YFM90RY ASSEMBLY MANUAL LIT-11666-22-13 43D-F8107-10 EBA00002 FOREWORD This Assembly Manual contains the information required for the correct assembly of this Yamaha machine prior to delivery to the customer. Since some external parts of the machine have been removed at the Yamaha factory for the convenience of packing, assembly by the Yamaha dealer is required. It should be noted that the assembled machine should be thoroughly cleaned, checked, and adjusted prior to delivery to the customer. EBA00003 IMPORTANT The service specifications given in this assembly manual are based on the model as manufactured. Modifications and significant changes in specifications and/or procedures will be forwarded to authorized Yamaha dealers. The procedures below are described in the order that the procedures are carried out correctly and completely. Failure to do so can result in poor performance and possible harm to the machine and/or rider. CONCERNING CRATE DAMAGE: Follow the instructions in the Dealer Warranty Handbook, Procedure Section. Particularly important information is distinguished in this manual by the following notations: This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. WARNING A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. NOTICE A NOTICE indicates special precautions that must be taken to avoid damage to the vehicle or other property. TIP A TIP provides key information to make procedures easier or clearer. * Product and specifications are subject to change without notice. YFM90RY ASSEMBLY MANUAL ©2008 by Yamaha Motor Corporation, U.S.A. 1st edition, July 2008 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. P/N LIT-11666-22-13 (1) EBA01001 (2) (4) (5) (6) (7) (8) (9) (10) T. (3) SYMBOLS USED IN THE ASSEMBLY MANUAL R. 10 (11) FWD (12) UP (13) (14) (15) D d d D d d In order to simplify descriptions in this assembly manual, the following symbols are used: (1): Filling fluid (2): Lubricant (3): Special tool (4): Tightening torque (5): Wear limit, clearance (6): Engine speed (7): Electrical data (8): Coat with lithium-soap-based grease. (9): Tighten to 10 Nm. (10 Nm = 1.0 m · kg, 7.2 ft · lb) (10):Towards the front of the machine (11):Clearance required (12):Install so that the arrow mark faces upward. (13):Apply motor oil. (14):Made of rubber or plastics (15): A: Ref. No. (indicating the order of operations.) B: Part name C: Quantity of parts per machine D: Place where parts are held (1): Refer to “PARTS LOCATION”. V: Stored in plastic bag C: Stored in carton box S: Fixed inside the steel frame and/or contained in the Styrofoam tray (upper or lower) : Temporarily installed or secured Example: (1)-V (1) signifies the location of the parts and V signifies that the part is stored in a plastic bag. E: Size or material of parts d/D: Diameter of part : Length of part e.g., 5 = 5 mm (0.2 in) * EBA00006 PREPARATION (1) (2) (3) (4) To assemble the vehicle correctly, supplies (e.g. oils, greases, and shop rags) and sufficient working space are required. Workshop The workshop where the vehicle is assembled should be clean, spacious, and have a level floor. Self-protection Protect your eyes with suitable safety glasses or goggles when using compressed air, when grinding or when doing any operation which may cause particles to fly off. Protect hands and feet by wearing safety gloves and shoes. EBA00007 (5) (6) (7) SYMBOLS USED ON TRANSPORT PACKAGE BAG (1) Contents of the transport package are fragile, therefore the package must be handled with care. (2) Indicates correct upright position of the transport package. (3) Transport package must be kept away from rain. (4) Do not step anywhere on the transport package. (5) Up to 9 of the transport packages can be piled up. (6) Only stack this unit with transport packages of the same size. (7) Made of high-density polyethylene. DO NOT STEP ON DO NOT STEP ON TAIWAN EBA00008 UNPACKING 1 b a 1. Remove the dustproof bag (1). a 2. Remove the packing frames (2). (Lift up and then move to the side.) TIP 2 2 Remove the plates ( a and b ) while holding the frame. 3. Remove the bolt (3) (frame). 3 –1– EBA00009 PARTS LOCATION (1) (2) (3) (4) (5) Carton box 1 Carton box 2 Bubble wrap pack 1 Rear wheels Front wheels (A) Right view (B) Left view A 2 5 4 B 1 3 5 4 –2– EBA00010 (1) Cart on box 1 1 1. 2. 3. 4. 2 5. 6. 3 7. 8. 9. 4 Rear carrier bar Front bumper Plastic bag Flange nuts (front and rear wheels) [d = 10 (0.39)] Flange bolts (front bumper) [d = 8 (0.31), = 18 (0.71)] Flange bolts (rear carrier bar) [d = 8 (0.31), = 12 (0.47)] Band (battery) Tag warning Tag NER (normalized Emissions Rating) 5 7 6 8 9 I l l I I l l l l l l l l 3.5 l l l l l l (2) Cart on box 2 1 1. 2. 3. 4. 5. 6. 7. 8. 9. 2 3 Handlebar cover Battery box Battery Electrolyte Filling funnel Strip of caps Plastic bag Bolts (battery) [d = 5 (0.20), Nuts (battery) [d = 5 (0.20)] 4 5 6 7 8 9 –3– = 9 (0.35)] (3) Bubble wrap pack 1. Rear brake master cylinder 2. Bracket (rear brake master cylinder) 3. Flange bolts (rear brake master cylinder) [d = 6 (0.24), = 25(0.98)] 1 3 2 1 1 (4) Rear wheels 1. Rear wheels (5) Front wheels 1. Front wheels –4– EBA00012 SETUP PROCEDURES TIP After opening the crate, place the ATV on a suitable rack and follow the setup procedures. Before starting the setup, supply the specified tire pressure to the four wheels. WARNING _ This model is equipped with low pressure tires. Refer to “ADJUSTMENTS AND PREDELIVERY SERVICE”. Perform the setup procedures in the order indicated by the numbers. Always follow the order as shown. 3,4,5 8 9,10,11 7 6 2 1 2 1 –5– EBA00033 1. FRONT WHEELS B A: Install the wheels so that the air valves are facing out. B: The arrow mark on the tire must point toward the rotating direction of the wheel. C: Tighten the nuts to specification. 2 C A 45 Front wheel 2 (5)-S 2 Flange nut 8 (1)-V d = 10 (0.39) R. 1 T. 1 Nut 45 Nm (4.5 m · kg, 32.5 ft · lb) EBA00034 2. REAR WHEELS A: Install the wheels so that the air valves are facing out. B: Tighten the nuts to specification. T. 2 B R. 45 1 Nut 45 Nm (4.5 m · kg, 32.5 ft · lb) A 1 Rear wheel 2 (4)-S 2 Flange nut 8 (1)-V d = 10 (0.39) 2 14 B 1 2 EBA00013 3 C 1 3. HANDLEBAR A: Install the handlebar, please align 1 and 2 . 1 a punch mark on handlebar 2 a gap at handlebar holder B: Install each handlebar holder with its flange facing forward. A NOTICE First tighten the bolts on the rear side, and then tighten the bolts on the front side. 1 Handlebar 1 2 Handlebar holder (upper) 2 3 Flange bolt 4 C: Tighten the bolts to specification. d = 6 (0.24), = 25 (0.98) T. * * * R. –6– Bolt 14 Nm (1.4 m · kg, 10.1 ft · lb) EBA00027 4. HANDLEBAR COVER A A: Pass the fuel tank breather hose through the hole in the handlebar cover. 1 2 1 Handlebar cover 1 2 Fuel tank breather hose 1 Refer to “CABLE ROUTING”. (2)-C * 5. REAR BRAKE MASTER CYLINDER B 1 D UP 2 A UP UP C 12 1 TIP 1 Rear brake master cylinder 2 Bracket 1 (3)-S 3 Flange bolt 2 (3)-S d = 6 (0.24), A: Fit the master cylinder projection into the collar indent. (a) 65 ~ 66 mm (2.56 ~ 2.60 in) B: Install the brake master cylinder, please align 1 and 2 . 1 a punch mark on handlebar 2 a gap at master cylinder bracket C: Tighten the bolts to specification. Bolt 12 Nm (1.2 m · kg, 8.7 ft · lb) (3)-S = 25 (0.98) TIP • Make sure that the “UP” mark on the bracket is pointed upwards. • First tighten the bolt on the upper side of the master cylinder bracket, and then tighten the bolt on the lower side. D: Check the brake lever for smooth action. Proper cable routing is essential to assure safe vehicle operation. Refer to “CABLE ROUTING”. EBA00042 6. FRONT BUMPER A: Tighten the bolts to specification. T. 1 R. 18 2 A 1 Front bumper 1 (1)-C 2 Flange bolt 4 (1)-V d = 8 (0.31), = 18 (0.71) –7– Bolt 18 Nm (1.8 m · kg, 13 ft · lb) EBA00042 7. REAR CARRIER BAR 1 A: Tighten the bolts to specification. 2 A T. R. Bolt 25 Nm (2.5 m · kg, 18.1 ft · lb) 25 1 Rear carrier bar 1 (1)-C 2 Flange bolt 4 (1)-V d = 8 (0.31), = 12 (0.47) 2 EBA00047 8. BATTERY 3 A: Before installing the battery, charge the battery. B 4 TIP C Refer to “ADJUSTMENTS AND PREDELIVERY SERVICE”. A 1 1 Battery 1 (2)-C 2 Battery band 1 (1)-V 3 Bolt 2 (2)-V d = 5 (0.20), 4 Nut 2 (2)-V d = 5 (0.20) = 9 (0.35) B: First, connect the positive lead (red color lead) to the positive terminal. C: Connect the negative lead (black color lead) to the negative terminal. Pass the negative lead (black color lead) through the clamp on the rear fender. T. R. Bolt 9 Nm (0.9 m · kg, 6.5 ft · lb) TIP Refer to “CABLE ROUTING”. EBA00048 A 3 2 9. KICKSTARTER AND OWNER’S TOOL KIT 1 of B e. ag 1 Owner’s tool kit 1 2 kickstarter 1 3 Band (owner’s tool kit) 1 A: Secure the kickstarter and the owner’s tool kit to the seat with the band. B: Fasten the kickstarter in the seat with the plastic band. * * * –8– t n Io ac ts SL 1- 38 ld ou Vsh E A r o m. AAT isis ThTh Y!D LL tit FUT af HRE t e I sy in CA ia -2 UA AN mno M i tar np G 26 IN 16 RN WA R nf t be o rid n de by an yo UA r de un L 28 of H- 5T ars ye 0R M9 AN ne YF SM R＇ NE OW no e. 9- ag 19 66 1- -2 26 NG 16 NI AR 38 ld ou Vsh AAT isis ThTh Y! n. LL io FU at RE form CA in AL fety NU sa MA nt IS rta TH impo AD s RE ntain co It W de rid n by R＇ NE OW t be no UA r de un 5T s 6 -6 99 e. ag 81 of H-2 ar ye 0R L M9 AN YF ne yo an 1 1 SM Owner’s manual Band (owner’s manual) * * 1 2 * 1 Seat 1 A: Secure the low-pressure air gauge and the owner’s manual to the seat with the band. A 10. OWNER’S MANUAL 1 EBA00049 2 A: Insert the lobes on the seat front into the receptacles on the fuel tank and frame, then push down the seat at the end. A 11. SEAT EBA00050 1 –9– EBA00100 CABLE ROUTING WARNING Proper cable and lead routing is essential to assure safe machine operation. (1) (2) (3) (4) (5) (6) Rear brake switch lead Rear brake hose Left front brake cable Rightfront brake cable Throttle cable Fuel tank breather hose (7) Battery (8) Positive battery lead (9) Negative battery lead (10)Choke cable (11)Handlebar switch lead (A) Insert the fuel tank breather hose into the hole in the handlebar cover. (B) Fasten the handlebar switch lead , rear brake switch lead and choke cable with a plastic band. (C) Face the opening of the positive battery lead holder inward. (D) Face the opening of the negative battery lead holder inward. (E) Connect the negative battery lead to the battery so that the lead is routed to the side of the battery. (F) Connect the positive battery lead to the battery so that the lead contacts the battery case. 1 2 B 3 5 4 2 4 3 1 5 A 11 B 6 7 C 8 A D 9 E F A –10– 10 EBA00101 ADJUSTMENTS AND PREDELIVERY SERVICE Perform the predelivery service in the order indicated by the letters. Always follow the order as shown. H C,E A I B B D B G B –11– F EBA00103 A. CHECKING AND CHARGING THE BATTERY 1. Fill: NOTICE 3 4 • Never remove the sealing sheet (aluminum seal) from the battery until the battery is filled with electrolyte. If battery plates are exposed to air, they will oxidize. As a result, power will not be generated as specified. • Use only the amount of electrolyte in the container which comes with the battery. An incorrect electrolyte level has an adverse effect on battery performance. The quantity of electrolyte varies with the type of the electrolyte container. • Avoid using any electrolyte other than specified. The specific gravity of the MF battery electrolyte is 1.320 (20 °C). (The specific gravity of the general type battery electrolyte is 1.280.) If electrolyte whose specific gravity is less than 1.320 is used, the sulfuric acid will decrease and thus low battery performance will result. Should any electrolyte, whose specific gravity is more than 1.320 be used, the battery plates will corrode and battery life will shorten. a. Place the battery on a level surface. b. Remove the sealing sheet (1). (2) Filler port c. Softly inlay the filling funnel (3) on the ports of the storage battery. d. Take out the electrolyte container. (4) Six sealed areas of container TIP Do not lose the strip of caps because it will be used as battery plugs. NOTICE Do not peel or pierce the sealed areas. e. Turn the electrolyte container upsidedown with the six sealed areas in line with the six filler ports of the battery. f. Push the container down with enough force to break the seals. The electrolyte will start to flow into the battery. NOTICE • Do not tilt the container as the electrolyte may stop flowing. • Never remove the container from the battery until all electrolyte has drained from the container. –12– g. Leave the container in this position for 20 minutes or longer to allow proper chemical reaction. TIP • Make sure air bubbles are rising from all six filler ports. • If air bubbles are not rising from a filler port, tap the top of the container a few times. h. Make sure that all the electrolyte has been drained from the container. i. Fit the strip of caps (battery plugs) securely into the filler ports. Make sure the top of the strip is flush with the top of the battery. (5)Press down with equal force with both hands. NOTICE Never remove the strip of caps, nor add any water or electrolyte. WARNING • Do not attempt boost charging under any circumstances. • Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flames, cigarettes, etc., away. Ventilate when charging or using in enclosed space. Always shield eyes when working near batteries. KEEP OUT OF THE REACH OF CHILDREN. 2. Check: Using a digital voltmeter, the state of a discharged MF battery can be checked by measuring open-circuit voltage (the voltage measured with the positive and negative terminals being disconnected). NOTICE The battery must charged after it is filled with electrolyte. If this is not done, the life of the battery will be shortened drastically. Since the procedure for charging the battery is not explained in the assembly manual, refer to the service manual for more details. EBA00105 B. CHECKING THE TIRE PRESSURE This model is equipped with low pressure tires. Pay attention to the following points: Recommended tire pressure: Front: 25 kPa (0.25 kg/cm2, 3.6 psi) Rear: 25 kPa (0.25 kg/cm2, 3.6 psi) Maximum vehicle load: 70 kg (154 lb) Tire size: Front AT18 × 7-8 Rear AT18 × 9-8 1. Excessive tire pressure [over 250 kPa (2.5 kg/cm2, 36 psi)] may cause the tires to burst. Inflate tires very slowly. Fast inflation can cause the tires to burst. 2. Too low a pressure [Front: 22 kPa (0.22 kg / cm 2 , 3.2 psi), Rear: 22 kPa (0.22 kg / cm 2 , 32 psi)] will cause the tire to dislodge from the rim. 3. Put the same pressure in both rear tires. Uneven tire pressure will severely affect the handling. 4. Set the tire pressures when the tires are cold. 1. Check: • tire pressure a. Use an appropriate low-pressure tire gauge. Set tire pressures to the following specifications: Reference tire pressure Front 25kPa (0.25 kg/cm2, 3.6 psi) Rear 25 kPa (0.25 kg/cm2, 3.6 psi) Minimum tire pressure Front 22 kPa (0.22 kg/cm2, 3.2 psi) Rear 22 kPa (0.22 kg/cm2, 3.2 psi) NOTICE Never use a tire pressure below minimum specification. The tire could separate from the wheel under severe operating conditions. –13– EBA00106 C. DRAINING THE FUEL 1. Put a rag under the carburetor drain hose so fuel does not contact the crankcase. 2. Loosen the drain screw (1) and drain the standing fuel. WARNING 1 FUEL IS HIGHLY FLAMMABLE: • Always turn off the engine when draining fuel. • Take care not to spill any fuel on the engine or muffler when draining fuel. • Never drain fuel while smoking or in the vicinity of an open flame. 3. Tighten the drain screw securely. EBA00107 3 2 1 10 0 30 50 70 90 110 130 F YAMALUBE 4 (20W-50) or SAE 20W-50 YAMALUBE 4 (10W-40) or SAE 10W-40 -10 0 10 20 30 1. Place the machine on a level surface. 2. Check: • engine oil level The engine oil level should be between the minimum level mark (1) and maximum level mark (2). Below the minimum level mark → Add the recommended engine oil to the proper level. TIP Do not screw the dipstick (3) in when checking the oil level. NOTICE SAE 5W-30 -20 D. CHECKING THE ENGINE OIL LEVEL 40 50 C Do not allow foreign material to enter the crankcase. 3. Start the engine, warm it up for several minutes, and then turn it off. 4. Check the engine oil level again. TIP Before checking the engine oil level, wait a few minutes until the oil has settled. Recommended engine oil At 0 °C (32 °F) or higher Yamalube 4 (20W-50) or SAE20W-50 type SG or higher, JASO standard MA At –10 °C (14 °F) or higher Yamalube 4 (10W-40) or SAE 10W-40 type SG or higher, JASO standard MA At 0 °C (32 °F) or lower SAE5W-30 type SG or higher JASO standard MA Oil quantity (periodic oil change) Engine 0.75 L (0.66 Imp qt, 0.80 US qt) WARNING Never remove the dipstick just after high speed operation because the heated oil could spurt out. Wait until the oil cools down before removing the dipstick. –14– EBA00121 (a) (b) E. ADJUSTING THE ENGINE IDLING SPEED 1 1. Start the engine and let it warm up for several minutes. 2. Check: • engine idling speed Out of specification → Adjust. Engine idling speed 1,600 ~ 1,800 r/min EBA00122 F. ADJUSTING THE THROTTLE LEVER FREE PLAY NOTICE _ Before adjusting the throttle lever free play, make sure that the adjuster and locknut on the carburetor side are fully tightened. If not, the throttle does not operate properly. a 1 (b) TIP 3 2 Engine idling speed should be adjusted properly before adjusting the throttle lever free play. (a) 3. Adjust: • engine idling speed a. Turn the throttle stop screw (1) in or out until specified idling speed is obtained. Direction(a) Idling speed becomes higher. Direction(b) Idling speed becomes lower. 2. Adjust: • throttle lever free play a. Pull back the adjuster cover (1). b. Loosen the locknut (2). c. Turn the adjuster (3) in or out until the correct free play is obtained. Direction(a) Free play is increased. Direction(b) Free play is decreased. d. Tighten the locknut. e. Push in the adjuster cover. WARNING 1. Check: • throttle lever free play (a) Out of specification → Adjust. Throttle lever free play 1.0 ~ 3.0 mm (0.04 ~ 0.12 in) a EBA00125 G. ADJUSTING THE FRONT BRAKE 1. Check: • front brake lever free play (a) • difference between (b) and (c) Out of either specification → Adjust. Front brake lever free play (a) 4 ~ 7 mm (0.16 ~ 0.28 in) Difference between (b) and (c) 0 ~ 2 mm (0 ~ 0.08 in) b 2. Adjust: • front brake lever free play (a) • difference between (b) and (c) c 1 2 a. Loosen the locknuts (1). b. Turn the adjusters (2) in or out until the specified free play and difference are obtained. c. Tighten the locknuts. –15– After adjusting the free play, turn the handlebar to right and left, and make sure that the engine idling speed does not increase. EBA00131 H. CHECKING THE REAR BRAKE FLUID LEVEL LOWER 1. Place the vehicle on a level surface. 1 TIP When checking the brake fluid level, make sure that the top of the brake fluid reservoir top is horizontal. 2. Check: • brake fluid level Below the minimum level mark (1) → Add the recommended brake fluid to the proper level. Recommended brake fluid DOT4 • 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 master cylinder and/or reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. NOTICE Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any split brake fluid immediately. EBA00132 I. BLEEDING THE HYDRAULIC BRAKE SYSTEM 2 1 Bleed the hydraulic brake system whenever: • the system was disassembled, • a brake hose or brake pipe was loosened or removed, • the brake fluid is very low, • the brake operation is faulty. A loss of braking performance may occur if the brake system is not properly bled. 1. Bleed: • hydraulic brake system a. Add the recommended brake fluid to the proper level. b. Install the diaphragm. Be careful not to spill any fluid or allow the reservoir to overflow. c. Connect a clear plastic hose (1) tightly to the bleed screw (2). d. Place the other end of the hose into a container. e. Slowly apply the brake lever or pedal several times. –16– f. Pull the lever in or push down on the pedal and hold it. g. Loosen the bleed screw and allow the lever or pedal to travel towards its limit. h. Tighten the bleed screw when the lever or pedal limit has been reached, then release the lever or pedal. i. Repeat steps (e) to (h) until all the air bubbles have disappeared from the fluid. j. Tighten the bleed screw to specification. Bleed screw 6 Nm (0.6 m·kg, 4.3 ft·lb) TIP 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 system have disappeared. k. Add brake fluid to the proper level. After bleeding the hydraulic brake system, check the brake operation. J. LUBRICATING THE AIR FILTER ELEMENT 1 1 2 1 1 1. Remove: • air filter case cover bolts (1) • air filter case covers (2) (left and right) 2 1 1 4 3 2. Remove: • screw and air filter element holder (3) • air filter element (4) NOTICE The engine should never be run without the air filter; excessive piston and/or cylinder wear may result. 3. Apply: • Yamaha foam air filter oil a. Squeeze the initial oil out of the element. NOTICE Do not twist or wring out the element. This could damage the foam material. b. Apply Yamaha foam air filter oil or other quality foam air filter oil. c. Squeeze out the excess oil. TIP The element should be wet but not dripping. 4. Install: • air filter element, air filter element holder and screw • air filter case covers • air filter case cover bolts –17– EBA00200 APPENDICES SERVICE DATA Engine idling speed: Spark plug: Type/Manufacturer Gap Fuel: Recommended fuel Fuel tank capacity Valve clearance (cold): IN EX 1,600 ~ 1,800 r/min CR7HSA/NGK 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) Unleaded gasoline only 4.8 L (1.06 Imp gal, 1.27 US gal) 0.07 mm (0.00275 in) 0.07 mm (0.00275 in) EBA00210 STANDARD EQUIPMENT 1. 2. 3. 4. 5. Owner’s manual Safety handbook Owner’s tool kit Low-pressure air gauge kickstarter 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. EBA00220 OWNER’S TOOL KIT 1. 2. 3. 4. Owner’s tool bag Spark plug wrench (16) Screwdriver grip Screwdriver bit (Phillips head and slotted head) 1 pc. 1 pc. 1 pc. 1 pc. –18– EBA00230 TIGHTENING TORQUES Part to be tightened Thread size Tightening torque Nm m · kg ft · lb 1.2 2.5 1.5 8.7 18.1 10.8 Engine: Spark plug Engine oil drain bolt Final gear case oil drain bolt M10 M12 M8 12 25 15 Chassis: Engine lower stay and engine Engine and frame Engine lower stay and frame Swingarm pivot shaft and frame Rear shock absorber and frame Rear shock absorber and swingarm Front shock absorber and frame Front shock absorber and lower front arm Steering stem and frame Steering stem and tie-rod ball joint Tie-rod locknut Steering stem bushing and frame Steering knuckle and tie-rod ball joint Steering knuckle and front arm (upper and lower) Steering knuckle and front brake drum Front wheel and front brake drum Front brake camshaft and camshaft lever Rear axle and rear axle nut Rear brake disc and disc bracket Rear brake caliper and brake caliper bracket Rear axle and wheel hub Rear wheel and wheel hub Handlebar holder and steering stem Throttle lever and housing Fuel tank and frame Front fender and frame Rear fender and frame Rear carrier and frame Front bumper and frame Footrest board and footrest bracket Footrest bracket and frame Front grill and dummy headlight Front grill and frame Driven sprocket and sprocket bracket M10 M10 M10 M14 M10 M10 M10 M10 M14 M10 M10 M8 M10 M10 M14 M10 M6 M28 M10 M8 M14 M10 M6 M6 M6 M6 M6 M8 M8 M6 M8 M6 M8 M10 35 35 35 75 35 35 35 35 55 35 35 25 35 35 65 45 14 –19– 35 28 80 45 14 12 12 9 9 25 18 9 22 9 25 35 3.5 3.5 3.5 7.5 3.5 3.5 3.5 3.5 5.5 3.5 3.5 2.5 3.5 3.5 6.5 4.5 1.4 Refer to TIP. 3.5 2.8 8.0 4.5 1.4 1.2 1.2 0.9 0.9 2.5 1.8 0.9 2.2 0.9 2.5 3.5 25.3 25.3 25.3 54.2 25.3 25.3 25.3 25.3 39.8 25.3 25.3 18.1 23.5 23.5 47.0 32.5 10.1 25.3 20.3 57.9 32.5 10.1 8.7 8.7 6.5 6.5 18.1 13.0 6.5 15.9 6.5 18.1 25.3 TIP 1. Before tightening the nuts, apply locking agent (LOCTITE®) to rear axle threads. 2. Tighten the inside nut to 170 Nm (17.0 m · kg, 123 ft · lb) 3. Tighten the outside nut to 170 Nm (17.0 m · kg, 123 ft · lb) while holding the inside nut. –20– YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U.S.A.