1. Ausgabe, August 1984 Alle Rechte vorbehalten. Nachdruck,
auch auszugsweise, oder nicht autorisierte Verwendung ist ohne
schriftliche Genehmigung der Yamaha Motor Co., Ltd. nicht gestattet.
Gedruckt in Japan
Y AMAHA SPECIAL TOOLS © 1984 de Yamaha Mo tor Co., Ltd.
1 a. ediciôn, Agosto 1984 Todos los derechos reservados. Se prohibe la reimpresi6n o uso de este material sin
la sutorizaci6n escrita de Yamaha Motor Co., Ltd.
Impreso en Japon
YAMAHA EINLEITUNG
Wir danken lhnen für lhre Bemühungen auf dem Gebiet des Yamaha Kundendienstes und mëchten lhnen hiermit eine Spezialwerkzeug­ Anleitung anbieten.
Spezialwerkzeuge sind für nicht zugangliche Teile bzw. dann erforderlich, wenn bei Ver­ wendung ungeeigneter Werkzeuge andere Teile beschadigt oder extrem lange Arbeitszeiten erforderlich werden. Diese Spezialwerkzeuge sind unentbehrlich für richtigen, effektiven und raschen Kundendienst.
Wir sind davon überzeugt, da~ diese Anleitung ein positiver Beitrag zu 1 hren Kundendienst­ tatigkeiten sein wird.
SPECIAL TOOLS
INTRODUCCION
En agradecinùento al esfuerzo por usted demostrado en las operaciones de servicio técnico Yamaha para sus clientes, nos place ofrecerle un manual de herramientas especiales.
Las herramientas especiales permiten acceso a areas que de otro modo no podrian ser alcanzadas, o podrian ser dafiadas o demandrian un trabajo de mucho tiempo. Las herramientas especiales son indispensables para un servicio técnico apropiado, correcto, efectivo y veloz.
Esperamos sinceramente que este manual sea de utilidad a las operaciones de servicio técnico que usted desarrolla.
YAMAHA FORMAT DIESER ANLEITUNG Diese Anleitung besteht aus den drei folgenden Abschnitten. Jeder Abschnitt wird jahrlich mit lnformationen über neue Modelle und Spezi alwerkzeuge erganzt.
Sie werden die Seiten mit diesen zusatzlichen 1 nformàtionen rechtzeitig erhalten und wer­ den gebeten, diese an richtiger Stelle in lhren Ordner einzulegen.
D ANWENDUNG "MOTORRADWERK- ZEUGE"
Dieser Abschnitt enthalt eine Liste der Spezialwerkzeuge, die für die einzelnen Modelle erforderlich sind.
fl LISTE DER SPEZIALWERKZEUGE
Dieser Abschnitt enthalt die Spezial­ werkzeuge in der numerischen Reihen­ folge gemeinsam mit Abbildungen über deren Anwendung.
D SPEZIALWERKZEUG- UND ALLGE­ MEINER WERKZEUGSATZ
ln diesem Abschnitt werden die Zwei- takt-Spezialwerkzeugsatze MBchanismensi:itze vorgestellt.
und die
SPECIAL TOOLS
FORMATO DELMANUAL
El manual consiste de las tres secciones siguientes. Cada secci6n sera actualizada anualmente con la informaci6n concerniente a nuevos modelas y herramientas especiales.
Usted recibira paginas adicionales conteniendo tal informaciôn, de manera que tiene que insertarlas en la parte requerida de su carpeta.
D APLICACIONES "HERRAMIENT AS DE MOTOCICLETAS"
Esta secciôn esp ecifica en una lista las herramientas especiales requeridas para los modelas individuales.
fl LISTA DE HERRAMIENTAS ES­ PECIALES
Esta secciôn contiene cada una de l'as herrarnientas especiales ordenadas numericarnente e ilustra su utilizaci6n.
JUEGOS DE HERRAMIENTAS ES- PECIALES GENERALES
y HERRAMIENT AS
Esta secciôn introduce las herrarnientas especiales para motores de 2 tiempos y los juegos de herrarnientas generales.
APPLICATIONS ttMOTORCYCLE TOOLS''
4-STROKE 2-CYLINDER ID 4-STROIΠ3-CYLINDER a
.. 4-STROKE 4-CYLINDER
ENGJNE TYPE: 2-Stroke 1-Cylinder
TOOL~ LB 50 LB 50 LB 50 NO. {YEAR) -l.BSO LBSO LBSO
Ha nd- Auto· Centri- elu teh clutch ffugal
90890- TOOL NAME elu teh
01023 Clutch helder
01052 Meter gear bush tool 0 0 0 01111 Armature puller
01135 Crankcase separating tool 0 0 0
01183 Piston pin/Rotary valve pin puller 0 0 0
01189 Magnet puller 0 0 0 01235 Rotor holding tool 0 0 0 01268 Ring nut wrench ·O 0 0
01274 Crank installer pot 0 0 0
01275 Crank installer boit 0 0 0
01276 Adapter (7 mm)
01290 Armature shock puller
03109 Timing light 0 0 0
03112 Poe ket tester 0 0 0
03113 Engine tachometer 0 0 0
04086 Clutch holding tool 0
YB 50 YB100 YBSO YB125
DX100 L2
0 0
E: Electric starter mode! F: Flywheel magneto mode! R: Rotary valve mode! "'-: '75 & '76 mode! 0 : '77 & '78 mode! ou: Outer rotor mode!
RX100 RS100 V 50 RX115 RS125 V80 RX135 Y80
0 0 0
90890- TOOL
01135 Crankcase separating tool 0 0 01189 Magneto puffer 0 0 01235 Rotor holding tool 0 0 01252 Dial gauge & Stand set
01256 Dial gauge & Stand No. 2
01268 Ring nut wrench 0 0 01274 Crank installer pot 0 0 01275 Crank installer boit 0 0 01278 Adaptor (12 mm) 0 0 01294 Holder 1
N 01304 Piston pin puffer set 0 0 01305 Crankcase separator boit (6 mm) 0 01306 Hex. wrench (25 mm)
01307 Hex. wrench (22 mm) 0 01326 T -handle
01334 Chain cutter guide
01337 Clutch spring compressor 0 01347 Clutch holder 0 - 01348 Locknut wrench 0 01701 Sheave holder 0 03019 Magnetic base 0 03021 Electro tester 0 0 03079 Thickness gauge 0 0 03090 AC regulator chee ker
03097 Dial gauge 0 03108 Timing tester
-
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
0 0 0
E: Electric starter mode! F: Flywheel magneto mode! R: Rotary valve mode! 6..: '75 & '76 mode! ® : '77 & '78 mode! ou: Outer rotor mode!
S50II CE 50 RX80 GT80
0 0 0 0 0 0 0 0 0 0 0 0
0 0
0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0
0 i
90890- -
S50 SA 50 MA 50
E: Electric starter madel F: Flywheel magneto madel R: Rotary valve madel .6.: '75 & '76 madel @: '77 & '78 madel ou: Outer rotor madel
S50II CE 50 RX80 GT80
0
01111 Armatuer pull er
01135 Crankcase separating tool
01184 Fork 'eal driver weight
01185 Attachment
01186 Attachment
01235 Rotor holding tool
01252 Dialgauge & Stand set
01268 Ring nut wrench
01273 Oil seal attachment
01274 Crank installer pot
01275 Crank installer boit
01276 Adaptor (7 mm)
01278 Adaptor (12 mm)
01291 Weight
01326 T-Handle
01369 Fork seal drive attachment (33 mm)
03021 Electro tester
Air- cooled cooled
0 0 0
Q9
E
---
E: Electric starter madel F: Flywheel magneto mode! R: Rotary valve model l:l: '75 & '76 mocfel 0: '77 & '78 mocfel ou: Outer rotor mocfel
DT 50 DT50/80 RD125 RD125 TY250 DT80 RD50/80 Air- RZ125 Air- Liquid- cooled Liquid-
cooled cooled cooled (~'83) ('84 ~)
0
0
0
0
0 0 0 0
0 0 0 0 0 0 0 0 0 0
0 0 ..
0 0 -··--·-- ---··---· -· . -
' 0 1 --
03109 Timing light
03112 Pocket tester
03113 Engine tachometer
Air- cooled cooled
0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
DT100 [22X]
-
E: Electric starter madel F; Flywheel magneto madel R: Rotary valve madel /:;.; '75 & '76 madel @: '77 & '78 madel ou: Outer rotor madel
DT5Q. DT50/80 RD125 RD125 TY250 DT80 RD50/80 Air- RZ125 Air- Liquid- cooled Liquid-
cooled cooled cooled (~'83) ('84~)
0 0 0 0 0 0
0
..
. . -·- --------------~ --··-··-·--
01135 Crankcase separating tool
01235 Rotor holding tool
01268 Ring nut wrench
01274 Crank installer pot
01275 Crank installer boit
01277 Adaptor (10 mm)
01278 Adaptor ( 12 mm)
01326 T-Handle
01367 F. fork seal driver weight
01368 Fork seal driver attachment (33 mm)
01373 Fork se al driver attachment (40 mm)
01374 Fork seal driver attachment (43 mm)
03074 Ignition coi! tester
04086 Clutch holding tool
0 0 0 0 0 ou 0 0
0 0
0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0
0
0
0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 - -----··-·
PW80
0
0
0
0
0
0
0
0
0
0
0
0
E: Electric starter mode! F: F lywheel magneto mode! R: Rotary valve mode! 1>: '75 & '76 mode! 0: '77 & '78 mode! ou: Outer rotor mode!
YZ8o· YZ80 YZ80 YZ80 YZ125 YZ125 YZ125
('81) ('82) ('83) ('84) ('81) ('82) ('83)
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 i
0 0 0 0 0 0 0 1
0 0 0 0 0 0 0
0 0 0 0 0 0 0
0 0 0 0 0
0 0 0 0 0 0 0
0 .. 0
0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 ·o 0 0 0 0
0 0 0 0 0 0 0 0 0
...
"-J
ENGINE TYPE: 2-Stroke 1-Cylinder E: Electric starter model F: Flywheel magneto mode! R: Rotary valve model .6: '75 & '76 model ®: '77 & '78 model ou: Outer rotor model
TOOL ~ _:zso YZ125 YZ250 YZ250 YZ250 YZ250 YZ465 YZ490 IT200 IT465 IT490 NO ) IT250 . ('84) ('81) ('82) ('83) ('84) ('81) ('82) ('84) ('81) ('83)
90890-
01135 Crankcase separating tool 0 0 0 0 0 0 0 0 0 0 0 01189 Magnetpuller 0 0 0 0 0 01235 Rotor holding tool 0 0 0 0 01252 Dial gauge & Stand set 0 0 0 0 0 0 0 0 0 0 0 01268 Ring nut wrench 0 0 0 0 0 0 0 0 0 0 0 01274 Crank installer pot 0 0 0 0 0 0 0 0 0 0 0 01275 Crank installer boit 0 0 0 0 0 0 0 0 0 0 0
------01277 Adapter (10 mm) 0 01278 Adapter (12 mm) 0 0 0 0 0 0 0 0 0 0 01286 Drive chain cutter 0 01288 Spacer 0 0 0 0 0 0 0 0 0 0 01294 Helder 1 0
~---+---+----4---~---+---~---4-----+-----+----4-------01326 T-Handle 0 0 0 0 0 0 0 0 0 0 0 01327 Handle-adaptor (30 mm) 0 0 0 0 0 0 0 01368 Front fork seal driver wieght 0 0 0 0 0 0 0 0 01372 Fork seal driver attachment (38 mm) 0 01374 Fork seal driver attachment (43 mm) 0 0 0 0 0 0 0 0 01375 Damper rod helder (29 mm) 0 0 0 ·· 0 0 0 03074 Ignition coil tester 0 0 0 0 , 0 0 0 0 0 0 0 03109 Timing light 0 0 0 0 0 0 0 0 0 0 0 03112 Pocket tester 0 0 0 0 0 0 0 0 0 0 0 04086 Clutch holding tool 0 0 0 0 0 0 0 0 0 0 0
1
01135 Crankcase separating tool
01235 Rotor holding tool
01268 Ring nut wrench
01274 Crank installer pot
01275 Crank installer boit
01278 Adaptor ( 12 mm)
01286 Drive chain cutter
01325 Radiator cap tester
01367 F .fork seal driver weight
01373 Fork se al driver attachment (40 mm)
03074 Ignition coil tester
03109 Timing light
03112 Pocket tester
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
E: Electric starter madel F: Fiywheel magneto model R: Rotary valve model .6.: '75 & '76 madel 0: '77 & '78 model ou: Outer rotor madel
1
01111 Armature puller
01189 Magnet puller
01235 Rotor holding tool
01256 Dial gauge stand No. 2
01268 Ring nut wrench
01286 Drive chain cutter
01290 Armature shock puller
01325 Radiator cap tester
01369 Fork seal driver attachment (35 mm)
03021 Electro tester
03064 Point checker
03097 Dial gauge
03109 Timing light
03112 Pocket tester
0
1
ENGINE TYPE: 2-Stroke 4-Cylinder
TOOL~ RD500 NO. ) RZ500
90890- E 011 04 Cap bol t wren ch 0 01268 Ring nut wrench 0 01286 Drive chain cutter 0
01304 Piston pin puffer set 0 r-~--r-----+-----+-----4-----~----~-----+------01312 Fuel leve! gauge 0 r---~r-----+-----+-----4-----~----~-----+------01325 Radiator captester 0 r-~--r-----+-----+-----4-----~----~-----+------01326 T -handle 0
01362 Flywheel puffer assy 0 01365 Damper rad holder (22 mm) 0 01367 Fork seal driver weight 0 01371 Fork seal driver attachment (37 mm) 0 01701 Sheave holder 0 03021 Electro tester 0
1 03109 Timing light 0 03112 Pocket tester 0 03113 Engine tachometer 0 04086 Clutch holding tool 0
1
TOOL
)
('82 ~) (~'81) ('84~) (~'83) ('83 ~j 90890- E
01052 Met er gear bush tool 0 0 01080 Rotor pull er
0 0 0 0 01083 Rocker shaft pull er boit 0 0 0 0 0 0 0 0 0 0 01084 Weight 0 0 0 0 0 0 0 0 0 0 01112 Cam chain catter set 0 0 01135 Crankcase separating tool 0 0 0 0 0 0 0 0 01189 Magnet puller 0 0 0 0 01200 Valve guide remover 0 0 01211 Valve guide reamer 0 0 01212 Fork spring guide wrench 0
01225 Valve guide remover 0 0 0 0 0 01227 Valve guide reamer 0 0 0 0 0 01235 Rotor holding tool 0 0 0 01253 Valve spring compressor 0
01268 Ring nut wrench 0 0 0 0 0 0 0 0 0 0 0 0 01274 Crank installer pot 0 0 0 0 0 0 01275 Cran k installer boit 0 0 0 0 0 0 01278 Adaptor (M12) 0 -- 0 01286 Drive chain cutter 0 0 0 0 0 0 0 0 01288 Spacer 0 0 01290 Armature shock pull er
0 01291 Weight 0 01294 Holder 1
~
01365 Front fork cylinder camp. holder (22 mm)
01367 F. fork seal driver weight
01369 Fork seal driver attachment (35 mm)
01370 Fork seal driver attachment (36 mm)
01372 Fork seal driver attachment (38 mm)
01375 Damper rod holder (29 mm)
01381 Fork seal driver attachment (41 mm)
01382 Crank shaft protector
01388 Damper rod holder (37 mm)
01701 Sheave holder
03021 Electro tester
03097 Dial gauge
03109 Timing light
03112 Pocket tester
03113 Engine tachometer
04017 Valve guide installer
04019 Valve spring compressor
04059 Crankshaft installer adaptor
04064 Valve guide remover
04065 Valve guide installer
04066 Valve guide reamer ~
('82~) (~ '81)
0 0
0 0
0
0 0
XT250 XT250 XT200 XT125 TT600 SR400 SR185 KR250 BW200 TT250 SR500 SR125 MG250 SR250
('84 ~) (~'83) ('83 ~)
0
0
0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0
0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 i
0 i
0
0 0 0 0 0 0 0 0 0 0 0
0
~
04086 Clutch holding tool
04106 Tappet adjusting tool
XT600 XT550 XT500 XT600Z XT400 XT400
('82~) (~ '81)
0 0
0 0
-
XT250 XT250 XT200 XT125 TT600 SR400 SR185 KR250 BW200 TT250 SR500 SR125 MG250 SR250 ('84 ~) (~'83) ('83 ~)
0
0 0 0 0 0 0 0 0 0 0
0
)
01080 Rotor pull er 0 0 01083 Rocker shaft pull er boit 0 0 01084 Weight 0 0 01235 Rotor holding tool 0 01268 Ring nut wrench 0 0 01304 Piston pin pull er set 0 0 0 0 01311 Tappet adjusting tool 0 01312 Fuel leve! gauge 0 0 0 o· 01326 T-Handle 0 01367 F. fork seal driver weight 0
.:>. 01369 Fork seal driver attachment (35 mm) 0 1 01701 Sheave holder 0
03021 Electro tester 0 0 03081 Compression gauge 0 0 03109 Timing light 0 0 03112 Pocket tester 0 0 03113 Engine tachometer 0 0 04019 Valve spring compressor 0 0 .. 04058 Middle driven shaft brg. rtr. wrench 0 04064 Valve guide remo ver 0 0 04065 Valve guide installer 0 0 04066 Valve guide reamer 0 0 04084 Damper rod holder 0 04086 Clutch holding tool 0 04093 Retainer wrench 0 - . 04095 Plane brg. install & remover 0 1
' 04102 Oi! seal guide 0 1
~
01066 Piston slider
01067 Piston base
01083 Rocker shaft pu lier boit
01084 Weight
01183 Piston pin/Rotary valve pin pu lier
01200 Valve guide remover
01211 Valve guide reamer
01225 Valve guide remover
01227 Valve guide reamer
01235 Rotor holding tool
01245 Tappet adjusting tool
01268 Ring nut wrench
01286 Drive chain cutter
01367 F. fork seal driver weight
01369 Fork seal driver attachment (35 mm)
03021 Electro tester
03081 Compression gauge
03094 Vacuum gauge
XS250 ('82 ~) (~ '81)
ENGINE TYPE: 4-Stroke 3-Cylinder
TOOL~ XS850 NO. ) - XS750
90890- ---~ir----~-----r-----r-----+-----+----~------~----+-----+---01 080 Rotor pull er 0
01083 Rocker shaft pull er boit 0 01084 Weight 0 01112 Cam chain cutter set 0 01183 Piston pin/Rotary valve pin puller 0
r-----r-----+-----~-----~----~-----+-----+----~------~-----~----+------01221 Socket wrench (32 mm) 0 01225 Valve guide remover 0 01227 Valve guide reamer 0 01229 Coupling gear/Middle shaft tool 0 01230 Final gear back Jash band 0
"-J 01231 Middle gear back lash band 0 01235 Rotor holding tool 0 01245 Tappet adjusting tool 0 01254 Ring gear fixed clamp 0 01257 Dialgaugestandset 0 01258 Dia! gauge stand set 0 01268 Ring nut wrench 0 01285 Needle(110mm) 0 ..
--4-------~----~------4-----~------~------+------+------~------05244 Torque wrench (0 ~ 15 cm· kg) 0 05258 Torx wrench (T25) 0 03021 Electro tester 0 03081 Compression gauge 0 03094 Vacuum gage 0
1 03097 Dia! gauge 0 ~----~--~----------------~--1~-----+-------+------+------+-----~------+-----~------+------+------~----~-----~ 03109 Timing light 0 • - 1 03112 Pocket tester 0
) ~-------- ---
}
-
01084 Weight
01104 Cap boit wrench
01112 Cam chain cutter set 0 01183 Piston pin/Rotary valve pin pu/1er
01196 Va Ive gu ide re am er 0 01225 Valve guide remover
01227 Valve guide reamer
01230 Final gear back lash band
01231 Middle gear back lash band
01235 Rotor holding too/
01245 Tappet adjusting tool
01257 D ial gauge stand set
01268 Ring nut wrench 0 01277 Adapter (10 mm)
01290 Armature shock pu/1er
01294 Ho/der 1
01304 Piston pin pu/1er set 0 01312 Fuel leve/ gauge 0 01326 T-Handle 0 01329 Fuel leve/ gauge adapter #5 (07)
01365 Front fork cylinder camp. ho/der (22 mm)
01367 F. fork sea/ driver weight 0
lflllll
' XJ900 XJ650 XJ650 FJ600 XJ550 XJ750 XJ750 TURBO XJ600 XJ500
XJ400 ('83 ~) (~'82)
--
0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0
0 0 0 0 0 0 0 0 0 0 0 b 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0
L.. --- - - -·-- -- - .... .. --
~ TOOL FJ1100
90890- E
01367 F. fork seal driver weight 0 01369 Fork seal driver attachment (33 mm)
01370 Fork seal driver attachment (36 mm)
01371 Fork seal driver attachment (37 mm)
01381 Fork seal driver attachment (41 mm) 0 01388 Damper rod helder (27 mm) 0 05244 Torque wrench (0 ~ 15 cm•kg)
05245 Torx wrench (T30)
03021 Electro tester 0 03081 Compression gauge 0 03094 Vacuum gauge 0 03097 Dial gauge
03109 Timing light 0 03112 Pocket tester 0 03113 Engine tachometer 0 03117 Turbo charger pressure gauge
04007 Clutch helder
04012 Drive shaft puller
04044 Piston ring compressor
04047 Piston ring compresser
04049 Torx wrench (T40)
-- ------
xs 1100 XJ900 XJ650 XJ650 FJ600 XJ550 XJ750 XJ750 TURBO XJ600 XJ5oo· XJ400
('83~) (~'82)
0 0 0 0
0
0
0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0 0
0
0
0
0
0
1
0 0 0 0 1
0 0 0 0 0 0 0 0 0 0 0 0
0 0 . 0 0 0
---------···-
TOOL
::;;~:: FJ1100 XJ1100 XS1100 XJ900 XJ650 XJ650 FJ600 XJ550 NO, -· XJ570 XJ750 TURBO XJ600 XJ500·
XJ400
('83 ~) (~'82) 90890- E
04050 Piston brg. retainer remover 0 04052 Rotor pu lier attachment 0 0 0 04064 Valve guide remover
0 0 04065 Valve guide installer
0 0 04066 Valve guide reamer
0 0 04067 Rotor holding tool
0 0 04068 Y !CS shut off tool 0 0 0 04077 Bea ring retainer wrench 0 0 04080 Middle gear back lash tool 0 0 0 04084 Damper rod holder (19 mm) 0 N 04086 Ciutch holding tool 0 0 0 0 0 0 04090 Damper spring compressor 0 0 0 04110 Tappet adjusting tool 0
1
.. 1
01084 Weight
01104 Cap boit wrench
01135 Crankcase separating tool
01200 Valve guide remover
01211 Valve guide reamer
01225 Valve guide remover
01227 Valve guide reamer
01230 Final gear back lash band
01231 Middle gear back lash band
01254 Ring gear fixed clamp
01268 Ring nut wrench
01274 Crank installer pot
01275 Crank installer boit
01277 Adaptor (10 mm)
01291 Weight
01312 Fuel leve! gauge
01325 Radiator cap tester
01365 Front fork cylinder comp. holder (22 mm)
01367 F. fork seal driver weight
)~VZ12
0
0
0
0
0
0
0
0
0
0
XV1000 XV1000 XV500 XZ400 XV750 XV920 XV400 XZ550 XV700 XV750 ('84 ~) (~'83)
0 0
0 0 0
0 0 0
0 0 0 0 0 .. 0 0 0 0
0
ENGINE TYPE: 4-Stroke V-Cylinder
TOOL ··~ )<VZ12 XV1000 XV1000 XV500 XZ400 NO. ) XV750 XV920 XV400 XZ550
XV700 XV750 ('84 ~) (~ '83)
01370 Fork seal driver attachment (36 mm) 0 0
01373 Fork seal driver attachment (40 mm) 0 0
01701 Sheave holder 0 0 0 0 0 03021 Electro tester 0 0 0 0 0 03081 Compression gauge 0 0 0 0 0 03094 Vacuum gauge 0 0 0 0 0 03097 Dial gauge 0 0 0 0 0 03109 Timing light 0 0 0 0 0 03112 Pocket tester 0 0 0 0 0 03113 Engine tachometer 0 0 0 0 0 04013 Valve guide installer 0 0
04017 Valve guide installer 0
04019 Valve spring compresser 0 0 0 0 0 04049 Torx-wrench (T40) 0
04050 Piston brg. retainer remover 0 0
04054 Middle drive shaft nut wrench 0 0 0 04055 Middle drive shaft holder 0 0 .. 04056 Middle drive shaft retainer 0 0
04057 Mid. drive shaft brg. rtr. wrench 0 0
04058 Mid. driven shaft brg. driver 0 0 0 0 0 04060 Spacer (Crankshaft) 0 0
04061 Spacer (Oil pump drive sprocket) 0 0
04062 Universal joint holder 0 0 0 0 0 04063 Flywheel pu lier attachment 0 0 04064 Valve guide remover 0 0 04065 Valve guide installer 0 0 04066 Valve guide reamer 0 0 -a
N .j:>.
04075 Tappet adjusting tool
04076 Socket wrench adapter
04077 Bearing retainer wrench
04078 Mechanical seal installer
04084 Damper rod holder
04086 Clutch holding tool
04089 Flywheel puller attachment
04090 Damper spring compresser
04105 Tappet adjusting tool
)~VZ12 XV1000 XV1000 XV500 XZ400 XV750 XV920 XV400 XZ550 XV700 XV7fiJ ('84 ~) (~'83)
0 0
0 0 0 0
0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0
N tn
01084 Weight
01189 Magnet puller
01235 Rotor holding tool
01268 Ring nut wrench
01274 Crank installer pot
01275 Crank installer boit
01277 Adapter (10 mm)
01278 Adapter (12 mm)
01306 Hex. wrench (25 mm)
01307 Hex. wrench (22 mm)
01312 Fuel level gauge
01362 Flywheel pull er assy
01367 Fork seal driver weight
01369 Fork seal driver attachment (35 mm)
01391 Ring nut wrench
01393 Coupling gear holder
0
0
0
YTM YTM YTM YTM YFM YTZ 200 200E 225 200ER 200 250
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
0 0 0 0 0
0 0 0 0 0
0 0 0 0 0 0 0 0 0
•
..
0 0 0 0 0 0 0 0 0 0
0 .. 0
0 0
0 0
0 0
04019 Valve spring compressor
04062 Universal joint holder
04064 Valve guide remover
04065 Valve guide installer
04066 Valve guide reamer
04077 Bearing retainer wrench
04086 Clutch holding tool
04088 Butter boss installer
04090 Damper spring compressor
04103 Coupling gear holder
04104 Bearing retainer wrench
0
YTM YTM YTM YFM YTZ 200E 225 200ER 200 250 '
0 0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
. ---~--- .. ~-· ----~ --··---- ------ - ---·--·---0
0 0 0 0 0 0 0 0
-- --0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 --
0
0
TOOL NO. 90890·
Armature puller
TOOL NO. 90890·
Spare parts for cam chain cutter set (90890-91112)
MXS Spare parts for MXS check gauge set (90890-01160)
MXS
MXS Spare parts for M XS check gauge set (90890-0 1160)
TOOL NO. 90890·
Fork seal driver weight
MXS Spare parts for M XS check gauge set (90890-01160)
TX500
TOOL NO. 90890-
Valve guide reamer
Ali flywheel magneto models
Timing adjustment for 2-stroke engines with 14 mm spark plug
5.5 mm Dia. valves.
DESCRIPTION
-34-
XS500 RD500 RZ500
8mm Dia. valves.
Front fork service
Valve guide remover
Final gear back lash b and
r/>38 ~58
-35-
Ali shaft drive models
Universal
XS500 XS11 00 XJ1100 Spare pa;ts for Valve spring compresser (90890-01253)
XS750 Spare parts for Valve spring compresser (90890-01253)
XS250/400 (DOHC) XS750 XS850 XS11 00 XJ series FJ600
Timing adjustment for 2-stroke models
TOOL NO. 90890·
Dial gauge stand set
DESCRIPTION
-37-
Timing adjustment for 2-stroke engine with 14 mm spark plug
XS750
Steering head bearing preload adjustment
MR50 DT100 Use with Fork seal driver weight (90890-01184)
Universal Use with Crank installer boit (90890-01275)
Universal Use with Crank installer pot (90890-01274)
TOOL NO. 90890·
Vertica 1 spi it cases
Timing adjustment
Prevent rim damage during tire change
V series YB125E DT125 RS125E Use with weight (90890-01291)
Use with Armature shock puller (90890- 01290)
TOOL NO. 90890·
MA50 OT50 MJ50 Use with Crankcase separating tool (90890-0 1135)
MA50 QT50 MJ50 For Final gear
MA 50
OT50 MJ50
M6xP0.75
M8xP1.0
M9xP1.0
DESCRIPTION
-42-
Use with Fuellevel gauge
0 1325-~-=---­Radiator c ap tester
Handl e adaptor (30 mm)
Handle adaptor (24 mm)
Chain cutter guide
Clutch spring holder
YAMAHA APPLICATION
XJ400 XJ500 XJ550 XJ600 FJ600 Use with Fuellevel gauge (90890·01312)
Spare parts for cam chain cutter (90890- 01112) ;
CA 50 CV50/80
CA 50 CV50/80
YTM200 YTM225 Use with Fork seal driver weight ( 90S90-0 11S4)
Use with Flywheel puller (90S90-01362)
TOOL NO. 90890-
Hex. wrench (32 mm)
-46-
XV series XZ series XVZ series XT600/5,50/500 400 RD/RZ500
T50/80 For Middle ge ar
T50/80 For Final gear
ILLUSTRATION 90890- DESCRIPTION APPLICATION
~
: ' '0.-{éi'lé,e;::;'%>~'
..
01368 Fork seal driver attachment n 33 mm. F. fork YZ80 '84 ... -01367 ... -01368
033~ 1
_,c- 01369 Fork seal driver attachment 35 mm, F. fork
XZ550 RZ250/350 XJ400
Ô35~ XS250/400 XT125/200/250 DT125
01370 Fork sea/ driver attachment 36 mm F. fork XV series XJ650/750
Ô36~ -
-47-
01371 Fork seal driver attachment 37 mm F. fork XJ900/1100
.,,~ 01372 Fork seal driver attachment 38 mm F. fork
XT550 YZ125
. . ,~ u c•
t------·01367
01373 Fork seal driver attachment .... -01368 40 mm F. fork 1
1-1- -01374 XVZ12
.40®)) _...c...
01374 Fork seal driver attachment 43 mm F. fork YZ250/490 TT600
-~~ 01375 Damper rad holder (29 mm) TT600, XT600
YZ250/490 '84
Crank shaft protector
Oil seal guide
DESCRIPTION
YAMAHA APPLICATION
41 mm F. fork XT600 Use with Fork seal driver weight (90890- 01367}
XT250 ('84 ~}
XT250 ('84 ~)
CE 50
Micrometer (0 ~ 25 mm)
Micrometer (25 ~ 50 mm)
Micrometer (50~ 75 mm)
Cyl inder gauge (50 ~ 100 mm)
Magnetic base
Electro tester
TOOL NO. 90890-
TX750
YB125
Universal
TOOL NO. 90890-
-55-
Un iv ersa 1
TOOL NO. 90890-
Timing tester
DESCRIPTION
-56-
Use with dia! gauge (90890-03097}
YB125
Universal
5.5 mm Dia. valves TX500 XS500 XT250 (DOHC)
5.5 mm Dia. valves
Piston ring c ompressor
Middle drive shaft ho/der
TOOL NO. 90890-
XJ650 XJ750 XJ900
XJ650 XJ750 XJ900
XJ650 XJ750 XJ900
TOOL NO. 90890·
Niddle drive shaft holder
Middle drive shaft retainer
DESCRIPTION
.()4055
-62-
Crank shaft installer adapter
.·~~~ b 1 U)
~ Universal joint holder
6.mm Dia. valves
XJ400 XJ550
XJ600 FJ600
Tappet adjusting tool
YAMAHA YICS system shut off for ca rb . · synchro- nlzation
Spa re parts for y ICS shut off tool {90890· 04069)
XZ550 XZ400
012.7
03/8"
Clutch holding tool
XT400 XT550 XT600 TT600
XZ550 XT550/400 XT600 TT600 Use with' cam pression gauge {90890- 03081)
XJ750
XT125
~~ILLUSTRATION YAMAHA Flywheel puller;t~ta;ci~~~~~~~~~~~~D~E~S~C~R~IP=T~IO~N~~~~~~~~~~~~ ment
APPLICATION
Damper spring compresser
T50/80 XC125 5mm Dia. va Ives
T50/80 XC125 5 mm Dia. valves
T50/80 XC125 5 mm Dia. valves
TOOL NO. 90890·
FJ1100
ILLUSTRATION
Tork wrench (T30)
• ® ®
@ (jJ) @
~~ 8
REF. NO. TOOL NAME Q'TY TOO L NO. (90890-) 1 Exhaust ring & Steering nut wrench 1 -01268 2 Rotor holding tool 1 -01235 3 Flywheel puller 1 -01189 4 Clutch holder 1 -01023 '5 Clutch holder 1 -04086 6 Meter gear bushing remover 1 -01052 7 Crankcase separating tool 1 -01135 8 Crank installer pot 1 -01274 9 Crank installer boit 1 -01275
10 Adapter (M7), Crank installer boit 1 -01276 11 Adapter (M10), Crank installer boit 1 -Q1277 12 Adapter (M12), Crank installer boit 1 -01278 13 Spacer 1 -01288 14 Armature puller boit 1 -01111 15 Dial gauge set 1 -01252 16 Thickness gauge 1 -03079 17 Timing tester 1 -03108 18 Tool box with key 1 -
-73-
CD ®
e REF. NO. TOOL NAME Q'TY TOOL NO. (90890-)
1 Exhaust ring & Steering nut wrench 1 -01268 2 Rotor holding tool 1 -01235 3 Flywheel puller 1 -01189 4 Clutch holder 1 -01023 5 Clutch holder 1 -04086 6 Meter gear bushing remover 1 -01052 7 Cran kea se separati ng tool 1 -01135 8 Crank installer pot 1 -01274 9 Crank installer boit 1 -01275
10 Adapter (M7), Crank installer boit 1 -01276 11 Adapter (M10), Crank installer boit 1 -01277 12 Adapter (M12), Crank installer boit 1 -01278 13 Spacer 1 -01288 14 Armature puller boit 1 -01111 15 Tool box with key 1 -
-74-
r----------------l :CD~ l ~~./ 1~ 1 1'-d'~ 1
:~: :~?/: : ~ 1 ------------------~ r;:------------l ® ~ 1 ~ 1
~; 1~1 1~1
:~: 1 1 l _____________ _j
~-------------~
NÔ. Description O'ty Remarks No.
8x9, 10x12, 11x13, 25 1 Double offset wrench 1 s 12x14,14x17,
26 19x22,24x27
6x7,8x9, 10x12 27
2 Open ended wrench 1 s 11x13, 12x14 28 17x19, 22x24
29 8,9,10,11,12
30 3 Socket wrench {3/8") 1 s 1 3' 14' 1 7' 19, 21 ' 22,24 31
4 Socket wrench {1/2") 1 s 26,27, 29,32 32
5 Deep socket wrench (3/8") 1 18x75 33
6 Deep socket wrench (3/8") 1 13/16x75 34
7 Adapter 1 3/8"x1 /2" 36
8 U'fliversal ratchet handle 1 3/8"x270 36
9 Extention bar 1 3/8"x150 37
10 Speed T-handle 1 3/8"x265 38
11 Bit helder (3/8") 1 MBH-2 (6.35 mm) 39
12 Hexagon bit 1 X32 M4x70 40
13 Hexago n bit 1 X-32 M5x70 41
14 Hexagon bit 1 X-32 M6x70 42
15 Hexago n bit 1 X32 M8x70 43
16 Screw driver bit 1 V-17 (+)No. 2x75 44
17 Screw driver bit 1 V-17 {+)No. 3x75 46
18 Tire pressure gauge 1 MG-50 46
19 Adjustable angle wrench 1 300 mm 47
20 Combination plier 1 200 mm 48
21 Clip plier 1 ST-1 49
22 Clip plier 1 RT-1 50
23 Plastic hammer 1 1 LB 51
24 Steel hammer 1 1 LB 52
-75-
Description
Penetrating screw driver (-)
Penetrating 'crew driver {-)
Penetrating screw driver (-)
Penetrating screw driver (+)
Penetrating screw driver (+)
Penetrating screw driver (+)
1 75 mm (3")
1 100 mm (4")
1 150 mm (6")
1 No. 1 (3")
1 No. 2 (4")
1 No. 3 (6")
No. Description O'ty Remark No. Description O'ty Remark .
1 Open ended wrench set 1 s 5.5x7, 8x10, 11 x13 25 Combination plier 1 200 mm 12x14, 17x19,22x24 26 Water pump plier 1 250 mm 2 Double offset wrench set 1 s 8x10, 11x13,12x14 27 Clip plier 1 ST-1 14x1~ 19x22,24x27 3 Socket wrench (1 /2") 1 8mm 28 Clip plier 1 RT-1 4 Socket wrench (1 /2") 1 10 mm 29 Steel hammer 1 1 LB 5 Socket wrench (1/2") 1 12mm 30 Plastic hammer , 1 LB 6 Socket wrench (1 /2") 1 14 mni 31 Shock screw driver set 1 s 7 Socket wrench (1 /2") 1 17 mm 32 Bit, shock screw driver (+) 1 No. 3x70 mm 8 Socket wrench (1 /2") 1 19mm 33 Plug wrench 1 18x21 mm 9 Socket wrench ( 1 /2") 1 21 mm 34 Thickness gauge 1
10 Socket wren ch ( 1 /2") 1 22 mm 35 Diagonal cutting nipper 1 150 mm 11 Socket wrench ( 1 /2") 1 23 mm 36 Radio plier 1 150 mm 12 Socket wrench (1 /2") 1 24 mm 37 Hexagon wrench set 1 2.5, 3, 4, 5, 6, 8 mm 13 Socket wrench (1 /2") 1 27 mm 38 Tire pressure gauge 1 MG-50 14 Socket wrench (1 /2") 1 29 mm 39 Wire brush 1 15 Socket wre nch ( 1 /2") 1 32 mm 40 T-type handle 1 265 mm 16 Rach et ha nd le (1 /2") 1 250 mm 41 Gasket scraper 1 17 Extention bar (1 /2") 1 150 mm 42 Plastic ha nd le screw driver(-) 1 100mm 18 Penetrating screw driver (-) 1 75 mm 43 Pincette 1 150mm 19 Penetrating screw driver (-) 1 100 mm 44 Center punch 1 125 mm 20 Penetrating screw driver (-) 1 150 mm 45 Chisel 1 13x160 mm 21 Penetrat i ng screw dr iv er ( +) 1 No. 1 46 Oil stone 1 100x25x13 mm 22 Penetrating screw driver (+) 1 No.2 47 File for contact point 1 23 Penetrating screw driver (+) 1 No.3 48 Second eut file set 1 24 Adjustable angle wrench 1 300 mm 49 Toolbox 1 390x220x145 mm
-76-
CD ® ® (j) ® @
®~ ~~ b:mJ '.. •0 : :,·:.1
This kit contains many types of terminais (male and female) for lead wire connections and couplers. Particularly, clippers (tools for stripping lead wire insulators and clinching of terminais) are of high qualitY, and allow easy modifications of lead wire routing and easy wiry connections instead of solderihg.
No. Description Remarks O'ty No. Description Re marks O'ty
1 Bali head plug 0.50 ~ 2.00 mm 50 pcs.
2 Bali heap socket 0.50 ~ 2.00 mm 50 10
110 insertion·type 0.50 ~ 1.50 mm 50 socket
3 lnsulation sleeve for Bali head plug 50 11 250 insertion-type 0.50 ~ 2.30 mm 50 plug
4 1 nsulation sleeve for Ba Il head
50 socket 12 250 insertion-type
0.50 ~ 2.30 mm 50 socket
5 Circular top 0.50 ~ 1.25 mm
50 terminal 6 mm Boit dia. 6 mm 13 250 coupler set 6- pole 1 set
6 110 coupler set 3- pole 2 set 14 Y sleeve 50
7 110 coupler set 4- pole 2 set 15 250 coupler set 4- pole 1 set
8 110 coupler set 6- pole 2 set 16 250 coupler set 3- pole 1 set
9 110 insertion-type 0.50 ~ 1.50 mm 50 plug
17 Cr imper Type B-125 1
18 Tool box 1
"HELI-SERT" KIT (P/No. 90890-05155) YAMAHA
"Heli-sert" is a term given to a screw bush resembling a coi! spring that consists of a wound wire with a rhombic section. When internai threads of a hale in aluminum or light alloy parts is damaged, normally the hale must be bored and threaded so as to fit an oversize screw. But this heli-sert kit eliminates such trouble­ sorne operation. The use of the heli-sert kit allows the quick reproduction of the original-size threads. This kit contains heli-serts for 5, 6, 8 and 10 mm screw hales and a set of tools required for heli-sert insertion.
i ..
~ ~ ~"' Heli-sert ~
0 0 ~' ®01 @ ®® ICD® ®CD
No. Description Q'ty No. Description Q'ty No. Description O'ty 1 Heli-sert M5 x O.S x 1.5D 20 10 Tap M5 x O.S No. 3 1 19 lnserting tool (S-type) 1 2 Heli-sert M5 x O.S x 2D 20 11 Tap M6 x 1.0 No. 2 1 20 lnserting tool (S-type) 1 3 Heli-sert M6 x 1.0 x 1.5D 20 12 Tap M6 x 1.0 No. 3 1 21 Tang break tool M5 1 4 Heli-sert M6 x 1.0 x 2D 20 13 Tap MS x 1.25 No. 2 1 23 Tang break tool MS 1 5 Heli-sert MS x 1.25 x 1.5D 20 14 Tap MS x 1.25 No. 3 1 22 Tank break tool MS 1 6 He li-sert MS x 1. 25 x 2D 20 15 Tap M10 x 1.25 No. 2 1 24 Tang break tool M1 0 1 7 Heli-sert M10 x 1.25 x 1.5D 20 16 Tap M10 x 1.25 No. 3 1 25 Extracting tool M3 ~ 5 1 s Heli-sert M10 x 1.25 x 2D 20 17 lnserting tool (P-type) 1 26 Extracting tool M6 ~ 10 1 9 Tap M5 x O.S No. 2 1 1S lnserting tool (S-type) 1 27 Tool box 1
-7S-
20130306083348
20130306083457
20130306083810