© YAMAHA NOOO Service ManualINDEX This manual has been combined with previous service manuals to provide complete service information for XT 550 K Please read and give special consideration to the “NOTICE” on the preceding page for your safety. | XT 550 K SUPPLEMENTARY / | XT 550 J SERVICE MANUAL BiNOTICE This manual has been written by Yamaha Motor Gompany for use by Authorized Yamaha Dealers and their qualified mechanics. In light of this purpose it nas been assumed that certain basic mechanical precepts and procedures inherent to our products are already known and understood by the reader. Without such basic knowledge, repairs or service to this mode) may render the motorcycle unsafe, and for this reason we must advise that all repairs and/or service be performed by an Authorized Yamaha Dealer who is in possession of the requisite basic product knowledge, This Research, Engineering and Overseas Service Department of Yamaha are continually striving to further improve all models manufactured by the company. Modifications are therefore inevitable and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha Dealers and will, where applicable, appear in future editions of this manual. Particularly important information is distinguished in this manual by the following notations: NOTE: A NOTE provides key information to make procedures easier or clearer. CAUTION: A CAUTION indicates special procedures that must be followed to avoid damage to the machine. WARNING: A WARNING indicates special procedures that must be followed to avoid injury to a machine operator or person inspecting or repairing the machine. XT550K SERVICE MANUAL 1st Edition - April 1983 JEM 0151/87 nd Printing - February 1985, ALL RIGHTS RESERVED BY YAMAHA MOTOR CORPORATION. 11S A, ‘CYPRESS, CALIFORNIA 90830 LIT-11616-XT-5tBeing a Yamaha owner, you obviously prefer a quality product. geéen.u.iIne adj. 1. Real 2. Authentic, not artificial 3. Yamaha. GENUINE YAMAHA PaRTS & ACCESSORIES Don’t compromise the quality and performance of your Yamaha with off-brand alternatives. You'll be getting exactly what you’re paying for.© YAMAHA NTOOOK ollpplementary pervice ManualFOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the XTS50K. For complete information on service procedure, it is necessary to use this Sup- plementary Service Manual together with the following manuals: ‘TS5OJ Service Manual (LIT-11616-08-00) ‘SERVICE DEPT. INTERNATIONAL DIVISION YAMAHA MOTOR CO., LTD. NOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to put an entire mechanic's education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on Yamaha motorcycles have a basic understanding of the mechanical concepts and procedures in- herent to motoreycle repair technology, Without such knowledge, attempted repairs or service to this mode! may render it unfit for us® and/or unsafe. ‘This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to ensure that the motorcycle will operate as designed. If there is any question about a service procedure it is imperative that you contact @ Yamaha dealer before continuing. Before attempting any service, check with your Yamaha dealer for any service information changes that apply to this model This policy is intended to provide the customer with the most satisfaction from his motorcycle and to conform with federal environmental quality objectives. Yamaha Motor Company, Ltd. is continually striving to further improve all models manufactured by Yamaha, Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual, = Starting Serial Number | xrosox | SIASYIOD-DATOOTOTPERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and ad- justments. These preventive maintenance procedures, if followed, will ensure more reliable vehi- cle operation and a longer service life. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service and to new vehicles that are being prepared for sale. All service technicians should be familiar with this entire chapter. MAINTENANCE INTERVALS CHARTS Proper periodic meintenance is important. Especially important are the maintenance services related to emissions control. These controls not only function to ensure cleaner air but are also vital ta proper engine operation and maximum performance. In the following maintenance tables, the services related to emissions control are grouped separately. PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM. hell saa onan ee sie oma, | feowea || coun | ano \Tomecnnace | Sesenmaacns | 2 We = lssian onc corti sinn,—] a oT awe repice aera ¥3. 000. 8.900 ‘Cancase venti oe & system mage:repincait necessary “rec ot how or caste on Samay, 4 Fain ° rence mocmenry Termine ghee 5 | Einav sytem | rerdoc'guata eh t nocomary ° [mee | Scatter | 2 [|eGENERAL MAINTENANCE/LUBRICATION aw bein Thewshe bey a sonia a8 aoe | samen | 40orm | accom | veo woo | 30mm | ascom | eox0m | aco | ertmort | or?monns | ocemont | omer | 2tmonhe : emvowore | oreatrome | 0 ° ° Setrvcraning | hp Stmotorot | Pasar 2 Jove | owntsbe vane « ° ° ° ais 105m icon wavoetter | vesaea. a 3 |Actter —|rmatbevamnes | Yamabinerae | ° ° Sssononswanon | Heron ‘tatoo ° ° ° - o fe 2 6 Jonechan | trvnstanboe | the SAE vnys001m 200m rowomearot | | omotans | sgoenanivne | Nerabnchenend | 5 ° immereabe | mowapiy ace forem — [Asovgwme | Lthimsou bse 3 & 8 |omeranon | at vee | eisonse |Asgcnentne | Novanecnanent o/s chenioe | einer SAE ° ° re ‘ano ‘ornenn._| we | Seams ‘oat cae nd 10 Jove | Aesreninioe | Sours ° ° ates | soreness rontton | tmRCOMPIetY; | Yamahe ore o {fe sro atom | ° smecrcaton | eanarnt ea manos | ming | mem | edumangnt | 12 [oswmpena [Bowram.mesr, | secneang | ° ° rom i ‘msm od Pes bearings - — a_i ty [vee | trsmoctte . " “i motos | non epacdl [| weet saree (SEE - a ° |eouercanen “ahaha nd | - 15 Jimwepwer | AamreNantioe | cater SAE eae | onnomorr otPRIMARY GEARS AND CLUTCH [Em (08 m bo, 5a RO] D sen ‘ [Ronn Om bg, 8 FB] FRICTION PLATE ~~ / TRee ata tock Waser WAVE PLATE — THausT Pare — PRIMARY DRIVEN GEAR COMPLETE. Lock wasHER \ Joint S PRIMARY DAVE GEAR sTAAIGHT Key [ (WASHER ~ ou sea CyuNomcaL aE Vis) Se A [2.Nm 2 mag, 87 WII]CLUTCH Push ever T Push rod? Man ae Balt “Thrust wave pate Pushvod™ Lockaut CAUTION: When installing the friction plates, pay careful attention to the inside diameter. 1. The friction plate with the larger of the inside diameters must be install- ed in the 2nd and last places. 2. The wave plate must be placed on the inside of the 2nd friction pla pom aes Spee. NE mm = 3.0 mm — " {8.57 in) (0.12 in) Treat isan 28m plate (883-00) ©KICK SHAFT ASSEMBLY Align the punched rark on the kick shatt | with this line on the ratchet wheel 6 . “Press the decomp. cam JQ on to the kick shat 1 Kick SHAFT KICK GEAR’ susH PLATE WASHER ciRCLIP RATCHET WHEEL COMPRESSION SPRING SPRING COVER cimcue DECOMP CaM TORSION SPRINGCARBURETION CARBURETOR SECONDARY CARB. CAP CABLE CONNECTOR 3 a} ba Jer NEEDLE eg | LP asus 3 % 4 —-SeconDARY THROTTLE VALVE OAR PLATE oleh ___— er NeeDLe . PRIMARY THROTTLE VALVE ‘SECONDARY NEEDLE Jer SECONDARY _ MAIN JET SYNCHRONIZING — ‘SCREW 6 xseme & } eg é B Sf Ng A ~) puno Jer iene : s PILOT JET aay PRIMARY NEEDLE JET PRIMARY MAIN JET . eee Bp im rom RS Q 3 b ‘Lines indicate straightedge measurement Cylinder: - Bore Size 92.0°2° mm (3.63 ind Taper Limit +<0.005 mm (0.0002 in)> Camshaft Drive Method Chain (Left) ‘Cam Cap Inside Diameter | 923°3' mm (@0.91 +0.0008in) Camshaft Outside Diameter ae noe agg at age ‘Camshaft Runout Limit ‘Cam Chain Type/ Number of Links Cam Chain Adjustment Method Rocker Arm/ Rocker Arm Shaft Bearing Inside Diameter Shaft Outside Diameter Arm-to-shaft Clearance Valve, Valve Seat, Valve Guide Valve Clearance (Cold? IN. x. 023-383 mm (00 91-288in) <0.020 ~ 0.084 mm (0,0008 ~ 0.002in)> 36.55 = 0.05mm (1.44 = 0.002in) 36,40 mm (1.4331 in)> 30.12 = 0.05 mmm (1.19 = 0.002in1 <28.97 mm (1.1405 in)> | 6.55 mm 10.26 in) | 36.72 + 0.05mm (1.45 +0.002in) | 38.57 mm (1.4388 n)> 30.14 0.05mm (1.19 + 0.002in} <28,99 mm (1.1413;n)> 6.72 mm{0.26ind <0.03mm (0.001 in)> 75.010/126 Links Automatic 12°90" mm (0.473% in} <12.05 mm (0.47 in)> 12 328mm (0.47388 int <11.95 mm (0.47 in}> (0.008 ~ 0.042 mm (0.0004 ~ 0.002 in} (0.05 ~ 0.10 mm (0.002 ~ 0.004 in) 0.12 ~ 0.17 mm (0.006 ~ 0.007 in} =nModel XTSBOK Valve Dimensions \ ye Gan “A” Head Dia. IN. x. 8" Face Width 1N, ex. “0” Seat Limit Width IN, ex. “'D” Margin Thickness Limit IN EX. ‘Stem Outside Diameter IN. EX. Guide Inside Diameter IN. EX. Stem-to-quide Clearance IN EX. ‘Stem Runout Limit Face Widtn Free Length Inner Spring IN. EX. Outer Spring IN. x ‘Seat Width Margin Thickress 36 +0.1 mm (1,42 + 0,004 in) 30 =0.1 mm (1.18 0.004 in} 2.26 mm {0.09 in) 2.26mm (0.09 in} 1,1 0.1mm (0.04 +0.004 in) 41.1.0, 1 mm {0.04 + 0.004 in) 1.2 + 0.2mm {0.06 + 0.008 in) 1-£0.2 mm (0,04 + 0,008 in) | 73Bimm (0.28-38ind 7338 mm (0.283%) | 19% mm (0.276°3°% ink <7.10 mm (0.280 in)> 79 men (0.276'3°™in) <7.10mm (0.280 int> 0.010 ~ 0.037 mm (0,0004 ~ 0,0018in) (0.030 ~ 0,057 mm {0.001 ~0.002 ind <0.01 mm (0.0004 in)> 1,3 0.1 mm {0.051 + 0.004 in} 40.1 men £1.58.) 40.1 mm (1.58 int 43.8mm (1.72in) 43. 8mm (1.72 in} 0 ¥ “13Model Compressed Length (Valve Closed) Inner Spring IN. EX. Outer Spring WW. EX. Tilt Limin® Inner Spring IN, & EX, Outer Spring IN. & EX, WS ‘Direction of ‘Winding {Top view) SOA Piston Piston Size/ Measuring Point® Piston Clearance Oversize st and ara ath Piston Ring Sectional Sketch re Top Rin; peng ZA As 2nd Ring ye oiRing zal XTSEOK 22.7 mm (0.89in) 22.T mm (0.89in) 25.7 men (1.01 in) 25.7 me (1,01 in) 2.59 or 1.7 mm (0.067 in} 2.5° o 1.9mm (0.074iin} Outer Spring Left Right Inner Spring 92:388mm (3.62-2ini/ “6mm (0.24in) (From bottom line of viston skirt) (0.045 ~ 0.065 mm (0.0018 ~ 0.0026 in} 0.25 mm (0.01 in) 0.50 mm (0.02in) 0.78 mm (0.03in) 1.00 mm (0.04 in) Plain 8 T Plain B = 1.5:38mm (0.06-38in) T = 420.1 mm (0.16 + 0,004in) Expender = 1,2-38mm (0.0533%in) 3.8 +0.1 mm (0,16 + 0.004in} 14Model XTS50K_ End Gop (Installed Top Ring 0.2~0.4mm (0.068 ~0.016in} 2nd Ring 0.2~0.4mm (0.068 ~0.016in} Oi Ring 0.3 ~0.9 mm (0.01 ~0.035in1 Side Clearance Top Ring 0.04 ~0.08:mm (0.0016 ~ 0.0031 in) 2nd Ring 0.03 ~0.07 mm (0.001 ~0.003in1 Oil Ring 0.02 ~ 0.6mm (0.0008 ~ 0.002 in) Crankshaft © ils [4 +t-o | fa Crank With "A" 751mm (2.95 Sain? Assembly Width “B” Runout Limit“C'* Small End Free Play Balancer Drive Method 74.95 ~ 75.00 mm (2,951 ~ 2.953 in <0.03mm (0.001 n> 0.8 mm (0.031 int Geor Clutch Friction Plate Thickness/ Quantity ‘Wear Limit Clutch Plate Thickness/ Quantity Warp Limit ‘Clutch Spring Free Length/ Quantity Clutch Spring Minimum Length 3.0 +0.1 mm (0.12 = 0.004 in} 1 2.8 +0.08mm (0.11 +9.003 in}/7 <2.8mm (0.11 in}> <2.6mm (0.10in)> 1.2mm (0.08in)/7 <0.2mm (0.008 in)> 42.8mm (1.69in!/5 Primary Reduction Gear Backlash Tolerance 7-Tie Clutch Release Method | Inner push (Cam push) Push Rod Bending Limit <0.5mm (0.02in)> Kick Starter Kick Starter Type Decompression Device Type Cable Froo Play Ratchet Kick synchronous 0.5mm (0.02in) Air Filter Oil Grade (Oiled Filter) SAE 10WA0 SE motor oil =is=XTS5OK Carburetor Type! Manufacturer Y26PV/TK-KIKAKI 1D. Mark BYT 02 Primary carb, Secondary carb. Main Jet mga #125 #135 Main Air Jet (MAb |01.0 ent Jet Nowdle-clp Position (J.N.) BCaB/1——4A70-1/1 Needle Jet Ws ‘yoo 00 Cutaway (CA) #45 Pilot Jet (PJ) #48 Pilot Air Jet (PA) 01.0 Air Screw ltunsout)(P.A.S.) = Pilot Screw Ps.) Preset (1-1/4 «1/21 Valve Seat vs) 025 Starter Jet (GS #64 (GS) #10 Fuel Level (Ly 6.0.2 Imm {0.24 + 0.04in) Float level 26.0 = 2.5mm (1.02=0.10in) Float valve seat 025 Engine ling Speed 1,200 = 80 ¢/min ‘Vacuum Pressure at cling Speed 26.6KPe (200 mmHg, 7.9inHgh Lubrication System: Oi Filter Type Paper, Wire mesh Oi Pump Type Trochoid pump Tip Clearance <0.12mm (9.008 n> Side Clearance (0.03 ~0.08 mm (0.001 ~ 0.003in) Bypass Value Setting Pressure 98.07 = 19.8kPa (1.0-+0.2kg/em?, 14.22 +2.84 psi) Relief Valve Opereting Pressure 98.07 = 19.6 KPa (1.0 #0.2kg/em!, 14.22 + 2.84 psi ~16-‘Mode! Lubrication Chart Cranksin ‘Cynder he Loft Side | Crankease Tightening Sequence =7-I. MAINTENANCE SPECIFICATIONS B. CHASSIS Model Steering System Steering Bearing Type Front Suspension Front Fork Travel Fork Spring Free Length Spring Rate/ Stroke i Capacity or Oil Level Oli Grade Enclosed Air Pressure Rear Suspension ‘Shock Absorber Travel Spring Free Length Fitting length ‘Spring Rate/ Stroke taper coil Enclosed Gas Pressure Rear Arm ‘Swing Arm Free Play Limit End Sige Whee! Front Wheel Type Rear Wheel Type Front Rim Size/ Material Rear Rim Size/Material Rim Runout Limit Vertical Lateral Drive Chain ‘Type’ Manufacturer Number of Links Chain Free Play Drum Brake Type Front Rear Drum Inside Dia Front Rear Taper raller bearing 205mm (8.1in} 4, = 88mm (f,= 3.5in, f= 34B.5mm (Ly = 13-7in} Ky = 3.4.N/mm (0.35 kg/mm, 19.6 bint 0~ 118mm (0~4.5 in) Ky = 5.5 N/mm (0.56 kg/mm, 31.3b/in) 115 ~205 mm (4.5 ~8.1 in) 369.cm(12.5 imp o2, 13.0 US oz) 168mm (6.2in} (From top of inner tube fully compressed without spring.) KAYABA G-10 39.2 kPa (0.4 kg/cm’, 5.7 psi) 100mm (3.9inb 293mm (11.5 in) | Ky = 39.7 ~93.2 N/mm (4.05 ~9, Skg/mm, 226.7 ~631.8 b/in} 0~ 120mm (6 ~8.7int | 1176.8 (12kg/em? 170.6 psi <1.0mm (0.04in)> <1.0mm (0.04in)> | Spoke Whee! ‘Spoke Wheel 4.60 <21/ Aluminum | 2.18% 18/Aluminum <1.0mm (0.04in)> <0.5mm (0.02in)> 52008/DAIDO S7links + Joint 60 ~ 70mm (2.4 ~2.8in} Leading and tailing Leading and trailing 150mm (5.91 in} <151 mm (5.94 inl > 150mm (5.91 int <151 mm (5.94 in) > 1e-Model XTS50K Brake Lever & Brake Pedal Brake Lever Free Play/position 79in)/ at lever pivot Brake Pedal Position 18in) Brake Pedal Free Play tical height below footrest top.) Chuteh Lever Free Play’ position ~0.12in)/ at lever pivot 19-Il, MAINTENANCE SPECIFICATIONS C. ELECTRICAL Model Voltage Ignition System Ignition Timing (8.7.0.C.) Advanced Timing (B.T.0.C.) Advancer Type XT550K wv 12 = 2° at 1,200r/min 35-+2° at 6,000r/min Electrical 1234 co Magneto-Model/ Manufacture Pickup Cail Resistance (Color) Charge Coil Resistance (Color) C.D.1. Unit-Model/ Manufacturer Ignition Coil -Model/ Manutacturer Minimum Spark Gap Primary Winding Resistance ‘Secondary Winding Resistance Charging System/ Type FW. Magneto Lighting Voltage BClighting SY1-81400-51/ NIPPONDENSO 90 ~ 1308 at 20°C (68°F! IG— WA) (G-wGt 160 ~ 2402 at 20°C (68°F! (Br — | '5Y1-85540-51/NIPPONDENSO ‘SY1-82310-50/ NIPPONDENSO- 17k or more at 300/in 25 kV or mare at 1,000 ~2,5001/min 47kV or move at 6,5001'min 0.52 + 20% at 20°C (68°F! 8KQ = 20% at 20°C (68°F) A.C. Magneto Generater 6.3A or more at 1,500r/enin | 108 or less at 5,000 r/min 12.6V or more at 1,5001/min __13.6V or less at 7,000¢/ minModel ighting Coil Resistance (Color) XTS5OK 0.2~0.62at 20°C 16°F — WM) Voltage Regulator 7 “Type -Model’ Manufacture No Load Reguisted Voltage | Rectifier “Model/ Manufacturer Battery Capacity Specific Gravity Horn Type/ Quantity Model/Manufacturar Maximum Amperage Model! Manufacturer Flasher Frequency Type ‘Amporage for Individual Circuit! Quantity Maio. w— a — | td I a4 TT 5 I sw {++ = 2 Lv. | a | PA 4 4 tL aa i TTI 5 3.4 Engine speed {* 10!r/miny | semi Conductor Short Control ‘SH222-2C/ SHINDENGEN 14.5v | ‘SH222-12C/ SHINDENGEN 12V 5AH 1.260 Plain type x1 MF-T2/NIKKO 158 Condenser type FU257SD/ NIPPONDENSO, 85 + 1cycle/min ZW»? + 3.AW | Non fuse breaker | Lax 2TIGHTENING TORQUE ENGINE ‘Strainer housing: panhead screw Tightening torque Thread Size] Oty | Nm | mig | fl Gylinder head: lange bolt Me 2 | 2 | 22 | 6 + flange bolt Me 1 10 | 10 | 72 plug wiz + [7s | ie | 2 Cylinder head cover: Internal hex. bolt M6 2 w | 10 | 72 + tntemal hex. bolt [m6 4 | 0 | 1 | 72 + Intemal hex. bolt M6 3 | 0 | 10 | 72 : tntemalhex. bolt M6 7 wo | 10 | 72 Cylinder headside cover: Intermathex.bot M6 | 2 =| 1 | 10 | 72 | Gear unit assembly: Internal hex. bolt M6 1 wl 10 | 72 Techometer cable, stopper at had nena ee 1 a lax | ef Cylinder body: nut Me 2 | 2% | 20 | = nut Mio 2 | a5 | 378 | 27 = nut wo | 2 | as | 375 + Internal hex. bolt MB 2 | 0 | 10 | 72 Gear balance weight: nut m6 + | @ | 60 TACG.Rotar nut mia 1 % | 90 | 6 | Valve clearance: nut nn) a | 35 | 135 | 94 ‘Stopper guide 2: hex. bolt Me | 2 8 | os | 58 Cam sprocket M7 2 | » | 20 | Tensioner assembly: Internal hex. bolt M6 2 | 0 | 10 | 72 Tensioner spring retainer: plug m6 1 wo | 20 | 14 Decompression cam: bolt “Me | 1 | 8 | os | sa Rocker shaft stopper bolt we 2 | 0 | 10 | 72 | Oil pump assembly: internal hex. bolt | 6 3) 1 | 10 | 7a Cover 2: panheadscrew ___t i] Drain plug: straight screw plug Element caver: Internal hex. bolt = Internal hex. bolt Element cover stud bolt: bind screw 1 5 | os | 36 Oilhose 1» Internal hex. bolt wo | 10 | 72 = union nut wo 50 | 36 Cithose 2: Internal hex. bot 2 wo | 10 | 72 union nut | 1 so | 50 | 36 Caburetor joint: Internal hex. bolt Me 4 [| 0 [ 1 | 72 -2.Tightening torque Caburetor assembly: hose clamp Exhaust pipe: nut Exhaust pine protector: bind serew ‘Muffler protector 1: bind screw Case Vand 2: Internal hex. batt + Internal hex, bolt Internal hex. bolt | Crank case 1 | Clamp (lead: panhead screw Crank case 2 Crankc38e cover 1: Internal hex. bolt Internal hex. bolt + Internal hex. bolt + Internal hex. bolt Crank case cover 2: Internel hex, bolt bolt Crank case cover 3: internat hex. bolt + Internal hex. bolt | Covert: Internal hex. bolt Plate \e cover: flat head ser | Ratchet wheel guide: hex. bolt Cablelever: hex. nut Kick crank boss: hex. bolt | _Guutch spring: W/W screw Clutch boss: aut "Primary drive ge Push ever assernb) “Push lever positioning: nut stopper screw Drive sprocket: hex. bolt Oil seal cover: hex. bolt + Internal hex. bolt Thread Size fb M20 Stopper lever: W/W screw Shift pedal: bolt Coil: pannesd W/V screw -2-Tightening torque Thread Sie] Qiy | Nm | mtg | fib Pulser: panhead W/W screw M6 2 7 | 07 | 61 [Neutral switch: neviral switch assembly “tT 2 | 20 | 14 | Cylinder nead side cover 1 Toa [2 | 12 | er Kick erank: screw Lo [7 [or] sa ~24-CHASSIS. Tightening torque Front wheel shaft and nut Outer tube and cover Handle crown and inner tubs Handle crown and steering shaft Under handle holder and Uppar handle holder Front engine stay and engine “Front engine stay and frame Engine top stayandengine Engine top stay and frame Rear engine and frame Nipple hose and frame AOlltankdrain plug Pivot shaft and nut Rear wheel shaft and nut Rear cushion and frame Lever cam shalt and cam shaft (Front, Rear? Sprocket wheel holder ‘Steering shatt and ring nut Under bracket and Inner tube Inner tube cap Front fork cylinder compressor and outer tube Footrest and frame Bead stopper and rim Steering lock and handle crown Spoke Seat bracket securing bolt | Tread Size | M4 Me Ms, Mia MB M10 Mio to v0 mio M22 ms m6 6 mio ano M25 me 3a m2 mig me Me #6 Ble mejele 8/218) [ets 100 10 23 58 58 58 90 18 100 190 10.0 07 02 07CONSUMER INFORMATION Stopping Distance correct under other conditions. This figure indicates braking performance that can be met or exceeded by the vehicles to which they apply, without locking the wheels, under different conditions of loading and with Partial failures of the braking system. The information presented represents results obtained by skilled drivers under controlled road and vehicle conditions and the information may not be Description of vehicles to which this table applies: Yamaha motorcycle XTS50K. A. Fully Operational Service Brake Load Light NOTE: The statement above is required by U.S. Federal law. “Partial failures’ of the brak ing system do not apply to this chart js —ji91 100-200 300 (Feet) ‘Stopping distance in feet from 60 mi/h GENERAL TORQUE SPECIFICATIONS. This chart specifies torque for standard fasteners with standard 1.8.0. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until ful torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature. General torque _ 7 specifications (Nut (Bott! nm | meg | fb 10mm émn 6 | o6 | 43 tzmm | am | | ts | 1 vamm | iomm | 90 | 30 | 2 7mm | tamm | 55 | 55 | 40 19mm | tamm | 05 | 86 | 6 zm | temm | ie | io | oe cotoa cove R Red BIW... lack’ Write a Black wR Yelow/ Red 30 ‘Sky Bue By Black! Yalow Be Brown sy (Geeen, Yellow a Chocolate L/W... Blues White Og Darkgieen—Bu/\W. Brown / nite L ue FuW «Red nite y YYetow vs Blue/Black ° Oraoge ww Bie Yelle 6 Green UR. Blue Res P Pink win) wna Rea w ‘Woe WIG... Whita/ Green 26-DEFINITION OF UNITS mm | millimeter 10" meter cm centimeter 10" meter ko kilogram 40° gram N Newton Tkg xm/sec! Nm Newton meter Nom mkg Meter kilogram makg Pa Pascal Nim? Nimm | Newton per milimeter N/mm L | Liter cm! | Cubic centimeter CONVERSION TABLES Measure: Length Length Weight Force Torque Torque Pressure: Spring rate Volume cor Capacity Engine Speed r/min | Rotation per minute -- [une] fea —~«”~S*«Cefntion’«=«=SSMcasure ‘Metric ta inch system Krown | Multipier | Resuit mig 7233 | tow roan 2680 ti omg aor |e emg | 0.8680 role ~ 2205 » 3 00307 os rent 2.082 pa wenvhe oars mon we beers 7 - 3.281 * 8 | vos \va cm 0.3997 in ia oo fin cotemy | o.oaaga or Us ba tetem) | 008 xin Vein 2a stUStq) Weer, | 1.057 (musi Weer; 02642 ge (US lt vglmm —-s6.007 tbr gem! | 142038 ssi t/t Centigrade (°C) 9751°C) +32 _| Fabren al Known fe wily fo alts moa mph er (US sa) cuin prUS iar at (US tq) gal (US iq) lovin psi ibn’) Inch to metre system Multigier Result 0.13825 mks g.ois2 mika 13831 em kg 11521 em-4g, 0.2835, kg 18.352 @ 0.0252 emit 609 env 1.603) km 0.3088 © ogtat ™ 254 em 254 men ct ae 2957 ce tem’i 16.387 ec lem'! 0.4732 hr titer) 0.9461 litter) 3785, weamert 9.017858 kg/mm 0.07031 kavem? Fahvenneit °C)) 5/9 (°F 22), L Centigrade (°F62 YAMAHA MOTOR CO.,LTD. PRINTEDINU S.A© YAMAHA NTooOd Service Manualayroads pue subisagNOTICE This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers, and their qualified mechanics. It is not possible to put an entire mechanic’s education into one manual, so it is assumed that persons using this book to perform maintenance and repairs on ‘Yamaha motorcycles have a basic understanding of the mechanical concepts and procedures in- herent to motorcycle repair technology. Without such knowledge, attempted repairs or service to this model may render it unfit to use and/or unsafe. This model has been designed and manufactured to perform within certain specifications in regard to performance and emissions. Proper service with the correct tools is necessary to en- sure that the motorcycle will operate as designed. If there is any question about a service pro- cedure, it is imperative that you contact a Yamaha desler for any service information changes that apply to this model. This policy is intended to provide the customer with the mast satisfac: tion from his motorcycle and to conform with federal environmental quality objectives. Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha. Modifications and significant changes in specifications or procedures will be forwarded to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this manuel. NOTE: This Service Manual contains information regarding periodic m: trol system for the XT860J. Please read this material carefully, ‘tenance to the emission con- Particularly important information is distinguished in this manual by the following notations: NOTE: ANOTE provides key information to make procedures easier or clearer. NEAUTION! 4 CAUTION indicates special procedures that must be followed to avoid damage to the motorcycle RGN Tsay A WARNING indicates special procedures that must be followed to avoid injury to a motorcycle operator or person inspecting or repairing the motorcycle. SERVICE DEPT. INTERNATIONAL DIVISION YAMAHA MOTOR CO.,LTD.GENERAL INFORMATION ii PERIODIC INSPECTIONS AND ADJUSTMENTS ENGINE OVERHAUL CARBURETION CHASSIS ELECTRICAL = APPENDICESCHAPTER 1. GENERAL INFORMATION MOTORCYCLE IDENTIFICATION A. Frame Serial Number . - ‘ @. Engine Serial Number... .... : ae C. Vehicle Identification Number MAIN FEATURES . cee ceeeee eed A. Dry Sump System and Monocross Suspension 12 8. Four-Valve Engine ...... : v8 C._ Yeriaha Duo Intake System (YDIS}... - : 14 D. Kick Synchronous Automatic Decompression : 16 £. D.C. Lighting System. we F. Detachable Lighting System . at G. Fuel Tank Cap with Check Valve . cece TB SPECIAL TOOLS... ce cee coho A. For Tuneup . 19 8. For Engine Service . 19 C. For Chassis Service : cece 12 D. For Electrical Components 412GENERAL INFORMATION MOTORCYCLE IDENTIFICATION A. Frame Serial Number The frame serial number is stamped into the right side of the steering head pipe. Tr Frame Sera Number Starting Serial Number: XTSBOJ. 8Y1-000101 B. Engine Serial Number ‘The engine serial number is stamped into the elevated pari of the right section of the engine. NOTE: The first three digits of these numbers are for model identification; the remaining digits are the unit production number. 1 Engne Seis Number C. Yehicle Identification Number The vehicle identification number is on the left side of the steering head pipe. 3. ‘Vehicle Identteaton NumberMAIN FEATURES ‘A. Dry Sump System and Monocross Suspension The XTS5QJ, which inherits the traditional XT500 dry sump system, features monoshack suspen- sion, light weight, and a new diamond-shaped frome with integrated oif tank,B. Four-Valve Engine Newly designed compact engine equipped with: §.0.H.C., 4-Valve head, Dual intake and dual ex- aust ports, gear-driven balancer, Yamaha Duo In- take System (YDIS), and 5-speed transmission 13C. Yamaha Duo Intake System (YDIS) For this system, the primary carburetor and the secondary carburetor are equipped as a unit: A cable-operated-slide type functions as the primary carb, and a vaccum-controlled-slide type provides a secondary bore. The engine has a 4-valve head, and each carb has its own intake port and valve. Although each carb bore and intake port is smaller than that of a more conventional engine, their conbined area is about 20% greater than a single, larger carb and intake layout Flow efficiency ot both the intake and exhaust sides is substantially improved. From idle to about kaif throttle, the primary carb supplies the air-fuel mixture, and almost the entire intake charge enters through just one valve; since the 4-valve layout offsets the intake ports relative to the cylinder-bore axis, a strong YICS-type swirl is produced in the low-to-medium rpm range. Combustion efficiency is significantly enhanced, resulting in improved fuel economy. In addi- tion, the single small bore provides excellent low- and medium-speed throttie response due to the high air velocity in the venturi. This eliminates the need for a mechanical accelerator pump, allowing minimal carb height and ample room for the Monocross rear suspension. As the throttle is turned from half to wide open, a linkage between the carburetors gradually opens the secondary-carb butterfly. The vaccum-controlled slide in the secondary carb opens as engine demand builds, providing superb mid-range smoothness. With both slides fully open, the engine receives more mixture and produces more power than a regular single-carb machine. SECONDARY CARB PRIMARY CARB 1D. Kick Synchronous Automatic Decompression The kick-starting mechanism is interlinked with one of the exhaust valves, thus automatically decompressing the combustion chamber for ease in kick-starting. Combined with electronic ad- vance ignition, kick-starting is free from possible kickback. Correct adjustment is required of this kick-synchronous automatic decompression system for effective performance. 15E. DC Lighting System (12V 45/45 Watt with sealed beam) ‘The DC lighting system provides a steady power source, enabling al lights to keep bright even at low RPM ‘This system also offers a safety advantage in that it keeps lights shining even when the engine is stalled HEAD LIGHT VOLTAGE AC LIGHTING x : g > ’ Oc LIGHTING La Se 7 2 3 © 8 8 9 8 ENGINE R/MIN (104F. Easy-maintenance Lighting System The Easy-maintenance Lighting System is a modular design integrating headlight and in- strument panel into one easy-to-remove-and- service package. A few securing bolts, an elec- trical connector, and the Easy-maintenance Lighting System can be removed for quick service. 7G. Fuel Tank Cap with Check Valve The fuel cap has a free steel ball inside it to prevent fuel from spilling out through the cap breather should the machine turnover. This steel ball normally settles at the bottom, but when the machine is inclined to less than 30° from the ground as in a turnover, the ball is made to roll accordingly while at the same time pushing up on the valve seat (see drawing). ‘When the machine is laid flat on the ground, the ‘O-ring on the valve contacts the tapered wall of the cap, thereby closing the breather passage completely. 18SPECIAL TOOLS ‘The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques A. For Tune-up 1, Valve adjusting soo! P/N. YM-08035 2. Compression gauge set Adopter (Miz) P/N. ¥U-33223 P/N. YU-33223-3 f x 3. Oil pressure gauge adapter P/N. YU-08030-1 ‘This adapta attached reniving theai bleed screw. he 199 of theo Mer cover ater 4, Inductive timing light nie vit oanay 5. Inductive tachometer P/N. YU-08036 B. For Engine Service 1, Universal clutch holder P/N, YM-91042 “This tool i used to holt the clutch whan removing oinstaling the teh bons lock nat.2. Valve guide reamer P/N. YM-01227 “Tis must be ysed won replacing tho valve guide, 3. Valve seat cutter P/N, YM-91043 This tool is needed to cesurtace the valve seat. 4, Valve guide remover P/N. %M-01225 ——_ This must be used to remove the valve guides, 5. Valve guide installer P/N. YM-04017 s This tools nooded fr proper istliaton ofthe valve guides 6. Valve spring compressor P/N. YM-04019 ‘This too! must be used for removing and insaling the valve assembles, 7. Slide hammer set PIN. YU-01083 ‘These tole 186 when renoving the rocker am sha 1 Bok P/N. YUOI08 2. Weiaht P/N. YU-0TOE-3 1.108. Crankshaft installing set 11, Crank protector P/N. YU-90050 P/N. YM-04063 “his tole uted whan rtaing he crankshaft ‘This tool pxuiets the throeds on te ernkshah 9. Adapter #10 crankshaft installing bolt «Mal P/N. YM-90069 12. Flywheel puller P/N, YU-33270 id “Tio nto meng te CO ot 114 mm * | Sadaptor for instaling the crankshalt, snd removing: a —_ tmetinsi-gear Sve orien, 13. Fuel level gauge 10 Grank pot spacer P/N, ¥M-01312 P/N, YM-90070A Se This too sreadad fo” checking the carburtor loved “Tis tools ueeo when nsating the crankshaft vn14. Piston pin puller 2. Elgctto tester P/N. ¥U-01304 P/N. YU-03921 ‘This tools used when remaueg thetight piston pin 3. Coil tester C. For Chassis Service P/N, YU-33261 1. Front-fork-cylinder holder P/N. YM-01327 T-handie P/N. YM-01301 or YM-01326 eo “This too fs used 10 foosen and tighten the Font-fork-cyind bot. D. For Electrical Components The uses of these tools are described in Chapter 6. 1. Pocket tester P/N. YU-03112, 112CHAPTER 2. PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION 224 MAINTENANCE INTERVALS CHARTS -...0.... 0000000000 eeee ee 2 ENGINE . : wee 28 A. Valve Clearance bees cine 1.23 B. Decompression System ..-. se... cee cee Bd C. Spark Plug..... cee beseteeee ee lh D. Crankcase Ventilation System... 0... cece scree eee eee cece OM) E. FualLine » 24 F. Exhaust System... 24 G. Idle Speed ........ ces : 24 H. Engine Oil.........+ re 26 |. Oil Fitter Replacement .. cee see 25 J. Engine Oil Replacement cee 26 K. Ok Pressure Check........ oe coven 26 L. Clutch Adjustment... 5... ce rrr 27 M. Checking Ignition Timing ....... . cee cee RT N. Compression Pressure Measurement ........ ++ cee 2B CHASSIS 0... 006s essere cerns . 28 A. Down Tube Strainer . beseeeees 28 B. Air Fiter........ : wee cee BD ©. Frontand Rear Brake seve esses cee 28 D. Cable Inspection and Lubrication ... cece RM E.Breke and Change Pedels/ Brake and Clutch Levere/Sidestend 211 F. Drive Chain ve neces tet ete t a eteee eee BAT G. Front Fork Oil Change coe esr) H. Front Fork and Rear Shock Absorber Adjustment woven BAB 1. Steeting Head Adjustment Bedeee rere 27} J. Wheel Bearings ..... cote e ee enees ---244 K. Fuel Cocks s.e.e eee e ee : cece BIS L. Tires and wheels 2215 ELECTRICAL foots wee 216 A. Battery 2.216 B. Crcuit Breaker . 2216PERIODIC INSPECTIONS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended inspections and ad- just ments, These preventive maintenance procedures, if followed, will ensure more reliable vehi- cle operation and a longer service lite. The need for costly overhaul work will be greatly reduced. This information applies to vehicles already in service and to new vehicles that are being prepared for sale. Alll service technicians should be familiar with this entire chapter. MAINTENANCE INTERVALS CHARTS Proper periodic maintenance is important. Especially important are the maintenance services related to emissions control. These controls not only function to ensure cleaner air but are also vital to proper engine operation and maximum performance. In the following maintenance tables, the services related to emissions control are grouped separately, PERIODIC MAINTENANCE EMISSION CONTROL SYSTEM ac hesitate ~ nem over ‘mim | sain | toi | aoman ‘com | Gamma | i2st0m | tsan0m! satmorin | orto | orémonme | of mente 1 | vabecurance | Somek wat te clewmren o | | + | ssuaie | eos 8. mi | @ [ ~— 4 [Suicmsenicin | Dt wonton 5 ° ‘Chek athe ore amon Lexi ‘mck fr akape toon neers [heel sea cable te pla rcesary ° © {eset __ - Se loses | creak na nat aacome eat : 7 ve Lev aervave cagonce mumerance | a4GENERAL MAINTENANCE/LUBRICATION aban Theoteter «| | — 1 aoe [soi | <0m0m | saovin | vem ‘cami | ami | soon | teem | cone ntmorn | -?mentna | cmon | tment |e menne Verne ree Engine of bassin oe olor SAE 20040 ° ° ° md type SE motor of ove - ° ° ° Yorba eyce sete — | martnmenbes | iin ° ° ° tracer ent -oet ny sroxenaten | eoace spot - e ° ° Owtch Aosht fwe oay = ° ° ° ‘Apply chain lube a a monn [A covet or Sat fy en 0 | ooo WOO Mer o#| Contra and — | Apply chan tbe Seana cwianeorsae | 9 ° ° emia | cate ee fewram | Aspverow | Uthumaceobae | i. ° ovreate | sner arene amet apiyranioe | Yerncenr’ ° © oe row aometrot ——— Yamaha chain and moe, [prenee | eee sat ° ° ae {Dare anole ‘Teme completely; | Yamaha fork - = 020 e810. or ° iad specication equvatent, ]eoee wings stoma | see Mecaentogns | Derngena [Roammtimatn, |e ping ° ° feos scons | anmmaterey |e vaoten veka vm | grenoomrete . 2 > teomos | ton ene — caren arene ° [benather pipe for 9 trot corton aeraach ‘eaten evr once | Remreminioe | cate ate cr SAE ane ewer 22ENGINE A. Valve Clearance Adjust the valve clearance as follows: NoTE: Valve clearance must be measured when the engine is cool to the touch. 1. Remove intake and exhaust tappet covers and two blind plugs on the left crankcase cover. 3. Use a focler gauge to determine the élearance. Intake valve (cold): 0.05 ~0.10 mm (0.002 ~ 0.004 in} Exhaust valve (cold): 0.12 ~ 0.17 mm (0.005 ~ 0.007 in} 1. Fooer gauge 4. Loosen the valve adjuster focknut. Turn the adjuster in or out to obtain the cor- rect clearance. Hold the adjuster to pre- vent it from moving and thoroughly tighten the locknut. Recheck the clearance after tightening. 2. Align the “T" mark on the flywheel with, the timing mark on the crankcase cover. This places the piston at the Top Dead Center and the valve clearance should be checked and adjusted st 7.0.C. on the compression stroke by observing when the valve adjusters have clearance 1. Adjuster 2, Lockmu——& Valve adjusting toot 5. Reinstall the intake and exhaust tappet covers and two blind plugs on the left crankcase cover,B. Decompression System NOTE: Decomp-coble adjustment must follow the ‘valve clearance adjustment 1, Remove the two blind plugs on the left crankcase cover. Align the “T" mark on the flywheel with the timing mark on the crankcase cover. This places the piston at Top Dead Center, and the decomp-cable adjust- ment should be checked and adjusted with the piston at T.D.C. on the com- pression stroke. Loosen the locknut on the decomp- cable adjuster. Then turn the adjuster so 0.5mm (0.02 in) free play can be provid: ed for the end of the decomp-lever. 2. FREE PLAY 03mm (0.02ini Lock NuT aouusTER 1 Aahster 2 Locknat 4. After the above adjustment, tighten the locknut on the decomp cable adjuster. 6. Reinstall the two blind plugs on the left crankcase cover. 3 Decomplever C. Spark Plug 1, Check electrode condition and wear, in- sulator color and electrode gap. 2. Clean the spark plug with a spark plug cleaner if necessary. Use a wire gauge to adjust the plug gap to the specification. 3. If the electrodes become too woin, replace it. 4, When installing the plug, always clean the gasket surface, wipe off any grime that might be present on the surface of the spark plug, and torque the spark plug property. 28 Standard spark plug: NGK D7EA ‘Spark plug gap: 0.6 ~0.7mm {0.024 ~ 0.028 in) ‘Spark plug tightening torque: 14 ft-ib) D. Crankcase Ventilation System Check ventilation pipe from cylinder head cover to oil tank and breather assembly from crankcase to air cleaner for cracks or damage; replace if necessary. E. Fuel Line Check fuel pipe from fuel petcock to car- Duretor for cracks er damage; replace if necessary. F, Exhaust System 1. Replace the joint gasketis) if necessary. 2. Tighten the joint bolt and nuts. G. Idle Speed 1. Start the engine and warm it up for a few minutes, 2. Set the engine idle speed to the specified level by adjusting the throttle stop screw on the carburetor. Turning the throttle stop screw in (clockwise) increases the engine speed; turing it out (counterclockwise! decreases the engine speed. Use a tachometer for checking and adjusting the engine speed. Engine Idle: 1,180 ~ 1,2501/min Th Trrote stop screwH. Engine Oil Recommended oi! Yamalube 4-cycle oll or SAE 20W40 type SE moter oil Oil level measurement 1, Loosen the air bleed screw on the oil filter cover. 1, Al bod sorow 2. Start the engine and let it elo 3. if no oil comes out of the blead bolt after 30 seconds, immediately turn off the engine and add engine oi 4. {foil comes out of the bleed bott, tighten the bleed bolt, and warm up the engine for several minutes. 5, Stop the engine, remove the oil filer cap, and check the oil level. NOTE: —— Be sure the motorcycle is positioned straight up when checking the oil level; a slight tilt toward the side can produce false readings. 1, OF filercap 1 Oifilersaa 2. Maxmumailevel 3. Minmum oi love! 6. Theol should be between the maximum and minimum marks an the filler cap gauge. If the level is lower, add sufficient oil to raise it to the proper level Gnas Never attempt to remave the oil tank filler cap just after high speed operation {and/or when engine is running). The heated oil could spout out, causing in- jury. Wait until the oil cools down to approx- imately 50°C (122°F). Oil capacity 1. Regular oil replacement 1.8.1.6 Imp at, 1.9 US qu 2. Oil fiter replacement 1.911.7 Imp at, 2.0 US qt 3. Total amount 2.2L11.9 Imp at, 2.3 US qt) Oil Filter Replacement Start the engine. After a few minutes of warm-up, stop the engine. 2. Place oil pans under the engine and under the dows tube. 3. Remove the oii tank filler cap, drain plugs (at two places), air bleed screw at- tached to the oil filter cover, and drain the engine oil.NOTE; ‘The oil filter cover is secured by three screws. ‘The lower one should be loosened until the threaded portion comes out completely. 1. Drain lug 2. Air blood screw NOTE: poe ‘When removing the drain plug on the down tube, take care not to get stained by the oil that spouts out, 4. Remove the oil filter cover, and replace the filter element, 1. Ob fite sement 5. Check the O-rings. if damaged, replace. Oring 6. Install the drain bolts, air bleed screw, oil filter, and oil filter cover 26 7. Add 1.8L (1.6 Imp qt, 1.9 US qt of engine oil. Install the oil tank filer cap and tighten. Use 2040 type SE oil. & Start the engine and allow a few minutes of warm-up. While warming UP, check for oil leakage. If oil teaks, stop the engine immediately, and check for the cause. After warm up, stop the engine and check the oil level. (Refer to page2-5, “Engine Oil”.) J. Engine Oil Replacement (without replacing filter) 1. Start the engine and stop after a few minutes of warm-up. Place an oil receiver under the engine. Remove the oil tank fiter cap, drain plugs (at two places), and air bleeder screw attached to the oi fiter cover, NOTE: ee, The oll filter cover is secured by three screws. The lower one should be loosened until the threaded portion comes out completely 4. Check each O-ring. if damaged, replace 6. Install the drain bolts {at two places) and the bleed screw, oil filter and filter cover. 6. Fill with 1.8 L (1.6 Imp qt, 1.9 US qt of engine oil. Install the oil tank filler cap and tighten. K. Oil Pressure Check Oil pressure can be checked using the follow: ing procedure: Start the engine and let it idle for a few minutes 2. Stop the engine. 3. Remove the air bleed screw from the oil filter cover 4, Remove the exhaust pipe protecter5. Install the oil pressure gauge adapter (special tool P/N, YU-04083). Install a oil pressure gauge or pass a vinyl tube over the handle bar and put it into the oil tank. 6. 1 Olpressure gauge adaoter 7. Start the engine, 8. If oil pressure is below the specified range or if oil does not flow into the oil tank, stop the engine immediately, and check for the cause. Specified oil pressure: 9.81 ~19.6kPa (0.1 ~0.2kg/om?, 1,42 ~ 2.84 psi) L. Clutch Adjustment This model has two clutch cable length ad justers and a clutch mechanism adjuster Cable length adjusters are used to take up slack from cable stretch and to provide suffi- cient free play for proper clutch operation under various operating conditions. The clutch mechanism adjuster is used to provide the correct amount of clutch "throw" for pro- per disengagement. Normally, once the mechanism is properly adjusted, the only ad- justment required is maintenance of free play at the clutch handle lever. Free play adjustment Loosen either the handle lever adjuster lock ut or the cable in-line length adjuster lock ut. Next, turn the length adjuster either in or ut until proper lever free play is achieved. 27 1. Adjustortocknut 2, Adjuster Mechanism adjustment See Chapter 3 “Clutch Mechanical Adjust- ment”. M. Checking Ignition Timing Check the ignition timing with a timing light by observing the stationary pointer and the marks stamped on the flywheel. 1 Tig mgr 1, Remove the upper blind plug on the left crankcase cover. 2. Connect the timing light to the spark plug wire. 3. Start the engine, and keep the engine running at the specified speed. Use @ tachometer to check the engine speed. Engine Speed: 1,200 r/min 4. The stationary pointer (in the timing window) should be within the firing range shown on the flywheel. If the pointer is not within the range or if it is not steady, check the flywheel and/or pickup assembiy for tightness and/or Gamage. (See “Chapter 6: Electrical” for further information.)5. Reinstall the blind plug, N. Compression Pressure Measurement Insufficient compression pressure will result in performance loss and may indicate leaking valves or worn or damaged piston rings, 1. Make sure the valve clearance is correct. 2. Warm up the engine for 2 ~ 3 minutes; stop the engine, 3. Remove the spark plug. 4. Install a compression gauge. 5. Tum over the engine with the kick starter with the throttle wide open until the pressure indicated on the gauge does not increase further. The compres- sion should be within the specified levels. i Compression pressure (at seal level): Standard, 1,079 kPa (11 kg/em?, 156 psi) Minimurn.. 883 kPa( 9kg/cm?, 128 psi? Maximum... 1,177 kPa (12 kg/cm?, 171 psi) spark plug wires to prevent sparking. 28 1 Compression gauge set special tool P/N. USES) 2. Compression gauge adapter (pecil ool P/N. YU 33358 3) 6. If the pressure is too tow, squirt @ few drops of ail into the cylinder. Measure compression again. If there is a higher reading than before (without oil), the piston rings may be worn or damaged. If the pressure remains the same after measuring with the oil, one o both rings and valves may be the source of the pro- blem: CHASSIS A. Down Tube Strainer 1. Remove the front bracket. 2. Removethe strainer.3. Wash the strainer thoroughly. Replace if necessary. 4. Reinsert the strainer into the down tube. 5. Reinstall the front bracket B. Air Filter 1, Remove the left-hand sidecover from the motorcycle. 2. Remove the air filter cover, and remove the air filter. 3. Remove the element from the guide. 4, Wash the eleinent gently, but thorough- ly, in solvent. 5. Squeeze the excess solvent out of the element and let dry. 6. Pour a small quantity of Yamalube 2- cycle oil orto the filter element and work thoroughly into the porous foam material. NOTE: In order to function properly, the element must be damp with oil at all times, but not “dripping” with oil 7. Reinsert the guide into the element, 8. Coat the mating surface of the filter with all-purpose grease for an airtight seal between the filter case and fiter seat 9. Install the filter element into the case. 10. Install the filter cover and sidecover. ©. Front and Rear Brake Front-brake-lever free play adjustment ‘The brake can be adjusted by simply ad- justing the free play of the brake lever. Adjustment is accomplished at one of two places, either the handle lever holder or the front brake hub. 1. Loosen the adjuster locknut 2. Turn the cable length adjuster in or out until adjustment is suitable. 291. boeken 3. Tighten the adjuster locknut 2. AGuster Rear-brake-pedal height adjustment 1, Loosen the adjuster locknut (for pedal height) By turning the adjuster bolt clockwise or counterclockwise, adjust the brake pedal position so that its top end is flush with the top of the footrest Socure the adjuster locknut. 3. After adjusting the pedal height, the brake-pedal free play should be adjusted. 2 Aduster 9, 20~30mm(0.8~1.2%9) Rear-brake-pedal free play adjustment 1, Tum the adjuster on the brake rod clockwise or counterclockwise to pro. vide the brake pedal end with a free play of 20 ~30 mm (0.8~1.2in). Rn Check to see whether or not the brake fight operates correctly after adjusting Front brake shoe lining check To check, examine the wear indicator posi- tion while pulling in the brake lever. ifthe in- dicator reaches to the weer limit line, replace the shoes. 1, Wear ia 2 Wor naiator Rear brake shoe lining check To check, examine the wear indicator posi- tion while depressing the brake pedal. If the indicator reaches to the wear limit line, replace the shoes. 2. Wear indicator 210D. Cable Inspection and Lubrication The throttle twist grip assembly should be greased when the cable is lubricated, since the grip must be removed to get at the end of the throttle cable. Two screws clamp the throttle housing to the handlebar. Once these two are removed, the end of the cable can be held high to pour in several drops of lubricant. With the throttle grip disassembled, coat the metal surface of the grip assembly with a suitable all-purpose grease to cut down fric- tion. 1. Damage to the outer housing of the various cables may cause corrosion. Often free movement will be obstructed. An unsafe condition may result, Replace such ¢ables 2s soon as possible. If the inner cables do not operste smoothly, lubricate or replace them. Recommended lubricant: ‘Yamaha Chain and Cable Lube or 10W30 motor oil €. Brake and Change Fedals/Brake and Clutch Levers/Sidestand Lubricate the pivoting parts of the lever, pedal, and sidestand. Recommended lubricant: | Yamaha Chain and Cable Lube or | 10W30 moter oil Le F. Drive Chain Drive Chain Tension Check Inspect the drive chain with both tires touching the ground and with rider on the seat, Check the tension at the position shown in the illustration. The normal vertical deflec: tion is approximately 60 ~ 70 mm (2.4 ~ 2.8 in). If the deflection exceeds 60 ~ 70 mm (2.4 ~2.8.in), adjust the chain tension. ive Chain Tension Adjustment 2. 60~ 70mm 24 ~2.8i0) 1, Loosen the rear brake adjust nut. 2. Loosen the rear wheal axle nut. 3. Loosen the adjust bolt locknuts on each side. To tighten chain, turn chain puller adjust bolts clockwise. To loosen chain, turn adjust bolts counterclockwise and push wheel forward. Turn each bolt ex- actly the same amount to maintain cor- rect axle alignment. (There are marks on each side of rear aim and an each chain puller; use them to check for proper aligament). Drive chain slack: 60 ~70 mm {2.4 ~2.8in) NOTE: Bofore adjusting, sotate rear wheel through several revolutions and check tension several times to find the tightest point. Adjust chain tension with rear wheel in this position 4. After adjusting be sure to tighten the locknuts and the rear wheel axle nut. Axle nut torque: 100.Nm (10.0m kg, 72.-Ib)8. Insert the cotter pin into the rear wheel axle nut and bend the end of the cotter pin as shown in the photo (if the nut notch and the cotter pin hole do not match, tighten the nut slightly to mat- chi. 1. Chainputer 2 Asemut 3, Cotterpin 6. In the final step, adjust the play in the brake pedal. Drive chain lubrication 1. First, remove dirt and mud from the chain with a brush or cloth and then spray the lubricant between both rows of side plates andon all center rollers. 2. To clean the entire chain, first remove the chain from the motorcycle, dip it in solvent and clean out as possible. Then take the chain out of the solvent and dry it, Immediately lubricate the chain to prevent the formation of rust Recommended lubricant: YAMAHA CHAIN AND CABLE LUBE, or SAE 10W30 type SE motor oif G. Front Fork Oil Change Securely support the motorcycle so there is no danger of it falling over. 1, Raise the motorcycle or remove the front wheel so that there is no weight on the front end of the motorcycle. Remove the handlebar if necessary 2, Remove the rubber cap from the top of each fork. 3. Keep the valve open by pressing it for several seconds so that the air can be tet out of the inner tube. 4, Remove the cap bolt, RUBBER CAP “VALVE Serine “STOPPER RING ~ eouLar SPRING SEAT “FORK SPRING 5. Place an open container uneler each drain hole. Remove the drain screw from each outer tube. 6. When most of the oil has drained, slowly raise and lower the outer tubes to pump Out the remaining oil.7. Inspect the drain screw gasket. Replace if damaged. Reinstall the drain screw. 8. Pour the specified amount of oil into the fork inner tube. Front fork oil {each fork}: 369 cm? (13.0 Imp 02, 12.5 US 02) Recommended oll: KAYABA FORK OIL G-100r equivalent 9. After filing, slowly purnp the forks up and down to distribute the oil 10. Inspect the O-ring on the cap bolt Replace if damaged. 1. Ong 11. Reinstall the spring seat and fill the forks with air. Use a manual air pump or pressurized air supply. Refer to "G. Front Fork and Rear Shock Adsorver Adjustment” for proper alr-pressure ad- justing procedures. Always use a new stopper ring (spring cable circlip) Maximum air pressure: 117.7 kPa (1.2kg/em*, 17 psi) Do not exceed this amount. H. Front Fork and Rear Shock Absorber Adjustment Front fork 1. Place the motoreycte on the stand, and elevate the front whee! NOTE: —— When checking and adjusting the air presse, there should be no weight on the frontend of the motoreyele, 2. Remove the rubber cap from the top of each fork, 3. Using the air gauge, check and adjust the air pressure. #f the air pressure is in- creased, the suspension becomes stif- fer: if decreased, the suspension becomes softer. To inctesse air pressure: Use a manual sir pump or pressurized ai supply. To decrease air pressure: Release the air by pushing the valve pin. Standard air pressure: 89.2 kPa (0.4 kg/em?, 5.7 psi) Maximum air pressure: 117.7 kPa (1.2kg/om?, 17 psi) Minimum air pressure: Zero * Never exceed the maximum pressure ‘oroil seal damage may occur. * The difference between both the left and right tubes should be 9.8 kPa (0.1 kg/cm’, 1.4 psi) orless. 4. Reinstall the rubber cap, 243Rear shock absorber See Chapter 5 "Rear Shock Absorber” I. Steering Head Adjustment Tne steering assembly should be checked periodically for looseness. 1. Raise the front end of the motorcycle so that there is no weight on the front wheel Grasp the bottom of the forks and gently rock the fork assembly backward and forward, checking for looseness in the steering assembly bearings. 3. If the steering head is loose, adjust it. Loosen the steering fitting bolt and front fork pinch bolts. 1. Front forkoineh bl 2, Steering fing bolt 3. Stoating ing nat 4. Using the ring nut wrench, adjust the steering ring nut until steering head is tight without binding when the forks are turned. NoTt Excessive tightening of this nut will cause rapid wear of the bearings and races, Recheck for looseness and freedom of movement. 214 Ring nut wrench 5, Retighten the top steering fitting nut, steering fitting bolt, and steering stem. and the front fork pinch bolts in that order. Recheck steering adjustment to make sure there is no binding when the forks are moved from lock to lock. If necessary, repeat the adjustment pre- cedure. J. Wheel Bearings Ia rolling rumble is noticed and increases with increasing wheel speed (not engine or ‘transmission speed), the wheel bearings may be worn. Check the wheel bearings on both the front and rear wheels. Front wheelRaise the front end of the motorcycle, and spin the wheel by hand. Touch the axle or front fender while spinning the wheel. If you feel any excessive vibra- tion, the bearings are rough and should be replaced. Rear wheel Remove the rear wheel, and check the bearing movement with your finger. Replace the bearings if they are rough or worn, K, Fuel Cock If either fuel cock is leaking or is excessively contaminated, it should be removed from the fuel tank and inspected, _-e-nING FILTER SCREEN Lever “ORAIN SCREW 2-15, 1. Remove the fuel tank and position it so that fuel will not spill when the fuel cock is removed. Remove the fuel cock and inspect the filter screen, Replace the fuel cock assembly if it is seriously contaminated. Remove the screws on the front and rear Of the fuel cock; remove the plate, gaskets, lever, and O-rings, Inspect all components, and replace any that are damaged. if the O-rings are damaged in any way or if the fuel cock gasket surfaces are scratched or corrod. ed, the fuel cosk assembly must be replaced, If there is abrasive damage to any components, the fuel tank must be drained and fushed. Reassemble the fuel cock, and install it on the fue! tank. L. Tires and Wheels To insure maximum performance, tong ser- vice, and safe operation, note the following precautions: 1. Check tire pressure before riding; adjust asnecessary. Before operation, always check the tire surfaces for wear and/or damage: look for cracks, glass, nails, metal fragments, stones, etc. Correct any such hazard before riding. Always inspect the wheels before a ride. Place the motorcycle on the sidestand and check for cracks, bends, or warpage of the wheels, Do not attempt even small repairs to the wheel. If a wheel is deformed or cracked, it must be replac- ed iter installing a tire, ride conservatively 10 allow the tire to seat itself on the rim properly. Failure to allow proper seating may cause tire failure resulting in damage to the motoreycle and injury to the rider. After repairing or replacing a tire, check to be sure the bead stopper locknut is securely fastened. If not, torque it as specified 2 TIGHTENING TORQUE: 10.Nm (1.0m-kg, 7.2 ft-lb)ELECTRICAL A. Battery’ 1, The fiuid level should be between the upper end lower level marks. Use only distilled water if refilling is necessary. 1 Upper eve 2. Lower love Normal tap water contains minerals which are harmful to a_ batter therefore, refill only with distilled water. 2. Always make sure the connections are correct when instaiiing the battery. Make sure the breather pipe is properly connected, properly routed, and is not damaged or obstructed. Wow 70 LAYOUT BATTERY BREATHER PIPE FSB / / pass i! P tHROUGH Guile Pass THROUGH GUIDE: _ BATTERY BREATHER. PIPE The battery must be charged before us- ing to ensure maximum performance. Failure to charge the battery properly before first use or a low electrolyte level will cause premature failure of the bat- tery. Charging current: 1.6 amps/10 hrs. ‘or until the specific gravity reaches 1.280 at 20°C (68°F). WARNING Battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes. or clothing Antidote: EXTERNAL — Flush with water, INTERNAL — Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg. or Vegetable oil Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Bat: teries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in clos- ed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN B. Circuit Breaker This model is equiped with the circuit breaker The circuit breaker is located at the rear side of the battery, Creu breaker 216If the breaker is open, turn off the ignition switch and the switch in the circuit in ques- tion; ragat the breaker. Turn on the switches, and see if the electrical device operates. Mf the breaker immediately opens again, check the circuit in question, (See Chapter 6. “ELECTRICAL".) CAUTION: Wait 30 seconds before resetting the cir- cuit breaker.CHAPTER 3. ENGINE OVERHAUL ENGINE REMOVAL..... ee weber ee . add A. Preparation for Removal... 0... 2.5.66. ++ sete eee eee dd B. Seatand Fuel Tank . .31 C. Muffler, Footrest, and Brake Pedal ..... 32 D. Oil Hoses . . 32 Carburetor 33 F, Drive Chain and Orive Sprocket . 33 G. Engine Mounting Bots, 134 DISASSEMBLY ve 35 A. Cylinder Head Cover dente tees 5 B. Cylinder Head .. eer res Beene . 35 C. Cylinder. . vote etneees 36 D. Piston Pin and Piston . es bee 1 36 E. Kick Crank occ eee ececeeeeeeeeeeeneee : 37 F. C.D.I. Rotor ae ae 37 G. Cam Chain and Guide Stoppers... 0sssssvescevssees fe BT H. Crankease Cover (Right) . . . . . 2 BT 4. Clutch Assembly and Drive: Goat beeen tee ee 38 J. Clutch Push Lever Axle . nee 2B K. Oil Pump Assembly ..... wee wee BD L. Kick Axle Assembly... 0... 139 M. Change Shaft Assembly. . fee 39 N. Balancer Gear .........- boc cnvcneteeeeees 38 0. Crankease .-..... +310 P. Transmission .310 Q. Crankshaft. . 31 R. Oil Strainer ‘Assembly. - 31 INSPECTION AND REPAIRING... . eee eee erent 312 A. Cylinder Head Cover nee hee 312 B. Cylinder Head .. . me se . 2 B81F, C. Valves, Valve Guides, Valve Seats, and Valve Springs. . 313 DB. Rocker Arms and Rocker Arm Shafts . bee 317 —. Camshafts, Cam Chains, and Cam Sprockets. ...... 318 F. Cylinder - 319 G. Piston and Piston Rings. veces 3-19 H. Crankshaft and Connecting Rod. +e B21 1. Oil Purp . an oe vee nee 3:23 J, Primary Drive... . on 323 K. Clutch ee eee vec vtevtsseseeees 323 L. Transmission : : 2325 M. Kick Starter... . bree on ee eee B26 N. Bearings and Oil Seals .... . . . 3-26 0. Installation ween oe 327ENGINE ASSEMBLY AND ADJUSTMENT... A, Important information . . Left-Side Crankcase. Crankshaft Installation... : cee Oil Pump . Shifter . Kick Starter... Balancer Drive Gear and Driven Gear Push Lever Assembly Primary Gears and Clutch. . Clutch : Clutch Meshanical Adjustment... . Crankcas2 Cover Right Kick Crank Assembly... Piston and Piston Ring....-.+-+ Cylinder ....... 5s Cylinder Head, Rocker Arm, and Camshott . Cylinder Head : Cam Shaft, Cam Sprocke:, Cam Chain ‘Cem Chain Tensioner... Cylinder Head Cover Flywheel... Crankcase Cover Decompression Cable... Drive Sprocket. .... Oil Delivery Pipe... Drain Plug... NXXE aencsnccit (SERVICE LIMIT) 1.7 mm (028m) MINIMUM LENGTH (SERVICE LIMIT) 40mm (0.157 in) 2. Valve stem wear must be measured and 3. Using a rounded scraper, remove the then combined with valve guide meas- carbon deposits from the combustion urements to obtain guide clearance. chamber. Take care to avoid damaging This clearance must be within tole- the spark plug threads and valve seats. ances, If it exceeds the maximum limit, Do not use a sharp instrument. Avoid then replace either or both valve and scratching the aluminum. guide as necessary. 4. Check the cylinder head warpage with a straightedge as shown. Valve Stem Clearance The warpage should not exceed the 9.010 ~0,037mm 010mm specified limit; if necessary, resurface wale: {0.0004 ~0,0015in) | (0.004in) the cylinder head. If the warpage ex aL | Mem ceeds allowable limit, the cylinder head Exmaust | 19.9012 ~0.00021n) | (0.006in} should be replaced with a new one. Cylinder head warpage: Jess than 0.03 mm {0.0012 in) Allowable limit: 0.25 mm (0.010 in) VALVE: 313SORE GAUGE 3, Inspect the end of the valve stem. If the end appears to be “mushroomed” or has a larger diameter than the rest of the stem, the valve, valve guide, and oil seal should be replaced. 4, Place the valve on V-blocks, and measure the amount of stem runout with a dial gauge. If it exceeds the max- imum limit, replace the valve. ‘Maximum valve stem runout: 0.61 mm (0.0004 in} Valve guides If oil leaks into the cylinder through a valve due to a worn valve guide or if a valve is replaced, the vaive guide should also be replaced NOTE: The valve oil seal should be replaced whenever a valve is removed or replaced. 1, Measure the valve guide inside diameter with a small bore gauge. If it exceeds the limit, replace it with an oversize valve guide. Guide diameter (1.0. Limit: 7.10 mm (0.280in} 2. To ease guide removal and reinstallation and to maintain the correct interference fit, heat the head to 100°C (212°F), Use ‘an oven to avoid any possibility of head warpage due to uneven heating 3. Use the valve guide remover and valve guide installer to drive the old guide out and drive the new guide in. NOTE: The vaive guide oii seal should be replaced whenever a valve is removed or replaced. 4, After installing the valve guide, use the 7 mm reamer (special tool P/N. YM- 01227) to obtain the proper valve-guide- to-valve-stem clearance. REAMER (7mm) ~~ valve GUIDE 5. After installing the valve guide in the cylinder head, the valve seat must be recut. The valve should be lapped to the new seat. a4Valve seat 1. The valve seat is subject to severe wear. Whenever the valve is replaced or the valve face is resurfaced (see caution), the valve seat should be resurfaced at a 45° angle. If a new valve guide has been installed, the valve seat must be recut to guarantee complete sealing between the valve face and seat ae Lr 8 owl es) If the valve seat is obviously pitted or worn, it should be cleaned with a valve seat cutter. Use the 45° cutter. When twisting the cutter, keep an even downward pressure to prevent chatter marks. If cutting section A of the valve seat, use 30° cutter. If cutting section 8, use the 45° cutter. If cutting section C, use the 60° cutter. Measure the valve seat width. Apply mechanic's bluing dye (such as Dykem! to the valve face and valve seat, apply a very small amount of fine grinding com- pound around the surface of the valve face, insert the valve into position, and spin the valve quickly back and forth. Lit the valve, clean off all grinding com- pound, and check valve seat width, The valve seat and valve face will have removed the bluing wherever they con- tacted each other. Measure the seat width with vernier calipers. It should measure approximately 1.3 mm (0.051 in}. The valve-seat contact area should be one uniform width. If vaive seat Width varies or if pits stil exist, further 316 cutting will be necessary. Remove just enough material to achieve @ satisfac- tory seat. J Standard wich | Wear Limit 1320.1 mm 20mm Searwidth | (0.051 +0.0039in) | (0.080%) 3. If the valve seat is uniform around the perimeter of the valve face but is too wide or not centered on the valve face, it must be altered. Use either the 30°, 45°, or 60° cutters to correct the improper seat location in the manner described below: ‘© If the valve face shows that the valve seat is centered on the valve face but is too wide, then lightly use both the 30° and the 60° cutters to reduce the seat width to 1.3mm (0,051+ If the seat shows to be in the middle of the valve face but too narrow, use the 45° cutter until the width equals 1.3 mm (0.051 in) If the seat is too narrow and right up neer the valve margin, then first use the 20° cutter and then the 45° cutter to get the correct seat width: If the seat is too narrow and down near the bottom edge of the valve face, then first use the 60° cutter and then the 45° cutter. Lapping The valve/valve seat assembly should be fap- ped if neither the seat nor the valve face are severely worn. 1. Apply a small amount of coarse lapping ‘compound to the valve face. Insert the valve Into the head. Rotate the vaive un- til the valve and valve seat are evenly polished. Clean off the coarse com: pound, then follow the same procedure with fine compound. Continue lapping until the valve face shows a complete and smooth surface all the way around, Clean off the com- pound material. Applying bluing dye to the valve face and seat, and rotate the valve. Check for full seat contact which icated by a grey surface all around the valve face where the bluing has been rubbed away. 36 2, After all work has been performed on the valve and valve seat end all head parts have been assembled, check for proper valve/vaive seat sealing by pour- ing solvent into each of the intake ports, then the exhaust ports. There should be no leakage past the seat, If fluid leaks, disassemble and continue to lap with fine lapping compound. Clean all parts thoroughly; reassemble and check again with solvent, Repeat this procedure as often as necessary to obtain a satistac- tory seal. Valve springs This engine uses two springs of different sizes to prevent valve float of surging. The valve spring specifications show the basic value characteristics. 1. Even though the spring is constructed of durable spring steel, it aredually loses some ofits tension. This is evidenced by a gradual shortening of free length. Use a vernier caliper to measure spring free length. If the free length of any spring has decreased more than 2 mm (0.080 in) from its specification, replace it. ONAnother symptom of spring fatigue is in- sufficient spring pressure. This can be checked with a valve-spring-compros sion-rate gauge. Test each spring in- dividually. Place a spring in the gauge and note the spring pressure when the spring is compressed to the installed length (valve closed). If the pressure does not equal the specified value, replace the spring. Valve Saring Specificavons| oversea | nena 7 aim | aim ror (72m) (1.58 in) ittetingh | 342mm | Siam (valve closed! (1.346 in} | (1.22810) Installed pressure | 16.0 kg Bitkg Mavecieat” | agi) | ab) Alot [ne | ase foment | dsm | item Valve installation peranens ‘cOLLAR-— “Ol SEAL Lubricate the valve stem and the oil seal with a high-quality molybdenum disulfide motor oil or molybdenum disulfide grease, or 2. Insert the valve in the cylinder head, and install the oil seal. Carefully fit the oil ‘seal aver the valve stem and push it into postion on top of the valve guide. 3. Install the spring seat, and install both valve springs. 37 NoT! All valve springs must be installed with the larger pitch upward as shown. 4, Install the collar. Be sure it is properly seated on the valve springs. 5. Install the valve spring compressor, and compress the springs. 6. Install the valve retainers. Be sure the re- tainers property engage the valve stem. 7. Carefully remove the valve spring com pressor. unites Proceed slowly. If a retainer has not been properly instelled, it could be ejected from the cylinder head. 8. Gently tap the end of the valve stem with a plastic mallet. This will ensure that the retainers are properly seated in the collar. D. Rocker Arms and Rocker Arm Shafts ‘The rocker arm usually wears at two locations: at the rocker shaft hole and at the cam-lobe contact surface. Check these areas for signs of unusual wear. 2. Measure the rocker arm inside diameter. If it exceeds specification, replace the rocker arm. Maximum inside diameter 12.05 mm (0.474 in}3. Measure the outside diameter of the rocker arm shaft. If it is less than the specified value, replace the rocker arm. Minimum outside diameter: V.95 mm (0.470in) 4, Calculate the clearance by subtracting the rocker-arm-shaft outside diameter from the rocker-arm inside diameter. If this clearance is greater than 0.1: mm (0.0039 in) replace either or both parts as necessary. 5. The rocker arm shaft has been harden- ed; it should not wear excessively. If a groove can be felt in the bearing surface or if the shaft shows a blue discolora- tion, the shaft should be replaced and the lubrication system checked. E, Camshafts, Cam Chains, and Cam Sprockets Camshaft The cam tobe metal surface may have a blue discoloration due to excessive friction. The metal surface could also start to flake off or become pitted. 1, If any of the above wear conditions are readily visible, the camshatt should be replaced 2. Evan though the cam lobe surface ap- pears to be in satisfactory condition, the lobes should be measured with a micrometer. Cam lobe wear can occur without scarring the surface, If this wear exceeds the wear limit, valve timing and lift are affected. Replace the camshaft if wear exceeds the limit (wee Ta e sk 26mm BSI mm ines (1.4331 in) (1.1405 im) oo earn) m8 “past (7.4398 in) 0.1413 in) Cam sprocket and cam drive sprocket 1, Check the cam sprocket and cam drive sprocket for wear.F. Cylinder 1 Visually check the cylinder walls for scratches. If verticel scratches are evi dent, the cylinder wall should be rebored or the cylinder should be replaced. Measure cylinder wall wear in the man- nner as shown. If wear is excessive, com- pression pressure will decrease, and engine trouble will occur. Rebore the cylinder wall, and replace the piston and piston rings. Cylinder wear should be measured at three depths by placing the measuring instrument perallel to and at right angles to the crankshaft. (See the illustration.) If the cylinder wall is worn beyond the ‘wear limit, it should be rebored. A 219 S =L...Jz= IP ames S| dyanav. _ => = z [eect ‘Standard | Waar limit isi (3.622 int {3.626 in} on G, Piston and Piston Rings Piston (0.0018 ~-0.6026 in) Using the micrometer, measure the out- ide ciameter of the piston at the piston skirt. Measurement should be made at a point 9.5 mm (0.37 in) above the bottom edge of the piston by placing the micrometer parallel to and at right angles to the piston pin. Piston clearance: 0.045 ~ 0.065 mm 6.0mm (0 236%)Sze A Standard 92.00 mm (.622in) Oversize | 92.25mm (3:632in) Oversize 2 92.50mm (3.682in) Oversize £2.75 (3.652n) Oversize 4 93.00 mm {3.662 in) 2. Piston ring/ring groove fit must have correct clearance. If the piston and ring have already been used in the engine, the ring must be removed, the ting groove cleaned of carbon, then the ring should be reinstalled. Use a feeler gauge to measure the gap between the ring and the land. 1 ] 0,.04~0.08mm °° | (0.0016 ~0.0031 nl aie Otring) (0.0008 ~0.0024nt Piston ring The oversize top and middle ring sizes are stamped on top of the ring. Oversize 1 (0.2 enm (0.009801 “Oversize? 0.50 mm (0.0197in) © Oversize 3 (0.75 mm {0.0296 int Oversize 4 | _1.00emm 10.0388in) ‘The expander spacer of the bottom ting (oil control ring) is color-coded to identify sizes. “The color mark is painted on the expander spacer 3-20 Sue | Color Oversize 1 [eon [Oversize 2 | eu Oversize 3 “Black Oversized | Yetow 1 Measure the end gap of each piston ting. Insert a ting into the cylinder, and push it approximately 20 mm (0.8 in) in- to the cylinder. Push the ring with the piston crown so the ring will be at a right angle to the cylinder bore. Measure the ring end gap with a feeler gauge. If the end gap exceeds tolerance, replace the whole set of rings. NOTE: You cannot measure the end gap on the ex- pander spacer of the oil control ring. If the oil control-ring rails show excessive gap, replace all three rings. Standard i epi 02-04mm 080mm ene (0.0073 ~0.0157in! | (0.0318in) 02~0.4mm 0.80mm 2nd in ‘aring (0.0073 ~0.0157in) Oiring 03~09mm - (fails) (0.0118 ~ 0.0354 in}Piston pin 1, Lightly oil the piston pin, and install it in the small end of the connecting rod. 2. Check the free play. There should be no noticeable vertical play. If any free play exists, check the connecting rod for wear. Replace the pin and connecting rod as recuired 3. Insert the piston pin in the pisten, and check the free play. There should be no noticeable fee play when the pin is in place in the piston. If the piston pin loose, replace the pin and/or the fiston as required. H. Crankshaft and Connecting Rod Crankshaft bearing 1. Bearings should be cleaned, dried, and the races visually checked for pits, rust spots, or chatter marks where the balis have dragged. If any of these conditions exist, the beerings should be replaced NOTE: Lubricate the bearings immediately after ex. amining then to prevent rust. 321Crankshaft 1. Check crankshaft components per chart. {Check connecting rod axial play at | Small end play should nat exceed 2 small end (to determine the amount | rm (0.079in) ‘of waar of crank pin and bearing at big end. Chock the connecting rod side | Move the connecting rod to one canny | Pededa. | Toeknes Troost |g | timm | 30mm — - (4.57in) (0.12in) Treat Tg | famm | zen fe ves! | asin | ort) r 5. Ball 2 6, Pustrodcck nut 3 7. Push ever 4 Fuses? 4, Install the clutch holding tool (special tool P/N. YM-91042) on clutch boss and tighten locknut. 334NOTE: — Align the arrow mark on the clutch boss and pressure plate mark, K. Clutch Mechanical Adjustment With the crankcase index mark and the pointed end of the push leverin line with each other, adjust the pushrod and then secure it 9. Install the clutch pressure plate and the with the locknut five clutch spiings. Torque the clutch plate bolts to specification. TIGHTENING TORGUE: 8Nm (0.8m-kg, 5.8ft-Ib) pat 10. Place a small piece of rolled rug or a piece of lead between the primary drive gears as shown in the photograph. It will hold the gears so you can tighten the primary-drive securing nut. Torque the 1. Lockout ut to specification, and bend the lock tab against a nut flat TIGHTENING TORQUE: 110 Nm (11.0 m-kg, 80L. Crankcase Cover Right 1. Before installing the crankcase cover, place the decompression lever as shown in the photo Install the crankcase cover, Install the oii filter element and cover: 4. Check to see the decompression lever assembly moves freely prior to tighten: ing the bolts. er NOTE: Tighten the screws using a crisscross pattern. M. Kick Crank Assembly Install the kick crank assembly and tighten the securing bolt. TIGHTENING TORQUE: 7Nm (0.7 m-kg, 5.1 ft-lb) N. Piston and Piston Ring 1, Mount the piston (rings installed) onto the connecting rod. Be sure the arrow stamped on the piston crown points forward. 2. Install new piston pin clips in their grooves. NOTE: Before installing the piston pin dips, cover the crankcase with a clean rag so you will not accidentally drop the clip into the crankcase. 3. During reassembly, coat the piston ring grooves, piston skirt areas, and piston pin with 4-stroke engine oil Ae « Be sure the ends of the oil ring expanders do not overlap. NoTe:_ The menufecturer’s marks or numbers stamped on the rings should be on the top of the rings. 3:360. Cylinder z ing (Lower ral 4. Giring Upper rad 4, Install the cylinder with one hand while sampressing piston rings with other hand. = ovina 6 Ouing 7 Cylinder gases 1. instal the cam chain guide to the : ‘ erankcase. 2. Install the new O-ring and cylinder base «5. Install the cam chein with @ wire in- gasket stalled. 6, Install the guide stopper and tighten the securing bolts. TIGHTENING TORQUE: “| 8Nm (0.8 m-kg, 5.8 4-lb} 3377. Tighten the cylinder securing nuts and bolts.Cylinder Head, Rocker Arm, and Camshaft on. seat exaust ‘rapper \ onine L- ‘CAM SPROCKET WAVE WASHER i Wy ROCKER ARM wy Y EXHAUST VALVE 0 Nem 1.0mm kg [rate ts come Leven AT iwrane raver coven “OR BLIND PLUG & Lockwur wave WasHEn_@) we? wi D mara howm 1.0m kg 7.28 O-RING g~ 7a VALVE COTTER = ~yatve ouren Senin “VALVE SPRING SEAT "INTAKE VALVE 3:39Q. Cylinder Head Install the two dowels and O-ring in the cylinder 2. Use a new gasket and tighten the secur ing bolts and nuts. R. Camshaft, Cam Sprocket, Cam Chain Install the camshaft onto the cylinder head as shown in the photograph(Com- pression stroke) Install the chain while aligning the marks on the crankshaft sprocket and crankcase, as shown in the following photo. 3.40 3. Install the cam sprocket onto the cam: shaft. The timing mark on the sprocket must be aligned as shown in the illustra tion, while pulling all the slack from the front side of the cam chain. The front side of the cam chain must be taut when thecam chain sprocket isinstlled. CAMSHAFT INSTALLATION Tin eS _-uppER Sx POSITION \ MARK scam -) sPmocker | CHAIN TENSIONER| FRONT CAM ASSEMBLY CHAIN GUIDE Te “ean CAM SMARE CHAIN GUIDES. CAM CHAIN TENSIONER 3. Adjust the valve clearance. (Refer to Chapter 2 “Valve clearance”.) 2ONm 120m kg, Ab} 4, Install the intake and exhaust tappet covers. U, Flywheel 1. Install the woodruff key into the crankshaft keyway. 2. Install the fiywheel assembly onto the crankshaft. The key in the crankshaft should engage the keyway in the flywheel. 3. Install the washer and the flywheel securing nut onto the crankshaft TENSION ROD TeNsionen BO0v 4. Install the rotor holding tool (special tool \ / SPRING P/N. YS-01880 (90890-01701) and so Wh TLE tighten the securing bolt. MND | 1G Za oneway can | END PLUG SPRING TIGHTENING TORQUE: 90 Nm (8.0 m--kg, 65 ft Ib) 1. Insert the frant cam chain guide in the cylinder. 2. Install the cam chain tensioner. First tighten the securing bolts. Then install and tighten the center bolt. 3. Install the tensioner to the cylinder and torque the bolts to the specification. TIGHTENING TORQUE: 10 Nm (1.0m-kg, 7.2ft Ib) i eseseater Lee} 1. install the two dowels and two O-rings 4. Reinstall the spring and end plug with in the left side crankcase as shown in the the gasket. Torque the end plug to the photograph specification. TIGHTENING TORQUE: 20.Nm (2.0m-kg, 14 ft-lb) T. Cylinder Head Cover 1. Install the O-ring and two dowels in the eylinder 2. Use a new gasket and tighten the secur- ing bolts. TIGHTENING TORQUE: 10 Nm (1.0m -kg, 7.2 ft-lb) 3412. Set the neutral cable into the left-side crankcase ditch and connect the neutral cable to the neutral switch. 3. Install the leit crankcase cover. Use a new gasket, and tighten the securing bolts. W. Decompression Cable 1. First install the decompression cable 10 the decompression levers. (1 and 2in the photo.) 2. Then install the cable holder (Bin the photo.) 1. Decompression ever 3. Cobble sedor 2. Decompressonlever 3. Adjust the decompression cable tree play. ® T * 2 Lockna 1. Auster 342 Decompression cable free play: 0.5mm (0.02in} Clamp the lead to the crankcase X. Drive Sprocket Install the collar, drive sprocket, and sprocket holder. Tighten the securing bolts TIGHTENING TORQUE: 10 Nm (1.0m-ka, 7.2 ft-Ib) Y. Oil Delivery Pipe Install the oil delivery gipe onto the crankcase. Install and finger tighten the securing bolts. NOTE: Ifthe O-ring is deteriorated, replace it Z. Drain Plug Install the drain plug using new gasket TIGHTENING TORQUE: 30 Nm |3.0.m-kg, 22 ft Ib}ENGINE MOUNTING 1 Supper wate Refer to ENGINE REMOVAL”. Reverse the engine removal procedure. 1. Mount the engine in the frame from the right side, NOTE: 1. Place a suitable stand under the engine. 2. Take care the left side swingarm collar is in the support plate. 2. Install the engine mounting bolts and nuts. 3. Install the engine protector and tighten the securing bolts. 4, Install the inlet and outlet hose and tighten the securing bolts and nuts. Nott Oil the inlet oll passage before installing the let oll hose and install the O-ring to the inlet hose.7. Install the lead, clutch cable, plug cap, and breather pipe. wy . 1. Breather pipe 8. Install carburetor assembly. Refer to removal procedure in Chapter 4, “Car- buretor.” 9. Install the drive chain and caulk the joint using the drive chain cutter 10. Install the exhaust pipes and mutfer. Tighten the securing bolts. 5. Install the tachometer gear unit and Tightening torque tighten the securing bolt me ie Pee Te M:Hex. bot 2 | 20 | 1 M6 Nut [wo | 7 11, Clamp the decompression cable to the frame. 12. Install the fuel tank and seat. Tighten the securing bolt. 13, Add 1.2 L (1.1 Imp at, 1.3 US at) of engine oil to the oil tank Do not force the tachometer unit. Put it in slowly. Twist and turn it gently until it fitsin place. 6. Fill the engine with 1.0 L (0.9 Imp qt, 1.1 US qt) of engine oil. 14, Start the engine and check oil pressure and oil leakage. Refer to Chapter 2, “Engine OilCHAPTER 4. CARBURETION CARBURETOR .. é seer AT A. Section View ... ce 43 B. Specifications ....-.... seegn ret Sarit tias.. ad C. Olsassembly. wre 44 D. Inspection 45 E. Assembly... : 7 “ se 46 F. Adjustment ...... ee at serves 46 AIR CLEANER AND CRANKCASE VENTILATION SYSTEM. .CARBURETION CARBURETOR SECONDARY NEEDLE JET — Ss sumo Piva — Am i 8 FZ & syychponizinc o Suaew @ SY A j "3 2 wine num —— : MSE Avge % seconoan / B® \ ~ waiver / Bl vate sea SQ | or fer ‘RBs, \ PRIMARY NEeoLE JeT— / ~@ \ PRIMARY MAIN JET Sienna - Hwa OF THROTTLE STOP. ’> 2 3enaw / asker if a ——FLOAT CHAMBER FRONT PLATE STAY ona @ Sg. _.-onan screw a1Primary Carb, Secondary Carb. VM type BStype (Cable — operated slide type) (Vacuum — controlled side type) SYNCHRONIZING screw PR serareanaer or L 4 x \ nus stor senew seconoany, HK - Sunommee PUSH LEVER L. imag) THROTTLE SHAFT. h SECONDARY 4 THROTTLE SHAFT a2A, Section View nna SECONDARY AIR JET \ \ | seconoane / | C | Neeoee ser Yo \y \ SECONSARY FUEL PASSAGE / \ / SECONDARY Jer PRIMARY AIR JET PRIMARY SYSTEM, SECONDARY SYSTEM. STARTER PLUNGER STARTER JETB, Specifications Main jet Jet needle Starter jet (GS.1 (Gs) Pilon screw Float valve Engineicle spoes 1,200 = 601/min WARNING The pilot screw settings are adjusted for maximum performance at the factory with special squipment. DO NOT at- tempt to change these settings. If all other engine systems are functioning correctly, any changes will decrease per- formance and cause increased exhaust emissions. C. Disassembly 1, Remove the seat. 2. Turn the fuel cock to “OFF”, and remove the fuel hose and the fuel tank. 3. Remove the throttle cables and the starter cable. 4. Loosen the four bolts securing the air cleaner case. 5. Loosen the four bolts securing the rub- ber joint band 6, Remove the carburetor. 7. Remove the rear and front plate stays from the carburetors. 8. Separate the primary carburetor and the secondary carburetor. NOTE: The primary and secondary carburetors are connected by @ rubber balance pipe and 4 metal fuel line. To separate the carburetors, pull them apart, applying an equal amount of force on each carburetor; see the photo- graph:Primary carburetor 1, Remove the starter plunger. 2, Remove the primary carb. cap. 3. Remove the shaft securing bolts. NOTE; Pay attention when removing the shaft secur- ing bolts, pressing the springs with one hand as they will turn. 4. Remove the drum wire assembly 5. Remove the wire holder springs. 6. Pull out the shaft, and remove the piston. 7. Remove the float chamber. 8. Remove the valve seat, the needle jet, the main jet, and the pilot jet. & e “7 “6 1. Remove the secondary carb. cap. 2. Remove the secondary piston. 3. Remove the needle jet out of the suction piston. NOTE: 1. Loosen the jot needle tightening screw and pull out the jet needle, then they can be pulled out with the needle holder. 2. Pay close attention to the small spring supporting the jet needle; it may jump ‘out when the jet needle is removed from the secondary piston 4, Assemble the secondary carb. cap and the secondary piston, then move and in- spect them. 5. Remove the blind plug and the needle jet. wo D. Inspection 1. Examine the carburetor body and fuel passages. If they are contaminated, wash the carburetor in 2 petroleum- based solvent. Do not use any caustic carburetor cleaning solutions. Blow out all passages and jets with compressed air,2. Examine the condition of the floats. If 6. Inspect the starter plunger. If it is worn the floats are damaged, thoy should be or damaged, replace it. replaced. 3. Inspect the float needle valve and seat for wear or contamination. Replace ‘these components asa set. A E. Assembly 1, To assemble the carburetors, reverse the disassembly procedures. 4, Inspect the primary and secondary NOTE: pistons. If the piston is scratched, it 7, The suction top has no set direction. must be replaced, 2. When tightening the secondary cap securing panhead screws, make sure ‘that the suction piston moves smoothly. Gradually tighten the two screws, alter = nating between them. Move the piston while the screws are tightened, ensuring that the piston does not bind. 3. Be sure that the suction piston moves smoothly after tightening the screws. F. Adjustment Fuel Level 5. Inspect the jet needle for bends or wear. NOTE: $$ It the needle is bent or severely worn, Before checking the fucl fevel, note the replace it. following: 1. Place the motorcycle on a level surface. 2. Adjust the motorcycle position by plac- ing a suitable stand or a garage jack under the engine so that the carburetor is positioned vertically. 1. Connect the level gauge (special too! P/N. YM-01312) or viny! pipe of 6 mm (0.24 in) in inside iameter to the float bow nazzle.on the cerburetor. 2. Set the gauge as shown and loosen the drain screw. 463. Start the engine and stop it after a few minutes. This procedure is necessary to obtain the correct fuel level. ‘The fuel level should be in the specified range. Fuel level: 5.0~ 7.0mm {0.197 ~0.276in) below the carb body edge 1, Float arm ting 7. Checkthe float height for reference Using a vernier caliper, measure the distance from the top of the float chamber gasket seat (with the gasket removed) to the top of the float; see the photograph, Float level: 26.0 +2.5mm{1.02 +0.10in) T Fonitevel 7 Sar. 0 295%) 2. Surface tension (20mm, 0.08.) 5. If the fuel level is incorrect, remove the carburetor from the motorcycle and check the fuel valve and float assembly for damage. Replace if damaged. §f no damage is found, correct the fuel level by slightly bending the float arm tang. 7 NOTE: The float should be just resting on, but not depressing, the spring-loaded inlet needle 8. Recheck the fuel level.Primary carb full-open adjustment Tum the grip to move the drum-wice assembly to the full-throttle position. Then turn the full-open adjusting screw in or aut so. the carb valve bottom is positioned within the limits a8 specified, then secure the locknut on it. FULL OPENING ADJUSTING SCREW ‘Secondary carb synchronization Raise the primary carb valve to a height of 10 mm (0.394 in) as indicated. Then adjust the synchronizing screw so the secondary throt- tle shaft just contacts the secondary throttle push lever. SYNCHRONIZING SCREW 40mm PRIMARY CARB ‘As the primary carb valve is further opened, the secondary butterfly valve will finally be opened to its full horizontal position. (a = b) SECONDARY CARB.AIR CLEANER AND CRANKCASE VENTILATION SYSTEM AIR cueaneRnCHAPTER 5. CHASSIS FRONT WHEEL. .. vette ee eens 51 a ee te 61 B. Checking Brake Shoe Wear . . 51 CC. Brake Drum ce 51 D. Brake Shoe Plate a coe a 51 E. Front Axle Inspection... . bon ee tees a F. Replacing Wheel Bearings . . cette eeeeeeee eee BZ G. Front Wheel Inspection . . . beeen eee cece BD H. Installing Front Wheel... - seeeeeeen es BR REAR WHEEL. . 58 A. Removal. ce veeeee -53 B. Checking Brake Shoe Wear 53 C. Brake Drum...... ; 54 D. Brake Shoe Plate .. . Ba E. Rear Axle Inspection . .. B4 F. Replacing Wheol Bearings --.....- 0.0.2.0. Ba G. Rear Wheel Inspection... cece eeeeeees veces 54 H. Installing Rear Wheel .......... beeen cB RIMS AND SPOKES............... cee cee Bd A. Checking far Loose Spokes fees oe 54 B. Checking Rim “’Run-Out”™ betes 54 TIRES AND TUBES so BS A. Removal. 55 8. Installation .. = . be 66 DRIVE CHAIN AND SPROCKETS ........ ae A. Drive Sprocket... B. Driven Sprocket. .... C. Chain Inspection . . D. Chain Maintenance FRONT FORK ... . . cece BB A. Removal and Disassembly . . cee 59 B. Inspection 02.2.2... . cee BD C. Assembly ceceeeee eens cee 5-10 STEERING HEAD en . seeeeeee BIT A. Adjustment 2.00.60... coe seve BIZ B, Removal... 612 C. Inspection . . feeb e tenet eee e eee eee eee eeee ences BAZ D. Assembly . + BISSWINGARM . A. Free Play Inspection B. Removal.......+.. . C. Inspection and Lubrication. 0. Assembly REAR SHOCK ABSORBER . A. Removal. . B. Inspection C. Installation and Adjustment wee Le CABLES AND FITTINGS. ..... A. Cable Maintenance 8. Throttle Maintenance. C. Lubrication of Levers, Pedals, etc. B14 +515 515 515 orl 518 519 519 5:20 521 6:21 52 521© YAMAHA KToobd service ManualCHASSIS FRONT WHEEL A. Removal 1. Remove the axle nut cotter pin and the axle nut. 2. Place the motorcycle on a suitable stand. Remove speedometer cable from front brake shoe plate: First remove clip and then pull cable out. 3. 4. Remove brake cable; loosen all cable ad- juster screws and remove cable from handle lever hokier. Then remove cable from cam lever at front brake shoe plate. 5. Remove the axle holder nuts at the right side of the axle. 6. Turn the wheel forward and remove the wheel with the axle. 51 8. Checking Brake Shoe We: 1, Measure the outside diameter at the brake shoes with slide calipers, Brake shoe diameter: 150 mm (5.91 in) Replacement limit: 146 mm (5.75 in) 2. Remove any glazing from the brake shoes with coarse sandpaper. C. Brake Drum Oil or scratches on the inner surface of the brake drum will impair braking performance or result in abnormal noises. Remove oil by wiping with a rag soaked in lacquer thinner or solvent. Remove scratches by lightly and evenly polishing with emery cloth. D. Brake Shoe Plate 1. Remove the camshaft and grease. If the cam face is warn, replace. NOTE: Before removing the cam lever, put a match mark (punches) on the cam lever and cam- shaft to indicate their positions for easy assembly. E. Front Axle Inspection Remove any corrosion from the axle with fine emery cloth. Place the axle on a surface plate, and check for bends. If bent, replace the axle. Do not attempt to straighten a bent axle.F. Replacing Wheel Bearings If the bearings allow play in the wheel hub or if the wheel does not tum smoothly, replace the bearings as follows: 1. Clean the outside of the wheel hub. 2. Drive the bearing out by pushing the spacer aside and tapping around the perimeter of the bearing inner race with a soft metal drift punch and hammer. The spacer “floats” between the bear- ings. Both bearings can be removed in this manner. To install the wheel bearing, reverse the above sequence. Use a socket that mat- ches the outside diameter of the race of the bearing to drive in the bearing. Do not strike the center race or balls of the bearing. Contact should be made on- ly with the outer race. G. Front Wheel Inspection 1. Check for cracks, bends, or warpage of the wheels. If a wheel is deformed or cracked, it must be replaced. Check wheel run-out. If the deflection exceeds the tolerance below, check the spoke-tension, rim deformation, and wheel bearings. Replace the wheel as re- quired. Rim run-out limits: Vertical: 2mm (0.079 in) Lateral: 2mm (0.079 in) 52 5 “fl 3. Check the wheel balance. Rotate the wheel lightly several times and note where the wheel comes to rest. If the wheel is not statically balanced, it will come to rest at the same point each time. Install an appropriate balance ‘weight at the lightest point (at top). 4. After installing a tire, ride conservatively to allow the tire to seat itself properly on the rim. Failure to allow proper seating may cause tire failure resulting in damage to the motorcycle and injury to the rider. After repairing or replacing a tire, check to be sure the valve-stem locknut is securely fastened. If not, torque it as specified. 5 TIGHTENING TORQUE: | 1.5.Nm (0.15 m-kg, 1.1 ft-lb) H. Installing Front Wheel ‘When installing the front wheel, reverse the removal procedure. Note the following points: 1. Lightly grease the lips of the front wheel oil seals and the gear teeth of the speedometer drive and driven gears. Use lightweight lthium-base grease. 2. Make sure the projecting portion (torque stopper) of the front fork is positioned correctly. 1 Dislaavee|3. Tighten the axle nut and install a new cotter pin. TIGHTENING TORQUE: 100 Nm (10.0m-kg, 72.3 ft Ib) Before tightening the axle holder nuts, compress the front forks several times to check for proper fork operation. Tighten the axle holder nuts. TIGHTENING TORQUE: 10.Nm (1.0m-kg, 7.2ft Ib) NOTE:, Always perform the following procedures when installing the front wheel shaft. 1. Finger-tighten the axle holder nuts. 2. Tighten the front wheel shaft. 3. Lock the motorcycle by the ‘ront brake and push/pull the front forks several times by the handlebars, so that the forks will move smoothly. Tighten the axle holder nuts. First tighten the nuts on the upper end of the axle holder, then tighten the nuts on the bottom. 4. 53 REAR WHEEL A. Removal 1. Remove the axle nut cotter pin and the axle nut 2. Place the motorcycle on a suitable stand. 3. Remove the brake rod from the brake shoe plate The brake rod can be removed by removing the adjuster. 4, Remove the drive chain from the driven sprocket while moving the rear wheel forward. The other recommendable procedure is cutting the drive chain joint with the drive chain cutter ‘See Chapter 3, “Engine Overhaul”. Age The chain joint must be replaced each time the chain is cut. 5. Pullout the rear axle. B. Checking Brake Shoe Wear 1, Measure the outside diameter at the brake shoes with slide calipers. Brake shoe diameter: 150 mm (5.91 in) Replacement limit 146 mm (5.75 in)2. Remove any glazing from the brake shoes with coarse sandpaper. C. Brake Drum Gil or scratches on the inner surface of the brake drum will impair braking performance or result in abnormal noises. Remove oil by wiping the brake drum with a rag soaked in lacquer thinner or solvent. Remove scratches by lightly and evenly polishing the brake drum with emery cloth. D. Brake Shoe Plate Remove the camshaft, and grease it. If the cam face is worn, replace the camshaft. NOTE: Before removing the cam Jever, put align- ‘ment marks on the cam lever and camshaft to indicate their relative positions for easy assembly. E. Rear Axle Inspection Refer to “Front Axle Inspection”. F. Replacing Wheel Bearings Rear whee! bearing replacement is similar to the procedure for the front wheel bearings. G. Rear Wheel Inspect See “Front Wheel Inspect H. Installing Rear Wheel 1. Lightly grease the lips of the rear wheel oil seals. 2. Install the wheel and the axle and the ax le nut 3. Connect the drive chain, the brake rod, and the adjuster. 54 Adjust the drive chain. See Chapter 2, “Drive Chain”. ‘Adjust the rear brake. See Chapter 2, "Front and Rear Brake”. Tighten the axle nut. TIGHTENING TORQUE: 490 Nm (10.0m-kg, 72 ft-lb) Install the new cotter pin on the axle nut. 7 RIMS AND SPOKES A. Checking for Loose Spokes Loose spokes can be checked by bracing the machine off the ground so that the wheel can spin freely. Slowly rotate the wheel and at the same time let the metal shaft of a fairly heavy screw- river bounce off each spoke. Ifall the spokes are tightened approximately the same, then the sound given off by the screwdriver hitting the spokes should sound the same. If one spoke makes a dull flat sound, then check it for looseness. Check each spoke for tightness. ‘Spoke torque Front wheel: 3Nm (0.3 m-kg, 2.2ft-Ib) Rear wheel: 3.Nm (0.3 m-kg, 2.2 ft-lb) B. Checking Rim “Run-Out” Raise the wheel off the ground. Spin wheel. Check rim run-out as shown in illustration. Rim run-out limits, Vertical: 2mm (0.08 in) Lateral: 2mm (0.08in)DIAL GAUGE a TIRES AND TUBES A. Removal 1. Remove valve cap, valve core, and valve stem locknut. Loosen bead spacer's), (rim locks). 2. When all air is out of tube, separate tire bead from rim (both sides) by stepping contre with your foot. 3. Use two tire removal irons (with round- ed edges) to work the tire bead over the ‘edge of the rim, starting 180° opposite the tube stem. Take care to avoid pin- ching the tube as you do this. 4. After you have worked one side of the tire completely off the rim, then you can slip the tube out. Be very careful not to damage the stem while pushing it back out of the rim hole, Nott If you are changing the tire itself, then finish ‘the removal by working the second bead off therim. B. Installation Reinstalling the tire and tube can be ac- ‘complished by reversing the disassembly pro- cecdure. The only difference in procedure would be right after the tube has been in- stalled. Before the tire has been completely slipped onto the rim, momentarily infiate the tube. This removes any creases that might exist. Release the ait and continue with reassembly. Also, right after the tire has been completely slipped onto the rim, check to make sure that the stem comes out of the hole in the rim at a right angle to the rim. Finally, inflate the tire. Front Tire Pressure: a Off-Road Riding Normal Riding High Speed Riding 167.1 kPa (1.Skg/em?, 21 pat Rear Tire Pressure: 98.1 kPa Seas (.0xg/em%, 145i) 147.1kPa Normal Ridin paises) (1.5kg/cm?,21 psi) 167.1 kPa High Speed Riding (1.8kg/em?,21 psi) DRIVE CHAIN AND SPROCKETS NOTE: Please refer to Maintenance Interval and Lubrication Interval charts for addit formation. A. Drive Sprocket With the left crankcase cover removed pro- ceed as follows: 1. With the drive chain in place and transmission in gear, firmly apply the reat brake. Remove the sprocket secur- 19 bolts. Remove the sprocket. 2. Check sprocket wear. Replace if wear decreases tooth width as shown. 3. Replace if tooth wear shows a pattern such as that in the illustration, or as precaution and common sense dictate. 4, Tighten the securing bolts. Drive Sprocket Securing Bolt Torque: 10 Nm{1.0m kg, 7.2 ft-lb)1 Watooth 2. Conect 7 Roller 4. Sprocket 1 Sipe 2 Bent teeth B. Driven Sprocket With the rear wheel removed, proceed as follows: 1. Using a blunt chisel, flatten the securing nuts lock-washer tabs. Remove the securing nuts. Remove the lock washers and sprocket. Check the sprocket wear using pro- cedures for the drive sprocket. Check the sprocket to see that it runs true. If bent, replace. During reassembly, make sure that sprocket and sprocket seat are clean. Tighten the securing nuts in a crisscross pattern, Bend the tabs of the lock washers fully against the securing nut flats. Driven Sprocket Securing Nut Torque: 30.Nm (3.0m-kg, 21.7 ft-lb} 1 Look wher 7 Nat C. Chain Inspection 1. With the chain installed on the machine, excessive wear may be roughly deter- mined by attempting to pull the chain away from the rear sprocket. If the chain will lift away more than one-half the length of the sprocket teeth, remove and inspect. {f any portion of the chain shows signs of damage or if either sprocket shows signs of excessive wear, remove and in- spect. Check the chain for stiffness. Hold as il- Justrated. if stiff, soak in solvent solu- tion, clean with wire brush and dry with high pressure air. Oil chain thoroughly and attempt to work out kinks. If still stiff, replace. Check the side plate for damage. Check to see if excessive play exists in pins and rollers. Check for damaged rollers. Re- place as required. 56 {8 Checking forexcessively worn chan 1. V2tooth 2 PalD. Chain Maintenance The chain should be lubricated according to ‘the recommendations given in the Mainte- nance and Lubrication Interval charts, or more often if possible. (Preferably after every use.) See ‘Chassis and Suspension, Swing Arm’, for additional information regarding chain gui Ap lide. Wipe off dirt with shop rag. \f accumula- tion is severe, use wire brush, then rag. 2. Apply lubricant between roller and side plates on both inside and outside of chain. Don’t skip a portion as this will cause uneven wear. Apply thoroughly. Wipe off excess. Recommended lubricant: YAMAHA CHAIN AND CABLE LUBE, or SAE 10W30 type SE motor oil Periodically remove the chain. Wipe and/or brush excess dirt off. Blow off ‘with high pressure air. 4, Soak chain in solvent, brushing off re- maining dirt. Dry with high pressure air. Lubricate thoroughly to make sure lubri- cant penetrates. Wipe off excess. Re- install. 57FRONT FORKA. Removal and Disassembly Cnc Securely support the motorcycle so there is no danger of it falling over 1 Disconnect the speedometer cable. Remove the brake drum and the front wheel. Remove the front fender. Remove the rubber cap from the too of each fork. Keep the air valve open by pressing it for several seconds so that the air can be let out of the inner fork tube. The spring seat and fork spring are re- tained by a stopper ring (spring cable circlip). It is necessary to depress the spring seat and fork spring to remove the stopper ring. Remove the stopper ring by carefully prying out one end with small screwdriver. Place an open container under each drain hole. Remove the drain screw from each outer tube. Loosen the pinch bolts on the upper and lower brackets, and remove the forks. Remove the cylinder securing bolt from the bottom of the fork assembly. Hold the inner tube with the front-fork: cylinder holder (special tool P/N. YM- 01327), Pull the inner fork tube from the ‘outer fork tube. 59 8, Remove the retaining clip from the outer fork tube, and pry out the fork seal. Be careful not to damage the fork tube sur- face. B. Inspection 1. Examine the inner fork tube. If the tube is severely scratched or bent, it should be replaced, Rant Do not attempt to straighten a bent fork tube; this may dangerously weaken the tube.2. Inspect the outer surface of the fork seal 5. Reinstall the spring seat and fill the fork seat in the outer fork tube. If this surface with air using a manual air pump or a is damaged, replace the outer fork tube. pressurized air supply. Refer to “Front If it is not damaged, repiace the fork fork and rear shock absorber adjust- seal. ment” on page 2-13 for proper air 3. Check the outer fork tubes for dents. pressure adjusting. Replace the tube if itis dented. 4. Check the free length of the springs. Maximum air pressure: 117.7 kPa (1.2 kg/em?, 17.1 psi) Fork spring free length: Do not exceed this amount. ese 88 mm (3.48 in) Lower 248.8mm(13.7in) 6. Check all suspension components for ; ‘ proper operation. 8. Sek oe ore rn ee "t 7. Check all suspension fittings for proper itis damaged, replace it. tightness. 1. Oring C. Assembly 1. Make sure all components are clean before assembly. Always install a new fork seal. Do not reuse a seal. 2. Apply oil to the fork seal, and install the fork seal by pressing it in with a large socket. Install the retaining clip 3. Install the inner fork tube into the outer fork tube. 4, Apply Loctite? Stud N’Bearing Mount (red) to the cylinder securing bolt, and install the bolt and a copper washer into the outer fork tube. Torque the bolt to specification. TIGHTENING TORQUE: 37. Nm (3.7 m-kg, 27 ft-Ib) 510STEERING HEAD [23 Nm 23 mika, 17 fib) ds : : BtA. Adjustment 6. Remove the ring nut supporting the Refer to D. Assembly” for steering head ad under bracket so that it may not fall justment procedures. down: B. Removal 1. Remove the seat, fuel tank, and the up- per bracket cover. 7. Remove the bearing cover and the upper and lower bearings. 2. Remove the headlight, meters and other attached component. See Chapter 6, ““Easy-maintenance Lighting System” C. Inspection 1. Wash the bearings in solvent. 2. Inspect the bearings for pitting or other damage. Replace the bearings if pitted or damaged. 3. Clean and inspect the bearings. Spin the bearings by hand. If the bearings are not smooth in their operation, replace the bearings. 3, Remove the handlebar 4, Remove the front fork assembly. 5. Remove the steering fitting bolt, and remove the handle crown 542D. Assembly 1, Grease the bearings and races with wheel bearing grease. m® 2. Install the under bracket and bearing, 3. Tighten the ring nut. TIGHTENING TORQU 38 Nm (3.8m -kg, 27 ft-Ib) 4. Continue assembly; reverse the disas- sembly procedurt 5. When assembly is complete, check the under bracket by turning it from lock to lock. If there is any binding or looseness, readjust the tightness of the under bracket. TIGHTENING TORQUE: Front fork pinch bolt: 23Nm (2.3m-kg, 17 ft-lb) Steering fitting bolt: 95 Nm (9.5m_kg, 68 ft-lb) 513SWINGARM Piyor SHAFT pare washer} THaust cover. BEARING ont SEAL a CHAIN TENSIONER 514A. Free Play Inspection 1. Remove the reat wheel and the shock absorber. Grasp the swingarm and try to move it from side to side as shown. Check for free play. ‘Swingarm free play: 1.0mm (0.04 in) at end of swing arm ===] Vale 3. Remove the swingarm pivot bolt, and remove the swingarm. ~ 2. If free play is excessive, remove the sw- ingarm and replace the bushings or bearings. Replace the thrust cover or oil seals if necessary. 3. The swingarm is mounted on needle bearings and bushings. Move the sw- _C. Inspection and Lubrication ingarm up and down as shown. The sw- 1, Examine the thrust covers and oil seals. ingarm should move smoothly, without Replace if they are damaged. tightness, binding, or rough spots that 2. Inspect the bearings and bushings in the couldindicate damaged bearings. swingarm member for scratches on other damage. Make sure that the needle bearing rolls freely. If the bearings or bushings are damag- ed, they should be replaced. NOTE: When pressing the new bearings and bushings, pay attention to the followin 1. Bearings should be exactly located as shown in the illustration. [4mm (0.16 in) from each side) B. Remov: 2. Grease them liberally with lithium-base 1, Remove the seat and the rear wheel waterproof wheel bearing grease. 2. Remove the cotter pin from the sw- ingarm, drive out the shock absorber pivot shaft, and disconnect the shock absorber from the swingarm. 515COLLAR SPACER 1 seat. CRANKCASE NEEDLE BEARING FRAME BRACKET PPORT PLA SUPPORT PLATE “CHAIN GUARD \ ‘SWINGARM MEMBER 4. Check the collar spacer length B. 3. Measure the length A. (Swingarm right-side member) Colfar spacer length: B = 77:33mm (3.037¢6%in) If B is not within specification, replace ‘the collar spacer. 5. Calculate the side clearance C by using the formula given below. C=B-A ‘Swingarm side clearance: C= 0.1~0.3mm (0.004 ~ 0.012 i 616NOTE: _ Make sure the bushings are securely pressed into the swingarm member. If the side clearance is nat within specification, adjust it by means of shims. If only one shim is used, install it on the right side. Two shims must be installed on both sides. ‘Swingarm side clearance: 0.1 ~0.3mm (0.004 ~ 0.012 in) 7. Grease the swingarm periodically. D. Assembly 1. Assemble the swingarm by reversing the removal procedures. Use a new lock plate, and torque the swingarm pivot bolt to specification. TIGHTENING TORQUE: 100 Nm (10 m-kg, 72 ft-lb) Use a new cotter pin when installing the shock absorber pivot shaft. Bend the cotter pin as shown in the photo. 2. Using a grease gun, lubricate the sw- ingarm pivot points; see the photo. 517 1. Grease ripeREAR SHOCK ABSORBERA. Removal Rear Shock Absorber This shock absorber contains highly pressurized nitrogen gas. Read and understand the following information before handling the shock absorber. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling. 1. Do not tamper with or attempt to remove the snap ring or bearing at the top of the cylinder Do not subject shock absorber to an ‘open flame or other high heat. TI may cause the unit to explode due to excessive gas pressure. Do not deform or damage the cylinder in any way. Cylinder damage will result in poor damping performance. Gas pressure must be released before disposing of the shock ab- sorber. To do so, drill a 2 ~ 3 mm (0.08 ~ 0.12 in) hole through the cylinder wall at a point 10 ~ 15 mm. (0.39 ~ 0.59 in) above the bottom of the cylinder. Wear eye protection to prevent eye damage from escaping gas and/or metal chips. 9 — 90 1. Dai12~Imme (0.08 ~0.12in6) 2. 10~ 15mm (0:39 ~0.58in) 1 a Remove the seat and the fuel tank. Remove the rear wheel. Refer to page 53. 3. Remove the cotter pin from the sw- ingarm, drive out the shock absorber pivot shaft, and disconnect the shock absorber from the swingarm. Remove the shock absorber mounting bolt, and remove the shock from the frame by carefully pulling it towards the rear of the motorcycle. B. Inspection 1. Remove the rear shock absorber from the motorcycle. 2. Loosen the locknut and loosen the spr- ing seat. This will make it easy to remove the spring. 1 Locknut 2. Spring seat 3. Push down the spring, remove the spr- ing retainer, and remove the spring. <> WU .—— i 5194. Check the rod, and ifit is bent or damag- ed, replace the shock absorber. 5. Check for oil leakage. If oil leakage is evident, replace the shock absorber. C. Installation and Adjustment 6. By moving the rod, check to see if it has proper damping effect. Slight resistance should be felt on the compression (down) stroke and considerable resist- ance should be felt on the return (up) stroke. 273 ~ 288mm (107-1131) - 0 1. Instaii the spring and guide, and turn to ‘set the seat spring as shown in the il lustration, Normal position 4 = 286mm (11.3in) 2. Install the shock absorber on the motor- cycle. Rear shock absorber Tightening torque: 48 Nm (4.8 m-kg, 35ft-Ibi 520CABLES AND FITTINGS A. Cable Maintenance NOTE: See “Maintenance and Lubrication” intervai charts. Cable maintenance is primarily con- cerned with preventing deterioration and pro- viding proper lubrication to allow the cable to move freely within its housing. Cable removal is straightforward and uncomplicated. Removal is not discussed within this section. Cnn Cable routing is very important. For details of cable routing, see the cable routing diagrams at the end of this manual. Improperly routed or adjusted cables may make the motorcycle unsafe for operation. 1. Remove the cable. 2. Check for free movement of the cable within its housing. If movement is obstructed, check for frayed strands or kinking of the cable. If damage is evi- dent, replace the cable. 3. To lubricate the cable, hold it in a ver- tical position. Apply lubricant to the up- permost end of the cable. Leave it in the vertical position until the lubricant ap- pears at the bottom. Allow any excess to drain, and reinstall the cable. No’ a Choice of a lubricant depends upon condi- tions and preferences. However, a Yamaha chain and cable lubricant or its equivalent will perform adequately under most conditions. B. Throttle Maintenance 1. Remove the Phillips head screws from the throttle housing assembly and ‘separate the two halves of the housing. 2. Disconnect the cable end from the throt- tle grip assembly, and remove the grip assembly. 3. Wash all parts in @ mild solvent, and check all contact surfaces for burrs or other damage. (Also clean and inspect the right-hand end of the handlebar.) 4, Lubricate all contact surfaces with a light coat of lithium-base grease and reassemble. NOTE: Tighten the housing screws evenly to main- tain an even gap between the two halves. 5. Check for smooth throttle operation and quick spring return. Make certain that the housing does not rotate on the handlebar. Nor! ae a The starter lever has been installed on the lever holder with Loctite. When reinstalling the starter lever screw, always use a new screw. Remove the old Loctite in the lever holder screw hole by using a 6 mm screw tap. Cc. Lub n of leve pedals, etc. 1. Lubricate the pivoting parts of the brake and clutch levers with motor oil (10W/30). 2. Lubricate the shaft of the brake pedal with lithium grease. 621CHAPTER6. ELECTRICAL ELECTRICAL COMPONENTS. ..... RTOOOUEWIRING DIAGRAM 5)... 0,022 +ese-sdrashe samen! CHARGING SYSTEM....... Mees lisa AC GENERATOR AND VOLTAGE REGULATOR . A. Inspection ...........5 B. Battery Inspection, C. Stator Coil Inspection. . . IGNITION SYSTEM A. Description . B. Ignition Timing. .... C. C.D.I. Unit Test ...... D. gE C.D.1, Unit Test by Yamaha Pocket Tester... Troubleshooting. ..........6...06 LIGHTING SYSTEM... eee ‘A. Easy-maintenance Lighting System ey B. Lighting Tests and Checks .....2....00.+ SIGNAL SYSTEM... A. Signal System Tests and Checks . Be Swhches tis, ¢ 0 ssce C. Battery. .ELECTRICAL ELECTRICAL COMPONENTS IMPONENT (1)REFLECTOR STOP SWITCH NEUTRAL TCH SIDESTAND,£9 XT550J WIRING DIAGRAM ommen swnrcx Beare STANO ON Sea a, ay STAND OFF IneurmaL swirow! SPEEDOMETER LIGHT wera ore rer a ans basen ape Black/White won ruse © Yellow Rec ecriieny Sreaken “Beck ¥eiow REGULATOR a E ect Yow E ‘iue/ White poor Brovn/ White Seal Rea/wnite Blue/Black Bive/YelowNon-fuse breaker Ae route cocoa 1 Case “ Semiatipie spring 2. Moveable spring 5. Contact point (tiretal) 6. Terminal 3. Knob ‘Operation If an excess current should flow through the above-shown circuit, the bimetal will heat up and deform. When its deformation exceeds a certain amount, the bimetal forces the knob out. The bimetal is kept warped by the semielliptic spring. In this manner, the circuit is left open. The circuit can be closed by simply pushing the knob down. By repeating this operation, the same circuit breaker can be used repeatedly. Wait 30 seconds before resetting the cir- cuit breaker. 64RECTIFIER WITH REGULATOR (UNDER SEAT)AC GENERATOR AND VOLTAGE REGULATOR A. Inspection 1. Connect the pocket tester to the battery terminals. 2. Start the engine. 3. Accelerate the engine to approximately 2,000 r/min or more, and check the ‘generator voltage. Generator voltage: 1 4. Ifthe indicated voltage cannot be reach- ed, check all connections. If the connec- tions are all good, check the battery, stator coil, and the regulator/rectifier. If both the battery and stator coil are in working order, the regulator is defective and should be replaced Never disconnect the cables from the battery while the generator is operating. If the battery is disconnected, the volt- age across the generator terminals will increase and you may be shocked. B. Battery Inspection 1. Check the battery terminals and couplers. They should be tight. 2. Measure the specific gravity of the bat- tery. If itis less than 1.260, remove and charge the battery until the specific gravity is greater than 1.260. 66 C, Stator Coil Inspection 1, Remove the seat. 2. Disconnect the stator coil leads from the voltage regulator, and connect the pocket tester as shown. If the resistance is not the specified value, the stator coil is defective and should be replaced. Charging coil resistance: 0.2~0,62(W — W)IGNITION SYSTEM MAIN swiTcH ENGINE STOP SWITCH (R.H.) JGNITION COL eo) UNITE, Troubleshooting The entire ignition system can be checked for misfire and weak spark by using the Electro Tester. If the ignition system will fire across a specified gap, the entire ignition system is good. If it will not fire across the gap, pro- ceed with the individual component tests un- til the source of the problem is located. 1. Warm up the engine thoroughly so all electrical components are at operating temperature. 2. Stop the engine, and connect the tester ‘as shown rexenn ption | =f covet. Recher vetage ona am vos & arery seit gy creck monte Pa ‘ores connec macTno Taran ‘SPARK PLUG WIRE SPARK PLUG ‘eater and onorrepace connectors oropan cet te T ox | ‘Checkers of ‘anon col pinay 0c) Secondary: 62 = 16a 20°C 68°F) , ox acim feoucsonon eiied ‘Start the engine, and increase the spark gap until a misfire occurs, (Test at various rpm between idle and red line.) 1 Creek pickup cots Penupcor tioas | "ried Replace pickup Womeron | Repaceeit 20 20°C 18°F) ‘Minimum spark gap: 6 mm (0.24 in) T Do not run the engine in neutral above 6,000 r/min for more than 1 or 2seconds. If the ignition system becomes inoperative or if the engine misfires at the minimum spark gap or at a smaller gap, there is @ problem in ‘the ignition system. Follow the trouble- ‘shooting chart until the source of the problem islocated. ox ae Ccoturitsteaty reokcesne Ignition spark gap test 1. Disconnect the ignition coil wires from the wiring harness and from the spark plug. 2. Connect the Electro Tester as shown. 610 | |PRIMARY COIL CHECK Ienrrion Eon. fgnrmion co 3. Connect a fully charged battery to the tester. 4, Turn on the spark gap switch, and in- crease the gap to maximum unless @ misfire occurs first. ‘SECONDARY COIL CHECK Minimum spark gap: 6 mm (0,24 in) Direct current resistance test Use the pocket tester to determine resistance and continuity of primary and secondary coi windings. Standard value: Primary coil resistance: 0.59 15% at 20°C (68°F) Secondary coil resistance: 6KQ + 15% at 20°C (68°F) en a a Spark plug The life of @ spark plug and its discoloring vary according to the habits of the rider. At each periodic inspection, replace burned or fouled plugs with new ones of the specified type. It is actually economica! to install new plugs often since it will tend to keep the engine in good condition and prevent ex- cessive fuel consumption. 1. Inspect and clean the spark plug every 4,000 km (2,500 mi), and replace after initiat 13,000 km (8,000 mi)2. Clean the electrodes of carbon, and ad- just the electrode gap to the specifica tion. Be sureto use a spark plug with the correct reach, electrode gap, and heat range to avoid overheating, fouling, or piston damage. Type: D7EA(NGK) Electrode gap: 0.6 ~ 0.7 mm (0.024 ~ 0.028 in) Tightening torque: 20 Nm (2.0m-kg, 14 ft-Ib) Sidestand switch 1, Remove the seat and disconnect the connector. 2. Connect the pocket tester leads as shown, and set the tester selector to ‘ohms % 1. When the sidestand is up, the tester should read zero ohms. When the sidestand is down, the tester should read infinity. Wire color Switch position FREE PusH 612LIGHTING SYSTEM eae 613A. Easy-maintenance Lighting System The headlight, meters, horn, and front flasher lights can be removed easily for off-road use. This detachable system has the added advantage of easy parts replacement and repair. Be sure to put the removed items back on the motorcycle correctly. Removal 1. Remove the connector cover and disconnect the wiring connector. Put the main harness connector back in its place. 2. Remove the three headlight bracket securing bolts. NOTE: When loosening the bolts, take care not to lose the underside clamp nuts. 3. Remove the cables from the speedo- and tachometer. Install the rubber caps. 4, Remove the headlight with the speedo- meter and tachometer mounted to it e145. Put the clamp nuts and bolts back in place while holding the meter cables and throttle and clutch wires inside. Installation Reverse the removal procedure, Make sure the removed parts are put back correctly. B. Lighting Tests and Checks The battery provides power for operation of the headiight, taillight, and meter lights. If none of the above operates, always check battery voltage before proceeding further. Low battery voltage indicates either a faulty battery, low battery electrolyte, or a detective charging system. See page 6-5’"CHARGING SYSTEM” for checks of the battery and charging system. WEADLIGHT DOES NOT [COME ON WHEN MAN ‘SWITCH IS TURNED TO (eee [Check bateryvotage at |. votege [mma waco ra] Sever teneme ere det | Check bare vag at heat igh bear oF ow Scent Wate OF betwen hada ong [Poor round or poor connectinotheadight NOTE: Check the headlight bulb filament first before performing the following check. 1. Headlight check. NOTE: When the main switch is turned to ON, the headlight, meter lights, and eailight come on. The main switch should be turned off. 2. Taillight does not work: * Check the bulb. ‘© Check for 12V on the blue/red wire. * Check for ground on black wire to tail/brake light and/or license light assembly. 615SIGNAL SYSTEM Main swircH FRONT BRAKE SWITCH (RH) TURN SWITCH (LH) DIMMER SWITCH (LH)A. Signal System Tests and Checks The battery provides power for operation of the hor, brake light, indicator lights, and flasher light. If none of the above operates, always check the battery voltage before pro- ceeding further. Low battery voltage in- dicates either a faulty battery, low battery electrolyte, or a defective charging system, See page 6-5 “CHARGING SYSTEM" for checks of the battery and charging system. Also check the non-fuse breaker. If the circuit is open, push the knob down. Horn does not work: 1. Check for 12V on the brown wire to the | horn, | 2. Check for good grounding of the horn | (pink wire) when the hom button is pressed. | Brake light does not work: 1, Check the bulb. 2. Check for 12V on the yellow wire to the brake light with brake pedal depressed. 3. Check for 12V on the brown wire to ‘each brake light switch (front brake and rear brake switches). Flasher light(s) do not work: 1. Check the bulb. 2. Right circuit: a. Check for 12V on the dark green wire to the light. b. Check for ground on the black wire to the light assembly. 3. Left circuit: a. Check for 12V on the dark brown wire to the light. b. Check for ground on the black wire to the light assembly. 4. Right and ieft circuits do not work: a. Check for 12V on the brown/white wire to the flasher switch on the left handlebar. b. Check for 12V on the brown wire to the flasher relay. c. Replace the flasher relay. d. Replace the flasher switch. Neutral light does not work: 1. Check the bulb. 2. Check for 12V on the sky blue wire to the neutral switch: Replace the neutral switch. B. Switches ‘Switches may be checked for continuity with a pocket tester on the “ohms x1" scale. 1. Main switch. ‘Wire color Switeh - postion ferw{ eB { x [oer | ur ON OFF oto Lock oto Pipaking) | oto | o- 2. Engine stop switch Wire color Switch; | SS ee position aw 8 RUN oFF o—t—o 3. Lights (dimmer) switch Wire color Switch postion 7 L ¢ HI Ee Lo o——o 4, Tum switch Wire color switch position dg | svw | cm R Cost N i oto 6175. Hom switch swten — |___Wrecolor_ position = . PUSH o—+-—o OFF C. Battery If the battery shows the following defects, it should be replaced: 1. The battery voltage will not rise to a specific value nor will bubbles rise in any cell even after many hours of charging. Sulfation of one or more cells is in- dicated by the plates turing white or an accumulation of material in the bottom ‘of the cell Specific gravity readings after a long, slow charge indicate a cell to be lower than any others. Warpage or buckling of plates or in- sulators is evident. WG Battery fluid is poisonous and danger- ous, causing severe burns, etc. It con- tains sulfuric acid. Avoid contact with the skin, eyes, or clothing. Antidote: EXTERNAL—Flush with water. INTERNAL-Drink large quantities of water or milk. Follow with milk of magnesia, beaten eggs, or vegetable Call physician immediately. Eyes: Flush with water for 15 minutes, and get prompt medical attention. Bat teries produce explosive gases. Keep away. sparks, flame, cigarettes, etc. Ventilate when charging or using enclosed space. Always shi when working near batteries. KEEP OUT OF REACH OF CHILDREN. 618 The service life of a battery is usually two to three years. Lack of care, as described below, will shorten the life of the battery: Negligence in keeping battery topped off with distilled water. Battery eft discharged. Freezing. ing with tap water or sulfuric acid containing impurities. Improper charging voltage or current on new battery. If the motorcycle is not to be used for a long time, remove the battery and have it stored. The following instructions should be obser- ved: 1. Recharge the battery periodically. 2. Store the battery in a cool, dry plac tion. Battery Yeq6AL Bectroivte Specific ravty: 1.280 Initia charging current | 1.6 amp for 10hours (new battery) Recharging current fOhours (or until specific oravity reaches 1.280) Refill uid Distiled water (to maximum level ine) Refill period Check once per month formore often, as required)CHAPTER?7. APPENDICES SPECIFICATIONS... i : TIGHTENING TORQUE ......... sie Feb s yes Rca EER CONSUMER INFORMATION ...... 102.0600. 0 00e cece e cece FB: GENERAL TORQUE SPECIFICATIONS. ............-.02-000222.. 718 (COLOR CODES. eek es ous sages 2718 DEFINITION OF UNITS......... aed ott ne reel ore meee CONVERSION TABLES = 719 EXPLODED DIAGRAMS... . 7-20 Cylinder . i Camshaft/Chain .. Kick Starter Front Wheel Rear Wheel Frame... Oil Purp/ il Cleaner ea7mo0om> POWER FLOW CHART... LUBRICATION CHARTS. CABLE ROUTING DIAGRAMS ........... 0.006220 e eee ce ee ee 782. WIRING DIAGRAM ...APPENDICES SPECIFICATIONS 1. GENERAL SPECIFICATIONS Model XT850) Model Code Number : ovr Federal V.I.N, Number ‘JYASY100*DA100101 (*Check digit) Frame Starting Number | s¥7-t00101 i Engine Starting Number ; ‘BYT- 100101 2 Dimensions: ‘Overall Length | 2,210mm (87.0in) Overall Width ‘865 mm (34.1 Overall Height, 3,180 (46.5 in) Seat Height £860 mm (33.9in) ‘Wheelbase 1,405 mm (55.3 in) Minimum Ground Clearance 250mm ( 9.8in) Basic Weight: With Oil and Full Fuel Tank 143 kg (3151b) Minimum Turning Radius 2,300 mm (90.6 in) Periodic Oil Change With Oil Filter Replacement Engine Engine Type ‘4-stroke, gasoline, SOHC, 4-valve Cylinder Arrangement Single cylinder Displacement $558 cm? (34.1 cu. in) Bore x Stroke 92 84mm (3.622 3.307 in) Compression Ratio 85:1 Compression Pressure 1,079 kPa (11 kg/cm’, 156 psi) Starting System Kick starter Lubrication System Dry sump il Type or Gr ; rae oe | SAE 20W40 type SE motor oi! Oil Capacity Engine Oil 1.8L (1.6 imp at, 1.9US at) 1.9L (1.7 Imp qt, 2.0US qt) Primary Reduction System Primary Reduction Ratio Total Amount 2.21 (1.9impat, 23 US at) Air Fiter Wet type element Fuel Type Regular gasoline Tank Capacity 1.4L (2.5 imp gal, 20US gal Reserve Amount 2((0.4 imp gal, 0.5US gal) Carburetor ‘Type/ Manufacturer Y26PV/TK-KIKAKI Spark Plug Type/ Manufacturer D7EA/NGK Gop 0.6 ~0.7 mmm (0.024 ~0.028in) (Clutch Type Wet, muitiple-dise Transmission: Helical gear 76/30 (2.523) mWModel XTS50J ‘Secondary Reduction System Chain drive ‘Secondary Reduction Ratio 42/15 (2.800) Transmission Type Constant mesh, 5-speed, Dog type Operation Left foot operation ‘Geer Ratio, 1st 30/13 (2.307) 2nd 217 1.588) 3rd 24/20.(1.200) 4th 21/22 (0.954) sth 20/27(0.77) Chassis: 5 Frame Type Diamond Caster Angle 28°10" Teal 115mm (4.53in) Tire Type With tbe Size (F) 3.00821 -4PR Size (R) 4.60S18-4PR Tire Pressure (Cold tire) Front Tire Rear Tire kPa [ko/em?| psi | kPa [kg/em’| psi ‘One Rider v7 [1s [a | wis | 2 Off-Road Riding ser | 10 | 14 | 981 | 10 | 14 High-Speed Riding wi las [a | 7 | 1s [ 2 Brake x Front Brake Type Drum brake ‘Operation Right hand operation Rear Brake Type Drum brake Operation Right foot operation Z Suspension Front Suspension ‘Telescopic fork (Preumio-mechanical) Rear Suspension Unit swing, (Monocross suspension) ‘Shock Absorber Front Shock Absorber Air & Coil spring, Oil damper Rear Shock Absorber Gas & Coil spring, Oil damper Wheel Travel Front Whee! Travel 205 mm (8.1 in} Rear Wheel Travel 190mm (7.5in) Blectrical: Ignition System €.D.1. Magneto Generator System Flywheet magneto, A.C. generator Battery Type or Model 12N5-38 Battery Capacity 12V SAH Headlight Type Sealed beam 72Model Bulb Wattage Quantity Headlight as w/4ow Tai Brake Light ewizTw Flasher Light ZWx4 J Indicator ight Wattage/ Quantity yava.awx3 METER LIGHT” 3.4wx2 “NEUTRAL 34w “HIGH BEAM” 3.4w “TURN 34w 73ll, MAINTENANGE SPECIFICATIONS (4 Cycle Engine) A. ENGINE Model TSO Gylinder Head ‘Warp Limit +<0.03 mm (0.00%2in1> “Lines indicate straightedge measurement. Cylinder: Bore Size 92.08% mm (3.63 in) Taper Limit -<0.005 mm (0.0002.in)> ‘Camshaft # Drive Method Chain (Left ‘Cam Cap Inside Diameter 23°92 mm (90.91 + 0.0008 in) ‘Camshaft Outside Diameter 233.9% mm (90.91-8258 in) <0,020 ~0.054 mm (0.0008 ~ 0.002in)> ‘Cam Dimensions Intake “Rp —_ | 36,860.05 mm (1.44 + 0.002in) <26.40 min (1.4331 int> “8 30.12 + 0.05 mm (1.19 + 0.002in) <28.97 mm (1.1405 in)> 6.55 mm (0.26 in) A Exhaust “me | 36,720.05 mm (1.45 +0.002in) --8, | <38.57 mm (1.4398:in)> “gr | 30.14:+0.05 mm (1.19 + 0.002in) } <28.99mm (1.1413in)> “ct | 6.72mm(0.2in Camshaft Runout Limit <0.03mm (0.001 in)> ‘Cam Chain Type/ Number of Links 75-010/ 126 Links Cam Chain Adjustment Method Automatic, Rocker Arm/Rocker Arm Shaft Bearing Inside Diameter ‘Shaft Outside Diameter Arm-to-shaft Clearance 128% mm (0.47°3" in) <12.05mm (0.47 in)> 12-4881mm (0.47335 in) <11.95mm (0.47 in)> 0.009 ~ 0.042mm (0.0004 ~0.002 in) Valve, Valve Seat, Vaive Guide Valve Clearance (Cold) IN. EX. (0.05 ~0.10 mm (0,002 ~ 0.004 in) 0.12 ~0.17 mm (0.005 ~ 0.007 in) 74[ Model XT850 a Valve Dimensions \ eNO ey i pie S< oh oe Pinte ae Morgin Thickness “A Head Die. iN, 36 £ 0.1 mm (1.42 +0,004in) x. 30.£0.1 mm (1.18 +0.004in) “B" Face Width IN. 2.26mm (0.09in) x. 2.26mm (0.09in) ‘C" Seat Limit Width IN. 1-1 £0.1 mm (0.04 = 0,008in) ex. | 1.1.0.1 mm (0.04 + 0.008in) “D" Margin Thickness Limit IN. 1.2£0.2mm (0.05 +0.008ini EX. 1 0.2mm (0,04 + 0.008in) Stem Outside Diameter IN, 7-488mm (0.28-338in) x. 7-258 mm (0.28-382i0} Guide inside Diameter nN. 74° mm (0.276'3™*in) <7.10mm (0,280 n)> x, 7$°% mm (0.2763*in) <7.10 mm (0,280 in)> Stem-to-guide Clearance IN. | 0.010 ~0.087 mm (0.0004 ~ 0.0015 in) EX 10.030 ~ 0.057 mm (0.001 ~ 0.002.) ‘Stem Runout Limit <0.01 mm (0.0004 in)> Valve Seat Width Standard 1.3 + 0.1 mm (0.051 0.004 in) Vaive Spring Free Length | nner Spring IN, 40.1 mem (1.58in) EX. 40.4. mm (1.58in) Outer Spring IN. 43.8mm (1-72in) Ex. 43.8:mm(1.72in 75W Model XT850) ‘Compressed Length (Valve Clossed) r: Inner Spring IN. 22.7 mm (0.89 in) x. 22.7 mm (0.89 in) ‘Outer Spring IN. 25.7 mm (1.01 in) Ex. 25.7 msn (1.01 in) Tilt Limit® x Inner Spring IN. & EX. 2.5° or 1.7 mm (0.067 in) Outer Spring IN. BEX, 2.5° or 1.9mm (0.074in} Direction of Winding {Top view) Inner Spring Outer Spring Left Right Piston Piston Size/ ‘Measuring Point* Piston Clearance 92:388mm (3.62-888in)/ "6mm (0.24in) (From bottom line of piston skirt) (0.045 ~ 0.065 mm (0.0018 ~ 0.0026in} Ist 0.25 mm (0.01 in) 2nd 0.50 mm (0.02in) 3rd 0.75 mm (0.03in) ath 1.00mm (0.04 in) Piston Ring Sectional Sketch eis Top Ring I Prain CZs B = 1.223 mm (0.05345 in) ea T = 380.1 mm (0.15 +0.004in) 2nd Ring bz. Prain al B = 1.5:88mm (0.06-28*in) : T = 40.1 mm (0.16 + 0.004in) Oil Ring bezeh | Expender 76[s ‘Model XT550) End Gap (Installed) ‘Assembly Width “B” Runout Limit “C’" Top Ring 0.2 ~0.4mm (0.008 ~0.016in} 2nd Ring 0.2 ~0.4mm (0.008 ~ 0.016 in} Oi Ring 0.3 ~ 0.9mm (0.01 ~0.096in) Side Clearance Top Ring 0.04 ~ 0.08 mm (0.0016 ~ 0.9081 in) 2nd Ring 0.03 ~ 0.07 mm (0.001 ~ 0.003 in} Oil Ring (0.02 ~ 0.08 mm (0.0008 ~ 0.002in) Crankshaft ‘ (4, pa Crank Width “A” 75.$mm (2.96-$ain) 74.95 ~ 75.00 mm (2.951 ~2.953in} <0.03 mm (0.001 in}> Clutch Plate Thickness/ Quantity Warp Limit Clutch Spring Free Length/ Quantity Clutch Spring Minimum Length Primary Reduction Gear Backlash Tolerance ‘Smail End Free Play “F” 0.8mm (0.031 in) Balancer Drive Method Gear Clutch Friction Plate Thickness/Quantity 3,0 0.1 mm (0,12 +0.004in)/1 2.8 + 0.08mm (0.11 +0.008in)/7 ‘Wear Limit <2.8mm (0.11 in)> <2.6mm (0.10in}> 1.2mm (0.05in)/7 <0.2mm (0.008 in)> 42.8mm (1.69 in)/5 7~Ne ‘Clutch Release Method Jnner push (Cam push) Push Rod Bending Limit <0.5mm (0.02in}> kick Starter Kick Starter Type Retchet Decompression Device Type Kick synchronous Cable Free Play 0.5mm (0.62in) Air Fitter Oil Grade (Oiled Filter) ‘SAE 10W30 SE motor ol Carburetor ‘Type/Manufacturer/ Quantity 1.0. Mark Primary carb, Secondary carb, Main Jot (m3) #130 #125 Main Air Jot (MAJ) 01.0 012 ‘Jet Needle-clip Position (J.N.) BC30-1/1— 4A70-1/1 Needle Jet (Wad voo 0 aModel Cutaway (C.A.) Pilot Jet Pilot Air Jet Air Screw (turns out) (P.A.S.) Pilot Screw (P.s.) Valve Seat ws) Starter Jet (Gs. (Gs. Fuel Level Pat level Float valve seat Engine Idling Speed .cuum Pressure at Idling Speed XT550J #45 #4 01.0 Preset 92.5 #64 #70 6.0 1mm (0.24 + 0.04 in) 26,0£2.5mm (1.02 +0.10in) 02.5 1,200 +501/min 28.8 kPa (200 mmHg, 7.9inHg) Lubrication System: il Filter Type il Pump Type Tip Clearance Side Clearance Bypass Valve Setting Pressure Relief Valve Operating Pressure Paper, Wire mesh Trochoid pump +<0.12mm (0.005in)> 0.03 ~ 0.08 mm (0.001 ~ 0.003 in) 98.07 + 19.6 kPa (1.00.2 kg/cm’, 14.22 +2.84psi) 98.07 + 19.6 kPa (1.00.2 kg/em?, 14.22 +2.84psi) 78Lubrication Chart > Fees Prossu ons Crankcase Tightening Sequence Left Side 79ll, MAINTENANCE SPECIFICATIONS B. CHASSIS Spring Rate/ Stroke taper coll ‘Model X50 ‘Steering System Steering Bearing Type Taper roller bearing Front Suspension Front Fork Travel 206 mmn (8.1 in) Fork Spring Free Length 1, = 88mm (f,= 38in), ty = 48.5mm(t, = 13.7im) ‘Spring Rate/Stroke Ky = 3.4N/mm (0.35 kg/mm, 19.6b/in) 0~115mm(0~4.5in) Ks = 5.5 N/mm (0.56 kg/mm, 31.31b/in) 115 ~205mm (4.5 ~8.1 in) il Capacity or £869 cm?(12.5 Imp 02, 13.0US 02) Oil Level 158mm 6.2in) (From top of inner tube fuly compressed without spring.) Ol Grade KAYABA G-10 Enclosed Air Pressure 39.2 kPa (0.4 kg/cm?, 6.7 psi) Rear Suspension ‘Shock Absorber Travel 100mm (3.9in) Spring Free Length 293 mm ‘14.5in) Fitting length Ky = 39.7 ~93.2 N/mm (4.05 ~9.5 kg/mm, 226.7 ~631.8b/in) 0~ 120mm (0 ~4. in) Enclosed Gas Pressure 1,176.8 kPa (12 kg/cm?, 170.6 psi) Rear Arm ‘Swing Arm Free Play Limit fend <1.0mm (0.08in1> ‘Side | <1.0 mm (0.04 in)> Wheel Front Wheel Type ‘Spoke Wheel Rear Wheel Type ‘Spoke Wheel Front Rim Size/ Material 1,60%21/ Aluminum: Rear Rim Size/Material 2.15 * 18/ Aluminum. fim Runout Limit Veetical <1.0mm 0.08in)> Lateral <0.5mm 0.02in|> Drive Chai Type/Manufecturer s2008/ Number of Links S7iinks + Joint Chain Free Play 60 ~ 70mm (2.4 ~2.8in) Drum Brake Type Front Leading and trang Rear Leading and wraiing Drum Inside Dia Front 150 mm (5.91 in) <151 mm (5.94 in)> Rear 150mm (58 nl <151 mm (6.94 in}> 710Mode! XTS5O Brake Lever & Brake Pedal ‘Brake Lever Free Play/position Brake Pedal Position Brake Pedal Free Play 10 ~20mm (0.39 ~0.79in}/ at lever pivot 20~30mm (0.79 ~ 1.18in) 20 mm (0.79 in) (Vertical height below footrest top. (Clutch Lever Free Play/ position 2.3mm (0.08 ~0.12in)/ atlever pivotIl, MAINTENANCE SPECIFICATIONS C. ELECTRICAL Model \Vorese XTS5OS 12 Ignition System Ignition Timing (8.T.D.C.) ‘Advanced Timing (B.T..C.) Advancer Type 32° at 1,200¢/min 35.5 =2° at 6,000r/min Blectrical lanition Timing (B.7.0.C) mi o®! 1 | C.0.4. ‘Magneto-Model/ Manufacture Pickup Coil Resistance (Color) 56789 speed ( <10%r/min) 5Y1-81400-51/ NIPPONDENSO- 90 ~ 1302at 20°C (68°F) (G—WiR) (G—wic) Charging Coil Resistance (Color) V0 ~ 2400 at 20°C (68°F) (Br — A) €.D.1, Unit-Model/ Manufacturer 8Y1-85540-51/NIPPONDENSO ‘gnition Coil -Model/ Manufacturer BY1-82310-50/NIPPONDENSO imum Spark Gap 17k or more at 300 r/min 25kV ot more at 1,000 ~2,500¢/min | 17kV or more at 6,500 r/min Primary Winding Resistance 0.50 20% at 20°C (68°F) ‘Secondary Winding Resistance 6K + 20% at 20°C (68°F) Charging System/Type A.C. Magneto Generator F.W, Magneto 6.3 or more at 1,500r/min 10A or less at 5,000.7 min ‘Charging Coil Resistance (Color) 160 ~ 2402 at 20°C (68°F) (Br — R) Lighting Voltage 12.6V oF more at 1,5001/min -DClighting 13,6V or less at 7,000r/minMode! Lighting Coil Resistance (Color! XT55OI 0.2 ~0.62 at 20°C (68°F) (W — Wy w cae CEES 8 10) = acc | g ? 2 3 4 s 6 Engine speed ( « 10°r/min) Votage Reger Type Point or Semi Conductor, |.C. Type, A.C. Regulator ‘Short or Field Control, Till type. ~-Modei/ Manufactur ‘SH222-12C/ SHINDENGEN, “No Load Regulated Volige 4sv Rectifier -Model/ Manufacturer (SH222-12C/ SHINDENGEN Barer, ‘Capacity 12V SAH Specific Gravity 1.260 Horn Type/ Quantity Pin ype «1 Model/ Manufacturer MF-12/ NIKKO Maximum Amperage 5A Rasher Rely Type Condenser type Noe Manufacturer FU257S0/NIPPONDENSO Flasher Frequency 85 2 10cycle/min wattage Zw? + 34W rev Breaker Type Non fuse breaker Amperage for nv uit Quantity Min bax 743TIGHTENING TORQUE ENGINE Tightening torque Thread Sie] Oty | Nm | mkg | fib ] Cylinder head: flange bolt Me ee es + flange bolt M6 1 | 0 | x0 [ 72 ‘Spark plug m2 1 ws | 175 | 12 rf inder head cover: Internal hex. bolt M6 25 | on abator lore + Internal hex. bolt Me 42a fie 105% [parton er + Internal hex. bolt M6 801] ond etconal Poe + Internal hex. bolt cc ziea[ ocean ahaa. Cylinder head side cover: Internal hex. bolt M6 2ahe eves btior ae [Gear nit assembly: Internal hex. bolt Mes | ot [10 | tonejaaae | Tchr cle: separ fathond Iniemal |g x 7 (72 ae Cylinder body: nut MB 25 leah. 20ea as + mut wo 2 | 75 | 3% | 2 : nut Mio 2 | 75 | am | 2 + Internal hex. bolt M6 oe ee oe (Gear balance weight: nut Mi6 1 o | 60 | A.C.G. Rotar: nut Mia 4 a | 90 | 6 Valve clearance: nut M6 4 | 135 [ 135 | 94 ‘Stopper guide 2: hex. bolt Me 2- |. 8, jase [68 Cam sprocket M7 Bo tear |p 20s Sod Tensioner assembly: Internal hex. bolt M6 2 or iuisoh anes | “Tensioner spring retainer: plug | ome 1 gant pagan ata Decompression cam: bolt M6 1 8 Rocker shaft stopper bolt M6 2 | 0 Oil pump assembly: Internal hex. bolt M6 3 | Cover 2: panhead screw met o7 | sa a ee “| 2 Ba Drain plug: straight screw plug 1 2 | Element cover: Internal hex. bolt | ae a2 Intemathex. bolt M6 2 72 ‘lement cover stud bolt: bind screw Ts 1 s | os | 36 Seahen M6 2 907 leetarslaae: + union nut Mi6 1 |» | 50 | 38 Me Be (oae= [is 1051 Fe, mie 1 | @ | 60 | 3 : me | 4 ee | 72 74Tightening torque Thread Size] Oty | Nm | mkg | tb Coburetor assembly: hose clamp M4 2 2 | -02. [aus Exhaust M6 ¢5 [210 | stone |r Exhaust pipe protector: bind screw Me fee o7 | 54 Mutfler protector 1; bind screw we | 4 Teej bor | Ba Outletpipe: panhead W/Wescrew Me | ot 7 [OF pa) Bc Exhaust pipe muffler joint: hex. bolt “MB 2 2 | 20 | 14 Mutfier mounting: flange bole MB 2itjsaoe[ 20 | Case Tand2: Internal hex. bolt M6 9 wo | 10 | 72 = Intemal hex. bolt Me Co ee x + Intermalhex. bolt M6 1 wo | 10 | 72 Crankease 1 [MIO [ier erp raer a fadOe [aaa Clamp (lead): panhead screw ve | 1 7 | 07 [ot Crankcase2 5 Mio 2 a | 20 | 14 Crank case cover 1: Internal hex. bolt Me 6) | so esos + Internal hex. bolt M6 1 ogi eow |e + Imeral hex. bolt M6 1 wo | 10 | 72 + Internal hex. bolt M6 {oO Paton [272 Crank case cover 2: Internal hex. bolt M6 2) | to orsieze + bolt | me | 3 26. Perea Crank case cover 3: Intemaifex. bolt MG 7 wo [| 10 | 72 = Internal hex. bolt | me 1 w | 10 | 72 | + Intemal hex. bolt Mé 25) an [ieee | Cover 1: Internal hex. bolt M6 | mo | az Plate bridge cover: fiat head screw M6 3 Paneer e[P ey Retchet wheel guide: hex. bolt Me 26] Socal aco Cable lever: hex. nut Mei | ts | aaa og "ss Kick erank boss: hex. bolt i v8 1 2 | 20 | 14 | Clutch spring: W/W screw Me 8 8 | os | 58 Clutch boss: nut 5 20 1 70 | 70° | 60 Primary drivegear: nut M20 1 | 10 [10 | @ Push lever assembly: stopper screw Me 1 dae asa? Push lever positioning: nut | M6 7 & | os | 58 Drive sprocket: hex. boft M6 2 wo | 10 | 72 Oil seal cover: hex. bolt we 2. ao ee ere ‘Stopper lever: W/W screw pat Me 1 some ROK a2 Shift pedal: bolt Me wf 20 f 72 Coil:_panhead W/W screw Me 7s | 8a 718Tightening torque Thread Size] Qty | Nm | m-kg | fib Pulser: panhead W/W screw M6 Zi Te Or eer Neutral switch: neutral switch assembly mio 1 2 | 20 | 14 Cylinder head side cover 1 32 2 aes |penae (oer Kick crank: screw M6 1 a a 7416CHASSIS Tightening torque Thread Size mk | felb Front wheel shaft and nut M4 10.0 R Outer tube and cover M6 aos Pore Handle crown and inner tube a Me 2B 23 7 Handle crown and steering shaft Mia 5 95 8 "Under handle holder and Upper handle holder MB 20 20 14 Front engine stay and engine BESS 58 | @ Front engine stay and frame 58 58 2 Engine top stay and engi se 58 2 Engine top stay and frame =a 8 58 a2 Rear engine and frame 58 2 | Nipple hose and frame 90 6 Oil tank drain plug ; eel aS Pivot shaft and nut é Mi6 100 10.0 R Rear wheel shaft and nut M6 100 10.0 2 Rear cushion andframe mio 8 6 Lever cam shaft and cam shaft (Front, Rear) M6 10 72 Sprocket wheel holder r mio a 46 ‘Steering shaft and ring nut Ma % ee Under bracket an¢ inner tube wet eae Inner tube cap M4 B Front fork eyinder compressor and outer tube m2 7 2 Foot rest and frame [M0 6 Bre eae Bead stopper and rim oe 100 | 100 Steering lockendhandle crown M6 07 Spoke = 2 02 ‘Seat bracket securing bolt Me 7 07 7CONSUMER INFORMATION Stopping Distance correct under other conditions. This figure indicates braking performance that can be met or exceeded by the vehiicles to which they apply, without locking the wheels, under different conditions of loading and Partial failures of the braking system. The information presented represents results obtained by skilled drivers under controlled road and vehicle conditions and the information may not be h ‘Description of vehicles to which this table applies: Yamaha motorcycle XTS50J A. Fully Operational Service Brake 173 191 NOTE: The statement above is required by U.S. Federal law. “Partial failures” of the brak- ing system do not apply to this chart. 200-300 (Feet) Stopping distance in feet from 60 mi/h GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard |.S.0. pitch threads. Torque specifications for special components ‘or assemblies are included in the applicable sections of this book, To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature. 1 @r 718 General torque - 5 specifications (Nut) (Bolt “7 Nm 6mm 6 amm | 16) 15 | 11 tomm | 30 | 30 | 2 ramm | 55 | 65 | 40 a | ss | 6 130 | 130 | 96 coLon cone R. Rea iw 8 Black YR Sb ‘Sky blue avy. Br Brown oy. ch Chocolte UW. 09 Darkareen B/W. i ave Rw y Yelow us ° range uy S Green UR e Pink win w. white wisDEFINITION OF UNITS ‘Unit Read Definiion [Measure mm | millimeter 10° meter cm —_| centimeter 10" meter kg kdlogram 10° gram N Newton kg «m/sec? Nm | Newton meter Nxm mckg_| Meter kilogram mXkg | Torque Pa Pascal Nim Pressure Nimm__| Newton per milimeter Spring rate tc Lite a Volume em? _| Cubic centimeter or Capacity r/min | Rotation perminute | —— [Engine Speed CONVERSION TABLES ‘Maric 0 inch systom Tne to metic system Maltpier Result Known | 7.233 feb fb 5.80 Hint int o.72s feb feb 0.9680 into ind | | 2.206 ‘ tb 0.03627 ot or 2352 09 m9 oezia | moh mph 0.6214 mi i 3.281 ft tt m 1004 ys ve ost cm 0.3897 in in 254 mm 0.03937 in in 254 | cctemy | 0.0382 22 (US ia) e2(USiq@) | 2957 ectem? cctem) | .o6t02 cuin evin 16387 eclem) fein 2.134 | ptiUstiqd puUusig — | 0.4732 fie liter liter 1.057 at (US lia) aUStiqg) | 0.9861 fitter) lt heer) 0.2642 gal (US tia) eausiig) | 3.785 Uelier) olan 56.007 lovin tbiin 0.017858 g/m kgfem* 14.2034 sion? paitib/in) | 0.07031 glo? Centigrade (°Cl| 9/5(°C) +32 _| Fahwenheit (F) Fabwenheit (°0)| 5/9(°F~321 __| Cantgrade (OF) 7419EXPLODED DIAGRAMS CYLINDER 7:20KICK STARTER sonocasr a 5, weet etme. a che ieven 0@ oxcoue sven on sea, Seid 722FRONT WHEEL r weet SHAFT Ne lea bust cover {a Vouser | \| sane | \ | (ner ? ye ' couan seanns QS Sracen fe Nin 10 mks, 7a RI : BEAD STOPPER Ay nee. BALAWoER oe en gore DRIVE GEAR a BRAKE SHOE REARING (e202) BRAKE SHOE PLATE 9 SS ee GEAR “APPLY LITHIUM: BASE GREASE a CAMSHAFT cams! AA LEVER (tim Ho mt, 123REAR WHEEL 100, Nn (10 rn-ka. 72 feb) CAMSHAFT LEVER aaa cry WHEEL SHAFTFRAME DRAIN BoLT. 18 Nm (1.8 mkg. 19 fet] a 58 Nm (6.8 mkg, 42 feibl goOIL PUMP/OIL CLEANER PUMP. DRIVEN GEAR Soven 2 3 (OL PASSAGE CovER) ©. 5 7-26POWER FLOW CHART cAM sProcKer—__| CAM SHAFTLUBRICATION CHARTS LUBRICATION CHART (1) (2239 scavence on (HD rev onLUBRICATION CHART (2) FEED OIL (2205 scavence onLUBRICATION CHART (3) FEED OIL (2 scavence otLUBRICATION CHART (4) FEED OIL [GE scavence on ee 731CABLE ROUTING DIAGRAMS CABLE ROUTING DIAGRAM (1) ‘Throttle cab 1 Arrange he thot cable 1 ‘tore the throttle cae 2 ain \ Men svtch ead ‘ | \ Handlebar swtchlead (Let) Stop etched GY | std cable Handtobar switch ead (Fight) Foute he lead onthe handle own, ad then instal the meters), ‘rent tasherghtiead (Let): \ Route sing therear side ofthe speedometer cable ‘Speedometer cable Horn switch lead ‘ont ashe ight ead (Right): Route along thereor side ofthe tachometer cable, 732fe) wwuovio BNINOY 318V9CABLE ROUTING DIAGRAM (4)YAMAHA MOTOR Co.,LTD. PRINTED IN U.S.A.