P8-9-10 hyoshi 12/5/04 2:31 PM Page 1 PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories YZ250T1 OWNER’S SERVICE MANUAL YZ250T1 PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN JAPAN 2004.5—2.
1P8-9-10 hyoshi 12/5/04 2:31 PM Page 2
EC010000 YZ250T1 OWNER’S SERVICE MANUAL ©2004 by Yamaha Motor Corporation, U.S.A. 1st Edition, May 2004 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U.S.A. is expressly prohibited. Printed in Japan P/N.
EC020000 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.
EC030002 YAMAHA MOTOR CORPORATION, U.S.A. YZ/WR MOTORCYCLE LIMITED WARRANTY Yamaha Motor Corporation, U.S.A. hereby warrants to the origi- a. Installation of parts or accessories that are not qualitatively nal retail purchaser that the following components equipped on equivalent to genuine Yamaha parts. FROM THIS WARRANTY ARE ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF USE. SOME new Yamaha YZ or WR motorcycles purchased from an autho- b. Abnormal strain, neglect, or abuse.
EC040001 IMPORTANT NOTICE THIS MACHINE IS DESIGNED STRICTLY FOR COMPETITION USE, ONLY ON A CLOSED COURSE. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regulations before riding. qSAFETY INFORMATION 1. THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY. Do not attempt to operate this machine at maximum power until you are totally familiar with its characteristics. 2.
5. GASOLINE IS HIGHLY FLAMMABLE. Always turn off the engine while refueling. Take care to not spill any gasoline on the engine or exhaust system. Never refuel in the vicinity of an open flame, or while smoking. 6. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes. 7.
EC050000 TO THE NEW OWNER This manual will provide you with a good basic understanding of features, operation, and basic maintenance and inspection items of this machine. Please read this manual carefully and completely before operating your new machine. If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer.
EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! w Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine. cC A CAUTION indicates special precautions that must be taken to avoid damage to the machine. NOTE: A NOTE provides key information to make procedures easier or clearer.
EC083000 MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., 9Bearings Pitting/Damage→ Replace.
1 EC085002 2 GEN INFO SPEC 3 4 INSP ADJ ENG 5 6 CHAS ELEC 7 TUN 0 q w e r t y u i o p a Illustrated symbols 1 to 7 are designed as thumb tabs to indicate the chapter’s number and content. 1 General information 2 Specifications 3 Regular inspection and adjustments 4 Engine 5 Chassis 6 Electrical 7 Tuning Illustrated symbols 8 to r are used to identify the specifications appearing in the text.
EC090000 INDEX GENERAL INFORMATION GEN INFO 1 SPEC 2 INSP ADJ 3 ENG 4 CHAS 5 ELEC 6 TUN 7 SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL TUNING
EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION ............................................1-1 MACHINE IDENTIFICATION ......................1-2 IMPORTANT INFORMATION .....................1-3 CHECKING OF CONNECTION ..................1-6 SPECIAL TOOLS........................................1-7 CONTROL FUNCTIONS.............................1-9 FUEL AND ENGINE MIXING OIL.............1-12 STARTING AND BREAK-IN .....................1-13 TORQUE-CHECK POINTS.......................
CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS .....................................................4-1 EXHAUST PIPE AND SILENCER ..............4-3 RADIATOR..................................................4-4 CARBURETOR AND REED VALVE...........4-7 CYLINDER HEAD , CYLINDER AND PISTON .....................................................4-18 CLUTCH AND PRIMARY DRIVEN GEAR .......................................................4-33 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR...........................
CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM .....................................6-1 IGNITION SYSTEM.....................................6-2 SOLENOID VALVE SYSTEM .....................6-7 TPS (THROTTLE POSITION SENSOR) SYSTEM......................................................6-9 CHAPTER 7 TUNING ENGINE.......................................................7-1 CHASSIS...................................................
DESCRIPTION GEN INFO EC100000 GENERAL INFORMATION EC110000 DESCRIPTION NOTE: 1 2 3 4 5 6 7 8 9 0 q w e r t y u i o 9The machine you have purchased may differ slightly from those shown in the following. 9Designs and specifications are subject to change without notice.
MACHINE IDENTIFICATION GEN INFO EC120001 MACHINE IDENTIFICATION There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own. 2. If your machine is stolen, the authorities will need the number to search for and identify your machine.
IMPORTANT INFORMATION GEN INFO EC130000 IMPORTANT INFORMATION EC131010 PREPARATION FOR REMOVAL AND DIS ASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. When washing the machine with high pressured water, cover the parts as follows. 9Silencer exhaust port 9Side cover air intake port 9Water pump housing hole at the bottom 2. Use proper tools and cleaning equipment. Refer to “SPECIAL TOOLS” section. 3. When disassembling the machine, keep mated parts together.
IMPORTANT INFORMATION GEN INFO EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled. All gasket surfaces, oil seal lips, and O-rings must be cleaned. 2. Properly oil all mating parts and bearings during reassembly. Apply grease to the oil seal lips.
IMPORTANT INFORMATION GEN INFO EC136000 CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1, make sure that the sharp-edged corner 2 is positioned opposite to the thrust 3 it receives. See the sectional view.
CHECKING OF CONNECTION GEN INFO EC1C0001 CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: 9Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off. 5. If the terminal comes off, bend up the pin 1 and reinsert the terminal into the connector. 6. Connect: 9Connector NOTE: The two connectors “click” together. 7. Check for continuity with a tester.
GEN INFO SPECIAL TOOLS EC140002 SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order. NOTE: 9For U.S.A. and Canada, use part number starting with “YM-”, “YU-” or “ACC -”.
GEN INFO SPECIAL TOOLS Part number YU-33975, 90890-01403 Tool name / How to use Ring nut wrench IIIustration YU-33975 90890-01403 YM-01442 90890-01442 YM-01500 90890-01500 YM-01501 90890-01501 YM-3112-C 90890-03112 YU-8036-B 90890-03113 YM-91042 90890-04086 YM-34487 90890-06754 ACC-QUICK-GS-KT 90890-85505 This tool is used when tighten the steering ring nut to specification. YM-01442, 90890-01442 Fork seal driver This tool is used when install the fork oil seal.
CONTROL FUNCTIONS GEN INFO EC150000 CONTROL FUNCTIONS EC151000 “ENGINE STOP” BUTTON The “ENGINE STOP” button 1 is located on the left handlebar. Continue pushing the “ENGINE STOP” button till the engine comes to a stop. EC152000 CLUTCH LEVER The clutch lever 1 is located on the left handlebar; it disengages or engages the clutch. Pull the clutch lever to the handlebar to disengage the clutch, and release the lever to engage the clutch.
CONTROL FUNCTIONS GEN INFO EC156000 FRONT BRAKE LEVER The front brake lever 1 is located on the right handlebar. Pull it toward the handlebar to activate the front brake. EC157000 REAR BRAKE PEDAL The rear brake pedal 1 is located on the right side of the machine. Press down on the brake pedal to activate the rear brake. EC158001 FUEL COCK The fuel cock supplies fuel from the tank to carburetor while filtering the fuel.
CONTROL FUNCTIONS GEN INFO EC15R001 DETACHABLE SIDESTAND This sidestand 1 is used to support only the machine when standing or transporting it. w 9Never apply additional force to the sidestand. 9Remove this sidestand before starting out. EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose. cC In this installation, make sure the arrow faces the fuel tank and also downward.
FUEL AND ENGINE MIXING OIL GEN INFO EC160051 FUEL AND ENGINE MIXING OIL Mix oil with the gas at the ratio specified below. Always use fresh, name-brand gasoline, and mix the oil and gas the day of the race. Do not use premix that is more than a few hours old. Recommended fuel: Premium unleaded gasoline only with a research octane number of 95 or higher. NOTE: If knocking or pinging occurs, use a different brand of gasoline or higher octane grade.
STARTING AND BREAK-IN GEN INFO EC190000 STARTING AND BREAK-IN cC Before starting the machine, perform the checks in the pre-operation check list. w Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time. Always operate the machine in a well-ventilated area. EC191001 STARTING A COLD ENGINE 1. Shift the transmission into neutral. 2. Turn the fuel cock to “ON” and full open the starter knob (CHOKE). 3.
STARTING AND BREAK-IN GEN INFO EC194001 BREAK-IN PROCEDURES 1. Before starting the engine, fill the fuel tank with a break-in oil-fuel mixture as follows. Mixing oil: Mixing ratio: Yamalube “2-R” 15:1 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” button. 4. Operate the machine in the lower gears at moderate throttle openings for five to eight minutes.
STARTING AND BREAK-IN GEN INFO cC 9After the break-in or before each race, you must check the entire machine for loose fittings and fasteners as per “TORQUECHECK POINTS”. Tighten all such fasteners as required. 9When any of the following parts have been replaced, they must be broken in. CYLINDER AND CRANKSHAFT: About one hour of break-in operation is necessary. PISTON, RING AND GEARS: These parts require about 30 minutes of break-in operation at half-throttle or less.
TORQUE-CHECK POINTS GEN INFO EC1A0013 TORQUE-CHECK POINTS Frame construction Combined seat and tank Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Suspension Wheel Steering shaft to handlebar Steering shaft to frame Steering shaft to handle crown Handle crown to handlebar Front Steering shaft to front fork Front fork to handle crown Front fork to under bracket Rear For link type Assembly of links Link to frame Link to shock absorber Link to swingarm
CLEANING AND STORAGE GEN INFO EC1B0000 CLEANING AND STORAGE EC1B1000 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many 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.
CLEANING AND STORAGE GEN INFO EC1B2001 STORAGE If your machine is to be stored for 60 days or more, some preventive measures must be taken to avoid deterioration. After cleaning the machine thoroughly, prepare it for storage as follows: 1. Drain the fuel tank, fuel lines, and the carburetor float bowl. 2. Remove the spark plug, pour a tablespoon of SAE 10W-30 motor oil in the spark plug hole, and reinstall the plug.
GENERAL SPECIFICATIONS SPEC EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: YZ250T1 (USA, CDN) YZ250 (EUROPE, ZA) YZ250T (AUS, NZ) Model code number: 1P81 (USA, CDN, ZA) 1P82 (EUROPE) 1P84 (AUS, NZ) Dimensions: USA, ZA AUS, NZ EUROPE CDN 2,179 mm (85.8 in) 827 mm (32.6 in) 1,306 mm (51.4 in) 989 mm (38.9 in) 1,481 mm (58.3 in) 383 mm (15.1 in) ← 2,188 mm (86.1 in) ← 2,186 mm (86.1 in) ← 1,310 mm (51.6 in) 992 mm (39.1 in) 1,485 mm (58.5 in) 386 mm (15.
SPEC GENERAL SPECIFICATIONS Carburetor: Type/Manufacturer PWK38S/KEIHIN Spark plug: Type/Manufacturer Gap BR8EG/NGK (resistance type) 0.5~0.6 mm (0.020~0.024 in) Clutch type: Wet, multiple-disc Transmission: Primary reduction system Primary reduction ratio Secondary reduction system Secondary reduction ratio Transmission type Operation Gear ratio: 1st 2nd 3rd 4th 5th Chassis: Frame type Caster angle Trail USA, ZA, AUS, NZ ← ← ← 49/14 (3.500) ← Gear 63/21 (3.000) Chain drive 50/14 (3.
MAINTENANCE SPECIFICATIONS SPEC EC212000 MAINTENANCE SPECIFICATIONS EC212100 ENGINE Item Cylinder head: Combustion chamber capacity Warp limit Cylinder: Bore size Taper limit Out of round limit Piston: Piston size/ Measuring point* Piston clearance Piston offset Piston pin: Piston pin outside diameter Piston ring: Sectional sketch End gap (installed) Side clearance (installed) : 1st : 2nd Standard USA, CDN, ZA, AUS, NZ EUROPE 21.0 cm3 (0.739 Imp oz, 0.710 US oz) … 21.5 cm3 (0.757 Imp oz, 0.
MAINTENANCE SPECIFICATIONS Item SPEC Standard Clutch housing thrust clearance Clutch housing radial clearance Clutch release method Limit 0.17~0.23 mm (0.007~0.009 in) 0.030~0.055 mm (0.001~0.002 in) Inner push, cam push … … … Transmission: Main axle deflection limit Drive axle deflection limit … … 0.01 mm (0.0004 in) 0.01 mm (0.0004 in) Shifter: Shifting type Guide bar bending limit Cam drum and guide bar … Kick starter type: Kick and ratchet type … 0.05 mm (0.
SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened ▲ ▲ ▲ ▲ ▲ ▲ Spark plug Cylinder head (nut) (stud) Cylinder (nut) (stud) Power valve : Holder Link rod Push rod Thrust plate Side holder Link lever Pulley Cover Governor fork Housing Impeller Water pump housing cover Coolant drain bolt Radiator Radiator panel Radiator hose clamp Air filter element Carburetor joint Air filter case Air filter guide clamp Reed valve Throttle cable adjust bolt and locknut Throttle cable Exhaust pipe (fro
SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Primary drive gear Clutch boss Clutch spring Clutch cable adjust bolt and locknut Push lever axle Drive sprocket Shift guide Stopper lever Torsion spring (shift shaft) stopper bolt Segment Bearing plate cover (shift cam right) Shift pedal Thread size M10 × 1.25 M20 × 1.0 M 6 × 1.0 M 6 × 0.75 M 5 × 0.8 M20 × 1.0 M 6 × 1.0 M 6 × 1.0 M 8 × 1.25 M 8 × 1.25 M 6 × 1.0 M 6 × 1.
MAINTENANCE SPECIFICATIONS SPEC EC212201 CHASSIS Item Steering system: Steering bearing type Front suspension: Front fork travel Fork spring free length Spring rate, STD Optional spring/Spacer Oil capacity Oil grade Inner tube outer diameter Front fork top end Rear suspension: Shock absorber travel Spring free length Fitting length
MAINTENANCE SPECIFICATIONS Item SPEC Standard Limit Wheel: Front wheel type Rear wheel type Front rim size/Material Rear rim size/Material Rim runout limit: Radial Lateral Spoke wheel Spoke wheel 21 × 1.60/Aluminum 19 × 2.15/Aluminum … … … … … … 2.0 mm (0.08 in) 2.0 mm (0.08 in) Drive chain Type/Manufacturer Number of links Chain slack Chain length (15 links) DID520DMA2 SDH/DAIDO 113 links + joint 48~58 mm (1.9~2.3 in) … … … … 250 × 3.0 mm (9.84 × 0.12 in) 4.4 mm (0.17 in) 11.0 mm (0.433 in) 27.
SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty Nm Handle crown and outer tube Under bracket and outer tube Handle crown and steering shaft Handlebar holder (upper) Steering ring nut Front fork and damper assembly Front fork and adjuster Damper assembly and base valve Adjuster and damper assembly Bleed screw (front fork) and base valve Front fork and protector Protector and brake hose holder Throttle cable cap Grip cap upper and lower Clutch lever (nut) Clutch le
SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Rear brake master cylinder cap Rear brake hose union bolt (caliper) Rear brake hose union bolt (master cylinder) Rear wheel axle and nut Driven sprocket and wheel hub Nipple (spoke) Disc cover and rear brake caliper Protector and rear brake caliper Chain puller adjust bolt and locknut Engine mounting: Engine bracket and frame Engine and frame (front) Engine and frame (upper) Engine and frame (lower) Pivot shaft and nut Relay arm and sw
SPEC MAINTENANCE SPECIFICATIONS EC212300 ELECTRICAL Item Ignition system: Ignition timing (B.T.D.C.) Advancer type Standard Limit 0.18 mm (0.007 in) Electrical … … … … CDI unit-model/Manufacturer 5CU-10/YAMAHA 720~1,080 Ω at 20°C (68°F) (Black-Black/Red) 44~66 Ω at 20°C (68°F) (Green/Blue-Green/White) 248~372 Ω at 20°C (68°F) (White/Blue-White/Red) 5NX-01/YAMAHA Ignition coil: Model/Manufacturer Minimum spark gap Primary winding resistance Secondary winding resistance 1P8-00/YAMAHA 6 mm (0.
GENERAL TORQUE SPECIFICATIONS/ DEFINITION OF UNITS SPEC EC220001 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.
CABLE ROUTING DIAGRAM SPEC EC240000 CABLE ROUTING DIAGRAM 1 2 3 4 5 6 7 Radiator hose Throttle cable Clutch cable “ENGINE STOP” button lead Radiator breather hose C.D.I. magneto lead Ignition coil lead A Pass the clutch cable on the out- H Pass the clutch cable in front of side of the throttle cable and the center of the cylinder head “ENGINE STOP” button lead. tightening nut.
CABLE ROUTING DIAGRAM 1 2 3 4 5 6 7 8 Clamp Radiator hose Solenoid valve lead TPS (throttle position sensor) lead Air vent hose (left) Crankcase breather hose Overflow hose Air vent hose (right) A Insert the tip of the fuel tank breather hose into the hole in the steering shaft cap. B Pass the radiator breather hose, ignition coil lead and C.D.I. magneto lead between the frame and the left of the radiator. C Clamp the C.D.I. magneto lead and ignition coil lead to the frame.
CABLE ROUTING DIAGRAM 1 2 3 4 5 6 7 8 9 0 Clamp High tension cord C.D.I.unit “ENGINE STOP” button lead Ignition coil lead Radiator hose Radiator breather hose Throttle cable Clutch cable Wireharness A Clamp the wireharness to the right engine bracket. B Pass the high tension cord to the right of the radiator hose. C Pass the C.D.I. unit lead between the frame and the right side of the radiator and then above the radiator fitting boss. D Pass the radiator breather hose behind the radiator hose.
CABLE ROUTING DIAGRAM SPEC A Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the caliper. B Pass the brake hose into the brake hose holders. C If the brake hose contacts the spring (rear shock absorber), correct its twist. D Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the master cylinder.
CABLE ROUTING DIAGRAM 1 2 3 4 5 6 7 8 Brake hose Master cylinder “ENGINE STOP” button lead “ENGINE STOP” button Throttle cable Clutch cable Clamp Cable guide SPEC A Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the master cylinder. B Pass the “ENGINE STOP” button lead in the middle of the clutch holder. C Clamp the “ENGINE STOP” button lead to the handlebar to 3 clicks. D Pass the brake hose in front of the number plate and through the cable guide.
MAINTENANCE INTERVALS INSP ADJ EC300000 REGULAR INSPECTION AND ADJUSTMENTS EC310013 MAINTENANCE INTERVALS The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.
MAINTENANCE INTERVALS Item COOLING SYSTEM Check coolant level and leakage Check radiator cap operation Replace coolant Inspect hoses OUTSIDE NUTS AND BOLTS Retighten After Every breakrace in ● ● ● FRAME Clean and inspect ● ● FUEL TANK, COCK Clean and inspect ● FRONT FORKS Inspect and adjust Replace oil Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube ● ● ● ● BRAKES Adjust lever position and pedal height Lubricate pivot point Check brake disc surface Check fluid level and leakage
PRE-OPERATION INSPECTION AND MAINTENANCE INSP ADJ EC320000 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. EC321000 GENERAL INSPECTION AND MAINTENANCE Item Routine Page Coolant Check that coolant is filled up to the radiator filler cap. Check the cooling system for leakage.
ENGINE/COOLANT LEVEL INSPECTION/ COOLANT REPLACEMENT INSP ADJ EC350000 ENGINE EC351011 COOLANT LEVEL INSPECTION w 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.
COOLANT REPLACEMENT INSP ADJ cC Take care so that coolant does not splash on painted surfaces. If it splashes, wash it away with water. 1. Place a container under the engine. 2. Remove: 9Coolant drain bolt 1 3. Remove: 9Radiator cap Drain the coolant completely. 4. Clean: 9Cooling system Thoroughly flush the cooling system with clean tap water. 5. Install: 9Copper washer 9Coolant drain bolt 10 Nm (1.0 m•kg, 7.2 ft•lb) 6. Fill: 9Radiator 9Engine To specified level.
RADIATOR CAP INSPECTION INSP ADJ cC 9Do not mix more than one type of ethylene glycol antifreeze containing corrosion inhibitors for aluminum engine. 9Do not use water containing impurities or oil. Handling notes of coolant: The coolant is harmful so it should be handled with special care. w 9When coolant splashes to your eye. Thoroughly wash your eye with water and see your doctor. 9When coolant splashes to your clothes. Quickly wash it away with water and then with soap. 9When coolant is swallowed.
RADIATOR CAP OPENING PRESSURE INSPECTION/ COOLING SYSTEM INSPECTION INSP ADJ EC356002 RADIATOR CAP OPENING PRESSURE INSPECTION 1. Attach: 9Radiator cap tester 1 and adapter 2 Radiator cap tester: YU-24460-01/90890-01325 Adapter: YU-33984/90890-01352 NOTE: Apply water on the radiator cap seal. 3 Radiator cap 2. Apply the specified pressure. Radiator cap opening pressure: 95~125 kPa (0.95~1.25 kg/cm2, 13.5~17.8 psi) 3.
CLUTCH ADJUSTMENT INSP ADJ 4. Inspect: 9Pressure Impossible to maintain the specified pressure for 10 seconds→Repair. 9Radiator 1 9Radiator hose joint 2 Coolant leakage→Repair or replace. 9Radiator hose 3 Swelling→Replace. EC359020 CLUTCH ADJUSTMENT 1. Check: 9Clutch lever free play a Out of specification→Adjust. Clutch lever free play a: 8~13 mm (0.31~0.51 in) 2. Adjust: 9Clutch lever free play Clutch lever free play adjustment steps: 9Loosen the locknut 1.
THROTTLE CABLE ADJUSTMENT/ THROTTLE LUBRICATION INSP ADJ EC35A001 THROTTLE CABLE ADJUSTMENT 1. Check: 9Throttle grip free play a Out of specification→Adjust. a: Throttle grip free play ? 3~5 mm (0.12~0.20 in) 2. Adjust: 9Throttle grip free play Throttle grip free play adjustment steps: 9Loosen the locknut 1. 9Turn the adjuster 2 until the specified free play is obtained. 9Tighten the locknut. Locknut: 7 Nm (0.7 m•kg, 5.
INSP ADJ AIR FILTER CLEANING 3. Install: 9Throttle cable cap 1 Nm (0.1 m•kg, 0.7 ft•lb) 9Cap cover EC35G041 AIR FILTER CLEANING NOTE: Proper air filter maintenance is the biggest key to preventing premature engine wear and damage. cC Never run the engine without the air filter element in place; this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage. 1. Remove: 9Seat 9Fitting bolt 1 9Washer 2 9Air filter element 3 9Filter guide 4 2.
TRANSMISSION OIL LEVEL CHECK INSP ADJ 3. Inspect: 9Air filter element Damage→Replace. 4. Apply: 9Foam-air-filter oil or equivalent oil To the element. NOTE: Squeeze out the excess oil. Element should be wet but not dripping. 5. Install: 9Filter guide 1 NOTE: Align the projection a on filter guide with the hole b in air filter element. 6. Apply: 9Lithium soap base grease On the matching surface a on air filter element. 7. Install: 9Air filter element 1 9Washer 2 Nm (0.2 m•kg, 1.
TRANSMISSION OIL REPLACEMENT INSP ADJ 3. Check: 9Transmission oil level Transmission oil level checking steps: 9Remove the oil check bolt 1. 9Inspect the oil level. NOTE: Be sure the machine is positioned straight up when inspecting the oil level. w Never attempt to remove the oil check bolt just after high speed operation. The heated oil could spout out, causing danger. Wait until the oil cools down. Oil flows out→Oil level is correct. Oil does not flow out→Oil level is low.
INSP ADJ PILOT AIR SCREW ADJUSTMENT 4. Remove: 9Oil drain bolt 1 9Oil filler cap 2 Drain the transmission oil. 5. Install: 9Aluminum washer 9Oil drain bolt 1 20 Nm (2.0 m•kg, 14 ft•lb) 6. Fill: 9Transmission oil Recommended oil: Yamalube 4 (10W-30) or SAE 10W-30 type SE motor oil Oil capacity (periodic oil change): 0.75 L (0.66 Imp qt, 0.79 US qt) 7. Check: 9Oil leakage 8. Check: 9Transmission oil level 9. Install: 9Oil filler cap 2 EC35L021 PILOT AIR SCREW ADJUSTMENT 1.
IDLE SPEED ADJUSTMENT/MUFFLER INSPECTION/ SILENCER FIBER REPLACEMENT INSP ADJ EC35M001 IDLE SPEED ADJUSTMENT 1. Start the engine and thoroughly warm it up. 2. Adjust: 9Idle speed Adjustment steps: Turn the throttle stop screw 1 until the engine runs at the lowest possible speed. To increase idle speed → Turn the throttle stop screw 1 in. To decrease idle speed → Turn the throttle stop screw 1 out. EC35P030 MUFFLER INSPECTION 1. Inspect: 9O-ring 1 Damage → Replace.
SILENCER FIBER REPLACEMENT INSP ADJ 2. Remove: 9Inner pipe 1 3. Replace: 9Fiber 2 4. Install: 9Inner pipe NOTE: Fully apply Quick gasket® (Yamaha bond No. 1215) or equivalent as shown. Quick gasket®: ACC-QUICK-GS-KT Yamaha bond No. 1215: 90890-85505 5. Install: 9Bolt (fiber) 1 10 Nm (1.0 m•kg, 7.2 ft•lb) 9Silencer 2 9Bolt (silencer) 3 12 Nm (1.2 m•kg, 8.7 ft•lb) 9Side cover (right) 7 Nm (0.7 m•kg, 5.
CHASSIS/BRAKE SYSTEM AIR BLEEDING INSP ADJ EC360000 CHASSIS EC361030 BRAKE SYSTEM AIR BLEEDING w Bleed the brake system if: 9The system has been disassembled. 9A brake hose has been loosened or removed. 9The brake fluid is very low. 9The brake operation is faulty. A dangerous loss of braking performance may occur if the brake system is not properly bled. 1. Remove: 9Master cylinder cap 9Diaphragm 9Reservoir float (front brake) 9Protector (rear brake) 2.
FRONT BRAKE ADJUSTMENT INSP ADJ NOTE: If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disappeared. j. Add brake fluid to the level line on the reservoir. w Check the operation of the brake after bleeding the brake system. 3. Install: 9Protector (rear brake) 9Reservoir float (front brake) 9Diaphragm 9Master cylinder cap EC362041 FRONT BRAKE ADJUSTMENT 1.
REAR BRAKE ADJUSTMENT/ FRONT BRAKE PAD INSPECTION AND REPLACEMENT INSP ADJ EC364005 REAR BRAKE ADJUSTMENT 1. Check: 9Brake pedal height a Out of specification→Adjust. Brake pedal height a: Zero mm (Zero in) NOTE: The brake pedal height is the vertical distance from the inside top end of the footrest. 2. Adjust: 9Brake pedal height Pedal height adjustment steps: 9Loosen the locknut 1. 9Turn the adjusting nut 2 until the pedal height a is within specified height. 9Tighten the locknut.
FRONT BRAKE PAD INSPECTION AND REPLACEMENT INSP ADJ 9Loosen the pad pin 2. 9Remove the caliper 3 from the front fork. 9Remove the pad pin and brake pads 4. 9Connect the transparent hose 5 to the bleed screw 6 and place the suitable container under its end. 9Loosen the bleed screw and push the caliper piston in. cC Do not reuse the drained brake fluid. 9Tighten the bleed screw. Bleed screw: 6 Nm (0.6 m•kg, 4.3 ft•b) 9Install the brake pads 7 and pad pin.
REAR BRAKE PAD INSPECTION AND REPLACEMENT INSP ADJ 9Install the pad pin plug 0. Pad pin plug: 3 Nm (0.3 m•kg, 2.2 ft•lb) 3. Inspect: 9Brake fluid level Refer to “BRAKE INSPECTION” section. FLUID LEVEL 4. Check: 9Brake lever operation A softy or spongy feeling → Bleed brake system. Refer to “BRAKE SYSTEM AIR BLEEDING” section. EC366060 REAR BRAKE PAD INSPECTION AND REPLACEMENT 1. Inspect: 9Brake pad thickness a Out of specification → Replace as a set. Brake pad thickness a: Standard 6.
REAR BRAKE PAD INSPECTION AND REPLACEMENT INSP ADJ 9Remove the pad pin 6 and brake pads 7. 9Connect the transparent hose 8 to the bleed screw 9 and place the suitable container under its end. 9Loosen the bleed screw and push the caliper piston in. cC Do not reuse the drained brake fluid. 9Tighten the bleed screw. Bleed screw: 6 Nm (0.6 m•kg, 4.3 ft•lb) 9Install the brake pads 0 and pad pin q. NOTE: 9Install the brake pads with their projections a into the caliper recesses b.
REAR BRAKE PAD INSULATOR INSPECTION BRAKE FLUID LEVEL INSPECTION INSP ADJ EC36b000 REAR BRAKE PAD INSULATOR INSPECTION 1. Remove: 9Brake pad Refer to “REAR BRAKE PAD INSPECTION AND REPLACEMENT” section. 2. Inspect: 9Rear brake pad insulator 1 Damage → Replace. EC367001 BRAKE FLUID LEVEL INSPECTION 1. Place the master cylinder so that its top is in a horizontal position. 2. Inspect: 9Brake fluid level Fluid at lower level → Fill up.
SPROCKETS INSPECTION/DRIVE CHAIN INSPECTION INSP ADJ EC368000 SPROCKETS INSPECTION 1. Inspect: 9Sprocket teeth a Excessive wear → Replace. NOTE: Replace the drive, driven sprockets and drive chain as a set. EC369002 DRIVE CHAIN INSPECTION 1. Measure: 9Drive chain length (15 links) a Out of specification→Replace. Drive chain length (15 links): Limit: 242.9 mm (9.563 in) NOTE: 9While measuring the drive chain length push down on the drive chain to increase its tension.
DRIVE CHAIN SLACK ADJUSTMENT INSP ADJ 4. Check: 9Drive chain stiffness a Clean and oil the chain and hold as illustrated. Stiff→Replace drive chain. 5. Install: 9Drive chain 1 9Joint 2 9Master link clip 3 cC Be sure to install the master link clip to the direction as shown. a Turning direction 6. Lubricate: 9Drive chain Drive chain lubricant: SAE 10W-30 motor oil or suitable chain lubricants EC36A061 DRIVE CHAIN SLACK ADJUSTMENT 1.
FRONT FORK INSPECTION INSP ADJ 3. Adjust: 9Drive chain slack Drive chain slack adjustment steps: 9Loosen the axle nut 1 and locknuts 2. 9Adjust chain slack by turning the adjusters 3. To tighten → Turn adjuster 3 counterclockwise. To loosen → Turn adjuster 3 clockwise and push wheel forward. 9Turn each adjuster exactly the same amount to maintain correct axle alignment. (There are marks a on each side of chain puller alignment.
FRONT FORK OIL SEAL AND DUST SEAL CLEANING/ FRONT FORK INTERNAL PRESSURE RELIEVING/ FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT INSP ADJ EC36D001 FRONT FORK OIL SEAL AND DUST SEAL CLEANING 1. Remove: 9Protector 9Dust seal 1 NOTE: Use a thin screw driver, and be careful not to damage the inner fork tube and dust seal. 2. Clean: 9Dust seal a 9Oil seal b NOTE: 9Clean the dust seal and oil seal after every run. 9Apply the lithium soap base grease on the inner tube.
FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT INSP ADJ Extent of adjustment: Maximum Fully turned in position Minimum 20 clicks out (from maximum position) 9STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. Standard position: 13 clicks out cC Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. w Always adjust each front fork to the same setting.
REAR SHOCK ABSORBER INSPECTION INSP ADJ Extent of adjustment: Maximum Fully turned in position Minimum 20 clicks out (from maximum position) 9STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. Standard position: 8 clicks out cC Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. w Always adjust each front fork to the same setting.
REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT INSP ADJ EC36M014 REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Remove: 9Rear frame 3. Loosen: 9Locknut 1 4. Adjust: 9Spring preload By turning the adjuster 2. Stiffer → Softer → Increase the spring preload. (Turn the adjuster 2 in.) Decrease the spring preload. (Turn the adjuster 2 out.) Spring length (installed) a: Standard length Extent of adjustment 251 mm (9.88 in) 240.
REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT INSP ADJ EC36N014 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1. Adjust: 9Rebound damping force By turning the adjuster 1. Stiffer a → Softer b → Increase the rebound damping force. (Turn the adjuster 1 in.) Decrease the rebound damping force. (Turn the adjuster 1 out.
REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT INSP ADJ EC36c000 REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: 9Low compression damping force By turning the adjuster 1. Stiffer a → Softer b → Increase the low compression damping force. (Turn the adjuster 1 in.) Decrease the low compression damping force. (Turn the adjuster 1 out.
REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT INSP ADJ EC36d000 REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: 9High compression damping force By turning the adjuster 1. Stiffer a → Softer b → Increase the high compression damping force. (Turn the adjuster 1 in.) Decrease the high compression damping force. (Turn the adjuster 1 out.
TIRE PRESSURE CHECK/SPOKES INSPECTION AND TIGHTENING/WHEEL INSPECTION INSP ADJ EC36Q001 TIRE PRESSURE CHECK 1. Measure: 9Tire pressure Out of specification → Adjust. Standard tire pressure: 100 kPa (1.0 kgf/cm2, 15 psi) NOTE: 9Check the tire while it is cold. 9Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low. 9A tilted tire valve stem indicates that the tire slips off its position on the rim.
STEERING HEAD INSPECTION AND ADJUSTMENT INSP ADJ 2. Inspect: 9Bearing free play Exist play → Replace. EC36U070 STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by placing a suitable stand under the engine. 2. Check: 9Steering shaft Grasp the bottom of the forks and gently rock the fork assembly back and forth. Free play → Adjust steering head. 3. Check: 9Steering smooth action Turn the handlebar lock to lock. Unsmooth action → Adjust steering ring nut. 4.
STEERING HEAD INSPECTION AND ADJUSTMENT INSP ADJ Ring nut wrench: YU-33975/90890-01403 Ring nut (initial tightening): 38 Nm (3.8 m•kg, 27ft•lb) 9Loosen the ring nut one turn. 9Retighten the ring nut using the ring nut wrench. w Avoid over-tightening. Ring nut (final tightening): 7 Nm (0.7 m•kg, 5.1 ft•lb) 9Check the steering shaft by turning it lock to lock. If there is any binding, remove the steering shaft assembly and inspect the steering bearings.
LUBRICATION INSP ADJ EC36a042 LUBRICATION To ensure smooth operation of all components, lubricate your machine during setup, after breakin, 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 Throttle roller sliding surface 8 Tube guide cable winding portion 9 Throttle cable end 0 Clutch cable end Å Use Yamaha cable lube or equivalent on these areas. ı Use SAE10W-30 motor oil or suitable chain lubricants.
ELECTRICAL/SPARK PLUG INSPECTION INSP ADJ EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: 9Spark plug 2. Inspect: 9Electrode 1 Wear/Damage → Replace. 9Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition. NOTE: When the engine runs for many hours at low speeds, the spark plug insulator will become sooty, even if the engine and carburetor are in good operating condition. 3.
IGNITION TIMING CHECK INSP ADJ EC372012 IGNITION TIMING CHECK 1. Remove: 9Fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 4. 9Spark plug 9Crankcase cover (left) 2. Attach: 9Dial gauge 1 9Spark plug hole dial stand 2 Dial gauge: YU-3097/90890-01252 Spark plug hole dial stand: YU-1256 3. Rotate the magneto rotor 1 until the piston reaches top dead center (TDC).
IGNITION TIMING CHECK INSP ADJ 7. Adjust: 9Ignition timing Adjustment steps: 9Loosen the screws (stator) 1. 9Align the punch mark on the rotor with punch mark on the stator 2 by moving the stator. 9Tighten the screws (stator). Screw (stator): 8 Nm (0.8 m•kg, 5.
SEAT, FUEL TANK AND SIDE COVERS ENG EC400000 ENGINE EC4R0000 SEAT, FUEL TANK AND SIDE COVERS 19 Nm (1.9 m•kg, 13 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 19 Nm (1.9 m•kg, 13 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 6 Nm (0.6 m•kg, 4.
SEAT, FUEL TANK AND SIDE COVERS ENG EC4R3000 REMOVAL POINTS EC413110 Side cover 1. Remove: 9 Bolt (side cover) 9 Side cover (left and right) 1 NOTE: Draw the side cover downward to remove it because its claws a are inserted in the air cleaner case.
EXHAUST PIPE AND SILENCER ENG EC4S0000 EXHAUST PIPE AND SILENCER 12 Nm (1.2 m•kg, 8.7 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 12 Nm (1.2 m•kg, 8.7 ft•lb) 25 Nm (2.5 m•kg, 18 ft•lb) 14 Nm (1.4 m•kg, 10 ft•lb) 1 Silencer removal Extent of removal: Extent of removal Order 1 2 Part name Q’ty EXHAUST PIPE AND SILENCER REMOVAL Side cover (right) Preparation for removal 2 2 Exhaust pipe removal 1 2 3 4 5 6 7 8 9 Bolt (silencer) Silencer Collar [D=ø10.5 mm (0.
ENG RADIATOR EC450001 RADIATOR 1 Nm (0.1 m•kg, 0.7 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Nm (0.1 m•kg, 0.7 ft•lb) 1 Radiator removal Extent of removal: Extent of removal Order Part name Q’ty RADIATOR REMOVAL Drain the coolant. Preparation for removal Refer to “COOLANT REPLACEMENT” section in the CHAPTER 3. Refer to “SEAT, FUEL TANK AND SIDE COVERS” section.
RADIATOR ENG EC456000 HANDLING NOTE w 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.
ENG RADIATOR EC455000 ASSEMBLY AND INSTALLATION EC445354 Radiator 1. Install: 9Radiator breather hose 1 9Radiator hose 2 2 1 Nm (0.1 m•kg, 0.7 ft•lb) To radiator (right) 3. 2. Install: 9Radiator (right) 1 9Plain washer 2 9Bolt [radiator (right)] 3 10 Nm (1.0 m•kg, 7.2 ft•lb) 9Radiator hose 4 4 1 Nm (0.1 m•kg, 0.7 ft•lb) Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. 3. Install: 9Radiator (left) 1 9Plain washer 2 9Bolt [radiator (left)] 3 10 Nm (1.0 m•kg, 7.
ENG CARBURETOR AND REED VALVE EC460000 CARBURETOR AND REED VALVE 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Nm (0.1 m•kg, 0.
CARBURETOR AND REED VALVE ENG EC468000 CARBURETOR DISASSEMBLY 4 Nm (0.4 m•kg, 2.9 ft•lb) 1 Carburetor disassembly Extent of removal: Extent of removal Order Part name Q’ty 1 1 2 3 4 5 6 7 8 9 0 q w e r t CARBURETOR DISASSEMBLY Mixing chamber top Throttle valve Needle holder Jet needle Float chamber Float pin Float Needle valve Main jet Pilot jet Starter plunger Throttle stop screw Pilot air screw Power jet Solenoid valve 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4-8 Remarks Refer to “REMOVAL POINTS”.
CARBURETOR AND REED VALVE ENG EC466020 HANDLING NOTE cC Do not loosen the screws {TPS (throttle position sensor)} except when changing the TPS (throttle position sensor) due to failure because it will cause a drop in engine performance. EC463000 REMOVAL POINTS EC463110 Throttle valve 1. Remove: 9Throttle valve 1 9Ring 2 9Spring (throttle valve) 3 9Mixing chamber top 4 9Throttle cable 5 NOTE: While compressing the spring (throttle valve), disconnect the throttle cable. EC463401 Pilot air screw 1.
CARBURETOR AND REED VALVE ENG EC464000 INSPECTION EC464130 Carburetor 1. Inspect: 9Carburetor body Contamination → Clean. NOTE: 9Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air. 9Never use a wire. 2. Inspect: 9Main jet 1 9Pilot jet 2 9Power jet 3 Contamination → Clean. NOTE: 9Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air. 9Never use a wire. EC464210 Needle valve 1.
CARBURETOR AND REED VALVE ENG EC464401 Jet needle 1. Inspect: 9Jet needle 1 Bends/Wear → Replace. 9Clip groove Free play exists/Wear → Replace. 9Clip position Standard clip position: No.2 Groove *No.3 Groove *For EUROPE EC464511 Float height 1. Measure: 9 Float height a Out of specification → Adjust. Float height: 5.5~7.5 mm (0.22~0.30 in) Measurement and adjustment steps: 9Hold the carburetor in an upside down position.
ENG CARBURETOR AND REED VALVE EC464600 Float 1. Inspect: 9Float 1 Damage → Replace. EC464701 Reed valve 1. Measure: 9Reed valve bending a Out of specification → Replace. Reed valve bending limit: 0.2 mm (0.008 in) 9Valve stopper height b Out of specification → Adjust stopper/ Replace valve stopper. Valve stopper height: 10.3 ~10.7 mm (0.406~0.421 in) EC465000 ASSEMBLY AND INSTALLATION EC465173 Reed valve 1. Install: 9Reed valve 1 9Stopper (reed valve) 2 9Screw (reed valve) 3 1 Nm (0.1 m•kg, 0.
CARBURETOR AND REED VALVE ENG 2. Install: 9Gasket (reed valve) 1 9Plate (reed valve) 2 9Reed valve assembly 3 9Reed valve spacer 4 NOTE: Install the reed valve spacer with its chamfered side a to the right. 3. Install: 9Carburetor joint 1 9Bolt (carburetor joint) 2 10 Nm (1.0 m•kg, 7.2 ft•lb) EC4652F0 Carburetor 1. Install: 9Power jet 1 To carburetor 2. 2. Install: 9O-ring 1 9Solenoid valve 2 9Clamp 3 9Screw (clamp) 4 To carburetor 5.
CARBURETOR AND REED VALVE ENG 3. Install: 9Pilot air screw 1 9Throttle stop screw 2 Note the following installation points: 9Turn in the pilot air screw until it is lightly seated. 9Turn out the pilot air screw by the number of turns recorded before removing. Pilot air screw: 1 turn out *7/8 turns out (for reference only) *For EUROPE 4. Install: 9Starter plunger 1 5. Install: 9Pilot jet 1 9Main jet 2 6.
CARBURETOR AND REED VALVE ENG 7. Install: 9Float chamber 1 9Plate 2 9Screw (float chamber) 3 8. Install: 9Air vent hose [/=580 mm (22.8 in)] 1 9Air vent hose [/=400mm (15.7 in)] 2 9Overflow hose [/=280mm (11.0 in)] 3 9Clamp 4 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. NOTE: Install the air vent hoses and overflow hose to the carburetor with their ends not having the cuts a toward the carburetor. 9. Install: 9Jet needle 1 9Collar 2 9Spring 3 9Needle holder 4 To throttle valve 5.
ENG CARBURETOR AND REED VALVE 10. Install: 9Throttle cable 1 9Locknut 2 4 Nm (0.4 m•kg, 2.9 ft•lb) 9Mixing chamber top 3 9Spring (throttle valve) 4 9Ring 5 9Throttle valve 6 NOTE: 9While compressing the spring, connect the throttle cable. 9Align the projection a on the ring with the groove b in the needle holder 7. 11. Install: 9Mixing chamber top 1 9Screw(mixing chamber top) 2 To carburetor 3. NOTE: 9Insert the throttle valve into the carburetor body while pulling up the lever 4.
CARBURETOR AND REED VALVE ENG 2. Tighten: 9Screw (carburetor joint) 1 3. Tighten: 9Screw (air cleaner joint) 1 NOTE: Place the screw head a with its top as shown and secure the clamp in alignment with the horizontal line b that passes the center of the carburetor bore. 4. Connect: 9TPS (throttle position sensor) lead 1 9Solenoid valve lead 2 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. 5. Adjust: 9Idle speed Refer to “IDLE SPEED ADJUSTMENT” section in the CHAPTER 3.
ENG CYLINDER HEAD, CYLINDER AND PISTON EC470000 CYLINDER HEAD, CYLINDER AND PISTON EC478000 CYLINDER HEAD AND CYLINDER 34 Nm (3.4 m•kg, 24 ft•lb) 64 Nm (6.4 m•kg, 46 ft•lb) 20 Nm (2.0 m•kg, 14 ft•lb) 5 Nm (0.5 m•kg, 3.6 ft•lb) 25 Nm (2.5 m•kg, 18 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 42 Nm (4.2 m•kg, 30 ft•lb) 5 Nm (0.5 m•kg, 3.6 ft•lb) 10 Nm (1.0 m•kg, 7.
CYLINDER HEAD, CYLINDER AND PISTON ENG EC478100 PISTON AND POWER VALVE 4 Nm (0.4 m•kg, 2.9 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 4 Nm (0.4 m•kg, 2.
CYLINDER HEAD, CYLINDER AND PISTON ENG EC473000 REMOVAL POINTS EC473220 Push rod 1. Remove: 9Bolt (push rod) 1 9Push rod 2 NOTE: Insert the set pin 3 included in owner’s tool kit to remove the bolt (push rod). cC Be sure to use the set pin. If the set pin is not used, the power valve constituent parts will result in damage. EC473402 Piston and piston ring 1.
CYLINDER HEAD, CYLINDER AND PISTON ENG 3. Remove: 9Piston ring 1 NOTE: Take care not to scratch the piston or damage the piston ring by expanding it more than necessary. EC474000 INSPECTION EC474102 Cylinder head 1. Eliminate: 9Carbon deposits Use a rounded scraper 1. NOTE: Take care to avoid damaging the spark plug threads. Do not use a sharp instrument. Avoid scratching the aluminum. 2. Inspect: 9Cylinder head water jacket Crust of minerals/Rust → Remove.
CYLINDER HEAD, CYLINDER AND PISTON ENG EC474201 Cylinder 1. Eliminate: 9Carbon deposits Use a rounded scraper 1. NOTE: Do not use a sharp instrument. Avoid scratching the aluminum. 2. Inspect: 9Cylinder inner surface Score marks → Repair or replace. Use #400~600 grit wet sandpaper. cC Do not rebore the cylinder. 3. Measure: 9Cylinder bore “C” Use cylinder gauge 1. Out of limit → Replace. NOTE: Measure the cylinder bore “C” in parallel (A, B, C) to and at right angles to the crankshaft (a, b).
CYLINDER HEAD, CYLINDER AND PISTON ENG 3. Measure: 9Piston skirt diameter Use micrometer 1. Measure the specific distance b from the stepped surface a on inside of the piston. Out of specification → Replace. Distance b 17.5 mm (0.69 in) Piston dia. 66.352~66.367 mm (2.6120~2.6129 in) EC474402 Piston pin and small end bearing 1. Inspect: 9Piston pin 9Small end bearing Signs of heat discoloration → Replace. 2. Measure: 9Piston pin outside diameter Use micrometer 1. Out of limit → Replace.
CYLINDER HEAD, CYLINDER AND PISTON ENG 5. Check: 9Free play There should be no noticeable free play. Free play exists → Inspect the connecting rod for wear/Replace the pin and/or connecting rod as required. EC474502 Piston ring 1. Install: 9Piston ring Into the cylinder. Push the ring with the piston crown. 2. Measure: 9End gap Use a thickness gauge 1. Out of limit → Replace. Ring end gap (installed): Standard 0.40~0.55 mm (0.016~0.022 in) 0.95 mm (0.037 in) 3.
ENG CYLINDER HEAD, CYLINDER AND PISTON EC474602 Piston clearance 1. Calculate: 9Piston clearance Out of limit → Replace piston, and piston ring and/or cylinder. Refer to “Cylinder” and “Piston”. PISTON CLEARANCE = CYLINDER – PISTON BORE DIAMETER Piston clearance: Standard 0.045~0.050 mm (0.0018~0.0020 in) 0.1 mm (0.004 in) EC474700 Combination of piston and cylinder 1. Check: 9Cylinder mark a Cylinder mark a A B C D Cylinder size 66.400~66.402 mm (2.61417~2.61425 in) 66.404~66.406 mm (2.
CYLINDER HEAD, CYLINDER AND PISTON ENG 3. Combination: Combine the piston and cylinder by the following chart. Cylinder mark A B C D Piston mark (color) A (red) B (orange) C (green) D (purple) NOTE: When you purchase a cylinder, you cannot designate its size. Choose the piston that matches the above chart. EC474841 Power valve 1. Inspect: 9Power valve 1, 2 1 Wear/Damage → Replace. Carbon deposits → Remove.
ENG CYLINDER HEAD, CYLINDER AND PISTON EC475000 ASSEMBLY AND INSTALLATION EC475193 Power valve 1. Install: 9Power valve 1 1 9Valve holder 2 2 9Bolt (valve holder 2) 3 6 Nm (0.6 m•kg, 4.3 ft•lb) NOTE: 9Install the power valve 1 with its gouge a facing upside. 9Apply the molybdenum disulfide oil on the power valve 1. 2. Install: 9Power valve 2 1 9Link rod 2 9Plain washer 3 9Screw (link rod) 4 6 Nm (0.6 m•kg, 4.
CYLINDER HEAD, CYLINDER AND PISTON ENG 4. Install: 9Spring 1 1 9Link lever 2 9Pulley 3 9Spring 2 4 9Plain washer 5 9Valve shaft 6 NOTE: 9Install the spring 1 to the link lever, and then to the cylinder. Install the spring 1 with its stopper portion a 9 facing inward. 9Apply the molybdnum disulfide oil on the grooves in the pulleys. 9Apply the lithium soap base grease on the oil seal lip.
ENG CYLINDER HEAD, CYLINDER AND PISTON 7. Install: 9O-ring 1 9Side holder 2 9Screw (side holder) 3 4 Nm (0.4 m•kg, 2.9 ft•lb) 9YPVS breather hose 4 NOTE: 9Apply the lithium soap base grease on the Orings. Install the side holder with its projection a 9 facing upward. 8. Install: 9Gasket (power valve cover) 1 9Power valve cover 2 9Screw (power valve cover) 3 4 Nm (0.4 m•kg, 2.9 ft•lb) NOTE: 9Install the gasket with its cut a facing downward and the seal print side toward the power valve cover.
CYLINDER HEAD, CYLINDER AND PISTON ENG 3. Install: 9Piston 1 9Piston pin 2 9Piston pin clip 3 NOTE: 9The arrow a on the piston dome must point to exhaust side. 9Before installing the piston pin clip, cover the crankcase with a clean rag to prevent the piston pin clip from falling into the crankcase cavity. cC Do not allow the clip open ends to meet the piston pin slot b . EC475383 Cylinder head and cylinder 1. Apply: 9Engine oil To piston 1 piston ring 2 and cylinder surface. 2.
ENG CYLINDER HEAD, CYLINDER AND PISTON 4. Install: 9Push rod 1 9Bolt (push rod) 2 5 Nm (0.5 m•kg, 3.6 ft•lb) NOTE: 9Insert the set pin 3 included in owner’s tool kit to install the bolt (push rod). 9Do not forget to remove the set pin. cC Be sure to use the set pin. If the set pin is not used, the power valve constituent parts will result in damage. 5. Install: 9Gasket (power valve housing) 9Power valve housing 1 9Bolt (power valve housing) 2 5 Nm (0.5 m•kg, 3.6 ft•lb) 6.
CYLINDER HEAD, CYLINDER AND PISTON ENG 8. Install: 9Engine bracket 1 9Bolt (engine bracket) 2 34 Nm (3.4 m•kg, 24 ft•lb) 9Engine mounting bolt (upper) 3 64 Nm (6.4 m•kg, 46 ft•lb) 9. Install: 9Spark plug 1 20 Nm (2.
CLUTCH AND PRIMARY DRIVEN GEAR ENG EC490000 CLUTCH AND PRIMARY DRIVEN GEAR EC498000 CLUTCH PLATE AND FRICTION PLATE 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Clutch plate and friction plate removal Extent of removal: Extent of removal Order Part name Q’ty CLUTCH PLATE AND FRICTION PLATE REMOVAL Drain the transmission oil. Preparation for removal Refer to “TRANSMISSION OIL REPLACEMENT“ section in the CHAPTER 3. Shift the brake pedal downward. Refer to“CDI MAGNETO“section.
CLUTCH AND PRIMARY DRIVEN GEAR ENG EC498200 PRIMARY DRIVEN GEAR, PUSH ROD AND PUSH LEVER AXLE 75 Nm (7.5 m•kg, 54 ft•lb) 6 Nm (0.6 m•kg, 4.
CLUTCH AND PRIMARY DRIVEN GEAR ENG EC493000 å REMOVAL POINTS EC483211 Clutch boss 1. Remove: 9Nut 1 9Lock washer 2 9Clutch boss 3 NOTE: Straighten the lock washer tab and use the clutch holding tool 4, 5 to hold the clutch boss. ∫ Clutch holding tool: YM-91042................................ 4 90890-04086............................5 å For USA and CDN ∫ Except for USA and CDN EC494000 INSPECTION EC484100 Clutch housing and boss 1. Inspect: 9Clutch housing 1 Cracks/Wear/Damage → Replace.
CLUTCH AND PRIMARY DRIVEN GEAR ENG EC484500 Friction plate 1. Measure: 9Friction plate thickness Out of specification → Replace friction plate as a set. Measure at all four points. Friction plate thickness: Standard 2.9~3.1 mm (0.114~0.122 in) 2.8 mm (0.110 in) EC484600 Clutch plate 1. Measure: 9Clutch plate warpage Out of specification → Replace clutch plate as a set. Use a surface plate 1 and thickness gauge 2. Warp limit: 0.2 mm (0.008 in) EC484700 Push lever axle 1.
ENG CLUTCH AND PRIMARY DRIVEN GEAR EC495230 Clutch 1. Install: 9Thrust plate [D=ø 42 mm (1.65 in)] 1 9Spacer 2 9Bearing 3 9Primary driven gear 4 NOTE: Apply the transmission oil on the bearing, spacer and primary driven gear inner circumference. 2. Install: 9Thrust plate [D=ø 44 mm (1.73 in)] 1 9Clutch boss 2 3. Install: 9Lock washer 1 9Nut (clutch boss) 2 å 75 Nm (7.5 m•kg, 54 ft•lb) NOTE: Use the clutch holding tool 3, 4 to hold the clutch boss. Clutch holding tool: YM-91042 ......................
CLUTCH AND PRIMARY DRIVEN GEAR ENG 5. Install: 9Friction plate 1 9Clutch plate 2 NOTE: 9Install the clutch plates and friction plates alternately on the clutch boss, starting with a friction plate and ending with a friction plate. 9Apply the transmission oil on the friction plates and clutch plates. 6. Install: 9Bearing 1 9Plain washer 2 9Circlip 3 To push rod 1 4. NOTE: Apply the lithium soap base grease on the bearing and plain washer. 7.
ENG CLUTCH AND PRIMARY DRIVEN GEAR 10. Install: 9O-ring 1 To clucth cover. 11. Install: 9Clutch cover 1 9Bolt (clutch cover) 2 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Tighten the bolts in stage, using a crisscross pattern. 12. Install: 9O-ring 1 9Clutch cable 2 NOTE: Apply the lithium soap base grease on the Oring.
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR ENG EC4C0000 KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C8000 PRIMARY DRIVE GEAR 30 Nm (3.0 m•kg, 22 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 55 Nm (5.5 m•kg, 40 ft•lb) 1 Primary drive gear removal Extent of removal: Extent of removal Order Part name Q’ty RPIMARY DRIVE GEAR REMOVAL Drain the transmission oil. Preparation for removal Refer to “TRANSMISSION OIL REPLACEMENT“ section in the CHAPTER 3. Shift the brake pedal downward.
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR ENG EC4C8100 KICK AXLE AND SHIFT SHAFT 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 10 Nm (1.0 m•kg, 7.
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR ENG EC4C3000 REMOVAL POINTS EC483111 Primary drive gear 1. Loosen: 9Bolt (primary drive gear) 1 NOTE: Place an aluminum plate a between the teeth of the primary drive gear 2 and driven gear 3. EC4B3101 Kick axle assembly 1. Remove: 9Kick axle assembly 1 NOTE: Unhook the torsion spring 2 from the hole a in the crankcase. EC4C3101 Shift guide and shift lever assembly 1.
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR ENG EC4C4300 Kick gear, kick idle gear and ratchet wheel 1. Inspect: 9Kick gear 1 9Kick idle gear 2 9Ratchet wheel 3 9Gear teeth a 9Ratchet teeth b Wear/Damage → Replace. EC4B4400 Shift shaft 1. Inspect: 9Shift shaft 1 Bend/Damage → Replace. 9Spring 2 Broken → Replace. EC4C4100 Shift guide and shift lever assembly 1. Inspect: 9Shift guide 1 9Shift lever 2 9Pawl 3 9Pawl pin 4 9Spring 5 Wear/Damage → Replace. EC4C4400 Stopper lever 1.
ENG KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C5000 ASSEMBLY AND INSTALLATION EC4C5130 Stopper lever 1. Install: 9Tension spring 1 9Holder 2 9Bolt (holder) 3 10 Nm (1.0 m•kg, 7.2 ft•lb) 9Plain washer 4 9Stopper lever 5 9Bolt (stopper lever) 6 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Align the stopper lever roller with the slot on segment. EC4C5202 Shift guide and shift lever assembly 1. Install: 9Spring 1 9Pawl pin 2 9Pawl 3 To shift lever 4. 2. Install: 9Shift lever assembly 1 To shift guide 2. 3.
ENG KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR 4. Install: 9Bolt (shift guide) 1 10 Nm (1.0 m•kg, 7.2 ft•lb) EC4C5310 Shift shaft 1. Install: 9Roller 1 9Plain washer 2 9Shift shaft 3 NOTE: Apply the transmission oil on the roller and shift shaft. EC4C5602 Kick axle assembly 1. Install: 9Kick gear 1 9Plain washer 2 9Circlip 3 9Ratchet wheel 4 9Spring 5 9Plain washer 6 9Circlip 7 To kick axle 8. NOTE: 9Apply the transmission oil on the kick gear inner circumference.
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR ENG 3. Install: 9Spring guide 1 NOTE: Slide the spring guide into the kick axle, make sure the groove a in the spring guide fits on the stopper of the torsion spring. 4. Install: 9Plain washer 1 9Kick axle assembly 2 NOTE: 9Apply the molybdenum disulfide grease on the contacting surfaces of the kick axle stopper a and stopper plate 3. 9Apply the transmission oil on the kick axle.
KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR ENG EC4C5531 Primary drive gear 1. Install: 9Thrust plate 1 9Primary drive gear 2 9Governor drive gear 3 9Plain washer 4 9Bolt (primary drive gear) 5 NOTE: 9Install the plain washer with its chamfered side a toward you. 9Temporarily tighten the bolt at this point. 2. Install: 9Primary driven gear Refer to “CLUTCH AND PRIMARY DRIVEN GEAR” section. 3. Tighten: 9Bolt (primary drive gear) 1 55 Nm (5.
ENG KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR 6. Install: 9Bolt [crankcase cover (right)] 1 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Tighten the bolts in stage, using a crisscross pattern. 7. Install: 9Kick starter 1 9Plain washer 2 9Bolt (kick starter) 3 30 Nm (3.0 m•kg, 22 ft•lb) NOTE: Install the kick starter closest to but not contacting the clutch cover mounting boss a. 8. Install: 9Shift pedal 1 9Bolt (shift pedal) 2 10 Nm (1.0 m•kg, 7.
YPVS GOVERNOR ENG EC4K0000 YPVS GOVERNOR 5 Nm (0.5 m•kg, 3.6 ft•lb) 1 YPVS governor removal and disassembly Extent of removal: Extent of removal Order Q’ty YPVS GOVERNOR REMOVAL Crankcase cover (right) Preparation for removal 1 Part name 1 2 3 4 5 6 7 8 9 10 11 12 Governor assembly Dowel pin Retainer Ball Retainer weight Plain washer Thrust bearing Collar Plate Compression spring Governor gear Governor shaft Refer to “KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR” section.
YPVS GOVERNOR ENG EC4K3000 REMOVAL POINTS EC4K3100 Governor 1. Remove: 9Dowel pin 1 NOTE: While compressing the spring, remove the dowel pin. EC4K4000 INSPECTION EC4K4100 Governor groove 1. Inspect: 9Plain washer 1 9Collar 2 Wear/Damage → Replace. EC4K4200 Bearing 1. Inspect: 9Thrust bearing 1 9Plain washer 2 Wear/Damage → Replace. EC4K5000 ASSEMBLY AND INSTALLATION EC4K5130 Governor 1.
YPVS GOVERNOR ENG 2. Install: 9Ball 1 9Retainer 2 To governor shaft 3. NOTE: Apply the transmission oil on the retainer and ball. 3. Install: 9Dowel pin 1 NOTE: 9While compressing the spring, install the dowel pin. 9Make sure the dowel pin fits into the groove a in the retainer. 4. Install: 9Governor assembly 1 NOTE: Align the groove a in the governor with the fork b and set the governor in the crankcase cover.
WATER PUMP ENG EC4G0000 WATER PUMP 10 Nm (1.0 m•kg, 7.2 ft•lb) 14 Nm (1.4 m•kg, 10 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Impeller shaft removal Extent of removal: Extent of removal Order Part name 2 Oil seal removal Q’ty WATER PUMP DISASSEMBLY Crankcase cover (right) Preparation for removal 1 2 1 2 3 4 5 6 Water pump housing cover Impeller Plain washer Impeller shaft Bearing Oil seal 4-52 Remarks Refer to “KICK AXLE, SHIFT SHAFT AND PRIMARY DRIVE GEAR” section.
WATER PUMP ENG EC4G3000 REMOVAL POINTS EC4G3110 Impeller shaft 1. Remove: 9Impeller 1 9Plain washer 2 9Impeller shaft 3 NOTE: Hold the impeller shaft on its width across the flats a with spanners, etc. and remove the impeller. EC4G3210 Oil seal NOTE: It is not necessary to disassemble the water pump, unless there is an abnormality such as excessive change in coolant level, discoloration of coolant, or milky transmission oil. 1. Remove: 9Bearing 1 2.
WATER PUMP ENG EC444300 Impeller shaft gear 1. Inspect: 9Gear teeth a Wear/Damage → Replace. EC4H4600 Bearing 1. Inspect: 9Bearing 1 Rotate inner race with a finger. Rough spot/Seizure → Replace. EC444400 Oil seal 1. Inspect: 9Oil seal 1 Wear/Damage → Replace. EC4G5000 ASSEMBLY AND INSTALLATION EC4G5111 Oil seal 1. Install: 9Oil seal 1 NOTE: 9Apply the lithium soap base grease on the oil seal lip. 9Install the oil seal with its manufacture's marks or numbers facing the crankcase cover (right) 2.
ENG WATER PUMP EC4G5220 Impeller shaft 1. Install: 9Impeller shaft 1 NOTE: 9Take care so that the oil seal lip is not damaged or the spring does not slip off its position. 9When installing the impeller shaft, apply the lithium soap base grease on the oil seal lip and impeller shaft. And install the shaft while turning it. 2. Install: 9Plain washer 1 9Impeller 2 14 Nm (1.4 m•kg, 10 ft•lb) NOTE: Hold the impeller shaft on its width across the flats a with spanners, etc. and install the impeller. 3.
CDI MAGNETO ENG EC4L0000 CDI MAGNETO 8 Nm (0.8 m•kg, 5.8 ft•lb) 8 Nm (0.8 m•kg, 5.8 ft•lb) 56 Nm (5.6 m•kg, 40 ft•lb) 1 CDI magneto removal Extent of removal: Extent of removal Order Part name Q’ty CDI MAGNETO REMOVAL Seat and fuel tank Preparation for removal Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Refer to “RADIATOR” section. Bolt [radiator (left)] Disconnect the CDI magneto lead.
CDI MAGNETO ENG EC4L3000 REMOVAL POINTS EC4L3102 Rotor 1. Remove: 9Nut (rotor) 1 9Plain washer 2 Use the rotor holding tool 3. Rotor holding tool: YU-1235/90890-01235 2. Remove: 9Rotor 1 Use the flywheel puller 2. Flywheel puller: YM-1189/90890-01189 NOTE: When installing the flywheel puller, turn it counterclockwise. EC4L4000 INSPECTION EC4L4101 CDI magneto 1. Inspect: 9Rotor inner surface a 9Stator outer surface b Damage → Inspect the crankshaft runout and crankshaft bearing.
CDI MAGNETO ENG 2. Install: 9Woodruff key 1 9Rotor 2 NOTE: 9Clean the tapered portions of the crankshaft and rotor. 9When installing the woodruff key, make sure that its flat surface a is in parallel with the crankshaft center line b. 9When installing the rotor, align the keyway c of the rotor with the woodruff key. 3. Install: 9Plain washer 1 9Nut (rotor) 2 56 Nm (5.6 m•kg, 40 ft•lb) Use the rotor holding tool 3. Rotor holding tool: YU-1235/90890-01235 4.
CDI MAGNETO ENG 7. Connect: 9CDI magneto lead 1 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. 8. Install: 9Gasket [crankcase cover (left)] 9Crankcase cover (left) 1 9Screw [crankcase cover (left)] 2 8 Nm (0.8 m•kg, 5.8 ft•lb) NOTE: Tighten the screws in stage, using a crisscross pattern.
ENG ENGINE REMOVAL EC4M0000 ENGINE REMOVAL 34 Nm (3.4 m•kg, 24 ft•lb) 64 Nm (6.4 m•kg, 46 ft•lb) 26 Nm (2.6 m•kg, 19 ft•lb) 85 Nm (8.5 m•kg, 61 ft•lb) 64 Nm (6.4 m•kg, 46 ft•lb) 75 Nm (7.5 m•kg, 54 ft•lb) 8 Nm (0.8 m•kg, 5.8 ft•lb) Extent of removal Preparation for removal Order Part name Q’ty ENGINE REMOVAL Hold the machine by placing the suitable stand under the engine.
ENG ENGINE REMOVAL 34 Nm (3.4 m•kg, 24 ft•lb) 64 Nm (6.4 m•kg, 46 ft•lb) 26 Nm (2.6 m•kg, 19 ft•lb) 85 Nm (8.5 m•kg, 61 ft•lb) 64 Nm (6.4 m•kg, 46 ft•lb) 75 Nm (7.5 m•kg, 54 ft•lb) 8 Nm (0.8 m•kg, 5.
ENGINE REMOVAL ENG EC4M3000 REMOVAL POINTS EC4F3100 Drive sprocket 1. Remove: 9Nut (drive sprocket) 1 9Lock washer 2 NOTE: 9Straighten the lock washer tab. 9Loosen the nut while applying the rear brake. 2. Remove: 9Drive sprocket 1 9Drive chain 2 NOTE: Remove the drive sprocket together with the drive chain. EC4M3340 Engine removal NOTE: Make sure that the couplers, hoses and cables are disconnected. 1.
ENG ENGINE REMOVAL EC4M5000 ASSEMBLY AND INSTALLATION EC4M5124 Engine installation 1. Install: 9Engine 1 Install the engine from right side. 9Pivot shaft 2 85 Nm (8.5 m•kg, 61 ft•lb) 9Engine mounting bolt (lower) 3 64 Nm (6.4 m•kg, 46 ft•lb) 9Engine mounting bolt (front) 4 64 Nm (6.4 m•kg, 46 ft•lb) 9Engine bracket 5 9Bolt (engine bracket) 6 34 Nm (3.4 m•kg, 24 ft•lb) 9Engine mounting bolt (upper) 7 64 Nm (6.4 m•kg, 46 ft•lb) NOTE: Apply the molybdenum disulfide grease on the pivot shaft.
ENG ENGINE REMOVAL EC4M5341 Drive sprocket 1. Install: 9Drive sprocket 1 9Drive chain 2 NOTE: Install the drive sprocket together with the drive chain. 2. Install: 9Lock washer 1 9Nut (drive sprocket) 2 75 Nm (7.5 m•kg, 54 ft•lb) NOTE: Tighten the nut while applying the rear brake. 3. Bend the lock washer tab to lock the nut. 4. Install: 9Chain guide 1 9Chain cover 2 9Screw (chain cover) 3 8 Nm (0.8 m•kg, 5.
ENG CRANKCASE AND CRANKSHAFT EC4N0000 CRANKCASE AND CRANKSHAFT 10 Nm (1.0 m•kg, 7.2 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 14 Nm (1.4 m•kg, 10 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 1 Crankcase separation Extent of removal: 2 Crankshaft removal 3 Crankshaft bearing removal Extent of removal Order Part name Q’ty CRANKCASE AND CRANKSHAFT REMOVAL Engine Piston Preparation for removal Refer to “ENGINE REMOVAL” section. Refer to “CYLINDER HEAD, CYLINDER AND PISTON” section.
CRANKCASE AND CRANKSHAFT ENG EC4N3000 REMOVAL POINTS EC4N3212 Crankcase 1. Remove: 9Crankcase (right) 1 Use the crankcase separating tool 2. Crankcase separating tool: YU-1135-A/90890-01135 NOTE: 9Make appropriate bolts 3 as shown available by yourself and attach the tool with them. 9Fully tighten the tool holding bolts, but make sure the tool body is parallel with the case. If necessary, one screw may be backed out slightly to level tool body.
CRANKCASE AND CRANKSHAFT ENG EC4N3401 Crankshaft bearing 1. Remove: 9Bearing 1 NOTE: 9Remove the bearing from the crankcase by pressing its inner race as shown in å. 9If the bearing is removed together with the crankshaft, remove the bearing using a general bearing puller 2 as shown in ∫. Do not use the removed bearing. 9 EC4N4000 INSPECTION EC4N4101 Crankcase 1. Inspect: 9Contacting surface a Scratches → Replace. 9Engine mounting boss b, crankcase Cracks/Damage → Replace. 2.
CRANKCASE AND CRANKSHAFT ENG EC4N4202 Crankshaft 1. Measure: 9Runout limit a 9Small end free play limit b 9Connecting rod big end side clearance c 9Crank width d Out of specification → Replace. Use the dial gauge and a thickness gauge. Dial gauge: YU-3097/90890-01252 Runout limit: Standard 0.03 mm (0.0012 in) 0.05 mm (0.0020 in) Small end 0.4~1.0 mm free play: (0.016~0.039 in) 2.0 mm (0.08 in) Side 0.25~0.75 mm clearance: (0.010~0.030in) — Crank width: — 59.95~60.00 mm (2.360~2.
CRANKCASE AND CRANKSHAFT ENG EC4N5284 Crankshaft 1. Install: 9Crankshaft 1 Use the crankshaft installing tool 2, 3, 4. Crankshaft installing tool: YU-90050/90890-01274 Pot 2: Bolt 3: YU-90050/90890-01275 Adapter 4: YU-90063/90890-01278 å B å For USA and CDN ∫ Except for USA and CDN NOTE: 9Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other. Operate the installing tool until the crankshaft bottoms against the bearing.
CRANKCASE AND CRANKSHAFT ENG 3. Install: 9O-ring 1 To crankcase (right) 2. 4. Apply: 9Sealant On the crankcase (right) 1. Quick gasket®: ACC-QUICK-GS-KT Yamaha bond No. 1215: 90890-85505 NOTE: Clean the contacting surface of crankcase (left and right) before applying the sealant. 5. Install: 9Dowel pin 1 9Crankcase (right) 2 To crankcase (left) 3. NOTE: 9Fit the crankcase (right) onto the crankcase (left). Tap lightly on the case with soft hammer.
ENG CRANKCASE AND CRANKSHAFT 6. Install: 9Bolt (crankcase) 1 14 Nm (1.4 m•kg, 10 ft•lb) NOTE: Tighten the crankcase tightening bolts in stage, using a crisscross pattern. 7. Install: 9Tension spring 1 9Holder 2 9Bolt (holder) 3 10 Nm (1.0 m•kg, 7.2 ft•lb) NOTE: Install the holder so that it contacts the projection a on the crankcase (right). 8. Tighten: 9Segment 1 9Bolt (segment) 2 30 Nm (3.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG EC4H0000 TRANSMISSION, SHIFT CAM AND SHIFT FORK 1 Main axle, drive axle, shift cam and shift fork removal Extent of removal: Extent of removal Order Q’ty TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVAL Engine Separate the crankcase. Preparation for removal 1 Part name 1 2 3 4 5 6 7 Main axle Drive axle Shift cam Shift fork 3 Shift fork 2 Shift fork 1 Spacer Refer to “ENGINE REMOVAL” section. Refer to “CRANKCASE AND CRANK SHAFT” section.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG EC4H3000 REMOVAL POINTS EC4H3230 Transmission 1. Remove: 9Main axle 1 9Drive axle 2 9Shift cam 9Shift fork 3 9Shift fork 2 9Shift fork 1 NOTE: 9Remove assembly carefully. Note the position of each part. Pay particular attention to the location and direction of shift forks. 9Remove the main axle, drive axle, shift cam and shift fork all together by tapping lightly on the transmission drive axle with a soft hammer. EC4H4000 INSPECTION EC4H4230 Gears 1.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG EC4H4810 Shift fork, shift cam and segment 1. Inspect: 9Shift fork 1 Wear/Damage/Scratches → Replace. 2. Inspect: 9Shift cam 1 9Segment 2 Wear/Damage → Replace. 3. Check: 9Shift fork movement Unsmooth operation → Replace shift fork. NOTE: For a malfunctioning shift fork, replace not only the shift fork itself but the two gears each adjacent to the shift fork. EC4H5000 ASSEMBLY AND INSTALLATION EC4H5242 Transmission 1.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG 2. Install: 92nd wheel gear (23 T) 1 94th wheel gear (24 T) 2 93rd wheel gear (23 T) 3 95th wheel gear (20 T) 4 91st wheel gear (27 T) 5 9O-ring 6 To drive axle 7. NOTE: 9Apply the molybdenum disulfide oil on the inner and end surface of the idler gear and on the inner surface of the sliding gear, then install. 9Apply the lithium soap base grease on the Oring. 3.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG 5. Install: 9Shift fork 1 (L) 1 9Shift fork 2 (C10) 2 9Shift fork 3 (R) 3 9Shift cam 4 To main axle and drive axle. NOTE: 9Apply the molybdenum disulfide oil on the shift fork grooves. 9Mesh the shift fork #1 (L) with the 4th wheel gear 5 and #3 (R) with the 5th wheel gear 7 on the drive axle. 9Mesh the shift fork #2 (C10) with the 3rd pinion gear 6 on the main axle. 6. Install: 9Transmission assembly 1 To crankcase (left) 2.
CHAS FRONT WHEEL AND REAR WHEEL EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL 23 Nm (2.3 m•kg, 17 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) 105 Nm (10.5 m•kg, 75 ft•lb) 5 12 Nm (1.2 m•kg, 8.
FRONT WHEEL AND REAR WHEEL CHAS EC598100 REAR WHEEL 14 Nm (1.4 m•kg, 10 ft•lb) 125 Nm (12.5 m•kg, 90 ft•lb) 16 Nm (1.6 m•kg, 11 ft•lb) 42 Nm (4.2 m•kg, 30 ft•lb) 16 Nm (1.
FRONT WHEEL AND REAR WHEEL CHAS EC593000 REMOVAL POINTS EC523101 Rear wheel 1. Remove: 9Wheel 1 NOTE: Push the wheel forward and remove the drive chain 2. EC513201 Wheel bearing (if necessary) 1. Remove: 9Bearing 1 NOTE: Remove the bearing using a general bearing puller 2. EC594000 INSPECTION EC514100 Wheel 1. Measure: 9Wheel runout Out of limit→Repair/Replace. Wheel runout limit: Radial 1: 2.0mm (0.08 in) Lateral 2: 2.0mm (0.08 in) 2. Inspect: 9Bearing Rotate inner race with a finger.
FRONT WHEEL AND REAR WHEEL CHAS EC514200 Wheel axle 1. Measure: 9Wheel axle bends Out of specification → Replace. Use the dial gauge 1. Wheel axle bending limit: 0.5 mm (0.020 in) NOTE: The bending value is shown by one half of the dial gauge reading. w Do not attempt to straighten a bent axle. EC594200 Brake disc 1. Measure: 9Brake disc deflection (only rear brake disc) Use the dial gauge 1. Out of specification→Inspect wheel runout. If wheel runout is in good condition, replace the brake disc.
CHAS FRONT WHEEL AND REAR WHEEL EC595000 ASSEMBLY AND INSTALLATION EC595101 Front wheel 1. Install: 9Bearing (left) 1 9Spacer 2 9Bearing (right) 3 9Oil seal 4 NOTE: 9Apply the lithium soap base grease on the bearing and oil seal lip when installing. 9Use a socket that matches the outside diameter of the race of the bearing. 9Left side of bearing shall be installed first. 9Install the oil seal with its manufacture’s marks or numbers facing outward. cC Do not strike the inner race of the bearing.
CHAS FRONT WHEEL AND REAR WHEEL 5. Install: 9Wheel axle 1 NOTE: Apply the lithium soap base grease on the wheel axle. 6. Install: 9Nut (wheel axle) 1 105 Nm (10.5 m•kg, 75 ft•lb) 7. Tighten: 9Bolt (axle holder) 1 23 Nm (2.3 m•kg, 17 ft•lb) NOTE: Before tightening the bolt, fit the wheel axle to the axle holder by stroking the front fork several times with the front brake applied.
CHAS FRONT WHEEL AND REAR WHEEL EC5251A1 Rear wheel 1. Install: 9Bearing (right) 1 9Circlip 2 9Spacer 3 9Bearing (left) 4 9Oil seal 5 NOTE: 9Apply the lithium soap base grease on the bearing and oil seal lip when installing. 9Install the bearing with seal facing outward. 9Use a socket that matches the outside diameter of the race of the bearing. 9Right side of bearing shall be installed first. 9Install the oil seal with its manufacture’s marks or numbers facing outward.
CHAS FRONT WHEEL AND REAR WHEEL 3. Install: 9Driven sprocket 1 9Bolt (driven sprocket) 2 9Plain washer (driven sprocket) 3 9Nut (driven sprocket) 4 NOTE: 42 Nm (4.2 m•kg, 30 ft•lb) Tighten the nuts in stage, using a crisscross pattern. 4. Install: 9Collar 1 NOTE: Apply the lithium soap base grease on the oil seal lip. 5. Install: 9Wheel NOTE: Install the brake disc 1 between the brake pads 2 correctly. 6. Install: 9Drive chain 1 NOTE: Push the wheel 2 forward and install the drive chain. 7.
CHAS FRONT WHEEL AND REAR WHEEL 8. Install: 9Chain puller (right) 1 9Plain washer 2 9Nut (wheel axle) 3 NOTE: Temporarily tighten the nut (wheel axle) at this point. 9. Adjust: 9Drive chain slack a Drive chain slack : 48~58 mm (1.9~2.3 in) Refer to “DRIVE CHAIN SLACK ADJUSTMENT” section in the CHAPTER 3. 10. Tighten: 9Nut (wheel axle) 1 125 Nm (12.5 m•kg, 90 ft•lb) 9Locknut 2 5-9 16 Nm (1.
FRONT BRAKE AND REAR BRAKE CHAS EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE 10 Nm (1.0 m•kg, 7.2 ft•lb) 9 Nm (0.9 m•kg, 6.5 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 3 Nm (0.3 m•kg, 2.2 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb) 23 Nm (2.3 m•kg, 17 ft•lb) 30 Nm (3.
FRONT BRAKE AND REAR BRAKE CHAS EC5A8100 REAR BRAKE 30 Nm (3.0 m•kg, 22 ft•lb) 1 Nm (0.1 m•kg, 0.7 ft•lb) 3 Nm (0.3 m•kg, 2.2 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb) 30 Nm (3.0 m•kg, 22 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 26 Nm (2.6 m•kg, 19 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) Extent of removal: Extent of removal 1 Master cylinder removal Order 2 Brake hose removal Part name Q’ty Support the machine securely so there is no danger of it falling over.
FRONT BRAKE AND REAR BRAKE CHAS EC5A8200 CALIPER DISASSEMBLY 18 Nm (1.8 m•kg, 13 ft•lb) 3 Nm (0.3 m•kg, 2.2 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 6 Nm (0.6 m•kg, 4.3 ft•lb) 18 Nm (1.8 m•kg, 13 ft•lb) 3 Nm (0.3 m•kg, 2.
FRONT BRAKE AND REAR BRAKE CHAS EC5A8300 MASTER CYLINDER DISASSEMBLY 2 Nm (0.2 m•kg, 1.4 ft•lb) 2 Nm (0.2 m•kg, 1.
FRONT BRAKE AND REAR BRAKE CHAS EC5A3000 REMOVAL POINTS EC5A3101 Brake fluid 1. Remove: [Front] 9Master cylinder cap 1 [Rear] 9Master cylinder cap 1 9Protector NOTE: Do not remove the diaphragm. A Front B Rear 2. Connect the transparent hose 2 to the bleed screw 1 and place a suitable container under its end. A Front B Rear 3. Loosen the bleed screw and drain the brake fluid while pulling the lever in or pushing down on the pedal. cC 9Do not reuse the drained brake fluid.
FRONT BRAKE AND REAR BRAKE CHAS EC533402 Piston seal kit 1. Remove: 9Dust seal 1 9Piston seal 2 NOTE: Remove the piston seals and dust seals by pushing them with a finger. cC Never attempt to pry out piston seals and dust seals. w Replace the piston seals and dust seals whenever a caliper is disassembled. A Front B Rear EC5A4000 INSPECTION EC534120 Master cylinder 1. Inspect: 9Master cylinder inner surface a Wear/Scratches→Replace master cylinder assembly. Stains→Clean. w Use only new brake fluid.
FRONT BRAKE AND REAR BRAKE CHAS 4. Inspect: 9Master cylinder piston 1 9Master cylinder cup 2 Wear/Damage/Score marks→Replace master cylinder kit. A Front B Rear EC534214 Caliper 1. Inspect: 9Caliper cylinder inner surface a Wear/Score marks→Replace caliper assembly. A Front B Rear 2. Inspect: 9Caliper piston 1 Wear/Score marks→Replace caliper piston assembly. w Replace the piston seals and dust seals 2 whenever a caliper is disassembled. EC534301 Brake hose 1.
FRONT BRAKE AND REAR BRAKE CHAS EC5A5801 Caliper piston 1. Clean: 9Caliper 9Piston seal 9Dust seal 9Caliper piston Clean them with brake fluid. 2. Install: 9Piston seal 1 9Dust seal 2 w Always use new piston seals and dust seals. NOTE: Fit the piston seals and dust seals onto the slot on caliper correctly. A Front B Rear 3. Install: 9Caliper piston 1 NOTE: Apply the brake fluid on the piston wall. cC 9Install the piston with its shallow depressed side a facing the caliper. 9Never force to insert.
CHAS FRONT BRAKE AND REAR BRAKE 2. Install: 9Caliper 1 9Bolt (caliper) 2 23 Nm (2.3 m•kg, 17 ft•lb) 3. Tighten: 9Pad pin 3 18 Nm (1.8 m•kg, 13 ft•lb) 4. Install: 9Pad pin plug 4 3 Nm (0.3 m•kg, 2.2 ft•lb) EC5A5121 Rear caliper 1. Install: 9Pad support 1 9Brake pad 2 9Pad pin 3 NOTE: 9Install the brake pads with their projections a into the caliper recesses b. 9Temporarily tighten the pad pin at this point. 2. Install: 9Disc cover 1 9Bolt (disc cover) 2 7 Nm (0.7 m•kg, 5.1 ft•lb) 3.
FRONT BRAKE AND REAR BRAKE CHAS EC5A5220 Master cylinder kit 1. Clean: 9Master cylinder 9Master cylinder kit Clean them with brake fluid. 2. Install: 9Master cylinder cup (primary) 1 9Master cylinder cup (secondary) 2 To master cylinder piston 3. NOTE: Apply the brake fluid on the master cylinder cup. w After installing, cylinder cup should be installed as shown direction. Wrong installation cause improper brake performance. A Front B Rear 3. Install: 9Spring 1 To master cylinder piston 2.
CHAS FRONT BRAKE AND REAR BRAKE 4. Install: [Front] 9Master cylinder kit 1 9Plain washer 2 9Circlip 3 9Master cylinder boot 4 To master cylinder 5. [Rear] 9Master cylinder kit 1 9Push rod 2 9Circlip 3 9Master cylinder boot 4 To master cylinder 5. NOTE: 9Apply the brake fluid on the master cylinder kit. 9Apply the lithium soap base grease on the tip of the push rod. When installing the circlip, use a long nose 9 circlip pliers. A Front B Rear EC5A5310 Front master cylinder 1.
CHAS FRONT BRAKE AND REAR BRAKE EC5A5401 Rear master cylinder 1. Install: 9Copper washer 1 9Brake hose 2 30 Nm (3.0 m•kg, 22 ft•lb) 9Union bolt 3 w Always use new copper washers. cC Install the brake hose so that its pipe portion a directs as shown and lightly touches the projection b on the master cylinder. 2. Install: 9Master cylinder 1 9Bolt (master cylinder) 2 10 Nm (1.0 m•kg, 7.2 ft•lb) 3. Install: 9Spring 1 9Brake pedal 2 9O-ring 3 9Bolt (brake pedal) 4 26 Nm (2.
FRONT BRAKE AND REAR BRAKE CHAS 4. Install: 9Pin 1 9Plain washer 2 9Cotter pin 3 NOTE: After installing, check the brake pedal height. Refer to “REAR BRAKE ADJUSTMENT” section in the CHAPTER 3. EC5A5911 Front brake hose 1. Install: 9Copper washer 1 9Brake hose 2 9Union bolt 3 30 Nm (3.0 m•kg, 22 ft•lb) w Always use new copper washers. cC Install the brake hose so that its pipe portion a directs as shown and lightly touches the projection b on the caliper. 2.
FRONT BRAKE AND REAR BRAKE CHAS 4. Pass the brake hose through the cable guide 1. 5. Install: 9Copper washer 1 9Brake hose 2 30 Nm (3.0 m•kg, 22 ft•lb) 9Union bolt 3 w Always use new copper washers. cC Install the brake hose so that its pipe portion a directs as shown and lightly touches the projection b on the master cylinder. EC5A5502 Rear brake hose 1. Install: 9Copper washer 1 9Brake hose 2 30 Nm (3.0 m•kg, 22 ft•lb) 9Union bolt 3 w Always use new copper washers.
FRONT BRAKE AND REAR BRAKE CHAS 2. Install: 9Brake hose holder 1 9Screw (brake hose holder) 2 1 Nm (0.1 m•kg, 0.7 ft•lb) cC After installing the brake hose holders, make sure the brake hose does not contact the spring (rear shock absorber). If it does, correct its twist. EC5A5620 Brake fluid 1. Fill: 9Brake fluid Until the fluid level reaches “LOWER” level line a.
FRONT BRAKE AND REAR BRAKE CHAS 2. Air bleed: 9Brake system Refer to “BRAKE SYSTEM AIR BLEEDING” section in the CHAPTER 3. 3. Inspect: 9Brake fluid level Fluid at lower level→Fill up. Refer to “BRAKE FLUID LEVEL INSPECTION” section in the CHAPTER 3. 4. Install: [Front] 9Reservoir float 9Diaphragm 9Master cylinder cap 1 9Screw (master cylinder cap) 2 2 Nm (0.2 m•kg, 1.4 ft•lb) [Rear] 9Diaphragm 9Master cylinder cap 1 9Bolt (master cylinder cap) 2 2 Nm (0.2 m•kg, 1.
FRONT FORK CHAS EC550000 FRONT FORK 23 Nm (2.3 m•kg, 17 ft•lb) 20 Nm (2.0 m•kg, 14 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb) Extent of removal: Extent of removal 1 Front fork removal Order Part name Q’ty FRONT FORK REMOVAL Hold the machine by placing the suitable stand under the engine. Front wheel Preparation for removal Remarks w Support the machine securely so there is no danger of it falling over.
FRONT FORK CHAS EC558000 FRONT FORK DISASSEMBLY 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.
FRONT FORK CHAS EC556000 HANDLING NOTE NOTE: The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers. cC To prevent an accidental explosion of air, the following instructions should be observed: 9The front fork with a built-in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material.
FRONT FORK CHAS Adjuster 1. Drain the outer tube of its front fork oil at its top. 2. Loosen: 9Adjuster 1 3. Remove: 9Adjuster 1 NOTE: 9While compressing the inner tube 2 , set the cap bolt ring wrench 4 between the inner tube and locknut 3 . 9Hold the locknut and remove the adjuster. cC Do not remove the locknut as it may go into the damper assembly and not be taken out. Cap bolt ring wrench: YM-01501/90890-01501 EC553201 Inner tube 1.
FRONT FORK CHAS Base valve 1. Remove: 9Base valve 1 From damper assembly 2. NOTE: Hold the damper assembly with the cap bolt ring wrench 3 and use the cap bolt wrench 4 to remove the base valve. Cap bolt wrench: YM-01500/90890-01500 Cap bolt ring wrench: YM-01501/90890-01501 EC554000 INSPECTION EC554100 Damper assembly 1. Inspect: 9Damper assembly 1 Bend/Damage→Replace. 9O-ring 2 Wear/Damage→Replace.
FRONT FORK CHAS Base valve 1. Inspect: 9Base valve 1 Wear/Damage→Replace. Contamination→Clean. 9O-ring 2 Wear/Damage→Replace. 9Bush 3 Wear/Damage→Replace base valve. 9Spring 4 Damage/Fatigue→Replace base valve. Air bleed screw 5 9 Wear/Damage→Replace base valve. EC554400 Fork spring 1. Measure: 9Fork spring free length a Out of specification→Replace. Fork spring free length: Standard 465 mm (18.3 in) 460 mm (18.1 in) EC554502 Inner tube 1.
FRONT FORK CHAS EC554600 Outer tube 1. Inspect: 9Outer tube 1 Score marks/Wear/Damage→Replace. Adjuster 1. Inspect: 9Adjuster 1 9O-ring 2 Wear/Damage→Replace. EC555000 ASSEMBLY AND INSTALLATION EC5551D0 Front fork assembly 1. Wash the all parts in a clean solvent. 2. Stretch the damper assembly fully. 3. Fill: 9Front fork oil 1 To damper assembly. Recommended oil: Suspension oil “S1” Oil capacity: 195cm3 (6.86 Imp oz, 6.59 US oz) cC 9Be sure to use recommended fork oil.
FRONT FORK CHAS 4. After filling, pump the damper assembly 1 slowly up and down (about 200 mm (7.9 in) stroke) several times to bleed the damper assembly of air. NOTE: Be careful not to excessive full stroke. A stroke of 200 mm (7.9 in) or more will cause air to enter. In this case, repeat the steps 2 to 4. 5. Inspect: 9Oil amount While keeping the damper assembly fully stretched, check that the oil is above the step a on the damper assembly. Below the step→Replenish fork oil above the step. 6.
FRONT FORK CHAS 9. Tighten: 9Base valve 1 29 Nm (2.9 m•kg, 21 ft•lb) NOTE: Hold the damper assembly with the cap bolt ring wrench 2 and use the cap bolt wrench 3 to tighten the base valve with specified torque. Cap bolt wrench: YM-01500/90890-01500 Cap bolt ring wrench: YM-01501/90890-01501 10. After filling, pump the damper assembly 1 slowly up and down more than 10 times to distribute the fork oil. 11.
FRONT FORK CHAS 14. Install: 9Dust seal 1 9Stopper ring 2 9Oil seal 3 9Oil seal washer 4 9Slide metal 5 To inner tube 6. NOTE: 9Apply the fork oil on the inner tube. 9When installing the oil seal, use vinyl seat a with fork oil applied to protect the oil seal lip. 9Install the oil seal with its manufacture's marks or number facing the axle holder side. 9Install the oil seal washer with its projections b facing upward. 15.
FRONT FORK CHAS 17. Install: 9Slide metal 1 9Oil seal washer 2 To outer tube slot. NOTE: Press the slide metal into the outer tube with fork seal driver 3. Fork seal driver: YM-01442/90890-01442 18. Install: 9Oil seal 1 NOTE: Press the oil seal into the outer tube with fork seal driver 2. Fork seal driver: YM-01442/90890-01442 19. Install: 9Stopper ring 1 NOTE: Fit the stopper ring correctly in the groove in the outer tube. 20.
FRONT FORK CHAS 21. Check: 9Inner tube smooth movement Tightness/Binding/Rough spots → Repeat the steps 14 to 20. 22. Measure: 9Distance a Out of specification→Turn into the locknut. Distance a: 19 mm (0.75 in) or more Between damper assembly 1 bottom and locknut 2 bottom. 23. Install: 9Spacer (metal) 1 9Fork spring 2 9Spacer (resin) 3 To damper assembly 4. NOTE: Install the spacer with the plate a facing the fork spring. 24. Install: 9Damper assembly 1 To inner tube 2.
CHAS FRONT FORK 26. Install: 9Push rod 1 9Copper washer 2 9Adjuster 3 To damper assembly 4. NOTE: 9While compressing the inner tube 5, set the cap bolt ring wrench 7 between the inner tube and locknut 6. 9Fully finger tighten the adjuster onto the damper assembly. Cap bolt ring wrench: YM-01501/90890-01501 27. Inspect: 9Gap a between adjuster 1 and locknut 2. Gap a between adjuster and locknut 0.5~1.0mm (0.02~0.04 in) Out of specification→ Retighten and readjust the locknut.
CHAS FRONT FORK w Never fail to make the oil amount adjustment between the maximum and minimum amount and always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability. cC 9Be sure to use recommended fork oil. If other oils are used, they may have an excessively adverse effect on the front fork performance. 9Never allow foreign materials to enter the front fork. 31. Install: 9Damper assembly 1 To outer tube.
CHAS FRONT FORK 3. Adjust: 9Front fork top end a Front fork top end (standard) a: Zero mm (Zero in) 4. Tighten: 9Pinch bolt (handle crown) 1 23 Nm (2.3 m•kg, 17 ft•lb) 9Pinch bolt (under bracket) 2 20 Nm (2.0 m•kg, 14 ft•lb) cC Tighten the under bracket to specified torque. If torqued too much, it may cause the front fork to malfunction. 5. Install: 9Protector 1 9Bolt (protector) 2 10 Nm (1.0 m•kg, 7.2 ft•lb) 6.
HANDLEBAR CHAS EC5B0000 HANDLEBAR 1 Nm (0.1 m•kg, 0.7 ft•lb) 9 Nm (0.9 m•kg, 6.5 ft•lb) 28 Nm (2.8 m•kg, 20 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 4 Nm (0.4 m•kg, 2.9 ft•lb) 4 Nm (0.4 m•kg, 2.
HANDLEBAR CHAS EC5B8000 THROTTLE DISASSEMBLY 4 Nm (0.4 m•kg, 2.9 ft•lb) Extent of removal: Extent of removal 1 1 Throttle disassembly Order 1 2 3 4 5 Part name Q’ty THROTTLE DISASSEMBLY Grip cap (lower) Grip cap (upper) Grip assembly Grip (right) Tube guide 5-42 1 1 1 1 1 Remarks Refer to “REMOVAL POINTS”.
HANDLEBAR CHAS EC5B3000 REMOVAL POINTS EC5B3100 Master cylinder 1. Remove: 9Master cylinder bracket 1 9Master cylinder 2 cC 9Do not let the master cylinder hang on the brake hose. 9Keep the master cylinder cap side horizontal to prevent air from coming in. EC5B3200 Grip 1. Remove: 9Grip 1 NOTE: Blow in air between the handlebar or tube guide and the grip. Then remove the grip which has become loose. EC5B4000 INSPECTION EC5B4100 Handlebar 1. Inspect: 9Handlebar 1 Bends/Cracks /Damage→Replace.
CHAS HANDLEBAR 2. Install: 9Grip cap (upper) 1 9Grip cap (lower) 2 9Bolt (grip cap) 3 NOTE: Temporarily tighten the bolts (grip cap). EC5B5210 Handlebar 1. Install: 9Handlebar 1 9Handlebar holder 2 9Bolt (handlebar holder) 3 28 Nm (2.8 m•kg, 20 ft•lb) NOTE: 9The upper handlebar holder should be installed with the punched mark a forward. 9Install the handlebar so that the marks b are in place on both sides.
HANDLEBAR CHAS 3. Install: 9Collar 1 9Cap cover 2 9Throttle 3 NOTE: 9Apply the lithium soap base grease on the throttle grip sliding surface. 9Tighten the grip cap bolts temporarily without the throttle being fixed to the handlebar. 4. Install: 9Throttle cable 1 To tube guide 2. NOTE: Apply the lithium soap base grease on the throttle cable end and tube guide cable winding portion. 5. Install: 9Roller 1 9Collar 2 NOTE: 9Apply the lithium soap base grease on the roller sliding surface.
HANDLEBAR CHAS 9. Install: 9Master cylinder 1 9Master cylinder bracket 2 9Bolt (master cylinder bracket) 3 9 Nm (0.9 m•kg, 6.5 ft•lb) NOTE: 9Install the bracket so that the arrow mark a faces upward. 9First tighten the bolt on the upper side of the master cylinder bracket, and then tighten the bolt on the lower side. 10. Install: 9Bolt (grip cap) 1 w 4 Nm (0.4 m•kg, 2.9 ft•lb) 9Install the grip cap so that the gaps a and b between the bolt (grip cap) and brake lever 2 are equal.
HANDLEBAR CHAS 12. Install: 9Clutch cable 1 NOTE: Apply the lithium soap base grease on the clutch cable end. 13. Adjust: 9Clutch lever free play Refer to “CLUTCH ADJUSTMENT” section in the CHAPTER 3. 14. Clamp the clamp portion a of the number plate to the handlebar. 15. Insert the end of the fuel breather hose 1 into the hole in the steering shaft cap 2.
STEERING CHAS EC560000 STEERING 23 Nm (2.3 m•kg, 17 ft•lb) 145 Nm (14.5 m•kg, 105 ft•lb) TIGHTENING STEPS: 9 Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb) 9 Loosen it one turn. 9 Retighten it. 7 Nm (0.7 m•kg, 5.1 ft•lb) 4Nm (0.4 m•kg, 2.9 ft•lb) 20 Nm (2.0 m•kg, 14 ft•lb) Extent of removal: Extent of removal 1 Under bracket removal 2 Bearing removal Order Part name Q’ty STEERING REMOVAL Hold the machine by placing the suitable stand under the engine.
STEERING CHAS EC563000 REMOVAL POINTS EC563202 Ring nut 1. Remove: 9Ring nut 1 Use the ring nut wrench 2. Ring nut wrench: YU-33975/90890-01403 w Support the steering shaft so that it may not fall down. EC563300 Bearing (lower) 1. Remove: 9Bearing (lower) 1 Use the floor chisel 2. cC Take care not to damage the steering shaft thread. EC563400 Bearing race 1. Remove: 9Bearing race 1 Remove the bearing race using long rod 2 and the hammer. EC564000 INSPECTION EC564200 Steering shaft 1.
STEERING CHAS EC564101 Bearing and bearing race 1. Wash the bearings and bearing races with a solvent. 2. Inspect: 9Bearing 1 9Bearing race Pitting/Damage → Replace bearings and bearing races as a set. Install the bearing in the bearing races. Spin the bearings by hand. If the bearings hang up or are not smooth in their operation in the bearing races, replace bearings and bearing races as a set. EC565000 ASSEMBLY AND INSTALLATION EC5651A0 Under bracket 1.
CHAS STEERING 4. Install: 9Ring nut 1 7 Nm (0.7 m•kg, 5.1 ft•lb) Tighten the ring nut using the ring nut wrench 2. Refer to “STEERING HEAD INSPECTION AND ADJUSTMENT” section in the CHAPTER 3. 5. Check the steering shaft by turning it lock to lock. If there is any binding, remove the steering shaft assembly and inspect the steering bearings. 6. Install: 9Plain washer 1 7. Install: 9Front fork 1 9Handle crown 2 NOTE: 9Temporarily tighten the pinch bolts (under bracket).
CHAS STEERING 9. Install: 9Steering shaft cap 1 10. After tightening the nut, check the steering for smooth movement. If not, adjust the steering by loosening the ring nut little by little. 11. Adjust: 9Front fork top end a Front fork top end (standard) a: Zero mm (Zero in) 12. Tighten: 9Pinch bolt (handle crown) 1 23 Nm (2.3 m•kg, 17 ft•lb) 9Pinch bolt (under bracket) 2 20 Nm (2.0 m•kg, 14 ft•lb) cC Tighten the under bracket to specified torque.
SWINGARM CHAS EC570000 SWINGARM 53 Nm (5.3 m•kg, 38 ft•lb) 7 Nm (0.7 m•kg, 5.1 ft•lb) 19 Nm (1.9 m•kg, 13 ft•lb) 85 Nm (8.5 m•kg, 61 ft•lb) 80 Nm (8.0 m•kg, 58 ft•lb) Extent of removal: Extent of removal 1 Swingarm removal Order Q’ty 1 2 3 4 5 6 Chain support Chain tensioner (lower) Bolt (rear shock absorber-relay arm) Bolt (connecting rod) Pivot shaft Swingarm 5-53 Remarks w SWINGARM REMOVAL Hold the machine by placing the suitable stand under the engine.
SWINGARM CHAS EC578000 SWINGARM DISASSEMBLY 80 Nm (8.0 m•kg, 58 ft•lb) 2 Nm (0.2 m•kg, 1.4 ft•lb) 5 Nm (0.5 m•kg, 3.6 ft•lb) 80 Nm (8.
SWINGARM CHAS EC573000 REMOVAL POINTS Cap 1. Remove: 9Cap (left) 1 NOTE: Remove with a slotted-head screwdriver inserted under the mark a on the cap (left). EC573201 Bearing 1. Remove: 9Bearing 1 NOTE: Remove the bearing by pressing its outer race. EC574010 INSPECTION Wash the bearings, bushes, collars, and covers in a solvent. EC574111 Swingarm 1. Inspect: 9Bearing 1 9Bush 2 Free play exists/Unsmooth revolution/Rust → Replace bearing and bush as a set. 2. Inspect: 9Oil seal 3 Damage → Replace.
SWINGARM CHAS EC574311 Connecting rod 1. Inspect: 9Bearing 1 9Collar 2 Free play exists/Unsmooth revolution/Rust → Replace bearing and collar as a set. 2. Inspect: 9Oil seal 3 Damage → Replace. EC575000 ASSEMBLY AND INSTALLATION EC575202 Bearing and oil seal 1. Install: 9Bearing 1 9Oil seal 2 To swingarm. NOTE: 9Apply the molybdenum disulfide grease on the bearing when installing. 9Install the bearing by pressing it on the side having the manufacture's marks or numbers.
SWINGARM CHAS 3. Install: 9Bearing 1 9Oil seal 2 To connecting rod. NOTE: 9Apply the molybdenum disulfide grease on the bearing when installing. 9Install the bearing by pressing it on the side having the manufacture's marks or numbers. Installed depth of bearings a: 5 mm (0.20 in) EC5751B3 Swingarm 1. Install: 9Bush 1 9Thrust bearing 2 9Oil seal 3 9 Collar 4 To swingarm 5.
SWINGARM CHAS 4. Install: 9Connecting rod 1 9Bolt (connecting rod) 2 9Plain washer 3 9Nut (connecting rod) 4 80 Nm (8.0 m•kg, 58 ft•lb) To relay arm 5. NOTE: Apply the molybdenum disulfide grease on the bolt. 5. Install: 9Relay arm 1 9Bolt (relay arm) 2 9Plain washer 3 9Nut (relay arm) 4 To swingarm. NOTE: 9Apply the molybdenum disulfide grease on the bolt. 9Do not tighten the nut yet. 6. Install: 9Swingarm 1 9Pivot shaft 2 85 Nm (8.
SWINGARM CHAS 8. Install: 9Bolt (connecting rod) 1 9Plain washer 2 9Nut (connecting rod) 3 NOTE: 9Apply the molybdenum disulfide grease on the bolt. 9Do not tighten the nut yet. 9. Install: 9Bolt (rear shock absorber-relay arm) 1 9Nut (rear shock absorber-relay arm) 2 53 Nm (5.3 m•kg, 38 ft•lb) NOTE: Apply the molybdenum disulfide grease on the bolt. 10. Tighten: 9Nut (connecting rod) 1 80 Nm (8.0 m•kg, 58 ft•lb) 11. Tighten: 9Nut (relay arm) 1 80 Nm (8.0 m•kg, 58 ft•lb) 12.
SWINGARM CHAS 13. Install: 9Bolt [chain tensioner (lower)] 1 9Plain washer 2 9Collar 3 9Chain tensioner 4 9Nut [chain tensioner (lower)] 5 19 Nm (1.9 m•kg, 13 ft•lb) 14. Install: 9Chain support 1 9Support cover 2 9Bolt {chain support [/=50mm (1.97in)]} 3 9Nut (chain support) 4 7 Nm (0.7 m•kg, 5.1 ft•lb) 9Bolt { support cover [/=10mm (0.39in)]} 5 7 Nm (0.7 m•kg, 5.
REAR SHOCK ABSORBER CHAS EC580000 REAR SHOCK ABSORBER 56 Nm (5.6 m•kg, 40 ft•lb) 53 Nm (5.3 m•kg, 38 ft•lb) 32 Nm (3.2 m•kg, 23 ft•lb) 29 Nm (2.9 m•kg, 21 ft•lb) Extent of removal: Extent of removal 1 Rear shock absorber removal 2 Rear shock absorber disassembly Order Part name Q’ty Preparation for removal Support the machine securely so there is no danger of it falling over. Hold the machine by placing the suitable stand under the engine.
REAR SHOCK ABSORBER CHAS EC586000 HANDLING NOTE w This 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. 1. Never tamper or attempt to disassemble the cylinder or the tank. 2.
REAR SHOCK ABSORBER CHAS EC583000 REMOVAL POINTS EC583320 Bearing 1. Remove: 9Stopper ring (upper bearing) 1 NOTE: Press in the bearing while pressing its outer race and remove the stopper ring. 2. Remove: 9Upper bearing 1 NOTE: Remove the bearing by pressing its outer race. 3. Remove: 9Lower bearing 1 NOTE: Remove the bearing by pressing its outer race. EC584000 INSPECTION EC584110 Rear shock absorber 1. Inspect: 9Damper rod 1 Bends/Damage → Replace absorber assembly.
REAR SHOCK ABSORBER CHAS EC585000 ASSEMBLY AND INSTALLATION EC585320 Bearing 1. Install: 9Upper Bearing 1 NOTE: Install the bearing parallel until the stopper ring groove appears by pressing its outer race. cC 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. 2. Install: 9Stopper ring (upper bearing) 1 NOTE: After installing the stopper ring, push back the bearing until it contacts the stopper ring. 3.
REAR SHOCK ABSORBER CHAS 3. Adjust: 9Spring length (installed) a Spring length (installed) a: Standard length 251 mm (9.88 in) *253 mm (9.96 in) Extent of adjustment 240.5~258.5 mm (9.47~10.18 in) *For EUROPE NOTE: The length of the spring (installed) changes 1.5 mm (0.06 in) per turn of the adjuster. cC Never attempt to turn the adjuster beyond the maximum or minimum setting. 4. Tighten: 9Locknut 1 EC5852B5 Rear shock absorber 1.
REAR SHOCK ABSORBER CHAS 3. Install: 9Rear shock absorber 4. Install: 9Bolt (rear shock absorber-frame) 1 9Plain washer 2 9Nut (rear shock absorber-frame) 3 56 Nm (5.6 m•kg, 40 ft•lb) NOTE: Apply the molybdenum disulfide grease on the bolt. 5. Install: 9Bolt (rear shock absorber-relay arm) 1 9Nut (rear shock absorber-relay arm) 2 53 Nm (5.3 m•kg, 38 ft•lb) NOTE: Apply the molybdenum disulfide grease on the bolt. 6. Install: 9Rear frame 1 9Bolt [rear frame (upper)] 2 32 Nm (3.
ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELEC EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS COLOR CODE 1 2 3 4 5 6 7 B...................Black L ...................Blue O ..................Orange R ..................Red Y...................Yellow B/L................Black/Blue B/R ...............Black/Red B/W ..............Black/White G/L ..............Green/Blue G/W..............Green/White W/L...............White/Blue W/R ..............
IGNITION SYSTEM ELEC EC620000 IGNITION SYSTEM EC621003 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 Spark gap test *Clean or replace spark plug. No Spark Check entire ignition system for connection. No good Repair or replace. OK No good Check “ENGINE STOP” button. Replace. OK Check ignition coil.
IGNITION SYSTEM ELEC EC622001 å SPARK GAP TEST 1. Disconnect the spark plug cap from spark plug. 2. Connect the dynamic spark tester 1 (ignition checker 2 ) as shown. 9Spark plug cap 3 9Spark plug 4 A For USA and CDN B Except for USA and CDN B 3. Kick the kick starter. 4. Check the ignition spark gap. 5. Start engine, and increase spark gap until misfire occurs. (for USA and CDN only) Minimum spark gap: 6.0 mm (0.24 in) EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1.
IGNITION SYSTEM ELEC EC626003 IGNITION COIL INSPECTION 1. Inspect: 9Primary coil resistance Out of specification → Replace. Tester (+) lead→Yellow lead 1 Tester (–) lead→Black lead 2 Primary coil resistance Tester selector position 0.20~0.30Ω at 20°C (68°F) Ω×1 2. Inspect: 9Secondary coil resistance Out of specification → Replace. Tester (+) lead→Spark plug lead 1 Tester (–) lead→Yellow lead 2 Secondary coil resistance Tester selector position 9.5~14.
IGNITION SYSTEM ELEC EC62B000 SPARK PLUG CAP INSPECTION 1.Inspect: 9Spark plug cap Loose connection → Tighten. Deteriorated/Damaged → Replace. 9Spark plug cap resistance Out of specification → Replace. Tester (+) lead→Spark plug lead terminal 1 Tester (–) lead→Spark plug terminal 2 Spark plug cap resistance Tester selector position 4~6kΩ at 20°C (68°F) kΩ × 1 EC627011 CDI MAGNETO INSPECTION 1. Inspect: 9Pick-up coil resistance Out of specification → Replace.
IGNITION SYSTEM ELEC 3. Inspect: 9Source coil 2 resistance Out of specification → Replace. Tester (+) lead→Green/Blue lead 1 Tester (–) lead→Green/White lead 2 Source coil 2 resistance Tester selector position 44~66Ω at 20°C (68°F) Ω × 10 EC628000 CDI UNIT INSPECTION Check all electrical components. If no fault is found, replace the CDI unit. Then check the electrical components again.
SOLENOID VALVE SYSTEM ELEC EC650001 SOLENOID VALVE SYSTEM EC651032 INSPECTION STEPS If the solenoid valve will not operate, use the following inspection steps. No good Check each couplers and wire connection. Repair or replace. OK Check solenoid valve. OK * Check CDI magneto. Check solenoid valve operation. No good Solenoid valve coil No good Source coil OK Replace CDI unit. * marked: Refer to "IGNITION SYSTEM" section. NOTE: 9Remove the following parts before inspection.
SOLENOID VALVE SYSTEM ELEC EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: 9Couplers and leads connection Rust/ Dust/ Looseness/Short-circuit → Repair or replace. EC652040 SOLENOID VALVE OPERATION 1. Disconnect the solenoid valve coupler. 2. Connect 12V battery to the solenoid valve coupler. R R 1 1 2 2 Battery (+) lead→Red lead 1 Battery (–) lead→Red lead 2 3. Inspectt: 9Solenoid valve 1 No click when connecting the battery → Replace. EC653002 SOLENOID VALVE COIL INSPECTION 1.
TPS (THROTTLE POSITION SENSOR) SYSTEM ELEC EC690000 TPS (THROTTLE POSITION SENSOR) SYSTEM EC691001 INSPECTION STEPS If the TPS will not operate, use the following inspection steps. No good Check entire ignition system for connection. Repair or replace. OK Check TPS. TPS coil No good Replace. OK *Check CDI magneto. Source coil No good Replace. OK Check CDI unit. TPS input voltage No good Replace. *marked: Refer to “IGNITION SYSTEM” section.
TPS (THROTTLE POSITION SENSOR) SYSTEM ELEC EC69A000 HANDLING NOTE cC Do not loosen the screws {TPS (throttle position sensor)} except when changing the TPS (throttle position sensor) due to failure because it will cause a drop in engine performance. EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: 9Couplers and leads connection Rust/ Dust/ Looseness/Short-circuit → Repair or replace. EC692000 TPS COIL INSPECTION 1.
TPS (THROTTLE POSITION SENSOR) SYSTEM 3. Inspect: 9TPS coil variable resistance Check that the resistance in increased as the lever 1 is moved from the full close position to the full open position. Out of specification → Replace. 2 2 1 3 ELEC L Y B 3 Tester (+) lead→Yellow lead 2 Tester (–) lead→Black lead 3 TPS coil variable Tester selector resistance position Full closed Full opened kΩ × 1 Zero~2kΩ at 4~6kΩ at 20°C (68°F) 20°C (68°F) EC693001 TPS REPLACEMENT AND ADJUSTMENT 1.
TPS (THROTTLE POSITION SENSOR) SYSTEM ELEC 4. Install: 9TPS 1 9Screw (TPS) 2 NOTE: 9Align the slot a in the TPS with the projection b on the carburetor while the lever 3 is held down. 9Temporarily tighten the screws (TPS). 5. Install: 9Mixing chamber top 9Carburetor Refer to “CARBURETOR AND REED VALVE” section in the CHAPTER 4. 6. Adjust: 9Idle speed for TPS adjustment Adjustment steps: 9Set the inductive tachometer (engine tachometer) to the high tension cord.
TPS (THROTTLE POSITION SENSOR) SYSTEM ELEC 8. Start the engine. 9. Adjust: 9TPS output voltage Adjustment steps: Adjust the installation angle of the TPS 1 to obtain the specified output voltage. TPS output voltage Tester selector position 0.5~0.7V DCV-20 10. Put the aligning marks a on the TPS and carburetor. 11. Stop the engine. 12. Remove: 9Carburetor Refer to “CARBURETOR AND REED VALVE” section in the CHAPTER 4. 13.
TPS (THROTTLE POSITION SENSOR) SYSTEM EC694000 1 TPS INPUT VOLTAGE INSPECTION 1. Disconnect the TPS coupler. 2. Start the engine. 3. Inspect: 9TPS input voltage Out of specification → Replace the CDI unit.
SETTING TUN EC700000 TUNING EC710000 ENGINE EC711001 Carburetor setting 9The role of fuel is to cool the engine, and in the case of a 2-stroke engine, to lubricate the engine in addition to power generation. Accordingly, if a mixture of air and fuel is too lean, abnormal combustion will occur, and engine seizure may result. If the mixture is too rich, spark plugs will get wet with oil, thus making it impossible to bring the engine into full play or if the worst comes to the worst, the engine may stall.
SETTING TUN That is: 9Higher temperature expands the air with its resultant reduced density. 9Higher humidity reduces the amount of oxygen in the air by so much of the water vapor in the same air. 9Lower atmospheric pressure (at a high altitude) reduces the density of the air.
SETTING TUN EC714032 Effects of setting parts in relation to throttle valve opening Setting part Throttle valve opening Full-closed 1/4 1/2 3/4 Full-open Jet needle Pilot jet Pilot air screw Diameter of straight portion Clip position Throttle valve Power jet Main jet NOTE: The power jet closes at 8,500 rpm of the engine, after which only the main jet dominates.
SETTING TUN EC716001 Pilot air screw adjustment The richness of air-fuel mixture with full closed to 1/8 throttle can be set by turning the pilot air screw 1. Turning in the pilot air screw will enrich the mixture at low speeds, and turning out it will lean out the mixture.
SETTING TUN 1. Too rich at intermediate speeds Rough engine operation is felt and the engine will not pick up speed smoothly. In this case, step up the jet needle clip by one groove and move down the needle to lean out the mixture. 2. Too lean at intermediate speeds The engine breathes hard and will not pick up speed quickly. Step up the jet needle clip by one groove and move up the needle to enrich the mixture.
SETTING TUN EC719081 Jet needle adjustment (For USA, CDN, ZA, AUS and NZ) On the carburetors used in the YZ250, the main nozzle is press-fitted, so it can not be replaced. Therefore, carburetor setting requires the change of the jet needle. 1. The jet needle setting parts, having the same taper angle, are available in different straight portion diameters and in different taper starting positions. Standard jet needle N3EJ N3EJ - 2 A B c d 2.
SETTING TUN EC719081 Jet needle adjustment (For EUROPE) On the carburetors used in the YZ250, the main nozzle is press-fitted, so it can not be replaced. Therefore, carburetor setting requires the change of the jet needle. 1. The jet needle setting parts, having the same taper angle, are available in different straight portion diameters and in different taper starting positions. Standard jet needle N3EW N3EW - 3 A B c d 2.
SETTING TUN EC71B011 Relationship with throttle opening The flow of the fuel through the carburetor main system is controlled by the main jet and then, it is further regulated by the area between the main nozzle and the jet needle.
TUN SETTING EC71Q000 Carburetor setting parts Part name Main jet 1 Rich *(STD) (STD) Lean Pilot jet 2 Rich *(STD) (STD) Lean Size Part number #190 #188 #185 #182 #180 #178 #175 #172 #170 #168 #165 #162 4MX-14943-45 4MX-14943-95 4MX-14943-44 4MX-14943-94 4MX-14943-43 4MX-14943-93 4MX-14943-42 4MX-14943-92 4MX-14943-41 4MX-14943-91 4MX-14943-40 4MX-14943-90 #62 #60 #58 #55 #52 #50 #48 #45 #42 #40 #38 4MX-14948-12 4MX-14948-11 4MX-14948-10 4MX-14948-09 4MX-14948-08 4MX-14948-07 4MX-14948-06 4MX-1
SETTING TUN EC71C030 Road condition and examples of carburetor setting Conditions General condition Sandy condition Under 10°C (50°F) (Winter) 10~25°C (50~77°F) (Spring, Autumn) Over 25°C (77°F) (Summer) Under 10°C (50°F) (Winter) 10~25°C (50~77°F) (Spring, Autumn) Over 25°C (77°F) (Summer) #178 *#180 #178 #178 #180 *#182 #178 *#180 #178 N3EW-3 N3EJ-2 *N3CW-3 N3CJ-2 *N3EW-2 N3CW-3 *N3CW-4 N3CW-3 *N3EW-3 N3CW-3 *N3EW-3 Pilot jet #50 #50 #50 #52 #52 #52 Pilot air screw -1/4 Ze
SETTING Symptom Setting TUN Checking Number of turns-back → Correct properly Overflow from carburetor 0~1/4 throttle Hard breathing Speed down Use jet needle having a smaller diameter. 0~1/4 throttle Poor acceleration White smoke Use jet needle having a larger diameter. Unstable at low speeds Pinking noise Lower jet needle clip position. (1 groove down) Turn in pilot air screw. Poor response at extremely low speed Reduce pilot jet calibration No. Turn out pilot air screw.
SETTING TUN EC71M010 Change of the heat range of spark plugs Judging from the discoloration of spark plugs, if they are found improper, it can be corrected by the following two methods; changing carburetor settings and changing the heat range of spark plug. Standard spark plug BR8EG/NGK (resistance type) 9In principle, it is advisable to first use spark plugs of standard heat range, and judging from the discoloration of spark plugs, adjust carburetor settings. 9If the calibration No.
SETTING TUN EC720000 CHASSIS EC71P002 Selection of the secondary reduction ratio (Sprocket) Secondary Number of driven sprocket teeth reduction = Number of drive sprocket teeth ratio Standard secondary reduction ratio 50/14 (3.571) *49/14 (3.500) *For EUROPE and CDN 9It 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.
SETTING TUN EC72N000 Drive and driven sprockets setting parts Part name Size Part number Drive sprocket 1 (STD) 13T 14T 9383E-13144 9383E-14215 Driven sprocket 2 47T 48T 49T 50T 51T 52T 1C3-25447-00 1C3-25448-00 1C3-25449-00 1C3-25450-00 1C3-25451-00 1C3-25452-00 *(STD) (STD) *For EUROPE and CDN EC721003 Tire pressure Tire pressure should be adjust to suit the road surface condition of the circuit. Standard tire pressure: 100 kPa (1.
SETTING TUN EC722011 Front fork setting The front fork setting should be made depending on the rider’s feeling of an actual run and the circuit conditions. The front fork setting includes the following three factors: 1. Setting of air spring characteristics 9Change the fork oil amount. 2. Setting of spring preload 9Change the spring. 9Install the adjustment washer. 3. Setting of damping force 9Change the compression damping. 9Change the rebound damping.
SETTING TUN EC727030 Spring preload adjustment The spring preload is adjusted by installing the adjustment washer 1 between the spacer 2 and fork spring 3. cC Do not install three or more adjustment washers for each front fork. w Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability.
SETTING TUN 2. Use of stiff spring Generally a stiff spring gives a stiff riding feeling. Rebound damping tends to become weaker, resulting in lack of a sense of contact with the road surface or in a vibrating handlebar. To set a stiff spring: 9Change the rebound damping. Turn in one or two clicks. 9Change the compression damping. Turn out one or two clicks.
SETTING TUN EC72P010 Front fork setting parts 9Adjustment washer 1 TYPE (thickness) PART NUMBER T=2.3 mm (0.09 in) 1C3-23364-00 9Front fork spring 2 TYPE SPRING SPRING RATE PART NUMBER I.D. MARK (slits) SOFT 0.398 0.408 0.418 0.428 1C3-23141-00 1C3-23141-10 1C3-23141-20 1C3-23141-30 I II III IIII STD 0.438 1P8-23141-L0 – STIFF 0.449 0.459 0.469 0.479 1C3-23141-50 1C3-23141-60 1C3-23141-70 1C3-23141-80 I-I I-II I-III I-IIII NOTE: The I.D.
SETTING TUN EC72B000 Rear suspension setting The rear suspension setting should be made depending on the rider’s feeling of an actual run and the circuit conditions. The rear suspension setting includes the following two factors: 1. Setting of spring preload 9Change the set length of the spring. 9Change the spring. 2. Setting of damping force 9Change the rebound damping. 9Change the compression damping. EC72C001 Choosing set length 1.
SETTING TUN NOTE: 9If the machine is new and after it is broken in, the same set length of the spring may change because of the initial fatigue, etc. of the spring. Therefore, be sure to make re-evaluation. 9If the standard figure cannot be achieved by adjusting the spring adjuster and changing the spring set length, replace the spring with an optional one and make re-adjustment.
SETTING TUN cC When using a rear cushion other than currently installed, use the one whose overall length a does not exceed the standard as it may result in faulty performance. Never use one whose overall length is greater than standard. Length a of standard shock: 490.5 mm (19.
SETTING TUN EC72Q011 Rear shock absorber setting parts 9Rear shock spring 1 [Equal pitch spring ] TYPE SPRING I.D. SPRING SPRING COLOR FREE RATE PART NUMBER /POINT LENGTH SOFT 4.3 4.5 4.7 5UN-22212-00 5UN-22212-10 5UN-22212-20 Brown/1 Green/1 Red/1 260 260 260 STD 4.9 5UN-22212-30 Black/1 260 STIFF 5.1 5.3 5.5 5.7 5UN-22212-40 5UN-22212-50 5UN-22212-60 5UN-22212-70 Blue/1 Yellow/1 Pink/1 White/1 260 260 260 260 [Unequal pitch spring ] SPRING I.D.
SETTING TUN EC72H010 Suspension setting 9Front fork NOTE: 9If 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. 9Before any change, set the rear shock absorber sunken length to the standard figure 90~100 mm (3.5~3.9 in).
SETTING TUN 9Rear shock absorber NOTE: 9If 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. 9Adjust the rebound damping in 2-click increments or decrements. 9Adjust the low compression damping in 1-click increments or decrements. 9Adjust the hight compression damping in 1/6 turn increments or decrements.
1P8-9-10 hyoshi 12/5/04 2:31 PM Page 1 PROTECT YOUR INVESTMENT Use Genuine YAMAHA Parts And Accessories YZ250T1 OWNER’S SERVICE MANUAL YZ250T1 PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN JAPAN 2004.5—2.
