Service manual

ManualsBrandsYamaha ManualsMotorcyclesYZ85(W)

2007

YZ85W1

5PA-28197-E0

SERVICE MANUAL

YZ85(W)

YZ85LW(W)

Summary of content (255 pages)

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2007 YZ85W1 YZ85(W) YZ85LW(W) SERVICE MANUAL 5PA-28197-E0
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EAS00000 YZ85W1 / YZ85 (W) / YZ85LW (W) SERVICE MANUAL ©2006 by Yamaha Motor Co., Ltd. First edition, April 2006 All rights reserved. Any reproduction or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
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EAS00002 NOTICE This manual was produced by the Yamaha Motor Company, Ltd. primarily for use by Yamaha dealers and their qualified mechanics. It is not possible to include all the knowledge of a mechanic in one manual. Therefore, anyone who uses this book to perform maintenance and repairs on Yamaha vehicles should have a basic understanding of mechanics and the techniques to repair these types of vehicles.
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EAS00007 HOW TO USE THIS MANUAL This manual is intended as a handy, easy-to-read reference book for the mechanic. Comprehensive explanations of all installation, removal, disassembly, assembly, repair and check procedures are laid out with the individual steps in sequential order. The manual is divided into chapters. An abbreviation and symbol in the upper right corner of each page indicate the current chapter. Refer to “SYMBOLS”. Each chapter is divided into sections.
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EAS00008 SYMBOLS The following symbols are not relevant to every vehicle. Symbols to indicate the subject of each chapter. General information Specifications Periodic checks and adjustments Chassis Engine Cooling system Carburetor(s) Electrical system Tuning Troubleshooting Symbols to indicate the following.
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EAS00010 TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC CHECKS AND ADJUSTMENTS CHASSIS ENGINE COOLING SYSTEM CARBURETOR ELECTRICAL SYSTEM TUNING TROUBLESHOOTING GEN INFO 1 SPEC 2 CHK ADJ 3 CHAS 4 ENG 5 COOL 6 CARB 7 ELEC 8 TUN 9 TRBL SHTG 10
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GEN INFO CHAPTER 1 GENERAL INFORMATION VEHICLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . 1-1 MODEL LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 IMPORTANT INFORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION FOR REMOVAL AND DISASSEMBLY . . . . . . . . . . REPLACEMENT PARTS . . . . . . . . . . . . . . . . . .
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VEHICLE IDENTIFICATION GEN INFO EAS00014 GENERAL INFORMATION VEHICLE IDENTIFICATION EAS00017 VEHICLE IDENTIFICATION NUMBER The vehicle identification number is stamped into the right side of the steering head pipe. EAS00018 MODEL LABEL The model label is affixed to the frame. This information will be needed to order spare parts.
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IMPORTANT INFORMATION GEN INFO EAS00020 IMPORTANT INFORMATION PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Before removal and disassembly, remove all dirt, mud, dust and foreign material. 2. Use only the proper tools and cleaning equipment. Refer to the “SPECIAL TOOLS”. 3. When disassembling, always keep mated parts together. This includes gears, cylinders, pistons and other parts that have been “mated” through normal wear. Mated parts must always be reused or replaced as an assembly. 4.
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IMPORTANT INFORMATION GEN INFO EAS00023 LOCK WASHERS / PLATES AND COTTER PINS After removal, replace all lock washers / plates and cotter pins. After the bolt or nut has been tightened to specification, bend the lock tabs along a flat of the bolt or nut. EAS00024 BEARINGS AND OIL SEALS Install bearings and oil seals so that the manufacturer’s marks or numbers are visible. When installing oil seals, lubricate the oil seal lips with a light coat of lithium-soap-based grease.
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FUEL AND ENGINE MIXING OIL GEN INFO 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 Premium unleaded gasoline only with a research octane number of 95 or higher. NOTE: If knocking or pinging occurs, use a different brand of gasoline or higher octane grade.
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CHECKING THE CONNECTIONS GEN INFO EAS00026 CHECKING THE CONNECTIONS Check the leads, couplers, and connectors for stains, rust, moisture, etc. 1. Disconnect: • lead • coupler • connector 2. Check: • lead • coupler • connector Moisture → Dry with an air blower. Rust / stains → Connect and disconnect several times. 3. Check: • all connections Loose connection → Connect properly. NOTE: If the pin on the terminal is flattened, bend it up. 4.
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SPECIAL TOOLS GEN INFO EAS00027 SPECIAL TOOLS The following special tools are necessary for complete and accurate tune-up and assembly. Use only the appropriate special tools as this will help prevent damage caused by the use of inappropriate tools or improvised techniques. Special tools, part numbers or both may differ depending on the country. When placing an order, refer to the list provided below to avoid any mistakes. NOTE: • For U.S.A.
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SPECIAL TOOLS Tool No. Radiator cap tester 90890-01325 YU-24460-01 Radiator cap tester adapter 90890-01352 YU-33984 Tool name / Function Radiator cap tester Radiator cap tester adapter These tools are used for checking the cooling system. Steering nut wrench 90890-01403 YU-33975 This tool is used when tighten the steering ring nut to specification. Rod holder 90890-01434 YM-01434 This tool is used to hold the fork spring.
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SPECIAL TOOLS Tool No. 90890-06754 YM-34487 Tool name / Function Dynamic spark tester Ignition checker This instrument is necessary for checking the ignition system components. Yamaha bond No.1215 (Three Bond No.1215®) 90890-85505 This sealant (Bond) is used for crankcase mating surface, etc.
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SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 CHASSIS SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7 ELECTRICAL SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 CONVERSION TABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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GENERAL SPECIFICATIONS SPEC SPECIFICATIONS GENERAL SPECIFICATIONS Item Model code Dimensions Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Dry weight Without oil and fuel Standard Limit YZ85 5PAG (EUR, CAN), 5PAH (AUS,NZL) YZ85LW 5SHG (EUR), 5SHH (AUS,NZL) ••• 1,818 mm (71.6 in) (YZ85) 1,903 mm (74.9 in) (YZ85LW) 758 mm (29.8 in) 1,161mm (45.7 in) (YZ85) 1,205 mm (47.4 in) (YZ85LW) 864 mm (34.0 in) (YZ85) 904 mm (35.6 in) (YZ85LW) 1,255 mm (49.
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ENGINE SPECIFICATIONS SPEC ENGINE SPECIFICATIONS Item Engine Engine type Displacement Cylinder arrangement Bore × stroke Compression ratio Fuel Recommended fuel Fuel tank capacity Total Lubrication system Transmission oil Recommended oil Standard Limit Liquid cooled 2-stroke, gasoline 84.7 cm3 (5.17 cu.in) Single cylinder, forward inclined 47.5 × 47.8 mm (1.870 × 1.882 in) 8.2 : 1 ••• ••• ••• ••• ••• Premium unleaded gasoline only ••• 5.0L (1.09 Imp gal, 1.
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ENGINE SPECIFICATIONS Item Cylinder Bore Max. taper limit Max. out-of-round Piston Piston-to-cylinder clearance Diameter D Height H Piston pin bore (in the piston) Diameter Offset Offset direction Piston pin Outside diameter SPEC Standard Limit 47.500 ~ 47.514 mm (1.8701 ~ 1.8706 in) 47.6 mm (1.874 in) ••• 0.05 mm (0.0020 in) ••• 0.01 mm (0.0004 in) 0.040 ~ 0.045 mm (0.0016 ~ 0.0018 in) 0.1 mm (0.004 in) 47.457 ~ 47.472 mm (1.8684 ~ 1.8690 in) 0.1 mm (0.004 in) 20.0 mm (0.79 in) ••• 14.004 ~ 14.
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ENGINE SPECIFICATIONS Item SPEC Standard Limit Crankshaft Crank width “A” Runout limit “C” 44.90 ~ 44.95 mm (1.768 ~ 1.770 in) 0.03 mm (0.0012 in) Big end side clearance “D” Small end free play “F” 0.20 ~ 0.70 mm (0.008 ~ 0.028 in) 0.5 ~ 1.2 mm (0.020 ~ 0.047 in) Clutch Clutch type Clutch release method Clutch cable free play (at the end of the clutch lever) Friction plates Thickness Wet, multiple disc Inner push, cam push 10.0 ~ 15.0 mm (0.39 ~ 0.59 in) 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 7 ••• 0.
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ENGINE SPECIFICATIONS Item Transmission Transmission type Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Operation Gear ratios 1st gear 2nd gear 3rd gear 4th gear 5th gear 6th gear Max.
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ENGINE SPECIFICATIONS Item Standard SPEC Limit Reed valve Thickness “T” Valve stopper height Valve bending limit 0.42 mm (0.017 in) 7.4 ~ 7.8 mm (0.291 ~ 0.307 in) 2-6 ••• ••• 0.2 mm (0.
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CHASSIS SPECIFICATIONS SPEC CHASSIS SPECIFICATIONS Item Frame Frame type Material Caster angle Trail Front wheel Wheel type Rim Size Material Wheel travel Wheel runout Radial wheel runout limit Lateral wheel runout limit Rear wheel Wheel type Rim Size Standard Limit Semi double cradle Steel 26.3° (YZ85) 26.9° (YZ85LW) 88.0 mm (3.46 in) (YZ85) 105.5 mm (4.15 in) (YZ85LW) ••• ••• ••• ••• ••• ••• Spoke wheel ••• 17 × 1.40 (YZ85) 19 × 1.40 (YZ85LW) Aluminum 275 mm (10.83 in) ••• ••• ••• ••• ••• 2.
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CHASSIS SPECIFICATIONS Item Front tire Tire type Size Model (manufacturer) Tire pressure (cold) Rear tire Tire type Size Model (manufacturer) Tire pressure (cold) Front brakes Brake type Operation Recommended fluid Brake lever free play Brake discs Diameter × thickness Thickness limit Standard ••• ••• ••• ••• ••• ••• ••• Tube 90 / 100-14 49M (YZ85) 90 / 100-16 52M (YZ85LW) D756 (DUNLOP) 100 kPa (1.0 kgf / cm2, 1.0 bar, 14.2 psi) ••• ••• ••• ••• ••• Single disc brake Right hand operation DOT 4 0 mm (0.
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CHASSIS SPECIFICATIONS Item Steering Steering bearing type Lock to lock angle (left) Lock to lock angle (right) Front suspension Suspension type Front fork type Front fork travel Spring Free length Installed length Spring rate, STD (K1) Spring stroke (K1) Inner tube outer diameter Inner tube bending limit Optional spring available Fork oil Recommended oil Quantity (each front fork leg) Level (from the top of the outer tube, with the outer tube fully compressed, and without the fork spring) Rebound damping
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CHASSIS SPECIFICATIONS Item Rear suspension Suspension type Rear shock absorber assembly type Rear shock absorber assembly travel Spring Free length Installed length Spring rate, STD (K1) Standard Drive chain slack Maximum 15-link section Limit Swingarm (link type monocross suspension) Coil spring / gas, oil damper 102 mm (4.02 in) ••• 220 mm (8.66 in) 215 mm (8.46 in) (YZ85) 212 mm (8.35 in) (YZ85LW for EUR) 207 mm (8.15 in) (YZ85LW for AUS, NZL) 49.0 N / mm (5.00 kg / mm, 280.0 lb / in) (YZ85) 47.
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ELECTRICAL SPECIFICATIONS SPEC ELECTRICAL SPECIFICATIONS Item Ignition system Ignition system type Ignition timing (B.T.D.C.) Advancer type C.D.I. Magneto model (manufacturer) Pickup coil resistance (color) Charging coil 1 resistance (color) Charging coil 2 resistance (color) C.D.I. unit model (manufacturer) Ignition coils Model (manufacturer) Minimum ignition spark gap Primary coil resistance Secondary coil resistance Spark plug cap Material Resistance Standard Limit CDI 0.9 mm (0.
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CONVERSION TABLE / GENERAL TIGHTENING TORQUE SPECIFICATIONS SPEC EAS00028 EAS00030 CONVERSION TABLE GENERAL TIGHTENING TORQUE SPECIFICATIONS All specification data in this manual are listed in SI and METRIC UNITS. Use this table to convert METRIC unit data to IMPERIAL unit data. Ex. METRIC MULTIPLIER This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch.
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TIGHTENING TORQUES SPEC TIGHTENING TORQUES ENGINE TIGHTENING TORQUES Item Spark plug Cylinder head Cylinder Water pump impeller Coolant drain bolt Water pump housing Radiator hose clamp Air filter element Carburetor joint Reed valve Exhaust pipe Exhaust pipe stay Silencer Fiber (silencer) Crankcase Left crankcase cover Right crankcase cover Right crankcase cover Clutch cover Transmission oil drain bolt Kickstarter crank Primary drive gear Clutch boss Clutch spring Drive sprocket Crankcase bearing stopper
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TIGHTENING TORQUES SPEC CHASSIS TIGHTENING TORQUES Tightening torque Item Fastener Thread size Q’ty Upper bracket and outer tube Lower bracket and outer tube Upper bracket and steering stem Handlebar holder and upper bracket Steering stem and steering ring nut Front fork and cap bolt Front fork and base valve Cap bolt and damper rod Front fork bleed screw and cap bolt Front fork and front fork protector Front fork and brake hose guide Front fork and brake hose holder Throttle grip cap Throttle cable
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TIGHTENING TORQUES Item Fastener Thread size Q’ty Relay arm and connecting rod Connecting rod and swingarm Rear shock absorber and frame Rear shock absorber and relay arm Rear frame (upper) Rear frame (lower) Swingarm and brake hose holder Drive chain support Drive chain support cover Drive chain guide and swingarm Fuel tank Fuel cock Fuel tank bracket and fuel tank Seat set bracket and fuel tank Air scoop Front fender Rear fender Flap guard Side cover Seat Number plate Ignition coil Nut Nut Nut Bolt B
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LUBRICATION POINTS AND LUBRICANT TYPES SPEC EAS00031 LUBRICATION POINTS AND LUBRICANT TYPES ENGINE Lubrication point Lubricant Oil seal lips O-rings Bearings Crankshaft pins Piston surfaces Piston pins Water pump impeller shaft Kick shaft Kick shaft stopper Kick idle gear inner surface Primary driven gear Push rod and push lever (upper) Push lever (lower) Transmission wheel gears inner surface Transmission pinion gears Shift forks and shift fork guide bers Shift shaft Shift dram Crankcase mating surfac
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CABLE ROUTING EAS00035 CABLE ROUTING Radiator breather hose Clutch cable Spark plug lead Radiator hose Brake hose holder Cable guide Brake hose Throttle cable Fuel tank breather hose Engine stop switch lead Ground lead Ignition coil Primary coil lead (orange color) Damper Clamp Air vent hoses CDI magneto lead Carburetor overflow hose Transmission oil breather hose 2-17 SPEC
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CABLE ROUTING Pass the fuel tank breather hose between the handlebar and tension bar, then insert its end into the hole of the steering stem. Fasten the ground lead together with the ignition coil. Insert the primary coil lead (orange color) in the ignition coil. Pass the transmission oil breather hose through the wire holder located at the right side of the vehicle. Route the air vent hose and carburetor overflow hose from the left side of the vehicle. Do not flatten out the radiator breather hose.
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CABLE ROUTING SPEC Route the clutch cable in front of the throttle cable. Pass the transmission oil breather hose through the hose guide. Clamp it between these parts. Clamp it using the white PVC tape as a guide. Pass the sub-wire harness on the left side of the CDI unit. Cut the tip of the clamp near the position of chain double-dashed line. Tighten the sub-wire harness to the CDI unit. Position the lock section under the CDI unit.
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CABLE ROUTING Install the clip pointing the clamp section to the rear side. Touch the brake pipe to the stopper. When installing the brake hose, install it so that the bend section of the brake hose attachment is pointed in the direction as shown in the illustration.
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CABLE ROUTING SPEC This is the number plate attaching section. The clutch cable and throttle cable shall be routed crossways above the number plate attaching section. At this time, make sure to route the clutch cable to the front side of the throttle cable. Route the clutch cable in front of the throttle cable. Fasten the engine stop switch lead to the handlebar with the plastic band. Pass the brake hose in front of the number plate.
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CHK ADJ CHAPTER 3 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 PERIODIC MAINTENANCE AND LUBRICATION INTERVALS . . . . . . 3-1 SEAT, SIDE COVERS AND FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . 3-3 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADJUSTING THE PILOT AIR SCREW . . . . . . . . . . . . . . . . . . . . . . .
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CHK ADJ INTRODUCTION / PERIODIC MAINTENANCE AND LUBRICATION INTERVALS 3 EAS00036 PERIODIC CHECKS AND ADJUSTMENTS INTRODUCTION This chapter includes all information necessary to perform recommended checks and adjustments. If followed, these preventive maintenance procedures will ensure more reliable vehicle operation, a longer service life and reduce the need for costly overhaul work. This information applies to vehicles already in service as well as to new vehicles that are being prepared for sale.
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CHK ADJ PERIODIC MAINTENANCE AND LUBRICATION INTERVALS NO. ITEM ROUTINE • Check coolant level and for leakage. 16 * Cooling system After break-in Every race √ √ √ Every 2 years • Check all chassis fitting and fasteners. • Correct or tighten if necessary. √ √ • Clean. √ √ √ * Chassis fasteners 18 * Air filter element 19 * Frame • Clean and check for damage. √ 20 * Fuel line • Clean and check for leakage. √ Brakes • • • • • √ • Replace.
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SEAT, SIDE COVERS AND FUEL TANK CHK ADJ EAS00042 SEAT, SIDE COVERS AND FUEL TANK 7 Nm (0.7 m•kg, 5.1 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 4 Nm (0.4 m•kg, 2.
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SEAT, SIDE COVERS AND FUEL TANK CHK ADJ 7 Nm (0.7 m•kg, 5.1 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) Order 14 Job / Part Number plate Q’ty 1 Remarks For installation, reverse the removal procedure.
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ADJUSTING THE PILOT AIR SCREW / ADJUSTING THE ENGINE IDLING SPEED CHK ADJ ENGINE ADJUSTING THE PILOT AIR SCREW 1. Adjust: • pilot air screw NOTE: To optimize the fuel flow at a smaller throttle opening, each vehicles 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. Record this number as the factory-set number of turns out. a. Turn in the pilot air screw until it is lightly seated. b.
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ADJUSTING THE THROTTLE CABLE FREE PLAY CHK ADJ EAS00058 ADJUSTING THE THROTTLE CABLE FREE PLAY NOTE: Prior to adjusting the throttle cable free play, the engine idling speed should be adjusted. 1. Check: • throttle cable free play Out of specification → Adjust. Throttle cable free play (at the flange of the throttle grip) 3.0 ~ 5.0 mm (0.12 ~ 0.20 in) 2. Adjust: • throttle cable free play Handlebar side a. Loosen the locknut . b.
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CHECKING THE SPARK PLUG CHK ADJ EAS00060 CHECKING THE SPARK PLUG 1. Disconnect: • spark plug cap 2. Remove: • spark plug CAUTION: Before removing the spark plug, blow away any dirt accumulated in the spark plug well with compressed air to prevent it from falling into the cylinder. 3. Check: • spark plug type Incorrect → Change. Spark plug type (manufacturer) BR10EG (NGK) 4. Check: • electrode Damage / wear → Replace the spark plug. • insulator Abnormal color → Replace the spark plug.
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CHECKING THE IGNITION TIMING CHK ADJ EAS00062 CHECKING THE IGNITION TIMING 1. Remove: • air scoop • spark plug • left crankcase cover 2. Attach: • dial gauge • dial gauge stand Dial gauge and stand 90890-01252, YU-3097 Stand YU-1256 3. Adjust: • top dead center (TDC) a. Rotate the rotor 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. b.
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CHECKING THE IGNITION TIMING / CHANGING THE TRANSMISSION OIL CHK ADJ Screw (stator) 8 Nm (0.8 m•kg, 5.8 ft•lb) 6. Check: • ignition timing Re-check the ignition timing. EAS00074 CHANGING THE TRANSMISSION OIL 1. Start the engine, warm it up for several minutes, and then turn it off. 2. Place the vehicle on a level place and hold it on upright position by placing the suitable stand under the engine. 3. Place a container under the transmission oil drain bolt. 4.
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ADJUSTING THE CLUTCH CABLE FREE PLAY / CLEANING THE AIR FILTER ELEMENT CHK ADJ EAS00081 ADJUSTING THE CLUTCH CABLE FREE PLAY 1. Check: • clutch cable free play Out of specification → Adjust. Clutch cable free play (at the end of the clutch lever) 10.0 ~ 15.0 mm (0.39 ~ 0.59 in) 2. Adjust: • clutch cable free play a. Loosen the locknut . b. Turn the adjusting nut in direction or until the specified clutch cable free play is obtained. Direction Direction Clutch cable free play is increased.
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CLEANING THE AIR FILTER ELEMENT • • • • CHK ADJ fitting bolt washer air filter guide air filter element CAUTION: Never operate the engine without the air filter element installed. Unfiltered air will cause rapid wear of engine parts and may damage the engine. Operating the engine without the air filter element will also affect the carburetor tuning, leading to poor engine performance and possible overheating. 3.
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CLEANING THE AIR FILTER ELEMENT / CHECKING THE CARBURETOR JOINT / CHECKING THE HOSES CHK ADJ 7. Apply: • lithium-soap-base grease On the matching surface ment. on air filter ele- 8. Install: • air filter element • washer 2 Nm (0.2 m•kg, 1.4 ft•lb) • fitting bolt NOTE: • Install the air filter element with its projection facing upward. • Make sure the air filter element is properly installed in the air filter case. EAS00094 CHECKING THE CARBURETOR JOINT 1.
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CHECKING THE CRANKCASE BREATHER HOSE / CHECKING THE EXHAUST SYSTEM CHK ADJ EAS00098 CHECKING THE CRANKCASE BREATHER HOSE 1. Check: • crankcase breather hose Cracks / damage → Replace. Loose connection → Connect properly. CAUTION: Make sure the crankcase breather hose is routed correctly. EAS00100 CHECKING THE EXHAUST SYSTEM The following procedure applies to all of the exhaust pipes, mufflers and gaskets. 1. Remove: • seat • side cover (right) Refer to “SEAT, SIDE COVERS AND FUEL TANK”. 2.
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CHECKING THE COOLANT LEVEL CHK ADJ EAS00102 CHECKING THE COOLANT LEVEL 1. Stand the vehicle on a level surface. NOTE: • Place the vehicle on a suitable stand. • Make sure the vehicle is upright. 2. Remove: • radiator cap CAUTION: A hot radiator is under pressure. Therefore, do not remove the radiator cap when the engine is hot. Scalding hot fluid and steam may be blown out, which could cause serious injury.
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CHECKING THE COOLING SYSTEM / CHANGING THE COOLANT CHK ADJ EAS00104 CHECKING THE COOLING SYSTEM 1. Remove: • air scoop Refer to “SEAT, SIDE COVERS AND FUEL TANK”. 2. Check: • radiator • radiator hose joint • radiator hose Cracks / damage → Replace. Refer to “COOLING SYSTEM” in chapter 6. 3. Install: • air scoop EAS00105 CHANGING THE COOLANT 1. Remove: • coolant drain bolt 2. Remove: • radiator cap WARNING A hot radiator is under pressure.
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CHANGING THE COOLANT CHK ADJ 5. Fill: • coolant (with the specified amount of the recommended coolant) Recommended antifreeze High-quality ethylene glycol antifreeze containing corrosion inhibitors for aluminum engines Mixing ratio 1:1 (antifreeze:water) Quantity Total amount 0.54 L (0.48 Imp qt, 0.57 US qt) Handling notes for coolant Coolant is potentially harmful and should be handled with special care. WARNING • If coolant splashes in your eyes, thoroughly wash them with water and consult a doctor.
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CHANGING THE COOLANT / ADJUSTING THE FRONT BRAKE CHK ADJ 8. Check: • coolant level Refer to “CHECKING THE COOLANT LEVEL”. NOTE: Before checking the coolant level, wait a few minutes until the coolant has settled. EAS00106 CHASSIS ADJUSTING THE FRONT BRAKE 1. Adjust: • brake lever position (distance from the throttle grip to the brake lever) Standard brake lever position 95 mm (3.74 in) Extent of adjustment 76 ~ 97 mm (2.99 ~ 3.82 in) a. Loosen the locknut . b.
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ADJUSTING THE REAR BRAKE CHK ADJ EAS00111 ADJUSTING THE REAR BRAKE 1. Check: • brake pedal height Out of specification → Adjust. Brake pedal height 4.0 ~ 10.0 mm (0.16 ~ 0.39 in) 2. Adjust: • brake pedal height a. Loosen the locknut . b. Turn the adjusting nut in direction or until the specified brake pedal position is obtained. Direction Direction Brake pedal is raised. Brake pedal is lowered. WARNING Adjust the pedal height between the maximum and the minimum as shown.
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CHECKING THE BRAKE FLUID LEVEL CHK ADJ EAS00115 CHECKING THE BRAKE FLUID LEVEL 1. Stand the vehicle on a level surface. NOTE: • Place the vehicle on a suitable stand. • Make sure the vehicle is upright. 2. Check: • brake fluid level Below the minimum level mark → Add the recommended brake fluid to the proper level. Recommended brake fluid DOT 4 Front brake Rear brake WARNING • Use only the designated brake fluid.
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CHECKING THE FRONT AND REAR BRAKE PADS / CHECKING THE FRONT AND REAR BRAKE HOSES CHK ADJ EAS00118 CHECKING THE FRONT AND REAR BRAKE PADS The following procedure applies to all of the brake pads. 1. Check: • front brake pad • rear brake pad Wear indicators or almost touch the brake disc → Replace the brake pads as a set. Refer to “REPLACING THE FRONT BRAKE PADS” and “REPLACING THE REAR BRAKE PADS” in chapter 4. Brake pad wear limit 0.8 mm (0.032 in) 1.0 mm (0.
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BLEEDING THE HYDRAULIC BRAKE SYSTEM CHK ADJ EAS00135 BLEEDING THE HYDRAULIC BRAKE SYSTEM WARNING Bleed the hydraulic brake system whenever: • the system is disassembled. • a brake hose is loosened, disconnected or replaced. • the brake fluid level is very low. • brake operation is faulty. NOTE: • Be careful not to spill any brake fluid or allow the brake fluid reservoir to overflow. • When bleeding the hydraulic brake system, make sure there is always enough brake fluid before applying the brake.
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BLEEDING THE HYDRAULIC BRAKE SYSTEM / ADJUSTING THE SHIFT PEDAL / ADJUSTING THE DRIVE CHAIN SLACK CHK ADJ i. Repeat steps (e) to (h) until all of the air bubbles have disappeared from the brake fluid in the plastic hose. j. Tighten the bleed screw to specification. Bleed screw 6 Nm (0.6 m•kg, 4.3 ft•lb) k. Fill the brake fluid reservoir to the proper level with the recommended brake fluid. Refer to “CHECKING THE BRAKE FLUID LEVEL”.
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ADJUSTING THE DRIVE CHAIN SLACK CHK ADJ 1. Elevate the rear wheel by placing the suitable stand under the engine. WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Move the rear wheel several times and find the tightest position of drive chain. 3. Check: • drive chain slack Out of specification → Adjust. Drive chain slack 35.0 ~ 45.0 mm (1.38 ~ 1.77 in) 4. Adjust: • drive chain slack a. Loosen wheel axle nut and both locknuts . b.
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LUBRICATING THE DRIVE CHAIN / CHECKING AND ADJUSTING THE STEERING HEAD CHK ADJ EAS00143 LUBRICATING THE DRIVE CHAIN The drive chain consists of many interacting parts. If the drive chain is not maintained properly, it will wear out quickly. Therefore, the drive chain should be serviced, especially when the vehicle is used in dusty areas. Use only kerosene to clean the drive chain.
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CHECKING AND ADJUSTING THE STEERING HEAD / CHECKING THE FRONT FORK CHK ADJ a. Remove the steering ring nut using the steering nut wrench . b. Tighten the steering ring nut with a steering nut wrench . NOTE: • Set the torque wrench at a right angle to the steering nut wrench. • Install the steering ring nut with its larger chamfered side downward. Steering nut wrench 90890-01403, YU-33975 Steering ring nut (initial tightening torque) 38 Nm (3.8 m•kg, 27 ft•lb) c.
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CHECKING THE FRONT FORK / ADJUSTING THE FRONT FORK LEGS CHK ADJ 2. Check: • inner tube Damage / scratches → Replace. • oil seal Oil leakage → Replace. 3. Hold the vehicle upright and apply the front brake. 4. Check: • front fork operation Push down hard on the handlebar several times and check if the front fork rebounds smoothly. Rough movement → Repair. Refer to “FRONT FORK” in chapter 4. EAS00155 ADJUSTING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs.
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ADJUSTING THE FRONT FORK LEGS CHK ADJ 1. Adjust: • rebound damping a. Turn the adjusting screw or . Direction Direction in direction Rebound damping is increased (suspension is harder). Rebound damping is decreased (suspension is softer). Adjusting positions Minimum: 20 clicks in direction * Standard: 7 clicks in direction * Maximum: 1 clicks in direction * * with the adjusting screw fully turned-in direction Compression damping CAUTION: Never go beyond the maximum or minimum adjustment positions.
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ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY CHK ADJ EAS00159 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY WARNING Securely support the vehicle so that there is no danger of it falling over. Spring preload CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: • spring preload a. Loosen the locknut wrench. with a ring nut Ring nut wrench 90890-01268 NOTE: • Be sure to remove all dirt and mud from around the locknut and adjuster before adjustment.
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ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY CHK ADJ Rebound damping CAUTION: Never go beyond the maximum or minimum adjustment positions. 1. Adjust: • rebound damping a. Turn the adjusting screw or . in direction . Direction Direction Rebound damping is increased (suspension is harder). Rebound damping is decreased (suspension is softer).
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ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY / CHECKING THE TIRES CHK ADJ NOTE: This is the position which is back by the specific number of clicks from the fully turned-in position. (Which align the punch mark on the adjuster with the punch mark on the bracket.
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CHECKING THE TIRES CHK ADJ 2. Check: • tire surfaces Damage / wear → Replace the tire. WARNING • Do not use a tubeless tire on a wheel designed only for tube tires to avoid tire failure and personal injury from sudden deflation. • When using tube tires, be sure to install the correct tube. • Always replace a new tube tire and a new tube as a set. • To avoid pinching the tube, make sure the wheel rim band and tube are centered in the wheel groove. • Patching a punctured tube is not recommended.
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CHECKING THE TIRES / CHECKING AND TIGHTENING THE SPOKES / LUBRICATING THE LEVERS AND PEDALS / LUBRICATING THE REAR SUSPENSION CHK ADJ WARNING New tires have a relatively low grip on the road surface until they have been slightly worn. NOTE: Align the mark point. with the valve installation EAS00169 CHECKING AND TIGHTENING THE SPOKES The following procedure applies to all of the spokes. 1. Check: • spoke Bends / damage → Replace. Loose → Tighten. Tap the spokes with a screwdriver.
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CHAS CHAPTER 4 CHASSIS FRONT WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE FRONT WHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE BRAKE DISCS. . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE FRONT WHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-3 4-3 4-6 4-7 REAR WHEEL AND BRAKE DISC . . . . . . . . . . . . . . . . . . . . . . . .
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CHAS HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE HANDLEBAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE HANDLEBAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55 4-57 4-57 4-57 STEERING HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . UNDER BRACKET . . . . . . . . . . . . . . . . .
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FRONT WHEEL AND BRAKE DISC EAS00512 CHAS CHASSIS FRONT WHEEL AND BRAKE DISC 70 Nm (7.0 m•kg, 50 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb) Order 1 2 3 4 Job / Part Q’ty Remarks Removing the front wheel and brake Remove the parts in the order listed. disc NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. Front wheel axle Front wheel Collar Front brake disc 1 1 2 1 For installation, reverse the removal procedure.
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FRONT WHEEL AND BRAKE DISC Order Job / Part Disassembling the front wheel Oil seal Wheel bearing Collar Q’ty CHAS Remarks Disassemble the parts in the order listed. 2 2 1 For assembly, reverse the disassembly procedure.
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FRONT WHEEL AND BRAKE DISC CHAS EAS00519 REMOVING THE FRONT WHEEL 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. 2. Remove: • front brake caliper NOTE: Do not apply the brake lever when removing the brake caliper. 3. Elevate: • front wheel NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. 4.
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FRONT WHEEL AND BRAKE DISC CHAS 2. Check: • tire • front wheel Damage / wear → Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3. 3. Check: • spokes Refer to “CHECKING AND TIGHTENING THE SPOKES” in chapter 3. NOTE: After tightening the spokes, measure the front wheel runout. 4. Measure: • front wheel radial runout • front wheel lateral runout Over the specified limits → Replace. Front wheel radial runout limit 2.0 mm (0.08 in) Front wheel lateral runout limit 2.0 mm (0.
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FRONT WHEEL AND BRAKE DISC CHAS c. Remove the wheel bearings with a general bearing puller . d. Install the new wheel bearings and oil seals in the reverse order of disassembly. CAUTION: Do not contact the wheel bearing inner race or balls . Contact should be made only with the outer race . NOTE: Use a socket that matches the diameter of the wheel bearing outer race and oil seal.
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FRONT WHEEL AND BRAKE DISC CHAS EAS00531 CHECKING THE BRAKE DISCS The following procedure applies to all of the brake discs. 1. Check: • brake discs Damage / galling → Replace. 2. Measure: • brake disc deflection Out of specification → Correct the brake disc deflection or replace the brake disc. Brake disc deflection limit (maximum) Front: 0.15 mm (0.006 in) Rear: 0.15 mm (0.006 in) a. Place the vehicle on a suitable stand so that the wheel is elevated. b.
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FRONT WHEEL AND BRAKE DISC CHAS Brake disc bolt 12 Nm (1.2 m•kg, 8.7 ft•lb) LOCTITE® d. Measure the brake disc deflection. e. If out of specification, repeat the adjustment steps until the brake disc deflection is within specification. f. If the brake disc deflection cannot be brought within specification, replace the brake disc. EAS00546 INSTALLING THE FRONT WHEEL 1. Lubricate: • front wheel axle • oil seal lips Recommended lubricant Lithium-soap-based grease 2.
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REAR WHEEL AND BRAKE DISC CHAS AS00551 REAR WHEEL AND BRAKE DISC REAR WHEEL 16 Nm (1.6 m•kg, 11 ft•lb) 16 Nm (1.6 m•kg, 11 ft•lb) 90 Nm (9.0 m•kg, 65 ft•lb) Order Job / Part Removing the rear wheel Q’ty Rear brake caliper 1 2 3 4 5 6 7 Remarks Remove the parts in the order listed. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. Remove Refer to “REMOVING THE REAR BRAK PADS”.
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REAR WHEEL AND BRAKE DISC CHAS 16 Nm (1.6 m•kg, 11 ft•lb) 16 Nm (1.6 m•kg, 11 ft•lb) 90 Nm (9.0 m•kg, 65 ft•lb) Order 8 Job / Part Collar Q’ty 2 Remarks For installation, reverse the removal procedure.
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REAR WHEEL AND BRAKE DISC CHAS EAS00560 REAR BRAKE DISC AND REAR WHEEL SPROCKET 12 Nm (1.2 m•kg, 8.7 ft•lb) Order 1 2 3 Job / Part Removing the rear brake disc and rear wheel sprocket Rear brake disc Rear wheel sprocket Rear wheel 42 Nm (4.2 m•kg, 30 ft•lb) Q’ty Remarks Remove the parts in the order listed. 1 1 1 For installation, reverse the disassembly procedure.
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REAR WHEEL AND BRAKE DISC Order Job / Part Disassembling the rear wheel Oil seal Circlip Bearing Collar Q’ty CHAS Remarks Disassemble the parts in the order listed. 2 1 2 1 For assembly, reverse the disassembly procedure.
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REAR WHEEL AND BRAKE DISC CHAS EAS00561 REMOVING THE REAR WHEEL 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • protector • brake caliper NOTE: Do not depress the brake pedal when removing the brake caliper. 3. Loosen: • locknut • adjusting bolt 4.
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REAR WHEEL AND BRAKE DISC CHAS EAS00566 CHECKING THE REAR WHEEL 1. Check: • rear wheel axle • rear wheel • wheel bearings • oil seals Refer to “CHECKING THE FRONT WHEEL”. 2. Check: • tire • rear wheel Damage / wear → Replace. Refer to “CHECKING THE TIRES” and “CHECKING THE WHEELS” in chapter 3. 3. Check: • spokes Refer to “CHECKING THE FRONT WHEEL”. 4. Measure: • radial wheel runout • lateral wheel runout Refer to “CHECKING THE FRONT WHEEL”. EAS00568 CHECKING AND REPLACING THE REAR WHEEL SPROCKET 1.
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REAR WHEEL AND BRAKE DISC CHAS 2. Replace: • rear wheel sprocket a. Remove the self-locking nuts and the rear wheel sprocket. b. Clean the rear wheel drive hub with a clean cloth, especially the surfaces that contact the sprocket. c. Install the new rear wheel sprocket. Rear wheel sprocket self-locking nut 42 Nm (4.2 m•kg, 30 ft•lb) NOTE: Tighten the self-locking nuts in stages and in a crisscross pattern. EAS00572 INSTALLING THE REAR WHEEL 1.
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FRONT AND REAR BRAKES CHAS EAS00577 FRONT AND REAR BRAKES FRONT BRAKE PADS 6 Nm (0.6 m•kg, 4.3 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) Order 1 2 3 4 Job / Part Removing the front brake pads Brake caliper Brake pad Brake pad support Bleed screw Q’ty Remarks Remove the parts in the order listed. 1 2 2 1 For installation, reverse the removal procedure.
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FRONT AND REAR BRAKES CHAS EAS00578 REAR BRAKE PADS 6 Nm (0.6 m•kg, 4.3 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) Order 1 2 3 4 5 6 7 8 Job / Part Removing the rear brake pads Protector Spacer Brake pad pin Rear brake caliper Brake pad Brake pad shim Brake pad spring Bleed screw Q’ty Remarks Remove the parts in the order listed. 1 1 2 1 2 1 1 1 For installation, reverse the removal procedure.
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FRONT AND REAR BRAKES CHAS EAS00579 CAUTION: Disc brake components rarely require disassembly. Therefore, always follow these preventive measures: WARNING • Never disassemble brake components unless absolutely necessary. • If any connection on the hydraulic brake system is disconnected, the entire brake system must be disassembled, drained, cleaned, properly filled, and bled after reassembly. • Never use solvents on internal brake components.
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FRONT AND REAR BRAKES CHAS 3. Measure: • brake pad wear limit Out of specification → Replace the brake pads as a set. Brake pad wear limit 0.8 mm (0.03 in) 4. Install: • brake pads NOTE: Always install new brake pads and a new brake pad spring as a set. a. Connect a clear plastic hose tightly to the bleed screw . Put the other end of the hose into an open container. b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. c. Tighten the bleed screw.
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FRONT AND REAR BRAKES CHAS 8. Check: • brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. EAS00583 REPLACING THE REAR BRAKE PADS NOTE: When replacing the brake pads, it is not necessary to disconnect the brake hose or disassemble the brake caliper. 1. Loosen: • brake pad pins 2. Remove: • brake caliper 3. Remove: • brake pad pins • brake pads (along with the brake pad shims) • brake pad spring 4.
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CHAS FRONT AND REAR BRAKES a. Connect a clear plastic hose tightly to the bleed screw . Put the other end of the hose into an open container. b. Loosen the bleed screw and push the brake caliper pistons into the brake caliper with your finger. c. Tighten the bleed screw. Bleed screw 6 Nm (0.6 m•kg, 4.3 ft•lb) d. Install a new brake pad shim new brake pad . e. Install the brake pad pins . onto each 6. Tighten: • brake pad pins 18 Nm (1.8 m•kg, 13 ft•lb) • brake caliper (front) 23 Nm (2.
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FRONT AND REAR BRAKES CHAS EAS00584 FRONT BRAKE MASTER CYLINDER 6 Nm (0.6 m•kg, 4.3 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 9 Nm (0.9 m•kg, 6.5 ft•lb) 26 Nm (2.6 m•kg, 19 ft•lb) Order 1 2 3 4 5 6 7 Job / Part Removing the front brake master cylinder Brake fluid Union bolt Copper washer Front brake hose Brake lever cover Brake lever Brake master cylinder holder Brake master cylinder Q’ty Remarks Remove the parts in the order listed. Drain. Refer to “CHANGING THE BRAKE FLUID” in chapter 3.
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FRONT AND REAR BRAKES CHAS EAS00585 2 Nm (0.2 m•kg, 1.4 ft•lb) Order Job / Part Disassembling the rear brake master cylinder Brake master cylinder cap Brake master cylinder reservoir diaphragm Brake master cylinder reservoir float Brake master cylinder boot Circlip Washer Brake master cylinder kit Q’ty Remarks Remove the parts in the order listed. 1 1 1 1 1 1 1 For assembly, reverse the disassembly procedure.
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FRONT AND REAR BRAKES CHAS EAS00586 REAR BRAKE MASTER CYLINDER 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Nm (0.1 m•kg, 0.7 ft•lb) 26 Nm (2.6 m•kg, 19 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) Order 1 2 3 4 5 6 7 8 9 10 Job / Part Removing the rear brake master cylinder Brake fluid Q’ty Remarks Remove the parts in the order listed. Drain. Refer to “CHANGING THE BRAKE FLUID” in chapter 3.
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FRONT AND REAR BRAKES CHAS EAS00587 Order Job / Part Removing the rear brake master cylinder Brake master cylinder kit Circlip Brake master cylinder joint O-ling Q’ty Remarks Remove the parts in the order listed. 1 1 1 1 For assembly, reverse the disassembly procedure.
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FRONT AND REAR BRAKES CHAS EAS00588 DISASSEMBLING THE FRONT BRAKE MASTER CYLINDER NOTE: Before disassembling the front brake master cylinder, drain the brake fluid from the entire brake system. 1. Remove: • union bolt • copper washers • brake hose NOTE: To collect any remaining brake fluid, place a container under the master cylinder and the end of the brake hose. 2. Remove: • brake master cylinder bracket • brake master cylinder 3.
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FRONT AND REAR BRAKES CHAS EAS00592 CHECKING THE FRONT AND REAR BRAKE MASTER CYLINDERS The following procedure applies to the both of the brake master cylinders. 1. Check: • brake master cylinder Damage / scratches / wear → Replace. • brake fluid delivery passages (brake master cylinder body) Obstruction → Blow out with compressed air. Front Rear 2. Check: • brake master cylinder kit Damage / scratches / wear → Replace. Front Rear 3. Check: • rear brake fluid reservoir Cracks / damage → Replace.
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CHAS FRONT AND REAR BRAKES EAS00598 ASSEMBLING AND INSTALLING THE FRONT BRAKE MASTER CYLINDER WARNING • Before installation, all internal brake components should be cleaned and lubricated with clean or new brake fluid. • Never use solvents on internal brake components. Recommended brake fluid DOT 4 1. Install: • brake master cylinder 9 Nm (0.9 m•kg, 6.5 ft•lb) NOTE: • Install the brake master cylinder holder with the “UP” mark facing up. • First, tighten the upper bolt, then the lower bolt. 2.
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FRONT AND REAR BRAKES CHAS NOTE: • While holding the brake hose, tighten the union bolt as shown. • Turn the handlebar to the left and right to make sure the brake hose does not touch other parts (e.g., wire harness, cables, leads). Correct if necessary. 3. Fill: • brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid.
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FRONT AND REAR BRAKES CHAS 6. Check: • brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. EAS00608 ASSEMBLING THE REAR BRAKE MASTER CYLINDER 1. Install: • O-ling • brake master cylinder joint • circlip • brake master cylinder kit 2. Install: • copper washers • brake hoses 26 Nm (2.6 m•kg, 19 ft•lb) • union bolt WARNING Proper brake hose routing is essential to insure safe vehicle operation.
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FRONT AND REAR BRAKES CHAS • When refilling, be careful that water does not enter the brake fluid reservoir. Water will significantly lower the boiling point of the brake fluid and could cause vapor lock. CAUTION: Brake fluid may damage painted surfaces and plastic parts. Therefore, always clean up any spilt brake fluid immediately. 4. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 5.
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FRONT AND REAR BRAKES CHAS EAS00613 FRONT BRAKE CALIPER 26 Nm (2.6 m•kg, 19 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) Order 1 2 3 4 5 6 Job / Part Removing the front brake caliper Brake fluid Protector Brake hose holder Union bolt Copper washer Brake hose Brake caliper Q’ty Remarks Remove the parts in the order listed. Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 1 1 1 2 1 1 For installation, reverse the removal procedure.
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FRONT AND REAR BRAKES CHAS EAS00614 6 Nm (0.6 m•kg, 4.3 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) Order Job / Part Disassembling the front brake caliper Brake pad Brake caliper bracket Brake pad support Sleeve boot Brake caliper piston Brake caliper piston seal Pin boot Bleed screw Q’ty Remarks Remove the parts in the order listed. 2 1 2 1 2 4 1 1 For assembly, reverse the disassembly procedure.
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FRONT AND REAR BRAKES CHAS EAS00616 REAR BRAKE CALIPER 26 Nm (2.6 m•kg, 19 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) Order 1 2 3 4 5 6 Job / Part Removing the rear brake caliper Brake fluid Union bolt Copper washer Brake hose Brake pad pin Protector Brake caliper Q’ty 1 2 1 2 1 1 Remarks Remove the parts in the order listed. Drain. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. Loosen.
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FRONT AND REAR BRAKES CHAS EAS00617 6 Nm (0.6 m•kg, 4.3 ft•lb) Order Job / Part Q’ty Remarks Disassembling the rear brake caliper Remove the parts in the order listed. Brake pad pin 2 Brake pad 2 Brake pad shim 1 Brake caliper seal 2 Brake caliper piston 1 Brake pad spring 1 Bleed screw 1 For assembly, reverse the disassembly procedure.
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FRONT AND REAR BRAKES CHAS EAS00619 DISASSEMBLING THE FRONT BRAKE CALIPER NOTE: Before disassembling the brake caliper, drain the brake fluid from the entire brake system. 1. Remove: • union bolt • copper washers • brake hose NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: • brake caliper pistons • brake caliper piston seals a. Blow compressed air into the brake hose joint opening to force out the pistons from the brake caliper.
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FRONT AND REAR BRAKES CHAS 1. Remove: • union bolt • copper washers • brake hose NOTE: Put the end of the brake hose into a container and pump out the brake fluid carefully. 2. Remove: • brake caliper piston • brake caliper piston seals a. Blow compressed air into the brake hose joint opening to force out the piston from the brake caliper. WARNING • Cover the brake caliper piston with a rag. Be careful not to get injured when the piston is expelled from the brake caliper.
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FRONT AND REAR BRAKES CHAS 1. Check: • brake caliper pistons Rust / scratches / wear → Replace the brake caliper pistons. • brake caliper cylinders Scratches / wear → Replace the brake caliper assembly. • brake caliper body Cracks / damage → Replace the brake caliper assembly. • brake fluid delivery passages (brake caliper body) Obstruction → Blow out with compressed air. WARNING Whenever a brake caliper is disassembled, replace the brake caliper piston seals. Front Rear 2.
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CHAS FRONT AND REAR BRAKES 1. Install: • brake caliper bracket 30 Nm (3.0 m•kg, 22 ft•lb) • brake pads • brake caliper 23 Nm (2.3 m•kg, 17 ft•lb) • copper washers • brake hose • union bolt 26 Nm (2.6 m•kg, 19 ft•lb) WARNING Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE ROUTING” in chapter 2. CAUTION: When installing the brake hose onto the brake caliper , make sure the brake pipe touches the projection on the brake caliper. 2.
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CHAS FRONT AND REAR BRAKES 3. Bleed: • brake system Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3. 4. Check: • brake fluid level Below the minimum level mark → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 5. Check: • brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
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FRONT AND REAR BRAKES CHAS WARNING Proper brake hose routing is essential to insure safe vehicle operation. Refer to “CABLE ROUTING” in chapter 2. CAUTION: When installing the brake hose onto the brake caliper , make sure the brake pipe touches the projection on the brake caliper. 3. Fill: • brake master cylinder reservoir (with the specified amount of the recommended brake fluid) Recommended brake fluid DOT 4 WARNING • Use only the designated brake fluid.
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FRONT AND REAR BRAKES CHAS 5. Check: • brake fluid level Below the minimum level mark → Add the recommended brake fluid to the proper level. Refer to “CHECKING THE BRAKE FLUID LEVEL” in chapter 3. 6. Check: • brake lever operation Soft or spongy feeling → Bleed the brake system. Refer to “BLEEDING THE HYDRAULIC BRAKE SYSTEM” in chapter 3.
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FRONT FORK CHAS EAS00646 FRONT FORK FRONT FORK LEGS 22 Nm (2.2 m•kg, 16 ft•lb) 20 Nm (2.0 m•kg, 14 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 20 Nm (2.0 m•kg, 14 ft•lb) Order Job / Part Removing the front fork legs Front wheel Q’ty Protector Front brake caliper Number plate 1 2 3 4 Cap bolt Upper bracket pinch bolt Lower bracket pinch bolt Front fork Remarks Remove the parts in the order listed. Refer to “FRONT WHEEL AND BRAKE DISC”. Refer to “FRONT AND REAR BRAKES”.
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FRONT FORK CHAS EAS00648 28 Nm (2.8 m•kg, 20 ft•lb) 15 Nm (1.5 m•kg, 11 ft•lb) 1 Nm (0.1 m•kg, 0.7 ft•lb) 55 Nm (5.5 m•kg, 40 ft•lb) Order Job / Part Disassembling the front fork legs Guide protector Cap bolt O-ring Damper adjusting rod Nut Washer Fork spring Spring guide Dust seal Oil seal clip Inner tube Outer tube Piston metal Slide metal Oil seal washer Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4-43 Remarks Remove the parts in the order listed.
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FRONT FORK CHAS 28 Nm (2.8 m•kg, 20 ft•lb) 15 Nm (1.5 m•kg, 11 ft•lb) 1 Nm (0.1 m•kg, 0.7 ft•lb) 55 Nm (5.5 m•kg, 40 ft•lb) Order Job / Part Oil seal Plug Base valve Gasket O-ring Damper rod O-ring Air bleed screw Q’ty 1 1 1 1 2 1 1 1 Remarks For assembly, reverse the disassembly procedure.
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FRONT FORK CHAS EAS00650 REMOVING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the front wheel is elevated. 2. Remove • front wheel • protector • front brake caliper • number plate 3. Loosen: • cap bolt 4.
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FRONT FORK CHAS EAS00652 DISASSEMBLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Remove: • cap bolt (from the damper adjusting rod) a. Install the rod holder between the nut and washer . NOTE: Use the side of the rod holder that is marked “A”. Rod holder 90890-01434, YM-01434 b. Loosen the nut. c. Remove the cap bolt. 2. Remove: • nut • washer • fork spring • spring guide 3. Drain: • fork oil NOTE: Stroke the damper rod draining the fork oil.
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FRONT FORK CHAS 6. Remove: • slide metal • oil seal washer • oil seal • piston metal • oil seal clip • dust seal 7. Remove: • base valve • damper rod NOTE: While holding the inner tube with the damper rod holder , loosen the base valve. Damper rod holder 90890-01454, YM-01454 EAS00656 CHECKING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Check: • inner tube • outer tube Bends / damage / scratches → Replace.
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FRONT FORK CHAS CAUTION: • The front fork leg has a built-in damper adjusting rod and a very sophisticated internal construction, which are particularly sensitive to foreign material. • When disassembling and assembling the front fork leg, do not allow any foreign material to enter the front fork. 4. Check: • base valve assembly Damage / wear → Replace. 5. Check: • cap bolt Damage / wear → Replace. • air bleed screw Damage / wear → Replace.
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CHAS FRONT FORK 1. Install: • damper rod assembly • inner tube CAUTION: Allow the damper rod assembly to slide slowly down the inner tube until it protrudes from the bottom of the inner tube. Be careful not to damage the inner tube. 2. Install: • gasket • base valve 3. Tighten: • base valve 55 Nm (5.5 m•kg, 40 ft•lb) LOCTITE® NOTE: While holding the damper rod with the damper rod holder , tighten the base valve. Damper rod holder 90890-01454, YM-01454 4.
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FRONT FORK CHAS 6. Install: • dust seal • oil seal clip • oil seal • oil seal washer • slide metal CAUTION: Make sure the numbered side of the oil seal faces up. NOTE: • Before installing the oil seal, lubricate its lips with lithium-soap-based grease. • Lubricate the outer surface of the inner tube with fork oil. • Before installing the oil seal, cover the top of the front fork leg with a plastic bag to protect the oil seal during installation. 7.
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FRONT FORK CHAS 10.Install: • oil seal (with the fork seal driver ) Fork seal driver 90890-01442, YM-01442 11.Install: • oil seal clip NOTE: Adjust the oil seal clip so that it fits into the outer tube’s groove. 12.Install: • dust seal 13.Fill: • front fork leg (with the specified amount of the recommended fork oil) Quantity (each front fork leg) 0.32 L (0.28 Imp qt, 0.
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FRONT FORK CHAS 14.Install: • fork spring • washer • cap bolt a. Install the fork spring, and washer. NOTE: Install the spring with the smaller pitch ing up . fac- b. Install the rod puller and rod puller attachment. Rod puller 90890-01437, YM-01437 Rod puller attachment (M10) 90890-01436, YM-01436 c. Pull up the rod puller and install the rod holder between the nut and the washer. NOTE: Use the side of the rod holder that is marked “A”. Rod holder 90890-01434, YM-01434 d.
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CHAS FRONT FORK g. Fully tighten the cap bolt onto the damper rod by hand. NOTE: Make sure that there is a clearance of 0 ~ 1 mm (0 ~ 0.04 in) between the front fork cap bolt and locknut . h. Hold the cap bolt to specification. and tighten the nut Nut 15 Nm (1.5 m•kg, 11 ft•lb) i. Remove the rod holder. j. Temporarily tighten the cap bolt 15.Install: • protector guide 4-53 . .
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CHAS FRONT FORK EAS00662 INSTALLING THE FRONT FORK LEGS The following procedure applies to both of the front fork legs. 1. Install: • front fork leg Temporarily tighten the upper and lower bracket pinch bolts. NOTE: Make sure the inner fork tube is flush with the top of the handlebar holder. 2. Tighten: • cap bolt 3. Adjust: • front fork top end 28 Nm (2.8 m•kg, 20 ft•lb) Front fork top end (standard) YZ85: 24 mm (0.94 in) YZ85LW: 0 mm (0.00 in) 4. Tighten: • upper bracket pinch bolt 22 Nm (2.
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HANDLEBAR CHAS EAS00664 HANDLEBAR 4 Nm (0.4 m•kg, 2.9 ft•lb) 1 Nm (0.1 m•kg, 0.7 ft•lb) 9 Nm (0.9 m•kg, 6.5 ft•lb) 27 Nm (2.7 m•kg, 1.9 ft•lb) 4 Nm (0.4 m•kg, 2.
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HANDLEBAR 4 Nm (0.4 m•kg, 2.9 ft•lb) CHAS 1 Nm (0.1 m•kg, 0.7 ft•lb) 9 Nm (0.9 m•kg, 6.5 ft•lb) 27 Nm (2.7 m•kg, 1.9 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) Order 14 15 16 Job / Part Left grip Handlebar upper holder Handlebar Q’ty 1 2 1 Remarks For installation, reverse the removal procedure.
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CHAS HANDLEBAR EAS00666 REMOVING THE HANDLEBAR 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • grip NOTE: Blow compressed air between the handlebar and the handlebar grip, and gradually push the grip off the handlebar. EAS00668 CHECKING THE HANDLEBAR 1. Check: • handlebar Bends / cracks / damage → Replace. WARNING Do not attempt to straighten a bent handlebar as this may dangerously weaken it.
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HANDLEBAR CHAS NOTE: • The upper handlebar holders should be installed with the punched mark forward. • First tighten the bolts on the front side of the handlebar upper holder, and then tighten the bolts on the rear side. FWD 3. Install: • left grip • apply the adhesive to the handlebar . NOTE: • Before applying the adhesive, wipe off grease or oil on the handlebar surface with a lacquer thinner. • Install the left grip to the handlebar so that the arrow mark (L) faces straight upward. 4.
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HANDLEBAR CHAS 6. Install: • throttle cable cap 1 Nm (0.1 m•kg, 0.7 ft•lb) • grip cap (lower) 4 Nm (0.4 m•kg, 2.9 ft•lb) • cover (grip cap) 7. Adjust: • throttle cable free play Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3. 8. Install: • brake master cylinder • brake master cylinder bracket 9 Nm (0.9 m•kg, 6.5 ft•lb) NOTE: Install the bracket so that the arrow mark face upward. 9. Install: • engine stop switch • clutch lever holder 4 Nm (0.4 m•kg, 2.
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HANDLEBAR CHAS 11.Adjust: • clutch lever free play Refer to “ADJUSTING THE CLUTCH CABLE FREE PRAY” in chapter 3. 12.Clamp the clamp portion of the number plate to the handlebar. 13.Insert the end of the fuel tank breather hose into the hole of the steering stem.
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STEERING HEAD CHAS EAS00675 STEERING HEAD UNDER BRACKET 22 Nm (2.2 m•kg, 16 ft•lb) 125 Nm (12.5 m•kg, 90 ft•lb) 1st 38 Nm (3.8 m•kg, 27 ft•lb) 2nd 3rd Loosen it 1 turn 4 Nm (0.4 m•kg, 2.9 ft•lb) 20 Nm (2.
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STEERING HEAD CHAS EAS00677 REMOVING THE LOWER BRACKET 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. 2. Remove: • steering stem nut • washer • upper bracket • steering ring nut (with the ring nut wrench ) Steering nut wrench 90890-01403, YU-33975 WARNING Securely support the lower bracket so that there is no danger of it falling. EAS00682 CHECKING THE STEERING HEAD 1.
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STEERING HEAD CHAS 3. Replace: • lower bearing • bearing races a. Remove the bearing races from the steering head pipe with a long rod and hammer. b. Remove the bearing race from the lower bracket with a floor chisel and hammer. c. Install a new dust seal and new bearing races. CAUTION: If the bearing race is not installed properly, the steering head pipe could be damaged. NOTE: • Always replace the bearing balls and bearing races as a set.
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STEERING HEAD CHAS 3. Install: • steering ring nut 4 Nm (0.4 m•kg, 2.9 ft•lb) (with the ring nut wrench ) Steering nut wrench 90890-01403, YU-33975 a. Tighten the steering ring nut. 38 Nm (3.8 m•kg, 27 ft•lb) b. Loosen it one turn. c. Retighten the steering ring nut. 4 Nm (0.4 m•kg, 2.9 ft•lb) 4. Install: • upper bracket • washer • steering stem nut 125 Nm (12.5 m•kg, 90 ft•lb) 5. Install: • front fork legs Refer to “INSTALLING THE FRONT FORK LEGS”.
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REAR SHOCK ABSORBER ASSEMBLY CHAS EAS00685 REAR SHOCK ABSORBER ASSEMBLY 36 Nm (3.6 m•kg, 26 ft•lb) 16 Nm (1.6 m•kg, 12 ft•lb) 26 Nm (2.6 m•kg, 19 ft•lb) 36 Nm (3.6 m•kg, 26 ft•lb) Order 1 2 3 4 5 6 7 8 9 Job / Part Removing the rear shock absorber assembly Seat Right side cover Silencer Clamp Rear frame Washer / bolt Self-locking nut / washer / bolt Rear shock absorber Spring guide Spring Adjuster Locknut Q’ty 1 1 1/1 1/1/1 1 1 1 1 1 Remarks Remove the parts in the order listed.
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REAR SHOCK ABSORBER ASSEMBLY CHAS EAS00687 HANDLING THE REAR SHOCK ABSORBER AND GAS CYLINDER WARNING This rear shock absorber and gas cylinder contain highly compressed nitrogen gas. Before handling the rear shock absorber or gas cylinder, read and make sure you understand the following information. The manufacturer cannot be held responsible for property damage or personal injury that may result from improper handling of the rear shock absorber and gas cylinder.
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REAR SHOCK ABSORBER ASSEMBLY CHAS EAS00694 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • seat and right side cover Refer to “SEAT, SIDE COVERS AND FUEL TANK” in chapter 3. • silencer Refer to “EXHAUST PIPE” in chapter 5. 3. Loosen: • air filter clamp 4. Remove: • rear frame 5.
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REAR SHOCK ABSORBER ASSEMBLY CHAS EAS00696 CHECKING THE REAR SHOCK ABSORBER ASSEMBLY AND GAS CYLINDER 1. Check: • rear shock absorber rod Bends / damage → Replace the rear shock absorber assembly. • rear shock absorber Gas leaks / oil leaks → Replace the rear shock absorber assembly. • spring Damage / wear → Replace the rear shock absorber assembly. • spring guide Damage / wear → Replace. • gas cylinder Damage / gas leaks → Replace. • bushings Damage / wear → Replace.
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REAR SHOCK ABSORBER ASSEMBLY CHAS 5. Install: • silencer Refer to “EXHAUST PIPE” in chapter 5. • seat and right side cover Refer to “SEAT, SIDE COVERS AND FUEL TANK” in chapter 3. 6. Adjust • spring preload • rebound damping • compression damping Refer to “ADJUSTING THE REAR SHOCK ABSORBER” in chapter 3.
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SWINGARM AND DRIVE CHAIN CHAS EAS00700 SWINGARM AND DRIVE CHAIN 16 Nm (1.6 m•kg, 12 ft•lb) 53 Nm (5.3 m•kg, 38 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 63 Nm (6.3 m•kg, 46 ft•lb) 36 Nm (3.6 m•kg, 26 ft•lb) Order 1 2 3 4 5 Job / Part Removing the swingarm and drive chain Rear wheel Brake hose holder Rear brake caliper Left crankcase cover Drive chain Drive chain support Drive chain support cover Pivot shaft Swingarm Q’ty Remarks Remove the parts in the order listed. Refer to “REAR WHEEL, AND BRAKE DISC”.
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SWINGARM AND DRIVE CHAIN CHAS 53 Nm (5.3 m•kg, 38 ft•lb) 54 Nm (5.4 m•kg, 39 ft•lb) Order Job / Part Disassembling the swingarm Relay arm Connecting rod Cover Dust seal Collar Bushing Oil seal Bearing Bushing Drive chain guide 10 Nm (1.0 m•kg, 7.2 ft•lb) Q’ty Remarks Disassemble the parts in the order listed. 1 1 2 2 5 5 8 9 2 1 For assembly, reverse the disassembly procedure.
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SWINGARM AND DRIVE CHAIN CHAS EAS00703 REMOVING THE SWINGARM 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • rear wheel Refer to “REAR WHEEL AND BRAKE DISC”. • brake hose holder and rear brake caliper Refer to “FRONT AND REAR BRAKES”. • left crankcase cover Refer to “CDI MAGNETO” in chapter 5. 3.
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SWINGARM AND DRIVE CHAIN CHAS EAS00706 REMOVING THE DRIVE CHAIN 1. Stand the vehicle on a level surface. WARNING Securely support the vehicle so that there is no danger of it falling over. NOTE: Place the vehicle on a suitable stand so that the rear wheel is elevated. 2. Remove: • master link clip • master link • master link plate • drive chain EAS00707 CHECKING THE SWINGARM 1. Check: • swingarm Bends / cracks / damage → Replace. 2. Check: • pivot shaft Roll the pivot shaft on a flat surface.
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SWINGARM AND DRIVE CHAIN CHAS 4. Check: • collars • oil seals Damage / wear → Replace. • bearings Damage / pitting → Replace. • bushings Damage / wear → Replace. 5. Check: • connecting rod • relay arm Damage / wear → Replace. 6. Check: • bearings • oil seals Damage / wear → Replace. • dust seals Damage / pitting → Replace. 7. Check: • bushings Damage / wear → Replace. • spacers Damage / scratches → Replace. EAS00710 CHECKING THE DRIVE CHAIN 1.
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SWINGARM AND DRIVE CHAIN CHAS NOTE: • While measuring the 15-link section, push down on the drive chain to increase its tension. • Perform this measurement at two or three different places. 2. Check: • drive chain Stiffness → Clean and lubricate or replace. 3. Clean: • drive chain a. Wipe the drive chain with a clean cloth. b. Put the drive chain in kerosene and remove any remaining dirt. c. Remove the drive chain from the kerosene and completely dry it. 4.
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SWINGARM AND DRIVE CHAIN CHAS 6. Check: • drive sprocket • rear wheel sprocket More than 1 / 4 tooth wear → Replace the drive chain sprockets as a set. Bent teeth → Replace the drive chain sprockets as a set. Correct Drive chain roller Drive chain sprocket CHECKING THE DRIVE CHAIN SUPPORT 1. Check: • dive chain support Limit reaches indicator → Replace. EAS00711 INSTALLING THE SWINGARM 1.
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SWINGARM AND DRIVE CHAIN CHAS 2. Install: • bearing • oil seal (with the relay arm) NOTE: • Apply the molybdenum disulfide grease on the bearing when installing. • Install the bearing by pressing it on the side having the manufacture’s marks or numbers. Installed depth of bearings Depth : 4.5 mm (0.18 in) Depth : 0.5 mm (0.02 in) Depth : 4.0 mm (0.16 in) 3. Install: • bearing • oil seal (with the connecting rod) NOTE: • Apply the molybdenum disulfide grease on the bearing when installing.
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SWINGARM AND DRIVE CHAIN 5. Install: • relay arm CHAS 54 Nm (5.4 m•kg, 39 ft•lb) 6. Install: • swingarm • pivot shaft • pivot shaft nut 63 Nm (6.3 m•kg, 46 ft•lb) 7. Install: • rear shock absorber • rear wheel Refer to “REAR WHEEL AND BRAKE DISC”. 8. Adjust: • drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. Drive chain slack 35 ~ 45 mm (1.38 ~ 1.77 in) EAS00714 INSTALLING THE DRIVE CHAIN 1.
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SWINGARM AND DRIVE CHAIN CHAS 3. Install: • master link clip CAUTION: • The closed end of the master link clip must face in the direction of drive chain rotation. • Never install a new drive chain onto worn drive chain sprockets; this will dramatically shorten the drive chain’s life. 4. Adjust: • drive chain slack Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. Drive chain slack 35 ~ 45 mm (1.38 ~ 1.
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ENG CHAPTER 5 ENGINE ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . DRIVE SPROCKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EXHAUST PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SILENCER FIBER REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE ENGINE .
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ENG KICK STARTER AND SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . PRIMARY DRIVE GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KICK STARTER AND SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . . . . . REMOVING THE PRIMARY DRIVE GEAR. . . . . . . . . . . . . . . . . . . . REMOVING THE KICK SHAFT ASSEMBLY. . . . . . . . . . . . . . . . . . . CHECKING THE KICK STARTER. . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE SHIFT SHAFT . . . . . . . . .
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ENGINE ENG ENGINE ENGINE DRIVE SPROCKET 60 Nm (6.0 m•kg, 43 ft•lb) 5 Nm (0.5 m•kg, 3.6 ft•lb) Order 1 2 3 4 Job / Part Removing the drive sprocket Drive chain Q’ty Left crank case cover Nut Lock washer Drive sprocket Remarks Remove the parts in the order listed. Loosen. Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. 1 1 1 1 For installation, reverse the removal procedure.
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ENGINE ENG EXHAUST PIPE 12 Nm (1.2 m•kg, 8.7 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb) Order 1 2 3 4 5 Job / Part Removing the exhaust pipe Seat Right side cover Silencer Exhaust pipe joint Exhaust pipe spring Exhaust pipe Exhaust pipe gasket Q’ty Remarks Remove the parts in the order listed. Refer to “SEAT, SIDE COVERS AND FUEL TANK” in chapter 3. 1 1 2 1 2 For installation, reverse the removal procedure.
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ENGINE ENG SILENCER FIBER REPLACEMENT 1. Remove: • seat • right side cover • bolt (silencer) • silencer • bolt (fiber) • washer 2. Remove: • inner pipe 3. Replace: • fiber 4. Install: • inner pipe NOTE: Fully apply Yamaha bond No. 1215 (Three bond No. 1215®) or equivalent as shown. Yamaha bond No.1215 (Three Bond No.1215®) 90890-85505 5. Install: • washer • bolt (fiber) 12 Nm (1.2 m•kg, 8.7 ft•lb) LOCTITE® • silencer • bolt (silencer) • right side cover • seat 5-3 12 Nm (1.2 m•kg, 8.
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ENGINE ENG EAS00191 ENGINE 63 Nm (6.3 m•kg, 46 ft•lb) 63 Nm (6.3 m•kg, 46 ft•lb) Order Job / Part Removing the engine Q’ty Coolant Remarks Remove the parts in the order listed. NOTE: Place a suitable stand under the frame and engine. Drain Refer to “CHANGING THE COOLANT” in chapter 3. Refer to “SEAT, SIDECOVERS AND FUEL TANK” in chapter 3. Refer to “CARBURETOR” in chapter 7. Seat Fuel tank Carburetor Exhaust pipe Silencer Clutch cable Radiator hose CDI magneto lead Refer to “EXHAUST PIPE”.
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ENGINE ENG 63 Nm (6.3 m•kg, 46 ft•lb) 63 Nm (6.3 m•kg, 46 ft•lb) Order 1 2 3 4 5 Job / Part CDI magneto lead Drive chain Q’ty Remarks Disconnect. Loosen. Refer to “ADJUSTING THE DRIVE CHAIN SLACK” in chapter 3. Engine mount nut Engine mount bolt Pivot shaft nut Pivot shaft Engine 2 2 1 1 1 For installation, reverse the removal procedure.
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ENGINE ENG EAS00192 INSTALLING THE ENGINE 1. Install: • engine • pivot shaft • engine mount bolt (front) • engine mount bolt (lower) NOTE: Do not fully tighten the bolts. 2. Tighten: 63 Nm (6.3 m•kg, 46 ft•lb) • pivot shaft nut • engine mount nut (front) 69 Nm (6.9 m•kg, 50 ft•lb) • engine mount nut (lower) 69 Nm (6.
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CYLINDER HEAD, CYLINDER AND PISTON ENG EAS00221 CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD 20 Nm (2.0 m•kg, 14 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) Order 1 2 3 4 5 Job / Part Removing the cylinder head Coolant Q’ty Seat Fuel tank Radiator hose Spark plug Cylinder head nut Copper washer Cylinder head O-ring Remarks Remove the parts in the order listed. Drain Refer to “CHANGING THE COOLANT” in chapter 3. Refer to “SEAT, SIDECOVERS AND FUEL TANK” in chapter 3. Refer to “RADIATOR” in chapter 6.
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CYLINDER HEAD, CYLINDER AND PISTON ENG EAS00222 REMOVING THE CYLINDER HEAD 1. Remove: • cylinder head nuts NOTE: • Loosen the nuts in the proper sequence as shown. • Loosen each nut 1 / 2 of a turn at a time. After all of the nuts are fully loosened, remove them. EAS00229 CHECKING THE CYLINDER HEAD 1. Eliminate: • combustion chamber carbon deposits (with a rounded scraper ) NOTE: Do not use a sharp instrument to avoid damaging or scratching: • spark plug bore threads 2.
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CYLINDER HEAD, CYLINDER AND PISTON ENG d. Place a 400 ~ 600 grit wet sandpaper on the surface plate and resurface the cylinder head using a figure-eight sanding pattern. NOTE: To ensure an even surface, rotate the cylinder head several times. EAS00233 INSTALLING THE CYLINDER HEAD 1. Lubricate: • O-rings Recommended lubricart Lithium-soap-based grease 2. Install: • O-rings 3. Install: • cylinder head • copper washer • cylinder head nuts 30 Nm (3.
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CYLINDER HEAD, CYLINDER AND PISTON ENG EAS00251 CYLINDER AND PISTON 28 Nm (2.8 m•kg, 20 ft•lb) 13 Nm (1.3 m•kg, 9.4 ft•lb) 13 Nm (1.3 m•kg, 9.4 ft•lb) Order 1 2 3 4 5 6 7 8 9 Job / Part Removing the cylinder and piston Cylinder head Cylinder nut Cylinder Dowel pin Cylinder gasket Piston pin clip Piston pin Piston Small end bearing Piston ring Q’ty Remarks Remove the parts in the order listed. Refer to “CYLINDER HEAD”. 4 1 4 1 2 1 1 1 1 For installation, reverse the removal procedure.
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CYLINDER HEAD, CYLINDER AND PISTON ENG EAS00253 REMOVING THE CYLINDER AND PISTON 1. Remove: • piston pin clip NOTE: Before removing the piston pin clip, cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase. 2. Remove: • piston pin • piston • small end bearing CAUTION: Do not use a hammer to drive the piston pin out. NOTE: Before removing the piston pin, deburr the piston pin clip’s groove and the piston’s pin bore area.
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CYLINDER HEAD, CYLINDER AND PISTON ENG 2. Measure: • piston-to-cylinder clearance a. Measure cylinder bore “C” with the cylinder bore gauge. NOTE: Measure cylinder bore “C” by taking side-toside and front-to-back measurements of the cylinder. Then, find the average of the measurements. Standard Wear limit Taper limit “T” Out of round “R” 47.500 ~ 47.514 mm (1.8701 ~ 1.8706 in) 47.6 mm (1.8740 in) 0.05 mm (0.0020 in) 0.05 mm (0.
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CYLINDER HEAD, CYLINDER AND PISTON ENG COMBINATION OF PISTON AND CYLINDER 1. Check: • cylinder mark Cylinder mark A B C D Cylinder size 47.500 ~ 47.502 mm (1.8701 ~ 1.8702 in) 47.504 ~ 47.506 mm (1.8702 ~ 1.8703 in) 47.508 ~ 47.510 mm (1.8704 ~ 1.8705 in) 47.512 ~ 47.514 mm (1.87055 ~ 1.87063 in) 2. Check: • piston mark Piston mark (color) A (red) B (orange) C (green) D (purple) Piston size 47.457 ~ 47.460 mm (1.8684 ~ 1.8685 in) 47.461 ~ 47.464 mm (1.8685 ~ 1.8687 in) 47.465 ~ 47.468 mm (1.8687 ~ 1.
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CYLINDER HEAD, CYLINDER AND PISTON ENG EAS00263 CHECKING THE PISTON RING 1. Measure: • piston ring side clearance Out of specification → Replace the piston and piston ring as a set. NOTE: Before measuring the piston ring side clearance, eliminate any carbon deposits from the piston ring grooves and piston ring. Piston ring side clearance Piston ring 0.030 ~ 0.065 mm (0.001 ~ 0.003 in) : 0.1 mm (0.004 in) 2.
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CYLINDER HEAD, CYLINDER AND PISTON ENG Piston pin outside diameter 13.996 ~ 14.000 mm (0.5510 ~ 0.5512 in) : 13.975 mm (0.5502 in) 3. Measure: • piston pin bore inside diameter Out of specification → Replace the piston. Piston pin bore inside diameter 14.004 ~ 14.015 mm (0.5513 ~ 0.5518 in) : 14.040 mm (0.5528 in) 4. Calculate: • piston-pin-to-piston clearance Out of specification → Replace the piston pin and piston as a set.
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CYLINDER HEAD, CYLINDER AND PISTON ENG EAS00267 INSTALLING THE PISTON AND CYLINDER 1. Install: • piston ring NOTE: • Take care not to scratch the piston or damage the piston ring. • Align the piston ring gap with the pin . • After installing the piston ring, check the smooth movement of it. 2. Install: • gasket (cylinder) • small end bearing (with the recomended lubricant) • dowel pin Recommended lubricant Engine oil 3.
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CYLINDER HEAD, CYLINDER AND PISTON ENG 4. Lubricate: • piston • piston ring • cylinder (with the recommended lubricant) Recommended lubricant Engine oil 5. Install: • cylinder 28 Nm (2.8 m•kg, 20 ft•lb) • cylinder nut NOTE: • While compressing the piston ring with one hand, install the cylinder with the other hand. • Tighten the nuts in stage, using a crisscross pattern.
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CLUTCH ENG EAS00274 CLUTCH CLUTCH 70 Nm (7.0 m•kg, 51 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) Order 1 2 3 4 5 6 7 8 9 10 11 12 Job / Part Removing the clutch Transmission oil Clutch cable Clutch cover Clutch cover gasket Dowel pin Compression spring Pressure plate Push rod 1 Ball Push rod 2 Friction plate 1 Clutch plate 1 Friction plate 2 Clutch boss nut Q’ty Remarks Drain Refer to “CHANGING THE TRANSMISSION OIL” in chapter 3.
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CLUTCH ENG 70 Nm (7.0 m•kg, 51 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) Order 13 14 15 16 17 18 19 20 21 22 Job / Part Conical washer Clutch boss Washer Primary drive gear Spacer Washer Push lever shaft Spring Oil seal Bearing Q’ty 1 1 1 1 1 1 1 1 1 1 Remarks For installation, reverse the removal procedure.
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CLUTCH ENG EAS00276 REMOVING THE CLUTCH 1. Remove: • clutch cover • gasket NOTE: Loosen each bolt 1 / 4 of a turn at a time, in stages and in a crisscross pattern. After all of the bolts are fully loosened, remove them. 2. Remove: • compression spring bolts • compression springs • pressure plate 3. Remove: • push rod 1 • ball • push rod 2 4. Remove: • friction plate 1 • clutch plate • friction plate 2 5.
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CLUTCH ENG EAS00280 CHECKING THE FRICTION PLATES The following procedure applies to all of the friction plates. 1. Check: • friction plate Damage / wear → Replace the friction plates as a set. 2. Measure: • friction plate thickness Out of specification → Replace the friction plates as a set. NOTE: Measure the friction plate at four places. Friction plate thickness 2.9 ~ 3.1 mm (0.114 ~ 0.112 in) : 2.7 mm (0.
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CLUTCH ENG EAS00282 CHECKING THE CLUTCH SPRINGS The following procedure applies to all of the clutch springs. 1. Check: • clutch spring Damage → Replace the clutch springs as a set. 2. Measure: • clutch spring free length Out of specification → Replace the clutch springs as a set. Clutch spring free length 33.0 mm (1.30 in) : 31.0 mm (1.22 in) EAS00284 CHECKING THE CLUTCH HOUSING 1.
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CLUTCH ENG CHECKING THE PUSH LEVER SHAFT 1. Check: • push lever shaft Wear / damage → Replace. EAS00288 CHECKING THE CLUTCH PUSH RODS 1. Check: • push rod 1 • ball • push rod 2 Wear / damage / bend → Replace. EAS00298 INSTALLING THE CLUTCH 1. Install: • washer • spacer • primary driven gear (with the recommended lubricant) Recommended lubricant Transmission oil 2. Install: • washer • clutch boss 3. Install: • washer NOTE: Install the conical washer to the main axle as shown in the illustration.
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CLUTCH ENG 4. Install: • clutch boss nut 70 Nm (7.0 m•kg, 51 ft•lb) NOTE: While holding the clutch boss with the universal clutch holder , tighten the clutch boss nut. Universal clutch holder 90890-04086, YM-91042 5. Lubricate: • friction plates • clutch plates (with the recommended lubricant) Recommended lubricant Transmission oil 6.
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CLUTCH 8. Install: • pressure plate 1 NOTE: Align the punch mark with the punch mark ENG on the pressure plate on the clutch boss. 9. Install: • clutch spring • clutch spring bolt 6 Nm (0.6 m•kg, 4.3 ft•lb) NOTE: Tighten the clutch spring bolts in stages and in a crisscross pattern. 10.Install • dowel pin • clutch cover gasket 10 Nm (1.0 m•kg, 7.2 ft•lb) • clutch cover NOTE: Tighten the bolts in stage, using a crisscross pattern.
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KICK STARTER AND SHIFT SHAFT ENG EAS00327 KICK STARTER AND SHIFT SHAFT PRIMARY DRIVE GEAR 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 79 Nm (7.9 m•kg, 57 ft•lb) Order Job / Part Removing the primary drive gear Transmission oil Q’ty Coolant 1 2 3 4 5 6 Water pump housing Radiator hose 2 Brake pedal Clutch Kick starter crank Right crankcase cover Gascket Dowel pin Primary drive gear nut Washer Remarks Remove the parts in the order listed. Drain.
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KICK STARTER AND SHIFT SHAFT ENG 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 79 Nm (7.9 m•kg, 57 ft•lb) Order 7 Job / Part Primary drive gear Q’ty 1 Remarks For installation, reverse the removal procedure.
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KICK STARTER AND SHIFT SHAFT ENG KICK STARTER AND SHIFT SHAFT 10 Nm (1.0 m•kg, 7.2 ft•lb) Order 1 2 3 4 5 6 7 8 9 10 11 12 13 Job / Part Removing the kick starter shaft and shift shaft Circlip Washer Kick idle gear Spring guide Torsion spring Washer Kick starter gear clip Kick starter gear Kick starter shaft Shift pedal Shift shaft Stopper lever spring Circlip Q’ty 1 2 1 1 1 1 1 1 1 1 1 1 1 5-28 Remarks Remove the parts in the order listed.
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KICK STARTER AND SHIFT SHAFT ENG 10 Nm (1.0 m•kg, 7.2 ft•lb) Order 14 15 16 17 18 19 Job / Part Washer Stopper lever Collar Shift shaft spring Oil seal Oil seal Q’ty 1 1 1 1 1 1 Remarks For installation, reverse the removal procedure.
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KICK STARTER AND SHIFT SHAFT ENG REMOVING THE PRIMARY DRIVE GEAR 1. Remove: • nut (primary drive gear) NOTE: Hold the drive gear holder onto the crankcase using the M6 bolts . Drive gear holder 90890-01495, YM-01495 REMOVING THE KICK SHAFT ASSEMBLY 1. Remove: • kick shaft assembly NOTE: Unhook the torsion spring from the hole in the crankcase. CHECKING THE KICK STARTER 1. Check: • kick starter gear smooth movement Unsmooth movement → Replace. • kick starter shaft Wear / damage → Replace. 2.
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KICK STARTER AND SHIFT SHAFT ENG EAS00328 CHECKING THE SHIFT SHAFT 1. Check: • shift shaft Bends / damage / wear → Replace. • spring Damage / wear → Replace. EAS00330 CHECKING THE STOPPER LEVER 1. Check: • stopper lever Bends / damage → Replace. • torsion spring Damage / ware → Replace. CHECKING THE PRIMARY DRIVE GEAR AND PRIMARY DRIVEN GEAR 1. Check: • primary drive gear Damage / wear → Replace. • primary driven gear Damage / wear → Replace. 2.
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KICK STARTER AND SHIFT SHAFT ENG 2. Install: • stopper lever assembly (with the shift shaft ) NOTE: Apply the transmission oil on the stopper lever assembly. 3. Install: • stopper lever • shift shaft NOTE: • Apply transmission oil on the shift shaft. • When installing the shift shaft, align the stopper lever roller with the slot on segment. • When installing the shift shaft, make sure that the torsion spring is in the position as shown. 4.
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KICK STARTER AND SHIFT SHAFT ENG INSTALLING THE KICK STARTER SHAFT ASSEMBLY 1. Install: • kick starter gear • washer • torsion spring NOTE: Make sure the stopper of the torsion spring fits into the hole in the other side of the stopper of the kick starter shaft . 2. Install: • spring guide NOTE: Slide the spring guide into the kick starter shaft, make sure the groove in the spring guide fits on the stopper of the torsion spring. 3.
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ENG KICK STARTER AND SHIFT SHAFT INSTALLING THE PRIMARY DRIVE GEAR 1. Install: • straight key 2. Install: • primary drive gear • washer • primary drive gear nut NOTE: Install the conical washer to the crankshaft as shown in the illustration. 3. Tighten: • primary drive gear nut 79 Nm (7.9 m•kg, 57 ft•lb) Drive gear holder 90890-01495, YM-01495 NOTE: Hold the drive gear holder case using the M6 bolts . onto the crank- 4. Install: • primary driven gear Refer to “CLUTCH”. 5.
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KICK STARTER AND SHIFT SHAFT ENG 7. Install: • bolt (right crankcase cover) 10 Nm (1.0 m•kg, 7.2 ft•lb) • copper washer (oil drain bolt) • oil drain bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) • copper washer (coolant drain bolt) • coolant drain bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Tighten the bolts in stage, using a crisscross pattern. 8. Install: • kick starter crank 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Install the kick starter crank closest to but not contacting the pillar tube and exhaust pipe . 9.
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CDI MAGNETO ENG EAS00343 CDI MAGNETO 8 Nm (0.8 m•kg, 5.8 ft•lb) 33 Nm (3.3 m•kg, 24 ft•lb) 5 Nm (0.5 m•kg, 3.6 ft•lb) Order 1 2 3 4 5 6 Job / Part Removing the CDI magneto Seat Fuel tank CDI magneto lead Left crankcase cover Left crankcase cover gasket Rotor Stator Woodruff key Q’ty 1 1 1 1 1 1 Remarks Remove the parts in the order listed. Disconnect. For installation, reverse the removal procedure.
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CDI MAGNETO ENG EAS00346 REMOVING THE ROTOR 1. Remove: • nut • washer NOTE: While holding the rotor with the rotor holding tool , loosen the rotor nut. Rotor holding tool 90890-01235, YU-1325 2. Remove: • rotor (with the flywheel puller • woodruff key ) Flywheel puller 90890-01189, YM-1189 NOTE: When installing the flywheel puller, turn it counterclockwise. CHECKING THE CDI MAGNETO 1. Check: • rotor inner surface • stator outer surface Damage → Inspect the crankshaft runout and crankshaft bearing.
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CDI MAGNETO ENG INSTALLING THE CDI MAGNETO 1. Install: • stator • screw NOTE: Temporarily tighten the screw at this point. 2. Install: • woodruff key • rotor NOTE: • Clean the tapered portions of the crankshaft and rotor. • When installing the woodruff key, make sure that its flat surface is in parallel with the crankshaft center line . • When installing the rotor, align the keyway of the rotor with the woodruff key. 3. Install: • washer 33 Nm (3.
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CDI MAGNETO ENG 5. Tighten: • screw (stator) 8 Nm (0.8 m•kg, 5.8 ft•lb) 6. Check: • ignition timing Re-check the ignition timing. 7. Connect: • CDI magneto lead Refer to “CABLE ROUTING” in chapter 2. 8. Install: • gasket (left crankcase cover) • left crankcase cover 5 Nm (0.5 m•kg, 3.6 ft•lb) NOTE: Tighten the screws in stage, using a crisscross pattern.
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CRANKCASE AND CRANKSHAFT ENG EAS00381 CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT 8 Nm (0.8 m•kg, 5.8 ft•lb) 20 Nm (2.0 m•kg, 14 ft•lb) Order 1 2 3 4 5 6 7 Job / Part Removing the crankcase and crankshaft Engine Piston Primary drive gear Kick idle gear Stopper lever Rotor and stator Crank case oil seal holder Right crankcase Left crankcase Dowel pin Crankshaft Oil seal Bearing 8 Nm (0.8 m•kg, 5.8 ft•lb) Q’ty Remarks Remove the parts in the order listed. Refer to “ENGINE”.
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CRANKCASE AND CRANKSHAFT ENG EAS00385 DISSASSEMBLING THE CRANKCASE 1. Remove: • right crankcase (with the crankcase separating tool ) Crankcase separating tool 90890-01135, YU-1135-A 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. • As pressure is applied, alternately tap on the front engine mounting boss and transmission shafts.
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CRANKCASE AND CRANKSHAFT ENG REMOVING THE CRANKSHAFT BEARING 1. Remove: • bearing NOTE: • Remove the bearing from the crankcase by pressing its inner race as shown in . • If the bearing is removed together with the crankshaft, remove the bearing using a general bearing puller as shown in . CAUTION: Do not use the removed bearing. EAS00394 CHECKING THE CRANKSHAFT AND CONNECTING ROD 1. Measure: • crankshaft runout Out of specification → Replace the crankshaft, bearing or both.
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CRANKCASE AND CRANKSHAFT ENG 3. Measure: • big end side clearance Out of specification → Replace the big end bearing, crankshaft pin, or connecting rod. Big end side clearance 0.20 ~ 0.70 mm (0.008 ~ 0.028 in) 4. Measure: • crankshaft width Out of specification → Replace the crankshaft. Crankshaft width 44.90 ~ 44.95 mm (1.768 ~ 1.770 in) EAS00399 CHECKING THE CRANKCASE 1. Check: • contacting surface Scratches → Replace. • engine mounting boss , crankcase Cracks / damage → Replace.
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CRANKCASE AND CRANKSHAFT ENG EAS00408 INSTALLING THE CRANKSHAFT 1. Install: • crankshaft assembly NOTE: • Install the crankshaft assembly with the crankshaft installer pot , crankshaft installer bolt , adapter (M10) .
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CRANKCASE AND CRANKSHAFT ENG 2. Install: • dowel pin • right crankcase (onto the left crankcase ) NOTE: • Turn the shift cam to the position shown in the figure so that it does not contact the crankcase when installing the crankcase. • Fit the right crankcase onto the left crankcase. Tap lightly on the case with soft hammer. • When installing the crankcase, the connecting rod should be positioned at TDC. 3. Install: • clamp • screw 8 Nm (0.8 m•kg, 5.
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TRANSMISSION ENG EAS00419 TRANSMISSION Order 1 2 3 4 5 6 7 8 9 10 11 Job / Part Removing the transmission Engine Crankcase Shift fork guide bar Shift drum Shift fork-R Shift fork-L Shift fork-C Bearing Circlip 2ND pinion gear 6TH pinion gear Washer Circlip Q’ty 2 1 1 1 1 1 1 1 1 1 1 5-46 Remarks Remove the parts in the order listed. Refer to “ENGINE”. Separate. Refer to “CRANKCASE AND CRANKSHAFT”.
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TRANSMISSION Order 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Job / Part 3RD pinion gear Circlip Washer 5TH pinion gear Main axle Bearing Circlip Washer 1ST wheel gear 5TH wheel gear Circlip Washer 4TH wheel gear 3RD wheel gear 6TH wheel gear Drive axle Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 5-47 ENG Remarks
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TRANSMISSION Order 28 29 30 31 32 Job / Part 2ND wheel gear Washer Bearing Oil seal Bearing Q’ty 1 1 1 1 2 ENG Remarks For installation, reverse the removal procedure.
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TRANSMISSION ENG EAS00420 REMOVING THE TRANSMISSION 1. Remove: • right crankcase Refer to “CRANKCASE AND CRANKSHAFT”. 2. Remove: • main axle • drive axle NOTE: • Remove assembly carefully. Note the position of each part. Pay particular attention to the location and direction of shift forks. • Remove the main axle and drive axle by tapping lightly on the transmission drive axle with a soft hammer. AS00421 CHECKING THE SHIFT FORKS The following procedure applies to all of the shift forks. 1.
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TRANSMISSION ENG EAS00422 CHECKING THE SHIFT DRUM ASSEMBLY 1. Check: • shift drum grooves Damage / scratches / wear → Replace the shift drum assembly. • shift drum segment Damage / wear → Replace the shift drum assembly. • shift drum bearing Damage / pitting → Replace the shift drum assembly. EAS00423 CHECKING THE TRANSMISSION 1. Measure: • main axle runout (with a centering device and dial gauge ) Out of specification → Replace the main axle. Main axle runout limit 0.01 mm (0.0004 in) 2.
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TRANSMISSION ENG 4. Check: • transmission gear engagement (each pinion gear to its respective wheel gear) Incorrect → Reassemble the transmission axle assemblies. 5. Check: • transmission gear movement Rough movement → Replace the defective part(s). 6. Check: • circlips Bends / damage / looseness → Replace. INSTALLING THE TRANSMISSION 1.
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TRANSMISSION ENG 3. Install: • washer • circlip NOTE: • Be sure the circlip sharp-edged corner is positioned opposite side to the washer and gear . • Be sure the circlip end is positioned at axle spline groove . 4. Install: • collar NOTE: • Apply the lithium soap base grease on the oil seal lip. • When installing the collar into the crankcase, pay careful attention to the crankcase oil seal lip. 5. Install: • main axle • drive axle 6.
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TRANSMISSION ENG NOTE: • Mesh the shift fork-L with the 6th wheel gear and shift fork-R with the 5TH on the drive axle. wheel gear • Mesh the shift fork-C with the 3RD / 4TH pinion gear on the main axle. 7. Install: • shift cam NOTE: Apply the transmission oil on the shift cam. 8. Install: • shift fork guide bar NOTE: • Apply the transmission oil on the guide bars. • Be sure the long bar is inserted into the shift fork-L and shift fork-R and the short one into shift fork-C. 9.
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COOL CHAPTER 6 COOLING SYSTEM RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 CHECKING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 INSTALLING THE RADIATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 CHECKING THE WATER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . .
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RADIATOR EAS00454 COOL COOLING SYSTEM RADIATOR 1 Nm (0.1 m•kg, 0.7 ft•lb) 1 Nm (0.1 m•kg, 0.7 ft•lb) 1 Nm (0.1 m•kg, 0.7 ft•lb) Order Job / Part Removing the radiator Air scoop Q’ty Coolant 1 2 3 4 5 6 Radiator guard Radiator inlet hose Radiator outlet hose Radiator breather hose Radiator Radiator cap Remarks Remove the parts in the order listed. Refer to “SEAT, SIDECOVERS AND FUEL TANK” in chapter 3. Drain. Refer to “CHANGING THE COOLANT” in chapter 3.
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RADIATOR COOL EAS00455 CHECKING THE RADIATOR 1. Check: • radiator fins Obstruction → Clean. Apply compressed air to the rear of the radiator. Damage → Repair or replace. NOTE: Straighten any flattened fins with a thin, flathead screwdriver. 2. Check: • radiator hoses Cracks / damage → Replace. 3. Measure: • radiator cap opening pressure Below the specified pressure → Replace the radiator cap. Radiator cap opening pressure 93 ~ 123 kPa (0.93 ~ 1.23 kg / cm2, 13.2 ~ 17.5 psi) a.
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RADIATOR COOL 2. Check: • cooling system Leaks → Repair or replace any faulty part. a. Attach the radiator cap tester ator. to the radi- Radiator cap tester 90890-01325, YU-24460-01 Radiator cap tester adapter 90890-01352, YU-33984 b. Apply 100 kPa (1.0 kg / cm2, 14.22 psi) of pressure. c. Measure the indicated pressure with the gauge.
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WATER PUMP COOL EAS00468 WATER PUMP 10 Nm (1.0 m•kg, 7.2 ft•lb) 14 Nm (1.4 m•kg, 10 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) Order Job / Part Removing the water pump Q’ty Right crankcase cover 1 2 3 4 5 6 Remarks Remove the parts in the order listed. NOTE: It is not necessary to remove the water pump unless the coolant level is extremely low or the coolant contains engine oil. Refer to “PRIMARY DRIVE GEAR” in chapter 5.
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WATER PUMP COOL EAS00472 CHECKING THE WATER PUMP 1. Check: • oil seal Damage / wear → Replace. 2. Check: • bearing Rough movement → Replace. 3. Check: • impeller Cracks / damage / wear → Replace. 4. Check: • water pump impeller shaft Damage / wear → Replace. • water pump drive gear Damage / wear → Replace. EAS00479 INSTALLING THE WATER PUMP 1. Install: • oil seal NOTE: Lubricate the oil seal with a thin coat of lithiumsoap-based grease.
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COOL WATER PUMP 2. Install: • bearing NOTE: Install the bearing by pressing its outer race parallel. 3. Install: • water pump impeller shaft • washer 14 Nm (1.4 m•kg, 10 ft•lb) • impeller NOTE: • Take care so that the oil seal lip is not damaged or the spring does not slip off its position. • When installing the water pump impeller shaft, apply the lithium-soap-base grease on the oil seal lip and water pump impeller shaft. And install the shaft while turning it.
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CARB CHAPTER 7 CARBURETOR CARBURETOR AND REED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . CHECKING THE REED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLY THE REED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . ASSEMBLING THE CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . INSTALLING THE REED VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . .
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CARBURETOR AND REED VALVE EAS00480 CARB CARBURETOR CARBURETOR AND REED VALVE 8 Nm (0.8 m•kg, 5.8 ft•lb) 1 Nm (0.1 m•kg, 0.7 ft•lb) Order 1 2 3 4 5 6 Job / Part Removing the carburetor and reed valve Clamp Carburetor assembly Carburetor joint Reed valve assembly Reed valve stopper Reed valve Q’ty 2 1 1 1 2 2 Remarks Remove the parts in the order listed. Loosen. For installation, reverse the removal procedure.
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CARBURETOR AND REED VALVE Order Job / Part Disassembling the carburetor Mixing chamber top Throttle valve Jet needle Ring Throttle valve spring Gascket (mixing chamber top) Float chamber Gascket (float chamber) Float pin Float Needle valve Main jet Main nozzle holder Main nozzle Pilot jet Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 7-2 CARB Remarks Remove the parts in the order listed
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CARBURETOR AND REED VALVE Order Job / Part Starter plunger Throttle stop screw Pilot air screw Q’ty 1 1 1 CARB Remarks For assembly, reverse the disassembly procedure.
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CARBURETOR AND REED VALVE CARB EAS00485 CHECKING THE CARBURETOR 1. Check: • carburetor body • float chamber • jet housing Cracks / damage → Replace. 2. Check: • fuel passages Obstruction → Clean. a. Wash the carburetor in a petroleum-based solvent. Do not use any caustic carburetor cleaning solution. b. Blow out all of the passages and jets with compressed air. 3. Check: • float chamber body Dirt → Clean. 4. Check: • float chamber rubber gasket Cracks / damage / wear → Replace. 5.
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CARBURETOR AND REED VALVE 7. • • • • • • CARB Check: jet needle main nozzle main jet main nozzle holder pilot jet starter plunger Bends / damage / wear → Replace. Obstruction → Clean. Blow out the jets with compressed air. 8. Check: • piston valve movement Insert the piston valve into the carburetor body and move it up and down. Tightness → Replace the piston valve. 9. Check: • hose joints Cracks / damage → Replace. 10.Check: • carburetor breather hoses • fuel hoses Cracks / damage / wear → Replace.
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CARBURETOR AND REED VALVE CARB ASSEMBLY THE REED VALVE 1. Install: • reed valve • reed valve stopper • screw (reed valve) 1 Nm (0.1 m•kg, 0.7 ft•lb) LOCTITE® NOTE: • Install the reed valve with the reed valve bending as shown. • Note the cut in the lower corner of the reed valve and stopper. • Tighten each screw gradually to avoid warping. EAS00487 ASSEMBLING THE CARBURETOR CAUTION: • Before assembling the carburetor, wash all of the parts in a petroleum-based solvent. • Always use a new gasket. 1.
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CARBURETOR AND REED VALVE CARB 2. Install: • starter plunger 3. Install: • pilot jet • main nozzle • main jet holder • main jet NOTE: Install the main nozzle with its chamfered side facing the carburetor. 4. Install: • needle valve • float • float pin NOTE: • After installing the needle valve to the float, install them to the carburetor. • Check the float for smooth movement. 5. Install: • float chamber • gascket (float chamber) • hose holder (carburetor breather hose) 6.
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CARBURETOR AND REED VALVE CARB 8. Install: • throttle cable • mixing chamber top • gascket (mixing chamber top) • spring (throttle valve) • ring • throttle valve NOTE: • While compressing the spring, connect the throttle cable. • Align the cut in the ring with the throttle cable. INSTALLING THE REED VALVE 1. Install: • reed valve assembly NOTE: Install the reed valve assembly with its projection facing upward. 2. Install: • carburetor joint 8 Nm (0.8 m•kg, 5.
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CARBURETOR AND REED VALVE CARB 2. Adjust: • throttle cable free play Throttle cable free play 3 ~ 5 mm (0.12 ~ 0.20 in) Refer to “ADJUSTING THE THROTTLE CABLE FREE PLAY” in chapter 3. EAS00498 MEASURING AND ADJUSTING THE FUEL LEVEL 1. Measure: • fuel height Out of specification → Adjust. Fuel height 18 ~ 20 mm (0.71 ~ 0.79 in) a. Hold the carburetor in an upside down position. b. Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers.
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ELEC CHAPTER 8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 CHECKING SWITCH CONTINUITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2 IGNITION SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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ELECTRICAL COMPONENTS EAS00729 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS Ignition coil Engine stop switch CDI unit CDI magneto 8-1 ELEC
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CHECKING SWITCH CONTINUITY ELEC CEAS00730 “∞” CHECKING SWITCH CONTINUITY “0” Check each switch for continuity with the pocket tester. If the continuity reading is incorrect, check the wiring connections and if necessary, replace the switch. “Ω × 1” CAUTION: Never insert the tester probes into the coupler terminal slots. Always insert the probes from the opposite end of the coupler taking care not to loosen or damage the leads.
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IGNITION SYSTEM EAS00736 ELEC EAS00740 IGNITION SYSTEM 1. Spark plug TROUBLESHOOTING • Check the condition of the spark plug. • Check the spark plug type. • Measure the spark plug gap. Refer to “CHECKING THE SPARK PLUG” in chapter 3. The ignition system fails to operate (no spark or intermittent spark). Check: 1. Spark plug 2. Ignition spark gap 3. Spark plug cap resistance 4. Ignition coil resistance 5. Engine stop switch 6. Pickup coil resistance 7. Charging coil resistance 8.
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ELEC IGNITION SYSTEM EAS00744 EAS00746 3. Spark plug cap resistance 4. Ignition coil resistance • Remove the spark plug cap from the spark plug lead. • Connect the pocket tester (“Ω × 1k” range) to the spark plug cap as shown. • Measure the spark plug cap resistance. • Disconnect the ignition coil connectors from the ignition coil terminals. • Connect the pocket tester (Ω × 1) to the ignition coil as shown.
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ELEC IGNITION SYSTEM EAS00750 EAS00748 5. Engine stop switch 6. Pickup coil resistance • Check the engine stop switch for continuity. • Connect the pocket tester (Ω × 1) to the engine stop switch as shown. • Disconnect the pickup coil coupler from the wire harness. • Connect the pocket tester (Ω × 100) to the pickup coil terminal as shown.
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IGNITION SYSTEM EAS00775 ELEC EAS00754 7. Charging coil resistance 8. Wiring • Disconnect the charging coil coupler from the wire harness. • Connect the pocket tester (Ω × 100) to the charging coil terminal as shown. • Check the entire ignition system’s wiring. Refer to “WIRING DIAGRAM”. • Is the ignition system’s wiring properly connected and without defects? Positive tester probe → black / red Negative tester probe → green / white YES Replace unit. • Measure the charging coil resistance.
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TUN CHAPTER 9 TUNING ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CARBURETOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ATMOSPHERIC CONDITIONS AND CARBURETOR SETTINGS . . TEST RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . EFFECTS OF THE SETTING PARTS ON THE THROTTLE VALVE OPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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ENGINE TUN TUNING ENGINE CARBURETOR SETTING • The role of fuel is to cool the engine, and in the case of a 2-stroke engine, to lubricate the engine in addition to power generation. Accordingly, if a mixture of air and fuel is too lean, abnormal combustion will occur, and engine seizure may result. If the mixture is too rich, spark plugs will get wet with oil, thus making it impossible to bring the engine into full play or if the worst comes to the worst, the engine may stall.
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ENGINE TUN TEST RUN After warming up the engine equipped with the standard type carburetor(s) and spark plug(s), run two or three laps of the circuit and check the smooth operation of the engine and discoloration of spark plug(s). Discoloration Condition of spark plug Insulator is dry and burnt Normal brown. Over burned Insulator is whitish. (too lean) Oil fouled Insulator is sooty and wet.
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ENGINE TUN MAIN JET ADJUSTMENT The richness of air-fuel mixture with 3 / 4 ~ 4 / 4 throttle can be set by changing the main jet . Standard main jet #138 1. Spark plug is too hot. Select a main jet having higher calibrating No. than standard. (To be enriched) 2. Spark plug is wet. Select a main jet having lower calibrating No. than standard.
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ENGINE TUN JET NEEDLE GROOVE POSITION ADJUSTMENT Should the engine be hard to run smoothly at intermediate speeds, the jet needle must be adjusted. If the mixture is too rich or too lean at intermediate speed operation, 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. Standard clip position No.2 groove 1.
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ENGINE Diameter of straight portion Clip position Rich 1 richer 0.5 richer STD 0.5 leaner 1 leaner Lean Rich φ 2.405 mm (0.0947 in) NBKE-3rd groove NBLE-2nd groove NBKE-2nd groove NBLE-1st groove NBKE-1st groove φ 2.415 mm (0.0951 in) NBKF-3rd groove NBLF-2nd groove NBKF-2nd groove (STD) NBLF-1st groove NBKF-1st groove TUN Lean φ 2.425 mm (0.
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TUN ENGINE Symptom Closed to 1 / 4 throttle Poor acceleration White smoke Unstable at low speeds Pinking noise Setting Use jet needle with a larger diameter. Turn in pilot air screw. Lower jet needle clip position. (1 groove down) Turn in pilot air screw. Poor response at extremely low Reduce pilot jet calibration No. speed Turn out pilot air screw. If not effect, reverse the above procedures. Poor response in the low to Raise jet needle clip position.
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ENGINE / CHASSIS TUN NOTE: • When checking the discoloration of spark plugs, be sure to stop the engine immediately after a run and check. • Avoid racing. • When changing the heat range of spark plugs, never attempt to change it more than ±1 rank. • When using a spark plug other than standard, check its heat range against the standard and check that it is a resistance type. • Note that even if the discoloration seems proper, it may slightly vary with the spark plug maker and oil in use.
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CHASSIS TUN • In actuality, it is very difficult to achieve settings suitable for the entire course and some settings may be sacrificed. Thus, the settings should be matched to the portion of the course that has the greatest effect on the race result. In such a case, run through the entire course while making notes of lap times to find the best balance; then, determine the secondary reduction ratio.
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CHASSIS TUN TIRE PRESSURE Tire pressure should be adjust to suit the road surface condition of the circuit. Standard tire pressure 100 kPa (1.0 kgf / cm2, 15 psi) • Under a rainy, muddy, sandy, or slippery condition, the tire pressure should be lower for a larger area of contact with the road surface. Extent of adjustment 60 ~ 80 kPa (0.6 ~ 0.8 kgf / cm2, 9.0 ~ 12 psi) • Under a stony or hard road condition, the tire pressure should be higher to prevent a flat tire. Extent of adjustment 100 ~ 120 kPa (1.
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CHASSIS TUN CHANGE IN LEVEL AND CHARACTERISTICS OF FORK OIL Damping characteristic near the final stroke can be changed by changing the fork oil amount. CAUTION: Adjust the oil level in 5 mm (0.2 in) increments or decrements. Too low oil level causes the front fork to produce a noise at full rebound or the rider to feel some pressure on his hands or body.
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CHASSIS TUN 2. Use of stiff spring Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, resulting in lack of a sense of contact with the road surface or in a vibrating handlebar. To set a stiff spring: • Change the rebound damping. Turn in one or two clicks. • Change the compression damping. Turn out one or two clicks. FRONT FORK SETTING PARTS • Front fork spring YZ85: TYPE SOFT STD STIFF SPRING SPRING RATE PART NUMBER 0.280 0.290 0.
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CHASSIS TUN REAR SUSPENSION SETTING The rear suspension setting should be made depending on the rider’s feeling of an actual run and the circuit conditions. The rear suspension setting includes the following two factors: 1. Setting of spring preload • Change the set length of the spring. • Change the spring. 2. Setting of damping force • Change the rebound damping. • Change the compression damping. CHOOSING SET LENGTH 1.
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CHASSIS TUN SETTING OF SPRING AFTER REPLACEMENT After replacement, be sure to adjust the spring to the set length [sunken length 75 ~ 85 mm (3.0 ~ 3.3 in)] and set it. 1. Use of soft spring • Set the soft spring for less rebound damping to compensate for its less spring load. Run with the rebound damping adjuster one or two clicks on the softer side and readjust it to suit your preference. 2. Use of stiff spring • Set the soft spring for more rebound damping to compensate for its greater spring load.
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CHASSIS TUN REAR SHOCK ABSORBER SETTING PARTS • Rear shock spring YZ85: For EUR SPRING SPRING I.D. RATE PART NUMBER COLOR SOFT 4.4 4ES-22212-M0 Brown STD 4.6 4ES-22212-K0 Green STIFF 4.8 4ES-22212-G0 Red TYPE For CAN, AUS, NZL SPRING SPRING I.D. RATE PART NUMBER COLOR SOFT 4.8 4ES-22212-G0 Red STD 5.0 4ES-22212-F0 – STIFF 5.2 4ES-22212-H0 Blue TYPE YZ85LW: For EUR SPRING SPRING I.D. RATE PART NUMBER COLOR SOFT 4.6 4ES-22212-K0 Green STD 4.8 4ES-22212-G0 Red STIFF 5.
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CHASSIS TUN SUSPENSION SETTING • Front fork NOTE: • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 75 ~ 85 mm (3.0 ~ 3.3 in).
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CHASSIS TUN • Rear shock absorber NOTE: • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Adjust the damping in 2-click increments or decrements.
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TRBL SHTG CHAPTER 10 TROUBLESHOOTING STARTING FAILURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1 10-1 10-1 10-1 INCORRECT ENGINE IDLING SPEED . . . . . . . . . . . . . . . . . . . . . . . .
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STARTING FAILURES TRBL SHTG EAS00844 TROUBLESHOOTING NOTE: The following guide for troubleshooting does not cover all the possible causes of trouble. It should be helpful, however, as a guide to basic troubleshooting. Refer to the relative procedure in this manual for checks, adjustments, and replacement of parts.
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INCORRECT ENGINE IDLING SPEED / POOR MEDIUM-ANDHIGH-SPEED PERFORMANCE / FAULTY GEAR SHIFTING TRBL SHTG EAS00846 INCORRECT ENGINE IDLING SPEED ENGINE Air filter • Clogged air filter element FUEL SYSTEM Carburetor(s) • Faulty starter plunger • Loose or clogged pilot jet • Loose or clogged pilot air jet • Damaged or loose carburetor joint • Improperly synchronized carburetors • Improperly adjusted engine idling speed (throttle stop screw) • Improper throttle cable free play • Flooded carburetor • Faulty air
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FAULTY CLUTCH / OVERHEATING TRBL SHTG EAS00851 FAULTY CLUTCH CLUTCH SLIPS Clutch • Improperly assembled clutch • Improperly adjusted clutch cable • Loose or fatigued clutch spring • Worn friction plate • Worn clutch plate Transmission oil • Incorrect oil level • Incorrect oil viscosity (low) • Deteriorated oil CLUTCH DRAGS Clutch • Unevenly tensioned clutch springs • Warped pressure plate • Bent clutch plate • Swollen friction plate • Bent clutch push rod • Broken clutch boss • Burnt primary driven gear
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POOR BRAKING PERFORMANCE / FAULTY FRONT FORK LEGS / UNSTABLE HANDLING TRBL SHTG EAS00857 POOR BRAKING PERFORMANCE • Worn brake pad • Worn brake disc • Air in hydraulic brake system • Leaking brake fluid • Faulty brake caliper kit • Faulty brake caliper seal • Loose union bolt • Damaged brake hose • Oil or grease on the brake disc • Oil or grease on the brake pad • Incorrect brake fluid level EAS00861 FAULTY FRONT FORK LEGS LEAKING OIL • Bent, damaged or rusty inner tube • Cracked or damaged outer tube
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YAMAHA MOTOR CO., LTD.
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YZ85W1 / YZ85(W) / YZ85LW(W) 2007 WIRING DIAGRAM YZ85W1 / YZ85(W) / YZ85LW(W) SCHALTPLAN 2007 YZ85W1 / YZ85(W) / YZ85LW(W) 2007 SCHEMA DE CABLAGE O COMPOSANTS ELECTRIQUES B B/W W/R Coupe-circuit du moteur Bobine d’allumage Bloc CDI Volant magnétique CDI Bougie B/R G/L G/W W/L W/L W/L W/R W/R B/R B/R G/W G/W G/L G/L O O B CODE DE COULEUR B. . . . . . . O. . . . . . . B / R. . . . . B/W . . . . G / L. . . . . G/W . . . . W/L . . . . W/R . . . .
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YZ85W1/YZ85(W)/YZ85LW(W) 2007 WIRING DIAGRAM YZ85W1/YZ85(W)/YZ85LW(W) SCHALTPLAN 2007 YZ85W1/YZ85(W)/YZ85LW(W) 2007 SCHEMA DE CABLAGE COMPOSANTS ELECTRIQUES Coupe-circuit du moteur Bobine d’allumage Bloc CDI Volant magnétique CDI Bougie CODE DE COULEUR B. . . . . . . O. . . . . . . B/R. . . . . B/W . . . . G/L. . . . . G/W . . . . W/L . . . . W/R . . . .