Yamaha WR250F 2008 Owner's And Service Manual
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Yamaha WR250F 2008 Owner's And Service Manual

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2008
OWNER'S SERVICE MANUAL
MANUEL D'ATELIER DU
PROPRIETAIRE
FAHRER- UND
WARTUNGSHANDBUCH
MANUALE DI SERVIZIO DEL
PROPRIETARIO
MANUAL DE SERVICIO
DEL PROPIETARIO
WR250F
5UM-28199-55

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  • Page 1 2008 OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE FAHRER- UND WARTUNGSHANDBUCH MANUALE DI SERVIZIO DEL PROPRIETARIO MANUAL DE SERVICIO DEL PROPIETARIO WR250F 5UM-28199-55...
  • Page 3 2008 OWNER’S SERVICE MANUAL WR250F 5UM-28199-55-E0...
  • Page 5 WR250F OWNER'S SERVICE MANUAL ©2007 by Yamaha Motor Co., Ltd. 1st Edition, October 2007 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan...

  • Page 6: Important Notice

    Always turn off the engine Congratulations on your purchase of damage to the machine. while refueling. Take care to a Yamaha WR series. This model is not spill any gasoline on the the culmination of Yamaha's vast ex- engine or exhaust system.
  • Page 7 The information has tion or maintenance of your machine, been complied to provide the me- please consult your Yamaha dealer. chanic with an easy to read, handy reference that contains comprehen- This manual should be considered a...
  • Page 8 2. Numbers "2" are given in the or- 4. A job instruction chart "4" accom- HOW TO READ DESCRIPTIONS der of the jobs in the exploded di- panies the exploded diagram, To help identify parts and clarify pro- agram. A number that is enclosed providing the order of jobs, names cedure steps, there are exploded dia- by a circle indicates a disassem-...

  • Page 9: Table Of Contents

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

  • Page 10: General Information

    CONTENTS CHAPTER 1 CHAPTER 3 CRANKCASE AND CRANKSHAFT ....5-57 GENERAL REGULAR TRANSMISSION, SHIFT INFORMATION INSPECTION AND CAM AND SHIFT FORK.5-63 ADJUSTMENTS CHAPTER 6 DESCRIPTION ....1-1 MACHINE CHASSIS MAINTENANCE IDENTIFICATION ..... 1-2 INTERVALS...... 3-1 INCLUDED PARTS ..1-2 PRE-OPERATION IMPORTANT FRONT WHEEL AND INSPECTION AND INFORMATION....

  • Page 11: Description

    DESCRIPTION GENERAL INFORMATION DESCRIPTION Clutch lever 14. Headlight Hot starter lever 15. Radiator Engine stop switch 16. Coolant drain bolt Multi-function display 17. Rear brake pedal Main switch 18. Valve joint Start switch 19. Fuel cock Front brake lever 20. Cold starter knob Throttle grip 21.

  • Page 12: Machine Identification

    There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own. SPARK PLUG WRENCH 2. If your machine is stolen, the au- This spark plug wrench "1"...

  • Page 13: Checking Of Connection

    CHECKING OF CONNECTION ALL REPLACEMENT PARTS 1. We recommend to use Yamaha • If there in no continuity, clean the genuine parts for all replace- terminals. ments. Use oil and/or grease rec- • Be sure to perform the steps 1 to 7...

  • Page 14: 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 techniques. The shape and part number used for the special tool differ by country, so two types are provided.
  • Page 15 SPECIAL TOOLS Tool name/Part number How to use Illustration Steering nut wrench This tool is used when tighten the YU-33975, 90890-01403 steering ring nut to specification. Damper rod holder Use this tool to remove and install YM-01494, 90890-01494 the damper rod. Fork seal driver This tool is used when install the fork YM-A0948, 90890-01502...
  • Page 16 SPECIAL TOOLS Tool name/Part number How to use Illustration Valve spring compressor This tool is needed to remove and YM-4019, 90890-04019 install the valve assemblies. Clutch holding tool This tool is used to hold the clutch YM-91042, 90890-04086 when removing or installing the clutch boss securing nut.
  • Page 17 How to use Illustration Vacuum/pressure pump gauge set This tool is used to check the air in- YB-35956-A, 90890-06756 duction system. YAMAHA Bond No. 1215 (ThreeB- This sealant (Bond) is used for ® No. 1215) crankcase mating surface, etc. 90890-85505...

  • Page 18: Control Functions

    CONTROL FUNCTIONS CONTROL FUNCTIONS CLUTCH LEVER The clutch lever "1" is located on the MAIN SWITCH left handlebar; it disengages or en- Functions of the respective switch po- gages the clutch. Pull the clutch lever sitions are as follows: to the handlebar to disengage the clutch, and release the lever to en- The engine can be started only at this gage the clutch.

  • Page 19: Multi-Function Display

    MULTI-FUNCTION DISPLAY MULTI-FUNCTION DISPLAY Be sure to stop the machine before making any setting changes to the multi-function display. The multi-function display is equipped with the following: COLD STARTER KNOB BASIC MODE: Setting the time When cold, the engine requires a •...
  • Page 20 MULTI-FUNCTION DISPLAY Returning to BASIC MODE from RACE MODE When the machine is made ready for a run by manual start, will It is possible to return to BASIC start flashing. MODE with timer measurement at a 2. Start timer measurement by stop.
  • Page 21 MULTI-FUNCTION DISPLAY If the machine is run while timer mea- • Resetting will reset the timer display surement is not made, no change will and travel distance display and put occur to the digit in tripmeter A (TRIP measurement on standby. •...
  • Page 22 MULTI-FUNCTION DISPLAY FUNCTION DIAGRAM A short push on the button changes the operation in the arrowed direction. Meter function A short push on the button changes the operation in both arrowed directions. Function that can be performed whether the time is or is not in operation. A long push on the button changes the operation in the arrowed direction.
  • Page 23 MULTI-FUNCTION DISPLAY The following diagram illustrates the multi-function display regarding the direction and operation condition in- volved in each of its functions. A short push on the button changes the operation in the ar- rowed direction. A short push on the button changes the operation in both arrowed directions.

  • Page 24: Starting And Break-In

    STARTING AND BREAK-IN AIR FILTER MAINTENANCE 7. Return the cold starter knob to its STARTING AND BREAK-IN According to "CLEANING THE AIR original position and run the en- FUEL FILTER ELEMENT" section in the gine at 3,000–5,000 r/min for 1 or Always use the recommended fuel as CHAPTER 3, apply the foam-air-filter 2 minutes.
  • Page 25 STARTING AND BREAK-IN The engine fails to start 4. Operate the machine in the lower Pull the hot starter lever all the way gears at moderate throttle open- out and while holding the lever, kick ings for five to eight minutes. the kickstarter crank 10 to 20 times to 5.

  • Page 26: 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 27: Cleaning And Storage

    CLEANING AND STORAGE CLEANING AND STORAGE STORAGE If your machine is to be stored for 60 CLEANING days or more, some preventive mea- Frequent cleaning of your machine sures must be taken to avoid deterio- will enhance its appearance, maintain ration.

  • Page 28: Specifications

    GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: WR250FX (USA, CDN, AUS, NZ) WR250F (EUROPE, ZA) Model code number: 5UMH (USA) 5UMK (CDN) 5UML (EUROPE) 5UMM (AUS, NZ, ZA) Dimensions: USA, CDN, ZA AUS, NZ EUROPE Overall length 2,165 mm (85.24 2,180 mm (85.83 2,190 mm (86.22 825 mm (32.48 in) ←...

  • Page 29: Chassis

    GENERAL SPECIFICATIONS Oil capacity: Engine oil Periodic oil change 1.1 L (0.97 Imp qt, 1.16 US qt) With oil filter replacement 1.2 L (1.06 Imp qt, 1.27 US qt) Total amount 1.4 L (1.23 Imp qt, 1.48 US qt) Coolant capacity (including all routes): 0.99 L (0.87 Imp qt, 1.05 US qt) Air filter: Wet type element...

  • Page 30: Maintenance Specifications

    MAINTENANCE SPECIFICATIONS Brake: Front brake type Single disc brake Operation Right hand operation Rear brake type Single disc brake Operation Right foot operation Suspension: Front suspension Telescopic fork Rear suspension Swingarm (link type monocross suspension) Shock absorber: Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/gas, oil damper...
  • Page 31 MAINTENANCE SPECIFICATIONS Item Standard Limit Cam dimensions Intake "A" 29.65–29.75 mm (1.1673–1.1713 in) 29.55 mm (1.1634 in) Intake "B" 22.45–22.55 mm (0.8839–0.8878 in) 22.35 mm (0.8799 in) Exhaust "A" 30.399–30.499 mm (1.1968–1.2007 in) 30.299 mm (1.1929 in) Exhaust "B" 22.45–22.55 mm (0.8839–0.8878 in) 22.35 mm (0.8799 in) Camshaft runout limit...

  • Page 32: Specifications

    MAINTENANCE SPECIFICATIONS Item Standard Limit "C" seat width (IN) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630 "C" seat width (EX) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630 "D" margin thickness (IN) 0.8 mm (0.0315 in) ---- "D" margin thickness (EX) 0.7 mm (0.0276 in) ---- Stem outside diameter (IN)
  • Page 33 MAINTENANCE SPECIFICATIONS Item Standard Limit Compressed force (installed) (EX) 126–144 N at 29.30 mm (12.85–14.68 kg ---- at 29.30 mm, 28.32–32.37 lb at 1.15 in) Tilt limit* (IN) ---- 2.5°/1.6 mm (2.5°/0.063 in) Tilt limit* (EX) ---- 2.5°/1.6 mm (2.5°/0.063 in) Direction of winding (top view) (IN) Clockwise ----...
  • Page 34 MAINTENANCE SPECIFICATIONS Item Standard Limit Side clearance 0.020–0.055 mm (0.0008–0.0022 in) 0.12 mm (0.005 Oil ring: Dimensions (B × T) 1.50 × 2.25 mm (0.06 × 0.09 in) ---- End gap (installed) 0.10–0.40 mm (0.004–0.016 in) ---- Crankshaft: Crank width "A" 55.95–56.00 mm (2.203–2.205 in) ---- Runout limit "C"...

  • Page 35: Engine

    MAINTENANCE SPECIFICATIONS Item Standard Limit Carburetor: USA, CDN, ZA, EUROPE AUS, NZ FCR-MX37/KEIHIN ← Type/manufacturer ---- I. D. mark 5UME E0 5UML L0 ---- Main jet (M.J) #170 #160 ---- ← Main air jet (M.A.J) #115 ---- Jet needle (J.N) NJRU NNGU ----...

  • Page 36: Chassis

    MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Taper roller bearing ---- Front suspension: Front fork travel 300 mm (11.8 in) ---- Fork spring free length 460 mm (18.1 in) 455 mm (17.9 Spring rate, STD K = 4.4 N/mm (0.449 kg/mm, 25.1 lb/in) ---- Optional spring/spacer ----...

  • Page 37: Electrical

    Minimum spark gap 6 mm (0.24 in) ---- 0.08–0.10 Ωat 20 °C (68 °F) Primary coil resistance ---- Secondary coil resistance 4.6–6.8 kΩat 20 °C (68 °F) ---- Charging system: System type AC magneto ---- Model (stator)/manufacturer 5UM 30/YAMAHA ---- 2-10...

  • Page 38: Tightening Torques

    Rectifier capacity (AC) 12 A ---- Rectifier capacity (DC) ---- Electric starting system: Type Constant mesh ---- Starter motor: Model/manufacturer 5UM01/YAMAHA ---- Operation voltage 12 V ---- Output 0.35 kW ---- 0.0189–0.0231 Ω at 20 °C (68 °F) Armature coil resistance ---- Brush overall length 7 mm (0.28 in)
  • Page 39 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Cylinder head (stud bolt) M8 × 1.25 Cylinder head (bolt) M9 × 1.25 Cylinder head (nut) M6 × 1.0 Cylinder head cover M6 × 1.0 Cylinder M6 × 1.0 Balancer weight M6 ×...
  • Page 40 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb △ Silencer M8 × 1.25 Silencer clamp M8 × 1.25 Spark arrester M5 × 0.8 Silencer cap M5 × 0.8 Air induction pipe M6 × 1.0 Air induction pipe clamp M6 ×...
  • Page 41 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Front fork and front fork cap bolt M51 × 1.5 Front fork and base valve M30 × 1.0 Front fork cap bolt and damper rod M12 × 1.25 Front fork bleed screw and front fork cap bolt M5 ×...
  • Page 42 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb △ Engine and engine bracket (upper) M10 × 1.25 △ Engine guard M6 × 1.0 Regulator M6 × 1.0 △ Pivot shaft and nut M16 × 1.5 △...
  • Page 43 TIGHTENING TORQUES 1. First, tighten the steering ring nut approximately 38 Nm (3.8 m•kg, 27 ft•lb) by using the steering nut wrench, then loosen the steering ring nut one turn. 2. Retighten the steering ring nut 7 Nm (0.7 m•kg, 5.1 ft•lb). ELECTRICAL Tightening torque Part to be tightened...
  • Page 44 TIGHTENING TORQUES GENERAL TORQUE TORQUE SPECIFI- SPECIFICATIONS CATION (Bolt This chart specifies torque for stan- (Nut) dard fasteners with standard I.S.O. m•kg ft•lb pitch threads. Torque specifications 6 mm for special components or assem- blies are included in the applicable sections of this book.

  • Page 45: Lubrication Diagrams

    LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS Oil filter element Oil pump Drive axle Main axle Intake camshaft Exhaust camshaft Oil tank Oil delivery pipe To oil tank 2-18...
  • Page 46 LUBRICATION DIAGRAMS Crankshaft Oil filter element Oil tank Oil hose From oil pump 2-19...
  • Page 47 LUBRICATION DIAGRAMS 2-20...

  • Page 48: Cable Routing Diagram

    CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM Fuel tank breather hose 10. Oil hose 19. Carburetor overflow hose Clamp 11. Clutch cable 20. Catch tank breather hose Diode 12. Starter motor lead Hot starter cable 13. Cable guide Wire harness 14. Negative battery lead Hump (frame) 15.
  • Page 49 CABLE ROUTING DIAGRAM Insert the end of the fuel tank Fasten the clutch cable, AC breather hose into the hole in magneto lead and neutral switch the steering stem. lead onto the frame. Locate the Fasten the throttle cable, hot clamp end near the clutch cable starter cable and rectifier/regula- and cut off the tie end.
  • Page 50 CABLE ROUTING DIAGRAM Throttle cable (pull) Fasten the catch tank hose and Pass the carburetor breather Throttle cable (return) air induction hose (air cut-off hose (of the throttle cable cover) Catch tank hose valve-rear of cylinder head) onto through the hose holder. Ignition coil the frame.
  • Page 51 CABLE ROUTING DIAGRAM Brake master cylinder If the brake hose contacts the Brake hose holder spring (rear shock absorber), Brake hose correct its twist. Install the brake hose so that its Install the brake hose so that its pipe portion directs as shown pipe portion directs as shown and lightly touches the projec- and lightly touches the projec-...
  • Page 52 CABLE ROUTING DIAGRAM Clamp Fasten the wire harness, nega- Fasten the wire harness, nega- Positive battery lead tive battery lead and starter mo- tive battery lead and starter mo- Battery tor lead to the upper engine tor lead to the upper engine Negative battery lead bracket (left side).
  • Page 53 CABLE ROUTING DIAGRAM Pass the starter motor lead through the hole in the relay holder. Fit the cover securely. Connect the wire harness to the starter relay. Fasten the catch tank breather hose and catch tank hose to the rear frame. Clamp them close to where they are joined to the frame.
  • Page 54 CABLE ROUTING DIAGRAM Throttle cable 12. Upper bracket Fasten the engine stop switch Clamp 13. Clutch switch coupler lead and clutch switch lead to Brake hose 14. Engine stop switch coupler the handlebar with the plastic Clutch cable 15. Multi-function display coupler bands.
  • Page 55 CABLE ROUTING DIAGRAM Pass the throttle cables, clutch cable and hot starter cable be- tween the upper bracket and multi-function display bracket. Fasten the multi-function display leads to the bracket. Cut off the tie end. Secure the coupler by pushing it into the hole in the multi-function display bracket.

  • Page 56: Regular Inspection And Adjustments

    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. Every...

  • Page 57: Maintenance Intervals

    MAINTENANCE INTERVALS Every Every After third fifth (or Every As re- Item break- Remarks race (or 500 1,000 quired CLUTCH ● ● Inspect and adjust Inspect housing, friction plate, clutch plate and spring. ● Replace TRANSMISSION ● Inspect ● Replace bearing SHIFT FORK, SHIFT CAM, GUIDE BAR ●...
  • Page 58 MAINTENANCE INTERVALS Every Every After third fifth (or Every As re- Item break- Remarks race (or 500 1,000 quired FUEL TANK, COCK ● ● Clean and inspect BRAKES ● ● Adjust lever position and pedal height ● ● Lubricate pivot point ●...
  • Page 59 Lubricate Lithium base grease THROTTLE, CONTROL CABLE ● ● Check routing and connection ● ● Lubricate Yamaha cable lube or SAE 10W-30 motor oil HOT STARTER, CLUTCH LEVER ● Inspect free play BATTERY ● Check terminal for looseness and corrosion...

  • Page 60: Inspection And Maintenance

    PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation or practice, 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. Check the cool- Coolant P.3-9 –...

  • Page 61: Engine

    ENGINE ENGINE 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) Fuel tank Left side cover Open the air filter case cover. Right side cover Refer to removal section.
  • Page 62 ENGINE REMOVING THE SIDE COVER 1. Remove: • Bolt (side cover) • Right side cover "1" Draw the side cover backward to re- move it because its claw "a" is insert- ed in the air filter case.
  • Page 63 ENGINE REMOVING THE EXHAUST PIPE AND SILENCER Order Part name Q'ty Remarks Refer to "REMOVING THE SEAT, FUEL Right side cover TANK AND SIDE COVERS" section. Bolt (silencer clamp) Only loosening. Bolt [silencer (front)] Bolt [silencer (rear)] Collar Silencer Silencer clamp Nut (exhaust pipe) Exhaust pipe Gasket...

  • Page 64: Engine

    ENGINE CHECKING THE SILENCER AND CHECKING THE COOLANT LEVEL 2. Remove: EXHAUST PIPE • Seat 1. Inspect: • Left side cover Do not remove the radiator cap • Gasket "1" 3. Remove the catch tank hose from "1", drain bolt and hoses when the Damage →...
  • Page 65 ENGINE Handling notes of coolant: The coolant is harmful so it should be handled with special care. • When coolant splashes to your eye. Thoroughly wash your eye with Radiator cap ADJUSTING THE CLUTCH CABLE water and see your doctor. 2.
  • Page 66 ENGINE Never run the engine without the air filter element in place; this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage. 1. Open the air filter case cover "1" 2. Adjust: 3.
  • Page 67 ENGINE 5. Inspect: CHECKING THE ENGINE OIL • Air filter element LEVEL • Do not add any chemical addi- Damage → Replace. 1. Start the engine, warm it up for tives or use oils with a grade of 6. Apply: several minutes, and then turn off CD "a"...
  • Page 68 ENGINE 4. Remove: 10. Fill: Oil filter element cover: • Engine guard "1" • Engine oil 10 Nm (1.0 m•kg, 7.2 • Bolt (oil tank) "2" Oil quantity: ft•lb) • Washer "3" Periodic oil change: • Oil filler cap "4" 1.1 L (0.97 Imp qt, 1.16 •...
  • Page 69 ENGINE 4. Remove: To increase idle speed→Turn the • Timing mark accessing screw "1" throttle stop screw "1" in "a". • Crankshaft end accessing screw To decrease idle speed→Turn the "2" throttle stop screw "1" out "b". • O-ring Engine idling speed: 1,750–1,950 r/min ADJUSTING THE PILOT SCREW 1.
  • Page 70 ENGINE c. Measure the valve clearance "e" Pad Availabili- using a feeler gauge "1". Pad range ty: 25 incre- ments Record the measured reading if the 1.20 clearance is incorrect. Pads are avail- 120– mm– able in 0.05 mm 2.40 increments g.
  • Page 71 ENGINE INTAKE EXHAUST 3-16...

  • Page 72: Chassis

    CHASSIS CLEANING THE SPARK 6. Install: ARRESTER (For USA) • Silencer cap Silencer cap: • Be sure the exhaust pipe and si- 5 Nm (0.5 m•kg, 3.6 lencer are cool before cleaning ft•lb) the spark arrester. • Do not start the engine when First tighten the two screws "a"...
  • Page 73 CHASSIS Pedal height adjustment steps: a. Loosen the locknut "1". b. Turn the adjusting nut "2" until the pedal height "a" is within specified height. c. Tighten the locknut. 2. Remove: b. Loosen the pad pin "2". • Brake lever cover •...
  • Page 74 CHASSIS Do not reuse the drained brake flu- g. Tighten the bleed screw. Bleed screw: 6 Nm (0.6 m•kg, 4.3 ft•lb) Install the brake caliper "8" and 2. Replace: tighten the pad pin "9". • Brake pad h. Install the brake pad "10" and pad pin "11".
  • Page 75 CHASSIS 3. Inspect: • Brake fluid level Refer to "CHECKING THE BRAKE FLUID LEVEL" section. 4. Check: • Brake pedal operation A softy or spongy feeling → Bleed brake system. Refer to "BLEEDING THE HY- Lower level 3. Clean: DRAULIC BRAKE SYSTEM" sec- A.
  • Page 76 CHASSIS e. Tighten the locknuts. When installing the drive chain, apply Before checking and/or adjusting, ro- Locknut: the lithium soap base grease on the tate the rear wheel through several 19 Nm (1.9 m•kg, 13 chain joint and O-rings. revolutions and check the slack sev- ft•lb) eral times to find the tightest point.
  • Page 77 CHASSIS 1. Elevate the front wheel by placing CHECKING THE REAR SHOCK a suitable stand under the engine. ABSORBER Always adjust each front fork to 2. Remove the air bleed screw "1" 1. Inspect: the same setting. Uneven adjust- and release the internal pressure •...
  • Page 78 CHASSIS • STANDARD POSITION: Standard position: This is the position which is back • Be sure to remove all dirt and mud About 12 clicks out by the specific number of clicks from around the locknut and adjust- * About 13 clicks out from the fully turned-in position.
  • Page 79 CHASSIS 4. Adjust: • Steering ring nut Do not force the adjuster past the minimum or maximum extent of Steering ring nut adjustment adjustment. The adjuster may be steps: damaged. a. Remove the headlight. b. Remove the handlebar and upper bracket.
  • Page 80 CHASSIS g. Check the steering stem by turn- ing it lock to lock. If there is any binding, remove the steering stem assembly and inspect the steer- ing bearings. h. Install the washer "5", collar "6", upper bracket "7", washer "8", steering stem nut "9", handlebar "10", handlebar upper holder "11"...
  • Page 81 Footrest pivot avoid getting grease on the brake Throttle-to-handlebar contact discs. Drive chain Tube guide cable winding por- tion Throttle cable end Clutch cable end 10. Hot starter cable end Use Yamaha cable lube or equivalent on these areas. 3-26...

  • Page 82: Electrical

    ELECTRICAL CHECKING THE IGNITION TIMING • Charge batteries in a well-venti- ELECTRICAL 1. Remove: lated area. CHECKING THE SPARK PLUG • Timing mark accessing screw "1" • Keep batteries away from fire, 1. Remove: sparks or open flames (e.g., • Spark plug welding equipment, lighted ciga- 2.
  • Page 83 ELECTRICAL • To reduce the chance of sparks, do not plug in the battery charger until the battery charger leads are connected to the battery. • Before removing the battery charger lead clips from the bat- tery terminals, be sure to turn off the battery charger.
  • Page 84 ELECTRICAL Charging method using a variable voltage charger 3-29...
  • Page 85 ELECTRICAL Charging method using a constant voltage charger 3-30...
  • Page 86 ELECTRICAL 6. Install: • Battery • Battery band 7. Connect: • Battery leads (to the battery terminals) First, connect the positive lead "1", Reserve fuse 3. Remove: then the negative lead "2". c. If the pocket tester indicates " ∞ ", •...
  • Page 87 ELECTRICAL ADJUSTING THE HEADLIGHT BEAMS 1. Adjust: • Headlight beam (vertically) Adjusting steps: a. Turn the adjusting screw "1" in di- rection "a" or "b". Direction "a" Headlight beam is raised. Direction "b" Headlight beam is lowered. 3-32...

  • Page 88: Tuning

    ENGINE TUNING • After installing the carburetor, CONSTRUCTION OF check that the throttle operates CARBURETOR AND SETTING ENGINE correctly and opens and closes PARTS CARBURETOR SETTING smoothly. The FLATCR carburetor has a prima- • The air/fuel mixture will vary de- ry main jet.
  • Page 89 ENGINE ADJUSTING THE PILOT JET Effects of changing the jet needle ADJUSTING THE LEAK JET The richness of the air-fuel mixture groove position (reference) (ADJUSTING THE ACCELERATOR with the throttle open 1/4 or less can PUMP) be set by adjusting the pilot jet "1". The leak jet "1"...
  • Page 90 ENGINE CARBURETOR SETTING PARTS Part Main jet Size number (-14943-) Rich #182 4MX-94 #180 4MX-43 #178 4MX-93 #175 4MX-42 #172 4MX-92 (STD) #170 4MX-41 #168 4MX-91 #165 4MX-40 #162 4MX-90 * (STD) #160 4MX-39 Lean #158 4MX-89 Part Pilot jet Size number (-14948-)
  • Page 91 ENGINE EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM Symptom Setting Checking Discoloration of spark plug → If tan color, it At full throttle Increase main jet calibration no. (Gradual- Hard breathing is in good condition. Shearing noise If cannot be corrected: Whitish spark plug Clogged float valve seat ↓...
  • Page 92 CHASSIS CHASSIS DRIVE AND REAR WHEEL • Under a stony or hard road condi- SPROCKETS SETTING PARTS tion, the tire pressure should be SELECTION OF THE SECONDARY higher to prevent a flat tire. REDUCTION RATIO (SPROCKET) Part Size Part number Extent of adjustment: name Secondary reduction ratio =...
  • Page 93 CHASSIS • Front fork spring "2" SPRING SPRI I.D. PART TYPE MARK NUMBER RATE (slits) (-23141-) 0.408 5TJ-00 0.418 5TJ-10 SOFT A. Load 0.428 5TJ-20 B. Fork stroke 0.438 5TJ-30 |||| Without adjustment washer 0.449 5TJ-A0 — (standard) 1 adjustment washer 0.459 5TJ-50 STIFF...
  • Page 94 CHASSIS CHOOSING SET LENGTH SETTING OF SPRING AFTER REAR SHOCK ABSORBER 1. Place a stand or block under the REPLACEMENT SETTING PARTS engine to put the rear wheel After replacement, be sure to adjust • Rear shock spring "1" above the floor, and measure the the spring to the set length [sunken SPRIN SPRI...
  • Page 95 CHASSIS SUSPENSION SETTING (FRONT FORK) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in). Section Medi- Symptom...
  • Page 96 CHASSIS SUSPENSION SETTING (REAR SHOCK ABSORBER) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Adjust the rebound damping in 2-click increments or decrements. •...

  • Page 97: Radiator

    RADIATOR ENGINE RADIATOR REMOVING THE RADIATOR Order Part name Q'ty Remarks Refer to "CHECKING THE COOLANT" sec- Drain the coolant. tion in the CHAPTER 3. Refer to "REMOVING THE SEAT, FUEL Seat, fuel tank and left side cover TANK AND SIDE COVERS" section in the CHAPTER 3.
  • Page 98 RADIATOR Order Part name Q'ty Remarks Radiator pipe 1 Catch tank breather hose Catch tank...
  • Page 99 RADIATOR HANDLING NOTE 2. Install: • Catch tank hose "1" • Radiator hose 2 "2" Do not remove the radiator cap • Radiator hose 3 "3" when the engine and radiator are • Radiator pipe 2 "4" hot. Scalding hot fluid and steam •...

  • Page 100: 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 101 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) Air cut valve cover Spring (air cut valve) Diaphragm (air cut valve) Float chamber Leak jet...
  • Page 102 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 Main air jet Pilot air jet Cold starter plunger...
  • Page 103 CARBURETOR HANDLING NOTE • Main air jet "7" Damage → Replace. Contamination → Clean. Do not loosen the screw (throttle position sensor) "1" except when • Use a petroleum based solvent for changing the throttle position sen- cleaning. Blow out all passages and sor due to failure because it will jets with compressed air.
  • Page 104 CARBURETOR 2. Inspect: 4. Install: • Throttle shaft "1" • Spring 2 "1" • Spring "2" To lever 2 "2". • Lever 1 "3" • Spring 1 "4" • Lever 2 "5" • Spring 2 "6" Dirt → Clean. f. Recheck the float height. CHECKING THE FLOAT 5.
  • Page 105 CARBURETOR • Apply the fluorochemical grease on the bearings. • Fit the projection "a" on the throttle shaft assembly into the slot "b" in the throttle position sensor. • Make sure the stopper "c" of the spring fits into the recess in the car- 11.
  • Page 106 CARBURETOR 17. Install: • Throttle valve assembly "1" • Screw (throttle shaft) "2" Install the valve lever rollers "3" into the slits "a" of the throttle valve. a. Fully turn in the accelerator pump 4. Tighten: adjusting screw "3". • Bolt (carburetor joint) "1" b.
  • Page 107 CARBURETOR 8. Install: • Throttle position sensor lead cou- pler "1" • Clamp "2" Refer to "CABLE ROUTING DIA- GRAM" section in the CHAPTER 9. Install: • Clamp "1" Refer to "CABLE ROUTING DIA- GRAM" section in the CHAPTER 5-11...

  • Page 108: Air Indictoin System

    AIR INDICTOIN SYSTEM AIR INDICTOIN SYSTEM REMOVING THE AIR INDUCTION SYSTEM 7 Nm (0.7 m kg, 5.1 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) Order Part name Q'ty Remarks Bracket Air cut-off valve assembly Air induction hose (air cut-off valve - front of cyl-...
  • Page 109 AIR INDICTOIN SYSTEM CHECKING THE AIR INDUCTION SYSTEM 1. Inspect: • Air induction hose Crack/damage → Replace. • Air induction pipe Crack/damage → Replace. 2. Check: • Operation of air cut valve From air filter Pass air through the pipe and To cylinder head (exhaust check the air cut valve for opera- port)

  • Page 110: Camshafts

    CAMSHAFTS CAMSHAFTS REMOVING THE CYLINDER HEAD COVER Order Part name Q'ty Remarks Refer to "REMOVING THE SEAT, FUEL Seat and fuel tank TANK AND SIDE COVERS" section in the CHAPTER 3. Air cut-off valve assembly Refer to "AIR INDUCTION SYSTEM" section. Spark plug Cylinder head breather hose Bolt (cylinder head cover)
  • Page 111 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 112 CAMSHAFTS REMOVING THE CAMSHAFT Cam lobes length: 1. Remove: Intake "a": • Timing mark accessing screw "1" 29.65–29.75 mm • Crankshaft end accessing screw (1.1673–1.1713 in) "2" <Limit>: 29.55 mm (1.1634 in) Intake "b": 22.45–22.55 mm 4. Remove: (0.8839–0.8878 in) •...
  • Page 113 CAMSHAFTS Camshaft-to-cap clear- ance: 0.028–0.062 mm (0.0011–0.0024 in) <Limit>:0.08 mm (0.003 CHECKING THE CAMSHAFT Measurement steps: SPROCKET a. Install the camshaft onto the cylin- 1. Inspect: der head. • Camshaft sprocket "1" ® b. Position a strip of Plastigauge Wear/damage → Replace the "1"...
  • Page 114 Apply the sealant on the cylinder d. Install the clips, camshaft caps "4" ft•lb) head cover gasket. and bolts (camshaft cap) "5". Bolt (camshaft cap): YAMAHA Bond No. 1215 10 Nm (1.0 m•kg, 7.2 ® (ThreeBond No. 1215): ft•lb) 90890-85505 c.

  • Page 115: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD REMOVING THE CYLINDER HEAD Order Part name Q'ty Remarks Refer to "REMOVING THE SEAT, FUEL Seat and fuel tank TANK AND SIDE COVERS" section in the CHAPTER 3. Refer to "REMOVING THE EXHAUST PIPE Exhaust pipe and silencer AND SILENCER"...
  • Page 116 CYLINDER HEAD CHECKING THE CYLINDER HEAD • Cylinder head "4" • Union bolt (M8) "3" 1. Eliminate: Union bolt (M8): • Carbon deposits (from the com- While pulling up the timing chain, in- 18 Nm (1.8 m•kg, 13 bustion chambers) stall the timing chain guide (exhaust ft•lb) Use a rounded scraper.

  • Page 117: 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 118 VALVES AND VALVE SPRINGS REMOVING THE VALVE LIFTER AND VALVE COTTER 1. Remove: • Valve lifter "1" • Pad "2" Identify each lifter "1" and pad "2" po- sition very carefully so that they can CHECKING THE VALVE b. Install the new valve guide using a be reinstalled in their original place.
  • Page 119 VALVES AND VALVE SPRINGS 4. Measure: • Margin thickness "a" Out of specification → Replace. Margin thickness: Intake: 0.8 mm (0.0315 in) Exhaust: 0.7 mm (0.0276 in) c. Install the valve into the cylinder head. Measurement steps: d. Turn the valve until the valve face a.
  • Page 120 VALVES AND VALVE SPRINGS INSTALLING THE VALVES 1. Apply: Hitting the valve tip with excessive • Molybdenum disulfide oil force could damage the valve. Onto the valve stem and valve stem seal. 2. Install: • Valve "1" • Valve spring seat "2" 2.

  • Page 121: 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 122 CYLINDER AND PISTON REMOVING THE PISTON AND 2. Measure: Piston-to-cylinder clear- PISTON RING • Piston-to-cylinder clearance ance: 1. Remove: 0.030–0.055 mm • Piston pin clip "1" (0.0012–0.0022 in) Measurement steps: • Piston pin "2" <Limit>:0.1 mm (0.004 a. Measure the cylinder bore "C" •...
  • Page 123 CYLINDER AND PISTON 3. Measure: • Ring end gap Out of specification → Replace. You cannot measure the end gap on the expander spacer of the oil control ring. If the oil control ring rails show excessive gap, replace all three rings. c.
  • Page 124 CYLINDER AND PISTON 3. Install: • Cylinder gasket "1" • Cylinder "2" Install the cylinder with one hand while compressing the piston rings with the other hand. • Pass the timing chain "3" through the timing chain cavity. • Be careful not to damage the tim- ing chain guide "4"...

  • Page 125: Clutch

    CLUTCH CLUTCH REMOVING THE CLUTCH Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Brake pedal Refer to "ENGINE REMOVAL" section. Clutch cable Disconnect at engine side. Clutch cover Clutch spring Pressure plate Push rod 1...
  • Page 126 CLUTCH Order Part name Q'ty Remarks Nut (clutch boss) Refer to removal section. Lock washer Refer to removal section. Clutch boss Refer to removal section. Thrust washer Primary driven gear Push lever shaft 5-30...
  • Page 127 CLUTCH REMOVING THE CLUTCH BOSS CHECKING THE CLUTCH CHECKING THE PUSH LEVER 1. Remove: SPRINGS SHAFT • Nut "1" 1. Measure: 1. Inspect: • Lock washer "2" • Clutch spring free length "a" • Push lever shaft "1" Out of specification → Replace Wear/damage →...
  • Page 128 CLUTCH Apply the engine oil on the primary • Install the seat plate with its cham- driven gear inner circumference. fered portion "a" facing the clutch boss "3". • Install the seat plate so that it is not caught on the step "b". •...
  • Page 129 CLUTCH 10. Install: • Dowel pin "1" • Gasket (clutch cover) "2" 11. Install: • Clutch cover "1" • Bolt (clutch cover) Bolt (clutch cover): 10 Nm (1.0 m•kg, 7.2 ft•lb) Tighten the bolts in stage, using a crisscross pattern. 5-33...

  • Page 130: 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 OIL" Drain the engine oil. section in the CHAPTER 3. Refer to "CHANGING THE COOLANT"...
  • Page 131 OIL FILTER ELEMENT AND WATER PUMP Order Part name Q'ty Remarks Washer Refer to removal section. Impeller shaft Refer to removal section. Oil seal Refer to removal section. Bearing Refer to removal section. 5-35...
  • Page 132 OIL FILTER ELEMENT AND WATER PUMP REMOVING THE IMPELLER INSTALLING THE OIL SEAL SHAFT 1. Install: 1. Remove: • Oil seal "1" • Impeller "1" • Washer "2" • Apply the lithium soap base grease • Impeller shaft "3" on the oil seal lip. •...
  • Page 133 OIL FILTER ELEMENT AND WATER PUMP INSTALLING THE KICKSTARTER INSTALLING THE WATER PUMP CRANK HOUSING 1. Install: 1. Install: • Kickstarter crank "1" • Dowel pin "1" • Washer "2" • O-ring "2" • Bolt (kickstarter crank) "3" Apply the lithium soap base grease Bolt (kickstarter crank): on the O-ring.

  • Page 134: Balancer

    BALANCER BALANCER REMOVING THE BALANCER Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Refer to "OIL FILTER ELEMENT AND WA- Right crankcase cover TER PUMP" section. Refer to "AC MAGNETO AND STARTER Stator CLUTCH" section. Nut (primary drive gear) Refer to removal section.
  • Page 135 BALANCER REMOVING THE BALANCER CHECKING THE BALANCER 1. Straighten the lock washer tab. SHAFT 2. Loosen: 1. Inspect: • Nut (primary drive gear) "1" • Balancer shaft Cracks/damage → Replace. • Nut (balancer shaft driven gear) "2" Place an aluminum plate "a" between 4.

  • Page 136: 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 AND WA- Right crankcase cover TER PUMP" section. Circlip Washer Oil pump drive gear Oil pump assembly Outer rotor 2 Circlip Inner rotor 2...
  • Page 137 OIL PUMP REMOVING THE OIL TANK Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Oil hose 2 Oil hose 1 Dowel pin Oil tank breather hose Oil tank Oil strainer 5-41...
  • Page 138 OIL PUMP CHECKING THE OIL PUMP 3. Check: 1. Inspect: • Unsmooth→Repeat steps #1 and • Oil pump drive gear "1" #2 or replace the defective parts. • Oil pump drive shaft "2" • Rotor housing "3" • Oil pump cover "4" Cracks/wear/damage →...

  • Page 139: 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 140 KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Remarks Pawl Pawl pin Spring Bolt (stopper lever) Stopper lever Torsion spring Segment Refer to removal section. 5-44...
  • Page 141 KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT • Kick shaft "2" CHECKING THE STOPPER LEVER Wear/damage → Replace. ASSEMBLY 1. Inspect: 1. Remove: • Spring "3" • Stopper lever "1" Broken → Replace. Wear/damage → Replace. • Kick shaft assembly "1" •...
  • Page 142 KICK SHAFT AND SHIFT SHAFT INSTALLING THE SHIFT GUIDE INSTALLING THE SHIFT SHAFT AND SHIFT LEVER ASSEMBLY 1. Install: 1. Install: • Roller "1" • Spring "1" • Collar "2" • Pawl pin "2" • Torsion spring "3" • Pawl "3" •...
  • Page 143 KICK SHAFT AND SHIFT SHAFT INSTALLING THE KICK IDLE GEAR 1. Install: • Kick idle gear "1" • Washer "2" • Circlip "3" • Apply the engine oil on the kick idle gear inner circumference. • Install the kick idle gear with its de- pressed side "a"...

  • Page 144: Ac Magneto And Starter Clutch

    AC MAGNETO AND STARTER CLUTCH AC MAGNETO AND STARTER CLUTCH REMOVING THE AC MAGNETO AND STARTER CLUTCH Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Refer to "REMOVING THE SEAT, FUEL Seat and fuel tank TANK AND SIDE COVERS"...
  • Page 145 AC MAGNETO AND STARTER CLUTCH Order Part name Q'ty Remarks Starter clutch Refer to removal section. Bearing Washer Idle gear plate Idle gear Holder Pickup coil Stator Tighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb), loosen and retighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb). 5-49...
  • Page 146 AC MAGNETO AND STARTER CLUTCH REMOVING THE ROTOR 1. Remove: a. Install the starter clutch drive gear • Nut (rotor) "1" "1" onto the starter clutch "2" and • Washer hold the starter clutch. Use the sheave holder "2". b. When turning the starter clutch Sheave holder: drive gear counterclockwise "B", YS-1880-A/90890-...
  • Page 147 Apply the sealant to the grommet of the AC magneto lead. YAMAHA Bond No. 1215 9. Install: ® (ThreeBond No. 1215): • Washer (rotor) 90890-85505 •...
  • Page 148 AC MAGNETO AND STARTER CLUTCH • Bolt [crankcase cover (left)] "3" 13. Connect: • AC magneto lead Bolt [crankcase cover Refer to "CABLE ROUTING DIA- (left)]: GRAM" section in the CHAPTER 12 Nm (1.2 m•kg, 8.7 ft•lb) Tighten the bolts in stage, using a crisscross pattern.

  • Page 149: Engine Removal

    ENGINE REMOVAL ENGINE REMOVAL REMOVING THE ENGINE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the frame. Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Refer to "REMOVING THE SEAT, FUEL Seat and fuel tank TANK AND SIDE COVERS"...
  • Page 150 ENGINE REMOVAL Order Part name Q'ty Remarks Disconnect the AC magneto lead. Negative battery lead Disconnect at the engine side. 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.
  • Page 151 ENGINE REMOVAL HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE DRIVE SPROCKET 1. Remove: INSTALLING THE ENGINE • Nut (drive sprocket) "1" 1. Install: • Lock washer "2" • Engine "1" Install the engine from right side.
  • Page 152 ENGINE REMOVAL 2. Install: • Lock washer "1" • Nut (drive sprocket) "2" Nut (drive sprocket): 75 Nm (7.5 m•kg, 54 ft•lb) Tighten the nut while applying the rear brake. 3. Bend the lock washer tab to lock the nut. 4.

  • Page 153: Crankcase And Crankshaft

    CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT REMOVING THE CRANKSHAFT Order Part name Q'ty Remarks Engie Refer to "ENGINE REMOVAL" section. Piston Refer to "CYLINDER AND PISTON" section. Refer to "KICK SHAFT AND SHIFT SHAFT" Kick shaft assembly section. Refer to "KICK SHAFT AND SHIFT SHAFT" Segment section.
  • Page 154 CRANKCASE AND CRANKSHAFT Order Part name Q'ty Remarks Right crankcase Refer to removal section. Left crankcase Refer to removal section. Oil strainer Crankshaft Refer to removal section. 5-58...
  • Page 155 CRANKCASE AND CRANKSHAFT REMOVING THE CRANKCASE BEARING Order Part name Q'ty Remarks Refer to "TRANSMISSION, SHIFT CAM AND Transmission SHIFT FORK" section. Refer to "TRANSMISSION, SHIFT CAM AND Shift cam and shift fork SHIFT FORK" section. Oil seal Bearing Refer to removal section. 5-59...
  • Page 156 CRANKCASE AND CRANKSHAFT DISASSEMBLING THE c. Remove the dowel pins and O- CHECKING THE CRANKCASE CRANKCASE ring. 1. Inspect: 1. Separate: • Contacting surface "a" Scratches → Replace. • Right crankcase REMOVING THE CRANKSHAFT • Left crankcase • Engine mounting boss "b", crank- 1.
  • Page 157 On the right crankcase "1". • Bearing other. Operate the installing tool un- • Bearing stopper YAMAHA Bond No. 1215 til the crankshaft bottoms against • Bolt (bearing stopper) ® (ThreeBond No.1215): the bearing.
  • Page 158 CRANKCASE AND CRANKSHAFT Apply the lithium soap base grease on the Orings. 5. Install: • Dowel pin "1" • O-ring "2" • Right crankcase 8. Install: To left crankcase. • Timing chain "1" • Timing chain guide (intake side) • Apply the lithium soap base grease "2"...

  • Page 159: 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 Engine Refer to "ENGINE REMOVAL" section. Refer to "CRANKCASE AND CRANK- Separate the crankcase. SHAFT" section. Main axle Refer to removal section.
  • Page 160 TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION 1. Remove: Apply the molybdenum disulfide oil • Main axle "1" on the inner and end surface of the • Drive axle "2" idler gear and on the inner surface of •...
  • Page 161 TRANSMISSION, SHIFT CAM AND SHIFT FORK 6. Install: 4. Install: • Transmission assembly "1" • Collar "1" To left crankcase "2". • Apply the lithium soap base grease Apply the engine oil on the bearings on the oil seal lip. and guide bars.

  • Page 162: Front Wheel And Rear Wheel

    FRONT WHEEL AND REAR WHEEL CHASSIS FRONT WHEEL AND REAR WHEEL REMOVING THE FRONT WHEEL 21 Nm (2.1 m kg, 15 ft lb) 21 Nm (2.1 m kg, 15 ft lb) 90 Nm (9.0 m kg, 65 ft lb) 12 Nm (1.2 m kg, 8.7 ft lb) Order Part name Q'ty...
  • Page 163 FRONT WHEEL AND REAR WHEEL REMOVING THE REAR WHEEL 14 Nm (1.4 m kg, 10 ft lb) 125 Nm (12.5 m kg, 90 ft lb) 19 Nm (1.9 m kg, 13 ft lb) 50 Nm (5.0 m kg, 36 ft lb) 19 Nm (1.9 m kg, 13 ft lb) Order Part name...
  • Page 164 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" CHECKING THE WHEEL AXLE 1. Measure: Push the wheel forward and remove •...
  • Page 165 FRONT WHEEL AND REAR WHEEL 2. Install: • Brake disc "1" • Bolt (brake disc) "2" Bolt (brake disc): 12 Nm (1.2 m•kg, 8.7 ft•lb) Tighten the bolts in stage, using a crisscross pattern. 6. Install: INSTALLING THE REAR WHEEL •...
  • Page 166 FRONT WHEEL AND REAR WHEEL 2. Install: • Brake disc "1" • Bolt (brake disc) "2" Bolt (brake disc): 14 Nm (1.4 m•kg, 10 ft•lb) 6. Install: 10. Tighten: Tighten the bolts in stage, using a • Drive chain "1" •...

  • Page 167: 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 suitable stand Refer to "HANDLING NOTE". under the engine. Drain the brake fluid. Refer to removal section. Brake hose holder (protector) Brake hose holder (brake caliper) Union bolt...
  • Page 168 FRONT BRAKE AND REAR BRAKE REMOVING THE REAR BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT WHEEL AND REAR Rear wheel WHEEL" section. Drain the brake fluid. Refer to removal section.
  • Page 169 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE CALIPER Order Part name Q'ty Remarks Front Rear Pad pin Brake pad Pad support Brake caliper piston Refer to removal section. Brake caliper piston dust seal Refer to removal section. Brake caliper piston seal Refer to removal section.
  • Page 170 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE MASTER CYLINDER Order Part name Q'ty Remarks Front Rear Brake master cylinder cap Diaphragm Reservoir float Brake master cylinder boot Circlip Use a long nose circlip pliers. Washer Push rod Brake master cylinder kit...
  • Page 171 FRONT BRAKE AND REAR BRAKE HANDLING NOTE • Cover piston with rag and use ex- Support the machine securely so treme caution when expelling there is no danger of it falling over. piston from cylinder. • Never attempt to pry out piston. DRAINING THE BRAKE FLUID 1.
  • Page 172 FRONT BRAKE AND REAR BRAKE HANDLING NOTE Apply the brake fluid on the piston wall. • All internal parts should be cleaned in new brake fluid only. • Internal parts should be lubricat- • Install the piston with its shallow ed with brake fluid when in- depressed side "a"...
  • Page 173 FRONT BRAKE AND REAR BRAKE 4. Install: 5. Install: • Pad pin plug "4" • Pad pin plug "4" Pad pin plug: Pad pin plug: 3 Nm (0.3 m•kg, 2.2 3 Nm (0.3 m•kg, 2.2 ft•lb) ft•lb) A. Front B. Rear 4.
  • Page 174 FRONT BRAKE AND REAR BRAKE 2. Install: 2. Install: INSTALLING THE FRONT BRAKE • Brake lever "1" • Brake master cylinder "1" HOSE • Bolt (brake lever) "2" • Bolt (brake master cylinder) "2" 1. Install: • Copper washer "1" Bolt (brake lever): Bolt (brake master cylin- •...
  • Page 175 FRONT BRAKE AND REAR BRAKE 3. Install: INSTALLING THE REAR BRAKE • Brake hose holder "1" HOSE • Nut (brake hose holder) "2" 1. Install: • Copper washer "1" Nut (brake hose holder): • Brake hose "2" 7 Nm (0.7 m•kg, 5.1 ft •...
  • Page 176 FRONT BRAKE AND REAR BRAKE 3. Inspect: • Brake fluid level Fluid at lower level → Fill up. Refer to "CHECKING THE BRAKE FLUID LEVEL" section in the CHAPTER 3. 4. Install: • Reservoir float (front brake) • Diaphragm • Brake master cylinder cap "1" •...

  • Page 177: Front Fork

    FRONT FORK FRONT FORK REMOVING THE FRONT FORK Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT WHEEL AND REAR Front wheel WHEEL" section. Refer to "FRONT BRAKE AND REAR Front brake caliper BRAKE"...
  • Page 178 FRONT FORK DISASSEMBLING THE FRONT FORK Order Part name Q'ty Remarks Front fork cap bolt Refer to removal section. Fork spring Drain the fork oil. 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 179 FRONT FORK HANDLING NOTE REMOVING THE INNER TUBE 1. Remove: The front fork with a built-in piston • Dust seal "1" Support the machine securely so rod has a very sophisticated inter- • Stopper ring "2" there is no danger of it falling over. nal construction and is particularly Using slotted-head screwdriver.
  • Page 180 FRONT FORK 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 dangerous- ly weaken the tube. 3. Install: 6. Install: • Copper washer "1" •...
  • Page 181 FRONT FORK 8. Install: 16. After filling, pump the damper rod • Outer tube "1" "1" slowly up and down more than To inner tube "2". 10 times to distribute the fork oil. 12. Install: • Dust seal "1" 9. Install: 17.
  • Page 182 FRONT FORK 26. Install: • Front fork cap bolt "1" Be sure to install the spring guide "2" To outer tube. when checking the oil level. Temporarily tighten the cap bolt. Never fail to make the oil level ad- justment between the maximum and minimum level and always ad- 23.
  • Page 183 FRONT FORK 6. Install: • Speed sensor lead "1" • Plate 2 "2" • Screw (plate 2) "3" Screw (plate 2): 0.5 Nm (0.05 m•kg, 0.36 ft•lb) To right protector "4". 4. Tighten: • Pinch bolt (upper bracket) "1" Install the plate 2 in the direction as Pinch bolt (upper brack- shown.

  • Page 184: Handlebar

    HANDLEBAR HANDLEBAR REMOVING THE HANDLEBAR Order Part name Q'ty Remarks Headlight Hot starter cable Disconnect at the lever side. Hot starter lever holder Clutch cable Disconnect at the lever side. Clutch lever holder Disconnect the clutch switch lead. Engine stop switch Disconnect the engine stop switch lead.
  • Page 185 HANDLEBAR REMOVING THE BRAKE MASTER CYLINDER • Install the handlebar lower holder 1. Remove: with its side having the greater dis- • Brake master cylinder bracket "1" tance "a" from the mounting bolt • Brake master cylinder "2" center facing forward. •...
  • Page 186 HANDLEBAR 5. Install: 8. Install: • Right grip "1" • Throttle cable cap "1" • The start switch and brake master • Collar "2" • Screw (throttle cable cap) "2" cylinder bracket should be installed Apply the adhesive on the tube according to the dimensions Screw (throttle cable guide "3".
  • Page 187 HANDLEBAR 12. Install: • Clutch cable "1" • Hot starter cable "2" Apply the lithium soap base grease on the clutch cable end and hot start- er cable end. 13. Adjust: • Clutch lever free play Refer to "ADJUSTING THE CLUTCH CABLE FREE PLAY"...

  • Page 188: 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 suitable stand Refer to "HANDLING NOTE".
  • Page 189 STEERING Order Part name Q'ty Remarks Bearing race cover Upper bearing Lower bearing Refer to removal section. Bearing race Refer to removal section. 6-28...
  • Page 190 STEERING HANDLING NOTE CHECKING THE STEERING STEM 1. Inspect: • Steering stem "1" Support the machine securely so Bend/damage → Replace. there is no danger of it falling over. REMOVING THE STEERING RING 1. Remove: 3. Install: • Steering ring nut "1" •...
  • Page 191 STEERING 11. Adjust: • Front fork top end "a" Front fork top end (stan- dard) "a": 5 mm (0.20 in) 7. Install: 14. Install: • Front fork "1" • Holder "1" • Upper bracket "2" Holder: • Main switch "3" 13 Nm (1.3 m•kg, 9.4 •...

  • Page 192: Swingarm

    SWINGARM SWINGARM REMOVING THE SWINGARM Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT BRAKE AND REAR Brake hose holder BRAKE" section. Refer to "FRONT BRAKE AND REAR Rear brake caliper BRAKE"...
  • Page 193 SWINGARM DISASSEMBLING THE SWINGARM Order Part name Q'ty Remarks Refer to removal section. Relay arm Connecting rod Collar Oil seal Thrust bearing Bushing Oil seal Bearing Refer to removal section. 6-32...
  • Page 194 SWINGARM HANDLING NOTE 2. Inspect: • Oil seal "3" Damage → Replace. Support the machine securely so there is no danger of it falling over. REMOVING THE CAP 1. Remove: • Left cap "1" 2. Install: • Bearing "1" Remove with a slotted-head screw- •...
  • Page 195 SWINGARM • Washer "3" • Swingarm up and down move- • Nut (connecting rod) "4" ment "b" Unsmooth movement/binding/ Nut (connecting rod): rough spots → Grease or replace 80 Nm (8.0 m•kg, 58 bearings, bushings and collars. ft•lb) To relay arm "5". INSTALLING THE SWINGARM Apply the molybdenum disulfide 1.
  • Page 196 SWINGARM • Nut (drive chain support) "4" Nut (drive chain sup- port): 7 Nm (0.7 m•kg, 5.1 ft•lb) • Bolt {drive chain support cover[L = 10 mm (0.39 in)]} "5" 11. Tighten: Bolt (drive chain support • Nut (relay arm) "1" cover): 7 Nm (0.7 m•kg, 5.1 Nut (relay arm):...

  • Page 197: 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 suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "REMOVING THE SEAT, FUEL Seat and side cover TANK AND SIDE COVERS"...
  • Page 198 REAR SHOCK ABSORBER Order Part name Q'ty Remarks Taillight coupler CDI unit coupler Plastic band Clamp (air filter joint) Only loosening. Rear frame Bolt (rear shock absorber-relay arm) Hold the swingarm. Bolt (rear shock absorber-frame) Rear shock absorber Locknut Only loosening. Adjuster Only loosening.
  • Page 199 To dispose of a damaged or worn- ABSORBER out rear shock absorber, take the After installing the stopper ring, push 1. Inspect: unit to your Yamaha dealer for this back the bearing until it contacts the • Damper rod "1" disposal procedure. stopper ring.
  • Page 200 REAR SHOCK ABSORBER Apply the molybdenum disulfide grease on the bolt. 3. Install: INSTALLING THE REAR SHOCK • Lower bearing "1" ABSORBER 1. Install: • Dust seal "1" Install the bearing by pressing it on 5. Install: • O-ring "2" the side having the manufacture's •...
  • Page 201 REAR SHOCK ABSORBER 7. Tighten: • Screw (air filter joint) "1" Screw (air filter joint): 3 Nm (0.3 m•kg, 2.2 ft•lb) 8. Install: • Plastic band • Taillight coupler • Locking tie 6-40...

  • Page 202: Components And Wiring Diagram

    ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS Headlight 12. Taillight Multi-function display 13. Neutral switch Engine stop switch 14. Starter motor Clutch switch 15. AC magneto Diode 16. Rectifier/regulator Starter relay diode 17. Ignition coil Throttle position sensor 18.

  • Page 203: Electrical Components And Wiring Diagram

    ELECTRICAL COMPONENTS AND WIRING DIAGRAM WIRING DIAGRAM Headlight COLOR CODE Multi-function display Black Engine stop switch Brown Clutch switch Chocolate Diode Dark green Starter relay diode Green Throttle position sensor Gray Starter relay Blue Fuse Orange 10. Starting circuit cut-off relay 11.

  • Page 204: 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. No good → *1 Check fuse. Replace fuse and check wire harness.
  • Page 205 IGNITION SYSTEM SPARK GAP TEST 2. Inspect: Result 1. Disconnect the ignition coil from • Main switch indicator light Conductive (while the spark plug. Use 12 V battery. engine stop switch is 2. Remove the ignition coil cap. Battery (+) lead → Red/Black lead pushed) 3.

  • Page 206: Electric Starting System

    ELECTRIC STARTING SYSTEM CHECKING THE NEUTRAL Secondary Tester se- SWITCH coil resis- lector posi- 1. Inspect: tance tion • Neutral switch conduction 4.6–6.8 Tester (+) lead→Sky blue lead "1" kΩat 20 °C kΩ × 1 Tester (-) lead → Ground "2" (68 °F) Result Conductive (while gear...
  • Page 207 ELECTRIC STARTING SYSTEM INSPECTION STEPS If the starter motor will not operate, use the following inspection steps. No good → *1 Check fuse. Replace fuse and check wire harness. OK ↓ No good → *2 Check battery. Recharge or replace. OK ↓...
  • Page 208 ELECTRIC STARTING SYSTEM CHECKING THE COUPLERS AND LEADS CONNECTION 1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. CHECKING THE STARTER MOTOR OPERATION CHECKING THE STARTER RELAY CHECKING THE DIODE 1. Connect the positive battery ter- 1. Remove: 1.
  • Page 209 ELECTRIC STARTING SYSTEM 2. Inspect: • Rubber part "a" Tears/damage → Replace.
  • Page 210 ELECTRIC STARTING SYSTEM REMOVING THE STARTER MOTOR Order Part name Q'ty Remarks Refer to "REMOVING THE EXHAUST PIPE Exhaust pipe AND SILENCER" section in the CHAPTER 3. Starter motor...
  • Page 211 ELECTRIC STARTING SYSTEM DISASSEMBLING THE STARTER MOTOR Order Part name Q'ty Remarks Starter motor front cover Washer (starter motor front cover) Gasket Starter motor yoke Armature assembly Starter motor rear cover Brush Brush spring 7-10...
  • Page 212 ELECTRIC STARTING SYSTEM CHECKING AND REPAIRING THE Armature assembly: STARTER MOTOR Commutator resis- 1. Check: tance "1": • Commutator 0.0189–0.0231 Ω at 20 Dirt → Clean with 600 grit sandpa- °C (68 °F) per. Insulation resistance 2. Measure: "2": • Commutator diameter "a" Above 1 MΩat 20 °C Out of specification→Replace the 2.
  • Page 213 ELECTRIC STARTING SYSTEM 5. Install: • Gasket • Bolt "1" • O-ring "2" Apply the lithium soap base grease on the O-ring. 7-12...

  • Page 214: Charging System

    CHARGING SYSTEM CHARGING SYSTEM INSPECTION STEPS If the battery is not charged, use the following inspection steps. No good → *1 Check fuse. Replace fuse and check wire harness. OK ↓ No good → *2 Check battery. Recharge or replace. OK ↓...
  • Page 215 CHARGING SYSTEM CHECKING THE COUPLERS AND LEADS CONNECTION 1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. CHECKING THE CHARGING VOLTAGE 1. Start the engine. 2. Inspect: • Charging voltage Out of specification → If no failure is found in checking the source coil resistance, replace the rectifi- er/regulator.

  • Page 216: 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. No good → Check entire ignition system for connection. Repair or replace. OK ↓ No good → Check throttle position sensor.(Throttle position Replace.
  • Page 217 THROTTLE POSITION SENSOR SYSTEM HANDLING NOTE 3. Inspect: • Throttle position sensor coil vari- • Align the slot "a" in the throttle posi- able resistance tion sensor with the projection "b" Do not loosen the screw (throttle Check that the resistance in in- on the carburetor.
  • Page 218 THROTTLE POSITION SENSOR SYSTEM Tester (+) lead → Blue lead "1" Measure the output voltage accurate- Tester (-) lead → Black/Blue lead ly with a digital electronic voltmeter "2" that gives an easy reading of a small voltage. Throttle po- Tester se- sition sen- lector posi-...

  • Page 219: Lighting System

    LIGHTING SYSTEM LIGHTING SYSTEM INSPECTION STEPS Refer to the following flow chart when inspecting the lighting system for possible problems. No good → Check the bulb and bulb socket. Replace the bulb and/or bulb socket. OK ↓ No good → Check the taillight (LEDs).
  • Page 220 LIGHTING SYSTEM CHECKING THE TAILLIGHT 4. Inspect: (LEDs) • Out-put voltage Out of specification → Replace 1. Disconnect the taillight coupler. 2. Connect two jumper leads "1" rectifier/regulator. from the battery terminals to the Tester (+) lead → Yellow lead "1" respective coupler terminal as Tester (-) lead →...

  • Page 221: Signaling System

    SIGNALING SYSTEM SIGNALING SYSTEM INSPECTION STEPS If the speedometer will not operate, use the following inspection steps. No good → *1 Check battery. Recharge or replace. OK ↓ No good → Check each coupler and wire connection. Repair or replace. OK ↓...
  • Page 222 SIGNALING SYSTEM CHECKING THE COUPLERS AND LEADS CONNECTION Make sure that a short-circuit does 1. Check: not develop between the terminals • Couplers and leads connection because it may cause damage to Rust/dust/looseness/short-circuit electrical components. → Repair or replace. CHECKING THE MULTI-FUNCTION DISPLAY INPUT VOLTAGE 1.
  • Page 224 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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