OWNER’S SERVICE MANUAL TZ125M1/(M) LIT-11626-13-42 4JT-28199-16
EC010000 TZ125M1/(M) OWNER’S SERVICE MANUAL ©1999 by Yamaha Motor Corporation, U.S.A. 1st Edition, August 1999 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U.S.A. is expressly prohibited. Printed in Japan P/N.
EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha TZ series. This model is the culmination of Yamaha’s vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader. This manual explains operation, inspection, basic maintenance and tuning of your machine. If you have any questions about this manual or your machine, please contact your Yamaha dealer.
EC030010 WARRANTY INFORMATION This model is sold AS IS, WITHOUT ANY WARRANTIES EXPRESSED OR IMPLIED REGARDLESS OF THE INTENDED USE. THE PURCHASER OF THIS MACHINE, which is intended for competition purposes, IS RESPONSIBLE FOR ALL COSTS, SERVICE AND/OR REPAIR.
EC040001 IMPORTANT NOTICE THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding. &SAFETY INFORMATION 1. THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY. Do not attempt to operate this machine at maximum power until you are totally familiar with its characteristics. 2.
. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes. 7. ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILATION. Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are poisonous.
EC050000 TO THE NEW OWNER This manual will provide you with a good basic understanding of features, operation, and basic maintenance and inspection items of this machine. Please read this manual carefully and completely before operating your new machine. If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer.
EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION ! The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! W Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine. CCAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the machine. NOTE: A NOTE provides key information to make procedures easier or clearer.
EC083000 MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., • Bearings Pitting/Damage ≥ Replace.
1 EC085002 2 GEN INFO SPEC 3 4 INSP ADJ ENG 5 6 CHAS ELEC 7 TUN 0 ¡ ™ £ ¢ ∞ § ¶ • ª º ! Illustrated symbols 1 to 7 are designed as thumb tabs to indicate the chapter’s number and content. 1 General information 2 Specifications 3 Regular inspection and adjustments 4 Engine 5 Chassis 6 Electrical 7 Tuning Illustrated symbols 8 to ¢ are used to identify the specifications appearing in the text.
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EC090000 INDEX GENERAL INFORMATION SPECIFICATION REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL TUNING GEN INFO 1 SPEC 2 INSP ADJ 3 ENG 4 CHAS 5 ELEC 6 TUN 7
EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION. . . . . . . . . . . . . . . . . . . . . 1-1 MACHINE IDENTIFICATION . . . . . . . . . . 1-2 IMPORTANT INFOMATION . . . . . . . . . . . 1-3 CHECKING OF CONNECTION . . . . . . . . 1-5 SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . 1-6 CONTROL FUNCTIONS . . . . . . . . . . . . . 1-9 FUEL AND ENGINE MIXING OIL . . . . . . 1-14 INFORMATION BEFORE PRE-OPERATION . . . . . . . . . . . . . . . . . 1-15 STARTING AND BREAK-IN . . . . . . . . . .
CHAPTER 4 ENGINE COWLING, SEAT AND FUEL TANK . . . . 4-1 EXHAUST PIPE AND SILENCER . . . . . . 4-3 RADIATOR . . . . . . . . . . . . . . . . . . . . . . . 4-4 CARBURETOR AND REED VALVE . . . . . 4-7 CYLINDER HEAD,CYLINDER AND PISTON . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 4-27 PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 4-35 SHIFT SHAFT AND OIL PUMP . . . . . . .
DESCRIPTION GEN INFO EC100000 GENERAL INFORMATION EC110000 DESCRIPTION 1 1 Clutch lever 2 “ENGINE STOP” button 3 Water temperature gauge 4 Front brake lever 5 Throttle grip 6 Radiator cap 7 Fuel tank cap 8 Valve joint 9 Front fork 0 Radiator ¡ Check bolt (Transmission oil level) ™ Rear brake pedal £ Steering damper ¢ Fuel cock ∞ Rear shock absorber § Drive chain ¶ Shift pedal • Starter knob ª CDI magneto NOTE: • The machine you have purchased may differ slightly from those shown in the following.
MACHINE IDENTIFICATION GEN INFO EC120001 MACHINE IDENTIFICATION There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own. 2. If your machine is stolen, the authorities will need the number to search for and identify your machine.
IMPORTANT INFORMATION GEN INFO EC130000 IMPORTANT INFORMATION EC131002 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. 2. Use proper tools and cleaning equipment. Refer to “SPECIAL TOOLS” section. 3. When disassembling the machine, keep mated parts together. They include gears, cylinders, pistons, and other mated parts that have been “mated” through normal wear. Mated parts must be reused as an assembly or replaced. 4.
IMPORTANT INFORMATION GEN INFO EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.
CHECKING OF CONNECTION GEN INFO EC1C0001 CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: • Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off. 5. If the terminal comes off, bend up the pin 1 and reinsert the terminal into the connector. 6. Connect: • Connector NOTE: The two connectors “click” together. 7. Check for continuity with a tester.
SPECIAL TOOLS GEN INFO EC140001 SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order. NOTE: • For U.S.A. and Canada, use part number starting with “YM-” or “YU-”.
SPECIAL TOOLS Part number YM-33975, 90890-01403 Tool name / How to use Ring nut wrench GEN INFO Illustration YM-33975 90890-01403 YM-01425 90890-01425 YM-01434 90890-01434 YM-01437 90890-01436 This tool is used when tighten the steering ring nut to specification. YM-01425, 90890-01425 Damper rod holder Use this tool to remove and install the damper rod. YM-01434, 90890-01434 Rod holder This tool is used to hold the fork spring.
SPECIAL TOOLS Part number Tool name / How to use ACC-11001-05-01 Quick gasket® 90890-85505 YAMAHA Bond No. 1215 GEN INFO Illustration ACC-11001-05-01 90890-85505 ACC-11001-30-00 90890-05143 This sealant (Bond) is used for crankcase mating surface, etc. ACC-11001-30-00 Quick gasket® 90890-05143 YAMAHA Bond No.4 This sealant (Bond) is used for crankcase mating surface, etc.
CONTROL FUNCTIONS GEN INFO EC150000 CONTROL FUNCTIONS EC151000 “ENGINE STOP” BUTTON The “ENGINE STOP” button 1 is located on the left handlebar. Continue pushing the “ENGINE STOP” button till the engine comes to a stop. EC152000 CLUTCH LEVER The clutch lever 1 is located on the left handlebar; it disengages or engages the clutch. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch.
CONTROL FUNCTIONS GEN INFO EC157000 REAR BRAKE PEDAL The rear brake pedal 1 is located on the right side of the machine. Press down on the brake pedal to activate the rear brake. EC158001 FUEL COCK The fuel cock supplies fuel from the tank to carburetor while filtering the fuel. The fuel cock has the two positions: OFF: With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running.
CONTROL FUNCTIONS GEN INFO NOTE: • If an out-of-step indication takes place, restarting the engine brings the tachometer back to a normal indication through its corrective action. • There is no functional problem involved with the out-of-step indication, which can be brought back to a normal indication through the corrective action of the tachometer. EC15B010 WATER TEMPERATURE GAUGE The water temperature gauge 1 displays different indications according to the change in the water temperature.
CONTROL FUNCTIONS GEN INFO EC15H000 CARBURETOR COVER The carburetor cover 1 is provided for carburetor space. CCAUTION: If the machine is run without this cover, the carburetor settings will become faulty. EC15L000 LOWER COWL Make sure that the lower cowl 1 is installed before riding the machine. CCAUTION: If the machine is run without lower cowl, the carburetor settings will become faulty. EC15M001 CATCH TANK Put the tip of the breather hose into the catch tank 1 and frame 2.
CONTROL FUNCTIONS GEN INFO EC15Q001 DETACHABLE MAINSTAND This mainstand 1 is used to support only the machine when standing or transporting it. NOTE: The mainstand can be used to support the machine two ways. 1. Hook the bracket of the mainstand onto the swingarm hooks 2. 2. Stand shaft (with supplying parts): Insert the stand shaft 3 through the hole of the mainstand and rear wheel axle. Be sure to install the clip 4 in the end of the stand shaft. W • Never apply additional force to the mainstand.
FUEL AND ENGINE MIXING OIL GEN INFO EC160040 FUEL AND ENGINE MIXING OIL Mix oil with the gas at the ratio specified below. Always use fresh, name-brand gasoline, and mix the oil and gas the day of the race. Do not use premix that is more than a few hours old. Recommended fuel: Except for AUS: Premium unleaded fuel with a research octane number of 95 or higher. For AUS: Unleaded fuel only 5 NOTE: Except for AUS: 1. If knocking or pinging occurs, use a different brand of gasoline or higher octane grade.
INFORMATION BEFORE PRE-OPERATION GEN INFO EC170011 INFORMATION OPERATION BEFORE PRE- 1. The brake disc 1 is coated with a rust inhibitor. Before riding the machine, thoroughly remove it using a lacquer thinner. W • LACQUER THINNER IS HIGHLY FLAMMABLE. Always turn off the engine while using lacquer thinner. Take care not to spill any lacquer thinner on the engine or exhaust system. Never use it in the vicinity of an open flame, or while smoking. • LACQUER THINNER CAN CAUSE INJURY.
STARTING AND BREAK-IN GEN INFO EC190000 STARTING AND BREAK-IN CCAUTION: Before starting the machine, perform the checks in the pre-operation check list. W Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time. Always operate the machine in a well-ventilated area. EC191020 STARTING A COLD ENGINE 1. Turn the fuel cock to “ON” and pull the starter knob (CHOKE). 2. Shift the transmission into “1st” gear. 3.
STARTING AND BREAK-IN GEN INFO EC193021 STARTING A WARM ENGINE Do not pull the starter knob (CHOKE). Open the throttle slightly and start the engine. CCAUTION: Observe the following break-in procedure during initial operation to ensure optimum performance and avoid engine damage. EC194013 BREAK-IN PROCEDURES 1. Before starting the engine, fill the fuel tank with a break-in oil-fuel mixture as follows. 2 Mixing oil Recommended oil: Castrol A747 Mixing ratio: 30 : 1 2.
STARTING AND BREAK-IN GEN INFO CCAUTION: After the break-in or before each race, you must check the entire machine for loose fittings and fasteners as per “TORQUECHECK POINTS”. Tighten all such fasteners as required. 8. Increase the engine speed up to 10,000 r/min and run about 10 km (6 miles). 9. Increase the engine speed up to 11,000 r/min and run about 10 km (6 miles). 10.Increase the engine speed up to 12,000 r/min and run about 10 km (6 miles). Then do the plug chop.
TORQUE-CHECK POINTS GEN INFO EC1A0032 TORQUE-CHECK POINTS Frame construction Frame to rear frame Engine mounting Frame to engine Steering Steering shaft to handlebar Steering shaft to frame Steering shaft to handle crown Front fork to handlebar Suspension Front Steering shaft to front fork Front fork to handle crown Front fork to under bracket Rear For link type Assembly of links Link to frame Link to shock absorber Link to swingarm Rear Installation of shock absorber Shock absorber to fr
CLEANING AND STORAGE GEN INFO EC1B0000 CLEANING AND STORAGE EC1B1000 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many components. 1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering. A plastic bag secured with a rubber band may be used for this purpose. 2. If the engine is excessively greasy, apply some degreaser to it with a paint brush.
CLEANING AND STORAGE GEN INFO EC1B2010 STORAGE If your machine is to be stored for 60 days or more, some preventive measures must be taken to avoid deterioration. After cleaning the machine thoroughly, prepare it for storage as follows: 1. Drain the fuel tank, fuel lines, and the carburetor float chambers. 2. Remove the spark plugs, pour a tablespoon of SAE 10W30 motor oil in the spark plug hole, and reinstall the plug.
GENERAL SPECIFICATIONS SPEC EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: TZ125M1 (USA) TZ125(M) (OTHERS) Model code number: 4JT7 Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance 1,828 mm (72.0 in) 510 mm (20.1 in) 1,033 mm (40.7 in) 701 mm (27.6 in) 1,242 mm (48.9 in) 110 mm (4.3 in) Basic weight: With oil and full fuel tank 82.
GENERAL SPECIFICATIONS 2 SPEC Transmission: primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio: 1st 2nd 3rd 4th 5th 6th Spur gear 60/21 (2.857) Chain drive 36/17 (2.118) Constant mesh, 6-speed Left foot operation 30/15 (2.000) 31/19 (1.632) 24/17 (1.412) 25/20 (1.250) 24/21 (1.143) 26/24 (1.083) Chassis: Frame type Caster angle Trail Delta box 22.6˚ 85.5 mm (3.
MAINTENANCE SPECIFICATIONS SPEC EC212000 MAINTENANCE SPECIFICATIONS EC212100 ENGINE Item Cylinder head: Combustion chamber capacity Piston: Piston clearance Piston offset Piston pin: Piston pin outside diameter Piston ring: Sectional sketch End gap (installed) Side clearance (installed) Crankshaft: Crank width “A” Runout limit “C” Connecting rod big end side clearance “D” Small end free play “F” Standard Limit 9.05 cm3 (0.319 lmp oz, 0.306 US oz) ? 0.075~0.085 mm (0.0030~0.0033 in) 1.0 mm (0.
MAINTENANCE SPECIFICATIONS Item Carburetor: Type/Manufacturer I.D. mark Main jet Jet needle-clip position Main nozzle Cutaway Pilot jet Pilot air screw Valve seat size Starter jet Power jet Float arm height Standard (M.J.) (J.N.) (N.J.) (C.A.) (P.J.) (P.A.S.) (V.S.) (G.S.) (P.W.J.) (F.H.
MAINTENANCE SPECIFICATIONS Part to be tightened Spark plug Cylinder head (bolt) Cylinder (nut) (stud) Balance weight gear Water pump housing cover Radiator Radiator and thermo unit Radiator hose clamp Oil pump cover Oil pump assembly Carburetor joint Clamp (carburetor joint) Reed valve Exhaust pipe Silencer Crankcase Transmission housing Holder (crankshaft oil seal) Blind plug Oil drain bolt Oil check bolt Crankcase cover (left) Crankcase cover (right) Primary drive gear Clutch boss Clutch spring Adjuster (
MAINTENANCE SPECIFICATIONS SPEC EC212201 CHASSIS Item Steering system: Steering bearing type Front suspension: Front fork travel Fork spring free length Spring rate, STD Standard Taper roller bearing ? 100 mm (3.94 in) 195 mm (7.68 in) K=6.00 N/mm (0.600 kg/mm, 33.7 lb/in) No 282 cm3 (9.9 lmp oz, 9.5 US oz) 110 mm (4.33 in) 80~140 mm (3.15~5.51 in) ? 193 mm (7.60 in) ? Optional spring Oil capacity Oil level
MAINTENANCE SPECIFICATIONS Item Front disc brake: Disc outside dia.XThickness Pad thickness Master cylinder inside dia. Caliper cylinder inside dia. SPEC Standard Limit 298X5.0 mm (11.73X0.20 in) 5.3 mm (0.21 in) 14.0 mm (0.551 in) 33.96 + 30.23 mm (1.337 + 1.190 in) DOT #4 ? Rear disc brake: Disc outside dia.XThickness Deflection limit Pad thickness Master cylinder inside dia. Caliper cylinder inside dia. Brake fluid type 185X4.0 mm (7.28X0.16 in) ? 4.0 mm (0.16 in) 12.7 mm (0.500 in) 25.4 mm (1.
MAINTENANCE SPECIFICATIONS ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ Part to be tightened Thread size Q’ty Handle crown and outer tube Under bracket and outer tube Handle crown and steering shaft Handle bracket and outer tube Handlebar and handle bracket Steering ring nut Steering damper and frame Steering damper and damper bracket Steering damper stay and outer tube Clutch lever holder Front master cylinder and master cylinder bracket Brake lever (bolt) Brake lever (nut) Front fork and cap bolt
MAINTENANCE SPECIFICATIONS ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ ∆ Part to be tightened Thread size Q’ty Engine mounting : Engine and frame (front) Engine and frame (upper) Engine and frame (lower) Pinch bolt (engine mounting bolt) Engine mounting adjust bolt Pivot shaft and nut Pivot adjust bolt Relay arm and frame Relay arm and connecting rod Connecting rod and swingarm Rear shock absorber and upper bracket Rear shock absorber and relay arm Rear shock absorber and locknut (preload) Seat height adjuster an
MAINTENANCE SPECIFICATIONS SPEC EC212300 ELECTRICAL Item Ignition system: Ignition timing (B.T.D.C) Advancer type Standard Limit 2.3 mm (0.091 in) Electrical … … … … CDI unit-model/Manufacturer 4JT-00/DENSO 1.3~1.9 Ω at 20˚C (68˚F) (White-White) 94~140 Ω at 20˚C (68˚F) (White/Black-White/Green) 4JT-60/DENSO Ignition coil: Model/Manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance TJ0294/DENSO 5 mm (0.20 in) 0.14~0.18 Ω at 20˚C (68˚F) 5.0~7.
GENERAL TORQUE SPECIFICATIONS/ DEFINITION OF UNITS SPEC EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads.
CABLE ROUTING DIAGRAM SPEC EC240000 CABLE ROUTING DIAGRAM 1 Clamp 2 Throttle cable 3 Wireharness 4 Clutch cable 5 Front brake hose 6 Cable 7 Frame A B C D Do not cut the end of the clamp. Install the clamp with its ends facing backward. Install the clamp with its ends facing upward. Clamp only the wireharness with the clamp ends downward. (Do not clamp the high tension cord.) E Cut the clamp so that the protruding portion is less than 5 mm (0.20 in).
CABLE ROUTING DIAGRAM 1 Tachometer assembly 2 Clamp 3 CDI unit 4 Water temperature gauge lead 5 Wireharness 6 “ENGINE STOP” button 7 CDI magneto lead A B C D SPEC Install the tachometer assembly with its figures standing upright. Align the tape on the wireharness with the CDI unit mounting boss. Install the CDI magneto lead so that it is not loose. Clamp the coupler with the clamp ends facing backward on the inside of the chassis. E Clamp the wireharness at the center of the tape on it.
CABLE ROUTING DIAGRAM 1 Throttle cable 2 Clamp 3 Front brake hose 4 Clutch cable A B C D E F SPEC Clamp the water temperature lead at its coupler portion. Position the end of the clamp to the front of the front fork. Be sure the brake hose is not twisted. Do not tighten the clamp too much. Clamp the clutch cable at its adjusting portion. Install the clamp with its ends facing backward.
CABLE ROUTING DIAGRAM 1 2 3 4 Brake hose holder Reservoir hose Rear brake hose Clamp SPEC A Position the reservoir hose with the paint facing upward. B Be sure the brake hose is not twisted. C Clamp the brake hose with the end of the clamp forward. Do not cut the end of the clamp.
MAINTENANCE INTERVALS INSP ADJ EC300000 REGULAR INSPECTION AND ADJUSTMENTS EC310062 MAINTENANCE INTERVALS The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.
MAINTENANCE INTERVALS Item After Every Every Every As rebreak1,000 race 500km quired in km PLUG CAP Inspect and replace COOLING SYSTEM Check cooling level and leakage Check radiator cap operation Replace cooling water Replace hoses ∂ ∂ OIL PUMP STRAINER Clean ∂ ∂ ∂ ∂ 3 ∂ ∂ ∂ ∂ FUEL TANK, COCK Clean and inspect ∂ ∂ ∂ ∂ ∂ ∂ ∂ ∂ ∂ ∂ ∂ FRONT FORKS Inspect and adjust Replace oil Replace oil seal ∂ REAR SHOCK ABSORBER Inspect and adjust Lube Retighten ∂ ∂ ∂ ∂ Every one year ∂ Suspension
MAINTENANCE INTERVALS Item DRIVE CHAIN Lubricate, slack, alignment Replace After Every Every Every As rebreak1,000 race 500km quired in km ∂ DRIVEN SPROCKET DAMPER Inspect and retighten Replace ∂ THROTTLE, CONTROL CABLE Check routing and connection Lubricate ∂ ∂ Remarks Use chain lube Chain slack: 30~40 mm (1.2~1.
PRE-OPERATION INSPECTION AND MAINTENANCE INSP ADJ EC320010 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. NOTE: • The brake disc is coated with a rush inhibitor. Before pre-operation thoroughly remove it using a lacquer thinner. • For storage, a coolant is used. Before riding the machine remove it with cooling water.
LOCKING WIRE INSTALLATION GUIDE EC340000 LOCKING WIRE INSTALLATION GUIDE Bolt to bolt Bolt Oil filler cap and check bolt Throttle cable adjuster Oil drain bolt Tank rail drain bolt 3-5 INSP ADJ
ENGINE/COOLING WATER LEVEL INSPECTION/ COOLING WATER REPLACEMENT INSP ADJ EC350011 ENGINE CCAUTION: • The cooling system is filled with coolant at the factory to prevent rusting. Be sure to replace coolant with soft water before riding. • Take care so that coolant does not splash on painted surfaces. If it splashes, wash it away with water. EC352000 COOLING WATER LEVEL INSPECTION W Do not remove the radiator cap 1, drain bolt and hoses when the engine and radiator are hot.
RADIATOR CAP INSPECTION INSP ADJ 3. Disconnect: • Radiator hose 2 1 4. Remove: • Radiator cap Drain the cooling water completely. 5. Clean: • Cooling system Thoroughly flush the cooling system with clean tap water. 6. Connect: • Radiator hose 2 T2 Nm (0.2 mdkg, 1.4 ftdlb) 7. Fill: • Radiator • Engine To specified level. 2 Recommended cooling water: Soft water Cooling water capacity: 0.85 L (0.75 Imp qt, 0.90 US qt) CCAUTION: Hard water or salt water is harmful to the engine parts.
RADIATOR CAP OPENING PRESSURE INSPECTION/ COOLING SYSTEM INSPECTION INSP ADJ EC356001 RADIATOR CAP OPENING PRESSURE INSPECTION 1. Attach: • Radiator cap tester 1 and adapter 2 C Radiator cap tester: YU-24460-1/90890-01325 Adapter: YU-33984/90890-01352 NOTE: Apply water on the radiator cap seal. 3 Radiator cap 2. Apply the specified pressure. b Radiator cap opening pressure: 95~125 kPa (0.95~1.25 kg/cm2, 13.5~17.8 psi) 3.
CLUTCH CARE/CLUTCH ADJUSTMENT/ THROTTLE CABLE ADJUSTMENT INSP ADJ 4. Inspect: • Pressure Impossible to maintain the specified pressure for 10 seconds ≥ Repair. • Radiator 1 • Radiator hose joint 2 Coolant leakage ≥ Repair or replace. • Radiator hose 3 Swelling ≥ Replace. EC358000 CLUTCH CARE NOTE: This machine is equipped with a dry type clutch. Be sure to clean with solvent or replace if grease or oil contacts either clutch or friction plates. EC359001 CLUTCH ADJUSTMENT 1.
TRANSMISSION OIL LEVEL CHECK INSP ADJ 2. Adjust: • Throttle grip free play Throttle grip free play adjustment steps: • Loosen the locknut 1. • Turn the adjuster 2 until the specified free play is obtained. • Tighten the locknut. W After adjusting, turn the handlebar to right and left and make sure that the engine idling does not run faster. EC35H030 TRANSMISSION OIL LEVEL CHECK 1. Start the engine, warm it up for several minutes and wait for five minutes. 2.
TRANSMISSION OIL REPLACEMENT INSP ADJ EC35K012 TRANSMISSION OIL REPLACEMENT 1. Start the engine and warm it up for several minutes and wait for five minutes. 2. Place the machine on a level place and hold it on upright position by placing the suitable stand. 3. Place a suitable container under the engine. 4. Remove: • Exhaust pipe • Oil drain bolt 1 • Oil filler cap 2 Drain the transmission oil. 5. Install: • Copper washerN • Oil drain bolt 1 T23 Nm (2.
PILOT AIR SCREW ADJUSTMENT/ MUFFLER INSPECTION/SILENCER INSPECTION INSP ADJ EC35L030 PILOT AIR SCREW ADJUSTMENT 1. Adjust: •Pilot air screw 1 Adjusting steps: • Turn in the pilot air screw until it is lightly seated. • Turn out the pilot air screw by the factoryset number of turns. NOTE: To optimize the fuel flow at a smaller throttle opening, each machine’s pilot air screw has been individually set at the factory. Before adjusting the pilot air screw, turn it in fully and count the number of turns.
CHASSIS/BRAKE SYSTEM AIR BLEEDING INSP ADJ EC360000 CHASSIS EC361002 BRAKE SYSTEM AIR BLEEDING W Bleed the brake system if: • The system has been disassembled. • A brake hose has been loosened or removed. • The brake fluid is very low. • The brake operation is faulty. A dangerous loss of braking performance may occur if the brake system is not properly bleed. 1. Remove: • Reservoir tank cap • Diaphragm 2. Bleed: • Brake fluid A Front B Rear Air bleeding steps: a.
FRONT BRAKE ADJUSTMENT/ REAR BRAKE ADJUSTMENT INSP ADJ NOTE: If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared. j. Add brake fluid to the level line on the reservoir. W Check the operation of the brake after bleeding the brake system. 3. Install: • Diaphragm • Reservoir tank cap EC363010 FRONT BRAKE ADJUSTMENT 1.
INSP ADJ FRONT BRAKE PAD INSPECTION AND REPLACEMENT 2. Adjust: • Brake pedal height Pedal height adjustment steps: • Loosen the locknut 1. • Turn the adjusting nut 2 until the pedal height is within specified height. • Tighten the locknut. EC365050 FRONT BRAKE PAD INSPECTION AND REPLACEMENT 1. Inspect: • Brake pad thickness a Out of specification ≥ Replace as a set. { Brake pad thickness a: Standard 5.3 mm (0.21 in) 1.0 mm (0.04 in) 2.
REAR BRAKE PAD INSPECTION AND REPLACEMENT INSP ADJ • Install the brake pads 9, pad support 0, pad pin ¡ and cotter pin ™. NOTE: • Always use a new cotter pin. • Temporarily tighten the pad pin at this point. ™ • Install the caliper £ and tighten the pad pin ¢. Bolt (caliper): 35 Nm (3.5 m•kg, 25 ft•lb) Pad pin: 18 Nm (1.8 m•kg, 13 ft•lb) 3. Inspect: • Brake fluid level Refer to “BRAKE FLUID LEVEL INSPECTION” section. 4. Check: • Brake lever operation A softy or spongy feeling ≥ Bleed brake system.
REAR BRAKE PAD INSPECTION AND REPLACEMENT INSP ADJ • Remove the cotter pin 3, pad pin 4, pad support 5 and brake pads 6. • Connect the transparent hose 7 to the bleed screw 8 and place the suitable container under its end. • Loosen the bleed screw and push the caliper piston in. CCAUTION: U Do not reuse the drained brake fluid. • Tighten the bleed screw. Bleed screw: 6 Nm (0.6 m•kg, 4.3 ft•lb) • Install the brake pads 9, pad support 0, pad pin ¡ and cotter pin ™. NOTE: • Always use a new cotter pin.
BRAKE FLUID LEVEL INSPECTION/ SPROCKETS INSPECTION INSP ADJ EC367001 BRAKE FLUID LEVEL INSPECTION 1. Place the master cylinder so that its top is in a horizontal position. 2. Inspect: • Brake fluid level Fluid at lower level ≥ Fill up. a Lower level A Front B Rear 0 Recommended brake fluid: DOT #4 W • Use only designated quality brake fluid to avoid poor brake performance. • Refill with same type and brand of brake fluid; mixing fluids could result in poor brake performance.
DRIVE CHAIN INSPECTION INSP ADJ EC369051 DRIVE CHAIN INSPECTION 1. Remove: • Master link clip • Joint 1 • O-ring 2 • Drive chain 3 2. Clean: • Drive chain Brush off as much dirt as possible. Then clean the chain using the chain cleaner. CCAUTION: This machine has a drive chain with small rubber O-rings 1 between the chain plates. Steam cleaning, high-pressure washes, certain solvent and kerosene can damage these O-rings. 3. Inspect: • O-rings 1 (drive chain) Damage ≥ Replace drive chain.
DRIVE CHAIN SLACK ADJUSTMENT INSP ADJ 5. Check: • Drive chain stiffness a Clean and oil the chain and hold as illustrated. Stiff ≥ Replace drive chain. 6. Install: • Joint 1 • O-ring 2 • Drive chain 3 • Master link clip 4N CCAUTION: Be sure to install the master link clip to the direction as shown. a Turning direction 7. Lubricate: • Drive chain $ Drive chain lubricant: SAE 30~50W motor oil or chain lubricants suitable for “O-ring” chains EC36A042 DRIVE CHAIN SLACK ADJUSTMENT 1.
DRIVE CHAIN SLACK ADJUSTMENT INSP ADJ NOTE: Before checking and/or adjusting, rotate the rear wheel through several revolutions and check the slack several times to find the tightest point. Check and/or adjust chain slack with rear wheel in this “tight chain” position. 3. Adjust: • Drive chain slack S S Drive chain slack adjustment steps: • Loosen the axle nut 1 and locknuts 2. • Adjust chain slack by turning the adjusters 3. To tighten ≥ Turn adjuster 3 counterclockwise.
WHEEL ALIGNMENT ADJUSTMENT INSP ADJ EC36B000 WHEEL ALIGNMENT ADJUSTMENT 1. Remove: • Lower cowl 2. Place the machine on a level place and hold it up on upright position. 3. Sit 1~2 m (3.3~6.6 ft) behind the machine and look at both sides of the wheels below the rear wheel axle. 4. Turn the handlebar left and right to make the front wheel straight.
FRONT FORK INSPECTION/ FRONT FORK TOP END ADJUSTMENT INSP ADJ 6. Adjust: • Wheel alignment Turn the chain puller adjuster while paying attention to the drive chain slack and make adjustment while moving the rear wheel. NOTE: • Figure C shows that the wheel alignment has been correctly made (b = c and d = e). • After the adjustment, record the difference in the graduation between the left and right chain pullers as it will provide convenience in your future similar adjustment. 7.
FRONT FORK TOP END ADJUSTMENT INSP ADJ • Adjust the front fork top end a. ≠ Front fork top end a: Standard 18 mm (0.71 in) Extent of adjustment Zero~20 mm (Zero~0.79 in) CCAUTION: Never attempt to install the front fork beyond the maximum or minimum setting. W Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability. • Tighten the pinch bolts (handle crown and under bracket). ¶ Pinch bolt (handle crown): 15 Nm (1.
FRONT FORK SPRING PRELOAD ADJUSTMENT INSP ADJ CCAUTION: Tighten the pinch bolts to specified torque. If torqued too much, it may cause the front fork to malfunction. NOTE: • Adjust the installation angle of the steering damper stay so that the dimension d is between 3 mm (0.12 in) and 5 mm (0.20 in) when the handlebar is turned fully to the left. • Tighten the pinch bolt (steering damper stay) toward the front of the chassis. 4.
FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT INSP ADJ • STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-out position. a Standard position: 2 clicks in NOTE: • Fully turn out the adjuster and then turn it in. Specify the position in which the first click is heard as the zero position . If a click is heard just when the adjuster is fully turned out, this position is zero. • Preload is 0.5 mm (0.02 in) changed per click of the adjuster.
FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT INSP ADJ • STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. a Standard position: 8 clicks out NOTE: Fully turn in the adjuster and then turn it out. Specify the position in which the first click is heard as the zero position. If a click is heard just when the adjuster is fully turned in, this position is zero.
REAR SHOCK ABSORBER INSPECTION/ SEAT HEIGHT ADJUSTMENT INSP ADJ • STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. a Standard position: 8 clicks out NOTE: Fully turn in the adjuster and then turn it out. Specify the position in which the first click is heard as the zero position. If a click is heard just when the adjuster is fully turned in, this position is zero.
REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT INSP ADJ Seat height adjustment steps: • Remove the cap 1. • Loosen the lock bolt 2 and locknut 3. • Turn the adjuster 4 in or out. ≠ Adjuster set length a: Standard length 19 mm (0.75 in) Extent of adjustment 15~25 mm (0.59~0.98 in) NOTE: If the adjuster set length a is changed, the seat height will be increased or decreased by twice the change. CCAUTION: Never attempt to turn the adjuster beyond the maximum or minimum length.
REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT INSP ADJ ] Spring length (installed) a: Standard length 138 mm (5.43 in) Extent of adjustment 130~150 mm (5.12~5.91 in) NOTE: The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjuster. CCAUTION: Never attempt to turn the adjuster beyond the maximum or minimum setting. 4. Tighten: • Locknut T40 Nm (4.0 mdkg, 29 ftdlb) EC36N030 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1.
REAR SHOCK ABSORBER COMPRESSION DAMPING FORCE ADJUSTMENT INSP ADJ NOTE: Fully turn in the adjuster and then turn it out. Specify the position in which the first click is heard as the zero position. If a click is heard just when the adjuster is fully turned in, this position is zero. CCAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. EC36P030 REAR SHOCK ABSORBER COMPRESSION DAMPING FORCE ADJUSTMENT 1.
TIRE PRESSURE CHECK/TIRE INSPECTION/ WHEEL INSPECTION INSP ADJ CCAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. EC36Q011 TIRE PRESSURE CHECK 1. Measure: • Tire pressure Out of specification ≥ Adjust. ] Standard tire pressure: Front 180 kPa (1.8 kg/cm2, 26 psi) Rear 180 kPa (1.8 kg/cm2, 26 psi) NOTE: Check the tire while it is cold. 1Air gauge EC36R000 TIRE INSPECTION 1. Inspect: • Tire surfaces Wear/Damage ≥ Replace.
STEERING HEAD INSPECTION AND ADJUSTMENT INSP ADJ 2. Inspect: • Bearing free play Exist play ≥ Replace. EC36U060 STEERING HEAD INSPECTION AND ADJUSTMENT 1. Remove the steering damper at front fork side. 2. Elevate the front wheel by placing a suitable stand. 3. Check: • Steering stem Grasp the bottom of the forks and gently rock the fork assembly back and forth. Free play ≥ Adjust steering head. 4. Check: • Steering smooth action Turn the handlebar lock to lock.
STEERING DAMPER ADJUSTMENT INSP ADJ • Tighten the ring nut 3 using ring nut wrench 4. NOTE: Set the torque wrench to the ring nut wrench so that they form a right angle. ª Ring nut wrench: YU-33975/90890-01403 Ring nut (initial tightening): 46 Nm (4.6 m•kg, 33 ft•lb) • Loosen the ring nut one turn. • Retighten the ring nut using the ring nut wrench. U W Avoid over-tightening. Ring nut (final tightening): 1 Nm (0.1 m•kg, 0.7 ft•lb) • Check the steering shaft by turning it lock to lock.
WIRES, CABLES/ COWLING INSTALLATION INSPECTION INSP ADJ ] Extent of adjustment: Maximum Fully turned-in position Minimum Fully turned-out position • STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-out position. a Standard position: 0 click in NOTE: Fully turn out the adjuster and then turn it in. Specify the position in which the first click is heard as the zero position .
LUBRICATION INSP ADJ A Use Yamaha cable lube or equivalent on these areas. B Use SAE 10W30 motor oil or suitable chain lubricants. C Lubricate the following areas with high quality, lightweight lithium-soap base grease. EC36a023 LUBRICATION To ensure smooth operation of all components lubricate your machine during setup, after break-in, and after every race.
ELECTRICAL/SPARK PLUG INSPECTION/ IGNITION TIMING CHECK INSP ADJ EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: • Spark plug 2. Inspect: • Electrode 1 Wear/Damage ≥ Replace. • Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color ≥ Check the engine condition. NOTE: When the engine runs for many hours at low speeds, the spark plug insulator will become sooty, even if the engine and carburetor are in good operating condition. 3.
IGNITION TIMING CHECK INSP ADJ 2. Attach: • Dial gauge 1 • Dial gauge stand 2 C Dial gauge: YU-03097/90890-01252 Stand: YU-01256 3. Rotate the magneto rotor 1 until the piston reaches top dead center (TDC). When this happens, the needle on the dial gauge will stop and reverse directions even though the rotor is being turned in the same direction. 4. Set the dial gauge to zero at TDC. a 5.
COWLING, SEAT AND FUEL TANK ENG EC400000 ENGINE EC4U0000 COWLING, SEAT AND FUEL TANK T 8 Nm (0.8 mdkg, 5.8 ftdlb) 4 Extend of removal: Extend of removal 1 Cowling removal 3 Fuel tank removal Order 2 Seat removal Part name Q’ty Remarks COWLING, SEAT AND FUEL TANK REMOVAL Turn the fuel cock to “OFF”. Disconnect the fuel hose.
COWLING, SEAT AND FUEL TANK ENG EC4U3000 REMOVAL POINTS EC4U3100 Fuel tank breather hose 1. Disconnect: • Fuel tank breather hose 1 NOTE: Disconnect the fuel tank breather hose with the valve joint 2 remaining on the fuel tank side so as to prevent fuel from spurting out by the tank inner pressure.
EXHAUST PIPE AND SILENCER ENG EC4S0000 EXHAUST PIPE AND SILENCER T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 21 Nm (2.1 mdkg, 15 ftdlb) Extend of removal: Extend of removal 1 Exhaust pipe removal Order 2 Silencer removal Part name Q’ty EXHAUST PIPE AND SILENCER REMOVAL Lower cowl Preparation for removal 1 2 1 2 3 4 5 Tension spring Bolt (exhaust pipe) Exhaust pipe Bolt (silencer) Silencer Refer to “COWLING, SEAT AND FUEL TANK” section.
RADIATOR ENG EC450001 RADIATOR T 2 Nm (0.2 mdkg, 1.4 ftdlb) T 2 Nm (0.2 mdkg, 1.4 ftdlb) T 7 Nm (0.7 mdkg, 5.1 ftdlb) T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 2 Nm (0.2 mdkg, 1.4 ftdlb) T 2 Nm (0.2 mdkg, 1.4 ftdlb) Extend of removal: Extend of removal 1 Radiator removal Order Part name Q’ty RADIATOR REMOVAL Cowling and fuel tank Preparation for removal Refer to “COWLING, SEAT AND FUEL TANK” section. Refer to “COOLANT REPLACEMENT” section in the CHAPTER 3. Refer to “STEERING” section in the CHAPTER 5.
RADIATOR ENG EC456000 HANDLING NOTE W Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radiator cap by the following procedure: Place a thick rag, like a towel, over the radiator cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape.
RADIATOR ENG 2. Install: • Radiator breather hose 1 • Radiator hose 4 2 T2 Nm (0.2 mdkg, 1.4 ftdlb) • Radiator hose 2 3 T2 Nm (0.2 mdkg, 1.4 ftdlb) • Thermo unit 4 GT11 Nm (1.1 mdkg, 8.0 ftdlb) • Water temperature gauge lead 5 NOTE: • Insert the end of the radiator breather hose into the catch tank. Refer to “CONTROL FUNCTION” section in the CHAPTER 1. • Before applying LOCTITE®, wipe off dirt on the thread of the thermo unit and its receptacle on the radiator.
ENG CARBURETOR AND REED VALVE EC460000 CARBURETOR AND REED VALVE T 2 Nm (0.2 mdkg, 1.4 ftdlb) T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 1 Nm (0.1 mdkg, 0.
CARBURETOR AND REED VALVE ENG EC468000 CARBURETOR DISASSEMBLY Extend of removal: 1 Carburetor disassembly Extend of removal Order Part name Q’ty 1 1 2 3 4 5 6 7 8 9 0 ¡ ™ £ ¢ CARBURETOR DISASSEMBLY Mixing chamber top Throttle valve Needle holder Jet needle Float chamber Float pin Float Needle valve Main jet Pilot jet Starter plunger Pilot air screw Power jet Solenoid valve 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4-8 Remarks Refer to “REMOVAL POINTS”. Refer to “REMOVAL POINTS”.
CARBURETOR AND REED VALVE ENG EC463000 REMOVAL POINTS EC463110 Throttle valve 1. Remove: • Throttle valve 1 • Ring 2 • Spring (throttle valve) 3 • Mixing chamber top 4 • Throttle cable 5 NOTE: While compressing the spring (throttle valve), disconnect the throttle cable. EC463401 Pilot air screw 1. Remove: • Pilot air screw 1 NOTE: To optimize the fuel flow at a smaller throttle opening, each machine’s pilot air screw has been individually set at the factory.
CARBURETOR AND REED VALVE ENG 2. Inspect: • Main jet 1 • Pilot jet 2 • Power jet 3 Contamination ≥ Clean. NOTE: • Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air. • Never use a wire. EC464210 Needle valve 1. Inspect: • Needle valve 1 • Valve seat 2 Grooved wear a ≥ Replace. Dust b ≥ Clean. EC464301 Throttle valve 1. Check: • Free movement Stick ≥ Repair or replace. NOTE: Insert the throttle valve 1 into the carburetor body, and check for free movement.
CARBURETOR AND REED VALVE ENG Measurement and adjustment steps: • Hold the carburetor in an upside down position. • Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers. NOTE: The float arm should be resting on the needle valve, but not compressing the needle valve. • If the float height is not within specification, inspect the valve seat and needle valve. • If either is worn, replace them both.
CARBURETOR AND REED VALVE ENG EC465000 ASSEMBLY AND INSTALLATION EC465140 Reed valve 1. Install: • Reed valve 1 1 • Reed valve 2 2 • Stopper (reed valve) 3 • Screw (reed valve) 4 GT1 Nm (0.1 mdkg, 0.7 ftdlb) NOTE: • Install the reed valve with the reed valve bending as shown. • Note the cut a in the lower corner of the reed and stopper plate. CCAUTION: Tighten each screw gradually to avoid warping. 2. Install: • Gasket (reed valve assembly) 1N • Reed valve assembly 2 3.
CARBURETOR AND REED VALVE ENG 2. Install: • O-ring 1 • Solenoid valve 2 • Clamp 3 • Screw (clamp) 4 To carburetor 5. CCAUTION: • Before installing the solenoid valve, blow air on the solenoid valve and its installing location on the carburetor in order to remove any foreign particles such as chips etc. • Apply the engine oil on the solenoid valve thread. 3. Install: • Pilot air screw 1 µ Note the following installation points: • Turn in the pilot air screw until it is lightly seated.
CARBURETOR AND REED VALVE ENG 6. Install: • Needle valve 1 • Float 2 • Float pin 3 NOTE: • After installing the needle valve to the float, install them to the carburetor. • Check the float for smooth movement. 7. Install: • Float chamber 1 • Screw (float chamber) 2 8. Install: • Air vent hose 1 • Joint 2 9. Install: • Jet needle 1 • Collar 2 • Spring 3 • Needle holder 4 To throttle valve 5.
CARBURETOR AND REED VALVE ENG 10.Install: • Throttle cable 1 • Mixing chamber top 2 • Spring (throttle valve) 3 • Ring 4 • Throttle valve 5 NOTE: • While compressing the spring, connect the throttle cable. • Align the projection a on the ring with the groove b in the needle holder 6. 11. Install: • Mixing chamber top 1 • Screw (mixing chamber top) 2 To carburetor 3. NOTE: After installing, check the throttle grip for smooth movement. EC465310 Carburetor installation 1.
CARBURETOR AND REED VALVE ENG 3. Tighten: • Clamp (carburetor joint) 1 T2 Nm (0.2 mdkg, 1.4 ftdlb) 4. Connect: • Solenoid valve lead 1 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2.
CYLINDER HEAD, CYLINDER AND PISTON ENG EC470000 CYLINDER HEAD, CYLINDER AND PISTON EC478000 CYLINDER HEAD AND CYLINDER T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 19 Nm (1.9 mdkg, 13 ftdlb) T 20 Nm (2.0 mdkg, 14 ftdlb) Extend of removal: Extend of removal 1 Cylinder head removal Order 2 Cylinder removal Part name Q’ty CYLINDER HEAD AND CYLINDER REMOVAL Cowling and fuel tank Preparation for removal Refer to “COWLING, SEAT AND FUEL TANK” section. Refer to “EXHAUST PIPE AND SILENCER” section.
CYLINDER HEAD, CYLINDER AND PISTON ENG EC478200 PISTON T 15 Nm (1.5 mdkg, 11 ftdlb) Extend of removal: 1 Piston and piston ring removal Extend of removal Order 1 1 2 3 4 5 Part name Q’ty PISTON REMOVAL Piston pin clip Piston pin Piston Small end bearing Piston ring 2 1 1 1 1 4-18 Remarks Refer to “REMOVAL POINTS”.
CYLINDER HEAD, CYLINDER AND PISTON ENG EC473000 REMOVAL POINTS EC473400 Piston and piston ring 1. Remove: • Piston pin clip 1 NOTE: Before removing the piston pin clip, cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase cavity. 2. Remove: • Piston pin 1 • Piston 2 • Small end bearing 3 NOTE: Before removing the piston pin, deburr the clip groove and pin hole area.
CYLINDER HEAD, CYLINDER AND PISTON ENG 2. Inspect: • Cylinder head water jacket Crust of minerals/Rust ≥ Remove. • Cylinder head contact surface Wear/Damage ≥ Replace. • Recess of insert portion a The contact surface b of the insert portion is recessed below the aluminum portion c ≥ Replace. EC474210 Cylinder 1. Remove: • Carbon deposits Use a rounded scraper 1. NOTE: Do not use a sharp instrument. Avoid scratching the aluminum. 2. Inspect: • Cylinder inner surface Score marks ≥ Repair or replace.
CYLINDER HEAD, CYLINDER AND PISTON ENG 2. Inspect: • Travel distance for piston 500 km (300 miles) or more≥ Replace. 3. Check: • Piston ring free movement Mechanical stick ≥ Repair. Install the piston ring 1 to the piston, and check for free movement. Repairing steps: • Remove the piston ring. • Chamfer the piston ring groove at its edge a where the piston ring tends to stick, using a triangle oil stone 2 with the engine mixing oil.
CYLINDER HEAD, CYLINDER AND PISTON ENG 2. Measure: • Piston pin outside diameter Use micrometer 1. Out of limit ≥ Replace. ] Piston pin outside diameter: Standard 14.995~15.000 mm (0.5904~0.5906 in) Limit 14.975 mm (0.5896 in) 3. Check: • Free play (when the piston pin 1 is in place in the piston 2) There should be no noticeable for the play. Free play exists ≥ Replace piston pin and/or piston. 4. Install: • Small end bearing • Piston pin Into the small end of connecting rod. 5.
CYLINDER HEAD, CYLINDER AND PISTON ENG EC474520 Piston ring 1. Install: • Piston ring Into the cylinder. Push the ring with the piston crown. 2. Measure: • End gap Use a thickness gauge 1. Out of limit ≥ Replace. ] Ring end gap (installed): Standard 0.22~0.37 mm (0.009~0.015 in) 0.59 mm (0.023 in) 3. Measure: • Side clearance Use a thickness gauge 1. Out of limit ≥ Replace piston and/or ring. ] Side clearance: Standard 0.02~0.06 mm (0.0008~0.0024 in) 0.1 mm (0.
CYLINDER HEAD, CYLINDER AND PISTON ENG 2. Check: • Piston mark a Piston mark a (color) A (red) B (orange) C (green) * 3. Combination: Combine the piston and cylinder by the following chart. Cylinder mark Piston mark (color) A A(red) B B(orange) C C (green) ( NOTE: When you purchase a cylinder, you cannot designate a specific one. Choose the piston that matches the above chart. EC475000 ASSEMBLY AND INSTALLATION EC475261 Piston ring and piston 1.
CYLINDER HEAD, CYLINDER AND PISTON ENG 3. Install: • Piston 1 • Piston pin 2 • Piston pin clip 3N NOTE: • The arrow a on the piston dome must point to exhaust side. • Before installing the piston pin clip, cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase cavity. CCAUTION: Do not allow the clip open ends to meet the piston pin slot b. EC4753B1 Cylinder head and cylinder 1. Apply: • Engine oil To piston 1, piston ring 2 and cylinder inner surface. 2.
CYLINDER HEAD, CYLINDER AND PISTON ENG 4. Install: • O-ring 1N • Dowel pin 2 NOTE: Apply the lithium soap base grease on the Orings. 5. Install: • Cylinder head 1 • Copper washer 2 • Bolt (cylinder head) 3 T11 Nm (1.1 mdkg, 8.0 ftdlb) NOTE: • Apply the lithium soap base grease on the thread and contact surface of the bolt (cylinder head). • Tighten the bolts (cylinder head) in stage, using a crisscross pattern. 6. Install: • Spark plug 1 T19 Nm (1.
CLUTCH ENG EC4A0000 CLUTCH EC4A8000 CLUTCH PLATE AND FRICTION PLATE T 6 Nm (0.6 mdkg, 4.3 ftdlb) T 6 Nm (0.6 mdkg, 4.3 ftdlb) Extend of removal: Extend of removal 1 Clutch plate and friction plate removal Order Part name Q’ty CLUTCH PLATE AND FRICTION PLATE REMOVAL Lower cowl Preparation for removal Refer to “COWLING, SEAT AND FUEL TANK” section. Disconnect at engine side.
CLUTCH ENG EC4A8100 CLUTCH HOUSING AND PUSH LEVER AXLE T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 50 Nm (5.
CLUTCH ENG EC4A3000 REMOVAL POINTS EC483211 Clutch boss 1. Remove: • Nut 1 • Lock washer 2 • Clutch boss 3 NOTE: Straighten the lock washer tab and use the clutch holding tool 4, 5 to hold the clutch boss. B Clutch holding tool: 4 YM-91042 . . . . . . . . . . . . . . . .4 5 90890-04086 . . . . . . . . . . . . .5 A For USA and CDN B Except for USA and CDN EC4A4000 INSPECTION EC484100 Clutch housing and boss 1. Inspect: • Clutch housing 1 Cracks/Wear/Damage ≥ Replace.
CLUTCH ENG EC484500 Friction plate 1. Measure: • Friction plate thickness Out of specification ≥ Replace friction plate as a set. Measure at all four points. ] Friction plate thickness: Standard 2.9~3.1 mm (0.114~0.122 in) 2.7 mm (0.106 in) EC484600 Clutch plate 1. Measure: • Clutch plate warpage Out of specification ≥ Replace clutch plate as a set. Use a surface plate 1 and thickness gauge 2. a Warp limit: 0.1 mm (0.004 in) EC4A4200 Push lever axle 1.
CLUTCH ENG EC4A5000 ASSEMBLY AND INSTALLATION EC4A5101 Push lever axle 1. Install: • Seat plate 1 • Torsion spring 2 • Push lever axle 3 NOTE: , Apply the lithium soap base grease on the push lever axle, oil seal lip and bearing. 2. Install: • Bolt (seat plate) 1 T11 Nm (1.1 mdkg, 8.0 ftdlb) NOTE: Fit the seat plate 2 in the groove a of the push lever axle 3 and tighten the bolt (seat plate). EC4A5221 Clutch 1.
CLUTCH ENG 3. Install: • O-ring 1N • Spacer 2 2 To clutch housing 3. NOTE: • Apply the lithium soap base grease on the Oring and oil seal lip. • When installing the spacer 2, pay careful attention to the clutch housing oil seal lip a. 4. Install: • Clutch housing 1 • Clutch boss 2 NOTE: Install the clutch housing with the clutch boss pushed on it so that the spacer 2 will not come off. 5. Install: • Lock washer 1N • Nut (clutch boss) 2 T50 Nm (5.
CLUTCH ENG 6. Bend the lock washer 1 tab. 7. Install: • Friction plate {yellow [d=ø95 mm (3.7 in)]} 1 • Clutch plate 2 • Friction plate {brown [d=ø100mm (3.9 in)]} 3 • Cushion spring 4 • Friction plate {brown [d=ø95 mm (3.7 in)]} 5 NOTE: • Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate. • Yellow colored friction plates are used for the first and final.
CLUTCH ENG 9. Install: • Pressure plate 1 NOTE: Align the punch mark a on the pressure plate with the punch mark b on the clutch boss. 10.Install: • Clutch spring 1 • Screw (clutch spring) 2 T6 Nm (0.6 mdkg, 4.3 ftdlb) NOTE: Tighten the screws in stages, using a crisscross pattern. 11. Check: • Push lever position Push the push lever 1 forward until it stops. With the push lever in this position, the projection a of the push lever should be aligned with the mating mark b on the crankcase.
PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT ENG EC4D0002 PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT EC4D8000 PRIMARY DRIVEN GEAR T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 9 Nm (0.9 mdkg, 6.5 ftdlb) Extend of removal: Extend of removal 1 Primary driven gear removal Order Part name Q’ty PRIMARY DRIVEN GEAR REMOVAL Lower cowl Preparation for removal Refer to “COWLING, SEAT AND FUEL TANK” section. Refer to “EXHAUST PIPE AND SILENCER” section. Refer to “CLUTCH” section.
PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT ENG EC4D8100 PRIMARY DRIVE GEAR AND BALANCER SHAFT T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) T 50 Nm (5.0 mdkg, 36 ftdlb) T55 Nm (5.
PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT ENG EC4D3000 REMOVAL POINTS EC4D3101 Primary drive gear and balancer weight gear 1. Loosen: • Bolt (primary drive gear) 1 NOTE: Place an aluminum plate a between the teeth of the balancer drive gear 2 and balancer weight gear 3. 2. Loosen: • Nut (balancer weight gear) 1 NOTE: Straighten the lock washer 2 tab and place an aluminum plate a between the teeth of the balancer drive gear 3 and balancer weight gear 4. 3.
PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT ENG EC4D4000 INSPECTION EC484300 Primary drive gear and primary driven gear 1. Inspect: • Primary drive gear 1 • Primary driven gear 2 Wear/Damage ≥ Replace. EC4D4200 Balancer weight gear and balancer drive gear 1. Inspect: • Balancer weight gear 1 • Balancer drive gear 2 Wear/Damage ≥ Replace. EC4D4300 Crankcase cover (right) 1. Inspect: • Contacting surface Scratches ≥ Replace. • Crankcase cover (right) Cracks/Damage ≥ Replace.
PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT ENG 2. Install: • Gasket [crankcase cover (left)]N • Crankcase cover (left) 1 • Screw [crankcase cover (left)] 2 GT11 Nm (1.1 mdkg, 8.0 ftdlb) • Bolt [crankcase cover (left)] 3 GT11 Nm (1.1 mdkg, 8.0 ftdlb) NOTE: • Be sure to tighten in numbered order as shown. • Tighten the screw using the T30 bit. 3. Install: • Weight 1 NOTE: Align the punch mark a on the balancer shaft with the punch mark b on the weight. 4.
PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT ENG 6. Install: • Lock washer 1N • Nut (balancer weight gear) 2 • Primary drive gear 3 • Plain washer 4 • Bolt (primary drive gear) 5 7. Tighten: • Nut (balancer weight gear) 1 T50 Nm (5.0 mdkg, 36 ftdlb) NOTE: Place an aluminum plate a between the teeth of the balancer drive gear 2 and balancer weight gear 3. 8. Bend the lock washer 1 tab. 9. Tighten: • Bolt (primary drive gear) 1 T55 Nm (5.
PRIMARY DRIVEN GEAR, PRIMARY DRIVE GEAR AND BALANCER SHAFT ENG 2. Install: • Dowel pin 1 • Gasket [crankcase cover (right)] 2N • Thrust plate 3 NOTE: Install the thrust plate with its chamfered portion a toward the transmission. 3. Install: • Crankcase cover (right) 1 NOTE: Mesh the primary drive gear 2 with the primary driven gear 3, and the oil pump drive gear 4 with the oil pump driven gear 5 by turning the rotor. 4. Install: • Bolt [crankcase cover (right)] 1 T11 Nm (1.1 mdkg, 8.
SHIFT SHAFT AND OIL PUMP ENG EC4E0000 SHIFT SHAFT AND OIL PUMP EC4E8000 SHIFT SHAFT T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 22 Nm (2.2 mdkg, 16 ftdlb) T 9 Nm (0.9 mdkg, 0.9 ftdlb) T 14 Nm (1.4 mdkg, 10 ftdlb) T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 11 Nm (1.1 mdkg, 8.0 ftdlb) Extend of removal: Extend of removal 1 Shift shaft removal Order 2 Stopper lever removal Part name Q’ty SHIFT SHAFT REMOVAL Lower cowl Preparation for removal Refer to “COWLING, SEAT AND FUEL TANK” section.
SHIFT SHAFT AND OIL PUMP ENG EC4E8100 OIL PUMP T 4 Nm (0.4 mdkg, 2.9 ftdlb) T 7 Nm (0.7 mdkg, 5.
SHIFT SHAFT AND OIL PUMP ENG EC4E4000 INSPECTION EC4B4400 Shift shaft 1. Inspect: • Shift shaft 1 Bend/Damage ≥ Replace. • Spring 2 Broken ≥ Replace. EC4E4100 Stopper lever 1. Inspect: • Stopper lever 1 Wear/Damage ≥ Replace. • Bearing 2 Rotate outer race with a finger. Rough spot/Seizure ≥ Replace the stopper lever. • Torsion spring 3 Broken ≥ Replace. EC4E4200 Oil pump 1. Measure: • Tip clearance Measure the clearance between the inner rotor 1 and outer rotor 2.
SHIFT SHAFT AND OIL PUMP ENG EC4E5000 ASSEMBLY AND INSTALLATION EC4E5101 Strainer 1. Install: • Strainer 1 1 • Strainer 2 2 NOTE: • Each strainer is installed with the rounded corner a facing inward. • Strainer 1 is installed with the flange b facing downward. • Strainer 2 is installed with the mesh c facing downward. • After installing the strainers, make sure the strainer 1 and 2 are not protruding from the crankcase surface d. EC4E5202 Oil pump 1.
SHIFT SHAFT AND OIL PUMP ENG 4. Install: • Gasket (oil pump) 1N NOTE: Install the gasket in accordance with the shapes of the oil passages a. 5. Install: • Oil pump assembly 1 NOTE: • Apply the molybdenum disulfide oil on the oil pump shaft 2. • When installing the oil pump assembly, turn the oil pump shaft until its key end a is in the recess b of the impeller shaft 3. 6. Install: • Screw (oil pump assembly) 1 T7 Nm (0.7 mdkg, 5.1 ftdlb) • Shim 2 7.
SHIFT SHAFT AND OIL PUMP ENG EC4B5111 Stopper lever 1. Install: • Torsion spring 1 • Stopper lever 2 • Bolt (stopper lever) 3 GT11 Nm (1.1 mdkg, 8.0 ftdlb) NOTE: Align the stopper lever roller with the slot on segment. EC4E5310 Shift shaft 1. Install: • Shift shaft 1 NOTE: Apply the transmission oil on the shift shaft. 2. Install: • Plain washer 1 • Shift pedal 2 • Bolt (shift pedal) 3 T22 Nm (2.2 mdkg, 16 ftdlb) • Shift arm 4 • Bolt (shift arm) 5 T14 Nm (1.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG EC4H0000 TRANSMISSION, SHIFT CAM AND SHIFT FORK T 8 Nm (0.8 mdkg, 5.8 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) T 14 Nm (1.4 mdkg, 10 ftdlb) T 60 Nm (6.0 mdkg, 43 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) Extend of removal Preparation for removal Order Part name Q’ty TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVAL Lower cowl Exhaust pipe Clutch Drain the transmission oil.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG T 8 Nm (0.8 mdkg, 5.8 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) T 14 Nm (1.4 mdkg, 10 ftdlb) T 60 Nm (6.0 mdkg, 43 ftdlb) T 8 Nm (0.8 mdkg, 5.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG EC4H3000 REMOVAL POINTS EC4F3100 Drive sprocket 1. Remove: • Nut (drive sprocket) 1 • Lock washer 2 NOTE: • Straighten the lock washer tab. • Loosen the nut while applying the rear brake. 2. Remove: • Drive sprocket 1 • Drive chain 2 NOTE: Remove the drive sprocket together with the drive chain. EC4H3100 Transmission housing 1.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG EC4H3300 Shift cam 1. Remove: • Bearing plate cover 1 2. Remove: • Shift cam 1 NOTE: Turn the segment 2 to the position shown in the figure so that it does not contact the transmission housing. EC4H4000 INSPECTION EC4H4100 Oil delivery pipe 1. Inspect: • Oil delivery pipe 1 • O-ring 2 Damage ≥ Replace. • Oil orifice a Clogged ≥ Blow. EC4H4210 Gears 1. Inspect: • Matching dog a • Gear teeth b Wear/Damage ≥ Replace. 2.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG EC4H4300 Shift fork groove 1. Measure: • 3rd/4th pinion gear 1 • 5th wheel gear 2 • 6th wheel gear 3 • Shift fork groove a Out of specification ≥ Replace. ] Shift fork groove a: Standard 5.05~5.18 mm (0.199~0.204 in) 5.35 mm (0.211 in) EC4H4600 Bearing 1. Inspect: • Bearing 1 Rotate inner race with a finger. Rough spot/Seizure ≥ Replace. EC4H4701 Shift fork and shift cam 1. Inspect: • Shift fork 1 Wear/Damage/Scratches ≥ Replace. 2.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG 3. Check: • Shift fork movement On its guide bar. Unsmooth operation ≥ Replace shift fork and/or guide bar. NOTE: For a malfunctioning shift fork, replace not only the shift fork itself but the two gears each adjacent to the shift fork. EC4H5000 ASSEMBLY AND INSTALLATION EC4H5100 Shift cam 1. Install: • Shift cam 1 NOTE: Turn the segment 2 to the position shown in the figure so that it does not contact the transmission housing. 2.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG 2. Install: • 2nd wheel gear (31 T) 1 • 5th wheel gear (24 T) 2 • 4th wheel gear (25 T) 3 • 3rd wheel gear (24 T) 4 • 6th wheel gear (26 T) 5 • 1st wheel gear (30 T) 6 To drive axle 7. NOTE: Apply the molybdenum disulfide oil on the gears inner circumference.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG 3. Install: • Plain washer 1 • Circlip 2N NOTE: • Be sure the circlip sharp-edged corner a is positioned opposite to the plain washer and gear b. • Be sure the circlip end c is positioned at axle spline groove d. 4. Install: • Main axle 1 • Drive axle 2 NOTE: • Apply the transmission oil on the main axle and drive axle bearings. • Install the main axle together with the drive axle into the transmission housing 3. 5.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG 7. Check: • Shift operation • Transmission operation Unsmooth operation ≥ Repair. 8. Install: • O-ring 1N To oil delivery pipe 2. NOTE: Apply the lithium soap base grease on the Orings. 9. Install: • Oil delivery pipe 1 NOTE: When installing the oil delivery pipe, fit the projection a of the oil delivery pipe into the hole b on the crankcase. 10.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG EC4F5500 Drive sprocket 1. Install: • Drive sprocket 1 • Drive chain 2 NOTE: • Install the drive sprocket with its stepped portion a facing the engine. • Install the drive sprocket together with the drive chain. 2. Install: • Lock washer 1N • Nut (drive sprocket) 2 T60 Nm (6.0 mdkg, 43 ftdlb) NOTE: Tighten the nut while applying the rear brake. 3. Bend the lock washer tab to lock the nut.
CDI MAGNETO ENG EC4L0000 CDI MAGNETO T 7 Nm (0.7 mdkg, 5.1 ftdlb) T 53 Nm (5.3 mdkg, 38 ftdlb) T 2 Nm (0.2 mdkg, 1.4 ftdlb) Extend of removal: Extend of removal 1 CDI magneto removal Order Part name Q’ty CDI MAGNETO REMOVAL Cowling and fuel tank Preparation for removal Remarks Refer to “COWLING, SEAT AND FUEL TANK” section. Disconnect the CDI magneto lead. 1 1 2 3 4 Nut (rotor) Rotor Stator Woodruff key 1 1 1 1 4-58 Use special tool. Refer to “REMOVAL POINTS”.
CDI MAGNETO ENG EC4L3000 REMOVAL POINTS EC4L3101 Rotor 1. Remove: • Nut (rotor) 1 • Plain washer 2 Use the rotor holding tool 3. A Rotor holding tool: YU-01235/90890-01235 A 2. Remove: • Rotor 1 Use the flywheel puller 2. Flywheel puller: YM-01189/90890-01189 NOTE: When installing the flywheel puller, turn it counterclockwise. EC4L4000 INSPECTION EC4L4101 CDI magneto 1. Inspect: • Rotor inner surface a • Stator outer surface b Damage ≥ Inspect the crankshaft runout and crankshaft bearing.
CDI MAGNETO ENG 2. Install: • Woodruff key 1 • Rotor 2 NOTE: • Clean the tapered portions of the crankshaft and rotor. • When installing the woodruff key, make sure that its flat surface a is in parallel with the crankshaft center line b. • When installing the rotor, align the keyway c of the rotor with the woodruff key. 3. Install: • Plain washer 1 • Nut (rotor) 2 T53 Nm (5.3 mdkg, 38 ftdlb) Use the rotor holding tool 3. A Rotor holding tool: YU-01235/90890-01235 a 4.
ENGINE REMOVAL ENG EC4M0000 ENGINE REMOVAL T 30 Nm (3.0 mdkg, 22 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) T 30 Nm (3.0 mdkg, 22 ftdlb) T 30 Nm (3.0 mdkg, 22 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) T11 Nm (1.1 mdkg, 8.0 ftdlb) Extend of removal Preparation for removal Order Part name Q’ty ENGINE REMOVAL Hold the machine by placing the suitable stand.
ENG ENGINE REMOVAL T 30 Nm (3.0 mdkg, 22 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) T 30 Nm (3.0 mdkg, 22 ftdlb) T 30 Nm (3.0 mdkg, 22 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) T11 Nm (1.1 mdkg, 8.0 ftdlb) Extend of removal: 1 Engine removal Extend of removal Order Part name Q’ty 1 1 2 3 4 5 Pinch bolt (engine mounting collar) Nut (engine mounting bolt) Engine mounting adjust bolt Engine mounting bolt Engine 2 3 2 3 1 4-62 Remarks Only loosening. Refer to “REMOVAL POINTS.
ENGINE REMOVAL ENG EC4M3000 REMOVAL POINTS EC4M3331 Engine removal 1. Loosen: • Engine mounting adjust bolt 1 NOTE: Use the adjust bolt wrench 2 to loosen the engine mounting adjust bolt. 2. Remove: • Engine mounting bolt 1 • Engine 2 NOTE: • Before removing the engine, make sure that the couplers, hoses and cables are disconnected. • Remove the engine by lowering it with a jack 3. EC4M5000 ASSEMBLY AND INSTALLATION EC4M5181 Engine installation 1.
ENGINE REMOVAL ENG 4. Install: • Nut (engine mounting bolt) (upper) 1 T30 Nm (3.0 mdkg, 22 ftdlb) • Nut (engine mounting bolt) (lower) 2 T30 Nm (3.0 mdkg, 22 ftdlb) • Nut (engine mounting bolt) (front) 3 T30 Nm (3.0 mdkg, 22 ftdlb) 5. Tighten: • Pinch bolt (engine mounting collar) 1 T11 Nm (1.1 mdkg, 8.0 ftdlb) CCAUTION: After tightening the nuts (engine mounting bolts), tighten the pinch bolts.
CRANKCASE, CRANKSHAFT AND WATER PUMP ENG EC4Q0000 CRANKCASE, CRANKSHAFT AND WATER PUMP T 16 Nm (1.6 mdkg, 11 ftdlb) T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 23 Nm (2.3 mdkg, 17 ftdlb) T 11 Nm (1.1 mdkg, 8.0 ftdlb) Extend of removal Preparation for removal Order Part name Q’ty CRANKCASE AND CRANK SHAFT REMOVAL Engine Reed valve Piston Push lever axle Rotor and stator Primary drive gear Balancer shaft Transmission 4-65 Remarks Refer to “ENGINE REMOVAL” section.
CRANKCASE, CRANKSHAFT AND WATER PUMP ENG T 16 Nm (1.6 mdkg, 11 ftdlb) T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 11 Nm (1.1 mdkg, 8.0 ftdlb) T 23 Nm (2.3 mdkg, 17 ftdlb) T 11 Nm (1.1 mdkg, 8.
CRANKCASE, CRANKSHAFT AND WATER PUMP ENG EC4Q3000 REMOVAL POINTS EC4Q3100 Crankcase 1. Remove: • Holder 1 • Blind plug 2 A 2. Remove: • Crankcase (right) 1 Use the crankcase separating tool 2. Crankcase separating tool: YU-01135-A/90890-01135 NOTE: • Fully tighten the tool holding bolts, but make sure the tool body is parallel with the case. If necessary, one screw may be backed out slightly to level tool body.
CRANKCASE, CRANKSHAFT AND WATER PUMP ENG EC4N3401 Crankshaft bearing 1. Remove: • Bearing 1 NOTE: • Remove the bearing from the crankcase by pressing its inner race as shown in A. • If the bearing is removed together with the crankshaft, remove the bearing using a general bearing puller 2 as shown in B. • Do not use the removed bearing.
CRANKCASE, CRANKSHAFT AND WATER PUMP ENG 3. Inspect: • Oil seal 1 Damage ≥ Replace. EC4N4201 Crankshaft 1. Measure: • Runout limit a • Small end free play limit b • Connecting rod big end side clearance c • Crank width d Out of specification ≥ Replace. Use the dial gauge and a thickness gauge. A Dial gauge: YU-03097/90890-01252 Runout limit Small end free play Side clearance Crank width Standard 0.03 mm (0.0012 in) 0.8~1.0 mm (0.031~0.039 in) 0.2~0.7 mm (0.008~0.028 in) 52.90~52.95 mm (2.
CRANKCASE, CRANKSHAFT AND WATER PUMP ENG EC4Q5000 ASSEMBLY AND INSTALLATION EC4Q5101 Oil seal (impeller shaft) 1. Install: • Oil seal 1N To crankcase (right). NOTE: • Install the oil seal with the “WATER SIDE” mark a on the outside. • Apply the lithium soap base grease on oil seal lip. EC4Q5201 Impeller shaft 1. Install: • Impeller shaft 1 NOTE: • Take care so that the oil seal lip is not damaged or the spring does not slip off its position.
CRANKCASE, CRANKSHAFT AND WATER PUMP ENG 4. Install: • Water pump housing cover 1 • Copper washer 2N • Bolt (water pump housing cover) 3 T11 Nm (1.1 mdkg, 8.0 ftdlb) EC4N5300 Crankshaft bearing 1. Install: • Bearing 1N To crankcase (left and right). NOTE: Install the bearing by pressing its outer race parallel. EC4Q5310 Oil seal (crankshaft) 1. Install: • Oil seal (left) 1N • Oil seal (right) 2N NOTE: • Apply the lithium soap base grease on the oil seal lip.
CRANKCASE, CRANKSHAFT AND WATER PUMP ENG NOTE: • Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other. Operate the installing tool until the crankshaft bottoms against the bearing. • Before installing the crankshaft, clean the contacting surface of crankcase. • Apply the lithium soap base grease on the oil seal lip. CCAUTION: Do not use a hammer to drive in the crankshaft. 2. Apply: • Sealant On the crankcase (right) 1.
CRANKCASE, CRANKSHAFT AND WATER PUMP ENG 4. Install: • Crankcase (left) 1 To crankcase (right). NOTE: • Fit the crankcase (left) to the crankcase (right). Tap lightly on the case with soft hammer. • When installing the crankcase, the connecting rod should be positioned at TDC (top dead center). 5. Tighten: • Bolt (crankcase) 1 T11 Nm (1.1 mdkg, 8.0 ftdlb) NOTE: Tighten the crankcase tightening bolts in stage, using a crisscross pattern. 6. Install: • Holder 1 • Bolt (holder) 2 GT16 Nm (1.
CHAS FRONT WHEEL AND REAR WHEEL EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL T 23 Nm (2.3 mdkg, 17 ftdlb) T 20 Nm (2.0 mdkg, 14 ftdlb) T 20 Nm (2.0 mdkg, 14 ftdlb) T 48 Nm (4.8 mdkg, 35 ftdlb) 5 Extend of removal: Extend of removal 1 Front wheel removal 3 Brake disc removal Order Part name Q’ty FRONT WHEEL REMOVAL Hold the machine by placing the suitable stand.
FRONT WHEEL AND REAR WHEEL CHAS EC598100 REAR WHEEL T 23 Nm (2.3 mdkg, 17 ftdlb) T 63 Nm (6.3 mdkg, 45 ftdlb) T 16 Nm (1.6 mdkg, 11 ftdlb) T 32 Nm (3.2 mdkg, 23 ftdlb) 5 T 2 Nm (0.2 mdkg, 1.4 ftdlb) Extend of removal: Extend of removal 1 Rear wheel removal 3 Brake disc removal Order Part name Q’ty REAR WHEEL REMOVAL Hold the machine by placing the suitable stand.
FRONT WHEEL AND REAR WHEEL CHAS EC593000 REMOVAL POINTS EC523101 Rear wheel 1. Remove: • Wheel 1 NOTE: Push the wheel forward and remove the drive chain 2. EC513201 Wheel bearing (if necessary) 1. Remove: • Bearing 1 NOTE: Remove the bearing using a general bearing puller 2. EC594000 INSPECTION EC514110 Wheel 1. Measure: • Wheel runout Out of limit ≥ Replace. b Wheel runout limit: Radial: 1.0 mm (0.04 in) Lateral: 0.5 mm (0.02 in) 2. Inspect: • Bearing Rotate inner race with a finger.
CHAS FRONT WHEEL AND REAR WHEEL NOTE: The bending value is shown by one half of the dial gauge reading. W Do not attempt to straighten a bent axle. EC594100 Brake disc 1. Measure: • Brake disc deflection (only rear brake disc) Use the dial gauge 1. Out of specification ≥ Inspect wheel runout. If wheel runout is in good condition, replace the brake disc. ≈ Disc deflection limit: Rear Standard – 0.15 mm (0.006 in) 2. Measure: • Brake disc thickness Use the micrometer 1.
FRONT WHEEL AND REAR WHEEL CHAS EC595000 ASSEMBLY AND INSTALLATION EC515142 Front wheel 1. Install: • Bearing (right) 1 • Spacer 2 • Bearing (left) 3 NOTE: • Apply the lithium soap base grease on the bearing when installing. • Use a socket that matches the outside diameter of the race of the bearing. • Right side of bearing shall be installed first. CCAUTION: Do not strike the inner race of the bearing. Contact should be made only with the outer race. 2.
FRONT WHEEL AND REAR WHEEL CHAS 5. Install: • Wheel axle 1 NOTE: • Apply the lithium soap base grease on the wheel axle. • Insert the wheel axle from right side. 6. Install: • Plain washer 1 • Nut (wheel axle) 2 T48 Nm (4.8 mdkg, 35 ftdlb) 7. Tighten: • Bolt (axle holder) 1 T20 Nm (2.0 mdkg, 14 ftdlb) EC525191 Rear wheel 1. Install: • Bearing (right) 1 • Spacer 2 • Bearing (left) 3 NOTE: • Apply the lithium soap base grease on the bearing when installing.
FRONT WHEEL AND REAR WHEEL CHAS 2. Install: • Brake disc 1 • Bolt (brake disc) 2 GT23 Nm (2.3 mdkg, 17 ftdlb) NOTE: Tighten the bolts in stage, using a crisscross pattern. 3. Install: • Sprocket damper 1 • Nut (sprocket damper) 2 T32 Nm (3.2 mdkg, 23 ftdlb) To driven sprocket 3. 4. Install: • Driven sprocket 1 To wheel. NOTE: Apply the lithium soap base grease on the sprocket damper. 5. Install: • Shim 1 • Clutch hub 2 • Collar 3 To wheel.
FRONT WHEEL AND REAR WHEEL CHAS 7. Install: • Drive chain 1 NOTE: Push the wheel 2 forward and install the drive chain. 8. Install: • Wheel axle 1 NOTE: • Apply the lithium soap base grease on the wheel axle. • Insert the wheel axle from left side. 9. Install: • Plain washer 1 • Nut (wheel axle) 2 NOTE: • Apply the lithium soap base grease on the wheel axle thread. • Temporarily tighten the nut (wheel axle) at this point. a 10.Adjust: • Drive chain slack a Drive chain slack: 30~40 mm (1.2~1.
FRONT BRAKE AND REAR BRAKE CHAS EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE T 5 Nm (0.5 mdkg, 3.6 ftdlb) T 1 Nm (0.1 mdkg, 0.7 ftdlb) T 6 Nm (0.6 mdkg, 4.3 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) T 30 Nm (3.0 mdkg, 22 ftdlb) T 35 Nm (3.5 mdkg, 25 ftdlb) T 18 Nm (1.8 mdkg, 13 ftdlb) T 14 Nm (1.4 mdkg, 10 ftdlb) T 26 Nm (2.6 mdkg, 19 ftdlb) T 6 Nm (0.6 mdkg, 4.
FRONT BRAKE AND REAR BRAKE CHAS EC5A8100 REAR BRAKE T 8 Nm (0.8 mdkg, 5.8 ftdlb) T 30 Nm (3.0 mdkg, 22 ftdlb) T 3 Nm (0.3 mdkg, 2.2 ftdlb) T 2 Nm (0.2 mdkg, 1.4 ftdlb) T 12 Nm (1.2 mdkg, 8.7 ftdlb) T 23 Nm (2.3 mdkg, 17 ftdlb) T 14 Nm (1.4 mdkg, 10 ftdlb) T 26 Nm (2.6 mdkg, 19 ftdlb) T 12 Nm (1.2 mdkg, 8.7 ftdlb) T 6 Nm (0.6 mdkg, 4.3 ftdlb) T 18 Nm (1.8 mdkg, 13 ftdlb) T 20 Nm (2.
FRONT BRAKE AND REAR BRAKE CHAS EC5A8200 CALIPER DISASSEMBLY A T 6 Nm (0.6 mdkg, 4.3 ftdlb) T 18 Nm (1.8 mdkg, 13 ftdlb) B T 6 Nm (0.6 mdkg, 4.3 ftdlb) T 18 Nm (1.
FRONT BRAKE AND REAR BRAKE CHAS EC5A8300 MASTER CYLINDER DISASSEMBLY A B T 2 Nm (0.2 mdkg, 1.
FRONT BRAKE AND REAR BRAKE CHAS EC536000 HANDLING NOTE W The brake components of this machine are suit for closed circuit use only. Never use on any public road. EC5A3000 REMOVAL POINTS EC5A3200 Brake fluid 1. Remove: • Reservoir tank cap 1 NOTE: Do not remove the diaphragm. A Front B Rear 2. Connect the transparent hose 2 to the bleed screw 1 and place a suitable container under its end. A Front B Rear 3.
FRONT BRAKE AND REAR BRAKE CHAS EC533301 Caliper piston 1. Remove: • Caliper piston Use compressed air and proceed carefully. W • Cover piston with rag and use extreme caution when expelling piston from cylinder. • Never attempt to pry out piston. Caliper piston removal steps: • Insert a piece of rag into the caliper to lock one caliper. • Carefully force the piston out of the caliper cylinder with compressed air. A Front B Rear EC543411 Piston seal kit 1.
FRONT BRAKE AND REAR BRAKE CHAS EC5A4000 INSPECTION EC534112 Master cylinder 1. Inspect: • Master cylinder inner surface a Wear/Scratches ≥ Replace master cylinder assembly. Stains ≥ Clean. W Use only new brake fluid. A Front B Rear 2. Inspect: • Diaphragm 1 Crack/Damage ≥ Replace. A Front B Rear 3. Inspect: • Master cylinder piston 1 • Master cylinder cup 2 Wear/Damage/Score marks ≥ Replace master cylinder kit. A Front B Rear EC534214 Caliper 1.
FRONT BRAKE AND REAR BRAKE CHAS 2. Inspect: • Caliper piston 1 Wear/Score marks ≥ Replace caliper piston assembly. W Replace the piston seals and dust seals 2 whenever a caliper is disassembled. EC534301 Brake hose 1. Inspect: • Brake hose 1 Crack/Damage ≥ Replace. EC5A5000 ASSEMBLY AND INSTALLATION W • All internal parts should be cleaned in new brake fluid only. • Internal parts should be lubricated with brake fluid when installed.
FRONT BRAKE AND REAR BRAKE CHAS 3. Install: • Caliper piston 1 NOTE: Apply the brake fluid on the piston wall. CCAUTION: • Install the piston with its shallow depressed side a facing the caliper. • Never force to insert. A Front B Rear EC535241 Front caliper 1. Install: • Brake pad 1 • Pad support 2 • Pad pin 3 • Cotter pin 4N NOTE: Temporarily tighten the pad pin at this point. 2. Install: • Caliper 1 • Bolt (caliper) 2 T35 Nm (3.5 mdkg, 25 ftdlb) 3. Tighten: • Pad pin 3 T18 Nm (1.
FRONT BRAKE AND REAR BRAKE CHAS 2. Install: • Caliper 1 • Bolt (caliper) 2 T23 Nm (2.3 mdkg, 17 ftdlb) 3. Tighten: • Pad pin 3 T18 Nm (1.8 mdkg, 13 ftdlb) EC5A5210 Master cylinder kit 1. Clean: • Master cylinder • Master cylinder kit Clean them with brake fluid. 2. Install: • Master cylinder cup (primary) 1 • Master cylinder cup (secondary) 2 To master cylinder piston 3. NOTE: Apply the brake fluid on the master cylinder cup. W After installing, cylinder cup should be installed as shown direction.
FRONT BRAKE AND REAR BRAKE CHAS 3. Install: [Front] • Spring 1 To master cylinder cup (secondary) 2. [Rear] • Spring 1 To master cylinder piston 2. NOTE: Install the spring at the smaller dia. side. W After installing, cylinder cup should be installed as shown direction. Wrong installation cause improper brake performance. A Front B Rear 4. Install: • Master cylinder kit 1 • Circlip 2 • Master cylinder boot 3 To master cylinder 4. NOTE: • Apply the brake fluid on the master cylinder kit.
FRONT BRAKE AND REAR BRAKE CHAS 2. Install: • Master cylinder 1 • Master cylinder bracket 2 • Bolt (master cylinder bracket) 3 T8 Nm (0.8 mdkg, 5.8 ftdlb) NOTE: • Install the bracket so that the arrow mark a face upward. • When installing master cylinder, align the contacting surface b of the master cylinder bracket with the punch mark c on the handlebar. 3. Install: • Brake lever 1 • Bolt (brake lever) 2 T1 Nm (0.1 mdkg, 0.7 ftdlb) • Nut (brake lever) 3 T6 Nm (0.6 mdkg, 4.
FRONT BRAKE AND REAR BRAKE CHAS 3. Install: • Brake pedal 1 • Brake pedal connecting bolt 2 • Nut (brake pedal connecting bolt) 3 T12 Nm (1.2 mdkg, 8.7 ftdlb) NOTE: After installing, check the brake pedal height. Refer to “REAR BRAKE ADJUSTMENT” section in the CHAPTER 3. EC535561 Front brake hose 1. Install: • Copper washer 1N • Brake hose 2 • Union bolt 3 T30 Nm (3.0 mdkg, 22 ftdlb) W Always use new copper washers.
FRONT BRAKE AND REAR BRAKE CHAS 4. Install: • Clamp 1 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. EC545442 Rear brake hose 1. Install: • Copper washer 1N • Brake hose 2 • Union bolt 3 T30 Nm (3.0 mdkg, 22 ftdlb) W Always use new copper washers. CCAUTION: When installing the brake hose to the master cylinder, lightly touch the brake pipe a with the projection b on the master cylinder. 2. Install: • Copper washer 1N • Adapter 2 T26 Nm (2.6 mdkg, 19 ftdlb) • Brake hose 3 T14 Nm (1.
FRONT BRAKE AND REAR BRAKE CHAS 3. Install: • Brake hose holder 1 • Bolt (brake hose holder) 2 T 8Nm (0.8 mdkg,5.8 ftdlb) 4. Install: • Brake hose 1 NOTE: Clamp the brake hose with the end of the clamp a forward. Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. EC5A5610 Brake fluid 1. Fill: • Brake fluid Until the fluid level reaches “LOWER” level line a.
FRONT BRAKE AND REAR BRAKE CHAS 2. Air bleed: • Brake system Refer to “BRAKE SYSTEM AIR BLEEDING” section in the CHAPTER 3. 3. Inspect: • Brake fluid level Fluid at lower level ≥ Fill up. Refer to “BRAKE FLUID LEVEL INSPECTION” section in the CHAPTER 3. 4.
FRONT FORK CHAS EC550000 FRONT FORK T 15 Nm (1.5 mdkg, 11 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) T 20 Nm (2.0 mdkg, 14 ftdlb) T 7 Nm (0.7 mdkg, 5.1 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) Extend of removal: Extend of removal 1 Front fork removal Order Part name Q’ty FRONT FORK REMOVAL Hold the machine by placing the suitable stand. Cowling Preparation for removal Remarks W Support the machine securely so there is no danger of it falling over.
CHAS FRONT FORK EC558000 FRONT FORK DISASSEMBLY T 23 Nm (2.3 mdkg, 17 ftdlb) T 15 Nm (1.5 mdkg, 11 ftdlb) T 40 Nm (4.0 mdkg, 29 ftdlb) Extend of removal: Extend of removal 1 2 1 Oil seal removal 2 Damper rod removal Order Part name Q’ty 1 FRONT FORK DISASSEMBLY Cap bolt 1 2 3 4 5 6 7 8 9 0 Spacer Spacer guide Fork spring Inner tube Stopper ring Oil seal Oil seal washer Bolt (damper rod) Damper rod 1 1 1 1 1 1 1 1 1 5-26 Remarks Use special tool. Refer to “REMOVAL POINTS”.
FRONT FORK CHAS EC556000 HANDLING NOTE NOTE: The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers. CCAUTION: To prevent an accidental explosion of air, the following instructions should be observed: • The front fork with a built-in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material.
FRONT FORK CHAS 3. Remove: • Cap bolt 1 NOTE: • While pressing down the spacer 3 with the fork spring compressor 2, set the rod holder 5 between the locknut 4 and spacer. • Hold the locknut and remove the cap bolt by turning the spring preload adjuster 6. C Fork spring compressor: YM-01441/90890-01441 Rod holder: YM-01434/90890-01434 EC553212 Oil seal 1. Remove: • Inner tube 1 Pull out the inner tube from the outer tube 2. 2. Remove: • Stopper ring 1 Using slotted-head screwdriver. 3.
FRONT FORK CHAS EC553321 Damper rod 1. Remove: • Locknut 1 2. Remove: • Bolt (damper rod) 1 • Damper rod 2 NOTE: A Use a damper rod holder 3 to lock the damper rod. Damper rod holder: YM-01425/90890-01425 EC554000 INSPECTION EC554100 Damper rod 1. Inspect: • Damper rod 1 Bend/Damage ≥ Replace damper rod. CCAUTION: The front fork with a built-in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material.
FRONT FORK CHAS EC554502 Inner tube 1. Inspect: • Inner tube surface a Score marks ≥ Repair or replace. Use #1,000 grit wet sandpaper. Damaged oil lock piece ≥ Replace. • Inner tube bends Out of specification ≥ Replace. Use the dial gauge 1. a Inner tube bending limit: 0.2 mm (0.008 in) NOTE: The bending value is shown by one half of the dial gauge reading. W Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube. EC554611 Outer tube 1.
FRONT FORK CHAS EC555000 ASSEMBLY AND INSTALLATION EC5551C0 Front fork assembly 1. Wash the all parts in a clear solvent. 2. Install: • Damper rod 1 To inner tube 2. CCAUTION: To install the damper rod into the inner tube, hold the inner tube aslant. If the inner tube is held vertically, the damper rod may fall into it, damaging the valve inside. 3. Install: • Copper washer 1N • Bolt (damper rod) 2 To inner tube 3. 4. Tighten: • Bolt (damper rod) 1 GT40 Nm (4.
FRONT FORK CHAS 6. Install: • Stopper ring 1 • Oil seal 2N • Oil seal washer 3 To inner tube 4. NOTE: • Apply the fork oil on the inner tube. • When installing the oil seal, use vinyl seat a with fork oil applied to protect the oil seal lip. • Install the oil seal with its manufacture’s marks or number facing the axle holder side. 7. Install: • Inner tube 1 To outer tube 2.
FRONT FORK CHAS 10.Install: • Stopper ring 1 NOTE: Fit the stopper ring correctly in the groove in the outer tube. 11. Check: • Inner tube smooth movement Tightness/Binding/Rough spots ≥ Repeat the steps 2 to 10. 12.Compress the front fork fully. 13.Fill: • Front fork oil Until outer tube top surface with recommended fork oil 1. 0 Recommended oil: Suspension oil “01” CCAUTION: • Be sure to use recommended fork oil.
FRONT FORK CHAS 15.Fill: • Front fork oil Until outer tube top surface with recommended fork oil once more. 16.After filling, pump the outer tube 1 slowly up and down (about 60 mm (2.4 in) stroke) to distribute the fork oil once more. NOTE: Be careful not to excessive full stroke. A stroke of 60 mm (2.4 in) or more will cause air to enter. In this case, repeat the steps 13 to 16. 17.
FRONT FORK CHAS 19.Install: • Fork spring 1 • Spacer guide 2 • Spacer 3 NOTE: Install the fork spring with its smaller dia. portion upward. 20.Attach: • Rod puller 1 • Rod puller attachment 2 • Fork spring compressor 3 • Rod holder 4 NOTE: • Pull up the damper rod with the rod puller and rod puller attachment. • While pressing down the spacer 5 with the fork spring compressor, set the rod holder between the locknut 6 and spacer.
FRONT FORK CHAS NOTE: Record the set position of the adjuster (the amount of turning in the adjuster to the fully turned in position) before adjusting it. CCAUTION: If the rebound damping adjuster position is out of specification, proper damping force cannot be obtained. 23.Install: • Push rod 1 • Cap bolt 2 NOTE: Turn in the cap bolt fully by holding the spring preload adjuster 4 with your hand until the rebound damping adjuster 3 hits the push rod tip. 24.
FRONT FORK CHAS 26.Install: • Cap bolt 1 To outer tube. NOTE: Temporarily tighten the cap bolt. EC555263 Installation 1. Install: • Front fork 1 • Steering damper stay 2 (left side only) • Handlebar 3 NOTE: • Temporarily tighten the pinch bolt (under bracket). • Do not tighten the pinch bolts (handle crown, steering damper stay and handle bracket) yet. 2. Tighten: • Cap bolt 1 T23 Nm (2.3 mdkg, 17 ftdlb) 3.
FRONT FORK CHAS 4. Tighten: • Pinch bolt (handle crown) 1 T15 Nm (1.5 mdkg, 11 ftdlb) • Pinch bolt (under bracket) 2 T20 Nm (2.0 mdkg, 14 ftdlb) • Pinch bolt (handle bracket) 3 T8 Nm (0.8 mdkg, 5.8 ftdlb) • Pinch bolt (steering damper stay) 4 (left side only) T7 Nm (0.7 mdkg, 5.1 ftdlb) Refer to “FRONT FORK TOP END ADJUSTMENT” in the CHAPTER 3. 5. Check: • Steering smooth action Turn the handlebar to make sure no parts are being contacted with others. Contact ≥ Repair. 6.
HANDLEBAR CHAS EC5B0000 HANDLEBAR T 8 Nm (0.8 mdkg, 5.8 ftdlb) T 5 Nm (0.5 mdkg, 3.6 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) T 8 Nm (0.8 mdkg, 5.
HANDLEBAR CHAS EC5B3000 REMOVAL POINTS EC5B3200 Grip 1. Remove: • Grip 1 NOTE: Blow in air between the handlebar or tube guide and the grip. Then remove the grip which has become loose. EC5B4000 INSPECTION EC5B4100 Handlebar 1. Inspect: • Handlebar 1 Bends/Cracks /Damage ≥ Replace. W Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar. EC5B5000 ASSEMBLY AND INSTALLATION EC5B5110 Throttle assembly 1.
HANDLEBAR CHAS 2. Install: • Throttle cable 1 To grip cap (lower) 2. NOTE: Install the throttle cable in the grip side slit a in the grip cap (lower). 3. Install: • Throttle 1 NOTE: Apply the lithium soap base grease on the throttle grip sliding surface. 4. Install: • Throttle cable 1 To tube guide 2. NOTE: • Apply the lithium soap base grease on the throttle cable end and tube guide cable widing portion. • Install the throttle cable in the grip side slit a in the tube guide. 5.
HANDLEBAR CHAS 7. Install: • Master cylinder 1 • Master cylinder bracket 2 • Bolt (master cylinder bracket) 3 T8 Nm (0.8 mdkg, 5.8 ftdlb) NOTE: • Install the bracket so that the arrow mark a faces upward. • When installing master cylinder, align the contacting surface b of the master cylinder bracket with the punch mark c on the handlebar. 8. Install: • Grip (left) 1 Apply the adhesive to the handlebar 2.
HANDLEBAR CHAS 11. Adjust: • Clutch lever free play Refer to “CLUTCH ADJUSTMENT” section in the CHAPTER 3. 12.Lock the throttle cables using a locking wire. Refer to “LOCKING WIRE INSTALLATION GUIDE” section in the CHAPTER 3.
CHAS STEERING EC560000 STEERING EC568000 HANDLE CROWN AND STEERING DAMPER T 15 Nm (1.5 mdkg, 11 ftdlb) T 80 Nm (8.0 mdkg, 58 ftdlb) T 15 Nm (1.5 mdkg, 11 ftdlb) T 18 Nm (1.8 mdkg, 13 ftdlb) T 5 Nm (0.5 mdkg, 3.6 ftdlb) Extend of removal: Extend of removal 1 Handle crown removal Order 2 Steering damper removal Part name Q’ty HANDLE CROWN AND STEERING DAMPER REMOVAL Hold the machine by placing the suitable stand.
CHAS STEERING EC568100 UNDER BRACKET t TIGHTENING STEPS: • Tighten ring nut. 46 Nm (4.6 mdkg, 33 ftdlb) • Loosen it one turn. • Retighten it. 1 Nm (0.1 mdkg, 0.7 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) T 7 Nm (0.7 mdkg, 5.1 ftdlb) T 20 Nm (2.0 mdkg, 14 ftdlb) T 20 Nm (2.
STEERING CHAS EC563000 REMOVAL POINTS EC563202 Ring nut 1. Remove: • Ring nut 1 Use the ring nut wrench 2. A Ring nut wrench: YM-33975/90890-01403 W Support the steering shaft so that it may not fall down. EC563300 Bearing (lower) 1. Remove: • Bearing (lower) 1 Use the floor chisel 2. CCAUTION: Take care not to damage the steering shaft thread. EC563400 Ball race 1. Remove: • Ball race 1 Remove the ball race using long rod 2 and the hammer. EC564000 INSPECTION EC564200 Steering shaft 1.
STEERING CHAS EC564101 Bearing and ball race 1. Wash the bearings and ball races with a solvent. 2. Inspect: • Bearing 1 • Ball race Pitting/Damage ≥ Replace bearings and ball races as a set. Install the bearing in the ball races. Spin the bearings by hand. If the bearings hang up or are not smooth in their operation in the ball races, replace bearings and ball races as a set. EC564300 Steering damper 1. Inspect: • Steering damper 1 Bend/Damage ≥ Replace. Oil leaks/Unsmooth movement ≥ Replace.
STEERING CHAS 4. Install: • Under bracket 1 NOTE: Apply the lithium soap base grease on the bearing. 5. Install: • Ring nut 1 T1 Nm (0.1 mdkg, 0.7 ftdlb) Tighten the ring nut using the ring nut wrench 2. Refer to “STEERING HEAD INSPECTION AND ADJUSTMENT” section in the CHAPTER 3. 6. Check the steering shaft by turning it lock to lock. If there is any binding, remove the steering shaft assembly and inspect the steering bearings. 7.
STEERING CHAS 8. Install: • Plain washer 1 • Steering shaft nut 2 T80 Nm (8.0 mdkg, 58 ftdlb) NOTE: Apply the lithium soap base grease on the steering shaft nut thread. 9. After tightening the nut, check the steering for smooth movement. If not, adjust the steering by loosening the ring nut little by little. 10.Install: • Steering damper bracket 1 • Pinch bolt (steering damper bracket) 2 T5 Nm (0.5 mdkg, 3.6 ftdlb) To steering damper 3.
STEERING CHAS 12.Adjust: • Front fork top end a • Handlebar position b • Steering damper stay position c (left side only) Front fork top end: 18 mm (0.71 in) Handlebar position: 20 mm (0.79 in) Steering damper stay position: Zero mm (Zero in) e Refer to “FRONT FORK TOP END ADJUSTMENT” in the CHAPTER 3. 13.Tighten: • Pinch bolt (handle crown) 1 T15 Nm (1.5 mdkg, 11 ftdlb) • Pinch bolt (under bracket) 2 T20 Nm (2.0 mdkg, 14 ftdlb) • Pinch bolt (handle bracket) 3 T8 Nm (0.8 mdkg, 5.
SWINGARM CHAS EC570000 SWINGARM T 2 Nm (0.2 mdkg, 1.4 ftdlb) T 63 Nm (6.3 mdkg, 45 ftdlb) T 5 Nm (0.5 mdkg, 3.6 ftdlb) T 34 Nm (3.4 mdkg, 24 ftdlb) T 2 Nm (0.2 mdkg, 1.4 ftdlb) T 10 Nm (1.0 mdkg, 7.2 ftdlb) T 8 Nm (0.8 mdkg, 5.8 ftdlb) T 34 Nm (3.4 mdkg, 24 ftdlb) Extend of removal: Extend of removal 1 Swingarm removal Order 2 Swingarm disassembly Part name Q’ty SWINGARM REMOVAL Hold the machine by placing the suitable stand.
SWINGARM CHAS EC573000 REMOVAL POINTS EC573152 Swingarm 1. Loosen: • Pivot shaft adjust bolt 1 NOTE: Loosen the pivot shaft adjust bolt using the pivot shaft wrench 2 and pivot shaft wrench adapter 3. C Pivot shaft wrench: YM-01455/90890-01455 Pivot shaft wrench adapter: YM-01476/90890-01476 2. Remove: • Pivot shaft 1 • Swingarm 2 EC573210 Bearing 1. Remove: • Bearing 1 Use a general bearing puller 2. EC574010 INSPECTION Wash the bearings, bushes, collars, and covers in a solvent.
SWINGARM CHAS EC574220 Relay arm 1. Inspect: • Bearing 1 • Collar 2 Free play exists/Unsmooth revolution/Rust ≥ Replace bearing and collar as a set. EC574320 Connecting rod 1. Inspect: • Connecting rod 1 Wear/Damage ≥ Replace. EC574520 Swingarm side clearance 1. Measure: • Bush length a 2. Measure: • Thrust bearing (right) thickness b • Thrust bearing (left) thickness c 3.
SWINGARM CHAS 4. Calculate: A + B” • Swingarm side clearance “A Out of specification ≥ Adjust side clearance using shim. By using formula given below. % a A + B” = a – ( b + c + d ) “A A + B”: Side clearance “A 0.05~0.35 mm (0.002~0.014 in) If the side clearance is out of specification, adjust it to specification by installing the adjust shim 1 at position, A and B. NOTE: • The adjust shim is available only in the 0.3 mm (0.012 in)-thick type.
SWINGARM CHAS 2. Install: • Bearing 1 To relay arm. NOTE: • Apply the lithium soap base grease on the bearing when installing. • Install the bearing by pressing it on the side having the manufacture’s marks or numbers. a Installed depth of bearings a: Zero mm (Zero in) EC575163 Swingarm 1. Install: • Collar 1 To relay arm 2. NOTE: Apply the lithium soap base grease on the collars and bearings. 2. Install: • Relay arm 1 • Bolt (relay arm) 2 • Nut (relay arm) 3 T34 Nm (3.
SWINGARM CHAS 4. Install: • Swingarm 1 • Pivot shaft 2 NOTE: • Apply the lithium soap base grease on the pivot shaft. • Insert the pivot shaft from left side. 5. Tighten: • Pivot adjust bolt 1 T5 Nm (0.5 mdkg, 3.6 ftdlb) NOTE: Use the pivot shaft wrench 2 and pivot shaft wrench adapter 3 to tighten the pivot adjust bolt. C Pivot shaft wrench: YM-01455/90890-01455 Pivot shaft wrench adapter: YM-01476/90890-01476 6. Install: • Plain washer 1 • Nut (pivot shaft) 2 T63 Nm (6.3 mdkg, 45 ftdlb) 7.
SWINGARM CHAS 9. Install: • Connecting rod 1 • Bolt (connecting rod) 2 • Nut (connecting rod) 3 T34 Nm (3.4 mdkg, 24 ftdlb) NOTE: • Install the connecting rods with the mark a outward of the chassis. • Apply the lithium soap base grease on the bolts.
REAR SHOCK ABSORBER CHAS EC580000 REAR SHOCK ABSORBER T 40 Nm (4.0 mdkg, 29 ftdlb) T 38 Nm (3.8 mdkg, 27 ftdlb) T 34 Nm (3.4 mdkg, 24 ftdlb) T 23 Nm (2.3 mdkg, 17 ftdlb) T 40 Nm (4.0 mdkg, 29 ftdlb) T 34 Nm (3.4 mdkg, 24 ftdlb) Extend of removal: Extend of removal 1 Rear shock absorber removal Order Part name 2 Rear shock absorber disassembly Q’ty REAR SHOCK ABSORBER REMOVAL Hold the machine by placing the suitable stand.
REAR SHOCK ABSORBER CHAS EC586000 HANDLING NOTE W This shock absorber is provided with a separate type tank filled with high-pressure nitrogen gas. To prevent the danger of explosion, read and understand the following information before handling the shock absorber. The manufacturer can not be held responsible for property damage or personal injury that may result from improper handling. 1. Never tamper or attempt to disassemble the cylinder or the tank. 2.
REAR SHOCK ABSORBER CHAS EC583000 REMOVAL POINTS EC583310 Bearing 1. Remove: • Stopper ring 1 2. Remove: • Bearing 1 NOTE: Remove the bearing by pressing its outer race. EC584000 INSPECTION EC584110 Rear shock absorber 1. Inspect: • Damper rod 1 Bends/Damage ≥ Replace absorber assembly. • Shock absorber 2 Oil leaks ≥ Replace absorber assembly. Gas leaks ≥ Replace absorber assembly. • Spring 3 Damage ≥ Replace spring. Fatigue ≥ Replace spring. Move spring up and down.
REAR SHOCK ABSORBER CHAS EC585000 ASSEMBLY AND INSTALLATION EC585310 Bearing 1. Install: • Stopper ring 1N • Bearing 2 NOTE: • Apply the lithium soap base grease on the bearing when installing. • Install the bearing parallel until it contacts the stopper ring by pressing its outer race. 2. Install: • Stopper ring 1N EC585130 Spring (rear shock absorber) 1. Install: • Spring 1 • Spring guide 2 2. Tighten: • Adjuster 1 3.
REAR SHOCK ABSORBER CHAS NOTE: The length of the spring (installed) changes 1.5mm (0.06 in) per turn of the adjuster. CCAUTION: Never attempt to turn the adjuster beyond the maximum or minimum setting. 4. Tighten: • Locknut 1 T40 Nm (4.0 mdkg, 29 ftdlb) EC585262 Rear shock absorber 1. Install: • Dust seal 1 • Collar 2 NOTE: Apply the lithium soap base grease on the bearings and collars. 2.
REAR SHOCK ABSORBER CHAS 5. Install: • Bolt (rear shock absorber–relay arm) 1 • Nut (rear shock absorber–relay arm) 2 T34 Nm (3.4 mdkg, 24 ftdlb) NOTE: Apply the lithium soap base grease on the bolt. 6. Install: • Rear frame 1 • Bolt (rear frame) 2 T23 Nm (2.
ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELEC EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 2 3 4 5 CDI unit Voltage regulator Condenser Tachometer assembly “ENGINE STOP” button 6 7 8 9 0 COLOR CODE B . . . . . .Black Br . . . . .Brown G . . . . . .Green Gy . . . . .Gray P . . . . . .Pink R . . . . . .Red W . . . . . .White Ignition coil Spark pulg Solenoid valve CDI magneto Thermo unit EC612000 WIRING DIAGRAM 6 6-1 B/L .
IGNITION SYSTEM ELEC EC620000 IGNITION SYSTEM EC621022 INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. Spark Spark gap test *Clean or replace spark plug. OK No good Check pulg cap. Replace. OK No good Check entire ignition system for connection. Repair or replace. OK No good Check “ENGINE STOP” button. Replace. OK Check ignition coil.
IGNITION SYSTEM ELEC EC622010 SPARK GAP TEST 1. Disconnect the spark plug cap from spark plug. 2. Connect the dynamic spark tester 1 (ignition checker 2) as shown. • Spark plug cap 3 • Spark plug 4 A For USA and CDN B Except for USA and CDN 3. Start the engine and increase the spark gap until misfire occurs. (for USA and CDN) 4. Rotate the rear wheel with gear in 3rd and check the spark gap. (except for USA and CDN) a Minimum spark gap: 5 mm(0.2 in) EC623001 SPARK PLUG CAP INSPECTION 1.
ELEC IGNITION SYSTEM EC625002 % “ENGINE STOP” BUTTON INSPECTION 1. Inspect: • “ENGINE STOP” button conduct Tester (+) lead ≥ Black/White lead 1 Tester (–) lead ≥ Black lead 2 u B/W 1 PUSH IN FREE B 2 Tester selector position ΩX1 Not continuous while being pushed ≥ Replace. Continuous while being freed ≥ Replace. EC626002 IGNITION COIL INSPECTION 1. Inspect: • Primary coil resistance Out of specification ≥ Replace.
IGNITION SYSTEM ELEC EC627001 CDI MAGNETO INSPECTION 1. Inspect: • Pick-up coil resistance Out of specification ≥ Replace. % Tester (+) lead ≥ White/Green lead 1 Tester (–) lead ≥ White/Black lead 2 ? Pick-up coil resistance 94~140 Ω at 20˚C (68˚F) Tester selector position Ω X 100 % 2. Inspect: • Source coil resistance Out of specification ≥ Replace. Tester (+) lead ≥ White lead 1 Tester (–) lead ≥ White lead 2 ? Source coil resistance 1.3~1.
SOLENOID VALVE SYSTEM ELEC EC650001 SOLENOID VALVE SYSTEM EC651012 INSPECTION STEPS If the solenoid valve will not operate, use the following inspection steps. No good Check each couplers and wire connection. OK Check solenoid valve operation. No good OK *Check CDI magneto. Repair or replace. Check solenoid valve coil. No good Replace. OK Replace CDI unit. Source coil No good Replace. OK Check voltage regulator. Out-put voltage OK Replace condenser.
SOLENOID VALVE SYSTEM ELEC EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/ Dust/ Looseness/Short-circuit ≥ Repair or replace. EC652030 SOLENOID VALVE OPERATION 1. Check: • Solenoid valve operation Checking steps: • Disconnect the condenser lead 1. • Connect the checking lead 2 between the wireharness 3 and battery (12V) 4. • Check the solenoid valve 5 operation. If a click can be heard the solenoid valve is working properly.
SOLENOID VALVE SYSTEM ELEC EC635002 VOLTAGE REGULATOR INSPECTION 1. Disconnect the condenser lead. 2. Start the engine. 3. Inspect: • Out-put voltage Out of specification ≥ Replace voltage regulator. % Tester (+) lead ≥ Red lead 1 Tester (–) lead ≥ Black lead 2 ? Out-put voltage 14.2~15.
THERMO UNIT SYSTEM ELEC EC6A0000 THERMO UNIT SYSTEM EC6A1000 INSPECTION STEPS If the water temperature gauge (thermo unit) will not operate, use the following inspection steps. No good Check each couplers and wire connection. OK No good Check thermo unit OK *1Check CDI magneto. Repair or replace. Source coil Replace. No good Replace. OK *2Check voltage regulator. Out-put voltage OK Replace condenser or tachometer assembly. *1 marked: Refer to “IGNITION SYSTEM” section.
THERMO UNIT SYSTEM ELEC EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/ Dust/ Looseness/Short-circuit ≥ Repair or replace. EC6A2000 THERMO UNIT INSPECTION 1. Drain the cooling water. 2. Remove: • Thermo unit 1 3. Immerse the thermo unit with a tester lead connected in a container containing cooling (tap) water 1 down to the upper threaded portion a. 2 Water temperature gauge 3 Poket tester 4.
SETTING TUN EC700000 TUNING EC710000 ENGINE EC711011 Carburetor setting • The role of fuel is not only to produce motive power but also to cool the engine and, in the case of a 2-stroke engine, to lubricate it. Therefore, too lean a mixture (of air and fuel) tends to cause an abnormal combustion (i.e.
SETTING TUN That is: • Higher temperature expands the air with its resultant reduced density. • Higher humidity reduces the amount of oxygen in the air by so much of the water vapor in the same air. • Lower atmospheric pressure (at a high altitude) reduces the density of the air. EC714032 Effects of setting parts in relation to throttle valve opening NOTE: The power jet closes at 12,150 rpm of the engine, after which only the main jet dominates.
SETTING TUN Next run a few laps of the circuit with this setting and check for any difference in engine revolutions. If no difference is noticed, use a main jet with a much smaller calibration number. w Example: #215 ≥ #210 Factory-set main jet A #220 2. Checking of spark plug and piston for discoloration Repeat the adjustment in the above “1” several times.
SETTING TUN Run a few laps of the circuit to check the engine for response to revolutions. On the other hand, if the use of a different jet needle appears to produce less power, change to a jet needle of a smaller size. w Example:N8VW ≥ N8VH Factory-set jet needle N8VH NOTE: • Refer to “Jet needle” (P7-5) about the jet needle specification. • Difference between individual riders or difference between circuit layouts greatly affect the jet needle setting. 1.
SETTING TUN 4. Adjustment of jet needle clip position Mid-open adjustment for the jet needle clip position 1 follows the completion of the adjustment of the jet needle. If the mixture is too rich or too lean in the mid-open position, irregular engine operation and poor acceleration will result. Whether or not the richness of the mixture is proper is hard to be determined by means of the spark plug and therefore, it should be judged from your feeling of actual engine operation.
SETTING TUN EC71B030 Relationship with throttle opening The flow of the fuel through the carburetor main system is controlled by the main jet and then, it is further regulated by the area between the main nozzle and the jet needle. On the relationship between the fuel flow and the throttle opening, the fuel flow relates to the jet needle straight portion diameter around 1/8 throttle opening, whereas around 1/4 to 1/2 throttle opening it relates to the taper starting position and to the clip position.
SETTING TUN 2. Pilot jet 1 The pilot jet is used in relation to the engine response at small throttle opening. This is changed when the jet needle setting is not enough. A larger size results in a richer mixture and a smaller size in a leaner mixture. w Factory-set pilot jet #42 3. Pilot air screw 1 The pilot air screw relates to the engine response at a smaller opening than for the pilot jet.
SETTING TUN EC71Q000 Carburetor setting parts Part name Main jet 1 Lean * Rich Lean * Rich Lean * Rich Lean Pilot jet 2 Jet needle 3 Rich Lean Power jet 4 * Rich * Factory installed 7-8 Size #160 #162 #165 #168 #170 #172 #175 #178 #180 #182 #185 #188 #190 #192 #195 #198 #200 #205 #210 #215 #220 #38 #40 #42 N8VK N8VJ N8VW N8VH N8WK N8WJ N8WW N8WH #40 #50 #60 Part number 4MX-14943-39 4MX-14943-90 4MX-14943-40 4MX-14943-91 4MX-14943-41 4MX-14943-92 4MX-14943-42 4MX-14943-93 4MX-14943-43 4MX-1
SETTING TUN EC71J001 Plug chop When checking the discoloration of the spark plug and piston head, push the “ENGINE STOP” button while running along a straight lane at full throttle, disengage the clutch at the same time and stop the engine. Then let your machine go back to the pit by inertia. This is called a “plug chop”. CCAUTION: • When you do a “plug chop”, pay attention to your surrounding environment to avoid interference with other riders.
SETTING TUN When the cylinder gasket is changed, measure the protruding (or sinking) amount of the piston above (below) the cylinder top and then change the cylinder gasket so that the following approximate relation can be achieved between the temperature and the piston protruding amount. (The table shows an example when the air pressure is 1013 hPa (760 mmHg).) CCAUTION: • Piston protruding amount must be a maximum 0.15 mm (0.006 in).
SETTING TUN 2. Loosen the stand installation bolt 1, then rotate the dial gauge stand and set it close to the center of the piston. Tighten the stand installation bolt again. NOTE: Do not loosen the dial gauge installation bolt 2 while doing the above. 3. Set the piston at top dead center (TDC), then measure the piston protrusion. NOTE: For measurement, avoid the top center projected area a on the piston head but measure several positions above the piston pin as close to the center as possible.
SETTING TUN 3rd gear Gear ratio Part number Number of groove Supplying part 23/16 (1.438) 4JT-17231-00/4JT-17131-00 – Factory installed 24/17 (1.412) 4JT-17231-30/4JT-17131-30 – Supplying part 26/19 (1.316) 4JT-17231-10/4JT-17131-10 1 Gear ratio Part number Number of groove Supplying part 28/22 (1.278) 4JT-17241-00/4JT-17131-00 – Factory installed 25/20 (1.250) 4JT-17241-30/4JT-17131-30 – Supplying part 27/22 (1.
SETTING TUN EC71U000 Transmission setting parts Part name Size Part number Main axle 1 * 2nd pinion gear 2 * 15T 17T 19T 21T 16T/22T 17T/20T 19T/20T 19T/22T 21T 23T 26T 21T 22T 24T 27T 29T 30T 27T 31T 35T 23T 24T 25T 26T 24T 25T 27T 28T 24T 26T 30T 23T 26T 29T 4JT-17411-00 4JT-17121-10 4JT-17121-30 4JT-17121-00 4JT-17131-00 4JT-17131-30 4JT-17131-21 4JT-17131-10 4JT-17151-20 4JT-17151-10 4JT-17151-00 4JT-17161-00 4JT-17161-20 4JT-17161-30 4JT-17161-11 4JT-17211-10 4JT-17211-00 4JT-17221-10 4JT-17221
SETTING TUN EC720000 CHASSIS EC72J001 Chassis setting How to go about setting the chassis • Measure the stroke of the front and rear suspension to get an idea of the operation. • If the time increases, the stroke increases. • If the tire grip becomes firmer, the stroke increases. (On the other hand, the stroke decreases on rainy weather.) • Rider’s position and posture affect the stroke. • Be careful not to allow the suspension to bottom out. • Start the setting with the preload.
SETTING TUN EC72M001 Tire and machine’s posture If a non-designated tire is used, the difference in radius between the front and the rear tire may affect the machine’s posture. To keep the machine in a proper posture, adjust the front fork top end or seat height. Basically, with a larger radius tire, lower the machine’s posture and vice versa. [Front] Tire brand 95/70R17 DUNLOP KR149 Tire circumference Tire radius Front fork top end About 1,810 mm (71.3 in) About 288 mm (11.3 in) 18 mm (0.
SETTING TUN EC72K014 Settings For full use of engine performance and safe riding, set the suspension as follows. (Ex-factory settings are intended for a rider approximately 164 cm (64.6 in) in height and approximately 53 kg (117 lb) in weight.) 1. Preparations To check for the remaining stroke in the front and rear suspension, either install a thin insu-lock tie or apply a small amount of grease at the front fork inner tube and at the rear shock absorber rod. 2.
SETTING TUN SETTING CHART ACTUAL RUN Check stroke NOTE: The remaining stroke value is provided just as a guide and may change according to the riding style. Front remaining stroke Rear remaining stroke 5 to 10 mm (0.20 ~ 0.39 in) 20 to 30 mm (0.79 ~ 1.18 in) NO YES NO Poor stroke Too much stroke Decrease the spring preload. •Front Every two clicks [1 mm (0.04 in)] •Rear Every one turn [1.5 mm (0.06 in)] Increase the spring preload. •Front Every two clicks [1 mm (0.
SETTING TUN EC71P011 Selection of the secondary reduction ratio (Sprocket) Secondary Number of driven sprocket teeth reduction = Number of drive sprocket teeth ratio w Factory-set secondary reduction ratio 36/17 (2.118) Driven sprocket Drive sprocket 35T 36T 37T 38T 39T 16T 17T 18T 2.188 2.059 1.944 2.250 2.118 2.000 2.313 2.177 2.056 2.375 2.235 2.111 2.438 2.294 2.
SETTING TUN EC72L003 Chassis setting troubleshooting Chattering (Small rebounds, up-and-down movements) Bottoming (full stroke) • Increase spring preload. • Increase damping force for compression. Further in stroke • Increase damping force for compression, or decrease damping force for rebound. Too stiff (poor stroke) • Decrease spring preload. • Decrease damping force for compression. • Down the oil level (for front fork only).
SETTING TUN Handlebar fluctuating Poor of front load • Decrease spring preload (for front). • Increase front fork top end. • Increase rear height. • Increase spring preload (for rear). Too soft of front • Increase spring preload (for front). • Increase damping force (for front). Machine tends to incline too much backward. (Too big caster angle) •Increase rear height. • Increase spring preload (for rear). • Decrease damping force for rebound (for rear).
SETTING TUN EC740010 Setting record table The data shown here is an example of entry. For your actual use, copy the necessary data.
SETTING TUN Event name Date Weather Place Setting specs: Ignition timing Spark plug Carburetor Main jet Power jet Jet needle Pilot jet Pilot air screw Float height Gearing 1st 2nd 3rd 4th 5th 6th Secondary Front fork Spring rate Spring preload Rebound damping Compression damping Top end Oil capacity Oil level Rear shock Spring fitting length Spring rate Rebound damping Compression damping Seat height Front tire (pressure) Rear tire (pressure) Fuel consumption NOTE: 1.
99.8-0.
