-39951-B
2. Check: Pocket tester
• Stator coil resistance 90890-03112
Out of specification → Replace the pickup Analog pocket tester
coil/stator coil assembly. YU-03112-C
Stator coil resistance • Positive tester probe

0.50–0.77 Ω (R/B) Positive battery terminal “1”
• Negative tester probe
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ Negative battery terminal “2”
a. Connect the pocket tester (Ω × 1) to the pick-
up coil/stator coil assembly coupler as 1
shown. 2
Pocket tester
90890-03112
YU-03112-C

Red “1”
• Negative tester probe c. Start the engine and let it run at approximate-
Blue “2”
ly 5000 r/min.
d. Measure the charging voltage.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Y B
R L
1
b. Measure the stator coil resistance.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
EBS30306
CHECKING THE RECTIFIER/REGULATOR

1. Check:
• Charging voltage
Out of specification → Replace the rectifi-
er/regulator.
Charging voltage
14 V at 5000 r/min
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Set the digital tachometer to the spark plug
lead.
b. Connect the pocket tester (DC 20 V) to the
battery terminal as shown.
7-30
7-31
TROUBLESHOOTING
TROUBLESHOOTING.....................................................................................8-1
GENERAL INFORMATION ....................................................................... 8-1
STARTING FAILURES..............................................................................8-1
INCORRECT ENGINE IDLING SPEED .................................................... 8-1
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE ........................... 8-2
SHIFT LEVER DOES NOT MOVE ............................................................ 8-2
JUMPS OUT OF GEAR.............................................................................8-2
FAULTY CLUTCH .....................................................................................8-2
OVERHEATING ........................................................................................8-3
POOR BRAKING PERFORMANCE.......................................................... 8-3
UNSTABLE HANDLING ............................................................................8-3
8
TROUBLESHOOTING
EBS20085
• Sucked-in air
TROUBLESHOOTING • Damaged float
EBS30321
• Worn needle valve
GENERAL INFORMATION • Incorrect fuel level
TIP • Improperly installed pilot jet
The following guide for troubleshooting does not
Electrical system
cover all the possible causes of trouble. It should
1. Battery
be helpful, however, as a guide to basic trouble-
• Discharged battery
shooting. Refer to the relative procedure in this
• Faulty battery
manual for checks, adjustments, and replace-
2. Fuse
ment of parts.
• Blown, damaged or incorrect fuse
• Improperly installed fuse
EBS30322
STARTING FAILURES 3. Spark plug

• Incorrect spark plug gap
Engine • Incorrect spark plug heat range
1. Cylinder and cylinder head • Fouled spark plug
• Loose spark plug • Worn or damaged electrode
• Loose cylinder head or cylinder • Worn or damaged insulator
• Damaged cylinder head gasket • Faulty spark plug cap
• Damaged cylinder gasket 4. Ignition coil
• Worn or damaged cylinder • Cracked or broken ignition coil body
• Incorrect valve clearance • Broken or shorted primary or secondary coils
• Improperly sealed valve • Faulty spark plug lead
• Incorrect valve-to-valve-seat contact 5. Ignition system
• Incorrect valve timing • Faulty CDI unit
• Faulty valve spring • Faulty pickup coil
• Seized valve • Faulty stator coil
2. Piston and piston ring • Broken CDI magneto rotor woodruff key
• Improperly installed piston ring 6. Switches and wiring
• Damaged, worn or fatigued piston ring • Faulty main switch
• Seized piston ring • Faulty engine stop switch
• Seized or damaged piston • Broken or shorted wiring
3. Air filter • Faulty gear position switch
• Improperly installed air filter • Faulty start switch
• Clogged air filter element • Faulty brake switch
4. Crankcase and crankshaft • Improperly grounded circuit
• Improperly assembled crankcase • Loose connections
• Seized crankshaft 7. Starting system
• Faulty starter motor
Fuel system • Faulty starter relay
1. Fuel tank • Faulty starter clutch
• Empty fuel tank EBS30323
• Clogged fuel strainer INCORRECT ENGINE IDLING SPEED
• Clogged fuel tank breather hose
• Deteriorated or contaminated fuel Engine
2. Fuel cock 1. Cylinder and cylinder head
• Clogged or damaged fuel hose • Incorrect valve clearance
• Clogged fuel filter • Damaged valve train components
3. Carburetor 2. Air filter
• Deteriorated or contaminated fuel • Clogged air filter element
• Clogged pilot jet • Loosen air filter joint
• Clogged pilot air passage
8-1
TROUBLESHOOTING
Fuel system • Bent shift fork guide bar

1. Carburetor
• Loose or clogged pilot jet Transmission
• Loose or clogged pilot air jet • Seized transmission gear
• Damaged or loose carburetor joint • Foreign object between transmission gears
• Improperly adjusted engine idling speed • Improperly assembled transmission
(throttle stop screw) EBS30328
• Improper throttle lever free play JUMPS OUT OF GEAR
• Flooded carburetor
Shift shaft
Electrical system • Incorrect shift lever position
1. Battery • Improperly returned stopper lever
• Discharged battery
• Faulty battery Shift forks
2. Spark plug • Worn shift fork
• Incorrect spark plug heat range Shift drum
• Fouled spark plug • Incorrect axial play
• Worn or damaged electrode • Worn shift drum groove
• Worn or damaged insulator
• Faulty spark plug cap Transmission
3. Ignition coil • Worn gear dog
• Broken or shorted primary or secondary coils
EBS30329
• Faulty spark plug lead FAULTY CLUTCH
• Cracked or broken ignition coil
4. Ignition system Engine operates but vehicle will not move
• Faulty CDI unit 1. V-belt
• Faulty pickup coil • Bent, damaged or worn V-belt
• Broken CDI magneto rotor woodruff key • Slipping V-belt
EBS30324
2. Primary sheave cam and primary sheave
POOR MEDIUM-AND-HIGH-SPEED slider(s)
PERFORMANCE • Damaged or worn primary sheave cam
Refer to “STARTING FAILURES” on page 8-1. • Damaged or worn primary sheave slider
3. Clutch spring
Engine • Damaged clutch spring
1. Air filter 4. Transmission gear(s)
• Clogged air filter element • Damaged transmission gear
Fuel system Clutch slips

1. Carburetor 1. Clutch shoe spring(s)
• Faulty diaphragm • Damaged, loose or worn clutch shoe spring
• Incorrect fuel level 2. Clutch shoe(s)
• Loose or clogged main jet • Damaged or worn clutch shoe
3. Primary sliding sheave
EBS30327
SHIFT LEVER DOES NOT MOVE • Seized primary sliding sheave
Shift shaft Poor starting performance

• Improperly adjusted shift rod 1. V-belt
• Bent shift shaft • Slipping V-belt
• Oil or grease on the V-belt
Shift drum and shift forks 2. Primary sliding sheave
• Foreign object in a shift drum groove • Faulty operation
• Seized shift fork
8-2
TROUBLESHOOTING
3. Clutch shoe(s) • Incorrect brake camshaft lever position

• Bent, damaged or worn clutch shoe • Incorrect brake shoe position
• Damaged or fatigued brake shoe spring
Poor speed performance • Oil or grease on the brake shoe
1. V-belt • Oil or grease on the brake drum
• Slipping V-belt • Broken brake torque rod
• Oil or grease on the V-belt
EBS30334
2. Primary sheave weight(s) UNSTABLE HANDLING
• Faulty operation 1. Handlebar
• Worn primary sheave weight • Bent or improperly installed handlebar
3. Primary fixed sheave 2. Steering components
• Worn primary fixed sheave • Incorrect toe-in
4. Primary sliding sheave • Improperly installed steering stem
• Worn primary sliding sheave • Bent tie-rods
5. Secondary fixed sheave • Bent steering stem
• Worn secondary fixed sheave • Damaged bushing
6. Secondary sliding sheave • Deformed steering knuckles
• Worn secondary sliding sheave 3. Front shock absorber assembly(-ies)
EBS30330 • Faulty front shock absorber spring
OVERHEATING • Leaking oil
4. Swingarm
Engine • Worn bearing or bushing
1. Cylinder head and piston • Bent or damaged swingarm
• Heavy carbon buildup 5. Rear shock absorber assembly
2. Engine oil • Faulty rear shock absorber spring
• Incorrect oil level • Leaking oil or gas
• Incorrect oil viscosity 6. Tire(s)
• Inferior oil quality • Uneven tire pressures (front and rear)
• Incorrect tire pressure
Fuel system • Uneven tire wear
1. Carburetor 7. Wheel(s)
• Incorrect main jet setting • Incorrect wheel balance
• Incorrect fuel level • Deformed cast wheel
• Damaged or loose carburetor joint • Damaged wheel bearing
2. Air filter • Bent or loose wheel axle
• Clogged air filter element • Excessive wheel runout
8. Frame
Chassis • Bent frame
1. Brake(s) • Improperly installed bushing
• Dragging brake
Electrical system
1. Spark plug
• Incorrect spark plug heat range
2. Ignition system
• Faulty CDI unit
EBS30332
POOR BRAKING PERFORMANCE

• Worn brake shoe
• Worn or rusty brake drum
• Incorrect brake lever position
• Incorrect brake lever free play
8-3
TROUBLESHOOTING
8-4
EBS20008 EBS30002
WIRING DIAGRAM COLOR CODE

YF09RG/YFM09RYXG 2016 B Black
1. Ignition coil Br Brown
2. Spark plug G Green
3. Rectifier/regulator L Blue
4. Starter relay R Red
5. Gear position switch Y Yellow
B/Y Black/Yellow
6. Battery
Br/W Brown/White
7. Starter motor
G/Y Green/Yellow
8. Fuse
G/W Green/White
9. CDI unit L/B Blue/Black
10. Pickup coil/stator coil assembly L/W Blue/White
11. Brake switch Y/R Yellow/Red
12. Handlebar switch (left) R/W Red/White
13. Start switch W/L White/Blue
15. Main switch
16. Reverse indicator light
17. Neutral indicator light
YF09RG/YFM09RYXG 2016 YF09RG/YFM09RYXG 2016
WIRING DIAGRAM SCHÉMA DE CÂBLAGE
3
4 5
2 6
1
7
R R B
G L R B
G L R R B
W/L B
R/W L/W
Y B
G/W L
8 R/W B
R Y/R G/Y
R
R R/W
G/W G/W G/W

17 Br Br Br
L L L
16 Br Br Br
Br/W Br L/W B Br
Y L/B
R B Br/W
L/B W/L L
Y/R B
G/Y Br
R B B/Y
Br Br L/W Y B
B L/W B/Y Br R L
Br R
Y R B L
ON
OFF
12 9
L/W B B/Y Br
13 14 10
15
11
YF09RG/YFM09RYXG 2016 YF09RG/YFM09RYXG 2016
WIRING DIAGRAM SCHÉMA DE CÂBLAGE
3
4 5
2 6
1
7
17
16
ON
OFF
12 9
13 14 10
15
11

Yfm90r 2016 Bd3-F8197-E0

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2016

IMPORTANT MANUAL INFORMATION

A WARNING indicates a hazardous situation which, if not avoided, could result

A NOTICE indicates special precautions that must be taken to avoid damage to

TIP A TIP provides key information to make procedures easier or clearer.

HOW TO USE THIS MANUAL

SYMBOL DEFINITION SYMBOL DEFINITION

Serviceable with engine mounted Gear oil

Filling fluid Molybdenum disulfide oil

Lubricant Brake fluid

Special tool B Wheel bearing grease

Tightening torque LS Lithium-soap-based grease

Wear limit, clearance M Molybdenum disulfide grease

Engine speed S Silicone grease

Electrical data Apply locking agent (LOCTITE®).

Engine oil New Replace the part with a new one.

IDENTIFICATION ............................................................................................ 1-1

IMPORTANT INFORMATION ......................................................................... 1-2

BASIC SERVICE INFORMATION...................................................................1-4

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

VEHICLE IDENTIFICATION NUMBER

PREPARATION FOR REMOVAL AND

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS RUBBER PARTS

BASIC SERVICE INFORMATION

TIP Turn the main switch to “OFF” before dis-

NOTICE Checking the electrical system

Thickness gauge 3-5

Tappet adjusting tool 3-5

Axle nut wrench (36 mm) 4-18, 4-20

Compression gauge 90890-03081 5-1

Valve spring compressor 5-17, 5-22

Valve spring compressor attachment 5-17, 5-22

Valve guide remover (ø5) 5-19

Valve guide installer (ø5) 5-19

Valve guide reamer (ø5) 5-19

Rotor holding tool 5-29, 5-30, 5-46,

Flywheel puller 5-29

Digital circuit tester 5-37

Rotor holding tool 5-46, 5-49

Socket wrench (39 mm) 5-46, 5-49

Clutch spring holder 5-47, 5-48

Fuel level gauge 6-10

Digital tachometer 7-30

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

ENGINE SPECIFICATIONS ............................................................................2-2

CHASSIS SPECIFICATIONS ..........................................................................2-6

ELECTRICAL SPECIFICATIONS ...................................................................2-8

TIGHTENING TORQUES ................................................................................ 2-9

LUBRICATION AND SEALING POINTS ......................................................2-14

LUBRICATION SYSTEM CHART AND DIAGRAMS.................................... 2-15

CABLE ROUTING ......................................................................................... 2-17

Spark plug (s)

Rocker arm/rocker arm shaft

Valve, valve seat, valve guide

Piston pin bore inside diameter limit 13.040 mm (0.5134 in)

Tire air pressure (measured on cold tires)

Brake drum inside diameter limit 86.0 mm (3.39 in)