Yamaha YZF1000RJ User manual

·•
'
!
,..
~
YAMAHA
r LIT-11616-10-60
~

YZF1 000RJ/YZF1 000R-:JC
SERVICE MANUAL.
©1996 by Yamaha Motor Corporation, U.S.A.
First edition, November 1996
All rights reserved.
Any reproduction
or unauthorized use
without the written permission of
Yamaha Motor Corporation, U.S.A.
is expressly prohibited.
Printed in U.S.A.
P/N LIT-11616-10-60

•
NOTICE
      
          

     
          


       
   
             
  
      


      

 



IMPORTANT INFORMATION

 

  




  



EB002000
HOW TO USE THIS MANUAL
MANUAL ORGANIZATION
This manual is intended as a handy, easy-to-read reference book for the mechanic. It is
divic:;1ed into chapters, sections and sub-sections, Comprehensive explanations of all installa-
tion, removal, disassembly, assembly, repair and inspection procedures are laid
out with the
individual steps in sequential order.
PAGE FEATURES
The circled numbers below refer to the features indicated in the sample page.
CD :An abbreviation and symbol in the upper right corner of each page indicates the current
chapter.
®: The current section title is shown at the top of each page.t
@: Sub-section titles appear in smaller print than the section title.t
@ : Lines of asterisks (*) mark the beginning and end of a particularly important procedure.
The steps
of such procedures are marked with bullets (•).
® : Important information such as fluids, special tools and torques are framed and marked
with a corresponding symbol,
® :A circled number refers to an illustrated part.
(J) : A circled lower case letter refers to an illustrated dimension or alignment mark.
®: An upper case letter in a box refers to other illustrated details.
®: An arrow mark after a given defect suggests the recommended course of action.
t : In Chapt~r
3, "Periodic Inspection and Adjustment", it is usually the current sub-section
title that appears at the top of each page, instead of the current section title.
EXPLODl:D DIAGRAMS
To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each disassembly section.
@
CYLN>l ■ MIAD
- I f-.n.i•
•C•bondeP0 .. 11
UH1•-dtc•-•
.. ,. ____ _
hll• u,.10 ,,...o-, ~ ... , ... IP.,._ ....
11\1 .... Oo,io, ., ..
1
,,..,,,,,.u_'"
'---------' Avoollltc,.ICf, .... t.._.,._..,
'"°""o•• \cHAs\~ \
---------
!!mmlllllllll---
D•-••"•"' .. ' 1ou,11.,.,,,.,i,.,.,utfte,
lot••uN1•thi1"'fYQ"f1•ou11,.- ■ 11.,.,
21nsp,c,
•O,.v1ch1,n
•.Joontld.,vlCh.,nl
~C> .....
........... ~ .............
.....,,,..,,
6
••
-•
•
•
•

CD ®
l~~i1~1
lsPEcl o--1
• @ ©
11:gr1~1
I ENGl\al
@ ®
•
!coot!~ I
lcARsl ljl I
(j) ®
lcHAsl~I
IELEclol
® ®
~
IJn~~ ? I
• ® E] ®
~
@)
~
®
~
• ®
(81
@)
[ii]
@
@)
®>
l
~
l
m
~
• @ ® @
'
I
::.
~
....
-cM»t
® ®
•
IIH
EB003000
ILLUSTRATED SYMBOLS
Illustrated symbols CD to ® are printed on
the top right
of each page and indicate the
subject
of each chapter.
CD General information
® Specifications
@ Periodic inspections and adjustments
@Engine
@ Cooling system
® Carburetion
(j) Chassis
@ Electrical
® Troubleshooting
Illustrated symbols @) to @) are used to
identify the specifications appearing in the
text.
@ Filling fluid
® Lubricant
® Special tool
@) Torque
® Wear limit, clearance
@ Engine speed
@)Q, V, A
Illustrated symbols @ to ® in the exploded
diagrams indicate the types
of lubricants
and lubrication points.
@ Apply engine oil
@) Apply gear oil
@) Apply molybdenum disulfide oil
@ Apply wheel bearing grease
@ Apply lightweight lithium-soap base grease
@
Apply molybdenum disulfide grease
Illustrated symbols @ to ® in the exploded
diagrams indicate where to
apply a locking
agent@ and when to install a new part®·
@ Apply the locking agent (LOCTITE®>
® Replace

I
•
CHAPTER TITLES
GENERAL INFORMATION
~
• SPECIFICATIONS
0--
I
',.
SPEC
PERIODIC INSPECTION AND
ADJUSTMENT
ENGINE
• COOLING
CARBURETION
CHASSIS A
,. CHAS
ELECTRICAL 0
I.
ELEC
?
►
I TROUBLESHOOTING .'
~
TRBL
•
' SHTG
,.
I

CONTENl"S
CHAPTER f.
GENERAL INFORMATION
MOTORCYCLE IDENTIFICATION................................................................. 1-1
VEHICLE IDENTIFICATION NUMBER .................................................. 1-1
ENGINE SERIAL NUMBER ................................................................... 1-1
MODEL LABEL ....................................................................................... 1-1
IMPORTANT INFORMATION.......................................................................1-2
PREPARATION.FOR REMOVAL PROCEDURES.................................. 1-2
REPLACEMENT PARTS ........................................................................1-2
GASKETS, OIL SEALS AND O-RINGS....:................ ~ ........................... 1-2
LOCK WASHERS/PLATES AND COTTER PINS...................................1-3
BEARINGS
AND OIL SEALS.................................................................1-3
CIRCLIPS................................................................................................1-3
SPECIAL TOOLS ...........................................................................................1-4
FOR TUNE-UP .......................................................................................1-4
FOR ENGINE SERVICE..........................................................................1-5
FOR CHASSIS SERVICE........................................................................1-7
FOR ELECTRICAL COMPONENTS.......................................................1-7
CHAPTER 2.
SPECIFICATIONS
GENERAL SPECIFICATIONS ........................................................................ 2-1
·MAINTENANCE SPECIFICATIONS ..............................................................2-4
ENGINE..................................................................................................2-4
CHASSIS..............................................................................................2-13
ELECTRICAL ........................................................................................2-17
HOW TO USE THE CONVERSION TABLE.................................................2-19
GENERAL TORQUE SPECIFICATIONS.............................;........................2-19
LUBRICATION POINTS AND LUBRICANT TYPES....................................2-20
ENGINE................................................................................................2-20
CHASSIS......................................:............................... ;-; ........•...............2-21
COOLING SYSTEM DIAGRAMS ................................................................2-22
LUBRICATION DIAGRAMS ....
1
................................................................... 2-25
\
•
•
•
•
•·

• CABLE ROUTING .........:..............................................................................2-29
EMISSION HOSE ROUTING (california only) ...........................................2-36
• CHAPTER
3.
PERIODIC INSPECTIONS AND ADJUSTMENTS
INTRODUCTION............................................................................................ 3-1
PERIODIC MAINTENANCE/EMISSION CONTROL SYSTEM..................... 3-1
GENERAL MAINTENANCE/LUBRICATION.................................................3-2
COWLING$...............,.....................................................................................3-4
REMOVAL..............................................................................................3-6
INSTALLATION .....................................................................................3-7
SEATS............................................................................................................
3-8
REMOVAL..............................................................................................3-8
INSTALLATION .....................................................................................3-8
FUEL TANK ...................................................................................................3-9
REMOVAL..............................................................................................3-9
INSTALLATION ...................................................................................3-10
ENGINE........................................................................................................3-11
VALVE CLEARANCE
ADJUSTMENT .................................................3-11
CARBURETOR SYNCHRONIZATION.................................................3-19
IDLING,SPEED
ADJUSTMENT ...........................................................3-21
THROTTLE CABLE
ADJUSTMENT ....................................................3-22
SPARK PLUG INSPECTION ................................................................3-24
• IGNITION TIMING CHECK ..................................................................3-25
COMPRESSION PRESSURE MEASUREMENT.................................3-27
ENGINE OIL LEVEL INSPECTION ......................................................3-29
ENGINE OIL REPLACEMENT .............................................................3-30
ENGINE OIL PRESSURE INSPECTION ..............................................3-32
• CLUTCH
ADJUSTMENT .....................................................................3-33
CLUTCH FLUID LEVEL INSPECTION .................................................3-34
AIR BLEEDING (HYDRAULIC CLUTCH SYSTEM).............................3-35
AIR FILTER CLEANING .......................................................................3-36
CARBURETOR
JOINT INSPECTION ..................................................3-37
FUEL LINE INSPECTION.....................................................................3-38
• CRANKCASE BREATHER HOSE INSPECTION..................................3-38
EXUP CABLE
ADJUSTMENT .............................................................3-39
EXHAUST SYSTEM INSPECTION .....................................................3-41
COOLANT LEVEL INSPECTION .........................................................3-42
GEN
INFO
SPEC
INSP
ADJ
CARB
CHAS
D
ELEC
?
•
TRBL
SHTG

COOLANT REPLACEMENT ................................................................3-42
COOLING SYSTEM INSPECTION ......................................................3-46
CHASSIS......................................................................................................3-47
FRONT BRAKE ADJUSTMENT ...........................................................3-47
REAR BRAKE ADJUSTMENT .....................,.............:.........................3-47
BRAKE FLUID LEVEL INSPECTION........:...........................................3-49 •
BRAKE PAD INSPECTION .................,................................................3-50
BRAKE LIGHT SWITCH
ADJUSTMENT .............................................3-50
BRAKE HOSE INSPECTION ................................................................3-51
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) ...............................3-51
SHIFT PEDAL
ADJUSTMENT .............................................................3-52
DRIVE CHAIN SLACK
ADJUSTMENT ................................................3-53 •DRIVE CHAIN LUBRICATION ...........................,.................................3-55
STEERING HEAD INSPECTION..........................................................3-55
FRONT FORK INSPECTION ................................................................3-58
FRONT FORK
ADJUSTMENT .............................................................3-58
REAR SHOCK ABSORBER ADJUSTMENT ........................................3-60
TIRE INSPECTION ...............................................................................3-62
WHEEL INSPECTION ..........................................................................3-65
CABLE INSPECTION
AND LUBRICATION .........................................3-65
LEVER AND PEDAL LUBRICATION ...................................................3-66
SIDESTAND LUBRICATION .................;.............................................3-66
REAR SUSPENSION LUBRICATION....,.............................................3-66 •
·ELECTRICAL ................................................................................................3-67
BATTERY INSPECTION .........................................
~ ...........................3-67
FUSE INSPECTION .............................................................................3-72
HEADLIGHT BEAM
ADJUSTMENT ...................................................3-74
HEADLIGHT BULB REPL.ACEMENT .. -.................................................3-75
CHAPTER 4.
ENGINE
ENGINE REMOVAL.........................................,...........;................................. 4-1
•
FUEL TANK AND COWLINGS.............................................................. 4-1
ENGINE OIL AND COOLANT ............................................................... 4-1
BATTERY LEADS ...................................................................................4-2
AIR FILTER CASE ..................................................................................4-2
CARBURETORS.....................................................................................4-2
RADIATOR .............................................................................................4-2 •
HOSES AND LEADS .............................................................................4-3
DRIVE SPROCKET..................................................................................4-3
WATER JACKET JOINTS
AND WATER PUMP...................................4-4
AC GENERATOR AND STARTER MOTOR ..........................................4-5
MUFFLER ASSEMBLY..........................................................................4-6 •
ENGINE REMOVAL.................................-................................................4-7

•
•
•
•
•
•
•
ENGINE DISASSEMBLV ...............................................................................4-9
OIL FILTER AND OIL COOLER..............................................................4-9
CYLINDER HEAD COVER, CYLINDER HEAD AND CAMSHAFTS .... 4-10
CYLINDERS AND PISTONS.......................:.......:................................4-14
CLUTCH ..............................................................•................................4-15
OIL PAN AND OIL STRAINER .....................................................:...... 4-17
OIL PUMP AND SHIFT SHAFT...........................................................4-19
CRANKCASE DISASSEMBLY.............................................................4-20
SHIFT FORKS AND SHIFT CAM ......................................................... 4-21
TRANSMISSION .................................................................................4-22
STARTER CLUTCH AND CRANKSHAFT ............•..............................4-22
VALVES AND CAMSHAFT CASE.......................................................4-23
CONNECTING RODS ..........................................................................4-25
OIL PUMP ............................................................................................4-25
INSPECTION AND REPAIR .........................................................................4-26
CYLINDER HEAD.................................................................................4-26
VALVES AND VALVE GUIDES ...........................................................4-27
VAL VE SEATS .....................................................................................4-28
VALVE SPRINGS .................................................................................4-30
CAMSHAFT CASE ............................................................................... 4-31
VALVE LIFTERS................................................................................... 4-31
CAMSHAFTS ....................................................................................... 4-31
TIMING CHAIN, HY-VO CHAIN, CAMSHAFT SPROCKETS
AND CHAIN GUIDES.......................................................................4-33
TIMING CHAIN TENSIONER ..............................................................4-33
CYLINDERS AND PISTONS............................•...................................4-33
PISTON RINGS ....................................................................................4-35
PISTON PINS.......................................................................................4-36
CRANKSHAFT AND CONNECTING RODS ........................................4-36
OIL PUMP ............................................................................................. 4-41
PRIMARY DRIVE..................·................................................................4-42
STARTER DRIVES ...............................................................................4-42
AC GENERATOR SHAFT ....................................................................4-43
CLUTCH .............,................................................................ .'. ................4-43
TRANSMISSION AND SHIFTER.........................................................4-45
SHIFT SHAFT AND STOPPER LEVER ................................................4-47
OIL-JET NOZZLE .................................................................................4-47
RELIEF VALVE, OIL PIPE AND STRAINER.........................................4-48
OIL COOLER ........................................................................................4-49
CRANKCASE .......................................................................................4-49
BEARINGS AND OIL SEALS...............................................................4-49
CIRCLIPS AND WASHERS..................................................................4-49
ENGINE ASSEMBLV AND ADJUSTMENT ................................................4-50
OIL PUMP ............................................................................................4-50
CONNECTING RODS ..........................................................................4-52
CAMSHAFT CASE AND VALVES.......................................................4-54
SPEC
INSP
ADJ
ENG

CRANKSHAFT AND STARTER CLUTCH ...........................................4-57
TRANSMISSION ...............................................................................
,. 4-60
SHIFT
CAM AND SHIFT FORKS.........................................................4-60
•·
CRANKCASE ASSEMBLY.................................................................... 4-61
SHIFT SHAFT AND OIL PUMP ...........................................................4-64
OIL PAN
AND OIL STRAINER ............................................................4-65
CLUTCH .............................................-..................................................4-67
PISTONS
AND CYLINDERS................................................................4-72 •CYLINDER HEAD
AND CAMSHAFTS .................................................4-76
TIMING CHAIN TENSIONER ..............................................................4-79
OIL COOLER
AND OIL FILTER........................................................., .. 4-81
ENGINE REMOUNTING......................................................................4-82 •
CHAPTER 5.
COOLING
RADIATOR/OIL COOLER.............................................................................. 5-1
RADIATOR.....................................................................................................5-2
REMOVAL..............................................................................................5-2
INSPECTION..........................................................................................5-4
INSTALLATION .....................................................................................5-5 •
OIL COOLER ...................................................................................................5-6
REMOVAL..............................................................................................5-6
INSPECTION .......................................
'. ..................................................5-6
INSTALLATION .....................................................................................5-7
THERMOSTATIC VALVE/WATER
PUMP ....................................................5-8 1
THERMOSTATIC VALVE ..............................................................................5-9
REMOVAL..............................................................................................5-9
INSPECTION........................................................................................5-10
INSTALLATION ...................................................................................5-11
WATER
PUMP ........................................-.....................................................5-13
REMOVAL............................................................................................5-13
INSPECTION...
.- ....................................................................................5-14
INSTALLATION ......................................•............................................5-17

• CHAPTER 6.
CARBURETION
CARBURETORS ............................................................................................ 6-1
REMOVAL..............................................................................................6-3
• DISASSEMBLY......................................................................................6-5
INSPECTION ..........................................................................................6-7
ASSEMBLY............................................................................................6-9
INSTALLATION ...................................................................................6-11
FUEL LEVEL
AOJUSTMENT ...............................................................6-12
• THROTTLE POSITION SENSOR (TPS)
ADJUSTMENT
AND INSPECTION ...........................................................................6-13
CHAPTER 7.
CHASSIS
FRONT WHEEL .............................................................................................. 7-1
REMOVAL..............................................................................................7-2
INSPECTION..........................................................................................7-3
INSTALLATION .....................................................................................7-4
FRONT WHEEL STATIC BALANCE
ADJUSTMENT ............................7-5
REAR WHEEL ........................;.......................................................................7-7
REMOVAL..............................................................................................7-8
INSPECTION..........................................................................................7-9
INSTALLATION .....................................................................................7-9
REAR WHEEL STATIC BALANCE ADJUSTMENT ..............................7-9
FRONT AND REAR BRAKES ...................................................................... 7-1 O
FRONT BRAKE ....................................................................................7-10
REAR BRAKE .......................................................................................7-11
BRAKE PAD REPLACEMENT..............................................................7-12
• BRAKE CALIPER DISASSEMBLY.......................................................7-16
MASTER CYLINDER DISASSEMBLY.................................................7-18
INSPECTION
AND REPAIR .................................................................7-20
BRAKE CALIPER ASSEMBLY .............................................................7-24
MASTER CYLINDER ASSEMBLY.......................................................7-28
1-•
HYDRAULIC CLUTCH .................................................................................7-33
DISASSEMBLY....................................................................................7-34
INSPECTION
AND REPAIR .................................................................7-36
ASSEMBLY..........................................................................................7-37
•
GEN
INFO
SPEC
INSP
ADJ
CARB
CHAS
D
ELEC
?
•
TRBL
SHTG

FRONT FORK.........................................· ....... :.,..............................................7-41
REMOVAL......................................:·f···i'····· ........................................... 7-42
DISASSEMBLY....................................................................................7-43
INSPECTION........................................................................................7-45
ASSEMBLY ..........................................................................................7-46
INSTALLATION ...................................................................................7-51
STEERING HEAD AND HANDLEBARS......................................................7-53
REMOVAL............................................................................................7-54
INSPECTION.............................................._...........................................7-57
INSTALLATION ...................................................................................7-58
REAR SHOCK ABSORBER AND SWINGARM ...........................................7-61
HANDLING NOTES........................,....................................................7-62
NOTES ON DISPOSAL...................... ·· ...·...............................................7-62
REMOVAL............................................................................................7-62
INSPECTION........................................................................................7-67
INSTALLATION ...................................................................................7-68
DRIVE CHAIN AND SPROCKETS...............................................................7- 71
REMOVAL............................................................................................7-72
INSPECTION........................................................................................7-73
INSTALLATION ...................................................................................7-75
CHAPTER 8.
ELECTRICAL
ELECTRICAL COMPONENTS ....................................................................... 8-1
CHECKING OF CONNECTIONS....................................................................8-3
IGNITION SYSTEM ..........................................:····:........................................8-4
CIRCUIT DIAGRAM ........................:··.... ,. ...............................................8-4
TROUBLESHOOTING .............................................................................8-5
ELECTRIC STARTING SYSTEM .................................................................8-11
CIRCUIT DIAGRAM .............................................................................8-11
STARTING CIRCUIT OPERATION ......................................................8-12
TROUBLESHOOTING .........................................................................8-13
STARTER MOTOR...............................................................................8-20
CHARGING SYSTEM ..................................................................................8-25
CIRCUIT DIAGRAM .............................................................................8-25
TROUBLESHOOTING .........................................................................8-26
.~
•
•
•
•
•·

• LIGHTING SYSTEM ....................................................................................8-30
CIRCUIT DIAGRAM .
.- ...........................................................................8-30
TROUBLESHOOTING .........................................................................8-31
LIGHTING SYSTEM CHECK ...............................................................8-33
SIGNAL SVSTEM.............................................................:..........................8-36
CIRCUIT DIAGRAM .............................................................................8-36
TROUBLESHOOTING .........................................................................8-38
SIGNAL SYSTEM CHECK ...................................................................8-40
• COOLING.SYSTEM.....................................................................................8-49
CIRCUIT DIAGRAM .............................................................................8-49
TROUBLESHOOTING .........................................................................8-50
FUEL PUMP SYSTEM.................................................................................8-54
CIRCUIT DIAGRAM .............................................................................8-54
FUEL PUMP CIRCUIT OPERATION....................................................8-55
TROUBLESHOOTING .........................................................................8-56
FUEL PUMP TEST...............................................................................8-61
EXUP SVSTEM.................................................................................. ;; ........8-62
CIRCUIT DIAGRAM ...............................................................;.............8-62
TROUBLESHOOTING .........................................................................8-63
SELF-DIAGNOSIS .......................................................................................8-68
TROUBLESHOOTING .........................................................................8-69
CHAPTER 9.
TROUBLESHOOTING
STARTING FAILURE/HARD STARTING...................................................... 9-1
FUEL SYSTEM....................................................................................... 9-1
• ELECTRICAL SYSTEM ..........................................................................
9-1
COMPRESSION SYSTEM.....................................................................9-2
POOR IDLE SPEED PERFORMANCE............................................................9-2
POOR IDLE SPEED PERFORMANCE....................................................9-2
-•
POOR MEDIUM-AND HIGH-SPEED PERFORMANCE.................................9-2
POOR MEDIUM-AND HIGH-SPEED PERFORMANCE.........................9-2
• FAUL
TV GEAR SHIFTING.............................................................................9-3
HARD SHIFTING............................................................................•.......9-3
SHIFT PEDAL DOES
NOT MOVE .........................................................9-3
JUMPS-OUT-OF GEAR .........................................................................9-3
GEN
INFO
SPEC
CARB
CHAS
D
ELEC
?
•
TRBL
SHTG

CLUTCH SLIPPING/DRAGGING ..................................................................9-3
CLUTCH SLIPPING................................................................................9-3
CLUTCH DRAGGING ............................................................................9-3
•·
OVERHEATING .............................................................................................9-4
OVERHEATING......................................................................................9-4 •
FAUL TY BRAKE ............................................................................................9-4
POOR BRAKING EFFECT ......................................................................9-4
FRONT FORK OIL LEAKAGE: AND FRONT FORK MALFUNCTION............9-4
MALFUNCTION.....................................................................................9-4
OIL LEAKAGE .........................................................................................9-4 •l
j
UNSTABLE HANDLING.................................................................................9-5
UNSTABLE HANDLING ........................................................................9-5
FAUL TV LIGHTING AND SIGNAL SYSTEMS .............................................9-5
HEADLIGHT DOES
NOT LIGHT............................................................9-5
BULB BURNT
OUT ................................................................................9-5
FLASHER DOES
NOT LIGHT..........,.....................................................9-5
FLASHER BLINKS SLOWLY .................................................................9-5
FLASHER REMAINS LIT .......................................................................9-5
FLASHER BLINKS OUICKLY.................................................................9-5 •
HORN DOES NOT SOLJND............../:...................................................9-5
YZF1000R WIRNING DIAGRAM
•
•

·•
•
•
•
•
~ --.
~~~ ',,,;,:.~4:~ ,.s{'.-.:,-;;c"L.,~.;;..+--;.~--- ~,,,_,
MOTORCYCLE IDENTIFICATION I~~ 1~1
~.~.
,, ~ "\
1 - 1
EB100000
GENERAL INFORMATION
1MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehic::le ide!ltificatiori number G) is
stamped
into the right side of the steering
head.
NOTE: ------------
Th.e vehicle identification number is used to
identify the motorcycle and may be used to
register the motorcycle with a licensing
authority.
EB100030
ENGINE SERIAL NUMBER
The engine serial number (D is stamped
into the crankcase.
NOTE: ------------
The first three digit$ of the engine serial
number indicate the model type; the
remaining digits are the
unit production
number.
MODEL LABEL
The model label (D is affixed to the frame.
This information
will be needed to order
spare parts.
,.

IMPORTANTINFORMATION I~~ 1~1
300·008
300,009
E!l101000
:IMPORTANT INFORMATION
PREPARATION FOR REMOVAL
PROCEDURES
1.Before removal and disassembly remove
all dirt, mud, dust and foreign material.
2.Use propertools and cleaning equipment.
Refer
to "SPECIAL TOOLS".
3.When disassembling the motorcycle,
always keep mated parts together. This
includes gears, cylinders, pistons and
other parts that have been
"mated"
through normal wear. Mated parts must
always be reused or replaced as an
assembly.
.4.t.>uring motorcycle disassembly, clean all
parts and place them in trays in the order
of disassembly. This will speed up assem-
bly and allow for the correct installation of
all parts.
5.Keep all parts away
from any source of
fire.
EB101010
.. REPLACEMENT PARTS
•
••
•
•
' 1.Use only genuine Yamaha parts for all
replacements. Use oil and grease recom-
mended
by Yamaha for all lubrication
jobs. Other brands may
be similar in func-
tion and appearance,
but inferior in qual- •
ity.
1 - 2
EB101020
GASKETS, OIL SEALS AND O-RINGS
1.When overhauling the engine replace all
gaskets, seals and O-rings. All gasket sur-
faces, oil seal lips and O-rings
must be
cleaned.
2.During reassembly properly oil all mating
parts and bearings.
Apply grease to the
oil seal lips.
••
•
-- - ·-·,' . . .
,,-,~.-:,,,_.;:~,i;,~~~ .. ,;~.d,.:kc: .. ~

•
•
..
•
•
•
•
IMPORTANT INFORMATION I::.~~,~,
300 000
300 003
300·002
300
001
1 - 3
EB101030 , , ..
LOCK WASHERS/PLATES AND COTTER
PINS,
1.After removal replace all lock washers/
plates G) and·cotter pins. After the bolt
or
nut has been· tightened ·to specification
bend the lock tab(s) along a
flat side of the
boltor nut.
EB101040
BEARINGS AND OIL SEALS
1.lnstall bearings and oil seals so that the
manufacturer's marks
or numbers are vis-
ible. When installing oil seals, apply a
light coating
of lightweight lithium base
grease to the seal lips. When installing
bearings oil them liberally,
if appropriate.
<D Oil seal
Do not use compressed air to spin the bear•
ings dry. This will damage
the bearing sur-
faces.
<D Bearing
EB101060
CIRCLIPS
1.Before reassembly, check all circlips care-
fully. Always replace piston pin clips after
one use. Replace distorted circlips. When
installing a circlip
CD, make sure that the
sharp-edged
corner® is positioned oppo-
site the
thrust@ it receives. See sectional
view.
© Shaft

EB102000
SPECIAL TOOLS
The following special tools are necessary for
complete and accurate tune-up and assembly.
Use onlythe appropriate special tools; this will
help prevent damage caused by the
use of
inappropriate tools or improvised techniques.
Special tools may differ in shape and part
number from country to country.
In such a
case, two types are provided.
ea,02010
FOR TUNl;-UP
Va~uum gcluge
VU,08030
This gauge is needed for carburetor synchro-
nization.
Carburetqr angle
driver
90890-03158
This tool is used to adjust the pilot screw.
Inductive
timing light
908~0-03141
This tool is necessary for checking ignition
timing.
1 - 4
SPECIAL TOOLS I ~~~ I~ I
When placing an order, referto the follow-
ing list to avoid any mistakes.
P/N, YM- □□□□□, YU-00000
YS- □□□□□, YK-00 □□□
ACC-000 □□
P/N.90890- □□□□□
Engine tachometer
YU-8036-A
90890-03113
For
CDN
Exceptfor
CDN
This tool is needed for detecting engine rpn,.
, Vacuum gauge
90890-03094
This gauge is needed for carburetor synchro-
nization.
Inductive
timing light
YM-33277-A
This tool is necessary for checking ignition
timing.
Compression gauge .-
YU-33223 : ~' , ,
l~ ',
,--s- -,
I I
' I
I
This gauge is used to measure the engine
compression.
•
••
•1
•
•
•

•
•
•
•
•
•
Compression gauge
90890-03081
This gauge is used to measure the engine
compression.
Fuel level gauge
YM-01312-A
90890-01312
This gauge is used to measure the fuel level in
the float chamber.
EB102020
FOR ENGINE SERVICE
Piston pin puller
YU-01304
90890-01304
\
This tool is used to remove the piston pin.
Universal clutch holder
90890-04086 ~
This tool is used to hold the clutch when
removing or installing the clutch boss locknut.
1 - 5
SPECIAL TOOLS I 1~~~1~1
Oil pressure gauge
90890-03153
Adapter
90890-03139
This gauge is used to measure engine oil pres-
sute.
Cam chain cutter
YM-01112
90890-01112
This tool is used When cutting the cam chaih.
Universal clutch holder
YM-91042
This tool is used to hold the clutch when
removing
or installing the clutch boss locknut.
Armature shock puller
YU-1047-3
90890-01290
Weight
YU-1047-4
90890-01291
These tools are used to remove the starter
clutch shaft.
'·• ;,
. ': "- ___ "? ~s-~4~~~44Yttihd'rt~;,,ta ~--~ Wzte "ittts#