Yamaha LIT-11626-16-27 manual

TT-R90R 5HN-28199-13 LIT-11626-16-27 OWNER’S SERVICE MANUAL[...]

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EC010000 TT-R90R OWNER’S SERVICE MANUAL ©2002 by Yamaha Motor Corporation, U.S.A. 1st Edition, April 2002 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U.S.A. is expressly prohibited. Printed in Japan P/N. LIT-11626-16-27[...]

INTRODUCTION Congratulations on your purchase of a Yamaha TT-R90R. This model is the culmina- tion of Yamaha’s vast experience in the pro- duction of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader. This manual explains operation, inspection, basic maintenance and tuning[...]

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IMPORTANT NOTICE This machine is designed for off-road use only by young operators under adult instruction and supervision. It is illegal for this machine to be operated on any public street, road, or high- way. Off-road use on public lands may be illegal. Please check local regulations before riding. 1. GASOLINE IS HIGHLY FLAMMABLE: * Always turn [...]

4. When transporting the machine in another vehicle, be sure is kept upright and that the fuel cock is turned to the “ OFF ” . If it should lean over, gasoline may leak out of the car- buretor or fuel tank. 5. Never start your engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and may cause loss of con[...]

SAFETY INFORMATION 1. Don ’ t ride it on the street. 2. Don ’ t run the engine inside a building. 3. This is a one-seater motorbike. Don ’ t give any person a ride. 4. Let ’ s learn how to ride properly. Ask your parents for any question. 5. When riding the machine, be sure to wear the protective apparel as illustrated. 1 Helmet 2 Goggles 3[...]

6. When going for riding, be sure to be with your family. Never go alone. 7. Before riding the machine, ask your par- ents to check the machine very carefully. 8. Don ’ t touch the areas shown, or you ’ ll get burnt in the hand. 9. Don ’ t touch rotating or moving parts. 10. Before starting the engine, be sure to shift the transmission into n[...]

EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine. A CAUTION indicates special p[...]

EC083000 MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condit[...]

ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols 1 to 6 are designed as thumb tabs to indicate the chapter ’ s number and content. 1 General information 2 Specifications 3 Regular inspection and adjustments 4 Engine 5 Chassis 6 Electrical Illustrated symbols 7 to D are used to identify the specifications appearing in the text. [...]

INDEX GENERAL INFORMATION 1 SPECIFICATIONS SPEC 2 REGULAR INSPECTION AND ADJUSTMENTS 3 ENGINE ENG 4 CHASSIS CHAS 5 ELECTRICAL ELEC 6 GEN INFO INSP ADJ – +[...]

CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION .......................................... 1-1 MACHINE IDENTIFICATION .................... 1-2 IMPORTANT INFORMATION ................... 1-3 CHECKING OF CONNECTION ................. 1-5 SPECIAL TOOLS ...................................... 1-6 CONTROL FUNCTIONS ........................... 1-9 FUEL .[...]

CHAPTER 4 ENGINE CARBURETOR ......................................... 4-1 CYLINDER HEAD ..................................... 4-8 CAMSHAFT AND ROCKER ARMS ........ 4-13 VALVES AND VALVE SPRINGS ........... 4-16 CYLINDER AND PISTON ....................... 4-21 CLUTCH .................................................. 4-27 KICK AXLE .................[...]

1 - 1 GEN INFO DESCRIPTION EC100000 GENERAL INFORMATION EC110000 DESCRIPTION 1 “ ENGINE STOP ” button 2 Front brake lever 3 Throttle grip 4 Fuel tank cap 5 Kick starter 6 Fuel tank 7 Air cleaner 8 Rear brake pedal 9 Fuel cock 0 Starter lever (choke) A Drive chain B Shift pedal C Front fork N OTE: ● The machine you have purchased may differ sl[...]

1 - 2 GEN INFO MACHINE IDENTIFICATION EC120001 MACHINE IDENTIFICATION There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for posi- tive identification of the model you own. 2. If your machine is stolen, the authorities will need the number to search [...]

1 - 3 GEN INFO IMPORTANT INFORMATION EC130000 IMPORTANT INFORMATION EC131002 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassem- bly. When washing the machine with high pressured water, cover the parts as fol- lows. ● Silencer exhaust port 2. Use proper tools and cleaning equip-[...]

1 - 4 GEN INFO IMPORTANT INFORMATION EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is over- hauled. All gasket su[...]

1 - 5 GEN INFO IMPORTANT INFORMATION/ CHECKING OF CONNECTION EC136000 CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace pis- ton pin clips after one use. Replace dis- torted circlips. When installing a circlip 1 , make sure that the sharp-edged cor- ner 2 is positioned opposite to the thrust 3 it receives. See[...]

1 - 6 GEN INFO SPECIAL TOOLS SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refe[...]

1 - 7 GEN INFO SPECIAL TOOLS YM-1312-A, 90890-01312 Fuel level gauge This gauge is used to measure the fuel level in the float chamber. YM-1312-A 90890-01312 YM-1326, 90890-01326 T-handle This tool is used for holding the damper rod holder when removing or installing the damper rod holder. YM-1326 90890-01326 90890-01186 Fork seal driver attachment[...]

1 - 8 GEN INFO SPECIAL TOOLS YU-33270-B, 90890-01362 Flywheel puller This tool is used to remove the rotor. YU-33270-B 90890-01362 ACC-QUICK-GS-KT 90890-85505 Quick gasket ® YAMAHA Bond No. 1215 This sealant (Bond) is used for crankcase mating surface, etc. ACC-QUICK-GS-KT 90890-85505 Part number Tool name/How to use Illustration[...]

1 - 9 GEN INFO CONTROL FUNCTIONS EC150000 CONTROL FUNCTIONS “ ENGINE STOP ” SWITCH Make sure that the engine stop switch 1 is positioned to “” . The engine stop switch has been equipped to ensure safety in an emer- gency such when the machine is up set or trouble takes place in the throttle system. The engine will not start or run when the [...]

1 - 10 GEN INFO CONTROL FUNCTIONS EC156000 FRONT BRAKE LEVER The front brake lever 1 is located on the right handlebar. Pull it toward the handlebar to acti- vate the front brake. EC157000 REAR BRAKE PEDAL The rear brake pedal 1 is located on the right side of the machine. Press down on the brake pedal to activate the rear brake. FUEL COCK The fuel[...]

1 - 11 GEN INFO CONTROL FUNCTIONS/FUEL FUEL TANK CAP Remove the fuel tank cap 1 by turning counter-clockwise. W ARNING Do not overfill the fuel tank. Avoid spilling fuel on the hot engine. FUEL Use regular gasoline. Always use fresh, name brand gasoline. W ARNING Do not overfill the fuel tank. Avoid spilling fuel on the hot engine. Do not fill the [...]

1 - 12 GEN INFO STARTING AND OPERATION STARTING AND OPERATION CAUTION: Prior to operating the machine, perform steps listed in pre-operation check list. W ARNING Never start your engine or let it run for any length of time in a closed area. The exhaust fumes are poisonous and can cause loss of consciousness and death within a short time. Always ope[...]

SPEC 2 - 1 EC200000 SPECIFICA TIONS EC211000 GENERAL SPECIFICA TIONS Model name: TT -R90R (USA, CDN, A US, NZ) TT -R90 (Europe , ZA) Model code number: 5HNB (USA) 5HNC (Europe, A US, NZ, ZA) 5HND (CDN) Dimensions: Ov erall length 1,525 mm (57.0 in) Ov erall width 605 mm (23.8 in) Ov erall height 865 mm (34.1 in) Seat height 625 mm (24.6 in) Wheelba[...]

SPEC 2 - 2 Oil capacity: Engine oil P er iodic oil change 0.8 L (0.70 Imp qt, 0.85 US qt) T otal amount 1.0 L (0.88 Imp qt, 1.06 US qt) Air fi lter : W et type element Fuel: T ype Unleaded gasoline only (USA, A US and NZ) Regular unleaded gasoline only (CDN, Europe) Regular gasoline (ZA) T ank capacity 4.1 L (0.90 lmp gal, 1.08 US gal) Reser ve am[...]

SPEC 2 - 3 Brak e: F ront brake type Drum brake Operation Right hand operation Rear brak e type Drum brake Operation Right f oot operation Suspension: F ront suspension T elescopic f ork Rear suspension Swingar m (monocross suspension) Shock absorber: F ront shock absorber Coil spring/oil damper Rear shock absorber Coil spring/gas, oil damper Wheel[...]

SPEC 2 - 4 MAINTENANCE SPECIFICA TIONS ENGINE Item Standard Limit Cylinder head: W arp limit ---- 0.03 mm (0.0012 in) Cylinder : Bore size 47.000 ~ 47.005 mm (1.8504 ~ 1.8506 in) 47.05 mm (1.8524 in) Out of round limit ---- 0.05 mm (0.0020 in) Camshaft: Drive method Chain drive (left) ---- Cam dimensions Intake “ A ” 25.428 ~ 25.528 mm (1.0011 [...]

SPEC 2 - 5 Cam chain: Cam chain type/No . of links 92RH2005-84M/84 ---- Cam chain adjustment method A utomatic ---- Rock er arm/rock er arm shaft: Shaft outside diameter 9.981 ~ 9.991 mm (0.3930 ~ 0.3933 in) 9.95 mm (0.3917 in) Rock er arm inside diameter 10.000 ~ 10.015 mm (0.3937 ~ 0.3943 in) 10.03 mm (0.3949 in) V alv e, v alv e seat, valv e gui[...]

SPEC 2 - 6 Stem runout limit ---- 0.02 mm (0.0008 in) V alv e seat width IN 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.0630 in) EX 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.0630 in) V alv e spring: F ree length IN 28.32 mm (1.11 in) 26.9 mm (1.06 in) EX 28.32 mm (1.11 in) 26.9 mm (1.06 in) Set length (v alv e closed) IN 24.2 mm (0.95 in) ---- EX[...]

SPEC 2 - 7 Piston: Piston to cylinder clearance 0.025 ~ 0.045 mm (0.0010 ~ 0.0018 in) 0.15 mm (0.0059 in) Piston size “ D ” 46.960 ~ 46.975 mm (1.8488 ~ 1.8494 in) ---- Piston ov er siz e (2nd) 47.5 mm (1.8701 in) ---- (4th) 48.0 mm (1.8898 in) ---- Measuring point “ H ” 4 mm (0.16 in) ---- Piston off-set 0.75 mm (0.0295 in) ---- Piston pin[...]

SPEC 2 - 8 Crankshaft: Crank width “ A ” 42.95 ~ 43.00 mm (1.691 ~ 1.693 in) ---- Runout limit C ---- 0.03 mm (0.0012 in) Big end side clearance “ D ” 0.10 ~ 0.40 mm (0.0039 ~ 0.0157 in) 0.50 mm (0.02 in) Big end radial clearance “ E ” 0.010 ~ 0.025 mm (0.0004 ~ 0.0010 in) 0.05 mm (0.002 in) Clutch: F r iction plate thickness 2.7 ~ 2.9 [...]

SPEC 2 - 9 Lubrication system: Oil fi lter type Wire mesh type ---- Oil pump type T rochoid type ---- Tip clearance “ A ” or “ B ” 0.15 mm (0.0059 in) 0.2 mm (0.0079 in) Side clearance 0.13 ~ 0.18 mm (0.0051 ~ 0.0071 in) 0.23 mm (0.0091 in) Housing and rotor clearance 0.06 ~ 0.10 mm (0.0024 ~ 0.0039 in) 0.15 mm (0.0059 in) Item Standard Li[...]

SPEC 2 - 10 P ar t to be tightened Thread size Q ’ ty Tightening torque Nm m • kg ft • lb Cylinder head nut M8 × 1.25 4 22 2.2 16 Cylinder head bolt M6 × 1.0 2 10 1.0 7.2 Spark plug M10 × 1.0 1 13 1.3 9.4 Camshaft sprock et co v er bolt M6 × 1.0 2 7 0.7 5.1 T appet cov er M45 × 1.5 2 18 1.8 13 Exhaust pipe stud bolt M6 × 1.0 2 7 0.7 5.1[...]

SPEC 2 - 11 CHASSIS Item Standard Limit Steering system: Steering bear ing type Angular bearing ---- F ront suspension: F ront fork tra v el 110 mm (4.33 in) ---- F ork spr ing free length 425.1 mm (16.74 in) 417 mm (16.4 in) F ork spr ing fi tting length 415.1 mm (16.34 in) ---- Spring rate, STD K = 3.4 N/mm (0.35 kg/mm, 19.41 lb/in) ---- Optiona[...]

SPEC 2 - 12 Drum brake: F ront dr um brake type Leading, trailing ---- Rear drum brake type Leading, tr ailing ---- F ront dr um inside diameter 95 mm (3.74 in) 96 mm (3.78 in) Rear drum inside diameter 110 mm (4.33 in) 111 mm (4.37 in) F ront lining thickness 3 mm (0.12 in) 2 mm (0.08 in) Rear lining thickness 4 mm (0.16 in) 2 mm (0.08 in) F ront [...]

SPEC 2 - 13 NOTE: ● 1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nut wrench and turn the steering right and left a few times; then loosen the ring nut one turn. 2. Retighten the ring nut 1 Nm (0.1 m • kg, 0.7 ft • lb). ● -marked portion shall be checked for torque tightening after break-i[...]

SPEC 2 - 14 EC212300 ELECTRICAL Item Standard Limit CDI: Magneto-model/manuf acturer F5HN 00/Y AMAHA ---- Source coil resistance (color) 688 ~ 1,032 Ω at 20 ˚ C (68 ˚ F) (Brown – Green) ---- Pickup coil resistance (color) 248 ~ 372 Ω at 20 ˚ C (68 ˚ F) (Red – White) ---- CDI unit-model/manuf acturer 4GL-20/Y AMAHA ---- Ignition coil: Mo[...]

2 - 15 SPEC GENERAL TORQUE SPECIFICATIONS/ DEFINITION OF UNITS EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasten- ers with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sec- tions of this book. To avoid warpage, tighten multi-fastener ass[...]

2 - 16 SPEC CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM 1 Crankcase breather hose 2 Wire harness 3 CDI magneto lead 4 Starter cable 5 Carburetor heating lead 6 Engine stop switch lead 7 Thermo switch 8 Thermo switch lead 9 Spark plug lead 0 Throttle cable A Cable holder B Fuel tank breather hose C Brake cable Å After fastening the starter cable, C[...]

2 - 17 SPEC CABLE ROUTING DIAGRAM 1 Cable guide 2 Brake cable 3 Throttle cable 4 Fuel tank breather hose 5 Engine stop switch lead 6 Air vent hose 7 Air intake duct 8 Ignition coil 9 Cable guide 0 Wire harness A Damper B CDI unit lead C CDI unit D Rectifier/regulator lead E Rectifier/regulator F Crankcase breather hose G Carburetor breather hose H [...]

2 - 18 SPEC CABLE ROUTING DIAGRAM Å Pass the fuel tank breather hose through the cable guide. ı Pass the throttle cable and engine stop switch lead through the cable guide. Ç Pass the air vent hose through the hose guide. Î Fasten the CDI unit lead and rectifier/regulator lead with the plastic clamp. ‰ Align the tape on the rectifier/regulato[...]

3 - 1 INSP ADJ MAINTENANCE INTERVALS/ PERIODIC MAINTENANCE AND LUBRICATION EC300000 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required mai[...]

3 - 2 INSP ADJ PRE-OPERATION INSPECTION AND MAINTENANCE *: Since these items requires special tools data and technical skills, they should be serviced. * 1 : For USA SERVICE NOTES: No. 1. DRIVE CHAIN: In addition to tension and alignment, chain must be lubricated every 0.5 ~ 1.0 hour. If unit is subjected to extremely hard usage and wet weather rid[...]

3 - 3 INSP ADJ ENGINE/THROTTLE CABLE ADJUSTMENT/ AIR FILTER CLEANING EC350000 ENGINE THROTTLE CABLE ADJUSTMENT 1. Check: ● Throttle grip free play a Out of specification → Adjust. Throttle grip free play a : 3 ~ 5 mm (0.12 ~ 0.20 in) 2. Adjust: ● Throttle grip free play AIR FILTER CLEANING N OTE: Proper air filter maintenance is the biggest k[...]

3 - 4 INSP ADJ AIR FILTER CLEANING 1. Install: ● Air scoop (right) 1 2. Install: ● Air filter case cover 1 3. Clean: ● Air filter element Clean them with solvent. N OTE: After cleaning, remove the remaining solvent by squeezing the element. CAUTION: ● Do not twist the element when squeezing the element. ● Leaving too much of solvent in th[...]

3 - 5 INSP ADJ ENGINE OIL LEVEL INSPECTION 1. Start the engine, warm it up for several minutes and wait for five minutes. 2. Place the machine on a level place and hold it up on upright position by placing the suitable stand under the engine. 3. Remove: ● Dipstick 1 4. Check: ● Oil level Oil level should be between maximum a and minimum b marks[...]

3 - 6 INSP ADJ ENGINE OIL REPLACEMENT (Except for USA and CDN) CAUTION: ● Do not add any chemical additives or use oils with a grade of CD a or higher. ● Do not use oils labeled “ ENERGY CON- SERVING II ” b or higher. Engine oil also lubricates the clutch and additives could cause clutch slippage. ● Do not allow foreign materials to enter[...]

3 - 7 INSP ADJ PILOT AIR SCREW ADJUSTMENT 5. Install: ● Gasket ● Drain bolt New T R . . 20 Nm (2.0 m · kg, 14 ft · lb) 6. Fill: ● Crankcase Oil quantity: Periodic oil change: 0.8 L (0.70 Imp qt, 0.85 US qt) 7. Install: ● Dipstick 8. Inspect: ● Engine (for oil leaks) ● Oil level Refer to “ ENGINE OIL LEVEL INSPEC- TION ” . PILOT AI[...]

3 - 8 INSP ADJ IDLE SPEED ADJUSTMENT/ VALVE CLEARANCE ADJUSTMENT IDLE SPEED ADJUSTMENT 1. Start the engine and thoroughly warm it up. 2. Attach: ● Inductive tachometer To spark plug lead. 3. Adjust: ● Idle speed VALVE CLEARANCE ADJUSTMENT N OTE: ● The valve clearance should be adjusted when the engine is cool to the touch. ● The piston must[...]

3 - 9 INSP ADJ VALVE CLEARANCE ADJUSTMENT 4. Check: ● Valve clearance Out of specification → Adjust. 5. Adjust: ● Valve clearance Valve clearance (cold): Intake valve: 0.05 ~ 0.09 mm (0.0020 ~ 0.0035 in) Exhaust valve: 0.08 ~ 0.12 mm (0.031 ~ 0.047 in) Checking steps: ● Turn the crankshaft counterclockwise with a wrench. ● Align the T.D.C[...]

3 - 10 INSP ADJ SPARK ARRESTER CLEANING (For USA) 6. Install: ● Tappet cover (intake side) 1 ● O-ring 2 N OTE: Apply the lithium soap base grease on the O-ring. 7. Install: ● Tappet cover (exhaust side) ● O-ring ● Spark plug ● Timing plug ● Crankshaft end cover N OTE: Apply the lithium soap base grease on the O-ring. 8. Install: ● A[...]

3 - 11 INSP ADJ CHASSIS/FRONT BRAKE ADJUSTMENT/ REAR BRAKE ADJUSTMENT CHASSIS FRONT BRAKE ADJUSTMENT 1. Check: ● Brake lever free play a Out of specification → Adjust. Free play (brake lever): 10 ~ 20 mm (0.39 ~ 0.79 in) (at brake lever end) a 2 1 2. Adjust: ● Brake lever free play REAR BRAKE ADJUSTMENT 1. Check: ● Brake pedal free play a O[...]

3 - 12 INSP ADJ DRIVE CHAIN SLACK ADJUSTMENT DRIVE CHAIN SLACK ADJUSTMENT 1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Check: ● Drive chain slack a In the center between the drive axle and rear wheel axle. Out of specification → Adjust. N OTE: Before checking and/or adjusting, rotate the rear wheel through severa[...]

3 - 13 INSP ADJ FRONT FORK INSPECTION/REAR SHOCK ABSORBER INSPECTION/ REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT ● Tighten the wheel axle nut while pushing down the drive chain. T R . . Axle nut: 60 Nm (6.0 m • kg, 43 ft • lb) EC36C000 FRONT FORK INSPECTION 1. Inspect: ● Front fork smooth action Operate the front brake and stroke the fro[...]

3 - 14 INSP ADJ 4. To stiffen the spring preload, install the circlip 1 into the groove a . To soften the spring preload, install the circlip into the groove b . N OTE: Do not spread the circlip too much. 5. Install: ● Spring guide 1 N OTE: While compressing the spring, install the spring guide. Standard installation position: Groove b 6. Install[...]

3 - 15 INSP ADJ SPOKES INSPECTION AND TIGHTENING/WHEEL INSPECTION/ STEERING HEAD INSPECTION AND ADJUSTMENT SPOKES INSPECTION AND TIGHTENING 1. Inspect: ● Spokes 1 Bend/damage → Replace. Loose spoke → Retighten. 2. Tighten: ● Spokes N OTE: Be sure to retighten these spokes before and after break-in. After a practice or a race check spokes fo[...]

3 - 16 INSP ADJ STEERING HEAD INSPECTION AND ADJUSTMENT 3. Check: ● Steering smooth action Turn the handlebar lock to lock. Unsmooth action → Adjust steering ring nut. 4. Adjust: ● Steering ring nut Steering ring nut adjustment steps: ● Remove the front fender 1 . ● Remove the handlebar and handle crown. ● Loosen the ring nut 2 using th[...]

3 - 17 INSP ADJ STEERING HEAD INSPECTION AND ADJUSTMENT CAUTION: Install the handlebar holder with its groove a facing outward, and tighten the bolts so that the gaps b are equal. T R . . Steering stem bolt: 40 Nm (4.0 m • kg, 2.9 ft • lb) Front fork cap bolt: 40 Nm (4.0 m • kg, 2.9 ft • lb) Handlebar upper holder: 13 Nm (1.3 m • kg, 9.4 [...]

3 - 18 INSP ADJ LUBRICATION LUBRICATION To ensure smooth operation of all compo- nents, lubricate your machine during setup, after break-in, and after every race. 1 All control cable 2 Brake lever pivot 3 Shift pedal pivot 4 Footrest pivot 5 Throttle-to-handlebar contact 6 Drive chain 7 Tube guide cable winding portion 8 Throttle cable end 9 Brake [...]

3 - 19 INSP ADJ ELECTRICAL/SPARK PLUG INSPECTION EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: ● Spark plug 2. Inspect: ● Electrode 1 Wear/damage → Replace. ● Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition. N OTE: When the engine runs for many hour[...]

4 - 1 ENG ENGINE CARBURETOR Extent of removal: 1 Carburetor removal Extent of removal Order Part name Q’ty Remarks CARBURETOR REMOVAL Preparation for removal Fuel tank 1 Clamp (air filter joint) 1 Loosen the screw (air filter joint). 2 Carburetor heater lead 1 3 Air vent hose 1 4 Fuel hose 1 5 Bolt 2 6 Carburetor assembly 1 7 O-ring 1 8 Spacer 1 [...]

4 - 2 ENG CARBURETOR EC468000 CARBURETOR DISASSEMBLY Extent of removal: 1 Carburetor disassembly Extent of removal Order Part name Q ’ ty Remarks CARBURETOR DISASSEMBLY 1 Throttle valve 1 2 Throttle cable 1 3 Spring 1 4 Gasket 1 5 Carburetor top cover 1 6 Jet needle stopper 1 7 Jet needle assembly 1 8 Starter plunger assembly 1 9 Starter cable 1 [...]

4 - 3 ENG CARBURETOR Extent of removal Order Part name Q ’ ty Remarks A Float pin 1 B Float 1 C Needle valve 1 D Main jet 1 E Pilot jet 1 F Needle jet 1 G Throttle stop screw assembly 1 H Pilot air screw assembly 1 I Carburetor heater 1 1[...]

4 - 4 ENG CARBURETOR EC464000 INSPECTION Carburetor 1. Inspect: ● Carburetor body Contamination → Clean. NOTE: ● Use a petroleum based solvent for cleaning. Blow out all passages and jets with com- pressed air. ● Never use a wire. 2. Inspect: ● Main jet 1 ● Pilot jet 2 ● Needle jet 3 Damage → Replace. Contamination → Clean. NOTE: [...]

4 - 5 ENG CARBURETOR EC464401 Jet needle 1. Inspect: ● Jet needle 1 Bends/wear → Replace. ● Clip groove Free play exists/wear → Replace. ● Clip position Float height 1. Measure: ● Float height a Out of specification → Adjust. Standard clip position: No.2 Groove Float height: 15.5 ~ 16.5 mm (0.61 ~ 0.65 in) Measurement and adjustment s[...]

4 - 6 ENG CARBURETOR EC464600 Float 1. Inspect: ● Float 1 Damage → Replace. ASSEMBLY AND INSTALLATION Carburetor 1. Install: ● Pilot air screw 1 Note the following installation points: ● Screw in the pilot air screw until it is lightly seated. ● Back out it by the specified number of turns. Pilot air screw: 1-3/4 turns out 2. Install: ●[...]

4 - 7 ENG CARBURETOR 1. Measure: ● Fuel level a Use a fuel level gauge 1 . Out of specification → Adjust. Fuel level gauge: YM-1312-A/90890-01312 Fuel level: 2 ~ 3 mm (0.08 ~ 0.12 in) below the float chamber line[...]

4 - 8 ENG CYLINDER HEAD CYLINDER HEAD Extent of removal: 1 Cylinder head removal Extent of removal Order Part name Q ’ ty Remarks CYLINDER HEAD REMOVAL Preparation for removal Seat, fuel tank and rear fender Exhaust pipe Carburetor Refer to “ CARBURETOR ” section. Air filter case and starter lever 1 Plug cap/spark plug 1/1 2 Crankshaft end co[...]

4 - 9 ENG CYLINDER HEAD Extent of removal Order Part name Q ’ ty Remarks 10 Camshaft sprocket 1 Refer to “ REMOVAL POINTS ” . 11 Timing chain 1 12 Cylinder head 1 13 Gasket 1 14 Dowel pin 2 1[...]

4 - 10 ENG CYLINDER HEAD REMOVAL POINTS Cylinder head 1. Align: ● “ I ” mark (with stationary pointer) Checking steps: ● Turn the crankshaft counterclockwise with a wrench. ● Align the “ I ” mark a on the rotor with the stationary pointer b on the crankcase cover. When the “ I ” mark is aligned with the stationary pointer, the pis[...]

4 - 11 ENG CYLINDER HEAD 4. Remove: ● Cylinder head NOTE: ● Loosen the bolts and nuts in their proper loosening sequence. ● Start by loosening each bolt and nut 1/2 turn until all are loose. ASSEMBLY AND INSTALLATION 1. Install: ● Cylinder head 2. Tighten: ● Nuts ● Bolts NOTE: ● Apply the engine oil on the contact surfaces of the nuts[...]

4 - 12 ENG CYLINDER HEAD CAUTION: . Do not turn the crankshaft during instal- lation of the camshaft. Damage or improper valve timing will result. ● Remove the safety wire from the timing chain. 4. Install: ● Washer ● Bolt 1 NOTE: Install the bolt 1 while holding the rotor nut with a wrench. T R . . 20 Nm (2.0 m · kg, 14 ft · lb) 5. Install[...]

4 - 13 ENG CAMSHAFT AND ROCKER ARMS CAMSHAFT AND ROCKER ARMS Extent of removal: 1 Rocker arm 2 Camshaft removal Extent of removal Order Part name Q ’ ty Remarks CAMSHAFT AND ROCKER ARMS Preparation for removal Cylinder head Refer to “ CYLINDER HEAD ” section. 1 Rocker arm shaft (intake) 1 Use special tool. 2 Rocker arm shaft (exhaust) 1 Refer[...]

4 - 14 ENG CAMSHAFT AND ROCKER ARMS REMOVAL POINTS Rocker arm shaft 1. Remove: ● Rocker arm shafts NOTE: Use a slide hammer bolt 1 and weight 2 to slide out the rocker arm shafts. Slide hammer set: YU-1083-A Slide hammer bolt: 90890-01085 W eight: 90890-01084 INSPECTION Camshaft 1. Measure: ● Cam lobes length a and b Out of specification → Re[...]

4 - 15 ENG CAMSHAFT AND ROCKER ARMS 3. Apply: ● Molybdenum disulfide oil (onto the rocker arm and rocker arm shaft) 4. Install: ● Rocker arm 1 ● Rocker arm shaft 2[...]

4 - 16 ENG VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS Extent of removal: 1 Valves removal Extent of removal Order Part name Q ’ ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to “ CYLINDER HEAD ” section. Rocker arm and camshaft Refer to “ CAMSHAFT AND ROCKER ARMS ” section. 1 Valve cotter 4[...]

4 - 17 ENG VALVES AND VALVE SPRINGS REMOVAL POINTS Valve removal 1. Remove: ● Valve cotters 1 NOTE: Attach a valve spring compressor 2 between the valve spring retainer and the cylinder head to remove the valve cotters. V alve spring compressor: YM-4019/90890-04019 INSPECTION Valve 1. Measure: ● Stem-to-guide clearance Out of specification → [...]

4 - 18 ENG VALVES AND VALVE SPRINGS Valve spring 1. Measure: ● Valve spring free length a Out of specification → Replace. 2. Measure: ● Spring tilt a Out of specification → Replace. Free length (valve spring): Intake: 28.32 mm (1.11 in) <Limit>: 26.9 mm (1.06 in) Exhaust: 28.32 mm (1.11 in) <Limit>: 26.9 mm (1.06 in) Spring tilt[...]

4 - 19 ENG VALVES AND VALVE SPRINGS 2. Lap: ● Valve face ● Valve seat NOTE: After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. Lapping steps: ● Apply a coarse lapping compound to the valve face. CAUTION: Do not let the compound enter the gap between the valve stem and the guid[...]

4 - 20 ENG VALVES AND VALVE SPRINGS ASSEMBLY AND INSTALLATION 1. Apply: ● Molybdenum disulfide oil (onto the valve stem and valve stem seal) 2. Install: ● Valve stem seats ● Valves ● Valve springs ● Valve spring retainers NOTE: ● Make sure that each valve is installed in its original place, also referring to the embossed mark as follows[...]

4 - 21 ENG CYLINDER AND PISTON CYLINDER AND PISTON Extent of removal: 1 Cylinder removal 2 Piston removal Extent of removal Order Part name Q ’ ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to “ CYLINDER HEAD ” section. 1 Timing chain guide (exhaust) 1 2 Cylinder 1 3 Dowel pin 2 4 Gasket 1 5 Piston pin cli[...]

4 - 22 ENG CYLINDER AND PISTON REMOVAL POINTS Piston 1. Remove: ● Piston pin clips 1 ● Piston pin 2 ● Piston 3 NOTE: ● Before removing the piston pin clip, cover the crankcase opening with a clean towel or rag to prevent the clip from falling into the crank- case cavity. ● Before removing each piston pin, deburr the clip groove and pin ho[...]

4 - 23 ENG CYLINDER AND PISTON Cylinder bore “ C ” 47.000 ~ 47.005 mm (1.8504 ~ 1.8506 in) Taper limit “ T ” 0.05 mm (0.002 in) Out of round “ R ” 0.05 mm (0.002 in) “ C ” = Maximum D “ T ” = (Maximum D 1 or D 2 ) – (Maximum D 5 or D 6 ) “ R ” = (Maximum D 1 , D 3 or D 5 ) – (Minimum D 2 , D 4 or D 6 ) ● If out of spec[...]

4 - 24 ENG CYLINDER AND PISTON Piston ring 1. Measure: ● Ring side clearance Use a feeler gauge. Out of specification → Replace the pis- ton and rings as a set. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance. 2. Position: ● Piston ring (in cylinder) NOTE: Insert a ring into the cylinder and push [...]

4 - 25 ENG CYLINDER AND PISTON Piston pin 1. Inspect: ● Piston pin Blue discoloration/grooves → Replace, then inspect the lubrication system. 2. Measure: ● Piston pin outside diameter ● Piston pin bore inside diameter ASSEMBLY AND INSTALLATION Piston 1. Install: ● Piston rings (onto the piston) NOTE: ● Be sure to install the piston ring[...]

4 - 26 ENG CYLINDER AND PISTON 2. Position: ● Top ring ● 2nd ring ● Oil ring Offset the piston ring end gaps as shown. a Top ring end b Oil ring end (lower) c Oil ring end (upper) d 2nd ring end 3. Install: ● Piston 1 ● Piston pin 2 ● Piston pin clips 3 NOTE: ● Apply engine oil onto the piston pin, piston ring and piston. ● Be sure [...]

4 - 27 ENG CLUTCH CLUTCH CRANKCASE COVER (LEFT AND RIGHT) Extent of removal: 1 Crankcase cover (left) removal 2 Crankcase cover (right) removal Extent of removal Order Part name Q ’ ty Remarks CRANKCASE COVER (LEFT AND RIGHT) REMOVAL Preparation for removal Drain the engine oil. Refer to “ ENGINE OIL REPLACEMENT ” section in the CHAPTER 3. 1 [...]

4 - 28 ENG CLUTCH CLUTCH Extent of removal: 1 Friction plate and clutch plate removal 2 Clutch housing removal 3 Primary clutch removal Extent of removal Order Part name Q ’ ty Remarks CLUTCH REMOVAL 1 Bolt/clutch spring 4/4 2 Pressure plate 1 3 Washer 1 4 Push rod #1 1 5 Friction plate 5 6 Clutch plate 4 7 Push rod #2 1 8 Clutch boss nut 1 Use s[...]

4 - 29 ENG CLUTCH Extent of removal Order Part name Q ’ ty Remarks 13 Spacer 1 14 Spacer 1 15 Primary clutch nut 1 Use special tool. Refer to “ REMOVAL POINTS ” . 16 Washer 1 17 Spacer 1 18 Primary clutch housing 1 19 Primary clutch boss 1 20 Clutch carrier 1 21 One-way clutch assembly 1 22 Washer 1 3 2[...]

4 - 30 ENG CLUTCH REMOVAL POINTS Clutch boss 1. Remove: ● Clutch boss nut 1 ● Lock washer 2 ● Clutch boss NOTE: Straighten the lock washer tab and use the clutch holding tool 3 to hold the clutch boss. Å For USA and CDN ı Except for USA and CDN Clutch holding tool: YM-91042/90890-04086 Å ı Primary clutch 1. Remove: ● Primary clutch nut [...]

4 - 31 ENG CLUTCH EC484600 Clutch plate 1. Measure: ● Clutch plate warpage Out of specification → Replace clutch plate as a set. Use a surface plate 1 and thickness gauge 2 . EC484400 Clutch spring 1. Measure: ● Clutch spring free length a Out of specification → Replace springs as a set. Push rod 1. Measure: ● Push rod #2 bend Out of spec[...]

4 - 32 ENG CLUTCH ASSEMBLY AND INSTALLATION Primary clutch 1. Install: ● Washer 1 ● Nut (primary clutch) 2 NOTE: Tighten the nut while holding the magneto rotor with the sheave holder 3 . Clutch 1. Install: ● Lock washer 1 ● Nut (clutch boss) 2 NOTE: Use the clutch holding tool 3 to hold the clutch boss. Å For USA and CDN ı Except for USA[...]

4 - 33 ENG KICK AXLE KICK AXLE Extent of removal: 1 Kick axle removal 2 Kick axle disassembly Extent of removal Order Part name Q ’ ty Remarks KICK AXLE REMOVAL AND DISASSEMBLY Preparation for removal Crankcase cover (right) Refer to “ CLUTCH ” section. 1 Kick axle assembly 1 2 Circlip 2 3 Spring cover 1 4 Torsion spring 1 5 Spring guide 1 6 [...]

4 - 34 ENG SHIFT SHAFT SHIFT SHAFT Extent of removal: 1 Shift shaft removal Extent of removal Order Part name Q ’ ty Remarks SHIFT SHAFT REMOVAL Preparation for removal Clutch housing and clutch carrier Refer to “ CLUTCH ” section. 1 Shift fork guide bar 1 2 Shift arm 3 1 3 Plate washer 1 4 Compression spring 1 5 Shift guide 1 6 Ball holder 1[...]

4 - 35 ENG SHIFT SHAFT Extent of removal Order Part name Q ’ ty Remarks 14 Stopper lever 1 15 Torsion spring 1 16 Circlip 1 17 Plate washer 1 18 Torsion spring 1 19 Shift lever 1 1[...]

4 - 36 ENG OIL PUMP OIL PUMP Extent of removal: 1 Oil pump removal 2 Oil strainer removal 3 Oil pump disassembly Extent of removal Order Part name Q ’ ty Remarks OIL PUMP REMOVAL AND DIS- ASSEMBLY Preparation for removal Clutch housing and clutch carrier Refer to “ CLUTCH ” section. Shift shaft Refer to “ SHIFT SHAFT ” section. 1 Rotary f[...]

4 - 37 ENG OIL PUMP Extent of removal Order Part name Q ’ ty Remarks 11 Oil pump cover 1 12 Dowel pin 2 13 Oil pump drive shaft 1 14 Pin 1 15 Inner rotor 1 16 Outer rotor 1 17 Rotor housing 1 3[...]

4 - 38 ENG OIL PUMP INSPECTION Oil pump 1. Measure: ● Tip clearance a (between the inner rotor 1 and the outer rotor 2 ) ● Side clearance b (between the outer rotor 2 and the rotor housing 3 ) Out of specification → Replace the oil pump assembly. ● Rotor housing and rotor clearance c (between the rotor housing 3 and the rotors 1 2 ) Out of [...]

4 - 39 ENG CDI MAGNETO CDI MAGNETO Extent of removal: 1 Pickup coil/stator assembly removal 2 Rotor removal Extent of removal Order Part name Q ’ ty Remarks CDI MAGNETO AND STATOR REMOVAL Preparation for removal Fuel tank Crankcase cover (left) Refer to “ CLUTCH ” section. 1 CDI magneto coupler 1 2 Pickup coil/stator assembly 1 3 Rotor nut 1 [...]

4 - 40 ENG CDI MAGNETO REMOVAL POINTS Rotor 1. Remove: ● Rotor nut 1 ● Washer 2 NOTE: ● Loosen the rotor nut while holding the rotor with sheave holder 3 . ● Do not allow the sheave holder to touch the projection on the rotor. Sheave holder: YS-1880-A/90890-01701 2. Remove: ● Rotor 1 ● Woodruff key NOTE: ● Use the flywheel puller 2 . [...]

4 - 41 ENG CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT Extent of removal Order Part name Q ’ ty Remarks CRANKCASE SEPARATION AND CRANKSHAFT REMOVAL Preparation for removal Seat, fuel tank and rear fender Exhaust pipe Air filter case Carburetor Refer to “ CARBURETOR ” section. Drain the engine oil Refer to “ ENGINE OIL REPLACEMENT ” [...]

4 - 42 ENG CRANKCASE AND CRANKSHAFT Extent of removal: 1 Timing chain removal 2 Crankcase separation 3 Crankshaft removal Extent of removal Order Part name Q ’ ty Remarks Shift shaft Refer to “ SHIFT SHAFT ” section. Oil pump and oil strainer Refer to “ OIL PUMP ” section. Rotor Refer to “ CDI MAGNETO ” section. 1 Timing chain guide ([...]

4 - 43 ENG CRANKCASE AND CRANKSHAFT INSPECTION Crankshaft 1. Measure: ● Runout limit a ● Connecting rod big end side clearance b ● Connecting rod big end radial clear- ance c ● Crank width d Out of specification → Replace. Use the dial gauge and a thickness gauge. Standard Limit Runout limit — 0.03 mm (0.0012 in) Side clearance 0.10 ~ 0[...]

4 - 44 ENG SHIFT FORK, SHIFT CAM AND TRANSMISSION SHIFT FORK, SHIFT CAM AND TRANSMISSION Extent of removal: 1 Shift fork, shift cam, main axle and drive axle removal 2 Main axle disassembly 3 Drive axle disassembly Extent of removal Order Part name Q ’ ty Remarks SHIFT FORK, SHIFT CAM TRANSMISSION REMOVAL Preparation for removal Engine assembly S[...]

4 - 45 ENG SHIFT FORK, SHIFT CAM AND TRANSMISSION Extent of removal Order Part name Q ’ ty Remarks 10 3th pinion gear 1 11 Main axle 1 12 Circlip 1 13 Washer 1 14 Collar 1 15 1st wheel gear 1 16 3rd wheel gear 1 17 Circlip 1 18 Washer 1 19 2nd wheel gear 1 20 Drive axle 1 2 3[...]

4 - 46 ENG SHIFT FORK, SHIFT CAM AND TRANSMISSION EC4H3000 REMOVAL POINTS Shift fork, shift cam and transmission 1. Remove: ● Shift forks ● Shift cam ● Drive axle assembly ● Main axle assembly NOTE: ● Tap lightly on the transmission drive axle and shift cam with a soft hammer to remove. ● Remove assembly carefully. Note the posi- tion o[...]

5 - 1 CHAS EC500000 CHASSIS FRONT WHEEL AND REAR WHEEL FRONT WHEEL AND FRONT BRAKE FRONT WHEEL AND REAR WHEEL Extent of removal: 1 Front wheel removal 2 Wheel bearing removal 3 Brake shoe plate assembly removal and disassembly Extent of removal Order Part name Q ’ ty Remarks FRONT WHEEL REMOVAL W ARNING Support the machine securely so there is no[...]

5 - 2 CHAS Extent of removal Order Part name Q ’ ty Remarks 10 Brake shoe 2 11 Brake camshaft lever 1 12 Brake camshaft 1 3 FRONT WHEEL AND REAR WHEEL[...]

5 - 3 CHAS FRONT WHEEL AND REAR WHEEL REAR WHEEL AND REAR BRAKE Extent of removal: 1 Rear wheel removal 2 Wheel bearing removal 3 Brake shoe plate assembly removal and disassembly Extent of removal Order Part name Q ’ ty Remarks REAR WHEEL REMOVAL W ARNING Support the machine securely so there is no danger of it falling over. Preparation for remo[...]

5 - 4 CHAS FRONT WHEEL AND REAR WHEEL Extent of removal Order Part name Q ’ ty Remarks 11 Collar (left) 1 12 Wheel drive hub assembly 1 13 Bearing 2 Refer to “ REMOVAL POINTS ” . 14 Brake shoe 2 15 Brake camshaft lever 1 16 Brake camshaft 1 3 2[...]

5 - 5 CHAS FRONT WHEEL AND REAR WHEEL EC593000 REMOVAL POINTS EC513201 Wheel bearing (if necessary) 1. Remove: ● Bearing 1 NOTE: Remove the bearing using a general bearing puller 2 . 1 1 2 1 EC594000 INSPECTION EC514100 Wheel 1. Measure: ● Wheel runout Out of limit → Repair/replace. Wheel runout limit: Radial 1 : 2.0 mm (0.08 in) Lateral 2 : [...]

5 - 6 CHAS FRONT FORK EC550000 FRONT FORK Extent of removal: 1 Front fork removal Extent of removal Order Part name Q ’ ty Remarks FRONT FORK REMOVAL W ARNING Support the machine securely so there is no danger of it falling over. Preparation for removal Hold the machine by placing the suitable stand under the engine. Front wheel Refer to “ FRON[...]

5 - 7 CHAS FRONT FORK EC558000 FRONT FORK DISASSEMBLY Extent of removal: 1 Oil seal removal 2 Damper rod removal Extent of removal Order Part name Q ’ ty Remarks FRONT FORK DISASSEMBLY Preparation for disas- sembly Drain the fork oil. 1 Adjuster 1 2 Fork spring 1 3 Dust cover 1 4 Stopper ring 1 5 Bolt (damper rod) 1 Use special tool. Refer to “[...]

5 - 8 CHAS FRONT FORK REMOVAL POINTS Inner tube 1. Remove: ● Bolt (damper rod) NOTE: While holding the damper rod with the damper rod holder 1 and T-handle 2 , loosen the bolt (damper rod). Damper rod holder: YM-1300/90890-01294 T -handle: YM-1326/90890-01326 EC555000 ASSEMBLY AND INSTALLATION Front fork assembly 1. Install: ● Oil seal 1 NOTE: [...]

5 - 9 CHAS HANDLEBAR EC5B0000 HANDLEBAR Extent of removal: 1 Handlebar removal Extent of removal Order Part name Q ’ ty Remarks HANDLEBAR REMOVAL 1 “ ENGINE STOP ” switch 1 2 Brake lever cable 1 Disconnect at the lever side. 3 Brake lever 1 4 Grip cap (lower) 1 5 Grip cap (upper) 1 6 Throttle cable 1 Disconnect at the throttle side. 7 Grip (r[...]

5 - 10 CHAS STEERING EC560000 STEERING LS LS T R . . TIGHTENING STEPS: •T ighten ring nut. 38 Nm (3.8 m • kg, 27 ft • Ib) •Loosen it completely. •Retighten it. 1 Nm (0.1 m • kg, 0.7 ft • Ib) T R . . 40 Nm (4.0 m • kg, 29 ft • Ib) 5 9 6 8 10 7 6 4 3 2 1 Extent of removal: 1 Under bracket removal 2 Bearing removal Extent of removal [...]

5 - 11 CHAS SWINGARM EC570000 SWINGARM Extent of removal: 1 Swingarm removal 2 Rear shock absorber removal Extent of removal Order Part name Q ’ ty Remarks SWINGARM REMOVAL W ARNING Support the machine securely so there is no danger of it falling over. Preparation for removal Hold the machine by placing the suitable stand under the engine. Rear w[...]

5 - 12 CHAS SWINGARM Extent of removal Order Part name Q ’ ty Remarks 9 Cotter pin 1 10 Nut (tension bar) 1 11 Bolt (tension bar) 1 12 Tension bar 1 1[...]

6 - 1 – + ELEC ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 CDI magneto 2 CDI unit 3 Ignition coil 4 Spark plug 5 “ ENGINE STOP ” switch 6 Thermo switch 7 Carburetor heater 8 Rectifier/regulator COLOR CODE B ...................... Black Br .....[...]

– + ELEC 6 - 2 IGNITION SYSTEM EC620000 IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. NOTE: ● Remove the following parts before inspection. 1) Seat 2) Fuel tank ● Use the foll[...]

6 - 3 – + ELEC IGNITION SYSTEM EC622001 SPARK GAP TEST 1. Disconnect the spark plug cap from spark plug. 2. Connect the dynamic spark tester 1 (ignition checker 2 ) as shown. ● Spark plug cap 3 ● Spark plug 4 Å For USA and CDN ı Except for USA and CDN 3. Kick the kick starter. 4. Check the ignition spark gap. 5. Start engine, and increase s[...]

6 - 4 – + ELEC IGNITION SYSTEM EC626002 IGNITION COIL INSPECTION 1. Inspect: ● Primary coil resistance Out of specification → Replace. Tester (+) lead → Orange lead 1 Tester ( – ) lead → Black lead 2 Primary coil resistance Tester selector position 0.18 ~ 0.28 Ω at 20 ˚ C (68 ˚ F) Ω × 1 2. Inspect: ● Secondary coil resistance O[...]

6 - 5 – + ELEC IGNITION SYSTEM 2. Inspect: ● Source coil resistance Out of specification → Replace. Tester (+) lead → Brown lead 1 Tester ( – ) lead → Green lead 2 Source coil resistance Tester selector position 688 ~ 1,032 Ω at 20 ˚ C (68 ˚ F) Ω × 100[...]

– + ELEC 6 - 6 CARBURETOR HEATING SYSTEM CARBURETOR HEATING SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning carburetor heating system. NOTE: ● Remove the following parts before inspection. 1) Seat 2) Fuel tank ● Use the following special tools in this inspection. Check entire carburetor heati[...]

6 - 7 – + ELEC CARBURETOR HEATING SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: ● Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. CDI MAGNETO INSPECTION 1. Inspect: ● Source coil resistance Refer to “ IGNITION SYSTEM ” section. THERMO SWITCH INSPECTION 1. Inspect: ● Thermo swit[...]

6 - 8 – + ELEC CARBURETOR HEATING SYSTEM Å The thermo switch circuit is open. ı The thermo switch circuit is closed. Test step Water temperature Continuity 1 Less than 23 ± 3 ˚ C (73.4 ± 5.4 ˚ F) YES 2 More than 23 ± 3 ˚ C (73.4 ± 5.4 ˚ F) NO 3 More than 12 ± 4 ˚ C (53.6 ± 7.2 ˚ F) NO 4 Less than 12 ± 4 ˚ C (53.6 ± 7.2 ˚ F) YES [...]

– + ELEC 6 - 9 NOISE REGULATION/MAINTENANCE RECORD NOISE REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED: Federal law prohibits the following acts or the causing thereof: (1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated i[...]

PRINTED IN JAPAN 2002.04-3.0 × 1 CR (E) PRINTED ON RECYCLED PAPER Y AMAHA MO T OR CO . , L TD . 2500 SHINGAI IW A T A SHIZUOKA JAP AN[...]