.

YAMAHA
lep ice IIIII
LlT-11616-04-84
YFM80N
SERVICE MANUAL
1986 by Yamaha Motor Corp., USA
1st Edition - September 1984 -JEM 8-170
3rd Printing - April 1986
ALL RIGHTS RESERVED BY
YAMAHA MOTOR CORPORATION, U.S.A.
CYPRESS, CALIFORNIA 90630
LI T -11616-04-84
NOTICE
This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers and
their qualified mechanics. It is not possible to put an entire mechanic's education into one manual
so it is assumed that persons using this book to perform majntenance and repairs on Yamaha machines
have a basic understanding of the mechanical concepts and procedures inherent in machine repair
technology. Without such knowledge, attempted repairs or service to this model may render it unfit
to use and/or unsafe.
Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by Yamaha.
Modifications and significant changes in specifications or procedures will be forwarded to all
Authorized Yamaha dealers and will, where applicable, appear in future editions of this manual.
TECHNICAL PUBLICATIONS
SERVICE DIVISION
MOTORCYCLE OPERATIONS
YAMAHA MOTOR CO., LTD.
HOW TO USE THIS MANUAL
PARTICULARLY IMPORTANT INFORMATION
This material is distinguished by the following notation.
NOTE:
WARNING:
A NOTE provides key information to make procedures easier or clearer.
A CAUTION indicates special procedures that must be followed to avoid damage to
the machine.
A WARNING indicates special procedures that must be followed to avoid injury to
a machine operator or person inspecting or repairing the machine.
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-
tion has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the
course of action required will follow the symbol, e.g.,
Bearings
Pitting/Damage -+ Replace.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying
correct disassembly and assembly procedures.
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ILLUSTRATED SYMBOLS
(Refer to the illustration)
Illustrated symbolsCDto@are designed as thumb
tabs to indicate the chapter's number and
content.
CD General information
Periodic inspection and adjustment
@ Engine
@ Cooling system
@ Carburetion
Chassis
(j) Electrical
@ Appendices
Illustrated symbols@to @ are used to identify
the specifications appearing in the text.
@ Filling fluid
@ Lubricant
@ Tightening
@ Wear limit, clearance
@ Engine speed
@n,V,A
Illustrated symbols @to in the exploded dia-
gram indicate grade of lubricant and location of
lubrication point.
@ Apply engine oil
@ Apply gear oil
@ Apply molybdenum disulfide oil
@ Apply wheel bearing grease
(j]) Apply I ightweight lithium-soap base grease
Apply molybdenum disulfide grease
Apply locking agent (LOCTITE@)
Being a Yamaha owner, you obviously prefer
a quality product.
\....J \....J
genulne
adj. 1. Real 2. Authentic,
not artificial 3. Yamaha.
GENUINE YAMAHA PARTS & ACCESSORIES
Don't compromise the quality and
performance of your Yamaha with off-brand
alternatives. You'll be getting exactly what
you're paying for.
INDEX
GENERAL INFORMATION
PERIODIC INSPECTIONS
AND ADJUSTMENTS
ENGINE
CARBURETION
CHASSIS
ELECTRICAL
APPENDICES
ENG
~
CHAS
~ ,
APPX
CHAPTER 1.
GENERAL INFORMATION
MACHINE IDENTIFICATION ...................................... 1-1
VEHICLE IDENTIFICATION NUMBER ........................... 1-1
ENGINE SERIAL NUMBER ..................................... 1-1
IMPORTANT INFORMATION ...................................... 1-2
ALL REPLACEMENT PARTS ................................... 1-2
GASKETS, OIL SEALS, AND O-RINGS ........................... 1-2
LOCK WASHERS/PLATES AND COTTER PINS ..................... 1-2
BEARINGS AND OIL SEALS ................................... 1-2
CIRCLIPS ................................................... 1-3
SPECIAL TOOLS ................................................ 1-3
FOR TUNE-UP ............................................... 1-3
FOR ENGINE SERViCE ....................................... 1-4
FOR CHASSIS SERVICE ....................................... 1-7
FOR ELECTRICAL COMPONENTS .............................. 1-7
,.,
MACHINE IDENTI FICATION
GENERAL
INFORMATION
MACHINE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number CD is stamped
into the left side of the frame.
NOTE: ________________________ _
The Vehicle identification number is used to
identify your machine and may be used to
register your machine with the licensing
outhority in your state.
Starting Serial Number:
JYA55XOO* FC00010l
ENGINE SERIAL NUMBER
The engine serial number CD is stamped into
the left side of the engine.
NOTE: ________________________ __
The first three digits of these numbers are for
model identifications; the remaining digits are
the unit production number.
Starting Serial Number:
55X-00010l
NOTE: ________________________ _
Designs and specifications are subject to change
without notice.
IMPORTANT INFORMATION I ~ ' I = ~ I ~ I
IMPORTANT INFORMATION
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha genuine
parts for all replacements. Use oil and/or
grease recommended by Yamaha for assem-
bly and adjustment.
GASKETS, OIL SEALS, AND a-RINGS
1. All gaskets, seals, and a-rings should be
replaced when an engine is overhauled. All
gasket surfaces, oil seal lips, and a-rings
must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the oil
seal lips.
LOCK WASHERS/PLATES AND COTTER PINS
1. All lock washers/plates CD and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt
or nut flat(s) after the bolt or nut has been
properly tightened.
BEARINGS AND OIL SEALS
1. I nstall the bearing(s) CD and oil seal (s) @
with their manufacturer's marksor numbers
facing outward. (In other words, the
stamped letters must be on the side exposed
to view.) When installing oil seal(s), apply a
light coating of light-weight lithium base
grease to the seal lip(s). Oil the bearings
liberally when installing.
Do not use compressed air to spin the bearings
dry. This causes damage to the bearing surfaces.
1-2
SPECIAL TOOLS
1-3
CIRCLIPS
1. All circlips should be inspected carefully
before reassembly. Always replace piston
pin clips after one use. Replace distorted
circlips. When installing a circlip CD , make
sure that the sharp-edged corner is
positioned opposite' to the thrust it
receives. See the sectional view.
@ Shaft
SPECIAL TOOLS
The proper special tools are necessary for com-
plete and accurate tune-up and assembly. Using
the correct special tool will help prevent damage
caused by the use of improper tools or improvis-
ed techniques.
FOR TUNE UP
1. Inductive Tachometer
PIN YU-08036
This tool is needed for detecting engine rpm.
2. Inductive Timing Light
PIN YM-33277
This tool is necessary for checking ignition
timing.
3. Compression Gauge
PIN YU-33223
This gauge is used to measure the engine com-
pression.
o
p
SPECIAL TOOLS
4. Fuel Level Gauge
PIN YM-01312
This gauge is used to measure the fuel level in
the float chamber.
5. Valve Adjusting Tool
PIN YM-08035
This tool is necessary for adjusting the valve
clearance.
FOR ENGINE SERVICE
1. Clutch Holder
PIN YM-91 042
This tool is used to hold the clutch when re-
moving or installing the clutch boss locknut.
2. Valve Spring Compressor
PIN YM-04019 - CD
Attachment
PIN YM-4108 -
This tool is needed to remove and install the
valve assemblies.
3. Slide Hammer Set
PIN YU-01083
These tools are used when removing the rocker
arm shaft and camshaft.
1-4
SPECIAL TOOLS
~
~
IbJ
1f1[][ J[ ]
/'ii1/JE9
1-5
4. Flywheel Puller
PIN YM-01189
This tool is used to remove the flywheel
magneto.
5. Valve Guide Remover (5.0 mm)
PIN YM-4097
This tool is used to remove the valve guides.
6. Valve Guide Reamer (5.0 mm)
PIN YM-4099
This tool is used to rebore the new valve guide.
7. Valve Guide Installer
PIN YM-4098
This tool is needed to install the valve guides
properly.
8. Valve Seat Cutter Set
PIN YM-91 043
This tool is needed to resurface the valve seat.
SPECIAL TOOLS
9. Piston Pin Puller
PIN YU-01304
This tool is used to remove the piston pin.
10. Hexagon Wrench (27 mm)
PIN YM-01388
This tool is used to loosen or tighten the middle-
drive-shaft-bearing retainer nut.
11. Rotor Holder
PIN YM-01235
This tool is used to hold the flywheel magneto
when removing or installing the flywheel
magneto securing nut.
12. Sealant (Quick Gasket)
PIN ACC-ll 001-05-01
This sealant (bond) is used for crankcase mating
surfaces, etc.
FOR CHASSIS SERVICE
1. Hexagon Wrench (32 mm)
PIN YM-01364
This tool is used to loosen and tighten the final-
drive-shaft retainer nut.
1-6
1 ~ 1 f = ~ 1 " ' 1 SPECIAL TOOLS
2. Ring Nut Wrench
PIN YU-33975
This tool is used to loosen and tighten the
steering ring nut.
3. Crankcase Separating Tool
PIN YU-01135
This tool is needed to disassemble and reassemble
the shaft drive assembly.
FOR ELECTRICAL COMPONENTS
1. Electro Tester
PIN YU-33260 -CD
This instrument is necessary for checking the
ignition system components.
2. Pocket Tester
PIN YU-33263 -<Vor
PIN YU-03112 -
1-7
This instrument is invaluable for checking the
electrical system.
CHAPTER 2.
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCITON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-1
PERIODIC MAINTENANCE/LUBRICATION ....................... 2-1
ENGINE .................................................... 2-2
CAM CHAIN TENSION ADJUSTMENT ......................... 2-2
VALVE CLEARANCE ADJUSTMENT ......................... 2-3
I DLE SPEED ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2-5
THROTTLE LEVER ADJUSTMENT ........................... 2-5
SPEED LIMITER ADJUSTMENT .............................. 2-6
FUEL LINE INSPECTION ................................... 2-7
AIR FILTER CLEANING .................................... 2-7
ENGINE OIL LEVEL INSPECTION ............................ 2-8
ENGINE OIL REPLACEMENT ............................... 2-9
OIL STRAINER CLEANING ................................. 2-10
COMPRESSION PRESSURE MEASUREMENT ................... 2-11
CHASSIS .................................................... 2-13
FUEL COCK CLEANING .................................... 2-13
BRAKE LEVER ADJUSTMENT .............................. 2-13
BRAKE PADAL ADJUSTMENT .............................. 2-14
BRAKE LINING INSPECTION ............................... 2-14
CLUTCH ADJUSTMENT .................................... 2-14
STEERING SYSTEM INSPECTION ............................ 2-15
WHEEL BEARINGS CHECK ................................. 2-16
CABLE INSPECTION AND LUBRiCATION ..................... 2-17
LEVERS, PEDALS, ETC. LUBRiCATION ....................... 2-17
KNUCKLE SHAFTS LUBRICATION ........................... 2-17
TIRES CHECK ............................................ 2-18
WHEELS CHECK .......................................... 2-19
ELECTRICAL ................................................ 2-20
IGNITION TIMING CHECK .................................. 2-20
BATTERY INSPECTION .................................... 2-21
SPARK PLUG INSPECTION ................................. 2-22
FUSE INSPECTION ........................................ 2-23
IINSP \ Q I INTRODUCTION/
ADJ PERIOD IC MAINTENANCE/LUBRICATION
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjustments.
These preventive maintenance procedures, if followed, will ensure more reliable vehicle operation and a
longer service life. The need for costly overhaul work will be greatly reduced. This information applies
to vehicles already in service as well as new vehicles that are being prepared for sale. All service tech-
nicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION
Item Remarks
Valve(s)* Check valve clearance. Adjust if necessary.
Cam chain* Check chain tension. Adjust if necessary.
Spark plug(s) C.heck condition. Clean or replace if necessary.
Air filter Clean. Replace if necessary.
Carburetor*
Check idle speed/starter operation.
Adjust if necessary.
Fuelline*
Check fuel hose for cracks or damage.
Replace if necessary.
Engine oil Replace (Warm engine before draining).
Oil strainer* Clean. Replace if necessary.
Brake* Check operation. Adjust if necessary.
Clutch* Check operation. Adjust if necessary.
Wheels* Check balance/damage/runout. Repair if necessary.
Wheel bearings*
Check bearings assembly for looseness/damage.
Replace if damaged.
Steering system*
Check operation/replace if damage.
Check toe-in/adjust if necessary.
Knuckle shafts* Lubricate every 6 months. * * *
Fittings/Fasteners *
Check all chassis fittings and fasterners.
Correct if necessary.
Check specific gravity.
Battery* Check breather pipe for proper operation.
Correct if necessary.
*
***
It is recommended that these items be serviced by a Yamaha dealer.
Lithium soap base grease.
2-1
Initial Every
1 3 6 6 1
month months months months year
0 0 0 0
0 0 0 0
0 0 0 0 0
0 0 0 0
0 0 0 0
0 0 0
0 0 0 0
0 0
0 0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0
0 0 0 0 0
0 0 0
0 0 0 0 0
0 0 0 0 0
-
CAM CHAIN TENSION AOJUSTMENT I ~ 8 ~ I ~ I
ENGINE
CAM CHAIN TENSION ADJUSTMENT
1. Remove:
Seat
Battery
Rear fender CD
.Change pedal
.Crankcase (left)
2. Remove:
Side cover (cylinder head) CD
Crown nut (chain tensioner)
3. Loosen:
Locknut (chain tensioner) CD
Adjuster (chain tensioner)
4. Adjust:
Cam chain tension
By the following adjustment steps.
Cam chain tension adjustment steps:
Turn the crankshaft counterclockwise with
wrench .
Align the "T" mark CD on the rotor with the
stationary pointer on the crnakcase.
When the "T" mark is aligned with the
stationary pointer, the piston is at Top Dead
Center (TDC).
2-2
2-3
VALVE CLEARANCE ADJUSTMENT
NOTE: ______________________ __
Be sure the match mark on the cam chain
sprocket is aligned with the match mark @
on the cylinder head.
- Turn the crankshaft counterclockwise to
lineup the cam sprocket mark and the
positioning pawl with the tensioner
adjuster .
-In this position, tighten the adjuster.
-Install the locknut and crown nut.
Locknut (Cam Chain Tensioner):
7 Nm (0.7 mkg, 5.1 ftlb)
Crown Nut (Cam Chain Tensioner):
5 Nm (0.5 m'kg, 3.6 ftlb)
5. Install:
-Components in above list (steps"2 and 1")
VALVE CLEARANCE ADJUSTMENT
1. Remove:
-Seat
- Battery
- Rear fender CD
-Change pedal
- Crankcase cover (left)
VALVE CLEARANCE ADJUSTMENT
2. Remove:
- Tappet cover (intake) CD
- Tappet cover (exhaust) @
3. Measure:
- Valve clearance
By the following measurement steps.
Valve clearance measurement steps:
-Turn the crankshaft counterclockwise with
wrench.
NOTE:
Valve clearance must be measured when the
engine is cold to touch.
- Align the "T" mark CD on the rotor with the
stationary pointer @ on the cran kcase. When
the "T" mark is aligned with the stationary
pointer, the piston is at Tad Dead Center
(TDC).
NOTE:
Be sure the match mark @ on the cam chain
sprocket is aligned with the match mark
on the cylinder head.
- Measu re the valve clearance using a Feeler
Gauge .
Out of specification -+- Adjust clearance.
Intake Valve (Cold):
~
0.05 - 0.10 mm (0.002 - 0.004 in)
Exhaust Valve (Cold):
0.075 - 0.125 mm
(0.003 - 0.005 in)
4. Adjust:
- Valve clearance
By the following adjustment steps.
Valve clearance adjustment steps:
- Loosen the locknut CD.
-Insert a Feeler Gauge @ between the
adjuster end and the valve end.
2-4
\INSP \ Q \ IDLING SPEED ADJUSTMENTI
ADJ THROTTLE LEVER ADJUSTMENT
2-5
Turn the adjuster @ clockwise or counter-
clockwise with the Valve Adjusting Tool
@ (YM-08035) until proper clearance is
attained.
Intake Valve (Cold):
0.05 - 0.10 mm (0.002 - 0.004 in)
...... - ~ Exhaust Valve (Cold):
0.075 - 0.125 mm
(0.003 - 0.005 in)
Hold the adjuster to prevent it from moving
and thoroughly tighten the locknut.
Valve Clearance Adjusting Locknut:
7 Nm (0.7 m'kg, 5.1 ftlb)
Measure the valve clearance.
If the clearance is incorrect, repeat above
steps until the proper clearance is obtained.
4. Install:
Components in above list (steps "2 and 1 ")
IDLE SPEED ADJUSTMENT
1. Adjust:
.Idle speed
Warm up the engine and turn the throt-
tle stop screw CD to adjust.
1
~ l l d l e Speed:
V ~ 1,800 50 r/min
THROTTLE LEVER ADJUSTMENT
NOTE: __________________________ _
Before adjusting the throttle lever free play,
the engine idling speed should be adjusted.
SPEED LIMITER ADJUSTMENT I ~ g r I Q I
1. Check:
- Throttle lever free play
Out of specification -+ Adjust.
Throttle Lever Free Play @:
3 ~ 5 mm (0.12 ~ 0.20 in)
2. Adjust:
- Throttle lever free play
By the following adjustment steps.
Throttle lever free play adjustment steps:
- Loosen the locknut CD.
-Turn the adjuster clockwise or counter-
clockwise until proper free play is attained.
- Tighten the locknut.
SPEED LIMITER ADJUSTMENT
The speed limiter keeps the carburetor throt-
tle from becoming full-open even when the
throttle grip is turned to a maximum. Screw-
ining in the adjuster stops the engine speed
from increasing.
1. Adjust:
-Speed limiter length
Bt the following adjustment steps.
Speed limiter length adjustment steps:
- Loosen the locknut CD.
-Turn the adjuster clockwise or counter-
clockwise until proper length is attained.
Speed Limiter Length @:
8 ~ 9 mm (0.31 ~ 0.35 in)
- Ti ghten the locknut.
WARNING:
Particularly for a beginner rider, the speed
limiter should be screwed in completely.
Screw it out little by little as his riding
technique improves. Never remove the
speed limiter from the outset.
2-6
2-7
FUEL LINE INSPECTION/AIR FILTER CLEANING
- ~ .
I , '"
For proper throttle lever operation, do not
turn out the adjuster more than 8 - 9 mm
(0.31 - 0.35 in). Also adjust the throttle
lever free play always to 3 - 5 mm (0.12 -
0.20 in).
FUEL LINE INSPECTION
1. Inspect:
Fuel hose CD
Cracks/Damage -+- Replace.
AIR FILTER CLEANING
NOTE: ________________________ _
There is a check hose CD at the bottom of the
air filter case. If dust and/or water collects
in this hose, clean the air filter element and
air filter case.
1. Remove:
Front cover CD
Rubber band CV
2. Pull out the air filter element assembly.
3. Remove:
.Air filter element @
The engine should never be run without the
air filter element; excessive piston and/or
cylinder wear may result.
4. Clean:
Air filter element
Clean it with solvent.
ENGINE OIL LEVEL INSPECTION
NOTE: ________________________ __
After cleaning, remove the remaining solvent by
squeezing the element.
Do not twist the filter element when squeezing
the filter element.
Never use low flash point solvents such as
gasoline to clean the air filter element. Such
solvent may lead to a fire or explosion.
5. Inspect:
Element
Damage .... Replace.
6. Apply:
.SAE 10W30 motor oil
7. Squeeze out the excess oil.
NOTE: ________________________ _
The element should be wet but not dripping.
8. Apply:
All-pu rpose grease
To the air filter seat.
9. Install:
Air filter lement
NOTE: ________________________ _
Make saure its sealing surface matches the seal-
ing surface of the case so there is no air leak .
Insert the lobe on the front cover into the
receptacle on the front fender.
ENGINE OIL LEVEL INSPECTION
1. Inspect:
Engine oil level
Oil level low --+- Add sufficient oil.
By the following inspection steps.
Engine oil level inspection steps:
Place the machine on a level place.
28
2-9
ENGINE OIL REPLACEMENT
Warm up the engine for several minutes, and
stop it .
Screw the di pstick CD completely out, and
then just rest the dipstick in the hole .
Pull up the dipstick, and inspect the oil
level whether or not it is between maximum
@ and minimum level .
If the level is lower, add the oil up to the
proper level.
ENGINE OIL REPLACEMENT
1. Place the machine on a level place.
2. Warm up the engine for several minutes, and
stop it.
3. Place an oil pan under the engine.
4. Remove:
Dipstick
Drain plug CD
Drain the engine oil.
5. Inspect:
Gasket
Damage -+ Replace.
6. Tighten:
Drain plug
Drain Plug:
20 Nm (2.0 m'kg, 14 ftlb)
7. Fill:
Engine
~
I
Recommended Oil:
SAE 10W40 Type SE Motor Oil
OIL STRAINER CLEANING
o 10 30 50 70 gOOF
. --- tyJe
SAE 10W40 type SE motor oil
Yamalube 4-cycle oil or
SAE type motor oj'
120W5Q)I I I
r
-20 -10 0 10 20
Periodic Oil Change:
0.85 L (0.75 Imp qt, 0.88 US qt)
NOTE: ________________________ _
Recommended engine oil classification; API
Service "SE", "SF" type or equivalent (e.g.
"SF-SE", "SF-SE-CC", "SF-SE-SD" etc.).
Do not allow foreign material to enter the
engine.
8. Install:
Dipstick
9. Inspect:
Oil leaks
.Oillevel
OIL STRAINER CLEANING
1. Place the machine on a level place.
2. Warm up the engine for several minutes,
and stop it.
3. Remove:
Seat
Battery
Rear fender CD
Muffler
4. Place an oil pan under the engine.
2-10
2-11
COMPRESSION PRESSURE MEASUREMENT
5. Remove:
Oil filler cap
Drain plug
Drain the engine oil.
Crankcase cover (right) @
Oil strainer @
6. Clean:
Oil strainer
Clean it with solvent.
7. Inspect:
Gaskets
Oil strainer
Damage ~ Replace.
8. Install:
.Components in above list (steps "5 and 4")
Crankcase Cover:
7 Nm (0.7 m'kg, 5.1 ftlb)
~ : ; ; a . .. Drain Plug:
20 Nm (2.0 m' kg, 14 ftlb)
Exhaust Pipe:
10 Nm (1.0 m'kg, 7.2 ftlb)
Muffler Stay:
25 Nm (2.5 mkg, 18 ftlb)
9. Fill:
Engine
Refer to "ENGINE OIL REPLACEMENT"
section.
10. Inspect:
.Oil leaks
Oil level
COMPRESSION PRESSURE MEASUREMENT
NOTE: ________________________ __
Insufficient compression pressure will result in
performance loss.
1. Measure:
Valve clearance
Out of specification ~ Adjust.
COMPRESSION PRESSURE MEASUREMENT
2. Warm up the engine, and stop it.
3. Remove:
-Spark plug
4. Measure:
- Compression pressure
By the following measurement steps.
Compression pressure measurement steps:
-Install the Compression Gauge CD (YU-
33223).
- Crank over the engine with the electric
starter (be sure the battery is fully charged)
with the throttle wide-open until the com-
pression reading on the gauge stabilizes.
- Check readings with specified levels (See
chart).
Compression Pressure (at sea level):
Standard:
1,177 kPa (12 kg/cm2, 171 psi)
Minimum:
981 kPa (10 kg/cm
2
, 142 psi)
Maximum:
1,275 kPa (13 kg/cm2 , 185 psi)
WARNING:
When cranking the engine, ground all of the
spark plug lead to prevent sparking.
-If pressure falls below the minimum level:
1 )Squirt a few drops of oil into the affected
sylinder.
2) Measure the compression again.
Compression Pressure
(with oil introduced into cylinder)
Reading
Higher than without oil
Same as without oil
Above maximum level
Diagnosis
Worn or damaged pistons
Defective ring(s), valves,
cylinder head gasket or
piston is possible.
Inspect cylinder head,
valve surfaces, or piston
crown for carbon deposit.
2-12
2-13
FUEL COCK CLEANING/BRAKE LEVER ADJUSTMENT
CHASSIS
FUEL COCK CLEANING
1_ Tu rn the fuel cock lever to the" OF F".
2. Disconnect:
Fuel pipe
3. Remove:
Seat
Fuel tank
Fuel cock
4. Clean:
Filter screen CD
Clean it with solvent.
5. Inspect:
Gasket
Filter screen CD
.O-ring
Damage --;. Replace.
6. Install:
Components in avove list (steps "3 and 2")
NOTE: ________________________ ___
Be careful not to clamp the fuel cock too tightly
as this may unseat the a-ring and gasket, and
lead to a fuel leak.
BRAKE LEVER ADJUSTMENT
WARNING:
Always adjust both the brake pedal and the
brake lever whenever adjusting the rear brake.
1. Loosen:
Locknut CD
2. Adjust:
Free play
Turn the adjuster until the free play a
is within the specified limits.
~ Free Play @:
10 - 20 mm (0.4 - 0.8 ;nJ
3. Tighten:
Locknut
I
BRAKE PEDAL ADJUSTMENT/ IINSP I ~ . I
BRAKE LINING INSPECTION/CLUTCH ADJUSTMENT-ADJ-- ~
BRAKE PEDAL ADJUSTMENT
WARNING:
Always adjust both the brake pedal abd brake
lever whenever adjusting the rear brake.
1. Adjust:
Free play
Turn the adjuster CD until the free play
is within the specified limits.
Free Play @:
20 ~ 30 mm (0.8 ~ 1.2 in)
BRAKE LINING INSPECTION
1. Apply the rear brake (brake pedal or brake
lever).
2. Inspect:
Wear indicator CD
Indicator reaches the wear limit --+
Replace shoes.
CLUTCH ADJUSTMENT
1. Remove:
Cap cover
2. Adjust:
Free play
By the following adjustment steps.
Clutch free play adjustment steps:
Loosen the locknut CD .
Slowly turn the adjuster clockwise until
resistance is fel t.
Turn it 1/8 counterclockwise.
NOTE: ________________________ __
Turn the adjuster counterclockwise to decrease
the clutch free play and turn it clockwise
to increase the free play.
2-14
2-15
STEERING SYSTEM INSPECTION
- Tighten the locknut.
Clutch Locknut:
8 Nm (0.8 m' kg, 5.8 ft-lb)
3. Install:
-Cap cover
STEERING SYSTEM INSPECTION
1. Place the machine on a level place.
2. Check:
-Steering assembly bushings
Move the handlebar up and down, and/or
back and forth.
Excessive play ~ Replace the steering shaft
bushings.
3. Check:
- Tie-rod ends
Turn the handlebar to the left and/or right
until it stops completely, then slightly
move the handlebar from left to right.
Tie-rod end CD has any vertical play ~
Replace the tie-rod end(s).
4. Rasise the front end of the machine so that
there is no weight on the front wheels.
5. Check:
- Knuckles and/or wheel bearings
Move the wheels laterally back and forth.
Excessive free play ~ Replace the follow-
ing parts.
WHEEL BEARINGS CHECK I ~ 8 f I Q I
,.-----------------.... 1) Wheel bearings and/or knuckle bushings CD
2) Thrust cover
3) Knuckle shaft(s)
4) Collar(s)
5) Cotter pin(s)
6. Lubricate:
Pivot points (knuckle and steering shaft) CD
Use a grease gun.
~ Uthium Base Grease
WHEEL BEARINGS CHECK
Front Wheel
1. Check:
Front wheel bearings
Raise the front end of the machine, and spin
the wheel by hand. Touch the front frame
or knuckle while spining the wheel.
Excessive vibration --> Replace bearings.
Rear Wheel
1. Block the front tire and raise the rear of
the machine.
216
2-17
CABLE INSPECTION AND LUBRICATION/LEVERS, PEDALS,
ETC. LUBRICATION/KNUCKLE SHAFTS LUBRICATION
2. Check:
Rear wheel bearings
Spin the wheel by hand and touch the rear
wheel hub while spining the wheel.
Excessive vibration --* Replace bearings.
CABLE INSPECTION AND LUBRICATION
1. Damage to the outer housing of the various
cables may cause corrosion. Often free
movement will be obstructed. An unsafe
condition may result. Replace such cables
as soon as possible.
2. If the inner cables do not operate smooth-
ly, lubricate or replace them.
Yamaha Chain and Cable Lube or
SAE 10W30 Motor Oil
LEVERS, PEDALS, ETC. LUBRICATION
1. Lubricate:
Pivot points
Yamaha Chain and Cable Lube or
SAE 10W30 Motor Oil
KNUCKLE SHAFTS LUBRICATION
1. Lubricate:
Pivot points CD
Use a grease gun.
~ Lithium Base Grease
TIRES CHECK
TIRES CHECK
This model is equipped with low pressure tires.
Pay attention to the following points:
Recommended tire pressure:
19.6 kPa (0.2 kg/cm2 , 2.8 psi)
Vehicle load limit: 95 kg (210 Ib)
Tire size: Front 17 x 7 . 7
Rear 18 x 97
eExcessive tire pressure (over 137 kPa (1.4
kg/cm
2
, 20 psi)) may cause tire to burst.
Inflate tires very slowly. Fast inflation could
cause tire to burst.
e Too low a pressure (below 16.7 kPa (0.17
kg/cm2, 2.4 psi)) could cause the tire to dis-
lodge from the rim.
e Put the same pressure in both front and rear
tires. Uneven tire pressure will severely affect
the handling.
e Set tire pressures cold.
1. Measure:
eTire pressure (cold tire pressure)
Out of specification -+ Adjust.
Use an appropriate low-pressure tire gauge.
Cold Tire
Front Rear
Pressure
Standard
19.6 kPa 19.6 kPa
(0.2 kg/cm
2
, 2.8 psi) (0.2 kg/cm
2
, 2.8 psi)
Minimum
16.7 kPa 16.7 kPa
(0.17 kg/cm
2
, 2.4 psi (0.17 kg/cm
2
, 2.4 psi)
Never use a tire pressure below minimum
specification. The tire could separate from
the wheel under severe operating conditions.
Tire inflation pressure should be checked and
adjusted when the temperature of the tire equals
the ambient air temperature.
2-18
I r8f I Q I WHEELS CHECK
,- - -...,
o / ~
2-19
2. Inspect:
Tire surfaces
Wear/Damage -+ Replace.
Tire Wear Limit @:
Front and Rear: 3.0 mm (0.12 in)
It is dangerous to ride with a worn out tire.
When a tire wear is out of specification, replace
the tire immediately.
3. Adjust:
Tire tread
Tire tread adjustment points:
The rear wheels can be mounted in two ways
to suit different riding conditions .
Standard mounting (Face the air valve
towards the outside): This is for normal
riding conditions .
Reversed mounting (Face the air valve
towards the inside): This is for high-
performance competition use.
NOTE: ___________ _
Cornering performance is diminished on the
reversely mounted rear wheels than on the
standard mounting. Thus, the standard moun-
ting is recommended for normal riding.
@Standard position
@ Reversed position
WHEELS CHECK
1. Inspect:
Wheels
Crack/Bend/Warpage -+ Replace.
NOTE: ____________ _
Always balance the wheel a tire or wheel has
been changed 01' replaced.
IGNITION TIMING CHECK I r8f I ~ I
Never attempt even small repairs to the wheel.
ELECTRICAL
IGNITION TIMING CHECK
1. Remove:
Seat
Battery
Rear fender CD
Change pedal
Crankcase cover (left)
2. Check:
Ignition timing
By the following steps.
Ignition timing check steps:
.Connect the Timing Light CD (YM-33277)
to the spark plug lead .
Warm up the engine and let it idle at the
specified idle speed of 1,800 r/min .
Visually check the stationary pointer
on the crankcase to verify it is within the
firing range indicated on the rotor.
Incorrect ~ Check flywheel and/or pick-up
assembly (tightness and/or damage).
Refer to "CHAPTER 6. ELECTRICAL"
for further information.
2-20
BATTERY INSPECTION
2-21
BATTERY INSPECTION
1. Inspect:
Battery fluid level
Battery fluid level low -+ Fill_
Fluid level should be between upper CD
and lower level marks.
Normal tap water contains minerals which
are harmful to a battery; therefore, refill only
with distilled water.
Battery electrolyte is poisonous and dangerous,
causing severe burns, etc. It contains sulfuric
acid. Avoid contact with skin, eyes or clothing.
Antidote: EXTERNAL-Flush with water. IN-
TERNAL-Drink large quantities of water or milk.
Follow with milk of magnesia, beaten egg, or
vegetable oil. Call a physician immediately.
Eyes: Flush with water for 15 minutes and get
prompt medical attention. Batteries produce
explosive gases. Keep sparks, flame, cigarettes
etc., away. Ventilate when chargeing or using
in an enclosed space. Always shield your eyes
when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
2. Remove:
Battery
3. Inspect:
Battery fluid specific gravity
Out of specification -+ Charge.
Charging Current:
0.7 Amps/10 Hrs.
Specific Gravity:
1,280 at 20
0
C (68 F)
CD
2
SPARK PLUG INSPECTION
4. Install:
Battery
5. Connect/Inspect:
Battery breather hose CD
Be sure the hose is properly attached and
routed.
Pass the battery breather hose through the hole.
When i nspecti ng the battery, be sure the breather
hose is routed correctly. If the breather hose
touches the frame or exits in such a way as to
cause battery electrolyte or gas to exit onto the
frame, structural and cosmetic damage to the
machine can occur.
6. Inspect:
Battery breather hose
Obstruction 4 Remove.
Damage 4 Replace.
SPARK PLUG INSPECTION
1. Inspect:
Electrode CD
Wear/Damage 4 Replace.
Insulator color
Normal condition is a medium to light
tan color.
Distinctly different color 4 Check the
engine condition.
Spark plug gap
2. Clean:
Spark plug
Clean the spark plug with a spark plug
cleaner or wi re brush.
3. Inspect:
Spark plug type
Incorrect 4 Replace.
2-22
I ~ 8 f I Q I FUSE INSPECTION
2-23
Standard Spark Plug:
C7HSA (NGK)/U22FS-U (NO)
4. Measure:
.Spark plug gap
Out of specification -+ Regap.
Use a wire gauge.
Spark Plug Gap:
0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
5. Tighten:
.Spark plug
NOTE: ________________________ __
Before installing a spark plug, clean the gasket
surface and plug surface.
Spark Plug:
12.5 Nm (1.25 mkg, 9.1 ftlb)
NOTE: __________________________ _
If a torque wrench is not available when you are
installing a spark plug, a good estimate of the
correct torque is 1/4 to 1/2 turns part finger
tight. Have the spark plug torqued to the correct
value as soon as possible with a torque wrench.
FUSE INSPECTION
1. Inspect:
Fuse CD
Defective -+ Repalce.
Blow fuse (new) -+ Inspect circuit.
(VSpare fuse
Do not use fuses of higher amperage rating
than those recommended.
Substitution of a fuse of improper rating can
cause extensive electrical system damage and
possibly a fire.
Description Amperage Quantity
Main 10A 1
Reserve 10A 1
1 ENG 1'-1
CHAPTER 3.
ENGINE OVERHAUL
ENGINE REMOVAL ........................................... 3-1
PREPARATION FOR REMOVAL .............................. 3-1
SEAT AND REAR FENDER ............. , .................... 3-2
MUFFLER ................................................ 3-2
CARBURETOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-2
WIRINGS AND PIPE .................................. , ..... 3-3
CRANKCASE COVER (LEFT). ................ ' ............... 3-3
DR IVE SHAFT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-3
STARTER MOTOR ......................................... 3-3
ENGINE REMOVAL ........................................ 3-3
DISASSEMBLY ............................................... 3-4
CARBURETOR JOINT ....................................... 3-4
CYLINDER HEAD AND CyLINDER ........................... 3-4
PISTON. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-4
CLUTCH ......................... , ........................ 3-5
CHANGE SHAFT .......................................... , 3-5
DRIVE GEAR AND STARTER ................................ 3-8
OIL PUMP AND OIL STRAINER ............................... 3-8
CDI MAGNETO ............................................ 3-9
MI DOLE GEAR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 3-9
CRANKCASE .............................................. 3-11
TRANSMiSSiON ........................................... 3-12
CRANKSHAFT ............................................. 3-12
INSPECTION AND REPAI R ..................................... 3-13
ROCKER ARMS AND ROCKER ARM SHAFTS ................... 3-13
CAMSHAFT ............................................... 3-14
CAM CHAIN ............................................... 3-15
CAM SPROCKET AND CAM DRIVE SPROCKET .................. 3-15
CHAIN DAMPERS .......................................... 3-16
CAM CHAIN TENSIONER .................................... 3-16
TAPPET COVER AND SIDE COVER ........................... 3-16
CYLINDER HEAD .......................................... 3-16
VALVE, VALVE GUIDE AND VALVE SEAT ..................... 3-17
CYLINDER ................................................ 3-24
PISTON, PISTON RING, AND PISTON PIN ...................... 3-24
PRIMARY GEARS AND STARTER ............................ 3-26
CLUTCH .................................................. 3-26
01 L PUMP ................................................. 3-29
CRANKSHAFT ............................................. 1-29
TRANSMISSION ........................................... 3-30
MI DDLE GEAR ............................................ 3-32
BEARINGS ..... , .......................................... 3-32
CIRCLIPS AND WASHERS ................................... 3-32
I ENG 1'-1
ENGINE ASSEMBLY AND ADJUSTMENT .......................... 3-33
CRANKSHAFT ....................... " .................... 3-33
TRANSMISSION ........................................... 3-33
CRANKCASE .............................................. 3-34
MI DDLE GEAR ........................................... 3-37
CDI MAGNETO ............................................ 3-39
OIL PUMP AND OIL STRAINER ............................... 3-40
DRIVE GEAR AND STARTER ................................ 3-40
CHANGE SHAFT ........................................... 3-41
CLUTCH .................................................. 3-42
PISTON ................................................... 3-46
CYLINDER AND CYLINDER HEAD ........................... 3-48
CARBURETOR JOINT ....................................... 3-54
REMOUNTING ENGINE ..................................... 3-55
1 ENG 1'-1
ENG
~
\II ENGINE REMOVAL
ENGINE OVERHAUL
ENGINE REMOVAL
NOTE: _____________ _
-It is not necessary to remove the engine in
order to remove the cylinder and/or the fly-
wheel magneto assembly.
-It is not necessary to remove the rear wheel
drive assembly in order to remove the engine
assembly.
PREPARATION FOR REMOVAL
1. Remove all dirt, mud, dust and foreign
material before removal and disassembly.
2. Use proper tools and cleaning equipment.
Refer to "CHAPTER 1. GENERAL INFOR-
MATION-SPECIAL TOOLS" section.
NOTE: ____________ _
When disassembling the engine, keep mated parts
together. This includes gears, cylinder, piston and
other parts that have been "mated" through nor-
mal wear. Mated parts must be reused as an
assembly or replaced.
3. During engine disassembly, clean all parts
and place them in trays in the order of
disassembly. This will speed up assembly
time and help assure that all parts are cor-
rectly reinstalled in the engine.
4. Start the engine and allow it to warm up.
5. Drain the engine oil completely. Refer to
"CHAPTER 2. PERIODIC INSPECTIONS
AND ADJUSTMENTS - ENGINE 01 L
REPLACEMENT" section.
I
I
'!
'ENG ~
ENGINE REMOVAL ..,
SEAT AND REAR FENDER
1. Remove:
Seat
Battery
Rear fender CD
MUFFLER
1. Remove:
Muffler
CARBURETOR
1. Turn the fuel cock to "OFF".
2. Disconnect:
Fuel hose CD
Breather pipe
Overflow pipe @
3. Remove:
Carburetor
NOTE: __________________________ _
Noting the presence, location, and routing of
all pipes, remove the carburetor.
3-2
.. ENGINE REMOVAL
I
ENG
I
~ I
-----------------------------------------------------------
3-3
WIRINGS AND PIPE
1. Disconnect:
Spark plug lead
.CDI magneto leads CD
Ventilation pipe
CRANKCASE COVER (LE FT)
1. Remove:
Change pedal CD
Crankcase cover (left)
Gasket
Dowel pins
DRIVE SHAFT
1. Remove:
Rubber boot CD
STARTER MOTOR
1. Remove:
Starter motor CD
2. Disconnect:
Starter motor cable
ENGINE REMOVAL
1. Remove:
Bolts (engine mounting-upper) CD
Bolts (engine mounting-rear)
2. Remove:
Engine
To the left.





DISASSEMBLY
I ENG 1'-1
DISASSEMBLY
CARBURETOR JOINT
1. Remove:
Carburetor joint CD
O-ring
CYLINDER HEAD AND CYLINDER
1. Remove:
Spark plug CD
Tappet covers (intake and exhaust)
2. Remove:
.Side cover (cylinder head) CD
NOTE: __________________________ _
The camshaft moves in the thrust direction.
Th is is norma I.
3. Remove:
Crown nut (chain tensioner) CD
Locknut (chain tensioner)
.O-ring @
Adjuster (chain tensioner) @
.Tensioner end plug
Gasket
Compressi on spring (j)
Chain tensioner rod
Straight plug
3-4
1 ENG 1'-1 DISASSEMBLY
3-5
4. Remove:
Cam sprocket CD
Use a Rotor Holder (YM-01235) to
hold the flywheel magneto.
NOTE: _____________ _
When removing the cam sprocket, it is not
necessary to separate the cam chain.
5. Remove:
Nuts (cylinder head) CD
Bolts (cylinder head)
Cylinder head
Gasket (cylinder head)
6. Remove:
Dowel pins CD
.Cam chain damper (intake)
Cam chain damper (exhaust)
.Cylinder @
Gasket (cylinder)
Dowel pins (crankcase)
PISTON
1. Remove:
Piston pin clip CD
NOTE: _______________ __
Before removing the piston pin clip, cover the
crankcase with a clean rag so you will not
accidentally drop the clip into the crankcase.
2. Remove:
Piston pin CD
Piston
NOTE:. _______________________ _
Before removing the piston pin, deburr the clip
groove and pin hole area. If the piston pin grrove
DISASSEMBLY 1 ENG 1'-1
is deburred and piston pin is still difficult to
remove, use Piston Pin Puller (YU-01304).
Do not use a hammer to drive the piston pin
out.
CLUTCH
1. Remove:
Crankcase cover (right) CD
Dowel pins
Gasket
2. Remove:
.Circlip CD
Pressure palte assembly
Push rod (small)
Push rod (large) @
3. Remove:
Friction plates (sliver) CD
Clutch plate (bent)
Clutch plates
Friction plate (black) @
Thrust weight plate
4. Straighten:
Lock washer tab
3-6
I ENG 1'-1 DISASSEMBLY
37
5. Remove:
Locknut (clutch boss) CD
Use a Clutch Boss Holding Tool (YM-
91042) to hold the clutch boss.
Lock washer
Clutch boss assembly
6. Remove:
Balls CD
Primary driven gear compo CV
7. Remove:
Spacer CD
Thrust plate
8. Remove:
Push rod guide CD
Push lever 1
CHANG E SHAFT
1. Remove:
.Circlip CD
Push lever 2
.Pin
Plain washers @
Bearing
-o
DISASSEMBLY I ENG I '\.1
2. Remove:
Change shaft CD
3. Unhook the spring CD from its position.
4. Remove:
Stopper lever
DRIVE GEAR AND STARTER
1. Remove:
Nut (primary drive gear) CD
Use a Rotor Holder (YM-01235) to
hold the flywheel magneto.
2. Remove:
.Conical spring washer CD
Primary drive gear
Starter clutch assembly @
Spacer @)
.Idle gear 2 ill
Starter wheel assembly
OIL PUMP AND OIL STRAINER
1. Remove:
.Circlip CD
Oil pump driven gear
Oi I pump drive gear @
3-8
I ENG 1'-1 DISASSEMBLY
3-9
2. Remove:
.Oilpump Q)
.Oil strainer
CDIMAGNETO
1. Remove:
Nut (flywheel) Q)
Use a Rotor Holder (YM-01235) to
hold the flywheel magneto.
Plain washer
2. Remove:
Flywheel Q)
Use a Flywheel Puller (YM-01189).
Woodruff key
3. Remove:
Base plate Q)
Neutral switch
.Cam chain
MIDDLE GEAR
1. Remove:
Bolts (driven gear housing)
Middle driven gear compo
Shim(s)
DISASSEMBLY 1 ENG 1 '\.1
2. Remove:
Circlips CD
3. Place the U-joint in a press. With a suitable
diameter pipe beneath the yoke, press the
bearing into the pipe as illustrated.
4. Remove:
Beari ngs
Tap lightly on the U-joint with a hammer.
5. Repeat the steps for the opposite bearing,
and remove the yoke.
6. Remove:
Nut (middle driven gear) CD
Clamp the U-joint securely in a vise having
soft jaws.
Plain washer
.U-joint
Middle driven gear @
Nut (middle driven housing) @
Use a Hexagon Wrench 27 mm (j) (YM-
01388).
Bearing
3-10
I
ENG
I
Ll
_ _ -__ DISASSEMBLY

3-11
CD

I

CRANKCASE
1. Remove:
Screws (cran kcase)
Bolts (crankcase)
NOTE: _____________ _
Remove the screws starting with the highest
numbered one.
2. Remove:
Shift cam stopper CD
3. Remove:
.Crankcase (Right)
Alternately tap on the engine mounting
boss, transmission shafts, shift cam, and
cran kshaft.
NOTE: ___________________ __
For this removal, slits in the crankcase can be
used as shown .
Be sure not to give damages to the mating
surface.
Use soft hammer to tap on the case half. Tap
only on reinforced portions of case. Do not
tap on gasket mating surface. Work slowly and
carefully. Make sure tha case halves separate
evenly. If one end "hangs up," take pressure
off the push screw, realign, and start over. If
the cases do not separate, check for a remaining
case screw or fitting. Do not force.
I
ENG
I
~ I DISASSEMBLY _ _ . ~ _
TRANSMISSION
1. Remove:
Guide bar CD
Shift forks
.Shift cam
NOTE: ________________________ __
Note the position of each part. Pay particular at-
tention to the location and direction of shift
forks.
2. Remove:
Transmission assembly CD
3. Remove:
Middle drive gear shim CD
CRANKSHAFT
1. Remove:
Crankshaft
Tap lightly on the crankshaft with a soft
hammer.
3-12
I ENG 1'-1 INSPECTION AND REPAIR
I e{)J
3-13
INSPECTION AND REPAIR
ROCKER ARMS AND ROCKER ARM SHAFTS
1. Loosen:
Locknut CD
Adjuster
2. Attach:
.Slide Hammer Set CD (YU-01083)
3. Remove:
Rocker shaft
Rocker arm
Camshaft
4. Inspect:
Rocker shaft
Rocker arm
Wear/Damage ~ Replace.
By the following inspection steps.
Rocker shaft and arm inspection steps:
Inspect the two areas on the rocker arm for
sings of unusual wear.
1) Rocker shaft hole
2) Cam-lobe-contact surface
Excessive wear ~ Replace .
Inspect the surface condition of the rocker
arm shaft.
Pitting/Scratches/Blue discoloration ~ Re-
place/Check lubrication.
a
INSPECTION AND REPAIR 1 ENG 1'-1
Measure the inside diameter of the rocker
arm hole.
Out of specification ~ Replace.
Rocker Arm Inside Diameter limit:
10.05 mm (0.3957 in)
Measure the outside diameter @ of the
rocker arm shaft.
Out of specification ~ Replace.
Rocker Arm Shaft Outside Diameter:
limit: 9.95 mm (0.3917 in)
.Calculate .the clearance by subtracting the
rocker-arm-shaft outside diameter from the
rocker-arm inside diameter.
Clearance is geather than 0.05 mm (0.002
in) ~ Replace either or both parts.
Arm-to-shaft Clearance (Standard):
0.009 - 0.0034 mm
(0.004 - 0.0013 in)
5. Install:
Rocker arm
Rocker shaft
NOTE: ____________ _
Thread hole of the rocker shaft should be placed
outside.
CAMSHAFT
1. Remove:
Camshaft
Refer to "ROCKER ARMS AND ROCK-
ER ARM SHAFTS" section.
3-14
I ENG ',-I INSPECTION AND REPAIR
A
B
3-15
2. Inspect:
.Cam lobes
Pitting/Scratches/Blue discoloration """* Re-
place.
3. Measure:
.Cam lobes
Use a Micrometer.
Out of specification """* Replace.
Cam lobe Cam lobe
limit" A" limit liB"
Intake
25.227 mm 20.971 mm
(0.993 in) (0.826 in)
Exhaust
25.228 mm 20.995 mm
(0.993 in) (0.827 in)
4. Install:
Camshaft
To the cylinder head.
NOTE: ________________________ __
large bearing should be placed outside.
CAM CHAIN
1. Inspect:
Cam chain CD
Chain stretch/Cracks """* Replace.
CAM SPROCKET AND CAM DRIVE SPROCK
ET
1. Inspect:
Cam sprocket
Cam drive sprocket
Wear/Damage"""* Replace.
~
I
INSPECTION AND REPAIR I ENG 1\.1
CHAIN DAMPERS
1. Inspect:
.Cam chain damper (intake) CD
.Cam chain damper (exhaust)
Wear ~ Replace.
CAM CHAIN TENSIONER
1. Inspect:
All parts
Damage/Wear ~ Repalce.
CDTensioner end plug
Gasket
Compression spring
Chain tensioner rod
Straight plug
TAPPET COVER AND SIDE COVER
1. Inspect:
Tappet covers (intake and exhaust) CD,
Side cover
.O-rings
Damage ~ Replace.
CYLINDER HEAD
1. Attach:
Valve Spring Compressor CD (YM-04019) .
Attachment (YM-4108)
2. Remove:
Valve retainers CD
Valve spring seat
Valve spring
.Oil seal
Valve spring seat
.Valve
3-16
1 ENG 1\.1
1
tOO
--II--
3-17
INSPECTION AND REPAIR
~ I I - -
'--"'-----...
NOTE: __________________________ _
Deburr any deformed valve stem end. Use an oil
stone to smooth the stem end.
CD Deburr
Valve stem
3. Eliminate:
Carbon deposit
Use the rounded scraper.
NOT E : _____________________ _
Do not use a sharp instrument and avoid damag-
ing or scratching:
Spark plug thread
Valve seat
Cylinder head
4. Measure:
Cylinder head warpage
Out of specification ~ Resurface/Re-
place.
Cylinder Head Warp Limit:
Less than 0.05 mm (0.002 in)
VALVE, VALVE GUIDE, AND VALVE SEAT
Intake and Exhaust Valve
1. Check:
Valve face
Stem end
Wear/Pitting/Out of specification ~ Re-
place.
Minimum Thickness (Service Limit) @:
0.7 mm (0.028 in)
Beveled @: 0.5 mm (0.020 in)
Minimum Length (Service Limit) @:
4.0 mm (0.157 in)
INSPECTION AND REPAIR 1 ENG 1'\.1
2. Measure:
Valve stem clearance
Use the Micrometer and Bore Gauge .
Out of specification -+ Replace either valve
CD and/or guide .
Valve Stem Clearance = B - A
Valve Stem Clearance Maximum
- -------- ----1----------1
Intake
0.010 ~ 0.037 mm 0.08 mm
(0.0004 ~ 0.0015 in) (0.0031 in)
Exhaust
0.025 ~ 0.052 mm 0.10 mm
(0.0010 ~ 0.0020 in) (0.0039 in)
[A] VALVE STEM OUTSIDE DIAMETER
ffilVALVE GUIDE INSIDE DIAMETER
3. Inspect:
Valve stem end
Mushroom shape/Larger diameter than rest
of stem -+ Replace valve, valve guide, and
oil seal.
4. Measure:
Valve stem runout
Out of specification -+ Replace.
Maximum Runout:
0.02 mm (0.0008 in)
Valve Guide
NOTE: __________________________ __
.Always replace valve guide if valve is replaced .
Always replace oil seal if valve is removed.
1. Remove:
Valve guide
Use a Valve Guide Remover CD (YM-4097).
3-18
1 ENG I\.I
3-19
INSPECTION AND REPAIR
NOTE: ________________________ __
Heat the head in an oven to 100C (212F) to
ease guide removal and installation and to
maintain correct interference fit.
2. Inspect:
Valve guides
Wear/Oil leakage into cylinder -+ Replace.
3. Install:
.Circlip (new)
Valve guide (oversize)
Use a Valve Guide Remove CD with Valve
Guide Installer (YM-4098).
NOTE: ________________________ __
After installing vlave guide :
Use the 5.0 mm Valve Guide Reamer @
(YM-4099) to obtain proper valve guide/valve
stem clearance .
Recut the valve seat.
Valve Seat
1. Inspect:
Valve seats
Wear/Pitting/Valve replacement -+ Resur-
face seat at 45 angle.
Clean valve seat if pitted or worn using the 45
Valve Seat Cutter (YM-91043) CD. When twist-
ing cutter, keep an even downward pressure to
prevent chatter marks.
Cut section as follows
,
Section Cutter
r-----.---
30 A
r----.---
B 45
1---
C 60
INSPECTION AND REPAIR 1 ENG 1'\.1
.-------------------. 2. Measure:
Valve seat width
3. Apply:
Mechanics bluing dye (Dykem)
To valve and seat.
Fine grinding compound (small amount)
Ground surface of valve face.
4. Position:
Valves
Into cylinder head.
Spin it rapidly back and forth, then lift
the valve and clean off all grinding com-
pound.
5. Inspect:
Valve seat surface
Wherever valve seat and valve face made
contact, bluing will have been removed.
6. Measure:
Valve seat width "a"
Out of specification/Pitting/Variation of
valve seat width....;. Cut valve seat further.

------------------------
Remove just enough material to achieve satis-
factory seat.
Seat Width:
Standard:
0.9 1.1 mm (0.035 0.043 in)
Wear Limit: 1.6 mm (0.063 in)
Valve seat recutting steps are necessary if:
Valve seat is uniform around perimeter of
valve face but too wide or not centered on
valve face.
I--
Valve Seat Cutter Set Desired result

30 cutter
Use To center the seat or
. h 45 cutter
to reduce its width elt er
60 cutter
1------
Valve face indicates that valve seat is center-
ed on valve face but is too wide (see
Ila"
diagram).
1-----
Valve Seat Cutter Set Desired result
1-------.--------
30 cutter
To reduce valve seat
Use
width to 1.0 mm
lightly
60 cutter
(0.039 in)
3-20
I ENG 1\.1 INSPECTION AND REPAIR
3-21
Valve seat is in the middle of the valve face
but too narrow (see "b" diagram).
- -- -
Valve Seat Cutter Set Desired Result

I To achieve a uniform
45 cutteri valve seat width of
1.0 mm (0.039 in)
--
Valve
seat is too narrow and right up near
valve margin (see "c" diagram).
_ Result
30 center the seat and
Use .. d h
45 cutter to Increase Its WI t
---
Valve
seat is too narrow and is located
down near the bottom edge of the valve
face (see diagram "d").
------
Valve Seat Cutter Set Desired Result
---- ._,----
60 cutter, fi rst
To center the seat and
Use
to increase its width
45 cutter
Valve/Valve Seat Assembly Lapping
1. Apply:
Coarse lapping compound (small amount)
To valve face.
Molybdenum disulfide oil
To valve stem.
2. Position:
Valves
In cylinder head.
3. Rotate:
Valve
Turn until valve and valve seat are evenly
polished, then clean off all compound.
4. Apply:
Fine lapping compound (small amount)
To valve face.
INSPECTION AND REPAIR ENG ~
5. Repeat steps 2 and 3.
NOTE: ________________________ __
Be sure to clean off all compound from valve
face after every lapping operation.
6. Inspect:
Valve face
Not yet uniformly smooth --> Repeat
procedu re from step 1.
7. Apply:
.Mechanics bluing dye (Dykem)
To valve face and seat.
8. Rotate:
Valve
9. Inspect:
Valve face
Valve must make full seat contact indi-
cated by grey surface all around. The
valve face where bluing was removed.
Faulty contact --> Replace.
See procedure below.
10. Apply:
Solvent
Into each intake and exhaust port.
NOTE: __________________________ __
Pour solvent into intake and exhaust ports only
after completion of all valve work and assembly
of all head parts.
11. Check:
Valve seals CD
Leakage past valve seat --> Replace valve.
(See procedure below)
Valve guide
Relapping steps:
Disassemble head parts.
Repeat lapping steps using fine lapping
compound.
Clean all parts thoroughly.
Reassemble and check for leakage again
using solvent.
Repeat steps as often as necessary to effect
a satisfactory seal.
3-22
I
ENG
I
~ I . _ ~ _ INSPECTION AND REPAIR
3-23
Valve Spring
1. Measure:
Spring free length
Out of specification ->- Replace.
Minimum Free Length:
25.4 mm (1.00 in)
2. Measure:
Spring force (installed length)
Out of specification ->- Replace.
Valve Compressed Force:
8.8 ~ 10.8 kg (19.4 ~ 23.8 Ib)
at 24.9 mm (0.98 in)
Valve Installation
1. Lubricate:
Valve stem
.Oil seal
~
High-Quality Molybdenum Disulfide
Motor Oil or Molybdenum Disulfide
Grease
2. Install:
Valve CD
Valve spring seat
.Oil seal
Valve spring
Valve spring seat
Valve retainers
NOTE: ________________________ __
Install spring with wider-gapped coil facing
upwards, as shown.
CD Larger pitch
Smaller pitch
10mm
(0_39 in)
_--P---.l
INSPECTION AND REPAI R
ENG \.
CYLINDER
1_ Inspect:
.Cylinder wall
Wear/Scratches -+ Rebore or replace_
2. Measure:
Cylinder bore "C"
Use a Cylinder Bore Gauge CD .
Out of specification -+ Rebore.
Standard Wear Limit
Cylinder 47.000 47.005 mm
Bore"C": 1.851 in)
47.1 mm
(1.854 in)
Cylinder
Taper liT":
0.05 mm
(0.002 in)
C = Maximum 0
T = Maximum (OJ or O2 )
- Minimum (05 or 0 6 )
PISTON, PISTON RING, AND PISTON PIN
Piston
1. Inspect:
Piston wa II
Wear/Scratches/Damage -+ Replace.
!
2. Measure:
Piston outside diameter "P"
Use a Micrometer.
Out of specification -+ Replace.
NOTE: __________________________ _
Measurement should be made at a point 10 mm
(0.39 in) above the bottom edge of the piston.
Piston Outside Diameter lip"
- -- ---1- 46.960:"46.975 mm
Standard (1.8488 1.8494 in)
------------ ---
Oversize 2 47.50 mm (1.8701 in)
- ------+--------
Oversize 4 48.00 mm (1.8898 in)
3-24
'
... /
)
~ ~
2
INSPECTION AND REPAI R
1 ENG 1'-1
Piston Pin
1. Lubricate:
Piston pin (lightly)
2. Install:
Piston pin
Into small end of connecting rod.
3. Check:
Free play
Free play -+ I nspect connecting rod and
piston pin for wear.
4. Position:
Piston pin
Into piston.
5. Check:
Free play
When pin is in place in piston .
Free play -+ Replace piston pin and/or
piston.
PRIMARY GEARS AND STARTER
1. Inspect:
Drive gear CD
Scratches/Wear/Damage -+ Replace crank-
shaft.
Driven gear
Scratches/Wear/Damage -+ Replace clutch
housing assembly.
Starter wheel @
Idler gear
Scratches/Wear/Damage -+ Replace.
CLUTCH
Clutch Housing
1. Inspect:
Dogs on the housing
Cracks/Wear/Damage -+ Deburr or replace.
Clutch housing bearing
Chafing/Wear/Damage -+ Replace.
326
I ENG 1'-1 INSPECTION AND REPAIR
3-27
Clutch Boss
1. Inspect:
Clutch boss splines
Scoring/Wear/Damage ~ Replace clutch
b()ss assembly_
NOTE: ____________ _
Scoring on the clutch plate splines will cause
erratic operation_
Clutch boss cam grooves
Wear/Damage ~ Replace.
One Way Boss
1. Inspect:
One way boss cams
Wear/Damage ~ Replace.
Friction Plates
1. Inspect:
Friction plate CD
DamagelWear ~ Replace friction plate as
a set.
2. Measure:
Friction plate thickness
Measure at all four points.
Out of specification ~ Replace friction
plate as a set.
Friction Plate Thickness
Standard 2.92 - 3.08 mm (0.115 - 0.121 in)
Wear Limit 2.9 mm (0.114 in)
INSPECTION AND REPAIR I ENG 1'\.1
r-----------------__ Clutch Plates
1. Measure:
Clutch plate warpage
Use surface plate and Feeler Gauge CD
Out of specification -7 Replace.
Warp Limit:
0.1 mm (0.004 in)
Pressure Plate
1. Inspect:
Pressure plate bearing
Wear/Damage -7 Replace.
Push Rod
1. Measure:
Push rod runout (long rod) CD
Use V-Blocks and a Dial Gauge.
Out of specification -7 Replace.
Bending Limit:
0.5 mm (0.02 in)
Clutch Balls
1. Inspect:
Balls
1
Pitting/Wear/Damage -7 Replace as a set.
Push Lever
1. Inspect:
Push lever
Push lever axle
Push rod guide
Wear/Damage -7 Replace.
3-28
1 ENG 1'-1
329
INSPECTION AND REPAI R
F
Clutch Spring
1. Inspect:
Clutch spring
Wear/Damage -;. Replace.
2. Measure:
Clutch spring free length
Out of specification -;. Replace springs as
a set.
Clutch Spring Minimum Length:
29.1 mm (1.15 in)
OIL PUMP
1. Measure:
Housing CD /Outer rotor clearance
Use a Feeler Gauge.
Out of specification -;. Replace oil pump
assembly.
Side Clearance :
0.06 ~ 0.10 mm
(0.0024 ~ 0.0039 in)
2. Measure:
Outer rotor CD /Inner rotor clearance
Use a Feeler Gauge.
Out of specification -;. Replace oil pump
assembly.
Tip Clearance :
0.15 mm (0.0059 in)
Limit:
0.20 mm (0.0079 in)
CRANKSHAFT
1. Measure:
Assembly width "A"
Use the V-blocks.
Out of specification -;. Replace.
INSPECTION AND REPAIR 1 ENG 1"-1
Assembly Width "A":
40.20 - 40.25 mm
(1.583 - 1.585 in)
Big end radial clearance "B"
Use a Feeler Gauge.
Out of specification ~ Disassemble the
crankshaft and replace worn parts, then
reassemble the crankshaft.
Big End Radial Clearance Limit "B":
0.5 mm (0.02 in)
Runout "c"
Use the V-vlocks and Dial Gauge.
Out of specification ~ Correct any mis-
alignment.
Runout Limit "C":
0.05 mm (0.002 in)
Small end free play "F"
Use the V-blocks and Dial Gauge.
Out of specification ~ Disassemble the
crankshaft, and replace the defective parts,
then reassemble the crankshaft.
~ ' Small End Free Play "F":
[61 Standard: 0.8 - 1.0 mm
(0.03'" 0.04 in)
Limit: 2.0 mm (0.08 in)
2. Inspect:
Crankshaft bearing surfaces
Wear/Scratches/Rust spots ~ Replace.
NOTE: ________________________ __
Lubricate the bearing immediately after examin-
ing then to prevent rust.
TRANSM ISSION
Shift Fork
1. Inspect:
.Shift forks
On the gear and shift cam contact surfaces.
Wear/Chafing/Bends/Damage ~ Replace.
3-30
I ENG 1'-1 INSPECTION AND REPAIR
3-31
2_ Check:
.Shift fork movement
On its guide bar.
Unsmooth operation ~ Replace fork and/
or guide bar.
Shift Cam
1. Inspect:
Shift cam grooves CD
Wear/Damage/Scratches ~ Replace.
Shift cam segment
Damage/Wear ~ Replace.
Shift cam bearing @
Pitting/Damage ~ Replace.
Main and Drive Axles
1. Measure:
Axle runout CD
Use centering device and Dial Gauge .
Out of speCification ~ Replace.
Runout Limit:
0.08 mm (0.0031 in)
Gears
1. Inspect:
Gears
Damage/Wear ~ Replace.
2. Check:
Gear movement
Unsmooth operation ~ Replace.
3. Inspect:
Mating dogs
Cracks/Wear/Damage ~ Replace.
INSPECTION AND REPAIR I ENG I ~ I
r - - - - - - - - - - - - - ~ ~ ~ - - - - - - - - - - ~ MIDDLE GEAR
~ r---........ 1. Inspect:
~ -Gears CD
~
~ -Bearings
DamagelWear ~ Replace.
~
~ 2. Check:
- Bearing movement
Turns roughly ~ Replace.
BEARINGS
1. Inspect:
- Axle bearings
- Shift cam bearing
Pitting/Damage ~ Replace.
CIRCLIPS AND WASHERS
1. Inspect:
-Circlips
-Washers
Damage/Looseness/Bends ~ Replace.
3-32
I ENG I '\.1 ENGINE ASSEMBLY AND ADJUSTMENT
3-33
ENGINE ASSEMBLY AND
ADJUSTMENT
CRANKSHAFT
1. Install:
Crankshaft
To the left-side crankcase.
NOTE: ____________ _
Hold the connecting rod at top dead center with
one hand while installing the crankshaft.
TRANSM ISSION
1. Install:
Middle drive gear shim CD
Transmission assembly
2. Install:
.Shift cam
Shift forks
Guide bars
NOTE: ____________ _
Be sure the embossed number @ /29/ on shift
fork #2 faces toward the O-ring CD , and
the embossed number /29F / on shift fork
#1 faces away from the O-ring CD .
3. Check:
.Transmission and shifter operation
Unsmooth operation -+ Repair.
NOTE: ________________ _
Oil each gear and bearing thoroughly.
ENGINE ASSEMBLY AND ADJUSTMENT
1 ENG 1'-1
CRANKCASE
1. Apply:
-Sealant (Quick Gasket) CD (ACC-11001-
05-01 )
2. Install:
- Dowel pins
3. Fit the right crankcase onto the left case.
Tap lightly on the case with a soft hammer.
Before installing and torquing the crankcase
holding screws, be sure to check whether
the transmission is functioning properly by
manually rotating the shift cam either way.
4. Tighten:
- Screws (crankcase)
- Bolts (crankcase)
NOTE: ________________________ __
Tighten the screws starting with the lowest
numbered one.
~ Screws (Crankcase):
~ 7 Nm (0.7 m' kg, 5.1 ftlb)
Bolts (Crankcase):
10 Nm (1.0 m kg, 7.2 ftlb)
5. Install:
-Shift cam stopper CD
Shift Cam Stopper:
8 Nm (0.8 m' kg, 5.8 ftlb)
6. Apply:
-4-stroke engine oil
To the crank pin, bearing and oil delivery
hole.
7. Check:
- Crankshaft and transmission operation
Unsmooth operation ---* Repair.
3-34
ENG ~
__ ENGINE ASSEMBLY AND ADJUSTMENT
CRANKSHAFT
CDWoodruff key
Crank (Left)
@Crankpin
@Cylinderica/ bearing
@Connecting rod
@Crank (Right)
(V Bearing
@Oil pump drive gear
@Piston
Piston ring set
~
3-35
C
0
7
PISTON CLEARANCE:
B 0.025 - 0.045 mm
(0.0010 - 0.0018 in)
TOP
RING
SIDE
0.12 mm
CLEARANCE
(0.0047 in)
LIMIT
END GAP 0.40 mm
LIMIT (0.016 in)
A CRANKSHAFT:
A:40.20 '" 40.25 mm
(1.583'" 1.585 in)
B: 0.1'" 0.4 mm
(0.004'" 0.016 in)
C: 0.05 mm (0.02 in)
F: 2.0 mm (0.08 in)
F 2ND
RING
0.12 mm
(0.0047 in)
0.40 mm
(0.016 in)
F
ENGINE ASSEMBLY AND ADJUSTMENT I ENG 1 .. 1
TRANSMISSION
CD Drive axle assembly
3rd wheel gear (31T)
@Circlip
4th wheel gear (27T)
Plain washer
1 st wheel gear (39T)
Cl)Circlip
Bearing
Bearing
@Main axle
9
I B62031
@4th pinion gear (24T)
@Circlip
@3rd pinion gear (22T)
@2nd pinion gear (17T)
@ Plain washer
@Circlip
@Bearing
8 ~ 6 3 0 1 I
7 6
A
RUNOUT LIMIT:
0.08 mm (0.0031 in) 11
5
4
. ~ .
. ,
~
/
..
@
13
@{,i\
\lJ;
1
I
I B6001 I
3-36
ENG
~
'- ENGINE ASSEMBLY AND ADJUSTMENT
3-37
MIDDLE GEAR
1. Install:
Bearing
Nut (middle driven housing)
Use a Hexagon Wrench 27 mm (YM-
01388).
Nut (Middle Driven Housing):
60 Nm (6.0 m' kg, 43 ftlb)
LOCTlTE@
Middle driven gear @
U-joint
Plain washer
Nut (middle driven gear) CD
Clamp the U-joint securely in a vise having
soft jaws.
[f]
Nut (Middle Driven Gear):
90 Nm (9.0 m' kg, 64 ftlb)
LOCTITE@
2. Install:
.Yoke
Into the U-joint.
3. Apply:
Grease
To the bearings.
4. Install:
Bearings
Tap lightly on the bearing with a hammer.
Check each bearing. The needles can easily fall
out of their races. Slide the yoke back and forth
on the bearings; the yoke will not go all the way
onto a bearing if a needle is out of place.
5. Using a suitable socket, press each bearing
further into the U-joint with a vise until
the circlip can be installed into each U-joint.
I E N G I ~ I ENGINE ASSEMBLY AND ADJUSTMENT _ _ ... _
6. Install:
Circlips CD
7. Select:
Driven gear shim
By the following selection steps.
Driven gear shim selection steps:
Measure the distance
ilL;'
between the
driven gear housing and the driven gear .
Determine the difference by the following
chart.
"L" (mm) Difference (mm)
37.83'S L'S 37.90 0.4
'--'
37.90 < L 'S 38.00 0.5
38.00 < L 'S 38.10 0.6
38.10 < L ~ 38.20 0.7
38.20 < L 'S 38.30 0.8
I-- -
-
-------
38.30 < L ~ 38.40 0.9
--
38.40 ~ L 'S 38.45 1.0
.Select the suitable shim(s) by the re-
commended chart.
Difference
Suitable Shim(s)
Thickness (mm) Q'ty (pes.)
0.4 0.4 1
0.5 0.5 1
0.6 0.3 2
0.7 0.3 + 0.4 1 + 1
0.8 0.4 2
~ - - - -
0.9 0.4 + 0.5 1 + 1
1.0 0.5 2
3-38
ENG
~
'- ENGINE ASSEMBLY AND ADJUSTMENT
3-39
8. Install:
.Proper shim(s) CD
Middle driven gear compo
Bolts (drive gear housing)
Bolts (Driven Gear Housing):
10 Nm (1.0 m kg, 7.2 ftlb)
CDIMAGNETO
1. Install:
Cam chain CD
O-rings
2. Install:
Neutral switch
Base plate CD
Neutral Switch:
10 Nm (1.0 m kg, 7.2 ftlb)
Base Plate:
7 Nm (0.7 m kg, 5.1 ftlb)
3. Install:
Woodruff key
Flywheel
Plain washer
Nut (flywheel)
NOTE: __________________________ _
When installing the COl magneto, make sure
the woodruff key is properly seated in the key
way of the crankshaft. Apply a light coating of
lithium soap base grease to the tapered portion
of the crankshaft end.
ENG ~
ENGINE ASSEMBLY AND ADJUSTMENT ...,
4. Tighten:
Nut (flywheel) CD
Use a Rotor Holder (YM-01235) to
hold the flywheel magneto.
Nut (Flywheel):
40 Nm (4.0 m' kg, 29 ftlb)
OIL PUMP AND OIL STRAINER
Apply a liberal amount of 4-stroke engine oil
to the oil pump passages in the crankcase,
or the engine may be damaged.
1. Apply:
.4-stroke engine oil
To the oi I passages CD.
2. Install:
Gasket (new)
.Oil pump
I ~ Oil Pump:
7 Nm (0.7 m kg. 5.1 ftlb)
.Oil stariner
3. Install:
.Oil pump drive gear
Oil pump driven gear
.Circlip CD
DRIVE GEAR AND STARTER
1. Install:
Starter wheel assembly
.'d'e gear 2
Spacer @
Starter clutch assembly
Primary drive gear
Conical spring washer CD
3-40
ENG
~ _
,. ENGINE ASSEMBLY AND ADJUSTMENT
3-41
2. Install:
Nut (primary drive gear) CD
Use a Rotor Holder (YM-01235) to
hold the flywheel magneto.
Nut (Primary Drive Gear):
50 Nm (5.0 m kg, 36 ft-lb)
CHANGE SHAFT
1. Install:
.Spring CD
Stopper lever
Bolt (Stopper Lever):
14 Nm (1.4 m kg, 10 ftlb)
LOCTITE
2. Set the stopper lever and torsion spring as
properly position.
3. Install:
Change shaft CD
NOTE: ____________ _
Be sure the shift lever correctly engages the
shift cam pins .
Be sure the stopper shaft is placed between
the spring hooks.
4. Install:
Bearing
Plain washers @
.Pin
Push lever 2
Circlip CD
ENG ~
ENGINE ASSEMBLY AND ADJUSTMENT ..
CLUTCH
CD Oil seal
Push plate assembly
@Circlip
Pressure plate assembly
@ Push rod (Small)
Clutch plate (Bent)
(J) Friction plate (Sliver)
@ Clutch plate
Friction plate (Black)
Thrust weight plate
@ Compression spring
@ Clutch boss set
CLUTCH BOSS HEIGHT:
@Clutch balls
@ Primary driven gear compo
@Spacer
(j]) Thrust plate
@ Push rod (Large)
@Bushing
@Oil seal
Clutch boss spring
@Push lever
@ Push rod guide
@ Primary drive gear
Push lever 2
E
0.2 - 0.4 mm (0.008 - 0.016 in)
14 Nm (1.4 mokg,
10 ftlb)
FRICTION PLATE HEIGHT:
1.30 - 1.65 mm (0.051 - 0.065 in)
F
CLUTCH SPRING MINIMUM LENGTH:
A 29.1mm(1.15in)
CLUTCH PLATE WARP LIMIT:
B
0.1 mm (0.004 in)
C PUSH ROD (LARGE) BENDING LIMIT:
0.5 mm (0.02 in)
FRICTION PLATE WEAR LIMIT:
2.9 mm (0.114 in)
3-42
ENG ~
__ ENGINE ASSEMBLY AND ADJUSTMENT
3-43
CLUTCH
1. Install:
Push lever 1
Push rod guide CD
Push Rod Guide:
8 Nm (0.8 m'kg, 5.8 ft'lb)
2. Install:
Thrust plate
Spacer
Primary driven gear camp.
Balls CD
Place the balls as illustrated position [A] .
3. Install:
Clutch Ball Q'ty:
12 pes.
Thrust weight plate CD
.Clutch boss assembly
@One way boss
Clutbh boss
Special washer
Conical washer
(J) Retainer
4. Adjust:
Clutch boss height
By the following adjustment steps.
ENGINE ASSEMBLY AND ADJUSTMENT
ENG
~ ' -
2
~
CD
/
i i
6
Clutch boss height adjustment steps:
Push the thrust weight plate CD down by
hand.
Measure the clutch boss height (distance
between the clutch boss

and thrust
weight plate CD .)
~
Clutch Boss Height :
0.2 ~ 0.4 mm (0.008 ~ 0.016 in)
.If the height is out of specification, adjust
the clutch boss height.
Remove the primary driven gear camp, and
remove the following parts.
1)Circlip
2) Adjusting washer @
3) Bearing
Select the suitable adjusting washers by the
following chart.
~
Adjusting Washer
-
Thickness
1.7
(mm)
2.1
Remeasure the clutch boss height.
5. Install:
Friction plate (black) CD
Clutbh plates
Friction plates (sliver)
.Clutbh plate (bent) @
Thrust weight plate
~ Pressure plate
1.9
2.3
NOTE: __________________________ _
Install the clutch plates and frction plates
alternately on the clutch boss, starting with
a friction plate and ending with a friction plate .
The friction plate (black) CD must be placed
on the outside of the thrust weight plate .
The clutch plate (bent) @ must be placed
on the inside of the first friction plate.
3-44
ENG "e ENGINE ASSEMBLY AND ADJUSTMENT
ly
-

3-45
6. Adjust:
Friction plate height
By the following adjustment steps.
Friction plate height adjustment steps:
Push the friction plates CD down by hand.
Measure the friction plate height@ (distance
between the driven gear housing

and
friction plate CD .)
Friction Plate Height ~ :
~
1.30 ~ 1.65 mm (0.051 ~ 0.065 in)
.If the height is out of specification, adjust
the friction plate height.
Remove the following parts.
1) Pressure plate
2)Clutch plate (bent)
3) Friction plates (sliver and black)
4) Clutch plates (4 pcs.)
Select the suitable clutch plates (4 pcs.) by
the following chart.
~
Clutch Plates (4 pcs.)
Thickness
1.2 1.4
(mm)
1.6
-
Install all parts. Refer to aforementioned
step 5.
Remeasure the friction plate height.
Remove all parts.
7. Install:
Lock washer (new)
Locknut (clutch boss)
8. Tighten:
Locknut (clutch boss) CD
Use a Clutch Boss Holding Tool (YM-
91042) to hold the clutch boss.
ENGINE ASSEMBLY AND ADJUSTMENT
ENG
\.

Locknut (Clutbh Boss):
60 Nm (6.0 m'kg, 43 ftlb)
9. Bend the lock washer tab along the nut
flats.
1 O. I nsta II :
.AII parts
Refer to aforementioned step 5.
11 . Install:
Push rod (large) @
.Push rod (small) @
Pressure plate assembly
.Circlip CD
12. Install:
Dowel pins
Gasket (new)
Crankcase cover (right) CD
NOTE: ____________ _
Tighten the screws in a crisscross pattern.
Crankcase Cover:
7 Nm (0.7 m' kg, 5.1 ftlb)
PISTON
1. Install:
.Piston CD
Piston pin
Piston pin clip @
NOTE: ____________ _
The arrow on the piston must point to the
front of the engine.
3-46
ENG ~
.. ENGINE ASSEMBLY AND ADJUSTMENT
3-47
e Before installing the piston pin clip, cover
the crankcase with a clean towel or rag so
you will not accidentally drop the pin clip
and material into the crankcase.
eAlways use a new piston pin clip.
2. Apply:
e4-stroke engine oil
To the piston pin, bearing, piston ring
grooves and piston skirt areas.
ENG ~
ENGINE ASSEMBLY AND ADJUSTMENT ..
CYLINDER AND CYLINDER HEAD
Q)Cylinder
00 Cam chain damper (Intake)
@Cam chain
@ Cam sprocket (28T)
Cam chain damper (Exhaust)
@Camshaft
(j) Locknut (Chain tensioner)
Adjuster (Chain tensioner)
Tensioner end plug
@Gasket
@ Compression spring
@Chain tensioner rod
@Straight plug
VALVE CLEARANCE:
@Tappet cover (Intake)
@Sidecover
@Tappet cover (Exhaust)
@ Locknut (Valve adjusting)
@ Adjuster (Valve adjusting)
@) Rocker arm
Rocker shaft
Valve retainers
@ Valve spring seat
@Valve spring
@Oil seal
@Valve
A INTAKE: 0.05 - 0.10 mm (0.002 - 0.004 in)
EXHAUST: 0.075 - 0.125 mm (0.003 - 0.005 in)
B CYLINDER HEAD WARP LIMIT:
0.05 mm (0.002 in)
C VALVE SPRING LENGTH LIMIT (FREE):
25.4 mm (1 00 in)
12.5 Nm (1.25 mokg.
9.1 ft"lb)
3-48
ENG
3-49
~
-.., ENGINE ASSEMBLY AND ADJUSTMENT
CYLINDER AND CYLINDER HEAD
1. Install:
Dowel pins CD
Gasket
2. Install:
Piston rings
Onto the piston.
NOTE: __________________________ __
Be sure to install the rings so that Manufacturer'S
marks or numbers are located on the top side of
the rings.
3. Oil liberally:
Piston
Rings
.Cylinder
4. Set:
.Piston ring ends
Make sure the ends of the oil ring expanders do
not overlap.
CD TOP
OIL RING (LOWER RAIL)
@ OIL RING (UPPER RAIL)
@2ND
5. Install:
.Cylinder CD
NOTE: ________________________ __
Install the cylinder with one hand while com-
pressing the piston rings with the other hand .
Be careful not to damage the cam chain
damper during installation .
Pass the cam chain through the cam chain
cavity.
ENGINE ASSEMBLY AND ADJUSTMENT
1 ENG 1'-1
4. Install:
Dowel pins CD
Cam chain damper (intake)
.Cam chain damper (exhaust)
Gasket (new)
5. Install:
.Cylinder head
NOTE: ____________ _
Tie the cam chain so that it does not fall into
the crankcase.
6. Tighten:
Nuts (cylinder head) CD
Bolts (cylinder head)
NOTE: ______________ _
Tighten the nuts in stage, using a crisscross
pattern.
Nuts (Cylinder Head):
10 Nm (1.0mkg, 7.2ftlb)
Bolts (Cylinder Head):
10 Nm (1.0 m'kg, 7.2 ftlb)
7. Install:
Cam sprocket
By the following steps.
Cam sprocket installing steps:
Rotate the camshaft to align the camshaft
groove CD with the cylinder head match
marks .
Turn the COl magneto until the "T" mark
is aligned with the stationary pointer @
on the crankcase .
Place the cam chain onto the cam chain
sprocket .
Install the cam chain sprocket onto the
camshaft, and finger tighten the sprocket
bolt.
3-50
1 ENG 1'\.1 ENGINE ASSEMBLY AND ADJUSTMENT
3-51
NOTE: ______________________ __
-Insert the cam chain sprocket pawl into
the camshaft groove .
- Be sure the match mark (j) on the cam chain
sprocket is aligned with the match mark
on the cylinder head.
- Force the camshaft clockwise and counter-
clockwise to remove the cam chain slack.
-Insert the screwdrive into the cam chain
tensioner hole, and push the cam chain
damper inward.
-While pushing the cam chain damper, be
sure cam sprocket match mark (j) align
the cylinder head match mark .
_If marks is aligned, tighten the cam sprocket
bolt. If marks do not align, change the
meshing position of sprocket and cam chain.
8. Tighten:
- Bolt (cam chain sprocket) CD
Use a Rotor Holder @ (YM-01235) to
hold the flywheel magneto.
Bolt (Cam Chain Sprocket):
20 Nm (2.0 m' kg, 14 ft'lb)
9. Install:
-Straight plug CD
- Chain tensioner rod @
- Compression spring @
- Gasket (new)
- Tensioner end plug
NOTE: __________________________ _
The flat surface of the tensioner rod should
face towards the adjuster thread hole CW .
ENG ~
ENGINE ASSEMBLY AND ADJUSTMENT . ~
10. Tighten:
e Tensioner end plug
Tensioner End Plug:
15 Nm (1.5 m'kg, 11 ftlb)
11. I nsta II :
eO-ring Q)
eAdjuster (chain tensioner)
e Locknut (chain tensioner) @
e Crown nut (chain tensioner) @
Refer to "CHAPTER 2. CAM CHAIN
TENSION ADJUSTMENT" section.
Locknut (Chain Tensioner):
7 Nm (0.7 m' kg, 5.1 ft'lb)
Crown Nut (Chain Tensioner):
5 Nm (0.5 m' kg, 3.6 ftlb)
12. Adjust:
e Valve clearance
Refer to CHAPTER 2. VALVE CLEAR-
ANCE ADJUSTMENT" section.
13. Install:
eSide cover (cylinder head)
e Tappet covers (intake and exhaust)
eSpark plug
Side Cover (Cylinder Head):
10 Nm (1.0 mkg, 7.2 ftlb)
Tappet Covers:
7 Nm (0.7 m' kg, 5.1 ftlb)
Spark Plug:
12.5 Nm (1.25 m'kg, 9.1 ftlb)
3-52
ENG
\.
3-53
ENGINE ASSEMBLY AND ADJUSTMENT
CARBURETOR JOINT
1. Inspect:
O-ring (carburetor joint)
Damage -> Replace.
2. Install:
O-ring CD
Carburetor joint
Carburetor Joint:
7 Nm (0.7 mkg,5.1 ftlb)
ENGINE ASSEMBLY AND ADJUSTMENT
ENG
,_
REMOUNTING ENGINE
@_Nm ( ~ . 4 mokg, 17 ftolb) I
3-54
ENG
3-55
ENGINE ASSEMBLY AND ADJUSTMENT
REMOUNTING ENGINE
When remounting the engine, reverse the re-
moval procedure. Note the following points.
1. Install:
Engine
Engine Mounting Bolts
(Upper and Rear):
24 Nm (2.4 m' kg, 17 ftlb)
2. Install:
Starter motor
Muffler
Starter Motor:
7 Nm (0.7 m' kg, 5.1 ftlb)
Muffler Stay:
25 Nm (2.5 m' kg, 18 ftlb)
Exhaust Pipe:
10 Nm (1.0 m' kg, 7.2 ftlb)
3. Install:
Dowel pins
Gasket (new)
Crankcase cover (left) CD
.Change pedal
NOTE: ____________ _
Tighten the screws in stage, using a crisscross
pattern.
Crankcase Cover:
7 Nm (0.7 m' kg, 5.1 ft-lb)
Change Pedal:
10 Nm (1.0 m' kg, 7.2 ftlb)
4. Adjust:
.Clutch free play
Refer to "CHAPTER 2. CLUTCH AO-
JUSTM ENT" section.
ENGINE ASSEMBLY AND ADJUSTMENT
1 ENG 1\.1
5. Install:
eO-rings G)
e Gasket (new)
e Carburetor
Refer to "CHAPTER 2. TH RaTTLE
lEVE R ADJUSTMENT" section.
NOTE: ________________________ __
Make sure that the air cleaner joint sealing
surface matches the sealing surface of the
front fender so there is not air leak.
Carburetor:
7 Nm (0.7 m
o
kg, 5.1 ftolb)
6. Apply:
eEngineoil
I ~ I Recommended Oil,
'V SAE 10W40 Type SE Motor Oil
Total Amount:
1.0 L (0.88 Imp qt, 1.06 US qt)
Refer to "CHAPTER 2. ENGI NE 01 l
REPLACEMENT" section.
7. Inspect:
eOil leakage
3-56
CHAPTER 4.
CARBURETION
CARBURETOR . ......................................... " ... 4-1
SECTIONAL VIEW .......................................... 4-2
REMOVAL ................................................ 4-3
DISASSEMBLY ............................................ 4-3
INSPECTION .............................................. 4-4
ASSEMB L Y ............................................... 4-5
INSTALLATION ........................................... 4-6
ADJUSTMENT ............................................. 4-6
FARBI f I CARBURETOR
CARBURETOR
CD Throttle valve spring
Needle set
Throttle valve
@ Throttle stop screw set
Air screw set
Choke lever
(j) Pilot jet
4-1
CA R BUR E T ION r-----S .... P"""":EC:-:-:I F:':"'I C:-:A-=T':-:::I O:7:'N;:"'"S ----,
J . - - . - - - ~ - - ~ ~ ~ , -
@ Main nozzle
Main jet
@ Needle valve
Float
@ Drain screw
Main jet
Jet needle
Pilot jet
Pilot screw
Fuel level
#80
3HP9
#12.5
2 1/2
3.5 1.0 mm
(0.14 0.04 in)
Float height 21.0 0.5 mm
(0.83 0.02 in)
Engine idling speed 1,800 50 r/min
SECTIONAL VIEW
CD Throttle valve
Choke valve
@ Main nozzle
@ Jet needle
Main jet
Pilot jet
(j) Needle valve
(j)------
[8J Air
[ill Mixture
~ Fuel
6
CARBURETOR ICARBI , I
4-2
ICARB\ I CARBURETOR
43
REMOVAL
1. Remove:
Carburetor assembly
Refer to engine removal section.
NOTE: ________________________ __
The following parts can be cleaned and ins-
pected without disassembly .
Throttle stop screw set
Air screw set
DISASSEMBL Y
1. Remove:
Carburetor top cover CD
.Gasket
Throttle valve spring
Spring (jet needle)
.Jet needle
Throttle valve
2. Remove:
Air screw set CD
Throttle stop screw set
3. Remove:
Float chamber cover
Float pin CD
Float
CARBURETOR
4. Remove:
Needle valve Q)
.Pilot jet
Main jet
Main nozzle @
INSPECTION
1. Inspect:
Carburetor body
Contamination -+ Clean.
NOTE: ________________________ __
Use a petroleum based solvent for cleaning.
Blowout all passages and jets with compressed
air.
2. Inspect:
Float Q)
Damage -+ Replace.
Gaskets/O-rings
Damage -+ Replace.
3. Inspect:
Needle valve Q)
Wear/Contamination -+ Replace.
4. Inspect:
Throttle valve Q)
Wear/Damage -+ Replace.
5. Check:
Free movement
Stick -+ Replace.
Insert the throttle valve into the carburetor
body, and check for free movement.
4-4
ICARBI f I CARBURETOR
4-5
6. Inspect:
Jet needle CD
Bends/Wear"""* Replace.
7. Inspect:
Air screw CD
Throttle stop screw
Wear/Contamination"""* Replace.
ASSEMBLY
To assemble the carburetor, reverse the dis-
assembly procedures. Note the following points .
Before reassembling, wash a/l parts in clean
gasoline .
Always use a new gasket.
1. Install:
Throttle valve CD
NOTE: ________________________ ___
Align the groove of the throttle valve with
the projection of the carburetor body.
2
CARBURETOR
INSTALLATION
1 . Install
Carburetor assembly
Reserve the removal procedure.
ADJUSTMENT
Fuel Level Adjustment
1. Measure:
Fuel level
Out of specification ~ Adjust.
By the following measurement steps.
Fuel Level:
3.5 1.0 mm (0.14 0.04 in)
Below the Carburetor Body Edge.
Fuel level measurement steps:
.Place the machine on a level place.
Use a garuge jack under the engine to ensure
that the carburetor is positioned vertically.
Attach the Fuel Level Gauge CD (YM-01312)
to the float chamber nozzle.
Loosen the drain screw and start the
engine.
Measure the fuel level with gauge.
If the fuel level is incorrect adjust the fuel
level.
2. Adjust:
Fuel level
By the following adjustment steps.
Fuel level adjustment steps:
Remove the carburetor .
Inspect the needle valve.
If it is worn, replace it.
4-6
ICARBI , I CARBURETOR
4-7
If it is fine, adjust the float height by
bending the float tang CD on the float .
Recheck the fuel level.
Float Height Adjustment
1. Measure:
Float height
Out of specification -+ Adjust.
By the following steps.
Float Height:
21.0 0.5 mm (0.83 0.02 in)
Float height measurement and adjustment
steps:
Remove the carburetor, and remove the
float chamber.
Hold the carburetor in an upside down
position.
Measure the distance between the mating
su rface of the float chamber (gasket re-
moved) and top of the float using a gauge.
Float height
NOTE: ______________________ __
The float arm should be resting on the needle
valve, but not compressing the needle valve .
If the float height is not within specification,
inspect the needle valve .
If it is worn, replace it .
If it is fine, adjust the float height by
bending the float tang CD on the float .
Recheck the float height.
CHAPTER 5.
CHASSIS
FRONTWHEEL ................................. .............. 5-1
REMOVAL ................................................ 5-2
INSPECTION ............................................ " 5-2
INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-3
REAR WHEEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-4
REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-5
iNSPECTION ........................................ , ..... 5-5
INSTALLATION ........................................... 5-6
REAR BRAKE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 5-7
REMOVAL ................................................ 5-8
INSPECTION ...................................... , . . . . . .. 5-9
INSTALLATION ............................ , .............. 5-10
STEERING SYSTEM . .......................................... 5-13
REMOVAL ................... " .... " ..................... 5-14
INSPECTION .............................................. 5-15
INSTALLATION ........................................... 5-16
STEERING KNUCKLES AND TIE-ROD ENDS .. . , ................... 5-17
REMOVAL .......................... , ..... , ..... , ......... 5-17
INSPECTION .............................................. 5-18
INSTALLATION ........................................... 5-19
ADJUSTMENT ............................................. 5-20
SHAFT DRIVE . ............................................... 5-22
REMOVAL ................................................ 5-23
INSPECTION .............................................. 5-24
INSTALLATION .... " ..................................... 5-25
I
CHAS
IciJ61 FRONT WHEEL
--.: RE AI R PRESSURE
TI _
FRONT WHEEL
CD Oil seal
Bearing
Bearing spacer
@ Front hub
@ Collar
5-1
Front Rear
196 kPa
- 19.6 kPa . / 2
2 (0.2 kg em ,
(0.2 kg/em, 2.S psi)
2.S psi)
16.7kPa
2
16.7kPa
2
/
(0.17 kg em
(0.17 kg/em 2.4 psi)
2.4 pssii:
17 x 77 TIRE SIZ_E_: __
5 __ 7 .
OUT LIMIT.
L RUN_ .
C _,!"HEE - - 2 mm (O.OS In) - - AL
D
VERTIC (0 OS in)
2mm .'
LATERAL . 30 mm (0.12 in)
.. TIRE WEAR _LIMIT.. _
FRONT WHEEL
REMOVAL
Front Wheel Removal
1. Place the machine on a level place.
2. Loosen:
Nuts (front wheel)
Apply the parking brake CD .
3. Elevate the front wheels by placing the
suitable stand under the frame.
4. Remove:
Nuts (front wheel)
Front wheel
Front Wheel Hub Removal
1. Remove:
.Wheel cap
Cotter pin CD
.Axle nut
Plain washer
.Wheel hub
INSPECTION
1. Inspect:
.Wheel
Cracks/Bends/Warpage -)0 Rep lace.
2. Measure:
Wheel runout
Out of specification -)0 Replace.
CD Dial gauge
3. Check:
Rim Runout Limit:
Vertical: 2.0 mm (0.08 in)
Lateral: 2.0 mm (0.08 in)
.Wheel balance
Out of balance -)0 Adjust.
5-2
ICHASI ~ I FRONT WHEEL
5-3
4. Check:
Wheel bearings
Bearing allow play in the wheel hub or
wheel turns roughly -+ Replace.
By the following replacement steps.
Wheel bearing replacement steps:
Clean the outside of the wheel hub.
Drive out the bearing.
WARNING:
Eye protection is recommenced when using
striking tools.
I nsta II the new bearing by reversi ng the
previous steps.
NOTE: ________________________ _
Use a socket that matches the outside d ia-
meter of the race of the bearing.
Do not strike the center race or balls of the
bearing. Contact should be made only with
the outer race.
INSTALLATION
When installing the front wheel and front wheel
hub, reserve the removal procedure. Note the
following points.
1. Apply:
Lighium base grease
Lightly grease to the oil seal.
2. Tighten:
.Axlenut
Nuts (front wheel)
Axle Nut:
65 Nm (6.5 m' kg, 47 ftlb)
Nut (Front Wheel):
28 Nm (2.8 mkg, 20 ftlb)
3. Install:
Cotter pin (new)
WARNING:
Always use a new cotter pin.
REAR WHEEL
CD Wheel hub
Hub dust cover
1FT TIRE TREAO*
I Standard position
@ Reversed position
REAR WHEEL I C H A S I ~ I
* Cornering performance is less good on the
reversely mounted rear wheels than on the
standard mounting. Thus, the standard
mounting is recommended for normal riding.
A TI RE SIZE: 18 x 97
B RIM SIZE: 6.5 x 7
C WHEEL RUNOUT LIMIT:
0 VERTICAL 2 mm (0.08 in)
E LATERAL 2 mm (0.08 in)
54
I C H A S I ~ I REAR WHEEL
5-5
REMOVAL
Rear Wheel Removal
1. Place the machine on a level place.
2. Loosen:
- Nuts (rear wheel)
Apply the parking brake CD .
3. Block the front wheels, and elevate the rear
wheels by placing the suitable stand under
the frame.
4. Remove:
-Nuts (rear wheel)
- Rear wheel
Rear Wheel Hub Removal
Refer to "FRONT WHEEL - REMOVAL"
section.
INSPECTION
1. Inspect:
-Wheel
Refer to "FRONT WHEEL - INSPEC-
TION" section.
2. Measure:
- Wheel runout
Refer to "FRONT WHEEL - INSPEC-
TION" section.
3. Check:
-Wheel balance
- Wheel bearings
Refer to "FRONT WHEEL - INSPEC-
TION" section.
INSTALLATION
Refer to "FRONT WHEEL -INSTALLATION"
section.
5-6
ICHASj0b61 REAR BRAKE
REAR BRAKE
CD Cover
Oil seal
@ Drum brake
@ O-ring
@ Ring
Brake shoe camp.
ill Oil seal
Bearing
5-7
@Spacer
Camshaft
([j) O-ring
@O-ring
@ Rear hub
Cover plate
@Wear indicator
@ Camshaft lever
LINING WEAR LIMIT:
A 2 mm (0.08 in)
REAR BRAKE
REMOVAL
1. Remove:
Rear wheels
Rear wheel hubs
Refer to "REAR WHEEL - REMOVAL"
section.
2. Remove:
Ring nuts (rear axle) ill, .
Use the Ring Nut Wrench.
3. Release the parking brake.
4. Remove:
Adjusters (brake pedal and brake lever)
5. Unhook the brake lever spring.
6. Remove:
Brake cover ill
Brake drum
Brake shoes
7. Remove:
Bolts (final gear housing)
B. Disconnect:
Breather hose ill
9. Remove:
Rear hub assembly ill
5-8
I c H A S I ~ 1 REAR BRAKE
5-9
'- 10. Remove:
Bolts (rear hub)
Final gear housing CD with rear axle
Refer to "SHAFT DRIVE REMOVAL"
section.
Rear hub
INSPECTION
1. Inspect:
Rear axle runout
Out of specification ---* Replace.
WARNING:
Rear Axle Runout Limit:
1.5 mm (0.06 in)
Do not attempt to straighten a dent axle.
2. Inspect:
O-rings
Oil seals
Damage ---* Replace.
3. Check:
Bearings
Bearings allow play in the final gear
housing and rear hub or rear axle turns
roughly ---* Replace.
Refer to "FRONT WHEEL - INSPEC-
TION" section.
REAR BRAKE
4. Inspect:
Brake lining surface
Glazed areas -4- Remove.
Use a coarse sand paper.
NOTE: ____________ _
After using the sand paper, clean of the polished
particles with cloth.
5. Measure:
Brake lining thickness
Out of specification -4- Replace.
(j)Measuring points
Brake Lining Thickness:
4 mm (0.16 in)
Wear Limit:
2 mm (0.08 in)
NOTE: _______________________ ___
Replace the brake shoes as a set if either IS
found to be worn to the wear limit.
6. Inspect:
Brake drum inner surface
Oil/Scratches -4- Remove.
Oil
Use a rag soaked in
lacquer thinner or solvent.
--------t- - ---- - - - ----- r-- -
Scratches
Use a emery cloth
(lightly and evenly polishing)
7. Inspect:
Camshaft face
Wear -4- Replace.
NOTE: ______________________ _
Before removing the cam lever, put a match
mark (punches) on the cam lever and camshaft
to indicate their positions for easy assembly.
INSTALLATION
When installing the rear brake, reverse the
removal procedure. Note the following points.
1. Apply:
Lithium base grease
Lightly grease to the oil seal lips.
510
ICHASIcf:I61 REAR BRAKE
5-11
2. Fill:
Final gear case
Final Gear Case Grease:
3. Install:
Recommended Grease:
Shell TG-0983 or equivalent
Grease Capacity:
0.1 L (0.09 Imp qt, 0.11 US qt)
Final gear housing with rear axle
To the rear hub.
Bolt (rear hub)
NOTE: ________________________ ___
Be sure to position the rear hub so that the
breather hose nippleCDis top.
4. Tighten:
Bolts (rear hub)
5. Apply:
Bolts (Rear Hub):
10 Nm (1.0 mkg, 7.2 ftlb)
LOCTITE@
Sealant (Quick Gasket) CD
(ACC-11 001-05-01 )
To the mating surfaces of both case halves.
6. Tighten:
Nuts (rear hub assembly)
Bolts (final gear housing)
Nuts (Rear Hub Assembly):
50 Nm (5.0 m kg, 36 ftlb)
Bolts (Final Gear Housing):
25 Nm (2.5 mkg, 18 ftlb)
7. Install:
Ring nuts (rear axle)
NOTE: ________________________ ___
The tapered side of the ring nut must face
inward.
REAR BRAKE ICHASI ~ I
8. Tighten:
Ring nuts (rear axle) CD ,
By the following tightening steps.
Ring nuts tightening steps:
Finger tighten the inside-ring nut .
Hold the inside-ring nut with the Ring
Nut Wrench (YU-33975).
Tighten the outside-ring nut CD to specifi-
cation.
Outside-ring Nut:
110 Nm (11.0 m' kg, 80 ftlb)
Hold the outside-ring nut CD with the Ring
Nut Wrench.
Tighten the inside-ring nut to specifica-
tion.
Inside-ring Nut:
145 Nm (14.5 m' kg, 105 ftlb)
9. Adjust:
Brake lever free play
Brake pedal free play
Refer to "CHAPTER 2. BRAKE LEVER
ADJUSTMENT and BRAKE PEDAL
ADJUSTMENT" section.
10. Install:
Rear wheel hubs
Rear wheels
Refer to "REAR WHEEL - INSTALLA-
TION" section.
5-12
STEERING SYSTEM
STEERING SYSTEM
CD Steering shaft bushing
Oil seal
Steering shaft
@) Knuckle
Knuckle shaft
Thrust cover
(j) Bushing
Spacer
Tie-rod
Tie-rod end
8
--
5-13
A TOE-IN: [
- ._-
_ j 0 3 _rllm (0 in)
3
STEERING SYSTEM
REMOVAL
1. Remove:
Front cover CD
Handlebar cover
2. Remove:
Front fender
3. Remove:
"NEUTRAL" indicator light CD
Main switch
4. Remove:
Clips CD
Bolts (handlebar holder)
Handlebar
5-14
I c H A S I ~ 1 STEERING SYSTEM
O-<D
515
5. Straighten:
Lock washer tabs
6. Remove:
Steering shaft bracket
.Steering shaft bushings CD
.Oil seals
7. Remove:
Under guard CD
8. Remove:
Cotter pin CD
Nut (steering shaft)
Plain washer
Tie-rod end @
Steering shaft
INSPECTION
1. Inspect:
Steering shaft
Bends ~ Replace.
WARNING:
Do not attempt to straighten a bent shaft;
this may dangerously weaken the shaft.
2. Inspect:
Oil seals CD
.Steering shaft bushings
Wear/Damage ~ Replace.
STEERING SYSTEM
3. Check:
Steering shaft free play
Steering shaft is loose -+ Replace bushings
and O-rings.
Insert the steering shaft into the frame, and
check for free play.
INSTALLATION
When installing the steering system, reverse
the removal procedure. Note the following
points.
1. Install:
Steering shaft
WARNING:
Make sure the brake cables and leads are
properly routed, and are not damaged or
twisted.
2. Tighten:
Nuts (tie-rod end) CD
Nut (steering shaft)
Nuts (Tie-rod End):
45 Nm (4.5 m kg, 32 ftlb)
Nut (Steering Shaft):
30 Nm (3.0 m kg, 22 ftlb)
3. Install:
Cotter pin (new)
WARNING:
Always use a new cotter pin.
4. Install:
.Oil seals
Steering shaft bushings CD
Steering shaft bracket
NOTE: ________________________ _
Lightly apply lighium soap base grease to
the oil seals .
Be careful not to damage the oil seals during
installation.
5-16
CHAS ~ ~ ~ ~ ~ R I N G SYSTEM/STEERING KNUCKLES AND TIE-ROD
517
5. Install:
Lock washers (new) CD
Bolts (steering shaft bracket)
Bolts (Steering Shaft Bracket):
23 Nm (2.3 m' kg, 17 ftlb)
6. Bend the lock washer tab along the bolt
flats.
7. Install:
Handlebar
Bolts (hand lebar holder)
Clips (new) CD
Bolts (Handlebar Holder):
23 Nm (2.3 m'kg, 17 ftlb)
8. Lubricate:
Pivot point (steerig shaft) CD
Use a grease gun.
Lithium Base Grease
]
STEERING KNUCKLES AND TIE-ROD
ENDS
REMOVAL
1. Remove:
Front wheels
Front hubs
Refer to "FRONTWHEEL - REMOVAL"
section.
2. Remove:
Cotter pins CD
Nuts (tie-rod end)
.Tie-rod
STEERING KNUCKLES AND TIE-ROD ENDS
CHASJ36
3. Remove:
Cotter pi n CD
Nut (steering knuckle)
Plain washer @
Thrust covers @
Bushings @
Spacer
Knuckle shaft (j)
INSPECTION
1. Check:
.Spacer free play
Spacer is loose --+ Replace spacer and
bushings as a set.
Insert the spacer into the knuckle, and
check for free play.
2. Check:
Tie-rid free play and movement
Tie-rod is exists free play --+ Replace tie-rod
end.
Tie-rod turns roughly --+ Replace tie-ro,
end.
3. Inspect:
Thrust cover
Wear/Damage --+ Replace.
5-18

CDA
5-19
STEERING KNUCKLES AND TIE-ROD ENDS

INSTALLATION
When installing the tie-rod, reverse the removal
procedure. Note the following points.
1. Apply:
Lith ium base grease
Lightly grease to the knuckle shaft,
bushings and thrust covers.
2. Tighten:
Nuts (steering knuckles)
Nuts (Steering Knuckles):
30 Nm (3.0 mkg, 22 ft-Ib)
_________ _
Avoid over-tightening.
3. Install:
Cotter pin
WARNING:
Always use a new cotter pin.
4. Adjust:
Tie-rod assembly length
By the following adjustment steps.
Tie-rod assembly length adjustment steps:
Loosen the locknuts CD .
Adjust tie-rod assembly length a by turning
both tie-rod ends.
Tie-rod Assembly Length :
240 mm (9.45 in)
NOTE: ______________________ _
The threads on both tie-rod ends must be
of the same length.
[8] Right-hand-threads
rnJ Left-hand-threads
To steering shaft
ill] To knuckle
Tighten the locknuts.
Locknut (Tie-rod):
30 Nm (3.0 m- kg, 22 ft-Ib)
STEERING KNUCKLES AND TIE-ROD ENDS FHASj ~ I
CD
F , / ~
t.
B
5. Install:
- Tie-rods (left and right)
NOTE: ________________________ _
Be sure to position the tie-rod so that its white
painted mark CD is right-hand rod.
6. Tighten:
-Nuts (tie-rod end)
Nuts (Tie-rod End):
45 Nm (4.5 mkg, 32 ftlb)
7. Install:
-Cotter pins
WARNING:
Always use a new cotter pin.
ADJUSTMENT
Tie-rod Adjustment
1. Place the machine on a level place.
2. Measure:
-Toe-in
By the following measurement steps.
Toe-in measurement steps:
- Mark both front tire tread centers.
- Measure the width
[A]
between the marks.
-Move the front tires 180 degrees either
forward or backward until the marks come
exactely opposite.
- Measure the width
lm
between the marks.
-Calculate the toe-in using the formula given
below.
Toe-in = lm - [A]
~
Toe-in:
o - 3 mm (0 - 0.12 in)
- If the toe-in is incorrect, adjust the toe-in.
520
521
STEERING KNUCKLES AND TIE-ROD ENDS
3. Adjust:
Toe-in
Refer to "Tie-rod assembly length adjust-
ment steps" section.
WARNING:
Be sure that both tie-rod are turned by the
same amount. If not, the machine will go
right or left even though the handlebar is
positioned straight and it may lead to mis-
handling and accident .
After setting the toe-in to specification, run
the machine slowly for some distance with
the hands lightly on the handlebar and check
that the handlebar responds correctly. If not,
turn either the right or left tie-rod within the
toe-in specification.
SHAFT DRIVE
CD Rear axle
Bearing
@ Oil seal
Drive pinion gear
Spacer
Bearing

(J) Nut (Drive pinion gear)

8 Coupling gear
Shaft drive assembl
@' Cross joint
10 Nm (1.0 m'kg, 7.2 ft'lb)
60 Nm (6.0 m'kg 43 ft'lb)
SHAFT DRIVE Ic
H
AS/cf.JOl
5-22
FHASI6J61 SHAFT DRIVE
523
REMOVAL
1. Remove:
Rear wheels
Rear wheel hubs
Refer to "REAR WHEEL - REMOVAL"
section.
2. R.emove:
Rear hub
Final gear housing with rear axle
Refer to "REAR BRAKE - REMOVAL"
section.
3. Remove:
Nut (drive pinion gear) CD
Use the hexagon wrench (32 mm ) YM-
01364.
4. Remove:
Bearing CD
Spacer
Drive pinion gear @
Rear axle
5. Remove:
Rubber bolt CD
Bearing housing
.Shaft drive assembly @
Coupling gear @
6. DR IVE ICHASI
Clrclip CD
Use the C
o rankcase S
1135) and th eparator
Spacer e homemade tool ( (YU
Push screw steel).
Plain washer
.Com pression spri '7'
Final d . ng \U
. rive shaft
.Spnng .
.' retainer
Clrclip
INSPECTION
1. Inspect:
Ring gear CD
pinion gear Drive ..
Coupling gear @
nve shaft @ Final d .
screw
Pltting/Wear/D
.C amage -+ R
om pression sprin eplace.
Fatigue -+ Rlg@
M
ep ace
ove' .
spring up and d own.
5-24
____________ _
5-25
2. Check:
Bearings CD
Bearings allow play in the final gear
housing or shaft turns roughly -+ Replace.
INSTALLATION
When installing the rear axle, reverse the removal
procedure. Note the following points.
1. Install:
.Circlip
Spring retainer
Final drive shaft
Compression spring (j)
Plain washer
Push screw
.Spacer @
.Circlip CD
Use the Crankcase Separator (90890-
01135) and the home-made tool @ (steel).
3. Apply:
Lithium base grease
Grease to the illustrated points.
4. Tighten:
Nut (drive pinion gear)
Use the hexagon wrench (32 mm).
Nut (Drive Pinion Gear):
60 Nm (6.0 m' kg, 43 ft'lb)
LOCTITE
SHAFT DRIVE ~ H A S I ~ I
5. Install:
Final gear housing with rear axle
Rear hub
Refer to "REAR BRAKE - INSTALLA-
TION" section.
6. Install:
Rear wheel hubs
Rear wheels
Refer to "REAR WHEEL - INSTALLA-
TION" section.
5-26
CHAPTER 6.
ELECTRICAL
YFM80N WIRING DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-1
ELECTRICAL COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-3
ELECTRICAL STARTING SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-5
WIRING DIAGRAM ......................................... 6-5
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 6-7
STARTING CIRCUIT OPERATION ............................. 6-8
BATTERY INSPECTION ..................................... 6-8
STARTER MOTOR TEST .................................... 6-9
STARTER RELAY TEST ..................................... 6-12
STARTING CIRCUIT CUT-OFF RELAY TEST .................... 6-13
CHARGING SYSTEM ........................................... 6-15
WIRING DIAGRAM ......................................... 6-15
TROUBLESHOOTING ....................................... 6-17
BATTERY INSPECTION ..................................... 6-18
CHARGING OUTPUT TEST .................................. 6-18
CHARGING COIL RESISTANCE TEST .......................... 6-19
IGNITION SYSTEM ............................................ 6-21
WIRING DIAGRAM ......................................... 6-21
TROUBLESHOOTING ....................................... 6-23
IGNITION TIMING CHECK ................................... 6-24
IGNITION SPARK GAP TEST ................................. 6-24
SPARK PLUG INSPECTION .................................. 6-24
IGNITION COIL RESISTANCE TEST ........................... 6-25
SOURCE COIL RESISTANCE TEST ............................ 6-26
IELECI iii I WIRING DIAGRAM
ELECTRICAL
YFM80N WIRING DIAGRAM
I -- C:)-+-- R-....c>I
B
Sb
B R/W
G/W
Sb W/R
B--+ ..... +-t-t-t--'
t--- B/R----Q::::]--- B/R

- R/W--.....

R/W B
...-=...
e..

B/WI' B

Br IR/W

o
Br Sb

-------,
I@
0
0 @
F
N
F
R/W
10
r-
,VIR
O
R
o
Br
Ie
Br Sb
R 0

u F
N F
B
10 I
B/W 1(-
I
L _______ J
0 (j)
Br R
0
F B/W B
F
N
Br
IC
R
10
10
B
B/W
10
6-1
WIRING DIAGRAM IELECIIiii I
Q) COl magneto
Neutral switch
@ COl unit
@ Ignition coil
Spark plug
@"ENGINE STOP" switch
(j]) "START" switch
@Starting circuit cut-off relay
(j]) Rectifier with regulator
Starter motor
"NEUTRAL" indicator light
(j) Main switch
@Starter relay
@Main fuse
@ For fog light lead
Handlebar switch
COLOR CODE
B ....... Black
O ....... Orange
R ....... Red
W ....... White
@Battery
Sb ...... Sky blue W/R .... White/Red
Br ....... Brown B/W ..... Black/White
Y/R ..... Yellow/Red G/W ..... Green/White
R/W ..... Red/White B/R ..... Black/Red
6-2
IELECIIii I ELECTRICAL COMPONENTS
ELECTRICAL COMPONENTS
CD Wire harness
Main fuse
Starting circuit cut-off
relay
@ Rectifier with regulator
@ Starter relay
Battery
6-3
(j) Neutral switch
Ignition coil
COl unit
Main switch
@ "NEUTRAL" indicator
light
SPECIFICATIONS
IGNITION COIL:
PRIMARY
SECONDARY
PICK-UP COl L
SOURCE COIL
CHARGING COIL
LIGHTING COIL
A
B
C
RESISTANCE
1.6n 10%
6.6Kn 20%
330n 10%
380n 10%
0.9n 10%
O.4n 10%
BATTERY:
CAPACITY:
12V,7AH
SPECIFIC GRAVITY:
1.280
ELECTRICAL COMPONENTS IELECI iii I
6-4
IELECI iii I ELECTRICAL STARTING SYSTEM
ELECTRICAL STARTING SYSTEM
WIRING DIAGRAM
~ R ........
R
~ - - n-Il---R--c>I
------..,

6-5
ELECTRICAL STARTING SYSTEM IELECI iii I
Aforementioned circuit diagram shows electrical
starting circuit in wiring diagram.
NOTE: ________________________ _
For the encircled numbers and color codes, see
page 6-2.
Neutral switch
(j) Main switch
Handlebar switch
@ "ENGINE STOP" switch
@ "START" switch
@Starting circuit cut-off relay
Starter motor
@ Starter relay
@Main fuse
@Battery
P
/
6-6
IELECI iii I ELECTRICAL STARTING SYSTEM
TROUBLESHOOTI NG
If the electrical starting system should become
inoperative (The starter motor does not
operative), the troubleshooting aids will be
useful.
The starter motor does not operate.
Check entire electrical starting system
for connections (Refer to "WI RING
DIAGRAM" section.)
Poor
connection
I ~ ~ I Correct.
6-7
Check battery for voltage and specific
gravity (Refer to "BATTERY INSPEC-
TION" section.)
Check fuse and fuse connections.
oJL
Check starting circuit cut-off relay condi-
tion (Refer to "STARTING CIRCUIT
CUT-OFF RELAY TEST" section.)
Check starter
"STARTING
OKOIIIII: ~
relay condition (Refer to
RELAY TEST" section.)
o ~ ..
Check starter motor condition (Refer to
"STARTER MOTOR TEST" section.)
Low voltage and
low specific gravitA
Recharge battery.
,L-______________ ~
Weak connection
or open circuit III.
Correct connection I
,. L-0_r_r_e_p_la_c_e _fu_s_e_. ___ ~ I
Poor condition ---'t. Replace starting
,. circuit cut-off relay.
Poor condition 110..1
_lIIiliiiiliiil____ Replace starter relay.
ylL-________________ ~
Poor condition ~ I \
1.lIIIiliililiiiiiiiiiiii p ~ Replace starter motor.
1
ELECTRICAL STARTING SYSTEM
CD
00
frrM--+ ------,kI
@
R/W
--..l--
Br
0
.. rnJ
_______ B
----,
I

______ .J
R/W
@
Sb
H
@
l
- [Q]
---[EJ
t
STARTING CIRCUIT OPERATION
The starting circuit on this model consist of the
starter motor, starter relay, neutral switch, and
the starting circuit cut-off relay. If the main
switch is on, the starter motor can be operated
only if:
The transmission is in neutral (the neutral
switch is on).
NOTE: __________________________ _
The starter motor can be operated irrespective
of the engine stop switch ("OFF" or "RUN");
however, the engine can be started if the engine
stop switch is at "R UN".
The starting circuit cut-off relay prevents the
starter from operating when the transmission
is in gear. In this instance, the starting circuit
cut-off relay is off so that current cannot reach
the starter motor.
CD Main fuse
@ Starter switch
@ Neutral switch
@ Starting circuit cut-off relay
Starter relay
Starter motor
(j) Battery
00 TO MAIN SWITCH
rnJ FROM MAIN SWITCH
TO COl UNIT
[Q] WHEN THE TRANSMISSION IS IN NEUTRAL
[] WHEN THE TRANSMISSION IS IN GEAR
BATTERY INSPECTION
Refer to "CHAPTER 2. BATTERY INSPEC-
TION" section.
6-8
\ELEC\ iii I ELECTRICAL STARTING SYSTEM
STARTER MOTOR TEST
CD O-ring
Brush set
@ Armature
7 Nm (0.7 mokg, 5.1 ftolb) A
B
C
-
D
ARMATURE COIL:
0.043D
-
BRUSH WEAR LIMIT:
3.5 mm (0.14 in)
---
COMMUTATOR WEAR LIMIT:
15.5mm (0.61 in)
---
MICA UNDERCUT:
1.0 mm (0.04 in)
"----'--.
CD
CD
6-9
ELECTRICAL STARTING SYSTEM
O.043D
Removal
1. Remove:
Starter motor
Refer to "CHAPTER 3. ENGINE OVER-
HAUL - ENGINE REMOVAL" section.
Inspection and Repair
1. Inspect:
Commutator
Dirty -+ Clean it with #600 grit sandpaper.
2. Measure:
Commutator diameter
Out of specification -+ Replace starter
motor.
3. Measure:
Commutator Wear Limit:
15.5 mm (0.61 in)
Mica undercut @
Out of specification -+ Scrape the mica to
proper value use a hacksaw blade can be
ground to fit.
Mica Undercut @ :
1.0 mm (0.04 in)
I
NOTE: ________________________ _
The mica insulation of the commutator must
be undercut to ensure proper operation of
commutator.
4. Inspect:
.Armature coil (insulation/continuity)
Defects(s) -+ Replace starter motor.
By the following inspecting steps.
Armature coil inspecting steps:
.Connect the Pocket Tester (YU-03112) for
continuity check CD and insulation check .
Measure the armature coil resistances.
6-10
IELEele I ELECTRICAL STARTING SYSTEM
6-11
~
Armature Coil Resistance:
Continuity Check CD*:
0.043n at 20C (68F)
Insulation Check :
More than 1 Mn at 20C (68F)
.If the resistance is incorrect, replace the
starter motor.
5. Measure:
.Brush length
Out of specification -+ Replace.
Brush Length Limit:
3.5 mm (0.14 in)
6. Measure:
Brush spring pressure
Fatigue/Out of specification -+ Replace as a
set.
Brush Spring Pressure:
310 ~ 450 9 (11 ~ 16 oz)
7. Inspect:
Bearing CD
.Oil seal
.O-rings
Wear/Damage -+ Replace.
Installation
1. Install:
Starter motor
NOTE: ________________________ __
Align the projection CD on the cover with the
groove on the housing.
Refer to "CHAPTER 3. ENGINE OVER-
HAUL - ENGINE ASSEMBLY AND
ADJUSTMENT" section.
0 0



I B
@
ELECTRICAL STARTING SYSTEM IELEC\ iii I
4.6n
EB
nx 1 0
@


L-
STARTER RELAY TEST
1. Remove:
.Seat
Battery
Rear fender
Refer to "CHAPTER 2.
TIMING CHECK" section.
2. Connect:
Battery (fully charged)
3. Inspect:
Starter relay CD
Poor condition -+ Replace.
IGNITION
By the following inspecting stesp.
Starter relay inspecting steps:
Disconnect the starter cable CV from the
starter relay .
Turn ignition switch to "ON", engine
stop switch to "RUN" and change pedal
to "NEUTRAL".
Push the "START" switch and check to see
if the starter relay clicks.
Starter relay clicking -+ Starter relay OK.
Starter relay not clicking -+ Measure coil
resista nce .
Connect the Pocket Tester (YU-03112)
leads to the starter relay.
Red/White
Black
Measure the coil resistance.
Starter Relay Resistance:
4.6n 5% at 20C (68
0
F)
.If the resistance is not within specification,
replace the starter relay.
6-12

6-13
ELECTRICAL STARTING SYSTEM
80[2
[2 x 10 0
STARTING CIRCUIT CUT-OFF RELAY TEST
1. Remove:
.Seat
Battery
Rear fender
Refer to "CHAPTER 2.
TIMING CHECK" section.
2. Inspect:
Relay coil resistance
IGNITION
Use the Pocket Tester (YU-03112).
Out of specification -+ Replace.
Starting Circu it Cut-off Relay
Resistance:
80[2 10% at 20C (68F)
3. Inspect:
Relay contacts
Use 12V battery and Pocket Tester @
(YU-03112l.
Out of specification -+ Replace.
Battery Connected CD: Zero[2
Battery Disconnected : 00
6-14
IELECI iii I CHARGING SYSTEM
CHARGING SYSTEM
WIRING DIAGRAM
6-15
Aforementioned circuit diagram shows charging
circuit in wiring diagram.
CHARGING SYSTEM IELECI iii I
NOTE: ________________________ __
For the encircled numbers and color codes, see
page 6-2.
CD CD I magneto
@ Rectifier with regulator
@Main fuse
@Battery
6-16
IELEcl iii I CHARGING SYSTEM
TROUBLESHOOTING
If the charing system should become inoperative,
the troubleshooting aids will be useful.
Check entire charging system for connec-
tions ( Refer to "WI RING DIAGRAM"
section.)
OK
~
Check battery for voltage and specific
gravity (Refer to "BATTERY INSPEC-
TION" section,)
OK I
&
Check fuse and fuse connections.
O K ~
Check charging amperage and charging coil
resistance of COl magneto (Refer to
"CHARING OUTPUT TEST" and
"CHARGING COIL RESISTANCE TEST"
section.)
OK.ll
Rectifier with regulator is fautly, replace it.
6-17
Poor
connection
~ I I
Correct.
Low voltage and
low specific gravity
IIrrr.
Recharge battery.
I ,
Weak connection
Correct connection or
I
or open circuit
IIrrr.
replace fuse.
w
If other than
specified
.... 1
Replace charging coil.
,
CHARGING SYSTEM
BATTERY INSPECTION
Refer to "CHAPTER 2. BATTERY INSPEC-
TION" section.
CHARGING OUTPUT TEST
NOTE: ________________________ ___
The battery must be fully charged when testing
the charging output.
1. Remove:
Seat
2. Disconnect:
Fuse positive lead (Red)
3. Connect:
Pocket Tester (YU-03112)
4. Start the engine.
5. Accelerate the engine to specifications and
check the charging amperage.
Never disconnect the leads from the battery
before stopping the engine.
6. Measure:
Charging output amperage
Out of specification -+ Perform the next
test.
CD Fuse positive leaa
Battery positive lead
Charging Output Amperage:
0.7A or more 3,000 r/min
3.0A or less 8,000 r/min
6-18
CHARGING SYSTEM
6-19
CHARGING COIL RESISTANCE TEST
1. Remove:
eSeat
e Battery
e Refer fender
Refer to "CHAPTER 2. IGNITION
TIMING CHECK" section.
2. Disconnect:
e One lead (Black)
e4-pin connector (White, White/Black
Yellow/Red, Black/White)
From COl magneto.
3. Connect:
ePocket Tester (YU-03112)
CD White
Black
4. Measure:
e Charging coi I resistance
Out of Specification -+ Replace.
Charging Coil Resistance:
0.9S? 10% at 20C (6S0 F)
6-20
IELEcl iii I IGNITION SYSTEM
IGNITION SYSTEM
WIRING DIAGRAM
621
Aforementioned circuit diagram shows ignition
circuit in wiring diagram.
IGNITION SYSTEM IElECI iii I
NOTE: ________________________ _
For the encircled numbers and color codes, see
page 6-2.
CD CD I magneto
CDI unit
@ Ignition coil
Spark plug
(j) Main switch
Handlebar switch
@ "ENGINE STOP" switch
@ Main fuse
@ Battery
6-22
IELECI iii I IGNITION SYSTEM
TROUBLESHOOTI NG
If the ignition system should become inoperative
(No spark or intermittent spark), the trouble-
shooting aids will be useful.
Check spark gap using Electro Tester
(Refer to "IGNITION SPARK GAP TEST"
section.)
If other
than specified
..... "
Check entire ignition system for connec-
tions (Refer to "WIRING DIAGRAM"
section.)
OK
Check spark plug condition (Refer to
"SPAR K PLUG I NSPECTION" section.)
OK
______ Ignition system
.. circuit is good.
Poor
connection .... 1
1Itl Correct.
Poor
condition

Replace spark plug.
rL-______________ ----'

If other
Check resistance of ignition coil (Refer to
"IGNITION COl L RESISTANCE TEST"
section.)
OK
Check pick-up and source coil resistance of
COl magneto (Refer to "PICK-UP COl L
RESISTANCE TEST" and "SOURCE
COIL RESISTANCE TEST" section.)
OK
COl unit is fautly, replace it.
6-23
than specified
Replace ignition coil.
rL---______________ ----'
If other
than specified ...... Replace pick-up
iIIII and/or source coil.
CD
IGNITION SYSTEM IELECI iii I
IGNITION TIMING CHECK
Refer to "CHAPTER 2. IGNITION TIMING
CHECK" section.
IGNITION SPARK GAP TEST
1. Warm up engine thoroughly so that all
electrical components are at operating
temperature.
2. Connect:
Electro Tester CD (YU-03112l
3. Check:
Minimum spark gap
Start the engine, and in crease the spark
gap until misfire occurs (Test at various
revolution between 1,300'" 8,000 r/min.l
Faulty ignition system operation (at the
minimum spark gap or smaller) "'"* Follow the
troubleshooting chart until the source of the
problem is located.
Minimum Spark Gap:
6 mm (0.24 in)
Spark plug lead
Spark plug
Do not run the engine in neutral above 6,000
r/min for more than 1 or 2 seconds.
SPARK PLUG INSPECTION
Refer to "CHAPTER 2. SPARK PLUG INS-
PECTION" section.
6-24
IGNITION SYSTEM
1.60
E2J
Ox1 0
6.6 kO
E]
{lx100 0
6-25
IGNITION COIL RESISTANCE TEST
1. Remove:
Seat
Battery
Rear fender
Fuel tank
2. Disconnect:
Ignition coil lead
.Spark plug lead
3. Connect:
Pocket Tester (YU-03112)
Set the tester selector to "Ohm x 1"
(For primary winding resistance check) or
"Ohm x 1 ~ O ' ' (For secondary winding
resistance check) position.
4. Measure:
.Primary coil resistance [A]/
Secondary coi I resistance [aJ
Out of specification """* Replace.
Primary Coil Resistance:
1.6n 10% at 20C (68F)
Secondary Coil Resistance:
6.6kn 20% at 20C (68F)
PICK-UP COIL RESISTANCE TEST
1. Remove:
Seat
Battery
Rear fender
2. Disconnect:
.One lead (Black)
.3-pin connector (White/Red, Green/White,
Sky blue)
From CD I magneto.
3. Connect:
Pocket Tester (YU-03112)
IGNITION SYSTEM IELECIIii I
4. Measure:
.Pick-up coil resistance
Out of specification --+- Replace.
Source Coil Resistance:
330n 10% at 20C (68F)
CD Black
Black/Red
SOURCE COIL RESISTANCE TEST
1. Remove:
Seat
Battery
Rear fender
2. Disconnect:
One lead (Black)
.4-pin connector (Black/Red, Yellow/Red,
White, White/Black)
From CD I magneto.
3. Connect:
Pocket Tester (YU-03112)
CD Black
White/Red
4. Measure:
Source coil resistance
Out of specification --+- Replace.
Source Coil Resistance:
380n 10% at 20C (68F)
6-26
CHAPTER 7.
APPENDICES
SPECIFICATIONS . ............................................. 7-1
GENERAL SPECIFICATIONS ..... , ......................... , .. 7-1
MAINTENANCE SPECiFiCATIONS ............................. 7-3
GENERAL TORQUE SPECIFICATIONS . ................. , .......... 7-12
DEFINITION OF UNITS . ........................................ 7-12
CONVERSION TABLES .. ................... , ................... 7-13
LUBRICATION DIAGRAM . ...................................... 7-13
CABLE ROUTING . ............................................. 7-15
YFM80N WIRING DIAGRAM
IAPPXI ~ 'I SPECIFICATIONS
APPENDICES
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model
Model Code Number
Vehicle Starting Number
Engine Starting Number
Dimensions:
Overall Length
Overall Width
Overall Height
Seat Height
Wheelbase
Minimum Ground Clearance
Basic Weight:
Wigh Oil and Full Fuel Tank
Minimum Turning Radius:
Engine:
Engine Type
Cylinder Arrangement
Displacement
Bore x Stroke
Compression Ratio
Compression Pressure
Starting System
Lubrication System:
Oil/Grease Type or Grade:
Engine Oil
0 10 30 50 70
SAE IlOW30 t y ~ e SE m ~ t 6 r oil
SAE 10W40 type SE motor oil
Yamalube 4<ycle oil or
gOOF
~
SAE 20W40 type SE motor oil
(20W50lj j I
-20 -10 0 10 20 30C
Final Gear Grease
Oil/Grease Capacity:
Engine Oil:
Periodic Oil Change
Total Amount
Final Gear Case Grease
Air Filter
7-1
YFM80N
55X
JYA55XOO* FCOO0101
55X-000101
1,415 mm (55.7 in)
825 mm (32.5 in)
865 mm (34.1 in)
560 mm (22.0 in)
945 mm (37.2 in)
105 mm ( 4.1 in)
99 kg (218 Ib)
2,000 mm (78.7 in)
4-stroke, gasoline, SOHC
Single cylinder, Forward inclined
79 cm
3
47.0 x 45.6 mm (1.850 x 1.795 in)
9.6: 1
1.177 kPa (12.0 kg/cm
2
, 171 psi)
Electric starter
Wet sump
SAE 10W40 type SE motor oil
Shell TG-0983 or equivalent
0.85 L (0.75 Imp qt, 0.90 US qt)
1.0 L (0.88 Imp qt, 1.06 US qt)
0.1 L (0.09 Imp qt, 0.11 US qt)
Wet type element
SPECIFICATIONS I APPX I ~ "I
Model YFM80N
Fuel:
Type Regular gasoline
Tank Capacity 5.4 L (1.2 Imp gal, 1.4 US gal)
Reserve Amount 1.1 L (0.2 Imp gal, 0.3 US gal)
Carburetor:
Type/Manufacturer VM16SH/MIKUNI
Spark Plug:
Type/Manufacturer C7HSA (NGK)/U22FS-U (NO)
Gap 0.6 - 0.7 mm (0.024 - 0.028 in)
Clutch Type: Wet, Centrifugal automatic
Transmission:
Pri mary R educti on System Gear
Primary Reduction Ratio 65/20 (3.250)
Secondary Reduction System Shaft drive
Secondary Reduction Ratio 19/18 x 34/10 (3.588)
Transmission Type Constant mesh, 4-speed
Operation Left foot operation
Gear Ratio:
1 st 39/11 (3.545)
2nd 35/17 (2.059)
3rd 31/22 (1.409)
4th 27/24 (1.125)
Chassis:
Frame Type Steel tube frame
Caster Angle 2.5
0
Trail 8.5 mm (0.33 in)
Toe-in 0- 3 mm (0- 0.12 in)
Tread (F) 630 mm (24.8 in)
Tread (R) 630 mm (24.8 in)
Tire:
Type Tubeless
Size (F) 17 x 7-7 x 2 pcs
Size (R) 1 8 x 9-7 x 2 pcs
Tire Pressure (Cold Tire):
Front and Rear:
Standard 19.6 kPa (0.20 kg/cm2 ,2.8 psi)
Minimum 16.7 kPa (0.17 kg/cm
2
, 2.4 psi)
Wear Limit 3 mm (0.12 in)
Brake:
Rear Brake Type Drum brake
Operation Left hand operation and Right foot operation
Electrical:
Ignition System COl Magneto
Generator System Flywheel Magneto
Battery Type/Capacity 12N7D-3B/12V,7AH
Indicator Light Wattage/Quantity:
"NEUTRAL" 3.4W x 1
7-2
I A P p X I ~ 'I SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
Engine
CyJ inder Head:
Warp Limit
Cylinder:
Bore Size
Taper Limit
Out-of-round Limit
Camshaft:
Drive Method
Cam Dimensions:
Intake
Exhaust
B
Model
Camshaft Runout Limit
I
A
Cam Chain Type/Number of Links
Cam Chain Adjustment Method
Rocker Arm/Rocker Arm Shaft:
Rocker Arm Inside Diameter
< Limit>
Shaft Outside Diameter
< Limit>
Arrn-to-shaft Clearance
< Limit>
Valve, Valve Seat, Valve Guide:
Valve Clearance (Cold)
7-3
*
YFM80N
< 0.05 mm (0.002 in) >
* Lines indicate straightedge measurement.
47.000'" 47.005 mm (1.850'" 1.851 in)
< 0.05 mm (0.002 in) >
< 0.01 mm (0.0004 in) >
Chain (Left)
"A" 25.257'" 25.357 mm (0.994'" 0.998 in)
< Limit> < 25.227 mm (0.993 in) >
liB" 21.001'" 21.101 mm (0.827'" 0.831 in)
< Limit> < 20.971 mm (0.826 in) >
"C" 4.247 '" 4.367 mm (0.167 '" 0.172 in)
< Limit> < 4.227 mm (0.166 in) >
"A"
< Limit>
"B"
< Limit>
"c"
< Limit>
25.258'" 25.358 mm (0.994'" 0.998 in)
< 25.228 mm (0.993 in) >
21.025'" 21.125 mm (0.828'" 0.832 in)
< 20.995 mm (0.827 in) >
4.248'" 4.368 mm (0.167'" 0.172 in)
< 4.228 mm (0.166 in) >
< 0.03 mm (0.0012 in) >
BUSH CHAI N/82 Links
Manual
9.979'" 9.990 mm (0.3929'" 0.3933 in)
< 10.05 mm (0.3957 in) >
9.981 - 9.991 mm (0.3930 - 0.3934 in)
< 9.95 mm (0.3917 in) >
0.009 - 0.034 mm (0.0004 - 0.0013 in)
< 0.08 mm (0.0032 in) >
IN. 0.05 - 0.10 mm (0.002 - 0.004 in)
EX. 0.075 - 0.125 mm (0.003 - 0.005 in)
Valve Dimensions:
~
I Head Dia. I
~ I I A " ~
Model
~ ..
Face Width
"A" Head Dia. IN.
EX.
"B" Face Width IN.
EX.
"c" Seat Width IN.
< Limit>
EX.
< Limit>
"0" Margin Thickness Limit IN.
EX.
Stem Outside Diameter IN.
< Limit>
EX.
< Limit>
Guide Inside Diameter IN.
< Limit>
EX.
< Limit>
Stem-to-guide Clearance IN.
Stem Runout Limit
Valve Seat Width
< Limit>
Valve Spring:
Free Length:
< Limit>
EX.
< Limit>
IN.
< Limit>
EX.
< Limit>
Compressed Length (Valve Closed):
IN.
EX.
Tilt Limit*: IN.&EX.
/
SPECIFICATIONS IAPPXI ~ "I
YFM80N
1\ ~
~ .. c ..
Seat Width ~
Margin Thickness
22.9 - 23.1 mm (0.902 - 0.909 in)
19.9 - 20.1 mm (0.784 - 0.791 in)
1.4 - 2.5 mm (0.055 - 0.098 in)
1.7 - 2.8 mm (0.067 - 0.110 in)
0.9 - 1.1 mm (0.035 - 0.043 in)
< 1.6 mm (0.063 in) >
0.9 - 1.1 mm (0.035 - 0.043 in)
< 1.6 mm (0.063 in) >
0.4 - 0.8 mm (0.016 - 0.032 in)
0.8 - 1.2 mm (0.032 - 0.047 in)
4.975 - 4.990 mm (0.1960 - 0.1965 in)
< 4.95 mm (0.1949 in) >
4.980 - 4.975 mm (0.1953 - 0.1959 in)
< 4.953 mm (0.1950 in) >
5.000 - 5.012 mm (0.1969 - 0.1973 in)
< 5.03 mm (0.1980 in) >
5.000 - 5.012 mm (0.1969 - 0.1973 in)
< 5.03 mm (0.1980 in) >
0.010 - 0.037 mm (0.0004 - 0.0015 in)
< 0.08 mm (0.0031 in) >
0.025 - 0.052 mm (0.0010 - 0.0021 in)
< 0.1 mm (0.0039 in) >
0.02 mm (0.0008 in)
0.9 - 1.1 mm (0.035 - 0.043 in)
< 1.6 mm (0.063 in) >
27.3 mm (1.08 in)
< 25.4 mm (1.00 in) >
27.3 mm (1.08 in)
< 25.4 mm (1.00 in) >
24.9 mm (0.980 in)
24.9 mm (0.980 in)
2.5
0
or 1.2 mm (0.047 in)
74
I A P p x l ~ 'I SPECIFICATIONS
Model
Direction of Winding (Top view)
Piston:
Piston Size "D"I
Measuring Point "H"
Piston Over Size: 2nd
4th
Piston Clearance
Piston Ring:
Sectional Sketch To Ring
2nd Ring
Oil Ring
End Gap (Installed) Top Ring
2nd Ring
Oil Ring
< Limit> Top Ring
2nd Ring
Side Clearance Top Ring
2nd Ring
Oil Ring
< Limit> Top Ring
2nd Ring
Oil Ring
Crankshaft:
7-5
Crank Width II A"
Big End Side Clearance "B"
< Limit>
Runout Limit "C"
Small End Free Play "F"
< Limit>
YFM80N
IN EX
c c
46.960 - 46.975 mm (1.8488 - 1.8494 in)1
10 mm (0.39 in)
(From bottom line of piston skirt)
47.50 mm (1.8701 in)
48.00 mm (1.8898 in)
0.025 - 0.045 mm (0.0010 - 0.0018 in)
Barrel
B = 1.0 mm (0.04 in)
T = 2.0 mm (0.08 in)
Taper
B = 1.0 mm (0.04 in)
T = 2.0 mm (0.08 in)
Expander
B = 2.0 mm (0.08 in)
T = 2.3 mm (0.09 in)
0.10- 0.25 mm (0.004 - 0.010 in)
0.10- 0.25 mm (0.004 - 0.010 in)
0.2 - 0.7 mm (0.08 - 0.028 in)
< 0.4 mm (0.016 in) >
< 0.4 mm (0.016 in) >
0.030 - 0.065 mm (0.0012 - 0.0026 in)
0.020 - 0.055 mm (0.0008 - 0.0022 in)
< 0.12 mm (0.0047 in) >
< 0.12 mm (0.0047 in) >
40.20 - 40.25 mm (1.583 - 1.585 in)
0.1 - 0.4 mm (0.004 - 0.016 in)
< 0.5 mm (0.02 in) >
< 0.05 mm (0.002 in) >
0.8 - 1.0 mm (0.03 - 0.04 in)
< 2.0 mm (0.08 in) >
SPECIFICATIONS IAPPX\' "\
Model YFM80N
Clutch:
Friction Plate Thickness/Quantity in)/6
Wear Limit < 2.9 mm (0.114 in) >
Clutch Plate Thickness/Quantity 1.2 1.6 mm (0.047 0.063 in)/5
Warp Limit < 0.1 mm (0.004 in) >
Clutch Spring Free Length/Quantity 30.1 mm (1.19 in)/8
Clutch Release Method Inner push
Clutch-In Revolution 2,1 00 2,300 r/min
Clutch-Stall Revolution 2,800 3,000 r/min
Transmission:
Main Axle Deflection Limit < 0.08 mm (O.0031 in) >
Drive Axe Deflection Limit < 0.08 mm (O.0031 in) >
Shifter:
Shifter Type Guide bar, Cam drum
Air Filter Oil Grade (Oiled Filter): Foarm-air-filter oil or
SAE 10W30 type SE motor
Carbu retor:
Type/Manufacturer/Quantity VM16SH/MI KUN 1/1
I.D. Mark 55XOO
Main Jet (M.J.) #80
Main Air Jet (M.A.J.) cpl.2
Jet Needle-clip Postion (J.N.) 3HP9-3
Needle Jet (N.J.) E-2
Cutaway (C.A.) 3.0
Pilot Jet (P.J .) #12.5
Pi lot Outlet (P.O.) cpO.7
Pilot Screw (P.S.) 2 1/2
Valve Seat (V.S.) cpl.2
Fuel Level (F.L.) 3.5 1.0 mm (0.14 0.04 in)
Float Height (F .H.) 21.0 0.5 mm (O.83 0.02 in)
Engine Idling Speed 1,800 50 r/min
Lubrication System:
Oil Filter Type Wire mesh
Oi I Pump Type Trochoid pump
Tip Clearance 0.15 mm (0.0059 in)
< Limit> < 0.20 mm (0.0079 in)
Side Clearance 0.06 0.10 mm (O.0024 0.0039 in)
Bypass Valve Setting Pressure 98 19.6 kPa (1.0 0.2 kg/cm
2
, 14 2,8 psi)
Middle Gear Lash: 0.17 0.31 mm (0.007 0.012 in)
Final Gear Lash: 0.17 0.31 mm (0.007 0.012 in)
7-6
IAPpxl. "I SPECIFICATIONS
Model
Lubrication Diagram:
'--_> Pressure feed
----Sp lashed scavenge
Oil Pan
Crankcase Tightening Sequence:
7-7
YFM80N
Cam Shaft
Oil Strainer
Cam Chain
Area
SPECIFICATIONS IAPPXI. 'I
TIGHTENING TORQUE:
Parts to be tightened Parts name Thread size Q'ty
Tightening torque
Remarks
Nm mkg ftlb
Cylinder Head Nut M6 x 1.0 4 10 1.0 7.2
Bolt M6 x 1.0 2 10 1.0 7.2
Tapper Cover Screw M6 x 1.0 2 7 0.7 5.1
Spark Plug - M10 x 1.0 1 12.5 1.25 9.1
Cam Sprocket Cover Screw M6 x 1.0 2 10 1.0 7.2
Flywheel Magneto Nut M10 x 1.25 1 40 4.0 29
Valve Clearance Adjusting Nut M5 x 0.5 2 7 0.7 5.1
Cam Sprocket Bolt M8 x 1.25 1 20 2.0 14
Chain Tensioner Plug M18 x 1.5 1 15 1.5 11
Nut M6 x 1.0 1 7 0.7 5.1
Crown nut M6 x 1.0 1 5 0.5 3.6
Bolt M6 x 1.0 1 4 0.4 2.9
Oil Pump Screw M5 x 0.8 1 4 0.4 2.9
Screw M6 x 1.0 2 7 0.7 5.1
Drain Plug - M12 x 1.5 1 20 2.0 14
Carburetor Joint Bolt M6 x 1.0 2 7 0.7 5.1
Carburetor Screw M6 x 1.0 2 7 0.7 5.1
Muffler Stay Bolt M8 x 1.25 2 25 2.5 18
Exhaust Pipe Nut M6 x 1.0 2 10 1.0 7.2
Crankcase Screw M6 x 1.0 9 7 0.7 5.1
~
Bolt M6 x 1.0 3 10 1.0 7.2
Bearing Cover Plate Screw M6 x 1.0 2 7 0.7 5.1
Crankcase Cover Screw M6 x 1.0 19 7 0.7 5.1
Stud bolt M6 x 1.0 4 10 1.0 7.2
Starter Clutch Screw M6 x 1.0 3 10 1.0 7.2
-G
Primary Drive Gear Nut M12 x 1.0 1 50 5.0 36
Clutch Push Plate Screw M6 x 1.0 4 8 0.8 5.8
Push Lever Axle Nut M6 x 1.0 1 8 0.8 5.8
Guide Screw M6 x 1.0 2 8 0.8 5.8
Clutch Boss Nut M14 x 1.0 1 60 6.0 43 Use lock washer
Bearing Housing (Middle) Nut M42 x 1.5 1 60 6.0 43
~
Bolt M6 x 1.0 3 10 1.0 7.2
Middle Driven Shaft Nut M12 x 1.25 1 90 9.0 64 -G
Stopper Plate Screw M6 x 1.0 2 8 0.8 5.8 ~
Stopper Lever Bolt M6 x 1.0 1 14 1.4 10 ~
Change Pedal Bolt M6 x 1.0 1 10 1.0 7.2
Stopper Screw Screw M8 x 1.25 1 25 2.5 18
~
Bearing Housing (Final) Nut M50 x 1.5 1 60 6.0 43
~
Bolt M6 x 1.0 6 10 1.0 7.2
~
Bolt M8 x 1.25 3 25 2.5 18
Pickup Coil Screw M5 x 0.8 1 4 0.4 2.9
Neutral Switch -- M10 x 1.25 1 10 1.0 7.2
Flywheel Magneto (Base Plate) Screw M6 x 1.0 2 7 0.7 5.1
Starter Motor Screw M6 x 1.0 2 7 0.7 5.1
7-8
IAPpxl'" I SPECIFICATIONS
Chassis
Model YFMBON
Wheel:
Front Wheel Type Panel Wheel
Rear Wheel Type Panel Wheel
Front Rim Size/Material 5.5 x 7/Steel
Rear Rim Size/Material 6.5 x 7/Steel
Rim Runout Limit:
Vertical < 2.0 mm (O.OB in) >
Lateral < 2.0 mm (O.OB in) >
Drum Brake:
Type Leading and trailing
Drum Inside Dia 130 mm (5.12 in)
< Limit> < 130.5 mm (5.14 in) >
Lining Thickness 4 mm (0.16 in)
< Limit> < 2 mm (O.OB in) >
Shoe Spring Free Length 36.5 mm (1.44 in)
Brake Lever & Brake Pedal:
Brake Lever Free Play 10- 20 mm (0.4 - O.B in) at lever end
Brake Pedal Position 5 mm (0.2 in)
Brake Pedal Free Play 20 - 30 mm (O.B - 1.2 in)
TIGHTENING TORQUE:
Parts to be tightened Parts name Thread size Q'ty
Tightening torque
Remarks
Nm mkg ftlb
Front Axle Shaft Nut M12x1.25 2 65 6.5 47
Panel Wheel Nut MB x 1.25 12 2B 2.B 20
Brake Cam Lever Bolt M6 x 1.0 2 9 0.9 6.5
Knuckle Shaft Bolt M10x1.25 2 30 3.0 22
Tie-rod End - Steering Shaft Nut M10 x 1.25 2 45, 4.5 32
Tie-rod End - Knuckle Nut M10 x 1.25 2 45 4.5 32
Tie-rod Lock Nut M10 x 1.25 4 30 3.0 22
Steering Shaft Nut M10 x 1.25 1 30 3.0 22
Steering Shaft Bracket Bolt MB x 1.25 2 23 2.3 17 Use lock washer
Handlebar Holder Bolt MB x 1.25 4 23 2.3 17
Engine Mounting (Upper) Bolt MB x 1.25 1 24 2.4 17
Engine Mounting (Rear) Bolt MB x 1.25 1 24 2.4 17
Footrest Bolt M12 x 1.25 4 BO B.O 5B
Rear Wheel Hub Bolt M10 x 1.25 4 50 5.0 36
Frame - Rear Hub Bolt M10x1.25 2 50 5.0 36
Final Gear Housing - Frame Bolt M10 x 1.25 2 50 5.0 36
Rear Axle Nut M14 x 1.5 2 B5 B.5 61
Under Guard Bolt MB x 1.25 4 23 2.3 17
Fuel Cock Screw M6 x 1.0 2 5 0.5 3.6
7-9
SPECIFICATIONS IAPPXI ~ "I
Electrical
Model YFM80N
Voltage 12V
Ignition System:
Ignition Timing (B.T.D.C.) 10at 1,700 r/min
Advanced Timing (B.T.D.C.) 30 at 5,000 r/min
Advancer Type Electrical
I I I
30 at 5,000 r/min
30
Cl
26 at 3,640 r':&
"".,-
c
'E ~
._ U
20
~ C l
v , ~ at 2,400 r/min
c .
. Q I-:
. ~ co
c-
10 Cl
0
1r at 1 r
o
rTin
2 4 6 8
Engine speed (x 10
3
r/min)
COl:
Magneto-Model/Manufacturer 55X/MORIYAMA
Pickup Coil Resistance (Color) 330n 10% at 20C (68F) (W/R - B)
Source Coil Resistance (Color) 380n 10% at 20C (68 F) (B/R - B)
COl Unit-Model/Manufacturer 55X/MO R I Y AMA
Ignition Coil:
Model/Manufacturer C2T4/MOR IYAMA
Minimum Spark Gap 6 mm (0.24 in)
Primary Winding Resistance 1.6n 10% at 20C (68F)
Secondary Winding Resistance 6.6kn 20% at 20C (68F)
Charging System/Type Flywheel magneto
F.w. Magneto:
Charging Current 0.7 A or more at 3,000 r/min
3.0A or more at 8,000 r/min
Charging Coil Resistance o.gn 10% at 20C (68F)
(Color) (W - B)
Lighting Voltage 11.0V or more at 3,000 r/min
15.5V or less at 8,000 r/min
Lighting Coil Resistance O.4n 10%at20C (68F)
(Color) (Y/R - B)
14
A
I-""'r-
3
I
12
-
:!
~
>
f
l
10 -;
... Cl
c
J
co
CI)
2 8
...
...
/
"0 ...
:::I
1"
>
U
6 Cl
Cl
\
c
c
...
. ~ 1
4
.J::.
/ ~ """'"
Cl
co
:J .J::.
U
If
2 S
8
1 2 3 4 5 6 7 8 9
Engine Speed (x 10
3
r/min)
7-10
IAPpxl ~ 'I SPECIFICATIONS
Model YFM80N
Voltage Regulator:
Type Short circuit type
Model/Manu factu re EHU-01 TR/MATSUSH ITA
No Load Regulated Voltage 12 - 16.5V
Rectifier:
Model/Manufacturer EHU-01 TR/MATSUSH ITA
Capacity 10A
Withstand Voltage 240V
Battery:
Capacity 12V,7AH
Specific Gravity 1.280
E lectri Starter System:
Type Constant mesh type
Starter Motor: Model/Manufacturer ADB4A4/N IPPONDENSO
Out put 0.2kW
Armature Coil Resistance 0.043n at 20C (68F)
Brush: Overall Length 7 mm (0.28 in)
< Limit> < 3.5 mm (0.14 in) >
Spring Pressure 310 - 450 g (11 - 16 oz)
Commutator: Diameter 16.5 mm (0.65 in)
< Wear Limit> < 15.5 mm (0.61 in) >
Mica Undercut 1.0 mm (0.04 in)
Starter Relay:
Model/Manufacturer A 104-132/HITACHI
Amperage Rating 4A
Coil Winding Resistance 4.6n 5% at 20C (68F)
Starting Circuit Cut-off Relay:
Model/Manufactu rer ACA 121 /MA TSUSH ITA
Coil Winding Resistance 80n 10% at 20C (68F)
Diode Yes
Circuit Breaker:
Type Fuse
Amperage for Individual Circu it/Quantity:
Main 10A x 1
Reserve 10A x 1
7-11
GENERAL TORQUE SPECIFICATIONS/ APPX .1 ~
DEFINITION OF UNITS "
GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasteners
with standard I.S.0. pitch threads. Torque
specifications for special components or assem-
blies are included in the applicable sections of
this book. To avoid warpage, tighten multi-
fastener assemblies in a crisscross fashion, in
progressive stages, until full torque is reached.
Unless otherwise specified, torque specifications
call for clean, dry threads. Components should
be at room temperature.
I
A
L ~
A B
(Nut) (Bolt)
10 mm 6mm
12 mm 8mm
14mm 10mm
17 mm 12mm
19mm 14 mm
22 mm 16mm
[A] Distance across flats
General torque
specifications
Nm mokg ftolb
6 0.6 4.3
15 1.5 11
30 3.0 22
55 5.5 40
85 8.5 51
130 13.0 94
'--________________ ....... rnJ Outside thread diameter
DEFINITION OF UNITS
Unit Read Definition Measure
mm Millimeter 10-
3
meter Length
cm Centimeter 10-
2
meter Length
kg Kilogram 10
3
gram Weight
N Newton 1 kg x m/sec Force
Nm Newton Meter Nxm Torque
m.kg Meter Kilogram m x kg Torque
Pa Pascal N/m2 Pressure
N/mm Newton per Millimeter N/mm Spring Rate
L Liter
Volume or Capacity
cm
3
Cubic Centimeter
-
r/min Rotation per Minute - Engine Speed
712
IAPpxl' 'I CONVERSION TABLES
CONVERSION TABLES
Metric to I neh System Inch to Metric System
Known Multiplier Result Known Multiplier Result
mkg 7.233 ftlb ftlb 0.13826 mkg
mkg 86.80 in-Ib inlb 0.01152 mkg
emkg 0.0723 ft-Ib ftlb 13.831 emkg
emkg 0.8680 inlb inlb 1.1521 emkg
kg 2.205 Ib Ib 0.4535 kg
9
0.03527 oz oz 28.352
9
km/lit 2.352 mpg mpg 0.4252 km/lit
km/hr 0.6214 mph mph 1.609 km/hr
km 0.6214 mi mi 1.609 km
m 3.281 ft ft 0.3048 m
m 1.094 yd yd 0.9141 m
em 0.3937 in in 2.54 em
mm 0.03937 in in 25.4 mm
ee (em
3
) 0.03382 oz (US liq) oz (US liq) 29.57 ee (em
3
)
ee (em
3
) 0.06102 eu in euin 16.387 ee (em
3
)
lit (liter) 2.1134 pt (US liq) pt (US liq) 0.4732 lit (liter)
lit (liter) 1.057 qt (US liq) qt (US liq) 0.9461 lit (liter)
lit (liter) 0.2642 gal (US liq) gal (US liq) 3.785 lit (liter)
kg/mm 56.007 Ib/in Ib/in 0.017855 kg/mm
kg/em2 14.2234 psi (lb/in
2
) psi (Ib/in 2 ) 0.07031 kg/em2
Centigrade
9/5 (OC) + 32
Fahrenheit
(OC) (0 F)
Fahrenheit
5/9 (OF - 32)
Centigrade
(OC) (OF)
7-13
LUBRICATION DIAGRAM I A P p X I ~ 'I
LUBRICATION DIAGRAM
CD Camshaft
Centrifugal oil filter
714
IAPPXI ~ "I LUBRICATION DIAGRAM
LUBRICATION DIAGRAM
CD Oil pump driven gear
@ Oil pump
@ Oil pump cover gasket
Oil strainer
@ Drain plug
Oil pump
7-15
CABLE ROUTING
CD Fuel tank breather pipe
Band
Fuel pipe
@Band
@ Battery negative lead
Rectifier with regulator
(j) Breather pipe
Battery breather pipe
CABLE ROUTING IAPPXI ~ "I
@Overflow pipe
@Band
@Crankcase ventilation pipe
@Carburetor ventilation pipe
@Cable guide
/
[A] Pass the battery breather pipe
through the hole.
rnJ Pass the throttle cable, brake
cable and fuel tank breather
pipe through the cable guide.
@ - - - - - t t " ~ ~
e
7-16
/APpxl. "I CABLE ROUTING
CABLE ROUTING
CD Ignition coil
@ Main switch
Band
@CDI unit
@ Cover
Brake cable
717
lAl Cover the handlebar switch lead coupler.
I
'------
CABLE ROUTING
ill Throttle cable
CV Fuel tank breather p.
@ Band Ipe
@ Brake cable
<r Starter motor negative lead
~ Battery negative lead
7 Battery positive lead
4
,-
CABLE ROUTING IAPPXI ~ " I
\
f- : = ~ = - ---
~ - --- --
ill
2
~ l _ _ ,V..------
718
--.---_ .. _---_.-.._---
YFM80N WIRING DIAGRAM
Handlebar switch
.-------------------l
Starting circuit cut-off relav Rectifier/R.lator
Starter relay
I I
I I
I "ENGINE STOP" .witch "START" .witch I
I R/W I
I I
I I
I I
L___ _ ___
R/W
B/W B B.
RUN OFF
OFF
10 fO
ON
10
--- -
----i
[]rrrr
B
R-t:>C:J.R
----B.
Starter motor
BI
Main switch
OFF
B/W 8 A Br
ON
A/W RIW
Sb R/W
W
R/W
B/W 8 B,
For fog light lead For fog light lead

...-----lHH---4-------+--------l-----v/R-----11 II
B/W
'-----8 R Br
'--------- B/W
'"NEUTRAL" indicator light
OJ

---Sb----o::::::::J< 5b----+-'
B/W B/R

Ignition coil
}------B-------'
COLOR CODE


..
COl unh
R Rod
W Whit_
Sb
Br
L-----------------j-------------W----------------,
L-__________________
..-+---------------------f-------------B/W----------___,



G/W W/R
COl magneto
Nell''''' switch
Sky bil,. Y/R Y.llow/Rod W/R Whl.. /Red G/W GreenlWhit.
Brown RIW RodIWhl.. BIW Black/White B/R Block/Rod