1992-2008 Yamaha YFM80 Badger Grizzly Raptor ATV's

EBS00004
HOW TO USE THIS MANUAL

MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “symbols”)
1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.
2nd title 2: This title indicates the section of the chapter and only appears on the first page of each
section. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa-
nied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.
2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed
by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
6. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition
to the exploded diagram and the job instruction chart.
EB003000
1 2 ILLUSTRATED SYMBOLS
GEN Illustrated symbols 1 to 9 are printed on the
INFO SPEC top right of each page and indicate the subject
of each chapter.
3 4 1 General information
2 Specifications
CHK 3 Periodic checks and adjustments
ADJ ENG 4 Engine
5 Carburetion
5 6 6 Drive train
7 Chassis
8 Electrical
CARB DRIV 9 Troubleshooting
7 8
– +
CHAS ELEC
9 0 Illustrated symbols 0 to F are used to identify
the specifications appearing in the text.
TRBL 0 Filling fluid
A Lubricant
SHTG B Special tool
A B C Torque
D Wear limit, clearance
E Engine speed
F Ω, V, A
C D
T.
R.
E F
G H I Illustrated symbols G to M in the exploded

diagrams indicate the types of lubricants and
lubrication points.
E G M G Apply engine oil
H Apply gear oil
J K L M I Apply molybdenum disulfide oil
J Apply wheel bearing grease
B LS M S K Apply lightweight lithium-soap-based grease
L Apply molybdenum disulfide grease
M Apply silicon grease
N O Illustrated symbols N to O in the exploded
diagrams indicate where to apply a locking
New agent N and when to install a new part O.
LT N Apply the locking agent (LOCTITE)
O Replace
CONTENTS
GENERAL INFORMATION ..............................................................................1

MACHINE IDENTIFICATION ....................................................................1
VEHICLE IDENTIFICATION NUMBER .................................................1
MODEL LABEL .....................................................................................1
SPECIFICATIONS ............................................................................................2
GENERAL SPECIFICATIONS ..................................................................2
MAINTENANCE SPECIFICATIONS .........................................................3
ENGINE ................................................................................................3
CHASSIS ..............................................................................................4
ELECTRICAL ........................................................................................4
CABLE ROUTING .....................................................................................6
PERIODIC CHECKS AND ADJUSTMENTS ..................................................15

INTRODUCTION .....................................................................................15
PERIODIC MAINTENANCE/LUBRICATION ...........................................15
SEAT, CARRIER AND FENDERS ..........................................................17
FRONT BUMPER ...............................................................................17
FRONT GRILL AND FRONT FENDER ...............................................18
REAR FENDER AND FOOTREST BOARDS .....................................19
ENGINE ...................................................................................................21
SPEED LIMITER ADJUSTMENT ........................................................21
CLEANING THE AIR FILTER ELEMENT ...........................................22
CLEANING THE SPARK ARRESTER ................................................24
CHASSIS ........................................................................................................25
STEERING SYSTEM ..............................................................................25
HANDLEBAR ......................................................................................25
INSTALLING THE HANDLEBAR ........................................................27
GEN
MACHINE IDENTIFICATION INFO
EBS00009
GENERAL INFORMATION
MACHINE IDENTIFICATION
EBS00010
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number 1 is
stamped into the left side of the frame.
1
EBS00011
MODEL LABEL
The model label 1 is affixed to the frame. This
information will be needed to order spare
parts.
–1–
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
GENERAL SPECIFICATIONS
Model YFM80GT
Model code number: 2D31
Dimensions:
Overall length 1,550 mm (61.0 in)
Overall width 855 mm (33.7 in)
Overall height 930 mm (36.6 in)
Seat height 665 mm (26.2 in)
Wheelbase 1,030 mm (40.6 in)
Minimum ground clearance 100 mm (3.94 in)
Basic weight:
With oil and full fuel tank 124 kg (273 lb)
Minimum turning radius: 2,400 mm (94.5 in)
Oil type or grade:
Engine oil API service SE, SF, SG type or higher
0° 10° 30° 50° 70° 90° 110° 130°F
YAMALUBE 4 (20W40) or SAE 20W40
YAMALUBE 4 (10W30) or SAE 10W30
SAE 5W30
-20° -10° 0° 10° 20° 30° 40° 50°C
Final gear oil SAE80 API GL-4 Hypoid gear oil

Spark plug:
Type/Manufacture CR7HSA/NGK
Spark plug gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
Tire pressure:
Maximum load* 95.0 kg (209 lb)
Off-road riding front 17.0 ~ 23.0 kPa
(0.17 ~ 0.23 kgf/cm2, 2.5 ~ 3.3 psi)
rear 17.0 ~ 23.0 kPa
(0.17 ~ 0.23 kgf/cm2, 2.5 ~ 3.3 psi)
*Load in total weight of cargo, rider and
accessories
Bulb voltage/wattage × quantity:
Neutral 12 V 1.7 W × 1
–2–
MAINTENANCE SPECIFICATIONS SPEC
MAINTENANCE SPECIFICATIONS
ENGINE
Model YFM80GT
Carburetor:
I.D. mark 5TH1 00
Main jet (M.J.) #76.3
Main air jet (M.A.J.) ø1.2
Jet needle (J.N.) 3PZ13-2
Needle jet (N.J.) D-8M
Cutaway (C.A.) 3.5
Pilot outlet (P.O.) 0.7
Pilot jet (P.J.) #12.5
Valve seat size (V.S) 1.2
Fuel level (F.L) 2.5 ~ 4.5 mm (0.10 ~ 0.18 in)
(Below carburetor body edge)
Float height (F.H.) 20.0 ~ 22.0 mm (0.79 ~ 0.87 in)
Engine idle speed 1,750 ~ 1,850 r/min
Intake vacuum 36.0 kPa (270 mmHg, 10.6 inHg)
Tightening torques
Parts Thread Tightening torque

Part to be tightened Q’ty Remarks
name size Nm m · kg ft · lb
Cylinder head Bolt M6 2 10 1.0 7.2
Camshaft sprocket cover Screw M6 2 7 0.7 5.1
Timing chain tensioner cap Plug M18 1 18 1.8 13
Intake manifold Screw M6 2 7 0.7 5.1
Spark arrester tailpipe Screw M6 2 8 0.8 5.8
Muffler purging bolt Bolt M6 1 10 1.0 7.2
Bearing cover plate Screw M6 2 8 0.8 5.8
Shift drum stopper lever Bolt M6 1 10 1.0 7.2 LT
Final gear case bearing retainer Nut M55 1 80 8.0 58 LT
Final gear bearing housing Bolt M6 6 20 2.0 14 LT
Bolt M8 4 20 2.0 14
Neutral switch — M10 1 20 2.0 14
–3–
CHASSIS
Model YFM80GT
Brake lever and brake pedal:
Front brake lever free play (pivot) 10.0 ~ 12.0 mm (0.39 ~ 0.47 in)
Rear brake lever free play (pivot) 5.0 ~ 8.0 mm (0.20 ~ 0.31 in)
Brake pedal free play 20.0 ~ 30.0 mm (0.79 ~ 1.18 in)
Throttle lever free play 3.0 ~ 5.0 mm (0.118 ~ 0.197 in)
Tightening torques
Tightening torque
Part to be tightened Thread size Remarks
Nm m · kg ft · lb
Lower arm and frame M12 60 6.0 43
Tie-rod and locknut M10 15 1.5 11
Steering shaft and frame M10 35 3.5 25
Steering shaft and handlebar holder M8 20 2.0 14
Front brake camshaft lever M6 9 0.9 6.5
Rear brake camshaft lever M6 9 0.9 6.5
Rear wheel and wheel hub M8 28 2.8 20
Footrest, brake pedal and frame M8 16 1.6 11
Front bumper and front fender M6 7 0.7 5.1
Front bumper and frame M8 23 2.3 17
Front fender and front grill M6 7 0.7 5.1
Front fender and frame M6 7 0.7 5.1
Rear carrier and frame M8 23 2.3 17
Footrest board and footrest bracket M6 10 1.0 7.2
Footrest bracket and frame M8 21 2.1 15
Rear fender and frame M6 7 0.7 5.1
ELECTRICAL
Model YFM80GT
C.D.I.:
Magneto model/manufacturer F2FM/MORIC
Pickup coil resistance/color 264 ~ 396 Ω at 20°C (68°F)/
White/Blue–White/Red
Source coil resistance/color 304 ~ 456 Ω at 20°C (68°F)/
Green/White–Black/Red
C.D.I.unit model/manufacturer 4EM/MORIC
A.C. magneto:
Standard output 14.0 V 45 W at 5,000 r/min
Charging coil resistance/color 0.72 ~ 1.08 Ω at 20°C (68°F)/
White–Black
Lighting coil resistance/color 0.32 ~ 0.48 Ω at 20°C (68°F)/
Yellow/Red–Black
–4–
Model YFM80GT
Rectifier/regulator:
Regulator type Semi conductor-short circuit
Model/manufacturer SH723AA/SHINDENGEN
No load regulated voltage (DC) 14.0 ~ 15.0 V
No load regulated voltage (AC) 12.8 ~ 13.8 V
Rectifier capacity (DC) 8.0 A
Rectifier capacity (AC) 8.0 A
Electric starter system:
Type Constant mesh type
Starter motor: Model/manufacturer ADB4A5/DENSO
Output 0.20 kW
Armature coil resistance 0.0288 ~ 0.0352 Ω at 20°C (68°F)
Brush: Overall length 6.0 mm (0.24 in)
<Limit> <3.50 mm (0.14 in)>
Spring force 3.24 ~ 4.22 N (330 ~ 430 gf, 11.66 ~ 15.19 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 MS5D-611/JIDECO
Amperage rating 100A
Coil winding resistance 3.87 ~ 4.73 Ω at 20°C (68°F)
Starting circuit cut-off relay:
Model/manufacturer ACA12115-3/MATSUSHITA
Coil winding resistance 72 ~ 88 Ω at 20°C (68°F)
Diode Yes
–5–
CABLE ROUTING SPEC
EBS00028
CABLE ROUTING
1 Rear brake cable 0 Positive battery lead I Left front brake cable
2 Throttle cable A Wire harness J Frame
3 Fuel tank breather hose B Negative battery lead
4 Carburetor air vent hose C Rectifier/regulator
5 Crankcase breather hose D Battery breather hose
6 Final gear case breather hose E Starter motor lead
7 Fuel hose F C.D.I. magnet leads
8 Starter relay G Fuel overflow hose
9 Starting circuit cut-off relay H Right front brake cable
Ø
J
8
×
A-A
É 3
B
Ê
2 4
1
È 5
Ë
Ö 6 C
Í
7
Õ Ì
89 0A
B
A
B A
Ô Î
Ï
D Ð
I Ó FÒ E Ñ
H G
–6–
CABLE ROUTING SPEC
È Route the rear brake cable to the right of the Ë Route the final gear case breather hose to the
steering stem. right of the ignition coil.
É Pass the fuel tank breather hose through the Ì Align the white tape of the wire harness with the
hole in the handlebar cover. bracket.
Ê Pass the carburetor air vent hose through the Í 200 mm (7.87 in)
hole on the left side of the steering stem bracket Î To starter motor
and then insert the hose between the bracket Ï Pass the final gear case breather hose through
and frame. Make sure that there is no slack or the hose guide.
bends in the hose. Do not route the hose over
the throttle cable.
Ø
J
8
×
A-A
É 3
B
Ê
2 4
1
È 5
Ë
Ö 6 C
Í
7
Õ Ì
89 0A
B
A
B A
Ô Î
Ï
D Ð
I Ó FÒ E Ñ
H G
–7–
CABLE ROUTING SPEC
Ð Pass the battery breather hose through the hole. Ô Route the cables under the frame.
Ñ Install both the negative battery lead terminal Õ Route the front brake cables to the left of the
and the starter motor to the bolt hole shown in steering stem. Route the left front brake cable to
the crankcase. Install the negative battery lead the right of the air filter joint. Route the right front
terminal on the right side of the bolt hole with the brake cable to the left of the air filter joint.
lead routed towards the left side of the machine. Ö To front fender
Ò To wire harness × 45°
Ó Fasten the fuel overflow hose with a plastic band, Ø 25° ~ 35°
making sure not to pinch the hose. The end of the Install the positive battery lead terminal to the
plastic band should be on the side of the frame starter relay, making sure that the lead does not
towards the rear of the machine, facing inward. contact the frame.
Ø
J
8
×
A-A
É 3
B
Ê
2 4
1
È 5
Ë
Ö 6 C
Í
7
Õ Ì
89 0A
B
A
B A
Ô Î
Ï
D Ð
I Ó FÒ E Ñ
H G
–8–
CABLE ROUTING SPEC
1 Rear brake cable B Fuel tank breather hose
2 Wire harness C Throttle cable
3 Frame ground lead D Front brake cables
4 Ignition coil E Crankcase breather hose
5 Handlebar switch lead
6 Neutral indicator light lead
7 Rear brake switch lead
8 Final gear case breather hose
9 C.D.I. unit lead
0 C.D.I. unit
A Fuel hose
C 7
B D
8
E
Ñ
Ò
5
1
C-C
Ð A-A 6
B
5
Ë B
Ì 6
34
12 Ê 7
É A Í
È Î
8
C C
A
9 Ï
0
A
–9–
CABLE ROUTING SPEC
È Fasten the rear brake cable, wire harness, Ì Fasten the main switch lead, handlebar switch
crankcase breather hose, and final gear case lead, rear brake switch lead, neutral indicator
breather hose with a plastic band. Be sure to not light lead, C.D.I. unit lead, and final gear case
pinch the hoses. breather hose with a plastic band. Install the
É 10 mm (0.39 in) plastic band with its buckle facing outward and
Ê Fasten the rear brake cable and wire harness its end facing forward.
near the ignition coil with a plastic locking tie. Í To main switch
Ë Route the final gear case breather hose and
crankcase breather hose over the wire harness.
Fasten the hoses with a plastic band. Be sure to
not pinch the hoses.
C 7
B D
8
E
Ñ
Ò
5
1
C-C
Ð A-A 6
B
5
Ë B
Ì 6
34
12 Ê 7
É A Í
È Î
8
C C
A
9 Ï
0
A
– 10 –
CABLE ROUTING SPEC
Î Route the crankcase breather hose and final
gear case breather hose under the frame cross
member.
Ï Fasten the final gear case breather hose with a
plastic band.
Ð The end of the plastic band should be under the
frame, facing inward.
Ñ Forward
Ò 45°
C 7
B D
8
E
Ñ
Ò
5
1
C-C
Ð A-A 6
B
5
Ë B
Ì 6
34
12 Ê 7
É A Í
È Î
8
C C
A
9 Ï
0
A
– 11 –
CABLE ROUTING SPEC
1 Rear brake switch
2 Rear brake cable
3 Right front brake cable
4 Left front brake cable
5 Throttle cable
6 Fuel tank breather hose
7 Negative battery lead
8 Main fuse
9 Positive battery lead
0 Battery band
A Handlebar switch
3
2
1 4
Ì 5
6
Í Î A
A
0
7È
Ë
9
8 B
B
9
7 Ê
B-B É
– 12 –
CABLE ROUTING SPEC
È To starter motor Î Connect the positive battery lead to the battery
É Pass the negative battery lead through the hole so that the lead contacts the battery case.
in the rear fender.
Ê Pass the leads through the hole.
Ë To starter relay
Ì Fasten the handlebar switch lead and rear brake
switch lead with a plastic band.
Í Connect the negative battery lead to the battery
so that the lead is routed to the side of the bat-
tery.
3
2
1 4
Ì 5
6
Í Î A
A
0
7È
Ë
9
8 B
B
9
7 Ê
B-B É
– 13 –
CABLE ROUTING SPEC
1 Throttle cable È Route the front brake cables to the left of the
2 Fuel tank breather hose steering stem. Route the left front brake cable to
3 Rear brake cable the right of the air filter joint. Route the right front
4 Handlebar switch lead brake cable to the left of the air filter joint.
5 Rear brake switch lead É Fasten the handlebar switch lead and rear brake
6 Air filter joint switch lead with a plastic band.
7 Neutral indicator light lead Ê Pass the neutral indicator light leads through the
8 Right front brake cable cutout in the damper.
9 Left front brake cable Ë Forward
0 Damper
2 3
9
8 4
5
0
A A
É
Ë
9 3
7
8
1
0
5
Ê
4
A-A
– 14 –
INTRODUCTION/ CHK
PERIODIC MAINTENANCE/LUBRICATION ADJ
EBS00029
PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION
This chapter includes all information necessary to perform recommended checks and adjustments.
These preventive maintenance procedures, if followed, will ensure more reliable machine operation
and a longer service life. The need for costly overhaul work will be greatly reduced. This information
applies to machines already in service as well as to new machines that are being prepared for sale.
All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION
NOTE:
• For ATVs not equipped with an odometer or an hour meter, follow the month maintenance inter-
vals.
• For ATVs equipped with an odometer or an hour meter, follow the km (mi) or hours maintenance
intervals. However, keep in mind that if the ATV isn’t used for a long period of time, the month
maintenance intervals should be followed.
INITIAL EVERY
Whichever month 1 3 6 6 12
ITEM ROUTINE comes first km 320 1,200 2,400 2,400 4,800
(mi) (200) (750) (1,500) (1,500) (3,000)
hours 20 75 150 150 300
• Check valve clearance.
Valves*
• Adjust if necessary.
• Check chain tension.
Cam chain*
• Check condition.
Spark plug • Adjust gap and clean.
• Replace if necessary.
• Clean. Every 20 ~ 40 hours
Air filter element
• Replace if necessary. (more often in wet or dusty areas)
• Check idle speed/choke lever operation.
Carburetor*
Crankcase breather • Check breather hose for cracks or damage.
system* • Replace if necessary.
• Check for leakage.
Exhaust system* • Tighten if necessary.
• Replace gasket if necessary.
Spark arrester • Clean.
• Check fuel hose for cracks or damage.
Fuel line*
Engine oil • Replace (warm engine before draining).
• Check oil level/oil leakage.
Final gear oil
• Replace every 12 months.
• Check operation.
Brakes*
Clutch*
• Check balance/damage/runout.
Wheels*
• Check bearing assemblies for looseness/damage.
Wheel bearings*
• Replace if damaged.
Steering system*
• Check toe-in.
– 15 –
CHK
PERIODIC MAINTENANCE/LUBRICATION ADJ
INITIAL EVERY
Whichever month 1 3 6 6 12
ITEM ROUTINE comes first km 320 1,200 2,400 2,400 4,800
(mi) (200) (750) (1,500) (1,500) (3,000)
hours 20 75 150 150 300
Knuckle shafts/ • Lubricate every 6 months with lithium-soap-based
steering shaft* grease.
Fittings and fasten- • Check all chassis fittings and fasteners.
ers* • Correct if necessary.
• Check specific gravity.
Battery* • Check breather hose for correct routing.
• Correct if necessary.
* Since these items require special tools, data and technical skills, have a Yamaha dealer perform
the service.
WARNING
_
Indicates a potential hazard that could result in serious injury or death.
– 16 –
CHK
SEAT, CARRIER AND FENDERS ADJ
SEAT, CARRIER AND FENDERS
FRONT BUMPER
1
2
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)

T.
R.
4
7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)

T.
R.
Order Job/Part Q’ty Remarks

Removing the front bumper Remove the parts in the order listed.
1 Fuel tank breather hose 1
2 Handlebar cover 1 NOTE:
Pass the neutral indicator light leads
through the cutout in the damper.
3 Neutral indicator light connector 2 Disconnect.

4 Front bumper 1
5 Front fender panel 1
For installation, reverse the removal pro-
cedure.
– 17 –
CHK
FRONT GRILL AND FRONT FENDER
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
2
5
(6)
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
R.
4 (6)

Removing the front grill and front Remove the parts in the order listed.
fender
Front bumper and front fender panel Refer to “FRONT BUMPER”.
1 Main switch 1 Disconnect.
2 Air filter cover 1
3 Front grill 1
4 Air duct 1 Disconnect.
5 Front fender 1
cedure.
– 18 –
CHK
EBS00039
REAR FENDER AND FOOTREST BOARDS
10 Nm (1.0 m • kg, 7.2 ft • Ib) 1

T.
R.
4
3
8 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
7 2
9
10
6
5
T
(6)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
(6)
(6)

Removing the rear fender and foot- Remove the parts in the order listed.
rest boards
Front fender panel Refer to “FRONT BUMPER”.
1 Seat 1 NOTE:
Pull the seat lock lever backward, then
pull up the seat at the rear.
2 Rear carrier 1
3 Battery band 1
4 Negative battery lead 1 Disconnect.
CAUTION:
_
First disconnect the negative lead,

then disconnect the positive lead.
5 Positive battery lead 1 Disconnect.
– 19 –
CHK
10 Nm (1.0 m • kg, 7.2 ft • Ib) 1

T.
R.
4
3
8 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
R.
23 Nm (2.3 m • kg, 17 ft • Ib)
T.
R.
7 2
9
10
6
5
T
(6)
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
(6)
(6)

6 Main fuse 1
7 Battery breather hose 1 Disconnect.
8 Battery 1
9 Footrest board 2
10 Rear fender 1
cedure.
– 20 –
CHK
SPEED LIMITER ADJUSTMENT ADJ
ENGINE
SPEED LIMITER ADJUSTMENT
The speed limiter keeps the carburetor throttle
from becoming fully-opened even when the
throttle lever is applied to the maximum posi-
tion. Screwing in the adjuster stops the engine
speed from increasing.
1. Check:
• speed limiter length a
Out of specification → Adjust.
a
Speed limiter length
20 mm (0.8 in)
2. Adjust:
• speed limiter length
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Loosen the locknut 1.
b. Turn the adjuster 2 in or out until the speci-
fied speed limiter length is obtained.
1 Speed limiter length is

Turning in
decreased.
2
Speed limiter length is
Turning out
increased.
c. Tighten the locknut.
WARNING
• Particularly for a beginner rider, the
speed limiter should be screwed in com-
pletely. Screw it out little by little as their
riding technique improves. Never remove
the speed limiter for a beginning rider.
• For proper throttle lever operation do not
turn out the adjuster more than 20 mm
(0.8 in). Also, always adjust the throttle
lever free play to 3.0 ~ 5.0 mm (0.118 ~
0.197 in).
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
– 21 –
SPEED LIMITER ADJUSTMENT/ CHK
CLEANING THE AIR FILTER ELEMENT ADJ
• Air intake restrictor plate removal
Refer to “CLEANING THE AIR FILTER
1 ELEMENT”.
NOTE:
To obtain full engine performance capability,
removing the air intake restrictor plate 1 is
required. Since removal of this plate will result
in a significant increase in power, turn the
speed limiter completely back in again.
EBS00071
CLEANING THE AIR FILTER ELEMENT
NOTE:
_
There is a check hose 1 at the bottom of the

air filter case. If dust and/or water collects in
1 this hose, clean the air filter element and air fil-
ter case.
1. Remove:
• front fender panel
Refer to “FRONT BUMPER”.
2. Remove:
• air filter cover 1
1
3. Disconnect:
4 • rubber band 1
3
4. Remove:
2 • air filter element guide 2
1 • air filter element 3
• air intake restrictor plate 4
CAUTION:
_
The engine should never be run without the

air filter element; excessive piston and/or
cylinder wear may result.
5. Check:
• air filter element
Damaged → Replace.
– 22 –
CHK
CLEANING THE AIR FILTER ELEMENT ADJ
6. Clean:
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wash the element gently, but thoroughly in
solvent.
WARNING
_
Use a cleaning solvent which is designed

to clean parts only. Never use gasoline or
low flash point solvents as they may cause
a fire or explosion.
b. Squeeze the excess solvent out of the ele-

ment and let it dry.
CAUTION:
_
Do not twist or wring out the element. This

could damage the foam material.
c. Apply engine oil to the element.

d. Squeeze out the excess oil.
NOTE:
_
The element should be wet but not dripping.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
7. Install:
• air filter element guide
8. Connect:
• rubber band
9. Install:
• air filter cover
NOTE:
_
Make sure its sealing surface matches the

sealing surface of the case so there is no air
leak.
10.Install:
• front fender panel
Refer to “FRONT BUMPER”.
– 23 –
CHK
CLEANING THE SPARK ARRESTER ADJ
CLEANING THE SPARK ARRESTER
1. Clean:
• spark arrester
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
1
WARNING
• Select a well-ventilated area free of com-
2
bustible materials.
• Always let the exhaust system cool
before performing this operation.
• Do not start the engine when removing
the tailpipe from the muffler.
2
a. Remove the screws 1.
b. Remove the tailpipe 2 by pulling it out of
the muffler.
c. Tap the tailpipe lightly with a soft-face ham-
mer or suitable tool, then use a wire brush
to remove any carbon deposits from the
spark arrester portion of the tailpipe and the
inner contact surfaces of the muffler.
d. Insert the tailpipe into the muffler and align
the screw holes.
e. Insert the screws and tighten them.
Screw
8 Nm (0.8 m · kg, 5.8 ft · lb)
T.
R.
3 f. Remove the purging bolt 3.

g. Start the engine and rev it up approximately
twenty times while momentarily creating
exhaust system back pressure by blocking
the end of the muffler with a shop towel.
h. Stop the engine and allow the exhaust pipe
to cool.
i Install the purging bolt 3 and tighten it.
Bolt
10 Nm (1.0 m · kg, 7.2 ft · lb)
T.
R.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
– 24 –
STEERING SYSTEM CHAS
CHASSIS
EBS00444
STEERING SYSTEM
HANDLEBAR

Removing the handlebar Remove the parts in the order listed.
Handlebar cover Refer to “SEAT, CARRIER AND FEND-
ERS”.
1 Handlebar grip 2
2 Front brake cable 2
3 Front brake lever assembly 1
4 Handlebar switch 1
5 Rear brake cable 1
6 Rear brake switch 1
7 Rear brake lever 1
8 Plastic band 1
9 Short tube 1
10 Upper handlebar holder 2
11 Handlebar 1
– 25 –

12 Lower handlebar holder 1
13 Damper 1
cedure.
– 26 –
EBS00449
INSTALLING THE HANDLEBAR
1. Install:
• lower handlebar holder
• handlebar
2
• upper handlebar holders
• bolts 20 Nm (2.0 m · kg, 14 ft · lb)
T.
R.
1 • short tube 1
NOTE:
Install the short tube 1 onto the end of the left
front handlebar holder bolt until it contacts the
top of the steering column 2.
– 27 –
EB002000

MANUAL ORGANIZATION
This manual consists of chapters for the main categories of subjects. (See “Illustrated symbols”)
1st title 1: This is the title of the chapter with its symbol in the upper right corner of each page.
2nd title 2: This title indicates the section of the chapter and only appears on the first page of each
section. It is located in the upper left corner of the page.
3rd title 3: This title indicates a sub-section that is followed by step-by-step procedures accompa-
nied by corresponding illustrations.
EXPLODED DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of each
removal and disassembly section.
1. An easy-to-see exploded diagram 4 is provided for removal and disassembly jobs.
2. Numbers 5 are given in the order of the jobs in the exploded diagram. A number that is enclosed
by a circle indicates a disassembly step.
3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks
6. The meanings of the symbol marks are given on the next page.
4. A job instruction chart 7 accompanies the exploded diagram, providing the order of jobs, names
of parts, notes in jobs, etc.
5. For jobs requiring more information, the step-by-step format supplements 8 are given in addition
to the exploded diagram and the job instruction chart.
EB003000
1 2
ILLUSTRATED SYMBOLS
GEN Illustrated symbols 1 to 9 are printed on the
INFO SPEC top right of each page and indicate the subject
of each chapter.
3 4
1 General information
2 Specifications
CHK 3 Periodic checks and adjustments
ADJ ENG 4 Engine
5 Carburetion
5 6
6 Drive train
7 Chassis
8 Electrical
CARB DRIV 9 Troubleshooting
7 8
– +
CHAS ELEC
9 0 Illustrated symbols 0 to F are used to identify
TRBL 0 Filling fluid
SHTG A Lubricant
B Special tool
A B C Torque
D Wear limit, clearance
E Engine speed
F Ω, V, A
C D
T.
R.
E F
Illustrated symbols G to M in the exploded

G H I
diagrams indicate the types of lubricants and
lubrication points.
E G M G Apply engine oil
H Apply gear oil
J K L M I Apply molybdenum disulfide oil
J Apply wheel bearing grease
B LS M S K Apply lightweight lithium soap base grease
L Apply molybdenum disulfide grease
M Apply silicon grease
N O Illustrated symbols N to O in the exploded
diagrams indicate where to apply a locking
LT
New agent N and when to install a new part O.
N Apply the locking agent (LOCTITE)
O Replace
CONTENTS
GENERAL INFORMATION .............................................................................. 1

MACHINE IDENTIFICATION ................................................................... 1
VEHICLE IDENTIFICATION NUMBER ................................................ 1
MODEL LABEL .................................................................................... 1
SPECIFICATIONS ........................................................................................... 2
GENERAL SPECIFICATIONS ................................................................. 2
MAINTENANCE SPECIFICATIONS ........................................................ 3
ENGINE ................................................................................................ 3
CHASSIS .............................................................................................. 3
ELECTRICAL ....................................................................................... 4
CABLE ROUTING .................................................................................... 5
PERIODIC CHECKS AND ADJUSTMENTS ................................................... 9

INTRODUCTION ...................................................................................... 9
PERIODIC MAINTENANCE/LUBRICATION INTERVALS ....................... 9
SEAT, FENDERS AND FUEL TANK ...................................................... 10
SEAT AND FRONT PANEL ............................................................... 10
FRONT FENDER ............................................................................... 11
REAR FENDER .................................................................................. 12
FUEL TANK ........................................................................................ 13
ENGINE .................................................................................................. 14
SPEED LIMITER ADJUSTMENT ....................................................... 14
AIR FILTER CLEANING ..................................................................... 15
SPARK ARRESTER CLEANING ....................................................... 17
GEN
MACHINE IDENTIFICATION INFO
GENERAL INFORMATION
The vehicle identification number 1 is
MODEL LABEL
The model label 1 is affixed to the frame. This
information will be needed to order spare
parts.
–1–
GENERAL SPECIFICATIONS SPEC
SPECIFICATIONS
Model YFM80WP
Model code number: 5TH1
Dimensions:
Overall height 940 mm (37 in)
Minimum ground clearance 100 mm (3.9 in)
Spark plug:
Type/Manufacturer CR7HS (NGK)
Gap 0.6 ~ 0.7 mm (0.024 ~ 0.028 in)
Tire pressure (cold tire): Front Rear
Recommended 20 kPa 20 kPa
(0.20 kg/cm2, 2.8 psi) (0.20 kg/cm2, 2.8 psi)
Minimum 17 kPa 17 kPa
2
(0.17 kg/cm , 2.4 psi) (0.17 kg/cm2, 2.4 psi)
Maximum 23 kPa 23 kPa
2
(0.23 kg/cm , 3.2 psi) (0.23 kg/cm2, 3.2 psi)
Maximum load-except motorcycle 95 kg
Indicator light wattage × quantity:
“NEUTRAL” 12 V 1.7 W × 1
–2–
ENGINE
Model YFM80WP
Carburetor:
Type/manufacturer/quantity VM16SH/MIKUNI/1
I. D. mark 5TH1 00
Main jet (M.J.) #76.3
Main air jet (M.A.J.) ø1.2
Jet needle-clip position (J.N.) 3PZ 13-2
Needle jet (N.J.) D-8M
Cutaway (C.A.) 3.5
Pilot outlet (P.O.) ø0.7
Valve seat (V.S.) ø1.2
Fuel level (F.L.) 2.5 ~ 4.5 mm (0.10 ~ 0.18 in)
Below carburetor body edge
Float height (F.H.) 20.0 ~ 22.0 mm (0.79 ~ 0.87 in)
Engine idling speed 1,750 ~ 1,850 r/min
Intake vacuum 36 kPa (270 mmHg)
CHASSIS
Model YFM80WP
Brake lever & brake pedal:
Brake lever free play (front brake) 10 ~ 12 mm (0.4 ~ 0.5 in) at lever pivot
Brake lever free play (rear brake) 5 ~ 8 mm (0.20 ~ 0.31 in) at lever pivot
Brake pedal free play 20 ~ 30 mm (0.8 ~ 1.2 in)
–3–
ELECTRICAL
Model YFM80WP
CDI:
Magneto model/manufacturer F2FM/MORIC
Pickup coil resistance (color) 264 ~ 396 Ω at 20°C (68°F) (W/L–W/R)
Source coil resistance (color) 304 ~ 456 Ω at 20°C (68°F) (G/W–B/R)
Lighting coil resistance (color) 0.72 ~ 1.08 Ω B–W
0.32 ~ 0.48 Ω B–Y/R
CDI unit model/manufacturer 4EM/MORIC
Ignition coil:
Model/manufacturer 2JN/MORIC
Minimum spark gap 6 mm (0.24 in)
Primary winding resistance 0.184 ~ 0.276 Ω at 20°C (68°F)
Secondary winding resistance 6.32 ~ 9.48 Ω at 20°C (68°F)
Type Semi conductor-short circuit
Model/manufacturer SH704-12/SHINDENGEN
No load regulated voltage (DC) 14 ~ 15 V
(AC) 13 ~ 14 V
Capacity (DC) 5A
(AC) 8A
Withstand voltage 200 V
Starter motor: Model/manufacturer ADB4A5/DENSO
Out put 0.2 kW
Armature coil resistance 0.0288 ~ 0.0352 Ω at 20°C (68°F)
Brush: Overall length 6 mm (0.24 in)
<Limit> <3.5 mm (0.14 in)>
Spring pressure 3.24 ~ 4.22 N (330 ~ 430 gf)
<Wear limit> <15.5 mm (0.61 in)>
Starter relay: Model/manufacturer MS5D-611/JIDECO
Amperage rating 100A
Coil winding resistance 3.87 ~ 4.73 Ω at 20°C (68°F)
Model/manufacturer ACA12115-3/MATSUSHITA
Coil winding resistance 72 ~ 88 Ω at 20°C (68°F)
Diode Yes
–4–
CABLE ROUTING SPEC
CABLE ROUTING
1 Throttle cable A Battery breather hose
2 Fuel tank breather hose B CDI magneto lead
3 Carburetor ventilation hose C Carburetor overflow hose
4 Final gear case breather hose D Front brake cable (right)
5 Crankcase breather hose E Front brake cable (left)
6 Fuel hose
7 Band È Pass the final gear case breather hose through
8 Starter relay the guide.
9 Starting circuit cut-off relay É Pass the battery breather hose through the hole.
0 Rectifier/regulator
–5–
CABLE ROUTING SPEC
1 Rear brake cable C Throttle cable
2 Band
3 Wireharness
4 Ignition coil
7 “NEUTRAL” indicator light lead
8 Main switch
9 CDI unit
0 Fuel hose
A Front brake cable
B Fuel tank breather hose
–6–
CABLE ROUTING SPEC
2 Throttle cable
3 Front brake cable (left)
4 Front brake cable (right)
5 Air filter joint
8 “NEUTRAL” indicator light lead
9 Rear brake cable
–7–
CABLE ROUTING SPEC
1 Front brake cable È Pass the leads through the hole.
2 Throttle cable
4 Battery negative lead
5 Fuse
6 Battery positive lead
7 Band
8 Handlebar switch
9 Rear brake switch
0 Rear brake cable
–8–
INTRODUCTION/PERIODIC MAINTENANCE/ CHK
LUBRICATION INTERVALS ADJ
EB300000
PERIODIC CHECKS AND ADJUSTMENTS

INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and adjust-
ments. 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 to new vehicles that are being prepared
for sale. All service technicians should be familiar with this entire chapter.
EB301000
PERIODIC MAINTENANCE/LUBRICATION INTERVALS

INITIAL EVERY
ITEM ROUTINE 1 3 6 6 1
month months months months year
• Check valve clearance.
Valves*
• Check chain tension.
Cam chain*
• Check condition.
Spark plug • Adjust gap and clean.
• Clean. Every 20 ~ 40 hours
Air filter element
• Replace if necessary. (more often in wet or dusty areas.)
• Check idle speed/choke lever operation.
Carburetor*
Crankcase breather • Check breather hose for cracks or damage.
system* • Replace if necessary.
• Check for leakage.
Exhaust system* • Retighten if necessary.
• Replace gasket if necessary.
Spark arrester • Clean.
• Check fuel hose for cracks or damage.
Fuel line*
Engine oil • Replace (warm engine before draining).
• Check oil level/oil leakage.
Final gear oil
• Replace every 12 months.
Brakes*
Clutch*
• Check balance/damage/runout.
Wheels*
• Check bearing assemblies for looseness/damage.
Wheel bearings*
• Repair if damaged.
Steering system*
• Check toe-in.
Knuckle shafts/
• Lubricate every 6 months.**
steering shaft*
Fittings and fasten- • Check all chassis fittings and fasteners.
ers* • Correct if necessary.
• Check specific gravity.
Battery* • Check breather hose for correct routing.
• Correct if necessary.
* It is recommended that these items be serviced by a Yamaha dealer.

** Lithium-soap-based grease.
–9–
CHK
SEAT, FENDERS AND FUEL TANK ADJ
SEAT, FENDERS AND FUEL TANK
SEAT AND FRONT PANEL
3 1
Order Job name/Part name Q’ty Remarks

Removing the seat and front panel Remove the parts in the order below.
1 Seat 1 NOTE:
Pull back the seat lock lever, than pull up
on the rear of the seat.
2 Front panel 1
3 Fuel tank breather hose 1
4 Handlebar cover 1
5 Neutral indicator light leads 2 Disconnect
For installation, reverse the removal
procedure.
– 10 –
CHK
FRONT FENDER
7 Nm (0.7 m • kg, 5.1 ft • Ib)

T.
3
R.

Removing the front fender Remove the parts in the order below.
Seat and front panel Refer to “SEAT AND FRONT PANEL”.
1 Fuel tank top panel 1
2 Air cleaner joint clamp screw 1 Loosen
3 Main switch 1
4 Front fender 1
procedure.
– 11 –
CHK
REAR FENDER
7 Nm (0.7 m • kg, 5.1 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib)
T.
T.
R.
3 R.
1
5
4 6
2
3

Removing the rear fender Remove the parts in the order below.
Seat Refer to “SEAT AND FRONT PANEL”.
Front fender Refer to “FRONT FENDER”.
1 Battery band 1
2 Main fuse 1
3 Battery lead 2 Disconnect.
CAUTION:
First disconnect the negative lead,
then disconnect the positive lead.
4 Battery breather hose 1
5 Battery 1
6 Rear fender 1
procedure.
– 12 –
CHK
FUEL TANK
10 Nm (1.0 m • kg, 7.2 ft • Ib)
T.
R.
1

Removing the fuel tank Remove the parts in the order below.
Seat and front panel Refer to “SEAT AND FRONT PANEL”.
Front fender Refer to “FRONT FENDER”.
1 Fuel hose 1 NOTE:
Before disconnecting the fuel hose, turn
the fuel cock to “OFF”.
2 Fuel tank 1
procedure.
– 13 –
CHK
SPEED LIMITER ADJUSTMENT ADJ
ENGINE
The speed limiter keeps the carburetor throttle
from becoming fully-opened even when the
throttle lever is applied to the maximum posi-
tion. Screwing in the adjuster stops the engine
speed from increasing.
1.Check:
● Speed limiter length a
Out of specification → Adjust.

a Speed limiter length:
Less than 20 mm (0.8 in)
2.Adjust:
● Speed limiter length
***********************************************
Speed limiter length adjustment steps:
● Loosen the locknut 1.
● Turn the adjuster 2 in or out until the speci-
1 fied speed limiter length is obtained.
2 Speed limiter length is

Turning in
decreased.
Speed limiter length is
Turning out
increased.
● Tighten the locknut.
WARNING
● Particularly for a beginner rider, the
speed limiter should be screwed in com-
pletely. Screw it out little by little as their
riding technique improves. Never remove
the speed limiter for a beginning rider.
● For proper throttle lever operation do not
(0.8 in). Also, always adjust the throttle
lever free play to 3 ~ 5 mm (0.12 ~ 0.20 in).
***********************************************
– 14 –
SPEED LIMITER ADJUSTMENT/ CHK
AIR FILTER CLEANING ADJ
● Air intake restrictor plate removal
Refer to “AIR FILTER CLEANING”.
1
NOTE:
To obtain full engine performance capability,
removing the air intake restrictor plate 1 is
required. Since removal of this plate will result
in a significant increase in power, turn the
speed limiter completely back in again.
AIR FILTER CLEANING

NOTE:
There is check hose 1 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
1
case.
1.Remove:
● Front panel
Refer to “SEAT, FENDERS AND FUEL

TANK”.
2.Remove:
● Air filter cover 1
3.Remove:
● Rubber band 2
4.Pull out the air filter element assembly.

5.Remove:
4 ● Guide
3 ● Air filter element 3
● Air intake restrictor plate 4
2
CAUTION:
– 15 –
CHK
AIR FILTER CLEANING ADJ
6.Check:
● Air filter element
Damage → Replace.
7.Clean:
***********************************************
Cleaning steps:
● Wash the element gently, but thoroughly in
solvent.
WARNING
Never use low flash point solvents such as
gasoline to clean the air filter element.
Such solvent may lead to a fire or explo-
sion.
● Squeeze the excess solvent out of the ele-
ment and let dry.
CAUTION:
Do not twist the filter element when
squeezing the filter element.
● Apply the engine oil.
● Squeeze out the excess oil.
NOTE:
***********************************************
8.Install:
NOTE:
Make sure its sealing surface matches the
leak.
– 16 –
CHK
SPARK ARRESTER CLEANING ADJ
SPARK ARRESTER CLEANING
1.Clean:
● Spark arrester
1
***********************************************
Cleaning steps:
2 WARNING
● Select a well-ventilated area free of com-
bustible materials.
● Always let the exhaust system cool
before performing this operation.
2 ● Do not start the engine when removing
the tailpipe from muffler.
● Remove the screws 1.
● Remove the tailpipe 2 by pulling it out of the
muffler.
● Tap the tailpipe lightly with a soft-face ham-
mer or suitable tool, then use a wire brush to
remove any carbon deposits from the spark
arrester portion of the tailpipe and the inner
contact surfaces of the muffler.
● Insert the tailpipe into the muffler and align
the bolt holes.
● Insert the bolt and tighten it.
● Remove the purging bolt 3.
● Start the engine and rev it up approximately
twenty times while momentarily creating
3 exhaust system back pressure by blocking
the end of the muffler with a shop towel.
● Stop the engine and allow the exhaust pipe
to cool.
● Install the purging bolt 3 and tighten it.
***********************************************
– 17 –
CONSTRUCTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See "Illustrated symbols")
1st titleCD: This is a chapter with its symbol on the upper right of each page.
2nd title ®: This title appears on the upper of each page on the left of the chapter sym-
bol. (For the chapter "Periodic inspection and adjustment" the 3rd title
appears.)
3rd title @: This is a final title.
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 inspections.
A set of particularly important procedure @ is placed between a line of asterisks "." with each pro-
cedure preceded by"e".
IMPORTANT FEATURES
• Data and a special tool are framed in a box preceded by a relevant symbol @.
• An encircled numeral ® indicates a part name, and an encircled alphabetical letter data or an
alignment mark (J), the others being indicated by an alphabetical letter in a box @.
• A condition of a faulty component will precede an arrow symbol ® and the course of action will
follow it.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section. for ease in identifying
correct disassembly and assembly procedures.
~~r=~-=~~==~~~----------~~~
ICHAS!'~.' I _ _ _ _ _ _ _'RONTFORK
.C ...n .....tl I INSPfCTIQfII

u •• ,,,.<: ••"., •••••,,•••,,",IOO' J
• Inn,., ,,,b.. ,
Iti
I,,,~
C'~:~;:-~""ln.IC" ·U..,.. , I,,,~ ,,,b.. :

!!BIIIIIIIII _ __
00_.,11 ...."11.111 ••,,1'11.".".,,., __
fO •• lull• • • ' .... _ y d ..........ly ••••• "
Ih., ....
INSPECTION AND REPAIR
·C.,bondaPOI.1I
U".'ounMdlc,.",
NOTE-----
T••• c: ••• 'Oh.. 'ded.......... th • • p ... II ....
L..-_ _ _----' ::;:=:C.:h:::l~:: . .';,,:';," '".",,-
_"'.I'."
.An . . . . .' ........... I .........OC.M -- _
r--~~~~~~ .::.=I!.:~:;:.....,.'h ....
I
.If , ............. 0 ..1 of ....c,hc.' ....... .
...., • • , ... c ............
8
L..-_ _ _ --=.=- ."*•• 400 1OO.'I ••'NncII....... _
I~~ :ifr-::::"-==-:.: mo",,,,,_ much "''''''''''0'''_''

....................................
.
~c••" ....
y ........ C ...." ...b. ••
.........."1
CD ® ILLUSTRATED SYMBOLS
(Refer to the illustration)
@
II~~~I"'I ISPECI ~I@
Illustrated symbols CD to ® are designed as
thumb tabs to indicate the chapter's number
and content.
CD General information
II:gSI'l1 ENG ~. ttl
® Specifications
@ Periodic inspections and adjustments
@ Engine overhaul
*.
® ® ® Carburetion
® Drive train
ICARBIIiII 1ORIV 1 1 (J) Chassis

® Electrical
® Troubleshooting
(J) ®
ICHASldsOl IELEClol Illustrated symbols @) to @ are used to identify

® @)
I ~
IJn~~ ? @) Filling fluid

@ Lubricant
® Special tool
@ ® @ Tightening
El ~
® Wear limit, clearance
@ Engine speed
@)n, V, A
@ ®
I~~I ~
@ @)
@
§]
@)
~
@)
Illustrated symbols @ to @ in the exploded
diagrams indicate grade of lubricant and loca-
1 1 1 tion of lubrication point.
G) ~ ~ @ Apply engine oil
@) Apply gear oil
® @ @ @) Apply molybdenum disulfide oil
® Apply wheel bearing grease
~ ~ ~ @ Apply lightweight lithium-soap base grease
@ Apply molybdenum disulfide grease
@ Apply the locking agent (LOCTITE®)
@ @ @Usenewone
A I
CONTENTS
SPECIFICATIONS ........................................................................................... 1
GENERAL SPECIFICATIONS .................................................................. 1
MAINTENANCE SPECIFICATIONS ......................................................... 3
ENGINE ................................................................................................. 3
CHASSIS .............................................................................................. 6
ELECTRICAL ........................................................................................ 7
YFM80MNFM80MC WIRING DIAGRAM

GENERAL SPECIFICATIONS ISPECI U-I
SPECIFICATIONS
-r-------------------------------~------------------------------~
Model YFM80MIYFM80MC
Model code: 4EMT (Except for California)
4EMS (for California)
Oil type or grade:
Engine oil
0° 10° 30° 50° 70° 90 0 110° 130°F
API service SE type or higher
I! ,ii,' ! 4 (F!OW40) !~r SAE ~OW40
!i YAMA~UBE !.
;,i ~ AMALU;BE 4 (16W30) 0; SAE 1o~:a i
l
-i-_+-
i! SAE SW30
-.;.!l I! I
!
I
!
I!
! ! ! ! ! !
-20° -10° 0° 10° 20 0 30° 40° 50°C
Final gear oil SAE 80API "GL-4" Hypoid gear oil

Fuel:
Type Unleaded fuel
Fuel tank capacity 6.8 L (1.50 Imp gal, 1.80 US gal)
Fuel reserve amount 0.9 L (0.20 Imp gal, 0.24 US gal)
Spark plug:
Type C7HSA/U22FS-U
Manufacturer NGKIDENSO
Spark plug gap 0.6 - 0.7 mm (0.024 - 0.028 in)
Chassis:
Frame type Steel tube frame
Caster angle 1 0
Trail 3.8 mm (0.15 in)

Tread (STD) front 665 mm (26.2 in)
Tread (STD) rear 630 mm (24.8 in)
Toe-in 5 mm (0.2 in)
Tire:
Type Tubeless
Size front AT18 x 7-7
rear AT18 x 8-7
Manufacturer front DUNLOP
rear DUNLOP
Type front .KT586
rear KT587
Tire pressure (cold tire):
Off-road riding
. front 17 - 23 kPa (0.17 - 0.23 kg/cm2, 2.5 - 3.3 psi)
rear 17 - 23 kPa (0.17 - 0.23 kg/cm2, 2.5 - 3.3 psi)
-1-
GENERAL SPECIFICATIONS ISPECI U-I
Wheel travel:
Front wheel travel 57 mm (2.2 in)
Rear wheel travel 56 mm (2.2 in)
Electrical:
Ignition system C.D.I.
Generator system C.D.I. magneto
Battery type 12N7D-3B
Battery capacity 12 V 7 AH
-2-
MAINTENANCE SPECIFICATIONS ISPECI U-I
ENGINE
Camshaft:
Drive method Chain drive (Left)
Cam dimensions
Intake "A" 25.30 - 25.31 mm (0.996 - 0.997 in)

"8" 20.99 - 21.09 mm (0.827 - 0.831 in)
"e" 4.20 - 4.41 mm (0.165 - 0.174 in)
Exhaust "A'~ 25.30 - 25.31 mm (0.996 - 0.997 in)
"8" 21.02 - 21.12 mm (0.828 - 0.832 in)
"e" 4.20 - 4.41 mm (0.165 - 0.174 in)
Rocker arm/rocker arm shaft:
Bearing inside diameter 10.000 - 1O.O~ 5 mm (0.3937 - 0.3943 in)
Shaft outside diameter 9.981 - 9.991 mm (0.3930 - 0.3933 in)
I .
Arm-to-shaft clearance 0.009 - 0.034 mm (0.0004 - 0.0013 In)
<Limit> <0.08 mm (0.0031 in»
Valve spring:
Free length IN 28.6 mm (1.13 in)
EX 28.6 mm (1.13 in)
<Limit> IN <25.4 mm (1.00 in»
EX <25.4 mm (1.00 in»
Set length (valve closed) IN 24.9 mm (0.98 in)
EX 24.9 mm (0.98 in)
Compressed pressure
(installed) IN 86.3 - 105.9 N (8.6 -10.5 kg, 19.4 - 23.81b)
EX 86.3 - 105.9 N (8.6 -10.5 kg, 19.4 - 23.81b)
Tilt limit IN 2.5°/1.2 mm (2.5%.047 in)
EX 2.5°/1.2 mm (2.5%.047 in)
11*
-3-
MAINTENANCE SPECIFICATIONS ISPEcl 0-1
Oirectionof winding
(top view) IN Clockwise
EX Clockwise
Piston:
Piston to cylinder clearance
n
0.025 - 0.045 mm (0.0010 - 0.0018 in)
<Limit> <0.15 mm (0.0059 in»
Piston size "0" 46.96 - 46.98 mm (1.849 - 1.850 in)
Measuring point "H" 6.5 mm (0.256 in)

Oversize 2nd 47.5 mm (1.870 in)
Oversize 4th 48 mm (1.890 in)
Piston off-set 0.75 mm (0.03 in)
Piston off-set direction Inside
Piston pin bore inside diameter 13.002 - 13.013 mm (0.5119 - 0.5123 in)
Piston pin outside diameter 12.996 - 13.000 mm (0.5117 - 0.5118 in)
Clutch:
Friction plate thickness 2.92 - 3.08 mm (0.115 - 0.121 in)
Quantity 6
Friction plate wear limit 2.9 mm (0.11 in)
Clutch plate thickness 1.2 - 1.6 mm (0.047 - 0.063 in)
Quantity 5
Warp limit 0.06 mm (0.002 in)
Clutch spring free length 28.3 mm (1.11 in)
Quantity. 8
Clutch release method Inner push, cam push
Carburetor: 4EMT 4EMS
I. O. mark 3GB 00 4EMS 00
Main jet (M.J.) #80 #76.3
Main air jet (M.A.J.) 01.2 f-
Jet needle (J.N.) 3PZ5-3 f-
Needle jet (N.J.) 0-8 (#5,59) f-
Pilot outlet (P.O.) 0.7 f-
Pilot jet (P.J.) #12.5 f-
Valve seat size (V.S.) 1.2 f-
-4-
MAINTENANCE SPECIFICATIONS ISPECI U-I
Model YFMSOMNFMSOMC
Float height (F.H.) 20 - 22 mm f-
(0.79 - 0.S7 in)
Fuel level (F.L.) 2.5 - 4.5 mm f-
(0.10 - 0.1S in)
Engine idle speed 1,700 - 1,900 r/min f-
Lubrication system:
Oil filter type Wire mesh type
Oil pump type Trochoid type
Tip clearance "A" or "8" 0.15 mm (0.006 in)
<Limit> <0.2 mm (O.OOS in»
Side clearance 0.06 - 0.10 mm (0.002 - 0.004 in)
-5-
MAINTENANCE SPECIFICATIONS ISPECI 0-1
CHASSIS
Rear wheel:
Type Panel wheel
Rim size 7 x 6.5AT
Rim material Steel
Rim runout limit radial 2 mm (0.08 in)
lateral 2 mm (0.08 in)
Brake lever free play (pivot) 2 - 5 mm (0.08 - 0.20 in)
Brake lever free play (left) 5 - 8 mm (0:20 - 0.31 in)
Brake pedal position 5 mm (0.2 in)
Brake pedal free play 20 - 30 mm (0.8 - 1.2 in)
Throttle lever free play 3 - 5 mm (0.1 - 0.2 in)
-6-
MAINTENANCE SPECIFICATIONS ISPECI u-I
ELECTRICAL
Model YFM80MNFM80MC
Voltage: 12 V
C.D.I.:
Magneto model/manufacturer F2FM/MORIYAMA
Pickup coil resistance/color 264 - 396 n at 20°C (68 °F)/white/Blue-
White/Red
C.D.I. unit model/manufacturer 4EM/MORIYAMA
Ignition coil:
Model/manufacturer 2JN/MORIYAMA
Primary winding resistance 0.18 - 0.28 n at 20°C (68 OF)
Secondary winding resistance 6.32 - 9.48 kn at 20°C (68 OF)
Rectifier:
Model/manufacturer EHU-01 TR31 AlMATSUSHITA
Capacity 8A
Withstand voltage 200 V
Starter motor:
Model/manufacturer ADB4AS/DENSO
Output 0.2kW
Armature coil resistance 0.043 Q at 20°C (68 OF)
Brush overall length 6 mm (0.24 in)
<Limit> <3.S mm (0.14 in»
Spring force 310 - 4S0 g (11 -16 oz)
Commutator diameter 16.S mm (0.6S in)
<Wear limit> <1S.S mm (0.61 in»
Starter relay:
Model/manufacturer MSSD-611/JIDECO
Amperage rating 100 A
Coil winding resistance 3.9 - 4.7 n at 20°C (68 OF)
Model/manufacturer ACA1211S-3/MATSUSHITA
Coil winding resistance 72 - 88 n at 20°C (68 OF)
Diode No
Circuit breaker:
Type Fuse
Amperage for individual circuit
Main fuse SAx1
Reserve fuse SA x 1
-7-
CONSTRACTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See "Illustrated symbols")
1st title CD : This is a chapter with its symbol on the upper right of each page.
2nd title ® : This title appears on the upper of each page on the left of the chapter
symbol. (For the chapter "Periodic inspection and adjustment" the 3rd
title appears.)
3rd title ®: This is a final title.
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The infor-
mation has been compiled to provide the mechanic with an easy to read, handy reference that
contains comprehensive explanations of all disassembly, repair, assembly, and 'inspections.
A set of particularly important procedure @ is placed between a line of asterisks" *" with each
procedure preceded by " • ".
IMPORT ANT FEATURES

• Data and a special tool are framed in a box preceded by a relevant symbol @ .
• An encircled numeral ® indicates a part name, and an encircled alphabetical letter data or an
alignment mark (j) , the others being indicated by an alphabetical letter in a box ® .
• A condition of a faulty component will precede an arrow symbol and the course of action re-
quired the symbol ®.
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identif-
ying correct disassembly and assembly procedures.
1
2r-~~====~~~~~~~= ________FR_ON_TF_OR_K ICHAS <#erG I

6
~
Use Il'IecrankClIse sepa'II""II 1001 2 , InspecT
It] C"."........."•• ,-"

YU-Ol1JS
"Inn",fo'k!u!)..
• OUle. 1o." luoe ~
:
SCralCheS Bends Damage .... Replace
~----
3 Do 1'101 .na.",,1 to sltllglllen I bent 'nnll'
Ip'klub. . . 'hllm • .,d.nll.·"... ,y ..... ken
9
• Ca.bondepOll1S
US" a.ounded s(:flPe'
NOTE'
TakeClI,e'Ohg,dedilmllg,nglhesp.rkp'ug
11'''"H1s Do 1'101 use" shll" ,nltrumenl • 7
~.
[§]
• Fork ~p"ng he"'"n!ll~ ..
® --1_________ oCyl,nde,hel4wa.,,-oe
O.,.,,,.,,',<.... ...,'.,, /
~
~ "~R
----------- fork.pring" •• I_"g,h
~"
l ..~
~w.rp'''lIml' 418511'111'11165,,,,
00210110110.00111'11 Min,mumh •• '·"I1'"
'...... '------'.'O_mm_''''--''_.,_-----'
.... II.Ch.str••ght.dgll I ."",.th.c"n.·

;------t-i¥-7;..::::~1iiS:-I-H •::.:= ,:.. =~:::I'nd'f h •• d
••1 th .....'pegII ..
out OI,p.c.l.c.t,on. f'·
lu,I..:.th.cWhnd.,,...d
8
L -_ _ _ _--=..::J ·;~:.·U:I= P~.:;O.~'f:.::::Cn:~:::.::
U.,"II.I'guf.· ..ghtUnd,nvo.n.'n
NOTE·-----
ROt.l.th.h... , • ., .... lom•• lo • .,o.df.
mO"'"IIOO much mit., ... "om 0f'I, s,d.
CD ® ILLUSTRATED SYMBOLS
(Refer to the illustration)
I~EF~I~I ISPECI ~~I Illustrated symbols CD to @ are designed as
thumb tabs to indicate the chapter's number
@ ill and content.
CD General information
Ik~Jlfil ENG \. ® Specifications
@ Periodic inspection and adjustment
ill Engine
® ® ® Cooling system
ICOOll ~I ICARBI f·1

® Carburetion
(j) Drive train
® Chassis
® Electrical
(j) ® @ Troubleshooting
IOR1vl-IG-1 ICHASI~I
® @
IHECI iii I I~~~~I? I Illustrated symbols (j]) to @ are used to

(j]) @
~ ~
identify the specifications appearing in the
text.
(j]) Filling fluid
@ Lubricant
@ @ @ Special tool
~ ~
@ Tightening
@ Wear limit, clearance
@ Engine speed
@o.,V,A
@ @
~ §
@ @
, Illustrated symbols @ to ® in the exploded
[mJ CLT)
diagram indicate grade of lubricant and loca-
tion of lubrication point.
@ Apply locking agent (Loctite@)
@ Apply engine oil
@ ® @ ® Apply gear oil
-1 1 1 @ Apply molybdenum disulfide oil
@
m @
m e ®
@ Apply wheel bearing grease
@ Apply lightweight lithium-soap base grease
® Apply molybdenum disulfide grease
~ ~ ~
INDEX
GENERAL INFORMATION ~
GEN
.-.
INFO
SPECIFICATIONS SPEC
PERIODIC INSPECTION II!a

t----
INSP
AND ADJUSTMENT ADJ
ENGINE OVERHAUL ENG
CARBURETION t----
CARB •
CHASSIS CHAS
ELECTRICAL ELEC
?•
TROUBLESHOOTING t----
TRBL
SHTG
CONTENTS
CHAPTER 1.
GENERAL INFORMATION
MACHINE IDENTIFiCATION ......................................................................... 1-1

INFO
t----
GEN
0".
VEHICLE IDENTIFICATION NUMBER (For AUS) ................................... 1-1
ENGINE SERIAL NUMBER (For USA, OCE and EUR) .......................... 1-1 I---~-=--
ENGINE SERIAL NUMBER ..................................................................... 1-1
IMPORTANT INFORMATION ....................................................................... 1-2 SPEC

PREPARATION FOR REMOVAL ............................................................. 1-2· t----
ALL REPLACEMENT PARTS ................................................................... 1-2 ~
GASKETS, OIL SEALS, AND O-RINGS .................................................. 1-2 ~
LOCK WASHERS/PLATES AND COTTER PINS ..................................... 1-3 t--IN-S=P-
BEARINGS AND OIL SEALS ................................................................... 1-3 ADJ
CIRCLIPS .................................................................................................. 1-3
SPECIAL TOOLS ........................................................................................... 1-4 ••

FOR TUNE-UP ......................................................................................... 1-4 t------..;
FOR ENGINE SERVICE ............................................................................ 1-5 ENG
FOR CHASSIS SERVICE .......................................................................... 1-6 t------
FOR ELECTRICAL COMPONENTS ......................................................... 1-7
CHAPTER 2. CARB
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
MAINTENANCE SPECIFICATIONS .............................................................. 2-3 CHAS

ENGINE .................................................................................................... 2-3 t----
CHASSIS .................................................................................................. 2-9 iii
ELECTRICAL .......................................................................................... 2-11
GENERAL TORQUE SPECIFICATIONS ...................................................... 2-13

ELEC
LUBRICATION POINTS AND LUBRICANT TYPE ...................................... 2-14 ?•
1----
LUBRICATION DIAGRAM .......................................................................... 2-15 TRBL
SHTG
CABLE ROUTING ....................................................................................... 2-17
CHAPTER 3.
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION ........................................................................................... 3-1
PERIODIC MAINTENANCE/LUBRICATION ................................................ 3-1
FENDERS AND FUEL TANK ........................................................................ 3-2

FRONT FENDER ...................................................................................... 3-2
REAR FENDER AND FUEL TANK ................................................................. 3-2
ENGINE .......................................................................................................... 3-4

CAM CHAIN TENSION ADJUSTMENT .................................................. 3-4
VALVE CLEARANCE ADJUSTMENT ..................................................... 3-5
IDLE SPEED ADJUSTMENT ................................................................... 3-7
THROTTLE LEVER ADJUSTMENT ......................................................... 3-7
SPEED LIMITER ADJUSTMENT ............................................................. 3-8
SPARK PLUG INSPECTION .................................................................... 3-9
IGNITION TIMING CHECK .................................................................... 3-10
COMPRESSION PRESSURE MEASUREMENT ................................... 3-11
AIR FILTER CLEANING ......................................................................... 3-12
ENGINE OIL LEVEL INSPECTION ......................................................... 3-13
ENGINE OIL REPLACEMENT ................................................................ 3-14
OIL STRAINER CLEANING ................................................................... 3-15
CLUTCH ADJUSTMENT ....................................................................... 3-16
CHASSIS ..................................................................................................... 3-18

FRONT BRAKE ADJUSTMENT ............................................................ 3-18
REAR BRAKE LEVER AND PEDAL ADJUSTMENT ............................. 3-18
BRAKE LINING INSPECTION ................................................................ 3-20
FINAL GEAR OIL LEVEL INSPECTION ................................................. 3-20
FINAL GEAR OIL REPLACEMENT ........................................................ 3-21
DRIVE SHAFT DUST BOOT INSPECTION ........................................... 3-22
STEERING SYSTEM INSPECTION ....................................................... 3-22
TOE-IN ADJUSTMENT ......................................................................... 3-23
TIRE INSPECTION .................................................................................. 3-24
WHEEL INSPECTION ............................................................................ 3-26
WHEEL BEARINGS CHECK ................................................................... 3-27
KNUCKLE SHAFT AND STEERING SHAFT LUBRICATION ................ 3-27
ELECTRICAL ................................................................................................ 3-28

BATTERY INSPECTION ..................................................... ;................... 3-28
FUSE INSPECTION ................................................................................ 3-30
CHAPTER 4.
ENGINE OVERHAUL
ENGINE REMOVAL ...................................................................................... 4-1 ._.

ENGINE OIL ............................................................................................. 4-1 1--.......---
SEAT AND REAR FENDER ...................................................................... 4-1 ~~~
MUFFLER ................................................................................................. 4-1
CARBURETOR ......................................................................................... 4-1 I---~~--
STARTER MOTOR ................................................................................... 4-2
LEADS AND HOSE .................................................................................. 4-2 1------.;
CRANKCASE COVER (LEFT) ................................................................... 4-2 SPEC
ENGINE REMOVAL ................................................................................. 4-2 1--_ _
DISASSEMBLY ............................................................................................. 4-3 fi

INTAKE MANIFOLD ................................................................................ 4-3 I--IN-S=--P-
CYLINDER HEAD AND CYLINDER ......................................................... 4-3 ADJ
PISTON .................................................................................................... 4-4
1-------
CLUTCH ................................................................................................... 4-5 ......
SHIFT SHAFT ........................................................................................... 4-7 ..,
DRIVE GEAR AND STARTER CLUTCH .................................................. 4-7 1------.;
Ol~ PUMP AND OIL STRAINER .............................................................. 4-8 ENG
CDI MAGNETO ........................................................................................ 4-9 1------
MIDDLE GEAR ......................................................................................... 4-9
CRANKCASE .......................................................................................... 4-11
TRANSMISSION .................................................................................... 4-12
CRANKSHAFT ....................................................................................... 4-12
ROCKER ARM AND CAMSHAFT .......................................................... 4-12
1----
CARB •
VALVE .................................................................................................... 4-13
INSPECTION AND REPAIR ......................................................................... 4-14

CYLINDER HEAD ................................................................................... 4-14 CHAS
VALVE AND VALVE GUIDE .................................................................. 4-15
VALVE SEAT .......................................................................................... 4-16
VALVE SPRING ...................................................................................... 4-20
CAMSHAFT ............................................................................................ 4-20
ROCKER ARM AND ROCKER ARM SHAFT ......................................... 4-21
ELEC
CAM CHAIN AND CAM SPROCKET ..................................................... 4-21
CAM CHAIN GUIDE .~ ............................................................................. 4-22
CAM CHAIN TENSIONER ..................................................................... 4-23
?•
1----
CYLINDER AND PISTON ....................................................................... 4-23 TRBL
PISTON RING ........................................................................................ 4-25 SHTG
PISTON PIN ........................................................................................... 4-26
CLUTCH ................................................................................................. 4-26
OIL PUMP .............................................................................................. 4-29
TRANSMISSION AND SHIFTER ........................................................... 4-29
SHIFT SHAFT AND STOPPER LEVER .................................................. 4-31
PRIMARY DRIVE .................................................................................... 4-31
STARTER DRIVE .................................................................................... 4-31
CRANKSHAFT ....................................................................................... 4-32
MIDDLE GEAR ....................................................................................... 4-33
ENGINE ASSEMBLY AND ADJUSTMENT ............................................... 4-34
VALVE .................................................................................................... 4-35
ROCKER ARM AND CAMSHAFT .......................................................... 4-35
CRANKSHAFT ....................................................................................... 4-37
TRANSMISSION .................................................................................... 4-37
CRANKCASE .......................................................................................... 4-38
MIDDLE GEAR ....................................................................................... 4-39
COl MAGNETO ...................................................................................... 4-41
OIL PUMP AND OIL STRAINER ............................................................ 4-42
DRIVE GEAR AND STARTER CLUTCH ................................................ 4-42
SHIFT SHAFT .............................................................................................. 4-43

CLUTCH ................................................................................................. 4-45
PISTON .................................................................................................. 4-50
CYLINDER AND CYLINDER HEAD .......................................................4-50
INTAKE MANIFOLD .............................................................................. 4-54
REMOUNTING ENGINE ........................................................................ 4-54
CHAPTER 5.
CARBURETION
CARBURETOR ............................................................................................... 5-1

REMOVAL ................................................................................................ 5-2
DISASSEMBLY ........................................................................................ 5-2
INSPECTION ............................................................................................ 5-3
ASSEMBLY .............................................................................................. 5-4
INSTALLATION ....................................................................................... 5-5
FUEL LEVEL ADJUSTMENT ................................................................... 5-6
CHAPTER 6.
CHASSIS
FRONT WHEEL AND FRONT BRAKE .......................................................... 6-1

REMOVAL ................................................................................................ 6-2
INSPECTION ............................................................................................ 6-3
INSTALLATION ....................................................................................... 6-5
REAR WHEEL ................................................................................................ 6-7

REMOVAL ................................................................................................ 6-8
INSPECTION ............................................................................................ 6-8
INSTALLATION ....................................................................................... 6-9
REAR BRAKE .............................................................................................. 6-1 0

REMOVAL .............................................................................................. 6-11
INSPECTION .......................................................................................... 6-11
INSTALLATION ...................................................................................... 6-12
STEERING SYSTEM .................................................................................. 6-14
REMOVAL ..............................................................................................6-15
INSPECTION .......................................................................................... 6-16
INSTALLATION ..................................................................................... 6-17
FRONT SHOCK ABSORBER AND LOWER ARM ...................................... 6-21

REMOVAL .............................................................................................. 6-22
GEN
0".
t-----
INFO
INSPECTION .......................................................................................... 6-23
INSTALLATION ..................................................................................... 6-23
REAR SHOCK ABSORBER AND SWINGARM .......................................... 6-25

REMOVAL .............................................................................................. 6-26
SPEC
INSPECTION ..........................................................................................6-27
INSTALLATION ..................................................................................... 6-28 pjJ
t---~-
SHAFT DRIVE ............................................................................................. 6-30 INSP

REMOVAL .............................................................................................. 6-31 ADJ
INSPECTION .......................................................................................... 6-32
INSTALLATION ..................................................................................... 6-33
CHAPTER 7.
••
t-----
ENG
•
ELECTRICAL
YFM80(D) WIRING DIAGRAM ...................................................................... 7-1 t-----

COLOR CODE .......................................................................................... 7-2 CARB
ELECTRICAL COMPONENTS ....................................................................... 7-3
CHECKING OF SWITCHES .......................................................................... 7-4

SWITCH CONNECTION AS SHOWN IN MANUAL ............................... 7-4 CHAS
CHECKING SWITCH FOR TERMINAL CONNECTION ........................... 7-5
CHECKING OF BULBS (FOR HEAD LIGHT, TAIL/BRAKE LIGHT, FLASHER

LIGHT, METER LIGHT, ETC.) ..................................................................... 7-8
CHECKING BULB CONDITION ............................................................... 7-8 ELEC
IGNITION SYSTEM .................................................................................... 7-10
CIRCUIT DIAGRAM ............................................................................... 7-10
?•
t-----
TROUBLESHOOTING ............................................................................ 7-11 TRBL
SHTG
ELECTRICAL STARTING SYSTEM ............................................................. 7-16
CIRCUIT DIAGRAM ............................................................................... 7-16
TROUBLESHOOTING .............. ;............................................................. 7-17
STARTER MOTOR .................................................................................. 7-22
CHARGING SYSTEM ................................................................................. 7-26

CIRCUIT DIAGRAM ............................................................................... 7-26
TROUBLESHOOTING ............................................................................ 7-27
SIGNAL SYSTEM ....................................................................................... 7-29
CIRCUIT DIAGRAM ............................................................................... 7-29
TROUBLESHOOTING ............................................................................ 7-30
SIGNAL SYSTEM CHECK ..................................................................... 7-32
CHAPTER 8.
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING ...................................................... 8-1

FUEL SYSTEM ......................................................................................... 8-1
ELECTRICAL SYSTEM ............................................................................ 8-1
COMPRESSION SYSTEM ....................................................................... 8-2
POOR IDLE SPEED PERFORMANCE ........................................................... 8-2

POOR IDLE SPEED PERFORMANCE ...................................................... 8-2
POOR MEDIUM AND HIGH SPEED PERFORMANCE ................................ 8-2

POOR MEDIUM AND HIGH SPEED PERFORMANCE ........................... 8-2
FAULTV DRIVE TRAIN ................................................................................. 8-3
FAULTV GEAR SHIFTING ............................................................................ 8-3

HARD SHIFTING ...................................................................................... 8-3
CHANGE PEDAL DOES NOT MOVE ...................................................... 8-3
JUMP-OUT GEAR ................................................................................... 8-4
CLUTCH SLIPPING/DRAGGING .................................................................. 8-4

CLUTCH SLIPPING .................................................................................. 8-4
CLUTCH DRAGGING ............................................................................... 8-4
OVERHEATING ............................................................................................. 8-4

OVERHEATING ........................................................................................ 8-4
FAULTV BRAKE ............................................................................................ 8-5

POOR BRAKING EFFECT ........................................................................ 8-5
SHOCK ABSORBER MALFUNCTION .......................................................... 8-5

MALFUNCTION ....................................................................................... 8-5
INSTABLE HANDLING ................................................................................. 8-5

INSTABLE HANDLING ............................................................................ 8-5
YFM80(D) WIRING DIAGRAM ...................................................................... 8-6

MACHINE IDENTIFICATION I~EF~I"'I
GENERAL
INFORMATION
(For AUS}
The vehicle identification number CD is
D
Starting serial number:

JV44EMWO*NA000101 (For AUS)
NOTE: ______________________
The vehicle identification number is used to
identify your machine and may be used to
register your machine with the licensing in
your state.
FRAME SERIAL NUMBER (For USA, OCE and

EUR)
The frame serial number CD is stamped into
the left side of the frame.
4EM-000101 (For USA and OCE)
4EM-016101 (For EUR)
NOTE: ______________________
The firstthree digits ofthese numbers are for
model identifications; the remaining digits
are the unit production number.
ENGINE SERIAL NUMBER

The engine serial number CD is stamped into
the left of the engine.

4EM-000101 (For USA and OCE)
NOTE: ______________________
• The first three digits of these numbers are
for model identifications; the remaining
digits are the unit production number.
• Designs and specifications are subject to
change without notice.
1-1
IMPORTANT INFORMATION 1 ~EF~ 1. . .1
IMPORTANT INFORMATION
PREPARATION FOR REMOVAL

1. Remove all dirt, mud dust, and foreign
material before removal and disassembly.
2. Use propertools and cleaning equipment.
Refer to "SPECIAL TOOL".
3. When disassembling the machine keep

mated parts together. This includes gears,
cylinders, pistons, and other mated parts
that have been "mated" through normal
wear. Mated parts must be reused as an
assembly or replaced.
4. During the machine disassembly, clean all

parts and place them in trays in the order
of disassembly. This will speed up assem-
bly time and help assure that all parts are
correctly reinstalled.
5. Keep away from fire.
ALL REPLACEMENT PARTS

1. Use only genuine Yamaha parts for all
replacements. Use oil and/or grease rec-
ommended by Yamaha for assembly and
adjustment. Other brands may be similar
in function and appearance, but inferior in
quality.
GASKETS, OIL SEALS, AND O-RINGS

1. All gaskets; seals and O-rings should be
replaced when an engine is overhauled.
All gaskets surfaces, oil seal lips and 0-
rings must be cleaned.
2. Properly oil all mating parts and bearing

during reassembly. Applygreasetotheoil
seal lips.
'-2
IMPORTANT INFORMATION 1~EF~ 1""1
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) shoul~ be bent along the bolt
or nut flat(s) after the bolt or nut has been
properly tightened.
BEARINGS AND OIL SEALS

1. Install the bearing(s) and oil seal(s) with
their manufacturer's marks or numbers
facing outward. (In other words, the
stamped letters must be on the side ex-
posed to view.) When installing cHI seal(s),
apply a lightcoating of light-weight lithium
base grease to the seal lip(s). Oil the
300-003
bearings liberally when installing.
CD Oil seal
Do not use compressed air to spin the bear-

ings dry. This causes damage to the bearing
surfaces.
300-002 CD Bearing
~----------------------------~
CIRCLIPS
1. All circlips should be inspected carefully
before reassem bly. Always replace piston
pin clips after one use. Replace distorted
circlips. When installing a circlipsCD, make
sure that the sharp edged corner ® is
positioned opposite to the thrust ® it
receives. See the sectional view.
300-001
® Shaft
1-3
SPECIAL TOOLS Refertothe list provided to avoid errors when
The proper special tools are necessary for placing an order.
com plete and accurate tune-u p and assem bly. PIN. YM- 00000, YU-DDDDD }
Using the correct special tool will help prevent YS- 00000, YK- 00000 For USA
and CON
damage caused by the use of improper tools ACC-DDDDD
or improvised techniques. Exceptfor
}
The shape and part number used for the P/N.90890-DDDDD USA and
CON
special tool differ by county, so two types are
provided.
1-A
Inductive tachometer
PIN. YU-08036-A
FOR TUNE UP
This tool is needed for detecting engine
rpm.
1-8 2-A
Inductive tachometer §2j~.
~ Inductive timing light
PIN. 90890-03113 h:~"l PIN. YM-33277-A
~"III
.....
~
,
~J
··0,
This tool is needed for detecting engine This tool is necessary for checking ignition
rpm. timing.
2-8 3-A ~ i-'"

Inductive timing light Compression gauge:~, I 8I
PIN. 90890-03141 PIN. YU-33223 l~ " I I
," I I
, ',I I
" 'j I
" I
''--- __ J
This tool is necessary for checking ignition These gauge are used to measure the en-
timing. gine compression.
3-8 --±J
Compression gauge Fuel level gauge
PIN. 90890-03081 PIN. YM-01312-A
Adapter PIN. 90890-01312
PIN. 90890-04082
This gauge is used to measure the engine This gauge is used to measure the fuel level
compression. in the float chamber.
1-4
SPECIAL TOOLS I~EF~I~I
5-A 5-8
Valve adjusting tool Valve adjusting tool
PIN. YM-08035 PIN. 90890-01311
IB
Thistool is necessaryfor adjusting the valve Thistool is necessaryfor adjusting the valve
clearance. clearance.
1
Piston pin puller
PIN. YU-01304
PIN. 90890-01304
FOR ENGINE SERVICE
This tool is necessary to remove the piston

pin.
2-8
Universal clutch holder Universal clutch holder
PIN. YM-91042 PIN. 90890-04086 ,
This tool is used to hold the clutch when

removing or installing the clutch boss This tool is used to loosen and tighten the
locknut. clutch boss locknut.
3 4
Rotor puller Rotor holder
PIN. YM-01189 PIN. YM-01235
PIN. 90890-01189 PIN. 90890-01235
This tool is used to hold the flywheel mag-

This tool is used to remove the flywheel neto when removing or installing the fly-
magneto. wheel magneto securing nut.
5 6
Slide hammer set Valve spring compresso~
PIN. YU-01083 PIN. YM-04019
Slide hammer bolt PIN. 90890-04019
PIN. 90890-01083 Attachment
Weight PIN. YM-4108 ~
PIN. 90890-01084 PIN. 90890-04108
These tools are used when removing the This tool is needed to remove and install the
rockerarm shaft and camshaft. valve assemblies.
1-5
SPECIAL TOOLS I~E~I""'I
7
Valve guide remover (5.0 mm)
W
Valve guide installer (5.0 mm)
PIN. YM-4097 PIN. YM-4098
PIN. 90890-04097 PIN. 90890-04098
Thistool is needed to install the valve guides

This tool is used to remove the valve guides. properly.
9 10 ,......,
Valve guide reamer (5.0 mm) Valve seat cutter
PIN. YM-4099 PIN. YM-91043-C
PIN. 90890-04099
This tool is used to rebore the new valve

guide. Thistool is used toadjustthevalve clearance.
.EJ
Sealant (Quick gasket®) Hexagon wrench (27mm)
PIN. ACC-11001-15-01 PIN. YM-01388 ~
YAMAHA bond No. 1215 PIN. 90890-01388 ~
PIN. 90890-85505
This sealant (bond) is used for crankcase This tool is used to loosen or tighten the
mating surface, etc. middle-drive-shaft-bearing retainer nut.
-.U
Hexagon wrench (32mm)
PIN. YM-01364 ~
PIN. 90890-01364 ~
FOR CHASSIS SERVICE
This tool is used to loosen and tighten the

final-drive-shaft retainer nut.
2-A 2-8
Rear axle nut wrench Rear axle nut wrench
PIN. YM-37132 PIN. 90890-01422
This tool is used to loosen and tighten the This tool is used to loosen and tighten the
rear axle nut. rear axle nut.
'-6
SPECIAL TOOLS I~EF~I.~I
1-A
Dynamic spark tester
PIN. YM-34487
FOR ELECTRICAL
COMPONENTS
This instrument is necessary for checking
the ignition system components.
1-8 2
Ignition checker Pocket tester
PIN. 90890-06754 PIN. YU-03112
PIN. 90890-03112
This instrument is necessary for checking This instsrument is invaluable for checking
the ignition system components. the electrical system.
1-7
GENERAL SPECIFICATIONS ISPECI j5~ I
SPECIFICATIONS
Model YFM80(D)
Model code number: 4EM 1 (For USA and aCE)
4EM 2 (For EUR)
Vehicle identification number: *
JY44EMWO NA000101 (For AUS)
Frame starting number: 4EM-000101 (For USA and aCE)
Engine starting number: 4EM-000101 (For USA and aCE)
Dimensions:
Overall height 960 mm (37.8 in)
Minimum ground clearance 100 mm ( 3.9 in)
Basic Weight:
With oil and full fuel tank 116 kg (256 Ib)
Engine:
Engine type Air cooled 4-stroke, SOHC
Cylinder arrangement Forward inclined single cylinder
Displacement 79 cm 3
Bore x stroke 47.0 x 45.6 mm (1.85 x 1.80 in)
Compression ratio 9.6: 1
Compression pressure 1,200 kPa (12 kg/cm2, 171 psi)
Starting system Electric starter
Lubrication system: Wet sump
Oil/Grease type of grade
Engine oil
Yamalube 4 (20W40) or SAE 20W40 type
30 40 50 60°F
I
-- I
0 5
14
1
10
.1--
15°C
SE motor oil
(If temperature does not go below 5·C/40·F)
Yamalube 4 (10W30) or SAE 10W30 type
SE motor oil
(If temperature does not go above 15°C/60·F)
Final gear oil SAE 80 API "GL-4" hypoid gear oil
Oil/Grease capacity:
Engine oil:
Periodic oil change 0.8 L (0.70 Imp qt, 0.85 US qt)
Total amount 0.95 L (0.84 Imp qt, 1.00 US qt)
Final gear case oil amount 0.12 L (0.11 Imp qt, 0.13 US qt)
Air filter: Wettype element
2-1
GENERAL SPECIFICATIONS ISPECI ~~ I
Model YFM80(D)
Fuel:
Type Unleaded· fuel recommended (For USA)
Unleaded fuel only (For AUS)
Regular unleaded gasoline (For EUR)
Regular gasoline (For other)
Tank capacity 6.8 L (1.5 Imp gal, 1.8 US gal)
Reserve amount 0.9 L (0.2 Imp gal, 0.2 US gal)
Carburetor:
Type/Ma n ufactu re r VM 16SH/M IKUNI
Spark plug:
Type/Manufacture C7HSA (NGK)/U22FS-U (ND)
(For USA and OCE)
CR7HS (NGK) (For EUR)
Gap 0.6 - 0.7 mm (0.024 - 0.028 in)
Clutch Type: Wet, centrifugal automatic
Transm ission:
Primary reduction system Spur 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, 3-speed
Operation Left foot operation
Gear ratio: 1st 39/11 (3.545)
2nd 35/17 (2.059)
3rd 31/22 (1.409)
Chassis:
Frame type Steel tube frame
Caster angle 1.0·
Trail 3.8 mm (0.15 in)
Toe-in 0- 10 mm (0 - 0.4 in)
Tread: Front 665 mm (26.2 in)
Rear 630 mm (24.8 in)
Tire: Front Rear
Type Tubeless Tubeless
Size AT18 x 7-7 AT20 x 9-8
Manufacture (type) BRIDGESTONE (MH03A) BRIDGESTONE (MH04A)
CHENG SHIN (C864N) CHENG SHIN (C865N)
< Wear limit> < 3 mm (0.12 in) > < 3 mm (0.12 in) >
Tire pressure (cold tire): Front Rear
Recommended 20 kPa 20 kPa
(0.20 kg/cm2, 2.8 psi) (0.20 kg/cm 2, 2.8 psi)
Minimum 17 kPa 17 kPa

(0.17 kg/cm2, 2.4 psi) (0.17 kg/cm2, 2.4 psi)
Maximum 23 kPa 23 kPa

(0.23 kg/cm2, 3.2 psi) (0.23 kg/cm2, 3.2 psi)
Brake:
Front brake type Drum brake
Front brake operation Right hand operation
Rear brake type Drum brake
Rear brake operation Left hand operation and right foot operation
2-2
MAINTENANCE SPECIFICATIONS ISPECI?'f I
Model YFM80(D)
Suspension:
Front Leading arm
Rear Swingarm
Shock absorber:
Front Coil spring/Oil damper
Rear Coil spring/Oil damper
Electrical:
Ignition system CDI magneto
Generator system Flywheel magneto
Battery type/Capacity 12N7D-3B/12V,7AH
Indicator light wattage x quantity
"NEUTRAL" 12V, 3.4W x 1
ENGINE
Model YFM80(D)
Cylinder head:
< Warp limit >* * < 0.05 mm (0.002 in) >
* Lines indicate straightedge measurement.
Cylinder:
Bore size 47.000 - 47.005 mm (1.8504 - 1.8506 in)
Taper limit <0.05 mm (0.002 in»
Out-of-round limit <0.01 mm (0.0004 in»
Camshaft:
Drive method Chain drive (Left)
Cam dimensions:
Intake: "A" 25.257 - 25.357 mm (0.994 - 0.998 in)
< Limit> <25.227 mm (0.993 in»
"B" 21.001 - 21.101 mm (0.827 - 0.831 in)
< Limit> <20.971 mm (0.826 in»
I
A
"e" 4.247 - 4.367 mm (0.167 - 0.172 in)
< Limit> <4.227 mm (0.166 in»
Exhaust: A"
II
25.258 -25.358 mm (0.994 - 0.998 in)
< Limit> <25.228 mm (0.993 in»
"B" 21.025 - 21.125 mm (0.828 - 0.832 in)
B < Limit> <20.995 mm (0.827 in»
"C,,· 4.248 - 4.368 mm (0.167 - 0.172 in)
< Limit> <4.228 mm (0.166 in»
Camshaft runout limit <0.03 mm (0.0012 in»
Cam chain type/number of links BUSH CHAIN/82 links
Cam chain adjustment method Manual
Rocker arm/rocker arm shaft:
Rocker arm inside diameter 9.979 - 9.990 mm (0.3929 - 0.3933 in)
Shaft outside diameter 9.981 - 9.991 mm (0.3930 - 0.3934 in)
Arm-to-shaft clearance 0.009 - 0.034 mm (0.0004 - 0.0013 in)
< Limit> <0.08 mm (0.0032 in»
Valve, valve seat, valve guide:
Valve clearance (cold) IN. 0.05 - 0.10 mm (0.002 - 0.004 in)
EX. 0.075 - 0.125 mm (0.003 - 0.005 in)
2-3
MAINTENANCE SPECIFICATIONS ISPECI)Df I
Model YFM80(0)
Valve dimensions:
~.
Face Width
~~C.
Seat Width
~+D. Margin Thickness
"A" Head diameter IN. 22.9 - 23.1 mm (0.902 - 0.909 in)

EX. 19.9 - 20.1 mm (0.784 - 0.791 in)
"8" Face width IN. 1.4 - 2.5 mm (0.055 - 0.098 in)
EX. 1.7 - 2.8 mm (0.067 - 0.110 in)
"c" Seat width IN. 0.9 - 1.1 mm (0.035 - 0.043 in)
EX. 0.9 - 1.1 m m (0.035 - 0.043 in)
< Limit> IN. <1.6 mm (0.063 in»
EX. <1.6 mm (0.063 in»
"0" Margin thickness limit IN. 0.4 - 0.8 mm (0.016 - 0.032 in)
EX. 0.8 - 1.2 mm (0.032 - 0.047 in)
Stem outside diameter IN. 4.975 - 4.990 mm (0.1960 - 0.1965 in)
EX. 4.960 - 4.975 mm (0.1953 - 0.1959 in)
<Limit> IN. <4.95 mm (0.1949 in»
EX. <4.953 mm (0.1950 in»
Guide 'inside diameter IN. 5.000 - 5.012 mm (0.1969 - 0.1973 in)
EX. 5.000 - 5.012 mm (0.1969 - 0.1973 in)
<Limit> IN. <5.03 mm (0.1980 in»
EX. <5.03 mm (0.1980 in»
Stem-to-guide clearance IN. 0.010 - 0.037 mm (0.0004 - 0.0015 in)
EX. 0.025 - 0.052 mm (0.0010 - 0.0021 in)
< Limit> IN. <0.08 mm (0.0031 in»
EX. <0.1 mm (0.0039 in»
< Stem runout limit> <0.02 mm (0.0008 in»
Valve seat width: 0.9 - 1.1 m m (0.035 - 0.043 in)

<Limit> <1.6 mm (0.063 in»
Valve Spring:
Free length: IN. 27.3 mm (1.07 in)
EX. 27.3 mm (1.07 in)
<Limit> IN. <25.4 mm (1.00 in»
EX. <25.4 mm (1.00 in»
Compressed length (valve closed):
IN. 24.9 mm (0.980 in)
EX. 24.9 mm (0.980 in)
<Tilt Limit>*: IN.&EX. <2.5° or 1.2 mm (0.047 in»
2-4
MAINTENANCE SPECIFICATIONS ISPECI Pf I
Model YFM80(D)
Direction of winding (top view): IN EX
Piston:
c c
Piston size "0" 46.960 - 46.975 m m (1.8488 - 1.8494 in)
Measuring point "H" 10 mm (0.39 in)
(From bottom line of piston skirt)
Piston over size: 2nd 47.50 mm (1.870 in)
4th 48.00 mm (1.890 in)
Piston clearance 0.025 - 0.045 mm (0.0010 - 0.0018 in)
<Limit> < 0.15 mm (0.006 in) >
,Piston pin bore inside diameter 13.002 - 13.013 mm (0.5119 - 0.5123 in)
Piston pin outside diameter 12.996 - 13.000 mm (0.5117 - 0.5118 in)
Piston ring:
Top ring
Type Barrel
DimensionsJB x T) 1.0 x 2.0 mm (0.039 x 0.079 in)
End gap (installed) 0.10 - 0.25 mm (0.004 - 0.010 in)
<Limit> <0.4 mm (0.016 in) >
Side clearance (installed) 0.030 - 0.065 mm (0.0012 - 0.0026 in)
<Limit> <0.12 mm (0,0047 in»
2nd ring:
Type Taper
Dimensions (B x T) 1.0 x 2.0 mm (0.039 x 0.079 in)
<Limit> <0.4 mm (0.016 in»
Side clearance (installed) 0.020 - 0.055 mm (0.0008 - 0.0022 in)
<Limit> <0.12 mm (0~0047 in»
Oil ring:
Dimensions (B x T) 2.0 x 2.3 mm (0.079 x 0.091 in)
<Limit> <0.4 mm (0.016 in»
Crankshaft: F
,....
~l _9
~fI-------~J
A
Crank width" A" 40.20 - 40.25 mm (1.583 - 1.585 in)
<Runout limit "C"> <0.05 mm (0.002 in»
Big end side clearance "0" 0.1 - 0.4 mm (0.004 - 0.016 in)
<Limit> <0.5 mm (0.020 in»
Big end radial clearance "E" 0.004 - 0.019 mm (0.0002 - 0.0007 in)
Small end free play "F" 0.8 - 1.0 mm (0.031 - 0.039 in)
< Limit> <1.5 mm (0.059 in»
2-5
Model YFMBO(O)
Clutch:
Friction plate:
Thickness x Quantity 2.92 - 3.0B mm (0.115 - 0.121 in) x 6
<Wear limit> <2.9 mm (0.114 in»
Clutch plate:
Thickness x Quantity 1.2 - 1.6 mm (0.047 - 0.063 in) x 5
<Warp limit> <0.06 mm (0.0024 in»
Clutch spring:
Free length x Quantity 30.1 mm (1.1B5 in) x B
Clutch release method Inner push, cam push
Clutch-in revolution 2,100 - 2,300 r/min
Clutch-stall revolution 2,BOO - 3,000 r/min
Transm ission:
<Main axle deflection limit> <O.OB mm (0.0031 in»
<Orive axle deflection limit> <O.OB mm (0.0031 in»
Shifter:
Shifter type Cam drum and guide bar
Carburetor:
Type/manufacturer/quantity VM16SH/MIKUNI/1
1.0. mark 3GBOO
Main jet (M.J.) #BO
Main air jet (M.A.J.) flj 1.2
Jet needle-clip position (J.N.) 3PZ5-3
Needle jet (N.J.) O-B (#559)
Cutaway (C.A.) 3.5
Pilot outlet (P.O.) fljO.7
Pilot screw (P.S.) 1-1/B
Valve seat (V.S.) flj 1.2
Fuel level (F .L.) 2.5 - 4.5 mm (0.10 - 0.1B in)
Below carburetor body edge
Float height (F. H.) 20.0 - 22.0 mm (0.79 - 0.B7 in)
Engine idling dpeed 1,700 - 1,900 r/min
Lubrication system:
Oil filter type Wire mesh
Oil pump type Trochoid type
Tip clearance 0.15 mm (0.0059 in)
<Limit> <0.20 mm (0.0079 in»
Side clearance 0.06 - 0.10 mm (0.0024 - 0.0039 in)
<Limit> <0.15 mm (0.0059 in»
Bypass valve setting pressure BO - 120 kPa (O.B - 1.2 kg/cm2, 11 - 17 psi)
Shaft drive:
Middle gear backlash 0.17 - 0.31 mm (0.007 - 0.012 in)
Final gear backlash 0.17 - 0.31 mm (0.007 - 0.012 in)
2-6
MAINTENANCE SPECIFICATIONS ISPECI ~f I
Model YFM80(D)
lubrication diagram:
'---> :
-----
Pressu re feed
: Splashed scavenge
Cam shaft
Cam chain
area
Oil pan Oil strainer
Crankcase tightening sequence:
2-7
MAINTENANCE SPECIFICATIONS ISPECI p~ I
TIGHTENING TORQUE:
Parts Tightening torque
Parts to be tightened Thread size Q'ty Remarks
name Nm m· kg ft· Ib
Cyl i nder head Cap nut M 6 x 1.0 4 12 1.2 8.7
Screw M 6 x 1.0 2 7 0.7 5.1
Spark plug - M10 x 1.0 1 13 1.3 9.4
Cam sprocket cover Screw M 6 x 1.0 2 10 1.0 7.2
Flywheel magneto Nut M10x1.25 1 40 4.0 29
Valve clearance adjusting Nut M 5 xO.5 2 7 0.7 5.1
Cam sprocket Bolt M 8 x 1.25 1 20 2.0 14
Chain tensioner Plug M18 x 1.5 1 15 1.5 11
Nut M 6 x 1.0 1 7 0.7 5.1
Cap nut M 6 x 1.0 1 5 0.5 3.6
Bolt M 6 x 1.0 1 4 0.4 2.9
Oil pimp Screw M 5 xO.8 1 4 0.4 2.9
Screw M 6 x 1.0 2 7 0.7 5.1
Dran plug - M12 x 1.5 1 20 2.0 14
Intake manifold Bolt M 6 x 1.0 2 7 0.7 5.1
Carburetor Screw M 6 x 1.0 2 7 0.7 5.1
Muffler stay Bolt M 8 x 1.25 2 25 2.5 18
Exhaust pipe Nut M 6 x 1.0 2 10 1.0 7.2
Crankcase Screw
Bolt
M 6 x 1.0
M 6 x 1.0
9
3
7
10
0.7
1.0
5.1
7.2
-C
Bearing cover plate Screw M 6 x 1.0 4 7 0.7 5.1
Crankcase cover Screw M 6 x 1.0 12 7 0.7 5.1
Stud bolt M 6 x 1.0 4 10 1.0 7.2
Starter clutch Screw M 6 x 1.0
M12 x 1.0
3
1
10
50
1.0
5.0
7.2
36
-G
Primary drive gear Nut
Clutch push plate Screw M 6 x 1.0 4 8 0.8 5.8
Push lever axle Nut M 6 x 1.0 1 8 0.8 5.8
Guide Screw M 6 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 M 6 x 1.0 3 10 1.0 7.2
Middle driven shaft Nut M12x1.25 1 90 9.0 64 -G
Stopper plate Screw M 6 x 1.0 2 8 0.8 5.8 ;C
Stopper lever Bolt M 6 x 1.0 1 14
10
1.4
1.0
10
7.2
-G
Shift pedal Bolt M 6 x 1.0 1
Stopper screw Screw M 8 x 1.25 1 25 2.5 18 -C
Bearing housing (final) Nut M50 x 1.5 1 60 6.0 43 i-C
Bolt M 6 x 1.0 6 10 1.0 7.2 ~
Bolt M 8x1.25 3 25 2.5 18
Pick-up coil Screw M 5 xO.8 1 4 0.4 2.9
Neutral switch - M10 x 1.25 1 10 1.0 7.2
Flywheel magneto (base plate) Screw M 6 x 1.0 2 7 0.7 5.1
Starter motor Bolt M 6 x 1.0 2 10 1.0 7.2
2-8
MAINTENANCE SPECIFICATIONS ISPECI ~fl
CHASSIS
Model YFM80(D)
Steering system:
Lock to lock angle:
Left 40°
Right 40°
Front suspension:
Cushion stroke 60 mm (2.36 in)
Optional spring No.
Rear suspension:
Cushion stroke 58 mm (2.28 in)
Optional spring No.
Wheel:
Front wheel type Panel wheel
Rear wheel type Panel wheel
Front rim size/material 7 x 5.5AT/steel
Rear rim size/material 8 x 7.5AT/steel
Rim runout limit:
Vertical <2.0 mm (0.08 in»
Lateral <2.0 mm (0.08 in»
Drum brake: Front Rear
Type Leading and trailing ~
Drum inside diameter 110 mm (4.33 in) 130 mm (5.12 in)
<Limit> <110.5 mm (4.35 in» <130.5 mm (5.14 in»
Lining thickness 4 mm (0.16 in) ~
<Limit> <2 mm (0.08 in» ~
Shoe spring free length 54 mm (2.13 in) 36.5 mm (1.44 in)
Brake lever free play (front brake) 10 ... 12 mm (0.4 ... 0.5 in) at lever pivot
Brake lever free play (rear brake) 3 ... 5 mm (0.12 ... 0.20 in) at lever pivot
Brake pedal free play 20 ... 30 mm (0.8 ... 1.2 in)
2-9
MAINTENANCE SPECIFICATIONS ISPECI ~fj I
TIGHTENING TOROUE:
Tightening torque
Parts to be tightened Thread size Remarks
Nm m· kg ft· Ib
Engine (upper) and frame M 8 x1.25 33 3.3 24
Engine (rear) and frame M 8 x 1.25 33 3.3 24
Frame and swingarm M12x1.25 85 8.5 61 Use lock washer
Swingarm and swingarm guard M 8 x 1.25 23 2.3 17
Rear shock absorber (top and bottom) M10 x 1.25 45 4.5 32
Lower arm and frame M12x1.25 55 5.5 40
Front shock absorber and frame M10x1.25 45 4.5 32
Front shock absorber and lower arm M12x1.25 45 4.5 32
Steering knuckle and lower arm M10x1.25 30 3.0 22
Steering knuckle and ball joint M10 x 1.25 40 4.0 29
Steering shaft and ball joint M10x1.25 40 4.0 29
Tie-rod and locknut M10 x 1.25 30 3.0 22
Steering shaft and frame M10 x 1.25 30 3.0 22
Steering shaft and bracket and frame M 8 x 1.25 23 2.3 17
Steering shaft and handlebar holder M 8 x 1.25 23 2.3 17
Fuel cock M 6 x 1.0 5 0.5 3.6
Front panel wheel and front hub M 8x1.25 28 2.8 20
Steering knuckle and castle nut M14 x 1.5 70 7.0 50
Brake camshaft lever M 6 x 1.0 9 0.9 6.5
Rear axle and rear axle nut M28 x 1.5 - - - See note
Rear panel wheel and wheel shaft collar M10x1.25 45 4.5 32
Wheel shaft collar and rear axle M12x1.25 70 7.0 50
Rear hub and swingarm M10x1.25 40 4.0 29
Footrest M12x1.25 85 8.5 61
Front bumper M 8 x 1.25 23 2.3 17
NOTE: ___________________________________________________
1.Apply Loctite® to the thread portion of the rear axle.
2.Finger tighten the inside nut while checking the ring gear engagement.
3.Tighten the inside nut to 110 Nm (11.0 m • kg, 80 ft ·Ib) while holding the rear axle.
4.Hold the inside nut and tighten the outside nut to 130 Nm (13.0 m • kg, 94 ft • Ib).
5.Hold the outside nut and tighten back the inside nut to 160 Nm (16.0 m • kg, 115 ft • Ib).
2-10
MAINTENANCE SPECIFICATIONS ISPECI p~ I
ELECTRICAL
Model YFMBO(D)
Voltage: 12V
Ignition system:
Ignition timing (B.T.D.C.) 10° at 1,700 r/min
Advanced timing (B.T.D.C.) 30° at 5,000 r/min
Advancer type Electrical
J J 1 .1
30° at 5,000 r/mm
30°
0)
c
'E
i=-: 20° /
c U
.o
_ C.
c t-=.
.'!: 10° 1/
,2)~
1
10 at 1(00 I'mi
l
0 2 4 6 8
Engine speed (x 103 rim in)
COl:
Magneto model/manufacturer 4EM/MORIYAMA
Pickup coil resistance (color) 297 ... 3630 at 20°C (6BOF) (W/L - W/R)
Source coil resistance (color) 342 ... 41BO at 20°C (6BOF) (GNI/ - B/R)
COl unit model/manufacturer 4EM/MORIYAMA
Ignition coil:
Model/manufacturer C2T4/MORIYAMA
Primary winding resistance 1.4 ... 1.BO at 20°C (6BOF)
Secondary winding resistance 5.3 ... 7.9kO at 20°C (6BOF)
Spark plug cap:
Type Resin
Resistance 10kQ at 20°C (6BOF)
Charging system!type Flywheel magneto
F.W. magneto:
Charging current Minimum 0.7A at 3,000 r/min
Maximum 3.0A at B,OOO r/min
Charging coil resistance (color) O.B ... 1.00 at 20°C (6BOF) (B - W)
lighting voltage Minimum 11.0V at 3,000 rIm in
Maximum 15.5V at B,OOO r/min
lighting coil resistance (color) 0.36 ... 0.440 at 20°C (6BOF) (Y/R - B)
14
.A ~ :>
~3 12
+-'
c: / 1\ 10 0)
Q)
...
...::J2
Q)
If !eV co
+-'
J 8 "0
>
U
0)
c
II ';I. 6 0)
c:
~1
co ~
!\ .~
4 ..r::
0)
..r::
U ~
~ :.J
If' 2§
e
1 2 3 4 5 6 7 8 9
Engine Speed (x 103 r/min)
I
2-11
Model YFM80(D)
Type Short circuit type
Model/manufacturer EHU-O 1TR/MATSU SH ITA
Capacity 10A
Withstand voltage 240V
Battery:
Capacity 12V,7AH
Specific gravity 1.280
Starter motor:Model/manufacturer ADB4A4/NIPPONDENSO
Out put 0.2kW
Armature coil resistance 0.043Q at 20°C (68°F)
Brush: Overall length 7 mm (0.28 in)
< Limit> < 3.5 mm (0.14 in) >
Spring pressure 310 .... 450 g (11 .... 16 oz)
< Wear limit> < 15.5 mm (0.61 in) >
Starter relay: Model/manufacturer A 104-132/HITACHI
Amperage rating 4A
Coil winding resistance 4.4 .... 4.8Q at 20°C (68°F)
Model/manufacturer ACA121/MATSUSHITA
Coil winding resistance 72 .... 88Q at 20°C (68°F)
Diode No.
Circuit breaker:
Type Fuse
Amperage for individual circuit/quantity:
Main 10Ax 1
Reserve 10Ax 1
2-12
GENERAL TORQUE SPECIFICATIONS ISPECI7'~ I
GENERAL TORQUE
SPECIFICATIONS General torque
A B specifications
This chart specifies torque for standard fas- (Nut) (Bolt)
teners with standard I.S.0. pitch threads. Nm m· kg ft· Ib
Torq ue specifications for special com ponents 10mm 6mm 6 0.6 4.3
or assemblies are included in the applicable 12mm 8mm 15 1.5 11
sections of this book. To avoid warpage,
14mm 10mm 30 3.0 22
tighten multifastener assemblies in a criss-
17mm 12mm 55 5.5 40
cross fashion, in progressive stages, until full
torque is reached. Unless otherwise speci- 19mm 14mm 85 8.5 51
fied, torque specifications call for 22mm 16mm 130 13.0 94
clean, dry threads. Components should be at
room temperature.
IA
L~
[AJ Distance across flats
ffil Outside thread diameter
2-13
LUBRICATION POINTS AND LUBRICANT TYPE ISPECI ~f I
LUBRICATION POINTS AND LUBRICANT TYPE
ENGINE
lubrication points lubricant type

Bearing retainer (all) -C!]
Oil seal lips (all) .~
a-rings (all) ~
Valve stem and valve guide -~

Oil seal (valve stem end) --Ie
Rocker arm shaft and rocker arm -Ie
Cam (camshaft) -Ie
Crank pin -Ie
Piston, piston rings and piston pin -Ie
Rotor and rotor housing (oil pump) -Ie
Cam chain guide -Ie
Push lever ~
Push rod ~
Primary driven gear -tel
Transmission gear -EJ
Shift fork guide bar, shift cam and shift shaft -tel
Drive shaft damper ~
Final gear case Shell TG-0983
Stator assembly
--~
Sealant (Quick Gasket)®
Crankcase mating surfaces
Yamaha Bond No.4
Sealant (Quick Gasket)®
Bearing housing and drive shaft housing mating surface
Yamaha Bond No.4
CHASSIS
lubrication points lubricant type

Oil seal lips (all) ~
a-rings (All) ~
Pivoting points (steering knuckle) ~
Cam shaft (front brake) ~
Bushes (steering column) ~
Brake cable end ~
Throttle cable end (at lever side) ~
Cam shafts (rear brake) ~
2-14
LUBRICATION DIAGRAM ISPECI p~ I
LUBRICATION DIAGRAM
CD Camshaft
® Centrifugal oil filter
2-15
LUBRICATION DIAGRAM ISPEcl)Of I
(DOil pum P d·
'2'. riven gear
w011 pump
~OO~II pu~p cover gasket
I strainer
@Orain plug
®Oil pump
2-16
CABLE ROUTING ISPEClpf I
CABLE ROUTING
CD Throttle cable ® Rectifier/regulator [A] Pass the final gear case
® Final tank breather hose (jJ) Battery breather hose breather hose through the
@ Carburetor ventilation hose @CDI magneto lead guide.
@ Final gear case breather hose @Carburetor overflow hose [ID Pass the battery breather
@ Crankcase breather hose @ Front brake cable hose through the hole.
@Fuel hose
(j) Band
® Starter relay
® Starting circuit cut-off relay
2-17
CABLE ROUTING ISPECI Y'f I
CD Rear brake switch lead ® Ignition coil
® Front brake cable @ Main switch
@Fuel tank breather hose @COI unit
@Rear brake cable @Fuel hose
® "NEUTRAL" indicator light lead
®Wire guide
(J) Handlebar switch lead
@Sand
®Wireharness
2-18
CABLE ROUTING ISPECI Pf I
CD Front brake cable [A] Pass the leads through the hole.
® Throttle cable
@ Fuel tank breather hose
@ Battery negative lead
®Fuse
® Battery positive lead
(j) Band
® Handlebar switch
® Rear brake switch
(j]) Rear brake cable
\,
({):')
. (.
'-.~--:......-.....-.---:---- --- /
5r--------+----4#~
4
G 0
1,- -_ ~-d0 i
~-=::=:::::__-LI
2-19
INTRODUCTION/ ~8.r I~I
PERIODIC MAINTENANCE/LUBRICATION _ _~_
I
PERIODIC INSPECTION AND ADJUSTMENT
INTRODUCTION
This chapter includes all information necessary to perform recommended inspections and
adjustments. These preventive maintenance procedures, iffollowed, 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 technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION
Initial EVERY
ITEM REMARKS 1 month 3 months 6 months 6 months 1 year
Valve(s)* Check valve clearance. Adjust if necessary. 0 0 0 0
Cam chain* Check chain tension. Adjust if necessary. 0 0 0 0
Spark plug Check condition. Clean or replace if necessary. 0 0 0 0 0
Air filter Clean. Replace if necessary. Every 20-40 hours (More often in wet or dusty arears.)
Check idle speed/starter operation.
Carburetor* Adjust if necessary. 0 0 0 0
Check fuel hose for cracks or damage.
Fuel line* Replace if necessary. 0 0 0
Engine oil Replace (Warm engine before draining). 0 0 0 0
Oil strainer* Clean. Replace if necessary. 0 0 0
Check oil level/oil leakage.
Final gear oil Replace every 12 months. 0 0
Brake* Check operation. Adjust if necessary. 0 0 0 0 0
Clutch* Check operation. Adjust if necessary. 0 0 0 0
Check balance/dar:nage/runout.
Wheels* Repair if necessary 0 0 0 0
Check bearings assembly for looseness/damage.
Wheel bearings* Replace if damaged. 0 0 0 0
Check operation/replace if damage.
Steering system* Check toe-in/adjust if necessary. 0 0 0 0 0
Knuckle shafts/
Steering shaft*
Lubricate every 6 months. ** 0 0 0
Check all chassis fittings and fasterners.
Fittings/Fasteners* Correct if necessary. 0 0 0 0 0
Check specific gravity.
Battery* Check breather pipe for proper operation. 0 0 0 0 0
Correct if necessary.
* : It is recommended that these items be serviced by a Yamaha dealer or other qualified mechanic.
** : Lithium soap base grease.
3-1
FRONT FENDER/
REAR FENDER AND FUEL TANK
IINSP
ADJ ~
I I
FENDERS AND FUEL TANK
FRONT FENDER
Removal
1. Place the machine on a level place.
2. Remove:
• Front cover CD
• Main switch holder ®
• Front fender ®
NOTE: _ _ _ _ _ _ _ _ _ __
When removing the front fender, loosen and
disconnect the carburetor joint @ .
Installation
Reverse the"Removal" procedures.
REAR FENDER AND FUEL TANK

Removal
2. Remove:
• Seat
NOTE: _ _ _ _ _ _ _ _ _ __
Pull the lock lever CD backward, then pull up
the seat at the rear.
3. Disconnect:
• Battery band CD
• Battery leads
• Battery breather hose ®
Disconnect the negative lead ® first, and

then disconnect the positive lead @ .
4. Remove:
• Battery @
• Fuse ®
3-2
REAR FENDER AND FUEL TANK I~gr Inl
5. Remove:
• Rear fender CD
NOTE: ______________________
When removing the rear fender, pass out the
all leads through the hole ® .
6. Turn the fuel cock to "OFF".

7. Disconnect:
• Fuel hose CD
a.Remove:
• Fuel tank CD
Installation
Reverse the "Removal" procedures.
Note the following points.
1. Install:
• Rear fender
NOTE: ______________________
Pass the battery leads through the hole ® of
the rear fender.
2. Install:
• Battery
• Connect the positive lead first, and then

connect the negative lead.
• Be sure the battery breather hose is properly
attached and routed. Referto the uBATTERV
INSPECTION" section.
3-3
CAM CHAIN TENSION ADJUSTMENT IIANOSJP I~ I _~ _
---------------------------------------------------------
ENGINE
CAM CHAIN TENSION ADJUSTMENT
1.Remove:
• Shift pedal CD
• Crankcase cover ® (left)
2. Remove:
• Side cover CD (cylinder head)
• Cap nut ® (chain tensioner)
3. Loosen:
• Locknut ® (chain tensioner)
• Adjuster @ (chain tensioner)
4. Adjust:
• Cam chain tension
*************************************
Adjustment steps:
• Turn the crankshaft counterclockwise with
wrench.
• Align the liT" mark ® on the rotor with the
stationary pointer ® on the crankcase.
When the "T" mark is aligned with the
stationary pointer, piston is at Top Dead
Center (TDC).
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 CD.
• In this position, tighten the adjuster.
• Install the locknut and crown nut.
Locknut (cam chain tensioner):

7 Nm (0.7 m • kg, 5.1 ft • Ib)
1----- Cap nut (cam chain tensioner):
5 Nm (0.5 m • kg, 3.6 ft • Ib)
*************************************
3-4
VALVE CLEARANCE ADJUSTMENT
5. Install:
I~8r IIfill
• Side cover (cylinder head)
• Crankcase cover (left)
• Shift pedal
Screw (cylinder head side cover):

7 Nm (0.7 m· kg, 5.1 ft ·Ib)
~-~ Screw (left crankcase cover):
7 Nm (0.7 m· kg, 5.1 ft ·Ib)
Bolt (shift pedal):
10 Nm (1.0 m • kg, 7.2 ft .Ib)
VALVE CLEARANCE ADJUSTMENT

1.Remove:
• Shift pedal CD
2. Remove:
• Tappet cover CD (intake)
• Tappet cover ® (exhaust)
3. Measure:
• Valve clearance
*************************************
Measurement steps:
• Turn the crankshaft counterclockwise with
wrench.
NOTE: _ _ _ _ _ _ _ _ _ __
Valve clearance must be measured when the
engine is cold to touch.
3-5
VALVE CLEARANCE ADJUSTMENT I~gf IIfiII
• Align the "T" mark ® on the rotor with the
stationary pointer @ on the crankcase.
When the "T" mark is aligned with the
stationary pointer, the piston is atTod Dead
Center (TDC).
NOTE: _______________________
Be sure the match mark © on the cam chain
sprocket is aligned with the match mark@on
the cylinder head .
• Measure the valve clearance using a feeler

gauge CD.
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
*************************************
Adjustment steps:
• Loosen the locknut CD .
• Insert a feeler ga uge®between the adjuster
end and the valve end.
• Turn the adjuster ® clockwise or counter-
clockwise with the valve adjusting tool ®
until proper clearance is attained.
Valve adjusting tool:

YM-08035, 90890-01311
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 adjusterto prevent itfrom moving

and thoroughly tighten the locknut.
Valve clearance adjusting locknut:

7 Nm (0.7 m • kg, 5.1 ft • Ib)
3-6
IDLE SPEED ADJUSTMENTI
THROTTLE LEVER ADJUSTMENT
IINSP I I
ADJ f i
• Measure the valve clearance .
• If the clearance is incorrect, repeat above
steps until the proper clearance is obtained.
*************************************
5. Install:
• Tappet covers (intake and exhaust)
• Shift pedal

7 Nm (0.7 m· kg, 5.1 ft ·Ib)
......-~ Screw. (left crankcase cover):
7 Nm (0.7 m • kg, 5.1 ft ·Ib)
Bolt (shift pedal):
10 Nm (1.0 m • kg, 7.2 ft· Ib)
IDLE SPEED ADJUSTMENT

1.Adjust:
• Idle speed
Warm upthe engine and turn the throttle
stop screw CD to adjust.
Idle speed:
1,700 - 1,900 r/min
THROTTLE LEVER ADJUSTMENT

NOTE: ______________________
Before adjusting the throttle lever free play,
the engine idling speed should be adjusted.

2.Check:
• Throttle lever free play ®
Out of specification ~ Adjust.
Throttle lever free play:

3 - 5 mm (0.12 - 0.20 in)
3-7
SPEED LIMITER ADJUSTMENT I~8f ,....,
3. Adjust:
• Throttle lever free play
*************************************
Adjustment steps:
• Pull up the adjuster cover CD .
• Loosen the locknut ® .
• Turn the adjuster @ clockwise or counter-
clockwise until specified free play is at-
tained.
Clockwise Free play is increased.
Counterclockwise Free play is decreased.
• Tighten the locknut.

Reset____________________
•NOTE: the adjuster covers. __
After adjusting the free play, turn the handle-
bar to right and left, and make sure that the
engine idling does not run faster.
*************************************
The speed lim iter keeps the carburetor throttle
from becoming full-open even when the
throttle grip is turned toa maximum. Screwing
in the adjuster stops the engine speed from
increasing.
1.Adjust:
• Speed limiter length ®
II; *************************************
Adjustment steps:
• Loosen the locknut CD.
• Turn the adjuster ® clockwise or counter-
clockwise until specified length is attained.
Speed limiter length:

15 mm (0.6 in)
A 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.
• For proper throttle lever operation, do not
(0.59 in). Also adjust the throttle lever free
play always to 3 ... 5 mm (0.12 ... 0.20 in).
*************************************
3-8
SPARK PLUG INSPECTION
SPARK PLUG INSPECTION
I'r8f lfil
1. Remove:
• Spark plug
2. Inspect:
• Spark plug type
Incorrect ~ Replace.
Standard spark plug:
C7HSA (NGK), U22FS-U (NO)
(For USA and OCE)
CR7HS (NGK) (For EUR)
3. Inspect:
• Electrode CD
Wear/Damage ~ Replace.
• Insulator color @
Normal condition is a medium to light
®t tan color.
Distinctly different color ~ Check the
engine condition.
4. Clean the spark plug with a spark plug

cleaner or wire brush.
5. 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)
6. Tighten:
• Speak plug
NOTE: ______________________
Before installing a spark plug, clean the gas-
ket surface and plug surface.
Spark plug:
13 Nm (1.3 m • kg, 9.4 ft· Ib)
NOTE: ______________________
If a torque wrench is not available when you
are installing a spark plug, a good estimate of
the correcttorque is 1/4 to 1/2 turns partfinger
tight. Have the spark plug torqued to the
correctvalue as soon as possible with a torque
wrench.
3-9
IGNITION TIMING CHECK I~8f Inl
IGNITION TIIYIING CHECK
NOTE: ______________________
Engine idling speed and throttle cable free
play should be adjusted properly before
checking the ignition timing.
1. Remove:
• Shift pedal CD
• Crankcase cover @ (left)
2.Check:
• Ignition timing
*************************************
Checking steps:
• Attach the timing light CD and inductive
tachometer to the spark plug lead.
Timing light:
YM-33277,90890-03109
.....- . . Inductive tachometer:
YU-08036, 90890-03113
• 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 (tigh.tness and/or damage).
*************************************
3. Install:
• Shift pedal
Screw (left crankcase cover):

7 Nm (0.7 m· kg, 5.1 ft ·Ib)
.............. Bolt (shift pedal):
10 Nm (1.0 m • kg, 7.2 ft • Ib)
3-10
COMPRESSION PRESSURE MEASUREMENT I~gf IIPJII
COMPRESSION PRESSURE MEASUREMENT
NOTE: _ _ _ _ _ _ _ _ _ __
• Insufficient compression pressure will re-
sult in performance loss.
• Valve clearance should be adjust properly
before measuring the compression pres-
sure.
1. Warm up the engine, and stop it.

2. Remove:
• Spark plug
3. Measure:
• Compression pressure
*************************************
Measurement steps:
• Attach the compression gauge CD.
Compression gauge:
YU-33223, 90890-03081
• Crank over the engine with the throttle

wide-open until the compression reading
on the gauge stabilizes.
A WARNING
When cranking the engine, ground the spark
plug lead to prevent from sparking.
Compression Pressure (at sea

level):
Standard:
1,177 kPa (12 kg/cm2, 171 psi)
Minimum:
981 kPa (10 kg/cm2, 142 psi)
Maximum:
1,275 kPa (13 kg/cm2, 185 psi)
Above the maximum pressure ~ Inspect cyl-

inder head, valve su rfaces, and piston crown
for carbon deposits.
Below the minimum pressure ~ Squirt a few
drops of oil into affected cylinder and cylin-
der and measure again.
Follow the table below.
Compression pressure
(with oil introduced into cylinder)
Reading Diagnosis
Higher than without oil Worn or damaged piston
Defective ring(s), valves,
Same as without oil cylinder head gasket or
piston is possible.
*************************************
3-11
AIR FILTER CLEANING IIANOSJP I~ I ~
-------------------------------------------------------
AIR FILTER CLEANING
NOTE: .
There is a check hose Q) 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 Q)
• Rubber band @
2. Pull out the air filter element assembly.
3. Remove:
• Air filter element ®

4. Inspect:
• Element
Damage ~ Replace.
5.Clean:
• Air filter element
*************************************
Cleaning steps:
• Wash the element gently, but throughly in
solvent.
A WARNING
Never use low flash point solvents such as
gasoline to clean the air filter element. Such
solvent may lead to a fire or explosion .
• Squeeze the excess solvent out of the ele-

ment and let dry.
Do not twist the filter element when

squeezing the filter element.
3-12
ENGINE OIL LEVEL INSPECTION I~gf IIP.iII
• Apply the engine oil.
• Squeeze out the excess oil.
NOTE: _ _ _ _ _ _ _ _ _ __
*************************************
6. Install:
• Air filter element
NOTE: _ _ _ _ _ _ _ _ _ __
• Make sure its sealing surface matches the
leak.
• Insert the lobe on the front cover into the
receptacle on the front fender.
ENGINE OIL LEVEL INSPECTION

1.Check:
• Engine oil level
Oil level low --+ Add sufficient oil.
*************************************
Checking steps:
• Place the machine on a level place.
• Warm up the engine for several minutes,
and stop it.
• Unscrew the. dipstick <D completely, and
wipe it off with a clean rag. Restthe dipstick
in the hole.
NOTE: _ _ _ _ _ _ _ _ _ __
When checking engine oil level, let the un-
screwed dipstickjust reston the case threads.
• Pull up the dipstick, and inspectthe 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.
Refer to the "ENGINE OIL REPLACEMENT"
section.
*************************************
3-13
ENGINE OIL REPLACEMENT IANOSJP I~I
---------------------------------------------------
rz:.- I
ENGINE OIL REPLACEMENT
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 ft • Ib)
7. Fill:
• Crankcase
30 40
Oil quantity:
Periodic oil change:
0.8 L (0.70 Imp qt, 0.85 US qt)
Total amount:
0.95 L (0.84 Imp qt, 1.00 US qt)
o 5 10 Recommended oil:
Vamalube 4 (20W40) or
SAE 20W40 type SE motor oil
SAE 1OW30 type SE motor oil
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.Check:
• Oil leaks
• Oil level
3-14
OIL STRAINER CLEANING 1~8f 1&1
OIL STRAINER CLEANING
2. Warm up the engine for several minutes,
and stop it.
4. Remove:
• Oil filler cap
• Drain plug
Drain the engine oil.
5. Remove:
• Seat
• Rear fender
• Muffler CD
6. Remove:
• Footrest CD (right)
• Fender stay @
7. Remove:
• Crankcase cover CD (right)
8. Remove:
• Oil strainer CD
3-15
CLUTCH ADJUSTMENT
-----------------------------------------------------
IIANOSJP I~I ~
9.Clean:
• Oil strainer
Clean it with solvent.
10. Inspect:
• Gaskets
• Oil strainer
Damage ~ Replace.
11.lnstall:
• Oil strainer
• Crankcase cover (right)
• Footrest
• Muffler
• Rear fender
• Seat
• Drain plug
Screw (right crankcase cover):

7 Nm (0.7 m· kg, 5.1 ft ·Ib)
Nut (exhaust pipe):
10 Nm (1.0 m • kg, 7.2 ft· Ib)
Bolt (Muffler):
25 Nm (2.5 m • kg, 18 ft • Ib)
Drain plug:
20 Nm (2.0 m • kg, 14 ft· Ib)
12. Fill:
• Crankcase
Refer to the "ENGINE OIL REPLACE-
MENT" section.
13.Check:
• Oil leaks
• Oil level
CLUTCH ADJUSTMENT
1.Remove:
• Cap cover
2. Adjust:
• Free play
*************************************
Adjustment steps:
• Loosen the locknut CD .
• Slowly turn the adjuster @ clockwise until
resistance is felt.
3-16
CLUTCH ADJUSTMENT 1~8f 1&1
• Turn it 1/8 counterclockwise.
NOTE: ______________________
Turn the adjuster counterclockwise to de-
crease the clutch free play and turn it clockwise
to increase the free play .
Locknut (clutch):
8 Nm (0.8 m • kg, 5.8 ft • Ib)
*************************************
3. Install:
• Cap cover
3-17
FRONT BRAKE ADJUSTMENTI iANOSJP I~I
REARBRAKELEVERANDPEDALADJUSTMENT. .~.
I
CHASSIS
FRONT BRAKE ADJUSTMENT
NOTE: ______________________
Before adjusting the front brake, the front
brake linings should be inspected.
1. Inspect:
• Front brake lever free play ®
• Difference between ® and ©
Out of either specification -)0 Adjust.
Front brake lever free play:

10 ... 12 mm (0.4 ... 0.5 in)
t - -liIIoI Difference between @ and ©:
Zero ... 2 mm (Zero ... 0.08 in)
2. Adjust:
• Front brake lever free play ®
• Difference between ® and ©
*************************************
Adjustment steps:
• Loosen the locknuts CD .
• Turn the adjusters @ in or out until the
specified free play and difference are ob-
tained.
• Tighten the locknuts.
*************************************
REAR BRAKE LEVER AND PEDAL

ADJUSTMENT
NOTE: ____________ ~-- __----
Before adjusting the rear brake, the rear brake
linings should be inspected.
A WARNING
Always adjust both the brake pedal and the
brake lever whenever adjusting the rear brake.

2.Check:
• Brake lever free play ®
• Brake pedal free play @
Out of specification -)0 Adjust.
3·18
REAR BRAKE LEVER AND PEDAL ADJUSTMENT I~8f lfil
Free play (brake lever):
5 - 8 mm (0.20 - 0.31 in)
at brake lever pivot.
Free play (brake pedal):
20 - 30 mm (0.79 - 1.18 in)
NOTE: _ _ _ _ _ _ _ _ _ __
Adjust free play of both brake cables if either
is out of specification.
3. Adjust:
• Brake cable free play (brake lever)
• Brake cable free play (brake pedal)
*************************************
Adjustment steps:
NOTE: _ _ _ _ _ _ _ _ _ __
Before adjusting the free plays, pump the
brake pedal 2 to 3 times.
• Fully loosen the brake lever cable adjuster

(handlebar) CD and locknut (handlebar) ® .
• Fully loosen both brake lever cable adjuster
(hub)@and bake pedal cable adjuster (hub)
@.
• Turn the brake lever cable adjuster (hub)@
until thegap@iswithinthespecified limits.
~Gap@:
r6l 0 - 1 mm (0 - 0.04 in)
® Brake cam lever

® Pin
• Turn the adjuster CD in or out until the
specified free play is obtained.
Free play (brake lever) ® :

5 - 8 mm (0.20 - 0.31 in)
A WARNING
After this adjustment is perform, block the
rear of the machine off the ground, and spin
the rear wheels to ensure there is no brake
drag. If any brake drag is noticed, perform the
above steps again.
3-19
BRALE LINING INSPECTIONI
FINAL GEAR OIL LEVEL INSPECTION
liNADJS P IR I
• Turn the adjuster @ in or out until the
specified free play is obtained.
Free play (brake pedal) © :

20 .. 30 mm (0.79 .. 1.81 in)
A WARNING
After this adjustment is performed, block the
rear of the machine off the ground, and spin
the rear wheels to ensure there is no brake
drag. If any brake drag is noticed, perform the
above steps again .
• Tighten the locknut (handlebar).
*************************************
BRAKE LINING INSPECTION

1. Apply the front and rear brake.
2. Inspect:
• Wear indicator CD
Indicator reaches the wear limit ® ~
Replace shoes.
[AI Front
[ill Rear
FINAL GEAR OIL LEVEL INSPECTION

2.Check:
• Final gear oil level
Oil level low ~ Add sufficient oil.
3-20
FINAL GEAR OIL LEVEL INSPECTION/IINSP I~I
FINAL GEAR OIL REPLACEMENT ADJ ~.
*************************************
Checking steps:
• Unscrew the dipstick CD completely, and
wipe it off with a clean rag. Restthe dipstick
in the hole.
NOTE: _ _ _ _ _ _ _ _ _ __
When checking final gear oil level, let the
unscrewed dipstick just rest on the case
threads.
• Pull up the dipstick, and inspectthe 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.
Refer to the "FINAL GEAR OIL REPLACE-
MENT" section.
*************************************
FINAL GEAR OIL REPLACEMENT

3. Remove:
• Dipstick CD
• Drain plug ®
Drain the final gear oil.
4. Inspect:
• Gasket
Damage ~ Replace.
5.lnstall:
• Drain plug
6. Fill:
• Final gear case
Oil quantity:
0.12 L (0.11 Imp qt, 0.13 US qt)
Recommended oil:
SAE 80 API uGL-4" hypoid gear
oil
3-21
DTIVE SHAFT DUST BOOT INSPECTIONI IINSP I~I
STEERING SYSTEM INSPECTION _ADJ _~ _
NOTE: ______________________
GL-4 is a quality and additive rating, GL-5 or
GL-6 rated hypoid gear oils may also be used.
Do not allow foreign material to enter the

final gear case_
7. Install:
• Dipstick
a.Check:
• Oil leaks
• Oil level
DRIVE SHAFT DUST BOOT INSPECTION

1. Inspect:
• Dust boot CD
Loose clamp ® ~ Tighten.
STEERING SYSTEM INSPECTION

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 handlebarfrom left to
right.
Tie-rod end CD has any vertical play ~
Replace the tie-rod end(s).
3-22
TOE-IN ADJUSTMENT I~8r IIIJIIiII
4. Raise the front end of the machine so that
there is no weight on the front wheels.
5. Check:
• Knuckles and/or wheel bearings
Movethe wheels laterally back and forth.
Excessive free play ~ Replace the fol-
lowing parts.
1)Wheel bearings and/or knuckle bushings CD

2)Thrust cover ®
3)Knuckle shaft(s) @
4)Collar(s) @
5)Cotter pin(s) @
TOE-IN ADJUSTMENT
2. Measure:
• Toe-in
Out of specification ~ Adjust
*************************************
Measurement steps:
• Mark both front tire tread centers.
• Raise the frqnt end of the machine so that
there is no weight on the front tires.
• Fix the handlebar straight ahead.
• Measure the width [A) between the marks.
• Rotate the front tires 180 degrees until the
marks come exactly opposite.
• Measure the width ffil between the marks.
3-23
TOE-IN ADJUSTMENT!
TIRE INSPECTION
IINSP I~I
ADJ rz:.-
• Calculate the toe-in usingtheformulagiven
below.
Toe-in = [ID - [AJ
Toe-in:
0- 10 mm (0 - 0.4 in)
• If the toe-in is incorrect, adjust the toe-in.

*************************************
3. Adjust:
• Toe-in
*************************************
Adjustment steps:
• Place a confirmation marks ® on the both
tie-rods end.
• loosen the rod end locknuts CD of both tie-
rods.
• The same numberofturns should be given
to both tie-rods ® right and left until the
specified toe-in is obtained, so that the
lengths of the rods will be kept the same.
• Tighten the rod end locknuts CD of both tie-
rods.
Locknut (rod end):

30 Nm (3.0 m • kg, 22 ft ·Ib)
A WARNING
• Be sure that both tie-rods (left and right)
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 mishandling and accident.
• After setting the toe-in to specification, run
the machine slowly for some distance with
the hands lightly on the handlebar and
checkthatthe handlebar responds correctly.
If not, turn either the right or left tie-rod
within the toe-in specification.
*************************************
TIRE INSPECTiON
A WARNING
This model is equipped with low pressure
tires. It is important that they be inflated
correctly and maintained at" the proper
pressures.
3·24
TIRE INSPECTION I~gr lfil
• TIRE CHARACTERISTICS
1) Tire characteristics influence the
handling of ATV's. The tires listed below
have been approved by Yamaha Motor
Co., Ltd. for this model. If other tire
combinations are used, they can
adversely affect your machine's handling
characteristics and are therefore not
recommended.
~ Manufacturer Size Type
DUNLOP AT18x 7-7 MH03A
Front
CHENG SHIN AT18x 7-7 C864N
DUNLOP AT20 x 9-8 MH04A
Rear
CHENG SHIN AT20x 9-8 C865N
• TIRE PRESSURE
1) Recommende tire pressure
Front 20 kPa (0.20 kgf/cm2, 2.8 psi)
Rear 20 kPa (0.20 kgf/cm2, 2.8 psi)
2) Tire pressure below the minimum
specified could cause the tire to dislodge
from the rim under severe riding
conditions.
The following are minimums:
Front 17 kPa (0.17 kgf/cm2, 2.4 psi)
Rear 17 kPa (0.17 kgf/cm2, 2.4 psi)
3) Use no more than
Front 250 kPa (2.5 kgf/cm2, 36 psi)
Rear 250 kPa (2.5 kgf/cm2, 36 psi)
When seating the tire beads. Higher
pressures may cause the tire to burst.
Inflate the tires very slowly and carefully.
Fast inflation could cause the tire to
burst.
• MAXIMUM LOADING LIMIT
1) Vehicle load limits: 100 kg (220 Ib)*
* Total weight of cargo, rider, and
accessories.
1. Measure:
• Tire pressure (Cold tire pressure)
A WARNING
Uneven or improper tire pressure may
adversely affect the handling of this machine
and may cause loss of control .
• Maintain proper tire pressures.
• Set tire pressures when the tires are cold.
• Tire pressures must be equal in both front
tires and equal in both rear tires.
3-25 - - - - - - - - - - - - - - - -
TIRE INSPECTION/WHEEL INSPECTION
NOTE: _ _ _ _ _ _ _ _ _ __
I~8f Inl
The low-pressure tire gauge CD is included in
the standard equipment.
Ifdustorthe like is stuck to this gauge, it does
not provide correct readings. Therefore, make
two measurements on the tire pressure and
get the second reading.
Cold Tire
Front Rear
Pressure
20 kPa 20kPa
Standard (0.20 kgf/cm2, (0.20 kgf/cm 2,
2.8 psi) 2.8 psi)
17 kPa 17 kPa
Minimum (0.17 kgf/cm2, (0.17 kgf/cm 2,
2.4 psi) 2.4 psi)
23 kPa 23 kPa
Maximum (0.23 kgf/cm2, (0.23 kgf/cm2,
3.2 psi) 3.2 psi)
2. Inspect:
• Tire surfaces
,- --, Wear/Damage ~ Replace.
A WARNING
It is dangerous to ride with a wornout tire.
When a tire wear is out of specification, replace
the tire immediately.
Tire wear limit @ :

Front and rear: 3.0 mm (0.12 in)
WHEEL INSPECTION
1. Inspect:
• Wheels
Cracks/Bends/Damage ~ Replace.
NOTE: _ _ _ _ _ _ _ _ _ __
Always balam:e the wheel when a tire or
wheel has been changed or replaced.
A WARNING
• Never attempt even small repairs to the
whee,1.
• Ride conservatively after installing a tire to
allow it to seat itself properly on the rim.
3-26
NSP I
WHEEL BEARINGS CHECKI
KNUCKLE SHAFT AND STEERING SHAFT LUBRICATION
IIADJ PJi I
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
frameorknucklewhilespiningthewheel.
Excessive vibration ---+ Replace bear-
ings.
Rear Wheel
1. Blockthe front tire and raise the rear of the
machine.
2.Check:
• Rear wheel bearings
Spin the wheel by hand and touch the
rear wheel hub while spining the wheel.
Excessive vibration ---+ Replace bear-
ings.
KNUCKLE SHAFT AND STEERING SHAFT

LUBRICATION
1. Lubricate:
• Pivot points CD
Use a grease gun.
~ Lithium soap base grease
3-27
BATTERY INSPECTION _ 1 ~~rl~1
_ ~_
ELECTRICAL
BATTERY INSPECTION
A WARNING
Battery electrolyte is dangerous; it contains
sulfuric acid and therefore is poisonous and
highly caustic.
Always follow these preventive measures:
• Avoid bodily contact with electrolyte as it
can cause severe burns or permanent eye
injury.
• Wear protective eye gear when handling or
working near batteries
Antidote (EXTERNAL):
• SKIN-Flush with water.
• EYES-Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
• Dring large quantities of water or mil k follow
with milk of magnesia beaten egg, or
vegetable oil. Get immediate medical
attention.
Batteries also generate explosive hydrogen
gas, therefore you should always follow these
preventive measures:
• Charge batteries in a well-ventilated area.
• Keep batteries away from fire, sparks, or
open flames (e.g., welding equipment,
lighted cigarettes; etc.)
• DO NOT SMOKE when charging or handling
batteries.
KEEP BATTERIES AND ELECTROLYTE OUT
OF REACH OF CHILDREN.
1. Remove:
• Seat
2. Disconnect:
• Battery leads (positive and negative)
A WARNING
Disconnect the negative lead fast CD .
3. Remove:
• Battery band @
• Battery ®
3-28
BATTERY INSPECTION . 1 ~8fl~1
. . ~
4. Inspect:
• Battery fluid level
Battery fluid level low ~ Fill.
LEVEL-- -If----t( Fluid level should be between upper
level CD and lower level ® marks.
Refill with distilled water only; tap water

contains minerals harmful to a battery.
5. Inspect:
• Battery fluid specific gravity
Out of specification ~ Charge.
Charging Current:
0.7 amps/10 hrs
Specific Gravity:
1.280 at 20°C (68°F)
*************************************
Replace the battery if:
• Battery voltage will not rise to a specific
value or bubbles fail to rise during charg-
ing.
• Sulfation of one or more cells occurs. (As
indicated by the plates turning white, or an
accumulation of material exists in the bot-
tom of the cell.)
• Specific gravity readings after a long, slow
charge indicate one cell to be lower than
the rest.
• Warpage or buckling of plates or insulators
is evident.
*************************************
Always charge a new battery before using it

to ensure maximum performance.
6. Inspect:
• Battery terminal
Dirty terminal ~ Clean with wire brush.
Poor connection ~ Correct.
NOTE: ________________________
Aftercleaning theterminals,apply a lightcoat

of greaseto the terminals.
3·29
FUSE INSPECTION IIANOSJP I~I ~
-------------------------------------------------------
7. Inspect:
• Breather hose
Obstruction ~ Remove.
Damage ~ Replace.
8. Install:
• Battery
9. Connect:
P •Battery breather hose CD
Be sure the hose is properly attached
and routed.
® Pass the battery breather hose through the

hole.
When inspecting 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.
10. Connect:
• Battery leads (positive and negative)
A WARNING
Connect the positive lead CD fast.
11. Install:
• Seat
FUSE INSPECTION
Always turn off the main switch when

checking or replacing a fuse. Otherwise, short-
circuiting may occur.
3-30
FUSE INSPECTION
---------------------------------------------------------
IIANOSJP I~I ~
1.Remove:
• Seat
• Fuse CD
(i)Spare fuse
2. Inspect:
[;J • Fuse
*************************************
Inspection steps:
~@~ • Connect the Pocket tester to the fuse and
~ check it for continuity.
NOTE: ______________________
~ ~ }4-- Set the tester selector to lin x 1" position.
Pocket tester:
VU-03112, 90890-03112
• If the tester is indicates atoo. Replace the

fuse.
*************************************
Description Amperage Quantity
Main 10A 1
Reserve 10A 1
3. Replace:
• Blown fuse
*************************************
Replacement steps:
• Turn off the ignition.
• Install a new fuse of proper amperage.
• Turn on the switches to verify operation of
the effected electrical device.
• If the fuse immediately blows again, check
the electrical circuit.
A WARNING
Never use a fuse with a rating other then
specified. Never use other material in place of
a fuse. An improper fuse may cause damage
to the electrical system, to possibly cause a
fire, the lighting and/or ignition.
*************************************
4. Install:
• Seat
3-31
ENGINE REMOVAL 1 1'-1
ENG
ENGINE OVERHAUL
ENGINE REMOVAL
NOTE: _ _ _ _ _ _ _ _ _ __
It is not necessary to remove the engine in
order to remove the following components:
• Cylinder head
• Cylinder
• Piston
• Clutch
• COl magneto
ENGINE OIL
1. Drain:
.Engine oil
..
J SEAT AND REAR FENDER
1. Remove:
·Seat
• Battery
• Rear fender CD
- MUFFLER
1.Remove:
• Muffler CD
CARBURETOR
1. Remove:
• Carburetor assembly
Refertothe "CARBURETOR-REMOVAL"
section in the CHAPTER 5.
NOTE: _ _ _ _ _ _ _ _ _ _ __
Cover the carburetor with a clean rag to pre-
vent dirt or foreign material from entering the
carburetor.
4-1
ENGINE REMOVAL 1ENG
STARTER MOTOR
1'-1
1. Disconnect:
• Starter motor lead CD
(from starter relay)
• Ground lead ®
2. Remove:
• Starter motor ®
LEADS AND HOSE

1. Disconnect:
• Spark plug lead
• Ventilation hose CD
• CDI magneto coupler ®
CRANKCASE COVER (LEFT)

1. Remove:
• Shift pedal CD
• Gasket
• Dowel pins
ENGINE REMOVAL
1.Remove:
• Rubber boot CD
2. Remove:
• Engine mount bolts CD
• Engine assembly
(to the left)
4-2
DISASSEMBLY
-----------------------------------------------------IENG I ~I ...
DISASSEMBLY
INTAKE MANIFOLD
1.Remove:
-Intake manifold CD
-O-ring
CYLINDER HEAD AND CYLINDER

NOTE: ______________________
With the engine mounted, cylinder head and
cylinder can be maintained by removing the
following parts.
- Muffler
- Carburetor
1.Remove:
- Spark plug CD
-Tappet covers ® (intake and exhaust)
2. Remove:
- Side cover ® (cylinder head)
3. Remove:
- Cap nut CD (chain tensioner)
- Locknut ® (chain tensioner)
-O-ring ®
-Adjuster @(chain tensioner)
-Tensioner end plug @
-Gasket ®
- Compression spring (j)
- Chain tensioner rod ®
- Straight plug ®
4-3
DISASSEMBLY
4. Remove:
1 1'-1
ENG
CD
• Cam sprocket
NOTE: ______________________
Hold the magneto rotor to loosen the bolt
(cam sprocket) by the rotor holder ® .
Rotor holder:
YM-01235,90890-01235
5. Remove:
• Nuts CD (cylinder head)
• Bolts ® (cylinder head)
• Cylinder head ®
• Gasket (cylinder head)
6. Remove:
• Dowel pins CD
• Cam cbain guide ® (intake)
• Cam chain guide ® (exhaust)
.Cylinder @
• Gasket (cylinder)
• Dowel pins (crankcase)
PISTON
NOTE: _____________
With the engine mounted, piston can be
maintained by removing the following parts.
• Muffler
• Carburetor
• Cylinder head
• Cylinder
1.Remove:
• Piston pin clip CD
NOTE: _____________________
Before removing the piston pin clip, coverthe
crankcase with a clean rag so you will not
accidentally drop the clip into the crankcase.
4-4
DISASSEMBLY
2. Remove:
1 1'-1
ENG
• Piston pin CD
.Piston ®
NOTE: ______________________
Before removing the piston pin, deburr the
clip groove and pin hole area. Ifthe piston pin
groove is deburred and piston pin is still
difficult to remove, use piston pin puller.
Piston pin puller:

VU-01304,90890-01304
Do not use a hammer to drive the piston pin

out.
CLUTCH
NOTE: ______________________
With the engine mounted, clutch can be main-
tained by removing the following parts .
• Footrest (right)
1.Remove:
• Dowel pins
• Gasket
2. Remove:
• Circlip CD
• Pressure plate assembly ®
• Push rod ® (small)
• Push rod @ (large)
4-5
DISASSEMBLY
3. Remove:
1 1'-1
ENG
• Friction plates CD (silver)

• Clutch plate ® (bent)
• Clutch plates @
• Friction plate ® (black)
• Thrust weight plate @
4. Straighten:
• Lock washer tab
5. Remove:
• Nut CD (clutch boss)
• Lock washer
• Clutch boss assembly
NOTE: ______________________
Hold the clutch boss to loosen the nut (clutch

boss) by the universal clutch holder ®.
Universal clutch holder:

YM-91 042, 90890-04086
6. Remove:
• Balls CD
• Primary driven gear compo ®
}G)
7. Remove:
• Spacer CD
• Th rust plate ®
8. Remove:
• Push rod guide CD
• Push lever 1 ®
4-6
DISASSEMBLY
SHIFT SHAFT
1ENG 1'-1
NOTE: _ _ _ _ _ _ _ _ _ __
With the engine mounted, shift shaft can be
maintained by removing the following parts.
• Crankcase covers (left and right)
• Clutch
1. Remove:
.Circlip CD
• Push lever 2 ®
.Pin ®
• Plain washers @
.Bearing ®
2. Remove:
• Shift shaft CD
3. Unhook the spring CD from its position.

4,Remove:
• Stopper lever ®
DRIVE GEAR AND STARTER CLUTCH

NOTE: _ _ _ _ _ _ _ _ _ __
With the engine mounted, drive gear and
starter clutch can be maintained by removing
the following parts.
• Clutch
4-7
DISASSEMBLY
1. Remove:
1 1'-1
ENG
• Nut CD (primary drive gear)
NOTE: ______________________
Hold the magneto rotor to loosen the nut
(primary drive gear) by the rotor holder ® .
Rotor holder:
YM-01235,90890-01235
2. Remove:
• Conical spring washer CD
• Primary drive gear ®
• Starter idle gear assembly @
• Starter clutch assembly/wheel gear @
.Spacer@
OIL PUMP AND OIL STRAINER

NOTE: ___________________
With the engine mounted, oil pump and oil
strainer can be maintained by removing the
following parts.
• Clutch
• Drive gear
• Starter clutch
1. Remove:
.Circlip CD
• Oil pump driven gear ®
• Oil pump drive gear @
2. Remove:
·Oil pump CD
• Gasket ® (oil pump)
• Oil strainer @
4-8
DISASSEMBLY
COl MAGNETO
1 1'-1
ENG
NOTE: ______________________
With the engine mounted, COl magneto can
be maintained by removing the following
parts .
1.Remove:
• Nut CD (rotor)
• Plain washer
NOTE: ______________________
Hold· the magneto rotor to loosen the nut
(rotor) by the rotor holder ® .
Rotor holder:
YM-01235,90890-01235
2. Remove:
• Rotor CD
• Woodruff key
NOTE: _______________
Remove the rotor by the rotor puller ® .
Rotor puller:
YM-01189,90890-01189
3. Remove:
• Base plate CD
• Neutral switch ®
.Cam chain
MIDDLE GEAR
1. Remove:
• Bolts (driven gear housing)
• Middle driven gear compo
• Shim(s)
4-9
DISASSEMBLY
'2. Remove:
1 1'-1
ENG
• 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:
• Bearings
Tap lightlyon the U-jointwith a hammer.
5. Repeat the steps for the opposite bearing,
and remove the yoke.
6. Remove:
• Nut CD (middle driven gear)
Clamp the U-joint securely. in a vise hav-
ing soft jaws.
• Plain washer @
• U-joint ®
• Middle driven gear @
• Nut ® (middle driven housing)
Use a hexagon wrench 27 mm (j) .
• Bearing ®.
Hexagpn wrench (27 mm):

YM-01388,90890-01388
4-10
DISASSEMBLY
CRANKCASE
1 1'-1
ENG
1. Remove:
• Screws (crankcase)
• Bolts (crankcase)
NOTE: ______________________
Remove the screws starting with the highest
3 ® numbered one.
2. Remove:
• Shift cam stopper CD
3. Remove:
• Crankcase (right)
Alternately tap on the engine mounting
boss, transmission shafts, shift cam, and
crankshaft.
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 the 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.
4-11
DISASSEMBLY
TRANSMISSION
1 1'-1
ENG
1. Remove:
- Shift cam CD
- Transmission assembly @
(with shift forks @ )
-Guide bar ®
NOTE: ______________________
Note the position of each part. Pay particular
attention to the location and direction of shift
forks.
2. Remove:
- Middle drive gear shim CD
CRANKSHAFT
1. Remove:
- Crankshaft
Tap lightly on the crankshaft with a soft
hammer.
ROCKER ARM AND CAMSHAFT

1. Loosen:
- Locknut CD
-Adjuster @
2. Remove:
- Rocker arm shaft CD
- Rocker arm @
-Camshaft @
NOTE: ______________________
Remove the rocker arm shaft by the slide
h.ammer bolt ® and weight @ .
4-12
DISASSEMBLY 1 1'-1
ENG
Slide hammer set:
YU-01083
......- ... Slide hammer bolt:
90890-01083
Weight:
90890-01084
VALVE
1. Check:
.Valve sealing
Leakage at valve seat ~ inspect the valve
face, valve seat and valve seat width.
Refer to the "INSPECTION AND REPAIR-
VALVE SEAT" section.
NOTE: ______________________
Before removing the internal parts (valve,
valve spring, spring seat, etc.) of the cylinder
head, the valve sealing should be checked.
*************************************
Checking steps:
• Supply a clean sOlventCDinto the intake and
exhaust ports.
• Check the valve sealing. There should be
no leakage at the valve seats @.
*************************************
2. Remove:
.Valve cotter CD
~
t
• Valve retainer @
I'~
.Valve spring ®
=z: .Oil seal @

• Valve retainer ®
.Valve ®
---® '~@ NOTE: ______________________
• Identify each part position very carefully so
that it can be reinstalled in its original place.
• Compress the valve spring to remove the
valve cotter by the valve spring compressor
(j) and attachment ® .
Valve spring compressor:

YM-04019,90890-04019
......- ... Attachment:
YM-41 08, 90890-04108
4-13
INSPECTION AND REPAIR 1 1'-1
ENG
CYLINDER HEAD
1. Eliminate:
• Carbon deposit
(from combustion chamber)
Use the rounded scraper.
NOTE: ______________________
Do not use a sharp instrument and avoid

damaging or scratching:
• Spark plug thread
• Valve seat
2. Inspect:
• Cylinder head
Scratches/Damage -+ Replace.
3. Measure:
• Cylinder head warpage
Out of specification --) Resurface/Re-
place.
Cylinder head warp limit:

Less than 0.05 mm (0.002 in)
4. Resu rface:
• Cylinder head
**************************.**********
Resurfacement steps:
Place a 400 - 600 grit wet sandpaper on the
surface plate, and resurface the head using a
figure-eight sanding pattern.
NOTE: ______________________
Rotate the head several times to avoid remov-
ing too much material from one side.
*************************************
4-14
VALVE AND VALVE GUIDE
1 1'-1
ENG
1. Measure:
• Stem-to-guide clearance
Stem-to-guide clearance =
Valve guide inside diameter @-
Valve stem diameter ®
Out of specification )- Replace valve guide.
Stem-to-guide clearance Limit
0.010 ... 0.037 mm 0.08mm

Intake (0.0031 in)
(0.0004 ... 0.0015 in)
0.025 ... 0.052 mm 0.10 mm
Exhaust
(0.0010 ... 0.0020 in) (0.0039 in)
302-029
CD Bore gauge
*************************************
Replacement steps:
NOTE: ______________________
Heat the cylinder head in an oven to 100°C
(212°F) to ease guide removal and installation
and to maintain correct interference fit.
• Remove the valve guide using the valve

guide remover CD.
• Install the valve guide (new) using the valve
guide installer® and valve guide remover
CD.
• After installing the valve guide, bore the
valve guide using the valve guide reamer@
to obtain proper stem-to-guide clearance.
Valve guide remover 5 mm (0.20 in):

YM-4097, 90890-04097
.....- ... Valve guide installer 5 mm (0.20 in):
YM-4098, 90890-04098
Valve guide reamer 5 mm (0.20 in):
YM-4099,90890-04099
*************************************
302-013
4-15
ENG
2.Clean the valve face to remove carbon
deposits.
3. Inspect:
.Valve face
Pitting/Wear -~ Grind the face.
4. Measure:
®-II- • Margin thickness ®
Out of specification ..~ Replace.
Margin thickness limit:

Intake: 0.4 ... 0.8 mm (0.016 ...
0.032 in)
Exhaust: 0.8 ... 1.2 mm (0.032 ...
0.047 in)
5. Check:
• Valve stem end
Mushroom shapeordiameter largerthan
rest of stem .~ Replace .
• Runout
Out of specification _... Replace.
Stem runout limit:

// 0.02 mm (0.0008 in)
302-004
NOTE: ______________________
• Always replace the guide if the valve is
replaced .
• Always replace the oil seal if the valve is
removed.
VALVE SEAT
1. Clean the valve face and valve seat to
remove carbon deposits.
2. Inspect:
.Valve seat
Pitting/Wear -). Reface the valve seat.
4-16
3. Measure:
1 1'-1
ENG
• Valve seat width @

Out of specification -- ~ Reface valve seat.
Valve seat width:
Intake 0.9 ... 1.1 mm (0.035 ... 0.043 in)

Exhaust 0.9 ... 1.1 mm (0.035 ... 0.043 in)
*************************************
Measurement steps:
• Apply the Mechanic's bluing dye (Dykem)
CD to the va Ive face.
• Install the valve into the cylinder head.
• Pressthevalvethrough the valve guide and
onto the valve seat to make a clear pattern.
• Measure the valve seat width. Wherever
the valve seat and valve face made contact,
bluing will have been removed.
• If the valve seat width is too wide, too
narrow, or seat has not centered, the valve
seat must be refaced.
*************************************
4. Reface:
.Valve seat
Use a 30°, 45° and 60° valve seat cutter
CD.
~ Valve seat cutt. er:
YM-91043
When twisting cutter, keep an even

downward pressure (4 ... 5 kg) to prevent
chatter marks.
4-17
ENG
Cut sections as follows
Section Cutter
A 30'
B 45'
C 60'
A
*************************************
Valve seat refacing steps:
IAl Valve face indicates that valve seat is
centered on valve face but is too wide.
Valve seat cutter set Desired result
30' cutter To reduce valve
Use
seat width to
lightly 60' cutter 1.0 mm (0.039 in)
B rnJ Valve seat is in the middle of the valve

I face but too narrow.
I
I Valve seat cutter set Desired result
I To achieve a
I uniform valve
I.......................... ~ Use 45' cutter
seat width of 1.0
mm(0.039 in)
c [g Valve seat is too narrow and right up near

I valve margin.
I
I To center the seat
I 30' cutter, first and to achieve its
Use
I ~. 45' cutter
width of 1.0 mm
..................................................~~ (0.039 in) .
o [Q) Valve seat is too narrow and is located

I down near the bottom edge of the valve
I face.
I
I ~
.........................•.........................
Use 60' cutter, first To center the seat
and increase its
45' cutter width.
*********************************.***
4-18
5.Lap:
1 1'-1
ENG
-Valve face
-Valve seat
NOTE: ______----____________
When refacing the valve seat or replacing the
valve and valve guide, the valve seat and
valve face should be lapped.
*************************************
Lapping steps:
• Apply a coarse lapping compound to the
valve face.
Be sure no compound enters the gap between

the valve stem and guide.
• Apply a molybdenum disulfide oil to the

valve stem.
302-024
• Turn the valve until the valve face and valve

seat are evenly polished, then clean off all
compound.
NOTE: ______________________
To obtain the best lapping results, lightly tap
the valve seat while rotating the valve back
and forth between your hands.
• Applya fine lapping compound to the va Ive

face and repeat the above steps.
NOTE: ____________
Be sure to clean off all compound from the
valve face and valve seat after every lapping
operation.
4-19
ENG
• Apply the Mechanic's bluing dye (Dykem)
to the valve face.
• Press the valve through thevalveguideand
onto the valve seat to make a clear pattern.
• Measure the valve seat width again. If th~
valve seat width is out of specification,
reface and lap the valve seat.
*************************************
VALVE SPRING
1. Measure:
-Valve spring free length ®
Out of specification ~ Replace.
Valve spring free length:

27.3 mm (1.07 in)
10----.. Limit:
25.4 mm (1.00 in)
302-005
2. Measure:
-H4--{a
-Spring tilt ®
~ Spring tiH:
1.2 mm (0.047 in)
302-028
CAMSHAFT
1. Inspect:
-Cam lobes
Pitting/Scratches/Blue discoloration ~
Replace.
4-20
INSPECTION AND REPAIR ENG
2. Measure:
1 1'-1
® -Cam lobes
®
Intake 25.257 ~ 25.357 mm 21.001 ~ 21.101 mm
(0.994 ~ 0.998 in) (0.827 ~ 0.831 in)
Exhaust 25.258 ~ 25.358 mm 21.025 ~ 21.125 mm
(0.994 ~ 0.998 in) (0.828 ~ 0.832 in)
3. Measure:
- Runout (camshaft)
Runout limit:
0.03 mm (0.0012 in)
ROCKER ARM AND ROCKER ARM SHAFT

1. Inspect:
- Rocker arm shaft
Blue discoloration/Grooves ~ Replace,
then inspect lubrication system.
2. Inspect:
- Rocker arm shaft hole ®
- Cam lobe contact surface @
-Adjuster surface ©
Wear/Pitting/Scratches/Blue discolora-
tion ~ Replace, then inspect lubrication
system.
4-21
INSPECTION AND REPAIR I 1'-1
ENG
3. Measure:
@
-Arm-ta-shaft clearance
Arm-to-shaft clearance =
Rocker arm inside diameter ® -
Rocker arm shaft outside diameter @
Out of specification ~ Replace as a set.
Arm-to-shaft clearance:
0.009 - 0.034 mm
(0.0004 - 0.0013 in)
Limit:
0.08 mm (0.0032 in)
CAM CHAIN AND CAM SPROCKET

1. Inspect:
-Cam chain
Stiff/Cracks ~- Replace cam chain and
cam sprocket as a set.
343-007
2. Inspect:
- Cam sprocket
Wear/Damage ~ Replace cam sprocket
and cam chain as a set.
CD 1/4 tooth
@Correct
@Roller
343-014 @Sprocket
CAM CHAIN GUrDE

1. Inspection:
- Cam chain guide CD (intake)
- Cam chain guide @ (exhaust)
Wear ~ Replace.
4-22
CAM CHAIN TENSIONER
1 1'-1
ENG
1. Inspect:
.AII parts
Damage/Wear--~ Replace.
CD Tensioner end plug @ Chain tensioner rod

® Gasket ® Straight plug
@ Compression spring
CYLINDER AND PISTON

1. Inspect:
• Cylinder and piston walls
Vertical scratches --~ Rebore or replace
cylinder and piston.
2. Eliminate:
• Carbon deposits
(from piston crown and ring grooves)
3. Inspect:
• Piston crown
Burrs/Nicks/Damage -~ Replace.
4. Eliminate:
• Score marks and lacquer deposits
(from piston wall)
Use a 600 - 800 grit wet sandpaper.
NOTE: ______________________
Sand in a crisscross pattern. Do not sand
excessively.
307002 5. Measure:
~------------------------------~ • Piston-to-cylinder clearance
*************************************
Measurement steps:
IFirst steps I
• Measure the cylinder bore "C" with a cylin-
der bore gauge.
NOTE: _______________________
Measure the cylinder bore "C" in parallel to
and at right angles to the crankshaft.
Then, find the average ofthe measurements.
4-23
INSPECTION AND REPAIR 1 1"-1
ENG
~ Standard Wear Limit
Cylinder 47.000 .. 47.005 mm

Bore "C": (1.8504 .. 1.8506 in) -
Cylinder 0.05mm
Taper liT": - (0.002 in)
C= Maximum °
T = Maximum (0, or 02)
- Minimum (05 or 06)
• If out of the specification, rebore or replace

the cylinder, and the piston and piston
rings as a set.
12nd steps I
• Measure the piston skirt diameter lip" with
a micrometer.
CD 10 mm (0.39 in) from the piston bottom
edge
~
p
Piston size P:
Standard 46.960 .. 46.975 mm
CloIJ Oversize 2
Oversize 4
(1.8488 .. 1.8494 in)
47.50 mm (1.870 in)
48.00 mm (1.890 in)
• If out of the specification, replace the pis-
307-001
ton and piston rings as a set.
13rd steps I
• Find the piston-to-cylinder clearance with
following formula.
Piton-to-cylinder clearance =
Cylinder bore "C" -
Piston skirt diameter lip"
Piston-to-cylinder clearance:
0.025 .. 0.045 mm
(0.0010 .. 0.0018 in)
Limit:
0.15 mm (0.006 in)
• If out of the specification, rebore or replace

the cylinder, and replace the piston and
piston rings as a set.
**************************w**********
4-24
-----------------------------------------------------
IENG I ~I
.
- .
PISTON RING
1. Measure:
• Ring side clearance
Out of specification-~ Replace piston.
NOTE: ______________________
Clean carbon from piston ring grooves and
rings before measuring side clearance.
~
Side clearance
Standard Limit
Top 0.030 ... 0.065 mm 0.12 mm
Ring (0.0012 ... 0.0026 in) (0.0047 in)
2nd 0.020 ... 0.055 mm 0.12 mm
Ring (0.0008 ... 0.0022 in) (0.0047 in)
2. Position:
• Piston ring
(in cylinder)
® NOTE: ______________________
Inserta ring into cylinder, and push itapproxi-
mately 20 mm (0.8 in) into cylinder. Push ring
l -.----------.-j 307027
with piston crown so that ring will be at a right
angle to cylinder bore.
® 20 mm (0.8 in)
3. Measure:
• Ring end gap
Out of specification-~ Replace.
NOTE: _ _ _ _ _ _ _ _ _ _ __
You cannot measure end gap on expander
spacer of oil control ring. If oil control ring
rails show excessive gap, replace all three
rings.
~
End Gap
Standard Limit
Top 0.10 ... 0.25 mm 0.4mm
Ring (0.004 ... 0.010 in) (0.016 in)
2nd 0.10 ... 0.25 mm 0.4mm
Ring (0.004 ... 0.010 in) (0.016 in)
Oil 0.2 ... 0.7 mm
Ring (0.008 ... 0.028 in) -
4-25
PISTON PIN
1 1'-1
ENG
1. Inspect:
• Piston pin
Blue discoloration/Grooves .~ Replace
then inspect lubrication system.
2. Measure:
• Outside diameter ® (piston pin)
Out of specification -~ Replace.
Outside diameter (piston pin):

12.996 ... 13.000 mm
(0.5117 ... 0.5118 in)
307-018
3. Measure:
• Piston pin-to-piston clearance
Out of specification -~ Replace piston.
Piston pin-to-piston clearance =

Bore size (piston pin) ® -
Outside diameter (piston pin) ®
Piston pin-to-piston clearance:

0.002 ... 0.017 mm
(0.0001 ... 0.0007 in)
Limit: 0.07 mm (0.003 in)
CLUTCH
1. Inspect:
• Dogs on the housing
CrankJWear/Damage ~ Deburr or re-
place.
• Clutch housing bearing
NOTE: ChafingJWear/Damage -~ Replace.
______________________ _
Pitting on the clutch housing dogs will cause
erratic operation.
4-26
2. Inspect:
1 1'-1
ENG
• Clutch boss splines

Scoring/Wear/Damage ~ Replace clutch
boss assembly.
NOTE: _ _ _ _ _ _ _ _ _ __
Pitting on the clutch boss splines will cause
erratic operation.
• Clutch boss cam grooves

3. Inspect:
• One way boss cams
4. Inspect:
• Friction plate CD
Damage/Wear ~ Replace friction plate
as a set.
5. Measure:
• Friction plate thickness
Measure at all four points.
Out of specification . ~ Replace friction
plate as a set.
Friction plate thickness

2.92 ... 3.08 mm
Standard 0.115 ... 0.121 in
Wear limit 2.90 mm (0.114 in)
4-27
6. Measure:
1 1'-1
ENG
• Clutch plate warpage

Out of specification- ~ Replace.
~ Warp limit:
rAl 0.06 mm (0.0024 in)
7. Inspect:
• Pressure plate bearing
8. Measure:
• Push rod runout (long rod) CD
Use V-blocks and a dial gauge.
~ Bending Limit:
0.5 mm (0.02 in)
9. Inspect:
• Balls
Pitting/Wear/Damage ~ Replace as a set.
10. Inspect:
.Push lever
• Push lever axle
• Push rod guide
Wear/Damage > Replace.
11. Inspect:
• Clutch spring
Wear/Damage > Replace.
12. Measure:
• Clutch spring free length
Out of specification > Replace springs as
a set.
Clutch spring minimum length:

29.1 mm (1.15 in)
4-28
Oil PUMP
1 1'-1
ENG
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 Feeler Gauge.
Out of speGification-~ Replace oil pump
assembly.
Tip clearance ® :
0.15 mm (0.0059 in)
l--_oM limit:
0.20 mm (0.0079 in)
3. Inspect:
• Oil pump drive gear CD
• Oil pump driven gear ®
Wear/Cracks/Damage - ~ Replace.
TRANSMISSION AND SHIFTER

1. Inspect:
• Shift fork cam follower CD
• Shift fork pawl ®
Scoring/Bends/Wear -~ Replace.
2. Inspect:
.Guide bar
Roll the guide bar on a flat surface.
Bends--~ Replace.
A WARNING
Do not attempt to straighten a bent guide
bar.
4-29
3. Check:
1 1'-1
ENG
• Shift fork movement

Unsmooth operation » Replace shift fork
and/or guide bar.
3 4. Inspect:
• Shift cam grooves CD
Wear/Damage/Scratches--~ Replace.
• Shift cam segment ®
Damage!Wear - ~ Replace.
• Shift cam bearing ®
Pitting/Damage ---~ Replace.
5. Measure:
• Axle runout CD
Use centering device and dial gauge ®.
Out of specification --~ Replace.
Runout limit:
0.08 mm (0.0031 in)
6. Inspect:
.Gear teeth
Blue discoloration/Pitting!Wear .-~ Re-
place .
• Mated dogs
Rounded edges/Cracks/Missing portions
->- Replace.
7. Check:
• Proper gear engagement (each gear)
(to its counter part)
• Gear movement
Roughness -~ Replace.
4-30
INSPECTION AND REPAIR ENG ~\8
SHIFT SHAFT AND STOPPER LEVER
1. Inspect:
.Shift shaft
Bends/Wear/Damage > Replace.
2. Inspect:
• Stopper lever CD
Roller turns roughly -> Replace.
Bends/Damage> Replace.
3. Inspect:
• Return spring ®
Damage/Cracks > Replace.
PRIMARY DRIVE
1. Inspect:
• Primary drive gear teeth CD
• Primary driven gear teeth ®
Wear/Damage > Replace both gears.
Excessive noises during operation>
Replace both gears.
2
STARTER DRIVE
1. Inspect:
• Starter one-way CD
Cracks/Damage ~ Replace.
*************************************
Starter clutch operation
• Install the starter wheel gear to the starter
clutch, and hold the starter clutch.
• When turning the starter wheel gear
clockwise [K] ,the starter clutch and the
wheel gear should turn freely.
If not, the starter clutch is faulty. Replace it.
• When turning the starter wheel gear coun-
terclockwise [ill ,the starter wheel gear
should be engaged.
If not, the starter clutch is faulty. Replace it.
*************************************
4-31
INSPECTION AND REPAIR I ENG I~I
2.lnspect:
• Starter idle gear 1 teeth CD
• Starter idle gear 2 teeth ®
• Starter wheel gear teeth ®
Burrs/Chips/Roughness/Wear Replace.
3. Inspect:
• Starter wheel gear
(contacting surfaces)
Pitting/Wear/Damage ~ Replace.
CRANKSHAFT
©
.......- - - ----+-
1. Measure:
• Crank width ®
Out of specification -~ Replace crank-
shaft.
Crank width:
40.20 .. 40.25 mm
(1.583 .. 1.585 in)
.Runout ®
Out of specification ...~ Replace crank-
shaft and/or bearing.
r~
Al
Runout limit:
0.05 mm (0.002 in)
• Small end free play ©

Out of specification .~ Replace big end
bearing, crank pin and/or connecting rod.
Small end free play:

0.8 .. 1.0 mm (0.031 .. 0.039 in)
t - -iU Limit: 1.5 mm (0.059 in)
• Side clearance @
Out of specification .-~ Replace connect-
ing rod.
Big end side clearance:

0.1 .... 0.4 mm (0.004 .. 0.016 in)
~_iU limit: 0.5 mm (0.020 in)
4-32
INSPECTION AND REPAIR' ENG , .... ,
Crankshaft reassembling point:
The crankshaft CD and the crank pin ® oil
passages must be properly interconnected
with a tolerance of less than 1 mm (0.04 in).
MIDDLE GEAR
1. Inspect:
• Gears CD
• Bearings ®
Damage/Wear • Replace.
2. Check:
• Bearing movement
Turns roughly • Replace.
4-33
ENGINE ASSEMBLY AND ADJUSTMENT
1 1"-1
ENG
VALVE AND ROCKER ARM

CD Locknut (valve adjusting) (j) Valve spring
® Adjuster (valve adjusting) ® Oil seal
® Rocker arm ® Valve
@ Rocker shaft
® Valve cotter
® Valve retainer
4-34
VALVE
1 1"-1
ENG
1. Lu bricate:
• Oil or grease
(to the valve stem and oil seal)
High-quality molybdenum disulfide

motor oil or molybdenum disulfide
t -.......u grease
2. Install:
.Valve ill
--ill .Oil seal ®
.Valve spring @
• Valve cotter ®
NOTE: _ _ _ _ _ _ _ _ _ __
Install spring with wider-gapped coil facing
upwards, as shown.
® Larger pitch
@ Smaller pitch
NOTE: _ _ _ _ _ _ _ _ _ __
Compress the valve spring to install the valve
cotter by the valve spring compressor (j) and
attachment ® .
Valve spring compressor:

YM-04019,90890-04019
.....- .... Attachment:
YM-4108, 90890-04108
ROCKER ARM AND CAMSHAFT

1. Lubricate:
.Engine oil
(to the camshaft and rocker arm shaft)
2. Install:
• Camshaft ill
• Rocker arm ®
• Rocker arm shaft ®
4-35
CRANKSHAFT AND TRANSMISSION
IENG 1'-1
CD Drive axle assembly (jJ) 3rd pinion gear (22T) ® Crank (right)
® 3rd wheel gear (31T) @ 2nd pinion gear (17T) @ Bearing
® Circlip @ Plain washer @ Oil pump drive gear
® 4th wheel gear (27T) @ Circlip ® Piston
@ Plain washer @ Bearing @ Piston ring set
® 1st wheel gear (39T) @ Woodruff key
(j) Circlip @ Crank (left)
® Bearing @ Crank pin
® Bearing (j]) Cylinderical bearing
@ Main axle ® Connecting rod
~ CRANKSHAFT: F
A : 40.20 - 40.25 mm ~
B:b\5~~~~~5in) ~~ 0 I ~
I
~
(O.004-0.016in)
C : 0.05 mm (0.02 in)
F : 0.8 - 1.0 mm
!
~
(0.031 - 0.039 in) A
101 USE NEW ONE 1
RUNOUT LIMIT:
0.08 mm (0.0031 in) 10
4-36
CRANKSHAFT
1 1"-1
ENG
1. Install:
- Crankshaft
(to the left-side crankcase)
NOTE: ______________________
Hold the connecting rod at top dead center
with one hand while installing the crankshaft.
TRANSMISSION
1. Lubricate:
-Engine oil
(to the guide bar o-ring)
2. Install:
- Guide bar CD
-Shim ®
3. Install:
- Transm ission assem bly CD
(with shift forks ®)
NOTE: ______________________
- The fork marked ® faces the left crankcase,
theforkmarked@facestherightcrankcase.
- Align the cuting © on the drive axle plate
with the guide bar ® .
4. Install:
-Shift cam
5.Check:
-Transmission and shifter operation
Unsmooth operation ~ Repair.
NOTE: ______________________
Oil each gear and bearing thoroughly.
4-37
CRANKCASE
1 1'-1
ENG
1.Apply:
• Quick gasket® CD (to the mating surfaces
of both case halves)
Ouick gasket®:
ACC-11001-05-01
.....- ... Yamaha bond NO.1215®:
90890-85505
2. Install:
• Dowel pins ®
3. Fit the right crankcase onto the left case.
Tap lightlyon 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
3 numbered one.
• Install the copper washer on screw No. ®
and @.
Screws (crankcase):
7 Nm (0.7 m· kg, 5.1 ft ·Ib)
t - - ; y Bolts (crankcase):
10 Nm (1.0 m • kg, 7.2 ft • Ib)
5. Install:
• Shift cam stopper CD
Screw (shift cam stopper):
7 Nm (0.7 m • kg, 5.1 ft • Ib
6.Apply:
• 4-stroke engine oil
(to the crank pin, bearing and oil delivery
hole)
7.Check:
• Crankshaft and transmission operation
Unsmooth operation ~ Repair.
4-38
ENGINE ASSEMBLV AND ADJUSTMENT IENG I ~I
...,
-----------------------------------------------------
MIDDLE GEAR
1. Install:
-Bearing CD
- Nut ® (middle driven housing)
Use a hexagon wrench 27 mm.
Hexagon wrench (27mm):

YM-01388,90890-01388
Nut (middle driven housing):

60 Nm (6.0 m • kg, 43 ft • Ib)
.....---'1 Loctite®
- Middle driven gear ®

-U-joint @
- Plain washer ®
- Nut ® (middle driven gear)
Clampthe U-jointsecurely in avise having
soft jaws.
Nut (middle. driven gear):

90 Nm (9.0 m • kg, 64 ft· Ib)
Loctite®
2. Install:
-Yoke
(into the U-joint)
3.Apply:
-Grease
(to the bearings)
4. Install:
- Bearings
Tap lightly on the bearing with a ham-
mer.
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 bear-
ing further into the U-joint with a vise until
the circlip can be installed into each U-
joint.
4-39
6. Install:
1 1'\.1
ENG
.Circlips CD
NOTE: _ _ _ _ _ _ _ _ _ __
Always use a new circlip.
7.Select:
• Driven gear shim
*************************************
Driven gear shim selection steps:
• Measure the distance "L" 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:s;; 38.20 0.7
38.20 < L :s;; 38.30 0.8
38.30 < L :s;; 38.40 0.9
38.40 :s;; L :s;; 38.45 1.0
• Select the suitable shim(s) by the recom-

mended chart.
Suitable shim(s)
Difference
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
*************************************
4-40
----------------------------------------------------
IENG I ~. I ...,
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 ft· Ib)
COl MAGNETO
1. Install:
• Cam chain CD
·O-rings ®
2. Install:
• Neutral switch CD
• Base plate ®
Neutral switch:
10 Nm (1.0 m • kg, 7.2 ft • Ib)
t---.u Base plate:
7 Nm (0.7 m· kg, 5.1 ft ·Ib)
3. Install:
.Woodruff key
• Flywheel
• Plain washer
• Nut (rotor)
NOTE: _ _ _ _ _ _ _ _ _ __
When installingthe COl magneto, make sure
the woodruff key is properly seated in the key
way ofthe crankshaft. Apply a light coating of
lithium soap base grease to the tapa red por-
tion of the crankshaft end.
4. Tighten:
• Nut CD (rotor)
Nut (rotor):
40 Nm (4.0 m • kg, 29 ft • Ib)
NOTE: _ _ _ _ _ _ _ _ _ __
Hold the magneto rotor to tighten the nut
(rotor) by the rotor holder ® .
4-41
ENGINE ASSEMBLY AND ADJUSTMENT 1 1'-1
ENG
Rotor holder:
YM-01235,90890-01235
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 oil passages G) )
2. Install:
- Gasket (new)
-Oil pump
- Oil strainer
Screw (oil pump):

7 Nm (0.7 m a kg, 5.1 ft alb)
3. Install:
- Oil pump drive gear G)
- Oil pump driven gear ®
- Circlip (new) @
DRIVE GEAR AND STARTER CLUTCH

1.lnstall:
-Spacer G)
-Starter clutch assembly/wheel gear 2®
-Starter idle gear assembly@
/1 - Primary drive gear @

- Conical spring washer ®
4-42
2. Tighten:
1 1'-1
ENG
- Nut CD (primary drive gear)
Nut (primary drive gear):

50 Nm (5.0 m • kg, 36 ft • Ib)
NOTE: ______________________
Hold the magneto rotor to tighten the nut
(primary drive gear) by the rotor horder ®.
Rotor holder:
YM-01235,90890-01235
SHIFT SHAFT
1. Install:
-Spring CD
- Stopper lever ®
Bolt (stopper lever):
14 Nm (1.4 m • kg, 10 ft· Ib)
t---~ Loctite®
NOTE: _________________
Set the stopper lever and torsion spring as
properly position.
2. Install:
-Shift 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.
3. Install:
- Plain washers CD
-Bearing ®
- Plain washers @
-Pin @
111.1 - Push lever 2 @

-Circlip (new) ®
4-43
ENGINE ASSEMBLY AND ADJUSTMENT 1ENG 1'-1
CLUTCH
CD Oil seal @ Clutch balls
® Push plate assembly ®Primary driven gear compo
® Circlip @ Spacer
@ Pressure plate assembly @ Thrust plate
® Push rod (small) @ Push rod (large)
® Clutch plate (bent) @ Bushing
(j) Friction plate (silver) @ Oil seal
® Clutch plate ® Clutch boss spring
® Friction plate (black) ® Push lever
@ Thrust weight plate @ Push rod guide
(jJ) Compression spring @ Primary drive gear
@ Clutch boss set ® Push lever 2
CLUTCH SPRING MINIMUM LENGTH:

A
29.1 mm (1.15 in)
CLUTCH PLATE WARP LIMIT:
3 B
0.06 mm (0.0024 in)
PUSH ROD (LARGE) BENDING LIMIT:
C 0.5 mm (0.02 in)
0 FRICTION PLATE WEAR LIMIT:

2.9 mm (0.114 in)
60 Nm (6.0 m • kg, 43 ft • Ib)
14 Nm (1.4 m· kg,
G USE NEW ONE 10ft·lb)
CLUTCH BOSS HEIGHT:
E 0.2 _ 0.4 mm (0.008 - 0.016 in)
FRICTION PLATE HEIGHT:
F 1.30 _ 1.65 mm (0.051 - 0.065 in)
4-44
CLUTCH
I 1'-1
ENG
1. Install:
- Push lever 1 CD
- Push rod guide ®
Push rod guide:
S Nm (O.S m • kg, 5.S ft • Ib)
2.Adjust:
-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 @ :

2
0.2 - 0.4mm (0.00S-0.016in)
• If the height is out of specification, adjust

the clutch boss height.
• Remove the primary driven gear comp,
and remove the following parts.
1)Circlip ®
2)Adjusting washer @
3)Bearing ®
• Select the suitable adjusting washers by
the following chart.
Adjusting washer
.~ .
1.7
2.1
1.9
2.3
o • Remeasure the clutch boss height.
*************************************
4-45
3. Install:
1 1'\.1
ENG
• Friction plate CD (black)

• Clutch plates ®
• Friction plates @ (silver)
• Clutch plate @ (bent)
@Thrustweight plate
® Pressure plate
NOTE: _ _ _ _ _ _ _ _ _ __
Install the clutch plates and friction 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.
4. Adjust:
• Friction plate height
*************************************
Adjustment steps:
• Push the friction plates CD down by hand.
• Measure the friction plate height ® (dis-
tance between the driven gear housing®
and friction plate CD.)
Friction plate height ® :

1.30 ... 1.65 mm (0.051 ... 0.065 in)
.Ifthe height is out of specification, adjust

the friction plate height.
• Remove the following parts.
1)Pressure plate
2)Clutch plate (bent)
3)Friction plates (silver 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
4-46
ENGINE ASSEMBLY AND ADJUSTMENT IENG I~I
• Install all parts. Refer to aforementioned
step 3.
• Remeasure the friction plate height.
• Remove all parts.
*************************************
5. Install:
- Thrust plate
-Spacer
-Primary driven gear compo CD
-Balls ®
Place the balls as illustrated position [AJ •
Clutch ball q'ty:

12 pcs.
6. Install:
- Thrust weight plate CD
- One way boss ®
- Lock washer @ (New)
-Nut@
5 -Clutch boss assembly @
7. Tighten:
- Nut CD (clutch boss)
Nut (clutch boss):

60 Nm (6.0 m • kg, 43 ft· Ib)
NOTE: _ _ _ _ _ _ _ _ _ __
Hold the clutch boss to tighten the nut (clutch
boss) by the uniyersal clutch holder ® .
Universal clutch holder:

YM-91042,90890-04086
8. Bend the lock washer tab along the nut

flats.
4-47
9. Install:
1 1'-1
ENG
• Friction plate CD (black)

• Clutch plates ®
• Frictfon plates ® (silver)
• Clutch plate @ (bent)
10. Install:
• Push rod CD (large)
• Push rod ® (small)
• Pressure plate assembly ®
• Circlip (new) @
11.lnstall:
• Dowel pins
• Gasket (new)
NOTE: ______________________
Tighten the screws in a crisscross pattern.
Crankcase cover:
7 Nm (0.7 m· kg, 5.1 ft ·Ib)
4-48
CYLINDER AND CYLINDER HEAD
ENGINE ASSEMBLY AND ADJUSTMENT 1 1'-1
ENG
CD Cylinder ® Tensioner end plug

® Cam chain damper (Intake) @ Gasket
@ Cam chain (jJ) Compression spring
@ Cam sprocket (28T) @ Chain tensioner rod
® Cam chain damper (Exhaust) @ Stra ig ht pI ug
® Camshaft ® Tappet cover (Intake)
(j) Locknut (Chain tensioner) @ Side cover
® Adjuster (Chain tensioner) @ Tappet cover (Exhaust)
VALVE CLEARANCE:
A INTAKE: 0.05 - 0.10 mm (0.002 - 0.004 in)
EXHAUST: 0.075 - 0.125 mm (0.003 - 0.004 in)
B CYLINDER HEAD WARP LIMIT:
0.05 mm (0.002 in)
.C VALVE SPRING LENGTH LIMIT (FREE):
25.4 mm (1.00 in)
15 Nm (1.5 m 0 kg, 11 ft olb)
12 Nm (1.2 m kg, 8.7 ft olb)

0
4-49
PISTON
1 1'-1
ENG
1. Install:
• Piston CD
• Piston pin ®
• Piston pin clip ®
NOTE: _ _ _ _ _ _ _ _ _ __
• The arrow on the piston must point to the
front of the engine.
• 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 intothe crankcase.
• Always use a new piston pin clip.
2.Apply:
• 4-stroke engine oil
To the piston pin, bearing, piston ring
grooves and piston skirt areas.
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 .
• Offset the piston ring end gaps as shown .
• Before installing the cylinder, apply a lib-
eral coating of 4-stroke oil to the piston
rings.
CD Top ring
® 2nd ring
® Oil ring (upper rail)
@ Oil ring (lower rail)
4-50
ENGINE ASSEMBLY AND ADJUSTMENT ...,
---------------------------------------------------~----~~--~
IENG I ~I.
3. Install:
CD
-Cylinder
NOTE: ______________________
Install the cylinder with one hand while com-
pressing the piston rings with the other hand.
Pass the cam chain through the cam chain

cavity.
4. Install:
- Dowel pins CD
-Cam chain guide ® (intake)
-Cam chain guide @ (exhaust)
- Gasket (New)
5. Install:
-Cylinder head
NOTE: ______________________
Tie the cam chain so that it does not fall into
the crankcase.
Be careful notto damage the cam chain guide

during installation.
6. Tighten:
- Nuts CD and bolts ® (cylinder head)
NOTE: ____________________
Tighten the nuts in stage, using a crisscross
pattern.
Nut CD (cylinder read):

12 Nm (1.2 m • kg, 8.7 ft ·Ib)
.....--:11 Bolt ® (cylinder head):
10 Nm (1.0 m • kg, 7.2 ft· Ib)
4-51
7. Install:
1 1'-1
ENG
• Cam sprocket
*************************************
Installing steps:
• Rotate the camshaft to align the cam-
shaft groove ® with the cylinder head
match marks ® .
• Turn the CDI 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.
NOTE: _____________________
• Insertthe cam chain sprocket pawl@ into
the camshaft groove <D.
• Be sure the match mark @ 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
guide inward.
• While pushing the cam chain guide, be
sure cam sprocket match mark ® 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 CD (cam'sprocket)
Bolt (cam sprocket):

20 Nm (2.0 m • kg, 14 ft ·Ib)
NOTE: _____________________
Hold the magneto rotor to tighten the bolt
(cam sprocket) by the rotor holder ® .
Rotor holder:
YM-01235,90890-01235
4-.52
9. Install:
1 1"-1
ENG
-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 @ .
10. Tighten:
-Tensioner end plug
Tensioner end plug:

15 Nm (1.5 m • kg, 11 ft· Ib)
11.lnstall:
-O-ring CD
-Adjuster ® (chain tensioner)
- Locknut @ (chain tensioner)
-Cap nut @ (chain tensioner)
12. Adjust:
- Cam chain tension
- Valve clearance
Valve clearance (cold):

Intake:
0.05 - 0.10mm (0.002 - 0.004in)
Exhaust:
0.075 - 0.125mm (0.003 -
0.005in)
Refer to the "CAM CHAIN TENSION ADJUST-

MENT" and "VALVE CLEARANCE ADJUST-
MENT" section in the CHAPTER 3.
13. Install:
-·Side cover (cylinder head)
-Tappet covers (intake and exhaust)
-Spark plug

7 Nm (0.7 m· kg, 5.1 ft ·Ib)
Spark plug:
13 Nm (1.3 m • kg, 9.4 ft· Ib)
4-53
INTAKE MANIFOLD
1 1'\.1
ENG
1. Install:
2
eO-ring CD
elntake manifold CV
Bolt (intake manifold):
7 Nm (0.7 m· kg, 5.1 ft .Ib)
REMOUNTING ENGINE
When remounting the engine, reverse the
"ENGINE REMOVAL" procedure. Note the
following points.
1. Install:
e Engine assembly
Engine mount bolt

(upper and lower):
t--~ 33 Nm (3.3 m • kg, 24 ft • Ib)
2. Install:
-Dowel pins
- Gasket (new)
- Crankcase cover CD (left)
-Shift pedal CV
Screw (crankcase cover):

7 Nm (0.7 m • kg, 5.1 ft .Ib)
Bolt (shift pedal):
10 Nm (1.0 m • kg, 7.2 ft • Ib)
3. Install:
- Starter motor
Bolt (starter motor):

10 Nm (1.0 m • kg, 7.2 ft • Ib)
4. Install:
- Muffler
Nut (exhaust pipe):

10 Nm (1.0 m • kg, 7.2 ft • Ib)
Bolt (muffler):
25 Nm (2.5 m • kg, 18 ft • Ib)
4-54
ENGINE ASSEMBLY AND ADJUSTMENT ENG \ .
5.Adjust:
e Clutch free play
Refer to the "CLUTCH ADJUSTMENT"
6.Apply:
eEngineoil
Recommended oil:
SAE 20 W 40 type SE motor oil
Vamalube 4 (10 W 30) or
SAE 10 W 30 type SE motor oil
Total amount:
0.95 L (0.84 Imp qt, 1.00 US qt)
Refer to the "ENGINE OIL REPLACE-

7. Adjust:
eldle speed
~ Idle speed:
V ~ 1,700 ... 1,900 r/min
Refertothe "IDLE SPEEDADJUSTMENT"

8. Adjust:
e Throttle lever free play

3 ... 5 mm (0.12 ... 0.20 in)
Refer to the "THROTTLE LEVER AD-

JUSTMENT" section in the CHAPTER 3.
4-55
__________________________C_A_R_BU_R_E_T_O__
R ICARBI ~ I
CARBURETION
CARBURETOR SPECIFICATION
CD Throttle valve spring ® Main nozzle Main jet #80
®Needle set @Mainjet Jet needle 3PZS-3
@Throttle valve @ Needle valve Pilot jet #12.S
@Throttle stop screw set (j]) Float Pilot screw 1-1/8
® Pilot screw set @Drain screw Fuel level 2.S 4.Smm
N
® Choke lever (0.10 0.18 in)

N
(J) Pi lot jet Float height 20.0 22.0 mm

N
(0.79 0.87 in)

N
Engine idling speed 1.700 1.900 r/min

N
IAI FUEL LEVELl
2.S - 4.S mm
(0.10 - 0.18 in)
5-1
_____________C_A_RB_U_R_E_ro_R_~R~fl
REMOVAL
1. Turn the fuel cock to "OFF".
2. Drain the fuel from the carburetor.
3. Disconnect:
• Fuel hose CD
• Breather pipe ®
• Overflow pipe @
4. Remove:
• Carburetor CD
• Joint plate
• O-ring
• Top cover ®
• Gasket
5. Disconnect:
• Throttle cable CD
6. Remove:
• Spring ®
• Stopper @
• Jet needle @
• Throttle valve ®
DISASSEMBLY
1.Remove:
• Pilot screw CD
• Throttle stop screw ®
2. Remove:
• Float chamber cover
• Gasket
• Float pin CD
• Float ®
• Needle valve @
5-2
CARBURETOR ICARSI , I
3. Remove:
• Pilot jet CD
• Main jet ®
• Main nozzle @
INSPECTION
1. Inspect:
• Carburetor body
• Fuel passage
Cracks/Damage ~ Replace.
Clog ~ Clean.
NOTE: ______________________
Use a petroleum based solvent for cleaning.
322-021
Blowout all passages and jets with com-
pressed air.
2. Inspect:
• Float CD
Damage ~ Replace.
• Gasket/O-rings
Damage ~ Replace.
3. Inspect:
• Needle valve CD
Wear/Contamination -) Replace.
• Jet needle ®
Bends/Wear ~ Replace.
• Air screw @
• Throttle stop screw @
Wear/Contamination ~ Replace.
• Pilot jet @
• Main jet ®
• Main nozzle (j)
Clog ~ Clean.
NOTE: ______________________
Blowout the jets with compressed air.
5-3
__________________________C_A_R_B_U_R_E_TO
__ R ICARsl ~ I
4. Inspect:
• Throttle valve CD
Wear/Damage -)0 Replace.
5.Check:
• Free movement
Stick -)0 Replace.
Insertthe throttle valve into the carbure-
tor body, and check for free movement.
ASSEMBLY
Reverse the "DISASSEMBLV" procedure.
• Before reassembling, wash all parts in clean

gasoline.
• Always use a new gasket.
1. Measure:
• Float height ®
Out of specification -)0 Adjust.
*************************************
Measurement steps:
• Hold the carburetor in an upside down
position.
• Measure the distance between the mating
surface of the float chamber (gasket re-
moved) and top of the float using a gauge.
Float height:
20.0 - 22.0 mm (0.79 - 0.87 in)
NOTE: _ _ _ _ _ _ _ _ _ __
The float arm should be resting on the needle
valve, but not compressing the needle valve.
• Ifthe float height is notwithin specification,

inspect the needle valve.
• If it is worn, replace it
• If it isfine, adjustthe float height by bending
the float tang CD on the float.
• Recheck the float height.
*************************************
5-4
CARBURETOR
2. Adjust:
ICARBI " I
• Pilot screw
Pilot screw:
1-1/8 turns out
INSTALLATION
Reverse the "REMOVAL" procedur,e.
1. Install:
• Throttle valve CD
NOTE: _ _ _ _ _ _ _ _ _ __
Align the groove ® of the throttle valve with
the projection @ of the carburetor body.
2. Install:
• Carburetor CD
Bolt (carburetor):
7 Nm (0.7 m· kg, 5.1 ft ·Ib)
3. Adjust:
• Idle speed
~ Idle speed:
V ): 1,700 ... 1,900 r/min
Refer to the "IDLE SPEED ADJUST-

4. Adjust:
• Throttle lever free play

3 ... 5 mm (0.12 ... 0.20 in)
Refer to the "THROTTLE LEVER AD-

JUSTMENT" section in the CHAPTER 3.
5-5
CARBURETOR ICARSI • I
FUEL LEVEL ADJUSTMENT
1.Measure:
• Fuel level ®
Fuel level:
2.5 ... 4.5 mm (0.10 ... 0.18 in)
Below the carburetor body edge.
*************************************
Measurement and adjustment steps:
• Place the machine on a level place.
• Use a garage jack under the engine to
ensure that the carburetor is positioned
vertically.
• Attach the fuel level gauge CD to the float
cham ber nozzle ® .
Fuel level gauge:

YM-01312,90890-01312
• Loosen the drain screw @ and start the

engine.
• Measure the fuel level ® with gauge.
• If the fuel level is incorrect adjust the fuel
level.
• Remove the carburetor.
• Inspect the needle valve.
• If it is worn, replace it.
• Ifitisfine, adjustthefloat heightby bending
the float tang @ on the float.
• Recheck the fuel level.
*************************************
5-6
FRONT WHEEL AND FRONT BRAKE ICHASI~I
CHASSIS
FRONT WHEEL AND FRONT BRAKE
Tire air pressure
CD Camshaft lever ® Bearing Cold Tire Pressure Front Rear
® Wear indicator plate ® Bearing spacer
20kPa 20kPa
® Brake shoe plate @Front hub
Standard (0.2 kg/em!, (0.2 kg/em!,
@Oil seal @ Bearing 2.8 psi) 2.8 psi)
(IDO-ring @Oilseal
17 kPa 17 kPa
®Camshaft @ Collar Minimum (0.17 kg/em!, (0.17 kg/em!,
(j) Brake shoe complete 2.4 psi) 2.4 psi)
23 kPa 23kPa
Maximum (0.23 kg/em!, (0.23 kg/em!,
3.2 psi) 3.2 psi)
9 Nm (0.9 m • kg, 6.5 ft • Ib) A TIRE SIZE: AT18 x 7-7

B RIM SIZE: 5.5 x 7
CD
WHEEL RUNOUT LIMIT:
C VERTICAL: 2 mm (0.08 in)
LATERAL: 2 mm (0.08 in)
0 TIRE WEAR LIMIT: 3 mm (0.12 in)
BRAKE LINING WEAR LIMIT:
E 2 mm (0.08 in)
6-1
REMOVAL
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
5. Remove:
• Cotter pin CD
• Axle nut ®
• Plain washer ®
• Wheel hub @
6. Disconnect:
• Brake cable CD
7.Remove:
• Brake linings CD
• Brake shoe plate ®
• Camshaft ®
• Cam lever @
NOTE: _ _ _ _ _ _ _ _ _ _ __
Before removing the cam lever, put a match
mark (punches) on the cam lever and cam-
shaft to indicate their positions for easy as-
sembly.
6-2
FRONT WHEEL AND FRONT BRAKE I lo\l6l
CHAS
INSPECTION
1. Inspect:
• Wheel
Cracks/Bends/Warpage ~ Replace.
2. Measure:
• Wheel runout
Q)Dial gauge
Rim Runout Limit

Vertical: 2.0 mm (0.08 in)
Lateral: 2.0 mm (0.08 in)
3.Check:
• Wheel balance
Out of balance ~ Adjust.
4.lnspect: ,
• Brake lining surface
Glazed areas ~ Remove.
Use a coarse sand paper.
NOTE: ________________------
After using the sand paper, clean of the pol-
ished particles with cloth.
5. Measure:
• Brake lining thickness
Brake lining thickness:

Wear limit: 2.0 mm (0.08 in)
® Measuring points
NOTE: ______________________
Replace the brake shoes as a set if either is
found to be worn to the wear limit.
6. Inspect:
• Shoe spring
7. Inspect:
• Camshaft face
Wear ~ Replace.
6-3
a. Measure:
• Brake drum inside diameter @
Brake drum inside diameter:

Wear limit:
110.5 mm (4.35 in)
9. Inspect:
• Brake drum inner surface
Oil/Scratches·~ Remove.
Use a rag soaked in lacquer

Oil thinner or solvent.
Use a emery cloth.
Scratches
(lightly and evenly polishing)
a.Check:
• Wheel bearings
Bearing allow play in the wheel hub or
wheel turns roughly ~ Replace.
*************************************
Replacement steps:
• Clean the outside of the wheel hub.
• Drive out the bearing.
A WARNING
Eye protection is recommended when using
striking tools.
• Install the new bearing by reversing the

previous steps.
NOTE: ______________________
Use a socket that matches the outside diam-
eter 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.
*************************************
6-4
INSTALLATION
Reverse the "REMOVAL" procedure.
1. Lubricate:
• Oil seal lip
• Bearing
• Camshaft
~ Lithium-soap base grease

2. Install:
• Cam lever
• Camshaft
• Brake shoe plate
• Brake linings
NOTE: ______________________
• Align the punched mark ® on the camshaft
with the punched mark ® on the cam lever.
• Be sure the boss © on the steering knuckle
correctly engages with the projecting por-
tion (torque stopper)@)on the brake shoe
plate.
3. Connect:
• Brake cable CD
NOTE: ______________________
Install the brake cable stopper ® onto the
brake cable CD with the flat side ® towards the
brake shoe plate.
4. Tighten:
• Axle nut
• Nut (front wheel)
Axle nut:
70 Nm (7.0 m' • kg, 50 ft • Ib)
~-:I Nut (front wheel):
28 Nm (2.8 m • kg, 20 ft • Ib)
6-5
FRONT WHEEL AND FRONT BRAKE IcHASI6J6I
5. Install:
• Cotter pin (New)
A WARNING
Always use a new cotter pin.
6.Adjust:
• Front brake lever free play
Refer to the "FRONT BRAKE ADJUST-
6-6
R~E~AU;R~WMHfiiEiE1L----- ___ ...!R~E~A~R~W~H:!!E~E!:..L ICHASI~I
CD Wheel hub - -
® Hub dust cover
,...
!- TIRE SIZE: AT20 x 9-8
~ RIM SIZE: 7.5 x 8
C WHEEL RUNOUT LIMIT·
0 ~RTICAL 2 mm (o.~8 in)
IE TERAL 2 mm (0.08~n]
.
45 Nm (45 m· kg, 32 ft· Ib)
2
70 Nm (7 .0 m· kg, 50 ft· Ib)
F USE NEW ONE
6·7
REAR WHEEL ICHASIJJoI
REMOVAL
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
5. Remove:
• Cotter pin CD
• Axle nut ®
• Plain washer ®
• Wheel hub @
INSPECTION
1. Inspect:
• Wheel
Refer to the "FRONT WHEEL AND
FRONT BRAKE -INSPECTION" section.
2.Measure:
• Wheel runout
3.Check:
• Wheel balance
• Wheel bearings
6-8
REAR WHEEL I IJ301
CHAS
INSTALLATION
1. Lubricate:
• Oil seal lip
• Bearing
~ Lithium-soap base gr.as8

2. Tighten:
• Axle nut
• Nut (rear wheel)
Axle nut:
70 Nm (7.0 m • kg, 50 ft ·Ib)
t--......:I Nut (rear wheel):
45Nm (4.5 m • kg, 32 ft ·Ib)
6-9
REAR BRAKE ICHASI~I
REAR BRAKE
CD Brake cover ® Bearing [A] 1. Apply Loctite® to the thread portion ofthe rear
® Oil seal @ Spacer axle.
@ Rear axle nut (outside) ® Brake camshaft 2. Finger tighten the inside nut while checking the
® Rear axle nut (inside) @Rear hub ring gear engagement.
@ Brake drum @Wear indicator 3. Tighten the inside nutto 110 Nm (11.0 m· kg,
® Boss @ Camshaft lever 80 ft· Ib) while holding the rear axle.
(j) a-ring @ Rear hub nut 4. Hold the inside nut and tighten the outside nut
® Brake shoe compo to 130 Nm (13.0 m • kg, 94 ft· Ib).
5. Hold the outside nut and tighten back the
inside nut to 160 Nm (16.0 m • kg, 115 ft· Ib).
BRAKE LINING WEAR LIMIT:

C 2 mm (0.08 in)
BRAKE DRUM WEAR LIMIT:
D
130.5 mm (5.14 in)
~ B USE NEW ONE
6-10
_____--------RE-A-R-B-R-A-~-§~~I
REMOVAL
1.Remove:
• Rear wheel (right)
• Rear wheel hub (right)
Refer to the "REARWHEEL-REMOVAL"
section.
2. Remove:
• Brake cover CD
3. Straighten:
• Lock washer tabs
4. Remove:
• Nuts ®
• Lock washer ®
• Brake drum @
5. Disconnect:
• Brake cables
6. Remove:
• Brake shoes CD
• Cam lever ®
• Wear indicator
• Camshaft ®
NOTE: ______________________
Before removing the cam lever, put a match
mark (punches) on the cam lever and cam-
shaft to indicate their positions for easy as-
sembly.
INSPECTION
4. Inspect:
• Brake lining surface
Glazed areas ~ Remove.
Use a coarse sand paper.
NOTE: ______________________
After using the sand paper, clean of the pol-
ished particles with cloth.
6-"
REAR BRAKE ICHASI~I
2. Measure:
• Brake lining thickness
Out of speCification -) Replace.
Brake lining thickness:
Wear limit: 2.0 mm (0.08 in)
® Measuring point
NOTE: ______________________
Replace the brake shoes as a set if either is
found to be worn to the wear limit.
3.1nspect:
• Shoe spring
Wear/Damage -) Replace.
4. Inspect:
• Camshaft face
Wear -) Replace.
5. Measure:
• Brake drum inside diameter ®
Out of specification -) Replace.
Brake drum inside diameter:

Wear limit:
t--......;:w 130.5 mm (5.14 in)
6. Inspect:
• Brake drum inner surface
Oil/Scratches -) Remove.
Use a rag soaked in lacquer
Oil
thinner or solv~nt.
Use a emery cloth.
Scratches
(Jig htly and evenly polishing)
INSTALLATION
1. Lubricate:
• Camshaft
• Pivot pin
~ Lithium-soap base grease

6-12
REAR BRAKE ICHASI~I
2. Install:
• Camshaft
• Wear indicator
• Cam lever
• Brake shoes
NOTE: ______________________
Align the punched mark ® on the camshaft
with the punched mark @ on the cam lever.
3.lnstall:
• Brake drum CD
• Lock washer ®
• Nuts
A WARNING
Always use a new lock washer.
Nut (brake drum):

21 Nm (2.1 m· kg, 15 ft ·Ib)
4. Bend the lock washer tab along the nut

flats.
5. Adjust:
• Brake cable free play
Refer to the "REAR BRAKE LEVER AND
PEDAL ADJUSTMENT" section in the
CHAPTER 3.
6-13
STEERING SYSTEM ICHASI~I
STEERING SYSTEM
CD Steering shaft bushing (j) Bushing
® Oil seal ® Spacer
® Steering shaft ® Tie-rod
@ Knuckle ® Tie-rod end
@ Knuckle shaft
® Thrust cover
~"13V;:0·N;-m-(;;;3--;:.O:-m~·k:-g-,2=2::-:ft:-·--;I.,...."b)j
®
® TOE-IN:
0- 10 mm (0 - 0.4 in)
~ 20 Nm (2.0 m· kg, 14 ft ·Ib)
23 Nm (2.3 m • kg, 17 ft· Ib)
30 Nm (3.0 m· kg, 22 ft·lbl ~

'"
IB I USE NEW ONE~ 30 Nm (3.0 m· kg, 22 ft· Ibl
6-14
STEERING SYSTEM ICHASl6Jo1
REMOVAL
1.Remove:
• Front cover
• Front fender
Refer to the "FRONT FENDER" section
in the CHAPTER 3.
2. Disconnect:
• Neutral indicator light lead CD
3. Remove:
• Handlebar cover ®
4. Remove:
• Handlebar holder CD
• Handlebar ®
5. Straighten:
• Lock washer tabs
6. Remove:
• Steering shaft bracket
• Steering shaft bushings CD
• Oil seals ®
7. Remove:
• Cotter pin CD
• Nut ® (steering shaft)
• Plain washer @
• Tie-rod end @
• Steering shaft
6-15
STEERING SYSTEM ICHASIJJ61
a.Remove:
• Front wheels
• Front hubs
FRONT BRAKE - REMOVAL" section.
9. Remove:
• Cotter pins CD
• Nuts ® (tie-rod end)
• Tie-rod @
10. Remove:
• Cotter pin CD
• Nut ® (steering knuckle)
• Plain washer @
• Thrust covers @
• Bushings ®
• Spacer ®
• Knuckle shaft (j)
INSPECTION
1.lnspect:
• Steering shaft
Bends ~ Replace.
A WARNING
Do not attempt to straighten a bent shaft;
this may dangerously weaken the shaft.
6-16
STEERING SYSTEM ICHASIJ361
2.lnspect:
of • Oil seals CD
• Steering shaft bushings @
3.Check:
• Steering shaft free play
Steering shaft is loose ~ Replace bush-
ings and O-rings.
Insert the steering shaft into the frame,
and check for free play.
4.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.
5.Check:
• Tie-rod free play and movement
Tie-rod is exists free play ~ Replace tie-
rod end.
Tie-rod turns roughly ~ Replace tie-rod
end.
6.lnspect:
• Thrust cover
wear/Damage ~ Replace.
INSTALLATION
1. Lubricate:
• Knuckle shaft
• Bushing
• Thrust cover
I'§rl Lithium-soap base grease
6-17
2.Tighten:
• Nuts (steering knuckles)
Nut (steering knuckle):

30 Nm (3.0 m • kg, 22 ft • Ib)
Avoid over-tightening.
3. Install:
• Cotter pin
A WARNING
4. Adjust:
® • Tie-rod assembly length @
*************************************
Adjustment steps:
• Loosen the locknuts CD •
• Adjust tie-rod assembly length ® by turn-
ing both tie-rod ends.
CDA
Tie-rod assembly length:
260 mm (10.2 in)
NOTE: _ _ _ _ _ _ _ _ _ __
The threads ® on both tie-rod ends must be
of the same length.
[AJ Right-hand-threads
rn:J Left-ha nd-th reads
[CJ To steering shaft
[Q] To knuckle
• Tighten the locknuts.
Locknut (tie-rod):
30 Nm (3.0 m • kg, 22 ft • Ib)
*************************************
6-18
5. Install:
I~
• 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)
Nut (tie-rod end):

40 Nm (4.0 m • kg, 29 ft • Ib)
7. Install:
• Cotter pins
A WARNING
a.lnstall:
• Steering shaft
A WARNING
Make sure the brake cables and leads are
properly routed, and are not damaged or
twisted.
9. Tighten:
• Nuts CD (tie-rod end)
• Nut ® (steering shaft)
Nut (tie-rod end):

40 Nm (4.0 m • kg, 29 ft ·Ib)
......- .. Nut (steering shaft):
30 Nm (3.0 m • kg, 22 ft • Ib)
1a.lnstall:
• Cotter pin (new)
A WARNING
6-19
STEERING SYSTEM ICHASlo\Jol
11.lnstall:
• Oil seals CD
• Steering shaft bushings ®
• Steering shaft bracket
NOTE: ______________________
• Lightly apply lithium soap base grease to
the oil seals .
• Be careful not to damage the oil seals dur-
ing installation.
12. Install :
• Lock washers CD (new)
• Bolts ® (steering shaft bracket)
Bolt (steering shaft bracket):

23 Nm (2.3 m • kg, 17 ft ·Ib)
13. Bend the lock washer tab along the bolt

flats.
14. Install :
• Handlebar CD
• Handlebar holder ®
Bolt (handlebar holder):
20 Nm (2.0 m • kg, 14 ft • Ib)
15. Lubricate:
• Knuckle shaft CD
• Steering shaft ®
Use a grease gun.
~ Lithium-soap bas. gr••S8
16.Adjust:
• Toe-in
Refer to the "TOE-IN ADJUSTMENT"
6-20
FRONT SHOCK ABSORBER AND LOWER ARM ICHASI~I.
FRONT SHOCK ABSORBER AND LOWER ARM
CD Front shock absorber
® Bushing
@Lowerarm
45 Nm (4.5 m· kg, 32 ft • Ib)
55 Nm (5.5 m • kg, 40 ft· Ib)
45 Nm (4.5 m· kg, 32 ft· Ib)
6-21
FRONT SHOCK ABSORBER AND LOWER ARM I
ICHAS JJ6I
REMOVAL
1.Remove:
• Front wheels
• Front hubs
• Front brake shoe plates
FRONT BRAKE-REMOVAL" section.
2. Remove:
• Tie-rods
• Knuckle shafts
Refer to the "STEERING SYSTEM - RE-
MOVAL" section.
3. Remove:
• Shock absorber CD
4.Check:
• Lower arm (side play)
Side play ~ Replace bushings as a set.
Move the lower arm from side to side.
There should be no noticeable side play.
5.Check:
• Lower arm (vertical movement)
Tightness/Binding/Rough spots ~ Re-
place bushings as a set.
Move the lower arm up and down.
6-22
FRONT SHOCK ABSORBER AND LOWER ARM ICHASI~I
6. Remove:
• Lower arm CD
• Bushings
INSPECTION
1. Inspect:
• Shock absorber rod
Bends/Damage ~ Replace the shock ab-
sorber assembly.
• Shock absorber assembly
Oil leaks ~ Replace the shock absorber
assembly.
• Spring
Fatigue ~ Replace the shock absorber
assembly.
Move the spring up and down.
2. Inspect:
• Front arm
Cracks/Bends/Damage ~ Replace.
A WARNING
Do not attempt to straighten a bent arm; this
may dangerously weaken the arm.
INSTALLATION
1. Lubricate:
r:s;
• Bushings
Lithium-soap base grease
6-23
FRONT SHOCK ABSORBER AND LOWER ARM ICHASIJJ61
2. Install:
• Lower arm
NOTE: ______________________
Be sure to position the bolts (right and left)
CD, ® so that the bolt head face outward.
@ Forward
3. Tighten:
• Nuts (lower arm)
Nut (lower arm):

55 Nm (5.5 m • kg, 40 ft • Ib)
@
4. Install:
• Front shock absorber
NOTE: ______________________
Be sure to position the bolts (upper and lower)
CD, ® so that the bolt head face outward.
5. Tighten:
• Nut (shock absorber)
Nut (shock absorber):

45 Nm (4.5 m • kg, 32 ft • Ib)
6-24
REAR SHOCK ABSORBER AND SWINGARM ICHASlctJel
REAR SHOCK ABSORBER AND SWINGARM
CD Rear shock absorber
® Pivot shaft
® Swingarm
® Rubber boot
85 Nm (8.5 m • kg, 61 ft· Ib)
A USE NEW ONE
23 Nm (2.3 m· kg, 17 ft· Ib)
6-25
REAR SHOCK ABSORBER AND SWINGARM ICHASI~I
REMOVAL
1.Remove:
• Rear fender
• Rear wheels
• Rear wheel hubs
Refer to the "REAR WHEEL" sections.
2. Remove:
• Rear shock absorber CD
3. Remove:
• Brake drum
• Brake shoe
Refer to the "REAR BRAKE" section.
4. Remove:
• Rubber boot CD
5. Remove:
• Swingarm guard CD
6. Disconnect:
• Final gear case breather hose CD
7. Remove:
• Rear hub assembly@
8.Check:
• Swingarm (side play)
Out of specification --» Replace collars.
Move the swingarm from side to side.
Swingarm side free play limit:

1.0 mm (0.04 in)
6-26
REAR SHOCK ABSORBER AND SWINGARM ICHASI0\J6I
9.Check:
• Swingarm (vertical movement)
Tightness/Binding/Rough spots --) Re-
place collars.
Move the swingarm up and down.
10. Remove:
• Pivot shaft CD
• Lock washer ®
• Swingarm @
NOTE: ______________________
When removing the swingarm, the coupling
gear@anddrive shaft®will fall off. Take care
not to lose these parts.
INSPECTION
1. Inspect:
• Shock absorber rod
Bends/Damage --) Replace the shock ab-
sorber assembly.
• Shock absorber
Oil leaks --) Replace the shock absorber
assembly.
• Spring
Fatigue --) Replace the shock absorber
assembly.
Move the spring up and down.
6-27
REAR SHOCK ABSORBER AND SWINGARM ICHASI~I
2. Inspect:
• Rubber boot CD
Damage ~ Replace.
INSTALLATION
Reverse the "REMOVAL" procedures. Note
the following points.
1. Lubricate:
• Pivot shaft
Lithium base waterproof wheel

bearing grease
2.Apply:
• Adhesive (for rubber)
®- (to the swingarm end CD)
3. Install:
• Rubber boot ®
NOTE: _ _ _ _ _ _ _ _ _ __
Be sureto position the rubber bootsothatthe
tang @ face downward.
4. Install:
• Swingarm CD
NOTE: _ _ _ _ _ _ _ _ _ ___
• Before installing the swingarm do not for-
get to fitthe drive shaft®and coupling gear
@.
• Insert the rear drive shaft into the universal
joint properly.
6-28
REAR SHOCK ABSORBER AND SWINGARM ICHASIcfl61
5.lnstall:
• Lock washer CD (new)
• Pivot shaft ®
NOTE: ______________________
Be sure the projection ® on the lock washer
correctly engages with the slot ® into the
boss.
A WARNING
Always use a new lock washer.
Pivot shaft:
85 Nm (8.5 m • kg, 61 ft • Ib)
6. Install:
• Rear hub assembly CD
Bolt (final gear case):
20 Nm (2.0 m • kg, 14 ft· Ib)
~-::::I Nut (brake shoe plate):
40 Nm (4.0 m • kg, 29 ft • Ib)
7. Install:
• Swingarm guard CD
Bolt (swing arm guard):
23 Nm (2.3 m • kg, 17 ft· Ib)
8.Apply:
• Lithium base grease
(to the bolts (rear shock absorber))
9. Install:
• Rear shock absorber
NOTE: _______________________
The rear shock absorber should be installed
so that the spring seat CD on the shock
absorber face downward @ .
Nut (rear shock absorber):

45 Nm (4.5 m • kg, 32 ft • Ib)
6-29
SHAFT DRIVE I IctJ61
CHAS
SHAFT DRIVE
CD Rear axle ~ ~ut (~rive pinion gear)
® Bearing ® ouplmg gear
@ Oil seal
~ SDrive pinion gear
® ~haft ~r~ve assembly
ross Jomt complete
w pacer
@Bearing
.
120Nm(20 m· kg, 14 ft· Ib)j
6-30
SHAFT DRIVE ICHASI~I
REMOVAL
1.Remove:
• Rear wheels
• Rear wheel hubs
Refertothe" REARWHEEL-REMOVAL"
section.
2. Remove:
• Rear axle nuts (outer CD and inner ®)
Use the rear axle nut wrench.
Rear axle nut wrench:

YM-37132,90890-01422
3. Remove:
• Brake drum
• Brake shoe
Refer to the "REAR BRAKE" section.
4. Remove:
• Rear shock absorber
• Swingarm guard
• Rear hub assembly
Refer to the "REAR SHOCK ABSORBER
AND SWINGARM" section.
5. Remove:
• Rear hub CD
6. Remove:
• Nut CD (drive pinion gear)
Use the hexagon wrench 32 mm.
Hexag()n wrench 32 mm :
YM-01364,90890-01364
6-31
SHAFT DRIVE ICHASIJJ61
7. Remove:
• Bearing CD
• Spacer ®
• Drive pinion gear ®
• Rear axle
INSPECTION
1.lnspect:
• Rear axle runout ®
Rear axle runout limit:

1.5 mm (0.06 in)
A WARNING
Do not attempt to straighten a dent axle.
2. Inspect:
• Ring gear CD
• Drive pinion gear ®
• Coupling gear ®
• Final drive shaft @
Pitting/Wear/Damage ~ Replace.
3.Check:
• Bearings CD
Bearings allow play in the final gear
housing or shaft turns roughly ~ Re-
place.
6-32
SHAFT DRIVE ICHASIcfJ61
INSTALLATION
1. Lubricate:
• Oil seal lips
• Coupling gear
• Final drive shaft
r:sd Lithium-soap base grease
2. Tighten:
• Nut (drive pinion gear)
Use the hexagon wrench 32 mm.
Hexagon wrench 32 mm:

YM-01364,90890-01364
Nut (drive pinion gear):

80 Nm (8.0 m • kg, 58 ft • Ib)
Loctite®
3. Install:
• Rear hub
Bolt (rear hub):

20 Nm (2.0 m • kg, 14 ft· Ib)
Loctite®
4. Tighten:
• Rear axle nuts (inner Q) and outer ®)
*************************************
Tightening steps:
NOTE: ______________________
Before tightening the nuts, apply the Loctite®
to the thread portion of the rear axle .
• Finger tighten the inner nut Q)while check-

ing the ring gear engagement.
• Tighten the inner nut with rear axle nut
wrench to specification while holding the
rear axle.
6-33
SH_A_F_T_D_R_IV_E~HA~~I
_____________
Rear axle nut wrench:
YM-37132,90890-01422
Inner nut (first tightening):
110 Nm (11.0 m • kg, 80 ft .Ib)
• Hold the inner nut CD an.d tighten the outer

nut ®with rear axle nut wrench to specifi-
cation.
Outer nut:
130 Nm (13.0 m • kg, 94 ft • Ib)
• Draw the line ® on inner and outer nut.

• Hold the outer nut ® and tighten BACK the
inner nut CD with rear axle nut wrench to
specification.
a Inner nut (final tightening):
160 Nm (16.0 m • kg, 115 ft • Ib)
• Measure the distance ® between lines. If

distance ® is less than 3 mm (0.12 in),
retighten BACK the inner nut.
*************************************
/
i
6-34
YFM80 (0) CIRCUIT DIAGRAM IElEel iii I
ELECTRICAL
YFM80 (D) CIRCUIT DIAGRAM
0
@
B/R W
W/R
® W/L
Y/R ® R
G/W
®
-
l. -=-
B/W B
1..
B
-L
B
1..
® (j)
B/W B R Br B/W B
OFF RUN
ON
B R Br B
..L ..J..
Br
®
Br R/W Br
® OFF
ON
R/W
R
L!W
@
@
Sb fi
Sb--1
R Sb
G/Y
@1 ®
TB B B B
..L ..1. ..1. ..1.
- - -=
7-1
YFM80 (D) CIRCUIT DIAGRAM IElECIIlliii I
CD Ignition coil ® "START" switch
®Spark plug ® Battery
@COI unit ([j) Srarter relay
@COI magneto @ Starter motor
@ Rectifier/regulator @ Starting circuit cutt-off relay
@Main switch @ Rear brake switch
(j) "ENGINE STOP" switch @ "NEUTRAL" indicator light
®Fuse @ Neutral switch
NOTE: __________________________________________________
• "START" switch is closed while the button (switch) is pushed .
• Neutral switch is closed while the transmission is in neutral.
• Brake switch is closed while the brake is applied.
COLOR CODE
B Black Gf\N Greenf\Nhite

Br Brown G/Y Green/Yellow
0 Orange L/W Bluef\Nhite
R Red Rf\N Redf\Nhite
Sb Sky blue W/L White/Blue
W White W/R White/Red
B/R Black/Red Y/R Yellow/Red
Bf\N Black/White
7-2
ElECTRICAL COMPONENTS IHEel iii I
ELECTRICAL COMPONENTS SPECIFICATIONS RESISTANCE
CD Wireharness (J) Neutral switch IGNITION COIL:
® Starter relay ® Ignition coil PRIMARY 1.4-1.80
® Starting circuit cut-off ® COl unit SECONDARY 5.3 - 7.9 kO
relay ® Main switch PICK-UP COIL 297 - 3630
@ Main fuse @ "NEUTRAL" indicator SOURCE COIL 342 - 4180
® Rectifier/regulator light CHARGING COIL 0.8 - 1.00
® Battery LIGHTING COIL 0.36 - 0.440
A BATTERY:
CAPACITY:
B
12V,7AH
SPECIFIC GRAVITY:
C
1.280
7-3
CHECKING OF SWITCHES IElECIiii I
CHECKING OF SWITCHES
Check the switches for the conti n u ity between
the terminal to determine correct connection.
Read the following for switch inspection.
SWITCH CONNECTION AS SHOWN IN

MANUAL
The manual contains a connection chart as
shown left showing the terminal connections
of the switches (e.g., main switch, handlebar
switch, bracket switch, lighting switch etc.)
The extreme left column indicates the switch

positions and the top line indicates the colors
of leads connected with the terminals in the
switch com ponent.
B B/W R Br L/W L/R "0--0" indicates the terminals between

ON which there is a continuity of electricity; i.e., a
closed circuit at the respective switch posi-
OFF
tions.
LOCK
p
In this chart:
"R and 8r" and "l/W and LJR" are countinuous
with the "ON" switch position.
"8 and 8/W" is continuous with the "OFF"

switch position.
"8 and 8/W" is continuous with the "LOCK"

switch position.
"8 and 8/W" and "R and LjR" are continuous

with the "P" switch position.
7-4
CHECKING OF SWITCHES IHEel iiiii I
CHECKING SWITCH FOR TERMINAL
CONNECTION
Before checking the switch, refer to the con-
nection chart as shown above and check for
the correctterminal connection (closed circuit)
by the color combination.
To explain how to check the switch, the main

switch, taken for example in the following.
1. Disconnect the main switch coupler from

the wire harness.
Never disconnect the main switch coupler by

pulling the leads. Otherwise, leads may be
pulled off the terminals inside the coupler.
2. Inspect whether any lead is off the termi-

nal inside the coupler. If it is, repair it.
NOTE: _ _ _ _ _ _ _ _ _ __
If the coupler is clogged with mud or dust,
blow it off by compressed air.
7-5
CHECKING OF SWITCHES IElECI iii I
3. Use the connection chart to check the
color com bination for continuity (a closed
~ B B/W R Br L/W l/R circuit). In this example, the continuity is
ON 0 to 0- ~ as follows.
OFF 0 k)
"R and 8r" and "L/W and L/R" are continu-
LOCK iok) ous with the "ON" switch position.
p
10k) 0 -0
L "8 and 8JVV" is continuous with the "OFF"
switch position.
"8 and 8JVV" is continuous with the

"LOCK" switch position.
"8 and 8JVV" and "R and L/R" are continu-

ous with the "P" switch position.
~ Br l/R [X
rfR l/W B
Please note that these is no continuity (an
open circuit) at all for the color combina-
tions other than the above.
4. Check the switch component for the con-
tinuity between "R and 8r".
*************************************
Checking steps:
• Turn the switch key to the "ON", "OFF",
"LOCK" and "P" several times.
• Setthepocket tester selector to the "Qx 1".
• Connect the tester (+) lead to the "R" lead
terminal in the coupler and the (-) lead to
the "8r" lead terminal.
NOTE: _ _ _ _ _ _ _ _ _ __
Use thin probes for checking the continuity.
Otherwise, the probes may contact other
terminals inside the coupler.
• Check the continuity between "R" and "8r" .

at the respective switch position of "ON" CD
, "OFF" ® , ~'LOCK" @ , and "P" @ .
2 CD There must be continuity (the tester indi-
cating "0") at the "ON" switch position,
and there must be no continuity (the tester
indicating "00") at "OFF", "LOCK", or "P".
There is something wrong between "R"
and "8r" if there is no continuity at the
"ON" position or ifthere is some continuity
either at the "OFF" or "LOCK" or "P".
7-6
CHECKING OF SWITCHES IHEel iii I
NOTE: _______________________
Check the switchfor continuity severaltimes.
*************************************
5. Next go on to checking of the continuity

between "8" and "8/W", "L/W and L/R",
and "R and L/R" at the respective switch
positions, as in the same manner men-
tioned above.
6.lf there is something wrong with anyone

of the combinations, replace the switch
component.
7-7
CHECKING OF BULBS IHEel iiiii I
CHECKING OF BULBS (FOR
HEADLIGHT, TAIL/BRAKE LIGHT,
FLASHER LIGHT, METER LIGHT,
ETC.)
Check the bulb terminal continuity for the

condition of the bulb.
KINDS OF BULBS
® The bulbs used in the motorcycle are classi-
fied as shown left by the shape of the bulb
socket.
® and ® are many used for the headlight.

© is mainly used for the flasher light and tail!
brake light.
@ and ® are mainly used for the meter light

and other indicator lights.
©
CHECKING BULB CONDITION

1. Remove the bulb
NOTE: _ _ _ _ _ _ _ _ _ _ __
• Bulbs of the ® and ® type uses a bulb
holder. Remove the bulb holder before re-
moving the bulb itself. Most of the bulb
holder for this type can be removed by
turning them counterclockwise .
• Most of the bulbs of © and @ type can be
removed from the bulb sockets by pushing
and turning them counterclockwise.
• Bulbs of the o® type can be removed from
the bulb sockets by simply pulling them
out.
7-8
CHECKING OF BULBS IHEel iii I
Be sure to hold the socket firmly when
removing the bulb. Never pull the lead.
Otherwise, the lead may be pulled off the
terminal in the coupler.
A WARNING
Keepflammable products oryour hands away
from the headlight bulb while it is on.
It will be hot. Do not touch the bulb until it
cools down.
2.Check the bulb terminals for continuity.
*************************************
Checking steps:
• Setthe pocket tester selectorto the "Qx 1" .
• Connect the tester lead to the respective
bulb terminals. Take for example a 3-termi-
nal bulb as shown left. First check the
continuity between the CD and ® terminal
by connecting the tester (+) lead to the CD
terminal and the tester (-) lead to the ®
terminal. Then checkthecontinuitybetween
the CD and @ terminals by connecting the
tester (+) lead still to theCDterminal and the
tester (-) lead to the@terminal.lfthetester
shown "00" in either case, replace the bulb.
*************************************
3. Check the bulbsocketbyinstalling a proven

bulb to it. As in the checking of bulbs,
connect the pocket tester leads to the re-
spective leads of the socket and check for
continuity in the same manner as men-
tioned above.
7-9
IGNITION SYSTEM IElECl1lii I
IGNITION SYSTEM
CIRCUIT DIAGRAM
0
@
B/R W
W/R
® W/L
® H
G/W
®
-
1 7
B/W B
1..
-=
B
1..
-
® (j)
B/W B
OFF
ON
B
...J...
- -
BrT-:--------
®
Br R/W Br
@
OFF
ON
R/W----
LlW--I--..I"'I
-4
_ _+--..:.........:'!..-I--- Sb
Sb
CD Ignition coil
®Spark plug
®COI unit
@CDI magneto
®Main switch
(j)"ENGINE STOP"
T
.L
B
.J..
B
.J..
B
..l..
switch
7-10
IGNITION SYSTEM I IIiiii I
ElEC
TROUBLESHOOTING
IF IGNITION SYSTEM SHOULD BECOME

INOPERATIVE
(NO SPARK OR INTERMITTENT SPARK)
Procedure
Check;
1. Spark plug 6. "ENGINE STOP" switch
2. Ignition spark gap 7. Pickup coil resistance
3. Spark plug gap resistance 8. Source coil resistance
4. Ignition coil resistance 9. Wiring connection
5. Main switch (entire ignition system)
NOTE: _ _ _ _ _ _ _ _ _ __
Ignition checker:
• Remove the following parts before YM-34487
troubleshooting. 90890-06754
1) Seat Pocket tester:
2) Front fender YU-03112
3) Fuel tank 90890-03112
1. Spark plug Standard spar k plug:

• Check the spark plug condition. C7HSA (NG K), U22FS-U (N.D.)
(For USA and OCE)
• Check the spark plug type.
CR7HS (NG K) (For EUR)
• Check the spark plug gap.
Replace to the "SPARK PLUG INSPEC-
TION" section in the CHAPTER 3.
INCORRECT
~
Spark plug gap:
0.6 ... 0.7 mm (0.024 ... 0.028 in)
~ CORRECT
I Repair or replace spark plug.
*
7-11
IGNITION SYSTEM IHEel iii I
*
2.19l'1ition spark gap

• Disconnectthe spark plug cap from spark
plug.
• Connect the ignition checkerCDasshown.
(VSpark plug cap
• Turn the main switch to "ON".
• Check the ignition spark gap.
• Start engine, and increase spark gap un- 2
til misfire occurs.
MEETS SPECIFICATION
Minimum spark gap: 11
6.0 mm (0.24 in) ~
• OUT OF SPECIFIC-
. . . ATION OR NO SPARK
I Ignition system is good .
3. Spark plug cap resistance

• Remove the spark plug cap.
• Connect the pocket tester (Q x 1k) to the
spark plug cap.
• Check the spark pi ug cap for specificated
resistance.
Spark plug cap resistance:
10 kQ at 20°C (68°F)
OUT OF SPECIFICATION
n
MEETS SPECIFI-
~ CATION
I
Replace spark plug cap.
i
4. Ignition coil resistance
• Disconnectthe ignition coil couplerfrom
the wireharness.
• Connect the pocket tester (0 x 1) to the
ignition coil.
~ Tester (+) lead ~ Orange lead terminal
A
Tester (-) lead ~ Ignition coil base
• Check the primary coil for specificated
resistance.
~
Primary coil resistance:
1.4 ... 1.8 n at 20°C (68°F)
7-12
IGNITION SYSTEM IElECI iii I
B
• Connect the pocket tester (n x 1k) to the
ignition coil.
B Tester (+) lead ~ Ignition coil base
Tester (-) lead ~ Spark plug lead
• Check the secondary coil for specificated
resistance.
~.
Secondary coil resistance:
S.3 - 7.9 kn at 20°C (68°F) OUT OF SPECIFICATION
(Spark plug lead-Spark plug lead)
n BOTH MEET
IReplace ignition coil.
i
'0 SPECIFICATION
S. Main switch
• Disconnect the main switch coupler CD
from the wire harness.
• Check the switch com ponentfor the con-
tinuity between "Red ® and Brown ®".
Refer to the "CHECKING OF SWITCHES"
section.
INCORRECT
I Replace main switch.

1
~ CORRECT
6. "ENGINE STOP" switch

• Disconnect the handlebar switch (right)
coupler from CD the wireharness.
• Check the switch component for the
continuity between "BlackAVhite ® and
Black ® ". Refer to the "CHECKING OF
SWITCHES" section.
7-13
IGNITION SYSTEM / ElEC/1iii /
B/W B
INCORRECT
Br R/W
Replace handlebar switch (right).
~ CORRECT
7. Pickup coil resistance

• Disconnect the pickup coil coupler CD
from the wireharness.
pickup coil coupler terminal.
Tester (+) lead ~ White/Red ® terminal
Tester (-) lead ~ White/Blue ® terminal
• Check the pickup coil for specificared OUT OF SPECIFICATION
7f
3
L1W/
2
resistance.
Pickup coil resistance:
297 - 363 0 at 20"C (68"F)
(White/Red-White/Blue) I Replace pickup coil.
1
n
~ CATION
MEET SPECIFI-
8. Source coil resistance

• Disconnect the COl magneto coupler CD
~
~
COl magneto coupler terminal.
Tester (+) lead ~ Green/White ®
terminal
Tester (-) lead ~ Black/Red ® terminal
OUT OF SPECIFICATION
• Check the source coil for specificated
resistance.
Source coil resistance:

342 - 418 0 at 20"C (68"F)
(Green/White - Black/Red)
I Replace COl magneto.
n
~
MEET
SPECIFICATION
* 7-14
IGNITION SYSTEM IElECIIiii I
*
9. Wiring connection POOR CONNECTION
1
• Check the entire ignition system for con-
nections.
Refer to the "WIRING DIAGRAM" sec- ---------,
tion. ICorrect.
~ CORRECT
I Replace ignitor unit.
7-15
ELECTRIC STARTING SYSTEM IElEC/1iiii /
ELECTRIC STARTING SYSTEM
CIRCUIT DIAGRAM
@
w,
® VIR @ R
-
1 BIW B'
J..
-
B
1-
B
J..
-
® (J)
.................-...........
BIW B R Br S/W B
OFF
ON
B R Br B
...L.
'*
Br
®
Br R/W Br
®
OFF
ON
R/W
@
L!W
@
Sb
R
Sb-i
R
G/V Sb
@1 (jJ)
@
®Main switch
®Fuse
® "START" switch
@Battery
@ Starter relay
@ Starter motor
TB B B B @ Starting circuit
~ .1. ...L .1.
-
cut-off relay
- - - - -= (jJ) Rear brake switch
@ Neutral switch
7-16
ELECTRIC STARTING SYSTEM IElEel iii I
TROUBLESHOOTING
I STARTER MOTOR DOES NOT OPERATE.
Procedure
Check;
1.Fuse 7. Neutral switch
2. Battery 8. Rear brake
3. Starter motor 9. "START" switch
4. Starter relay 10. Wiring connection
5. Starting circuit cut off relay (entire electric starting system)
6. Main switch
NOTE: ______________________
Pocket tester:
Remove the following parts before trouble- VU-03112
shooting. 90890-03112
1) Seat
2) Front fender
3) Fuel tank
1.Fuse NO CONTINUITY
1
• Remove the fuse.
• Connect the pocket tester (0 xl) to the
fuse.
• Check the fuse for continuity. IReplace fuse.
~ CONTINUITY
2. Battery INCORRECT
• Check the battery condition.
Refer to the "BATTERY INSPECTION"
• Refill battery fluid.
Specific gravity: • Clean the battery t erminals.
1.280 at 200 e (68°F) • Recharge or replac e the battery.
7-17
ELECTRIC STARTING SYSTEM IHEel iii I
*
~ CORRECT
3. Starter motor
• Connect the battery positive terminal CD
and starter motor cable ®using ajumper
lead@.
A WARNING
• A wire for jumper lead must have the
equivalent capacity as that of the battery
lead or more, otherwise it may cause the =-
jumper lead to be burned.
DOES NOT MOVE
• This check is likely to produce sparks, so
be sure that no flammable gas or fluid is
in the vic'inity.
• Check the starter motor for operation. I

i
Repair or replace starter motor.
~ MOVES
4. Starter relay
• Disconnectthe starter relay couplerfrom
the wireharness.
• Connect the starter relay coupler "Red/
White" CDterminal to the battery positive
terminal and ground "Blue/White" ® to
the frame using the jumper leads @ .
• Check the starter motor for operation. DOES NOT MOVE
~ MOVES 1
[RePlace starter relay.
5. Starting circuit cut-off relay (relay unit)
• Disconnect the relay unit lead from the
wireharness.
• Connect the pocket tester (0 x 1) and
battery (12 V) to the relay unit coupler,
terminals.
7-18
ElECTRIC STARTING SYSTEM IHEel iii I
Step 1
Battery (+) terminal ~ Red/White CD ®
terminal.
Battery (-) terminal ~ Green/Yellow ®
terminal.
Step 2
Battery (+) terminal ~ Red/White CD
terminal.
Battery (-) terminal ~ Sky blue ®
terminal.
Tester (+) lead ~ Red/White @terminal NO CONTINUITY
Tester (-) lead ~ Blue/White@terminal
• Check the starting circuit cut-off relay for
continuity. I Replace relay unit assembly.
~ CONTINUITY
6.Main switch
• Disconnect the main switch coupler CD
continuity between "Red®and Brown®
". Refer to the "CHECKING OF
SWITCHES" section.
INCORRECT
I
1
Replace main switch.
~ CORRECT
7.Neutral switch
• Disconnect the neutral switch coupler CD
continuity between "Sky blue ® and
Ground". Refer to the "CHECKING OF
SWITCHES" section.
7-19
ELECTRIC STARTING SYSTEM IHEel iii I
B Y/R
Sb W INCORRECT
I
l
Replace neutral switch.
~ CORRECT
8. Rear brake switch
• Disconnect the rear brake switch leads CD
• Check the switch com ponentforthe con-
tinuity between "Green/Yellow ® and
Black ® ". Refer to the "CHECKING OF
SWITCHES" section.
I
GIY
I
B
l INCORRECT
1
IReplace rear brake switch.
~ CORRECT
9. START" switch
I
• Disconnect handlebarswitch (right) cou-

pler CD from wireharness.
• Check the "START" switch component
forthe continuity between RedJWhite ®
II
and Brown ® ". Refer to the "CHECKING

OF SWITCHES" section.
7-20
ELECTRIC STARTING SYSTEM IElEc11iii I
8/W 8
INCORRECT
8r R/W
I
1
Replace handlebar switch (right).
~CORRECT
• Checkthe entire starting system for con-
nections.
Refer to the "WIRING DIAGRAM" sec-
tion. I
Correct.
1
7-21
ELECTRICAL STARTING SYSTEM IElEel iii I
STARTER MOTOR
(DO-ring
® Brush set
@Armature
ARMATURE COIL RESISTANCE:

10 Nm (1.0 m • kg, 7.2 ft· Ib) A
0.043 Q at 20"C (68"F)
BRUSH WEAR LIMIT:
B 3.5 mm (0.14 in)
COMMUTATOR WEAR LIMIT:
C 15.5 mm (0.61 in)
MICA UNDERCUT:
D
1.0 mm (0.04 in)
"
7-22
ELECTRICAL STARTING SYSTEM IHEel iii I
Removal
1. Remove:
• Starter motor
Refer to the "ENGINE OVERHAUL -
ENGINE REMOVAL" section in the
CHAPTER 4.
Disassembly
1.Remove:
• Bolt CD
• Yoke ®
• Armature @
• Brush assembly @
• Bracket ®
Inspection and Repair

1. Inspect:
• Commutator
Dirty ~ Clean it with #600 grit sandpa-
per.
2. Measure:
• Commutator diameter ®
Out of specification ~ Replace starter
motor.
Commutator wear limit:

15.5 mm (0.61 in)
7-23
ELECTRICAL STARTING SYSTEM
3. Measure:
I ElECI iiiii I
• Mica undercut @
Out of specification -)- Scrape the mica
to propervalue usea hacksaw blade can
be ground to fit.
Mica undercut @ :
1.0 mm (0.04 in)
NOTE: _______________________
The mica insulation of the commutator must

be undercut to ensure proper operation of
commutator.
4. Inspect:
[Q]
nx 1 0
• Armature coil (insulation/continuity)
Defects -)- Replace starter motor.
*************************************
Inspecting steps:
• Connect the pocket tester for continuity
check CD and insulation check ® .
• Measure the armature resistances.
Armature coil resistance:

Continuity check CD :
o n at 20·C (68·F)
Insulation check ® :
More than 1Mn at 20·C (68·F)
• 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)
7-24
ELECTRICAL STARTING SYSTEM
6. Measure:
IElEel iii I
• Brush spring pressure
Fatigue/Out of specification ~ Replace
as a set.
Brush spring pressure:

310 ... 450 g (11 ... 16 oz)
7. Inspect:
• Bearing CD
• Oil seal ®
• a-rings @
Assembly
Reverse the "Disassembly" procedure.
1.lnstall:
• Yoke CD
NOTE: _ _ _ _ _ _ _ _ _ __
Align the projection ® on the cover with the
groove ® on the housing.
Installation
Reverse the "Removal" procedure.
1. Install:
• Starter motor
NOTE: _ _ _ _ _ _ _ _ _ __
Apply a lightly grease to the O-ring.
Bolt (starter motor):

10 Nm (1.0 m • kg, 7.2 ft· Ib)
7-25
CHARGING SYSTEM IflEel iii I
CHARGING SYSTEM
CIRCUIT DIAGRAM
@
B/R W
W/R
® W/L
Y/R ® R
G/W
®
-
1 -
B/W B
..1
B
..L
B
..1
-
@ (j)
R Br B/W B
OFF RUN
ON
B R Br B
.L ..L.
Br
®
Br R/W Br
@
OFF
ON
R/W
@
L/W
@
Sb
R
. Sb-i
R Sb
GIY
@1 @
@
@ COl magneto
® Rectifier/regulator
@Fuse
@ Battery
TB B B.
..L J.. ..L J.. -
- - - - .
7-26
CHARGING SYSTEM IELECIIiii I
TROUBLESHOOTING
ITHE BATTERY IS NOT CHARGED.
Procedure
Check;
1. Fuse 4. Startor coil resistance
2. Battery 5. Wiring connection
3. C~arging voltage (entire charging system)
NOTE: ______________________
Inductive tachometer:
• Remove the following parts before YU-08036
1) Seat Pocket tester:
• Use the following special tool(s) in this YU-03112
1. Fuse NO CONTINUITY
1--------
• Connect the pocket tester (Q x 1) to the
fuse.
• Check the fuse for continuity. I Replace fuse.
~ CONTINUITY
Specific gravity: • Clean the battery te rminals.
1.280 at 20°C (68°F) • Rechatrge or replac e the battery.
~ CORRECT
3. Charging voltage
• Connect the inductive tachometer to
spark plug lead. [Dc2ovl
• Connect the pocket tester (DC 20 V) to the
battery. - ~ +
l 1
+
~ 9
I.-......
Tester (+) lead ~ Battery (+) terminal
Tester (-) lead ~ Battery (-) terminal
7-27
CHARGING SYSTEM IElEel iii I
• Start the engine and accelerate to about,
5,000 r/min .
• Check charging voltage.
~
Charging voltage: MEETS SPECIFICATION
14.0 - 15.0 V at 5,000 r/min
NOTE:
Use a full charged battery.
I Charging circuit is good.
• OUT OF SPECIFI-
• CATION
3
4.Startor coil resistance B Y/R
• Disconnect the COl magneto coupler CD Sb W
• Connect the pocket tester "n x 1" to the
startor coils.
Tester (+) lead ~ White ® terminal
Tester (-) lead ~ Black ® terminal OUT OF SPECIFICATION
• Measure the startor coil resistances.
Startor coil resistance:
0.8 - 1.0 n at 20°C (68°F)
1
IReplace startor assembly.
nBOTH MEET
~ SPECIFICATIONS

• Check the entire ignition system for con-
nections.
tion. ICorrect.
~ CORRECT
I Replace rectifier/regulator.
7-28
SIGNAL SYSTEM IElEel iii I
SIGNAL SYSTEM
CIRCUIT DIAGRAM
B
..L
1 R Br B
:-:-"
-
..J..
BrT-~-----
Br
R/W-------
.J>I-~=---Sb~b
.......
Sb
® Main switch
@Fuse
® Battery
@"NEUTRAL"
indicator light
(j]) Neutral switch
T
.1.
B
J.. ..L
B
7-29
SIGNAL SYSTEM IElECIIiii I
TROUBLESHOOTING
IINEUTRAL" INDICATOR LIGHT DOES NOT

COME ON.
Procedure
Check;
1. Fuse
2. Battery
3. Main switch
4. Wiring connection
(entire signal system)
NOTE: _ _ _ _ _ _ _ _ _ __
Pocket tester:
• Remove the following parts befor trouble VU-03112
shooting. 90890-03112
1) Seat
2) Front fender
3) Fuel tank
• Use the following special tool in this
troubleshooting.
1. Fuse NO CONTINUITY
1
fuse.
• Check the fuse for continuity. Replace fuse.
~ CONTINUITY
Specific gravity: • Clean the battery term inals.
1.280 at 20°C (68°F) • Recharge or replace th e battery.
~ CORRECT
7-30
SIGNAL SYSTEM IELECIIii I
3. Main switch
• Disconnect the main switch coupler Q)
• Check the switch componentforthe con-
tinuity between "Red ® and Brown ® ".
Refertothe "CHECKING OF SWITCHES"
section.
INCORRECT
i
Replace main switch
~ CORRECT

• Check the entire signal system for con-
nections.
tion. ICorrect.
1
~ CORRECT
Check condition of each circuit for signal

system. Refer to the "SIGNAL SYSTEM·
CHECK" section.
7-31
SIGNAL SYSTEM CHECK
SIGNAL SYSTEM IHEel iii I
1. "NEUTRAL" indicatorlightdoes notcome
on.
NO CONTINUITY
1. Bulb and bulb socket
• Check the bulb and bulb socket for con-
tinuity. Refer to the "CHECKING OF
BULBS" section. I
1
Replace bulb and/or bulb socket.
~ CONTINUITY
2. Neutral switch
• Disconnect the neutral switch coupler CD
• Check the switch com ponent for the
continuity between "Sky blue ® and
Ground". Refer to the "CHECKING OF
SWITCHES" section.
~.
B Y/R
Sb W INCORRECT
l
Replace neutral switch.
~ CORRECT
3.Voltage
• Connectthe pocket tester (DC 20 V) to the
bulb socket leads CD .
Tester (+) lead ~ Brown ® terminal
Tester (-) lead ~ Sky blue ® terminal
• Turn the main switch to "ON".
• Check for voltage (12 V) on the" Brown" OUT OF SPECIFICATION
lead at bulb socket connector.
n MEETS SPECIFICA-
i
Wiring circuit from main switch to bulb
'0 TION socket connector is faulty, repair.
I
This circuit is good.
7-32
STARTING FAILURE/HARD STARTING THRTBGLI?
IS I
-----------------------------------------------------
TROUBLESHOOTING
NOTE: ____________________________________________________
The following troubleshooting does not cover all the possible causes of trouble. It should be
helpful, however, as a guide to troubleshooting. Refer to the relative procedure in this manual
for inspection, adjustment and replacement of parts.
STARTING FAILURE/HARD STARTING.

FUEL SYSTEM
Fuel tank Carburetor
-Empty -Deteriorated fuel, fuel containing wateror
-Clogged fuel filter foreign material
-Clogged fuel breather hose -Clogged pilot jet
-Deteriorated fuel or fuel containing water -Clogged pilot air passage
or foreign material -Sucked-in air
-Deformed float
Fuel cock -Groove-worn needle valve
-Clogged fuel hose -Improperly sealed valve seat
-Improperly adjusted fuel level
Air cleaner -Improperly set pilot jet
-Clogged air filter
ELECTRICAL SYSTEM
Spark plug COl unit system
-Improper plug gap -Faulty COl unit
-Worn electrodes -Faulty source coil
-Wire between terminals broken -Faulty pick-up coil
-Improper heat range -Broken woodruff key
-Faulty spark plug cap
Switches and wiring
Ignition coil -Faulty main switch
-Broken or shorted primary/secondary -Faulty "START" switch
-Faulty spark plug lead -Faulty "ENGINE STOP" switch
-Broken body -Faulty" NEUTRAL" switch
-Faulty "BRAKE" switch
Starter motor -Broken or shorted wiring
-Faulty starter motor
-Faulty starter relay
-Faulty circuit cut-off relay
8-1
POOR IDLE SPEED PERFORMANCEI
POOR MEDIUM AND HIGH SPEED PERFORMANCE _
ISTHRTBGLI?
_
I_
COMPRESSION SYSTEM
Cylinder and cylinder head Piston and piston rings
-Loose spark plug -Improperly installed piston ring
-Loose cylinder head or cylinder -Worn, fatigued or broken piston ring
-Broken cylinder head gasket -Seized piston ring
-Broken cylinder gasket -Seized or damaged piston
-Worn, damaged or seized cylinder
-Improperly sealed valve Crankcase and crankshaft
-1m properly contacted va Ive and va Ive seat -Improperly seated crankcase
-Improper valve timing -Seized crankshaft
-Broken valve spring
POOR IDLE SPEED PERFORMANCE

POOR IDLE SPEED PERFORMANCE
Carburetor Electrical system
-Clogged or loose pilot jet -Faulty battery
-Clogged pilot air jet -Faulty spark plug
-Improperly adjusted idle speed -Faulty COl unit
(Throttle stop screw) -Faulty pickup coil
-Improper throttle cable play -Faulty ignition coil
-Flooded carburetor
Valve train
Air cleaner -Improperly adjusted valve clearance
-Clogged air filter
POOR MEDIUM AND HIGH SPEED PERFORMANCE

POOR MEDIUM AND HIGH SPEED PERFORMANCE
Refer to "Starting failure/Hard starting."
(Fuel system, electrical system, compression system and valve train)
Carburetor Air cleaner
-Improper jet needle clip position -Clogged air filter
-Improperly adjusted fuel level
-Clogged or loose main jet
8-2
Is
FAULTY DRIVE TRAIN/FAULTY GEAR SHIFTING _THRTBGll?
-------------------------------------------------------
I
FAULTY DRIVE TRAIN
The following conditions may indicate damage drive train components:
Symptoms Possible causes
1. A pronounced hesitation or "jerky" move- A. Bearing damage.

ment during acceleration, deceleration, or
sustained speed. (This must not be confused B . Improper gear lash.
with engine surging or transmission charac-
teristics.) C . Gear tooth damage.
2. A "rolling rumble" noticeable at low speed; D. Broken constant velocity joint.

a high-piched "whine"; a "clank" from a
drive train component or area. E . Broken gear teeth.
3.A locked-up condition of the drive train F . Seizure due to lack of lubrication.
mechanism, no power transmitted from
engine to rear wheel. G . Small foreign object lodged between
moving parts.
NOTE: ______________________________________________ ~ _____

Areas A, B, and C above may be extremely difficult to diagnose. The symptoms are quite subtle
and difficult to distinguish from normal machine operating noise. If there is reason to believe
these components are damaged, remove the components for specific inspection.
FAULTY GEAR SHIFTING

HARD SHIFTING
Clutch Engine oil
-Improperly adjusted clutch release lever -High oil level
free play -Improper quality (High viscosity)
-Broken one way clutch of primary clutch -Deterioration
-Broken primary clutch carrier
-Broken clutch damperofsecondaryclutch
housing
-Warped clutch plate
-Swollen friction plate
-Broken clutch plate
CHANGE PEDAL DOES NOT MOVE

Shift shaft Transmission
-Bent shift shaft -Seized transmission gear
-Jammed impurities
Shift cam and shift fork -Incorrectly assembled transmission
-Groove jammed with impurities
-Seized shift fork Shift guide
-Bent shift fork guide bar -Broken shift guide
8-3
CLUTCH SLIPPING/DRAGGING/OVERHEATING IS LI ? I
THRTBG
-----------------------------------------------------
JUMP-OUT GEAR
Shift shaft Shift cam
-Improperly adjusted shift lever position -Improper thrust play
-Improperly returned stopper lever -Worn shift cam groove
Shift fork Transmission

-Worn shift fork -Worn gear dog
CLUTCH SLIPPING/DRAGGING
CLUTCH SLIPPING
Clutch Engine oil
-Improperly adjusted clutch release lever -Low oil level
free play -Improper quality (Low viscosity)
-Loose clutch spring -Deterioration
-Fatigued clutch spring
-Worn friction plate
-Worn clutch plate
CLUTCH DRAGGING
Clutch Engine oil
-Improperly adjusted clutch release lever -High oil level
free play -Improper quality (High viscosity)
-Improper engagement of release lever - Deterioration
and push rod
-Warped clutch plate
-Swollen friction plate
-Broken clutch boss
OVERHEATING
OVERHEATING
Ignition system Compression system
-Improper spark plug gap -Heavy carbon build-up
-Improper spark plug heat range
'-Faulty COl unit Engine oil
-Incorrect oil level
Fuel system -Improper oil viscosity
-Improper carburetor main jet -Inferior oil quality
(Improper setting)
-Improperly adjusted fuel height Brake
-Clogged air cleaner element -Dragging brake
8-4
FAULTY BRAKE/SHOCK ABSORBER MALFUNCTION/ B
INSTABLE HANDLINGSHTG.
ITR LI ? I
FAULTY BRAKE
POOR BRAKING EFFECT
Drum brake
-Worn brake shoe
-Worn or rusty brake drum
-Improperly adjusted brake free play
-Improper brake cam lever position
-Improper brake shoe position
-Fatigue/Damaged return spring
-Oily or greasy brake shoe
-Oily or greasy brake drum
-Broken brake cable
SHOCK ABSORBER
MALFUNCTION
MALFUNCTION
-Bent or damaged damper rod
-Damaged oil seal lip
-Fatigued shock absorber spring
INSTABLE HANDLING
INSTABLE HANDLING
Handlebars Wheels
-Improperly installed or bent -Deformed wheel
-Loose bearing
Steering -Bent or loose wheel axle
-Incorrect toe-in -Excessive wheel run-out
-Bent steering shaft
-Improperly installed steering shaft Frame
-Damaged bearing or bearing race -Twisted
-Bent tie-rods -Damaged frame
-Deformed steering knuckles -Improperly installed bearing race
Tires Swingarm
-Uneven tire pressures on both sides -Worn bearing or bush
-Incorrect tire pressure -Bent or damaged
-Unevenly worn tires
8-5
YFM80MNFM80MC WIRING DIAGRAM
CD COl magneto (stater coil)

® Neutral switch
-----------,
® Main switch
----------------------------,,, ,, @ Rectifier/regulator
,, ® Fuse
,
®
' ,
'\-----w, W , R Battery
1--_ _ _-'-, Y/R T Y/R"7Y@ ,..-----r-L/W (j) Starter motor
(GRAY)
6r
8
B
® Starter relay
(SPARE) : BIR BIR : o @) Rear brake switch
,--------------- ' (j]) : G/w--G/W: @ COl magneto (Source coil and pickup coil)
,.~}-! I~~':II tII§ jW]I , W/R--W/R'
rsbtwl rwiB1:
tB§! [I B , W/L--W/L'
@ COl unit
Y R
~
- - - - - - - - - - - I I
@ Ignition coil
,
,
I ____________________________ ,
J ~-------- _ _ _ _ _ _I m:EB @ Spark plug
@ Neutral indicator light
R
®--~L~--~~~~~i @
®
Handlebar switch
Engine stop switch
,
- - - - - -c- - - - - - - - - - - - - I : G/Yi B/w
B
...... @) Start switch
~
~
______________ : Sb
[I BJSIW]1 :I~
R Br
, R/W t
r
BrB/W B
,---_--.J ......
B/W
R/W'-------------------~~
----------------- --------, B
, ......
B Br
L.....-....---+--=---------1 Br
Sb
COLOR CODE
B ", ..... " .. Black B/R ........ Black/Red , W/R ....... White/Red
Br ........... Brown BIW........ BlacklWhite Y/R ........ Yellow/Red
O ............ Orange GIW ....... GreenlWhite
R ............ Red GIY ...... ;.GreenlYeliow
Sb .......... Sky blue UW ........ BluelWhite
W ........... White RIW ....... RedlWhite
Y ............ Yeliow W/L. ....... White/Blue
YFM80(D) WIRING DIAGRAM
®
RUN ~-------------B------------~
OFF
,----IR------~
~" :®qJl CD "ENGINE STOP" switch

® "START" switch
~ ~ ~
B
I L/W R
Q
r--'®"----'''-'o
@ Rectifier/regulator
® Starter motor
® Starter relay
(j) Fuse
Y/R R
_ ® ® Battery
® Nautral switch
~-----+~~------~----- @ COl magneto
@CDI unit
@~"----------~H---~----++----~++~--~--~--~ @ Ignition coil
@Spark plug
G/Y---------l--I-t---+---------.J
® "NEUTRAL" indicator light
@ Main switch
@ Rear brake switch
@j-=O,:,..:FF-+-='---l-'='+-+--l
ON
"-------t------------r-+t--------------+-------------- YIR---c:::J
Br-------------~
B--------------..J.
® CJJ::L Br---[I:::>CJJ--- Br
Sb---n:::=:J<::]]Sb-----+---+-t---+-+---4-+-+----I----I---+-l--~
COLOR CODE
B .............. Black
Br ............ Brown
o ............. Orange
R .............. Red
B
Sb ............ Sky blue
W/L
B/W B
W ............. White
Y .............. Yeliow
b~~ m®
B/R .......... Black/Red
BNI ......... Black/White
GNI ......... Green/White
~"m
B/R G/Y .......... Green/Yellow
GW
" L/W .......... Blue/White
RNI ......... Red/White
W/L.. ........ White/Blue
° W/R ......... White/Red
Y/R .......... Yellow/Red
@ @

1992-2008 Yamaha YFM80 Badger Grizzly Raptor ATV&#39;s

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1992-2008 Yamaha YFM80 Badger Grizzly Raptor ATV&#39;s

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EBS00004

HOW TO USE THIS MANUAL

G H I Illustrated symbols G to M in the exploded

GENERAL INFORMATION ..............................................................................1

PERIODIC CHECKS AND ADJUSTMENTS ..................................................15

YAMALUBE 4 (20W40) or SAE 20W40

YAMALUBE 4 (10W30) or SAE 10W30

-20° -10° 0° 10° 20° 30° 40° 50°C

Final gear oil SAE80 API GL-4 Hypoid gear oil

Parts Thread Tightening torque

Final gear case bearing retainer Nut M55 1 80 8.0 58 LT

Final gear bearing housing Bolt M6 6 20 2.0 14 LT

PERIODIC CHECKS AND ADJUSTMENTS

Indicates a potential hazard that could result in serious injury or death.

7 Nm (0.7 m • kg, 5.1 ft • Ib)

23 Nm (2.3 m • kg, 17 ft • Ib)

23 Nm (2.3 m • kg, 17 ft • Ib)

Order Job/Part Q’ty Remarks

3 Neutral indicator light connector 2 Disconnect.

FRONT GRILL AND FRONT FENDER

7 Nm (0.7 m • kg, 5.1 ft • Ib)

7 Nm (0.7 m • kg, 5.1 ft • Ib)

Order Job/Part Q’ty Remarks

REAR FENDER AND FOOTREST BOARDS

10 Nm (1.0 m • kg, 7.2 ft • Ib) 1

10 Nm (1.0 m • kg, 7.2 ft • Ib)

Order Job/Part Q’ty Remarks

First disconnect the negative lead,

5 Positive battery lead 1 Disconnect.

10 Nm (1.0 m • kg, 7.2 ft • Ib) 1

10 Nm (1.0 m • kg, 7.2 ft • Ib)

Order Job/Part Q’ty Remarks

1 Speed limiter length is

There is a check hose 1 at the bottom of the

The engine should never be run without the

Use a cleaning solvent which is designed

b. Squeeze the excess solvent out of the ele-

Do not twist or wring out the element. This

c. Apply engine oil to the element.

The element should be wet but not dripping.

Make sure its sealing surface matches the

3 f. Remove the purging bolt 3.

Order Job/Part Q’ty Remarks

Order Job/Part Q’ty Remarks

HOW TO USE THIS MANUAL

Illustrated symbols G to M in the exploded

GENERAL INFORMATION .............................................................................. 1

PERIODIC CHECKS AND ADJUSTMENTS ................................................... 9

PERIODIC CHECKS AND ADJUSTMENTS

PERIODIC MAINTENANCE/LUBRICATION INTERVALS

* It is recommended that these items be serviced by a Yamaha dealer.

Order Job name/Part name Q’ty Remarks

7 Nm (0.7 m • kg, 5.1 ft • Ib)

Order Job name/Part name Q’ty Remarks

7 Nm (0.7 m • kg, 5.1 ft • Ib) 7 Nm (0.7 m • kg, 5.1 ft • Ib)

Order Job name/Part name Q’ty Remarks

10 Nm (1.0 m • kg, 7.2 ft • Ib)

Order Job name/Part name Q’ty Remarks

Out of specification → Adjust.

2 Speed limiter length is

● Tighten the locknut.

AIR FILTER CLEANING

Refer to “SEAT, FENDERS AND FUEL

4.Pull out the air filter element assembly.

1992-2008 Yamaha YFM80 Badger Grizzly Raptor ATV's

1992-2008 Yamaha YFM80 Badger Grizzly Raptor ATV's

2r-====~~~~~= ________FR_ON_TF_OR_K ICHAS <#erG I