Yamaha YZ85(W) Service manual

2007
YZ85W1
YZ85(W)
YZ85LW(W)
SERVICE MANUAL
5PA-28197-E0
EAS00000
YZ85W1 / YZ85 (W) / YZ85LW (W)
SERVICE MANUAL
©2006 by Yamaha Motor Co., Ltd.
First edition, April 2006
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EAS00002
NOTICE
This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one
manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha
vehicles should have a basic understanding of mechanics and the techniques to repair these types
of vehicles.
Repair and maintenance work attempted by anyone without this knowledge is likely to render the
vehicle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all of its models. Modifications and
significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
EAS00004
IMPORTANT MANUAL INFORMATION
Particularly important information is distinguished in this manual by the following.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING
CAUTION:
NOTE:
Failure to follow WARNING instructions could result in severe injury or death
to the vehicle operator, a bystander or a person checking or repairing the
vehicle.
A CAUTION indicates special precautions that must be taken to avoid damage to the vehicle.
A NOTE provides key information to make procedures easier or clearer.
EAS00007
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. An abbreviation and symbol in the upper right corner of
each page indicate the current chapter.
Refer to “SYMBOLS”.
Each chapter is divided into sections. The current section title is shown at the top of each page,
except in Chapter 3 (“PERIODIC CHECKS AND ADJUSTMENTS”), where the sub-section title(s)
appears.
Sub-section titles appear in smaller print than the section title.
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
Numbers are given in the order of the jobs in the exploded diagram. A circled number indicates a
disassembly step.
Symbols indicate parts to be lubricated or replaced.
Refer to “SYMBOLS”.
A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
Jobs requiring more information (such as special tools and technical data) are described sequentially.
EAS00008
SYMBOLS
The following symbols are not relevant to every
vehicle.
Symbols
to
indicate the subject of each
chapter.
General information
Specifications
Periodic checks and adjustments
Chassis
Engine
Cooling system
Carburetor(s)
Electrical system
Tuning
Troubleshooting
Symbols
to
indicate the following.
Serviceable with engine mounted
Filling fluid
Lubricant
Special tool
Tightening torque
Wear limit, clearance
Engine speed
Electrical data
Symbols
to
in the exploded diagrams
indicate the types of lubricants and lubrication
points.
Engine oil
Gear oil
Molybdenum-disulfide oil
Wheel-bearing grease
Lithium-soap- based grease
Molybdenum-disulfide grease
Symbols
to
in the exploded diagrams
indicate the following.
Apply locking agent (LOCTITE®)
Replace the part with a new one.
EAS00010
TABLE OF CONTENTS
GENERAL INFORMATION
SPECIFICATIONS
PERIODIC CHECKS AND
ADJUSTMENTS
CHASSIS
ENGINE
COOLING SYSTEM
CARBURETOR
ELECTRICAL SYSTEM
TUNING
TROUBLESHOOTING
GEN
INFO
1
SPEC
2
CHK
ADJ
3
CHAS
4
ENG
5
COOL
6
CARB
7
ELEC
8
TUN
9
TRBL
SHTG
10
GEN
INFO
CHAPTER 1
GENERAL INFORMATION
VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . 1-1
MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
IMPORTANT INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . .
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GASKETS, OIL SEALS AND O-RINGS. . . . . . . . . . . . . . . . . . . . . . .
LOCK WASHERS / PLATES AND COTTER PINS . . . . . . . . . . . . . . .
BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
1-2
1-2
1-2
1-3
1-3
1-3
FUEL AND ENGINE MIXING OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
VEHICLE IDENTIFICATION
GEN
INFO
EAS00014
GENERAL INFORMATION
VEHICLE IDENTIFICATION
EAS00017
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number
is
stamped into the right side of the steering
head pipe.
EAS00018
MODEL LABEL
The model label
is affixed to the frame. This
information will be needed to order spare
parts.
1-1
IMPORTANT INFORMATION
GEN
INFO
EAS00020
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly, remove
all dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to the “SPECIAL TOOLS”.
3. When disassembling, always keep mated
parts together. This includes gears, cylinders, pistons and other parts that have
been “mated” through normal wear. Mated
parts must always be reused or replaced as
an assembly.
4. During disassembly, clean all of the parts
and place them in trays in the order of disassembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
EAS00021
REPLACEMENT PARTS
Use only genuine Yamaha parts for all replacements. Use oil and grease recommended by
Yamaha for all lubrication jobs. Other brands
may be similar in function and appearance, but
inferior in quality.
EAS00022
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket surfaces, oil seal lips and O-rings must be
cleaned.
2. During reassembly, properly oil all mating
parts and bearings and lubricate the oil seal
lips with grease.
lip
lip
spring
oil
grease
1-2
IMPORTANT INFORMATION
GEN
INFO
EAS00023
LOCK WASHERS / PLATES AND COTTER
PINS
After removal, replace all lock washers / plates
and cotter pins. After the bolt or nut has
been tightened to specification, bend the lock
tabs along a flat of the bolt or nut.
EAS00024
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When
installing oil seals, lubricate the oil seal lips
with a light coat of lithium-soap-based grease.
Oil bearings liberally when installing, if appropriate.
Oil seal
CAUTION:
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
Bearing
EAS00025
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip
, make sure the
sharp-edged corner
is positioned opposite
the thrust
that the circlip receives.
Shaft
1-3
FUEL AND ENGINE MIXING OIL
GEN
INFO
FUEL AND ENGINE MIXING OIL
Mix oil with the gas at the ratio specified below.
Always use fresh, name-brand gasoline, and
mix the oil and gas the day of the race. Do not
use premix that is more than a few hours old.
Recommended fuel
Premium unleaded gasoline
only with a research octane
number of 95 or higher.
NOTE:
If knocking or pinging occurs, use a different
brand of gasoline or higher octane grade.
CAUTION:
Never mix two types of oil in the same
batch; clotting of the oil could result. If you
wish to change oil types, be sure to drain
the fuel tank and the carburetor float bowl
of old premix prior to filling with the new
type.
YAMALUBE “2-R”
Fuel tank capacity
5.0 L (1.10 Imp gal, 1.32 US gal)
Mixing oil
Recommended oil
Yamalube “2-R”
(Yamalube racing 2-cycle oil)
Mixing ratio: 30 : 1
If unavailable, use an equivalent
type of oil.
1-4
CHECKING THE CONNECTIONS
GEN
INFO
EAS00026
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• lead
• coupler
• connector
2. Check:
• lead
• coupler
• connector
Moisture → Dry with an air blower.
Rust / stains → Connect and disconnect
several times.
3. Check:
• all connections
Loose connection → Connect properly.
NOTE:
If the pin
on the terminal is flattened, bend it
up.
4. Connect:
• lead
• coupler
• connector
NOTE:
Make sure all connections are tight.
5. Check:
• continuity
(with the pocket tester)
Pocket tester
90890-03112, YU-3112-C
NOTE:
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
1-5
SPECIAL TOOLS
GEN
INFO
EAS00027
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools as this will help prevent damage caused by the use of 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.
NOTE:
• For U.S.A. and Canada, use part number starting with “YM-”, “YU-”, or “ACC-”.
• For others, use part number starting with “90890-”.
Tool No.
Tool name / Function
Crankcase separating tool
90890-01135
YU-1135-A
This tool is used to split the crankcase as well
as remove the crankshaft from either case.
Flywheel puller
90890-01189
YM-1189
This tool is used to remove the flywheel
magneto.
Rotor holding tool
90890-01235
YU-1235
Dial gauge set
90890-01252
Dial gauge and
stand
YU-3097
YU-1256
This tool is used when loosening or tightening
the flywheel magneto securing nut.
Dial gauge and stand
Stand
These tools are used to check each part for
runout or bent.
Ringnut wrench
90890-01268
This tool is used to loosen and tighten the
exhaust and steering ringnut.
Crankshaft installing tool
For EUR, OCE
90890-01274
90890-01275
90890-01277
For U.S.A, CAN
YU-90050
YM-1277
Crankshaft installing tool
Crankshaft installing pot
Crankshaft installing bolt
Adapter (M10)
These tools are used to install the crankshaft.
Piston pin puller set
90890-01304
YU-1304
This tool is used to remove the piston pin.
1-6
Illustration
SPECIAL TOOLS
Tool No.
Radiator cap tester
90890-01325
YU-24460-01
Radiator cap
tester adapter
90890-01352
YU-33984
Tool name / Function
Radiator cap tester
Radiator cap tester adapter
These tools are used for checking the cooling
system.
Steering nut wrench
90890-01403
YU-33975
This tool is used when tighten the steering
ring nut to specification.
Rod holder
90890-01434
YM-01434
This tool is used to hold the fork spring.
Rod puller
90890-01437
YM-01437
Rod puller
attachment
90890-01436
YM-01436
Rod puller
Rod puller attachment (M10)
These tools are used to pull up the fork
damper rod.
Fork seal diver
90890-01442
YM-01442
This tool is used when install the fork oil seal.
Damper rod holder
90890-01454
YM-01454
Use this tool to remove and install the damper
rod.
Drive gear holder
90890-01495
YM-01495
This tool is used when removing or tightening
the primary drive gear securing nut.
Pocket tester
90890-03112
YU-3112-C
Use this tool to inspect the coil resistance,
output voltage and amperage.
Universal clutch holder
90890-04086
YM-91042
This tool is used to hold the clutch when
removing or installing the clutch boss
securing nut.
1-7
GEN
INFO
Illustration
SPECIAL TOOLS
Tool No.
90890-06754
YM-34487
Tool name / Function
Dynamic spark tester
Ignition checker
This instrument is necessary for checking the
ignition system components.
Yamaha bond No.1215
(Three Bond No.1215®)
90890-85505
This sealant (Bond) is used for crankcase
mating surface, etc.
1-8
GEN
INFO
Illustration
SPEC
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
ELECTRICAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
GENERAL TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . 2-12
TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . 2-16
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
CABLE ROUTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
GENERAL SPECIFICATIONS
SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item
Model code
Dimensions
Overall length
Overall width
Overall height
Seat height
Wheelbase
Minimum ground clearance
Dry weight
Without oil and fuel
Standard
Limit
YZ85
5PAG (EUR, CAN), 5PAH (AUS,NZL)
YZ85LW
5SHG (EUR), 5SHH (AUS,NZL)
•••
1,818 mm (71.6 in) (YZ85)
1,903 mm (74.9 in) (YZ85LW)
758 mm (29.8 in)
1,161mm (45.7 in) (YZ85)
1,205 mm (47.4 in) (YZ85LW)
864 mm (34.0 in) (YZ85)
904 mm (35.6 in) (YZ85LW)
1,255 mm (49.4 in) (YZ85)
1,286 mm (50.6 in) (YZ85LW)
351 mm (13.8 in) (YZ85)
393 mm (15.5 in) (YZ85LW)
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
66 kg (145.5 lb) (YZ85)
69 kg (152.2 lb) (YZ85LW)
•••
•••
2-1
•••
ENGINE SPECIFICATIONS
SPEC
ENGINE SPECIFICATIONS
Item
Engine
Engine type
Displacement
Cylinder arrangement
Bore × stroke
Compression ratio
Fuel
Recommended fuel
Fuel tank capacity
Total
Lubrication system
Transmission oil
Recommended oil
Standard
Limit
Liquid cooled 2-stroke, gasoline
84.7 cm3 (5.17 cu.in)
Single cylinder, forward inclined
47.5 × 47.8 mm (1.870 × 1.882 in)
8.2 : 1
•••
•••
•••
•••
•••
Premium unleaded gasoline only
•••
5.0L (1.09 Imp gal, 1.30 US gal)
Premix (30 : 1) (Yamalube 2-R)
•••
•••
Yamalube 4 (10W-30) or SAE 10W-30
API service SG type or higher
JASO standard MA
0.50 L (0.44 Imp qt, 0.53 US qt)
0.55 L (0.48 Imp qt, 0.58 US qt)
•••
Periodic oil change
Total amount
Cooling system
Coolant capacity (including all routes) 0.54 L (0.48 Imp qt, 0.57 US qt)
Radiator capacity
0.32 L (0.28 Imp qt, 0.34 US qt)
Radiator cap opening pressure
93 ~ 123 kPa (0.93 ~ 1.23 kg / cm2,
13.2 ~ 17.5 psi)
Radiator core
Width
117.8 mm (4.64 in)
Height
240.0 mm (9.45 in)
Depth
32.0 mm (1.26 in)
Water pump
Water pump type
Single suction centrifugal pump
Reduction ratio
25 / 18 (1.388)
Starting system
Kickstarter
Spark plug
Model (manufacturer) × quantity
BR10EG (NGK) × 1
Spark plug gap
0.5 ~ 0.6 mm (0.0197 ~ 0.0236 in)
Cylinder head
Volume
7.14 cm3 (0.44 cu.in)
Max. warpage
•••
2-2
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
0.03 mm
(0.0012 in)
ENGINE SPECIFICATIONS
Item
Cylinder
Bore
Max. taper limit
Max. out-of-round
Piston
Piston-to-cylinder clearance
Diameter D
Height H
Piston pin bore (in the piston)
Diameter
Offset
Offset direction
Piston pin
Outside diameter
SPEC
Standard
Limit
47.500 ~ 47.514 mm (1.8701 ~ 1.8706 in) 47.6 mm
(1.874 in)
•••
0.05 mm
(0.0020 in)
•••
0.01 mm
(0.0004 in)
0.040 ~ 0.045 mm (0.0016 ~ 0.0018 in)
0.1 mm
(0.004 in)
47.457 ~ 47.472 mm (1.8684 ~ 1.8690 in) 0.1 mm
(0.004 in)
20.0 mm (0.79 in)
•••
14.004 ~ 14.015 mm (0.5513 ~ 0.5518 in) 14.040 mm
(0.5528 in)
1.0 mm (0.039 in)
•••
Exhaust side
•••
13.996 ~ 14.000 mm (0.5510 ~ 0.5512 in) 13.975 mm
(0.5502 in)
Piston ring
Ring type
Dimensions (B × T)
End gap (installed)
Ring side clearance
Plain
0.8 × 2.0 mm (0.032 × 0.079 in)
0.30 ~ 0.45 mm (0.012 ~ 0.018 in)
0.030 ~ 0.065 mm (0.001 ~ 0.003 in)
2-3
•••
•••
0.8 mm
(0.032 in)
0.1 mm
(0.004 in)
ENGINE SPECIFICATIONS
Item
SPEC
Standard
Limit
Crankshaft
Crank width “A”
Runout limit “C”
44.90 ~ 44.95 mm (1.768 ~ 1.770 in)
0.03 mm (0.0012 in)
Big end side clearance “D”
Small end free play “F”
0.20 ~ 0.70 mm (0.008 ~ 0.028 in)
0.5 ~ 1.2 mm (0.020 ~ 0.047 in)
Clutch
Clutch type
Clutch release method
Clutch cable free play (at the end of
the clutch lever)
Friction plates
Thickness
Wet, multiple disc
Inner push, cam push
10.0 ~ 15.0 mm (0.39 ~ 0.59 in)
2.9 ~ 3.1 mm (0.114 ~ 0.122 in)
7
•••
0.05 mm
(0.002 in)
(YZ85)
0.08 mm
(0.003 in)
(YZ85LW)
•••
2.0 mm
(0.08 in)
•••
•••
•••
•••
2.7 mm
(0.106 in)
•••
Plate quantity
Clutch plates
Thickness
Plate quantity
Max. warpage
1.8 ~ 2.2 mm (0.071 ~ 0.087 in)
6
•••
•••
•••
0.1 mm
(0.004 in)
Clutch springs
Free length
33.0 mm (1.30 in)
Spring quantity
Clutch housing thrust clearance
Clutch housing radial clearance
5
0.10 ~ 0.35 mm (0.0039 ~ 0.0138 in)
0.022 ~ 0.051 mm (0.0009 ~ 0.0020 in)
31.0 mm
(1.22 in)
•••
•••
•••
2-4
ENGINE SPECIFICATIONS
Item
Transmission
Transmission type
Primary reduction system
Primary reduction ratio
Secondary reduction system
Secondary reduction ratio
Operation
Gear ratios
1st gear
2nd gear
3rd gear
4th gear
5th gear
6th gear
Max. main axle runout
Standard
Air filter type
Air filter oil glade
Carburetors
Model (manufacturer)
Throttle cable free play (at the flange
of the throttle grip)
ID mark
Main jet
Main air jet
Jet needle-clip position
Needle jet
Cutaway
Pilot jet
Bypass
Pilot outlet
Pilot screw turns out
Valve seat size
Starter jet
Float height
Limit
Constant mesh, 6-speed
Spur gear
65 / 18 (3.611)
Chain drive
47 / 14 (3.357) (YZ85 for EUR, CAN)
48 / 14 (3.428) (YZ85 for AUS, NZL)
52 / 14 (3.714) (YZ85LW)
Left-foot operation
•••
•••
•••
•••
•••
•••
•••
•••
27 / 11 (2.454)
32 / 17 (1.882)
26 / 17 (1.529)
22 / 17 (1.294)
26 / 23 (1.130)
25 / 25 (1.000)
•••
•••
•••
•••
•••
•••
0.01 mm
(0.004 in)
0.01 mm
(0.004 in)
Cam drum / Guide bar
•••
Wet element
Form air filter oil or 2-stroke motor oil
•••
0.05 mm
(0.002 in)
•••
•••
PWK28 (KEIHIN)
3.0 ~ 5.0 mm (0.118 ~ 0.197 in)
•••
•••
5PA1 00
#138
#60
NBKF-2
ø2.6
3.0
#45
ø0.8
ø0.4
2
ø2.6
#62
18 ~ 20 mm (0.71 ~ 0.79 in)
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
Max. drive axle runout
Shifting mechanism
Shift mechanism type
Guide bar bending limit
SPEC
2-5
ENGINE SPECIFICATIONS
Item
Standard
SPEC
Limit
Reed valve
Thickness “T”
Valve stopper height
Valve bending limit
0.42 mm (0.017 in)
7.4 ~ 7.8 mm (0.291 ~ 0.307 in)
2-6
•••
•••
0.2 mm
(0.008 in)
CHASSIS SPECIFICATIONS
SPEC
CHASSIS SPECIFICATIONS
Item
Frame
Frame type
Material
Caster angle
Trail
Front wheel
Wheel type
Rim
Size
Material
Wheel travel
Wheel runout
Radial wheel runout limit
Lateral wheel runout limit
Rear wheel
Wheel type
Rim
Size
Standard
Limit
Semi double cradle
Steel
26.3° (YZ85)
26.9° (YZ85LW)
88.0 mm (3.46 in) (YZ85)
105.5 mm (4.15 in) (YZ85LW)
•••
•••
•••
•••
•••
•••
Spoke wheel
•••
17 × 1.40 (YZ85)
19 × 1.40 (YZ85LW)
Aluminum
275 mm (10.83 in)
•••
•••
•••
•••
•••
2.0 mm
(0.08 in)
2.0 mm
(0.08 in)
•••
Spoke wheel
•••
14 × 1.60 (YZ85)
16 × 1.85 (YZ85LW)
Aluminum
282 mm (11.10 in) (YZ85)
287 mm (11.30 in) (YZ85LW)
•••
•••
•••
•••
•••
Wheel runout
Radial wheel runout limit
•••
Lateral wheel runout limit
•••
2.0 mm
(0.08 in)
2.0 mm
(0.08 in)
Material
Wheel travel
2-7
CHASSIS SPECIFICATIONS
Item
Front tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
Rear tire
Tire type
Size
Model (manufacturer)
Tire pressure (cold)
Front brakes
Brake type
Operation
Recommended fluid
Brake lever free play
Brake discs
Diameter × thickness
Thickness limit
Standard
•••
•••
•••
•••
•••
•••
•••
Tube
90 / 100-14 49M (YZ85)
90 / 100-16 52M (YZ85LW)
D756 (DUNLOP)
100 kPa (1.0 kgf / cm2, 1.0 bar, 14.2 psi)
•••
•••
•••
•••
•••
Single disc brake
Right hand operation
DOT 4
0 mm (0.00 in)
•••
•••
•••
•••
220 × 3 mm (8.66 × 0.12 in)
•••
11.0 mm (0.433 in)
22.2 mm (0.874 in) × 2
•••
2.5 mm
(0.10 in)
0.15 mm
(0.006 in)
0.8 mm
(0.03 in)
•••
•••
Single disc brake
Right foot operation
4.0 ~ 10.0 mm (0.16 ~ 0.39 in)
•••
•••
•••
DOT 4
0 mm (0.00 in)
•••
•••
190 × 3 mm (7.48 × 0.12 in)
•••
•••
2.5 mm
(0.10 in)
0.15 mm
(0.006 in)
1.0 mm
(0.04 in)
•••
•••
•••
Brake pad lining thickness
4.0 mm (0.16 in)
Deflection limit
•••
Brake pad lining thickness
3.7 mm (0.15 in)
Master cylinder inside diameter
Caliper cylinder inside diameter
Limit
Tube
70 / 100-17 40M (YZ85)
70 / 100-19 42M (YZ85LW)
D739FA (DUNLOP) (YZ85 for EUR, CAN)
D756F (DUNLOP)( YZ85 for AUS, NZL)
D756F (DUNLOP) (YZ85LW)
100 kPa (1.0 kgf / cm2, 1.0 bar, 14.2 psi)
Deflection limit
Master cylinder inside diameter
Caliper cylinder inside diameter
Rear brake
Brake type
Operation
Brake pedal position (vertical height
above footrest top)
Recommended fluid
Brake pedal freeplay
Brake discs
Diameter × thickness
Thickness limit
SPEC
12.7 mm (0.500 in)
27.0 mm (1.063 in)
2-8
CHASSIS SPECIFICATIONS
Item
Steering
Steering bearing type
Lock to lock angle (left)
Lock to lock angle (right)
Front suspension
Suspension type
Front fork type
Front fork travel
Spring
Free length
Installed length
Spring rate, STD (K1)
Spring stroke (K1)
Inner tube outer diameter
Inner tube bending limit
Optional spring available
Fork oil
Recommended oil
Quantity (each front fork leg)
Level (from the top of the outer tube,
with the outer tube fully compressed,
and without the fork spring)
Rebound damping adjusting positions
Minimum*
Standard*
Maximum*
Compression damping adjusting
positions
Minimum*
Standard*
Maximum*
*from the fully turned-in position
SPEC
Standard
Limit
Taper roller bearing
45°
45°
•••
•••
•••
Telescopic fork
Coil spring / oil damper
275 mm (10.83 in)
•••
•••
•••
430 mm (16.93 in)
425 mm
(16.73 in)
•••
•••
430 mm (16.93 in)
2.84 N / mm (0.29 kg / mm, 16.2 lb / in)
(YZ85)
2.94 N / mm (0.30 kg / mm, 16.8 lb / in)
(YZ85LW)
0 ~ 275 mm (0 ~ 10.82 in)
36 mm (1.42 in)
•••
•••
Yes
•••
•••
0.2 mm
(0.008 in)
•••
Suspension oil “01”
318 cm3 (11.2 Imp oz, 10.8 US oz)
90 mm (3.54 in)
•••
•••
•••
20
7
1
•••
•••
•••
20
10 (YZ85)
9 (YZ85LW)
1
•••
•••
•••
•••
2-9
CHASSIS SPECIFICATIONS
Item
Rear suspension
Suspension type
Rear shock absorber assembly type
Rear shock absorber assembly travel
Spring
Free length
Installed length
Spring rate, STD (K1)
Standard
Drive chain slack
Maximum 15-link section
Limit
Swingarm (link type monocross
suspension)
Coil spring / gas, oil damper
102 mm (4.02 in)
•••
220 mm (8.66 in)
215 mm (8.46 in) (YZ85)
212 mm (8.35 in) (YZ85LW for EUR)
207 mm (8.15 in) (YZ85LW for AUS, NZL)
49.0 N / mm (5.00 kg / mm, 280.0 lb / in)
(YZ85)
47.0 N / mm (4.80 kg / mm, 268.2 lb / in)
(YZ85LW for EUR)
51.0 N / mm (5.20 kg / mm, 291.1 lb / in)
(YZ85LW for AUS, NZL)
102 mm (4.02 in)
Yes
1,000 kPa (10.0 kg / cm2, 142 psi)
•••
•••
•••
•••
•••
Spring stroke, STD (K1)
Optional spring available
Standard spring preload gas/air
pressure
Rebound damping adjusting positions
Minimum*
20
Standard*
6 (YZ85)
12 (YZ85LW for EUR)
7 (YZ85LW for AUS, NZL)
Maximum*
1
Compression damping adjusting
positions
Minimum*
20
Standard*
9 (YZ85)
12 (YZ85LW for EUR)
7 (YZ85LW for AUS, NZL)
Maximum*
1
*from the fully turned-in position
Swingarm
Free play (at the end of the swingarm)
Radial
•••
Drive chain
Model (manufacturer)
Link quantity
SPEC
DID428DS (DAIDO)
117 links + joint (YZ85)
123 links + joint (YZ85LW)
35.0 ~ 45.0 mm (1.38 ~ 1.77 in)
•••
2-10
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
•••
1.0 mm
(0.04 in)
•••
•••
•••
•••
194.3 mm
(7.65 in)
ELECTRICAL SPECIFICATIONS
SPEC
ELECTRICAL SPECIFICATIONS
Item
Ignition system
Ignition system type
Ignition timing (B.T.D.C.)
Advancer type
C.D.I.
Magneto model (manufacturer)
Pickup coil resistance (color)
Charging coil 1 resistance (color)
Charging coil 2 resistance (color)
C.D.I. unit model (manufacturer)
Ignition coils
Model (manufacturer)
Minimum ignition spark gap
Primary coil resistance
Secondary coil resistance
Spark plug cap
Material
Resistance
Standard
Limit
CDI
0.9 mm (0.035 in)
Digital
•••
•••
•••
5PA-01 (YAMAHA)
248 ~ 372 Ω at 20 °C (68 °F) (W / L-W / R)
720 ~ 1,080 Ω at 20 °C (68 °F) (G / W-B / R)
44 ~ 66 Ω at 20 °C (68 °F) (B-G / L)
5PA-01 (YAMAHA)
•••
•••
•••
•••
•••
2JN (YAMAHA)
6 mm (0.24 in)
0.18 ~ 0.28 Ω at 20 °C (68 °F)
6.3 ~ 9.5 kΩ at 20 °C (68 °F)
•••
•••
•••
•••
Resin
5 kΩ
•••
•••
2-11
CONVERSION TABLE /
GENERAL TIGHTENING TORQUE SPECIFICATIONS
SPEC
EAS00028
EAS00030
CONVERSION TABLE
GENERAL TIGHTENING TORQUE
SPECIFICATIONS
All specification data in this manual are listed
in SI and METRIC UNITS.
Use this table to convert METRIC unit data to
IMPERIAL unit data.
Ex.
METRIC
MULTIPLIER
This chart specifies tightening torques for
standard fasteners with a standard ISO thread
pitch. Tightening torque specifications for special components or assemblies are provided
for each chapter of this manual. To avoid
warpage, tighten multi-fastener assemblies in
a crisscross pattern and progressive stages
until the specified tightening torque is reached.
Unless otherwise specified, tightening torque
specifications require clean, dry threads. Components should be at room temperature.
IMPERIAL
** mm
×
0.03937
=
** in
2 mm
×
0.03937
=
0.08 in
CONVERSION TABLE
METRIC TO IMPERIAL
Metric unit
m•kg
Tightening m•kg
torque
cm•kg
cm•kg
Multiplier
Imperial unit
7.233
86.794
0.0723
0.8679
ft•lb
in•lb
ft•lb
in•lb
Weight
kg
g
2.205
0.03527
lb
oz
Speed
km/hr
0.6214
mph
Distance
km
m
m
cm
mm
0.6214
3.281
1.094
0.3937
0.03937
mi
ft
yd
in
in
Volume /
Capacity
cc (cm3)
cc (cm3)
lt (liter)
lt (liter)
0.03527
0.06102
0.8799
0.2199
oz (IMP liq.)
cu•in
qt (IMP liq.)
gal (IMP liq.)
Misc.
kg / mm
kg / cm2
Centigrade
(°C)
55.997
14.2234
9 / 5 + 32
lb / in
psi (lb / in2)
Fahrenheit
(°F)
A: Distance between flats
B: Outside thread diameter
2-12
A
(nut)
B
(bolt)
10 mm
General tightening
torques
Nm
m•kg
ft•lb
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
TIGHTENING TORQUES
SPEC
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Item
Spark plug
Cylinder head
Cylinder
Water pump impeller
Coolant drain bolt
Water pump housing
Radiator hose clamp
Air filter element
Carburetor joint
Reed valve
Exhaust pipe
Exhaust pipe stay
Silencer
Fiber (silencer)
Crankcase
Left crankcase cover
Right crankcase cover
Right crankcase cover
Clutch cover
Transmission oil drain bolt
Kickstarter crank
Primary drive gear
Clutch boss
Clutch spring
Drive sprocket
Crankcase bearing stopper
Crankcase oil seal holder
Shift pedal
Stator assembly
Rotor
Fastener
Thread
size
Q’ty
—
Nut
Stud bolt
Nut
Studbolt
—
Bolt
Bolt
Clamp
Bolt
Bolt
Screw
Bolt
Bolt
Bolt
Bolt
Screw
Screw
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
Nut
Bolt
Nut
Screw
Bolt
Bolt
Screw
Nut
M14
M8
M8
M8
M8
M8
M6
M6
M6
M6
M6
M3
M6
M6
M6
M6
M6
M6
M6
M6
M6
M8
M6
M12
M12
M5
M16
M6
M8
M6
M6
M10
1
4
4
4
4
1
1
2
4
1
4
4
2
1
1
2
11
4
4
1
6
1
1
1
1
5
1
2
1
1
2
1
2-13
Tightening torque
Nm
20
30
13
28
13
14
10
10
1
2
8
1
12
12
12
12
8
5
10
10
10
10
10
79
70
6
60
8
20
10
8
33
m•kg
2.0
3.0
1.3
2.8
1.3
1.4
1.0
1.0
0.1
0.2
0.8
0.1
1.2
1.2
1.2
1.2
0.8
0.5
1.0
1.0
1.0
1.0
1.0
7.9
7.0
0.6
6.0
0.8
2.0
1.0
0.8
3.3
ft•lb
14
22
9.4
20
9.4
10
7.2
7.2
0.7
1.4
5.8
0.7
8.7
8.7
8.7
8.7
5.8
3.6
7.2
7.2
7.2
7.2
7.2
57
51
4.3
43
5.8
14
7.2
5.8
24
Remarks
TIGHTENING TORQUES
SPEC
CHASSIS TIGHTENING TORQUES
Tightening torque
Item
Fastener
Thread
size
Q’ty
Upper bracket and outer tube
Lower bracket and outer tube
Upper bracket and steering stem
Handlebar holder and upper bracket
Steering stem and steering ring nut
Front fork and cap bolt
Front fork and base valve
Cap bolt and damper rod
Front fork bleed screw and cap bolt
Front fork and front fork protector
Front fork and brake hose guide
Front fork and brake hose holder
Throttle grip cap
Throttle cable cap
Front brake master cylinder
Brake lever mounting bolt
Brake lever mounting nut
Brake lever position locknut
Clutch lever holder
Front brake master cylinder cap
Front brake hose union bolt
Front fork and brake caliper bracket
Brake caliper support bolt
Front brake caliper and bleed screw
Rear brake caliper and brake caliper
bracket
Rear brake caliper and pad pin
Rear brake caliper and bleed screw
Front wheel axle and axle nut
Front brake disc
Rear brake disc
Rear brake master cylinder
Rear brake reservoir tank
Rear brake hose union bolt
Rear wheel axle and axle nut
Nipple (spoke)
Rear wheel sprocket
Rear brake caliper protector
Drive chain puller adjust locknut
Engine and frame (front)
Engine and frame (lower)
Pivot shaft and nut
Relay arm and frame
Bolt
Bolt
Nut
Bolt
Nut
Bolt
—
Nut
Bolt
Bolt
Screw
Bolt
Screw
Screw
Bolt
Bolt
Nut
Nut
Bolt
Screw
Bolt
Bolt
Bolt
Bolt
Bolt
M8
M8
M22
M8
M25
M40
M22
M10
M5
M6
M5
M6
M5
M4
M6
M6
M6
M6
M5
M4
M10
M8
M8
M7
M8
2
4
1
4
1
2
2
2
2
6
1
1
2
2
2
1
1
1
2
2
2
2
1
1
2
Nm m•kg ft•lb
22
2.2
16
20
2.0
14
125 12.5
90
27
2.7
20
See NOTE.
28
2.8
20
55
5.5
40
15
1.5
11
1
0.1
0.7
7
0.7
5.1
4
0.4
2.9
10
1.0
7.2
4
0.4
2.9
1
0.1
0.7
9
0.9
6.5
6
0.6
4.3
6
0.6
4.3
5
0.5
3.6
4
0.4
2.9
2
0.2
1.4
26
2.6
19
30
3.0
22
23
2.3
17
6
0.6
4.3
23
2.3
17
Bolt
Screw
Nut
Bolt
Bolt
Bolt
Bolt
Bolt
Nut
—
Nut
Bolt
Nut
Nut
Nut
Nut
Nut
M10
M8
M12
M6
M6
M6
M6
M10
M14
—
M8
M6
M8
M10
M10
M12
M10
2
1
1
3
4
2
1
2
1
64
4
1
2
1
1
1
1
18
6
70
12
12
10
10
26
90
3
42
10
16
69
69
63
54
2-14
1.8
0.6
7.0
1.2
1.2
1.0
1.0
2.6
9.0
0.3
4.2
1.0
1.6
6.9
6.9
6.3
5.4
13
4.3
51
8.7
8.7
7.2
7.2
19
65
2.2
30
7.2
12
50
50
46
39
Remarks
TIGHTENING TORQUES
Item
Fastener
Thread
size
Q’ty
Relay arm and connecting rod
Connecting rod and swingarm
Rear shock absorber and frame
Rear shock absorber and relay arm
Rear frame (upper)
Rear frame (lower)
Swingarm and brake hose holder
Drive chain support
Drive chain support cover
Drive chain guide and swingarm
Fuel tank
Fuel cock
Fuel tank bracket and fuel tank
Seat set bracket and fuel tank
Air scoop
Front fender
Rear fender
Flap guard
Side cover
Seat
Number plate
Ignition coil
Nut
Nut
Nut
Bolt
Bolt
Bolt
Screw
Nut
Nut
Bolt
Bolt
Screw
Bolt
Screw
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
Bolt
M12
M12
M10
M10
M8
M8
M5
M8
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
M6
1
1
1
1
1
2
4
2
1
2
2
2
4
1
3
4
4
2
2
2
1
2
SPEC
Tightening torque
Nm
53
53
36
36
26
16
1
16
7
10
7
4
7
7
4
7
7
7
7
7
7
7
m•kg
5.3
5.3
3.6
3.6
2.6
1.6
0.1
1.6
0.7
1.0
0.7
0.4
0.7
0.7
0.4
0.7
0.7
0.7
0.7
0.7
0.7
0.7
ft•lb
38
38
26
26
19
12
0.7
12
5.1
7.2
5.1
2.9
5.1
5.1
2.9
5.1
5.1
5.1
5.1
5.1
5.1
5.1
Remarks
NOTE:
1. First, tighten the steering nut approximately 38 Nm (3.8 m•kg, 27 ft•lb) by using the steering nut
wrench, then loosen the steering nut one turn.
2. Retighten the steering nut 4 Nm (0.4 m•kg, 2.9 ft•lb).
2-15
LUBRICATION POINTS AND LUBRICANT TYPES
SPEC
EAS00031
LUBRICATION POINTS AND LUBRICANT TYPES
ENGINE
Lubrication point
Lubricant
Oil seal lips
O-rings
Bearings
Crankshaft pins
Piston surfaces
Piston pins
Water pump impeller shaft
Kick shaft
Kick shaft stopper
Kick idle gear inner surface
Primary driven gear
Push rod and push lever (upper)
Push lever (lower)
Transmission wheel gears inner surface
Transmission pinion gears
Shift forks and shift fork guide bers
Shift shaft
Shift dram
Crankcase mating surface
Yamaha bond
No.1215
EAS00032
CHASSIS
Lubrication point
Steeling bearings and bearing race (upper and lower)
Brake lever pivoting point and metal-to-metal moving parts
Clutch lever pivoting point and metal-to-metal moving parts
Throttle tube guide inner surface
Rear brake pedal
Swing arm bearing and bushing inner surface
Swingarm oil seal , dust seal and bushing
Pivot shaft
Reray arm oil seal, bearing, bushing, collar and bolt surface
Connecting rod oil seal, bearing, bushing and bolt surface
Front wheel oil seal (left and right)
Front wheel axle shaft
Front wheel collar
Rear wheel oil seal (left and right)
Rear wheel axle shaft
Rear wheel collar
2-16
Lubricant
CABLE ROUTING
EAS00035
CABLE ROUTING
Radiator breather hose
Clutch cable
Spark plug lead
Radiator hose
Brake hose holder
Cable guide
Brake hose
Throttle cable
Fuel tank breather hose
Engine stop switch lead
Ground lead
Ignition coil
Primary coil lead (orange color)
Damper
Clamp
Air vent hoses
CDI magneto lead
Carburetor overflow hose
Transmission oil breather hose
2-17
SPEC
CABLE ROUTING
Pass the fuel tank breather hose between the handlebar and tension bar, then insert its end into the
hole of the steering stem.
Fasten the ground lead together with the ignition
coil.
Insert the primary coil lead (orange color) in the
ignition coil.
Pass the transmission oil breather hose through
the wire holder located at the right side of the vehicle. Route the air vent hose and carburetor overflow hose from the left side of the vehicle.
Do not flatten out the radiator breather hose.
2-18
SPEC
Securely install the spark plug cap to the spark
plug. Route the spark plug lead by the inner side of
the vehicle than the radiator hose and throttle
cable.
Clamp the brake hose with the brake hose holder.
Fit the brake hose into the guides of the protector.
40 mm (1.57 in)
CABLE ROUTING
SPEC
Route the clutch cable in front of the throttle cable.
Pass the transmission oil breather hose through
the hose guide.
Clamp it between these parts.
Clamp it using the white PVC tape as a guide.
Pass the sub-wire harness on the left side of the
CDI unit.
Cut the tip of the clamp near the position of chain
double-dashed line.
Tighten the sub-wire harness to the CDI unit. Position the lock section under the CDI unit.
Route the reservoir tank hose by the outer side of
the vehicle than the brake hose.
Pass the brake fluid reservoir hose through the
cable guides.
Sub-wire harness
CDI unit
Ignition coil
Clutch cable
Cable guide
Transmission oil breather hose
CDI unit band
Clamp
Brake hose
Brake hose holder
Brake fluid reservoir hose
Reservoir tank
Brake master cylinder
2-19
CABLE ROUTING
Install the clip pointing the clamp section to the
rear side.
Touch the brake pipe to the stopper.
When installing the brake hose, install it so that the
bend section of the brake hose attachment is
pointed in the direction as shown in the illustration.
2-20
SPEC
CABLE ROUTING
SPEC
This is the number plate attaching section. The
clutch cable and throttle cable shall be routed
crossways above the number plate attaching section. At this time, make sure to route the clutch
cable to the front side of the throttle cable.
Route the clutch cable in front of the throttle cable.
Fasten the engine stop switch lead to the handlebar with the plastic band.
Pass the brake hose in front of the number plate.
Vertical direction
40° ± 10°
Master cylinder
Throttle cable
Clutch cable
Clamp
Engine stop switch lead
Brake hose
Cable guide
2-21
CHK
ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS . . . . . . 3-1
SEAT, SIDE COVERS AND FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . 3-3
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE PILOT AIR SCREW . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . .
ADJUSTING THE THROTTLE CABLE FREE PLAY . . . . . . . . . . . . .
CHECKING THE SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE TRANSMISSION OIL . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE CLUTCH CABLE FREE PLAY . . . . . . . . . . . . . . .
CLEANING THE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CARBURETOR JOINT . . . . . . . . . . . . . . . . . . . . .
CHECKING THE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKCASE BREATHER HOSE. . . . . . . . . . . . .
CHECKING THE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . .
CHANGING THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5
3-5
3-5
3-6
3-7
3-8
3-9
3-10
3-10
3-12
3-12
3-13
3-13
3-14
3-15
3-15
CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE PADS . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE HOSES . . . . . . . . . .
BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . .
ADJUSTING THE SHIFT PEDAL . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE DRIVE CHAIN SLACK . . . . . . . . . . . . . . . . . . . . .
LUBRICATING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND ADJUSTING THE STEERING HEAD . . . . . . . . . .
CHECKING THE FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . .
CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND TIGHTENING THE SPOKES . . . . . . . . . . . . . . . .
LUBRICATING THE LEVERS AND PEDALS . . . . . . . . . . . . . . . . . .
LUBRICATING THE REAR SUSPENSION . . . . . . . . . . . . . . . . . . . .
3-17
3-17
3-18
3-19
3-20
3-20
3-21
3-22
3-22
3-24
3-24
3-25
3-26
3-28
3-30
3-32
3-32
3-32
CHK
ADJ
INTRODUCTION / PERIODIC MAINTENANCE
AND LUBRICATION INTERVALS
3
EAS00036
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a
longer service life and reduce the need for costly overhaul work. This information applies to vehicles
already in service as well as to new vehicles that are being prepared for sale. All service technicians
should be familiar with this entire chapter.
EAS00037
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
NOTE:
• From the seventh race, repeat the maintenance intervals starting from “Every race”.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
NO.
1
*
ROUTINE
After
break-in
Every
race
• Check piston for carbon deposits and cracks or damage.
• Clean.
√
√
√
√
ITEM
Piston
Every
third race
• Replace.
2
3
4
*
Piston rings
*
Piston pin and small
end bearing
*
Cylinder head
• Check piston ring end gap and rings for damage.
Every
fifth race
As
required
√
√
√
• Replace.
√
√
• Check piston pin and small end bearing for damage.
√
• Replace.
• Check cylinder head for carbon deposits.
• Clean.
√
√
• Check cylinder head gasket for damage.
• Tighten cylinder head bolts if necessary.
√
√
√
• Replace cylinder head gasket.
5
*
Cylinder
• Check cylinder for score marks or wear.
• Clean.
√
√
√
• Replace.
6
*
Clutch
• Check clutch housing, friction plates, clutch plates and
clutch springs for wear or damage.
• Adjust.
√
√
√
• Replace.
√
• Change the transmission oil.
7
*
Transmission
• Check transmission for damage.
√
• Replace bearings.
√
• Check all parts for wear and damage.
• Replace if necessary.
√
8
*
Shift forks, guide
bars, shift cam
9
*
Rotor nut
(flywheel magneto)
• Tighten.
10
*
Kickstarter system
• Check idle gear for damage.
• Replace if necessary.
11
*
Exhaust system
12
13
14
*
*
Crankshaft
√
√
√
√
• Check exhaust pipe and muffler for carbon deposits.
√
√
• Clean.
√
• Check crankshaft for carbon deposits and damage.
√
√
• Clean.
√
√
• Check carburetor settings and for obstructions.
√
√
• Adjust and clean.
√
√
Spark plug
• Check condition.
• Clean and regap.
√
√
Drive chain
• Check chain slack, alignment and condition.
• Adjust and thoroughly lubricate chain with Yamaha
chain and cable lube or equivalent.
Carburetor
√
• Replace.
15
√
√
√
• Replace.
3-1
CHK
ADJ
PERIODIC MAINTENANCE
AND LUBRICATION INTERVALS
NO.
ITEM
ROUTINE
• Check coolant level and for leakage.
16
*
Cooling system
After
break-in
Every
race
√
√
√
Every 2 years
• Check all chassis fitting and fasteners.
• Correct or tighten if necessary.
√
√
• Clean.
√
√
√
*
Chassis fasteners
18
*
Air filter element
19
*
Frame
• Clean and check for damage.
√
20
*
Fuel line
• Clean and check for leakage.
√
Brakes
•
•
•
•
•
√
• Replace.
Adjust lever position and pedal height.
Lubricate pivot points.
Check brake disk surface.
Check fluid level and for leakage.
Tighten brake disk bolts, caliper bolts, master cylinder
bolts and union bolts.
√
√
√
√
• Replace brake pads.
• Replace brake fluid.
22
*
Front fork
√
Every year
• Check operation and for oil leakage.
• Adjust if necessary.
• Clean dust seal and lubricate with lithium-soap-based
grease.
√
• Replace fork oil.
√
√
√
√
• Replace oil seals.
• Check operation and adjust.
• Tighten if necessary.
23
24
25
26
*
*
*
*
Shock absorber
assembly
Drive chain roller and
support guide
Rear suspension
Steering head
√
√
*
Tires and wheels
• Check for wear or damage.
• Replace if necessary.
√
• Check operation and tighten if necessary.
√
√
• Lubricate with molybdenum disulfide grease.
√
√
• Check operation, free play, and tighten if necessary.
√
√
√
• Clean and lubricate with lithium-soap-based grease.
√
• Check tire air pressure, wheel runout, spokes for looseness, and tires for wear.
√
√
• Tighten sprocket bolts if necessary.
√
√
• Check wheel bearings for looseness.
√
• Lubricate wheel bearings with lithium-soap-based
grease.
√
√
• Replace wheel bearings.
28
29
*
*
√
(After
washing
the vehicle
or riding in
the rain)
√
• Lubricate with molybdenum disulfide grease.
• Replace bearings.
27
As
required
√
• Check radiator cap spring operation.
17
*
Every
fifth race
√
• Check hoses for cracks or damage.
• Change coolant.
21
Every
third race
Moving parts and
cables
• Lubricate.
√
√
Throttle grip housing
and cable
• Check operation and free play.
• Adjust the throttle cable free play if necessary.
• Lubricate the throttle grip housing and cable.
√
√
NOTE:
• Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-2
SEAT, SIDE COVERS AND FUEL TANK
CHK
ADJ
EAS00042
SEAT, SIDE COVERS AND FUEL TANK
7 Nm (0.7 m•kg, 5.1 ft•lb)
7 Nm (0.7 m•kg, 5.1 ft•lb)
7 Nm (0.7 m•kg, 5.1 ft•lb)
7 Nm (0.7 m•kg, 5.1 ft•lb)
4 Nm (0.4 m•kg, 2.9 ft•lb)
4 Nm (0.4 m•kg, 2.9 ft•lb)
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job / Part
Removing the seat, side covers and
fuel tank
Seat
Side covers (left and right)
Air scoop
Fuel pipe
Fuel cock
O-ring
Grommet
Collar
Hose
Joint pipe
Hose
Fuel tank cap
Fuel tank
Q’ty
3-3
1
2
1
1
1
1
2
2
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Disconnect.
Disconnect.
Disconnect.
SEAT, SIDE COVERS AND FUEL TANK
CHK
ADJ
7 Nm (0.7 m•kg, 5.1 ft•lb)
7 Nm (0.7 m•kg, 5.1 ft•lb)
7 Nm (0.7 m•kg, 5.1 ft•lb)
7 Nm (0.7 m•kg, 5.1 ft•lb)
4 Nm (0.4 m•kg, 2.9 ft•lb)
4 Nm (0.4 m•kg, 2.9 ft•lb)
Order
14
Job / Part
Number plate
Q’ty
1
Remarks
For installation, reverse the removal
procedure.
3-4
ADJUSTING THE PILOT AIR SCREW /
ADJUSTING THE ENGINE IDLING SPEED
CHK
ADJ
ENGINE
ADJUSTING THE PILOT AIR SCREW
1. Adjust:
• pilot air screw
NOTE:
To optimize the fuel flow at a smaller throttle
opening, each vehicles pilot air screw has
been individually set at the factory. Before
adjusting the pilot air screw, turn it in fully and
count the number of turns. Record this number
as the factory-set number of turns out.
a. Turn in the pilot air screw until it is lightly
seated.
b. Turn out the pilot air screw by the specified
number of turns.
Pilot air screw setting
2 turns out
EAS00054
ADJUSTING THE ENGINE IDLING SPEED
NOTE:
Prior to adjusting the engine idling speed, the
air filter element should be clean, and the
engine should have adequate compression.
1. Start the engine and let it warm up for several minutes.
2. Adjust:
• engine idling speed
a. Turn the throttle stop screw
in direction
or
until the engine runs at the lowest
possible speed.
Direction
Direction
Engine idling speed is
increased.
Engine idling speed is
decreased.
3. Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY”.
Throttle cable free play
(at the flange of the throttle grip)
3.0 ~ 5.0 mm (0.12 ~ 0.20 in)
3-5
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHK
ADJ
EAS00058
ADJUSTING THE THROTTLE CABLE FREE
PLAY
NOTE:
Prior to adjusting the throttle cable free play,
the engine idling speed should be adjusted.
1. Check:
• throttle cable free play
Out of specification → Adjust.
Throttle cable free play
(at the flange of the throttle grip)
3.0 ~ 5.0 mm (0.12 ~ 0.20 in)
2. Adjust:
• throttle cable free play
Handlebar side
a. Loosen the locknut .
b. Turn the adjusting nut
in direction
or
until the specified throttle cable free play
is obtained.
Direction
Direction
Throttle cable free play is
increased.
Throttle cable free play is
decreased.
c. Tighten the locknut.
WARNING
After adjusting the throttle cable free play,
start the engine and turn the handlebar to
the right or left to ensure that this does not
cause the engine idling speed to change.
3-6
CHECKING THE SPARK PLUG
CHK
ADJ
EAS00060
CHECKING THE SPARK PLUG
1. Disconnect:
• spark plug cap
2. Remove:
• spark plug
CAUTION:
Before removing the spark plug, blow away
any dirt accumulated in the spark plug well
with compressed air to prevent it from falling into the cylinder.
3. Check:
• spark plug type
Incorrect → Change.
Spark plug type (manufacturer)
BR10EG (NGK)
4. Check:
• electrode
Damage / wear → Replace the spark plug.
• insulator
Abnormal color → Replace the spark plug.
Normal color is medium-to-light tan.
5. Clean:
• spark plug
(with a spark plug cleaner or wire brush)
6. Measure:
• spark plug gap
(with a wire thickness gauge)
Out of specification → Regap.
Spark plug gap
0.5 ~ 0.6 mm (0.0197 ~ 0.0236 in)
7. Install:
• spark plug
Spark plug
20 Nm (2.0 m•kg, 14 ft•lb)
NOTE:
Before installing the spark plug, clean the
spark plug and gasket surface.
8. Connect:
• spark plug cap
3-7
CHECKING THE IGNITION TIMING
CHK
ADJ
EAS00062
CHECKING THE IGNITION TIMING
1. Remove:
• air scoop
• spark plug
• left crankcase cover
2. Attach:
• dial gauge
• dial gauge stand
Dial gauge and stand
90890-01252, YU-3097
Stand
YU-1256
3. Adjust:
• top dead center (TDC)
a. Rotate the rotor
until the piston reaches
top dead center (TDC). When this happens,
the needle on the dial gauge will stop and
reverse directions even though the rotor is
being turned in the same direction.
b. Set the dial gauge to zero at TDC.
c. From TDC, rotate the rotor clockwise until
the dial gauge indicates that the piston in at
a specified distance from TDC.
Ignition timing (B.T.D.C.)
0.9 mm (0.035 in)
4. Check:
• ignition timing
Punch mark
on rotor should be aligned with
punch mark
on stator.
Not aligned → Adjust.
5. Adjust:
• ignition timing
a. Loosen the screws (stator) .
b. Align the punch mark on the rotor with
punch mark on stator
by moving the stator.
c. Tighten the screws (stator).
3-8
CHECKING THE IGNITION TIMING /
CHANGING THE TRANSMISSION OIL
CHK
ADJ
Screw (stator)
8 Nm (0.8 m•kg, 5.8 ft•lb)
6. Check:
• ignition timing
Re-check the ignition timing.
EAS00074
CHANGING THE TRANSMISSION OIL
1. Start the engine, warm it up for several minutes, and then turn it off.
2. Place the vehicle on a level place and hold
it on upright position by placing the suitable
stand under the engine.
3. Place a container under the transmission oil
drain bolt.
4. Remove:
• transmission oil filler cap
• transmission drain bolt
5. Drain:
• transmission oil
(completely from the crankcase)
6. Install:
• transmission oil drain bolt gasket
• transmission oil drain bolt
(along with the new gasket)
10 Nm (1.0 m•kg, 7.2 ft•lb)
7. Fill:
• transmission oil
(with the specified amount of the recommended transmission oil)
Quantity
Total amount
0.5 L (0.44 Imp qt, 0.53 US qt)
8. Install:
• transmission oil filler cap
9. Start the engine, warm it up for several minutes, and then turn it off.
10.Check:
• oil leakage
3-9
ADJUSTING THE CLUTCH CABLE FREE PLAY /
CLEANING THE AIR FILTER ELEMENT
CHK
ADJ
EAS00081
ADJUSTING THE CLUTCH CABLE FREE
PLAY
1. Check:
• clutch cable free play
Out of specification → Adjust.
Clutch cable free play
(at the end of the clutch lever)
10.0 ~ 15.0 mm (0.39 ~ 0.59 in)
2. Adjust:
• clutch cable free play
a. Loosen the locknut .
b. Turn the adjusting nut
in direction
or
until the specified clutch cable free play
is obtained.
Direction
Direction
Clutch cable free play is
increased.
Clutch cable free play is
decreased.
c. Tighten the locknut.
EAS00090
CLEANING THE AIR FILTER ELEMENT
1. Remove:
• seat
• side covers (left and right)
Refer to “SEAT, SIDE COVERS AND FUEL
TANK”.
2. Remove:
• air filter case cover
a. Set the air filter case cover as shown, and
install it to the seat rail of the rear frame
while rotating air filter case cover in the
direction of the arrow.
b. Using a conventional screwdriver, hold up
the front of the air filter case cover.
Then engage the groove
in the cover
over the air filter case edge .
3-10
CLEANING THE AIR FILTER ELEMENT
•
•
•
•
CHK
ADJ
fitting bolt
washer
air filter guide
air filter element
CAUTION:
Never operate the engine without the air filter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the carburetor tuning, leading to poor
engine performance and possible overheating.
3. Clean:
• air filter element
(with solvent)
NOTE:
After cleaning, remove the remaining solvent
by squeezing the element.
CAUTION:
• Do not twist the element when squeezing
the element.
• Leaving too much of solvent in the element may result in poor starting.
4. Check:
• air filter element
Damage → Replace.
5. Apply:
• foam-air-filter oil or equivalent oil
To the element.
NOTE:
Squeeze out the excess oil. Element should be
wet but not dripping.
6. Install:
• air filter guide
• air filter element
3-11
CLEANING THE AIR FILTER ELEMENT / CHECKING
THE CARBURETOR JOINT / CHECKING THE HOSES
CHK
ADJ
7. Apply:
• lithium-soap-base grease
On the matching surface
ment.
on air filter ele-
8. Install:
• air filter element
• washer
2 Nm (0.2 m•kg, 1.4 ft•lb)
• fitting bolt
NOTE:
• Install the air filter element with its projection
facing upward.
• Make sure the air filter element is properly
installed in the air filter case.
EAS00094
CHECKING THE CARBURETOR JOINT
1. Remove:
• carburetor
Refer to “CARBURETOR” in chapter 7.
2. Check:
• carburetor joint
Cracks / damage → Replace.
Refer to “CARBURETOR” in chapter 7.
3. Install:
• carburetor joint
• carburetor
EAS00096
CHECKING THE HOSES
The following procedure applies to all of the
fuel and vacuum hoses.
1. Check:
• fuel hose
• carburetor breather hose
• over flow hose
Cracks / damage → Replace.
Loose connection → Connect properly.
3-12
CHECKING THE CRANKCASE BREATHER HOSE /
CHECKING THE EXHAUST SYSTEM
CHK
ADJ
EAS00098
CHECKING THE CRANKCASE BREATHER
HOSE
1. Check:
• crankcase breather hose
Cracks / damage → Replace.
Loose connection → Connect properly.
CAUTION:
Make sure the crankcase breather hose is
routed correctly.
EAS00100
CHECKING THE EXHAUST SYSTEM
The following procedure applies to all of the
exhaust pipes, mufflers and gaskets.
1. Remove:
• seat
• side cover (right)
Refer to “SEAT, SIDE COVERS AND FUEL
TANK”.
2. Remove:
• silencer
• exhaust joint
• exhaust pipe
• gasket
3. Check:
• silencer
• exhaust joint
• exhaust pipe
Cracks / damage → Replace.
4. Install:
• gasket
• exhaust pipe
• exhaust joint
• silencer
Exhaust pipe bolt
12 Nm (1.2 m•kg, 8.7 ft•lb)
Silencer bolt
12 Nm (1.2 m•kg, 8.7 ft•lb)
3-13
CHECKING THE COOLANT LEVEL
CHK
ADJ
EAS00102
CHECKING THE COOLANT LEVEL
1. Stand the vehicle on a level surface.
NOTE:
• Place the vehicle on a suitable stand.
• Make sure the vehicle is upright.
2. Remove:
• radiator cap
CAUTION:
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the
engine is hot. Scalding hot fluid and steam
may be blown out, which could cause serious injury. When the engine has cooled,
open the radiator cap as follows:
Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap
counterclockwise toward the detent to
allow any residual pressure to escape.
When the hissing sound has stopped,
press down on the radiator cap and turn it
counterclockwise to remove.
3. Check:
• coolant level
Coolant level
low → Add coolant.
CAUTION:
• Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant check,
and if necessary, correct the antifreeze
concentration of the coolant.
• Use only distilled water. However, if distilled water is not available, soft water may
be used.
4. Start the engine, warm it up for several minutes, and then turn it off.
5. Check:
• coolant level
NOTE:
Before checking the coolant level, wait a few
minutes until it settles.
6. Install:
• radiator cap
3-14
CHECKING THE COOLING SYSTEM /
CHANGING THE COOLANT
CHK
ADJ
EAS00104
CHECKING THE COOLING SYSTEM
1. Remove:
• air scoop
Refer to “SEAT, SIDE COVERS AND FUEL
TANK”.
2. Check:
• radiator
• radiator hose joint
• radiator hose
Cracks / damage → Replace.
Refer to “COOLING SYSTEM” in chapter 6.
3. Install:
• air scoop
EAS00105
CHANGING THE COOLANT
1. Remove:
• coolant drain bolt
2. Remove:
• radiator cap
WARNING
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the
engine is hot. Scalding hot fluid and steam
may be blown out, which could cause serious injury. When the engine has cooled,
open the radiator cap as follows:
Place a thick rag or a towel over the radiator cap and slowly turn the radiator cap
counterclockwise toward the detent to
allow any residual pressure to escape.
When the hissing sound has stopped,
press down on the radiator cap and turn it
counterclockwise to remove.
3. Drain:
• coolant
4. Install:
• copper washer
• coolant drain bolt
Coolant drain bolt
10 Nm (1.0 m•Kg, 7.2 ft•lb)
3-15
CHANGING THE COOLANT
CHK
ADJ
5. Fill:
• coolant
(with the specified amount of the recommended coolant)
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Quantity
Total amount
0.54 L (0.48 Imp qt, 0.57 US qt)
Handling notes for coolant
Coolant is potentially harmful and should be
handled with special care.
WARNING
• If coolant splashes in your eyes, thoroughly wash them with water and consult
a doctor.
• If coolant splashes on your clothes,
quickly wash it away with water and then
with soap and water.
• If coolant is swallowed, induce vomiting
and get immediate medical attention.
CAUTION:
• Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant check,
and if necessary, correct the antifreeze
concentration of the coolant.
• Use only distilled water. However, if distilled water is not available, soft water may
be used.
• If coolant comes into contact with painted
surfaces, immediately wash them with
water.
• Do not mix different types of antifreeze.
6. Install:
• radiator cap
7. Start the engine, warm it up for several minutes, and then stop it.
3-16
CHANGING THE COOLANT /
ADJUSTING THE FRONT BRAKE
CHK
ADJ
8. Check:
• coolant level
Refer to “CHECKING THE COOLANT
LEVEL”.
NOTE:
Before checking the coolant level, wait a few
minutes until the coolant has settled.
EAS00106
CHASSIS
ADJUSTING THE FRONT BRAKE
1. Adjust:
• brake lever position
(distance
from the throttle grip to the
brake lever)
Standard brake lever position
95 mm (3.74 in)
Extent of adjustment
76 ~ 97 mm (2.99 ~ 3.82 in)
a. Loosen the locknut .
b. Turn the adjusting bolt
in direction
or
until the brake lever is in the desired
position.
Direction
Direction
Brake lever distance is
increased.
Brake lever distance is
decreased.
c. Tighten the locknut.
Locknut
5 Nm (0.5 m•kg, 3.6 ft•lb)
CAUTION:
After adjusting the brake lever position,
make sure there is no brake drag.
3-17
ADJUSTING THE REAR BRAKE
CHK
ADJ
EAS00111
ADJUSTING THE REAR BRAKE
1. Check:
• brake pedal height
Out of specification → Adjust.
Brake pedal height
4.0 ~ 10.0 mm (0.16 ~ 0.39 in)
2. Adjust:
• brake pedal height
a. Loosen the locknut .
b. Turn the adjusting nut
in direction
or
until the specified brake pedal position is
obtained.
Direction
Direction
Brake pedal is raised.
Brake pedal is lowered.
WARNING
Adjust the pedal height between the maximum
and the minimum
as shown. (In
this adjustment, the bolt
end
should
protrude out of the lower adjusting nut
but not be less than 2.0 mm (0.08 in)
away from the brake pedal ).
c. Tighten the locknut
to specification.
Locknut
17 Nm (1.7 m•kg, 12 ft•lb)
CAUTION:
After adjusting the brake pedal position,
make sure there is no brake drag.
3-18
CHECKING THE BRAKE FLUID LEVEL
CHK
ADJ
EAS00115
CHECKING THE BRAKE FLUID LEVEL
1. Stand the vehicle on a level surface.
NOTE:
• Place the vehicle on a suitable stand.
• Make sure the vehicle is upright.
2. Check:
• brake fluid level
Below the minimum level mark
→ Add
the recommended brake fluid to the proper
level.
Recommended brake fluid
DOT 4
Front brake
Rear brake
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
NOTE:
In order to ensure a correct reading of the
brake fluid level, make sure the top of the
brake fluid reservoir is horizontal.
3-19
CHECKING THE FRONT AND REAR BRAKE PADS /
CHECKING THE FRONT AND REAR BRAKE HOSES
CHK
ADJ
EAS00118
CHECKING THE FRONT AND REAR BRAKE
PADS
The following procedure applies to all of the
brake pads.
1. Check:
• front brake pad
• rear brake pad
Wear indicators
or
almost touch the
brake disc → Replace the brake pads as a
set.
Refer to “REPLACING THE FRONT
BRAKE PADS” and “REPLACING THE
REAR BRAKE PADS” in chapter 4.
Brake pad wear limit
0.8 mm (0.032 in)
1.0 mm (0.039 in)
Front brake
Rear brake
EAS00131
CHECKING THE FRONT AND REAR BRAKE
HOSES
The following procedure applies to all of the
brake hoses and brake hose clamps.
1. Check:
• brake hose
Cracks / damage / wear → Replace.
2. Check:
• brake hose holder
Loose → Tighten the holder bolt .
NOTE:
• Align the brake hose holder with the projection
on the front fork and clamp the brake
hose.
• Pass the brake hose behind the rib
on the
front fork.
3. Hold the vehicle upright and apply the
brake several times.
4. Check:
• brake hose
Brake fluid leakage → Replace the damaged hose.
Refer to “FRONT AND REAR BRAKES” in
chapter 4.
3-20
BLEEDING THE HYDRAULIC BRAKE SYSTEM
CHK
ADJ
EAS00135
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNING
Bleed the hydraulic brake system whenever:
• the system is disassembled.
• a brake hose is loosened, disconnected or
replaced.
• the brake fluid level is very low.
• brake operation is faulty.
NOTE:
• Be careful not to spill any brake fluid or allow
the brake fluid reservoir to overflow.
• When bleeding the hydraulic brake system,
make sure there is always enough brake fluid
before applying the brake. Ignoring this precaution could allow air to enter the hydraulic
brake system, considerably lengthening the
bleeding procedure.
• If bleeding is difficult, it may be necessary to
let the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the hose have disappeared.
1. Bleed:
• hydraulic brake system
a. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
b. Install the brake fluid reservoir diaphragm.
c. Connect a clear plastic hose
tightly to
the bleed screw .
Front
Rear
d. Place the other end of the hose into a container.
e. Slowly apply the brake several times.
f. Fully pull the brake lever or fully press down
the brake pedal and hold it in position.
g. Loosen the bleed screw.
NOTE:
Loosening the bleed screw will release the
pressure and cause the brake lever to contact
the throttle grip or the brake pedal to fully
extend.
h. Tighten the bleed screw and then release
the brake lever or brake pedal.
3-21
BLEEDING THE HYDRAULIC BRAKE SYSTEM / ADJUSTING
THE SHIFT PEDAL / ADJUSTING THE DRIVE CHAIN SLACK
CHK
ADJ
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
Bleed screw
6 Nm (0.6 m•kg, 4.3 ft•lb)
k. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
EAS00137
ADJUSTING THE SHIFT PEDAL
1. Adjust:
• shift pedal
a. Install the shift pedal with the bottom of the
pedal outer diameter
as close to the
center of the engine mounting bolt
as
possible.
EAS00138
ADJUSTING THE DRIVE CHAIN SLACK
NOTE:
The drive chain slack must be checked at the
tightest point on the chain.
CAUTION:
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
swingarm or cause an accident. Therefore,
keep the drive chain slack within the specified limits.
3-22
ADJUSTING THE DRIVE CHAIN SLACK
CHK
ADJ
1. Elevate the rear wheel by placing the suitable stand under the engine.
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
2. Move the rear wheel several times and find
the tightest position of drive chain.
3. Check:
• drive chain slack
Out of specification → Adjust.
Drive chain slack
35.0 ~ 45.0 mm (1.38 ~ 1.77 in)
4. Adjust:
• drive chain slack
a. Loosen wheel axle nut
and both locknuts .
b. Turn both adjusting nuts
in direction
or
until the specified drive chain slack is
obtained.
Direction
Direction
Drive chain is tightened.
Drive chain is loosened.
NOTE:
• To maintain the proper wheel alignment,
adjust both sides evenly.
• Turn each adjuster exactly the same amount
to maintain correct axle alignment.
(There are marks
on each side of chain
puller alignment.)
c. Tighten the wheel axle nut to specification.
Wheel axle nut
90 Nm (9.0 m•kg, 65 ft•lb)
d. Tighten the locknuts to specification.
Locknut
16 Nm (1.6 m•kg, 11 ft•lb)
3-23
LUBRICATING THE DRIVE CHAIN /
CHECKING AND ADJUSTING THE STEERING HEAD
CHK
ADJ
EAS00143
LUBRICATING THE DRIVE CHAIN
The drive chain consists of many interacting
parts. If the drive chain is not maintained properly, it will wear out quickly. Therefore, the drive
chain should be serviced, especially when the
vehicle is used in dusty areas.
Use only kerosene to clean the drive chain.
Wipe the drive chain dry and thoroughly lubricate it with engine oil or chain lubricant that is
suitable for non-O-ring chains.
Recommended lubricant
Engine oil or chain lubricant
suitable for non-O-ring chains
EAS00147
CHECKING AND ADJUSTING THE
STEERING HEAD
1. Stand the vehicle on a level surface.
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that
the front wheel is elevated.
2. Check:
• steering head
Grasp the bottom of the front fork legs and
gently rock the front fork.
Binding / looseness → Adjust the steering
head.
3. Remove:
• handlebar
• upper bracket
Refer to “HANDLEBAR” and “STEERING
HEAD” in chapter 4.
4. Adjust:
• steering head
3-24
CHECKING AND ADJUSTING THE STEERING HEAD /
CHECKING THE FRONT FORK
CHK
ADJ
a. Remove the steering ring nut
using the
steering nut wrench .
b. Tighten the steering ring nut
with a
steering nut wrench .
NOTE:
• Set the torque wrench at a right angle to the
steering nut wrench.
• Install the steering ring nut with its larger
chamfered side
downward.
Steering nut wrench
90890-01403, YU-33975
Steering ring nut
(initial tightening torque)
38 Nm (3.8 m•kg, 27 ft•lb)
c. Loosen the steering ring nut
one turn
and then tighten it to specification with a
steering nut wrench.
WARNING
Do not overtighten the ring nut.
Steering ring nut
(final tightening torque)
4 Nm (0.4 m•kg, 2.9 ft•lb)
d. Check the steering head for looseness or
binding by turning the front fork all the way
in both directions. If any binding is felt,
remove the lower bracket and check the
upper and lower bearings.
Refer to “STEERING HEAD” in chapter 4.
5. Install:
• upper bracket
• handlebar
Refer to “HANDLEBAR” and “STEERING
HEAD” in chapter 4.
EAS00149
CHECKING THE FRONT FORK
1. Stand the vehicle on a level surface.
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
3-25
CHECKING THE FRONT FORK /
ADJUSTING THE FRONT FORK LEGS
CHK
ADJ
2. Check:
• inner tube
Damage / scratches → Replace.
• oil seal
Oil leakage → Replace.
3. Hold the vehicle upright and apply the front
brake.
4. Check:
• front fork operation
Push down hard on the handlebar several
times and check if the front fork rebounds
smoothly.
Rough movement → Repair.
Refer to “FRONT FORK” in chapter 4.
EAS00155
ADJUSTING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
WARNING
• Always adjust both front fork legs evenly.
Uneven adjustment can result in poor handling and loss of stability.
• Securely support the vehicle so that there
is no danger of it falling over.
Front fork internal pressure bleeding
NOTE:
If the front fork initial movement feels stiff during a run, bleed the front fork internal pressure.
1. Elevate the front wheel by placing a suitable
stand under the engine.
2. Remove the air bleed screw
and release
the internal pressure from the front fork.
3. Install:
1 Nm (0.1 m•kg, 0.7 ft•lb)
• air bleed screw
Rebound damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
3-26
ADJUSTING THE FRONT FORK LEGS
CHK
ADJ
1. Adjust:
• rebound damping
a. Turn the adjusting screw
or .
Direction
Direction
in direction
Rebound damping is
increased (suspension is
harder).
Rebound damping is
decreased (suspension is
softer).
Adjusting positions
Minimum: 20 clicks in direction *
Standard: 7 clicks in direction *
Maximum: 1 clicks in direction *
* with the adjusting screw fully turned-in
direction
Compression damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
• compression damping
a. Turn the adjusting screw
or .
Direction
Direction
in direction
Compression damping is
increased (suspension is
harder).
Compression damping is
decreased (suspension is
softer).
Adjusting positions
Minimum: 20 clicks in direction *
Standard (YZ85): 10 clicks in
direction *
Standard (YZ85LW): 9 clicks in
direction *
Maximum: 1 clicks in direction *
* with the adjusting screw fully turned-in
direction
3-27
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
CHK
ADJ
EAS00159
ADJUSTING THE REAR SHOCK
ABSORBER ASSEMBLY
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
Spring preload
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
• spring preload
a. Loosen the locknut
wrench.
with a ring nut
Ring nut wrench
90890-01268
NOTE:
• Be sure to remove all dirt and mud from
around the locknut and adjuster before
adjustment.
• The length of the spring (installed) changes
1.5 mm (0.06 in) per turn of the adjuster.
b. Turn the adjusting nut
.
Direction
Direction
in direction
or
Spring preload is
increased (suspension is
harder).
Spring preload is
decreased (suspension is
softer).
Adjusting length
Standard (YZ85): 215 mm (8.46 in)
Standard (YZ85LW):
207 mm (8.15 in) (for AUS, NZL)
212 mm (8.35 in) (for EUR)
c. Tighten the locknut.
3-28
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY
CHK
ADJ
Rebound damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
• rebound damping
a. Turn the adjusting screw
or .
in direction
.
Direction
Direction
Rebound damping is
increased (suspension is
harder).
Rebound damping is
decreased (suspension is
softer).
Adjusting positions
Minimum: 20 clicks in direction *
Standard (YZ85): 6 clicks in direction *
Standard (YZ85LW): 12 clicks in
direction * (for EUR)
Standard (YZ85LW): 7 clicks in
direction * (for AUS, NZL)
Maximum: 1 clicks in direction *
* with the adjusting knob fully turned-in
direction
Compression damping
CAUTION:
Never go beyond the maximum or minimum
adjustment positions.
1. Adjust:
• compression damping
a. Turn the adjusting screw
or .
Direction
Direction
3-29
in direction
Compression damping is
increased (suspension is
harder).
Compression damping is
decreased (suspension is
softer).
ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY /
CHECKING THE TIRES
CHK
ADJ
NOTE:
This is the position which is back by the specific number of clicks from the fully turned-in
position. (Which align the punch mark
on
the adjuster with the punch mark
on the
bracket.)
Adjusting positions
Minimum: 20 clicks in direction *
Standard (YZ85): 9 clicks in direction *
Standard (YZ85LW): 12 clicks in
direction * (for EUR)
Standard (YZ85LW): 7 clicks in
direction * (for AUS, NZL)
Maximum: 1 clicks in direction *
* with the adjusting knob fully turned-in
direction
EAS00164
CHECKING THE TIRES
The following procedure applies to both of the
tires.
1. Check:
• tire pressure
Out of specification → Regulate.
WARNING
• The tire pressure should only be checked
and regulated when the tire temperature
equals the ambient air temperature.
• The tire pressure and the suspension
must be adjusted according to the total
weight (including rider) and the anticipated riding speed.
Standard tire pressure:
100 kpa (1.0 kgf / cm2, 15 psi)
WARNING
It is dangerous to ride with a worn-out tire.
When the tire tread reaches the wear limit,
replace the tire immediately.
3-30
CHECKING THE TIRES
CHK
ADJ
2. Check:
• tire surfaces
Damage / wear → Replace the tire.
WARNING
• Do not use a tubeless tire on a wheel
designed only for tube tires to avoid tire
failure and personal injury from sudden
deflation.
• When using tube tires, be sure to install
the correct tube.
• Always replace a new tube tire and a new
tube as a set.
• To avoid pinching the tube, make sure the
wheel rim band and tube are centered in
the wheel groove.
• Patching a punctured tube is not recommended. If it is absolutely necessary to do
so, use great care and replace the tube as
soon as possible with a good quality
replacement.
• After extensive tests, the tires listed below
have been approved by Yamaha Motor Co.,
Ltd. for this model. The front and rear tires
should always be by the same manufacturer and of the same design. No guarantee concerning handling characteristics
can be given if a tire combination other
than one approved by Yamaha is used on
this vehicle.
Front tire
YZ85:
Manufacturer
Size
Model
70 / 100-17 40M
D739FA
(EUR, CAN)
D756F
(AUS, NZL)
Manufacturer
Size
Model
DUNLOP
70 / 100-19 42M
D756F
Manufacturer
Size
Model
DUNLOP
90 / 100-14 49M
D756
Manufacturer
Size
Model
DUNLOP
90 / 100-16 52M
D756
DUNLOP
YZ85LW:
Rear tire
YZ85:
YZ85LW:
3-31
CHECKING THE TIRES / CHECKING AND TIGHTENING THE SPOKES /
LUBRICATING THE LEVERS AND PEDALS /
LUBRICATING THE REAR SUSPENSION
CHK
ADJ
WARNING
New tires have a relatively low grip on the
road surface until they have been slightly
worn.
NOTE:
Align the mark
point.
with the valve installation
EAS00169
CHECKING AND TIGHTENING THE
SPOKES
The following procedure applies to all of the
spokes.
1. Check:
• spoke
Bends / damage → Replace.
Loose → Tighten.
Tap the spokes with a screwdriver.
NOTE:
A tight spoke will emit a clear, ringing tone; a
loose spoke will sound flat.
2. Tighten:
• spoke (with a spoke wrench
)
3 Nm (0.3 m•kg, 2.2 ft•lb)
NOTE:
Be sure to tighten the spokes before and after
break-in. After a practice or a race check
spokes for looseness.
EAS00171
LUBRICATING THE LEVERS AND PEDALS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers and pedals.
Recommended lubricant
Lithium-soap-based grease
EAS00174
LUBRICATING THE REAR SUSPENSION
Lubricate the pivoting point and metal-to-metal
moving parts of the rear suspension.
Recommended lubricant
Molybdenum disulfide grease
3-32
CHAS
CHAPTER 4
CHASSIS
FRONT WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRONT WHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BRAKE DISCS. . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT WHEEL. . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
4-3
4-3
4-6
4-7
REAR WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE DISC AND REAR WHEEL SPROCKET . . . . . . . . . .
REMOVING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING AND REPLACING THE REAR WHEEL SPROCKET . .
INSTALLING THE REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8
4-8
4-10
4-12
4-13
4-13
4-14
FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE PADS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE FRONT BRAKE PADS. . . . . . . . . . . . . . . . . . . . .
REPLACING THE REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . .
FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE MASTER CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER . . . .
DISASSEMBLING THE REAR BRAKE MASTER CYLINDER . . . . .
CHECKING THE FRONT AND REAR BRAKE MASTER
CYLINDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER
CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE REAR BRAKE MASTER CYLINDER . . . . . . . .
FRONT BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT BRAKE CALIPER . . . . . . . . . . . . .
DISASSEMBLING THE REAR BRAKE CALIPER . . . . . . . . . . . . . . .
CHECKING THE FRONT AND REAR BRAKE CALIPERS . . . . . . . .
ASSEMBLING AND INSTALLING THE FRONT BRAKE CALIPER .
ASSEMBLING AND INSTALLING THE REAR BRAKE CALIPER . .
4-15
4-15
4-16
4-17
4-19
4-21
4-23
4-25
4-25
4-27
4-29
4-31
4-33
4-35
4-35
4-36
4-37
4-39
FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . .
DISASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . .
CHECKING THE FRONT FORK LEGS. . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . .
INSTALLING THE FRONT FORK LEGS. . . . . . . . . . . . . . . . . . . . . .
4-42
4-42
4-45
4-46
4-47
4-48
4-54
4-26
CHAS
HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE HANDLEBAR. . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-55
4-57
4-57
4-57
STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNDER BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE LOWER BRACKET . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . .
4-61
4-61
4-62
4-62
4-63
REAR SHOCK ABSORBER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .
HANDLING THE REAR SHOCK ABSORBER AND GAS
CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPOSING OF A REAR SHOCK ABSORBER AND GAS
CYLINDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . . .
CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND
GAS CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE REAR SHOCK ABSORBER ASSEMBLY . . . . . .
4-65
4-68
4-68
SWINGARM AND DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SWINGARM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE DRIVE CHAIN SUPPORT . . . . . . . . . . . . . . . . . . .
INSTALLING THE SWINGARM. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE DRIVE CHAIN . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-70
4-72
4-73
4-73
4-74
4-76
4-76
4-78
4-66
4-66
4-67
FRONT WHEEL AND BRAKE DISC
EAS00512
CHAS
CHASSIS
FRONT WHEEL AND BRAKE DISC
70 Nm (7.0 m•kg, 50 ft•lb)
12 Nm (1.2 m•kg, 8.7 ft•lb)
Order
1
2
3
4
Job / Part
Q’ty
Remarks
Removing the front wheel and brake
Remove the parts in the order listed.
disc
NOTE:
Place the vehicle on a suitable stand so
that the front wheel is elevated.
Front wheel axle
Front wheel
Collar
Front brake disc
1
1
2
1
For installation, reverse the removal
procedure.
4-1
FRONT WHEEL AND BRAKE DISC
Order
Job / Part
Disassembling the front wheel
Oil seal
Wheel bearing
Collar
Q’ty
CHAS
Remarks
Disassemble the parts in the order listed.
2
2
1
For assembly, reverse the disassembly
procedure.
4-2
FRONT WHEEL AND BRAKE DISC
CHAS
EAS00519
REMOVING THE FRONT WHEEL
1. Stand the vehicle on a level surface.
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that
the front wheel is elevated.
2. Remove:
• front brake caliper
NOTE:
Do not apply the brake lever when removing
the brake caliper.
3. Elevate:
• front wheel
NOTE:
Place the vehicle on a suitable stand so that
the front wheel is elevated.
4. Remove:
• front wheel axle nut
• front wheel axle
• front wheel
• collar
EAS00526
CHECKING THE FRONT WHEEL
1. Check:
• wheel axle
Roll the wheel axle on a flat surface.
Bends → Replace.
Wheel axle bending limit
0.5 mm (0.020 in)
NOTE:
The bending value is shown by one half of the
dial gauge reading.
WARNING
Do not attempt to straighten a bent wheel
axle.
4-3
FRONT WHEEL AND BRAKE DISC
CHAS
2. Check:
• tire
• front wheel
Damage / wear → Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
3. Check:
• spokes
Refer to “CHECKING AND TIGHTENING
THE SPOKES” in chapter 3.
NOTE:
After tightening the spokes, measure the front
wheel runout.
4. Measure:
• front wheel radial runout
• front wheel lateral runout
Over the specified limits → Replace.
Front wheel radial runout limit
2.0 mm (0.08 in)
Front wheel lateral runout limit
2.0 mm (0.08 in)
5. Check:
• collars
Damage / wear → Replace.
6. Check:
• wheel bearings
Front wheel turns roughly or is loose →
Replace the wheel bearings.
• oil seals
Damage / wear → Replace.
7. Replace:
• wheel bearings
• oil seals
a. Clean the outside of the front wheel hub.
b. Remove the oil seals
with a flat-head
screwdriver.
NOTE:
To prevent damaging the wheel, place a rag
between the screwdriver and the wheel surface.
4-4
FRONT WHEEL AND BRAKE DISC
CHAS
c. Remove the wheel bearings
with a general bearing puller .
d. Install the new wheel bearings and oil seals
in the reverse order of disassembly.
CAUTION:
Do not contact the wheel bearing inner race
or balls . Contact should be made only
with the outer race .
NOTE:
Use a socket
that matches the diameter of
the wheel bearing outer race and oil seal.
4-5
FRONT WHEEL AND BRAKE DISC
CHAS
EAS00531
CHECKING THE BRAKE DISCS
The following procedure applies to all of the
brake discs.
1. Check:
• brake discs
Damage / galling → Replace.
2. Measure:
• brake disc deflection
Out of specification → Correct the brake
disc deflection or replace the brake disc.
Brake disc deflection limit
(maximum)
Front: 0.15 mm (0.006 in)
Rear: 0.15 mm (0.006 in)
a. Place the vehicle on a suitable stand so
that the wheel is elevated.
b. Before measuring the front brake disc
deflection, turn the handlebar to the left or
right to ensure that the front wheel is stationary.
c. Remove the brake caliper.
d. Hold the dial gauge at a right angle against
the brake disc surface.
e. Measure the deflection 1.5 mm (0.06 in)
below the edge of the brake disc.
3. Measure:
• brake disc thickness
Measure the brake disc thickness at a few
different locations.
Out of specification → Replace.
Brake disc thickness limit
(minimum)
Front: 2.5 mm (0.10 in)
Rear: 2.5 mm (0.10 in)
4. Adjust:
• brake disc deflection
a. Remove the brake disc.
b. Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages and in a
crisscross pattern.
4-6
FRONT WHEEL AND BRAKE DISC
CHAS
Brake disc bolt
12 Nm (1.2 m•kg, 8.7 ft•lb)
LOCTITE®
d. Measure the brake disc deflection.
e. If out of specification, repeat the adjustment
steps until the brake disc deflection is within
specification.
f. If the brake disc deflection cannot be
brought within specification, replace the
brake disc.
EAS00546
INSTALLING THE FRONT WHEEL
1. Lubricate:
• front wheel axle
• oil seal lips
Recommended lubricant
Lithium-soap-based grease
2. Install:
• collar
• front wheel
• front wheel axle
NOTE:
Install the brake disc between the brake pads
correctly.
3. Tighten:
• front wheel axle
4-7
70 Nm (7.0 m•kg, 51 ft•lb)
REAR WHEEL AND BRAKE DISC
CHAS
AS00551
REAR WHEEL AND BRAKE DISC
REAR WHEEL
16 Nm (1.6 m•kg, 11 ft•lb)
16 Nm (1.6 m•kg, 11 ft•lb)
90 Nm (9.0 m•kg, 65 ft•lb)
Order
Job / Part
Removing the rear wheel
Q’ty
Rear brake caliper
1
2
3
4
5
6
7
Remarks
Remove the parts in the order listed.
NOTE:
Place the vehicle on a suitable stand so
that the rear wheel is elevated.
Remove
Refer to “REMOVING THE REAR BRAK
PADS”.
Rear wheel axle nut
Locknut
Adjusting bolt
Rear wheel axle
Washer
Drive chain puller
Rear wheel
1
2
2
1
2
2
1
4-8
Loosen.
Loosen.
REAR WHEEL AND BRAKE DISC
CHAS
16 Nm (1.6 m•kg, 11 ft•lb)
16 Nm (1.6 m•kg, 11 ft•lb)
90 Nm (9.0 m•kg, 65 ft•lb)
Order
8
Job / Part
Collar
Q’ty
2
Remarks
For installation, reverse the removal
procedure.
4-9
REAR WHEEL AND BRAKE DISC
CHAS
EAS00560
REAR BRAKE DISC AND REAR WHEEL SPROCKET
12 Nm (1.2 m•kg, 8.7 ft•lb)
Order
1
2
3
Job / Part
Removing the rear brake disc and
rear wheel sprocket
Rear brake disc
Rear wheel sprocket
Rear wheel
42 Nm (4.2 m•kg, 30 ft•lb)
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1
For installation, reverse the disassembly
procedure.
4-10
REAR WHEEL AND BRAKE DISC
Order
Job / Part
Disassembling the rear wheel
Oil seal
Circlip
Bearing
Collar
Q’ty
CHAS
Remarks
Disassemble the parts in the order listed.
2
1
2
1
For assembly, reverse the disassembly
procedure.
4-11
REAR WHEEL AND BRAKE DISC
CHAS
EAS00561
REMOVING THE REAR WHEEL
1. Stand the vehicle on a level surface.
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that
the rear wheel is elevated.
2. Remove:
• protector
• brake caliper
NOTE:
Do not depress the brake pedal when removing the brake caliper.
3. Loosen:
• locknut
• adjusting bolt
4. Remove:
• wheel axle nut
• wheel axle
• rear wheel
NOTE:
Push the rear wheel forward and remove the
drive chain from the rear wheel sprocket.
5. Remove:
• left collar
• right collar
4-12
REAR WHEEL AND BRAKE DISC
CHAS
EAS00566
CHECKING THE REAR WHEEL
1. Check:
• rear wheel axle
• rear wheel
• wheel bearings
• oil seals
Refer to “CHECKING THE FRONT
WHEEL”.
2. Check:
• tire
• rear wheel
Damage / wear → Replace.
Refer to “CHECKING THE TIRES” and
“CHECKING THE WHEELS” in chapter 3.
3. Check:
• spokes
Refer to “CHECKING THE FRONT
WHEEL”.
4. Measure:
• radial wheel runout
• lateral wheel runout
Refer to “CHECKING THE FRONT
WHEEL”.
EAS00568
CHECKING AND REPLACING THE REAR
WHEEL SPROCKET
1. Check:
• rear wheel sprocket
More than 1 / 4 tooth
wear → Replace
the rear wheel sprocket and drive chain as
set.
Bent teeth → Replace the rear wheel
sprocket and drive chain as a set.
Correct
Drive chain roller
Rear wheel sprocket
4-13
REAR WHEEL AND BRAKE DISC
CHAS
2. Replace:
• rear wheel sprocket
a. Remove the self-locking nuts and the rear
wheel sprocket.
b. Clean the rear wheel drive hub with a clean
cloth, especially the surfaces that contact
the sprocket.
c. Install the new rear wheel sprocket.
Rear wheel sprocket self-locking
nut
42 Nm (4.2 m•kg, 30 ft•lb)
NOTE:
Tighten the self-locking nuts in stages and in a
crisscross pattern.
EAS00572
INSTALLING THE REAR WHEEL
1. Lubricate:
• rear wheel axle
• wheel bearings
• oil seal lips
Recommended lubricant
Lithium-soap-based grease
2. Tighten:
• rear wheel axle nut
90 Nm (9.0 m•kg, 65 ft•lb)
• brake caliper bolts (side)
23 Nm (2.3 m•kg, 17 ft•lb)
(front)
10 Nm (1.0 m•kg, 7.2 ft•lb)
4-14
FRONT AND REAR BRAKES
CHAS
EAS00577
FRONT AND REAR BRAKES
FRONT BRAKE PADS
6 Nm (0.6 m•kg, 4.3 ft•lb)
23 Nm (2.3 m•kg, 17 ft•lb)
Order
1
2
3
4
Job / Part
Removing the front brake pads
Brake caliper
Brake pad
Brake pad support
Bleed screw
Q’ty
Remarks
Remove the parts in the order listed.
1
2
2
1
For installation, reverse the removal
procedure.
4-15
FRONT AND REAR BRAKES
CHAS
EAS00578
REAR BRAKE PADS
6 Nm (0.6 m•kg, 4.3 ft•lb)
23 Nm (2.3 m•kg, 17 ft•lb)
18 Nm (1.8 m•kg, 13 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
23 Nm (2.3 m•kg, 17 ft•lb)
Order
1
2
3
4
5
6
7
8
Job / Part
Removing the rear brake pads
Protector
Spacer
Brake pad pin
Rear brake caliper
Brake pad
Brake pad shim
Brake pad spring
Bleed screw
Q’ty
Remarks
Remove the parts in the order listed.
1
1
2
1
2
1
1
1
For installation, reverse the removal
procedure.
4-16
FRONT AND REAR BRAKES
CHAS
EAS00579
CAUTION:
Disc brake components rarely require disassembly.
Therefore, always follow these preventive
measures:
WARNING
• Never disassemble brake components
unless absolutely necessary.
• If any connection on the hydraulic brake
system is disconnected, the entire brake
system must be disassembled, drained,
cleaned, properly filled, and bled after
reassembly.
• Never use solvents on internal brake components.
• Use only clean or new brake fluid for
cleaning brake components.
• Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
• Avoid brake fluid coming into contact with
the eyes as it can cause serious injury.
• FIRST AID FOR BRAKE FLUID ENTERING
THE EYES:
• Flush with water for 15 minutes and get
immediate medical attention.
EAS00581
REPLACING THE FRONT BRAKE PADS
NOTE:
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
1. Remove:
• brake caliper
2. Remove:
• brake pads
4-17
FRONT AND REAR BRAKES
CHAS
3. Measure:
• brake pad wear limit
Out of specification → Replace the brake
pads as a set.
Brake pad wear limit
0.8 mm (0.03 in)
4. Install:
• brake pads
NOTE:
Always install new brake pads and a new
brake pad spring as a set.
a. Connect a clear plastic hose
tightly to
the bleed screw . Put the other end of the
hose into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
Bleed screw
6 Nm (0.6 m•kg, 4.3 ft•lb)
d. Install new brake pads and a new brake
pad support.
5. Lubricate:
• brake pad bolts
• brake caliper guide bar
Recommended lubricant
Lithium-soap-based grease
CAUTION:
• Do not allow grease to contact the brake
pads.
• Remove any excess grease.
6. Install:
23 Nm (2.3 m•kg, 17 ft•lb)
• brake caliper
7. Check:
• brake fluid level
Below the minimum level mark
→ Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
4-18
FRONT AND REAR BRAKES
CHAS
8. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00583
REPLACING THE REAR BRAKE PADS
NOTE:
When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper.
1. Loosen:
• brake pad pins
2. Remove:
• brake caliper
3. Remove:
• brake pad pins
• brake pads
(along with the brake pad shims)
• brake pad spring
4. Measure:
• brake pad wear limit
Out of specification → Replace the brake
pads as a set.
Brake pad wear limit
1.0 mm (0.04 in)
5. Install:
• brake pad spring
• brake pad shims
(onto the brake pads)
• brake pads
• brake pad pins
• brake caliper
NOTE:
Always install new brake pads, brake pad
shims, and a brake pad spring as a set.
4-19
CHAS
FRONT AND REAR BRAKES
a. Connect a clear plastic hose
tightly to
the bleed screw . Put the other end of the
hose into an open container.
b. Loosen the bleed screw and push the brake
caliper pistons into the brake caliper with
your finger.
c. Tighten the bleed screw.
Bleed screw
6 Nm (0.6 m•kg, 4.3 ft•lb)
d. Install a new brake pad shim
new brake pad .
e. Install the brake pad pins .
onto each
6. Tighten:
• brake pad pins
18 Nm (1.8 m•kg, 13 ft•lb)
• brake caliper
(front)
23 Nm (2.3 m•kg, 17 ft•lb)
(rear)
23 Nm (2.3 m•kg, 17 ft•lb)
LOCK TITE®
7. Check:
• brake fluid level
Below the minimum level mark
→ Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
8. Check:
• brake pedal operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-20
FRONT AND REAR BRAKES
CHAS
EAS00584
FRONT BRAKE MASTER CYLINDER
6 Nm (0.6 m•kg, 4.3 ft•lb)
6 Nm (0.6 m•kg, 4.3 ft•lb)
9 Nm (0.9 m•kg, 6.5 ft•lb)
26 Nm (2.6 m•kg, 19 ft•lb)
Order
1
2
3
4
5
6
7
Job / Part
Removing the front brake master
cylinder
Brake fluid
Union bolt
Copper washer
Front brake hose
Brake lever cover
Brake lever
Brake master cylinder holder
Brake master cylinder
Q’ty
Remarks
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE BRAKE
FLUID” in chapter 3.
1
2
1
1
1
1
1
For installation, reverse the removal
procedure.
4-21
FRONT AND REAR BRAKES
CHAS
EAS00585
2 Nm (0.2 m•kg, 1.4 ft•lb)
Order
Job / Part
Disassembling the rear brake
master cylinder
Brake master cylinder cap
Brake master cylinder reservoir diaphragm
Brake master cylinder reservoir float
Brake master cylinder boot
Circlip
Washer
Brake master cylinder kit
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1
1
1
1
1
For assembly, reverse the disassembly
procedure.
4-22
FRONT AND REAR BRAKES
CHAS
EAS00586
REAR BRAKE MASTER CYLINDER
10 Nm (1.0 m•kg, 7.2 ft•lb)
1 Nm (0.1 m•kg, 0.7 ft•lb)
26 Nm (2.6 m•kg, 19 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
Order
1
2
3
4
5
6
7
8
9
10
Job / Part
Removing the rear brake master
cylinder
Brake fluid
Q’ty
Remarks
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE BRAKE
FLUID” in chapter 3.
Brake fluid reservoir cap
Brake fluid reservoir diaphragm holder
Brake fluid reservoir diaphragm
Brake fluid reservoir tank
Brake fluid reservoir hose
Hose holder
Union bolt
Copper washer
Brake hose
Brake master cylinder
1
1
1
1
1
1
1
2
1
1
For installation, reverse the removal
procedure.
4-23
FRONT AND REAR BRAKES
CHAS
EAS00587
Order
Job / Part
Removing the rear brake master
cylinder
Brake master cylinder kit
Circlip
Brake master cylinder joint
O-ling
Q’ty
Remarks
Remove the parts in the order listed.
1
1
1
1
For assembly, reverse the disassembly
procedure.
4-24
FRONT AND REAR BRAKES
CHAS
EAS00588
DISASSEMBLING THE FRONT BRAKE
MASTER CYLINDER
NOTE:
Before disassembling the front brake master
cylinder, drain the brake fluid from the entire
brake system.
1. Remove:
• union bolt
• copper washers
• brake hose
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
2. Remove:
• brake master cylinder bracket
• brake master cylinder
3. Remove:
• brake master cylinder boot
• circlip
EAS00589
DISASSEMBLING THE REAR BRAKE
MASTER CYLINDER
1. Remove:
• union bolt
• copper washers
• brake hose
NOTE:
To collect any remaining brake fluid, place a
container under the master cylinder and the
end of the brake hose.
2. Remove:
• brake master cylinder
3. Remove:
• circlip
• brake master cylinder joint
4-25
FRONT AND REAR BRAKES
CHAS
EAS00592
CHECKING THE FRONT AND REAR BRAKE
MASTER CYLINDERS
The following procedure applies to the both of
the brake master cylinders.
1. Check:
• brake master cylinder
Damage / scratches / wear → Replace.
• brake fluid delivery passages
(brake master cylinder body)
Obstruction → Blow out with compressed
air.
Front
Rear
2. Check:
• brake master cylinder kit
Damage / scratches / wear → Replace.
Front
Rear
3. Check:
• rear brake fluid reservoir
Cracks / damage → Replace.
• rear brake fluid reservoir diaphragm
Cracks / damage → Replace.
4. Check:
• front brake master cylinder reservoir
Cracks/damage → Replace.
• front brake master cylinder reservoir diaphragm
Damage / wear → Replace.
5. Check:
• brake hoses
Cracks / damage / wear → Replace.
Refer to “CHECKING THE FRONT AND
REAR BRAKE HOSES” in chapter 3.
4-26
CHAS
FRONT AND REAR BRAKES
EAS00598
ASSEMBLING AND INSTALLING THE
FRONT BRAKE MASTER CYLINDER
WARNING
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake components.
Recommended brake fluid
DOT 4
1. Install:
• brake master cylinder
9 Nm (0.9 m•kg, 6.5 ft•lb)
NOTE:
• Install the brake master cylinder holder
with the “UP” mark facing up.
• First, tighten the upper bolt, then the lower
bolt.
2. Install:
• copper washers
• brake hose
• union bolt
26 Nm (2.6 m•kg, 19 ft•lb)
WARNING
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“CABLE ROUTING” in chapter 2.
CAUTION:
Install the brake hose so that its pipe portion
directs as shown and lightly
touches the projection
on the brake
master cylinder.
4-27
FRONT AND REAR BRAKES
CHAS
NOTE:
• While holding the brake hose, tighten the
union bolt as shown.
• Turn the handlebar to the left and right to
make sure the brake hose does not touch
other parts (e.g., wire harness, cables, leads).
Correct if necessary.
3. Fill:
• brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reservoir. Water will significantly lower the boiling point of the brake fluid and could
cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. Check:
• brake fluid level
Below the minimum level mark
→ Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
4-28
FRONT AND REAR BRAKES
CHAS
6. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00608
ASSEMBLING THE REAR BRAKE MASTER
CYLINDER
1. Install:
• O-ling
• brake master cylinder joint
• circlip
• brake master cylinder kit
2. Install:
• copper washers
• brake hoses
26 Nm (2.6 m•kg, 19 ft•lb)
• union bolt
WARNING
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“CABLE ROUTING” in chapter 2.
CAUTION:
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe touches the projection
as shown.
3. Fill:
• brake fluid reservoir
(to the maximum level mark
)
Recommended brake fluid
DOT 4
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
4-29
FRONT AND REAR BRAKES
CHAS
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
5. Check:
• brake fluid level
Below the minimum level mark
→ Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
6. Check:
• brake pedal operation
WARNING
A soft or spongy feeling in the brake pedal
can indicate the presence of air in the brake
system. Before the vehicle is operated, the
air must be removed by bleeding the brake
system. Air in the brake system will considerably reduce braking performance and
could result in loss of control and possibly
an accident. Therefore, check and, if necessary, bleed the brake system.
7. Adjust:
• brake pedal position
Refer to “ADJUSTING THE REAR BRAKE”
in chapter 3.
Brake pedal position (above the
top of the rider footrest)
4.0 ~ 10.0 mm (0.16 ~ 0.39 in)
4-30
FRONT AND REAR BRAKES
CHAS
EAS00613
FRONT BRAKE CALIPER
26 Nm (2.6 m•kg, 19 ft•lb)
7 Nm (0.7 m•kg, 5.1 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
23 Nm (2.3 m•kg, 17 ft•lb)
Order
1
2
3
4
5
6
Job / Part
Removing the front brake caliper
Brake fluid
Protector
Brake hose holder
Union bolt
Copper washer
Brake hose
Brake caliper
Q’ty
Remarks
Remove the parts in the order listed.
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
1
1
1
2
1
1
For installation, reverse the removal
procedure.
4-31
FRONT AND REAR BRAKES
CHAS
EAS00614
6 Nm (0.6 m•kg, 4.3 ft•lb)
30 Nm (3.0 m•kg, 22 ft•lb)
Order
Job / Part
Disassembling the front brake
caliper
Brake pad
Brake caliper bracket
Brake pad support
Sleeve boot
Brake caliper piston
Brake caliper piston seal
Pin boot
Bleed screw
Q’ty
Remarks
Remove the parts in the order listed.
2
1
2
1
2
4
1
1
For assembly, reverse the disassembly
procedure.
4-32
FRONT AND REAR BRAKES
CHAS
EAS00616
REAR BRAKE CALIPER
26 Nm (2.6 m•kg, 19 ft•lb)
23 Nm (2.3 m•kg, 17 ft•lb)
18 Nm (1.8 m•kg, 13 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
23 Nm (2.3 m•kg, 17 ft•lb)
Order
1
2
3
4
5
6
Job / Part
Removing the rear brake caliper
Brake fluid
Union bolt
Copper washer
Brake hose
Brake pad pin
Protector
Brake caliper
Q’ty
1
2
1
2
1
1
Remarks
Remove the parts in the order listed.
Drain.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
Loosen.
For installation, reverse the removal
procedure.
4-33
FRONT AND REAR BRAKES
CHAS
EAS00617
6 Nm (0.6 m•kg, 4.3 ft•lb)
Order
Job / Part
Q’ty
Remarks
Disassembling the rear brake caliper
Remove the parts in the order listed.
Brake pad pin
2
Brake pad
2
Brake pad shim
1
Brake caliper seal
2
Brake caliper piston
1
Brake pad spring
1
Bleed screw
1
For assembly, reverse the disassembly
procedure.
4-34
FRONT AND REAR BRAKES
CHAS
EAS00619
DISASSEMBLING THE FRONT BRAKE
CALIPER
NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
1. Remove:
• union bolt
• copper washers
• brake hose
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
• brake caliper pistons
• brake caliper piston seals
a. Blow compressed air into the brake hose
joint opening
to force out the pistons
from the brake caliper.
WARNING
• Cover the brake caliper pistons with a rag.
Be careful not to get injured when the pistons are expelled from the brake caliper.
• Never try to pry out the brake caliper pistons.
b. Remove the brake caliper piston seals.
EAS00626
DISASSEMBLING THE REAR BRAKE
CALIPER
NOTE:
Before disassembling the brake caliper, drain
the brake fluid from the entire brake system.
4-35
FRONT AND REAR BRAKES
CHAS
1. Remove:
• union bolt
• copper washers
• brake hose
NOTE:
Put the end of the brake hose into a container
and pump out the brake fluid carefully.
2. Remove:
• brake caliper piston
• brake caliper piston seals
a. Blow compressed air into the brake hose
joint opening
to force out the piston from
the brake caliper.
WARNING
• Cover the brake caliper piston with a rag.
Be careful not to get injured when the piston is expelled from the brake caliper.
• Never try to pry out the brake caliper piston.
b. Remove the brake caliper piston seals.
EAS00633
CHECKING THE FRONT AND REAR BRAKE
CALIPERS
Recommended brake component
replacement schedule
Brake pads
If necessary
Piston seals
Every two years
Brake hoses
Every four years
Every two years
and whenever the
Brake fluid
brake is
disassembled
4-36
FRONT AND REAR BRAKES
CHAS
1. Check:
• brake caliper pistons
Rust / scratches / wear → Replace the brake
caliper pistons.
• brake caliper cylinders
Scratches / wear → Replace the brake caliper assembly.
• brake caliper body
Cracks / damage → Replace the brake caliper assembly.
• brake fluid delivery passages
(brake caliper body)
Obstruction → Blow out with compressed
air.
WARNING
Whenever a brake caliper is disassembled,
replace the brake caliper piston seals.
Front
Rear
2. Check:
• front brake caliper bracket
Cracks / damage → Replace.
• guide pin
Rust / damage → Replace.
• sleeve boot
Crack / damage → Replace.
• pin boot
Wear / damage → Replace.
EAS00634
ASSEMBLING AND INSTALLING THE
FRONT BRAKE CALIPER
WARNING
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake components as they will cause the piston
seals to swell and distort.
• Whenever a brake caliper is disassembled, replace the brake caliper piston
seals.
Recommended brake fluid
DOT 4
4-37
CHAS
FRONT AND REAR BRAKES
1. Install:
• brake caliper bracket
30 Nm (3.0 m•kg, 22 ft•lb)
• brake pads
• brake caliper
23 Nm (2.3 m•kg, 17 ft•lb)
• copper washers
• brake hose
• union bolt
26 Nm (2.6 m•kg, 19 ft•lb)
WARNING
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“CABLE ROUTING” in chapter 2.
CAUTION:
When installing the brake hose onto the
brake caliper , make sure the brake pipe
touches the projection
on the brake
caliper.
2. Fill:
• brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reservoir. Water will significantly lower the boiling point of the brake fluid and could
cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4-38
CHAS
FRONT AND REAR BRAKES
3. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4. Check:
• brake fluid level
Below the minimum level mark
→ Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
5. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
EAS00642
ASSEMBLING AND INSTALLING THE REAR
BRAKE CALIPER
WARNING
• Before installation, all internal brake components should be cleaned and lubricated
with clean or new brake fluid.
• Never use solvents on internal brake components as they will cause the piston
seals to swell and distort.
• Whenever a brake caliper is disassembled, replace the brake caliper piston
seals.
Recommended brake fluid
DOT 4
1. Install:
• brake pad spring
• brake pad shim
• brake pad pins
2. Install:
• brake caliper
(front)
23 Nm (2.3 m•kg, 17 ft•lb)
(rear)
•
•
•
•
4-39
protector
copper washers
brake hose
union bolt
23 Nm (2.3 m•kg, 17 ft•lb)
LOCK TITE®
10 Nm (1.0 m•kg, 7.2 ft•lb)
26 Nm (2.6 m•kg, 19 ft•lb)
FRONT AND REAR BRAKES
CHAS
WARNING
Proper brake hose routing is essential to
insure safe vehicle operation. Refer to
“CABLE ROUTING” in chapter 2.
CAUTION:
When installing the brake hose onto the
brake caliper , make sure the brake pipe
touches the projection
on the brake
caliper.
3. Fill:
• brake master cylinder reservoir
(with the specified amount of the recommended brake fluid)
Recommended brake fluid
DOT 4
WARNING
• Use only the designated brake fluid. Other
brake fluids may cause the rubber seals to
deteriorate, causing leakage and poor
brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake fluids may result in a harmful chemical reaction, leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake master cylinder reservoir. Water will significantly lower the boiling point of the brake fluid and could
cause vapor lock.
CAUTION:
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
4. Bleed:
• brake system
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-40
FRONT AND REAR BRAKES
CHAS
5. Check:
• brake fluid level
Below the minimum level mark
→ Add
the recommended brake fluid to the proper
level.
Refer to “CHECKING THE BRAKE FLUID
LEVEL” in chapter 3.
6. Check:
• brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM” in chapter 3.
4-41
FRONT FORK
CHAS
EAS00646
FRONT FORK
FRONT FORK LEGS
22 Nm (2.2 m•kg, 16 ft•lb)
20 Nm (2.0 m•kg, 14 ft•lb)
4 Nm (0.4 m•kg, 2.9 ft•lb)
20 Nm (2.0 m•kg, 14 ft•lb)
Order
Job / Part
Removing the front fork legs
Front wheel
Q’ty
Protector
Front brake caliper
Number plate
1
2
3
4
Cap bolt
Upper bracket pinch bolt
Lower bracket pinch bolt
Front fork
Remarks
Remove the parts in the order listed.
Refer to “FRONT WHEEL AND BRAKE
DISC”.
Refer to “FRONT AND REAR BRAKES”.
1
1
2
1
Refer to “SEAT, SIDE COVERS AND
FUEL TANK” in chapter 3.
Loosen.
Loosen.
Loosen.
For installation, reverse the removal
procedure.
4-42
FRONT FORK
CHAS
EAS00648
28 Nm (2.8 m•kg, 20 ft•lb)
15 Nm (1.5 m•kg, 11 ft•lb)
1 Nm (0.1 m•kg, 0.7 ft•lb)
55 Nm (5.5 m•kg, 40 ft•lb)
Order
Job / Part
Disassembling the front fork legs
Guide protector
Cap bolt
O-ring
Damper adjusting rod
Nut
Washer
Fork spring
Spring guide
Dust seal
Oil seal clip
Inner tube
Outer tube
Piston metal
Slide metal
Oil seal washer
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4-43
Remarks
Remove the parts in the order listed.
FRONT FORK
CHAS
28 Nm (2.8 m•kg, 20 ft•lb)
15 Nm (1.5 m•kg, 11 ft•lb)
1 Nm (0.1 m•kg, 0.7 ft•lb)
55 Nm (5.5 m•kg, 40 ft•lb)
Order
Job / Part
Oil seal
Plug
Base valve
Gasket
O-ring
Damper rod
O-ring
Air bleed screw
Q’ty
1
1
1
1
2
1
1
1
Remarks
For assembly, reverse the disassembly
procedure.
4-44
FRONT FORK
CHAS
EAS00650
REMOVING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Stand the vehicle on a level surface.
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that
the front wheel is elevated.
2. Remove
• front wheel
• protector
• front brake caliper
• number plate
3. Loosen:
• cap bolt
4. Loosen:
• upper bracket pinch bolt
• lower bracket pinch bolts
WARNING
Before loosening the upper and lower
bracket pinch bolts, support the front fork
leg.
5. Remove:
• front fork leg
4-45
FRONT FORK
CHAS
EAS00652
DISASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Remove:
• cap bolt
(from the damper adjusting rod)
a. Install the rod holder
between the nut
and washer .
NOTE:
Use the side of the rod holder that is marked
“A”.
Rod holder
90890-01434, YM-01434
b. Loosen the nut.
c. Remove the cap bolt.
2. Remove:
• nut
• washer
• fork spring
• spring guide
3. Drain:
• fork oil
NOTE:
Stroke the damper rod
draining the fork oil.
several times while
4. Remove:
• dust seal
• oil seal clip
(with a flat-head screwdriver)
CAUTION:
Do not scratch the inner tube.
5. Remove:
• inner tube
a. Push in slowly
the inner tube just before
it bottoms out and then pull it back quickly
.
b. Repeat this step until the inner tube can be
pulled out from the outer tube.
4-46
FRONT FORK
CHAS
6. Remove:
• slide metal
• oil seal washer
• oil seal
• piston metal
• oil seal clip
• dust seal
7. Remove:
• base valve
• damper rod
NOTE:
While holding the inner tube with the damper
rod holder , loosen the base valve.
Damper rod holder
90890-01454, YM-01454
EAS00656
CHECKING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Check:
• inner tube
• outer tube
Bends / damage / scratches → Replace.
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken it.
2. Measure:
• spring free length
Out of specification → Replace.
Spring free length
430 mm (16.9 in)
<Limit>: 425 mm (16.7 in)
3. Check:
• damper rod
Bend / damage → Replace.
Obstruction → Blow out all of the oil passages with compressed air.
• damper rod adjusting rod
Bend / damage → Replace.
4-47
FRONT FORK
CHAS
CAUTION:
• The front fork leg has a built-in damper
adjusting rod and a very sophisticated
internal construction, which are particularly sensitive to foreign material.
• When disassembling and assembling the
front fork leg, do not allow any foreign
material to enter the front fork.
4. Check:
• base valve assembly
Damage / wear → Replace.
5. Check:
• cap bolt
Damage / wear → Replace.
• air bleed screw
Damage / wear → Replace.
EAS00661
ASSEMBLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
WARNING
• Make sure the oil levels in both front fork
legs are equal.
• Uneven oil levels can result in poor handling and a loss of stability.
NOTE:
When assembling the front fork leg, be sure to
replace the following parts:
– outer tube and inner tube bushing
– oil seal
– dust seal
– Before assembling the front fork leg, make
sure all of the components are clean.
4-48
CHAS
FRONT FORK
1. Install:
• damper rod assembly
• inner tube
CAUTION:
Allow the damper rod assembly to slide
slowly down the inner tube until it protrudes from the bottom of the inner tube.
Be careful not to damage the inner tube.
2. Install:
• gasket
• base valve
3. Tighten:
• base valve
55 Nm (5.5 m•kg, 40 ft•lb)
LOCTITE®
NOTE:
While holding the damper rod
with the
damper rod holder , tighten the base valve.
Damper rod holder
90890-01454, YM-01454
4. Lubricate:
• inner tube’s outer surface
Recommended lubricant
Suspension oil “01”
5. Install:
• spring guide
• nut
NOTE:
Install the spring guide with its cut
downward.
4-49
facing
FRONT FORK
CHAS
6. Install:
• dust seal
• oil seal clip
• oil seal
• oil seal washer
• slide metal
CAUTION:
Make sure the numbered side of the oil seal
faces up.
NOTE:
• Before installing the oil seal, lubricate its lips
with lithium-soap-based grease.
• Lubricate the outer surface of the inner tube
with fork oil.
• Before installing the oil seal, cover the top of
the front fork leg with a plastic bag to protect
the oil seal during installation.
7. Install:
• piston metal
NOTE:
Install the piston metal on to the slot on inner
tube.
8. Install:
• outer tube
9. Install:
• slide metal
• oil seal washer
(with the fork seal driver
)
Fork seal driver
90890-01442, YM-01442
4-50
FRONT FORK
CHAS
10.Install:
• oil seal
(with the fork seal driver
)
Fork seal driver
90890-01442, YM-01442
11.Install:
• oil seal clip
NOTE:
Adjust the oil seal clip so that it fits into the
outer tube’s groove.
12.Install:
• dust seal
13.Fill:
• front fork leg
(with the specified amount of the recommended fork oil)
Quantity (each front fork leg)
0.32 L (0.28 Imp qt, 0.34 US qt)
Recommended oil
Suspension oil “01”
Front fork leg oil level
(from the
top of the outer tube, with the
outer tube fully compressed and
without the fork spring)
Standard: 90 mm (3.54 in)
Extent of adjustment:
80 ~ 120 mm (3.15 ~ 4.72 in)
NOTE:
• While filling the front fork leg, keep it upright.
• After filling, slowly pump the front fork leg up
and down to distribute the fork oil.
4-51
FRONT FORK
CHAS
14.Install:
• fork spring
• washer
• cap bolt
a. Install the fork spring, and washer.
NOTE:
Install the spring with the smaller pitch
ing up .
fac-
b. Install the rod puller and rod puller attachment.
Rod puller
90890-01437, YM-01437
Rod puller attachment (M10)
90890-01436, YM-01436
c. Pull up the rod puller
and install the rod
holder
between the nut
and the
washer.
NOTE:
Use the side of the rod holder that is marked
“A”.
Rod holder
90890-01434, YM-01434
d. Remove the rod puller and adapter.
e. Install the nut
and position it as specified
.
Distance
18 mm (0.71 in)
f. Loosen the rebound damping force adjusting screw
finger tight.
NOTE:
Record the set position of the adjuster (the
amount of turning out the fully turned in position).
4-52
CHAS
FRONT FORK
g. Fully tighten the cap bolt
onto the
damper rod by hand.
NOTE:
Make sure that there is a clearance
of 0 ~ 1
mm (0 ~ 0.04 in) between the front fork cap
bolt and locknut .
h. Hold the cap bolt
to specification.
and tighten the nut
Nut
15 Nm (1.5 m•kg, 11 ft•lb)
i. Remove the rod holder.
j. Temporarily tighten the cap bolt
15.Install:
• protector guide
4-53
.
.
CHAS
FRONT FORK
EAS00662
INSTALLING THE FRONT FORK LEGS
The following procedure applies to both of the
front fork legs.
1. Install:
• front fork leg
Temporarily tighten the upper and lower
bracket pinch bolts.
NOTE:
Make sure the inner fork tube is flush with the
top of the handlebar holder.
2. Tighten:
• cap bolt
3. Adjust:
• front fork top end
28 Nm (2.8 m•kg, 20 ft•lb)
Front fork top end (standard)
YZ85: 24 mm (0.94 in)
YZ85LW: 0 mm (0.00 in)
4. Tighten:
• upper bracket pinch bolt
22 Nm (2.2 m•kg, 16 ft•lb)
• lower bracket pinch bolt
20 Nm (2.0 m•kg, 14 ft•lb)
WARNING
Make sure the brake hoses are routed properly.
5. Install:
7 Nm (0.7 m•kg, 5.1 ft•lb)
• protector
6. Adjust:
• spring preload
• rebound damping
• compression damping
Refer to “ADJUSTING THE FRONT FORK
LEGS” in chapter 3.
4-54
HANDLEBAR
CHAS
EAS00664
HANDLEBAR
4 Nm (0.4 m•kg, 2.9 ft•lb)
1 Nm (0.1 m•kg, 0.7 ft•lb)
9 Nm (0.9 m•kg, 6.5 ft•lb)
27 Nm (2.7 m•kg, 1.9 ft•lb)
4 Nm (0.4 m•kg, 2.9 ft•lb)
Order
Job / Part
Removing the handlebar
Number plate
Q’ty
1
2
3
4
5
6
7
8
9
10
11
12
13
Clutch cable
Clutch lever holder
Clutch lever
Engine stop switch
Brake master cylinder cap
Brake master cylinder
Throttle cable cap
Grip cap (lower)
Grip cap (upper)
Throttle cable
Right grip
Tube guide
Collar
1
1
1
1
1
1
1
1
1
1
1
1
1
4-55
Remarks
Remove the parts in the order listed.
Refer to “SEAT, SIDE COVERS AND
FUEL TANK” in chapter 3.
HANDLEBAR
4 Nm (0.4 m•kg, 2.9 ft•lb)
CHAS
1 Nm (0.1 m•kg, 0.7 ft•lb)
9 Nm (0.9 m•kg, 6.5 ft•lb)
27 Nm (2.7 m•kg, 1.9 ft•lb)
4 Nm (0.4 m•kg, 2.9 ft•lb)
Order
14
15
16
Job / Part
Left grip
Handlebar upper holder
Handlebar
Q’ty
1
2
1
Remarks
For installation, reverse the removal
procedure.
4-56
CHAS
HANDLEBAR
EAS00666
REMOVING THE HANDLEBAR
1. Stand the vehicle on a level surface.
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
2. Remove:
• grip
NOTE:
Blow compressed air between the handlebar
and the handlebar grip, and gradually push the
grip off the handlebar.
EAS00668
CHECKING THE HANDLEBAR
1. Check:
• handlebar
Bends / cracks / damage → Replace.
WARNING
Do not attempt to straighten a bent handlebar as this may dangerously weaken it.
EAS00670
INSTALLING THE HANDLEBAR
1. Stand the vehicle on a level surface.
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
2. Install:
• handlebar
• handlebar upper holder
27 Nm (2.7 m•kg, 19 ft•lb)
CAUTION:
• First, tighten the bolts on the front side of
the handlebar holder, and then on the rear
side.
• Turn the handlebar all the way to the left
and right. If there is any contact with the
fuel tank, adjust the handlebar position.
4-57
HANDLEBAR
CHAS
NOTE:
• The upper handlebar holders should be
installed with the punched mark
forward.
• First tighten the bolts on the front side of the
handlebar upper holder, and then tighten the
bolts on the rear side.
FWD
3. Install:
• left grip
• apply the adhesive to the handlebar .
NOTE:
• Before applying the adhesive, wipe off grease
or oil on the handlebar surface
with a lacquer thinner.
• Install the left grip to the handlebar so that the
arrow mark (L) faces straight upward.
4. Install:
• right grip
• apply the adhesive on the tube guide .
NOTE:
• Before applying the adhesive, wipe off grease
or oil on the tube guide surface
with a lacquer thinner.
• Locate the mating mark
on the grip as
shown.
5. Install:
• collar
• tube guide
• grip cap (upper)
• throttle cable
NOTE:
Apply the lithium soap base grease on the
throttle cable end and tube guide cable winding portion.
4-58
HANDLEBAR
CHAS
6. Install:
• throttle cable cap
1 Nm (0.1 m•kg, 0.7 ft•lb)
• grip cap (lower)
4 Nm (0.4 m•kg, 2.9 ft•lb)
• cover (grip cap)
7. Adjust:
• throttle cable free play
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
8. Install:
• brake master cylinder
• brake master cylinder bracket
9 Nm (0.9 m•kg, 6.5 ft•lb)
NOTE:
Install the bracket so that the arrow mark
face upward.
9. Install:
• engine stop switch
• clutch lever holder
4 Nm (0.4 m•kg, 2.9 ft•lb)
• clamp
NOTE:
The engine stop switch and clutch lever holder
should be installed according to the dimensions shown.
10 mm
(0.4 in)
15 mm
(0.6 in)
10.Install:
• clutch cable
NOTE:
Apply the lithium soap base grease on the
clutch cable end.
4-59
HANDLEBAR
CHAS
11.Adjust:
• clutch lever free play
Refer to “ADJUSTING THE CLUTCH
CABLE FREE PRAY” in chapter 3.
12.Clamp the clamp portion
of the number
plate to the handlebar.
13.Insert the end of the fuel tank breather hose
into the hole of the steering stem.
4-60
STEERING HEAD
CHAS
EAS00675
STEERING HEAD
UNDER BRACKET
22 Nm (2.2 m•kg, 16 ft•lb)
125 Nm (12.5 m•kg, 90 ft•lb)
1st
38 Nm (3.8 m•kg, 27 ft•lb)
2nd
3rd
Loosen it 1 turn
4 Nm (0.4 m•kg, 2.9 ft•lb)
20 Nm (2.0 m•kg, 14 ft•lb)
Order
1
2
3
4
5
6
7
8
9
10
Job / Part
Removing the lower bracket
Number plate
Handlebar
Front fender
Steering stem nut
Washer
Upper bracket
Steering ring nut
Lower bracket
Bearing race cover
Washer
Upper bearing
Lower bearing
Bearing race
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “SEAT, SIDE COVERS AND
FUEL TANK” in chapter 3.
Refer to “HANDLEBAR”.
1
1
1
1
1
1
1
1
1
2
For installation, reverse the removal
procedure.
4-61
STEERING HEAD
CHAS
EAS00677
REMOVING THE LOWER BRACKET
1. Stand the vehicle on a level surface.
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
2. Remove:
• steering stem nut
• washer
• upper bracket
• steering ring nut
(with the ring nut wrench
)
Steering nut wrench
90890-01403, YU-33975
WARNING
Securely support the lower bracket so that
there is no danger of it falling.
EAS00682
CHECKING THE STEERING HEAD
1. Wash:
• bearings
• bearing races
Recommended cleaning solvent
Kerosene
2. Check:
• bearings
• bearing races
Damage / pitting → Replace.
4-62
STEERING HEAD
CHAS
3. Replace:
• lower bearing
• bearing races
a. Remove the bearing races
from the
steering head pipe with a long rod
and
hammer.
b. Remove the bearing race
from the lower
bracket with a floor chisel
and hammer.
c. Install a new dust seal and new bearing
races.
CAUTION:
If the bearing race is not installed properly,
the steering head pipe could be damaged.
NOTE:
• Always replace the bearing balls and bearing
races as a set.
• Whenever the steering head is disassembled,
replace the dust seal.
4. Check:
• upper bracket
• lower bracket
(along with the steering stem)
Bends / cracks / damage → Replace.
EAS00683
INSTALLING THE STEERING HEAD
1. Lubricate:
• upper bearing
• lower bearing
• bearing races
Recommended lubricant
Lithium-soap-based grease
2. Install:
• lower bracket
• upper bearing
• washer
• bearing race cover
Refer to “CHECKING THE STEERING
HEAD”.
4-63
STEERING HEAD
CHAS
3. Install:
• steering ring nut
4 Nm (0.4 m•kg, 2.9 ft•lb)
(with the ring nut wrench
)
Steering nut wrench
90890-01403, YU-33975
a. Tighten the steering ring nut.
38 Nm (3.8 m•kg, 27 ft•lb)
b. Loosen it one turn.
c. Retighten the steering ring nut.
4 Nm (0.4 m•kg, 2.9 ft•lb)
4. Install:
• upper bracket
• washer
• steering stem nut
125 Nm (12.5 m•kg, 90 ft•lb)
5. Install:
• front fork legs
Refer to “INSTALLING THE FRONT FORK
LEGS”.
NOTE:
Temporarily tighten the upper and lower
bracket pinch bolts.
4-64
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00685
REAR SHOCK ABSORBER ASSEMBLY
36 Nm (3.6 m•kg, 26 ft•lb)
16 Nm (1.6 m•kg, 12 ft•lb)
26 Nm (2.6 m•kg, 19 ft•lb)
36 Nm (3.6 m•kg, 26 ft•lb)
Order
1
2
3
4
5
6
7
8
9
Job / Part
Removing the rear shock absorber
assembly
Seat
Right side cover
Silencer
Clamp
Rear frame
Washer / bolt
Self-locking nut / washer / bolt
Rear shock absorber
Spring guide
Spring
Adjuster
Locknut
Q’ty
1
1
1/1
1/1/1
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Refer to “SEAT, SIDE COVERS AND
FUEL TANK” in chapter 3.
Refer to “EXHAUST PIPE” in chapter 5.
Loosen
For installation, reverse the removal
procedure.
4-65
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00687
HANDLING THE REAR SHOCK ABSORBER
AND GAS CYLINDER
WARNING
This rear shock absorber and gas cylinder
contain highly compressed nitrogen gas.
Before handling the rear shock absorber or
gas cylinder, read and make sure you
understand the following information. The
manufacturer cannot be held responsible
for property damage or personal injury that
may result from improper handling of the
rear shock absorber and gas cylinder.
• Do not tamper or attempt to open the rear
shock absorber or gas cylinder.
• Do not subject the rear shock absorber or
gas cylinder to an open flame or any other
source of high heat. High heat can cause
an explosion due to excessive gas pressure.
• Do not deform or damage the rear shock
absorber or gas cylinder in any way. If the
rear shock absorber, gas cylinder or both
are damaged, damping performance will
suffer.
EAS00689
DISPOSING OF A REAR SHOCK
ABSORBER AND GAS CYLINDER
1. Gas pressure must be released before disposing of a rear shock absorber and gas
cylinder. Before disposing the rear shock
absorber, be sure to extract the nitrogen
gas from valve .
WARNING
Wear eye protection to prevent eye damage
from released gas or metal chips.
4-66
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00694
REMOVING THE REAR SHOCK ABSORBER
ASSEMBLY
1. Stand the vehicle on a level surface.
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that
the rear wheel is elevated.
2. Remove:
• seat and right side cover
Refer to “SEAT, SIDE COVERS AND FUEL
TANK” in chapter 3.
• silencer
Refer to “EXHAUST PIPE” in chapter 5.
3. Loosen:
• air filter clamp
4. Remove:
• rear frame
5. Remove:
• rear shock absorber lower bolt
• washer
6. Remove:
• rear shock absorber upper bolt
• washer
• self-locking nut
• rear shock absorber
4-67
REAR SHOCK ABSORBER ASSEMBLY
CHAS
EAS00696
CHECKING THE REAR SHOCK ABSORBER
ASSEMBLY AND GAS CYLINDER
1. Check:
• rear shock absorber rod
Bends / damage → Replace the rear shock
absorber assembly.
• rear shock absorber
Gas leaks / oil leaks → Replace the rear
shock absorber assembly.
• spring
Damage / wear → Replace the rear shock
absorber assembly.
• spring guide
Damage / wear → Replace.
• gas cylinder
Damage / gas leaks → Replace.
• bushings
Damage / wear → Replace.
• dust seals
Damage / wear → Replace.
• bolts
Bends / damage / wear → Replace.
EAS00698
INSTALLING THE REAR SHOCK
ABSORBER ASSEMBLY
1. Lubricate:
• spacers
• bolts
Recommended lubricant
Molybdenum disulfide grease
2. Install:
• rear shock absorber
NOTE:
• When installing the rear shock absorber
assembly, lift up the swingarm.
• Install the connecting arm front bolt from the
right.
3. Tighten:
• rear shock absorber upper nut
36 Nm (3.6 m•kg, 26 ft•lb)
• rear shock absorber lower bolt
36 Nm (3.6 m•kg, 26 ft•lb)
4. Install:
• rear frame (upper)
26 Nm (2.6 m•kg, 19 ft•lb)
• rear frame (lower)
16 Nm (1.6 m•kg, 12 ft•lb)
• clamp
4-68
REAR SHOCK ABSORBER ASSEMBLY
CHAS
5. Install:
• silencer
Refer to “EXHAUST PIPE” in chapter 5.
• seat and right side cover
Refer to “SEAT, SIDE COVERS AND FUEL
TANK” in chapter 3.
6. Adjust
• spring preload
• rebound damping
• compression damping
Refer to “ADJUSTING THE REAR SHOCK
ABSORBER” in chapter 3.
4-69
SWINGARM AND DRIVE CHAIN
CHAS
EAS00700
SWINGARM AND DRIVE CHAIN
16 Nm (1.6 m•kg, 12 ft•lb)
53 Nm (5.3 m•kg, 38 ft•lb)
7 Nm (0.7 m•kg, 5.1 ft•lb)
63 Nm (6.3 m•kg, 46 ft•lb)
36 Nm (3.6 m•kg, 26 ft•lb)
Order
1
2
3
4
5
Job / Part
Removing the swingarm and drive
chain
Rear wheel
Brake hose holder
Rear brake caliper
Left crankcase cover
Drive chain
Drive chain support
Drive chain support cover
Pivot shaft
Swingarm
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “REAR WHEEL, AND BRAKE
DISC”.
Refer to “FRONT AND REAR BRAKES”.
Refer to “CDI MAGNETO” in chapter 5.
1
1
1
1
1
For installation, reverse the removal
procedure.
4-70
SWINGARM AND DRIVE CHAIN
CHAS
53 Nm (5.3 m•kg, 38 ft•lb)
54 Nm (5.4 m•kg, 39 ft•lb)
Order
Job / Part
Disassembling the swingarm
Relay arm
Connecting rod
Cover
Dust seal
Collar
Bushing
Oil seal
Bearing
Bushing
Drive chain guide
10 Nm (1.0 m•kg, 7.2 ft•lb)
Q’ty
Remarks
Disassemble the parts in the order listed.
1
1
2
2
5
5
8
9
2
1
For assembly, reverse the disassembly
procedure.
4-71
SWINGARM AND DRIVE CHAIN
CHAS
EAS00703
REMOVING THE SWINGARM
1. Stand the vehicle on a level surface.
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that
the rear wheel is elevated.
2. Remove:
• rear wheel
Refer to “REAR WHEEL AND BRAKE
DISC”.
• brake hose holder and rear brake caliper
Refer to “FRONT AND REAR BRAKES”.
• left crankcase cover
Refer to “CDI MAGNETO” in chapter 5.
3. Measure:
• swingarm side play
• swingarm vertical movement
a. Measure the tightening torque of the pivot
shaft nut.
Pivot shaft nut
63 Nm (6.3 m•kg, 46 ft•lb)
b. Measure the swingarm side play
by
moving the swingarm from side to side.
c. If the swingarm side play is out of specification, check the spacers, bearings, washers,
and dust covers.
Swingarm sideplay
(at the end of the swingarm)
1.0 mm (0.04 in)
d. Check the swingarm vertical movement
by moving the swingarm up and down.
If swingarm vertical movement is not
smooth or if there is binding, check the
spacers, bearings, washers, and dust covers.
4-72
SWINGARM AND DRIVE CHAIN
CHAS
EAS00706
REMOVING THE DRIVE CHAIN
1. Stand the vehicle on a level surface.
WARNING
Securely support the vehicle so that there
is no danger of it falling over.
NOTE:
Place the vehicle on a suitable stand so that
the rear wheel is elevated.
2. Remove:
• master link clip
• master link
• master link plate
• drive chain
EAS00707
CHECKING THE SWINGARM
1. Check:
• swingarm
Bends / cracks / damage → Replace.
2. Check:
• pivot shaft
Roll the pivot shaft on a flat surface.
Bends → Replace.
WARNING
Do not attempt to straighten a bent pivot
shaft.
3.
•
•
•
Wash:
pivot shaft
collar
bearings
Recommended cleaning solvent
Kerosene
4-73
SWINGARM AND DRIVE CHAIN
CHAS
4. Check:
• collars
• oil seals
Damage / wear → Replace.
• bearings
Damage / pitting → Replace.
• bushings
Damage / wear → Replace.
5. Check:
• connecting rod
• relay arm
Damage / wear → Replace.
6. Check:
• bearings
• oil seals
Damage / wear → Replace.
• dust seals
Damage / pitting → Replace.
7. Check:
• bushings
Damage / wear → Replace.
• spacers
Damage / scratches → Replace.
EAS00710
CHECKING THE DRIVE CHAIN
1. Measure:
• Measure the dimension between 15-links
on the inner side
and outer side
of the
roller and calculate the dimension between
pin centers.
• Dimension
between pin centers = (Inner
dimension
+ Outer dimension )/2
• 15-link section
of the drive chain
Out of specification → Replace the drive
chain, front drive sprocket and rear drive
sprocket as a set.
15-link drive chain section limit
(maximum)
194.3 mm (6.75 in)
4-74
SWINGARM AND DRIVE CHAIN
CHAS
NOTE:
• While measuring the 15-link section, push
down on the drive chain to increase its tension.
• Perform this measurement at two or three different places.
2. Check:
• drive chain
Stiffness → Clean and lubricate or replace.
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.
4. Check:
• drive chain rollers
Damage / wear → Replace the drive chain.
• drive chain side plates
Damage / wear → Replace the drive chain.
Cracks → Replace the drive chain and
make sure the battery breather hose is
properly routed away from the drive chain
and below the swingarm.
5. Lubricate:
• drive chain
Recommended lubricant
Engine oil or chain lubricant
suitable for non-O-ring chains
4-75
SWINGARM AND DRIVE CHAIN
CHAS
6. Check:
• drive sprocket
• rear wheel sprocket
More than 1 / 4 tooth
wear → Replace
the drive chain sprockets as a set.
Bent teeth → Replace the drive chain
sprockets as a set.
Correct
Drive chain roller
Drive chain sprocket
CHECKING THE DRIVE CHAIN SUPPORT
1. Check:
• dive chain support
Limit reaches indicator
→ Replace.
EAS00711
INSTALLING THE SWINGARM
1. Install:
• bearing
• bushing (swingarm)
• oil seal
(with the swingarm)
NOTE:
• Apply the molybdenum disulfide grease on
the bearing and bushing when installing.
• Install the bearing by pressing it on the side
having the manufacture’s marks or numbers.
• First install the bushing and then the bearing
to a specified depth from inside.
Installed depth of bearings and
bushings
Bearing : 4.5 mm (0.18 in)
Bushing : 4.5 mm (0.18 in)
4-76
SWINGARM AND DRIVE CHAIN
CHAS
2. Install:
• bearing
• oil seal
(with the relay arm)
NOTE:
• Apply the molybdenum disulfide grease on
the bearing when installing.
• Install the bearing by pressing it on the side
having the manufacture’s marks or numbers.
Installed depth of bearings
Depth : 4.5 mm (0.18 in)
Depth : 0.5 mm (0.02 in)
Depth : 4.0 mm (0.16 in)
3. Install:
• bearing
• oil seal
(with the connecting rod)
NOTE:
• Apply the molybdenum disulfide grease on
the bearing when installing.
• Install the bearing by pressing it on the side
having the manufacture’s marks or numbers.
Installed depth of bearings
6.5 mm (0.26 in)
4. Install:
• connecting rod
53 Nm (5.3 m•kg, 38 ft•lb)
4-77
SWINGARM AND DRIVE CHAIN
5. Install:
• relay arm
CHAS
54 Nm (5.4 m•kg, 39 ft•lb)
6. Install:
• swingarm
• pivot shaft
• pivot shaft nut
63 Nm (6.3 m•kg, 46 ft•lb)
7. Install:
• rear shock absorber
• rear wheel
Refer to “REAR WHEEL AND BRAKE
DISC”.
8. Adjust:
• drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
Drive chain slack
35 ~ 45 mm (1.38 ~ 1.77 in)
EAS00714
INSTALLING THE DRIVE CHAIN
1. Lubricate:
• drive chain
• master link
Recommended lubricant
Engine oil or chain lubricant
suitable for non-O-ring chains
2. Install:
• master link
• master link plate
4-78
SWINGARM AND DRIVE CHAIN
CHAS
3. Install:
• master link clip
CAUTION:
• The closed end of the master link clip
must face in the direction of drive chain
rotation.
• Never install a new drive chain onto worn
drive chain sprockets; this will dramatically shorten the drive chain’s life.
4. Adjust:
• drive chain slack
Refer to “ADJUSTING THE DRIVE CHAIN
SLACK” in chapter 3.
Drive chain slack
35 ~ 45 mm (1.38 ~ 1.77 in)
CAUTION:
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
swingarm or cause an accident. Therefore,
keep the drive chain slack within the specified limits.
4-79
ENG
CHAPTER 5
ENGINE
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SILENCER FIBER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
5-1
5-2
5-3
5-4
5-6
CYLINDER HEAD, CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . .
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . .
CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . .
CHECKING THE CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . .
COMBINATION OF PISTON AND CYLINDER . . . . . . . . . . . . . . . . .
CHECKING THE PISTON RING . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PISTON PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SMALL END BEARING . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE PISTON AND CYLINDER . . . . . . . . . . . . . . . . . .
5-7
5-7
5-8
5-8
5-9
5-10
5-11
5-11
5-13
5-14
5-14
5-15
5-16
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE FRICTION PLATES . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH PLATES . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH SPRINGS . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH HOUSING . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH BOSS . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PRESSURE PLATE. . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PUSH LEVER SHAFT . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CLUTCH PUSH RODS . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-18
5-18
5-20
5-21
5-21
5-22
5-22
5-22
5-22
5-23
5-23
5-23
ENG
KICK STARTER AND SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . .
PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
KICK STARTER AND SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE PRIMARY DRIVE GEAR. . . . . . . . . . . . . . . . . . . .
REMOVING THE KICK SHAFT ASSEMBLY. . . . . . . . . . . . . . . . . . .
CHECKING THE KICK STARTER. . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE STOPPER LEVER. . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE PRIMARY DRIVE GEAR AND PRIMARY
DRIVEN GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE KICK STARTER SHAFT ASSEMBLY . . . . . . . . .
INSTALLING THE KICK IDLE GEAR . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . .
5-26
5-26
5-28
5-30
5-30
5-30
5-31
5-31
CDI MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE ROTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CDI MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE WOODRUFF KEY . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CDI MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . .
5-36
5-37
5-37
5-37
5-38
CRANKCASE AND CRANKSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . .
CRANKCASE AND CRANKSHAFT. . . . . . . . . . . . . . . . . . . . . . . . . .
DISSASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . .
REMOVING THE CRANKSHAFT BEARING. . . . . . . . . . . . . . . . . . .
CHECKING THE CRANKSHAFT AND CONNECTING ROD . . . . . .
CHECKING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . .
INSTALLING THE CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . .
5-40
5-40
5-41
5-41
5-42
5-42
5-43
5-43
5-44
5-44
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING THE TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE SHIFT DRUM ASSEMBLY . . . . . . . . . . . . . . . . . .
CHECKING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . .
5-46
5-49
5-49
5-50
5-50
5-51
5-31
5-31
5-33
5-33
5-34
ENGINE
ENG
ENGINE
ENGINE
DRIVE SPROCKET
60 Nm (6.0 m•kg, 43 ft•lb)
5 Nm (0.5 m•kg, 3.6 ft•lb)
Order
1
2
3
4
Job / Part
Removing the drive sprocket
Drive chain
Q’ty
Left crank case cover
Nut
Lock washer
Drive sprocket
Remarks
Remove the parts in the order listed.
Loosen.
Refer to “ADJUSTING THE DRIVE
CHAIN SLACK” in chapter 3.
1
1
1
1
For installation, reverse the removal
procedure.
5-1
ENGINE
ENG
EXHAUST PIPE
12 Nm (1.2 m•kg, 8.7 ft•lb)
12 Nm (1.2 m•kg, 8.7 ft•lb)
12 Nm (1.2 m•kg, 8.7 ft•lb)
12 Nm (1.2 m•kg, 8.7 ft•lb)
Order
1
2
3
4
5
Job / Part
Removing the exhaust pipe
Seat
Right side cover
Silencer
Exhaust pipe joint
Exhaust pipe spring
Exhaust pipe
Exhaust pipe gasket
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “SEAT, SIDE COVERS AND
FUEL TANK” in chapter 3.
1
1
2
1
2
For installation, reverse the removal
procedure.
5-2
ENGINE
ENG
SILENCER FIBER REPLACEMENT
1. Remove:
• seat
• right side cover
• bolt (silencer)
• silencer
• bolt (fiber)
• washer
2. Remove:
• inner pipe
3. Replace:
• fiber
4. Install:
• inner pipe
NOTE:
Fully apply Yamaha bond No. 1215 (Three
bond No. 1215®) or equivalent as shown.
Yamaha bond No.1215
(Three Bond No.1215®)
90890-85505
5. Install:
• washer
• bolt (fiber)
12 Nm (1.2 m•kg, 8.7 ft•lb)
LOCTITE®
• silencer
• bolt (silencer)
• right side cover
• seat
5-3
12 Nm (1.2 m•kg, 8.7 ft•lb)
7 Nm (0.7 m•kg, 5.1 ft•lb)
7 Nm (0.7 m•kg, 5.1 ft•lb)
ENGINE
ENG
EAS00191
ENGINE
63 Nm (6.3 m•kg, 46 ft•lb)
63 Nm (6.3 m•kg, 46 ft•lb)
Order
Job / Part
Removing the engine
Q’ty
Coolant
Remarks
Remove the parts in the order listed.
NOTE:
Place a suitable stand under the frame
and engine.
Drain
Refer to “CHANGING THE COOLANT” in
chapter 3.
Refer to “SEAT, SIDECOVERS AND
FUEL TANK” in chapter 3.
Refer to “CARBURETOR” in chapter 7.
Seat
Fuel tank
Carburetor
Exhaust pipe
Silencer
Clutch cable
Radiator hose
CDI magneto lead
Refer to “EXHAUST PIPE”.
Refer to “HANDLEBAR” in chapter 4.
Refer to “RADIATOR” in chapter 6.
Disconnect.
Loosen.
5-4
ENGINE
ENG
63 Nm (6.3 m•kg, 46 ft•lb)
63 Nm (6.3 m•kg, 46 ft•lb)
Order
1
2
3
4
5
Job / Part
CDI magneto lead
Drive chain
Q’ty
Remarks
Disconnect.
Loosen.
Refer to “ADJUSTING THE DRIVE
CHAIN SLACK” in chapter 3.
Engine mount nut
Engine mount bolt
Pivot shaft nut
Pivot shaft
Engine
2
2
1
1
1
For installation, reverse the removal
procedure.
5-5
ENGINE
ENG
EAS00192
INSTALLING THE ENGINE
1. Install:
• engine
• pivot shaft
• engine mount bolt (front)
• engine mount bolt (lower)
NOTE:
Do not fully tighten the bolts.
2. Tighten:
63 Nm (6.3 m•kg, 46 ft•lb)
• pivot shaft nut
• engine mount nut (front)
69 Nm (6.9 m•kg, 50 ft•lb)
• engine mount nut (lower)
69 Nm (6.9 m•kg, 50 ft•lb)
5-6
CYLINDER HEAD, CYLINDER AND PISTON
ENG
EAS00221
CYLINDER HEAD, CYLINDER AND PISTON
CYLINDER HEAD
20 Nm (2.0 m•kg, 14 ft•lb)
30 Nm (3.0 m•kg, 22 ft•lb)
Order
1
2
3
4
5
Job / Part
Removing the cylinder head
Coolant
Q’ty
Seat
Fuel tank
Radiator hose
Spark plug
Cylinder head nut
Copper washer
Cylinder head
O-ring
Remarks
Remove the parts in the order listed.
Drain
Refer to “CHANGING THE COOLANT” in
chapter 3.
Refer to “SEAT, SIDECOVERS AND
FUEL TANK” in chapter 3.
Refer to “RADIATOR” in chapter 6.
1
4
4
1
2
For installation, reverse the removal
procedure.
5-7
CYLINDER HEAD, CYLINDER AND PISTON
ENG
EAS00222
REMOVING THE CYLINDER HEAD
1. Remove:
• cylinder head nuts
NOTE:
• Loosen the nuts in the proper sequence as
shown.
• Loosen each nut 1 / 2 of a turn at a time. After
all of the nuts are fully loosened, remove
them.
EAS00229
CHECKING THE CYLINDER HEAD
1. Eliminate:
• combustion chamber carbon deposits
(with a rounded scraper )
NOTE:
Do not use a sharp instrument to avoid damaging or scratching:
• spark plug bore threads
2. Check:
• cylinder head
Damage / scratches → Replace.
• cylinder head water jacket
Mineral deposits / rust → Eliminate.
3. Measure:
• cylinder head warpage
Out of specification → Resurface the cylinder head.
Maximum cylinder head warpage
0.03 mm (0.012 in)
a. Place a straightedge
and a thickness
gauge
across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylinder head as follows.
5-8
CYLINDER HEAD, CYLINDER AND PISTON
ENG
d. Place a 400 ~ 600 grit wet sandpaper on
the surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
NOTE:
To ensure an even surface, rotate the cylinder
head several times.
EAS00233
INSTALLING THE CYLINDER HEAD
1. Lubricate:
• O-rings
Recommended lubricart
Lithium-soap-based grease
2. Install:
• O-rings
3. Install:
• cylinder head
• copper washer
• cylinder head nuts
30 Nm (3.0 m•kg, 22 ft•lb)
NOTE:
Tighten the cylinder head nuts in stage, using
a crisscross pattern.
4. Install:
• spark plug
• spark plug cap
• radiator hoses.
5-9
CYLINDER HEAD, CYLINDER AND PISTON
ENG
EAS00251
CYLINDER AND PISTON
28 Nm (2.8 m•kg, 20 ft•lb)
13 Nm (1.3 m•kg, 9.4 ft•lb)
13 Nm (1.3 m•kg, 9.4 ft•lb)
Order
1
2
3
4
5
6
7
8
9
Job / Part
Removing the cylinder and piston
Cylinder head
Cylinder nut
Cylinder
Dowel pin
Cylinder gasket
Piston pin clip
Piston pin
Piston
Small end bearing
Piston ring
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “CYLINDER HEAD”.
4
1
4
1
2
1
1
1
1
For installation, reverse the removal
procedure.
5-10
CYLINDER HEAD, CYLINDER AND PISTON
ENG
EAS00253
REMOVING THE CYLINDER AND PISTON
1. Remove:
• piston pin clip
NOTE:
Before removing the piston pin clip, cover the
crankcase opening with a clean rag to prevent
the piston pin clip from falling into the crankcase.
2. Remove:
• piston pin
• piston
• small end bearing
CAUTION:
Do not use a hammer to drive the piston
pin out.
NOTE:
Before removing the piston pin, deburr the piston pin clip’s groove and the piston’s pin bore
area. If both areas are deburred and the piston
pin is still difficult to remove, remove it with the
piston pin puller set .
Piston pin puller set
90890-01304, YU-1304
3. Remove:
• piston ring
NOTE:
When removing a piston ring, open the end
gap with your fingers and lift the other side of
the ring over the piston crown.
EAS00257
CHECKING THE CYLINDER AND PISTON
1. Check:
• piston wall
• cylinder wall
Vertical scratches → Replace the cylinder,
and the piston and piston rings as a set.
5-11
CYLINDER HEAD, CYLINDER AND PISTON
ENG
2. Measure:
• piston-to-cylinder clearance
a. Measure cylinder bore “C” with the cylinder
bore gauge.
NOTE:
Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the
cylinder. Then, find the average of the measurements.
Standard
Wear limit
Taper limit “T”
Out of round “R”
47.500 ~ 47.514 mm
(1.8701 ~ 1.8706 in)
47.6 mm (1.8740 in)
0.05 mm (0.0020 in)
0.05 mm (0.0020 in)
“C” = maximum of D1 ~ D6
maximum of D1 or D2 –
“T” =
maxmum of D5 or D6
maximum of D1 D3 or D5 –
“R” =
minimum of D2 D4 or D6
b. If out of specification, replace the cylinder,
and the piston and piston rings as a set.
c. Measure piston skirt diameter “P” with the
micrometer.
20.0 mm (0.79 in) from the bottom edge of the
piston
Piston size “P”
Standard
47.457 ~ 47.472 mm (1.8684 ~ 1.8690 in)
d. If out of specification, replace the piston
and piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.040 ~ 0.045 mm
(0.0016 ~ 0.0018 in)
<Limit>: 0.10 mm (0.0039 in)
f. If out of specification, replace the cylinder,
and the piston and piston rings as a set.
5-12
CYLINDER HEAD, CYLINDER AND PISTON
ENG
COMBINATION OF PISTON AND CYLINDER
1. Check:
• cylinder mark
Cylinder mark
A
B
C
D
Cylinder size
47.500 ~ 47.502 mm
(1.8701 ~ 1.8702 in)
47.504 ~ 47.506 mm
(1.8702 ~ 1.8703 in)
47.508 ~ 47.510 mm
(1.8704 ~ 1.8705 in)
47.512 ~ 47.514 mm
(1.87055 ~ 1.87063 in)
2. Check:
• piston mark
Piston mark
(color)
A (red)
B (orange)
C (green)
D (purple)
Piston size
47.457 ~ 47.460 mm
(1.8684 ~ 1.8685 in)
47.461 ~ 47.464 mm
(1.8685 ~ 1.8687 in)
47.465 ~ 47.468 mm
(1.8687 ~ 1.8688 in)
47.469 ~ 47.472 mm
(1.8689 ~ 1.8690 in)
3. Combination:
• combine the piston and cylinder by the following chart.
Cylinder mark
A
B
C
D
Piston mark (color)
A (red)
B (orange)
C (green)
D (purple)
NOTE:
When you purchase a cylinder, you cannot
designate its size. Choose the piston that
matches the above chart.
5-13
CYLINDER HEAD, CYLINDER AND PISTON
ENG
EAS00263
CHECKING THE PISTON RING
1. Measure:
• piston ring side clearance
Out of specification → Replace the piston
and piston ring as a set.
NOTE:
Before measuring the piston ring side clearance, eliminate any carbon deposits from the
piston ring grooves and piston ring.
Piston ring side clearance
Piston ring
0.030 ~ 0.065 mm
(0.001 ~ 0.003 in)
<Limit>: 0.1 mm (0.004 in)
2. Install:
• piston ring
(into the cylinder)
NOTE:
Level the piston ring into the cylinder with the
piston crown.
3. Measure:
• piston ring end gap
Out of specification → Replace the piston
ring.
Piston ring end gap
Top ring
0.30 ~ 0.45 mm
(0.012 ~ 0.018 in)
<Limit>: 0.80 mm (0.032 in)
CHECKING THE PISTON PIN
1. Check:
• piston pin
Blue discoloration / grooves → Replace the
piston pin and then check the fuel and
engine mixing oil.
2. Measure:
• piston pin outside diameter
Out of specification → Replace the piston
pin.
5-14
CYLINDER HEAD, CYLINDER AND PISTON
ENG
Piston pin outside diameter
13.996 ~ 14.000 mm
(0.5510 ~ 0.5512 in)
<Limit>: 13.975 mm (0.5502 in)
3. Measure:
• piston pin bore inside diameter
Out of specification → Replace the piston.
Piston pin bore inside diameter
14.004 ~ 14.015 mm
(0.5513 ~ 0.5518 in)
<Limit>: 14.040 mm (0.5528 in)
4. Calculate:
• piston-pin-to-piston clearance
Out of specification → Replace the piston
pin and piston as a set.
Piston-pin-to-piston clearance =
Piston pin bore size –
Piston pin outside diameter
Piston-pin-to-piston clearance
0.008 ~ 0.015 mm
(0.0003 ~ 0.0006 in)
<Limit>: 0.065 mm (0.0026 in)
CHECKING THE SMALL END BEARING
1. Check:
• small end bearing
Signs of heat discoloration → Replace.
5-15
CYLINDER HEAD, CYLINDER AND PISTON
ENG
EAS00267
INSTALLING THE PISTON AND CYLINDER
1. Install:
• piston ring
NOTE:
• Take care not to scratch the piston or damage
the piston ring.
• Align the piston ring gap with the pin .
• After installing the piston ring, check the
smooth movement of it.
2. Install:
• gasket (cylinder)
• small end bearing
(with the recomended lubricant)
• dowel pin
Recommended lubricant
Engine oil
3. Install:
• piston
• piston pin
• piston pin clip
NOTE:
• Apply engine oil the piston pin.
• Make sure the arrow mark
on the piston
points towards the exhaust side of the cylinder.
• Before installing the piston pin clip, cover the
crankcase opening with a clean rag to prevent the clip from falling into the crankcase.
• Do not allow the clip open ends to meet the
piston pin slat .
5-16
CYLINDER HEAD, CYLINDER AND PISTON
ENG
4. Lubricate:
• piston
• piston ring
• cylinder
(with the recommended lubricant)
Recommended lubricant
Engine oil
5. Install:
• cylinder
28 Nm (2.8 m•kg, 20 ft•lb)
• cylinder nut
NOTE:
• While compressing the piston ring with one
hand, install the cylinder with the other hand.
• Tighten the nuts in stage, using a crisscross
pattern.
5-17
CLUTCH
ENG
EAS00274
CLUTCH
CLUTCH
70 Nm (7.0 m•kg, 51 ft•lb)
6 Nm (0.6 m•kg, 4.3 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
Order
1
2
3
4
5
6
7
8
9
10
11
12
Job / Part
Removing the clutch
Transmission oil
Clutch cable
Clutch cover
Clutch cover gasket
Dowel pin
Compression spring
Pressure plate
Push rod 1
Ball
Push rod 2
Friction plate 1
Clutch plate 1
Friction plate 2
Clutch boss nut
Q’ty
Remarks
Drain
Refer to “CHANGING THE
TRANSMISSION OIL” in chapter 3.
Disconnect
1
1
2
5
1
1
1
1
2
6
5
1
5-18
CLUTCH
ENG
70 Nm (7.0 m•kg, 51 ft•lb)
6 Nm (0.6 m•kg, 4.3 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
Order
13
14
15
16
17
18
19
20
21
22
Job / Part
Conical washer
Clutch boss
Washer
Primary drive gear
Spacer
Washer
Push lever shaft
Spring
Oil seal
Bearing
Q’ty
1
1
1
1
1
1
1
1
1
1
Remarks
For installation, reverse the removal
procedure.
5-19
CLUTCH
ENG
EAS00276
REMOVING THE CLUTCH
1. Remove:
• clutch cover
• gasket
NOTE:
Loosen each bolt 1 / 4 of a turn at a time, in
stages and in a crisscross pattern.
After all of the bolts are fully loosened, remove
them.
2. Remove:
• compression spring bolts
• compression springs
• pressure plate
3. Remove:
• push rod 1
• ball
• push rod 2
4. Remove:
• friction plate 1
• clutch plate
• friction plate 2
5. Remove:
• clutch boss nut
• washer
• clutch boss
NOTE:
While holding the clutch boss with the universal clutch holder
, loosen the clutch boss
nut.
Universal clutch holder
90890-04086, YM-91042
6. Remove:
• washer
• primary driven gear
• spacer
5-20
CLUTCH
ENG
EAS00280
CHECKING THE FRICTION PLATES
The following procedure applies to all of the
friction plates.
1. Check:
• friction plate
Damage / wear → Replace the friction
plates as a set.
2. Measure:
• friction plate thickness
Out of specification → Replace the friction
plates as a set.
NOTE:
Measure the friction plate at four places.
Friction plate thickness
2.9 ~ 3.1 mm (0.114 ~ 0.112 in)
<Limit>: 2.7 mm (0.106 in)
EAS00281
CHECKING THE CLUTCH PLATES
The following procedure applies to all of the
clutch plates.
1. Check:
• clutch plate
Damage → Replace the clutch plates as a
set.
2. Measure:
• clutch plate warpage
(with a surface plate and thickness gauge
)
Out of specification → Replace the clutch
plates as a set.
Clutch plate warpage limit
0.1 mm (0.004 in)
5-21
CLUTCH
ENG
EAS00282
CHECKING THE CLUTCH SPRINGS
The following procedure applies to all of the
clutch springs.
1. Check:
• clutch spring
Damage → Replace the clutch springs as a
set.
2. Measure:
• clutch spring free length
Out of specification → Replace the clutch
springs as a set.
Clutch spring free length
33.0 mm (1.30 in)
<Limit>: 31.0 mm (1.22 in)
EAS00284
CHECKING THE CLUTCH HOUSING
1. Check:
• clutch housing dogs
Damage / pitting / wear → Deburr the clutch
housing dogs or replace the clutch housing.
NOTE:
Pitting on the clutch housing dogs will cause
erratic clutch operation.
EAS00285
CHECKING THE CLUTCH BOSS
1. Check:
• clutch boss splines
Damage / pitting / wear → Replace the clutch
boss.
NOTE:
Pitting on the clutch boss splines will cause
erratic clutch operation.
EAS00286
CHECKING THE PRESSURE PLATE
1. Check:
• pressure plate
Cracks / damage → Replace.
5-22
CLUTCH
ENG
CHECKING THE PUSH LEVER SHAFT
1. Check:
• push lever shaft
Wear / damage → Replace.
EAS00288
CHECKING THE CLUTCH PUSH RODS
1. Check:
• push rod 1
• ball
• push rod 2
Wear / damage / bend → Replace.
EAS00298
INSTALLING THE CLUTCH
1. Install:
• washer
• spacer
• primary driven gear
(with the recommended lubricant)
Recommended lubricant
Transmission oil
2. Install:
• washer
• clutch boss
3. Install:
• washer
NOTE:
Install the conical washer to the main axle
as shown in the illustration.
5-23
CLUTCH
ENG
4. Install:
• clutch boss nut
70 Nm (7.0 m•kg, 51 ft•lb)
NOTE:
While holding the clutch boss with the universal clutch holder
, tighten the clutch boss
nut.
Universal clutch holder
90890-04086, YM-91042
5. Lubricate:
• friction plates
• clutch plates
(with the recommended lubricant)
Recommended lubricant
Transmission oil
6. Install:
• friction plate 1
• clutch plate
• friction plate 2
NOTE:
• Install the clutch plates and friction plates
alternately on the clutch boss, starting with a
friction plate and ending with a friction plate.
• Use the friction plate for the first and final
while paying attention to the difference in surface pattern.
7. Install:
• push rod 2
• ball
• push rod 1
(with the recommended lubricant)
Recommended lubricant
Transmission oil
5-24
CLUTCH
8. Install:
• pressure plate 1
NOTE:
Align the punch mark
with the punch mark
ENG
on the pressure plate
on the clutch boss.
9. Install:
• clutch spring
• clutch spring bolt
6 Nm (0.6 m•kg, 4.3 ft•lb)
NOTE:
Tighten the clutch spring bolts in stages and in
a crisscross pattern.
10.Install
• dowel pin
• clutch cover gasket
10 Nm (1.0 m•kg, 7.2 ft•lb)
• clutch cover
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
5-25
KICK STARTER AND SHIFT SHAFT
ENG
EAS00327
KICK STARTER AND SHIFT SHAFT
PRIMARY DRIVE GEAR
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
79 Nm (7.9 m•kg, 57 ft•lb)
Order
Job / Part
Removing the primary drive gear
Transmission oil
Q’ty
Coolant
1
2
3
4
5
6
Water pump housing
Radiator hose 2
Brake pedal
Clutch
Kick starter crank
Right crankcase cover
Gascket
Dowel pin
Primary drive gear nut
Washer
Remarks
Remove the parts in the order listed.
Drain.
Refer to “CHANGING THE TRANSMISSION OIL” in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
Refer to “WATER PUMP” in chapter 6.
Refer to “RADIATOR” in chapter 6.
Refer to “CLUTCH”.
1
1
1
2
1
1
5-26
KICK STARTER AND SHIFT SHAFT
ENG
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
79 Nm (7.9 m•kg, 57 ft•lb)
Order
7
Job / Part
Primary drive gear
Q’ty
1
Remarks
For installation, reverse the removal
procedure.
5-27
KICK STARTER AND SHIFT SHAFT
ENG
KICK STARTER AND SHIFT SHAFT
10 Nm (1.0 m•kg, 7.2 ft•lb)
Order
1
2
3
4
5
6
7
8
9
10
11
12
13
Job / Part
Removing the kick starter shaft and
shift
shaft
Circlip
Washer
Kick idle gear
Spring guide
Torsion spring
Washer
Kick starter gear clip
Kick starter gear
Kick starter shaft
Shift pedal
Shift shaft
Stopper lever spring
Circlip
Q’ty
1
2
1
1
1
1
1
1
1
1
1
1
1
5-28
Remarks
Remove the parts in the order listed.
KICK STARTER AND SHIFT SHAFT
ENG
10 Nm (1.0 m•kg, 7.2 ft•lb)
Order
14
15
16
17
18
19
Job / Part
Washer
Stopper lever
Collar
Shift shaft spring
Oil seal
Oil seal
Q’ty
1
1
1
1
1
1
Remarks
For installation, reverse the removal
procedure.
5-29
KICK STARTER AND SHIFT SHAFT
ENG
REMOVING THE PRIMARY DRIVE GEAR
1. Remove:
• nut (primary drive gear)
NOTE:
Hold the drive gear holder
onto the crankcase using the M6 bolts .
Drive gear holder
90890-01495, YM-01495
REMOVING THE KICK SHAFT ASSEMBLY
1. Remove:
• kick shaft assembly
NOTE:
Unhook the torsion spring
from the hole
in the crankcase.
CHECKING THE KICK STARTER
1. Check:
• kick starter gear smooth movement
Unsmooth movement → Replace.
• kick starter shaft
Wear / damage → Replace.
2. Check:
• kick starter gear
Wear / damage → Replace.
• kick idle gear
Wear / damage → Replace.
• gear teeth
Wear / damage → Replace.
3. Measure:
• kick starter gear clip friction force
Out of specification → Replace.
(with the spring gauge )
Kick starter gear clip force
0.6 ~ 1.5 kg (1.3 ~ 3.3 lb)
5-30
KICK STARTER AND SHIFT SHAFT
ENG
EAS00328
CHECKING THE SHIFT SHAFT
1. Check:
• shift shaft
Bends / damage / wear → Replace.
• spring
Damage / wear → Replace.
EAS00330
CHECKING THE STOPPER LEVER
1. Check:
• stopper lever
Bends / damage → Replace.
• torsion spring
Damage / ware → Replace.
CHECKING THE PRIMARY DRIVE GEAR
AND PRIMARY DRIVEN GEAR
1. Check:
• primary drive gear
Damage / wear → Replace.
• primary driven gear
Damage / wear → Replace.
2. Check:
• primary driven gear circumferencial play
Free play exists → Replace.
EAS00331
INSTALLING THE SHIFT SHAFT
1. Install:
• stopper lever
• washer
• circlip
• torsion spring
(with thw collar )
NOTE:
Install the torsion spring with its shorter end
aligning with the stopper .
5-31
KICK STARTER AND SHIFT SHAFT
ENG
2. Install:
• stopper lever assembly
(with the shift shaft )
NOTE:
Apply the transmission oil on the stopper lever
assembly.
3. Install:
• stopper lever
• shift shaft
NOTE:
• Apply transmission oil on the shift shaft.
• When installing the shift shaft, align the stopper lever roller with the slot on segment.
• When installing the shift shaft, make sure that
the torsion spring
is in the position as
shown.
4. Check:
• shift lever
position
Gaps
and
are not equal except in
neutral → Replace the shift shaft.
5-32
KICK STARTER AND SHIFT SHAFT
ENG
INSTALLING THE KICK STARTER SHAFT
ASSEMBLY
1. Install:
• kick starter gear
• washer
• torsion spring
NOTE:
Make sure the stopper
of the torsion spring
fits into the hole
in the other side of the
stopper
of the kick starter shaft .
2. Install:
• spring guide
NOTE:
Slide the spring guide into the kick starter
shaft, make sure the groove
in the spring
guide fits on the stopper of the torsion spring.
3. Install:
• kick starter shaft assembly
NOTE:
• Apply the transmission oil on the kick shaft.
• Apply the lithium soap base grease on the
kick shaft stopper.
• Slide the kick starter shaft assembly into the
crankcase, make sure the clip
and kick
starter shaft stopper
fit into their home
positions , .
4. Install:
• torsion spring
NOTE:
Turn the torsion spring clockwise and hook into
the proper hole
in the crankcase.
INSTALLING THE KICK IDLE GEAR
1. Install:
• washer
• kick idle gear
• circlip
NOTE:
• Apply the transmission oil on the kick idle
gear inner circumference.
• Install the kick idle gear with its groove
facing the engine.
5-33
ENG
KICK STARTER AND SHIFT SHAFT
INSTALLING THE PRIMARY DRIVE GEAR
1. Install:
• straight key
2. Install:
• primary drive gear
• washer
• primary drive gear nut
NOTE:
Install the conical washer to the crankshaft
as shown in the illustration.
3. Tighten:
• primary drive gear nut
79 Nm (7.9 m•kg, 57 ft•lb)
Drive gear holder
90890-01495, YM-01495
NOTE:
Hold the drive gear holder
case using the M6 bolts .
onto the crank-
4. Install:
• primary driven gear
Refer to “CLUTCH”.
5. Install:
• dowel pin
• gasket (right crankcase cover)
6. Install:
• right crankcase cover
NOTE:
Mesh the impeller shaft gear
drive gear .
5-34
with primary
KICK STARTER AND SHIFT SHAFT
ENG
7. Install:
• bolt (right crankcase cover)
10 Nm (1.0 m•kg, 7.2 ft•lb)
• copper washer (oil drain bolt)
• oil drain bolt
10 Nm (1.0 m•kg, 7.2 ft•lb)
• copper washer (coolant drain bolt)
• coolant drain bolt
10 Nm (1.0 m•kg, 7.2 ft•lb)
NOTE:
Tighten the bolts in stage, using a crisscross
pattern.
8. Install:
• kick starter crank
10 Nm (1.0 m•kg, 7.2 ft•lb)
NOTE:
Install the kick starter crank closest to but not
contacting the pillar tube
and exhaust pipe
.
9. Install:
10 Nm (1.0 m•kg, 7.2 ft•lb)
• shift pedal
NOTE:
Install the shift pedal with the bottom of the
pedal outer diameter
as close to the center
of the engine mounting bolt
as possible.
5-35
CDI MAGNETO
ENG
EAS00343
CDI MAGNETO
8 Nm (0.8 m•kg, 5.8 ft•lb)
33 Nm (3.3 m•kg, 24 ft•lb)
5 Nm (0.5 m•kg, 3.6 ft•lb)
Order
1
2
3
4
5
6
Job / Part
Removing the CDI magneto
Seat
Fuel tank
CDI magneto lead
Left crankcase cover
Left crankcase cover gasket
Rotor
Stator
Woodruff key
Q’ty
1
1
1
1
1
1
Remarks
Remove the parts in the order listed.
Disconnect.
For installation, reverse the removal
procedure.
5-36
CDI MAGNETO
ENG
EAS00346
REMOVING THE ROTOR
1. Remove:
• nut
• washer
NOTE:
While holding the rotor with the rotor holding
tool , loosen the rotor nut.
Rotor holding tool
90890-01235, YU-1325
2. Remove:
• rotor
(with the flywheel puller
• woodruff key
)
Flywheel puller
90890-01189, YM-1189
NOTE:
When installing the flywheel puller, turn it
counterclockwise.
CHECKING THE CDI MAGNETO
1. Check:
• rotor inner surface
• stator outer surface
Damage → Inspect the crankshaft runout
and crankshaft bearing.
If necessary, replace CDI magneto and/or
stator.
CHECKING THE WOODRUFF KEY
1. Check:
• woodruff key
Damage → Replace.
5-37
CDI MAGNETO
ENG
INSTALLING THE CDI MAGNETO
1. Install:
• stator
• screw
NOTE:
Temporarily tighten the screw at this point.
2. Install:
• woodruff key
• rotor
NOTE:
• Clean the tapered portions of the crankshaft
and rotor.
• When installing the woodruff key, make sure
that its flat surface
is in parallel with the
crankshaft center line .
• When installing the rotor, align the keyway
of the rotor with the woodruff key.
3. Install:
• washer
33 Nm (3.3 m•kg, 24 ft•lb)
• nut
(with the rotor holding tool )
Rotor holding tool
90890-01235, YU-1325
4. Adjust:
• ignition timing
Ignition timing (B.T.D.C.)
0.9 mm (0.035 in)
Refer to “CHECKING THE IGNITION TIMING”
in chapter 3.
5-38
CDI MAGNETO
ENG
5. Tighten:
• screw (stator)
8 Nm (0.8 m•kg, 5.8 ft•lb)
6. Check:
• ignition timing
Re-check the ignition timing.
7. Connect:
• CDI magneto lead
Refer to “CABLE ROUTING” in chapter 2.
8. Install:
• gasket (left crankcase cover)
• left crankcase cover
5 Nm (0.5 m•kg, 3.6 ft•lb)
NOTE:
Tighten the screws in stage, using a crisscross
pattern.
5-39
CRANKCASE AND CRANKSHAFT
ENG
EAS00381
CRANKCASE AND CRANKSHAFT
CRANKCASE AND CRANKSHAFT
8 Nm (0.8 m•kg, 5.8 ft•lb)
20 Nm (2.0 m•kg, 14 ft•lb)
Order
1
2
3
4
5
6
7
Job / Part
Removing the crankcase and
crankshaft
Engine
Piston
Primary drive gear
Kick idle gear
Stopper lever
Rotor and stator
Crank case oil seal holder
Right crankcase
Left crankcase
Dowel pin
Crankshaft
Oil seal
Bearing
8 Nm (0.8 m•kg, 5.8 ft•lb)
Q’ty
Remarks
Remove the parts in the order listed.
Refer to “ENGINE”.
Refer to “CYLINDER AND PISTON”.
Refer to “CLUTCH”.
Refer to “KICK STARTER AND SHIFT
SHAFT”.
Refer to “CDI MAGNETO”.
1
1
1
2
1
2
2
For installation, reverse the removal
procedure.
5-40
CRANKCASE AND CRANKSHAFT
ENG
EAS00385
DISSASSEMBLING THE CRANKCASE
1. Remove:
• right crankcase
(with the crankcase separating tool )
Crankcase separating tool
90890-01135, YU-1135-A
NOTE:
• Fully tighten the tool holding bolts, but make
sure the tool body is parallel with the case. If
necessary, one screw may be backed out
slightly to level tool body.
• As pressure is applied, alternately tap on the
front engine mounting boss and transmission
shafts.
CAUTION:
• Turn the segment
to the position shown
in the figure so that it does not contact the
crankcase.
• Use soft hammer to tap on the case half.
Tap only on reinforced portions of case.
Do not tap on gasket mating surface. Work
slowly and carefully. Make sure the case
halves separate evenly. If one end “hangs
up”, take pressure off the push screw,
realign, and start over. If the cases do not
separate, check for a remaining case
screw or fitting. Do not force.
M6×1.0
EAS00388
REMOVING THE CRANKSHAFT ASSEMBLY
1. Remove:
• crankshaft
(with the crankcase separating tool )
100 mm (3.94 in)
Crankcase separating tool
90890-01135, YU-1135-A
NOTE:
Make appropriate bolts
as shown available
by yourself and attach the tool with them.
CAUTION:
Do not use a hammer to drive out the
crankshaft.
5-41
CRANKCASE AND CRANKSHAFT
ENG
REMOVING THE CRANKSHAFT BEARING
1. Remove:
• bearing
NOTE:
• Remove the bearing from the crankcase by
pressing its inner race as shown in .
• If the bearing is removed together with the
crankshaft, remove the bearing using a general bearing puller
as shown in .
CAUTION:
Do not use the removed bearing.
EAS00394
CHECKING THE CRANKSHAFT AND
CONNECTING ROD
1. Measure:
• crankshaft runout
Out of specification → Replace the crankshaft, bearing or both.
NOTE:
Turn the crankshaft slowly.
Maximum crankshaft runout
0.08 mm (0.003 in)
2. Measure:
• small end free play
Out of specification → Replace the small
end bearing or piston pin.
Maximum small end free play
2.0 mm (0.08 in)
5-42
CRANKCASE AND CRANKSHAFT
ENG
3. Measure:
• big end side clearance
Out of specification → Replace the big end
bearing, crankshaft pin, or connecting rod.
Big end side clearance
0.20 ~ 0.70 mm (0.008 ~ 0.028 in)
4. Measure:
• crankshaft width
Out of specification → Replace the crankshaft.
Crankshaft width
44.90 ~ 44.95 mm
(1.768 ~ 1.770 in)
EAS00399
CHECKING THE CRANKCASE
1. Check:
• contacting surface
Scratches → Replace.
• engine mounting boss , crankcase
Cracks / damage → Replace.
EAS00401
CHECKING THE BEARINGS AND OIL
SEALS
1. Check:
• bearings
Clean and lubricate the bearings, then
rotate the inner race with your finger.
Rough movement → Replace.
2. Check:
• oil seals
Damage / wear → Replace.
5-43
CRANKCASE AND CRANKSHAFT
ENG
EAS00408
INSTALLING THE CRANKSHAFT
1. Install:
• crankshaft assembly
NOTE:
• Install the crankshaft assembly with the
crankshaft installer pot
, crankshaft
installer bolt , adapter (M10) .
Crankshaft installer pot
90890-01274, YU-90050
Crankshaft installer bolt
90890-01275, YU-90050
Adapter (M10)
90890-01277, YM-1277
CAUTION:
To avoid scratching the crankshaft and to
ease the installation procedure, lubricate
the oil seal lips with lithium-soap-based
grease and each bearing with engine oil.
NOTE:
Hold the connecting rod at top dead center
with one hand while turning the nut of the
crankshaft installer bolt with the other. Turn the
crankshaft installer bolt until the crankshaft
assembly bottoms against the bearing.
EAS00416
ASSEMBLING THE CRANKCASE
1. Apply:
• sealant
(onto the crankcase mating surfaces)
Yamaha bond No. 1215
(Three Bond No. 1215®)
90890-85505
NOTE:
Do not allow any sealant to come into contact
with the oil gallery.
5-44
CRANKCASE AND CRANKSHAFT
ENG
2. Install:
• dowel pin
• right crankcase
(onto the left crankcase )
NOTE:
• Turn the shift cam
to the position shown in
the figure so that it does not contact the
crankcase when installing the crankcase.
• Fit the right crankcase onto the left crankcase. Tap lightly on the case with soft hammer.
• When installing the crankcase, the connecting rod should be positioned at TDC.
3. Install:
• clamp
• screw
8 Nm (0.8 m•kg, 5.8 ft•lb)
NOTE:
Tighten the crankcase tightening screws in
stage, using a crisscross pattern.
4. Install:
• crankcase oil seal holder
20 Nm (2.0 m•kg, 14 ft•lb)
• bolt
LOCTITE®
5. Remove:
• sealant
• forced out on the cylinder mating surface.
6. Apply:
• Transmission oil
To the crank pin, bearing, oil delivery hole
and connecting rod end washer.
7. Check:
• crankshaft and transmission operation
Unsmooth operation → Repair.
5-45
TRANSMISSION
ENG
EAS00419
TRANSMISSION
Order
1
2
3
4
5
6
7
8
9
10
11
Job / Part
Removing the transmission
Engine
Crankcase
Shift fork guide bar
Shift drum
Shift fork-R
Shift fork-L
Shift fork-C
Bearing
Circlip
2ND pinion gear
6TH pinion gear
Washer
Circlip
Q’ty
2
1
1
1
1
1
1
1
1
1
1
5-46
Remarks
Remove the parts in the order listed.
Refer to “ENGINE”.
Separate.
Refer to “CRANKCASE AND
CRANKSHAFT”.
TRANSMISSION
Order
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
Job / Part
3RD pinion gear
Circlip
Washer
5TH pinion gear
Main axle
Bearing
Circlip
Washer
1ST wheel gear
5TH wheel gear
Circlip
Washer
4TH wheel gear
3RD wheel gear
6TH wheel gear
Drive axle
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
5-47
ENG
Remarks
TRANSMISSION
Order
28
29
30
31
32
Job / Part
2ND wheel gear
Washer
Bearing
Oil seal
Bearing
Q’ty
1
1
1
1
2
ENG
Remarks
For installation, reverse the removal
procedure.
5-48
TRANSMISSION
ENG
EAS00420
REMOVING THE TRANSMISSION
1. Remove:
• right crankcase
Refer to “CRANKCASE AND CRANKSHAFT”.
2. Remove:
• main axle
• drive axle
NOTE:
• Remove assembly carefully. Note the position
of each part. Pay particular attention to the
location and direction of shift forks.
• Remove the main axle and drive axle by tapping lightly on the transmission drive axle with
a soft hammer.
AS00421
CHECKING THE SHIFT FORKS
The following procedure applies to all of the
shift forks.
1. Check:
• shift fork pin
• shift fork cam follower
Bends / damage / scoring / wear → Replace
the shift fork.
2. Check:
• shift fork guide bar
Roll the shift fork guide bar on a flat surface.
Bends → Replace.
WARNING
Do not attempt to straighten a bent shift
fork guide bar.
3. Check:
• shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift forks
and shift fork guide bar as a set.
5-49
TRANSMISSION
ENG
EAS00422
CHECKING THE SHIFT DRUM ASSEMBLY
1. Check:
• shift drum grooves
Damage / scratches / wear → Replace the
shift drum assembly.
• shift drum segment
Damage / wear → Replace the shift drum
assembly.
• shift drum bearing
Damage / pitting → Replace the shift drum
assembly.
EAS00423
CHECKING THE TRANSMISSION
1. Measure:
• main axle runout
(with a centering device and dial gauge )
Out of specification → Replace the main
axle.
Main axle runout limit
0.01 mm (0.0004 in)
2. Measure:
• drive axle runout
(with a centering device and dial gauge )
Out of specification → Replace the drive
axle.
Drive axle runout limit
0.01 mm (0.0004 in)
3. Check:
• transmission gears
Blue discoloration / pitting / wear → Replace
the defective gear(s).
• transmission gear dogs
Cracks / damage / rounded
edges
→
Replace the defective gear(s).
• transmission shift fork groove
Wear / damage → Replace.
5-50
TRANSMISSION
ENG
4. Check:
• transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect → Reassemble the transmission
axle assemblies.
5. Check:
• transmission gear movement
Rough movement → Replace the defective
part(s).
6. Check:
• circlips
Bends / damage / looseness → Replace.
INSTALLING THE TRANSMISSION
1. Install:
• 5TH pinion gear
• 3RD/4TH pinion gear
• 6TH pinion gear
• 2ND pinion gear
(onto the main axle )
NOTE:
• Apply the molybdenum disulfide oil on the
5TH and 6TH pinion gears inner circumference and on the end surface.
• Apply the transmission oil on the 3RD/4TH
and 2ND pinion gears inner circumference.
2. Install:
• 2ND wheel gear
• 6TH wheel gear
• 3RD wheel gear
• 4TH wheel gear
• 5TH wheel gear
• 1ST wheel gear
(onto the drive axle )
NOTE:
• Apply the molybdenum disulfide oil on the
1ST, 2ND, 3RD and 4TH wheel gears inner
circumference and on the end surface.
• Apply the transmission oil on the 5TH and
6TH wheel gears inner circumference.
5-51
TRANSMISSION
ENG
3. Install:
• washer
• circlip
NOTE:
• Be sure the circlip sharp-edged corner
is
positioned opposite side to the washer and
gear .
• Be sure the circlip end
is positioned at axle
spline groove .
4. Install:
• collar
NOTE:
• Apply the lithium soap base grease on the oil
seal lip.
• When installing the collar into the crankcase,
pay careful attention to the crankcase oil seal
lip.
5. Install:
• main axle
• drive axle
6. Install:
• shift fork-L
• shift fork-C
• shift fork-R
• shift fork pin
5-52
TRANSMISSION
ENG
NOTE:
• Mesh the shift fork-L
with the 6th wheel
gear
and shift fork-R
with the 5TH
on the drive axle.
wheel gear
• Mesh the shift fork-C
with the 3RD / 4TH
pinion gear
on the main axle.
7. Install:
• shift cam
NOTE:
Apply the transmission oil on the shift cam.
8. Install:
• shift fork guide bar
NOTE:
• Apply the transmission oil on the guide bars.
• Be sure the long bar is inserted into the shift
fork-L and shift fork-R and the short one into
shift fork-C.
9. Check:
• shifter operation
• transmission operation
5-53
COOL
CHAPTER 6
COOLING SYSTEM
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
CHECKING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
INSTALLING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
CHECKING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
INSTALLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
RADIATOR
EAS00454
COOL
COOLING SYSTEM
RADIATOR
1 Nm (0.1 m•kg, 0.7 ft•lb)
1 Nm (0.1 m•kg, 0.7 ft•lb)
1 Nm (0.1 m•kg, 0.7 ft•lb)
Order
Job / Part
Removing the radiator
Air scoop
Q’ty
Coolant
1
2
3
4
5
6
Radiator guard
Radiator inlet hose
Radiator outlet hose
Radiator breather hose
Radiator
Radiator cap
Remarks
Remove the parts in the order listed.
Refer to “SEAT, SIDECOVERS AND
FUEL TANK” in chapter 3.
Drain.
Refer to “CHANGING THE COOLANT” in
chapter 3.
1
1
1
1
1
1
For installation, reverse the removal
procedure.
6-1
RADIATOR
COOL
EAS00455
CHECKING THE RADIATOR
1. Check:
• radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the
radiator.
Damage → Repair or replace.
NOTE:
Straighten any flattened fins with a thin, flathead screwdriver.
2. Check:
• radiator hoses
Cracks / damage → Replace.
3. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Radiator cap opening pressure
93 ~ 123 kPa
(0.93 ~ 1.23 kg / cm2, 13.2 ~ 17.5
psi)
a. Install the radiator cap tester
and radiator cap tester adapter
to the radiator cap
.
Radiator cap tester
90890-01325, YU-24460-01
Radiator cap tester adapter
90890-01352, YU-33984
b. Apply the specified pressure for ten seconds and make sure there is no drop in
pressure.
EAS00456
INSTALLING THE RADIATOR
1. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
6-2
RADIATOR
COOL
2. Check:
• cooling system
Leaks → Repair or replace any faulty part.
a. Attach the radiator cap tester
ator.
to the radi-
Radiator cap tester
90890-01325, YU-24460-01
Radiator cap tester adapter
90890-01352, YU-33984
b. Apply 100 kPa (1.0 kg / cm2, 14.22 psi) of
pressure.
c. Measure the indicated pressure with the
gauge.
6-3
WATER PUMP
COOL
EAS00468
WATER PUMP
10 Nm (1.0 m•kg, 7.2 ft•lb)
14 Nm (1.4 m•kg, 10 ft•lb)
10 Nm (1.0 m•kg, 7.2 ft•lb)
Order
Job / Part
Removing the water pump
Q’ty
Right crankcase cover
1
2
3
4
5
6
Remarks
Remove the parts in the order listed.
NOTE:
It is not necessary to remove the water
pump unless the coolant level is extremely
low or the coolant contains engine oil.
Refer to “PRIMARY DRIVE GEAR” in
chapter 5.
Water pump housing
Gasket
Impeller
Water pump impeller shaft
Bearing
Oil seal
1
1
1
1
1
2
For installation, reverse the removal
procedure.
6-4
WATER PUMP
COOL
EAS00472
CHECKING THE WATER PUMP
1. Check:
• oil seal
Damage / wear → Replace.
2. Check:
• bearing
Rough movement → Replace.
3. Check:
• impeller
Cracks / damage / wear → Replace.
4. Check:
• water pump impeller shaft
Damage / wear → Replace.
• water pump drive gear
Damage / wear → Replace.
EAS00479
INSTALLING THE WATER PUMP
1. Install:
• oil seal
NOTE:
Lubricate the oil seal with a thin coat of lithiumsoap-based grease.
6-5
COOL
WATER PUMP
2. Install:
• bearing
NOTE:
Install the bearing by pressing its outer race
parallel.
3. Install:
• water pump impeller shaft
• washer
14 Nm (1.4 m•kg, 10 ft•lb)
• impeller
NOTE:
• Take care so that the oil seal lip is not damaged or the spring does not slip off its position.
• When installing the water pump impeller
shaft, apply the lithium-soap-base grease on
the oil seal lip and water pump impeller shaft.
And install the shaft while turning it.
• Hold the impeller shaft on its width across the
flats
with spanners, etc. and install the
impeller.
4. Install:
• gasket
• water pump housing
10 Nm (1.0 m•kg, 7.2 ft•lb)
• copper washer
5. Fill:
• cooling system
(with the specified amount of the recommended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
6. Check:
• cooling system
Refer to “CHECKING THE COOLING SYSTEM” in chapter 3.
6-6
CARB
CHAPTER 7
CARBURETOR
CARBURETOR AND REED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING THE REED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLY THE REED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE REED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . .
MEASURING AND ADJUSTING THE FUEL LEVEL. . . . . . . . . . . . .
CHECKING THE FUEL COCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1
7-4
7-5
7-6
7-6
7-8
7-8
7-9
7-9
CARBURETOR AND REED VALVE
EAS00480
CARB
CARBURETOR
CARBURETOR AND REED VALVE
8 Nm (0.8 m•kg, 5.8 ft•lb)
1 Nm (0.1 m•kg, 0.7 ft•lb)
Order
1
2
3
4
5
6
Job / Part
Removing the carburetor and reed
valve
Clamp
Carburetor assembly
Carburetor joint
Reed valve assembly
Reed valve stopper
Reed valve
Q’ty
2
1
1
1
2
2
Remarks
Remove the parts in the order listed.
Loosen.
For installation, reverse the removal
procedure.
7-1
CARBURETOR AND REED VALVE
Order
Job / Part
Disassembling the carburetor
Mixing chamber top
Throttle valve
Jet needle
Ring
Throttle valve spring
Gascket (mixing chamber top)
Float chamber
Gascket (float chamber)
Float pin
Float
Needle valve
Main jet
Main nozzle holder
Main nozzle
Pilot jet
Q’ty
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
7-2
CARB
Remarks
Remove the parts in the order listed
CARBURETOR AND REED VALVE
Order
Job / Part
Starter plunger
Throttle stop screw
Pilot air screw
Q’ty
1
1
1
CARB
Remarks
For assembly, reverse the disassembly
procedure.
7-3
CARBURETOR AND REED VALVE
CARB
EAS00485
CHECKING THE CARBURETOR
1. Check:
• carburetor body
• float chamber
• jet housing
Cracks / damage → Replace.
2. Check:
• fuel passages
Obstruction → Clean.
a. Wash the carburetor in a petroleum-based
solvent. Do not use any caustic carburetor
cleaning solution.
b. Blow out all of the passages and jets with
compressed air.
3. Check:
• float chamber body
Dirt → Clean.
4. Check:
• float chamber rubber gasket
Cracks / damage / wear → Replace.
5. Check:
• float
Damage → Replace.
6. Check:
• needle valve
• needle valve seat
Damage / wear
→ Replace.
Obstruction
→ Clean.
7-4
CARBURETOR AND REED VALVE
7.
•
•
•
•
•
•
CARB
Check:
jet needle
main nozzle
main jet
main nozzle holder
pilot jet
starter plunger
Bends / damage / wear → Replace.
Obstruction → Clean.
Blow out the jets with compressed air.
8. Check:
• piston valve movement
Insert the piston valve
into the carburetor body and move it up and down.
Tightness → Replace the piston valve.
9. Check:
• hose joints
Cracks / damage → Replace.
10.Check:
• carburetor breather hoses
• fuel hoses
Cracks / damage / wear → Replace.
Obstruction → Clean.
Blow out the hoses with compressed air.
CHECKING THE REED VALVE
1. Measure:
• reed valve bending
Out of limit → Replace.
Reed valve bending limit
0.2 mm (0.008 in)
• valve stopper height
Out of specification → Replace.
Valve stopper height
7.4 ~ 7.8 mm (0.291 ~ 0.307 in)
7-5
CARBURETOR AND REED VALVE
CARB
ASSEMBLY THE REED VALVE
1. Install:
• reed valve
• reed valve stopper
• screw (reed valve)
1 Nm (0.1 m•kg, 0.7 ft•lb)
LOCTITE®
NOTE:
• Install the reed valve with the reed valve
bending as shown.
• Note the cut
in the lower corner of the reed
valve and stopper.
• Tighten each screw gradually to avoid warping.
EAS00487
ASSEMBLING THE CARBURETOR
CAUTION:
• Before assembling the carburetor, wash
all of the parts in a petroleum-based solvent.
• Always use a new gasket.
1. Install:
• pilot air screw
• throttle stop screw
NOTE:
• Turn in the pilot air screw until it is lightly
seated.
• Turn out the pilot air screw by the number of
turns recorded before removing.
Pilot air screw setting
2 turns out
7-6
CARBURETOR AND REED VALVE
CARB
2. Install:
• starter plunger
3. Install:
• pilot jet
• main nozzle
• main jet holder
• main jet
NOTE:
Install the main nozzle with its chamfered side
facing the carburetor.
4. Install:
• needle valve
• float
• float pin
NOTE:
• After installing the needle valve to the float,
install them to the carburetor.
• Check the float for smooth movement.
5. Install:
• float chamber
• gascket (float chamber)
• hose holder (carburetor breather hose)
6. Install:
• carburetor breather hose
• overflow hose
7. Install:
• jet needle
• throttle valve
7-7
CARBURETOR AND REED VALVE
CARB
8. Install:
• throttle cable
• mixing chamber top
• gascket (mixing chamber top)
• spring (throttle valve)
• ring
• throttle valve
NOTE:
• While compressing the spring, connect the
throttle cable.
• Align the cut
in the ring with the throttle
cable.
INSTALLING THE REED VALVE
1. Install:
• reed valve assembly
NOTE:
Install the reed valve assembly with its projection
facing upward.
2. Install:
• carburetor joint
8 Nm (0.8 m•kg, 5.8 ft•lb)
EAS00492
INSTALLING THE CARBURETOR
1. Adjust:
• engine idle speed
Refer to “ADJUSTING THE ENGINE IDLING
SPEED” in chapter 3.
7-8
CARBURETOR AND REED VALVE
CARB
2. Adjust:
• throttle cable free play
Throttle cable free play
3 ~ 5 mm (0.12 ~ 0.20 in)
Refer to “ADJUSTING THE THROTTLE
CABLE FREE PLAY” in chapter 3.
EAS00498
MEASURING AND ADJUSTING THE FUEL
LEVEL
1. Measure:
• fuel height
Out of specification → Adjust.
Fuel height
18 ~ 20 mm (0.71 ~ 0.79 in)
a. Hold the carburetor in an upside down position.
b. Measure the distance between the mating
surface of the float chamber and top of the
float using a vernier calipers.
NOTE:
The float arm should be resting on the needle
valve, but not compressing the needle valve
2. Adjust:
• fuel level
a. Check the needle valve seat and needle
valve.
b. If either is worn, replace them as a set.
c. If both are fine, adjust the float level by
slightly bending the float tang .
d. Measure the fuel height again.
e. Repeat steps (c) to (d) until the fuel level is
within specification.
EAS00505
CHECKING THE FUEL COCK
1. Check:
• fuel cock
Cracks / damage / wear → Replace.
2. Check:
• fuel cock strainer
Obstruction → Clean.
Blow out the jets with compressed air.
Damage → Replace.
7-9
ELEC
CHAPTER 8
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
CHECKING SWITCH CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
IGNITION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
ELECTRICAL COMPONENTS
EAS00729
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS
Ignition coil
Engine stop switch
CDI unit
CDI magneto
8-1
ELEC
CHECKING SWITCH CONTINUITY
ELEC
CEAS00730
“∞”
CHECKING SWITCH CONTINUITY
“0”
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.
“Ω × 1”
CAUTION:
Never insert the tester probes into the coupler terminal slots. 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-3112
NOTE:
• 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.
8-2
IGNITION SYSTEM
EAS00736
ELEC
EAS00740
IGNITION SYSTEM
1. Spark plug
TROUBLESHOOTING
• Check the condition of the spark plug.
• Check the spark plug type.
• Measure the spark plug gap.
Refer to “CHECKING THE SPARK PLUG”
in chapter 3.
The ignition system fails to operate (no
spark or intermittent spark).
Check:
1. Spark plug
2. Ignition spark gap
3. Spark plug cap resistance
4. Ignition coil resistance
5. Engine stop switch
6. Pickup coil resistance
7. Charging coil resistance
8. Wiring connections (of the entire ignition
system)
NOTE:
• Before troubleshooting, remove the following
part(s):
1. seat
2. air scoop
3. fuel tank
• Troubleshoot with the following special
tool(s).
Standard spark plug
BR10EG (NGK)
Spark plug gap
0.5 ~ 0.6 mm (0.0197 ~ 0.0236 in)
• Is the spark plug in good condition, is it of
the correct type, and is its gap within specification?
YES
NO
Re-gap or replace
the spark plug.
EAS00742
2. Ignition spark gap
• Disconnect the spark plug cap from the
spark plug.
• Connect the ignition checker / dynamic
spark tester
as shown.
•
Spark plug cap
• Kick the kicstarter crank.
• Measure the ignition spark gap .
• Crank the engine, and gradually increase
the spark gap until a misfire occurs.
Dynamic spark tester
YM-34487
Ignition checker
90890-06754
Pocket tester
90890-03112, YU-3112-C
Minimum ignition spark gap
6.0 mm (0.24 in)
• Is there a spark and is the spark gap within
specification?
NO
YES
The ignition system
is OK.
8-3
ELEC
IGNITION SYSTEM
EAS00744
EAS00746
3. Spark plug cap resistance
4. Ignition coil resistance
• Remove the spark plug cap from the spark
plug lead.
• Connect the pocket tester (“Ω × 1k” range)
to the spark plug cap as shown.
• Measure the spark plug cap resistance.
• Disconnect the ignition coil connectors from
the ignition coil terminals.
• Connect the pocket tester (Ω × 1) to the
ignition coil as shown.
Positive tester probe → orange
Negative tester probe → black
Positive tester probe →
spark plug lead terminal
Negative tester probe →
spark plug terminal
• Measure the primary coil resistance.
Primary coil resistance
0.18 ~ 0.28 Ω at 20 °C (68 °F)
Spark plug cap resistance
4 ~ 6 kΩ at 20 °C (68 °F)
• Connect the pocket tester (Ω × 1k) to the
ignition coil as shown.
• Is the spark plug cap OK?
YES
Positive tester probe →
spark plug lead
Negative tester probe → orange
NO
Replace the spark
plug cap.
• Measure the secondary coil resistance.
Secondary coil resistance
6.3 ~ 9.5 kΩ at 20 °C (68 °F)
• Is the ignition coil OK?
YES
NO
Replace the ignition
coil.
8-4
ELEC
IGNITION SYSTEM
EAS00750
EAS00748
5. Engine stop switch
6. Pickup coil resistance
• Check the engine stop switch for continuity.
• Connect the pocket tester (Ω × 1) to the
engine stop switch as shown.
• Disconnect the pickup coil coupler from the
wire harness.
• Connect the pocket tester (Ω × 100) to the
pickup coil terminal as shown.
Positive tester probe → black / white
Negative tester probe → black
Positive tester probe → white / red
Negative tester probe → white / blue
Engine stop switch continuity
PUSH → continuity
FREE → no continuity
• Measure the pickup coil resistance.
Pickup coil resistance
248 ~ 372 Ω at 20 °C (68 °F)
(between white / red and
white / blue)
• Is the engine stop switch OK?
YES
NO
• Is the pickup coil OK?
Replace the engine
stop switch.
YES
NO
Replace the pickup
coil.
8-5
IGNITION SYSTEM
EAS00775
ELEC
EAS00754
7. Charging coil resistance
8. Wiring
• Disconnect the charging coil coupler from
the wire harness.
• Connect the pocket tester (Ω × 100) to the
charging coil terminal as shown.
• Check the entire ignition system’s wiring.
Refer to “WIRING DIAGRAM”.
• Is the ignition system’s wiring properly connected and without defects?
Positive tester probe → black / red
Negative tester probe → green / white
YES
Replace
unit.
• Measure the charging coil resistance.
Charging coil resistance
720 ~ 1,080 Ω at 20 °C (68 °F)
• Connect the pocket tester (Ω × 10) to the
charging coil
Positive tester probe → green / blue
Negative tester probe → black
• Measure the charging coil resistance.
Charging coil resistance
44 ~ 66 Ω at 20 °C (68 °F)
• Is the charging coil OK?
YES
NO
Replace the charging coil.
8-6
the
CDI
NO
Properly connect or
repair the ignition
system’s wiring.
TUN
CHAPTER 9
TUNING
ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBURETOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ATMOSPHERIC CONDITIONS AND CARBURETOR SETTINGS . .
TEST RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EFFECTS OF THE SETTING PARTS ON THE THROTTLE VALVE
OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAIN JET ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PILOT AIR SCREW ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . .
PILOT JET ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JET NEEDLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
JET NEEDLE GROOVE POSITION ADJUSTMENT . . . . . . . . . . . . .
CARBURETOR SETTING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . .
ROAD CONDITION AND EXAMPLES OF CARBURETOR
SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EXAMPLES OF CARBURETOR SETTING DEPENDING ON
SYMPTOM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHANGE OF THE HEAT RANGE OF SPARK PLUGS. . . . . . . . . . .
9-1
9-1
9-1
9-2
CHASSIS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SELECTION OF THE SECONDARY REDUCTION RATIO
(SPROCKET). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRIVE AND DRIVEN SPROCKETS SETTING PARTS . . . . . . . . . .
TIRE PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT FORK SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHANGE IN LEVEL AND CHARACTERISTICS OF FORK OIL . . . .
SETTING OF SPRING AFTER REPLACEMENT . . . . . . . . . . . . . . .
FRONT FORK SETTING PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . .
REAR SUSPENSION SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHOOSING SET LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SETTING OF SPRING AFTER REPLACEMENT . . . . . . . . . . . . . . .
REAR SHOCK ABSORBER SETTING PARTS. . . . . . . . . . . . . . . . .
SUSPENSION SETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-7
9-2
9-3
9-3
9-3
9-3
9-4
9-4
9-5
9-5
9-6
9-7
9-8
9-9
9-9
9-10
9-10
9-11
9-12
9-12
9-13
9-14
9-15
ENGINE
TUN
TUNING
ENGINE
CARBURETOR SETTING
• The role of fuel is to cool the engine, and in
the case of a 2-stroke engine, to lubricate
the engine in addition to power generation.
Accordingly, if a mixture of air and fuel is
too lean, abnormal combustion will occur,
and engine seizure may result. If the mixture is too rich, spark plugs will get wet with
oil, thus making it impossible to bring the
engine into full play or if the worst comes to
the worst, the engine may stall.
• The richness of the air-fuel mixture required
for the engine will vary with atmospheric
conditions of the day and therefore, the settings of the carburetor must be properly
suited to the atmospheric conditions (air
pressure, humidity and temperature).
• Finally, the rider himself must make a test
run and check his vehicle for conditions
(pick-up of engine speed, road surface conditions) and for the discoloration of the
spark plug(s).
After taking these into consideration, he
must select the best possible carburetor
settings.
* It is advisable to make a note of settings,
atmospheric conditions, road surface condition, lap-time, etc. so that the memorandum
can be used as a reference useful for
future.
ATMOSPHERIC CONDITIONS AND
CARBURETOR SETTINGS
Air temp.
Humidity
Air
pressure
(altitude)
High
High
Low
Low
Mixture
Setting
Low (high)
Richer
Leaner
High (low)
Leaner
Richer
The air density (i.e., concentration of oxygen in
the air) determines the richness or leanness of
the air / fuel mixture. Therefore, refer to the
above table for mixture settings.
That is:
• Higher temperature expands the air with its
resultant reduced density.
• Higher humidity reduces the amount of oxygen in the air by so much of the water vapor
in the same air.
• Lower atmospheric pressure (at a high altitude) reduces the density of the air.
9-1
ENGINE
TUN
TEST RUN
After warming up the engine equipped with the
standard type carburetor(s) and spark plug(s),
run two or three laps of the circuit and check
the smooth operation of the engine and discoloration of spark plug(s).
Discoloration Condition of spark plug
Insulator is dry and burnt
Normal
brown.
Over burned
Insulator is whitish.
(too lean)
Oil fouled
Insulator is sooty and wet.
(too rich)
Normal
Over burned (too lean)
Oil fouled (too rich)
EFFECTS OF THE SETTING PARTS ON THE
THROTTLE VALVE OPENING
Setting part
Throttle valve opening
Full-closed 1 / 4
Jet needle
Pilot jet
Pilot air screw
Diameter of
straight
portion
Clip position
Main jet
Throttle valve opening
Full-open
Full-closed
9-2
1/2
3 / 4 Full-open
ENGINE
TUN
MAIN JET ADJUSTMENT
The richness of air-fuel mixture with 3 / 4 ~ 4 / 4
throttle can be set by changing the main jet .
Standard main jet
#138
1. Spark plug is too hot.
Select a main jet having higher calibrating
No. than standard. (To be enriched)
2. Spark plug is wet.
Select a main jet having lower calibrating
No. than standard. (To be leaned out)
PILOT AIR SCREW ADJUSTMENT
The richness of the air-fuel mixture with the
throttle fully closed to 1 / 4 open can be set by
turning the pilot air screw .
Turning in the pilot air screw will make the mixture enrich at low speeds, and turning it out will
lean it.
Standard pilot air
screw position
2 turns out
PILOT JET ADJUSTMENT
The richness of air-fuel mixture with the throttle
fully closed to 1 / 2 open can be set by turning
the pilot jet . It is changed when adjustment
cannot be made by the pilot air screw alone.
A larger size jet results in a richer mixture at
low speeds, and a smaller size in a leaner mixture.
Standard pilot jet
#45
JET NEEDLE ADJUSTMENT
The richness of air-fuel mixture with 1 / 4 ~ 3 / 4
throttle can be set by changing the jet needle
.
A smaller diameter jet needle results in a richer
mixture at middle speeds, and a larger diameter in a leaner mixture.
Standard jet needle
9-3
NBKF
ENGINE
TUN
JET NEEDLE GROOVE POSITION
ADJUSTMENT
Should the engine be hard to run smoothly at
intermediate speeds, the jet needle
must be
adjusted. If the mixture is too rich or too lean at
intermediate speed operation, irregular engine
operation and poor acceleration will result.
Whether or not the richness of the mixture is
proper is hard to be determined by means of
the spark plug and therefore, it should be
judged from your feeling of actual engine operation.
Standard clip position
No.2 groove
1. Too rich at intermediate speeds
Rough engine operation is felt and the
engine will not pick up speed smoothly.
In this case, step up the jet needle clip by
one groove and move down the needle to
lean out the mixture.
2. Too lean at intermediate speeds
The engine breathes hard and will not pick
up speed quickly.
In this case, step down the jet needle clip
by one groove and move up the needle to
enrich the mixture.
CARBURETOR SETTING PARTS
Part name
Main jet
Rich
Size
#148
#145
#142
#140
(STD)
#138
#135
Lean #132
Pilot jet
Rich
#48
(STD)
#45
Lean
#42
NBLE
Jet needle
Refer to the
NBLF
following table
NBLG
about the change in
NBKE
the air-fuel mixture
ratio due to a
NBKF
different jet needle. NBKG
9-4
Part number
4MX-14943-87
4MX-14943-36
4MX-14943-86
4MX-14943-35
4MX-14943-85
4MX-14943-34
4MX-14943-84
4MX-14948-06
4MX-14948-05
4MX-14948-04
5PA-14916-LE
5PA-14916-LF
5PA-14916-LG
5PA-14916-KE
5PA-14916-KF
5PA-14916-KG
ENGINE
Diameter of straight portion
Clip position
Rich
1 richer
0.5 richer
STD
0.5 leaner
1 leaner
Lean
Rich
φ 2.405 mm (0.0947 in)
NBKE-3rd groove
NBLE-2nd groove
NBKE-2nd groove
NBLE-1st groove
NBKE-1st groove
φ 2.415 mm (0.0951 in)
NBKF-3rd groove
NBLF-2nd groove
NBKF-2nd groove (STD)
NBLF-1st groove
NBKF-1st groove
TUN
Lean
φ 2.425 mm (0.0955 in)
NBKG-3rd groove
NBLG-2nd groove
NBKG-2nd groove
NBLG-1st groove
NBKG-1st groove
ROAD CONDITION AND EXAMPLES OF CARBURETOR SETTING
Conditions
Parts
Main jet
Jet needle
Pilot jet
Pilot air screw
Under 10 °C
(50 °F)
(Winter)
#140
NBKF-2
#45
Zero
General condition
15 ~ 25 °C
(59 ~ 77 °F)
(Spring, Autumn)
#138
NBKF-2
#45
Zero
Over 30 °C
(86 °F)
(Summer)
#135 ~ #138
NBKF-2
#45
+1/4
Under 10 °C
(50 °F)
(Winter)
#142
NBKF-2
#48
–1/2
Sandy condition
15 ~ 25 °C
(59 ~ 77 °F)
(Spring, Autumn)
#142
NBKF-2
#48
–1/2
Over 30 °C
(86 °F)
(Summer)
#142
NBKF-2
#48
Zero ~ +1/2
NOTE:
Optimum pilot air screw setting can be obtained by adding the ex-factory number of the same screw
back-out turns to any required value provided in the chart.
For example, if the ex-factory number is “2”, add “2” to the value chosen in the chart.
EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM
Symptom
At full throttle
Stall at high speeds
*Hard breathing
Shearing noise
Whitish spark plug
↓
Lean mixture
At full throttle
Speed pick-up stops
Slow speed pick-up
Slow response
Sooty spark plug
↓
Rich mixture
Lean mixture
Rich mixture
1 / 4 ~ 3 / 4 throttle
*Hard breathing
Lack of speed
1 / 4 ~ 1 / 2 throttle
Slow speed pick-up
White smoke
Poor acceleration
Closed to 1 / 4 throttle
*Hard breathing
Speed down
Setting
Increase main jet calibration no.
(Gradually)
Checking
Discoloration of spark plug →
If tan color, it is in good condition.
If cannot be corrected:
Clogged float valve seat
Clogged fuel hose
Clogged fuel cock
Decrease main jet calibration no.
Discoloration of spark plug →
(Gradually)
If tan color, it is in good condition.
*In case of racing slight enrichment of mix- If cannot be corrected:
ture reduces engine trouble.
Clogged air filter
Fuel overflow from carburetor
Use jet needle with a smaller diameter, or
NBLF.
Lower jet needle clip position.
Use jet needle with a larger diameter, or
NBKG.
Raise jet needle clip position.
Use jet needle with a smaller diameter, or
NBLF.
Lower jet needle clip position.
Use jet needle with a larger diameter, or
NBKG.
Raise jet needle clip position.
Use jet needle with a smaller diameter.
Turn out pilot air screw.
9-5
Groove 1
Groove 2
Groove 3
Groove 4
Groove 5
Clip
Leaner
(Standard)
Richer
Jet needle
The clip position is the jet needle groove
on which the clip is installed. The positions
are numbered from the top.
TUN
ENGINE
Symptom
Closed to 1 / 4 throttle
Poor acceleration
White smoke
Unstable at low speeds
Pinking noise
Setting
Use jet needle with a larger diameter.
Turn in pilot air screw.
Lower jet needle clip position.
(1 groove down)
Turn in pilot air screw.
Poor response at extremely low Reduce pilot jet calibration No.
speed
Turn out pilot air screw.
If not effect, reverse the above procedures.
Poor response in the low to
Raise jet needle clip position.
intermediate speeds
If this has no effect, lower the jet needle
clip position.
Poor response when throttle is Check overall settings.
opened quickly
Use main jet with a lower calibration no.
Raise jet needle clip position.
Use jet needle with a larger diameter.
If these have no effect, use a main jet with
a higher calibration no. and lower the jet
needle clip position.
Poor engine operation
Turn in pilot air screw.
Adjust the throttle stop screw.
Checking
Dragging brake
Overflow from carburetor
Check air filter for fouling.
Check throttle valve operation.
* marked: In case of hard breathing, check the carburetor breather hoses for clogging.
This should be taken simply for an example. It
is necessary to set the carburetor while checking the operating conditions of the engine and
discoloration of spark plugs.
Normally, carburetor setting is made by means
of the main jet, jet needle clip position, pilot jet
and pilot air screw.
CHANGE OF THE HEAT RANGE OF SPARK
PLUGS
Judging from the discoloration of spark plugs,
if they are found improper, it can be corrected
by the following two methods; changing carburetor settings and changing the heat range of
spark plug.
Standard spark plug
BR10EG / NGK
(resistance type)
• In principle, it is advisable to first use spark
plugs of standard heat range, and judging
from the discoloration of spark plugs, adjust
carburetor settings.
• If the calibration No. of the main jet must be
changed by ±30, it is advisable to change
the heat range of spark plugs and newly
select the proper main jet.
9-6
ENGINE / CHASSIS
TUN
NOTE:
• When checking the discoloration of spark
plugs, be sure to stop the engine immediately
after a run and check.
• Avoid racing.
• When changing the heat range of spark
plugs, never attempt to change it more than
±1 rank.
• When using a spark plug other than standard,
check its heat range against the standard and
check that it is a resistance type.
• Note that even if the discoloration seems
proper, it may slightly vary with the spark plug
maker and oil in use.
CHASSIS
SELECTION OF THE SECONDARY
REDUCTION RATIO (SPROCKET)
Number of rear wheel sprocketteeth
Secondary
=
reduction ratio
Number of drive sprocket teeth
Standard secondary
reduction ratio
YZ85:
47 / 14 (3.357)
(for EUR, CAN)
48 / 14 (3.429)
(for AUS, NZL)
YZ85LW:
52 / 14 (3.714)
<Requirement for selection of secondary gear
reduction ratio>
• It is generally said that the secondary gear
ratio should be reduced for a longer straight
portion of a speed course and should be
increased for a course with many corners.
Actually, however, as the speed depends
on the ground condition of the day of the
race, be sure to run through the circuit to
set the vehicle suitable for the entire
course.
9-7
CHASSIS
TUN
• In actuality, it is very difficult to achieve settings suitable for the entire course and
some settings may be sacrificed. Thus, the
settings should be matched to the portion
of the course that has the greatest effect on
the race result. In such a case, run through
the entire course while making notes of lap
times to find the best balance; then, determine the secondary reduction ratio.
• If a course has a long straight portion
where a vehicle can run at maximum
speed, the vehicle is generally set such that
it can develop its maximum revolutions
toward the end of the straight line, with care
taken to avoid the engine over-revving.
NOTE:
Riding technique varies from rider to rider and
the performance of a vehicle also vary from
vehicle to vehicle. Therefore, do not imitate
other rider’s settings from the beginning but
choose your own setting according to the level
of your riding technique.
DRIVE AND DRIVEN SPROCKETS SETTING
PARTS
YZ85:
Part name
Size Part number
(STD)
14T 9382A-14227
Drive
Sprocket
15T 9382A-15228
46T 5PA-25446-00
Real wheel *(STD) 47T 4ES-25447-10
sprocket
**(STD) 48T 5PA-25448-00
49T 5PA-25449-00
*For EUR, CAN
**For AUS, NZL
YZ85LW:
Part name
Size Part number
(STD) 14T 9382A-14227
Drive
Sprocket
15T 9382A-15228
51T 5PA-25451-00
Real wheel
(STD) 52T 5PA-25452-00
sprocket
53T 5PA-25453-00
9-8
CHASSIS
TUN
TIRE PRESSURE
Tire pressure should be adjust to suit the road
surface condition of the circuit.
Standard tire pressure
100 kPa (1.0 kgf / cm2, 15 psi)
• Under a rainy, muddy, sandy, or slippery
condition, the tire pressure should be lower
for a larger area of contact with the road
surface.
Extent of adjustment
60 ~ 80 kPa
(0.6 ~ 0.8 kgf / cm2, 9.0 ~ 12 psi)
• Under a stony or hard road condition, the
tire pressure should be higher to prevent a
flat tire.
Extent of adjustment
100 ~ 120 kPa
(1.0 ~ 1.2 kgf / cm2, 15 ~ 18 psi)
FRONT FORK SETTING
The front fork setting should be made depending on the rider’s feeling of an actual run and
the circuit conditions.
The front fork setting includes the following
three factors:
1. Setting of air spring characteristics
• Change the fork oil level.
2. Setting of spring preload
• Change the spring.
3. Setting of damping force
• Change the compression damping.
• Change the rebound damping.
The spring acts on the load and the damping force acts on the cushion travel speed.
9-9
CHASSIS
TUN
CHANGE IN LEVEL AND
CHARACTERISTICS OF FORK OIL
Damping characteristic near the final stroke can
be changed by changing the fork oil amount.
CAUTION:
Adjust the oil level in 5 mm (0.2 in) increments or decrements. Too low oil level
causes the front fork to produce a noise at
full rebound or the rider to feel some pressure on his hands or body. Alternatively,
too high oil level will develop unexpectedly
early oil lock with the consequent shorter
front fork travel and deteriorated performance an characteristics. Therefore, adjust
the front fork within the specified range.
[kg (lb)]
Front fork leg oil level
(from the top of the outer tube,
with the outer tube fully
compressed and without the fork
spring)
Standard: 90 mm (3.54 in)
Extent of adjustment:
80 ~ 120 mm (3.15 ~ 4.72 in)
[mm (in)]
Air spring characteristics in relation to oil level
change
Load
Stroke
Max. oil level
Standard oil level
Min. oil level
SETTING OF SPRING AFTER
REPLACEMENT
As the front fork setting can be easily affected
by rear suspension, take care so that the vehicle front and rear are balanced (in position,
etc.) when setting the front fork.
1. Use of soft spring
Generally a soft spring gives a soft riding
feeling. Rebound damping tends to become
stronger and the front fork may sink deeply
over a series of gaps.
To set a soft spring:
• Change the rebound damping.
Turn out one or two clicks.
• Change the compression damping.
Turn in one or two clicks.
9-10
CHASSIS
TUN
2. Use of stiff spring
Generally a stiff spring gives a stiff riding
feeling. Rebound damping tends to become
weaker, resulting in lack of a sense of contact with the road surface or in a vibrating
handlebar.
To set a stiff spring:
• Change the rebound damping.
Turn in one or two clicks.
• Change the compression damping.
Turn out one or two clicks.
FRONT FORK SETTING PARTS
• Front fork spring
YZ85:
TYPE
SOFT
STD
STIFF
SPRING
SPRING
RATE PART NUMBER
0.280
0.290
0.300
4ES-23141-50
4ES-23141-40
4ES-23141-60
I.D.
MARK
(slits)
I
–
II
YZ85LW:
SPRING
SPRING
TYPE
RATE PART NUMBER
SOFT
STD
STIFF
0.290
0.300
0.310
NOTE:
The I.D. mark (slits)
the spring.
9-11
4ES-23141-40
4LB-23141-10
4ES-23141-70
I.D.
MARK
(slits)
–
–
III
is proved on the end of
CHASSIS
TUN
REAR SUSPENSION SETTING
The rear suspension setting should be made
depending on the rider’s feeling of an actual
run and the circuit conditions.
The rear suspension setting includes the following two factors:
1. Setting of spring preload
• Change the set length of the spring.
• Change the spring.
2. Setting of damping force
• Change the rebound damping.
• Change the compression damping.
CHOOSING SET LENGTH
1. Place a stand or block under the engine to
put the rear wheel above the floor, and
measure the length
between the rear
wheel axle center and the rear fender holding bolt.
2. Remove the stand or block from the engine
and with a rider astride the seat, measure
the sunken length
between the rear
wheel axle center and the rear fender holding bolt.
3. Loosen the locknut
and make adjustment by turning the spring adjuster
to
achieve the standard figure from the subtraction of the length
from the length .
Standard figure
75 ~ 85 mm (3.0 ~ 3.3 in)
NOTE:
• If the vehicle is new and after it is broken in,
the same set length of the spring may change
because of the initial fatigue, etc. of the
spring. Therefore, be sure to make reevaluation.
• If the standard figure cannot be achieved by
adjusting the spring adjuster and changing
the spring set length, replace the spring with
an optional one and make re-adjustment.
9-12
CHASSIS
TUN
SETTING OF SPRING AFTER
REPLACEMENT
After replacement, be sure to adjust the spring
to the set length [sunken length 75 ~ 85 mm
(3.0 ~ 3.3 in)] and set it.
1. Use of soft spring
• Set the soft spring for less rebound damping to compensate for its less spring load.
Run with the rebound damping adjuster
one or two clicks on the softer side and
readjust it to suit your preference.
2. Use of stiff spring
• Set the soft spring for more rebound damping to compensate for its greater spring
load. Run with the rebound damping
adjuster one or two clicks on the stiffer side
and readjust it to suit your preference.
* Adjusting the rebound damping will be followed more or less by a change in the compression damping. For correction, turn the
compression damping adjuster on the
softer side.
CAUTION:
When using a rear shock absorber other
than currently installed, use the one whose
overall length
does not exceed the standard as it may result in faulty performance.
Never use one whose overall length is
greater than standard.
Length
of standard shock
403.5 mm (15.89 in)
9-13
CHASSIS
TUN
REAR SHOCK ABSORBER SETTING
PARTS
• Rear shock spring
YZ85:
For EUR
SPRING
SPRING
I.D.
RATE PART NUMBER COLOR
SOFT
4.4
4ES-22212-M0 Brown
STD
4.6
4ES-22212-K0
Green
STIFF
4.8
4ES-22212-G0
Red
TYPE
For CAN, AUS, NZL
SPRING
SPRING
I.D.
RATE PART NUMBER COLOR
SOFT
4.8
4ES-22212-G0
Red
STD
5.0
4ES-22212-F0
–
STIFF
5.2
4ES-22212-H0
Blue
TYPE
YZ85LW:
For EUR
SPRING
SPRING
I.D.
RATE PART NUMBER COLOR
SOFT
4.6
4ES-22212-K0
Green
STD
4.8
4ES-22212-G0
Red
STIFF
5.0
4ES-22212-F0
–
TYPE
For AUS, NZL
SPRING
SPRING
I.D.
RATE PART NUMBER COLOR
SOFT
5.0
4ES-22212-F0
–
STD
5.2
4ES-22212-H0
Blue
STIFF
5.4
4ES-22212-J0
Black
TYPE
NOTE:
The I.D. color
spring.
9-14
is marked at the end of the
CHASSIS
TUN
SUSPENSION SETTING
• Front fork
NOTE:
• If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart.
• Before any change, set the rear shock absorber sunken length to the standard figure 75 ~ 85 mm
(3.0 ~ 3.3 in).
Section
Symptom
Stiff over entire range
Unsmooth
movement over
entire range
Jump
Large
gap
Medium
gap
Check
Adjust
Compression damping
Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).
Replace with soft spring.
Small
gap
Oil level (oil amount)
Spring
Outer tube
Inner tube
Under bracket
tightening torque
Check for any bends, dents, and other noticeable
scars, etc. If any, replace affected parts.
Retighten to specified torque.
Rebound damping
Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Apply grease in oil seal wall.
Poor initial movement
Oil seal
Compression damping
Oil level (oil amount)
Spring
Turn adjuster clockwise (about 2 clicks) to increase
damping.
Increase oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).
Replace with stiff spring.
Stiff toward
stroke end
Oil level (oil amount)
Decrease oil level by about 5 mm (0.2 in).
Soft toward stroke
end, bottoming out
Oil level (oil amount)
Increase oil level by about 5 mm (0.2 in).
Compression damping
Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Compression damping
Turn adjuster clockwise (about 2 clicks) to increase
damping.
Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Set sunken length for 80 ~ 85 mm (3.1 ~ 3.3 in)
when one passenger is astride seat (lower rear posture).
Increase oil level by about 5 mm (0.2 in).
Soft over entire
range, bottoming out
Stiff initial movement
Rebound damping
Low front, tending to
lower front posture
Balance with rear end
Oil level (oil amount)
Compression damping
“Obtrusive” front,
tending to upper
front posture
Balance with rear end
Spring
Oil level (oil amount)
9-15
Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Set sunken length for 75 ~ 80 mm (3.0 ~ 3.1 in)
when one passenger is astride seat (upper rear posture).
Replace with soft spring.
Decrease oil level by about 5 ~ 10 mm (0.2 ~ 0.4 in).
CHASSIS
TUN
• Rear shock absorber
NOTE:
• If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart.
• Adjust the damping in 2-click increments or decrements.
Section
Symptom
Large
Jump
gap
Medium
gap
Check
Small
gap
Rebound damping
Stiff, tending to sink
Spring set length
Rebound damping
Spongy and unstable
Spring
Rebound damping
Heavy and dragging
Spring
Rebound damping
Compression damping
Poor road gripping
Spring set length
Spring
Compression damping
Bottoming out
Spring set length
Spring
Rebound damping
Bouncing
Spring
Compression damping
Stiff travel
Spring set length
Spring
9-16
Adjust
Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Set sunken length for 75 ~ 80 mm (3.0 ~ 3.1 in)
when one passenger is astride seat.
Turn adjuster clockwise (about 2 clicks) to increase
damping.
Replace with stiff spring.
Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Replace with soft spring.
Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Turn adjuster clockwise (about 2 clicks) to increase
damping.
Set sunken length for 75 ~ 80 mm (3.0 ~ 3.1 in)
when one passenger is astride seat.
Replace with soft spring.
Turn adjuster clockwise (about 2 clicks) to increase
damping.
Set sunken length for 75 ~ 80 mm (3.0 ~ 3.1 in)
when one passenger in astride seat.
Replace with stiff spring.
Turn adjuster clockwise (about 2 clicks) to increase
damping.
Replace with soft spring.
Turn adjuster counterclockwise (about 2 clicks) to
decrease damping.
Set sunken length for 80 ~ 85 mm (3.1 ~ 3.3 in)
when one passenger is astride seat.
Replace with soft spring.
TRBL
SHTG
CHAPTER 10
TROUBLESHOOTING
STARTING FAILURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1
10-1
10-1
10-1
INCORRECT ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2
10-2
10-2
10-2
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE. . . . . . . . . . . . . 10-2
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
FAULTY GEAR SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFTING IS DIFFICULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIFT PEDAL DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . .
JUMPS OUT OF GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2
10-2
10-2
10-2
FAULTY CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
CLUTCH SLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
CLUTCH DRAGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3
10-3
10-3
10-3
10-3
10-3
POOR BRAKING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
FAULTY FRONT FORK LEGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
LEAKING OIL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
UNSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
STARTING FAILURES
TRBL
SHTG
EAS00844
TROUBLESHOOTING
NOTE:
The following guide for troubleshooting does not cover all the possible causes of trouble. It should
be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
STARTING FAILURES
FUEL SYSTEM
Fuel tank
• Empty fuel tank
• Clogged fuel strainer
• Clogged fuel tank drain hose
• Clogged rollover valve
• Clogged rollover valve hose
• Deteriorated or contaminated fuel
Fuel cock
• Clogged or damaged fuel hose
Carburetor(s)
• Deteriorated or contaminated fuel
• Clogged pilot jet
• Clogged pilot air passage
• Sucked-in air
• Damaged float
• Worn needle valve
• Improperly installed needle valve seat
• Incorrect fuel level
• Improperly installed pilot jet
• Clogged starter jet
• Faulty starter plunger
• Improperly adjusted starter cable
ENGINE
Cylinder(s) and cylinder head(s)
• Loose spark plug
• Loose cylinder head or cylinder
• Damaged cylinder gasket
• Worn or damaged cylinder
Piston(s) and piston ring(s)
• Improperly installed piston ring
• Damaged, worn or fatigued piston ring
• Seized piston ring
• Seized or damaged piston
Air filter
• Improperly installed air filter
• Clogged air filter element
Crankcase and crankshaft
• Improperly assembled crankcase
• Seized crankshaft
Reed valve
• Deformed reed valve stopper
• Improperly seald reed valve stopper
• Incorrect tightened manifold
• Damaged gasket
• Damaged reed valve
ELECTRICAL SYSTEMS
Spark plug(s)
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
Ignition coil(s)
• Cracked or broken ignition coil body
• Broken or shorted primary or secondary
coils
• Faulty spark plug lead
Ignition system
• Faulty CDI unit
• Faulty pickup coil
• Broken generator rotor woodruff key
Switches and wiring
• Faulty engine stop switch
• Broken or shorted wiring
• Improperly grounded circuit
• Loose connections
10-1
INCORRECT ENGINE IDLING SPEED / POOR MEDIUM-ANDHIGH-SPEED PERFORMANCE / FAULTY GEAR SHIFTING
TRBL
SHTG
EAS00846
INCORRECT ENGINE IDLING SPEED
ENGINE
Air filter
• Clogged air filter element
FUEL SYSTEM
Carburetor(s)
• Faulty starter plunger
• Loose or clogged pilot jet
• Loose or clogged pilot air jet
• Damaged or loose carburetor joint
• Improperly synchronized carburetors
• Improperly adjusted engine idling speed
(throttle stop screw)
• Improper throttle cable free play
• Flooded carburetor
• Faulty air induction system
ELECTRICAL SYSTEMS
Spark plug(s)
• Incorrect spark plug gap
• Incorrect spark plug heat range
• Fouled spark plug
• Worn or damaged electrode
• Worn or damaged insulator
• Faulty spark plug cap
Ignition coil(s)
• Broken or shorted primary or secondary
coils
• Faulty spark plug lead
• Cracked or broken ignition coil
Ignition system
• Faulty CDI unit
• Faulty pickup coil
• Broken generator rotor woodruff key
EAS00848
POOR MEDIUM-AND-HIGH-SPEED PERFORMANCE
Refer to “STARTING FAILURES”.
ENGINE
Air filter
• Clogged air filter element
FUEL SYSTEM
Carburetor(s)
• Faulty diaphragm
• Incorrect fuel level
• Loose or clogged main jet
EAS00850
FAULTY GEAR SHIFTING
SHIFTING IS DIFFICULT
Refer to “CLUTCH DRAGS”.
SHIFT PEDAL DOES NOT MOVE
Shift shaft
• Improperly adjusted shift rod
• Bent shift shaft.
Shift drum and shift forks
• Foreign object in a shift drum groove
• Seized shift fork
• Bent shift fork guide bar
Transmission
• Seized transmission gear
• Foreign object between transmission gears
• Improperly assembled transmission
JUMPS OUT OF GEAR
Shift shaft
• Incorrect shift pedal position
• Improperly returned stopper lever
Shift forks
• Worn shift fork
Shift drum
• Incorrect axial play
• Worn shift drum groove
Transmission
• Worn gear dog
10-2
FAULTY CLUTCH / OVERHEATING
TRBL
SHTG
EAS00851
FAULTY CLUTCH
CLUTCH SLIPS
Clutch
• Improperly assembled clutch
• Improperly adjusted clutch cable
• Loose or fatigued clutch spring
• Worn friction plate
• Worn clutch plate
Transmission oil
• Incorrect oil level
• Incorrect oil viscosity (low)
• Deteriorated oil
CLUTCH DRAGS
Clutch
• Unevenly tensioned clutch springs
• Warped pressure plate
• Bent clutch plate
• Swollen friction plate
• Bent clutch push rod
• Broken clutch boss
• Burnt primary driven gear bushing
• Match marks not aligned
Transmission oil
• Incorrect oil level
• Incorrect oil viscosity (high)
• Deteriorated oil
EAS00855
OVERHEATING
FUEL SYSTEM
Carburetor(s)
• Incorrect main jet setting
• Incorrect fuel level
• Damaged or loose carburetor joint
Air filter
• Clogged air filter element
CHASSIS
Brake(s)
• Dragging brake
ELECTRICAL SYSTEMS
Spark plug(s)
• Incorrect spark plug gap
• Incorrect spark plug heat range
Ignition system
• Faulty CDI unit
ENGINE
Clogged coolant passages
• Cylinder head(s) and piston(s)
• Heavy carbon buildup
Transmission oil
• Incorrect oil level
• Incorrect oil viscosity
• Inferior oil quality
COOLING SYSTEM
Coolant
• Low coolant level
Radiator
• Damaged or leaking radiator
• Faulty radiator cap
• Bent or damaged radiator fin
Water pump
• Damaged or faulty water pump
• Hose(s) and pipe(s)
• Damaged hose
• Improperly connected hose
• Damaged pipe
• Improperly connected pipe
10-3
POOR BRAKING PERFORMANCE /
FAULTY FRONT FORK LEGS / UNSTABLE HANDLING
TRBL
SHTG
EAS00857
POOR BRAKING PERFORMANCE
• Worn brake pad
• Worn brake disc
• Air in hydraulic brake system
• Leaking brake fluid
• Faulty brake caliper kit
• Faulty brake caliper seal
• Loose union bolt
• Damaged brake hose
• Oil or grease on the brake disc
• Oil or grease on the brake pad
• Incorrect brake fluid level
EAS00861
FAULTY FRONT FORK LEGS
LEAKING OIL
• Bent, damaged or rusty inner tube
• Cracked or damaged outer tube
• Improperly installed oil seal
• Damaged oil seal lip
• Incorrect oil level (high)
• Loose damper rod assembly bolt
• Damaged damper rod assembly bolt
copper washer
• Cracked or damaged cap bolt O-ring
MALFUNCTION
• Bent or damaged inner tube
• Bent or damaged outer tube
• Damaged fork spring
• Worn or damaged outer tube bushing
• Bent or damaged damper rod
• Incorrect oil viscosity
• Incorrect oil level
EAS00864
UNSTABLE HANDLING
Rear shock absorber assembly(-ies)
• Faulty rear shock absorber spring
• Leaking oil or gas
Tire(s)
• Uneven tire pressures (front and rear)
• Incorrect tire pressure
• Uneven tire wear
Wheel(s)
• Incorrect wheel balance
• Broken or loose spoke
• Damaged wheel bearing
• Bent or loose wheel axle
• Excessive wheel runout
Frame
• Bent frame
• Damaged steering head pipe
• Improperly installed bearing race
Handlebar
• Bent or improperly installed handlebar
Steering head components
• Improperly installed upper bracket
• Improperly installed lower bracket
(improperly tightened ring nut)
• Bent steering stem
• Damaged ball bearing or bearing race
Front fork leg(s)
• Uneven oil levels (both front fork legs)
• Unevenly tensioned fork spring (both front
fork legs)
• Broken fork spring
• Bent or damaged inner tube
• Bent or damaged outer tube
Swingarm
• Worn bearing or bushing
• Bent or damaged swingarm
10-4
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
YZ85W1 / YZ85(W) / YZ85LW(W)
2007 WIRING DIAGRAM
YZ85W1 / YZ85(W) / YZ85LW(W)
SCHALTPLAN 2007
YZ85W1 / YZ85(W) / YZ85LW(W)
2007 SCHEMA DE CABLAGE
O
COMPOSANTS ELECTRIQUES
B B/W W/R
Coupe-circuit du moteur
Bobine d’allumage
Bloc CDI
Volant magnétique CDI
Bougie
B/R G/L G/W W/L
W/L
W/L
W/R
W/R
B/R
B/R
G/W
G/W
G/L
G/L
O
O
B
CODE DE COULEUR
B. . . . . . .
O. . . . . . .
B / R. . . . .
B/W . . . .
G / L. . . . .
G/W . . . .
W/L . . . .
W/R . . . .
B/W
B
B/W
W/R G/W B
ELECTRICAL COMPONENTS
Engine stop switch
Ignition coil
CDI unit
CDI magneto
Spark plug
OFF
RUN
B
W/L B/R G/L
B G/W W/R
B
G/L B/R W/L
Noir
Orange
Noir / Rouge
Noir / Blanc
Vert / Bleu
Vert / Blanc
Blanc / Bleu
Blanc / Rouge
ELEKTRISCHEBAUTEILE
Motorstoppschalter
Zündspule
CDI-Magnetzünder
CDI-Magnet
Zündkerze
COLOR CODE
FARB-CODIERUNG
B......
O. . . . . .
B/R . . . .
B/W . . .
G/L . . . .
G /W . . .
W/L. . . .
W/R . . .
B ......
O ......
B/R . . . .
B/W . . . .
G/L . . . .
G/W . . . .
W/L . . . .
W/R . . . .
Black
Orange
Black / Red
Black / White
Green / Blue
Green / White
White / Blue
White / Red
Schwarz
Orange
Schwarz / Rot
Schwarz / Weiß
Grün / Blau
Grün / Weiß
Weiß / Blau
Weiß / Rot
YZ85W1/YZ85(W)/YZ85LW(W)
2007 WIRING DIAGRAM
YZ85W1/YZ85(W)/YZ85LW(W)
SCHALTPLAN 2007
YZ85W1/YZ85(W)/YZ85LW(W)
2007 SCHEMA DE CABLAGE
COMPOSANTS ELECTRIQUES
Coupe-circuit du moteur
Bobine d’allumage
Bloc CDI
Volant magnétique CDI
Bougie
CODE DE COULEUR
B. . . . . . .
O. . . . . . .
B/R. . . . .
B/W . . . .
G/L. . . . .
G/W . . . .
W/L . . . .
W/R . . . .
ELECTRICAL COMPONENTS
OFF
RUN
Engine stop switch
Ignition coil
CDI unit
CDI magneto
Spark plug
Noir
Orange
Noir/Rouge
Noir/Blanc
Vert/Bleu
Vert/Blanc
Blanc/Bleu
Blanc/Rouge
ELEKTRISCHEBAUTEILE
Motorstoppschalter
Zündspule
CDI-Magnetzünder
CDI-Magnet
Zündkerze
COLOR CODE
FARB-CODIERUNG
B......
O. . . . . .
B/R . . . .
B/W . . .
G/L . . . .
G/W . . .
W/L . . . .
W/R . . .
B ......
O ......
B/R . . . .
B/W . . . .
G/L . . . .
G/W . . . .
W/L . . . .
W/R . . . .
Black
Orange
Black/Red
Black/White
Green/Blue
Green/White
White/Blue
White/Red
Schwarz
Orange
Schwarz/Rot
Schwarz/Weiß
Grün/Blau
Grün/Weiß
Weiß/Blau
Weiß/Rot