Page 113 of 188

4-45
KICK SHAFT AND SHIFT SHAFT
INSTALLING THE SHIFT GUIDE
AND SHIFT LEVER ASSEMBLY
1. Install:
• Spring "1"
• Pawl pin "2"
•Pawl "3"
To shift lever "4".
Apply the engine oil on the spring,
pawl pin and pawl.
2. Install:
• Shift lever assembly "1"
To shift guide "2".
3. Install:
• Shift lever assembly "1"
• Shift guide "2"
• The shift lever assembly is installed
at the same time as the shift guide.
• Apply the engine oil on the bolt
(segment) shaft.
4. Install:
• Bolt (shift guide) "1" INSTALLING THE SHIFT SHAFT
1. Install:
• Roller "1"
• Collar "2"
• Torsion spring "3"
• Washer "4"
• Shift shaft "5"
Apply the engine oil on the roller and
shift shaft.
2. Install:
• Shift pedal "1"
• Bolt (shift pedal) "2"
When installing the shift pedal onto
the shift shaft, be sure that the center
of the shift pedal is about 4.4 mm
(0.17 in) "a" above the top of the foot-
rest.
INSTALLING THE KICK SHAFT
ASSEMBLY
1. Install:
• Kick gear "1"
• Washer "2"
• Circlip "3"
• Ratchet wheel "4"
• Spring "5"
• Washer "6"
• Circlip "7"
To kick shaft "8".
• Apply the molybdenum disulfide oil
on the inner circumferences of the
kick gear and ratchet wheel.
• Align the punch mark "a" on the
ratchet wheel with the punch mark
"b" on the kick shaft.
2. Install:
• Torsion spring "1"
To kick shaft "2".
Make sure the stopper "a" of the tor-
sion spring fits into the hole "b" on the
kick shaft.
3. Install:
• Spring guide "1"
Slide the spring guide into the kick
shaft, make sure the groove "a" in the
spring guide fits on the stopper of the
torsion spring.
4. Install:
• Kick shaft assembly "1"
• Washer "2"
• Apply the molybdenum disulfide
grease on the contacting surfaces
of the kick shaft stopper "a" and kick
shaft ratchet wheel guide "3".
• Apply the engine oil on the kick
shaft.
• Slide the kick shaft assembly into
the crankcase and make sure the
kick shaft stopper "a" fits into the
kick shaft ratchet wheel guide.
Bolt (shift guide):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Bolt (shift pedal):
12 Nm (1.2 m•kg, 8.7
ft•lb)
Page 114 of 188
4-46
KICK SHAFT AND SHIFT SHAFT
5. Hook:
• Torsion spring "1"
Turn the torsion spring clockwise and
hook into the proper hole "a" in the
crankcase.
INSTALLING THE KICK IDLE
GEAR
1. Install:
• Kick idle gear "1"
• Washer "2"
• Circlip "3"
• Apply the engine oil on the kick idle
gear inner circumference.
• Install the kick idle gear with its de-
pressed side "a" toward you.
Page 115 of 188
4-47
CDI MAGNETO
CDI MAGNETO
REMOVING THE CDI MAGNETO
Order Part name Q'ty Remarks
Seat and fuel tank Refer to "SEAT, FUEL TANK AND SIDE
COVERS" section.
Disconnect the CDI magneto lead.
1 Left crankcase cover 1
2 Gasket 1
3 Dowel pin 2
4 Nut (rotor) 1 Refer to removal section.
5 Rotor 1 Refer to removal section.
6 Stator 1
7 Woodruff key 1
Page 116 of 188

4-48
CDI MAGNETO
REMOVING THE ROTOR
1. Remove:
• Nut (rotor) "1"
• Washer
2. Remove:
• Rotor "1"
Use the rotor puller 2.
CHECKING THE CDI MAGNETO
1. Inspect:
• Rotor inner surface "a"
• Stator outer surface "b"
Damage
→Inspect the crankshaft
runout and crankshaft bearing.
If necessary, replace CDI magne-
to and/or stator.
CHECKING THE WOODRUFF KEY
1. Inspect:
• Woodruff key "1"
Damage
→Replace.
INSTALLING THE CDI MAGNETO
1. Install:
•Stator "1"
• Screw (stator) "2"
• Apply the sealant on the grommet
of the CDI magneto lead.
• Tighten the screws using the T30
bit.
2. Install:
• Woodruff key "1"
• Rotor "2"
• Degrease the contact surfaces of
the tapered portions of the crank-
shaft and rotor.
• When installing the woodruff key,
make sure that its flat surface "a" is
in parallel with the crankshaft center
line "b".
• When installing the rotor, align the
keyway "c" of the rotor with the
woodruff key.
3. Install:
• Washer
• Nut (rotor) "1"
4. Connect:
• CDI magneto lead
Refer to "CABLE ROUTING DIA-
GRAM" section in the CHAPTER
2.5. Install:
• Dowel pin
• O-ring
• Gasket (left crankcase cover)
• Left crankcase cover "1"
• Hose guide (cylinder head breath-
er hose) "2"
• Bolt (left crankcase cover)
• Apply the lithium soap base grease
on the O-ring.
• Tighten the bolts in stage, using a
crisscross pattern.
Rotor puller:
YM-04151/90890-04151
Screw (stator):
10 Nm (1.0 m•kg,
7.2ft•lb)
YAMAHA Bond No. 1215
(ThreeBond® No. 1215):
90890-85505
Nut (rotor):
56 Nm (5.6 m•kg, 40
ft•lb)
Bolt (left crankcase cov-
er):
10 Nm (1.0 m•kg, 7.2
ft•lb)
Page 117 of 188
4-49
ENGINE REMOVAL
ENGINE REMOVAL
REMOVING THE ENGINE
Order Part name Q'ty Remarks
Hold the machine by placing the suitable stand
under the frame.Refer to "HANDLING NOTE".
Seat and fuel tank Refer to "SEAT, FUEL TANK AND SIDE
COVERS" section.
Rear shock absorber Refer to "REAR SHOCK ABSORBER" sec-
tion in the CHAPTER 5.
Carburetor Refer to "CARBURETOR" section.
Exhaust pipe and silencer Refer to "EXHAUST PIPE AND SILENCER"
section.
Clutch cable Disconnect at the engine side.
Radiator Refer to "RADIATOR" section.
Shift pedalRefer to "KICK SHAFT AND SHIFT SHAFT"
section.
Cylinder head breather hose Refer to "CAMSHAFTS" section.
Drain the engine oil.Refer to "CHANGING THE ENGINE OIL"
section in the CHAPTER 3.
Ignition coil
Disconnect the CDI magneto lead.
Page 118 of 188
4-50
ENGINE REMOVAL
Engine guard
1 Neutral switch 1
2 Drive chain sprocket cover 1
3 Nut (drive sprocket) 1 Refer to removal section.
4 Lock washer 1 Refer to removal section.
5 Drive sprocket 1 Refer to removal section.
6Clip 1
7 Bolt (brake pedal) 1
8 Brake pedal 1
9 Upper engine bracket 2
10 Lower engine bracket 2
11 Engine mounting bolt 3
12 Pivot shaft 1 Refer to removal section.
13 Engine 1 Refer to removal section. Order Part name Q'ty Remarks
Page 119 of 188

4-51
ENGINE REMOVAL
HANDLING NOTE
Support the machine securely so
there is no danger of it falling over.
REMOVING THE DRIVE
SPROCKET
1. Remove:
• Nut (drive sprocket) "1"
• Lock washer "2"
• Straighten the lock washer tab.
• Loosen the nut while applying the
rear brake.
2. Remove:
• Drive sprocket "1"
• Drive chain "2"
Remove the drive sprocket together
with the drive chain.
REMOVING THE ENGINE
1. Remove:
• Pivot shaft "1"
If the pivot shaft is pulled all the way
out, the swingarm will come loose. If
possible, insert a shaft of similar di-
ameter into the other side of the swin-
garm to support it.
2. Remove:
• Engine "1"
From right side.
Make sure that the couplers, hoses
and cables are disconnected.
INSTALLING THE ENGINE
1. Install:
• Engine "1"
Install the engine from right side.
• Pivot shaft "2"
• Engine mounting bolt (lower) "3"
• Lower engine bracket "4"
• Bolt (lower engine bracket) "5"
• Patch "6"
• Engine mounting bolt (front) "7"
• Upper engine bracket "8"
• Bolt (upper engine bracket) "9"
• Engine mounting bolt (upper) "10"
• Apply the molybdenum disulfide
grease on the pivot shaft.
• Install the patch with the claw "a"
facing outside the chassis.
INSTALLING THE BRAKE PEDAL
1. Install:
• Spring "1"
• Brake pedal "2"
• O-ring "3"
• Bolt (brake pedal) "4"
• Clip "5"
Apply the lithium soap base grease
on the bolt, O-rings and brake pedal
bracket.
INSTALLING THE DRIVE
SPROCKET
1. Install:
• Drive sprocket "1"
• Drive chain "2"
Install the drive sprocket together
with the drive chain.
Pivot shaft:
85 Nm (8.5 m•kg, 61
ft•lb)
Engine mounting bolt
(lower):
53Nm (5.3 m•kg, 38
ft•lb)
Bolt (lower engine brack-
et):
34 Nm (3.4 m•kg, 24
ft•lb)
Engine mounting bolt
(front):
53 Nm (5.3 m•kg, 38
ft•lb)
Bolt (upper engine brack-
et):
55 Nm (5.5 m•kg, 40
ft•lb)
Engine mounting bolt
(upper):
55 Nm (5.5 m•kg, 40
ft•lb)
Bolt (brake pedal):
26 Nm (2.6 m•kg, 19
ft•lb)
Page 120 of 188
4-52
ENGINE REMOVAL
2. Install:
• Lock washer "1"
• Nut (drive sprocket) "2"
Tighten the nut while applying the
rear brake.
Make sure to tighten to specifica-
tion; otherwise, it may damage the
other part that is fastened togeth-
er.
3. Bend the lock washer tab to lock
the nut.
4. Install:
• Drive chain sprocket guide
• Drive chain sprocket cover "1"
• Screw (drive chain sprocket cov-
er) "2"
INSTALLING THE NEUTRAL
SWITCH
1. Install:
• Spring "1"
•Pin "2"
• O-ring "3"
• Neutral switch "4"
• Screw (neutral switch) "5"
Apply the lithium soap base grease
on the O-ring.
Nut (drive sprocket):
75 Nm (7.5 m•kg, 54
ft•lb)
Screw (drive chain
sprocket cover):
8 Nm (0.8 m•kg, 5.8
ft•lb)
Screw (neutral switch):
4 Nm (0.4 m•kg, 2.9
ft•lb)