2010 Read this manual carefully before operating this vehicle. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen. Leggere attentamente questo manuale prima di utilizzare questo veicolo. YZ250F(Z) 2010 PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN JAPAN 2009.05-2.
Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit être remis avec le véhicule en cas de vente de ce dernier. Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen. Diese Bedienungsanleitung muss, wenn das Fahrzeug verkauft wird, beim Fahrzeug verbleiben.
2010 Read this manual carefully before operating this vehicle.
YZ250F(Z) OWNER'S SERVICE MANUAL ©2009 by Yamaha Motor Co., Ltd. 1st Edition, May 2009 All rights reserved.Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited.
FOREWORD INTRODUCTION Congratulations on your purchase of a Yamaha YZ series. This model is the culmination of Yamaha's vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader. This manual explains operation, inspection, basic maintenance and tuning of your machine. If you have any questions about this manual or your machine, please contact your Yamaha dealer.
HOW TO USE THIS MANUAL FINDING THE REQUIRED PAGE 1. This manual consists of seven chapters; "General Information", "Specifications", "Regular inspection and adjustments", "Engine", "Chassis", "Electrical" and "Tuning" 2. The table of contents is at the beginning of the manual. Look over the general layout of the book before finding then required chapter and item. Bend the book at its edge, as shown, to find the required fore edge symbol mark and go to a page for required item and description.
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. 3 2. Numbers "2" are given in the order of the jobs in the exploded diagram. A number that is enclosed by a circle indicates a disassembly step. 3. An explanation of jobs and notes is presented in an easy-to-read way by the use of symbol marks "3".
TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 REGULAR INSPECTION AND ADJUSTMENTS 3 ENGINE 4 CHASSIS 5 ELECTRICAL 6 TUNING 7
CONTENTS CHAPTER 1 GENERAL INFORMATION LOCATION OF IMPORTANT LABELS ..... 1-1 DESCRIPTION ................. 1-5 CONSUMER INFORMATION................. 1-6 INCLUDED PARTS .......... 1-6 IMPORTANT INFORMATION................. 1-6 CHECKING OF CONNECTION.................. 1-7 SPECIAL TOOLS ............. 1-8 CONTROL FUNCTIONS ................... 1-12 STARTING AND BREAK-IN ...................... 1-13 TORQUE-CHECK POINTS........................... 1-15 CLEANING AND STORAGE ......................
LOCATION OF IMPORTANT LABELS GENERAL INFORMATION LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle.
LOCATION OF IMPORTANT LABELS EUROPE 1-2
LOCATION OF IMPORTANT LABELS AUS, NZ, ZA 1-3
LOCATION OF IMPORTANT LABELS Familiarize yourself with the following pictograms and read the explanatory text. Read Owner’s service manual. This unit contains high-pressure nitrogen gas. Mishandling can cause explosion. Do not incinerate, puncture or open. Turn off the main switch after riding to avoid draining the battery. Use unleaded gasoline only. Measure tire pressure when tires are cold. Adjust tire pressure. Improper tire pressure can cause loss of control.
DESCRIPTION DESCRIPTION 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Clutch lever Hot starter lever Front brake lever Throttle grip Radiator cap Fuel tank cap Engine stop switch Kickstarter crank Fuel tank Radiator Coolant drain bolt Rear brake pedal Valve joint 14. 15. 16. 17. 18. 19. 20. Fuel cock Cold starter knob Air filter Drive chain Shift pedal Oil level check window Front fork • The machine you have purchased may differ slightly from those shown in the following.
CONSUMER INFORMATION CONSUMER INFORMATION There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own. 2. If your machine is stolen, the authorities will need the number to search for and identify your machine. VEHICLE IDENTIFICATION NUMBER The vehicle identification number "1" is stamped on the right of the steering head pipe.
CHECKING OF CONNECTION 4. During the machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled. 5. Keep away from fire. ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. GASKETS, OIL SEALS AND ORINGS 1.
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. Refer to the list provided to avoid errors when placing an order. • For U.S.A. and Canada, use part number starting with "YM-", "YU-" or "ACC-".
SPECIAL TOOLS Tool name/Part number How to use Radiator cap tester YU-24460-01, 90890-01325 Radiator cap tester adapter YU-33984, 90890-01352 These tools are used for checking the cooling system. Steering nut wrench YU-33975, 90890-01403 This tool is used when tighten the steering ring nut to specification. Cap bolt wrench YM-01500, 90890-01500 This tool is used to loosen or tighten the base valve.
SPECIAL TOOLS Tool name/Part number How to use Timing light YM-33277-A, 90890-03141 This tool is necessary for checking ignition timing. Valve spring compressor YM-4019, 90890-04019 This tool is needed to remove and install the valve assemblies. Clutch holding tool YM-91042, 90890-04086 This tool is used to hold the clutch when removing or installing the clutch boss securing nut. Valve guide remover Intake 4.0 mm (0.16 in) Exhaust 4.5 mm (0.
SPECIAL TOOLS Tool name/Part number How to use Dynamic spark tester YM-34487 Ignition checker 90890-06754 This instrument is necessary for checking the ignition system components. Digital tachometer YU-39951-B, 90890-06760 This tool is needed for observing engine rpm. YAMAHA Bond No. 1215 (ThreeBond® No. 1215) 90890-85505 This sealant (Bond) is used for crankcase mating surface, etc.
CONTROL FUNCTIONS CONTROL FUNCTIONS ENGINE STOP SWITCH The engine stop switch "1" is located on the left handlebar. Continue pushing the engine stop switch till the engine comes to a stop. THROTTLE GRIP The throttle grip "1" is located on the right handlebar; it accelerates or decelerates the engine. For acceleration, turn the grip toward you; for deceleration, turn it away from you. CLUTCH LEVER The clutch lever "1" is located on the left handlebar; it disengages or engages the clutch.
STARTING AND BREAK-IN STARTING AND BREAK-IN FUEL Always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race. Recommended fuel: Premium unleaded gasoline only with a research octane number of 95 or higher. Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine internal parts such as valves, piston rings, and exhaust system, etc.
STARTING AND BREAK-IN BREAK-IN PROCEDURES 1. Before starting the engine, fill the fuel tank with the fuel. 2. Perform the pre-operation checks on the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the engine stop switch. Then, restart the engine and check its operation within no more than 5 minutes after it is restarted. 4. Operate the machine in the lower gears at moderate throttle openings for five to eight minutes. 5.
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 Suspension Front Steering stem to front fork Rear For link type Front fork to upper bracket Front fork to lower bracket Assembly of lin
CLEANING AND STORAGE CLEANING AND STORAGE CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many components. 1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering. A plastic bag secured with a rubber band may be used for this purpose. 2. If the engine is excessively greasy, apply some degreaser to it with a paint brush. Do not apply degreaser to the chain, sprockets, or wheel axles.
GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: YZ250FZ (USA, CDN, AUS, NZ) YZ250F (EUROPE, ZA) Model code number: 17D5 (USA,CDN) 17D6 (EUROPE) 17D8 (AUS, NZ, ZA) Dimensions: USA, CDN EUROPE 2,168 mm (85.35 in) AUS, NZ, ZA Overall length 2,159 mm (85.00 in) Overall width 825 mm (32.48 in) ← ← Overall height 1,303 mm (51.30 in) ← Seat height 988 mm (38.90 in) 991 mm (39.02 in) 990 mm (38.98 in) Wheelbase 1,466 mm (57.72 in) Minimum ground clearance 375 mm (14.
GENERAL SPECIFICATIONS Carburetor: Type FCR-MX37 Manufacturer KEIHIN Spark plug: Type/manufacturer CR8E/NGK (resistance type) Gap 0.7–0.8 mm (0.028–0.031 in) Clutch type: Wet, multiple-disc Transmission: USA, CDN EUROPE, AUS, NZ, ZA Primary reduction system Gear ← Primary reduction ratio 57/17 (3.353) ← Secondary reduction system Chain drive ← Secondary reduction ratio 49/13 (3.769) 51/13 (3.
MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.05 mm (0.002 in) Bore size 77.00–77.01 mm (3.0315–3.0319 in) ---- Out of round limit ---- 0.05 mm (0.002 in) Drive method Chain drive (Left) ---- Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in) ---- Camshaft outside diameter 21.959–21.972 mm (0.8645–0.8650 in) ---- Shaft-to-cap clearance 0.028–0.062 mm (0.0011–0.0024 in) 0.08 mm (0.003 in) Intake "A" 30.
MAINTENANCE SPECIFICATIONS Item Standard Limit Valve, valve seat, valve guide: Valve clearance (cold) IN 0.12–0.17 mm (0.0047–0.0067 in) ---- EX 0.17–0.22 mm (0.0067–0.0087 in) ---- "A" head diameter (IN) 22.9–23.1 mm (0.9016–0.9094 in) ---- "A" head diameter (EX) 24.4–24.6 mm (0.9606–0.9685 in) ---- "B" face width (IN) 2.26 mm (0.089 in) ---- "B" face width (EX) 2.26 mm (0.089 in) ---- "C" seat width (IN) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630 in) "C" seat width (EX) 0.9–1.
MAINTENANCE SPECIFICATIONS Item Standard Limit Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width (IN) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630 in) Valve seat width (EX) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630 in) Free length (IN) 39.76 mm (1.57 in) 38.76 mm (1.53 in) Free length (EX) 37.78 mm (1.49 in) 36.78 mm (1.45 in) Set length (valve closed) (IN) 28.98 mm (1.14 in) ---- Set length (valve closed) (EX) 28.30 mm (1.
MAINTENANCE SPECIFICATIONS Item Standard Limit Piston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in) 16.043 mm (0.6316 in) Piston pin outside diameter 15.991–16.000 mm (0.6296–0.6299 in) 15.971 mm (0.6288 in) Piston rings: Top ring: Type Barrel ---- Dimensions (B × T) 0.90 × 2.75 mm (0.04 × 0.11 in) ---- End gap (installed) 0.15–0.25 mm (0.006–0.010 in) 0.50 mm (0.020 in) Side clearance (installed) 0.030–0.065 mm (0.0012–0.0026 in) 0.12 mm (0.
MAINTENANCE SPECIFICATIONS Item Standard Limit Clutch: Friction plate thickness Quantity 2.9–3.1 mm (0.114–0.122 in) 2.8 mm (0.110 in) 9 ---- 1.1–1.3 mm (0.043–0.051 in) ---- Quantity 8 ---- Warp limit ---- 0.1 mm (0.004 in) 35.7 mm (1.41 in) 34.7 mm (1.37 in) 5 ---- Clutch housing thrust clearance 0.050–0.300 mm (0.0020–0.0118 in) ---- Clutch housing radial clearance 0.010–0.044 mm (0.0004–0.
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 (0.0067 in) Width 121.4 mm (4.8 in) ---- Height 235 mm (9.3 in) ---- Thickness 28 mm (1.
MAINTENANCE SPECIFICATIONS Item Standard Limit Swingarm: Swingarm free play limit End ---- 1.0 mm (0.04 in) Front wheel type Spoke wheel ---- Rear wheel type Spoke wheel ---- Front rim size/material 21 × 1.60/Aluminum ---- Rear rim size/material 19 × 1.85/Aluminum ---- Radial ---- 2.0 mm (0.08 in) Lateral ---- 2.0 mm (0.
TIGHTENING TORQUES ELECTRICAL Item Standard Limit Ignition system: Advancer type Electrical ---- CDI: Magneto-model (stator)/manufacturer 17D-50/YAMAHA ---- Charging coil 1 resistance (color) 720–1,080 Ωat 20 °C (68 °F) (Green–Brown) ---- Charging coil 2 resistance (color) 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 CD
TIGHTENING TORQUES Part to be tightened △ △ Thread size Q'ty Oil filter element drain bolt M6 × 1.0 Oil filter element cover Tightening torque Nm m•kg ft•lb 1 10 1.0 7.2 M6 × 1.0 2 10 1.0 7.2 Oil strainer (crankcase) M6 × 1.0 2 10 1.0 7.2 Oil delivery pipe 1 (M10) M10 × 1.25 1 20 2.0 14 Oil delivery pipe 1 (M8) M8 × 1.25 2 18 1.8 13 Oil hose M6 × 1.0 2 8 0.8 5.8 Oil hose clamp — 1 2 0.2 1.4 Oil strainer (oil tank) M6 × 1.0 1 9 0.9 6.
TIGHTENING TORQUES Part to be tightened Thread size Q'ty Drive sprocket M18 × 1.0 Drive axle oil seal stopper Tightening torque Nm m•kg ft•lb 1 75 7.5 54 M6 × 1.0 2 10 1.0 7.2 Segment M8 × 1.25 1 30 3.0 22 Shift guide M6 × 1.0 2 10 1.0 7.2 Stopper lever M6 × 1.0 1 10 1.0 7.2 Shift pedal M6 × 1.0 1 12 1.2 8.7 CHASSIS △ - marked portion shall be checked for torque tightening after break-in or before each race.
TIGHTENING TORQUES Part to be tightened Thread size Q'ty Tightening torque Nm m•kg ft•lb △ Front brake disc M6 × 1.0 6 12 1.2 8.7 △ Rear brake disc M6 × 1.0 6 14 1.4 10 △ Footrest bracket and frame M10 × 1.25 4 55 5.5 40 △ Brake pedal M8 × 1.25 1 26 2.6 19 △ Rear brake master cylinder M6 × 1.0 2 10 1.0 7.2 Rear brake master cylinder cap M4 × 0.7 2 2 0.2 1.4 △ Rear brake hose union bolt M10 × 1.25 2 30 3.0 22 △ Rear wheel axle and axle nut M22 × 1.
TIGHTENING TORQUES Part to be tightened Radiator mounting boss and frame Thread size Q'ty M10 × 1.25 M6 × 1.0 Tightening torque Nm m•kg ft•lb 2 20 2.0 14 4 10 1.0 7.2 △ Front fender △ Rear fender (front) M6 × 1.0 2 7 0.7 5.1 △ Rear fender (rear) M6 × 1.0 2 16 1.6 11 △ Side cover M6 × 1.0 2 7 0.7 5.1 Seat M8 × 1.25 2 23 2.3 17 Number plate M6 × 1.0 1 7 0.7 5.1 △ 1. First, tighten the steering ring nut approximately 38 Nm (3.
TIGHTENING TORQUES GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasteners with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages, until full torque is reached. Unless otherwise specified, torque specifications call for clean, dry threads. Components should be at room temperature.
LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1. 2. 3. 4. 5. 6. 7. 8. A.
LUBRICATION DIAGRAMS 1. 2. 3. 4. A.
CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM C C A A B B 1. 2. 3. 4. 5. 6. 7. 8. 9. Fuel tank breather hose Radiator hose 1 Cylinder head breather hose Radiator hose 3 Clutch cable Throttle position sensor lead Hot starter cable Fuel hose Carburetor breather hose 10. Carburetor overflow hose 11. Throttle position sensor lead protector 12. Throttle position sensor cover 2-18 A. B. Insert the end of the fuel tank breather hose into the hole in the steering stem.
CABLE ROUTING DIAGRAM C. D. E. F. G. Pass the cylinder head breather hose on the outside of front engine bracket. Pass the cylinder head breather hose between the radiator and radiator hose 3. Pass the fuel hose on the outside of throttle position sensor lead. Pass the carburetor breather hoses and overflow hose so that all there hoses do not contact the rear shock absorber. Insert the throttle position sensor lead protector into the throttle position sensor cover.
CABLE ROUTING DIAGRAM I F-F J B A-A A C B L A C M D J H-H L M-M D I K K G D-D H H K-K M F G F E E E-E 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Sub-wire harness Hot starter cable Oil hose Neutral switch lead Radiator hose 2 Clamp Ignition coil lead CDI magneto lead Neutral switch lead coupler CDI unit lead coupler 11. 12. 13. 14. 15. 16.
CABLE ROUTING DIAGRAM A. B. C. D. E. F. G. H. I. J. K. L. M. N. O. P. Q. Pass the hot starter cable over the radiator mounting boss. Pass the throttle position sensor lead under the hot starter cable. Fasten the throttle position sensor lead and the hot starter cable. Locate the clamp between the hot starter cable protector and rubber cap. Fasten the neutral switch lead below the oil hose. and pass the neutral switch lead on the inside of the oil hose.
CABLE ROUTING DIAGRAM B A C C B A 1. 2. 3. 4. 5. 6. Radiator hose 2 Radiator breather hose Ignition coil Throttle cable (pull) Throttle cable (return) Engine stop switch lead A. B. C. D. Put a cover over the ignition coil. Pass the throttle cables through the cable guide. Pass the throttle cable over the radiator mounting boss. Cross the throttle cable behind the radiator. Pass the throttle cables on the outside of the ignition coil. 2-22 E. F.
CABLE ROUTING DIAGRAM 1. 2. 3. Brake master cylinder Brake hose holder Brake hose A. B. Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the brake caliper. Pass the brake hose into the brake hose holders. 2-23 C. D. If the brake hose contacts the spring (rear shock absorber), correct its twist. Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the brake master cylinder.
CABLE ROUTING DIAGRAM A B C A B C 1. 2. 3. 4. 5. 6. 7. 8. Throttle cable Clamp Hot starter cable Clutch cable Engine stop switch lead Cable guide Brake hose Hose guide A. B. C. Fasten the engine stop switch lead to the handlebar. Pass the clutch cable and hot starter cable through the cable guide. Pass the engine stop switch lead behind the CDI unit. D. E. F. G. 2-24 Pass the brake hose in front of the number plate. Pass the throttle cables through the cable guide.
MAINTENANCE INTERVALS REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS • The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals.
MAINTENANCE INTERVALS Item After breakin Every race (about 2.5 hours) Every third (about 7.5 hours) Every fifth (about 12.5 hours) As required Remarks PISTON PIN Inspect ● Replace ● CYLINDER HEAD Inspect carbon deposits and eliminate them. Inspect and clean ● Change gasket. ● Inspect score marks. CYLINDER Inspect and clean Replace ● Inspect wear. CLUTCH Inspect and adjust ● Inspect housing, friction plate, clutch plate and spring.
MAINTENANCE INTERVALS Item After breakin Every race (about 2.5 hours) ● ● Every third (about 7.5 hours) Every fifth (about 12.5 hours) As required Remarks COOLING SYSTEM Check coolant level and leakage Check radiator cap operation ● Replace coolant ● Inspect hoses Every two years ● OUTSIDE NUTS AND BOLTS Retighten ● ● Refer to "STARTING AND BREAKIN" section in the CHAPTER 1. ● ● Use foam air-filter oil or equivalent oil.
MAINTENANCE INTERVALS Item After breakin Every race (about 2.5 hours) ● ● Every third (about 7.5 hours) Every fifth (about 12.
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 Coolant Check that coolant is filled up to the radiator cap. Check the cooling system for leakage. P.3-6 – 7 Fuel Check that a fresh gasoline is filled in the fuel tank. Check the fuel line for leakage.
ENGINE ENGINE CHECKING THE COOLANT LEVEL Do not remove the radiator cap "1", drain bolt and hoses when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, place a thick towel over the radiator cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape.
ENGINE 3. Radiator cap 2. Apply the specified pressure. Radiator cap opening pressure: 110 kPa (1.1 kg/cm2, 15.6 psi) 3. Inspect: • Pressure Impossible to maintain the specified pressure for 10 seconds → Replace. CHECKING THE COOLING SYSTEM 1. Inspect: • Coolant level 2. Attach: • Radiator cap tester "1" and adapter "2" Radiator cap tester: YU-24460-01/9089001325 Radiator cap tester adapter: YU-33984/90890-01352 ADJUSTING THE CLUTCH LEVER POSITION 1.
ENGINE 2. Adjust: • Throttle grip free play Throttle grip free play adjustment steps: a. Slide the adjuster cover. b. Loosen the locknut "1". c. Turn the adjuster "2" until the specified free play is obtained. d. Tighten the locknut. Locknut: 4 Nm (0.4 m•kg, 2.9 ft•lb) Before adjusting the throttle cable free play, the engine idle speed should be adjusted.
ENGINE 6. Apply: • Lithium soap base grease On the matching surface "a" on air filter element. 7. • • • Install: Air filter element "1" Washer Fitting bolt Fitting bolt: 2 Nm (0.2 m•kg, 1.4 ft•lb) Align the projection "a" on filter guide with the hole "b" in air filter case. CHECKING THE ENGINE OIL LEVEL 1. Start the engine, warm it up for several minutes, and then turn off the engine and wait for five minutes. 2.
ENGINE • Oil tank drain bolt Replacement steps: a. Remove the oil filter element cover "1" and oil filter element "2". b. Check the O-rings "3", if cracked or damaged, replace them with a new one. c. Install the oil filter element and oil filter element cover. Oil filter element cover: 10 Nm (1.0 m•kg, 7.2 ft•lb) 8. Install: • O-ring "1" • Oil strainer "2" Oil tank drain bolt: 18 Nm (1.8 m•kg, 13 ft•lb) • Lower engine guard 10. Fill: • Engine oil Oil quantity: Periodic oil change: 0.95 L (0.84 Imp qt, 1.
ENGINE b. Turn the throttle stop screw "1" until the specified engine idling speed. Using a digital engine tachometer for idle speed adjustment, detect the engine idling speed by bringing the sensing element "c" of the engine tachometer close to the ignition coil "2". To increase idle speed→Turn the throttle stop screw "1" in "a". To decrease idle speed→Turn the throttle stop screw "1" out "b". Engine idling speed: 1,900–2,100 r/min 1.
ENGINE f. c. Select the proper pad using the pad selecting table. Pad range No. 120–N o. 240 Pad Availability: 25 increments Install the new pads "3" and the valve lifters "4". • Apply the engine oil on the valve lifters. • Apply the molybdenum disulfide oil on the valve stem ends. • Valve lifter must turn smoothly when rotated with a finger. • Be careful to reinstall valve lifters and pads in their original place. 1.20 Pads are availmm–2. able in 0.
ENGINE INTAKE MEASURED CLEARANCE 0.00 - 0.01 0.02 - 0.06 0.07 - 0.11 0.12 - 0.17 0.18 - 0.22 0.23 - 0.27 0.28 - 0.32 0.33 - 0.37 0.38 - 0.42 0.43 - 0.47 0.48 - 0.52 0.53 - 0.57 0.58 - 0.62 0.63 - 0.67 0.68 - 0.72 0.73 - 0.77 0.78 - 0.82 0.83 - 0.87 0.88 - 0.92 0.93 - 0.97 0.98 - 1.02 1.03 - 1.07 1.08 - 1.12 1.13 - 1.17 1.18 - 1.22 1.23 - 1.27 1.28 - 1.32 1.33 - 1.
CHASSIS CHASSIS BLEEDING THE HYDRAULIC BRAKE SYSTEM Bleed the brake system if: • The system has been disassembled. • A brake hose has been loosened or removed. • The brake fluid is very low. • The brake operation is faulty. A dangerous loss of braking performance may occur if the brake system is not properly bled. 1. • • • • 2. • Remove: Brake master cylinder cap Diaphragm Reservoir float (front brake) Protector (rear brake) Bleed: Brake fluid Air bleeding steps: a.
CHASSIS d. Remove the pad pin and brake pads "4". j. e. Connect the transparent hose "5" to the bleed screw "6" and place the suitable container under its end. CHECKING AND REPLACING THE FRONT BRAKE PADS 1. Inspect: • Brake pad thickness "a" Out of specification → Replace as a set. Brake pad thickness: 4.4 mm (0.17 in) : 1.0 mm (0.04 in) f. Loosen the bleed screw and push the brake caliper piston in. Do not reuse the drained brake fluid. g. Tighten the bleed screw. Bleed screw: 6 Nm (0.
CHASSIS 2. Replace: • Brake pad h. Install the brake pad "10" and pad pin "11". Brake pad replacement steps: a. Remove the protector "1" and pad pin plug "2". • Install the brake pads with their projections "a" into the brake caliper recesses "b". • Temporarily tighten the pad pin at this point. b. Loosen the pad pin "3". c. Remove the rear wheel "4" and brake caliper "5". Refer to "FRONT WHEEL AND REAR WHEEL" section in the CHAPTER 5. i. j. Install the brake caliper "12" and rear wheel "13".
CHASSIS CHECKING THE SPROCKET 1. Inspect: • Sprocket teeth "a" Excessive wear → Replace. Replace the drive sprocket, rear wheel sprocket and drive chain as a set. 3. Clean: • Drive chain Place it in kerosene, and brush off as much dirt as possible. Then remove the drive chain from the kerosene and dry the drive chain. ADJUSTING THE DRIVE CHAIN SLACK 1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Check: • Drive chain slack "a" Above the seal guard installation bolt.
CHASSIS CLEANING THE FRONT FORK OIL SEAL AND DUST SEAL 1. Remove: • Protector • Dust seal "1" A. Right B. Left Use a thin screw driver, and be careful not to damage the inner fork tube and dust seal. Turn the adjuster so that the drive chain is in line with the sprocket, as viewed from the rear. e. Tighten the locknuts. Locknut: 21 Nm (2.1 m•kg, 15 ft•lb) Maximum 2.
CHASSIS ADJUSTING THE FRONT FORK COMPRESSION DAMPING FORCE 2. Adjust: • Compression damping force By turning the adjuster "1". Stiffer "a" → Increase the compression damping force. (Turn the adjuster "1" in.) Softer "b" → Decrease the compression damping force. (Turn the adjuster "1" out.) Extent of adjustment: Maximum Fully turned in position Minimum 20 clicks out (from maximum position) ADJUSTING THE REAR SHOCK ABSORBER SPRING PRELOAD 1.
CHASSIS Extent of adjustment: Maximum Fully turned in position Minimum 20 clicks out (from maximum position) • STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. (Which align the punch mark "a" on the adjuster with the punch mark "b" on the bracket.
CHASSIS CHECKING AND TIGHTENING THE SPOKES The following procedure applies to all of the spokes. 1. Check: • Spokes Bend/damage → Replace. Loose spoke → Retighten. Tap the spokes with a screwdriver. A tight spoke will emit a clear, ringing tone; a loose spoke will sound flat. 2. Tighten: • Spokes (with a spoke nipple wrench "1") 2. Inspect: • Bearing free play Exist play → Replace. CHECKING AND ADJUSTING THE STEERING HEAD 1. Place a stand under the engine to raise the front wheel off the ground.
CHASSIS h. Install the washer "5", upper bracket "6", steering stem nut "7", handlebar "8", handlebar upper holder "9" and number plate "10". • Apply the lithium soap base grease on the contact surface of the steering stem nut when installing. • The handlebar upper holder should be installed with the punched mark "a" forward. • Install the handlebar so that the marks "b" are in place on both sides.
CHASSIS LUBRICATION To ensure smooth operation of all components, lubricate your machine during setup, after break-in, and after every race. 1. All control cable 2. Clutch lever pivot 3. Shift pedal pivot 4. Footrest pivot 5. Throttle-to-handlebar contact 6. Drive chain 7. Tube guide cable winding portion 8. Throttle cable end 9. Clutch cable end 10. Hot starter cable end A. B. C. Use Yamaha cable lube or equivalent on these areas. Use SAE 10W-40 motor oil or suitable chain lubricants.
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. Distinctly different color → Check the engine condition. When the engine runs for many hours at low speeds, the spark plug insulator will become sooty, even if the engine and carburetor are in good operating condition. 3. Measure: • Plug gap "a" Use a wire gauge or thickness gauge. Out of specification → Regap.
SEAT, FUEL TANK AND SIDE COVERS ENGINE 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 knowledge and skill concerning servicing are requested not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical damage.
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 because its claws "a" are inserted in the air filter case. REMOVING THE NUMBER PLATE 1. Remove: • Bolt (number plate) • Number plate "1" • The projection "a" is inserted into the band of the number plate. Pull the band off the projection before removal.
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 SIDE COVERS" section. Right side cover 1 Bolt (silencer clamp) 1 2 Bolt [silencer (front)] 1 3 Bolt [silencer (rear)] 1 4 Silencer 1 5 Silencer clamp 1 6 Nut (exhaust pipe) 2 7 Exhaust pipe 1 8 Gasket 2 9 Wave washer 3 4-3 Only loosening.
EXHAUST PIPE AND SILENCER CHECKING THE SILENCER AND EXHAUST PIPE 1. Inspect: • Gasket "1" Damage → Replace. CHANGING THE SILENCER FIBER 1. Remove: • Rivet (front) "1" • Inner pipe "2" Take care not to damage the rivet fitting holes (ø4.9 mm) "a" in removal. • Install the gasket with its meshed area "a" toward the exhaust pipe side. • The gasket should be installed according to the dimension shown. New INSTALLING THE SILENCER AND EXHAUST PIPE 1.
RADIATOR RADIATOR REMOVING THE RADIATOR 2 T. 20 Nm (2.0 m kg, 14 ft Ib) R. 4 12 2 5 13 9 2 10 2 2 1 1 2 6 2 2 8 3 2 7 2 11 Order Part name Q'ty Remarks Drain the coolant. Refer to "CHANGING THE COOLANT" section in the CHAPTER 3. Seat and fuel tank Refer to "SEAT, FUEL TANK AND SIDE COVERS" section.
RADIATOR HANDLING NOTE Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radiator cap by the following procedure: Place a thick rag, like a towel, over the radiator cap, slowly rotate the cap counterclockwise to the detent. This procedure allows any residual pressure to escape.
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 Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND SIDE COVERS" section.
CARBURETOR DISASSEMBLING THE CARBURETOR Order Part name Q'ty 1 Carburetor breather hose 4 2 Valve lever housing cover 1 3 Screw (throttle shaft) 1 4 Throttle valve 1 5 Needle holder 1 6 Jet needle 1 7 Accelerator pump cover 1 8 Spring 1 9 Diaphragm (accelerator pump) 1 10 Float chamber 1 11 Leak jet 1 12 Pilot screw 1 13 Float pin 1 14 Float 1 15 Needle valve 1 16 Main jet 1 17 Needle jet 1 18 Spacer 1 4-8 Remarks Refer to removal section.
CARBURETOR Order Part name Q'ty 19 Pilot jet 1 20 Starter jet 1 21 Push rod 1 22 Throttle shaft assembly 1 23 Push rod link lever assembly 1 24 Pilot air jet 1 25 Cold starter plunger 1 4-9 Remarks Pull the push rod.
CARBURETOR HANDLING NOTE Do not loosen the screw (throttle position sensor) "1" except when changing the throttle position sensor due to failure because it will cause a drop in engine performance. 2. • • • • • • Inspect: Main jet "1" Pilot jet "2" Needle jet "3" Starter jet "4" Pilot air jet "5" Leak jet "6" Damage → Replace. Contamination → Clean. CHECKING THE JET NEEDLE 1. Inspect: • Jet needle "1" Bends/wear → Replace. • Clip groove Free play exists/wear → Replace.
CARBURETOR c. If the float height is not within specification, inspect the valve seat and needle valve. d. If either is worn, replace them both. e. If both are fine, adjust the float height by bending the float tab "b" on the float. 4. Install: • Spring 2 "1" To lever 2 "2". 2. • • • • • • f. Inspect: Throttle shaft "1" Spring "2" Lever 1 "3" Spring 1 "4" Lever 2 "5" Spring 2 "6" Dirt → Clean. Recheck the float height. 5.
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 carburetor. • Turn the throttle shaft assembly left while holding down the lever 1 "5" and fit the throttle stop screw tip "d" to the stopper "e" of the throttle shaft assembly pulley. 11.
CARBURETOR 17. Install: • O-ring "1" • Valve lever housing cover "2" • Bolt (valve lever housing cover) "3" c. Gradually turn out the adjusting screw while moving the link lever until it has no more free play. INSTALLING THE CARBURETOR 1. Install: • Carburetor joint "1" Carburetor joint: 10 Nm (1.0 m•kg, 7.2 ft•lb) 18. Install: • Carburetor breather hose "1" Install the carburetor breather hoses to the carburetor so that the hoses do not bend near where they are installed. 5.
CAMSHAFTS CAMSHAFTS REMOVING THE CYLINDER HEAD COVER Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND SIDE COVERS" section.
CAMSHAFTS REMOVING THE CAMSHAFTS Order Part name Q'ty Remarks 1 Timing mark accessing screw 1 Refer to removal section. 2 Crankshaft end accessing screw 1 Refer to removal section. 3 Timing chain tensioner cap bolt 1 Refer to removal section. 4 Timing chain tensioner 1 Refer to removal section. 5 Camshaft cap 2 Refer to removal section. 6 Clip 2 Refer to removal section. 7 Exhaust camshaft 1 Refer to removal section. 8 Intake camshaft 1 Refer to removal section.
CAMSHAFTS REMOVING THE CAMSHAFT 1. Remove: • Timing mark accessing screw "1" • Crankshaft end accessing screw "2" 4. • • • Remove: Bolt (camshaft cap) "1" Camshaft cap "2" Clip 2. Align: • T.D.C. mark With align mark. Remove the bolts (camshaft cap) in a crisscross pattern, working from the outside in. Checking steps: a. Turn the crankshaft counterclockwise with a wrench. b. Align the T.D.C. mark "a" on the rotor with the align mark "b" on the crankcase cover when piston is at T.D.C.
CAMSHAFTS 4. Measure: • Camshaft-to-cap clearance Out of specification → Measure camshaft outside diameter. Camshaft-to-cap clearance: 0.028–0.062 mm (0.0011–0.0024 in) :0.08 mm (0.003 in) Measurement steps: a. Install the camshaft onto the cylinder head. b. Position a strip of Plastigauge® "1" onto the camshaft. c. Install the clip, dowel pins and camshaft caps. Bolt (camshaft cap): 10 Nm (1.0 m•kg, 7.2 ft•lb) • Tighten the bolts (camshaft cap) in a crisscross pattern from innermost to outer caps.
CAMSHAFTS c. Fit the timing chain "3" onto both camshaft sprockets and install the camshafts on the cylinder head. The camshafts should be installed onto the cylinder head so that the punch mark "c" on the exhaust camshaft and the punch mark "d" on the intake camshaft must align with the cylinder head surface, as shown in the illustration. Do not turn the crankshaft during the camshaft installation. Damage or improper valve timing will result. d.
CYLINDER HEAD CYLINDER HEAD REMOVING THE CYLINDER HEAD Order 1 Part name Q'ty Remarks Seat and fuel tank Refer to "SEAT, FUEL TANK AND SIDE COVERS" section. Exhaust pipe and silencer Refer to "EXHAUST PIPE AND SILENCER" section. Radiator hose 1 Disconnect at cylinder head side. Carburetor Refer to "CARBURETOR" section. Camshaft Refer to "CAMSHAFTS" section. Upper engine bracket Refer to "ENGINE REMOVAL" section. Radiator pipe 1 2 Oil delivery pipe 1 3 Nut 2 4 Bolt [L = 135 mm (5.
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 damaging or scratching: • Spark plug threads • Valve seats INSTALLING THE CYLINDER HEAD 1. Install: • Dowel pin "1" • Cylinder head gasket "2" • Timing chain guide (exhaust side) "3" • Cylinder head "4" While pulling up the timing chain, install the timing chain guide (exhaust side) and cylinder head. 3.
VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS REMOVING THE VALVES AND VALVE SPRINGS Order Part name Q'ty Cylinder head Remarks Refer to "CYLINDER HEAD" section. 1 Valve lifter 5 Refer to removal section. 2 Adjusting pad 5 Refer to removal section. 3 Valve cotter 10 Refer to removal section.
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" position very carefully so that they can be reinstalled in their original place. CHECKING THE VALVE 1. Measure: • Stem-to-guide clearance b. Install the new valve guide using a valve guide remover "1" and valve guide installer "2". Stem-to-guide clearance = valve guide inside diameter "a" valve stem diameter "b" Out of specification→Replace the valve guide. 2.
VALVES AND VALVE SPRINGS 4. Measure: • Margin thickness "a" Out of specification → Replace. Do not let the compound enter the gap between the valve stem and the guide. Margin thickness: Intake: 0.8 mm (0.0315 in) Exhaust: 0.7 mm (0.0276 in) Measurement steps: a. Apply Mechanic's blueing dye (Dykem) "b" to the valve face. b. Apply molybdenum disulfide oil to the valve stem. 5. Measure: • Runout (valve stem) Out of specification → Replace. Runout limit: 0.01 mm (0.
VALVES AND VALVE SPRINGS CHECKING THE VALVE SPRINGS 1. Measure: • Valve spring free length "a" Out of specification → Replace. Free length (valve spring): Intake: 39.76 mm (1.57 in) : 38.76 mm (1.53 in) Exhaust: 37.78 mm (1.49 in) : 36.78 mm (1.45 in) 2. Measure: • Compressed spring force "a" Out of specification → Replace. Compressed spring force: Intake: 99–114 N at 28.98 mm (9.9–11.4 kg at 28.98 mm, 22.27–25.57 lb at 1.14 in) Exhaust: 126–145 N at 28.30 mm (12.6–14.5 kg at 28.30 mm, 28.
CYLINDER AND PISTON CYLINDER AND PISTON REMOVING THE CYLINDER AND PISTON Order Part name Q'ty Cylinder head Remarks Refer to "CYLINDER HEAD" section. 1 Bolt (cylinder) 1 2 Cylinder 1 3 Piston pin clip 2 Refer to removal section. 4 Piston pin 1 Refer to removal section. 5 Piston 1 Refer to removal section. 6 Piston ring set 1 Refer to removal section.
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. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller set "4". Piston pin puller set: YU-1304/90890-01304 Do not use a hammer to drive the piston pin out.
CYLINDER AND PISTON 2. Position: • Piston ring (in cylinder) 2. • • • Insert a ring into the cylinder and push it approximately 10 mm (0.39 in) into the cylinder. Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore. Position: Top ring 2nd ring Oil ring Offset the piston ring end gaps as shown. b. Measure the inside diameter (piston) "b". Inside diameter (piston): 16.002–16.013 mm (0.6300–0.6304 in) a. 10 mm (0.39 in) 3.
CYLINDER AND PISTON INSTALLING THE CYLINDER 1. Lubricate: • Piston • Piston ring • Cylinder Apply a liberal coating of engine oil. 2. Install: • Dowel pin "1" • O-ring "2" Apply the lithium soap base grease on the O-ring. 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 timing chain guide "4" during installation. 4.
CLUTCH CLUTCH REMOVING THE CLUTCH Order 1 Part name Q'ty Remarks Drain the engine oil. Refer to "CHANGING THE ENGINE OIL" section in the CHAPTER 3. Brake pedal Refer to "ENGINE REMOVAL" section. Clutch cable Disconnect at engine side. Clutch cover 1 2 Clutch spring 5 3 Pressure plate 1 4 Push rod 1 1 5 Circlip 1 6 Washer 1 7 Bearing 1 8 Ball 1 9 Push rod 2 1 10 Friction plate 9 11 Clutch plate 8 12 Nut (clutch boss) 1 Refer to removal section.
CLUTCH Order Part name Q'ty 14 Clutch boss 1 15 Thrust washer 1 16 Primary driven gear 1 17 Spacer 1 18 Washer 1 19 Push lever shaft 1 4-30 Remarks Refer to removal section.
CLUTCH REMOVING THE CLUTCH BOSS 1. Remove: • Nut "1" • Lock washer "2" • Clutch boss "3" Straighten the lock washer tab and use the clutch holding tool "4" to hold the clutch boss. Clutch holding tool: YM-91042/90890-04086 CHECKING THE CLUTCH SPRINGS 1. Measure: • Clutch spring free length "a" Out of specification → Replace springs as a set. Clutch spring free length: 35.7 mm (1.41 in) : 34.7 mm (1.37 in) CHECKING THE FRICTION PLATES 1.
CLUTCH INSTALLING THE CLUTCH 1. Install: • Washer "1" • Spacer "2" • Primary driven gear "3" • Thrust washer "4" • Clutch boss "5" Apply the engine oil on the primary driven gear inner circumference. 2. Install: • Lock washer "1" • Nut (clutch boss) "2" Nut (clutch boss): 75 Nm (7.5 m•kg, 54 ft•lb) 4. Install: • Friction plate "1" • Clutch plate 1 "2" • Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate.
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 Drain the engine oil. Refer to "CHANGING THE ENGINE OIL" section in the CHAPTER 3. Drain the coolant. Refer to "CHANGING THE COOLANT" section in the CHAPTER 3. Radiator hose 3 Disconnect at water pump side. Exhaust pipe Refer to "EXHAUST PIPE AND SILENCER" section. Brake pedal Refer to "ENGINE REMOVAL" section.
OIL FILTER ELEMENT AND WATER PUMP Order Part name Q'ty Remarks 9 Washer 1 Refer to removal section. 10 Impeller shaft 1 Refer to removal section. 11 Oil seal 2 Refer to removal section. 12 Bearing 1 Refer to removal section.
OIL FILTER ELEMENT AND WATER PUMP REMOVING THE IMPELLER SHAFT 1. Remove: • Impeller "1" • Washer "2" • Impeller shaft "3" CHECKING THE OIL DELIVERY PIPE 1. Inspect: • Oil delivery pipe "1" Bend/damage → Replace. Clogged → Blow. CHECKING THE OIL SEAL 1. Inspect: • Oil seal "1" Wear/damage → Replace. Hold the impeller shaft on its width across the flats "a" with spanners, etc. and remove the impeller. CHECKING THE IMPELLER SHAFT 1. Inspect: • Impeller shaft "1" Bend/wear/damage → Replace.
OIL FILTER ELEMENT AND WATER PUMP INSTALLING THE IMPELLER SHAFT 1. Install: • Impeller shaft "1" • Washer "2" • Impeller "3" Impeller: 14 Nm (1.4 m•kg, 10 ft•lb) • Take care so that the oil seal lip is not damaged or the spring does not slip off its position. • When installing the impeller shaft, apply the lithium soap base grease on the oil seal lip and impeller shaft. And install the shaft while turning it. • Hold the impeller shaft on its width across the flats "a" with spanners, etc.
OIL FILTER ELEMENT AND WATER PUMP INSTALLING THE WATER PUMP HOUSING 1. Install: • Dowel pin "1" • O-ring "2" Apply the lithium soap base grease on the O-ring. 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) INSTALLING THE OIL FILTER ELEMENT 1. Install: • Oil filter element "1" • O-ring "2" • Oil filter element cover "3" • Bolt (oil filter element cover) Bolt (oil filter element cover): 10 Nm (1.0 m•kg, 7.
BALANCER BALANCER REMOVING THE BALANCER Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Right crankcase cover Refer to "OIL FILTER ELEMENT AND WATER PUMP" section. Stator Refer to "CDI MAGNETO" section. 1 Nut (primary drive gear) 1 Refer to removal section. 2 3 Nut (balancer shaft driven gear) 1 Refer to removal section.
BALANCER REMOVING THE BALANCER 1. Straighten the lock washer tab. 2. Loosen: • Nut (primary drive gear) "1" • Nut (balancer shaft driven gear) "2" CHECKING THE BALANCER SHAFT 1. Inspect: • Balancer shaft Cracks/damage → Replace. Place an aluminum plate "a" between the teeth of the balancer shaft drive gear "3" and driven gear "4". 3. Install: • Balancer shaft drive gear "1" • Align the punched mark "a" on the balancer shaft drive gear with the punched mark "b" on the balancer shaft driven gear "2".
OIL PUMP OIL PUMP REMOVING THE OIL PUMP Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Right crankcase cover Refer to "OIL FILTER ELEMENT AND WATER PUMP" section.
OIL PUMP REMOVING THE OIL TANK Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE OIL" section in the CHAPTER 3. Drain the engine oil.
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") • Side clearance "b" (between the outer rotor "2" and rotor housing "3") • Housing and rotor clearance "c" (between the rotor housing "3" and rotors "1" "2") Out of specification→Replace the oil pump assembly. Tip clearance "a": 0.12 mm or less (0.
OIL PUMP IINSTALLING 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. • Insert the oil tank breather hose so that its end "a" comes where the oil tank pipe begins to bend. • Install the clamp 3 mm (0.12 in) away from the oil tank breather hose end "a".
KICK SHAFT AND SHIFT SHAFT KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Oil pump Remarks Refer to "OIL PUMP" section. 1 Kick idle gear 1 2 Kick shaft assembly 1 3 Spring guide 1 4 Torsion spring 1 5 Ratchet wheel 1 6 Kick gear 1 7 Kick shaft 1 8 Washer 1 Refer to removal section. 9 Shift pedal 1 10 Shift shaft 1 11 Collar 1 12 Torsion spring 1 13 Roller 1 14 Shift guide 1 Refer to removal section.
KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty 17 Pawl 2 18 Pawl pin 2 19 Spring 2 20 Bolt (stopper lever) 1 21 Stopper lever 1 22 Torsion spring 1 23 Segment 1 4-45 Remarks Refer to removal section.
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. REMOVING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1. Remove: • Bolt (shift guide) • Shift guide "1" • Shift lever assembly "2" The shift lever assembly is disassembled at the same time as the shift guide. REMOVING THE SEGMENT 1. Remove: • Bolt (segment) "1" • Segment "2" Turn the segment counterclockwise until it stops and loosen the bolt.
KICK SHAFT AND SHIFT SHAFT INSTALLING THE STOPPER LEVER 1. Install: • Torsion spring "1" • Stopper lever "2" • Bolt (stopper lever) "3" Bolt (stopper lever): 10 Nm (1.0 m•kg, 7.2 ft•lb) Align the stopper lever roller with the slot on segment. INSTALLING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1. Install: • Spring "1" • Pawl pin "2" • Pawl "3" To shift lever "4". Apply the engine oil on the spring, pawl pin and pawl. 2. Install: • Shift lever assembly "1" To shift guide "2". 4.
KICK SHAFT AND SHIFT SHAFT 4. Install: • Kick shaft assembly "1" • Washer "2" • Apply the molybdenum disulfide grease on the contacting surfaces of the kick shaft stopper "a" and kick shaft ratchet wheel guide "3". • Apply the engine oil on the kick shaft. • Slide the kick shaft assembly into the crankcase and make sure the kick shaft stopper "a" fits into the kick shaft ratchet wheel guide. 5. Hook: • Torsion spring "1" Turn the torsion spring clockwise and hook into the proper hole "a" in the crankcase.
CDI MAGNETO CDI MAGNETO REMOVING THE CDI MAGNETO Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND SIDE COVERS" section. Seat and fuel tank Disconnect the CDI magneto lead. Refer to "KICK SHAFT AND SHIFT SHAFT" section. Shift pedal 1 Left crankcase cover 1 2 Nut (rotor) 1 Refer to removal section. 3 Rotor 1 Refer to removal section.
CDI MAGNETO REMOVING THE ROTOR 1. Remove: • Nut (rotor) "1" • Washer "2" Use the rotor holding tool "3". CHECKING THE WOODRUFF KEY 1. Inspect: • Woodruff key "1" Damage → Replace. Rotor holding tool: YU-1235/90890-01235 3. Install: • Washer "1" • Nut (rotor) "2" Nut (rotor): 56 Nm (5.6 m•kg, 40 ft•lb) Use the rotor holding tool "3". Rotor holding tool: YU-1235/90890-01235 INSTALLING THE CDI MAGNETO 1. Install: • Stator "1" • Screw (stator) "2" 2. Remove: • Rotor "1" Use the flywheel puller "2".
ENGINE REMOVAL ENGINE REMOVAL REMOVING THE ENGINE Order Part name Q'ty Hold the machine by placing the suitable stand under the frame. Refer to "HANDLING NOTE". Seat and fuel tank Refer to "SEAT, FUEL TANK AND SIDE COVERS" section. Carburetor Refer to "CARBURETOR" section. Exhaust pipe and silencer Refer to "EXHAUST PIPE AND SILENCER" section. Clutch cable Disconnect at the engine side. Radiator Refer to "RADIATOR" section. Shift pedal Refer to "KICK SHAFT AND SHIFT SHAFT" section.
ENGINE REMOVAL Order Part name Q'ty Remarks 2 Neutral switch 1 3 Drive chain sprocket cover 1 4 Nut (drive sprocket) 1 Refer to removal section. 5 Lock washer 1 Refer to removal section. 6 Drive sprocket 1 Refer to removal section. 7 Clip 1 8 Bolt (brake pedal) 1 9 Brake pedal 1 10 Upper engine bracket 2 11 Front engine bracket 2 12 Engine mounting bolt 3 13 Pivot shaft 1 Refer to removal section. 14 Engine 1 Refer to removal section.
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: • Engine "1" From right side. • Lower engine guard "11" • Bolt (lower engine guard) "12" Bolt (lower engine guard): 10 Nm (1.0 m•kg, 7.2 ft•lb) Make sure that the couplers, hoses and cables are disconnected. • Apply the molybdenum disulfide grease on the pivot shaft.
ENGINE REMOVAL INSTALLING THE DRIVE SPROCKET 1. Install: • Drive sprocket "1" • Drive chain "2" Install the drive sprocket together with the drive chain. INSTALLING THE NEUTRAL SWITCH 1. Install: • Spring "1" • Pin "2" • O-ring "3" • Neutral switch "4" • Screw (neutral switch) "5" Screw (neutral switch): 4 Nm (0.4 m•kg, 2.9 ft•lb) Apply the lithium soap base grease on the O-ring. 2. Install: • Lock washer "1" • Nut (drive sprocket) "2" Nut (drive sprocket): 75 Nm (7.
CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT REMOVING THE CRANKSHAFT Order Part name Q'ty Remarks Engine Refer to "ENGINE REMOVAL" section. Piston Refer to "CYLINDER AND PISTON" section. Kick shaft assembly Refer to "KICK SHAFT AND SHIFT SHAFT" section. Segment Refer to "KICK SHAFT AND SHIFT SHAFT" section. Stator Refer to "CDI MAGNETO" section. Balancer shaft Refer to "BALANCER" section.
CRANKCASE AND CRANKSHAFT Order Part name Q'ty 10 Left crankcase 1 11 Oil strainer 1 12 Crankshaft 1 4-56 Remarks Refer to removal section. Refer to removal section.
CRANKCASE AND CRANKSHAFT REMOVING THE CRANKCASE BEARING Order Part name Q'ty Remarks Transmission Refer to "TRANSMISSION, SHIFT CAM AND SHIFT FORK" section. Shift cam and shift fork Refer to "TRANSMISSION, SHIFT CAM AND SHIFT FORK" section. 1 Oil seal 2 2 Bearing 10 4-57 Refer to removal section.
CRANKCASE AND CRANKSHAFT DISASSEMBLING THE CRANKCASE 1. Separate: • Right crankcase • Left crankcase Separation steps: a. Remove the crankcase bolts "1", hose guide "2" and clutch cable holder "3". REMOVING THE CRANKSHAFT 1. Remove: • Crankshaft "1" Use the crankcase separating tool "2". Crankcase separating tool: YU-1135-A/9089001135 CHECKING THE CRANKCASE 1. Inspect: • Contacting surface "a" Scratches → Replace. • Engine mounting boss "b", crankcase Cracks/damage → Replace.
CRANKCASE AND CRANKSHAFT • Screw [bearing stopper (crankshaft)] "1" Screw [bearing stopper (crankshaft)]: 14 Nm (1.4 m•kg, 10 ft•lb) To left and right crankcase. CHECKING THE OIL STRAINER 1. Inspect: • Oil strainer Damage → Replace. CHECKING THE OIL DELIVERY PIPE 2 1. Inspect: • Oil delivery pipe 2 "1" • O-ring "2" Damage → Replace. • Oil orifice "a" Clogged → Blow. INSTALLING THE CRANKCASE BEARING 1. Install: • Bearing • Bearing stopper • Bolt (bearing stopper) Bolt (bearing stopper): 10 Nm (1.
CRANKCASE AND CRANKSHAFT Apply the lithium soap base grease on the Orings. 5. • • • Install: Dowel pin "1" O-ring "2" Right crankcase To left crankcase. • Apply the lithium soap base grease on the O-ring. • Fit the right crankcase onto the left crankcase. Tap lightly on the case with soft hammer. • When installing the crankcase, the connecting rod should be positioned at TDC (top dead center). 6. • • • Tighten: Hose guide "1" Clutch cable holder "2" Bolt (crankcase) "3" Bolt (crankcase): 12 Nm (1.
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. Separate the crankcase. Refer to "CRANKCASE AND CRANKSHAFT" section. 1 Main axle 1 Refer to removal section. 2 Drive axle 1 Refer to removal section. 3 Shift cam 1 Refer to removal section. 4 Shift fork 3 1 Refer to removal section. 5 Shift fork 2 1 Refer to removal section.
TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION 1. Remove: • Main axle "1" • Drive axle "2" • Shift cam • Shift fork 3 • Shift fork 2 • Shift fork 1 • Remove assembly with the collar "3" installed to the crankcase. • Remove assembly carefully. Note the position of each part. Pay particular attention to the location and direction of shift forks. • Remove the main axle, drive axle, shift cam and shift fork all together by tapping lightly on the transmission drive axle with a soft hammer.
TRANSMISSION, SHIFT CAM AND SHIFT FORK 3. Install: • Washer "1" • Circlip "2" • Be sure the circlip sharp-edged corner "a" is positioned opposite side to the washer and gear "b". • Install the circlip with its ends "c" settled evenly on the spline crests. 6. Install: • Transmission assembly "1" To left crankcase "2". Apply the engine oil on the bearings and guide bars. 4. Install: • Collar "1" • Apply the lithium soap base grease on the oil seal lip.
FRONT WHEEL AND REAR WHEEL CHASSIS 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 knowledge and skill concerning servicing are requested not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical damage.
FRONT WHEEL AND REAR WHEEL REMOVING THE REAR WHEEL 5 Order Part name Q'ty Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". 1 Nut (rear wheel axle) 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 3 10 Brake disc 1 5-2 Remarks Refer to removal section. Refer to removal section.
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 chain "2". CHECKING THE WHEEL AXLE 1. Measure: • Wheel axle bends Out of specification → Replace. Use the dial gauge "1". Wheel axle bending limit: 0.5 mm (0.020 in) The bending value is shown by one half of the dial gauge reading. REMOVING THE WHEEL BEARING 1.
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) 6. Install: • Nut (wheel axle) "1" Nut (wheel axle): 105 Nm (10.5 m•kg, 75 ft•lb) Do not strike the inner race of the bearing. Contact should be made only with the outer race. Tighten the bolts in stage, using a crisscross pattern. 7. Tighten: • Bolt (axle holder) "1" 3. Install: • Collar "1" • Apply the lithium soap base grease on the oil seal lip.
FRONT WHEEL AND REAR WHEEL 4. Install: • Collar "1" Apply the lithium soap base grease on the oil seal lip. 8. • • • Install: Right drive chain puller "1" Washer "2" Nut (wheel axle) "3" Temporarily tighten the nut (wheel axle) at this point. 5. Install: • Wheel Install the brake disc "1" between the brake pads "2" correctly. 9. Adjust: • Drive chain slack "a" Drive chain slack: 50–60 mm (2.0–2.4 in) Refer to "ADJUSTING THE DRIVE CHAIN SLACK" section in the CHAPTER 3. 6.
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 under the engine. Refer to "HANDLING NOTE". Drain the brake fluid. Refer to removal section. 1 Brake hose holder (protector) 2 2 Union bolt 2 3 Brake hose 1 4 Pad pin plug 1 Remove when loosening the pad pin. 5 Pad pin 1 Loosen when disassembling the brake caliper.
FRONT BRAKE AND REAR BRAKE REMOVING THE REAR BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". Rear wheel Refer to "FRONT WHEEL AND REAR WHEEL" section. Drain the brake fluid. Refer to removal section. 1 Brake pedal 1 2 Brake master cylinder 1 3 Brake hose holder 2 4 Union bolt 2 5 Brake hose 1 6 Pad pin plug 1 Remove when loosening the pad pin. Loosen when disassembling the brake caliper.
FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE CALIPER Order Part name Q'ty Remarks A. B. Front Rear A B 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Brake caliper piston 2 1 Refer to removal section. 5 Brake caliper piston dust seal 2 1 Refer to removal section. 6 Brake caliper piston seal 2 1 Refer to removal section.
FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE MASTER CYLINDER Order Part name Q'ty Remarks A. B. 1 Brake master cylinder cap 1 2 Diaphragm 1 3 Reservoir float 1 4 Push rod (Front) 1 5 Brake master cylinder boot 1 6 Circlip 1 7 Washer 1 8 Push rod (Rear) 1 9 Brake master cylinder kit 1 5-9 Front Rear Use a long nose circlip pliers.
FRONT BRAKE AND REAR BRAKE HANDLING NOTE Support the machine securely so there is no danger of it falling over. DRAINING THE BRAKE FLUID 1. Remove: • Brake master cylinder cap "1" • Protector (rear brake) Do not remove the diaphragm. REMOVING THE BRAKE CALIPER PISTON 1. Remove: • Brake caliper piston Use compressed air and proceed carefully. Replace the brake caliper piston seals and brake caliper piston dust seals whenever a caliper is disassembled.
FRONT BRAKE AND REAR BRAKE 3. Inspect: (front brake only) • Reservoir float "1" Damage → Replace. 4. Inspect: • Brake master cylinder piston "1" • Brake master cylinder cup "2" Wear/damage/score marks → Replace brake master cylinder kit. CHECKING THE BRAKE CALIPER 1. Inspect: • Brake caliper cylinder inner surface "a" Wear/score marks → Replace brake caliper assembly. CHECKING THE BRAKE HOSE 1. Inspect: • Brake hose "1" Crack/damage → Replace. A. Front B. Rear 3.
FRONT BRAKE AND REAR BRAKE 2. Install: • Brake caliper "1" • Bolt (brake caliper) "2" Bolt (brake caliper): 28 Nm (2.8 m•kg, 20 ft•lb) 3. Tighten: • Pad pin "3" Pad pin: 18 Nm (1.8 m•kg, 13 ft•lb) 4. Install: • Pad pin plug "4" Pad pin plug: 3 Nm (0.3 m•kg, 2.2 ft•lb) 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. 3.
FRONT BRAKE AND REAR BRAKE INSTALLING THE FRONT BRAKE MASTER CYLINDER 1. Install: • Brake master cylinder "1" • Brake master cylinder bracket "2" • Bolt (brake master cylinder bracket) "3" Bolt (brake master cylinder bracket): 9 Nm (0.9 m•kg, 6.5 ft•lb) 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) Always use new copper washers. • Install the bracket so that the arrow mark "a" face upward.
FRONT BRAKE AND REAR BRAKE Install the brake hose so that its pipe portion "a" directs as shown and lightly touches the projection "b" on the brake caliper. Install the brake hose so that its pipe portion "a" directs as shown and lightly touches the projection "b" on the brake master cylinder. 2. Install: • Brake hose holder "1" • Bolt (brake hose holder) "2" INSTALLING THE REAR BRAKE HOSE 1. Install: • Copper washer "1" • Brake hose "2" • Union bolt "3" Bolt (brake hose holder): 8 Nm (0.8 m•kg, 5.
FRONT BRAKE AND REAR BRAKE 5. Install: (rear brake only) • Protector "1" • Bolt (protector) "2" Bolt (protector): 7 Nm (0.7 m•kg, 5.1 ft•lb) 2. • 3. • 4. • • • • A. Front B. Rear Air bleed: Brake system Refer to "BLEEDING THE HYDRAULIC BRAKE SYSTEM" section in the CHAPTER 3. Inspect: Brake fluid level Fluid at lower level → Fill up. Refer to "CHECKING THE BRAKE FLUID LEVEL" section in the CHAPTER 3.
FRONT FORK FRONT FORK REMOVING THE FRONT FORK Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". Front wheel Refer to "FRONT WHEEL AND REAR WHEEL" section. Front brake caliper Refer to "FRONT BRAKE AND REAR BRAKE" section. Number plate Refer to "SEAT, FUEL TANK AND SIDE COVERS" section in the CHAPTER 4. 1 Protector 1 2 Pinch bolt (upper bracket) 2 Only loosening.
FRONT FORK DISASSEMBLING THE FRONT FORK 30 Nm (3.0 m kg, 22 ft lb) 29 Nm (2.9 m kg, 21 ft lb) 1 Nm (0.1 m kg, 0.7 ft lb) 29 Nm (2.9 m kg, 21 ft lb) 55 Nm (5.5 m kg, 40 ft lb) Order Part name Q'ty Remarks 1 Adjuster 1 Drain the fork oil. Refer to removal section. 2 Fork spring 1 3 Dust seal 1 Refer to removal section. 4 Stopper ring 1 Refer to removal section. 5 Inner tube 1 Refer to removal section.
FRONT FORK HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE ADJUSTER 1. Drain the outer tube of its front fork oil at its top. 2. Loosen: • Adjuster "1" The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers.
FRONT FORK CHECKING THE DAMPER ASSEMBLY 1. Inspect: • Damper assembly "1" Bend/damage → Replace. • O-ring "2" Wear/damage → Replace. The front fork with a built-in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material. Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled. CHECKING THE BASE VALVE 1. Inspect: • Base valve "1" Wear/damage → Replace.
FRONT FORK 5. Measure: • Oil level (left and right) "a" Out of specification → Adjust. Standard oil level: 145-148 mm (5.71-5.83 in) From top of fully stretched damper assembly. 8. Install: • Base valve "1" To damper assembly "2". First bring the damper rod pressure to a maximum. Then install the base valve while releasing the damper rod pressure. 9. Check: • Damper assembly Not fully stretched → Repeat the steps 2 to 8. 10. Tighten: • Base valve "1" 6.
FRONT FORK 19. Install: • Oil seal "1" Press the oil seal into the outer tube with fork seal driver "2". 16. Install: • Piston metal "1" Fork seal driver: YM-A0948/90890-01502 23. Measure: • Distance "a" Out of specification → Turn into the locknut. Distance "a": 16 mm (0.63 in) or more Between the damper assembly "1" bottom and locknut "2" bottom. Install the piston metal onto the slot on inner tube. 20. Install: • Stopper ring "1" 17. Install: • Outer tube "1" To inner tube "2". 18.
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 position). 29. Tighten: • Adjuster (locknut) "1" Adjuster (locknut): 29 Nm (2.9 m•kg, 21 ft•lb) 27. Install: • Push rod "1" • Copper washer "2" • Adjuster "3" To damper assembly "4". • While compressing the inner tube "5", set the cap bolt ring wrench "7" between the inner tube and locknut "6".
FRONT FORK INSTALLING THE FRONT FORK 1. Install: • Front fork "1" • Temporarily tighten the pinch bolts (lower bracket). • Do not tighten the pinch bolts (upper bracket) yet. 4. Tighten: • Pinch bolt (upper bracket) "1" Pinch bolt (upper bracket): 21 Nm (2.1 m•kg, 15 ft•lb) • Pinch bolt (lower bracket) "2" Pinch bolt (lower bracket): 21 Nm (2.1 m•kg, 15 ft•lb) 2. Tighten: • Damper assembly "1" Tighten the lower bracket to specified torque. If torqued too much, it may cause the front fork to malfunction.
HANDLEBAR HANDLEBAR REMOVING THE HANDLEBAR Order Part name Q'ty Number plate Remarks Remove the band only. 1 Hot starter cable 1 2 Hot starter lever holder 1 3 Clutch cable 1 4 Clutch lever holder 1 Disconnect at the lever side. Disconnect at the lever side. 5 Engine stop switch 1 6 Brake master cylinder 1 7 Throttle cable cap 1 8 Throttle cable #1 (pulled) 1 Disconnect at the throttle side. Refer to removal section.
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. REMOVING THE GRIP 1. Remove: • Grip "1" INSTALLING THE HANDLEBAR 1.
HANDLEBAR 3. Tighten: • Nut (handlebar lower holder) "1" Nut (handlebar lower holder): 34 Nm (3.4 m•kg, 24 ft•lb) 6. • • • 4. Install: • Left grip "1" Apply the adhesive to the handlebar "2". • Before applying the adhesive, wipe off grease or oil on the handlebar surface "a" with a lacquer thinner. • Install the left grip to the handlebar so that the line "b" between the two arrow marks faces straight upward.
HANDLEBAR • Clamp "6" • The engine stop switch, clutch lever holder and clamp should be installed according to the dimensions shown. • Pass the engine stop switch lead in the middle of the clutch lever holder. 12. Install: • Clutch cable "1" • Hot starter cable "2" Apply the lithium soap base grease on the clutch cable end and hot starter cable end. 13. Adjust: • Clutch lever free play Refer to "ADJUSTING THE CLUTCH CABLE FREE PLAY" section in the CHAPTER 3.
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 under the engine. Refer to "HANDLING NOTE". Number plate Refer to "SEAT, FUEL TANK AND SIDE COVERS" section in the CHAPTER 4. Handlebar Refer to "HANDLEBAR" section.
STEERING HANDLING NOTE Support the machine securely so there is no danger of it falling over. CHECKING THE STEERING STEM 1. Inspect: • Steering stem "1" Bend/damage → Replace. Support the steering stem so that it may not fall down. REMOVING THE LOWER BEARING 1. Remove: • Lower bearing "1" Use the floor chisel "2". Install: Bearing race Upper bearing "1" Bearing race cover "2" Apply the lithium soap base grease on the bearing and bearing race cover lip. REMOVING THE STEERING RING NUT 1.
STEERING 5. Check the steering stem by turning it lock to lock. If there is any binding, remove the steering stem assembly and inspect the steering bearings. 9. After tightening the nut, check the steering for smooth movement. If not, adjust the steering by loosening the steering ring nut little by little. 10. Adjust: • Front fork top end "a" Front fork top end (standard) "a": 5 mm (0.20 in) 6. Install: • Washer "1" 11. Tighten: • Pinch bolt (upper bracket) "1" 7.
SWINGARM SWINGARM REMOVING THE SWINGARM Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". Brake hose holder Refer to "FRONT BRAKE AND REAR BRAKE" section. Rear brake caliper Refer to "FRONT BRAKE AND REAR BRAKE" section. Bolt (brake pedal) Shift the brake pedal backward.
SWINGARM DISASSEMBLING THE SWINGARM Order Part name Q'ty 1 Relay arm 1 2 Connecting rod 1 3 Collar 2 4 Oil seal 2 5 Thrust bearing 2 6 Bushing 2 7 Oil seal 8 8 Bearing 10 5-32 Remarks Refer to removal section.
SWINGARM HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE BEARING 1. Remove: • Bearing "1" Remove the bearing by pressing its outer race. CHECKING THE CONNECTING ROD 1. Inspect: • Bearing "1" • Collar "2" Free play exists/unsmooth revolution/rust → Replace bearing and collar as a set. 2. Inspect: • Oil seal "3" Damage → Replace. 2. • • • Install: Bearing "1" Washer "2" Oil seal "3" To relay arm.
SWINGARM INSTALLING THE SWINGARM 1. Install: • Bushing "1" • Thrust bearing "2" • Oil seal "3" • Collar "4" To swingarm "5". Apply the molybdenum disulfide grease on the bushings, thrust bearings, oil seal lips and contact surfaces of the collar and thrust bearing. 2. Install: • Collar "1" • Washer "2" To relay arm "3". Apply the molybdenum disulfide grease on the bolt. 5. • • • • Install: Relay arm "1" Bolt (relay arm) "2" Washer "3" Nut (relay arm) "4" To swingarm.
SWINGARM 11. Tighten: • Nut (relay arm) "1" Nut (relay arm): 70 Nm (7.0 m•kg, 50 ft•lb) 12. Install: • Bolt (lower chain tensioner) "1" • Washer "2" • Collar "3" • Lower chain tensioner "4" • Nut (lower chain tensioner) "5" Nut (lower chain tensioner): 16 Nm (1.6 m•kg, 11 ft•lb) 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.
REAR SHOCK ABSORBER REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER 11 2 B 10 9 8 11 Order Part name Q'ty Remarks Hold the machine by placing the suitable stand under the engine. Refer to "HANDLING NOTE". Seat Refer to "SEAT, FUEL TANK AND SIDE COVERS" section in the CHAPTER 4. Silencer Refer to "EXHAUST PIPE AND SILENCER" section in the CHAPTER 4. 1 Clamp (air filter joint) 1 2 Rear frame 1 3 Bolt (rear shock absorber-relay arm) 1 Only loosening. Hold the swingarm.
REAR SHOCK ABSORBER HANDLING NOTE • Support the machine securely so there is no danger of it falling over. • This rear shock absorber is provided with a separate type tank filled with high-pressure nitrogen gas. To prevent the danger of explosion, read and understand the following information before handling the shock absorber. The manufacturer can not be held responsible for property damage or personal injury that may result from improper handling.
REAR SHOCK ABSORBER INSTALLING THE BEARING 1. Install: • Upper bearing "1" Install the bearing parallel until the stopper ring groove appears by pressing its outer race. Do not apply the grease on the bearing outer race because it will wear the rear shock absorber surface on which the bearing is press fitted. INSTALLING THE SPRING (REAR SHOCK ABSORBER) 1. Install: • Spring "1" • Upper spring guide "2" • Lower spring guide "3" 2.
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) 7. Tighten: • Bolt (air filter joint) "1" Bolt (air filter joint): 3 Nm (0.3 m•kg, 2.
ELECTRICAL 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 knowledge and skill concerning servicing are requested not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to servicing trouble and mechanical damage.
ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS 1. 2. 3. Engine stop switch Throttle position sensor Neutral switch 4. 5. 6. 7.
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 ↓ Check entire ignition system for connection. (couplers, leads and ignition coil) No good → Repair or replace. OK ↓ Check engine stop switch. No good → Replace. OK ↓ Check ignition coil.
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" (ignition checker "2") as shown. • Ignition coil "3" • Spark plug "4" CHECKING THE ENGINE STOP SWITCH 1. Inspect: • Engine stop switch conduction Tester (+) lead→Black/White lead "1" Tester (-) lead → Black lead "2" 3. Inspect: • Secondary coil resistance Out of specification → Replace.
IGNITION SYSTEM 2. Inspect: • Charging coil 1 resistance Out of specification → Replace. Tester (+) lead → Brown lead "1" Tester (-) lead → Green lead "2" Charging Tester secoil 1 resis- lector positance tion 720-1,080 Ω at 20 °C (68 °F) Ω ×100 W Br P R G B CHECKING THE NEUTRAL SWITCH 1. Inspect: • Neutral switch conduction Tester (+) lead→Sky blue lead "1" Tester (-) lead → Ground "2" Result Conductive (while gear is in neutral) Not conductive while it is in neutral → Replace.
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 connection. No good → Repair or replace. OK ↓ Check throttle position sensor. (Throttle position No good → sensor coil) Replace. OK ↓ *Check CDI magneto. (Charging coil) No good → Replace. OK ↓ Check CDI unit.
THROTTLE POSITION SENSOR SYSTEM HANDLING NOTE Do not loosen the screw (throttle position sensor) "1" except when changing the throttle position sensor due to failure because it will cause a drop in engine performance. 3. Inspect: • Throttle position sensor coil variable resistance Check that the resistance in increased as the throttle grip is moved from the full close position to the full open position. Out of specification → Replace. Tester (+) lead → Yellow lead "1" Tester (-) lead → Black lead "2" 4.
THROTTLE POSITION SENSOR SYSTEM 8. Start the engine. 9. Adjust: • Throttle position sensor output voltage Adjustment steps: a. Adjust the installation angle of the throttle position sensor "1" to obtain the specified output voltage. Measure the output voltage accurately with a digital electronic voltmeter that gives an easy reading of a small voltage. Throttle poTester sesition senlector posisor output tion voltage 0.58–0.78 V DCV CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1.
ENGINE TUNING ENGINE CARBURETOR SETTING • The air/fuel mixture will vary depending on atmospheric conditions. Therefore, it is necessary to take into consideration the air pressure, ambient temperature, humidity, etc., when adjusting the carburetor. • Perform a test run to check for proper engine performance (e.g., throttle response) and spark plug(-s) discoloration or fouling. Use these readings to determine the best possible carburetor setting.
ENGINE ADJUSTING THE PILOT SCREW The richness of the air-fuel mixture with the throttle fully closed to 1/4 open can be set by turning the pilot screw "1". Turning in the pilot screw will make the mixture lean at low speeds, and turning it out will enrich it. Standard pilot screw position (example) 1-3/4 • If the engine idling speed fluctuates, turn the pilot screw only 1/2 of a turn in either direction.
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 throttle opening (each engine speed). 1.
ENGINE SPECIFICATIONS OF JET NEEDLE For USA and CDN Diameter of straight portion Rich N Rich Lean P Q R S T U 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 STD NDJN-4 NDJP-4 NDJQ-4 NDJR-4 NDJS-4 NDJT-4 NDJU-4 0.
ENGINE Symptom Setting Closed to 1/4 throttle Hard breathing Speed down Use jet needle with a smaller diameter. Closed to 1/4 throttle Poor acceleration Use jet needle with a larger diameter. Raise jet needle clip position. (1 groove up) Poor response in the low to intermediate speeds Raise jet needle clip position. If this has no effect, lower the jet needle clip position. Checking Slow-speed-circuit passage Clogged → Clean.
CHASSIS CHASSIS SELECTION OF THE SECONDARY REDUCTION RATIO (SPROCKET) Secondary reduction ratio = Number of rear wheel sprocket teeth/Number of drive sprocket teeth Standard secondary reduction ratio 49/13 (3.769) * 51/13 (3.923) * Except for USA and CDN • It is generally said that the secondary gear ratio should be reduced for a longer straight portion of a speed course and should be increased for a course with many corners.
CHASSIS FRONT FORK SETTING PARTS • Front fork spring "1" TY PE SO FT A. Air spring characteristics in relation to oil amount change B. Load C. Stroke 1. Max. oil amount 2. Standard oil amount 3. Min. oil amount SETTING OF SPRING AFTER REPLACEMENT As the front fork setting can be easily affected by rear suspension, take care so that the machine front and rear are balanced (in position, etc.) when setting the front fork. 1. Use of soft spring • Change the rebound damping. Turn out one or two clicks.
CHASSIS SETTING OF SPRING AFTER REPLACEMENT After replacement, be sure to adjust the spring to the set length [sunken length 90–100 mm (3.5–3.9 in)] and set it. 1. Use of soft spring • Set the soft spring for less rebound damping to compensate for its less spring load. Run with the rebound damping adjuster one or two clicks on the softer side and readjust it to suit your preference. 2. Use of stiff spring • Set the soft spring for more rebound damping to compensate for its greater spring load.
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).
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. • Adjust the low compression damping in 1-click increments or decrements. • Adjust the high compression damping in 1/6 turn increments or decrements.
PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO., LTD.
