T105se Manual de Servicio

T105SE
SERVICEMANUAL
5SD-F8197-E0
EB000000
T105SE
SERVICE MANUAL
© 2001 by Yamaha Motor Co., Ltd.
1st Edition, September 2001
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
EB001000
NOTICE
This manual was produced by the Yamaha Motor Company 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, so it is assumed that anyone who uses this book to perform maintenance and repairs on
Yamaha motorcycle has a basic understanding of the mechanical ideas and the procedures of
motorcycle repair. Repairs attempted by anyone without this knowledge are likely to render the
motorcycle unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
NOTE:
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR
SAFETY IS INVOLVED!
WARNING Failure to follow WARNING instructions could result in severe injury or death to
the motorcycle operator, a bystander or a person inspecting or repairing the
motorcycle.
CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage
to the motorcycle.
NOTE: A NOTE provides key information to make procedures easier or clearer.
YP002000
HOW TO USE THIS MANUAL

MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title 1: This is the title of the chapter with its symbol on the upper right corner of each page.
2nd title 2: This title indicates the section of the chapter and only appears on the first page of each
section. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa-
nied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at start of each
removal and disassembly section.
1.An easy-to-see exploded diagram 4 is provided for disassembly and assembly jobs.
2.Numbers 5 are given in the order of jobs in the exploded diagram. A number that is enclosed by a
circle indicates a disassembly step.
3.An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
6. The meanings of the symbol marks are given on the next page.
4.A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5.For jobs requiring more information, the step-by-step format supplements 8 are given in addition
to the exploded diagram and the job instruction chart.
EB003000
1 2 ILLUSTRATED SYMBOLS
Illustrated symbols 1 to 8 are designed as
GEN
INFO SPEC thumb tabs to indicate the chapter’s number
and content.
3 4
1 General information
2 Specifications
INSP 3 Periodic inspection and adjustment
ADJ ENG 4 Engine
5 Carburation
5 6 6 Chassis
7 Electrical
8 Troubleshooting
CARB CHAS
7 8
ELEC – + TRBL
SHTG
Illustrated symbols 9 to F are used to identify
9 0
the specifications appearing in the text.
9 Possible to maintain with engine mounted
0 Filling fluid
A Lubricant
B Special tool
A B
C Tightening
D Wear limit, clearance
E Engine speed
F Ω, V, A
C D
T.
R.
E F
Illustrated symbols G to L in the exploded

G H I
diagrams indicate the types of lubricants and
lubrication points.
G Apply engine oil
E G M
H Apply gear oil
J K L I Apply molybdenum disulfide oil
J Apply wheel bearing grease
K Apply lightweight lithium-soap base grease
B LS M
L Apply molybdenum disulfide grease
Illustrated symbols M to N in the exploded
M N diagrams indicate the where to apply locking
agent M and when to install new parts N.
LT
New M Apply locking agent (LOCTITE®)
N Use new one
INDEX
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC
2
PERIODIC INSPECTION AND
INSP
ADJUSTMENTS ADJ 3
ENGINE ENG
4
CARBURETION CARB
5
CHASSIS CHAS
6
– +
ELECTRICAL ELEC
7
TROUBLESHOOTING TRBL
SHTG 8
CHAPTER 1
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION .................................................................1-1

FRAME SERIAL NUMBER ....................................................................... 1-1
ENGINE SERIAL NUMBER ..................................................................... 1-1
IMPORTANT INFORMATION ........................................................................ 1-2

PREPARATION FOR REMOVAL PROCEDURES ..................................1-2
REPLACEMENT PARTS ..........................................................................1-2
GASKETS, OIL SEALS AND O-RINGS ................................................... 1-2
LOCK WASHERS/PLATES AND COTTER PINS ....................................1-3
BEARINGS AND OIL SEALS ...................................................................1-3
CIRCLIPS .................................................................................................1-3
CHECKING OF CONNECTIONS ............................................................. 1-4
SPECIAL TOOLS ........................................................................................... 1-5
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ....................................................................... 2-1
MAINTENANCE SPECIFICATIONS .............................................................. 2-4

ENGINE .................................................................................................... 2-4
TIGHTENING TORQUES ......................................................................... 2-8
CHASSIS ..................................................................................................2-9
TIGHTENING TORQUES ....................................................................... 2-11
ELECTRICAL ......................................................................................... 2-12
CONVERSION TABLE ................................................................................. 2-14
GENERAL TIGHTENING TORQUE SPECIFICATIONS ..............................2-14
LUBRICATION POINT AND GRADE OF LUBRICANT ...............................2-15

ENGINE .................................................................................................. 2-15
CHASSIS ................................................................................................2-16
CABLE ROUTING ........................................................................................ 2-17

CHAPTER 3
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION ............................................................................................. 3-1
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ............................ 3-1
COVER AND PANEL .....................................................................................3-3

PROTECTOR, FRONT COVER AND LEG SHIELD ................................3-3
REAR PANEL AND REAR COVER .........................................................3-4
ENGINE ..........................................................................................................3-5
VALVE CLEARANCE ADJUSTMENT ......................................................3-5
IDLING SPEED ADJUSTMENT ............................................................... 3-6
THROTTLE CABLE ADJUSTMENT .........................................................3-7
SPARK PLUG INSPECTION .................................................................... 3-8
IGNITION TIMING CHECK ...................................................................... 3-9
COMPRESSION PRESSURE MEASUREMENT ................................... 3-10
ENGINE OIL LEVEL INSPECTION ........................................................ 3-11
ENGINE OIL REPLACEMENT ...............................................................3-12
EXHAUST SYSTEM INSPECTION ........................................................ 3-13
AIR FILTER CLEANING .........................................................................3-13
CLUTCH RELEASE SYSTEM ADJUSTMENT ...................................... 3-15
CHASSIS ...................................................................................................... 3-16

REAR BRAKE ADJUSTMENT ...............................................................3-16
BRAKE FLUID LEVEL INSPECTION .....................................................3-16
BRAKE PAD INSPECTION .................................................................... 3-17
BRAKE HOSE INSPECTION .................................................................3-17
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) .................................3-18
BRAKE SHOE INSPECTION .................................................................3-19
BRAKE LIGHT SWITCH ADJUSTMENT ............................................... 3-19
DRIVE CHAIN SLACK ADJUSTMENT .................................................. 3-20
STEERING HEAD INSPECTION ........................................................... 3-21
FRONT FORK INSPECTION .................................................................3-23
SWINGARM INSPECTION .................................................................... 3-23
REAR SHOCK ABSORBER INSPECTION ............................................3-24
TIRE INSPECTION ................................................................................ 3-24
WHEEL INSPECTION ............................................................................3-26
ELECTRICAL ...............................................................................................3-27
BATTERY INSPECTION ........................................................................3-27
FUSE INSPECTION ............................................................................... 3-30
HEADLIGHT BEAM ADJUSTMENT .......................................................3-31
CHAPTER 4
ENGINE OVERHAUL
ENGINE REMOVAL .......................................................................................4-1

BATTERY,FOOTREST, MUFFLER AND ENGINE GUARD .................... 4-1
DRIVE CHAIN, ENGINE MOUNT BOLT AND ENGINE ........................... 4-2
ENGINE REMOUNTING ..........................................................................4-3
CYLINDER HEAD ........................................................................................... 4-4

CYLINDER HEAD REMOVAL ..................................................................4-6
CYLINDER HEAD INSPECTION ............................................................. 4-7
CYLINDER HEAD INSTALLATION .......................................................... 4-7
CAMSHAFT AND ROCKER ARMS ............................................................. 4-10

ROCKER ARM AND ROCKER ARM SHAFT REMOVAL ......................4-11
CAMSHAFT INSPECTION ..................................................................... 4-11
ROCKER ARMS AND ROCKER ARM SHAFTS INSPECTION ............. 4-12
CAMSHAFT AND ROCKER ARM INSTALLATION ...............................4-12
VALVES AND VALVE SPRINGS .................................................................4-14

VALVES AND VALVE SPRINGS REMOVAL .........................................4-15
VALVES AND VALVE SPRINGS INSPECTION .................................... 4-15
VALVE SEATS INSPECTION ................................................................4-16
VALVES AND VALVE SPRINGS INSTALLATION .................................4-18
CYLINDER AND PISTON ............................................................................. 4-20

PISTON AND PISTON RINGS REMOVAL ............................................4-21
CYLINDER INSPECTION ...................................................................... 4-21
PISTON AND PISTON PIN INSPECTION ............................................. 4-22
PISTON RINGS INSPECTION ...............................................................4-23
PISTON RINGS, PISTON AND CYLINDER INSTALLATION ................ 4-24
CLUTCH ....................................................................................................... 4-26

CRANKCASE COVER (LEFT AND RIGHT) ..........................................4-26
CLUTCH .................................................................................................4-27
CLUTCH REMOVAL .............................................................................. 4-29
CLUTCH INSPECTION ..........................................................................4-30
CLUTCH INSTALLATION ...................................................................... 4-32
KICK STARTER ........................................................................................... 4-35

KICK STARTER INSPECTION ..............................................................4-37
KICK STARTER INSTALLATION ........................................................... 4-37
SHIFT SHAFT ...............................................................................................4-38

SHIFT SHAFT INSPECTION .................................................................4-40
SHIFT SHAFT INSTALLATION ..............................................................4-41
OIL PUMP ..................................................................................................... 4-42
OIL PUMP INSPECTION ....................................................................... 4-44
OIL PUMP INSTALLATION .................................................................... 4-44
AC MAGNETO AND STARTER CLUTCH ...................................................4-45

AC MAGNETO REMOVAL ..................................................................... 4-47
STARTER DRIVE GEAR INSPECTION ................................................. 4-48
AC MAGNETO INSTALLATION ............................................................. 4-48
CRANKCASE AND CRANKSHAFT ............................................................ 4-49

CRANKSHAFT REMOVAL ..................................................................... 4-51
CRANKSHAFT INSPECTION ................................................................4-51
CRANKSHAFT INSTALLATION ............................................................. 4-52
CRANKCASE INSTALLATION ...............................................................4-52
TRANSMISSION ........................................................................................... 4-53

TRANSMISSION, SHIFT CAM AND SHIFT FORK ................................4-53
DRIVE AXLE/MAIN AXLE DISASSEMBLY ............................................4-54
TRANSMISSION REMOVAL .................................................................. 4-56
SHIFT FORK SHIFT CAM INSPECTION ............................................... 4-56
SHIFT FORK AND SHIFT CAM INSTALLATION ................................... 4-57
CHAPTER 5
CARBURETION
CARBURETOR ............................................................................................... 5-1

FLOAT HEIGHT INSPECTION ................................................................5-4
ASSEMBLY .............................................................................................. 5-4
FUEL LEVEL ADJUSTMENT ...................................................................5-5
CHAPTER 6
CHASSIS
FRONT WHEEL AND BRAKE DISC .............................................................. 6-1

FRONT WHEEL DISASSEMBLY ............................................................. 6-3
FRONT WHEEL INSPECTION ................................................................6-3
BRAKE DISC INSPECTION ..................................................................... 6-4
FRONT WHEEL ASSEMBLY ...................................................................6-5
FRONT WHEEL INSTALLATION ............................................................. 6-5
REAR WHEEL, REAR BRAKE, SPROCKET AND DRIVE CHAIN ............... 6-7
REAR WHEEL AND REAR BRAKE .........................................................6-7
DRIVE CHAIN AND DRIVEN SPROCKET ..............................................6-9
REAR WHEEL DISASSEMBLY ............................................................. 6-11
REAR WHEEL INSPECTION .................................................................6-11
REAR BRAKE INSPECTION .................................................................6-11
BRAKE SHOE PLATE ASSEMBLY .......................................................6-12
REAR WHEEL ASSEMBLY ................................................................... 6-12
REAR WHEEL INSTALLATION ............................................................. 6-12
DRIVE CHAIN INSPECTION .................................................................6-13
CLUTCH HUB INSPECTION .................................................................6-14
DRIVEN SPROCKET ASSEMBLY ......................................................... 6-14
DRIVE CHAIN INSTALLATION ..............................................................6-14
FRONT BRAKE ............................................................................................ 6-15

FRONT BRAKE PADS ...........................................................................6-15
BRAKE PAD REPLACEMENT ...............................................................6-16
MASTER CYLINDER ............................................................................. 6-18
MASTER CYLINDER REMOVAL ........................................................... 6-20
MASTER CYLINDER INSPECTION ......................................................6-20
MASTER CYLINDER ASSEMBLY ......................................................... 6-20
MASTER CYLINDER INSTALLATION ...................................................6-21
FRONT BRAKE CALIPER ...................................................................... 6-23
CALIPER DISASSEMBLY ...................................................................... 6-25
CALIPER INSPECTION .........................................................................6-25
CALIPER ASSEMBLY ............................................................................6-26
CALIPER INSTALLATION ...................................................................... 6-26
FRONT FORK ...............................................................................................6-28

FRONT FORK ........................................................................................ 6-28
FRONT FORK DISASSEMBLY ..............................................................6-30
FRONT FORK INSPECTION .................................................................6-30
FRONT FORK ASSEMBLY .................................................................... 6-30
FRONT FORK INSTALLATION ..............................................................6-33
HANDLEBAR ...............................................................................................6-34
METER ASSEMBLY AND HEADLIGHT UNIT ....................................... 6-34
HANDLEBAR .......................................................................................... 6-35
HANDLEBAR REMOVAL ....................................................................... 6-37
HANDLEBAR INSPECTION ................................................................... 6-37
HANDLEBAR INSTALLATION ...............................................................6-37
STEERING .................................................................................................... 6-39

STEERING REMOVAL ...........................................................................6-40
STEERING INSPECTION ...................................................................... 6-40
STEERING INSTALLATION ................................................................... 6-41
REAR SHOCK ABSORBER AND SWINGARM ..........................................6-42

SWINGARM INSPECTION .................................................................... 6-43
SEAT, FUEL TANK AND FUEL COCK .......................................................6-44

FUEL COCK INSPECTION .................................................................... 6-45
FUEL COCK OPERATION ..................................................................... 6-45
CHAPTER 7
ELECTRICAL
ELECTRICAL COMPONENTS ....................................................................... 7-1
CIRCUIT DIAGRAM .......................................................................................7-2
SWITCH INSPECTION ................................................................................... 7-4

INSPECTION STEPS ............................................................................... 7-4
SWITCH CONNECTION AS SHOWN IN THIS MANUAL ........................7-4
SWITCH CONTINUITY INSPECTION .....................................................7-5
IGNITION SYSTEM ........................................................................................7-7

CIRCUIT DIAGRAM ................................................................................. 7-7
TROUBLESHOOTING .............................................................................7-8
ELECTRIC STARTING SYSTEM .................................................................7-12

CIRCUIT DIAGRAM ............................................................................... 7-12
TROUBLESHOOTING ...........................................................................7-13
STARTER MOTOR ................................................................................ 7-16
INSPECTION AND REPAIR ................................................................... 7-17
ASSEMBLY ............................................................................................ 7-18
CHARGING SYSTEM ...................................................................................7-19

CIRCUIT DIAGRAM ............................................................................... 7-19
LIGHTING SYSTEM .....................................................................................7-23

CIRCUIT DIAGRAM ............................................................................... 7-23
LIGHTING SYSTEM CHECK .................................................................7-25
SIGNAL SYSTEM ......................................................................................... 7-29

CIRCUIT DIAGRAM ............................................................................... 7-29
SIGNAL SYSTEM CHECK ..................................................................... 7-32
CHAPTER 8
TROUBLESHOOTING
TROUBLESHOOTING .................................................................................... 8-1

ELECTRICAL SYSTEM ............................................................................8-1
COMPRESSION SYSTEM ....................................................................... 8-2
INTAKE AND EXHAUST SYSTEM .......................................................... 8-3
GEN
MOTORCYCLE IDENTIFICATION INFO
YP100000
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION
YP100020
FRAME SERIAL NUMBER

The frame serial number 1 is stamped into the
frame.
EB100030
ENGINE SERIAL NUMBER

The engine serial number 1 is stamped into
the crankcase.
NOTE:
Designs and specifications are subject to
change without notice.
1-1
GEN
IMPORTANT INFORMATION INFO
EB101000
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL
PROCEDURES
1. Remove all dirt, mud, dust and foreign
material before removal and disassembly.
2. Use proper tools and cleaning equipment.
3. Refer to the “SPECIAL TOOLS” section.
4. When disassembling the machine, 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.
5. During machine disassembly, clean all parts
and place them in trays in the order of dis-
assembly. This will speed up assembly and
allow for the correct installation of all parts.
6. Keep all parts away from any source of fire.
EB101010
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all
replacements. Use oil and grease recom-
mended by Yamaha for all lubrication jobs.
Other brands may be similar in function and
appearance, but inferior in quality.
EB101020
GASKETS, OIL SEALS AND O-RINGS

1. Replace all gaskets, seals and O-rings
when overhauling the engine. All gasket
surfaces, oil seal lips and O-rings must be
cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
1-2
GEN
EB101030
LOCK WASHERS/PLATES AND COTTER

PINS
1. Replace all lock washers/plates 1 and cot-
ter pins after removal. Bend lock tabs along
the bolt or nut flats after the bolt or nut has
been tightened to specification.
EB101040
BEARINGS AND OIL SEALS

Install bearings and oil seals so that the manu-
facturer’s marks or numbers are visible. When
installing oil seals, apply a light coating of light-
weight lithium base grease to the seal lips. Oil
bearings liberally when installing, if appropri-
ate.
1 Oil seal
CAUTION:
Do not use compressed air to spin the
bearings dry. This will damage the bearing
surfaces.
1 Bearing
EB101050
CIRCLIPS
1. Check all circlips carefully before reassem-
bly. Always replace piston pin clips after one
use. Replace distorted circlips. When
installing a circlip 1, make sure that the
sharp-edged corner 2 is positioned oppo-
site the thrust 3 it receives. See sectional
view.
4 Shaft
1-3
GEN
EB801000
CHECKING OF CONNECTIONS
Dealing with stains, rust, moisture, etc. on the
connector.
1. Disconnect:
• Connector
2. Dry each terminal with an air blower.
3. Connect and disconnect the connector two

or three.
4. Pull the lead to check that it will not come
off.
5. If the terminal comes off, bend up the pin 1
and reinsert the terminal into the connector.
6. Connect:
• Connector
NOTE:
The two connectors “click” together.
7. Check for continuity with a tester.

NOTE:
• If there is no continuity, clean the terminals.
• Be sure to perform the steps 1 to 7 listed
above when checking the wireharness.
• For a field remedy, use a contact revitalizer
available on the market.
• Use the tester on the connector as shown.
1-4
GEN
SPECIAL TOOLS INFO
EB102000
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools; this will help prevent damage caused by the use of inappropriate
tools or improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes
Tool No. Tool name/Usage Illustration
Weight
Slide hammer bolt
90890-01084
90890-01085
These tools are used when removing or
installing the rocker arm shafts.
Fork seal driver weight
90890-01184
This tool is used to installing the oil seal.

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

Valve spring compressor
90890-01253
These tools are used when removing or
installing the valve and the valve spring.
Ringnut wrench
90890-01268
This tool is used to loosen and tighten
the exhaust and steering ringnut.
Tappet adjusting tool
90890-01311
This tool is necessary for adjusting
valve clearance.
Fuel level gauge
90890-01312
This gauge is used to measure the fuel
level in the float chamber.
1-5
GEN
SPECIAL TOOLS INFO
T-handle
90890-01326
This tool is used for holding the damper
rod holder when removing or installing
the damper rod holder.
Flywheel puller
90890-01362
This tool is used for removing the rotor.

Ring nut wrench
90890-01403
This tool is used to loosen and tighten
the steering ring nut.
Sheave holder
90890-01701
This tool is used for holding the second-
ary sheave.
Thickness gauge
90890-03079
This tool is used to measure the valve
clearance.
Compression gauge
90890-03081
These tools are used to measure the
engine compression.
Pocket tester
90890-03112
These instruments are invaluable for
checking the electrical system.
Engine tachometer
90890-03113
This tool is needed for detecting engine
rpm.
1-6
GEN
SPECIAL TOOLS INFO
Timing light
90890-03141
This tool is needed for detecting ignition
timing.
Universal clutch holder
90890-04086
This tool is used to hold the clutch boss
when removing or installing the clutch
boss nut.
Valve lapper
90890-04101
This tool is used for removing and
installing the lifter and for lapping the
valve.
Ignition checker
90890-06754
This instrument is necessary for check-
ing the ignition system components.
Yamaha bond No. 1215
90890-85505
This sealant (bond) is used for crank-
case mating surface, etc.
1-7
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model T105SE
Model code: 5SD1
Dimensions:
Overall length 1,890 mm
Overall width 670 mm
Overall height 1,055 mm
Seat height 770 mm
Wheelbase 1,210 mm
Minimum ground clearance 145 mm
Minimum turning radius 1,800 mm
Basic weight:
With oil and full fuel tank 99 kg
Engine:
Engine type Air-cooled 4-stroke, SOHC
Cylinder arrangement Forward-inclined single cylinder
Displacement 0.1018 L (101.8 cm3)
Bore × stroke 49.0 × 54.0 mm
Compression ratio 9.0 : 1
Compression pressure (STD) 1,200 kPa (12 kg/cm2, 12 bar) at 500 r/min
Starting system Kick and electric starter
Lubrication system: Wet sump
Oil type or grade:
Engine oil
YAMALUBE 4 (20W40) or equivalent
SAE 20W40 type SE or higher grade motor oil
SAE 20W40 type SF/CC motor oil
Periodic oil change 0.8 L
Total amount 1.0 L
Air filter: Wet type element
Fuel:
Type Regular gasoline
Fuel tank capacity 4.5 L
2-1
Model T105SE
Carburetor:
Type/quantity VM16-SH/1
Manufacturer MIKUNI
Spark plug:
Type C7HSA/U22FS-U
Manufacturer NGK/DENSO
Spark plug gap 0.6 ~ 0.7 mm
Clutch type: Wet, multiple - disc and centrifugal automatic
Transmission:
Primary reduction system Spur gear
Primary reduction ratio 67/18 (3.722)
Secondary reduction system Chain drive
Secondary reduction ratio 38/15 (2.533)
Transmission type Constant mesh 4 speed
Operation Left foot operation
Gear ratio 1st 38/12 (3.166)
2nd 33/17 (1.941)
3rd 29/21 (1.380)
4th 23/21 (1.095)
Chassis:
Frame type Steel tube underbone
Caster angle 26.5 °
Trail 79.0 mm
Tire:
Type With tube
Size front 2.50-17 38L
rear 2.75-17 41P
Manufacturer front LOCAL MADE
rear LOCAL MADE
Tire pressure (cold tire):
Maximum load-except motorcycle 110 kg
Loading condition A * 0 ~ 90 kg
front 200 kPa (2.00 kg/cm2, 2.00 bar)
rear 225 kPa (2.25 kg/cm2, 2.25 bar)
Loading condition B * 90 ~ 110 kg
front 200 kPa (2.0 kg/cm2, 2.0 bar)
rear 225 kPa (2.25 kg/cm2, 2.25 bar)
*Load is the total weight of cargo, rider, passenger, and accessories.
2-2
Model T105SE
Brake:
Front brake type Single disc brake
operation Right hand operation
Rear brake type Drum brake
operation Right foot operation
Suspension:
Front suspension Telescopic fork
Rear suspension Swingarm
Shock absorber:
Front shock absorber Coil spring/Oil damper
Rear shock absorber Coil spring/Oil damper
Wheel travel:
Front wheel travel 90 mm
Rear wheel travel 66 mm
Electrical:
Ignition system DC.C.D.I.
Generator system AC magneto
Battery type GM5Z-3B
Battery capacity 12V 5 AH
Headlight type: Incandescence
Bulb wattage × quantity:
Headlight 12V 25 W/25 W × 1
Tail/brake light 12V 5 W/21 W × 1
Turn signal light 12V 10 W × 4
Meter light 12V 3.0 W × 1
High beam indicator light 12V 1.7 W × 1
Neutral indicator 12V 1.7 W × 1
Turn indicator light 12V 1.7 W × 1
Gear position indicator light 12V 1.7 W × 4
2-3
MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Item Standard Limit
Cylinder head:
Warp limit ---- 0.03 mm
Cylinder:
Bore size 49.000 ~ 49.018 mm 49.1 mm
Out of round limit ---- 0.03 mm
Camshaft:
Cam dimensions
Intake “A” 25.428 ~ 25.528 mm 22.398 mm
“B” A 21.034 ~ 21.134 mm 21.004 mm
Exhaust “A” 25.286 ~ 25.386 mm 25.260 mm

“B” 21.047 ~ 21.147 mm 21.031 mm
B
Camshaft runout limit ---- 0.03 mm
Cam chain:
Cam chain type/No. of links BUSH CHAIN/84 ----
Tensioning system Automatic ----
Rocker arm/rocker armshaft:
Rocker arm inside diameter 10.000 ~ 10.015 mm 10.030 mm
Rocker shaft outside diameter 9.981 ~ 9.991 mm 9.950 mm
Rocker arm-to-rocker armshaft 0.009 ~ 0.034 mm 0.080 mm
clearance
Valve, valve seat, valve guide:
Valve clearance (cold) IN 0.05 ~ 0.10 mm ----
EX 0.08 ~ 0.13 mm ----
Valve dimensions
B C
D
A
Head Diameter Face Width Seat Width Margin Thickness
“A” head diameter IN 22.9 ~ 23.1 mm ----
EX 19.9 ~ 20.1 mm ----
“B” face width IN 1.2 ~ 2.5 mm ----
EX 1.6 ~ 2.9 mm ----
“C” seat width IN 0.9 ~ 1.1 mm ----
EX 0.9 ~ 1.1 mm ----
“D” margin thickness IN 0.5 ~ 0.9 mm ----
EX 0.8 ~ 1.2 mm ----
Stem outside diameter IN 4.475 ~ 4.490 mm 4.45 mm
EX 4.460 ~ 4.475 mm 4.435 mm
Guide inside diameter IN 4.500 ~ 4.512 mm 4.542 mm
EX 4.500 ~ 4.512 mm 4.542 mm
2-4
Item Standard Limit
Valve stem-to-guide clearance IN 0.010 ~ 0.037 mm 0.08 mm
EX 0.025 ~ 0.052 mm 0.1 mm
Valve stem runout limit ---- 0.01 mm
Valve seat width IN 0.9 ~ 1.1 mm 1.6 mm
EX 0.9 ~ 1.1 mm 1.6 mm
Valve spring:
Free length IN/EX 32.09 mm 30.6 mm
Set length (valve closed) IN/EX 24.2 mm ----
Compressed pressure IN/EX 136 ~ 158 N (13.9 ~ 16.1 kg) ----
Tilt limit IN/EX ---- 2.5°/1.4 mm
Winding direction IN/EX Clockwise ----
Piston:
Piston to cylinder 0.015 ~ 0.020 mm 0.15 mm
clearance
Piston size “D” 48.985 ~ 49.001 mm ----
H
Measuring point “H” 5.5 mm ----
D
Offset 0.75 mm ----
Offset direction Intake side ----
Piston pin bore inside diameter 13.002 ~ 13.013 mm 13.043 mm
Piston pin outside diameter 12.996 ~ 13.000 mm 12.976 mm
Piston rings:
Top ring:
Type Barrel ----
Dimensions (B × T) 1.0 × 2.0 mm ----
End gap (installed) 0.15 ~ 0.30 mm 0.40 mm
Side clearance (installed) 0.03 ~ 0.07 mm 0.12 mm
2nd ring:
Type Taper ----
Dimensions (B × T) 1.0 × 2.0 mm ----
End gap (installed) 0.15 ~ 0.30 mm 0.40 mm
Side clearance 0.02 ~ 0.06 mm 0.12 mm
Oil ring:
Dimensions (B × T) 2.0 × 2.2 mm ----
End gap (installed) 0.3 ~ 0.9 mm ----
Crankshaft:
C C
A
Crank width “A” 42.95 ~ 43.00 mm ----
Runout limit “C” 0.03 mm ----
Big end side clearance “D” 0.11 ~ 0.41 mm ----
2-5
Item Standard Limit
Clutch:
Friction plate thickness 2.7 ~ 2.9 mm 2.6 mm
Quantity 5 pcs ----
Clutch plate thickness 1.1 ~ 1.3 mm 0.05 mm
Quantity 4 pcs ----
Clutch spring free length 28.7 mm 26.7 mm
Quantity 4 pcs ----
Clutch release method Innerpush, campush ----
Push rod bending limit ---- 0.5 mm
Clutch housing inside diameter 105 mm 106 mm
Clutch shoe slit depth 1.0 mm 0.1 mm
Weight outside diameter 104.7 mm 103.5 mm
Clutch - in revolution 1,700 ~ 2,100 r/min ----
Clutch - stall revolution 3,100 ~ 3,700 r/min ----
Kick starter:
Kick starter type Ratchet type ----
Kick clip friction force 8.8 ~ 14.7 N (0.9 ~ 1.5 kg) ----
Carburetor:
Type VM16SH
I.D. mark 5LM1-00 ----
Venturi outside diameter ø16 ----
Main jet (M.J) #87.5 ----
Main air jet (M.A.J) ø1.4 ----
Jet needle (J.N) 4DH31-2 ----
Needle jet (N.J) E-2 ----
Cutaway 3.0 ----
Pilot outlet (P.O) ø0.8 ----
Pilot jet (P.J) #15 WJ ----
Air screw 1-1/2 turns out ----
Valve seat size (V.S) ø1.5 ----
Starter jet 1 (G.S.1) #30 ----
Starter jet 2 (G.S.2) ø0.5 ----
Float height (F.H) 15 mm ----
Engine idle speed 1,400 ~ 1,600 r/min ----
Intake vacuum 32.0 ~ 34.7 kPa (240 ~ 260 mmHg) ----
Oil temperature 65 ~ 75 °C ----
Oil pump:
Type Trochoid type ----
Tip clearance 0.15 mm 0.2 mm
Side clearance 0.06 ~ 0.10 mm 0.15 mm
Housing and rotor clearance 0.06 ~ 0.10 mm 0.15 mm
2-6
Item Size
Bearings and oil seals:
Camshaft bearing (left) 6003
Camshaft bearing (right) 6002Z
Crankshaft bearing (left) 6304
Big end bearing 26 × 31 × 13.8 × 2 (needle bearing)
Crankshaft bearing (right) 6205
Clutch push rod oil seal S5-10-18-6-3KS
Main axle bearing (left) 6001
Main axle bearing (right) 6202
Drive axle bearing (left) 6204
Drive axle bearing (right) 6202RS
Drive axle oil seal MHSA-20-35-5U-C
Shift shaft oil seal SD-12-22-5-HS
Kick axle oil seal SD-15-26-5-HS
2-7
TIGHTENING TORQUES
ENGINE
Tightening
Thread torque
Part to be tightened Part name Q’ty Remarks
size
Nm m·kg
Cam sprocket cover Screw M6 2 7 0.7
Cylinder head and cylinder Nut M8 4 22 2.2
Cylinder head and cylinder Bolt M6 2 10 1.0
(Cam chain side)
Cylinder head stud bolt Bolt M6 2 7 0.7
Spark plug — M10 1 12.5 1.25
Valve cover — M45 2 17.5 1.75
AC magneto Nut M12 1 48 4.8
Guide stopper Bolt M6 2 10 1.0 LT
Valve adjuster locknut Nut M5 2 7 0.7

Cam sprocket Bolt M8 1 20 2.0
Cam shaft bearing stopper Bolt M6 1 10 1.0 LT
Timing chain tensioner

(Body) Bolt M6 2 10 1.0
(Plug) Bolt M6 1 8 0.8
Oil pump Screw M6 2 7 0.7
Drain bolt Bolt M12 1 20 2.0
Carburetor joint Bolt M6 2 10 1.0
Carburetor joint and carburetor Bolt M6 2 10 1.0
Exhaust pipe and cylinder head Nut M6 2 7 0.7
Crankcase (left and right) Bolt M6 9 10 1.0
Crankcase cover (left) Bolt M6 8 10 1.0
Drive sprocket cover Bolt M6 2 7 0.7
Crankcase cover (right) Bolt M6 9 10 1.0
Center plug — M32 1 7 0.7
Timing check plug — M14 1 7 0.7
Crankcase stud bolt Bolt M8 4 12.5 1.25
Kick crank Bolt M6 1 10 1.0
AC magneto and starter clutch Bolt M6 3 14 1.4
Primary drive gear Nut M12 1 50 5.0
Pressure plate Bolt M5 4 6 0.6
Clutch boss Nut M14 1 60 6.0
Shift pedal Bolt M6 1 17.5 1.75
Adjust screw locknut (clutch) Nut M6 1 8 0.8
Pickup coil Bolt M6 2 10 1.0 LT
Neutral switch Screw M5 2 4 0.4

Stator coil Bolt M6 3 10 1.0 LT
2-8
CHASSIS
Item Standard Limit

Steering system:
Steering bearing type Angular bearing ----
Front suspension:
Front fork travel 90 mm ----
Fork spring free length 286.7 mm 269.7 mm
Spring rate (K1) 7.84 N/mm (0.8 kg/mm) ----
(K2) 22.9 N/mm (2.34 kg/mm) ----
Stroke (K1) 0 ~ 70 mm ----
(K2) 70 ~ 90 mm ----
Oil capacity 0.0575 L (57.5 cm3) ----
Oil level 102 mm ----
Oil grade Fork oil 10 W or equivalent ----
Inner tube vend limit ---- 0.2 mm
Rear suspension:
Shock absorber stroke 60 mm ----
Spring free length 194 mm 190.0 mm
Installed length 174.5 mm ----
Spring rate (K1) 14.0 N/mm (1.42 kg/mm) ----
(K2) 39.9 N/mm (4.07 kg/mm) ----
Stroke (K1) 0 ~ 34 mm ----
(K2) 34 ~ 60 mm ----
Front wheel:
Type Spoke wheel ----
Rim size 17 × 1.40 ----
Rim material Steel ----
Rim runout limit radial ---- 2 mm
lateral ---- 2 mm
Rear wheel:
Type Spoke wheel ----
Rim size 17 × 1.40 ----
Rim material Steel ----
Rim runout limit radial ---- 2 mm
lateral ---- 2 mm
Front brake:
Type Single disc ----
Disc outside diameter × thickness 220 × 3.5 mm 220 × 3.0 mm
Pad thickness inner 5.2 mm 1.5 mm
Pad thickness outer 5.2 mm 1.5 mm
Master cylinder inside diameter 12.7 mm ----

Caliper cylinder inside diameter 25.4 mm ----
Brake fluid type DOT 4 ----
2-9
Item Standard Limit
Rear brake:
Type Leading, trailing ----
Drum inside diameter 110 mm 111 mm
Lining thickness 4 mm 2 mm
Brake pedal:
Brake pedal free play 20 ~ 30 mm ----
Throttle cable free play 3 ~ 5 mm ----
Item Size
Bearings and oil seals:
Front wheel bearing (left) 6300-6
Front wheel bearing (right) 6300-6
Front wheel oil seal (left) Toku DD-20-35-7
Rear wheel bearing (left) 6301-11
Rear wheel bearing (right) 6301 LU-3A
Rear wheel oil seal (clutch hub) Toku DD-26-42-8
2 - 10
TIGHTENING TORQUES
CHASSIS
Tightening
Part to be tightened Thread size torque Remarks
Nm m·kg
Handlebar and steering shaft M10 43 4.3
Steering shaft and front fork M10 50 5.0
Steering ring nut M25 75 7.5 See NOTE
Frame and engine bracket M8 34 3.4
Engine mount (front) M8 34 3.4
Engine mount (rear upper) M8 34 3.4
Engine mount (rear under) M8 34 3.4
Swingarm M12 51 5.1
Rear shock absorber and frame M10 32 3.2
Rear shock absorber and swingarm M10 32 3.2
Swingarm and tension plate M8 16 1.6
Tension plate and brake shoe plate M8 19 1.9
Chain case M6 4 0.4
Front fork and brake caliper M10 35 3.5
Brake hose union bolt M10 26 2.6
Front fork and brake hose clamp M6 10 1.0
Rear view mirror (left and right) 32 3.2
Front fork cap bolt M20 50 5.0
Damper rod bolt M8 23 2.3
Brake disc and wheel hub M8 23 2.3
Brake master cylinder and handlebar M6 13 1.3
Fuel tank and fuel sender M5 4 0.4
Fuel tank and frame
(under) M8 16 1.6
(rear) M6 7 0.7
Fuel tank and seat M6 9 0.9
Footrest and engine M8 23 2.3
Sidestand (bolt) M8 26 2.6
(nut) M8 16 1.6
Centerstand M10 48 4.8
Passenger footrest bracket M8 16 1.6
Front wheel axle and nut M10 39 3.9
Rear wheel axle and nut M12 60 6.0
Clutch hub and driven sprocket M8 30 3.0
Fuel cock M6 9 0.9
Brake cam lever M6 7 0.7
Front cover (left and right) M6 5 0.5
Front fender and steering shaft M6 10 1.0
NOTE:
NOTE:
1.When tighten the ring nut, should be steady the boll bearings and the steering shaft moving
smoothly.
2.Then, hold the ring nuts (lower) and tighten the ring nut (upper) 75 Nm (7.5 m • kg) by using the
torque wrench.
2 - 11
ELECTRICAL
Item Standard Limit

System voltage: 12 V ----
Ignition system:
Ignition timing (B.T.D.C.) 10 ° at 1,700 r/min ----
Advanced type Electrical (digital) ----
DC.C.D.I.:
Pickup coil resistance/color 248 ~ 372 Ω at 20 °C/Red — White ----
C.D.I. unit model/manufacturer 5LL/YAMAHA ----
Ignition coil:
Model/manufacturer 4ST/LOCAL MADE ----
Minimum spark gap 6 mm ----
Primary winding resistance 0.32 ~ 0.48 Ω at 20 °C ----
Secondary winding resistance 5.68 ~ 8.52 kΩ at 20 °C ----
Spark plug cap:
Material Resin ----
Resistance 10 kΩ ----
Charging system:
Type AC magneto ----
Model/manufacturer F5AV /YAMAHA ----
Charging current (Min.) 1.5 A/3,000 r/min ----
Charging coil resistance/color 0.26 ~ 0.40 Ω at 20 °C/White — Black ----
Lighting voltage (Min.) 12.0 V/3,000 r/min ----
(Max.) 14.5 V/8,000 r/min ----
Lighting coil resistance/color 0.2 ~ 0.3 Ω at 20 °C/Yellow/Red — Black ----
Rectifier/regulator:
Model/manufacturer SH656-12/YIMM ----
No load regulated voltage (DC) 14.1 ~ 14.9 V ----
(AC) 13 ~ 14 V ----
Rectifier capacity (DC) 8A ----
(AC) 12 A ----
Withstand voltage 600 V ----
2 - 12
Item Standard Limit
Battery:
Specific gravity 1.280 ----
Electric starting system:
Type Constant mesh
Starter motor:
Model/manufacturer 4ST/YIMM ----
Operation voltage 12 V ----
Output 0.25 kW ----
Armature coil resistance 0.035 ~ 0.044 Ω at 20 °C ----
Brush overall length 7 mm 3.5 mm
Brash quantity 2 pcs. ----
Spring force 6.86 ~ 7.84 N (700 ~ 800 g) 6.86 N (700 g)
Commutator diameter 17.5 mm 16.0 mm
Mica undercut (depth) 0.6 mm ----
Starter relay:
Model/manufacturer MS5F-481/JIDECO ----
Amperage rating 180 A ----
Coil winding resistance 4.2 ~ 4.6 Ω at 20 °C ----
Horn:
Model/manufacturer LOCAL MADE ----
Maximum amperage 1.5 A ----
Turn signal relay:
Type Condenser type ----
Model/manufacturer FR-2201/MITSUBA ----
Flasher frequency 75 ~ 95 cycle/min ----
Fuel gauge:
Model/manufacturer 5SD/LOCAL MADE ----
Sender unit resistance - full 4 ~ 10 Ω ----
- empty 90 ~ 100 Ω ----
Circuit breaker:
Type Fuse ----
Main 7A ----
Reserve 7A ----
2 - 13
CONVERSION TABLE/
GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC
EB201000 EAS00030
CONVERSION TABLE GENERAL TIGHTENING TORQUE

All specification data in this manual are listed SPECIFICATIONS
in SI and METRIC UNITS. This chart specifies tightening torques for stan-
Use this table to convert METRIC unit data to dard fasteners with a standard ISO thread
IMPERIAL unit data. pitch. Tightening torque specifications for spe-
Ex. cial components or assemblies are provided
for each chapter of this manual. To avoid
METRIC MULTIPLIER IMPERIAL warpage, tighten multi-fastener assemblies in
** mm 0.03937 ** in a crisscross pattern and progressive stages
2 mm 0.03937 0.08 in until the specified tightening torque is reached.
Unless otherwise specified, tightening torque
CONVERSION TABLE specifications require clean, dry threads. Com-
ponents should be at room temperature.
METRIC TO IMPERIAL
Metric unit Multiplier Imperial unit
m·kg 7.233 ft·lb
Tighten-
ing torque m·kg 86.794 in·lb
cm·kg 0.0723 ft·lb
cm·kg 0.8679 in·lb
kg 2.205 lb
Weight
g 0.03527 oz
Speed km/hr 0.6214 mph
km 0.6214 mi
m 3.281 ft
Distance m 1.094 yd A: Width across flats
cm 0.3937 in
B: Thread diameter
mm 0.03937 in
cc (cm3) 0.03527 oz (IMP lip.) General tightening
Volume/ cc (cm3) 0.06102 cu-in A B torques
Capacity lt (liter) 0.8799 qt (IMP liq.) (nut) (bolt)
lt (liter) 0.2199 gal (IMP liq.) Nm m•kg ft•lb
kg/mm 55.997 lb/in
10 mm 6 mm 6 0.6 4.3
kg/cm2 14.2234 psi (lb/in2)
Misc.
Centigrade 9/5+32 Fahrenheit (°F) 12 mm 8 mm 15 1.5 11
(°C)
14 mm 10 mm 30 3.0 22
17 mm 12 mm 55 5.5 40
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
2 - 14
LUBRICATION POINT AND GRADE OF LUBRICANT SPEC
LUBRICATION POINT AND GRADE OF LUBRICANT
ENGINE
Lubrication Point Symbol

Oil seal lips LS
Bearings E
O-rings LS
Cylinder head tightening nut and stud bolt contact surfaces E
Crank pin outside E
Connecting rod big end surface and thrust surfaces E
Cam chain sprocket M
Piston pin E
Piston outside and ring groove E
Camshaft profile M
Valve stem (IN, EX) E
Valve stem end (IN, EX) E
Rocker arm shaft E
Rocker arm inner surfaces M
Kick gear inner surfaces E
Kick axle thrust surfaces E
Idle gear inner surfaces E
Stater wheel gear inner surfaces M
Stater clutch assembly E
Primary driven gear inner surfaces E
Clutch housing inner surface E
Clutch boss E
Push rod E
Shift cam grooves E
Shift contact surfaces M
Shift fork guide bar thrust surfaces E
Shift shaft thrust surfaces E
Main axle and drive axle M
Crankcase mating surfaces Yamaha bond No. 1215

Stator grommet Yamaha bond No. 1215
Suction pipe LT
2 - 15
LUBRICATION POINT AND GRADE OF LUBRICANT SPEC
CHASSIS
Lubrication Point Symbol

Front wheel oil seal lips (left/right) LS
Front and rear wheel axle LS
Swingarm pivot shaft LS
Steering head pipe bearing (upper/lower) LS
Steering head pipe dust seal lips (upper/lower) LS
Tube guide (throttle grip) inner surface LS
Brake cable (brake lever) LS
Brake lever pivot bolt LS
Sidestand pivot LS
Centerstand pivot LS
Centerstand stopper pivot shaft LS
Brake cam pivot shaft and cam surface LS
2 - 16
CABLE ROUTING SPEC
CABLE ROUTING
1 Front brake switch È Put the couplers into the space between the
2 Handlebar switch lead (left) handlebar and speedometer unit, after connect-
3 Starter cable ing them.
4 Speedometer cable É Fasten the wire harness, speedometer cable,
5 Wire harness throttle cable and starter cable with the plastic
6 Headlight unit band.
7 Brake hose Ê Align the clamp with the white tape.
8 Throttle cable Ë Hand the wire strap on the wire guide.
9 Handlebar switch lead (right)
2 - 17
CABLE ROUTING SPEC
1 Speedometer cable È Pass the wire harness through the guide.
2 Starter cable É Pass the throttle cable and starter cable
3 Throttle cable between the guide and frame.
4 Overflow hose (carburation) Ê Fasten the wire harness and leg shield (left and
5 Vacuum hose right) with the plastic band.
6 Fuel hose Ë Pass the plastic band through the holes in the
7 Air vent hose front cover (left).
8 Wire harness Ì Align the clamp with the white tape.
9 Brake hose Í Pass the vacuum hose and fuel hose through
the guide.
Î Pass the vacuum hose and fuel hose through
the hole in the front cover (left).
2 - 18
CABLE ROUTING SPEC
1 Wire harness È Clamp the starter motor lead on the inside of the
2 Rectifier/regulator crankcase.
3 Overflow hose (fuel tank) É Pass the fuel hose and vacuum hose under the
4 Flasher relay guide.
5 Fuel hose Ê Install the fuel hose to the fuel cock horizontally.
6 Fuel cock Ë 90 °
7 Vacuum hose
8 Crankcase breather hose
9 Starter motor lead
2 - 19
CABLE ROUTING SPEC
1 Main switch lead B Starter relay
2 Brake hose
3 Throttle cable È Pass the air vent hose throttle the hole in the leg
4 Starter cable shield bracket and then match the white paint-
5 Horn mark with bracket outer surface.
6 Ignition coil
7 High tension cord
8 Air vent hose
0 Rear brake switch
A Battery positive lead
2 - 20
CABLE ROUTING SPEC
1 CDI unit È Pass the battery breather hose between the
2 Fuse swingarm and frame.
3 Starter relay
5 Rear brake switch
6 Battery breather hose
7 Battery negative lead
8 Battery positive lead
9 Tail/brake light lead
0 Starter motor
2 - 21
CABLE ROUTING SPEC
1 Wire harness B Fuel cock
2 Rectifier/regulator
3 Battery È To fuse.
4 Battery positive lead É Pass the tail/brake lead through the guide.
5 Battery negative lead
6 C.D.I. unit
7 Tail/brake light lead
8 Tail/brake light
9 Flasher relay
0 Fuel sender
A Fuel hose
2 - 22
INTRODUCTION/PERIODIC MAINTENANCE/ INSP
LUBRICATION INTERVALS ADJ
EB300000
PERIODIC INSPECTIONS AND ADJUSTMENTS

INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjust-
ments. These preventive maintenance procedures, if followed, will ensure more reliable vehicle
operation and a longer service life. The need for costly overhaul work will be greatly reduced. 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.
YP301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALS

INITIAL EVERY
No. ITEM CHECK OR MAINTENANCE JOB
500 km 2,000 km 4,000 km 8,000 km
• Check valve clearance.
1 * Valve(s) √ √
• Adjust if necessary.
• Check condition.
2 * Spark plug √ √ √ √
• Clean or replace if necessary.
• Clean.
3 Air filter √ √
• Replace if necessary.
• Check engine idling speed and starter operation.
4 * Carburetor √ √ √ √
• Adjust if necessary.
• Check fuel hose and vacuum hose for cracks or
5 Fuel line damage. √ √
6 * Engine oil • Replace. (Warm engine before draining.) √ √ Every 2,000 km
7 * Engine oil filter • Check, clean and replace if necessary. √ √ √ √
• Check operation, fluid level and fluid leakage.
8 * Front brake √ √
• Replace brake pads if necessary.
• Check operation and adjust brake pedal free
9 * Rear brake play. √ √
• Replace brake shoes if necessary.
• Check swingarm assembly for looseness.
• Correct if necessary.
10 * Swingarm pivot √
• Lubricate with lithium soap base grease every
16,000 km.
• Check balance, runout, spoke tightness and for
11 * Wheels damage. √ √
• Check bearing assembly for looseness or dam-
12 * Wheels bearings age. √ √ √
• Replace if damaged.
• Check bearing assembly for looseness.
13 * Steering bearing √ √
• Lubricate medium weight wheel bearing grease
every 8,000 km.
• Check operation and for oil leakage.
14 * Front forks √ √
• Repair if necessary.
Rear shock • Check operation and for oil leakage.
15 * √ √
absorber • Repair if necessary.
• Check chain slack and alignment.
16 * Drive chain • Adjust if necessary. Every 500 km
• Clean and lubricate.
• Check all chassis fitting and fasterners.
17 Fittings/Fasteners √ √ √ √
Centerstand and • Check operation.
18 * √ √
sidestand • Repair if necessary.
3-1
INSP
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ADJ
INITIAL EVERY
No. ITEM CHECK OR MAINTENANCE JOB
500 km 2,000 km 4,000 km 8,000 km
• Check specific gravity.
19 * Battery • Check that the breather hose is working properly. √ √
* It is recommended that these items be serviced by a Yamaha dealer.

NOTE:
● The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
● Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinder and caliper, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
3-2
INSP
COVER AND PANEL ADJ
COVER AND PANEL
PROTECTOR, FRONT COVER AND LEG SHIELD
Order Job name/Part name Q’ty Remarks

Protector, front cover and leg shield Remove the parts in the order listed.
removal
1 Main switch cover 1
2 Protector 1
3 Front cover (right) 1
4 Front cover (left) 1
5 Leg shield (right) 1
6 Leg shield (left) 1
7 Front panel 1
For installation, reverse the removal
procedure.
3-3
INSP
COVER AND PANEL ADJ
REAR PANEL AND REAR COVER

Rear panel and rear cover removal Remove the parts in the order listed.
Front cover (left and right) Refer to “PROTECTOR, FRONT COVER
AND LEG SHIELD” section.
1 Storage compartment 1
2 Rear panel 1
3 Center cover 1
4 Center panel (left) 1 Rear cover
5 Center panel (right) 1
6 Rear cover (left) 1
7 Rear cover (right) 1
procedure.
3-4
INSP
VALVE CLEARANCE ADJUSTMENT ADJ
T303004
ENGINE
VALVE CLEARANCE ADJUSTMENT
NOTE:
Valve clearance adjustment should be made
with the engine cool, at room temperature.
When the valve clearance is to be measured
or adjusted, the piston must be at Top Dead
Center (T.D.C.) on the compression stroke.
1. Remove:
• Protector
• Front cover (left and right)
Refer to “COVER AND PANEL” section.
2. Remove:
• Spark plug
• Valve cover (intake side) 1
• Valve cover (exhaust side) 2
3. Remove:
• Timing check plug (with O-ring) 1
• Center plug (with O-ring) 2
4. Measure:
• Valve clearance
Out of specification → Adjust.
Valve clearance (cold):

Intake valve 0.05 ~ 0.10 mm
Exhaust valve 0.08 ~ 0.13 mm
*****************************************************
Measurement steps:
● Rotate the crankshaft counterclockwise to
align the slit a on the rotor with the station-
ary pointer b on the crankcover 1 when the
piston is Top Dead Center (TDC).
● Measure the valve clearance by using a
feeler gauge.
Out of specification → Adjust clearance.
*****************************************************
3-5
VALVE CLEARANCE ADJUSTMENT/ INSP
IDLING SPEED ADJUSTMENT ADJ
5. Adjust:
• Valve clearance
*****************************************************
Adjustment steps:
● Loosen the locknut 1.
● Turn the adjuster 3 in or out with the tappet
adjusting tool 2 until specified clearance is
obtained.
Valve clearance is
Turning in
decreased.
Valve clearance is
Turning out
increased.
Tappet adjusting tool:

90890-01311
● Hold the adjuster to prevent it from moving

and tighten the locknut.
7 Nm (0.7 m · kg)
T.
R.
● Measure the valve clearance.
● If the clearance is incorrect, repeat above
steps until specified clearance is obtained.
*****************************************************
6. Install:
• Valve cover (intake side) 1
17.5 Nm (1.75 m · kg)
T.
R.
• O-ring 2 New
7. Install:
• Valve cover (exhaust side)
17.5 Nm (1.75 m · kg)
T.
R.
• O-ring
• Spark plug 12.5 Nm (1.25 m · kg)
T.
R.
• Timing check plug

(with O-ring) 7 Nm (0.7 m · kg)
T.
R.
• Center plug
(with O-ring) 7 Nm (0.7 m · kg)
T.
R.
YP303022
IDLING SPEED ADJUSTMENT
1. Start the engine and let it warm up for sev-
eral minutes.
2. Attach:
• Engine tachometer
to the spark plug lead.
Engine tachometer:
90890-03113
3-6
IDLING SPEED ADJUSTMENT/ INSP
THROTTLE CABLE ADJUSTMENT ADJ
3. Check:
• Engine idling speed
Engine idling speed:

1,400 ~ 1,600 r/min
4. Adjust:
• Engine idle speed
*****************************************************
Adjustment steps:
● Turn the air screw 1 until it is lightly seated.
● Turn the air screw out by the specified num-
ber of turns.
Air screw:
1-1/2 turns out
● Turn the throttle stop screw 2 in or out until

the specified idling speed is obtained.
Turning in Idling speed is increased.
Turning out Idling speed is decreased.
*****************************************************
5. Adjust:
• Throttle cable free play
Refer to “THROTTLE CABLE ADJUST-
MENT” section.
YP303032
THROTTLE CABLE ADJUSTMENT
NOTE:
Prior to adjusting the throttle cable free play,
the engine idling speed should be adjusted.
1. Check:
• Throttle cable free play a
Free play (throttle cable):

3 ~ 5 mm at throttle grip flange
2. Adjust:
• Throttle cable free play
*****************************************************
Adjustment steps:
NOTE:
Never accelerate the throttle when stopping
the engine.
3-7
THROTTLE CABLE ADJUSTMENT/ INSP
SPARK PLUG INSPECTION ADJ
● Loosen the locknut 1 on the throttle cable.
● Turn the adjuster 2 in or out until specified
free play is obtained.
Turning in Free play is increased.
Turning out Free play is decreased.
● Tighten the locknut.

WARNING
After adjusting, turn the handlebar to the
right and to the left to ensure that this does
not cause the engine idling speed to
change.
*****************************************************
EB303040
SPARK PLUG INSPECTION
1. Remove:
• Spark plug cap
• Spark plug
CAUTION:
Before removing the spark plug, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug wells to prevent it
from falling into the cylinder.
2. Check:
• Spark plug type
Incorrect → Replace.
Standard spark plug:

C7HSA (NGK),
U22FS-U (DENSO)
3. Inspect:
• Electrode 1
Wear/damage → Replace.
• Insulator 2
Abnormal color → Replace.
Normal color is a medium-to-light tan color.
4. Clean:
• Spark plug
(with spark plug cleaner or wire brush)
5. Measure:
• Spark plug gap a
(with a wire gauge)
Out of specification → Adjust gap.
3-8
SPARK PLUG INSPECTION/ INSP
IGNITION TIMING CHECK ADJ
Spark plug gap:
0.6 ~ 0.7 mm
6. Install:
T.
R.
NOTE:
• Before installing a spark plug, clean the gas-
ket surface and plug surface.
• If a torque wrench is not available when you
are installing a spark plug, a good estimate
of the correct torque 2 is 1/4 to 1/2 turns
past finger tight 1. Have the spark plug
torque to the correct value as soon as possi-
ble with a torque wrench.
YP303052
IGNITION TIMING CHECK
NOTE:
Prior to checking the ignition timing, check all
electrical connections related to the ignition
system. Make sure all connections are tight
and free of corrosion and that all ground con-
nections are tight.
1. Remove:
2. Attach:
• Timing light 1
Engine tachometer 2 (to the spark plug lead)
Timing light:
90890-03141
Engine tachometer:
90890-03113
3. Check:
• Ignition timing
*****************************************************
Checking steps:
● Start the engine and let it warm up for sev-
eral minutes. Let the engine run at the speci-
fied speed.
Engine idling speed:

1,400 ~ 1,600 r/min
● Visually check the stationary pointer a to

verify it is within the required firing range b
indicated on the flywheel.
Incorrect firing range → Check the ignition
system.
*****************************************************
3-9
IGNITION TIMING CHECK/ INSP
COMPRESSION PRESSURE MEASUREMENT ADJ
NOTE:
Ignition timing is not adjustable.
3. Install:
YP303060
COMPRESSION PRESSURE
MEASUREMENT
NOTE:
Insufficient compression pressure will result in
performance loss.
1. Remove:
• Front cover (right)
2. Check:
• Valve clearance
Refer to “VALVE CLEARANCE ADJUST-
MENT” section.
eral minutes.
4. Turn off the engine.
5. Remove:
• Spark plug
CAUTION:
Before removing the spark plug, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug well to prevent it
from falling into the cylinder.
6. Attach:
• Compression gauge 1
Compression gauge:
90890-03081
7. Measure:
• Compression pressure
If it exceeds the maximum pressure allowed
→ Inspect the cylinder head, valve surfaces
and piston crown for carbon deposits.
If it is below the minimum pressure → Squirt
a few drops of oil into the affected cylinder
and measure again.
3 - 10 Follow the table below.
COMPRESSION PRESSURE MEASUREMENT/ INSP
ENGINE OIL LEVEL INSPECTION ADJ
Compression pressure
(With oil applied into cylinder)
Reading Diagnosis
Higher than Worn or damaged
without oil pistons
Possible defective
Same as ring(s), valves, cylinder
without oil head gasket or piston →
Repair.
Compression pressure (at sea

level):
Standard:
1,200 kPa
(12.0 Kg/cm2, 12.0 bar)
Minimum:
1,050 kPa
(10.5 Kg/cm2, 10.5 bar)
*****************************************************
Measurement steps:
● Crank the engine with the throttle wide-open
until the reading on the compression gauge
stabilizes.
WARNING
Before cranking the engine, ground all
spark plug leads to prevent sparking.
*****************************************************
8. Install:
T.
R.
9. Install:
• Front cover (right)
YP303070
ENGINE OIL LEVEL INSPECTION
1. Stand the motorcycle on a level surface.
NOTE:
Make sure the motorcycle is upright when
inspecting the oil level.
2. Start the engine and let it warm up for a few

minutes.
4. Remove:
• Oil filler plug 1
5. Inspect:
Oil level should be between maximum a
and minimum b marks.
Oil level is below the minimum mark
3 - 11 → Add oil up to the proper level.
ENGINE OIL LEVEL INSPECTION/ INSP
ENGINE OIL REPLACEMENT ADJ
RECOMMENDED ENGINE OIL
YAMALUBE 4 (20W40) or equiva-

lent
SAE20W40 type SE or higher
grade motor oil
SAE20W40 type SF/CC motor
oil
5. Start the engine and let it warm up for a few

minutes.
NOTE:
Wait a few minutes until the oil settles before
inspecting the oil level.
T*****
ENGINE OIL REPLACEMENT
eral minutes.
2. Turn off the engine and place an oil pan
under the engine.
3. Remove:
• Oil filler plug
• Drain bolt 1
• Gasket
Drain the crankcase of its oil.
4. Install:
• Gasket 1 New
• Drain bolt 2 20 Nm (2.0 m · kg)
T.
R.
NOTE:
Check the gasket (drain bolt). If damaged,
replace it with a new one.
5. Fill:
• Crankcase
Oil quantity:
0.8 L
6. Install:
• Oil filler plug
7. Check:
• Engine oil level
Refer to “ENGINE OIL LEVEL INSPEC-
TION” section.
3 - 12
EXHAUST SYSTEM INSPECTION/ INSP
AIR FILTER CLEANING ADJ
T******
EXHAUST SYSTEM INSPECTION
1. Inspect:
• Nut 1 (exhaust pipe)
Loose/Damage → Tighten/replace.
7 Nm (0.7 m · kg)
T.
R.
• Gasket (exhaust pipe)
Exhaust gas leaks → Tighten/replace.
2. Inspect:
• Nut 2 (muffler)
Loose/Damage → Tighten/replace.
T303123
AIR FILTER CLEANING
1. Remove:
• Protector
• Front cover (left)
• Air filter case cover 1
2. Remove:
• Air filter element 2
CAUTION:
Never operate the engine without the air fil-
ter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the filter element will also affect the
carburetor tuning, leading to poor engine
performance and possible overheating.
3 - 13
INSP
AIR FILTER CLEANING ADJ
3. Inspect:
• Air filter element
Damaged → Replace.
4. Clean:
• Air filter element 1
Use solvent to clean the element.
NOTE:
After cleaning, remove the remaining solvent
by squeezing the element.
CAUTION:
Do not twist the element when squeezing
the element.
5. Apply the recommended oil to the entire

surface of the filter and squeeze out the
excess oil. The element should be wet but
not dripping.
Recommended oil:
YAMALUBE 4 (20W40) or equiv-
alent
WARNING
Never use low flash point solvents such as
gasoline to clean the air filter element.
Such solvents may cause a fire or an explo-
sion.
6. Install:
• Air filter element
• Air filter case cover
• Front cover (left)
3 - 14
INSP
CLUTCH RELEASE SYSTEM ADJUSTMENT ADJ
T******
CLUTCH RELEASE SYSTEM ADJUSTMENT
1. Adjust:
• Clutch release system
*****************************************************
Adjustment steps:
● Loosen the locknut 1. (clutch release)
● Turn the adjuster 2 in, than the adjuster
turns out the specifications.
Adjusting screw:
1/8 turns out
• Tighten the locknut.

8 Nm (0.8 m · kg)
T.
R.
NOTE:
Hold the screw and tighten the locknut.
*****************************************************
3 - 15
REAR BRAKE ADJUSTMENT/ INSP
BRAKE FLUID LEVEL INSPECTION ADJ
CHASSIS
YP******
REAR BRAKE ADJUSTMENT
1. Check:
• Brake pedal free play a
Free play:
20 ~ 30 mm
2. Adjust:
• Brake pedal free play
*****************************************************
Adjustment steps:
● Turn the adjuster 1 in or out until the speci-
fied free play is obtained.
Turning in Free play is decreased.
Turning out Free play is increased.
CAUTION:
Make sure that the brake does not drag
after adjusting it.
*****************************************************
3. Adjust:
• Brake light switch
Refer to “BRAKE LIGHT SWITCH
ADJUSTMENT”.
EB304020
BRAKE FLUID LEVEL INSPECTION
NOTE:
When inspecting the brake fluid level, make
sure the motorcycle is upright.
2. Inspect:
• Brake fluid level
Brake fluid level is below the “LOWER”
level line a → Fill to proper level.
Recommended brake fluid:

DOT 4
NOTE:
For a correct reading of the brake fluid level,
make sure the top of the handlebar brake fluid
reservoir is horizontal.
3 - 16
BRAKE FLUID LEVEL INSPECTION/BRAKE PAD INSP
INSPECTION/BRAKE HOSE INSPECTION ADJ
CAUTION:
Brake fluid may corrode painted surfaces
or plastic parts. Always clean up any spilt
fluid immediately.
WARNING
• Use only the designated brake fluid.
Other fluids may deteriorate the rubber
seals, causing leakage and poor brake
performance.
• Refill with the same type of fluid. Mixing
fluids may result in a harmful chemical
reaction leading to poor brake perfor-
mance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the fluid and may cause vapor lock.
EB304030
BRAKE PAD INSPECTION
1. Operate the brake lever.
2. Inspect:
• Brake pad
Wear indicators 1 almost touch the brake
disc → Replace the brake pads as a set.
Refer to “BRAKE PAD REPLACEMENT”
section in CHAPTER 6.
EB304060
BRAKE HOSE INSPECTION
1. Inspect:
• Brake hose
Cracks/wear/damage → Replace.
2. Check:
• Brake hose clamp(s)
Loose → Tighten.
3. Hold the motorcycle upright and apply the
front brake.
4. Check:
• Brake hose
Activate the brake lever several times.
Brake fluid leakage → Replace the faulty
hose.
Refer to “FRONT BRAKE” section in CHAP-
TER 6.
3 - 17
INSP
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ADJ
EB304070
AIR BLEEDING (HYDRAULIC BRAKE
SYSTEM)
WARNING
Bleed the brake system whenever:
• the system is disassembled
• a brake hose is loosened or removed
• the brake fluid level is very low
• brake operation is faulty
If the brake system is not properly bled, a
loss of braking performance may occur.
1. Bleed:
• Brake system
*****************************************************
Air bleeding steps:
a. Fill the reservoir with the proper brake fluid.
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
caliper bleed screw 2.
d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake lever several times.
f. Pull the lever in. Hold the lever in position.
g. Loosen the bleed screw and allow the lever
to travel towards its limit.
h. Tighten the bleed screw when the lever limit
has been reached, then release the lever.
i. Repeat steps (e) to (h) until all the air bub-
bles have disappeared from the brake fluid.
NOTE:
When bleeding the brake system, make sure
that there is always enough brake fluid in the
brake fluid reservoir, before applying the brake
lever. Ignoring this precaution could allow air
to enter the brake system, lengthening the
bleeding procedure, considerably.
j. Tighten the bleed screw.
Bleed screw:
6 Nm (0.6 m • kg)
T.
R.
NOTE:
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 brake system have disap-
peared.
3 - 18
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/BRAKE SHOE INSP
INSPECTION/BRAKE LIGHT SWITCH ADJUSTMENT
ADJ
k. Fill the brake fluid reservoir to the proper
level.
Refer to “BRAKE FLUID LEVEL INSPEC-
TION”.
WARNING
After bleeding the brake system check the
brake operation.
*****************************************************
EB304040
BRAKE SHOE INSPECTION
1. Operate the brake lever or pedal.
2. Inspect:
• Brake shoes
Wear indicator 1 reaches the wear limit
line 2 → Replace the brake shoes as a set.
Refer to “REAR WHEEL AND REAR
BRAKE” section in CHAPTER 6.
EB304050
BRAKE LIGHT SWITCH ADJUSTMENT
NOTE:
• The brake light switch is operated by move-
ment of the brake pedal.
• Adjustment is correct when the brake light
comes on just before the braking effect actu-
ally starts.
1. Check:
• Brake light operation timing
Incorrect → Adjust.
2. Adjust:
• Brake light operating timing
*****************************************************
Adjustment steps:
● Hold the main body 1 of the switch with your
hand so that it does not rotate, and turn the
adjuster 2 in or out until the proper opera-
tion timing is obtained.
brake light comes on
Turning in
first.
brake light comes on
Turning out
slow.
*****************************************************
3 - 19
INSP
DRIVE CHAIN SLACK ADJUSTMENT ADJ
T304093
DRIVE CHAIN SLACK ADJUSTMENT
NOTE:
• Before checking and adjusting, rotate the
rear wheel several revolutions and check the
slack at several points to find the tightest
point.
• Check and if necessary adjust the drive
chain slack with the rear wheel in this “tight-
est” position.
CAUTION:
Too little chain slack will overload the
engine and other vital parts; keep the slack
within the specified limits.
WARNING
• Securely support the motorcycle so that
there is no danger of it falling over.
• Stand the motorcycle on its centerstand.
1. Check:
• Drive chain slack a
Drive chain slack:

10 ~ 20 mm
2. Adjust:
• Drive chain slack
*****************************************************
Adjustment steps:
● Loosen the each locknuts 1 and chain
adjuster nut 2.
● Loosen the axle nuts 3.
● Turn the chain adjuster nuts 2 clockwise or
counterclockwise until the specified drive
chain slack is obtained.
Drive chain slack is
Turning in
decreased.
Drive chain slack is
Turning out
increased.
3 - 20
DRIVE CHAIN SLACK ADJUSTMENT/ INSP
STEERING HEAD INSPECTION ADJ
NOTE:
• Turn each chain adjuster nuts exactly the
same amount to maintain correct axle align-
ment. (There are marks a on each chain
adjuster nuts. Use them when adjusting the
slack for proper alignment.)
• Before tightening the axle nut and locknuts to
specification, make sure that there is no
clearance at the adjuster nuts (or the swing-
arm end) on both sides by pushing the wheel
forward.
● Tighten the axle nut 1.

60 Nm (6.0 m · kg)
T.
R.
● Tighten the locknut 2.
7 Nm (0.7 m · kg)
T.
R.
*****************************************************
T304130
STEERING HEAD INSPECTION
WARNING
Securely support the motorcycle so that

NOTE:
Stand the motorcycle on its centerstand.
2. Elevate the front wheel by placing a suitable

stand under the engine.
3. Check:
• Handlebar assembly
Grasp the handlebar and gently rock the
steering.
Looseness → Adjust the handlebar.
• Steering assembly bearings
Grasp the bottom of the lower front fork
tubes and gently rock the fork assembly.
Looseness → Adjust the steering head.
4. Adjust:
• Steering head
5. Remove:
• Protector
3 - 21
INSP
STEERING HEAD INSPECTION ADJ
6. Adjust:
• Steering head
*****************************************************
Adjustment steps:
● Pull the rubber cover 1 off.
● Loosen the ring nut 2 (upper) completely.
● Loosen the ring nut (lower) 3 completely,
then tighten it.
NOTE:
• Fitting the ring nut (lower), should be below
the larger chamfering side.
• When tighten the ring nut, should be steady
the ball bearings and steering shaft moving
smoothly.
Exhaust and ring nut wrench:

90890-01268
● Check the steering head for looseness or

binding by turning it all the way in both direc-
tions.
● Hold the ring nut (lower), using the exhaust
and ring nut wrench, and tighten the ring nut
(upper) using the ring nut wrench.
T.
R.
75 Nm (7.5 m · kg)
NOTE:
Set the torque wrench at right angles to the
ring nut wrench.
Ring nut wrench:

90890-01403
● Pull the rubber cover in.

*****************************************************
7. Install:
• Protector
3 - 22
FRONT FORK INSPECTION/ INSP
SWINGARM INSPECTION ADJ
YP304140
FRONT FORK INSPECTION
WARNING
Securely support the motorcycle so that

2. Check:
• Inner tube
Scratches/damage → Replace.
• Oil seal
Excessive oil leakage → Replace.
Hold the motorcycle upright and apply the
front brake.
3. Check:
• Operation
Push down hard on the handlebars several
times.
Unsmooth operation → Repair.
Refer to “FRONT FORK” section in CHAP-
TER 6.
YP*****
SWINGARM INSPECTION
WARNING
Securely support the motorcycle so there
is no danger of it falling over.
1. Place the motorcycle on the level place.

2. Check:
• Operation
Grasp the end of the swingarm and gently
rock the swingarm assembly back and forth.
Unsmooth operation → Repair.
Refer to “REAR SHOCK ABSORBER AND
SWINGARM” section in CAPTER 6.
3 - 23
REAR SHOCK ABSORBER INSPECTION/ INSP
TIRE INSPECTION ADJ
YP******
REAR SHOCK ABSORBER INSPECTION
1. Remove:
• Rear cover (left and right)
2. Check:
• Rear shock absorber mount
Looseness → Tighten.
Nut (upper) 1 32 Nm (3.2 m · kg)
T.
R.
Bolt (lower) 2 32 Nm (3.2 m · kg)
T.
R.
Refer to “REAR SHOCK ABSORBER AND
SWINGARM” section in CAPTER 6.
EB304171
TIRE INSPECTION
1. Measure:
• Tire inflation pressure
WARNING
• Tire inflation pressure should only be
checked and adjusted when the tire tem-
perature equals the ambient air tempera-
ture. Tire inflation pressure and
suspension must be adjusted according
to the total weight of the cargo, rider, pas-
senger and accessories (fairing, saddle-
bags, etc.if approved for this model), and
according to whether the motorcycle will
be operated at high speed or not.
NEVER OVERLOAD THE MOTORCYCLE.
• Operation of an overloaded motorcycle
could cause tire damage, accident or
injury.
Basic weight
(with oil and full fuel 99 kg
tank)
Maximum load* 110 kg
Cold tire pressure Front Rear
200 kPa 225 kPa
Up to 90 kg load* (2.00 kg/cm2, (2.25 kg/cm2,
2.00 bar) 2.25 bar)
90 kg ~ 200 kPa 225 kPa
(2.0 kg/cm2, (2.25 kg/cm2,
maximum. load* 2.0 bar) 2.25 bar)
* Load is the total weight of the cargo, rider, pas-

senger and accessories.
3 - 24
INSP
TIRE INSPECTION ADJ
2. Inspect:
• Tire surfaces
Minimum tire tread depth

(front and rear):
1.0 mm
1 Tread depth
2 Side wall
3 Wear indicator
WARNING
• It is dangerous to ride with a worn–out
tire. When the tire tread begins to show
signs of wear, replace the tire immedi-
ately.
• Patching a punctured tube is not recom-
mended. If it is absolutely necessary to
do so, use great care and replace the tube
as soon as possible with a good quality
replacement tube.
• Do not use tubeless tires on a wheel
designed for tube type tires only. Tire fail-
ure and personal injury may result from
sudden deflation.
Tube type
Tube type tire only
wheel
Tubeless type
Tube type or tubeless tire
wheel out
• Be sure to install the correct tube when
using tube type tires.
• After extensive tests, the tires listed
below have been approved by Yamaha
Motor Co., Ltd. for this model. No guaran-
tee concerning handling characteristics
can be given if a tire combination other
than one approved by Yamaha is used on
this motorcycle. The front and rear tires
should always be by the same manufac-
turer and of the same design.
WARNING
After mounting a tire, ride conservatively
for a while to give the tire time to seat itself
properly in the rim. Failure to do so could
lead to an accident with possible injury to
the rider or damage to the motorcycle.
3 - 25
INSP
TIRE INSPECTION/WHEEL INSPECTION ADJ
2. After a tire repair or replacement, be sure to
tighten the valve stem locknut 1 to specifi-
cation.
EB304180
WHEEL INSPECTION
1. Inspect:
• Wheels
Damage/bends → Replace.
NOTE:
Always balance the wheel when a tire or wheel
has been changed or replaced.
WARNING
Never attempt to make any repairs to the
wheel.
3 - 26
INSP
BATTERY INSPECTION ADJ
EB305001
ELECTRICAL
BATTERY INSPECTION
1. Remove:
• Rear cover (right)
2. Disconnect:
• Breather hose
• Battery leads
(from the battery terminals)
CAUTION:
First, disconnect the negative battery lead,
and then the positive battery lead.
3. Remove:
• Battery
4. Inspect:
• Electrolyte level
Electrolyte level should be between the
upper 1 and lower 2 level marks. Electro-
lyte level is too low → Add electrolyte to
proper level.
CAUTION:
Refill with distilled water only. Tap water
contains minerals which are harmful to a
battery.
5. Inspect:
• Battery terminals
Dirt → Clean with a wire brush.
Poor connection → Correct.
NOTE:
After cleaning the terminals, apply a light coat
of grease to the terminals.
6. Inspect:
• Breather hose
Obstruction → Remove.
Damage → Replace.
CAUTION:
When inspecting the battery, make sure
that the breather hose is routed correctly. If
the breather hose is positioned in such a
way as to allow battery electrolyte or gas to
come into contact with the frame, this
could damage the motorcycle and ruin its
finish.
3 - 27
INSP
7. Connect:
• Breather hose 1
Make sure that the hose is properly
attached and routed.
8. Check:
• Specific gravity
Less than 1.280 → Recharge the battery.
Charging Current:
0.5 amps/10 hrs
Specific Gravity:
1.280 at 20 °C
*****************************************************
Replace the battery if:
● Battery voltage will not rise to a specific
value or bubbles fail to rise during charging.
● Sulphation of one or more cells occurs, (as
indicated by the plates turning white, or
material accumulating in the bottom of the
cell).
● Specific gravity readings after a long, slow
charge indicate that one cell is charged lower
than the rest.
● Warpage or buckling of plates or insulators is
evident.
*****************************************************
CAUTION:
Always charge a new battery before using
it to ensure maximum performance.
WARNING
Battery electrolyte is dangerous. It con-
tains sulfuric acid which is poisonous and
highly caustic.
Always follow these preventive measures:
• Avoid bodily contact with electrolyte as it
can cause severe burns and permanent
eye injury.
• Wear protective eye gear when handling
or working near batteries.
• Antidote (EXTERNAL):
• SKIN – Flush with water.
• EYES – Flush with water for 15 minutes
and get immediate medical attention.
• Antidote (INTERNAL):
• Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
3 - 28
INSP
• Batteries generate explosive hydrogen
gas.
• Always follow these preventive mea-
sures:
• Charge batteries in a well – ventilated
area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes, etc.)
• DO NOT SMOKE when charging or han-
dling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
9. Install:
• Battery
10.Connect:
• Battery leads
CAUTION:
Connect the positive lead first and then
connect the negative lead.
11.Connect:
• Breather hose
Be sure the hose is properly attached and
routed.
Refer to “CABLE ROUTING” section in
CHAPTER 2.
12.Install:
3 - 29
INSP
FUSE INSPECTION ADJ
T305010
FUSE INSPECTION
CAUTION:
Always turn off the main switch when
checking or replacing the fuse. Otherwise,
a short circuit may occur.
1. Remove:
• Fuse holder 1
2. Inspect:
• Fuse
*****************************************************
Inspection steps:
● Connect the pocket tester to the fuse and
check it for continuity.
NOTE:
Set the tester selector to “Ω × 1” position.
Pocket tester:
90890-03112
● Ifthe tester is indicated at “∞.” Replace the

fuse.
*****************************************************
3. Replace:
• Blown fuse
*****************************************************
Replacement steps:
● Turn off the main switch.
● Install a new fuse with the proper current rat-
ing.
● Turn on switches to verify operation of
related electrical devices.
● If the fuse blows again immediately, check
the electrical circuit.
WARNING
Never use a fuse with a rating other than
that specified. Never use other materials in
place of a fuse. An improper fuse may
cause extensive damage to the electrical
system, malfunction of lighting and ignition
systems and could possibly cause a fire.
3 - 30
*****************************************************
FUSE INSPECTION/ INSP
HEADLIGHT BEAM ADJUSTMENT ADJ
4. Install:
• Fuse holder
EB305022
HEADLIGHT BEAM ADJUSTMENT
1. Adjust:
• Headlight beam (vertical)
Loosen the bolt 1 and adjust the headlight
unit.
3 - 31
ENGINE REMOVAL ENG
EB400000
ENGINE OVERHAUL
ENGINE REMOVAL
BATTERY, FOOTREST, MUFFLER AND ENGINE GUARD

Battery, footrest, muffler and engine Remove the parts in the order listed.
guard removal
Front cover (left and right) Refer to “COVER AND PANEL” section in
Rear cover (left and right) CHAPTER 3.
1 Battery 1
2 Footrest 1
3 Muffler 1
4 Muffler gasket 1
5 Engine guard 1
6 Spark plug cap 1
7 Starter motor 1
8 Starting motor lead 1
procedure.
4-1
ENGINE REMOVAL ENG
DRIVE CHAIN, ENGINE MOUNT BOLT AND ENGINE

Drive chain, engine mount bolt and Remove the parts in the order listed.
engine removal
Carburetor assembly Refer to “CARBURETOR” section in
CHAPTER 5.
1 Shift pedal 1
2 Drive sprocket cover 1
3 Clip/chain joint 1/1 Refer to “ENGINE REMOUNTING” sec-
4 Drive chain 1 tion.
5 Stator coil assembly coupler 2
6 Gear position switch coupler 1
7 Vacuum hose 1
8 Self locknut/plane washer 5/5
9 Bolt (engine mount) 5 Refer to “ENGINE REMOUNTING” sec-
10 Engine bracket 2 tion.
11 Engine 1
procedure.
4-2
ENGINE REMOVAL ENG
YP******
ENGINE REMOUNTING
When remounting the engine, reverse the
removal procedure in job instruction chart.
Note the following points:
1. Install:
• Engine
Route the hose (crankcase breather)
between the engine and frame.
NOTE:
Make sure that the breather hose is not vend
and pinch.
2. Tighten:
• Bolt and nut (engine mount)
34 Nm (3.4 m · kg)
T.
R.
3. Install:
• Drive chain 1
• Chain joint 2
• Plate 3
Route the hose (crankcase breather)
between the engine and frame.
4. Install:
• Clip 1
CAUTION:
Be sure to install the chain joint clip to the
direction as shown.
4-3
CYLINDER HEAD ENG
CYLINDER HEAD

Cylinder head removal Remove the parts in the order listed.
Front cover (left and right) Refer to the “COVER AND PANELS” sec-
tion in CHAPTER 3.
Carburetor Refer to “CARBURETOR” section in
CHAPTER 5.
1 Plug cap/spark plug 1/1
2 Center plug/O-ring 1/1
3 Timing check plug/O-ring 1/1
4 Cam sprocket cover/O-ring 1/1
5 Valve cover (intake side)/O-ring 1/1
Refer to “CYLINDER HEAD REMOVAL/
6 Valve cover (exhaust side)/O-ring 1/1
INSTALLATION” section.
7 Timing chain tensioner assembly 1
8 Timing chain tensioner gasket 1
9 Bolt/spring washer 1/1
4-4
CYLINDER HEAD ENG

10 Cam sprocket 1
11 Timing chain 1 Refer to “CYLINDER HEAD REMOVAL/
12 Cylinder head 1 INSTALLATION” section.
13 Cylinder head gasket 1
14 Dowel pin 2
procedure.
4-5
CYLINDER HEAD ENG
T401030
CYLINDER HEAD REMOVAL
1. Align:
• Slit a on the magneto
(with stationary pointer b on the crank case
cover)
NOTE:
NOTE:
Turn the crank shaft counterclockwise with a

wrench and align the “I” mark c with the cylin-
der head match mark d when the piston is at
TDC on the compression stroke.
2. Loosen:
• Bolt 1
3. Remove:
• Timing chain tensioner assembly
• Timing chain tensioner gasket
4. Remove:
• Cam sprocket 2
• Timing chain 3
NOTE:
NOTE:
• Fasten a safety wire to the timing chain to

prevent it from falling into the crankcase.
• Remove the bolt 1 while holding the mag-
neto mounting bolt with a wrench.
5. Remove:
• Cylinder head
NOTE:
NOTE:
• Loosen the nuts in their proper loosening

sequence.
• Start by loosening each nut 1/2 turn until all
are loose.
4-6
CYLINDER HEAD ENG
YP402000
CYLINDER HEAD INSPECTION
1. Eliminate:
• Carbon deposits
(from combustion chambers)
Use a rounded scraper.
NOTE:
NOTE:
Do not use a sharp instrument to avoid damag-

ing or scratching:
• Spark plug threads
• Valve seats
2. Inspect:
• Cylinder head
Scratches/damage → Replace.
3.Measure:
• Cylinder head warpage
Out of specification → Resurface.
Cylinder head warpage:

Less than 0.03 mm
*****************************************************
Warpage measurement and resurfacement
steps:
● Place a straightedge and a feeler gauge
across the cylinder head.
● Measure the warpage.
● If the warpage is out of specification, resur-
face the cylinder head.
● Place a 400 ~ 600 grit wet abrasive paper on
the surface plate, and resurface the head
using a figure-eight sanding pattern.
NOTE:
NOTE:
Rotate the cylinder head several times for an

even resurfacement.
*****************************************************
T404190
CYLINDER HEAD INSTALLATION
1. Install:
• Gasket (cylinder head) New
• Dowel pins
• Cylinder head
NOTE:
NOTE:
• Apply engine oil onto the nut threads.

• Tighten the nuts in a crisscross pattern.
4-7
CYLINDER HEAD ENG
2. Tighten:
• Nuts (cylinder head)
22 Nm (2.2 m · kg)
T.
R.
• Bolts (cylinder) 10 Nm (1.0 m · kg)
T.
R.
3. Install:
• Cam sprocket 1
• Timing chain 2
*****************************************************
Installing steps:
● Turn the crank shaft counterclockwise until
the slit a matches the stationary pointer b.
● Align the “I” mark c on the cam sprocket
with the stationary pointer d on the cylinder
head.
● Fit the timing chain onto cam sprocket and
install the cam sprocket on the camshaft.
NOTE:
NOTE:
When installing the cam sprocket, keep the

timing chain as tense as possible on the
exhaust side.
CAUTION:
Do not turn the crankshaft during installa-
tion of the camshaft. Damage or improper
valve timing will result.
● Remove the safety wire from the timing

chain.
*****************************************************
4. Install:
• Bolt 1 20 Nm (2.0 m · kg)
T.
R.
NOTE:
NOTE:
Install the bolt 1 while holding the magneto

mounting nut with a wrench.
4-8
CYLINDER HEAD ENG
5. Install:
• Timing chain tensioner
*****************************************************
Installation steps:
● Remove the tensioner cap bolt 1 and spring 2.
● Release the timing chain tensioner one-way
cam 3 and push the tensioner rod 4 all the
way in.
● Install the tensioner with a new gasket 5
onto the cylinder.
● Install the springs 2 and cap bolt 1.
● Tighten the bolt (with gasket) to the specified
torque.
Bolt (chain tensioner)
10 Nm (1.0 m · kg)
T.
R.
Cap bolt (timing chain tensioner) 1
8 Nm (0.8 m · kg)
T.
R.
*****************************************************
6. Check:
• Valve clearance
Refer to the “VALVE CLEARANCE
ADJUSTMENT” section in CHAPTER 3.
4-9
CAMSHAFT AND ROCKER ARMS ENG
CAMSHAFT AND ROCKER ARMS

Camshaft and rocker arms removal Remove the parts in the order listed.
Cylinder head Refer to “CYLINDER HEAD” section.
1 Plate 1
2 Rocker arm shaft (intake) 1 Refer to “ROCKER ARM AND ROCKER
3 Rocker arm shaft (exhaust) 1 ARM SHAFT REMOVAL/CAMSHAFT
4 Rocker arm 2 AND ROCKER ARM INSTALLATION”
section.
5 Camshaft 1 Refer to “CAMSHAFT AND ROCKER
6 Locknut 2 ARM INSTALLATION” section.
7 Adjuster 2
procedure.
4 - 10
YP******
ROCKER ARM AND ROCKER ARM SHAFT
REMOVAL
1. Remove:
• Rocker arm shaft (intake)
• Rocker arm shaft (exhaust)
NOTE:
NOTE:
Attach a rocker arm shaft puller bolt 1 and

weight 2 to the rocker arm shaft and slide out
the shaft.
Slide hammer bolt:

90890-01085
Weight:
90890-01084
YP402052
CAMSHAFT INSPECTION
1. Inspect:
• Cam lobes
Pitting/Scratches/Blue discoloration →
Replace.
2. Measure:
• Cam lobes length a and b
Out of specification → Replace.
Cam lobes length:

Intake:
a 25.428 ~ 25.528 mm
<Limit: 25.398 mm>
b 21.034 ~ 21.134 mm
<Limit: 21.004 mm>
Exhaust:
a 25.286 ~ 25.386 mm
<Limit: 25.260 mm>
b 21.047 ~ 21.147 mm
<Limit: 21.031 mm>
3. Inspect:
• Camshaft oil passage
Stuffed → Blow out oil passage with com-
pressed the air.
4 - 11
YP402060
ROCKER ARMS AND ROCKER ARM
SHAFTS INSPECTION
1. Inspect:
• Cam lobe contact surface 1
• Adjuster surface 2
Wear/pitting/scratches/blue discoloration →
Replace.
*****************************************************
Inspection steps:
● Inspect the two contact areas on the rocker
arms for signs of unusual wear.
● Rocker arm shaft hole.
● Cam-lobe contact surface.
Excessive wear → Replace.
● Inspect the surface condition of the rocker
arm shafts.
Pitting/scratches/blue discoloration →
Replace or check lubrication.
● Measure the inside diameter of the rocker
arm holes.
Inside diameter (rocker arm):

10.000 ~ 10.015 mm
<Limit: 10.03 mm>
● Measure the outside diameter of the rocker

arm shafts.
Outside diameter
(rocker arm shaft):
9.981~9.991 mm
<Limit: 9.95 mm>
*****************************************************
YP******
CAMSHAFT AND ROCKER ARM
INSTALLATION
1. Lubricate:
• Camshaft 1
Camshaft:
Molybdenum disulfide grease
Camshaft bearing:
Engine oil
4 - 12
2. Lubricate:
• Rocker arm shaft
• Rocker arm inner surface
Rocker arm shaft:

Engine oil
Rocker arm inner surface:
Molybdenum disulfide grease
3. Install:
• Rocker arm 1
• Rocker arm shaft 2
NOTE:
NOTE:
Install the rocker arm shaft (exhaust) com-

pletely pushed in.
4. Install:
• Plate 1
• Bolt 2 10 Nm (1.0 m · kg)
T.
R.
4 - 13
VALVES AND VALVE SPRINGS ENG
VALVES AND VALVE SPRINGS

Valves and valve springs removal Remove the parts in the order listed.
Rocker arm, camshaft Refer to “CAMSHAFT AND ROCKER
ARMS” section.
1 Valve cotters 4 Refer to “VALVES AND VALVE
SPRINGS REMOVAL/INSTALLATION”
section.
2 Spring retainer 2
3 Valve spring 2
4 Valve (intake) 1 Refer to “VALVES AND VALVE
5 Valve (exhaust) 1 SPRINGS INSTALLATION” section.
6 Valve stem seal 2
7 Spring seat 2
procedure.
4 - 14
YP401150
VALVES AND VALVE SPRINGS REMOVAL
1. Remove:
• Valve cotters 1
NOTE:
NOTE:
Attach a valve spring compressor 2 between

the valve spring retainer and cylinder head to
remove the valve cotters.
CAUTION:
Do not compress so much as to avoid dam-
age to the valve spring.
Valve spring compressor:

90890-01253
YP******
INSPECTION
1. Measure:
• Valve stem diameter
Valve stem diameter:
Intake:
4.475 ~ 4.490 mm
<Limit: 4.45 mm>
Exhaust:
4.460 ~ 4.475 mm
<Limit: 4.435 mm>
YP402010
2. Measure:
• Runout (valve stem)
Runout limit:
0.01 mm
YP402030
3. Measure:
• Free length (valve spring)
Valve spring free length:
32.09 mm
<Limit: 30.6 mm>
4 - 15
YP402030
4. Measure:
• Spring tilt
Spring tilt limit:

2.5°/1.4 mm
5. Inspect:
• Spring contact face
Wear/pitting/scratches → Replace.
6. Measure:
• Valve guide inside diameter
Valve guide inside diameter:

Intake:
4.500 ~ 4.512 mm
<Limit: 4.542 mm>
Exhaust:
4.500 ~ 4.512 mm
<Limit: 4.542 mm>
YP402010
7. Measure:
Stem-to-guide clearance =
Valve guide inside diameter –
Valve stem diameter
Out of specification → Replace the valve

guide.
Stem-to-guide clearance limit:

Intake:
0.08 mm
Exhaust:
0.1 mm
EB402020
VALVE SEATS INSPECTION
1. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
2. Inspect:
• Valve seats
Pitting/wear → Reface the valve seat.
4 - 16
3. Measure:
• Valve seat width a
Out of specification → Reface the valve
seat.
Valve seat width:

Intake:
0.9 ~ 1.1 mm
<Limit: 1.6 mm>
Exhaust:
0.9 ~ 1.1 mm
<Limit: 1.6 mm>
*****************************************************
Measurement steps:
● Apply Mechanic’s blueing dye (Dykem) 1 to
the valve face.
● Install the valve into the cylinder head.
● Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
● Measure the valve seat width. Where the
valve seat and valve face made contact,
blueing will have been removed.
● If the valve seat is too wide, too narrow, or
the seat is not centered, the valve seat must
be replaced.
*****************************************************
EB402020
4. Lap:
• Valve face
• Valve seat
NOTE:
NOTE:
After replacing the valve seat, valve and valve

guide, the valve seat and valve face should be
lapped.
*****************************************************
Lapping steps:
● Apply a coarse lapping compound a to the
valve face.
CAUTION:
Do not let compound enter the gap
between the valve stem and the guide.
● Apply molybdenum disulfide oil to the valve

stem.
4 - 17
● Turn the valve until the valve face and valve
seat are evenly polished, then clean off all
compound.
NOTE:
NOTE:
For best lapping results, lightly tap the valve

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

face and repeat the above steps.
NOTE:
NOTE:
Make sure to clean off all compound from the

valve face and valve seat after every lapping
operation.
● Apply Mechanic’s blueing dye (Dykem) b to

the valve face.
● Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
● Measure the valve seat width c again.
*****************************************************
EB404032
INSTALLATION
1. Deburr:
• Valve stem end
Use an oil stone to smooth the stem end.
2. Apply:
• Molybdenum disulfide oil
(onto the valve stem 3 and oil seal 2)
Molybdenum disulfide oil
3. Install:
• Valve spring seat 1
• Valve stem seal 2 New
• Valve 3
(into the cylinder head)
• Valve spring 4
• Spring retainer 5
NOTE:
NOTE:
Install the valve spring with the larger pitch a

facing upwards.
b Smaller pitch
4 - 18
4. Install:
• Valve cotters 1
NOTE:
NOTE:
Install the valve cotters while compressing the

valve spring with a valve spring compressor
2.
Valve spring compressor:

90890-01253
5. Secure the valve cotters onto the valve

stem by tapping lightly with a piece of wood.
CAUTION:
Do not hit so much as to damage the valve.
4 - 19
CYLINDER AND PISTON ENG
CYLINDER AND PISTON

Cylinder and piston removal Remove the parts in the order listed.
Muffler Refer to “ENGINE REMOVAL” section
1 Timing chain guide (exhaust side) 1
2 Cylinder 1
Refer to “PISTON RINGS, PISTON AND
3 Dowel pin 2
CYLINDER INSTALLATION” section.
4 Cylinder gasket 1
5 Piston pin circlip 2
6 Piston pin 1 Refer to “PISTON AND PISTON RINGS
7 Piston 1 REMOVAL” section.
8 Piston ring (top) 1 Refer to “PISTON RINGS, PISTON AND
9 Piston ring (2nd) 1 CYLINDER INSTALLATION” section.
10 Side rail/spacer 2/1
procedure.
4 - 20
YP******
PISTON AND PISTON RINGS REMOVAL
1. Remove:
• Piston pin circlip 1
• Piston pin 2
• Piston 3
NOTE:
NOTE:
Before removing the piston pin circlip, cover

the crankcase opening with a clean towel or
rag to prevent the circlip from falling into the
crankcase cavity.
2. Remove:
• Top ring
• 2nd ring
• Oil ring
NOTE:
NOTE:
When removing the piston ring, open the end

gap of the ring by fingers, and push up the
other side of the ring.
YP402100
CYLINDER INSPECTION
1. Measure:
• Cylinder bore
Out of specification → Rebore or replace.
NOTE:
NOTE:
• Measure the cylinder bore with a cylinder

bore gauge.
• Measure the cylinder bore in parallel to and
at right angles to the crankshaft. Then, find
the average of the measurements.
Cylinder bore:
49.000 ~ 49.018 mm
<Limit: 49.1 mm>
<Difference limit between A, B
and C: 0.03 mm>
2. Measure:
• Warpage
Cylinder warpage limit:

0.03 mm
4 - 21
YP******
PISTON AND PISTON PIN INSPECTION
1. Measure:
• Piston skirt diameter
a 5.5 mm from the piston bottom edge
Piston skirt diameter:

48.985 ~ 49.001 mm
Oversize (1): 49.25 mm
2. Calculate:
• Piston-to-cylinder clearance
Piston-to-cylinder clearance =
Cylinder bore – Piston skirt diameter
Refer to “CYLINDER” section for cylinder

bore measurement.
Out of specification → Replace the piston
and piston rings as a set.
Piston-to-cylinder clearance:
0.015 ~ 0.020 mm
3. Measure:
• Piston pin bore diameter
Piston pin bore diameter:

13.002 ~ 13.013 mm
<Limit: 13.043 mm>
4. Measure:
• Piston pin outside diameter
Piston pin outside diameter:

12.996 ~ 13.000 mm
<Limit: 12.976 mm>
5. Inspect:
• Piston pin
Blue discoloration/groove → Clean or
replace.
4 - 22
YP402111
PISTON RINGS INSPECTION
1. Measure:
• Side clearance
Out of specification → Replace the piston
and the piston rings as a set.
NOTE:
NOTE:
Eliminate the carbon deposits from the piston

ring grooves and rings before measuring the
side clearance.
Side clearance (piston ring):

Top ring:
0.03 ~ 0.07 mm
<Limit: 0.12 mm>
2nd ring:
0.02 ~ 0.06 mm
<Limit: 0.12 mm>
2. Position:
• Piston ring
(into the cylinder)
NOTE:
NOTE:
Push the ring with the piston crown so that the

ring will be at a right angle to the cylinder bore.
3. Measure:
• End gap
NOTE:
NOTE:
You cannot measure the end gap on the

expander spacer of the oil ring. If the oil ring
rails show excessive gap, replace all three
rings.
a 5.0 mm
End gap:
Top ring:
0.15 ~ 0.30 mm
<Limit: 0.40 mm>
2nd ring:
0.15 ~ 0.30 mm
<Limit: 0.40 mm>
Oil ring:
0.3 ~ 0.9 mm
4 - 23
EB404184
PISTON RINGS, PISTON AND CYLINDER
INSTALLATION
1. Install:
• Top ring 1
• 2nd ring 2
• Side rails (oil ring) 3
• Expander spacer (oil ring) 4
NOTE:
NOTE:
• Make sure to install the piston rings so that

the manufacturer’s marks or numbers are
located on the upper side of the rings.
• Lubricate the pistons and piston rings liber-
ally with engine oil.
2. Install:
• Piston 1
• Piston pin 2
• Piston pin clip 3 New
NOTE:
NOTE:
• Apply engine oil onto the piston pins.

• The “→” mark a on the piston must face the
exhaust side of the cylinder.
• Before installing the piston pin clip, cover the
crankcase opening with a clean rag to pre-
vent the piston pin clip from falling into the
crankcase.
• Make sure to install each piston in its respec-
tive cylinder.
3. Install:
• Gasket (cylinder) New
• Dowel pins
4. Position:
• Piston rings
NOTE:
NOTE:
Offset the piston ring end gaps as shown.
a Top ring end

b Oil ring end (lower)
c Oil ring end (upper)
d 2nd ring end
4 - 24
5. Lubricate:
• Piston outer surface
• Piston ring
• Cylinder inner surface
Engine oil
6. Install:
• Cylinder 1
NOTE:
NOTE:
• Install the cylinder with one hand while com-

pressing the piston rings with the other hand.
• Pass the timing chain and timing chain guide
(exhaust side) through the timing chain cav-
ity.
4 - 25
CLUTCH ENG
CLUTCH
CRANKCASE COVER (LEFT AND RIGHT)

Crankcase cover (left and right) Remove the parts in the order listed.
removal
CHAPTER 3.
Drain the engine oil Refer to “ENGINE OIL REPLACEMENT”
1 Shift pedal 1
2 Drive sprocket cover 1
3 Crankcase cover (left) 1
4 Crankcase cover gasket (left) 1
5 Dowel pin 2
Refer to “CLUTCH REMOVAL/INSTAL-
6 Adjuster screw assembly 1
LATION” section.
7 Kick crank assembly 1
8 Crankcase cover (right) 1
9 Crankcase cover gasket (right) 1
10 Dowel pin 2
procedure.
4 - 26
CLUTCH ENG
CLUTCH

Clutch removal Remove the parts in the order listed.
1 Bolts/clutch springs 4/4
Refer to “CLUTCH REMOVAL/INSTAL-
2 Pressure plate 1
LATION” section.
3 Thrust bearing 1
4 Push rod #1 1
5 Friction plates 5 Refer to “CLUTCH INSTALLATION” sec-
6 Clutch plates 2 3 tion.
7 Clutch plate 1/spring 1/3
8 Push rod #2 1
9 Nut (clutch boss) 1 Refer to “CLUTCH REMOVAL/INSTAL-
10 Lock washer 1 LATION” section.
11 Clutch boss 1
12 Plate washer 1
4 - 27
CLUTCH ENG

13 Primary driven gear 1
14 Spacer 2 1
15 Spacer 1 1
16 Nut (primary drive) 1 Refer to “CLUTCH REMOVAL/INSTAL-
LATION” section.
17 Plate washer 1
18 Collar 1
19 Clutch housing comp (primary drive) 1
20 Clutch housing boss (primary drive) 1
21 Clutch carrier (primary drive) 1 Refer to “CLUTCH INSTALLATION” sec-
22 Cage 1 tion.
23 Dowel pin 3
24 Spring 2
25 Plate washer 1
procedure.
4 - 28
CLUTCH ENG
T401061
CLUTCH REMOVAL
• Clutch plates
NOTE:
NOTE:
Make sure that the clutch release adjusting

screw has been loosened before removing the
crankcase (left).
2. Remove:
• Bolts (pressure plate) 1
• Clutch springs
• Pressure plate 2
• Friction plates
• Clutch plates
NOTE:
NOTE:
Loosen the pressure plate bolts in a crisscross

pattern.
2. Remove:
• Nut (clutch boss) 1
Straighten the lock washer tab 2.
NOTE:
NOTE:
Loosen the clutch boss nut 1 while holding

the clutch boss with a clutch holding tool 3.
Universal clutch holder:

90890-04086
3. Remove:
• Nut (primary drive gear) 1
NOTE:
NOTE:
Loosen the nut (primary drive gear) while hold-

ing the magneto with the sheave holder 2.
Sheave holder:
90890-01701
4 - 29
CLUTCH ENG
T402181
CLUTCH INSPECTION
1. Inspect:
• Friction plates
Damage/wear → Replace the friction plates
as a set.
2. Measure:
• Friction plate thickness
Out of specification → Replace the friction
plates as a set.
Measure at four places.
Thickness (friction plate):

2.7 ~ 2.9 mm
<Limit: 2.6 mm>
3. Inspect:
• Clutch plates
Damage → Replace the clutch plates as a
set.
4. Measure:
• Clutch plate warpage
Out of specification → Replace the clutch
plates as a set.
Use a surface plate and a feeler gauge 1.
Warp limit (clutch plate):

Less than 0.05 mm
5. Inspect:
• Clutch springs
Damage → Replace the clutch springs as a
set.
6. Measure:
• Free length (clutch spring) a
Out of specification → Replace the clutch
springs as a set.
Free length (clutch spring):

28.7 mm
<Limit: 26.7 mm>
4 - 30
CLUTCH ENG
7. Inspect:
• Push rod #2
Wear/crack/damage → Replace.
8. Measure:
• Push rod #2
Bending limit (push rod #2):

0.5 mm
9. Inspect:
• Clutch housing inside diameter
10.Measure:
• Clutch housing inside diameter
Housing inside diameter:

105 mm
<Limit: 106 mm>
11.Inspect:
• Clutch shoe groove depth
Scratches → Glaze using coarse sandpa-
per.
Wear/damage → Replace
12.Measure:
• Clutch shoe groove depth a
Clutch shoe slit depth:

1.0 mm
<Limit: 0.1 mm>
13.Inspect:
• Cage 1
Wear/crack/damage → Replace.
• Dowel pins 2
Wear/bend → Replace.
• Compression springs 3
Wear → Replace.
14.Measure:
• Push rod #2
4 - 31
CLUTCH ENG
T******
CLUTCH INSTALLATION
1. Install:
• Washer
• Cage 1
• Compression springs 2
• Dowel pins 3
• Clutch housing boss 4
2. Install:
• Plate washer 1
• Nut (primary drive gear) 2
50 Nm (5.0 m · kg)
T.
R.
NOTE:
NOTE:
Tighten the nut (primary drive gear) while hold-

ing the rotor with the sheave holder 3.
Sheave holder:
90890-01701
3. Install:
• Lock washer 1 New
• Nut (clutch boss) 2 60 Nm (6.0 m · kg)
T.
R.
NOTE:
NOTE:
Install the clutch boss nut 2 while holding the

clutch boss with a clutch holding tool 3.
Universal clutch holder:

90890-04086
4. Bend:
• Lock washer tab 1
(along a flat side of the end)
5. Install:
• Friction plate 1
• Clutch plate 1 2
• Spring 3
• Clutch plate 2 4
• Push rod #2 5
• Push rod #1 6
• Thrust bearing 7
NOTE:
NOTE:
Install the clutch plates and friction plates alter-

nately on the clutch boss, starting with a fric-
tion plate and ending with a friction plate.
4 - 32
CLUTCH ENG
6. Install:
• Pressure plate 1
• Clutch springs 2
• Bolts (clutch springs) 3
6 Nm (0.6 m · kg)
T.
R.
NOTE:
NOTE:
Tighten the bolts in a crisscross pattern.
7. Install:
• Dowel pins 1
• Gasket (crankcase cover left) 2 New
• Crankcase cover (right)
10 Nm (1.0 m · kg)
T.
R.
NOTE:
NOTE:
Take care not to damage the crank and main

axle oil seas.
8. Install:
• Kick crank 1
9. Install:
• Dowel pins
• Gasket (crankcase cover left) New
• Crankcase cover (left)
(align the top of adjusting screw a with the
groove of the shift cam b.)
10 Nm (1.0 m · kg)
T.
R.
10.Adjust:
• Clutch release system
Refer to the “CLUTCH RELEASE SYSTEM
ADJUSTMENT” section in CHAPTER 3.
4 - 33
CLUTCH ENG
11.Tighten:
• Locknut 1 8 Nm (0.8 m · kg)
T.
R.
NOTE:
NOTE:
Hold the screw 2 and tighten the locknut 1.
12.Install:
• Shift pedal 1 17.5 Nm (1.75 m · kg)
T.
R.
4 - 34
KICK STARTER ENG
KICK STARTER

Kick starter removal Remove the parts in the order listed.
Crankcase cover (right) Refer to “CLUTCH REMOVAL” section.
1 Kick axle 1 Refer to “KICK STARTER INSTALLA-
TION” section.
For installation, reverse the removal pro-
cedure.
Kick axle disassembly Remove the parts in the order listed.
1 Circlip 2
2 Cover (spring) 1
3 Torsion spring 1
4 Spring guide 1
5 Circlip 1
6 Latchet wheel 1
7 Clip 1
4 - 35
KICK STARTER ENG

8 Circlip 1
9 Wave washer 1
0 Kick gear 1
A Kick axle 1
For assembly, reverse the disassembly
procedure.
4 - 36
KICK STARTER ENG
T*****
KICK STARTER INSPECTION
1. Inspect:
• Gear teeth (kick gear) 1
• Gear teeth (ratchet wheel) 2
2. Inspect:
• Torsion spring
Wear/crack → Replace.
3. Measure:
• Kick clip friction force (torsion spring 1)
Use a spring gauge.
Kick clip friction force:

0.9 ~ 1.5 kg
T******
KICK STARTER INSTALLATION
1. Install:
• Kick axle assembly 1
• Kick gear clip 2
• Torsion spring 3
NOTE:
NOTE:
Turn the torsion spring clockwise and hook

into the proper hole a in the crankcase.
4 - 37
SHIFT SHAFT ENG
SHIFT SHAFT

Shift shaft removal Remove the parts in the order listed.
Clutch Refer to “CLUTCH” section.
1 Shift fork guide bar 1
2 Shift arm 3 1
3 Plate washer 1
4 Compression spring 1
5 Shift guide 1
6 Boll holder 1
7 Guide 1
8 Dowel pin 1
Refer to “SHIFT SHAFT INSTALLATION”
9 Plate washer 2
section.
10 Thrust bearing 1
11 Circlip 1
4 - 38
SHIFT SHAFT ENG

12 Shift lever assembly 1
13 Shift shaft 1 Refer to “SHIFT SHAFT INSTALLATION”
14 Stopper lever 1 section.
15 Torsion spring 1
16 Circlip 1
17 Plate washer 1
18 Torsion spring 1
19 Shift lever 1
procedure.
4 - 39
SHIFT SHAFT ENG
T402200
SHIFT SHAFT INSPECTION
1. Inspect:
• Stopper lever
Roller turns roughly → Replace.
Bends/damage → Replace.
2. Inspect:
• Torsion spring (stopper lever)
3. Inspect:
• Shift lever assembly
• Torsion spring (shift arm)
Bends/wear/damage → Replace.
4. Inspect:
• Shift shaft
• Torsion spring (shift shaft)
Bends/wear/damage → Replace.
4 - 40
SHIFT SHAFT ENG
T404090
SHIFT SHAFT INSTALLATION
1. Install:
• Stopper lever
• Torsion spring
• Shift shaft 1
• Shift lever assembly 2
NOTE:
NOTE:
Align the stopper lever roller with the slot of the

segment, then mesh the shift lever assembly
match mark a and shift lever match mark b.
2. Install
• Plate washer (thin) 1
• Bearing 2
• Plate washer (thick) 3
• Dowel pin 4
NOTE:
NOTE:
Apply grease to the bearing.
3. Install:
• Guide 1
NOTE:
NOTE:
Align the guide slot with the dowel pin.
4 - 41
OIL PUMP ENG
OIL PUMP

Oil pump removal Remove the parts in the order listed.
Shift shaft Refer to “SHIFT SHAFT” section.
1 Oil filter 1 Refer to “OIL PUMP INSTALLATION”
section.
2 Oil pump assembly 1
3 Gasket 1
4 Drive gear 1
5 Oil strainer 1
procedure.
4 - 42
OIL PUMP ENG

Oil pump disassembly Remove the parts in the order listed.
1 Circlip 1
2 Driven gear 1
3 Spring washer 1
4 Circlip 1
5 Plate washer 1
6 Screw 1
7 Cover 1
8 Dowel pin 2
9 Shaft 1
0 Dowel pin 1
A Inner rotor 1
B Outer rotor 1
C Housing 1
procedure.
4 - 43
OIL PUMP ENG
T402140
OIL PUMP INSPECTION
1. Measure:
• Tip clearance È
(between the inner rotor 1 and the outer
rotor 2)
• Side clearance É
(between the outer rotor 2 and the pump
housing 3)
Out of specification → Replace the oil pump
assembly.
• Housing and rotor clearance Ê
(between the pump housing 3 and the
rotors 1, 2)
Out of specification → Replace the oil pump
assembly.
Tip clearance È:
0.15 mm
<Limit: 0.20 mm>
Side clearance É:
0.06 ~ 0.10 mm
<Limit: 0.15 mm>
Housing and rotor clearance Ê:
0.06 ~ 0.10 mm
<Limit: 0.15 mm>
2. Inspect:
• Oil filter
Cracks/damage → Replace.
Contamination → Clean the flushing oil.
3. Inspect:
• Oil stainer
Contamination → Clean the flushing oil.
T*****
OIL PUMP INSTALLATION
1. Install:
• Oil filter 1
NOTE:
NOTE:
Align the rotary filter match mark a with crank-

shaft oil journal b.
4 - 44
AC MAGNETO AND STARTER CLUTCH ENG
AC MAGNETO AND STARTER CLUTCH

AC magneto and starter clutch Remove the parts in the order listed.
removal
Front cover (left and right)
Rear cover (left and right)
Drive sprocket cover Refer to “ENGINE REMOVAL” section.
Crankcase cover (right) Refer to “CLUTCH REMOVAL” section.
1 Stator coil assembly coupler 2 NOTE:
2 Gear position switch coupler 1 Disconnect the couplers.
3 Crankcase cover (left) 1
4 Gasket (crankcase cover left) 1
5 Dowel pin 2
6 Nut (AC magneto) 1
Refer to “AC MAGNETO REMOVAL/
7 AC magneto 1
INSTALLATION” section.
8 Wood ruff key 1
4 - 45

9 Shaft 1
10 Idler gear 1
11 Starter clutch/wheel gear 1/1
12 Stator assembly 1
procedure.
4 - 46
YP401081
AC MAGNETO REMOVAL
1. Remove:
• Nut (magneto) 1
• Plain washer 2
NOTE:
NOTE:
• Loosen the nut (magneto) 1 while holding

the rotor with a sheave holder 3.
• Do not allow the sheave holder to touch the
projection on the magneto.
Sheave holder:
90890-01701
2. Remove:
• AC magneto 1
• Woodruff key
NOTE:
NOTE:
• Remove the magneto using the flywheel

puller 2.
• Center the flywheel puller over the magneto.
Make sure after installing the holding bolts
that the clearance between the flywheel
puller and the magneto is the same every-
where. If necessary, one holding bolt may be
turned out slightly to adjust the flywheel
puller’s position.
CAUTION:
Cover the crankshaft end with the box
wrench for protection.
Flywheel puller:
90890-01362
4 - 47
YP402163
STARTER DRIVE GEAR INSPECTION
1. Inspect:
• Starter idle gear teeth a
• Starter drive gear teeth b
• Starter wheel gear teeth c
Burrs/chips/roughness/wear → Replace.
2. Check:
• Starter clutch operation
Push the dowel pins to the arrow direction.
Unsmooth operation → Replace.
*****************************************************
Checking steps:
● Hold the starter clutch.
● When turning the starter wheel gear clock-
wise È, the starter clutch and the starter
wheel gear should be engaged.
● If not, the starter clutch is faulty. Replace it.
● When turning the starter wheel gear counter-
clockwise É, it should turn freely.
● If not, the starter clutch is faulty. Replace it.
*****************************************************
YP404131
AC MAGNETO INSTALLATION
1. Install:
• Woodruff key 1
• AC magneto 2
NOTE:
NOTE:
• Clean the tapered portion of the crankshaft

and the magneto hub.
• When installing the magneto rotor, make
sure the woodruff key is properly seated in
the key way of the crankshaft.
2. Tighten:
• Nut (magneto) 1
NOTE:
NOTE:
Tighten the nut (magneto) 1 while holding the

magneto 2 with a sheave holder 3.
Sheave holder:
90890-01701
4 - 48
CRANKCASE AND CRANKSHAFT ENG
CRANKCASE AND CRANKSHAFT

Crankcase and crankshaft removal Remove the parts in the order listed.
Engine removal Refer to “ENGINE REMOVAL” section.
Cylinder, piston Refer to “CYLINDER AND PISTON” sec-
tion.
Kick starter Refer to “KICK STARTER” section.
Shift shaft Refer to “SHIFT SHAFT” section.
Oil pump Refer to “OIL PUMP” section.
AC magneto, starter clutch Refer to “AC MAGNETO AND STARTER
CLUTCH” section.
1 Timing chain guide (intake) 1
2 Crankcase (right) 1 Refer to “CRANKCASE INSTALLATION”
section.
3 Dowel pin 2
4 - 49

4 Crankshaft assembly 1 Refer to “CRANKSHAFT REMOVAL/
BALANCER WEIGHT INSTALLATION”
section.
5 Timing chain 1
6 Crankcase (left) 1
procedure.
4 - 50
T******
CRANKSHAFT REMOVAL
1. Remove:
• Crankshaft assembly 1
NOTE:
NOTE:
• Before removing the crankshaft assembly,

disconnect the timing chain from the crank
shaft sprocket.
• If the timing chain hooks to the crankshaft
sprocket, the crankshaft cannot be removed.
T******
CRANKSHAFT INSPECTION
1. Measure:
• Crankshaft runout
Out of specification → Replace crankshaft
and/or bearing.
NOTE:
NOTE:
Measure the crankshaft runout with the crank-

shaft assembly turning slowly.
Runout limit:
0.03 mm
2. Measure:
• Big end side clearance
Out of specification → Replace big end
bearing, crank pin and/or connecting rod.
Big end side clearance:

0.11 ~ 0.41 mm
3. Measure:
• Crank width
Out of specification → Replace crankshaft.
Crank width:
42.95 ~ 43.00 mm
4 - 51
4. Inspect:
• Crankshaft sprocket 1
Wear/damage → Replace crankshaft.
• Bearing 2
Wear/crack/damage → Replace crankshaft.
5. Inspect:
• Crankshaft journal
Clogged → Blow out the journal with com-
pressed air.
T*****
CRANKSHAFT INSTALLATION
1. Install:
• Crankshaft assembly 1
CAUTION:
Do not use the hammer forcedly during
installation of the crankshaft. Damage the
crankcase oil seal lip and gear teeth.
T404073
CRANKCASE INSTALLATION
1. Clean all the gasket mating surface and
crankcase mating surface thoroughly.
2. Apply:
• Sealant
(onto the crankcase mating surfaces)
Yamaha bond No. 1215:

90890-85505
NOTE:
NOTE:
DO NOT ALLOW any sealant to come in con-

tact with the oil gallery a.
4 - 52
TRANSMISSION ENG
TRANSMISSION
TRANSMISSION, SHIFT CAM AND SHIFT FORK

Transmission, shift cam and shift Remove the parts in the order listed.
fork removal
Crankcase Refer to “CRANKCASE AND CRANK-
SHAFT” section.
1 Guide bar 1
2 Shift fork 2 1 Refer to “SHIFT FORK AND SHIFT CAM
3 Shift fork 1 1 INSTALLATION” section.
4 Shift cam 1
5 Drive sprocket 1
6 Drive axle assembly 1 Refer to “TRANSMISSION REMOVAL/
7 Main axle assembly 1 SHIFT FORK AND SHIFT CAM INSTAL-
LATION” section.
8 2nd pinion gear 1
9 3rd pinion gear 1
procedure.
4 - 53
TRANSMISSION ENG
DRIVE AXLE/MAIN AXLE DISASSEMBLY

Drive axle disassembly Remove the parts in the order listed.
1 Circlip 1
2 Plate washer 1
3 Collar 1
4 1st wheel gear 1
5 4th wheel gear 1
6 Circlip 1
7 Washer 1
8 3rd wheel gear 1
9 2nd wheel gear 1
procedure.
4 - 54
TRANSMISSION ENG

Main axle disassembly Remove the parts in the order listed.
0 Circlip 1
A Washer 1
B 4th pinion gear 1
procedure.
4 - 55
TRANSMISSION ENG
T*****
TRANSMISSION REMOVAL
1. Remove:
• Drive axle assembly 1
• Main axle assembly 2
Use the soft hammer.
T402190
SHIFT FORK SHIFT CAM INSPECTION
1. Inspect:
• Shift fork cam follower 1
• Shift fork pawl 2
Scoring/bends/wear/damage → Replace.
2. Inspect:
• Shift cam grooves 1
Wear/damage/scratches → Replace.
• Shift cam segment 2
Damage/wear → Replace.
3. Inspect:
• Shift fork 1 1
• Shift fork 2 2
• Guide bar 3
• Shift cam 4
• Pin 5
Roll the guide bar on a flat surface.
Bends → Replace.
WARNING
Do not attempt to straighten a bent guide
bar.
4. Check:
• Shift fork movement
(on the guide bar)
Unsmooth operation → Replace the shift
fork and the guide bar.
NOTE:
NOTE:
When damaged the shift fork and mission

4 - 56 gear, replace the facing each gear as set.
TRANSMISSION ENG
T404060
SHIFT FORK AND SHIFT CAM
INSTALLATION
1. Install:
• Main axle assembly 1
• Drive axle assembly 2
2. Install:
• Shift fork “R” 1 1
• Shift fork “L” 2 2
• Shift cam 3
• Guide bars (shift fork) 4
NOTE:
NOTE:
Install the shift forks with the embossed mark

to the right and in sequence (R, L) beginning
from the right.
3. Check:
• Gear smooth operation
4 - 57
CARBURETOR CARB
EB600000
CARBURETION
CARBURETOR

Carburetor removal Remove the parts in the order listed.
CHAPTER 3.
Horn
1 Screw (air filter joint) 1
2 Air vent pipe 1
3 Fuel hose 1
4 Bolt/nut 2/2
5 Carburetor assembly 1
6 O-ring 2
7 Gasket 1
8 Carburetor top 1
9 Starter plunger assembly 1 Refer to “Carburetor assembly” section.
procedure.
5-1
CARBURETOR CARB

Carburetor disassembly Remove the parts in the order listed.
1 Throttle valve 1 Refer to “Carburetor assembly” section.
2 Throttle cable 1
3 Spring 1
4 Gasket 1
5 Carburetor top cover 1
6 Spring seat 1
7 Jet needle assembly 1
8 Starter pullanger set 1
9 Starter cable 1
5-2
CARBURETOR CARB

0 Float chamber 1
A Float pin 1
B Float 1
C Needle valve 1
D Main jet 1
E Pilot jet 1
F Main nozzle 1
G Throttle stop screw set 1
H Air screw set 1
procedure.
5-3
CARBURETOR CARB
T*****
FLOAT HEIGHT INSPECTION
1. Inspect:
• Float height a
*****************************************************
Inspection and adjustment steps:
● Hold the carburetor in an upside down posi-
tion.
● Measure the distance from the mating sur-
face of the float chamber (gasket removed)
to the top of the float.
● If the float height is not within specification,
inspect the valve seat and valve needle.
● If either is worn, replace them both.
● If both are fine, adjust the float height by
bending the float tang 1 on the float.
● Check the float height again.
NOTE:
The float arm should be resting on the valve
needle without compressing it.
Float height (F.H):

15 mm

*****************************************************
T600041
ASSEMBLY
Reverse the “DISASSEMBLY” procedure.
Note the following points.
CAUTION:
• Before assembling, wash all parts in
clean petroleum based solvent.
• Always use a new gasket.
1. Install:
• Throttle valve 1
• Starter pullanger 2
NOTE:
Align the slit a of the throttle valve with the tab
b of the carburetor top.
5-4
CARBURETOR CARB
YP600060
FUEL LEVEL ADJUSTMENT
WARNING
Gasoline (fuel) and its vapors are highly
flammable and explosive. Keep away from
sparks, cigarettes, flames or other sources
of ignition.
1. Measure:
• Fuel level a
Fuel level:
2.0 ~ 3.0 mm below the float
chamber line
*****************************************************
Measurement and adjustment steps:
● Place the motorcycle on a level surface.
● Put a garage jack under the engine to ensure
that the carburetors are positioned vertically.
● Connect the fuel level gauge 1 to the drain
pipe 2.
Fuel level gauge:

90890-01312
● Loosen the drain screw 3.

● Hold the gauge vertically next to the float
chamber line.
● Measure the fuel level a with the gauge.
● If the fuel level is incorrect, adjust the fuel
level.
● Remove the carburetor.
● Inspect the valve seat and needle valve.
● If either is worn, replace them both.
● If both are fine, adjust float level by bending
the float tang 4 slightly.
● Install the carburetor.
● Recheck the fuel level.
*****************************************************
5-5
FRONT WHEEL AND BRAKE DISC CHAS
CHASSIS
FRONT WHEEL AND BRAKE DISC

Front wheel and brake disc removal Remove the parts in the order listed.
Stand the motorcycle on a level surface.
WARNING
Securely support the motorcycle so
1 Speedometer cable 1 Disconnect

2 Front wheel axle/nut 1/1
3 Front wheel assembly 1 Refer to “FRONT WHEEL INSTALLA-
4 Speedometer gear unit 1 TION” section.
5 Collar 1
6 Brake disc 1
procedure.
6-1

Front wheel disassembly Remove the parts in the order listed.
1 Oil seal 1
2 Bearing 1
Refer to “FRONT WHEEL DISASSEM-
3 Spacer 1
BLY/ASSEMBLY” section.
4 Bearing 1
procedure.
6-2
T******
FRONT WHEEL DISASSEMBLY
1. Remove:
• Bearings 1
• Spacer 2
Remove the bearings using a general bear-
ing puller 3.
T700021
FRONT WHEEL INSPECTION
1. Inspect:
• Front wheel axle
(by rolling it on a flat surface)
Bends → Replace.
WARNING
Do not attempt to straighten a bent axle.
Wheel axle bending limit:

0.25 mm
2. Inspect:
• Front tire
Refer to “TIRE INSPECTION” in CHAPTER
3.
• Front wheel
Refer to “WHEEL INSPECTION” in CHAP-
TER 3.
3. Check:
• Spokes
Bends/damage → Replace.
Loose spokes → Retighten.
Turn the wheel and tap the spokes with a
screwdriver.
NOTE:
A tight spoke will emit a clear, ringing tone, a
loose spoke will sound flat.
6-3
4. Tighten:
• Loose spokes
• Nipple
NOTE:
Check the front wheel runout after tightening
the spokes.
5. Measure:
• Front wheel runout
Over the specified limits → Replace.
Front wheel runout limits:

Radial: 2.0 mm
Lateral: 2.0 mm
6. Inspect:
• Front wheel bearings
Bearings allow free play in the wheel hub or
the wheel does not turn smoothly →
Replace.
• Oil seals
7. Inspect:
• Collar
Grooved wear → Replace the collar and the
oil seal as a set.
BRAKE DISC INSPECTION

1. Inspect:
• Brake disc
Galling/damage → Replace.
2. Measure:
• Brake disc deflection a
Out of specification → Inspect the wheel
runout.
If wheel runout is within the limits, replace
the brake disc.
Brake disc maximum deflection:

0.15 mm
Measuring point 2 mm.

• Brake disc thickness b
Brake disc minimum thickness:

3.0 mm
6-4
YP******
FRONT WHEEL ASSEMBLY
1. Install:
• Bearing 1
• Spacer
• Bearing
• Oil seal
NOTE:
• Apply the lithium soap base grease on the
bearing and oil seal lip when installing.
• Use a socket that matches the outside diam-
eter of the race of the bearing.
• Always use a new oil seal.
• Install the oil seal with its manufacturer’s
marks or numbers facing outward.
CAUTION:
Do not strike the inner race of balls of the
bearing. Contact should be made only with
the outer race.
FRONT WHEEL INSTALLATION

1. Install:
• Brake disc 1 23 Nm (2.3 m · kg)
T.
R.
NOTE:
• Apply LOCTITE® to the threads of the brake
disc bolts.
• Tighten the brake disc bolts in stages using a
crisscross pattern.
2. Install:
• Speedometer gear unit 1
NOTE:
Be sure that projection a inside the wheel hub
mesh with the slot b in the gear unit assem-
bly.
6-5
3. Tighten:
• Front wheel axle nut
39 Nm (3.9 m · kg)
T.
R.
NOTE:
Be sure that the projection (torque stopper) a
of the gear unit housing is positioned correctly.
4. Connect:
• Speedometer cable 1
NOTE:
Be sure that slit a on the speedometer cable
mesh with the projection b in the speedome-
ter gear unit 2.
6-6
REAR WHEEL, REAR BRAKE, SPROCKET AND DRIVE
CHAIN CHAS
REAR WHEEL, REAR BRAKE, SPROCKET AND DRIVE CHAIN
REAR WHEEL AND REAR BRAKE

Rear wheel and rear brake removal Remove the parts in the order listed.
1 Adjuster 1
2 Pin 1
3 Compression spring 1
4 Tension bar 1
5 Rear wheel axle nut 1
6 Chain puller (right) 1
7 Rear wheel axle 1
8 Chain puller (left) 1
9 Collar 1
10 Rear wheel assembly 1 Refer to “REAR WHEEL INSTALLA-
11 Brake shoe plate assembly 1 TION” section.
12 Damper 4
procedure.
6-7
CHAIN CHAS

Rear wheel disassembly Remove the parts in the order listed.
1 Bearing 1
Refer to “REAR WHEEL DISASSEMBLY/
2 Spacer/collar 1/1
ASSEMBLY” section.
3 Bearing 1
procedure.
Brake shoe plate disassembly Remove the parts in the order listed.
4 Brake shoe kit 1
5 Cam lever 1
Refer to “BRAKE SHOE PLATE ASSEM-
6 Indicator plate 1
BLY” section.
7 Camshaft 1
procedure.
6-8
CHAIN CHAS
DRIVE CHAIN AND DRIVEN SPROCKET

Drive chain and driven sprocket Remove the parts in the order listed.
removal
Rear wheel assembly Refer to “REAR WHEEL AND REAR
BRAKE” section.
Drive sprocket cover Refer to “ENGINE REMOVAL” section in
CAPTER 4.
1 Drive chain case 1 Refer to “DRIVE CHAIN INSTALLATION”
2 Drive chain 1 section.
3 Drive sprocket 1
4 Driven sprocket assembly 1
procedure.
6-9
CHAIN CHAS

Driven sprocket hub disassembly Remove the parts in the order listed.
1 Driven sprocket 1 Refer to “DRIVEN SPROCKET ASSEM-
BLY” section.
2 Collar 1
3 Oil seal 1
4 Bearing 1
5 Driven sprocket hub 1
procedure.
6 - 10
CHAIN CHAS
T******
REAR WHEEL DISASSEMBLY
1. Remove:
• Bearings 1
• Spacer 2
• Collar 3
Refer to “FRONT WHEEL AND BRAKE DISC”
section.
T701020
REAR WHEEL INSPECTION
1. Inspect:
• Rear wheel axle
• Rear wheel
• Rear wheel bearings
• Oil seals
section.
2. Measure:
• Rear wheel runout
section.
3. Inspect:
• Clutch hub damper
EB701021
REAR BRAKE INSPECTION
1. Inspect:
• Brake lining surface
2. Measure:
• Brake lining thickness
3. Measure:
• Brake drum inside diameter
4. Inspect:
• Brake drum inner surface
• Oil
• Scratches
5. Inspect:
• Cam shaft face
Refer to “FRONT WHEEL AND BRAKE
DISC” section.
6 - 11
CHAIN CHAS
T******
BRAKE SHOE PLATE ASSEMBLY
1. Install:
• Camshaft 1
• Indicator plate 2
*****************************************************
Installation steps:
● Set the camshaft with its punched mark a
facing the direction as shown.
● Align the projection b on the indicator plate
with the camshaft notch and install.
● Check the proper position of the brake shoe.
*****************************************************
2. Install:
• Camshaft lever 1
Install the camshaft lever with its slit and the
indicator plate at right angle as shown.
T******
REAR WHEEL ASSEMBLY
1. Install:
• Bearing 1
• Spacer 2
• Collar 3
Refer to “FRONT WHEEL AND BRAKE
DISC” section.
T701032
REAR WHEEL INSTALLATION
Reverse the “REMOVAL” procedure.
1. Install:
• Brake shoe plate assembly
• Rear wheel assembly
NOTE:
Make sure that the slot in the rear wheel hub
damper fits over the tab on the driven sprocket
hub assembly.
6 - 12
CHAIN CHAS
T701020
DRIVE CHAIN INSPECTION
1. Inspect:
• Drive chain stiffness
Stiffness → Clean and lubricate or replace.
2. Inspect:
• Drive chain 1
• Driven sprocket 2
More than 1/2 tooth a wear → Replace the
drive chain.
Use new driven sprocket.
3. Measure:
• 10 link length (drive chain) a
Out of specification → Replace the drive
chain.
10 link length limit:

121.4 mm
NOTE:
• Tighten the drive chain with a finger before
measuring.
• 10 link length is the distance between the
inside edge of roller 1 and A as shown.
• 10 link length measurement should be done
at two or three different places.
4. Clean:
• Drive chain
Put it in kerosene, and brush off as much
dirt as possible. Then remove the drive
chain from the kerosene and dry it.
Drive chain lubricant:

Yamalube 4 (20W40) or chain
lubricant
6 - 13
CHAIN CHAS
T*****
CLUTCH HUB INSPECTION
1. Inspect:
• Clutch hub
Wear/damage/cracks → Replace.
T******
DRIVEN SPROCKET ASSEMBLY
1. Install:
• Driven sprocket 1
• Lock washer 2 New
• Nut 3
• Bolt 4 30 Nm (3.0 m · kg)
T.
R.
NOTE:
Tighten the nuts in a crisscross pattern.
2. Bend:
• Lock washer tab 1
(along a flat side of the end)
T*****
DRIVE CHAIN INSTALLATION
1. Install:
• Drive chain 1
• Chain joint 2
• Plate 3
2. Install:
• Clip 1
CAUTION:
Be sure to install the chain joint clip to the
direction as shown.
6 - 14
FRONT BRAKE CHAS
FRONT BRAKE
FRONT BRAKE PADS

Front brake pad removal Remove the parts in the order listed.
1 Brake caliper bolts 2
2 Brake caliper 1 Refer to “BRAKE PAD REPLACEMENT”
3 Brake pads 2 section.
4 Pad spring 1
5 Brake pad pin 2
procedure.
6 - 15
FRONT BRAKE CHAS
CAUTION:
Disc brake components rarely require dis-
assembly. DO NOT:
• disassemble components unless abso-
lutely necessary;
• use solvents on internal brake compo-
nents;
• use spent brake fluid for cleaning; (use
only clean brake fluid)
• allow brake fluid to come in contact with
the eyes, as this may cause eye injury;
• splash brake fluid onto painted surfaces
or plastic parts, as this may cause dam-
age;
• disconnect any hydraulic connection, as
this would require the entire brake sys-
tem to be disassembled, drained,
cleaned, properly filled and bled after
reassembly.
BRAKE PAD REPLACEMENT

NOTE:
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.
1. Remove:
• Brake caliper bolts
• Brake caliper
2. Remove:
• Brake pad pins
• Pad spring
• Brake pads 1
NOTE:
• Install new brake pad spring when the brake
pads have to be replaced.
• Replace the brake pads as a set if either is
found to be worn to the wear limit.
3. Install:
• Brake pads
• Brake pads spring
*****************************************************
Installation steps:
● Connect a suitable hose 1 tightly to the
brake caliper bleed screw 2. Put the other
end of this hose into an open container.
6 - 16
FRONT BRAKE CHAS
● Loosen the brake caliper bleed screw and
using a finger push the caliper pistons into
the brake caliper.
● Tighten the brake caliper bleed screw.
Brake caliper bleed screw:

6 Nm (0.6 m • kg)
T.
R.
● Install new brake pad spring and a new
brake pads.
● Install the brake caliper 3 and caliper bolts
4.
Retaining bolt:
27 Nm (2.7 m • kg)
T.
R.
*****************************************************
4. Inspect:
TION” section in CHAPTER 3.
a “LOWER” level line
5. Check:
• Brake lever operation
Soft or spongy feeling → Bleed the brake
system.
Refer to “AIR BLEEDING (HYDRAULIC
BRAKE SYSTEM)” section in CHAPTER 3.
6 - 17
FRONT BRAKE CHAS
MASTER CYLINDER

Master cylinder removal Remove the parts in the order listed.
Brake fluid Drain.
Headlight cover
Headlight unit
Refer to “HANDLEBAR” section.
Handlebar cover
Meter assembly
1 Union bolt 1
Refer to “MASTER CYLINDER INSTAL-
2 Copper washers 2
LATION” section.
3 Brake hose 1
4 Master cylinder bracket 1
5 Master cylinder assembly 1
6 Brake lever/compression spring 1/1
7 Front brake switch 1 Refer to “MASTER CYLINDER REMOVAL”
section.
procedure.
6 - 18
FRONT BRAKE CHAS

Master cylinder disassembly Remove the parts in the order listed.
1 Dust boot 1
2 Circlip 1 Refer to “MASTER CYLINDER ASSEM-
3 Washer 1 BLY” section.
4 Master cylinder cup kit 1
procedure.
6 - 19
FRONT BRAKE CHAS
MASTER CYLINDER REMOVAL
1. Remove:
• Front brake switch 1
NOTE:
Remove the front brake switch from the master
cylinder while pushing the tab of the front
brake switch with a narrow screwdriver.
MASTER CYLINDER INSPECTION

1. Inspect:
• Master cylinder
Wear/scratches → Replace the master cyl-
inder assembly.
• Master cylinder body
• Oil delivery passage
(master cylinder body)
Blockage → Blow out with compressed air.
2. Inspect:
• Master cylinder cup kit
Scratches/wear/damage → Replace as a
set.
3. Inspect:
• Diaphragm
4. Inspect:
• Brake hose
Cracks/wear/damage → Replace.
EB702060
MASTER CYLINDER ASSEMBLY
WARNING
• All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.

DOT 4
• Whenever a master cylinder is disassem-

bled replace the piston seals and dust
seals.
6 - 20
FRONT BRAKE CHAS
MASTER CYLINDER INSTALLATION
1. Install:
• Copper washers 1 New
• Brake hose 2
• Union bolt 3 26 Nm (2.6 m · kg)
T.
R.
NOTE:
• Make sure that the brake hose 2 touches
the stopper a.
• Turn the handlebar to the left and to the right
to check that the brake hose does not touch
other parts (throttle cable, wire harness,
leads, etc.). Correct if necessary.
WARNING
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
2. Fill:
• Reservoir tank

DOT 4
CAUTION:
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.
WARNING
• Use only the designated quality brake
fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid:
mixing brake fluids may result in a harm-
ful chemical reaction and lead to poor
brake performance.
• Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
brake fluid and may result in vapor lock.
6 - 21
FRONT BRAKE CHAS
3. Air bleed:
• Brake system
4. Inspect:
Brake fluid level is under the “LOWER” level
line → Fill up.
6 - 22
FRONT BRAKE CHAS
FRONT BRAKE CALIPER

Front brake caliper removal Remove the parts in the order listed.
Brake fluid Drain.
1 Brake hose holder 1
2 Union bolt 1
Refer to “CALIPER INSTALLATION” sec-
3 Copper washers 2
tion.
4 Brake hose 1
5 Brake caliper assembly 1
procedure.
6 - 23
FRONT BRAKE CHAS

Front brake caliper disassembly Remove the parts in the order listed.
1 Brake caliper bracket 1
2 Brake pads 2 Refer to “FRONT BRAKE PADS” section.
3 Pad spring 2
4 Brake pad pin 2
5 Brake caliper pistons 2
Refer to “CALIPER DISASSEMBLY/
6 Dust seals 2
ASSEMBLY” section.
7 Caliper piston seals 2
8 Bleed screw 1
procedure.
6 - 24
FRONT BRAKE CHAS
CALIPER DISASSEMBLY
1. Remove:
• Brake caliper pistons
• Dust seals 1
• Caliper piston seals 2
*****************************************************
Removal steps:
● Blow compressed air into the hose joint
opening to force out the caliper piston from
the brake caliper body.
WARNING
• Never try to pry out the caliper pistons.
• Cover the caliper piston with a rag. Be
careful not to get injured when the piston
is expelled from the master cylinder.
● Remove the caliper piston seals.

*****************************************************
EB702040
CALIPER INSPECTION
Recommended brake component
replacement schedule:
Brake pads As required
Piston seals, dust
Every two years
seals
Brake hoses Every two years
Replace when
Brake fluid brakes are disas-
sembled.
WARNING
All internal brake components should be
cleaned in new brake fluid only. Do not use
solvents as they will cause seals to swell
and distort.
1. Inspect:
• Brake caliper piston 1
Scratches/rust/wear → Replace the brake
caliper assembly.
• Brake caliper cylinder 2
Wear/scratches → Replace the brake cali-
per assembly.
• Brake caliper body 3
6 - 25
FRONT BRAKE CHAS
• Oil delivery passage (brake caliper body)
Blockage → Blow out with compressed air.
WARNING
Replace the caliper piston seal and dust
seal whenever the brake caliper is disas-
sembled.
CALIPER ASSEMBLY
WARNING
• All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.

DOT 4
• Replace the caliper piston seals when-

ever a brake caliper is disassembled.
1. Install:
• Caliper piston seals 1 New
• Dust seals 2 New
2. Install:
• Brake caliper pistons 1
CALIPER INSTALLATION
1. Install:
• Brake caliper assembly
• Brake hose 1 35 Nm (3.5 m · kg)
T.
R.
• Copper washers 2 New

• Union bolt 3 26 Nm (2.6 m · kg)
T.
R.
6 - 26
FRONT BRAKE CHAS
CAUTION:
When installing the brake hose on the
brake caliper, make sure that the brake
pipe touches the projection a on the brake
caliper.
WARNING
Proper brake hose routing is essential to
insure safe motorcycle operation. Refer to
“CABLE ROUTING”.
2. Fill:
• Brake reservoir

DOT 4
CAUTION:
Brake fluid may damage painted surfaces
or plastic parts. Always clean up spilled
brake fluid immediately.
WARNING
• Use only the designated quality brake
fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid:
mixing brake fluids may result in a harm-
ful chemical reaction and lead to poor
brake performance.
• Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
brake fluid and may result in vapor lock.
3. Air bleed
• Brake system
4. Inspect:
Brake fluid level is under the “LOWER” level
line → Fill up.
6 - 27
FRONT FORK CHAS
FRONT FORK
FRONT FORK

Front fork removal Remove the parts in the order listed.
Front cover leg shield Refer to “COVER AND PANEL” section in
CHAPTER 3.
Front wheel assembly Refer to “FRONT WHEEL AND BRAKE
DISC” section.
Brake caliper assembly Refer to “FRONT BRAKE CALIPER” sec-
tion.
1 Brake hose holder 1
2 Cover (front fork) (left/right) 1/1
3 Front fender 1
4 Cap bolt/O-ring 2/2
Refer to “FRONT FORK INSTALLATION”
5 Bolt (under bracket) 2
section.
6 Front fork (left/right) 1/1
procedure.
6 - 28
FRONT FORK CHAS

Front fork disassembly Remove the parts in the order listed.
1 Fork spring 1
Refer to “FRONT FORK ASSEMBLY”
2 Dust cover 1
section.
3 Retaining clip 1
4 Bolt (Damper rod)/gasket 1/1
5 Inner tube 1 Refer to “FRONT FORK DISASSEMBLY/
6 Damper rod 1 ASSEMBLY” section.
7 Oil seal 1
procedure.
6 - 29
FRONT FORK CHAS
T703020
FRONT FORK DISASSEMBLY
1. Remove:
• Bolt (damper rod) 1
Loosen the bolt (damper rod) 1 while hold-
ing the damper rod with T-handle 2 and
10 mm hexagon nut/socket wrench 3.
T-handle:
90890-01326
2. Remove:
• Inner tube
• Damper rod
Pull out the inner tube with damper rod.
3. Remove:
• Oil seal 1
CAUTION:
Never reuse the oil seal.
2 Rag
YP703030
FRONT FORK INSPECTION
1. Inspect:
• Inner tube bending
Inner tube bending limit:

0.2 mm
Scratches/bends/damage → Replace.
WARNING
Do not attempt to straighten a bent inner
tube as this may dangerously weaken the
tube.
2. Measure:
• Fork spring a
Front fork spring free length:

286.7 mm
<Wear limit>:
269.7 mm
Over the specified limit → Replace.

T******
FRONT FORK ASSEMBLY
Reverse the “DISASSEMBLY” procedure.
1. Install:
• Damper rod 1
• Rebound spring
• Inner tube 2
6 - 30
FRONT FORK CHAS
2. Install:
• Inner tube 1
Into outer tube 2.
3. Install:
• Plain washer 1 New
4. Tighten:
23 Nm (2.3 m · kg)
T.
R.
NOTE:
Tighten the damper rod bolt 1 while holding
the damper rod with a T-handle 2 and 10 mm
hexagon nut/socket wrench 3.
T-handle:
90890-01326
5. Install:
• Oil seal 1 New
• Retaining clip
• Dust seal
Use the fork seal driver weight 3 and the
fork seal driver attachment 2.
NOTE:
• Before installing the oil seal 1, apply lithium
soap base grease onto the oil seal lips.
• Fit retaining clip correctly in the groove in the
outer tube.
CAUTION:
Make sure that the oil seal numbered side
faces upward.
Fork seal driver weight:

90890-01184
Fork seal driver attachment:
90890-01186
6 - 31
FRONT FORK CHAS
6. Inspect:
• Inner tube operation
Unsmooth operation → Disassembly and
recheck.
7. Fill:
• Fork oil
Oil quantity:
0.0575 L (57.5 cm3)
Recommended oil:
Fork oil 10WT or equivalent
8. After filling up, slowly pump the fork up and

down to distribute the fork oil.
9. Measure:
• Oil level a
Oil level:
102 mm
(from the top of the inner tube
fully compressed and without the
fork spring)
NOTE:
Hold the fork in an upright position.
10.Install:
• Front fork spring 1
NOTE:
Install the fork spring with its smaller pitch
upward.
6 - 32
FRONT FORK CHAS
EB703050
FRONT FORK INSTALLATION
1. Install:
• Front fork 1
• Cap bolt 2
Temporary tighten the pinch bolts.
NOTE:
Pull up the inner tube until it is stopped, then
install the cap bolt 2.
2. Tighten:
• Cap bolts 1 50 Nm (5.0 m · kg)
T.
R.
• Pinch bolts (under bracket) 2
50 Nm (5.0 m · kg)
T.
R.
6 - 33
HANDLEBAR CHAS
HANDLEBAR
METER ASSEMBLY AND HEADLIGHT UNIT

Meter assembly and headlight unit Remove the parts in the order listed.
assembly removal
1 Rear view mirror 2
2 Headlight cover 1
3 Headlight unit 1
4 Handlebar cover 1
5 Speedometer cable 1
6 Meter assembly 1
7 Coupler/wire (meter lead) 2/1
procedure.
6 - 34
HANDLEBAR CHAS
HANDLEBAR

Handlebar removal Remove the parts in the order listed.
Meter assembly Refer to “METER ASSEMBLY AND
Headlight unit HEADLIGHT UNIT” section.
1 Plastic band 3
2 Starter cable 1
3 Handlebar switch (right) 1
Refer to “HANDLEBAR INSTALLATION”
4 Throttle cable 1
section.
5 Grip assembly (right) 1
6 Front brake switch 1
7 Lever holder (right) 1 Refer to “HANDLEBAR INSTALLATION”
8 Handlebar switch (left) 1 section.
9 Grip assembly (left) 1 Refer to “HANDLEBAR REMOVAL” sec-
tion.
6 - 35
HANDLEBAR CHAS

10 Wire harness 1
Refer to “HANDLEBAR INSTALLATION”
11 Bolt/nut 1/1
section.
12 Handlebar 1
procedure.
6 - 36
HANDLEBAR CHAS
YP******
HANDLEBAR REMOVAL
1. Remove:
• Grip (left)
*****************************************************
Removal steps:
● Remove the grip end (left).
● Blow with compressed air between the han-
dlebar and adhesive side of the grip to
remove.
*****************************************************
YP704020
HANDLEBAR INSPECTION
1. Inspect:
• Handlebar
Bends/cracks/damage → Replace.
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken the
handlebar.
T******
HANDLEBAR INSTALLATION
1. Install:
• Handlebar 1
NOTE:
• Apply a light coat of lithium soap base
grease onto the handlebar right end.
• Align the slot a on the handlebar with the
steering shaft surface.
2. Tighten:
• Handlebar assembly
43 Nm (4.3 m · kg)
T.
R.
3. Hook:
• Wire harness
4. Install:
• Handlebar switch (left) 1
NOTE:
Align the handlebar switch projection with the
hole a on the handlebar.
6 - 37
HANDLEBAR CHAS
5. Install:
• Lever holder (right) 1
6. Install:
• Throttle cable 1
• Grip assembly 2
NOTE:
Apply a light coat of lithium soap base grease
onto the inside of the grip assembly and install
it to the handlebar.
7. Install:
• Handlebar switch (right) 1
*****************************************************
Installation steps:
● Align the handlebar switch (right) projection
with hole a on the handlebar.
● Provide a clearance of 3.0 mm between the
grip assembly and handlebar grip.
Otherwise, the grip may not move.
WARNING
Check the throttle grip for smooth opera-
tion.
*****************************************************
6 - 38
STEERING CHAS
STEERING

Steering removal Remove the parts in the order listed.
Handlebar assembly Refer to “HANDLEBAR” section.
Front fork Refer to “FRONT FORK” section.
Front panel 1 Refer to “COVER AND PANEL” section in
CHAPTER 3.
1 Front panel bracket 1
2 Cover 1
3 Ring nut (upper) 1 Refer to “STEERING REMOVAL/
4 Ring nut (lower) 1 INSTALLATION” section.
5 Ball race cover 1
6 Ball race 1 1 Refer to “STEERING INSTALLATION”
7 Lower bracket 1 section.
8 Ball bearing 22
9 Ball bearing 19 Refer to “STEERING INSTALLATION”
10 Ball race 1 1 section.
11 Ball race 2 1
procedure.
6 - 39
STEERING CHAS
T704010
STEERING REMOVAL
WARNING
• Securely support the motorcycle so that
• Stand the motorcycle on a level surface.
1. Remove:
• Ring nut (upper) 1
• Ring nut (lower) 2
NOTE:
Hold the lower ring nut with exhaust and steer-
ing nut wrench, then remove the upper ring nut
using ring nut wrench.
Exhaust and steering nut wrench:

90890-01268
Ring nut wrench:
90890-01403
WARNING
Securely support the steering shaft so that
there is no danger of it falling down.
STEERING INSPECTION
1. Wash the bearing and bearing races with a
solvent.
2. Inspect:
• Bearings
• Bearing races
Pitting/damage → Replace.
*****************************************************
Bearing race replacement steps:
● Remove the bearing races on the head pipe
using long rod 1 and the hammer as shown.
● Remove the bearing race on the under
bracket using the floor chisel 2 and the
hammer as shown.
● Install the new dust seal and races.
*****************************************************
6 - 40
STEERING CHAS
NOTE:
• Always replace bearings and races as a set.
• Replace the dust seal whenever a steering
head disassembled.
CAUTION:
If the bearing race is fitted not squarely, the
head pipe could be damaged.
EB704030
STEERING INSTALLATION
1. Lubricate:
• Bearings (upper and lower)
• Bearing races
Recommended lubricant:
Lithium-soap base grease
2. Install:
• Ring nut (lower)
• Ring nut (upper)
Refer to “STEERING HEAD INSPECTION”
6 - 41
REAR SHOCK ABSORBER AND SWINGARM CHAS
REAR SHOCK ABSORBER AND SWINGARM

Rear shock absorber and swingarm Remove the parts in the order listed.
removal
Muffler assembly Refer to “ENGINE OVERHAUL” section
Shift pedal in CHAPTER 4.
Rear cover Refer to “COVER AND PANEL” section in
CHAPTER 3.
Rear wheel Refer to “REAR WHEEL, REAR BRAKE,
Driven sprocket assembly SPROCKET AND DRIVE CHAIN” section.
1 Rear shock absorber 2
2 Axle shaft 1
3 Swingarm 1
4 Chain guard 1
5 Tension bar 1
procedure.
6 - 42
REAR SHOCK ABSORBER AND SWINGARM CHAS
T*****
SWINGARM INSPECTION
1. Inspect:
• Swingarm side play
Free play exists → Check side clearance.
• Swingarm up and down movement
Unsmooth movement/bending/rough spots
→ Grease or replace bearings, solid bushes
and collars.
6 - 43
SEAT, FUEL TANK AND FUEL COCK CHAS
SEAT, FUEL TANK AND FUEL COCK

Seat, fuel tank and fuel cock Remove the parts in the order listed.
removal
Rear cover (left and right) Refer to “COVER AND PANEL” section in
CHAPTER 3.
1 Seat 1
2 Coupler (fuel sender) 1
3 Fuel hose 1
4 Vacuum hose 1
5 Fuel cock 1
6 Fuel tank 1
7 Fuel filter 1
8 Fuel sender 1
procedure.
6 - 44
SEAT, FUEL TANK AND FUEL COCK CHAS
T*****
FUEL COCK INSPECTION
1. Inspect:
• Fuel cock body
Damage → Replace
T*****
FUEL COCK OPERATION
NOTE:
This inspection after the fuel cock installation.
1. Place the suitable container under the fuel

hose end.
2. Inspect:
• Vacuum operation
Check the flow out the fuel from the fuel
hose, absorbing the vacuum hose by
mouth.
Not blow out → Replace.
6 - 45
– +
ELECTRICAL COMPONENTS ELEC
EB800000
ELECTRICAL
ELECTRICAL COMPONENTS
1 Wireharness 9 Rectifier/regulator
2 Main switch 0 Horn
3 Starter relay A Spark plug cap
4 Fuse B Ignition coil
5 Battery
6 C.D.I. unit
7 Fuel sender
8 Flasher relay
7-1
– +
CIRCUIT DIAGRAM ELEC
CIRCUIT DIAGRAM
1
OFF R R
ON Br Br
Br B O
R W
Br R
W W R R
R 9 Y Y/R
0 W W
A O O
B
R
W B W W B
Y/R Y
R Y
B B C
Br B
2 B
W R R W
R
B
L/W Br
R
R R Br
R
4
R L/W
B
6 L/W Y/R
3 7 8
B
B OFF OFF
START ON Y/R L/R L/W Y/R
B
5 L B B L/B
B L/B
Br
Br Br
G Br/W
F
Br
Y
R Br L Ch Dg E D
Br/W
P Br
Y/W Sb Sb Y/W
H P L/B Br/W
W W
TUV WXYZ[
L/W P
(BLACK)
P L/W
(BLACK)
I J K
G/Y G/Y
OFF HI L Br/W Ch Ch Br/W
S PUSH LO N P B B P
R Dg L/B L/B Dg
L Br Br L
Dg Ch Ch Dg (RED) (RED)
B G G B
B Ch Dg
G B Sb W P Y/W L/W
Y G
Sb W P Y/W L/W YY G
Ch Dg
Ch Dg L G/Y
N N
G Q O O MM L
B B L L B
B B Y G/Y
P W W P
B
P Y/W Sb Sb Y/W
Ch
Dg
Ch
Dg
Ch Dg Dg Ch
L/W L/W
B B
B
7-2
– +
CIRCUIT DIAGRAM ELEC
1 Main switch J Dimmer switch
2 Fuse K Turn switch
3 Battery L Tail/brake light
4 Starter relay M Rear flasher light
5 Starter motor N Front flasher light
6 Handlebar switch (right) O Headlight
7 Start switch P Gear position switch
8 Light switch Q Fuel sender
9 Rectifier/regulator R Meter assembly
0 AC magneto S Fuel gauge
A C.D.I. unit T Meter light
B Ignition coil U High beam indicator light
C Spark plug V Turn indicator light
D Rear brake switch W Neutral indicator light
E Front brake switch X 1st gear position indicator light
F Flasher relay Y 2nd gear position indicator light
G Horn Z 3rd gear position indicator light
H Handlebar switch (left) [ 4th gear position indicator light
I Horn switch
NOTE:
• Start switch is closed while the button (switch) is pushed.
• Brake switch is closed while the brake is applied.
COLOR CODE
B Black Y Yellow
Br Brown W White
Ch Chocolate Br/W Brown/White
Dg Dark green G/Y Green/Yellow
G Green L/B Blue/Black
L Blue L/R Blue/Red
O Orange L/W Blue/White
Sb Sky blue Y/R Yellow/Red
P Pink Y/W Yellow/White
R Red
7-3
– +
SWITCH INSPECTION ELEC
YP-N
SWITCH INSPECTION
INSPECTION STEPS
Using pocket tester, check switches for conti-
nuity between their terminals to determine
whether they are correctly connected.
Replace the switch component if any of the
combinations does not produce the correct
reading.
Pocket tester:
90890-03112
NOTE:
• Turn the switch to the “ON”, “OFF” positions
several times.
• Adjust the pocket tester to correct “0” posi-
tion before checking switches.
• Set the pocket tester selector to “×1”Ω.
SWITCH CONNECTION AS SHOWN IN THIS

MANUAL
This manual contains connection charts, like
the one shown on the left, showing the termi-
nal connections of switches (e.g. the main
switch, handlebar switch, brake switch, lighting
switch etc.)
The column on the extreme left indicates the

different switch positions, the top line indicates
the colors of the leads connected to the termi-
nals on the switch.
“ ” indicates terminals between which

there is continuity, i.e. a closed circuit, in the
given switch position.
In this chart:
“Br and R” have continuity with the switch in
the “ON” position.
7-4
– +
SWITCH CONTINUITY INSPECTION
Refer to “SWITCH INSPECTION” and check for continuity between lead terminals.
Poor connection, no continuity → Correct or replace.
*The coupler locations are circled.
2 3 4 5 6
P B Y L/B G Ch Br/W Dg L/W B Y/R L/B
OFF HI L Br/W Ch OFF OFF
PUSH LO N P B START ON Y/R L/R
R Dg L/B L B
Y G
(RED)
1
Br
G/Y
P W
0 9 Y/W Sb
R L/W
B
B
(BLACK) R
8
OFF R
ON Br
7-5
– +
1 Front brake switch
2 Horn switch
3 Dimmer switch
4 Turn switch
5 Start switch
6 Light switch
7 Gear position switch
8 Main switch
9 Fuse
0 Rear brake switch
7-6
– +
IGNITION SYSTEM ELEC
EB802000
IGNITION SYSTEM
CIRCUIT DIAGRAM
1
OFF R R
ON Br Br
Br B O
R W
Br R
W W R R
R 9 Y Y/R
0 W W
A O O
B
R
W B W W B
Y/R Y
R Y
B B C
Br B
2 B
W R R W
R
B
L/W Br
R
R R Br
R
4
R L/W
B
6 L/W Y/R
3 7 8
B
B OFF OFF
B
5 L B B L/B
B L/B
Br
Br Br
G Br/W
F
Br
Y
R Br L Ch Dg E D
Br/W
P Br
Y/W Sb Sb Y/W
H P L/B Br/W
W W
TUV WXYZ[
L/W P
(BLACK)
P L/W
(BLACK)
I J K
G/Y G/Y
S PUSH LO N P B B P
R Dg L/B L/B Dg
L Br Br L
B G G B
B Ch Dg
G B Sb W P Y/W L/W
Y G
Sb W P Y/W L/W YY G
Ch Dg
Ch Dg L G/Y
N N
G Q O O MM L
B B L L B
B B Y G/Y
P W W P
B
P Y/W Sb Sb Y/W
Ch
Dg
Ch
Dg
Ch Dg Dg Ch
L/W L/W
B B
B
1 Main switch C Spark plug

2 Fuse
3 Battery
0 AC magneto
A C.D.I. unit
B Ignition coil
7-7
– +
YP802010
TROUBLESHOOTING
IF THE IGNITION SYSTEM FAILS TO OPERATE.

(NO SPARK OR INTEMITTENT SPARK)
Procedure
Check:
1. Spark plug 6. Battery
2. Ignition spark gap 7. Main switch
3. Spark plug cap resistance 8. Pickup coil resistance
4. Ignition coil 9. Wiring connection
5. Fuse (entire ignition system)
NOTE:
• Remove the following parts before trouble- Ignition checker:
shooting. 90890-06754
1)Protector Pocket tester:
2)Front cover (left and right) 90890-03112
3)Center panel (right)
4)Rear cover (right)
• Use the special tools specified in the trouble
shooting section.
YP******
1.Spark plug Standard spark plug:

C7HSA/NGK, U22FS-U/DENSO
• Check the spark plug condition.
• Check the spark plug type.
• Check the spark plug gap. OUT OF SPECIFICATION
Refer to “SPARK PLUG INSPECTION”
Spark plug gap:
0.6 ~ 0.7 mm Repair or replace the spark plug
MEETS
SPECIFICATION
7-8
– +
*
C0NTINUITY
YP******
2.Ignition spark gap

• Disconnect the spark plug cap from the
spark plug.
• Connect the ignition checker 1 as shown.
2 Spark plug
• Turn the main switch to “ON”.
• Check the ignition spark gap a.
• Check the spark by pushing the starter
switch or kicking the kick starter, and
increase the spark gap until a misfire MEETS SPECIFICATION
occurs.
Minimum spark gap:
6 mm
The ignition system is not faulty.
OUT OF
SPECIFICATION
OR NO SPARK
YP******
3.Spark plug cap resistance Tester (+) lead → Spark plug side 1
• Remove the spark plug cap. Tester (–) lead → High tension cord side 2
• Connect the pocket tester (Ω × 1k) to the
spark plug cap.
NOTE:
• When removing the spark plug cap, do not
pull the spark plug cap from high tension
cord.
Remove → Turning counterclockwise.
Connect → Turning clockwise.
• Check the high tension cord when connect-
ing the spark plug cap.
• When connecting the spark plug cap, cut OUT OF SPECIFICATION
the high tension cord about 5 mm.
Spark plug cap resistance:

10 kΩ (20 °C)
Replace the spark plug cap.
MEETS
SPECIFICATION
7-9
– +
* Tester (+) lead → Orange Terminal 1
C0NTINUITY
Tester (–) lead → Black Terminal 2
YP******
4.Ignition coil resistance

• Disconnect the ignition coil connector from
the ignition coil.
• Connect the pocket tester (Ω × 1) to the
ignition coil.
• Check if the primary coil has the specified
resistance.
Primary coil resistance:
0.32 ~ 0.48 Ω (20 °C)
Tester (+) lead → Spark plug lead 1
Tester (–) lead → Orange Terminal 2
• Connect the pocket tester (Ω × 1k) to the

ignition coil.
• Check the secondary coil has the specified
resistance. OUT OF SPECIFICATION
Secondary coil resistance:
5.68 ~ 8.52 kΩ (20 °C)
BOTH MEET Replace the ignition coil.

SPECIFICATION
YP******
5.Fuse NO CONTINUITY
Refer to “SWITCH INSPECTION” section.
CONTINUITY
YP******
Replace the fuse.
6.Battery
• Check the battery condition. INCORRECT
Refer to “BATTERY INSPECTION” section
in CHAPTER 3.
Specific gravity: • Refill the battery fluid.
1.280 at 20 °C
• Clean battery terminals.
CORRECT • Recharge or replace the battery.
*
7 - 10
– +
*
C0NTINUITY
YP******
NO CONTINUITY
7.Main switch
CONTINUITY Replace the main switch.

YP******
8.Pickup coil resistance

• Disconnect the staotr coil assembly coupler
from the wireharness.
pickup coil coupler.
Tester (+) lead → White Terminal 1 B Y W R W
Tester (–) lead → Red Terminal 2

2 1
• Check the pickup coil has the specified
Pickup coil resistance:
248 ~ 372 Ω (20 °C)
MEETS Replace the stator coil assembly.

SPECIFICATION
YP******
9.Wiring connection
POOR CONNECTIONS
• Check the connection of the entire ignition
system.
Refer to “CIRCUIT DIAGRAM”.
Correct.
CORRECT
Replace the C.D.I. unit.
7 - 11
– +
ELECTRIC STARTING SYSTEM ELEC
EB80300
ELECTRIC STARTING SYSTEM

CIRCUIT DIAGRAM
1
OFF R R
ON Br Br
Br B O
R W
Br R
W W R R
R 9 Y Y/R
0 W W
A O O
B
R
W B W W B
Y/R Y
R Y
B B C
Br B
2 B
W R R W
R
B
L/W Br
R
R R Br
R
4
R L/W
B
6 L/W Y/R
3 7 8
B
B OFF OFF
B
5 L B B L/B
B L/B
Br
Br Br
G Br/W
F
Br
Y
R Br L Ch Dg E D
Br/W
P Br
Y/W Sb Sb Y/W
H P L/B Br/W
W W
TUV WXYZ[
L/W P
(BLACK)
P L/W
(BLACK)
I J K
G/Y G/Y
S PUSH LO N P B B P
R Dg L/B L/B Dg
L Br Br L
B G G B
B Ch Dg
G B Sb W P Y/W L/W
Y G
Sb W P Y/W L/W YY G
Ch Dg
Ch Dg L G/Y
N N
G Q O O MM L
B B L L B
B B Y G/Y
P W W P
B
P Y/W Sb Sb Y/W
Ch
Dg
Ch
Dg
Ch Dg Dg Ch
L/W L/W
B B
B
1 Main switch
2 Fuse
3 Battery
4 Starter relay
5 Starter motor
7 Start switch
7 - 12
– +
YP803020
TROUBLESHOOTING
IF THE STARTER MOTOR FAILS TO OPERATE.
Procedure
Check:
1. Fuse 5. Main switch
2. Battery 6. Start switch
3. Starter motor 7. Wiring connection (entire starting system)
4. Starter relay
NOTE:
• Remove the following parts before trouble- Pocket tester:
shooting. 90890-03112
1)Protectot
2)Front cover (left and right)
4)Footrest
5)Engine skid plate
• Use the special tools specified in the trouble
shooting section.
YP******
NO CONTINUITY
1. Fuse
CONTINUITY Replace the fuse.

YP******
2. Battery
• Check the battery condition.
in CHAPTER 3.
INCORRECT
Specific gravity:
1.280 at 20 °C
CORRECT
• Refill the battery fluid.
* • Clean battery terminals.
• Recharge or replace the battery.
7 - 13
– +
*
C0NTINUITY
YP******
3. Starter motor *
• Connect the battery positive terminal 1 WARNING
and starter motor cable 2 using a jumper ● A wire used as a jumper lead must have
lead 3 . the equivalent capacity as that of the bat-
*
• Check the starter motor operation. tery lead or more, otherwise it may burn.
● This check is likely to produce sparks, so
be sure that no flammable gas or fluid is
in the vicinity.
DOES NOT MOVE
Repair or replace the starter motor.
MOVES
YP******
4. Starter relay
3
• Disconnect the relay unit coupler from the
wireharness.
• Connect the pocket tester (Ω × 1) and bat-
tery (12 V) to the relay unit coupler termi- /
nals.
2 1
Battery (+) lead → Brown terminal 1 4
Battery (–) lead → Blue/White terminal 2
• Check the starter relay for continuity. NO CONTINUITY
Tester (+) lead → 3 terminal
Tester (–) lead → 4 terminal
CONTINUITY Repair the starter relay.
YP******
5. Main switch NO CONTINUITY

CONTINUITY
Replace the main switch.
*
7 - 14
– +
*
C0NTINUITY
YP******
6. Start switch NO CONTINUITY
CORRECT
Replace the right handlebar switch.
YP******
POOR CONNECTION
7. Wiring connection
• Check the connections of the entire starting
system.
Refer to “CIRCUIT DIAGRAM”. Correct.
7 - 15
– +
STARTER MOTOR

Starter motor removal Remove the parts in the order listed.
Drain the engine oil Refer to “ENGINE OIL REPLACEMENT”
Footrest assembly 1
Refer to “ENGINE OVERHAUL” section
Engine guard 1
in CHAPTER 4.
1 Starter motor 1
procedure.
Starter motor disassembly Remove the parts in the order listed.
1 Front bracket 1
2 Gasket 1
Refer to “Starter motor assembly” sec-
3 Brush holder set 1
tion.
4 Armature ass’y 1
5 Stator ass’y 1
procedure.
7 - 16
– +
YP803034
INSPECTION AND REPAIR
1. Inspect:
• Commutator
Dirt → Clean it with #600 grit sandpaper.
2. Measure:
• Commutator diameter a
Commutator wear limit:

16.0 mm
Out of specification → Replace the starter

motor
3. Measure:
• Mica undercut a
Mica undercut:
0.6 mm
Out of specification → Scrape the mica to

the proper value (a hacksaw blade can be
ground to fit).
NOTE:
The mica insulation of the commutator must be
undercut to ensure proper operation of com-
mutator.
4. Inspect:
• Armature coil resistances
(installation/continuity)
Defects → Replace the starter motor.
If commutator is dirty, clean it with sandpa-
per.
Good
condition
Bad condition
È × ×
É × ×
: Continuity
× : No continuity
Bad condition → Replace.
5. Measure:
• Brush length a
Brush length wear limit:

3.5 mm
7 - 17
– +
6. Measure:
• Brush spring force
Fatigue/out of specification → Replace as a
set.
Brush spring force:

6.86 ~ 7.84 N (700 ~ 800 g)
YP******
ASSEMBLY
Reverse the “Removal” procedure.
1. Install:
• Brush holder
2. Install:
• Shims
• Armature coil 1
3. Install:
• Ring 1 New
• Stator ass’y 2
• Front bracket 3
NOTE:
• Apply molybdenum grease lightly on to the
bearings of the starter motor.
• Align the match marks on the yoke with the
match marks on the brackets.
7 - 18
– +
CHARGING SYSTEM ELEC
YP804000
CHARGING SYSTEM
CIRCUIT DIAGRAM
1
OFF R R
ON Br Br
Br B O
R W
Br R
W W R R
R 9 Y Y/R
0 W W
A O O
B
R
W B W W B
Y/R Y
R Y
B B C
Br B
2 B
W R R W
R
B
L/W Br
R
R R Br
R
4
R L/W
B
6 L/W Y/R
3 7 8
B
B OFF OFF
B
5 L B B L/B
B L/B
Br
Br Br
G Br/W
F
Br
Y
R Br L Ch Dg E D
Br/W
P Br
Y/W Sb Sb Y/W
H P L/B Br/W
W W
TUV WXYZ[
L/W P
(BLACK)
P L/W
(BLACK)
I J K
G/Y G/Y
S PUSH LO N P B B P
R Dg L/B L/B Dg
L Br Br L
B G G B
B Ch Dg
G B Sb W P Y/W L/W
Y G
Sb W P Y/W L/W YY G
Ch Dg
Ch Dg L G/Y
N N
G Q O O MM L
B B L L B
B B Y G/Y
P W W P
B
P Y/W Sb Sb Y/W
Ch
Dg
Ch
Dg
Ch Dg Dg Ch
L/W L/W
B B
B
2 Fuse
3 Battery
9 Rectifier/regulator
0 AC magneto
7 - 19
– +
YP804010
TROUBLESHOOTING
IF THE BATTERY IS NOT CHARGED
Procedure
Check:
1. Fuse 4. Charging coil resistance
2. Battery 5. Wiring system (entire charging system)
3. Charging voltage
NOTE:
• Remove the following parts before trouble- Engine tachometer:
shooting. 90890-03113
Pocket tester:
1)Protector
90890-03112
2)Front cover (left)
4)Center cover
• Use the special tools specified in the trouble-
shooting section.
YP******
1. Fuse NO CONTINUITY
YP******
2. Battery INCORRECT

in CHAPTER 3. • Refill the battery fluid.
Specific gravity: • Clean battery terminals.
1.280 at 20 °C • Recharge or replace the battery.
CORRECT
7 - 20
– +
*
C0NTINUITY
YP******
3. Charging voltage
• Connect the engine tachometer to the
spark plug lead.
• Connect the pocket tester (DC 20 V) to the
battery.
Tester (+) lead → Battery (+) terminal 1
Tester (–) lead → Battery (–) terminal 2
• Measure the battery terminal voltage.
• Start the engine and accelerate to about
5,000 r/min.
• Check the terminal voltage.
MEETS SPECIFICATION
Charging voltage:
14.5 V at 5,000 r/min
NOTE: The charging circuit is not faulty.

Use a fully charged battery. Replace the battery.
OUT OF
SPECIFICATION
7 - 21
– +
*
YP******
4. Charging coil resistance

• Remove the stator coil assembly coupler
from wireharness.
charging coil.
Tester (+) lead → White terminal 1
Tester (–) lead → Black terminal 2
B Y W R W
2 1 OUT OF SPECIFICATION
• Measure the charging coil resistance.

Charging coil resistance:
0.26 ~ 0.40 Ω (20 °C) Replace the stator coil assembly.
MEETS
SPECIFICATION
YP******
• Check the entire charging system for con- POOR CONNECTION
nections.
Refer to “CIRCUIT DIAGRAM” section.
CORRECT Correct.
Replace the rectifier/regulator.
7 - 22
– +
LIGHTING SYSTEM ELEC
EB804000
LIGHTING SYSTEM
CIRCUIT DIAGRAM
1
OFF R R
ON Br Br
Br B O
R W
Br R
W W R R
R 9 Y Y/R
0 W W
A O O
B
R
W B W W B
Y/R Y
R Y
B B C
Br B
2 B
W R R W
R
B
L/W Br
R
R R Br
R
4
R L/W
B
6 L/W Y/R
3 7 8
B
B OFF OFF
B
5 L B B L/B
B L/B
Br
Br Br
G Br/W
F
Br
Y
R Br L Ch Dg E D
Br/W
P Br
Y/W Sb Sb Y/W
H P L/B Br/W
W W
TUV WXYZ[
L/W P
(BLACK)
P L/W
(BLACK)
I J K
G/Y G/Y
S PUSH LO N P B B P
R Dg L/B L/B Dg
L Br Br L
B G G B
B Ch Dg
G B Sb W P Y/W L/W
Y G
Sb W P Y/W L/W YY G
Ch Dg
Ch Dg L G/Y
N N
G Q O O MM L
B B L L B
B B Y G/Y
P W W P
B
P Y/W Sb Sb Y/W
Ch
Dg
Ch
Dg
Ch Dg Dg Ch
L/W L/W
B B
B
8 Light switch L Tail/brake light

9 Rectifier/regulator O Headlight
0 AC magneto T Meter light
J Dimmer switch U High beam indicator light
7 - 23
– +
YP805010
TROUBLESHOOTING
IF THE HEADLIGHT, HIGH BEAM INDICATOR LIGHT,

TAILLIGHT AND/OR METER LIGHT FAIL TO COME ON.
Procedure
Check:
1. Lighting coil resistance 3. Dimmer switch
2. Light switch 4. Wiring connection (entire lighting system)
NOTE:
shooting. 90890-03112
1)Headlight cover
2)Protector
3)Front cover (left)
4)Tray
• Use the special tools specified in the trouble-
shooting section.
YP******
1. Lighting coil resistance

• Remove the stator coil assembly coupler
from wireharness.
lighting coil.
Tester (+) lead → Yellow terminal 1
B Y W R W
2 1 OUT OF SPECIFICATION
• Measure the lighting coil resistance.

Lighting coil resistance:
0.20 ~ 0.30 Ω (20 °C) Replace the stator coil assembly.
MEETS
SPECIFICATION
7 - 24
– +
*
C0NTINUITY
YP******
NO CONTINUITY
2. Light switch
CONTINUITY Replace the right handlebar switch.

YP******
NO CONTINUITY
3. Dimmer switch
CONTINUITY Replace the left handlebar switch.
YP******
POOR CONNECTIONS
• Check the connections of the entire lighting
system.
Refer to “WIRING DIAGRAM”. Correct.
CORRECT
Check the condition of each of the lighting

system’s circuits.
Refer to “LIGHTING SYSTEM CHECK”.
YP805020
LIGHTING SYSTEM CHECK
1. If the headlight and the high beam indicator light fail to come on.
NO CONTINUITY
1. Bulb and bulb socket
CONTINUITY Replace the bulb and/or bulb socket.
7 - 25
– +
*
C0NTINUITY
2. Voltage
• Connect the pocket tester (AC 20 V) to the
headlight and high beam indicator light
connectors.
È When the dimmer switch is on low beam.
É When dimmer switch is on high beam.
Headlight:
Tester (+) lead → Green 1 or Yellow 2 lead
Tester negative (–) lead → Black 3 lead
High beam indicator light:
Tester (+) lead → Yellow 4 lead
Tester (–) lead → Black 5 lead
• Start the engine.
• Turn the light switch to on position.
• Turn the dimmer switch to low beam or
high beam.
• Check for voltage (12 V) on the lead at bulb
socket connectors. OUT OF SPECIFICATION
MEETS
SPECIFICATION
Replace the rectifier/regulator.
This circuit is not faulty.
YP805021
2. If the meter light fails to come on.
1. Bulb and bulb socket NO CONTINUITY
CONTINUITY
Replace the bulb and/or bulb socket.
7 - 26
– +
*
C0NTINUITY
2. Voltage
bulb socket coupler.
Tester (+) lead → Blue terminal 1
OUT OF SPECIFICATION
• Turn the lights switch to on position.
• Check the voltage (12 V) of the leads on
the bulb socket connector. Replace the rectifier/regulator.
MEETS
SPECIFICATION
YP805022
3. The taillight fails to come on.
NO CONTINUITY
CONTINUITY
* Replace the bulb and/or bulb socket.
7 - 27
– +
*
C0NTINUITY
2. Voltage
bulb socket couper.
Tester (+) lead → Blue terminal 1
• Turn the light switch to on position.
• Check the voltage (12 V) on the bulb
socket connector.
Peplace the rectifier/regulator.
MEET
SPECIFICATION
Replace the bulb and/or bulb socket.
7 - 28
– +
SIGNAL SYSTEM ELEC
EB806000
SIGNAL SYSTEM
CIRCUIT DIAGRAM
1
OFF R R
ON Br Br
Br B O
R W
Br R
W W R R
R 9 Y Y/R
0 W W
A O O
B
R
W B W W B
Y/R Y
R Y
B B C
Br B
2 B
W R R W
R
B
L/W Br
R
R R Br
R
4
R L/W
B
6 L/W Y/R
3 7 8
B
B OFF OFF
B
5 L B B L/B
B L/B
Br
Br Br
G Br/W
F
Br
Y
R Br L Ch Dg E D
Br/W
P Br
Y/W Sb Sb Y/W
H P L/B Br/W
W W
TUV WXYZ[
L/W P
(BLACK)
P L/W
(BLACK)
I J K
G/Y G/Y
S PUSH LO N P B B P
R Dg L/B L/B Dg
L Br Br L
B G G B
B Ch Dg
G B Sb W P Y/W L/W
Y G
Sb W P Y/W L/W YY G
Ch Dg
Ch Dg L G/Y
N N
G Q O O MM L
B B L L B
B B Y G/Y
P W W P
B
P Y/W Sb Sb Y/W
Ch
Dg
Ch
Dg
Ch Dg Dg Ch
L/W L/W
B B
B
1 Main switch I Horn switch S Fuel gauge Z 3rd gear position indi-
2 Fuse K Turn switch V Turn indicator light cator light
3 Battery L Tail/brake light W Neutral indicator light [ 4th gear position indi-
D Rear brake switch M Rear flasher light X 1st gear position indicator light
E Front brake switch N Front flasher light cator light
F Flasher relay P Gear position switch Y 2nd gear position indi-
G Horn Q Fuel sender cator light
7 - 29
– +
SIGNAL SYSTEM ELEC
YP806010
TROUBLESHOOTING
IF THE FLASHER LIGHT, BRAKE LIGHT AND/OR INDICATOR LIGHT

FAIL TO COME ON. IF THE HORN FAILS TO SOUND.
Procedure
Check:
1. Fuse 4. Wiring connection (entire signal system)
2. Battery
3. Main switch
NOTE:
shooting. 90890-03112
1)Headlight cover
2)Protector
3)Front cover (left and right)
4)Tray
5)Center cover
• Use the special tools in the troubleshooting
section.
YP******
NO CONTINUITY
1. Fuse
YP******
2. Battery INCORRECT

in CHAPTER 3. • Refill the battery fluid.
Specific gravity: • Clean battery terminals.
1.280 at 20 °C • Recharge or replace the battery.
CORRECT
YP******
3. Main switch NO CONTINUITY
CONTINUITY Replace the main switch.
7 - 30
– +
SIGNAL SYSTEM ELEC
*
C0NTINUITY
4. Wireharness POOR CONNECTION

• Check the connections of the entire signal
system.
Refer to “CIRCUIT SYSTEM WIRING DIA-
GRAM” section. Correct.
CORRECT
Check condition of each of the signal sys-

tem’s circuits.
Refer to “SIGNAL SYSTEM CHECK” sec-
tion.
7 - 31
– +
SIGNAL SYSTEM ELEC
YP806020
SIGNAL SYSTEM CHECK
1. If the horn fails to sound.
1. Horn switch NO CONTINUITY
2. Voltage
horn lead.
Tester (+) lead → Brown terminal 1
Tester (–) lead → Frame ground
• Turn the main switch to on.
• Check for voltage (12 V) on the “Brown”
lead at the horn terminal.
MEETS
SPECIFICATION
The wiring circuit from the main switch to the
horn is faulty. Repair.
3. Horn
horn at the “Pink” terminal.
Tester (+) lead → Pink terminal 1
• Check for voltage on the “Pink” lead to
NO CONTINUITY
frame ground.
CONTINUITY
Replace the horn.

Adjust or replace horn.
7 - 32
– +
SIGNAL SYSTEM ELEC
YP806022
2. If the brake light fails to come on:
NO CONTINUITY
NO CONTINUITY
2. Brake switch (front/rear)
CONTINUITY Replace brake switch.
3. Voltage
bulb socket coupler.
Tester (+) lead → Yellow terminal 1
• The brake lever (or brake pedal) is pulled in
(down).
• Check for voltage (12 V) of the “Yellow” 4. Wiring connection
lead on the bulb socket connector.
• Wiring circuit from the main switch to the
MEETS bulb socket connector is faulty. Repair.
SPECIFICATION Refer to “SIGNAL SYSTEM WIRING DIA-
GRAM”.
7 - 33
– +
SIGNAL SYSTEM ELEC
YP806023
3. If the flasher light and/or turn indicator light
fails to blink.
NO CONTINUITY
NO CONTINUITY
2. Turn switch
3. Voltage
flasher relay coupler.
Tester (+) lead → Brown terminal 1
• Check for voltage (12 V) of the “Brown” 1
lead at the flasher relay terminal.
MEETS
SPECIFICATION
The wiring circuit from main switch to flasher
relay connector is faulty. Repair.
4. Flasher relay
flasher relay coupler.
Tester (+) lead → Brown/White terminal 1
• Check for voltage (12 V) on the “Brown/
White” lead at the flasher relay terminal.
MEETS
SPECIFICATION
* The flasher relay is faulty. Replace.
7 - 34
– +
SIGNAL SYSTEM ELEC
*
C0NTINUITY
5. Voltage
bulb socket connector.
At flasher light (left)
Tester (+) lead → Chocolate lead 1
At flasher light (right)
Tester (+) lead → Dark green lead 2
Tester (–) lead → Black terminal 3 OUT OF SPECIFICATION
• Turn the turn switch to left or right.
• Check for voltage (12 V) on the “Choco- Wiring connection
late” lead and “Dark green” at the flasher
light terminal. Wiring circuit from the turn switch to bulb
socket connector is fault. Repair.
MEETS Refer to “CIRCUIT DIAGRAM”.
SPECIFICATION
YP806027
4. If the fuel gauge fails to operate.
1. Fuel sender 2 1
• Disconnect the fuel sender coupler from B G
the fuel sender.
• Remove the fuel sender from the fuel tank.
• Connect the pocket tester (Ω × 10) to the 3
fuel sender coupler lead.
Tester (+) lead → Green terminal 1
Tester (–) lead → Black terminal 2 4
• Check the fuel sender for specificated

Specificated
Float position
resistance
UP 3 4 ~ 10 Ω
DOWN 4 90 ~ 100 Ω Replace the fuel sender.
BOTH MEET
SPECIFICATION
7 - 35
– +
SIGNAL SYSTEM ELEC
*
C0NTINUITY
2. Voltage
F

E
meter assembly coupler.
Tester (+) lead → Brown terminal 1 1
Br L L Br
Ch Dg Dg Ch
G B B G
• Check for voltage (12 V) of the “Brown”
lead on the fuel sender lead.
MEETS Check the connection of the entire signal
SPECIFICATION system.
Refer to “CIRCUIT DIAGRAM”.
3. Fuel gauge
• Connect the fuel sender to wireharness. NOTE:
• Move the float to “UP” 1 or “DOWN” 2. Before reading the meter, stay put the float for
more than three minutes respectively at “UP”
or “DOWN”.

• Check the fuel gauge needle moves “F” or
“E”. DOES NOT MOVE
Float position Needle moves
Float “UP” 1 “F”
Float “DOWN” 2 “E” Replace the fuel gauge.
MOVES
7 - 36
TRBL
TROUBLESHOOTING SHTG
TROUBLESHOOTING
TROUBLESHOOTING
ELECTRICAL SYSTEM
8-1
TRBL
COMPRESSION SYSTEM
8-2
TRBL
INTAKE AND EXHAUST SYSTEM
8-3
YAMAHA MOTOR CO., LTD.
2500 SHINGAI IWATA SHIZUOKA JAPAN
T105SE WIRING DIAGRAM
1 Main switch
1 2 Fuse
OFF R
Br
R
Br
3 Battery
4 Starter relay
ON
Br
R
B
W
O
5 Starter motor
Br R
6 Handlebar switch
7 Start switch
W W
0 R R
A 8 Light switch
R 9 Y Y/R W W
O O
B 9 Rectifier/regulator
R
W B W
Y/R
W
Y
B
0 AC magneto
R Y
B B C A C.D.I. unit
Br B
2 B
W R R W
B Ignition coil
R C Spark plug
B D Rear brake switch
L/W Br
E Front brake switch
F Flasher relay
R
R R Br
G Horn
R
4
R L/W H Handlebar switch (left)
B
6 L/W Y/R
I Horn switch
3 7 8
B J Dimmer switch
B OFF
START
OFF
ON Y/R L/R L/W Y/R
K Turn switch
B
5 L B B L/B L Tail/brake light
M Rear flasher light
B L/B
N Front flasher light
O Headlight
P Gear position switch
Br Q Fuel sender
Br Br R Meter assembly
G S Fuel gauge
T Meter light
Br/W
Br
F
Y U High beam indicator light
R D V Turn indicator light
Br L Ch Dg
Br/W E
P Br W Neutral indicator light
Y/W Sb Sb Y/W
H P L/B Br/W X 1st gear position indicator light
W W
TUV WXYZ[ Y 2nd gear position indicator light
L/W P P L/W
I J K
(BLACK) (BLACK)
G/Y G/Y Z 3rd gear position indicator light
S PUSH LO N P B
Dg L/B
B P
L/B Dg
[ 4th gear position indicator light
R
L Br Br L
B G G B
B Ch Dg
G B Sb W P Y/W L/W
Y G
Sb W P Y/W L/W YY G
Ch Dg
Ch Dg L G/Y
N N
G Q O O MM L
B B L L B
B B Y G/Y
P W W P
B
P Y/W Sb Sb Y/W
Ch
Dg
Ch
Dg
Ch Dg Dg Ch
L/W L/W
B B
B
COLOR CODE
B............ Black Sb.......... Sky blue L/B .........Blue/Black
Br .......... Brown P............ Pink L/R .........Blue/Red
Ch ......... Chocolate R ........... Red L/W ........Blue/White
Dg ......... Dark green Y............ Yellow Y/R.........Yellow/Red
G ........... Green W........... White Y/W ........Yellow/White
L ............ Blue Br/W ...... Brown/White
O ........... Orange G/Y........ Green/Yellow

T105se Manual de Servicio

Uploaded by

Copyright:

Available Formats

T105se Manual de Servicio

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

T105se Manual de Servicio

Uploaded by

Copyright:

Available Formats

T105SE

HOW TO USE THIS MANUAL

Illustrated symbols G to L in the exploded

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

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

SPECIAL TOOLS ........................................................................................... 1-5

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

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

CONVERSION TABLE ................................................................................. 2-14

GENERAL TIGHTENING TORQUE SPECIFICATIONS ..............................2-14

LUBRICATION POINT AND GRADE OF LUBRICANT ...............................2-15

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

INTRODUCTION ............................................................................................. 3-1

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

COVER AND PANEL .....................................................................................3-3

CHASSIS ...................................................................................................... 3-16

ENGINE REMOVAL .......................................................................................4-1

CYLINDER HEAD ........................................................................................... 4-4

CAMSHAFT AND ROCKER ARMS ............................................................. 4-10

VALVES AND VALVE SPRINGS .................................................................4-14

CYLINDER AND PISTON ............................................................................. 4-20

CLUTCH ....................................................................................................... 4-26

KICK STARTER ........................................................................................... 4-35

SHIFT SHAFT ...............................................................................................4-38

AC MAGNETO AND STARTER CLUTCH ...................................................4-45

CRANKCASE AND CRANKSHAFT ............................................................ 4-49

TRANSMISSION ........................................................................................... 4-53

CARBURETOR ............................................................................................... 5-1

FRONT WHEEL AND BRAKE DISC .............................................................. 6-1

FRONT BRAKE ............................................................................................ 6-15

FRONT FORK ...............................................................................................6-28

STEERING .................................................................................................... 6-39

REAR SHOCK ABSORBER AND SWINGARM ..........................................6-42

SEAT, FUEL TANK AND FUEL COCK .......................................................6-44

ELECTRICAL COMPONENTS ....................................................................... 7-1

CIRCUIT DIAGRAM .......................................................................................7-2

SWITCH INSPECTION ................................................................................... 7-4

IGNITION SYSTEM ........................................................................................7-7

ELECTRIC STARTING SYSTEM .................................................................7-12

CHARGING SYSTEM ...................................................................................7-19

LIGHTING SYSTEM .....................................................................................7-23

SIGNAL SYSTEM ......................................................................................... 7-29

TROUBLESHOOTING .................................................................................... 8-1

FRAME SERIAL NUMBER

ENGINE SERIAL NUMBER

4. When disassembling the machine, always

GASKETS, OIL SEALS AND O-RINGS

LOCK WASHERS/PLATES AND COTTER

BEARINGS AND OIL SEALS

3. Connect and disconnect the connector two

7. Check for continuity with a tester.

This tool is used to installing the oil seal.

This tool is used to installing the oil seal.

This tool is used for removing the rotor.

Exhaust “A” 25.286 ~ 25.386 mm 25.260 mm

Valve adjuster locknut Nut M5 2 7 0.7

Timing chain tensioner

Neutral switch Screw M5 2 4 0.4

Item Standard Limit