This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha deal- ers and their qualified mechanics. All of the procedures in this manual are organized in a sequential, step-by-step format.
MOTORCYCLE IDENTIFICATION INFO
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
IMPORTANT INFORMATION INFO
IMPORTANT INFORMATION
Install bearings and oil seals so that the manu- facturer’s marks or numbers are visible. When installing a circlip 1, make sure the sharp-edged corner 2 is positioned opposite the thrust 3 that the circlip receives.
CHECKING THE CONNECTIONS INFO
CHECKING THE CONNECTIONS
SPECIAL TOOLS INFO
SPECIAL TOOLS
This tool is used for holding the damper rod holder when removing or installing the damper rod holder. This tool is used to loosen and tighten the clutch carrier locknut of the second- ary sheave.
SPEC
CHAPTER 2 SPECIFICATIONS
SPECIFICATIONS
GENERAL SPECIFICATIONS
ENGINE SPECIFICATIONS SPEC
ENGINE SPECIFICATIONS
CHASSIS SPECIFICATIONS SPEC
CHASSIS SPECIFICATIONS
ELECTRICAL SPECIFICATIONS SPEC
ELECTRICAL SPECIFICATIONS
CONVERSION TABLE/ SPEC
GENERAL TIGHTENING TORQUE SPECIFICATIONS
CONVERSION TABLE
GENERAL TIGHTENING TORQUE SPECIFICATIONS
TIGHTENING TORQUES SPEC
TIGHTENING TORQUES
Front brake hose holder and front fork outer tube M Front brake hose holder, bracket, and lower.
LUBRICATION POINTS AND LUBRICANT TYPES SPEC
LUBRICATION POINTS AND LUBRICANT TYPES
CABLE ROUTING SPEC
CABLE ROUTING
ËPass the wire harness and speedometer cable through the guide, and then install the grommet on the front brake hose in the holder. ÊPass the positive battery lead, fuse lead, and starter relay lead through the hole in the storage box.
CHK ADJ
CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
PERIODIC MAINTENANCE AND LUBRICATION CHART
INTRODUCTION/PERIODIC MAINTENANCE AND LUBRICATION CHART
PERIODIC MAINTENANCE AND LUBRICATION CHART ADJ
COVERS ADJ
COVERS
Remove the main switch cover by turning it in the direction of the arrow shown. Connect the front turn signal light couplers (left and right) 3, and then install the couplers in the holders on the front cowling.
ADJUSTING THE VALVE CLEARANCE ADJ
ENGINE
When the piston is at the Top Dead Center (TDC) on the compression stroke, align the.
ADJUSTING THE VALVE CLEARANCE/
ADJUSTING THE ENGINE IDLING SPEED
ADJUSTING THE ENGINE IDLING SPEED ADJ
ADJUSTING THE ENGINE IDLING SPEED/
ADJUSTING THE THROTTLE CABLE FREE PLAY
CHECKING THE SPARK PLUG ADJ
CHECKING THE SPARK PLUG/
MEASURING THE COMPRESSION PRESSURE
MEASURING THE COMPRESSION PRESSURE ADJ
MEASURING THE COMPRESSION PRESSURE/
CHECKING THE ENGINE OIL LEVEL
CHECKING THE ENGINE OIL LEVEL/
CHANGING THE ENGINE OIL
CHANGING THE ENGINE OIL/
CHANGING THE TRANSMISSION OIL
CHANGING THE TRANSMISSION OIL/
CLEANING THE AIR FILTER ELEMENT
CLEANING THE AIR FILTER ELEMENT/
CHECKING THE V-BELT
CLEANING THE V-BELT CASE AIR FILTER ELEMENT ADJ
Apply oil of the recommended type to the entire surface of the element, and then squeeze the excess oil out.
CHECKING THE BREATHER HOSES/
CHECKING THE EXHAUST SYSTEM
ADJUSTING THE REAR BRAKE/
CHECKING THE BRAKE FLUID LEVEL
CHASSIS
CHECKING THE BRAKE FLUID LEVEL/
CHECKING THE FRONT BRAKE PADS
CHECKING THE REAR BRAKE SHOES/CHECKING THE FRONT BRAKE HOSE/BLEEDING THE HYDRAULIC BRAKE SYSTEM.
BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ
BLEEDING THE HYDRAULIC BRAKE SYSTEM/
CHECKING AND ADJUSTING THE STEERING HEAD
CHECKING AND ADJUSTING THE STEERING HEAD ADJ
CHECKING THE FRONT FORK/
CHECKING THE TIRES
CHECKING THE TIRES ADJ
Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. To avoid pinching the tube, make sure the wheel rim band and tube are centered in the wheel groove. 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. The front and rear tires should always be by the same manufacturer and of the same design. No guarantee concerning han- dling characteristics can be given if a tire combination other than one approved by Yamaha is used on this motorcycle.
New tires have a relatively low grip on the road surface until they have been slightly worn. After a tire has been repaired or replaced, be sure to tighten the tire air valve stem locknut 1 to specification.
CHECKING THE WHEELS/
CHECKING AND TIGHTENING THE SPOKES
Hold the cable end upright and pour a few drops of lubricant into the cable sheath or use a suitable lubricating device.
LUBRICATING THE CENTERSTAND ADJ
CHECKING AND CHARGING THE BATTERY ADJ
ELECTRICAL SYSTEM
When checking the battery, make sure the battery breather hose is properly installed and routed correctly. If the battery breather hose is positioned so as to allow electrolyte or hydrogen gas from the bat- tery to contact the frame, the motorcycle and its finish may be damaged.
CHECKING AND CHARGING THE BATTERY/
CHECKING THE FUSE
CHECKING THE FUSE/
REPLACING THE HEADLIGHT BULB
REPLACING THE HEADLIGHT BULB/
ADJUSTING THE HEADLIGHT BEAM
CHAPTER 4 ENGINE
REMOVING THE ENGINE
REMOVING THE ENGINE ENG
INSTALLING THE ENGINE
CYLINDER HEAD ENG
CYLINDER HEAD
While lightly pressing the timing chain ten- sioner rod by hand, turn the tensioner rod fully clockwise with a thin screwdriver 1. Make sure that the timing chain tensioner rod comes out of the timing chain tensioner housing smoothly. Align the “I” mark c on the camshaft sprocket with the stationary pointer d on the cylinder head.
Install the timing chain onto the camshaft sprocket, and then install the camshaft sprocket onto the camshaft. When installing the camshaft sprocket, be sure to keep the timing chain as tight as pos- sible on the exhaust side. Turn the timing chain tensioner rod counter- clockwise with a thin screwdriver 1, make sure it releases, and then install the plug cap.
Be sure to tighten the camshaft sprocket bolt to the specified torque to avoid the possibility of the bolt coming loose and damaging the engine. Align the “I” mark on the camshaft sprocket with the stationary pointer d on the cylinder head.
CAMSHAFT ENG
CAMSHAFT
Calculate the clearance by subtracting the rocker arm shaft outside diameter from the rocker arm inside diameter.
VALVES AND VALVE SPRINGS ENG
VALVES AND VALVE SPRINGS
The following procedure applies to all of the valves and valve seats. from the valve face and valve seat). Press the valve through the valve guide and onto the valve seat to make a clear impres- sion. Where the valve seat and valve face contacted one another, the blueing will have been removed.
After replacing the cylinder head or replacing the valve and valve guide, the valve seat and valve face should be lapped. Do not let the lapping compound enter the gap between the valve stem and the valve guide. Turn the valve until the valve face and valve seat are evenly polished, then clean off all of the lapping compound.
After every lapping procedure, be sure to clean off all of the lapping compound from the valve face and valve seat. If the valve seat width is out of specification, reface and lap the valve seat.
CYLINDER AND PISTON ENG
CYLINDER AND PISTON
If out of specification, rebore or replace the cylinder, and replace the piston and piston rings as a set. Before measuring the piston ring side clear- ance, eliminate any carbon deposits from the piston ring grooves and piston rings. Be sure to install the piston rings so that the manufacturer’s marks or numbers face up.
Make sure the arrow mark a on the piston points towards the exhaust side of the cylin- der. Before installing the piston pin clip, cover the crankcase opening with a clean rag to pre- vent the clip from falling into the crankcase. with the recommended lubricant). While compressing the piston rings with one hand, install the cylinder with the other hand.
KICKSTARTER ENG
KICKSTARTER
Turn the kickstarter crank attached to the kick- starter shaft in the direction of the arrow a and remove the kickstarter pinion gear and kick- starter pinion gear clip together. Hook the straight end of the kickstarter spring onto the notch 1 in the kickstarter shaft and hook the hooked end of the kick- starter spring onto the projection 2 as shown. To install the kickstarter crank, align the notch a in the kickstarter crank with the projection b on the V-belt case cover.
BELT DRIVE ENG
BELT DRIVE
BELT, PRIMARY AND SECONDARY SHEAVE 1 O-ring
While holding the clutch carrier with the rotor holding tool 1, loosen the clutch carrier nut one full turn with the socket wrench 2. Pull the secondary sliding sheave out as shown, remove the V-belt along with the sec- ondary sheave 1, and then remove the V-belt 2 from the primary sheave. While holding the primary fixed sheave with the sheave holder 3, loosen the primary sheave nut.
When installing the primary sliding sheave, hold the slider to prevent the primary sheave weights from falling out of the primary sliding sheave. While holding the primary fixed sheave with the sheave holder, tighten the primary sheave nut. Install the secondary sliding sheave onto the secondary fixed sheave 2 with the oil seal guide 3.
Install the clutch carrier nut with the beveled side of the nut facing the clutch carrier. Install the V-belt on the primary sheave, then install the secondary sheave 3 along with the V-belt 2. When installing the secondary sheave, do not get grease from the inner surface of the secondary sheave on the primary drive gear.
While holding the clutch carrier with the rotor holding tool 1, tighten the clutch carrier nut with the socket wrench 2. Position the V-belt in the primary sheave 2 (when the sheave is at its widest position) and in the secondary sheave 3 (when the sheave is at its narrowest position), and make sure the V-belt is tight.
STARTER CLUTCH ENG
STARTER CLUTCH
C. MAGNETO ENG
C. MAGNETO
OIL PUMP ENG
OIL PUMP
Install the inner rotor and outer rotor with their punch marks a facing away from the oil pump housing. When installing the inner rotor, align the pin in the oil pump driven gear with the groove b in the inner rotor.
TRANSMISSION ENG
TRANSMISSION
Prior to remove the transmission, remove the muffler, rear wheel and secondary sheave. completely from the transmission case) Refer to “CHANGING THE TRANSMIS- SION OIL” in chapter 3. with primary drive gear, bearings). Install the conical spring washers as shown in the illustration. with primary drive gear, bearings).
CRANKSHAFT ENG
CRANKSHAFT
The crankshaft assembly cannot be removed if the timing chain is attached onto the crank- shaft drive sprocket. 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. After installing the crankshaft to the left crank- case, make sure that the timing chain meshes with the camshaft drive sprocket and the crankshaft turns smoothly. onto the crankcase mating surfaces).
Insert an 8 mm bolt or similar rod into the hole in the engine bracket and into the hole in the left crankcase to ease the installation procedure. First tighten the nuts on the left crankcase side, and then tighten the nuts on the right crankcase side. Push the engine bracket in the direction of the arrow shown and install the upper engine mounting bolts.
CARB
CHAPTER 5 CARBURETOR
CARBURETOR
CARBURETOR CARB
When installing the jet needle holder, align the notches a in the jet needle holder with the projections b on the piston valve. Match the tab a on the piston diaphragm to the matching recess b in the carburetor body. Make sure that the rim of the piston dia- phragm is installed in the groove in the car- buretor body.
When installing the carburetor assembly, align the slot a in the carburetor assembly with the projection b on the intake manifold.
FUEL TANK CARB
FUEL TANK
AIR FILTER CASE CARB
AIR FILTER CASE
CHAS
CHAPTER 6 CHASSIS
