Home

ENG - Pdfstream.manualsonline.com

1. s Be careful not to excessive full stroke A stroke of 200 mm 7 9 in or more will cause air to enter In this case repeat the steps 15 to 18 FRONT FORK CHASSO 19 Wait ten minutes until the air bubbles have been removed from the front fork and the oil has dispense evenly in system before setting recommended oil level NOTE Fill with the fork oil up to the top end of the outer tube or the fork oil will not spread over to every part of the front forks thus making it impossible to obtain the correct level Be sure to fill with the fork oil up to the top of the outer tube and bleed the front forks 20 Measure Oil level left and right Out of specification Adjust Standard oil level 135 mm 5 31 in 130 mm 5 12 in 125 mm 4 92 in Extent of adjustment 80 150 mm 3 15 5 91 in From top of outer tube with inner tube and damper rod CO fully compressed without spring For EUROPE For AUS NZ and ZA NOTE M Be sure to install the spring guide 2 when checking the oil level 311404 A WARNING Never fail to make the oil level adjustment between the maximum and minimum level and always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability FRONT FORK CHASSO 21 Measure e Distance 8 Out of specification Turn into the
2. Piston pin puller set YU 1304 90890 01304 I1221001 pin out 2 Remove e Piston ring NOTE 2L opread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown as shown in the illustration INSPECTION Cylinder and piston 1 Inspect e Cylinder and piston walls Vertical scratches Replace cylinder and piston 2 Measure e Piston to cylinder clearance Measurement steps 1st step e Measure the cylinder bore C with a cylin der bore gauge NOTE Measure the cylinder bore C in parallel to and at right angles to the crankshaft Then find the average of the measurements 11210102 CYLINDER AND PISTON Taper limit T T Maximum D or Dz Maximum Ds or De e R Maximum Di D or Ds Minimum Dz D or De e f out of specification replace the cylinder and replace the piston and piston rings as set 2nd step e Measure the piston skirt diameter P with a micrometer 8 8 mm 0 31 in from the piston bottom edge Piston size Standard 76 955 76 970 mm 3 0297 3 0303 in e f out of specification replace the piston and piston rings as a set 3rd step e Calculate the piston to cylinder clearance with following formula Piston to cylinder clearance Cylinder bore C Piston skirt diameter P Piston to cylinder clearance 0 040 0 065 mm 0 0016 0 0026 in Limi
3. Except for USA 13 Install e O ring e Leak jet 1 e Float chamber e Screw float chamber e Cable holder throttle stop screw cable e Hose holder carburetor breather hose 5 RY 14 Install e Diaphragm air cut valve 1 e Spring air cut valve e O ring 3 e Air cut valve cover 4 e Screw air cut valve cover 15 Install e Diaphragm accelerator pump e Spring e O ring 3 e Accelerator pump cover 4 e Hose holder drain hose e Screw accelerator pump cover NOTE ees Install the diaphragm accelerator pump with its mark 8 facing the spring D K 1c Mies 16 Install e Jet needle 1 e Collar 2 e Spring e Needle holder e Throttle valve plate 5 To throttle valve 17 Install e Throttle valve assembly 1 e Screw throttle shaft mm NOTE c Install the valve lever rollers 3 into the slits a of the throttle valve 18 Install e O ring D e Valve lever housing cover e Bolt valve lever housing cover Z 19 Install e Carburetor breather hose 1 NOTE Install the carburetor breather hoses to the carburetor so that the hoses do not bend near where they are installed Accelerator pump timing adjustment Adjustment steps NOTE In order for the throttle valve height to achieve the specified value tuck under the throttle valve plate 1 the rod 2
4. 2 Replace e Brake pad Brake pad replacement steps e Remove the pad pin plug D INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT e Loosen the pad pin 2 e Remove the brake hose holder and brake caliper 4 from the front fork e Remove the pad pin and brake pads e Connect the transparent hose to the bleed screw 7 and place the suitable con tainer under its end e Loosen the bleed screw and push the brake caliper piston in e Tighten the bleed screw NN Bleed screw A 6 Nm 0 6 m kg 4 3 ft Ib e Install the brake pads 8 and pad pin NOTE L OO X e Install the brake pads with their projections a into the brake caliper recesses b e Temporarily tighten the pad pin at this point e Install the brake hose holder and brake caliper do and tighten the pad pin 12 NOTE m Fit the brake hose holder cut O over the projection d on the front fork and clamp the brake hose Bolt brake caliper 23 Nm 2 3 m kg 17 ft Ib Pad pin 18 Nm 1 8 m kg 13 ft Ib INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT e Install the pad pin plug 2 ne Pad pin plug A 3 Nm 0 3 m kg 2 2 ft Ib 3 Inspect e Brake fluid level Refer to BRAKE FLUID LEVEL INSPEC TION section 4 Check e Brake lever operation A softy or spongy feeling Bleed brake system Refer to BRAKE SYSTEM AIR BLEED ING section R
5. 2 19 CABLE ROUTING DIAGRAM 2 20 CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS 3 1 PRE OPERATION INSPECTION AND MAINTENANCE eese 3 4 ENGINE 25 ce Rv Deb Deka PEv ex Desi 3 5 CHASSIS eene ees 3 25 ELECTRICAL wget hs 3 47 CHAPTER 4 ENGINE SEAT FUEL TANK AND SIDE ENEE 4 1 EXHAUST PIPE AND SILENCER 4 3 FOKUS ege 4 5 CARBURETOR sees 4 8 CAMSHAFTS EE 4 22 CYLINDER HEAD 4 31 VALVES AND VALVE SPRINGS 4 34 CYLINDER AND PISTON 4 43 CLUTGDEL ee 4 50 OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANKCASE COVER 4 57 BALANCER RM Peta te 4 64 OIL PUMP piano a 4 67 KICK SHAFT AND SHIFT SHAFT 4 72 AC MAGNETO AND STARTER CLUTCH 4 79 ENGINE REMOVAL 4 86 CRANKCASE AND CRANKSHAFT 4 92 TRANSMISSION SHIFT CAM AND SHET FORK eege gesprengt 4 101 CHAPTER 5 CHASSIS FRONT WHEEL AND REAR WHEEL 5 1 FRONT BRAKE AND REAR BRAKE 5 11 FRONT FORK Ate eege 5 27 HANDLEBAR EE 5 40 STEERING ses eon tS DESIRES 5 46 SWINGARM 5 53 REAR SHOCK ABSORBER 5 61 CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM reee eeen 6 1 MAP CONTROLLED CDI UNIT 6 2 IG
6. 4 104 TRANSMISSION SHIFT CAM AND SHIFT FORK ENG 5 Install e Shift fork 1 L e Shift fork 2 C e Shift fork 3 R e Shift cam To main axle and drive axle NOTE 7777 e Apply the molybdenum disulfide oil on the shift fork grooves e Mesh the shift fork 1 L with the 4th wheel gear and 3 R with the 5th wheel gear on the drive axle e Mesh the shift fork 2 C with the 3rd pinion gear 6 on the main axle GC 6 Install e Transmission assembly 1 To left crankcase NOTE L M Apply the engine oil on the bearings and guide bars 7 Check e Shifter operation e Transmission operation Unsmooth operation Repair 4 105 FRONT WHEEL AND REAR WHEEL CHASSO CHASSIS FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL 23 Nm 2 3 m kg 17 ft Ib 23 Nm 2 3 m kg 17 ft Ib lge Nm 10 5 m kg 75 ft Ib 12 Nm 1 2 m kg 8 7 ft A 12 Nm 12 m kg 8 7 ft Ib 10 Nm 1 0 m kg 7 2 ft b Extent of removal D Front wheel removal 2 Wheel bearing removal 3 Brake disc removal FRONT WHEEL REMOVAL Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine danger of it falling over Trip meter cable Brake hose cover Bolt brake hose holder Bolt axle holder Nut front wheel axle Front wheel axle Front wheel Trip me
7. Fully turned in position FRONT FORK COMPRESSION DAMPING FORCE INSP ADJUSTMENT INSP QR e STANDARD POSITION This is the position which is back by the spe cific number of clicks from the fully turned in position Standard position 9 clicks out 5 clicks out Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged A WARNING Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability EC36J001 FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT 1 Remove e Rubber cap 2 Adjust e Compression damping force By turning the adjuster 1 Stiffer Gi Increase the compression damping force Turn the adjuster 1 in Softer Decrease the compression damping force Turn the adjuster 1 out ex Extent of adjustment 20 clicks out from maximum position Fully turned in position REAR SHOCK ABSOR INSP BER INSPECTION e STANDARD POSITION This is the position which is back by the spe cific number of clicks from the fully turned in position Standard position 14 clicks out 12 clicks out Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged A WARNING Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability 3 Install e Rubber cap EC36K000 RE
8. Recommended oil At 5 C 40 F or higher Yamalube 4 20W 40 or SAE 20W 40 type SG motor oil Non Friction modified At 15 C 60 F or lower Yamalube 4 10W 30 or SAE 10W 30 type SG motor oil Non Friction modified and or Yamalube 4 R 15W 50 Non Friction modified e Do not add any chemical additives Engine oil also lubricates the clutch and additives could cause clutch slippage e Do not allow foreign material to enter the crankcase INSP ENGINE OIL REPLACEMENT Except for USA and CDN Recommended oil Refer to the following chart for selection of oils which are suited to the atmospheric temperatures Recommended engine oil classi fication API STANDARD API SG or higher grade Designed primarily for motorcycles e Do not add any chemical additives or use oils with a grade of CD 8 or higher e Do not use oils labeled ENERGY CON SERVING II or higher Engine oil also lubricates the clutch and additives could cause clutch slippage e Do not allow foreign materials to enter the crankcase 5 Install e Oil tank cap 6 Start the engine and let it warm up for sev eral minutes 7 Turn off the engine and inspect the oil level once again NOTE LL D Wait a few minutes until the oil settles before inspecting the oil level ENGINE OIL REPLACEMENT 1 Start the engine and warm it up for several m
9. 3 Measure e Cylinder head warpage Out of specification Resurface Cylinder head warpage Less than 0 05 mm 0 002 in Warpage measurement and resurfacing steps e Place a straightedge and a feeler gauge across the cylinder head e Use a feeler gauge to measure the warpage e H the warpage is out of specification resurface the cylinder head e Place a 400 600 grit wet sandpaper on the surface plate and resurface the head using a figure eight sanding pattern NOTE S To ensure an even surface rotate the cylin der head several times FS CYLINDER HEAD ENG ASSEMBLY AND INSTALLATION Cylinder head 1 Install e Dowel pin 1 Cylinder head gasket 2 e Timing chain guide exhaust side 3 e Cylinder head LO NOTE While pulling up the timing chain install the timing chain guide exhaust side and cylinder head 2 Install e Washer e Cable guide e Bolts L 145 mm 5 71 in e Bolts L 135 mm 5 31 in 10 Nm 1 0 m kg 7 2 ft Ib e Nuts 5 NOTE e Apply the molybdenum disulfide grease on the thread and contact surface of the bolts e Follow the numerical order shown in the illus tration Tighten the bolts and nuts in two stages 3 Install e Copper washer 1 e Oil delivery pipe e Union bolt M8 e Union bolt M10 2 xX 20 Nm 2 0 m kg 14 ft Tb 4 Install e Radiator pipe 1 e Bolt radiator pipe VALVES AND VA
10. 6 Start engine and increase spark gap until misfire occurs for USA and CDN only Minimum spark gap 6 0 mm 0 24 in COUPLERS LEADS AND IGNITION COIL CONNECTION INSPECTION 1 Check e Couplers and leads connection Rust dust looseness short circuit gt Repair or replace e Ignition coil and spark plug as they are fit ted Push in the ignition coil until it closely contacts the spark plug hole in the cylin der head cover ENGINE STOP SWITCH INSPECTION 1 Inspect e Engine stop switch conduct Tester lead Black lead Q Tester lead Black lead Tester selector position Q x1 No continuity while being pushed Replace Continuity while being freed Replace IGNITION System ELEC 2 Inspect N e Rubber part 8 Tears damage Replace MAIN SWITCH INSPECTION 1 Inspect e Main switch conduct Tester lead Red lead Oo Tester lead Brown lead R Br Tester selector a position Q x1 Continuous while the main switch is moved to OFF Replace Not continuous while the main switch is moved to ON Replace 2 Inspect e Main switch indicator light Use 12 V battery Battery lead Red Black lead 1 Battery lead Black lead Indicator light does not come on Replace 3 Inspect e Rubber part 8 Tears damage Replace IGNITION system ELEC EC626002 IGNITION COIL INSPECTION 1 Remove the igniti
11. CHECKING OF CONNECTION GEN aes EC1C0001 CHECKING OF CONNECTION Dealing with stains rust moisture etc on the connector 1 Disconnect e Connector 2 Dry each terminal with an air blower 3 Connect and disconnect the connector two or three times 4 Pull the lead to check that it will not come off 5 f the terminal comes off bend up the pin D and reinsert the terminal into the con nector 6 Connect e Connector NOTE The two connectors click together 7 Check for continuity with a tester NOTE e f there in no continuity clean the terminals Be sure to perform the steps 1 to 7 listed above when checking the wire harness e For a field remedy use a contact revitalizer available on the market Use the tester on the connector as shown SPECIAL TOOLS gr 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 The shape and part number used for the special tool differ by country so two types are provided Refer to the list provided to avoid errors when placing an order NOTE e For U S A and Canada use part number starting with YM YU or ACC e For others use part number starting with 90890 Tool name How to use Illustration YU 1135 A 90890 01135 Crankcase separating tool YU 1135 A 90980 01
12. Diaphragm air cut valve Float chamber Leak jet Pilot screw Refer to REMOVAL POINTS FS o Float pin Float Needle valve Main jet Needle jet Spacer Pilot jet Starter jet Push rod Throttle shaft assembly Push rod link lever assembly Pilot air jet Cold starter plunger Pull the push rod GBYWOOVOOOOGOONV RY HANDLING NOTE Do not loosen the screws throttle position sensor 1 except when changing the throt tle position sensor due to failure because it will cause a drop in engine performance REMOVAL POINTS Pilot screw 1 Remove e Pilot screw 1 NOTE To optimize the fuel flow at a small throttle opening each machine s pilot screw has been individually set at the factory Before removing the pilot screw turn it in fully and count the number of turns Record this number as the factory set number of turns out INSPECTION Carburetor 1 Inspect e Carburetor body Contamination Clean NOTE Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air e Never use a wire FS 2 Inspect e Main jet 1 e Pilot jet e Needle jet 3 e Starter jet e Pilot air jet e Leak jet Damage Replace Contamination Clean ING TES ee a B Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air e Never use a wire Needle val
13. MAP CONTROLLED CDI UNIT A map controlled CDI ignition system is used in the WR250F The microcomputer in the CDI unit detects the engine speed and throttle position thus determining the optimum ignition timing through the entire operating range In this way quick throttle response can be achieved according to various riding conditions Ignition coil Throttle position sensor CDI unit Pickup coil AC magneto rotor E Function of Component Throttle position sensor Detects throttle valve opening and inputs it into the computer in the CDI unit as a throttle opening signal Pickup coil Detects signal rotor revolutions and inputs them into the computer in the CDI unit as engine revolution signals CDI unit The signals of the throttle position sensor and pickup coil sensor are analyzed by the computer in the CDI unit which then adjusts ignition timing for the operation requirements B Principal of 3 Dimensional Control Conventionally ignition timing was controlled only by engine revolutions 2 dimensional control However ignition timing needs advancement also by engine load Thus accurate ignition timing can be determined by adding throttle opening to deter mine ignition timing 3 dimensional control Buu uous 3 D Image Map of Ignition Timing different from actual characteristics IGNITION system ELEC EC620000 GNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of t
14. NOTE OO e The unequal pitch spring is softer in initial characteristic than the equal pitch spring and is difficult to bottom out under full compres sion e The I D color 8 is marked at the end of the spring e Extent of adjustment spring length SPRING FREE EXTENT OF LENGTH ADJUSTMENT 240 5 258 5 mm 260 mm 10 24 in 9 47 10 18 in 9 d G 255 5 273 5 mm 10 06 10 77 in S of 275 mm 10 83 in SETTING EC72H002 Suspension setting e Front fork NOTE e f any of the following symptoms is experienced with the standard position as the base make resetting by reference to the adjustment procedure given in the same chart e Before any change set the rear shock absorber sunken length to the standard figure 90 100 mm 3 5 3 9 in Sen Large Ln E Check gap gap Compression damping Turn adjuster counterclockwise about 2 clicks to decrease damping Oil level oil amount Decrease oil level by about 5 10 mm 0 2 0 4 in Spring Replace with soft spring Stiff over entire range Outer tube Check for any bends dents and other noticeable Unsmooth movement Inner tube scars etc If any replace affected parts over entire range Under bracket tightening Retighten to specified torque torque Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease dam
15. Red 5UM 00 YAMAHA For USA 5UM 10 YAMAHA Except for USA CDI unit model manufacturer Ignition coil Model manufacturer Minimum spark gap Primary coil resistance Secondary coil resistance Charging system 5UL 00 DENSO 6 mm 0 24 in 0 08 0 10 Q at 20 C 68 F 4 6 6 8 KQ at 20 C 68 F System type Model manufacturer Normal output Charging coil resistance color Lighting coil resistance color Rectifier regulator Regulator type Model manufacture AC magneto 5UM 00 YAMAHA 14 V 120 W at 5 000 r min 0 288 0 432 Q at 20 C 68 F White Ground 0 224 0 336 Q at 20 C 68 F Yellow Ground Semiconductor short circuit SH712AA SHINDENGEN Regulated voltage AC 13 0 14 0 V Regulated voltage DC 14 1 14 9 V Rectifier capacity AC 12 A Rectifier capacity DC 8A Electric starting system Type Constant mesh Starter motor Model manufacturer 5UMOO YAMAHA Operation voltage 12V Output 0 35 kW Armature coil resistance 0 0189 0 0231 Q at 20 C 68 F Brush overall length 7 mm 0 28 in Brush quantity 2 pcs Spring force 3 92 5 88 N 400 600 g 14 1 21 2 oz 17 6 mm 0 69 in 1 5 mm 0 06 in 3 5 mm 0 14 in Commutator diameter Mica undercut depth 16 6 mm 0 65 in MAINTENANCE SPECIFICATIONS SPEC y Starter relay Model manufacturer 2768090 A JIDECO 180A 4 2 4 6 Q at 20 C 68 F Amperage rating Coil winding resistance
16. 0 037 mm 0 0004 0 0015 in lt Limit gt 0 08 mm 0 003 in Exhaust 0 025 0 052 mm 0 0010 0 0020 in lt Limit gt 0 10 mm 0 004 in 2 Replace e Valve guide Replacement steps NOTE LL To ease guide removal installation and to maintain correct fit heat the cylinder head in an over to 100 C 212 F e Remove the valve guide using a valve guide remover 1 e Install the new valve guide using a valve guide remover 1 and valve guide installer 2 e After installing the valve guide bore the valve guide using a valve guide reamer 3 to obtain proper stem to guide clearance FS VALVES AND VALVE SPRINGS ENG Valve guide remover Intake 4 0 mm 0 16 in YM 4111 90890 041 11 Exhaust 4 5 mm 0 18 in YM 4116 90890 04116 Valve guide installer Intake 4 0 mm 0 16 in YM 4112 90890 041 12 Exhaust 4 5 mm 0 18 in YM 4117 90890 04117 Valve guide reamer Intake 4 0 mm 0 16 in YM 4113 90890 04113 Exhaust 4 5 mm 0 18 in YM 4118 90890 04118 NOTE LL After replacing the valve guide reface the valve seat 3 Inspect e Valve face Pitting wear Grind the face e Valve stem end Mushroom shape or diameter larger than the body of the stem Replace 4 Measure e Margin thickness Out of specification Replace Margin thickness Intake 0 8 mm 0 0315 in Exhaust 0 7 mm 0 0276 in FS VALVES AND VALVE SPRINGS ENG op 5 Mea
17. 1 e Brake master cylinder cup secondary To brake master cylinder piston 3 NOTE I Apply the brake fluid on the brake master cylin der cup A WARNING After installing cylinder cup should be installed as shown direction Wrong instal lation cause improper brake performance Front Rear FRONT BRAKE AND REAR BRAKE CHASSO 3 Install e Spring 1 To brake master cylinder piston NOTE Install the spring at the smaller dia side Front Rear 4 Install Front e Brake master cylinder kit 1 e Washer e Circlip e Brake master cylinder boot 4 To brake master cylinder 5 Rear e Brake master cylinder kit 1 e Push rod 2 e Circlip e Brake master cylinder boot 4 To brake master cylinder 5 NOTE LL e Apply the brake fluid on the brake master cyl inder kit e Apply the lithium soap base grease on the tip of the push rod e When installing the circlip use a long nose circlip pliers Front Rear Front brake master cylinder 1 Install e Brake master cylinder 1 e Brake master cylinder bracket e Bolt brake master cylinder bracket 9 Nm 0 9 m kg 6 5 ft Ib NOTE e e Install the bracket so that the arrow mark 3 face upward e First tighten the bolts on the upper side of the brake master cylinder bracket and then tighten the bolts on the lower side FRONT BRAKE AND REAR BRAKE CHAS g 2 Install e Brake lever 1
18. FS REMOVAL POINTS Balancer shaft drive gear and balancer shaft driven gear 1 Straighten the lock washer tab 2 Loosen e Nut primary drive gear 1 e Nut balancer shaft driven gear NOTE L ll Place an aluminum plate 8 between the teeth of the balancer shaft drive gear 3 and driven gear 4 Balancer shaft 1 Remove e Balancer shaft 1 NOTE When removing the balancer shaft align the center 8 of the balancer shaft weight along the line connecting the centers of the crank shaft and balancer shaft INSPECTION Primary drive gear balancer shaft drive gear and balancer shaft driven gear 1 Inspect e Primary drive gear 1 e Balancer shaft drive gear e Balancer shaft driven gear Wear damage Replace Balancer shaft 1 Inspect e Balancer shaft Cracks damage Replace BALANCER ENG o ASSEMBLY AND INSTALLATION Balancer shaft balancer shaft drive gear and balancer shaft driven gear 1 Install e Balancer shaft 1 NOTE e Apply the engine oil on the bearing e When installing the balancer shaft align the center 8 of the balancer shaft weight along the line connecting the centers of the crank shaft and balancer shaft 2 Install e Balancer shaft driven gear NOTE 2 LLL Install the balancer shaft driven gear onto the balancer shaft while aligning the punch mark 8 on the balancer shaft driven gear with the lower spli
19. Front fork top end standard 8 5 mm 0 20 in 10 mm 0 39 in For AUS NZ and ZA 12 Tighten e Pinch bolt upper bracket 1 e Pinch bolt lower bracket 20 Nm 2 0 m kg 14 ft Ib Tighten the lower bracket to specified torque If torqued too much it may cause the front fork to malfunction STEERING CHASSO 13 Install e Trip meter 1 e Bolt trip meter 7 Nm 0 7 m kg 5 1 ft Ib NOTE Install the trip meter over the coupler bracket 3 swiNGARM CHASIS EC570000 SWINGARM 53 Nm 5 3 m kg 38 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib 85 Nm 8 5 m kg 61 ft Ib 80 Nm 8 0 m kg 58 ft Ib Extent of removal Swingarm removal SWINGARM REMOVAL Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine danger of it falling over Brake hose holder Refer to FRONT BRAKE AND REAR Rear brake caliper BRAKE section Bolt brake pedal Drive chain Drive chain support 1 Lower chain tensioner 1 Bolt rear shock absorber relay 1 Hold the swingarm arm Bolt connecting rod 1 Pivot shaft 1 Swingarm 1 Shift the brake pedal backward swiNGAnM CHAS EC578000 SWINGARM DISASSEMBLY Extent of removal C Swingarm disassembly 2 Connecting rod removal and disassembly 3 Relay arm removal and disassembly SWINGARM DISASSEMBLY Cap Relay arm Conne
20. NIPPLE WRENCH This nipple wrench 1 is used to tighten the spoke eas FUEL Always use the recommended fuel as stated below Also be sure to use new gasoline the day of a race Recommended fuel Except for ZA Premium unleaded gasoline only with a research octane number of 95 or higher For ZA Premium gasoline CAUTION Use o unleaded gasoline The use of leaded gasoline will cause severe damage to the engine internal parts such as valves piston rings and exhaust system etc NOTE nmm If knocking or pinging occurs use a different brand of gasoline or higher octane grade A WARNING e For refueling be sure to stop the engine and use enough care not to spill any fuel Also be sure to avoid refueling close to a fire e Refuel after the engine exhaust pipe etc have cooled off 1 14 STARTING AND BREAK IN GEN aes 1 15 STARTING AND BREAK IN Never start or run the engine in a closed area The exhaust fumes are poisonous they can cause loss of consciousness and death in a very short time Always operate the machine in a well ventilated area built in accelerator pump Therefore when starting the engine do not operate the throttle or the spark plug will foul e Unlike a two stroke engine this engine cannot be kick started when the throttle is open because the kickstarter may kick back Also if the throttle is open the air fuel mixture may be too lean for the eng
21. Replace 6 Apply e Foam air filter oil or equivalent oil to the element NOTE e Squeeze out the excess oil Element should be wet but not dripping e Wipe off the oil left on the element surface using a clean dry cloth Excess oil in the ele ment may adversely affect engine starting 7 Install e Filter guide 1 NOTE e Align the projection on filter guide with the hole b in air filter element e Apply the lithium soap base grease on the matching surface on air filter element 8 Install e Air filter element 1 NOTE L L Align the projection on filter guide with the hole in air filter case 9 Hook e Binder 1 NOTE S Hook the binder 1 so that it contacts the filter guide projections 8 INSP ENGINE OIL LEVEL INSPECTION ENGINE OIL LEVEL INSPECTION 1 Start the engine warm it up for several minutes and then turn off the engine and wait for five minutes 2 Place the machine on a level place and hold it up on upright position by placing the suitable stand under the engine 3 Hemove e Oil tank cap 4 Inspect e Oil level Oil level should be between maximum 8 and minimum b marks Oil level is low Add oil to proper level NOTE L When inspecting the oil level do not screw the oil tank cap into the oil tank Insert the gauge lightly For USA and CDN
22. YAMAHA A WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm YAMAHA LIT CALIF 65 01 WR250FR OWNER S SERVICE MANUAL 2002 by Yamaha Motor Corporation U S A 1st Edition November 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 16 48 ECO020000 INTRODUCTION Congratulations on your purchase of a Yamaha WR series This model is the culmina tion of Yamaha s vast experience in the pro duction of pacesetting racing machines It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader This manual explains operation inspection basic maintenance and tuning of your machine If you have any questions about this manual or your machine please contact your Yamaha dealer NOTE As improvements are made on this model some data in this manual may become out dated If you have any questions please con sult your Yamaha dealer WARNING PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR
23. 1 e Cylinder head cover gasket e Cylinder head cover 3 e Bolt cylinder head cover 10 Nm 1 0 m kg 7 2 ft Ib NOTE 2 LL Apply the sealant on the cylinder head cover gasket Z Quick gasket ACC QUICK GS KT YAMAHA Bond No 1215 90890 85505 7 Install e Oil tank breather hose e Cylinder head breather hose e Spark plug x 13 Nm 1 3 m kg 9 4 ft Ib CYLINDER HEAD g CYLINDER HEAD 10Nm 1 0 m kg 7 2ft Ib 10Nm 1 0 m kg 7 2ft Ib Extent of removal CD Oylinder head removal CYLINDER HEAD REMOVAL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Refer to EXHAUST PIPE AND SILENCER section Exhaust pipe and silencer Radiator hose 1 Carburetor Camshaft Upper engine bracket Radiator pipe Oil delivery pipe Nut Bolt L2135 mm 5 31 in Bolt L 145 mm 5 71 in Cylinder head Timing chain guide exhaust side Disconnect at cylinder head side Refer to CARBURETOR section Refer to CAMSHAFTS section Hefer to ENGINE REMOVAL section NOOR WD NNN 4 31 7 CYLINDER HEAD ENG INSPECTION Cylinder head 1 Eliminate e Carbon deposits from the combustion chambers Use a rounded scraper NOTE Do not use a sharp instrument to avoid damag ing or scratching e Spark plug threads e Valve seats 2 Inspect e Cylinder head Scratches damage Replace
24. 1 4 2 2 1 2 1 2 2 1 1 8 1 4 6 2 1 1 3 1 2 2 1 2 2 2 1 2 1 1 1 2 1 2 1 1 1 3 Tightening torque Ns me tb 1 3 9 4 MAINTENANCE SPECIFICATIONS SPEC y Partio eser ecd Thread si Ot Tightening torque art to De tl ene read SIZe 35 3 5 25 A Silencer M8 x 1 25 Silencer clamp M8 x 1 25 Spark arrester for USA M6 x 1 0 Silencer end pipe for USA M6 x 1 0 Crankcase M6 x 1 0 Crankcase bearing stopper M6 x 1 0 Crankcase bearing stopper crankshaft M6 x 1 0 Left crankcase cover M6 x 1 0 Idle gear cover starter motor M6 x 1 0 Idle gear plate M6 x 1 0 Right crankcase cover M6 x 1 0 Clutch cover M6 x 1 0 Crankcase oil drain bolt M10 x 1 25 Drive chain sprocket cover M6 x 1 0 Kick shaft ratchet wheel guide M6 x 1 0 Kickstarter crank M8 x 1 25 Starter clutch M6 x 1 0 Primary drive gear M18 x 1 0 Clutch spring M6 x 1 0 Clutch boss M16 x 1 0 Push lever shaft M6 x 1 0 Drive sprocket M18 x 1 0 Drive axle oil seal stopper M6 x 1 0 Segment M8 x 1 25 Shift guide M6 x 1 0 Stopper lever M6 x 1 0 Shift pedal M6 x 1 0 OW n ch MM zb MM HF ch sch UI sch ON sk MM sch NWN W OW SF NOTE A marked portion shall be checked for torque tightening after break in or before each race MAINTENANCE SPECIFICATIONS SPEC CHASSIS Steering system Steering bearing type Taper roller bearing Front suspension USA CDN EUROPE AUS NZ ZA Front fork travel 300 mm 11 8 in lt c Fork sprin
25. 1 4 1 2 3 4 10 185 10 Idle Fully open SETTING E Pilot screw adjustment The richness of the air fuel mixture with the throttle fully closed to 1 4 open can be set by turning the pilot screw Q Turning in the pilot screw will make the mixture lean at low speeds and turning it out will enrich it Standard pilot 2 example screw position 1 7 8 Except for USA NOTE e f the engine idling speed fluctuates turn the pilot screw only 1 2 of a turn in either direc tion e To optimize the fuel flow at a smaller throttle opening each machine s pilot screw has been individually set at the factory Before adjusting the pilot screw turn it in fully and count the number of turns Record this num ber as the factory set number of turns out Effects of adjusting the pilot screw reference 1 4 1 2 3 4 ee 5 AC Idle Fully open D 2 1 2 turns out 1 1 2 turns out 3 2 turns out Pilot jet adjustment The richness of the air fuel mixture with the throttle open 1 4 or less can be set by adjust ing the pilot jet 1 Standard pilot jet EM SETTING E Effects of adjusting the pilot jet reference 1 4 1 2 3 4 Idle Fully open Jet needle groove position adjustment Adjusting the jet needle 1 position affects the acceleration when the throttle is 1 8 to 3 4 open 1 Too rich at intermediate speeds Rough engine operation is felt and th
26. 7 SE e Clutch boss DOCERE AUTEURE Scoring wear damage Replace 9 Primary driven gear 1 18 17 D Push rod and push lever removal Push pod 1 disassembly 1 Check 3 Friction plate and clutch plate removal Clutch housing removal K Extent of removal e Circumferential play Extent of remova 4 Remarks oD Free play exists Replace D CLUTCH REMOVAL SA e Gear teeth Preparatieni for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT M gt Wear damage Replace section in the CHAPTER 3 K A Brake pedal Refer to ENGINE REMOVAL section Clutch cable Disconnect at engine side Clutch cover Gasket Dowel pin Clutch spring Pressure plate Push rod 1 Circlip Plain washer Bearing Ball Push rod 2 1 Measure e Clutch spring free length 8 Out of specification Replace springs as a set Clutch spring free length DO JO OD P WN Standard Limit 50 mm 1 97 in 49 mm 1 93 in mo nin gn 0 ILLUSTRATED SYMBOLS Refer to the illustration Illustrated symbols 1 to are designed as thumb tabs to indicate the chapters number and content D General information Specifications 3 Regular inspection and adjustments 4 Engine 5 Chassis 6 Electrical Tuning Illustrated symbols 8 to are used to identify the specifications appearing in the text With engine mounted 9 Special tool F
27. Bolt brake lever Nut brake lever 6 Nm 0 6 m kg 4 3 ft Ib NOTE 2 LLL Apply the lithium soap base grease on the brake lever sliding surface bolt and contacting surface of the brake master cylinder piston Rear brake master cylinder 1 Install e Copper washer 1 e Brake hose e Union bolt A WARNING Always use new copper washers Install the brake hose so that its pipe por tion 8 directs as shown and lightly touches the projection b on the brake master cylinder 2 Install e Brake master cylinder 1 e Bolt brake master cylinder 11 Nm 1 1 m kg 8 0 ft Ib 3 Install e Spring 1 e Brake pedal O ring e Bolt brake pedal e Clip 5 NOTE LL e Apply the lithium soap base grease on the bolt O ring and brake pedal bracket e Install the clip with its stopper portion 8 fac ing inward FRONT BRAKE AND REAR BRAKE CHASSO 4 Install e Pin 1 e Washer e Cotter pin NOTE After installing check the brake pedal height Refer to REAR BRAKE ADJUSTMENT sec tion in the CHAPTER 3 Front brake hose 1 Install e Brake hose 1 To brake hose holder NOTE 7777 Before tightening the bolt brake hose holder align the top 8 of the brake hose neck with the brake hose holder bottom b Then pass the brake hose in front of the axle boss O and fit it into the hose groove d so that the brake hose does not contact the nut wh
28. Eegenen Tester gt Blue Yellow terminal 3 Tester gt Sky blue terminal No Tester gt continuous Blue Red terminal 1 Tester gt Blue Yellow terminal 3 No Tester gt continuous Blue Red terminal 1 Incorrect continuity Replace START SWITCH INSPECTION 1 Inspect e Start switch continuity Tester lead Black lead Tester lead Black lead Tester selector EM No continuous while being lon Replace Continuous while being freed Replace 2 Inspect e Rubber part 8 Tears damage Replace ELECTRIC STARTING SYSTEM ELEC STARTER MOTOR 8 Gs Kee A LN SS OD EUN au d Extent of removal D Starter motor disassembly STARTER MOTOR REMOVAL Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 4 Preparation for removal Starter motor STARTER MOTOR DISASSEM BLY Starter motor front cover Washer starter motor front cover Gasket Starter motor yoke Armature assembly Starter motor rear cover Brush Brush spring N N sech a YO sch 4 ELECTRIC STARTING SYSTEM ELEC INSPECTION AND REPAIR 1 Check e Commutator Dirt Clean with 600 grit sandpaper Measure e Commutator diameter 8 Out of specification Replace the starter motor N 18210101 Min commutator diameter 16 6 mm 0 65 in 3 Measure e Mica undercut 8 OT N EE Out
29. FRONT FORK REMOVAL Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine danger of it falling over Front wheel Refer to FRONT WHEEL AND REAR WHEEL section Front brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Headlight Handlebar Refer to HANDLEBAR section Protector Brake hose holder Pinch bolt upper bracket Only loosening Cap bolt Loosen when disassembling the front fork Pinch bolt lower bracket Only loosening Front fork FRONT FORK CHAS Go EC558000 FRONT FORK DISASSEMBLY 29 Nm 2 9 m kg 21 ft Ib 1 Nm 0 1 m kg 0 7 ft Ib 55 Nm 5 5 m kg 40 ft Ib Extent of removal D Oil seal removal Damper rod removal FRONT FORK DISASSEMBLY Refer to REMOVAL POINTS Drain the fork oil Front fork cap bolt Fork spring Dust seal Stopper ring Inner tube Outer tube Piston metal Slide metal Oil seal washer Oil seal Spring guide Base valve Damper rod Refer to REMOVAL POINTS Use special tool Refer to REMOVAL POINTS ch sesch sesch sch zech sesch wesch wesch wesch sesch ll D 2 3 FRONT FORK CHASSO EC556000 HANDLING NOTE NOTE The front fork requires careful attention So it is recommended that the front fork be maintained at the dealers To prevent an accidental explosio
30. INSPECTIONS AND CAREFUL MAINTE NANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFETY ENJOY THE CAPABILITIES AND THE RELI ABILITY OF THIS MACHINE Yamaha Motor Corporation U S A hereby war rants to the original retail purchaser that the fol lowing components equipped on new Yamaha YZ or WR motorcycles purchased from an authorized Yamaha motorcycle dealer in the continental United States will be free from defects in material and workmanship for the period of time stated herein subject to certain stated limitations YZ or WR components included under this warranty are the engine frame swingarm and monoshock It is understood that the balance of the YZ or WR com ponents are not covered by any warranty expressed or implied The balance of the compo nents equipped on the unit are sold on an as is basis This warranty applies to the original pur chaser only and is not transferable THE PERIOD OF WARRANTY for the above listed Yamaha YZ or WR components as originally installed on the unit shall be thirty 30 days from the date of purchase MODELS EXCLUDED FROM WARRANTY include those used for non Yamaha authorized renting leasing or other commercial purposes DURING THE PERIOD OF WARRANTY any autho rized Yamaha motorcycle dealer will free of charge repair or replace at Yamaha s option any part adjudged defective by Yamaha due to faulty workmanship or material from the factory Parts used in warranty repairs
31. Ib Ki 23 Nm 2 3 m kg 17 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib Extent of removal CD Starter clutch wheel gear removal Rotor removal 3 Pickup coil stator removal AC MAGNETO AND STATOR REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Bolt radiator left Refer to RADIATOR section Disconnect the AC magneto lead Shift pedal Engine guard left Cover idle gear 1 Idle gear 1 Bearing Shaft Crankcase cover left Gasket Dowel pin N sch sch sch sch ol 1 2 3 4 5 6 D 8 9 AC MAGNETO AND STARTER CLUTCH 7 Nm 0 7 m kg 5 1 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib Ge 23 Nm 2 3 m kg 17 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 1 Nut rotor Rotor 1 Use special tool Refer to REMOVAL POINTS Woodruff key Starter clutch Starter clutch drive gear Bearing Plain washer Idle gear plate Idle gear 2 A Holder Pickup coil Stator ch sesch sesch wesch ll AC MAGNETO AND STARTER CLUTCH ENG EC4L3000 REMOVAL POINTS Rotor 1 Remove e Nut rotor e Plain washer 2 Remove e Rotor 1 Use the rotor puller Rotor puller YM 04141 90890 04141 EC4L4000 INSPECTION AC magneto 1 Inspect e Rotor inner surface e Stator outer
32. Pass the starter motor lead in front of the radiator the tie end hose 4 Pass the carburetor breather hoses carburetor R Pass the clutch cable through the cable guide overflow hose and coolant reservoir breather hose Pass the wire harness on the outside of the neu so that the hoses do not contact the rear shock tral switch lead and AC magneto lead absorber Fit the brake hose into the guides on the protector M A8 SE oe I p ws S S i St ok k N 9 d CABLE ROUTING DIAGRAM SPEC y Hot starter cable 2 Cable guide 3 Throttle cable return 4 Throttle cable pull 5 Ignition coil 6 Coolant reservoir breather hose CG Rectifier regulator Coolant reservoir hose 9 Rectifier regulator lead Clamp oO CDI unit lead 2 CDI unit d3 CDI unit band CDI unit stay 5 Rectifier regulator bracket Pass the throttle cables and hot starter cable through the cable guides Pass the throttle cables and hot starter cable between the radiator and frame then under the radiator mounting boss Pass the throttle cables on the outside of the ignition coil D Pass the carburetor breather hose of the throttle cable cover through the hose holder CABLE ROUTING DIAGRAM SPEC y Fasten the coolant reservoir breather hose and carburetor breather hoses together Fasten the CDI unit lead Insert the CDI unit band over the CDI unit stay as far as possible Fasten the rectifi
33. STI HANDLEBAR CHAS 11 Install e Clutch cable 0 e Hot starter cable NOTE 2222222 LLL Apply the lithium soap base grease on the clutch cable end and hot starter cable end 12 Adjust e Clutch lever free play Refer to CLUTCH ADJUSTMENT sec tion in the CHAPTER 3 e Hot starter lever free play Refer to HOT STARTER LEVER ADJUSTMENT section in the CHAPTER 3 13 Fasten the hot starter cable 1 and clutch cable with a clamp 14 Insert the end of the fuel breather hose 1 into the hole in the steering stem cap STEERING CHAS AOS EC560000 STEERING e Tighten ring nut 38 Nm 3 8 m kg 27 ft Ib e Loosen it one turn e Retighten it 7 Nm 0 7 m kg 5 1 ft Ib 23 Nm 2 3 m kg 17 ft Ib 4 Nm 0 4 m kg 2 9 ft Ib 20 Nm 2 0 m kg 14 ft Ib Extent of removal CD Lower bracket removal 2 Bearing removal STEERING REMOVAL Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine danger of it falling over Headlight Handlebar Refer to HANDLEBAR section Front brake hose guide Front fender Coupler bracket Trip meter Main switch Steering stem cap Steering stem nut Front fork Upper bracket Steering ring nut Disconnect the main switch lead Refer to FRONT FORK section sch N sch sch oL 1 2 3 4 5 6 D 8 Use special tool Refer t
34. drive sprocket 1 e Lock washer NOTE e Straighten the lock washer tab e Loosen the nut while applying the rear brake 2 Hemove e Drive sprocket 1 e Drive chain 2 NOTE 777 Remove the drive sprocket together with the drive chain EC4M3301 Engine removal 1 Remove e Pivot shaft 1 NOTE If the pivot shaft is pulled all the way out the swingarm will come loose If possible insert a shaft of similar diameter into the other side of the swingarm to support it 2 Remove e Engine 1 From right side NOTE Make sure that the couplers hoses and cables are disconnected ENGINE REMOVAL ENG EC4M5000 ASSEMBLY AND INSTALLATION Engine installation 1 Install e Engine 1 Install the engine from right side e Pivot shaft 2 85 Nm 8 5 m kg 61 ft Ib e Engine mounting bolt lower e Lower engine bracket 4 e Bolt engine bracket e Engine mounting bolt front w 69 Nm 6 9 m kg 50 ft Ib e Upper engine bracket 7 e Engine mounting bolt upper e Bolt left engine guard e Lower engine guard e Bolt lower engine guard 1 x 10 Nm 1 0 m kg 7 2 ft Ib NOTE Apply the molybdenum disulfide grease on the pivot shaft e ECAMB 1 1 Brake pedal 1 Install e Spring 1 e Brake pedal O ring e Bolt brake pedal x 26 Nm 2 6 m kg 19 ft Ib e Clip 5 NOTE s e Apply t
35. e Protector rear brake 2 Bleed e Brake fluid Front Rear Air bleeding steps a Add proper brake fluid to the reservoir b Install the diaphragm Be careful not to spil any fluid or allow the reservoir to overflow Connect the clear plastic tube 2 tightly to the caliper bleed screw 1 Place the other end of the tube into a con tainer Slowly apply the brake lever or pedal sev eral times Pull the lever in or push down on the pedal Hold the lever or pedal in position Loosen the bleed screw and allow the lever or pedal to travel towards its limit Tighten the bleed screw when the lever or pedal limit has been reached then release the lever or pedal Bleed screw 6 Nm 0 6 m kg 4 3 ft Ib i Repeat steps e to h until of the air bub bles have been removed from the system INSP FRONT BRAKE ADJUSTMENT NOTE If bleeding is difficult it may be necessary to let the brake fluid system stabilize for a few hours Repeat the bleeding procedure when the tiny bubbles in the system have disap peared j Add brake fluid to the level line on the res ervoir 4 WARNING Check the operation of the brake after bleeding the brake system 3 Install e Protector rear brake e Diaphragm e Brake master cylinder cap EC362040 FRONT BRAKE ADJUSTMENT 1 Check e Brake lever position ex Brake lever position 3 Standard
36. gt OK No good Check starter relay gt OK No good 4 Check neutral switch Replace OK Check clutch switch poses c OK gt OK Check start switch EE Replace 1 marked Refer to FUSE INSPECTION section in the CHAPTER 3 2 marked Refer to BATTERY INSPECTION AND CHARGING section in the CHAPTER 3 3 marked Refer to MAIN SWITCH INSPECTION section 4 marked Refer to NEUTRAL SWITCH INSPECTION section NOTE e Remove the following parts before inspection 1 Seat Rear fender e Use 12 V battery in this inspection Use the following special tools in this inspection NO Pocket tester YU 3112 C 90890 03112 ELECTRIC STARTING SYSTEM ELEC 18210801 EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check e Couplers and leads connection Rust dust looseness short circuit gt Repair or replace STARTER MOTOR OPERATION 1 Connect the positive battery terminal 1 and starter motor lead with a jumper lead Not operate Repair or replace the starter motor WARNING A wire that is used as a jumper lead must have at least the same capacity or more as that of the battery lead otherwise the jumper lead may burn e This check is likely to produce sparks therefore make sure nothing flammable is in the vicinity STARTING CIRCUIT CUT OFF RELAY INSPECTION 1 Remove e Starting circuit cut off relay 2 Inspect e Starting circui
37. ing range Restart the machine and oper ate it for about 10 to 15 more minutes The machine will now be ready to race e After the break in or before each race you must check the entire machine for loose fittings and fasteners as per TORQUE CHECK POINTS Tighten all such fasteners as required e When any of the following parts have been replaced they must be broken in CYLINDER AND CRANKSHAFT About one hour of break in operation is necessary PISTON RING VALVES CAMSHAFTS AND GEARS These parts require about 30 minutes of break in operation at half throttle or less Observe the condition of the engine care fully during operation TORUE CHECK POINTS INFO BiS TORQUE CHECK POINTS Frame construction Frame to rear frame Combined seat and fuel tank Fuel tank to frame Exhaust system Silencer to rear frame Engine mounting Frame to engine 8 Engine bracket to engine Engine bracket to frame Steering Steering stem to 4 Steering stem to frame handlebar Steering stem to upper bracket Upper bracket to handlebar Suspension Front Steering stem to front 7 Front fork to upper bracket fork Front fork to lower bracket Rear For link type Assembly of links Link to frame Link to rear shock absorber Link to sw
38. 10 links Front disc brake Disc outside dia x Thickness Pad thickness Master cylinder inside dia Caliper cylinder inside dia Brake fluid type Rear disc brake Disc outside dia x Thickness Deflection limit Pad thickness Master cylinder inside dia Caliper cylinder inside dia Brake fluid type Brake lever and brake pedal Brake lever position Brake pedal height vertical height above footrest top Clutch lever free play lever end Throttle grip free play Standard USA CDN ZA EUROPE AUS NZ Spoke wheel Spoke wheel 21 x 1 60 Aluminum 18 x 1 85 Aluminum 18 x 2 15 Aluminum DID520VM DAIDO 113 links joint 40 50 mm 1 6 2 0 in 250 x 3 0 mm 9 84 x 0 12 in 4 4 mm 0 17 in 11 0 mm 0 433 in 27 0 mm 1 063 in x 2 DOT 4 245 x 4 0 mm 9 65 x 0 16 in 6 4 mm 0 25 in 11 0 mm 0 433 in 25 4 mm 1 000 in x 1 DOT 4 95 mm 3 74 in 5 mm 0 20 in 8 13 mm 0 31 0 51 in 3 5 mm 0 12 0 20 in 2 0mm 0 08 in 2 0mm 0 08 in 150 1 mm 5 91 in 250 x 2 5 mm 9 84 x 0 10 in 1 0 mm 0 04 in 245 x 3 5 mm 9 65 x 0 14 in 0 15 mm 0 006 in 1 0 mm 0 04 in bb P MAINTENANCE SPECIFICATIONS SPEC y kg ft lb 23 2 9 17 Part to be tightened Pe Pree yee qe Upper bracket and outer tube M8 x 1 25 4 Lower bracket and outer tube M8 x 1 25 4 20 2 0 14 Upper bracket and steering stem M24 x 1 0 1 145 14 5 105 Handlebar upper holder and upper brac
39. 2 projects from the camshaft Timing chain tensioner 1 Check e While pressing the tensioner rod lightly with fingers use a thin screwdriver 1 and wind the tensioner rod up fully clock wise e When releasing the screwdriver by press ing lightly with fingers make sure that the tensioner rod will come out smoothly e f not replace the tensioner assembly ASSEMBLY AND INSTALLATION Camshaft 1 Install e Exhaust camshaft 1 e Intake camshaft Installation steps e Turn the crankshaft counterclockwise with a wrench NOTE W e Apply the molybdenum disulfide oil on the camshafts e Apply the engine oil on the decompression system e Squeezing the decompression lever allows the crankshaft to be turned easily e Align the T D C mark 8 on the rotor with the align mark b on the crankcase cover when piston is at T D C on compression stroke CAMSHAFTS ENG O e Fit the timing chain 3 onto both camshaft sprockets and install the camshafts on the cylinder head NOTE aaaaaaaaaaaaaaaaaaaaaaaaaaauu The camshafts should be installed onto the cylinder head so that the punch mark O on the exhaust camshaft and the punch mark d on the intake camshaft must align with the cylinder head surface as shown in the illustration camshaft installation Damage or improper valve timing will result e Install the clips camshaft caps and bolts camshaft cap Bolt camshaft cap a
40. 9 Install e Slide metal 1 e Oil seal washer To outer tube slot NOTE eee Press the slide metal into the outer tube with fork seal driver 3 Fork seal driver YM 01442 90890 01442 10 Install e Oil seal NOTE Press the oil seal into the outer tube with fork seal driver 2 Fork seal driver YM 01442 90890 01442 11 Install e Stopper ring NOT E c Fit the stopper ring correctly in the groove in the outer tube 12 Install e Dust seal NOTE LL Apply the lithium soap base grease on the inner tube FRONT FORK CHASSO 13 Check e Inner tube smooth movement Tightness binding rough spots Repeat the steps 2 to 12 14 Compress the front fork fully 15 Fill e Front fork oil Until outer tube top surface with recom mended fork oil D Recommended oil Suspension oil 01 e Be sure to use recommended fork oil If other oils are used they may have an excessively adverse effect on the front fork performance e Never allow foreign materials to enter the front fork 16 After filling pump the damper rod Q slowly up and down more than 10 times to distrib ute the fork oil 17 Fill e Front fork oil Until outer tube top surface with recom mended fork oil once more 18 After filling pump the outer tube 1 slowly up and down about 200 mm 7 9 in stroke to distribute the fork oil once more NOTE
41. By turning the adjuster 1 Stiffer Increase the rebound damp ing force Turn the adjuster 1 in Softer O Decrease the rebound damp ing force Turn the adjuster 1 out ex Extent of adjustment 20 clicks out from maximum position Fully turned in position e STANDARD POSITION This is the position which is back by the spe cific number of clicks from the fully turned in position Which align the punch mark on the adjuster with the punch mark on the bracket Standard position About 7 clicks out About 10 clicks out For EUROPE AUS NZ and ZA Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged REAR SHOCK ABSORBER LOW COMPRESSION INSP 40 DAMPING FORCE ADJUSTMENT ADJ Q EC36c000 REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT 1 Adjust e Low compression damping force By turning the adjuster 1 Stiffer Increase the low compres sion damping force Turn the adjuster D in Softer Decrease the low compres sion damping force Turn the adjuster O7 out ex Extent of adjustment 20 clicks out from maximum position Fully turned in position e STANDARD POSITION This is the position which is back by the spe cific number of clicks from the fully turned in position Which align the punch mark 8 on the adjuster with the punch mark on the high compression damping
42. CHAS KO EC5B0000 HANDLEBAR 2 Nm 0 2 m kg 1 4 ft Ib Extent of removal Q Handlebar removal HANDLEBAR REMOVAL Preparation for removal Headlight Hot starter cable Disconnect at the lever side Hot starter lever holder Clutch cable Clutch lever holder Engine stop switch Light switch Brake master cylinder Start switch Throttle cable cap Throttle cable 2 pushed Throttle cable 1 pulled Right grip Tube guide Grip cap cover Left grip Handlebar upper holder Handlebar Disconnect at the lever side Disconnect the clutch switch lead Disconnect the engine stop switch lead Refer to REMOVAL POINTS Disconnect the start switch lead ONOaoahKWN Disconnect at the throttle side Disconnect at the throttle side Refer to REMOVAL POINTS Refer to REMOVAL POINTS N sech c lc lb ol l sch l l l cl c 12410201 HANDLEBAR CHAS EC5B3000 REMOVAL POINTS Brake master cylinder 1 Remove e Brake master cylinder bracket 1 e Brake master cylinder on the brake hose e Keep the brake master cylinder cap side horizontal to prevent air from coming in EC5B3200 Grip 1 Remove e Grip D NOTE Blow in air between the handlebar or tube guide and the grip Then remove the grip which has become loose EC5B4000 INSPECTION EC5B4100 Handlebar 1 Inspect e Handlebar Bends cracks damage Repl
43. CORPORATION U S A WARRANTY DEPARTMENT P O Box 6555 Cypress California 90630 This will ensure that Yamaha Motor Corporation U S A has an up to date regis tration record in accordance with federal law IMPORTANT NOTICE THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE ONLY ON A CLOSED COURSE It is illegal for this machine to be operated on any public street road or highway Off road use on public lands may also be illegal Please check local regula tions before riding AA SAFETY INFORMATION 1 THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY Do not attempt to operate this machine at maximum power until you are totally familiar with its character Istics 2 THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY Do not carry passengers on this machine 3 ALWAYS WEAR PROTECTIVE APPAREL When operating this machine always wear an approved helmet with gog gles or a face shield Also wear heavy boots gloves and protective cloth ing Always wear proper fitting cloth ing that will not be caught in any of the moving parts or controls of the machine 4 ALWAYS MAINTAIN YOUR MACHINE IN PROPER WORKING ORDER For safety and reliability the machine must be proerly maintained Always perform the pre operation checks indicated in this manual Correcting a mechanical problem before you ride may prevent an accident 5 GASOLINE IS HIGHLY FLAMMABLE Always turn off the engine while refu eli
44. ELEC 8 Tighten e Screw throttle position sensor 1 9 Stop the engine THROTTLE POSITION SENSOR INPUT VOLTAGE INSPECTION 1 Disconnect the throttle position sensor cou pler 2 Start the engine 3 Inspect e Throttle position sensor input voltage Out of specification Replace the CDI unit Tester lead Blue lead 1 Tester lead Black Blue lead 2 Tut Throttle position Tester selector sensor input ER St voltage position 4 6V Devo LIGHTING system ELEC LIGHTING SYSTEM INSPECTION STEPS Refer to the following flow chart when inspecting the ignition system for possible problems Check the bulb and bulb No good Replace the bulb and socket or bulb socket JL OK Check the light switch Ge JL OK ee No good Check the AC magneto Lighting coil JL OK ire lighti Improperly connected Check the entire lighting sys properly Repair or replace tem proper for connections JL OK No good Check the rectifier regulator U pl Replace voltage NOTE e Replace the bulb and or bulb socket 1 Seat 2 Fuel tank Use the following special tool Pocket tester Inductive tachometer YU 3112 C 90890 031 12 gp YU 8036 B Engine tachometer 90890 03113 LIGHTING SYsTEM ELEC LIGHT SWITCH INSPECTION 1 Inspect e Light switch conduct Tester lead Yellow lead 1 Tester lead Blue lead Y L Tester selector Gi Onno position SR e al No continuous
45. FRONT FORK INSPECTION 1 Inspect e Front fork smooth action Operate the front brake and stroke the front fork Unsmooth action oil leakage Repair or replace EC36D001 FRONT FORK OIL SEAL AND DUST SEAL CLEANING 1 Remove e Protector e Dust seal 1 NOTE Use a thin screw driver and be careful not to damage the inner fork tube and dust seal 2 Clean e Dust seal 8 e Oil seal NOTE M t IA e Clean the dust seal and oil seal after every run e Apply the lithium soap base grease on the inner tube FRONT FORK INTERNAL PRESSURE RELIEVING FRONT INSP e FORK REBOUND DAMPING FORCE ADJUSTMENT ADJ Q FRONT FORK INTERNAL PRESSURE RELIEVING NOTE If the front fork initial movement feels stiff dur ing a run relieve the front fork internal pres sure 1 Elevate the front wheel by placing a suit able stand under the engine 2 Remove the air bleed screw 1 and release the internal pressure from the front fork 3 Install e Air bleed screw w 1 Nm 0 1 m kg 0 7 ft Ib ECS36H0 02 FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT TKO 1 Adjust e Rebound damping force H S By turning the adjuster 1 Stiffer Increase the rebound damp ing force Turn the adjuster 1 in Softer O Decrease the rebound damp ing force Turn the adjuster 1 out ex Extent of adjustment 20 clicks out from maximum position
46. O CHARGING System ELEC EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check e Couplers and leads connection Rust dust looseness short circuit gt Repair or replace CHARGING VOLTAGE INSPECTION 1 Start the engine 2 Inspect e Charging voltage Out of specification If no failure is found in checking the source coil resis tance replace the rectifier regulator Tester lead Red lead Oo Tester lead Black lead i Charging Tester selector voltage position 14 1 14 9 V at M 5 000 r min EE 3 Inspect e Charging coil resistance Out of specification Replace Tester lead White lead 1 Tester lead Ground Charging coil Tester selector resistance position 0 288 0 432 O at 20 C 68 F THROTTLE POSITION SENSOR SYSTEM ELEC THROTTLE POSITION SENSOR SYSTEM INSPECTION STEPS If the throttle position sensor will not operate use the following inspection steps Check entire ignition No good Repair or replace system for connection OK Check throttle position Throttle posi No good Replace sensor tion sensor coil JL OK Throttle posi Check CDI unit tion sensor No good Replace input voltage NOTE Use the following special tools in this inspection Inductive tachometer YU 8036 B Engine tachometer 90890 03113 THROTTLE POSITION SENSOR SYSTEM ELEC HANDLING NOTE Do not eg the screws throttle po
47. OFF SYSTEM OPERATION If the main switch is set to ON the starter motor can only operate if at least one of the fol lowing conditions is met e The transmission is in neutral the neutral switch is closed e he clutch lever is pulled to the handlebar the clutch switch is closed The starting circuit cut off relay prevents the starter motor from operating when neither of these conditions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above condi tions has been met the starting circuit cut off relay is closed and the engine can be started by pressing the start switch 4a WHEN THE TRANSMISSION IS IN NEUTRAL 4xxx WHEN THE CLUTCH LEVER IS PULLED TO THE HANDLEBAR D Battery 2 Main fuse 3 Main switch 4 Starting circuit cut off relay 5 Start switch 6 Diode Clutch switch Neutral switch 9 Starter relay Starter motor ELECTRIC STARTING SYSTEM ELEC INSPECTION STEPS If the starter motor will not operate use the following inspection steps 4 Check fuse No good Replace fuse and check wire harness gt OK No good 2 Check battery Recharge or replace IT OK Check each coupler and No good Repair or replace wire connection gt OK N d 3 Check main switch TE OK Check starter motor No good i Repair or replace operation JG OK Check starting circuit No good Replace cut off relay
48. RIGHT CRANKCASE COVER OIL FILTER ELEMENT WATER PUMP AND RIGHT AE CRANKCASE COVER 20Nm 2 0m kg 14ft Ib Extent of removal CD Oil filter element removal 2 Water pump removal 3 Right crankcase cover removal OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANK CASE COVER REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Drain the coolant Refer to COOLANT REPLACEMENT section in the CHAPTER 3 Radiator hose 3 Disconnect at water pump side Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section Brake pedal Refer to ENGINE REMOVAL section Right engine guard o u 1 Oil filter element cover 1 i i 2 Oil filter element 1 4 57 OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANKCASE COVER 20Nm 2 0 m kg 14 ft Ib 3 Water pump housing Oil delivery pipe Bolt oil hose Kickstarter crank Right crankcase cover Impeller Washer Impeller shaft Oil seal Bearing Refer to REMOVAL POINTS sch N sch LL ol ol ol o CRANKCASE COVER REMOVAL POINTS Impeller shaft OIL FILTER ELEMENT WATER PUMP AND RIGHT ENG 1 Remove e Impeller 1 e Washer e Impeller shaft 3 NOTE Hold the impeller shaft on its width across the flats 8 with spanners etc and remove the impeller EC4G3210 Oil seal NOTE It is not necessary to disassemble the water pump unless there is an abnormal
49. RX e Brake fluid may erode painted surfaces or D LGI plastic parts Always clean up spilled SA DNN fluid immediately Brake caliper piston 1 Remove e Brake caliper piston Use compressed air and proceed care fully WARNING e Cover piston with rag and use extreme caution when expelling piston from cylin der e Never attempt to pry out piston Caliper piston removal steps e Insert a piece of rag into the brake caliper to lock one brake caliper e Carefully force the piston out of the brake caliper cylinder with compressed air Front Rear FRONT BRAKE AND REAR BRAKE CHASSO Brake caliper piston seal kit 1 Remove e Dust seal 1 e Piston seal 2 NOTE Remove the piston seals and dust seals by pushing them with a finger dust seals A WARNING Replace the piston seals and dust seals whenever a caliper is disassembled Front Rear EC5A4000 INSPECTION Brake master cylinder 1 Inspect e Brake master cylinder inner surface 8 Wear scratches Replace master cylin der assembly Stains Clean A WARNING Use only new brake fluid Front Rear 2 Inspect e Diaphragm 1 Crack damage Replace Front Rear 3 Inspect e Brake master cylinder piston 1 e Brake master cylinder cup Wear damage score marks Replace brake master cylinder kit Front Rear FRONT BRAKE AND REAR BRAKE CHASSO Brake caliper 1 Inspect Brake caliper cylind
50. Rinse the dirt and degreaser off with a gar den hose use only enough pressure to do the job Excessive hose pressure may cause water seepage and contamination of wheel bear ings front forks brakes and transmission seals Many expensive repair bills have resulted from improper high pressure detergent applications such as those avail able in coin operated car washers 4 After the majority of the dirt has been hosed off wash all surfaces with warm water and a mild detergent Use an old toothbrush to clean hard to reach places 5 Rinse the machine off immediately with clean water and dry all surfaces with a soft towel or cloth 6 Immediately after washing remove excess water from the chain with a paper towel and lubricate the chain to prevent rust 7 Clean the seat with a vinyl upholstery cleaner to keep the cover pliable and glossy 8 Automotive wax may be applied to all painted or chromed surfaces Avoid combi nation cleaner waxes as they may contain abrasives 9 After completing the above start the engine and allow it to idle for several min utes CLEANING AND STORAGE GEN gfr5 EC1B2001 STORAGE If your machine is to be stored for 60 days or more some preventive measures must be taken to avoid deterioration After cleaning the machine thoroughly prepare it for storage as follows 1 21 1 2 Drain the fuel tank fuel lines and the car buretor float bowl Remove the spark plug pour a
51. Starting circuit cut off relay Model manufacturer Coil winding resistance Fuse amperage x quantity Main fuse 10A x 1 Reserve fuse 10A x 1 Part to be tightened Thread Qt Tightening torque art to be tightene read size i 7 0 7 5 1 Stator M5 x 0 8 Holder AC magneto lead M5 x 0 8 ACM33221 MO6 MATSUSHITA 75 69 92 51 Q at 20 C 68 F Rotor M12 x 1 25 Neutral switch M5 x 0 8 Starter motor M6 x 1 0 Starter relay terminal M6 x 1 0 Negative lead and cylinder head M6 x 1 0 GENERAL TORQUE SPECIFICATIONS DEFINITION OF UNITS SPEC EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasten ers with standard l S O pitch threads Torque specifications for special components or assemblies are included in the applicable sec tions of this book To avoid warpage tighten multi fastener assemblies in a crisscross fash ion in progressive stages until full torque is reached Unless otherwise specified torque specifications call for clean dry threads Com ponents should be at room temperature A Distance between flats TORQUE B Outside thread diameter A B SPECIFICATION Nut Bolt ELSECTELA 6 0 6 4 3 EC230000 DEFINITION OF UNITS Um Red Demon Measure millimeter 103 meter centimeter 10 meter N Newton t kg x mise Foe Newton meter Nxm Torque Meter kilogram m x kg Torque Pascal NMP L Liter Volume or capacity cm Cubic centimeter Volume or ca
52. The engine must be cold Inspect Check the valve seats Replace and valve stems for wear VALVE SPRINGS Inspect Heplace VALVE LIFTERS Inspect Heplace CAMSHAFTS Inspect Replace Inspect the decompres sion system TIMING CHAIN SPROCKETS TIMING CHAIN Inspect Check for wear on the Replace teeth and for damage PISTON Inspect Inspect crack Clean Inspect carbon deposits Replace and eliminate them PISTON RING Inspect Replace PISTON PIN Inspect Replace CYLINDER HEAD Inspect carbon deposits Inspect and clean and eliminate them Change gasket CYLINDER Inspect and clean Inspect score marks Replace Inspect wear CLUTCH Inspect and adjust Replace Inspect housing friction plate clutch plate and spring TRANSMISSION Inspect Replace bearing MAINTENANCE INTERVALS After Every iE w ud As re Item Hemarks break in race ran 1 eg quired SHIFT FORK SHIFT CAM GUIDE BAR Inspect Inspect wear ROTOR NUT Retighten EXHAUST PIPE SILENCER PROTECTOR Inspect and retighten Clean Replace Whichever comes first SPARK ARRESTER Clean months CRANK CARBURETOR SPARK PLUG Inspect and clean Replace DRIVE CHAIN Use chain lube Lubricate slack alignment Chain slack Replace 40 50 mm 1 6 2 0 in COOLING SYSTEM Check coolant level and leakage Check radiator cap operation Replace coolant Inspect hoses OUTSIDE NUTS AND BOLTS Refer to STARTING emt eT SE in the CHAPTER 1 AIR FILTER Clean and
53. adjuster Standard position About 9 clicks out About 10 clicks out For EUROPE AUS NZ and ZA Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged DAMPING FORCE ADJUSTMENT ADJ EC36d000 REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT 1 Adjust e High compression damping force By turning the adjuster 1 REAR SHOCK ABSORBER HIGH COMPRESSION INSP Stiffer Increase the high compres sion damping force Turn the adjuster D in Softer bi Decrease the high compres sion damping force Turn the adjuster O7 out ex Extent of adjustment 2 turns out from maximum position Fully turned in position e STANDARD POSITION This is the position which is back by the spe cific number of turns from the fully turned in position Which align the punch mark on the adjuster with the punch mark on the adjuster body Standard position About 1 1 4 turns out Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged TIRE PRESSURE CHECK SPOKES INSPECTION AND INSP 40 TIGHTENING WHEEL INSPECTION ADJ Q EC36Q000 TIRE PRESSURE CHECK 1 Measure e Tire pressure Out of specification Adjust Standard tire pressure 100 kPa 1 0 kgf cm 15 psi 12070102 NOTE e Check the tire while it is cold Loose bead stoppers allow the tire to slip off
54. at 29 30 mm 12 6 14 4 kg at 29 30 mm 28 44 32 41 Ib at 1 15 in 3 Measure e Spring tilt Out of specification Replace Spring tilt limit Intake 2 5 1 7 mm 0 067 in Exhaust 2 5 1 6 mm 0 063 in Valve lifter 1 Inspect e Valve lifter Scratches damage Replace both lift ers and cylinder head VALVES AND VALVE SPRINGS ENG FS Combination of cylinder head and valve lifter 1 Combination For this combination match the paint color on the cylinder head with that on the valve lifter according to the chart below Cylinder head mark Valve lifter mark a color color Yellow Yellow NOTE LL When you purchase a cylinder head you can not designate its size Choose the valve lifter that matches the above chart ASSEMBLY AND INSTALLATION Valve and valve spring 1 Apply e Molybdenum disulfide oil Onto the valve stem and valve stem seal 2 Install e Valve 1 e Valve spring seat Valve stem seal 3 e Valve spring e Valve spring retainer 5 To cylinder head NOTE 2222222 e Make sure that each valve is installed in its original place also referring to the painted color as follows Intake middle 8 yellow Intake right left D white Exhaust no paint e Install the valve springs with the larger pitch C facing upward d Smaller pitch 11171201 VALVES AND VALVE SPRINGS ENG Z A 3 Install e Valve cotter NOTE W
55. cable holder 3 NOTE WW Loosen each bolt 1 4 of a turn at a time and after all the bolts are loosened remove them e Remove the right crankcase 2 NOTE e Place the crankcase with its left side downward and split it by inserting a screw driver tip into the splitting slit in the crankcase e Lift the right crankcase horizontally while lightly patting the case splitting slit and engine mounting boss using a soft ham mer and leave the crankshaft and trans mission with the left crankcase Use soft hammer to tap on the case half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If one end hangs up take pressure off the push screw realign and start over If the cases do not separate check for a remaining case screw or fitting Do not force e Remove the dowel pins and O ring FS CRANKCASE AND CRANKSHAFT ENG Crankshaft 1 Remove e Crankshaft 1 Use the crankcase separating tool 2 Crankcase separating tool YU 1135 A 90890 01135 Do not use a hammer to drive out the crankshaft Crankcase bearing 1 Remove Bearing NOTE e Remove the bearing from the crankcase by pressing its inner race e Do not use the removed bearing INSPECTION Timing chain and timing chain guide 1 Inspect e Timing chain Cracks stiff Replace the timing chain and camshaft sprocket as
56. cleaner if necessary 5 Tighten e Spark plug x 13 Nm 1 3 m kg 9 4 ft Ib NOTE e Before installing a spark plug clean the gas ket surface and plug surface e Finger tighten 8 the spark plug before torqu ing to specification b 18040301 IGNITION TIMING CHECK 1 Remove e Timing mark accessing screw 1 INSP IGNITION TIMING CHECK 2 Attach e Timing light e Inductive tachometer To the ignition coil lead orange lead 1 Timing light YM 33277 A 90890 03141 Inductive tachometer YU 8036 B Engine tachometer 90890 03113 3 Check e Ignition timing Checking steps e Start the engine and let it warm up Let the engine run at the specified speed e Adjust the engine idling speed Refer to ENGINE IDLING SPEED ADJUSTMENT section e Visually check the stationary pointer 8 is within the firing range on the rotor Incorrect firing range Check rotor and pickup assembly 4 Install e Timing mark accessing screw INSP 4o BATTERY INSPECTION AND CHARGING ADJ BATTERY INSPECTION AND CHARGING A WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid Therefore always follow these preventive measures e Wear protective eye gear when handling or working near batteries e Charge batteries in a well ventilated area e Keep batteries away from fire sparks or open flames e g welding e
57. e Radiator e Engine To specified level Recommended coolant High quality ethylene glycol anti freeze containing anti corrosion for aluminum engine Coolant 1 and water soft water 2 mixing ratio 5096 5096 Coolant capacity 1 3 L 1 14 Imp qt 1 37 US qt ene glycol antifreeze containing corro sion inhibitors for aluminum engine e Do not use water containing impurities or oil Handling notes of coolant The coolant is harmful so it should be han dled with special care A WARNING e When coolant splashes to your eye Thoroughly wash your eye with water and see your doctor e When coolant splashes to your clothes Quickly wash it away with water and then with soap e When coolant is swallowed Quickly make him vomit and take him to a doctor 10 Install e Radiator cap 11 Fill e Coolant reservoir tank Midway 8 between maximum and mini mum marks on the tank RADIATOR CAP INSPECTION INSP e RADIATOR CAP OPENING PRESSURE INSPECTION ADJ Q 14110101 14110202 12 Install e Coolant reservoir cap 13 Start the engine and let it warm up for sev eral minutes 14 Turn off the engine and inspect the coolant level Refer to COOLANT LEVEL INSPECTION section NOTE L L Before checking the coolant level wait a few minutes until the coolant settles EC355000 RADIATOR CAP INSPECTION 1 Inspect e Seal radiator cap e Valve and valve sea
58. eral times with the front brake applied 9 Install e Brake hose 1 To brake hose holder 2 NOTE LL Before tightening the bolt brake hose holder align the top 8 of the brake hose neck with the brake hose holder bottom b Then pass the brake hose in front of the axle boss O and fit it into the hose groove d so that the brake hose does not contact the nut wheel axle 10 Install e Brake hose cover 1 e Washer e Bolt brake hose cover M8 e Bolt brake hose cover M6 7 Nm 0 7 m kg 5 1 ft Ib FRONT WHEEL AND REAR WHEEL CHAS 11 Install e Trip meter cable 1 Rear wheel 1 Install e Bearing right 1 e Circlip e Spacer 3 e Bearing left Oil seal 5 NOTE 2 LLL e Apply the lithium soap base grease on the bearing and oil seal lip when installing e Install the bearing with seal facing outward e Use a socket that matches the outside diam eter of the race of the bearing e Right side of bearing shall be installed first e Install the oil seal with its manufacture s marks or numbers facing outward Do not strike the inner race of the bearing Contact should be made only with the outer race 2 Install e Brake disc 1 e Bolt brake disc 2 mm 14 Nm 1 4 m kg 10 ft Ib NOTE LLL Tighten the bolts in stage using a crisscross pattern FRONT WHEEL AND REAR WHEEL CHAS 3 Install e Rear wheel sprocket 1 e Bolt
59. kg 5 1 ft Ib LUBRICATION To ensure smooth operation of all components lubricate your machine during setup after break in and after every race CD All control cable 2 Clutch lever pivot 3 Shift pedal pivot 4 Footrest pivot 5 Throttle to handlebar contact 6 Drive chain Tube guide cable winding portion Throttle cable end 9 Clutch cable end Hot starter cable end INSP LUBRICATION Use Yamaha cable lube or equivalent on these areas Use SAE 10W 30 motor oil or suitable chain lubri cants Lubricate the following areas with high quality lightweight lithium soap base grease Wipe off any excess grease and avoid get ting grease on the brake discs ELECTRICAL SPARK PLUG INSPECTION INSP Oo IGNITION TIMING CHECK ADJ Q ELECTRICAL EC371001 SPARK PLUG INSPECTION 1 Remove e Spark plug 2 Inspect e Electrode 1 Wear damage Replace e Insulator color 2 Normal condition is a medium to light tan color Distinctly different color Check the engine condition NOTE L When the engine runs for many hours at low speeds the spark plug insulator will become sooty even if the engine and carburetor are in good operating condition 3 Measure e Plug gap 8 Use a wire gauge or thickness gauge Out of specification Regap Spark plug gap 0 7 0 8 mm 0 028 0 031 in 4 Clean the plug with a spark plug
60. kick start the engine in order to avoid the load on the motor e Do not open the throttle while kicking the kickstarter crank Otherwise the kick starter crank may kick back 7 Return the cold starter knob to its original position and run the engine at 3 000 5 000 r min for 1 or 2 minutes NOTE Since this model is equipped with an accelera tor pump if the engine is raced the throttle opened and closed the air fuel mixture will be too rich and the engine may stall Also unlike a two stroke engine this model can idle Do not warm up the engine for extended periods of time STARTING AND BREAK IN GEN aes STARTING A WARM ENGINE Do not operate the cold starter knob and throt tle Pull the hot starter lever 1 and start the engine by pushing the start switch or by kick ing the kickstarter crank forcefully with a firm stroke As soon as the engine starts Release the hot starter lever to close the air passage Restarting an engine after a fall Pull the hot starter lever and start the engine As soon as the engine starts Release the hot starter lever to close the air passage The engine fails to start Pull the hot starter lever all the way out and while holding the lever kick the kickstarter crank 10 to 20 times to clear the engine Then restart the engine Refer to Restarting an engine after a fall Throttle Cold Hot grip starter starter operation k
61. lock nut Distance 3 20 mm 0 79 in or more Between damper rod 1 top and 5 37 locknut top 22 Loosen e Rebound damping adjuster 1 NOTE e Loosen the rebound damping adjuster finger tight e Record the set position of the adjuster the amount of turning out the fully turned in posi tion 23 Install e Cushion rubber 1 e Washer e Spacer 3 To front fork cap bolt 4 NOTE Install the cushion rubber with its smaller dia end 8 facing the front fork cap bolt 24 Install e Push rod 0 e Fork spring NOTE L e Install the fork spring with the damper rod 3 pulled up e After installing the fork spring hold the damper rod end so that it will not go down 25 Install e Front fork cap bolt 1 Fully tighten the front fork cap bolt onto the damper rod by hand FRONT FORK CHASSO 26 Tighten e Front fork cap bolt locknut 1 29 Nm 2 9 m kg 21 ft Ib NODE c M e While compressing the fork spring set the thin type spanners 2 between the spacer 3 and spring guide 2 e Hold the locknut and tighten the front fork cap bolt with specified torque 27 Install e Front fork cap bolt 1 To outer tube NOTE Temporarily tighten the cap bolt 28 Install e Protector guide 1 Installation 1 Install e Front fork 1 NOTE LL e Temporarily ti
62. lower Front fender Rear fender front Rear fender rear Side cover Meter cable holder and front fork protector Headlight stay lower and lower bracket Headlight body and headlight unit M8 x 1 25 M6 x 1 0 M6 x 1 0 M8 x 1 25 M10 x 1 25 M10 x 1 25 M8 x 1 25 M10 x 1 25 M6 x 1 0 M8 x 1 25 M8 x 1 25 M6 x 1 0 M6 x 1 0 M16 x 1 5 M14 x 1 5 M14 x 1 5 M14 x 1 5 M10 x 1 25 M10 x 1 25 M8 x 1 25 M8 x 1 25 M5 x 0 8 M4 x 0 7 M8 x 1 25 M8 x 1 25 M6 x 1 0 M5 x 0 8 M6 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M8 x 1 25 M6 x 1 0 M5 x 0 8 M8 x 1 25 M6 x 1 0 72 MODNMONDNNNNDNNNAFTNOOHX HNN SS GO ch AANS HE Ke zk zb zb zk MM MM GO A OO ch Tightening torque 3 0 3 2 2 NO nN NNABNQGNONNAFPANNN GON GOOD 3 MAINTENANCE SPECIFICATIONS SPEC y Partio eser ecd Thread si Ot Tightening torque art to De lU ene read Size Headlight left and right Headlight lower M6 x 1 0 10 M6 x 1 0 M6 x 1 0 M4 x 1 59 M6 x 1 0 M10 x 1 25 M10 x 1 25 Taillight Taillight lead clamp and rear fender Coolant reservoir Sidestand bracket and frame Sidestand NOTE A marked portion shall be checked for torque tightening after break in or before each race MAINTENANCE SPECIFICATIONS SPEC y EC212300 ELECTRICAL Ignition system Advancer type Electrical CDI Pickup coil resistance color 248 372 Q at 20 C 68 F White
63. more than l 30 minutes before measuring its open circuit voltage prior to charging voltage Charger Ammeter NOTE Connect a charger and Set the charging voltage to 16 17 V If the ammeter to the battery charging voltage is lower charging will be insufficient if it is higher the battery will be and start charging over charged Is the amperage higher than the standard charging amperage written on the battery Adjust the charging voltage to 20 25 V Monitor the amperage for 3 5 minutes Is the standard charging amperage exceeded Adjust the voltage to obtain the standard charging amperage Set the timer to the charging If the amperage does not time determined by the open exceed the standard circuit voltage charging amperage after Refer to BATTERY 5 minutes replace the battery INSPECTION AND CHARGING section If the required charging time exceeds 5 hours it is advisable to check the charging amperage after 5 hours If there is any change in the amperage readjust the voltage to obtain the standard charging amperage Leave the battery unused for more than 30 minutes before measuring its open circuit voltage 12 8 V gt Charging is complete 12 0 12 7 V gt Recharging is required Under 12 0 V gt Replace the battery BATTERY INSPECTION AND CHARGING Charging method using a constant voltage charger NOTE Measure the ope
64. of specification Scrape the mica to the proper measurement with a hacksaw blade which has been grounded to fit the commutator Mica undercut 1 5 mm 0 06 in 18210901 The mica must be undercut to ensure proper operation of the commutator 4 Measure e Armature assembly resistances commu tator and insulation Out of specification Replace the starter motor e Measure the armature assembly resis tances with the pocket tester 18210201 Pocket tester YU 3112 C 90890 031 12 Armature assembly Commutator resistance 1 0 0189 0 0231 at 20 C 68 F Insulation resistance C Above 1 MQ at 20 C 68 F e f any resistance is out of specification replace the starter motor 6 14 ELECTRIC STARTING SYSTEM ELEC 5 Measure e Brush length Out of specification Replace the brushes as a set Min brush length 3 5 mm 0 14 in 6 Measure e Brush spring force Out of specification Replace the brush springs as a set 18210401 Brush spring force 3 92 5 88 N 400 600 gf 14 1 21 2 oz ASSEMBLY 1 Install e Brush spring e Brush 2 Install e Armature assembly 1 Install while holding down the brush using a thin screw driver installation 3 Install e Gasket 1 e Starter motor yoke NOTE 2 LLL e Install the starter motor yoke with its groove 8 facing front cover e Align the match mark on the starter mot
65. on the throttle cable end and tube guide cable wind ing portion 6 Install e Throttle cable cap D e Screw throttle cable cap A WARNING After tightening the screws check that the throttle grip moves smoothly If it does not retighten the bolts for adjustment 7 Install e Grip cap cover 1 e Cover throttle cable cap HANDLEBAR CHAS 8 Install e Start switch 1 e Brake master cylinder e Brake master cylinder bracket 3 e Bolt brake master cylinder bracket 9 Nm 0 9 m kg 6 5 ft Ib EN W Zb UE A xls u uo Mi 5 e he start switch and brake master cylinder bracket should be installed according to the dimensions shown e Install the bracket so that the arrow mark 8 faces upward e First tighten the bolt on the upper side of the brake master cylinder bracket and then tighten the bolt on the lower side Zero mm Zero mm Zero in Zero in 9 Install e Light switch 1 2 Nm 0 2 m kg 1 4 ft Ib 10 Install e Engine stop switch 1 e Clutch lever holder 2 e Bolt clutch lever holder 3 e Hot starter lever holder e Bolt hot starter lever holder 4 Nm 0 4 m kg 2 9 ft Ib e Clamp NOTE nmm e The engine stop switch clutch lever holder and clamp should be installed according to the dimensions shown e Pass the engine stop switch lead in the mid dle of the clutch lever holder Zero mm Zero in Esc
66. pin to piston clearance Measurement steps e Measure the outside diameter piston pin 8 If out of specification replace the piston pin Outside diameter piston pin 15 991 16 000 mm 0 6296 0 6299 in e Measure the inside diameter piston Inside diameter piston 16 002 16 013 mm 0 6300 0 6304 in e Calculate the piston pin to piston clear ance with the following formula Piston pin to piston clearance z Inside diameter piston Outside diameter piston pin 8 e f out of specification replace the piston Piston pin to piston clearance 0 002 0 022 mm 0 0001 0 0009 in Limit 0 07 mm 0 003 in ASSEMBLY AND INSTALLATION Piston ring and piston 1 Install e Piston ring Onto the piston o NOTE LL Be sure to install the piston rings so that the manufacturers marks or numbers are located on the upper side of the rings e Lubricate the piston and piston rings liberally E with engine oil CYLINDER AND PISTON ENG 2 Position e Top ring e 2nd ring e Oil ring Offset the piston ring end gaps as shown 8 Top ring end b 2nd ring end C Oil ring end upper Oil ring Oil ring end lower 3 Install e Piston 1 e Piston pin 2 e Piston pin clip 3 NOTE e Apply engine oil onto the piston pin and pis ton Be sure that the arrow mark 8 on the piston points to the exhaust side of the engine Before insta
67. removal Part name SEAT FUEL TANK AND SIDE COVERS REMOVAL Turn the fuel cock to OFF Disconnect the fuel hose Seat Air scoop left and right Fitting band Bolt fuel tank Fuel tank Left side cover Right side cover Headlight coupler Headlight Preparation for removal 1 2 3 4 5 6 D 8 9 7 Nm 0 7 m kg 5 1 ft Ib 23 Nm 2 3 m kg 17 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib 2 Fuel tank removal 4 Headlight removal Remove on fuel tank side Refer to REMOVAL POINTS c c NN NI SEAT FUEL TANK AND SIDE COVERS ENG REMOVAL POINTS Side cover 1 Remove e Bolt side cover e Left side cover 1 e Right side cover NOTE m Draw the side cover downward to remove it because its claws 3 are inserted in the air fil ter case EXHAUST PIPE AND SILENCER EC4S000 EXHAUST PIPE AND SILENCER ui Except for USA Extent of removal CD Silencer removal 2 Exhaust pipe removal EXHAUST PIPE AND SILENCER REMOVAL Right side cover Refer to SEAT FUEL TANK AND SIDE COVERS section Bolt silencer clamp Only loosening Bolt silencer front Bolt silencer rear Silencer Silencer clamp Nut exhaust pipe Bolt exhaust pipe Exhaust pipe Gasket N sch sch oL ol ol lo 1 2 3 4 5 6 D 8 9 EXHAUST PIPE AND SILENCER ENG Z A OD INSPECTION Silencer and exhaust
68. reservoir hose at the white tape for the tor lead at its protecting tube negative battery lead M A8 SE oe I p ws S S CABLE ROUTING DIAGRAM SPEC y Fasten the wire harness at its white tape Fasten the wire harness throttle position sensor lead in the wire harness starter motor lead and negative battery lead L Make sure that the throttle position sensor coupler does not go outside the chassis Fasten the throttle position sensor lead Pass the carburetor breather hoses carburetor overflow hose and coolant reservoir breather hose between the connecting rod and cross tube frame Fasten the neutral switch lead and oil hose together with the plastic locking ties and cut off the tie ends Pass the cylinder head breather hose through the hose guide Fasten the neutral switch lead O Fasten the neutral switch lead and AC magneto lead M A8 SE oe I p ws S S i St ok k N 9 d CABLE ROUTING DIAGRAM SPEC y P Pass the cylinder head breather hose on the Pass the wire harness clutch cable and light inside of the radiator hose 1 and on the outside of switch lead through the cable guide the radiator pipe radiator hose 4 Make sure that Fasten the AC magneto lead neutral switch lead the cylinder head breather hose does not go for and light switch lead to the cable guide at their ward of the chassis protecting tube with a plastic locking tie and cut off o
69. spring fits on the stopper b of the throttle shaft pulley 8 Install e Throttle shaft assembly 1 e Washer metal e Washer resin e Valve lever 2 NOTE L e Apply the fluorochemical grease on the bear ings e Fit the projection 8 on the throttle shaft assembly into the slot b in the throttle posi tion sensor e Make sure the stopper of the spring fits into the recess in the carburetor e Turn the throttle shaft assembly left while holding down the lever 1 and fit the throt tle stop screw tip d to the stopper 9 of the throttle shaft assembly pulley SK e A aS Kix 2 9 Install J e Push rod SGA NOTE While holding down the lever 1 2 insert the push rod farthest into the carburetor Xs S y FS 10 Install e Starter jet 1 e Pilot jet e Spacer 3 e Needle jet 4 e Main jet 11 Install e Needle valve 1 e Float e Float pin 3 NOTE je e After installing the needle valve to the float install them to the carburetor e Check the float for smooth movement 12 Install e Pilot screw 1 e Spring e Washer 3 e O ring Note the following installation points e Turn in the pilot screw until it is lightly seated e Turn out the pilot screw by the number of turns recorded before removing Pilot screw 2 turns out example 1 7 8 turns out
70. used to adjust a fuel mixture ratio for quick throttle opening and is therefore different from other setting parts that adjust a fuel mixture for each throttle opening each engine speed 1 The engine breathes hard in quick throttle opening Select a leak jet having lower calibrating No than standard to enrich the mixture Example 90 80 2 Rough engine operation is felt in quick throttle opening Select a leak jet having higher calibrating No than standard to lean out the mixture Example 90 100 Standard leak jet 90 Relationship with throttle opening The flow of the fuel through the carburetor main system is controlled by the main jet and then it is further regulated by the area between the main nozzle and the jet needle The fuel flow relates to the diameter of the straight portion of the jet needle with the throt tle 1 8 to 1 4 open and relates to the clip posi tion with the throttle 1 8 to 3 4 open Therefore the fuel flow is balanced at each stage of throttle opening by the combination of the jet needle straight portion diameter and clip position SETTING EC71Q000 Carburetor setting parts Parname Size Part number Main jet Rich Pilot jet Rich Jet needle Rich STD Y Lean Leak jet Rich STD Lean Except for USA 4MX 14943 97 4MX 14943 46 4MX 14943 96 4MX 14943 45 4MX 14943 95 4MX 14943 44 4MX 14943 94 4MX 14943 43 4MX 14943 93 4MX 14943 4
71. while being X Replace Continuous while being OFF Replace AC MAGNETO INSPECTION Wii 1 Inspect e Lighting coil resistance Out of specification Replace Tester lead Yellow lead 1 Tester lead Ground NDS DNS i IS Lighting coil Tester selector ri resistance position CM ME 0 224 0 336 Q at Ges 20 C 68 F RECTIFIER REGULATOR INSPECTION 1 Connect the battery leads 2 Start the engine 3 Turn on the headlight and taillight by turn ing on the light switch 4 Inspect e Out put voltage Out of specification Replace rectifier regulator Tester lead Yellow lead 1 Tester lead Black lead Out put voltage ES SEH position 13 0 14 0 V at mE 5 000 r min iid J SETTING TUNING EC710000 ENGINE Carburetor setting The air fuel mixture will vary depending on atmospheric conditions Therefore it is nec essary to take into consideration the air pres sure ambient temperature humidity etc when adjusting the carburetor e Perform a test run to check for proper engine performance e g throttle response and spark plug s discoloration or fouling Use these readings to determine the best possi ble carburetor setting NOTE C C It is recommended to keep a record of all car buretor settings and external conditions e g atmospheric conditions track surface condi tions lap times to mak
72. 00 SHIFT PEDAL The gear ratios of the constant mesh 5 speed transmission are ideally spaced The gears can be shifted by using the shift pedal 1 on the left side of the engine KICKSTARTER CRANK Rotate the kickstarter crank 1 away from the engine Push the starter down lightly with your foot until the gears engage then kick smoothly and forcefully to start the engine This model has a primary kickstarter crank so the engine can be started in any gear if the clutch is disen gaged In normal practices however shift to neutral before starting EC155001 THROTTLE GRIP The throttle grip 1 is located on the right han dlebar it accelerates or decelerates the engine For acceleration turn the grip toward you for deceleration turn it away from you EC156000 FRONT BRAKE LEVER The front brake lever 1 is located on the right handlebar Pull it toward the handlebar to acti vate the front brake 1 11 K CONTROL FUNCTIONS INFO 2S 1 12 EC157000 REAR BRAKE PEDAL The rear brake pedal 1 is located on the right side of the machine Press down on the brake pedal to activate the rear brake FUEL COCK The fuel cock supplies fuel from the tank to carburetor and also filters the fuel The fuel cock has three positions OFF With the lever in this position fuel will not flow Always return the lever to this posi tion when the engine is not running ON With the lever in this position fuel flows t
73. 1 4 10 Brake pedal M8 x 1 25 1 26 2 6 19 Rear brake master cylinder M6 x 1 0 2 11 1 1 8 0 Rear brake master cylinder cap M4 x 0 7 2 2 0 2 1 4 Rear brake hose union bolt M10 x 1 25 2 30 3 0 22 Rear wheel axle and axle nut M20 x 1 5 1 125 12 5 90 NOTE 1 First tighten the steering nut approximately 38 Nm 3 8 m kg 27 ft Ib by using the steering nut wrench then loosen the steering nut one turn 2 Retighten the steering nut 7 Nm 0 7 m kg 5 1 ft Ib 2 14 IN A Pl ee ED gt e e ee gt gt b gt MAINTENANCE SPECIFICATIONS SPEC ge Part to be tightened Nipple spoke Rear wheel sprocket Rear brake disc cover Rear brake caliper protector Drive chain puller adjust bolt and locknut Engine mounting Engine and engine bracket front Engine and frame lower Engine bracket and frame Engine and engine bracket upper Lower engine guard Left engine guard Right engine guard Regulator bracket and frame Regulator Pivot shaft and nut Relay arm and swingarm Relay arm and connecting rod Connecting rod and frame Rear shock absorber and frame Rear shock absorber and relay arm Rear frame upper Rear frame lower Swingarm and brake hose holder Swingarm and patch Upper drive chain tensioner Lower drive chain tensioner Drive chain support Seal guard and swingarm Fuel tank Fuel cock Seat set bracket and fuel tank Hooking screw fitting band and fuel tank Air scoop and fuel tank Air scoop and radiator guard
74. 1 46 in Quantity 5 Clutch housing thrust clearance 0 10 0 35 mm 0 0039 0 0138 in Clutch housing radial clearance 0 010 0 044 mm 0 0004 0 0017 in Clutch release method Inner push cam push Shifter Shifter type Cam drum and guide bar Guide bar bending limit 0 05 mm 0 002 in Kickstarter Te andra ype ae ZA AUS NZ Type manufacturer FCR MX37 KEIHIN c D mark 5UM1 00 5UM2 10 Main jet 185 172 Main air jet 2 0 c Jet needle OBDVS 4 OBELP 4 Cutaway 1 5 Pilot jet 40 Pilot air jet 75 Pilot outlet 0 9 Pilot screw example 2 Bypass 1 0 Valve seat size 93 8 Starter jet 72 Leak jet 90 Float height 8 mm 0 31 in Engine idle speed 1 900 2 100 r min Intake vacuum 26 7 32 0 kPa 200 240 mmHg 7 87 9 45 inHg 3 6 mm 0 12 0 24 in E FS TE E C ouwoo r Ni DD HHH HD ss NN P c Pm a Pc OTST Os LI m Dp upper ls Hot starter lever free play MAINTENANCE SPECIFICATIONS SPEC y Lubrication system Oil filter type Paper type Oil pump type Trochoid type Tip clearance 0 12 mm or less 0 20 mm 0 0047 in or less 0 008 in Side clearance 0 09 0 17 mm 0 24 mm 0 0035 0 0067 in 0 009 in Housing and rotor clearance 0 03 0 10 mm 0 17 mm 0 0012 0 0039 in 0 0067 in Cooling Radiator core size Width 117 8 mm 4 6 in Height 220 mm 8 7 in ise Thickness 32 mm 1 26 in m Radiator cap opening pressure 110 k
75. 135 These tool is used to remove the crankshaft from either case YU 3097 90890 01252 Dial gauge and stand 90890 01252 YU 1256 Stand These tools are used to check each part for runout or bent Crankshaft installing tool 90890 01274 YU 90050 90890 01274 Crankshaft installing pot ee YU 90050 90890 01275 Crankshaft installing bolt ef 7 90890 04081 YM 91044 90890 04081 Spacer crankshaft installer YU 90063 90890 01278 Adapter M12 e S These tools are used to install the crankshaft D YU 1304 90890 01304 Piston pin puller set 90980 01304 This tool is used to remove the piston pin YU 24460 01 90890 01325 Radiator cap tester YU 24460 01 90980 01325 YU 33984 90890 01352 Radiator cap tester adapter YU 33984 90980 01352 These tools are used for checking the cooling sys 5 2S tem YU 33975 90890 01403 Steering nut wrench YU 33975 90890 01403 This tool is used when tighten the steering ring nut to C 6 specification YM 1423 90890 01423 Damper rod holder YM 1423 90980 01423 Use this tool to remove and install the damper rod SPECIAL TOOLS Tool name How to use Illustration YM 01442 90890 01442 Fork seal driver 90890 01442 This tool is used when install the fork oil seal YU 3112 C 90890 03112 Pocket tester Use this tool to inspect the coil resistance output voltage and amperage YU 8036 B Inductive tachometer 90890 03113 Engine tachometer This tool is needed for observ
76. 2 4MX 14943 92 4MX 14943 41 4MX 14943 91 4MX 14943 40 4MX 14943 90 4MX 14943 39 4MX 14948 07 4MX 14948 06 4MX 14948 05 4MX 14948 04 4MX 14948 03 4MX 14948 02 4MX 14948 01 OBDVP 5BE 14916 DP OBDVQ 5BE 14916 D1 OBDVR 5BE 14916 DR OBDVS 5BE 14916 DS OBDVT 5BE 14916 DT OBDVU 5BE 14916 DU OBDVV 5BE 14916 DV OBELL 5NL 14916 EL OBELM 5NL 14916 EM OBELN 5NL 14916 EN OBELP 5NL 14916 EP OBELQ 5NL 14916 E1 OBELR 5NL 14916 ER OBELS 5NL 14916 ES 4JT 1494F 11 4JT 1494F 15 4JT 1494F 19 4JT 1494F 23 4JT 1494F 27 4JT 1494F 29 4JT 1494F 31 Examples of carburetor setting depending on symptom SETTING Symptom Setting Checking At full throttle Hard breathing Shearing noise Whitish spark plug l Increase main jet calibration no Gradually Lean mixture At full throttle Speed pick up stops Slow speed pick up Slow response Decrease main jet calibration no Gradually Sooty spark plug T Rich mixture 1 4 3 4 throttle Hard breathing Lack of speed 1 4 1 2 throttle Slow speed pick up Poor acceleration Lower jet needle clip position 1 groove down Raise jet needle clip position 1 groove up Lower jet needle clip position 1 groove down Raise jet needle clip position 1 groove up Closed to 1 4 throttle Hard breathing Speed down Closed to 1 4 throttle Poor acceleration Use jet needle with a smaller diameter Use jet needle with a larger diameter Raise je
77. 3 5 mm 0 20 in Swingarm 1 Install e Bushing e Thrust bearing e Oil seal 9 e Collar 4 To swingarm NOTE LL Apply the molybdenum disulfide grease on the bushings thrust bearings and oil seal lips D 2 Install e Collar To relay arm NOTE Apply the molybdenum disulfide grease on the collars and oil seal lips swiNGARnM CHAS 3 Install e Collar 1 To connecting rod 2 NOTE Apply the molybdenum disulfide grease on the collar and oil seal lips 4 Install e Connecting rod 1 e Bolt connecting rod e Washer 3 e Nut connecting rod 80 Nm 8 0 m kg 58 ft Ib To relay arm 5 NOTE LL Apply the molybdenum disulfide grease on the bolt 5 Install e Relay arm 1 e Bolt relay arm e Washer 3 e Nut relay arm 4 To swingarm NOTE 2 LLL e Apply the molybdenum disulfide grease on the bolt e Do not tighten the nut yet 6 Install e Swingarm 1 e Pivot shaft 2 x 85 Nm 8 5 m kg 61 ft Ib NOTE we e Apply the molybdenum disulfide grease on SO the pivot shaft OE i e Insert the pivot shaft from right side 7 Check e Swingarm side play 3 Free play exists Replace thrust bear ing e Swingarm up and down movement Unsmooth movement binding rough spots Grease or replace bearings bushings and collars swiNGAnM CHAS 8 Install e Bolt connecting rod 1 e Washe
78. 3 2 385 2nd 28 16 1 750 3rd 28 21 1 333 4th 25 24 1 042 5th 22 27 0 815 Chassis Frame type Semi double cradle Caster angle 27 1 Trail 117 4 mm 4 62 in Tire Type With tube Size front 80 100 21 51M For USA CDN and ZA 90 90 21 54R For EUROPE AUS and NZ Size rear 100 100 18 59M For USA CDN and ZA 130 90 18 69R For EUROPE AUS and NZ Tire pressure front and rear 100 kPa 1 0 kgf cm 15 psi Brake Front brake type Operation Rear brake type Operation Suspension Front suspension Rear suspension Shock absorber Front shock absorber Rear shock absorber Wheel travel Front wheel travel Rear wheel travel Electrical Ignition system Generator system Battery type Battery voltage capacity Specific gravity Headlight type Bulb wattage x quantity Headlight Taillight GENERAL SPECIFICATIONS SPEC e oingle disc brake Right hand operation Single disc brake Right foot operation Telescopic fork owingarm link type monocross suspension Coil spring oil damper Coil spring gas oil damper 300 mm 11 8 in 315 mm 12 4 in CDI AC magneto YTX5L BS 12 V 4 AH 1 320 Quartz bulb halogen 12 V 60 55 W x 1 12 V 21 5 W x 1 MAINTENANCE SPECIFICATIONS SPEC ge MAINTENANCE SPECIFICATIONS ENGINE Item Cylinder head Warp limit Cylinder Bore size Out of round limit Camshaft Drive method Camshaft cap inside diameter Camshaft outside diameter Shaft to cap
79. 5 6 T7 8 9 sch zeck eck sch sch 01 sch curren ENG 10Nm 1 0 m kg 7 2ft Ib 8Nm 0 8m kg 5 8ft Ib 10 Friction plate e v Clutch plate Cushion spring Seat plate Nut clutch boss Look washer Use special tool Refer to REMOVAL POINTS Clutch boss Thrust washer Primary driven gear ol Push lever shaft sch sch sch sch eck CO CO curren ENG REMOVAL POINTS Clutch boss 1 Remove e Nut 1 e Lock washer e Clutch boss 3 NOTE 777 7 otraighten the lock washer tab and use the clutch holding tool 4 to hold the clutch boss Vz Clutch holding tool YM 91042 90890 04086 For USA and CDN Except for USA and CDN EC4A4000 INSPECTION EC484100 Clutch housing and boss 1 Inspect e Clutch housing Cracks wear damage Replace e Clutch boss 2 scoring wear damage Replace EC484201 Primary driven gear 1 Check e Circumferential play Free play exists Replace e Gear teeth 8 Wear damage Replace Clutch spring 1 Measure Clutch spring free length Out of specification Replace springs as a set Clutch spring free length 37 0 mm 1 46 in Limit 36 0 mm 1 42 in 11412901 11411101 11411901 curren ENG Friction plate 1 Measure e Friction plate thickness Out of specification Replace friction plate as a set Measure at all four p
80. 50000 CONTROL FUNCTIONS MAIN SWITCH Functions of the respective switch positions are as follows ON The engine can be started only at this position OFF All electrical circuits are switched off Main switch indicator light The main switch 1 is equipped with an indica tor light to avoid forgetting to turn it off This light functions as follows e It lights up with the main switch ON e t goes out when the engine increases its speed after being started e t lights up again when the engine is stopped NOTE L If the indicator light will not light up with the main switch ON it shows a lack of the battery voltage Recharge the battery If the engine is kick started turn off the light switch ENGINE STOP SWITCH The engine stop switch 1 is located on the left handlebar Continue pushing the engine stop switch till the engine comes to a stop Nis wal e g um START SWITCH The start switch 1 is located on the right han dlebar Push this switch to crank the engine with the starter 1 10 CONTROL FUNCTIONS INFO 265 EC152000 CLUTCH LEVER l The clutch lever 1 is located on the left han Siren dlebar it disengages or engages the clutch a 7 Gi ALL Pull the clutch lever to the handlebar to disen EN gage the clutch and release the lever to p engage the clutch The lever should be pulled rapidly and released slowly for smooth starts EC1530
81. 65 0 1571 in 4 460 4 475 mm 0 1756 0 1762 in 4 000 4 012 mm 0 1575 0 1580 in 4 500 4 512 mm 0 1772 0 1776 in 0 010 0 037 mm 0 0004 0 0015 in 0 025 0 052 mm 0 0010 0 0020 in Ed D Margin thickness 1 6 mm 0 0630 in 1 6 mm 0 0630 in 3 945 mm 0 1553 in 4 430 mm 0 1744 in 4 050 mm 0 1594 in 4 550 mm 0 1791 in 0 08 mm 0 003 in 0 10 mm 0 004 in MAINTENANCE SPECIFICATIONS SPEC y Stem runout limit Valve seat width Valve spring Free length Set length valve closed Compressed force installed Tilt limit Direction of winding top view Piston Piston to cylinder clearance Piston size D Measuring point H Piston off set 0 9 1 1 mm 0 0354 0 0433 in 0 9 1 1 mm 0 0354 0 0433 in 37 81 mm 1 49 in 37 54 mm 1 48 in 29 13 mm 1 15 in 29 30 mm 1 15 in 99 114 N at 29 13 mm 9 9 11 4 kg at 29 13 mm 22 27 25 57 Ib at 1 15 in 126 144 N at 29 30 mm 12 6 14 4 kg at 29 30 mm 28 44 32 41 Ib at 1 15 in Clockwise Clockwise 0 040 0 065 mm 0 0016 0 0026 in 76 955 76 970 mm 3 0297 3 0303 in 8 mm 0 31 in 0 5 mm 0 020 in IN side 0 01 mm 0 0004 in 1 6 mm 0 0630 in 1 6 mm 0 0630 in 35 9 mm 1 41 in 35 7 mm 1 41 in 2 5 1 7 mm 2 5 0 067 in 2 5 1 6 mm 2 5 0 063 in 0 1 mm 0 004 in MAINTENANCE SPECIFICATIONS SPEC y Piston pin bor
82. ADJUSTMENT 2 Adjust e Clutch lever free play Clutch lever free play adjustment steps e Loosen the locknuts 1 e Adjust the free play by changing their tight S EIxX PAN Ne P0 alt ening position e Tighten the locknuts NOTE O e Make minute adjustment on the lever side using the adjuster 2 e After adjustment check proper operation of clutch lever 1 Check e Throttle grip free play Out of specification Adjust SS Throttle grip free play 3 5 mm 0 12 0 20 in 2 Adjust e Throttle grip free play N THROTTLE CABLE ADJUSTMENT Throttle grip free play adjustment steps e Slide the adjuster cover e Loosen the locknut 1 e Turn the adjuster 2 until the specified free play is obtained e Tighten the locknut NOTE 2 LL Before adjusting the throttle cable free play the engine idle speed should be adjusted A WARNING After adjusting the throttle cable free play start the engine and turn the han dlebar to right and left and make sure that the engine idling does not run faster THROTTLE LUBRICATION INSP e HOT STARTER LEVER ADJUSTMENT ADJ Q THROTTLE LUBRICATION 1 Remove e Cover throttle cable cap e Cover grip cap e Throttle grip cap 2 Apply e Lithium soap base grease On the throttle cable end 3 Install e Throttle grip cap e Screw throttle grip cap e Cover grip cap e Cover thr
83. AR SHOCK ABSORBER INSPECTION 1 Inspect e Swingarm smooth action Abnormal noise unsmooth action Grease the pivoting points or repair the pivoting points Damage oil leakage Replace REAR SHOCK ABSORBER SPRING PRELOAD INSP 4o ADJUSTMENT ADJ Q REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT Z 1 Elevate the rear wheel by placing the suit E able stand under the engine tS 2 Remove e Rear frame 3 Loosen e Locknut 4 Adjust e Spring preload By turning the adjuster Stiffer Increase the spring preload Turn the adjuster in Softer Decrease the spring preload Turn the adjuster out ex Spring length installed 3 Standard length Extent of adjustment 245 mm 9 65 in 240 5 258 5 mm 246 5 mm 9 70 in 9 47 10 18 in For EUROPE NOTE 22222222 LLL e Be sure to remove all dirt and mud from around the locknut and adjuster before adjustment e The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster C CAUTION Never attempt to turn the adjuster beyond the maximum or minimum setting 5 Tighten e Locknut 6 Install e Rear frame upper o 32 Nm 3 2 m kg 23 ft Ib e Rear frame lower o 29 Nm 2 9 m kg 21 ft Ib REAR SHOCK ABSORBER REBOUND DAMPING FORCE INSP de ADJUSTMENT ADJ Q REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1 Adjust e Rebound damping force
84. BATTERY INSPECTION AND CHARGING ADJ 4 Measure e Battery charge Measurement steps e Connect a pocket tester 1 to the battery terminals Tester positive probe battery positive terminal Tester negative probe battery negative terminal NOTE e The charge state of an MF battery can be checked by measuring its open circuit volt age i e the voltage when the positive ter minal is disconnected e No charging is necessary when the open circuit voltage equals or exceeds 12 8 V e Check the charge of the battery as shown in the charts and the following example Example Open circuit voltage 12 0 V Charging time 6 5 hours Charge of the battery 20 30 Relationship between the open circuit voltage and the charging time at 20 C 68 F These values vary with the temperature the condition of the battery plates and the electro lyte level Open circuit voltage Charging time hours D Time minutes Charging condition of the battery Ambient temperature 20 C 68 F 8 Charging D Check the open circuit voltage INSP 4o BATTERY INSPECTION AND CHARGING ADJ 5 Charge e Battery refer to the appropriate charging method illustration A WARNING Do not quick charge a battery Never remove the MF battery sealing caps Do not use a high rate battery charger since it forces a high amperage current into the battery
85. C5 Za H Sm Ok e EE m O S ME Qi E oe S85 9 oO OU o C 0 CH A ij j 2 LLA WANTS EU SRS Po V 4 21 CAMSHAFTS g CAMSHAFTS CYLINDER HEAD COVER Go Extent of removal CD Cylinder head cover removal CYLINDER HEAD COVER REMOVAL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Carburetor Refer to CARBURETOR section Spark plug Cylinder head breather hose Oil tank breather hose Bolt cylinder head cover Cylinder head cover Cylinder head cover gasket Timing chain guide top side CAMSHAFTS CAMSHAFTS 10 Nm 1 0 m kg 7 2 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib Extent of removal 1 Camshaft removal CAMSHAFTS REMOVAL Timing mark accessing screw Crankshaft end accessing screw Timing chain tensioner cap bolt Timing chain tensioner Camshaft cap Clip Exhaust camshaft Intake camshaft Refer to REMOVAL POINTS ON OOF WD H N N sech sch ae NF a E c AES UK TERES EE V J 7 NV is CO FS REMOVAL POINTS Camshaft 1 Remove e Timing mark accessing screw 1 e Crankshaft end accessing screw 2 Align e T D C mark With align mark Checking steps e Turn the crankshaft counterclockwise with a wrench Align the T D C mark on the rotor with the align mark b on the crankcase cover w
86. CE cold 0 91 0 95 0 17 0 22 mm 0 96 1 00 Example Installed is 175 Wem Measured clearance is 0 27 mm 111 145 Replace 175 pad with 185 pad 116 24 50 Pad number example 1 21 1 25 Pad No 175 2 1 75 mm 1 26 1 30 Pad No 185 2 1 85 mm 1 31 1 35 1 36 1 40 INSP SPARK ARRESTER CLEANING For USA Wer SPARK ARRESTER CLEANING For USA A WARNING e Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester e Do not start the engine when cleaning the exhaust system 1 Remove e Bolt spark arrester 1 2 Remove e Spark arrester 1 Pull the spark arrester out of the muffler 3 Clean e Spark arrester Tap the spark arrester lightly then use a wire brush to remove any carbon depos its 4 Install e Spark arrester Insert the spark arrester into the muffler and align the bolt holes e Bolt spark arrester w 10 Nm 1 0 m kg 7 2 ft Ib INSP 4o CHASSIS BRAKE SYSTEM AIR BLEEDING ADJ CHASSIS EC361012 BRAKE SYSTEM AIR BLEEDING A WARNING Bleed the brake system if e The system has been disassembled e A brake hose has been loosened or removed e The brake fluid is very low e The brake operation is faulty A dangerous loss of braking performance may occur if the brake system is not prop erly bled 1 Remove e Brake master cylinder cap e Diaphragm
87. CLEARANCE INSPECTION AND ADJUSTMENT ADJ Q INTAKE MEASURED INSTALLED PAD NUMBER CLEARANCE 165 170 175 180 185 190 195 0 00 0 04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 0 05 0 09 0 10 0 15 0 16 0 20 0 21 0 25 0 26 0 30 0 31 0 35 0 36 0 40 0 41 0 45 0 46 0 50 0 51 0 55 0 56 0 60 0 61 0 65 0 66 0 70 0 71 0 75 oe VALVE CLEARANCE cold 0 81 0 85 0 10 0 15 0 86 0 90 dor LUN 0 91 0 95 Example Installed is 175 0 96 1 00 Measured clearance is 0 22 mm 1 01 1 05 Replace 175 pad with 185 pad 1 06 1 10 Pad number example 1 11 1 15 Pad No 175 1 75 mm 1 16 1 20 B 121 125 Pad No 185 1 85 mm 1 26 1 30 1 31 1 35 EXHAUST MEASURED INSTALLED PAD NUMBER CLEARANCE 165 170 175 180 185 190 195 0 00 0 04 120 125 130 135 140 145 150 155 160 165 170 175 180 0 05 0 09 0 10 0 16 0 17 0 22 0 23 0 25 0 26 0 30 0 31 0 35 0 36 0 40 0 41 0 45 0 46 0 50 0 51 0 55 0 56 0 60 0 61 0 65 0 66 0 70 0 71 0 75 0 76 0 80 0 81 0 85 0 86 0 90 VALVE CLEARAN
88. E D L 7A ae SE SS Ge CE Sum s epe Sg X vr Am If a l CABLE ROUTING DIAGRAM SPEC y D Throttle cable 2 Brake hose 3 Clamp GO Light switch lead 5 Hot starter cable 6 Clutch cable Hose guide Clutch switch lead 9 Engine stop switch lead Trip meter cable n Main switch lead 2 Trip meter 3 Main switch Light switch 5 Start switch lead Fasten the start switch lead and light switch lead Fasten the engine stop switch lead and clutch switch lead Pass the brake hose through the hose guide D Pass the start switch lead in front of the main switch lead Fasten the start switch lead F Pass the hot starter cable clutch cable and light switch lead between the upper bracket and coupler bracket Pass the throttle cables between the upper bracket and trip meter MAINTENANCE INTERVALS EC300000 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS The following schedule is intended as a general guide to maintenance and lubrication Bear in mind that such factors as weather terrain geographical location and individual usage will alter the required maintenance and lubrication intervals If you are a doubt as to what intervals to follow in maintaining and lubricating your machine consult your Yamaha dealer Im pae or jl pae reo mm Item or or Hemarks break in race 500 km 1 000 km quired ENGINE OIL Heplace Inspect VALVES Check the valve clearances
89. EAR BRAKE PAD INSPECTION AND REPLACEMENT 1 Inspect e Brake pad thickness 8 Out of specification Replace as a set Brake pad thickness 6 4 mm 0 25 in Limit 1 0 mm 0 04 in 2 Replace e Brake pad Brake pad replacement steps e Remove the protector 1 and pad pin plug 2 e Loosen the pad pin e Remove the rear wheel 2 and brake cali per Refer to FRONT WHEEL AND REAR WHEEL section in the CHAPTER 5 Ay e SS P ES SANG ws INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT e Remove the pad pin and brake pads 2 e Connect the transparent hose to the bleed screw 9 and place the suitable con tainer under its end e Loosen the bleed screw and push the brake caliper piston in Bleed screw 6 Nm 0 6 m kg 4 3 ft Ib e Install the brake pad 9 and pad pin 4 NOTE I c e Install the brake pads with their projections a into the brake caliper recesses b e Temporarily tighten the pad pin at this point e Install the brake caliper 2 and rear wheel 3 Refer to FRONT WHEEL AND REAR WHEEL section in the CHAPTER 5 e Tighten the pad pin 4 XY Pad pin ZN 18 Nm 1 8 me kg 13 ft Ib e Install the pad pin plug 5 and protector 6 Pad pin plug oa 3 Nm 0 3 me kg 2 2 ft Ib Bolt protector 7 Nm 0 7 m kg 5 1 ft Ib REAR BRAKE PAD INSULATOR INSPECTION
90. ERING HEAD INSPECTION AND ADJUSTMENT ADJ e Tighten the steering ring nut 3 using steering nut wrench 2 NOTE nmm oet the torque wrench to the steering nut wrench so that they form a right angle Steering nut wrench YU 33975 90890 01403 Steering ring nut initial tightening 38 Nm 3 8 m kg 27 ft Ib e Loosen the steering ring nut one turn e Retighten the steering ring nut using the steering nut wrench A WARNING Avoid over tightening Steering ring nut final tightening 7 Nm 0 7 m kg 5 1 ft Ib e Check the steering stem by turning it lock to lock If there is any binding remove the steering stem assembly and inspect the steering bearings e nstall the washer 5 upper bracket 6 washer 7 steering stem nut 8 steering stem cap 9 handlebar 9 handlebar upper holder Op and headlight 2 NOTE e The handlebar upper holder should be installed with the punched mark 8 forward e Insert the end of the fuel breather hose 3 into the hole in the steering stem cap I i 2 y 2 di 7 VJ V SE the handlebar upper holder and then tighten the bolts on the rear side Steering stem nut 145 Nm 14 5 m kg 105 ft Ib Handlebar upper holder 28 Nm 2 8 m kg 20 ft Ib Pinch bolt upper bracket 23 Nm 2 3 m kg 17 ft Ib Headlight left and right 10 Nm 1 0 m kg 7 2 ft Ib Headlight lower 7 Nm 0 7 m
91. INSP Oo BRAKE FLUID LEVEL INSPECTION ADJ Q 3 Inspect e Brake fluid level Refer to BRAKE FLUID LEVEL INSPEC TION section 4 Check e Brake pedal operation A softy or spongy feeling Bleed brake system Refer to BRAKE SYSTEM AIR BLEED ING section EC36b000 REAR BRAKE PAD INSULATOR INSPECTION 1 Remove e Brake pad Refer to REAR BRAKE PAD INSPEC TION AND REPLACEMENT section 2 Inspect e Rear brake pad insulator 1 Damage Replace BRAKE FLUID LEVEL INSPECTION 1 Place the brake master cylinder so that its top is in a horizontal position 2 Inspect e Brake fluid level Fluid at lower level Fill up 8 Lower level Front Rear Recommended brake fluid DOT 4 A WARNING e Use only designated quality brake fluid to avoid poor brake performance e Refill with same type and brand of brake fluid mixing fluids could result in poor brake performance e Be sure that water or other contaminants do not enter master cylinder when refill ing e Clean up spilled fluid immediately to avoid erosion of painted surfaces or plas tic parts INSP SPROCKETS INSPECTION DRIVE CHAIN INSPECTION SPROCKETS INSPECTION 1 Inspect e Sprocket teeth 8 Excessive wear Replace NOTE Replace the drive sprocket rear wheel sprocket and drive chain as a set DRIVE CHAIN INSPECTION 1 Remove e Drive chain 1 NOTE 777 222 Remove the drive chain u
92. Ib NOTE ee Fit the hook on the inner side first into the radiator 7 Install e Coolant reservoir 1 e Bolt coolant reservoir e Coolant reservoir hose 3 e Coolant reservoir breather hose 2 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 8 Fill e Radiator e Engine e Coolant reservoir Hefer to COOLANT REPLACEMENT section in the CHAPTER 3 CARBURETOR CARBURETOR Oui A 4 Nm 0 4 m kg 2 9 ft Ib A A 4 Nm 0 4 m kg 2 9 ft Ib 3 Nm 0 3 m kg 2 2 ft Ib 3 Nm 0 3 m kg 2 2 ft Ib Extent of removal Carburetor removal CARBURETOR REMOVAL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Clamp Throttle position sensor lead cou pler Throttle cable cover Throttle cable Clamp air filter joint Loosen the screw air filter joint Clamp carburetor joint Loosen the screws carburetor joint Hot starter plunger Carburetor assembly Carburetor joint CARBURETOR EC468000 CARBURETOR DISASSEMBLY M 0 CO CT Extent of removal D Carburetor disassembly re sch sch o sch A D 2 3 5 CARBURETOR DISASSEMBLY Carburetor breather hose Valve lever housing cover Screw throttle shaft Throttle valve Needle holder Jet needle Accelerator pump cover Spring Diaphragm accelerator pump Air cut valve cover Spring air cut valve
93. LVE SPRINGS ENG VALVES AND VALVE SPRINGS Extent of removal Valve removal VALVES AND VALVE SPRINGS REMOVAL 5 5 0 Valve lifter Adjusting pad Valve cotter Valve spring retainer Use special tool Refer to REMOVAL POINTS Valve spring Valve stem seal Valve spring seat Exhaust valve Intake valve EEGEN VALVES AND VALVE SPRINGS ENG FS REMOVAL POINTS Valve lifter and valve cotter 1 Remove e Valve lifter 1 e Pad NOTE Identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place 2 Check e Valve sealing Leakage at the valve seat Inspect the valve face valve seat and valve seat width Checking steps e Pour a clean solvent into the intake and exhaust ports e Check that the valve seals properly There should be no leakage at the valve seat 2 3 Remove e Valve cotter NOTE LL Attach a valve spring compressor 1 between the valve spring retainer and the cylinder head to remove the valve cotters Valve spring compressor 11171201 YM 4019 90890 04019 VALVES AND VALVE SPRINGS ENG op 11172102 11170601 Z A INSPECTION Valve 1 Measure e Stem to guide clearance Stem to guide clearance valve guide inside diameter 8 valve stem diameter Out of specification Replace the valve guide Clearance stem to guide Intake 0 010
94. ME STATES DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS SO THE ABOVE WARRANTY QUESTIONS AND ANSWERS Q What costs are my responsibility during the warranty period A The customer s responsibility includes all costs of normal maintenance services non war ranty repairs accident and collision damage and oil oil filters air filters spark plugs and brake shoes or pads I e What are some examples of abnorma A These terms are general and overlap each other in areas Specific examples include Run strain neglect or abuse LIMITATION MAY NOT APPLY TO YOU ALSO EXCLUDED FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE SOME STATES DO NOT ALLOW THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES SO THE ABOVE EXCLUSION MAY NOT APPLY TO YOU THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE YAMAHA MOTOR CORPORATION U S A Post Office Box 6555 Cypress California 90630 CUSTOMER SERVICE If your machine requires warranty service you must take it to any authorized Yamaha motorcycle dealer within the continental United States Be sure to bring your warranty registration identification or other valid proof of the original date of purchase If a question or problem arises regarding warranty first contact the owner of the dealer ship Since all warranty matters are handled at the dea
95. NITION SYSTEM ssss 6 3 ELECTRIC STARTING SYSTEM 6 8 CHARGING SYSTEM 6 17 THROTTLE POSITION SENSOR SYSTEM EE 6 19 LIGHTING SYSTEM sss 6 24 CHAPTER 7 TUNING ENGINE eneen 7 1 CHASSIS sse 7 11 GENERAL INFORMATION DESCRIPTION Clutch lever 2 Hot starter lever 3 Engine stop switch 2 Trip meter Main switch 6 Light switch 7 Start switch Front brake lever 9 Throttle grip Radiator cap 0 Fuel tank cap 2 Taillight OO Kickstarter crank Fuel tank 5 Headlight Radiator OO Coolant drain bolt Rear brake pedal Valve joint GO Fuel cock Gi Cold starter knob GH Air cleaner 3 Drive chain Gi Shift pedal 65 Oil dipstick 6 Front fork DESCRIPTION GEN aes NOTE e The machine you have purchased may differ slightly from those shown in the following e Designs and specifications are subject to change without notice Ac qo XA y MACHINE IDENTIFICATION GEN aes EC120001 MACHINE IDENTIFICATION There are two significant reasons for knowing the serial number of your machine 1 When ordering parts you can give the number to your Yamaha dealer for positive identification of the model you own 2 If your machine is stolen the authorities will need the number to search for and identify your machine EC121001 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 0 is stamped on the right of t
96. NOTE 2 LLL Remove the bearing by pressing its outer race RN A b N 3 Remove i Lower bearing 1 NOTE 2L Remove the bearing by pressing its outer race EC584000 INSPECTION Rear shock absorber 1 Inspect e Damper rod 1 Bends damage Replace rear shock absorber assembly e Shock absorber 2 Oil leaks Replace rear shock absorber assembly Gas leaks Replace rear shock absorber assembly e Spring 3 Damage Replace spring Fatigue Replace spring Move spring up and down e Spring guide 4 Wear damage Replace spring guide Bearing Free play exists unsmooth revolution rust Replace REAR SHOCK ABSORBER CHAS EC585000 ASSEMBLY AND INSTALLATION EC585300 Bearing 1 Install e Upper bearing CO NOTE nmm Install the bearing parallel until the stopper ring groove appears by pressing its outer race o not apply the grease on the bearing outer race because it will wear the rear shock absorber surface on which the bear ing is press fitted 2 Install e Stopper ring upper bearing NOTE After installing the stopper ring push back the bearing until it contacts the stopper ring 3 Install i Lower bearing 1 NOTE Install the bearing by pressing it on the side having the manufacture s marks or numbers Installed depth of the bearing 3 4 mm 0 16 in Spring rear shock absorber 1 Install ez e Spring 7
97. OTE Align the notch 8 on the segment with the pin D on the shift cam g KICK SHAFT AND SHIFT SHAFT ENG EC4B5111 Stopper lever 1 Install e Torsion spring e Stopper lever Bolt stopper lever 3 gt 10 Nm 1 0 m kg 7 2 ft Ib NOTE S Align the stopper lever roller with the slot on segment Shift guide and shift lever assembly 1 Install e Spring 1 e Pawl pin e Pawl 3 To shift lever 4 NOTE Apply the engine oil on the spring pawl pin and pawl 2 Install e Shift lever assembly 1 To shift guide 2 3 Install e Shift lever assembly 1 e Shift guide NOTE LL M e The shift lever assembly is installed at the same time as the shift guide e Apply the engine oil on the bolt segment shaft 4 Install Bolt shift guide Q gt 10 Nm 1 0 m kg 7 2 ft Ib KICK SHAFT AND SHIFT SHAFT ENG Shift shaft 1 Install e Roller e Collar 2 e Torsion spring 3 e Shift shaft 4 NOTE cl l Apply the engine oil on the roller and shift shaft 2 Install e Shift pedal Refer to AC MAGNETO AND STARTER CLUTCH section Kick shaft assembly 1 Install e Kick gear 1 e Washer e Circlip e Ratchet wheel 4 e Spring 5 e Washer 6 e Circlip To kick shaft 8 NOTE 7777 e Apply the molybdenum disulfide oil on the in
98. Pa 1 1 kg cm 15 6 psi Radiator capacity total 0 6 L 0 53 Imp qt 0 63 US qt Water pump Type Single suction centrifugal pump Exhaust pipe protector MAINTENANCE SPECIFICATIONS SPEC y Spark plug Camshaft cap Cylinder head blind plug screw Cylinder head stud bolt stud bolt bolt nut Cylinder head cover Cylinder Balancer weight Balancer shaft driven gear Timing chain guide intake side Timing chain tensioner Timing chain tensioner cap bolt Impeller Radiator hose clamp Coolant drain bolt Water pump housing Radiator Radiator guard Radiator pipe Oil pump cover Oil pump Oil filter element drain bolt Cil filter element cover Oil strainer Oil delivery pipe 1 M10 M8 Oil hose Oil hose clamp Oil strainer and frame Carburetor joint clamp Air filter joint clamp Throttle cable pull Throttle cable return Throttle cable cover Hot starter plunger Air filter case Air filter joint and air filter case Exhaust pipe nut bolt M10S x 1 0 M6 x 1 0 M12 x 1 0 M6 x 1 0 M8 x 1 25 M9 x 1 25 M6 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M14 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M8 x 1 25 M6 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M4 x 0 7 M6 x 1 0 M6 x 1 0 M6 x 1 0 M6 x 1 0 M10 x 1 25 M8 x 1 25 M6 x 1 0 M14 x 1 5 M4 x 0 7 M6 x 1 0 M6 x 1 0 M12 x 1 0 M5 x 0 8 M12 x 1 0 M6 x 1 0 M5 x 0 8 M8 x 1 25 M8 x 1 25 M6 x 1 0 Part to be tightened Y m 13 O 1 2
99. REMOVAL Preparation for removal Engine Refer to ENGINE REMOVAL section Piston Refer to CYLINDER AND PISTON sec tion Kick shaft assembly Refer to KICK SHAFT AND SHIFT Segment SHAFT section Stator Refer to AC MAGNETO AND STARTER CLUTCH section Balancer shaft Refer to BALANCER section Timing chain guide intake side Timing chain Oil delivery pipe 2 4 92 CRANKCASE AND CRANKSHAFT 10Nm 1 0m kg 7 2ft Ib D M PP Ze ema 10Nm 1 0m kg 7 2ft Ib 10Nm 1 0m kg 7 2ft Ib 12Nm 1 2m kg 8 7 ft lb Bolt L 2 45 mm 1 77 in Bolt L 2 55 mm 2 17 in Bolt L 2 70 mm 2 76 in Hose guide Clutch cable holder Right crankcase Left crankcase Oil strainer Crankshaft Use special tool Refer to REMOVAL POINTS Refer to REMOVAL POINTS FS CRANKCASE AND CRANKSHAFT ENG CRANKCASE BEARING 10Nm 1 0 m kg 7 2ft Ib 10Nm 1 0 m kg 7 2ft Ib 10Nm 1 0m kg 7 2ft Ib Extent of removal Crankcase bearing removal CRANKCASE BEARING REMOVAL Preparation for removal Transmission Refer to TRANSMISSION SHIFT Shift cam and shift fork CAM AND SHIFT FORK section a 1 Oil seal 2 i 2 Bearing 10 Refer to REMOVAL POINTS RY CRANKCASE AND CRANKSHAFT ENG REMOVAL POINTS Crankcase 1 Separate e Right crankcase e Left crankcase Separation steps e Remove the crankcase bolts 0D hose guide 2 and clutch
100. SS e Union bolt M10 o o gt NS Z ax N ops SBS AS TTA CRANKCASE COVER Water pump housing 1 Install e Dowel pin 1 e O ring NOTE Apply the lithium soap base grease on the O ring OIL FILTER ELEMENT WATER PUMP AND RIGHT ENG 2 Install e Water pump housing 1 Bolt water pump housing 10 Nm 1 0 m kg 7 2 ft Ib Oil filter element 1 Install e Oil filter element 1 e O ring e Oil filter element cover Bolt oil filter element cover 10 Nm 1 0 m kg 7 2 ft Ib NOTE 2L Apply the lithium soap base grease on the O ring BALANCER BALANCER 75 Nm 7 5 m kg 54 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 50 Nm 5 0 m kg 36 ft Ib Extent of removal CD Balancer shaft drive gear 2 Balancer shaft BALANCER REMOVAL Preparation for removal Primary driven gear Refer to CLUTCH section Right crankcase cover Refer to OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANK CASE COVER section Stator Refer to AC MAGNETO AND STARTER CLUTCH section Nut primary drive gear Nut balancer shaft driven gear Lock washer Primary drive gear Balancer shaft drive gear Lock washer Balancer shaft driven gear Balancer shaft Refer to REMOVAL POINTS ch wesch sesch sesch wesch zech Il ll 1 2 3 4 5 6 D 8 Refer to REMOVAL POINTS 4 64 4 65
101. a set 2 Inspect e Timing chain guide Wear damage Replace Crankcase 1 Inspect e Contacting surface 8 Scratches Replace e Engine mounting boss b crankcase Cracks damage Replace 2 Inspect e Bearing Rotate inner race with a finger Rough spot seizure Replace 3 Inspect e Oil seal Damage Replace CRANKCASE AND CRANKSHAFT EC4N4201 Crankshaft 1 Measure e Runout limit e Small end free play limit e Connecting rod big end side clearance C e Crank width Out of specification Replace Use the dial gauge and a thickness gauge e Dial gauge and stand YU 3097 90890 01252 Standard Limit 0 03 mm 0 05 mm 0 0012 in 0 002 in Small end 0 4 1 0 mm 2 0 mm free play 0 016 0 039 in 0 08 in Side 0 15 0 45 mm 0 50 mm clearance 0 0059 0 0177 in 0 02 in Crack 55 95 56 00 mm width 2 203 2 205 in Oil strainer 1 Inspect e Oil strainer Damage Replace Oil delivery pipe 2 1 Inspect Oil delivery pipe 2 1 e O ring Damage Replace e Oil orifice Gi Clogged Blow CRANKCASE AND CRANKSHAFT EC4N5000 ASSEMBLY AND INSTALLATION Crankcase bearing 1 Install Bearing e Bearing stopper Bolt bearing stopper e Screw bearing stopper gt e Screw bearing stopper crankshaft 10 Nm 1 0 m kg 7 2 ft Ib To left and right crankcase NOTE e Install the bearing by pressing it
102. absorber The manufacturer can not be held respon sible for property damage or personal injury that may result from improper han dling 1 2 Never tamper or attempt to disassemble the cylinder or the tank Never throw the rear shock absorber into an open flame or other high heat The rear shock absorber may explode as a result of nitrogen gas expansion and or damage to the hose Be careful not to damage any part of the gas tank A damaged gas tank will impair the damping performance or cause a malfunction Take care not to scratch the contact sur face of the piston rod with the cylinder or oil could leak out Never attempt to remove the plug at the bottom of the nitrogen gas tank It is very dangerous to remove the plug When scrapping the rear shock absorber follow the instructions on dis posal NOTES ON DISPOSAL YAMAHA DEALERS ONLY Before disposing the rear shock absorber be sure to extract the nitrogen gas from valve 1 Wear eye protection to prevent eye damage from escaping gas and or metal chips A WARNING To dispose of a damaged or worn out rear shock absorber take the unit to your Yamaha dealer for this disposal procedure REAR SHOCK ABSORBER CHAS EC583000 REMOVAL POINTS EC583320 Bearing 1 Remove e Stopper ring upper bearing NOTE Press in the bearing while pressing its outer race and remove the stopper ring 2 Hemove e Upper bearing
103. ace A WARNING Do not attempt to straighten a bent handle bar as this may dangerously weaken the handlebar HANDLEBAR CHAS EC5B5000 ASSEMBLY AND INSTALLATION Handlebar 1 Install e Handlebar e Handlebar upper holder e Bolt handlebar upper holder 3 NONE c3 e The handlebar upper holder should be installed with the punched mark 8 forward e First tighten the bolts on the front side of the handlebar upper holder and then tighten the bolts on the rear side 2 Install s Left grip Apply the adhesive to the handlebar 2 NOTE e Before applying the adhesive wipe off grease or oil on the handlebar surface 8 with a lacquer thinner e Install the left grip to the handlebar so that the line b between the two arrow marks faces straight upward 3 Install e Right grip e Collar Apply the adhesive on the tube guide 3 NOTE 77777 e Before applying the adhesive wipe off grease or oil on the tube guide surface 8 with a lacquer thinner e Install the grip to the tube guide so that the grip match mark b and tube guide slot C form the angle as shown HANDLEBAR CHAS 4 Install e Grip cap cover 1 e Throttle grip NOTE Apply the lithium soap base grease on the throttle grip sliding surface 5 Install e hrottle cables 1 To tube guide NOTE Apply the lithium soap base grease
104. al lip and bearing inner circumference 2 Install e Ball race e Upper bearing CO e Ball race cover NOTE z L o Apply the lithium soap base grease on the bearing and ball race cover lip 3 Install e Lower bracket 1 NOTE Apply the lithium soap base grease on the bearing and the portion 8 of the steering stem STEERING CHASSO 4 Install e Washer 1 e Steering ring nut Tighten the steering ring nut using the steering nut wrench 3 Refer to STEERING HEAD INSPEC TION AND ADJUSTMENT section in the CHAPTER 3 5 Check the steering stem by turning it lock to lock If there is any binding remove the steering stem assembly and inspect the steering bearings 6 Install e Washer 1 7 Install e Front fork 1 e Upper bracket e Main switch e Coupler bracket 4 e Front brake hose guide bracket NOTE C e Install the coupler bracket on the outside of the front brake hose guide bracket Temporarily tighten the pinch bolts lower bracket e Do not tighten the pinch bolts upper bracket yet STEERING CHASSO 8 Install e Washer 1 e Steering stem nut 2 145 Nm 14 5 m kg 105 ft Ib 9 Install e Steering stem cap 1 10 After tightening the nut check the steering for smooth movement If not adjust the steering by loosening the steering ring nut little by little 11 Adjust e Front fork top end 3
105. am Shift fork 3 Shift fork 2 Shift fork 1 Collar Refer to REMOVAL POINTS 4 101 TRANSMISSION SHIFT CAM AND SHIFT FORK ENG EC4H3000 REMOVAL POINTS EC4H3230 Transmission 1 Remove e Main axle 1 e Drive axle e Shift cam e Shift fork 3 e Shift fork 2 e Shift fork 1 NOTE e Remove assembly with the collar 3 installed to the crankcase e Remove assembly carefully Note the posi tion of each part Pay particular attention to the location and direction of shift forks e Remove the main axle drive axle shift cam and shift fork all together by tapping lightly on the transmission drive axle with a soft ham mer EC4H4000 INSPECTION EC4H4200 Gears 1 Inspect e Matching dog 8 e Gear teeth e Shift fork groove Wear damage Replace 2 Inspect e O ring D Damage Replace 3 Check e Gears movement Unsmooth movement Repair or replace EC4H4600 Bearing 1 Inspect e Bearing 1 Rotate inner race with a finger Rough spot seizure Replace 4 102 FS TRANSMISSION SHIFT CAM AND SHIFT FORK ENG op EC4H4810 Shift fork shift cam and segment 1 Inspect e Shift fork 1 Wear damage scratches Replace 2 Inspect e Shift cam e Segment Wear damage Replace 3 Check e Shift fork movement Unsmooth operation Replace shift fork NOTE oe For a malfunctioning shift fork replace not only the shift fork itsel
106. and disassembly section 1 An easy to see exploded diagram 1 is provided for removal and disassembly jobs 2 Numbers 2 are given in the order of the jobs in the exploded diagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy to read way by the use of symbol marks 3 The meanings of the symbol marks are given on the next page 4 Ajob instruction chart 4 accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc 5 Extent of removal 5 is provided in the job instruction chart to save the trouble of an unneces sary removal job 6 For jobs requiring more information the step by step format supplements 6 are given in addi tion to the exploded diagram and job instruction chart e CLUTCH CLUTCH ENG o EC493000 CLUTCH D 7 REMOVAL POINTS 2 EC483211 SEN d 4 Clutch boss 1 Remove e T d Fa Toni ork 7 ep PEs WEE G NS e Lock washer e Clutch boss NOTE Z2 s Straighten the lock washer tab and use the clutch holding tool to hold the clutch boss CZ Clutch holding tool Gf YM 91042 90890 04086 For USA and CDN Except for USA and CDN INSPECTION EC484100 Clutch housing and boss 1 Inspect x Za N Ke E l A 2 OD 20 EN WA Pd ES A Jh AN DP H e e Clutch housing D WE gt di g efi B Cracks wear damage Replace be a OE
107. ankcase NOTE eege e Fit the right crankcase onto the left crank case Tap lightly on the case with soft ham mer e When installing the crankcase the connect ing rod should be positioned at TDC top dead center CRANKCASE AND CRANKSHAFT ENG nu 6 Tighten e Hose guide 1 e Clutch cable holder 2 e Bolt crankcase 12 Nm 1 2 m kg 8 7 ft Ib NOTE Tighten the crankcase tightening bolts in stage using a crisscross pattern 7 Install e Oil delivery pipe 2 1 O ring e Bolt oil delivery pipe 2 x 10 Nm 1 0 m kg 7 2 ft Ib NOTE Apply the lithium soap base grease on the O rings 8 Install e Timing chain 1 e Timing chain guide intake side e Bolt timing chain guide 10 Nm 1 0 m kg 7 2 ft Ib 9 Remove e Sealant Forced out on the cylinder mating sur face 10 Apply e Engine oil To the crank pin bearing and oil delivery hole 11 Check e Crankshaft and transmission operation Unsmooth operation Repair 4 100 TRANSMISSION SHIFT CAM AND SHIFT FORK v EC4H0000 TRANSMISSION SHIFT CAM AND SHIFT FORK Extent of removal Shift fork shift cam main axle and drive axle removal TRANSMISSION SHIFT CAM AND SHIFT FORK REMOVAL Preparation for removal Engine Refer to ENGINE REMOVAL section Separate the crankcase Refer to CRANKCASE AND CRANK SHAFT section Main axle Drive axle Shift c
108. assembly 1 NOTE 2 LLL Unhook the torsion spring 2 from the hole 8 in the crankcase ECAC3101 y amd Shift guide and shift lever assembly J Gay Ce 1 Remove Bolt shift guide c e Shift guide D N e Shift lever assembly NOTE The shift lever assembly is disassembled at the same time as the shift guide EC4N3100 Segment 1 Remove e Bolt segment e Segment NOTE 7777 2 Turn the segment counterclockwise until it stops and loosen the bolt INSPECTION Kick shaft and ratchet wheel 1 Check e Ratchet wheel 1 smooth movement Unsmooth movement Replace e Kick shaft 2 Wear damage Replace e Spring 3 Broken Replace EC4C4300 Kick gear kick idle gear and ratchet wheel 1 Inspect e Kick gear 1 e Kick idle gear e Ratchet wheel 3 e Gear teeth 8 e Ratchet teeth Wear damage Replace KICK SHAFT AND SHIFT SHAFT ENG D EC4B4400 Shift shaft 1 Inspect e Shift shaft Bend damage Replace e Spring Broken Replace EC4C4100 Shift guide and shift lever assembly 1 Inspect e Shift guide 1 e Shift lever e Pawl e Pawl pin 4 e Spring Wear damage Replace EC4B4500 Stopper lever 1 Inspect e Stopper lever 1 Wear damage Replace e Torsion spring Broken Replace ASSEMBLY AND INSTALLATION Segment 1 Install e Segment 1 e Bolt segment x 30 Nm 3 0 m kg 22 ft Ib N
109. b 2 10 Nm 1 0 m kg 7 2 ft Ib 130 Nm 3 0 m kg 22 ft Ib Extent of removal CD Brake hose removal Brake caliper removal 3 Brake master cylinder removal FRONT BRAKE REMOVAL Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine danger of it falling over Drain the brake fluid Refer to REMOVAL POINTS Brake hose cover Brake hose holder Bolt brake hose holder Only loosening Union bolt Brake hose Pad pin plug Remove when loosening the pad pin Pad pin Loosen when disassembling the brake Caliper Brake caliper Brake lever Brake master cylinder bracket Brake master cylinder FRONT BRAKE AND REAR BRAKE CHASSO EC5A8100 REAR BRAKE 30 Nm 3 0 m kg 22 ft Ib 30 Nm 3 0 m kg 22 ft Ib Extent of removal CD Brake master cylinder removal Brake hose removal 3 Brake caliper removal REAR BRAKE REMOVAL Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine danger of it falling over Preparation for removal Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section Refer to REMOVAL POINTS Drain the brake fluid Brake pedal Brake master cylinder Brake hose holder Union bolt Brake hose Pad pin plug Pad pin Remove when loosening the pad pin Loosen when disassembling the brake Caliper gt G k
110. by Yamaha for assembly and adjustment EC133000 GASKETS OIL SEALS AND O RINGS 1 All gaskets oil 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 EC134000 LOCK WASHERS PLATES AND COTTER PINS 1 All lock washers plates 1 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 EC135001 BEARINGS AND OIL SEALS 1 Install the bearing s D and oil seal s with their manufacturer 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 lightweight 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 bearing surfaces N RS IMPORTANT INFORMATION GEN gb EC136000 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 1 make sure that the sharp edged corner is posi tioned opposite to the thrust 3 it receives See the sectional view Shaft 18020103 18020107
111. ch front fork A WARNING Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability kg Ib Standard washer quantity Zero adjustment washers Extent of adjustment Zero 2 adjustment washers mm in Load Fork stroke CD Without adjustment washer standard 2 1 adjustment washer 3 2 adjustment washers 80 kg 176 Ib 70 kg 154 Ib 60 kg 132 Ib _ 50 kg 110 Ib _ 40 kg 88 Ib SETTING E EC72A001 Setting of spring after replacement As the front fork setting can be easily affected by rear suspension take care so that the machine front and rear are balanced in posi tion etc when setting the front fork 1 Use of soft spring Generally a soft spring gives a soft riding feeling Rebound damping tends to become stronger and the front fork may sink deeply over a series of gaps To set a soft spring e Change the rebound damping Turn out one or two clicks e Change the compression damping Turn in one or two clicks Use of stiff spring Generally a stiff spring gives a stiff riding feeling Rebound damping tends to become weaker resulting in lack of a sense of contact with the road surface or in a vibrating handlebar To set a stiff spring e Change the rebound damping Turn in one or two clicks e Change the compression damping Turn out one or two clicks Coverage of spring by weight Rider w
112. clearance Cam dimensions Intake Exhaust Camshaft runout limit 77 00 77 01 mm 3 0315 3 0319 in Chain drive Left 22 000 22 021 mm 0 8661 0 8670 in 21 967 21 980 mm 0 8648 0 8654 in 0 020 0 054 mm 0 0008 0 0021 in 30 296 30 346 mm 1 1923 1 1947 in 22 45 22 55 mm 0 8839 0 8878 in 30 399 30 499 mm 1 1968 1 2007 in 22 45 22 55 mm 0 8839 0 8878 in 0 05 mm 0 002 in 0 05 mm 0 002 in 0 08 mm 0 003 in 30 196 mm 1 1888 in 22 35 mm 0 8799 in 30 299 mm 1 1929 in 22 35 mm 0 8799 in 0 03 mm 0 0012 in Item Timing chain Timing chain type No of links MAINTENANCE SPECIFICATIONS SPEC y 92RH2010 114M 114 Timing chain adjustment method Valve valve seat valve guide Valve clearance cold Valve dimensions A Head diameter A head diameter B face width C seat width D margin thickness Stem outside diameter Guide inside diameter Stem to guide clearance Face width IN EX IN EX IN EX IN EX IN EX IN EX IN EX Automatic 0 10 0 15 mm 0 0039 0 0059 in 0 17 0 22 mm 0 0067 0 0087 in Seat width 22 9 23 1 mm 0 9016 0 9094 in 24 4 24 6 mm 0 9606 0 9685 in 2 26 mm 0 089 in 2 26 mm 0 089 in 0 9 1 1 mm 0 0354 0 0433 in 0 9 1 1 mm 0 0354 0 0433 in 0 8 mm 0 0315 in 0 7 mm 0 0276 in 3 975 3 990 mm 0 15
113. cting rod Collar Oil seal Thrust bearing Bushing Oil seal Bearing CONN MM A N GI Refer to REMOVAL POINTS swiNGARM CHAS REMOVAL POINTS EC573200 Bearing 1 Remove e Bearing NOTE 77777 Remove the bearing by pressing its outer race INSPECTION Wash the bearings bushings collars and cov ers in a solvent Swingarm 1 Inspect e Bearing 1 e Bushing Free play exists unsmooth revolution rust Replace bearing and bushing as a set 2 Inspect e Oil seal Damage Replace EC574210 Relay arm 1 Inspect Bearing polylube bearing D Collar 2 Free play exists unsmooth revolution rust Replace bearing and collar as a set 2 Inspect e Bearing polylube bearing Loss of solid lubrication Replace e Oil seal Damage Replace NOTE nmm Polylube bearings with solid lubrication have been adopted with the intent to make the nee dle bearings used in this model maintenance free With polylube bearings no grease nipple and regular lubrication is necessary However grease should be applied to all oil seals and collars when removed or installed swiNGARM CHAS Connecting rod 1 Inspect e Bearing polylube bearing e Collar Free play exists unsmooth revolution rust Replace bearing and collar as a set 2 Inspect e Bearing polylube bearing Loss of solid lubrication Replace e Oil
114. d the guide e Apply molybdenum disulfide oil to the valve stem e Install the valve into the cylinder head 11171601 i e Turn the valve until the valve face and valve seat are evenly polished then clean off all of the compound NOTE 2 LL For best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands e Apply a fine lapping compound to the valve face and repeat the above steps NOTE After every lapping operation be sure to clean off all of the compound from the valve face and valve seat e Apply Mechanic s blueing dye Dykem to the valve face e Install the valve into the cylinder head Press the valve through the valve guide and onto the valve seat to make a clear pattern e Measure the valve seat width again If the valve seat width is out of specification reface and relap the valve seat I1171502 11171902 11170701 VALVES AND VALVE SPRINGS ENG op FS Valve spring 1 Measure e Valve spring free length Out of specification Replace Free length valve spring Intake 37 81 mm 1 49 in Limit 35 9 mm 1 41 in Exhaust 37 54 mm 1 48 in Limit 35 7 mm 1 41 in 2 Measure e Compressed spring force 8 Out of specification Replace D Installed length Compressed spring force Intake 99 114 N at 29 13 mm 9 9 11 4 kg at 29 13 mm 22 27 25 57 Ib at 1 15 in Exhaust 126 144 N
115. d throttle cables move smoothly Check Cables wires that they are not caught when the handlebars are turned or when the front forks travel up and down Exhaust pipe RASA that the exhaust pipe is tightly mounted and has no Rear wheel sprocket Check that the rear wheel sprocket tightening bolt is not loose Check for smooth operation Lubricate if necessary Bolts and nuts Check the chassis and engine for loose bolts and nuts Check that the AC magneto CDI unit and ignition coil are con Lead connectors nected tightly Is the machine set suitably for the condition of the racing course and weather or by taking into account the results of test runs Settings l l l before racing Are inspection and maintenance completely done ENGINE COOLANT LEVEL INSPECTION INSP Oo COOLANT REPLACEMENT ADJ Q EC350000 ENGINE COOLANT LEVEL INSPECTION A WARNING Do not remove the radiator cap drain bolt and hoses when the engine and radia tor are hot Scalding hot fluid and steam may be blown out under pressure which could cause serious injury When the engine has cooled place a thick towel over the radiator cap slowly rotate the cap counterclockwise to the detent This procedure allows any residual pres sure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remove it engine parts You may use distilled water if you can t get soft water 1 Place the mac
116. e engine will not pick up speed smoothly In this case step up the jet needle clip by one groove and move down the needle to lean out the mixture 2 Too lean at intermediate speeds The engine breathes hard and will not pick up speed quickly Step down the jet needle clip by one groove and move up the needle to enrich the mixture Standard clip position Effects of changing the jet needle groove position reference 1 4 me 1 2 3 4 io No Pp INDIA Idle Fully open D No 5 groove 2 No 3 groove 3 No 4 groove 10 10 SETTING E Jet needle adjustment The jet needle is adjusted by changing it OBDVS Standard jet needle OBELP Except for USA The tapered sections of all jet needles have the same starting positions but the needles are available with different straight portion diameters Example OBDVS 4 Clip position Diameter 8 of straight portion Effects of changing the jet needle reference Diameter of the straight portion Changing the diameter of the straight portion adjusts the air fuel mixture when the throttle is 1 8 to 1 4 open 1 4 1 2 3 4 CAL L LL 10 96 Pep I Jg Jw Idle Fully open SETTING E Leak jet adjustment accelerator pump adjustment The leak jet is a setting part that adjusts the flow of fuel discharged by the accelerator pump Since the accelerator pump operates only when throttle is open the leak jet is
117. e Upper spring guide dE Lower spring guide 3 Ca N REAR SHOCK ABSORBER CHAS 12340602 2 Tighten e Adjuster 1 3 Adjust e Spring length installed ex Spring length installed 3 Extent of Standard length adjustment 245 mm 9 65 in 240 5 258 5 mm 246 5 mm 9 70 in 9 47 10 18 in For EUROPE NOTE 2L The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster Never attempt to turn the adjuster beyond the maximum or minimum setting 4 Tighten e Locknut Rear shock absorber 1 Install e Dust seal 1 O ring e Collar 3 NOTE 2L e Apply the molybdenum disulfide grease on the bearing e Apply the lithium soap base grease on the dust seals O rings and collars REAR SHOCK ABSORBER CHAS XXe vV DY fr 1 wt Ef ae o Hi 2 Install e Bushing e Collar e Dust seal NOTE e Apply the molybdenum disulfide grease on the bearing e Apply the lithium soap base grease on the bushing collars and dust seals e Install the dust seals with their lips facing out ward 3 Install e Rear shock absorber 4 Install e Bolt rear shock absorber frame 1 e Nut rear shock absorber frame 56 Nm 5 6 m kg 40 ft Ib NOTE Apply the molybdenum disulfide grease on the bolt 5 Install e Bolt rear shock absorber relay arm 1 e Nut rear shock abso
118. e future carburetor set ting easier A WARNING e The carburetor is a part of the fuel line Therefore be sure to install it in a well ventilated area away from flammable objects and any sources of fire e Never look into the carburetor intake Flames may shoot out from the pipe if the engine backfires while it is being started Gasoline may be discharged from the accelerator pump nozzle when the carbu retor has been removed J SETTING S CAUTION e The carburetor is extremely sensitive to foreign matter dirt sand water etc During installation do not allow foreign matter to get into the carburetor Always handle the carburetor and its components carefully Even slight scratches bends or damage to carburetor parts may prevent the carburetor from functioning correctly Carefully perform all servicing with the appropriate tools and without applying excessive force When the engine is stopped or when riding at no load do not open and close the throttle unnecessarily Otherwise too much fuel may be discharged starting may become difficult or the engine may not run well After installing the carburetor check that the throttle operates correctly and opens and closes smoothly Atmospheric conditions and carburetor settings Air Air temp Humidity pressure Mixture Setting altitude Low high Lov High ow The air density i e concentration of oxygen in the air determines the
119. e inside diameter 16 002 16 013 mm 16 043 mm 0 6300 0 6304 in 0 6316 in 15 991 16 000 mm 0 6296 0 6299 in 15 971 mm 0 6288 in Piston pin outside diameter Piston rings Top ring Barrel 0 90 x 2 75 mm 0 04 x 0 11 in 0 15 0 25 mm 0 006 0 010 in 0 030 0 065 mm 0 0012 0 0026 in Type m Dimensions B x T End gap installed 0 50 mm 0 020 in 0 12 mm 0 005 in Side clearance installed 2nd ring ON IB LL Taper M 0 80 x 2 75 mm 0 03 x 0 11 in 0 30 0 45 mm 0 012 0 018 in 0 020 0 055 mm 0 0008 0 0022 in Type Dimensions B x T End gap installed 0 80 mm 0 031 in 0 12 mm 0 005 in Side clearance Oil ring E Dimensions B x T End gap installed 1 50 x 2 25 mm 0 06 x 0 09 in 0 10 0 40 mm 0 004 0 016 in Crankshaft Crank width A ZE 55 95 56 00 mm 2 203 2 205 in Runout limit C SILS 0 03 mm 0 0012 in 0 05 mm 0 002 in Big end side clearance D 0 15 0 45 mm 0 50 mm D L 0 0059 0 0177 in 0 02 in Small end free play F 0 4 1 0 mm 0 02 0 04 in 2 0 mm 0 08 in MAINTENANCE SPECIFICATIONS SPEC y Clutch Friction plate thickness 2 9 3 1 mm 0 114 0 122 in 2 7 mm 0 106 in Quantity 9 Clutch plate thickness 1 1 1 3 mm 0 043 0 051 in Quantity 8 Warp limit 0 1 mm 0 004 in 36 0 mm 1 42 in Clutch spring free length 37 0 mm
120. e performance of a machine also vary from machine to machine Therefore do not imitate other riders settings from the beginning but choose your own setting according to the level of your riding technique SETTING Se Drive and rear wheel sprockets setting parts Part number Drive sprocket 1 STD 13T 9383B 13218 Rear wheel 5GS 25448 50 sprocket 2 5NY 25448 00 5NY 25449 00 5GS 25450 50 5SNY 25450 00 5NY 25451 00 5GS 25452 50 5NY 25452 00 5PH 25454 50 For AUS and NZ EC721002 Tire pressure Tire pressure should be adjust to suit the road surface condition of the circuit Standard tire pressure 100 kPa 1 0 kgf cm 15 psi e Under a rainy muddy sandy or slippery condition the tire pressure should be lower for a larger area of contact with the road sur face Extent of adjustment 60 80 kPa 0 6 0 8 kgf cm 9 0 12 psi e Under a stony or hard road condition the tire pressure should be higher to prevent a flat tire Extent of adjustment 100 120 kPa 1 0 1 2 kgf cm 15 18 psi SETTING lc Front fork setting The front fork setting should be made depend ing on the rider s feeling of an actual run and the circuit conditions The front fork setting includes the following three factors 1 Setting of air spring characteristics e Change the fork oil level 2 Setting of spring preload e Change the spring e Install the adjustment washer 3 Settin
121. e position sensor using the T25 bit 2 Replace e Throttle position sensor 3 Install e Throttle position sensor 1 e Screw throttle position sensor e Throttle position sensor coupler NOTE nmm e Align the slot in the throttle position sensor with the projection on the carburetor e Temporarily tighten the screws throttle posi tion sensor THROTTLE POSITION SENSOR SYSTEM ELEC 4 Adjust e Engine idling speed Refer to ENGINE IDLING SPEED ADJUSTMENT section in the CHAPTER 3 5 Insert the thin electric conductors 2 lead into the throttle position sensor coupler as shown and connect the tester to them Tester lead Yellow lead 3 Tester lead Black lead 2 e Do not insert the electric conductors more than required because it may reduce the waterproof function of the coupler e Make sure that a short circuit does not develop between the terminals because it may cause damage to electrical compo nents 6 Start the engine 7 Adjust e Throttle position sensor output voltage Adjustment steps Adjust the installation angle of the throttle position sensor 1 to obtain the specified output voltage NOTE nmm Measure the output voltage accurately with a digital electronic voltmeter that gives an easy reading of a small voltage L Throttle position Tester selector sensor output d voltage position 958 078V THROTTLE POSITION SENSOR SYSTEM
122. e the rear wheel by placing the suit able stand under the engine 2 Check e Drive chain slack 8 Above the seal guard installation bolt Out of specification Adjust Drive chain slack 40 50 mm 1 6 2 0 in NOTE Before checking and or adjusting rotate the rear wheel through several revolutions and check the slack several times to find the tight est point Check and or adjust the drive chain slack with the rear wheel in this tight chain position 3 Adjust e Drive chain slack Drive chain slack adjustment steps e Loosen the axle nut 1 and locknuts e Adjust the drive chain slack by turning the adjusters 3 To tighten Turn the adjuster 3 coun terclockwise To loosen Turn the adjuster 3 clock wise and push wheel forward e Turn each adjuster exactly the same amount to maintain correct axle alignment There are marks on each side of the drive chain puller alignment NOTE LL Turn the adjuster so that the drive chain is in line with the sprocket as viewed from the rear Too small drive chain slack will overload the engine and other vital parts keep the slack within the specified limits FRONT FORK INSPECTION INSP Oo FRONT FORK OIL SEAL AND DUST SEAL CLEANING ADJ Q e Tighten the axle nut while pushing down the drive chain Axle nut 125 Nm 12 5 m kg 90 ft Ib e Tighten the locknuts Locknut 16 Nm 1 6 m kg 11 ft Ib EC36C000
123. ear damage Replace EC555000 ASSEMBLY AND INSTALLATION Front fork assembly 1 Wash the all parts in a clean solvent 2 Install e Damper rod 1 To inner tube tube hold the inner tube aslant If the inner tube is held vertically the damper rod may fall into it damaging the valve inside 3 Install e Copper washer 1 e O ring e Base valve 3 To inner tube 2 4 Tighten e Base valve 1 mmm x 55 Nm 5 5 m kg 40 ft Ib NOTE L e Use a damper rod holder 2 to lock the damper rod e Apply the LOCTITE on the base valve thread Damper rod holder YM 1423 90890 01423 12311310 FRONT FORK CHASSO 5 Install e Spring guide 1 e Locknut To damper rod 3 NOTE z e Install the spring guide with its cut 8 facing upward e With its thread b facing upward fully finger tighten the locknut onto the damper rod 6 Install e Dust seal e Stopper ring Oil seal 3 e Oil seal washer 4 e Slide metal To inner tube 6 NOTE e Apply the fork oil on the inner tube e When installing the oil seal use vinyl seat with fork oil applied to protect the oil seal lip e Install the oil seal with its manufacture s marks or number facing the axle holder side 7 Install Piston metal NOTE Install the piston metal onto the slot on inner tube 8 Install e Outer tube 1 To inner tube FRONT FORK CHASSO
124. eel axle 2 Install e Brake hose cover 1 e Washer 2 e Bolt brake hose cover M8 e Bolt brake hose cover M6 7 Nm 0 7 m kg 5 1 ft Ib Pass the brake hose through the front brake hose guide D then through the guide 8 on the protector 2 P eo SD l D QA A A lt t New 9 FRONT BRAKE AND REAR BRAKE CHAS dH r6 C2 ET SSES 4 Install e Copper washer 1 e Brake hose e Union bolt A WARNING Always use new copper washers Ins brake hose so that it contacts the brake master cylinder projection and that its bent portion b faces downward Rear brake hose 1 Install Copper washer 1 e Brake hose e Union bolt A WARNING Always use new copper washers Install the brake hose so that its pipe por tion directs as shown and lightly touches the projection b on the brake cali per FRONT BRAKE AND REAR BRAKE CHASSO 9 25 2 Install e Brake hose holder 1 e Screw brake hose holder 1 Nm 0 1 m kg 0 7 ft Ib After installing the brake hose holders make sure the brake hose does not contact the spring rear shock absorber If it does correct its twist Brake fluid 1 Fill e Brake fluid Until the fluid level reaches LOWER level line 3 Recommended brake fluid DOT 4 A WARNING e Use only the designated quality brake fluid otherwise the rubber seals may deterio rate causi
125. eight D Soft 2 Standard 3 Stiff J SETTING Front fork setting parts e Adjustment washer 1 TYPE thickness PART NUMBER T 2 3 mm 0 09 in 4SS 23364 L0 e Front fork spring Equal pitch spring LD MARK slits SPRING RATE SPRING PART NUMBER TYPE SOFT 4SS 23141 10 4SS 23141 20 4SS 23141 30 4SS 23141 40 STD 0 420 4SR 23141 LO STD ow mastaro 0 450 0 460 0 470 5BE 23141 L0 5BE 23141 00 5GR 23141 00 For EUROPE For AUS NZ and ZA Unequal pitch spring LD MARK slits SPRING PART NUMBER 5ET 23141 20 5ET 23141 00 5ET 23141 30 5ET 23141 10 5ET 23141 40 NOTE 2L e The unequal pitch spring is softer in initial characteristic than the equal pitch spring and is difficult to bottom out under full compres sion e The I D mark slits is proved on the end of the spring SETTING fc Rear suspension setting The rear suspension setting should be made depending on the riders feeling of an actual run and the circuit conditions The rear suspension setting includes the fol lowing two factors 1 Setting of spring preload e Change the set length of the spring e Change the spring 2 Setting of damping force e Change the rebound damping e Change the compression damping EC72C001 Choosing set length 1 Place a stand or block under the engine to put the rear wheel above the floor and measure the length between t
126. er left 3 12 Nm 1 2 m kg 8 7 ft Ib NOTE Tighten the bolts in stage using a crisscross pattern AC MAGNETO AND STARTER CLUTCH ENG oR 9 Install e Shaft D f ANNE E e Bearing ANN ERA Idle gear 1 9 WE Na NOTE S Apply the engine oil on the shaft bearing and idle gear inner circumference 10 Install e Cover idle gear 1 e Bolt 2 NOTE Install the cover idle gear 1 with its mark facing upward 11 Install e Engine guard e Clamp e Bolt engine guard front e Bolt engine guard rear 2 e Cylinder head breather hose 12 Connect AC magneto lead Hefer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 13 Install e Shift pedal 1 e Bolt shift pedal NOTE 7777 2 When installing the shift pedal onto the shift shaft be sure that the center of the shift pedal is about 1 mm 0 04 in 8 above the top of the footrest ENGINE REMOVAL EC4M0000 ENGINE REMOVAL 26 Nm 2 6 m kg 19 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 6 B 69 Nm 6 9 m kg 50 ft Ib 34 Nm 3 4 m kg 24 ft Ib g 75 Nm 7 5 m kg 54 ft Ib 69 Nm 6 9 m kg 50 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib 34 Nm 3 4 m kg 24 ft Ib 23 Nm 2 3 m kg 17 ft Ib 8 Nm 0 8 m kg 5 8 ft Ib ENGINE REMOVAL Hold the machine by placing the suitable stand under the frame Preparation for removal Drain the engine o
127. er inner surface 8 Wear score marks Replace brake cali per assembly Front Rear 2 Inspect e Brake caliper piston 1 Wear score marks Replace brake cali per piston assembly WARNING Replace the piston seals and dust seals 2 whenever a caliper is disassembled EC534301 Brake hose 1 Inspect e Brake hose 1 Crack damage Replace EC5A5000 ASSEMBLY AND INSTALLATION A WARNING e All internal parts should be cleaned in new brake fluid only e Internal parts should be lubricated with brake fluid when installed e Replace the piston seals and dust seals whenever a caliper is disassembled Brake caliper piston 1 Clean e Brake caliper e Piston seal e Dust seal e Brake caliper piston Clean them with brake fluid FRONT BRAKE AND REAR BRAKE CHASSO 2 Install Piston seal 1 e Dust seal A WARNING Always use new piston seals and dust seals NOTE Il c Fit the piston seals and dust seals onto the slot on brake caliper correctly Front Rear 3 Install e Brake caliper piston 1 NOTE Apply the brake fluid on the piston wall e Install the piston with its shallow depressed side facing the brake cali per e Never force to insert Front Rear Front brake caliper 1 Install e Pad support 1 e Brake pad e Pad pin 3 NOTE e Install the brake pads with their projections a into the brake calip
128. er recesses b e Temporarily tighten the pad pin at this point FRONT BRAKE AND REAR BRAKE CHASSO 2 Install e Copper washer 1 e Union bolt 2 30 Nm 3 0 m kg 22 ft Ib A WARNING Always use new copper washers Install the brake hose so that its pipe por tion directs as shown and lightly touches the projection on the brake cali per 3 Install e Brake hose holder 1 e Brake caliper e Bolt brake caliper NOTE u Fit the brake hose holder cut 8 over the pro jection on the front fork and clamp the brake hose 4 Tighten e Pad pin 4 5 Install e Pad pin plug Rear brake caliper 1 Install e Pad support 1 e Brake pad e Pad pin 3 NOTE e Install the brake pads with their projections a into the brake caliper recesses b e Temporarily tighten the pad pin at this point FRONT BRAKE AND REAR BRAKE CHASSO 2 Install e Brake disc cover 1 e Bolt brake disc cover 7 Nm 0 7 m kg 5 1 ft Ib 3 Install e Brake caliper 1 e Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section 4 Tighten e Pad pin 3 5 Install e Pad pin plug 3 Nm 0 3 m kg 2 2 ft Ib Brake master cylinder kit 1 Clean e Brake master cylinder e Brake master cylinder kit Clean them with brake fluid 2 Install e Brake master cylinder cup primary
129. er regulator lead to the rectifier regulator bracket with a plastic locking tie and cut off the tie end 8 q e e Y eg j d j i ry uw y NOS Seu iv NS inue de SJ E tf 1 M A TZ E Ge DOHEEM se A X Ay K XO a 4 CD Brake master cylinder 2 Brake hose holder 3 Brake hose CABLE ROUTING DIAGRAM SPEC y Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the brake caliper Pass the brake hose into the brake hose holders If the brake hose contacts the spring rear shock absorber correct its twist D Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the brake master cylinder CABLE ROUTING DIAGRAM SPEC y CD Starter motor lead Position the starter motor lead negative battery Negative battery lead lead and wire harness in the tank damper slit 8 Wire harness Fasten the wire harness GO Clamp Do not allow the taillight lead to slacken 5 Taillight lead D Fasten the coolant reservoir breather hose cool 6 Coolant reservoir breather hose ant reservoir hose and rectifier regulator lead 7 Coolant reservoir hose Fasten the coolant reservoir breather hose and Positive battery lead coolant reservoir hose 9 Starting circuit cut off relay Pass the coolant reservoir hose on the outside of Battery the coolant reservoir breather hose
130. etc with the same outer diameter as the specified value Throttle valve height 1 5 mm 0 06 in e Fully turn in the accelerator pump adjust ing screw 3 e Check that the link lever has free play D by pushing lightly on it e Gradually turn out the adjusting screw while moving the link lever until it has no more free play Carburetor installation 1 Install e Carburetor joint 1 3 Nm 0 3 m kg 2 2 ft Ib NOTE je V M Install the projection 8 on the cylinder between the carburetor joint slots 2 Install e Carburetor 1 NOTE LL Install the projection 8 between the carburetor joint slots alia c y CE CARBURETOR ENG 8 Install e Hot starter plunger 1 2 Nm 0 2 m kg 1 4 ft Ib Tighten e Screw air filter joint 1 3 Nm 0 3 m kg 2 2 ft Ib e Screw carburetor joint 3 Nm 0 3 m kg 2 2 ft Ib Install e Throttle cable pull Throttle cable return 2 11 Nm 1 1 m kg 8 0 ft Ib e Throttle grip free play Refer to THROTTLE CABLE ADJUST MENT section in the CHAPTER 3 Adjust Install e Throttle cable cover 1 e Screw throttle cable cover 4 Nm 0 4 m kg 2 9 ft Ib Install e Throttle position sensor lead coupler 1 e Clamp Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 we CARBURETOR ENG S et CC C5 lt Q
131. etor or fuel tank EC050000 TO THE NEW OWNER This manual will provide you with a good basic understanding of features operation and basic maintenance and inspection items of this machine Please read this manual carefully and completely before operating your new machine If you have any questions regarding the operation or maintenance of your machine please consult your Yamaha dealer NOTE OO This manual should be considered a perma nent part of this machine and should remain with it even if the machine is subsequently sold ECO060000 NOTICE Some data in this manual may become out dated due to improvements made to this model in the future If there is any question you have regarding this manual or your machine please consult your Yamaha dealer ECO070001 FIN MACHINE WEIGHTS Weights of machines without fuel The minimum weights for motocross machines are tor the class 125 66 uu cane sabe ens minimum 88 kg 194 Ib for the class 250 cc minimum 98 kg 216 Ib for the class 500 cc minimum 102 kg 225 Ib In modifying your machine e g for weight reduction take note of the above limits of weight ECO080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION AN The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED A WARNING Failure to follow WARNING instructions cou
132. f but the two gears each adja cent to the shift fork EC4H5000 ASSEMBLY AND INSTALLATION Transmission 1 Install e 5th pinion gear 27T e 3rd pinion gear 21T e Collar 3 e 4th pinion gear 24T e 2nd pinion gear 16T To main axle NOTE e Apply the molybdenum disulfide oil on the 4th and 5th pinion gears inner circumference and on the end surface e Apply the molybdenum disulfide oil on the 2nd and 3rd pinion gears inner circumfer ence QO OO 4 103 TRANSMISSION SHIFT CAM AND SHIFT FORK ENG 2 Install e 2nd wheel gear 28T e 4th wheel gear 25T e 3rd wheel gear 28T e 5th wheel gear 22T e ist wheel gear 31T O ring To drive axle NOTE e Apply the molybdenum disulfide oil on the 1st 2nd and 3rd wheel gears inner circum ference and on the end surface e Apply the molybdenum disulfide oil on the 4th and 5th wheel gears inner circumference e Apply the lithium soap base grease on the O ring 3 Install e Washer 1 e Circlip NOTE e Be sure the circlip sharp edged corner is positioned opposite side to the washer and gear e Be sure the circlip end is positioned at axle spline groove 4 Install e Collar 1 NOTE e Apply the lithium soap base grease on the oil seal lip e When installing the collar into the crankcase pay careful attention to the crankcase oil seal lip
133. ft Out of specification Replace Runout camshaft Less than 0 03 mm 0 0012 in 11151402 11151003 CAMSHAFTS ENG o 4 Measure e Camshaft to cap clearance Out of specification Measure camshaft outside diameter Camshaft to cap clearance 0 020 0 054 mm 0 0008 0 0021 in Limit 0 08 mm 0 003 in Measurement steps e Install the camshaft onto the cylinder head Position a strip of Plastigauge onto the camshaft e Install the clip dowel pins and camshaft caps NS Bolt camshaft cap a 10 Nm 1 0 m kg 7 2 ft Ib NOTE LL e Tighten the bolts camshaft cap in a criss cross pattern from innermost to outer caps Do not turn the camshaft when measuring clearance with the Plastigauge e Remove the camshaft caps and measure the width of the Plastigauge 5 Measure e Camshaft outside diameter 8 Out of specification Replace the cam shaft Within specification Replace camshaft case and camshaft caps as a set Camshaft outside diameter 21 967 21 980 mm 0 8648 0 8654 in Camshaft sprocket 1 Inspect e Camshaft sprocket 1 Wear damage Replace the camshaft assembly and timing chain as a set FS CAMSHAFTS ENG Decompression system 1 Check e Decompression system Checking steps e Check that the decompression mecha nism cam 1 moves smoothly e Check that the decompression mechanism cam lever pin
134. g free length 460 mm 18 1 in c Spring rate STD K 4 31 N mm K 4 12 N mm K 4 22 N mm 0 44 kg mm 0 42 kg mm 0 43 kg mm 24 6 Ib in 23 5 lb in 24 1 Ib in Optional spring spacer Yes c c Oil capacity 568 cm 573 cm 578 cm 20 0 Imp oz 20 2 Imp oz 20 3 Imp oz 19 2 US oz 19 4 US oz 19 5 US oz Oil level 135 mm 5 31 in 180 mm 5 12 in 125 mm 4 92 in Min Max 80 150 mm c From top of outer tube with inner 3 15 5 91 in tube and damper rod fully com pressed without spring Oil grade Suspension oil c 49 Inner tube outer diameter 46 mm 1 81 in c Front fork top end 5 mm 0 20 in 10 mm 0 39 in Rear suspension Shock absorber travel 132 mm 5 20 in c Spring free length 260 mm 10 24 in c Fitting length 245 mm 9 65 in 246 5 mm 9 70 in 245 mm 9 65 in Min Max 240 5 258 5 mm c 9 47 10 18 in Spring rate STD K 49 0 N mm K 46 0 N mm K 50 0 N mm 5 00 kg mm 4 70 kg mm 5 10 kg mm 280 0 Ib in 263 2 lb in 285 6 Ib in Optional spring Yes c c Enclosed gas pressure 1 000 kPa c c 10 kg cm 142 psi Swingarm Swingarm free play limit End 1 0 mm 0 04 in MAINTENANCE SPECIFICATIONS SPEC y Wheel Front wheel type Rear wheel type Front rim size material Rear rim size material Rim runout limit Radial Lateral Drive chain Type manufacturer Number of links Chain slack Chain length
135. g of damping force e Change the compression damping e Change the rebound damping The spring acts on the load and the damping force acts on the cushion travel speed EC723001 Change in level and characteristics of fork oil Damping characteristic near the final stroke can be changed by changing the fork oil amount CCAUTION Adjust the oil level in 5 mm 0 2 in incre ments or decrements Too low oil level causes the front fork to produce a noise at full rebound or the rider to feel some pres sure on his hands or body Alternatively too high oil level will develop unexpectedly early oil lock with the consequent shorter front fork travel and deteriorated perfor mance an characteristics Therefore adjust the front fork within the specified range Standard oil level 135 mm 5 31 in 130 mm 5 12 in 125 m 4 92 in Extent of adjustment 80 150 mm 3 15 5 91 in From top of outer tube with inner tube and damper rod fully compressed without spring For EUROPE For AUS NZ and ZA SETTING E Air spring characteristics in relation to oil level change Load Stroke CD Max oil level 2 Standard oil level 3 Min oil level kg Ib mm in EC727020 Spring preload adjustment The spring preload is adjusted by installing the adjustment washer 1 between the fork spring T 2 3 mm 2 and damper rod 3 0 09 in Do not install three or more adjustment washers for ea
136. get caught with each other Also take care to pass the leads so that they do not become loose at the bend of the holder in order to avoid their con tacting the starter clutch drive gear NOTE 2 LL Apply the sealant to the grommet of the AC magneto lead ACC QUICK GS KT YAMAHA Bond No 1215 90890 85505 Z Quick gasket 3 Install e Idle gear 2 e Dowel pin NOTE Apply the engine oil on the idle gear 2 4 Install e Idle gear plate 1 e Bolt idle gear plate AC MAGNETO AND STARTER CLUTCH ENG 5 Install e Plain washer 1 e Bearing e Starter clutch drive gear e Starter clutch 4 NOTE nmm Apply the engine oil on the plain washer bear ing and starter clutch drive gear inner circum ference 6 Install e Woodruff key 1 e Rotor NOTE e Clean the tapered portions of the crankshaft and rotor e When installing the woodruff key make sure that its flat surface 8 is in parallel with the crankshaft center line b e When installing the rotor align the keyway of the rotor with the woodruff key 7 Install Bolt starter clutch 1 m e Plain washer rotor e Nut rotor 70 Nm 7 0 m kg 50 ft Ib 8 Install e Dowel pin e Gasket crankcase cover left e Crankcase cover left 1 e Bolt crankcase cover left x 10 Nm 1 0 m kg 7 2 ft Ib Bolt crankcase cov
137. ghten the pinch bolts lower bracket e Do not tighten the pinch bolts upper bracket yet 2 Tighten e Front fork cap bolt 1 30 Nm 3 0 m kg 22 ft Ib 3 Adjust e Front fork top end Front fork top end standard 3 5 mm 0 20 in 10 mm 0 39 in For AUS NZ and ZA FRONT FORK CHAS 4 Tighten e Pinch bolt upper bracket 1 23 Nm 2 3 m kg 17 ft Ib e Pinch bolt lower bracket 20 Nm 2 0 m kg 14 ft Ib g Tighten the lower bracket to specified torque If torqued too much it may cause the front fork to malfunction 5 Install e Brake hose holder 1 e Brake caliper e Bolt brake caliper 23 Nm 2 3 m kg 17 ft Ib NOTE Fit the brake hose holder cut 8 over the pro jection on the front fork and clamp the brake hose 6 Install e Brake hose holder 1 e Bolt brake hose holder e Protector 3 e Bolt protector 10 Nm 1 0 m kg 7 2 ft Ib NOTE nmm When installing the brake hose holder align the top 8 of the brake hose neck with the brake hose holder bottom b Then pass the brake hose in front of the axle boss and fit it into the hose groove so that the brake hose does not contact the nut wheel axle 7 Adjust e Rebound damping force NOTE nmm Turn in the damping adjuster 1 finger tight SACS and then turn out to the originally set position HANDLEBAR
138. he lithium soap base grease on the bolt O rings and brake pedal bracket e Install the clip with its stopper portion 8 fac ing inward FS ENGINE REMOVAL ENG ENSE V Drive sprocket cA 1 Install o e Drive sprocket 07 E ge e Drive chain NOTE Install the drive sprocket together with the drive chain 2 Install e Lock washer 1 e Nut drive sprocket 75 Nm 7 5 m kg 54 ft Ib NOTE 2L Tighten the nut while applying the rear brake Ney 3 Bend the lock washer tab to lock the nut 4 Install e Drive chain sprocket guide 1 e Drive chain sprocket cover 2 e Screw drive chain sprocket cover 8 Nm 0 8 m kg 5 8 ft Ib Oil hose and neutral switch 1 Install O ring D e Dowel pin e Oil hose 9 e Bolt oil hose NOTE LL Apply the lithium soap base grease on the O ring ENGINE REMOVAL ENG doce 2 ds PAX imme gt Q O ring DEW e Neutral switch 4 e Screw neutral switch 5 l w 4Nm 0 4 m kg 2 9 ft 1b NOTE Apply the lithium soap base grease on the O ring A Y P 9 N n 9 i woes mel CRANKCASE AND CRANKSHAFT 10Nm 1 0 m kg 7 2ft Ib CRANKCASE AND CRANKSHAFT D M PP Ze ema 10Nm 1 0m kg 7 2ft Ib 10Nm 1 0m kg 7 2ft Ib 12Nm 1 2m kg 8 7 ft lb Extent of removal CD Crankcase separation Crankshaft removal CRANKCASE AND CRANK SHAFT
139. he malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark N d 1 Check fuse o goo Replace fuse and check wire harness c OK No good 2 Ch ttery S Recharge or replace eck ba M OK J b No spark Check entire ignition system for connection No good Repair or replace couplers leads and H p ignition coil g On No good Check engine stop switch Replace OK Check main switch EE J b OK N d Check ignition coil LET ll OK Secondary cot No good Check AC magneto Pickup coil EE Replace OK N Check neutral switch amo Repair or replace OK 1 marked Refer to FUSE INSPECTION section in the CHAPTER 3 2 marked Refer to BATTERY INSPECTION AND CHARGING section in the CHAPTER 3 3 marked Only when the ignition checker is used NOTE e Remove the following parts before inspection 1 Seat 2 Fuel tank Use the following special tools in this inspection Dynamic spark tester Pocket tester YM 34487 K YU 3112 C 90890 03112 Ignition checker 90890 06754 IGNITION System ELEC SPARK GAP TEST 1 Disconnect the ignition coil from spark plug 2 Remove the ignition coil cap 3 Connect the dynamic spark tester 1 igni tion checker 2 as shown e Ignition coil 3 e Spark plug 18110201 For USA and CDN Except for USA and CDN 4 Kick the kickstarter crank 5 Check the ignition spark gap
140. he rear wheel axle center and the rear fender hold ing bolt N Remove the stand or block from the engine and with a rider astride the seat measure the sunken length b between the rear wheel axle center and the rear fender hold ing bolt e Loosen the locknut 1 and make adjust ment by turning the spring adjuster 2 to achieve the standard figure from the sub traction of the length b from the length 3 Standard figure 90 100 mm 3 5 3 9 in SETTING fc NOTE e f the machine is new and after it is broken in the same set length of the spring may change because of the initial fatigue etc of the spring Therefore be sure to make re evaluation e f the standard figure cannot be achieved by adjusting the spring adjuster and changing the spring set length replace the spring with an optional one and make re adjustment Setting of spring after replacement After replacement be sure to adjust the spring to the set length sunken length 90 100 mm 3 5 3 9 in and set it 1 Use of soft spring e Set the soft spring for less rebound damping to compensate for its less spring load Run with the rebound damping adjuster one or two clicks on the softer side and readjust it to suit your prefer ence 2 Use of stiff spring e Set the soft spring for more rebound damping to compensate for its greater spring load Run with the rebound damp ing adjuster one or two clicks on the stiffer side a
141. he steering head pipe EC123001 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the right side of the engine EC124000 MODEL LABEL The model label is affixed to the frame under the rider s seat This information will be needed to order spare parts IMPORTANT INFORMATION GEN gb EC13000 IMPORTANT INFORMATION EC131010 PREPARATION FOR REMOVAL AND DISASSEMBLY 1 Remove all dirt mud dust and foreign material before removal and disassembly When washing the machine with high pres sured water cover the parts follows e Silencer exhaust port e Side cover air intake port e Water pump housing hole at the bottom e Drain hole on the cylinder head right side All electrical components Use proper tools and cleaning equipment Refer to SPECIAL TOOLS section When disassembling the machine keep mated parts together They include gears cylinders pistons and other mated parts that have been mated through normal wear Mated parts must be reused as an assembly or replaced During the machine disassembly clean all parts and place them in trays in the order of disassembly This will soeed up assembly time and help assure that all parts are cor rectly reinstalled Keep away from fire IMPORTANT INFORMATION GEN aes EC132000 ALL REPLACEMENT PARTS 1 We recommend to use Yamaha genuine parts for all replacements Use oil and or grease recommended
142. hen piston is at T D C on compression stroke NOTE CL In order to be sure that the piston is at Top Dead Center the punch mark O on the exhaust camshaft and the punch mark on the intake camshaft must align with the cyl inder head surface as shown in the illustra tion 3 Remove e Timing chain tensioner cap bolt 1 e Timing chain tensioner e Gasket 4 Remove e Bolt camshaft cap e Camshaft cap e Clip NOTE Hemove the bolts camshaft cap in a criss cross pattern working from the outside in The bolts camshaft cap must be removed evenly to prevent damage to the cylinder head camshafts or camshaft caps FS 5 Remove e Exhaust camshaft 1 e Intake camshaft NOTE n Attach a wire 3 to the timing chain to prevent it from falling into the crankcase INSPECTION Camshaft 1 Inspect e Cam lobe Pitting scratches blue discoloration gt Replace 2 Measure e Cam lobe length and 11151001 Out of specification Replace Cam lobes length Intake 30 296 30 346 mm 1 1923 1 1947 in Limit 30 196 mm 1 1888 in D 22 45 22 55 mm 0 8839 0 8878 in Limit 22 35 mm 0 8799 in Exhaust 30 399 30 499 mm 1 1968 1 2007 in Limit 30 299 mm 1 1929 in p 22 45 22 55 mm 0 8839 0 8878 in Limit 22 35 mm 0 8799 in 11151002 3 Measure e Runout camsha
143. hile compressing the valve spring with a valve spring compressor Q install the valve cotters Valve spring compressor YM 4019 90890 04019 4 To secure the valve cotters onto the valve stem lightly tap the valve tip with a piece of wood Hitting the valve tip with excessive force could damage the valve 5 Install e Adjusting pad D e Valve lifter NOTE LL e Apply the molybdenum disulfide oil on the valve stem end e Apply the engine oil on the valve lifters e Valve lifter must turn smoothly when rotated with a finger e Be careful to reinstall valve lifters and pads in their original place CYLINDER AND PISTON d CYLINDER AND PISTON 10Nm 1 0 m kg 7 2ft Ib Extent of removal C Cylinder removal 2 Piston removal CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section Bolt cylinder Cylinder Piston pin clip Piston pin Use special tool Piston Refer to REMOVAL POINTS Piston ring set CYLINDER AND PISTON ENG REMOVAL POINTS Piston and piston ring 1 Remove e Piston pin clip 1 e Piston pin e Piston 3 NOTE e Put identification marks on each piston head for reference during reinstallation e Before removing each piston pin deburr the clip groove and pin hole area If the piston pin groove is deburred and the piston pin is still difficult to remove use the piston pin MEE E ie e puller set 2
144. hine on a level place and hold it in an upright position 2 Inspect e Coolant level Coolant level should be between the maximum 8 and minimum b marks Coolant level is below the LOW level line Add soft water tap water up to the proper level 3 Start the engine and let it warm up for sev eral minutes 4 Turn off the engine and check the coolant level again NOTE Before checking the coolant level wait a few minutes until the coolant settles COOLANT REPLACEMENT A WARNING Do not remove the radiator cap when the engine is hot VE NEE 77 COOLANT FULL x ee AP INSP COOLANT REPLACEMENT INSP QR Take care so that coolant does not splash on painted surfaces If it splashes wash it away with water 1 2 Place a container under the engine Remove e Seat Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 Disconnect e Coolant reservoir hose Drain the coolant completely Connect e Coolant reservoir hose Remove e Engine guard 1 e Coolant drain bolt Hemove e Radiator cap Drain the coolant completely Clean e Cooling system Thoroughly flush the cooling system with clean tap water Install Copper washer e Coolant drain bolt e Engine guard e Bolt engine guard front 34 Nm 3 4 m kg 24 ft Ib e Bolt engine guard rear w 23 Nm 2 3 m kg 17 ft Ib INSP COOLANT REPLACEMENT 9 Fill
145. ht by bending the float tab on the float e Recheck the float height EC464600 Float 1 Inspect e Float Damage Replace CARBURETOR ENG D Starter plunger 1 Inspect e Cold starter plunger 1 e Hot starter plunger Wear damage Replace Accelerator pump 1 Inspect e Diaphragm accelerator pump e Spring accelerator pump e Accelerator pump cover 3 e O ring e Push rod 5 Tears diaphragm damage Replace Dirt Clean 2 Inspect e Throttle shaft 1 e Spring e Lever 1 3 e Spring 1 e Lever 2 e Spring 2 6 Dirt Clean Air cut valve 1 Inspect e Diaphragm air cut valve 1 e Spring air cut valve 2 e Air cut valve cover 3 e O ring Tears diaphragm damage Replace ASSEMBLY AND INSTALLATION Carburetor 1 Install e Cold starter plunger 1 FS CARBURETOR ENG 2 Install e Pilot air jet 1 L 3 Install e Spring 1 e Lever 1 2 To lever 2 3 NOTE 2L Make sure the spring 1 fits on the stopper 8 of the lever 2 4 Install e Spring 2 1 To lever 2 into the recess in the carburetor yr m 5 Install SZ E e Push rod link lever assembly QE S NOTE S o ZO uc Ob Make sure the stopper of the spring 2 fits Cae 6 Install e Washer e Circlip CARBURETOR ENG 7 Install e Spring To throttle shaft NOTE Install the bigger hook of the
146. id and steam may be blown out under pressure which could cause serious injury When the engine has cooled open the radi ator cap by the following procedure Place a thick rag like a towel over the radi ator cap slowly rotate the cap counter clockwise to the detent This procedure allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning coun terclockwise and remove it EC454000 INSPECTION EC444100 Radiator 1 Inspect e Radiator core 1 Obstruction Blow out with compressed air through rear of the radiator Bent fin gt Repair replace EC455000 ASSEMBLY AND INSTALLATION Radiator 1 Install O ring e Radiator pipe e Bolt radiator pipe x 10 Nm 1 0 m kg 7 2 ft Ib NOTE Apply the lithium soap base grease on the O ring 2 Install e Radiator hose 4 longer D e Radiator hose 2 shorter To right radiator 3 g RADIATOR ENG 3 Install e Right radiator 1 e Bolt right radiator e Radiator hose 3 3 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 4 Install e Left radiator 1 e Bolt left radiator 10 Nm 1 0 m kg 7 2 ft Ib e Radiator hose 1 3 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 5 Tighten e Radiator hose clamp 4 2 Nm 0 2 m kg 1 4 ft Ib 6 Install e Radiator guard 1 e Bolt radiator guard 10 Nm 1 0 m kg 7 2 ft
147. il Seat and fuel tank Carburetor Exhaust pipe and silencer Clutch cable Radiator Shift pedal Cylinder head breather hose and oil tank breather hose A WARNING Support the machine securely so there is no danger of it falling over Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Refer to SEAT FUEL TANK AND SIDE COVERS section Refer to CARBURETOR section Refer to EXHAUST PIPE AND SILENCER section Disconnect at the engine side Refer to RADIATOR section Refer to AC MAGNETO AND STARTER CLUTCH section Refer to CAMSHAFTS section ENGINE REMOVAL 26 Nm 2 6 m kg 19 ft Ib 10 Nm 1 0 m kg 7 2 ft Ib X75 Nm 7 5 m kg 54 ft Ib 6 B 69 Nm 6 9 m kg 50 ft Ib 34 Nm 3 4 m kg 24 ft Ib 69 Nm 6 9 m kg 50 ft Ib Ignition coil Disconnect the AC magneto lead Starter motor lead Disconnect at the starter motor side Negative battery lead Disconnect at the engine side Right engine guard Neutral switch Drive chain sprocket cover Nut drive sprocket Lock washer Drive sprocket Clip Bolt brake pedal Brake pedal Upper engine bracket Lower engine bracket Engine mounting bolt Pivot shaft Engine Refer to REMOVAL POINTS DA MO NYO sech sch sch lo Refer to REMOVAL POINTS 4 87 ENGINE REMOVAL ENG EC4M3000 REMOVAL POINTS EC4F3100 Drive sprocket 1 Remove e Nut
148. illing fluid D Lubricant d2 Tightening 3 Specified value Service limit Resistance Q Voltage V Electric current A Illustrated symbols 5 to in the exploded diagrams indicate grade of lubricant and loca tion of lubrication point 5 Apply engine oil Apply molybdenum disulfide oil OO Apply lightweight lithium soap base grease Apply molybdenum disulfide grease Illustrated symbols to in the exploded diagrams indicate where to apply a locking agent and where to install new parts Apply locking agent LOCTITE GO Use new one MEMO EC090000 INDEX ane P g SPECIFICATIONS 2 D REGULAR INSPECTION AND ADJUSTMENTS SN ADs 3 aen 1 e L4 CHASSIS 5 dx CHA ECOA0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION 1 1 MACHINE IDENTIFICATION 1 2 IMPORTANT INFORMATION 1 3 CHECKING OF CONNECTION 1 6 SPECIAL TOOLS ib e eios 1 7 CONTROL FUNCTIONS 1 10 EUEL eege 1 14 STARTING AND BREAK IN 1 15 TORQUE CHECK POINTS 1 19 CLEANING AND STORAGE 1 20 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 GENERAL TORQUE SPECIFICATIONS 2 19 DEFINITION OF UNITS
149. ine to start e Before starting the machine perform the checks in the pre operation check list AIR FILTER MAINTENANCE According to AIR FILTER CLEANING section in the CHAPTER 3 apply the foam air filter oil or its equivalent to the element Excess oil in the element may adversely affect engine start ing STARTING A COLD ENGINE NOTE This model is equipped with an ignition circuit cut off system The engine can be started under the following conditions e When the transmission is in neutral e When the clutch is disengaged with the transmission in any position However it is recommended to shift into neutral before starting the engine Inspect the coolant level Turn the fuel cock to ON Push on the main switch to ON Shift the transmission into neutral Fully open the cold starter knob D Start the engine by pushing the start switch or by kicking the kickstarter crank prre SYS STARTING AND BREAK IN GEN aes 1 16 NOTE LL If the engine fails to start by pushing the start switch release the switch wait a few seconds and then try again Each starting attempt should be as short as possible to preserve the battery Do not crank the engine more than 10 seconds on any one attempt If the engine does not start with the starter motor try using the kickstarter crank A WARNING e If the starter motor will not turn when pushing the start switch stop pushing it immediately and
150. ing engine rpm YM 33277 A 90890 03141 Timing light This tool is necessary for checking ignition timing YM 4019 90890 04019 Valve spring compressor 90890 04019 This tool is needed to remove and install the valve assemblies YM 91042 90890 04086 Clutch holding tool 90890 04086 This tool is used to hold the clutch when removing or installing the clutch boss securing nut YM 4111 90890 04111 Valve guide remover YM 4111 90980 041 1 1 YM 4116 90890 04116 Intake 4 0 mm 0 16 in YM 4116 90980 04116 Exhaust 4 5 mm 0 18 in This tool is needed to remove and install the valve guide YM 4112 90890 04112 Valve guide installer YM 4112 90890 04112 YM 4117 90890 04117 Intake 4 0 mm 0 16 in YM 4117 90890 04117 Exhaust 4 5 mm 0 18 in This tool is needed to install the valve guide YM 4113 90890 04113 Valve guide reamer YM 4113 90890 04113 YM 4118 90890 04118 Intake 4 0 mm 0 16 in YM 4118 90890 04118 Exhaust 4 5 mm 0 18 in This tool is needed to rebore the new valve guide SPECIAL TOOLS gere YM 04141 90890 04141 Rotor puller YM 04141 90980 04141 This tool is used to remove the flywheel magneto YM 34487 Dynamic spark tester 90980 06754 90890 06754 Ignition checker This instrument is necessary for checking the ignition system components ACC QUICK GS KT Quick gasket 90890 85505 YAMAHA Bond No 1215 This sealant Bond is used for crankcase mating sur face etc CONTROL FUNCTIONS INFO 2S EC1
151. ingarm Rear Installation of rear Rear shock absorber to frame shock absorber L Rear Installation of swing Tightening of pivot shaft arm Wheel Installation of wheel Front NE Tightening of wheel axle Tightening of axle holder Rear Tightening of wheel axle E Wheel to rear wheel sprocket Brake Front Brake caliper to front fork Brake disc to wheel Tightening of union bolt Brake master cylinder to handlebar Tightening of bleed screw Rear Brake pedal to frame Brake disc to wheel Tightening of union bolt Brake master cylinder to frame Tightening of bleed screw Fuel system ___ Ee tank to fuel cock Lubrication system _____________________________ Tightening of oil hose clamp NOTE Concerning the tightening torque refer to MAINTENANCE SPECIFICATIONS section in the CHAPTER 2 1 19 CLEANIN 1 20 e AND STORAGE INFO ZS CLEANING AND STORAGE EC1B1000 CLEANING Frequent cleaning of your machine will enhance its appearance maintain good overall performance and extend the life of many com ponents 1 Before washing the machine block off the end of the exhaust pipe to prevent water from entering A plastic bag secured with a rubber band may be used for this purpose 2 If the engine is excessively greasy apply some degreaser to it with a paint brush Do not apply degreaser to the chain sprock ets or wheel axles 3
152. inutes and then turn off the engine and wait for five minute 2 Place the machine on a level place and hold it on upright position by placing the suitable stand under the engine 3 Place a suitable container under the engine INSP ENGINE OIL REPLACEMENT ADJ 4 Remove e Oil tank cap 1 e Oil filler cap e Frame oil drain bolt e Crankcase oil drain bolt e Oil filter element drain bolt Drain the crankcase and oil tank frame of its oil 5 Remove Lower engine bracket e Oil hose clamp e Bolt oil hose e Oil hose e Oil strainer frame 4 6 Inspect Oil strainer frame Clogged Blow 7 If the oil filter is to be replaced during this oil change remove the following parts and reinstall them Replacement steps e Remove the oil filter element cover 1 and oil filter element e Check the O rings 9S if cracked or dam aged replace them with a new one e Install the oil filter element and oil filter ele ment cover Oil filter element cover 10 Nm 1 0 m kg 7 2 ft Ib INSP ENGINE OIL REPLACEMENT ADJ 8 Install e Copper washer 1 e Oil strainer frame 70 Nm 7 0 m kg 50 ft Ib e Oil hose 9 e Bolt oil hose e Oil hose clamp 2 Nm 0 2 m kg 1 4 ft Ib Lower engine bracket 10 Nm 1 0 m kg 7 2 ft Ib x x x 9 Install Copper washer e Oil filter element drain bolt w 10 Nm 1 0
153. ion marked For USA INSP 4o PRE OPERATION INSPECTION AND MAINTENANCE AD EC320000 PRE OPERATION INSPECTION AND MAINTENANCE Before riding for break in operation practice or a race make sure the machine is in good operating condition Before using this machine check the following points GENERAL INSPECTION AND MAINTENANCE Routine Page Dose Check that coolant is filled up to the radiator cap P3 5 9 Check the cooling system for leakage Check that a fresh gasoline is filled in the fuel tank Check the Fuel e P 1 14 fuel line for leakage Engine oil Check that the oil level is correct Check the crankcase and P 3 44 18 frame oil line for leakage Soap dba e Check that gears can be shifted correctly in order and that the P 3 9 10 clutch operates smoothly l i Check that the throttle grip operation and free play are correctly Tarore RAUSING adjusted Lubricate the throttle grip and housing if necessary PE Check the play of front brake and effect of front and rear brake P 3 25 31 Drive chain Check drive chain slack and alignment Check that the drive P 3 32 35 chain is lubricated properly Wheels Check for excessive wear and tire pressure Check for loose P 3 43 44 spokes and have no excessive play Check that the handlebar can be turned smoothly and have no s excessive play Front forks and rear shock GE E Check that they operate smoothly and there is no oil leakage P 3 35 42 Check that the clutch an
154. ion 8 facing the clutch boss 3 e Install the seat plate so that it is not caught on the step O e Install the cushion spring with the paint facing out 5 Install e Friction plate 1 1 e Clutch plate 1 e Friction plate 2 3 e Clutch plate 2 4 NOTE a nstall the clutch plates and friction plates alternately on the clutch boss starting with a friction plate and ending with a friction plate Use the friction plates 1 for the first and final while paying attention to the difference in surface pattern Apply the engine oil on the friction plates and clutch plates e Unlike the clutch plate 2 the clutch plate 1 has no surface gloss Use the clutch plate 1 for the first while paying attention to the dif ference in surface gloss 6 Install Bearing 1 e Washer e Circlip To push rod 1 2 NOTE Apply the engine oil on the bearing and washer curren ENG 7 Install e Push rod 2 D e Ball e Push rod 1 9 NOTE 2 LLL Apply the engine oil on the push rod 1 2 and ball 8 Install e Pressure plate 1 9 Install e Clutch spring 1 e Bolt clutch spring NOTE 2 LLL Tighten the bolts in stage using a crisscross pattern 10 Install e Dowel pin 1 e Gasket clutch cover 11 Install e Clutch cover 1 e Bolt clutch cover NOTE Tighten the bolts in stage using a crisscross pattern OIL FILTER ELEMENT WATER PUMP AND
155. its position on the rim when the tire pressure is low A tilted tire valve stem indicates that the tire slips off its position on the rim e f the tire valve stem is found tilted the tire is considered to be slipping off its position Cor rect the tire position EC36S002 SPOKES INSPECTION AND TIGHTENING 1 Inspect e Spokes 1 Bend damage Replace Loose spoke Retighten 2 Tighten e Spokes 12010801 NOTE Be sure to retighten these spokes before and after break in After a practice or a race check spokes for looseness EC36T000 WHEEL INSPECTION 1 Inspect e Wheel runout Elevate the wheel and turn it Abnormal runout Replace INSP STEERING HEAD INSPECTION AND ADJUSTMENT 2 Inspect Bearing free play Exist play Replace EC36U013 STEERING HEAD INSPECTION AND ADJUSTMENT 1 Elevate the front wheel by placing a suit able stand under the engine 2 Check e Steering stem Grasp the bottom of the forks and gently rock the fork assembly back and forth Free play Adjust steering head 3 Check e Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steering ring nut 4 Adjust e Steering ring nut Steering ring nut adjustment steps e Remove the headlight e Remove the handlebar and handlebar upper bracket Loosen the steering ring nut 1 using the steering nut wrench 2 Steering nut wrench YU 33975 90890 01403 INSP STE
156. ity such as excessive change in coolant level discolora tion of coolant or milky transmission oil 1 Remove Bearing 1 2 Hemove e Oil seal INSPECTION Oil delivery pipe 1 Inspect e Oil delivery pipe 1 Bend damage Replace Clogged Blow CRANKCASE COVER EC444200 Impeller shaft 1 Inspect e Impeller shaft 1 Bend wear damage Replace Fur deposits Clean OIL FILTER ELEMENT WATER PUMP AND RIGHT ENG EC444300 Impeller shaft gear 1 Inspect e Gear teeth 8 Wear damage Replace EC4H4600 Bearing 1 Inspect e Bearing Rotate inner race with a finger Rough spot seizure Replace 11610101 EC444400 Oil seal 1 Inspect e Oil seal Wear damage Replace ASSEMBLY AND INSTALLATION Oil seal 1 Install e Oil seal NOTE X e Apply the lithium soap base grease on the oil seal lip e Install the oil seal with its manufacture s marks or numbers facing the right crankcase cover OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANKCASE COVER e 2 Install e Bearing NOTE LL Install the bearing by pressing its outer race parallel Impeller shaft sO 1 Install e er e Impeller shaft Se OM MTS e Washer ASA e Impeller Lei KW x ED s pee g CULA NOTE e ake care so that the oil seal lip is not dam aged or the spring does not slip off its posi tion e When insta
157. ket M8 x 1 25 4 28 2 8 20 Steering stem and steering ring nut M28 x 1 0 1 Refer to NOTE Front fork and front fork cap bolt M48 x 1 0 2 30 3 0 22 Front fork and base valve M30 x 1 0 2 55 5 5 40 Front fork cap bolt and damper rod M12 x 1 25 2 29 2 9 21 Front fork bleed screw and front fork cap bolt M5 x 0 8 2 1 0 1 0 7 Front fork and front fork protector M6 x 1 0 6 10 1 0 7 2 Front fork and brake hose holder M6 x 1 0 2 10 1 0 7 2 Front fork and brake hose cover M8 M8 x 1 25 1 16 1 6 11 M6 x 1 0 1 7 0 7 5 1 Throttle grip cap M5 x 0 8 2 4 0 4 2 9 Front brake master cylinder M6 x 1 0 2 9 0 9 6 5 Brake lever mounting bolt M6 x 1 0 1 6 0 6 4 3 Brake lever mounting nut M6 x 1 0 1 6 0 6 4 3 Brake lever position locknut M6 x 1 0 1 5 0 5 3 6 Front brake hose guide M5 x 0 8 2 4 0 4 2 9 Clutch lever holder M5 x 0 8 2 4 0 4 2 9 Hot starter lever holder M5 x 0 8 2 4 0 4 2 9 Hot starter lever mounting nut M5 x 0 8 1 2 0 2 1 4 Light switch M4 x 0 7 2 2 0 2 1 4 Front brake master cylinder cap M4 x 0 7 2 2 0 2 1 4 Front brake hose union bolt M10 x 1 25 2 30 3 0 22 Front brake caliper M8 x 1 25 2 23 2 3 17 Pad pin plug M10 x 1 0 2 3 0 3 2 2 Front brake caliper and pad pin M10 x 1 0 1 18 1 8 13 Hear brake caliper and pad pin M10 x 1 0 1 18 1 8 13 Brake caliper and bleed screw M8 x 1 25 2 6 0 6 4 3 Front wheel axle and axle nut M16 x 1 5 1 105 10 5 75 Front wheel axle holder M8 x 1 25 4 23 2 3 17 Front brake disc M6 x 1 0 6 12 1 2 8 7 Rear brake disc M6 x 1 0 6 14
158. ld result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the machine indicates special precautions that must be taken to avoid damage to the machine NOTE A NOTE provides key information to make pro cedures easier or clearer EC082000 FINDING THE REQUIRED PAGE 1 This manual consists of seven chapters General information Specifications Regular inspection and adjustments Engine Chassis Electrical and Tun ing 2 The table of contents is at the beginning of the manual Look over the general layout of the book before finding then required chap ter and item Bend the book at its edge as shown to find the required fore edge symbol mark and go to a page for required item and description 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 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 e Bearings Pitting damage Replace EC084002 HOW TO READ DESCRIPTIONS To help identify parts and clarify procedure steps there are exploded diagrams at the start of each removal
159. ler ning the machine without oil operating the machine with a broken or damaged part which causes another part to fail damage or failure due to improper or careless transpor tation and or tie down and so on If you have any specific questions on operation or maintenance please contact your dealer for advice Q Does the warranty cover incidental costs such as towing or transportation due to a fail ure No The warranty is limited to repair of the machine itself May perform any or all of the recommended maintenance shown in the Owner s Service Manual instead of having the dealer do them A Yes if you are a qualified mechanic and follow the procedures specified in the Owner s Service Manual We do recommend however that items requiring special tools or equip ment be done by a Yamaha motorcycle dealer Q Will the warranty be void or canceled if do not operate or maintain my new YZ or WR exactly as specified in the Owner s Service Manual A No The warranty on a new motorcycle cannot be voided or cancelled However if a particular failure is caused by operation or maintenance other than as shown in the Owner s Service Manual that failure may not be covered under warranty Q What responsibility does my dealer have under this warranty A Each Yamaha motorcycle dealer is expected to 1 Completely set up every new machine before sale level this person is in the best position to help you If you are sti
160. ll not satisfied and require additional assistance please write YAMAHA MOTOR CORPORATION U S A CUSTOMER RELATIONS DEPARTMENT P O Box 6555 Cypress California 90630 When contacting Yamaha Motor Corporation U S A don t forget to include any dates and receipts important information such as names addresses model VIN frame number CHANGE OF ADDRESS The federal government requires each manufacturer of a motor vehicle to main tain a complete up to date list of all first purchasers against the possibility of a safety related defect and recall This list is compiled from the purchase registra of your purchase Mail to 2 Explain the operation maintenance and warranty requirements to your satisfaction at the time of sale and upon your request at any later date In addition each Yamaha motorcycle dealer is held responsible for his setup service and warranty repair work Q Does the warranty on the engine include the carburetor air filter air box and exhaust pipe A No The warranty covers only the engine components tions sent to Yamaha Motor Corporation U S A by the selling dealer at the time If you should move after you have purchased your new motorcycle please advise us of your new address by sending a postcard listing your motorcycle model name VIN frame number dealer number or deale s name as it is shown on your warranty identification your name and new mailing address YAMAHA MOTOR
161. lling the impeller shaft apply the lithium soap base grease on the oil seal lip and impeller shaft And install the shaft while turning it e Hold the impeller shaft on its width across the flats with spanners etc and install the impeller Right crankcase cover 1 Install e Dowel pin 1 O ring e Collar 3 e Gasket 2 NOTE 2 LL Apply the lithium soap base grease on the O ring OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANKCASE COVER 2 Install e Right crankcase cover 1 e Bolt right crankcase cover 10 Nm 1 0 m kg 7 2 ft Ib NOTE e Apply the engine oil on the impeller shaft end e Mesh the impeller shaft gear 3 with primary drive gear e Tighten the bolts in stage using a crisscross pattern Kickstarter crank 1 Install e Kickstarter crank 1 e Washer 2 e Bolt kickstarter crank 3 mmm 33 Nm 3 3 m kg 24 ft Ib NOTE Install the kickstarter crank so that the kick starter crank is as vertical as possible with the distance 8 between the kickstarter crank and the frame being 8 mm 0 31 in or more 2 Install e Oil hose e Bolt oil hose x 10 Nm 1 0 m kg 7 2 ft Ib Install pde qu aa New J E e Copper washer ZR Pu a f Dio M Y e Oil delivery pipe IRS L XA e Union bolt M8 3 G3 D Pi um 18 Nm 1 8 m kg 13 ft Ib LL TA OKA
162. lling the piston pin clip cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase e Install the piston pin clips with their ends fac ing downward Cylinder 1 Lubricate e Piston e Piston ring e Cylinder NOTE Apply a liberal coating of engine oil 2 Install e Dowel pin 1 O ring NOTE LLL Apply the lithium soap base grease on the O ring CYLINDER AND PISTON ENG 3 Install e Cylinder gasket 1 e Cylinder NOTE 777 Install the cylinder with one hand while com pressing the piston rings with the other hand A LE Se E L e Pass the timing chain through the tim ing chain cavity e Be careful not to damage the timing chain guide 2 during installation 4 Install e Bolt cylinder x 10 Nm 1 0 m kg 7 2 ft Ib CLUTCH EC4A0000 SWS CLUTCH 10Nm 1 0m kg 7 2ft Ib 8Nm 0 8m kg 5 8 ft lb Extent of removal CD Push rod 1 2 and push lever shaft removal 2 Push pod 1 disassembly 3 Friction plate and clutch plate removal 4 Primary driven gear removal CLUTCH REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Brake pedal Refer to ENGINE REMOVAL section Clutch cable Disconnect at engine side Clutch cover Clutch spring Pressure plate Push rod 1 Circlip Washer Bearing Ball Push rod 2 1 2 3 4
163. lubricate Use foam air filter oil or Replace ee equivalent oil OIL FILTER we le le OIL STRAINER frame Hm le FRAME Genee o De e o oo ooo FUEL TANK COCK Geseis e o oo BRAKES Adjust lever position and pedal height Lubricate pivot point Check brake disc surface Check fluid level and leakage Retighten brake disc bolts caliper bolts master cylinder bolts and union bolts Replace pads Replace brake fluid Every one year 3 2 Every two years FRONT FORKS Inspect and adjust Replace oil Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube REAR SHOCK ABSORBER Inspect and adjust Lube Molybdenum disulfide After rain ride Retighten DRIVE CHAIN GUIDE AND ROLLERS spe ele R G SWINGARM ien e RELAY ARM CONNECTING ROD Molybdenum disulfide grease STEERING HEAD Inspect free play and retighten Molybdenum disulfide grease Clean and lube Lithium base grease Replace bearing TIRE WHEELS Inspect air pressure wheel run out tire wear and spoke looseness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate Lithium base grease THROTTLE CONTROL CABLE Yamaha cable lube or Check routing and connection SAE 10W 30 motor oil Lubricate Inspect dirt and wear on Inspect and clean throttle cable EEN xa on the carburetor side HOT STARTER CLUTCH LEVER Umeamey je BATTERY Check terminal for looseness and p dle corros
164. m kg 7 2 ft Ib e Crankcase oil drain bolt e Frame oil drain bolt 23 Nm 2 3 m kg 17 ft Ib 10 Fill e Engine oil Cil quantity Total amount 1 4 L 1 23 Imp qt 1 48 US qt Periodic oil change 1 2 L 1 06 Imp qt 1 27 US qt With oil filter replacement 1 3 L 1 14 Imp qt 1 37 US qt 11 Check e Oil leakage 12 Install e Oil tank cap 13 Check e Engine oil level OIL PRESSURE INSPECTION INSP 4o PILOT SCREW ADJUSTMENT ADJ Q OIL PRESSURE INSPECTION 1 Check e Oil pressure Checking steps e Slightly loosen the oil pressure check bolt D e Start the engine and keep it idling until oil starts to seep from the oil pressure check bolt If no oil comes out after one minute turn the engine off so it will not seize e Check oil passages and oil pump for dam age or leakage e Start the engine after solving the prob lem s and recheck the oil pressure e Tighten the oil pressure check bolt Oil pressure check bolt a 10 Nm 1 0 m kg 7 2 ft Ib PILOT SCREW ADJUSTMENT 1 Adjust e Pilot screw 1 Adjustment steps NOTE LL To optimize the fuel flow at a smaller throttle opening each machine s pilot screw has been individually set at the factory Before adjusting the pilot screw turn it in fully and count the number of turns Record this num ber as the factory set number of turns out e Turn in the pilot screw until it is lightly seated Turn ou
165. m zl Oo Om Go h sch Ni NO sech 8 Brake caliper 1 FRONT BRAKE AND REAR BRAKE CHASSO BRAKE CALIPER DISASSEMBLY 3 Nm 0 3 m kg 2 2 ft Ib e 18 Nm 1 8 m kg 13 ft Ib al Front Rear Extent of removal D Front brake caliper disassembly Rear brake caliper disassembly BRAKE CALIPER DISASSEM BLY Pad pin Brake pad Pad support Brake caliper piston Dust seal Refer to REMOVAL POINTS Piston seal FRONT BRAKE AND REAR BRAKE CHAS BRAKE MASTER CYLINDER DISASSEMBLY g 2 Nm 0 2 m kg 1 4 ft Ib Front Rear Extent of removal CD Front brake master cylinder disassembly 2 Rear brake master cylinder disassembly BRAKE MASTER CYLINDER DISASSEMBLY Brake master cylinder cap Diaphragm Brake master cylinder boot Circlip Use a long nose circlip pliers Washer Push rod Brake master cylinder kit 4 FRONT BRAKE AND REAR BRAKE CHASSO EC5A3000 REMOVAL POINTS Brake fluid 1 Remove Front e Brake master cylinder cap 1 Rear e Brake master cylinder cap 1 e Protector NOTE Do not remove the diaphragm Front Rear 2 Connect the transparent hose Gi to the bleed screw 1 and place a suitable con tainer under its end A Front B Rear 3 Loosen the bleed screw and drain the brake fluid while pulling the lever in or pushing down on the pedal AC E Do not reuse the drained brake fluid 5 S
166. n circuit Leave the battery unused for more than 30 voltage prior to charging minutes before measuring its open circuit voltage Connect a charger and ammeter to the battery and start charging Is the amperage higher YES than the standard charging amperage written on the battery Charge the battery until the charging This type of battery charger cannot charge an MF battery A variable voltage charger is recommended voltage reaches 15 V NOTE Set the charging time to a maximum of 20 hours Charger Leave the battery unused for more than 30 minutes before measuring its open circuit voltage Ammeter Voltmeter 12 8 V gt Charging is complete 12 0 12 7 V gt Recharging is required Under 12 0 V gt Replace the battery CAUTION Constant amperage chargers are not suitable for harging MF batteries INSP 4o BATTERY REPLACEMENT FUSE INSPECTION ADJ 6 Install e Battery e Battery band 7 Connect e Battery leads to the battery terminals First nect the positive lead 1 then the negative lead 8 Check e Battery terminals Dirt Clean with a wire brush Loose connection Connect properly 9 Lubricate e Battery terminal Recommended lubricant Lithium soap base grease 10 Install e Seat BATTERY REPLACEMENT 1 Replace e Battery This battery is for YAMAHA WR250F After filling the battery with elec
167. n of air the following instructions should be observed e The front fork with a built in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled e Before removing the cap bolts or front forks be sure to extract the air from the air chamber completely EC553000 REMOVAL POINTS Front fork cap bolt 1 Remove e Front fork cap bolt 1 From the outer tube NOTE LL Before removing the front fork from the machine loosen the front fork cap bolt 2 Hemove e Front fork cap bolt 1 NOTE e While compressing the fork spring set the thin type spanners 2 between the spacer 3 and spring guide 2 e Hold the locknut 5 and remove the front fork cap bolt FRONT FORK CHASSO EC553201 Inner tube 1 Remove e Dust seal 1 e Stopper ring Using slotted head screwdriver CCAUTION Take care not to scratch the inner tube 2 Hemove e Inner tube 1 Oil seal removal steps e Push in slowly 8 the inner tube just before it bottoms out and then pull it back quickly p e Repeat this step until the inner tube can be pulled out from the outer tube EC55331 1 Damper rod 1 Remove e Base valve 1 e Damper rod NOTE 7 Use a damper rod holder 3 to lock the damper rod Damper
168. nd readjust it to suit your preference Adjusting the rebound damping will be followed more or less by a change in the compression damping For correction turn the low compression damping adjuster on the softer side J SETTING When using a rear shock absorber other than currently installed use the one whose overall length 8 does not exceed the stan dard as it may result in faulty performance Never use one whose overall length is greater than standard Length 8 of standard shock 490 5 mm 19 31 in 80 kg 176 Ib Coverage of spring by weight 70 kg Rider weight 154 Ib CD Soft 60 kg 2 Standard 132 Ib Stiff 50 kg 110 Ib _ 40 kg 88 Ib J SETTING EC72Q000 Rear shock absorber setting parts e Rear shock spring 1 Equal pitch spring SPRING SPRING PART e SPRING RATE NUMBER COOR TREE POINT LENGTH 5UN 22212 00 Brown 1 260 5UN 22212 10 Green 1 260 2 d 49 ausmsn Bie i 260 sro 56 suN 22212 80 Oramge 260 STD zu muss Bel 260 5 3 5UN 22212 50 Yellow 1 5UN 22212 60 Pink 1 5UN 22212 70 White 1 For EUROPE For AUS NZ and ZA Ke WM exte Unequal pitch spring SPRING LD SPRING TYPE RATE Mun ML MN COLOR FREE approx POINT LENGTH 4 5 4 7 5UN 22212 A0 Green 2 5UN 22212 B0 Red 2 5UN 22212 C0O Black 2 5UN 22212 D0 Blue 2 5UN 22212 E0 Yellow 2 5UN 22212 F0 Pink 2 5UN 22212 GO White 2
169. ne b on the balancer shaft end 3 Install e Balancer shaft drive gear 1 NOTE e Align the punched mark 8 on the balancer shaft drive gear with the punched mark on the balancer shaft driven gear 2 e Align the punched mark on the balancer shaft drive gear with the lower spline d on the crankshaft end 4 Install e Lock washer 1 e Nut balancer shaft driven gear e Primary drive gear 3 e Nut primary drive gear NOTE L Q e Install the primary drive gear with its stepped side 8 facing the engine e Place an aluminum plate b between the teeth of the balancer shaft drive gear and driven gear 5 Bend the lock washer tab OIL PUMP OIL PUMP Extent of removal CD Oil pump removal 2 Oil pump disassembly OIL PUMP REMOVAL AND DIS ASSEMBLY Preparation for removal Primary driven gear Right crankcase cover Refer to CLUTCH section Refer to OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANK CASE COVER section Circlip Washer Oil pump drive gear Oil pump assembly Outer rotor 2 Circlip Inner rotor 2 Dowel pin Oil pump cover Outer rotor 1 Inner rotor 1 1 2 3 4 5 6 D 8 9 el l O 4 67 OIL PUMP ENG 12 Dowel pin 13 Washer 14 Oil pump drive shaft 15 Rotor housing ZZ INSPECTION Oil pump 1 Inspect e Oil pump drive gear 1 e Oil pump drive shaft e Roto
170. ner circumferences of the kick gear and ratchet wheel e Align the punch mark 3 on the ratchet wheel with the punch mark on the kick shaft 2 Install Torsion spring 1 To kick shaft 2 NOTE Make sure the stopper 8 of the torsion spring fits into the hole on the kick shaft KICK SHAFT AND SHIFT SHAFT ENG ES TA DY 2M c S SAN cae Geh A NS ON N 7 3 Install e Spring guide 1 NOTE Slide the spring guide into the kick shaft make sure the groove 8 in the spring guide fits on the stopper of the torsion spring 4 Install e Kick shaft assembly 1 e Washer NOTE LL e Apply the molybdenum disulfide grease on the contacting surfaces of the kick shaft stop per 8 and stopper plate 3 e Apply the engine oil on the kick shaft e Slide the kick shaft assembly into the crank case and make sure the kick shaft stopper 8 fits into the stopper plate 5 Hook e Torsion spring 1 NOTE Turn the torsion spring clockwise and hook into the proper hole 3 in the crankcase Kick idle gear 1 Install e Kick idle gear 1 e Washer 2 e Circlip NOTE e Apply the engine oil on the kick idle gear inner circumference e Install the kick idle gear with its depressed side toward you AC MAGNETO AND STARTER CLUTCH BMS g AC MAGNETO AND STARTER CLUTCH 10 Nm 1 0 m kg 7 2 ft
171. ner race of the bearing Contact should be made only with the outer race 2 Install e Brake disc 1 e Bolt brake disc 2 mmm NOTE LL Tighten the bolts in stage using a crisscross pattern 3 Install e Collar NOTE e Apply the lithium soap base grease on the oil seal lip e Install the collar with their projection 8 fac ing the wheel 4 Install e Trip meter gear unit 1 NOTE e Apply the lithium soap base grease on the oil seal lip of the trip meter gear unit e Make sure the two projections 8 in the wheel hub are meshed with the two slots b in the trip meter gear unit FRONT WHEEL AND REAR WHEEL CHAS 5 Install e Wheel NOTE mmmn e nstall the brake disc 1 between the brake pads correctly e Make sure that the projections 8 in the trip meter gear unit fits over the stopper on the front fork outer tube mc 6 Install e Wheel axle 1 NOTE OO X C Apply the lithium soap base grease on the os wheel axle Me X NI 7 Install Nut wheel axle 105 Nm 10 5 m kg 75 ft Ib FRONT WHEEL AND REAR WHEEL CHAS 8 Tighten e Bolt axle holder 1 23 Nm 2 3 m kg 17 ft Ib NOTE Before tightening the bolt fit the wheel axle to the axle holder by stroking the front fork sev
172. ng Take care to not spill any gaso line on the engine or exhaust system Never refuel in the vicinity of an open flame or while smoking 6 10 GASOLINE CAN CAUSE INJURY If you should swallow some gasoline inhale excess gasoline vapors or allow any gasoline to get into your eyes contact a doctor immediately If any gasoline spills onto your skin or clothing immediately wash skin areas with soap and water and change your clothes ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILA TION Never start the engine or let it run for any length of time in an enclosed area Exhaust fumes are poisonous These fumes contain carbon monoxide which by itself is odorless and color less Carbon monoxide is a danger ous gas which can cause unconsciousness or can be lethal PARK THE MACHINE CAREFULLY TURN OFF THE ENGINE Always turn off the engine if you are going to leave the machine Do not park the machine on a slope or soft ground as it may fall over THE ENGINE EXHAUST PIPE MUF FLER AND OIL TANK WILL BE VERY HOT AFTER THE ENGINE HAS BEEN RUN Be careful not to touch them or to allow any clothing item to contact them during inspection or repair PROPERLY SECURE THE MACHINE BEFORE TRANSPORTING IT When transporting the machine in another vehicle always be sure it is properly secured and in an upright position and that the fuel cock is in the OFF position Otherwise fuel may leak out of the carbur
173. ng leakage and poor brake per formance e Refill with the same type of brake fluid mixing fluids may result in a harmful chem ical reaction and lead to poor performance e Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock plastic parts Always clean up spilled fluid immediately Front Rear FRONT BRAKE AND REAR BRAKE CHASSO 2 Air bleed e Brake system Refer to BRAKE SYSTEM AIR BLEED ING section in the CHAPTER 3 3 Inspect e Brake fluid level Fluid at lower level Fill up Refer to BRAKE FLUID LEVEL INSPEC TION section in the CHAPTER 3 4 Install Front e Diaphragm e Brake master cylinder cap 1 e Screw brake master cylinder cap 2 Nm 0 2 m kg 1 4 ft Ib Rear e Diaphragm e Brake master cylinder cap 1 e Bolt brake master cylinder cap 2 Nm 0 2 m kg 1 4 ft Ib After installation while pulling the brake lever in or pushing down on the brake pedal check whether there is any brake fluid leaking where the union bolts are installed respectively at the brake master cylinder and brake caliper Front Rear 5 Install rear brake only e Protector 1 e Bolt protector 7 Nm 0 7 m kg 5 1 ft Ib FRONT FORK CHAS Go EC550000 FRONT FORK 10 Nm 1 0 m kg 7 2 ft Ib Extent of removal 1 Front fork removal
174. nob lever Air temperature less than Open 3 ON 5 C 41 F or 4 times Air temperature more None ON han 5 C 41 F LEN F Air temperature normal tem perature between 5 C None ON OFF 41 F and 25 C 77 F Air temperature more F than 25 C 77 F Starti i ft ing an engine after a long None ON period of time Restarting a warm engine None OFF ON Restarting an engine after a fall OFF ON Operate the throttle grip before kick starting o CH c D Q O CH ps D o O O O O O O FF FF FF FF FF ON Observe the following break in procedures during initial operation to ensure optimum performance and avoid engine damage 1 17 STARTING AND BREAK IN GEN aes 1 18 BREAK IN PROCEDURES 1 Before starting the engine fill the fuel tank with the fuel 2 Perform the pre operation checks on the machine 3 Start and warm up the engine Check the idle speed and check the operation of the controls and the engine stop switch Then restart the engine and check its operation within no more than 5 minutes after it is restarted 4 Operate the machine in the lower gears at moderate throttle openings for five to eight minutes 5 Check how the engine runs when the machine is ridden with the throttle 1 4 to 1 2 open low to medium speed for about one hour 6 Restart the engine and check the operation of the machine throughout its entire operat
175. nt tend ing to upper front pos ture e Hear shock absorber NOTE SETTING e f any of the following symptoms is experienced with the standard position as the base make resetting by reference to the adjustment procedure given in the same chart e Adjust the rebound damping in 2 click increments or decrements e Adjust the low compression damping in 1 click increments or decrements e Adjust the high compression damping in 1 6 turn increments or decrements Section Rebound damping Spring set length Rebound damping Low compression damping Spring Rebound damping Spring Rebound damping Low compression damping Poor road gripping High compression damp ing Spring set length Spring High compression damp ing Bottoming out Spring set length Spring Rebound damping Bouncing Spring High compression damp ing Stiff travel Spring set length Spring Large ge EE Check Adjust gap gap Turn adjuster counterclockwise about 2 clicks t decrease damping Set sunken length for 90 100 mm 3 5 3 9 in when one passenger is astride seat Turn adjuster clockwise about 2 clicks to increase damping Turn adjuster clockwise about 1 click to increase damping Replace with stiff spring Turn adjuster counterclockwise about 2 clicks to decrease damping Replace with soft spring Turn adjuster counterclockwise about 2 clicks to decrease damping Turn adjuster clockwise abo
176. o REMOVAL POINTS Lower bracket STEERING CHASSO TIGHTENING STEPS e Tighten ring nut 38 Nm 3 8 m kg 27 ft Ib e Loosen it one turn e Retighten it 7 Nm 0 7 m kg 5 1 ft Ib 23 Nm 2 3 m kg 17 ft Ib 4 Nm 0 4 m kg 2 9 ft Ib 1 10 Ball race cover 1 i Upper bearing 1 P TL Refer to REMOVAL POINTS Ball race 2 STEERING CHASSO REMOVAL POINTS Steering ring nut 1 Remove e Steering ring nut 1 Use the steering nut wrench Steering nut wrench YU 33975 90890 01403 WARNING Support the steering stem so that it may not fall down Lower bearing 1 Remove Lower bearing 1 Use the floor chisel thread EC563400 Ball race 1 Remove e Ball race 1 Remove the ball race using long rod 2 and the hammer 12460503 EC564000 INSPECTION Steering stem 1 Inspect e Steering stem 1 Bend damage Replace STEERING CHAS dH Bearing and ball race 1 Wash the bearings and ball races with a solvent 2 Inspect Bearing 1 Ball race Pitting damage Replace bearings and ball races as a set Install the bearing in the ball races Spin the bearings by hand If the bearings hang up or are not smooth in their opera tion in the ball races replace bearings and ball races as a set EC565000 ASSEMBLY AND INSTALLATION Lower bracket 1 Install Lower bearing 1 NOTE Apply the lithium soap base grease on the dust se
177. o the carburetor Normal riding is done with the lever in this position RES With the lever in this position fuel flows to the carburetor from the reserve section of the fuel tank after the main supply of the fuel has been depleted Normal riding is possible with the lever is in this position but it is recommended to add fuel as soon as possible COLD STARTER KNOB When cold the engine requires a richer air fuel mixture for starting A separate starter circuit which is controlled by the cold starter knob Q supplies this mixture Pull the cold starter knob out to open the circuit for starting When the engine has warmed up push it in to close the circuit HOT STARTER LEVER The hot starter lever 1 is used when starting a warm engine Use the hot starter lever when starting the engine again immediately after it was stopped the engine is still warm Pulling the hot starter lever injects secondary air to thin the air fuel mixture temporarily allowing the engine to be started more easily CONTROL FUNCTIONS INFO 2S LIGHT SWITCH Za The light switch 1 is located on the handlebar ZZ AB Aen j UES aN VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose In this installation make sure the arrow faces the fuel tank and also downward SPARK PLUG WRENCH This spark plug wrench 1 is used to remove and install the spark plug WSIS 0 SLO 7
178. of the engine J SETTING CHASSIS Selection of the secondary reduction ratio Sprocket Secondary Number of rear wheel sprocket teeth reduction ratio Number of drive sprocket teeth Standard secondary reduction ratio 92 13 4 000 Requirement for selection of secondary gear reduction ratio e t is generally said that the secondary gear ratio should be reduced for a longer straight portion of a speed course and should be increased for a course with many corners Actually however as the speed depends on the ground condition of the day of the race be sure to run through the circuit to set the machine suitable for the entire course In actuality it is very difficult to achieve set tings suitable for the entire course and some settings may be sacrificed Thus the settings should be matched to the portion of the course that has the greatest effect on the race result In such a case run through the entire course while making notes of lap times to find the best balance then determine the secondary reduction ratio If a course has a long straight portion where a machine can run at maximum speed the machine is generally set such that it can develop its maximum revolutions toward the end of the straight line with care taken to avoid the engine over revving NOTE ja c Riding technique varies from rider to rider and th
179. oil pump assembly L 25 mm 0 94 in 10 Nm 1 0 m kg 7 2 ft Ib e Bolt oil pump assembly L 30 mm 1 18 in 10 Nm 1 0 m kg 7 2 ft Ib NOTE Apply the engine oil on the outer rotor 2 5 Install e Oil pump drive gear 1 e Washer 2 e Circlip NOTE aa Apply the engine oil on the oil pump drive gear inner circumference KICK SHAFT AND SHIFT SHAFT ENG KICK SHAFT AND SHIFT SHAFT 10Nm 1 0m kg 7 2f Extent of removal CD Kick shaft removal 2 Kick shaft disassembly 3 Shift shaft removal 4 Segment removal KICK SHAFT AND SHIFT SHAFT REMOVAL Preparation for removal Oil pump Refer to OIL PUMP section Kick idle gear Kick shaft assembly Spring guide Torsion spring Ratchet wheel Kick gear Kick shaft Washer Shift pedal Shift shaft Collar Refer to REMOVAL POINTS 1 2 3 4 5 6 D 8 9 ch sch wesch sesch sesch sch sesch sesch wesch ch O EI KICK SHAFT AND SHIFT SHAFT ENG 10Nm 1 0 m kg 7 2f 12 Torsion spring Roller Shift guide Shift lever assembly Shift lever Pawl Pawl pin Spring Bolt stopper lever Stopper lever Torsion spring Segment Refer to REMOVAL POINTS sch PN NO WHO sech sch sch sch Refer to REMOVAL POINTS KICK SHAFT AND SHIFT SHAFT ENG REMOVAL POINTS Kick shaft assembly 1 Remove e Kick shaft
180. oints e Friction plate thickness 2 9 3 1 mm 0 114 0 122 in Limit 2 7 mm 0 106 in EC484600 Clutch plate 1 Measure e Clutch plate warpage Out of specification Replace clutch plate as a set Use a surface plate 1 and thickness gauge 2 Warp limit 0 1 mm 0 004 in Push lever shaft 1 Inspect e Push lever shaft Wear damage Replace Push rod 1 Inspect e Push rod 1 D e Bearing e Washer 3 e Push rod 2 2 e Ball Wear damage bend Replace ur ASSEMBLY AND INSTALLATION Push lever shaft 1 Install e Push lever shaft 1 e Bolt push lever shaft NOTE pa e Apply the lithium soap base grease on the oil seal lip e Apply the engine oil on the push lever shaft e Fit the seat plate in the groove of the push lever shaft and tighten the bolt seat plate Clutch 1 Install e Primary driven gear 1 e hrust washer 2 e Clutch boss Gi NOTE L Apply the engine oil on the primary driven gear inner circumference 2 Install e Lock washer 1 e Nut clutch boss NOTE Use the clutch holding tool 3 to hold the clutch boss Va Clutch holding tool YM 91042 90890 04086 For USA and CDN Except for USA and CDN ur 3 Bend the lock washer 1 tab 8 4 Install e Seat plate 1 e Cushion spring NOTE e Install the seat plate with its chamfered por t
181. on coil cap 2 Inspect e Primary coil resistance Out of specification Replace Tester lead Orange lead 1 Tester lead Black lead l ij Primary coil Tester selector ri resistance position 0 08 0 10 Q at 20 C 68 F 3 Inspect e Secondary coil resistance Out of specification Replace Tester lead Orange lead 1 Tester lead Spark plug terminal ij Secondary coil Tester selector ri resistance position 4 6 6 8 kO at NET 4 Inspect e Sealed portion of ignition coil e Spark plug terminal pin e Threaded portion of spark plug Wear Replace X9 IGNITION system ELEC AC MAGNETO INSPECTION 1 Inspect e Pickup coil resistance Out of specification Replace Tester lead Red lead 0 Tester lead White lead resistance position Pickup coil Tester selector 248 372 Q at 20 C 68 F NEUTRAL SWITCH INSPECTION 1 Inspect e Neutral switch conduct Tester lead Sky blue lead 1 Tester lead Ground C Sb Ground Tester selector ri 9 e position weem No continuity while in neutral Replace Continuity while in gear Replace EC628000 CDI UNIT INSPECTION Check all electrical components If no fault is found replace the CDI unit Then check the electrical components again ELECTRIC STARTING SYSTEM ELEC ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT
182. or yoke with the match mark O on the starter motor rear cover ELECTRIC STARTING SYSTEM ELEC 4 Install e Gasket e Circlip e Plain washer e Washer starter motor front cover 3 e Starter motor front cover 2 NOTE LL For installation align the projections on the washer with the slots in the front cover e Align the match mark 8 on the starter motor yoke with the match mark on the starter motor front cover 5 Install e Gasket e Bolt 1 e O ring NOTE Apply the lithium soap base grease on the O ring CHARGING system ELEC CHARGING SYSTEM EC681001 INSPECTION STEPS If the battery is not charged use the following inspection steps 1 Check fuse Replace fuse and check wire harness J L O 2 Check battery IT OK Check each coupler and No good i i Repair or replace wire connection OK Check charging voltage te IS J bL No good Check AC magneto Charging coil ER Replace OK Recharge or replace it d Replace rectifier regulator 1 marked Refer to FUSE INSPECTION section in the CHAPTER 3 2 marked Refer to BATTERY INSPECTION AND CHARGING section in the CHAPTER 3 NOTE e Remove the following parts before inspection 1 Seat 2 Fuel tank Use the following special tool in this inspection Pocket tester Inductive tachometer YU 3112 C 90890 031 12 H YU 8036 B Engine tachometer 90890 03113 Uy WES Y NU
183. ottle cable cap HOT STARTER LEVER ADJUSTMENT 1 Check e Hot starter lever free play Out of specification Adjust Hot starter lever free play 3 6 mm 0 12 0 24 in 2 Adjust Hot starter lever free play Hot starter lever free play adjustment steps e Loosen the locknut e Turn the adjuster until free play 8 is within the specified limits e Tighten the locknut NOTE O After adjustment check proper operation of hot starter INSP AIR FILTER CLEANING Wer AIR FILTER CLEANING len Proper air filter maintenance is the biggest key to preventing premature engine wear and damage Never run the engine without the air filter element in place this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage 1 Remove e Air filter case cover 1 NOTE Loosen the quick screw 2 and draw the air fil ter case cover to remove it because its claws 8 are inserted in the side cover as shown 2 Unhook e Binder 1 3 Hemove e Air filter element 1 e Filter guide 4 Clean e Air filter element Clean them with solvent NOTE After cleaning remove the remaining solvent by squeezing the element INSP AIR FILTER CLEANING e Do not twist the element when squeezing the element e Leaving too much of solvent in the ele ment may result in poor starting 5 Inspect Air filter element Damage
184. pacity Revolution per minute Engine speed CABLE ROUTING DIAGRAM SPEC y EC240000 CABLE ROUTING DIAGRAM D Fuel tank breather hose 9 Oil hose 7 Cable guide 2 Oil tank breather hose Hose guide Negative battery lead 3 Clamp b AC magneto lead Light switch lead 4 Diode 2 Cylinder head breather hose GO Brake hose 5 Wire harness 3 Starter motor lead Carburetor breather hose 6 Hot starter cable Clutch cable 62 Carburetor overflow hose Throttle position sensor lead 5 Radiator hose 1 3 Coolant reservoir breather Neutral switch lead Radiator pipe radiator hose 4 hose 9 OF Siem 4 Eu A Ze 2 244 CABLE ROUTING DIAGRAM SPEC y Insert the fuel tank breather hose into the hole in D Fasten the wire harness starter motor lead and the steering stem cap negative battery lead so that the plastic locking tie Pass the oil tank breather hose on the outside of ends do not contact the ignition coil lead the AC magneto lead neutral switch lead light Fasten the wire harness rectifier regulator lead switch lead wire harness starter motor lead neg coolant reservoir hose hot starter cable negative ative battery lead and cylinder head breather battery lead and starter motor lead hose Fasten the wire harness negative battery lead Fasten the diode and rectifier regulator lead with starter motor lead rectifier regulator lead and the diode at its white tape and the rectifier regula coolant
185. ping Oil seal Apply grease in oil seal wall Poor initial movement Compression damping Turn adjuster clockwise about 2 clicks to increase Soft over entire range damping bottoming out Oil level oil amount Increase oil level by about 5 10 mm 0 2 0 4 in Spring Replace with stiff spring Stiff toward stroke end toward stroke od o EBEN Oil level oil amount DecreaseoilevelbyaboutSmm 02im oil level DecreaseoilevelbyaboutSmm 02im about 5 mm 0 2 in waren ene Oil level oil amount Increase oil level by about 5 mm 0 2 in bottoming out Turn adjuster counterclockwise about 2 clicks t Stiff initial movement Compression damping decrease damping Compression damping Turn adjuster clockwise about 2 clicks to increase damping Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Balance with rear end Set sunken length for 95 100 mm 3 7 3 9 in when one passenger is astride seat lower rear posture Oil level oil amount Increase oil level by about 5 mm 0 2 in Low front tending to lower front posture Compression damping Turn adjuster counterclockwise about 2 clicks to decrease damping Balance with rear end Set sunken length for 90 95 mm 3 5 3 7 in when one passenger is astride seat upper rear posture Spring Replace with soft spring Oil lever oil amount Decrease oil level by about 5 10 mm 0 2 0 4 in Obtrusive fro
186. pipe 1 Inspect e Gasket 1 Damage Replace ASSEMBLY AND INSTALLATION Silencer and exhaust pipe 1 Install e Gasket e Exhaust pipe 1 e Nut exhaust pipe e Bolt exhaust pipe NOTE 77777 First temporarily tighten the nut exhaust pipe then tighten the bolt exhaust pipe 20Nm 2 0mekg 14ftelb After that retighten the nut exhaust pipe 13 Nm 1 3mekg 9 4ftelb and then the bolt exhaust pipe 24 Nm 2 4 m kg 17 ft Ib 2 Install e Silencer clamp 1 e Gasket e Silencer 3 e Washer 2 e Bolt silencer 35 Nm 3 5 m kg 25 ft Ib RADIATOR g RADIATOR d 7 Nm 0 7 m kg 5 1ft Ib 7 Nm 0 7 m kg 5 1 ft Ib i 10Nm 1 0m kg 7 2ft Ib 10Nm 1 0 m kg 7 2ft Ib Extent of removal Radiator removal RADIATOR REMOVAL Preparation for removal Drain the coolant Refer to COOLANT REPLACEMENT section in the CHAPTER 3 Refer to SEAT FUEL TANK AND SIDE COVERS section Seat fuel tank and left side cover Radiator guard Radiator hose clamp Radiator hose 1 Left radiator Radiator hose 3 Coolant reservoir hose Right radiator Radiator hose 2 Radiator hose 4 Radiator pipe Coolant reservoir breather hose Coolant reservoir Only loosening 1 2 3 4 5 6 D 8 i sch sch sch sch c c QO WM RY HANDLING NOTE A WARNING Do not remove the radiator cap when the engine and radiator are hot Scalding hot flu
187. position Extent of adjustment 76 97 mm So EES ttn 2 99 3 82 in 2 Remove NS Brake lever cover PS A 3 Adjust D e Brake lever position N Brake lever position adjustment steps e Loosen the locknut 1 e Turn the adjusting bolt until the lever position 8 is within specified position e Tighten the locknut Locknut oa 5 Nm 0 5 me kg 3 6 ft Ib Be sure to tighten the locknut as it will cause poor brake performance 4 nstall e Brake lever cover 3 26 REAR BRAKE ADJUSTMENT INSP e FRONT BRAKE PAD INSPECTION AND REPLACEMENT ADJ Q REAR BRAKE ADJUSTMENT 1 Check Brake pedal height 8 Out of specification Adjust Brake pedal height 3 5 mm 0 20 in 2 Adjust e Brake pedal height Pedal height adjustment steps e Loosen the locknut e Turn the adjusting nut until the pedal height 8 is within specified height e Tighten the locknut A WARNING e Adjust the pedal height between the maximum and the minimum as shown In this adjustment the bolt 3 end b should protrude out of the threaded portion 2 but not be less than 2 mm 0 08 in O away from the brake pedal 5 e After the pedal height adjustment make sure that the rear brake does not drag FRONT BRAKE PAD INSPECTION AND REPLACEMENT 1 Inspect e Brake pad thickness 8 Out of specification Replace as a set Brake pad thickness 4 4 mm 0 17 in Limit 1 0 mm 0 04 in
188. quickly and can cause battery overheating and battery plate damage If it is impossible to regulate the charging current on the battery charger be careful not to overcharge the battery When charging a battery be sure to remove it from the machine If charging has to be done with the battery mounted on the machine disconnect the negative battery lead from the battery terminal To reduce the chance of sparks do not plug in the battery charger until the bat tery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the battery charger Make sure the battery charger lead clips are in full contact with the battery termi nal and that they are not shorted A cor roded battery charger lead clip may generate heat in the contact area and a weak clip spring may cause sparks If the battery becomes hot to the touch at any time during the charging process disconnect the battery charger and let the battery cool before reconnecting it Hot batteries can explode As shown in the following illustration the open circuit voltage of an MF battery sta bilizes about 30 minutes after charging has been completed Therefore wait 30 minutes after charging is completed before measuring the open circuit volt age BATTERY INSPECTION AND CHARGING Charging method using a variable voltage charger NOTE Measure the open circuit Leave the battery unused for
189. quipment lighted cigarettes e DO NOT SMOKE when charging or han dling batteries e KEEP BATTERIES AND ELECTROLYTE OUT OF REACH OF CHILDREN e Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury FIRST AID INCASE OF BODILY CONTACT EXTERNAL e Skin Wash with water e Eyes Flush with water for 15 minutes and get immediate medical attention INTERNAL e Drink large quantities of water or milk fol lowed with milk of magnesia beaten egg or vegetable oil Get immediate medical attention Charging time charging amperage and charging voltage for an MF battery are dif ferent from those of conventional batteries The MF battery should be charged as explained in the charging method illustra tions If the battery is overcharged the electrolyte level will drop considerably Therefore take special care when charging the battery INSP 4o BATTERY INSPECTION AND CHARGING ADJ NOTE Since MF batteries are sealed it is not possi ble to check the charge state of the battery by measuring the specific gravity of the electro lyte Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals 1 Remove e Seat 2 Disconnect e Battery leads from the battery terminals First disconnect the negative battery lead CD and then the positive battery lead 3 Remove e Battery band e Battery INSP 4o
190. r e Nut connecting rod NOTE e Apply the molybdenum disulfide grease on the bolt e Do not tighten the nut yet 9 Install e Bolt rear shock absorber relay arm 1 e Nut rear shock absorber relay arm 2 53 Nm 5 3 m kg 38 ft Ib LAT x9 DE NOTE CL eg p Apply the molybdenum disulfide grease on the bolt 10 Tighten e Nut connecting rod 80 Nm 8 0 m kg 58 ft Ib 11 Tighten e Nut relay arm leg Nm 8 0 m kg 58 ft Ib 12 Install e Cap NOTE Install the right cap with its mark 8 facing for ward swiNGARnM CHAS 13 Install e Bolt lower chain tensioner 1 e Washer 2 e Collar 3 e Lower chain tensioner e Nut lower chain tensioner 20 Nm 2 0 m kg 14 ft Ib 14 Install e Drive chain support 1 e Drive chain support cover e Bolt drive chain support g 50 mm 1 97 in 9 e Nut drive chain support e Bolt drive chain support cover g 10 mm 0 39 inh 7 Nm 0 7 m kg 5 1 ft Ib REAR SHOCK ABSORBER CHAS Go EC580000 REAR SHOCK ABSORBER 56 Nm 5 6 m kg 40 ft Ib 32 Nm 3 2 m kg 23 ft Ib Extent of removal Rear shock absorber removal Rear shock absorber disassembly REAR SHOCK ABSORBER REMOVAL Support the machine securely so there is no Preparation for removal Hold the machine by placing the danger of it falling over suitable stand under the engine Seat fi
191. r housing 3 e Oil pump cover Cracks wear damage Replace 2 Measure e Tip clearance between the inner rotor 1 and outer 7 rotor e Side clearance between the outer rotor 2 and rotor housing e Housing and rotor clearance C between the rotor housing 3 and rotors 0 Out of specification gt Replace the oil pump assembly Sy Tip clearance 0 12 mm or less 0 0047 in or less lt Limit gt 0 20 mm 0 008 in Side clearance b 0 09 0 17 mm 0 0035 0 0067 in Limit 0 24 mm 0 009 in Housing and rotor clearance C 0 03 0 10 mm 0 0012 0 0039 in Limit 0 17 mm 0 0067 in 3 Check e Unsmooth Repeat steps 1 and 2 or replace the defective parts ASSEMBLY AND INSTALLATION Oil pump 1 Install e Oil pump drive shaft 1 e Washer e Dowel pin e Inner rotor 1 4 NOTE e Apply the engine oil on the oil pump drive shaft and inner rotor 1 e Fit the dowel pin into the groove in the inner rotor 1 2 Install e Outer rotor 1 1 NOTE Apply the engine oil on the outer rotor 1 3 Install e Oil pump cover 1 e Screw oil pump cover e Dowel pin e Inner rotor 2 4 e Circlip NOTE e Apply the engine oil on the inner rotor 2 e Fit the dowel pin into the groove in the inner rotor 2 OIL PUMP ENG o 4 Install e Outer rotor 2 1 e Dowel pin e Oil pump assembly 3 e Bolt
192. rber relay arm 2 53 Nm 5 3 m kg 38 ft Ib NOTE Apply the molybdenum disulfide grease on the bolt Install e Rear frame 0 e Bolt rear frame upper 32 Nm 3 2 m kg 23 ft Ib e Bolt rear frame lower 29 Nm 2 9 m kg 21 ft Ib Tighten e Screw air filter joint 1 3 Nm 0 3 m kg 2 2 ft Ib REAR SHOCK ABSORBER CHAS 8 Install e Plastic band 1 e Starting circuit cut off relay coupler 2 e Taillight coupler 3 e Locking tie 4 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC600000 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS CD Headlight 2 Engine stop switch 3 Clutch switch 4 Diode 5 Starter relay diode 6 Throttle position sen sor Starter relay Fuse Starting circuit cut off relay Taillight EC612000 WIRING DIAGRAM D Neutral switch 02 Starter motor 3 AC magneto Rectifier regulator 5 Ignition coil Spark plug Start switch Light switch Main switch GO CDI unit Battery COLOR CODE Black IMMENSE Brown GY m n Gray EE ET Blue 6 ee Orange RON Hed ojo PEE Sky blue E White O Yellow gt re Black Blue gt GS SE SS Ka Ew DI Black White L B Blue Black L R Blue Red I EE Blue Y ellow Wu eee Blue White RB NE RE Red Black 7X8 19 BOO l D L L MAP CONTROLLED CDI UNIT ELEC
193. rear wheel sprocket e Washer rear wheel sprocket 3 e Nut rear wheel sprocket 50 Nm 5 0 m kg 36 ft Ib NOTE Tighten the nuts in stage using a crisscross pattern 4 Install e Collar 1 NOTE Apply the lithium soap base grease on the oil seal lip 5 Install e Wheel NOTE 5S S S Install the brake disc D between the brake pads correctly 6 Install e Drive chain 1 NOTE L Push the wheel forward and install the drive chain 7 Install e Left drive chain puller 1 e Wheel axle NOTE LLL e Install the left drive chain puller and insert the wheel axle from left side e Apply the lithium soap base grease on the wheel axle FRONT WHEEL AND REAR WHEEL CHAS 8 Install e Right drive chain puller 1 e Washer e Nut wheel axle T ch E NOTE Temporarily tighten the nut wheel axle at this lt lt point 9 Adjust e Drive chain slack a Drive chain slack 40 50 mm 1 6 2 0 in Refer to DRIVE CHAIN SLACK ADJUSTMENT section in the CHAPTER b 3 PE O 10 Tighten ee pO Y e Nut wheel axle 1 OG X e Locknut qu QV SC SS FRONT BRAKE AND REAR BRAKE CHA FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE 6 Nm 0 6 m kg 4 3 ft Ib 3 18 Nm 1 8 m kg 13 ft Ib d E 3 hye 16 Nm 1 6 m kg 11 ft I
194. richness or lean ness of the air fuel mixture Therefore refer to the above table for mixture settings That is e Higher temperature expands the air with its resultant reduced density e Higher humidity reduces the amount of oxy gen in the air by so much of the water vapor in the same air e Lower atmospheric pressure at a high alti tude reduces the density of the air SETTING E Effects of the setting parts on the throttle valve opening 1 8 1 4 1 2 3 4 Closed Fully open D Pilot screw pilot jet 2 Throttle valve cutaway 3 Jet needle Main jet Main system The FLATCR carburetor has a primary main jet This type of main jet is perfect for racing motorcycles since it supplies an even flow of fuel even at full load Use the main jet and the jet needle to set the carburetor Pilot system The FLATCR carburetor is manufactured with a pilot screw The pilot screw adjustment ranges from fully closed throttle to 1 4 open throttle J SETTING D Jet needle u 2 Pilot air jet UI i Needle jet Sn eee j 5 Pilot jet 6 Pilot screw Main jet adjustment The richness of the air fuel mixture at full throt tle can be set by changing the main jet 1 185 Standard main jet 4472 Except for USA If the air fuel mixture is too rich or too lean the engine power will drop resulting in poor accel eration Effects of changing the main jet reference
195. rk plug Upper engine bracket e Cylinder head cover Refer to CAMSHAFTS section in the CHAPTER 4 Remove e Timing mark accessing screw 1 e Crankshaft end accessing screw e O ring Check e Valve clearance Out of specification Adjust Valve clearance cold Intake valve 0 10 0 15 mm 0 0039 0 0059 in Exhaust valve 0 17 0 22 mm 0 0067 0 0087 in Checking steps e Turn the crankshaft counterclockwise with a wrench e Align the T D C mark on the rotor with the align mark on the crankcase cover when piston is at T D C on compression stroke NOTE c In order to be sure that the piston is at Top Dead Center the punch mark O on the exhaust camshaft and the punch mark on the intake camshaft must align with the cyl inder head surface as shown in the illustra tion INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT e Measure the valve clearance using a feeler gauge 1 NOTE 7777 777 22 Record the measured reading if the clear ance is incorrect 6 Adjust e Valve clearance Adjustment steps e Remove the camshaft intake and exhaust Refer to CAMSHAFTS section in the CHAPTER 4 e Remove the valve lifters 1 and the pads 2 NOTE 7 e Place a rag in the timing chain space to prevent pads from falling into the crank case e Identity each valve lifter and pad position very caref
196. rod holder YM 1423 90890 01423 EC554000 INSPECTION EC554100 Damper rod 1 Inspect e Damper rod 1 Bend damage Replace damper rod The front fork with a built in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled FRONT FORK CHASSO EC554200 Base valve 2 1 Inspect zm e Valve assembly 1 Wear damage Replace A s O ring Damage Replace Q EC554400 Fork spring 1 Measure e Fork spring free length Out of specification Replace Fork spring free length 460 mm 18 1 in Limit 455 mm 17 9 in EC554502 Inner tube 1 Inspect e Inner tube surface 8 Score marks Repair or replace Use 1 000 grit wet sandpaper Damaged oil lock piece Replace e Inner tube bends Out of specification Replace Use the dial gauge Inner tube bending limit 0 2 mm 0 008 in NOTE nmm The bending value is shown by one half of the dial gauge reading A WARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube EC554600 Outer tube 1 Inspect e Outer tube 1 score marks wear damage Replace FRONT FORK CHASSO Front fork cap bolt 1 Inspect e Front fork cap bolt 1 e O ring e Air bleed screw 3 W
197. s outer race parallel e o prevent the screw bearing stopper crankshaft from becoming loose crush the screw head periphery into the concave b using a punch etc In so doing take care not to damage the screwdriver receiving hole in the screw head Crankshaft 1 Install e Crankshaft 1 Use the crankshaft installing tool 4 and S Crankshaft installing pot Yo YU 90050 90890 01274 Crankshaft installing bolt YU 90050 90890 01275 Adapter M12 YU 90063 90890 01278 Spacer crankshaft installer YM 91044 90890 04081 For USA and CDN Except for USA and CDN NOTE e Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other Operate the installing tool until the crankshaft bottoms against the bearing e Before installing the crankshaft clean the contacting surface of crankcase shaft 4 98 CRANKCASE AND CRANKSHAFT ENG 2 Check e Shifter operation e Transmission operation Unsmooth operation Repair 3 Install e Oil strainer 1 Bolt oil strainer 10 Nm 1 0 m kg 7 2 ft Ib 4 Apply e Sealant On the right crankcase 1 CZ Quick gasket ACC QUICK GS KT YAMAHA Bond No 1215 90890 85505 NOTE W Clean the contacting surface of left and right crankcase before applying the sealant 5 Install e Dowel pin 1 O ring e Right crankcase To left cr
198. seal Damage Replace NOTE LLL Polylube bearings with solid lubrication have been adopted with the intent to make the nee dle bearings used in this model maintenance free With polylube bearings no grease nipple and regular lubrication is necessary However grease should be applied to all oil seals and collars when removed or installed EC575000 ASSEMBLY AND INSTALLATION EC575201 Bearing and oil seal 1 Install Bearing 1 e Oil seal To swingarm NOTE e Apply the molybdenum disulfide grease on the bearing when installing e Install the bearing by pressing it on the side having the manufacture s marks or numbers e First install the outer and then the inner bear ings to a specified depth from inside Installed depth of bearings Outer 8 Zero mm Zero in Inner 8 5 mm 0 33 in swiNGAnM CHAS 2 Install Bearing 1 e Oil seal To relay arm NOTE e Apply the molybdenum disulfide grease on the bearing when installing e Install the bearing by pressing it on the side having the manufacture s marks or numbers Installed depth of bearings 3 5 mm 0 20 in 3 Install e Bearing 1 e Oil seal To connecting rod NOTE 2 ALL e Apply the molybdenum disulfide grease on the bearing when installing e Install the bearing by pressing it on the side having the manufacture s marks or numbers Installed depth of bearings
199. sing a drive chain cutter 2 Clean e Drive chain Brush off as much dirt as possible Then clean the drive chain using the chain cleaner This machine has a drive chain with small rubber O rings 1 between the side plates Steam cleaning high pressure washes certain solvent and kerosene can damage these O rings 3 Inspect e O ring CD drive chain Damage Replace the drive chain e Roller e Side plate 3 Damage wear Replace the drive chain 4 Measure e Drive chain length 10 links Out of specification Replace Drive chain length 10 links Limit 150 1 mm 5 91 in 12510206 INSP DRIVE CHAIN INSPECTION 12510204 12510503 5 Check e Drive chain stiffness a Clean and oil the drive chain and hold as illustrated Stiff Replace the drive chain 6 Install Chain joint 1 e O ring e Drive chain NOTE When installing the drive chain apply the lith ium soap base grease on the chain joint and O rings 7 Install e Link plate NOTE e Press the link plate onto the chain joint using a drive chain riveter 5 Rivet the end of the chain joint using a drive chain riveter e After riveting the chain joint make sure its movement is smooth 8 Lubricate e Drive chain Drive chain lubricant SAE 10W 30 motor oil or suitable chain lubricants INSP DRIVE CHAIN SLACK ADJUSTMENT DRIVE CHAIN SLACK ADJUSTMENT 1 Elevat
200. sition sensor 1 except when changing the throt tle position sensor due to failure because it will cause a drop in engine performance EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check e Couplers and leads connection Rust dust looseness short circuit gt Repair or replace THROTTLE POSITION SENSOR COIL INSPECTION 1 Inspect e Throttle position sensor coil resistance Out of specification Replace Tester lead Blue lead 0 Tester lead Black lead Throttle position Tester selector sensor coil iti resistance position 4 6kQ at 2 Loosen e Throttle stop screw 1 NOTE Turn out the throttle stop screw until the throt tle shaft is in the full close position THROTTLE POSITION SENSOR SYSTEM ELEC 3 Inspect e Throttle position sensor coil variable resistance Check that the resistance in increased as the throttle grip is moved from the full close position to the full open position Out of specification Replace Tester lead Yellow lead Tester lead Black lead L j Throttle position sensor Tester coil variable resistance 99lector position Full closed Full opened kQ x 1 THROTTLE POSITION SENSOR REPLACEMENT AND ADJUSTMENT 1 Remove e Throttle position sensor coupler e Screw throttle position sensor 1 e Throttle position sensor NOTE LL Loosen the screws throttl
201. spot seizure Replace NOTE 77 Replace the bearings oil seal and wheel collar as a set FRONT WHEEL AND REAR WHEEL CHAS EC514200 Wheel axle 1 Measure e Wheel axle bends Out of specification Replace Use the dial gauge Wheel axle bending limit 0 5 mm 0 020 in NOTE 2L The bending value is shown by one half of the dial gauge reading A WARNING Do not attempt to straighten a bent axle EC594200 Brake disc 1 Measure e Brake disc deflection only rear brake disc Use the dial gauge Out of specification Inspect wheel runout If wheel runout is in good condition replace the brake disc Brake disc deflection limit Rear Limit 0 15 mm 0 006 in 2 Measure e Brake disc thickness 8 Out of limit Replace Brake disc thickness Front 3 0 mm 0 12 in Limit 2 5 mm 0 10 in 12210203 Rear 4 0 mm 0 16 in Limit 3 5 mm 0 14 in FRONT WHEEL AND REAR WHEEL CHAS EC595000 ASSEMBLY AND INSTALLATION Front wheel 1 Install e Bearing left 1 e Spacer 2 e Bearing right e Oil seal 2 NOTE e Apply the lithium soap base grease on the bearing and oil seal lip when installing Use a socket that matches the outside diam eter of the race of the bearing Left side of bearing shall be installed first e Install the oil seal with its manufacture s marks or numbers facing outward Do not strike the in
202. sure e Runout valve stem Out of specification Replace Runout limit 0 01 mm 0 0004 in NOTE e When installing a new valve always replace the guide e f the valve is removed or replaced always replace the oil seal 11172103 6 Eliminate e Carbon deposits from the valve face and valve seat 7 Inspect e Valve seat Pitting wear Reface the valve seat 8 Measure e Valve seat width 8 Out of specification Reface the valve seat Intake 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in 11171603 Exhaust 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in 8 Valve seat width Measurement steps e Apply Mechanic s blueing dye Dykem to the valve face e Install the valve into the cylinder head e Press the valve through the valve guide and onto the valve seat to make a clear pattern e Measure the valve seat width Where the valve seat and valve face made contact blueing will have been removed e f the valve seat is too wide too narrow or the seat is not centered the valve seat must be refaced 11171601 Z VALVES AND VALVE SPRINGS ENG 9 Lap e Valve face e Valve seat NOTE After refacing the valve seat or replacing the valve and valve guide the valve seat and valve face should be lapped Lapping steps e Apply a coarse lapping compound to the valve face Do not let the compound enter the gap between the valve stem an
203. surface b Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace AC magneto and or stator EC4L4200 Woodruff key 1 Inspect e Woodruff key 1 Damage Replace Starter clutch 1 Check e Starter clutch Damage wear Replace 2 Check e Idle gear e Idle gear shaft e Starter clutch gear Pitting burrs chips roughness wear Replace the defective parts e AC MAGNETO AND STARTER CLUTCH ENG 3 Check e Starter clutch operation Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch When turning the starter clutch drive gear counterclockwise B the starter clutch and the starter clutch drive gear should engage If the starter clutch drive gear and starter clutch do not engage the starter clutch is faulty and must be replaced When turning the starter clutch drive gear clockwise A it should turn freely If the starter clutch drive gear does not turn freely the starter clutch is faulty and must be replaced EC4L5000 ASSEMBLY AND INSTALLATION AC magneto and starter clutch 1 Install e Stator 1 e Bolt stator e Pickup coil e Bolt pickup coil 10 Nm 1 0 m kg 7 2 ft Ib AC MAGNETO AND STARTER CLUTCH 2 Install e Holder 1 e Bolt 2 7 Nm 0 7 m kg 5 1 ft Ib Pass the pickup coil lead and charging coil lead under the holder while taking care not to allow these leads to
204. t Crack damage Replace Exist fur deposits 3 Clean or replace RADIATOR CAP OPENING PRESSURE INSPECTION 1 Attach e Radiator cap tester 1 and adapter Radiator cap tester YU 24460 01 90890 01325 Radiator cap tester adapter YU 33984 90890 01352 NOTE Apply water on the radiator cap seal 3 Radiator cap COOLING SYSTEM INSPECTION INSP 4o CLUTCH ADJUSTMENT ADJ Q 2 Apply the specified pressure Radiator cap opening pressure 110 kPa 1 1 kg cm 15 6 psi 3 Inspect e Pressure Impossible to maintain the specified pres sure for 10 seconds Replace COOLING SYSTEM INSPECTION eS B N 1 Inspect EN ET e Coolant level AS dr y 2 Attach AV T e Radiator cap tester 1 and adapter 2 P Radiator cap tester YU 24460 01 90890 01325 Radiator cap tester adapter YU 33984 90890 01352 3 Apply the specified pressure Standard pressure 180 kPa 1 8 kg cm 25 6 psi NOTE LL e Do not apply pressure more than specified pressure e Radiator should be filled fully 4 Inspect e Pressure Impossible to maintain the specified pres sure for 10 seconds Repair e Radiator 1 e Radiator hose joint 2 Coolant leakage Repair or replace e Radiator hose 3 Swelling Replace CLUTCH ADJUSTMENT 1 Check e Clutch lever free play 8 Out of specification Adjust Clutch lever free play 8 13 mm 0 31 0 51 in INSP THROTTLE CABLE
205. t 0 1 mm 0 004 in e f out of specification replace the cylinder and replace the piston and piston rings as Set Z CYLINDER AND PISTON ENG Piston ring 1 Measure 11221401 e Ring side clearance Use a feeler gauge 0 Out of specification gt Replace the piston and rings as a set NOTE qe Clean carbon from the piston ring grooves and rings before measuring the side clearance e Side clearance Toon 0 030 0 065 mm 0 12 mm P FING 0 0012 0 0026 in 0 005 in 0 020 0 055 mm 0 12 mm 0 0008 0 0022 in 0 005 in 2 Position e Piston ring in cylinder NOTE 777 2 Insert a ring into the cylinder and push it approximately 10 mm 0 39 in into the cylin der Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore 8 10 mm 0 39 in 3 Measure e Ring end gap Out of specification Replace NOTES You cannot measure the end gap on the expander spacer of the oil control ring If the oil control ring rails show excessive gap replace all three rings End gap Top rin 0 15 0 25 mm 0 50 mm pring 0 006 0 010 in 0 020 in 0 10 0 40 mm 0 004 0 016 in 0 30 0 45 mm 0 80 mm 0 012 0 018 in 0 031 in CYLINDER AND PISTON ENG e Piston pin 1 Inspect e Piston pin Blue discoloration grooves Replace then inspect the lubrication system 2 Measure e Piston
206. t Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 2 Remove e Headlight bulb holder cover 1 3 Detach e Headlight bulb holder 4 Remove Ga Headlight bulb A LFS v P Saz Since the headlight bulb gets extremely hot a keep flammable products and your hands away from the bulb unit it has cooled down 5 Install e Headlight bulb secure the new headlight bulb with the headlight bulb holder Avoid touching the glass part of the head light bulb to keep it free form oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the headlight bulb gets soiled thoroughly clean it with a cloth moistened with alcohol or lacquer thinner 6 Attach e Headlight bulb holder 7 Install e Headlight bulb holder cover 8 Install Headlight Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 ADJUSTING THE HEADLIGHT BEAMS 1 Adjust e Headlight beam vertically Adjusting steps e Turn the adjusting screw in direction 8 or Headlight beam is raised Headlight beam is lowered SEAT FUEL TANK AND SIDE COVERS d EC400000 ENGINE SEAT FUEL TANK AND SIDE COVERS 10 Nm 1 0 m kg 7 2 ft Ib 4 Nm 0 4 m kg 2 9 ft Ib a WS TES 7 Nm 0 7 m kg 5 1 ft Ib 7 Nm 0 7 m kg 5 1 ft Ib Extent of removal Extent of removal D Seat removal 3 Side covers
207. t cut off relay conduct Use 12 V battery Battery lead Blue Black lead 1 Battery lead Brown lead Tester lead Blue White lead 3 Tester lead Black lead 2 L W B Tester selector ri ellen position Connected to Q x1 Not connected to battery ELECTRIC STARTING SYSTEM ELEC STARTER RELAY INSPECTION 1 Remove e Starter relay 2 Inspect e Starter relay conduct Use 12 V battery Battery lead gt Starter relay terminal 1 Battery lead gt Starter relay terminal 2 18211002 Tester lead gt Starter relay terminal 3 Tester lead gt Starter relay terminal 4 Ter Ter Tester selector minal minal we ri 3 position Connected to Q x 1 Not connected to battery Continuous while not connected to the battery HReplace Not continuous while connected to the battery Replace CLUTCH SWITCH INSPECTION 1 Inspect e Clutch switch continuity Tester lead Black lead Tester lead Black lead Tester selector position No continuous while being pulled Replace Continuous while being freed Replace ELECTRIC STARTING SYSTEM ELEC DIODE INSPECTION 1 Remove the diode from wire harness 2 Inspect e Diode continuity Use pocket tester tester selection position Q x 1 Tester gt Blue Red terminal 1 Conimuons Tester gt Sky blue terminal 2 Tester gt Blue Red terminal 1
208. t needle clip position 1 groove up Raise jet needle clip position If this has no effect lower the jet needle clip position Poor response in the low to intermediate speeds Poor response when throttle is opened quickly Check overall settings Use main jet with a lower calibration no Raise jet needle clip position 1 groove up If these have no effect use a main jet with a higher calibration no and lower the jet needle clip position Discoloration of spark plug gt If tan color it is in good condition If cannot be corrected Clogged float valve seat Clogged fuel hose Clogged fuel cock Check that the accelerator pump oper ates smoothly Discoloration of spark plug gt If tan color it is in good condition If cannot be corrected Clogged air filter Fuel overflow from carburetor Groobe 1 Groobe 2 f Groobe 3 Clip Groobe AR amp Groobe 5 4 Groobe 7 Leaner Standard l Richer Jet needle The clip position is the jet needle groove on which the clip is installed The positions are numbered from the top Check that the accelerator pump oper ates smoothly except for rich mixture symptom Slow speed circuit passage Clogged Clean Overflow from carburetor Check air filter for fouling Check that the accelerator pump oper ates smoothly This should be taken simply for an example It is necessary to set the carburetor while checking the operating conditions
209. t the pilot screw by the factory set number of turns Pilot screw 2 turns out example 1 7 8 turns out Except for USA ENGINE IDLING SPEED ADJUSTMENT INSP o VALVE CLEARANCE INSPECTION AND ADJUSTMENT ADJ Q ENGINE IDLING SPEED ADJUSTMENT 1 Start the engine and thoroughly warm it up 2 Attach e Inductive tachometer To spark plug lead 3 Adjust e Engine idling speed Adjustment steps e Adjust the pilot screw Refer to PILOT SCREW ADJUSTMENT section e Turn the throttle stop screw 1 until the engine runs at the lowest possible speed To increase idle speed Turn the throt tle stop screw CO in 3 To decrease idle speed Turn the throt tle stop screw out Inductive tachometer YU 8036 B Engine tachometer 90890 03113 Engine idling speed 1 900 2 100 r min VALVE CLEARANCE INSPECTION AND ADJUSTMENT NOTE S e he valve clearance should be adjusted when the engine is cool to the touch e The piston must be at Top Dead Center T D C on compression stroke to check or adjust the valve clearance 1 Remove e Seat e Fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 2 Drain e Coolant Refer to COOLANT REPLACEMENT section INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT 3 Remove e Right radiator Refer to RADIATOR section in the CHAPTER 4 e Carburetor Refer to CARBURETOR section in the CHAPTER 4 e Spa
210. tablespoon of SAE 10W 30 motor oil in the spark plug hole and reinstall the plug With the engine stop switch pushed in kick the engine over several times to coat the cylinder walls with oil Remove the drive chain clean it thoroughly with solvent and lubricate it Reinstall the chain or store it in a plastic bag tied to the frame Lubricate all control cables Block the frame up to raise the wheels off the ground Tie a plastic bag over the exhaust pipe out let to prevent moisture from entering If the machine is to be stored in a humid or salt air environment coat all exposed metal surfaces with a film of light oil Do not apply oil to rubber parts or the seat cover NOTE M M M Make any necessary repairs before the machine is stored GENERAL SPECIFICATIONS SPEC e SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name WR250FR USA WR250F EUROPE WR250F R CDN AUS NZ ZA 5UM1 USA 5UM2 EUROPE 5UM4 CDN AUS NZ ZA Model code number Dimensions Overall length 2 165 mm 85 2 in 827 mm 32 6 in 1 303 mm 51 3 in 998 mm 39 3 in Wheelbase 1 475 mm 58 1 in Minimum ground clearance 382 mm 15 0 in Basic weight With oil and full fuel tank 115 1 kg 253 7 Ib Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement Single cylinder forward inclined Displacement 249 cm 8 76 Imp oz 8 42 US oz Bore x stroke 77 0 x 53 6 mm 3 03
211. ter gear unit Collar Oil seal Bearing Brake disc Only loosening Only loosening 1 2 3 4 5 6 D 8 Refer to REMOVAL POINTS sch NI sch sch o o ANA IN o FRONT WHEEL AND REAR WHEEL CHASSO EC598100 REAR WHEEL 125 Nm 12 5 m kg 90 ft Ib 14 Nm 1 4 m kg 10 ft Ib 16 Nm 1 6 m kg 11 ft Ib Extent of removal D Rear wheel removal Wheel bearing removal 3 Brake disc removal REAR WHEEL REMOVAL A WARNING Hold the machine by placing the Preparation for removal Support the machine securely so there is no suitable stand under the engine danger of it falling over Nut rear wheel axle Rear wheel axle Drive chain puller Rear wheel Collar Rear wheel sprocket Oil seal Circlip Bearing Brake disc Refer to REMOVAL POINTS Refer to REMOVAL POINTS ee O FRONT WHEEL AND REAR WHEEL CHAS EC593000 REMOVAL POINTS EC523101 Rear wheel 1 Remove e Wheel 1 NOTE 222222 LLL Push the wheel forward and remove the drive chain EC513201 Wheel bearing if necessary 1 Remove e Bearing 1 NOTE Remove the bearing using a general bearing puller EC594000 INSPECTION EC514100 Wheel 1 Measure e Wheel runout Out of limit Repair replace Wheel runout limit Radial 1 2 0 mm 0 08 in Lateral 2 2 0 mm 0 08 in 2 Inspect e Bearing Rotate inner race with a finger Rough
212. trolyte either charge it for at least 3 hours at the amperage specified on the battery or let it sit for at least 15 hours before using it EAS00181 FUSE INSPECTION To avoid a short circuit always set the main switch to OFF when checking or replacing a fuse 1 Remove e Seat e Fuse cover INSP FUSE INSPECTION INSP QR 2 Check e Continuity Checking steps e Remove the fuse e Connect the pocket tester to the fuse and check the continuity NOTE Set the pocket tester selector to Q x 1 Pocket tester YU 3112 C 90890 03112 7 e f the pocket tester indicates co replace the fuse 2 Reserve fuse 3 Replace e Blown fuse Replacement steps e Set the main switch to OFF e Install a new fuse of the correct amperage e Set on the switches to verify if the electri cal circuit is operational e f the fuse immediately blows again check the electrical circuit 18030103 tems Amperage ang a wense wa A WARNING Never use a fuse with an amperage rating other than that specified Improvising or using a fuse with the wrong amperage rat ing may cause extensive damage to the electrical system cause the starting and ignition systems to malfunction and could possibly cause a fire 4 Install e Fuse cover e Seat REPLACING THE HEADLIGHT BULBS INSP e ADJUSTING THE HEADLIGHT BEAMS ADJ Q REPLACING THE HEADLIGHT BULBS 1 Remove e Headligh
213. tting band and side covers Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 Air filter case cover Refer to AIR FILTER CLEANING sec tion in the CHAPTER 3 Silencer Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 4 Drain the coolant Refer to COOLANT REPLACEMENT section in the CHAPTER 3 Coolant reservoir breather hose Disconnect at the coolant reservoir side Coolant reservoir hose Disconnect at the coolant reservoir side Battery Refer to BATTERY INSPECTION AND CHARGING section in the CHAPTER 3 Disconnect the starter relay coupler Starter motor lead Disconnect at the starter relay side REAR SHOCK ABSORBER CHAS Go 56 Nm 5 6 m kg 40 ft Ib NN AAA 32 Nm 3 2 m kg 23 ft Ib 1 Locking tie Taillight coupler Starting circuit cut off relay coupler Plastic band Clamp air filter joint Only loosening Rear frame Bolt Hold the swingarm rear shock absorber relay arm Bolt rear shock absorber frame Rear shock absorber Locknut Adjuster Lower spring guide Upper spring guide Spring rear shock absorber Bearing Refer to REMOVAL POINTS Only loosening REAR SHOCK ABSORBER CHAS HANDLING NOTE A WARNING This rear shock absorber is provided with a separate type tank filled with high pressure nitrogen gas To prevent the danger of explosion read and understand the follow ing information before handling the shock
214. ully so that they can be rein stalled in their original place e Select the proper pad using the pad select ing table podus Pad Availability g 25 increments No 120 1 20 mm Pads are available in 0 05 mm increments av av No 240 2 40 mm INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT NOTE c o The thickness 8 of each pad is indicated in O hundreths of millimeters on the pad upper surface D e Round off the last digit of the installed pad number to the nearest increment Last digit of pad Rounded value number Boro 10 J EXAMPLE Installed pad number 148 Rounded off value 150 CO I Pads can only be selected in 0 05 mm incre ments e Locate the rounded off value and the mea sured valve clearance in the chart PAD SELECTION TABLE The field where these two coordinates intersect shows the new pad number to use NOTE MMM Use the new pad number only as a guide when verifying the valve clearance adjust ment e Install the new pads 3 and the valve lifters 4 NOTE e Apply the engine oil on the valve lifters e Apply the molybdenum disulfide oil on the valve stem ends e Valve lifter must turn smoothly when rotated with a finger e Be careful to reinstall valve lifters and pads in their original place e Install the camshafts exhaust and intake Refer to CAMSHAFTS section in the CHAPTER 4 INSP VALVE
215. ut 1 clicks to increase damping Turn adjuster clockwise about 1 6 clicks to increase damping Set sunken length for 90 100 mm 3 5 3 9 in when one passenger is astride seat Replace with soft spring Turn adjuster clockwise about 1 6 turn to increase damping Set sunken length for 90 100 mm 3 5 3 9 in when one passenger in astride seat Replace with stiff spring Turn adjuster clockwise about 2 clicks to increase damping Replace with soft spring Turn adjuster counterclockwise about 1 6 turn to decrease damping Set sunken length for 90 100 mm 3 5 3 9 in when one passenger is astride seat Replace with soft spring PRINTED IN JAPAN 2002 11 1 8x1 CR
216. ve 1 Inspect e Needle valve 1 e Valve seat Grooved wear 8 Replace Dust b gt Clean EC464301 Throttle valve 1 Check e Free movement Stick Repair or replace NOTE L B V Insert the throttle valve 1 into the carburetor body and check for free movement EC464401 Jet needle 1 Inspect e Jet needle 1 Bends wear Replace e Clip groove Free play exists wear Replace e Clip position Standard clip position No 4 Groove 4 12 CARBURETOR ENG Float height 1 Measure e Float height 8 Out of specification Adjust Float height 8 0 mm 0 31 in Measurement and adjustment steps e Hold the carburetor in an upside down position NOTE LL S e Slowly tilt the carburetor in the opposite direction then take the measurement when the needle valve aligns with the float arm e f the carburetor is level the weight of the float will push in the needle valve resulting in an incorrect measurement e e Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers NOTE LL The float arm should be resting on the nee dle valve but not compressing the needle valve e f the float height is not within specification inspect the valve seat and needle valve e f either is worn replace them both e f both are fine adjust the float heig
217. will be warranted for the balance of the product s warranty period All parts replaced under warranty become property of Yamaha Motor Corporation U S A GENERAL EXCLUSIONS from this warranty shall include any failures caused by EC030002 YAMAHA MOTOR CORPORATION U S A YZ WR MOTORCYCLE LIMITED WARRANTY a Installation of parts or accessories that are not qualitatively equivalent to genuine Yamaha parts Abnormal strain neglect or abuse Accident or collision damage Modification to original parts Lack of proper maintenance onapo Damage due to improper transportation SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or rou tine maintenance THE CUSTOMER S RESPONSIBILITY under this warranty shall be to 1 Operate and maintain the YZ or WR as speci fied in the appropriate Owner s Service Man ual and 2 Give notice to an authorized Yamaha motorcy cle dealer of any and all apparent defects within ten 10 days after discovery and make the machine available at that time for inspec tion and repairs at such dealer s place of busi ness YAMAHA MOTOR CORPORATION U S A MAKES NO OTHER WARRANTY OF ANY KIND EXPRESSED OR IMPLIED ALL IMPLIED WARRAN TIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHICH EXCEED THE OBLIGATIONS AND TIME LIMITS STATED IN THIS WARRANTY ARE HEREBY DISCLAIMED BY YAMAHA MOTOR CORPORATION U S A AND EXCLUDED FROM THIS WARRANTY SO
218. x 2 11 in Compression ratio 12 5 1 otarting system Kick and electric starter Lubrication system Oil type or grade Engine oil For USA and CDN At 5 C 40 F or higher Yamalube 4 20W 40 or SAE 20W 40 type SG motor oil Non Friction modified At 15 C 60 F or lower Yamalube 4 10W 30 or SAE 10W 30 type SG motor oil Non Friction modified and or Overall width Overall height Seat height 30 Yamalube 4 R 15W 50 Non Friction modified Except for USA and CDN API SG or higher grade GENERAL SPECIFICATIONS SPEC e Oil capacity Engine oil Periodic oil change 1 2 L 1 06 Imp qt 1 27 US qt With oil filter replacement 1 3 L 1 14 Imp qt 1 37 US at Total amount 1 4 L 1 23 Imp at 1 48 US at Coolant capacity including all routes 1 3 L 1 14 Imp qt 1 37 US qt Wet type element Premium unleaded gasoline only with a research octane number of 95 or higher Except for ZA Premium gasoline For ZA Tank capacity 10 L 2 2 Imp gal 2 64 US gal Reserve 1 2 L 0 26 Imp gal 0 32 US gal Carburetor Type FCR MX37 Manufacturer KEIHIN Spark plug Type manufacturer CR8E NGK resistance type Gap 0 7 0 8 mm 0 028 0 031 in Transmission Primary reduction system Gear Primary reduction ratio 57 17 3 353 Secondary reduction system Chain drive Secondary reduction ratio 52 13 4 000 Transmission type Constant mesh 5 speed Operation Left foot operation Gear ratio 1st 31 1
219. y 10 Nm 1 0 m kg 7 2 ft Ib NOTE nmm e Before removing the clips cover the cylin der head with a clean rag to prevent the clips from into the cylinder head cavity e Apply the engine oil on the thread and con tact surface of the bolts camshaft cap e Tighten the bolts camshaft cap in a criss cross pattern ened evenly or damage to the cylinder head camshaft caps and camshaft will result 2 Install e Timing chain tensioner Installation steps e While pressing the tensioner rod lightly with fingers use a thin screwdriver and wind the tensioner rod up fully clockwise CAMSHAFTS ENG o e With the rod fully wound and the chain ten sioner UP mark facing upward install the gasket 1 and the timing chain ten sioner 2 and tighten the bolt 3 to the specified torque Bolt timing chain tensioner 10 Nm 1 0 m kg 7 2 ft Ib e Release the screwdriver check the ten sioner rod to come out and tighten the gasket 4 and the cap bolt to the speci fied torque Tensioner cap bolt 7 Nm 0 7 m kg 5 1 ft Ib 3 Turn e Crankshaft Counterclockwise several turns 4 Check e Rotor T D C mark Align with the crankcase align mark e Camshaft match marks Align with the cylinder head surface Out of alignment Adjust 5 Install e Timing mark accessing screw 1 e Crankshaft end accessing screw FS 6 Install e Timing chain guide top side

ENG - Pdfstream.manualsonline.com

Contents

Download Pdf Manuals

Related Search

Related Contents