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ENG - TZ250 Racing

1. Bearing Drive axle Dy d Circlip are E y maiie S j Plain washer Plain washer 6th wheel gear Washer Circlip 2nd wheel gear Ze Circlip pa Wee ea 3rd wheel gear 4th wheel gear 3 Install e Plain washer e Circlip NOTE e Be sure the circlip sharp edged corner is positioned opposite to the plain washer and gear e Be sure the circlip end is positioned at axle spline groove 4 62 e TRANSMISSION SHIFT CAM AND SHIFT FORK ENG 4 Install e Main axle e Drive axle NOTE e Apply the transmission oil on the main axle and drive axle bearings e Install the main axle together with the drive axle into the transmission housing 5 Install e Shift fork 1 e Shift fork 2 e Shift fork 3 NOTE e Mesh the shift fork 1 with the 5th wheel gear GU and 3 with the 6th gear on the drive axle e Mesh the shift fork 2 with the 3rd 4th pinion gear on the main axle 6 Install e Guide bar 1 short e Guide bar 2 long NOTE OO e Apply the transmission oil on the guide bars e Be sure the short bar is inserted into the shift fork 2 and the long one into 1 and 3 d KI 0 i Ze T le is a 7 Check e Shift operation e Transmission operation Unsmooth operation Repair 8 Insta
2. Measurement and adjustment steps e Remove the drain plug e Connect the fuel level gauge adapter and fuel level gauge to the float cham Fuel level gauge adapter YM 01470 90890 01470 Fuel level gauge YM 01312 A 90890 01312 A CARBURETOR AND REED VALVE ENG oD 4 12 e Hold the fuel level gauge vertically next to the float chamber mating surface e Measure the fuel level with the fuel level gauge NOTE _____ll NW SSO Keep the carburetor and fuel level gauge vertically when measuring the fuel level e H the fuel level is not within specification inspect the valve seat and needle valve e H either is worn replace them both e H both are fine adjust the fuel level by bending the float tab on the float e Recheck the fuel level EC464600 Float 1 Inspect e Float Damage Replace EC464701 Reed valve 1 Measure e Reed valve bending Out of specification Replace Se Reed valve bending limit 0 2 mm 0 008 in e Valve stopper height Out of specification Adjust stopper Replace valve stopper Se Valve stopper height 6 5 6 9 mm 0 256 0 272 in D D CARBURETOR AND REED VALVE ENG 4 13 EC464900 Induction box 1 Inspect e Seal Peeled Stick using the instantaneous adhesive Crack Wear Damage Replace EC465000 ASSEMBLY AND INSTALLATION EC465180 Reed valve 1 Install e Reed valve 1 e Reed valve 2 e Stopper
3. V 2 Nm 0 2 mekg 1 4 ftelb e Fuel hose To carburetor NOTE e Install the fuel hose right cylinder after pass ing it through the hole of the induction cap Refer to CABLE ROUTING DIAGRAM sec tion in the CHAPTER 2 e After installing check the throttle grip for smooth movement CARBURETOR AND REED VALVE ENG V OA ma 7 EC465370 Carburetor installation 1 Install e Carburetor NOTE Install the projection between the carburetor joint slots 2 Tighten e Clamp carburetor joint V 2 Nm 0 2 mekg 1 4 ftelb 3 Connect e Solenoid valve lead NOTE Install the solenoid valve lead right cylinder after passing it through the hole of the induction cap Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 4 Install e Induction cap left cylinder only 5 Install e Grommet right cylinder only e Band right cylinder only CYLINDER HEAD CYLINDER AND PISTON EC470000 CYLINDER HEAD CYLINDER AND PISTON EC478000 CYLINDER HEAD AND CYLINDER e gt 19 Nm 1 9 mekg 13 ftelb 11 Nm 1 1 mekg 8 0 ftelb V 20 Nm 2 0 mekg 14 ftelb y 15 Nm 1 5 mekg 11 ftelb 7 Nm 0 7 mekg 5 1 ftelb Extend of removal Cylinder head removal 2 Cylinder removal CYLINDER HEAD AND CYLINDER REMOVAL Preparation for Cowling and fuel tank Refer to COWLING INDUCTION removal GUIDE SEAT AND FUEL
4. and e After the adjustment record the difference in the graduation between the left and right chain pullers as it will provide convenience in your future similar adjustment 7 Install e Lower cowl EC36C000 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 EC36E021 FRONT FORK TOP END ADJUSTMENT 1 Hold the machine on upright position by placing the suitable stand 2 Remove e Cowling e Induction guide left cylinder e Front wheel e Front fender 3 Adjust e Front fork top end 6 Ka E ih Soe ee Adjustment steps NO ERS e Loosen the pinch bolts handlebar and EG amp YV steering damper stay e Loosen the pinch bolts handle crown and 7 VSS under bracket OBE ei 3 2 7 D FRONT FORK TOP END ADJUSTMENT e Adjust the front fork top end ox Front fork top end Gi Standard Extent of adjustment Zero 16 mm i Zero 0 63 in CAUTION Never attempt to install the front fork beyond the maximum or minimum set ting AWARNING Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stabili ty under bracket Pinch bolt handle crown 20 Nm 2 0 mekg 14 ft lb Pinch bolt under bracket 23 Nm 2 3 mekg 17 ft lb LER Ww gt CAUTION Tighten the under bracket to specified torque If torqued
5. 4 1 EXHAUST PIPE AND SILENCER 4 3 RADIATOR 2 oseseccivctecsds oh ohh 4 4 CARBURETOR AND REED VALVE 4 7 CYLINDER HEAD CYLINDER AND PISTON WEE 4 18 CLUTCH 2taeceenuss te ue fuss 4 31 PRIMARY DRIVEN GEAR PRIMARY DRIVE GEAR AND BALANCER OMAP EE 4 38 SFL SHAFT Bitcirken si sos EE 4 44 WATER PUMP 2 4 4 51 TRANSMISSION SHIFT CAM AND SHIFT FORK siecusdee cee goa hae es 4 55 OIL PUMP icr cee teew ote rereas ees 4 64 CDI MAGNETO 4 68 ENGINE REMOVAL 4 71 CRANKCASE AND CRANKSHAFT 4 76 CHAPTER 5 CHASSIS FRONT WHEEL AND REAR WHEEL 5 1 FRONT BRAKE AND REAR BRAKE 5 10 FRONT FOR eee 5 26 VOIR CT 1 BEE 5 40 STEERING d uerg eee ge ge 5 46 GVVINGARM 000 e eee 5 53 REAR SHOCK ABSORBER 5 60 CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM 6 1 IGNITION SYSTEM 6 2 CHARGING SYSTEM 6 7 YPVS SYSTEM een 6 10 SOLENOID VALVE SYSTEM 6 12 THERMO UNIT SYSTEM 6 14 FUEL PUMP SYSTEM 6 16 ENGINE CHAPTER 7 TUNING Biel EE 7 14 EC100000 GENERAL INFORMATION EC110000 DESCRIPTION 1 Clutch lever Valve joint 3 Main switch Water temperature gauge 5 Front brake lever Throttle grip CO Radiator cap Fuel tank cap Gi Starter lever Choke Battery 1 Fuel pump 2 Fuel cock 3 Steering damper Servomotor 5 Radiator Check bolt
6. Apply the lithium soap base grease on the oil seal lip 2 Install e Thrust plate e Dowel pin e Gasket crankcase cover right NOTE Install the thrust plate with its larger diameter side toward the transmission 3 Install e Crankcase cover right NOTE Mesh the primary drive gear with the prima ry driven gear and the oil pump drive gear GO with the oil pump driven gear by turning the rotor 4 Install e Bolt crankcase cover right V 11 Nm 1 1 mekg 8 0 ftelb NOTE Tighten the bolts in stages using a crisscross pattern 4 43 SHIFT SHAFT EC4F0000 SHIFT SHAFT K Gi Qs 10 Nm 1 0 mekg 7 2 ftelb Ny eo S Gy Extend of removal Shift shaft removal 2 Stopper lever removal SHIFT SHAFT REMOVAL Preparation for Crankcase cover right Refer to PRIMARY DRIVEN GEAR removal PRIMARY DRIVE GEAR AND BALANCER SHAFT section Nut drive sprocket Lock washer Drive sprocket Shift arm Transmission housing Circlip Shift shaft Roller Shift guide Shift lever assembly Stopper lever Iren to REMOVAL POINTS Refer to REMOVAL POINTS 1 2 3 4 5 6 r 8 9 Refer to REMOVAL POINTS ech sesch h sesch zech wesch sesch M sesch wesch sesch ch ch 4 44 4 45 SHIFT SHAFT ENG EC4F3000 REMOVAL POINTS EC4F3100 Drive sprocket 1 Remove e N
7. Decrease the spring preload Turn the adjuster out REAR SHOCK ABSORBER REBOUND DAMPING INST e FORCE ADJUSTMENT 3 34 l S Spring length installed Standard length Extent of adjustment 133 142 mm 137 mm 5 39 in 5 24 5 59 in NOTE The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster CAUTION Never attempt to turn the adjuster beyond the maximum or minimum setting 4 Tighten e Locknut 20 Nm 2 0 mekg 14 ftelb EC36N040 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1 Adjust e Rebound damping force By turning the adjuster Stiffer Increase the rebound damp ing force Turn the adjuster in Softer Decrease the rebound damp ing force Turn the adjuster out l S Extent of adjustment Fully turned in Fully turned out position position e STANDARD POSITION This is the position which is back by the spe cific number of clicks from the fully turned in position EA Standard position PA 20 clicks out REAR SHOCK ABSORBER COMPRESSION DAMPING INST e FORCE ADJUSTMENT 3 35 NOTE Fully turn in the adjuster and then turn it out Specify the position in which the first click is heard as the zero position If a click is heard just when the adjuster is fully turned in this position is zero CAUTION Do not force the adjuster past the minimum or maximum extent of adjustme
8. Hold the swingarm Refer to REMOVAL POINTS Loosen Loosen 5 61 REAR SHOCKABSORBER CHAS ds EC586000 HANDLING NOTE AWARNING This shock absorber is provided with a sep arate 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 absorber The manufacturer can not be held respon sible for property damage or personal injury that may result from improper han dling 1 Never tamper or attempt to disassemble the cylinder or the tank 2 Never throw the shock absorber into an open flame or other high heat The shock absorber may explode as a result of nitrogen gas expansion and or dam age to the hose 3 Be careful not to damage any part of the gas tank A damaged gas tank will impair the damping performance or cause a malfunction 4 Take care not to scratch the contact sur face of the piston rod with the cylinder or oil could leak out 5 Never attempt to remove the plug at the bottom of the nitrogen gas tank It is very dangerous to remove the plug 6 When scrapping the shock absorber fol low the instructions on disposal EC587011 NOTES ON DISPOSAL YAMAHA DEALERS ONLY Before disposing of the shock absorber be sure to extract the nitrogen gas To do so drill a 2 or 3 mm 0 08 0 12 in hole through the tank at a position 30 mm 1 2 in from the bot tom end of the tank At this
9. Standard length 137 mm 5 39 in 133 142 mm 5 24 5 59 in NOTE The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster CAUTION Never attempt to turn the adjuster beyond the maximum or minimum setting 5 63 near sock aasonser CHAS ds 4 Tighten e Locknut 20 Nm 2 0 mekg 14 ftelb EC5852A0 Rear shock absorber 1 Install e Upper bracket e Bolt rear shock absorber upper bracket e Plain washer rear shock absorber upper bracket e Nut rear shock absorber upper bracket V 34 Nm 3 4 mekg 24 ftelb NOTE Apply the lithium soap base grease on the bolt 2 Install e Rear shock absorber 3 Install e Bolt upper bracket v 40 Nm 4 0 mekg 29 ftelb e Cap 4 Install e Bolt rear shock absorber relay arm e Nut rear shock absorber relay arm V Da Nm 3 4 mekg 24 ftelb NOTE Apply the lithium soap base grease on the bolt 5 64 ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS CDI unit Fuel pump relay COLOR CODE Voltage regulator Fuel pump stop switch B ae de Black B L Black Blue 3 Tachometer assembly 00 Battery Br aad Brown B R Black Red 4 Fuse 2 CDI magneto G Green B W Black White 6 Main switch 3 Spark pulg Gy A we Gray G W
10. 3 2 TADS Q MAINTENANCE INTERVALS ADJ After Every Ever Every As re Item m J y 1 GE Remarks race 500km quired TIRE WHEELS Inspect air pressure wheel run out and tire wear Inspect bearings Replace bearings Lubricate DRIVE CHAIN Use chain lube Lubricate slack alignment Chain slack 40 50 mm Replace 1 6 2 0 in DRIVEN SPROCKET DAMPER Inspect and retighten Replace THROTTLE CONTROL CABLE Check routing and connection Yamaha cable lube or SAE Lubricate 10W30 motor oil BATTERY Check battery voltage 12 5V or more Replace 3 3 PRE OPERATION INSPECTION AND MAINTENANCE Q EC320010 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 e The brake disc is coated with a rush inhibitor Before pre operation thoroughly remove it using a lacquer thinner e For storage a coolant is used Before riding the machine remove it with cooling water Refer to INFORMATION BEFORE PRE OPERATION EC321020 GENERAL INSPECTION AND MAINTENANCE Cooling water Check that cooling water is filled up to the radiator filler cap P3 6 9 Check the cooling system for leakage Fuel Check that a fresh mixture of oil and gasoline is filled in the P1 15 fuel tank Check the fuel line for leakage Transmission oil Check that the oil level is correct Check the crankcase
11. 9 9 FRONT WHEEL AND REAR WHEEL CHAS d0 10 Adjust e Drive chain slack EA Drive chain slack PA 40 50 mm 1 6 2 0 in Refer to DRIVE CHAIN SLACK ADJUST MENT section in the CHAPTER 3 11 Tighten e Nut wheel axle 80 Nm 8 0 mekg 58 ftelb e Adjuster V 2 Nm 0 2 mekg 1 4 ftelb e Locknut V 16 Nm 1 6 mekg 11 ft Ib NOTE e Tighten the axle nut while pushing down the drive chain e After tightening the axle nut tighten the lock nut with the turned out the adjuster 12 Adjust e Wheel alignment Refer to WHEEL ALIGNMENT ADJUST MENT section in the CHAPTER 3 FRONT BRAKE AND REAR BRAKE CHAS FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE x T Nm 0 8 mekg 58 ft lb 5 Nm 0 5 mekg 3 6 ft lb Lo en SS Ce a R Ve SN Tas Nm 3 5 mekg 25 ftelby NO Extend of removal Brake hose removal 2 Caliper removal 3 Master cylinder removal FRONT BRAKE REMOVAL Preparation for Hold the machine by placing Support the machine securely so there removal the suitable stand is no danger of it falling over Cowling Refer to COWLING INDUCTION Induction guide left cylinder GUIDE SEAT AND FUEL TANK section in the CHAPTER 4 Drain the brake fluid Refer to REMOVAL POINTS Adapter Union bolt Brake hose Pad pin Loosen when disassembling the caliper Caliper Brake lever Reservoir tank Reservoir hose Mas
12. Increase rear height e Increase spring preload for rear e Decrease damping force for rebound for rear e Increase front fork top end e Decrease spring preload for front e Decrease front fork top end e Decrease rear height e Increase spring preload for front e Increase damping force for compression for front e Increase damping force for compression for front Decrease damping force for rebound e Increase spring preload EC740002 Setting record table The data shown here is an example of entry For your actual use copy the necessary data pEventname PE pate S S weater Li Setting specs ignition timing ll ll Spark plug TO a Carburetor Main jet Power jet Jet needle Main nozzle Pilot jet Pilot air screw Float height Gearing 1st 2nd 3rd 4th 5th 6th Secondary Front fork Spring rate Spring preload Rebound damping Compression damping Top end Oil capacity Oil level Rear shock Spring fitting length Spring rate Rebound damping Compression damping Seat height Front tire pressure Rear tire pressure ff Fuel consumption 1 21 wema S S S wm S S S wae o S S G Setting specs ont OOOO S S S Carburetor Main jet Power jet Jet needle Main nozzle Pilot jet Pilot air screw Float height Gearing 1st 2nd 3rd Ath 5th 6th Secondary Front fork Spring rate Spring preload Rebound damping Compression damping Top end Oil capacity Oil
13. NOTE e Pull up the damper rod with the rod puller and rod puller attachment e While pressing down the spacer with the fork spring compressor set the rod holder between the locknut and spacer Rod puller YM 01437 90890 01437 Rod puller attachment 90890 01435 Fork spring compressor YM 01441 90890 01441 Rod holder YM 01434 90890 01434 21 Adjust e Distance Out of specification gt Turn the locknut until the specified distance is obtained Distance Gi 13 mm 0 51 in Between damper rod top and locknut top 22 Adjust e Rebound damping adjuster position Out of specification Turn the adjuster until the specified position is obtained ON Rebound damping adjuster posi tion Zero mm Zero in 5 37 FRONT FORK CHAS NOTE Record the set position of the adjuster the amount of turning in the adjuster to the fully turned in position before adjusting it CAUTION If the rebound damping adjuster position is out of specification proper damping force cannot be obtained 23 Install e Push rod e Cap bolt NOTE See Turn in the cap bolt fully by holding the spring preload adjuster with your hand until the rebound damping adjuster hits the push rod tip 24 Check e Cap bolt clearance Out of specification Repeat the steps 21 to 23 EA Cap bolt clearance s Zero 2 mm Zero 0 08 in CAUTION ____ O O o
14. NOTES eg e Apply the lithium soap base grease on the bearing when installing 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 CAUTION Do not strike the inner race of the bearing Contact should be made only with the outer race 2 Install e Brake disc e Bolt brake disc ge 2 0 mkg ERT NOTE Tighten the bolts in stage using a crisscross pattern 3 Install e Collar NOTE lf the collar is hard to install apply the lithium soap base grease on the collar and press it in df Milt yy I pada 5 6 FRONT WHEEL AND REAR WHEEL CHAS ds 4 Install e Wheel e Caliper e Bolt caliper op Nm 3 5 mekg 25 ft lb NOTE Before installing the wheel axle install the Caliper 5 Install e Wheel axle NOTE e Apply the lithium soap base grease on the wheel axle e Insert the wheel axle from right side 6 Install e Plain washer e Nut wheel axle vy 80 Nm 8 0 mekg 58 ftelb NOTE Apply the lithium soap base grease on the wheel axle thread 7 Tighten e Bolt axle holder V 11 Nm 1 1 mekg 8 0 ftelb FRONT WHEEL AND REAR WHEEL CHAS 5 7 EC5251B0 Rear wheel 1 Install e Fitting plate right e Bearing right e Spacer e Fitting plate left e Bearing left NOTE e Apply the lithium soap base grease on th
15. Revolution per minute Engine speed 2 12 CABLE ROUTING DIAGRAM SPEC vs EC240000 CABLE ROUTING DIAGRAM 1 Brake hose 3 Throttle cable 2 Clamp Transmission oil breather hose 3 Cable Cut the clamp so that the protruding portion is less than 5 mm 0 20 in Frame Position the cable from bottom to top in the following order Radiator breather hose e Starter cable YPVS cable 1 2 right cylinder e Throttle cable Ignition coil lead e Solenoid valve lead Starter cable Q Solenoid valve lead Fuel hose a Clutch cable 2 Fuel pump lead A a Zero 5mm Zero 0 20 in Clamp a Zeromm Zero in prs i To E S Servomotor HEX Dem D R 7 A CG Ss S Sy SS ae AS D Ss Q NV RN RN N N N T KH Ly A j ON i G Ray A an Kr A f SCT Co a 20 mm 0 79 in 2 13 CABLE ROUTING DIAGRAM SPEC vs 1 Fuel pump lead Clamp 3 Fuse holder Servomotor 6 Front brake hose right YPVS cable 1 2 right cylinder CO Clutch cable Clamp the fuel hose and clutch cable Position the upside ends of the clamp inside of the seat rail Clamp the radiator hose 3 and ignition coil lead Clamp the radiator hose 3 and YPVS cable right cylinder D Do not cut the end of the clamp Connect the left cylinder YPVS cables silver cables to the inner YPVS servomotor pulley and right cylinder YPVS cables black cables to the outer T
16. COWLING INSTALLATION INSPECTION 1 Inspect e Cowling Loosen Tighten Stroke the front fork to make sure no parts are being contacted with others Contact Repair or replace e Screen Scratches fogging Clean or replace EC36a023 LUBRICATION To ensure smooth operation of all components lubricate your machine during setup after break in and after every race All control cable 2 Brake and clutch lever pivots 3 Throttle to handlebar contact 4 Drive chain Throttle cable end Clutch cable end INSP LUBRICATION Q Use Yamaha cable lube or equivalent on these areas Use SAE 10W30 motor oil or suitable chain lubricants Lubricate the following areas with high qual ity lightweight lithium soap base grease CAUTION Wipe off any excess grease and avoid get ting grease on the brake discs DS ei ELECTRICAL SPARK PLUG INSPECTION 3 41 EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1 Remove e Spark plug 2 Inspect e Electrode Wear Damage Replace e Insulator color Normal condition is a medium to light tan color Distinctly different color Check the engine condition NOTE 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 Use a wire gauge or thickness gauge Out of specification Regap EA Spark
17. Green White Ignition coil Thermo unit O srera Orange W B White Black 7 Solenoid valve 5 Servomotor H Pink W G White Green Fuel pump White Blue White Red Yellow Blue EC612000 WIRING DIAGRAM at We a 6 1 IGNITION system ELEC EC620000 IGNITION SYSTEM EC621030 INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark Brace ice Replace fuse and check wireharness 1b ok Ao coed o goo 1 Check battery S Recharge or replace Jb o 2 Clean or replace spark plug JL No spark Jl OK system for connection Jb ok N d Check main switch _ Replace OK Check ignition coil Spark No good Primary coil 2 Replace No good Secondary coil 2 Replace No good Pick up coil Replace No good Source coil Replace Replace CDI unit 1 marked Refer to BATTERY INSPECTION section in the CHAPTER 3 2 marked Only when the ignition checker is used NOTE e Remove the following parts before inspection 1 Cowling 3 Seat 2 Fuel tank e Use the following special tools in this inspection L Dynamic spark tester Pocket tester SCH YM 34487 SCH YU 03112 90890 03112 Ignition checker 90890 06754 6 2 IGNITION system ELEC EC629000 FUSE INSPECTION 1 Remove e Fuse 2
18. YAMAHA EC010000 TZ250M1 M OWNER S SERVICE MANUAL 1999 by Yamaha Motor Corporation U S A 1st Edition September 1999 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 13 41 EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha TZ series This model is the culmination of Yamaha s vast experience in the production 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 outdat ed If you have any questions please consult your Yamaha dealer AWARNING 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 PROP ER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTE NANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFELY ENJOY THE CAPABILITIES AND THE RELIABILITY OF THIS MACHINE EC030010 WARRANTY
19. e Piston crown Damage and crack due to detonation gt Replace e Piston pin hole Crack Replace e Contact with cylinder Excessive scuffing score Use 240 320 grit wet sandpaper in a criss cross manner bi e Heat discoloration Replace 2 Inspect e Travel distance for piston 500 km 300 miles or more Replace 3 Check e Piston ring free movement Mechanical stick Repair Install the piston ring to the piston and check for free movement Repairing steps e Remove the piston ring e Chamfer the piston ring groove at its edge a where the piston ring tends to stick using a triangle oil stone with the engine mixing oil NOTE e Set the triangle oil stone to the piston ring groove to form an angle of 45 Do the chamfering with force applied to this edge Chamfer until the piston ring moves smoothly CAUTION Do not over chamfer 4 22 CYLINDER HEAD CYLINDER AND PISTON ENG EC474402 Piston pin and small end bearing 1 Inspect e Piston pin e Small end bearing Signs of heat discoloration Replace 2 Measure e Piston pin outside diameter Use micrometer Out of limit Replace Piston pin outside diameter 0 5904 0 5906 in 0 5896 in 3 Check e Free play when the piston pin is in place in the piston There should be no noticeable for the play Free play exists Replace piston pin and or piston 307 023 4 Install e Small
20. 9 Install e Air bleeding bolt right cylinder 10 Fill e Radiator e Engine To specified level 11 Install e Radiator cap Start the engine and warm it up for a sever al minute 3 7 RADIATOR CAP INSPECTION INS e RADIATOR CAP OPENING PRESSURE INSPECTION 12 Check e Cooling water level Cooling water level low Add cooling water 13 Install the lower cowl EC355000 RADIATOR CAP INSPECTION 1 Inspect e Seal radiator cap e Valve and valve seat Crack Damage Replace Exist fur deposits Clean or replace EC356001 RADIATOR CAP OPENING PRESSURE INSPECTION 1 Attach e Radiator cap tester and adapter Vaz Radiator cap tester J YU 24460 1 90890 01325 Adapter YU 33984 90890 01352 NOTE Apply water on the radiator cap seal 3 Radiator cap 2 Apply the specified pressure VAA Radiator cap opening pressure 95 125 kPa 0 95 1 25 kg cm 13 5 17 8 psi 3 Inspect e Pressure Impossible to maintain the specified pres sure for 10 seconds Replace 3 8 3 9 Beie COOLING SYSTEM INSPECTION CLUTCH CARE EC357002 COOLING SYSTEM INSPECTION 1 Inspect e Coolant level 2 Attach e Radiator cap tester and adapter Vaz Radiator cap tester A YU 24460 1 90890 01325 Adapter YU 33984 90890 01352 3 Apply the specified pressure EA Standard pressure ex 180 kPa 1 8 kg cm 25 6 psi NOTE e Do not apply pressure
21. Air temp Humidity pressure Mixture Setting ATOS a Low Low Leaner Richer low The reason for the above tendency is that the richness or leanness of a fuel mixture depends on the density of the air i e the concentration of oxygen in it rae 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 EC714032 Effects of setting parts in relation to throttle valve opening Throttle valve PE a aan Setting parts oun up 3 4 7181 1 1 8 1 4 3 4 7 8 1 1 mier a Jet needle Power jet O NOTE The power jet closes at 12 300 rom of the engine after which only the main jet domi nates Throttle valve opening 2 Full open 3 Full closed EC71E003 Basic process of carburetor setting Ex factory setting is on the richer side which should basically have no problems with the brake in procedure Refer to STARTING AND BREAK IN section in the CHAPTER 1 1 Adjustment of main jet Use a main jet with a smaller calibration number if the engine does not develop more than 12 000 rpm after a few laps of the circuit when the water temperature becomes stable 55 C 131 F or more Example 580 560 1 3 Next run a few laps of the circuit with this setting a
22. Check e Fuse conduct Use pocket tester tester selector position Q x 1 Not continuous Replace fuse and check that the wireharness is not shorted EC622020 SPARK GAP TEST 1 Disconnect the fuel pump coupler to pre vent the fuel pump operating 2 Disconnect the spark plug cap from spark plug Connect the dynamic spark tester igni tion checker as shown e Spark plug cap e Spark plug For USA and CDN Except for USA and CDN 4 Start the engine and increase the spark gap until misfire occurs for USA and CDN Move the main switch to RUN and rotate the rear wheel with gear in 3rd and check the spark gap except for USA and CDN Minimum spark gap 5 0 mm 0 20 in EC623001 SPARK PLUG CAP INSPECTION 1 Remove e Spark plug cap CAUTION Do not pull the spark plug lead out of the spark plug cap Turn the spark plug cap counterclockwise to remove it and clock wise to install it Q O1 DA 2 Check e Spark plug cap resistance Out of specification Replace SI Spark plug cap Tester selector resistance position 4 6 kQ at 6 3 IGNITION system ELEC EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check e Couplers and leads connection Huet Dust Looseness Short circuit Repair or replace EC62A000 MAIN SWITCH INSPECTION 1 Inspect e Main switch conduct Tester lead Red lead Tester lead Brown lead Br Tester selector Gi posit
23. Pinch bolt steering damper stay Only loosening right side only Pinch bolt handlebar Only loosening Pinch bolt handle crown Only loosening Cap bolt Loosen when disassembling the front fork Pinch bolt under bracket Only loosening Front fork 5 26 FRONT FORK CHAS EC558000 FRONT FORK DISASSEMBLY Ny ER ex Extend of removal Oil seal removal 2 Damper rod removal FRONT FORK DISASSEMBLY Cap bolt Use special tool Refer to REMOVAL POINTS Spacer Spacer guide Fork spring Inner tube Stopper ring Oil seal Oil seal washer Bolt damper rod Damper rod Drain the fork oil Refer to REMOVAL POINTS esch zech sch sesch sesch sech sesch sch sesch Si special tool Refer to REMOVAL POINTS 3 2 Ve ww d Kees FA Ee 0954 GE KL DEE SL RELL d E RSS SL Kaes gef GE ee Se 5 28 FRONT FORK CHAS EC556010 HANDLING NOTE NOTE e With the 97 or later models the dampar rod diameter is 12 5 mm 0 49 in If the dimen sion of your dampar rod holders is 12 mm 0 47 in drill it to expand its diameter to 14 mm 0 55 in e The front fork requires careful attention So it is recommended that the front fork be main tained at the dealers CAUTION To prevent an accidental explosion of air the following instructions should be observed e The front fork with a built
24. Transmission oil level 7 Rear brake pedal Rear shock absorber Drive chain Shift pedal Gn CDI magneto 2 Front fork DESCRIPTION INFO NOTE e The machine you have purchased may differ e slightly from those shown in the following e Designs and specifications are subject to change without notice 1 1 A SP MACHINE IDENTIFICATION REN ees A KA N E KO lez EC120001 MACHINE IDENTIFICATION There are two significant reasons for knowing the serial number of your machine 1 When ordering parts you can give the num ber to your Yamaha dealer for positive iden tification 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 For USA CDN AUS NZ and E The vehicle identification number is stamped on the right of the steering head pipe EC122001 FRAME SERIAL NUMBER Except for USA CDN AUS NZ and E The frame serial number is stamped on the right of the steering head pipe EC123020 ENGINE SERIAL NUMBER The engine serial number Q is stamped into the elevated part of the rear 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 SP IMPORTANT INFORMATION ka GES EC130000 IMPORTANT INFORMATION EC131002 PREPARATION
25. e Master cylinder cup Secondary To master cylinder piston NOTE Apply the brake fluid on the master cylinder Cup AWARNING After installing cylinder cup should be installed as shown direction Wrong instal lation cause improper brake performance Front Rear FRONT BRAKE AND REAR BRAKE CHAS 3 Install Front e Spring To master cylinder cup Secondary Rear e Spring To master cylinder piston NOTE Install the spring at the smaller dia side AWARNING After installing cylinder cup should be installed as shown direction Wrong instal lation cause improper brake performance Front Rear 4 Install e Master cylinder kit e Circlip e Master cylinder boot To master cylinder NOTE e Apply the brake fluid on the master cylinder kit e When installing the circlip use a long nose circlip pliers Front Rear EC535441 Front master cylinder 1 Install e Reservoir tank e Bolt reservoir tank V 5 Nm 0 5 mekg 3 6 ftelb e Reservoir hose FRONT BRAKE AND REAR BRAKE CHAS 2 Install e Master cylinder e Master cylinder bracket e Bolt master cylinder bracket v 8 Nm 0 8 mekg 5 8 ftelb NOTE Install the bracket so that the arrow mark face upward 3 Install e Brake lever e Bolt brake lever 1 Nm 0 1 mekg 0 7 ftelb e Nut brake lever v 6 Nm 0 6 mekg 4 3 ftelb NOTE e Apply t
26. it may cause the steer ing damper to malfunction 12 Install e Din e Plain washer e Steering damper e Cp e Bolt steering damper 18 Nm 1 8 mekg 13 ftelb O CA de OX FBS Een 4 Pie a iy U K a 5 52 STEERING CHAS 13 Adjust e Front fork top end e Handlebar position e Steering damper stay position right side only A Front fork top end fA 13 mm 0 51 in Handlebar position 9 mm 0 35 in Steering damper stay position 73 mm 2 87 in Refer to FRONT FORK TOP END ADJUSTMENT in the CHAPTER 3 14 Tighten e Pinch bolt handle crown e Pinch bolt under bracket gt 23 Nm 2 3 mekg 17 ftelb e Pinch bolt handlebar e Pinch bolt steering damper stay right side only gt 10 Nm 1 0 mekg 7 2 ftelb Refer to FRONT FORK TOP END ADJUSTMENT in the CHAPTER 3 15 Check e Steering smooth action Turn the handlebar to make sure no parts are being contacted with others Contact Repair swincarm CHAS 10 Nm 1 0 mekg 7 2 ftelb EC570000 SWINGARM K Le Qs Extend of removal OO Swingarm removal Swingarm disassembly SWINGARM REMOVAL Preparation for Hold the machine by placing Support the machine securely so there removal the suitable stand is no danger of it falling over Lower cowl and fuel tank Refer to COWLING INDUCTION GUIDE SEAT AND FUEL TANK section in the CHAPTE
27. peared j Add brake fluid to the level line on the reservoir AWARNING Check the operation of the brake after bleeding the brake system 3 Install e Diaphragm e Reservoir tank cap EC363010 FRONT BRAKE ADJUSTMENT 1 Adjust e Brake lever position Adjustment steps e Turn the adjuster while pushing the brake lever forward until the desired lever position is obtained Closer Turn the adjuster in Farther Turn the adjuster out NOTE Align the mating mark on the adjuster with the arrow mark on the brake lever EC364011 REAR BRAKE ADJUSTMENT 1 Check e Brake pedal height Out of specification Adjust EA Brake pedal height s 148 152 mm 5 8 6 0 in Fei Q FRONT BRAKE PAD INSPECTION AND REPLACEMENT 3 19 2 Adjust e Brake pedal height Pedal height adjustment steps e Loosen the locknut e Turn the adjusting nut until the pedal height is within specified height e Tighten the locknut EC365050 FRONT BRAKE PAD INSPECTION AND REPLACEMENT 1 Inspect e Brake pad thickness Gi Out of specification Replace as a set 2 k Brake pad thickness Gi Standard 5 3 mm 0 21 in 1 0 mm 0 04 in 2 Replace e Brake pad Brake pad replacement steps e Loosen the pad pin and remove the caliper e Remove the cotter pin pad pin pad support and brake pads e Connect the transparent hose to the bleed s
28. reed valve e Screw reed valve ER Nm 0 1 mekg 0 7 ft lb NOTE _sssmssssssssssSSSSSSSSS e Install the reed valve with the reed valve bending as shown e Note the cut in the lower corner of the reed and stopper plate CAUTION Tighten each screw gradually to avoid warping 2 Install e Gasket reed valve assembly e Reed valve assembly NOTE Install the gasket left cylinder with its projec tion facing upward and the seal print side toward the crankcase CARBURETOR AND REED VALVE ENG 3 Install e Carburetor joint e Induction box e Bolt carburetor joint 2 25 mm 0 98 in e Bolt carburetor joint 2 20 mm 0 79 in Hi Nm 1 1 mekg 8 0 ftelb EC4652E0 Carburetor 1 Install e Solenoid valve To carburetor 2 2 Install e Pilot air screw 1 Note the following installation points e Screw in the pilot air screw until it is lightly seated e Back out it by the specified number of turns EA Pilot air screw cA 1 1 2 of turns out 3 Install e Main nozzle e Main jet e Pilot jet e Valve seat e Screw valve seat 4 14 CARBURETOR AND REED VALVE ENG 4 15 4 Install e Needle valve e Float e Float pin e Screw float pin NOTE e After installing the needle valve to the float install them to the carburetor e Check the float for smooth movement 5 Ins
29. removal GUIDE SEAT AND FUEL TANK section Tension spring Bolt exhaust pipe Exhaust pipe Bolt silencer Silencer 4 3 RADIATOR EC450001 er RADIATOR 2 Nm 0 2 mekg 1 4 ftelb gt 11 Nm 1 1 mekg 8 0 ftelb Ny E e Extend of removal Radiator removal RADIATOR REMOVAL Preparation for Cowling induction guide Refer to COWLING INDUCTION removal and fuel tank GUIDE SEAT AND FUEL TANK section Drain the cooling water Refer to COOLANT REPLACEMENT section in the CHAPTER 3 Water temperature gauge lead Thermo unit Radiator hose 2 Radiator hose 4 Radiator hose 3 Radiator breather hose Radiator 4 4 yA RADIATOR ENG O HANDLING NOTE AWARNING Do not remove the radiator cap when the engine and radiator are hot Scalding hot fluid 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 ee ee EC444100 BEE Radiator MIM TTT 1 In spe ct I r e Radiator core 1 TMM TTT Obstruction Blow out with compressed M e e TL LE air through rear of the radiato
30. slowly up and down about 60 mm 2 4 in stroke to distribute the fork oil once more NOTE Be careful not to excessive full stroke A stroke of 60 mm 2 4 in or more will cause air to enter In this case repeat the steps 13 to 16 17 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 18 Measure e Oil level left and right Out of specification Adjust Standard oil level 135 mm 5 31 in Extent of adjustment 97 157 mm 3 82 6 18 in From top of outer tube with inner tube and damper rod fully compressed without spring AWARNING 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 5 36 FRONT FORK CHAS 19 Install e Fork spring e Spacer guide e Spacer NOTE Install the fork spring with its smaller dia por tion upward 20 Attach e Rod puller e Rod puller attachment e Fork spring compressor e Rod holder
31. whenever a caliper is disassembled EC535113 Caliper piston 1 Clean e Caliper e Piston seal e Dust seal e Caliper piston Clean them with brake fluid 2 Install e Piston seal e Dust seal AWARNING Always use new piston seals and dust seals NOTE Fit the piston seals and dust seals onto the slot on caliper correctly Front Rear oie ememr AND REAR prake CHAS A 3 Install e Caliper piston NOTE Apply the brake fluid on the piston wall CAUTION eInstall the piston with its shallow depressed side facing the caliper e Never force to insert Front Rear EC535241 Front caliper 1 Install e Brake pad e Pad support e Pad pin e Cotter pin NOTE Temporarily tighten the pad pin at this point 2 Install e Caliper e Bolt caliper V 35 Nm 3 5 mekg 25 ftelb 3 Tighten Padpin 18 Nm 1 8 mekg 13 ft lb EC545141 Rear caliper 1 Install e Brake pad e Pad support e Pad pin e Cotter pin NOTE Temporarily tighten the pad pin at this point 5 18 FRONT BRAKE AND REAR BRAKE CHAS 2 19 2 Install e Caliper e Bolt caliper 23 Nm 2 3 mekg 17 ftelb 3 Tighten Padpin 18 Nm 1 8 mekg 13 ft lb EC5A5210 Master cylinder kit 1 Clean e Master cylinder e Master cylinder kit Clean them with brake fluid 2 Install e Master cylinder cup primary
32. with a soft hammar to settle it CRANKCASE AND CRANKSHAFT ENG 4 82 ef 7 Tighten e Bolt crankcase M8 O e Bolt crankcase M6 M NOTE Tighten all bolts in 2 steps as follows and be sure to tighten in numbered order as shown First M8 11 Nm 1 1 mekg 8 0 ftelb D M6 Ehm 0 6 mekg 4 3 ftelb Final M8 26 Nm 2 6 mekg 19 ftelb D M6 11 Nm 1 1 mekg 8 0 ftelb 8 Remove e Sealant Forced out on the crankcase mating sur face 9 Apply e Engine oil To the crank pin bearing and oil delivery hole 10 Check e Crankshaft operation Unsmooth operation Repair EC4A5101 Push lever axle 1 Install e Seat plate e Torsion spring e Push lever axle NOTE Apply the lithium soap base grease on the push lever axle oil seal lip and bearing 2 Install e Bolt seat plate TS Nm 0 7 mekg 5 1 ftelb NOTE mmm Fit the seat plate in the groove of the push lever axle and tighten the bolt seat plate FRONT WHEEL AND REAR WHEEL CHAS CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL yy ER S Ss GQ Co Qs Extend of removal Front wheel removal 2 Wheel bearing removal 3 Brake disc removal FRONT WHEEL REMOVAL AGT Te Preparation for Hold the machine by placing Support the machine securely so there removal the suitable stand is no danger of it falling over Bolt axle holder Nut front wh
33. 45 Cowling Check that the cowling is tightly mounted and has no cracks in it Check that it dose not contact other parts by stroking Check that the screen is clean P3 39 Settings Is the machine set suitably for the condition of the racing course and weather or by taking into account the results of test runs before racing Are inspection and maintenance completely done P7 1 22 INSP Q LOCKING WIRE INSTALLATION GUIDE LOCKING WIRE INSTALLATION GUIDE Bolt to bolt Bolt YPVS pulley Throttle cable adjuster Oil filler cap Starter cable 3 5 ENGINE COOLING WATER LEVEL INSPECTION INS e COOLING WATER REPLACEMENT 3 6 EC350011 ENGINE CAUTION e The cooling system is filled with coolant at the factory to prevent rusting Be sure to replace coolant with soft water before rid ing e Take care so that coolant does not splash on painted surfaces If it splashes wash it away with water EC352000 COOLING WATER LEVEL INSPECTION AWARNING 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 counterclo
34. 8 Install e Bolt rear shock absorber relay arm e Nut rear shock absorber relay arm V 34 Nm 3 4 mekg 24 ftelb NOTE Apply the lithium soap base grease on the bolt swincarm CHAS Be 9 Install e Collar swingarm NOTE Apply the lithium soap base grease on the col lars and bearings 10 Install e Connecting rod e Bolt connecting rod e Nut connecting rod gt 34 Nm 3 4 mekg 24 ftelb MOIE e Install the connecting rods with the mark Gi outward of the chassis e Apply the lithium soap base grease on the bolts 9 99 nan shock ABSORBER CHAS ds EC580000 REAR SHOCK ABSORBER SA a Qs vy 34 Nm 3 4 mekg 24 ftelb Extend of removal Rear shock absorber removal 2 Rear shock absorber disassembly Preparation for removal 1 REAR SHOCK ABSORBER REMOVAL Hold the machine by placing the suitable stand Lower cowl seat and fuel tank Exhaust pipe Bolt rear shock absober relay arm Cap Bolt Upper bracket Rear shock absober Bolt rea shock absober upper bracket Upper bracket Locknut Adjuster Spring guide Spring rear shock absober 5 60 AWARNING Support the machine securely so there is no danger of it falling over Refer to COWLING INDUCTION GUIDE SEAT AND FUEL TANK section in the CHAPTER 4 Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 4
35. EA Warp limit ON 0 1 mm 0 004 in EC4A4301 Push rod 1 Inspect e Push rod e Ball Wear Damage Bend Replace bt Bending limit ex 0 2 mm 0 008 in NOTE The bending value is shown by one half of the dial gauge reading CLUTCH ENG EC4A5000 ASSEMBLY AND INSTALLATION EC4A5213 Clutch 1 Install e Spacer 1 e Bearing NOTE Apply the transmission oil on the spacer 1 and bearing 2 Install e O ring NOTE Apply the lithium soap base grease on the O ring 3 Install O ring RA To clutch housing NOTE Apply the lithium soap base grease on the O ring 4 Install e Clutch housing 5 Install e Plain washer 1 e Clutch boss 4 36 6 Install e Lock washer 1 e Nut clutch boss 75 Nm 7 5 mekg 54 ftelb NOTE Use the clutch holding tool to hold the clutch boss CAUTION Align the projections on the lock washer with the holes in the clutch boss Z Clutch holding tool 90890 04086 For USA and CDN Except for USA and CDN 7 Bend the lock washer tab 8 Install e Friction plate yellow e Clutch plate e Friction plate brown NOTE e Install the clutch plates and friction plates alternately on the clutch boss starting with a friction plate and ending with a friction plate e Yellow colored friction plates are used for the first and final This machine is equi
36. INFORMATION This model is sold AS IS WITHOUT ANY WARRANTIES EXPRESSED OR IMPLIED REGARD LESS OF THE INTENDED USE THE PURCHASER OF THIS MACHINE which is intended for competition purposes IS RESPON SIBLE FOR ALL COSTS SERVICE AND OR REPAIR EC040001 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 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 APPAR EL 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 properly 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 FLAM
37. Nm 5 0 mekg 36 ftelb CRANKCASE AND CRANK SHAFT REMOVAL Preparation for Engine Refer to ENGINE REMOVAL removal section Reed valve Refer to CARBURETOR AND REED VALVE section Piston Refer to CYLINDER HEAD CYLIN DER AND PISTON section Primary drive gear Refer to PRIMARY DRIVEN GEAR PRIMARY DRIVE GEAR AND BALANCER SHAFT section Rotor and stator Refer to CDI MAGNETO section Engine bracket 4 76 CRANKCASE AND CRANKSHAFT 11 Nm 1 1 mekg 8 0 ftelb 1l 8 Nm 0 8 mekg 5 8 ft lb yy A Extend of removal OO Crankcase separation 2 Crankshaft removal 3 Crankshaft bearing removal 4 Push lever axle removal Bolt crankcase Mei 2 30 mm 1 18 in Bolt crankcase Mei 2 35 mm 1 38 in Bolt crankcase M8 2 45 mm 1 77 in Crankcase upper Crankcase lower Crankshaft Oil seal crankshaft Bearing crankshaft Refer to REMOVAL POINTS Bolt seat plate Seat plate Push lever axle Refer to REMOVAL POINTS 4 St 6 T 8 9 ch ech 4 7 CRANKCASE AND CRANKSHAFT ENG d EC4N3000 REMOVAL POINTS EC4N3230 Crankcase 1 Remove e Bolt crankcase M6 e Bolt crankcase M8 NOTE e The M6 size bolts should be removed first e Loosen the bolts from the outer sides inward 2 Remove e Crankcase upper From crankcase lower CAUTION Use soft hammer to tap on the case half Tap only on reinforce
38. OoOo If the cap bolt is installed out of specifica tion proper damping force cannot be obtained 25 Install e Cap bolt locknut V 29 Nm 2 9 mekg 21 ftelb NOTE eee Hold the locknut and tighten the cap bolt by turning the spring preload adjuster with specified torque CAUTION Do not tighten the cap bolt It may cause damage to the spring preload adjuster FRONT FORK CHAS 26 Install e Cap bolt 4 To outer tube Seg NOTE Temporarily tighten the cap bolt SS KV gt RSS IZ EC555290 CR ES Installation 1 Install a CES g DA e Front fork DY 3 e Steering damper stay right side only e Handlebar NOTE Temporarily tighten the pinch bolt under bracket e Do not tighten the pinch bolts handle crown steering damper stay and handlebar yet 2 Tighten Gap bolt 23 Nm 2 3 mekg 17 ftelb 3 Adjust e Front fork top end e Handlebar position e Steering damper stay position left side only A Front fork top end PA 13 mm 0 51 in A K Eech OS Handlebar position BE Gey SS 9 mm 0 35 in Steering damper stay position 73 mm 2 87 in Refer to FRONT FORK TOP END ADJUSTMENT in the CHAPTER 3 5 38 FRONT FORK CHAS 4 Tighten e Pinch bolt handle crown 20 Nm 2 0 mekg 14 ftelb e Pinch bolt under bracket e Pinch bolt handlebar D Nm 0 7 mekg 5 1 ftelb e Pinch
39. TANK section Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section Radiator hose 3 4 Disconnect at cylinder head side Carburetor left cylinder Induction guide left cylinder Servicing the left cylinder Spark plug Cable stay s o YPVS cable Refer to REMOVAL POINTS Bolt cylinder head Loosen each bolt 1 4 turn and remove them after all bolts are loosened Cylinder head Nut cylinder Cylinder 4 18 CYLINDER HEAD CYLINDER AND PISTON EC478100 PISTON AND POWER VALVE V 12 Nm 1 2 mekg 8 7 ftelb yy A 4 Nm 0 4 mekg 2 9 ftelb V 4 Nm 0 4 mekg 2 9 ftelb Extend of removal Piston and piston ring removal 2 Power valve removal PISTON REMOVAL Piston pin clip Piston pin Piston Refer to REMOVAL POINTS Small end bearing Piston ring Valve cover Valve shaft Power valve Valve pulley Circlip Plain washer Oil seal Solid bush OoOnNDOORWND 4 19 CYLINDER HEAD CYLINDER AND PISTON ENG EC473000 REMOVAL POINTS EC473310 YPVS cable 1 Remove e Bolt cable stay 2 Remove e YPVS cable From the valve pulley NOTE Remove the YPVS cable together with the cable stay EC473400 Piston and piston ring 1 Remove e Piston pin clip NOTE Before removing the piston pin clip cover the Ki 4 S crankcase with a clean rag to prevent the pis AY xh ton pin clip from falling into the crankcase c
40. a target of a 5 10 mm 0 20 0 39 in remaining stroke for front and a 10 20 mm 0 39 0 79 in remaining EXAMPLE 10 mm stroke for rear 0 39 in Basically the best settings can be obtained by repeating the following steps NOTE 5mm 0 20 in The figures show the bottom out positions of In the case of the front and rear suspension RUBBER the above remain ing stroke is 15 mm 0 59 in Front Rear 7 16 SETTING CHART ACTUAL RUN Check stroke NOTE The remaining stroke value is provid ed just aS a guide and may change according to the riding style 5 to 10 mm 0 20 0 39 in 10 to 20 mm 0 39 0 79 in Front remaining stroke Rear remaining stroke Poor stroke Decrease the spring preload Front Every two clicks 1 mm 0 04 mi eRear Every one turn 1 5 mm 0 06 in Too stiff from the beginning and not smooth in mid range as well Decrease damping force on compression side Front Every one turn eRear Every two clicks 1 17 Too much stroke Increase the spring preload eFront Every two clicks 1 mm 0 04 mi eRear Every one turn 1 5 mm 0 06 in NOTE Preload increase results in relative lack of damping force If the preload is increased two times increase the damping force a little Unstable and spongy Increase damping force both on compression and rebound eFront Every one turn eRear Every two clicks Sele
41. between the teeth of the balancer drive gear and balancer weight gear 3 Remove e Bolt primary drive gear e Primary drive gear e Balancer drive gear Gi e Nut balancer weight gear e Lock washer e Balancer weight gear NOTE It may sometimes happens that the primary drive gear and balancer drive gear are fitted too tight as in force fitting In that case use a general gear puller to remove them without too much force on the crankshaft EC4D4000 INSPECTION EC4D4100 Primary drive gear primary driven gear and oil pump drive gear 1 Inspect e Primary drive gear e Primary driven gear e Oil pump drive gear Wear Damage Replace PRIMARY DRIVEN GEAR PRIMARY DRIVE GEAR AND BALANCER SHAFT 4 41 OD EC4D4200 Balancer weight gear and balancer drive gear 1 Inspect e Balancer weight gear e Balancer drive gear Wear Damage Replace EC4D4300 Crankcase cover right 1 Inspect e Contacting surface Scratches Replace e Crankcase cover right Cracks Damage Replace e Oil seal Wear Damage Replace EC4D4500 Balancer shaft 1 Inspect e Balancer shaft Bend Wear Damage Replace EC4D5000 ASSEMBLY AND INSTALLATION EC4D5130 Balancer shaft and primary drive gear 1 Install e Balancer shaft e Collar 2 Install e Gasket crankcase cover ef e Crankcase cover left e Bolt crankcase cover left V 11 Nm 1 1
42. cleaner to keep the cover pliable and glossy 8 Automotive wax may be applied to all paint ed or chromed surfaces Avoid combination cleaner waxes as they may contain abra Sives 9 After completing the above start the engine and allow it to idle for several minutes SP CLEANING AND STORAGE ka GES EC1B2010 STORAGE lf 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 22 1 2 Drain the fuel tank fuel lines and the car buretor float chambers Remove the spark plugs pour a tablespoon of SAE 10W30 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 Drain the cooling water completely And then fill the coolant and water 50 50 in the engine a
43. for P3 13 15 leakage YPVS Check operation PS 12713 Gear shifter and clutch Check that gears can be shifted correctly in order and that P3 9 10 the clutch operates smoothly Throttle grip Housing Check that the throttle grip operation and free play are correctly adjusted Lubricate the throttle grip and housing if necessary Brakes Check the effect of front and rear brake Check brake disc P3 17 22 surface Chain Check chain slack and alignment Check that the chain is P3 23 25 lubricated properly Wheels Check for excessive wear tire pressure and tire wear P3 36 Steering Check that the handlebars can be turned smoothly and P3 37 38 have no excessive play Front forks and Check that they operate smoothly and there is no oil rear shock absorber leakage P3 10 11 P3 27 35 Cables wires Check that the clutch and throttle cables move smoothly Check that they are not caught when the handlebars are P3 39 turned or when the front forks travel up and down Muffler Check that the muffler is tightly mounted and has no cracks P3 16 Sprocket Check that the driven sprocket damper is not loose P3 22 Lubrication Check for smooth operation Lubricate if necessary P3 40 Bolts and nuts Check the chassis and engine for loose bolts and nuts P1 20 Check that the locking wire is correct Lead connectors Check that the CDI magneto CDI unit and ignition coil are P1 5 connected tightly Battery Check the battery voltage P3 43
44. level SC Rear shock Spring fitting length Spring rate Rebound damping Compression damping Seat height Front tire pressure Rear tire pressure Fuel consumption NOTE 1 Make setting changes in small increments 2 When the proper settings have been determined for a particular track they should be written down for reference upon returning to that track 3 Always make adjustment in cold state 1 22 PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories i O LTD OKA JAPAN PRINTED IN JAPAN 99 9 0 1x1 Q E
45. locknuts e Turn the adjusters fully in e Turn out the right carburetor adjuster until the specified free play is obtained e Tighten the right carburetor locknut e Turn out the left carburetor adjuster until the left throttle valve moves together with the right throttle valve NOTE Ltr e When adjusting left throttle cable watch NS She the right throttle valve and touch the left git NY c throttle valve II 3 e After adjusting the throttle cables open the ve awe throttle grip and check that both throttle valves are completely open e Tighten the left carburetor locknut e Tighten the locknuts AWARNING After adjusting turn the handlebar to right and left and make sure that the engine idling dose not run faster EC35B002 STARTER CABLE ADJUSTMENT 1 Check e Starter lever free play Out of specification Adjust VAA Starter lever free play PA 5 10 mm 0 20 0 39 in 2 Adjust e Starter lever free play Starter lever free play adjustment steps e Loosen the locknuts e Turn the adjusters until the specified free play is obtained e Tighten the locknuts Bei ei YPVS OPEN SIDE CABLE ADJUSTMENT EC35D012 YPVS OPEN SIDE CABLE ADJUSTMENT 1 Disconnect the fuel pump coupler to pre vent the fuel pump operation 2 Check e YPVS open side cable free play Checking steps e Move the main switch to RUN e The servomotor will be f
46. obtained e Tighten the locknuts EC35F000 YPVS COMPONENTS RETIGHTENING NOTE Before riding the machine retighten all YPVS components 1 Retighten e Valve cover 1 gt a Nm 0 4 mekg 2 9 ftelb e Pulley j4 Nm 0 4 mekg 2 9 ftelb e Cable stay IX Nm 0 7 mekg 5 1 ft lb EC35H030 TRANSMISSION OIL LEVEL CHECK 1 Start the engine warm it up for several min utes 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 DS ei TRANSMISSION OIL REPLACEMENT 3 Check e Transmission oil level Transmission oil level checking steps e Remove the oil check bolt e Inspect the oil level NOTE Be sure the machine is positioned straight up when inspecting the oil level AWARNING Never attempt to remove the checking bolt just after high speed operation The heated oil could spout out causing dan ger Wait until the oil cools down Oil flows out Oil level is correct Oil does not flow out Oil level is low Add transmis sion oil until oil flows out Recommended oil Castrol R30 e Inspect the gasket oil check bolt replace if damaged e Tighten the oil check bolt Oil check bolt 9 Nm 0 9 mekg 6 5 ft lb EC35kK021 TRANSMISSION OIL REPLACEMENT 1 Start the engine and warm it up for several minutes and wait for five minutes 2 Place the machine on a level place and hold it on
47. shaft so that it may not fall down EC563300 Bearing lower 1 Remove e Bearing lower Use the floor chisel CAUTION Take care not to damage the steering shaft thread EC563400 Ball race 1 Remove e Ball race Remove the ball race using long rod and the hammer EC564000 INSPECTION EC564200 Steering shaft 1 Inspect e Steering shaft Bend Damage Replace 5 48 5 49 sTEERING CHAS Bearing and ball race 1 Wash the bearings and ball races with a solvent 2 Inspect e Bearing e 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 operation in the ball races replace bearings and ball races as a set EC564300 Steering damper 1 Inspect e Steering damper Bend Damage Replace Oil leaks Unsmooth movement Replace EC565000 ASSEMBLY AND INSTALLATION EC565190 Under bracket 1 Install e Bearing lower NOTE Apply the lithium soap base grease on the dust seal lip and bearing inner circumference 2 Install e Inner fender e Screw inner fender To under bracket NOTE Install the inner fender with its brake hose through hole facing to the right 3 Install e Ball race e Bearing e Ball race cover NOTE Apply the lithium soap base grease on the bearing sTEERING CHA
48. the rainy weather wipe the moisture completely off the disc e H rust appears on the brake disc carefully remove it using 400 sand paper 2 The cooling system is filled with coolant at the factory to prevent rusting Be sure to replace coolant with soft water before rid ing CAUTION ____ O O O O o Hard water or salt water is harmful to the engine parts You may use distilled water if you can t get soft water CH STARTING AND BREAK IN REN EC190000 STARTING AND BREAK IN CAUTION Before starting the machine perform the checks in the pre operation check list AWARNING 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 EC191032 STARTING A COLD ENGINE 1 Connect the power supply coupler 2 Turn the fuel cock to ON and push the starter lever CHOKE 3 Move the main switch to RUN Shift the transmission into 1st gear 5 Apply the clutch lever and push the machine 6 After gaining some momentum release the clutch lever 7 As soon as the engine starts quickly apply the clutch lever again and open the throttle grip slightly at the same time so as to sus tain idling of the engine Then shift the transmission into neutral 8 After applying full throttle a few times turn the starter lever CHOKE to the original po
49. then turn it out Specify the position in which the first click is heard as the zero position If a click is heard just when the adjuster is fully turned in this position is zero CAUTION Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged AWARNING Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability EC36J030 FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT 1 Adjust e Compression damping force By turning the adjuster Stiffer Increase the compression damping force Turn the adjuster in Softer Decrease the compression damping force Turn the adjuster out b gt x Extent of adjustment Fully turned in Fully turned out position position REAR SHOCK ABSORBER INSPECTION INST Q SEAT HEIGHT ADJUSTMENT 3 32 e STANDARD POSITION This is the position which is back by the spe cific number of clicks from the fully turned in position EA Standard position ee 10 clicks out NOTE Fully turn in the adjuster and then turn it out Specify the position in which the first click is heard as the zero position If a click is heard just when the adjuster is fully turned in this position is zero CAUTION Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged AWARNING Always adjust each front fork to the same set
50. time wear eye pro tection to prevent eye damage from escaping gas and or metal chips AWARNING To dispose of a damaged or worn out shock absorber take the unit to your Yamaha dealer for this disposal procedure KY r 5 62 REAR SHOCKABSORBER CHAS ds EC583000 REMOVAL POINTS EC583160 Rear shock absorber 1 Remove e Rear shock absorber NOTE Remove the rear shock absorber between the rear frame and swingarm EC583221 Spring rear shock absorber 1 Remove Spring guide Spring NOTE Remove the spring guide while compressing the spring by using the spring compressor EC584000 INSPECTION EC584130 Rear shock absorber 1 Inspect e Damper rod Bends Damage Replace absorber assembly e Shock absorber Oil leaks Replace absorber assembly Gas leaks Replace absorber assembly e Spring Damage Replace spring Fatigue Replace spring Move spring up and down e Spring guide Wear Damage Replace spring guide e Plate Wear Damage Replace plate near sock aasonser CHAS ds EC585000 ASSEMBLY AND INSTALLATION EC585143 Spring rear shock absorber 1 Install e Plate e Spring e Spring guide NOTE Install the spring guide while compressing the spring by using the spring compressor 2 Tighten e Adjuster 3 Adjust e Spring length installed b gt x Spring length installed
51. 0 2 9 0 8 0 8 3 0 1 4 2 6 3 5 0 7 1 8 0 6 8 0 1 1 2 0 2 0 0 8 1 2 1 2 2 0 0 2 0 7 2 3 14 17 58 5 1 13 3 6 7 2 8 0 14 3 6 5 8 3 6 0 7 4 3 1 4 17 29 21 5 8 5 8 22 10 19 25 5 1 13 4 3 58 8 0 14 14 5 8 8 7 8 7 14 1 4 5 1 17 First tighten the ring nut approximately 46 Nm 4 6 mekg 33 ftelb by using the ring nut wrench a GG gt gt GG GGG Rear wheel axle and nut Driven sprocket and sprocket damper Rear brake disc and wheel hub Chain puller adjust bolt and locknut Chain puller adjust bolt Engine mounting Engine and frame upper Engine and frame lower Engine bracket and frame Engine bracket and engine Pinch bolt engine mounting collar Engine mounting adjust bolt Pivot adjust bolt Pivot shaft and nut Relay arm and frame Relay arm and connecting rod Connecting rod and swingarm Rear shock absorber and upper bracket Rear shock absorber and relay arm Seal guard and swingarm Swingarm and hook Swingarm and chain guard Rear shock absorber and locknut preload Seat height adjuster and locknut Seat height adjuster and upper bracket Seal guard and frame Radiator stay and frame Cowling stay bracket and frame Cowling stay and cowling stay bracket Cowling stay left and right and frame Upper cowl and screen Fuel tank and fuel cock M18 x 1 5 M8 xX 1 25 M8 xX 1 25 M8 xX 1 25 M8 xX 1 25 M10 x 1 25 M10 x 1 25 M10 x 1 25 M8 xX 1 25 M6 xX 1 0 M
52. 0 01352 Adapter YU 33984 KN a These tools are used for checking the cooling system YM 33975 90890 01403 Ring nut wrench This tool is used when tighten the steering ring nut to specification 1 6 SPECIAL TOOLS Tool name How to use YM 01425 90890 01425 YM 01434 90890 01434 90890 01435 YM 01437 90890 01437 YM 01441 90890 01441 YM 01442 90890 01442 YM 01455 90890 01455 YM 01476 90890 01476 YU 03112 90890 03112 YM 91042 90890 04086 YM 34487 90890 06754 ACC 11001 05 01 90890 85505 Damper rod holder YM 01425 Use this tool to remove and install the damper rod Rod holder This tool is used to hold the fork spring Rod puller attachment Rod puller These tools are used to pull up the fork damper rod Fork spring compressor This tool is used to compress the fork spring Fork seal driver This tool is used when install the fork oil seal Pivot shaft wrench YM 0145 Pivot shaft wrench adapter YM 01476 These tools are used to loosen or tighten the pivot adjust bolt Yamaha pocket tester Use this tool to inspect the coil resistance output voltage and amperage Clutch holding tool This tool is used to hold the clutch when removing or installing the clutch boss securing nut Dynamic spark tester Ignition checker This instrument is necessary for checking the ignition system components Quick gasket YAMAHA Bond No 1215 This sealant Bond is used for crankcase m
53. 00 INSPECTION EC4H4210 Gears 1 Inspect e Matching dog e Gear teeth Wear Damage Replace 2 Check e Gears movement Unsmooth movement Repair or replace 4 57 TRANSMISSION SHIFT CAM AND SHIFT FORK ENG 4 58 EC4H4300 Shift fork groove 1 Measure e 3rd 4th pinion gear e 5th wheel gear e 6th wheel gear e Shift fork groove Out of specification Replace l k Shift fork groove Gi 5 05 5 18 mm 5 35 mm 0 199 0 204 in 0 211 in EC4H4400 Thrust clearance 1 Check e After assembling the transmission check whether the idle gear turns smoothly with out a thrust If the thrust clearance is too large or the idle gear moves with difficulty Replace the shim and Choose the shims by the following chart Part name _ Size thickness him STD t 1 0 mm 90201 253K0 0 039 in t 0 9 mm 90201 256E6 0 035 in S S him STD t 1 0 mm 0 039 in t 0 9 mm 0 035 in Shim STD t 0 7 mm 0 028 in t 0 5 mm 0 020 in NOTE It is necessary to adjust the thrust clearance when the transmission gear axle washer cir clip bearing or crankcase is replaced TRANSMISSION SHIFT CAM AND SHIFT FORK ENG EC4H4501 Dog clearance NOTE elt is necessary to adjust the dog clearance when the transmission gear axle washer cir clip bearing or crankcase is replaced e H there is any shifting trouble it is necessa
54. 03112 90890 03112 6 10 ee sl R SSC ypvs system ELEC EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check e Couplers and leads connection Huet Dust Looseness Short circuit Repair or replace EC642020 SERVOMOTOR OPERATION 1 Disconnect the fuel pump coupler to pre vent the fuel pump operating 2 Inspect e Servomotor Operative when the main switch is moved to RUN OK EC643001 SERVOMOTOR INSPECTION 1 Disconnect the YPVS cable from the servo motor 2 Disconnect the servomotor lead 3 Connect 12V battery to the servomotor lead Battery lead Black Red lead Battery lead Black Brown lead 4 Inspect e Servomotor Not operate Replace servomotor SOLENOID VALVE system ELEC EC650001 SOLENOID VALVE SYSTEM EC651020 INSPECTION STEPS If the solenoid valve will not operate use the following inspection steps No good Replace fuse and 1 Check fuse check wireharness N d 2 Check battery edb Recharge or replace ab o Check each coupler and No good Repair or replace wire connection JC o N d 1 Check main switch EE ab OK Check solenoid valve No good No good ao OK Replace CDI unit 1 marked Refer to IGNITION SYSTEM section 2 marked Refer to BATTERY INSPECTION section in the CHAPTER 3 NOTE e Remove the following parts before inspection 1 Cowling 4 Induction guide right cylind
55. 10 Crankshaft bearing 1 Install e Bearing To crankshaft NOTE Install the bearing by pressing its inner race parallel EC4N5290 Crankshaft 1 Install e Oil seal To crankshaft NOTE Apply the lithium soap base grease on the oil seal lip 2 Install e Circlip To crankcase lower wel 3 Install E e Crankshaft i e To crankcase lower rie e NOTE e Wien installing the crankshaft into the crankcase lower apply the transmission oil EI on the oil seal outer circumference SE a e Align the bearing knock pin with the pin slot in the crankcase lower and the projection of oil seal with the groove bim the crankcase lower e After installing the crankshaft push the oil seal to the crankcase lower CRANKCASE AND CRANKSHAFT ENG d 4 81 4 Install e Dowel pin e O ring To crankcase lower 5 Apply e Sealant On the crankcase upper KL Quick gasket CA ACC 11001 05 01 ACC 11001 30 00 YAMAHA Bond No 1215 90890 85505 YAMAHA Bond No 4 90890 05143 NOTE Clean the contacting surface of crankcase upper and lower before applying the sealant CAUTION If the engine is started soon after reinstalla tion use this quick drying Quick gasket ACC 11001 30 00 or YAMAHA Bond No 4 6 Install e Crankcase upper To crankcase lower NOTE After installation tap the crankcase upper
56. 16 x 1 0 M25 x 1 0 M18 x 1 5 M10 x 1 25 M10 x 1 25 M10 x 1 25 M10 x 1 25 M10 x 1 25 M6 xX 1 0 M6 xX 1 0 M6 xX 1 0 M52 x 1 5 M22 x 1 0 M10 x 1 25 M5 x 0 8 M6 xX 1 0 M6 xX 1 0 M6 xX 1 0 M6 xX 1 0 MA x 0 7 M6 xX 1 0 MPO ww Oo gt mp mia MAINTENANCE SPECIFICATIONS SPEC Tightening torque torque CON A CO M6 x1 0 M6 x1 0 Seat and rear frame Rear frame and frame P P en b i bi h sch M sch sch sch M P sch aoe ee sch zk h AD esch ch NOTE A marked portion shall be checked for torque tightening after break in or before each race 2 10 MAINTENANCE SPECIFICATIONS SPEC EC212300 ELECTRICAL Standard Ignition system Ignition timing B T D C Advancer type CDI Magneto model Manufacturer Source coil resistance color Pickup coil resistance left cylinder color right cylinder CDI unit model Manufacturer Ignition coll Model Manufacturer left cylinder right cylinder Minimum spark gap Primary winding resistance Secondary winding resistance Battery Model Manufacturer Capacity Voltage when charged Fuel pump Model Manufacturer Coil resistance Fuel pump relay Model Manufacturer Coil resistance Circuit breaker Type Main Part to be tightened Stator Rotor CDI unit Servomotor pulley Servomotor Voltage regulator Fuel pump and bracket 2 4 mm 0 094 in Electrical 5KE 00 TLGZ06 DENSO 2 3 3 5 Q at
57. 20 C 68 F White White 94 140 Q at 20 C 68 F White Black White Blue 94 140 Q at 20 C 68 F White Black White Green 5SKE 00 DENSO TJ0285 DENSO TJ0277 DENSO 5 mm 0 20 in 0 14 0 18 Q at 20 C 68 F 5 0 7 4 KQ at 20 C 68 F PE12V0 8 JAPAN STORAGE BATTERY 12V0 8Ah 12 8V or more UC Z6V MITSUBISHI 1 3 Q at 20 C 68 F 1 UY 92 MATSUSHITADENKO 72 88 Q at 20 C 68 F Tightening torque Nm Q ty M6 x1 0 M12 x 1 25 M6 x1 0 M5 x0 8 M6 x1 0 M6 x1 0 M5 x0 8 GENERAL TORQUE SPECIFICATIONS SPEC DEFINITION OF UNITS GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasten ers with standard 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 Components should be at room temperature A Distance across flats TORQUE SPECIFICATION SPECIFICATION B Outside thread diameter Nu pen an ee ee EC230000 DEFINITION OF UNITS Se Botae Wen millimeter 10 meter Length 2 centimeter 10 meter Length Wegen goen Weight Newton meter NXm Torque Meter kilogram m kg Torque Newton per millimeter Spring rate Liter Volume or capacity Cubic centimeter Volume or capacity
58. 3000 REMOVAL POINTS EC463110 Throttle valve 1 Remove e Throttle valve e Ring e Spring throttle valve e Mixing chamber top e Throttle cable NOTE While compressing the spring throttle valve disconnect the throttle cable EC464000 INSPECTION EC464120 Carburetor 1 Inspect e Carburetor body Contamination Clean NOTE e Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air e Never use a wire 2 Inspect e Main jet e Main nozzle e Pilot jet e Power jet Contamination Clean NOTE OO e Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air e Never use a wire 4 10 CARBURETOR AND REED VALVE ENG EC464200 Needle valve 1 Inspect e Needle valve e Valve seat Grooved wear Replace Dust Clean NOTE Always replace the needle valve and valve seat as a Set EC464301 Throttle valve 1 Check e Free movement Stick Repair or replace NOTE Insert the throttle valve into the carburetor body and check for free movement EC464420 Jet needle 1 Inspect e Jet needle Bends Wear Replace e Clip groove Free play exists Wear Replace EC464801 FUEL LEVEL 1 Measure e Fuel level Out of specification Adjust Fuel level 6 0 7 0 mm 0 24 0 28 in Above the float chamber mating surface
59. 8 0 Crankcase M8 x 1 25 6 Crankcase M6 x 1 0 8 Bele Oe Transmission housing M6 xX 1 0 6 16 1 6 11 Oil check bolt M6 x 1 0 1 9 0 9 6 5 Oil drain bolt M12 x 1 25 1 23 2 3 17 Crankcase cover right M6 x1 0 10 11 1 1 8 0 Crankcase cover left M6 x1 0 3 11 1 1 8 0 Primary drive gear M10 x 1 25 1 55 5 5 40 Clutch boss M20 x 1 0 1 75 7 5 54 Clutch spring MG x1 0 6 9 0 9 6 5 Push rod adjuster M6 x1 0 1 6 0 6 4 3 Seat plate push lever M5 x0 8 1 7 0 7 5 1 Clutch cable holder M6 x1 0 2 8 0 8 5 8 Bearing plate cover M6 x1 0 3 10 1 0 ie Oil seal plate cover M5 x 0 8 2 7 0 7 5 1 Drive sprocket M20 x 1 0 1 rks 7 5 54 Bearing plate cover shift cam M5 x0 8 1 4 0 4 2 9 Segment M8 x 1 25 1 23 2 3 17 Shift guide M6 x1 0 2 11 1 1 8 0 Shift lever adjuster and locknut M6 x 1 0 1 9 0 9 6 5 Stopper bolt torsion spring M8 x1 25 1 8 0 8 5 8 Shift arm M6 x 1 0 1 14 1 4 10 Joint rod 1 and shift rod M6 x1 0 1 9 0 9 6 5 2 9 EE PPP OT wala eg Joint rod 2 and shift rod Joint rod 1 2 Shift pedal pivot bolt Front pedal Crankcase tighten sequence NOTE Tighten all bolts in 2 steps as follows and be sure to tighten in numbered order as shown First M8 11 Nm 1 1 mekg 8 0 ftelb D M6 6 Nm 0 6 mekg 4 3 ftelb Final M8 26 Nm 2 6 mekg 19 ftelb D M6 11 Nm 1 1 mekg 8 0 ftelb 2 6 MAINTENANCE SPECIFICATIONS SPEC EC212201 CHASSIS Standard Steering system Steering bearing type Taper rol
60. 9 40 HANDLEBAR CHAS EC5B3000 REMOVAL POINTS EC5B3200 Grip 1 Remove e Grip MOIE 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 Replace AWARNING Do not attempt to straighten a bent handle bar as this may dangerously weaken the handlebar EC5B5000 ASSEMBLY AND INSTALLATION EC5B5110 6mm 0 24in Throttle assembly 1 Install e Ring plate e Grip right Apply the adhesive on the tube guide NOTE Before applying the adhesive wipe off grease or oil on the tube guide surface with a lac quer thinner EC5B5230 Handlebar 1 Install e Handlebar CO e Grip end NOTE Temporarily tighten the bolts handlebar 5 41 HANDLEBAR CHAS 2 Install e Throttle cable carburetor left cylinder AXA SA e Throttle cable carburetor right cylinder a e To grip cap lower NOTE Install the throttle cable carburetor left cylin der in the grip side slit in the grip cap lower 3 Install e Throttle NOTE Apply the lithium soap base grease on the throttle grip sliding surface 4 Install e Throttle cable carburetor left cylinder e Throttle cable carburetor right cylinder To tube guide NOTE e Apply the lithium soap base grease on the throttle cable ends
61. C4F5100 Stopper lever 1 Install e Stopper lever e Plain washer e Circlip To collar NOTE Be sure the circlip sharp edged corner is positioned opposite side to the plain washer 4 46 SHIFT SHAFT ENG 2 Install e Plain washer e Torsion spring e Stopper lever assembly ef EC4F5202 Shift guide and shift lever assembly 1 Install e Spring e Pawl pin e Pawl To shift lever NOTE e When installing the pawl into the shift lever make sure the chamfered side face the pawl pin side e Apply the transmission oil on the pawl pin 2 Install e Shift lever assembly To shift guide 3 Install e Shift lever assembly e Shift guide NOTE gt EO e The shift lever assembly is installed at the same time as the shift guide e Apply the transmission oil on the bolt seg ment shaft 4 Install e Bolt shift guide gt JO Nm 1 1 mekg 8 0 ftelb 4 47 4 48 SHIFT SHAFT ENG EC4F5302 Shift shaft 1 Install e Roller e Torsion spring e Shift shaft NOTE Apply the transmission oil on the roller and shift shaft 2 Install e Plain washer e Circlip To shift shaft NOTE Be sure the circlip sharp edged corner is positioned opposite side to the plain washer 3 Check e Shift lever position Checking steps e Attach the collar with supplying parts onto the roll
62. EN GEAR REMOVAL Preparation for Cowling Refer to COWLING INDUCTION removal GUIDE SEAT AND FUEL TANK section Clutch Refer to CLUTCH section Drain the transmission oil Refer to TRANSMISSION OIL REPLACEMENT section in the CHAPTER 3 Crankcase cover right Primary driven gear Oil pump drive gear Thrust plate 4 38 PRIMARY DRIVEN GEAR PRIMARY DRIVE GEAR AND BALANCER SHAFT EC4D8100 PRIMARY DRIVE GEAR AND BALANCER SHAFT V 50 Nm 5 0 mekg 36 ftelb V 55 Nm 5 5 mekg 40 ftelb 11 Nm 1 1 mekg 8 0 ftelb Extend of removal OO Primary drive gear removal Balancer shaft removal PRIMARY DRIVE GEAR AND BALANCER SHAFT REMOVAL Bolt primary drive gear Primary drive gear Balancer drive gear Nut balancer weight gear Lock washer Balancer weight gear Collar Crankcase cover left Balancer shaft Refer to REMOVAL POINTS 1 2 3 4 5 6 7 8 9 esch wesch h sch zech wesch sesch wesch sesch 4 39 PRIMARY DRIVEN GEAR PRIMARY DRIVE GEAR AND BALANCER SHAFT 4 40 ef EC4D3000 REMOVAL POINTS EC4D3101 Primary drive gear and balancer weight gear 1 Loosen e Bolt primary drive gear NOTE See Place an aluminum plate between the teeth of the balancer drive gear and balancer weight gear 2 Loosen e Nut balancer weight gear NOTE Straighten the lock washer tab and place an aluminum plate
63. FOR REMOVAL AND DISAS SEMBLY 1 Remove all dirt mud dust and foreign material before removal and disassembly 2 Use proper tools and cleaning equipment Refer to SPECIAL TOOLS section 3 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 4 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 5 Keep away from fire 1 3 SP IMPORTANT INFORMATION ka GES EC132000 ALL REPLACEMENT PARTS 1 We recommend to use Yamaha genuine parts for all replacements Use oil and or grease recommended by Yamaha for assembly and adjustment EC13300 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 a LOCK WASHERS PLATES AND COTTER PINS 1 All lock washers plates 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 EC1350 BEARINGS AND OIL SEALS 1 Install the beari
64. Fully turned out position position 3 29 FRONT FORK REBOUND DAMPING FORCE INSP 3 30 ADJUSTMENT e STANDARD POSITION This is the position which is back by the spe cific number of clicks from the fully turned out position AN es 6 clicks in NOTE e Fully turn out the adjuster and then turn it in Specify the position in which the first click is heard as the zero position If a click is heard just when the adjuster is fully turned out this position is zero e Preload is 0 5 mm 0 02 in changed per click of the adjuster CAUTION Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged AWARNING Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability EC36H010 FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT 1 Adjust e Rebound damping force By turning the adjuster Gitter Gi Increase the rebound damping force Turn the adjuster in Softer Decrease the rebound damping force Turn the adjuster out Extent of adjustment Fully turned in Fully turned out position position FRONT FORK COMPRESSION DAMPING FORCE INSP 3 31 ADJUSTMENT e STANDARD POSITION This is the position which is back by the spe cific number of clicks from the fully turned in position EA Standard position es 10 clicks out NOTE Fully turn in the adjuster and
65. Inspect e Outer tube e Piston metal e Slide metal Damage Score marks Wear Replace outer tube assembly EC554710 Cap bolt 1 Inspect e Cap bolt e O ring Wear Damage Replace 5 32 FRONT FORK CHAS EC555000 ASSEMBLY AND INSTALLATION EC555190 Front fork assembly 1 Wash the all parts in a clear solvent 2 Install e Damper rod To inner tube CAUTION To install the damper rod into the inner 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 Bolt damper rod To inner tube 4 Tighten e Bolt damper rod EE ap Nm 4 0 mekg 29 ftelb NOTE Use a damper rod holder to lock the damper rod 2 iL Damper rod holder J YM 01425 90890 01425 5 Install e Locknut To damper rod NOTE _ Install the locknut with its width across flat facing upward 9 33 FRONT FORK CHAS 6 Install e Stopper ring e Oil seal KZA e Oil seal washer To inner tube 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 e Inner tube To outer tube 2 CAUTION When installing
66. LAY The fuel pump stop switch and fuel pump relay are provided so as to control the fuel pump and prevent the carburetor overflowing during a turnover lf the machine is turned over the fuel pump stop switch is turned ON which allow electric current to flow in the coil inside the relay causing the relay switch to turn OFF and shutting of the electric current flow to the fuel oump Thus the pump comes to a stop Fuel pump Fuel pump L ns OFF ON ON During run turnover NOTES I e When the machine is picked up from turnover the fuel pump is restored to an operation con dition e nstall the fuel pump stop switch so that UPPER mark faces upward EC15M011 CATCH TANK Put the tip of the breather hose into the catch tank and frame Take care not to allow the fuel oil and cooling water to spill on the course 3 Radiator breather hose Fuel tank breather hose 5 Transmission oil breather hose NOTE When putting in the transmission oil breather hose its tip having a cut should be on the frame side ZZ EL Iess e N ep e SAA AA N O WA Za Us CH CONTROL FUNCTIONS REN EC15Q001 DETACHABLE MAINSTAND This mainstand is used to support only the machine when standing or transporting it NOTE mmm The mainstand can be used to support the machine two ways 1 Hook the bracket of the mainstand onto the swingarm hooks 2 Sta
67. MABLE Always turn off the engine while refu eling 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 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 7 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 monox ide which by itself is odorless and colorless Carbon monoxide is a dan gerous gas which can cause uncon sciousness or can be lethal 8 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 9 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 carburetor or fuel tank EC050000 TO THE NEW OWNER This manual will provide you with a good basic understanding of features operation and basic mainten
68. NANCE SPECIFICATIONS section in the CHAPTER 2 1 20 SP CLEANING AND STORAGE ka GES 1 21 EC1B0000 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 ponenis 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 sprockets or wheel axles 3 Rinse the dirt and degreaser off with a gar den hose use only enough pressure to do the job CAUTION 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
69. NDUCTION Induction guide left cylinder leue SEAT AND FUEL TANK section in the CHAPTER 4 Bolt Front brake reservoir tank Front brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Front wheel Refer to FRONT WHEEL AND REAR WHEEL section Front fender Steering shaft nut Pinch bolt handle crown Only loosening Handle crown Clip Bolt steering damper Steering damper Steering damper bracket 5 46 EC568100 sTEERING CHAS Be UNDER BRACKET 7 Nm 0 7 mekg 5 1 ftelb TIGHTENING STEPS e Tighten ring nut 46 Nm 4 6 mekg 33 ftelb e Loosen it one turn e Retighten it 1 Nm 0 1 mekg 0 7 ftelb 10 Nm 1 0 mekg 7 2 ftelb O 1 oS f dee 3 V 23 Nm 2 3 mekg 17 ftelb Extend of removal Under bracket removal 2 Bearing removal UNDER BRACKET REMOVAL Pinch bolt steering damper stay Only loosening Pin Pinch bolt handlebar Only loosening Pinch bolt under bracket Only loosening Front fork Refer to FRONT FORK section Ring nut Use special tool Refer to REMOVAL POINTS Under bracket Inner fender Ball race cover Bearing upper Bearing lower Refer to REMOVAL POINTS Ball race Refer to REMOVAL POINTS 5 47 sTEERING CHAS EC563000 REMOVAL POINTS EC563202 Ring nut 1 Remove e Ring nut Use the ring nut wrench iL Ring nut wrench J YM 33975 90890 01403 AWARNING Support the steering
70. NE REMOVAL ENG 4 74 2 Install e Engine NOTE Install the engine by raising it into the frame with a jack 3 Install e Engine mounting bolt upper e Engine mounting bolt lower 4 Tighten e Engine mounting adjust bolt V 8 Nm 0 8 mekg 5 8 ftelb NOTE e Use the adjust bolt wrench to tighten the engine mounting adjust bolts e Tighten the adjust bolts to specified torque alternately two times 5 Install e Nut engine mounting bolt upper e Nut engine mounting bolt lower V 30 Nm 3 0 mekg 22 ftelb ENGINE REMOVAL ENG 6 Install e Engine mounting collar left e Engine mounting bolt left e Engine mounting nut left 30 Nm 3 0 mekg 22 ftelb e Bolt engine bracket left 23 Nm 2 3 mekg 17 ftelb e Pinch bolt engine mounting collar left 11 Nm 1 1 mekg 8 0 ft lb 7 Tighten 8 Tighten 9 Install e Engine mounting collar right e Engine mounting bolt right e Engine mounting nut right gt 30 Nm 3 0 mskg 22 ftelb e Bolt engine bracket right e Pinch bolt engine mounting collar right V 11 Nm 1 1 mekg 8 0 ftelb 10 Tighten 11 Tighten e ES 3 S OK 4 75 CRANKCASE AND CRANKSHAFT EC4N0000 CRANKCASE AND CRANKSHAFT 11 Nm 1 1 mekg 8 0 ftelb 9 1 8 Nm 0 8 mekg 5 8 ft lb yy A V 50
71. OVAL POINTS 1 2 3 4 5 6 7 8 9 eck sesch wesch sech ee sesch wech sesch wesch O 4 32 cuurcH ENG REMOVAL POINTS EC483211 Clutch boss 1 Remove Nut e Lock washer e Clutch boss NOTE Straighten the lock washer tab and use the clutch holding tool to hold the clutch boss Z Clutch holding tool CH 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 Scoring Wear Damage Replace EC4A4100 Clutch housing 1 Check e Circumferential play Free play exists Replace e Gear teeth Wear Damage Replace e O ring Damage Replace EC484400 Clutch spring 1 Measure e Clutch spring free length Out of specification Replace springs as a set ON Clutch spring free length Standard 30 6 mm 1 205 in 29 6 mm 1 165 in 4 34 CLUTCH ENG Friction plate 1 Measure e Friction plate thickness Out of specification Replace friction plate as a set Measure at all four points C k Friction plate thickness Standard 2 9 3 1 mm 2 mm 0 114 0 122 in 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 and thickness gauge Gi
72. R 4 Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section Brake hose holder Refer to FRONT BRAKE AND REAR BRAKE section Drive chain Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section Connecting rod Hold the swingarm Bolt rear shock absorber relay arm Pivot shaft adjust bolt Pivot shaft Swingarm Relay arm Cover Thrust bearing Bush Bearing Use special tool Refer to REMOVAL POINTS O CO NOD O1 P Go O Refer to REMOVAL POINTS 9 93 5 54 swincarm CHAS Be REMOVAL POINTS EC573152 Swingarm 1 Loosen e Pivot shaft adjust bolt NOTE Loosen the pivot shaft adjust bolt using the pivot shaft wrench OG and pivot shaft wrench adapter Pivot shaft wrench YM 01455 90890 01455 Pivot shaft wrench adapter YM 01476 90890 01476 2 Remove e Pivot shaft e Swingarm EC573210 Bearing 1 Remove e Bearing Use a general bearing puller EC574010 INSPECTION Wash the bearings bushes collars and cov ers in a solvent EC574131 Swingarm 1 Inspect e Bearing e Bush Free play exists Unsmooth revolution Rust Replace bearing and bush as a set 2 Inspect e Bearing e Collar Free play exists Unsmooth revolution Rust Replace bearing and collar as a set swincarm CHAS Be Relay arm 1 Inspect e Bearing e Collar Free play exists Unsmooth revolution Rust Replace bearing
73. Rotate inner race with a finger Rough spot Seizure Replace 4 52 4 53 WATER PUMP ENG EC444400 Oil seal 1 Inspect e Oil seal Wear Damage Replace EC4G5000 ASSEMBLY AND INSTALLATION EC4G5120 Oil seal 1 Install e OU seal KAA NOTE mmm 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 crankcase 2 Install e Bearing NOTE Install the bearing by pressing its outer race parallel EC4G5202 Impeller shaft 1 Install e Impeller shaft NOTE e Take care so that the oil seal lip is not dam aged or the spring does not slip off its posi tion e When installing the impeller shaft apply the lithium soap base grease on the oil seal lip and impeller shaft And install the shaft while turning it 2 Install e Plain washer e Circlip To impeller shaft NOTE Be sure the circlip sharp edged corner is positioned opposite side to the plain washer WATER PUMP ENG ef 3 Install e Dowel pin e Gasket water pump housing cover New 4 Install e Water pump housing cover 1 e Bolt water pump housing cover 11 Nm 1 1 mekg 8 0 ftelb 5 Install e Radiator hose 2 v 2 Nm 0 2 mekg 1 4 ftelb 4 54 TRANSMISSION SHIFT CAM AND SHIFT FORK ENG EC4H0000 TRANSMISSION SHIFT CAM AND SHIFT FORK Ny CO Qs Cy Preparation for r
74. S 4 Install RE Zot e Under bracket ISS SES NOTE Z G SN Apply the lithium soap base grease on the bearing 5 Install Ring nut H Nm 0 1 mekg 0 7 ftelb Tighten the ring nut using the ring nut wrench Refer to STEERING HEAD INSPECTION AND ADJUSTMENT section in the CHAP TER 3 6 Check the steering shaft by turning it lock to lock If there is any binding remove the steering shaft assembly and inspect the steering bearings 7 Install e Plain washer 8 Install e Front fork e Steering damper stay right side only e Handlebar e Handle crown NOTE e Temporarily tighten the pinch bolts under bracket e Do not tighten the pinch bolts handle crown steering damper stay and handlebar yet 5 50 5 51 STEERING CHAS 9 Install e Plain washer e Steering shaft nut V ep Nm 8 0 mekg 58 ftelb NOTE Apply the lithium soap base grease on the steering shaft nut thread 10 After tightening the nut check the steering for smooth movement If not adjust the steering by loosening the ring nut little by lit tle 11 Install e Steering damper bracket e Pinch bolt steering damper bracket gt 5 Nm 0 5 mekg 3 6 ftelb To steering damper NOTE When installing the steering damper bracket provide a distance Gi of 9 mm 0 35 in from its edge CAUTION Tighten the pinch bolt to specified torque If torqued too much
75. STALLATION EC4J5102 Oil pump 1 Install O ring RA To oil delivery pipe NOTE Apply the lithium soap base grease on the O rings 4 65 4 66 OIL PUMP ENG 2 Install e Oil delivery pipe NOTE See When installing the oil delivery pipe fit the pro jection of the oil delivery pipe into the hole b on the crankcase 3 Install e Plain washer D 22 mm 0 87 in e Oil pump gear shaft To transmission housing 4 Install e Plain washer D 015 mm 0 87 in e Dowel pin e Inner rotor e Outer rotor To oil pump gear shaft NOTE e Apply the transmission oil on the inner rotor and outer rotor e Make sure the dowel pin fits into the groove a in the inner rotor e When installing the outer rotor make sure the punch mark on the outer rotor face the transmission housing side 5 Install e Dowel pin A 6 Install e Oil pump cover e Plain washer e Bolt oil pump cover V 8 Nm 0 8 mekg 5 8 ftelb NOTE While turning the oil pump gear shaft install the oil pump cover 7 Install e Strainer e Screw strainer V 7 Nm 0 7 mekg 5 1 ftelb NOTE Strainer is installed with the mesh facing outward 4 67 ef cormacnero ENG EC4L0000 ee CDI MAGNETO 7 Nm 0 7 mekg 5 1 ftelb V 53 Nm 5 3 mekg 38 ftelb Extend of removal CDI magneto removal CDI MAGNETO REMOVAL Prep
76. STER CYLINDER DISASSEMBLY D Master cylinder boot 1 d GI Circlip 1 Si Master cylinder kit 1 5 13 FRONT BRAKE AND REAR BRAKE CHAS EC536000 HANDLING NOTE AWARNING The brake components of this machine are suit for closed circuit use only Never use on any public road EC5A3000 VY REMOVAL POINTS EC5A3200 Brake fluid 1 Remove e Reservoir tank cap NOTE Do not remove the diaphragm Front Rear z lt n ee UPPER OWER I ek ONS P 2 Connect the transparent hose to the bleed screw and place a suitable con tainer under its end Front Rear 3 Loosen the bleed screw and drain the brake fluid while pulling the lever in or pushing down on the pedal CAUTION e Do not reuse the drained brake fluid e Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately 5 14 FRONT BRAKE AND REAR BRAKE CHAS EC533301 Caliper piston 1 Remove e Caliper piston Use compressed air and proceed carefully AWARNING 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 caliper to lock one caliper e Carefully force the piston out of the caliper cylinder with compressed air Front Rear EC543411 Piston seal kit 1 Remove e Dust seal e Piston seal NOTE Remove the piston seal
77. TER 2 FRONT BRAKE AND REAR BRAKE CHAS EC545451 Rear brake hose 1 Install e Copper washer 1 e Brake hose e Union bolt Go Nm 3 0 mekg 22 ft lb Always use new copper washers CAUTION When installing the brake hose to the mas ter cylinder lightly touch the brake pipe with the projection on the master cylin der 2 Install e Copper washer 1 e Adapter gt 26 Nm 2 6 mekg 19 ft lb e Brake hose gt 14 Nm 1 4 mekg 10 fteIb _ AWARNING _ Always use a new copper washer NOTE When turning the adapter over the brake hose hold the brake hose so that it may not be twist ed 3 Install e Brake hose holder e Bolt brake hose holder V 8Nm 0 8 mekg 5 8 ftelb 4 Install e Brake hose 1 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 9 23 2 FRONT BRAKE AND REAR BRAKE CHAS EC5A5610 Brake fluid 1 Fill e Brake fluid Until the fluid level reaches LOWER level line Recommended brake fluid DOT 4 AWARNING e Use only the designated quality brake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per L formance PANG leck Refill with the same type of brake fluid mixing fluids may result in a harmful chemical reaction and lead to poor perfor mance e Be careful that water does not enter the master cylinder when refilling Water will significantly lower the
78. above the piston pin as close to the center as possible The average of these measurements indicates the piston protrusion EC71N001 Selection of transmission gear ratio The following gear sets are contained in the packing or optional to allow the rider to change the gear ratios according to the circuit condition or rider s preference CAUTION Select the transmission gears so that the number of grooves in the wheel gear match that of the pinion gear as shown below Trouble may be occurred if the selection is different than that listed below a Groove 1st gear Number of Factory installed 34 18 1 889 SKE 17211 20 5KE 17411 20 Supplying part 28 14 2 000 SKE 17211 10 5KE 17411 10 2nd gear Number of Gear ratio Part number groove 31 21 1 476 4DP 17221 11 4DP 17121 11 1 27 19 1 421 5F7 17221 21 3YL 17121 21 28 18 1 556 5F7 17221 00 3YL 17121 00 Fe sETTING TUN 3rd gear Number of O 1 ewo OOOO rannm Naert Factory installed 29 23 1 261 5KE 17231 00 5KE 17131 00 a Supplying part 25 21 1 190 5KE 17231 20 5KE 17131 10 Supplying part 26 21 1 238 5KE 17231 10 5KE 17131 10 6th gear Number of O 1 arte raume 1 Factory installed 20 22 0 909 5KE 17261 00 5KE 17191 00 Supplying part 22 25 0 880 5KE 17261 10 5KE 17161 10 7 12 7 13 Transmission setting parts Part name Size Part number Main axle 14T 5KE 17411 10 zl 18T 5KE 17411 20 2nd pinion g
79. ace oil Castrol R30 Inspect transmission Replace bearing SHIFT FORK SHIFT CAM GUIDE BAR Inspect Inspect wear ROTOR NUT Retighten MUFFLER Inspect Inspect crack Clean CRANK 1 500 km Inspect and replace CARBURETOR Inspect adjust and clean Inspect jet needle clip groove 3 1 MAINTENANCE INTERVALS ADJ After Ever Ever Every As re Item break y y 1 000 Remarks in race 500km Se quired SPARK PLUG Inspect and clean Replace PLUG CAP 1 500 km Inspect and replace kal COOLING SYSTEM Check cooling level and leakage Check radiator cap operation Replace cooling water Use soft water Replace hoses Refer to STARTING AND BREAK IN section in the CHAPTER 1 OUTSIDE NUTS AND BOLTS Retighten OIL PUMP STRAINER Clean REED VALVE Inspect Replace FRAME Clean and inspect FUEL TANK COCK Clean and inspect BRAKES Adjust lever position and pedal position Check brake disc surface Check brake fluid level and leakage Retighten brake disc bolts caliper bolts and master cylinder bolts Replace pads Replace brake fluid FRONT FORKS Inspect and adjust Replace oil Replace oil seal REAR SHOCK ABSORBER H Every one year Suspension oil 01 Inspect and adjust After rain Lube Retighten Replace Inspect and retighten RELAY ARM CONNECTING ROD Inspect and retighten STEERING HEAD Inspect free play and retighten Clean and lube Lithium base grease Replace bearings
80. ace shift fork and or guide bar NOTE For a malfunctioning shift fork replace not only the shift fork itself but the two gears each adja cent to the shift fork EC4H5000 ASSEMBLY AND INSTALLATION EC4H5112 Shift cam 1 Install e Shift cam NOTE SSS Apply the transmission oil on the shift cam bearing TRANSMISSION SHIFT CAM AND SHIFT FORK ENG gt nee 4 61 2 Install e Segment e Bolt segment ER gt 23 Nm 2 3 mekg 17 ftelb NOTE mmmn e When installing the segment onto the shift cam align the punch mark with the dowel pin e Clamp the shift cam securely in a vise using soft protecting material to tighten the bolt segment EC4H5232 Transmission 1 Install e 6th pinion gear 227 e 3rd 4th pinion gear 23T 25T e 5th pinion gear 27T e 2nd pinion gear 21T To main axle NOTE Apply the molybdenum disulfide oil on the gears inner circumference 2 Install e 2nd wheel gear 31T e 5th wheel gear 26T e 3rd wheel gear 29T e 4th wheel gear 27T e 6th wheel gear 20T e 1st wheel gear 34T To drive axle NOTE Apply the molybdenum disulfide oil on the gears inner circumference Gi TRANSMISSION SHIFT CAM AND SHIFT FORK ENG 5th pinion gear Circlip 2nd pinion gear 3rd 4th Plain pinion gear washer e 6th pinion gear Plain washer l Main axle Circlip el
81. aller size in a leaner mixture Factory set pilot jet Q Pilot air screw The pilot air screw relates to the engine response at a smaller opening than for the pilot jet This setting may be changed for want of time or in emergency but it is basically set at the factory set pilot air screw position Factory set pilot air w 1 1 2 turns out screw position Spark plug The spark plug heat range is not basically changed Constant attention to the discoloration of the spark plug and piston head will enable you to tell to some extent whether the set ting is good or bad iN Standard spark plug R6179A 105P NGK NOTE For the effects each setting part has refer to Effects of setting parts in relation to throttle valve opening P7 2 7 8 Carburetor setting parts Part name Size Partnumber _ Main jet Lean 350 137 14143 70 137 14143 72 137 14143 74 137 14143 76 137 14143 78 137 14143 80 137 14143 82 137 14143 84 137 14143 86 137 14143 88 137 14143 90 137 14143 92 137 14143 94 137 14143 96 137 14143 98 137 1414K 00 137 1414K 08 137 1414K 12 Rech 580 137 1414K 16 Pilot jet Lean 20 4KM 14142 20 25 4KM 14142 25 Rich 30 4KM 14142 30 Main nozzleA Lean 3TC 14141 R6 Gi A 3TC 14141 R7 3TC 14141 R8 3TC 14141 R9 3TC 14141 S0 3TC 14141 S1 3TC 14141 S2 3TC 14141 S3 3TC 14141 S4 S 4 power ONG Rien 88 SE Rich 830 14231 11 NOTE e Th
82. alve pulley NOTE Connect thhe silver cables to the left side cylin der and the black cables to the right cylinder Refer to CABLE ROUTING DIAGRAM sec tion in the CHAPTER 2 A CYLINDER HEAD CYLINDER AND PISTON ENG km 8 Install e Cable stay e Bolt cable stay gt 7 Nm 0 7 mekg 5 1 ftelb 9 Adjust e YPVS cable Refer to YPVS OPEN SIDE CABLE ADJUSTMENT and YPVS CLOSE SIDE CABLE ADJUSTMENT section in the CHAPTER 3 10 Install e Spark plug OO 1 9 Nm 1 9 mekg 13 ft lb e Spark plug cap e Radiator hose 3 y 2 Nm 0 2 mekg 1 4 ftelb e Radiator hose 4 4 30 CLUTCH EC4A0000 CLUTCH ges EC4A8000 CLUTCH PLATE AND FRICTION PLATE 6 Nm 0 6 mekg 4 3 ftelb 9 Nm 0 9 mekg 6 5 ftelb Extend of removal Clutch plate and friction plate removal CLUTCH PLATE AND FRICTION PLATE REMOVAL Preparation for Lower cowl Refer to COWLING SEAT AND removal FUEL TANK section Screw clutch spring Clutch spring Pressure plate Friction plate Clutch plate 4 31 CLUTCH EC4A8200 CLUTCH HOUSING AND PUSH ROD 75 Nm 7 5 mekg 54 ftelb Extend of removal Clutch housing removal 2 Push rod removal CLUTCH HOUSING AND PUSH ROD REMOVAL Nut clutch boss Lock washer Clutch boss Plain washer Clutch housing O ring Bearing Spacer 1 Ball Push rod Use special tool Refer to REM
83. ance 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 mmm This manual should be considered a perma nent part of this machine and should remain with it even if the machine is subsequently sold EC060000 NOTICE Some data in this manual may become outdat ed 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 EC070011 FIN MACHINE WEIGHTS Weights of machines without fuel The minimum weights for road race machines are forthe class 125 CC minimum 70 kg 154 Ib forthe class 250 cc minimum 95 kg 209 Ib for the class 500 cc minimum 131 kg 289 Ib In modifying your machine e g for weight reduction take note of the above limits of weight EC080000 HOW TO USE THIS MANUAL PARTICULARLY IMPORTANT INFOR MATION A The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED AWARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person inspecting or repairing the machine CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the
84. and collar as a set EC574320 Connecting rod 1 Inspect e Connecting rod Wear Damage Replace EC574520 Swingarm side clearance 1 Measure e Bush length 2 Measure e Thrust bearing right thickness 6 e Thrust bearing left thickness 3 Measure e Swingarm head pipe length 5 99 5 56 swincarm CHAS Be 4 Calculate e Swingarm side clearance r Out of specification Adjust side clear ance using shim By using formula given below A O O VAA Side clearance SCH 0 05 0 35 mm 0 002 0 014 in lf the side clearance is out of specification adjust it to specification by installing the adjust shim at position and NOTE e The adjust shim is available only in the 0 3 mm 0 012 in thick type e When only one shim is required install it on the left side and when two shims are neces sary install them on both right and left sides EC575000 ASSEMBLY AND INSTALLATION EC575300 Bearing 1 Install e Bearing To swingarm NOTE e Apply the lithium soap base 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 For head pipe Gi 1 0 mm 0 04 in For connecting rod bracket 0 5 mm 0 02 in swincarm CHAS Be 2 Install e Bearing To relay arm NOTE e Apply the lithium soap b
85. and tube guide cable wid ing portions e Install the throttle cable carburetor left cylin der in the grip side slit in the tube guide 5 Install e Grip cap upper e Bolt grip cap NOTE e Align the contacting surface of the grip cap upper with the punch mark on the han dlebar e Tighten the bolts so that the upper side con tacting surface is closed 6 Adjust e Throttle grip free play Refer to THROTTLE CABLE ADJUST MENT section in the CHAPTER 3 5 42 9 43 HANDLEBAR CHAS 7 Install e Master cylinder e Master cylinder bracket e Bolt master cylinder bracket V 8 Nm 0 8 mekg 5 8 ftelb NOTE Install the bracket so that the arrow mark faces upward 8 Install e Starter lever e Screw starter lever NOTE The starter lever should be installed according to the dimension shown 9 Install e Starter cable carburetor left cylinder e Starter cable carburetor right cylinder To starter lever NOTE e Apply the lithium soap base grease on the starter lever ends e Install the starter cable carburetor left cylin der in the upper side slit in the starter lever 10 Install e Grip left Apply the adhesive to the handlebar NOTE Before applying the adhesive wipe off grease or oil on the handlebar surface GG with a lac quer thinner HANDLEBAR CHAS 11 Install e Main
86. aration for Cowling and fuel tank Refer to COWLING INDUCTION removal GUIDE SEAT AND FUEL TANK section Disconnect the CDI magneto lead Nut rotor en special tool Rotor Refer to REMOVAL POINTS Stator Woodruff key 4 68 pes g Vi OE ME A LN 2 ZX ON VA ENOJ dy VASE LR AFN AN get CX iS a E Ee H S SE M Se 4 69 om meer ENG EC4L3000 REMOVAL POINTS EC4L3101 Rotor ef 1 Remove e Nut rotor e Plain washer Use the rotor holding tool Z Rotor holding tool F YU 01235 90890 01235 2 Remove e Rotor 1 Use the flywheel puller Flywheel puller YM 01189 90890 01189 NOTE When installing the flywheel puller turn it coun terclockwise EC4L4000 INSPECTION EC4L4101 CDI magneto 1 Inspect e Rotor inner surface e Stator outer surface Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace CDI magneto and or Stator EC4L4200 Woodruff key 1 Inspect e Woodruff key Damage Replace EC4L5000 ASSEMBLY AND INSTALLATION EC4L5190 CDI magneto 1 Install e Stator e Screw stator NOTE Temporarily tighten the screw stator at this point CGO A NS i gt N TE SO lA ANCS ee LL 4 70 om meer ENG 2 Install e Woodruff key e Rotor NOTE e Clean the tapered portions of t
87. arts EC368011 SPROCKETS INSPECTION 1 Inspect e Sprocket teeth Excessive wear Replace NOTE Replace the drive driven sprockets and drive chain as a set 2 Inspect e Sprocket damper Wear Damage Replace INSP_ Q DRIVE CHAIN INSPECTION 3 23 EC369040 DRIVE CHAIN INSPECTION 1 Remove e Drive chain NOTE Remove the drive chain using a chain cutter 2 Clean e Drive chain Brush off as much dirt as possible Then clean the chain using the chain cleaner CAUTION This machine has a drive chain with small rubber O rings between the chain plates Steam cleaning high pressure washes certain solvent and kerosene can damage these O rings 3 Inspect e O rings drive chain Damage Replace drive chain e Rollers e Side plates Gi Damage Wear Replace drive chain 4 Measure e Drive chain length 10 links Out of specification Replace VAA Drive chain length 10 links PA Limit 150 1 mm 5 909 in INSP Q DRIVE CHAIN SLACK ADJUSTMENT 5 Check e Drive chain stiffness Clean and oil the chain and hold as illus trated Stiff Replace drive chain 6 Install e Chain joint e O ring e Drive chain Gi NOTE When installing the drive chain apply the lithi um 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 chain r
88. ase grease on the bearing when installing e Install the bearing by pressing it on the side having the manufacture s marks or numbers EA Installed depth of bearings SCH Zero mm Zero in EC575141 Swingarm 1 Install e Collar To relay arm NOTE Apply the lithium soap base grease on the col lars and bearings 2 Install e Relay arm e Bolt relay arm e Nut relay arm V 34 Nm 3 4 mekg 24 ftelb NOTE Apply the lithium soap base grease on the bolt 3 Install e Bush e Thrust bearing e Cover GI To swingarm NOTE Apply the lithium soap base grease on the bush bearings and cover lips 5 57 5 58 swincarm CHAS Be 4 Install e Swingarm e Pivot shaft NOTE e Apply the lithium soap base grease on the pivot shaft e Insert the pivot shaft from left side 5 Tighten e Pivot adjust bolt gt 5 Nm 0 5 mekg 3 6 ftelb NOTE Sse Use the pivot shaft wrench and pivot shaft wrench adapter to tighten the pivot adjust bolt Pivot shaft wrench YM 01455 90890 01455 Pivot shaft wrench adapter YM 01476 90890 01476 6 Install e Plain washer e Nut pivot shaft DIS Nm 11 5 mekg 85 ft lb 7 Check e Swingarm side play Gi Free play exists Check side clearance e Swingarm up and down movement Unsmooth movement Binding Rough spots Grease or replace bearings bushes and collars
89. ating surface etc 1 7 90890 01435 90890 01437 SPECIAL TOOLS ACC 11001 30 00 Quick gasket ACC 11001 30 00 90890 05143 90890 05143 YAMAHA Bond No 4 This sealant Bond is used for crankcase mating surface etc 1 8 SP CONTROL FUNCTIONS REN 1 9 EC150000 CONTROL FUNCTIONS EC15W000 MAIN SWITCH While the battery is connected moving the main switch to RUN causes the tachome ter servomotor fuel pump and solenoid valves to be initially activated To prevent the battery from being discharge do not move the main switch to RUN except when the engine is started or when electric parts are checked EC152000 CLUTCH LEVER The clutch lever is located on the left han dlebar it disengages or engages the clutch Pull the clutch lever to the handlebar to disen gage the clutch and release the lever to engage the clutch The lever should be pulled rapidly and released slowly for smooth starts EC153000 SHIFT PEDAL The gear ratios of the constant mesh 6 speed transmission are ideally spaced The gears can be shifted by using the shift pedal on the left side of the engine EC155001 THROTTLE GRIP The throttle grip 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 is located on the right handle
90. av Ss ity 2 Remove e Piston pin e Piston d EA e Small end bearing a ue SES NOTE S Ie Before removing the piston pin deburr the clip S groove and pin hole area If the piston pin groove is deburred and piston pin is still difficult to remove use the piston pin puller Piston pin puller YU 01304 90890 01304 CAUTION _____ O O O O OoOo Do not use a hammer to drive the piston pin out 4 20 CYLINDER HEAD CYLINDER AND PISTON ENG 4 21 3 Remove e Piston ring NOTE Take care not to scratch the piston and dam age the piston ring EC474000 INSPECTION EC474110 Cylinder head 1 Remove e Carbon deposits Use 400 600 grit wet sandpaper 2 Inspect e Cylinder head water jacket Crust of minerals Rust Remove e Cylinder head contact surface Wear Damage Replace e Recess of insert portion The contact surface of the insert portion is recessed below the aluminum portion Replace EC474210 Cylinder 1 Remove e Carbon deposits Use a rounded scraper NOTE Do not use a sharp instrument Avoid scratch ing the aluminum 2 Inspect e Cylinder inner surface Score marks Repair or replace Use 400 600 grit wet sandpaper CAUTION Do not rebore the cylinder OD CYLINDER HEAD CYLINDER AND PISTON ENG 3 Inspect e Travel distance for cylinder 3 000 km 1 800 miles or more Replace EC474313 Piston 1 Inspect
91. bar Pull it toward the handlebar to acti vate the front brake SP CONTROL FUNCTIONS REN G 1 10 EC157000 REAR BRAKE PEDAL The rear brake pedal is located on the right side of the machine Press down on the brake pedal to activate the rear brake EC158001 FUEL COCK The fuel cock supplies fuel from the tank to carburetor while filtering the fuel The fuel cock has the two positions OFF With the lever in this position fuel will not flow Always return the lever to this position when the engine is not run ning ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position EC15A020 STARTER LEVER CHOKE When cold the engine requires a richer air fuel mixture for starting A separate starter circuit which is controlled by the starter lever sup plies this mixture Push the starter lever out to open the circuit for starting When the engine has warmed up pull it in to close the circuit EC15V010 TACHOMETER A stepping motor type tachometer is provided for greater accuracy of the tachometer This tachometer features the following Sweeping Moving the main switch to RUN the tachometer hand sweeps widely once over the tachometer face and then returns to the zero position as initial operation This is called sweeping When the engine is started during sweeping the tachometer indicates the correct revolutions after sweep
92. bdenum disulfide grease Illustrated symbols 0 to on in the exploded dia grams indicate where to apply a locking agent and where to install new parts Apply locking agent LOCTITE D Use new one MEMO EC090000 INDEX GENERAL INFORMATION SPECIFICATION REGULAR INSPECTION AND ADJUSTMENTS CHASSIS ELECTRICAL TUNING SS eh spec Q WS 3 1 oe E de oss E sec B n Wi ECOA0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION neues 1 1 MACHINE IDENTIFICATION 1 2 IMPORTANT INFORMATION 1 3 CHECKING OF CONNECTION 1 5 SPECIAL TOOLS 000005 1 6 CONTROL FUNCTIONS 1 9 FUEL AND ENGINE MIXING OIL 1 15 INFORMATION BEFORE PRE OPERATION 000 5 1 16 STARTING AND BREAK IN 1 17 TORQUE CHECK POINTS 1 20 CLEANING AND STORAGE 1 21 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 3 GENERAL TORQUE SPECIFICATIONS 2 12 DEFINITION OF UNITS 2 12 CABLE ROUTING DIAGRAM 2 13 CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS 3 1 PRE OPERATION INSPECTION AND MAINTENANCE aaoanaannnannnnnanae 3 4 LOCKING WIRE INSTALLATION GUIDE 3 5 ENGINE 0000 eee es 3 6 CHASSIS bs d EEN twee SEN EEN KEEN 3 17 CHAPTER 4 ENGINE COWLING INDUCTION GUIDE SEAT AND FUEL TANK
93. boiling point of the fluid and may result in vapor lock CAUTION Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately Front Rear 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 i 5 24 FRONT BRAKE AND REAR BRAKE CHAS J 4 Install e Diaphragm e Reservoir tank cap CAUTION After installation while pulling the lever in or pushing down on the pedal check whether there is any brake fluid leaking where the union bolts are installed respec La tively at the master cylinder and caliper Front Rear N 9 25 FRONT FORK CHAS v 7 Nm 0 7 mekg 5 1 ftelb EC550000 FRONT FORK V 20 Nm 2 0 mekg 14 ftelb v 10 Nm 1 0 mekg 7 2 ftelb V 23 Nm 2 3 mekg 17 ftelb K KH gt Extend of removal Front fork removal FRONT FORK REMOVAL Preparation for Hold the machine by placing Support the machine securely so there removal the suitable stand is no danger of it falling over Cowling Refer to COWLING INDUCTION Induction guide left cylinder GUIDE SEAT AND FUEL TANK section in the CHAPTER 4 Front caliper Refer to FRONT BRAKE AND REAR BRAKE section Front wheel Refer to FRONT WHEEL AND REAR WHEEL section Front fender
94. bolt steering damper stay right side only 10 Nm 1 0 mekg 7 2 ftelb Refer to FRONT FORK TOP END ADJUSTMENT in the CHAPTER 3 5 Check e Steering smooth action Turn the handlebar to make sure no parts are being contacted with others Contact Repair 6 Adjust e Rebound damping force e Spring preload NOTE e Turn in the rebound damping adjuster fully then turn out it to the originally set position e Turn in the spring preload adjuster to the Originally set position 7 Install e Front fender e Bolt front fender v 8 Nm 0 8 mekg 5 8 ftelb 5 39 HANDLEBAR CHAS EC5B0000 HANDLEBAR 7 Nm 0 7 mekg 5 1 ftelb 7 Nm 0 7 mekg 5 1 ftelb 2 Nm 0 2 mekg 1 4 ftelb 8 Nm 0 8 mekg 5 8 ftelb Extend of removal O7 Handlebar removal Throttle disassembly HANDLEBAR REMOVAL Preparation for Cowling Refer to COWLING INDUCTION removal Induction guide left cylinder GUIDE SEAT AND FUEL TANK section in the CHAPTER 4 Handle crown Refer to STEERING section Clutch cable Disconnect at the lever side Clutch lever holder Main switch Grip left Refer to REMOVAL POINTS Starter cable Disconnect at the lever side Starter lever Master cylinder Grip cap upper Throttle cable Throttle Grip cap lower Grip end Handlebar Grip right Refer to REMOVAL POINTS Tube guide 2 3 4 5 6 7 8 9
95. ckwise and remove it CAUTION Hard water or salt water is harmful to the engine parts You may use distilled water if you can t get soft water 1 Place the machine on a level place and hold it in an upright position 2 Remove e Radiator cap 3 Check e Cooling water level Cooling water level low gt Add cooling water O7 Radiator EC354012 COOLING WATER REPLACEMENT AWARNING Do not remove the radiator cap when the engine is hot 1 Remove the lower cowl 2 Place a container under the radiator hose Dei ei COOLING WATER REPLACEMENT 3 Disconnect e Radiator hose 2 4 Remove e Radiator cap Drain the cooling water completely 5 Clean e Cooling system Thoroughly flush the cooling system with clean tap water 6 Connect e Radiator hose 2 v 2 Nm 0 2 mekg 1 4 ftelb 7 Fill e Radiator e Engine To specified level Recommended cooling water Soft water Cooling water capacity 1 4 L 1 23 Imp qt 1 48 US qt CAUTION e When filling the radiator with anti freeze tilt the motorcycle so that the filler hole is at the highest position If the radiator is positioned upright air is difficult to escape which may result in excessive engine heating e Hard water or salt water is harmful to the engine parts You may use distilled water if you can t get soft water 8 Remove e Air bleeding bolt right cylinder Bleeding the air until coming out the cooling water
96. crew 8 and place the suitable con tainer under its end e Loosen the bleed screw and push the caliper piston in CAUTION Do not reuse the drained brake fluid e Tighten the bleed screw Bleed screw 6 Nm 0 6 m kg 4 3 ft lb Fei e REAR BRAKE PAD INSPECTION AND REPLACEMENT 3 20 e Install the brake pads pad support 00 pad pin 4 and cotter pin NOTE e Always use a new cotter pin e Temporarily tighten the pad pin at this point e Install the caliper 3 and tighten the pad pin 00 Bolt caliper 35 Nm 3 5 mekg 25 ft lb Pad pin 18 Nm 1 8 mekg 13 ft lb 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 EC366031 REAR BRAKE PAD INSPECTION AND REPLACEMENT 1 Inspect e Brake pad thickness Gi Out of specification Replace as a set l k Brake pad thickness Gi Standard 4 0 mm 0 16 in 1 0 mm 0 04 in 2 Replace e Brake pad Brake pad replacement steps e Loosen the pad pin and remove the caliper NOTE Before removing the caliper from the swingarm loosen the pad pin Fei Q REAR BRAKE PAD INSPECTION AND REPLACEMENT e Remove the cotter pin CG pad pin pad support and brake pads e Connect the transparent hose to the bleed screw 8 and place the suitable con
97. ction of the secondary reduction ratio Sprocket Sie aY Number of driven sprocket teeth reduction EOE ae Number of drive sprocket teeth Factory set secondary 36 14 2 571 reduction ratio Die spa ee SEE ial Drive sprocket AT 7 18 The larger value the higher speed ratio The smaller value the lower speed ratio EC72N000 Drive and driven sprockets setting parts Partname Size Part number Drive sprocket 14T 93834 14178 15T 93834 15079 16T 93834 16104 Driven sprocket A4TW 25435 02 4TW 25436 02 4TW 25437 02 4TW 25438 02 4TW 25439 02 4TW 25440 02 Factory installed EC72L003 Chassis setting troubleshooting lt Symptom gt Chattering Small rebounds up and down movements Too stiff feeling Spongy feeling lt Cause gt lt Measures gt Bottoming full stroke e Increase spring preload e Increase damping force for compression Further in stroke e Increase damping force for compression or decrease damping force for rebound Too stiff poor stroke e Decrease spring preload H e Decrease damping force for compression e Down the oil level for front fork only Looseness in parts Check bolts bearings etc as well as their installation Tire Rim a r e Recheck balance e Check deformation runout Poor operation e Check the shock absorber Check rod inner tube etc for bending I
98. d portions of case Do not tap on gasket mating surface Work slowly and carefully If the cases do not separate check for a remaining case screw or fitting Do not force EC4N3410 Crankshaft bearing 1 Remove e Bearing NOTE e Remove the bearing from the crankshaft using a general bearing puller e Do not use the removed bearing EC4N4000 INSPECTION EC4N4112 Crankcase 1 Inspect e Contacting surface Gi scratches Replace crankcase assembly e Engine mounting boss 6 crankcase Cracks Damage Replace crankcase assembly 4 78 ef CRANKCASE AND CRANKSHAFT ENG EC4N4213 Crankshaft 1 Inspect e Bearing Rotate outer race with a finger Rough spot Seizure Replace 2 Inspect e Oil seal Wear Damage Replace 3 Measure e Runout limit e Small end free play limit e Connecting rod big end side clearance e Crank width crank pin side Out of specification Replace Use the dial gauge and a thickness gauge L Dial gauge J YU 03097 90890 01252 Se fim Leen 00020 n _ 0 0012 in 0 0020 in Small end 0 8 1 0 mm 2 0 mm Side 0 45 0 95 mm Clearance 0018 0007 In T Crank 49 975 50 025 mm with 908 1960 T EC4A4200 Push lever axle 1 Inspect e Push lever axle Wear Damage Replace e Torsion spring Broken Damage Replace 4 79 ef CRANKCASE AND CRANKSHAFT ENG EC4N5000 ASSEMBLY AND INSTALLATION EC4N53
99. der 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 amp brake pedal Brake pedal position Clutch lever free play at lever pivot Throttle grip free play 298 X 5 0 mm 11 73 X 0 20 in 5 3 mm 0 21 in 15 87 mm 0 625 in 33 96 30 23 mm 1 337 1 190 in DOT 4 1 0 mm 0 04 in 185 x 4 0 mm 7 28 x 0 16 in di i 0 15 mm 0 006 in 4 0 mm 0 16 in 1 0 mm 0 04 in 12 7 mm 0 500 in d 25 4 mm 1 000 in DOT 4 148 152 mm 5 8 6 0 in 2 3 mm 0 08 0 12 in 2 4 mm 0 08 0 16 in 2 8 ee GGG GGG GGG gt gt gt gt Handle crown and outer tube Under bracket and outer tube Steering shaft and steering shaft nut Handlebar and outer tube Steering ring nut Steering damper and fame Steering damper and damper bracket Steering damper stay and outer tube Steering stopper bolt and locknut Fuel tank fitting bolt and locknut Clutch lever holder Front master cylinder and master cylinder bracket Front brake reservoir tank and stay Brake lever bolt Brake lever nut Main switch and handleber Front fork and cap bolt Front fork and damper rod Cap bolt and damper rod Front fork and front fender Brake hose holder and swingarm Brake hose front and rear and union bolt master cylinder Brake hose front and
100. e bearing when installing 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 CAUTION Do not strike the inner race of the bearing Contact should be made only with the outer race 2 Install e Brake disc e Bolt brake disc age 2 3 mkg 17 feb NOTE Tighten the bolts in stage using a crisscross pattern 3 Install e Collar NOTE If the collar is hard to install apply the lithium soap base grease on the collar and press it in 4 Install e Clutch hub e Sprocket damper e Nut sprocket damper V 32 Nm 3 2 mekg 23 ftelb To driven sprocket FRONT WHEEL AND REAR WHEEL CHAS 5 8 5 Install e Driven sprocket e Collar To wheel NOTE Apply the lithium soap base grease on the sprocket damper 6 Install e Wheel NOTE _ _ Install the brake disc between the brake pads correctly 7 Install e Drive chain NOTE _ Push the wheel forward and install the drive chain 8 Install e Wheel axle NOTE e Apply the lithium soap base grease on the wheel axle e Insert the wheel axle from left side 9 Install e Plain washer e Nut wheel axle NOTE SSS e Apply the lithium soap base grease on the wheel axle thread e Temporarily tighten the nut wheel axle at this point
101. e Replace the oil seal whenever removed 342 038 V 9 30 FRONT FORK CHAS EC553321 Damper rod 1 Remove e Locknut 2 Remove e Bolt damper rod e Damper rod NOTE Use a damper rod holder to lock the damper rod iL Damper rod holder J YM 01425 90890 01425 EC554000 INSPECTION EC554100 Damper rod 1 Inspect e Damper rod Bend Damage Replace damper rod CAUTION 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 EC554400 Fork spring 1 Measure e Fork spring free length Out of specification Replace l vi Fork spring free length 212 5 mm 210 5 mm 8 37 in 8 29 in 5 31 FRONT FORK CHAS EC554502 Inner tube 1 Inspect e Inner tube surface 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 VA Inner tube bending limit PA 0 2 mm 0 008 in NOTE _ sSsSssSsSsSsses The bending value is shown by one half of the dial gauge reading AWARNING Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube EC554611 Outer tube 1
102. e chain NOTE e Install the drive sprocket with its depressed side facing the engine e Install the drive sprocket together with the ef drive chain 2 Install e Lock washer 1 e Nut drive sprocket 75 Nm 7 5 mekg 54 ftelb NOTE EO Tighten the nut while applying the rear brake 3 Bend the lock washer tab to lock the nut 4 50 WATER PUMP EC4G0000 ws WATER Pump V 11 Nm 1 1 mekg 8 0 ftelb Extend of removal Impeller shaft removal Oil seal removal WATER PUMP DISASSEMBLY Preparation for Cowling Refer to COWLING INDUCTION removal GUIDE SEAT AND FUEL TANK section Drain the cooling water Refer to COOLING WATER REPLACEMENT section in the CHAPTER 3 Transmission housing Refer to SHIFT SHAFT section Radiator hose 2 Water pump housing cover Circlip Plain washer Impeller shaft Bearing Refer to REMOVAL POINTS Oil seal 4 51 WATER PUMP ENG EC4G3000 REMOVAL POINTS EC4G3210 Oil seal NOTE It is not necessary to disassemble the water pump unless there is an abnormality such as excessive change in coolant level discol oration of coolant or milky transmission oil 1 Remove e Bearing 2 Remove e Oil seal EC4G4000 INSPECTION EC444200 Impeller shaft 1 Inspect e Impeller shaft Bend Wear Damage Replace Fur deposits Clean EC4H4600 Bearing 1 Inspect e Bearing
103. e parts marked A are not supplied togeth er There are available on order as YAMAHA genuine parts e Use a 500 main jet when selecting a next smaller size jet than a 540 1 9 Plug chop When checking the discoloration of the spark plug and piston head move the main switch to OFF while running along a straight lane at full throttle disengage the clutch at the same time and stop the engine Then let your machine go back to the pit by inertia This is called a plug chop CAUTION e When you do a plug chop pay attention to your surrounding environment to avoid interference with other riders e Do not shift down while riding your machine by inertia as it may cause a seizure of the clutch push rod and ball EC71K010 Setting of cylinder gasket The use of the supplied gaskets of different thicknesses makes it possible to change the combustion chamber volume Not much torque is felt with slow engine accel eration Reduce the combustion chamber volume Torque is felt with no higher revolutions Expand the combustion chamber volume Actual combustion 0 031 in 0 340 Imp oz 0 327 US os 0 7 mm Approx 9 43 cm 0 6 mm Approx 9 20 em 0 5 mm Approx 8 98 cm parts 0 4 mm Approx 8 75 cm NOTE e Finish the break in before changing the gas ket e A change of 0 1 mm 0 004 in for the gasket causes a change of approximately 0 23 cm 0 008 Imp oz 0 008 US oz of the combus
104. ear Al 18T 5F7 17121 00 Ai 19T SF7 17121 21 21T 4DP 17121 11 gear CG 123T 25T 5KE 17131 00 25T 5KE 17161 10 Il 34T 5KE 17211 20 2nd wheel gear A 27T 5F7 17221 21 A 28T 5F7 17221 00 31T 4DP 17221 11 3rd wheel gear 25T 5KE 17231 20 26T 5KE 17231 10 29T 5KE 17231 00 4th wheel gear 5KE 17241 00 5th wheel gear 4 3YL 17251 00 6th wheel gear 20T 5KE 17261 00 22T 5KE 17261 10 Factory installed NOTE e The mark A shows that this part is not sup plied together and that it is available on order as a YAMAHA genuine part 3rd 4th pinion gear 5KE 17131 10 allows for a combination of 3rd wheel gear 5KE 17231 10 and 5KE 17231 20 7 14 CHASSIS EC72J001 Chassis setting How to go about setting the chassis e Measure the stroke of the front and rear sus pension to get an idea of the operation e f the time increases the stroke increases elf the tire grip becomes firmer the stroke increases On the other hand the stroke decreases on rainy weather e Rider s position and posture affect the stroke e Be careful not to allow the suspension to bot tom out e Start the setting with the preload Next go to the damping force adjustment and if this not enough then adjust the machine height On the side where the machine height is greater the stroke increases whereas it decreases on the side with a smaller machine height e f the damping force is increased either
105. ed Refer to BATTERY INSPECTION section in the CHAPTER 3 NOTE e Remove the following parts before inspection 1 Cowling e Use the following special tools in this inspection iL Pocket tester y YU 03112 90890 03112 6 14 THERMO UNIT SYSTEM ELEC 6 15 EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check e Couplers and leads connection Rust Dust Looseness Short circuit Repair or replace EC6A2000 THERMO UNIT INSPECTION 1 Drain the cooling water 2 Remove e Thermo unit 3 Immerse the thermo unit with a tester lead connected in a container containing cooling tap water down to the upper threaded portion 2 Water temperature gauge 3 Poket tester 4 Inspect e Thermo unit resistance Measure the resistance while gradually heating the cooling water Out of specification Replace C Cooling Thermo Tester OL water unit selector temperature resistance position GEAR Sg NOTE Do not allow the thermo unit to contact the test container bottom FUEL Pump system ELEC FUEL PUMP SYSTEM EC671000 INSPECTION STEPS If the fuel pump will not operate use the following inspection steps No good Replace fuse and 1 Check fuse check wireharness N d 2 Check battery ed Recharge or replace ab o Check each coupler and No good Repair or replace wire connection JC o N d D Check main switch Jb ok Check fuel t No g
106. eel axle Front wheel axle Caliper Front wheel Collar Bearing Brake disk Only loosening Refer to REMOVAL POINTS Refer to REMOVAL POINTS hihi AM ch A 1 2 3 4 z 6 T 8 5 1 FRONT WHEEL AND REAR WHEEL CHAS EC598100 REAR WHEEL 7 WY CoO R K GA Qs Extend of removal CO Rear wheel removal 2 Wheel bearing removal 3 Brake disc removal REAR WHEEL REMOVAL Preparation for Hold the machine by placing removal the suitable stand Nut rear wheel axle Rear wheel axle Rear wheel Collar Driven sprocket Sprocket damper Clutch hub Collar Bearing Brake disc i 2 3 4 J 6 E 8 9 N N L I ch O 5 2 AWARNING Support the machine securely so there is no danger of it falling over Refer to REMOVAL POINTS Refer to REMOVAL POINTS Refer to REMOVAL POINTS FRONT WHEEL AND REAR WHEEL CHAS 5 3 EC593000 REMOVAL POINTS EC523101 Rear wheel 1 Remove e Wheel NOTE Push the wheel forward and remove the drive chain EC513300 Collar 1 Remove e Collar Knock out of wheel on inside NOTE Knock the collar out of the wheel gradually not to deform it EC513201 Wheel bearing if necessary 1 Remove e Bearing NOTE Remove the bearing using a general bearing puller EC594000 INSPECTION EC514110 Wheel 1 Measure e Wheel runout Out of li
107. emoval TRANSMISSION SHIFT CAM AND SHIFT FORK REMOVAL Cowling Refer to COWLING INDUCTION GUIDE SEAT AND FUEL TANK section Transmission housing Shift shaft and shift lever assembly Stopper lever iw to SHIFT SHAFT section 4 55 ef TRANSMISSION SHIFT CAM AND SHIFT FORK ENG K ee SS KR A Extend of removal 1 Shift fork removal 2 Main axle and drive axle removal 3 Shift cam removal Guide bar 1 short Guide bar 2 long Shift fork 1 Shift fork 2 Shift fork 3 Thrust plate Main axle Drive axle Bolt segment Segment Shift cam Refer to REMOVAL POINTS OO OO JO Om P OUN Refer to REMOVAL POINTS ech sesch sesch sesch zech wesch sesch wesch sesch wesch sesch ck ch 4 56 TRANSMISSION SHIFT CAM AND SHIFT FORK ENG EC4H3000 REMOVAL POINTS EC4H3210 O i oy Transmission f C ER e SA gt S x gc e Drive axle svar NOTE A ke ly e Remove the main axle together with the drive axle from the transmission housing e Remove assembly carefully Note the position of each part Pay particular attention to the location and direction of shift forks es 4 EC4H3400 Segment 1 Remove e Bolt segment e Segment NOTE Clamp the shift cam securely in a vise using soft protecting material to loosen the bolt segment EC4H40
108. emove the steering shaft assembly and inspect the steering bearings e Install the handle crown and reservoir tank Steering shaft nut 80 Nm 8 0 m kg 58 ft lb Pinch bolt front fork 20 Nm 2 0 mekg 14 ft lb Bolt reservoir tank 5 Nm 0 5 mekg 3 6 ft lb e Install the cowling 6 Install e Steering damper EC36V002 STEERING DAMPER ADJUSTMENT 1 Adjust e Damping force By turning the adjuster Stiffer Gi Increase the compression damping force Turn the adjuster in Softer Decrease the compression damping force Turn the adjuster out 3 38 WIRES CABLES INSP Q COWLING INSTALLATION INSPECTION 3 39 C k Extent of adjustment Fully turned in Fully turned out position position e STANDARD POSITION This is the position which is back by the spe cific number of clicks from the fully turned out position VAA Standard position PA 0 click in Cen Fully turn out the adjuster and then turn it in Specify the position in which the first click is heard as the zero position If a click is heard just when the adjuster is fully turned out this position is zero CAUTION ss Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged EC36X001 WIRES CABLES 1 Inspect e Smooth movement for steering handle By turning the handlebar lock to lock If any caught rubbed Repair Replace EC36Z000
109. end bearing e Piston pin Into the small end of connecting rod 5 Check e Free play There should be no noticeable free play Free play exists Inspect the connecting rod for wear Replace the pin and or con necting rod as required 4 23 CYLINDER HEAD CYLINDER AND PISTON ENG 4 24 EC474520 Piston ring 1 Install e Piston ring Into the cylinder Push the ring with the piston crown 2 Measure e End gap Use a thickness gauge Out of limit Replace b gt x Ring end gap installed Standard 0 22 0 37 mm 0 59 mm 0 009 0 015 in 0 023 in 3 Measure e Side clearance Use a thickness gauge Out of limit Replace piston and or ring p K Side clearance Standard 0 02 0 06 mm 0 1 mm 0 0008 0 0024 in 0 004 in NOTE 8 e Insert the thickness gauge deep in the piston ring groove Then measure the clearance with both sliding surfaces being flush with each other e Check at several points EC474720 Combination of piston and cylinder 1 Check e Cylinder mark Cylinder mark Gi CYLINDER HEAD CYLINDER AND PISTON ENG 2 Check e Piston mark a Piston mark color A red B orange C green 3 Combination Combine the piston and cylinder by the fol lowing chart Cylinder mark Piston mark color A red B orange C green NOTE When you purchase a cylinder you cannot designate a specific one Choose the piston that matches
110. er e Check the shift lever position Gaps and are not equal Adjust 4 Adjust e Shift lever position Adjusting steps e Loosen the locknut e Turn the adjuster in or out e Tighten the locknut Locknut 9 Nm 0 9 mekg 6 5 ft lb Remove the collar SHIFT SHAFT ENG EC4F5411 Transmission housing 1 Apply e Transmission oil On the bearing crankcase lower and impeller shaft 2 Install e Dowel pin e Transmission housing NOTE When installing the transmission housing turn the oil pump driven gear until the key end o of the oil pump gear shaft is in the recess of the impeller shaft 3 Install e Bolt transmission housing 40 mm 1 57 in gt 16 Nm 1 6 mekg 11 ftelb e Bolt transmission housing 2 30 mm 1 18 in 16 Nm 1 6 mekg 11 ftelb NOTE SSS e Tighten the bolts in stages using a crisscross pattern e Apply the transmission oil on the thread and contact surface of the bolt transmission housing 4 Install e Plain washer e Spacer e Shift arm e Bolt shift arm V 14 Nm 1 4 mekg 10 ftelb NOTE e Make sure that the joint rod distance is 104 5 106 5 mm 4 1 4 2 in e Install the shift arm so that the shift pedal cen ter is highest without exceeding the inside line of the footrest bracket SHIFT SHAFT ENG EC4F5510 Drive sprocket 1 Install e Drive sprocket e Driv
111. er 2 Fuel tank 5 Seat 3 Induction cap left cylinder e Use DV battery in this inspection e Use the following special tools in this inspection Pocket tester YU 03112 90890 03112 6 12 SOLENOID VALVE system ELEC EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check e Couplers and leads connection Rust Dust Looseness Short circuit Repair or replace EC652020 SOLENOID VALVE OPERATION 1 Disconnect the fuel pump and servomotor coupler to prevent the fuel pump and ser vomotor operating Inspect e Solenoid valve Click when the main switch is moved to RUN OK NOTE Before checking the solenoid valve disconnect the other solenoid valve lead EC653002 NO SOLENOID VALVE COIL INSPECTION 1 Inspect e Solenoid valve coil resistance Out of specification Replace Tester lead Yellow lead Tester lead White lead Solenoid Tester selector resistance position 52 0 63 6 at Pare 6 13 THERMO UNIT SYSTEM ELEC THERMO UNIT SYSTEM EC6A1010 INSPECTION STEPS lf the water temperature gauge thermo unit will not operate use the following inspection steps 1 Check fuse EES check wireharness No good 2 Check battery a Recharge or replace Jb o Check each coupler and No good Repair or replace wire connection Jb ok JC ok JL ok Replace tachometer assembly 1 marked Refer to IGNITION SYSTEM section 2 mark
112. exhaust pipe left cylinder 4 7 CARBURETOR AND REED VALVE V 2 Nm 0 2 mekg 1 4 ftelb 2 Nm 0 2 mekg 1 4 ftelb V 1 Nm 0 1 mekg 0 7 ftelb Extend of removal Carburetor removal 1 Induction cap left cylinder Servicing the left cylinder Solenoid valve lead Disconnect the solenoid valve lead Clamp carburetor joint Loosen the screw carburetor joint Carburetor Fuel hose Grommet Pull up by slit end horas the Induction cap right cylinder right cylinder Induction box Carburetor joint Reed valve assembly Stopper reed valve Reed valve 2 Reed valve 1 4 8 ef CARBURETOR AND REED VALVE ENG EC468000 CARBURETOR DISASSEMBLY z 2 Nm 0 2 mekg 1 4 ftelb mm ff ES bk gt 8 Lhe Seel Extend of removal OO Carburetor disassembly CARBURETOR DISASSEMBLY Mixing chamber top Throttle valve Needle holder Jet needle Starter plunger Float chamber Power jet Float pin Float Valve seat Main jet Main nozzle Pilot jet Pilot air screw Solenoid valve Refer to REMOVAL POINTS wesch h wesch sesch sch sesch zech sesch sesch sch sesch wesch sch wesch O 4 9 CARBURETOR AND REED VALVE ENG EC466010 HANDLING NOTE CAUTION Do not disassemble the venturi block because it will cause a drop in carburetor performance EC46
113. f bent replace e Check for any deviation from center after tightening front wheel axle Replace if deviated in any way e Too much tightened bolts for front fork outer tube Retorque the bolts to specification handle crown under bracket steering damper stay handlebar Too stiff poor stroke e Decrease spring preload e Decrease damping force for both compres sion and rebound Bottoming full stroke e Increase spring preload e Increase oil level for front fork only e Increase damping force for compression or decrease damping force for rebound Poor of damping force e Increase damping force for both compres sion and rebound Too soft Increase spring preload 7 19 lt Symptom gt lt Cause gt Handlebar fluctuating Poor corner Machine tends to incline maneuvering too much backward Too big caster angle Too much knifing at cornering Front dives in too early Swinging on bounding over gaps Too much damping force for rebound Bottoming 7 20 Poor of front load E Too soft of front _ ES Machine tend to incline too much forward Too small caster angle lt Measures gt e Decrease spring preload for front e Increase front fork top end e Increase rear height e Increase spring preload for rear e Increase spring preload for front e Increase damping force for front
114. he crankshaft and rotor e When installing the woodruff key make sure that its flat surface is in parallel with the crankshaft center line e When installing the rotor align the keyway of the rotor with the woodruff key e 3 Install e Plain washer e Nut rotor 53 Nm 5 3 mekg 38 ft lb Use the rotor holding tool Z Rotor holding tool F YU 01235 90890 01235 4 Adjust e Ignition timing EA Ignition timing PA 2 4 mm 0 094 in Refer to IGNITION TIMING CHECK sec tion in the CHAPTER 3 5 Connect e CDI magneto lead Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 EC4M0000 ENGINE REMOVAL NY A yy A S AN Qs ENGINE REMOVAL 30 Nm 3 0 mekg 22 ftelb V 23 Nm 2 3 mekg 17 ftelb Preparation for removal ENGINE REMOVAL Hold the machine by placing the suitable stand Cowling and fuel tank Carburetor and carburetor box Exhaust pipe Clutch cable Radiator hose 2 Radiator hose 3 4 Drive sprocket Shift arm Spark plug cap YPVS cable Disconnect the CDI magneto lead 4 71 Support the machine securely so there is no danger of it falling over Refer to COWLING INDUCTION GUIDE SEAT AND FUEL TANK section Refer to CARBURETOR AND REED VALVE section Refer to EXHAUST PIPE AND SILENCER section Disconnect at engine side Disconnect at water pump side Disconnect at cylinder head side Reter t
115. he lithium soap base grease on the bolt e When installing the brake lever apply the molybdenum disulfide grease on the contact ing surface of the master cylinder piston EC545270 Rear master cylinder 1 Install e Reservoir hose e Reservoir tank e Nut reservoir tank E 7 Nm 0 7 mekg 5 1 ftelb 2 Install e Master cylinder e Bolt master cylinder V 20 Nm 2 0 mekg 14 ftelb Cate A gt 0 21 FRONT BRAKE AND REAR BRAKE CHAS 3 Install e Brake pedal e Brake pedal connecting bolt e Nut brake pedal connecting bolt V 12 Nm 1 2 mekg 8 7 ftelb NOTE After installing check the brake pedal height Refer to REAR BRAKE ADJUSTMENT sec tion in the CHAPTER 3 EC535541 Front brake hose 1 Install e Copper washer 1 e Brake hose e Union bolt 30 Nm 3 0 mekg 22 ftelb AWARNING Always use new copper washers CAUTION Install both brake hoses so that they form an angle of 60 to the brake lever 2 Install e Copper washer 1 e Adapter V 26 Nm 2 6 mekg 19 ftelb KI OR e Brake hose 14 Nm 1 4 mekg 10 ftelb ae NY AWARNING w H SE Sm 4 ES SCH Always use a new copper washer L d AAA ID A SS NOTE When turning the adapter over the brake hose hold the brake hose so that it may not be twist ed 3 Install e Clamp Refer to CABLE ROUTING DIAGRAM section in the CHAP
116. he sleeved cables must be connected to the top side open side of the YPVS servomotor Position the ends of the clamp on the under portion of the under brack et Be sure the brake hose is not twisted a Zeromm Zero ml IB GC D a Zeromm Zero in G 2 14 CABLE ROUTING DIAGRAM SPEC vs Clamp 2 Throttle cable 3 Fuel tank breather hose GO Fuel pump stop switch lead Battery lead Fuel pump relay lead D Power supply coupler CDI magneto lead Q Front brake hose left a Zeromm Zero in Clamp the wireharness together with couplers of the fuse lead under the cowling stay mounting bolt so that the tape on the wireharness aligns with the bolt Fasten the primary ground lead together with the cowling stay bracket mounting bolt Do not cut the end of the clamp D Clamp the couplers of the main switch lead together with the wirehar ness E Disconnect the power supply coupler except when the engine is started or when electric parts are checked Be sure the brake hose is not twisted a Zeromm Zero in a Zeromm Zero ml 6 a Zeromm a Zeromm Zero in Zero in 2 15 CABLE ROUTING DIAGRAM SPEC vs 1 Tachometer assembly 2 Coupler for speed shift 3 CDI unit Voltage regulator Servomotor Brake hose holder Reservoir hose Rear brake hose GG Clamp To radiator a Zero mm Zero ml N Install the tachometer a
117. hift fork X For warming up and inspection during break in refer to PRE OPERATION CHECK LIST and if there is any problem stop the engine immediately and check Q TORQUE CHECK POINTS REN G TORQUE CHECK POINTS EC1A0032 Frame construction ____HI Frame to rear frame Engine mounting __ Frame to engine Steering Steering shaft to handlebar Steering shaft to frame Steering shaft to handle crown Front fork to handlebar Suspension Front Steering shaft to front fork IT Front fork to handle crown Front fork to under bracket For link type Assembly of links Link to frame 7 Link to shock absorber Link to swingarm Rear Installation of shock absorber Shock absorber to frame Rear Rear Installation of swingarm Tightening of pivot shaft Wheel Installation of wheel Front Tightening of front axle Tightening of axle holder Rear Tightening of rear axle Sprocket damper to sprocket Jr Brake Hydraulic type Front Caliper to front fork Brake disc to wheel Tightening of union bolt Master cylinder to handlebar Tightening of air bleeder Rear Caliper to caliper bracket Brake disc to wheel Tightening of union bolt Master cylinder to frame Tightening of air bleeder Fuel system __ Fuel tank to fuel cock NOTE Concerning the tightening torque refer to MAINTE
118. ie AAEE e Circumferential play Nut clutch boss SE CSS Free play exists Replace se special tool e d ais xed Gs to REMOVAL POINTS S Gear teeth z utc SE d Z Wear Damage Replace pacer 7 Ori O ring small O ring Clutch housing ca Damage gt Replace O ring large Clutch spring SE i 1 Measure Ball e Clutch spring free length Push rod Out of specification Replace springs as Bolt seat plate Seat plate Push lever axle oO OO JO Om GO A ox Clutch spring free length Standard lt Limit gt 36 0 mm 1 417 in 35 0 mm 1 378 in EC085002 ILLUSTRATED SYMBOLS Refer to the illustration Illustrated symbols to are designed as thumb tabs to indicate the chapter s number and content General information Specifications 3 Regular inspection and adjustments GO Engine Chassis 6 Electrical Tuning Illustrated symbols to are used to identi fy the specifications appearing in the text With engine mounted Q Special tool Filling fluid D Lubricant 2 Tightening 3 Specified value Service limit Resistance Q Voltage V Electric cur rent A Illustrated symbols to 9 in the exploded dia grams indicate grade of lubricant and location of lubrication point 5 Apply transmission oil Apply engine mixing oil 2 Apply molybdenum disulfide oil Apply lightweight lithium soap base grease Apply moly
119. imits e Tighten the axle nut while pushing down the drive chain N Axle nut A 80 Nm 8 0 m kg 58 ft lb e urn out the adjusters to the specified torque N Adjuster A 2 Nm 0 2 m kg 1 4 ft lb e Tighten the locknuts Locknut 16 Nm 1 6 mekg 11 ft lb 3 25 DS ei WHEEL ALIGNMENT ADJUSTMENT 3 26 EC36B000 WHEEL ALIGNMENT ADJUSTMENT 1 Remove e Lower cowl 2 Place the machine on a level place and hold it up on upright position 3 Sit 1 2 m 3 3 6 6 ft behind the machine and look at both sides of the wheels below the rear wheel axle 4 Turn the handlebar left and right to make the front wheel straight NOTE e To make the front wheel straight provide and with the same distance as seen along the extension of the line connecting the rear end of the front wheel and the front end of the rear wheel e Figure A shows that the front wheel is turned clockwise gt e Figure shows that the front wheel is straight 5 Check e Wheel alignment With the front wheel straight check whether the distances and are equal If not Adjust FRONT FORK INSPECTION INS e FRONT FORK TOP END ADJUSTMENT 6 Adjust e Wheel alignment Turn the chain puller adjuster while paying attention to the drive chain slack and make adjustment while moving the rear wheel NOTE e Figure C shows that the wheel alignment has been correctly made
120. in 0 5896 in Piston ring Sectional sketch Keystone B 1 0 mm 0 039 in T 2 2 mm 0 087 in Se End gap installed 0 22 0 37 mm 0 009 0 015 in 0 59 mm 0 023 in Side clearance installed 0 02 0 06 mm 0 0008 0 0024 in 0 1 mm 0 004 in Crank width A Crankshaft Ka C i C Runout limit C a a Connecting rod big end side clearance D 0 45 0 95 mm 0 018 0 037 in gt Small end free play F 0 8 1 0 mm 0 031 0 039 in 2 0 mm 0 08 in Clutch Friction plate thickness 2 9 3 1 mm 0 114 0 122 in 2 mm 0 106 in Quantity 6 Se Clutch plate thickness 2 2 2 4 mm 0 087 0 094 in Quantity 5 d Warp limit Ss 0 1 mm 0 004 in Clutch spring free length 30 6 mm 1 205 in 29 6 mm 1 165 in Quantity 6 d Clutch housing thrust clearance 0 07 0 18 mm 0 003 0 007 in Clutch housing radial clearance 0 009 0 071 mm 0 0004 0 0028 in Clutch release method Inner push cam push zz Push rod bending limit d 0 2mm 0 008 in Transmission Main axle deflection limit 0 01 mm 0 0004 in Drive axle deflection limit 0 01 mm 0 0004 in Shifter Shifting type Cam drum and guide bar d Guide bar bending limit d 0 04 mm 0 0016 in 49 975 50 025 mm 1 968 1 969 in 0 03 mm 0 0012 in 0 05 mm 0 0020 in 2 3 waer speciricarions SPEC gz Standard Carburetor Type Manufacturer I D mark left side right side Main jet Jet needle Main nozzle Cutaway Pilot jet Pilot air screw Valve seat size Sta
121. 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 disas sembled 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 EC553143 Cap bolt 1 Remove e Cap bolt From the outer tube NOTE _ _ _ _ Before removing the front fork from the machine loosen the cap bolt 2 Loosen e Spring preload adjuster NOTE Record the set position of the adjuster the amount of turning out the adjuster to the fully turned out position before loosening it 9 29 FRONT FORK CHAS 3 Remove e Cap bolt NOTE e While pressing down the spacer with the fork spring compressor set the rod holder between the locknut and spacer e Hold the locknut and remove the cap bolt by turning the spring preload adjuster Fork spring compressor YM 01441 90890 01441 Rod holder YM 01434 90890 01434 EC553212 Oil seal 1 Remove e Inner tube Pull out the inner tube from the outer tube 2 Remove e Stopper ring Using slotted head screwdriver 3 Remove e Oil seal e Oil seal washer Using slotted head screwdriver CAUTION ____ O oo e Take care not to scratch the outer tube inner surface
122. ing and then suddenly respond to further throttle open ing Example S 4 S 3 7 4 If the main jet is fully adjusted with not much allowance for discoloration use a main jet which is approximately 20 lager Run a few laps of the circuit to check the engine for response to revolutions Also check for the discoloration of the spark plug s and piston s Use a main jet of a smaller size if good response to engine revolutions is achieved with an allowance for the discoloration of the spark plug s and piston s On the other hand if the use of a different main nozzle appears to produce less power change to a main nozzle of a larger size Example S 1 S 2 Factory set main nozzle sn NOTE Difference between individual riders or differ ence between circuit layouts greatly affect the main nozzle setting 1 Rider who frequently uses mid open throttle 2 Circuit that requires frequent throttle open ing and closing 3 Wet environment Conditions as mentioned above require a longer period of throttle closing resulting in the drawn in mixture staying longer in the crankcase Such setting in turn will inevitably cause the mixture to be richer at the next throt tle opening a main nozzle of a smaller size has to be used Carburetor settings by correction coeffi cient Now you should be able to understand the essentials of basic carburetor setting from an explanation given under Basic process
123. ing is over Out of step indication lf this tachometer is subjected to impact etc it may allow its hand to point to the position stepping out of the position where the hand should be for correct indication This is called an out of step indication A similar phenome non may take place when the main switch is moved to OFF during sweeping or at high rom as in a plug chop or while the machine is transported though it never happens in normal riding SP CONTROL FUNCTIONS REN G NOTE e H an out of step indication takes place mov ing the main switch to OFF once and then to RUN brings the tachometer back to a nor mal indication through its corrective action e There is no functional problem involved with the out of step indication which can be brought back to a normal indication through the corrective action of the tachometer EC15B010 WATER TEMPERATURE GAUGE The water temperature gauge CO displays dif ferent indications according to the change in the water temperature NOTE Water temperature may be 70 C 158 E when engine is operated in good conditions temp 19 CG 66 F LO is display 20 119 C Temperature is 68 247 E displayed 120 140 GC un Temperature 248 284 F 141 C Lu Message HI 285 F u flash EC15F000 VALVE JOINT This valve joint prevents fuel from flowing out and is installed to the fuel tan
124. ion Continuous while the main switch is moved to OFF Replace Not continuous while the main switch is moved to RUN Replace EC626002 IGNITION COIL INSPECTION 1 Inspect e Primary coil resistance Out of specification Replace Tester lead Orange Gray lead Tester lead Black lead SI Primary coil Tester selector resistance position 0 14 0 18 Q at Lager 6 4 IGNITION system ELEC 2 Inspect e Secondary coil resistance Out of specification Replace Tester lead Spark plug lead Tester lead Orange Gray lead SI Secondary coil Tester selector resistance position 5 0 7 4 kQ at Mik SEI NOTE When inspecting the secondary coil resis tance remove the spark plug cap EC627031 CDI MAGNETO INSPECTION 1 Inspect e Pick up coil resistance left cylinder Out of specification Replace Tester lead White Blue lead Tester lead White Black lead SI Pick up coil Tester selector resistance position 94 140 Q at 2 Inspect e Pick up coil resistance right cylinder Out of specification Replace Tester lead White Green lead Tester lead White Black lead SI Pick up coil Tester selector resistance position 94 140 Q at 6 5 6 6 IGNITION system ELEC 3 Inspect e Source coil resistance Out of specification Replace Tester lead gt White lead Te
125. is advisable to check the degree of discoloration of the spark plug s for final selection according to an explanation under Atmospheric conditions and carburetor setting P7 1 e As the main nozzle is more susceptible to other than atmospheric conditions no correc tion coefficient is used for main nozzle set ting EC71G002 Table of correction coefficients for carburetor setting Air pressure hPa mmHg Zero 32 10 50 15 59 20 68 25 77 30 86 35 95 40 104 Air temperature C F Altitude 220 722 165 0 338 1 109 396 CH 453 1 486 512 1 680 570 1 870 629 2 064 688 2 257 747 2 451 807 2 648 867 2 845 928 3 045 989 3 245 1 050 3 445 1 111 3 645 1 173 3 848 1 236 4 055 1 299 4 262 1 362 4 469 1 425 4 675 1 489 4 885 1 554 5 099 1 1 SETTING H Cc lt a EC71H040 Other setting parts Power jet Power jet is not basically changed Since the areas of the main jet and main nozzle overlap each other special knowledge is required for a setting change A larger size results in a richer mixture and a smaller size in a leaner mixture zech Factory set power jet DO Pilot jet The pilot jet is used in relation to the engine response at small throttle opening This is changed when the main nozzle setting is not enough A larger size results in a richer mixture and a sm
126. istance from TDC VA Ignition timing 2 2 4 mm 0 094 in D ei BATTERY INSPECTION 3 43 6 Check e Ignition timing Punch mark on rotor should be aligned with punch mark on stator Not aligned Adjust NOTE Be sure to use the punch mark F1 7 Adjust e Ignition timing Adjustment steps e Loosen the screws stator e Align the punch marks by turning the stator e Tighten the screws stator Ny Screw stator 7 Nm 0 7 m ekg 5 8 ft lb EC375000 BATTERY INSPECTION AWARNING To prevent danger read the battery label carefully before handling the battery 1 Connect the checking lead supplying parts to the power supply coupler 2 Check e Battery voltage Out of specification Replace Tester lead Red lead Tester lead Black lead Tester selector Battery voltage ge position Wi 12 5V or more DCV 20 INSP Q RECHARGING BATTERY 3 44 EC376000 RECHARGING BATTERY AWARNING e Keep the battery away from fire e When charging the battery be sure to remove it from the chassis and use the checking lead supplying parts e Be sure to use the specific charging cur rent and voltage when charging the bat tery e Do not quick charge the battery e For battery replacement be sure to use a sealed type specified for the TZ250 NOTE Battery can be recharged using either an MF battery devoted charger or auto
127. ivetter e Rivet the end of the chain joint using a chain rivetter e After rivetting the chain joint make sure its movement is smooth 8 Lubricate e Drive chain Drive chain lubricant SAE 30 50W motor oil or chain lubricants suitable for O ring chains EC36A042 DRIVE CHAIN SLACK ADJUSTMENT 1 Hold the machine on upright position by placing the suitable stand 2 Check NO 7H e Drive chain slack ai oe 9 Sg Out of specification Adjust p VAA Drive chain slack IN PA 40 50 mm 1 6 2 0 in 3 24 INSP Q DRIVE CHAIN SLACK ADJUSTMENT 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 chain slack with rear wheel in this tight chain position 3 Adjust e Drive chain slack Drive chain slack adjustment steps e Loosen the axle nut and locknuts e Adjust chain slack by turning the adjusters To tighten Turn adjuster counter clockwise To loosen Turn adjuster clockwise e Turm each adjuster exactly the same amount to maintain correct axle alignment There are marks on each side of chain puller alignment NOTE Turn the adjuster so that the chain is in line with the sprocket as viewed from the rear CAUTION Too small chain slack will overload the engine and other vital parts keep the slack within the specified l
128. k breather hose CAUTION In this installation make sure the arrow faces the fuel tank and also downward EC15X000 BATTERY The battery is provided as power supply for the electric parts Except when the machine is run disconnect the power supply coupler of the wireharness to prevent battery discharge CH CONTROL FUNCTIONS REN EC15Y000 INDUCTION BOX INTAKE SYSTEM The induction boxes and induction guides 2 are provided for the purpose of applying pressure inside the carburetor float chamber and thereby improving the intake performance If the machine is run without them the carbu retor settings will become faulty NOTE mmm Be sure to fix the induction guides with band or hooks so that they do not come off by wind pressure while running EC15Z000 FUEL PUMP The fuel pump is provided in order to pro vide steady supply of fuel even when the pres sure inside the carburetor float chamber becomes higher than inside the fuel tank because of the induction box intake system lf the fuel level is not up to the specified level in the float chamber this pump is activated with an operation sound and stops operating when the specified level is reached CAUTION Do not idle run the fuel pump with no fuel flowing as when the fuel tank is empty or when the fuel cock is OFF It may damage the fuel pump SP CONTROL FUNCTIONS REN G EC15a000 FUEL PUMP STOP SWITCH FUEL PUMP RE
129. ler bearing Front suspension Front fork travel 110 mm 4 33 in d Fork spring free length 212 5 mm 8 37 in 210 5 mm 8 29 in Spring rate STD K 7 00 N mm d 0 700 kg mm 39 Ib in Optional spring No Oil capacity 386 cm 13 6 Imp oz 13 1 US oz Oil level 135 mm 5 31 in lt Min Max gt 80 140 mm 8 15 5 51 in From top of outer tube with inner tube and damper rod fully compressed without spring Oil grade Suspension oil 01 Inner tube outer diameter 41 mm 1 61 in Front fork top end 13 mm 0 51 in Rear suspension Shock absorber travel 53 mm 2 09 in Spring free length 150 mm 5 91 in Fitting length 137 mm 5 39 in lt Min Max gt 133 142 mm 5 24 5 59 in Spring rate STD K 72 N mm 7 2 kg mm 403 bim Optional spring No Enclosed gas pressure 1 200 kPa 12 kg cm 171 psi Swingarm Swingarm free play limit End 1 0 mm 0 04 in Side clearance 0 05 0 35 mm 0 002 0 014 in Wheel Front wheel type Cast wheel Rear wheel type Cast wheel Front rim size Material MT 3 75 x 17 Magnesium Rear rim size Material MT 5 50 x 17 Magnesium Wheel runout limit Radial d 1 0 mm 0 04 in Lateral di 0 5 mm 0 02 in Drive chain Type Manufacturer RKGB520TRU RK EXCEL Number of links 109 links joint Chain slack 40 50 mm 1 6 2 0 in Chain length 10 links d 150 1 mm 5 909 in 2 waer speciricarions SPEC gz Standard Front disc brake Disc outside dia x Thickness Pad thickness Master cylin
130. ll e Thrust plate e Spacer 1 O ring RA NOTE Apply the lithium soap base grease on the O ring 4 63 OIL PUMP EC4J0000 S OIL Pump x 8 Nm 0 8 mekg 5 8 ftelb 7 Nm 0 7 mekg 5 1 ftelb Extend of removal Oil pump removal and disassembly OIL PUMP REMOVAL Preparation for Transmission housing r removal Shift shaft and Stopper lever BEE let Ser Heh Transmission and shift fork Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section Strainer Oil pump cover Outer rotor Inner rotor Dowel pin Plain washer D 915 mm 0 59 in Plain washer D 922 mm 0 87 in Oil pump gear shaft Oil delivery pipe 4 64 on pump ENG INSPECTION EC4J4100 Oil pump 1 Measure e Tip clearance Measure the clearance between the inner rotor and outer rotor Out of limit Replace the inner rotor and outer rotor as a Set EA Tip clearance limit PA 0 15 mm 0 0059 in EC4E4310 Strainer 1 Clean e Strainer Use compressed air NOTE _ SssssSsSSSSSSSSSSSSSSSs e Clean the strainer every 500 km 300 miles e f a lot of metallic dust in noticed disassemble the engine and check EC4J4200 Oil pump gear shaft 1 Inspect e Oil pump gear shaft Wear Damage Replace EC4H4100 Oil delivery pipe 1 Inspect e Oil delivery pipe e O ring Damage Replace e Oil orifice Clogged Blow EC4J5000 ASSEMBLY AND IN
131. m 0 08 in EC36T000 WHEEL INSPECTION 1 Inspect e Wheel runout Elevate the wheel and turn it Abnormal runout Replace D 2 Inspect e Bearing free play Exist play Replace 3 36 Dei ei STEERING HEAD INSPECTION AND ADJUSTMENT EC36U060 STEERING HEAD INSPECTION AND ADJUSTMENT 1 Remove the steering damper at front fork side 2 Elevate the front wheel by placing a suit able stand 3 Check e Steering stem Grasp the bottom of the forks and gently rock the fork assembly back and forth Free play Adjust steering head 4 Check e Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steering ring nut 5 Adjust e Steering ring nut Steering ring nut adjustment steps e Remove the cowling e Remove the reservoir tank and handle crown e Loosen the ring nut using ring nut wrench 2 Ring nut wrench YU 33975 90890 01403 3 37 DS ei STEERING DAMPER ADJUSTMENT e Tighten the ring nut using ring nut wrench NOTE Set the torque wrench to the ring nut wrench so that they form a right angle F YU 33975 90890 01403 N Ring nut initial tightening A 46 Nm 4 6 m kg 33 ft lb e Loosen the ring nut one turn Retighten the ring nut using the ring nut wrench AWARNING Avoid over tightening Ring nut final tightening 1 Nm 0 1 mekg 0 7 ft lb e Check the steering shaft by turning it lock to lock If there is any binding r
132. 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 Tuning 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 infor mation has been complied to provide the mechanic with an easy to read handy reference that con tains 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 and disassembly section 1 An easy to see exploded diagram is provided for removal and disassembly jobs 2 Numbers are given in the order of the jobs in the exploded diagram A number tha
133. mekg 8 0 ftelb NOTE m Install the gasket and crankcase cover left with their recesses facing the rotor PRIMARY DRIVEN GEAR PRIMARY DRIVE GEAR AND BALANCER SHAFT 4 42 ef 3 Install e Balancer weight gear NOTE See Align the punch mark on the balancer shaft with the hole of the balancer weight gear 4 Install e Balancer drive gear NOTE Align the punch marks balancer drive gear with crankshaft and balancer drive gear with balancer weight gear as shown 5 Install e Lock washer 1 e Nut balancer weight gear e Primary drive gear e Plain washer e Bolt primary drive gear NOTE Install the plain washer with its chamfered por tion toward you 6 Tighten e Nut balancer weight gear V 50 Nm 5 0 mekg 36 ftelb NOTE Place an aluminum plate between the teeth of the balancer drive gear and balancer weight gear 7 Bend the lock washer tab A PRIMARY DRIVEN GEAR PRIMARY DRIVE GEAR AND BALANCER SHAFT J 8 Tighten e Bolt primary drive gear V 55 Nm 5 5 mekg 40 ftelb O S CS G el NOTE Groe Place an aluminum plate between the teeth NOFT of the balancer drive gear and balancer S K E eee O i way lt weight gear d CA EC4D5212 Primary driven gear 1 Install e Primary driven gear e Oil pump drive gear To crankcase cover right NOTE
134. mit Replace Ag Wheel runout limit CA Radial 1 0 mm 0 04 in Lateral 0 5 mm 0 02 in 2 Inspect e Bearing Rotate inner race with a finger Rough spot Seizure Replace NOTE Replace the bearings and wheel collar as a set FRONT WHEEL AND REAR WHEEL CHAS 5 4 EC514200 Wheel axle 1 Measure e Wheel axle bends Out of specification Replace Use the dial gauge bt Wheel axle bending limit s 0 25 mm 0 010 in NOTE The bending value is shown by one half of the dial gauge reading AWARNING Do not attempt to straighten a bent axle EC594100 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 b gt k Disc deflection limit _ Standard Rear Tag mm 0 006 in 2 Measure e Brake disc thickness Use the micrometer Out of limit Replace eegen _ Standard Front 5 0 mm 0 20 in 4 5 mm 0 18 in Bear 4 0 mm 0 16 in 3 5 mm 0 14 in 3 Inspect e Brake disc surface Score marks Damege Replace FRONT WHEEL AND REAR WHEEL CHAS 5 5 EC524100 Clutch hub 1 Inspect e Bearing Rotate inner race with a finger Rough spot Seizure Replace EC595000 ASSEMBLY AND INSTALLATION EC515172 Front wheel 1 Install e Bearing right e Spacer e Bearing left
135. mobile battery Using the MF battery devoted charger 1 Remove e Seat e Battery 2 Connect the battery charger for MF bat teries to the battery using the checking lead supplying parts and recharge the battery Battery charger lead Red lead Battery charger lead Black lead Battery charger for MF batteries GS TYPE BC 601 12V y k Charging time 5 hours Voltage when charged 12 8V or more CAUTION Make sure that the red and black leads do not contact each other during recharge INSP Q RECHARGING BATTERY 3 45 Using the automobile battery 1 Remove e Seat e Battery 2 Connect an automobile battery to the battery using the checking lead supply ing parts and recharge the battery Automobile battery lead Red lead Automobile battery lead Black lead 3 hours ox Charge time Voltage when charged 12 8V or more or 12 5V or more Voltage of the automobile battery for power supply 12 8 13 8V maximum 14 9V NOTE SSS If the battery is recharging using an automobile battery the charge may not exceed 12 8V Then 12 5V or more will be OK CAUTION e For an automobile battery for supply use a battery with a capacity of 12V20Ah or more with a voltage 12 8 to 13 2 e During the battery recharge do not recharge the power supply battery by starting or running the engine e Connect only one battery fo
136. more than specified pressure e Radiator should be filled fully 4 Inspect e Pressure Impossible to maintain the specified pres sure for 10 seconds gt Repair e Radiator e Radiator hose joint Coolant leakage Repair or replace e Radiator hose Swelling Replace EC358000 CLUTCH CARE NOTE This machine is equipped with a dry type clutch Be sure to clean with solvent or replace if grease or oil contacts either clutch or friction plates CLUTCH ADJUSTMENT PS ei THROTTLE CABLE ADJUSTMENT EC359001 CLUTCH ADJUSTMENT 1 Check e Clutch lever free play Gi Out of specification Adjust EA Clutch lever free play PA 2 3 mm 0 08 0 12 in 2 Adjust e Clutch lever free play Clutch lever free play adjustment steps e Loosen the locknut e Turn the adjuster until free play is within the specified limits e Tighten the locknut NOTE After adjustment check proper operation of clutch lever EC35A040 THROTTLE CABLE ADJUSTMENT 1 Check e Throttle grip free play Out of specification Adjust EA Throttle grip free play fA 2 4 mm 0 08 0 16 in 2 Remove e Lower cowl e Fuel tank e Induction guide right cylinder 3 Loosen the screw right carburetor joint clamp then take out the carburetor 3 10 DS ei STARTER CABLE ADJUSTMENT 4 Adjust e Throttle grip free play Throttle grip free play adjustment steps e Loosen the
137. n about 10 km 6 miles While running in this way get an idea of the riding position and approximate set tings 7 Go back to the pit again check the machine fully for looseness leakage and other fail ures in installation especially for loose cables and wires excessive brake free play and a chain slack Also make adjust ment for a riding position according to your preference CH STARTING AND BREAK IN REN CAUTION After the break in or before each race you must check the entire machine for loose fit tings and fasteners as per TORQUE CHECK POINTS Tighten all such fasteners as required 8 Increase the engine speed up to 10 000 r min and run about 10 km 6 miles 9 Increase the engine speed up to 11 000 r min and run about 10 km 6 miles 10 Increase the engine speed up to 12 000 r min and run about 10 km 6 miles Then do the plug chop Check the piston head for burning to see if there is any problem Refer to SETTING section in the CHAPTER 7 Run about 10 km 6 miles in a usual man ner Then do the plug chop Check the pis ton head for burning to see if there is any problem 1 EC195001 BREAKING IN AFTER REPLACEMENT After a part is replaced with a new one it is necessary to break it in as in a new machine This is required especially when the following engine related parts are replaced Cylinder Piston Piston ring eCrankshaft Clutch Transmission gear eS
138. nd check for any difference in engine revolutions If no difference is noticed use a main jet with a much smaller calibration number Example 560 540 Factory set main jet 580 2 Checking of spark plug and piston for dis coloration Repeat the adjustment in the above 1 several times If the engine begins to run at more than 12 000 rom at full throttle pro ceed to the spark plug chopping step refer to P7 9 to check for the discoloration of the spark plug s and piston s Refer to the photo for judgment on the dis coloration As a novice will find it difficult to determine how much smaller number main jet can be used just by looking at discoloration he should consult an experienced person for his own experience too Whether the setting is proper or not can be judged by engine revolutions Approximate criteria for such judgment are given below on condition that the sec ondary reduction ratio is fit for conditions of the circuit 13 000 rom in 1st and 2nd 12 500 rom in 5th and 6th Normal Over burned too lean Oil fouled too rich 3 Adjustment of main nozzle The main nozzle adjustment follows the completion of the adjustment of the main jet Check that engine revolutions smoothly respond to throttle opening from where throttle is about to be opened to 1 2 throttle opening Use a main nozzle of a smaller size if engine revolutions appear to falter at the beginning of throttle open
139. nd radiator NOTE Make any necessary repairs before the machine is stored GENERAL SPECIFICATIONS SPEC SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name TZ250M1 USA TZ250 M OTHERS Model code number 5KE1 Dimensions Overall length 1 955 mm 77 0 in Overall width 650 mm 25 6 in Overall height 1 083 mm 42 6 in Seat height 788 mm 31 0 in Wheelbase 1 342 mm 52 8 in Minimum ground clearance 112 mm 4 4 in Basic weight With oil and full fuel tank 119 5 kg 263 Ib Engine Engine type Liquid cooled 2 stroke gasoline Cylinder arrangement V type 2 cylinder Displacement 249 cm 8 76 Imp oz 8 42 US oz Bore x Stroke 54 lt 54 5 mm 2 126 X 2 146 in Compression ratio 7 2 1 Starting system Push to start Lubrication system Premix 30 1 Castrol A747 Oil type or grade 2 Cycle Transmission oil Castrol R30 Periodic oil change 0 5 L 0 44 Imp qt 0 53 US qt Total amount 0 5 L 0 44 Imp qt 0 53 US qt Cooling water capacity including all routes 1 4 L 1 23 Imp qt 1 48 US qt Except for AUS Premium unleaded fuel with a research octane number of 95 or higher For AUS Unleaded fuel only Tank capacity 23 0 L 5 06 Imp gal 6 08 US gal Carburetor Type Manufacturer TMXx38 MIKUNI Spark plug Type Manufacturer R6179A 105P NGK Gap 0 5 0 6 mm 0 020 0 024 in Clutch type Dry multiple disc 2 1 GENERAL SPECIFICATIONS SPEC vs Transmission primar
140. nd shaft with supplying parts Insert the stand shaft through the hole of the mainstand and rear wheel axle Be sure to install the clip in the end of the stand shaft AWARNING e Never apply additional force to the main stand e Remove this mainstand before starting out EC15R001 DETACHABLE SIDESTAND This sidestand is used to support only the machine when standing or transporting it AWARNING e Never apply additional force to the side stand e Remove this sidestand before starting out EC15T003 FIRE RETARDANT MATERIAL For racing be sure to fill the fuel tank com pletely with fire retardant material with supply ing parts EC15b000 COUPLER FOR SPEED SHIFT lf an after marked speed shift is installed the coupler should be used NOTE If the speed shift is not installed be sure to fix the coupler to the wireharness using a vinyl tape for protection against water entry as well because if the coupler contacts the frame sparks will be shut off causing the engine to stop CASTROL A747 a CH FUEL AND ENGINE MIXING OIL REN EC160040 FUEL AND ENGINE MIXING OIL Mix oil with the gas at the ratio specified below Always use fresh name brand gasoline and mix the oil and gas the day of the race Do not use premix that is more than a few hours old Recommended fuel Except for AUS Premium unleaded fuel with a research octane number of 95 or higher For AUS U
141. ng s 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 light weight lithium base grease to the seal lip s Oil the bearings liberally when installing CAUTION Do not use compressed air to spin the bear PAN ings dry This causes damage to the bear i N ing surfaces 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 make sure that the sharp edged corner is posi tioned opposite to the thrust it receives See the sectional view 4 Shaft 1 4 Lu Jee CH CHECKING OF CONNECTION REN G 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 d Pull the lead to check that it will not come off 5 If the terminal comes off bend up the pin and reinsert the terminal into the connector 6 Connect e Connector NOTE The two connectors click together 7 Check for continuity with a tester NOTE e H there in no continuity clean the terminals e Be sure to perform the steps 1 to 7 listed above when checking
142. nleaded fuel only NOTE Except for AUS 1 If knocking or pinging occurs use a differ ent brand of gasoline or higher octane grade 2 If unleaded gasoline is not available then leaded gasoline can be used CAUTION Never mix two types of oil in the same batch clotting of the oil could result If you wish to change oil types be sure to drain the fuel tank and the carburetor float bowl of old premix prior to filling with the new type Fuel tank capacity 23 0 L 5 06 Imp gal 6 08 US gal Mixing oil Recommended oil Castrol A747 Mixing ratio 30 1 INFORMATION BEFORE CH PRE OPERATION kad GES EC170011 INFORMATION BEFORE PRE OPERATION 1 The brake disc is coated with a rust inhibitor Before riding the machine thor oughly remove it using a lacquer thinner AWARNING e LACQUER THINNER IS HIGHLY FLAMMA BLE Always turn off the engine while using lacquer thinner Take care not to spill any lacquer thinner on the engine or exhaust system Never use it in the vicinity of an open flame or while smoking e LACQUER THINNER CAN CAUSE INJURY Always use lacquer thinner in a well venti lated area If you should swallow some lacquer thinner inhale excess lacquer thinner vapors or allow any lacquer thin ner to get into your eyes contact a doctor immediately NOTE e When the machine is not in use for a long time apply a rust inhibitor to the brake disc eAfter riding in
143. nnected to battery Continuous while connected to the battery Replace Not continuous while not connected to the bat tery Replace 3 Inspect e Fuel pump relay resistance Out of specification Replace Tester lead gt Green lead Tester lead Black lead OL Fuel pump relay Tester selector resistance position 72 80 Q at EC674000 FUEL PUMP OPERATION CAUTION Do not operate the fuel pump on an empty fuel tank because it may damage the pump 1 Loosen the drain plug carburetor and drain the fuel from the float chamber FUEL Pump system ELEC 6 19 2 Install e Drain plug 3 Turn the fuel cock to ON 4 Inspect e Fuel pump Operation sound when the main switch is moved to RUN OK EC675000 FUEL PUMP COIL INSPECTION 1 Disconnect the fuel pump coupler 2 Inspect e Fuel pump coil resistance Out of specification Replace Tester lead Black Blue lead Tester lead Black lead SI Fuel pump coil Tester selector resistance position 1 3 Oat EC676000 FUEL PUMP INSPECTION CAUTION Do not operate the fuel pump on an empty fuel tank because it may damage the pump 1 Remove the fuel outlet hose from the fuel pump 2 Connect another plastic hose to the fuel pump and place its other end into a con tainer FUEL Pump system ELEC 3 Turn the fuel cock to ON 4 Disconnect the fuel pump coupler 5 Connec
144. nt The adjuster may be damaged EC36P040 REAR SHOCK ABSORBER COMPRESSION DAMPING FORCE ADJUSTMENT 1 Adjust e Compression damping force By turning the adjuster Stiffer Increase the compression damping force Turn the adjuster in Softer Decrease the compression damping force Turn the adjuster out ON Extent of adjustment Fully turned in Fully turned out position position e STANDARD POSITION This is the position which is back by the spe cific number of clicks from the fully turned in position VA Standard position PA 12 clicks out NOTE _ _ _ _ Fully turn in the adjuster and then turn it out Specify the position in which the first click is heard as the zero position If a click is heard just when the adjuster is fully turned in this position is zero CAUTION ____ O O Y Oo Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged TIRE PRESSURE CHECK TIRE INSPECTION INSP Q WHEEL INSPECTION EC36Q011 TIRE PRESSURE CHECK 1 Measure e ire pressure Out of specification Adjust ON Standard tire pressure Fon 200 kPa 200 kPa 2 0 kg cm 29 psi 2 0 kg cm 29 psi NOTE Check the tire while it is cold Gi 3 EH Q M RSA i K A aes Ren Ge Air gauge EC36R000 TIRE INSPECTION 1 Inspect e Tire surfaces Wear Damage Replace Se Minimum tire tread depth 2 m
145. o SHIFT SHAFT section ENGINE REMOVAL KR A yy A Lo ECAN QS V 30 Nm 3 0 mekg 22 ftelb V 23 Nm 2 3 mekg 17 ftelb Extend of removal Engine removal 1 2 Pinch bolt engine mounting collar Only loosening Nut engine mounting bolt Engine mounting adjust bolt Engine mounting bolt Rete to REMOVAL POINTS Engine Engine bracket 2 3 4 5 6 4 72 ENGINE REMOVAL ENG 4 73 EC4M6000 HANDLING NOTE When the frame alone is stored insert the engine mounting collars into the brackets and tighten them with the pinch bolts to 6 Nm 0 6 mekg 4 3 ftelb in order to prevent the brackets from damage EC4M3000 REMOVAL POINTS EC4M3331 Engine removal 1 Loosen e Engine mounting adjust bolt NOTE Use the adjust bolt wrench to loosen the engine mounting adjust bolt 2 Remove e Engine mounting bolt e Engine NOTE e Before removing the engine make sure that the couplers hoses and cables are discon nected e Remove the engine by lowering it with a jack 8 EC4M5000 ASSEMBLY AND INSTALLATION EC4M5190 Engine installation 1 Install e Engine bracket e Bolt engine bracket NOTE e Install the engine brackets with their OUT SIDE marks facing outward e Tighten the bolts engine brackets to 23 Nm 2 3 mekg 17 ftelb then loosen them by 1 4 turn for temporary fitting ENGI
146. o the crankcase Cavity CAUTION e When installing the piston pin clip use the hand so that it may not be distorted e Do not allow the clip open ends to meet the piston pin slot EC475351 Cylinder head and cylinder 1 Apply e Engine oil To piston piston ring and cylinder inner surface 2 Install e Cylinder CAUTION Make sure the piston ring is properly posi tioned Install the cylinder with one hand while compressing the piston ring with the other hand NOTE After installing check the smooth movement of the piston 3 Install e Nut cylinder NOTE Tighten the nuts in stages using a crisscross pattern ef CYLINDER HEAD CYLINDER AND PISTON ENG 4 Install O ring ERA e Dowel pin NOTE Apply the lithium soap base grease on the O rings 5 Install e Cylinder head e Copper washer e Bolt cylinder head v 11 Nm 1 1 mekg 8 0 ftelb NO TE e Apply the lithium soap base grease on the thread and contact surface of the bolt cylin der head e Tighten the bolts cylinder head in stage using a crisscross pattern 6 Install e YPVS cable 2 4 open side e YPVS cable 1 3 close side To cable stay NO Te Install the open side cables sleeve cables to the O marked side of the cable stay LA 4 7 Connect e YPVS cable 2 4 open side e YPVS cable 1 3 close side To v
147. of car buretor setting P7 2 Next is an explanation of how to select a main jet to deal with changes in weather conditions by means of a correction coefficient NOTE e Before this correction coefficient can be used satisfactory carburetor setting must have been made e This correction coefficient can not be used if there is a change in specification e g igni tion timing compression ratio etc Illustration Suppose the best setting was represented by a 450 main jet at an air pressure of 1013 hPa 760 mmHg and an air temperature of 20 C 68 F in the previous riding In this riding there has been a substantial change in conditions namely an air pressure of 1007 hPa 755 mmHg and an air tempera ture of 30 C 86 F 1 Refer to a table of correction coefficients P7 6 to find the correction coefficient for the previous riding The correction coefficient A 100 0 2 Find the correction coefficient for this time The correction coefficient B 96 1 3 Use the following equation to calculate the size of a main jet needed in this particular case Previous main jet size X B A Currently required main jet size 450 X 96 1 100 432 5 Thus a 430 main jet can be selected SETTING TUN E CAUTION If a change in conditions require a main jet of a larger size use the size to which 20 is added for safety NOTE e Since this correction coefficient table lacks a column for humidity it
148. on the compression or the expansion side it results in less smooth movement so do not depart too far from the standard settings e Adjust the machine height in an increment of mm in e H you lose your way while doing the setting go back to the standard settings e Oil level adjustment in the front fork produces a greater effect in further stroke than in mid stroke Increase or decrease the oil level in an approximately 5 10 mm 0 20 0 39 in inter val Tire and machine s posture lf a non designated tire is used the difference in radius between the front and the rear tire may affect the machine s posture To keep the machine in a proper posture adjust the front fork top end or seat height Basically with a larger radius tire lower the machine s posture and vice versa Front brand 3 10 4 80 R17 DUNLOP KR106 About 1 875 mm 73 8 in About 298 5 mm 11 8 in 13 mm 0 51 in 120 70 R17 DUNLOP MR977 About 1 885 mm 74 2 in About 300 mm 11 8 in 11 5 mm 0 45 in Designated tire Rear Tire circumference Tire radius Seat height brand 165 55 R17 l DUNLOP KR108 About 1 975 mm 77 8 in About 314 5 mm 12 4 in 24 mm 0 94 in 165 50 R17 DUNLOP KR244 About 1 957 mm 77 0 in About 311 5 mm 12 3 in 25 5 mm 1 00 in Designated tire Example lf the front tire radius is 1 mm 0 04 in larger lower the front posture by 1 mm 0 04 in by increasiry the front fork top end b
149. ood switch 1b ok N d Check fuel pump relay a 1b ok No good No good Check fuel pump operation Fuel pump coil ab o No good 1 marked Refer to IGNITION SYSTEM section 2 marked Refer to BATTERY INSPECTION section in the CHAPTER 3 NOTE e Remove the following parts before inspection 1 Cowling 3 Seat 2 Fuel tank 4 Induction cap left cylinder e Use 12V battery in this inspection e Use the following special tool in this inspection Pocket tester YU 03112 90890 03112 6 16 FUEL Pump system ELEC EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check e Couplers and leads connection Huet Dust Looseness Short circuit Repair or replace EC672000 FUEL PUMP STOP SWITCH INSPECTION 1 Remove e Fuel pump stop switch 2 Inspect e Fuel pump stop switch conduct To inspect tilt the fuel pump stop switch to the right and left Tester lead Black lead Tester lead Black lead C B B Tester selector QM position ees Norma Continuous if normal Replace Not continuous if tilted 90 Replace EC673000 FUEL PUMP RELAY INSPECTION 1 Remove e Fuel pump relay 6 17 FUEL Pump system ELEC 6 18 2 Inspect e Fuel pump relay conduct Use 12V battery Battery lead gt Black lead Battery lead gt Green lead Tester lead Black Blue lead Gi Tester lead gt Brown lead Co
150. plug gap SCH 0 5 0 6 mm 0 020 0 024 in Standard spark plug R6179A 105P 4 Clean the plug with a spark plug cleaner if necessary 5 Tighten e Spark plug 1 9 Nm 1 9 mekg 13 ftelb NOTE e Before installing a spark plug clean the gas ket surface and plug surface Finger tighten the spark plug before torquing to specification INS e IGNITION TIMING CHECK 3 42 EC372070 IGNITION TIMING CHECK NOTE e The right pick up coil is provided so that ignition timing can be set for both cylinders by adjusting for the left cylinder only Therefore do not loosen the screws right pick up coil 2 e When the portion of the right pick up coil aligns with the punch mark on the stator the right pick up coil forms an angle of 90 with the left pick up coil indicating that the ignition timing is the same for both cylinders 1 Remove e Cowling e Fuel tank e Spark plugs left and right cylinder 2 Attach e Dial gauge e Dial gauge stand To left cylinder head Dial gauge YU 03097 90890 01252 Stand YU 01256 3 Rotate the magneto rotor until the piston reaches top dead center TDC When this happens the needle on the dial gauge will stop and reverse directions even though the rotor is being turned in the same direc tion 4 Set the dial gauge to zero at TDC 5 From TDC rotate the rotor clockwise until the dial gauge indicates that the piston is at a specified d
151. pped with a dry type clutch Be sure to clean with solvent or replace if grease or oil contacts either clutch or friction plates CLUTCH ENG 9 Install e Push rod e Ball NOTE Apply the lithium soap base grease on the push rod and ball 10 Install e Pressure plate NOTE Align the arrow marks on the pressure plate the arrow marks hi on the clutch boss 11 Install e Clutch spring e Screw clutch spring 9 Nm 0 9 mekg 6 5 ftelb NOTE Tighten the screws in stages using a criss cross pattern 12 Check e Push lever position Push the push lever upward until it stops I 9 O OO With the push lever in this position the rear ay Se D te 5 edge of the push lever should be aligned ER Ka X j NT with the center of the push lever installation gt bolt oS Not aligned Adjust f J A 13 Adjust e Push lever position Push lever position adjustment steps e Loosen the locknut e Turn the adjuster to align the rear edge of the push lever with the center of the push lever installation bolt e Tighten the locknut Ny Locknut 6 Nm 0 6 m ekg 4 3 ft lb 4 37 PRIMARY DRIVEN GEAR PRIMARY DRIVE GEAR AND BALANCER SHAFT ef EC4D0002 PRIMARY DRIVEN GEAR PRIMARY DRIVE GEAR AND BALANCER SHAFT EC4D8000 PRIMARY DRIVEN GEAR 11 Nm 1 1 mekg 8 0 ftelb Extend of removal OO Primary driven gear removal PRIMARY DRIV
152. r lead Red lead Tester lead Black lead Charging Tester selector voltage position 14 2 15 2 V at 5 000 r min sein EC683000 VOLTAGE REGULATOR INSPECTION 1 Check e Voltage regulator conduct Use pocket tester tester selection posi tion Q X 1 Tester Wi W2 R B olojoje lead WI OI indicates continuity and x non continu ity In case of continuity for x Replace In case of non continuity for O Replace CHARGING system ELEC 6 9 NOTE If nothing is wrong with the continuity of the voltage regulator and with all the others in the charging system replace the voltage regulator ypvs system ELEC EC640000 YPVS SYSTEM EC641020 INSPECTION STEPS lf the servomotor will not turn use the following inspection steps No good Replace fuse and 1 Check fuse check wireharness N d 2 Check battery ed Recharge or replace ab o Check each coupler and No good Repair or replace wire connection JC o N d 1 Check main switch a ib o Check servomotor No good No good SE OK Replace CDI unit 1 marked Refer to IGNITION SYSTEM section 2 marked Refer to BATTERY INSPECTION section in the CHAPTER 3 NOTE e Remove the following parts before inspection 1 Cowling 2 Fuel tank e Use 12V battery in this inspection e Use the following special tool in this inspection e GA Pocket tester YU
153. r DOO TTT Bent fin Repair replace EC455000 ASSEMBLY AND INSTALLATION EC455140 Radiator 1 Install e Radiator e Bolt radiator e Nut radiator v 7 Nm 0 7 mekg 5 1 ftelb 4 5 4 6 RADIATOR ENG d 2 Install e Radiator breather hose 1 e Radiator hose 3 gt 2 Nm 0 2 mekg 1 4 ftelb e Radiator hose 4 e Radiator hose 2 gt 2 Nm 0 2 mekg 1 4 ftelb e Thermo unit ER 1 Nm 1 1 mekg 8 0 ft lb e Water temperature gauge lead NOTE e Insert the end of the radiator breather hose into the frame Refer to CONTROL FUNC TION section in the CHAPTER 1 e Before applying LOCTITE wipe off dirt on the thread of the thermo unit and its recepta cle on the radiator e Apply LOCTITE to half of the thermo unit thread portion on the coupler side so as to prevent LOCTITE from protruding into the radiator CARBURETOR AND REED VALVE EC460000 S amp S CARBURETOR AND REED VALVE y 2 Nm 0 2 mekg 1 4 ftelb V 2 Nm 0 2 mekg 1 4 ftelb 1 Nm 0 1 mekg 0 7 ftelb CARBURETOR AND REED VALVE REMOVAL Preparation for Cowling induction guide Refer to COWLING INDUCTION removal and fuel tank GUIDE SEAT AND FUEL TANK section Spark plug cap left cylinder Radiator hose 3 Refer to RADIATOR section Bolt radiator stay Shift the radiator Servicing the forward right cylinder Tension spring
154. r recharge COWLING INDUCTION GUIDE SEAT AND FUEL TANK EC400000 ENGINE EC4V0000 SS COWLING INDUCTION GUIDE SEAT AND FUEL TANK 4 Nm 0 4 mekg 2 9 ftelb 8 Nm 0 8 mekg 5 8 ftelb Extend of removal Cowling removal 2 Induction guide removal 3 Seat removal GO Fuel tank removal COWLING INDUCTION GUIDE SEAT AND FUEL TANK REMOVAL Preparation for Turn the fuel cock to OFF removal Disconnect the fuel hose Clip lower cowl Quick fastener Lower cowl Clip upper cowl Upper cowl Induction guide left cylinder Induction guide right cylinder Screw seat Seat Fuel tank breather hose Refer to REMOVAL POINTS Clip fuel tank Fuel tank 1 2 3 4 St 6 7 8 9 4 1 COWLING INDUCTION GUIDE SEAT AND FUEL TANK ENG 4 2 EC4V3000 REMOVAL POINTS EC4U3100 Fuel tank breather hose 1 Disconnect e Fuel tank breather hose NOTE Disconnect the fuel tank breather hose with the valve joint remaining on the fuel tank side so as to prevent fuel from spurting out by the tank inner pressure EXHAUST PIPE AND SILENCER EC4S0000 S amp S EXHAUST PIPE AND SILENCER 11 Nm 1 1 mekg 8 0 ftelb Ny eA Qs 11 Nm 1 1 mekg 8 0 ftelb 21 Nm 2 1 mekg 15 ftelb Extend of removal Exhaust pipe removal Silencer removal EXHAUST PIPE AND SILENCER REMOVAL Preparation for Lower cowl Refer to COWLING INDUCTION
155. rear and adapter Brake caliper front and rear and adapter Front brake caliper and front fork Front brake union bolt and bleed screw Brake caliper front and rear and pad pin Brake caliper front and rear and bleed screw Front wheel axle and nut Front wheel axle holder Front brake disc and wheel hub Footrest bracket and frame Footrest bracket and plate left and right Footrest and footrest bracket Brake pedal and master cylinder Rear master cylinder and footrest bracket Rear master cylinder and reservoir connector Rear brake reservoir tank and bolt rear frame Rear brake caliper and caliper bracket NOTE 1 then loosen the ring nut one turn M8 x 1 25 M8 x 1 25 M22 x 1 0 M6 x1 0 M25 x 1 0 M8 x 1 25 M6 x1 0 M6 x1 0 M6 x1 0 M8 x 1 25 M5 x0 8 M6 xX 1 0 M 6 M 6 x 1 0 x 1 0 M6 x1 0 MA x0 7 M44 x 1 0 M12 x 1 25 M12 x 1 25 M6 x1 0 M6 x1 0 M10 x 1 25 M10 x 1 25 M10 x 1 25 M10 x 1 25 M8 x 1 25 M10 x 1 25 M8 x1 25 M18 x 1 5 M6 x1 0 M8 x 1 25 M8 x 1 25 M5 x0 8 M6 x1 0 M6 x1 0 M8 x 1 25 MA x0 7 M6 x1 0 M8 x1 25 2 Retighten the ring nut 1 Nm 0 1 mekg 0 7 ftelb 2 9 Nya Mi sch sch ch sch Ra AD 1 1 1 2 2 2 2 4 2 2 VA b i AUW hi A pe hi E P waer speciricarions SPEC gz Tightening torque torque we mkg feb 20 23 80 7 18 5 10 11 2 0 2 3 8 0 0 7 Refer to NOTE 1 8 0 5 1 0 1 1 2 0 0 5 0 8 0 5 0 1 0 6 0 2 2 3 4
156. rter jet Power jet Float height Reed valve Thickness reed valve 1 reed valve 2 Valve stopper height Valve bending limit Cooling Radiator core size Width Height Thickness Radiator cap opening pressure Radiator capacity Water pump Type TMXx38 MIKUNI SKE1 OOL 5KE1 OOR 580 6EGJ4 63 G A 5 0 30 1 1 2 1 5 80 55 6 0 7 0 mm 0 24 0 28 in 0 42 mm 0 017 in 0 34 mm 0 013 in 6 5 6 9 mm 0 256 0 272 in 380 mm 14 96 in 198 mm 7 80 in 24 mm 0 94 in 95 125 kPa 0 95 1 25 kg cm 13 5 17 8 psi 0 5 L 0 44 Imp at 0 53 US at Single suction centrifugal pump 2 4 0 2 mm 0 008 in EE PPP wala eg Spark plug M14S x 1 25 Cylinder head bolt M6 x1 0 i E we Cylinder nut M8 x 1 25 20 2 0 14 stud M8 xX 1 25 15 15 11 Power valve Cover M5 x0 8 8 4 0 4 2 9 Holder power valve M5 x 0 8 2 9 0 9 6 5 Pulley M5 x0 8 2 4 0 4 2 9 Cable stay M5 x0 8 4 7 0 7 5 1 Air bleed bolt cylinder MG x1 0 2 12 1 2 8 7 Balance weight gear M14 x 1 0 1 50 5 0 36 Water pump housing cover M6 x1 0 5 11 1 1 8 0 Radiator M6 x1 0 3 7 0 7 Sa Radiator and thermo unit M16 x 1 5 1 11 1 1 8 0 Radiator hose clamp 6 2 0 2 1 4 Oil pump cover M5 x0 8 3 8 0 8 5 8 Oil strainer M6 x 1 0 4 7 0 7 5 1 Carburetor joint M6 x 1 0 9 11 1 1 8 0 Clamp carburetor joint MA x0 7 2 2 0 2 1 4 Reed valve M3 x0 5 12 1 0 1 0 7 Mixing chamber top MA x0 7 2 2 0 2 1 4 Exhaust pipe M8 x 1 25 2 21 2 1 15 Silencer MG x1 0 4 11 1 1
157. ry to check the shift fork shift cam shift lever and gears But if there are in good condition the dog clearance should be inspected 1 Install the transmission shift cam and shift fork into the transmission housing 2 Position the transmission is neutral Pull the main axle toward the clutch side 4 Bring the 3rd 4th pinion gear into light contact with the 6th pinion gear to the extent that they are not engaged and mea sure the clearance between 3rd 4th pin ion gear and 6th pinion gear Bring the 3rd 4th pinion gear into light con tact with the 5th pinion gear to the extent that they are not engaged and measure the clearance between 3rd 4th pinion gear and 5th pinion gear EA Dog clearance f 0 5 mm 0 020 in or more Out of specification or clearance and are not equal Replace the shim Choose the shim by the following chart Shim STD t 1 0 mm 90201 253K0 0 039 in t 0 9 mm 90201 256E6 0 035 in Q EC4H4600 Bearing 1 Inspect e Bearing Rotate inner race with a finger Rough spot Seizure Replace 4 59 TRANSMISSION SHIFT CAM AND SHIFT FORK ENG 4 60 EC4H4801 Shift fork shift cam and segment 1 Inspect e Shift fork Wear Damage Scratches Replace 2 Inspect e Shift cam e Segment e Guide bar Bend Wear Damage Replace 3 Check e Shift fork movement On its guide bar Unsmooth operation Repl
158. s and dust seals by pushing them with a finger CAUTION e Never attempt to pry out piston seals and dust seals e Do not loosen the bolts and nuts AWARNING Replace the piston seals and dust seals whenever a caliper is disassembled Front Rear 9 15 FRONT BRAKE AND REAR BRAKE CHAS 5 16 EC5A4000 INSPECTION EC534112 Master cylinder 1 Inspect e Master cylinder inner surface Wear Scratches Replace master cylin der assembly Stains Clean AWARNING Use only new brake fluid Front Rear 2 Inspect e Diaphragm CO Crack Damage Replace Front Rear 3 Inspect e Master cylinder piston e Master cylinder cup Wear Damage Score marks Replace master cylinder kit Front Rear EC534214 Caliper 1 Inspect e Caliper cylinder inner surface Gi Wear Score marks Replace caliper assembly Front Rear __ S FRONT BRAKE AND REAR BRAKE CHAS 2 Inspect e Caliper piston Wear Score marks Replace caliper pis ton assembly je AWARNING Replace the piston seals and dust seals whenever a caliper is disassembled 20 Si Ke EC534301 Brake hose 1 Inspect e Brake hose Crack Damage Replace EC5A50 ASSEMBLY AND INSTALLATION AWARNING e All internal parts should be cleaned in new brake fluid only e nternal parts should be lubricated with brake fluid when installed e Replace the piston seals and dust seals
159. shaft Clean the contacting surface of the valve cover and cylinder before applying the sealant CAUTION If the engine is started soon sfter reinstalla tion use this quick drying Quick gasket ACC 11001 30 00 or YAMAHA Bond No 4 KL Quick gasket g ACC 11001 05 01 ACC 11001 30 00 YAMAHA Bond No 1215 90890 85505 YAMAHA Bond No 4 90890 05143 CYLINDER HEAD CYLINDER AND PISTON ENG 5 Check e Power valve smooth movement Unsmooth movement Repair or replace EC475270 Piston ring and piston 1 Install e Piston ring NOTE e Take care not to scratch the piston or damage the piston ring e Install the piston ring with its mark N upward e Align the piston ring gap with the pin e After installing the piston ring check the smooth movement of it 2 Install e Gasket cylinder OO e Small end bearing e Dowel pin NOTE e Apply the engine oil on the bearing crank shaft and connecting rod and connecting rod big end washers e Install the gasket with the seal print side toward the crankcase 4 27 D E iS GC CYLINDER HEAD CYLINDER AND PISTON ENG M g 4 28 ef 3 Install e Piston e Piston pin e Piston pin clip Gi NOTE e The arrow on the piston dome must point to exhaust side e Before installing the piston pin clip cover the crankcase with a clean rag to prevent the pis ton pin clip from falling int
160. sition Take some time to allow the engine to warm up IN EC192000 WARMING UP Run the engine at varying speeds 5 000 6 000 r min for 1 2 minutes Fully warm up until the water temperature gauge reads 70 C 158 E or SO CAUTION Do not warm up the engine for extended periods CH STARTING AND BREAK IN REN EC193031 STARTING A WARM ENGINE Do not push the starter lever CHOKE Open the throttle slightly and start the engine CAUTION Observe the following break in procedure during initial operation to ensure optimum performance and avoid engine damage EC194020 BREAK IN PROCEDURES 1 Before starting the engine fill the fuel tank with a break in oil fuel mixture as follows Mixing oil Recommended oil Castrol A747 Mixing ratio 30 1 2 Perform the pre operation checks on the machine 3 Start and warm up the engine Check the operation of the controls and check that the engine comes to a stop when moving the main switch to OFF NOTE During break in mask part of the radiator core so that the water temperature is 55 65 C 131 149 F 4 Operate the machine under 8 000 r min and run on a course about 10 km 6 miles While making a straight line run open the throttle from time to time taking care not to exceed the revolution limit 5 Go back to the pit to check for looseness leakage and other failures in installation 6 Next operate the machine under 9 000 r min and ru
161. ssembly with its figures standing upright Do not make the clamp grip face outside of the chassis Position the reservoir hose with its paint mark upward D Be sure the brake hose is not twisted E Do not cut the end of the clamp ea VW QS J ANA Geer SE 72 62775 ware CZI lt P N L H N L Q N N N O A vi vi lt gt Wass Dees gege 2 16 INSP ei MAINTENANCE INTERVALS 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 NOTE Replace earlier depending on the operating condition Every i ira quired km Check ring end gap After Item _ ec race 500km sch ao PISTON Inspect and clean Replace PISTON PIN SMALL END BEARING Inspect Replace PISTON RING Inspect Replace CYLINDER HEAD Inspect and clean Retighten Remove carbon Check O ring CYLINDER Inspect and clean Replace Retighten YPVS Inspect Retighten CLUTCH 3 e km Inspect score marks Inspect wear Inspect housing friction Inspect and adjust plate clutch plate and Replace spring TRANSMISSION Repl
162. ster lead White lead SI Source coil Tester selector resistance position 2 30 3 5 Q at EC628000 CDI UNIT INSPECTION Check all electrical components If no fault is found replace the CDI unit Then check the electrical components again CHARGING system ELEC CHARGING SYSTEM EC681000 INSPECTION STEPS lf the battery is not charged use the following inspection steps No good Replace fuse and 1 Check fuse check wireharness N d 2 Check battery ed Recharge or replace ab o Check each coupler and No good Repair or replace wire connection ab ok Charging system is good Check charging voltage JL No good No good OK No good Check voltage regulator J 1 marked Refer to IGNITION SYSTEM section 2 marked Refer to BATTERY INSPECTION section in the CHAPTER 3 NOTE e Remove the following parts before inspection 1 Cowling 2 Fuel tank e Use the following special tool in this inspection L GA Pocket tester YU 03112 90890 03112 6 CHARGING system ELEC 6 8 EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check e Couplers and leads connection Huet Dust Looseness Short circuit Repair or replace EC682000 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 resistance check the voltage regulator Teste
163. switch e Main switch holder e Screw main switch holder gt 2 Nm 0 2 mekg 1 4 ftelb e Clutch lever holder e Bolt clutch lever holder v 5 Nm 0 5 mekg 3 6 ftelb MOIE The main switch and clutch lever holder should be installed according to the dimensions shown 12 Install e Clutch cable NOTE Apply the lithium soap base grease on the clutch cable end 13 Install e Handle crown 0 Refer to STEERING section 14 Adjust e Handlebar position VA Handlebar position fx 9 mm 0 35 in lt E 5 44 9 45 HANDLEBAR CHAS 15 Tighten e Pinch bolt handlebar V 7 Nm 0 7 mekg 5 1 ftelb CAUTION Tighten the pinch bolts to specified torpue If torpue too much it may cause the front fork to malfunction 16 Adjust e Clutch lever free play Refer to CLUTCH ADJUSTMENT section in the CHAPTER 3 17 Lock the throttle cables and starter cables using a locking wire Refer to LOCKING WIRE INSTALLATION GUIDE section in the CHAPTER 3 STEERING CHAS EC560000 STEERING EC568000 HANDLE CROWN AND STEERING DAMPER y A y A Extend of removal Handle crown removal 2 Steering damper removal HANDLE CROWN AND STEERING DAMPER REMOVAL Preparation for Hold the machine by placing removal the suitable stand Support the machine securely so there is no danger of it falling over Cowling Refer to COWLING I
164. t 12V battery to the fuel pump cou pler Battery lead Black Blue lead Battery lead gt Black lead 6 Inspect e Fuel pump No fuel flows from the plastic hose gt Replace g s TUNING ENGINE EC711011 Carburetor setting e The role of fuel is not only to produce motive power but also to cool the engine and in the case of a 2 stroke engine to lubricate it Therefore too lean a mixture of air and fuel tends to cause an abnormal combustion e detonation whereas too rich a mixture makes it difficult for the engine to develop its full performance with the result that in some cases the spark plug may be fouled causing the engine to stop running e The richness of the air fuel mixture required for the engine will vary with atmospheric con ditions of the day and therefore the settings of the carburetor must be properly suited to the atmospheric conditions air pressure humidity and temperature e As a basic setting method only the factory set main jet is first changed to check for the dis coloration of the spark plug s and piston s at full throttle in 6th and then the setting is deter mined at mid open throttle X Recording and storing the data on the set tings weather conditions road surface con ditions of the circuit lap times etc will enable quick setting under different condi tions at a later time EC712000 Atmospheric conditions and carburetor setting Air
165. t 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 accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc 5 Extent of removal 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 are given in addi tion to the exploded diagram and job instruction chart cuuron ENG EC4A8100 EC4A3000 CLUTCH HOUSING AND PUSH LEVER AXLE REMOVAL POINTS Clutch boss 1 Remove A d S CH e Nut AE Ei SC Lock washer CR TT s Clutch bose C WN ez NOTE D A a AS Straighten the lock washer tab and use the XC a I clutch holding tool to hold the clutch B At j as K 11 gt ai IA el x boss eer Ze d S S ZS 21 a X Z Clutch holding tool Na POA N Veg Q YM 91042 ke KOY 6 90890 04086 S 1 RWA E EE For USA and CDN Except for USA and CDN INSPECTION EC484100 Clutch housing and boss 1 Inspect e Clutch housing Cracks Wear Damage Replace e Clutch boss Scoring Wear Damage Replace Push lever axle removal Order Part name i Remarks Clutch housing CLUTCH HOUSING AND 1 Check
166. tainer under its end e Loosen the bleed screw and push the caliper piston in CAUTION Do not reuse the drained brake fluid e Tighten the bleed screw Bleed screw 6 Nm 0 6 m ekg 4 3 ft lb e Install the brake pads pad support 0 pad pin 4 and cotter pin NOTE e Always use a new cotter pin e Temporarily tighten the pad pin at this point e Install the caliper 3 and tighten the pad pin 4 Bolt caliper 23 Nm 2 3 mekg 17 ft lb Pad pin 18 Nm 1 8 mekg 13 ft lb 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 3 21 BRAKE FLUID LEVEL INSPECTION INS e SPROCKETS INSPECTION 3 22 EC367001 BRAKE FLUID LEVEL INSPECTION 1 Place the master cylinder so that its top is in a horizontal position 2 Inspect e Brake fluid level Fluid at lower level Fill up a Lower level Front Rear Recommended brake fluid DOT 4 AWARNING 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 plastic p
167. tall e Power jet To float chamber CAUTION Do not tighten the power jet too hard or you may not remove it when checking and replacing it 6 Install e Float chamber 1 e Screw float chamber CAUTION Do not confuse the left and right float chambers in installation because they are different from each other The overflow hole is in the bottom of the float chamber for the left cylinder and for the right one in the side 7 Install e Air vent hose e Joint 8 Install e Induction cap right cylinder only e Starter plunger To carburetor NOTE VE Install the stater plunger right cylinder after passing it through the hole of the induction cap Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 CARBURETOR AND REED VALVE ENG 4 16 9 Install e Collar e Jet needle e Spring guide e Spring e Needle holder To throttle valve 10 Install e Throttle cable e Mixing chamber top e Spring throttle valve e Ring e Throttle valve NOTE e Install the throttle cable right cylinder after passing it through the hole of the induction cap Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 e While compressing the spring connect the throttle cable e Align the projection on the ring with the groove in the needle holder 11 Install e Mixing chamber top e Screw mixing chamber top
168. ter cylinder bracket Master cylinder 1 2 3 4 5 6 T 8 9 O 5 10 FRONT BRAKE AND REAR BRAKE CHAS EC5A8100 REAR BRAKE 7 Nm 0 7 mekg 5 1 ftelb 8 Nm 0 8 mekg 5 8 ft lb 20 Nm 2 0 mekg 14 ftelb gt 6 Nm 0 6 mekg 4 3 ft lb Extend of removal Brake hose removal 2 Caliper removal 3 Master cylinder removal REAR BRAKE REMOVAL AWARNING Preparation for Hold the machine by placing Support the machine securely so there removal the suitable stand is no danger of it falling over Drain the brake fluid Refer to REMOVAL POINTS Brake hose holder Adapter Union bolt Brake hose Pad pin Caliper Brake pedal connecting bolt Reservoir tank Reservoir hose Master cylinder Loosen when disassembling the caliper eck i sch ck sch sch ck sch NS O FRONT BRAKE AND REAR BRAKE CHAS EC5A8200 CALIPER DISASSEMBLY 6 Nm 0 6 mekg 4 3 ftelb ea QS 18 Nm 1 8 mekg 13 ftlb Front Rear Extend of removal Front caliper disassembly 2 Rear caliper disassembly Remarks CALIPER DISASSEMBLY Cotter pin Pad pin Pad support Brake pad Caliper piston Refer to REMOVAL POINTS Dust seal Reter to REMOVAL POINTS Piston seal i 9 12 FRONT BRAKE AND REAR BRAKE CHAS EC5A8300 MASTER CYLINDER DISASSEMBLY Front Rear Extend of removal OO Front master cylinder disassembly 2 Rear master cylinder disassembly MA
169. the above chart EC474821 Power valve 1 Inspect e Power valve Wear Damage Replace Carbon deposits Remove e Valve shaft e Solid bush e Oil seal Wear Damage Replace EC474901 Power valve hole on cylinder 1 Remove e Carbon deposits From power valve hole surface NOTE Do not use a sharp instrument Avoid scratch ing the aluminum EC475000 ASSEMBLY AND INSTALLATION EC475180 Power valve 1 Install e Power valve e Bolt power valve EE gt 9 Nm 0 9 mekg 6 5 ft lb NOTE Install the power valve at cut away faced for down side CYLINDER HEAD CYLINDER AND PISTON ENG 4 26 2 Install e Solid bush e Oil seal e Plain washer e Circlip e Valve pulley e Screw valve pulley v 4 Nm 0 4 mekg 2 9 ftelb To valve shaft NOTE Apply the lithium soap base grease on the valve shaft and oil seal lip 3 Lock the pulley holding screw using an appropriate wire around the groove on the valve pulley 4 Install e Valve shaft e Valve cover e Screw valve cover v 4 Nm 0 4 mekg 2 9 ftelb NOTE SS e Install the valve shaft so that its pulley faces left of the chassis for the left cylinder and right of the chassis for the right cylinder e When installing the valve shaft into the cylin der lightly touch the solid bush with the oil seal and provide an equal gap for the power valve and valve
170. 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 bleed 1 Remove e Reservoir tank cap e Diaphragm 2 Bleed e Brake fluid Front Rear Air bleeding steps Add proper brake fluid to the reservoir Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow Connect the clear plastic tube tightly to the caliper bleed screw Place the other end of the tube into a container Slowly apply the brake lever or pedal several 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 master cylinder 7 Nm 0 7 mekg 5 1 ft lb Bleed screw caliper 6 Nm 0 6 m ekg 4 3 ft lb i Repeat steps e to h until of the air bubbles have been removed from the system FRONT BRAKE ADJUSTMENT INSP e REAR BRAKE ADJUSTMENT 3 18 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
171. the inner tube slowly and take care to insert it carefully so that the slide metal and piston metal will not be scratched 8 Install e Oil seal washer To outer tube slot 9 Install e Oil seal NOTE Press the oil seal into the outer tube with fork seal driver Fork seal driver YM 01442 90890 01442 FRONT FORK CHAS 10 Install e Stopper ring NOTE Fit the stopper ring correctly in the groove in the outer tube 11 Check e Inner tube smooth movement Tightness Binding Rough spots Repeat the steps 2 to 10 12 Compress the front fork fully 13 Fill e Front fork oil Until outer tube top surface with recom mended fork oil Recommended oil Suspension oil 01 CAUTION 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 14 After filling pump the damper rod slowly up and down more than 10 times to distrib ute the fork oil NOTE Use the rod puller and rod puller attachment 3 to pull up and down the damper rod D F y Gi B se one Gei Gei Gei ese Rod puller YM 01437 90890 01437 Rod puller attachment 90890 01435 YQ E 5 34 9 35 FRONT FORK CHAS EE e Front fork oil Until outer tube top surface with recom mended fork oil once more 16 After filling pump the outer tube
172. the wireharness e For a field remedy use a contact revitalizer available on the market e Use the tester on the connector as shown CH SPECIAL TOOLS ES EC140001 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 or YU e For others use part number starting with 90890 Tool name How to use YM 01189 90890 01189 Flywheel puller YM 01189 90890 01189 This tool is used to remove the flywheel magneto YU 01235 90890 01235 Rotor holding tool YU 01235 90890 01235 This tool is used when loosening or tightening the flywheel magneto securing nut YU 03097 90890 01252 Dial gauge and stand YU 01256 Stand These tools are used to set the ignition timing YU 01304 90890 01304 Piston pin puller This tool is used to remove the piston pin YM 01312 A 90890 01312 Fuel level gauge YM 01312 A 90890 01312 YM 01470 90890 01470 Fuel level gauge adapter YM 01470 90890 01470 This gauge is used to measure the fuel level in the float chamber YU 24460 1 90890 01325 Radiator cap tester YU 24460 1 YU 33984 9089
173. ting Uneven adjustment can cause poor handling and loss of stability EC36K000 REAR SHOCK ABSORBER INSPECTION 1 Inspect e Swingarm smooth action Abnormal noise Unsmooth action Grease the pivoting points or repair the piv oting points Damage Oil leakage Replace EC36L001 SEAT HEIGHT ADJUSTMENT 1 Remove e Fuel tank 2 Adjust e Seat height REAR SHOCK ABSORBER SPRING PRELOAD INSP Q ADJUSTMENT Seat height adjustment steps e Remove the cap e Loosen the lock bolt and locknut e Turn the adjuster in or out y K ox Adjuster set length Standard length Extent of adjustment 21 33 mm i 0 83 1 30 in NOTE If the adjuster set length is changed the seat height will be increased or decreased by twice the change CAUTION Never attempt to turn the adjuster beyond the maximum or minimum length e Tighten the lock bolt and locknult Lock bolt 40 Nm 4 0 mekg 29 ft lb Locknut 38 Nm 3 8 mekg 27 ft lb e Install the cap 3 Install e Fuel tank EC36M051 REAR SHOCK ABSORBER SPRING PRE LOAD ADJUSTMENT 1 Hold the machine on upright position by placing the suitable stand 2 Loosen e Locknut NOTE When loosening the locknut use the special a S tool which is included in the owner s tool kit CH e Spring preload N eer By turning the adjuster 1 Stiffer Increase the spring preload Turn the adjuster in Softer
174. tion chamber volume e After break in change to an appropriate gas ket to allow the piston protrusion to be 0 15 mm 0 006 in to 0 05 mm 0 002 in CAUTION e Piston protruding amount must be a max imum 0 15 mm 0 006 in Above this value the piston and cylinder head may contact each other e Too much random piston protrusion at low temperature may develop an abnormal combustion detonation which may adversely affect the intended performance of the engine Air temperature Piston protruding amount EC71T000 Cylinder gasket setting parts Size thickness 4JT 11351 02 t 0 8 mm 0 031 in 4JT 11351 12 t 0 7 mm 0 028 in 4JT 11351 22 t 0 6 mm 0 024 in 4DP 11351 31 t 0 5 mm 0 020 in 4DP 11351 40 t 0 4 mm 0 016 in Factory installed EC71L002 Measuring piston protrusion 1 Install the dial gauge and dial gauge stand to the cylinder contact surface and set the scale of the dial gauge to zero Dial gauge YU 03097 90890 01252 Stand YU 01256 2 Loosen the stand installation bolt then rotate the dial gauge stand and set it close to the center of the piston Tighten the stand installation bolt again NOTE Do not loosen the dial gauge installation bolt while doing the above 3 Set the piston at top dead center TDC then measure the piston protrusion NOTE For measurement avoid the top center pro jected area on the piston head but measure several positions
175. too much it may cause the front fork to malfunction FEED Z e Adjust the handlebar position and steer ing damper stay position ON Handlebar position PA 9 mm 0 35 in Steering damper stay position 73 mm 2 87 in N GaL op RIA AE Y eg HE Le Gelb O IS lt SE OK g WSS SS Ac amp SZ Li AL i ls e Tighten the pinch bolts handlebar and steering damper stay Pinch bolt handlebar 7 Nm 0 7 mekg 5 1 ft lb Pinch bolt steering damper stay 10 Nm 1 0 mekg 7 2 ft lb 3 28 Beie FRONT FORK SPRING PRELOAD ADJUSTMENT CAUTION TE Tighten the pinch bolts to specified torque If torqued too much it may cause the front fork to malfunction NOTE Adjust the installation angle of the steering damper stay so that the dimension is between 3 mm 0 12 in and 5 mm 0 20 in when the handlebar is turned fully to the right 4 Check e Steering smooth action Turn the handlebar to make sure no parts are being contacted with others Contact Repair 5 Install e Front fender e Front wheel e Induction guide left cylinder e Cowling EC36F012 FRONT FORK SPRING PRELOAD ADJUST MENT 1 Adjust e Spring preload By turning the adjuster k G Wasser k T X A Oy Stiffer Increase the spring preload Turn the adjuster in Softer Decrease the spring preload Turn the adjuster out l K Extent of adjustment Fully turned in
176. ully opened NOTE After the main switch is moved to RUN the servomotor will be operated as follows 1 The servomotor will be fully closed about 1 second 2 And then it will be kept fully opened e Check the free play for the YPVS open side cables 0 Out of specification Adjust ESA YPVS open side cable free AY play 2 3 mm 0 08 0 12 in 3 Adjust e YPVS open side cable free play Adjusting steps e Fully open the servomotor e Loosen the locknuts e Turn the adjusters until the specified free play is obtained e Tighten the locknuts 3 12 YPVS CLOSE SIDE CABLE ADJUSTMENT YPVS COMPO INS e NENTS RETIGHTENING TRANSMISSION OIL LEVEL CHECK 3 13 EC35E011 YPVS CLOSE SIDE CABLE ADJUSTMENT 1 Disconnect the fuel pump coupler to pre vent the fuel pump operation 2 Check e YPVS close side cable free play Checking steps e Move the main switch to RUN e The servomotor will be fully closed about 1 second e During this 1 second move the main switch to OFF e The servomotor will be kept fully closed e Check the free play for the YPVS close side cables 0 Out of specification Adjust ESA YPVS close side cable free ZY play 2 3 mm 0 08 0 12 in 3 Adjust e YPVS close side cable free play Adjusting steps e Fully close the servomotor e Loosen the locknuts e Turn the adjusters until the specified free play is
177. upright position by placing the Suitable stand 3 Place a suitable container under the engine 3 14 DS ei PILOT AIR SCREW ADJUSTMENT 4 Remove e Oil drain bolt e Oil filler cap Drain the transmission oil 5 Install e Copper washer e Oil drain bolt V 23 Nm 2 3 mekg 17 ftelb NOTE After tightening the oil drain bolt to specified torque lock it using a wire 6 Fill e Transmission oil Recommended oil Castrol R30 Oil capacity periodic oil change 0 50 L 0 44 Imp qt 0 53 US qt 7 Check e Oil leakage 8 Check e Transmission oil level 9 Install e Oil filler cap EC35L00 PILOT AIR SCREW ADJUSTMENT 1 Adjust e Pilot air screw 1 Adjusting steps e Screw in the pilot air screw until it is lightly seated e Back out by the specified number of turns EA Pilot air screw cA 1 1 2 turns out 3 15 DS ei MUFFLER INSPECTION SILENCER INSPECTION EC35P010 MUFFLER INSPECTION 1 Inspect e O ring Damage Replace EC35Q001 SILENCER INSPECTION 1 Inspect e Silencer Inside of silencer loose Repair Silencer repair steps e Drill the silencer for riveting e Rivet the silencer using the rivet NOTE Rivet the silencer in a different area than previously riveted 3 16 DS ei CHASSIS BRAKE SYSTEM AIR BLEEDING 3 17 EC360000 CHASSIS EC361021 BRAKE SYSTEM AIR BLEEDING AWARNING Bleed
178. ut drive sprocket e Lock washer NOTE e Straighten the lock washer tab e Loosen the nut while applying the rear brake 2 Remove e Drive sprocket e Drive chain NOTE Remove the drive sprocket together with the drive chain EC4F3201 Transmission housing 1 Remove e Bolt transmission housing e Transmission housing NOTE ___ COCO OT Remove the transmission housing together with the transmission shift cam shift fork and shift shaft EC4C3101 Shift guide and shift lever assembly 1 Remove e Bolt shift guide e Shift guide e Shift lever assembly NOTE The shift lever assembly is disassembled at the same time as the shift guide EC4F3401 Stopper lever 1 Remove e Stopper lever assembly e Torsion spring e Plain washer NOTE Remove the stopper lever assembly with its roller aligning with the top of the segment SHIFT SHAFT ENG 2 Remove e Circlip e Plain washer e Stopper lever EC4F4000 INSPECTION 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 e Shift lever Pawl e Pawl pin e Spring Wear Damage Replace EC4B4500 Stopper lever 1 Inspect e Stopper lever Wear Damage Replace e Torsion spring Broken Replace EC4F5000 ASSEMBLY AND INSTALLATION E
179. y 1 mm 0 04 in If the rear tire radius is 2 mm 0 08 in smaller raise the rear posture by 2 mm 0 08 in by decreasiry the adjuster set length by 1 mm 0 04 in NOTE e Find the tire radius by calculating the mea sured circumference of the tire e A change of 1 mm 0 04 in in the front fork top end results in a change of about 1 mm 0 04 in in the front posture A change of 1 mm 0 04 in in the adjuster set length results in a change of about 2 mm 0 08 in in the rear posture 7 15 EC72K014 Settings For full use of engine performance and safe riding set the suspension as follows Ex fac tory settings are intended for a rider approxi mately 170 cm 66 9 in in height and approxi mately 60 kg 132 Ib in weight 1 Preparations INSU LOCK TIE To check for the remaining stroke in the front and rear suspension either install a thin insu lock tie or apply a small amount of grease at the front fork inner tube and at the rear shock absorber rod APPROX 2 Settings 10 mm 0 39 in 25 mm At the beginning of the break in period always record the remaining stroke as data To judge front and rear balance in relation to the machine height the usual way is to In the case of shift from full braking to turning and get the 13 mm 0 51 in the above feel when the clipper riding In case of be case of ate After making an actual run proceed to the SS insu lock tle 12 mm 0 47 in settings for
180. y reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio 1st 2nd 3rd 4th 5th 6th Chassis Frame type Caster angle Trail Tire Type Size front Size rear Tire pressure front and rear 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 Spur gear 53 21 2 524 Chain drive 36 14 2 571 Constant mesh 6 speed Left foot operation 34 18 1 889 31 21 1 476 29 23 1 261 27 25 1 080 26 27 0 963 20 22 0 909 Delta box 22 82 mm 3 23 in Tubeless 3 10 4 80 R17 165 55 R17 200 kPa 2 0 kg cm 29 psi Dual disc brake Right hand operation Single disc brake Right foot operation Telescopic fork Swingarm link type monocross suspension Coil spring oil damper Coil spring gas oil damper 110 mm 4 33 in 118 mm 4 65 in Electrical Ignition system CDI magneto 2 2 waer speciricarions SPEC gz EC212000 MAINTENANCE SPECIFICATIONS EC212111 ENGINE Cylinder head Combustion chamber capacity 9 0 cm 0 317 Imp oz 0 304 US oz Piston Piston clearance 0 090 0 100 mm 0 0035 0 0039 in Piston offset 1 0 mm 0 039 in EX side Piston pin Piston pin outside diameter 14 995 15 000 mm 14 975 mm 0 5904 0 5906

ENG - TZ250 Racing

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