REAR SHOCK ABSORBER ASSEMBLY

NOTE:
Install the washer with the brim pointing back
of the vehicle and the “UP” punch mark facing
up.

4. Tighten:
• Spacer bolt

Spacer bolt
16 Nm (1.6 m·kg, 12 ft·lb)

• Rear shock absorber assembly lower nut

Rear shock absorber assembly
lower nut
40 Nm (4.0 m·kg, 30 ft·lb)
• Rear shock absorber assembly upper nut
Rear shock absorber assembly
upper nut
44 Nm (4.4 m·kg, 33 ft·lb)
• Rear shock absorber assembly bracket
nut
Rear shock absorber assembly
bracket nut
52 Nm (5.2 m·kg, 38 ft·lb)
5. Install:
• Connecting arms
NOTE:
When installing the connecting arms, lift up the
swingarm.
6. Tighten:
• Connecting arm nuts

Connecting arm nuts

40 Nm (4.0 m·kg, 30 ft·lb)

4-62
 SWINGARM

EAS23330
SWINGARM
Removing the swingarm

4
11
12
LS
1
2
LS
3 1
13 19 2
LS 3
21
New 20
16 20 New
15 LS

LS 21
14 6
8
7
10
9 18
LS
17
15
LS

Order Job/Parts to remove Q’ty Remarks

Rear wheel Refer to “REAR WHEEL” on page 4-12.
Refer to “REAR SHOCK ABSORBER
Rear shock absorber
ASSEMBLY” on page 4-59.
Drive chain guide (drive sprocket side) Refer to “CHAIN DRIVE” on page 4-68.
1 Drive chain adjusting locknut 2
2 Drive chain puller 2
3 Drive chain adjusting bolt 2
4 Rear fender 1
5 Left footrest assembly 1
6 Drive chain guard 1
7 Drive chain guide (swingarm side) 1
8 Drive chain 1
9 Swingarm pivot shaft nut 1
10 Washer 1
11 Swingarm pivot shaft ring nut 1
12 Washer 1
13 Swingarm pivot shaft 1
14 Swingarm 1
15 Dust cover 2

4-63
 SWINGARM

Removing the swingarm

4
11
12
LS
1
2
LS
3 1
13 19 2
LS 3
21
New 20
16 20 New
15 LS

LS 21
14 6
8
7
10
9 18
LS
17
15
LS

Order Job/Parts to remove Q’ty Remarks

16 Bearing 1
17 Bearing 1
18 Collar 1
19 Collar 1
20 Oil seal 2
21 Bearing 2
For installation, reverse the removal proce-
dure.

4-64
 SWINGARM

EAS23350 Refer to “REMOVING THE DRIVE

REMOVING THE SWINGARM CHAIN” on page 4-69.
1. Stand the vehicle on a level surface. 4. Remove:
EWA13120
• Swingarm pivot shaft ring nut “1”
WARNING
Securely support the vehicle so that there NOTE:
is no danger of it falling over. Loosen the swingarm pivot shaft ring nut with
the ring nut wrench “2”.
NOTE:
Place the vehicle on a suitable stand so that Ring nut wrench
the rear wheel is elevated. 90890-01507
2. Measure:
• Swingarm side play
• Swingarm vertical movement
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ 1
a. Measure the tightening torque of the pivot
shaft nut, pivot shaft ring nut, and pivot
shaft.
Swingarm pivot shaft nut
70 Nm (7.0 m·kg, 52 ft·lb)
2
Swingarm pivot shaft ring nut
95 Nm (9.5 m·kg, 70 ft·lb)
Swingarm pivot shaft 5. Remove:
16 Nm (1.6 m·kg, 12 ft·lb) • Swingarm pivot shaft “1”
NOTE:
b. Measure the swingarm side play “A” by
Loosen the swingarm pivot shaft with the
moving the swingarm from side to side.
damper rod holder (24 mm) “2”.
c. If the swingarm side play is out of specifica-
tion, check the collars, bearings, washers,
and dust covers. Damper rod holder (24 mm)
90890-01328
Swingarm side play (at the end YM-01328
of the swingarm)
1.0 mm (0.04 in)
d. Check the swingarm vertical movement “B”
2
by moving the swingarm up and down. 1
If swingarm vertical movement is not
smooth or if there is binding, check the col-
lars, bearings, washers, and dust covers.

EAS23360
CHECKING THE SWINGARM
B 1. Check:
• Swingarm
A Bends/cracks/damage → Replace.
2. Check:
• Pivot shaft
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Roll the pivot shaft on a flat surface.
3. Remove: Bends → Replace.
• Drive chain

4-65
 SWINGARM

EWA13770
WARNING Installed depth of bearing “a”
Do not attempt to straighten a bent pivot 0–1.0 mm (0–0.04 in)
shaft. Installed depth of bearing “b”
4.0 mm (0.16 in)
Installed depth of oil seal “c”
1.0 mm (0.04 in)

1 2

A B
3. Wash:
• Pivot shaft
• Dust covers
• Collars a 5 6 a
• Washers
c 5 c
• Bearings
7
Recommended cleaning solvent
A B
Kerosene

4. Check: 4 4
• Dust covers 3
• Collars b b
• Oil seals
Damage/wear → Replace.
5. Swingarm
• Bearings
6. Swingarm pivot shaft
Damage/pitting → Replace.
7. Bolt
EAS23380
INSTALLING THE SWINGARM A. Left side
1. Lubricate: B. Right side
• Bearings
• Collars 3. Install:
• Dust covers • Swingarm pivot shaft “1”
• Pivot shaft
Swingarm pivot shaft
Recommended lubricant 16 Nm (1.6 m·kg, 12 ft·lb)
Lithium-soap-based grease
NOTE:
2. Install: Tighten the swingarm pivot shaft with the
• Bearing “1” damper rod holder (24 mm) “2”.
• Bearing “2”
• Bearings “3” Damper rod holder (24 mm)
• Oil seals “4” 90890-01328
YM-01328

4-66
 SWINGARM

Drive chain slack

30.0–45.0 mm (1.18–1.77 in)
2
1

4. Install:
• Swingarm pivot shaft ring nut “1”

Swingarm pivot shaft ring nut

95 Nm (9.5 m·kg, 70 ft·lb)

NOTE:
• Lubricate the swingarm pivot ring nut threads
and mating surfaces with lithium-soap-based
grease.
• Tighten the swingarm pivot shaft ring nut with
the ring nut wrench “2”.

Ring nut wrench

90890-01507

5. Install:
• Swingarm pivot shaft nut

Swingarm pivot shaft nut

70 Nm (7.0 m·kg, 52 ft·lb)

NOTE:
Lubricate the swingarm pivot shaft nut threads
and mating surfaces with lithium-soap-based
grease.
6. Adjust:
• Drive chain slack
Refer to “ADJUSTING THE DRIVE
CHAIN SLACK” on page 3-26.

4-67
 CHAIN DRIVE

EAS23400
CHAIN DRIVE
Removing the drive sprocket and drive chain

10 Nm (1.0 m • kg, 7.4 ft • Ib)

T.
R.
1

4
3
New 2
6

Order Job/Parts to remove Q’ty Remarks

Left lower side cowling Refer to “GENERAL CHASSIS” on page 4-1.
Left bottom cowling Refer to “GENERAL CHASSIS” on page 4-1.
Shift rod Refer to “ENGINE REMOVAL” on page 5-1.
1 Drive sprocket cover 1
2 Drive sprocket nut 1
3 Washer 1
4 Drive sprocket 1
5 Drive chain 1
6 Drive chain guide (drive sprocket side) 1
For installation, reverse the removal proce-
dure.

4-68
 CHAIN DRIVE

EAS23410
REMOVING THE DRIVE CHAIN NOTE:
1. Stand the vehicle on a level surface. • When measuring a 15-link section of the
EWA13120 drive chain, make sure that the drive chain is
WARNING taut.
Securely support the vehicle so that there • Perform this procedure 2–3 times, at a differ-
is no danger of it falling over. ent location each time.

NOTE:
Place the vehicle on a suitable stand so that
the rear wheel is elevated.
2. Remove:
• Drive chain
(with the drive chain cutter)
NOTE:
Only cut the drive chain if it or the swingarm is
to be replaced. ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
2. Check:
EAS23440 • Drive chain
CHECKING THE DRIVE CHAIN Stiffness → Clean and lubricate or
1. Measure: replace.
• 15-link section “a” of the drive chain
Out of specification → Replace the drive
chain.

15-link length limit

239.3 mm (9.42 in)

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the length “a” between the inner
sides of the pins and the length “b”
between the outer sides of the pins on a
3. Clean:
15-link section of the drive chain as shown
• Drive chain
in the illustration.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Wipe the drive chain with a clean cloth.
b. Put the drive chain in kerosene and remove
any remaining dirt.
c. Remove the drive chain from the kerosene
and completely dry it.
EC2C01014
CAUTION:
• This vehicle has a drive chain with small
rubber O-rings “1” between the drive
b. Calculate the length “c” of the 15-link sec- chain side plates. Never use high-pres-
tion of the drive chain using the following sure water or air, steam, gasoline, certain
formula. solvents (e.g., benzine), or a coarse brush
Drive chain 15-link section length “c” = to clean the drive chain. High-pressure
(length “a” between pin inner sides + length methods could force dirt or water into the
“b” between pin outer sides)/2 drive chain’s internals, and solvents will
deteriorate the O-rings. A coarse brush
can also damage the O-rings. Therefore,
use only kerosene to clean the drive
chain.

4-69
 CHAIN DRIVE

• Do not soak the drive chain in kerosene More than 1/4 tooth “a” wear → Replace
for more than ten minutes, otherwise the the drive chain sprockets as a set.
O-rings can be damaged. Bent teeth → Replace the drive chain
sprockets as a set.

b. Correct

1. Drive chain roller

2. Drive chain sprocket
EAS23470
CHECKING THE REAR WHEEL SPROCKET
Refer to “CHECKING AND REPLACING THE
REAR WHEEL SPROCKET” on page 4-15.
EAS23480
CHECKING THE REAR WHEEL DRIVE HUB
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲ Refer to “CHECKING THE REAR WHEEL
4. Check: DRIVE HUB” on page 4-15.
• O-rings “1”
Damage → Replace the drive chain.
EAS28800
INSTALLING THE DRIVE CHAIN
• Drive chain rollers “2” 1. Lubricate:
Damage/wear → Replace the drive • Drive chain
chain.
• Drive chain side plates “3” Recommended lubricant
Damage/wear/cracks → Replace the Engine oil or chain lubricant
drive chain. suitable for O-ring chains
2. Install:
• Drive sprocket “1”
• Washer “2”
• Drive sprocket nut “3” New
NOTE:
• While applying the rear brake, tighten the
drive sprocket nut.
• Stake the drive sprocket nut “3” at a cutout
“a” in the drive axle.
5. Lubricate:
• Drive chain
Drive sprocket nut
Recommended lubricant 85 Nm (8.5 m·kg, 63 ft·lb)
Engine oil or chain lubricant LOCTITE®
suitable for O-ring chains

EAS23460
CHECKING THE DRIVE SPROCKET
1. Check:
• Drive sprocket

4-70
 CHAIN DRIVE

1
a 2

a
New 3

4-71
 ENGINE

ENGINE REMOVAL ......................................................................................5-1

INSTALLING THE ENGINE ....................................................................5-6

CAMSHAFTS................................................................................................5-7
REMOVING THE CAMSHAFTS .............................................................5-9
CHECKING THE CAMSHAFTS .............................................................5-9
CHECKING THE TIMING CHAIN, CAMSHAFT
SPROCKETS, AND TIMING CHAIN GUIDES......................................5-11
CHECKING THE TIMING CHAIN TENSIONER ...................................5-11
INSTALLING THE CAMSHAFTS ..........................................................5-12

CYLINDER HEAD.......................................................................................5-15
REMOVING THE CYLINDER HEAD ....................................................5-16
CHECKING THE CYLINDER HEAD ....................................................5-16
INSTALLING THE CYLINDER HEAD ...................................................5-16

VALVES AND VALVE SPRINGS ................................................................5-18

REMOVING THE VALVES ....................................................................5-19
CHECKING THE VALVES AND VALVE GUIDES .................................5-19
CHECKING THE VALVE SEATS ..........................................................5-21
CHECKING THE VALVE SPRINGS......................................................5-23
CHECKING THE VALVE LIFTERS .......................................................5-24
INSTALLING THE VALVES...................................................................5-24
5
GENERATOR AND STARTER CLUTCH....................................................5-26
REMOVING THE GENERATOR ...........................................................5-27
CHECKING THE STARTER CLUTCH..................................................5-27
INSTALLING THE STARTER CLUTCH ................................................5-27
INSTALLING THE GENERATOR ..........................................................5-28

PICKUP ROTOR .........................................................................................5-29

REMOVING THE PICKUP ROTOR ......................................................5-30
INSTALLING THE PICKUP ROTOR .....................................................5-30

ELECTRIC STARTER.................................................................................5-32
CHECKING THE STARTER MOTOR ...................................................5-34
ASSEMBLING THE STARTER MOTOR ...............................................5-35

CLUTCH......................................................................................................5-36
REMOVING THE CLUTCH...................................................................5-40
CHECKING THE FRICTION PLATES ..................................................5-40
CHECKING THE CLUTCH PLATES.....................................................5-40
CHECKING THE CLUTCH SPRINGS ..................................................5-41
CHECKING THE CLUTCH HOUSING .................................................5-42
CHECKING THE CLUTCH BOSS ........................................................5-42
CHECKING THE PRESSURE PLATE ..................................................5-42
 CHECKING THE PRIMARY DRIVE GEAR ..........................................5-42
CHECKING THE PRIMARY DRIVEN GEAR........................................5-42
CHECKING THE PULL LEVER SHAFT AND PULL ROD....................5-43
CHECKING THE OIL PUMP DRIVE SPROCKET
AND OIL PUMP DRIVE CHAIN ............................................................5-43
INSTALLING THE CLUTCH..................................................................5-43

SHIFT SHAFT .............................................................................................5-46

CHECKING THE SHIFT SHAFT ..........................................................5-47
CHECKING THE STOPPER LEVER....................................................5-47
INSTALLING THE SHIFT SHAFT .........................................................5-47

OIL PUMP ...................................................................................................5-48

REMOVING THE OIL PAN ...................................................................5-51
CHECKING THE OIL PUMP ................................................................5-51
CHECKING THE RELIEF VALVE .........................................................5-51
CHECKING THE OIL PIPES ................................................................5-52
CHECKING THE OIL STRAINER.........................................................5-52
ASSEMBLING THE OIL PUMP ............................................................5-52
INSTALLING THE OIL PAN ..................................................................5-52

CRANKCASE .............................................................................................5-53
DISASSEMBLING THE CRANKCASE .................................................5-55
CHECKING THE CRANKCASE ...........................................................5-55
CHECKING THE OIL PIPE...................................................................5-55
CHECKING THE TIMING CHAIN .........................................................5-55
ASSEMBLING THE CRANKCASE .......................................................5-55

CONNECTING RODS AND PISTONS .......................................................5-57

REMOVING THE CONNECTING RODS AND PISTONS.....................5-58
CHECKING THE CYLINDERS AND PISTONS....................................5-58
CHECKING THE PISTON RINGS ........................................................5-59
CHECKING THE PISTON PINS ...........................................................5-60
CHECKING THE CONNECTING RODS ..............................................5-61
INSTALLING THE CONNECTING RODS AND PISTONS ...................5-62

CRANKSHAFT ...........................................................................................5-65
REMOVING THE CRANKSHAFT JOURNAL BEARINGS ...................5-66
CHECKING THE OIL NOZZLES ..........................................................5-66
CHECKING THE CRANKSHAFT AND CONNECTING RODS ............5-66
INSTALLING THE CRANKSHAFT........................................................5-68

TRANSMISSION.........................................................................................5-69
REMOVING THE TRANSMISSION ......................................................5-73
CHECKING THE SHIFT FORKS ..........................................................5-73
CHECKING THE SHIFT DRUM ASSEMBLY........................................5-73
CHECKING THE TRANSMISSION ......................................................5-74
ASSEMBLING THE MAIN AXLE AND DRIVE AXLE ...........................5-74
INSTALLING THE TRANSMISSION.....................................................5-75
 ENGINE REMOVAL

EAS23710
ENGINE REMOVAL
Removing the exhaust pipe assembly

8 Nm (0.8 m • kg, 5.9 ft • Ib)

7

T.
R.
2 18 15
7 Nm (0.7 m • kg, 5.2 ft • Ib)
T.
R.

8 Nm (0.8 m • kg, 5.9 ft • Ib)

T.
R.

3
45 Nm (4.5 m • kg, 33 ft • Ib) 14
T.
R.

16
17
7 Nm (0.7 m • kg, 5.2 ft • Ib)

T.
R.
20 Nm (2.0 m • kg, 15 ft • Ib)

T.
R.
LT

LS
10 New LT
8 LT
1
13 2 5

3 4
LT
12 6 New
10 Nm (1.0 m • kg, 7.4 ft • Ib)
T.
R.

9 6 Nm (0.6 m • kg, 4.4 ft • Ib)

11
T.
R.

20 Nm (2.0 m • kg, 15 ft • Ib) 30 Nm (3.0 m • kg, 22 ft • Ib)

T.
R.
T.
R.

20 Nm (2.0 m • kg, 15 ft • Ib) 34 Nm (3.4 m • kg, 25 ft • Ib)

T.
R.
T.
R.

Order Job/Parts to remove Q’ty Remarks

Side cowling assembly Refer to “GENERAL CHASSIS” on page 4-1.
Upper side cowling Refer to “GENERAL CHASSIS” on page 4-1.
Radiator bracket Refer to “RADIATOR” on page 6-1.
1 EXUP valve pulley cover 1
2 EXUP cable 1 Black adjusting bolt
3 EXUP cable 1
4 Clamp 1
5 Muffler 1
6 Gasket 1
7 O2 sensor coupler 1 Disconnect.
8 O2 sensor 1
9 Exhaust pipe assembly 1
10 Gasket 4
11 Exhaust pipe assembly bracket (left lower side) 1
12 Exhaust pipe assembly bracket (left upper side) 1
13 Exhaust pipe assembly bracket (right side) 1
14 EXUP servo motor assembly 1
15 EXUP servo motor bracket 1

5-1
 ENGINE REMOVAL

Removing the exhaust pipe assembly

8 Nm (0.8 m • kg, 5.9 ft • Ib)

7

T.
R.
2 18 15
7 Nm (0.7 m • kg, 5.2 ft • Ib)
T.
R.

8 Nm (0.8 m • kg, 5.9 ft • Ib)

T.
R.

3
45 Nm (4.5 m • kg, 33 ft • Ib) 14
T.
R.

16
17
7 Nm (0.7 m • kg, 5.2 ft • Ib)

T.
R.
20 Nm (2.0 m • kg, 15 ft • Ib)

T.
R.
LT

LS
10 New LT
8 LT
1
13 2 5

3 4
LT
12 6 New
T.
R.
10 Nm (1.0 m • kg, 7.4 ft • Ib)
9 6 Nm (0.6 m • kg, 4.4 ft • Ib)
11
T.
R.

20 Nm (2.0 m • kg, 15 ft • Ib) 30 Nm (3.0 m • kg, 22 ft • Ib)

T.
R.
T.
R.

20 Nm (2.0 m • kg, 15 ft • Ib) 34 Nm (3.4 m • kg, 25 ft • Ib)

T.
R.
T.
R.

Order Job/Parts to remove Q’ty Remarks

16 EXUP servo motor cover 1
17 EXUP servo motor 1
18 EXUP servo motor coupler 1 Disconnect.
For installation, reverse the removal proce-
dure.

5-2
 ENGINE REMOVAL

Disconnecting the leads and hoses

10 Nm (1.0 m • kg, 7.4 ft • Ib)

T.
R.
5 6
8
7

10 9 10 Nm (1.0 m • kg, 7.4 ft • Ib)

T.
R.
14 70 Nm (7.0 m • kg, 52 ft • lb)

T.
R.
10 Nm (1.0 m • kg, 7.4 ft • Ib)

T.
R.
11

2
13
New 1
4
15 15
LS LS

12 3

7 Nm (0.7 m • kg, 5.2 ft • Ib)

T.
R.

New
17 Nm (1.7 m • kg, 13 ft • Ib)
T.
R.

Order Job/Parts to remove Q’ty Remarks

Fuel tank Refer to “FUEL TANK” on page 7-1.
Air filter case Refer to “AIR FILTER CASE” on page 7-4.
Throttle body Refer to “THROTTLE BODIES” on page 7-9.
Refer to “AIR INDUCTION SYSTEM” on
Air cut-off valve
page 7-15.
Refer to “ELECTRIC STARTER” on page 5-
Starter motor
32.
Thermostat Refer to “THERMOSTAT” on page 6-6.
Radiator Refer to “RADIATOR” on page 6-1.
Oil cooler Refer to “OIL COOLER” on page 6-4.
Water pump Refer to “WATER PUMP” on page 6-8.
Drive sprocket Refer to “CHAIN DRIVE” on page 4-68.
1 Shift rod 1
2 Shift arm 1
3 Oil filter cartridge 1
4 Oil filter cartridge bolt 1
5 Crankcase breather hose 1
6 Negative battery terminal 1 Disconnect.
7 Engine ground terminal 1 Disconnect.
8 Oil level switch coupler 1 Disconnect.
9 Crankshaft position sensor coupler 1 Disconnect.

5-3
 ENGINE REMOVAL

Disconnecting the leads and hoses

10 Nm (1.0 m • kg, 7.4 ft • Ib)

T.
R.
5 6
8
7

10 9 10 Nm (1.0 m • kg, 7.4 ft • Ib)

T.
R.
14 70 Nm (7.0 m • kg, 52 ft • lb)

T.
R.
10 Nm (1.0 m • kg, 7.4 ft • Ib)

T.
R.
11

2
13
New 1
4
15 15
LS LS

12 3

7 Nm (0.7 m • kg, 5.2 ft • Ib)

T.
R.

New
17 Nm (1.7 m • kg, 13 ft • Ib)
T.
R.

Order Job/Parts to remove Q’ty Remarks

10 Neutral switch coupler 1 Disconnect.
11 Speed sensor 1
12 Stator coil assembly coupler 1 Disconnect.
13 Clutch cable 1 Disconnect.
14 Cylinder identification sensor coupler 1 Disconnect.
15 Ignition coil coupler 4 Disconnect.
For installation, reverse the removal proce-
dure.

5-4
 ENGINE REMOVAL

Removing the engine

10 45 Nm (4.5 m • kg, 33 ft • Ib)

T.
R.
64 Nm (6.4 m • kg, 47 ft • Ib)
T.
R.

5
9
7 8 15
6 5

2 3 4
12 14

11
13 3 4
1 2

45 Nm (4.5 m • kg, 33 ft • Ib)

T.
R.

64 Nm (6.4 m • kg, 47 ft • Ib)

T.
R.

45 Nm (4.5 m • kg, 33 ft • Ib)

T.
R.

16

Order Job/Parts to remove Q’ty Remarks

NOTE:
Place a suitable stand under the engine.

1 Engine mounting bolt (front right side) 2

2 Engine mounting collar (outside) 2
3 Engine mounting collar (center) 2
4 Engine mounting collar (inside) 2
5 Engine mounting bolt (front left side) 2
6 Engine mounting nut (rear upper side) 1
7 Engine mounting collar (outside) 1
8 Engine mounting collar (center) 1
9 Engine mounting collar (inside) 1
10 Engine mounting bolt (rear upper side) 1
11 Engine mounting nut (rear lower side) 1
12 Engine mounting collar (outside) 1
13 Engine mounting collar (center) 1
14 Engine mounting collar (inside) 1
15 Engine mounting bolt (rear lower side) 1
16 Engine 1
For installation, reverse the removal proce-
dure.

5-5
 ENGINE REMOVAL

EAS23720
INSTALLING THE ENGINE 3
1. Install: 54
• Engine “1” 8 6 9
• Engine mounting bolt (rear lower side) “2” 2
• Engine mounting bolt (rear upper side) 9
“3”
• Engine mounting collars (inside) “4” 13
10
• Engine mounting collar (center) “5” 12 11
• Engine mounting collars (outside) “6”
• Engine mounting nut (rear lower side) “7” 54
(temporarily tighten) 76
• Engine mounting nut (rear upper side) “8”
(temporarily tighten) 11 10
13 12
• Engine mounting bolts (front left side) “9”
(temporarily tighten)
1
• Engine mounting collars (inside) “10”
• Engine mounting collar (center) “11” 3. Install:
• Engine mounting collars (outside) “12” • Shift arm “1”
• Engine mounting bolts (front right side)
“13” Shift arm bolt
(temporarily tighten) 10 Nm (1.0 m·kg, 7.4 ft·lb)
NOTE:
NOTE:
• Be sure to pass the drive axle through the
drive chain when installing the engine “1”. Install the shift arm “1” with its punch mark “a”
• Do not fully tighten the bolts and nuts. aligned with the notch “b” in end of the shift
shaft.
2. Tighten:
• Engine mounting nut (rear lower side) “7”
• Engine mounting nut (rear upper side) “8”
• Engine mounting bolts (front left side) “9” 1
• Engine mounting bolts (front right side)
“13”
Engine mounting nut (rear a
lower side)
64 Nm (6.4 m·kg, 47 ft·lb)
Engine mounting nut (rear b
upper side)
64 Nm (6.4 m·kg, 47 ft·lb)
Engine mounting bolt (front left
side)
45 Nm (4.5 m·kg, 32 ft·lb)
Engine mounting bolt (front
right side)
45 Nm (4.5 m·kg, 32 ft·lb)

5-6
 CAMSHAFTS

EAS23760
CAMSHAFTS
Removing the cylinder head cover

8 Nm (0.8 m • kg, 5.9 ft • Ib)

T.
R.
12 Nm (1.2 m • kg, 8.9 ft • Ib)

T.
R.
1
13 Nm (1.3 m • kg, 9.6 ft • Ib)

T.
R.
2

4 LT
LT

3
6
LS

New

5 New

Order Job/Parts to remove Q’ty Remarks

Radiator Refer to “RADIATOR” on page 6-1.
Throttle body Refer to “THROTTLE BODIES” on page 7-9.
Refer to “AIR INDUCTION SYSTEM” on
Air cut-off valve/Reed valve assembly
page 7-15.
1 Ignition coil 4
2 Spark plug 4
3 Cylinder identification sensor 1
4 Cylinder head cover 1
5 Cylinder head cover gasket 1
6 Timing chain guide (upper side) 1
For installation, reverse the removal proce-
dure.

5-7
 CAMSHAFTS

Removing the camshafts

10 Nm (1.0 m • kg, 7.4 ft • Ib)

T.
R.
4
4
4

12 Nm (1.2 m • kg, 8.9 ft • Ib)

T.
R.

1 6 7
5
5
5
M
2
6 8
24 Nm (2.4 m • kg, 18 ft • Ib)
1
T.

New 3
R.

10
10 Nm (1.0 m • kg, 7.4 ft • Ib)

T.
R.
9

11

Order Job/Parts to remove Q’ty Remarks

Pickup rotor cover Refer to “PICKUP ROTOR” on page 5-29.
1 Camshaft sprocket bolt 4 Loosen.
2 Timing chain tensioner 1
3 Timing chain tensioner gasket 1
4 Intake camshaft cap 3
5 Exhaust camshaft cap 3
6 Camshaft sprocket 2
7 Intake camshaft 1
8 Exhaust camshaft 1
9 Pin 2
10 Timing chain guide (intake side) 1
11 Timing chain guide (exhaust side) 1
For installation, reverse the removal proce-
dure.

5-8
 CAMSHAFTS

EAS23810 ECA13720
REMOVING THE CAMSHAFTS CAUTION:
1. Remove: To prevent damage to the cylinder head,
• Pickup rotor cover camshafts or camshaft caps, loosen the
Refer to “PICKUP ROTOR” on page 5-29. camshaft cap bolts in stages and in a criss-
2. Align: cross pattern, working from the outside in.
• TDC mark on the pickup rotor
(with the crankcase mating surface)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.

4. Remove:
• Intake camshaft
• Exhaust camshaft
b. When piston #1 is at TDC on the compres- NOTE:
sion stroke, align the TDC mark “a” on the To prevent the timing chain from falling into the
pickup rotor with the crankcase mating sur- crankcase, fasten it with a wire “1”.
face “b”.

b 1
a

EAS23850
NOTE:
CHECKING THE CAMSHAFTS
TDC on the compression stroke can be found
1. Check:
when the camshaft lobes are turned away from
• Camshaft lobes
each other.
Blue discoloration/pitting/scratches →
Replace the camshaft.
IN EX
2. Measure:
• Camshaft lobe dimensions “a” and “b”
Out of specification → Replace the cam-
shaft.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Remove:
• Camshaft caps “1”

5-9
 CAMSHAFTS

3. Measure:
Camshaft lobe dimensions • Camshaft runout
Intake A Out of specification → Replace.
33.725–33.875 mm (1.3278–
1.3337 in) Camshaft runout limit
Limit 0.030 mm (0.0012 in)
33.675 mm (1.3258 in)
Intake B
25.225–25.325 mm (0.9931–
0.9970 in)
Limit
25.175 mm (0.9911 in)
Exhaust A
32.925–33.075 mm (1.2963–
1.3022 in)
Limit
32.875 mm (1.2943 in)
Exhaust B 4. Measure:
25.082–25.182 mm (0.9875– • Camshaft-journal-to-camshaft-cap clear-
0.9914 in) ance
Limit Out of specification → Measure the cam-
25.032 mm (0.9855 in) shaft journal diameter.
Camshaft-journal-to-camshaft-
cap clearance
0.028–0.062 mm (0.0011–
0.0024 in)
A Limit
0.080 mm (0.0032 in)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
B
a. Install the camshaft into the cylinder head
(without the camshaft caps).
b. Position a strip of Plastigauge® “1” onto the
camshaft journal as shown.

c. Install the camshaft caps.

NOTE:
• Tighten the camshaft cap bolts in stages and
in a crisscross pattern, working from the
inner caps out.
• Do not turn the camshaft when measuring
the camshaft journal-to-camshaft cap clear-
ance with the Plastigauge®.

5-10
 CAMSHAFTS

Camshaft cap bolt

10 Nm (1.0 m·kg, 7.4 ft·lb)

d. Remove the camshaft caps and then mea-

sure the width of the Plastigauge® “1”.

a. 1/4 tooth
b. Correct

1. Timing chain roller

2. Camshaft sprocket

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
5. Measure:
• Camshaft journal diameter “a”
Out of specification → Replace the cam-
shaft.
Within specification → Replace the cylin-
der head and the camshaft caps as a set.
Camshaft journal diameter
22.459–22.472 mm (0.8842–
0.8847 in)
3. Check:
• Timing chain guide (exhaust side)
• Timing chain guide (intake side)
• Timing chain guide (upper side)
Damage/wear → Replace the defective
part(s).
EAS23970
CHECKING THE TIMING CHAIN TEN-
SIONER
1. Remove:
• Timing chain tensioner rod “1”
• Timing chain tensioner spring seat “2”
• Timing chain tensioner inner spring “3”
• Timing chain tensioner outer spring “5”
• Timing chain tensioner housing “6”
NOTE:
Squeeze the timing chain tensioner clip “4”,
and then remove the timing chain tensioner
springs and timing chain tensioner rod.

6
EAS23870 1 2 3 4 5
CHECKING THE TIMING CHAIN, CAM-
SHAFT SPROCKETS, AND TIMING CHAIN
GUIDES
1. Check:
• Timing chain “1”
Damage/stiffness → Replace the timing
chain and camshaft and camshaft 2. Check:
sprocket as a set. • Timing chain tensioner housing
2. Check: • Timing chain tensioner rod
• Camshaft sprocket • Timing chain tensioner spring seat
More than 1/4 tooth wear “a” → Replace • Timing chain tensioner springs
the camshaft sprocket and the timing Damage/wear → Replace the as a set.
chain as a set. 3. Assemble:
• Timing chain tensioner springs
• Timing chain tensioner spring seat
• Timing chain tensioner rod

5-11
 CAMSHAFTS

NOTE:
Prior to installing the timing chain tensioner
rod, drain the engine oil from the timing chain
tensioner housing.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Install the timing chain tensioner springs,
timing chain tensioner spring seat, and tim-
ing chain tensioner rod “1”.

b. Squeeze the timing chain tensioner clip “2”,

and then push the timing chain tensioner ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
rod “3” into the timing chain tensioner hous-
EAS24010
ing. INSTALLING THE CAMSHAFTS
NOTE: 1. Align:
Do not release the timing chain tensioner clip • TDC mark on the pickup rotor
while pushing the rod into the housing, other- (with the crankcase mating surface)
wise the rod may be ejected. ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Turn the crankshaft clockwise.

c. Hook the clip “4” to the timing chain ten- b. When piston #1 is at TDC on the compres-
sioner rod “3”. sion stroke, align the TDC mark “a” on the
NOTE: pickup rotor with the crankcase mating sur-
Hook the timing chain tensioner rod pin “5” to face “b”.
the center of the clip “4”. After the installation,
check that the clip “4” can come off by its own
weight by pushing the timing chain tensioner
rod “3” at the position of installation.

b
a

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

5-12
 CAMSHAFTS

2. Install:
a a
• Timing chain “1”
• Exhaust camshaft “2”
• Intake camshaft “3”
(with the camshaft sprockets temporarily a
tightened)
NOTE:
• Make sure the match marks “a” on the cam-
shaft sprockets are aligned with the cylinder
a a
head edge “b”.
• Be sure to install the timing chain so that the 4. Install:
exhaust side of the chain is taut and the • Camshaft cap bolts
intake side is slack.
Camshaft cap bolt
10 Nm (1.0 m·kg, 7.4 ft·lb)
ECA13730
CAUTION:
The camshaft cap bolts must be tightened
evenly or damage to the cylinder head,
camshaft caps, and camshafts will result.
NOTE:
Tighten the camshaft cap bolts in stages and
in a crisscross pattern, working from the inner
3. Install: caps out.
• Intake camshaft caps
• Exhaust camshaft caps 5. Install:
NOTE: • Timing chain tensioner gasket “1” New
• Make sure each camshaft cap is installed in • Timing chain tensioner “2”
its original place. Refer to the identification
marks as follows: Timing chain tensioner bolt
“I1”, “I2”: Intake 12 Nm (1.2 m·kg, 8.9 ft·lb)
“E1”, “E2”: Exhaust
• Make sure the arrow mark “a” on each cam- NOTE:
shaft points towards the right side of the • Be sure to install the timing chain tensioner
engine. gasket so that its section with the “L” mark “a”
is protruding from the lower left side of the
E2 E1 timing chain tensioner.
• The punch mark “b” on the timing chain ten-
E1 sioner should face up.

b
I1 a
L
2
I2 I1

5-13
 CAMSHAFTS

6. Rotate the crankshaft a few times to

release the timing chain tensioner rod.

9. Measure:
• Valve clearance
NOTE: Out of specification → Adjust.
If the engine is not disassembled, set the Refer to “ADJUSTING THE VALVE
engine stop switch to “ ”, and then crank the CLEARANCE” on page 3-4.
engine a few times by pressing the start switch 10. Install:
for approximately 0.5–1.0 second each time. • Cylinder head cover gasket New
• Cylinder head cover
7. Check that the timing chain is taut. If the
chain is slack, reinstall the timing chain ten- Cylinder head cover bolt
sioner. 12 Nm (1.2 m·kg, 8.9 ft·lb)
NOTE:
If the engine is not disassembled, start the NOTE:
engine and check for any abnormal noise. If • Apply bond TB1541B “1” onto the mating
any abnormal noise is heard, reinstall the tim- surfaces of the cylinder head cover and cylin-
ing chain tensioner. der head cover gasket.
• Apply bond TB1215B “2” onto the mating
8. Check: surfaces of the cylinder head cover gasket
• TDC mark “a” and cylinder head.
Make sure the TDC mark on the pickup • Tighten the cylinder head cover bolts stages
rotor is aligned with the crankcase mating and in a crisscross pattern.
surface “b”.
1

b
a
1 1
• Camshaft sprocket match mark “c”
Make sure the marks on the camshaft 2
sprockets are aligned with the edge of the
cylinder head “d”.
Out of alignment → Adjust.
Refer to the installation steps above.

5-14
 CYLINDER HEAD

EAS24100
CYLINDER HEAD
Removing the cylinder head

Order Job/Parts to remove Q’ty Remarks

Engine Refer to “ENGINE REMOVAL” on page 5-1.
Camshafts Refer to “CAMSHAFTS” on page 5-7.
1 Coolant temperature sensor 1
2 Cylinder head 1
3 Cylinder head gasket 1
4 Dowel pin 2
For installation, reverse the removal proce-
dure.

5-15
 CYLINDER HEAD

EAS24120 Mineral deposits/rust → Eliminate.

REMOVING THE CYLINDER HEAD 3. Measure:
1. Remove: • Cylinder head warpage
• Cylinder head bolts Out of specification → Resurface the cyl-
• Cylinder head nuts inder head.
NOTE:
• Loosen the nuts, cap nuts, and bolts in Warpage limit
decreasing numerical order (refer to the 0.05 mm (0.0020 in)
numbers in the illustration).
• Loosen each nut 1/2 of a turn at a time. After
all of the nuts are fully loosened, remove
them.

6 2 4 10
8 12

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
11 a. Place a straightedge “1” and a thickness
9
gauge “2” across the cylinder head.
3 1 5 7

EAS24160
CHECKING THE CYLINDER HEAD
1. Eliminate:
• Combustion chamber carbon deposits
(with a rounded scraper)
NOTE:
Do not use a sharp instrument to avoid damag-
ing or scratching:
• Spark plug bore threads
b. Measure the warpage.
• Valve seats
c. If the limit is exceeded, resurface the cylin-
der head as follows.
d. Place a 400–600 grit wet sandpaper on the
surface plate and resurface the cylinder
head using a figure-eight sanding pattern.
NOTE:
To ensure an even surface, rotate the cylinder
head several times.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

2. Check: EAS24240

• Cylinder head INSTALLING THE CYLINDER HEAD

Damage/scratches → Replace. 1. Install:
• Cylinder head
NOTE:
Replace the titanium valves with the cylinder NOTE:
head. Pass the timing chain through the timing chain
cavity.
Refer to “CHECKING THE VALVE SEATS”
on page 5-21. 2. Tighten:
• Cylinder head water jacket • Cylinder head nuts “1”–“7”, “10”

5-16
 CYLINDER HEAD

Cylinder head nut (1st)

25 Nm (2.5 m·kg, 18 ft·lb)
Cylinder head nut (final)
42 Nm (4.2 m·kg, 31 ft·lb)
• Cylinder head cap nuts “8”, “9”
Cylinder head cap nut (1st)
30 Nm (3.0 m·kg, 22 ft·lb)
Cylinder head cap nut (final)
60 Nm (6.0 m·kg, 44 ft·lb)
• Cylinder head bolts “11”, “12”

Cylinder head bolt

12 Nm (1.2 m·kg, 8.9 ft·lb)

NOTE:
• Lubricate the bolt threads and the bearing
surfaces with engine oil.
• Tighten the cylinder head nuts, cap nuts, and
bolts in the proper tightening sequence as
shown and torque them in two stages.

6 2 4 10
8 12

9 11
3 1 5 7

5-17
 VALVES AND VALVE SPRINGS

EAS24270
VALVES AND VALVE SPRINGS
Removing the valves and valve springs

1
E
2
3 M

4 3
New 9 M
E

1
M 5

2 3
10
3 M
4
New 9

M
10 M
12
11
8
7

Order Job/Parts to remove Q’ty Remarks

Cylinder head Refer to “CYLINDER HEAD” on page 5-15.
1 Valve lifter 16
2 Valve pad 16
3 Valve cotter 32
4 Upper spring seat 16
5 Intake valve spring 8
6 Exhaust valve spring 8
7 Intake valve 8
8 Exhaust valve 8
9 Valve stem seal 16
10 Lower spring seat 16
11 Intake valve guide 8
12 Exhaust valve guide 8
For installation, reverse the removal proce-
dure.

5-18
 VALVES AND VALVE SPRINGS

EAS24280 • Valve cotters “1”

REMOVING THE VALVES
The following procedure applies to all of the NOTE:
valves and related components. Remove the valve cotters by compressing the
valve spring with the valve spring compressor
NOTE: “1” and the valve spring compressor attach-
Before removing the internal parts of the cylin- ment “2”.
der head (e.g., valves, valve springs, valve
seats), make sure the valves properly seal.
Valve spring compressor
1. Remove: 90890-04019
• Valve lifter “1” YM-04019
• Valve pad “2” Valve spring compressor
NOTE: attachment
Make a note of the position of each valve lifter 90890-04108
and valve pad so that they can be reinstalled in Valve spring compressor
their original place. adapter 22 mm
YM-04108

2. Check:
• Valve sealing 4. Remove:
Leakage at the valve seat → Check the • Upper spring seat “1”
valve face, valve seat, and valve seat • Valve spring “2”
width. • Valve “3”
Refer to “CHECKING THE VALVE • Valve stem seal “4”
SEATS” on page 5-21. • Lower spring seat “5”
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼ NOTE:
a. Pour a clean solvent “a” into the intake and Identify the position of each part very carefully
exhaust ports. so that it can be reinstalled in its original place.
b. Check that the valves properly seal.
NOTE:
There should be no leakage at the valve seat
“1”.

EAS24290
CHECKING THE VALVES AND VALVE
GUIDES
The following procedure applies to all of the
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
valves and valve guides.
3. Remove: 1. Measure:

5-19
 VALVES AND VALVE SPRINGS

• Valve-stem-to-valve-guide clearance
Out of specification → Replace the valve
guide.
• Valve-stem-to-valve-guide clearance =
Valve guide inside diameter “a” -
Valve stem diameter “b”

Valve-stem-to-valve-guide clear-
ance (intake)
0.010–0.037 mm (0.0004– b. Install the new valve guide with the valve
0.0015 in) guide installer “2” and valve guide remover
Limit “1”.
0.080 mm (0.0032 in)
Valve-stem-to-valve-guide clear- Valve guide position
ance (exhaust) 15.80 mm–16.20 mm (0.622–
0.025–0.052 mm (0.0010– 0.638 in)
0.0020 in)
Limit
0.095 mm (0.0037 in)

a. Valve guide position

c. After installing the valve guide, bore the

valve guide with the valve guide reamer “3”
to obtain the proper valve-stem-to-valve-
guide clearance.

2. Replace:
• Valve guide
NOTE:
NOTE:
To ease valve guide removal and installation,
After replacing the valve guide, reface the
and to maintain the correct fit, heat the cylinder
valve seat.
head to 100 °C (212 °F) in an oven.
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Remove the valve guide with the valve
guide remover “1”.

5-20
 VALVES AND VALVE SPRINGS

Valve guide remover (ø4.5) NOTE:

90890-04116 • When installing a new valve, always replace
Valve guide remover (4.5 mm) the valve guide.
YM-04116 • If the valve is removed or replaced, always
Valve guide installer (ø4.5) replace the valve stem seal.
90890-04117
Valve guide installer (4.5 mm) Valve stem runout
YM-04117 0.040 mm (0.0016 in)
Valve guide reamer (ø4.5)
90890-04118
Valve guide reamer (4.5 mm)
YM-04118
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
3. Eliminate:
• Carbon deposits
(from the valve face and valve seat)
4. Check:
• Valve face
Pitting/wear → Grind the valve face. EAS24300
• Valve stem end CHECKING THE VALVE SEATS
Mushroom shape or diameter larger than The following procedure applies to all of the
the body of the valve stem → Replace the valves and valve seats.
valve. 1. Eliminate:
5. Measure: • Carbon deposits
• Valve margin thickness D “a” (from the valve face and valve seat)
Out of specification → Replace the valve. 2. Check:
• Valve seat
Valve margin thickness D
Pitting/wear → Replace the cylinder
(intake)
head.
0.90–1.10 mm (0.0354–0.0433
3. Measure:
in)
• Valve seat width C “a”
Limit
Out of specification → Replace the cylin-
0.8 mm (0.03 in)
der head.
Valve margin thickness D
(exhaust) Valve seat width C (intake)
1.10–1.30 mm (0.0433–0.0512 0.90–1.10 mm (0.0354–0.0433
in) in)
Limit Limit
1.0 mm (0.04 in) 1.6 mm (0.06 in)
Valve seat width C (exhaust)
1.10–1.30 mm (0.0433–0.0512
in)
Limit
1.8 mm (0.07 in)

6. Measure:
• Valve stem runout
Out of specification → Replace the valve.

5-21
 VALVES AND VALVE SPRINGS

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply a coarse lapping compound “a” to
the valve face.
ECA13790
CAUTION:
Do not let the lapping compound enter the
gap between the valve stem and the valve
guide.

▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Apply Mechanic’s blueing dye (Dykem) “b”
onto the valve face.

b. Apply molybdenum disulfide oil onto the

b. Install the valve into the cylinder head.
c. Press the valve through the valve guide
and onto the valve seat to make a clear
impression.
d. Measure the valve seat width.
NOTE:
Where the valve seat and valve face contacted
one another, the blueing will have been
removed.
valve stem.
c. Install the valve into the cylinder head.
d. Turn the valve until the valve face and valve
seat are evenly polished, then clean off all
of the lapping compound.
NOTE:
For the best lapping results, lightly tap the
valve seat while rotating the valve back and
forth between your hands.

▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
4. Lap:
• Valve face
• Valve seat
EC2C01028
CAUTION:
This model uses titanium intake and e. Apply a fine lapping compound to the valve
exhaust valves. Titanium valves that have face and repeat the above steps.
been used to lap the valve seats must not f. After every lapping procedure, be sure to
be used. Always replace lapped valves with clean off all of the lapping compound from
new valves. the valve face and valve seat.
g. Apply Mechanic’s blueing dye (Dykem) “b”
NOTE: onto the valve face.
• When replacing the cylinder head, replace
the valves without lapping the valve seats
and valve faces.
• When replacing the valves or valve guides,
use new valves to lap the valve seats, and
then replace them with new valves.

5-22
 VALVES AND VALVE SPRINGS

h. Install the valve into the cylinder head. 2. Measure:

i. Press the valve through the valve guide • Compressed valve spring force “a”
and onto the valve seat to make a clear Out of specification → Replace the valve
impression. spring.
j. Measure the valve seat width “c” again. If
the valve seat width is out of specification, Installed compression spring
reface and lap the valve seat. force (intake)
166.00–190.00 N (37.32–42.71
lbf) (16.93–19.37 kgf)
Installed compression spring
force (exhaust)
165.00–189.00 N (37.09–42.49
lbf) (16.83–19.27 kgf)
Installed length (intake)
32.80 mm (1.29 in)
Installed length (exhaust)
32.80 mm (1.29 in)
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

EAS24310
CHECKING THE VALVE SPRINGS
The following procedure applies to all of the
valve springs.
1. Measure:
• Valve spring free length “a”
Out of specification → Replace the valve
spring.
Free length (intake) b. Installed length
37.47 mm (1.48 in)
Limit 3. Measure:
35.60 mm (1.40 in) • Valve spring tilt “a”
Free length (exhaust) Out of specification → Replace the valve
37.67 mm (1.48 in) spring.
Limit
35.79 mm (1.42 in) Spring tilt (intake)
2.5°/1.6 mm
Spring tilt (exhaust)
2.5°/1.6 mm

5-23
 VALVES AND VALVE SPRINGS

3. Install:
• Lower spring seat “1”
• Valve stem seal “2”
• Valve “3”
• Valve spring “4”
• Upper spring seat “5”
(into the cylinder head)
NOTE:
• Make sure each valve is installed in its origi-
nal place.
EAS24320 • Install the valve springs with the larger pitch
CHECKING THE VALVE LIFTERS “a” facing up.
The following procedure applies to all of the
valve lifters.
1. Check:
• Valve lifter
Damage/scratches → Replace the valve
lifters and cylinder head.
EAS24340
INSTALLING THE VALVES
The following procedure applies to all of the
valves and related components.
1. Deburr:
• Valve stem end
(with an oil stone)

b. Smaller pitch

4. Install:
2. Lubricate: • Valve cotters “1”
• Valve stem “1”
• Valve stem seal “2” NOTE:
(with the recommended lubricant) Install the valve cotters by compressing the
valve spring with the valve spring compressor
Recommended lubricant “1” and the valve spring compressor attach-
Molybdenum disulfide oil ment “2”.

Valve spring compressor

90890-04019
YM-04019
Valve spring compressor
attachment
90890-04108
Valve spring compressor
adapter 22 mm
YM-04108

5-24
 VALVES AND VALVE SPRINGS

5. To secure the valve cotters onto the valve

stem, lightly tap the valve tip with a soft-
face hammer.
ECA13800
CAUTION:
Hitting the valve tip with excessive force
could damage the valve.

6. Lubricate:
• Valve lifter
(with the recommended lubricant)

Recommended lubricant
Engine oil

7. Install:
• Valve pad
• Valve lifter
NOTE:
• The valve lifter must move smoothly when
rotated with a finger.
• Each valve lifter and valve pad must be rein-
stalled in its original position.

5-25
 GENERATOR AND STARTER CLUTCH

EAS24480
GENERATOR AND STARTER CLUTCH
Removing the generator and starter clutch

Order Job/Parts to remove Q’ty Remarks

Side cowling assembly Refer to “GENERAL CHASSIS” on page 4-1.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-11.
1 Stator coil assembly coupler 1 Disconnect.
2 Generator cover 1
3 Generator cover gasket 1
4 Dowel pin 2
5 Stator coil assembly lead holder 1
6 Stator coil assembly 1
7 Starter clutch idle gear shaft 1
8 Starter clutch idle gear 1
9 Generator rotor 1
10 Starter clutch 1
11 Starter clutch gear 1
For installation, reverse the removal proce-
dure.

5-26
 GENERATOR AND STARTER CLUTCH

EAS24490 Damage/wear → Replace.

REMOVING THE GENERATOR 2. Check:
1. Remove: • Starter clutch idle gear
• Generator rotor bolt “1” • Starter clutch gear
• Washer Burrs/chips/roughness/wear → Replace
NOTE: the defective part(s).
While holding the generator rotor “2” with the 3. Check:
sheave holder “3”, loosen the generator rotor • Starter clutch gear’s contacting surfaces
bolt. Damage/pitting/wear → Replace the
starter clutch gear.
Sheave holder 4. Check:
90890-01701 • Starter clutch operation
Primary clutch holder ▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
YS-01880-A a. Install the starter clutch gear “1” onto the
generator rotor “2” and hold the generator
rotor.
b. When turning the starter clutch gear clock-
wise “A”, the starter clutch and the starter
3
clutch gear should engage, otherwise the
starter clutch is faulty and must be
replaced.
1 c. When turning the starter clutch gear coun-
terclockwise “B”, it should turn freely, other-
2 wise the starter clutch is faulty and must be
replaced.
2. Remove:
• Generator rotor “1”
(with the flywheel puller “2”)
ECA13880
CAUTION:
To protect the end of the crankshaft, place
an appropriate sized socket between the
flywheel puller set’s center bolt and the
crankshaft.

Flywheel puller ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲

90890-01404
EAS24600
Flywheel puller
INSTALLING THE STARTER CLUTCH
YM-01404
1. Install:
• Starter clutch “1”
NOTE:
Be sure to install the starter clutch so that its
1 side with the arrow mark “a” is facing inward,
away from the rotor.
2

EAS24570
CHECKING THE STARTER CLUTCH
1. Check:
• Starter clutch rollers

5-27
 GENERATOR AND STARTER CLUTCH

a Yamaha bond No. 1215

1
90890-85505
(Three Bond No.1215®)

EAS24500
INSTALLING THE GENERATOR
1. Install:
• Generator rotor
• Washer New
• Generator rotor bolt
NOTE:
• Clean the tapered portion of the crankshaft
and the generator rotor hub.
• Lubricate the generator rotor bolt threads
and washer mating surfaces with engine oil.
2. Tighten:
• Generator rotor bolt “1”

Generator rotor bolt

70 Nm (7.0 m·kg, 52 ft·lb)

NOTE:
While holding the generator rotor “2” with the
sheave holder “3”, tighten the generator rotor
bolt.

Sheave holder
90890-01701
Primary clutch holder
YS-01880-A

2
3. Apply:
• Sealant
(onto the stator coil assembly lead grom-
met)

5-28
 PICKUP ROTOR

EAS24520
PICKUP ROTOR
Removing the pickup rotor

35 Nm (3.5 m • kg, 26 ft • Ib)

T.
R.

6
15 Nm (1.5 m • kg, 11 ft • Ib)
T.
R.

12 Nm (1.2 m • kg, 8.9 ft • Ib)

. T
R.

New 4
5
New 3

New LT
LT

10 Nm (1.0 m • kg, 7.4 ft • Ib)

T.
R.

LS

1
12 Nm (1.2 m • kg, 8.9 ft • Ib)
T.
R.

Order Job/Parts to remove Q’ty Remarks

Side cowling assembly Refer to “GENERAL CHASSIS” on page 4-1.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Refer to “GENERATOR AND STARTER
Generator cover
CLUTCH” on page 5-26.
1 Clutch cable 1 Disconnect.
2 Crankshaft position sensor coupler 1 Disconnect.
3 Pickup rotor cover 1
4 Pickup rotor cover gasket 1
5 Crankshaft position sensor 1
6 Pickup rotor 1
For installation, reverse the removal proce-
dure.

5-29
 PICKUP ROTOR

EAS24530
REMOVING THE PICKUP ROTOR
1. Remove:
b a
• Pickup rotor bolt “1”
• Washer
• Pickup rotor
NOTE:
While holding the generator rotor “2” with the 1
rotor sheave holder “3”, loosen the pickup rotor
bolt.
2. Tighten:
Sheave holder • Pickup rotor bolt “1”
90890-01701
Pickup coil rotor bolt
Primary clutch holder
35 Nm (3.5 m·kg, 26 ft·lb)
YS-01880-A
NOTE:
While holding the generator rotor “2” with the
sheave holder “3”, tighten the pickup rotor bolt.

Sheave holder
90890-01701
1 Primary clutch holder
YS-01880-A

2
EAS24540
INSTALLING THE PICKUP ROTOR
3
1. Install:
• Pickup rotor “1”
• Washer
• Pickup rotor bolt
NOTE:
When installing the pickup rotor, align the 2
groove “a” in the crankshaft with the projection
3. Apply:
“b” on the pickup rotor.
• Sealant
(onto the crankshaft position sensor lead
grommet)
Yamaha bond No. 1215
90890-85505
(Three Bond No.1215®)

5-30
 PICKUP ROTOR

5-31
 ELECTRIC STARTER

EAS24780
ELECTRIC STARTER
Removing the starter motor

10 Nm (1.0 m • kg, 7.4 ft • Ib)

T.
R.
LT
LT

Order Job/Parts to remove Q’ty Remarks

Rider seat Refer to “GENERAL CHASSIS” on page 4-1.
Air filter case Refer to “AIR FILTER CASE” on page 7-4.
Fuel tank Refer to “FUEL TANK” on page 7-1.
Thermostat Refer to “THERMOSTAT” on page 6-6.
1 Starter motor lead 1
2 Starter motor assembly 1
For installation, reverse the removal proce-
dure.

5-32
 ELECTRIC STARTER

Disassembling the starter motor

7 Nm (0.7 m • kg, 5.2 ft • Ib)

T.
R.

Order Job/Parts to remove Q’ty Remarks

1 O-ring 1
2 Starter motor front cover 1
3 Lock washer 1
4 Oil seal 1
5 Bearing 1
6 Washer set 1
7 Starter motor yoke 1
8 Armature assembly 1
9 Gasket 2
10 Washer set 2
11 Brush holder (along with the brushes) 1
12 Starter motor rear cover 1
For assembly, reverse the disassembly pro-
cedure.

5-33
 ELECTRIC STARTER

EAS24790
CHECKING THE STARTER MOTOR Pocket tester
1. Check: 90890-03112
• Commutator Analog pocket tester
Dirt → Clean with 600 grit sandpaper. YU-03112-C
2. Measure:
• Commutator diameter “1” Armature coil
Out of specification → Replace the Commutator resistance “1”
starter motor. 0.0012–0.0022 Ω at 20 °C (68
°F)
Limit
Insulation resistance “2”
27.0 mm (1.06 in)
Above 1 MΩ at 20 °C (68 °F)
b. If any resistance is out of specification,
replace the starter motor.

3. Measure:
• Mica undercut “a”
Out of specification → Scrape the mica to ▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
the proper measurement with a hacksaw 5. Measure:
blade that has been grounded to fit the • Brush length “a”
commutator. Out of specification → Replace the
brushes as a set.
Mica undercut (depth)
0.70 mm (0.03 in) Limit
3.50 mm (0.14 in)
NOTE:
The mica of the commutator must be undercut
to ensure proper operation of the commutator.

6. Measure:
• Brush spring force
Out of specification → Replace the brush
4. Measure: springs as a set.
• Armature assembly resistances (commu-
tator and insulation) Brush spring force
Out of specification → Replace the 7.16–9.52 N (25.77–34.27 oz)
starter motor. (730–971 gf)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Measure the armature assembly resis-
tances with the pocket tester.

5-34
 ELECTRIC STARTER

7. Check:
• Gear teeth
Damage/wear → Replace the gear.
8. Check:
• Bearing
• Oil seal
Damage/wear → Replace the defective
part(s).
EAS24800
ASSEMBLING THE STARTER MOTOR
1. Install:
• Starter motor yoke “1”
NOTE:
Align the tab “a” on the brush holder with the
slot “b” in the starter motor yoke.

2. Install:
• Starter motor yoke “1”
• Starter motor front cover “2”
• Starter motor rear cover “3”
NOTE:
Align the match marks “a” on the starter motor
yoke with the match marks “b” on the front and
starter motor rear covers.

5-35
 CLUTCH

EAS25060
CLUTCH
Removing the clutch cover

12 Nm (1.2 m • kg, 8.9 ft • Ib)

T.
R.
1
6 New
LS
5 New

12 Nm (1.2 m • kg, 8.9 ft • Ib)

T.
R.

7
LT

LT
4
2
3
New
12 Nm (1.2 m • kg, 8.9 ft • Ib)
T.
R.

Order Job/Parts to remove Q’ty Remarks

Side cowling assembly Refer to “GENERAL CHASSIS” on page 4-1.
Drain.
Engine oil Refer to “CHANGING THE ENGINE OIL” on
page 3-11.
Drain.
Coolant Refer to “CHANGING THE COOLANT” on
page 3-19.
1 Water pump breather hose 1 Disconnect.
2 Clutch cable 1 Disconnect.
3 Pull lever 1
4 Pull lever spring 1
5 Clutch cover 1
6 Clutch cover gasket 1
7 Dowel pin 2
For installation, reverse the removal proce-
dure.

5-36