I

-
NOTICE
This manual was written by the Yamaha Motor Company primarily for use by Yamaha dealers
- and their qualified mechanics. It is not possible to put an entire mechanic’s education into one
manual, so it is assumed that persons using this book to perform maintenance and repairs on
Yamaha motorrepair technology. Without such knowledge, attempted repairs or service to this
model may render it unfit to use and/or unsafe.
-

Yamaha Motor Company, Ltd. is continually striving to improve all models manufactured by
- Yamaha. Modifications and significant changes in specifications or procedures will be forwarded
to all Authorized Yamaha dealers and will, where applicable, appear in future editions of this
manual.
TECHNICAL PUBLICATIONS
SERVICE DIVISION
MOTORCYCLE OPERATIONS
YAMAHA MOTOR CO., LTD

HOW TO USE THIS MANUAL

PARTICULARLY IMPORTANT INFORMATION
This material is distinguished by the following notation.

NOTE: A NOTE provides key information to make procedures easier or clearer

CAU~fON: A CAUTION indicates special procedures that must be followed to avoid

damage to the motorcycle.

A WARNING indicates special procedures that must be followed to avoid injury

to a motorcycle operator or person inspecting or repairing the motorcycle.

MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The
information has been compiled to provide the mechanic with an easy to read, handy reference
that contains comprehensive explanations of all disassembly, repair, assembly, and inspection
operations. In this revised format, the condition of a faulty component will precede an arrow
symbol and the course of action required will follow the symbol, e.g.,
*Bearings
Pitting/Damage - Replace.
-
EXPLODED DIAGRAM
Each chapter provides exploded diagrams before each disassembly section for ease in identifying
correct disassembly and assembly procedures.
 --
I
I

ILLUSTRATED SYMBOLS
(Refer to the illustration)

Illustrated symbols @ to @I are designed as

thumb tabs to indicate the chapter’s number
and content.

@General information
@Periodic inspection and adjustment
@ Engine
@Cooling system
@ Carburetion
@Chassis
0 Electrical
@J Appendices

Illustrated symbols @ to @I are used to

identify the specifications appearing.

0m @Filling fluid
@Lubricant
@Tightening
@Wear limit, clearance
@Engine speed
@Cl, V. A

Illustrated symbols @ to @J i n t h e e x -
ploded diagram indicate grade of lubricant
and location of lubrication point.

N&pp;y engine oil

hApply gear oil
pp y molybdenum disulfide oil
@Apply wheel bearing grease
@Apply lightweight lithium-soap base grease
@I Apply molybdenum disulfide grease
@I Apply locking agent (LOCTITE @)
-
INDEX
GENERAL INFORMATION
-

PERIODIC INSPECTIONS
AND ADJUSTMENTS
-

- ENGINE OVERHAUL

- CARBURETION

1 CHASSIS
\
-
uii
ELECTRICAL
-
-
APPENDICES
-
-
CHAPTER 1. .’

GENERAL INFORMATION
- MOTORCYCLE IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-1
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . 1-l
ENGINE SERIAL NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-l

IMPORTANT IN FORMATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-2

ALL REPLACEMENT PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-2
- GASKET, OIL SEALS, AND O-RINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . l-2
LOCK WASHERS/PLATES AND COTTER PINS. . . . . . . . . . . . . . . . . . . . l-2
BEARINGS AND OIL SEALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-2
- CIRCLIPS..................................................l- 3

SPEClALTOOLS...............................................l- 3
FOR TUNE UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-3
FOR ENGINE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-4
FOR CHASSIS SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-7
FOR ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l-8

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-
f-mmq MOTORCYCLE IDENTIFICATION

GENERAL -
INFORMATION
MOTORCYCLE IDENTIFICATION
VEHICLE IDENTIFICATION NUMBER
The vehicle identification number @ is stemped
into the right side of the steering head.

NOTE:
The vehicle identification number is used to
identify your motorcycle and may be used to
register your motorcycle with the licensing
authority in your state.

I SRX6OOS
Starting Serial Number:
. . . . . .JYA2EHOO +? GA000101 I

ENGINE SERIAL NUMBER

The engine serial number @ is stamped into the
right side of the engine.

The first three digits of these numbers are for

model identifications; the remaining digits are
the unit production number.

I Starting Serial Number:

SRXGOOS . . . . . . . .2EH-000101 I

NOTE:
Designs and specifications are subject to change
without notice.

l-l
 IMPORTANT lNFORMATl6N
-

IMPORTANT INFORMATION
ALL REPLACEMENT PARTS
1. We recommend to use Yamaha genuine
parts for all replacements. Use oil and/or
grease recommended by Yamaha for as-
senmbly and adjustment.

GASKETS, OIL SEALS, AND O-RINGS

1. All gaskets, seals, and O-rings should be
replaced when an engine is overhauled.
All gasket surfaces, oil seal lips, and O-
rings must be cleaned.
2. Properly oil all mating parts and bearings
during reassembly. Apply grease to the
oil seal lips.

LOCK WASHERS/PLATES AND COT-

TER PINS
1. All lock washers/plates (iJ and cotter pins
must be replaced when they are removed.
Lock tab(s) should be bent along the bolt
or nut flat(s) after the bolt or nut has been
properly tightened.

BEARINGS AND OIL SEALS

1. Install the bearing(s) @ and oil seal(s)
0 with their manufacture’s marks or
numbers facing outward. (In other words,
the stamped letters must be on the side
exposed to view.) When installing oil
seal(s), apply a light coating of
light-weight lithium base grease to the
seal lip(s). Oil the bearings liberally when
installing.

Do not use compressed air to spin the

bearings dry. This causes damage to the
bearinn surfaces.

1-2
 -
-1
S P E C I A L T O O L S
CIRCLIPS
1. All circlips should be inspected carefully -
before reassembly. Always replace piston
pin clips after one use. Replace distorted
circlips. When installing a circlip 0, make
sure that the sharp-edged corner @ is
positioned opposite to the thrust @I it
receives. See the sectional view.

@Shaft

SPECIAL TOOLS
The proper special tools are necessary for
complete and accurate tune-up and assembly.
Using the correct special tool will help prevent
damage caused by the use of improper tools
or improvised techniques.

FOR TUNE UP
1. Inductive Tachometer
P/N Y U-08036
This tool is needed for detecting engine rpm.

2. Inductive Timing Light

P/N YM-33277
This tool is necessary for checking ignition
timing.

3. Compression Gauge
P/N Y U-33223
This gauge is used to measure the engine com-
pression.

l-3
-
SPECIAL TOOLS pmq
4. Fuel Level Gauge
P/N YM-01312-A
This gauge is used to measure the fuel level in
the float chamber.

FOR ENGINE SERVICE

1. Universal Clutch Holder
P/N YM-91042
This tool is used to hold the clutch when re-
moving or installing the clutch boss locknut.

2. Valve Adjusting Tool

P/N Y M-08035
This tool is necessary for adjusting the valve
clearance.

3. Valve Spring Compressor

P/N YM-01253
This tool is needed to remove and install the
valve assemblies.

4. Valve Guide Remover (7.0 mm)

P/N YM-01225
- This tool is used to remove the valve guides.

l-4
L
w
S P E C[
I A L T O O L S
5. Valve Guide Reamer (7.0 mm)
P/N YM-01227
This tool is used to rebore the new valve guide.
-

6. Valve Guide installer

P/N YM-04017
This tool is needed to install the valve guides

I
properly.

\c9
\\’
%
7. Valve Seat Cutter Set
P/N YM-91043
This tool is needed to resurface the valve seat.

1 8. Piston Pin Puller

P/N YU-01304
This tool is used to remove the piston pin.

9. Flywheel Puller Set

P/N Y U-33270
This tool is used to remove the CDI rotor.
-
SPECIAL TOOLS m
10. Slide Hammer Set
- P/N Y U-01 083
These tools are used to remove the rocker arm
and rocker arm shaft.
-

- 11. Sheave Holder

P/N YS-01880
This tool is removing to hold the rotor when
-
removing or installing the rotor securing nut.

12. Crankcase Separating Tool

P/N YU-01135
-
This tool is necessary to separate the crankcase.

- 13. Crankshaft Installing Set

P/N Y U-90050
These tools are used to install the crankshaft.
-

-
14. Adapter #lO (Ml41
P/N YM-90069
- This tool is used to install the crankshaft.

1-6
-
w SPECIAL TOOLS
15. Crank Pot Spacer
P/N YM-91044
This tool is used to install the crankshaft.

16. Plastigage@ Set “Green”

P/N Y U-3321 0
This gauge is needed to measure the clearance
for the connecting rod bearing.

17. Sealant (Quick Gasket@)

P/N ACC-11001-05-01
This sealant (bond) is used for crankcase mating
surfaces, etc.

FOR CHASSIS SERVICE

1. T-Handle
P/N YM-01326 - @
Damper Rod Holder (22 mm)
P/N YM-33298 - @
These tools are used to loosen and tighten the
front fork cylinder holding bolt.

2. Front Fork Cap Socket (17 mm)

P/N YM-01104
This tool is needed when loosening and tighten-
ing the front fork cap bolt.

1-7
- SPECIAL TOOLS
3. Front Fork Seal Driver (Weight)
P/N YM-33963 - @)
Adapter (36 mm)
P/N YM-08010 - @
These tools are used when installing the fork
seal.

4. Ring Nut Wrench

P/N YU-01268
This tool is used to loosen and tighten the steer-
ing ring nut.

FOR ELECTRICAL COMPONENTS

1. Electra Tester
- P/N YU-33260 - 0
This instrument is necessary for checking the
ignition system components.
- 2. Pocket Tester
P/N YU-33263 - @ or Y U-031 12 - @
This instrument is invaluable for checking the
electrical system.

l-8