Yamaha 2011 YZ250FA Owner's Service Manual
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Yamaha 2011 YZ250FA Owner's Service Manual

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2011
Read this manual carefully before operating this vehicle.
OWNER'S SERVICE MANUAL
FA
LIT-11626-24-17
17D-28199-11

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  • Page 1 2011 Read this manual carefully before operating this vehicle. OWNER’S SERVICE MANUAL LIT-11626-24-17 17D-28199-11...
  • Page 2 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold.
  • Page 3 YZ250FA OWNER'S SERVICE MANUAL ©2010 by Yamaha Motor Corporation, U.S.A. 1st Edition, May 2010 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-11626-24-17...

  • Page 4: Important Manual Information

    INTRODUCTION IMPORTANT MANUAL INFORMATION Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Ya- Particularly important information is distin- maha's vast experience in the production of guished in this manual by the following nota- pacesetting racing machines.

  • Page 5: Safety Information

    SAFETY INFORMATION • PARK THE MACHINE CAREFULLY; TURN OFF THE ENGINE. THIS MACHINE IS DESIGNED STRICTLY Always turn off the engine if you are going to FOR COMPETITION USE, ONLY ON A leave the machine. Do not park the machine CLOSED COURSE.
  • Page 6 YAMAHA MOTOR CORPORATION, U.S.A. YZ MOTORCYCLE LIMITED WARRANTY...

  • Page 7: General Information

    HOW TO USE THIS MANUAL FINDING THE REQUIRED PAGE 1. This manual consists of seven chapters; "General Information", "Specifications", "Regular inspec- tion 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 chapter and item.
  • Page 8 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 "1" is provided for removal and disassembly jobs. 2. Numbers "2" are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step.
  • Page 9 ILLUSTRATED SYMBOLS (Refer Illustrated symbols "1" to "7" are used to identi- to the illustration) fy the specifications appearing in the text. 1. With engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening 6. Specified value, Service limit 7.
  • Page 10 MEMO...

  • Page 11: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL TUNING...

  • Page 12: General Information

    CONTENTS CHAPTER 1 GENERAL INFORMATION LOCATION OF IMPORTANT LABELS ..1-1 DESCRIPTION ........... 1-2 CONSUMER INFORMATION ....1-3 INCLUDED PARTS ........1-4 IMPORTANT INFORMATION ....1-5 CHECKING OF CONNECTION ....1-7 SPECIAL TOOLS........1-8 CONTROL FUNCTIONS ......1-12 STARTING AND BREAK-IN ....1-14 TORQUE-CHECK POINTS ......

  • Page 13: Engine

    CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS ............ 4-2 EXHAUST PIPE AND SILENCER ..... 4-4 RADIATOR..........4-7 CARBURETOR ........4-11 CAMSHAFTS ........... 4-22 CYLINDER HEAD ........4-30 VALVES AND VALVE SPRINGS .... 4-33 CYLINDER AND PISTON ......4-40 CLUTCH ...........

  • Page 14: Electrical

    CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ........6-2 IGNITION SYSTEM ........6-4 THROTTLE POSITION SENSOR SYSTEM ............. 6-8 CHAPTER 7 TUNING ENGINE ............7-1 CHASSIS............ 7-8...

  • Page 15: Location Of Important Labels

    LOCATION OF IMPORTANT LABELS GENERAL INFORMATION LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle. For use only on a closed course Premium unleaded in sanctioned competition. gasoline only. This motorcycle does not meet 3FB-2415E-02 EPA noise and emissions standards and is not for general...

  • Page 16: Description

    DESCRIPTION DESCRIPTION 1. Clutch lever 11. Coolant drain bolt 2. Hot starter lever 12. Rear brake pedal 3. Front brake lever 13. Valve joint 4. Throttle grip 14. Fuel cock 5. Radiator cap 15. Cold starter knob 6. Fuel tank cap 16.

  • Page 17: Consumer Information

    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.

  • Page 18: Included Parts

    INCLUDED PARTS INCLUDED PARTS NIPPLE WRENCH This nipple wrench "1" is used to tighten the DETACHABLE SIDESTAND spoke. This sidestand "1" is used to support only the machine when standing or transporting it. • Never apply additional force to the side- stand.

  • Page 19: Important Information

    5. Keep away from fire. 2. Use proper tools and cleaning equipment. ALL REPLACEMENT PARTS Refer to "SPECIAL TOOLS" section. 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for as- sembly and adjustment.
  • Page 20 IMPORTANT INFORMATION LOCK WASHERS/PLATES AND COTTER CIRCLIPS PINS 1. All circlips should be inspected carefully be- 1. All lock washers/plates "1" and cotter pins fore reassembly. Always replace piston pin must be replaced when they are removed. clips after one use. Replace distorted cir- Lock tab(s) should be bent along the bolt or clips.

  • Page 21: Checking Of Connection

    CHECKING OF CONNECTION CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: • Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off. 5.

  • Page 22: Special Tools

    SPECIAL TOOLS 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 tech- niques. The shape and part number used for the special tool differ by country, so two types are pro- vided.
  • Page 23 SPECIAL TOOLS Tool name/Part number How to use Illustration Piston pin puller set This tool is used to remove YU-1304, 90890-01304 the piston pin. Radiator cap tester These tools are used for YU-24460-01, 90890-01325 checking the cooling system. Radiator cap tester adapter YU-33984, 90890-01352 Steering nut wrench This tool is used when tighten...
  • Page 24 SPECIAL TOOLS Tool name/Part number How to use Illustration Pocket tester Use this tool to inspect the YU-3112-C, 90890-03112 coil resistance, output voltage and amperage. Timing light This tool is necessary for YM-33277-A, 90890-03141 checking ignition timing. Valve spring compressor This tool is needed to remove YM-4019, 90890-04019 and install the valve assem-...
  • Page 25 Ignition checker tem components. 90890-06754 Digital tachometer This tool is needed for ob- YU-39951-B, 90890-06760 serving engine rpm. YAMAHA Bond No. 1215 This sealant (Bond) is used ® (ThreeBond No. 1215) for crankcase mating surface, 90890-85505 etc.

  • Page 26: Control Functions

    CONTROL FUNCTIONS CONTROL FUNCTIONS KICKSTARTER CRANK Rotate the kickstarter crank "1" away from the ENGINE STOP SWITCH engine. Push the starter down lightly with your The engine stop switch "1" is located on the left foot until the gears engage, then kick smoothly handlebar.
  • Page 27 CONTROL FUNCTIONS REAR BRAKE PEDAL COLD STARTER KNOB The rear brake pedal "1" is located on the right When cold, the engine requires a richer air-fuel side of the machine. Press down on the brake mixture for starting. A separate starter circuit, pedal to activate the rear brake.

  • Page 28: Starting And Break-In

    STARTING AND BREAK-IN STARTING AND BREAK-IN AIR FILTER MAINTENANCE According to "CLEANING THE AIR FILTER FUEL ELEMENT" section in the CHAPTER 3, apply Always use the recommended fuel as stated the foam-air-filter oil or its equivalent to the ele- below. Also, be sure to use new gasoline the ment.
  • Page 29 STARTING AND BREAK-IN STARTING A WARM ENGINE Do not operate the cold starter knob and throt- Observe the following break-in procedures tle. Pull the hot starter lever "1" and start the during initial operation to ensure optimum engine by kicking the kickstarter crank forceful- performance and avoid engine damage.

  • Page 30: Torque-Check Points

    TORQUE-CHECK POINTS TORQUE-CHECK POINTS Frame construction Frame to rear frame Combined seat and fuel tank Fuel tank to frame Exhaust system Silencer to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Steering stem to handlebar Steering stem to frame Steering stem to upper bracket Upper bracket to handlebar...

  • Page 31: Cleaning And Storage

    CLEANING AND STORAGE CLEANING AND STORAGE STORAGE If your machine is to be stored for 60 days or CLEANING more, some preventive measures must be tak- Frequent cleaning of your machine will en- en to avoid deterioration. After cleaning the ma- hance its appearance, maintain good overall chine thoroughly, prepare it for storage as performance, and extend the life of many com-...

  • Page 32: General Specifications

    GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: YZ250FA (USA, CDN, AUS, NZ) YZ250F (EUROPE, ZA) Model code number: 17DD (USA,CDN) 17DE (EUROPE) 17DG (AUS, NZ, ZA) Dimensions: USA, CDN EUROPE AUS, NZ, ZA Overall length 2,159 mm 2,168 mm 2,166 mm (85.00 in) (85.35 in) (85.28 in)

  • Page 33: Chassis

    GENERAL SPECIFICATIONS Oil capacity: Engine oil Periodic oil change 0.95 L (0.84 Imp qt, 1.00 US qt) With oil filter replacement 1.05 L (0.92 Imp qt, 1.11 US qt) Total amount 1.20 L (1.06 Imp qt, 1.27 US qt) Coolant capacity (including all routes): 1.00 L (0.88 Imp qt, 1.06 US qt) Air filter: Wet type element...
  • Page 34 GENERAL SPECIFICATIONS Tire: Type With tube Size (front) 80/100-21 51M Size (rear) 100/90-19 57M Tire pressure (front and rear) 100 kPa (1.0 kgf/cm , 15 psi) Brake: Front brake type Single disc brake Operation Right hand operation Rear brake type Single disc brake Operation Right foot operation...

  • Page 35: Maintenance Specifications

    MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.05 mm (0.002 in) Cylinder: Bore size 77.00–77.01 mm (3.0315–3.0319 ---- Out of round limit ---- 0.05 mm (0.002 in) Camshaft: Drive method Chain drive (Left) ---- Camshaft cap inside diameter 22.000–22.021 mm (0.8661–...
  • Page 36 MAINTENANCE SPECIFICATIONS Item Standard Limit Camshaft runout limit ---- 0.03 mm (0.0012 in) Timing chain: Timing chain type/No. of links 92RH2010-114M/114 ---- Timing chain adjustment method Automatic ---- Valve, valve seat, valve guide: Valve clearance (cold) 0.12–0.17 mm (0.0047–0.0067 in) ---- 0.17–0.22 mm (0.0067–0.0087 in) ---- Valve dimensions: "A"...
  • Page 37 MAINTENANCE SPECIFICATIONS Item Standard Limit "D" margin thickness (IN) 0.8 mm (0.0315 in) ---- "D" margin thickness (EX) 0.7 mm (0.0276 in) ---- Stem outside diameter (IN) 3.975–3.990 mm (0.1565–0.1571 3.945 mm (0.1553 in) Stem outside diameter (EX) 4.460–4.475 mm (0.1756–0.1762 4.430 mm (0.1744 in) Guide inside diameter (IN)
  • Page 38 MAINTENANCE SPECIFICATIONS Item Standard Limit Tilt limit* (IN) ---- 2.5°/1.7 mm (2.5°/0.067 Tilt limit* (EX) ---- 2.5°/1.6 mm (2.5°/0.063 Direction of winding (top view) (IN) Clockwise ---- Direction of winding (top view) (EX) Clockwise ---- Piston: Piston to cylinder clearance 0.030–0.055 mm (0.0012–0.0022 0.1 mm (0.004 in)
  • Page 39 MAINTENANCE SPECIFICATIONS Item Standard Limit 2nd ring: Type Taper ---- Dimensions (B × T) 0.80 × 2.75 mm (0.03 × 0.11 in) ---- End gap (installed) 0.30–0.45 mm (0.012–0.018 in) 0.80 mm (0.031 in) Side clearance 0.020–0.055 mm (0.0008–0.0022 0.12 mm (0.005 in) Oil ring: Dimensions (B ×...
  • Page 40 MAINTENANCE SPECIFICATIONS Item Standard Limit Clutch housing thrust clearance 0.050–0.300 mm (0.0020–0.0118 ---- Clutch housing radial clearance 0.010–0.044 mm (0.0004–0.0017 ---- Clutch release method Inner push, cam push ---- Shifter: Shifter type Cam drum and guide bar ---- Guide bar bending limit ---- 0.05 mm (0.002 in)
  • Page 41 MAINTENANCE SPECIFICATIONS Item Standard Limit Lubrication system: Oil filter type Paper type ---- Oil pump type Trochoid type ---- Tip clearance 0.12 mm or less (0.0047 in or less) 0.20 mm (0.008 in) Side clearance 0.09–0.17 mm (0.0035–0.0067 in) 0.24 mm (0.009 in) Housing and rotor clearance 0.03–0.10 mm (0.0012–0.0039 in) 0.17 mm...
  • Page 42 MAINTENANCE SPECIFICATIONS Item Standard Limit Rear suspension: EUROPE, AUS, USA, CDN NZ, ZA Shock absorber travel 131.5 mm (5.18 in) ← ---- Spring free length 260 mm (10.24 in) ---- ← Fitting length 250 mm (9.84 in) ← Preload length <Min.–Max.>...
  • Page 43 44–66 Ωat 20 °C (68 °F) (Black– ---- Pink) Pickup coil resistance (color) 248–372 Ωat 20 °C (68 °F) ---- (White–Red) CDI unit-model/manufacturer 17D-50/YAMAHA (For USA and ---- CDN) 17D-60/YAMAHA (Except for USA ---- and CDN) Ignition coil: Model/manufacturer 5UL-20/DENSO...

  • Page 44: Tightening Torques

    TIGHTENING TORQUES TIGHTENING TORQUES ENGINE △ - marked portion shall be checked for torque tightening after break-in or before each race. Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Spark plug M10S × 1.0 Camshaft cap M6 × 1.0 Cylinder head blind plug screw M12 ×...
  • Page 45 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Air filter joint clamp M6 × 1.0 Throttle cable adjust bolt and locknut M6 × 0.75 Throttle cable (pull) M6 × 1.0 Throttle cable (return) M12 × 1.0 Throttle cable cover M5 ×...
  • Page 46 TIGHTENING TORQUES CHASSIS △ - marked portion shall be checked for torque tightening after break-in or before each race. Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb △ Upper bracket and outer tube M8 × 1.25 △ Lower bracket and outer tube M8 ×...
  • Page 47 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb △ Brake pedal M8 × 1.25 △ Rear brake master cylinder M6 × 1.0 Rear brake master cylinder cap M4 × 0.7 △ Rear brake hose union bolt M10 ×...
  • Page 48 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb △ Air scoop and fuel tank M6 × 1.0 △ Air scoop and radiator guard M6 × 1.0 Air scoop and frame M6 × 1.0 Radiator mounting boss and frame M10 ×...
  • Page 49 TIGHTENING TORQUES GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasten- ers with standard I.S.O. pitch threads. Torque specifications for special components or as- semblies 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.
  • Page 50 TIGHTENING TORQUES DEFINITION OF UNITS Unit Read Definition Measure millimeter meter Length centimeter meter Length kilogram gram Weight Newton 1 kg × m/sec Force Newton meter N × m Torque m•kg Meter kilogram m × kg Torque Pascal Pressure N/mm Newton per millimeter N/mm Spring rate...

  • Page 52: Lubrication Diagrams

    LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 2-20...
  • Page 53 LUBRICATION DIAGRAMS 1. Oil filter element 2. Oil pump 3. Drive axle 4. Main axle 5. Intake camshaft 6. Exhaust camshaft 7. Oil tank 8. Oil delivery pipe A. To oil tank 2-21...
  • Page 54 LUBRICATION DIAGRAMS 2-22...
  • Page 55 LUBRICATION DIAGRAMS 1. Crankshaft 2. Oil filter element 3. Oil tank 4. Oil hose A. From oil pump 2-23...

  • Page 56: Cable Routing Diagram

    CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM 2-24...
  • Page 57 CABLE ROUTING DIAGRAM 1. Fuel tank breather hose 2. Radiator hose 1 3. Cylinder head breather hose 4. Radiator hose 3 5. Clutch cable 6. Throttle position sensor lead 7. Hot starter cable 8. Fuel hose 9. Carburetor breather hose 10.
  • Page 58 CABLE ROUTING DIAGRAM 2-26...
  • Page 59 CABLE ROUTING DIAGRAM 1. Sub-wire harness N. Pass each lead under the clamp. Locate 2. Hot starter cable the CDI magneto lead on the outside of the 3. Oil hose ignition coil lead. Locate the throttle posi- 4. Neutral switch lead tion sensor lead, neutral switch lead, CDI 5.
  • Page 60 CABLE ROUTING DIAGRAM 2-28...
  • Page 61 CABLE ROUTING DIAGRAM 1. Radiator hose 2 2. Radiator breather hose 3. Ignition coil 4. Throttle cable (pull) 5. Throttle cable (return) 6. Engine stop switch lead A. Put a cover over the ignition coil. B. Pass the throttle cables through the cable guide.
  • Page 62 CABLE ROUTING DIAGRAM 2-30...
  • Page 63 CABLE ROUTING DIAGRAM 1. Brake master cylinder 2. Brake hose holder 3. Brake hose A. Install the brake hose so that its pipe por- tion directs as shown and lightly touches the projection on the brake caliper. B. Pass the brake hose into the brake hose holders.
  • Page 64 CABLE ROUTING DIAGRAM 2-32...
  • Page 65 CABLE ROUTING DIAGRAM 1. Throttle cable 2. Clamp 3. Hot starter cable 4. Clutch cable 5. Engine stop switch lead 6. Cable guide 7. Brake hose 8. Hose guide A. Fasten the engine stop switch lead to the handlebar. B. Pass the clutch cable and hot starter cable through the cable guide.

  • Page 66: Maintenance Intervals

    If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer • Periodic inspection is essential in making full use of the machine performance. The service life of the parts varies substantially according to the environment in which the machine runs (e.g., rain,...
  • Page 67 MAINTENANCE INTERVALS Every Every Every After race third fifth As re- Item break Remarks (about (about (about quired 12.5 hours) hours) hours) PISTON Inspect Inspect crack. ● ● Clean Inspect carbon deposits and ● eliminate them. Replace It is recommended that the pis- ●...
  • Page 68 MAINTENANCE INTERVALS Every Every Every After race third fifth As re- Item break Remarks (about (about (about quired 12.5 hours) hours) hours) CRANK Inspect and clean ● ● CARBURETOR Inspect, adjust and clean ● ● SPARK PLUG Inspect and clean ●...
  • Page 69 MAINTENANCE INTERVALS Every Every Every After race third fifth As re- Item break Remarks (about (about (about quired 12.5 hours) hours) hours) BRAKES Adjust lever position and ● ● pedal height Lubricate pivot point ● ● Check brake disc surface ●...
  • Page 70 Lithium base grease ● THROTTLE, CONTROL CABLE Check routing and con- ● ● nection Lubricate Yamaha cable lube or SAE ● ● 10W-40 motor oil Inspect and clean (throttle Inspect dirt and wear on the ● ● cable) throttle cable on the carburetor side.

  • Page 71: Pre-Operation Inspection And Maintenance

    PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. GENERAL INSPECTION AND MAINTENANCE Item Routine Page Check that coolant is filled up to the radiator cap.

  • Page 72: Engine

    ENGINE ENGINE CHANGING THE COOLANT CHECKING THE COOLANT LEVEL Do not remove the radiator cap when the en- gine is hot. Do not remove the radiator cap "1", drain bolt and hoses when the engine and radia- tor are hot. Scalding hot fluid and steam Take care so that coolant does not splash may be blown out under pressure, which on painted surfaces.
  • Page 73 ENGINE • Do not mix more than one type of ethylene glycol antifreeze containing corrosion in- hibitors for aluminum engine. • Do not use water containing impurities or oil. CHECKING THE RADIATOR CAP OPENING PRESSURE 1. Attach: • Radiator cap tester "1" and adapter "2" Radiator cap tester: YU-24460-01/90890-01325 Radiator cap tester adapter:...
  • Page 74 ENGINE 3. Apply the specified pressure. c. Tighten the locknuts. Standard pressure: Locknut: 180 kPa (1.8 kg/cm , 25.6 psi) 5 Nm (0.5 m•kg, 3.6 ft•lb) • Do not apply pressure more than specified 2. Adjust: pressure. • Clutch cable free play •...
  • Page 75 ENGINE 2. Adjust: • Throttle grip free play • Before adjustment, expose the adjuster by moving the boot "3" and cap "4" away. • Make minute adjustment on the lever side us- Throttle grip free play adjustment steps: ing the adjuster "5". a.
  • Page 76 ENGINE 2. Apply: • Lithium soap base grease On the throttle cable end "a". CLEANING THE AIR FILTER ELEMENT 3. Install: Proper air filter maintenance is the biggest key • Throttle grip cap to preventing premature engine wear and dam- •...
  • Page 77 ENGINE 3. Inspect: 7. Install: • Air filter element • Air filter element "1" Damage → Replace. • Washer 4. Apply: • Fitting bolt • Foam-air-filter oil or equivalent oil to the ele- Fitting bolt: ment 2 Nm (0.2 m•kg, 1.4 ft•lb) Squeeze out the excess oil.
  • Page 78 ENGINE 4. Remove: • Lower engine guard "1" • Engine oil also lubricates the clutch and • Bolt (oil tank) "2" the wrong oil types or additives could • Washer "3" cause clutch slippage. Therefore, do not • Oil filler cap "4" add any chemical additives or use engine •...
  • Page 79 ENGINE 6. Inspect: 9. Install: • Oil strainer • Copper washer Clogged → Blow. • Oil filter element drain bolt 7. If the oil filter is to be replaced during this oil Oil filter element drain bolt: change, remove the following parts and rein- 10 Nm (1.0 m•kg, 7.2 ft•lb) stall them.
  • Page 80 ENGINE 12.Install: a. Turn in the pilot screw until it is lightly seat- • Oil filler cap • Washer (oil tank) b. Turn out the pilot screw by the factory-set • Bolt (oil tank) number of turns. Bolt (oil tank): Pilot screw (example): 4 Nm (0.4 m•kg, 2.9 ft•lb) 1-3/4 turns out...
  • Page 81 "b" on the crankcase cover basic knowledge and skill concerning the ser- when piston is at T.D.C. on compression vicing of Yamaha motorcycles (e.g., Yamaha stroke. dealers, service engineers, etc.) Those who have little knowledge and skill concerning ser-...
  • Page 82 ENGINE c. Select the proper pad using the pad select- ing table. Pad Availability: 25 Pad range increments 1.20 Pads are available in 120–No. mm–2.40 0.05 mm increments The thickness "a" of each pad is indicated in hundredths of millimeters on the pad upper sur- face.
  • Page 83 ENGINE e. Locate the rounded-off value and the mea- sured valve clearance in the chart "PAD SE- LECTION TABLE". The field where these two coordinates intersect shows the new pad number to use. Use the new pad number only as a guide when verifying the valve clearance adjustment.
  • Page 84 ENGINE INTAKE MEASURED INSTALLED PAD NUMBER CLEARANCE 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 - 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.02 - 0.06...

  • Page 85: Chassis

    CHASSIS CHASSIS d. Place the other end of the tube into a con- tainer. BLEEDING THE HYDRAULIC BRAKE e. Slowly apply the brake lever or pedal sever- SYSTEM al times. f. Pull the lever in or push down on the pedal. Hold the lever or pedal in position.
  • Page 86 CHASSIS 2. Remove: 2. Adjust: • Brake lever cover • Brake pedal height 3. Adjust: • Brake lever position Pedal height adjustment steps: a. Loosen the locknut "1". Brake lever position adjustment steps: b. Turn the adjusting nut "2" until the pedal a.
  • Page 87 CHASSIS CHECKING AND REPLACING THE FRONT d. Remove the pad pin and brake pads "4". BRAKE PADS 1. Inspect: • Brake pad thickness "a" Out of specification → Replace as a set. Brake pad thickness: 4.4 mm (0.17 in) <Limit>: 1.0 mm (0.04 in) e.
  • Page 88 CHASSIS i. Install the brake caliper "8" and tighten the pad pin "9". Bolt (brake caliper): 28 Nm (2.8 m•kg, 20 ft•lb) Pad pin: 18 Nm (1.8 m•kg, 13 ft•lb) 2. Replace: • Brake pad Brake pad replacement steps: a. Remove the protector "1" and pad pin plug "2".
  • Page 89 CHASSIS e. Connect the transparent hose "8" to the bleed screw "9" and place the suitable con- tainer under its end. k. Install the pad pin plug "15" and protector "16". Pad pin plug: f. Loosen the bleed screw and push the brake 3 Nm (0.3 m•kg, 2.2 ft•lb) caliper piston in.

  • Page 90: Specifications

    CHASSIS CHECKING THE BRAKE FLUID LEVEL CHECKING THE DRIVE CHAIN 1. Place the brake master cylinder so that its 1. Measure: top is in a horizontal position. • Drive chain length (15 links) "a" 2. Inspect: Out of specification → Replace. •...

  • Page 91: Adjustments

    CHASSIS 3. Clean: 6. Lubricate: • Drive chain • Drive chain Place it in kerosene, and brush off as much Drive chain lubricant: dirt as possible. Then remove the drive SAE 10W-40 motor oil or suitable chain from the kerosene and dry the drive chain lubricants chain.

  • Page 92: Engine

    CHASSIS CHECKING THE FRONT FORK To tighten → Turn the adjuster "3" counter- 1. Inspect: clockwise. • Front fork smooth action To loosen → Turn the adjuster "3" clock- Operate the front brake and stroke the front wise and push wheel forward. fork.

  • Page 93: Chassis

    CHASSIS 2. Clean: ADJUSTING THE FRONT FORK REBOUND • Dust seal "a" DAMPING FORCE • Oil seal "b" 1. Adjust: • Rebound damping force By turning the adjuster "1". • Clean the dust seal and oil seal after every run. Stiffer "a"...
  • Page 94 CHASSIS CHECKING THE REAR SHOCK ABSORBER 1. Inspect: Always adjust each front fork to the same • Swingarm smooth action setting. Uneven adjustment can cause poor Abnormal noise/unsmooth action → Grease handling and loss of stability. the pivoting points or repair the pivoting points.
  • Page 95 CHASSIS 5. Install: • Rear frame (upper) The I.D. mark "a" is marked at the end of the spring. Rear frame (upper): 32 Nm (3.2 m•kg, 23 ft•lb) 4. Adjust: • Spring preload • Rear frame (lower) Rear frame (lower): Adjustment steps: 32 Nm (3.2 m•kg, 23 ft•lb) a.
  • Page 96 CHASSIS Do not force the adjuster past the minimum or maximum extent of adjustment. The ad- juster may be damaged. ADJUSTING THE REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE 1. Adjust: • Low compression damping force By turning the adjuster "1". ADJUSTING THE REAR SHOCK ABSORBER HIGH COMPRESSION Stiffer "a"...
  • Page 97 CHASSIS CHECKING AND TIGHTENING THE Standard position: SPOKES About 1-3/4 turns out The following procedure applies to all of the *About 1-1/2 turns out spokes. * Except for USA and CDN 1. Check: • Spokes Bend/damage → Replace. Do not force the adjuster past the minimum Loose spoke →...
  • Page 98 CHASSIS CHECKING THE WHEELS 3. Check: 1. Inspect: • Steering smooth action • Wheel runout Turn the handlebar lock to lock. Elevate the wheel and turn it. Unsmooth action → Adjust steering ring nut. Abnormal runout → Replace. 4. Adjust: 2.
  • Page 99 CHASSIS Steering stem nut: 145 Nm (14.5 m•kg, 105 ft•lb) Handlebar upper holder: 28 Nm (2.8 m•kg, 20 ft•lb) Pinch bolt (upper bracket): 21 Nm (2.1 m•kg, 15 ft•lb) Number plate: 7 Nm (0.7 m•kg, 5.1 ft•lb) e. Loosen the steering ring nut one turn. f.
  • Page 100 CHASSIS LUBRICATION To ensure smooth operation of all components, A. Use Yamaha cable lube or equivalent on lubricate your machine during setup, after these areas. break-in, and after every race. B. Use SAE 10W-40 motor oil or suitable 1. All control cable chain lubricants.

  • Page 101: Electrical

    ELECTRICAL ELECTRICAL CHECKING THE SPARK PLUG 1. Remove: • Spark plug 2. Inspect: • Electrode "1" Wear/damage → Replace. • Insulator color "2" Normal condition is a medium to light tan color. CHECKING THE IGNITION TIMING Distinctly different color → Check the engine 1.
  • Page 102 ELECTRICAL 4. Check: • Ignition timing Visually check the stationary pointer "a" is within the firing range "b" on the rotor. Incorrect firing range→Check rotor and pick- up assembly. 5. Install: • Timing mark accessing screw 3-37...
  • Page 103 This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.

  • Page 104: Covers

    SEAT, FUEL TANK AND SIDE COVERS SEAT, FUEL TANK AND SIDE COVERS REMOVING THE SEAT, FUEL TANK AND SIDE COVERS Order Part name Q'ty Remarks Turn the fuel cock to "OFF". Disconnect the fuel hose. Seat Air scoop (left and right) Bolt (fuel tank) Fitting band Fuel tank...
  • Page 105 SEAT, FUEL TANK AND SIDE COVERS REMOVING THE SIDE COVER 1. Remove: • Bolt (side cover) • Left side cover "1" • Right side cover "2" Draw the side cover downward to remove it be- cause its claws "a" are inserted in the air filter case.

  • Page 106: Exhaust Pipe And Silencer

    EXHAUST PIPE AND SILENCER EXHAUST PIPE AND SILENCER REMOVING THE EXHAUST PIPE AND SILENCER Order Part name Q'ty Remarks A. Except for USA and CDN Refer to "SEAT, FUEL TANK AND Right side cover SIDE COVERS" section. Bolt (silencer clamp) Only loosening.
  • Page 107 EXHAUST PIPE AND SILENCER CHECKING THE SILENCER AND EXHAUST 3. Install: PIPE • Inner pipe "1" 1. Inspect: • Rivet (front) "2" • Gasket "1" Damage → Replace. • Apply heat resistant sealant along the plate edge "a" on the inside of the silencer and also along the silencer edge "b"...
  • Page 108 EXHAUST PIPE AND SILENCER 2. Install: • Silencer clamp "1" Silencer clamp: 14 Nm (1.4 m•kg, 10 ft•lb) • Gasket "2" • Silencer "3" • Washer "4" • Bolt (silencer) "5" Bolt (silencer): 30 Nm (3.0 m•kg, 22 ft•lb) • Install the gasket with its meshed area "a" to- ward the exhaust pipe side.

  • Page 109: Radiator

    RADIATOR RADIATOR REMOVING THE RADIATOR 20 Nm (2.0 m kg, 14 ft Ib) Order Part name Q'ty Remarks Refer to "CHANGING THE COOL- Drain the coolant. ANT" section in the CHAPTER 3. Refer to "SEAT, FUEL TANK AND Seat and fuel tank SIDE COVERS"...
  • Page 110 RADIATOR 20 Nm (2.0 m kg, 14 ft Ib) Order Part name Q'ty Remarks Radiator hose 3 Radiator breather hose Radiator pipe 1...
  • Page 111 RADIATOR HANDLING NOTE Do not remove the radiator cap when the en- gine and radiator are hot. Scalding hot fluid and steam may be blown out under pres- sure, 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-...
  • Page 112 RADIATOR 4. Install: • Left radiator "1" • Bolt (left radiator) "2" Bolt (left radiator): 10 Nm (1.0 m•kg, 7.2 ft•lb) • Radiator hose 1 "3" Radiator hose 1: 2 Nm (0.2 m•kg, 1.4 ft•lb) Refer to "CABLE ROUTING DIAGRAM" section in the CHAPTER 2.

  • Page 113: Carburetor

    CARBURETOR CARBURETOR REMOVING THE CARBURETOR 4 Nm (0.4 m kg, 2.9 ft lb) 2 Nm (0.2 m kg, 1.4 ft lb) 11 Nm (1.1 m kg, 8.0 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 3 Nm (0.3 m kg, 2.2 ft lb) 3 Nm (0.3 m kg, 2.2 ft lb) Order...
  • Page 114 CARBURETOR DISASSEMBLING THE CARBURETOR Order Part name Q'ty Remarks Carburetor breather hose Valve lever housing cover Screw (throttle shaft) Throttle valve Needle holder Jet needle Accelerator pump cover Spring Diaphragm (accelerator pump) Float chamber Leak jet Pilot screw Refer to removal section. Float pin Float Needle valve...
  • Page 115 CARBURETOR Order Part name Q'ty Remarks Main jet Needle jet Spacer Pilot jet Starter jet Push rod Pull the push rod. Throttle shaft assembly Push rod link lever assembly Pilot air jet Cold starter plunger 4-13...
  • Page 116 CARBURETOR HANDLING NOTE Do not loosen the screw (throttle position sensor) "1" except when changing the throttle position sensor due to failure be- cause it will cause a drop in engine perfor- mance. 2. Inspect: • Main jet "1" • Pilot jet "2" •...
  • Page 117 CARBURETOR CHECKING THE THROTTLE VALVE 1. Check: • Free movement Stick → Repair or replace. Insert the throttle valve "1" into the carburetor body, and check for free movement. Measurement and adjustment steps: a. Hold the carburetor in an upside down posi- tion.
  • Page 118 CARBURETOR CHECKING THE FLOAT 2. Inspect: 1. Inspect: • Throttle shaft "1" • Float "1" • Spring "2" Damage → Replace. • Lever 1 "3" • Spring 1 "4" • Lever 2 "5" • Spring 2 "6" Dirt → Clean. CHECKING THE STARTER PLUNGER 1.
  • Page 119 CARBURETOR 3. Install: 6. Install: • Spring 1 "1" • Washer "1" • Lever 1 "2" • Circlip "2" To lever 2 "3". Make sure the spring 1 fits on the stopper "a" of the lever 2. 7. Install: • Spring "1" To throttle shaft "2".
  • Page 120 CARBURETOR 10.Install: • Starter jet "1" • Pilot jet "2" • Spacer "3" • Needle jet "4" • Main jet "5" 11.Install: • Needle valve "1" • Float "2" • Float pin "3" • After installing the needle valve to the float, in- stall them to the carburetor.
  • Page 121 CARBURETOR 15.Install: • Jet needle "1" • Collar "2" • Spring "3" • Needle holder "4" • Throttle valve plate "5" To throttle valve "6". 13.Install: • O-ring • Leak jet "1" • Float chamber "2" • Bolt (float chamber) "3" •...
  • Page 122 CARBURETOR 18.Install: • Carburetor breather hose "1" Install the carburetor breather hoses to the car- buretor so that the hoses do not bend near where they are installed. c. Gradually turn out the adjusting screw while moving the link lever until it has no more free play.
  • Page 123 CARBURETOR 3. Install: 6. Adjust: • Hot starter plunger "1" • Throttle grip free play Refer to "ADJUSTING THE THROTTLE CA- Hot starter plunger: BLE FREE PLAY" section in the CHAPTER 2 Nm (0.2 m•kg, 1.4 ft•lb) 7. Install: • Throttle cable cover "1" •...

  • Page 124: Camshafts

    CAMSHAFTS CAMSHAFTS REMOVING THE CYLINDER HEAD COVER Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND Seat and fuel tank SIDE COVERS" section. Spark plug Cylinder head breather hose Bolt (cylinder head cover) Cylinder head cover Cylinder head cover gasket Timing chain guide (top side) 4-22...
  • Page 125 CAMSHAFTS REMOVING THE CAMSHAFTS Order Part name Q'ty Remarks Timing mark accessing screw Refer to removal section. Crankshaft end accessing screw Refer to removal section. Timing chain tensioner cap bolt Refer to removal section. Timing chain tensioner Refer to removal section. Camshaft cap Refer to removal section.
  • Page 126 CAMSHAFTS REMOVING THE CAMSHAFT 3. Remove: 1. Remove: • Timing chain tensioner cap bolt "1" • Timing mark accessing screw "1" • Timing chain tensioner "2" • Crankshaft end accessing screw "2" • Gasket 2. Align: 4. Remove: • T.D.C. mark •...
  • Page 127 CAMSHAFTS 5. Remove: • Exhaust camshaft "1" • Intake camshaft "2" Attach a wire "3" to the timing chain to prevent it from falling into the crankcase. CHECKING THE CAMSHAFT 1. Inspect: • Cam lobe Pitting/scratches/blue discoloration → Re- 3. Measure: place.
  • Page 128 CAMSHAFTS CHECKING THE CAMSHAFT SPROCKET 1. Inspect: • Camshaft sprocket "1" Wear/damage → Replace the camshaft as- sembly and timing chain as a set. c. Install the clip, dowel pins and camshaft caps. Bolt (camshaft cap): 10 Nm (1.0 m•kg, 7.2 ft•lb) CHECKING THE DECOMPRESSION •...
  • Page 129 CAMSHAFTS CHECKING THE TIMING CHAIN TENSIONER Installation steps: 1. Check: a. Turn the crankshaft counterclockwise with a • While pressing the tensioner rod lightly with wrench. fingers, use a thin screwdriver "1" and wind the tensioner rod up fully clockwise. •...
  • Page 130 CAMSHAFTS d. Install the clips, camshaft caps "4" and bolts b. With the rod fully wound and the chain ten- (camshaft cap) "5". sioner UP mark "a" facing upward, install the gasket "1" and the timing chain tensioner Bolt (camshaft cap): "2", and tighten the bolt "3"...
  • Page 131 • Cylinder head cover "3" • Bolt (cylinder head cover) "4" Bolt (cylinder head cover): 10 Nm (1.0 m•kg, 7.2 ft•lb) Apply the sealant on the cylinder head cover gasket. YAMAHA Bond No. 1215 (Three- ® Bond No. 1215): 90890-85505 4-29...

  • Page 132: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD REMOVING THE CYLINDER HEAD Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND Seat and fuel tank SIDE COVERS" section. Refer to "EXHAUST PIPE AND SI- Exhaust pipe and silencer LENCER" section. Radiator hose 1 Disconnect at cylinder head side.
  • Page 133 CYLINDER HEAD CHECKING THE CYLINDER HEAD 1. Eliminate: • Carbon deposits (from the combustion chambers) Use a rounded scraper. Do not use a sharp instrument to avoid damag- ing or scratching: • Spark plug threads • Valve seats INSTALLING THE CYLINDER HEAD 1.
  • Page 134 CYLINDER HEAD 4. Install: • Radiator pipe "1" • Apply the molybdenum disulfide grease on • Bolt (radiator pipe) "2" the thread and contact surface of the bolts. • Follow the numerical order shown in the illus- Bolt (radiator pipe): tration.

  • Page 135: Valves And Valve Springs

    VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS REMOVING THE VALVES AND VALVE SPRINGS Order Part name Q'ty Remarks Cylinder head Refer to "CYLINDER HEAD" section. Valve lifter Refer to removal section. Adjusting pad Refer to removal section. Valve cotter Refer to removal section.
  • Page 136 VALVES AND VALVE SPRINGS REMOVING THE VALVE LIFTER AND 3. Remove: VALVE COTTER • Valve cotter 1. Remove: • Valve lifter "1" Attach a valve spring compressor "1" between • Pad "2" the valve spring retainer and the cylinder head to remove the valve cotters.
  • Page 137 VALVES AND VALVE SPRINGS c. After installing the valve guide, bore the valve guide using a valve guide reamer "3" to obtain proper stem-to-guide clearance. 2. Replace: • Valve guide Replacement steps: Valve guide remover: Intake:4.0 mm (0.16 in) YM-4111/90890-04111 To ease guide removal, installation and to Exhaust:4.5 mm (0.18 in) maintain correct fit heat the cylinder head in an...
  • Page 138 VALVES AND VALVE SPRINGS 5. Measure: • Runout (valve stem) Measurement steps: Out of specification → Replace. a. Apply Mechanic's blueing dye (Dykem) "b" to the valve face. Runout limit: 0.01 mm (0.0004 in) • When installing a new valve always replace the guide.
  • Page 139 VALVES AND VALVE SPRINGS e. Apply a fine lapping compound to the valve face and repeat the above steps. Lapping steps: a. Apply a coarse lapping compound to the After every lapping operation be sure to clean valve face. off all of the compound from the valve face and valve seat.
  • Page 140 VALVES AND VALVE SPRINGS INSTALLING THE VALVES 1. Apply: • Molybdenum disulfide oil Onto the valve stem and valve stem seal. 2. Install: • Valve "1" • Valve spring seat "2" • Valve stem seal "3" • Valve spring "4" •...
  • Page 141 VALVES AND VALVE SPRINGS 3. Install: • Valve cotter While compressing the valve spring with a valve spring compressor "1" install the valve cotters. Valve spring compressor: YM-4019/90890-04019 4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood.

  • Page 142: Cylinder And Piston

    CYLINDER AND PISTON CYLINDER AND PISTON REMOVING THE CYLINDER AND PISTON Order Part name Q'ty Remarks Cylinder head Refer to "CYLINDER HEAD" section. Bolt (cylinder) Cylinder Piston pin clip Refer to removal section. Piston pin Refer to removal section. Piston Refer to removal section.
  • Page 143 CYLINDER AND PISTON REMOVING THE PISTON AND PISTON RING 1. Remove: • Piston pin clip "1" • Piston pin "2" • Piston "3" • Put identification marks on each piston head for reference during reinstallation. • Before removing each piston pin, deburr the clip groove and pin hole area.
  • Page 144 CYLINDER AND PISTON c. Measure the piston skirt diameter "P" with a micrometer. 2. Position: • Piston ring a. 8 mm (0.31 in) from the piston bottom (in cylinder) edge Insert a ring into the cylinder and push it ap- Piston size "P"...
  • Page 145 CYLINDER AND PISTON CHECKING THE PISTON PIN INSTALLING THE PISTON RING AND 1. Inspect: PISTON • Piston pin 1. Install: Blue discoloration/grooves → Replace, then • Piston ring inspect the lubrication system. Onto the piston. 2. Measure: • Piston pin-to-piston clearance •...
  • Page 146 CYLINDER AND PISTON 3. Install: • Piston "1" • Piston pin "2" • Piston pin clip "3" • Apply engine oil onto the piston pin and pis- ton. • Be sure that the arrow mark "a" on the piston points to the exhaust side of the engine. •...

  • Page 147: Clutch

    CLUTCH CLUTCH REMOVING THE CLUTCH Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE Drain the engine oil. OIL" section in the CHAPTER 3. Refer to "ENGINE REMOVAL" sec- Brake pedal tion. Clutch cable Disconnect at engine side. Clutch cover Clutch spring Pressure plate Push rod 1...
  • Page 148 CLUTCH Order Part name Q'ty Remarks Clutch plate Nut (clutch boss) Refer to removal section. Lock washer Refer to removal section. Clutch boss Refer to removal section. Thrust washer Primary driven gear Spacer Washer Push lever shaft 4-46...
  • Page 149 CLUTCH REMOVING THE CLUTCH BOSS CHECKING THE PRIMARY DRIVEN GEAR 1. Remove: 1. Check: • Nut "1" • Circumferential play • Lock washer "2" Free play exists → Replace. • Clutch boss "3" • Gear teeth "a" Wear/damage → Replace. Straighten the lock washer tab and use the clutch holding tool "4"...
  • Page 150 CLUTCH CHECKING THE CLUTCH PLATES INSTALLING THE PUSH LEVER SHAFT 1. Measure: 1. Install: • Clutch plate warpage • Push lever shaft "1" Out of specification → Replace clutch plate • Bolt (push lever shaft) "2" as a set. Bolt (push lever shaft): Use a surface plate "1"...
  • Page 151 CLUTCH 3. Bend the lock washer "1" tab. 2. Install: • Lock washer "1" 4. Install: • Nut (clutch boss) "2" • Friction plate "1" • Clutch plate 1 "2" Nut (clutch boss): 75 Nm (7.5 m•kg, 54 ft•lb) • Install the clutch plates and friction plates al- ternately on the clutch boss, starting with a Use the clutch holding tool "3"...
  • Page 152 CLUTCH 6. Install: 9. Install: • Push rod 2 "1" • Dowel pin "1" • Ball "2" • Gasket (clutch cover) "2" • Push rod 1 "3" Apply the engine oil on the push rod 1, 2 and ball. 10.Install: •...

  • Page 153: Oil Filter Element And Water Pump

    OIL FILTER ELEMENT AND WATER PUMP OIL FILTER ELEMENT AND WATER PUMP REMOVING THE OIL FILTER ELEMENT AND WATER PUMP Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE Drain the engine oil. OIL" section in the CHAPTER 3. Refer to "CHANGING THE COOL- Drain the coolant.
  • Page 154 OIL FILTER ELEMENT AND WATER PUMP Order Part name Q'ty Remarks Kickstarter crank Right crankcase cover Impeller Refer to removal section. Washer Refer to removal section. Impeller shaft Refer to removal section. Oil seal Refer to removal section. Bearing Refer to removal section. 4-52...
  • Page 155 OIL FILTER ELEMENT AND WATER PUMP REMOVING THE IMPELLER SHAFT 2. Remove: 1. Remove: • Oil seal "1" • Impeller "1" • Washer "2" • Impeller shaft "3" Hold the impeller shaft on its width across the flats "a" with spanners, etc. and remove the im- peller.
  • Page 156 OIL FILTER ELEMENT AND WATER PUMP CHECKING THE IMPELLER SHAFT GEAR 1. Inspect: • Gear teeth "a" Wear/damage → Replace. 2. Install: • Bearing "1" Install the bearing by pressing its outer race CHECKING THE BEARING parallel. 1. Inspect: • Bearing Rotate inner race with a finger.
  • Page 157 OIL FILTER ELEMENT AND WATER PUMP INSTALLING THE RIGHT CRANKCASE INSTALLING THE KICKSTARTER CRANK COVER 1. Install: 1. Install: • Kickstarter crank "1" • Dowel pin "1" • Washer • O-ring "2" • Bolt (kickstarter crank) • Collar "3" Bolt (kickstarter crank): •...
  • Page 158 OIL FILTER ELEMENT AND WATER PUMP 2. Install: • Water pump housing "1" • Bolt (water pump housing) "2" Bolt (water pump housing): 10 Nm (1.0 m•kg, 7.2 ft•lb) 3. Install: • Copper washer "1" • Oil delivery pipe "2" •...

  • Page 159: Balancer

    BALANCER BALANCER REMOVING THE BALANCER Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Refer to "OIL FILTER ELEMENT Right crankcase cover AND WATER PUMP" section. Stator Refer to "CDI MAGNETO" section. Nut (primary drive gear) Refer to removal section. Nut (balancer shaft driven gear) Refer to removal section.
  • Page 160 BALANCER REMOVING THE BALANCER CHECKING THE PRIMARY DRIVE GEAR, 1. Straighten the lock washer tab. BALANCER SHAFT DRIVE GEAR AND 2. Loosen: BALANCER SHAFT DRIVEN GEAR • Nut (primary drive gear) "1" 1. Inspect: • Nut (balancer shaft driven gear) "2" •...
  • Page 161 BALANCER 2. Install: • Balancer shaft driven gear "1" • Install the primary drive gear with its stepped side "a" facing the engine. Install the balancer shaft driven gear onto the • Place an aluminum plate "b" between the balancer shaft while aligning the punch mark teeth of the balancer shaft drive gear "6"...

  • Page 162: Oil Pump

    OIL PUMP OIL PUMP REMOVING THE OIL PUMP Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Refer to "OIL FILTER ELEMENT Right crankcase cover AND WATER PUMP" section. Circlip Washer Oil pump drive gear Oil pump assembly Outer rotor 2 Circlip Inner rotor 2...
  • Page 163 OIL PUMP Order Part name Q'ty Remarks Inner rotor 1 Dowel pin Washer Oil pump drive shaft Rotor housing 4-61...
  • Page 164 OIL PUMP REMOVING THE OIL TANK Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE Drain the engine oil. OIL" section in the CHAPTER 3. Oil hose 2 Oil hose 1 Dowel pin Oil tank breather hose Oil tank Oil strainer 4-62...
  • Page 165 OIL PUMP CHECKING THE OIL PUMP 1. Inspect: • Oil pump drive gear "1" • Oil pump drive shaft "2" • Rotor housing "3" • Oil pump cover "4" Cracks/wear/damage → Replace. 2. Measure: • Tip clearance "a" (between the inner rotor "1" and outer rotor "2") 3.
  • Page 166 OIL PUMP 4. Install: • Outer rotor 2 "1" • Dowel pin "2" • Oil pump assembly "3" • Bolt (oil pump assembly) [L = 25 mm (0.94 in)] "4" Bolt (oil pump assembly): 10 Nm (1.0 m•kg, 7.2 ft•lb) •...
  • Page 167 OIL PUMP INSTALLING THE OIL TANK BREATHER HOSE 1. Install: • Oil tank "1" • Oil tank breather hose "2" • Clamp "3" Clamp: 2 Nm (0.2 m•kg, 1.4 ft•lb) Install the clamp so that it does not contact the oil tank. •...

  • Page 168: Kick Shaft And Shift Shaft

    KICK SHAFT AND SHIFT SHAFT KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Remarks Oil pump Refer to "OIL PUMP" section. Kick idle gear Kick shaft assembly Refer to removal section. Spring guide Torsion spring Ratchet wheel Kick gear...
  • Page 169 KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Remarks Collar Torsion spring Roller Shift guide Refer to removal section. Shift lever assembly Refer to removal section. Shift lever Pawl Pawl pin Spring Bolt (stopper lever) Stopper lever Torsion spring Segment Refer to removal section.
  • Page 170 KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT ASSEMBLY 1. Remove: • Kick shaft assembly "1" Unhook the torsion spring "2" from the hole "a" in the crankcase. CHECKING THE KICK SHAFT AND RATCHET WHEEL 1. Check: • Ratchet wheel "1" smooth movement Unsmooth movement →...
  • Page 171 KICK SHAFT AND SHIFT SHAFT CHECKING THE SHIFT SHAFT INSTALLING THE SEGMENT 1. Inspect: 1. Install: • Shift shaft "1" • Segment "1" Bend/damage → Replace. • Bolt (segment) • Spring "2" Bolt (segment): Broken → Replace. 30 Nm (3.0 m•kg, 22 ft•lb) Align the notch "a"...
  • Page 172 KICK SHAFT AND SHIFT SHAFT INSTALLING THE SHIFT GUIDE AND SHIFT 4. Install: LEVER ASSEMBLY • Bolt (shift guide) "1" 1. Install: Bolt (shift guide): • Spring "1" 10 Nm (1.0 m•kg, 7.2 ft•lb) • Pawl pin "2" • Pawl "3" To shift lever "4".
  • Page 173 KICK SHAFT AND SHIFT SHAFT Install with the punch mark "a" on the shift ped- al in alignment with the punch mark "b" on the shift shaft. 3. Install: • Spring guide "1" Slide the spring guide into the kick shaft, make sure the groove "a"...
  • Page 174 KICK SHAFT AND SHIFT SHAFT 5. Hook: • Torsion spring "1" Turn the torsion spring clockwise and hook into the proper hole "a" in the crankcase. INSTALLING THE KICK IDLE GEAR 1. Install: • Kick idle gear "1" • Washer "2" •...

  • Page 175: Cdi Magneto

    CDI MAGNETO CDI MAGNETO REMOVING THE CDI MAGNETO Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND Seat and fuel tank SIDE COVERS" section. Disconnect the CDI magneto lead. Refer to "KICK SHAFT AND SHIFT Shift pedal SHAFT" section. Left crankcase cover Nut (rotor) Refer to removal section.
  • Page 176 Screw (stator): 10 Nm (1.0 m•kg, 7.2 ft•lb) • Apply the sealant on the grommet of the CDI magneto lead. • Tighten the screws using the T30 bit. YAMAHA Bond No. 1215 (Three- ® Bond No. 1215): CHECKING THE CDI MAGNETO 90890-85505 1.
  • Page 177 CDI MAGNETO 2. Install: • Woodruff key "1" • Rotor "2" • Clean the tapered portions of the crankshaft and rotor. • When installing the woodruff key, make sure that its flat surface "a" is in parallel with the crankshaft center line "b". •...

  • Page 178: Engine Removal

    ENGINE REMOVAL ENGINE REMOVAL REMOVING THE ENGINE Order Part name Q'ty Remarks Hold the machine by placing the suit- Refer to "HANDLING NOTE". able stand under the frame. Refer to "SEAT, FUEL TANK AND Seat and fuel tank SIDE COVERS" section. Carburetor Refer to "CARBURETOR"...
  • Page 179 ENGINE REMOVAL Order Part name Q'ty Remarks Ignition coil Disconnect the CDI magneto lead. Lower engine guard Neutral switch Drive chain sprocket cover Nut (drive sprocket) Refer to removal section. Lock washer Refer to removal section. Drive sprocket Refer to removal section. Clip Bolt (brake pedal) Brake pedal...
  • Page 180 ENGINE REMOVAL HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE DRIVE SPROCKET 1. Remove: • Nut (drive sprocket) "1" • Lock washer "2" 2. Remove: • Straighten the lock washer tab. •...
  • Page 181 ENGINE REMOVAL • Upper engine bracket "8" • Bolt (upper engine bracket) "9" Bolt (upper engine bracket): 34 Nm (3.4 m•kg, 24 ft•lb) • Engine mounting bolt (upper) "10" Engine mounting bolt (upper): 55 Nm (5.5 m•kg, 40 ft•lb) • Front engine guard "11" •...
  • Page 182 ENGINE REMOVAL 4. Install: • Drive chain sprocket guide "1" • Drive chain sprocket cover "2" • Bolt (drive chain sprocket cover) "3" Bolt (drive chain sprocket cover): 7 Nm (0.7 m•kg, 5.1 ft•lb) INSTALLING THE NEUTRAL SWITCH 1. Install: •...

  • Page 183: Crankcase And Crankshaft

    CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT REMOVING THE CRANKSHAFT Order Part name Q'ty Remarks Refer to "ENGINE REMOVAL" sec- Engine tion. Refer to "CYLINDER AND PISTON" Piston section. Refer to "KICK SHAFT AND SHIFT Kick shaft assembly SHAFT" section. Refer to "KICK SHAFT AND SHIFT Segment SHAFT"...
  • Page 184 CRANKCASE AND CRANKSHAFT Order Part name Q'ty Remarks Bolt [L = 70 mm (2.76 in)] Refer to removal section. Hose guide Refer to removal section. Clutch cable holder Refer to removal section. Right crankcase Refer to removal section. Left crankcase Refer to removal section.
  • Page 185 CRANKCASE AND CRANKSHAFT REMOVING THE CRANKCASE BEARING Order Part name Q'ty Remarks Refer to "TRANSMISSION, SHIFT Transmission CAM AND SHIFT FORK" section. Refer to "TRANSMISSION, SHIFT Shift cam and shift fork CAM AND SHIFT FORK" section. Oil seal Bearing Refer to removal section. 4-83...
  • Page 186 CRANKCASE AND CRANKSHAFT DISASSEMBLING THE CRANKCASE REMOVING THE CRANKSHAFT 1. Separate: 1. Remove: • Right crankcase • Crankshaft "1" • Left crankcase Use the crankcase separating tool "2". Crankcase separating tool: Separation steps: YU-1135-A/90890-01135 a. Remove the crankcase bolts "1", hose guide "2"...
  • Page 187 CRANKCASE AND CRANKSHAFT CHECKING THE TIMING CHAIN AND CHECKING THE CRANKSHAFT TIMING CHAIN GUIDE 1. Measure: 1. Inspect: • Runout limit "a" • Timing chain • Small end free play limit "b" Cracks/stiff → Replace the timing chain and • Connecting rod big end side clearance "c" camshaft sprocket as a set.
  • Page 188 CRANKCASE AND CRANKSHAFT CHECKING THE OIL STRAINER 1. Inspect: • Install the bearing by pressing its outer race • Oil strainer parallel. Damage → Replace. • To prevent the screw [bearing stopper (crank- shaft)] from becoming loose, crush the screw head periphery "a"...
  • Page 189 CRANKCASE AND CRANKSHAFT 4. Apply: • Sealant On the right crankcase "1". YAMAHA Bond No.1215 (Three- ® Bond No.1215): 90890-85505 Clean the contacting surface of left and right crankcase before applying the sealant. A. For USA and CDN 5. Install: B.
  • Page 190 CRANKCASE AND CRANKSHAFT 9. Remove: • Sealant Tighten the crankcase tightening bolts in stage, Forced out on the cylinder mating surface. using a crisscross pattern. 10.Apply: • Engine oil To the crank pin, bearing and oil delivery hole. 11.Check: • Crankshaft and transmission operation. Unsmooth operation →...

  • Page 191: Transmission, Shift Cam And Shift Fork

    TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION, SHIFT CAM AND SHIFT FORK Order Part name Q'ty Remarks Refer to "ENGINE REMOVAL" sec- Engine tion. Refer to "CRANKCASE AND Separate the crankcase. CRANKSHAFT" section. Main axle Refer to removal section.
  • Page 192 TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION 2. Inspect: 1. Remove: • O-ring "1" • Main axle "1" Damage → Replace. • Drive axle "2" • Shift cam • Shift fork 3 • Shift fork 2 • Shift fork 1 •...
  • Page 193 TRANSMISSION, SHIFT CAM AND SHIFT FORK 2. Inspect: • Shift cam "1" • Segment "2" Wear/damage → Replace. 3. Check: • Shift fork movement Unsmooth operation → Replace shift fork. 2. Install: • 2nd wheel gear (28T) "1" • 4th wheel gear (22T) "2" •...
  • Page 194 TRANSMISSION, SHIFT CAM AND SHIFT FORK 3. Install: 5. Install: • Washer "1" • Shift fork 1 (L) "1" • Circlip "2" • Shift fork 2 (C) "2" • Shift fork 3 (R) "3" • Shift cam "4" • Be sure the circlip sharp-edged corner "a" is To main axle and drive axle.
  • Page 195 TRANSMISSION, SHIFT CAM AND SHIFT FORK 7. Check: • Shifter operation • Transmission operation Unsmooth operation → Repair. 4-93...
  • Page 196 This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.

  • Page 197: Front Wheel And Rear Wheel

    FRONT WHEEL AND REAR WHEEL FRONT WHEEL AND REAR WHEEL REMOVING THE FRONT WHEEL Order Part name Q'ty Remarks Hold the machine by placing the suit- Refer to "HANDLING NOTE". able stand under the engine. Bolt (axle holder) Only loosening. Nut (front wheel axle) Front wheel axle Front wheel...
  • Page 198 FRONT WHEEL AND REAR WHEEL REMOVING THE REAR WHEEL Order Part name Q'ty Remarks Hold the machine by placing the suit- Refer to "HANDLING NOTE". able stand under the engine. Nut (rear wheel axle) Rear wheel axle Drive chain puller Rear wheel Refer to removal section.
  • Page 199 FRONT WHEEL AND REAR WHEEL HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE REAR WHEEL 1. Remove: • Wheel "1" Push the wheel forward and remove the drive 2. Inspect: chain "2". •...
  • Page 200 FRONT WHEEL AND REAR WHEEL CHECKING THE BRAKE DISC • Left side of bearing shall be installed first. 1. Measure: • Install the oil seal with its manufacture's • Brake disc deflection (only rear brake disc) marks or numbers facing outward. Use the dial gauge "1".
  • Page 201 FRONT WHEEL AND REAR WHEEL 3. Install: 6. Install: • Collar "1" • Nut (wheel axle) "1" Nut (wheel axle): • Apply the lithium soap base grease on the oil 105 Nm (10.5 m•kg, 75 ft•lb) seal lip. • Install the collars with their projections "a" fac- ing the wheel.
  • Page 202 FRONT WHEEL AND REAR WHEEL INSTALLING THE REAR WHEEL 1. Install: • Bearing (right) "1" • Circlip "2" • Spacer "3" • Bearing (left) "4" • Oil seal "5" • Apply the lithium soap base grease on the bearing and oil seal lip when installing. •...
  • Page 203 FRONT WHEEL AND REAR WHEEL 5. Install: 8. Install: • Wheel • Right drive chain puller "1" • Washer "2" • Nut (wheel axle) "3" Install the brake disc "1" between the brake pads "2" correctly. Temporarily tighten the nut (wheel axle) at this point.

  • Page 204: Front Brake And Rear Brake

    FRONT BRAKE AND REAR BRAKE FRONT BRAKE AND REAR BRAKE REMOVING THE FRONT BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suit- Refer to "HANDLING NOTE". able stand under the engine. Drain the brake fluid. Refer to removal section. Brake hose holder (protector) Union bolt Brake hose...
  • Page 205 FRONT BRAKE AND REAR BRAKE REMOVING THE REAR BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suit- Refer to "HANDLING NOTE". able stand under the engine. Refer to "FRONT WHEEL AND Rear wheel REAR WHEEL" section. Drain the brake fluid.
  • Page 206 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE CALIPER Order Part name Q'ty Remarks A. Front B. Rear Pad pin Brake pad Pad support Brake caliper piston 1 Refer to removal section. Brake caliper piston dust seal 1 Refer to removal section. Brake caliper piston seal 1 Refer to removal section.
  • Page 207 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE MASTER CYLINDER Order Part name Q'ty Remarks A. Front B. Rear Brake master cylinder cap Diaphragm Reservoir float Push rod (Front) Brake master cylinder boot Circlip Use a long nose circlip pliers. Washer Push rod (Rear) Brake master cylinder kit...
  • Page 208 FRONT BRAKE AND REAR BRAKE HANDLING NOTE 3. Loosen the bleed screw and drain the brake fluid while pulling the lever in or pushing down on the pedal. Support the machine securely so there is no danger of it falling over. •...
  • Page 209 FRONT BRAKE AND REAR BRAKE REMOVING THE BRAKE CALIPER PISTON SEAL KIT 1. Remove: • Brake caliper piston dust seal "1" • Brake caliper piston seal "2" Remove the brake caliper piston seals and brake caliper piston dust seals by pushing them with a finger.
  • Page 210 FRONT BRAKE AND REAR BRAKE CHECKING THE BRAKE CALIPER HANDLING NOTE 1. Inspect: • Brake caliper cylinder inner surface "a" • All internal parts should be cleaned in new Wear/score marks → Replace brake caliper brake fluid only. assembly. • Internal parts should be lubricated with brake fluid when installed.
  • Page 211 FRONT BRAKE AND REAR BRAKE INSTALLING THE FRONT BRAKE CALIPER 1. Install: • Pad support "1" • Brake pad "2" • Pad pin "3" • Install the brake pads with their projections "a" into the brake caliper recesses "b". • Temporarily tighten the pad pin at this point. A.
  • Page 212 FRONT BRAKE AND REAR BRAKE INSTALLING THE REAR BRAKE CALIPER 1. Install: • Pad support "1" • Brake pad "2" • Pad pin "3" • Install the brake pads with their projections "a" into the brake caliper recesses "b". • Temporarily tighten the pad pin at this point. INSTALLING THE BRAKE MASTER CYLINDER KIT 1.
  • Page 213 FRONT BRAKE AND REAR BRAKE 3. Install: INSTALLING THE FRONT BRAKE MASTER • Spring "1" CYLINDER To brake master cylinder piston "2". 1. Install: • Brake master cylinder "1" • Brake master cylinder bracket "2" Install the spring at the smaller dia. side. •...
  • Page 214 FRONT BRAKE AND REAR BRAKE INSTALLING THE REAR BRAKE MASTER CYLINDER 1. Install: • Copper washer "1" • Brake hose "2" • Union bolt "3" Union bolt: 30 Nm (3.0 m•kg, 22 ft•lb) 3. Install: Always use new copper washers. •...
  • Page 215 FRONT BRAKE AND REAR BRAKE INSTALLING THE FRONT BRAKE HOSE 1. Install: • Copper washer "1" • Brake hose "2" • Union bolt "3" Union bolt: 30 Nm (3.0 m•kg, 22 ft•lb) Always use new copper washers. 3. Pass the brake hose through the cable guide "1".
  • Page 216 FRONT BRAKE AND REAR BRAKE After installing the brake hose holders, make sure the brake hose does not contact the spring (rear shock absorber). If it does, correct its twist. INSTALLING THE REAR BRAKE HOSE 1. Install: • Copper washer "1" •...
  • Page 217 FRONT BRAKE AND REAR BRAKE Brake fluid may erode painted surfaces or After installation, while pulling the brake le- plastic parts. Always clean up spilled fluid ver in or pushing down on the brake pedal, immediately. check whether there is any brake fluid leak- ing where the union bolts are installed re- spectively at the brake master cylinder and brake caliper.

  • Page 218: Front Fork

    FRONT FORK FRONT FORK REMOVING THE FRONT FORK Order Part name Q'ty Remarks Hold the machine by placing the suit- Refer to "HANDLING NOTE". able stand under the engine. Refer to "FRONT WHEEL AND Front wheel REAR WHEEL" section. Refer to "FRONT BRAKE AND Front brake caliper REAR BRAKE"...
  • Page 219 FRONT FORK DISASSEMBLING THE FRONT FORK Order Part name Q'ty Remarks Drain the fork oil. Refer to removal Adjuster section. Fork spring Dust seal Refer to removal section. Stopper ring Refer to removal section. Inner tube Refer to removal section. Outer tube Piston metal Slide metal...
  • Page 220 FRONT FORK HANDLING NOTE REMOVING THE ADJUSTER 1. Drain the outer tube of its front fork oil at its top. Support the machine securely so there is no 2. Loosen: danger of it falling over. • Adjuster "1" The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers.
  • Page 221 FRONT FORK 2. Remove: CHECKING THE DAMPER ASSEMBLY • Inner tube "1" 1. Inspect: • Damper assembly "1" Bend/damage → Replace. Oil seal removal steps: • O-ring "2" a. Push in slowly "a" the inner tube just before Wear/damage → Replace. it bottoms out and then pull it back quickly "b".
  • Page 222 FRONT FORK Inner tube bending limit: 0.2 mm (0.008 in) The bending value is shown by one half of the dial gauge reading. Do not attempt to straighten a bent inner tube as this may dangerously weaken the CHECKING THE COLLAR tube.
  • Page 223 FRONT FORK ASSEMBLING THE FRONT FORK 5. Measure: 1. Wash the all parts in a clean solvent. • Oil level (left and right) "a" 2. Stretch the damper assembly fully. Out of specification → Adjust. 3. Fill: Standard oil level: •...
  • Page 224 FRONT FORK 8. Install: 11.After filling, pump the damper assembly "1" • Base valve "1" slowly up and down more than 10 times to To damper assembly "2". distribute the fork oil. First bring the damper rod pressure to a maxi- mum.
  • Page 225 FRONT FORK 13.Allow the overflowing oil to escape at the hole "a" in the damper assembly. 16.Install: • Piston metal "1" 14.Check: • Damper assembly smooth movement Install the piston metal onto the slot on inner Tightness/binding/rough spots → Repeat tube.
  • Page 226 FRONT FORK 21.Install: • Dust seal "1" Apply the lithium soap base grease on the inner tube. 19.Install: • Oil seal "1" Press the oil seal into the outer tube with fork seal driver "2". 22.Check: Fork seal driver: • Inner tube smooth movement YM-A0948/90890-01502 Tightness/binding/rough spots →...
  • Page 227 FRONT FORK 26.Loosen: • Rebound damping adjuster "1" • Loosen the rebound damping adjuster finger tight. • Record the set position of the adjuster (the amount of turning out the fully turned in posi- tion). 24.Install: • Collar "1" • Fork spring "2" To damper assembly "3".
  • Page 228 FRONT FORK 31.Fill: • Front fork oil "1" If the adjuster is installed out of specification, From outer tube top. proper damping force cannot be obtained. Recommended oil: Suspension oil "S1" Standard oil amount: 350 cm (12.3 Imp oz, 11.8 US oz) *337 cm (11.9 Imp oz, 11.4 US oz) Extent of adjustment:...
  • Page 229 FRONT FORK 33.Install: 3. Adjust: • Protector guide "1" • Front fork top end "a" Front fork top end (standard) "a": 5 mm (0.20 in) INSTALLING THE FRONT FORK 1. Install: • Front fork "1" 4. Tighten: • Pinch bolt (upper bracket) "1" •...
  • Page 230 FRONT FORK 5. Install: • Protector "1" • Bolt (protector) "2" Bolt (protector): 5 Nm (0.5 m•kg, 3.6 ft•lb) 6. Adjust: • Rebound damping force Turn in the damping adjuster "1" finger-tight and then turn out to the originally set position. 7.

  • Page 231: Handlebar

    HANDLEBAR HANDLEBAR REMOVING THE HANDLEBAR Order Part name Q'ty Remarks Number plate Remove the band only. Hot starter cable Disconnect at the lever side. Hot starter lever holder Clutch cable Disconnect at the lever side. Clutch lever holder Engine stop switch Brake master cylinder Refer to removal section.
  • Page 232 HANDLEBAR Order Part name Q'ty Remarks Handlebar upper holder Handlebar Handlebar lower holder 5-37...
  • Page 233 HANDLEBAR REMOVING THE BRAKE MASTER CYLINDER 1. Remove: • Brake master cylinder bracket "1" • Brake master cylinder "2" • Do not let the brake master cylinder hang on the brake hose. • Keep the brake master cylinder cap side horizontal to prevent air from coming in.
  • Page 234 HANDLEBAR 2. Install: • Handlebar "1" • Handlebar upper holder "2" • Bolt (handlebar upper holder) "3" Bolt (handlebar upper holder): 28 Nm (2.8 m•kg, 20 ft•lb) • The handlebar upper holder should be in- stalled with the punched mark "a" forward. •...
  • Page 235 HANDLEBAR 5. Install: 7. Install: • Right grip "1" • Throttle cables "1" • Collar "2" To tube guide "2". Apply the adhesive on the tube guide "3". Apply the lithium soap base grease on the • Before applying the adhesive, wipe off grease throttle cable end and tube guide cable winding or oil on the tube guide surface "a"...
  • Page 236 HANDLEBAR 9. Install: • Grip cap cover "1" • The engine stop switch, clutch lever holder • Cover (throttle cable cap) "2" and clamp should be installed according to the dimensions shown. • Pass the engine stop switch lead in the middle of the clutch lever holder.

  • Page 237: Steering

    STEERING STEERING REMOVING THE STEERING Order Part name Q'ty Remarks TIGHTENING STEPS: • Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb) • Loosen it one turn. • Retighten it. 7 Nm (0.7 m•kg, 5.1 ft•lb) Hold the machine by placing the suit- Refer to "HANDLING NOTE".
  • Page 238 STEERING Order Part name Q'ty Remarks Steering ring nut Refer to removal section. Lower bracket Bearing race cover Upper bearing Lower bearing Refer to removal section. Bearing race Refer to removal section. 5-43...
  • Page 239 STEERING HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE STEERING RING NUT 1. Remove: • Steering ring nut "1" Use the steering nut wrench "2". Steering nut wrench: CHECKING THE STEERING STEM YU-33975/90890-01403 1.
  • Page 240 STEERING INSTALLING THE LOWER BRACKET 4. Install: 1. Install: • Steering ring nut "1" • Lower bearing "1" Steering ring nut: 7 Nm (0.7 m•kg, 5.1 ft• lb) Apply the lithium soap base grease on the dust seal lip and bearing inner circumference. Install the steering nut with its stepped side "a"...
  • Page 241 STEERING 7. Install: 10.Adjust: • Front fork "1" • Front fork top end "a" • Upper bracket "2" Front fork top end (standard) "a": 5 mm (0.20 in) • Temporarily tighten the pinch bolts (lower bracket). • Do not tighten the pinch bolts (upper bracket) yet.

  • Page 242: Swingarm

    SWINGARM SWINGARM REMOVING THE SWINGARM Order Part name Q'ty Remarks Hold the machine by placing the suit- Refer to "HANDLING NOTE". able stand under the engine. Refer to "FRONT BRAKE AND Brake hose holder REAR BRAKE" section. Refer to "FRONT BRAKE AND Rear brake caliper REAR BRAKE"...
  • Page 243 SWINGARM DISASSEMBLING THE SWINGARM Order Part name Q'ty Remarks Relay arm Connecting rod Collar Oil seal Thrust bearing Bushing Oil seal Bearing Refer to removal section. 5-48...
  • Page 244 SWINGARM HANDLING NOTE 2. Inspect: • Oil seal "3" Damage → Replace. Support the machine securely so there is no danger of it falling over. CHECKING THE SWINGARM 1. Inspect: • Bearing "1" • Bushing "2" Free play exists/unsmooth revolution/rust → Replace bearing and bushing as a set.
  • Page 245 SWINGARM 2. Install: • Bearing "1" • Washer "2" • Oil seal "3" To relay arm. • Apply the molybdenum disulfide grease on the bearing when installing. • Install the bearing by pressing it on the side having the manufacture's marks or numbers. •...
  • Page 246 SWINGARM 3. Install: • Collar "1" To connecting rod "2". Apply the molybdenum disulfide grease on the collar and oil seal lips. 6. Install: • Swingarm "1" • Pivot shaft "2" Pivot shaft: 85 Nm (8.5 m•kg, 61 ft•lb) 4. Install: •...
  • Page 247 SWINGARM 8. Install: 10.Tighten: • Bolt (connecting rod) "1" • Nut (connecting rod) "1" • Washer "2" Nut (connecting rod): • Nut (connecting rod) "3" 80 Nm (8.0 m•kg, 58 ft•lb) • Apply the molybdenum disulfide grease on the bolt. •...
  • Page 248 SWINGARM 13.Install: • Drive chain support "1" • Drive chain support cover "2" • Bolt {drive chain support [L = 50 mm (1.97 in)]} "3" • Nut (drive chain support) "4" Nut (drive chain support): 7 Nm (0.7 m•kg, 5.1 ft•lb) •...

  • Page 249: Rear Shock Absorber

    REAR SHOCK ABSORBER REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER Order Part name Q'ty Remarks Hold the machine by placing the suit- Refer to "HANDLING NOTE". able stand under the engine. Refer to "SEAT, FUEL TANK AND Seat SIDE COVERS" section in the CHAPTER 4.
  • Page 250 REAR SHOCK ABSORBER Order Part name Q'ty Remarks Lower spring guide Upper spring guide Spring (rear shock absorber) Bearing Refer to removal section. 5-55...
  • Page 251 Remove the bearing by pressing its outer race. • When scrapping the rear shock absorb- er, follow the instructions on disposal. NOTES ON DISPOSAL (YAMAHA DEALERS ONLY) Before disposing the rear shock absorber, be sure to extract the nitrogen gas from valve "1".
  • Page 252 REAR SHOCK ABSORBER 3. Remove: • Lower bearing "1" Remove the bearing by pressing its outer race. INSTALLING THE BEARING 1. Install: • Upper bearing "1" Install the bearing parallel until the stopper ring CHECKING THE REAR SHOCK ABSORBER groove appears by pressing its outer race. 1.
  • Page 253 REAR SHOCK ABSORBER 3. Install: 3. Adjust: • Lower bearing "1" • Spring length (installed) Refer to "ADJUSTING THE REAR SHOCK ABSORBER SPRING PRELOAD" section in Install the bearing by pressing it on the side the CHAPTER 3. having the manufacture's marks or numbers. 4.
  • Page 254 REAR SHOCK ABSORBER 6. Install: • Rear frame "1" • Bolt [rear frame (upper)] "2" Bolt [rear frame (upper)]: 32 Nm (3.2 m•kg, 23 ft•lb) • Bolt [rear frame (lower)] "3" Bolt [rear frame (lower)]: 32 Nm (3.2 m•kg, 23 ft•lb) 3.
  • Page 255 This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, disas- sembly, or reassembly only by reference to this manual.

  • Page 256: Wiring Diagram

    ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS 1. Engine stop switch 5. Ignition coil 2. Throttle position sensor 6. Spark plug 3. Neutral switch 7. CDI unit 4. CDI magneto...

  • Page 257: Electrical Components And Wiring Diagram

    ELECTRICAL COMPONENTS AND WIRING DIAGRAM WIRING DIAGRAM 1. Engine stop switch COLOR CODE 2. Throttle position sensor Black 3. Neutral switch Brown 4. CDI magneto Green 5. Ignition coil Blue 6. Spark plug Orange 7. CDI unit Pink Sky blue White Yellow Black/Blue...

  • Page 258: Ignition System

    IGNITION SYSTEM IGNITION SYSTEM 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. Spark gap test Spark → *Clean or replace spark plug. No spark ↓...
  • Page 259 IGNITION SYSTEM SPARK GAP TEST 1. Disconnect the ignition coil from spark plug. 2. Remove the ignition coil cap. 3. Connect the dynamic spark tester "1" (igni- tion checker "2") as shown. • Ignition coil "3" • Spark plug "4" CHECKING THE ENGINE STOP SWITCH 1.
  • Page 260 IGNITION SYSTEM CHECKING THE CDI MAGNETO 1. Inspect: • Pickup coil resistance Out of specification → Replace. Tester (+) lead → Red lead "1" Tester (-) lead → White lead "2" Pickup coil resis- Tester selector tance position 248-372 Ω at 20 Ω...
  • Page 261 IGNITION SYSTEM 3. Inspect: • Charging coil 2 resistance Out of specification → Replace. Tester (+) lead → Pink lead "1" Tester (-) lead → Black lead "2" Charging coil 2 Tester selector resistance position 44-66 Ω at 20 °C Ω...

  • Page 262: Throttle Position Sensor System

    THROTTLE POSITION SENSOR SYSTEM THROTTLE POSITION SENSOR SYSTEM INSPECTION STEPS If the throttle position sensor will not operate, use the following inspection steps. Check entire ignition system for connec- No good → Repair or replace. tion. OK ↓ Check throttle position sensor. (Throttle No good →...
  • Page 263 THROTTLE POSITION SENSOR SYSTEM HANDLING NOTE 2. Loosen: • Throttle stop screw "1" Do not loosen the screw (throttle position Turn out the throttle stop screw until the throttle sensor) "1" except when changing the shaft is in the full close position. throttle position sensor due to failure be- cause it will cause a drop in engine perfor- mance.
  • Page 264 THROTTLE POSITION SENSOR SYSTEM CHANGING AND ADJUSTING THE 6. Adjust: THROTTLE POSITION SENSOR • Engine idling speed 1. Remove: Refer to "ADJUSTING THE ENGINE • Throttle position sensor coupler IDLING SPEED" section in the CHAPTER 3. • Carburetor 7. Insert the thin electric conductors "2" (lead) 2.
  • Page 265 THROTTLE POSITION SENSOR SYSTEM Throttle position Tester selector sensor input position voltage 4–6 V DCV-20 10.Put the aligning marks "a" on the throttle po- sition sensor and carburetor. 11.Stop the engine. 12.Remove the carburetor. 13.Tighten: • Screw (throttle position sensor) "1" Tighten the screw (throttle position sensor) us- ing the T25 bit.
  • Page 266 ENGINE TUNING ATMOSPHERIC CONDITIONS AND CARBURETOR SETTINGS ENGINE CARBURETOR SETTING pres- • The air/fuel mixture will vary depending on at- Humidi- sure Mixture Setting mospheric conditions. Therefore, it is neces- temp. (alti- sary to take into consideration the air tude) pressure, ambient temperature, humidity, etc., when adjusting the carburetor.
  • Page 267 ENGINE CONSTRUCTION OF CARBURETOR AND SETTING PARTS The FLATCR carburetor has a primary main jet. This type of main jet is perfect for racing ma- chines since it supplies an even flow of fuel, even at full load. Use the main jet and the jet needle to set the carburetor.
  • Page 268 ENGINE Effects of adjusting the pilot screw (refer- 2. Too lean at intermediate speeds ence) • The engine breathes hard and will not pick up speed quickly. Step down the jet needle clip by one groove and move up the needle to enrich the mix- ture.
  • Page 269 ENGINE ADJUSTING THE LEAK JET (ADJUSTING THE ACCELERATOR PUMP) The leak jet "1" is a setting part that adjusts the flow of fuel discharged by the accelerator pump. Since the accelerator pump operates only when throttle is open, the leak jet is used to adjust a fuel mixture ratio for quick throttle opening and is therefore different from other setting parts that adjust a fuel mixture for each...
  • Page 270 ENGINE CARBURETOR SETTING PARTS Jet needle Size Part number Rich NFPN 5TA-14916-PN Main jet Size Part number NFPP 5TA-14916-PP Rich #190 4MX-14943-45 NFPQ 5TA-14916-P1 #188 4MX-14943-95 NFPR 5TA-14916-PR #185 4MX-14943-44 NFPS 5TA-14916-PS #182 4MX-14943-94 NFPT 5TA-14916-PT (STD) #180 4MX-14943-43 Lean NFPU 5TA-14916-PU #178...
  • Page 271 ENGINE SPECIFICATIONS OF JET NEEDLE For USA and CDN Diameter of straight portion Rich Lean Rich 1 richer NDJN-5 NDJP-5 NDJQ-5 NDJR-5 NDJS-5 NDJT-5 NDJU-5 0.5 richer NCVN-4 NCVP-4 NCVQ-4 NCVR-4 NCVS-4 NCVT-4 NCVU-4 NDJN-4 NDJP-4 NDJQ-4 NDJR-4 NDJS-4 NDJT-4 NDJU-4 0.5 leaner NCVN-3...
  • Page 272 ENGINE Symptom Setting Checking Lean mixture Lower jet needle clip position. (1 Groove 1 groove down) Groove 2 Clip Groove 3 Leaner Groove 4 Rich mixture Raise jet needle clip position. (1 Groove 5 Groove 6 Groove 7 groove up) (Standard) 1/4–3/4 throttle Lower jet needle clip position.
  • Page 273 CHASSIS CHASSIS DRIVE AND REAR WHEEL SPROCKETS SETTING PARTS SELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET) Part name Size Part number Drive sprocket "1" Secondary reduction ratio = Number of rear wheel sprocket teeth/Number of (STD) 9383B-13218 drive sprocket teeth Rear wheel sprocket "2"...
  • Page 274 CHASSIS • Under a stony or hard road condition, the tire pressure should be higher to prevent a flat tire. Extent of adjustment: 100–120 kPa (1.0–1.2 kgf/cm 15–18 psi) FRONT FORK SETTING The front fork setting should be made depend- ing on the rider's feeling of an actual run and the circuit conditions.
  • Page 275 CHASSIS REAR SUSPENSION SETTING The rear suspension setting should be made Generally a stiff spring gives a stiff riding feel- depending on the rider's feeling of an actual run ing. Rebound damping tends to become weak- and the circuit conditions. er, resulting in lack of a sense of contact with The rear suspension setting includes the fol- the road surface or in a vibrating handlebar.
  • Page 276 CHASSIS Length "a" of standard shock: • If the machine is new and after it is broken in, 490 mm (19.29 in) the same set length of the spring may change because of the initial fatigue, etc. of the spring. Therefore, be sure to make reevalua- tion.
  • Page 277 CHASSIS • Extent of adjustment (spring preload) SPRING PART Maximum Minimum NUMBER (-22212-) 5UN-00 Position in 5UN-10 which the 5UN-20 spring is 5UN-30 turned in 18 Position in mm (0.71 in) which the from its free spring is length. turned in 1.5 5UN-40 Position in mm (0.06 in)
  • Page 278 CHASSIS SUSPENSION SETTING (FRONT FORK) • If any of the following symptoms is experienced with the standard position as the base, make reset- ting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in).
  • Page 279 CHASSIS SUSPENSION SETTING (REAR SHOCK ABSORBER) • If any of the following symptoms is experienced with the standard position as the base, make reset- ting by reference to the adjustment procedure given in the same chart. • Adjust the rebound damping in 2-click increments or decrements. •...
  • Page 282 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2010.05-0.6×1 CR 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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