Page 26 of 633
GEN
INFO
 
1 - 1 
DESCRIPTION 
EC100000 
GENERAL INFORMATION 
EC110000 
DESCRIPTION 
1  
Clutch lever  
2  
Decompression lever  
3 
Front brake lever  
4 
Throttle grip 
5 
Radiator cap 
6 
Fuel tank cap 
7 
Oil filler plug/dipstick 
8 
“ENGINE STOP” button 
9 
Kick starter 
0 
Fuel tank 
A 
Radiator 
B 
Coolant drain bolt 
C 
Rear brake pedal 
D 
Valve joint 
E 
Fuel cock 
F 
Cold starter knob 
G 
Hot starter knob (red) 
H 
Drive chain 
I 
Air cleaner 
J 
Shift pedal 
K 
Front fork
NOTE:
 
 
The machine you have purchased may differ
slightly from those shown in the following. 
 
Designs and specifications are subject to 
change without notice. 
     
        
        Page 234 of 633
3 - 44
INSP
ADJ
LUBRICATION
LUBRICATION
To ensure smooth operation of all compo-
nents, lubricate your machine during setup,
after break-in, and after every race.
1All control cable
2Clutch lever pivot
3Shift pedal pivot
4Footrest pivot
5Throttle-to-handlebar contact
6Drive chain
7Tube guide cable winding portion
8Throttle cable end
9Clutch cable end
0Decompression cable endÅUse Yamaha cable lube or equivalent on these
areas.
ıUse SAE 10W-30 motor oil or suitable chain
lubricants.
ÇLubricate the following areas with high quality,
lightweight lithium-soap base grease.
CAUTION:
Wipe off any excess grease, and avoid get-
ting grease on the brake discs.
AAA
AAB
CC 
     
        
        Page 466 of 633
5 - 18
CHASFRONT BRAKE AND REAR BRAKE
2. Install:
Copper washer 1
Union bolt 2 
WARNING
Always use new copper washers.
ACHTUNG:CAUTION:
Install the brake hose so that its pipe por-
tion a directs as show and lightly touches
the projection b on the caliper.
New
T R..30 Nm (3.0 m · kg, 22 ft · lb)
3. Install:
Brake hose holder 1 
Caliper 2 
Bolt (caliper) 3 
NOTE:
Fit the brake hose holder cut a over the pro-
jection b on the front fork and clamp the brake
hose.
4. Tighten:
Pad pin 4 
5. Install:
Pad pin plug 5 
EC5A5100
Rear caliper
1. Install:
Pad support 1 
Brake pad 2 
Pad pin 3 
NOTE:
Install the brake pads with their projections
a into the caliper recesses b.
Temporarily tighten the pad pin at this point.
T R..23 Nm (2.3 m · kg, 17 ft · lb)
T R..18 Nm (1.8 m · kg, 13 ft · lb)
T R..3 Nm (0.3 m · kg, 2.2 ft · lb) 
     
        
        Page 478 of 633
5 - 24
CHASFRONT BRAKE AND REAR BRAKE
4. Install:
Copper washer 1 
Brake hose 2 
Union bolt 3 
WARNING
Always use new copper washers.
ACHTUNG:CAUTION:
Install the brake hose so that its pipe por-
tion a directs as show and lightly touches
the projection b on the master cylinder.
New
T R..30 Nm (3.0 m · kg, 22 ft · lb)
EC5A5500
Rear brake hose
1. Install:
Copper washer 1 
Brake hose 2 
Copper washer 3
Union bolt 4 
WARNING
Always use new copper washers.
ACHTUNG:CAUTION:
When installing the brake hose, first align
the tooth a on the copper washer 1 with
the projection b on the master cylinder.
Then, align the pipe portion c on the end
of the brake hose with the tooth d on the
copper washer 1 and tighten the union
bolt.
New
New
T R..30 Nm (3.0 m · kg, 22 ft · lb)