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3 - 17
INSP
ADJ
FRONT BRAKE ADJUSTMENT
3. Install:
Reservoir float (front brake)
Diaphragm
Reservoir cap NOTE:
If bleeding is difficult, it may be necessary to
let the brake fluid system stabilize for a few
hours. Repeat the bleeding procedure when
the tiny bubbles in the system have disap-
peared.
j. Add brake fluid to the level line on the res-
ervoir.
WARNING
Check the operation of the brake after
bleeding the brake system.
EC362040
FRONT BRAKE ADJUSTMENT
1. Check:
Brake lever position a
2. Remove:
Lever cover
3. Adjust:
Brake lever position
4. Install:
Lever cover
Standard brake lever position:
95 mm (3.74 in)
Extent of adjustment:
76 ~ 97 mm (2.99 ~ 3.82 in)
Brake lever position adjustment steps:
Loosen the locknut 1.
Turn the adjusting bolt 2 until the lever
position a is within specified position.
Tighten the locknut.
T R..
Locknut:
5 Nm (0.5 m kg, 3.6 ft lb)
CAUTION:
Be sure to tighten the locknut, as it will
cause poor brake performance.
5PA30310
5PA30320
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3 - 18
INSP
ADJREAR BRAKE ADJUSTMENT/
FRONT BRAKE PAD INSPECTION AND REPLACEMENT
EC364002
REAR BRAKE ADJUSTMENT
1. Check:
Brake pedal height a
Out of specification → Adjust.
Brake pedal height
a:
4 ~ 10 mm (0.16 ~ 0.39 in)
5PA30330
2. Adjust:
Brake pedal height
Pedal height adjustment steps:
Loosen the locknut 1.
Turn the adjusting nut 2 until the pedal
height a is within specified height.
Tighten the locknut.
WARNING
Adjust the pedal height between the
maximum
È and the minimum
É as
shown. (In this adjustment, the bolt
3
end
b should protrude out of the lower
adjusting nut
4 but not be less than
2 mm (0.08 in)
c away from the brake
pedal
5).
After the pedal height adjustment, make
sure that the rear brake does not drag.
5PA30340
ÈÉ
5PA30350
FRONT BRAKE PAD INSPECTION AND
REPLACEMENT
1. Remove:
Rubber cap
2. Inspect:
Brake pad thickness a
Out of limit → Replace as a set.
Brake pad thickness:
4.0 mm (0.16 in)
: 0.8 mm (0.03 in)5PA30360
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3 - 19
INSP
ADJ
FRONT BRAKE PAD INSPECTION AND REPLACEMENT
3. Replace:
Brake pad
4. Inspect:
Brake fluid level
Refer to “BRAKE FLUID LEVEL INSPEC-
TION” section.
5. Check:
Brake lever operation
A softy or spongy feeling → Bleed brake
system.
Refer to “BRAKE SYSTEM AIR BLEED-
ING” section. Brake pad replacement steps:
Remove the brake caliper support bolt 1.
Turn the brake caliper 2 counterclockwise
a.
Replace the brake pads 3.
Connect the transparent hose 4 to the
bleed screw 5 and place the suitable con-
tainer under its end.
Loosen the bleed screw and push the
brake caliper piston in.
CAUTION:
Do not reuse the drained brake fluid.
Tighten the bleed screw.
T R..
Bleed screw:
6 Nm (0.6 m kg, 4.3 ft lb)
Install the brake caliper 6 and brake cali-
per support bolt 7.
NOTE:
Apply the lithium soap base grease on the
brake caliper support bolt.
T R..
Brake caliper support bolt:
30 Nm (3.0 m kg, 22 ft lb)
5PA30370
5PA30380
5PA30390
5PA30400
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3 - 20
INSP
ADJ
REAR BRAKE PAD INSPECTION AND REPLACEMENT
REAR BRAKE PAD INSPECTION AND
REPLACEMENT
1. Inspect:
Brake pad thickness a
Out of limit → Replace as a set.
Brake pad thickness:
3.7 mm (0.15 in)
: 1.0 mm (0.04 in)
5PA30410
2. Replace:
Brake pad
Brake pad replacement steps:
Loosen the pad pins 1 and remove the
brake caliper 2.
NOTE:
Before removing the brake caliper from the
swingarm, loosen the pad pins.
Remove the pad pins 3 and brake pads
4.
Connect the transparent hose 5 to the
bleed screw 6 and place the suitable con-
tainer under its end.
Loosen the bleed screw and push the
brake caliper piston in.
CAUTION:
Do not reuse the drained brake fluid.
Tighten the bleed screw.
T R..
Bleed screw:
6 Nm (0.6 m kg, 4.3 ft lb)
Install the brake pads 7 and pad pins 8.
NOTE:
Install the brake pad fitted with the brake
pad shim 9 on the brake caliper piston side.
5PA30420
5PA30430
5PA30440
5PA30450
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3 - 21
INSP
ADJ
BRAKE FLUID LEVEL INSPECTION
3. Inspect:
Brake fluid level
Refer to “BRAKE FLUID LEVEL INSPEC-
TION” section.
4. Check:
Brake pedal operation
A softy or spongy feeling → Bleed brake
system.
Refer to “BRAKE SYSTEM AIR BLEED-
ING” section.
BRAKE FLUID LEVEL INSPECTION
1. Place the brake master cylinder (reservoir
tank) so that its top is in a horizontal posi-
tion.
2. Inspect:
Brake fluid level
Fluid at lower level a → Fill up.
ÈFront
ÉRear
WARNING
Use only designated quality brake fluid to
avoid poor brake performance.
Refill with same type and brand of brake
fluid; mixing fluids could result in poor
brake performance.
Be sure that water or other contaminants
do not enter master cylinder when refill-
ing.
Clean up spilled fluid immediately to
avoid erosion of painted surfaces or plas-
tic parts.
Install the brake caliper 0 and tighten the
pad pins A.
T R..
Bolt (brake caliper):
23 Nm (2.3 m kg, 17 ft lb)
Pad pin:
18 Nm (1.8 m kg, 13 ft lb)
NOTE:
Apply the LOCTITE® on the bolt (brake cali-
per rear side).
Recommended brake fluid:
DOT #4
5PA30460
È
5PA30470
É
Page 168 of 506
3 - 24
INSP
ADJDRIVE CHAIN SUPPORT INSPECTION/
FRONT FORK INSPECTION
3. Adjust:
Drive chain slack
DRIVE CHAIN SUPPORT INSPECTION
1. Inspect:
Drive chain support wear limit
Limit reaches indicator a → Replace.
Refer to “SWINGARM” section in the
CHAPTER 5. Drive chain slack adjustment steps:
Loosen the axle nut 1 and locknuts 2.
Adjust chain slack by turning the adjusters 3.
To tighten
→ Turn adjuster
3 clockwise.
To loosen
→ Turn adjuster
3 counter-
clockwise and push wheel forward.
Turn each adjuster exactly the same
amount to maintain correct axle alignment.
(There are marks a on each side of chain
puller alignment.)
NOTE:
Turn the adjuster so that the chain is in line
with the sprocket, as viewed from the rear.
CAUTION:
Too small chain slack will overload the
engine and other vital parts; keep the
slack within the specified limits.
Tighten the axle nut while pushing down
the drive chain.
T R..
Axle nut:
90 Nm (9.0 m kg, 65 ft lb)
Tighten the locknuts.
T R..
Locknut:
16 Nm (1.6 m kg, 11 ft lb)
5PAR0004
5PAR0005
a a
EC36C000
FRONT FORK INSPECTION
1. Inspect:
Front fork smooth action
Operate the front brake and stroke the front
fork.
Unsmooth action/oil leakage → Repair or
replace.
5PA30570
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3 - 35
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 endÈUse Yamaha cable lube or equivalent on these
areas.
ÉUse SAE 10W-30 motor oil or suitable chain
lubricants.
ÊLubricate 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
5PA307705PA307805PA30790
5PA308005PA308105PA30820
5PA308005PA30840
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ENGKICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR
KICK SHAFT, SHIFT SHAFT AND PRIMARY DRIVE GEAR
PRIMARY DRIVE GEAR
5PAR0008
Extent of removal:
1 Primary drive gear removal
Extent of removal Order Part name Q’ty Remarks
PRIMARY DRIVE GEAR
REMOVAL
Drain the transmission oil. Refer to“TRANSMISSION OIL
REPLACEMENT” section in the CHAP-
TER 3.
Brake pedal
Radiator hose 2 Disconnect at water pump side.
1 Kickstarter crank 1
2 Right crankcase cover 1
3 Primary driven gear 1 Refer to “CLUTCH AND PRIMARY
DRIVEN GEAR” section.
4 Nut (primary drive gear) 1 Refer to “REMOVAL POINTS”.
5 Primary drive gear 1
1
