Yamaha Scorpio Z (2005-2008)

Manual Yamaha Scorpio Z ini merangkum panduan penggunaan dan perawatan utama kendaraan. Pembahasan utama mencakup Perawatan Berkala, Mengatasi Masalah, Spesifikasi, Keamanan Berkendara, Petunjuk Pengoperasian

Yamaha Scorpio Z Service Manual

Unduh gratis Service Manual Yamaha Scorpio Z dalam format PDF. Panduan servis, spesifikasi, dan prosedur perawatan.

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YAMAHA
SCORPIO
( SX-4 )
SERVICE MANUAL

5BP-F8197-B0

Page 1

Page 2

PENDAHULUAN

Service Manual ini dibuat oleh  Yamaha Motor Company, Ltd. dan dialih bahasakan oleh, Technical 
Publication Yamaha Indonesia diharapkan dapat dipakai oleh Teknisi Bengkel dan Dealer Yamaha
Kami menyadari bahwa tidak mungkin menjelaskan seluruh pelajaran teknik perbaikan sepeda motor
dalam satu buku saja. sehingga kami meyarankan kepada para mekanik harus terlebih dahulu
menguasai dasar-dasar perbaikan sepeda motor Yamaha dengan mengikuti training-training reguler
yang diadakan oleh Yamaha. Tanpa pengetahuan ini, usaha perbaikan akan kurang sempurna.

Yamaha Motor Indonesia akan terus menerus berusaha meningkatkan mutu produksinya, untuk itu,
jika ada perubahan yang mendasar dalam spesifikasi dan prosedur pengerjaan, kami akan sampaikan
ke seluruh jaringan Yamaha melalui buletin "Servioce Information"

INFORMASI PENTING YANG ADA DIDALAM BUKU PETUNJUK INI :
Informasi penting secara khusus ditandai dengan tanda-tanda sebagai berikut :

Simbol ini, mengharuskan anda BERHATI-HATI MENYANGKUT KESELAMATAN
ANDA !

Memberikan petunjuk khusus, yang harus diikuti untuk menghindari kecelakaan
bagi pengendara dan orang lain yang sedang memperbaiki sepeda-motor

PERINGATAN

PERHATIAN

Perlu perhatian khusus yang harus diikuti untuk menghindari kerusakan pada
sepeda motor.

CATATAN :

Memberikan keterangan tambahan, untuk mempermudah pengerjaan.

TECHNICAL PUBLICATION GROUP 1
SERVICE INFORMATION DIV.
YAMAHA MOTOR CO., LTD

Page 3

TEKNIK MEMBACA CEPAT BUKU PETUNJUK

SUSUNAN BUKU PETUNJUK
Buku ini terdiri dari beberapa BAB utama yang didalamnya terdapat beberapa judul (lihat "simbol")

Judul pertama  1: BAB yang disertai simbol, terletak disudut kanan atas, pada setiap halaman. 

Judul kedua 2: Judul ini adalah judul bagian BAB yang terletak hanya pada halaman pertama
dari tiap-tiap bagian, judul ini terletak disudut kiri atas halaman

Judul ketiga 3: Judul ini adalah judul yang lebih spesifik.

FORMAT  BUKU
Semua prosedur dalam buku ini, dikemas dalam rangkaian tahap demi tahap, sehingga petunjuk-
petunjuk yang ada secara lengkap dapat diterima dengan mudah oleh para mekanik.
Petunjuk yang ada meliputi berbagai hal, antara lain tentang cara membongkar, memperbaiki, dan
pemeriksaan, jika ada prosedur yang penting, dan perlu perhatian khusus 4 kami beri garis “*” dengan
tiap-tiap prosedur kami beri tanda “G”

INFORMASI PENTING

G Data spesifikasi dan special tool, diinformasikan dalam frame dengan gambar alat 5.

G  Angka didalam lingkaran 6 menunjukkan nama komponen dan penjelasan yang melengkapi
gambar 7, ada kalanya kita gunakan huruf didalam segi empat/box 8.

G Untuk penjelasan tentang tindakan lebih lanjut, kita gunakan tanda panah. sebagai contoh, tindakan
lebih lanjut jika diluar spesifikasi dengan simbol panah  ---> 9.

DIAGRAM
Semua BAB, dilengkapi dengan gambaran sebelum dibongkar, hal ini untuk mempermudah prosedur
yang benar cara memasang dan membongkar.

Page 4

1
2

GEN
INFO
SPEC

3
4

INSP
ADJ
ENG

5
6

CARB
CHAS

7
8

–
+
ELEC
TRBL
SHTG

9
0

A
B

C
D

T R
.

.

E
F

G
H
I

E
G
M

J
K
L 

B
LS
M

M
N

LT
New

SIMBOL
(sesuai illustrasi)

Illustrasi simbol 1 hingga 8 merupakan simbol
di setiap BAB, yang menggambarkan isi dari
setiap BAB.
1 Informasi Umum
2 Spesifikasi
3 Perawatan berkala dan pelumasan
4 Membongkar mesin
5 Karburator
6 Rangka/Chassis
7 Kelistrikan/Electrical
8 Cara mengatasi masalah/Troubleshooting

Illustrasi simbol 9 hingga F menjelaskan sebagai
berikut.
9 Perbaikan dengan mesin terpasang
0 Pengisian cairan
A Pelumasan
B Alat khusus/Special tool
C Pengencangan.
D Bats keausan/kelonggaran
E Putaran mesin
F Ω, V, A

Illustrasi simbol G hingga N pada gambar 
menunjukkan tipe pelumas dan bagian yang
perlu dilumasi.
G Lumasi dengan oli mesin
H Lumasi dengan oli gear
I Lumasi dengan molybdenum disulfide oil
J Lumasi dengan gemuk bearing roda
K Lumasi dengan gemuk  lightweight lithium-soap base
L Lumasi dengan gemuk molybdenum disulfide 
M Berikan cairan pengunci (LOCTITE®)
N Ganti dengan yang baru.

Page 5

DAFTAR ISI

INFORMASI  UMUM
GEN 
INFO 1 

SPESIFIKASI
SPEC 2 
PERAWATAN BERKALA DAN
PENYETELAN 
INSP

MEMBONGKAR MESIN
ENG 4 

CARBURATOR
CARB 5 

RANGKA/CHASSIS
CHAS 6 

KELISTRIKAN
ELEC 7 

TRBL
SHTG 8 

ADJ 3 

–
+

Page 6

GEN
INFO
BAB 1.
INFORMASI  UMUM

IDENTIFIKASI SEPEDA MOTOR  ............................................................... 1-1
NOMOR RANGKA ................................................................................ 1-1
NOMOR MESIN .................................................................................... 1-1

INFORMASI PENTING ................................................................................. 1-2
PROSEDUR PERSIAPAN MEMBONGKAR ......................................... 1-2
PART PENGGANTI .............................................................................. 1-2
GASKETS, OIL SEALS DAN O-RINGS ................................................ 1-2
LOCK WASHERS/PLATES DAN COTTER PINS ................................. 1-3
BEARING DAN SEAL OIL ..................................................................... 1-3
CIRCLIPS .............................................................................................. 1-3
MEMERIKSA SAMBUNGAN KABEL .................................................... 1-4

SPECIAL TOOLS ......................................................................................... 1-5

Page 7

| GEN INFO | [Motorcycle Icon] |
| :--- | :--- |

---

Page 8

IDENTIFIKASI SEPEDA MOTOR

1

2

1 - 1

GEN
INFO

YP100000
INFORMASI UMUM
IDENTIFIKASI SEPEDA MOTOR

YP100020
NOMOR RANGKA/CHASIS
Nomor rangka 1 tercetak pada rangka di bagian
down tube

EB100030
NOMOR MESIN
Nomor mesin (2) tercetak pada crankcase mesin
sebelah kanan.

CATATAN:
bentuk dan spesifikasi sewaktu-waktu dapat
berubah tanpa pemberitahuan.

Page 9

GEN
INFO
INFORMASI  PENTING

1 - 2

EB101000
INFORMASI PENTING
PROSEDUR PERSIAPAN
MEMBONGKAR
1. Bersihkan dari debu, dan kotoran yang 
menempel pada sepeda motor
2. Pergunakan peralatan yang tepat dan bersih
3. Lihat bagian “ SPECIAL TOOLS” 

4. Komponen yang telah dibongkar, tempatkan
dalam kondisi terangkai. Misalnya rangkaian
gears, cylinders, pistons dan komponen lain
yang memerlukan pengepasan. komponen 
komponen yang bekerja bersamaan, harus
diganti lengkap satu set.
5. Pada saat konsdisi komponen part dilepas, 
bersihkan dari kotoran yang menempel pada
komponen, untuk mempermudah dan mem-
percepat pemasangan kembali.
6. Jaga semua komponern dari pengaruh panas.

EB101010
PART PENGGANTI
1. Pergunakan hanya spare part asli Yamaha/ 
genuine part. pergunakan juga oli dan gemuk
yang disarankan Yamaha untuk pelumasan.
Komponen imitasi, terlihat sama dengan yang
asli, tetapi kualitasnya jauh lebih buruk.

EB101020
GASKETS, SEAL OIL DAN O-RINGS
1. Ganti semua gaskets, seals dan O-rings pada
saat membongkar mesin. bersihkan gasket
yang menempel pada permukaan sambungan
dengan sempurna.
2. Lumasi dengan pelumas pada saat memasang
bearing. dan lumasi gemuk pada permukaan
singgung seal oli.

Page 10

INFORMASI  PENTING

1 - 3

GEN
INFO

EB101030
LOCK WASHERS/PLATES DAN COTTER 
PINS
1. Ganti lock washers/plates dan cotter pin setelah 
dibuka. Tekuk lock washer plat, di bagian yang
rata pada bagian Mur, setelah mur dikencang-
sesuai spesifikasi pengencangan.

EB101040
BEARING DAN SEAL OIL 
Pasang bearing dan seal oli dengan posisi marking
berada di luar. Pada saat memasang seal oli, 
lumasi dengan gemuk light weight lithium pada-
pada permukaan lidah seal. dan pada saat mema-
sang bearings lumasi dengan oli dan pastikan
bearing berputar lancar.

1 Oil seal

PERHATIAN
Jangan menggunakan udara bertekanan, untuk
membersihkan bearing, hal ini akan merusak
permukaan bearing

1 Bearing

EB101050
CIRCLIPS
1. Periksa dengan seksama circlip, sebelum
pemasangan. Selalu ganti circlip pin piston
dengan yang baru. Ganti circlip, jika telah rusak
Pemasangan circlip 1, pastikan sudut yang
tajam pada permukaan tekanan 2 berlawa-
nan dengan gaya tekanan 3 lihat gambar 
penjelasan disamping.

4 As/Shaft

Page 11

GEN
INFO
INFORMASI  PENTING

1 - 4

EB801000
MEMERIKSA SISTIM PENYAMBUNGAN
Bersihkan debu dan kotoran yang terdapat pada
pada connector.
1. Lepaskan:
• Connector
2. Semprot dengan udara bertekanan.

3. Pasang dan cabut connector dua atau tiga
kali pemasangan
4. Tarik kabel untuk memeriksa, agar kabel tidak
tercabut, terlepas.
5. Jika mudah tercabut, bengkokkan pin pengait 1
dan pasangkan kembali ke terminal connector.

6. Pasang:
• Connector

CATATAN:
Kedua connectors harus “click” bersamaan

7. Periksa sistim penyambungan dengan tester.

CATATAN:
• Jika tidak ada sambungan, bersihkan terminal.
• Lakukan langkah pemeriksaan 1 hingga 7 pada
saat memeriksa kabel bodi.
• Untuk pemeriksaan, dapat menggunakan tester
yang ada di pasaran.
• Pergunakan tester, seperti pada gambar.

Page 12

EB102000
SPECIAL TOOLS
The following special tools are necessary for complete and accurate tune-up and assembly. Use
only the appropriate special tools; this will help prevent damage caused by the use of inappropriate
tools or improvised techniques.
When placing an order, refer to the list provided below to avoid any mistakes

Nomor tool Nama tool Gambar illustrasi

Weight
Slide hammer bolt

90890-01084
90890-01085

Alat ini digunakan untuk melepas, dan
memasang as rocker arm.

Crankcase separating tool

90890-01135

Alat ini digunakan untuk memisahkan 
crank case.

Crankshaft installer pot
Crankshaft installer bolt

Pot
90890-01274
Bolt
90890-01275

Alat ini digunakan untuk memasang
poros engkol/crankshaft.

Spacer
Adapter (M10)

Spacer
90890-01288
Adapter (M10)
90890-01383

Alat ini digunakan untuk memasang
poros engkol/crankshaft.

Tappet adjusting tool

90890-01311

Alat ini digunakan untuk menyetel
kelonggaran klep/valve clearance.

Fuel level gauge

90890-01312

Alat ini digunakan untuk mengukur ke-
tinggian pelampung kondisi terpasang

T-handle
Damper rod holder (19 mm)

T-handle
90890-01326
Rod holder
90890-04084

Alat ini digunakan untuk mengendorkan
dan mengencangkan baut damper rod 

1 - 5

GEN
INFO
SPECIAL TOOLS

Page 13

Nomor Tool. 
 
  Nama Tool Gambar Illustrasi

Flywheel puller

90890-01362

Alat ini digunakan untuk melepas magnet

Fork seal driver weight
Fork seal driver attachment (ø33)

Weight
90890-01367
Attachment
90890-01368

Alat ini digunakan untuk memasang
seal oli dan seal debu pada fork depan.

Steering nut wrench

90890-01403

Alat ini digunakan untuk mengencangkan,
dan mengendorkan baut kemudi/steering

Sheave holder

90890-01701

Alat ini digunakan untuk menahan magnet 
secondary sheave.

Compression gauge

90890-03081

Alat ini digunakan untuk mengukur
tekanan kompresi mesin.

Pocket tester

90890-03112

Alat ini digunakan untuk memeriksa
rangkaian kelistrikan.

Engine tachometer

90890-03113

Alat ini digunakan untuk menyetel
putaran langsam mesin

Valve spring compressor

90890-04019

Alat ini digunakan untuk memasang, 
dan melepas rangkaian klep.

1 - 6

GEN
INFO
SPECIAL TOOLS

Page 14

Nomor Tool Nama Tool Gambar Illustrasi

Universal clutch holder

90890-04086

Alat ini digunakan untuk menahan clutch 
boss, pada saat memasang dan melepas
 baut clutch boss nut.

Ignition checker

90890-06754

Alat ini digunakan untuk memeriksa
komponen sistim pengapian.

1 - 7

GEN
INFO
SPECIAL TOOLS

Page 15

BAB 2.
SPESIFIKASI

SPESIFIKASI UMUM ................................................................................. 2-1

SPESIFIKASI PERAWATAN ..................................................................... 2-4
MESIN .................................................................................................. 2-4
RANGKA/CHASSIS ............................................................................ 2-12
KELISTRIKAN .................................................................................... 2-15

SPESIFIKASI TORSI UMUM ..................................................................... 2-17

UNIT SATUAN ............................................................................................ 2-17

POIN PELUMASAN DAN TIPE PELUMAS YANG DIPAKAI .................... 2-18
MESIN ................................................................................................. 2-18
RANGKA/CHASSIS ............................................................................. 2-19

JALUR KABEL ........................................................................................... 2-20

SPEC

Page 16

Page 17

SPEC
SPESIFIKASI  UMUM

SPESIFIKASI
SPESIFIKASI  UMUM

Model
SX-4

Kode model : 
5BP1
Dimensi:
Panjang 2.020 mm
Lebar 770 mm
Tinggi 1.090 mm
Tinggi tempat duduk 770 mm
Jarak sumbu roda 1.295 mm
Jarak ketanah 
165 mm
Berat:
Dengan Oli dan bahan bakar terisi penuh 131 kg
Kemampuan berbelok : 2.100 mm
Mesin :
Tipe Mesin  
pendingin udara 4-tak bensin, SOHC
Susunan Cylinder Tegak single cylinder
Volume cylinder 223 cm3 

Diameter × Langkah 70 × 58 mm
Perbandingan kompresi 9.5 : 1
Tekanan kompresi 
8.5 kg/cm2/370 r/min
Sistim starter 
Motor starter dan kick starter
Sistem pelumasan : 
Pelumasan basah
Tipe oli atau grade:
Oli mesin

SAE 20W40 tipe SE motor oil (YAMALUBE)
(jika temperature dibawah 15°C)
SAE 10W30 tipe SE motor oil
(jika temperatur diatas 15°C)
Kapasitas oli
Oli mesin :
Penggantian berkala 1.2 Liter
Dengan melepas filter oli 
1.3 Liter
Kapasitas total 1.4 Liter
Saringan udara: Element tipe kering
Bahan bakar :
Tipe 
Bensin reguler
Kapasitas tangki bensin :
Total 
12 Liter
Cadangan/Reserve 3 Liter
Karburator:
Tipe/pabrik pembuat BS30/MIKUNI

2 - 1

Page 18

SPEC
SPESIFIKASI  UMUM

Model
SX-4

Busi :
Tipe/pabrik pembuat D8EA/NGK atau X24ES-U/DENSO
Gap
0.6 ~ 0.7 mm
Tipe kopling : Basah, multiple-disc
Transmisi :
Sistim reduksi Primary 
Spur gear
Perbandingan reduksi primary 74/24 (3.083)
Sistim reduksi secondary 
Rantai penggerak
Perbandingan reduksi secondary 44/15 (2.933)
Tipe  Transmission Constant mesh, 5-kecepatan
Operation
Left foot operation
Gear ratio:
1st
36/14 (2.571)
2nd
32/19 (1.684)
3rd
28/22 (1.273)
4th
26/25 (1.040)
5th
23/27 (0.852)
Chassis:
Frame type
Double-cradle
Caster angle
25.3°
Trail
85 mm
Tire:
Type
With tube
Size (F)
80/100-18 M/C 47P
Size (R)
100/90-18 M/C 56P
Wear limit
0.8 mm
Tire pressure (cold tire):
Basic weight:
With oil and full fuel tank
131 kg
Maximum load *
180 kg
Cold tire pressure:
FRONT
REAR
Rider
2.00 kg/cm2
2.00 kg/cm2

With passenger
2.00 kg/cm2
2.25 kg/cm2

* Load is the total weight of cargo, rider, pas-
senger, and accessories.
Brake:
Front
Single disc brake
Operation
Right hand operation
Rear
Drum brake
Operation
Right foot operation
Suspension:
Front suspension
Telescopic fork
Rear suspension
Swing arm

2 - 2

Page 19

Page 20

SPEC
MAINTENANCE SPECIFICATIONS

MAINTENANCE SPECIFICATIONS
ENGINE

Model
SX-4

Cylinder head:
Warp limit
<0.03 mm>
Lines indicate straight edge measurement.

*
*

Cylinder:
Bore size/measuring point
70.000 ~ 70.018 mm
40 mm

*

Wear limit
<0.01 mm>
Camshaft:
Drive method
Chain drive (right)
Camshaft outside dia.
24.96 ~ 24.98 mm
Cam dimensions:
Intake:
“A”
36.52 ~ 36.62 mm
“B”
30.201 ~ 30.301 mm
Exhaust:
“A”
36.564 ~ 36.664 mm
“B”
30.216 ~ 30.316 mm
Camshaft runout limit
<0.03 mm>
Rocker arm and rocker arm shaft:
Rocker arm inside diameter
14.992 ~ 15.000 mm
Shaft outside diameter
14.960 ~ 14.981 mm
Arm-to-shaft clearance
0.009 ~ 0.037 mm
Cam chain:
Cam chain type/no. of links
DID SCR-0404SDH
Cam chain adjustment method
Automatic
Valve, valve seat, valve guide:
Valve clearance (cold):
IN.
0.05 ~ 0.10 mm
EX.
0.10 ~ 0.15 mm

A

B

2 - 4

Page 21

Page 22

# MAINTENANCE SPECIFICATIONS

| Model | SX-4 |
| :--- | :--- |
| **Tilt limit \*** IN. EX. | &lt;2.5°/1.6 mm&gt; &lt;2.5°/1.6 mm&gt; |
| **Direction of winding** Inner IN. Inner EX. Outer IN. Outer EX. | Counterclockwise Counterclockwise Clockwise Clockwise |
| **Piston:** Piston-to-cylinder clearance &lt;Limit&gt; Piston size "D" Measuring point "H" | 0.020 ~ 0.025 mm &lt;0.05 mm&gt; 69.977 ~ 69.996 mm 4 mm |
| **Piston ring:** **Top ring:** Type Dimensions (B × T) End gap (installed) Side clearance (installed) **2nd ring:** Type Dimensions (B × T) End gap (installed) Side clearance **Oil ring:** Dimensions (B × T) End gap (installed) | Barrel 1.2 × 2.8 mm 0.15 ~ 0.30 mm 0.03 ~ 0.07 mm Taper 1.2 × 2.8 mm 0.15 ~ 0.30 mm 0.02 ~ 0.06 mm 2.5 × 2.8 mm 0.3 ~ 0.9 mm |

---
**2 - 6**

Page 23

SPEC
MAINTENANCE SPECIFICATIONS

Model
SX-4

Crankshaft:

B
B

C

A

Crank width “A”
69.25 ~ 69.30 mm
Runout limit “B”
<0.03 mm>
Big end side clearance “C”
0.35 ~ 0.85 mm
Clutch:
Friction plate: 
Thickness
2.9 ~ 3.1 mm
Quantity
6 pcs.
Wear limit
<2.8 mm>
Clutch plate: 
Thickness
1.5 ~ 1.7 mm
Quantity
5 pcs.
Warp limit
<0.2 mm>
Clutch spring: 
Free length
34.9 mm
Quantity
4 pc.
Minimum length
<33.2 mm>
Push rod bending limit
<0.5 mm>
Transmission:
Main axle deflection limit
<0.08 mm>
Drive axle deflection limit
<0.08 mm>
Shifter:
Shifter type
Cam drum and guide bar
Guide bar bending limit
<0.025 mm>
Carburetor:
I.D. mark
5BP1 00
Main jet 
(M.J.)
#110
Main air jet 
(M.A.J.)
#120
Jet needle 
(J.N.)
4EL10-2
Needle jet 
(N.J.)
O-2
Pilot jet 
(P.J.)
#17.5
Pilot air jet 
(P.A.J. #1)
#65
(P.A.J. #2)
1.2
Pilot screw 
(P.S.) 
3
Pilot outlet 
(P.O.)
ø0.8
Bypass 
(B.P.1)
ø0.9
(B.P.2)
ø0.8
(B.P.3)
ø0.8
Valve seat size 
(V.S.)
ø2.0
Starter jet 
(G.S.1)
#25
(G.S.2)
0.7

2 - 7

Page 24

SPEC
MAINTENANCE SPECIFICATIONS

Model
SX-4

Fuel level
2.7 ~ 4.7 mm below the float chamber line
Engine idling speed
1,350 ~ 1,450 r/min
Lubrication system:
Oil filter type
Paper and wire mesh type
Oil pump type:
Trochoid type
Tip clearance
0.15 mm
Side clearance
0.04 ~ 0.09 mm

2 - 8

Page 25

SPEC
MAINTENANCE SPECIFICATIONS

Model
SX-4

Lubrication chart:

PIN WITH
HOLE

OIL PUMP
MAIN AXLE
DRIVE AXLE

CRANKSHAFT

OIL PAN

2 - 9

OIL CLEANER

CYLINDER HEAD

CAMSHAFT

OIL STRAINER

Page 26

# MAINTENANCE SPECIFICATIONS [SPEC]

## Tightening torque

| Part to be tightened | Part name | Thread size | Q'ty | Tightening torque (Nm) | Tightening torque (m·kg) | Remarks |
| :--- | :--- | :--- | :---: | :---: | :---: | :--- |
| Camshaft sprocket cover | Bolt | M6 | 2 | 10 | 1.0 | |
| Tappet cover | Bolt | M55 | 2 | 18 | 1.8 | |
| Cylinder head | Flange bolt | M8 | 4 | 22 | 2.2 | [Icon: E] |
| (Cylinder head) | Bolt | M8 | 2 | 20 | 2.0 | |
| Cylinder head (exhaust pipe) | Stud bolt | M8 | 4 | 15 | 1.5 | |
| Cylinder head bearing plate | Bolt | M6 | 2 | 8 | 0.8 | |
| Cylinder head breather plate | Bolt | M6 | 3 | 8 | 0.8 | |
| Oil pressure checking screw | Screw | M6 | 1 | 7 | 0.7 | |
| Spark plug | — | M12 | 1 | 18 | 1.8 | |
| Rotor (CDI magneto) | Flange bolt | M10 | 1 | 60 | 6.0 | |
| Valve adjusting locknut | Nut | M6 | 2 | 14 | 1.4 | |
| Cam sprocket | Bolt | M10 | 2 | 60 | 6.0 | |
| Chain guide | Bolt | M6 | 2 | 8 | 0.8 | [Icon: LT] |
| Chain tensioner | Bolt | M6 | 2 | 10 | 1.0 | |
| (Chain tensioner) | Bolt | M8 | 1 | 8 | 0.8 | |
| Oil pump | Screw | M6 | 3 | 6 | 0.6 | |
| Oil filter cover | Bolt | M6 | 3 | 10 | 1.0 | |
| Oil delivery pipe (crankcase cover) | Union bolt | M10 | 1 | 20 | 2.0 | |
| Oil delivery pipe (cylinder) | Union bolt | M8 | 1 | 18 | 1.8 | |
| Carburetor joint | Bolt | M6 | 2 | 10 | 1.0 | |
| Air filter case (lower) | Bolt | M6 | 2 | 6 | 0.6 | |
| Air filter case (upper) | Bolt | M6 | 2 | 10 | 1.0 | |
| Exhaust pipe joint (lower) | Flange bolt | M8 | 2 | 20 | 2.0 | |
| Exhaust pipe | Nut | M8 | 2 | 18 | 1.8 | |
| Muffler | Flange bolt | M8 | 2 | 30 | 3.0 | |
| Crankcase | Flange bolt | M6 | 12 | 10 | 1.0 | |
| Crankcase cover (left) | Flange bolt | M6 | 9 | 10 | 1.0 | |
| Crankcase cover (right) | Flange bolt | M6 | 13 | 10 | 1.0 | |
| Magneto lead clamp | Bolt | M5 | 1 | 7 | 0.7 | [Icon: LT] |
| Neutral switch lead clamp | Screw | M6 | 1 | 7 | 0.7 | |
| Drain bolt | — | M12 | 1 | 20 | 2.0 | |
| Starter clutch | Bolt | M8 | 3 | 30 | 3.0 | Stake [Icon: LT] |
| Primary drive gear | Nut | M16 | 1 | 80 | 8.0 | Use lock washer |
| Clutch boss | Nut | M14 | 1 | 70 | 7.0 | Use lock washer |
| Clutch spring | Screw | M5 | 4 | 6 | 0.6 | |
| Clutch adjuster locknut | Nut | M6 | 1 | 8 | 0.8 | |
| Clutch push lever | Screw | M8 | 1 | 12 | 1.2 | |
| Drive sprocket | Nut | M18 | 1 | 110 | 11.0 | |
| Shiftcam stopper | Bolt | M6 | 1 | 10 | 1.0 | [Icon: LT] |
| Shift arm | Bolt | M6 | 1 | 10 | 1.0 | |
| Neutral switch | — | M10 | 1 | 20 | 2.0 | |
| Stator | Bolt | M6 | 3 | 7 | 0.7 | |

 

<div style="text-align: center;">2 - 10</div>

Page 27

## MAINTENANCE SPECIFICATIONS SPEC

| Part to be tightened     | Part name | Thread size | Q'ty | Tightening torque | Remarks         |
| :----------------------- | :-------- | :---------- | :--- | :---------------- | :---------------- |
|                          |           |             |      | Nm  | m·kg            |                   |
| Pickup coil              | Bolt      | M6          | 2    | 7   | 0.7             |                   |
| Starter motor            | Bolt      | M6          | 2    | 10  | 1.0             |                   |
| Kick crank               | Bolt      | M8          | 1    | 20  | 2.0             |                   |
| Kick racket wheel guide | Bolt      | M6          | 2    | 10  | 1.0             | Use lock washer |

2 - 11

Page 28

SPEC
MAINTENANCE SPECIFICATIONS

CHASSIS

Item
SX-4

Steering system:
Steering bearing type
Angular bearing
Front suspension:
Front fork travel
140 mm
Fork spring free length
391.5 mm
Spring rate: 
K1
0.75 kg/mm
K2
1.0 kg/mm
Stroke 
K1
0 ~ 95 mm
K2
95 ~ 140 mm
Optional spring
No.
Oil capacity
252 cm3 
Oil level
95 mm
From top of fully compressed inner tube without 
fork spring
Oil grade
Yamaha fork oil 10W or equivalent
Rear suspension:
Shock absorber travel
32 mm
Spring rate: 
K1
16.01 kg/mm
Stroke: 
K1
0 ~ 32 mm
Optional spring
No.
Swingarm:
Swingarm free play limit: 
End
<1 mm>
Swingarm free play limit: 
Side
<1 mm>
Front wheel:
Type
Spoke wheel
Rim size
1.85 × 1.60
Rim material
Steel
Rim runout limit: 
Vertical
<2 mm>
Lateral
<2 mm>
Rear wheel:
Type
Spoke wheel
Rim size
1.85 × 2.15
Rim material
Steel
Rim runout limit: 
Vertical
<2 mm>
Lateral
<2 mm>
Drive chain:
Type/manufacturer
428 V/DAIDO
No. of links
118
Drive chain slack
20 ~ 30 mm

2 - 12

Page 29

SPEC
MAINTENANCE SPECIFICATIONS

Item
SX-4

Front disc brake:
Disc brake type
Single
Disc outside diameter × thickness
267 × 4
<Limit>
<3.5 mm>
Brake pad lining thickness
5.3 mm
<Limit>
<0.8 mm>
Master cylinder inside diameter
11 mm
Caliper cylinder inside diameter
26.99 mm
22.22 mm
Recommended fluid
DOT 3 or 4
Rear drum brake:
Type
Leading and trailing
Drum inside diameter
130 mm
<Limit>
<131 mm>
Lining thickness
4 mm
<Limit>
<1 mm>
Shoe spring free length
50.5 mm
Brake lever and brake pedal:
Brake lever free play
2 ~ 5 mm
Brake pedal free play
20 ~ 30 mm
Clutch lever:
Clutch lever free play
10 ~ 15 mm

2 - 13

Page 30

SPEC
MAINTENANCE SPECIFICATIONS

Tightening torque

Part to be tightened
Thread size
Tightening 
torque
Remarks
Nm
m·kg

Handle crown and inner tube
M8 × 1.25
23
2.3
Handle crown and steering stem
M22 × 1.0
110
11.0
Steering stem and ring nut
–
18
1.8
See NOTE
Handle crown and upper holder
M8 × 1.25
19
1.9
Master cylinder
M6 × 1.0
7
0.7
Engine stay and engine
M10 × 1.25
58
5.8
Engine stay and frame
M8 × 1.25
30
3.0
Engine mounting (rear-lower) and frame
M10 × 1.25
79
7.9
Engine mounting (rear-upper) and frame
M10 × 1.25
58
5.8
Engine mounting (front) and frame
M10 × 1.25
58
5.8
Tension bar and swingarm
M8 × 1.25
16
1.6
Kick starter and frame
M10 × 1.25
52
5.2
Front wheel axle
M14 × 1.5
58
5.8
Front brake disc
M6 × 1.0
23
2.3
Front brake caliper
M10 × 1.25
30
3.0
Brake hose union bolt
M10 × 1.25
26
2.6
Brake caliper bleed screw
M7 × 1.0
6
0.6
Rear wheel axle
M14 × 1.5
85
8.5
Sprocket and wheel hub
M8 × 1.25
30
3.0
Tension bar and rear brake shoe plate
M8 × 1.25
16
1.6
Brake lever camshaft
M6 × 1.0
10
1.0
Fuel sender and fuel tank
M5 × 0.8
4
0.4
Footrest and footrest bracket
M8 × 1.25
30
3.0
Footrest bracket and brake pedal
M10 × 1.25
30
3.0
Footrest bracket and frame
M8 × 1.25
30
3.0
Rear footrest bracket and frame
M8 × 1.25
30
3.0
Pivot shaft 
M12 × 1.25
59
5.9
Rear shock absorber (upper)
M12 × 1.25
59
5.9
Rear shock absorber (lower)
M12 × 1.25
59
5.9
Relay arm and frame
M12 × 1.25
59
5.9
Relay arm and connecting rod
M12 × 1.25
59
5.9
Connecting rod and frame
M12 × 1.25
59
5.9
Chain case and swingarm
M6 × 1.0
7
0.7
Chain guide and swingarm
M6 × 1.0
7
0.7

NOTE:

1. First, tighten the ring nut approximately 48 Nm (4.8 m • kg) by using the torque wrench, then
loosen the ring nut one turn.
2. Retighten the ring nut 18 Nm (1.8 m • kg).

2 - 14

Page 31

Page 32

SPEC
MAINTENANCE SPECIFICATIONS

Item
SX-4

Horn:
Type/quantity
Plain type × 2
Model/manufacturer
5BP/IMASEN
Maximum amperage
1.5 A
Flasher relay:
Type
Condenser type
Model/manufacturer
3RS/DENSO
Self cancelling device
No
Flasher frequency
75 ~ 95 cycle/min
Wattage
10 W × 2 + 3.4 W
Starting circuit cut-off relay:
Model/manufacturer
ACA12115-3/MATSUSHITA
Diode 
Yes
Circuit breaker:
Type
Fuse
Amperage for individual circuit × quantity:
Main
15 A × 1
Reserve
15 A × 1

2 - 16

Page 33

GENERAL TORQUE SPECIFICATIONS/
DEFINITION OF UNITS

GENERAL TORQUE SPECIFICATIONS
This chart specifies torque for standard fasten-
ers with standard I.S.O. pitch threads.
Torque specifications for special components
or assemblies are included in the applicable
sections of this book. To avoid warpage, tighten
multifastener assemblies in a crisscross fash-
ion, in progressive stages, until full torque is
reached. Unless otherwise specified, torque
specifications call for clean, dry threads. Com-
ponents should be at room temperature.

A
B

A: Distance across flats
B: Outside thread diameter

DEFINITION OF UNITS

Unit
Read
Definition
Measure

mm
cm
millimeter
centimeter
10-3 meter
10-2 meter
Length
Length

kg
kilogram
103 gram
Weight

N
Newton
1 kg × m/sec2 
Force

Nm
m • kg
Newton meter
Meter kilogram
N × m
m × kg
Torque
Torque

Pa
N/mn
Pascal
Newton per millimeter
N/m2 
N/mn
Pressure
Spring rate

L
cm3 
Liter
Cubic centimeter
– 
Volume or capacity

r/min
Rotation per minute
–
Engine speed

2 - 17

SPEC

General torque 
specifications
Nm
m·kg
ft·lb
10 mm
6 mm
6
0.6
4.3
12 mm
8 mm
15
1.5
11
14 mm
10 mm
30
3.0
22
17 mm
12 mm
55
5.5
40
19 mm
14 mm
85
8.5
61
22 mm
16 mm
130
13.0
94

A
(Nut)
B
(Bolt)

Page 34

SPEC
LUBRICATION POINTS AND LUBRICANT TYPE

LUBRICATION POINTS AND LUBRICANT TYPE
ENGINE

Lubrication
Symbol
Lubricant type

Oil seal lip
LS
Lithium-soap base grease

O-Ring
LS
Lithium-soap base grease

Bearing
E
Engine oil

Cylinder head bolt/washer
E
Engine oil

Rocker shaft
M
Molybdeum disulfide oil

Crankshaft pin
E
Engine oil

Connecting rod
E
Engine oil

Piston surface
E
Engine oil

Piston pin
E
Engine oil

Camshaft cam lobe/journal
E
Engine oil

Valve stem (IN, EX)
M
Molybdeum disulfide oil

Valve stem end (IN, EX)
M
Molybdeum disulfide oil

Cam chain/cam sprocket
E
Engine oil

Oil pump shaft, rotor (IN, OUT), housing
E
Engine oil

Kick shaft
E
Engine oil

Kick idle sprocket (inside)
E
Engine oil

Kick crank shaft
LS
Lithium-soap base grease

Kick idle gear/kick gear
E
Engine oil

Starter clutch
E
Engine oil

Primary driven gear
E
Engine oil

Push lever axle
M
Molybdeum disulfide oil

Transmission gear (wheel/pinion)
M
Molybdeum disulfide oil

Axle (main/drive)
M
Molybdeum disulfide oil

Shift cam
M
Molybdeum disulfide oil

Shift fork/guide bar
E
Engine oil

Crankcase mating surfaces
Yamaha bond No.1215® 

2 - 18

Page 35

SPEC
LUBRICATION POINTS AND LUBRICANT TYPE

CHASSIS

Lubrication
Symbol
Lubricant type

Steering bearing (upper/lower)
LS
Lithium-soap base grease

Wheel bearing/axle 
LS
Lithium-soap base grease

Front wheel oil seal (right/left)
LS
Lithium-soap base grease

Rear wheel oil seal
LS
Lithium-soap base grease

Clutch hub oil seal
LS
Lithium-soap base grease

Clutch hub fitting area
LS
Lithium-soap base grease

Rear brake pedal shaft
LS
Lithium-soap base grease

Change pedal
LS
Lithium-soap base grease

Side/main stand sliding surface
LS
Lithium-soap base grease

Tube guide (throttle grip) inner surface
LS
Lithium-soap base grease

Brake lever bolt, sliding surface
LS
Lithium-soap base grease

Clutch lever collar, sliding surface
LS
Lithium-soap base grease

Swingarm pivot/bearing
LS
Lithium-soap base grease

Rear shock absorber bolt
LS
Lithium-soap base grease

Relay arm color/oil seal
LS
Lithium-soap base grease

Speedometer gear unit
LS
Lithium-soap base grease

Rear brake camshaft
LS
Lithium-soap base grease

Brake shoe plate pivot
LS
Lithium-soap base grease

2 - 19

Page 36

CABLE ROUTING

1 Tachometer cable
2 Brake hose
3 Brake hose holder
4 Wire harness
5 Air vent hose
6 Starting motor lead
7 Battery negative lead
8 Battery positive lead
9 Rear brake switch lead
0 Taillight lead

A Fuel sender lead
B Breather hose
C Air vent hose
D Throttle cable
E Clutch cable
F Magneto lead
G Pick-up coil lead
H Wire harness

Ó
Ñ

F
G

H

0
A
B
C D E

Ë
Ì
Í
Î

9

7
8

6

5

2 - 20

SPEC

CABLE ROUTING

È Clamp the wire harness.
É Pass the cable holder through
the tachometer cable.
Ê Install the horn lead (short side)
to the right side of the horn.
Ë Clamp the taillight lead.
Ì Clamp the wire harness.
Í Clamp the wire harness at the
white tape portion.

Ò

Ð

Ï

È

1

2

3
4

É
Ê

Page 37

Î To fuel tank
Ï Clamp the throttle cable and clutch cable. Turn the clamp end to inside of motorcycle.
Ð Clamp the throttle cable and clutch cable.
Ñ Insert the air vent hose into the frame.
Ò Clamp the wire harness and turn the clamp end to inside of motorcycle.
Ó Clamp the magneto lead and pick-up coil lead and push the leads into holder.

Ó
Ñ

F
G

H

0
A
B
C D E

Ë
Ì
Í
Î

9

7
8

6

5

2 - 21

SPEC

CABLE ROUTING

Ò

Ð

Ï

È

1

2

3
4

É
Ê

Page 38

1 Clutch cable
2 Breather hose
3 Fuel tank over flow hose
4 Magneto lead
5 Battery breather hose
6 Carburetor over flow hose
7 Fuel tank over flow hose
8 Speedometer cable
9 Wire harness
0 Pick-up coil lead
A Magneto lead

B Fuel tank over flow hose

È Install the horn lead (long side)
to the left side of the horn
É Clamp the battery breather
hose, carburetor over flow
hose and fuel tank over flow
hose.
Ê Pass the speedometer cable
through the holder

1

9

8

Ê

2 - 22

SPEC

CABLE ROUTING

Ë Clamp the magneto lead and
pick-up coil lead.
Ì Clamp the battery breather
hose.

0
A B

Ë
Ë

E

Ì

D

A

C

È

2
3

A

4

5
6
7

É

Page 39

Page 40

INSP
ADJ
BAB 3.
PARAWATAN BERKALA DAN PENYETELAN

PENDAHULUAN ........................................................................................... 3-1

PERAWATAN BERKALA/PELUMASAN .................................................... 3-1

TEMPAT DUDUK/JOK ................................................................................. 3-3

PENUTUP SAMPING/SIDE COVER ............................................................ 3-3

TANGKI BENSIN .......................................................................................... 3-3

MESIN .......................................................................................................... 3-4
MENYETEL KELONGGARAN KLEP .................................................... 3-4
MENYETEL PUTARAN LANGSAM .......................... 3-5 ..........
MENYETL GAS. 3-6
SPARK PLUG INSPECTION ................................................................ 3-8
COMPRESSION PRESSURE MEASUREMENT .................................. 3-8
ENGINE OIL LEVEL INSPECTION ....................................................... 3-9
ENGINE OIL REPLACEMENT ............................................................ 3-10
CLUTCH ADJUSTMENT ..................................................................... 3-12
AIR FILTER CLEANING ...................................................................... 3-13
CARBURETOR JOINT INSPECTION ................................................. 3-15
FUEL LINE INSPECTION ................................................................... 3-15
EXHAUST SYSTEM INSPECTION ..................................................... 3-16

CHASSIS .................................................................................................... 3-17
FRONT BRAKE ADJUSTMENT .......................................................... 3-17
BRAKE PAD INSPECTION ................................................................. 3-17
BRAKE FLUID LEVEL INSPECTION .................................................. 3-18
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM) .............................. 3-18
BRAKE HOSE INSPECTION .............................................................. 3-19
REAR BRAKE ADJUSTMENT ............................................................ 3-20
BRAKE SHOE INSPECTION .............................................................. 3-21
BRAKE LIGHT SWITCH ADJUSTMENT ............................................ 3-21
DRIVE CHAIN SLACK ADJUSTMENT ............................................... 3-22
TIRE INSPECTION ............................................................................. 3-23
STEERING HEAD INSPECTION ........................................................ 3-23
REAR SHOCK ABSORBER INSPECTION ......................................... 3-25
WHEEL INSPECTION ......................................................................... 3-26
SPOKE INSPECTION AND TIGHTENING ......................................... 3-26
CABLE INSPECTION .......................................................................... 3-26
LUBRICATION .................................................................................... 3-27

Page 41

┌──────┬───┐
│ INSP │ 🔧│
│ ADJ  │   │
└──────┴───┘

---

**ELECTRICAL** .................................................................................................... 3-28
* BATTERY INSPECTION ............................................................................... 3-28
* FUSE INSPECTION .................................................................................... 3-31
* HEADLIGHT BEAM ADJUSTMENT .............................................................. 3-32
* HEADLIGHT BULB REPLACEMENT .............................................................. 3-32

Page 42

INSP
ADJ
INTRODUCTION/PERIODIC MAINTENANCE/
LUBRICATION

PERIODIC INSPECTION AND ADJUSTMENT
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 new vehicles that are being prepared for
sale. All service technicians should be familiar with this entire chapter.
PERIODIC MAINTENANCE/LUBRICATION

NO.
ITEM
CHECK OR MAINTENANCE JOB
ODOMETER READING (× 1,000 km)

1
*
Fuel line
• Check fuel hoses for cracks or damage.

2
*
Fuel filter
• Check condition. Replace if necessary.

• Check condition.
• Clean and regap.

3
Spark plug

• Replace if necessary.

4
*
Valves
• Check valve clearance.
• Adjust.

5
Air filter element
• Clean. Replace if necessary.

6
*
Battery
• Check electrolyte level and specific gravity.
• Make sure that the breather hose is properly 
routed.

7
Clutch
• Check operation.
• Adjust.

8
*
Front brake
• Check operation, fluid level and vehicle for fluid 
leakage.
• Replace brake pads if necessary.

9
*
Rear brake
• Check operation and adjust brake pedal free 
play.
• Replace brake shoes if necessary.

10
*
Wheels
• Check runout, spoke tightness and for damage.
• Tighten spokes if necessary.

11
*
Wheel bearings
• Check bearing for looseness damage.

12
*
Swingarm
• Check operation and for excessive play.

• Lubricate with lithium-soap based grease, every 24,000 km.

13
Drive chain
• Check chain slack.
• Make sure that the rear wheel is properly aligned.
• Clean and lubricate.

14
*
Steering bearings
• Check bearing play and steering for roughness.

• Lubricate with lithium-soap-based grease, every 12,000 km.

15
*
Chassis fasteners
• Make sure that all nuts, bolts and screws are 
properly tightened.

16
Sidestand/center-
stand
• Check operation.
• Lubricate.

17
*
Front fork
• Check operation and for oil leakage.

18
*
Shock absorber 
assembly
• Check operation and shock absorber for oil leak-
age.

Rear suspension 
relay arm and con-
necting arm pivoting 
points

• Check operation.

19
*

• Lubricate with lithium-soap-base grease, every 24,000 km.

3 - 1

0.5
2
4
8
12

Every 500 km and after washing the motorcycle 
or riding in the rain.

Page 43

INSP
ADJ
PERIODIC MAINTENANCE/LUBRICATION

NO.
ITEM
CHECK OR MAINTENANCE JOB
ODOMETER READING (× 1,000 km)

20
*
Carburetor
• Check starter (choke) operation.
• Adjust engine idling speed.

21
Engine oil
• Change.

22
Engine oil filter ele-
ment
• Clean.

23
*
Engine oil strainer
• Clean.

24
*
Front and rear brake 
switches
• Check operation.

25
Moving parts and 
cables
• Lubricate.

26
*
Lights, signals and 
switches
• Check operation.
• Adjust headlight beam.

*Since these items require special tools, data and technical skills, have a Yamaha dealer perform the service.

NOTE:

G The air filter needs more frequent service if you are riding in unusually wet or dusty areas.

G Hydraulic brake systems

G After disassembling the brake master cylinder, and caliper cylinder, always change the fluid.
Regularly check the brake fluid levels and fill the reservoirs as required.

G Replace the oil seals on the inner parts of the brake master cylinder and caliper cylinder every
two years.

G Replace the brake hose every four years or if cracked or damaged.

3 - 2

0.5
2
4
8
12

Page 44

INSP
ADJ
SEAT/SIDE COVER/FUEL TANK

3 - 3

SEAT
1.Install:

G Seat 1 

NOTE:

Insert the projection a on the front of the seat
into the seat holder b as shown.

SIDE COVER
1.Remove:

G Seat
2.Remove:

G Side covers (left and right)

NOTE:

Remove screws a and knob b, and then pull
the side cover off as shown.

FUEL TANK
1.Remove:

G Air scoop (left and right)

G Bolt

G Washer

G Fuel sender coupler

G Breather hose

G Fuel hose

G Fuel tank 1 

NOTE:

Turn the fuel cock to “OFF” position before
removing fuel hose.

Page 45

INSP
ADJ
VALVE CLEARANCE ADJUSTMENT

3 - 4

ENGINE
VALVE CLEARANCE ADJUSTMENT

NOTE:

Valve clearance adjustment should be made
with the engine cool, at room temperature.
When the valve clearance is to be measured
or adjusted, the piston must be at Top Dead
Center (T.D.C) on the compression stroke.

1.Remove:

G Air scoop (left and right) 1 

2.Remove:

G Spark plug

G Tappet cover (intake side) 1 

G Tappet cover (exhaust side) 2 

3.Remove:

G Timing mark accessing screw (with O-ring) 1 

G Camshaft end cover (with O-ring) 2 

4.Measure:

G Valve clearance
Out of specification → Adjust.

Valve clearance (cold):
Intake valve 0.05 ~ 0.10 mm
Exhaust valve 0.10 ~ 0.15 mm

*****************************************************
Measurement steps:

GRotate the crankshaft counterclockwise to
align the slit a on the rotor with the slit b on
the crankcase cover when the piston is Top
Dead Center (TDC).

Page 46

INSP
ADJ
VALVE CLEARANCE ADJUSTMENT/
IDLING SPEED ADJUSTMENT

3 - 5

GMeasure the valve clearance by using a
feeler gauge.
Out of specification → Adjust clearance.

*****************************************************

5.Adjust:

G Valve clearance

*****************************************************
Adjustment steps:

GLoosen the locknut 1.

GTurn the adjuster 2 in or out with the tappet
adjusting tool 3 until specified clearance is
obtained.

Turning in
Valve clearance is 
decreased.

Turning out
Valve clearance is 
increased.

Tappet adjusting tool:
90890-01311

GHold the adjuster to prevent it from moving
and tighten the locknut.

14 Nm (1.4 m • kg)

T R
.

.

GMeasure the vale clearance.

GIf the clearance is incorrect, repeat above
steps until specified clearance is obtained.

*****************************************************
6.Install:

G O-ring

G Tappet cover (intake side)

18 Nm (1.8 m • kg)

T R
.

.

IDLING SPEED ADJUSTMENT
1.Start the engine and let it warm up for sev-
eral minutes.
2.Attach:

G Engine tachometer to the spark plug lead.

Engine tachometer:
90890-03113

Page 47

INSP
ADJ
IDLING SPEED ADJUSTMENT/
THROTTLE CABLE ADJUSTMENT

3 - 6

3.Check:

G Engine idling speed 
Out of specification → Adjust.

Engine idling speed:
1,350 ~ 1,450 r/min.

4.Adjust:

G Engine idle speed

*****************************************************
Adjustment steps:

GTurn the pilot screw 1 until it is lightly
seated.

GTurn the pilot screw out by the specified
number of turns.

Pilot screw:
3 turns out

GTurn the throttle stop screw 2 in or out until
the specified idling speed is obtained.

Turning in
Idling speed is increased.

Turning out
Idling speed is decreased.

*****************************************************
5.Adjust:

G Throttle cable free play
Refer to the “THROTTLE CABLE ADJUST-
MENT” section.

THROTTLE CABLE ADJUSTMENT

NOTE:

Prior to adjusting the throttle cable free play,
the engine idling speed should be adjusted.

1.Check:

G Throttle cable free play a
Out of specification → Adjust.

Free play (throttle cable):
3 ~ 5 mm at throttle grip flange

Page 48

INSP
ADJ
THROTTLE CABLE ADJUSTMENT

3 - 7

2.Adjust:

G Throttle cable free play

*****************************************************
Adjustment steps:
Carburetor side

GLoosen the locknut 1.

GTurn the adjusting nut 2 in or out until the
specified throttle cable free play is obtained.

Turn in
Throttle cable free play is 
increased.

Turn out
Throttle cable free play is 
decreased.

GTighten the locknut.

NOTE:

If the specified throttle cable free play cannot
be obtained on the carburetor side of the
cable, use the adjusting nut on the handlebar
side.

Handlebar side

GLoosen the locknut 1.

GTurn the adjusting nut 2 in or out until the
specified throttle cable free play is obtained.

Turn in
Throttle cable free play is 
increased.

Turn out
Throttle cable free play is 
decreased.

GTighten the locknut.

WARNING
After adjusting the throttle cable free play,
start the engine and turn the handlebar to
the right or left to ensure that this does not
cause the engine idling speed to change.

*****************************************************

Page 49

INSP
ADJ
SPARK PLUG INSPECTION/
COMPRESSION PRESSURE MEASUREMENT

3 - 8

EB303040
SPARK PLUG INSPECTION
1.Check:

G Spark plug type
Incorrect → Replace.

Standard spark plug:
D8EA (NGK),
X24ES-U (DENSO)

2.Inspect:

G Electrode 1 
Wear/damage → Replace.

G Insulator 2 
Abnormal color → Replace.
Normal color is a medium-to-light tan color.
3.Clean:

G Spark plug
(with spark plug cleaner or wire brush)
4.Measure:

G Spark plug gap a
(with a wire gauge)
Out of specification → Adjust gap.

Spark plug gap:
0.6 ~ 0.7 mm

COMPRESSION PRESSURE 
MEASUREMENT

NOTE:

Insufficient compression pressure will result in
performance loss.

1.Start the engine and let it warm up for sev-
eral minutes.
2.Turn off the engine.
3.Remove:

G Spark plug
4.Attach:

G Compression gauge 1 

Compression gauge:
90890-03081

Page 50

INSP
ADJ
COMPRESSION PRESSURE MEASUREMENT/
ENGINE OIL LEVEL INSPECTION

3 - 9

5.Measure:

G Compression pressure
If it exceeds the maximum pressure allowed
→ Inspect the cylinder head, valve surfaces
and piston crown for carbon deposits.
If it is below the minimum pressure → Squirt
a few drops of oil into the affected cylinder
and measure again.
Follow the table below.

Compression pressure
(With oil applied into cylinder)

Reading
Diagnosis

Higher than 
without oil
Worn or damaged pistons

Possible defective ring(s), 
valves, cylinder head gas-
ket or piston → Repair.

Same as 
without oil

Compression pressure (at sea 
level):
Standard:
1,200 kPa (12.0 Kg/cm2, 12.0 bar)
Minimum:
1,050 kPa (10.5 Kg/cm2, 10.5 bar)

*****************************************************
Measurement steps:

GCrank the engine with the throttle wide-open
until the reading on the compression gauge
stabilizes.

WARNING
Before cranking the engine, ground all
spark plug leads to prevent sparking.

*****************************************************

ENGINE OIL LEVEL INSPECTION
1.Stand the motorcycle on a level surface.

NOTE:

Place the motorcycle on a suitable stand.

2.Start the engine, warm it up for several min-
utes, and then turn it off.

Page 51

INSP
ADJ
ENGINE OIL LEVEL INSPECTION/
ENGINE OIL REPLACEMENT

3 - 10

3.Check:

G Engine oil level
The engine oil level should be between the
minimum level mark a and maximum level
mark b.
Below the minimum level mark → Add the
recommended engine oil to the proper level.

Recommended oil:
Refer to the chart for the engine
oil grade
API standard
SE or higher grade

CAUTION:
Do not allow foreign materials to enter the
crankcase.

NOTE:

Before checking the engine oil level, wait a few
minutes until the oil has settled.

ENGINE OIL REPLACEMENT
1.Start the engine, warm it up for several min-
utes, and then turn it off.
2.Place a container under the engine oil drain
bolt.
3.Remove:

G Engine oil filler bolt

G Engine oil drain bolt 1 
(along with the gasket)

G Oil filter element drain bolt 2 
(along with the gasket)
4.Drain:

G Engine oil
(completely from the crankcase)

Page 52

INSP
ADJ
ENGINE OIL REPLACEMENT

3 - 11

5.If the oil filter element is also to be replaced,
perform the following procedure.

*****************************************************
Replacement steps:

GRemove the oil filter element cover 1 and oil
filter element 2.

GCheck the O-rings 3 and replace them if
they are cracked or damaged.

GInstall the new oil filter element and the oil fil-
ter element cover.

Oil filter element cover bolt:
10 Nm (1.0 m • kg)

T R
.

.

È Outside
É Inside

*****************************************************
6.Check:

G Engine oil drain bolt gasket

G Oil filter element drain bolt gasket
Damage → Replace.
7.Install:

G Engine oil drain bolt
(along with the gasket)

20 Nm (2.0 m • kg)

T R
.

.

G Oil filter element drain bolt
(along with he gasket)

10 Nm (1.0 m • kg)

T R
.

.

8.Fill:

G Crankcase
(With the specified amount of the recom-
mended engine oil)

Quantity:
Total amount:
1.4 L
Without oil filter element 
replacement:
1.2 L
With oil filter element replace-
ment:
1.3 L

9.Install:

G Engine oil filler cap

Page 53

INSP
ADJ
ENGINE OIL REPLACEMENT/
CLUTCH ADJUSTMENT

3 - 12

10.Start the engine, warm it up for several min-
utes, and then turn it off.
11.Check:

G Engine
(for engine oil leaks)
12.Check:

G Engine oil level
Refer to the “ENGINE OIL LEVEL INSPEC-
TION” section.
13.Check:

G Engine oil pressure

*****************************************************
Checking steps:

GSlightly loosen the oil gallery bolt 1.

GStart the engine and keep it idling until engine
oil starts to seep from the oil gallery bolt. If no
engine oil comes out after one minute, turn
the engine off so that it will not seize.

GCheck the engine oil passages and the oil
pump for damage or leakage. Refer to the
“OIL PUMP” section in CHAPTER 4.

GStart the engine after solving the problem(s)
and check the engine oil pressure again.

GTighten the oil gallery bolt to specification.

Oil gallery bolt:
7 Nm (0.7 m • kg)

T R
.

.

*****************************************************

CLUTCH ADJUSTMENT
1.Check:

G Clutch cable free play a
Out of specification → Adjust.

Clutch cable free play (at the end
of the clutch lever):
10 ~ 15 mm

Page 54

INSP
ADJ
CLUTCH ADJUSTMENT/
AIR FILTER CLEANING

3 - 13

2.Adjust:

G Clutch cable free play

*****************************************************
Adjustment steps:
Handlebar side

GLoosen the locknut 1.

GTurn the adjusting bolt 2 in or out until the
specified clutch cable free play is obtained.

Turn in
Clutch cable free play is 
increased.

Turn out
Clutch cable free play is 
decreased.

GTighten the locknut.

NOTE:

If the specified clutch cable free play cannot be
obtained on the handlebar side of the cable,
use the adjusting nut on the engine side.

Engine side

GLoosen the locknuts 1.

GTurn the adjusting bolt 2 in or out until the
specified clutch cable free play is obtained.

Turn in
Clutch cable free play is 
increased.

Turn out
Clutch cable free play is 
decreased.

GTighten the locknuts.

*****************************************************
AIR FILTER CLEANING
1.Check:

G Air filter check hoses 1 

NOTE:

On the bottom of the air filter case is a check
hoses 1. If dust or water or both collects in
this hoses, clean the air filter element and air
filter case.

2.Remove:

G Side cover (left)
Refer to the “SIDE COVER” section.

Page 55

INSP
ADJ
AIR FILTER CLEANING

3 - 14

3.Remove:

G Air filter case cover 1 

G Air filter element 2 

4.Clean:

G Air filter element
(with solvent)

WARNING
Never use low flash point solvents, such as
gasoline, to clean the air filter element.
Such solvents may cause a fire or an explo-
sion.

NOTE:

After cleaning, gently squeeze the air filter ele-
ment to remove the excess solvent.

CAUTION:
Do not twist the air filter element when
squeezing it.

5.Check:

G Air filter element
Damage → Replace.
6.Apply the recommended oil to the entire sur-
face of the air filter element and squeeze out
the excess oil. The air filter element should
be wet but not dripping.

Recommended oil:
Engine oil

Page 56

INSP
ADJ
AIR FILTER CLEANING/CARBURETOR JOINT
INSPECTION/FUEL LINE INSPECTION

3 - 15

7.Install:

G Air filter element

G Air filter case cover

CAUTION:
Never operate the engine without the air fil-
ter element installed. Unfiltered air will
cause rapid wear of engine parts and may
damage the engine. Operating the engine
without the air filter element will also affect
the carburetor tuning, leading to poor
engine performance and possible overheat-
ing.

CARBURETOR JOINT INSPECTION
1.Inspect:

G Carburetor joint 1 
Cracks/Damage → Replace.

FUEL LINE INSPECTION
1.Inspect:

G Fuse hose
Cracks/Damage → Replace.

Page 57

INSP
ADJ
EXHAUST SYSTEM INSPECTION

3 - 16

EXHAUST SYSTEM INSPECTION
1.Inspect:

G Exhaust pipe 1 

G Muffler 2 
Cracks/Damage/Leak → Repair or replace.

G Exhaust pipe Joint 3 

G gasket 4 
Damage/Leak → Repair or replace.
2.Tighten:

G Muffler and exhaust pipe

Nuts (exhaust pipe joint) 5:
18 Nm (1.8 m • kg)
Bolt (exhaust pipe joint) 6:
20 Nm (2.0 m • kg)
Bolts (muffler) 7:
30 Nm (3.0 m • kg)

T R
.

.

Page 58

FRONT BRAKE ADJUSTMENT/
BRAKE PAD INSPECTION

3 - 17

INSP
ADJ

CHASSIS
FRONT BRAKE ADJUSTMENT
1.Check:

G Brake lever free play a
Out of specification → Adjust.

Free play (brake lever):
2 ~ 5 mm (at brake lever end)

2.Adjust:

G Brake lever free play

*****************************************************
Adjustment steps:

GLoosen the locknut 1.

GTurn the adjuster 2 in or out until the speci-
fied free play is obtained.

Turning in
brake lever free play is 
decreased.

Turning out
brake lever free play is 
increased.

GTighten the locknut.

CAUTION:
After adjusting the front brake lever free
play, make sure that there is no brake drag.

*****************************************************

BRAKE PAD INSPECTION
1.Operate the brake lever.
2.Inspect:

G Brake pad
Wear indicators 1 almost touch the brake
disc → Replace the brake pads as set.
Refer to the “BRAKE PAD PEPLCEMENT”
section in CHPTER 6.

Page 59

INSP
ADJ
BRAKE FLUID LEVEL INSPECTION/
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)

3 - 18

BRAKE FLUID LEVEL INSPECTION
1.Stand the motorcycle on a level surface.

NOTE:

When inspecting the brake fluid level, make
sure the motorcycle is upright.

2.Inspect:

G Brake fluid level
Brake fluid level is below the “LOWER” level
line a → Fill to proper level.

Recommended brake fluid:
DOT 3 or 4

NOTE:

For a correct reading of the brake fluid level,
make sure the top of the handlebar brake fluid
reservoir is horizontal.

AIR BLEEDING (HYDRAULIC BRAKE 
SYSTEM)

WARNING
Bleed the brake system whenever:

G The system is disassembled

G A brake hose is loosened or removed

G The brake fluid level is very low

G Brake operation is faulty
If the brake system is not properly bled, a
loss of braking performance may occur.

1.Bleed:

G Brake system

*****************************************************
Air bleeding steps:
a. Fill the reservoir with the proper brake fluid.
b. Install the diaphragm. Be careful not to spill
any fluid or allow the reservoir to overflow.
c. Connect a clear plastic hose 1 tightly to the
caliper bleed screw 2.
d. Place the other end of the hose into a con-
tainer.
e. Slowly apply the brake lever several times.
f. Pull the lever in. Hold the lever in position.
g. Loosen the bleed screw and allow the lever
to travel towards its limit.
h. Tighten the bleed screw when the lever limit
has been reached, then release the lever.

Page 60

INSP
ADJ
AIR BLEEDING (HYDRAULIC BRAKE SYSTEM)/
BRAKE HOSE INSPECTION

3 - 19

i. Repeat steps (e) to (h) until all the air bub-
bles have disappeared from the bake fluid.

NOTE:

When bleeding the brake system, make sure
that there is always enough brake fluid in the
brake fluid reservoir, before applying the brake
lever. Ignoring this precaution could allow air
to enter the brake system, lengthening the
bleeding procedure, considerably.

j. Tighten the bleed screw.

Bleed screw:
6 Nm (0.6 m • kg)

T R
.

.

NOTE:

If bleeding is difficult, it may be necessary to let
the brake fluid settle for a few hours. Repeat the
bleeding procedure when the tiny bubbles in the
brake system have disappeared.

k. Fill the brake fluid reservoir to the proper
level.
Refer 
to 
the 
“BRAKE 
FLUID 
LEVEL
INSPECTION” section.

WARNING
After bleeding the brake system check the
brake operation.

*****************************************************

BRAKE HOSE INSPECTION
1.Inspect:

G Brake hose
Cracks/wear/damage → Replace.
2.Check:

G Brake hose clamp(s)
Loose → Tighten.
3.Hold the motorcycle upright and apply the
front brake.
4.Check:

G Brake hose
Activate the brake lever several times.
Brake fluid leakage → Replace the faulty
hose.
Refer to the “FRONT BRAKE” section in
CHAPTER 6.

Page 61

INSP
ADJ
REAR BRAKE ADJUSTMENT

3 - 20

REAR BRAKE ADJUSTMENT
1.Check:

G Brake pedal position
(distance a from the top of the rider footrest
to the top of the brake pedal)
Out of specification → Adjust.

Brake pedal position (below the
top of the rider footrest):
30 mm

2.Adjust:

G Brake pedal position

*****************************************************
Adjustment steps:

GLoosen the locknut 1.

GTurn the adjusting bolt 2 in or out until the
specified brake pedal position is obtained.

Turn in
Brake pedal is raised.

Turn out
Brake pedal is lowered.

GTighten the locknut to specification.

Locknut:
10 Nm (1.0 m • kg)

T R
.

.

*****************************************************

3.Check:

G Brake pedal free play a
Out of specification → Adjust.

Free play:
20 ~ 30 mm

Page 62

INSP
ADJ
REAR BRAKE ADJUSTMENT/BRAKE SHOE
INSPECTION/BRAKE LIGHT SWITCH ADJUSTMENT

3 - 21

4.Adjust:

G Brake pedal free play

*****************************************************
Adjustment steps:

GTurn the adjuster 1 in or out until the speci-
fied free play is obtained.

Turning in
Free play is decreased.

Turning out
Free play is increased.

CAUTION:
Make sure that the brake does not drag
after adjusting it.

*****************************************************
5.Adjust:

G Brake light switch
Refer to the “BRAKE LIGHT SWITCH
ADJUSTMENT” section.

BRAKE SHOE INSPECTION
1.Operate the brake pedal.
2.Inspect:

G Brake shoes
Wear indicator 1 reaches the wear limit line
2 → Replace the brake shoes as a set.
Refer to the “REAR WHEEL AND REAR
BRAKE” section in CHAPTER 6.

BRAKE LIGHT SWITCH ADJUSTMENT
1.Check:

G Brake light operation timing
Incorrect → Adjust.
2.Adjust:

G Brake light operation timing

*****************************************************
Adjustment steps:

GHold the main body 1 of the switch with your
hand so that it does not rotate, and turn the
adjuster 2 in or out until the proper opera-
tion timing is obtained.

Turning in
Brake light comes on first.

Turning out
Brake light comes on slow.

*****************************************************

Page 63

DRIVE CHAIN SLACK ADJUSTMENT

3 - 22

INSP
ADJ

DRIVE CHAIN SLACK ADJUSTMENT

WARNING

G Securely support the motorcycle so that
there is no danger of it falling over.

G Stand the motorcycle on its centerstand.

1.Check:

G Drive chain slack a
Out of specification → Adjust.

Drive chain slack:
20 ~ 30 mm

2.Adjust:

G Drive chain slack

*****************************************************
Adjustment steps:

GLoosen the each locknuts 1 and chain
adjuster nuts 2.

GLoosen the axle nut 3.

GTurn the chain adjustment nuts 2 clockwise
or counterclockwise until the specified drive
chain slack is obtained.

Turning in
Drive chain slack is 
decreased.

Turning out
Drive chain slack is 
increased.

NOTE:

G Turn each chain adjuster nuts exactly the
same amount to maintain correct axle align-
ment. (There are marks a on each chain
adjuster nuts. Use them when adjusting the
slack for proper alignment.)

G Before tightening the axle nut and locknuts to
specification, make sure that there is no
clearance at the adjuster nuts (or the swin-
garm end) on both sides by pushing the
wheel forward.

GTighten the axle nut.

85 Nm (8.5 m • kg)

T R
.

.

GTighten the locknut.

7 Nm (0.7 m • kg)

T R
.

.

*****************************************************

Page 64

INSP
ADJ
TIRE INSPECTION/
STEERING HEAD INSPECTION

3 - 23

TIRE INSPECTION
1.Measure:

G Tire inflation pressure
Out of specification → Adjust.

Basic weight (with 
oil and full fuel 
tank)
131 kg

Maximum load*
180 kg

Cold tire pressure
Front
Rear

Up to 100 kg load*
200 kPa 
(2.0 kg/cm2)
200 kPa
(2.0 kg/cm2)

100 kg ~ maximum. 
Load*
200 kPa 
(2.0 kg/cm2)
225 kPa 
(2.25 kg/cm2)

*
Load is the total weight of the cargo, rider, pas-
senger and accessories.

2.Inspect:

G Tire surfaces
Wear/Damage → Replace.

Minimum tire tread depth (front 
and rear):
0.8 mm

1 Tread depth
2 Side wall
3 Wear indicator

3.After a tire repair or replacement, be sure to
tighten the valve stem locknut 1 to specifi-
cation.

STEERING HEAD INSPECTION
1.Stand the motorcycle on a level surface.

NOTE:

Stand the motorcycle on its centerstand.

2.Elevate the front wheel by placing a suitable
stand under the engine.

Page 65

INSP
ADJ
STEERING HEAD INSPECTION

3 - 24

3.Check:

G Handlebar assembly
Grasp the handlebar and gently rock the
steering.
Looseness → Adjust the handlebar.

G Steering assembly bearings
Grasp the bottom of the lower front fork
tubes and gently rock the fork assembly.
Looseness → Adjust the steering head.
4.Adjust:

G Steering head
5.Remove:

G Handlebar

G Pinch bolt

G Steering stem nut

G Handle crown

6.Adjust:

G Steering head

*****************************************************
Adjustment steps:

GRemove the lock washer 1, the upper ring
nut 2, and the rubber washer 3.

GLoosen the lower ring nut 4 and then tighten
it to specification with a ring nut wrench 5.

NOTE:

Set the torque wrench at a right angle to the
ring nut wrench.

Steering nut wrench:
90890-01403

Lower ring nut (initial tightening 
torque):
48 Nm (4.8 m • kg)

T R
.

.

GLoosen the lower ring nut 4 completely,
then tighten it to specification.

WARNING
Do not overtighten the lower ring nut.

Lower ring nut (final tightening 
torque):
18 Nm (1.8 • kg)

T R
.

.

Page 66

INSP
ADJ
STEERING HEAD INSPECTION/
REAR SHOCK ABSORBER INSPECTION

3 - 25

GCheck the steering head for looseness or
binding by turning the front fork all the way in
both directions. If any binding is felt, remove
the lower bracket and inspect the upper and
lower bearings.
Refer to the “STEERING HEAD AND HAN-
DLEBAR” in section CHAPTER 6.

GInstall the rubber washer 3.

GInstall the upper ring nut 2.

GFinger tighten the upper ring nut 2, then
align the slots of both ring nuts. If necessary,
hold the lower ring nut and tighten the upper
ring nut until their slots are aligned.

GInstall the lock washer 1.

NOTE:

Make sure that the lock washer tabs a sit cor-
rectly in the ring nut slots b.

*****************************************************
7.Install:

G Handle crown

G Steering stem nut

110 Nm (11.0 m • kg)

T R
.

.

G Pinch bolt

23 Nm (2.3 m • kg)

T R
.

.

REAR SHOCK ABSORBER INSPECTION
1.Remove:

G Seat

G Side cover (right)
Refer to the “SIDE COVER” section.

G Fuel tank
Refer to the “FUEL TANK” section.
2.Check:

G Rear shock absorber mount
Looseness → Tighten.
Bolt (upper) 1 
Nut (lower) 2 
Refer to the “REAR SHOCK ABSORBER
AND SWINGARM” section in CHAPTER 6.

59 Nm (5.9 m • kg)

T R
.

.

59 Nm (5.9 m • kg)

T R
.

.

Page 67

INSP
ADJ
WHEEL INSPECTION/SPOKE INSPECTION AND
TIGHTENING/CABLE INSPECTION

3 - 26

WHEEL INSPECTION
1.Inspect:

G Wheels
Damage/Bends → Replace.

NOTE:

Always balance the wheel when a tire or wheel
has been changed or replaced.

WARNING

G Never attempt even small repairs to the
wheel.

G Ride conservatively after installing a tire
to allow it to seat itself properly on the
rim.

SPOKE INSPECTION AND TIGHTENING
1.Inspect:

G Spokes 1 
Bend/Damage → Replace.
Loose spoke → Retighten.
2.Tighten:

G Spokes

Nipple:
0.6 m • kg

T R
.

.

CABLE INSPECTION

WARNING
Damage cable sheath may cause corrosion
and interfere with the cable movement. An
unsafe condition may result so replace
such cable as soon as possible.

1.Inspect:

G Cable sheath

G Cables (throttle, clutch and starter)
Damage → Replace.

Page 68

3 - 27

INSP
ADJ
LUBRICATION

LUBRICATION
Cables
1.Check:

G Cable operation
Unsmooth operation → Lubricate.

Recommended lubricant:
Engine oil

NOTE:

Hold cable end high and apply several drops of
lubricant to cable.

2.Apply the grease to the throttle cable end
and cable guide groove at inside of throttle
housing 1.

Lithium soap base grease

Level/pedal
1.Lubricate the pivoting parts of the each lever
and pedal.

Recommended lubricant:
Engine oil

Sidestand/centerstand
1.Lubricate the pivoting parts.

Recommended lubricant:
Engine oil

Rear suspension
1.Lubricate the pivoting parts.

Recommended lubricant:
Lithium-soap base grease

Page 69

INSP
ADJ
BATTERY INSPECTION

3 - 28

ELECTRICAL
BATTERY INSPECTION

WARNING
Battery electrolyte is dangerous. It con-
tains sulfuric acid which is poisonous and
highly caustic. 
Always follow these preventive measures:

G Avoid bodily contact with electrolyte as it
can cause severe burns and permanent
eye injury.

G Wear protective eye gear when handling
or working near batteries.

G Antidote (EXTERNAL):

G SKIN - Flush with water.

G EYES - Flush with water for 15 minutes
and get immediate medical attention.

G Antidote (INTERNAL):

G Drink large quantities of water or milk fol-
lowed with milk of magnesia, beaten egg
or vegetable oil. Get immediate medical
attention.

G Batteries generate explosive hydrogen
gas.

G Always follow these preventive measures:

G Change batteries in a well - ventilated area.

G Keep batteries away from fire, sparks or
open flames (e.g., welding equipment,
lighted cigarettes, etc.)

G DO NOT SMOKE when charging or han-
dling batteries.

G KEEP BATTERIES AND ELECTROLYTE

OUT OF REACH OF CHILDREN.

1.Remove:

G Side cover (right)
Refer to the “SIDE COVER” section.

G battery band 1 
2.Disconnect:

G battery leads
(from the battery terminals)

CAUTION:
First, disconnect the negative lead 2, then
the positive lead 3.

3.Remove:

G battery

Page 70

INSP
ADJ
BATTERY INSPECTION

3 - 29

4.Inspect:

G Electrolyte level
Electrolyte level should be between the
upper 1 and lower 2 level marks. Electro-
lyte level is too low → Add electrolyte to
proper level.

CAUTION:
Refill with distilled water only. Tap water
contains minerals which are harmful to a
battery.

5.Inspect:

G Breather hose
Obstruction → Remove.
Damage → Replace.

CAUTION:
When inspecting the battery, make sure
that the breather hose is routed correctly. If
the breather hose is positioned in such a
way as to allow battery electrolyte or gas to
come into contact with the frame, this
could damage the motorcycle and ruin its
finish.

6.Check:

G Specific gravity
Less than 1.280 → Recharge the battery.

Charging Current:
0.7 amps/10 hr
Specific Gravity:
1.280 at 20 °C

*****************************************************
Replace the battery if:

GBattery voltage will not rise to a specific
value or bubbles fail to rise during charging.

GSulphation of one or more cells occurs, (as
indicated by the plates turning white, or
material accumulating in the bottom of the
cell).

Page 71

INSP
ADJ
BATTERY INSPECTION

3 - 30

GSpecific gravity readings after a long, slow
charge indicate that one cell is charged lower
than the rest.

GWarpage or buckling of plates or insulators is
evident.

*****************************************************

7.Connect:

G Breather hose (battery)
Be sure the hose is properly attached and
routed.

CAUTION:
When inspecting the battery, be sure the
breather pipe is routed correctly. If the
breather pipe 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 motorcycle can
occur.

8.Inspect:

G Battery terminals
Dirty → Clean with a wire brush.
Poor connection → Correct.

NOTE:

After cleaning the terminals, apply a light coat
of grease.

9.Install:

G Battery
10.Connect:

G Battery leads

CAUTION:
First, connect the positive lead 1, then
connect the negative lead 2.

11.Install:

G Battery band 3 

G Side cover (right)
Refer to the “SIDE COVER” section.

Page 72

3 - 31

INSP
ADJ
FUSE INSPECTION

FUSE INSPECTION
1.Remove:

G Side cover (right)
Refer to the “SIDE COVER” section.
2.Remove:

G Fuse 1 
3.Inspect:

G Fuse
Defective → Replace.
Blown fuse (new) → Inspect circuit.

NOTE:

Install new fuse of proper amperage.

Amperage: 10 A

4.Replace:

G Blown fuse

*****************************************************
Blown fuse replacement steps:

GTurn off ignition and the circuit.

GInstall a new fuse of proper amperage.

GTurn on switches to verify operation of elec-
trical device.

GIf fuse blows immediately again check circuit
in question.

*****************************************************

WARNING
Do not use fuse of higher amperage rating
than recommended. Extensive electrical
system damage and fire could result from
substitution of a fuse of improper amper-
age.

5.Install:

G Fuse

Page 73

INSP
ADJ
HEADLIGHT BEAM ADJUSTMENT/
HEADLIGHT BULB REPLACEMENT

3 - 32

HEADLIGHT BEAM ADJUSTMENT
1.Remove:

G Holding screw 1 

G Headlight unit 2 
2.Adjust:

G Headlight beam (vertical)

*****************************************************
Headlight beam adjustment steps:

GLoosen the bolt (headlight body).

GPosition the headlight body up or down to
adjust the headlight beam.

*****************************************************
3.Install:

G Headlight unit

HEADLIGHT BULB REPLACEMENT
1.Remove:

G Holding screw 1 

G Headlight unit 2 

2.Remove:

G Cover 1 

G Bulb (defective)

NOTE:

Turn the bulb holder 2 counterclockwise to
remove the bulb.

WARNING
Keep flammable products and your hands
away from the bulb while it is on, it will be
hot. Do not touch the bulb until it cools
down.

Page 74

INSP
ADJ
HEADLIGHT BULB REPLACEMENT

3 - 33

3.Install:

G Bulb (new)
Secure the new bulb with the bulb holder.

CAUTION:
Avoid touching glass part of bulb. Also
keep it free from oil otherwise, transpar-
ency of glass, bulb life and illuminous flux
will be adversely affected. If oil gets on
bulb, clean it with a cloth moistened thor-
oughly with alcohol or lacquer thinner.

4.Install:

G Cover

G Headlight unit

Page 75

CHAPTER 4.
ENGINE OVERHAUL

ENGINE REMOVAL ......................................................................................4-1
ENGINE OIL ..........................................................................................4-1
EXHAUST PIPE ASSEMBLY ................................................................4-1
LEFT FOOTREST BRACKET ...............................................................4-2
DRIVE CHAIN ........................................................................................4-2
CARBURETOR ......................................................................................4-3
WIRE, CABLE AND TUBE ....................................................................4-3
STARTER MOTOR ................................................................................4-4
ENGINE .................................................................................................4-4

ENGINE INSTALLATION .............................................................................4-5
ENGINE ASSEMBLY .............................................................................4-5
STARTER MOTOR ................................................................................4-5
WIRE AND CABLES ..............................................................................4-5
CARBURETOR ......................................................................................4-6
DRIVE CHAIN ........................................................................................4-6
LEFT FOOTREST BRACKET ...............................................................4-6
EXHAUST ASSEMBLY .........................................................................4-7
FUEL TANK AND SEAT ........................................................................4-7

CYLINDER HEAD .........................................................................................4-9
CYLINDER HEAD REMOVAL .............................................................4-10
CYLINDER HEAD INSPECTION .........................................................4-12
TIMING CHAIN TENSIONER INSPECTION .......................................4-13
CYLINDER HEAD INSTALATION .......................................................4-14

CAMSHAFT AND ROCKER ARMS  ..........................................................4-16
ROCKER ARM AND CAMSHAFT REMOVAL ....................................4-17
CAMSHAFT INSPECTION ..................................................................4-18
ROCKER ARMS AND ROCKER ARM SHAFTS INSPECTION ..........4-18
CAMSHAFT AND ROCKER ARM INSTALLATION ............................4-19

VALVES AND VALVE SPRINGS ...............................................................4-21
VALVE AND VALVE SPRINGS REMOVAL ........................................4-22
VALVES AND VALVE SPRINGS INSPECTION .................................4-24
VALVE SEATS INSPECTION .............................................................4-25
VALVES AND VALVE SPRINGS INSTALLATION ..............................4-27

CYLINDER AND PISTON ...........................................................................4-29
PISTON REMOVAL .............................................................................4-30
CYLINDER INSPECTION ....................................................................4-31
PISTON AND PISTON PIN INSPECTION ..........................................4-32
PISTON RINGS INSPECTION ............................................................4-33
PISTON RINGS, PISTON AND CYLINDER INSTALLATION .............4-34

ENG

Page 76

GENERATOR  .............................................................................................4-36
CRANKCASE COVER (LEFT) REMOVAL ..........................................4-37
GENERATOR ROTOR REMOVAL .....................................................4-38
STARTER CLUTCH INSPECTION .....................................................4-39
GENERATOR INSTALLATION ...........................................................4-39
CRANKCASE COVER (LEFT) INSTALLATION ..................................4-40

CLUTCH ......................................................................................................4-42
CRANKCASE COVER (RIGHT) REMOVAL .......................................4-43
CLUTCH REMOVAL ............................................................................4-44
CLUTCH INSPECTION .......................................................................4-45
CLUTCH INSTALLATION ....................................................................4-47

KICK STARTER AND SHIFT SHAFT .........................................................4-50
KICK SHAFT AND SHIFT SHAFT REMOVAL ....................................4-51
KICK STARTER INSPECTION ............................................................4-51
SHIFT SHAFT INSPECTION ...............................................................4-52
KICK SHAFT ASSEMBLING ...............................................................4-53
SHIFT SHAFT AND KICK STARTER INSTALLATION .......................4-53

OIL PUMP ...................................................................................................4-54
OIL PUMP REMOVAL .........................................................................4-55
OIL PUMP INSPECTION .....................................................................4-55
OIL PUMP INSTALLATION .................................................................4-56

CRANKCASE AND CRANKSHAFT ...........................................................4-57
CRANKCASE SEPARATING ..............................................................4-58
CRANKSHAFT INSPECTION .............................................................4-59
BEARINGS AND OIL SEALS INSPECTION .......................................4-60
TIMING CHAIN, TIMING CHAIN DRIVE SPROCKET 
AND TIMING CHAIN GUIDES INSPECTION ..................................4-60
CRANKSHAFT INSTALLATION ..........................................................4-61
CRANKCASE ASSEMBLING ..............................................................4-61

TRANSMISSION .........................................................................................4-63
TRANSMISSION REMOVAL ...............................................................4-64
SHIFT FORK SHIFT CAM INSPECTION ............................................4-64
TRANSMISSION INSPECTION ..........................................................4-65
TRANSMISSION INSTALLATION .......................................................4-67

ENG

Page 77

4 - 1

ENG
ENGINE REMOVAL

ENGINE OVERHAUL
ENGINE REMOVAL

NOTE:
It is not necessary to remove the engine in
order to remove the following components.

G Cylinder head

G Cylinder

G Piston

G Clutch

G Kickstarter shaft and shift shaft

G Oil pump

G Generator

1.Remove:

G Seat

G Fuel tank
Refer to the “SEAT, FUEL TANK” section in
CHAPTER 3.

WARNING
Securely support the motorcycle so there
is no danger of it falling over.

ENGINE OIL
1.Remove:

G Drain plug
Refer to the “ENGINE OIL REPLACEMENT”
section in CHAPTER 3.

EXHAUST PIPE ASSEMBLY
1.Remove:

G Bolts (right footrest bracket)

G Right footrest bracket 1

Page 78

4 - 2

ENG
ENGINE REMOVAL

2.Loosen:

G Bolt 1 (exhaust pipe joint)

3.Remove:

G Nuts 1 (exhaust pipe)
4.Remove:

G Exhaust pipe assembly

5.Remove:

G Bolts (muffler)

G Nut (muffler)

G Muffler 1 

LEFT FOOTREST BRACKET
1.Remove:

G Bolt (shift pedal)

G Bolts (left footrest bracket)

G Left footrest bracket 1 

NOTE:
When removing shift pedal, shift the transmis-
sion into 1st gear.

DRIVE CHAIN
1.Remove:

G Drive chain case 1

Page 79

4 - 3

ENG
ENGINE REMOVAL

2.Remove:

G Lock washer 1 

G Drive sprocket 2 
3.Loosen:

G Rear wheel axle nut

G Locknuts

G Drive chain adjuster nuts

CARBURETOR
1.Remove:

G Carburetor
Refer to the “CARBURETOR” section in
CHAPTER 5.

WIRE, CABLE AND TUBE
1.Remove:

G Spark plug lead cap 1 

G Ignition coil 2 

2.Straighten:

G Stopper
3.Remove:

G Clutch cable 1 

4.Remove:

G Breather hose 1 

G Tachometer cable 2

Page 80

4 - 4

ENG
ENGINE REMOVAL

5.Remove:

G Neutral switch lead 1 

G Generator lead coupler 2 

G Generator leads 3

STARTER MOTOR
1.Remove:

G Starter motor
Refer to the “ELECTRIC STARTING SYS-
TEM” in CHAPTER 7.

ENGINE
1.Remove:

G Engine mounting bracket 1 

2.Remove:

G Rear upper mounting bolt 1 

G Front mounting bolt 2 

G Rear lower mounting bolt 3

Page 81

ENG
ENGINE INSTALLATION

4 - 5

ENGINE INSTALLATION
ENGINE ASSEMBLY

WARNING
Securely support the motorcycle so there
is no danger of it falling over when install-
ing engine.

1.Install:

G Engine assembly

G Rear lower mounting bolt

G Rear upper mounting bolt 

Rear lower mounting bolt:
79 Nm (7.9 m • kg)
Rear upper mounting bolt:
58 Nm (5.8 m • kg)

T R
.

.

2.Install:

G Front mounting bolt 

Front mounting bolt:
58 Nm (5.8 m • kg)

T R
.

.

3.Install:

G Engine mounting bracket

G Bolt (engine mounting bracket-frame)

G Bolt (engine mounting bracket-engine) 

Bolt (engine mounting bracket-
frame):
30 Nm (3.0 m • kg)
Bolt (engine mounting bracket-
engine):
58 Nm (5.8 m • kg)

T R
.

.

STARTER MOTOR
1.Install:

G Starter motor
Refer to the “ELECTRIC STARTING SYS-
TEM” in CHAPTER 7.

WIRE AND CABLES
1.Install:

G Generator leads 1 

G Generator lead coupler 2 

G Neutral switch lead 3

Page 82

ENG
ENGINE INSTALLATION

4 - 6

2.Install:

G Tachometer cable

G Breather hose
3.Install:

G Clutch cable
4.Install:

G Ignition coil

G Spark plug lead cap

CARBURETOR
1.Install:

G Carburetor
Refer to the “CARBURETOR” section in
CHAPTER 5.

DRIVE CHAIN
1.Install:

G Drive chain

G Drive sprocket

G Lock washer

Nut (drive chain):
110 Nm (11.0 m • kg)

T R
.

.

2.Install:

G Drive chain case

LEFT FOOTREST BRACKET
1.Install:

G Left footrest bracket

Bolt (shift arm):
10 Nm (1.0 m • kg)
Bolt (footrest bracket):
30 Nm (3.0 m • kg)

T R
.

.

Page 83

ENGINE INSTALLATION

4 - 7

ENG

EXHAUST ASSEMBLY
1.Install:

G Muffler

G Nut (muffler)

G Bolts (muffler)
2.Install:

G Exhaust pipe
3.Tighten:

G Bolt (exhaust pipe joint)
4.Tighten:

G Nuts

G Bolts

Nuts (exhaust pipe):
18 Nm (1.8 m • kg)
Bolt (exhaust pipe joint):
20 Nm (2.0 m • kg)
Bolts (muffler)
30 Nm (3.0 m • kg)

T R
.

.

5.Install:

G Right footrest bracket

G Bolts (right footrest bracket)

FUEL TANK AND SEAT
1.Install:

G Fuel tank

G Seat
Refer to the “SEAT, FUEL TANK REMOVAL
AND INSTALLATION” section in CHAPTER
3.
2.Fill:

G Engine oil
Into crankcase
Refer to the “ENGINE OIL REPLACEMENT”
section in CHAPTER 3.

Page 84

ENG
ENGINE INSTALLATION

4 - 8

3.Adjust:

G Throttle cable free play

G Clutch lever free play
Refer to the “THROTTLE CABLE ADJUST-
MENT”, “CLUTCH ADJUSTMENT” section in
CHAPTER 3.

Throttle cable free play:
3 ~ 5 mm
Clutch lever free play:
10 ~ 15 mm

4.Adjust:

G Drive chain slack
Refer 
to 
the 
“DRIVE 
CHAIN 
SLACK
ADJUSTMENT” section in CHAPTER 3.

Drive chain slack:
20 ~ 30 mm

Page 85

# CYLINDER HEAD

| | |
| :--- | :--- |
| ① O-ring | ⑦ Gasket |
| ② Tappet cover | ⑧ Camshaft sprocket |
| ③ O-ring | ⑨ Gasket |
| ④ Camshaft sprocket cover | ⑩ Dowel pin |
| ⑤ Plate | ⑪ Cylinder head |
| ⑥ Cam chain tensioner | ⑫ Spark plug |
| | ⑬ Timing chain guide (exhaust side) |

---

### Torque Specifications

* **Camshaft sprocket cover bolts:** $10\text{ Nm } (1.0\text{ m} \cdot \text{kg})$
* **Camshaft sprocket bolt:** $60\text{ Nm } (6.0\text{ m} \cdot \text{kg})$
* **Camshaft sprocket cover bolts (alternative/secondary):** $10\text{ Nm } (1.0\text{ m} \cdot \text{kg})$
* **Camshaft sprocket bolts (to cam):** $20\text{ Nm } (2.0\text{ m} \cdot \text{kg})$
* **Breather hose bolt:** $8\text{ Nm } (0.8\text{ m} \cdot \text{kg})$
* **Cylinder head nuts/bolts:** $22\text{ Nm } (2.2\text{ m} \cdot \text{kg})$ <img src="oil_icon.png" alt="Apply engine oil" width="15"/> *(Apply engine oil)*
* **Cam chain tensioner bolts:** $18\text{ Nm } (1.8\text{ m} \cdot \text{kg})$
* **Cylinder head side bolt:** $7\text{ Nm } (0.7\text{ m} \cdot \text{kg})$
* **Spark plug:** $18\text{ Nm } (1.8\text{ m} \cdot \text{kg})$

---

* **New** (Replace gasket ⑦)
* **New** (Replace gasket ⑨)

---
**4 - 9**

Page 86

4 - 10

ENG
CYLINDER HEAD

CYLINDER HEAD REMOVAL

NOTE:
Prior to remove the cylinder head, remove the
seat, fuel tank and air scoop, and drain the
engine oil.

1.Remove:

G Exhaust pipe assembly
Refer to the “ENGINE REMOVAL” section in
CHAPTER 3.
2.Remove:

G Carburetor
Refer to the “CARBURETOR” section in
CHAPTER 5.
3.Remove:

G Carburetor joint 1 

G Spark plug 2 

4.Remove:

G Tappet cover 1 

G Tachometer cable 2 

G Camshaft sprocket cover 3 

5.Remove:

G Timing mark accessing screw (with O-ring) 1 

G Camshaft end cover (with O-ring) 2 

6.Align:

G Camshaft sprocket “I” mark 
With the stationary pointer on the cylinder
head.

***********************************************
TDC alignment steps:

GTurn the crankshaft counter clockwise with a
wrench.

GAlign the camshaft sprocket “I” mark 1 with
the stationary pointer 2 on the cylinder
head. When the “I” mark is aligned with the
stationary pointer, the piston is at Top Dead
Center (TDC).

Page 87

4 - 11

ENG

CYLINDER HEAD

NOTE:
TDC on compression stroke check:

G Both rocker arms must have a valve clearance
when the “l” mark a on the flywheel is aligned
with the slit b on the crankcase cover.

G If not, give the crankshaft one counter clock-

wise turn to meet above condition.

***********************************************

7.Loosen:

G Bolt (camshaft sprocket) 1 

NOTE:
Hold the crankshaft end with a wrench 2.

8.Remove:

G Cam chain tensioner 1 
9.Remove:

G Camshaft sprocket

NOTE:
Fasten a safety wire to the cam chain.

10.Remove:

G Engine mounting bracket
Refer to the “ENGINE REMOVAL” section.
11.Remove:

G Cylinder head 1 

NOTE:
Loosen the bolts in this stage, using a criss-
cross pattern.

Page 88

4 - 12

ENG
CYLINDER HEAD

12.Remove:

G Dowel pins 1 

G Gasket (cylinder head) 2

G Timing chain guide (exhaust side) 3 

CYLINDER HEAD INSPECTION
1.Eliminate:

G Carbon deposits
(from combustion chambers)
Use a rounded scraper.

NOTE:
Do not use a sharp instrument to avoid damag-
ing or scratching:

G Spark plug threads

G Valve seats

2.Inspect:

G Cylinder head
Scratches/damage → Replace.
3.Measure:

G Cylinder head warpage
Out of specification → Resurface.

Cylinder head warpage:
Less than 0.03 mm

***********************************************
Warpage measurement and resurfacement
steps:

GPlace a straightedge and feeler gauge
across the cylinder head.

GMeasure the warpage.

GIf the warpage is out of specification, resur-
face the cylinder head.

GPlace a 400 ~ 600 grit wet abrasive paper on
the surface plate, and resurface the head
using a figure-eight sanding pattern.

NOTE:
Rotate the cylinder head several times for an
even resurfacement.

***********************************************

Page 89

4 - 13

ENG
CYLINDER HEAD

TIMING CHAIN TENSIONER INSPECTION
1.Check:

G timing chain tensioner
Cracks/damage/rough movement → 
Replace.

***********************************************
a. Lightly press the timing chain tensioner rod
into the timing chain tensioner housing by
hand.

NOTE:
While pressing the timing chain tensioner rod,
wind it clockwise with stopper 1 until it stops.

b. Remove your finger and slowly release the
timing chain tensioner rod.

c. Make sure that the timing chain tensioner
rod comes out of the timing chain tensioner
housing smoothly. If there is rough move-
ment, replace the timing chain tensioner.

***********************************************

Page 90

4 - 14

ENG
CYLINDER HEAD

CYLINDER HEAD INSTALATION
1.Install:

G Cylinder

Bolt:
22 Nm (2.2 m • kg)
Bolt:
20 Nm (2.0m • kg)

T R
.

.

2.Install:

G Camshaft sprocket

G Timing chain

G Washer

G Bolt (camshaft sprocket)

***********************************************
Camshaft sprocket installing steps (rear
cylinder):

GTurn the crankshaft counter clockwise with
wrench.

GAlign the mark “l” on the flywheel with the slit
on the crankcase cover.

GInstall the camshaft sprocket with the “I”
mark facing outward.

GForce the camshaft counter clockwise to
remove the cam chain slack.

GInsert your finger into the cam chain ten-
sioner hole, and push the cam chain damper
inward.

GWhile pushing the cam chain damper be
sure the camshaft sprocket “I” mark 1 aligns
with the stationary pointer 2 on the cylinder
head at TDC.

GIf marks are aligned, tighten the camshaft
sprocket bolt temporary.

GIf marks do not align, change the meshing
position of sprocket and chain.

***********************************************
3.Install:

G Gasket (new)

G Timing chain tensioner

NOTE:
Use the gasket (new).

Page 91

4 - 15

ENG
CYLINDER HEAD

***********************************************
Timing chain tension installation steps:

GTurn the stopper clockwise.

GHold the stopper with the bolt 1.

GInstall the tensioner with a new gasket into
the cylinder.

Bolt (tensioner-cylinder):
10 Nm (1.0 m • kg)

T R
.

.

***********************************************
4.Tighten:

G Bolt (camshaft sprocket)

Bolt (camshaft sprocket):
60 Nm (6.0 m • kg)

5.Check:

G Alignment marks
If the marks do not align → Adjust.
6.Adjust:

G Valve clearance
Refer to the “VALVE CLEARANCE ADJUST-
MENT” section in CHAPTER 3.

Intake valve (cold):
0.05 ~ 0.10 mm
Exhaust valve (cold):
0.10 ~ 0.15 mm

7.Install:

G Tappet cover

G Camshaft sprocket cover

Tappet cover:
18 Nm (1.8 m • kg)
Camshaft sprocket cover:
10 Nm (1.0 m • kg)

T R
.

.

8.Install:

G Spark plug

G Carburetor joint

Spark plug:
18 Nm (1.8 m • kg)
Carburetor joint:
10 Nm (1.0 m • kg)

T R
.

.

Page 92

ENG
CAMSHAFT AND ROCKER ARMS

CAMSHAFT AND ROCKER ARMS 

1 Locknut
2 Valve adjuster
3 Rocker arm
4 Rocker arm shaft (exhaust)
5 Rocker arm shaft (intake)
6 O-ring
7 Bearing
8 Camshaft
9 Plate

4 - 16

Page 93

ENG
CAMSHAFT AND ROCKER ARMS

4 - 17

ROCKER ARM AND CAMSHAFT REMOVAL

NOTE:
Prior to remove the rocker arm and camshaft,
remove the cylinder head.

1.Loosen:

G Locknut 1 

G Valve adjuster 2 
2.Remove

G Stopper plate 3 

3.Remove:

G Camshaft 1 

G Bearing 2 

NOTE:
Remove the camshaft and collar by using 10
mm bolt 3.

4.Attach:

G Slide hammer set 1 

Slide hammer bolt:
90890-01085
Weight:
90890-01084

5.Remove:

G Rocker arm shaft

G Rocker arm (intake/exhaust)

Page 94

ENG
CAMSHAFT AND ROCKER ARMS

4 - 18

YP402052
CAMSHAFT INSPECTION
1.Inspect:

G Cam lobes
Pitting/Scratches/Blue discoloration → 
Replace.

2.Measure:

G Cam lobes length a and b.
Out of specification → Replace.

Cam lobes length:
Intake:
a 36.52 ~ 36.62 mm
<Limit: 36.42 mm>
b 30.201 ~ 30.301 mm
<Limit: 30.1 mm>
Exhaust: 
a 36.564 ~ 36.664 mm
<Limit: 36.46 mm>
b 30.216 ~ 30.316 mm
<Limit: 30.12 mm>

3.Inspect:

G Camshaft oil passage
Stuffed → Blow out oil passage with com-
pressed the air.

YP402060
ROCKER ARMS AND ROCKER ARM 
SHAFTS INSPECTION
1.Inspect:

G Cam lobe contact surface 1 

G Adjuster surface 2 
Wear/Pitting/Scratches/Blue discoloration → 
Replace.

***********************************************
Inspection steps:

GInspect the two contact areas on the rocker
arms for signs of unusual wear.

GRocker arm shaft hole.

GCam-lobe contact surface.

GExcessive wear → Replace.

Page 95

ENG
CAMSHAFT AND ROCKER ARMS

4 - 19

GInspect the surface condition of the rocker
arm shafts.

GPitting/scratches/blue discoloration → 
Replace or check lubrication.

GMeasure the inside diameter of the rocker
arm holes.
Out of specification → Replace.

Inside diameter (rocker arm):
14.992 ~ 15.000 mm
<Limit: 15.02 mm>

GMeasure the outside diameter of the rocker
arm shafts.
Out of specification → Replace.

Outside diameter
(rocker arm shaft):
14.960 ~ 14.981 mm
<Limit 14.94 mm>

***********************************************

YP******
CAMSHAFT AND ROCKER ARM 
INSTALLATION
1.Lubricate:

G Rocker arm shaft

G Rocker arm inner surface

Rocker arm shaft:
Engine oil
Rocker arm inner surface:
Molybdenum disulfide grease

2.Install:

G Rocker arm 1 

G Rocker arm shaft 2 

NOTE:
Install the rocker arm shaft (exhaust) com-
pletely pushed in.

Page 96

ENG
CAMSHAFT AND ROCKER ARMS

4 - 20

3.Lubricate:

G Camshaft 1 

Camshaft:
Molybdenum disulfide grease
Camshaft bearing:
Engine oil

4.Install:

G Plate 1 

G Bolts 2 

8 Nm (0.8 m • kg)

T R
.

.

Page 97

ENG
VALVES AND VALVE SPRINGS

VALVES AND VALVE SPRINGS

1 Valve cotter
2 Upper spring seat
3 Lower spring seat
4 Oil seal
5 Inner valve spring
6 Outer valve spring
7 Valve

4 - 21

Page 98

ENG
VALVES AND VALVE SPRINGS

4 - 22

VALVE AND VALVE SPRINGS REMOVAL

NOTE:

G Prior to remove the valves, remove the cylin-
der head, rocker arm and camshaft.

G Before removing the internal parts (Valve,
valve spring, valve seat etc.) of the cylinder
head, the valve sealing should be checked.

1.Check:

G Valve sealing
Leakage at valve seat → Inspect the valve
face, valve seat and valve seat width.
Refer to the “VALVE SEATS INSPECTION”
section.

***********************************************
Valve seat checking steps:

GPour a clean solvent 1 into the intake and
exhaust ports.

GCheck the valve seating.
There should be no leakage at the valve seat
2.

***********************************************

Service Manual Yamaha Scorpio Z

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