Yamaha TTR90(M) Service Manual

TT-R90R5HN-28199-13LIT-11626-16-27OWNER’S SERVICE MANUAL

EC080000 HOW TO USETHIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION!BECOME ALERT! YOUR SAFETY ISINVOLV

4 - 36ENGOIL PUMPOIL PUMPExtent of removal: 1 Oil pump removal 2 Oil strainer removal3 Oil pump disassemblyExtent of removal Order Part name Q’ty Rema

4 - 37ENGOIL PUMPExtent of removal Order Part name Q’ty Remarks11 Oil pump cover 112 Dowel pin 213 Oil pump drive shaft 114 Pin 115 Inner rotor 116 Ou

4 - 38ENGOIL PUMPINSPECTIONOil pump1. Measure:● Tip clearance a (between the inner rotor 1 and theouter rotor 2)● Side clearance b (between the outer

4 - 39ENGCDI MAGNETOCDI MAGNETOExtent of removal: 1 Pickup coil/stator assembly removal 2 Rotor removalExtent of removal Order Part name Q’ty RemarksC

4 - 40ENGCDI MAGNETOREMOVAL POINTSRotor1. Remove:● Rotor nut 1 ● Washer 2 NOTE:● Loosen the rotor nut while holding the rotorwith sheave holder 3.● Do

4 - 41ENGCRANKCASE AND CRANKSHAFTCRANKCASE AND CRANKSHAFTExtent of removal Order Part name Q’ty RemarksCRANKCASE SEPARATION AND CRANKSHAFT REMOVAL Pre

4 - 42ENGCRANKCASE AND CRANKSHAFTExtent of removal: 1 Timing chain removal 2 Crankcase separation3 Crankshaft removalExtent of removal Order Part name

4 - 43ENGCRANKCASE AND CRANKSHAFTINSPECTIONCrankshaft1. Measure:● Runout limit a ● Connecting rod big end side clearanceb ● Connecting rod big end rad

4 - 44ENGSHIFT FORK, SHIFT CAM AND TRANSMISSIONSHIFT FORK, SHIFT CAM AND TRANSMISSIONExtent of removal: 1 Shift fork, shift cam, main axle and drive a

4 - 45ENGSHIFT FORK, SHIFT CAM AND TRANSMISSIONExtent of removal Order Part name Q’ty Remarks10 3th pinion gear 111 Main axle 112 Circlip 113 Washer 1

EC083000 MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-tion has been complied to

4 - 46ENGSHIFT FORK, SHIFT CAM AND TRANSMISSIONEC4H3000REMOVAL POINTSShift fork, shift cam and transmission1. Remove:● Shift forks● Shift cam● Drive a

5 - 1CHASEC500000CHASSISFRONT WHEEL AND REAR WHEELFRONT WHEEL AND FRONT BRAKEFRONT WHEEL AND REAR WHEELExtent of removal: 1 Front wheel removal 2 Whee

5 - 2CHASExtent of removal Order Part name Q’ty Remarks10 Brake shoe 211 Brake camshaft lever 112 Brake camshaft 13FRONT WHEEL AND REAR WHEEL

5 - 3CHASFRONT WHEEL AND REAR WHEELREAR WHEEL AND REAR BRAKEExtent of removal: 1 Rear wheel removal 2 Wheel bearing removal3 Brake shoe plate assembly

5 - 4CHASFRONT WHEEL AND REAR WHEELExtent of removal Order Part name Q’ty Remarks11 Collar (left) 112 Wheel drive hub assembly 113 Bearing 2 Refer to

5 - 5CHASFRONT WHEEL AND REAR WHEELEC593000REMOVAL POINTSEC513201Wheel bearing (if necessary)1. Remove:● Bearing 1 NOTE:Remove the bearing using a gen

5 - 6CHASFRONT FORKEC550000FRONT FORKExtent of removal: 1 Front fork removalExtent of removal Order Part name Q’ty RemarksFRONT FORK REMOVALWARNINGSup

5 - 7CHASFRONT FORKEC558000FRONT FORK DISASSEMBLYExtent of removal: 1 Oil seal removal 2 Damper rod removalExtent of removal Order Part name Q’ty Rema

5 - 8CHASFRONT FORKREMOVAL POINTSInner tube1. Remove:● Bolt (damper rod)NOTE:While holding the damper rod with the damperrod holder 1 and T-handle 2,

5 - 9CHASHANDLEBAREC5B0000HANDLEBARExtent of removal: 1 Handlebar removalExtent of removal Order Part name Q’ty RemarksHANDLEBAR REMOVAL1 “ENGINE STOP

ILLUSTRATED SYMBOLS (Refer to the illustration) Illustrated symbols 1 to 6 are designed asthumb tabs to indicate the chapter’s numberand content.

5 - 10CHASSTEERINGEC560000STEERINGLSLST R..TIGHTENING STEPS:•Tighten ring nut. 38 Nm (3.8 m • kg, 27 ft • Ib)•Loosen it completely.•Retighten it. 1 Nm

5 - 11CHASSWINGARMEC570000SWINGARMExtent of removal: 1 Swingarm removal 2 Rear shock absorber removalExtent of removal Order Part name Q’ty RemarksSWI

5 - 12CHASSWINGARMExtent of removal Order Part name Q’ty Remarks9 Cotter pin 110 Nut (tension bar) 111 Bolt (tension bar) 112 Tension bar 11

6 - 1– +ELECELECTRICAL COMPONENTS AND WIRING DIAGRAMEC600000ELECTRICALEC610000ELECTRICAL COMPONENTS AND WIRING DIAGRAMEC611000ELECTRICAL COMPONENTS1 C

– +ELEC6 - 2IGNITION SYSTEMEC620000IGNITION SYSTEMINSPECTION STEPSUse the following steps for checking the possibility of the malfunctioning engine be

6 - 3– +ELECIGNITION SYSTEMEC622001SPARK GAP TEST1. Disconnect the spark plug cap from sparkplug.2. Connect the dynamic spark tester 1(ignition checke

6 - 4– +ELECIGNITION SYSTEMEC626002IGNITION COIL INSPECTION1. Inspect:● Primary coil resistanceOut of specification → Replace.Tester (+) lead → Orange

6 - 5– +ELECIGNITION SYSTEM2. Inspect:● Source coil resistanceOut of specification → Replace.Tester (+) lead → Brown lead 1 Tester (–) lead → Green le

– +ELEC6 - 6CARBURETOR HEATING SYSTEMCARBURETOR HEATING SYSTEMINSPECTION STEPSUse the following steps for checking the possibility of the malfunctioni

6 - 7– +ELECCARBURETOR HEATING SYSTEMEC624000COUPLERS AND LEADS CONNECTION INSPECTION1. Check:● Couplers and leads connectionRust/dust/looseness/short

INDEXGENERAL INFORMATION1 SPECIFICATIONSSPEC2 REGULAR INSPECTION AND ADJUSTMENTS3 ENGINEENG4 CHASSISCHAS5 ELECTRICALELEC6 GENINFOINSPADJ– +

6 - 8– +ELECCARBURETOR HEATING SYSTEMÅ The thermo switch circuit is open.ı The thermo switch circuit is closed.Test step Water temperature Continuity1

– +ELEC6 - 9NOISE REGULATION/MAINTENANCE RECORDNOISE REGULATIONTAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED:Federal law prohibits the following acts

PRINTED IN JAPAN2002.04-3.0×1 CR(E)PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO., LTD.2500 SHINGAI IWATA SHIZUOKA JAPAN

CONTENTSCHAPTER 1GENERAL INFORMATIONDESCRIPTION ... 1-1MACHINE IDENTIFICATION ... 1-2IMPORTA

CHAPTER 4ENGINECARBURETOR ... 4-1CYLINDER HEAD ... 4-8CAMSHAFT AND ROCKER AR

1 - 1GENINFODESCRIPTIONEC100000GENERAL INFORMATIONEC110000DESCRIPTION1 “ENGINE STOP” button2 Front brake lever3 Throttle grip4 Fuel tank cap5 Kick sta

1 - 2GENINFOMACHINE IDENTIFICATIONEC120001MACHINE IDENTIFICATIONThere are two significant reasons for knowingthe serial number of your machine:1. When

1 - 3GENINFOIMPORTANT INFORMATIONEC130000IMPORTANT INFORMATIONEC131002PREPARATION FOR REMOVAL AND DISASSEMBLY1. Remove all dirt, mud, dust, and foreig

1 - 4GENINFOIMPORTANT INFORMATIONEC132000ALL REPLACEMENT PARTS1. We recommend to use Yamaha genuineparts for all replacements. Use oil and/orgrease re

1 - 5GENINFOIMPORTANT INFORMATION/CHECKING OF CONNECTIONEC136000CIRCLIPS1. All circlips should be inspected carefullybefore reassembly. Always replace

1 - 6GENINFOSPECIAL TOOLSSPECIAL TOOLSThe proper special tools are necessary for complete and accurate tune-up and assembly. Using thecorrect special

1 - 7GENINFOSPECIAL TOOLSYM-1312-A, 90890-01312 Fuel level gaugeThis gauge is used to measure the fuel level in the float chamber.YM-1312-A 90890-0131

1 - 8GENINFOSPECIAL TOOLSYU-33270-B, 90890-01362 Flywheel pullerThis tool is used to remove the rotor.YU-33270-B 90890-01362ACC-QUICK-GS-KT90890-85505

1 - 9GENINFOCONTROL FUNCTIONSEC150000CONTROL FUNCTIONS“ENGINE STOP” SWITCHMake sure that the engine stop switch 1 ispositioned to “”. The engine stop

1 - 10GENINFOCONTROL FUNCTIONSEC156000FRONT BRAKE LEVERThe front brake lever 1 is located on the righthandlebar. Pull it toward the handlebar to acti-

1 - 11GENINFOCONTROL FUNCTIONS/FUELFUEL TANK CAPRemove the fuel tank cap 1 by turningcounter-clockwise.WARNINGDo not overfill the fuel tank. Avoid spi

1 - 12GENINFOSTARTING AND OPERATIONSTARTING AND OPERATIONCAUTION:Prior to operating the machine, performsteps listed in pre-operation check list.WARNI

SPEC2 - 1EC200000SPECIFICATIONSEC211000GENERAL SPECIFICATIONSModel name: TT-R90R (USA, CDN, AUS, NZ)TT-R90 (Europe, ZA)Model code number: 5HNB (USA)5H

SPEC2 - 2Oil capacity:Engine oilPeriodic oil change 0.8 L (0.70 Imp qt, 0.85 US qt)Total amount 1.0 L (0.88 Imp qt, 1.06 US qt)Air filter: Wet type ele

EC010000 TT-R90ROWNER’S SERVICE MANUAL©2002 by Yamaha Motor Corporation, U.S.A.1st Edition, April 2002All rights reserved. Any reprinting orunauthori

SPEC2 - 3Brake:Front brake type Drum brakeOperation Right hand operationRear brake type Drum brakeOperation Right foot operationSuspension:Front suspe

SPEC2 - 4MAINTENANCE SPECIFICATIONSENGINEItem Standard LimitCylinder head:Warp limit ---- 0.03 mm (0.0012 in)Cylinder:Bore size 47.000 ~ 47.005 mm(1.8

SPEC2 - 5Cam chain:Cam chain type/No. of links 92RH2005-84M/84 ----Cam chain adjustment method Automatic ----Rocker arm/rocker arm shaft:Shaft outside

SPEC2 - 6Stem runout limit ---- 0.02 mm(0.0008 in)Valve seat width IN 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in)1.6 mm(0.0630 in)EX 0.9 ~ 1.1 mm (0.0354 ~ 0.04

SPEC2 - 7Piston:Piston to cylinder clearance 0.025 ~ 0.045 mm(0.0010 ~ 0.0018 in)0.15 mm(0.0059 in)Piston size “D” 46.960 ~ 46.975 mm(1.8488 ~ 1.8494

SPEC2 - 8Crankshaft:Crank width “A” 42.95 ~ 43.00 mm(1.691 ~ 1.693 in)----Runout limit C ---- 0.03 mm (0.0012 in)Big end side clearance “D” 0.10 ~ 0.4

SPEC2 - 9Lubrication system:Oil filter type Wire mesh type ----Oil pump type Trochoid type ----Tip clearance “A” or “B” 0.15 mm(0.0059 in)0.2 mm (0.007

SPEC2 - 10Part to be tightened Thread size Q’tyTightening torqueNm m•kg ft•lbCylinder head nut M8 × 1.25 4 22 2.2 16Cylinder head bolt M6 × 1.0 2 10 1

SPEC2 - 11CHASSISItem Standard LimitSteering system:Steering bearing type Angular bearing ----Front suspension:Front fork travel 110 mm (4.33 in) ----

SPEC2 - 12Drum brake:Front drum brake type Leading, trailing ----Rear drum brake type Leading, trailing ----Front drum inside diameter 95 mm (3.74 in)

INTRODUCTION Congratulations on your purchase of aYamaha TT-R90R. This model is the culmina-tion of Yamaha’s vast experience in the pro-duction of pa

SPEC2 - 13NOTE:● 1. First, tighten the ring nut approximately 38 Nm (3.8 m • kg, 27 ft • lb) by using the ring nutwrench and turn the steering right a

SPEC2 - 14EC212300ELECTRICALItem Standard LimitCDI:Magneto-model/manufacturer F5HN 00/YAMAHA ----Source coil resistance (color) 688 ~ 1,032 Ω at 20 ˚C

2 - 15SPECGENERAL TORQUE SPECIFICATIONS/DEFINITION OF UNITSEC220001GENERAL TORQUE SPECIFICATIONSThis chart specifies torque for standard fasten-ers wi

2 - 16SPECCABLE ROUTING DIAGRAMCABLE ROUTING DIAGRAM1 Crankcase breather hose2 Wire harness3 CDI magneto lead4 Starter cable5 Carburetor heating lead6

2 - 17SPECCABLE ROUTING DIAGRAM1 Cable guide2 Brake cable3 Throttle cable4 Fuel tank breather hose5 Engine stop switch lead6 Air vent hose7 Air intake

2 - 18SPECCABLE ROUTING DIAGRAMÅ Pass the fuel tank breather hose through thecable guide.ı Pass the throttle cable and engine stop switchlead through

3 - 1INSPADJMAINTENANCE INTERVALS/PERIODIC MAINTENANCE AND LUBRICATIONEC300000REGULAR INSPECTION AND ADJUSTMENTSMAINTENANCE INTERVALSThe following sch

3 - 2INSPADJPRE-OPERATION INSPECTION AND MAINTENANCE*: Since these items requires special tools data and technical skills, they should be serviced.*1:

3 - 3INSPADJENGINE/THROTTLE CABLE ADJUSTMENT/AIR FILTER CLEANINGEC350000ENGINETHROTTLE CABLE ADJUSTMENT1. Check:● Throttle grip free play a Out of spe

3 - 4INSPADJAIR FILTER CLEANING1. Install:● Air scoop (right) 1 2. Install:● Air filter case cover 1 3. Clean:● Air filter elementClean them with solv

3 - 5INSPADJENGINE OIL LEVEL INSPECTION1. Start the engine, warm it up for severalminutes and wait for five minutes.2. Place the machine on a level pl

3 - 6INSPADJENGINE OIL REPLACEMENT(Except for USA and CDN)CAUTION:● Do not add any chemical additives or useoils with a grade of CD a or higher.● Do n

3 - 7INSPADJPILOT AIR SCREW ADJUSTMENT5. Install:● Gasket● Drain boltNewT R..20 Nm (2.0 m · kg, 14 ft · lb)6. Fill:● CrankcaseOil quantity:Periodic oi

3 - 8INSPADJIDLE SPEED ADJUSTMENT/VALVE CLEARANCE ADJUSTMENTIDLE SPEED ADJUSTMENT1. Start the engine and thoroughly warm itup.2. Attach:● Inductive ta

3 - 9INSPADJVALVE CLEARANCE ADJUSTMENT4. Check:● Valve clearanceOut of specification → Adjust. 5. Adjust:● Valve clearanceValve clearance (cold):Intak

3 - 10INSPADJSPARK ARRESTER CLEANING (For USA)6. Install:● Tappet cover (intake side) 1 ● O-ring 2NOTE:Apply the lithium soap base grease on the O-rin

3 - 11INSPADJCHASSIS/FRONT BRAKE ADJUSTMENT/REAR BRAKE ADJUSTMENTCHASSISFRONT BRAKE ADJUSTMENT1. Check:● Brake lever free play a Out of specification

3 - 12INSPADJDRIVE CHAIN SLACK ADJUSTMENTDRIVE CHAIN SLACK ADJUSTMENT1. Elevate the rear wheel by placing thesuitable stand under the engine.2. Check:

3 - 13INSPADJFRONT FORK INSPECTION/REAR SHOCK ABSORBER INSPECTION/REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT● Tighten the wheel axle nut while push

3 - 14INSPADJ4. To stiffen the spring preload, install thecirclip 1 into the groove a. To soften thespring preload, install the circlip into thegroove

IMPORTANT NOTICE This machine is designed for off-road use onlyby young operators under adult instruction andsupervision. It is illegal for this mach

3 - 15INSPADJSPOKES INSPECTION AND TIGHTENING/WHEEL INSPECTION/STEERING HEAD INSPECTION AND ADJUSTMENTSPOKES INSPECTION AND TIGHTENING1. Inspect:● Spo

3 - 16INSPADJSTEERING HEAD INSPECTION AND ADJUSTMENT3. Check:● Steering smooth actionTurn the handlebar lock to lock.Unsmooth action → Adjust steering

3 - 17INSPADJSTEERING HEAD INSPECTION AND ADJUSTMENTCAUTION:Install the handlebar holder with itsgroove a facing outward, and tightenthe bolts so tha

3 - 18INSPADJLUBRICATIONLUBRICATIONTo ensure smooth operation of all compo-nents, lubricate your machine during setup,after break-in, and after every

3 - 19INSPADJELECTRICAL/SPARK PLUG INSPECTIONEC370000ELECTRICALEC371001SPARK PLUG INSPECTION1. Remove:● Spark plug2. Inspect:● Electrode 1 Wear/damage

4 - 1ENG ENGINE CARBURETOR Extent of removal: 1 Carburetor removalExtent of removal Order Part name Q’ty Remarks CARBURETOR REMOVAL Preparation for

4 - 2ENG CARBURETOR EC468000 CARBURETOR DISASSEMBLY Extent of removal: 1 Carburetor disassemblyExtent of removal Order Part name Q’ty Remarks CARBUR

4 - 3ENG CARBURETOR Extent of removal Order Part name Q’ty Remarks A Float pin 1 B Float 1 C Needle valve 1 D Main jet 1 E Pilot jet 1 F Needle jet 1

4 - 4ENG CARBURETOR EC464000 INSPECTIONCarburetor 1. Inspect: ● Carburetor bodyContamination → Clean.NOTE: ● Use a petroleum based solvent for clea

4 - 5ENG CARBURETOR EC464401 Jet needle 1. Inspect: ● Jet needle 1 Bends/wear → Replace.● Clip grooveFree play exists/wear → Replace.● Clip posit

4. When transporting the machine inanother vehicle, be sure is keptupright and that the fuel cock isturned to the “OFF”. If it should leanover, gasol

4 - 6ENGCARBURETOREC464600Float1. Inspect:● Float 1 Damage → Replace.ASSEMBLY AND INSTALLATIONCarburetor1. Install:● Pilot air screw 1 Note the follow

4 - 7ENGCARBURETOR1. Measure:● Fuel level a Use a fuel level gauge 1.Out of specification → Adjust.Fuel level gauge:YM-1312-A/90890-01312Fuel level:2

4 - 8ENGCYLINDER HEADCYLINDER HEADExtent of removal: 1 Cylinder head removalExtent of removal Order Part name Q’ty RemarksCYLINDER HEAD REMOVAL Prepar

4 - 9ENGCYLINDER HEADExtent of removal Order Part name Q’ty Remarks10 Camshaft sprocket 1Refer to “REMOVAL POINTS”.11 Timing chain 112 Cylinder head 1

4 - 10ENGCYLINDER HEADREMOVAL POINTSCylinder head1. Align:● “I” mark(with stationary pointer)Checking steps:● Turn the crankshaft counterclockwise wit

4 - 11ENGCYLINDER HEAD4. Remove:● Cylinder headNOTE:● Loosen the bolts and nuts in their properloosening sequence.● Start by loosening each bolt and n

4 - 12ENGCYLINDER HEADCAUTION:.Do not turn the crankshaft during instal-lation of the camshaft. Damage orimproper valve timing will result.● Remove th

4 - 13ENGCAMSHAFT AND ROCKER ARMSCAMSHAFT AND ROCKER ARMSExtent of removal: 1 Rocker arm 2 Camshaft removalExtent of removal Order Part name Q’ty Rema

4 - 14ENGCAMSHAFT AND ROCKER ARMSREMOVAL POINTSRocker arm shaft1. Remove:● Rocker arm shaftsNOTE:Use a slide hammer bolt 1 and weight 2 toslide out th

4 - 15ENGCAMSHAFT AND ROCKER ARMS3. Apply:● Molybdenum disulfide oil(onto the rocker arm and rocker armshaft)4. Install:● Rocker arm 1 ● Rocker arm sh

SAFETY INFORMATION 1. Don’t ride it on the street. 2. Don’t run the engine inside a building. 3. This is a one-seater motorbike. Don’t giveany person

4 - 16ENGVALVES AND VALVE SPRINGSVALVES AND VALVE SPRINGSExtent of removal: 1 Valves removalExtent of removal Order Part name Q’ty RemarksVALVES AND V

4 - 17ENGVALVES AND VALVE SPRINGSREMOVAL POINTSValve removal1. Remove:● Valve cotters 1 NOTE:Attach a valve spring compressor 2 betweenthe valve sprin

4 - 18ENGVALVES AND VALVE SPRINGSValve spring1. Measure:● Valve spring free length a Out of specification → Replace.2. Measure:● Spring tilt a Out of

4 - 19ENGVALVES AND VALVE SPRINGS2. Lap:● Valve face● Valve seatNOTE:After refacing the valve seat or replacing thevalve and valve guide, the valve se

4 - 20ENGVALVES AND VALVE SPRINGSASSEMBLY AND INSTALLATION1. Apply:● Molybdenum disulfide oil(onto the valve stem and valve stemseal)2. Install:● Valv

4 - 21ENGCYLINDER AND PISTONCYLINDER AND PISTONExtent of removal: 1 Cylinder removal 2 Piston removalExtent of removal Order Part name Q’ty RemarksCYL

4 - 22ENGCYLINDER AND PISTONREMOVAL POINTSPiston1. Remove:● Piston pin clips 1 ● Piston pin 2 ● Piston 3 NOTE:● Before removing the piston pin clip, c

4 - 23ENGCYLINDER AND PISTONCylinder bore “C”47.000 ~ 47.005 mm(1.8504 ~ 1.8506 in)Taper limit “T” 0.05 mm (0.002 in)Out of round “R” 0.05 mm (0.002 i

4 - 24ENGCYLINDER AND PISTONPiston ring1. Measure:● Ring side clearanceUse a feeler gauge. Out of specification → Replace the pis-ton and rings as a s

4 - 25ENGCYLINDER AND PISTONPiston pin1. Inspect:● Piston pinBlue discoloration/grooves → Replace, then inspect the lubricationsystem.2. Measure:● Pis

6. When going for riding, be sure to be withyour family.Never go alone. 7. Before riding the machine, ask your par-ents to check the machine very car

4 - 26ENGCYLINDER AND PISTON2. Position:● Top ring● 2nd ring● Oil ringOffset the piston ring end gaps asshown.a Top ring endb Oil ring end (lower)c Oi

4 - 27ENGCLUTCHCLUTCHCRANKCASE COVER (LEFT AND RIGHT)Extent of removal: 1 Crankcase cover (left) removal 2 Crankcase cover (right) removalExtent of re

4 - 28ENGCLUTCHCLUTCHExtent of removal: 1 Friction plate and clutch plate removal 2 Clutch housing removal3 Primary clutch removalExtent of removal Or

4 - 29ENGCLUTCHExtent of removal Order Part name Q’ty Remarks13 Spacer 114 Spacer 115 Primary clutch nut 1 Use special tool. Refer to “REMOVAL POINTS”

4 - 30ENGCLUTCHREMOVAL POINTSClutch boss1. Remove:● Clutch boss nut 1 ● Lock washer 2 ● Clutch boss NOTE:Straighten the lock washer tab and use theclu

4 - 31ENGCLUTCHEC484600Clutch plate1. Measure:● Clutch plate warpageOut of specification → Replace clutchplate as a set.Use a surface plate 1 and thic

4 - 32ENGCLUTCHASSEMBLY AND INSTALLATIONPrimary clutch1. Install:● Washer 1 ● Nut (primary clutch) 2 NOTE:Tighten the nut while holding the magnetorot

4 - 33ENGKICK AXLEKICK AXLEExtent of removal: 1 Kick axle removal 2 Kick axle disassemblyExtent of removal Order Part name Q’ty RemarksKICK AXLE REMOV

4 - 34ENGSHIFT SHAFTSHIFT SHAFTExtent of removal: 1 Shift shaft removalExtent of removal Order Part name Q’ty RemarksSHIFT SHAFT REMOVAL Preparation f

4 - 35ENGSHIFT SHAFTExtent of removal Order Part name Q’ty Remarks14 Stopper lever 115 Torsion spring 116 Circlip 117 Plate washer 118 Torsion spring