Yamaha Grizzly 300 YFM300 PDF

Pgs. 306 0.625 Fo.
GRIZZLY 300
GRIZZLY 300 2012

2012
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Service Manual
*LIT116162516*
LIT-11616-25-16
YAMAHA MOTOR CORPORATION, U.S.A.

PRINTED IN U.S.A. BY CRESTEC USA LIT-11616-25-16
YFM30GB
SERVICE MANUAL
©2011 by Yamaha Motor Corporation, U.S.A.
First edition, September 2011
All rights reserved.
Any reproduction or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
LIT-11616-25-16
IMPORTANT
This manual was produced by the Yamaha Motor Company primarily for use by Yamaha dealers and
their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one man-
ual, so it is assumed that anyone who uses this book to perform maintenance and repairs on
Yamaha machine has a basic understanding of the mechanical ideas and the procedures of
machine repair. Repairs attempted by anyone without this knowledge are likely to render the
machine unsafe and unfit for use.
Yamaha Motor Company, Ltd. is continually striving to improve all its models. Modifications and sig-
nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers
and will appear in future editions of this manual where applicable.
TIP
Designs and specifications are subject to change without notice.
IMPORTANT INFORMATION
Particularly important information is distinguished in this manual by the following notations:
This is the safety alert symbol.It is used to alert you to potential

personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided,

WARNING
could result in death or serious injury.
A NOTICE indicates special precautions that must be taken to avoid

NOTICE
damage to the vehicle or other property.
TIP A TIP provides key information to make procedures easier or clearer.
*Product and specifications are subject to change without notice.

HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “symbols”)
1st title : This is the title of the chapter with its symbol in the upper right corner of each page.
2nd title : This title indicates the section of the chapter and only appears on the first page of each
section. It is located in the upper left corner of the page.
3rd title : This title indicates a sub-section that is followed by step-by-step procedures accompa-
nied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
1. An easy-to-see exploded diagram is provided for removal and disassembly jobs.
2. Numbers are given in the order of the jobs in the exploded diagram. A number that is enclosed
by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
. The meanings of the symbol marks are given on the next page.
4. A job instruction chart accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements are given in addition
to the exploded diagram and the job instruction chart.
1 2 SYMBOLS
GEN The following symbols are not relevant to every
INFO SPEC machine.

Symbols 1 to 10 indicate the subject of each
3 4 chapter.
1 General information
CHK 2 Specifications
ADJ ENG 3 Periodic checks and adjustments
4 Engine
5 6
5 Cooling system
6 Carburetor
COOL CARB 7 Drive train
8 Chassis
7 8 9 Electrical
10 Troubleshooting
DRIV CHAS
9 10 Symbols 11 to 18 indicate the following
TRBL 11 Serviceable with engine mounted
ELEC – +
SHTG
12 Filling fluid
13 Lubricant
11 12 14 Special tool
15 Torque
16 Wear limit, clearance
17 Engine speed
18 Electrical data (Ω, V, A)
13 14
15 16
T.
R.
17 18 Symbols 19 to 24 in the exploded diagrams

indicate the types of lubricants and lubrication
points.
19 Apply engine oil
19 20 21 20 Apply gear oil
21 Apply molybdenum disulfide oil
22 Apply wheel bearing grease
E G M 23 Apply lithium-soap-based grease
22 23 24 24 Apply molybdenum disulfide grease
B LS M Symbols 25 to 26 in the exploded diagrams

indicate where to apply a locking agent 25 and
25 26
when to install a new part 26 .
25 Apply the locking agent (LOCTITE®)
LT
New 26 Replace
TABLE OF CONTENTS
GENERAL INFORMATION GEN
INFO 1
SPECIFICATIONS SPEC 2
PERIODIC CHECKS AND
ADJUSTMENTS CHK
ADJ 3
ENGINE ENG 4
COOLING SYSTEM COOL 5
CARBURETOR CARB 6
DRIVE TRAIN DRIV 7
CHASSIS CHAS 8
– +
ELECTRICAL ELEC 9
TROUBLESHOOTING TRBL
SHTG 10
CHAPTER 1
GENERAL INFORMATION
MACHINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

VEHICLE IDENTIFICATION NUMBER. . . . . . . . . . . . . . . . . . . . . . . . 1-1
MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
IMPORTANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . . 1-2
REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
GASKETS, OIL SEALS AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . 1-2
LOCK WASHERS/PLATES AND COTTER PINS . . . . . . . . . . . . . . . 1-2
BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
CIRCLIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
CHECKING THE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
ENGINE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
CHASSIS SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
TIGHTENING TORQUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
CHASSIS TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
HOW TO USE THE CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . 2-19
GENERAL TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . . 2-19
LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . . 2-20

ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-20
COOLANT FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
OIL FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

CHAPTER 3
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL

SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
GENERAL MAINTENANCE AND LUBRICATION CHART . . . . . . . . . . 3-2
SEAT, FENDERS AND FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

SEAT, SIDE COVERS AND FOOTREST BOARDS . . . . . . . . . . . . . . . . . . 3-4
FRONT CARRIER, FRONT BUMPER AND FRONT FENDER . . . . . 3-5
REAR FENDER AND AIR FILLTER CASE . . . . . . . . . . . . . . . . . . . . 3-6
FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
ADJUSTING THE VALVE CLEARANCE . . . . . . . . . . . . . . . . . . . . . . 3-9
ADJUSTING THE ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . 3-11
ADJUSTING THE THROTTLE LEVER FREE PLAY . . . . . . . . . . . . 3-12
ADJUSTING THE SPEED LIMITER . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
CHECKING THE SPARK PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
CHECKING THE IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . 3-16
MEASURING THE COMPRESSION PRESSURE . . . . . . . . . . . . . 3-17
CHECKING THE ENGINE OIL LEVEL . . . . . . . . . . . . . . . . . . . . . . 3-19
CHANGING THE ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
CLEANING THE AIR FILTER ELEMENT . . . . . . . . . . . . . . . . . . . . . 3-22
CLEANING THE SPARK ARRESTER . . . . . . . . . . . . . . . . . . . . . . . 3-24
CHECKING THE COOLANT LEVEL . . . . . . . . . . . . . . . . . . . . . . . . 3-25
CHANGING THE COOLANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
CHECK THE COOLANT TEMPERATURE INDICATOR LIGHT. . . . 3-28
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
CHECKING THE FRONT BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
ADJUSTING THE REAR BRAKE LEVER. . . . . . . . . . . . . . . . . . . . . 3-30
ADJUSTING THE REAR PEDAL POSITION . . . . . . . . . . . . . . . . . 3-32
ADJUSTING THE PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . 3-33
CHECKING THE BRAKE FLUID LEVEL . . . . . . . . . . . . . . . . . . . . . 3-34
CHECKING THE FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . 3-35
CHECKING THE REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . 3-35
ADJUSTING THE REAR BRAKE LIGHT SWITCH . . . . . . . . . . . . . 3-36
CHECKING THE BRAKE HOSES . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
BLEEDING THE HYDRAULIC BRAKE SYSTEM . . . . . . . . . . . . . . . 3-38
ADJUSTMENT THE SELECT LEVER CONTROL CABLE AND
SHIFT ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-39
CHANGING THE TRANSFER GEAR OIL . . . . . . . . . . . . . . . . . . . . 3-42
CHANGING THE FINAL DRIVE GEAR . OIL . . . . . . . . . . . . . . . . . . . 3-43
CHECKING THE REAR AXLE BOOT . . . . . . . . . . . . . . . . . . . . . . . . 3-44
CHECKING THE STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . 3-44
ADJUSTING THE TOE-IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45
CHECKING THE FRONT AND REAR SHOCK ABSORBERS . . . . . 3-46
ADJUSTING THE REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . 3-47
CHECKING THE TIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48
CHECKING THE WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50
CHECKING AND LUBRICATING THE CABLES . . . . . . . . . . . . . . . 3-50
LUBRICATING THE LEVERS AND PEDALS . . . . . . . . . . . . . . . . . . 3-51
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

CHECKING AND CHARGING THE BATTERY. . . . . . . . . . . . . . . . . 3-52
CHECKING THE FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-59
ADJUSTING THE HEADLIGHT BEAM . . . . . . . . . . . . . . . . . . . . . . . 3-60
REPLACING A HEADLIGHT BULB . . . . . . . . . . . . . . . . . . . . . . . . . 3-61
CHAPTER 4
ENGINE
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -1
AIR DUCTS, A.I.C.V., MUFFLER AND EXHAUST PIPE . . . . . . . . . . 4 -1
SELECT LEVER SHIFT ROD, CABLES, LEAD AND HOSES . . . . . . 4 -2
ENGINE MOUNTING BOLTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -3
INSTALLING THE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -4
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -5
REMOVING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . 4 -6
CHECKING THE CAMSHAFT SPROCKETS AND
TIMING CHAIN TENSIONER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
CHECKING THE CYLINDER HEAD COVER ASSY. . . . . . . . . . . . . . 4 -7
CHECKING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -7
INSTALLING THE CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . 4 -8
ROCKER ARMS AND CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -10

REMOVING THE ROCKER ARMS AND CAMSHAFT . . . . . . . . . . .4 -11
CHECKING THE ROCKER ARMS AND ROCKER ARM
SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 -12
CHECKING THE CAMSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -13
INSTALLING THE CAMSHAFT AND ROCKER ARMS . . . . . . . . . . 4 -14
VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -15

REMOVING THE VALVES AND VALVE SPRINGS. . . . . . . . . . . . . 4 -16
CHECKING THE VALVES AND VALVE SPRINGS . . . . . . . . . . . . . 4 -17
INSTALLING THE VALVES AND VALVE SPRINGS . . . . . . . . . . . . 4 -20
CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -22

REMOVING THE PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -23
CHECKING THE CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . 4 -23
CHECKING THE PISTON RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -25
CHECKING THE PISTON PIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -26
INSTALLING THE PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -27
INSTALLING THE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -28
C.D.I. MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -29

REMOVING THE C.D.I. MAGNETO ROTOR. . . . . . . . . . . . . . . . . . 4 -30
CHECKING THE PICKUP COIL/STATOR ASSEMBLY . . . . . . . . . . 4 -30
INSTALLING THE PICKUP COIL/STATOR ASSEMBLY . . . . . . . . . 4 -31
INSTALLING THE C.D.I. MAGNETO ROTOR . . . . . . . . . . . . . . . . . 4 -31
BELT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
CRANKCASE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32
V-BELT, CLUTCH, PRIMARY AND SECONDARY SHEAVE. . . . . . . 4-33
DISASSEMBLING THE SECONDARY SHEAVE . . . . . . . . . . . . . . . . 4-34
REMOVING THE PRIMARY SHEAVE. . .. . . . . . . . . . . . . . . . . . . . . . 4-36
REMOVING THE SECONDARY SHEAVE AND V-BELT. . . . . . . . . . 4-36
DISASSEMBLING THE SECONDARY SHEAVE . . . . . . . . . . . . . . . . 4-37
CHECKING THE CLUTCH SHOE. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
CHECKING THE V-BELT. .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
CHECKING THE PRIMARY SHEAVE. . . . . . . . . . . . . . . . . . . . . . . . 4-38
CHECKING THE PRIMARY SHEAVE WEIGHTS . . . . . . . . . . . . . . . 4-38
CHECKING THE SLIDER . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39
CHECKING THE SECONDARY SHEAVE. . . . . . . . . . . . . . . . . . . . . 4-39
ASSEMBLING THE PRIMARY SHEAVE. . . . . . . . . . . . . . . . . . . . . . 4-40
ASSEMBLING THE SECONDARY SHEAVE. . . . . . . . . . . . . . . . . . . 4-41
INSTALLING THE BELT DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42
STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

REMOVING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 4-45
CHECKING THE STARTER WHEEL GEAR . . . . . . . . . . . . . . . . . . . 4-45
INSTALLING THE STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . 4-46
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47

CHECKING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
INSTALLING THE OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49
CRANKCASE AND CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

REMOVING THE CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . 4-51
CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDES. . . . 4-52
CHECKING THE CRANKSHAFT AND CONNECTING ROD . . . . . . . 4-52
INSTALLING THE CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . 4-53
ASSEMBLING THE CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55
TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-56
REMOVING THE TRANSFER CASE ASSY . . . . . . . . . . . . . . . . . . . 4-58
CHECKING THE SHAFT-1 AND DRIVEN PINION . . . . . . . . . . . . . . . 4-58
INSTALLINGTHE TRANSFER CASE ASSY. . . . . . . . . . . . . . . . . . . . . 4-59
ADJUSTING THE BEARING-2 SHIM . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
ADJUSTING THE BEARING-1 SHIM . . . . . . . . . . . . . . . . . . . . . . . . . . 4-59
REMOVING TRANSMISSION COVER . . . . . . . . . . . . . . . . . . . . . . . 4-62
REMOVING SHIFT CAM AND SHIFT SHAFT . . . . . . . . . . . . . . . . . . 4-63
CHECKING THE SHIFT FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-64
CHECKING THE SHIFT CAM ASSEMBLY. . . . . . . . . . . . . . . . . . . . . 4-64
REMOVING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-65
CHECKING THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . 4-67
ADJUSTING THE DRIVE PINION SHIM . . . . . . . . . . . . . . . . . . . . . 4-68
SELECTING THE FINAL SHAFT CIRCLIP WASHER . . . . . . . . . . . . 4-69
CHAPTER 5
COOLING SYSTEM
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
CHECKING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
INSTALLING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
THERMOSTAT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
CHECKING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
INSTALLING THE THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
WATER PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

REMOVING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
CHECKING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
INSTALLING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
CHAPTER 6
CARBURETOR
CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
DISASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . 6-4
CHECKING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
ASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
INSTALLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
MEASURING AND ADJUSTING THE FUEL LEVEL . . . . . . . . . . . . . 6-8
CHAPTER 7
DRIVE TRAIN
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT. . . . . . . . . . . . . 7-1

REMOVING THE REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
DISASSEMBLING THE FINAL DRIVE GEAR. . . . . . . . . . . . . . . . . . . 7-4
REMOVING THE FINAL DRIVE ROLLER . . . . . . . . . . . . . . . . . . . . 7-5
ASSEMBLING THE FINAL DRIVE ROLLER BEARING . . . . . . . . . . . 7-5
INSTALLING THE REAR AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
INSTALLING THE DRIVE SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
CHECKING THE FINAL DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . . 7-6
ASSEMBLING THE FINAL DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . 7-7
INSTALLING THE FINAL DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . 7-8
ADJUSTING THE BACKLASH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
CHAPTER 8
CHASSIS
FRONT AND REAR WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

FRONT WHEELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
REAR WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
CHECKING THE WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
CHECKING THE WHEEL HUBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
CHECKING THE BRAKE DISCS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6
INSTALLING THE BRAKE DISCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7
INSTALLING THE REAR BRAKE DISC ON THE REAR AXLE . . . . . . 8-7
INSTALLING THE FRONT WHEEL HUB BEARINGS . . . . . . . . . . . . . 8-8
INSTALLING THE WHEEL HUBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
INSTALLING THE WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-8
FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

FRONT BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9
REAR BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-11
REMOVING THE PARKING BRAKE CABLE . . . . . . . . . . . . . . . . . . . 8-13
CHECKING THE BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . . 8-13
INSTALLING THE BRAKE CALIPER . . . . . . . . . . . . . . . . . . . . . . . . . 8-14
REPLACING THE FRONT BRAKE PADS . . . . . . . . . . . . . . . . . . . . . 8-16
REPLACING THE REAR BRAKE PADS . . . . . . . . . . . . . . . . . . . . . . 8-17
FRONT BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . 8-18
REAR BRAKE MASTER CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . 8-20
CHECKING THE MASTER CYLINDERS . . . . . . . . . . . . . . . . . . . . . . 8-23
ASSEMBLING THE FRONT BRAKE MASTER CYLINDER . . . . . . . . 8-24
ASSEMBLING THE REAR BRAKE MASTER CYLINDER . . . . . . . . . 8-24
INSTALLING THE FRONT BRAKE MASTER CYLINDER . . . . . . . . . 8-25
INSTALLING THE REAR BRAKE MASTER CYLINDER . . . . . . . . . . 8-27
STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29

HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29
REMOVING THE HANDLEBAR GRIPS . . . . . . . . . . . . . . . . . . . . . . 8-31
REMOVING THE CLUTCH SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
CHECKING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-31
INSTALLING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-32
INSTALLING THE HANDLEBAR GRIPS . . . . . . . . . . . . . . . . . . . . . . 8-32
INSTALLING THE REAR BRAKE LEVER . . . . . . . . . . . . . . . . . . . . . . . . 8-33
INSTALLING THROTTLE LEVER ASSEMBLY . . . . . . . . . . . . . . . . . 8-33
INSTALLING THE PARKING BRAKE LEVER . . . . . . . . . . . . . . . . . . . . . 8-34
STEERING STEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-35
REMOVING THE STEERING STEM. . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
CHECKING THE STEERING STEM . . . . . . . . . . . . . . . . . . . . . . . . . . 8-36
INSTALLING THE STEERING STEM . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
INSTALLING THE LOCK WASHER . . . . . . . . . . . . . . . . . . . . . . . . . . 8-37
TIE-RODS AND STEERING KNUCKLES . . . . . . . . . . . . . . . . . . . . . . 8-38
REMOVING THE TIE-RODS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-39
REMOVING THE STEERING KNUCKLES . . . . . . . . . . . . . . . . . . . . . 8-39
CHECKING THE TIE-RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
CHECKING THE STEERING KNUCKLES . . . . . . . . . . . . . . . . . . . . . 8-40
INSTALLING THE TIE-RODS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-40
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES . . . . 8-41

REMOVING THE FRONT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
CHECKING THE FRONT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-42
CHECKING THE FRONT SHOCK ABSORBERS . . . . . . . . . . . . . . . 8-42
CHECKING THE BALL JOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43
INSTALLING THE FRONT ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-43
REAR SHOCK ABSORBER AND SWINGARM . . . . . . . . . . . . . . . . . . . 8-44

REMOVING THE REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . 8-46
CHECKING THE REAR SHOCK ABSORBER . . . . . . . . . . . . . . . . . . 8-46
REMOVING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-46
CHECKING THE SWINGARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-47
CHECKING THE RUBBER BOOT . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-48
INSTALLING THE RUBBER BOOT . . . . . . . . . . . . . . . . . . . . . . . . . 8-48
CHAPTER 9
ELECTRICAL
ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
CHECKING SWITCH CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
CHECKING THE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3
CHECKING THE BULBS AND BULB SOCKETS . . . . . . . . . . . . . . . . . . . 9-4

TYPES OF BULBS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4
CHECKING THE CONDITION OF THE BULBS . . . . . . . . . . . . . . . . . . 9-4
IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7
ELECTRIC STARTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
STARTING CIRCUIT OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13
STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15
CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16
LIGHTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19
CHECKING THE LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . 9-21
SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23
CHECKING THE SIGNALING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . 9-25
COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29

CIRCUIT DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29
CHAPTER 10
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING . . . . . . . . . . . . . . . . . . . . . . . . 10-1

FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
COMPRESSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
POOR IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

POOR IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . 10-2
POOR MEDIUM AND HIGH-SPEED PERFORMANCE . . . . . . . . . . . . . 10-2

POOR MEDIUM AND HIGH-SPEED PERFORMANCE . . . . . . . . . . . 10-2
FAULTY GEAR SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

HARD SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
SHIFT PEDAL DOES NOT MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
JUMPS OUT GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
FAULTY CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3

ENGINE OPERATES BUT VEHICLE WILL NOT MOVE . . . . . . . . . . 10-3
CLUTCH SLIPPING . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . . . . . 10-3
POOR STARTING PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . 10-3
POOR SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
OVERHEATING . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . . . 10-4
FAULTY BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

POOR BRAKING EFFECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
SHOCK ABSORBER MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4

MALFUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-4
UNSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5

UNSTABLE HANDLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
LIGHTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5

HEADLIGHT DOES NOT COME ON . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
TAIL/BRAKE LIGHT DOES NOT LIGHT . . . . . . . . . . . . . . . . . . . . . . 10-5
BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-5
TAIL/BRAKE LIGHT BULB BURNT OUT . . . . . . . . . . . . . . . . . . . . . 10-5
GEN
MACHINE IDENTIFICATION INFO
GENERAL INFORMATION
MACHINE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number is 1 stamped
into the front side of the frame.
1
MODEL LABEL
The model label 1 is affixed to the air filter case
cover. This information will be needed to order
spare parts.
1-1
GEN
IMPORTANT INFORMATION INFO
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL AND
DISASSEMBLY
1. Before removal and disassembly remove all
dirt, mud, dust and foreign material.
2. Use only the proper tools and cleaning
equipment.
Refer to “SPECIAL TOOLS”.
3. When disassembling always keep mated
1
parts together. This includes gears, cylin-
ders, pistons and other parts that have
been “mated” through normal wear. Mated
parts must always be reused or replaced as
an assembly.
2
4. During disassembly, clean all of the parts
3
and place them in trays in the order of dis-
assembly. This will speed up assembly and
allow for the correct installation of all parts.
5. Keep all parts away from any source of fire.
REPLACEMENT PARTS
1. Use only genuine Yamaha parts for all
replacements. Use oil and grease recom-
4
mended by Yamaha for all lubrication jobs.
5
Other brands may be similar in function and
appearance, but inferior in quality.
6
GASKETS, OIL SEALS AND O-RINGS
1. When overhauling the engine, replace all
gaskets, seals and O-rings. All gasket sur-
faces, oil seal lips and O-rings must be
cleaned.
7
2. During reassembly properly oil all mating
parts and bearings, and lubricate the oil
seal lips with grease.
LOCK WASHERS/PLATES AND COTTER

PINS
After removal, replace all lock washers/plates
8
and cotter pins. After the bolt or nut has
been tightened to specification, bend the lock
tabs along a flat of the bolt or nut.
1-2
GEN
BEARINGS AND OIL SEALS
Install bearings and oil seals so that the manu-
facturer’s marks or numbers are visible. When
installing oil seals, lubricate the oil seal lips
with a light coat of lithium-soap-based grease.
Oil bearings liberally when installing, if appro-
priate.
Oil seal
NOTICE
Do not spin the bearing with compressed
air because this will damage the bearing
surfaces.
Bearing
CIRCLIPS
Before reassembly, check all circlips carefully
and replace damaged or distorted circlips.
Always replace piston pin clips after one use.
When installing a circlip , make sure the
sharp-edged corner is positioned opposite
the thrust that the circlip receives.
Shaft
1-3
GEN
CHECKING THE CONNECTIONS
Check the leads, couplers, and connectors for
stains, rust, moisture, etc.
1. Disconnect:
• lead
• coupler
• connector
2. Check:
• lead
• coupler
• connector
Moisture → Dry with an air blower.
Rust /stains → Connect and disconnect
several times.
3. Check:
• all connections
Loose connection → Connect properly.
TIP
If the pin on the terminal is flattened, bend it
up.
4. Connect:
• lead
• coupler
• connector
TIP
Make sure all connections are tight.
5. Check:
• continuity (with the pocket tester)
Pocket tester
90890-03112
Analog pocket tester
YU-03112-C
TIP
• If there is no continuity, clean the terminals.
• When checking the wire harness, perform
steps (1) to (3).
• As a quick remedy, use a contact revitalizer
available at most part stores.
1-4
GEN
SPECIAL TOOLS INFO
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools; this will help prevent damage caused by the use of inappropriate
tools or improvised techniques. Special tools may differ by shape and part number from country to
country. In such a case, two types are provided.
When placing an order, refer to the list provided below to avoid any mistakes.
For US and CAN
P/N. YM-, YU-, YS-, YK-, ACC-
Except for US and CAN
P/N. 90890
Tool No. Tool name/Function Illustration

Bolt Slide hammer bolt (M5)/weight
90890-04158
YM-04158
Weight
90890-01084 This tool is used to remove the rocker arm
YU-01083-3 shaft.
Crankcase separating tool
Crankcase separator
90890-04152
YU-A9642
This tool is used to separate the crankcase.

Rotor holding tool
90890-01235
YU-01235 This tool is needed to hold the starter puller
when removing/installing the starter puller
bolt or camshaft sprocket bolts.
Ring nut wrench
Spanner wrench
90890-01268
YU-01268
This tool is used to adjusting the front shock
absorbers.
Piston pin puller
90890-01304
YU-01304
This tool is used to remove the piston pin.

Tappet adjusting tool (3 mm)
Six piece tappet set
90890-01311 ø8 ø9 ø10
YM-A5970 ø3 ø4
These tools are necessary for adjusting the

valve clearance.
1-5
GEN
SPECIAL TOOLS INFO
Crankshaft installer pot
Pot
Crankshaft installer bolt
90890-01274
Bolt
90890-01275
These tools are used to install the crankshaft.
Crankshaft installer set
YU-90050
90890-01288 Spacer
90890-04164
YM-04164
Adapter(M14xP1.5/M14 x P1.25) M14xP1.5
90890-04163 M14xP1.25
YM-04163
This tool is used to install the drive shaft.
90890-01337 Clutch spring holder

YM-33285 Universal clutch compressor holder
Clutch spring holder arm
90890-01464 Compressor holder adapter
YM-33285-6 These tool are used for removing or installing
the clutch.
Locknut wrench
90890-01348
YM-01348
This tool is needed when removing or installing
the clutch nut.
90890-04058 Middle driven shaft bearing driver

YM-04058-1 Mechanical seal installer
90890-04078
These tools are used to install the water
YM-33221
pump seal.
Flywheel puller
90890-01404
YM-01404
These tools are needed to remove the rotor. M14xP1.25
1-6
GEN
SPECIAL TOOLS INFO
Set Compression gauge set
90890-03081 Adapter
YU-33223
Adapter
90890-04082 This tool is needed to measure the engine
YU-33223-3 compression.
Engine tachometer
90890-03113
YU-8036-B
This tool is needed for observing engine rpm.

Pocket tester
90890-03112
YU-03112-C
This instrument is needed for checking the
electrical system.
Timing light
Inductive clamp timing light
90890-03141
YU-03141
This tool is necessary for checking ignition
timing.
Valve spring compressor
Compressor
90890-04019
YM-04019
This tool is needed to remove and install the
valve assemblies.
Valve spring compressor attachment
Valve spring compressor adapter (26 mm)
90890-01243
YM-01253-1
valve assemblies.
Universal clutch holder
90890-04086
YM-91042
This tool is needed to hold the clutch carrier
when removing or installing the carrier nut.
Valve guide remover (ø6)
Valve guide remover (6.0 mm)
90890-04064
YM-04064-A
valve guides.
1-7
GEN
SPECIAL TOOLS INFO
Fuel level gauge
90890-01312
YM-01312-A
This gauge is used to measure the fuel level
in the float chamber.
Radiator cap tester
90890-01325
YU-24460-01
This tool is used to check the cooling system.

Adapter
90890-01325
YU-24460-01
This tool is used to check the cooling system.

Sheave holder
Primary clutch holder
90890-01701
YS-01880-A This tool is needed to hold the AC magneto
rotor when loosen or tighten the AC magneto
rotor nut.
Thickness gauge
Narrow gauge set
90890-03079
YM-34483
This tool is used to measure the valve clear-
ance and spark plug gap.
90890-01474 Ball joint remover

YM-01474 Ball joint remover attachment set
90890-01480 Ball joint remover short shaft set
YM-01480
90890-01514 These tools are used for removing and in-
YM-01514 stalling the ball joints.
90890-01498 Axle nut wrench

YM-37134
This tool is used for removing and install-

ing the rear axle nut.
1-8
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Item Standard
Model code 1SC1
Dimensions
Overall length 1895 mm (74.6 in)
Overall width 1069 mm (42.1 in)
Overall height 1124 mm (44.3 in)
2
Seat height 794 mm (31.3 in)
Wheelbase 1199 mm (47.2 in)
Minimum ground clearance 137 mm (5.4 in)
Minimum turning radius 3150 mm (124 in)
Basic weight
With oil and full fuel tank 232 kg (511 lb)
Engine
Engine type Liquid cooled 4-stroke, SOHC
Cylinder arrangement Vertical single cylinder
Displacement 287 cm³ (17.51 cu.in)
Bore × stroke 75.0 × 65.0 mm (29.5 × 2.56 in)
Compression ratio 8.6 : 1
Standard compression pressure (at sea level) 1,200 kPa (12.0 kg/cm2, 174.0 psi)
Starting system Electric starter
Lubrication system Wet sump
Oil type or grade
Engine oil
YAMALUBE, SAE10W-30, SAE10W-40,
SAE20W-40, SAE20W-50 or SAE5W-30
YAMALUBE (10W-40) or SAE 10W40 API service SG type or higher, JASO standard
MA
YAMALUBE (20W-50), or SAE20W-50
Transfer gear oil SAE 90 API GL-5 Hypoid gear oil

Final gear oil SAE 80 API GL-4 Hypoid gear oil
Oil capacity
Engine oil
Periodic oil change 1.20 L (1.27 US qt, 1.06 Imp.qt)
Total amount 1.40 L (1.48 US qt, 1.23 Imp.qt)
Transfer gear oil
Periodic oil change 1.20 L (1.27 US qt, 1.06 Imp.qt)
2-1
Item Standard
Final gear oil
Radiator capacity (including all routes) 0.94 L (0.99 US qt, 0.83 Imp.qt)
Air filter Wet type element
Fuel
Type Unleaded gasoline only
Fuel tank capacity 10.7 L (2.35 lmp gal, 2.83 US gal)
Fuel reserve amount 3.0 L (0.66 Imp gal, 0.79 US gal)
Carburetor
Type/quantity CVK 32 / 1
Manufacturer KTW
Spark plug
Type/manufacturer NGK/CR8E
Spark plug gap 0.7 - 0.8 mm (0.028 - 0.031 in)
Clutch type Dry, centrifugal automatic
Transmission
Primary reduction system V-belt
Secondary reduction system Shaft drive
Transmission type V-belt automatic
Operation Right hand operation
Reverse gear 47/17 × 31/26 × 32/18 × 19/17 (6.54)
Low range 44/17 × 32/18 × 19/17 (5.14)
High range 44/17 × 26/23 × 19/17 (3.27)
Transfer gear 36/10
Chassis
Frame type Steel tube frame
Caster angle 8.1°
Camber angle 2°
Kingpin angle 8.8°
Trail 39.8 mm (1.57 in)
Tread (STD) front 805 mm (31.69 in)
rear 825 mm (32.48 in)
Toe-in (with tires touching the ground)) 15 mm (0.59 in)
Tire
Type Tubeless
Size front AT22 x 7-10
rear AT22 x 10-9
Manufacturer front MAXXIS
rear MAXXIS
Type front M919
rear M920
2-2
Item Standard
Tire pressure (cold tire)
Maximum load* 155.0 kg (342 lb)
Off-road riding front 27 ~ 30 kPa (0.27 ~ 0.30 kgf/cm2 , 4.0 ~ 4.4 psi)
rear 22 ~ 25 kPa (0.22 ~ 0.25 kgf/cm 2 , 3.2 ~ 3.6 psi)
*Load in total weight of rider and accessories
Brake
Front brake type Dual disc brake
operation Right hand operation
Rear brake type Single disc brake
operation Left hand and right foot operation
Suspension
Front suspension Double wishbone / Independent
Rear suspension Swingarm
Shock absorber
Front shock absorber Coil spring/oil damper
Rear shock absorber Coil spring/oil damper
Wheel travel
Front wheel travel 151 mm (5.9 in)
Rear wheel travel 141 mm (5.6 in)
Electrical
Ignition system DC-CDI
Generator system AC magneto
Battery type GTX12-BS
Battery capacity 12 V 10.0 Ah
Headlight type Halogen bulb
Bulb wattage x quantity:
Headlight 12 V, 35/35 W × 2
Tail/brake light 12 V, 5.0/21.0 W × 1
Indicator lights
Neutral 12 V, 1.7 W × 1
Reverse 12 V, 1.7 W × 1
Coolant temperature 12 V, 1.7 W × 1
2-3
ENGINE SPECIFICATIONS SPEC
EBS01002
ENGINE SPECIFICATIONS
Item Standard L imit
Cylinder head
3
Volume 20.30 ~ 21.30 cm (1.24 ~ 1.30 cu.in) ----
Warp limit ---- 0 .0 5 m m
(0.0020 in)
Cylinder
Bore size 74.995 ~ 75.015 mm (2.9526 ~ 2.9533 in) 75.100 mm
(2.9567 in)
Camshaft
Drive method Chain drive (Right)
Camshaft lobe dimensions
Intake “A” 34.780 ~ 34.980 mm (1.3693 ~ 1.3701 in) 34.680 mm

(1.4484 in)
“B” 29.000 ~ 29.100 mm (1.1417 ~ 1.1457in) 28.900 mm
(1.1378 in)
Exhaust “A” 34.640 ~ 34.840 mm (1.3638 ~ 1.3655 in) 34.540 mm
(1.3598 in)
“B” 29.000 ~ 29.100 mm (1.1417 ~ 1.1457in) 28.900 mm
(1.1484 in)
Camshaft runout limit ---- 0 .0 3 m m
(0.0012 in)
Timing chain
Timing chain type 92RH2010-100M ----
Timing chain adjustment method Automatic ----
Rocker arm/rocker arm shaft
Rocker arm inside diameter 11.982 ~ 12.000 mm (0.4717 ~ 0.4724 in) 12.018 mm
(0.4731 in)
Rocker arm shaft outside diameter 11.966 ~ 11.984 mm (0.4711 ~ 0.4718 in) 11.925 mm
(0.4695 in)
Rocker-arm-to-rocker-arm-shaft -0.002 ~ 0.034 mm (0.00008 ~ 0.0013 in) ----
clearance
2-4

Valve, valve seat, valve guide
Valve clearance (cold) IN 0.08 ~ 0.12 mm (0.0031 ~ 0.0047 in) ----
EX 0.13 ~ 0.17 mm (0.0051 ~ 0.0067 in) ----
Valve dimensions
Head Diameter Face Width Seat Width Margin Thickness
“A” head diameter IN 25.40 ~ 25.60 mm (1.0000 ~ 1.0079 in) ----

EX 21.90 ~ 22.10 mm (0.8622 ~ 0.8701 in) ----
“B” face width IN 1.20 mm (0.0472 in) ----
EX 1.20 mm (0.0472 in) ----
“C” seat width IN 0.50 ~ 0.90 mm (0.0197 ~ 0.0354 in) 1.2 mm
(0.05 in)
EX 0.50 ~ 0.90 mm (0.0197 ~ 0.0354 in) 1.2 mm
(0.05 in)
“D” margin thickness IN 0.50 ~ 0.90 mm (0.0197 ~ 0.0354 in) ----
EX 0.80 ~ 1.20 mm (0.0315 ~ 0.0472 in) ----
Stem outside diameter IN 4.975 ~ 4.990 mm (0.1959 ~ 0.1965 in) 4.900 mm
(0.193 in)
EX 4.950 ~ 4.975 mm (0.1949 ~ 0.1959 in) 4.900 mm
(0.193 in)
Guide inside diameter IN 5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in) 5.030 mm
(0.198 in)
EX 5.000 ~ 5.012 mm (0.1969 ~ 0.1973 in) 5.030 mm
(0.198 in)
Stem-to-guide clearance IN 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) 0.080 mm
(0.003 in)
EX 0.025 ~ 0.062 mm (0.0010 ~ 0.0024 in) 0.100 mm
(0.004 in)
Valve stem runout ---- 0 .0 1 m m
(0.0004 in)
Valve seat width IN 3.30 ~ 3.50 mm (0.1299 ~ 0.1378 in) 4.0 mm
(0.16 in)
EX 3.30 ~ 3.50 mm (0.1299 ~ 0.1378 in) 4.0 mm
(0.16 in)
2-5

Valve spring
Inner spring
Free length IN 38.70 mm (1.52 in) 35.20 mm
(1.38 in)
EX 38.70 mm (1.52 in) 35.20 mm
(1.38 in)
Installed length
(valve closed) IN 31.80 mm (1.25 in) ----
EX 31.80 mm (1.25 in) ----
Spring rate K1 IN 7.15 N/mm (0.73 kg/mm, 40.84 lb/in) ----
K2 IN 9.54 N/mm (0.97 kg/mm, 54.38 lb/in) ----
K1 EX 7.15 N/mm (0.73 kg/mm, 40.84 lb/in) ----
K2 EX 9.54 N/mm (0.97 kg/mm, 54.38 lb/in) ----
Compressed spring force
(installed) IN 41.49 ~ 57.19 N ----
(4.23~ 5.83 kg, 9.32 ~ 12.85 lb)
EX 41.49 ~ 57.19 N ----
(4.23~ 5.83 kg, 9.32 ~ 12.85 lb)
Tilt limit IN ---- 2.5°/1.60 mm
(2.5°/0.063 in)
EX ---- 2.5°/1.60 mm
(2.5°/0.063 in)
Direction of winding
(top view) IN Counter clockwise ----
EX Counter clockwise ----
Outer spring
Free length IN 40.40 mm (1.59 in) 36.90 mm
(1.45 in)
EX 40.40 mm (1.59 in) 36.90 mm
(1.45 in)
Installed length
(valve closed) IN 32.00 mm (1.26 in) ----
EX 32.00 mm (1.26 in) ----
Spring rate K1 EX 15.79 N/mm (1.61 kg/mm, 90.07 lb/in) ----
Spring rate K2 EX 20.30 N/mm (2.07 kg/mm, 115.81 lb/in) ----
(installed) IN 73.97 ~ 103.40 N ----
(7.54 ~ 10.54 kg, 16.63 ~ 23.243 lb)
EX 73.97 ~ 103.40 N ----
(7.54 ~ 10.54 kg, 16.63 ~ 23.243 lb)
2-6

Tilt limit IN ---- 2.5°/1.60 mm
(2.5°/0.063 in)
EX ---- 2.5°/1.60 mm
(2.5°/0.063 in)
Direction of winding
(top view) IN Clockwise ----
EX Clockwise ----
Piston
Piston to cylinder clearance 0.010 ~ 0.040 mm (0.0004 ~ 0.0016 in) 0.10 mm
(0.004 in)
Piston size “D” 74.975 ~ 74.985 mm (2.9518 ~ 2.9522 in) ----
Piston off set 0.50 mm (0.0197 in) ----

Offset direction Intake side ----
Piston pin bore inside diameter 17.002 ~ 17.008 mm (0.6694 ~ 0.6696 in) 17.020 mm
(0.6700 in)
Piston pin outside diameter 16.994 ~ 17.000 mm (0.6690 ~ 0.6693 in) 16.960 mm
(0.6677 in)
Piston-pin-to-piston-pin-bore 0.002 ~ 0.014 mm (0.0001 ~ 0.0005 in) 0.072 mm
clearance (0.0028 in)
2-7

Piston rings
Top ring
Type Barrel ----

Dimensions (B × T) 1.00 × 2.61 mm (0.039 × 0.103 in) ----
End gap (installed) 0.15 ~ 0.30 mm (0.006 ~ 0.012 in) 0.50 mm
(0.020 in)
Side clearance 0.015 ~ 0.050 mm (0.0005 ~ 0.0019 in) 0.09 mm
(0.0035 in)
2nd ring
Type Taper ----

End gap (installed) 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) 0.65 mm
(0.026 in)
Side clearance 0.015 ~ 0.050 mm (0.0005 ~ 0.0019 in) 0.09 mm
(0.0035 in)
Oil ring

End gap (installed) 0.20 ~ 0.70 mm (0.008 ~ 0.028 in) ----
Crankshaft
Crank width “A” 56.00 ~ 56.05 mm (2.205 ~ 2.207 in) ----

Runout limit C1 ---- 0 .0 3 m m
(0.0012 in)
C2 ---- 0 .0 3 m m
(0.0012 in)
Big end side clearance “D” 0.100 ~ 0.400 mm (0.0039 ~ 0.0157 in) 0.60 mm
(0.0236 in)
Big end radial clearance “E” 0.005 ~ 0.008 mm (0.0002 ~ 0.0003 in) ----
2-8

Balancer
Balancer drive method Gear ----
Transmission
Main axle runout limit ---- 0 .0 6 m m
(0.0024 in)
Drive axle runout limit ---- 0 .0 6 m m
(0.0024 in)
Main axle assembly width 102.2 ~ 102.4 mm (4.02 ~ 4.03 in) ----
Shifter
Shifter type Shift drum and guide bar ----
Max. shift fork guide bar bending ---- 0 .0 5 m m
(0.002 in)
Air filter oil grade Foam air filter oil or equivalent oil ----
2-9
Item Standard Limit

Carburetor
I. D. mark 1SC1 00 ----
Main jet (M.J) #138 ----
Main air jet (M.A.J) #70 ----
Jet needle (J.N) NPPC ----
Needle jet (N.J) ø3.8 ----
Pilot air jet 1 (P.A.J.1) #100 ----
Pilot outlet (P.O) ø0.8x3 ----
Pilot jet (P.J) #35 ----
Bypass 1 (B.P.1) ø4.8 ----
Valve seat size (V.S) ø2.4 ----
Star ter jet 1 (G.S.1) #95 ----
Float height (F.H) 17.0 mm (0.67 in) ----
Oil filter type Wire mesh ----
Oil pump
Oil pump type Trochoid ----
Inner-rotor-to-outer-rotor-tip clearance 0.15 mm (0.0059 in) 0 .20 mm
(0.0078 in)
Outer-rotor-to-oil-pump-housing 0.150 ~ 0.200 mm (0.0059 ~ 0.0078 in) 0.25 mm
clearance (0.0098 in)
2-10
CHASSIS SPECIFICATIONS SPEC
CHASSIS SPECIFICATIONS
Item Standard Limit
Front suspension
Shock absorber travel 75.0 mm (2.95 in) ----
Fork spring free length 281.0 mm (11.06 in)
Spring rate (K 1) 1.8 kg/mm
(K 2) 3.0 kg/mm
Optional spring No
Rear suspension
Shock absorber travel 100.0mm (3.94 in) ----
Spring free length 295.0 mm (11.61 in)
Spring rate (K 1) 2.85 kg/mm
Optional spring No
Front wheel
Type Panel wheel ----
Rim size 10 x 5.5AT ----
Rim material Steel ----
Rim runout limit radial ---- 2.0 mm
(0.08 in)
lateral ---- 2.0 mm
(0.08 in)
Rear wheel
Type Panel wheel ----
Rim size 9 x 8AT ----
Rim material Steel ----
Rim runout limit radial ---- 2.0 mm
(0.08 in)
lateral ---- 2.0 mm
(0.08 in)
Front disc brake
Type Dual disc brake ----
Disc outside diameter × thickness 175.0 mm × 3.5 mm 3.00 mm
(6.89 in × 0.14 in) (0.12 in)
Brake disk maximum deflection 0.15 mm
(0.006 in)
Pad thickness inner 4.7 mm (0.19 in) 1.0 mm
(0.04 in)
Pad thickness outer 4.7 mm (0.19 in) 1.0 mm
(0.04 in)
Master cylinder inside diameter 12.70 mm (0.50 in) ----
Caliper cylinder inside diameter 30.23 mm (1.19 in) ----
Brake fluid type DOT 4 ----
2-11
CHASSIS SPECIFICATIONS SPEC
Item Standard Limit

Rear disc brake
Type Single cylinder ----
Disc outside diameter × thickness 220.0 mm × 4.0 mm 3.00 mm
(8.66 in × 0.16 in) (0.12 in)
Brake disk maximum deflection 0.15 mm
(0.006 in)
Pad thickness inner 4.8 mm (0.19 in) 1.00 mm
(0.04 in)
Pad thickness outer 4.8 mm (0.19 in) 1.00 mm
(0.08 in)
Master cylinder inside diameter 12.70 mm (0.50 in) ----
Caliper cylinder inside diameter 30.23 mm (1.19 in) ----
Brake fluid type DOT 4 ----
Brake lever pedal

Brake lever free play front 0 mm (0 in) ----
rear 4.0 ~ 7.0 mm (0.16 ~ 0.28 in) ----
Brake pedal position 47 ~ 57 mm (1.85 ~ 2.24 in) ----
Parking brake cable end length 48 ~ 52 mm (1089 ~ 2.05 in) ----
Throttle lever free play 5.0 ~ 10.0 mm (0.20 ~ 0.39 in) ----
Speed limiter length Less than 12 mm (0.47 in) ----
2-12
ELECTRICAL SPECIFICATIONS SPEC
EBS01004
ELECTRICAL SPECIFICATIONS
Item Standard Limit
Voltage 12 V ----
Ignition system
Ignition timing (B.T.D.C.) 10.0°/1,700 r/min ----
Advanced timing (B.T.D.C.) 27°/4,000 r/min ----
Advancer type Electrical (digital) ----
C.D.I.
Magneto model/manufacturer 31120-RFS-0000/SHIHLIN ----
Pickup coil resistance/color 96 ~ 144 Ω at 20 °C (68 °F)/ ----
Blue – Green
C.D.I. unit model/manufacturer C0410-MAA0-0000/SHIHLIN ----
Ignition coil
Model/manufacturer C0510-MAA0-0000/SHIHLIN ----
Minimum spark gap 6 mm (0.24 in) ----
Primary winding resistance 0.19 ~ 0.23 Ω at 20 °C (68 °F) ----
Secondary winding resistance 2.79 ~ 3.41 k Ω at 20 °C (68 °F) ----
Spark plug cap
Type Resin ----
Resistance 5 kΩ ----
Charging system
Type A.C. magneto ----
Model/manufacturer 31120-RFS-0000/SHIHLIN ----
Nominal output 14 V 375 W at 5,000 r/min ----
Charging coil resistance/color 0.19~ 0.29 Ω at 20 °C (68 °F)/ ----
Yellow – Yellow
Rectifier/regulator
Regulator type Shunt type ----
No-load regulated voltage (DC) 14.1 ~ 14.9 V ----
Model/manufacturer C1600-MAA0-0001/E-YANG ----
Capacity (DC) 20 A ----
2-13
ELECTRICAL SPECIFICATIONS SPEC
Item Standard Limit

Electric starter system
Type Constant mesh ----
Starter motor
Model/manufacturer 31200-RFS-0000/SHIHLIN ----
Output 0.60 kW ----
Armature coil resistance 0.018 ~ 0.028 Ω at 20 °C (68 °F) ----
Brush overall length 12.7 mm (0.50 in) 8.2 mm
(0.32 in)
Spring force 7.2 ~ 8.5 N ----
(734 ~ 866 gf, 25.89~30.56 oz)
Commutator diameter 28 mm (1.10 in) 27 mm
(1.06 in)
Mica undercut 0.75 mm ( 0.03 in) ----
Starter relay
Model/manufacturer C585A-MAA0-0000/E-YANG ----
Model/manufacturer 150 A ----
Coil winding resistance 3.2 ~ 4.8 Ω at 20 °C (68 °F) ----
Headlight relay
Headlight relay
Model/manufacturer C8500-MAA0-0000/KOSO
Coil resistance 80.0 Ω ~ 100.0 Ω
Circuit breakers
Type Fuse ----
Amperage for individual circuit
Main fuse 30A × 1 ----
Ignition fuse 10A × 1
Signal fuse 10A × 1
Head fuse 10A × 1
Fan motor fuse 10A × 1
2-14
TIGHTENING TORQUES SPEC
EBS01005
TIGHTENING TORQUES
ENGINE TIGHTENING TORQUES
Part Thread Tightening torque

Part to be tightened Q’ty Remarks
name size Nm m•kg ft•lb
Reed valve comp. Bolt M6 2 12 1.2 8.7
Air pipe Bolt M6 2 12 1.2 8.7
Cylinder head cover Bolt M6 4 12 1.2 8.7
Cylinder head Nut M10 4 38 3.8 27.4
Cylinder head side cover Bolt M6 3 12 1.2 8.7
Camshaft sprocket washer Bolt M6 2 12 1.2 8.7
Spark plug M10 1 12 1.2 8.9
Therm unit M10 1 11 1.1 8.0
Timing chain tensioner Bolt M6 2 12 1.2 8.7
Cylinder head (timing chain side) Bolt M6 2 12 1.2 8.7
Carburetor joint Bolt M6 2 12 1.2 8.7
Cylinder head (Carb. joint) Stud bolt M6 2 12 1.2 8.7
Cylinder head (exhaust pipe) Stud bolt M8 2 27 2.7 19.5
Clearance adjusting locknut Nut M5 4 9 0.9 6.5
Rocker arm shaft plate Bolt M6 1 12 1.2 8.7
Cylinder stud bolt 1 Stud bolt M10 2 12 1.2 8.7
Cylinder stud bolt 2 Stud bolt M10 2 12 1.2 8.7
Water pump cover Bolt M6 4 12 1.2 8.7
Water pump impeller Bolt M7 1 12 1.2 8.7
Engine oil drain bolt Bolt M30 1 15 1.5 10.8
Crankcase cover(R) Bolt M6 10 12 1.2 8.7
Stator assy Bolt M6 3 12 1.2 8.7
C.D.I. magneto rotor Nut M14 1 55 5.5 40.0
Pulse Bolt M5 2 5 0.5 3.6
One-way clutch Bolt M6 3 12 1.2 8.7
Crankcase cover(L) Bolt M6 9 12 1.2 8.7
Sheave primary fixed Bolt M14 1 55 5.5 40.0
Clutch housing Bolt M14 1 55 5.5 40.0
Sheave secondary fixed Nut M36 1 95 9.5 68.7
Mission case Bolt M8 9 28 2.8 20.3
Transmission oil drain bolt Bolt M12 1 40 4.0 30.0
Mission box rear cover Bolt M6 4 12 1.2 8.7
Mission box Bolt M8 6 28 2.8 20.3
Mission shaft drum fixing Bolt M14 1 40 4.0 30.0
Mission box front cover Bolt M6 4 9 0.9 6.5
Mission box oil drain bolt Bolt M8 1 14 1.4 10.7
2-15
Part Thread Tightening torque

Part to be tightened Q’ty Remarks
name size Nm m•kg ft•lb
Starter motor Bolt M6 1 12 1.2 8.7
Oil pump Bolt M3 2 1.5 0.2 1.1
Crankcase L and R Bolt M6 2 12 1.2 8.7
Crankcase L Bolt M6 7 10 1.0 7.2
Change switch Bolt M6 2 12 1.2 8.7
Air clean case Bolt M6 4 8 0.8 5.8
Muffler Bolt M8 2 25 2.5 18.1
Exhaust pipe Nut M8 2 25 2.5 18.1
TIP
*1: Apply oil to the bearing surface of (upper) cylinder head bolt.
Further, apply molybdenum disulfide grease to thread part.
2-16
CHASSIS TIGHTENING TORQUES

Tightening torque
Part to be tightened Thread size Remarks
Nm m•kg ft•lb
Engine bracket (front) and frame M10 60 6.0 43.4
Engine bracket (front) and engine M12 60 6.0 43.4
Engine and frame M12 60 6.0 43.4
Select lever assembly and frame M8 25 2.5 18.1
Shift tie-rod and select lever assembly M8 25 2.5 18.1
Shift tie-rod and engine M8 25 2.5 18.1
Swingarm pivot shaft and frame M22 75 7.5 54.2
Rear shock absorber and frame M10 38 3.8 27.5
Rear shock absorber and swingarm M10 38 3.8 27.5
Final gear case and swingarm M10 35 3.5 25.3
Final gear case and rear axle housing M10 35 3.5 25.3
Front arm and frame M10 35 3.5 25.3
Front shock absorber and frame M10 35 3.5 25.3
Front shock absorber and lower front arm M10 35 3.5 25.3
Steering stem and frame M14 55 5.5 39.8
Steering stem bushing and frame M8 25 2.5 18.1 Use a lock
washer.
Steering stem and handlebar holder M8 25 2.5 18.1
Steering stem and tie-rod ball joint M10 35 3.5 25.3
Steering knuckle and tie-rod ball joint M10 35 3.5 25.3
Tie-rod locknut M10 35 3.5 25.3
Steering knuckle and front arm (upper and lower) M12 45 4.5 32.5
Steering knuckle and brake caliper M8 28 2.8 20.3
Front wheel and wheel hub M10 45 4.5 32.5
Front brake disc and wheel hub M10 35 3.5 25.3
Steering knuckle and wheel hub M14 80 8.0 57.9
Rear axle and rear axle nut M33 170 17.0 123.0
Rear brake disc and disc bracket M10 35 3.5 25.3
Rear brake caliper and brake caliper bracket M8 28 2.8 20.3
Parking brake case and caliper M8 25 2.5 18.1
Parking brake adjusting bolt and locknut M8 16 1.6 11.6
Rear axle and wheel hub M14 135 13.5 97.6
Rear wheel and wheel hub M10 55 5.5 40.0
Throttle lever and housing M5 8 0.8 5.8
Master cylinder and parking brake lever M6 13 1.3 9.4
Rear brake lever and handle bar M6 13 1.3 9.4
2-17
Tightening torque
Part to be tightened Thread size Remarks
Nm m•kg ft•lb
brake hose union bolt M10 28 2.8 20.3
Bleed screw M6 7 0.7 5.1
Rear brake master cylinder and M8 25 2.5 18.1
brake pedal bracket
Brake pedal bracket and frame M8 25 2.5 18.1
Brake master cylinder cup and frame M6 8 0.8 5.8
Fuel tank and fuel cock M16 16 1.6 11.6
Fuel tank and frame M6 13 1.3 9.4
Seat stay and frame M6 13 1.3 9.4
Front fender holder and frame M8 25 2.5 18.1
Front fender and frame M6 8 0.8 5.8
Rear fender and frame M6 8 0.8 5.8
Footrest bracket and frame M8 25 2.5 18.1
Footrest board and footrest bracket M6 8 0.8 5.8
Front bumper and frame M8 25 2.5 18.1
Front carrier and frame M8 25 2.5 18.1
Front carrier and front bumper M8 25 2.5 18.1
Rear carrier and frame M8 25 2.5 18.1
Battery holding bracket M6 8 0.8 5.8
Air duct (front) and frame M6 8 0.8 5.8
Air duct (rear) and frame M6 8 0.8 5.8
2-18
HOW TO USE THE CONVERSION TABLE/
GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC
EBS00022 EBS00023
HOW TO USE THE CONVERSION GENERAL TIGHTENING TORQUE

TABLE SPECIFICATIONS
All specification data in this manual are listed This chart specifies tightening torques for
in SI and METRIC UNITS. standard fasteners with a standard ISO thread
Use this table to convert METRIC unit data to pitch. Tightening torque specifications for spe-
IMPERIAL unit data. cial components or assemblies are provided
Ex. for each chapter of this manual. To avoid
warpage, tighten multi-fastener assemblies in
METRIC MULTIPLIER IMPERIAL
a crisscross pattern and progressive stages
** mm × 0.03937 = ** in until the specified tightening torque is reached.
2 mm × 0.03937 = 0.08 in Unless otherwise specified, tightening torque
specifications require clean, dry threads. Com-
CONVERSION TABLE ponents should be at room temperature.
METRIC TO IMPERIAL
Metric unit Multiplier Imperial unit
m•kg 7.233 ft•lb
m•kg 86.794 in•lb
Torque
cm•kg 0.0723 ft•lb
cm•kg 0.8679 in•lb
kg 2.205 lb
Weight
g 0.03527 oz
Speed km/hr 0.6214 mph
km 0.6214 mi A: Distance between flats
m 3.281 ft B: Outside thread diameter
Distance m 1.094 yd
cm 0.3937 in General tightening
mm 0.03937 in A B torques
cc (cm3) 0.03527 oz (IMP liq.)
(nut) (bolt)
Nm m•kg ft•lb
Volume/ cc (cm3) 0.06102 cu•in
Capacity lt (liter) 0.8799 qt (IMP liq.) 10 mm 6 mm 6 0.6 4.3
lt (liter) 0.2199 gal (IMP liq.)
12 mm 8 mm 15 1.5 11
kg/mm 55.997 lb/in
kg/cm2 14.2234 psi (lb/in2) 14 mm 10 mm 30 3.0 22
Misc.
Centigrade 9/5+32 Fahrenheit 17 mm 12 mm 55 5.5 40
(°C) (°F)
19 mm 14 mm 85 8.5 61
22 mm 16 mm 130 13.0 94
2-19
LUBRICATION POINTS AND LUBRICANT TYPES SPEC
EBS00024
LUBRICATION POINTS AND LUBRICANT TYPES

ENGINE
Lubrication point Lubricant
Oil seal lips
O-rings
Bearings E
Cylinder head bolts (bearing surface of bolts) E
Cylinder head bolts (thread part)

Cylinder body surface E
Crankshaft journals E
Connecting rod small end and big end E
Piston pin E
Piston surface E
Boss periphery E
Valve stems (intake and exhaust) M
Valve stem ends (intake and exhaust) M
Rocker arm shafts (intake and exhaust) E
Camshaft M
Valve rocker arms

Oil pump rotors (inner and outer) and oil pump housing and shaft E
Starter idle gears 1 E
Starter idle gears 2 E
Starter wheel gear E
Push rods
Clutch housing (primary driven gear) E
Push lever shaft E
Push rod ball

Drive axle M
Main axle M
Transmission gears (inside and end) M
Shift fork guide bar E
Shift drum E
Shift shaft E
2-20
LUBRICATION POINTS AND LUBRICANT TYPES SPEC
Lubrication point Lubricant

Sealant
Crankcase mating surfaces (Three Bond No.1215®)
Yamaha bond
No.1215
Sealant
AC magneto lead grommet (AC magneto cover) (Three Bond No.1215®)
Yamaha bond
No.1215
2-21
COOLANT FLOW DIAGRAMS SPEC
COOLANT FLOW DIAGRAMS

1 Fan motor
2 Radiator
3 Thermostat
2-22
COOLANT FLOW DIAGRAMS SPEC
1 Fan motor
2 Radiator
3 Thermo switch
4 Thermostat
2-23
OIL FLOW DIAGRAMS SPEC
OIL FLOW DIAGRAMS

1 Press-In Lubrication 7 Cam Shaft
2 Spray Lubrication 8 Spray Lubrication
3 Con-Rod 9 Oil Route
4 Oil Route 10 Oil Pump
5 Press-In Lubrication 11 Oil Strainer
6 Valve Rocker Arm
7
4
3
9
10
11
2-24
CABLE ROUTING SPEC
CABLE ROUTING
1 Fuel tank breather hose 4 Handlebar switch lead 7 Parking brake cable
2 Choke cable 5 Front brake hose 8 Throttle cable
3 Rear brake cable 6 Front brake switch lead
A Insert the fuel tank breather hose into the hole in the handlebar cover.
B Fasten the front brake switch lead and front brake hose with plastic bands.
C Route the front brake hose, parking brake cable and throttle cable through the guide of the handlebar protector.
D Route the rear brake cable through the guide of the handlebar protector.
E Fasten the handlebar switch lead and choke cable with a plastic band.
B 8 7 C D 3 4
6
5
2
3 E 4 D B C 5 B 6
2 7
8
1
A
2-25
CABLE ROUTING SPEC
1 Headlight couplers 9 Positive battery lead 17 Coolant reservoir breather hose

2 Thermo switch coupler 10 Start relay 18 Reserve rubber tube
3 Handlebar switch couplers 11 Starter motor lead 19 A.I.C.V. inlet tube
4 Shift controller 12 Fuse boxes 20 C.V.T. inlet tube
5 CDI unit 13 Head relay 21 Coolant temperature warning light
6 Negative battery lead 14 Indicator light terminals 22 Neutral indicator light
7 Battery 15 Front brake switch terminals 23 Reverse indicator light
8 Taillight lead coupler 16 Main switch coupler
2 1 20 B 19 1
18
17
A
A 16
15
3
14
A
13
4 12
21 22 23
D E
5 11 F
C
10
6
9
B
7 B 8
2-26
CABLE ROUTING SPEC
A Fasten the coolant reservoir breather hose and reserve rubber tube with a plastic band, then route the
coolant reservoir breather hose through the front fender.
B Route the A.I.C.V. inlet tube and C.V.T. inlet tube through the hole in the front fender.
C Fasten the negative battery lead with plastic bands.
D Fasten the start relay lead and shift controller lead on the wire harness and the negative battery lead with
plastic bands.
E Connect the negative battery lead to the battery so that the lead is routed to the side of the battery.
F Connect the positive battery lead to the battery so that the lead contacts the battery case.
2 1 20 B 19 1
18
17
A
A 16
15
3
14
A
13
4 12
21 22 23
D E
5 11 F
C
10
6
9
B
7 B 8
2-27
CABLE ROUTING SPEC
1 Front brake hose 8 Throttle cable 15 Negative battery lead
2 Fan motor coupler 9 Rear brake cable 16 Taillight lead coupler
3 Heater control switch coupler 10 Select lever control cable 17 Parking brake cable
4 Generator & wire harness coupler 11 Carburetor air vent hose 18 Rear brake hose
5 Rectifier/regulator & wire harness coupler 12 Rear brake switch coupler 19 Blow by tube
6 Generator & rectifier/regulator coupler 13 Change switch terminals 20 Fuel overflow hose
7 Earth lead on wire harness 14 Starter motor lead 21 Thermostat terminal
A Route the front brake hose through the guides on the upper front arms.
B Fasten the fan motor lead and the heater control switch lead on the wire harness with plastic bands.
G H I
16 13 12 11 10 9 8 7 6 5
15 14
4
3
2
17 1
18
19 20 21
F E D D C B A
2-28
CABLE ROUTING SPEC
C Route the radiator outlet hose and coolant reservoir breather hose through the guides on the frame.
D Fasten the generator lead and heater control switch lead on the wire harness with plastic bands.
E Fasten the generator lead and wire harness with plastic bands.
F Fasten the front brake switch lead and change switch lead with plastic bands.
G Fasten the taillight lead on the wire harness with plastic bands.
H Pass these leads through rear fender.
I Fasten the starter motor lead, negative battery lead and wire harness with plastic bands.
G H I
16 13 12 11 10 9 8 7 6 5
15 14
4
3
2
17 1
18
19 20 21
F E D D C B A
2-29
CABLE ROUTING SPEC
1 Front brake hose 6 Choke cable 11 Negative battery lead
2 Rectifier/regulator 7 Rear brake hose 12 A.I.C.V. rubber tube
3 Thermo switch coupler 8 Transfer gear case breather hose 13 A.I.C.V. outlet tube
4 Ignition coil 9 Fuel tube 14 A.I.C.V. inlet tube
5 Parking brake cable 10 Carburetor air vent hose 15 A.I.C.V. connecting tube
A Route the choke cable and parking brake cable through the guides on the frame.
B Fasten the radiator inlet hose with plastic bands.
C Route the front brake hose through the guides on the upper front arms.
6
B E
5 A
A
3
2
B
H
1
7
14 13 12 11 10 9 8 E F G
C D
10
13
15
12
14
8
A
B
2-30
CABLE ROUTING SPEC
D Fixed the negative battery lead on engine by a bolt of the starter motor.
E Fasten the parking brake cable with plastic bands.
F Route the rear brake hose through the guide on the swingarm.
G Fasten the rear brake hose and parking brake cable with plastic bands
H Route the parking brake cable through the guide on the swingarm.
6
B E
5 A
A
3
2
B
H
1
7
14 13 12 11 10 9 8 E F G
C D
10
13
15
12
14
8
A
B
2-31
CABLE ROUTING SPEC
1 Front brake hose 7 Horn switch terminals
2 Generator & rectifier/regulator coupler 8 Rectifier/regulator
3 Wire harness 9 Ignition coil
4 Generator & wire harness coupler 10 Rectifier/regulator & wire harness coupler
5 Fan motor coupler 11 Rear brake cable
6 Heater control switch coupler
A Route the Front brake hose through the guides on the frame and upper front arms.
B Insert the couplers on the bracket of the front fender holder.
11
B 2
10 B
9
4
8
5
A
7
A A
2-32
INTRODUCTION/PERIODIC MAINTENANCE CHK
CHART FOR THE EMISSION CONTROL SYSTEM ADJ
PERIODIC CHECKS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
These preventive maintenance procedures, if followed, will ensure more reliable machine operation
and a longer service life. The need for costly overhaul work will be greatly reduced. This information
applies to machines already in service as well as to new machines that are being prepared for sale.
All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL
SYSTEM
TIP
• For ATVs not equipped with an odometer or an hour meter, follow the month maintenance inter-
vals.
• For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance
intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month main-
tenance intervals should be followed.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
INITIAL EVERY
month 1 3 6 6 12
CHECK OR MAINTENANCE Whichever
NO. ITEM comes km 320 1300 2500 2500 5000
JOB
first (mi) (200) (800) (1600) (1600) (3200)
hours 20 80 160 160 320
• Check fuel hoses for cracks or other damage, and
1 * Fuel line √ √ √
replace if necessary.
• Check condition and clean, regap, or replace if
2 Spark plug √ √ √ √ √
necessary.
3 * Valves • Check valve clearance and adjust if necessary. √ √ √ √
• Check starter (choke) operation and correct if nec-
essary.
4 * Carburetor √ √ √ √
• Check engine idling speed and adjust if neces-
sary.
Crankcase breather • Check breather hose for cracks or other damage,
5 * √ √ √
system and replace if necessary.
• Check for leakage and replace gasket(s) if neces-
sary.
6 * Exhaust system √ √ √
• Check for looseness and tighten all screw clamps
and joints if necessary.
7 Spark arrester • Clean. √ √ √
3-1
CHK
GENERAL MAINTENANCE AND LUBRICATION CHART ADJ
GENERAL MAINTENANCE AND LUBRICATION CHART
INITIAL EVERY
month 1 3 6 6 12
NO. ITEM comes km 320 1300 2500 2500 5000
JOB
first (mi) (200) (800) (1600) (1600) (3200)
1
hours 20 80 160 160 320
Every 20–40 hours (more often in wet or
1 Air filter element • Clean and replace if necessary.
dusty areas)
• Check operation and correct if necessary.
• Check fluid level and ATV for fluid leakage, and √ √ √ √ √
2 * Front brake correct if necessary.
2
• Replace brake pads. Whenever worn to the limit
• Check brake lever free play, and adjust if necessary.
√ √ √ √ √
3 * Rear brake • Check fluid level and ATV for fluid leakage, and
correct if necessary.
• Replace brake pads. Whenever worn to the limit
3
4 * Parking brake • Check operation and correct if necessary. √ √ √ √ √
• Check for cracks or other damage, and replace if
√ √ √ √
5 * Brake hoses necessary.
• Replace. Every 4 years
• Check runout and for damage, and replace if nec-
6 * Wheels √ √ √ √
essary.
4
• Check tread depth and for damage, and replace if
necessary.
7 * Tires √ √ √ √
• Check air pressure and balance, and correct if
necessary.
• Check for looseness or damage, and replace if
8 * Wheel hub bearings √ √ √ √
necessary.
• Check for wear, cracks or other damage, and re-
9 V-belt √ √ √ √
5
*
place if necessary.
• Make sure that all nuts, bolts, and screws are
10 * Chassis fasteners √ √ √ √ √
properly tightened.
Shock absorber as- • Check operation and correct if necessary.
11 * √ √ √
semblies • Check for oil leakage and replace if necessary.
12 * Stabilizer bushes √ √ √
6
necessary.
13 * Steering shaft • Lubricate with lithium-soap-based grease. √ √ √
• Check operation and repair or replace if damaged.
14 * Steering system √ √ √ √ √
• Check toe-in and adjust if necessary.
15 * Engine mount √ √ √
necessary.
7
16 * Axle boot √ √ √ √ √
necessary.
• Change.
17 Engine oil • Check ATV for oil leakage, and correct if neces- √ √ √ √
sary.
18 * Engine oil strainer • Clean. √ √ √
• Change.
8
19 Final transmission oil • Check ATV for oil leakage, and correct if neces- √ √
sary.
• Change.
20 Final gear oil • Check ATV for oil leakage, and correct if neces- √ √ √
sary.
• Check coolant level and ATV for coolant leakage,
√ √ √ √ √
21 Cooling system and correct if necessary.
• Replace coolant. Every 2 years
Moving parts and
22 * • Lubricate. √ √ √ √
cables
Drive select lever • Check operation and adjust or replace if neces-
23 * √ √ √
safety system cable sary.
3-2
CHK
GENERAL MAINTENANCE AND LUBRICATION CHART ADJ
INITIAL EVERY
month 1 3 6 6 12
NO. ITEM comes km 320 1300 2500 2500 5000
JOB
first (mi) (200) (800) (1600) (1600) (3200)
hours 20 80 160 160 320
Throttle lever hous- • Check throttle cable free play and adjust if neces-
24 * √ √ √ √ √
ing and cable sary.
• Lubricate throttle lever housing and cable.
Front and rear brake
25 * • Check operation and correct if necessary. √ √ √ √ √
switches
26 * Lights and switches √ √ √ √ √
• Adjust headlight beams.
TIP
• The air filter needs more frequent service if you are riding in unusually wet or dusty areas.
• Hydraulic brake service
• Regularly check and, if necessary, correct the brake fluid level.
• Every two years replace the internal components of the brake master cylinders and calipers, and
change the brake fluid.
• Replace the brake hoses every four years and if cracked or damaged.
WARNING
Indicates a potential hazard that could result in serious injury or death.
3-3
CHK
SEAT, FENDERS AND FUEL TANK ADJ
EBS00033
SEAT, FENDERS AND FUEL TANK

SEAT, SIDE COVERS AND FOOTREST BOARDS
9 Nm (0.9 m • kg, 6.5 ft • Ib) 3

T
.R
.
(X6)
(X6)
6
(X4)
2
(X4)
(X6)
5
(X6)
9 Nm (0.9 m • kg, 6.5 ft • Ib)

T
.R
.
Order Job/Part Q’ty Remarks

Removing the seat,side covers and Remove the parts in the order listed.
footrest boards
1 Seat 1 TIP
Pull back the seat lock lever, than pull up
on the rear of the seat.
2 Left side cover 1

3 Right side cover 1
4 Left footrest board 1
5 Right footrest board 1
6 Handle plastics 1
For installation, reverse the removal
procedure.
3-4
CHK
FRONT CARRIER, FRONT BUMPER AND FRONT FENDER
1 6 4
9 Nm (0.9 m • kg, 6.5 ft • Ib)
(X2)
T
.R
.
25 Nm (2.5 m • kg, 18.1 ft • Ib) 5
(X2)
T
.R
.
(X2)
3
9 Nm (0.9 m • kg, 6.5 ft • Ib)
T
.R
.
(X2)
(X2)
(X2) (X2)
7
(X2)
(X4)
(X2)
25 Nm (2.5 m • kg, 18.1 ft • Ib) 9 Nm (0.9 m • kg, 6.5 ft • Ib)

T
.R
.
T
.R
.

Removing the front carrier, front Remove the parts in the order listed.
bumper and front fender
Seat, side covers and footrest boards Refer to “SEAT, SIDE COVERS AND
FOOTREST BOARDS”.
1 Front carrier 1
2 Front bumper 1
3 Front fender panel 1
4 Fuel tank cap 1 Remove the fuel tank cover and install
fuel tank cap.
5 Fuel tank cover 1
6 Handlebar cover 1 Disconnect the main switch coupler.
7 Front fender 1 Disconnect the headlight couplers and
thermo switch coupler.

procedure.
3-5
CHK
REAR FENDER AND AIR FILLTER CASE
25 Nm (2.5 m • kg, 18.1 ft • Ib)

3
T
.R
.
4 2
8 9 (X2) 1
(X2)
3 (X2)
5
6
7
11 (X3)
(X4)
10
9 Nm (0.9 m • kg, 6.5 ft • Ib)
T
.R
.
9 Nm (0.9 m • kg, 6.5 ft • Ib)
T
.R
.
12
(X4)
25 Nm (2.5 m • kg, 18.1 ft • Ib)
T
.R
.

Removing the rear fender and air Remove the parts in the order listed.
fillter case
Seat, side covers and footrest boards Refer to “SEAT, SIDE COVERS AND
FOOTREST BOARDS”.
1 Rear carrier 1
2 Battery band 1
3 Battery lead 2
NOTICE
First disconnect the negative lead,
then disconnect the positive lead.
4 Battery 1
5 CDI unit 1 Disconnect.
6 Shift gear control unit 1 Disconnect.
7 Relay 1 Disconnect.
8 Start relay 1 Disconnect.
9 Rear fender 1
3-6
CHK
REAR FENDER AND AIR FILLTER CASE
25 Nm (2.5 m • kg, 18.1 ft • Ib)

3
T
.R
.
4 2
8 9 (X2) 1
(X2)
3 (X2)
5
6
7
11 (X3)
(X4)
10
9 Nm (0.9 m • kg, 6.5 ft • Ib)
T
.R
.
9 Nm (0.9 m • kg, 6.5 ft • Ib)
T
.R
.
12
(X4)
25 Nm (2.5 m • kg, 18.1 ft • Ib)
T
.R
.

10 Clamp 1 Loosen.
11 Air filter case 1
12 Footrest bar 4
procedure.
3-7
CHK
FUEL TANK
13 Nm (1.3 m•kg, 9.4 ft•Ib)
.
4
13 Nm (1.3 m•kg, 9.4 ft•Ib)

.

Removing the fuel tank Remove the parts in the order listed.
Seat / front fender Refer to “SEAT, FENDERS AND FUEL
TANK”.
1 Fuel tank cap 1 Remove the fuel tank shield and install
fuel tank cap.
2 Fuel tank shield 1
3 Fuel hose (fuel cock side) 1 TIP
Before disconnecting the fuel hose, turn
the fuel cock to “OFF”.
4 Fuel tank 1 TIP

When installing the fuel tank, pass the fuel
tank breather hose through the hole in the
handlebar protector.
procedure.
3-8
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
ENGINE
ADJUSTING THE VALVE CLEARANCE
The following procedure applies to all of the
valves.
TIP
• Valve clearance adjustment should be made
on a cold engine, at room temperature.
• When the valve clearance is to be measured
or adjusted, the piston must be at the Top
Dead Center (TDC) on the compression
stroke.
1. Remove:
• seat
• front fender
• fuel tank
Refer to “SEAT, FENDERS AND FUEL
TANK”.
2. Remove:
• A.I.C.V. outlet tube 1
1
• air pipe 2
• cylinder head cover 3
2
3. Remove:
1
• breather tube 1
• cylinder head side cover 2
4. Measure:
• valve clearance
Out of specification → Adjust.
Valve clearance (cold)

Intake valve
2
0.08 ~ 0.12 mm
(0.0031 ~ 0.0047 in)
Exhaust valve
0.13 ~ 0.17 mm
(0.0051 ~ 0.0067 in)
3-9
CHK
ADJUSTING THE VALVE CLEARANCE ADJ
a. Turn camshaft bolt in clockwise direction.
TIP
• Do not turn the bolt in Counterclockwise
direction to prevent from camshaft bolt
looseness.
b. Align the “ I ” mark on the camshaft sprocket

with the stationary pointer on the cylinder
head. When the “ I ” mark is aligned with
the stationary pointer, the piston is at the Top
Dead Center (TDC) on the compression stroke.
TIP
• When the piston is at the Top Dead Center
(TDC) on the compression stroke, there
should be clearance between the valve stem
tips and their respective adjusting screws.
c. Measure the valve clearance with a thick-

ness gauge .
Thickness gauge
90890-03079
Narrow gauge set
YM-34483
5. Adjust:
• valve clearance
a. Loosen the locknut 1 .

b. Insert a thickness gauge 2 between the
adjuster end and the valve end.
c. Turn the adjuster 3 clockwise or counter-
clockwise with the tappet adjusting tool 4
until the proper clearance is obtained.
Tappet adjusting tool

90890-01311
YM-A5970
3-10
ADJUSTING THE VALVE CLEARANCE/ CHK
ADJUSTING THE ENGINE IDLING SPEED ADJ
d. Hold the adjusting screw to prevent it from
moving and tighten the locknut to specifica-
tion.
Locknut:
9 Nm (0.9 m • kg, 6.5 ft • lb)
T.
R.
e. Measure the valve clearance again.
f. If the valve clearance is still out of specifica-
tion, repeat all of the valve clearance
adjustment steps until the specified clear-
ance is obtained.
6. Install:
• cylinder head side cover
Cylinder head side cover bolt:
12 Nm (1.2 m • kg, 8.7 ft • lb)
T.
R.
• breather tube
• cylinder head cover
Cylinder head cover bolt:
12 Nm (1.2 m • kg, 8.7 ft • lb)
T.
R.
• air pipe
Cylinder head cover bolt:

12 Nm (1.2 m • kg, 8.7 ft • lb)
T.
R.
• A.I.C.V outlet tube
ADJUSTING THE ENGINE IDLING SPEED

1. Remove:
• seat
• left side cover and right side cover
Refer to “SEAT AND FENDERS”.
2. Start the engine and let it warm up for sev-
eral minutes.
3. Attach:
• digital tachometer 1
(to the spark plug lead)
Inductive self-powered tachome-

ter
P/N. YU-8036-B
Engine tachometer
P/N. 90890-03113
3-11
ADJUSTING THE ENGINE IDLING SPEED/ CHK
ADJUSTING THE THROTTLE LEVER FREE PLAY ADJ
4. Measure:
• engine idling speed
Engine idling speed

1,600 ~ 1,800 r/min
5. Adjust:
b
a. Turn the throttle stop screw 1 in direction
a or b until the specified idling speed is
a
obtained.
Idling speed becomes

1 Direction a
higher.
Idling speed becomes
Direction b
lower.
6. Detach:
• digital tachometer
7. Adjust:
• throttle lever free play
Refer to “ADJUSTING THE THROTTLE
LEVER FREE PLAY”.
Throttle lever free play

5 ~ 10 mm (0.20 ~ 0.39 in)
8. Install:
• seat
ADJUSTING THE THROTTLE LEVER FREE

PLAY
TIP
Engine idling speed should be adjusted prop-
erly before adjusting the throttle lever free play.
1. Measure:
• throttle lever free play a
Throttle lever free play

5 ~ 10 mm (0.20 ~ 0.39 in)
3-12
CHK
ADJUSTING THE THROTTLE LEVER FREE PLAY ADJ
2. Remove:
• seat
• right side cover
3. Adjust:
First step:
a. Remove the throttle cover 1 .
b. Loosen the locknut 2 on the carburetor
side.
c. Turn the adjusting nut 3 in direction a or
b until the correct free play is obtained.
Direction a Free play is increased.

Direction b Free play is decreased.
1
d. Tighten the locknut.
e. Install the throttle cover
3
TIP
b If the free play cannot be adjusted here, adjust
it at the throttle lever side of the cable.
a 2
4. Install:
• seat
Second step:
4 6 5
d f. Slide back the rubber cover 4 .
g. Loosen the locknut 5 .
h. Turn the adjusting bolt 6 in direction c or
c d until the correct free play is obtained.
Direction c Free play is increased.

Direction d Free play is decreased.
i. Tighten the locknut.
j. Slide the rubber cover to its original posi-
tion.
WARNING
After adjusting the free play, turn the han-
dlebar to the right and left to make sure
that the engine idling speed does not
increase.
3-13
CHK
ADJUSTING THE SPEED LIMITER ADJ
ADJUSTING THE SPEED LIMITER

The speed limiter keeps the carburetor throttle
from becoming fully-opened even when the
throttle lever is applied to the maximum posi-
tion. Screwing in the adjusting screw stops the
engine speed from increasing.
1. Measure:
a • Speed limiter length a
c
1 Speed limiter length
Less than 12 mm (0.47 in)
b
2. Adjust:
• speed limiter length
2
b. Turn the adjusting screw 2 in or out until
the specified speed limiter length is
obtained.
Speed limiter length is

Direction b
decreased.
Speed limiter length is
Direction c
increased.
c. Tighten the locknut.
WARNING
• Particularly for a beginner rider, the speed
limiter should be screwed in completely.
Screw it out little by little as their riding
technique improves. Never remove the
speed limiter for a beginning rider.
• For proper throttle lever operation do not
turn out the adjusting screw more than 12
mm (0.47 in). Also, always adjust the throt-
tle lever free play to 5 ~ 10 mm (0.20 ~ 0.39
in).
3-14
CHK
CHECKING THE SPARK PLUG ADJ
CHECKING THE SPARK PLUG
1. Remove:
• seat
• left side cover
2. Disconnect:
• spark plug cap
3. Remove:
• spark plug
4. Check:
• spark plug type
Incorrect → Change.
Standard spark plug
NGK/CR8E
5. Check:
• electrode 1
Wear/damage → Replace.
• insulator 2
Abnormal color → Replace.
Normal color is a medium-to-light tan color.
6. Clean:
• spark plug
(with a spark plug cleaner or wire brush)
7. Measure:
• spark plug gap a
Use a wire gauge or thickness gauge.
Out of specification → Regap.
Spark plug gap

0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
8. Install:
• spark plug
Spark plug
12.0 Nm (1.20 m·kgf, 8.9 ft · lbf)
TIP
Before installing a spark plug, clean the gasket
surface and plug surface.
9. Install:
• spark plug cap
10. Install:
• seat
3-15
CHK
CHECKING THE IGNITION TIMING ADJ
CHECKING THE IGNITION TIMING
TIP
Engine idling speed and throttle cable free play
should be adjusted properly before checking
the ignition timing.
1. Attach:
Digital tachometer
90890-06760, YU-39951-B
• timing light
(to spark plug lead)
Timing light
90890-03141
Inductive clamp timing light
YU-03141
2. Check:
• ignition timing
1 a. Warm up the engine and keep it at the

specified speed.
Engine speed
1,600 ~ 1,800 r/min
b. Remove the timing mark accessing screw

1 .
c. Visually check the stationary pointer a to
a verify it is within the required firing range b
indicated on the AC magneto rotor.
F
b Incorrect firing range → Check the pickup

coil assembly.
d. Install the timing mark accessing screw.
3. Detach:
• timing light
3-16
CHK
MEASURING THE COMPRESSION PRESSURE ADJ
MEASURING THE COMPRESSION
PRESSURE
The following procedure applies to the cylinder.
TIP
Insufficient compression pressure will result in
a loss of performance.
1. Remove:
• seat
2. Measure:
• Valve clearance
Refer to “ADJUSTING THE VALVE CLEAR-
ANCE”
3. Start the engine, warm it up for several min-
utes, and then turn it off.
4. Disconnect:
• Spark plug cap
5. Remove:
• Spark plug
NOTICE
Before removing the spark plug, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug wells to prevent it
from falling into the cylinder.
6. Install:
1
• Compression gauge 1
• Extension 2
Compression gauge
90890-03081
Engine compression tester
YU-33223
Extension
2
90890-04082
3-17
CHK
MEASURING THE COMPRESSION PRESSURE ADJ
7. Measure:
• Compression pressure
Out of specification → Refer to steps (c)
and (d).
Compression pressure (standard)

1,200 kPa/720 r/min
(12.2 kgf/cm2, 174 psi/720 r/min)
Compression pressure
(maximum)
1,400 kPa/720 r/min
(14.3 kgf/cm2, 203 psi /720 r/min)
Compression pressure (minimum)
1000 kPa/720 r/min
(10.2 kgf/cm2,145 psi /720 r/min)
a. Set the main switch to “ON”.

b. With the throttle wide open, crank the
engine until the reading on the compres-
sion gauge stabilizes.
WARNING
To prevent sparking, ground the spark plug
lead before cranking the engine.
c. If the compression pressure is above the

maximum specification, check the cylinder
head, valve surfaces and piston crown for
carbon deposits.
Carbon deposits → Eliminate.
d. If the compression pressure is below the
minimum specification, pour a teaspoonful
of engine oil into the spark plug bore and
measure again.
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
Reading Diagnosis
Higher than without Piston ring(s) wear or
oil damage → Repair.
Piston, valves, cylin-
der head gasket or
Same as without oil
piston possibly
defective → Repair.
3-18
MEASURING THE COMPRESSION PRESSURE/ CHK
CHECKING THE ENGINE OIL LEVEL ADJ
8. Install:
• Spark plug
Spark plug
12.0 Nm (1.20 m·kgf, 8.9 ft · lbf)
9. Connect:
• Spark plug cap
10. Install:
• seat
CHECKING THE ENGINE OIL LEVEL

1. Place the machine on a level surface.
2. Start the engine, warm it up several min-
3. Remove engine oil cap cover 1 .
2 4. Check:
b • engine oil level
Oil level should be between the minimum
a level mark a and the maximum level mark
b .
Low oil level → Add oil to the proper level.
TIP
• Wait a few minutes until the oil settles before
checking the oil level.
• Do not screw the dipstick 2 in when check-
ing the oil level.
0˚ 10˚ 30˚ 50˚ 70˚ 90˚ 110˚ 130˚F
SAE 10W-30
Recommended engine oil type
YAMALUBE (10W-40) or SAE 10W40
YAMALUBE, SAE10W-30,
SAE 20W-40 SAE10W-40, SAE20W-40,
YAMALUBE (20W-50), or SAE20W-50 SAE20W-50 or SAE5W-30
SAE 5W-30 Recommended engine oil grade
-20 -10 0 10 20 30 40 50˚C API service SG type or higher,
JASO standard MA
3-19
CHECKING THE ENGINE OIL LEVEL/ CHK
CHANGING THE ENGINE OIL ADJ
NOTICE
• Do not add any chemical additives.
Engine oil also lubricates the clutch and
additives could cause clutch slippage.
• Do not allow foreign material to enter the
crankcase.
5. Start the engine, warm it up for several min-

6. Check:
• engine oil level
7. Install engine oil cap cover.
TIP
Before checking the engine oil level, wait a few
minutes until the oil has settled.
CHANGING THE ENGINE OIL

2 2. Start the engine, warm it up for several min-
1
3. Place a container under the engine oil drain
bolt.
4. Remove:
• engine oil cap cover 1
• dipstick 2
5. Remove:
• engine oil drain bolt 1
(along with the O-ring, spring and oil filter
screen)
6. Drain:
1
• engine oil
(completely from the crankcase)
7. Check:
• O-ring
Damage → Replace
8. Install:
• engine oil drain bolt
(along with the O-ring, spring and oil filter
screen)
Engine oil drain bolt

15 Nm (1.5 m·kgf, 10.8 ft · lbf)
3-20
CHK
CHANGING THE ENGINE OIL ADJ
9. Fill:
• crankcase
(with the specified amount of the recom-
mended engine oil)
Quantity
Periodic oil change
1.20 L (1.27 US qt, 1.06 Imp.qt)
10.Install:
• dipstick
11.Start the engine, warm it up for several min-
12.Check:
• engine
(for engine oil leaks)
13.Check:
• engine oil level
Refer to “CHECKING THE ENGINE OIL”
14.Install:
• engine oil cap cover
3-21
CHK
CLEANING THE AIR FILTER ELEMENT ADJ
CLEANING THE AIR FILTER ELEMENT
TIP
There is a check hose 1 at the bottom of the
1 air filter case. If dust and/or water collects in
this hose, clean the air filter element and air fil-
ter case.
1. Remove:
• seat
Refer to “SEAT, FENDERS AND FUEL TANK”.
2. Remove:
• air filter case cover 1
3. Remove:
• bolt 1
1
• air filter element assembly 2
2
4. Remove:
• bolt 1
1 • air filter element cap 2
4
2 • air filter element 3
• air filter element frame 4
3
3-22
CHK
CLEANING THE AIR FILTER ELEMENT ADJ
NOTICE
The engine should never be run without the
air filter; excessive piston and / or cylinder
wear may result.
5. Check:
• air filter element
Damage → Replace.
6. Clean:
a. Wash the element gently, but thoroughly in

solvent.
WARNING
Use a cleaning solvent which is designed
to clean parts only. Never use gasoline or
low flash point solvents as they may cause
a fire or explosion.
b. Squeeze the excess solvent out of the ele-

ment and let it dry.
NOTICE
Do not twist or wring out the element. This
could damage the foam material.
c. Apply Yamaha foam air filter oil or other

quality foam air filter oil.
d. Squeeze out the excess oil.
TIP
The element should be wet but not dripping.
7. Install:
• air filter element assembly
• air filter element frame
• air filter element cap
• bolt
8. Install:
• air filter element assembly
• bolt
TIP
Make sure its sealing surface matches the
sealing surface of the case so there is no air
leak.
3-23
CHK
CLEANING THE SPARK ARRESTER ADJ
9. Install:
• air filter case cover
10. Install:
• seat
Refer to “SEAT, FENDERS AND FUEL TANK”.
CLEANING THE SPARK ARRESTER

1 2 1. Clean:
• Spark arrester
WARNING
• Select a well-ventilated area free of com-
bustible materials.
• Always let the exhaust system cool before
performing this operation.
• Do not start the engine when removing the
tailpipe from the muffler.
a. Remove the bolts 1 .

b. Remove the tailpipe 2 and gasket 3 from
the muffler.
c. Tap the tailpipe lightly with a soft-face ham-
mer or suitable tool, then use a wire brush
3 to remove any carbon deposits from the
2 spark arrester portion of the tailpipe and the
inner contact surfaces of the muffler.
d. Insert the tailpipe and gasket into the muffler.
e. Install the bolts and tighten it.
12 Nm (1.2 m·kgf, 8.7 ft·lbf)
T
.R
.
3-24
CHECKING THE COOLANT LEVEL/ CHK
CHANGING THE COOLANT ADJ
CHECKING THE COOLANT LEVEL
2. Check:
b • Coolant level
The coolant level should be between the
a
minimum level mark a and maximum level
mark b .
Below the minimum level mark → Add the
recommended coolant to the proper level.
NOTICE
• Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant, check
and if necessary, correct the antifreeze
concentration of the coolant.
• Use only distilled water. However, soft
water may be used if distilled water is not
available.
3. Start the engine, warm it up for several
minutes, and then turn it off.
4. Check:
• Coolant level
TIP
Before checking the coolant level, wait a few
minutes until the coolant has settled.
CHANGING THE COOLANT

1. Remove:
• front carrier
• front panel
Refer to “FRONT CARRIER, FRONT BUMPER
AND FRONT FENDER”.
2. Disconnect:
• coolant reservoir hose 1
3. Drain:
• Coolant
(from the coolant reservoir)
4. Connect:
1
• coolant reservoir hose
3-25
CHK
5. Remove:
• radiator cap 1
WARNING
A hot radiator is under pressure. Therefore,
do not remove the radiator cap when the
engine is hot. Scalding hot fluid and steam
may be blown out, which could cause seri-
1
ous injury. When the engine has cooled,
open the radiator cap as follows:
Place a thick rag or a towel over the radia-
tor cap and slowly turn the radiator cap
counterclockwise toward the detent to
allow any residual pressure to escape.
When the hissing sound has stopped, turn
the radiator cap counterclockwise while
pressing down on it and then remove it.
6. Remove:
• coolant drain bolt (water pump) 1
(along with the copper washer)
7. Drain:
1 • Coolant
8. Check:
• copper washer 1 New
• coolant drain bolt 2
Damage → Replace.
9. Install:
• coolant drain bolt (water pump)
Coolant drain bolt:

12 Nm (1.2 m • kg, 8.7 ft • lb)
T.
R.
3-26
CHK
10.Fill:
• cooling system
mended coolant)
Recommended antifreeze
High-quality ethylene glycol
antifreeze containing corrosion
inhibitors for aluminum engines
Mixing ratio
1:1 (antifreeze:water)
Quantity
Total amount
0.94L
(0.83 lmp qt, 0.99 US qt)
Coolant reservoir capacity
0.25 L
(0.22 lmp qt, 0.26 US qt)
Handling notes for coolant

Coolant is potentially harmful and should
be handled with special care.
WARNING
• If coolant splashes in your eyes, thor-
oughly wash them with water and con-
sult a doctor.
• If coolant splashes on your clothes,
quickly wash it away with water and then
with soap and water.
• If coolant is swallowed, induce vomiting
and get immediate medical attention.
NOTICE
• Adding water instead of coolant lowers
the antifreeze content of the coolant. If
water is used instead of coolant, check,
and if necessary, correct the antifreeze
concentration of the coolant.
• Use only distilled water. However, soft
water may be used if distilled water is not
available.
• If coolant comes into contact with
painted surfaces, immediately wash them
with water.
• Do not mix different types of antifreeze.
11.Install:
• radiator cap
3-27
CHANGING THE COOLANT/ CHK
CHECK THE COOLANT TEMPERATURE INDICATOR LIGHT ADJ
12.Fill:
a • coolant reservoir
(with the recommended coolant to the
maximum level mark a )
13.Install:
• coolant reservoir cap
14.Start the engine, warm it up for ten minutes,

and then rev the engine five times.
15.Pour the recommended coolant into the radi-
ator until it is full.
16.Stop the engine and allow it to cool. If the
coolant level has dropped after the engine
has cooled add sufficient coolant until it re-
aches the top of the radiator, and then install
the radiator cap.
17.Start the engine, and then check for coolant
leakage.
Cracks/wear/damage → Replace.
18.Inspect:
• coolant level
Refer to “CHECKING THE COOLANT
LEVEL”.
TIP
Before inspecting the coolant level, wait a few
minutes until the coolant has settled.
19.Install:
• front panel
• front carrier
Refer to “FRONT CARRIER, FRONT BUMPER
AND FRONT FENDER”.
CHECK THE COOLANT TEMPERATURE

1
INDICATOR LIGHT
1. Check:
• coolant indicator light 1
3-28
CHK
CHECK THE COOLANT TEMPERATURE INDICATOR LIGHT ADJ
Coolant temperature indicator light checking method
Turn the main switch “ON” and

the engine stop switch to “ ”.
Coolant temperature indicator Coolant temperature indicator

light does not come on. light comes on.
Push start switch with

transmission in “neutral”.
Coolant temperature Coolant temperature indicator

indicator light comes light does not come on.
on momentarily.
Coolant temperature Ask a Yamaha dealer to

and electrical circuit are inspect the electrical circuit.
OK. Go ahead with riding.
3-29
CHECKING THE FRONT BRAKE/ CHK
ADJUSTING THE REAR BRAKE LEVER ADJ
CHASSIS
a
CHECKING THE FRONT BRAKE
1. Measure:
• brake lever free play a
Out of specification → Bleed the front brake
system.
Refer to “BLEEDING THE HYDRAULIC
BRAKE SYSTEM”.
Brake lever free play

(at the end of the brake lever)
0 mm (0 in)
ADJUSTING THE REAR BRAKE LEVER

TIP
Before adjusting the rear brake lever, the rear
brake linings should be checked.
NOTICE
Proper lever free play is essential to avoid
excessive brake drag.
1. Measure:
a
• rear brake lever free play a
Front brake lever free play

4 –7 mm (0.16 –0.28 in)
2. Remove:
• seat
• right footboard
Refer to “SEAT, SIDE COVERS AND
FOOTREST BOARDS”.
3-30
CHK
ADJUSTING THE REAR BRAKE LEVER ADJ
3. Adjust:
• rear brake lever free play
b a
2 First step:
a. Loosen the locknut .
b. Turn the adjuster in or out until the
specified rear brake lever free play is
obtained.
1
Direction Free play is increased.
Direction Free play is decreased.
c. Tighten the locknuts.
TIP
If the free play cannot be adjusted here, adjust
it at the throttle lever side of the cable.
Second step:
1 2 a
a. Loosen the locknut .
b. Turn the adjuster in or out until the
specified rear brake lever free play is
b obtained.
Direction Free play is increased.
Direction Free play is decreased.
c. Tighten the locknuts.
4. Install:
• right footboard
• seat
FOOTREST BOARDS”.
3-31
CHK
ADJUSTING THE REAR PEDAL POSITION ADJ
ADJUSTING THE REAR PEDAL POSITION
1. Measure:
• rear brake pedal height a
Rear brake pedal height

a 47.0–57.0 mm (1.85–2.24 in)
2. Remove:
• seat
• right footboard
FOOTREST BOARDS”.
3. Adjust:
• rear brake pedal height
2 a. Loosen the locknut 1 .

b. Turn the adjusting bolt 2 until the brake
a pedal height is within the specified limits.
c. Tighten the locknut.
1 TIP
When adjusting the brake pedal height make
sure the locknut-to-adjusting bolt clearance a
does not exceed 8 mm (0.31 in).
WARNING
After this adjustment is performed, lift the
front and rear wheels off the ground by
placing a block under the engine, and spin
the rear wheels to ensure there is no brake
drag. If any brake drag is noticed, perform
the above steps again.
4. Install:
• right footboard
• seat
FOOTREST BOARDS”.
3-32
CHK
ADJUSTING THE PARKING BRAKE ADJ
ADJUSTING THE PARKING BRAKE
a
1. Check:
• parking brake cable end length a
Parking brake cable end length

52–56 mm (2.05–2.20 in)
2. Adjust:
• parking brake cable end length
a. Loosen the locknut 1 and adjusting bolt

2 .
b. Loosen the locknut 3 .
c. Turn the adjusting nut 4 in direction a or
b until the specified brake cable end
length is obtained.
1 2
Parking brake cable end length
52–56 mm (2.05–2.20 in)
d. Tighten the locknut 3 .

e. Slowly tighten the adjusting bolt to the speci-
b
fied torque.
Tighten the adjusting bolt:

3
0.3 Nm (0.03 m • kg, 0.22 ft • lb)
a
T.
R.
4
f. Turn it 1/8 counterclockwise.
g. Tighten the locknut 1 .
Tighten the locknut:

16 Nm (1.6 m • kg, 11 ft • lb)
T.
R.
WARNING
After this adjustment is performed, lift the
rear wheels off the ground by placing a
block under the engine, and spin the rear
wheels to ensure there is no brake drag. If
any brake drag is noticed perform the
above steps again.
3-33
CHK
CHECKING THE BRAKE FLUID LEVE ADJ
CHECKING THE BRAKE FLUID LEVEL
TIP
When checking the brake fluid level, make sure
that the top of the brake master cylinder reser-
voir or brake fluid reservoir is horizontal.
2. Check:
1
• brake fluid level
Below the minimum level mark 1 → Add
the recommended brake fluid to the proper
level.
Recommended brake fluid

DOT 4
Front brake
Rear brake
WARNING
1
• Use only the designated brake fluid.
Other brake fluids may cause the rubber
seals to deteriorate, causing leakage and
poor brake performance.
• Refill with the same type of brake fluid that
is already in the system. Mixing brake flu-
ids may result in a harmful chemical reac-
tion, leading to poor brake performance.
• When refilling, be careful that water does
not enter the brake fluid reservoir. Water
will significantly lower the boiling point of
the brake fluid and could cause vapor
lock.
NOTICE
Brake fluid may damage painted surfaces
and plastic parts. Therefore, always clean
up any spilt brake fluid immediately.
TIP
In order to ensure a correct reading of the
brake fluid level, make sure that the top of the
brake master cylinder reservoir or brake fluid
reservoir is horizontal.
3-34
CHECKING THE FRONT BRAKE PADS/ CHK
CHECKING THE REAR BRAKE PADS ADJ
CHECKING THE FRONT BRAKE PADS
1. Remove:
• front wheels
Refer to “FRONT AND REAR WHEELS” in
chapter 6.
2. Check:
• brake pads
Wear indicators almost touch the brake disc
a → Replace the brake pads as a set.
Refer to “FRONT AND REAR BRAKES” in
chapter 6.
Brake pad wear limit a

1.0 mm (0.04 in)
3. Operate the front brake lever.

4. Install:
• front wheels
Refer to “FRONT AND REAR WHEELS” in
chapter 6.
CHECKING THE REAR BRAKE PADS

1. Check:
• brake pads
Wear indicators almost touch the brake disc
a → Replace the brake pads as a set.
chapter 6.

1.0 mm (0.04 in)
2. Operate the brake pedal and the rear brake

lever.
3-35
CHK
ADJUSTING THE REAR BRAKE LIGHT SWITCH ADJ
ADJUSTING THE REAR BRAKE LIGHT
SWITCH
TIP
• The rear brake light switch is operated by
movement of the brake pedal.
• The rear brake light switch is properly
adjusted when the brake light comes on just
before the braking effect starts.
1. Check:
• rear brake light operation timing
Incorrect → Adjust.
2. Adjust:
1 a • rear brake light operation timing
b
2
a. Hold the main body 1 of the rear brake
light switch so that it does not rotate and
turn the adjusting nut 2 in direction a or
b until the rear brake light comes on at the
proper time.
Brake light comes on

Direction a
sooner.
Brake light comes on
Direction b
later.
3-36
CHK
CHECKING THE BRAKE HOSES ADJ
CHECKING THE BRAKE HOSES
1. Remove:
• seat
• front fender
TANK”.
2. Check:
• front brake hoses 1
• rear brake hose 2
Cracks/wear/damage → Replace.
1
3. Check:
• brake hose clamps
Loosen → Tighten.
1 4. Hold the machine in an upright position and
1 apply the front or rear brake.
5. Check:
• brake hoses
Apply the brake lever or brake pedal several
times.
Fluid leakage → Replace the hoses or pipe.
chapter 6.
6. Install:
• front fender
• seat
TANK”.
3-37
CHK
BLEEDING THE HYDRAULIC BRAKE SYSTEM ADJ
BLEEDING THE HYDRAULIC BRAKE
SYSTEM
WARNING
Bleed the hydraulic brake system when-
ever:
• the system is disassembled.
• a brake hose is loosened, disconnected or
replaced.
• the brake fluid level is very low.
• brake operation is faulty.
TIP
• Be careful not to spill any brake fluid or allow
the brake master cylinder reservoir or brake
fluid reservoir to overflow.
• When bleeding the hydraulic brake system,
make sure there is always enough brake fluid
before applying the brake. Ignoring this pre-
caution could allow air to enter the hydraulic
brake system, considerably lengthening the
bleeding procedure.
• If bleeding is difficult, it may be necessary to
let the brake fluid settle for a few hours.
Repeat the bleeding procedure when the tiny
bubbles in the hose have disappeared.
1. Bleed:
2 • hydraulic brake system
1 a. Fill the brake fluid reservoir to the proper

level with the recommended brake fluid.
b. Install the diaphragm (brake master cylin-
der reservoir or brake fluid reservoir).
c. Connect a clear plastic hose 1 tightly to
the bleed screw 2 .
Front
Rear
d. Place the other end of the hose into a con-
2
tainer.
e. Slowly apply the brake lever or brake pedal
several times.
f. Fully squeeze the brake lever or fully
1 depress the brake pedal and hold it in posi-
tion.
g. Loosen the bleed screw.
TIP
Loosening the bleed screw will release the
pressure and cause the brake lever to contact
the grip or the brake pedal to fully extend.
3-38
BLEEDING THE HYDRAULIC BRAKE SYSTEM/ADJUSTMENT CHK
THE SELECT LEVER CONTROL CABLE AND SHIFT ROD ADJ
h. Tighten the bleed screw and then release
the brake lever or brake pedal.
i. Repeat steps (e) to (h) until all of the air
bubbles have disappeared from the brake
fluid in the plastic hose.
j. Tighten the bleed screw to specification.
Bleed screw:
7 Nm (0.7 m·kg, 5.1 ft·lb)
T.
R.
k. Fill the brake fluid reservoir to the proper
level with the recommended brake fluid.
Refer to “CHECKING THE BRAKE FLUID
LEVEL”.
WARNING
After bleeding the hydraulic brake system,
check the brake operation.
ADJUSTMENT THE SELECT LEVER CONTROL

CABLE AND SHIFT ROD
4 1 • neutral 1
2 • high 2
3
• low 3
• reverse 4
• control cable 5
• select lever shift rod 6
WARNING
Before moving the select lever, bring the
machine to a complete stop and return the
5
throttle lever to its closed position. Other-
wise the transmission may be damaged.
1. Adjust:
• rear brake pedal position
6 Refer to “ADJUSTING THE REAR PEDAL
POSITION”.
2. Remove:
• seat
• right footboard
FOOTREST BOARDS”.
3-39
ADJUSTMENT THESELECT LEVER CONTROL CABLE CHK
AND SHIFT ROD ADJ
3. Adjust:
• select lever control cable
• select lever shift rod
2 Select lever control cable and select lever

shift rod adjustment steps:
Control cable:
a. Make sure the select lever is in NEUTRAL.
b. Adjust the control cable so there is zero
free play in the cable. When the adjust-
ment is correct, slack in the return spring
1
1 will be taken up.
TIP
In some cases it will be necessary to further
adjust the cable with the locknuts 2
arrangement that holds the cable to its
mount.
c. When the brake begins to work “ a = 20 ~

30 mm (0.8 ~ 1.2 in)”, verify that the select
lever can be shifted to REVERSE from
NEUTRAL and to NEUTRAL from REVERSE.
a
d. Before the brake begins to work “ a = 0 ~
20 mm (0 ~ 0.8 in)”, verify that the select
lever cannot be shifted to REVERSE from
NEUTRAL and to NEUTRAL from REVERSE.
3 e. Check that locknuts 2 are tightened cor-

rectly.
4
f. If the operation of the select lever is incor-
2 rect, adjust the select lever control cable
3 with the adjuster 4 .
3-40
ADJUSTMENT THESELECT LEVER CONTROL CABLE CHK
AND SHIFT ROD ADJ
Select lever shift rod:
g. Make sure the select lever is in NEUTRAL.
1
h. Loosen both locknuts 1 .
i. Adjust the shift rod length for smooth and
correct shifting.
j. Tighten the locknuts 1 .
3-41
CHK
CHANGING THE TRANSFER GEAR OIL ADJ
CHANGING THE TRANSFER GEAR OIL
2. Place a receptacle under the transfer gear
case.
3. Remove:
• right footboard
• seat
4. Remove:
• transfer gear filling bolt
• transfer gear oil drain bolt
5. Drain:
• transfer gear oil
6. Install:
• transfer gear oil drain bolt
40 Nm (4.0 m·kgf, 28.9 ft·lbf)
T
.R
.
TIP
Check the gasket (drain bolt). If it is damaged,
replace it with a new one.
7. Fill:
• transfer gear case
Total amount
1.30 L (1.37 US qt) (1.14 Imp.qt)
Recommended oil
SAE 90 API GL-5 Hypoid gear oil
NOTICE
_
Take care not to allow foreign material to

enter the transfer gear case.
8. Install:
• transfer gear filling bolt
15 Nm (1.5 m·kg, 10.8 ft·lb)
T
.R
.
9. Install:
• right footboard
• seat
FOOTREST BOARDS”.
3-42
CHK
CHANGING THE FINAL DRIVE GEAR OIL ADJ
CHANGING THE FINAL DRIVE GEAR OIL
2. Place a receptacle under the final gear case.
1 3. Remove:
• final drive gear filling bolt 1
• final drive gear oil drain bolt 2
4. Drain:
• final drive gear oil
5. Install:
• final drive gear oil drain bolt
30 Nm (3.0 m·kgf, 21.7 ft·lbf)
T
.R
.
2 TIP
Check the gasket (drain bolt). If it is damaged,
replace it with a new one.
6. Fill:
• final drive gear case
_ Total amount
0.15 L (0.16 US qt, 0.13 Imp.qt)
Recommended oil
SAE 80 API GL-4 Hypoid gear oil
NOTICE
Take care not to allow foreign material to
enter the final gear case.
7. Install:
• final drive gear filling bolt
15 Nm (1.5 m·kgf, 10.8 ft·lbf)
T
.R
.
3-43
CHECKING THE REAR AXLE BOOT / CHK
CHECKING THE STEERING SYSTEM ADJ
CHECKING THE REAR AXLE BOOT
1.Check:
• dust boots 1
Damage → Replace.
Refer to “DIFFERENTIAL GEAR AND CON-
1
STANT VELOCITY JOINT” in CHAPTER 6.
CHECKING THE STEERING SYSTEM

2. Check:
• steering assembly bushings
Move the handlebar up and down, and/or
back and forth.
Excessive play → Replace the steering
stem bushings.
3. Check:
• tie-rod ends
Turn the handlebar to the left and right until
it stops completely, and then move the han-
dlebar slightly in the opposite direction.
Tie-rod end(s) have vertical play →
Replace the tie-rod end(s).
4. Raise the front end of the machine so that

there is no weight on the front wheels.
5. Check:
• ball joints and/or wheel bearings
Move the wheels laterally back and forth.
Excessive free play → Replace the front
arms (upper and lower) and/or wheel bear-
ings.
3-44
CHK
ADJUSTING THE TOE-IN ADJ
ADJUSTING THE TOE-IN
2. Measure:
• toe-in
Toe-in
15 mm (0.59 in)
TIP
Before measuring the toe-in, make sure that
the tire pressure is correct.
a. Mark both front tire tread centers.

b. Face the handlebar straight ahead.
c. Measure the width between the marks.
d. Rotate the front tires 180° until the marks
are exactly opposite one another.
e. Measure the width between the marks.
f. Calculate the toe-in using the formula given
below.
Toe-in = –
g. If the toe-in is incorrect, adjust it.

Forward
3. Adjust:
• toe-in
WARNING
• Be sure that both tie-rods are turned the
same amount. If not, the machine will drift
right or left even though the handlebar is
positioned straight. This may lead to mis-
handling and an accident.
• After setting the toe-in to specification,
run the machine slowly for some distance
with both hands lightly holding the han-
dlebar and check that the handlebar
responds correctly. If not, turn either the
right or left tie-rod within the toe-in speci-
fication.
3-45
ADJUSTING THE TOE-IN/CHECKING THE FRONT AND CHK
REAR SHOCK ABSORBERS ADJ
2
a. Mark both tie-rods ends.
This reference point will be needed during
adjustment.
b. Loosen the locknuts (tie-rod end) of both
tie-rods.
c. The same number of turns should be given
to both the right and left tie-rods until the
specified toe-in is obtained. This is to keep
the length of the rods the same.
d. Tighten the rod end locknuts of both tie-
rods. 35 Nm (3.5 m·kg, 25.3 ft·lb)
TIP
Adjust the rod ends so that A and B are equal.
CHECKING THE FRONT AND REAR SHOCK

ABSORBERS
1 1 2. Check:
• damper rod 1
Bends/damage → Replace the front/rear
shock absorber assembly.
• oil leakage
Excessive oil leakage → Replace the front/
rear shock absorber assembly.
• cylinder
Damage → the front/rear shock absorber
assembly.
• spring
Fatigue → the front/rear shock absorber
assembly.
Refer to “FRONT ARMS AND FRONT SHOCK
ABSORBER ASSEMBLIES” and “REAR
SHOCK ABSORBER AND SWINGARM”
1 in chapter 8.
3. Check:
• operation
Pump the shock absorbers up and down for
several times.
Unsmooth operation → Replace the front/
rear shock absorber assembly.
Refer to “ADJUSTING THE REAR SHOCK
ABSORBERS”.
Front shock absorber
Rear shock absorber
3-46
CHK
ADJUSTING THE REAR SHOCK ABSORBER ADJ
ADJUSTMENT THE REAR SHOCK
ABSORBER
1. Adjust:
1
• Spring preload
Turn the adjuster 1 to increase or decrease
the spring preload.
TIP
The spring preload of the rear shock absorber
can be adjusted to suit the rider’s preference,
weight, and the riding conditions.
Standard position: 2
Minimum (Soft) position: 1
Maximum (Hard) position: 4
3-47
CHK
CHECKING THE TIRES ADJ
CHECKING THE TIRES
WARNING
This model is equipped with low pressure
tires. It is important that they be inflated
correctly and maintained at the proper
pressures.
• TIRE CHARACTERISTICS
1) Tire characteristics influence the han-
dling of ATVs. The tires listed below
have been approved by Yamaha Motor
Co., Ltd. for this model. If other tire com-
binations are used, they can adversely
affect your machine’s handling charac-
teristics and are therefore not recom-
mended.
Manufacturer Size Type

AT22 ×
Front MAXXIS M919
7-10
AT22 ×
Rear MAXXIS M920
10-9
• TIRE PRESSURE
1) Recommended tire pressure
Front 30.0 kPa (0.300 kgf/cm², 4.4 psi)
Rear 25.0 kPa (0.250 kgf/cm², 3.6 psi)
2) Tire pressure below the minimum speci-
fication could cause the tire to dislodge
from the rim under severe riding condi-
tions.
The following are minimums:
Front 27.0 kPa (0.270 kgf/cm², 4.0 psi)
Rear 22.0 kPa (0.220 kgf/cm², 3.2 psi)
3) Use no more than
Front 250 kPa (2.6 kg / cm2, 36 psi)
Rear 250 kPa (2.6 kg / cm2, 36 psi)
when seating the tire beads. Higher
pressures may cause the tire to burst.
Inflate the tires slowly and carefully.
Fast inflation could cause the tire to
burst.
• MAXIMUM LOADING LIMIT
1) Vehicle load limits: 155.0 kg (342 lb)
*Total weight of the cargo, rider, and
accessories.
Be extra careful of the machine balance
and stability when towing a trailer.
3-48
CHK
CHECKING THE TIRES ADJ
1. Measure:
• tire pressure
TIP
• The low-pressure tire gauge is included as
standard equipment.
• If dust or the like is stuck to this gauge, it will
1
not provide the correct readings. Therefore,
take two measurements of the tire’s pressure
and use the second reading.
Cold tire
Front Rear
pressure
30.0 kPa 25.0 kPa
Standard (0.300 kgf/cm², (0.250 kgf/cm²,
4.4 psi) 3.6 psi)
27.0 kPa 22.0 kPa

Minimum (0.270 kgf/cm², (0.220 kgf/cm²,
4.0 psi) 3.2 psi)
33.0 kPa 28.0 kPa

Maximum (0.330 kgf/cm², (0.280 kgf/cm²,
4.8 psi) 4.1 psi)
WARNING
Uneven or improper tire pressure may
adversely affect the handling of this
machine and may cause loss of control.
• Maintain proper tire pressures.
• Set tire pressures when the tires are cold.
• Tire pressures must be equal in both front
tires and equal in both rear tires.
2. Check:
• tire surfaces
Tire wear limit

Front and rear: 3.0 mm (0.12 in)
a
WARNING
It is dangerous to ride with a worn-out tire.
When tire wear is out of specification,
replace the tire immediately.
3-49
CHECKING THE WHEELS/CHECKING AND CHK
LUBRICATING THE CABLES ADJ
CHECKING THE WHEELS
1. Check:
1 • wheel
Damage → Replace.
TIP
Always balance the wheel when a tire or wheel
has been changed or replaced.
WARNING
• Never attempt even small repairs to the
wheel.
• Ride conservatively after installing a tire
to allow it to seat itself properly on the rim.
CHECKING AND LUBRICATING THE

CABLES
WARNING
A damaged cable sheath may cause corro-
sion and interfere with the cable movement.
An unsafe condition may result so replace
a damaged cable as soon as possible.
1. Check:
• cable sheath
Damage → Replace.
2. Check:
• cable operation
Unsmooth operation → Lubricate or replace.
Recommended lubricant
Yamaha chain and cable lube or
engine oil
TIP
Hold the cable end up and apply several drops
of lubricant to the cable.
3. Apply:
• Lithium-soap-based grease
(onto end of the cable)
3-50
CHK
LUBRICATING THE LEVERS AND PEDALS ADJ
LUBRICATING THE LEVERS AND PEDALS
Lubricate the pivoting point and metal-to-metal
moving parts of the levers and pedal.
Recommended lubricants
Brake lever
Silicone grease
Clutch lever and brake pedal
Lithium-soap-based grease
3-51
CHK
CHECKING AND CHARGING THE BATTERY ADJ
ELECTRICAL SYSTEM
CHECKING AND CHARGING THE BATTERY
WARNING
Batteries generate explosive hydrogen gas
and contain electrolyte which is made of
poisonous and highly caustic sulfuric acid.
Therefore, always follow these preventive
measures:
• Wear protective eye gear when handling
or working near batteries.
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes).
• DO NOT SMOKE when charging or han-
dling batteries.
• KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
FIRST AID IN CASE OF BODILY CONTACT:
EXTERNAL
• Skin — Wash with water.
• Eyes — Flush with water for 15 minutes
and get immediate medical attention.
INTERNAL
• Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.
NOTICE
• This is a sealed battery. Never remove the
sealing caps because the balance
between cells will not be maintained and
battery performance will deteriorate.
• Charging time, charging amperage and
charging voltage for an VRLA (Valve Re-
gulated Lead Acid) battery are different
from those of conventional batteries. The
VRLA (Valve Regulated Lead Acid)battery
should be charged as explained in the
charging method illustrations. If the battery
is overcharged, the electrolyte level will
drop considerably. Therefore, take special
care when charging the battery.
3-52
CHK
TIP
Since VRLA (Valve Regulated Lead Acid)
batteries are sealed, it is not possible to check
the charge state of the battery by measuring
the specific gravity of the electrolyte. Therefore,
the charge of the battery has to be checked by
measuring the voltage at the battery terminals.
1. Remove:
• seat
• battery holding plate
TANK”.
2. Disconnect:
• battery leads
(from the battery terminals)
2
NOTICE
First, disconnect the negative battery lead
, and then the positive battery lead .
1
3. Remove:
• battery
4. Check:
• battery charge
a. Connect a pocket tester to the battery ter-

minals.
Positive tester probe →

positive battery terminal
Negative tester probe →
negative battery terminal
TIP
Relationship between the open-circuit voltage
•The charge state of an VRLA (Valve Regulated
Open-circuit voltage (V)
and the charging time at 20 °C (68 °F)

Lead Acid) battery can be checked by measur-
ing its open-circuit voltage (i.e., the voltage
when the positive terminal is disconnected).
• No charging is necessary when the open-cir-
cuit voltage equals or exceeds 12.8 V.
Charging time (hours)
These values vary with the temperature, the condition of
the battery plates, and the electrolyte level.
b. Check the charge of the battery, as shown
in the charts and the following example.
3-53
CHK
Example
c. Open-circuit voltage = 12.0 V
d. Charging time = 6.5 hours
e. Charge of the battery = 20 ~ 30%
Charging Ambient temperature 5. Charge:

20°C (68°F)
18 • battery
17 (refer to the appropriate charging method

16
15 illustration)
14
13 WARNING
12
11 Do not quick charge a battery.
10
0 10 20 30 40 50 60 Time (minutes)
Check the open-circuit
voltage. NOTICE
•NeverremovetheVRLA (Valve Regulated
Lead Acid) battery sealing caps.
14 Ambient • Do not use a high-rate battery charger
13 temperature
20°C (68°F) since it forces a high-amperage current
12 into the battery quickly and can cause bat-
11
tery overheating and battery plate dam-
age.
10 • If it is impossible to regulate the charging
current on the battery charger, be careful
100 75 50 30 25 20 0
Charging condition of the battery (%)
not to overcharge the battery.
• When charging a battery, be sure to
remove it from the machine. (If charging
has to be done with the battery mounted
on the machine, disconnect the negative
battery lead from the battery terminal.)
• To reduce the chance of sparks, do not
plug in the battery charger until the bat-
tery charger leads are connected to the
battery.
• Before removing the battery charger lead
clips from the battery terminals, be sure to
turn off the battery charger.
• Make sure the battery charger lead clips
are in full contact with the battery terminal
and that they are not shorted. A corroded
battery charger lead clip may generate
heat in the contact area and a weak clip
spring may cause sparks.
• If the battery becomes hot to the touch at
any time during the charging process, dis-
connect the battery charger and let the
battery cool before reconnecting it. Hot
batteries can explode!
3-54
CHK
• As shown in the following illustration, the
open-circuit voltage of an VRLA (Valve
Regulated Lead Acid) battery stabilizes
about 30 minutes after charging has been
completed. Therefore, wait 30 minutes after
charging is completed before measuring
the open-circuit voltage.
3-55
CHK
Charging method using a variable-current (voltage) charger
Charger
Ammeter
TIP
Measure the open-circuit Leave the battery unused for
voltage prior to charging. more than 30 minutes before
measuring its open-circuit voltage.
Connect a charger and TIP

ammeter to the battery Set the charging voltage to 16 ~
and start charging. 17 V. (If the charging voltage is
lower, charging will be insufficient,
if it is higher, the battery will be
over-charged.)
Is the amperage higher
YES than the standard charg- NO
ing amperage written on
the battery?
Adjust the charging voltage

to 20 ~ 25 V.
Monitor the amperage for 3 ~ 5

Adjust the voltage to obtain YES minutes. Is the standard charg-
the standard charging amper-
ing amperage exceeded?
age.
NO
If the amperage does not

Set the timer to the charging exceed the standard charg-
time determined by the opening amperage after 5 min-
circuit voltage. utes, replace the battery.
Refer to “CHECKING AND
CHARGING THE BATTERY”.
If the required charging time exceeds 5 hours, it is advisable to

check the charging amperage after 5 hours. If there is any change in
the amperage, readjust the voltage to obtain the standard charging
amperage.
Leave the battery unused for more than 30 minutes before measur-
ing its open-circuit voltage.
12.8 V → Charging is complete.
12.0 ~ 12.7 V → Recharging is required.
Under 12.0 V → Replace the battery.
3-56
CHK
Charging method using a constant voltage charger
Measure the open-circuit TIP

voltage prior to charging. Leave the battery unused for more
than 30 minutes before measuring
its open-circuit voltage.
Connect a charger and

ammeter to the battery
and start charging.
Is the amperage higher

than the standard charg-
ing amperage written on
the battery?
Charge the battery until the charging This type of battery charger cannot
voltage reaches 15 V. charge an VRLA battery. A variable-
voltage charger is recommended.
TIP
Set the charging time to a maxi-
mum of 20 hours.
Charger
Leave the battery unused for more than 30

Ammeter
minutes before measuring its open-circuit
Voltmeter
voltage.
12.8 V → Charging is complete.
12.0 ~ 12.7 V → Recharging is required.
Under 12.0 V → Replace the battery.
NOTICE
Constant amperage chargers are not
suitable for charging VRLA batteries.
3-57
CHK
6. Install:
• battery
7. Connect:
• battery leads
(to the battery terminals)
2
NOTICE
First, connect the positive battery lead ,
and then the negative battery lead .
1
8. Check:
• battery terminals
Dirt → Clean with a wire brush.
Loose connection → Connect properly.
9. Lubricate:
• battery terminals
Dielectric grease
10.Install:
• battery holding plate
• seat
TANK”.
3-58
CHK
CHECKING THE FUSES ADJ
CHECKING THE FUSES
fuses.
NOTICE
To avoid a short circuit, always set the main
switch to “OFF” when checking or replac-
ing a fuse.
1. Remove:
• seat
TANK”.
2. Check:
• fuse
a. Connect the pocket tester to the fuse and

check the continuity.
TIP
Set the pocket tester selector to “Ω × 1”.
Pocket tester
90890-03112
YU-03112-C
b. If the pocket tester indicates “∞”, replace the

fuse.
3. Replace:
• blown fuse
a. Set the main switch to “OFF”.

b. Install a new fuse of the correct amperage.
c. Set on the switches to verify if the electrical
circuit is operational.
d. If the fuse immediately blows again, check
the electrical circuit.
3-59
CHECKING THE FUSES/ CHK
ADJUSTING THE HEADLIGHT BEAM ADJ
Amperage
Items Q’ty
rating
Main fuse 30.0 A 1
Fan fuse 10.0 A 1
Ignition fuse 10.0 A 1
Headlight fuse 10.0 A 1
Signaling system
10.0 A 1
fuse
WARNING
Never use a fuse with an amperage rating
other than that specified. Improvising or
using a fuse with the wrong amperage rat-
ing may cause extensive damage to the
electrical system, cause the lighting and
ignition systems to malfunction and could
possibly cause a fire.
4. Install:
• battery cover
• seat
TANK”.
ADJUSTING THE HEADLIGHT BEAM

1. Adjust:
• headlight beam (vertically)
a. Turn the adjusting bolt in direction or

1
.
b Headlight beam is
a Direction
raised.
Headlight beam is
Direction
lowered.
3-60
CHK
REPLACING A HEADLIGHT BULB ADJ
REPLACING A HEADLIGHT BULB
1. Remove:
• Front carrier
• Front fender panel
Refer to “FRONT CARRIER, FRONT
BUMPER AND FRONT FENDER”.
2. Disconnect:
• headlight lead coupler
3. Remove:
• cover 1
4. Remove:
1 • headlight bulb holder cover 1
5. Remove:
• connector 1
1
3-61
CHK
REPLACING A HEADLIGHT BULB ADJ
6. Remove:
1 • Headlight bulb holder 1
• bulb
TIP
Push the headlight bulb holder inward, pull it out-
ward and remove the defective bulb.
1
WARNING
Keep flammable products and your hands
away from the bulb while it is on. since it
will be hot. Do not touch the bulb until it
cools down.
7. Install:
• bulb
Secure the new bulb with the headlight unit.
NOTICE
Avoid touching the glass part of the bulb.
Keep it free from oil; otherwise, the trans-
parency of the glass, life of the bulb, and
luminous flux will be adversely affected. If
oil gets on the bulb, thoroughly clean it
with a cloth moistened with alcohol or lac-
quer thinner.
3-62
ENGINE REMOVAL ENG
ENGINE
ENGINE REMOVAL
AIR DUCTS, A.I.C.V., MUFFLER AND EXHAUST PIPE
25 Nm (2.5 m•kg, 18.1 ft•Ib)
1
New 6 Nm (0.6 m•kg, 4.3 ft•Ib)
.
7 8 Nm (0.8 m•kg, 5.8 ft•Ib)
.
4
2
2
1
3
6
4
3
6 Nm (0.6 m•kg, 4.3 ft•Ib)
5
.
5
25 Nm (2.5 m•kg, 18.1 ft•Ib)
6
.
25 Nm (2.5 m•kg, 18.1 ft•Ib)

.
Order Job/Parts to remove Q’ty Remarks

Removing the air ducts, A.I.C.V., Remove the parts in the order listed.
muffler and exhaust pipe
Seat, side covers and footrest boards
Front carrier, front bumper and front
7
fender
TANK” in chapter 3.
8
Rear fender and air fillter case
Fuel tank
1 Air duct assembly 1 1
2 Air duct assembly 2 1
3 A.I.C.V. assembly 1
4 Spark plug lead 1
5 Muffler 1
6 Exhaust pipe 1
7 Gasket 1
procedure.
4-1
ENGINE REMOVAL ENG
ENGINE
ENGINE REMOVAL
SELECT LEVER SHIFT ROD, CABLES, LEAD AND HOSES
8
3
2
1
4
5
6
2
7
3
4
1
6 Nm (0.6 m•kg, 4.3 ft•Ib)

5
.
6
25 Nm (2.5 m•kg, 18.1 ft•Ib)
.

Removing the elect lever shift rod, Remove the parts in the order listed.
cables, lead and hoses.
Seat, side covers and footrest boards
Front carrier, front bumper and front
7
fender
Rear fender and air fillter case
1
2
Fuel tank
Select lever shift rod
AC magneto coupler
1
1 Disconnect.
8
3 Throttle cable 1
4 Starter cable 1
5 Coolant reservoir hose 1 Disconnect.
6 Radiator inlet hose 1 Disconnect.
7 Radiator outlet hose 1 Disconnect.
8 A.I.C.V. valve assembly 1 Disconnect.
procedure.
4-2
ENGINE REMOVAL ENG
ENGINE
ENGINE MOUNTING BOLTS
60 Nm (6 m•kg, 43.4 ft•Ib)
.
60 Nm (6 m•kg, 43.4 ft•Ib)
60 Nm (6 m•kg, 43.4 ft•Ib)
.
.
2
3
4
1
5 5
4
6
3

Removing the engine mounting Remove the parts in the order listed.
1
2
bolts
Engine mounting bolt (front)
Engine bracket (L/R)
1
1/1
7
3 Engine mounting bolt (rear upper) 1
8
4 Engine mounting bolt (rear lower) 1
5 Engine assembly 1
procedure.
4-3
ENGINE REMOVAL ENG
INSTALLING THE ENGINE
1. Install:
• Engine mounting bolt (rear lower side) 1
• Engine mounting bolt (rear upper side) 2
• Engine brackets (front side) 3 4
• Engine mounting bolt (front side) 5
TIP
2 • The direction of the bolt insertion is made
5
from the right side of the body.
• Do not fully tighten the bolts and nuts.
4 3
2. Tighten:
• Engine mounting nut (rear lower side) 1
• Engine mounting nut (rear upper side) 2
• Engine mounting nut (front side) 5
1 • Engine bracket bolts (front side)
Engine mounting nut (rear lower

side)
60 Nm (6.0 m•kg, 43.4 ft•lb)
40 Nm (4.0 m
Engine mounting nut (rear upper

side)
60 Nm (6.0 m•kg, 43.4 ft•lb)
Engine mounting nut (front side)
60 Nm (6.0 m•kg, 43.4 ft•lb)
Engine bracket bolt (M10)
60 Nm (6.0 m•kg, 43.4 ft•lb)
4-4
CYLINDER HEAD ENG
EBS00218
CYLINDER HEAD
3
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T
.R
.
4
New 5
38 Nm (3.8 m • kg, 27.4 ft • Ib)
T
.R
.
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T
.R
.
2 New
7
6
11 Nm (1.1 m • kg, 8.0 ft • Ib)

T
.R
.
12 1
12 Nm (1.2 m • kg, 8.7 ft • Ib)
11 Nm (1.1 m • kg, 8.0 ft • Ib)
T
.R
.
T
.R
.
11 2 New
10 16 New
13 New
9
14
8 15 New
12 Nm (1.2 m • kg, 8.7 ft • Ib)

T
.R
.

Removing the cylinder head Remove the parts in the order listed.
Carburetor assembly Refer to “CARBURETOR” in chapter 5.
Exhaust pipe/muffler Refer to “ENGINE”.
1 Pipe 1
2 air pipe gasket 2
3 Reed valve assembly 1
4 Cylinder head cover 1
5 Head cover gasket 1
6 Spark plug 1
7 Therm unit 1
8 Breather assembly 1
9 Bolt stopper plate 1
10 Breather plate 1
11 Sprocket 1
12 Cylinder head 1
13 Cylinder head gasket 1
14 Timing chain tensioner 1
15 gasket 1
16 exhaust pipe gasket 1 For installation, reverse the removal
procedure.
4-5
CYLINDER HEAD ENG
REMOVING THE CYLINDER HEAD
1.Remove:
2 • pipe 1
(x4)
• reed pipe assy. 2
4 3 • cylinder head cover 3
• head cover gasket 4
11 1 • spark plug 5
6 (x4) • therm unit 6
• breather assy. 7
• bolt stopper plate 8
5
10 TIP
9
8 Working in a crisscross pattern, loosen e-
7
ach nut 1/4 of a turn.
• breather plate 9
12 • sprocket 10
13 • holding nut/ sealing washer 11
• cylinder head gasket 12
• timing chain tensioner 13
.
TIP
Fasten a safety wire to the timing chain to
prevent it from falling into crankcase.
CHECKING THE CAMSHAFT SPROCKET

AND THE TIMING CHAIN TENSIONER
1 3
1. Check:
• camshaft sprocket
2 More than 1/4 tooth wear 1 → Replace the
cam shaft comp. and timing chain as a set.
1 1/4 of a tooth
4
2 correct
3 roller
4 sprocket
2. Check:
• timing chain tensioner
Cracks/damage Replace.
4-6
CYLINDER HEAD ENG
CHECKING THE CYLINDER HEAD COVER
ASSY.
1. Check:
• cylinder head cover assy.
• o-rings
Cracks/damage → Replace.
EBS00230
CHECKING THE CYLINDER HEAD
1. Eliminate:
• combustion chamber carbon deposits
(with a rounded scraper)
TIP
Do not use a sharp instrument to avoid damag-
ing or scratching:
• spark plug bore threads
• valve seats
2. Check:
• cylinder head
Damage/scratches → Replace.
3. Measure:
• cylinder head warpage
Out of specification → Resurface the cylin-
der head.
Maximum cylinder head warpage

<Limit>: 0.05 mm (0.002 in)
a. Place a straightedge and a thickness gauge

across the cylinder head.
b. Measure the warpage.
c. If the limit is exceeded, resurface the cylin-
der head as follows.
d. Place a 400 ~ 600 grit wet sandpaper on
the surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
TIP
To ensure an even surface, rotate the cylinder
head several times.
4-7
CYLINDER HEAD ENG
INSTALLING THE CYLINDER HEAD
1.Install:
12 • timing chain tensioner 1
(x4)
• cylinder head gasket 2
10 11 • holding nut/ sealing washer 3
• sprocket 4
3 13 • breather plate 5
8 (x4) • bolt stopper plate 6
• breather assy. 7
• therm unit 8
9
• spark plug 9
4
6
5 • head cover gasket 10
7 • cylinder head cover 11
• reed pipe assy. 12
• pipe 13
1
2 TIP
Tighten the nuts in two stages and a crisscross
pattern.
.
2. Install:
• camshaft sprocket
1 a. Turn camshaft bolt 1 in clockwise direction.
TIP
Do not turn the bolt in Counterclockwise
looseness.
b. Align the “ I ” mark 1 on the camshaft sprocket

with the stationary pointer 2 on the cylinder
2
TIP
1
tips and their respective adjusting screws.
4-8
CYLINDER HEAD ENG
c. Measure the valve clearance with a thick-
ness gauge 1 .
Thickness gauge
1
90890-03079
Narrow gauge set
YM-34483
3. Adjust:
• valve clearance
3
1 b. Insert a thickness gauge 2 between the
adjuster end and the valve end.
c. Turn the adjuster 3 clockwise or counter-
clockwise with the tappet adjusting tool
2 until the proper clearance is obtained.
Tappet adjusting tool

90890-01311
Six piece tappet set
YM-A5970
4-9
ROCKER ARMS AND CAMSHAFT ENG
ROCKER ARMS AND CAMSHAFT
5
9 Nm (0.9 m • kg, 6.5 ft • Ib)
3
T
.R
.
2
1
2
12 Nm (1.2 m • kg, 8.7 ft • Ib)

T
.R
.

Removing the camshaft and rocker Remove the parts in the order listed.
arms
Cylinder head Refer to “CYLINDER HEAD”.
1 Plate 1
2 Rocker arm shaft 4 Refer to “REMOVING THE ROCKER
3 Locknut 4 ARMS AND CAMSHAFT” and
“INSTALLING THE CAMSHAFT AND
4 Valve adjusting screw 4
ROCKER ARMS”.
5 Rocker arm 2
6 Camshaft 1
For installation, reverse the removal pro-

cedure.
4-10
REMOVING THE ROCKER ARMS AND
CAMSHAFT
1. Loosen:
2 • bolt 1
1 2. Remove:
• plate 2
• intake rocker arm shaft
• exhaust rocker arm shaft
• intake rocker arm
• exhaust rocker arm
TIP
Remove the rocker are shafts with a hammer
bolt and weight.
Slide hammer bolt (M5)

P/N. 90890-04158
YM-04158
Weight
P/N. 90890-01084
YU-01083-3
3. Remove:
• Camshaft comp. 1
4-11
EAS00206
1 CHECKING THE ROCKER ARMS AND
ROCKER ARM SHAFTS
2 The following procedure applies to all of the
rocker arms and rocker arm shafts.
1. Check:
2
• rocker arm 1
• Valve clearance adjusting screws 2
Damage/wear Replace.
2. Check:
• rocker arm shaft
Blue discoloration/excessive wear/pitting/
scratches Replace or check the lubri-
cation system.
3. Measure:
• rocker arm inside diameter a
Out of specification Replace.
a
Rocker arm inside diameter
11.982~12.000 mm (0.4717~
0.4724 in)
<Limit>: 12.080mm (0.4756 in)
4. Measure:
• rocker arm shaft outside diameter a
Rocker arm shaft outside diameter

11.996~11.984 mm (0.4723~
a 0.4718 in)
<Limit>: 11.936 mm (0.4699 in)
5. Calculate:
• rocker-arm-to-rocker-arm-shaft clearance
NOTE:
Calculate the clearance by subtracting the rocker
arm shaft outside diameter from the rocker arm
inside diameter.
Above 0.034 mm(0.001 in) Replace the de-

fective part(s).
Rocker-arm-to-rocker-arm-shaft
clearance
0.016 mm (0.0006 in)
<Limit>: 0.144 mm (0.0057 in)
4-12
EAS00205
CHECKING THE CAMSHAFT

1. Check:
• camshaft bushings
Damage/wear Replace.
2. Check:
• camshaft lobes
Blue discoloration/pitting/scratches
Replace the camshaft.
3. Measure:
• camshaft lobe dimensions a and b
Out of specification Replace the cam-
shaft.
Camshaft lobe dimension limit

Intake
a 34.880 mm (1.3732 in)
a b <Limit>: 34.860 mm (1.3724 in)
b 34.740 mm (1.3677 in)
<Limit>: 34.725 mm (1.3671 in)
Exhaust
a 34.880 mm (1.3732 in)
<Limit>: 34.860 mm (1.3724 in)
b 34.740 mm (1.3677 in)
<Limit>: 34.725 mm (1.3671 in)
4. Check:
• camshaft oil passage
Obstruction Blow out with compressed
air.
4-13
INSTALLING THE CAMSHAFT AND
ROCKER ARMS
1. Lubricate:
• camshaft 1
1 Camshaft
Molybdenum disulfide oil
Camshaft bearing
Engine oil
2. Lubricate:
• rocker arm shafts
Molybdenum disulfide oil
3. Install:
• camshaft comp.
1 a. Turn camshaft bolt 1 in clockwise direction.
TIP
• Do not turn the bolt in Counterclockwise
looseness.
b. Align the “ I ” mark 1 on the camshaft sprocket

with the stationary pointer 2 on the cylinder
2
TIP
1 tips and their respective adjusting screws.
4. Apply:
• engine oil
(onto the rocker arm shafts)
5. Install:
1 • rocker arms 1
• rocker arm shafts
TIP
_
Use a slide hammer bolt 2 to install the rocker

arm shaft.
4-14
VALVES AND VALVE SPRINGS ENG
VALVES AND VALVE SPRINGS
8 4 1
7
2
4
7
8

Removing the valves and valve Remove the parts in the order listed.
springs
Rocker arm and rocker arm shaft Refer to “REMOVING THE ROCKER
ARMS AND CAMSHAFT”
1 Valve cotter 8
2 Valve spring retainer 4
3 Valve outer spring 4
4 Valve inner spring 4 Refer to “INSTALLING THE VALVES
5 Valve (intake) 2 AND VALVE SPRINGS “.
6 Valve (exhaust) 2
7 Valve stem seal 4
8 Valve spring seat 4
cedure.
4-15
EBS00238
REMOVING THE VALVES AND VALVE
SPRINGS
1. Check:
• valve sealing
1
Leakage at the valve seat → Check the
valve face, valve seat and valve seat width.
Refer to “CHECKING THE VALVES AND
VALVE SPRINGS”.
2
a. Pour a clean solvent 1 into the intake and
exhaust ports.
b. Check that the valve seals properly.
There should be no leakage at the valve
seat 2 .
2. Remove:
• valve cotters
TIP
2 Attach a valve spring compressor and
attachment between the valve spring
retainer and the cylinder head to remove the
1 valve cotters.

P/N. YM-04019, 90890-04019
Valve spring compressor attach-
ment
P/N. YM-01253-1, 90890-01243
4-16
EBS00240
CHECKING THE VALVES AND VALVE
SPRINGS
1. Measure:
• stem-to-guide clearance
Stem-to-guide clearance =
valve guide inside diameter a –
valve stem diameter b
Out of specification → Replace the cylinder

head ass'y.
Stem-to-guide clearance
Intake
0.010 ~ 0.037 mm
(0.0004 ~ 0.0015 in)
<Limit>: 0.08 mm (0.0031 in)
Exhaust
0.025 ~ 0.052 mm
(0.0010 ~ 0.0020 in)
<Limit>: 0.10 mm (0.0039 in)
2. Check:
• valve face
Pitting/wear → Grind the face.
• valve stem end
Mushroom shape or diameter larger than
the body of the stem → Replace.
3. Measure:
• margin thickness a
Out of specification → Replace.
Margin thickness
Intake
0.50 ~ 0.90 mm
(0.0197 ~ 0.0354 in)
Exhaust
0.80 ~ 1.20 mm
(0.0315 ~ 0.0472 in)
4-17
4. Measure:
• runout (valve stem)
Runout limit
0.01 mm (0.0004 in)
TIP
• When installing a new valve always replace
the guide.
• If the valve is removed or replaced always
replace the oil seal.
5. Eliminate:
• carbon deposits
(from the valve face and valve seat)
6. Check:
• valve seats
Pitting/wear → Reface the valve seat.
7. Measure:
• valve seat width a
Out of specification → Reface the valve
seat.
Valve seat width

Intake
<Limit>: 1.6 mm (0.063 in)
Exhaust
<Limit>: 1.6 mm (0.063 in)
a. Apply Mechanic’s blueing dye (Dykem) b to

the valve face.
b. Install the valve into the cylinder head.
c. Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
d. Measure the valve seat width. Where the
valve seat and valve face made contact,
blueing will have been removed.
e. If the valve seat is too wide, too narrow, or
the seat is not centered, the valve seat must
be refaced.
4-18
8. Lap:
• valve face
• valve seat
TIP
_
After refacing the valve seat or replacing the

valve and valve guide, the valve seat and
valve face should be lapped.
a. Apply a coarse lapping compound to the

valve face.
NOTICE
Do not let the compound enter the gap
between the valve stem and the guide.
b. Apply molybdenum disulfide oil to the valve

stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all
of the compound.
TIP
_
For best lapping results, lightly tap the valve

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

face and repeat the above steps.
TIP
_
After every lapping operation be sure to clean

off all of the compound from the valve face and
valve seat.
f. Apply Mechanic’s blueing dye (Dykem) to

the valve face.
g. Install the valve into the cylinder head.
h. Press the valve through the valve guide and
onto the valve seat to make a clear pattern.
i. Measure the valve seat width again. If the
valve seat width is out of specification,
reface and relap the valve seat.
4-19
9.Measure:
• valve spring free length
Valve spring free length
Inner spring
38.700 mm (1.5236 in)
<limit>: 35.200 mm (1.3858 in)
Outer spring
40.400 mm (1.5906 in)
<limit>: 36.900 mm (1.4528 in)
10.Measure:
• compressed spring force
Installed length
Inner spring
41.49 ~57.19 N
(4.23 ~ 5.83 kg, 9.32 ~ 12.85 lb)
Outer spring
73.97 ~ 103.40 N
(7.54 ~ 10.54 kg, 16.63 ~
23.243 lb)
11.Measure:
• spring tilt
Spring tilt limit

Inner
2.5°/1.60 mm(2.5°/0.063 in)
EBS00241
INSTALLING THE VALVES AND VALVE
SPRINGS
1. Apply:
• molybdenum disulfide oil
(onto the valve stem and valve stem seal)
2. Install:
• valve spring seats
• valve stem seals New
• valves
• valve springs
• valve spring retainers
TIP
Install the valve springs with the larger pitch
facing upwards.
Smaller pitch
4-20
3. Install:
• valve cotters
TIP
Install the valve cotters while compressing the
valve spring with the valve spring compressor
2 and attachment .
1
P/N. YM-04019, 90890-04019
Valve spring compressor attach-
ment
P/N. YM-01253-1, 90890-01243
4. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a piece of
wood.
NOTICE
Hitting the valve tip with excessive force
could damage the valve.
4-21
CYLINDER AND PISTON ENG
EBS00245
CYLINDER AND PISTON
4
New 6
3
5
E
4
New
7
3
2 New

Removing the cylinder and piston Remove the parts in the order listed.
1 Cylinder 1 Refer to “INSTALLING THE CYLINDER”.
2 Cylinder gasket 1
3 Dowel pin 2
4 Piston pin clip 2
5 Piston pin 1 Refer to “REMOVING THE PISTON”
6 Piston 1 and “INSTALLING THE PISTON”.
7 Piston ring set 1
cedure.
4-22
EBS00247
REMOVING THE PISTON
1. Remove:
3
• piston pin clips 1
2 • piston pin 2
• piston 3
TIP
• Before removing the piston pin clip, cover the
1 crankcase opening with a clean rag to prevent
the piston pin clip from falling into the crankcase.
• Before removing each piston pin, deburr the
clip groove and pin hole area. If the piston pin
groove is deburred and the piston pin is still
3 difficult to remove, use the piston pin puller 4 .
2
Piston pin puller set

P/N. YU-01304, 90890-01304
NOTICE
4 Do not use a hammer to drive the piston
pin out.
2. Remove:
• piston rings
TIP
Spread the end gaps apart while at the same
time lifting the piston ring over the top of the
piston crown.
EBS00249
CHECKING THE CYLINDER AND PISTON
1. Check:
• piston wall
• cylinder wall
Vertical scratches → Rebore or replace the
cylinder, and replace the piston and piston
rings as a set.
2. Measure:
• piston-to-cylinder clearance
a. Measure cylinder bore “C” with the cylinder

bore gauge.
TIP
_
Measure cylinder bore “C” by taking side-to-

side and front-to-back measurements of the
cylinder. Then, find the average of the mea-
surements.
4-23
74.995~75.015 mm
Cylinder bore “C”
(2.9526~2.9533 in)
Taper limit “T” 0.05 mm (0.002 in)
Out-of-round “R” 0.01 mm (0.0004 in)
“C” = maximum of D1 ~ D2
“T” = maximum of D1 or D2 –
maximum of D5 or D6
“R” = maximum of D1, D3 or D5 –
minimum of D2, D4 or D6
b. If out of specification, rebore or replace the

rings as a set.
c. Measure piston skirt diameter “P” with the
micrometer.
a 5 mm (0.20 in) from the bottom edge of the pis-
ton
Piston size “P”
74.430~75.480 mm
Standard
(2.9303~2.9717 in)
d. If out of specification, replace the piston and

piston rings as a set.
e. Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance =
Cylinder bore “C” –
Piston skirt diameter “P”
Piston-to-cylinder clearance
0.010 ~ 0.040 mm
(0.0004 ~ 0.0016 in)
<Limit>: 0.10 mm (0.0039 in)
f. If out of specification, rebore or replace the

rings as a set.
4-24
EBS00250
CHECKING THE PISTON RINGS
1. Measure:
• piston ring side clearance
Out of specification → Replace the piston
and piston rings as a set.
TIP
Before measuring the piston ring side clear-
ance, eliminate any carbon deposits from the
piston ring grooves and piston rings.
Piston ring side clearance

Top ring
0.015 ~ 0.055 mm
(0.0006 ~ 0.0022 in)
<Limit>: 0.09 mm (0.0035 in)
2nd ring
0.015 ~ 0.055 mm
(0.0006 ~ 0.0022 in)
<Limit>: 0.09 mm (0.0035 in)
2. Install:
• piston ring
(into the cylinder)
TIP
Level the piston ring into the cylinder with the
piston crown.
3. Measure:
• piston ring end gap
ring.
TIP
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings.
Piston ring end gap

Top ring
0.150~0.300 mm
(0.0059~0.0118 in)
<Limit>: 0.500 mm (0.0197 in)
2nd ring
0.300~0.450 mm
(0.0118~0.0177 in)
<Limit>: 0.650 mm (0.0256 in)
Oil ring
0.200 ~ 0.700 mm
(0.0079 ~ 0.0276 in)
4-25
EBS00251
CHECKING THE PISTON PIN
1. Check:
• piston pin
Blue discoloration/grooves → Replace the
piston pin and then check the lubrication
system.
2. Measure:
• piston pin outside diameter a
pin.
Piston pin outside diameter

16.994~17.000 mm
(0.6691~0.6693 in)
<Limit>: 16.960 mm (0.6677 in)
3. Measure:
• piston pin bore diameter b
Out of specification → Replace the piston.
Piston pin bore diameter

17.002~17.008 mm
(0.6694~0.6696 in)
<Limit>: 17.020 mm (0.671 in)
4. Calculate:
• piston-pin-to-piston-pin-bore clearance
pin and piston as a set.
Piston-pin-to-piston-pin-bore clearance =
Piston pin bore diameter b
Piston pin outside diameter a
Piston-pin-to-piston clearance
0.002 ~ 0.014 mm
(0.0001 ~ 0.0006 in)
4-26
EBS00252
INSTALLING THE PISTON
1. Install:
• piston rings
(onto the piston)
TIP
• Be sure to install the piston rings so that the
manufacturer’s marks or numbers are
located on the upper side of the rings.
• Lubricate the piston and piston rings liberally
with engine oil.
e 120˚ a 2. Position:
• top ring
• 2nd ring
120˚ 120˚ • oil ring
Offset the piston ring end gaps as shown.
f f a top ring end
d b b upper oil ring rail end
c c expander end
d lower oil ring rail end
e 2nd ring end
f 20 mm (0.79 in)
3. Install:
a • piston 1
IN
• piston pin 2
1 • piston pin clips 3 New
TIP
2 3 New • Apply engine oil onto the piston pin, piston
rings and piston.
• Be sure that the “ IN ” mark a on the piston
points to the intake side of the engine.
• Before installing the piston pin clips, cover
the crankcase with a clean rag to prevent the
piston pin clips from falling into the crank-
case.
4. Lubricate:
• piston
• piston rings
• cylinder
TIP
Apply a liberal coating of engine oil.
4-27
EBS00253
INSTALLING THE CYLINDER
1. Install:
• cylinder
TIP
Install the cylinder with one hand while com-
pressing the piston rings with the other hand.
NOTICE
• Be careful not to damage the timing chain
damper during installation.
• Pass the timing chain through the timing
chain cavity.
4-28
C.D.I. MAGNETO ENG
C.D.I. MAGNETO
12 Nm (1.2 m • kg, 8.7 ft • Ib)

T
.R
.
3
4 New
2
55 Nm (5.5 m • kg, 40 ft • Ib)
T
.R
.

Removing the C.D.I. magneto Disassemble the parts in the order listed.
1 Stator coil assembly 1 Refer to “INSTALLING STATOR COIL

ASSEMBLY “.
2 C.D.I. magneto rotor 1 NOTICE
3 Starter clutch assembly 1 Disconnect the C.D.I. magneto lead
4 Gasket 1 coupler.

cedure.
4-29
C.D.I. MAGNETO ENG
EBS00259
REMOVING THE C.D.I. MAGNETO ROTOR

1. Remove:
2 nut 1
plate washer
bolt 2
2. Remove:
C.D.I. magneto rotor 1
(with flywheel puller 2 )
Flywheel puller
90890-01404 (YM-01404)
2
1
EBS00262
CHECKING THE PICKUP COIL/STATOR
ASSEMBLY
1. Check:
• pickup coil/stator assembly
Damage → Replace.
4-30
C.D.I. MAGNETO ENG
INSTALLING THE PICKUP COIL AND STATOR

ASSEMBLY
1. Install:
Stator assembly 1
2. Install:
2 Pickup coil
TIP
Tighten the bolts 2 to secure the stator
1 assembly cable 1 .
EBS00268
3
INSTALLING THE C.D.I. MAGNETO ROTOR
1. Install:
C.D.I. magneto rotor 1
2
TIP
Clean the tapered portion of the crankshaft
and the magneto rotor hub.
1
When installing the magneto rotor, make
sure the woodruff key is properly seated in
the keyway of the crankshaft.
2. Tighten:
nut 2
55 Nm (5.5 m • kg, 40.0 ft • lb)
T.
R.
bolt 3
4-31
BELT DRIVE ENG
EAS00316
BELT DRIVE
CRANKCASE COVER
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T
.R
.
5
6
(x4)
2 New
12 Nm (1.2 m • kg, 8.7 ft • Ib)

T
.R
.
4
(x9)
1 12 Nm (1.2 m • kg, 8.7 ft • Ib)

T
.R
.

Removing the belt drive Remove the parts in the order listed.
1 Crankcase cover 1
2 Crankcase cover gasket 1
3 Bearing cover plate 1
4 Bearing 1
5 Dust seal plate 1
6 Gasket 1

cedure.
4-32
BELT DRIVE ENG
V-BELT, CLUTCH, PRIMARY AND SECONDARY SHEAVE
6 10
9
8
7
2 5
1 4
3
55Nm (5.5m．kg,
• 39.8ft．lb)
•
T
.R
.

Removing the V-belt, clutch, primary Remove the parts in the order listed.
and secondary sheave
1 Primary sheave nut / Plate washer 1/1
2 Primary fixed sheave 1 Refer to “ REMOVING THE PRIMARY
SHEAVE “.
3 Secondary sheave nut/ Washer 1/1
4 Clutch housing 1
5 Secondary sheave assembly 1
6 V-belt 1 Refer to “ REMOVING THE SECONDARY
SHEAVE AND V-BELT “.
7 Collar 1
8 Primary sliding sheave 1
9 Cam / Weight 1/6
10 Slider 3

cedure.
4-33
BELT DRIVE ENG
DISASSEMBLING THE SECONDARY SHEAVE
6
10
7 8
9 10 5 4
11
6 7 LS
LS
95Nm (9.5m．kg,
• 68.7ft．lb)
•
T
.R
.
2
3

Disassembling the secondary Disassemble the parts in the order listed.
sheave
1 Nut 1
2 Clutch carrier assembly 1
3 Spring seat -1 1 Refer to “ REMOVING THE SECONDARY
SHEAVE AND V-BELT “.
4 Compression spring 1
5 Spring seat - 2 1
6 Guide pin 4
4-34
BELT DRIVE ENG
DISASSEMBLING THE SECONDARY SHEAVE
6
10
7 8
9 10 5 4
11
6 7 LS
LS
95Nm (9.5m．kg,
• 68.7ft．lb)
•
T
.R
.
2
3

7 Guide roller 4
8 Secondary sliding sheave 1
9 O-ring 2
10 Oil seal 2
11 Secondary fixed sheave 1
For assembly, reverse the disassembly

procedure.
4-35
BELT DRIVE ENG
EAS00317
REMOVING THE PRIMARY SHEAVE

1. Remove:
• primary sheave nut 1
• plate washer 22
• primary fixed sheave 3
• collar 4
• primary sliding sheave 5
1 a
5 TIP
While holding the clutch housing with the
rotor holding tool a , loosen the secondary
4 sheave nut.
4
2 3 Rotor holding tool:
1 90890-01235 (YU-01235)
EAS00318
REMOVING THE SECONDARY SHEAVE AND

V-BELT
1. Remove:
1
• secondary sheave nut 1
• clutch housing 22
3 TIP
While holding the clutch housing with the
rotor holding tool 3 , loosen the secondary
sheave nut.
Rotor holding tool:

2 90890-01235 (YU-01235)
2. Loosen:
• clutch carrier nut
NOTICE
Do not remove the clutch carrier nut at this
stage.
1 TIP
2
While holding the clutch carrier with the rotor
holding tool 11 , loosen the clutch carrier nut one
full turn with the socket wrench (39 mm) 2 .
Rotor holding tool:

90890-01235 (YU-01235)
Socket wrench(39 mm):
90890-01493 (YM-01493)
4-36
BELT DRIVE ENG
3. Remove:
• secondary sheave assembly 1
• V-belt 2
TIP
Remove the V-belt and clutch assembly from the
primary sheave side.
2
1
EAS00319
2 3 DISASSEMBLINGTHE SECONDARY SHEAVE
1. Remove:
• clutch carrier nut 1
1
TIP
Install the clutch spring holder 22 and clutch
spring holder arm 3 onto the secondary sheave
as shown. Then, compress the spring, and re-
move the clutch carrier nut 1 .
Clutch spring holder

90890-01337(YM-33285)
90890-01464(YM-33285-6)
a CHECKING THE CLUTCH SHOE

1. Measure:
• Clutch shoe
Scratches Glaze using coarse sand-
a
paper.
Damage/wear Replace the clutch
carrier assembly
a Clutch shoe thickness

<Limit>: 3.000mm (0.0181 in)
TIP
• Inspect clutch shoes a .
• After removing the clutch weight spring, do
not use them again.
• Replace the all three as a set.
4-37
BELT DRIVE ENG
EAS00320
CHECKING THE V-BELT

1. Check:
• V-belt 1
Cracks/damage/wear Replace.
Grease/oil Clean the primary and sec-
ondary sheave.
2. Measure:
• V-belt width a
1 Out of specification Replace.
V-belt width
a <Limit>: 22.500 mm (0.8858 in)
CHECKING THE PRIMARY SHEAVE

1. Check:
• Primary sliding sheave 1
• Primary fixed sheave 2
Cracks/damage/wear Replace the pri-
mary sliding sheave, primary fixed sheave
and V-belt.
2
1
EAS00321
CHECKINGTHE PRIMARY SHEAVE WEIGHTS
The following procedure applies to all of the pri-

mary sheave weights.
1. Check:
• primary sheave weight
2. Measure:
• primary sheave weight outside diameter
a
Primary sheave weight outside di-

ameter
19.500~20.000 mm (0.7677~
a 0.7874 in)
<Limit>: 19.000 mm (0.7480 in)
4-38
BELT DRIVE ENG
CHECKING THE SLIDER
1. Check:
slider 1
11
Damage/wear Replace
EAS00322
CHECKING THE SECONDARY SHEAVE

1. Check:
• secondary fixed sheave 1
• secondary sliding sheave 22
Cracks/damage/wear Replace the sec-
ondary fixed and sliding sheaves as a set.
2 1
2. Check:
2 • torque cam groove 1
1
Damage/wear Replace the secondary
fixed and sliding sheaves as a set.
3. Check:
• guide pin 2
Damage/wear Replace the secondary
1
fixed and sliding sheaves as a set.
4. Measure:
• Compression spring free length
Compression spring free length

102.400 mm (4.0315 in)
<Limit>: 97.400 mm (3.8346 in)
4-39
BELT DRIVE ENG
5. Measure:
• Clutch housing internal diameter a
Clutch housing internal diameter

a 144.850~145.150 mm (5.7028~
5.7146 in)
<Limit>: 145.450 mm (5.7264 in)
EAS00323
5
ASSEMBLING THE PRIMARY SHEAVE
1. Clean:
• primary fixed sheave 2
• collar 3
4 • primary sheave weights 4
3
2 1
TIP
Use thinner to clean up grease, dirt on the pri-
mary sliding sheave cam side 55 .
2. Install:
• primary sheave weights 1
2 • collar 2
3. Install:
• slider 1
1 • cam 3
4-40
BELT DRIVE ENG
EAS00324
2 ASSEMBLING THE SECONDARY SHEAVE

1. Lubricate:
• secondary fixed sheave’s inner surface 11
• secondary sliding sheave’s inner surface
2
• torque cam groove
• oil seals
1
• bearings
(with the recommended lubricant)
BEL-RAY assembly lube
2. Install:
• secondary sliding sheave 1
3
TIP
1 Install the secondary sliding sheave onto the
secondary fixed sheave 2 with the oil seal guide
3 .
Oil seal guide

90890-01384 (YM-33299)
3. Install:
New 3
• guide pin and guide roller 11
4. Lubricate:
• guide pin groove 2
1 • o-ring New 3
(with the recommended lubricant)
2 BEL-RAY assembly lube
4-41
BELT DRIVE ENG
5. Install:
4 • secondary sheave 1
• spring
2
• clutch carrier 2
3 5 TIP
Attach the clutch spring holder 3 and clutch
spring holder arm 4 onto the secondary sheave
1
as shown. Then, compress the spring, and
tighten the clutch carrier nut 5 .
Clutch spring holder

90890-01337(YM-33285)
90890-01464(YM-33285-6)
EAS00325
INSTALLING THE BELT DRIVE

1. Install:
• V-belt 1
• clutch assembly 2
NOTICE
Do not allow grease to contact the V-belt,
1 secondary sheave assembly.
2
TIP
Install the V-belt onto the primary sheave side.
4-42
BELT DRIVE ENG
2. Install:
• clutch carrier nut 1
90 Nm (9.0 m • kg, 65.1 ft • lb)
T
.R
.
TIP
While holding the clutch carrier with the rotor
2 holding tool 2 , tighten the clutch carrier nut with
3
1 the locknut wrench 3 .
Rotor holding tool

90890-01235
Locknut wrench
90890-01348 (YM-01348)
1 3. Install:
• clutch housing 1
3
• secondary sheave nut 2
55 Nm (5.5 m • kg, 39.8 ft • lb)
T
.R
.
TIP
Tighten the secondary sheave nut with the
2
rotor holding tool 3 .
Rotor holding tool

90890-01235
4. Position:
3
• V-belt 1
TIP
Position the V-belt in the primary sheave 2
(when the pulley is at its widest position) and in
the secondary sheave 3 (when the pulley is at
2 its narrowest position), and make sure the V-
belt is tight.
1
4-43
STARTER CLUTCH ENG
STARTER CLUTCH
2 B
12 Nm (1.2 m • kg, 8.7 ft • Ib)

T
.R
.
3 4
8
7
LS
6
5
55 Nm (5.5 m • kg, 39.8 ft • Ib)

T.
R.

Removing the starter clutch Disassemble the parts in the order listed.
1 Shaft 1
2 Idle gear 1
3 Nut 1
4 Washer 1
5 Bolt 3
6 Rotor assembly 1
7 Starter clutch assembly 1
8 Starter wheel gear 1

cedure.
4-44
STARTER CLUTCH ENG
REMOVING THE STARTER CLUTCH
1. Remove:
1
3 • starter clutch bolts 1
TIP
• Hold the AC magneto rotor 2 with the sheave
holder 3 while removing the starter clutch
bolts.
• Do not allow the shave holder to touch the pro-
2 jection on the AC magneto rotor.
Sheave holder
90890-01701
YS-01880-A
CHECKING THE STARTER WHEEL GEAR

1. Check:
• starter wheel gear 1
• idle gear 2
Burrs/chips/roughness/wear Replace
1 2
2. Check:
• starter clutch operation
A
a. Install the starter wheel gear 11 onto the

idle gear 2 and hold the starter clutch.
b. When turning the starter wheel gear clock-
B wise A , the starter clutch and the starter
wheel gear should engage, otherwise the
starter clutch is faulty and must be replaced.
c. When turning the starter wheel gear coun-
terclockwise B , it should turn freely. other-
wise the starter clutch is faulty and must be
replaced.
4-45
STARTER CLUTCH ENG
INSTALLING THE STARTER CLUTCH
1. Install:
1 • starter clutch bolts 1
3
Starter clutch bolt
30 Nm (3.0 m • kg, 22 ft • lb)
T.
R.
LOCTITE R
TIP
2 • While holding the AC magneto rotor 2 with the
sheave holder 3 , tighten the starter clutch
bolts.
• Do not allow the shave holder to touch the pro-
jection on the AC magneto rotor.
Sheave holder
90890-01701
YS-01880-A
4-46
OIL PUMP ENG
EBS00315
OIL PUMP
E
4
5
7
1.5 Nm (0.15 m • kg, 1.1 ft • Ib) 10 8
T
.R
.
1 2

Disassembling the oil pump Remove the parts in the order listed.
C.D.I. magneto Refer to “ C.D.I. MAGNETO “
1 Circlip 1
2 Oil pump driven sprocket 1
3 Screw 1
4 Oil pump housing 1
5 Dowel pin 1
6 Roller 1
7 Inner rotor 1
8 Outer motor 1
9 Oil pump body 1
10 Dowel pin 2

procedure.
4-47
OIL PUMP ENG
EAS00364
CHECKING THE OIL PUMP

1
1. Check:
• oil pump driven gear 1
Cracks/damage/wear Replace the de-
fective part(s).
2. Measure:
• inner-rotor-to-outer-rotor-tip clearance a
outer-rotor-to-oil-pump-housing clear-
ance b
a
2 • oil-pump-housing-to-inner-rotor-and-
outer-rotor clearance c
• Out of specification Replace the oil
pump.
1 Inner rotor
2 Outer rotor
3 Oil pump housing
3
b 1
Inner-rotor-to-outer-rotor-tip clear-
c
ance
<Limit>: 0.200mm (0.0079 in)
Outer-rotor-to-oil-pump-housing
clearance
<Limit>: 0.250 mm (0.0098 in)
Oil-pump-housing-to-inner-rotor-
and-outer-rotor clearance
<Limit>: 0.120 mm (0.0047 in)
4-48
OIL PUMP ENG
3. Check:
• oil pump operation
Rough movement Repeat steps (1) and
(2) or replace the defective part(s).
EAS00376
INSTALLING THE OIL PUMP

1 1. Install:
• oil pump assembly 1
• oil pump screws 2
2
1.5 Nm (0.15 m • kg, 1.1 ft • lb)
T
.R
.
NOTICE
After tightening the bolts, make sure the oil
pump turns smoothly.
4-49
CRANKCASE AND CRANKSHAFT ENG
EBS00319
CRANKCASE AND CRANKSHAFT

10Nm (1.0m．kg,
• 7.2ft．lb)
•
T.
10Nm (1.0m．kg,
• 7.2ft．lb)
• 7
T.
12Nm (1.2m．kg,
• 8.7ft．lb)
•
12
T.
12Nm (1.2m．kg,
• 8.7ft．lb)
•
10 5
T.
(x9)
10Nm (1.0m．kg,
• 7.2ft．lb)
•
4
T.
1
3
11
6
E

Removing the crankshaft assembly Remove the parts in the order listed.
Engine Refer to “ ENGINE “.
Cylinder head Refer to “CYLINDER HEAD “.
Cylinder piston Refer to “CYLINDER AND PISTON “.
V-belt, clutch, primary / Secondary Refer to “V-BELT, CLUTCH, PRIMARY
sheave AND SECONDARY SHEAVE “.
Starter clutch Refer to “STARTER CLUTCH AND
STARTER MOTOR“.
C.D.I. magneto Refer to “C.D.I. MAGNETO “.
Oil pump Refer to “OIL PUMP “.
1 Bearing cover plate 2
2 Change switch assembly 2
3 Change switch collar 2
4 Bolt-1 10
5 Bolt-2 2
6 Left crankcase 1
7 Timing chain guide 1
8 Timing chain 1
9 Crankshaft assembly 1
10 Balance shaft 1 Refer to “INSTALLING THE CRANK-
SHAFT “.
11 Crankcase cover 1
12 Right crankcase 1
cedure.
4-50
EAS00389
REMOVING THE CRANKSHAFT ASSEMBLY

1. Remove:
• timing chain 1
TIP
• Before removing the crankshaft assembly,
remove the timing chain from the crankshaft
1 sprocket.
• The crankshaft assembly cannot be re-
moved if the timing chain is attached onto
the crankshaft sprocket.
2. Remove:
• crankshaft 1
2
TIP
• Remove the crankshaft with the crankcase
1
separating tool 2 .
• Make sure the crankcase separating tool
is centered over the crankshaft.
NOTICE
• To protect the end of the crankshaft, place
an appropriate sized socket between the
crankcase separating tool bolt and the
crankshaft.
• Do not tap on the crankcase.
Crankcase separating tool

90890-04152
Crankcase separator
YU-A9642
4-51
EAS00207
CHECKING THE TIMING CHAIN AND TIMING

CHAIN GUIDES
1. Check:
• timing chain
Damage/stiffness Replace the timing
chain.
2. Check:
• timing chain guide
Damage/wear Replace the timing chain
guide.
EAS00394
CHECKING THE CRANKSHAFT AND CON-

NECTING ROD
1. Measure:
• crankshaft runout
Out of specification Replace the crank-
shaft, bearing or both.
TIP
Turn the crankshaft slowly.
Maximum crankshaft runout

0.100 mm (0.0039 in)
2. Measure:
• big end side clearance
Out of specification Replace the big end
bearing, crankshaft pin, or connecting rod.
Big end side clearance

0.600 mm (0.0236 in)
4-52
3. Measure:
• crankshaft width
Out of specification Replace the crank-
shaft.
Crankshaft width
56.00 ~ 56.05 mm (2.205 ~
2.207 in)
4. Check:
2 • crankshaft sprocket 1
2 Damage/wear Replace the crankshaft.
3 1 • bearing 2
Cracks/damage/wear Replace the
crankshaft.
• oil pump drive gear 3
Damage/wear Replace the crankshaft.
5. Check:
• crankshaft journal
Scratches/wear Replace the crank-
shaft.
EAS00408
INSTALLING THE CRANKSHAFT

1. Install:
• balance shaft 1
TIP
Replace the balance shaft if there are cracks,
wear or damages.
1
4-53
2. Install:
1 • crankshaft 1
4 2 TIP
Install the crankshaft assembly with the crank-
3 shaft installer pot 2 , crankshaft installer bolt
3 , adapter (M14) 4 , spacer (crankshaft in-
staller) 5 and spacer 6 .
5
6
Crankshaft installer pot

90890-01274
Installing pot
YU-90058
Crankshaft installer bolt
90890-01275
Bolt
YU-90060
Adapter (M14)
90890-04163
Adapter
YM-04163
Spacer (crankshaft installer)
90890-04164
YM-04164
Pot spacer
YM-91044
Spacer
90890-01288
Pot spacer
YU-90059
NOTICE
Apply engine oil to each bearing to protect
the crankshaft against scratches and to make
installation easier.
TIP
Hold the connecting rod at top dead center
(TDC) with one hand while turning the nut of the
crankshaft installer bolt with the other. Turn the
crankshaft installer bolt until the crankshaft
assembly bottoms against the bearing.
4-54
EAS00418
ASSEMBLING THE CRANKCASE

1 1. Thoroughly clean all the gasket mating sur-
faces and crankcase mating surfaces.
2. Install:
• crankcase gasket
(onto the crankcase mating surfaces)
3. Install:
• crankshaft 1
1 • timing chain 2
4. Tighten:
• crankcase
10 Nm (1.0 m • kg, 7.2ft • lb)
T
. R
.
2 NOTICE
To avoid scratching the crankshaft and to
ease the installation procedure, lubricate the
oil seal lips with lithium-soap-based grease
and each bearing with engine oil.
TIP
Put the timing chain in parallel into the
crankcase. Manually rotate the crankshaft to
check whether it is tightly engaged with the
timing chain (if not, install again.)
4-55
TRANSMISSION ENG
EAS00419
TRANSMISSION
12 Nm (1.2 m • kg, 8.7 ft • Ib)

T
.R
.
(x4)
13 New
28 Nm (2.8 m • kg, 20.3 ft • Ib) 2
T
.R
.
1
11
12
14
15 (x4)
(x2)
10
9
16 8
18 7
New 17 6
5
40 Nm (4.0 m • kg, 28.9 ft • Ib)
28 Nm (2.8 m • kg, 20.3 ft • Ib)
T
.R
4
.
T
.R
.
(x4)
3
9 Nm (0.9 m • kg, 6.5 ft • Ib)
T
.R
.

Removing the transfer case Remove the parts in the order listed.
assembly
Transmission oil Drain.
Crankcase cover
Refer to “BELT DRIVE “.
Belt drive
Secondary sheave Refer to “V-BELT, CLUTCH, PRIMARY
AND SECONDARY SHEAVE “.
1 Transfer case-1 1
2 O-ring 1
3 Transfer case-2 1
4 Gasket 1
5 Bolt 1
6 Bearing-2 1
7 Thrust shim 3
8 Washer 1
9 Spring 1
10 Driven cam 1
11 Bearing housing 1
4-56
TRANSMISSION ENG
EAS00419
TRANSMISSION
12 Nm (1.2 m • kg, 8.7 ft • Ib)

T
.R
.
(x4)
13 New
28 Nm (2.8 m • kg, 20.3 ft • Ib) 2
T
.R
.
1
11
12
14
15 (x4)
(x2)
10
9
16 8
18 7
New 17 6
5
40 Nm (4.0 m • kg, 28.9 ft • Ib)
28 Nm (2.8 m • kg, 20.3 ft • Ib)
T
.R
4
.
T
.R
.
(x4)
3
9 Nm (0.9 m • kg, 6.5 ft • Ib)
T
.R
.

12 Housing cap gasket 1
13 Oil seal 1
14 Shaft 1
15 Driven pinion 1
16 Shim 4
17 Circlip 1
18 Bearing-1 1

cedure.
4-57
TRANSMISSION ENG
REMOVING THE TRANSFER CASE ASSY
4 1. Remove:
• bolt-1 1
3
• bolt-2 2
1 • transfer case-1 3
2
• o-ring 4
(x4)
(x2)
2. Remove:
6 • bolt 1
• transfer case-2 2
2 • gasket 3
• cap bolt 4
8
9 7 • bearing-2 5
1
• thrust shim 6
5 • washer 7
4
(x4) • spring 8
3
• driven cam 9
3. Remove:
(x4)
• bolt 1
• bearing housing 2
1 • gasket 3
• oil seal 4
2 • shaft 5
3 4
8 • driven pinion 6
5 • shim 7
9
6 7 • circlip 8
• bearing-1 9
CHECKING THE SHAFT-1 AND DRIVEN

PINION
1. Measure:
• shaft runout
(with a centering device and dial gauge )
Out of specification Replace the drive
axle.
Shaft runout limit

0.08 mm (0.0031 in)
4-58
TRANSMISSION ENG
2. Check:
• driven pinion
Blue discoloration/pitting/wear Replace
the defective gear(s).
3. Check:
• driven pinion engagement
(each pinion gear to its respective wheel
gear)
Incorrect Reassemble the transmission
axle assemblies.
4. Check:
• driven pinion movement
Rough movement Replace the defec-
tive part(s).
INSTALLING THE TRANSFER CASE ASSY

(x4)
1. Install:
• bearing-1 1
• circlip 2
9
• shim 3
• driven pinion 4
8
7 • shaft 5
6
5 2 • oil seal 6
1 • housing cap gasket 7
4 3 • bearing housing bolt 8
• bolt 9
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T
.R
.
2. Install:
4 • driven cam 1
• spring 2
7 9 • washer 3
2 • thrust shim 4
1 3 • bearing-2 5
10
• washer 6
5 6
• cap bolt 7
(x4)
8 • gasket 8
• bolt 10
9 Nm ( 0.9 m • kg, 6.5 ft • Ib)
T
.R
.
3. Install:
1 • o-ring 1
2 • bolt-2 3
4 28 Nm (2.8 m • kg, 20.3 ft • Ib)
T.
R
.
3 • bolt-1 4
28 Nm (2.8 m • kg, 20.3 ft • Ib)
T
.R
.
(x4)
(x2)
4-59
TRANSMISSION ENG
ADJUSTING THE BEARING-2 SHIM
1. Measure:
• Washer-to-bore bottom clearance c
a = bore bottom-to case back clearance
b = washer-to-case back clearance

a b
c = a - b
c
2. Calculate:
• Number of shims
(with the following formula)
Washer-to-bore bottom clearance c

b 0.1(shim thickness)
a = number of shims required (truncated)
3. Install:
• Required quantity of shims
ADJUSTING THE BEARING-1 SHIM

1. Measure:
d
• Driven pinion-to-bearing clearance g
e f
d = pitch point-to-bore bottom clearance
(specified as 57.8 mm or 2.276 in)
e = bearing height
f = pitch point-to-crown clearance

e f
g = d -( e + f )
4-60
TRANSMISSION ENG
2. Calculate:
• Number of shims
Driven pinion-to-bearing clearance g

0.1(shim thickness)
= number of shims required (truncated)
3. Install:
4-61
TRANSMISSION ENG
28 Nm (2.8 m • kg, 20.2 ft • Ib)
T.
R.
1 New
(x9)
2
3 6 7 New
4
5

Removing the transmission cover Remove the parts in the order listed.
Transmission oil Drain.
Crankcase cover
Refer to “BELT DRIVE “.
Belt drive
Secondary sheave Refer to “V-BELT, CLUTCH, PRIMARY
AND SECONDARY SHEAVE “.
1 Circlip 1
2 Thrust washer 1
3 Drive pinion 1
4 Cover stay 1
5 Cover plate 1
6 Dowel pin 2
7 Gear case gasket 1

cedure.
4-62
TRANSMISSION ENG
5 1
3 4
2
G

Removing the shift cam and shift Remove the parts in the order listed.
shaft
1 Shift fork guide bar 1

2 Spring-1 1
3 Shift fork-1 1
4 Spring-2 1
5 Shift fork-2 1
6 Shift cam assembly 1
7 Shift shaft assembly 1
cedure.
4-63
TRANSMISSION ENG
CHECKING THE SHIFT FORKS
3
6
shift forks.
1
1. Check:
5
• Shift fork movement
(along the shift fork guide bar)
Rough movement → Replace the shift forks
and shift fork guide bar as a set.
4
2 1 Shift forks 1 and 2
2 Springs 1 and 2
3 Shift fork guide bar
4 Gear indication drill spring
5 Gear indication drill
6 Shift cam assembly
2. Check:
• Shift fork follower 1
1
• Shift fork pawl 2
Bends/damage/scoring/wear → Replace
the shift fork.
3. Check:
• Shift fork guide bar 1
Roll the shift fork guide bar on a flat sur-
face.
Bends → Replace.
WARNING
Do not attempt to straighten a bent shift
1 fork guide bar.
CHECKING THE SHIFT CAM ASSEMBLY

1. Check:
1 • Shift cam groove 1
Damage/scratches/wear → Replace the
shift drum assembly.
• Shift cam segment 2
Damage/wear → Replace the shift drum
assembly.
2 • Shift drum bearing
Damage/pitting → Replace the shift drum
assembly.
4-64
TRANSMISSION ENG
G
6
4
New 2 3
G
1
30
G
29
28
27 26
17 25
G
24
13 New 22 23
11 21 33 New
9 10 20 32
78
18 31
G
16
14 15 19 New
12

Removing the transmission Remove the parts in the order listed.
1 Pinion shim 3
2 Circlip-1 1
3 Bearing-1 1
4 Low wheel gear 1
5 Middle shaft 1
6 Bearing-2 1
7 Bearing-3 1
8 Gear hold washer-1 1
9 Low pinion gear 1
10 Collar-1 1
12 Dog clutch-1 1
13 Circlip-2 1
14 Thrush washer 1
15 High pinion gear 1
16 Reverse wheel gear-1 1
17 Collar-2 1
4-65
TRANSMISSION ENG
G
6
4
New 2 3
G
1
30
G
29
28
27 26
17 25
G
24
13 New 22 23
11 21 33 New
9 10 20 32
78
18 31
G
16
14 15 19 New
12

19 Circlip-3 1
20 Drive axle 1
21 Dog clutch-2 1
23 1st wheel gear 1
24 Collar-3 1
26 Bearing-4 1
27 Bearing-5 1
28 Idle axle 1
29 Reverse wheel gear-2 1
30 Bearing-6 1
31 Counter axle 1
32 Bearing-7 1
33 Oil seal 1

cedure.
4-66
TRANSMISSION ENG
EAS00425
CHECKING THE TRANSMISSION

1. Measure:
• counter axle runout
Out of specification Replace the main
axle.
Counter axle runout limit

0.08 mm (0.0031 in)
2. Measure:
• middle shaft runout
axle.
Middle shaft runout limit

0.08 mm (0.0031 in)
3. Measure:
• idle axle runout
axle.
Idle axle runout limit

0.08 mm (0.0031 in)
4. Measure:
• drive axle runout
axle.
Drive axle runout limit

0.08 mm (0.0031 in)
4-67
TRANSMISSION ENG
5. Check:
• transmission gears
Blue discoloration/pitting/wear Replace
the defective gear(s).
6. Check:
• transmission gear engagement
(each pinion gear to its respective wheel
gear)
Incorrect Reassemble the transmission
axle assemblies.
7. Check:
• transmission gear movement
Rough movement Replace the defec-
tive part(s).
ADJUSTING THE DRIVE PINION SHIM

1. Measure:
• Shaft axis-to-coupling surface clearance
a
TIP
Shaft axis-to-coupling surface clearance can
be derived from the transfer case-1 (as illus-
trated).
2. Calculate:
• Number of shims
b
a -( b + c )
0.1(shim thickness)
c
= number of shims required (truncated)
4-68
TRANSMISSION ENG
b = pitch point-to-back clearance

c = coupling surface-to-bearing
clearance
TIP
Calculate the coupling surface-to-bearing
clearance by subtracting crown-to-bearing
clearance d from crown-to-coupling sur-
face clearance e .
e d
TIP
Coupling surface-to-bearing clearance can be
derived from the mission case (as illustrated).
3. Install:
SELECTING THE FINAL SHAFT CIRCLIP

WASHER
1. Install:
• Circlip
2. Measure:
• Drive pinion-to-circlip clearance
(with a thckness gauge)
4-69
TRANSMISSION ENG
Thickness gauge
90890-03079
Narrow gauge set
YM-34483
3. Select:
• Suitable wahser
(using the following table)
P/N SPEC. COLOR
1SC-E7529-00 2.1 ± 0.01 GREEN
1SC-E7529-10 2.2 ± 0.01 BROWN
1SC-E7529-20 2.3 ± 0.01 YELLOW
1SC-E7529-30 2.4 ± 0.01 BLUE
1SC-E7529-40 2.5 ± 0.01 RED
TIP
Each size has its corresponding color.
4-70
RADIATOR COOL
COOLING SYSTEM
RADIATOR
28 Nm (2.8 m • kg, 20.3 ft • Ib)
T.
R.
13 Nm (1.3 m • kg, 9.4 ft • Ib)
T.
R.
1
2
7
3

Removing the radiator Remove the parts in the order listed.
Seat/fuel tank cover/side covers Refer to “SEAT, FENDERS AND FUEL
/front fender TANK” in chapter 3.
Coolant Drain.
1 Coolant reservoir hose 1 Disconnect.
2 Rubber tube 1 Disconnect.
3 Radiator outlet hose 1 Disconnect.
4 Radiator inlet hose 1 Disconnect.
5 Radiator 1
6 Radiator fan 1 Disconnect radiator fan coupler.
7 Thermo switch 1 Disconnect thermo switch coupler.
procedure.
5-1
RADIATOR COOL
EBS00127
CHECKING THE RADIATOR
1. Check:
• radiator fins
Obstruction → Clean.
Apply compressed air to the rear of the radi-
ator.
Damage → Repair or replace.
TIP
Straighten any flattened fins with a thin, flat-
head screwdriver.
2. Check:
• radiator hoses
3. Measure:
• radiator cap opening pressure
Below the specified pressure → Replace
the radiator cap.
Radiator cap opening pressure

107.9 ~ 137.3 kPa
(1.079 ~ 1.373 kg/cm2,
15.35 ~ 19.53 psi)
a. Install the radiator cap tester 1 and radiator

cap tester adapter 2 to the radiator cap 3 .
Radiator cap tester

P/N. YU-24460-01, 90890-01325
Radiator cap tester adapter
P/N. YU-33984, 90890-01352
b. Apply the specified pressure for ten sec-

onds and make sure there is no drop in
pressure.
4. Check:
• radiator fan
Damage → Replace.
Malfunction → Check and repair.
Refer to “COOLING SYSTEM” in chapter 8.
5-2
RADIATOR COOL
EBS00128
INSTALLING THE RADIATOR
1. Fill:
• cooling system
mended coolant)
Refer to “CHANGING THE COOLANT” in
chapter 3.
2. Check:
• cooling system
Leaks → Repair or replace any faulty part.
5-3
THERMOSTAT COOL
THERMOSTAT
3
2
1
12 Nm (1.2 m • kg, 8.7 ft • Ib)
T.
R.

Thermostat removal Remove the parts in the order below.
Coolant Drain.
Refer to “CHANGING THE COOLANT”
in CHAPTER 3.
1 Radiator inlet hose 1
2 Thermostat cover 1
3 Thermostat 1
procedure.
5-4
THERMOSTAT COOL
CHECKING THE THERMOSTAT
1.Check:
• Thermostat 1
Does not open at 63.5 ~ 65.5 ˚C (146.3 ~
149.9 ˚F) → Replace.
Checking steps:
• Suspend the thermostat in a container filled
with water.
• Slowly heat the water.
• Place a thermometer in the water.
• While stirring the water, observe the thermostat
and thermometer’s indicated temperature.
1 Thermostat
2 Thermometer
3 Water
4 Container
A Fully closed
B Fully open
B TIP
3 mm
(0.12 in)
If the accuracy of the thermostat is in doubt,
replace it. A faulty thermostat could cause serious
Opening
overheating or overcooling.
A
2.Inspect:
0
82˚C 95˚C • Thermostat housing cover
(179.6˚F) (203˚F)
Temperature
• Thermostat housing
INSTALLING THE THERMOSTAT

1.Install:
• Thermostat
• Thermostat housing cover
2.Fill:
• Cooling system
(with the specified amount of the recommended
coolant)
Refer to “COOLANT REPLACEMENT” in
CHAPTER 3.
3.Check:
• Cooling system
Leak → Repair or replace any faulty part.
5-5
WATER PUMP COOL
WATER PUMP
(x9) 3 New
4
1
12 Nm (1.2 m • kg, 8.7 ft • Ib)

T.
R.

Water pump removal Remove the parts in the order below.
Seat, right side cover, right footboard Refer to “SEAT, SIDE COVERS AND
and engine side cover FOOTREST BOARDS” in CHAPTER 3.
Engine oil Drain.
Refer to “CHANGING THE ENGINE OIL”
in CHAPTER 3.
1 Water pump outlet hose 1
2 Water pump inlet hose 1
3 Gasket 1
4 Water pump assembly 1

cedure.
5-6
WATER PUMP COOL
11
6 New 10
12 Nm (1.2 m • kg, 8.7 ft • Ib)

T.
R.
2 New
7
9
5
8 New
4
12 Nm (1.2 m • kg, 8.7 ft • Ib)

T.
R.

Water pump disassembly Remove the parts in the order below.
1 Water pump housing cover 1
2 Gasket 1
3 Circlip 1
4 Water pump impeller 1
5 Washer 1
6 Water pump seal 1
7 Water pump shaft 1
8 Oil seal 1
9 Bearing 1
10 Bearing 1
11 Water pump housing 1
procedure.
5-7
WATER PUMP COOL
REMOVING THE WATER PUMP
1
1.Remove:
5
6 3
• Water pump housing 1
• Gasket 2
• Water pump impeller 3
(remove the impeller with a pump impeller.)
TIP
The impeller is provided with left turn thread.
4
2
• Washer 4
• Circlip 5
• Water pump shaft 6
TIP
Do not scratch the impeller shaft.
2.Remove:
• Bearing 1
2
TIP
Tap out the bearing from the outside
of the water pump housing.
1 • Water pump housing 2
2 3.Remove:
• Water pump seal 1
TIP
Tap out the water pump seal the inside of the
water pump housing.
1 • Water pump housing 2
4.Remove:
3
1 • Oil seal 1
• Bearing 2
2 TIP
Tap out the bearing and oil seal from the outside
of the water pump housing.
5-8
WATER PUMP COOL
CHECKING THE WATER PUMP
4
1.Check:
3
• Water pump housing cover 1
2 • Water pump impeller 2
1
Cracks/damage/wear → Replace.
2.Check:
• Water pump seal
• Oil seal
Cracks/damage/wear → Replace.
• Bearing
Rough movement → Replace.
INSTALLING THE WATER PUMP

2 3
1.Install:
• Bearing 1
(into the water pump housing 2 )
• Inner bearing puller 3
2 3 2.Install:
• Bearing 1
• Inner bearing puller 3
5-9
WATER PUMP COOL
3.Install:
3
2 • Oil seal 1 New
• Water pump oil seal driver 3
TIP
• Before installing the oil seal, apply tap water
or coolant onto its outer surface.
1
4.Install:
3 • Water pump seal 1 New
2
• Water pump mechanical seal driver 3
NOTICE
Never lubricate the water pump seal sur-
1 face with oil or grease.
TIP
Install the water pump seal with the special
tools.
Mechanical seal installer 3 :

P/N. YM-33221, 90890-04078
5.Install:
6
2
1
4 • Circlip 2
• Washer 3
TIP
Do not scratch the impeller shaft.
• Water pump impeller 4
3
5 • Gasket 5
(Install the impeller with a pump impeller.)
TIP
The impeller is provided with left turn thread.
5-10
CARB
CARBURETOR
CARBURETOR
3 2

Carburetor removal Remove the parts in the order below.
Seat/side covers/fuel tank cover/ Refer to “SEAT, FENDERS AND FUEL
fuel tank TANK” in CHAPTER 3.
1 Drain hose 1
2 Starter cable/starter plunger 1/1
3 Carburetor assembly 1
4 Throttle valve cover 1
5 Throttle cable 1 TIP
After removing the carburetor assembly,
remove the throttle cable.
procedure.
6-1
CARB
CARBURETOR
CARBURETOR
4
2
8 5
New 6
12
14 7
17 9
11
13
16
15
10

Carburetor disassembly Disassemble the parts in the order
below.
1 Air vent hose 1
2 Throttle stop screw 1
3 Vacuum chamber cover 1
4 Spring 1
5 Jet needle holder 1
6 Jet needle set 1
7 Piston valve 1
8 Coasting enricher 1
9 Float chamber 1
10 Drain screw 1
11 Float 1 Refer to “CARBURETOR ASSEMBLY”.
12 Needle valve 1
6-2
CARB
4
2
8 5
New
6
12
14 7
17 9
11
13
16
15
10

13 Pilot jet 1
14 Air adjusting screw 1
Refer to “DISASSEMBLY THE CAR-
15 Main jet 1
BURETOR” AND “ASSEMBLY
16 Needle jet 1 THE CARBURETOR”.
17 Starter jet 1

procedure.
6-3
CARBURETOR CARB
EBS00146
DISASSEMBLING THE CARBURETOR
TIP
Before disassembling the carburetor, make sure
to note the number of times the pilot screw is
turned out from the seated position to its set
position.
EAS00485
CHECKING THE CARBURETOR

1. Check:
• carburetor body
• float chamber
• fuel passages
Obstruction Clean.
• float chamber body
New Dirt Clean.
• float chamber rubber gasket New
a. Wash the carburetor in a petroleum-based

solvent. Do not use any caustic carburetor
cleaning solution.
b. Blow out all of the passages and jets with
compressed air.
2. Check:
• float
• float tang
Damage Replace.
3. Check:
• needle valve
Damage/obstruction/wear Replace the
needle valve.
6-4
CARBURETOR CARB
4. Check:
• piston valve
Damage/scratches/wear Replace.
• piston valve diaphragm
Cracks/tears Replace.
5. Check:
• vacuum chamber cover
• piston valve spring
6. Check:
• diaphragm (coasting enricher)
• spring
• cover
• o-ring New
New
7. Check:
• jet needle
• main jet
7
• needle jet holder
• needle jet
• starter jet
• pilot jet
• air adjusting screw 7 (Except for CAN)
Bends/damage/wear Replace.
Obstruction Clean.
Blow out the jets with compressed air.
6-5
CARBURETOR CARB
8. Check:
• fuel hoses
Obstruction Clean.
Blow out the hoses with compressed air.
9. Check:
• piston valve movement
Insert the piston valve into the carburetor
body and move it up and down.
Tightness Replace the piston valve.
10. Check:
• throttle valve movement
Sticks Replace.
11. Check:
• choke valve movement
Sticks Replace.
12. Check:
• starter plunger
• starter plunger spring
Bends/cracks/damage Replace.
6-6
CARBURETOR CARB
EBS00150
ASSEMBLING THE CARBURETOR
TIP
Before assembling the carburetor, make sure
to turn out the pilot air screw the same number
of times, as noted before disassembly, from the
seated position to the set position.
NOTICE
• Before assembling the carburetor, wash
all of the parts in a petroleum-based sol-
vent.
• Always use a new gasket.
3 2
1. Install:
5 4
• needle jet 1
• main jet 2
1 • pilot jet 3
• starter jet 4
• air adjusting screw 5
1 2. Install:
3
• float 1
• needle valve 2
2 • float pin 3
3. Install:
• float chamber
• piston valve
• jet needle
• piston valve spring
• vacuum chamber cover
6-7
CARBURETOR CARB
INSTALLING THE CARBURETOR
1. Install:
• carburetor
TIP
Align the projection on the carburetor with
the slot in the carburetor joint.
2. Install:
• throttle cable
• throttle cable cover
3. Adjust:
Engine idling speed

1,600 ~ 1,800r/min
Refer to “ADJUSTING THE ENGINE

IDLING SPEED” in chapter 3.
4. Adjust:
• throttle cable free play
Throttle cable free play (at the flange

of the throttle grip)
5 ~ 10 mm (0.20 ~ 0.39 in)
Refer to “ADJUSTING THE THROTTLE

CABLE FREE PLAY” in chapter 3.
6-8
CARBURETOR CARB
EBS00154
MEASURING AND ADJUSTING THE FUEL
LEVEL
1. Measure:
• fuel level a
Fuel level
(above the float chamber mating
a surface)
5.0 mm (0.20 in)
a. Stand the machine on a level surface.

b. Install the fuel level gauge onto the fuel
drain pipe .
Fuel level gauge

P/N.YM-01312-A, 90890-01312
c. Loosen the fuel drain screw .

d. Hold the fuel level gauge vertically next to
the line on the float chamber.
e. Measure the fuel level a .
2. Adjust:
• fuel level
a. Remove the carburetor assembly.

b. Check the needle valve seat and needle
valve.
c. If either is worn, replace them as a set.
d. If both are fine, adjust the float level by slightly
bending the float tang .
e. Install the carburetor assembly.
f. Measure the fuel level again a .
g. Repeat steps (a) to (f) until the fuel level is
within specification.
6-9
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT DRIV
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT

Rear axle, final drive gear assembly Remove the parts in the order below.
and drive shaft removal
Final gear oil Drain.
Rear wheel hubs/brake disc Refer to “FRONT AND REAR WHEELS”
in CHAPTER 8.
1 Rear axle 1
2 O-ring 1 Refer to “REMOVING
Disconnect.
3 Axle gear under protect 1 THE REAR AXLE”.
4 Final drive gear case 1
5 Drive shaft 1
6 Drive shaft spring 1
procedure.
7-1

30 Nm (3.0 m • kg, 21.7 ft • Ib)
T.
R.
T.
R.
T.
R.
20 Nm (2.0 m • kg, 14.5 ft • Ib)
T.
R.
3
6
(X6)
18 4
5
14
15 17
LS
1
8
35 Nm (3.5 m • kg, 25.3 ft • Ib)
T.
R.
16
LS 8
LS
4
13
12 9
11 100 Nm (10 m • kg, 72.3 ft • Ib)
7
T.
R.
LS New
10 New

Final drive gear disassembly Disassemble the parts in the order
below.
1 Bolt 2 TIP
2 Bolt 6 Working in a crisscross pattern, loosen
each bolt 1/4 of a turn. After all the
bolts are loosened, remove them.
3 Final drive gear case cover (L) 1
4 O-ring 2
5 Ring gear stopper 1
6 Ring gear stopper shim 1
7 Oil seal/bearing 1/1
8 Ring gear shim (L/R) 2
9 Ring gear 1
7-2
REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT

30 Nm (3.0 m • kg, 21.7 ft • Ib)
T.
R.
T.
R.
T.
R.
20 Nm (2.0 m • kg, 14.5 ft • Ib)
T.
R.
3
6
(X6)
18 4
5
14
15 17
LS
1
8
35 Nm (3.5 m • kg, 25.3 ft • Ib)
T.
R.
16
LS 8
LS
4
13
12 9
11 100 Nm (10 m • kg, 72.3 ft • Ib)
7
T.
R.
LS New
10 New

10 Oil seal 1
11 Bearing retainer 1
Refer to “DISASSEMBLING THE FINAL
12 Bearing 1 DRIVE GEAR” AND “ASSENBLING THE
13 Final drive pinion gear shim 1 FINAL DRIVE GEAR”.
14 Final drive pinion gear 1
15 Final drive pinion gear stopper 1
16 Bearing 1 Refer to “REMOVING THE FINAL DRIVE
ROLLER BEARING” AND “ASSENBLING
17 Bearing/oil seal 1/1
THE FINAL DRIVE ROLLER BEARING”
18 Final gear case cover (R) 1
procedure.
7-3
REMOVING THE REAR AXLE
1.Remove:
1
• Rear axle 1
(with dust seal)
• O-ring
NOTICE
• Never directly tap the axle end with a
hammer, since this will result in damage
to the axle thread and spline.
• Attach a suitable socket 2 on the axle
2 end and tap it with a soft hammer. Pull
out the rear axle to the right.
DISASSEMBLING THE FINAL DRIVE GEAR

1.Remove:
1 • Bearing retainer (final drive pinion gear)
TIP
Use a bearing retainer wrench 1 .
Bearing retainer wrench:

P/N. YM-04050, 90890-04050
NOTICE
The final drive shaft bearing retainer has
left-handed threads. To loosen the retainer,
turn it clockwise.
2.Remove:
• Final drive pinion gear assembly
With a soft hammer, lightly tap on the
final drive pinion gear end.
NOTICE
Removal of the final drive pinion gear
should only be performed if gear replace-
ment is necessary.
WARNING
Always use new bearings and races.
7-4
REMOVING THE FINAL DRIVE ROLLER
BEARING
3 1.Remove:
2
1 • Oil seal 1
• Roller bearing (ring gear) 2
Use a suitable press tool 3 and an appro-
priate support for the main housing.
2.Remove:
2 • Roller bearing (final drive pinion gear) 1
1
Removal steps:
• Heat the main housing only to 150 ˚C
(302 ˚F).
• Remove the roller bearing outer race with
an appropriately shaped punch 2 .
• Remove the inner race from the final drive
pinion gear.
TIP
The removal of the final drive pinion gear
roller bearing is difficult and seldom neces-
sary.
ASSEMBLING THE FINAL DRIVE ROLLER

BEARING
1.Install:
3
• Roller bearing (final drive pinion gear) New
1
Installation steps:
• Heat the main housing only to 150 ˚C
(302 ˚F).
• Install the roller bearing outer race using
the proper adapter.
• Install the inner race onto the drive pinion
gear.
2.Install:
2 • Oil seal 1 New
• Roller bearing 2
Use a suitable press tool 3 and a press to
install the above components into the
main housing.
7-5
INSTALLING THE REAR AXLE
1.Check:
• Rear axle runout a
a a Out of specification → Replace.
WARNING
Do not attempt to straighten a bent axle.
Rear axle runout limit:

1.5 mm (0.06 in)
INSTALLING THE DRIVE SHAFT

1.Check:
• Drive shaft (splines)
CHECKING THE FINAL DRIVE GEAR

1.Check:
1 • Final gear case 1
2
• Bearing housing (ring gear) 2
TIP
When the final gear case and/or the ring
gear bearing housing are replaced, be sure
to adjust the shim of the final drive pinion
gear and/or ring gear.
2.Check:
• Gear teeth
Pitting/galling/wear → Replace the drive
pinion gear and ring gear as a set.
• Oil seals
• O-rings
Damage → Replace.
7-6
3.Check:
• Bearings
Damage → Replace.
TIP
• Reusing roller bearings is acceptable, but
Yamaha recommends installing new
ones. Do not reuse the oil seal.
• When the final drive pinion gear and/or
ring gear are replaced, be sure to adjust
the shim of the final drive pinion gear and/
or ring gear.
ASSEMBLING THE FINAL DRIVE GEAR

1.Install:
1
• Drive pinion gear (with shim(s) and bear-
ing)
(proper shim size as calculated)
• Bearing retainer (drive pinion gear)
100 Nm (10.0 m • kg, 72 ft • lb)
T.
R.
Use a bearing retainer wrench 1 .
NOTICE
• Always use a new bearing.
• The final drive shaft bearing retainer has
left-hand threads. Turn the retainer coun-
terclockwise to tighten it.
Bearing retainer wrench:

P/N. YM-04050, 90890-04050
7-7
INSTALLING THE FINAL DRIVE GEAR

1.Lubricate:
• Drive shaft
• Coupling gear
• O-ring
• Oil seal
• Bearing
Lithium-soap base grease
2.Install:
• Drive shaft 1
(to the universal joint)
3.Install:
• Final drive gear
• Bolts LT 35 Nm (3.5 m • kg, 25.3 ft • lb)
T.
R.
ADJUSTING THE BACKLASH

1. Install:
• Final drive pinion gear shim 1
1 TIP
Use only shims 2.00 mm (0.08 in) thick.
2.Install:
• Left ring gear shim 2
• Right ring gear shim 3
TIP
Use only shims 1.50 mm (0.06 in) thick.
2 3
7-8
3.Remove:
• Final drive gear case filling bolt 1
1 • O-ring 2
2
4.Install:
• Dial indicator 1
1 (on the ring gear through the filling hole)
5.Measure:
• Backlash
TIP
Install the dial indicator onto the tip of the ring
gear 1 . Slightly rotate it back and forth from
engagement to engagement to read the
backlash.
6.Remove:
• Dial indicator
7.Rotate:
a • Ring gear
(120˚ in direction a )
8.Re-install:
• Dial indicator
9.Measure:
• Backlash
TIP
Repeat this procedure three times. Average the
three measurements. Replace the shims using
the table given on page 7-10.
7-9
Name
Size Ring gear shim (L) Ring gear shim (R)
Avg.
0.15~0.28 mm 1.5 mm 1.5 mm
Avg.＞0.25 mm 1.55 mm 1.45 mm
Avg.＜0.15 mm 1.45 mm 1.55 mm
7-10
FRONT AND REAR WHEELS CHAS
CHASSIS
FRONT AND REAR WHEELS
FRONT WHEELS
40 Nm (4.0 m • kg, 28.9 ft • Ib)

T.
R.
(x4) LT
135 Nm (13.5 m • kg, 97.6 ft • Ib)
T.
R.
6 45 Nm (4.5 m • kg, 32.5 ft • Ib)
T.
R.
5
7
LS
28 Nm (2.8 m • kg, 20.3 ft • Ib)
(x4)
T.
R.
4
2
1
New 3

Removing the front wheels Remove the parts in the order listed.
Place the machine on a level surface.
WARNING
Securely support the machine so there
is no danger of it falling over.
The following procedure applies to both of
the front wheels.
1 Front wheel 1 Refer to “INSTALLING THE FRONT WHEELS”.
2 Rubber cap 1
3 Cotter pin 1
Refer to “INSTALLING THE WHEEL HUBS”.
4 Axle nut 1
8-1
40 Nm (4.0 m • kg, 28.9 ft • Ib)

T.
R.
(x4) LT
135 Nm (13.5 m • kg, 97.6 ft • Ib)
T.
R.
6 45 Nm (4.5 m • kg, 32.5 ft • Ib)
T.
R.
5
7
LS
28 Nm (2.8 m • kg, 20.3 ft • Ib)
(x4)
T.
R.
4
2
1
New 3

5 Brake caliper assembly 1 TIP
Do not squeeze the brake lever when the
brake caliper is off of the brake discs as
the brake pads will be forced shut.
6 Wheel hub 1 Refer to “INSTALLING THE WHEEL HUB

BEARINGS”.
7 Brake disc 1 Refer to “INSTALLING FRONT BRAKE

DISCS”.
cedure.
8-2
REAR WHEELS
55 Nm (5.5 m • kg, 40.0 ft • Ib)

New
T.
T .R.
3
(x4) 2
55 Nm (5.5 m • kg, 40.0 ft • Ib) 4

T.
T .R.
170 Nm (17.0 m • kg, 123.0 ft • Ib)

T.
T .R.
40 Nm (4.0 m • kg, 28.9 ft • Ib)

T.
T .R.
(x2)
LT
1
(x3) 5
9
7 28 Nm (2.8 m • kg, 20.3 ft • Ib)
T.
R.
135 Nm (13.5 m • kg, 97.6 ft • Ib)
6
T.
R.
New
LT 8
(x4)
5
New 3
1
2 4
135 Nm (13.5 m • kg, 97.6 ft • Ib)
T.
R.

Removing the rear wheels Remove the parts in the order listed.
Place the machine on a level surface.
WARNING
Securely support the machine so there
is no danger of it falling over.

the rear wheels.
1 Rear wheel 2 Refer to “INSTALLING THE REAR WHEELS”.

2 Rubber cap 2
Refer to “INSTALLING THE WHEEL HUBS”.
3 Cotter pin 2
4 Axle nut 2
5 Shaft connecter 2
8-3
REAR WHEELS
55 Nm (5.5 m • kg, 40.0 ft • Ib)

New
T.
T .R.
3
(x4) 2
55 Nm (5.5 m • kg, 40.0 ft • Ib) 4

T.
T .R.
170 Nm (17.0 m • kg, 123.0 ft • Ib)

T.
T .R.
40 Nm (4.0 m • kg, 28.9 ft • Ib)

T.
T .R.
(x2)
LT
1
(x3) 5
9
7 28 Nm (2.8 m • kg, 20.3 ft • Ib)
T.
R.
135 Nm (13.5 m • kg, 97.6 ft • Ib)
6
T.
R.
New
LT 8
(x4)
5
New 3
1
2 4
135 Nm (13.5 m • kg, 97.6 ft • Ib)
T.
R.

6 Brake caliper 1 TIP
Do not squeeze the brake lever when the
brake caliper is off of the brake discs as
the brake pads will be forced shut.
7 Nut 1 Refer to “INSTALLING THE REAR

8 Conical spring washer 1 BRAKE DISC”.
9 Brake disc/brake disc bracket 1/1

cedure.
8-4
CHECKING THE WHEELS
The following procedure applies to both of the
front and rear wheels.
1. Check:
• wheel
2. Measure:
3 • wheel runout
Over the specified limit → Replace the
wheel or check the wheel bearing play 1 .
Wheel runout limit

2 Radial 2 : 2.0 mm (0.08 in)
Lateral 3 : 2.0 mm (0.08 in)
1 1
3. Check:
• wheel balance
Out of balance → Adjust.
WARNING
After replacing the tire, ride conservatively
to allow the tire to be properly seated in the
rim. Failure to do so may cause an accident
resulting in machine damage and possible
operator injury.
CHECKING THE WHEEL HUBS

front and rear wheel hubs.
1. Check:
• wheel hub 1
• splines (wheel hub)
Wear/damage → Replace the wheel hub.
Front
Rear
8-5
2. Check:
• wheel bearings
Wheel hub play/ wheel turns roughly → Replace.
a. Clean wheel hub exterior.

b. Drive bearing out by pushing spacer aside
and tapping around perimeter of bearing
inner race. Use soft metal drift punch and
1 hammer. The spacer 1 “floats” between
bearings. Remove both bearings as
described.
WARNING
Eye protection is recommended when using
striking tools.
c. To install the wheel bearings, reverse the

above sequence. Use a socket that
matches outside diameter of bearing outer
race to drive in bearing.
NOTICE
Do not strike the center race or balls of the
bearing. Contact should be made only with
the outer race.
A CHECKING THE BRAKE DISCS

a 1. Check:
• brake discs
Galling/damage → Replace.
2. Measure:
• brake disc deflection
A Front
B Rear
Brake disc maximum deflection

B Front: 0.15 mm (0.006 in)
a Rear: 0.15 mm (0.006 in)
• brake disc thickness

Brake disc minimum thickness

Front: 3.0 mm (0.12 in)
Rear: 3.0 mm (0.12 in)
8-6
A INSTALLING THE BRAKE DISCS
1. Install:
• brake discs
TIP
Install the brake disc with its spot-faced side
facing the bolt heads.
A Front
B Rear
INSTALLING THE REAR BRAKE DISC ON

THE REAR AXLE
2 1. Install:
1 • rear brake disc 1
2 • conical spring washer 2
TIP
3
Install the conical spring washer with the con-
vex side of the washer facing inward as shown.
• nut 3
2. Tighten:
2 • nut 1
Tighten the nut with axle nut wrench 46 or axle

1 nut wrench (46 mm) 2 to specification while
holding the rear axle.
170 Nm (17.0 m• kg, 123 ft • Ib)
T.
R.
Axle nut wrench 46

90890-01498
Axle nut wrench (46 mm)
YM-37134
8-7
INSTALLING THE FRONT WHEEL HUB
BEARINGS
1. Install:
• bearings 1
TIP
Face the oil seal side of the bearing inward.
INSTALLING THE WHEEL HUBS

1 front and rear wheel hubs.
1. Install:
• axle nut 1
Front wheel hub:
80 Nm (8.0 m • kg, 57.9 ft • lb)
T.
R.
Rear wheel hub:
2 New
135 Nm (13.5 m • kg, 97.6 ft • lb)
T.
R.
• cotter pin 2 New

TIP
• Do not loosen the axle nut after torquing it. If
the axle nut groove is not aligned with the cot-
ter pin hole, align the groove with the hole by
tightening the axle nut.
• Bend the longer cotter pin up.
INSTALLING THE WHEELS

1. Install:
1
• wheels
TIP
2 The arrow mark 1 on the must point in the
direction of rotation of the wheel.
2. Tighten:
• nuts 2
Front wheel nuts:
2
45 Nm (4.5 m • kg, 32.5 ft • Ib)
T.
R.
Rear wheel nuts:

55 Nm (5.5 m • kg, 40.0 ft • Ib)
T.
R.
WARNING
Tapered wheel nuts 2 are used for both
the front and rear wheels. Install each nut
with its tapered side towards the wheel.
8-8
FRONT AND REAR BRAKES CHAS
FRONT AND REAR BRAKES
FRONT BRAKE CALIPER
New 2
3
1
T.
R.
T.
R.

Removing the front brake caliper Remove the parts in the order listed.
Brake fluid Drain.
BRAKE SYSTEM” in chapter 3.
1 Union bolt 1
2 Copper washer 2 Refer to “INSTALLING THE
3 Brake hose 1 Disconnect. REAR BRAKE CALIPER”.
4 Brake caliper assembly 1
For installation, reverse the removal procedure.
8-9

Removing the front brake pads Remove the parts in the order listed.
1 Brake pad 2
2 Brake pad spring 1
8-10
REAR BRAKE CALIPER
2 New
1
30 Nm (3.0 m • kg, 21.7 ft • Ib)

T.
R.
28 Nm (2.8 m • kg, 20.3 ft • Ib)

T.
R.

Removing the rear brake caliper Remove the parts in the order listed.
Brake fluid Drain.
1 Union bolt 1
2 Copper washer 2 Refer to “INSTALLING THE
3 Brake hose 1 Disconnect. REAR BRAKE CALIPER”.
4 Brake caliper assembly 1
5 Parking brake cable 1 Refer to “REMOVING THE PARKING
BRAKE CABLE”.
8-11
11
8 Nm (0.8 m• kg, 6.5 ft • Ib)
T.
R.
55
2
3
3
2
44
25 Nm (2.5 m• kg, 18.1 ft • Ib)
T.
R.

Disassembling the rear brake cali- Remove the parts in the order listed.
per
1 Adjusting bolt 1
2 Brake pad 2
3 Brake pad spring 1
4 Caliper bracket 1
5 Bleed screw 1

procedure.
8-12
REMOVING THE PARKING BRAKE CABLE
1. Loosen:
• nut
• adjusting bolt
2. Disconnect:
• parking brake cable
(from parking brake lever)
3. Disconnect:
• parking brake cable
(from rear brake)
CHECKING THE BRAKE CALIPER

Recommended brake component
replacement schedule
Brake pads As required
Caliper ass'y Every two years
Brake hoses Every four years
Replace when
Brake fluid brakes are
disassembled.
1. Check:
A
• brake caliper body 1
1 • brake fluid delivery passage
(brake caliper body)
Blockage → Blow out with compressed air.
WARNING
Replace the caliper piston seal and dust
seal whenever the brake caliper is disas-
B sembled.
1
A Front brake caliper
B Rear brake caliper
8-13
2. Check:
B a
• parking brake arm to parking brake bracket
distance a
Parking brake arm to parking

brake bracket distance
63.0 mm (2.48 in)
B Rear brake caliper
INSTALLING THE BRAKE CALIPER

A 1. Install:
• brake caliper assembly
2 • brake caliper mounting bolts 1
Brake caliper mounting bolt

28 Nm (2.8 m•kg, 20.3 ft•lb)
1 • brake hose 2
3 • copper washers
• union bolt 3
B 2 Union bolt
28 Nm (2.8 m•kg, 20.3 ft•lb)
3
WARNING
Proper brake hose routing is essential to
insure safe machine operation. Refer to
“CABLE ROUTING” in chapter 2.
A Front
1
B Rear
2. Fill:
• brake reservoir

DOT 4
NOTICE
or plastic parts. Always clean up spilled
brake fluid immediately.
8-14
WARNING
• Use only the designated quality brake
fluid: other brake fluids may deteriorate
the rubber seals, causing leakage and
• Refill with the same type of brake fluid:
mixing brake fluids may result in a harm-
ful chemical reaction and lead to poor
brake performance.
• Be careful that water does not enter the
master cylinder when refilling. Water will
significantly lower the boiling point of the
brake fluid and may result in vapor lock.
3. Air bleed:
• brake system
4. Check:
Brake fluid level is below the “LOWER” level
line → Add the recommended brake fluid to
the proper level.
LEVEL” in chapter 3.
5. Adjust:
• parking brake cable end length
Refer to “ADJUSTING THE PARKING
BRAKE” in chapter 3.
NOTICE
Disc brake components rarely require dis-
assembly.
DO NOT:
• disassemble components unless abso-
lutely necessary;
• use solvents on internal brake components;
• use spent brake fluid for cleaning; (use
only clean brake fluid)
• allow brake fluid to come in contact with
the eyes, as this may cause eye injury;
• splash brake fluid onto painted surfaces
or plastic parts, as this may cause damage;
• disconnect any hydraulic connection, as
this would require the entire brake system
to be disassembled, drained, cleaned,
properly filled and bled after reassembly.
8-15
REPLACING THE FRONT BRAKE PADS
TIP
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.
1. Remove:
• brake pads
wear limit
a
1.0 mm (0.04 in)
TIP
Replace the brake pads as a set if either is
found to be worn to the wear limit.
2. Install:
• brake pads
• brake pad spring
TIP
Always install new brake pads and brake pad
spring as a set.
a. Connect a suitable hose tightly to the

brake caliper bleed screw . Put the other
end of this hose into an open container.
b. Loosen the brake caliper bleed screw and,
using a finger, push the caliper piston into
the brake caliper.
c. Tighten the brake caliper bleed screw.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
d. Install a new brake pad spring and new

brake pads.
3. Install:
• brake caliper
• brake caliper mounting bolts
28 Nm (2.8 m•kg, 20.3 ft•lb)
4. Check:
Refer to “CHECKING THE FRONT BRAKE
FLUID LEVEL” in chapter 3.
5. Check:
• brake lever or brake pedal operation
Soft or spongy feeling → Bleed the brake
system.
8-16
REPLACING THE REAR BRAKE PADS
TIP
It is not necessary to disassemble the brake
caliper and brake hose to replace the brake
pads.
1. Remove:
• brake pads
wear limit

1.0 mm (0.04 in)
TIP
Replace the brake pads as a set if either is
found to be worn to the wear limit.
2. Install:
• brake pads
• brake pad spring
TIP
Always install new brake pads and brake pad
spring as a set.
a. Connect a suitable hose tightly to the

brake caliper bleed screw . Put the other
end of this hose into an open container.
b. Loosen the brake caliper bleed screw and,
using a finger, push the caliper piston into
the brake caliper.
c. Tighten the brake caliper bleed screw.
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
d. Install a new brake pad spring and new

brake pads.
3. Install:
• brake caliper
• brake caliper mounting bolts
28 Nm (2.8 m•kg, 20.3 ft•lb)
4. Check:
Refer to “CHECKING THE REAR BRAKE
FLUID LEVEL” in chapter 3.
5. Check:
• brake lever or brake pedal operation
Soft or spongy feeling → Bleed the brake
system.
8-17
FRONT BRAKE MASTER CYLINDER
13 Nm (1.3 m • kg, 9.4 ft • Ib)
T.
R.
8
9
3
6 Nm (0.6 m • kg, 4.3 ft • Ib)

T.
R.
LS
7
4
6
New
5
28 Nm (2.8 m • kg, 20.3 ft • Ib)
T.
R.

Removing the front brake master Remove the parts in the order listed.
cylinder
Brake fluid Drain.
1 Brake fluid reservoir cap 1
2 Brake fluid reservoir diaphragm 1
3 Front brake light switch 1
4 Brake lever 1
5 Union bolt 1
6 Copper washer 2 Refer to “INSTALLING
7 Brake hose 1 Disconnect. THE FRONT BRAKE
8 Parking brake lever 1 MASTER CYLINDER”.
9 Brake master cylinder 1
procedure.
8-18

Disassembling the front brake Remove the parts in the order listed.
master cylinder
1 Brake master cylinder kit 1

procedure.
8-19
REAR BRAKE MASTER CYLINDER

Removing the rear brake master Remove the parts in the order listed.
cylinder
Rihgt foot portector Refer to “SEAT, FENDERS AND FUEL
Brake fluid Drain.
1 Rear brake cable 1
2 Brake fluid reservoir cap 1
3 Brake fluid reservoir diaphragm holder 1
4 Brake fluid reservoir diaphragm 1
5 Brake fluid reservoir 1
6 Brake fluid reservoir hose 1
8-20

7 Union bolt 1
Refer to “INSTALLING
8 Copper washer 2
Disconnect. THE REAR BRAKE
9 Brake hose 1
MASTER CYLINDER”.
10 Brake master cylinder 1
11 Control cable 1
12 Rear brake light switch/spring 1/1/1
13 Brake master cylinder arm/spring 1/2
14 Brake pedal 1
15 Master cylinder holder 1
16 Axle fixed 1
procedure.
8-21
17 Nm (1.7 m • kg, 12.3 ft • Ib)

T.
R.

Disassembling the rear brake Remove the parts in the order listed.
master cylinder
1 Brake master cylinder kit 1

procedure.
8-22
EBS00413
CHECKING THE MASTER CYLINDERS

1. Check:
• brake master cylinder
Wear/scratches → Replace the brake mas-
ter cylinder assembly.
• brake master cylinder body
1
• brake fluid delivery passage
(brake master cylinder body)
Blockage → Blow out with compressed air.
Front
Rear
2. Check:
• brake master cylinder kit
Scratches/wear/damage → Replace as a
set.
Front
Rear
3. Check:
1
• front brake master cylinder reservoir
2 • front brake master cylinder reservoir dia-
phragm
4. Check:
1 2 • rear brake fluid reservoir
• rear brake fluid reservoir diaphragm
8-23
ASSEMBLING THE FRONT BRAKE

MASTER CYLINDER
WARNING
• All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.

DOT 4
• Whenever a master cylinder is disassem-

bled, replace the piston seals and dust
seals.
ASSEMBLING THE REAR BRAKE MASTER

CYLINDER
WARNING
• All internal brake components should be
cleaned and lubricated with new brake
fluid only before installation.

DOT 4
• Whenever a master cylinder is disassem-

bled, replace the piston seals and dust
a seals.
1. Install:
3
• brake master cylinder kit
• nut 1
1
• joint 2
2
TIP
Turn the adjusting bolt 3 until the clearance
a is within the specified limits when install the
joint 2 .
Clearance
5.2 ~ 6.2 mm (0.20 ~ 0.24 in)
2. Tighten:
• nut 1
Nut
17 Nm (1.7 m•kg, 13 ft•lb)
8-24
1 INSTALLING THE FRONT BRAKE MASTER

CYLINDER
1. Install:
• brake master cylinder 1
• parking brake lever 2
Brake master cylinder holder bolt

13 Nm (1.3 m•kg, 9.4 ft•lb)
2
TIP
• The parking brake lever installing, please refer to
“INSTALLING THE PARKING BRAKE LEVER”.
• Install the brake master cylinder so that the
gaps between the brake master cylinder and
the parking brake lever are equal.
1 2. Install:
• copper washers
a • brake hose 2
2
• union bolt 1
Union bolt
28 Nm (2.8 m•kg, 20.3 ft•lb)
b
NOTICE
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe a touches the projection b as
shown.
TIP
• Tighten the union bolt while holding the brake
hose as shown.
• Turn the handlebar to the left and to the right
to check that the brake hose does not touch
other parts (throttle cable, wire harness,
leads, etc.). Correct if necessary.
WARNING
8-25
3. Fill:
• brake fluid reservoir

DOT 4
NOTICE
WARNING
ful reaction and lead to poor brake perfor-
mance.
brake master cylinder when refilling.
Water will significantly lower the boiling
point of the brake fluid and may result in
vapor lock.
4. Air bleed:
• brake system
5. Check:
Brake fluid level is under the “LOWER” level
the proper level.
8-26
INSTALLING THE REAR BRAKE MASTER

2 a CYLINDER
1. Install:
• copper washers
• brake hose 1
b
1 • union bolt 2
Union bolt
28 Nm (2.8 m•kg, 20.3 ft•lb)
NOTICE
When installing the brake hose onto the
brake master cylinder, make sure the brake
pipe a touches the projection b as
shown.
WARNING
2. Install:
1
• brake fluid reservoir hose
3. Fill:
• brake fluid reservoir

DOT 4
NOTICE
8-27
WARNING
ful chemical reaction and lead to poor
brake performance.
brake master cylinder when refilling.
Water will significantly lower the boiling
point of the brake fluid and may result in
vapor lock.
4. Air bleed:
• brake system
5. Check:
Brake fluid level is under the “LOWER” level
the proper level.
8-28
STEERING SYSTEM CHAS
STEERING SYSTEM
HANDLEBAR
1
7
LS
13 Nm (1.3 m • kg, 9.4 ft • Ib)
T
.R
.
10
6 LS
9
11
25 Nm (2.5 m • kg, 18.1 ft • Ib)
T
.R
.
14 15 13 Nm (1.3 m • kg, 9.4 ft • Ib)
T
.R
.
8
5
8 Nm (0.8 m • kg, 5.8 ft • Ib) 3
T
.R
.
13 1
16
12 4
LS

Removing the handlebar Remove the parts in the order listed.
Handlebar cover Refer to “SEAT, FENDERS AND FUEL
1 Handlebar grip 2 Refer to “REMOVING THE HANDLEBAR
GRIPS” and “INSTALLING THE HAN-
DLEBAR GRIPS”.
2 Choke cable 1
3 Handlebar switch 1
4 Rear brake cable 2
5 Rear brake lever assembly 1 Refer to “INSTALLING THE REAR
BRAKE LEVER ASSEMBLY”.
6 Throttle cable 1
7 Throttle lever assembly 1 Refer to “INSTALLING THE THROTTLE
LEVER ASSEMBLY”.
8-29
1
7
LS
13 Nm (1.3 m • kg, 9.4 ft • Ib)
T
.R
.
10
6 LS
9
11
25 Nm (2.5 m • kg, 18.1 ft • Ib)
T
.R
.
14 15 13 Nm (1.3 m • kg, 9.4 ft • Ib)
T
.R
.
8
5
8 Nm (0.8 m • kg, 5.8 ft • Ib) 3
T
.R
.
13 1
16
12 4
LS

8 Front brake switch 1
9 Parking brake cable 1
10 Parking brake lever 1 Refer to “INSTALLING THE FRONT BRAKE
11 Front brake master cylinder 1 LEVER ASSEMBLY” and “INSTALLING
THE PARKING BRAKE LEVER”.
12 Plastic band 1 Fasten the choke cable and handlebar
switch lead.
13 Plastic band 1 Fasten the front brake switch.
14 Upper handlebar holder 1
15 Handlebar 1 Refer to “INSTALLING THE HANDLEBAR”.
16 Lower handlebar holder 1
cedure.
8-30
REMOVING THE HANDLEBAR GRIPS
1. Remove:
• handlebar grips
TIP
Blow compressed air between the handlebar
and handlebar grip, and gradually push the grip
off the handlebar.
REMOVING THE REAR BRAKE SWITCH

1. Remove:
• rear brake switch
TIP
Push the fastener when removing the rear brake
switch out of the rear brake lever holder.
CHECKING THE HANDLEBAR

1. Check:
• handlebar
Bends/cracks/damage → Replace.
WARNING
Do not attempt to straighten a bent handle-
bar as this may dangerously weaken the
handlebar.
8-31
INSTALLING THE HANDLEBAR
1. Install:
• handlebar
• upper handlebar holders
25 Nm (2.5 m · kg, 18.1 ft · lb)
T.
R.
TIP
• Install the handlebar, please align the punch
mark 1 and the gap at handlebar holder 2 .
• The upper handlebar holders should be
installed with the flange 3 forward 4 .
NOTICE
First tighten the bolt 5 on the rear side of
3 the handlebar holder, and then tighten the
bolt 6 on the front side.
5 6
INSTALLING THE HANDLEBAR GRIPS

1. Install:
• rear brake lever
• handlebar grips 1
TIP
• Before installing the handlebar grips, please
placing the rear brake lever.
• Before applying the adhesive, wipe off grease
or oil on the handlebar surface a with a lac-
quer thinner.
• Install the handlebar grips so that the “L” arrow
on the left grip and “R” arrow on the right
grip are placed vertically.
8-32
a 3 INSTALLING THE REAR BRAKE LEVER
2
1. Install:
• handlebar switch
TIP
1 • Installing the rear brake lever, make sure the
handlebar switch 1 , handlebar grip 2 , and
rear brake lever 3 are in the positions shown
in the illustration.
4 • Install the rear brake lever, please align the
punch mark 4 and the gap 5 at rear brake
lever holder.
• a 65 ~ 66 mm (2.56 ~ 2.60 in)
Rear brake lever

5
13 Nm (1.3 m•kg, 9.4 ft•lb)
2. Adjust:
Refer to “ADJUSTING THE REAR BRAKE
LEVER” in chapter 3.
INSTALLING THROTTLE LEVER ASSEMBLY
1. Install:
• throttle lever assembly
TIP
1 • Install the throttle lever assembly, please align
2
the punch mark 1 and the gap 2 at the throttle
lever assembly.
• Installing the throttle lever assembly, make
sure the clearance the throttle lever assembly
3
3 and handlebar grip 4 .
Throttle lever assembly

8 Nm (0.8 m•kg, 5.8 ft•lb)
2. Adjust:
4
Refer to “ ADJUSTING THE THROTTLE
LEVER FREE PLAY” in chapter 3.
8-33
INSTALLING THE PARKING BRAKE LEVER
1 1. Install:
• parking brake lever 1
• parking brake cable 2
3 • damper 3
• parking brake lever plate 4
• Brake master cylinder 5
5 4
2
TIP
Align the holder plate a on the handlebar with
the align position b of the parking brake lever.
Throttle lever assembly

13 Nm (1.3 m•kg, 9.4 ft•lb)
a b
2. Adjust:
• parking brake
Refer to “ADJUSTING THE PARKING
BRAKE” in chapter 3.
8-34
EBS00454
STEERING STEM
25 Nm (2.5 m • kg, 18.1 ft • Ib)

T
.R
.
New 5
4 3
New 2 3
1
LS
LS
6
New 5
New
New
New
35 Nm (3.5 m • kg, 25.3 ft • Ib) New 55 Nm (5.5 m • kg, 39.8 ft • Ib)
T
T
.R
.R
.

Removing the steering stem Remove the parts in the order listed.
Front fender Refer to “SEAT, FENDERS AND FUEL
Handlebar Refer to “HANDLEBAR”.
1 Lock washer 1 Refer to “INSTALLING THE LOCK
WASHER”.
2 Bracket 1
3 Steering stem bushing 2
4 Collar 2
5 Oil seal 2
6 Steering stem 1 Refer to “INSTALLING THE STEERING
STEM”.
cedure.
8-35
REMOVING THE STEERING STEM

1. Remove:
• steering stem
TIP
When loosening each tie-rod end nut , hold
the tie-rod ball joint with a 14-mm wrench .
1
2
CHECKING THE STEERING STEM

1. Check:
• steering stem
Bends → Replace.
WARNING
Do not attempt to straighten a bent stem;
this may dangerously weaken the stem.
2. Check:
• steering stem bushings
• oil seal
8-36
INSTALLING THE STEERING STEM
1. Tighten:
• steering stem nut 1
55 Nm (5.5 m·kg, 39.8 ft·lb)
T.
R.
• tie-rod end nut 2
35 Nm (3.5 m·kg, 25.3 ft·lb)
T.
R.
TIP
When tightening each tie-rod end nut 2, hold
the tie-rod ball joint with a 14-mm wrench 3.
INSTALLING THE LOCK WASHER

1. Install:
• lock washer 1 New
• bolts 25 Nm (2.5 m·kg, 18.1 ft·lb)
T.
R.
2. Bend the lock washer tab along a flat side
of the bolt.
8-37
TIE-RODS AND STEERING KNUCKLES
35 Nm (3.5 m • kg, 25.3 ft • Ib)
T
.R
.
13 Nm (1.3 m • kg, 9.4 ft • Ib)
T
.R
.
3 2
5
New
35 Nm (3.5 m • kg, 25.3 ft • Ib) New

T
.R
.
4
35 Nm (3.5 m • kg, 25.3 ft • Ib)
T
.R
.
New
45 Nm (4.5 m • kg, 32.5 ft • Ib)
T
.R
.
35 Nm (3.5 m • kg, 25.3 ft • Ib)

T
.R
.

Removing the tie-rods and steering Remove the parts in the order listed.
knuckles
the tie-rods and steering knuckles.
Front brakes Refer to “FRONT BRAKES”.
1 Brake disc guard 1
2 Front brake hose 1
3 Tie-rod 1 Refer to “INSTALLING THE TIE-RODS”.
4 Lower front arm 1
5 Upper front arm 1
6 Steering knuckle 1 Refer to “REMOVING THE STEERING
KNUCKLES”.
procedure.
8-38
REMOVING THE TIE-RODS

tie-rods.
1. Remove:
• tie-rod
1
TIP
When removing the tie-rod, hold each tie-rod
ball joint with a 14-mm wrench and then
2 loosen the tie-rod end nut.
REMOVING THE STEERING KNUCKLES

steering knuckles.
1. Remove:
• steering knuckles
TIP
• Attatch the ball joint remover/attatchment
set/short set and new ball joint (with rubber
boot and retaining ring) “7” to the steering
knuckle “8”.
• Always use a new ball joint set.
• Do not tap or damage the top of the ball
joint.
Ball joint remover

90890-01474
Ball joint remover attatchment set
90890-01480
Ball joint adapter set
YM-01480
Ball joint remover short shaft set
90890-01514
YM-01514
Body 90890-01474
9
YM-01474
10 Installer spacer
90890-01480
11 Installer washer
YM-01480
12 Base
13 Guide bolt 90890-01514
YM-01514
14 Short bolt
8-39
CHECKING THE TIE-RODS
tie-rods.
1. Check:
• tie-rod free play and movement
Free play → Replace the tie-rod end.
Turns roughly → Replace the tie-rod end.
2. Check:
• tie-rod
Bends/damage → Replace.
CHECKING THE STEERING KNUCKLES

steering knuckles.
1. Check:
• steering knuckle
Damage/pitting → Replace.
INSTALLING THE TIE-RODS

tie-rods.
1. Install:
1 • tie-rod 35 Nm (3.5 m · kg, 25.3 ft · lb)
T.
R.
TIP
• The tie-rod side which must be installed on
the outside has grooves .
• When installing the tie-rod, hold each tie-rod
ball joint with a 14-mm wrench and then
tighten the tie-rod end nut.
2. Adjust:
• toe-in
1 Refer to “ADJUSTING THE TOE-IN” in
chapter 3.
8-40
FRONT ARMS AND FRONT SHOCK ABSORBER
ASSEMBLIES CHAS
FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES
35 Nm (3.5 m • kg, 25.3 ft • Ib)
T
.R
.
35 Nm (3.5 m • kg, 25.3 ft • Ib)
T
.R
.
New 2
5
7
35 Nm (3.5 m • kg, 25.3 ft • Ib) New 6
7
T
.R
.
7
7
1
3
35 Nm (3.5 m • kg, 25.3 ft • Ib) New
T
.R
.
45 Nm (4.5 m • kg, 32.5 ft • Ib)

T
.R
.
35 Nm (3.5 m • kg, 25.3 ft • Ib)

T
.R
.

Removing the tie-rods and steering Remove the parts in the order listed.
knuckles
the tie-rods and steering knuckles.
Front brakes Refer to “FRONT BRAKES”.
1 Brake disc guard 1
2 Tie-rod 1 Disconnect.
3 Lower front arm 1 Refer to “REMOVING THE FRONT ARMS”
4 Upper front arm 1 and “INSTALLING THE FRONT ARMS”.
5 Front shock absorber 1
6 Steering knuckle 1
7 Bush 4
procedure.
8-41
ASSEMBLIES CHAS
REMOVING THE FRONT ARMS

1. Check:
• front arm free play
A
a. Check the front arm side play by moving
it from side to side.
If side play is noticeable, check the bush-
A ings.
b. Check the front arm vertical movement
by moving it up and down.
If the vertical movement is tight or rough, or
if there is binding, check the bushings.
2. Remove:
B • front arm
2
CHECKING THE FRONT ARMS
2 1. Check:
• front arms 1
Bends/damage → Replace.
2. Check:
1 • bushes 2
1
CHECKING THE FRONT SHOCK

ABSORBERS
front shock absorber assemblies.
1. Check:
• shock absorber
Oil leaks → Replace the front shock absorber
assembly.
• shock absorber rod
Bends/damage → Replace the front shock
absorber assembly.
• spring
Fatigue → Replace the front shock absorber
assembly.
Move the spring up and down.
8-42
ASSEMBLIES CHAS
EBS00472
CHECKING THE BALL JOINTS

front arm ball joints.
1. Check:
• ball joint
Damage/pitting → Replace the front arm.
Free play → Replace the front arm.
Turns roughly → Replace the front arm.
EBS00473
INSTALLING THE FRONT ARMS

front arms.
1. Install:
• upper front arm
• lower front arm
Front arm (upper, lower)

35 Nm (3.5 m•kg, 25.3 ft•lb)
8-43
REAR SHOCK ABSORBER AND SWINGARM CHAS
REAR SHOCK ABSORBER AND SWINGARM
38 Nm (3.8 m • kg, 27.5 ft • Ib)
T
.R
.
5
75 Nm (7.5 m • kg, 54.2 ft • Ib) 6
T
.R
.
38 Nm (3.8 m • kg, 27.5 ft • Ib)

T
.R
.
New LS
2
11 10
LS 3 9
New 7
6 5
4
11 75 Nm (7.5 m • kg, 54.2 ft • Ib)
T
.R
.
LS
12 8
13 New
8 Nm (0.8 m • kg, 5.38 ft • Ib)

T
.R
.

Removing the rear shock absorber Remove the parts in the order listed.
and swingarm
1 Brake disc protect 1

2 Rear shock absorber 1
3 Rear brake hose 1
4 Parking brake cable 1
5 Plug 2
6 Swing ram bolt(R)/swing ram bolt(L)/nut 1/1/1
7 Metal clamp A 1
8 Swingarm 1
9 Metal clamp B 1
10 Rubber boot 1
8-44
38 Nm (3.8 m • kg, 27.5 ft • Ib)
T
.R
.
5
75 Nm (7.5 m • kg, 54.2 ft • Ib) 6
T
.R
.
38 Nm (3.8 m • kg, 27.5 ft • Ib)

T
.R
.
New LS
2
11 10
LS 3 9
New 7
6 5
4
11 75 Nm (7.5 m • kg, 54.2 ft • Ib)
T
.R
.
LS
12 8
13 New
8 Nm (0.8 m • kg, 5.38 ft • Ib)

T
.R
.

11 Bearing A/oil seal A 2/2
12 Bearing B/oil seal B 2/1
13 Bearing spacer 1
cedure.
8-45
REMOVING THE REAR SHOCK ABSORBER

1. Remove:
• rear shock absorber lower bolt
• rear shock absorber upper bolt
TIP
While removing the rear shock absorber lower
bolt, hold the swingarm so that it does not drop
down.
CHECKING THE REAR SHOCK ABSORBER

1. Check:
• shock absorber
Oil leaks → Replace the rear shock absorber
assembly.
• shock absorber rod
Bends/damage → Replace the rear shock
absorber assembly.
• spring
Fatigue → Replace the rear shock absorber
assembly.
Move the spring up and down.
REMOVING THE SWINGARM

1. Check:
B • swingarm free play
A
a. Check the tightening torque of the pivot
shaft bolt (R) and nut (L).
75 Nm (7.5 m · kg, 54.2 ft · lb)
T.
R.
Swingarm free play limit

(at the end of the swingarm)
1.0 mm (0.04 in)
b. Check the swingarm side play A by mov-

ing it from side to side.
If side play is noticeable, check the spacer,
bearings and frame pivot.
8-46
c. Check the swingarm vertical movement

by moving it up and down.
If vertical movement is tight or rough, or if
there is binding, check the spacer, bearings
and frame pivot.
2. Remove:
• plug
• swing arm nut
• swing ram left bolt
• swing ram right bolt
• swingarm
CHECKING THE SWINGARM

1. Check:
• swingarm
Bends/cracks/damage → Replace.
2. Check:
• oil seals
• bearings
swingarm play/ swingarm turns roughly → Re-
place.
3. Check:
• oil seal
• bearings
Wheel hub play/ wheel turns roughly → Re-
place.
8-47
CHECKING THE RUBBER BOOT

1. Check:
1 • Rubber boot 1
Damage → Replace.
2 INSTALLING THE RUBBER BOOT

1
1. Apply:
• Adhesive (for rubber)
3
(to the swingarm 1 )
2. Install:
• Rubber boot 2
TIP
Be sure to position the rubber boot so that the
3
ellipsoid 3 towards the swingarm.
8-48
ELECTRICAL COMPONENTS ELEC – +
EBS00500
ELECTRICAL
ELECTRICAL COMPONENTS
1 Indicator light 7 Indicator light 13 Headlight relay 19 Headlight
2 Main switch 8 Diode 14 Gear position switch 20 Circuit breaker (fan)
3 Rear brake switch 9 Starter relay 15 Thermo unit
4 Front brake switch 10 C.D.I. unit 16 Ignition coil
5 Handlebar switch (left) 11 Fuse box 17 Thermo switch
6 Battery 12 Shift gear control unit 18 Fan motor
4
2 3
20 7
8
19 9
10
18
11
17 12
13
15
16
14
9-1
CHECKING THE SWITCHES ELEC – +
EBS01028
CHECKING SWITCH CONTINUITY

Check each switch for continuity with the
pocket tester. If the continuity reading is incor-
rect, check the wiring connections and if nec-
essary, replace the switch.
NOTICE
Never insert the tester probes into the cou-
pler terminal slots 1 . Always insert the
probes from the opposite end of the cou-
pler, taking care not to loosen or damage
the leads.
Pocket tester
P/N. YU-03112-C, 90890-03112
TIP
• Before checking for continuity, set the pocket
tester to “0” and to the “Ω x 1” range.
• When checking for continuity, switch back
b and forth between the switch positions a few
times.
Br R R/L R
a OFF
The terminal connections for switches (e.g.,
ON
main switch, engine stop switch) are shown in
an illustration similar to the one on the left.
R/L R
The switch positions a are shown in the far
Br R
left column and the switch lead colors b are
shown in the top row in the switch illustration.
TIP
“ ” indicates a continuity of electricity
between switch terminals (i.e., a closed circuit
at the respective switch position).
The example illustration on the left shows

that:
There is continuity between brown and red/blue
and red when the switch is set to “ON”.
9-2
CHECKING THE SWITCHES ELEC – +
EBS01029
CHECKING THE SWITCHES

Check each switch for damage or wear, proper connections, and also for continuity between the
terminals. Refer to “CHECKING SWITCH CONTINUITY”.
Damage/wear → Repair or replace.
Improperly connected → Properly connect.
Incorrect continuity reading → Replace the switch.
2 3 4
R Y L Y/R Y/B Br W/B
OFF OFF OFF
LO ON PUSH
HI 1
Br Y Br R R/L R
R L W/BY/B Y/R OFF
ON
Y Br Y/R Y/B W/B
L R R R/L R/L R
W/B R Br Br R
6
G/Y
8
R/B L 7
Br/Y H
W/B G/Y
G/R
N G/Y W/B
R
W/R
1 Main switch 4 Engine stop switch 7 Gear position switch

2 Dimmer switch 5 Rear brake light switch 8 Fuse
3 Start switch 6 Front brake light switch
9-3
CHECKING THE BULBS AND BULB SOCKETS ELEC – +
EBS01030
CHECKING THE BULBS AND BULB

SOCKETS
Check each bulb and bulb socket for damage
or wear, proper connections, and also for con-
tinuity between the terminals.
Damage/wear → Repair or replace the bulb,bulb
socket or both.
Improperly connected → Properly connect.
No continuity → Repair or replace the bulb,bulb
socket or both.
TYPES OF BULBS
a The bulbs used on this scooter are shown in
b the illustration on the left.
• Bulbs a and b are used for the headlights
and usually use a bulb holder that must be
detached before removing the bulb. The
majority of these types of bulbs can be
removed from their respective socket by
turning them counterclockwise.
• Bulbs c is used for turn signal and tail/brake
lights and can be removed from the socket
by pushing and turning the bulb counterclockwise.
• Bulbs d and e are used for meter and indi-
cator lights and can be removed from their
c respective socket by carefully pulling them out.
d e
CHECKING THE CONDITION OF THE BULBS
bulbs.
1. Remove:
• bulb
WARNING
Since the headlight bulb gets extremely hot, check
flammable products and your hands away from
the bulb until it has cooled down.
NOTICE
• Be sure to hold the socket firmly when removing
the bulb. Never pull the lead, otherwise it may
be pulled out of the terminal in the coupler.
• Avoid touching the glass part of the head
light bulb to keep it free from oil, otherwise
the transparency of the glass, the life of the
bulb, and the luminous flux will be adversely
affected. If the head light bulb gets soiled, tho-
roughly clean it with a cloth moistened with
alcohol or lacquer thinner.
9-4
CHECKING THE BULBS AND BULB SOCKETS ELEC – +
2. Check:
• bulb (for continuity)
(with the pocket tester)
No continuity → Replace.
Pocket tester
P/N. YU-03112-C, 90890-03112
TIP
Before checking for continuity, set the pocket
tester to “0” and to the “Ω × 1” range.
a. Connect the positive tester probe to termi-

nal 1 and the negative tester probe to ter-
minal 2 , and check the continuity.
b. Connect the positive tester probe to termi-
nal 1 and the negative tester probe to ter-
minal 3 , and check the continuity.
c. If either of the readings indicate no continu-
ity, replace the bulb.
9-5
W/R B/W L B
G W/G G B/L
EBS00503
G B/L
Y Y Br R R Br
Y Y
L 14
Y G B
Y B G
Y Y R
W/R B
2 Y Y
3 Br
15
Y Y
L G G
B/W W/G
B
G L
CIRCUIT DIAGRAM
IGNITION SYSTEM
R R R W/G
R/L R/L R/L 38
1 5 W/B
OFF
ON
8 7 6
30A
10A
10A
10A
R R/L R/L R
R Br Br R R Y/R W/B W/BW/G
R W/B Br
11 W/B Y/R
Br R/L
9
R 12
G/Y B/W W/B W/R L
W/B
Br R G/R Br/Y R/B Y/B B
W/B L B/W
29 4 Y/R
B
10A
R B
Y/R Y/B W/B Y/R Br
G/Y 20
10 13
DL W/BY/B Y/R
17 16 19 18 B
G MOTOR
OFF OFF OFF OFF
ON ON PUSH
9-6
Y Br Br Y LO Y/B W/R G/R Br/Y R/B
B
L R R L HI
Y L Y/B W/B
27
R/B L
DL B/L B Br/Y H
DL
Y W L G/R N
30 B/L DL L W B W/B W/R R
DL
W/B W/B G/Y
21
G/Y W/B 23
Gr Br Br
Y 1 Main switch
26
B/L 22 G/L
2 C.D.I. magneto
L L
G/Y 4 Battery
G/Y
IGNITION SYSTEM
B 25
31 B/L W 5 Main fuse
G/L Br Gr
G/Y G/Y
Reverse indicator
Neutral indicator
Coolant temperature
33 6 Ignition fuse
35 36 37
W
L W L W
Y G/Y
34 9 Battery (+) lead
32 28 28
24 G G/R W/R 10 Battery (-) lead
Gr G/L G/L Gr
Br B B Br
ELEC
14 C.D.I. unit
12V 35/35W
12V 35/35W
12V 21W/5W
G G G B 15 Ignition coil
W L B
–
G W L G G/Y Y Y G/Y
G
18 Engine stop switch
B B B B B
L W L W
+
20 Shift gear control unit

IGNITION SYSTEM ELEC – +
EBS01045 EBS01032
TROUBLESHOOTING
1. Spark plug
The ignition system fails to operate (no • Check the condition of the spark plug.
spark or intermittent spark). • Check the spark plug type.
Check: • Measure the spark plug gap.
1. Spark plug Refer to “CHECKING THE SPARK PLUG”
2. Ignition spark gap in chapter 3.
3. Spark plug cap resistance Standard spark plug
4. Ignition coil resistance CR8E (NGK)
5. Main switch Spark plug gap
6. Engine stop switches 0.7 ~ 0.8 mm (0.028 ~ 0.031 in)
7. Pickup coil resistance • Is the spark plug in good condition, is it of
8. Wiring connections (of the entire ignition the correct type, and is its gap within spec-
system) ification?
TIP YES NO
• Before troubleshooting, remove the following
part(s):
1. seat Re-gap or replace
2. front fender the spark plug.
3. fuel tank
• Troubleshoot with the following special
tool(s).
Dynamic spark tester

P/N. YM-34487
Ignition checker
P/N. 90890-06754
Pocket tester
P/N. YU-03112-C, 90890-03112
9-7
EBS01034 EBS01036
2. Ignition spark gap 3. Spark plug cap resistance

• Disconnect the spark plug cap from the • Remove the spark plug cap from the spark
spark plug. plug lead.
• Connect the ignition dynamic spark tester • Connect the pocket tester (“ Ω × 1k” range)
1 as shown. to the spark plug cap as shown.
2 Spark plug cap
3 Spark plug
• Set the main switch to “ON” .
• Measure the ignition spark gap a .
• Crank the engine by pushing the starter
switch and gradually increase the spark
gap until a misfire occurs.
• Measure the spark plug cap resistance.

Spark plug cap resistance
5 kΩ at 20 °C (68 °F)
• Is the spark plug cap OK?
YES NO
Minimum ignition spark gap
6 mm (0.24 in)
Replace the spark
• Is there a spark and is the spark gap within plug cap.
specification?
NO YES
The ignition system

is OK.
9-8
EBS01038 EBS01041
4. Ignition coil resistance 5. Main switch

• Disconnect the ignition coil connectors • Check the main switch for continuity.
from theignitioncoil terminals. Refer to “CHECKING THE SWITCHES”.
• Connect the pocket tester (Ω×1) to the • Is the main switch OK?
ignition coil as shown.
YES NO
Positive tester probe →black terminal 1
Negative tester probe →green terminal 2
Replace the main
2
switch.
1 EBS01042
Ω×1
6. Engine stop switches
• Check the engine stop switches for conti-
nuity.
Refer to “CHECKING THE SWITCHES”.
• Are the engine stop switches OK?
• Measure the primary coil resistance.
YES NO
Primary coil resistance
0.19 ~ 0.23 Ω at 20 °C (68 °F)
Replace the handle-
• Connect the pocket tester(Ω×1k)to the bar switch or engine
ignition coil as shown. stop switch (frame).
Positive tester probe →spark plug lead 3
Negative tester probe→green terminal 2
• Measure the secondary coil resistance.

Secondary coil resistance
2.79~ 3.41kΩ at 20 °C (68 °F)
• Is the ignition coil OK?
YES NO
Replace the ignition

coil.
9-9
EBS01040
7. Pickup coil resistance

• Disconnect the C.D.I. magneto coupler
from the wire harness.
• Connect the pocket tester (Ω× 100) to the
pickup coil terminal as shown.
Positive tester probe →blue terminal 1

Negative tester probe →green terminal 2
Y Y L G
Y
1 2
• Measure the pickup coil resistance.

Pickup coil resistance
96 ~ 144 Ω at 20 °C (68 °F)
(between white/red and white/
blue)
• Is the pickup coil OK?
YES NO
Replace the pickup

coil/stator assembly.
EBS01047
8. Wiring
• Check the entire ignition system’s wiring.
Refer to “CIRCUIT DIAGRAM”.
• Is the ignition system’s wiring properly
connected and without defects?
YES NO
Replace the C.D.I. Properly connect or

unit. repair the ignition
system’s wiring.
9-10
W/R B/W L B
G W/G G B/L
EBS00506
G B/L
Y Y Br R R Br
Y Y
L 14
Y G B
Y B G
Y Y R
W/R B
2 Y Y
3 Br
15
Y Y
L G G
B/W W/G
B
G L
CIRCUIT DIAGRAM
R R R W/G
R/L R/L R/L 38
1 5 W/B
OFF
8 7 6
30A
ON
10A
10A
10A
R R/L R/L R
R Y/R W/B W/BW/G
R Br Br R
R W/B Br
11 W/B Y/R
Br R/L
9 R
12
G/Y B/W W/B W/R L
W/B
ELECTRIC STARTING SYSTEM

W/B L B/W
29 4 Y/R
B
10A
R B
Y/R Y/B W/B Y/R Br
G/Y 20
10 13
DL W/BY/B Y/R
17 16 18 B
G MOTOR
OFF OFF OFF
LO ON PUSH Y/B W/R G/R Br/Y R/B
Y Br Br Y B
9-11
L R R L HI
Y L Y/B W/B
27
R/B L
DL B/L B Br/Y H
DL
Y W L G/R N
W/B W/B G/Y
21
G/Y W/B 23
Gr Br Br
Y
B/L 22 G/L
L L
G/Y
G/Y
ELECTRIC STARTING SYSTEM
31 B/L W 25 1 Main switch C Starter motor

G/L Br Gr
G/Y G/Y
Reverse indicator
Neutral indicator
Coolant temperature
33 4 Battery F Start switch

W
35 36 37
L W L W 5 Main fuse H Engine stop switch
Y G/Y
34
32 28 28 6 Ignition fuse J Shift gear control unit

24 G G/R W/R
Gr G/L G/L Gr
Br B B Br
7 Signal fuse L Rear brake light switch
ELEC
12V 35/35W
12V 35/35W
12V 21W/5W
G G G
9 Battery (+) lead M Front brake light switch
B
W L B
–
G W L G G/Y Y Y G/Y
G 0 Battery (-) lead O Diode
B B B B A Wire lead Q Gear position switch
B
L W L W
+
B Starter relay
ELECTRIC STARTING SYSTEM ELEC – +
EBS00507
STARTING CIRCUIT OPERATION
1 The starting circuit on this model consists of
R A the starter motor, starter relay, engine stop
switch, rear brake switch, Shift gear control
unit, neutral switch. If the main switch is on and
the engine stop switch is in the RUN position, the
2 starter motor can be operated only if:
W/B
• The transmission is in neutral (the neutral
4
switch is closed).
Y/R
• You pull in the rear brake lever (the rear
brake switch is ON).
3 Y/R 1 Main fuse

2 Battery
5
3 Starter motor
4 Starter relay
5 Start switch
Y/B
6 Engine stop switch
7 Ignition fuse
8 Shift gear control unit
G/Y 8
9 Rear brake switch
10 Signal fuse
11 Neutral switch
G/Y A TO MAIN SWITCH
G/R W/B
B FROM MAIN SWITCH
9 9
11 6
W/B W/B
Br
10 7
B B
9-12
EBS01050 EBS01044
TROUBLESHOOTING
2. Battery
The starter motor fails to turn. • Check the condition of the battery.
Check: Refer to “CHECKING AND CHARGING
1. main fuse THE BATTERY” in chapter 3.
2. battery Minimum open-circuit voltage
3. starter motor 12.0 V or more at 20°C (68°F)
4. starter relay
5. main switch • Is the battery OK?
6. rear brake switch YES NO
7. start switch
8. engine stop switch
9. wiring connections • Clean the battery
(of the entire starting system) terminals.
• Recharge or
TIP
replace the battery.
part(s):
EBS01051
1. seat
2. front fender panel 3. Starter motor
3. fuel tank cover • Connect the positive battery terminal 1
4. side cover and starter motor lead 2 with a jumper
• Troubleshoot with the following special lead 3 .
tool(s). 3
Pocket tester 2
P/N. YU-03112-C, 90890-03112
1
EBS01043 W/B
M
1. Main fuse Y/R
• Check the main fuse for continuity.

WARNING
• Is the mainfuse OK? _
• A wire that is used as a jumper lead

YES NO must have at least the same capacity or
more as that of the battery lead, other-
wise the jumper lead may burn.
Replace the fuse.
• This check is likely to produce sparks,
therefore make sure nothing flammable
is in the vicinity.
• Does the starter motor turn?
YES NO
Repair or replace the

starter motor.
9-13
EBS01054 EBS01046
4. Starter relay 6. Rear brake switch

• Disconnect the starter relay coupler from • Check the rear brake switch for continuity.
the coupler. Refer to “CHECKING THE SWITCHES”.
• Connect the pocket tester ( Ω× 1) and bat- • Is the rear brake switch OK?
tery (12 V) to the starter relay coupler as
shown. YES NO
Positive battery terminal → white/black 1

Negative battery terminal → yellow/red 2 Replace the rear
brake switch.
Positive tester probe → red 3
Negative tester probe → red 4 EBS01057
3
7. Start switch
R
• Check the start switch for continuity.
1 Refer to “CHECKING THE SWITCHES”.
W/B • Is the start switch OK?
Y/R 2
YES NO
B
4
Replace the handle-
• Does the starter relay have continuity bar switch.
between red and black? EBS01042
YES NO 8. Engine stop switch

• Check the engine stop switch for continuity.
Replace the starter Refer to “CHECKING THE SWITCHES”.
relay. • Is the engine stop switch OK?
EBS01041 YES NO
5. Main switch
• Check the main switch for continuity. Replace the handle-
Refer to “CHECKING THE SWITCHES”. bar switch.
• Is the main switch OK? EBS01059
YES NO 9.Wiring
• Check the entire starting system’s wiring.
Replace the main Refer to “CIRCUIT DIAGRAM”.
switch. • Is the starting system’s wiring properly
YES NO
The starting system Properly connect or

circuit is OK. repair the starting
system’s wiring.
9-14
EBS01061
STARTER MOTOR
9 Nm (0.9 m • kg, 6.5 ft • Ib)
T
.R
.
1

Removing the starter motor Remove the parts in the order listed.
Exhaust pipe Refer to “ ENGINE REMOVAL ” in
chapter 4.
1 Starter motor lead 1
2 Starter motor 1
procedure.
9-15
W/R B/W L B
G W/G G B/L
EBS00516
G B/L
Y Y Br R R Br
Y Y
L 14
Y G B
Y B G
Y Y R
W/R B
2 Y Y
3 Br
15
Y Y
L G G
B/W W/G
B
G L
CIRCUIT DIAGRAM
R R R W/G
CHARGING SYSTEM
R/L R/L R/L 38

1 5 W/B
OFF
8 7 6
30A
ON
10A
10A
10A
R R/L R/L R
Br R R Y/R W/B W/BW/G
R Br
R W/B Br
11 W/B Y/R
Br R/L
9 R
12
G/Y B/W W/B W/R L
W/B
W/B L B/W
29 4 Y/R
B
10A
R B
Y/R Y/B W/B Y/R Br
G/Y 20
10 13
DL W/BY/B Y/R
17 16 18 B
G MOTOR
OFF OFF OFF
Y Br Br Y B
9-16
L R R L HI
Y L Y/B W/B
27
R/B L
DL B/L B Br/Y H
DL
Y W L G/R N
W/B W/B G/Y
21
G/Y W/B 23
Gr Br Br
Y
B/L 22 G/L
L L
G/Y
G/Y
CHARGING SYSTEM
31 B/L W 25
G/L Br Gr
G/Y G/Y
Reverse indicator
Neutral indicator
Coolant temperature
33
35 36 37
W
L W L W
Y G/Y
34 2 C.D.I. magneto
32 28 28
24 G G/R W/R 3 Rectifier/Regulator
Gr G/L G/L Gr
ELEC
Br B B Br 4 Battery
12V 35/35W
12V 35/35W
12V 21W/5W
G G G B 5 Main fuse
W L B
–
G W L G G/Y Y Y G/Y
G
9 Battery (+) lead
B B B B B
L W L W
+
10 Battery (-) lead

CHARGING SYSTEM ELEC – +
EBS01065 EBS01043
TROUBLESHOOTING
1. Main fuse
The battery is not being charged. • Check the main fuse for continuity.
Check: Refer to “CHECKING THE FUSE” in chap-
1. main fuse ter 3.
2. battery • Is the main fuse OK?
3. charging voltage NO
YES
4. charging coil resistance
5. wiring connections
(of the entire charging system) Replace the fuse.
TIP EBS01044
part(s): 2. Battery
1. seat • Check the condition of the battery.
2. front fender Refer to “CHECKING AND CHARGING
• Troubleshoot with the following special THE BATTERY” in chapter 3.
tool(s).
Minimum open-circuit voltage
12.0 V or more at 20°C (68°F)
Inductive tachometer • Is the battery OK?
P/N. YU-8036-A
Engine tachometer YES NO
P/N. 90890-03113
Pocket tester
P/N. YU-03112-C, 90890-03112 • Clean the battery
terminals.
• Recharge or
replace the battery.
9-17
CHARGING SYSTEM ELEC – +
EBS01066 EBS01100
3. Charging voltage 4. Charging coil resistance

• Connect the engine tachometer to the • Disconnect the C.D.I. magneto coupler
spark plug lead. from the wire harness.
• Connect the pocket tester (DC 20 V) to the • Connect the pocket tester (Ω×1) to the
battery as shown. charging coils.
Positive tester probe → Positive tester probe → yellow terminal
positive battery terminal Negative tester probe → yellow terminal 2
Negative tester probe →
Positive tester probe → yellow terminal
negative battery terminal
Negative tester probe → yellow terminal 3
DC20V Ω×1
1 3
Y Y
Y
2
• Start the engine and let it run at approxi- • Measure the charging coil resistance.
mately 5,000 r/min.
Charging coil resistance
• Measure the charging voltage.
0.20 ~ 0.40 Ω at 20 °C (68 °F)
Charging voltage (between yellow and yellow)
14 V at 5,000 r/min
YES NO
TIP
Make sure the battery is fully charged.
Replace the rectifier/ Replace the pickup
regulator. coil/stator assembly.
• Is the charging voltage within specifica-
tion?
NO YES
5.Wiring
• Check the entire charging system’s wiring.
The charging circuit
is OK.
• Is the charging system’s wiring properly
YES NO
Replace the rectifier/ Replace the diode

regulator. and properly con-
nect or repair the
charging system’s
wiring.
9-18
W/R B/W L B
G G B/L
EBS00518
G B/L
Y Y Br R R Br
Y Y
L 14
Y G B
Y B G
Y Y R
W/R B
2 Y Y
3 Br
15
Y Y
L G G
B/W W/G
B
G L
CIRCUIT DIAGRAM
LIGHTING SYSTEM
R R R W/G
R/L R/L R/L 38
1 5 W/B
OFF
ON
8 7 6
30A
10A
10A
10A
R R/L R/L R
Br R R Y/R W/B W/BW/G
R Br
R W/B Br
11 W/B Y/R
Br R/L
9 R
12
G/Y B/W W/B W/R L
W/B
W/B L B/W
29 4 Y/R
B
10A
R B
Y/R Y/B W/B Y/R Br
G/Y 20
10 13
DL W/BY/B Y/R
17 16 18 B
G MOTOR
OFF OFF OFF
Y Br Br Y B
9-19
L R R L HI
Y L Y/B W/B
27
R/B L
DL B/L B Br/Y H
DL
Y W L G/R N
W/B W/B G/Y
21 1 Main switch
G/Y W/B 23
Gr Br Br
Y
2 C.D.I. magneto
B/L 22 G/L
3 Rectifier/Regulator
L L
G/Y
G/Y
4 Battery
LIGHTING SYSTEM
31 B/L W 25
G/L Br Gr 5 Main fuse
G/Y G/Y
Reverse indicator
Neutral indicator
Coolant temperature
33
W
35 36 37 8 Head fuse
L W L W
Y G/Y
34
9 Battery (+) lead
32 28 28
24 G G/R W/R
Gr G/L G/L Gr
10 Battery (-) lead
ELEC
Br B B Br
12V 35/35W
12V 35/35W
17 Dimmer switch
12V 21W/5W
G G G B
W L B 21
–
G W L G G/Y Y Y G/Y
Headlight relay
G
B B B B B
24 Tail/brake light
L W L W
+
28 Head light
LIGHTING SYSTEM ELEC – +
EBS01067 EBS01100
TROUBLESHOOTING
2. Charging coil resistance
Any of the following fail to light: headl- • Disconnect the C.D.I. magneto coupler
ight, tail/brake light. from the wire harness.
• Connect the pocket tester (Ω×1) to the
Check: charging coils.
1. light switch Positive tester probe → yellow terminal
2. Stator coil resistance Negative tester probe → yellow terminal 2
Positive tester probe → yellow terminal
(of the entire charging system)
Negative tester probe → yellow terminal 3
TIP
part(s): Ω×1
1. seat
2. front fender 3
1
• Troubleshoot with the following special Y Y
tool(s). Y
2
Pocket tester • Measure the charging coil resistance.

P/N. YU-03112-C, 90890-03112
Charging coil resistance
0.20 ~ 0.40 Ω at 20 °C (68 °F)
(between yellow and yellow)
EAS00783
YES NO
1. Light switch
• Check the light switch for continuity. Replace the rectifier/ Replace the pickup
regulator. coil/stator assembly.
• Is the light switch OK?
YES NO
Replace the handle-

bar switch.
9-20
EBS01069
3. Wiring 2. Voltage
• Check the entire lighting system’s wiring. • Connect the pocket tester (AC 20 V) to the
Refer to “CIRCUIT DIAGRAM”. headlight couplers as shown.
• Is the lighting system’s wiring properly con- When the light switch is set to “LO”
nected and without defects? When the light switch is set to “HI”
Headlight coupler (wire harness side)
YES NO
Headlight
Positive tester probe →
Check the condition Properly connect or white 1 or yellow 2
of each of the light- repair the lighting Negative tester probe → black 3
ing system’s circuits. system’s wiring.
Refer to “CHECK-
ING THE LIGHT- 3
ING SYSTEM”. DC20V
2
EBS01070 B
CHECKING THE LIGHTING SYSTEM L W
1. The headlights fail to come on.
1
1. Headlight bulb and socket
• Check the headlight bulb and socket for
continuity. • Set the main switch to “ON”.
Refer to “CHECKING THE BULBS AND • Start the engine.
BULB SOCKETS”. • Set the light switch to “LO” or “HI”.
• Are the headlight bulb and socket OK? • Measure the voltage (AC 12 V) of white 1
or yellow 2 on the headlight coupler (wire
YES NO harness side).
• Is the voltage within specification?
Replace the head-
YES NO
light bulb, socket or
both.
This circuit is OK. Replace the rectifier/
regulator.
9-21
2. The tail/brake light fails to come on.

1. Tail/brake light bulb and bulb socket
• Check the tail/brake light bulb and socket
for continuity.
Refer to “CHECKING THE BULBS AND
BULB SOCKETS”.
• Are the tail/brake light bulb and socket OK?
YES NO
Replace the tail/brake

both.
2. Voltage
• Connect the pocket tester (AC 20 V) to the
tail/brake light coupler as shown.
Tail/brake light coupler (wire harness side)
Tail/brake light
Positive tester probe → yellow 1
Negative tester probe → black 2
G B
G/Y Y Y G/Y
• Set the main switch to “ON”.

• Start the engine.
• Measure the voltage (AC 12 V) of yellow 1
on the tail/brake light coupler (wire har-
ness side).
YES NO
This circuit is OK. Replace the rectifier/

regulator.
9-22
W/R B/W L B 1 Main switch
G W/G G B/L
EB806000
L 4 Battery
G
Y Y Br R R Br 5 B/LMain fuse
Y Y
L 14
Y G B
Y G
6B Ignition fuse
Y Y R
W/R
2 Y Y
3 Br
7 B Signal15 fuse
Y Y
L G G
9 Battery (+) lead
B/W W/G
B 10 Battery (-) lead
G L
CIRCUIT DIAGRAM
22
SIGNAL SYSTEM
Rear brake light switch

R R
23 Front brake light switch
R W/G
R/L R/L R/L 38
1 5 24W/B Tail/brake light
OFF
ON
8 7 6
30A
25 Diode
10A
10A
10A
R R/L R/L R 27
R Br Br R R Y/R W/B
Gear position switch
W/BW/G
R W/B Br 33 Thermo unit
11 W/B Y/R
Br R/L
9 R
34 Controller comp., water temp. light
12
B/W W/B W/R L
W/B 35G/Y Coolant temperature
W/B L B/W
29 4 Y/R 36 Neutral indicator

B
R B 37 Reverse indicator
Y/R Y/B W/B Y/R Br
G/Y 20
10 13
DL W/BY/B Y/R
17 16 18 B
G MOTOR
OFF OFF OFF
Y Br Br Y B
9-23
L R R L HI
Y L Y/B W/B
27
R/B L
DL B/L B Br/Y H
DL
Y W L G/R N
W/B W/B G/Y
21
G/Y W/B 23
Gr Br Br
Y
B/L 22 G/L
L L
G/Y
G/Y
SIGNAL SYSTEM
31 B/L W 25
G/L Br Gr
G/Y G/Y
Reverse indicator
Neutral indicator
Coolant temperature
33
35 36 37
W
L W L W
Y G/Y
34
32 28 28
24 G G/R W/R
Gr G/L G/L Gr
B Br
ELEC
Br B
12V 35/35W
12V 35/35W
12V 21W/5W
G G G B
W L B
–
G W L G G/Y Y Y G/Y
G
B B B B B
L W L W
+
SIGNAL SYSTEM ELEC – +
EB806010 EBS01044
TROUBLESHOOTING
2. Battery
Any of the following fail to light: indica- • Check the condition of the battery.
tor light, brake light. Refer to “CHECKING AND CHARGING
THE BATTERY” in chapter 3.
Check: Minimum open-circuit voltage
1. Fuse (main, ignition, signal) 12.0 V or more at 20°C (68°F)
2. Battery
3. Main switch • Is the battery OK?
4. wiring connections YES NO
TIP • Clean the battery

• Before troubleshooting, remove the following terminals.
part(s): • Recharge or
1. seat replace the battery.
2. fuse box
3. front fender
• Troubleshoot with the following special EBS01041
tool(s). 3. Main switch

• Check the main switch for continuity.
Pocket tester • Is the main switch OK?
P/N. YU-03112-C, 90890-03112
YES NO
Replace the main

EAS00783 switch.
1. Fuse (main, ignition, signal)
• Check the fuse for continuity.
EBS01074
• Is the fuse OK? 4.Wiring
• Check the entire signal system’s wiring.
YES NO Refer to “CIRCUIT DIAGRAM”.
• Is the signal system’s wiring properly
Replace the fuse. connected and without defects?
YES NO
Check the condition Properly connect or

of each of the signaling repair the signaling
system’s circuits. system’s wiring.
Refer to “CHECKING
THE SIGNALING
SYSTEM”.
9-24
EBS01075
CHECKING THE SIGNALING SYSTEM • Set the main switch to “ON”.

EBS01076
• Pull in the brake levers.
1. The tail/brake light fails to come on.
• M e a s u r e t h e v o l t a g e ( D C 1 2 V) of
1. Tail/brake light bulb and bulb socket green/yellow 1 on the tail/brake light coupler
• Check the tail/brake light bulb and bulb (wire harness side).
socket for continuity. • Is the voltage within specification?
BULB SOCKETS”. YES NO
• Are the tail/brake light bulb and bulb socket
OK? This circuit is OK. The wiring circuit from
the main switch to the
tail/brake light coupler
2. Brake light switches is faulty and must be
repaired.
• Check the brake light switches for continuity.
• Is the brake light switches OK?
YES NO
EBS01077
2. The neutral indicator light fails to come on.
Replace the brake 1. Neutral indicator light bulb and socket
light switch.
• Check the neutral indicator light bulb and
socket for continuity.
3. Voltage Refer to “CHECKING THE BULBS AND
• Connect the pocket tester (AC 20 V) to the BULB SOCKETS”.
tail/brake light coupler as shown. • Are the neutral indicator light bulb and socket
OK?
Tail/brake light coupler (wire harness side)
Tail/brake light YES NO
Positive tester probe → yellow 1
Negative tester probe → black 2
Replace the neutral
indicator light bulb,
2 socket or both.
G B
G/Y Y Y G/Y
2. Gear position switch

1 • Check the gear position switch for continuity.
• Is the gear position switch OK?
YES NO
Replace the gear

position switch.
9-25
3. Voltage 2. Gear position switch

• Connect the pocket tester (AC 20 V) to the • Check the gear position switch for continuity.
neutral light coupler as shown. Refer to “CHECKING THE SWITCHES”.
• Is the gear position switch OK?
Positive tester probe → brown 1
Negative tester probe → green/red 2 YES NO
Br Br
Replace the gear
1 position switch.
2
G/R G/R 3. Voltage

treverse light coupler as shown.
• Measure the voltage (DC 12 V).
• Is the voltage within specification? Positive tester probe → brown 1
Negative tester probe → white/red 2
YES NO
Br Br
This circuit is OK. The wiring circuit from 1
indicator light coupler 2
is faulty and must be W/R W/R
repaired.
• Set the gear position to “ R ”.
• Measure the voltage (DC 12 V).
3. The reverse indicator light fails to come on. • Is the voltage within specification?
1. Reversel indicator light bulb and socket
YES NO
• Check the reverse indicator light bulb and
socket for continuity.
Refer to “CHECKING THE BULBS AND This circuit is OK. The wiring circuit from
BULB SOCKETS”. the main switch to the
indicator light coupler
• Are the reverse indicator light bulb and socket is faulty and must be
OK? repaired.
YES NO
Replace the reverse

indicator light bulb,
socket or both.
9-26
EBS01076
4. The coolant temperature warning light does 2.Thermo unit

not come on when the start switch is pushed • Remove the thermo unit from the cylinder
on. head.
1. Coolant temperature warning light bulb • Connect the pocket tester (Ω × 1) to the
and socket. thermo unit 1 .
• Immerse the thermo unit in coolant 2 .
• Check the coolant temperature warning light • Place a thermometer 3 in the coolant.
bulb and socket for continuity. • Slowly heat the coolant, then let it cool
Refer to “CHECKING THE BULBS AND down to the specified temperature.
BULB SOCKETS”. • Measure the thermo unit resistance the
• Are the coolant temperature warning light temperatures indicated below.
bulb and socket OK? Test Water temperature Resistance
step Thermo unit Ω
YES NO
50 °C
1 134~149
(122 °F)
Replace the coolant Replace the coolant 80 °C
2 47~57
temperature temperature warning (176 °F)
warning light light bulb, socket or 100 °C
controller. both. 3 26~29
(212 °F)
120 °C
4 14~17
(248 °F)
5. The coolant temperature warning light does
not come on when the temperature is high Tests : Heating phase
(more than 117~123 °C (242.6 ~ 253.4 °F)).
ON
1. Coolant temperature warning light bulb
and socket.
• Check the coolant temperature warning light
bulb and socket for continuity. OFF
BULB SOCKETS”. 112 ± 3 ˚C 120 ± 3 ˚C
• Are the coolant temperature warning light (234 ± 5.5 ˚F) (248 ± 5.5 ˚F)
bulb and socket OK?
WARNING
YES NO
• Handle the thermo unit with special care.
• Never subject the thermo unit to strong
Replace the coolant shocks. If the thermo unit is dropped, rep-
temperature warning lace it.
both. Thermo unit
11 Nm (1.1 m • kg, 8.0 ft • lb)
• Does the thermo unit operate properly as

described above?
YES NO
Replace the thermo

unit.
9-27
3. Voltage
indicator light connector (wire harness
side) as shown.
Positive tester probe → gray 1
Negative tester probe → green 2
Gr Gr
G G

• Measure the voltage (12 V) of gray 1 and
green 2 at the indicator light coupler.
YES NO
The wiring circuit from

indicator light coupler
is faulty and must be
repaired.
6. Start switch
• Check the start switch for continuity.
• Is the start switch OK?
YES NO
Replace the start

switch.
9-28
W/R B/W L B
G W/G G B/L
EBS00532
G B/L
Y Y Br R R Br
Y Y
L 14
Y G B
Y B G
Y Y R
W/R B
2 Y Y
3 Br
15
Y Y
L G G
B/W W/G
B
G L
CIRCUIT DIAGRAM
COOLING SYSTEM
R R R W/G
R/L R/L R/L 38
1 OFF 5 W/B
ON 8 7 6
30A
10A
10A
10A
R R/L R/L R
R Y/R W/B W/BW/G
R Br Br R
R W/B Br
11 W/B Y/R
Br R/L
9 R
12
G/Y B/W W/B W/R L
W/B
W/B L B/W
29 4 Y/R
B
10A
R B
Y/R Y/B W/B Y/R Br
G/Y 20
10 13
DL W/BY/B Y/R
17 16 18 B
G MOTOR
OFF OFF OFF
Y Br Br Y B
9-29
L R R L HI
Y L Y/B W/B
27
R/B L
DL B/L B Br/Y H
DL
Y W L G/R N
W/B W/B G/Y
21
G/Y W/B 23
Gr Br Br
Y
B/L 22 G/L
L L
G/Y 1 Main switch
G/Y
COOLING SYSTEM
31 B/L W 25
G/L Br Gr 4 Battery
G/Y G/Y
Reverse indicator
Neutral indicator
Coolant temperature
33 5 Main fuse
35 36 37
W
L W L W
Y G/Y
34 9 Battery (+) lead
32 28 28
24 G G/R W/R 10 Battery (-) lead
Gr G/L G/L Gr
Br
ELEC
Br B B 29 Fan motor fuse
12V 35/35W
12V 35/35W
12V 21W/5W
G G G Fan motor
B 30
W L B
–
G W L G G/Y Y Y G/Y
G
31 Thermo switch
B B B B B Circuit breaker
L W L W 32
+
COOLING SYSTEM ELEC – +
EBS01085 EBS01044
TROUBLESHOOTING
2. Battery
The radiator fan motor fails to turn. • Check the condition of the battery.
Refer to “CHECKING AND CHARGING
Check: THE BATTERY” in chapter 3.
1. fuse
2. battery Minimum open-circuit voltage
3. main switch 12.0 V or more at 20°C (68°F)
4. radiator fan motor • Is the battery OK?
5. circuit breaker (fan motor)
6. thermo switch YES NO
• Clean the battery
TIP terminals.
• Before troubleshooting, remove the following • Recharge or
part(s): replace the battery.
1. seat
2. right side covers
3. front fender EBS01041
• Troubleshoot with the following special 3. Main switch

tool(s). • Check the main switch for continuity.
• Is the main switch OK?
Pocket tester
YES NO
P/N. YU-03112-C, 90890-03112
EBS01043
Replace the main
switch.
1. Fuse
• Check the fuse for continuity.
• Are the fuse OK?
YES NO
Replace the fuse.
9-30
EBS01086 EBS01088
4. Radiator fan motor 6. Thermo switch

• Disconnect the radiator fan motor coupler • Remove the thermo switch from the radi-
from the wire harness. ator.
• Connect the battery (DC 12 V) as shown. • Connect the pocket tester (Ω × 1) to the
thermo switch 1 as shown.
Positive tester probe → deep blue 1
• Immerse the thermo switch in a container
Negative tester probe → black/blue 2
filled with coolant 2.
• Place a thermometer 3 in the coolant.
2 • Slowly heat the coolant, then let it cool
1
down to the specified temperature.
B/L DL • Check the thermo switch for continuity at
the temperatures indicated below.
DL B/L
12V Coolant temperature Continu-
Test step
Thermo switch ity
• Does the radiator fan motor turn? Less than 98 ± 3°C
1 NO
(208.4 ± 5.4 °F)
YES NO
More than 98 ± 3 °C
2 YES
(208.4 ± 5.4 °F)
The radiator fan motor More than 92 ± 3 °C
is faulty and must be 3* YES
(197.6 ± 5.4 °F)
repaired.
Less than 92 ± 3 °C.
4* NO
(197.6 ± 5.4 °F)
5. Circuit breaker (fan motor)
Steps 1 & 2: Heating phase
• Remove the circuit breaker from the wire Steps 3* & 4*: Cooling phase
harness.
• Connect the pocket tester (Ω × 1) to the
circuit breaker.
Circuit breaker resistance

Zero Ω at 20 °C (68 °F)
YES NO
Replace the circuit

breaker.
9-31
WARNING
• Handle the thermo switch with special
care.
• Never subject the thermo switch to
strong shocks. If the thermo switch is
dropped, replace it.
Thermo switch
28 Nm (2.8 m · kg, 20 ft · lb)
T.
R.
A The thermo switch circuit is open and the radia-

tor fan is off.
B The thermo switch circuit is closed and the
radiator fan is on.
92 ± 3 ˚C 98± 3 ˚C
(197.6 ± 5.5 ˚F) (208.4 ± 5.5 ˚F)
• Does the thermo switch operate properly

as described above?
YES NO
Replace the thermo

switch.
EBS01090
7. Wiring
• Check the entire cooling system’s wiring.
• Is the cooling system’s wiring properly
YES NO
This circuit is OK. Properly connect or

repair the cooling
system’s wiring.
9-32
TRBL
STARTING FAILURE/HARD STARTING SHTG
EBS00537
TROUBLESHOOTING
TIP
The following troubleshooting does not cover all the possible causes of trouble. It should be helpful,
however, as a guide to troubleshooting. Refer to the relative procedure in this manual for check,
adjustment and replacement of parts.
STARTING FAILURE/HARD STARTING

FUEL SYSTEM ELECTRICAL SYSTEM
Fuel tank Spark plug
• Empty • Improper plug gap
• Clogged fuel filter • Worn electrodes
• Clogged fuel strainer • Wire between terminals broken
• Clogged fuel breather hose • Improper heat range
• Deteriorated or contaminated fuel • Faulty spark plug cap
Fuel cock Ignition coil
• Clogged fuel hose • Broken or shorted primary/secondary
Carburetor • Faulty spark plug lead
• Deteriorated or contaminated fuel • Broken body
• Clogged pilot jet C.D.I. system
• Clogged pilot air passage • Faulty C.D.I. unit
• Sucked-in air • Faulty pickup coil
• Deformed float • Faulty lighting coil
• Worn needle valve • Faulty charging coil
• Improperly sealed valve seat • Broken woodruff key
• Improperly adjusted fuel level Switches and wiring
• Improperly set pilot jet • Faulty main switch
• Clogged starter jet • Faulty engine stop switch
• Choke valve malfunction • Broken or shorted wiring
Air filter • Faulty gear position switch
• Clogged air filter element • Loose connections
• Faulty start switch
Starter motor
• Faulty starter motor
• Faulty starter relay
Battery
• Faulty battery
• Discharged battery
10-1
STARTING FAILURE/HARD STARTING/POOR IDLE SPEED TRBL
PERFORMANCE/POOR MEDIUM AND HIGH-SPEED PERFORMANCE
SHTG
COMPRESSION SYSTEM
Cylinder and cylinder head Piston and piston rings
• Loose spark plug • Improperly installed piston ring
• Loose cylinder head or cylinder • Worn, fatigued or broken piston ring
• Broken cylinder head gasket • Seized piston ring
• Broken cylinder gasket • Seized or damaged piston
• Worn, damaged or seized cylinder Crankcase and crankshaft
Valve and camshaft • Improperly seated crankcase
• Improperly sealed valve • Seized crankshaft
• Improperly contacted valve and valve seat Valve train
• Improper valve timing • Improperly adjusted valve clearance
• Broken valve spring • Improperly adjusted valve timing
• Seized camshaft
EBS00538
POOR IDLE SPEED PERFORMANCE

POOR IDLE SPEED PERFORMANCE
Carburetor Electrical system
• Improperly returned choke • Faulty battery
• Loose or clogged pilot jet • Faulty C.D.I. unit
• Loose or clogged pilot air jet • Faulty pickup coil
• Improperly adjusted idle speed • Faulty ignition coil
(throttle stop screw) Valve train
• Improper throttle cable play • Improperly adjusted valve clearance
• Flooded carburetor Air filter
Intake manifold • Clogged air filter element
• Loosen carburetor joint • Loosen air filter joint
EBS00539
POOR MEDIUM AND HIGH-SPEED PERFORMANCE

POOR MEDIUM AND HIGH-SPEED PERFORMANCE
Refer to “STARTING FAILURE/HARD STARTING” and “POOR IDLE SPEED PERFORMANCE—
Valve train”.
Carburetor Air filter
• Improper jet needle clip position • Clogged air filter element
• Improperly adjusted fuel level
• Clogged or loose main jet
• Deteriorated or contaminated fuel
10-2
FAULTY GEAR SHIFTING/CLUTCH SLIPPING/ TRBL
DRAGGING/OVERHEATING SHTG
EBS00541
FAULTY GEAR SHIFTING

HARD SHIFTING
Refer to “CLUTCH DRAGGING”.
SHIFT PEDAL DOES NOT MOVE

Shift shaft Transmission
• Bent shift shaft • Seized transmission gear
Shift drum and shift forks • Jammed impurities
• Groove jammed with impurities • Incorrectly assembled transmission
• Seized shift fork Shift guide
• Bent shift fork guide bar • Broken shift guide
JUMPS OUT GEAR

Shift shaft Shift drum
• Improperly adjusted shift lever position • Improper thrust play
• Improperly returned stopper lever • Worn shift drum groove
Shift forks Transmission
• Worn shift fork • • Worn gear dog
EAS00853
FAULTY CLUTCH
ENGINE OPERATES BUT VEHICLE WILL POOR STARTING PERFORMANCE
NOT MOVE V-belt
V-belt • V-belt slips
• Bent, damaged or worn V-belt • Oil or grease on the V-belt
• Slipping V-belt Primary sliding sheave
Primary pulley cam and primary pulley slider • Faulty operation
• Damaged or worn primary pulley cam • Worn pin groove
• Damaged or worn primary pulley slider • Worn pin
Clutch spring(s) Clutch shoes
• Damaged clutch spring • Bent, damaged or worn clutch shoe
Transmission gears
POOR SPEED PERFORMANCE
• Damaged transmission gear
V-belt
CLUTCH SLIPPING • Oil or grease on the V-belt
Clutch shoe springs Primary pulley weight(s)
• Damaged, loose or worn clutch shoe • Faulty operation
spring • Worn primary pulley weight
Clutch shoes Primary fixed sheave
• Damaged or worn clutch shoe • Worn primary fixed sheave
Primary sliding sheave Primary sliding sheave
• Seized primary sliding sheave • Worn primary sliding sheave
Secondary fixed sheave
• Seized primary sliding sheave
Secondary sliding sheave
• Worn secondary sliding sheave
10-3
OVERHEATING/FAULTY BRAKE/ TRBL
SHOCK ABSORBER MALFUNCTION SHTG
EBS00547
OVERHEATING
OVERHEATING
Ignition system Engine oil
• Improper spark plug gap • Improper oil level
• Improper spark plug heat range • Improper oil viscosity
• Faulty C.D.I. unit • Inferior oil quality
Fuel system Brake
• Improper carburetor main jet • Brake drag
(improper setting) Cooling system
• Improper fuel level • Low coolant level
• Clogged air filter element • Clogged or damaged radiator
Compression system • Damaged or faulty water pump
• Heavy carbon deposit • Faulty fan motor
• Faulty thermo switch
EBS00550
FAULTY BRAKE
POOR BRAKING EFFECT
Front drum brake
• Worn brake pads
• Worn disc
• Air in brake fluid
• Leaking brake fluid
• Faulty master cylinder kit cup
• Faulty caliper kit seal
• Loose union bolt
• Broken brake hose and pipe
• Oily or greasy disc/brake pads
• Improper brake fluid level
EBS00551
SHOCK ABSORBER MALFUNCTION

MALFUNCTION
• Bent or damaged damper rod
• Damaged oil seal lip
• Fatigued shock absorber spring
• Leaking oil or gas
10-4
UNSTABLE HANDLING/ TRBL
LIGHTING SYSTEM SHTG
EBS00552
UNSTABLE HANDLING
UNSTABLE HANDLING
Handlebar Wheels
• Improperly installed or bent • Deformed wheel
Steering • Loose bearing
• Incorrect toe-in • Bent or loose wheel axle
• Bent steering stem • Excessive wheel runout
• Improperly installed steering stem Frame
• Damaged bearing or bearing race • Bent
• Bent tie-rods • Damaged frame
• Deformed steering knuckles Swingarm
Tires • Worn bearing or bushing
• Uneven tire pressures on both sides • Bent or damaged
• Incorrect tire pressure
• Uneven tire wear
EBS00553
LIGHTING SYSTEM
HEADLIGHT DOES NOT COME ON BULB BURNT OUT
• Improper bulb • Improper bulb
• Too many electric accessories • Faulty battery
• Hard charging (broken stator coil and/or • Faulty rectifier/regulator
faulty rectifier/regulator) • Improperly grounded
• Incorrect connection • Faulty main and/or light switch
• Improperly grounded • Bulb life expired
• Poor contacts (main or light switch)
• Bulb life expired
TAIL/BRAKE LIGHT BULB BURNT OUT
• Wrong tail/brake light bulb
TAIL/BRAKE LIGHT DOES NOT LIGHT • Faulty battery
• Wrong tail/brake light bulb • Faulty rectifier/regulator
• Too many electric accessories • Improperly grounded
• Hard charging (broken stator coil and/or • Faulty main and/or light switch
faulty rectifier/regulator) • Incorrectly adjusted rear brake light switch
• Incorrect connection • Tail/brake light bulb life expired
• Improperly grounded
• Poor contacts (main or light switch)
• Burnt-out tail/brake light bulb
10-5
PRINTED IN U.S.A.
YFM30GB WIRING DIAGRAM
W/R B/W L B
G G B/L
L 1 Main switch
R
G B/L
2 C.D.I. magneto
Y Y Br R Br
Y
Y Y
G B
L 14 3 Rectifier/Regulator
Y
R
B G
4 Battery
Y Y
3
W/R B
15 5 Main fuse
2 Y Y Br
Y Y
6 Ignition fuse
L G G 7 Signal fuse
B
B/W W/G 8 Head fuse
G L
9 Battery (+) lead
10 Battery (-) lead
11 Wire lead
R R R W/G
12 Starter relay
R/L R/L R/L 38
1 5 W/B 13 Starter motor
OFF
8 7 6 C.D.I. unit
30A
ON 14
10A
10A
10A
15 Ignition coil
R R/L R/L R
R Br Br R R Y/R W/B W/BW/G 16 Start switch
R W/B Br 17 Dimmer switch
11
Br R/L
W/B Y/R 18 Engine stop switch
9
R 12 20 Shift gear control unit
G/Y B/W W/B W/R L
Br R
W/B 21 Headlight relay
W/B L B/W G/R Br/Y R/B Y/B B
22 Rear brake light switch
29 4 Y/R
B 23 Front brake light switch
10A
Y/R Y/B W/B R Y/R Br

B
24 Tail/brake light
10 13
G/Y 20 25 Diode
DL W/BY/B Y/R
17 16 18 B
27 Gear position switch
MOTOR
OFF OFF OFF
G 28 Head light
LO ON PUSH Y/B W/R G/R Br/Y R/B 29 Fan motor fuse
Y Br Br Y
L R R L HI
B
30 Fan motor
31 Thermo switch
32 Circuit breaker
Y L Y/B W/B
33 Thermo unit
27
34 Controller comp., water temp. light
R/B L 35 Coolant temperature
DL DL B/L B Br/Y H 36 Neutral indicator
Y W L G/R N 37 Reverse indicator
A.I.C.V. solenoid
W/B W/B G/Y 38
21
G/Y W/B 23
Gr Br Br
Y
B/L 22 G/L
Coolant temperature
Reverse indicator
Neutral indicator
L L
G/Y
G/Y
31 25
Color Cod
B/L W
G/L Br Gr
G/Y G/Y
33
35 36 37 B Black W White G/Y Green/Yellow
W
L W L W
34 Br Brown Y Yellow R/B Red/Black
Y G/Y
DL Deep blue B/L Black/Blue R/L Red/Blue
32 28 28
G Green B/W Black/White W/B White/Black
12V 35/35W
12V 35/35W
24 G G/R W/R
12V 21W/5W
Gr G/L G/L Gr Gr Gray Br/Y Brown/Yellow W/R White/Red

Br B B Br
L Blue G/L Green/Blue Y/B Yellow/Black
G G G B R Red G/W Green/White Y/R Yellow/Red
W L B
G W L G G/Y Y Y G/Y
G
B B B B B
L W L W

Yamaha Grizzly 300 YFM300 PDF

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Pgs. 306 0.625 Fo.

GRIZZLY 300 2012

PROTECT YOUR INVESTMENT

YAMAHA MOTOR CORPORATION, U.S.A.

This is the safety alert symbol.It is used to alert you to potential

A WARNING indicates a hazardous situation which, if not avoided,

A NOTICE indicates special precautions that must be taken to avoid

TIP A TIP provides key information to make procedures easier or clearer.

*Product and specifications are subject to change without notice.

INFO SPEC machine.

17 18 Symbols 19 to 24 in the exploded diagrams

B LS M Symbols 25 to 26 in the exploded diagrams

MACHINE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

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

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

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

ENGINE SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

CHASSIS SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

ELECTRICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

TIGHTENING TORQUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15

HOW TO USE THE CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . 2-19

GENERAL TIGHTENING TORQUE SPECIFICATIONS . . . . . . . . . . . . . 2-19

LUBRICATION POINTS AND LUBRICANT TYPES . . . . . . . . . . . . . . . . 2-20

COOLANT FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22

OIL FLOW DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24

CABLE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-25

PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL

GENERAL MAINTENANCE AND LUBRICATION CHART . . . . . . . . . . 3-2

SEAT, FENDERS AND FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52

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

VALVES AND VALVE SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -15

CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -22

C.D.I. MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 -29

STARTER CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47

CRANKCASE AND CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-50

WATER PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

REAR AXLE/FINAL DRIVE GEAR AND DRIVE SHAFT. . . . . . . . . . . . . 7-1

FRONT AND REAR WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1

FRONT AND REAR BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

STEERING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-29

FRONT ARMS AND FRONT SHOCK ABSORBER ASSEMBLIES . . . . 8-41

REAR SHOCK ABSORBER AND SWINGARM . . . . . . . . . . . . . . . . . . . 8-44

ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1

CHECKING SWITCH CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2

CHECKING THE SWITCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3

CHECKING THE BULBS AND BULB SOCKETS . . . . . . . . . . . . . . . . . . . 9-4

IGNITION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

ELECTRIC STARTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11

STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15

CHARGING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16

LIGHTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-19

SIGNAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-23

COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-29

STARTING FAILURE/HARD STARTING . . . . . . . . . . . . . . . . . . . . . . . . 10-1

POOR IDLE SPEED PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2

POOR MEDIUM AND HIGH-SPEED PERFORMANCE . . . . . . . . . . . . . 10-2

FAULTY GEAR SHIFTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3