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Yamaha 2011 YZ250FA, Owner'S Service Manual

The Yamaha 2011 YZ250FA Owner's Service Manual is a comprehensive guide for maintaining and troubleshooting this powerful off-road motorcycle. Available for free download on manualshive.com, this manual provides detailed instructions and diagrams to help riders optimize their bike's performance and ensure a smooth and safe riding experience.

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2-16

TIGHTENING TORQUES

△

Brake pedal

M8 × 1.25

1

26

2.6

19

△

Rear brake master cylinder

M6 × 1.0

2

10

1.0

7.2

Rear brake master cylinder cap

M4 × 0.7

2

2

0.2

1.4

△

Rear brake hose union bolt

M10 × 1.25

2

30

3.0

22

△

Rear wheel axle and axle nut

M22 × 1.5

1

135

13.5

98

△

Nipple (spoke)

—

72

3

0.3

2.2

△

Rear wheel sprocket

M8 × 1.25

6

42

4.2

30

△

Rear brake disc cover

M6 × 1.0

2

10

1.0

7.2

△

Rear brake caliper protector

M6 × 1.0

2

7

0.7

5.1

Drive chain puller adjust bolt and locknut

M8 × 1.25

2

21

2.1

15

Engine mounting:

△

Engine and engine bracket (front)

M10 × 1.25

1

53

5.3

38

△

Engine and frame (lower)

M10 × 1.25

1

53

5.3

38

△

Upper engine bracket and frame

M8 × 1.25

4

34

3.4

25

△

Front engine bracket and frame

M8 × 1.25

4

34

3.4

25

△

Engine and engine bracket (upper)

M10 × 1.25

2

55

5.5

40

Lower engine guard

M6 × 1.0

3

10

1.0

7.2

CDI unit bracket

M6 × 1.0

2

7

0.7

5.1

Cable guide and frame

M6 × 1.0

2

7

0.7

5.1

△

Pivot shaft and nut

M16 × 1.5

1

85

8.5

61

△

Relay arm and swingarm

M14 × 1.5

1

70

7.0

50

△

Relay arm and connecting rod

M14 × 1.5

1

80

8.0

58

△

Connecting rod and frame

M14 × 1.5

1

80

8.0

58

△

Rear shock absorber and frame

M10 × 1.25

1

56

5.6

40

△

Rear shock absorber and relay arm

M10 × 1.25

1

53

5.3

38

△

Rear frame (upper)

M8 × 1.25

2

32

3.2

23

△

Rear frame (lower)

M8 × 1.25

2

32

3.2

23

△

Swingarm and brake hose holder

M5 × 0.8

4

3

0.3

2.2

Upper drive chain tensioner

M8 × 1.25

1

16

1.6

11

Lower drive chain tensioner

M8 × 1.25

1

16

1.6

11

Drive chain support

M6 × 1.0

3

7

0.7

5.1

△

Seal guard and swingarm

M5 × 0.8

4

6

0.6

4.3

△

Fuel tank

M6 × 1.0

1

9

0.9

6.5

△

Fuel cock

M6 × 1.0

2

4

0.4

2.9

Seat set bracket and fuel tank

M6 × 1.0

1

7

0.7

5.1

Fuel tank bracket and fuel tank

M6 × 1.0

2

7

0.7

5.1

Side cover set bracket and fuel tank

M6 × 1.0

2

7

0.7

5.1

Fitting band set screw and fuel tank

M6 × 1.0

1

7

0.7

5.1

Part to be tightened

Thread size

Q'ty

Tightening torque

Nm

m•kg

ft•lb

Summary of Contents for 2011 YZ250FA

Page 1: ...LIT 11626 24 17 17D 28199 11 OWNER S SERVICE MANUAL FA Read this manual carefully before operating this vehicle 2011 ...

Page 2: ...Read this manual carefully before operating this vehicle This manual should stay with this vehicle if it is sold ...

Page 3: ... by Yamaha Motor Corporation U S A 1st Edition May 2010 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in Japan P N LIT 11626 24 17 ...

Page 4: ...ANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OP ERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWL EDGE OF ITS CONTROLS AND OPERATING FEATURES AND UNTIL YOU HAVE BEEN TRAINED IN SAFE AND PROPER RIDING TECHNIQUES REGULAR INSPECTIONS AND CAREFUL MAINTENANCE ALONG WITH GOOD RIDING SKILLS WILL ENSURE THAT YOU SAFETY ENJOY THE CAPABILI TIES AND THE RELIABI...

Page 5: ...ill any gasoline on the en gine or exhaust system Never refuel in the vi cinity of an open flame or while smoking 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 imme diately If any gasoline spills onto your skin or clothing immediately wash skin areas with soap and water and change your clothe...

Page 6: ...YAMAHA MOTOR CORPORATION U S A YZ MOTORCYCLE LIMITED WARRANTY ...

Page 7: ...wn to find the required fore edge symbol mark and go to a page for required item and description MANUAL FORMAT All of the procedures in this manual are organized in a sequential step by step format The informa tion 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 t...

Page 8: ...iagram A number that is enclosed by a circle indicates a disassembly step 3 An explanation of jobs and notes is presented in an easy to read way by the use of symbol marks 3 The meanings of the symbol marks are given on the next page 4 A job instruction chart 4 accompanies the exploded diagram providing the order of jobs names of parts notes in jobs etc 5 For jobs requiring more information the st...

Page 9: ...c cur rent A Illustrated symbols 8 to 13 in the exploded diagrams indicate grade of lubricant and loca tion of lubrication point 8 Apply engine oil 9 Apply molybdenum disulfide oil 10 Apply brake fluid 11 Apply lightweight lithium soap base grease 12 Apply molybdenum disulfide grease 13 Apply silicone grease Illustrated symbols 14 to 15 in the exploded diagrams indicate where to apply a locking ag...

Page 10: ...MEMO ...

Page 11: ...TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 REGULAR INSPECTION AND ADJUSTMENTS 3 ENGINE 4 CHASSIS 5 ELECTRICAL 6 TUNING 7 ...

Page 12: ...L FUNCTIONS 1 12 STARTING AND BREAK IN 1 14 TORQUE CHECK POINTS 1 16 CLEANING AND STORAGE 1 17 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 TIGHTENING TORQUES 2 13 LUBRICATION DIAGRAMS 2 20 CABLE ROUTING DIAGRAM 2 24 CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS 3 1 PRE OPERATION INSPECTION AND MAINTENANCE 3 6 ENGINE 3 7 CHASSIS 3 20 ELECT...

Page 13: ...TON 4 40 CLUTCH 4 45 OIL FILTER ELEMENT AND WATER PUMP 4 51 BALANCER 4 57 OIL PUMP 4 60 KICK SHAFT AND SHIFT SHAFT 4 66 CDI MAGNETO 4 73 ENGINE REMOVAL 4 76 CRANKCASE AND CRANKSHAFT 4 81 TRANSMISSION SHIFT CAM AND SHIFT FORK 4 89 CHAPTER 5 CHASSIS FRONT WHEEL AND REAR WHEEL 5 2 FRONT BRAKE AND REAR BRAKE 5 9 FRONT FORK 5 23 HANDLEBAR 5 36 STEERING 5 42 SWINGARM 5 47 REAR SHOCK ABSORBER 5 54 ...

Page 14: ...CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM 6 2 IGNITION SYSTEM 6 4 THROTTLE POSITION SENSOR SYSTEM 6 8 CHAPTER 7 TUNING ENGINE 7 1 CHASSIS 7 8 ...

Page 15: ...asoline only 3FB 2415E 02 4AA 22259 80 WARNING This unit contains high pressure nitrogen gas Mishandling can cause explosion Read owner s manual for instructions Do not incinerate puncture or open 17D 2812P 00 For use only on a closed course in sanctioned competition This motorcycle does not meet EPA noise and emissions standards and is not for general off road recreational riding 1 ...

Page 16: ...nge without notice 1 Clutch lever 2 Hot starter lever 3 Front brake lever 4 Throttle grip 5 Radiator cap 6 Fuel tank cap 7 Engine stop switch 8 Kickstarter crank 9 Fuel tank 10 Radiator 11 Coolant drain bolt 12 Rear brake pedal 13 Valve joint 14 Fuel cock 15 Cold starter knob 16 Air filter 17 Drive chain 18 Shift pedal 19 Oil level check window 20 Front fork ...

Page 17: ... machine is stolen the authorities will need the number to search for and identify your machine VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped on the right of the steering head pipe ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the right side of the engine MODEL LABEL The model label 1 is affixed to the frame un der the rider s s...

Page 18: ...lowing out and is installed to the fuel tank breather hose In this installation make sure the arrow fac es the fuel tank and also downward SPARK PLUG WRENCH This spark plug wrench 1 is used to remove and install the spark plug NIPPLE WRENCH This nipple wrench 1 is used to tighten the spoke JET NEEDLE PULL UP TOOL The jet needle pull up tool 1 is used to pull the jet needle out of the carburetor HA...

Page 19: ... mated parts that have been mated through normal wear Mated parts must be reused as an as sembly or replaced 4 During the machine disassembly clean all parts and place them in trays in the order of disassembly This will speed up assembly time and help assure that all parts are cor rectly reinstalled 5 Keep away from fire ALL REPLACEMENT PARTS 1 We recommend to use Yamaha genuine parts for all repl...

Page 20: ...ds the stamped letters must be on the side ex posed to view When installing oil seal s apply a light coating of lightweight lithium base grease to the seal lip s Oil the bear ings liberally when installing Do not use compressed air to spin the bear ings dry This causes damage to the bearing surfaces CIRCLIPS 1 All circlips should be inspected carefully be fore reassembly Always replace piston pin ...

Page 21: ...eck 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 The two connectors click together 7 Check for continuity with a tester If there in no continuity clean the terminals Be sure to perform the steps 1 to 7 listed above when checking the wire harness For a field remedy use a contact revitalizer available on the ...

Page 22: ...e Part number How to use Illustration Crankcase separating tool YU 1135 A 90890 01135 These tool is used to remove the crankshaft from either case Flywheel puller YM 1189 90890 01189 This tool is used to remove the flywheel magneto Rotor holding tool YU 1235 90890 01235 This tool is used when loos ening or tightening the fly wheel magneto securing nut Dial gauge and stand YU 3097 90890 01252 Stand...

Page 23: ...0 01403 This tool is used when tighten the steering ring nut to speci fication Cap bolt wrench YM 01500 90890 01500 This tool is used to loosen or tighten the base valve Cap bolt ring wrench YM 01501 90890 01501 This tool is used to loosen or tighten the damper assembly Fork seal driver YM A0948 90890 01502 This tool is used when install the fork oil seal Spoke nipple wrench YM 01521 90890 01521 T...

Page 24: ...ld the clutch when removing or in stalling the clutch boss secur ing nut Valve guide remover Intake 4 0 mm 0 16 in Exhaust 4 5 mm 0 18 in YM 4111 90890 04111 YM 4116 90890 04116 This tool is needed to remove and install the valve guide Valve guide installer Intake 4 0 mm 0 16 in Exhaust 4 5 mm 0 18 in YM 4112 90890 04112 YM 4117 90890 04117 This tool is needed to install the valve guide Valve guid...

Page 25: ... necessary for checking the ignition sys tem components Digital tachometer YU 39951 B 90890 06760 This tool is needed for ob serving engine rpm YAMAHA Bond No 1215 ThreeBond No 1215 90890 85505 This sealant Bond is used for crankcase mating surface etc Tool name Part number How to use Illustration ...

Page 26: ...ears can be shifted by using the shift pedal 1 on the left side of the engine KICKSTARTER CRANK Rotate the kickstarter crank 1 away from the engine Push the starter down lightly with your foot until the gears engage then kick smoothly and forcefully to start the engine This model has a primary kickstarter crank so the engine can be started in any gear if the clutch is disen gaged In normal practic...

Page 27: ...l riding is done with the lever in this position COLD STARTER KNOB When cold the engine requires a richer air fuel mixture for starting A separate starter circuit which is controlled by the cold starter knob 1 supplies this mixture Pull the cold starter knob out to open the circuit for starting When the en gine has warmed up push it in to close the cir cuit HOT STARTER LEVER The hot starter lever ...

Page 28: ...the throttle is open because the kickstarter may kick back Also if the throttle is open the air fuel mixture may be too lean for the engine to start Before starting the machine perform the checks in the pre operation check list AIR FILTER MAINTENANCE According to CLEANING THE AIR FILTER ELEMENT section in the CHAPTER 3 apply the foam air filter oil or its equivalent to the ele ment Excess oil in t...

Page 29: ... moderate throttle openings for five to eight minutes 5 Check how the engine runs when the ma chine is ridden with the throttle 1 4 to 1 2 open low to medium speed for about one hour 6 Restart the engine and check the operation of the machine throughout its entire operat ing range Restart the machine and operate it for about 10 to 15 more minutes The ma chine will now be ready to race After the br...

Page 30: ...ink type Assembly of links Link to frame Link to rear shock absorber Link to swingarm Installation of rear shock absorber Rear shock absorber to frame Installation of swingarm Tightening of pivot shaft Wheel Installation of wheel Front Tightening of wheel axle Tightening of axle holder Rear Tightening of wheel axle Wheel to rear wheel sprocket Brake Front Brake caliper to front fork Brake disc to ...

Page 31: ...ith a vinyl upholstery clean er to keep the cover pliable and glossy 8 Automotive wax may be applied to all paint ed or chromed surfaces Avoid combination cleaner waxes as they may contain abra sives 9 After completing the above start the engine and allow it to idle for several minutes STORAGE If your machine is to be stored for 60 days or more some preventive measures must be tak en to avoid dete...

Page 32: ... 990 mm 38 98 in Wheelbase 1 466 mm 57 72 in 1 473 mm 57 99 in Minimum ground clearance 375 mm 14 76 in 377 mm 14 84 in 376 mm 14 80 in Weight With oil and fuel 102 kg 225 lb Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement Single cylinder forward inclined Displacement 250 cm3 8 80 Imp oz 8 45 US oz Bore stroke 77 0 53 6 mm 3 03 2 11 in Compression ratio 13 5 1 Starting system K...

Page 33: ... FCR MX37 Manufacturer KEIHIN Spark plug Type manufacturer CR8E NGK resistance type Gap 0 7 0 8 mm 0 028 0 031 in Clutch type Wet multiple disc Transmission USA CDN EUROPE AUS NZ ZA Primary reduction system Gear Primary reduction ratio 57 17 3 353 Secondary reduction system Chain drive Secondary reduction ratio 49 13 3 769 51 13 3 923 Transmission type Constant mesh 5 speed Operation Left foot ope...

Page 34: ...ar brake type Single disc brake Operation Right foot operation Suspension Front suspension Telescopic fork Rear suspension Swingarm link type monocross suspension Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring gas oil damper Wheel travel USA CDN EUROPE AUS NZ ZA Front wheel travel 300 mm 11 8 in Rear wheel travel 307 mm 12 1 in 310 mm 12 2 in Electrical ...

Page 35: ...amshaft cap inside diameter 22 000 22 021 mm 0 8661 0 8670 in Camshaft outside diameter 21 959 21 972 mm 0 8645 0 8650 in Shaft to cap clearance 0 028 0 062 mm 0 0011 0 0024 in 0 08 mm 0 003 in Cam dimensions Intake A 30 330 30 430 mm 1 1941 1 1980 in 30 230 mm 1 1902 in Intake B 22 45 22 55 mm 0 8839 0 8878 in 22 35 mm 0 8799 in Exhaust A 30 399 30 499 mm 1 1968 1 2007 in 30 299 mm 1 1929 in Exha...

Page 36: ...ve clearance cold IN 0 12 0 17 mm 0 0047 0 0067 in EX 0 17 0 22 mm 0 0067 0 0087 in Valve dimensions A head diameter IN 22 9 23 1 mm 0 9016 0 9094 in A head diameter EX 24 4 24 6 mm 0 9606 0 9685 in B face width IN 2 26 mm 0 089 in B face width EX 2 26 mm 0 089 in C seat width IN 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in C seat width EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Item Standard...

Page 37: ... mm 0 003 in Stem to guide clearance EX 0 025 0 052 mm 0 0010 0 0020 in 0 10 mm 0 004 in Stem runout limit 0 01 mm 0 0004 in Valve seat width IN 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Valve seat width EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in Valve spring Free length IN 39 76 mm 1 57 in 38 76 mm 1 53 in Free length EX 37 78 mm 1 49 in 36 78 mm 1 45 in Set length valve closed IN 28 98 m...

Page 38: ...5 76 970 mm 3 0297 3 0303 in Measuring point H 8 mm 0 31 in Piston off set 0 5 mm 0 020 in IN side Piston pin bore inside diameter 16 002 16 013 mm 0 6300 0 6304 in 16 043 mm 0 6316 in Piston pin outside diameter 15 991 16 000 mm 0 6296 0 6299 in 15 971 mm 0 6288 in Piston rings Top ring Type Barrel Dimensions B T 0 90 2 75 mm 0 04 0 11 in End gap installed 0 15 0 25 mm 0 006 0 010 in 0 50 mm 0 02...

Page 39: ...0 016 in Crankshaft Crank width A 55 95 56 00 mm 2 203 2 205 in Runout limit C 0 03 mm 0 0012 in 0 05 mm 0 002 in Big end side clearance D 0 15 0 45 mm 0 0059 0 0177 in 0 50 mm 0 02 in Small end free play F 0 4 1 0 mm 0 016 0 039 in 2 0 mm 0 08 in Clutch Friction plate thickness 2 9 3 1 mm 0 114 0 122 in 2 8 mm 0 110 in Quantity 9 Clutch plate thickness 1 1 1 3 mm 0 043 0 051 in Quantity 8 Warp li...

Page 40: ...N EUROPE AUS NZ ZA Type manufacturer FCR MX37 KEIHIN I D mark 17D5 50 17D6 60 Main jet M J 180 Main air jet M A J ø2 0 Jet needle clip position J N NDJR 4 NHKR 4 Cutaway C A 1 5 Pilot jet P J 45 42 Pilot air jet P A J 105 Pilot outlet P O ø0 9 Pilot screw example P S 1 3 4 Bypass B P ø1 0 Valve seat size V S ø3 8 Starter jet G S 72 Leak jet Acc P 70 110 Float height F H 8 mm 0 31 in Engine idle sp...

Page 41: ...re 110 kPa 1 1 kg cm2 15 6 psi Radiator capacity total 0 64 L 0 56 Imp qt 0 68 US qt Water pump Type Single suction centrifugal pump Item Standard Limit Item Standard Limit Steering system Steering bearing type Taper roller bearing Front suspension USA CDN EUROPE AUS NZ ZA Front fork travel 300 mm 11 8 in Fork spring free length 454 mm 17 9 in 449 mm 17 7 in Spring rate STD K 4 4 N mm 0 449 kg mm ...

Page 42: ...t End 1 0 mm 0 04 in Wheel Front wheel type Spoke wheel Rear wheel type Spoke wheel Front rim size material 21 1 60 Aluminum Rear rim size material 19 1 85 Aluminum Rim runout limit Radial 2 0 mm 0 08 in Lateral 2 0 mm 0 08 in Drive chain USA CDN EUROPE AUS NZ ZA Type manufacturer DID520DMA2 SDH DAIDO Number of links 111 links joint 113 links joint Chain slack 50 60 mm 2 0 2 4 in Chain length 15 l...

Page 43: ...eight above footrest top Zero mm Zero in Clutch lever free play lever end 7 12 mm 0 28 0 47 in Throttle grip free play 3 5 mm 0 12 0 20 in Item Standard Limit Item Standard Limit Ignition system Advancer type Electrical CDI Magneto model stator manufacturer 17D 50 YAMAHA Charging coil 1 resistance color 720 1 080 Ωat 20 C 68 F Green Brown Charging coil 2 resistance color 44 66 Ωat 20 C 68 F Black ...

Page 44: ...side M6 1 0 2 10 1 0 7 2 Timing chain tensioner M6 1 0 2 10 1 0 7 2 Timing chain tensioner cap bolt M6 1 0 1 7 0 7 5 1 Impeller M8 1 25 1 14 1 4 10 Radiator hose clamp M6 1 0 10 2 0 2 1 4 Coolant drain bolt M6 1 0 1 10 1 0 7 2 Water pump housing M6 1 0 4 10 1 0 7 2 Radiator M6 1 0 6 10 1 0 7 2 Radiator pipe M6 1 0 1 10 1 0 7 2 Oil pump cover M4 0 7 1 1 7 0 17 1 2 Oil pump M6 1 0 3 10 1 0 7 2 Oil f...

Page 45: ...crankshaft M6 1 0 4 14 1 4 10 Left crankcase cover M6 1 0 8 10 1 0 7 2 Right crankcase cover M6 1 0 8 10 1 0 7 2 Clutch cover M6 1 0 7 10 1 0 7 2 Crankcase oil drain bolt M10 1 25 1 20 2 0 14 Crankshaft end accessing screw M32 1 5 1 Timing mark accessing screw M14 1 5 1 Drive chain sprocket cover M6 1 0 2 7 0 7 5 1 Kick shaft ratchet wheel guide M6 1 0 2 12 1 2 8 7 Kickstarter crank M8 1 25 1 33 3...

Page 46: ... bracket and brake hose guide M6 1 0 1 9 0 9 6 5 Front fork protector and brake hose holder M6 1 0 2 8 0 8 5 8 Throttle grip cap M5 0 8 2 4 0 4 2 9 Front brake master cylinder M6 1 0 2 9 0 9 6 5 Brake lever mounting bolt M6 1 0 1 6 0 6 4 3 Brake lever mounting nut M6 1 0 1 6 0 6 4 3 Brake lever position locknut M6 1 0 1 5 0 5 3 6 Clutch lever holder M6 1 0 2 5 0 5 3 6 Clutch lever mounting nut M6 ...

Page 47: ...acket M6 1 0 2 7 0 7 5 1 Cable guide and frame M6 1 0 2 7 0 7 5 1 Pivot shaft and nut M16 1 5 1 85 8 5 61 Relay arm and swingarm M14 1 5 1 70 7 0 50 Relay arm and connecting rod M14 1 5 1 80 8 0 58 Connecting rod and frame M14 1 5 1 80 8 0 58 Rear shock absorber and frame M10 1 25 1 56 5 6 40 Rear shock absorber and relay arm M10 1 25 1 53 5 3 38 Rear frame upper M8 1 25 2 32 3 2 23 Rear frame low...

Page 48: ...4 7 0 7 5 1 Air scoop and frame M6 1 0 2 7 0 7 5 1 Radiator mounting boss and frame M10 1 25 2 20 2 0 14 Front fender M6 1 0 4 10 1 0 7 2 Rear fender front M6 1 0 2 7 0 7 5 1 Rear fender rear M6 1 0 2 16 1 6 11 Side cover M6 1 0 2 7 0 7 5 1 Seat M8 1 25 2 23 2 3 17 Number plate M6 1 0 1 7 0 7 5 1 Part to be tightened Thread size Q ty Tightening torque Nm m kg ft lb Part to be tightened Thread size...

Page 49: ...warpage tighten multi fastener assemblies in a crisscross fash ion in progressive stages until full torque is reached Unless otherwise specified torque specifications call for clean dry threads Com ponents should be at room temperature A Distance between flats B Outside thread diameter A Nut B Bolt TORQUE SPECIFICA TION Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 ...

Page 50: ...imeter 10 2 meter Length kg kilogram 103 gram Weight N Newton 1 kg m sec2 Force Nm Newton meter N m Torque m kg Meter kilogram m kg Torque Pa Pascal N m2 Pressure N mm Newton per millimeter N mm Spring rate L Liter Volume or capacity cm3 Cubic centimeter Volume or capacity r min Revolution per minute Engine speed ...

Page 51: ......

Page 52: ...2 20 LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS ...

Page 53: ...2 21 LUBRICATION DIAGRAMS 1 Oil filter element 2 Oil pump 3 Drive axle 4 Main axle 5 Intake camshaft 6 Exhaust camshaft 7 Oil tank 8 Oil delivery pipe A To oil tank ...

Page 54: ...2 22 LUBRICATION DIAGRAMS ...

Page 55: ...2 23 LUBRICATION DIAGRAMS 1 Crankshaft 2 Oil filter element 3 Oil tank 4 Oil hose A From oil pump ...

Page 56: ...2 24 CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM A B A C B C ...

Page 57: ...hose into the hole in the steering stem B Aligh the paint mark on the cylinder head breather hose with the front end of the hose guide C Pass the cylinder head breather hose on the outside of front engine bracket D Pass the cylinder head breather hose be tween the radiator and radiator hose 3 E Pass the fuel hose on the outside of throttle position sensor lead F Pass the carburetor breather hoses ...

Page 58: ...2 26 CABLE ROUTING DIAGRAM E K E F G H H F I J A A B D D C J C G B K E M M H H K K E E D D M M F F A A I L L ...

Page 59: ... J Pass the hot starter cable on the inside of the cylinder head breather hose K Fit the coupler projection into the hole in the cover L Fasten the sub wire harness on the CDI unit bracket M Fasten the sub wire harness at the posi tion taped portion N Pass each lead under the clamp Locate the CDI magneto lead on the outside of the ignition coil lead Locate the throttle posi tion sensor lead neutra...

Page 60: ...2 28 CABLE ROUTING DIAGRAM C A B B A C ...

Page 61: ...il B Pass the throttle cables through the cable guide C Pass the throttle cable over the radiator mounting boss Cross the throttle cable be hind the radiator D Pass the throttle cables on the outside of the ignition coil E Insert the engine stop switch lead into the CDI unit band Align the coupler lower end with the band lower end F Fit the hole in the CDI unit band over the CDI unit bracket ...

Page 62: ...2 30 CABLE ROUTING DIAGRAM ...

Page 63: ...n directs as shown and lightly touches the projection on the brake caliper B Pass the brake hose into the brake hose holders C If the brake hose contacts the spring rear shock absorber correct its twist D Install the brake hose so that its pipe por tion directs as shown and lightly touches the projection on the brake master cylinder ...

Page 64: ...2 32 CABLE ROUTING DIAGRAM A C B C B A ...

Page 65: ...andlebar B Pass the clutch cable and hot starter cable through the cable guide C Pass the engine stop switch lead behind the CDI unit D Pass the brake hose in front of the number plate E Pass the throttle cables through the cable guide F Pass the clutch cable and hot starter cable through the cable guide on the number plate G Pass the engine stop switch lead over the number plate mounting location...

Page 66: ...ially according to the environment in which the machine runs e g rain dirt etc Therefore earlier inspection is required by reference to the list below Item After break in Every race about 2 5 hours Every third about 7 5 hours Every fifth about 12 5 hours As re quired Remarks ENGINE OIL Replace Inspect OIL FILTER ELEMENT OIL STRAINER Clean VALVES Check the valve clearanc es The engine must be cold ...

Page 67: ...sket CYLINDER Inspect and clean Inspect score marks Replace Inspect wear CLUTCH Inspect and adjust Inspect housing friction plate clutch plate and spring Replace TRANSMISSION Inspect Replace bearing SHIFT FORK SHIFT CAM GUIDE BAR Inspect Inspect wear ROTOR NUT Retighten EXHAUST PIPE SILENC ER PROTECTOR Inspect and retighten Clean Replace Replace fiber When the exhaust sound be comes louder or when...

Page 68: ...cap opera tion Replace coolant Every two years Inspect hoses OUTSIDE NUTS AND BOLTS Retighten Refer to STARTING AND BREAK IN section in the CHAPTER 1 AIR FILTER Clean and lubricate Use foam air filter oil or equiva lent oil Replace OIL FILTER Replace OIL STRAINER Clean ENGINE GUARD Replace Breakage FRAME Clean and inspect FUEL TANK COCK Clean and inspect Item After break in Every race about 2 5 ho...

Page 69: ...ce oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube Lithium base grease PROTECTOR GUIDE Replace REAR SHOCK ABSORBER Inspect and adjust Lube After rain ride Molybdenum disulfide grease Replace spring seat Every one year Retighten DRIVE CHAIN GUIDE AND ROLLERS Inspect SWINGARM Inspect lube and retighten Molybdenum disulfide grease RELAY ARM CONNECT ING ROD Inspect lube and retighten Molybde...

Page 70: ...ct bearings Replace bearings Lubricate Lithium base grease THROTTLE CONTROL CABLE Check routing and con nection Lubricate Yamaha cable lube or SAE 10W 40 motor oil Inspect and clean throttle cable Inspect dirt and wear on the throttle cable on the carburetor side HOT STARTER CLUTCH LEVER Inspect free play Item After break in Every race about 2 5 hours Every third about 7 5 hours Every fifth about ...

Page 71: ...hain slack and alignment Check that the drive chain is lubricated properly P 3 25 27 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 32 33 Steering Check that the handlebar can be turned smoothly and have no excessive play P 3 33 34 Front forks and rear shock absorber Check that they operate smoothly and there is no oil leakage P 3 27 32 Cabl...

Page 72: ...n a level place and hold it in an upright position 2 Remove Radiator cap 3 Check Coolant level a Coolant level low Add coolant 1 Radiator CHANGING THE COOLANT Do not remove the radiator cap when the en gine is hot 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 Coolant drain bolt 1 3 Remove Radiator ...

Page 73: ... 8 Check Coolant level Coolant level low Add coolant CHECKING THE RADIATOR CAP 1 Inspect Seal radiator cap 1 Valve and valve seat 2 Crack damage Replace Exist fur deposits 3 Clean or replace CHECKING THE RADIATOR CAP OPENING PRESSURE 1 Attach Radiator cap tester 1 and adapter 2 Apply water on the radiator cap seal 3 Radiator cap 2 Apply the specified pressure 3 Inspect Pressure Impossible to maint...

Page 74: ...s 1 b Turn the adjusting bolt 2 until the clutch le ver position a is in the desiered position c Tighten the locknuts 2 Adjust Clutch cable free play Refer to ADJUSTING THE CLUTCH CA BLE FREE PLAY ADJUSTING THE CLUTCH CABLE FREE PLAY 1 Check Clutch lever free play a Out of specification Adjust 2 Adjust Clutch lever free play Clutch lever free play adjustment steps a Loosen the locknuts 1 b Turn th...

Page 75: ...y Throttle grip free play adjustment steps a Slide the adjuster cover b Loosen the locknut 1 c Turn the adjuster 2 until the specified free play is obtained d Tighten the locknut Before adjusting the throttle cable free play the engine idle speed should be adjusted After adjusting the throttle cable free play start the engine and turn the handlebar to right and left and make sure that the engine i...

Page 76: ...G THE AIR FILTER ELEMENT Proper air filter maintenance is the biggest key to preventing premature engine wear and dam age Never run the engine without the air filter el ement in place this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage 1 Remove Seat Fitting bolt 1 Washer 2 Air filter element 3 Air filter guide 4 2 Clean Air filter element Clean them w...

Page 77: ...lter element 1 Washer Fitting bolt Align the projection a on filter guide with the hole b in air filter case CHECKING THE ENGINE OIL LEVEL 1 Start the engine warm it up for several min utes 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 suit able stand under the engine 3 Inspect Oil level The engine oil ...

Page 78: ...ENGINE OIL 1 Start the engine and warm it up for several minutes and then turn off the engine and wait for five minute 2 Place the machine on a level place and hold it on upright position by placing the suitable stand under the engine 3 Place a suitable container under the engine 4 Remove Lower engine guard 1 Bolt oil tank 2 Washer 3 Oil filler cap 4 Oil tank drain bolt 5 Crankcase oil drain bolt ...

Page 79: ...er washer Oil filter element drain bolt Crankcase oil drain bolt Oil tank drain bolt Lower engine guard 10 Fill Engine oil 11 Check Oil leakage Oil filter element cover 10 Nm 1 0 m kg 7 2 ft lb Oil strainer 9 Nm 0 9 m kg 6 5 ft lb Bolt oil hose 8 Nm 0 8 m kg 5 8 ft lb Oil hose clamp 2 Nm 0 2 m kg 1 4 ft lb Oil filter element drain bolt 10 Nm 1 0 m kg 7 2 ft lb Crankcase oil drain bolt 20 Nm 2 0 m ...

Page 80: ...e pilot screw turn it in fully and count the number of turns Record this number as the factory set number of turns out a Turn in the pilot screw until it is lightly seat ed b Turn out the pilot screw by the factory set number of turns ADJUSTING THE ENGINE IDLING SPEED 1 Start the engine and thoroughly warm it up 2 Adjust Engine idling speed Adjustment steps a Adjust the pilot screw Refer to ADJUST...

Page 81: ...ERS section in the CHAPTER 4 2 Remove Spark plug Cylinder head cover Refer to CAMSHAFTS section in the CHAPTER 4 3 Remove Timing mark accessing screw 1 Crankshaft end accessing screw 2 O ring 4 Check Valve clearance Out of specification Adjust Checking steps a Turn the crankshaft counterclockwise with a wrench b Align the T D C mark a on the rotor with the align mark b on the crankcase cover when ...

Page 82: ...einstalled in their original place c Select the proper pad using the pad select ing table The thickness a of each pad is indicated in hundredths of millimeters on the pad upper sur face d Round off the last digit of the installed pad number to the nearest increment EXAMPLE Installed pad number 148 Rounded off value 150 Pads can only be selected in 0 05 mm incre ments Pad range Pad Availability 25 ...

Page 83: ...s a guide when verifying the valve clearance adjustment f Install the new pads 3 and the valve lifters 4 Apply the engine oil on the valve lifters Apply the molybdenum disulfide oil on the valve stem ends Valve lifter must turn smoothly when rotated with a finger Be careful to reinstall valve lifters and pads in their original place g Install the camshafts exhaust and intake Refer to CAMSHAFTS sec...

Page 84: ...EASURED CLEARANCE INSTALLED PAD NUMBER STANDARD CLEARANCE Pad number example Pad No 175 1 75 mm Pad No 185 1 85 mm MEASURED CLEARANCE INSTALLED PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0 05 0 09 120 125 130 135 140 145 150 155 160 1...

Page 85: ... sever al times f Pull the lever in or push down on the pedal Hold the lever or pedal in position g Loosen the bleed screw and allow the lever or pedal to travel towards its limit h Tighten the bleed screw when the lever or pedal limit has been reached then release the lever or pedal i Repeat steps e to h until of the air bub bles have been removed from the system If bleeding is difficult it may b...

Page 86: ...eight a Out of specification Adjust 2 Adjust Brake pedal height Pedal height adjustment steps a Loosen the locknut 1 b Turn the adjusting nut 2 until the pedal height a is within specified height c Tighten the locknut Adjust the pedal height between the maxi mum A and the minimum B as shown In this adjustment the bolt 3 end b should protrude out of the threaded por tion 4 but not be less than 2 mm...

Page 87: ...d brake pads 4 e Connect the transparent hose 5 to the bleed screw 6 and place the suitable con tainer under its end f Loosen the bleed screw and push the brake caliper piston in Do not reuse the drained brake fluid g Tighten the bleed screw h Install the brake pads 7 and pad pin Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at th...

Page 88: ...CING THE REAR BRAKE PADS 1 Inspect Brake pad thickness a Out of specification Replace as a set 2 Replace Brake pad Brake pad replacement steps a Remove the protector 1 and pad pin plug 2 b Loosen the pad pin 3 c Remove the rear wheel 4 and brake caliper 5 Refer to FRONT WHEEL AND REAR WHEEL section in the CHAPTER 5 d Remove the pad pin 6 and brake pads 7 Bolt brake caliper 28 Nm 2 8 m kg 20 ft lb ...

Page 89: ...l 13 Refer to FRONT WHEEL AND REAR WHEEL section in the CHAPTER 5 j Tighten the pad pin 14 k Install the pad pin plug 15 and protector 16 3 Inspect Brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL section 4 Check Brake pedal operation A softy or spongy feeling Bleed brake sys tem Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM section CHECKING THE REAR BRAKE PAD INSULATOR 1 Remove Brake pad ...

Page 90: ...ly to avoid erosion of painted surfaces or plastic parts a Lower level A Front B Rear CHECKING THE SPROCKET 1 Inspect Sprocket teeth a Excessive wear Replace Replace the drive sprocket rear wheel sprock et and drive chain as a set CHECKING THE DRIVE CHAIN 1 Measure Drive chain length 15 links a Out of specification Replace While measuring the drive chain length push down on the drive chain to incr...

Page 91: ...K 1 Elevate the rear wheel by placing the suit able stand under the engine 2 Check Drive chain slack a Above the seal guard installation bolt Out of specification Adjust Before checking and or adjusting rotate the rear wheel through several revolutions and check the slack several times to find the tightest point Check and or adjust the drive chain slack with the rear wheel in this tight chain posi...

Page 92: ...ive chain e Tighten the locknuts CHECKING THE FRONT FORK 1 Inspect Front fork smooth action Operate the front brake and stroke the front fork Unsmooth action oil leakage Repair or re place CHECKING THE FRONT FORK PROTECTOR GUIDE 1 Inspect Protector guide 1 Out of specification Replace The protector guide reaches the limit of its use when it is worn down to the same height a as of the outer tube ci...

Page 93: ...w ADJUSTING THE FRONT FORK REBOUND DAMPING FORCE 1 Adjust Rebound damping force By turning the adjuster 1 STANDARD POSITION This is the position which is back by the spe cific number of clicks from the fully turned in position Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be damaged Air bleed screw 1 Nm 0 1 m kg 0 7 ft lb Stiffer a Increase the reboun...

Page 94: ... and loss of stability CHECKING THE REAR SHOCK ABSORBER 1 Inspect Swingarm smooth action Abnormal noise unsmooth action Grease the pivoting points or repair the pivoting points Damage oil leakage Replace ADJUSTING THE REAR SHOCK ABSORBER SPRING PRELOAD 1 Elevate the rear wheel by placing the suit able stand under the engine 2 Remove Rear frame 3 Measure Spring fitting length Stiffer a Increase the...

Page 95: ...r of clicks from the fully turned in position Which align the punch mark a on the adjuster with the punch mark b on the bracket Do not force the adjuster past the minimum or maximum extent of adjustment The ad juster may be damaged Stiffer Increase the spring preload Turn the adjuster 2 in Softer Decrease the spring preload Turn the adjuster 2 out Extent of adjustment Maximum Minimum Position in w...

Page 96: ...uster 1 STANDARD POSITION This is the position which is back by the spe cific number of turns from the fully turned in position Which align the punch mark a on the adjuster with the punch mark b on the adjuster body Stiffer a Increase the low compression damping force Turn the adjuster 1 in Softer b Decrease the low compres sion damping force Turn the adjuster 1 out Extent of adjustment Maximum Mi...

Page 97: ...d the tire is considered to be slipping off its position Cor rect the tire position CHECKING AND TIGHTENING THE SPOKES The following procedure applies to all of the spokes 1 Check Spokes Bend damage Replace Loose spoke Retighten Tap the spokes with a screwdriver A tight spoke will emit a clear ringing tone a loose spoke will sound flat 2 Tighten Spokes with a spoke nipple wrench 1 Be sure to retig...

Page 98: ...st steering head 3 Check Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steering ring nut 4 Adjust Steering ring nut Steering ring nut adjustment steps a Remove the number plate b Remove the handlebar and upper bracket c Loosen the steering ring nut 1 using the steering nut wrench 2 d Tighten the steering ring nut 3 using steer ing nut wrench 4 Apply the lithium soap...

Page 99: ...handlebar upper holder should be in stalled with the punched mark a forward Install the handlebar so that the marks b are in place on both sides Install the handlebar so that the projection c of the handlebar upper holder is positioned at the mark on the handlebar as shown Insert the end of the fuel breather hose 11 into the hole in the steering stem First tighten the bolts on the front side of th...

Page 100: ...vot 5 Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding portion 8 Throttle cable end 9 Clutch cable end 10 Hot starter cable end A Use Yamaha cable lube or equivalent on these areas B Use SAE 10W 40 motor oil or suitable chain lubricants C Lubricate the following areas with high quality lightweight lithium soap base grease Wipe off any excess grease and avoid get ting grease o...

Page 101: ...a wire gauge or thickness gauge Out of specification Regap 4 Clean the plug with a spark plug cleaner if necessary 5 Tighten Spark plug Before installing a spark plug clean the gas ket surface and plug surface Finger tighten a the spark plug before torqu ing to specification b CHECKING THE IGNITION TIMING 1 Remove Timing mark accessing screw 1 2 Attach Timing light Digital tachometer To the igniti...

Page 102: ...ECTRICAL 4 Check Ignition timing Visually check the stationary pointer a is within the firing range b on the rotor Incorrect firing range Check rotor and pick up assembly 5 Install Timing mark accessing screw ...

Page 103: ...icing of Yamaha motorcycles e g Yamaha dealers service engineers etc Those who have little knowl edge and skill concerning servicing are requested not to undertake inspection adjustment disas sembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage 4 ...

Page 104: ...OVERS Order Part name Q ty Remarks Turn the fuel cock to OFF Disconnect the fuel hose 1 Seat 1 2 Air scoop left and right 2 3 Bolt fuel tank 1 4 Fitting band 1 5 Fuel tank 1 6 Left side cover 1 Refer to removal section 7 Right side cover 1 Refer to removal section 8 Number plate 1 Refer to removal section ...

Page 105: ...ter case REMOVING THE NUMBER PLATE 1 Remove Bolt number plate Number plate 1 The projection a is inserted into the band of the number plate Pull the band off the projec tion before removal Remove the hot starter cable 2 and clutch cable 3 from the cable guide b on the num ber plate The projection c on the lower bracket is in serted into the number plate Remove the number plate by pulling it off th...

Page 106: ...der Part name Q ty Remarks A Except for USA and CDN Right side cover Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Bolt silencer clamp 1 Only loosening 2 Bolt silencer front 1 3 Bolt silencer rear 1 4 Silencer 1 5 Silencer clamp 1 6 Nut exhaust pipe 2 7 Exhaust pipe 1 8 Gasket 2 9 Wave washer 3 ...

Page 107: ...oft hammer 2 Replace Fiber 1 3 Install Inner pipe 1 Rivet front 2 Apply heat resistant sealant along the plate edge a on the inside of the silencer and also along the silencer edge b as shown Take care not to allow the fiber out of place when installing the inner pipe INSTALLING THE SILENCER AND EXHAUST PIPE 1 Install Gasket Exhaust pipe 1 Nut exhaust pipe 2 First temporarily tighten both nuts to ...

Page 108: ...asket 2 Silencer 3 Washer 4 Bolt silencer 5 Install the gasket with its meshed area a to ward the exhaust pipe side The gasket should be installed according to the dimension shown Silencer clamp 14 Nm 1 4 m kg 10 ft lb Bolt silencer 30 Nm 3 0 m kg 22 ft lb New ...

Page 109: ...t and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Radiator guard 2 2 Radiator hose clamp 10 Only loosening 3 Clutch cable holder 1 4 Radiator hose 1 1 5 Left radiator 1 6 Radiator hose 4 1 7 Pipe 1 8 Radiator hose 5 1 9 Right radiator 1 10 Radiator hose 2 1 2 4 2 3 13 2 2 2 2 2 11 7 8 2 2 6 9 2 10 12 1 5 1 T R 20 Nm 2 0 m kg 14 ft Ib ...

Page 110: ...4 8 RADIATOR 11 Radiator hose 3 1 12 Radiator breather hose 1 13 Radiator pipe 1 1 Order Part name Q ty Remarks 2 4 2 3 13 2 2 2 2 2 11 7 8 2 2 6 9 2 10 12 1 5 1 T R 20 Nm 2 0 m kg 14 ft Ib ...

Page 111: ... on the cap while turning counter clockwise and remove it CHECKING THE RADIATOR 1 Inspect Radiator core 1 Obstruction Blow out with compressed air through rear of the radiator Bent fin Repair replace INSTALLING THE RADIATOR 1 Install O ring 1 Radiator pipe 1 2 Bolt radiator pipe 3 Apply the lithium soap base grease on the O ring 2 Install Radiator breather hose 1 Radiator hose 2 2 Radiator hose 4 ...

Page 112: ...NG DIAGRAM section in the CHAPTER 2 5 Tighten Radiator hose clamp 4 6 Install Radiator guard 1 First fit the inner hook portion a and then the outer one b onto the radiator Bolt left radiator 10 Nm 1 0 m kg 7 2 ft lb Radiator hose 1 2 Nm 0 2 m kg 1 4 ft lb Radiator hose clamp 2 Nm 0 2 m kg 1 4 ft lb ...

Page 113: ...Throttle cable cover 1 4 Throttle cable 2 5 Clamp air filter joint 1 Loosen the screw air filter joint 6 Clamp carburetor joint 1 Loosen the screws carburetor joint 7 Hot starter plunger 1 8 Carburetor assembly 1 9 Carburetor joint 1 4 Nm 0 4 m kg 2 9 ft lb 4 Nm 0 4 m kg 2 9 ft lb 2 Nm 0 2 m kg 1 4 ft lb 3 Nm 0 3 m kg 2 2 ft lb 3 Nm 0 3 m kg 2 2 ft lb 11 Nm 1 1 m kg 8 0 ft lb 10 Nm 1 0 m kg 7 2 ft...

Page 114: ...se 4 2 Valve lever housing cover 1 3 Screw throttle shaft 1 4 Throttle valve 1 5 Needle holder 1 6 Jet needle 1 7 Accelerator pump cover 1 8 Spring 1 9 Diaphragm accelerator pump 1 10 Float chamber 1 11 Leak jet 1 12 Pilot screw 1 Refer to removal section 13 Float pin 1 14 Float 1 15 Needle valve 1 ...

Page 115: ...1 17 Needle jet 1 18 Spacer 1 19 Pilot jet 1 20 Starter jet 1 21 Push rod 1 Pull the push rod 22 Throttle shaft assembly 1 23 Push rod link lever assembly 1 24 Pilot air jet 1 25 Cold starter plunger 1 Order Part name Q ty Remarks ...

Page 116: ... count the number of turns Record this number as the factory set number of turns out CHECKING THE CARBURETOR 1 Inspect Carburetor body Contamination Clean Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air Never use a wire 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 Use a petro...

Page 117: ...e direc tion 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 in correct measurement b Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers The float arm should be resting on the needle valve but not compressing the ...

Page 118: ... Replace CHECKING THE 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 ASSEMBLING THE CARBURETOR 1 Install Cold starter plunger 1 2 Install Pilot air jet 1 ...

Page 119: ...the bigger hook a of the spring fits on the stopper b of the throttle shaft pulley 8 Install Throttle shaft assembly 1 Washer metal 2 Washer resin 3 Valve lever 4 Apply the fluorochemical grease on the bear ings Fit the projection a on the throttle shaft as sembly into the slot b in the throttle position sensor Make sure the stopper c of the spring fits into the recess in the carburetor Turn the t...

Page 120: ...edle valve 1 Float 2 Float pin 3 After installing the needle valve to the float in stall 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 a Turn in the pilot screw until it is lightly seat ed b Turn out the pilot screw by the number of turns recorded before removing Pilot screw example 1 3 4 turns ...

Page 121: ...4 Hose holder drain hose 5 Screw accelerator pump cover 6 Install the diaphragm accelerator pump with its mark a facing the spring 15 Install Jet needle 1 Collar 2 Spring 3 Needle holder 4 Throttle valve plate 5 To throttle valve 6 16 Install Throttle valve assembly 1 Screw throttle shaft 2 Install the valve lever rollers 3 into the slits a of the throttle valve 17 Install O ring 1 Valve lever hou...

Page 122: ...valve plate 1 the rod 2 etc with the same outer diameter as the specified value a Fully turn in the accelerator pump adjusting screw 3 b Check that the link lever 4 has free play b by pushing lightly on it c Gradually turn out the adjusting screw while moving the link lever until it has no more free play INSTALLING THE CARBURETOR 1 Install Carburetor joint 1 2 Install Carburetor 1 Install the proj...

Page 123: ...CHAPTER 3 7 Install Throttle cable cover 1 Bolt throttle cable cover 2 8 Install Throttle position sensor lead coupler 1 Clamp 2 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 Hot starter plunger 2 Nm 0 2 m kg 1 4 ft lb Bolt carburetor joint 3 Nm 0 3 m kg 2 2 ft lb Bolt air filter joint 3 Nm 0 3 m kg 2 2 ft lb Throttle cable pull 4 Nm 0 4 m kg 2 9 ft lb Throttle cable return 11 Nm 1 1 m k...

Page 124: ... Order Part name Q ty Remarks Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Spark plug 1 2 Cylinder head breather hose 1 3 Bolt cylinder head cover 2 4 Cylinder head cover 1 5 Cylinder head cover gasket 1 6 Timing chain guide top side 1 ...

Page 125: ...shaft end accessing screw 1 Refer to removal section 3 Timing chain tensioner cap bolt 1 Refer to removal section 4 Timing chain tensioner 1 Refer to removal section 5 Camshaft cap 2 Refer to removal section 6 Clip 2 Refer to removal section 7 Exhaust camshaft 1 Refer to removal section 8 Intake camshaft 1 Refer to removal section ...

Page 126: ...roke In order to be sure that the piston is at Top Dead Center the punch mark c on the ex haust camshaft and the punch mark d on the intake camshaft must align with the cylinder head surface as shown in the illustration 3 Remove Timing chain tensioner cap bolt 1 Timing chain tensioner 2 Gasket 4 Remove Bolt camshaft cap 1 Camshaft cap 2 Clip Remove the bolts camshaft cap in a criss cross pattern w...

Page 127: ...Out of specification Measure camshaft outside diameter Measurement steps a Install the camshaft onto the cylinder head b Position a strip of Plastigauge 1 onto the camshaft Cam lobes length Intake a 30 330 30 430 mm 1 1941 1 1980 in Limit 30 230 mm 1 1902 in Intake b 22 45 22 55 mm 0 8839 0 8878 in Limit 22 35 mm 0 8799 in Exhaust a 30 399 30 499 mm 1 1968 1 2007 in Limit 30 299 mm 1 1929 in Exhau...

Page 128: ... Replace the camshaft Within specification Replace camshaft case and camshaft caps as a set CHECKING THE CAMSHAFT SPROCKET 1 Inspect Camshaft sprocket 1 Wear damage Replace the camshaft as sembly and timing chain as a set CHECKING THE DECOMPRESSION SYSTEM 1 Check Decompression system Checking steps a Check that the decompression mechanism cam 1 moves smoothly b Check that the decompression mechani...

Page 129: ... with a wrench Apply the molybdenum disulfide oil on the camshafts Apply the engine oil on the decompression system b Align the T D C mark a on the rotor with the align mark b on the crankcase cover when piston is at T D C on compression stroke c Fit the timing chain 3 onto both camshaft sprockets and install the camshafts on the cylinder head The camshafts should be installed onto the cyl inder h...

Page 130: ...ile pressing the tensioner rod lightly with fingers use a thin screwdriver and wind the tensioner rod up fully clockwise b With the rod fully wound and the chain ten sioner UP mark a facing upward install the gasket 1 and the timing chain tensioner 2 and tighten the bolt 3 to the specified torque c Release the screwdriver check the tension er rod to come out and tighten the gasket 4 and the cap bo...

Page 131: ...side 1 Cylinder head cover gasket 2 Cylinder head cover 3 Bolt cylinder head cover 4 Apply the sealant on the cylinder head cover gasket 7 Install Cylinder head breather hose Spark plug Bolt cylinder head cover 10 Nm 1 0 m kg 7 2 ft lb YAMAHA Bond No 1215 Three Bond No 1215 90890 85505 Spark plug 13 Nm 1 3 m kg 9 4 ft lb ...

Page 132: ...cer Refer to EXHAUST PIPE AND SI LENCER section Radiator hose 1 Disconnect at cylinder head side Carburetor Refer to CARBURETOR section Camshaft Refer to CAMSHAFTS section Upper engine bracket Refer to ENGINE REMOVAL sec tion 1 Radiator pipe 1 2 Oil delivery pipe 1 3 Nut 2 4 Bolt L 135 mm 5 31 in 2 5 Bolt L 145 mm 5 71 in 2 6 Cylinder head 1 7 Timing chain guard exhaust side 1 ...

Page 133: ...e the warpage c If the warpage is out of specification resur face the cylinder head d Place a 400 600 grit wet sandpaper on the surface plate and resurface the head using a figure eight sanding pattern To ensure an even surface rotate the cylinder head several times INSTALLING THE CYLINDER HEAD 1 Install Dowel pin 1 Cylinder head gasket 2 Timing chain guide exhaust side 3 Cylinder head 4 While pul...

Page 134: ...ag es 3 Install Copper washer 1 Oil delivery pipe 2 Union bolt M8 3 Union bolt M10 4 First tighten the union bolts temporarily Then retighten them with the width a across flats of the oil delivery pipe held tight with a spanner 4 Install Radiator pipe 1 Bolt radiator pipe 2 Union bolt M8 18 Nm 1 8 m kg 13 ft lb Union bolt M10 20 Nm 2 0 m kg 14 ft lb Bolt radiator pipe 10 Nm 1 0 m kg 7 2 ft lb ...

Page 135: ...me Q ty Remarks Cylinder head Refer to CYLINDER HEAD section 1 Valve lifter 5 Refer to removal section 2 Adjusting pad 5 Refer to removal section 3 Valve cotter 10 Refer to removal section 4 Valve spring retainer 5 5 Valve spring 5 6 Valve stem seal 5 7 Valve spring seat 5 8 Exhaust valve 2 9 Intake valve 3 ...

Page 136: ... b Check that the valve seals properly There should be no leakage at the valve seat 2 3 Remove Valve cotter Attach a valve spring compressor 1 between the valve spring retainer and the cylinder head to remove the valve cotters CHECKING THE VALVE 1 Measure Stem to guide clearance Out of specification Replace the valve guide Valve spring compressor YM 4019 90890 04019 Stem to guide clearance valve g...

Page 137: ...e the valve seat 3 Inspect Valve face Pitting wear Grind the face Valve stem end Mushroom shape or diameter larger than the body of the stem Replace 4 Measure Margin thickness a Out of specification Replace Valve guide installation height a Intake 11 8 12 2 mm 0 46 0 48 in Exhaust 11 3 11 7 mm 0 44 0 46 in Valve guide remover Intake 4 0 mm 0 16 in YM 4111 90890 04111 Exhaust 4 5 mm 0 18 in YM 4116...

Page 138: ...tern d Measure the valve seat width Where the valve seat and valve face made contact blueing will have been removed e If the valve seat is too wide too narrow or the seat is not centered the valve seat must be refaced 9 Lap Valve face Valve seat This model uses titanium intake and ex haust valves Titanium valves that have been used to lap the valve seats must not be used Always replace lapped valv...

Page 139: ...l of the compound from the valve face and valve seat f Apply Mechanic s blueing dye Dykem to the valve face g Install the valve into the cylinder head h Press the valve through the valve guide and onto the valve seat to make a clear pattern i Measure the valve seat width again If the valve seat width is out of specification reface and relap the valve seat CHECKING THE VALVE SPRINGS 1 Measure Valve...

Page 140: ...alve stem and valve stem seal 2 Install Valve 1 Valve spring seat 2 Valve stem seal 3 Valve spring 4 Valve spring retainer 5 To cylinder head Make sure that each valve is installed in its original place also referring to the painted color as follows Intake middle a Sky blue Intake right left b not paint Exhaust c Purple Install the valve springs with the larger pitch d facing upward e Smaller pitc...

Page 141: ...e valve tip with a piece of wood Hitting the valve tip with excessive force could damage the valve 5 Install Adjusting pad 1 Valve lifter 2 Apply the molybdenum disulfide oil on the valve stem end Apply the engine oil on the valve lifters Valve lifter must turn smoothly when rotated with a finger Be careful to reinstall valve lifters and pads in their original place Valve spring compressor YM 4019...

Page 142: ...STON Order Part name Q ty Remarks Cylinder head Refer to CYLINDER HEAD section 1 Bolt cylinder 1 2 Cylinder 1 3 Piston pin clip 2 Refer to removal section 4 Piston pin 1 Refer to removal section 5 Piston 1 Refer to removal section 6 Piston ring set 1 Refer to removal section ...

Page 143: ...of the pis ton crown as shown in the illustration CHECKING THE CYLINDER AND PISTON 1 Inspect Cylinder and piston walls Vertical scratches Replace cylinder and piston 2 Measure Piston to cylinder clearance Measurement steps a Measure the cylinder bore C with a cylin der bore gauge Measure the cylinder bore C in parallel to and at right angles to the crankshaft Then find the average of the measureme...

Page 144: ... 10 mm 0 39 in into the cylinder Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore a 10 mm 0 39 in 3 Measure Ring end gap Out of specification Replace You cannot measure the end gap on the ex pander spacer of the oil control ring If the oil control ring rails show excessive gap replace all three rings Piston size P Standard 76 955 76 970 mm 3 0297 3...

Page 145: ...STON 1 Install Piston ring Onto the piston Be sure to install the piston rings so that the manufacturer s marks or numbers are located on the upper side of the rings Lubricate the piston and piston rings liberally with engine oil 2 Position Top ring 2nd ring Oil ring Offset the piston ring end gaps as shown a Top ring end b 2nd ring end c Oil ring end upper d Oil ring e Oil ring end lower Outside ...

Page 146: ...e piston pin clips with their ends fac ing downward INSTALLING THE CYLINDER 1 Lubricate Piston Piston ring Cylinder Apply a liberal coating of engine oil 2 Install Dowel pin 1 O ring 2 Apply the lithium soap base grease on the O ring 3 Install Cylinder gasket 1 Cylinder 2 Install the cylinder with one hand while com pressing the piston rings with the other hand Pass the timing chain 3 through the ...

Page 147: ... Refer to CHANGING THE ENGINE OIL section in the CHAPTER 3 Brake pedal Refer to ENGINE REMOVAL sec tion Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Clutch spring 5 3 Pressure plate 1 4 Push rod 1 1 5 Circlip 1 6 Washer 1 7 Bearing 1 8 Ball 1 9 Push rod 2 1 10 Friction plate 9 ...

Page 148: ...lutch boss 1 Refer to removal section 13 Lock washer 1 Refer to removal section 14 Clutch boss 1 Refer to removal section 15 Thrust washer 1 16 Primary driven gear 1 17 Spacer 1 18 Washer 1 19 Push lever shaft 1 Order Part name Q ty Remarks ...

Page 149: ...CKING THE PRIMARY DRIVEN GEAR 1 Check Circumferential play Free play exists Replace Gear teeth a Wear damage Replace CHECKING THE CLUTCH SPRINGS 1 Measure Clutch spring free length a Out of specification Replace springs as a set CHECKING THE FRICTION PLATES 1 Measure Friction plate thickness Out of specification Replace friction plate as a set Measure at all four points Clutch holding tool YM 9104...

Page 150: ...age bend Replace INSTALLING THE PUSH LEVER SHAFT 1 Install Push lever shaft 1 Bolt push lever shaft 2 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 INSTALLING THE CLUTCH 1 Install Washer 1 Spacer 2 Primary driven gear 3 Thrust washer 4 Clutch boss 5 App...

Page 151: ... 1 Clutch plate 1 2 Install the clutch plates and friction plates al ternately on the clutch boss starting with a friction plate and ending with a friction plate Apply the engine oil on the friction plates and clutch plates 5 Install Bearing 1 Washer 2 Circlip 3 To push rod 1 4 Apply the engine oil on the bearing and washer Nut clutch boss 75 Nm 7 5 m kg 54 ft lb Clutch holding tool YM 91042 90890...

Page 152: ...1 8 Install Clutch spring 1 Bolt clutch spring 2 Tighten the bolts in stage using a crisscross pattern 9 Install Dowel pin 1 Gasket clutch cover 2 10 Install Clutch cover 1 Bolt clutch cover Tighten the bolts in stage using a crisscross pattern Bolt clutch spring 10 Nm 1 0 m kg 7 2 ft lb Bolt clutch cover 10 Nm 1 0 m kg 7 2 ft lb ...

Page 153: ... ENGINE OIL section in the CHAPTER 3 Drain the coolant Refer to CHANGING THE COOL ANT section in the CHAPTER 3 Radiator hose 3 Disconnect at water pump side Exhaust pipe Refer to EXHAUST PIPE AND SI LENCER section Brake pedal Refer to ENGINE REMOVAL sec tion Right engine guard 1 Oil filter element cover 1 2 Oil filter element 1 3 Water pump housing 1 4 Oil delivery pipe 1 5 Bolt oil hose 1 ...

Page 154: ...ank 1 7 Right crankcase cover 1 8 Impeller 1 Refer to removal section 9 Washer 1 Refer to removal section 10 Impeller shaft 1 Refer to removal section 11 Oil seal 2 Refer to removal section 12 Bearing 1 Refer to removal section Order Part name Q ty Remarks ...

Page 155: ...G THE OIL SEAL It is not necessary to disassemble the water pump unless there is an abnormality such as excessive change in coolant level discolor ation of coolant or milky transmission oil 1 Remove Bearing 1 2 Remove Oil seal 1 CHECKING THE OIL DELIVERY PIPE 1 Inspect Oil delivery pipe 1 Bend damage Replace Clogged Blow CHECKING THE IMPELLER SHAFT 1 Inspect Impeller shaft 1 Bend wear damage Repla...

Page 156: ...h its manufacture s marks or numbers facing the right crankcase cover 2 2 Install Bearing 1 Install the bearing by pressing its outer race parallel INSTALLING THE IMPELLER SHAFT 1 Install Impeller shaft 1 Washer 2 Impeller 3 Take care so that the oil seal lip is not dam aged or the spring does not slip off its posi tion When installing the impeller shaft apply the lithium soap base grease on the o...

Page 157: ... 4 Tighten the bolts in stage using a crisscross pattern INSTALLING THE KICKSTARTER CRANK 1 Install Kickstarter crank 1 Washer Bolt kickstarter crank Install so that the clearance a between the kickstarter crank and engine bracket mounting bolt is 8 mm 0 31 in or more and that the kick starter crank does not contact the right crank case cover when it is pulled out 2 Install Oil hose 1 Bolt oil hos...

Page 158: ...1 Install Dowel pin 1 O ring 2 Apply the lithium soap base grease on the O ring 2 Install Water pump housing 1 Bolt water pump housing 2 INSTALLING THE OIL FILTER ELEMENT 1 Install Oil filter element 1 O ring 2 Oil filter element cover 3 Bolt oil filter element cover Apply the lithium soap base grease on the O ring Union bolt M8 18 Nm 1 8 m kg 13 ft lb Union bolt M10 20 Nm 2 0 m kg 14 ft lb Bolt w...

Page 159: ... OIL FILTER ELEMENT AND WATER PUMP section Stator Refer to CDI MAGNETO section 1 Nut primary drive gear 1 Refer to removal section 2 Nut balancer shaft driven gear 1 Refer to removal section 3 Lock washer 1 4 Primary drive gear 1 5 Balancer shaft drive gear 1 6 Lock washer 1 7 Balancer shaft driven gear 1 8 Balancer shaft 1 Refer to removal section ...

Page 160: ...the centers of the crank shaft and balancer shaft CHECKING THE PRIMARY DRIVE GEAR BALANCER SHAFT DRIVE GEAR AND BALANCER SHAFT DRIVEN GEAR 1 Inspect Primary drive gear 1 Balancer shaft drive gear 2 Balancer shaft driven gear 3 Wear damage Replace CHECKING THE BALANCER SHAFT 1 Inspect Balancer shaft Cracks damage Replace INSTALLING THE BALANCER 1 Install Balancer shaft 1 Apply the engine oil on the...

Page 161: ...n the balancer shaft driven gear 2 Align the punched mark c on the balancer shaft drive gear with the lower spline d on the crankshaft end 4 Install Lock washer 1 Nut balancer shaft driven gear 2 Primary drive gear 3 Lock washer 4 Nut primary drive gear 5 Install the primary drive gear with its stepped side a facing the engine Place an aluminum plate b between the teeth of the balancer shaft drive...

Page 162: ...ry driven gear Refer to CLUTCH section Right crankcase cover Refer to OIL FILTER ELEMENT AND WATER PUMP section 1 Circlip 1 2 Washer 1 3 Oil pump drive gear 1 4 Oil pump assembly 1 5 Outer rotor 2 1 6 Circlip 1 7 Inner rotor 2 1 8 Dowel pin 1 9 Oil pump cover 1 10 Outer rotor 1 1 ...

Page 163: ...4 61 OIL PUMP 11 Inner rotor 1 1 12 Dowel pin 1 13 Washer 1 14 Oil pump drive shaft 1 15 Rotor housing 1 Order Part name Q ty Remarks ...

Page 164: ...G THE OIL TANK Order Part name Q ty Remarks Drain the engine oil Refer to CHANGING THE ENGINE OIL section in the CHAPTER 3 1 Oil hose 2 1 2 Oil hose 1 1 3 Dowel pin 2 4 Oil tank breather hose 1 5 Oil tank 1 6 Oil strainer 1 ...

Page 165: ...t of specification Replace the oil pump assembly 3 Check Unsmooth Repeat steps 1 and 2 or re place the defective parts INSTALLING THE OIL PUMP 1 Install Oil pump drive shaft 1 Washer 2 Dowel pin 3 Inner rotor 1 4 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 Tip clearance a 0 12 mm or less 0 0047 in or less Limit 0 20 mm 0...

Page 166: ...ner rotor 2 4 Install Outer rotor 2 1 Dowel pin 2 Oil pump assembly 3 Bolt oil pump assembly L 25 mm 0 94 in 4 Bolt oil pump assembly L 30 mm 1 18 in 5 Apply the engine oil on the outer rotor 2 5 Install Oil pump drive gear 1 Washer 2 Circlip 3 Apply the engine oil on the oil pump drive gear inner circumference Screw oil pump cover 1 7 Nm 0 17 m kg 1 2 ft lb Bolt oil pump assembly 10 Nm 1 0 m kg 7...

Page 167: ...breather hose 2 Clamp 3 Install the clamp so that it does not contact the oil tank Insert the oil tank breather hose so that its end a comes where the oil tank pipe begins to bend Install the clamp 3 mm 0 12 in away from the oil tank breather hose end a Clamp 2 Nm 0 2 m kg 1 4 ft lb ...

Page 168: ...HAFT AND SHIFT SHAFT Order Part name Q ty Remarks Oil pump Refer to OIL PUMP section 1 Kick idle gear 1 2 Kick shaft assembly 1 Refer to removal section 3 Spring guide 1 4 Torsion spring 1 5 Ratchet wheel 1 6 Kick gear 1 7 Kick shaft 1 8 Washer 1 9 Shift pedal 1 10 Shift shaft 1 ...

Page 169: ... 14 Shift guide 1 Refer to removal section 15 Shift lever assembly 1 Refer to removal section 16 Shift lever 1 17 Pawl 2 18 Pawl pin 2 19 Spring 2 20 Bolt stopper lever 1 21 Stopper lever 1 22 Torsion spring 1 23 Segment 1 Refer to removal section Order Part name Q ty Remarks ...

Page 170: ...THE SEGMENT 1 Remove Bolt segment 1 Segment 2 Turn the segment counterclockwise until it stops and loosen the bolt If the segment gets an impact it may be damaged Take care not to give an impact to the segment when removing the bolt CHECKING THE KICK SHAFT AND RATCHET WHEEL 1 Check Ratchet wheel 1 smooth movement Unsmooth movement Replace Kick shaft 2 Wear damage Replace Spring 3 Broken Replace CH...

Page 171: ... damage Replace Torsion spring 2 Broken Replace INSTALLING THE SEGMENT 1 Install Segment 1 Bolt segment Align the notch a on the segment with the pin b on the shift cam If the segment gets an impact it may be damaged Take care not to give an impact to the segment when tightening the bolt INSTALLING THE STOPPER LEVER 1 Install Torsion spring 1 Stopper lever 2 Bolt stopper lever 3 Align the stopper ...

Page 172: ... Shift lever assembly 1 Shift guide 2 The shift lever assembly is installed at the same time as the shift guide Apply the engine oil on the bolt segment shaft 4 Install Bolt shift guide 1 INSTALLING THE SHIFT SHAFT 1 Install Roller 1 Collar 2 Torsion spring 3 Shift shaft 4 Apply the engine oil on the roller and shift shaft 2 Install Shift pedal 1 Bolt shift pedal 2 Bolt shift guide 10 Nm 1 0 m kg ...

Page 173: ... the kick shaft 2 Install Torsion spring 1 To kick shaft 2 Make sure the stopper a of the torsion spring fits into the hole b on the kick shaft 3 Install Spring guide 1 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 Apply the molybdenum disulfide grease on the contacting surfac...

Page 174: ...on spring clockwise and hook into the proper hole a in the crankcase INSTALLING THE KICK IDLE GEAR 1 Install Kick idle gear 1 Washer 2 Circlip 3 Apply the engine oil on the kick idle gear inner circumference Install the kick idle gear with its depressed side a toward you ...

Page 175: ...s Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Disconnect the CDI magneto lead Shift pedal Refer to KICK SHAFT AND SHIFT SHAFT section 1 Left crankcase cover 1 2 Nut rotor 1 Refer to removal section 3 Rotor 1 Refer to removal section 4 Stator 1 5 Woodruff key 1 ...

Page 176: ...e Inspect the crankshaft runout and crankshaft bearing If necessary replace CDI magneto and or stator CHECKING THE WOODRUFF KEY 1 Inspect Woodruff key 1 Damage Replace INSTALLING THE CDI MAGNETO 1 Install Stator 1 Screw stator 2 Apply the sealant on the grommet of the CDI magneto lead Tighten the screws using the T30 bit Rotor holding tool YU 1235 90890 01235 Flywheel puller YM 1189 90890 01189 Sc...

Page 177: ...with the woodruff key 3 Install Washer 1 Nut rotor 2 Use the rotor holding tool 3 4 Connect CDI magneto lead Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 5 Install Dowel pin Gasket left crankcase cover Left crankcase cover 1 Hose guide cylinder head breather hose 2 Bolt left crankcase cover Tighten the bolts in stage using a crisscross pattern Nut rotor 56 Nm 5 6 m kg 40 ft lb Rotor hol...

Page 178: ... Carburetor Refer to CARBURETOR section Exhaust pipe and silencer Refer to EXHAUST PIPE AND SI LENCER section Clutch cable Disconnect at the engine side Radiator Refer to RADIATOR section Shift pedal Refer to KICK SHAFT AND SHIFT SHAFT section Cylinder head breather hose Refer to CAMSHAFTS section Drain the engine oil Refer to CHANGING THE ENGINE OIL section in the CHAPTER 3 Oil hose and oil tank ...

Page 179: ...sprocket 1 Refer to removal section 5 Lock washer 1 Refer to removal section 6 Drive sprocket 1 Refer to removal section 7 Clip 1 8 Bolt brake pedal 1 9 Brake pedal 1 10 Upper engine bracket 2 11 Lower engine bracket 2 12 Engine mounting bolt 3 13 Pivot shaft 1 Refer to removal section 14 Engine 1 Refer to removal section Order Part name Q ty Remarks ...

Page 180: ...he way out the swingarm will come loose If possible insert a shaft of similar diameter into the other side of the swingarm to support it 2 Remove Engine 1 From right side Make sure that the couplers hoses and cables are disconnected INSTALLING THE ENGINE 1 Install Engine 1 Install the engine from right side Pivot shaft 2 Engine mounting bolt lower 3 Front engine bracket 4 Bolt front engine bracket...

Page 181: ... the lithium soap base grease on the bolt O rings and brake pedal bracket INSTALLING THE DRIVE SPROCKET 1 Install Drive sprocket 1 Drive chain 2 Install the drive sprocket together with the drive chain 2 Install Lock washer 1 Nut drive sprocket 2 Tighten the nut while applying the rear brake 3 Bend the lock washer tab to lock the nut Bolt upper engine bracket 34 Nm 3 4 m kg 24 ft lb Engine mountin...

Page 182: ...AL SWITCH 1 Install Spring 1 Pin 2 O ring 3 Neutral switch 4 Screw neutral switch 5 Apply the lithium soap base grease on the O ring 2 Install Hose guide cylinder head breather hose 1 Bolt hose guide 2 Bolt drive chain sprocket cover 7 Nm 0 7 m kg 5 1 ft lb Screw neutral switch 4 Nm 0 4 m kg 2 9 ft lb Bolt hose guide 10 Nm 1 0 m kg 7 2 ft lb ...

Page 183: ...STON section Kick shaft assembly Refer to KICK SHAFT AND SHIFT SHAFT section Segment Refer to KICK SHAFT AND SHIFT SHAFT section Stator Refer to CDI MAGNETO section Balancer shaft Refer to BALANCER section 1 Timing chain guide intake side 1 2 Timing chain 1 3 Oil delivery pipe 2 1 4 Bolt L 45 mm 1 77 in 6 Refer to removal section 5 Bolt L 55 mm 2 17 in 1 Refer to removal section ...

Page 184: ...section 7 Hose guide 1 Refer to removal section 8 Clutch cable holder 1 Refer to removal section 9 Right crankcase 1 Refer to removal section 10 Left crankcase 1 Refer to removal section 11 Oil strainer 1 12 Crankshaft 1 Refer to removal section Order Part name Q ty Remarks ...

Page 185: ...CRANKCASE BEARING Order Part name Q ty Remarks Transmission Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section Shift cam and shift fork Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section 1 Oil seal 2 2 Bearing 10 Refer to removal section ...

Page 186: ...ting it leave the crankshaft and transmission with the left half Use soft hammer to tap on the case half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If the cases do not separate check for a remaining case bolt or fitting Do not force c Remove the dowel pins and O ring REMOVING THE CRANKSHAFT 1 Remov...

Page 187: ...g Rotate inner race with a finger Rough spot seizure Replace 3 Inspect Oil seal Damage Replace CHECKING THE 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 Standard Limit Runout lim it 0 03 mm 0 0012 in 0 05 mm 0 002 in...

Page 188: ... dam age the screwdriver receiving hole in the screw head INSTALLING THE CRANKSHAFT 1 Install Crankshaft 1 Use the crankshaft installing tool 2 3 4 and 5 Hold the connecting rod at top dead center with one hand while turning the nut of the in stalling tool with the other Operate the install ing tool until the crankshaft bottoms against the bearing Before installing the crankshaft clean the contact...

Page 189: ...ng the sealant 5 Install Dowel pin 1 O ring 2 Right crankcase To left crankcase Apply the lithium soap base grease on the O ring Fit the right crankcase onto the left crankcase Tap lightly on the case with soft hammer When installing the crankcase the connecting rod should be positioned at TDC top dead center 6 Tighten Hose guide 1 Clutch cable holder 2 Bolt crankcase 3 Bolt oil strainer 10 Nm 1 0...

Page 190: ...grease on the Or ings 8 Install Timing chain 1 Timing chain guide intake side 2 Bolt timing chain guide 3 9 Remove Sealant Forced out on the cylinder mating surface 10 Apply Engine oil To the crank pin bearing and oil delivery hole 11 Check Crankshaft and transmission operation Unsmooth operation Repair Bolt oil delivery pipe 2 10 Nm 1 0 m kg 7 2 ft lb Bolt timing chain guide 10 Nm 1 0 m kg 7 2 ft...

Page 191: ...s Engine Refer to ENGINE REMOVAL sec tion Separate the crankcase Refer to CRANKCASE AND CRANKSHAFT section 1 Main axle 1 Refer to removal section 2 Drive axle 1 Refer to removal section 3 Shift cam 1 Refer to removal section 4 Shift fork 3 1 Refer to removal section 5 Shift fork 2 1 Refer to removal section 6 Shift fork 1 1 Refer to removal section 7 Collar 1 ...

Page 192: ... forks Remove the main axle drive axle shift cam and shift fork all together by tapping lightly on the transmission drive axle with a soft ham mer CHECKING THE GEARS 1 Inspect Matching dog a Gear teeth b Shift fork groove c Wear damage Replace 2 Inspect O ring 1 Damage Replace 3 Check Gears movement Unsmooth movement Repair or replace CHECKING THE BEARING 1 Inspect Bearing 1 Rotate inner race with...

Page 193: ...on gear 18T 2 Collar 3 4th pinion gear 18T 4 2nd pinion gear 16T 5 To main axle 6 Apply the molybdenum disulfide oil on the inner and end surface of the idler gear and on the in ner surface of the sliding gear then install 2 Install 2nd wheel gear 28T 1 4th wheel gear 22T 2 3rd wheel gear 26T 3 5th wheel gear 25T 4 1st wheel gear 30T 5 O ring 6 To drive axle 7 Apply the molybdenum disulfide oil on...

Page 194: ...n installing the collar into the crankcase pay careful attention to the crankcase oil seal lip 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 Apply the engine 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 t...

Page 195: ...4 93 TRANSMISSION SHIFT CAM AND SHIFT FORK 7 Check Shifter operation Transmission operation Unsmooth operation Repair ...

Page 196: ...vicing of Yamaha motorcycles e g Yamaha dealers service engineers etc Those who have little knowl edge and skill concerning servicing are requested not to undertake inspection adjustment disas sembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage ...

Page 197: ...r Part name Q ty Remarks Hold the machine by placing the suit able stand under the engine Refer to HANDLING NOTE 1 Bolt axle holder 4 Only loosening 2 Nut front wheel axle 1 3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Oil seal 2 7 Bearing 2 Refer to removal section 8 Brake disc 1 5 ...

Page 198: ...chine by placing the suit able stand under the engine Refer to HANDLING NOTE 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 Refer to removal section 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 3 Refer to removal section 10 Brake disc 1 ...

Page 199: ...ING THE WHEEL 1 Measure Wheel runout Out of limit Repair replace 2 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace Replace the bearings oil seal and wheel collar as a set CHECKING THE WHEEL AXLE 1 Measure Wheel axle bends Out of specification Replace Use the dial gauge 1 The bending value is shown by one half of the dial gauge reading Do not attempt to straighten a bent ...

Page 200: ...ing and oil seal lip when installing Use a socket that matches the outside diam eter 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 Do not strike the inner race of the bearing Contact should be made only with the outer race 2 Install Brake disc 1 Bolt brake disc 2 Tighten the bolts in stage using ...

Page 201: ... brake disc 1 between the brake pads 2 correctly 5 Install Wheel axle 1 Apply the lithium soap base grease on the wheel axle 6 Install Nut wheel axle 1 7 Tighten Bolt axle holder 1 Before tightening the bolt fit the wheel axle to the axle holder by stroking the front fork several times with the front brake applied Nut wheel axle 105 Nm 10 5 m kg 75 ft lb Bolt axle holder 21 Nm 2 1 m kg 15 ft lb ...

Page 202: ...l the oil seal with its manufacture s marks or numbers facing outward Do not strike the inner race of the bearing Contact should be made only with the outer race 2 Install Brake disc 1 Bolt brake disc 2 Tighten the bolts in stage using a crisscross pattern 3 Install Rear wheel sprocket 1 Bolt rear wheel sprocket 2 Washer rear wheel sprocket 3 Nut rear wheel sprocket 4 Tighten the nuts in stage usi...

Page 203: ...n puller and insert the wheel axle from left side Apply the lithium soap base grease on the wheel axle 8 Install Right drive chain puller 1 Washer 2 Nut wheel axle 3 Temporarily tighten the nut wheel axle at this point 9 Adjust Drive chain slack a Refer to ADJUSTING THE DRIVE CHAIN SLACK section in the CHAPTER 3 10 Tighten Nut wheel axle 1 Locknut 2 Drive chain slack 50 60 mm 2 0 2 4 in Nut wheel ...

Page 204: ...stand under the engine Refer to HANDLING NOTE Drain the brake fluid Refer to removal section 1 Brake hose holder protector 2 2 Union bolt 2 3 Brake hose 1 4 Pad pin plug 1 Remove when loosening the pad pin 5 Pad pin 1 Loosen when disassembling the brake caliper 6 Brake caliper 1 7 Brake lever 1 8 Brake master cylinder bracket 1 9 Brake master cylinder 1 ...

Page 205: ...ine Refer to HANDLING NOTE Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section Drain the brake fluid Refer to removal section 1 Brake pedal 1 2 Brake master cylinder 1 3 Brake hose holder 2 4 Union bolt 2 5 Brake hose 1 6 Pad pin plug 1 Remove when loosening the pad pin 7 Pad pin 1 Loosen when disassembling the brake caliper 8 Brake caliper 1 ...

Page 206: ...Order Part name Q ty Remarks A Front B Rear A B 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Brake caliper piston 2 1 Refer to removal section 5 Brake caliper piston dust seal 2 1 Refer to removal section 6 Brake caliper piston seal 2 1 Refer to removal section ...

Page 207: ...LINDER Order Part name Q ty Remarks A Front B Rear 1 Brake master cylinder cap 1 2 Diaphragm 1 3 Reservoir float 1 4 Push rod Front 1 5 Brake master cylinder boot 1 6 Circlip 1 Use a long nose circlip pliers 7 Washer 1 8 Push rod Rear 1 9 Brake master cylinder kit 1 ...

Page 208: ...while pulling the lever in or pushing down on the pedal Do not reuse the drained brake fluid Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately REMOVING THE BRAKE CALIPER PISTON 1 Remove Brake caliper piston Use compressed air and proceed carefully Cover piston with rag and use extreme caution when expelling piston from cylin der Never attempt to pry ...

Page 209: ... the brake caliper piston seals and brake caliper piston dust seals whenever a caliper is disassembled A Front B Rear CHECKING THE BRAKE MASTER CYLINDER 1 Inspect Brake master cylinder inner surface a Wear scratches Replace master cylinder assembly Stains Clean Use only new brake fluid A Front B Rear 2 Inspect Diaphragm 1 Crack damage Replace A Front B Rear 3 Inspect front brake only Reservoir flo...

Page 210: ...ernal parts should be lubricated with brake fluid when installed Replace the brake caliper piston seals and brake caliper piston dust seals whenever a caliper is disassembled INSTALLING THE BRAKE CALIPER PISTON 1 Clean Brake caliper Brake caliper piston seal Brake caliper piston dust seal Brake caliper piston Clean them with brake fluid 2 Install Brake caliper piston seal 1 Brake caliper piston du...

Page 211: ...Front B Rear INSTALLING THE FRONT BRAKE CALIPER 1 Install Pad support 1 Brake pad 2 Pad pin 3 Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point 2 Install Brake caliper 1 Bolt brake caliper 2 3 Tighten Pad pin 3 4 Install Pad pin plug 4 Bolt brake caliper 28 Nm 2 8 m kg 20 ft lb Pad pin 18 Nm 1 8 m kg 13 ft lb Pad pin plu...

Page 212: ...Tighten Pad pin 3 5 Install Pad pin plug 4 INSTALLING THE BRAKE MASTER CYLINDER KIT 1 Clean Brake master cylinder Brake master cylinder kit Clean them with brake fluid 2 Install Brake master cylinder cup primary 1 Brake master cylinder cup secondary 2 To brake master cylinder piston 3 Apply the brake fluid on the brake master cylin der cup After installing cylinder cup should be in stalled as show...

Page 213: ... circlip pliers A Front B Rear INSTALLING THE FRONT BRAKE MASTER CYLINDER 1 Install Brake master cylinder 1 Brake master cylinder bracket 2 Bolt brake master cylinder bracket 3 Install the bracket so that the arrow mark a face upward First tighten the bolts on the upper side of the brake master cylinder bracket and then tight en the bolts on the lower side 2 Install Brake lever 1 Bolt brake lever ...

Page 214: ...linder 2 Install Brake master cylinder 1 Bolt brake master cylinder 2 3 Install Spring 1 Brake pedal 2 O ring 3 Bolt brake pedal 4 Clip 5 Apply the lithium soap base grease on the bolt O ring and brake pedal bracket 4 Install Pin 1 Washer 2 Cotter pin 3 After installing check the brake pedal height Refer to ADJUSTING THE REAR BRAKE section in the CHAPTER 3 Union bolt 30 Nm 3 0 m kg 22 ft lb Bolt b...

Page 215: ...e holder 1 Bolt brake hose holder 2 Align the top a of the brake hose holder with the paint b of the brake hose 3 Pass the brake hose through the cable guide 1 4 Install Copper washer 1 Brake hose 2 Union bolt 3 Always use new copper washers Install the brake hose so that its pipe por tion a directs as shown and lightly touch es the projection b on the brake master cylinder Union bolt 30 Nm 3 0 m ...

Page 216: ...oes correct its twist FILLING THE BRAKE FLUID 1 Fill Brake fluid Until the fluid level reaches LOWER level line a Use only the designated quality brake flu id otherwise the rubber seals may deterio rate causing leakage and poor brake per formance Refill with the same type of brake fluid mixing fluids may result in a harmful chemical reaction and lead to poor perfor mance Be careful that water does...

Page 217: ...ction in the CHAPTER 3 4 Install Reservoir float front brake Diaphragm Brake master cylinder cap 1 Screw bolt brake master cylinder cap 2 After installation while pulling the brake le ver in or pushing down on the brake pedal check whether there is any brake fluid leak ing where the union bolts are installed re spectively at the brake master cylinder and brake caliper A Front B Rear 5 Install rear...

Page 218: ...er to FRONT WHEEL AND REAR WHEEL section Front brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Number plate Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 1 Protector 1 2 Pinch bolt upper bracket 2 Only loosening 3 Damper assembly 1 Loosen when disassembling the front fork Refer to removal section 4 Pinch bolt lower bracket 2 Only loosening 5 Front fork 1 ...

Page 219: ...k spring 1 3 Dust seal 1 Refer to removal section 4 Stopper ring 1 Refer to removal section 5 Inner tube 1 Refer to removal section 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Oil seal washer 1 10 Oil seal 1 11 Base valve 1 Drain the fork oil Refer to removal section 12 Damper assembly 1 Drain the fork oil Refer to removal section ...

Page 220: ...es or front forks be sure to extract the air from the air chamber completely REMOVING THE DAMPER ASSEMBLY 1 Loosen Damper assembly 1 Before removing the front fork from the ma chine loosen the damper assembly with the cap bolt ring wrench 2 REMOVING THE ADJUSTER 1 Drain the outer tube of its front fork oil at its top 2 Loosen Adjuster 1 3 Remove Adjuster 1 While compressing the inner tube 2 set th...

Page 221: ...mper assembly 1 Bend damage Replace O ring 2 Wear damage Replace The front fork with a built in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign mate rial Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled CHECKING THE BASE VALVE 1 Inspect Base valve 1 Wear da...

Page 222: ... oil lock piece Replace Inner tube bends Out of specification Replace Use the dial gauge 1 The bending value is shown by one half of the dial gauge reading Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube CHECKING THE OUTER TUBE 1 Inspect Outer tube 1 Score marks wear damage Replace CHECKING THE ADJUSTER 1 Inspect Adjuster 1 O ring 2 Wear damage Replace Fork s...

Page 223: ...d the damper assembly of air Be careful not to excessive full stroke A stroke of 200 mm 7 9 in or more will cause air to en ter In this case repeat the steps 2 to 4 5 Measure Oil level left and right a Out of specification Adjust 6 Tighten Locknut 1 Fully finger tighten the locknut onto the damper assembly 7 Loosen Compression damping adjuster 1 Loosen the compression damping adjuster finger tight...

Page 224: ...the cap bolt ring wrench 2 and use the cap bolt wrench 3 to tighten the base valve with specified torque 11 After filling pump the damper assembly 1 slowly up and down more than 10 times to distribute the fork oil 12 While protecting the damper assembly 1 with a rag and compressing fully allow ex cessive oil to overflow on the base valve side Take care not to damage the damper assem bly Base valve...

Page 225: ... 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 Install the oil seal with its manufacture s marks or number facing the axle holder side 16 Install Piston metal 1 Install the piston metal onto the slot on inner tube 17 Install Outer tube 1 To inner tube 2 18 Install Slide metal 1 Oil seal washer 2 To outer tube slot Press t...

Page 226: ...the outer tube 21 Install Dust seal 1 Apply the lithium soap base grease on the inner tube 22 Check Inner tube smooth movement Tightness binding rough spots Repeat the steps 15 to 21 23 Measure Distance a Out of specification Turn into the locknut Fork seal driver YM A0948 90890 01502 Distance a 16 mm 0 63 in or more Between the damper assembly 1 bottom and locknut 2 bottom ...

Page 227: ...er 1 Loosen the rebound damping adjuster finger tight Record the set position of the adjuster the amount of turning out the fully turned in posi tion 27 Install Push rod 1 Copper washer 2 Adjuster 3 To damper assembly 4 While compressing the inner tube 5 set the cap bolt ring wrench 7 between the inner tube and locknut 6 Fully finger tighten the adjuster onto the damper assembly 28 Inspect Gap a b...

Page 228: ...etting Uneven adjustment can cause poor handling and loss of stability Be sure to use recommended fork oil If other oils are used they may have an ex cessively adverse effect on the front fork performance Never allow foreign materials to enter the front fork 32 Install Damper assembly 1 To outer tube Temporarily tighten the damper assembly Adjuster locknut 29 Nm 2 9 m kg 21 ft lb Adjuster 55 Nm 5 ...

Page 229: ...he damper assembly with specified torque 3 Adjust Front fork top end a 4 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 Tighten the lower bracket to specified torque If torqued too much it may cause the front fork to malfunction Damper assembly 30 Nm 3 0 m kg 22 ft lb Cap bolt ring wrench YM 01501 90890 01501 Front fork top end standard a 5 mm 0 20 in Pinch bolt upper bracket 21 Nm ...

Page 230: ...damping force Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 7 Adjust Compression damping force Turn in the damping adjuster 1 finger tight and then turn out to the originally set position Bolt protector 5 Nm 0 5 m kg 3 6 ft lb ...

Page 231: ... Clutch cable 1 Disconnect at the lever side 4 Clutch lever holder 1 5 Engine stop switch 1 6 Brake master cylinder 1 Refer to removal section 7 Throttle cable cap 1 8 Throttle cable 1 pulled 1 Disconnect at the throttle side 9 Throttle cable 2 pushed 1 Disconnect at the throttle side 10 Right grip 1 Refer to removal section 11 Tube guide 1 12 Collar 1 13 Left grip 1 Refer to removal section ...

Page 232: ...5 37 HANDLEBAR 14 Handlebar upper holder 2 15 Handlebar 1 16 Handlebar lower holder 2 Order Part name Q ty Remarks ...

Page 233: ...ace Do not attempt to straighten a bent handle bar as this may dangerously weaken the handlebar INSTALLING THE HANDLEBAR 1 Install Handlebar lower holder 1 Washer 2 Nut handlebar lower holder 3 Be sure the side of the handlebar lower holder having the greater distance a from the mounting bolt center faces forward And in stall it in the hole b in the rear of the upper bracket Apply the lithium soap...

Page 234: ...he handlebar as shown First tighten the bolts on the front side of the handlebar upper holder and then tighten the bolts on the rear side 3 Tighten Nut handlebar lower holder 1 4 Install Left grip 1 Apply the adhesive to the handlebar 2 Before applying the adhesive wipe off grease or oil on the handlebar surface a with a lac quer thinner Install the left grip to the handlebar so that the line b be...

Page 235: ...wn 6 Install Collar 1 Grip cap cover 2 Throttle grip 3 Apply the lithium soap base grease on the throttle grip sliding surface 7 Install Throttle cables 1 To tube guide 2 Apply the lithium soap base grease on the throttle cable end and tube guide cable winding portion 8 Install Throttle cable cap 1 Screw throttle cable cap 2 After tightening the screws check that the throttle grip 3 moves smoothly...

Page 236: ...5 Clamp 6 The engine stop switch clutch lever holder and clamp should be installed according to the dimensions shown Pass the engine stop switch lead in the middle of the clutch lever holder 12 Install Clutch cable 1 Hot starter cable 2 Apply the lithium soap base grease on the clutch cable end and hot starter cable end 13 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH CA BLE FREE PLA...

Page 237: ...e turn Retighten it 7 Nm 0 7 m kg 5 1 ft lb Hold the machine by placing the suit able stand under the engine Refer to HANDLING NOTE Number plate Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 Handlebar Refer to HANDLEBAR section 1 Front fender 1 2 Steering stem nut 1 3 Front fork 2 Refer to FRONT FORK section 4 Upper bracket 1 ...

Page 238: ...Steering ring nut 1 Refer to removal section 6 Lower bracket 1 7 Bearing race cover 1 8 Upper bearing 1 9 Lower bearing 1 Refer to removal section 10 Bearing race 2 Refer to removal section Order Part name Q ty Remarks ...

Page 239: ...BEARING RACE 1 Remove Bearing race 1 Remove the bearing race using long rod 2 and the hammer CHECKING THE STEERING STEM 1 Inspect Steering stem 1 Bend damage Replace CHECKING THE BEARING AND BEARING RACE 1 Wash the bearings and bearing races with a solvent 2 Inspect Bearing 1 Bearing race Pitting damage Replace bearings and bearing races as a set Install the bearing in the bearing races Spin the b...

Page 240: ...he lithium soap base grease on the bearing the portion a and thread of the steer ing stem 4 Install Steering ring nut 1 Install the steering nut with its stepped side a facing downward Tighten the steering ring nut using the steer ing nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD section in the CHAPTER 3 5 Check the steering stem by turning it lock to lock If there is any binding ...

Page 241: ...t check the steering for smooth movement If not adjust the steering by loosening the steering ring nut little by little 10 Adjust Front fork top end a 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 Tighten the lower bracket to specified torque If torqued too much it may cause the front fork to malfunction Steering stem nut 145 Nm 14 5 m kg 105 ft lb Front fork top end standard a ...

Page 242: ...LING NOTE Brake hose holder Refer to FRONT BRAKE AND REAR BRAKE section Rear brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Bolt brake pedal Shift the brake pedal backward Drive chain 1 Drive chain support 1 2 Lower chain tensioner 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt connecting rod 1 5 Pivot shaft 1 6 Swingarm 1 ...

Page 243: ...8 SWINGARM DISASSEMBLING THE SWINGARM Order Part name Q ty Remarks 1 Relay arm 1 2 Connecting rod 1 3 Collar 2 4 Oil seal 2 5 Thrust bearing 2 6 Bushing 2 7 Oil seal 8 8 Bearing 10 Refer to removal section ...

Page 244: ...spect Oil seal 3 Damage Replace CHECKING THE CONNECTING ROD 1 Inspect Bearing 1 Collar 2 Free play exists unsmooth revolution rust Replace bearing and collar as a set 2 Inspect Oil seal 3 Damage Replace INSTALLING THE BEARING AND OIL SEAL 1 Install Bearing 1 Oil seal 2 To swingarm Apply the molybdenum disulfide grease on the bearing when installing Install the bearing by pressing it on the side ha...

Page 245: ...se on the bearing when installing Install the bearing by pressing it on the side having the manufacture s marks or numbers INSTALLING THE SWINGARM 1 Install Bushing 1 Thrust bearing 2 Oil seal 3 Collar 4 To swingarm 5 Apply the molybdenum disulfide grease on the bushings thrust bearings oil seal lips and con tact surfaces of the collar and thrust bearing 2 Install Collar 1 Washer 2 To relay arm 3 ...

Page 246: ...arm 4 To swingarm Apply the molybdenum disulfide grease on the bolt circumference and threaded portion Do not tighten the nut yet 6 Install Swingarm 1 Pivot shaft 2 Apply the molybdenum disulfide grease on the pivot shaft Insert the pivot shaft from right side 7 Check Swingarm side play a Free play exists Replace thrust bearing Swingarm up and down movement b Unsmooth movement binding rough spots ...

Page 247: ...er relay arm 2 Apply the molybdenum disulfide grease on the bolt 10 Tighten Nut connecting rod 1 11 Tighten Nut relay arm 1 12 Install Bolt lower chain tensioner 1 Washer 2 Collar 3 Lower chain tensioner 4 Nut lower chain tensioner 5 Nut rear shock absorber relay arm 53 Nm 5 3 m kg 38 ft lb Nut connecting rod 80 Nm 8 0 m kg 58 ft lb Nut relay arm 70 Nm 7 0 m kg 50 ft lb Nut lower chain tensioner 1...

Page 248: ...Drive chain support cover 2 Bolt drive chain support L 50 mm 1 97 in 3 Nut drive chain support 4 Bolt drive chain support cover L 10 mm 0 39 in 5 Nut drive chain support 7 Nm 0 7 m kg 5 1 ft lb Bolt drive chain support cover 7 Nm 0 7 m kg 5 1 ft lb ...

Page 249: ... NOTE Seat Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 Silencer Refer to EXHAUST PIPE AND SI LENCER section in the CHAPTER 4 1 Clamp air filter joint 1 Only loosening 2 Rear frame 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt rear shock absorber frame 1 5 Rear shock absorber 1 6 Locknut 1 Only loosening 7 Adjuster 1 Only loosening B 2 9 8 10 11 11 ...

Page 250: ...5 55 REAR SHOCK ABSORBER 8 Lower spring guide 1 9 Upper spring guide 1 10 Spring rear shock absorber 1 11 Bearing 2 Refer to removal section Order Part name Q ty Remarks B 2 9 8 10 11 11 ...

Page 251: ...rt of the gas tank A damaged gas tank will impair the damping performance or cause a malfunction Take care not to scratch the contact sur face of the piston rod with the cylinder or oil could leak out Never attempt to remove the plug at the bottom of the nitrogen gas tank It is very dangerous to remove the plug When scrapping the rear shock absorb er follow the instructions on disposal NOTES ON DI...

Page 252: ...place spring Move spring up and down Spring guide 4 Wear damage Replace spring guide Bearing 5 Free play exists unsmooth revolution rust Replace INSTALLING THE BEARING 1 Install Upper bearing 1 Install the bearing parallel until the stopper ring groove appears by pressing its outer race Do not apply the grease on the bearing out er race because it will wear the rear shock absorber surface on which...

Page 253: ...o ADJUSTING THE REAR SHOCK ABSORBER SPRING PRELOAD section in the CHAPTER 3 4 Tighten Locknut 1 INSTALLING THE REAR SHOCK ABSORBER 1 Install Dust seal 1 O ring 2 Collar 3 Apply the molybdenum disulfide grease on the dust seal lips and collars Apply the lithium soap base grease on the O rings 2 Install Bushing 1 Collar 2 Dust seal 3 Apply the molybdenum disulfide grease on the bearing and dust seal...

Page 254: ...ut rear shock absorber relay arm 2 Apply the molybdenum disulfide grease on the bolt 6 Install Rear frame 1 Bolt rear frame upper 2 Bolt rear frame lower 3 7 Tighten Bolt air filter joint 1 Nut rear shock absorber frame 56 Nm 5 6 m kg 40 ft lb Nut rear shock absorber relay arm 53 Nm 5 3 m kg 38 ft lb Bolt rear frame upper 32 Nm 3 2 m kg 23 ft lb Bolt rear frame lower 32 Nm 3 2 m kg 23 ft lb Bolt a...

Page 255: ...rvicing of Yamaha motorcycles e g Yamaha dealers service engineers etc Those who have little knowl edge and skill concerning servicing are requested not to undertake inspection adjustment disas sembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage 6 ...

Page 256: ...AL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS 1 Engine stop switch 2 Throttle position sensor 3 Neutral switch 4 CDI magneto 5 Ignition coil 6 Spark plug 7 CDI unit ...

Page 257: ...ODE B Black Br Brown G Green L Blue O Orange P Pink R Red Sb Sky blue W White Y Yellow B L Black Blue B W Black White B Y Black Yellow G B Green Black L W Blue White R W Red White B W B W B L B Y Sb Sb G B L Y L Y P B B B B G O W R P G W R P B Br W W B Y G Br G R R O B Sb Sb Y Y W Y W G G B P P Br Br R R O L B Sb Y L L B L B W B W G B B B B L L Sb B L G B G B B Y B Y B W O B W Br Br P ...

Page 258: ... following special tools in this inspection Spark gap test Spark Clean or replace spark plug No spark Check entire ignition system for connec tion couplers leads and ignition coil No good Repair or replace OK Check engine stop switch No good Replace OK Check ignition coil primary coil and secondary coil No good Replace OK Check CDI magneto pickup coil and charging coil No good Replace OK Check neu...

Page 259: ...gnition coil and spark plug as they are fitted Push in the ignition coil until it closely con tacts the spark plug hole in the cylinder head cover CHECKING THE ENGINE STOP SWITCH 1 Inspect Engine stop switch conduction Not conductive while it is pushed Replace Conductive while it is freed Replace Set the tester selection position to Ω 1 CHECKING THE IGNITION COIL 1 Remove the ignition coil cap 2 I...

Page 260: ...2 Inspect Charging coil 1 resistance Out of specification Replace Tester lead Orange lead 1 Tester lead Spark plug terminal 2 Secondary coil resistance Tester selector position 4 6 6 8 kΩat 20 C 68 F kΩ 1 Tester lead Red lead 1 Tester lead White lead 2 Pickup coil resis tance Tester selector position 248 372 Ω at 20 C 68 F Ω 100 Tester lead Brown lead 1 Tester lead Green lead 2 Charging coil 1 res...

Page 261: ...ged Replace Set the tester selection position to Ω 1 CHECKING THE CDI UNIT Check all electrical components If no fault is found replace the CDI unit Then check the electrical components again Tester lead Pink lead 1 Tester lead Black lead 2 Charging coil 2 resistance Tester selector position 44 66 Ω at 20 C 68 F Ω 10 Tester lead Sky blue lead 1 Tester lead Ground 2 Result Conductive while gear is ...

Page 262: ...IGNITION SYSTEM section Use the following special tools in this inspection Check entire ignition system for connec tion No good Repair or replace OK Check throttle position sensor Throttle position sensor coil No good Replace OK Check CDI magneto Charging coil No good Replace OK Check CDI unit Throttle position sen sor input voltage No good Replace Pocket tester YU 3112 C 90890 03112 ...

Page 263: ...osen Throttle stop screw 1 Turn out the throttle stop screw until the throttle shaft is in the full close position 3 Inspect Throttle position sensor coil variable resis tance Check that the resistance in increased as the throttle grip is moved from the full close position to the full open position Out of specification Replace Tester lead Blue lead 1 Tester lead Black lead 2 Throttle position sens...

Page 264: ...SPEED section in the CHAPTER 3 7 Insert the thin electric conductors 2 lead into the throttle position sensor coupler 1 as shown and connect the tester to them Do not insert the electric conductors more than required because it may reduce the waterproof function of the coupler Make sure that a short circuit does not de velop between the terminals because it may cause damage to electrical compo nen...

Page 265: ...throttle position sensor us ing the T25 bit 14 Install the carburetor CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1 Disconnect the throttle position sensor cou pler 2 Start the engine 3 Inspect Throttle position sensor input voltage Out of specification Replace the CDI unit Tester lead Blue lead 1 Tester lead Black Blue lead 2 Throttle position sensor input voltage Tester selector position...

Page 266: ...foreign mat ter to get into the carburetor Always handle the carburetor and its com ponents 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 ap plying excessive force When the engine is stopped or when riding at no load do not open and close the throt tle ...

Page 267: ...o rich or too lean the engine power will drop resulting in poor accel eration Effects of changing the main jet reference A Idle B Fully open 1 182 2 178 3 180 ADJUSTING THE PILOT SCREW The richness of the air fuel mixture with the throttle fully closed to 1 4 open can be set by turning the pilot screw 1 Turning in the pilot screw will make the mixture lean at low speeds and turning it out will enr...

Page 268: ...own the needle to lean out the mixture 2 Too lean at intermediate speeds The engine breathes hard and will not pick up speed quickly Step down the jet needle clip by one groove and move up the needle to enrich the mix ture Effects of changing the jet needle groove position reference A Idle B Fully open 1 No 5 groove 2 No 3 groove 3 No 4 groove ADJUSTING THE JET NEEDLE The jet needle is adjusted by...

Page 269: ...ng by the combination of the jet needle straight portion diameter and clip position ADJUSTING THE LEAK JET ADJUSTING THE ACCELERATOR PUMP The leak jet 1 is a setting part that adjusts the flow of fuel discharged by the accelerator pump Since the accelerator pump operates only when throttle is open the leak jet is used to adjust a fuel mixture ratio for quick throttle opening and is therefore diffe...

Page 270: ...JT Lean NDJU 5TA 14916 JU Rich NCVN 5TA 14916 VN NCVP 5TA 14916 VP NCVQ 5TA 14916 V1 NCVR 5TA 14916 VR NCVS 5TA 14916 VS NCVT 5TA 14916 VT Lean NCVU 5TA 14916 VU Rich NFLN 5TA 14916 LN NFLP 5TA 14916 LP NFLQ 5TA 14916 L1 STD NHKR 5TA 14916 KR NFLS 5TA 14916 LS NFLT 5TA 14916 LT Lean NFLU 5TA 14916 LU Jet needle Size Part number Rich NFPN 5TA 14916 PN NFPP 5TA 14916 PP NFPQ 5TA 14916 P1 NFPR 5TA 14...

Page 271: ...6 NFPR 6 NFPS 6 NFPT 6 NFPU 6 STD NFLN 6 NFLP 6 NFLQ 6 NHKR 4 NFLS 6 NFLT 6 NFLU 6 0 5 leaner NFPN 5 NFPP 5 NFPQ 5 NFPR 5 NFPS 5 NFPT 5 NFPU 5 Lean 1 leaner NFLN 5 NFLP 5 NFLQ 5 NHKR 3 NFLS 5 NFLT 5 NFLU 5 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 ...

Page 272: ...ottle Hard breathing Speed down Use jet needle with a smaller diam eter Slow speed circuit passage Clogged Clean Overflow from carburetor Closed to 1 4 throttle Poor acceleration Use jet needle with a larger diame ter Raise jet needle clip position 1 groove up Poor response in the low to intermediate speeds Raise jet needle clip position If this has no effect lower the jet needle clip position Poo...

Page 273: ...set such that it can develop its maximum revolutions toward the end of the straight line with care taken to avoid the en gine over revving Riding technique varies from rider to rider and the performance of a machine also vary from machine to machine Therefore do not imitate other rider s settings from the beginning but choose your own setting according to the level of your riding technique DRIVE A...

Page 274: ...se the air spring characteristics to have a tendency to be stiffer with the consequent deteriorated performance and characteris tics Therefore adjust the front fork within the specified range A Air spring characteristics in relation to oil amount change B Load C Stroke 1 Max oil amount 2 Standard oil amount 3 Min oil amount SETTING OF SPRING AFTER REPLACEMENT As the front fork setting can be easil...

Page 275: ... compression damping CHOOSING SET LENGTH 1 Place a stand or block under the engine to put the rear wheel above the floor and mea sure the length a between the rear wheel axle center and the rear fender holding bolt 2 Remove the stand or block from the engine and with a rider astride the seat measure the sunken length b between the rear wheel axle center and the rear fender hold ing bolt 3 Loosen t...

Page 276: ...s greater spring load Run with the rebound damping adjuster one or two clicks on the stiffer side and readjust it to suit your preference Adjusting the rebound damping will be followed more or less by a change in the compression damping For correction turn the low compres sion damping adjuster on the softer side When using a rear shock absorber other than currently installed use the one whose over...

Page 277: ...HAPTER 3 SPRING PART NUMBER 22212 Maximum Minimum 5UN 00 5UN 10 5UN 20 5UN 30 Position in which the spring is turned in 18 mm 0 71 in from its free length Position in which the spring is turned in 1 5 mm 0 06 in from its free length 5UN 40 5UN 50 5UN K0 5UN L0 5UN 60 5UN 70 Position in which the spring is turned in 20 mm 0 79 in from its free length ...

Page 278: ...ntire range bottoming out Compression damping Turn adjuster clockwise about 2 clicks to in crease damping Oil amount Increase oil amount by about 5 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz Spring Replace with stiff spring Stiff toward stroke end Oil amount Decrease oil amount by about 5 cm3 0 2 Imp oz 0 2 US oz Soft toward stroke end bottoming out Oil amount Increase oil amount by about 5 cm3 0 2 Imp o...

Page 279: ...Heavy and dragging Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Spring Replace with soft spring Poor road gripping Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Low compression damping Turn adjuster clockwise about 1 clicks to in crease damping High compression damping Turn adjuster clockwise about 1 6 turn to in crease dampi...

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Page 282: ...PRINTED IN JAPAN 2010 05 0 6 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

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