Steering head adjustment
1. Raise the front end of the motorcycle so that there is no weight on the front wheel.
WARNING: Securely support the motorcycle so there is no danger of it falling over.
2. Grasp the bottom of the forks and gently rock the fork assembly backward and forward, checking for looseness in the steering assembly bearings.
TRANSMISSION
3. Crankcase assembly a. Apply Yamaha bond #4 sealant or equivalent to the crankcase mating surface. Be very careful not to allow any sealant to come in contact with the oil gallery "O-ring" and crankshaft bearings. It is extremely important, however, that sealant be applied around the case stud holes. Apply sealant to within 2 — 3 mm (0.08 — 0.12 in) of the bearings.
Engine oil level measurement
1. Place the motorcycle on its centerstand. Warm up the engine for several minutes.
NOTE:
Be sure the motorcycle is positioned straight up when checking the oil level; a slight tilt toward the side can produce false readings.
ELECTRICAL
Battery
1. The fluid level should be between the upper and lower level marks. Use only distillod water if refilling is necessary.
CAUTION: Normal tap water contains minerals which are harmful to a battery; therefore, refill only with distilled water.
11. Pistons and cylinder
a. Install the pistons on the rods. The arrow on the piston must point to the front of the engine.
NOTE: Before installing the piston pin clips, cover the crankcase with a clean rag so you will not accidentally drop the circlip into the crank-case. Always install new piston pin circlips.
Final gear removal
1. Remove the rear axle and left shock absorber. Remove the rear wheel (see "REAR WHEEL" section in this chapter).
2. Remove the 4 nuts holding the final drive unit to the swing arm.
3. Remove the final gear assembly.
Piston and piston rings
1. Piston
a. Measure the outside diameter of the piston at the piston skirt. Measurement should be made at a point 7.8 mm (0.307 in) above the bottom edge of the piston. Place the micrometer at right angles to the piston pin.
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Size |
Removal
1. Remove the rear wheel.
2. Remove the final gear case assembly.
3. Remove the drive shaft.
Front brake adjustment
The brake can be adjusted by simply adjusting the free play of the brake lever. The piston in the caliper moves forward as the brake pad wears out, automatically adjusting the clearance between the brake pads and brake disc.
CAUTION: Proper lever free play is essential to avoid excessive brake drag.
Middle gear
1. Damper disassembly
NOTE: Disassembly of the middle gear damper requires the damper compressor (special tool) and a hydraulic press.
a. Place the middle drive shaft in a press with the damper compressor (special tool) in place as shown.
