Service manual

CHK
ADJ
3-1
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. All service technicians
should be familiar with this entire chapter.
EAS00037
PERIODIC MAINTENANCE AND LUBRICATION INTERVALS
N
O
TE:
• From the seventh race, repeat the maintenance intervals starting from “Every race”.
• Items marked with an asterisk should be performed by a Yamaha dealer as they require special
tools, data and technical skills.
NO. ITEM ROUTINE
After
break-in
Every
race
Every
third race
Every
fifth race
As
required
1*Piston
• Check piston for carbon deposits and cracks or damage.
• Clean.
√√
• Replace. √√
2 * Piston rings
• Check piston ring end gap and rings for damage. √√
• Replace. √√
3*
Piston pin and small
end bearing
• Check piston pin and small end bearing for damage. √
• Replace. √
4 * Cylinder head
• Check cylinder head for carbon deposits.
• Clean.
√√
• Check cylinder head gasket for damage.
• Tighten cylinder head bolts if necessary.
√√
• Replace cylinder head gasket. √
5 * Cylinder
• Check cylinder for score marks or wear.
• Clean.
√√
• Replace. √
6*Clutch
• Check clutch housing, friction plates, clutch plates and
clutch springs for wear or damage.
•Adjust.
√√
• Replace. √
7 * Transmission
• Change the transmission oil. √√
• Check transmission for damage. √
• Replace bearings. √
8*
Shift forks, guide
bars, shift cam
• Check all parts for wear and damage.
• Replace if necessary.
√
9*
Rotor nut
(flywheel magneto)
•Tighten. √√
10 * Kickstarter system
• Check idle gear for damage.
• Replace if necessary.
√
11 * Exhaust system
• Check exhaust pipe and muffler for carbon deposits. √√
• Clean. √
12 * Crankshaft
• Check crankshaft for carbon deposits and damage. √√
• Clean. √√
13 * Carburetor
• Check carburetor settings and for obstructions. √√
• Adjust and clean. √√
14 Spark plug
• Check condition.
• Clean and regap.
√√
• Replace. √
15 Drive chain
• Check chain slack, alignment and condition.
• Adjust and thoroughly lubricate chain with Yamaha
chain and cable lube or equivalent.
√√
• Replace.
√
INTRODUCTION / PERIODIC MAINTENANCE
AND LUBRICATION INTERVALS