OWNER’S SERVICE MANUAL WR250FR LIT-11626-16-48 5UM-28199-10
WR250FR OWNER’S SERVICE MANUAL ©2002 by Yamaha Motor Corporation, U.S.A. 1st Edition, November 2002 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 WR 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.
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. SAFETY INFORMATION 1. THIS MACHINE IS TO BE OPERATED BY AN EXPERIENCED RIDER ONLY. Do not attempt to operate this machine at maximum power until you are totally familiar with its characteristics. 2.
6. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes. 7. ONLY OPERATE THE MACHINE IN AN AREA WITH ADEQUATE VENTILATION. Never start the engine or let it run for any length of time in an enclosed area. Exhaust fumes are poisonous.
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. NOTE: This manual should be considered a permanent part of this machine and should remain with it even if the machine is subsequently sold.
EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the 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., • Bearings Pitting/damage → Replace.
1 ILLUSTRATED SYMBOLS (Refer to the illustration) 2 GEN INFO 3 Illustrated symbols 1 to 7 are designed as thumb tabs to indicate the chapter’s number and content. SPEC 4 INSP ADJ 5 ENG 6 CHAS ELEC – + 1 General information 2 Specifications 3 Regular inspection and adjustments 4 Engine 5 Chassis 6 Electrical 7 Tuning 8 Illustrated symbols 8 to D are used to identify the specifications appearing in the text.
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EC090000 INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS GEN INFO 1 SPEC 2 INSP ADJ 3 ENG 4 CHAS 5 – ELECTRICAL TUNING + ELEC 6 TUN 7
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 ......................... 1-10 FUEL ....................................................... 1-14 STARTING AND BREAK-IN ................... 1-15 TORQUE-CHECK POINTS .....................
CHAPTER 4 ENGINE SEAT, FUEL TANK AND SIDE COVERS .......................................... 4-1 EXHAUST PIPE AND SILENCER ............ 4-3 RADIATOR ................................................ 4-5 CARBURETOR ......................................... 4-8 CAMSHAFTS .......................................... 4-22 CYLINDER HEAD ................................... 4-31 VALVES AND VALVE SPRINGS ........... 4-34 CYLINDER AND PISTON ....................... 4-43 CLUTCH ...........................................
CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ................................... 6-1 MAP-CONTROLLED CDI UNIT ................ 6-2 IGNITION SYSTEM ................................... 6-3 ELECTRIC STARTING SYSTEM .............. 6-8 CHARGING SYSTEM ............................. 6-17 THROTTLE POSITION SENSOR SYSTEM .................................................. 6-19 LIGHTING SYSTEM ................................ 6-24 CHAPTER 7 TUNING ENGINE ...............................................
GEN INFO DESCRIPTION EC100000 GENERAL INFORMATION EC110000 DESCRIPTION 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N O P Clutch lever Hot starter lever Engine stop switch Trip meter Main switch Light switch Start switch Front brake lever Throttle grip Radiator cap Fuel tank cap Taillight Kickstarter crank Fuel tank Headlight Radiator Coolant drain bolt Rear brake pedal Valve joint Fuel cock Cold starter knob Air cleaner Drive chain Shift pedal Oil dipstick Front fork B C D NOTE: • The machine you h
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. EC121001 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped on the right of the steering head pipe.
IMPORTANT INFORMATION GEN INFO EC130000 IMPORTANT INFORMATION EC131010 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. When washing the machine with high pressured water, cover the parts follows. • Silencer exhaust port • Side cover air intake port • Water pump housing hole at the bottom • Drain hole on the cylinder head (right side) • All electrical components 2. Use proper tools and cleaning equipment.
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 Orings 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: • Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off. 5. If the terminal comes off, bend up the pin 1 and reinsert the terminal into the connector. 6. Connect: • Connector NOTE: The two connectors “click” together. 7. Check for continuity with a tester.
SPECIAL TOOLS GEN INFO 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: • For U.S.A. and Canada, use part number starting with “YM-”, “YU-” or “ACC-”.
SPECIAL TOOLS Part number YM-01442, 90890-01442 Tool name/How to use Fork seal driver This tool is used when install the fork oil seal. YU-3112-C, 90890-03112 Pocket tester Use this tool to inspect the coil resistance, output voltage and amperage. YU-8036-B 90890-03113 Inductive tachometer Engine tachometer This tool is needed for observing engine rpm. YM-33277-A, 90890-03141 Timing light This tool is necessary for checking ignition timing.
SPECIAL TOOLS Part number YM-04141, 90890-04141 Tool name/How to use Rotor puller This tool is used to remove the flywheel magneto. YM-34487 90890-06754 Dynamic spark tester Ignition checker This instrument is necessary for checking the ignition system components. ACC-QUICK-GS-KT 90890-85505 Quick gasket YAMAHA Bond No. 1215 This sealant (Bond) is used for crankcase mating surface, etc.
CONTROL FUNCTIONS GEN INFO EC150000 CONTROL FUNCTIONS MAIN SWITCH Functions of the respective switch positions are as follows: ON: The engine can be started only at this position. OFF: All electrical circuits are switched off. Main switch indicator light The main switch 1 is equipped with an indicator light 2 to avoid forgetting to turn it off. This light functions as follows. • It lights up with the main switch “ON”. • It goes out when the engine increases its speed after being started.
CONTROL FUNCTIONS GEN INFO 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. The lever should be pulled rapidly and released slowly for smooth starts. EC153000 SHIFT PEDAL The gear ratios of the constant-mesh 5 speed transmission are ideally spaced. The gears can be shifted by using the shift pedal 1 on the left side of the engine.
CONTROL FUNCTIONS GEN INFO 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. FUEL COCK The fuel cock supplies fuel from the tank to carburetor and also filters the fuel. The fuel cock has three positions: OFF:With the lever in this position, fuel will not flow. Always return the lever to this position when the engine is not running. ON: With the lever in this position fuel flows to the carburetor.
CONTROL FUNCTIONS GEN INFO LIGHT SWITCH The light switch 1 is located on the handlebar. EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose. CAUTION: In this installation, make sure the arrow faces the fuel tank and also downward. SPARK PLUG WRENCH This spark plug wrench 1 is used to remove and install the spark plug. 1 1 NIPPLE WRENCH This nipple wrench 1 is used to tighten the spoke.
FUEL GEN INFO FUEL Always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race. Recommended fuel: Except for ZA: Premium unleaded gasoline only with a research octane number of 95 or higher. For ZA: Premium gasoline CAUTION: Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine internal parts such as valves, piston rings, and exhaust system, etc.
STARTING AND BREAK-IN GEN INFO STARTING AND BREAK-IN WARNING 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. CAUTION: • The carburetor on this machine has a built-in accelerator pump. Therefore, when starting the engine, do not operate the throttle or the spark plug will foul.
STARTING AND BREAK-IN GEN INFO NOTE: If the engine fails to start by pushing the start switch, release the switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt. If the engine does not start with the starter motor, try using the kickstarter crank.
STARTING AND BREAK-IN GEN INFO STARTING A WARM ENGINE Do not operate the cold starter knob and throttle. Pull the hot starter lever 1 and start the engine by pushing the start switch or by kicking the kickstarter crank forcefully with a firm stroke. As soon as the engine starts, Release the hot starter lever to close the air passage. Restarting an engine after a fall Pull the hot starter lever and start the engine. As soon as the engine starts, Release the hot starter lever to close the air passage.
STARTING AND BREAK-IN GEN INFO BREAK-IN PROCEDURES 1. Before starting the engine, fill the fuel tank with the fuel. 2. Perform the pre-operation checks on the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the engine stop switch. Then, restart the engine and check its operation within no more than 5 minutes after it is restarted. 4. Operate the machine in the lower gears at moderate throttle openings for five to eight minutes. 5.
TORQUE-CHECK POINTS GEN INFO TORQUE-CHECK POINTS Frame construction Combined seat and fuel tank Frame to rear frame Fuel tank to frame Exhaust system Silencer to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Suspension Wheel Steering stem to frame Steering stem to upper bracket Upper bracket to handlebar Steering stem to handlebar Front Steering stem to front fork Front fork to upper bracket Front fork to lower bracket Rear For link typ
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: WR250FR (USA) WR250F (EUROPE) WR250F(R) (CDN, AUS, NZ, ZA) 5UM1 (USA) 5UM2 (EUROPE) 5UM4 (CDN, AUS, NZ, ZA) Model code number: 2 Dimensions: Overall length Overall width Overall height Seat height Wheelbase Minimum ground clearance Basic weight: With oil and full fuel tank Engine: Engine type Cylinder arrangement Displacement Bore × stroke Compression ratio Starting system Lubrication system: Oil type or
GENERAL SPECIFICATIONS Oil capacity: Engine oil Periodic oil change With oil filter replacement Total amount Coolant capacity (including all routes): Air filter: Fuel: Type Tank capacity Reserve Carburetor: Type Manufacturer Spark plug: Type/manufacturer Gap Clutch type: 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 Tire: Type Size (front)
GENERAL SPECIFICATIONS Brake: Front brake type Operation Rear brake type Operation Suspension: Front suspension Rear suspension Shock absorber: Front shock absorber Rear shock absorber Wheel travel: Front wheel travel Rear wheel travel Electrical: Ignition system Generator system Battery type Battery voltage/capacity Specific gravity Headlight type: Bulb wattage × quantity: Headlight Taillight SPEC Single disc brake Right hand operation Single disc brake Right foot operation Telescopic fork Swingarm (link
MAINTENANCE SPECIFICATIONS SPEC MAINTENANCE SPECIFICATIONS ENGINE Item Standard Cylinder head: Warp limit Cylinder: Bore size Out of round limit Camshaft: Drive method Camshaft cap inside diameter Camshaft outside diameter Shaft-to-cap clearance Limit ---- 0.05 mm (0.002 in) 77.00 ~ 77.01 mm (3.0315 ~ 3.0319 in) ---- ---0.05 mm (0.002 in) Chain drive (Left) 22.000 ~ 22.021 mm (0.8661 ~ 0.8670 in) 21.967 ~ 21.980 mm (0.8648 ~ 0.8654 in) 0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in) ------- 30.296 ~ 30.
MAINTENANCE SPECIFICATIONS Item SPEC Standard Timing chain: Timing chain type/No. of links Timing chain adjustment method Valve, valve seat, valve guide: Valve clearance (cold) IN EX Limit 92RH2010-114M/114 Automatic ------- 0.10 ~ 0.15 mm (0.0039 ~ 0.0059 in) 0.17 ~ 0.22 mm (0.0067 ~ 0.
MAINTENANCE SPECIFICATIONS Item Standard Stem runout limit Valve seat width 0.01 mm (0.0004 in) 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 0.9 ~ 1.1 mm (0.0354 ~ 0.0433 in) 1.6 mm (0.0630 in) 1.6 mm (0.0630 in) IN 37.81 mm (1.49 in) EX 37.54 mm (1.48 in) IN EX IN IN 29.13 mm (1.15 in) 29.30 mm (1.15 in) 99 ~ 114 N at 29.13 mm (9.9 ~ 11.4 kg at 29.13 mm, 22.27 ~ 25.57 lb at 1.15 in) 126 ~ 144 N at 29.30 mm (12.6 ~ 14.4 kg at 29.30 mm, 28.44 ~ 32.41 lb at 1.15 in) ---- 35.9 mm (1.41 in) 35.7 mm (1.
MAINTENANCE SPECIFICATIONS Item SPEC Standard Piston pin bore inside diameter Piston pin outside diameter Limit 16.002 ~ 16.013 mm (0.6300 ~ 0.6304 in) 15.991 ~ 16.000 mm (0.6296 ~ 0.6299 in) 16.043 mm (0.6316 in) 15.971 mm (0.6288 in) Barrel 0.90 × 2.75 mm (0.04 × 0.11 in) 0.15 ~ 0.25 mm (0.006 ~ 0.010 in) 0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in) ------0.50 mm (0.020 in) 0.12 mm (0.005 in) Taper 0.80 × 2.75 mm (0.03 × 0.11 in) 0.30 ~ 0.45 mm (0.012 ~ 0.018 in) 0.020 ~ 0.055 mm (0.0008 ~ 0.
MAINTENANCE SPECIFICATIONS Item SPEC Standard Limit Clutch: Friction plate thickness 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) Quantity Clutch plate thickness Quantity Warp limit 9 1.1 ~ 1.3 mm (0.043 ~ 0.051 in) 8 ---- Clutch spring free length 37.0 mm (1.46 in) Quantity Clutch housing thrust clearance 5 0.10 ~ 0.35 mm (0.0039 ~ 0.0138 in) 0.010 ~ 0.044 mm (0.0004 ~ 0.
MAINTENANCE SPECIFICATIONS Item Lubrication system: Oil filter type Oil pump type Tip clearance Side clearance Housing and rotor clearance Cooling: Radiator core size Width Height Thickness Radiator cap opening pressure Radiator capacity (total) Water pump Type SPEC Standard Limit Paper type Trochoid type 0.12 mm or less (0.0047 in or less) 0.09 ~ 0.17 mm (0.0035 ~ 0.0067 in) 0.03 ~ 0.10 mm (0.0012 ~ 0.0039 in) ------0.20 mm (0.008 in) 0.24 mm (0.009 in) 0.17 mm (0.0067 in) 117.8 mm (4.
MAINTENANCE SPECIFICATIONS Part to be tightened Spark plug Camshaft cap Cylinder head blind plug screw Cylinder head (stud bolt) (stud bolt) (bolt) (nut) Cylinder head cover Cylinder Balancer weight Balancer shaft driven gear Timing chain guide (intake side) Timing chain tensioner Timing chain tensioner cap bolt Impeller Radiator hose clamp Coolant drain bolt Water pump housing Radiator Radiator guard Radiator pipe Oil pump cover Oil pump Oil filter element drain bolt Oil filter element cover Oil strainer O
MAINTENANCE SPECIFICATIONS Part to be tightened Silencer Silencer clamp Spark arrester (for USA) Silencer end pipe (for USA) Crankcase Crankcase bearing stopper Crankcase bearing stopper (crankshaft) Left crankcase cover Idle gear cover (starter motor) Idle gear plate Right crankcase cover Clutch cover Crankcase oil drain bolt Drive chain sprocket cover Kick shaft ratchet wheel guide Kickstarter crank Starter clutch Primary drive gear Clutch spring Clutch boss Push lever shaft Drive sprocket Drive axle oil
MAINTENANCE SPECIFICATIONS SPEC 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 level (From top of outer tube with inner tube and damper rod fully compressed without spring.) Oil grade Inner tube outer diameter Front fork top end Rear suspension: Shock absorber travel Spring free length Fitting length
MAINTENANCE SPECIFICATIONS Item Wheel: Front wheel type Rear wheel type Front rim size/material Rear rim size/material Rim runout limit: Radial Lateral SPEC Standard USA, CDN, ZA EUROPE, AUS, NZ Spoke wheel ← Spoke wheel ← 21 × 1.60/Aluminum ← 18 × 1.85/Aluminum 18 × 2.15/Aluminum ---- ---- ---- ---- Limit ------------2.0 mm (0.08 in) 2.0 mm (0.08 in) Drive chain: Type/manufacturer Number of links Chain slack Chain length (10 links) DID520VM/DAIDO 113 links + joint 40 ~ 50 mm (1.6 ~ 2.
MAINTENANCE SPECIFICATIONS Part to be tightened Upper bracket and outer tube Lower bracket and outer tube Upper bracket and steering stem Handlebar upper holder and upper bracket Steering stem and steering ring nut Front fork and front fork cap bolt Front fork and base valve Front fork cap bolt and damper rod Front fork bleed screw and front fork cap bolt Front fork and front fork protector Front fork and brake hose holder Front fork and brake hose cover (M8) (M6) Throttle grip cap Front brake master cylind
MAINTENANCE SPECIFICATIONS Part to be tightened Nipple (spoke) Rear wheel sprocket Rear brake disc cover Rear brake caliper protector Drive chain puller adjust bolt and locknut Engine mounting: Engine and engine bracket (front) Engine and frame (lower) Engine bracket and frame Engine and engine bracket (upper) Lower engine guard Left engine guard Right engine guard Regulator bracket and frame Regulator Pivot shaft and nut Relay arm and swingarm Relay arm and connecting rod Connecting rod and frame Rear shoc
MAINTENANCE SPECIFICATIONS Part to be tightened Headlight (left and right) Headlight (lower) Taillight Taillight lead clamp and rear fender Coolant reservoir Sidestand bracket and frame Sidestand Thread size Q’ty M6 × 1.0 M6 × 1.0 M6 × 1.0 M4 × 1.59 M6 × 1.0 M10 × 1.25 M10 × 1.25 2 1 3 2 2 2 1 SPEC Tightening torque Nm m·kg ft·lb 10 7 4 0.5 7 66 64 1.0 0.7 0.4 0.05 0.7 6.6 6.4 7.2 5.1 2.9 0.36 5.
MAINTENANCE SPECIFICATIONS SPEC EC212300 ELECTRICAL Item Ignition system: Advancer type CDI: Pickup coil resistance (color) CDI unit-model/manufacturer Ignition coil: Model/manufacturer Minimum spark gap Primary coil resistance Secondary coil resistance Charging system: System type Model/manufacturer Normal output Charging coil resistance (color) Lighting coil resistance (color) Rectifier/regulator: Regulator type Model/manufacture Regulated voltage (AC) Regulated voltage (DC) Rectifier capacity (AC) Rec
MAINTENANCE SPECIFICATIONS Item Starter relay: Model/manufacturer Amperage rating Coil winding resistance Starting circuit cut-off relay: Model/manufacturer Coil winding resistance Fuse (amperage × quantity): Main fuse Reserve fuse Part to be tightened Stator Holder (AC magneto lead) Rotor Neutral switch Starter motor Starter relay terminal Negative lead and cylinder head SPEC Standard Limit 2768090-A/JIDECO 180 A 4.2 ~ 4.6 Ω at 20 °C (68 °F) ---------- ACM33221 M06/MATSUSHITA 75.69 ~ 92.
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 Fuel tank breather hose 2 Oil tank breather hose 3 Clamp 4 Diode 5 Wire harness 6 Hot starter cable 7 Throttle position sensor lead 8 Neutral switch lead 9 Oil hose 0 Hose guide A AC magneto lead B Cylinder head breather hose C Starter motor lead D Clutch cable E Radiator hose 1 F Radiator pipe (radiator hose 4) 2 - 20 G Cable guide H Negative battery lead I Light switch lead J Brake hose K Carburetor breather hose L Carburetor overflow hose
CABLE ROUTING DIAGRAM È Insert the fuel tank breather hose into the hole in the steering stem cap. É Pass the oil tank breather hose on the outside of the AC magneto lead, neutral switch lead, light switch lead, wire harness, starter motor lead, negative battery lead and cylinder head breather hose. Ê Fasten the diode and rectifier/regulator lead, with the diode at its white tape and the rectifier/regulator lead at its protecting tube.
CABLE ROUTING DIAGRAM Î Fasten the wire harness at its white tape. Ï Fasten the wire harness, throttle position sensor lead (in the wire harness), starter motor lead and negative battery lead. Ð Make sure that the throttle position sensor coupler does not go outside the chassis. Ñ Fasten the throttle position sensor lead. Ò Pass the carburetor breather hoses, carburetor overflow hose and coolant reservoir breather hose between the connecting rod and cross tube (frame).
CABLE ROUTING DIAGRAM × Pass the cylinder head breather hose on the inside of the radiator hose 1 and on the outside of the radiator pipe (radiator hose 4). Make sure that the cylinder head breather hose does not go forward of the chassis. Ø Pass the starter motor lead in front of the radiator hose 4. Ù Pass the clutch cable through the cable guide. Ú Pass the wire harness on the outside of the neutral switch lead and AC magneto lead. Û Fit the brake hose into the guides on the protector.
CABLE ROUTING DIAGRAM 1 Hot starter cable 2 Cable guide 3 Throttle cable (return) 4 Throttle cable (pull) 5 Ignition coil 6 Coolant reservoir breather hose 7 Rectifier/regulator 8 Coolant reservoir hose 9 Rectifier/regulator lead 0 Clamp A CDI unit lead B CDI unit C CDI unit band D CDI unit stay E Rectifier/regulator bracket È Pass the throttle cables and hot starter cable through the cable guides.
CABLE ROUTING DIAGRAM Ì Fasten the coolant reservoir breather hose and carburetor breather hoses together. Í Fasten the CDI unit lead. Î Insert the CDI unit band over the CDI unit stay as far as possible. Ï Fasten the rectifier/regulator lead to the rectifier/ regulator bracket with a plastic locking tie and cut off the tie end.
CABLE ROUTING DIAGRAM 1 Brake master cylinder 2 Brake hose holder 3 Brake hose SPEC È Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the brake caliper. É Pass the brake hose into the brake hose holders. Ê If the brake hose contacts the spring (rear shock absorber), correct its twist. Ë Install the brake hose so that its pipe portion directs as shown and lightly touches the projection on the brake master cylinder.
CABLE ROUTING DIAGRAM 1 Starter motor lead 2 Negative battery lead 3 Wire harness 4 Clamp 5 Taillight lead 6 Coolant reservoir breather hose 7 Coolant reservoir hose 8 Positive battery lead 9 Starting circuit cut-off relay 0 Battery SPEC È Position the starter motor lead, negative battery lead and wire harness in the tank damper slit. É Fasten the wire harness. Ê Do not allow the taillight lead to slacken. Ë Fasten the coolant reservoir breather hose, coolant reservoir hose and rectifier/regulator lead.
CABLE ROUTING DIAGRAM 1 Throttle cable 2 Brake hose 3 Clamp 4 Light switch lead 5 Hot starter cable 6 Clutch cable 7 Hose guide 8 Clutch switch lead 9 Engine stop switch lead 0 Trip meter cable A Main switch lead B Trip meter C Main switch D Light switch E Start switch lead È Fasten the start switch lead and light switch lead. É Fasten the engine stop switch lead and clutch switch lead. Ê Pass the brake hose through the hose guide.
MAINTENANCE INTERVALS INSP ADJ EC300000 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer.
MAINTENANCE INTERVALS Item After Every Every third Every fifth As re(or (or break-in race 500 km) 1,000 km) quired SHIFT FORK, SHIFT CAM, GUIDE BAR Inspect ROTOR NUT Retighten EXHAUST PIPE, SILENCER, PROTECTOR Inspect and retighten Clean Replace *SPARK ARRESTER Clean INSP ADJ Remarks Inspect wear * Whichever comes first (Every six months) CRANK Inspect and clean CARBURETOR Inspect, adjust and clean SPARK PLUG Inspect and clean Replace DRIVE CHAIN Lubricate, slack, alignment Replace COOLING SYSTEM Che
MAINTENANCE INTERVALS Item INSP ADJ After Every Every third Every fifth As re(or (or break-in race 500 km) 1,000 km) quired FRONT FORKS Inspect and adjust Replace oil Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube REAR SHOCK ABSORBER Inspect and adjust Lube Remarks Suspension oil “01” Lithium base grease Molybdenum disulfide (After grease rain ride) Retighten DRIVE CHAIN GUIDE AND ROLLERS Inspect SWINGARM Inspect, lube and retighten RELAY ARM, CONNECTING ROD Inspect, lube and reti
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.
ENGINE/COOLANT LEVEL INSPECTION/ COOLANT REPLACEMENT INSP ADJ EC350000 ENGINE COOLANT LEVEL INSPECTION WARNING 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 CAUTION: 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: • Seat Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 4. 3. Disconnect: • Coolant reservoir hose 1 Drain the coolant completely. 4. Connect: • Coolant reservoir hose COOLANT FULL 1 LOW 5. Remove: • Engine guard 1 • Coolant drain bolt 2 6. Remove: • Radiator cap Drain the coolant completely. 7.
COOLANT REPLACEMENT INSP ADJ 9. Fill: • Radiator • Engine To specified level. Recommended coolant: High quality ethylene glycol anti-freeze containing anti-corrosion for aluminum engine Coolant 1 and water (soft water) 2 mixing ratio: 50%/50% Coolant capacity: 1.3 L (1.14 Imp qt, 1.37 US qt) CAUTION: • Do not mix more than one type of ethylene glycol antifreeze containing corrosion inhibitors for aluminum engine. • Do not use water containing impurities or oil.
RADIATOR CAP INSPECTION/ RADIATOR CAP OPENING PRESSURE INSPECTION INSP ADJ 12. Install: • Coolant reservoir cap 13. Start the engine and let it warm up for several minutes. 14. Turn off the engine and inspect the coolant level. Refer to “COOLANT LEVEL INSPECTION” section. NOTE: Before checking the coolant level wait a few minutes until the coolant settles. EC355000 RADIATOR CAP INSPECTION 1. Inspect: • Seal (radiator cap) 1 • Valve and valve seat 2 Crack/damage → Replace.
COOLING SYSTEM INSPECTION/ CLUTCH ADJUSTMENT INSP ADJ 2. Apply the specified pressure. Radiator cap opening pressure: 110 kPa (1.1 kg/cm2, 15.6 psi) 3. Inspect: • Pressure Impossible to maintain the specified pressure for 10 seconds → Replace. COOLING SYSTEM INSPECTION 1. Inspect: • Coolant level 2. Attach: • Radiator cap tester 1 and adapter 2 Radiator cap tester: YU-24460-01/90890-01325 Radiator cap tester adapter: YU-33984/90890-01352 3. Apply the specified pressure. Standard pressure: 180 kPa (1.
THROTTLE CABLE ADJUSTMENT INSP ADJ 2. Adjust: • Clutch lever free play Clutch lever free play adjustment steps: • Loosen the locknuts 1. • Adjust the free play by changing their tightening position. • Tighten the locknuts. NOTE: • Make minute adjustment on the lever side using the adjuster 2. • After adjustment, check proper operation of clutch lever. THROTTLE CABLE ADJUSTMENT 1. Check: • Throttle grip free play a Out of specification → Adjust. Throttle grip free play a: 3 ~ 5 mm (0.12 ~ 0.20 in) 2 2.
THROTTLE LUBRICATION/ HOT STARTER LEVER ADJUSTMENT INSP ADJ THROTTLE LUBRICATION 1. Remove: • Cover (throttle cable cap) 1 • Cover (grip cap) 2 • Throttle grip cap 3 2. Apply: • Lithium soap base grease On the throttle cable end a. 3. Install: • Throttle grip cap • Screw (throttle grip cap) T. R. 4 Nm (0.4 m · kg, 2.9 ft · lb) • Cover (grip cap) • Cover (throttle cable cap) HOT STARTER LEVER ADJUSTMENT 1. Check: • Hot starter lever free play a Out of specification → Adjust.
AIR FILTER CLEANING INSP ADJ AIR FILTER CLEANING NOTE: Proper air filter maintenance is the biggest key to preventing premature engine wear and damage. CAUTION: 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: • Air filter case cover 1 NOTE: Loosen the quick screw 2 and draw the air filter case cover to remove it because its claws a are inserted in the side cover as shown. 2.
AIR FILTER CLEANING INSP ADJ CAUTION: • Do not twist the element when squeezing the element. • Leaving too much of solvent in the element may result in poor starting. 5. Inspect: • Air filter element Damage → Replace. 6. Apply: • Foam-air-filter oil or equivalent oil to the element NOTE: • Squeeze out the excess oil. Element should be wet but not dripping. • Wipe off the oil left on the element surface using a clean dry cloth. (Excess oil in the element may adversely affect engine starting.) 7.
ENGINE OIL LEVEL INSPECTION INSP ADJ ENGINE OIL LEVEL INSPECTION 1. Start the engine, warm it up for several minutes, and then turn off the engine and wait for five minutes. 2. Place the machine on a level place and hold it up on upright position by placing the suitable stand under the engine. 3. Remove: • Oil tank cap 1 1 4. Inspect: • Oil level Oil level should be between maximum a and minimum b marks. Oil level is low → Add oil to proper level.
ENGINE OIL REPLACEMENT -20 -10 Temp. 0 10 (Except for USA and CDN) ˚C 20 30 40 50 Recommended oil: Refer to the following chart for selection of oils which are suited to the atmospheric temperatures. Recommended engine oil classification: API STANDARD: API “SG” or higher grade (Designed primarily for motorcycles) 10W-30 10W-40 15W-40 20W-40 20W-50 -4 14 30 50 68 86 104 INSP ADJ 122 ˚F a CAUTION: • Do not add any chemical additives or use oils with a grade of CD a or higher.
ENGINE OIL REPLACEMENT INSP ADJ 4. Remove: • Oil tank cap 1 • Oil filler cap 2 • Frame oil drain bolt 3 • Crankcase oil drain bolt 4 • Oil filter element drain bolt 5 Drain the crankcase and oil tank (frame) of its oil. 1 5. Remove: • Lower engine bracket • Oil hose clamp 1 • Bolt (oil hose) 2 • Oil hose 3 • Oil strainer (frame) 4 6. Inspect: • Oil strainer (frame) Clogged → Blow. 7. If the oil filter is to be replaced during this oil change, remove the following parts and reinstall them.
ENGINE OIL REPLACEMENT INSP ADJ 8. Install: • Copper washer 1 New • Oil strainer (frame) 2 T. R. 70 Nm (7.0 m · kg, 50 ft · lb) • Oil hose 3 • Bolt (oil hose) 4 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) • Oil hose clamp 5 T. R. 2 Nm (0.2 m · kg, 1.4 ft · lb) • Lower engine bracket T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) 9. Install: • Copper washer New • Oil filter element drain bolt T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) • Crankcase oil drain bolt T. R. 20 Nm (2.
OIL PRESSURE INSPECTION/ PILOT SCREW ADJUSTMENT INSP ADJ OIL PRESSURE INSPECTION 1. Check: • Oil pressure Checking steps: • Slightly loosen the oil pressure check bolt 1. • Start the engine and keep it idling until oil starts to seep from the oil pressure check bolt. If no oil comes out after one minute, turn the engine off so it will not seize. • Check oil passages and oil pump for damage or leakage. • Start the engine after solving the problem(s) and recheck the oil pressure.
ENGINE IDLING SPEED ADJUSTMENT/ VALVE CLEARANCE INSPECTION AND ADJUSTMENT INSP ADJ ENGINE IDLING SPEED ADJUSTMENT 1. Start the engine and thoroughly warm it up. 2. Attach: • Inductive tachometer To spark plug lead. 3. Adjust: • Engine idling speed Adjustment steps: • Adjust the pilot screw. Refer to “PILOT SCREW ADJUSTMENT” section. • 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 a.
VALVE CLEARANCE INSPECTION AND ADJUSTMENT INSP ADJ 3. Remove: • Right radiator Refer to “RADIATOR” section in the CHAPTER 4. • Carburetor Refer to “CARBURETOR” section in the CHAPTER 4. • Spark plug • Upper engine bracket • Cylinder head cover Refer to “CAMSHAFTS” section in the CHAPTER 4. 4. Remove: • Timing mark accessing screw 1 • Crankshaft end accessing screw 2 • O-ring 5. Check: • Valve clearance Out of specification → Adjust. Valve clearance (cold): Intake valve: 0.10 ~ 0.15 mm (0.0039 ~ 0.
VALVE CLEARANCE INSPECTION AND ADJUSTMENT INSP ADJ • Measure the valve clearance e using a feeler gauge 1. NOTE: Record the measured reading if the clearance is incorrect. 6. Adjust: • Valve clearance Adjustment steps: • Remove the camshaft (intake and exhaust). Refer to “CAMSHAFTS” section in the CHAPTER 4. • Remove the valve lifters 1 and the pads 2. NOTE: • Place a rag in the timing chain space to prevent pads from falling into the crankcase.
VALVE CLEARANCE INSPECTION AND ADJUSTMENT INSP ADJ NOTE: The thickness a of each pad is indicated in hundreths of millimeters on the pad upper surface. • Round off the last digit of the installed pad number to the nearest increment. Last digit of pad Rounded value number 0, 1 or 2 0 4, 5 or 6 5 8 or 9 10 EXAMPLE: Installed pad number = 148 Rounded off value = 150 NOTE: Pads can only be selected in 0.05 mm increments.
VALVE CLEARANCE INSPECTION AND ADJUSTMENT INSP ADJ INTAKE MEASURED CLEARANCE 0.00 ~ 0.04 0.05 ~ 0.09 0.10 ~ 0.15 0.16 ~ 0.20 0.21 ~ 0.25 0.26 ~ 0.30 0.31 ~ 0.35 0.36 ~ 0.40 0.41 ~ 0.45 0.46 ~ 0.50 0.51 ~ 0.55 0.56 ~ 0.60 0.61 ~ 0.65 0.66 ~ 0.70 0.71 ~ 0.75 0.76 ~ 0.80 0.81 ~ 0.85 0.86 ~ 0.90 0.91 ~ 0.95 0.96 ~ 1.00 1.01 ~ 1.05 1.06 ~ 1.10 1.11 ~ 1.15 1.16 ~ 1.20 1.21 ~ 1.25 1.26 ~ 1.30 1.31 ~ 1.
SPARK ARRESTER CLEANING (For USA) INSP ADJ SPARK ARRESTER CLEANING (For USA) WARNING • Be sure the exhaust pipe and muffler are cool before cleaning the spark arrester. • Do not start the engine when cleaning the exhaust system. 1. Remove: • Bolt (spark arrester) 1 1 1 2. Remove: • Spark arrester 1 Pull the spark arrester out of the muffler. 1 3. Clean: • Spark arrester Tap the spark arrester lightly, then use a wire brush to remove any carbon deposits. 4.
CHASSIS/BRAKE SYSTEM AIR BLEEDING INSP ADJ EC360000 CHASSIS EC361012 BRAKE SYSTEM AIR BLEEDING WARNING Bleed the brake system if: • The system has been disassembled. • A brake hose has been loosened or removed. • The brake fluid is very low. • The brake operation is faulty. A dangerous loss of braking performance may occur if the brake system is not properly bled. 1. Remove: • Brake master cylinder cap • Diaphragm • Protector (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. WARNING Check the operation of the brake after bleeding the brake system. 3. Install: • Protector (rear brake) • Diaphragm • Brake master cylinder cap EC362040 FRONT BRAKE ADJUSTMENT 1.
REAR BRAKE ADJUSTMENT/ FRONT BRAKE PAD INSPECTION AND REPLACEMENT INSP ADJ EC364002 REAR BRAKE ADJUSTMENT 1. Check: • Brake pedal height a Out of specification → Adjust. Brake pedal height a: 5 mm (0.20 in) 2. Adjust: • Brake pedal height Pedal height adjustment steps: • Loosen the locknut 1. • Turn the adjusting nut 2 until the pedal height a is within specified height. • Tighten the locknut. È WARNING • Adjust the pedal height between the maximum È and the minimum É as shown.
FRONT BRAKE PAD INSPECTION AND REPLACEMENT INSP ADJ • Loosen the pad pin 2. • Remove the brake hose holder 3 and brake caliper 4 from the front fork. • Remove the pad pin and brake pads 5. • Connect the transparent hose 6 to the bleed screw 7 and place the suitable container under its end. • Loosen the bleed screw and push the brake caliper piston in. CAUTION: Do not reuse the drained brake fluid. • Tighten the bleed screw. T. R. Bleed screw: 6 Nm (0.6 m • kg, 4.
REAR BRAKE PAD INSPECTION AND REPLACEMENT INSP ADJ • Install the pad pin plug B. T. R. Pad pin plug: 3 Nm (0.3 m • kg, 2.2 ft • lb) 3. Inspect: • Brake fluid level Refer to “BRAKE FLUID LEVEL INSPECTION” section. 4. Check: • Brake lever operation A softy or spongy feeling → Bleed brake system. Refer to “BRAKE SYSTEM AIR BLEEDING” section. REAR BRAKE PAD INSPECTION AND REPLACEMENT 1. Inspect: • Brake pad thickness a Out of specification → Replace as a set. Brake pad thickness: 6.4 mm (0.
REAR BRAKE PAD INSPECTION AND REPLACEMENT INSP ADJ • Remove the pad pin 6 and brake pads 7. • Connect the transparent hose 8 to the bleed screw 9 and place the suitable container under its end. • Loosen the bleed screw and push the brake caliper piston in. CAUTION: Do not reuse the drained brake fluid. • Tighten the bleed screw. T. R. Bleed screw: 6 Nm (0.6 m • kg, 4.3 ft • lb) • Install the brake pad 0 and pad pin A.
REAR BRAKE PAD INSULATOR INSPECTION/ BRAKE FLUID LEVEL INSPECTION INSP ADJ 3. Inspect: • Brake fluid level Refer to “BRAKE FLUID LEVEL INSPECTION” section. 4. Check: • Brake pedal operation A softy or spongy feeling → Bleed brake system. Refer to “BRAKE SYSTEM AIR BLEEDING” section. EC36b000 REAR BRAKE PAD INSULATOR INSPECTION 1. Remove: • Brake pad Refer to “REAR BRAKE PAD INSPECTION AND REPLACEMENT” section. 2. Inspect: • Rear brake pad insulator 1 Damage → Replace. È BRAKE FLUID LEVEL INSPECTION 1.
SPROCKETS INSPECTION/DRIVE CHAIN INSPECTION INSP ADJ SPROCKETS INSPECTION 1. Inspect: • Sprocket teeth a Excessive wear → Replace. NOTE: Replace the drive sprocket, rear wheel sprocket and drive chain as a set. DRIVE CHAIN INSPECTION 1. Remove: • Drive chain 1 NOTE: Remove the drive chain using a drive chain cutter 2. 2. Clean: • Drive chain Brush off as much dirt as possible. Then clean the drive chain using the chain cleaner.
DRIVE CHAIN INSPECTION INSP ADJ 5. Check: • Drive chain stiffness a Clean and oil the drive chain and hold as illustrated. Stiff → Replace the drive chain. 6. Install: • Chain joint 1 New • O-ring 2 • Drive chain 3 NOTE: When installing the drive chain, apply the lithium soap base grease on the chain joint and O-rings. 7. Install: • Link plate 4 New NOTE: • Press the link plate onto the chain joint using a drive chain riveter 5. • Rivet the end of the chain joint using a drive chain riveter.
DRIVE CHAIN SLACK ADJUSTMENT INSP ADJ DRIVE CHAIN SLACK ADJUSTMENT 1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Check: • Drive chain slack a Above the seal guard installation bolt. Out of specification → Adjust. Drive chain slack: 40 ~ 50 mm (1.6 ~ 2.0 in) NOTE: Before checking and/or adjusting, rotate the rear wheel through several revolutions and check the slack several times to find the tightest point.
FRONT FORK INSPECTION/ FRONT FORK OIL SEAL AND DUST SEAL CLEANING INSP ADJ • Tighten the axle nut while pushing down the drive chain. T. R. Axle nut: 125 Nm (12.5 m • kg, 90 ft • lb) • Tighten the locknuts. T. R. Locknut: 16 Nm (1.6 m • kg, 11 ft • lb) EC36C000 FRONT FORK INSPECTION 1. Inspect: • Front fork smooth action Operate the front brake and stroke the front fork. Unsmooth action/oil leakage → Repair or replace. EC36D001 FRONT FORK OIL SEAL AND DUST SEAL CLEANING 1.
FRONT FORK INTERNAL PRESSURE RELIEVING/FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT INSP ADJ FRONT FORK INTERNAL PRESSURE RELIEVING NOTE: If the front fork initial movement feels stiff during a run, relieve the front fork internal pressure. 1. Elevate the front wheel by placing a suitable stand under the engine. 2. Remove the air bleed screw 1 and release the internal pressure from the front fork. 3. Install: • Air bleed screw T. R. 1 Nm (0.1 m · kg, 0.
FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT INSP ADJ • STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. Standard position: 9 clicks out * 5 clicks out * For EUROPE, AUS, NZ and ZA CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. WARNING Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability.
REAR SHOCK ABSORBER INSPECTION INSP ADJ • STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. Standard position: 14 clicks out * 12 clicks out * For EUROPE, AUS, NZ and ZA CAUTION: Do not force the adjuster past the minimum or maximum extent of adjustment. The adjuster may be damaged. WARNING Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability. 3.
REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT INSP ADJ REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1. Elevate the rear wheel by placing the suitable stand under the engine. 2. Remove: • Rear frame 3. Loosen: • Locknut 1 4. Adjust: • Spring preload By turning the adjuster 2. Stiffer → Increase the spring preload. (Turn the adjuster 2 in.) Softer → Decrease the spring preload. (Turn the adjuster 2 out.) Spring length (installed) a: Standard length Extent of adjustment 245 mm (9.65 in) * 246.5 mm (9.
REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT INSP ADJ EC36N014 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1. Adjust: • Rebound damping force By turning the adjuster 1. Stiffer a → Increase the rebound damping force. (Turn the adjuster 1 in.) Softer b → 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: • Low compression damping force By turning the adjuster 1. b 1 a Stiffer a → Increase the low compression damping force. (Turn the adjuster 1 in.) Softer b → 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: • High compression damping force By turning the adjuster 1. b 1 a Stiffer a → Increase the high compression damping force. (Turn the adjuster 1 in.) Softer b → Decrease the high compression damping force. (Turn the adjuster 1 out.
TIRE PRESSURE CHECK/SPOKES INSPECTION AND TIGHTENING/WHEEL INSPECTION INSP ADJ EC36Q000 TIRE PRESSURE CHECK 1. Measure: • Tire pressure Out of specification → Adjust. Standard tire pressure: 100 kPa (1.0 kgf/cm2, 15 psi) NOTE: • Check the tire while it is cold. • Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low. • A tilted tire valve stem indicates that the tire slips off its position on the rim.
STEERING HEAD INSPECTION AND ADJUSTMENT INSP ADJ 2. Inspect: • Bearing free play Exist play → Replace. EC36U013 STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by placing a suitable stand under the engine. 2. Check: • Steering stem Grasp the bottom of the forks and gently rock the fork assembly back and forth. Free play → Adjust steering head. 3. Check: • Steering smooth action Turn the handlebar lock to lock. Unsmooth action → Adjust steering ring nut. 4.
STEERING HEAD INSPECTION AND ADJUSTMENT INSP ADJ • Tighten the steering ring nut 3 using steering nut wrench 4. NOTE: Set the torque wrench to the steering nut wrench so that they form a right angle. Steering nut wrench: YU-33975/90890-01403 T. R. Steering ring nut (initial tightening): 38 Nm (3.8 m • kg, 27 ft • lb) • Loosen the steering ring nut one turn. • Retighten the steering ring nut using the steering nut wrench. WARNING Avoid over-tightening. T. R.
LUBRICATION LUBRICATION To ensure smooth operation of all components, lubricate your machine during setup, after break-in, and after every race. 1 All control cable 2 Clutch lever pivot 3 Shift pedal pivot 4 Footrest pivot 5 Throttle-to-handlebar contact 6 Drive chain 7 Tube guide cable winding portion 8 Throttle cable end 9 Clutch cable end 0 Hot starter cable end INSP ADJ È Use Yamaha cable lube or equivalent on these areas. É Use SAE 10W-30 motor oil or suitable chain lubricants.
ELECTRICAL/SPARK PLUG INSPECTION/ IGNITION TIMING CHECK INSP ADJ EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: • Spark plug 2. Inspect: • Electrode 1 Wear/damage → Replace. • Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition. 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 2. Attach: • Timing light • Inductive tachometer To the ignition coil lead (orange lead 1). 1 Timing light: YM-33277-A/90890-03141 Inductive tachometer: YU-8036-B Engine tachometer: 90890-03113 3. Check: • Ignition timing Checking steps: • Start the engine and let it warm up. Let the engine run at the specified speed. • Adjust the engine idling speed. Refer to “ENGINE IDLING SPEED ADJUSTMENT” section.
BATTERY INSPECTION AND CHARGING INSP ADJ BATTERY INSPECTION AND CHARGING WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries. • Charge batteries in a well-ventilated area. • Keep batteries away from fire, sparks or open flames (e.g., welding equipment, lighted cigarettes).
BATTERY INSPECTION AND CHARGING INSP ADJ NOTE: Since MF batteries are sealed, it is not possible to check the charge state of the battery by measuring the specific gravity of the electrolyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals. 1. Remove: • Seat 2. Disconnect: • Battery leads (from the battery terminals) CAUTION: First, disconnect the negative battery lead 1, and then the positive battery lead 2. 3.
BATTERY INSPECTION AND CHARGING INSP ADJ 4. Measure: • Battery charge Measurement steps: • Connect a pocket tester 1 to the battery terminals. Tester positive probe → battery positive terminal Tester negative probe → battery negative terminal NOTE: • The charge state of an MF battery can be checked by measuring its open-circuit voltage (i.e., the voltage when the positive terminal is disconnected). • No charging is necessary when the opencircuit voltage equals or exceeds 12.8 V.
BATTERY INSPECTION AND CHARGING INSP ADJ 5. Charge: • Battery (refer to the appropriate charging method illustration) WARNING Do not quick charge a battery. CAUTION: • Never remove the MF battery sealing caps. • Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause battery overheating and battery plate damage. • If it is impossible to regulate the charging current on the battery charger, be careful not to overcharge the battery.
BATTERY INSPECTION AND CHARGING Charging method using a variable voltage charger 3 - 53 INSP ADJ
BATTERY INSPECTION AND CHARGING Charging method using a constant voltage charger 3 - 54 INSP ADJ
BATTERY REPLACEMENT/FUSE INSPECTION INSP ADJ 6. Install: • Battery • Battery band 7. Connect: • Battery leads (to the battery terminals) CAUTION: First, connect the positive lead 1, then the negative lead 2. 8. Check: • Battery terminals Dirt → Clean with a wire brush. Loose connection → Connect properly. 9. Lubricate: • Battery terminal Recommended lubricant: Lithium soap base grease 10. Install: • Seat BATTERY REPLACEMENT 1. Replace: • Battery CAUTION: This battery is for YAMAHA WR250F.
FUSE INSPECTION INSP ADJ 2. Check: • Continuity 2 Checking steps: • Remove the fuse 1. • Connect the pocket tester to the fuse and check the continuity. 1 NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester: YU-3112-C/90890-03112 • If the pocket tester indicates “∞”, replace the fuse. 2 Reserve fuse 3. Replace: • Blown fuse Replacement steps: • Set the main switch to “OFF”. • Install a new fuse of the correct amperage.
REPLACING THE HEADLIGHT BULBS/ ADJUSTING THE HEADLIGHT BEAMS INSP ADJ REPLACING THE HEADLIGHT BULBS 1. Remove: • Headlight Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 4. 2. Remove: • Headlight bulb holder cover 1 3. Detach: • Headlight bulb holder 1 4. Remove: • Headlight bulb 2 WARNING Since the headlight bulb gets extremely hot, keep flammable products and your hands away from the bulb unit it has cooled down. 5.
SEAT, FUEL TANK AND SIDE COVERS ENG EC400000 ENGINE SEAT, FUEL TANK AND SIDE COVERS 4 4 1 Seat removal 3 Side covers removal Extent of removal: Extent of removal Order Preparation for removal 1 3 2 3 4 1 2 3 4 5 6 7 8 9 Part name 2 Fuel tank removal 4 Headlight removal Q’ty SEAT, FUEL TANK AND SIDE COVERS REMOVAL Turn the fuel cock to “OFF”. Disconnect the fuel hose.
SEAT, FUEL TANK AND SIDE COVERS ENG REMOVAL POINTS Side cover 1. Remove: • Bolt (side cover) • Left side cover 1 • Right side cover 2 NOTE: Draw the side cover downward to remove it because its claws a are inserted in the air filter case.
EXHAUST PIPE AND SILENCER ENG EC4S0000 EXHAUST PIPE AND SILENCER È Except for USA 1 Silencer removal Extent of removal: Extent of removal Order 1 2 Part name Q’ty EXHAUST PIPE AND SILENCER REMOVAL Right side cover Preparation for removal 2 2 Exhaust pipe removal 1 2 3 4 5 6 7 8 9 Bolt (silencer clamp) Bolt [silencer (front)] Bolt [silencer (rear)] Silencer Silencer clamp Nut (exhaust pipe) Bolt (exhaust pipe) Exhaust pipe Gasket 1 1 1 1 1 1 1 1 2 4-3 Remarks Refer to “SEAT, FUEL TANK AN
EXHAUST PIPE AND SILENCER ENG INSPECTION Silencer and exhaust pipe 1. Inspect: • Gasket 1 Damage → Replace. 1 ASSEMBLY AND INSTALLATION Silencer and exhaust pipe 1. Install: • Gasket New • Exhaust pipe 1 • Nut (exhaust pipe) 2 T. R. 13 Nm (1.3 m · kg, 9.4 ft · lb) • Bolt (exhaust pipe) 3 T. R. 24 Nm (2.4 m · kg, 17 ft · lb) NOTE: First, temporarily tighten the nut (exhaust pipe), then tighten the bolt (exhaust pipe) 20 Nm (2.0 m • kg, 14 ft • lb).
RADIATOR ENG EC450001 RADIATOR 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 WARNING 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.
RADIATOR ENG 3. Install: • Right radiator 1 • Bolt (right radiator) 2 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) • Radiator hose 3 3 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. 4. Install: • Left radiator 1 • Bolt (left radiator) 2 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) • Radiator hose 1 3 T. R. 2 Nm (0.2 m · kg, 1.4 ft · lb) Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. 5. Tighten: • Radiator hose clamp 4 T. R. 2 Nm (0.2 m · kg, 1.4 ft · lb) 6.
CARBURETOR ENG CARBURETOR 1 T. 4 Nm (0.4 m • kg, 2.9 ft • Ib) R. T. R. 2 Nm (0.2 m • kg, 1.4 ft • Ib) T. R. 7 11 Nm (1.1 m • kg, 8.0 ft • Ib) 3 8 4 1 2 4 T. R. 4 Nm (0.4 m • kg, 2.9 ft • Ib) 5 6 T. R. 3 Nm (0.3 m • kg, 2.2 ft • Ib) 6 9 T. R. 1 Carburetor removal Extent of removal: Extent of removal Order Part name Q’ty CARBURETOR REMOVAL Seat and fuel tank Preparation for removal 1 2 1 3 Nm (0.3 m • kg, 2.
CARBURETOR ENG EC468000 CARBURETOR DISASSEMBLY 1 Carburetor disassembly Extent of removal: Extent of removal 1 Order Part name Q’ty 1 2 3 4 5 6 7 8 9 0 A B C D E CARBURETOR DISASSEMBLY Carburetor breather hose Valve lever housing cover Screw (throttle shaft) Throttle valve Needle holder Jet needle Accelerator pump cover Spring Diaphragm (accelerator pump) Air cut valve cover Spring (air cut valve) Diaphragm (air cut valve) Float chamber Leak jet Pilot screw 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 4-9 Re
ENG CARBURETOR Extent of removal Order 1 F G H I J K L M N O P Q R Part name Float pin Float Needle valve Main jet Needle jet Spacer Pilot jet Starter jet Push rod Throttle shaft assembly Push rod link lever assembly Pilot air jet Cold starter plunger 4 - 10 Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 Remarks Pull the push rod.
CARBURETOR ENG HANDLING NOTE CAUTION: 1 Do not loosen the screws (throttle position sensor) 1 except when changing the throttle position sensor due to failure because it will cause a drop in engine performance. REMOVAL POINTS Pilot screw 1. Remove: • Pilot screw 1 NOTE: To optimize the fuel flow at a small throttle opening, each machine’s pilot screw has been individually set at the factory. Before removing the pilot screw, turn it in fully and count the number of turns.
CARBURETOR ENG 2. Inspect: • Main jet 1 • Pilot jet 2 • Needle jet 3 • Starter jet 4 • Pilot air jet 5 • Leak jet 6 Damage → Replace. Contamination → Clean. NOTE: • Use a petroleum based solvent for cleaning. Blow out all passages and jets with compressed air. • Never use a wire. Needle valve 1. Inspect: • Needle valve 1 • Valve seat 2 Grooved wear a → Replace. Dust b → Clean. EC464301 Throttle valve 1. Check: • Free movement Stick → Repair or replace.
CARBURETOR ENG Float height 1. Measure: • Float height a Out of specification → Adjust. Float height: 8.0 mm (0.31 in) Measurement and adjustment steps: • Hold the carburetor in an upside down position. NOTE: • Slowly tilt the carburetor in the opposite direction, then take the measurement when the needle valve aligns with the float arm. • If the carburetor is level, the weight of the float will push in the needle valve, resulting in an incorrect measurement.
CARBURETOR ENG Starter plunger 1. Inspect: • Cold starter plunger 1 • Hot starter plunger 2 Wear/damage → Replace. Accelerator pump 1. Inspect: • Diaphragm (accelerator pump) 1 • Spring (accelerator pump) 2 • Accelerator pump cover 3 • O-ring 4 • Push rod 5 Tears (diaphragm)/damage → Replace. Dirt → Clean. 2. Inspect: • Throttle shaft 1 • Spring 2 • Lever 1 3 • Spring 1 4 • Lever 2 5 • Spring 2 6 Dirt → Clean. 2 1 5 6 3 4 1 Air cut valve 1.
CARBURETOR ENG 2. Install: • Pilot air jet 1 1 1 3. Install: • Spring 1 1 • Lever 1 2 To lever 2 3. a 3 NOTE: Make sure the spring 1 fits on the stopper a of the lever 2. 2 4. Install: • Spring 2 1 To lever 2 2. 1 2 5. Install: • Push rod link lever assembly 1 1 NOTE: Make sure the stopper a of the spring 2 fits into the recess b in the carburetor. b a 6.
CARBURETOR ENG 7. Install: • Spring 1 To throttle shaft 2. NOTE: Install the bigger hook a of the spring fits on the stopper b of the throttle shaft pulley. 1 23 8. Install: • Throttle shaft assembly 1 • Washer (metal) 2 • Washer (resin) 3 • Valve lever 4 4 b a c NOTE: • Apply the fluorochemical grease on the bearings. • Fit the projection a on the throttle shaft assembly into the slot b in the throttle position sensor. • Make sure the stopper c of the spring fits into the recess in the carburetor.
CARBURETOR ENG 10. Install: • Starter jet 1 • Pilot jet 2 • Spacer 3 • Needle jet 4 • Main jet 5 11. Install: • Needle valve 1 • Float 2 • Float pin 3 NOTE: • After installing the needle valve to the float, install them to the carburetor. • Check the float for smooth movement. 12. Install: • Pilot screw 1 • Spring 2 • Washer 3 • O-ring 4 Note the following installation points: • Turn in the pilot screw until it is lightly seated.
CARBURETOR 14. Install: • Diaphragm (air cut valve) 1 • Spring (air cut valve) 2 • O-ring 3 • Air cut valve cover 4 • Screw (air cut valve cover) 5 1 2 4 5 ENG 3 15. Install: • Diaphragm (accelerator pump) 1 • Spring 2 • O-ring 3 • Accelerator pump cover 4 • Hose holder (drain hose) 5 • Screw (accelerator pump cover) 6 NOTE: Install the diaphragm (accelerator pump) with its mark a facing the spring. 16.
CARBURETOR ENG 19. Install: • Carburetor breather hose 1 NOTE: Install the carburetor breather hoses to the carburetor so that the hoses do not bend near where they are installed. Accelerator pump timing adjustment Adjustment steps: NOTE: In order for the throttle valve height a to achieve the specified value, tuck under the throttle valve plate 1 the rod 2 etc. with the same outer diameter as the specified value. Throttle valve height: 1.5 mm (0.
CARBURETOR ENG 3. Install: • Hot starter plunger 1 T. R. 2 Nm (0.2 m · kg, 1.4 ft · lb) 1 4. Tighten: • Screw (air filter joint) 1 T. R. 3 Nm (0.3 m · kg, 2.2 ft · lb) • Screw (carburetor joint) 2 T. R. 3 Nm (0.3 m · kg, 2.2 ft · lb) 5. Install: • Throttle cable (pull) 1 2 T. R. 4 Nm (0.4 m · kg, 2.9 ft · lb) • Throttle cable (return) 2 T. R. 11 Nm (1.1 m · kg, 8.0 ft · lb) 6. Adjust: • Throttle grip free play Refer to “THROTTLE CABLE ADJUSTMENT” section in the CHAPTER 3. 1 7.
CARBURETOR ENG 9. Install: • Clamp 1 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2.
CAMSHAFTS ENG CAMSHAFTS CYLINDER HEAD COVER 1 Cylinder head cover removal Extent of removal: Extent of removal Order Q’ty CYLINDER HEAD COVER REMOVAL Seat and fuel tank Preparation for removal 1 Part name 1 2 3 4 5 6 7 Carburetor Spark plug Cylinder head breather hose Oil tank breather hose Bolt (cylinder head cover) Cylinder head cover Cylinder head cover gasket Timing chain guide (top side) 4 - 22 Remarks Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Refer to “CARBURETOR” section.
CAMSHAFTS ENG CAMSHAFTS 1 Camshaft removal Extent of removal: Extent of removal Order Part name Q’ty 1 1 2 3 4 5 6 7 8 CAMSHAFTS REMOVAL Timing mark accessing screw Crankshaft end accessing screw Timing chain tensioner cap bolt Timing chain tensioner Camshaft cap Clip Exhaust camshaft Intake camshaft 1 1 1 1 2 2 1 1 4 - 23 Remarks Refer to “REMOVAL POINTS”.
CAMSHAFTS ENG REMOVAL POINTS Camshaft 1. Remove: • Timing mark accessing screw 1 • Crankshaft end accessing screw 2 2. Align: • T.D.C. mark With align mark. Checking steps: • Turn the crankshaft counterclockwise with a wrench. • Align the T.D.C. mark a on the rotor with the align mark b on the crankcase cover when piston is at T.D.C. on compression stroke.
CAMSHAFTS 1 ENG 5. Remove: • Exhaust camshaft 1 • Intake camshaft 2 2 NOTE: Attach a wire 3 to the timing chain to prevent it from falling into the crankcase. 3 INSPECTION Camshaft 1. Inspect: • Cam lobe Pitting/scratches/blue discoloration → Replace. 2. Measure: • Cam lobe length a and b Out of specification → Replace. Cam lobes length: Intake: a 30.296 ~ 30.346 mm (1.1923 ~ 1.1947 in) : 30.196 mm (1.1888 in) b 22.45 ~ 22.55 mm (0.8839 ~ 0.8878 in) : 22.35 mm (0.8799 in) Exhaust: a 30.
CAMSHAFTS ENG 4. Measure: • Camshaft-to-cap clearance Out of specification → Measure camshaft outside diameter. Camshaft-to-cap clearance: 0.020 ~ 0.054 mm (0.0008 ~ 0.0021 in) : 0.08 mm (0.003 in) Measurement steps: • Install the camshaft onto the cylinder head. • Position a strip of Plastigauge® 1 onto the camshaft. • Install the clip, dowel pins and camshaft caps. T. R. Bolt (camshaft cap): 10 Nm (1.0 m • kg, 7.
CAMSHAFTS ENG Decompression system 1. Check: • Decompression system Checking steps: • Check that the decompression mechanism cam 1 moves smoothly. • Check that the decompression mechanism cam lever pin 2 projects from the camshaft. Timing chain tensioner 1. Check: • While pressing the tensioner rod lightly with fingers, use a thin screwdriver 1 and wind the tensioner rod up fully clockwise.
CAMSHAFTS ENG • Fit the timing chain 3 onto both camshaft sprockets and install the camshafts on the cylinder head. NOTE: The camshafts should be installed onto the cylinder head so that the punch mark c on the exhaust camshaft and the punch mark d on the intake camshaft must align with the cylinder head surface, as shown in the illustration. CAUTION: Do not turn the crankshaft during the camshaft installation. Damage or improper valve timing will result.
CAMSHAFTS ENG • With the rod fully wound and the chain tensioner UP mark a facing upward, install the gasket 1 and the timing chain tensioner 2, and tighten the bolt 3 to the specified torque. T. R. Bolt (timing chain tensioner): 10 Nm (1.0 m • kg, 7.2 ft • lb) • Release the screwdriver, check the tensioner rod to come out and tighten the gasket 4 and the cap bolt 5 to the specified torque. T. R. 4 New Tensioner cap bolt: 7 Nm (0.7 m • kg, 5.1 ft • lb) 3.
CAMSHAFTS ENG 6. Install: • Timing chain guide (top side) 1 • Cylinder head cover gasket 2 • Cylinder head cover 3 • Bolt (cylinder head cover) 4 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Apply the sealant on the cylinder head cover gasket. Quick gasket®: ACC-QUICK-GS-KT YAMAHA Bond No. 1215: 90890-85505 7. Install: • Oil tank breather hose • Cylinder head breather hose • Spark plug T. R. 4 - 30 13 Nm (1.3 m · kg, 9.
CYLINDER HEAD ENG CYLINDER HEAD 1 Cylinder head removal Extent of removal: Extent of removal Order Part name Q’ty CYLINDER HEAD REMOVAL Seat and fuel tank Preparation for removal Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Refer to “EXHAUST PIPE AND SILENCER” section. Disconnect at cylinder head side. Refer to “CARBURETOR” section. Refer to “CAMSHAFTS” section. Refer to “ENGINE REMOVAL” section.
CYLINDER HEAD ENG INSPECTION Cylinder head 1. Eliminate: • Carbon deposits (from the combustion chambers) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damaging or scratching: • Spark plug threads • Valve seats 2. Inspect: • Cylinder head Scratches/damage → Replace. 3. Measure: • Cylinder head warpage Out of specification → Resurface. Cylinder head warpage: Less than 0.05 mm (0.
CYLINDER HEAD ENG ASSEMBLY AND INSTALLATION Cylinder head 1. Install: • Dowel pin 1 • Cylinder head gasket 2 New • Timing chain guide (exhaust side) 3 • Cylinder head 4 NOTE: While pulling up the timing chain, install the timing chain guide (exhaust side) and cylinder head. 2. Install: • Washer 1 • Cable guide 2 • Bolts [L=145 mm (5.71 in)] 3 T. R. 38 Nm (3.8 m · kg, 27 ft · lb) • Bolts [L=135 mm (5.31 in)] 4 T. R. 38 Nm (3.8 m · kg, 27 ft · lb) • Nuts 5 T. R. 10 Nm (1.0 m · kg, 7.
VALVES AND VALVE SPRINGS ENG VALVES AND VALVE SPRINGS 1 Valve removal Extent of removal: Extent of removal Order Part name Q’ty 1 2 3 4 5 6 7 8 9 VALVES AND VALVE SPRINGS REMOVAL Cylinder head Valve lifter Adjusting pad Valve cotter Valve spring retainer Valve spring Valve stem seal Valve spring seat Exhaust valve Intake valve 5 5 10 5 5 5 5 2 3 Preparation for removal 1 4 - 34 Remarks Refer to “CYLINDER HEAD” section. Use special tool. Refer to “REMOVAL POINTS”.
VALVES AND VALVE SPRINGS ENG REMOVAL POINTS Valve lifter and valve cotter 1. Remove: • Valve lifter 1 • Pad 2 NOTE: Identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place. 2. Check: • Valve sealing Leakage at the valve seat → Inspect the valve face, valve seat and valve seat width. Checking steps: • Pour a clean solvent 1 into the intake and exhaust ports. • Check that the valve seals properly. There should be no leakage at the valve seat 2. 3.
VALVES AND VALVE SPRINGS ENG INSPECTION Valve 1. Measure: • Stem-to-guide clearance Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b Out of specification → Replace the valve guide. Clearance (stem to guide): Intake: 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) : 0.08 mm (0.003 in) Exhaust: 0.025 ~ 0.052 mm (0.0010 ~ 0.0020 in) : 0.10 mm (0.004 in) 2.
VALVES AND VALVE SPRINGS ENG Valve guide remover: Intake: 4.0 mm (0.16 in) YM-4111/90890-04111 Exhaust: 4.5 mm (0.18 in) YM-4116/90890-04116 Valve guide installer: Intake: 4.0 mm (0.16 in) YM-4112/90890-04112 Exhaust: 4.5 mm (0.18 in) YM-4117/90890-04117 Valve guide reamer: Intake: 4.0 mm (0.16 in) YM-4113/90890-04113 Exhaust: 4.5 mm (0.18 in) YM-4118/90890-04118 NOTE: After replacing the valve guide reface the valve seat. 3. Inspect: • Valve face Pitting/wear → Grind the face.
VALVES AND VALVE SPRINGS ENG 5. Measure: • Runout (valve stem) Out of specification → Replace. Runout limit: 0.01 mm (0.0004 in) NOTE: • When installing a new valve always replace the guide. • If the valve is removed or replaced always replace the oil seal. 6. Eliminate: • Carbon deposits (from the valve face and valve seat) 7. Inspect: • Valve seat Pitting/wear → Reface the valve seat. 8. Measure: • Valve seat width a Out of specification → Reface the valve seat. Valve seat width: Intake: 0.9 ~ 1.
VALVES AND VALVE SPRINGS ENG 9. Lap: • Valve face • Valve seat NOTE: After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. Lapping steps: • Apply a coarse lapping compound to the valve face. CAUTION: Do not let the compound enter the gap between the valve stem and the guide. • Apply molybdenum disulfide oil to the valve stem. • Install the valve into the cylinder head.
VALVES AND VALVE SPRINGS ENG Valve spring 1. Measure: • Valve spring free length a Out of specification → Replace. Free length (valve spring): Intake: 37.81 mm (1.49 in) : 35.9 mm (1.41 in) Exhaust: 37.54 mm (1.48 in) : 35.7 mm (1.41 in) 2. Measure: • Compressed spring force a Out of specification → Replace. b Installed length Compressed spring force: Intake: 99 ~ 114 N at 29.13 mm (9.9 ~ 11.4 kg at 29.13 mm, 22.27 ~ 25.57 lb at 1.15 in) Exhaust: 126 ~ 144 N at 29.30 mm (12.6 ~ 14.
VALVES AND VALVE SPRINGS a ENG Combination of cylinder head and valve lifter 1. Combination: For this combination, match the paint color on the cylinder head with that on the valve lifter according to the chart below. b Combination Cylinder head mark a (color) Valve lifter mark b (color) Red Red Blue Blue Yellow Yellow Purple Black NOTE: When you purchase a cylinder head, you cannot designate its size. Choose the valve lifter that matches the above chart.
VALVES AND VALVE SPRINGS ENG 3. Install: • Valve cotter NOTE: While compressing the valve spring with a valve spring compressor 1 install the valve cotters. Valve spring compressor: YM-4019/90890-04019 4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood. CAUTION: Hitting the valve tip with excessive force could damage the valve. 5. Install: • Adjusting pad 1 • Valve lifter 2 NOTE: • Apply the molybdenum disulfide oil on the valve stem end.
ENG CYLINDER AND PISTON CYLINDER AND PISTON 1 Cylinder removal Extent of removal: Extent of removal Order Preparation for removal 1 2 1 2 3 4 5 6 2 Piston removal Part name CYLINDER AND PISTON REMOVAL Cylinder head Bolt (cylinder) Cylinder Piston pin clip Piston pin Piston Piston ring set 4 - 43 Q’ty Remarks Refer to “CYLINDER HEAD” section. 1 1 2 1 1 1 Use special tool. Refer to “REMOVAL POINTS”.
CYLINDER AND PISTON ENG REMOVAL POINTS Piston and piston ring 1. Remove: • Piston pin clip 1 • Piston pin 2 • Piston 3 NOTE: • Put identification marks on each piston head for reference during reinstallation. • Before removing each piston pin, deburr the clip groove and pin hole area. If the piston pin groove is deburred and the piston pin is still difficult to remove, use the piston pin puller set 4. Piston pin puller set: YU-1304/90890-01304 CAUTION: Do not use a hammer to drive the piston pin out. 2.
CYLINDER AND PISTON ENG Cylinder bore “C” 77.00 ~ 77.01 mm (3.0315 ~ 3.0319 in) Taper limit “T” 0.05 mm (0.002 in) Out of round “R” 0.05 mm (0.002 in) “C” = Maximum D “T” = (Maximum D1 or D2) – (Maximum D5 or D6) “R” = (Maximum D1, D3 or D5) – (Minimum D2, D4 or D6) • If out of specification, replace the cylinder, and replace the piston and piston rings as set. 2nd step: • Measure the piston skirt diameter “P” with a micrometer. a 8 mm (0.
CYLINDER AND PISTON ENG Piston ring 1. Measure: • Ring side clearance Use a feeler gauge 1. Out of specification → Replace the piston and rings as a set. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance. Side clearance: Standard Top ring 0.030 ~ 0.065 mm (0.0012 ~ 0.0026 in) 0.12 mm (0.005 in) 2nd ring 0.020 ~ 0.055 mm (0.0008 ~ 0.0022 in) 0.12 mm (0.005 in) 2.
CYLINDER AND PISTON ENG Piston pin 1. Inspect: • Piston pin Blue discoloration/grooves → Replace, then inspect the lubrication system. 2. Measure: • Piston pin-to-piston clearance Measurement steps: • Measure the outside diameter (piston pin) a. If out of specification, replace the piston pin. Outside diameter (piston pin): 15.991 ~ 16.000 mm (0.6296 ~ 0.6299 in) • Measure the inside diameter (piston) b. Inside diameter (piston): 16.002 ~ 16.013 mm (0.6300 ~ 0.
CYLINDER AND PISTON 2. Position: • Top ring • 2nd ring • Oil ring Offset the piston ring end gaps as shown. ad 45˚ 135˚ c ENG 135˚ a Top ring end b 2nd ring end c Oil ring end (upper) d Oil ring e Oil ring end (lower) be 3. Install: • Piston 1 • Piston pin 2 • Piston pin clip 3 New NOTE: • Apply engine oil onto the piston pin and piston. • Be sure that the arrow mark a on the piston points to the exhaust side of the engine.
CYLINDER AND PISTON ENG 3. Install: • Cylinder gasket 1 New • Cylinder 2 NOTE: Install the cylinder with one hand while compressing the piston rings with the other hand. CAUTION: • Pass the timing chain 3 through the timing chain cavity. • Be careful not to damage the timing chain guide 4 during installation. 4. Install: • Bolt (cylinder) 5 T. R. 4 - 49 10 Nm (1.0 m · kg, 7.
CLUTCH ENG EC4A0000 CLUTCH 1 Push rod 1, 2 and push lever shaft removal 3 Friction plate and clutch plate removal Extent of removal: Extent of removal Order 1 1 2 4 Q’ty CLUTCH REMOVAL Drain the engine oil. Preparation for removal 3 Part name 1 2 3 4 5 6 7 8 9 2 Push pod 1 disassembly 4 Primary driven gear removal Remarks Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Refer to “ENGINE REMOVAL” section. Disconnect at engine side.
CLUTCH Extent of removal 3 4 1 Order 10 11 12 13 14 15 16 17 18 19 Part name Friction plate Clutch plate Cushion spring Seat plate Nut (clutch boss) Look washer Clutch boss Thrust washer Primary driven gear Push lever shaft Q’ty 9 8 1 1 1 1 1 1 1 1 4 - 51 ENG Remarks Use special tool. Refer to “REMOVAL POINTS”.
CLUTCH ENG EC4A3000 REMOVAL POINTS Clutch boss 1. Remove: • Nut 1 • Lock washer 2 • Clutch boss 3 NOTE: Straighten the lock washer tab and use the clutch holding tool 4 to hold the clutch boss. È É Clutch holding tool: YM-91042/90890-04086 È For USA and CDN É Except for USA and CDN EC4A4000 INSPECTION EC484100 Clutch housing and boss 1. Inspect: • Clutch housing 1 Cracks/wear/damage → Replace. • Clutch boss 2 Scoring/wear/damage → Replace. EC484201 Primary driven gear 1.
CLUTCH ENG Friction plate 1. Measure: • Friction plate thickness Out of specification → Replace friction plate as a set. Measure at all four points. Friction plate thickness: 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) : 2.7 mm (0.106 in) EC484600 Clutch plate 1. Measure: • Clutch plate warpage Out of specification → Replace clutch plate as a set. Use a surface plate 1 and thickness gauge 2. Warp limit: 0.1 mm (0.004 in) Push lever shaft 1. Inspect: • Push lever shaft 1 Wear/damage → Replace. Push rod 1.
CLUTCH 2 a ENG EC4A5000 3 ASSEMBLY AND INSTALLATION Push lever shaft 1. Install: • Push lever shaft 1 • Bolt (push lever shaft) 2 1 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: • Apply the lithium soap base grease on the oil seal lip. • Apply the engine oil on the push lever shaft. • Fit the seat plate 3 in the groove a of the push lever shaft and tighten the bolt (seat plate). Clutch 1.
CLUTCH ENG 3. Bend the lock washer 1 tab. 4. Install: • Seat plate 1 • Cushion spring 2 3 1 ab 2 c NOTE: • Install the seat plate with its chamfered portion a facing the clutch boss 3. • Install the seat plate so that it is not caught on the step b. • Install the cushion spring with the paint c facing out. 5.
CLUTCH ENG 7. Install: • Push rod 2 1 • Ball 2 • Push rod 1 3 NOTE: Apply the engine oil on the push rod 1, 2 and ball. 8. Install: • Pressure plate 1 9. Install: • Clutch spring 1 • Bolt (clutch spring) 2 T. R. 8 Nm (0.8 m · kg, 5.8 ft · lb) NOTE: Tighten the bolts in stage, using a crisscross pattern. 10. Install: • Dowel pin 1 • Gasket (clutch cover) 2 New 11. Install: • Clutch cover 1 • Bolt (clutch cover) T. R. 10 Nm (1.0 m · kg, 7.
OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER ENG OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER 1 Oil filter element removal 3 Right crankcase cover removal Extent of removal: Extent of removal Order Part name 2 Water pump removal Q’ty OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER REMOVAL Drain the engine oil. Preparation for removal Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Refer to “COOLANT REPLACEMENT” section in the CHAPTER 3.
OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER Extent of removal 3 2 Order 3 4 5 6 7 8 9 10 11 12 Part name Water pump housing Oil delivery pipe Bolt (oil hose) Kickstarter crank Right crankcase cover Impeller Washer Impeller shaft Oil seal Bearing 4 - 58 Q’ty 1 1 1 1 1 1 1 1 2 1 ENG Remarks Refer to “REMOVAL POINTS”.
OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER ENG REMOVAL POINTS Impeller shaft 1. Remove: • Impeller 1 • Washer 2 • Impeller 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: • Bearing 1 2.
OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER ENG EC444200 Impeller shaft 1. Inspect: • Impeller shaft 1 Bend/wear/damage → Replace. Fur deposits → Clean. EC444300 Impeller shaft gear 1. Inspect: • Gear teeth a Wear/damage → Replace. EC4H4600 Bearing 1. Inspect: • Bearing Rotate inner race with a finger. Rough spot/seizure → Replace. EC444400 Oil seal 1. Inspect: • Oil seal 1 Wear/damage → Replace. ASSEMBLY AND INSTALLATION Oil seal 1.
OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER ENG 2. Install: • Bearing 1 NOTE: Install the bearing by pressing its outer race parallel. Impeller shaft 1. Install: • Impeller shaft 1 • Washer 2 • Impeller 3 T. R. 14 Nm (1.4 m · kg, 10 ft · lb) NOTE: • Take care so that the oil seal lip is not damaged or the spring does not slip off its position. • When installing the impeller shaft, apply the lithium soap base grease on the oil seal lip and impeller shaft.
OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER ENG 2. Install: • Right crankcase cover 1 • Bolt (right crankcase cover) 2 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: • Apply the engine oil on the impeller shaft end. • Mesh the impeller shaft gear 3 with primary drive gear 4. • Tighten the bolts in stage, using a crisscross pattern. Kickstarter crank 1. Install: • Kickstarter crank 1 • Washer 2 • Bolt (kickstarter crank) 3 T. R. 33 Nm (3.
OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER ENG Water pump housing 1. Install: • Dowel pin 1 • O-ring 2 New NOTE: Apply the lithium soap base grease on the Oring. 2. Install: • Water pump housing 1 • Bolt (water pump housing) 2 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) Oil filter element 1. Install: • Oil filter element 1 • O-ring 2 New • Oil filter element cover 3 • Bolt (oil filter element cover) T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Apply the lithium soap base grease on the Oring.
ENG BALANCER BALANCER 1 Balancer shaft drive gear Extent of removal: Extent of removal Order Part name 2 Balancer shaft Q’ty BALANCER REMOVAL Primary driven gear Right crankcase cover Preparation for removal Refer to “CLUTCH” section. Refer to “OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER” section. Refer to “AC MAGNETO AND STARTER CLUTCH” section.
BALANCER ENG REMOVAL POINTS Balancer shaft drive gear and balancer shaft driven gear 1. Straighten the lock washer tab. 2. Loosen: • Nut (primary drive gear) 1 • Nut (balancer shaft driven gear) 2 NOTE: Place an aluminum plate a between the teeth of the balancer shaft drive gear 3 and driven gear 4. Balancer shaft 1. Remove: • Balancer shaft 1 NOTE: When removing the balancer shaft, align the center a of the balancer shaft weight along the line connecting the centers of the crankshaft and balancer shaft.
BALANCER ENG ASSEMBLY AND INSTALLATION Balancer shaft, balancer shaft drive gear and balancer shaft driven gear 1. Install: • Balancer shaft 1 NOTE: • Apply the engine oil on the bearing. • When installing the balancer shaft, align the center a of the balancer shaft weight along the line connecting the centers of the crankshaft and balancer shaft. 2.
OIL PUMP ENG OIL PUMP 1 Oil pump removal Extent of removal: Extent of removal Order 2 Part name Q’ty OIL PUMP REMOVAL AND DISASSEMBLY Primary driven gear Right crankcase cover Preparation for removal 1 2 Oil pump disassembly 1 2 3 4 5 6 7 8 9 10 11 Circlip Washer Oil pump drive gear Oil pump assembly Outer rotor 2 Circlip Inner rotor 2 Dowel pin Oil pump cover Outer rotor 1 Inner rotor 1 Refer to “CLUTCH” section. Refer to “OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER” section.
OIL PUMP Extent of removal 2 Order 12 13 14 15 Part name Dowel pin Washer Oil pump drive shaft Rotor housing Q’ty 1 1 1 1 4 - 68 ENG Remarks
OIL PUMP 1 ENG INSPECTION Oil pump 1. Inspect: • Oil pump drive gear 1 • Oil pump drive shaft 2 • Rotor housing 3 • Oil pump cover 4 Cracks/wear/damage → Replace. 2 3 4 2. Measure: • Tip clearance a (between the inner rotor 1 and outer rotor 2) • Side clearance b (between the outer rotor 2 and rotor housing 3) • Housing and rotor clearance c (between the rotor housing 3 and rotors 1 2) Out of specification → Replace the oil pump assembly. Tip clearance a: 0.12 mm or less (0.0047 in or less) : 0.
OIL PUMP ENG ASSEMBLY AND INSTALLATION Oil pump 1. Install: • Oil pump drive shaft 1 • Washer 2 • Dowel pin 3 • Inner rotor 1 4 NOTE: • Apply the engine oil on the oil pump drive shaft and inner rotor 1. • Fit the dowel pin into the groove in the inner rotor 1. 2. Install: • Outer rotor 1 1 NOTE: Apply the engine oil on the outer rotor 1. 3. Install: • Oil pump cover 1 • Screw (oil pump cover) 2 T. R. 2 Nm (0.2 m · kg, 1.
OIL PUMP ENG 4. Install: • Outer rotor 2 1 • Dowel pin 2 • Oil pump assembly 3 • Bolt (oil pump assembly) [L = 25 mm (0.94 in)] 4 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) • Bolt (oil pump assembly) [L = 30 mm (1.18 in)] 5 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Apply the engine oil on the outer rotor 2. 5. Install: • Oil pump drive gear 1 • Washer 2 • Circlip 3 New NOTE: Apply the engine oil on the oil pump drive gear inner circumference.
KICK SHAFT AND SHIFT SHAFT ENG KICK SHAFT AND SHIFT SHAFT 1 Kick shaft removal 3 Shift shaft removal Extent of removal: Extent of removal Order Preparation for removal 1 2 1 3 4 1 2 3 4 5 6 7 8 9 10 11 Part name KICK SHAFT AND SHIFT SHAFT REMOVAL Oil pump Kick idle gear Kick shaft assembly Spring guide Torsion spring Ratchet wheel Kick gear Kick shaft Washer Shift pedal Shift shaft Collar 4 - 72 2 Kick shaft disassembly 4 Segment removal Q’ty Remarks Refer to “OIL PUMP” section.
KICK SHAFT AND SHIFT SHAFT Extent of removal 3 4 Order 12 13 14 15 16 17 18 19 20 21 22 23 Part name Torsion spring Roller Shift guide Shift lever assembly Shift lever Pawl Pawl pin Spring Bolt (stopper lever) Stopper lever Torsion spring Segment Q’ty 1 1 1 1 1 2 2 2 1 1 1 1 4 - 73 ENG Remarks Refer to “REMOVAL POINTS”. Refer to “REMOVAL POINTS”.
KICK SHAFT AND SHIFT SHAFT ENG REMOVAL POINTS Kick shaft assembly 1. Remove: • Kick shaft assembly 1 NOTE: Unhook the torsion spring 2 from the hole a in the crankcase. EC4C3101 Shift guide and shift lever assembly 1. Remove: • Bolt (shift guide) • Shift guide 1 • Shift lever assembly 2 NOTE: The shift lever assembly is disassembled at the same time as the shift guide. EC4N3100 Segment 1. Remove: • Bolt (segment) 1 • Segment 2 NOTE: Turn the segment counterclockwise until it stops and loosen the bolt.
KICK SHAFT AND SHIFT SHAFT ENG EC4B4400 Shift shaft 1. Inspect: • Shift shaft 1 Bend/damage → Replace. • Spring 2 Broken → Replace. EC4C4100 Shift guide and shift lever assembly 1. Inspect: • Shift guide 1 • Shift lever 2 • Pawl 3 • Pawl pin 4 • Spring 5 Wear/damage → Replace. EC4B4500 Stopper lever 1. Inspect: • Stopper lever 1 Wear/damage → Replace. • Torsion spring 2 Broken → Replace. ASSEMBLY AND INSTALLATION Segment 1. Install: • Segment 1 • Bolt (segment) T. R. 30 Nm (3.
KICK SHAFT AND SHIFT SHAFT ENG EC4B5111 Stopper lever 1. Install: • Torsion spring 1 • Stopper lever 2 • Bolt (stopper lever) 3 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Align the stopper lever roller with the slot on segment. Shift guide and shift lever assembly 1. Install: • Spring 1 • Pawl pin 2 • Pawl 3 To shift lever 4. NOTE: Apply the engine oil on the spring, pawl pin and pawl. 2. Install: • Shift lever assembly 1 To shift guide 2. 3.
KICK SHAFT AND SHIFT SHAFT ENG Shift shaft 1. Install: • Roller 1 • Collar 2 • Torsion spring 3 • Shift shaft 4 NOTE: Apply the engine oil on the roller and shift shaft. 2. Install: • Shift pedal Refer to “AC MAGNETO AND STARTER CLUTCH” section. Kick shaft assembly 1. Install: • Kick gear 1 • Washer 2 • Circlip 3 New • Ratchet wheel 4 • Spring 5 • Washer 6 • Circlip 7 New To kick shaft 8. NOTE: • Apply the molybdenum disulfide oil on the inner circumferences of the kick gear and ratchet wheel.
KICK SHAFT AND SHIFT SHAFT ENG 3. Install: • Spring guide 1 NOTE: Slide the spring guide into the kick shaft, make sure the groove a in the spring guide fits on the stopper of the torsion spring. 4. Install: • Kick shaft assembly 1 • Washer 2 NOTE: • Apply the molybdenum disulfide grease on the contacting surfaces of the kick shaft stopper a and stopper plate 3. • Apply the engine oil on the kick shaft.
ENG AC MAGNETO AND STARTER CLUTCH AC MAGNETO AND STARTER CLUTCH 1 Starter clutch/wheel gear removal 3 Pickup coil/stator removal Extent of removal: Extent of removal Order Part name 2 Rotor removal Q’ty AC MAGNETO AND STATOR REMOVAL Drain the engine oil. Preparation for removal Refer to “ENGINE OIL REPLACEMENT” section in the CHAPTER 3. Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. Refer to “RADIATOR” section.
AC MAGNETO AND STARTER CLUTCH Extent of removal 2 1 3 Order Part name Q’ty 10 11 Nut (rotor) Rotor 1 1 12 13 14 15 16 17 18 19 20 21 Woodruff key Starter clutch Starter clutch drive gear Bearing Plain washer Idle gear plate Idle gear 2 Holder Pickup coil Stator 1 1 1 1 1 1 1 1 1 1 4 - 80 ENG Remarks Use special tool. Refer to “REMOVAL POINTS”.
AC MAGNETO AND STARTER CLUTCH ENG EC4L3000 REMOVAL POINTS Rotor 1. Remove: • Nut (rotor) 1 • Plain washer 1 2. Remove: • Rotor 1 Use the rotor puller 2. Rotor puller: YM-04141/90890-04141 EC4L4000 INSPECTION AC magneto 1. Inspect: • Rotor inner surface a • Stator outer surface b Damage → Inspect the crankshaft runout and crankshaft bearing. If necessary, replace AC magneto and/or stator. EC4L4200 Woodruff key 1. Inspect: • Woodruff key 1 Damage → Replace. Starter clutch 1.
AC MAGNETO AND STARTER CLUTCH ENG 3. Check: • Starter clutch operation • Install the starter clutch drive gear 1 onto the starter clutch 2 and hold the starter clutch. • When turning the starter clutch drive gear counterclockwise É, the starter clutch and the starter clutch drive gear should engage. If the starter clutch drive gear and starter clutch do not engage, the starter clutch is faulty and must be replaced. • When turning the starter clutch drive gear clockwise È, it should turn freely.
AC MAGNETO AND STARTER CLUTCH ENG 2. Install: • Holder 1 • Bolt 2 a T. 2 R. 7 Nm (0.7 m · kg, 5.1 ft · lb) CAUTION: 1 Pass the pickup coil lead and charging coil lead under the holder while taking care not to allow these leads to get caught with each other. Also take care to pass the leads so that they do not become loose at the bend of the holder a in order to avoid their contacting the starter clutch drive gear. NOTE: Apply the sealant to the grommet of the AC magneto lead.
AC MAGNETO AND STARTER CLUTCH 5. Install: • Plain washer 1 • Bearing 2 • Starter clutch drive gear 3 • Starter clutch 4 1 2 E 3 4 ENG NOTE: Apply the engine oil on the plain washer, bearing and starter clutch drive gear inner circumference. 6. Install: • Woodruff key 1 • Rotor 2 NOTE: • Clean the tapered portions of the crankshaft and rotor. • When installing the woodruff key, make sure that its flat surface a is in parallel with the crankshaft center line b.
AC MAGNETO AND STARTER CLUTCH ENG 9. Install: • Shaft 1 • Bearing 2 • Idle gear 1 3 1 2 NOTE: Apply the engine oil on the shaft, bearing and idle gear inner circumference. E 3 10. Install: • Cover (idle gear 1) 1 • Bolt 2 a 2 T. R. 1 NOTE: Install the cover (idle gear 1) with its mark a facing upward. 2 11. Install: • Engine guard 1 • Clamp 2 • Bolt [engine guard (front)] 3 5 1 T. R. 3 23 Nm (2.3 m · kg, 17 ft · lb) • Bolt [engine guard (rear)] 4 T. 2 R. 2 10 Nm (1.0 m · kg, 7.
ENGINE REMOVAL ENG EC4M0000 ENGINE REMOVAL Extent of removal Preparation for removal Order Part name ENGINE REMOVAL Hold the machine by placing the suitable stand under the frame. Drain the engine oil. Seat and fuel tank Carburetor Exhaust pipe and silencer Clutch cable Radiator Shift pedal Cylinder head breather hose and oil tank breather hose 4 - 86 Q’ty Remarks WARNING Support the machine securely so there is no danger of it falling over.
ENGINE REMOVAL 1 Engine removal Extent of removal: Extent of removal 1 ENG Order Part name 1 2 3 4 5 6 7 8 9 10 11 12 13 Ignition coil Disconnect the AC magneto lead. Starter motor lead Negative battery lead Right engine guard Neutral switch Drive chain sprocket cover Nut (drive sprocket) Lock washer Drive sprocket Clip Bolt (brake pedal) Brake pedal Upper engine bracket Lower engine bracket Engine mounting bolt Pivot shaft Engine 4 - 87 Q’ty Remarks Disconnect at the starter motor side.
ENGINE REMOVAL ENG EC4M3000 REMOVAL POINTS EC4F3100 Drive sprocket 1. Remove: • Nut (drive sprocket) 1 • Lock washer 2 NOTE: • Straighten the lock washer tab. • Loosen the nut while applying the rear brake. 2. Remove: • Drive sprocket 1 • Drive chain 2 NOTE: Remove the drive sprocket together with the drive chain. EC4M3301 Engine removal 1. Remove: • Pivot shaft 1 NOTE: If the pivot shaft is pulled all the way out, the swingarm will come loose.
ENGINE REMOVAL ENG EC4M5000 ASSEMBLY AND INSTALLATION Engine installation 1. Install: • Engine 1 Install the engine from right side. • Pivot shaft 2 T. R. 85 Nm (8.5 m · kg, 61 ft · lb) • Engine mounting bolt (lower) 3 T. R. 69 Nm (6.9 m · kg, 50 ft · lb) • Lower engine bracket 4 • Bolt (engine bracket) 5 T. R. 34 Nm (3.4 m · kg, 24 ft · lb) • Engine mounting bolt (front) 6 T. R. 69 Nm (6.9 m · kg, 50 ft · lb) • Upper engine bracket 7 • Engine mounting bolt (upper) 8 T. R. 55 Nm (5.
ENGINE REMOVAL ENG Drive sprocket 1. Install: • Drive sprocket 1 • Drive chain 2 NOTE: Install the drive sprocket together with the drive chain. 2. Install: • Lock washer 1 New • Nut (drive sprocket) 2 T. R. 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: • Drive chain sprocket guide 1 • Drive chain sprocket cover 2 • Screw (drive chain sprocket cover) 3 T. R. 8 Nm (0.8 m · kg, 5.
ENGINE REMOVAL ENG 2. Install: • Spring 1 • Pin 2 • O-ring 3 New • Neutral switch 4 • Screw (neutral switch) 5 T. R. 4 Nm (0.4 m · kg, 2.9 ft · lb) NOTE: Apply the lithium soap base grease on the Oring.
CRANKCASE AND CRANKSHAFT ENG CRANKCASE AND CRANKSHAFT 1 Crankcase separation Extent of removal: Extent of removal Order Part name 2 Crankshaft removal Q’ty CRANKCASE AND CRANKSHAFT REMOVAL Engine Piston Preparation for removal Refer to “ENGINE REMOVAL” section. Refer to “CYLINDER AND PISTON” section. Kick shaft assembly Segment Stator 1 2 1 2 3 Remarks Refer to “KICK SHAFT AND SHIFT SHAFT” section.
CRANKCASE AND CRANKSHAFT Extent of removal 1 2 Order 4 5 6 7 8 9 10 11 12 Part name Bolt [L = 45 mm (1.77 in)] Bolt [L = 55 mm (2.17 in)] Bolt [L = 70 mm (2.76 in)] Hose guide Clutch cable holder Right crankcase Left crankcase Oil strainer Crankshaft 4 - 93 Q’ty 6 1 4 1 1 1 1 1 1 ENG Remarks Refer to “REMOVAL POINTS”. Use special tool. Refer to “REMOVAL POINTS”.
CRANKCASE AND CRANKSHAFT ENG CRANKCASE BEARING 1 Crankcase bearing removal Extent of removal: Extent of removal Order Preparation for removal 1 1 2 Part name CRANKCASE BEARING REMOVAL Transmission Shift cam and shift fork Oil seal Bearing 4 - 94 Q’ty Remarks Refer to “TRANSMISSION, SHIFT CAM AND SHIFT FORK” section. 2 10 Refer to “REMOVAL POINTS”.
CRANKCASE AND CRANKSHAFT ENG REMOVAL POINTS Crankcase 1. Separate: • Right crankcase • Left crankcase Separation steps: • Remove the crankcase bolts 1, hose guide 2 and clutch cable holder 3. NOTE: Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them. • Remove the right crankcase 4. NOTE: • Place the crankcase with its left side downward and split it by inserting a screwdriver tip into the splitting slit a in the crankcase.
CRANKCASE AND CRANKSHAFT ENG Crankshaft 1. Remove: • Crankshaft 1 Use the crankcase separating tool 2. Crankcase separating tool: YU-1135-A/90890-01135 CAUTION: Do not use a hammer to drive out the crankshaft. Crankcase bearing 1. Remove: • Bearing 1 NOTE: • Remove the bearing from the crankcase by pressing its inner race. • Do not use the removed bearing. INSPECTION Timing chain and timing chain guide 1. Inspect: • Timing chain Cracks/stiff → Replace the timing chain and camshaft sprocket as a set. 2.
CRANKCASE AND CRANKSHAFT ENG EC4N4201 Crankshaft 1. Measure: • Runout limit a • Small end free play limit b • Connecting rod big end side clearance c • Crank width d Out of specification → Replace. Use the dial gauge and a thickness gauge. Dial gauge and stand: YU-3097/90890-01252 Runout limit: Small end free play: Standard 0.03 mm (0.0012 in) 0.05 mm (0.002 in) 0.4 ~ 1.0 mm (0.016 ~ 0.039 in) 2.0 mm (0.08 in) Side 0.15 ~ 0.45 mm 0.50 mm clearance: (0.0059 ~ 0.0177 in) (0.
CRANKCASE AND CRANKSHAFT ENG EC4N5000 ASSEMBLY AND INSTALLATION Crankcase bearing 1. Install: • Bearing New • Bearing stopper • Bolt (bearing stopper) T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) • Screw (bearing stopper) T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) • Screw [bearing stopper (crankshaft)] 1 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) To left and right crankcase. NOTE: • Install the bearing by pressing its outer race parallel.
CRANKCASE AND CRANKSHAFT ENG 2. Check: • Shifter operation • Transmission operation Unsmooth operation → Repair. 3. Install: • Oil strainer 1 • Bolt (oil strainer) 2 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) 4. Apply: • Sealant On the right crankcase 1. Quick gasket®: ACC-QUICK-GS-KT YAMAHA Bond No. 1215: 90890-85505 NOTE: Clean the contacting surface of left and right crankcase before applying the sealant. 5. Install: • Dowel pin 1 • O-ring 2 New • Right crankcase To left crankcase.
CRANKCASE AND CRANKSHAFT ENG 6. Tighten: • Hose guide 1 • Clutch cable holder 2 • Bolt (crankcase) 3 T. R. 12 Nm (1.2 m · kg, 8.7 ft · lb) NOTE: Tighten the crankcase tightening bolts in stage, using a crisscross pattern. 7. Install: • Oil delivery pipe 2 1 • O-ring 2 New • Bolt (oil delivery pipe 2) 3 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Apply the lithium soap base grease on the Orings. 8. Install: • Timing chain 1 • Timing chain guide (intake side) 2 • Bolt (timing chain guide) 3 T. R.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG EC4H0000 TRANSMISSION, SHIFT CAM AND SHIFT FORK 1 Shift fork, shift cam, main axle and drive axle 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 Collar Refer to “ENGINE REMOVAL” section. Refer to “CRANKCASE AND CRANKSHAFT” section.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG EC4H3000 REMOVAL POINTS EC4H3230 Transmission 1. Remove: • Main axle 1 • Drive axle 2 • Shift cam • Shift fork 3 • Shift fork 2 • Shift fork 1 NOTE: • Remove assembly with the collar 3 installed to the crankcase. • Remove assembly carefully. Note the position of each part. Pay particular attention to the location and direction of shift forks.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG EC4H4810 Shift fork, shift cam and segment 1. Inspect: • Shift fork 1 Wear/damage/scratches → Replace. 2. Inspect: • Shift cam 1 • Segment 2 Wear/damage → Replace. 3. Check: • Shift 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 Transmission 1.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG 2. Install: • 2nd wheel gear (28T) 1 • 4th wheel gear (25T) 2 • 3rd wheel gear (28T) 3 • 5th wheel gear (22T) 4 • 1st wheel gear (31T) 5 • O-ring 6 New To drive axle 7. NOTE: • Apply the molybdenum disulfide oil on the 1st, 2nd and 3rd wheel gears inner circumference and on the end surface. • Apply the molybdenum disulfide oil on the 4th and 5th wheel gears inner circumference. • Apply the lithium soap base grease on the Oring. 3.
TRANSMISSION, SHIFT CAM AND SHIFT FORK ENG 5. Install: • Shift fork 1 (L) 1 • Shift fork 2 (C) 2 • Shift fork 3 (R) 3 • Shift cam 4 To main axle and drive axle. NOTE: • Apply the molybdenum disulfide oil on the shift fork grooves. • Mesh the shift fork #1 (L) with the 4th wheel gear 5 and #3 (R) with the 5th wheel gear 7 on the drive axle. • Mesh the shift fork #2 (C) with the 3rd pinion gear 6 on the main axle. 6. Install: • Transmission assembly 1 To left crankcase 2.
FRONT WHEEL AND REAR WHEEL CHAS EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL 1 Front wheel removal 3 Brake disc removal Extent of removal: Extent of removal Order 3 2 3 Q’ty FRONT WHEEL REMOVAL Hold the machine by placing the suitable stand under the engine.
FRONT WHEEL AND REAR WHEEL CHAS EC598100 REAR WHEEL 5 1 Rear wheel removal 3 Brake disc removal Extent of removal: Extent of removal Order 3 2 3 Q’ty 1 2 3 4 5 6 7 8 9 10 Nut (rear wheel axle) Rear wheel axle Drive chain puller Rear wheel Collar Rear wheel sprocket Oil seal Circlip Bearing Brake disc Support the machine securely so there is no danger of it falling over.
FRONT WHEEL AND REAR WHEEL CHAS EC593000 REMOVAL POINTS EC523101 Rear wheel 1. Remove: • Wheel 1 NOTE: Push the wheel forward and remove the drive chain 2. EC513201 Wheel bearing (if necessary) 1. Remove: • Bearing 1 NOTE: Remove the bearing using a general bearing puller 2. EC594000 INSPECTION EC514100 Wheel 1. Measure: • Wheel runout Out of limit → Repair/replace. Wheel runout limit: Radial 1: 2.0 mm (0.08 in) Lateral 2: 2.0 mm (0.08 in) 2. Inspect: • Bearing Rotate inner race with a finger.
FRONT WHEEL AND REAR WHEEL CHAS EC514200 Wheel axle 1. Measure: • Wheel axle bends Out of specification → Replace. Use the dial gauge 1. Wheel axle bending limit: 0.5 mm (0.020 in) NOTE: The bending value is shown by one half of the dial gauge reading. WARNING Do not attempt to straighten a bent axle. EC594200 Brake disc 1. Measure: • Brake disc deflection (only rear brake disc) Use the dial gauge 1. Out of specification → Inspect wheel runout.
FRONT WHEEL AND REAR WHEEL CHAS EC595000 ASSEMBLY AND INSTALLATION Front wheel 1. Install: • Bearing (left) 1 • Spacer 2 • Bearing (right) 3 • Oil seal 4 New NOTE: • Apply the lithium soap base grease on the bearing and oil seal lip when installing. • Use a socket that matches the outside diameter of the race of the bearing. • Left side of bearing shall be installed first. • Install the oil seal with its manufacture’s marks or numbers facing outward. CAUTION: Do not strike the inner race of the bearing.
FRONT WHEEL AND REAR WHEEL CHAS 5. Install: • Wheel NOTE: • Install the brake disc 1 between the brake pads 2 correctly. • Make sure that the projections a in the trip meter gear unit fits over the stopper b on the front fork outer tube. 6. Install: • Wheel axle 1 NOTE: Apply the lithium soap base grease on the wheel axle. 7. Install: • Nut (wheel axle) 1 T. R. 5-6 105 Nm (10.
FRONT WHEEL AND REAR WHEEL CHAS 8. Tighten: • Bolt (axle holder) 1 T. R. 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. 9. Install: • Brake hose 1 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) To brake hose holder 2. NOTE: Before tightening the bolt (brake hose holder), align the top a of the brake hose neck with the brake hose holder bottom b.
FRONT WHEEL AND REAR WHEEL CHAS 11. Install: • Trip meter cable 1 1 Rear wheel 1. Install: • Bearing (right) 1 • Circlip 2 New • Spacer 3 • Bearing (left) 4 • Oil seal 5 New NOTE: • Apply the lithium soap base grease on the bearing and oil seal lip when installing. • Install the bearing with seal facing outward. • Use a socket that matches the outside diameter of the race of the bearing. • Right side of bearing shall be installed first.
FRONT WHEEL AND REAR WHEEL CHAS 3. Install: • Rear wheel sprocket 1 • Bolt (rear wheel sprocket) 2 • Washer (rear wheel sprocket) 3 • Nut (rear wheel sprocket) 4 T. R. 50 Nm (5.0 m · kg, 36 ft · lb) NOTE: Tighten the nuts in stage, using a crisscross pattern. 4. Install: • Collar 1 NOTE: Apply the lithium soap base grease on the oil seal lip. 5. Install: • Wheel NOTE: Install the brake disc 1 between the brake pads 2 correctly. 6.
FRONT WHEEL AND REAR WHEEL CHAS 8. Install: • Right drive chain puller 1 • Washer 2 • Nut (wheel axle) 3 NOTE: Temporarily tighten the nut (wheel axle) at this point. 9. Adjust: • Drive chain slack a Drive chain slack: 40 ~ 50 mm (1.6 ~ 2.0 in) Refer to “DRIVE CHAIN SLACK ADJUSTMENT” section in the CHAPTER 3. 10. Tighten: • Nut (wheel axle) 1 T. R. 125 Nm (12.5 m · kg, 90 ft · lb) • Locknut 2 T. R. 5 - 10 16 Nm (1.
FRONT BRAKE AND REAR BRAKE CHAS EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE 1 Brake hose removal 3 Brake master cylinder removal Extent of removal: Extent of removal Order 1 3 2 3 Q’ty FRONT BRAKE REMOVAL Hold the machine by placing the suitable stand under the engine. Preparation for removal 2 Part name 2 Brake caliper removal WARNING Support the machine securely so there is no danger of it falling over. 1 2 3 4 5 6 7 Drain the brake fluid.
FRONT BRAKE AND REAR BRAKE CHAS EC5A8100 REAR BRAKE 1 Brake master cylinder removal 3 Brake caliper removal Extent of removal: Extent of removal Order Part name 2 Brake hose removal Q’ty REAR BRAKE REMOVAL Hold the machine by placing the suitable stand under the engine. Preparation for removal WARNING Support the machine securely so there is no danger of it falling over. Rear wheel 1 1 2 3 3 Refer to “FRONT WHEEL AND REAR WHEEL” section. Refer to “REMOVAL POINTS”.
FRONT BRAKE AND REAR BRAKE CHAS BRAKE CALIPER DISASSEMBLY È Front É Rear 1 Front brake caliper disassembly Extent of removal: Extent of removal 1 2 Order 1 2 3 4 5 6 Part name BRAKE CALIPER DISASSEMBLY Pad pin Brake pad Pad support Brake caliper piston Dust seal Piston seal 5 - 13 2 Rear brake caliper disassembly Q’ty A B 1 2 1 2 2 2 1 2 1 1 1 1 Remarks Refer to “REMOVAL POINTS”.
FRONT BRAKE AND REAR BRAKE CHAS BRAKE MASTER CYLINDER DISASSEMBLY È Front É Rear Extent of removal: Extent of removal 1 1 2 2 1 Front brake master cylinder disassembly Order 1 2 3 4 5 6 7 Part name BRAKE MASTER CYLINDER DISASSEMBLY Brake master cylinder cap Diaphragm Brake master cylinder boot Circlip Washer Push rod Brake master cylinder kit 5 - 14 2 Rear brake master cylinder disassembly Q’ty 1 1 1 1 1 1 1 Remarks Use a long nose circlip pliers.
FRONT BRAKE AND REAR BRAKE CHAS EC5A3000 È REMOVAL POINTS Brake fluid 1. Remove: [Front] • Brake master cylinder cap 1 [Rear] • Brake master cylinder cap 1 • Protector NOTE: Do not remove the diaphragm. É È Front É Rear 2. Connect the transparent hose 2 to the bleed screw 1 and place a suitable container under its end. È Front É Rear È 3. Loosen the bleed screw and drain the brake fluid while pulling the lever in or pushing down on the pedal. É CAUTION: • Do not reuse the drained brake fluid.
FRONT BRAKE AND REAR BRAKE CHAS Brake caliper piston seal kit 1. Remove: • Dust seal 1 • Piston seal 2 È NOTE: Remove the piston seals and dust seals by pushing them with a finger. CAUTION: Never attempt to pry out piston seals and dust seals. É WARNING Replace the piston seals and dust seals whenever a caliper is disassembled. È Front É Rear È EC5A4000 É INSPECTION Brake master cylinder 1. Inspect: • Brake master cylinder inner surface a Wear/scratches → Replace master cylinder assembly.
FRONT BRAKE AND REAR BRAKE È CHAS Brake caliper 1. Inspect: • Brake caliper cylinder inner surface a Wear/score marks → Replace brake caliper assembly. É È Front É Rear 2. Inspect: • Brake caliper piston 1 Wear/score marks → Replace brake caliper piston assembly. WARNING Replace the piston seals and dust seals 2 whenever a caliper is disassembled. EC534301 Brake hose 1. Inspect: • Brake hose 1 Crack/damage → Replace.
FRONT BRAKE AND REAR BRAKE CHAS 2. Install: • Piston seal 1 New • Dust seal 2 New È WARNING Always use new piston seals and dust seals. É NOTE: Fit the piston seals and dust seals onto the slot on brake caliper correctly. È Front É Rear 3. Install: • Brake caliper piston 1 È NOTE: Apply the brake fluid on the piston wall. CAUTION: • Install the piston with its shallow depressed side a facing the brake caliper. • Never force to insert. É È Front É Rear Front brake caliper 1.
FRONT BRAKE AND REAR BRAKE CHAS 2. Install: • Copper washer 1 New • Union bolt 2 T. R. 30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers. CAUTION: Install the brake hose so that its pipe portion a directs as shown and lightly touches the projection b on the brake caliper. 3. Install: • Brake hose holder 1 • Brake caliper 2 • Bolt (brake caliper) 3 T. R. 23 Nm (2.
FRONT BRAKE AND REAR BRAKE CHAS 2. Install: • Brake disc cover 1 • Bolt (brake disc cover) 2 T. R. 7 Nm (0.7 m · kg, 5.1 ft · lb) 3. Install: • Brake caliper 1 • Rear wheel 2 Refer to “FRONT WHEEL AND REAR WHEEL” section. 4. Tighten: • Pad pin 3 T. R. 18 Nm (1.8 m · kg, 13 ft · lb) 5. Install: • Pad pin plug 4 T. R. È É È É 3 Nm (0.3 m · kg, 2.2 ft · lb) Brake master cylinder kit 1. Clean: • Brake master cylinder • Brake master cylinder kit Clean them with brake fluid. 2.
FRONT BRAKE AND REAR BRAKE È CHAS 3. Install: • Spring 1 To brake master cylinder piston 2. É NOTE: Install the spring at the smaller dia. side. È Front É Rear 4. Install: [Front] • Brake master cylinder kit 1 • Washer 2 • Circlip 3 • Brake master cylinder boot 4 To brake master cylinder 5. [Rear] • Brake master cylinder kit 1 • Push rod 2 • Circlip 3 • Brake master cylinder boot 4 To brake master cylinder 5. È É NOTE: • Apply the brake fluid on the brake master cylinder kit.
FRONT BRAKE AND REAR BRAKE CHAS 2. Install: • Brake lever 1 • Bolt (brake lever) 2 T. R. 6 Nm (0.6 m · kg, 4.3 ft · lb) • Nut (brake lever) 3 T. R. 6 Nm (0.6 m · kg, 4.3 ft · lb) NOTE: Apply the lithium soap base grease on the brake lever sliding surface, bolt and contacting surface of the brake master cylinder piston. Rear brake master cylinder 1. Install: • Copper washer 1 New • Brake hose 2 • Union bolt 3 T. R. 30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers.
FRONT BRAKE AND REAR BRAKE 4. Install: • Pin 1 • Washer 2 • Cotter pin 3 CHAS New NOTE: After installing, check the brake pedal height. Refer to “REAR BRAKE ADJUSTMENT” section in the CHAPTER 3. Front brake hose 1. Install: • Brake hose 1 T. R. 10 Nm (1.0 m · kg, 7.2 ft · lb) To brake hose holder 2. NOTE: Before tightening the bolt (brake hose holder), align the top a of the brake hose neck with the brake hose holder bottom b.
FRONT BRAKE AND REAR BRAKE 4. Install: • Copper washer 1 • Brake hose 2 • Union bolt 3 CHAS New T. R. 30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers. CAUTION: Install the brake hose so that it contacts the brake master cylinder projection a and that its bent portion b faces downward. Rear brake hose 1. Install: • Copper washer 1 • Brake hose 2 • Union bolt 3 New T. R. 30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers.
FRONT BRAKE AND REAR BRAKE CHAS 2. Install: • Brake hose holder 1 • Screw (brake hose holder) 2 T. R. 1 Nm (0.1 m · kg, 0.7 ft · lb) CAUTION: 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. Brake fluid 1. Fill: • Brake fluid Until the fluid level reaches “LOWER” level line a.
FRONT BRAKE AND REAR BRAKE CHAS 2. Air bleed: • Brake system Refer to “BRAKE SYSTEM AIR BLEEDING” section in the CHAPTER 3. 3. Inspect: • Brake fluid level Fluid at lower level → Fill up. Refer to “BRAKE FLUID LEVEL INSPECTION” section in the CHAPTER 3. 4. Install: [Front] • Diaphragm • Brake master cylinder cap 1 • Screw (brake master cylinder cap) 2 È T. R. 2 Nm (0.2 m · kg, 1.4 ft · lb) [Rear] • Diaphragm • Brake master cylinder cap 1 • Bolt (brake master cylinder cap) 2 T. É R. 2 Nm (0.
FRONT FORK CHAS EC550000 FRONT FORK 1 Front fork removal Extent of removal: Extent of removal Order Part name Q’ty FRONT FORK REMOVAL Hold the machine by placing the suitable stand under the engine. Preparation for removal WARNING Support the machine securely so there is no danger of it falling over. Front wheel Refer to “FRONT WHEEL AND REAR WHEEL” section. Refer to “FRONT BRAKE AND REAR BRAKE” section.
FRONT FORK CHAS EC558000 FRONT FORK DISASSEMBLY 1 Oil seal removal Extent of removal: Extent of removal 1 2 Order 1 2 3 4 5 6 7 8 9 0 A B C 2 Damper rod removal Part name FRONT FORK DISASSEMBLY Front fork cap bolt Fork spring Dust seal Stopper ring Inner tube Outer tube Piston metal Slide metal Oil seal washer Oil seal Spring guide Base valve Damper rod 5 - 28 Q’ty 1 1 1 1 1 1 1 1 1 1 1 1 1 Remarks Refer to “REMOVAL POINTS”. Drain the fork oil. Refer to “REMOVAL POINTS”. Use special tool.
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. CAUTION: To prevent an accidental explosion of air, the following instructions should be observed: • The front fork with a built-in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material.
FRONT FORK CHAS EC553201 Inner tube 1. Remove: • Dust seal 1 • Stopper ring 2 Using slotted-head screwdriver. CAUTION: Take care not to scratch the inner tube. 2. Remove: • Inner tube 1 Oil seal removal steps: • Push in slowly a the inner tube just before it bottoms out and then pull it back quickly b. • Repeat this step until the inner tube can be pulled out from the outer tube. EC553311 Damper rod 1. Remove: • Base valve 1 • Damper rod 2 NOTE: Use a damper rod holder 3 to lock the damper rod.
FRONT FORK CHAS EC554200 Base valve 1. Inspect: • Valve assembly 1 Wear/damage → Replace. • O-ring 2 Damage → Replace. EC554400 Fork spring 1. Measure: • Fork spring free length a Out of specification → Replace. Fork spring free length: 460 mm (18.1 in) : 455 mm (17.9 in) EC554502 Inner tube 1. Inspect: • Inner tube surface a Score marks → Repair or replace. Use #1,000 grit wet sandpaper. Damaged oil lock piece → Replace. • Inner tube bends Out of specification → Replace. Use the dial gauge 1.
FRONT FORK CHAS Front fork cap bolt 1. Inspect: • Front fork cap bolt 1 • O-ring 2 • Air bleed screw 3 Wear/damage → Replace. EC555000 ASSEMBLY AND INSTALLATION Front fork assembly 1. Wash the all parts in a clean solvent. 2. Install: • Damper rod 1 To inner tube 2. CAUTION: To install the damper rod into the inner tube, hold the inner tube aslant. If the inner tube is held vertically, the damper rod may fall into it, damaging the valve inside. 3.
FRONT FORK CHAS 5. Install: • Spring guide 1 • Locknut 2 To damper rod 3. NOTE: • Install the spring guide with its cut a facing upward. • With its thread b facing upward, fully finger tighten the locknut onto the damper rod. 6. Install: • Dust seal 1 • Stopper ring 2 • Oil seal 3 New • Oil seal washer 4 • Slide metal 5 New To inner tube 6. NOTE: • Apply the fork oil on the inner tube. • When installing the oil seal, use vinyl seat a with fork oil applied to protect the oil seal lip.
FRONT FORK CHAS 9. Install: • Slide metal 1 • Oil 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 10. Install: • Oil seal 1 NOTE: Press the oil seal into the outer tube with fork seal driver 2. Fork seal driver: YM-01442/90890-01442 11. Install: • Stopper ring 1 NOTE: Fit the stopper ring correctly in the groove in the outer tube. 12.
FRONT FORK CHAS 13. Check: • Inner tube smooth movement Tightness/binding/rough spots → Repeat the steps 2 to 12. 14. Compress the front fork fully. 15. Fill: • Front fork oil Until outer tube top surface with recommended fork oil 1. Recommended oil: Suspension oil “01” CAUTION: • Be sure to use recommended fork oil. If other oils are used, they may have an excessively adverse effect on the front fork performance. • Never allow foreign materials to enter the front fork. 16.
FRONT FORK CHAS 19. Wait ten minutes until the air bubbles have been removed from the front fork, and the oil has dispense evenly in system before setting recommended oil level. NOTE: Fill with the fork oil up to the top end of the outer tube, or the fork oil will not spread over to every part of the front forks, thus making it impossible to obtain the correct level. Be sure to fill with the fork oil up to the top of the outer tube and bleed the front forks. 20.
FRONT FORK CHAS 21. Measure: • Distance a Out of specification → Turn into the locknut. Distance a: 20 mm (0.79 in) or more Between damper rod 1 top and locknut 2 top. 22. Loosen: • Rebound damping adjuster 1 NOTE: • Loosen the rebound damping adjuster finger tight. • Record the set position of the adjuster (the amount of turning out the fully turned in position). 23. Install: • Cushion rubber 1 • Washer 2 • Spacer 3 To front fork cap bolt 4. NOTE: Install the cushion rubber with its smaller dia.
FRONT FORK CHAS 26. Tighten: • Front fork cap bolt (locknut) 1 T. R. 29 Nm (2.9 m · kg, 21 ft · lb) NOTE: • While compressing the fork spring, set the thin type spanners 2 between the spacer 3 and spring guide 4. • Hold the locknut 5 and tighten the front fork cap bolt with specified torque. 27. Install: • Front fork cap bolt 1 To outer tube. NOTE: Temporarily tighten the cap bolt. 28. Install: • Protector guide 1 Installation 1.
FRONT FORK CHAS 4. Tighten: • Pinch bolt (upper bracket) 1 T. R. 23 Nm (2.3 m · kg, 17 ft · lb) • Pinch bolt (lower bracket) 2 T. R. 20 Nm (2.0 m · kg, 14 ft · lb) CAUTION: Tighten the lower bracket to specified torque. If torqued too much, it may cause the front fork to malfunction. 5. Install: • Brake hose holder 1 • Brake caliper 2 • Bolt (brake caliper) 3 T. R. 23 Nm (2.
HANDLEBAR CHAS EC5B0000 HANDLEBAR 1 Handlebar removal Extent of removal: Extent of removal Order Preparation for removal 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part name HANDLEBAR REMOVAL Headlight Hot starter cable Hot starter lever holder Clutch cable Clutch lever holder Engine stop switch Light switch Brake master cylinder Start switch Throttle cable cap Throttle cable #2 (pushed) Throttle cable #1 (pulled) Right grip Tube guide Grip cap cover Left grip Handlebar upper holder Handlebar 5
HANDLEBAR CHAS EC5B3000 REMOVAL POINTS Brake master cylinder 1. Remove: • Brake master cylinder bracket 1 • Brake master cylinder 2 CAUTION: • Do not let the brake master cylinder hang on the brake hose. • Keep the brake master cylinder cap side horizontal to prevent air from coming in. EC5B3200 Grip 1. Remove: • Grip 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.
HANDLEBAR CHAS EC5B5000 ASSEMBLY AND INSTALLATION Handlebar 1. Install: • Handlebar 1 • Handlebar upper holder 2 • Bolt (handlebar upper holder) 3 T. R. 28 Nm (2.8 m · kg, 20 ft · lb) NOTE: • The handlebar upper holder should be installed with the punched mark a forward. • First tighten the bolts on the front side of the handlebar upper holder, and then tighten the bolts on the rear side. 2. Install: • Left grip 1 Apply the adhesive to the handlebar 2.
HANDLEBAR CHAS 4. Install: • Grip cap cover 1 • Throttle grip 2 NOTE: Apply the lithium soap base grease on the throttle grip sliding surface. 5. Install: • Throttle cables 1 To tube guide 2. NOTE: Apply the lithium soap base grease on the throttle cable end and tube guide cable winding portion. 6. Install: • Throttle cable cap 1 • Screw (throttle cable cap) 2 T. R. 4 Nm (0.4 m · kg, 2.9 ft · lb) WARNING After tightening the screws, check that the throttle grip 3 moves smoothly.
HANDLEBAR CHAS 8. Install: • Start switch 1 • Brake master cylinder 2 • Brake master cylinder bracket 3 • Bolt (brake master cylinder bracket) 4 T. R. 9 Nm (0.9 m · kg, 6.5 ft · lb) • Clamp 5 NOTE: • The start switch and brake master cylinder bracket should be installed according to the dimensions shown. • Install the bracket so that the arrow mark a faces upward. • First tighten the bolt on the upper side of the brake master cylinder bracket, and then tighten the bolt on the lower side.
HANDLEBAR CHAS 11. Install: • Clutch cable 1 • Hot starter cable 2 NOTE: Apply the lithium soap base grease on the clutch cable end and hot starter cable end. 12. Adjust: • Clutch lever free play Refer to “CLUTCH ADJUSTMENT” section in the CHAPTER 3. • Hot starter lever free play Refer to “HOT STARTER LEVER ADJUSTMENT” section in the CHAPTER 3. 13. Fasten the hot starter cable 1 and clutch cable 2 with a clamp 3. 1 3 2 14.
STEERING CHAS EC560000 STEERING 1 Lower bracket removal Extent of removal: Extent of removal Order Part name 1 2 3 4 5 6 7 8 STEERING REMOVAL Hold the machine by placing the suitable stand under the engine.
STEERING Extent of removal 2 Order 10 11 12 13 Part name Ball race cover Upper bearing Lower bearing Ball race Q’ty 1 1 1 2 5 - 47 CHAS Remarks Refer to “REMOVAL POINTS”.
STEERING CHAS EC563000 REMOVAL POINTS Steering ring nut 1. Remove: • Steering ring nut 1 Use the steering nut wrench 2. Steering nut wrench: YU-33975/90890-01403 WARNING Support the steering stem so that it may not fall down. Lower bearing 1. Remove: • Lower bearing 1 Use the floor chisel 2. CAUTION: Take care not to damage the steering shaft thread. EC563400 Ball race 1. Remove: • Ball race 1 Remove the ball race using long rod 2 and the hammer. EC564000 INSPECTION Steering stem 1.
STEERING CHAS EC564101 Bearing and ball race 1. Wash the bearings and ball races with a solvent. 2. Inspect: • Bearing 1 • Ball race Pitting/damage → Replace bearings and ball races as a set. Install the bearing in the ball races. Spin the bearings by hand. If the bearings hang up or are not smooth in their operation in the ball races, replace bearings and ball races as a set. EC565000 ASSEMBLY AND INSTALLATION Lower bracket 1.
STEERING CHAS 4. Install: • Washer 1 • Steering ring nut 2 T. R. 7 Nm (0.7 m · kg, 5.1 ft · lb) Tighten the steering ring nut using the steering nut wrench 3. Refer to “STEERING HEAD INSPECTION AND ADJUSTMENT” section in the CHAPTER 3. 5. Check the steering stem by turning it lock to lock. If there is any binding, remove the steering stem assembly and inspect the steering bearings. 6. Install: • Washer 1 7.
STEERING CHAS 8. Install: • Washer 1 • Steering stem nut 2 T. 145 Nm (14.5 m · kg, 105 ft · lb) R. 9. Install: • Steering stem cap 1 10. After tightening the nut, check the steering for smooth movement. If not, adjust the steering by loosening the steering ring nut little by little. 11. Adjust: • Front fork top end a Front fork top end (standard) a: 5 mm (0.20 in) * 10 mm (0.39 in) * For AUS, NZ and ZA 12. Tighten: • Pinch bolt (upper bracket) 1 T. R. 23 Nm (2.
STEERING CHAS 13. Install: • Trip meter 1 • Bolt (trip meter) 2 T. R. 7 Nm (0.7 m · kg, 5.1 ft · lb) NOTE: Install the trip meter over the coupler bracket 3.
SWINGARM CHAS EC570000 SWINGARM 1 Swingarm removal Extent of removal: Extent of removal Order Q’ty SWINGARM REMOVAL Hold the machine by placing the suitable stand under the engine.
SWINGARM CHAS EC578000 SWINGARM DISASSEMBLY 1 Swingarm disassembly 3 Relay arm removal and disassembly Extent of removal: Extent of removal 3 2 1 2 3 Order 1 2 3 4 5 6 7 8 9 Part name SWINGARM DISASSEMBLY Cap Relay arm Connecting rod Collar Oil seal Thrust bearing Bushing Oil seal Bearing 5 - 54 Q’ty 2 1 1 2 2 2 2 8 8 2 Connecting rod removal and disassembly Remarks Refer to “REMOVAL POINTS”.
SWINGARM CHAS EC573000 REMOVAL POINTS EC573200 Bearing 1. Remove: • Bearing 1 NOTE: Remove the bearing by pressing its outer race. INSPECTION Wash the bearings, bushings, collars, and covers in a solvent. Swingarm 1. Inspect: • Bearing 1 • Bushing 2 Free play exists/unsmooth revolution/rust → Replace bearing and bushing as a set. 2. Inspect: • Oil seal 3 Damage → Replace. EC574210 Relay arm 1.
SWINGARM CHAS EC574310 Connecting rod 1. Inspect: • Bearing (polylube bearing) 1 • Collar 2 Free play exists/unsmooth revolution/rust → Replace bearing and collar as a set. 2. Inspect: • Bearing (polylube bearing) 1 Loss of solid lubrication → Replace. • Oil seal 3 Damage → Replace. NOTE: Polylube bearings, with solid lubrication, have been adopted with the intent to make the needle bearings, used in this model, maintenance free.
SWINGARM CHAS 2. Install: • Bearing 1 • Oil seal 2 To relay arm. NOTE: • Apply the molybdenum disulfide grease on the bearing when installing. • Install the bearing by pressing it on the side having the manufacture’s marks or numbers. Installed depth of bearings a: 5 mm (0.20 in) 3. Install: • Bearing 1 • Oil seal 2 To connecting rod. NOTE: • Apply the molybdenum disulfide grease on the bearing when installing. • Install the bearing by pressing it on the side having the manufacture’s marks or numbers.
SWINGARM CHAS 3. Install: • Collar 1 To connecting rod 2. NOTE: Apply the molybdenum disulfide grease on the collar and oil seal lips. 4. Install: • Connecting rod 1 • Bolt (connecting rod) 2 • Washer 3 • Nut (connecting rod) 4 T. R. 80 Nm (8.0 m · kg, 58 ft · lb) To relay arm 5. NOTE: Apply the molybdenum disulfide grease on the bolt. 5. Install: • Relay arm 1 • Bolt (relay arm) 2 • Washer 3 • Nut (relay arm) 4 To swingarm. NOTE: • Apply the molybdenum disulfide grease on the bolt.
SWINGARM CHAS 8. Install: • Bolt (connecting rod) 1 • Washer 2 • Nut (connecting rod) 3 NOTE: • Apply the molybdenum disulfide grease on the bolt. • Do not tighten the nut yet. 9. Install: • Bolt (rear shock absorber-relay arm) 1 • Nut (rear shock absorber-relay arm) 2 T. R. 53 Nm (5.3 m · kg, 38 ft · lb) NOTE: Apply the molybdenum disulfide grease on the bolt. 10. Tighten: • Nut (connecting rod) 1 T. R. 80 Nm (8.0 m · kg, 58 ft · lb) 11. Tighten: • Nut (relay arm) 1 T. R. 80 Nm (8.
SWINGARM CHAS 13. Install: • Bolt (lower chain tensioner) 1 • Washer 2 • Collar 3 • Lower chain tensioner 4 • Nut (lower chain tensioner) 5 T. R. 20 Nm (2.0 m · kg, 14 ft · lb) 14. Install: • Drive chain support 1 • Drive chain support cover 2 • Bolt {drive chain support [ = 50 mm (1.97 in)]} 3 • Nut (drive chain support) 4 T. R. 7 Nm (0.7 m · kg, 5.1 ft · lb) • Bolt {drive chain support cover [ = 10 mm (0.39 in)]} 5 T. R. 5 - 60 7 Nm (0.7 m · kg, 5.
REAR SHOCK ABSORBER CHAS EC580000 REAR SHOCK ABSORBER 1 Rear shock absorber removal Extent of removal: Extent of removal Preparation for removal Order Part name REAR SHOCK ABSORBER REMOVAL Hold the machine by placing the suitable stand under the engine. Seat, fitting band and side covers Air filter case cover Silencer Drain the coolant. Coolant reservoir breather hose Coolant reservoir hose Battery Disconnect the starter relay coupler.
CHAS REAR SHOCK ABSORBER Extent of removal 1 2 Order Part name Q’ty 1 2 3 4 5 6 7 Locking tie Taillight coupler Starting circuit cut-off relay coupler Plastic band Clamp (air filter joint) Rear frame Bolt (rear shock absorber-relay arm) Bolt (rear shock absorber-frame) Rear shock absorber Locknut Adjuster Lower spring guide Upper spring guide Spring (rear shock absorber) Bearing 2 1 1 2 1 1 1 8 9 10 11 12 13 14 15 5 - 62 1 1 1 1 1 1 1 2 Remarks Only loosening. Hold the swingarm.
REAR SHOCK ABSORBER CHAS HANDLING NOTE WARNING This rear shock absorber is provided with a separate type tank filled with high-pressure nitrogen gas. To prevent the danger of explosion, read and understand the following information before handling the shock absorber. The manufacturer can not be held responsible for property damage or personal injury that may result from improper handling. 1. Never tamper or attempt to disassemble the cylinder or the tank. 2.
REAR SHOCK ABSORBER CHAS EC583000 REMOVAL POINTS EC583320 Bearing 1. Remove: • Stopper ring (upper bearing) 1 NOTE: Press in the bearing while pressing its outer race and remove the stopper ring. 2. Remove: • Upper bearing 1 NOTE: Remove the bearing by pressing its outer race. 3. Remove: • Lower bearing 1 NOTE: Remove the bearing by pressing its outer race. EC584000 INSPECTION Rear shock absorber 1. Inspect: • Damper rod 1 Bends/damage → Replace rear shock absorber assembly.
REAR SHOCK ABSORBER CHAS EC585000 ASSEMBLY AND INSTALLATION EC585300 Bearing 1. Install: • Upper bearing 1 NOTE: Install the bearing parallel until the stopper ring groove appears by pressing its outer race. CAUTION: 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: • Stopper ring (upper bearing) 1 New NOTE: After installing the stopper ring, push back the bearing until it contacts the stopper ring.
REAR SHOCK ABSORBER CHAS 2. Tighten: • Adjuster 1 3. Adjust: • Spring length (installed) a Spring length (installed) a: Standard length Extent of adjustment 245 mm (9.65 in) * 246.5 mm (9.70 in) 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. CAUTION: Never attempt to turn the adjuster beyond the maximum or minimum setting. 4. Tighten: • Locknut 1 Rear shock absorber 1.
REAR SHOCK ABSORBER CHAS 2. Install: • Bushing 1 • Collar 2 • Dust seal 3 NOTE: • Apply the molybdenum disulfide grease on the bearing. • Apply the lithium soap base grease on the bushing, collars and dust seals. • Install the dust seals with their lips facing outward. 3. Install: • Rear shock absorber 4. Install: • Bolt (rear shock absorber-frame) 1 • Nut (rear shock absorber-frame) 2 T. R. 56 Nm (5.6 m · kg, 40 ft · lb) NOTE: Apply the molybdenum disulfide grease on the bolt. 5.
REAR SHOCK ABSORBER 2 CHAS 8.
ELECTRICAL COMPONENTS AND WIRING DIAGRAM – ELEC + EC600000 ELECTRICAL EC610000 ELECTRICAL COMPONENTS AND WIRING DIAGRAM EC611000 ELECTRICAL COMPONENTS 1 Headlight 2 Engine stop switch 3 Clutch switch 4 Diode 5 Starter relay diode 6 Throttle position sensor 7 Starter relay 8 Fuse 9 Starting circuit cutoff relay 0 Taillight A Neutral switch B Starter motor C AC magneto D Rectifier/regulator E Ignition coil F Spark plug G Start switch H Light switch I Main switch J CDI unit K Battery 45 78 9 6 23 1
MAP-CONTROLLED CDI UNIT – ELEC + MAP-CONTROLLED CDI UNIT A map-controlled, CDI ignition system is used in the WR250F. The microcomputer in the CDI unit detects the engine speed and throttle position, thus determining the optimum ignition timing through the entire operating range. In this way, quick throttle response can be achieved according to various riding conditions.
IGNITION SYSTEM ELEC – + EC620000 IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. *1 Check fuse. OK *2 Check battery. No good Replace fuse and check wire harness. No good Recharge or replace. OK Spark gap test No spark Check entire ignition system for connection.
IGNITION SYSTEM ELEC – + SPARK GAP TEST 1. Disconnect the ignition coil from spark plug. 2. Remove the ignition coil cap. 3. Connect the dynamic spark tester 1 (ignition checker 2) as shown. • Ignition coil 3 • Spark plug 4 È È For USA and CDN É Except for USA and CDN É 4. Kick the kickstarter crank. 5. Check the ignition spark gap. 6. Start engine, and increase spark gap until misfire occurs. (for USA and CDN only) Minimum spark gap: 6.0 mm (0.
IGNITION SYSTEM ELEC – + 2. Inspect: • Rubber part a Tears/damage → Replace. a MAIN SWITCH INSPECTION 1. Inspect: • Main switch conduct Tester (+) lead → Red lead 1 Tester (–) lead → Brown lead 2 R 1 Br 2 Tester selector position ON OFF Ω ×1 Continuous while the main switch is moved to “OFF” → Replace. Not continuous while the main switch is moved to “ON” → Replace. 2. Inspect: • Main switch indicator light Use 12 V battery.
IGNITION SYSTEM ELEC – + EC626002 IGNITION COIL INSPECTION 1. Remove the ignition coil cap. 2. Inspect: • Primary coil resistance Out of specification → Replace. Tester (+) lead → Orange lead 1 Tester (–) lead → Black lead 2 Primary coil resistance Tester selector position 0.08 ~ 0.10 Ω at 20 °C (68 °F) Ω×1 3. Inspect: • Secondary coil resistance Out of specification → Replace.
IGNITION SYSTEM ELEC – + AC MAGNETO INSPECTION 1. Inspect: • Pickup coil resistance Out of specification → Replace. 1 R Tester (+) lead → Red lead 1 Tester (–) lead → White lead 2 2 W 1 Sb Pickup coil resistance Tester selector position 248 ~ 372 Ω at 20 °C (68 °F) Ω × 100 NEUTRAL SWITCH INSPECTION 1.
ELECTRIC STARTING SYSTEM ELEC – + ELECTRIC STARTING SYSTEM 2 STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is set to “ON”, the starter motor can only operate if at least one of the following conditions is met: 3 1 • The transmission is in neutral (the neutral switch is closed). • The clutch lever is pulled to the handlebar (the clutch switch is closed). The starting circuit cut-off relay prevents the starter motor from operating when neither of these conditions has been met.
ELECTRIC STARTING SYSTEM ELEC – + INSPECTION STEPS If the starter motor will not operate, use the following inspection steps. *1 Check fuse. No good Replace fuse and check wire harness. OK *2 Check battery. OK Check each coupler and wire connection. No good No good Recharge or replace. Repair or replace. OK *3 Check main switch. No good Replace. OK Check starter motor operation. OK No good Check starting circuit cut-off relay. No good Repair or replace. Replace. OK Check starter relay.
ELECTRIC STARTING SYSTEM ELEC – + EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. STARTER MOTOR OPERATION 1. Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3. Not operate → Repair or replace the starter motor. WARNING • A wire that is used as a jumper lead must have at least the same capacity or more as that of the battery lead, otherwise the jumper lead may burn.
ELECTRIC STARTING SYSTEM ELEC – + STARTER RELAY INSPECTION 1. Remove: • Starter relay 2. Inspect: • Starter relay conduct Use 12 V battery. Battery (+) lead → Starter relay terminal 1 Battery (–) lead → Starter relay terminal 2 Tester (+) lead → Starter relay terminal 3 Tester (–) lead → Starter relay terminal 4 TerTerminal minal 3 4 Tester selector position Connected to battery Ω ×1 Not connected to battery Continuous while not connected to the battery → Replace.
ELECTRIC STARTING SYSTEM – + DIODE INSPECTION 1. Remove the diode from wire harness. 2.
ELECTRIC STARTING SYSTEM ELEC – + STARTER MOTOR 1 6 8 7 3 New 4 8 7 5 3 New New 2 B 1 1 Starter motor disassembly Extent of removal: Extent of removal Order Part name Q’ty STARTER MOTOR REMOVAL Exhaust pipe Preparation for removal 1 1 1 2 3 4 5 6 7 8 Starter motor STARTER MOTOR DISASSEMBLY Starter motor front cover Washer (starter motor front cover) Gasket Starter motor yoke Armature assembly Starter motor rear cover Brush Brush spring 6 - 13 Remarks Refer to “EXHAUST PIPE AND SILE
ELECTRIC STARTING SYSTEM ELEC – + INSPECTION AND REPAIR 1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Commutator diameter a Out of specification → Replace the starter motor. Min. commutator diameter: 16.6 mm (0.65 in) 3. Measure: • Mica undercut a Out of specification → Scrape the mica to the proper measurement with a hacksaw blade which has been grounded to fit the commutator. Mica undercut: 1.5 mm (0.
ELECTRIC STARTING SYSTEM ELEC – + 5. Measure: • Brush length a Out of specification → Replace the brushes as a set. Min. brush length: 3.5 mm (0.14 in) 6. Measure: • Brush spring force Out of specification → Replace the brush springs as a set. Brush spring force: 3.92 ~ 5.88 N (400 ~ 600 gf, 14.1 ~ 21.2 oz) ASSEMBLY 1. Install: • Brush spring 1 • Brush 2 2. Install: • Armature assembly 1 Install while holding down the brush using a thin screw driver.
ELECTRIC STARTING SYSTEM b 4 3 New 1 + NOTE: • For installation, align the projections on the washer with the slots in the front cover. • Align the match mark a on the starter motor yoke with the match mark b on the starter motor front cover. 5. Install: • Gasket • Bolt 1 • O-ring 2 2 New 1 – 4. Install: • Gasket 1 New • Circlip • Plain washer 2 • Washer (starter motor front cover) 3 • Starter motor front cover 4 a 2 ELEC New NOTE: Apply the lithium soap base grease on the O-ring.
CHARGING SYSTEM ELEC – + EC680000 CHARGING SYSTEM EC681001 INSPECTION STEPS If the battery is not charged, use the following inspection steps. *1 Check fuse. No good Replace fuse and check wire harness. OK *2 Check battery. OK Check each coupler and wire connection. No good Recharge or replace. No good Repair or replace. OK OK Check charging voltage. Charging system is good. No good Check AC magneto. Charging coil No good Replace. OK Replace rectifier/regulator.
CHARGING SYSTEM ELEC – + EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. CHARGING VOLTAGE INSPECTION 1. Start the engine. 2. Inspect: • Charging voltage Out of specification → If no failure is found in checking the source coil resistance, replace the rectifier/regulator. Y W R B 1 2 Tester (+) lead → Red lead 1 Tester (–) lead → Black lead 2 Charging voltage Tester selector position 14.1 ~ 14.
THROTTLE POSITION SENSOR SYSTEM ELEC – THROTTLE POSITION SENSOR SYSTEM INSPECTION STEPS If the throttle position sensor will not operate, use the following inspection steps. Check entire ignition system for connection. OK Check throttle position sensor. OK Check CDI unit. No good Throttle position sensor coil Throttle position sensor input voltage Repair or replace. No good No good Replace. Replace. NOTE: Use the following special tools in this inspection.
THROTTLE POSITION SENSOR SYSTEM ELEC – + HANDLING NOTE CAUTION: 1 Do not loosen the screws (throttle position sensor) 1 except when changing the throttle position sensor due to failure because it will cause a drop in engine performance. EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. THROTTLE POSITION SENSOR COIL INSPECTION 1.
THROTTLE POSITION SENSOR SYSTEM – ELEC + 3. Inspect: • Throttle position sensor coil variable resistance Check that the resistance in increased as the throttle grip is moved from the full close position to the full open position. Out of specification → Replace.
THROTTLE POSITION SENSOR SYSTEM ELEC – + 4. Adjust: • Engine idling speed Refer to “ENGINE IDLING SPEED ADJUSTMENT” section in the CHAPTER 3. 5. Insert the thin electric conductors 2 (lead) into the throttle position sensor coupler 1, as shown, and connect the tester to them. Tester (+) lead → Yellow lead 3 Tester (–) lead → Black lead 4 CAUTION: • Do not insert the electric conductors more than required because it may reduce the waterproof function of the coupler.
THROTTLE POSITION SENSOR SYSTEM ELEC – + 8. Tighten: • Screw (throttle position sensor) 1 9. Stop the engine. 1 THROTTLE POSITION SENSOR INPUT VOLTAGE INSPECTION 1. Disconnect the throttle position sensor coupler. 2. Start the engine. 3. Inspect: • Throttle position sensor input voltage Out of specification → Replace the CDI unit.
LIGHTING SYSTEM ELEC – + LIGHTING SYSTEM INSPECTION STEPS Refer to the following flow chart when inspecting the ignition system for possible problems. Check the bulb and bulb socket. Replace the bulb and/ or bulb socket. No good OK Check the light switch. No good Replace. OK Check the AC magneto. Lighting coil No good Replace. OK Check the entire lighting system proper for connections. Improperly connected Repair or replace. OK Check the rectifier/regulator.
ELEC LIGHTING SYSTEM – + LIGHT SWITCH INSPECTION 1. Inspect: • Light switch conduct Tester (+) lead → Yellow lead 1 Tester (–) lead → Blue lead 2 Y 1 L 2 OFF Tester selector position Ω ×1 No continuous while being → Replace. Continuous while being OFF → Replace. AC MAGNETO INSPECTION 1. Inspect: • Lighting coil resistance Out of specification → Replace. Tester (+) lead → Yellow lead 1 Tester (–) lead → Ground 2 Lighting coil resistance Tester selector position 0.224 ~ 0.
SETTING TUN EC700000 TUNING EC710000 ENGINE Carburetor setting • The air/fuel mixture will vary depending on atmospheric conditions. Therefore, it is necessary to take into consideration the air pressure, ambient temperature, humidity, etc., when adjusting the carburetor. • Perform a test run to check for proper engine performance (e.g., throttle response) and spark plug(-s) discoloration or fouling. Use these readings to determine the best possible carburetor setting.
SETTING TUN CAUTION: • The carburetor is extremely sensitive to foreign matter (dirt, sand, water, etc.). During installation, do not allow foreign matter to get into the carburetor. • Always handle the carburetor and its components carefully. Even slight scratches, bends or damage to carburetor parts may prevent the carburetor from functioning correctly. Carefully perform all servicing with the appropriate tools and without applying excessive force.
SETTING TUN Effects of the setting parts on the throttle valve opening 1 2 3 4 È 1/8 1/4 1/2 3/4 É È Closed É Fully open 1 Pilot screw/pilot jet 2 Throttle valve cutaway 3 Jet needle 4 Main jet Main system The FLATCR carburetor has a primary main jet. This type of main jet is perfect for racing motorcycles since it supplies an even flow of fuel, even at full load. Use the main jet and the jet needle to set the carburetor. Pilot system The FLATCR carburetor is manufactured with a pilot screw.
SETTING TUN 1 Jet needle 2 Pilot air jet 3 Needle jet 4 Main jet 5 Pilot jet 6 Pilot screw Main jet adjustment The richness of the air-fuel mixture at full throttle can be set by changing the main jet 1. #185 * #172 Standard main jet * Except for USA If the air-fuel mixture is too rich or too lean, the engine power will drop, resulting in poor acceleration.
SETTING TUN Pilot screw adjustment The richness of the air-fuel mixture with the throttle fully closed to 1/4 open can be set by turning the pilot screw 1. Turning in the pilot screw will make the mixture lean at low speeds, and turning it out will enrich it. 1 Standard pilot screw position 2 (example) * 1-7/8 * Except for USA NOTE: • If the engine idling speed fluctuates, turn the pilot screw only 1/2 of a turn in either direction.
SETTING TUN Effects of adjusting the pilot jet (reference) È 1/4 1/2 3/4 É +5% #42 #40 #38 –5% È Idle É Fully open Jet needle groove position adjustment Adjusting the jet needle 1 position affects the acceleration when the throttle is 1/8 to 3/4 open. 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.
SETTING TUN Jet needle adjustment The jet needle is adjusted by changing it. OBDVS * OBELP Standard jet needle * Except for USA The tapered sections of all jet needles have the same starting positions, but the needles are available with different straight-portion diameters.
SETTING TUN Leak jet adjustment (accelerator pump adjustment) The leak jet 1 is a setting part that adjusts the flow of fuel discharged by the accelerator pump. Since the accelerator pump operates only when throttle is open, the leak jet is used to adjust a fuel mixture ratio for quick throttle opening and is therefore different from other setting parts that adjust a fuel mixture for each throttle opening (each engine speed). 1. The engine breathes hard in quick throttle opening.
SETTING TUN EC71Q000 Carburetor setting parts Part name Main jet Rich (STD) * (STD) Pilot jet Lean Rich (STD) Jet needle Lean Rich (STD) Lean * Jet needle Rich (STD) Leak jet Lean Rich (STD) Lean * Except for USA 7-9 Size #198 #195 #192 #190 #188 #185 #182 #180 #178 #175 #172 #170 #168 #165 #162 #160 #50 #48 #45 #42 #40 #38 #35 OBDVP OBDVQ OBDVR OBDVS OBDVT OBDVU OBDVV OBELL OBELM OBELN OBELP OBELQ OBELR OBELS #60 #70 #80 #90 #100 #110 #120 Part number 4MX-14943-97 4MX-14943-46 4MX-14943
SETTING TUN Examples of carburetor setting depending on symptom Symptom Setting Checking At full throttle Hard breathing Shearing noise Whitish spark plug ↓ Lean mixture Increase main jet calibration no. (Gradually) Discoloration of spark plug → If tan color, it is in good condition. If cannot be corrected: Clogged float valve seat Clogged fuel hose Clogged fuel cock Check that the accelerator pump operates smoothly.
SETTING TUN EC720000 CHASSIS Selection of the secondary reduction ratio (Sprocket) Secondary reduction = ratio Number of rear wheel sprocket teeth Number of drive sprocket teeth Standard secondary reduction ratio 52/13 (4.000) • It is generally said that the secondary gear ratio should be reduced for a longer straight portion of a speed course and should be increased for a course with many corners.
SETTING TUN EC72N000 Drive and rear wheel sprockets setting parts Part name Drive sprocket 1 (STD) Rear wheel sprocket 2 (STD) * (STD) Size Part number 13T 48T * 48T * 49T 50T * 50T * 51T 52T * 52T 54T 9383B-13218 5GS-25448-50 5NY-25448-00 5NY-25449-00 5GS-25450-50 5NY-25450-00 5NY-25451-00 5GS-25452-50 5NY-25452-00 5PH-25454-50 * For AUS and NZ EC721002 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 • Change the fork oil level. 2. Setting of spring preload • Change the spring. • Install the adjustment washer. 3. Setting of damping force • Change the compression damping. • Change the rebound damping.
SETTING TUN È Air spring characteristics in relation to oil level change É Load Ê Stroke 1 Max. oil level 2 Standard oil level 3 Min. oil level EC727020 Spring preload adjustment The spring preload is adjusted by installing the adjustment washer 1 between the fork spring 2 and damper rod 3. CAUTION: Do not install three or more adjustment washers for each front fork. WARNING Always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability.
SETTING TUN EC72A001 Setting of spring after replacement As the front fork setting can be easily affected by rear suspension, take care so that the machine front and rear are balanced (in position, etc.) when setting the front fork. 1. Use of soft spring Generally a soft spring gives a soft riding feeling. Rebound damping tends to become stronger and the front fork may sink deeply over a series of gaps. To set a soft spring: • Change the rebound damping. Turn out one or two clicks.
SETTING TUN EC72P000 Front fork setting parts • Adjustment washer 1 TYPE (thickness) PART NUMBER T = 2.3 mm (0.09 in) 4SS-23364-L0 • Front fork spring 2 [Equal pitch spring] SPRING SPRING TYPE RATE PART NUMBER I.D. MARK (slits) SOFT 0.380 0.390 0.400 0.410 4SS-23141-10 4SS-23141-20 4SS-23141-30 4SS-23141-40 I-I I-II I-III I * STD 0.420 4SR-23141-L0 – ** STD 0.430 4XL-23141-L0 – STD 0.440 5NL-23141-00 – STIFF 0.450 0.460 0.
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 • Change the set length of the spring. • Change the spring. 2. Setting of damping force • Change the rebound damping. • Change the compression damping. EC72C001 Choosing set length 1.
SETTING TUN NOTE: • If 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 reevaluation. • If 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 CAUTION: When using a rear shock absorber 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 EC72Q000 Rear shock absorber setting parts • Rear shock spring 1 [Equal pitch spring] I.D. SPRING SPRING SPRING PART COLOR/ FREE RATE NUMBER POINT LENGTH TYPE SOFT 4.3 4.5 5UN-22212-00 Brown/1 5UN-22212-10 Green/1 260 260 * STD 4.7 5UN-22212-20 260 4.9 5UN-22212-30 Black/1 260 STD 5.0 5UN-22212-80 Orange/1 260 ** STD 5.1 5UN-22212-40 260 STIFF 5.3 5.5 5.
SETTING TUN EC72H002 Suspension setting • Front fork NOTE: • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90 ~ 100 mm (3.5 ~ 3.9 in).
SETTING TUN • Rear shock absorber NOTE: • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Adjust the rebound damping in 2-click increments or decrements. • Adjust the low compression damping in 1-click increments or decrements. • Adjust the high compression damping in 1/6 turn increments or decrements.
PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO., LTD. 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN JAPAN 2002.11-1.
