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CHAPTER 4

ENGINE

COWLING, INDUCTION GUIDE, SEAT
AND FUEL TANK. . . . . . . . . . . . . . . . . . . 4-1
EXHAUST PIPE AND SILENCER . . . . . . 4-3
RADIATOR . . . . . . . . . . . . . . . . . . . . . . . 4-4
CARBURETOR AND REED VALVE . . . . . 4-7
CYLINDER HEAD,CYLINDER AND
PISTON . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . 4-31
PRIMARY DRIVEN GEAR, PRIMARY
DRIVE GEAR AND BALANCER
SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . 4-38
SHIFT SHAFT . . . . . . . . . . . . . . . . . . . . 4-44
WATER PUMP . . . . . . . . . . . . . . . . . . . . 4-51
TRANSMISSION, SHIFT CAM AND
SHIFT FORK . . . . . . . . . . . . . . . . . . . . . 4-55
OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . 4-64
CDI MAGNETO . . . . . . . . . . . . . . . . . . . 4-68
ENGINE REMOVAL . . . . . . . . . . . . . . . . 4-71
CRANKCASE AND CRANKSHAFT . . . . 4-76

CHAPTER 5

CHASSIS

FRONT WHEEL AND REAR WHEEL. . . . 5-1
FRONT BRAKE AND REAR BRAKE . . . 5-10
FRONT FORK . . . . . . . . . . . . . . . . . . . . 5-26
HANDLEBAR. . . . . . . . . . . . . . . . . . . . . 5-40
STEERING. . . . . . . . . . . . . . . . . . . . . . . 5-46
SWINGARM . . . . . . . . . . . . . . . . . . . . . . 5-53
REAR SHOCK ABSORBER. . . . . . . . . . 5-60

CHAPTER 6

ELECTRICAL

ELECTRICAL COMPONENTS AND
WIRING DIAGRAM . . . . . . . . . . . . . . . . . 6-1
IGNITION SYSTEM . . . . . . . . . . . . . . . . . 6-2
CHARGING SYSTEM . . . . . . . . . . . . . . . 6-7
YPVS SYSTEM . . . . . . . . . . . . . . . . . . . 6-10
SOLENOID VALVE SYSTEM . . . . . . . . . 6-12
THERMO UNIT SYSTEM . . . . . . . . . . . . 6-14
FUEL PUMP SYSTEM . . . . . . . . . . . . . . 6-16

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Summary of Contents for TZ250M

Page 1: ...5KE 28199 10 LIT 11626 13 41 OWNER S SERVICE MANUAL TZ250M1 M ...

Page 2: ...maha Motor Corporation U S A 1st Edition September 1999 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 13 41 EC010000 ...

Page 3: ...ne please contact your Yamaha dealer NOTE As improvements are made on this model some data in this manual may become outdat ed If you have any questions please consult your Yamaha dealer W PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND U...

Page 4: ...ON This model is sold AS IS WITHOUT ANY WARRANTIES EXPRESSED OR IMPLIED REGARD LESS OF THE INTENDED USE THE PURCHASER OF THIS MACHINE which is intended for competition purposes IS RESPON SIBLE FOR ALL COSTS SERVICE AND OR REPAIR ...

Page 5: ...WEAR PROTECTIVE APPAR EL When operating this machine always wear an approved helmet with gog gles or a face shield Also wear heavy boots gloves and protective cloth ing Always wear proper fitting cloth ing that will not be caught in any of the moving parts or controls of the machine 4 ALWAYS MAINTAIN YOUR MACHINE IN PROPER WORKING ORDER For safety and reliability the machine must be properly maint...

Page 6: ...t fumes are poisonous These fumes contain carbon monox ide which by itself is odorless and colorless Carbon monoxide is a dan gerous gas which can cause uncon sciousness or can be lethal 8 PARK THE MACHINE CAREFULLY TURN OFF THE ENGINE Always turn off the engine if you are going to leave the machine Do not park the machine on a slope or soft ground as it may fall over 9 PROPERLY SECURE THE MACHINE...

Page 7: ...his machine and should remain with it even if the machine is subsequently sold EC060000 NOTICE Some data in this manual may become outdat ed due to improvements made to this model in the future If there is any question you have regarding this manual or your machine please consult your Yamaha dealer Weights of machines without fuel The minimum weights for road race machines are for the class 125 cc...

Page 8: ...ust be taken to avoid damage to the machine NOTE A NOTE provides key information to make pro cedures easier or clearer EC082000 FINDING THE REQUIRED PAGE 1 This manual consists of seven chapters General Information Specifications Regular inspection and adjustments Engine Chassis Electrical and Tuning 2 The table of contents is at the beginning of the manual Look over the general layout of the book...

Page 9: ... job 6 For jobs requiring more information the step by step format supplements 6 are given in addi tion to the exploded diagram and job instruction chart CLUTCH 4 25 ENG EC4A8100 CLUTCH HOUSING AND PUSH LEVER AXLE Extend of removal 1 Clutch housing removal 2 Push lever axle removal Extend of removal Order Part name Q ty Remarks CLUTCH HOUSING AND PUSH LEVER AXLE REMOVAL 1 Nut clutch boss 1 2 Lock ...

Page 10: ...ling fluid Lubricant Tightening Specified value Service limit Resistance Ω Voltage V Electric cur rent A Illustrated symbols to ª in the exploded dia grams indicate grade of lubricant and location of lubrication point Apply transmission oil Apply engine mixing oil Apply molybdenum disulfide oil Apply lightweight lithium soap base grease ª Apply molybdenum disulfide grease Illustrated symbols º to ...

Page 11: ...MEMO ...

Page 12: ...EC090000 INDEX GENERAL INFORMATION GEN INFO 1 TUNING TUN 7 CHASSIS CHAS 5 ELECTRICAL ELEC 6 ENGINE ENG 4 REGULAR INSPECTION AND ADJUSTMENTS INSP ADJ 3 SPECIFICATION SPEC 2 ...

Page 13: ...ON 1 16 STARTING AND BREAK IN 1 17 TORQUE CHECK POINTS 1 20 CLEANING AND STORAGE 1 21 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 3 GENERAL TORQUE SPECIFICATIONS 2 12 DEFINITION OF UNITS 2 12 CABLE ROUTING DIAGRAM 2 13 CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS 3 1 PRE OPERATION INSPECTION AND MAINTENANCE 3 4 LOCKING WIRE INSTALLATION GU...

Page 14: ... TRANSMISSION SHIFT CAM AND SHIFT FORK 4 55 OIL PUMP 4 64 CDI MAGNETO 4 68 ENGINE REMOVAL 4 71 CRANKCASE AND CRANKSHAFT 4 76 CHAPTER 5 CHASSIS FRONT WHEEL AND REAR WHEEL 5 1 FRONT BRAKE AND REAR BRAKE 5 10 FRONT FORK 5 26 HANDLEBAR 5 40 STEERING 5 46 SWINGARM 5 53 REAR SHOCK ABSORBER 5 60 CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM 6 1 IGNITION SYSTEM 6 2 CHARGING SYSTEM 6 7 YPVS...

Page 15: ...CHAPTER 7 TUNING ENGINE 7 1 CHASSIS 7 14 ...

Page 16: ... GENERAL INFORMATION EC110000 DESCRIPTION 1 Clutch lever 2 Valve joint 3 Main switch 4 Water temperature gauge 5 Front brake lever 6 Throttle grip 7 Radiator cap 8 Fuel tank cap 9 Starter lever Choke 0 Battery Fuel pump Fuel cock Steering damper Servomotor Radiator Check bolt Transmission oil level Rear brake pedal Rear shock absorber ª Drive chain º Shift pedal CDI magneto Front fork 1 ...

Page 17: ...ne EC121001 VEHICLE IDENTIFICATION NUMBER For USA CDN AUS NZ and E The vehicle identification number 1 is stamped on the right of the steering head pipe EC122001 FRAME SERIAL NUMBER Except for USA CDN AUS NZ and E The frame serial number 1 is stamped on the right of the steering head pipe EC123020 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the rear side of...

Page 18: ...OOLS section 3 When disassembling the machine keep mated parts together They include gears cylinders pistons and other mated parts that have been mated through normal wear Mated parts must be reused as an assembly 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 r...

Page 19: ... bolt or nut flat s after the bolt or nut has been properly tightened EC135001 BEARINGS AND OIL SEALS 1 Install the bearing s 1 and oil seal s 2 with their manufacturer s marks or numbers facing outward In other words the stamped letters must be on the side exposed to view When installing oil seal s apply a light coating of light weight lithium base grease to the seal lip s Oil the bearings libera...

Page 20: ...that it will not come off 5 If the terminal comes off bend up the pin 1 and reinsert the terminal into the connector 6 Connect Connector NOTE The two connectors click together 7 Check for continuity with a tester NOTE If there in no continuity clean the terminals Be sure to perform the steps 1 to 7 listed above when checking the wireharness For a field remedy use a contact revitalizer available on...

Page 21: ...eto YU 01235 90890 01235 Rotor holding tool YU 01235 90890 01235 This tool is used when loosening or tightening the flywheel magneto securing nut YU 03097 90890 01252 Dial gauge and stand YU 03097 90890 01252 YU 01256 Stand YU 01256 These tools are used to set the ignition timing YU 01304 90890 01304 Piston pin puller YU 01304 90890 01304 This tool is used to remove the piston pin YM 01312 A 90890...

Page 22: ... when install the fork oil seal YM 01455 90890 01455 Pivot shaft wrench YM 01455 90890 01455 YM 01476 90890 01476 Pivot shaft wrench adapter YM 01476 90890 01476 These tools are used to loosen or tighten the pivot adjust bolt YU 03112 90890 03112 Yamaha pocket tester YU 03112 90890 03112 Use this tool to inspect the coil resistance output voltage and amperage YM 91042 90890 04086 Clutch holding to...

Page 23: ...TOOLS 1 8 GEN INFO Part number Tool name How to use Illustration ACC 11001 30 00 Quick gasket ACC 11001 30 00 90890 05143 90890 05143 YAMAHA Bond No 4 This sealant Bond is used for crankcase mating surface etc ...

Page 24: ...h lever to the handlebar to disen gage the clutch and release the lever to engage the clutch The lever should be pulled rapidly and released slowly for smooth starts EC153000 SHIFT PEDAL The gear ratios of the constant mesh 6 speed transmission are ideally spaced The gears can be shifted by using the shift pedal 1 on the left side of the engine EC155001 THROTTLE GRIP The throttle grip 1 is located...

Page 25: ...n the circuit for starting When the engine has warmed up pull it in to close the circuit EC15V010 TACHOMETER A stepping motor type tachometer is provided for greater accuracy of the tachometer 1 This tachometer features the following Sweeping Moving the main switch to RUN the tachometer hand sweeps widely once over the tachometer face and then returns to the zero position as initial operation This...

Page 26: ...hange in the water temperature NOTE Water temperature may be 70 C 158 F when engine is operated in good conditions Cooling water Display Conditions temp 19 C LO is display 66 F 20 119 C Temperature is 68 247 F displayed 120 140 C Temperature 248 284 F flash 141 C Message HI 285 F flash EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather...

Page 27: ...e off by wind pressure while running EC15Z000 FUEL PUMP The fuel pump 1 is provided in order to pro vide steady supply of fuel even when the pres sure inside the carburetor float chamber becomes higher than inside the fuel tank because of the induction box intake system If the fuel level is not up to the specified level in the float chamber this pump is activated with an operation sound and stops ...

Page 28: ...e pump comes to a stop Fuel pump Fuel pump Fuel pump 5 stop switch 1 relay switch 4 During run OFF ON ON During ON OFF OFF turnover q NOTE When the machine is picked up from turnover the fuel pump is restored to an operation con dition Install the fuel pump stop switch so that UPPER mark a faces upward EC15M011 CATCH TANK Put the tip of the breather hose into the catch tank 1 and frame 2 Take care...

Page 29: ...starting out EC15R001 DETACHABLE SIDESTAND This sidestand 1 is used to support only the machine when standing or transporting it W Never apply additional force to the side stand Remove this sidestand before starting out EC15T003 FIRE RETARDANT MATERIAL For racing be sure to fill the fuel tank 2 com pletely with fire retardant material with supply ing parts 1 EC15b000 COUPLER FOR SPEED SHIFT If an ...

Page 30: ...S Unleaded fuel only 5 NOTE Except for AUS 1 If knocking or pinging occurs use a differ ent brand of gasoline or higher octane grade 2 If unleaded gasoline is not available then leaded gasoline can be used C CCAUTION Never mix two types of oil in the same batch clotting of the oil could result If you wish to change oil types be sure to drain the fuel tank and the carburetor float bowl of old premi...

Page 31: ...n a well venti lated area If you should swallow some lacquer thinner inhale excess lacquer thinner vapors or allow any lacquer thin ner to get into your eyes contact a doctor immediately NOTE When the machine is not in use for a long time apply a rust inhibitor to the brake disc After riding in the rainy weather wipe the moisture completely off the disc If rust appears on the brake disc carefully ...

Page 32: ...4 Shift the transmission into 1st gear 5 Apply the clutch lever and push the machine 6 After gaining some momentum release the clutch lever 7 As soon as the engine starts quickly apply the clutch lever again and open the throttle grip slightly at the same time so as to sus tain idling of the engine Then shift the transmission into neutral 8 After applying full throttle a few times turn the starter...

Page 33: ...n switch to OFF NOTE During break in mask part of the radiator core so that the water temperature is 55 65 C 131 149 F 4 Operate the machine under 8 000 r min and run on a course about 10 km 6 miles While making a straight line run open the throttle from time to time taking care not to exceed the revolution limit 5 Go back to the pit to check for looseness leakage and other failures in installatio...

Page 34: ...piston head for burning to see if there is any problem Refer to SETTING section in the CHAPTER 7 11 Run about 10 km 6 miles in a usual man ner Then do the plug chop Check the pis ton head for burning to see if there is any problem EC195001 BREAKING IN AFTER REPLACEMENT After a part is replaced with a new one it is necessary to break it in as in a new machine This is required especially when the fo...

Page 35: ... For link type Assembly of links Link to frame Link to shock absorber Link to swingarm Rear Installation of shock absorber Shock absorber to frame Rear Installation of swingarm Tightening of pivot shaft Wheel Installation of wheel Front Tightening of front axle Tightening of axle holder Rear Tightening of rear axle Sprocket damper to sprocket Brake Hydraulic type Front Caliper to front fork Brake ...

Page 36: ...wheel bear ings front forks brakes and transmission seals Many expensive repair bills have resulted from improper high pressure detergent applications such as those avail able in coin operated car washers 4 After the majority of the dirt has been hosed off wash all surfaces with warm water and a mild detergent Use an old toothbrush to clean hard to reach places 5 Rinse the machine off immediately ...

Page 37: ...the cylinder walls with oil 3 Remove the drive chain clean it thoroughly with solvent and lubricate it Reinstall the chain or store it in a plastic bag tied to the frame 4 Lubricate all control cables 5 Block the frame up to raise the wheels off the ground 6 Tie a plastic bag over the exhaust pipe out let to prevent moisture from entering 7 If the machine is to be stored in a humid or salt air env...

Page 38: ...nt 249 cm3 8 76 lmp oz 8 42 US oz BoreXStroke 54X54 5 mm 2 126X2 146 in Compression ratio 7 2 1 Starting system Push to start Lubrication system Premix 30 1 Castrol A747 Oil type or grade 2 Cycle Transmission oil Castrol R30 Periodic oil change 0 5 L 0 44 lmp qt 0 53 US qt Total amount 0 5 L 0 44 lmp qt 0 53 US qt Cooling water capacity including all routes 1 4 L 1 23 lmp qt 1 48 US qt Fuel Type E...

Page 39: ...ngle 22 Trail 82 mm 3 23 in Tire Type Tubeless Size front 3 10 4 80 R17 Size rear 165 55 R17 Tire pressure front and rear 200 kPa 2 0 kg cm2 29 psi Brake Front brake type Dual disc brake Operation Right hand operation Rear brake type Single disc brake Operation Right foot operation Suspension Front suspension Telescopic fork Rear suspension Swingarm link type monocross suspension Shock absorber Fr...

Page 40: ...1 969 in Runout limit C 0 03 mm 0 0012 in 0 05 mm 0 0020 in Connecting rod big end side clearance D 0 45 0 95 mm 0 018 0 037 in Small end free play F 0 8 1 0 mm 0 031 0 039 in 2 0 mm 0 08 in Clutch Friction plate thickness 2 9 3 1 mm 0 114 0 122 in 2 7 mm 0 106 in Quantity 6 Clutch plate thickness 2 2 2 4 mm 0 087 0 094 in Quantity 5 Warp limit 0 1 mm 0 004 in Clutch spring free length 30 6 mm 1 2...

Page 41: ...er jet G S 80 Power jet P W J 55 Float height F H 6 0 7 0 mm 0 24 0 28 in Reed valve Thickness reed valve 1 0 42 mm 0 017 in reed valve 2 0 34 mm 0 013 in Valve stopper height 6 5 6 9 mm 0 256 0 272 in Valve bending limit 0 2 mm 0 008 in Cooling Radiator core size Width 380 mm 14 96 in Height 198 mm 7 80 in Thickness 24 mm 0 94 in Radiator cap opening pressure 95 125 kPa 0 95 1 25 kg cm2 13 5 17 8...

Page 42: ...ng chamber top M 4 X 0 7 2 2 0 2 1 4 Exhaust pipe M 8 X 1 25 2 21 2 1 15 Silencer M 6 X 1 0 4 11 1 1 8 0 Crankcase M 8 X 1 25 6 Refer to NOTE Crankcase M 6 X 1 0 8 Transmission housing M 6 X 1 0 6 16 1 6 11 Oil check bolt M 6 X 1 0 1 9 0 9 6 5 Oil drain bolt M12 X 1 25 1 23 2 3 17 Crankcase cover right M 6 X 1 0 10 11 1 1 8 0 Crankcase cover left M 6 X 1 0 3 11 1 1 8 0 Primary drive gear M10 X 1 2...

Page 43: ... 1 2 M 6 X 1 0 2 11 1 1 8 0 Shift pedal pivot bolt M 8 X 1 25 1 22 2 2 16 Front pedal M 6 X 1 0 1 10 1 0 7 2 NOTE Tighten all bolts in 2 steps as follows and be sure to tighten in numbered order as shown First 1 6 M8 11 Nm 1 1 m kg 8 0 ft lb 7 M6 6 Nm 0 6 m kg 4 3 ft lb Final 1 6 M8 26 Nm 2 6 m kg 19 ft lb 7 M6 11 Nm 1 1 m kg 8 0 ft lb Crankcase tighten sequence ...

Page 44: ...n Front fork top end 13 mm 0 51 in Rear suspension Shock absorber travel 53 mm 2 09 in Spring free length 150 mm 5 91 in Fitting length 137 mm 5 39 in Min Max 133 142 mm 5 24 5 59 in Spring rate STD K 72 N mm 7 2 kg mm 403 lb in Optional spring No Enclosed gas pressure 1 200 kPa 12 kg cm3 171 psi Swingarm Swingarm free play limit End 1 0 mm 0 04 in Side clearance 0 05 0 35 mm 0 002 0 014 in Wheel ...

Page 45: ...337 1 190 in Brake fluid type DOT 4 Rear disc brake Disc outside dia XThickness 185X4 0 mm 7 28X0 16 in Deflection limit 0 15 mm 0 006 in Pad thickness 4 0 mm 0 16 in 1 0 mm 0 04 in Master cylinder inside dia 12 7 mm 0 500 in Caliper cylinder inside dia 25 4 mm 1 000 in Brake fluid type DOT 4 Brake lever brake pedal Brake pedal position 148 152 mm 5 8 6 0 in Clutch lever free play at lever pivot 2...

Page 46: ...8 Brake hose holder and swingarm M 6 X 1 0 2 8 0 8 5 8 Brake hose front and rear and union bolt M10 X 1 25 2 30 3 0 22 master cylinder Brake hose front and rear and adapter M10 X 1 25 3 14 1 4 10 Brake caliper front and rear and adapter M10 X 1 25 3 26 2 6 19 Front brake caliper and front fork M10 X 1 25 4 35 3 5 25 Front brake union bolt and bleed screw M 8 X 1 25 1 7 0 7 5 1 Brake caliper front ...

Page 47: ...od M10 X 1 25 1 34 3 4 24 Connecting rod and swingarm M10 X 1 25 1 34 3 4 24 Rear shock absorber and upper bracket M10 X 1 25 1 34 3 4 24 Rear shock absorber and relay arm M10 X 1 25 1 34 3 4 24 Seal guard and swingarm M 6 X 1 0 4 8 0 8 5 8 Swingarm and hook M 6 X 1 0 2 10 1 0 7 2 Swingarm and chain guard M 6 X 1 0 2 8 0 8 5 8 Rear shock absorber and locknut preload M52 X 1 5 1 20 2 0 14 Seat heig...

Page 48: ...k gap 5 mm 0 20 in Primary winding resistance 0 14 0 18 Ω at 20 C 68 F Secondary winding resistance 5 0 7 4 kΩ at 20 C 68 F Battery Model Manufacturer PE12V0 8 JAPAN STORAGE BATTERY Capacity 12V0 8Ah Voltage when charged 12 8V or more Fuel pump Model Manufacturer UC Z6V MITSUBISHI Coil resistance 1 3 Ω at 20 C 68 F Fuel pump relay Model Manufacturer 1UY 92 MATSUSHITADENKO Coil resistance 72 88 Ω a...

Page 49: ...pecified torque specifications call for clean dry threads Components should be at room temperature A B TORQUE SPECIFICATION Nut Bolt Nm md dkg ftd dlb 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 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 94 EC230000 DEFINITION OF UNITS Unit Read Definition Measure mm millimeter 10 3 meter Length cm centimeter 10 2 meter Leng...

Page 50: ...right cylinder 7 Ignition coil lead 8 Starter cable 9 Solenoid valve lead 0 Fuel hose Clutch cable Fuel pump lead Throttle cable Transmission oil breather hose A Cut the clamp so that the protruding portion is less than 5 mm 0 20 in B Position the cable from bottom to top in the following order Starter cable Throttle cable Solenoid valve lead ...

Page 51: ...ator hose 3 and ignition coil lead C Clamp the radiator hose 3 and YPVS cable right cylinder D Do not cut the end of the clamp E Connect the left cylinder YPVS cables silver cables to the inner YPVS servomotor pulley and right cylinder YPVS cables black cables to the outer The sleeved cables must be connected to the top side open side of the YPVS servomotor F Position the ends of the clamp on the ...

Page 52: ...plers of the fuse lead under the cowling stay mounting bolt so that the tape on the wireharness aligns with the bolt B Fasten the primary ground lead together with the cowling stay bracket mounting bolt C Do not cut the end of the clamp D Clamp the couplers of the main switch lead together with the wirehar ness E Disconnect the power supply coupler except when the engine is started or when electri...

Page 53: ...tor 6 Brake hose holder 7 Reservoir hose 8 Rear brake hose 9 Clamp A Install the tachometer assembly with its figures standing upright B Do not make the clamp grip face outside of the chassis C Position the reservoir hose with its paint mark upward D Be sure the brake hose is not twisted E Do not cut the end of the clamp ...

Page 54: ...ery As re Item break race 500km 1 000 quired Remarks in km PISTON Inspect and clean Inspect crack Replace PISTON PIN SMALL END BEARING Inspect Replace PISTON RING Inspect Check ring end gap Replace CYLINDER HEAD Inspect and clean Remove carbon Retighten Check O ring CYLINDER Inspect and clean 3 000 km Inspect score marks Replace Inspect wear Retighten YPVS Inspect Retighten CLUTCH Inspect housing ...

Page 55: ...place FRAME Clean and inspect FUEL TANK COCK Clean and inspect BRAKES Adjust lever position and pedal position Check brake disc surface Check brake fluid level and leakage Retighten brake disc bolts caliper bolts and master cylinder bolts Replace pads Replace brake fluid Every one year FRONT FORKS Inspect and adjust Replace oil Suspension oil 01 Replace oil seal REAR SHOCK ABSORBER After rain Insp...

Page 56: ...ace bearings Lubricate Lithium base grease DRIVE CHAIN Use chain lube Lubricate slack alignment Chain slack 40 50 mm Replace 1 6 2 0 in DRIVE DRIVEN SPROCKET Inspect and replace Inspect wear DRIVEN SPROCKET DAMPER Inspect and retighten Replace THROTTLE CONTROL CABLE Check routing and connection Yamaha cable lube or SAE Lubricate 10W30 motor oil BATTERY Check battery voltage 12 5V or more Replace ...

Page 57: ...effect of front and rear brake Check brake disc surface P3 17 22 Chain Check chain slack and alignment Check that the chain is lubricated properly P3 23 25 Wheels Check for excessive wear tire pressure and tire wear P3 36 Steering Check that the handlebars can be turned smoothly and have no excessive play P3 37 38 Front forks and Check that they operate smoothly and there is no oil rear shock abso...

Page 58: ...IRE INSTALLATION GUIDE 3 5 EC340000 LOCKING WIRE INSTALLATION GUIDE INSP ADJ Bolt to bolt Oil drain bolt and check bolt YPVS pulley Oil filler cap Bolt Tank rail drain bolt Throttle cable adjuster Starter cable ...

Page 59: ... injury When the engine has cooled place a thick towel over the radiator cap slowly rotate the cap counterclockwise to the detent This procedure allows any residual pres sure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remove it C CCAUTION Hard water or salt water is harmful to the engine parts You may use distilled water if you can t get s...

Page 60: ...tor with anti freeze tilt the motorcycle so that the filler hole b b is at the highest position If the radiator is positioned upright air a a is difficult to escape which may result in excessive engine heating Hard water or salt water is harmful to the engine parts You may use distilled water if you can t get soft water 8 Remove Air bleeding bolt right cylinder 1 Bleeding the air until coming out ...

Page 61: ...ace Exist fur deposits 3 Clean or replace INSP ADJ EC356001 RADIATOR CAP OPENING PRESSURE INSPECTION 1 Attach Radiator cap tester 1 and adapter 2 Radiator cap tester YU 24460 1 90890 01325 Adapter YU 33984 90890 01352 C NOTE Apply water on the radiator cap seal 3 Radiator cap 2 Apply the specified pressure Radiator cap opening pressure 95 125 kPa 0 95 1 25 kg cm2 13 5 17 8 psi b 3 Inspect Pressure...

Page 62: ...180 kPa 1 8 kg cm2 25 6 psi a NOTE Do not apply pressure more than specified pressure Radiator should be filled fully 4 Inspect Pressure Impossible to maintain the specified pres sure for 10 seconds Repair Radiator 1 Radiator hose joint 2 Coolant leakage Repair or replace Radiator hose 3 Swelling Replace EC358000 CLUTCH CARE NOTE This machine is equipped with a dry type clutch Be sure to clean wit...

Page 63: ...sen the locknut 1 Turn the adjuster 2 until free play a is within the specified limits Tighten the locknut INSP ADJ NOTE After adjustment check proper operation of clutch lever EC35A040 THROTTLE CABLE ADJUSTMENT 1 Check Throttle grip free play a Out of specification Adjust Throttle grip free play a a 2 4 mm 0 08 0 16 in a 2 Remove Lower cowl Fuel tank Induction guide right cylinder 3 Loosen the sc...

Page 64: ...e valve and touch the left throttle valve After adjusting the throttle cables open the throttle grip and check that both throttle valves are completely open Tighten the left carburetor locknut 3 Tighten the locknuts 1 W After adjusting turn the handlebar to right and left and make sure that the engine idling dose not run faster INSP ADJ EC35B002 STARTER CABLE ADJUSTMENT 1 Check Starter lever free ...

Page 65: ...e main switch is moved to RUN the servomotor will be operated as follows 1 The servomotor will be fully closed about 1 second 2 And then it will be kept fully opened Check the free play a for the YPVS open side cables 1 Out of specification Adjust µ YPVS open side cable free play a a 2 3 mm 0 08 0 12 in 3 Adjust YPVS open side cable free play Adjusting steps Fully open the servomotor Loosen the lo...

Page 66: ...ation Adjust µ YPVS close side cable free play a a 2 3 mm 0 08 0 12 in 3 Adjust YPVS close side cable free play Adjusting steps Fully close the servomotor Loosen the locknuts 1 Turn the adjusters 2 until the specified free play is obtained Tighten the locknuts INSP ADJ EC35F000 YPVS COMPONENTS RETIGHTENING NOTE Before riding the machine retighten all YPVS components 1 Retighten Valve cover 1 T4 Nm...

Page 67: ...er Wait until the oil cools down S Oil flows out Oil level is correct Oil does not flow out Oil level is low Add transmis sion oil until oil flows out Recommended oil Castrol R30 R Inspect the gasket oil check bolt replace if damaged Tighten the oil check bolt T Oil check bolt 9 Nm 0 9 m kg 6 5 ft lb EC35K021 TRANSMISSION OIL REPLACEMENT 1 Start the engine and warm it up for several minutes and wa...

Page 68: ...ck it using a wire 6 Fill Transmission oil Recommended oil Castrol R30 Oil capacity periodic oil change 0 50 L 0 44 Imp qt 0 53 US qt 3 7 Check Oil leakage 8 Check Transmission oil level 9 Install Oil filler cap 2 EC35L001 PILOT AIR SCREW ADJUSTMENT 1 Adjust Pilot air screw 1 Adjusting steps Screw in the pilot air screw until it is lightly seated Back out by the specified number of turns Ω Pilot a...

Page 69: ...nspect O ring 1 Damage Replace EC35Q001 SILENCER INSPECTION 1 Inspect Silencer Inside of silencer loose Repair Silencer repair steps Drill the silencer for riveting Rivet the silencer using the rivet NOTE Rivet the silencer in a different area than previously riveted INSP ADJ ...

Page 70: ...m Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic tube 2 tightly to the caliper bleed screw 1 d Place the other end of the tube into a container e Slowly apply the brake lever or pedal several 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 toward...

Page 71: ...g the brake system 3 Install Diaphragm Reservoir tank cap EC363010 FRONT BRAKE ADJUSTMENT 1 Adjust Brake lever position a Adjustment steps Turn the adjuster 1 while pushing the brake lever 2 forward until the desired lever position is obtained S Closer Turn the adjuster in b b Farther Turn the adjuster out c c S NOTE Align the mating mark d on the adjuster with the arrow mark e on the brake lever ...

Page 72: ...ation Replace as a set Brake pad thickness a a Standard Limit 5 3 mm 0 21 in 1 0 mm 0 04 in 2 Replace Brake pad Brake pad replacement steps Loosen the pad pin 1 and remove the caliper 2 Remove the cotter pin 3 pad pin 4 pad support 5 and brake pads 6 Connect the transparent hose 7 to the bleed screw 8 and place the suitable con tainer under its end Loosen the bleed screw and push the caliper pisto...

Page 73: ... Refer to BRAKE FLUID LEVEL INSPEC TION section 4 Check Brake lever operation A softy or spongy feeling Bleed brake system Refer to BRAKE SYSTEM AIR BLEED ING section EC366031 REAR BRAKE PAD INSPECTION AND REPLACEMENT 1 Inspect Brake pad thickness a Out of specification Replace as a set Brake pad thickness a a Standard Limit 4 0 mm 0 16 in 1 0 mm 0 04 in 2 Replace Brake pad Brake pad replacement s...

Page 74: ...ighten the bleed screw Bleed screw 6 Nm 0 6 m kg 4 3 ft lb U Install the brake pads 9 pad support 0 pad pin and cotter pin NOTE Always use a new cotter pin Temporarily tighten the pad pin at this point Install the caliper and tighten the pad pin Bolt caliper 23 Nm 2 3 m kg 17 ft lb Pad pin 18 Nm 1 8 m kg 13 ft lb 3 Inspect Brake fluid level Refer to BRAKE FLUID LEVEL INSPEC TION section 4 Check Br...

Page 75: ...ke fluid to avoid poor brake performance Refill with same type and brand of brake fluid mixing fluids could result in poor brake performance Be sure that water or other contaminants do not enter master cylinder when refill ing Clean up spilled fluid immediately to avoid erosion of painted surfaces or plastic parts EC368011 SPROCKETS INSPECTION 1 Inspect Sprocket teeth a Excessive wear Replace NOTE...

Page 76: ... C CCAUTION This machine has a drive chain with small rubber O rings 1 1 between the chain plates Steam cleaning high pressure washes certain solvent and kerosene can damage these O rings 3 Inspect O rings 1 drive chain Damage Replace drive chain Rollers 2 Side plates 3 Damage Wear Replace drive chain 4 Measure Drive chain length 10 links a Out of specification Replace Drive chain length 10 links ...

Page 77: ...OTE Press the link plate onto the chain joint using a chain rivetter 5 Rivet the end of the chain joint using a chain rivetter 6 After rivetting the chain joint make sure its movement is smooth 8 Lubricate Drive chain Drive chain lubricant SAE 30 50W motor oil or chain lubricants suitable for O ring chains EC36A042 DRIVE CHAIN SLACK ADJUSTMENT 1 Hold the machine on upright position by placing the ...

Page 78: ...ter clockwise To loosen Turn adjuster 3 3 clockwise S Turn each adjuster exactly the same amount to maintain correct axle alignment There are marks a on each side of chain puller alignment NOTE Turn the adjuster so that the chain is in line with the sprocket as viewed from the rear C CCAUTION Too small chain slack will overload the engine and other vital parts keep the slack within the specified l...

Page 79: ...left and right to make the front wheel straight NOTE To make the front wheel straight provide b and c with the same distance as seen along the extension of the line a connecting the rear end of the front wheel 1 and the front end of the rear wheel 2 Figure A shows that the front wheel is turned clockwise b c Figure B shows that the front wheel is straight b c 5 Check Wheel alignment With the front...

Page 80: ...as it will provide convenience in your future similar adjustment 7 Install Lower cowl EC36C000 FRONT FORK INSPECTION 1 Inspect Front fork smooth action Operate the front brake and stroke the front fork Unsmooth action oil leakage Repair or replace EC36E021 FRONT FORK TOP END ADJUSTMENT 1 Hold the machine on upright position by placing the suitable stand 2 Remove Cowling Induction guide left cylind...

Page 81: ...nch bolts handle crown and under bracket Pinch bolt handle crown 20 Nm 2 0 m kg 14 ft lb Pinch bolt under bracket 23 Nm 2 3 m kg 17 ft lb C CCAUTION Tighten the under bracket to specified torque If torqued too much it may cause the front fork to malfunction Adjust the handlebar position b and steer ing damper stay position c Handlebar position b b 9 mm 0 35 in Steering damper stay position c c 73 ...

Page 82: ... the right 4 Check Steering smooth action Turn the handlebar to make sure no parts are being contacted with others Contact Repair 5 Install Front fender Front wheel Induction guide left cylinder Cowling EC36F012 FRONT FORK SPRING PRELOAD ADJUST MENT 1 Adjust Spring preload By turning the adjuster 1 Stiffer a a Increase the spring preload Turn the adjuster 1 1 in Softer b b Decrease the spring prel...

Page 83: ...0 5 mm 0 02 in changed per click of the adjuster C CCAUTION Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged W Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability Stiffer a a Increase the rebound damping force Turn the adjuster 1 1 in Softer b b Decrease the rebound damping force Tur...

Page 84: ...tion is zero C CCAUTION Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged W Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability INSP ADJ Stiffer a a Increase the compression damping force Turn the adjuster 1 1 in Softer b b Decrease the compression damping force Turn the adjuster 1 1 ...

Page 85: ... just when the adjuster is fully turned in this position is zero C CCAUTION Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged W Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability EC36K000 REAR SHOCK ABSORBER INSPECTION 1 Inspect Swingarm smooth action Abnormal noise Unsmooth action G...

Page 86: ... to turn the adjuster beyond the maximum or minimum length Tighten the lock bolt and locknut Lock bolt 40 Nm 4 0 m kg 29 ft lb Locknut 38 Nm 3 8 m kg 27 ft lb Install the cap 3 Install Fuel tank EC36M051 REAR SHOCK ABSORBER SPRING PRE LOAD ADJUSTMENT 1 Hold the machine on upright position by placing the suitable stand 2 Loosen Locknut 1 NOTE When loosening the locknut use the special tool 2 which ...

Page 87: ...cknut T20 Nm 2 0 mdkg 14 ftdlb EC36N040 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1 Adjust Rebound damping force By turning the adjuster 1 INSP ADJ Stiffer a a Increase the rebound damp ing force Turn the adjuster 1 1 in Softer b b Decrease the rebound damp ing force Turn the adjuster 1 1 out Extent of adjustment Maximum Minimum Fully turned in Fully turned out position position STANDAR...

Page 88: ...DJ Stiffer a a Increase the compression damping force Turn the adjuster 1 1 in Softer b b Decrease the compression damping force Turn the adjuster 1 1 out Extent of adjustment Maximum Minimum Fully turned in Fully turned out position position STANDARD POSITION This is the position which is back by the spe cific number of clicks from the fully turned in position Standard position 12 clicks out a NO...

Page 89: ...r 200 kPa 200 kPa 2 0 kg cm2 29 psi 2 0 kg cm2 29 psi NOTE Check the tire while it is cold 1Air gauge EC36R000 TIRE INSPECTION 1 Inspect Tire surfaces Wear Damage Replace Minimum tire tread depth a a 2 mm 0 08 in a EC36T000 WHEEL INSPECTION 1 Inspect Wheel runout Elevate the wheel and turn it Abnormal runout Replace INSP ADJ 2 Inspect Bearing free play Exist play Replace ...

Page 90: ...p the bottom of the forks and gently rock the fork assembly back and forth Free play Adjust steering head 4 Check Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steering ring nut Steering ring nut adjustment steps Remove the cowling Remove the reservoir tank and handle crown Loosen the ring nut 1 using ring nut wrench 2 Ring nut wrench YU 33975 90890 01403 INSP ADJ 5...

Page 91: ...eering shaft by turning it lock to lock If there is any binding remove the steering shaft assembly and inspect the steering bearings Install the handle crown 5 and reservoir tank 6 Steering shaft nut 7 7 80 Nm 8 0 m kg 58 ft lb Pinch bolt front fork 8 8 20 Nm 2 0 m kg 14 ft lb Bolt reservoir tank 9 9 5 Nm 0 5 m kg 3 6 ft lb º Install the cowling 6 Install Steering damper EC36V002 STEERING DAMPER A...

Page 92: ...heard as the zero position If a click is heard just when the adjuster is fully turned out this position is zero C CCAUTION Do not force the adjuster past the minimum or maximum extent of adjustment The adjuster may be damaged EC36X001 WIRES CABLES 1 Inspect Smooth movement for steering handle By turning the handlebar lock to lock If any caught rubbed Repair Replace INSP ADJ EC36Z000 COWLING INSTAL...

Page 93: ...ever pivots 3 Throttle to handlebar contact 4 Drive chain 5 Throttle cable end 6 Clutch cable end INSP ADJ A Use Yamaha cable lube or equivalent on these areas B Use SAE 10W30 motor oil or suitable chain lubricants C Lubricate the following areas with high qual ity lightweight lithium soap base grease C CCAUTION Wipe off any excess grease and avoid get ting grease on the brake discs A A A B C C ...

Page 94: ...s the spark plug insulator will become sooty even if the engine and carburetor are in good operating condition 3 Measure Plug gap a Use a wire gauge or thickness gauge Out of specification Regap Spark plug gap 0 5 0 6 mm 0 020 0 024 in a Standard spark plug R6179A 105P 4 Clean the plug with a spark plug cleaner if necessary 5 Tighten Spark plug T19 Nm 1 9 mdkg 13 ftdlb NOTE Before installing a spa...

Page 95: ...l the dial gauge indicates that the piston is at a specified distance from TDC Ignition timing 2 4 mm 0 094 in a INSP ADJ EC372070 IGNITION TIMING CHECK NOTE The right pick up coil 1 is provided so that ignition timing can be set for both cylinders by adjusting for the left cylinder only Therefore do not loosen the screws right pick up coil 2 When the portion a of the right pick up coil aligns wit...

Page 96: ... the punch marks by turning the stator 2 Tighten the screws stator T Screw stator 7 Nm 0 7 m kg 5 8 ft lb EC375000 BATTERY INSPECTION W To prevent danger read the battery label carefully before handling the battery 1 Connect the checking lead supplying parts 2 to the power supply coupler 1 2 Check Battery voltage Out of specification Replace Tester lead Red lead 3 3 Tester lead Black lead 4 4 Batt...

Page 97: ...he TZ250 NOTE Battery can be recharged using either an MF battery devoted charger or automobile battery Using the MF battery devoted charger 1 Remove Seat Battery 2 Connect the battery charger 1 for MF bat teries to the battery 2 using the checking lead supplying parts 3 and recharge the battery Battery charger lead Red lead 4 4 Battery charger lead Black lead 5 5 Battery charger for MF batteries ...

Page 98: ...ed 12 8V or more or 12 5V or more Voltage of the automobile battery for power supply 12 8 13 8V maximum 14 9V o NOTE If the battery is recharging using an automobile battery the charge may not exceed 12 8V Then 12 5V or more will be OK C CCAUTION For an automobile battery for supply use a battery with a capacity of 12V20Ah or more with a voltage 12 8 to 13 2 During the battery recharge do not rech...

Page 99: ...rks COWLING INDUCTION GUIDE SEAT AND FUEL TANK REMOVAL Preparation for Turn the fuel cock to OFF removal Disconnect the fuel hose 1 Clip lower cowl 1 2 Quick fastener 5 3 Lower cowl 1 4 Clip upper cowl 3 5 Upper cowl 1 6 Induction guide left cylinder 1 7 Induction guide right cylinder 1 8 Screw seat 4 9 Seat 1 10 Fuel tank breather hose 1 Refer to REMOVAL POINTS 11 Clip fuel tank 1 12 Fuel tank 1 ...

Page 100: ...REMOVAL POINTS EC4U3100 Fuel tank breather hose 1 Disconnect Fuel tank breather hose 1 NOTE Disconnect the fuel tank breather hose with the valve joint 2 remaining on the fuel tank side so as to prevent fuel from spurting out by the tank inner pressure ENG 4 ...

Page 101: ...t name Q ty Remarks EXHAUST PIPE AND SILENCER REMOVAL Preparation for Lower cowl Refer to COWLING INDUCTION removal GUIDE SEAT AND FUEL TANK section 1 Tension spring 2ea 2 Bolt exhaust pipe 1ea 3 Exhaust pipe 1ea 4 Bolt silencer 2ea 5 Silencer 1ea 2 1 T 11 Nm 1 1 mdkg 8 0 ftdlb T 11 Nm 1 1 mdkg 8 0 ftdlb T 21 Nm 2 1 mdkg 15 ftdlb T 21 Nm 2 1 mdkg 15 ftdlb ...

Page 102: ...ank GUIDE SEAT AND FUEL TANK section Drain the cooling water Refer to COOLANT REPLACEMENT section in the CHAPTER 3 1 Water temperature gauge lead 1 2 Thermo unit 1 3 Radiator hose 2 1 4 Radiator hose 4 1 5 Radiator hose 3 1 6 Radiator breather hose 1 7 Radiator 1 1 T 2 Nm 0 2 mdkg 1 4 ftdlb T 2 Nm 0 2 mdkg 1 4 ftdlb T 2 Nm 0 2 mdkg 1 4 ftdlb T 7 Nm 0 7 mdkg 5 1 ftdlb T 7 Nm 0 7 mdkg 5 1 ftdlb T 11...

Page 103: ...ap slowly rotate the cap counter clockwise to the detent This procedure allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning coun terclockwise and remove it EC454000 INSPECTION EC444100 Radiator 1 Inspect Radiator core 1 Obstruction Blow out with compressed air through rear of the radiator Bent fin Repair replace ENG EC455000 ASSEMBLY AND IN...

Page 104: ...kg 8 0 ftdlb Water temperature gauge lead 6 NOTE Insert the end of the radiator breather hose into the frame Refer to CONTROL FUNC TION section in the CHAPTER 1 Before applying LOCTITE wipe off dirt on the thread of the thermo unit and its recepta cle on the radiator Apply LOCTITE to half of the thermo unit thread portion on the coupler side so as to prevent LOCTITE from protruding into the radiat...

Page 105: ...NDUCTION removal and fuel tank GUIDE SEAT AND FUEL TANK section Spark plug cap left cylinder Radiator hose 3 Refer to RADIATOR section Bolt radiator stay Shift the radiator Servicing the forward right cylinder Tension spring exhaust pipe left cylinder T 2 Nm 0 2 mdkg 1 4 ftdlb T 2 Nm 0 2 mdkg 1 4 ftdlb T 11 Nm 1 1 mdkg 8 0 ftdlb T 11 Nm 1 1 mdkg 8 0 ftdlb T 1 Nm 0 1 mdkg 0 7 ftdlb T 1 Nm 0 1 mdkg ...

Page 106: ...retor joint 1ea Loosen the screw carburetor joint 4 Carburetor 1ea 5 Fuel hose 1ea 6 Grommet 2 Pull up by slit end Servicing the 7 Induction cap right cylinder 1 right cylinder 8 Induction box 1ea 9 Carburetor joint 1ea 10 Reed valve assembly 1ea 11 Stopper reed valve 2ea 12 Reed valve 2 2ea 13 Reed valve 1 2ea T 2 Nm 0 2 mdkg 1 4 ftdlb T 2 Nm 0 2 mdkg 1 4 ftdlb T 11 Nm 1 1 mdkg 8 0 ftdlb T 11 Nm ...

Page 107: ...Part name Q ty Remarks CARBURETOR DISASSEMBLY 1 Mixing chamber top 1 2 Throttle valve 1 Refer to REMOVAL POINTS 3 Needle holder 1 4 Jet needle 1 5 Starter plunger 1 6 Float chamber 1 7 Power jet 1 8 Float pin 1 9 Float 1 0 Valve seat 1 Main jet 1 Main nozzle 1 Pilot jet 1 Pilot air screw 1 Solenoid valve 1 1 T2 Nm 0 2 mdkg 1 4 ftdlb ...

Page 108: ...tle cable 5 NOTE While compressing the spring throttle valve disconnect the throttle cable ENG EC464000 INSPECTION EC464120 Carburetor 1 Inspect Carburetor body Contamination Clean NOTE 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 Main nozzle 2 Pilot jet 3 Power jet 4 Contamination Clean NOTE Use a petroleum ba...

Page 109: ...body and check for free movement EC464420 Jet needle 1 Inspect Jet needle 1 Bends Wear Replace Clip groove Free play exists Wear Replace ENG EC464801 FUEL LEVEL 1 Measure Fuel level a Out of specification Adjust Fuel level 6 0 7 0 mm 0 24 0 28 in Above the float chamber mating surface c Measurement and adjustment steps Remove the drain plug Connect the fuel level gauge adapter 2 and fuel level gau...

Page 110: ...fuel level If the fuel level is not within specification inspect the valve seat and needle valve If either is worn replace them both If both are fine adjust the fuel level by bending the float tab b on the float Recheck the fuel level EC464701 Reed valve 1 Measure Reed valve bending a Out of specification Replace Reed valve bending limit 0 2 mm 0 008 in a Valve stopper height b Out of specificatio...

Page 111: ... Stopper reed valve 3 Screw reed valve 4 GT1 Nm 0 1 mdkg 0 7 ftdlb NOTE Install the reed valve with the reed valve bending as shown Note the cut a in the lower corner of the reed and stopper plate C CCAUTION Tighten each screw gradually to avoid warping 2 Install Gasket reed valve assembly 1N Reed valve assembly 2 NOTE Install the gasket left cylinder with its projec tion a facing upward and the s...

Page 112: ...79 in 4 T11 Nm 1 1 mdkg 8 0 ftdlb EC4652E0 Carburetor 1 Install Solenoid valve 1 To carburetor 2 Note the following installation points Screw in the pilot air screw until it is lightly seated Back out it by the specified number of turns Ω Pilot air screw 1 1 2 of turns out 3 Install Main nozzle 1 Main jet 2 Pilot jet 3 Valve seat 4 Screw valve seat 5 2 Install Pilot air screw 1 ...

Page 113: ... needle valve to the float install them to the carburetor Check the float for smooth movement 5 Install Power jet 1 To float chamber 2 C CCAUTION Do not tighten the power jet too hard or you may not remove it when checking and replacing it 6 Install Float chamber 1 Screw float chamber 2 C CCAUTION Do not confuse the left and right float chambers in installation because they are different from each...

Page 114: ...p Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 While compressing the spring connect the throttle cable Align the projection b on the ring with the groove c in the needle holder 6 11 Install Mixing chamber top 1 Screw mixing chamber top 2 T2 Nm 0 2 mdkg 1 4 ftdlb Fuel hose 3 To carburetor 4 NOTE Install the fuel hose right cylinder after pass ing it through the hole a of the induction ca...

Page 115: ...Clamp carburetor joint 1 T2 Nm 0 2 mdkg 1 4 ftdlb 3 Connect Solenoid valve lead 1 NOTE Install the solenoid valve lead right cylinder after passing it through the hole a of the induction cap Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 4 Install Induction cap 1 left cylinder only ENG 5 Install Grommet 1 right cylinder only Band 2 right cylinder only ...

Page 116: ...ANK section Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section Radiator hose 3 4 Disconnect at cylinder head side Carburetor left cylinder Servicing the left cylinder Induction guide left cylinder 1 Spark plug 1ea 2 Cable stay 1ea Refer to REMOVAL POINTS 3 YPVS cable 2ea 4 Bolt cylinder head 6ea Loosen each bolt 1 4 turn and remove them after all bolts are loosened 5 Cylinder head 1ea 6 Nut c...

Page 117: ...emarks PISTON REMOVAL 1 Piston pin clip 2ea 2 Piston pin 1ea 3 Piston 1ea Refer to REMOVAL POINTS 4 Small end bearing 1ea 5 Piston ring 1ea 6 Valve cover 1ea 7 Valve shaft 1ea 8 Power valve 1ea 9 Valve pulley 1ea 10 Circlip 2ea 11 Plain washer 2ea 12 Oil seal 2ea 13 Solid bush 2ea T 12 Nm 1 2 mdkg 8 7 ftdlb T 4 Nm 0 4 mdkg 2 9 ftdlb T 9 Nm 0 9 mdkg 6 5 ftdlb T 4 Nm 0 4 mdkg 2 9 ftdlb 1 2 ...

Page 118: ...om falling into the crankcase cav ity 2 Remove Piston pin 1 Piston 2 Small end bearing 3 NOTE Before removing the piston pin deburr the clip groove and pin hole area If the piston pin groove is deburred and piston pin is still difficult to remove use the piston pin puller 4 Piston pin puller YU 01304 90890 01304 A C CCAUTION Do not use a hammer to drive the piston pin out ENG 2 Remove YPVS cable 1...

Page 119: ...Crust of minerals Rust Remove Cylinder head contact surface Wear Damage Replace Recess of insert portion a The contact surface b of the insert portion is recessed below the aluminum portion c Replace EC474210 Cylinder 1 Remove Carbon deposits Use a rounded scraper 1 NOTE Do not use a sharp instrument Avoid scratch ing the aluminum 2 Inspect Cylinder inner surface Score marks Repair or replace Use ...

Page 120: ...over chamfer CYLINDER HEAD CYLINDER AND PISTON 4 22 3 Inspect Travel distance for cylinder 3 000 km 1 800 miles or more Replace EC474313 Piston 1 Inspect Piston crown Damage and crack due to detonation Replace Piston pin hole Crack Replace Contact with cylinder Excessive scuffing score a Use 240 320 grit wet sandpaper in a criss cross manner b Heat discoloration Replace 2 Inspect Travel distance f...

Page 121: ...n the piston 2 There should be no noticeable for the play Free play exists Replace piston pin and or piston 4 Install Small end bearing Piston pin Into the small end of connecting rod 5 Check Free play There should be no noticeable free play Free play exists Inspect the connecting rod for wear Replace the pin and or con necting rod as required ENG EC474402 Piston pin and small end bearing 1 Inspec...

Page 122: ...mm 0 009 0 015 in 0 023 in ENG 3 Measure Side clearance Use a thickness gauge 1 Out of limit Replace piston and or ring Side clearance Standard Limit 0 02 0 06 mm 0 1 mm 0 0008 0 0024 in 0 004 in NOTE Insert the thickness gauge deep in the piston ring groove Then measure the clearance with both sliding surfaces being flush with each other Check at several points EC474720 Combination of piston and ...

Page 123: ...ton that matches the above chart EC474821 Power valve 1 Inspect Power valve 1 Wear Damage Replace Carbon deposits Remove Valve shaft 2 Solid bush 3 Oil seal 4 Wear Damage Replace EC474901 Power valve hole on cylinder 1 Remove Carbon deposits From power valve hole surface a NOTE Do not use a sharp instrument Avoid scratch ing the aluminum EC475000 ASSEMBLY AND INSTALLATION EC475180 Power valve 1 In...

Page 124: ...TE Install the valve shaft so that its pulley faces left of the chassis for the left cylinder and right of the chassis for the right cylinder When installing the valve shaft into the cylin der lightly touch the solid bush 4 with the oil seal 5 and provide an equal gap a for the power valve 6 and valve shaft Clean the contacting surface of the valve cover and cylinder before applying the sealant C ...

Page 125: ...damage the piston ring Install the piston ring with its mark N upward Align the piston ring gap with the pin 2 After installing the piston ring check the smooth movement of it 2 Install Gasket cylinder 1N Small end bearing 2 Dowel pin 3 NOTE Apply the engine oil on the bearing crank shaft and connecting rod and connecting rod big end washers Install the gasket with the seal print side toward the c...

Page 126: ... hand so that it may not be distorted Do not allow the clip open ends to meet the piston pin slot b b EC475351 Cylinder head and cylinder 1 Apply Engine oil To piston 1 piston ring 2 and cylinder inner surface ENG 2 Install Cylinder 1 C CCAUTION Make sure the piston ring is properly posi tioned Install the cylinder with one hand while compressing the piston ring with the other hand NOTE After inst...

Page 127: ... cylin der head Tighten the bolts cylinder head in stage using a crisscross pattern 6 Install YPVS cable 2 4 open side 1 YPVS cable 1 3 close side 2 To cable stay 3 NOTE Install the open side cables sleeve a cables to the 0 marked b side of the cable stay ENG 7 Connect YPVS cable 2 4 open side 1 YPVS cable 1 3 close side 2 To valve pulley 3 NOTE Connect thhe silver cables to the left side cylin de...

Page 128: ...dkg 5 1 ftdlb 9 Adjust YPVS cable Refer to YPVS OPEN SIDE CABLE ADJUSTMENT and YPVS CLOSE SIDE CABLE ADJUSTMENT section in the CHAPTER 3 10 Install Spark plug 1 T19 Nm 1 9 mdkg 13 ftdlb Spark plug cap 2 Radiator hose 3 3 T2 Nm 0 2 mdkg 1 4 ftdlb Radiator hose 4 4 T2 Nm 0 2 mdkg 1 4 ftdlb ENG ...

Page 129: ... removal Extend of removal Order Part name Q ty Remarks CLUTCH PLATE AND FRICTION PLATE REMOVAL Preparation for Lower cowl Refer to COWLING SEAT AND removal FUEL TANK section 1 Screw clutch spring 6 2 Clutch spring 6 3 Pressure plate 1 4 Friction plate 6 5 Clutch plate 5 T 6 Nm 0 6 mdkg 4 3 ftdlb T 9 Nm 0 9 mdkg 6 5 ftdlb 1 ...

Page 130: ...removal Extend of removal Order Part name Q ty Remarks CLUTCH HOUSING AND PUSH ROD REMOVAL 1 Nut clutch boss 1 2 Lock washer 1 Use special tool 3 Clutch boss 1 Refer to REMOVAL POINTS 4 Plain washer 1 5 Clutch housing 1 6 O ring 1 7 Bearing 1 8 Spacer 1 1 9 Ball 1 10 Push rod 1 T 75 Nm 7 5 mdkg 54 ftdlb 2 1 ...

Page 131: ...SA and CDN EC4A4000 INSPECTION EC484100 Clutch housing and boss 1 Inspect Clutch housing 1 Cracks Wear Damage Replace Clutch boss 2 Scoring Wear Damage Replace EC4A4100 Clutch housing 1 Check Circumferential play Free play exists Replace Gear teeth a Wear Damage Replace O ring 1 Damage Replace EC484400 Clutch spring 1 Measure Clutch spring free length a Out of specification Replace springs as a se...

Page 132: ... 9 3 1 mm 2 7 mm 0 114 0 122 in 0 106 in EC484600 Clutch plate 1 Measure Clutch plate warpage Out of specification Replace clutch plate as a set Use a surface plate 1 and thickness gauge 2 Warp limit 0 1 mm 0 004 in a ENG EC4A4301 Push rod 1 Inspect Push rod 1 Ball 2 Wear Damage Bend Replace Bending limit 0 2 mm 0 008 in a NOTE The bending value is shown by one half of the dial gauge reading ...

Page 133: ...OTE Apply the transmission oil on the spacer 1 and bearing 2 Install O ring 1N NOTE Apply the lithium soap base grease on the O ring 3 Install O ring 1N To clutch housing 2 NOTE Apply the lithium soap base grease on the O ring ENG 4 Install Clutch housing 1 5 Install Plain washer 1 Clutch boss 2 ...

Page 134: ...nd CDN B Except for USA and CDN 7 Bend the lock washer 1 tab 8 Install Friction plate yellow 1 Clutch plate 2 Friction plate brown 3 NOTE Install the clutch plates and friction plates alternately on the clutch boss starting with a friction plate and ending with a friction plate Yellow colored friction plates are used for the first and final This machine is equipped with a dry type clutch Be sure t...

Page 135: ...ages using a criss cross pattern ENG 12 Check Push lever position Push the push lever 1 upward until it stops With the push lever in this position the rear edge a of the push lever should be aligned with the center of the push lever installation bolt 2 Not aligned Adjust 13 Adjust Push lever position Push lever position adjustment steps Loosen the locknut 1 Turn the adjuster 2 to align the rear ed...

Page 136: ...al Extend of removal Order Part name Q ty Remarks PRIMARY DRIVEN GEAR REMOVAL Preparation for Cowling Refer to COWLING INDUCTION removal GUIDE SEAT AND FUEL TANK section Clutch Refer to CLUTCH section Drain the transmission oil Refer to TRANSMISSION OIL REPLACEMENT section in the CHAPTER 3 1 Crankcase cover right 1 2 Primary driven gear 1 3 Oil pump drive gear 1 4 Thrust plate 1 T 11 Nm 1 1 mdkg 8...

Page 137: ...removal Order Part name Q ty Remarks PRIMARY DRIVE GEAR AND BALANCER SHAFT REMOVAL 1 Bolt primary drive gear 1 2 Primary drive gear 1 3 Balancer drive gear 1 4 Nut balancer weight gear 1 Refer to REMOVAL POINTS 5 Lock washer 1 6 Balancer weight gear 1 7 Collar 1 8 Crankcase cover left 1 9 Balancer shaft 1 T 11 Nm 1 1 mdkg 8 0 ftdlb T 50 Nm 5 0 mdkg 36 ftdlb T55 Nm 5 5 mdkg 40 ftdlb 1 2 4 39 ...

Page 138: ...f the balancer drive gear 3 and balancer weight gear 4 3 Remove Bolt primary drive gear 1 Primary drive gear 2 Balancer drive gear 3 Nut balancer weight gear 4 Lock washer 5 Balancer weight gear 6 NOTE It may sometimes happens that the primary drive gear and balancer drive gear are fitted too tight as in force fitting In that case use a general gear puller to remove them without too much force on ...

Page 139: ...kcase cover right Cracks Damage Replace Oil seal 1 Wear Damage Replace EC4D4500 Balancer shaft 1 Inspect Balancer shaft 1 Bend Wear Damage Replace EC4D5000 ASSEMBLY AND INSTALLATION EC4D5130 Balancer shaft and primary drive gear 1 Install Balancer shaft 1 Collar 2 2 Install Gasket crankcase cover left N Crankcase cover left 1 Bolt crankcase cover left 2 T11 Nm 1 1 mdkg 8 0 ftdlb NOTE Install the g...

Page 140: ...ear with b crankshaft and c balancer drive gear with d balancer weight gear as shown 5 Install Lock washer 1N Nut balancer weight gear 2 Primary drive gear 3 Plain washer 4 Bolt primary drive gear 5 NOTE Install the plain washer with its chamfered por tion a toward you 6 Tighten Nut balancer weight gear 1 T50 Nm 5 0 mdkg 36 ftdlb NOTE Place an aluminum plate a between the teeth of the balancer dri...

Page 141: ...ight 3 NOTE Apply the lithium soap base grease on the oil seal lip 2 Install Thrust plate 1 Dowel pin 2 Gasket crankcase cover right 3N NOTE Install the thrust plate with its larger diameter side a toward the transmission 3 Install Crankcase cover right 1 NOTE Mesh the primary drive gear 2 with the prima ry driven gear 3 and the oil pump drive gear 4 with the oil pump driven gear 5 by turning the ...

Page 142: ... removal 1 Shift shaft removal 2 Stopper lever removal Extend of removal Order Part name Q ty Remarks SHIFT SHAFT REMOVAL Preparation for Crankcase cover right Refer to PRIMARY DRIVEN GEAR removal PRIMARY DRIVE GEAR AND BALANCER SHAFT section 1 Nut drive sprocket 1 2 Lock washer 1 Refer to REMOVAL POINTS 3 Drive sprocket 1 4 Shift arm 1 5 Transmission housing 1 Refer to REMOVAL POINTS 6 Circlip 1 ...

Page 143: ... Bolt transmission housing Transmission housing 1 NOTE Remove the transmission housing together with the transmission shift cam shift fork and shift shaft EC4C3101 Shift guide and shift lever assembly 1 Remove Bolt shift guide Shift guide 1 Shift lever assembly 2 NOTE The shift lever assembly is disassembled at the same time as the shift guide EC4F3401 Stopper lever 1 Remove Stopper lever assembly...

Page 144: ...assembly 1 Inspect Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear Damage Replace EC4B4500 Stopper lever 1 Inspect Stopper lever 1 Wear Damage Replace Torsion spring 2 Broken Replace EC4F5000 ASSEMBLY AND INSTALLATION EC4F5100 Stopper lever 1 Install Stopper lever 1 Plain washer 2 Circlip 3N To collar 4 NOTE Be sure the circlip sharp edged corner a is positioned opposite side to the pl...

Page 145: ...pawl into the shift lever make sure the chamfered side a face the pawl pin side Apply the transmission oil on the pawl pin 2 Install Shift lever assembly 1 To shift guide 2 3 Install Shift lever assembly 1 Shift guide 2 NOTE The shift lever assembly is installed at the same time as the shift guide Apply the transmission oil on the bolt seg ment shaft 4 Install Bolt shift guide 1 T11 Nm 1 1 mdkg 8 ...

Page 146: ...e circlip sharp edged corner a is positioned opposite side to the plain washer 3 Check Shift lever position Checking steps Attach the collar with supplying parts 2 onto the roller 1 Check the shift lever position Gaps a and b are not equal Adjust 4 Adjust Shift lever position ENG Adjusting steps Loosen the locknut 3 Turn the adjuster 4 in or out Tighten the locknut Locknut 9 Nm 0 9 m kg 6 5 ft lb ...

Page 147: ...housing L 40 mm 1 57 in 1 T16 Nm 1 6 mdkg 11 ftdlb Bolt transmission housing L 30 mm 1 18 in 2 T16 Nm 1 6 mdkg 11 ftdlb NOTE Tighten the bolts in stages using a crisscross pattern Apply the transmission oil on the thread and contact surface of the bolt transmission housing 4 Install Plain washer 1 Spacer 2 Shift arm 3 Bolt shift arm 4 T14 Nm 1 4 mdkg 10 ftdlb NOTE Make sure that the joint rod dist...

Page 148: ...all the drive sprocket with its depressed side a facing the engine Install the drive sprocket together with the drive chain 2 Install Lock washer 1N Nut drive sprocket 2 T75 Nm 7 5 mdkg 54 ftdlb NOTE Tighten the nut while applying the rear brake 3 Bend the lock washer tab to lock the nut ENG ...

Page 149: ...fer to COWLING INDUCTION removal GUIDE SEAT AND FUEL TANK section Drain the cooling water Refer to COOLING WATER REPLACEMENT section in the CHAPTER 3 Transmission housing Refer to SHIFT SHAFT section 1 Radiator hose 2 1 2 Water pump housing cover 1 3 Circlip 1 4 Plain washer 1 5 Impeller shaft 1 6 Bearing 1 7 Oil seal 2 Refer to REMOVAL POINTS T2 Nm 0 2 mdkg 1 4 ftdlb T11 Nm 1 1 mdkg 8 0 ftdlb 1 2...

Page 150: ...uch as excessive change in coolant level discol oration of coolant or milky transmission oil 1 Remove Bearing 1 2 Remove Oil seal 1 EC4G4000 INSPECTION EC444200 Impeller shaft 1 Inspect Impeller shaft 1 Bend Wear Damage Replace Fur deposits Clean EC4H4600 Bearing 1 Inspect Bearing 1 Rotate inner race with a finger Rough spot Seizure Replace ENG ...

Page 151: ...NOTE Install the bearing by pressing its outer race parallel EC4G5202 Impeller shaft 1 Install Impeller shaft 1 NOTE 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 oil seal lip and impeller shaft And install the shaft while turning it 2 Install Plain washer 1 Circlip 2N To...

Page 152: ... 54 3 Install Dowel pin 1 Gasket water pump housing cover 2 N 4 Install Water pump housing cover 1 Bolt water pump housing cover 2 T11 Nm 1 1 mdkg 8 0 ftdlb 5 Install Radiator hose 2 1 T2 Nm 0 2 mdkg 1 4 ftdlb ENG ...

Page 153: ...HIFT CAM AND SHIFT FORK REMOVAL Preparation for Cowling Refer to COWLING INDUCTION removal GUIDE SEAT AND FUEL TANK section Transmission housing Shift shaft and shift lever Refer to SHIFT SHAFT section assembly Stopper lever T 7 Nm 0 7 mdkg 5 1 ftdlb T 23 Nm 2 3 mdkg 17 ftdlb T 10 Nm 1 0 mdkg 7 2 ftdlb T 10 Nm 1 0 mdkg 7 2 ftdlb T 4 Nm 0 4 mdkg 2 9 ftdlb ...

Page 154: ...ve axle 1 Refer to REMOVAL POINTS 9 Bolt segment 1 10 Segment 1 Refer to REMOVAL POINTS 11 Shift cam 1 TRANSMISSION SHIFT CAM AND SHIFT FORK 4 56 ENG Extend of removal 1 Shift fork removal 2 Main axle and drive axle removal 3 Shift cam removal 1 T 7 Nm 0 7 mdkg 5 1 ftdlb T 23 Nm 2 3 mdkg 17 ftdlb T 10 Nm 1 0 mdkg 7 2 ftdlb T 10 Nm 1 0 mdkg 7 2 ftdlb T 4 Nm 0 4 mdkg 2 9 ftdlb 2 ...

Page 155: ...y carefully Note the position of each part Pay particular attention to the location and direction of shift forks EC4H3400 Segment 1 Remove Bolt segment 1 Segment 2 NOTE Clamp the shift cam 3 securely in a vise using soft protecting material 4 to loosen the bolt segment EC4H4000 INSPECTION EC4H4210 Gears 1 Inspect Matching dog a Gear teeth b Wear Damage Replace ENG 2 Check Gears movement Unsmooth m...

Page 156: ...ns smoothly with out a thrust If the thrust clearance is too large or the idle gear moves with difficulty Replace the shim 1 2 and 3 Choose the shims by the following chart Part name Size thickness Part number Shim 1 1 STD t 1 0 mm 90201 253K0 0 039 in t 0 9 mm 90201 256E6 0 035 in Shim 2 2 STD t 1 0 mm 90201 20276 0 039 in t 0 9 mm 90201 206E5 0 035 in Shim 3 3 STD t 0 7 mm 5F7 17136 00 0 028 in ...

Page 157: ...3rd 4th pinion gear 1 into light contact with the 6th pinion gear 2 to the extent that they are not engaged and mea sure the clearance a between 3rd 4th pin ion gear and 6th pinion gear Bring the 3rd 4th pinion gear into light con tact with the 5th pinion gear 3 to the extent that they are not engaged and measure the clearance b between 3rd 4th pinion gear and 5th pinion gear Dog clearance a a b b...

Page 158: ...nd Wear Damage Replace 3 Check Shift fork movement On its guide bar Unsmooth operation Replace shift fork and or guide bar NOTE For a malfunctioning shift fork replace not only the shift fork itself but the two gears each adja cent to the shift fork EC4H5000 ASSEMBLY AND INSTALLATION EC4H5112 Shift cam 1 Install Shift cam 1 NOTE Apply the transmission oil on the shift cam bearing ENG ...

Page 159: ...4 to tighten the bolt segment EC4H5232 Transmission 1 Install 6th pinion gear 22T 1 3rd 4th pinion gear 23T 25T 2 5th pinion gear 27T 3 2nd pinion gear 21T 4 To main axle 5 NOTE Apply the molybdenum disulfide oil on the gears inner circumference 2 Install 2nd wheel gear 31T 1 5th wheel gear 26T 2 3rd wheel gear 29T 3 4th wheel gear 27T 4 6th wheel gear 20T 5 1st wheel gear 34T 6 To drive axle 7 NO...

Page 160: ... AND SHIFT FORK 4 62 3 Install Plain washer 1 Circlip 2N NOTE Be sure the circlip sharp edged corner a is positioned opposite to the plain washer and gear b Be sure the circlip end c is positioned at axle spline groove d ENG ...

Page 161: ... fork 1 with the 5th wheel gear 4 and 3 with the 6th gear 6 on the drive axle Mesh the shift fork 2 with the 3rd 4th pinion gear 5 on the main axle 6 Install Guide bar 1 short 1 Guide bar 2 long 2 NOTE Apply the transmission oil on the guide bars Be sure the short bar is inserted into the shift fork 2 and the long one into 1 and 3 7 Check Shift operation Transmission operation Unsmooth operation R...

Page 162: ...efer to SHIFT SHAFT section removal Shift shaft and Stopper lever Transmission and shift fork Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section 1 Strainer 1 2 Oil pump cover 1 3 Outer rotor 1 4 Inner rotor 1 5 Dowel pin 1 6 Plain washer 1 D ø15 mm 0 59 in 7 Plain washer 1 D ø22 mm 0 87 in 8 Oil pump gear shaft 1 9 Oil delivery pipe 1 T7 Nm 0 7 mdkg 5 1 ftdlb T8 Nm 0 8 mdkg 5 8 ftdlb 1 ...

Page 163: ...1 Use compressed air NOTE Clean the strainer every 500 km 300 miles If a lot of metallic dust in noticed disassemble the engine and check EC4J4200 Oil pump gear shaft 1 Inspect Oil pump gear shaft 1 Wear Damage Replace EC4H4100 Oil delivery pipe 1 Inspect Oil delivery pipe 1 O ring 2 Damage Replace Oil orifice a Clogged Blow EC4J5000 ASSEMBLY AND INSTALLATION EC4J5102 Oil pump 1 Install O ring 1N ...

Page 164: ... gear shaft 2 To transmission housing 3 4 Install Plain washer D ø15 mm 0 87 in 1 Dowel pin 2 Inner rotor 3 Outer rotor 4 To oil pump gear shaft 5 NOTE Apply the transmission oil on the inner rotor and outer rotor Make sure the dowel pin fits into the groove a in the inner rotor When installing the outer rotor make sure the punch mark b on the outer rotor face the transmission housing side 5 Insta...

Page 165: ...asher 2 Bolt oil pump cover 3 T8 Nm 0 8 mdkg 5 8 ftdlb NOTE While turning the oil pump gear shaft install the oil pump cover 7 Install Strainer 1 Screw strainer 2 T7 Nm 0 7 mdkg 5 1 ftdlb NOTE Strainer is installed with the mesh a facing outward ENG ...

Page 166: ...Remarks CDI MAGNETO REMOVAL Preparation for Cowling and fuel tank Refer to COWLING INDUCTION removal GUIDE SEAT AND FUEL TANK section Disconnect the CDI magneto lead 1 Nut rotor 1 Use special tool 2 Rotor 1 Refer to REMOVAL POINTS 3 Stator 1 4 Woodruff key 1 T 53 Nm 5 3 mdkg 38 ftdlb T 7 Nm 0 7 mdkg 5 1 ftdlb 1 4 68 ...

Page 167: ...ing the flywheel puller turn it coun terclockwise EC4L4000 INSPECTION EC4L4101 CDI magneto 1 Inspect Rotor inner surface a Stator outer surface b Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace CDI magneto and or stator EC4L4200 Woodruff key 1 Inspect Woodruff key 1 Damage Replace EC4L5000 ASSEMBLY AND INSTALLATION EC4L5190 CDI magneto 1 Install Stator 1 Screw stat...

Page 168: ...ne b When installing the rotor align the keyway c of the rotor with the woodruff key 3 Install Plain washer 1 Nut rotor 2 T53 Nm 5 3 mdkg 38 ftdlb Use the rotor holding tool 3 Rotor holding tool YU 01235 90890 01235 A 4 Adjust Ignition timing Ignition timing 2 4 mm 0 094 in a Refer to IGNITION TIMING CHECK sec tion in the CHAPTER 3 5 Connect CDI magneto lead 1 Refer to CABLE ROUTING DIAGRAM sectio...

Page 169: ...pe Refer to EXHAUST PIPE AND SILENCER section Clutch cable Disconnect at engine side Radiator hose 2 Disconnect at water pump side Radiator hose 3 4 Disconnect at cylinder head side Drive sprocket Refer to SHIFT SHAFT section Shift arm Spark plug cap YPVS cable Disconnect the CDI magneto lead T 30 Nm 3 0 mdkg 22 ftdlb T 23 Nm 2 3 mdkg 17 ftdlb T 23 Nm 2 3 mdkg 17 ftdlb T 30 Nm 3 0 mdkg 22 ftdlb T ...

Page 170: ...r 2 Only loosening 2 Nut engine mounting bolt 4 3 Engine mounting adjust bolt 2 4 Engine mounting bolt 4 Refer to REMOVAL POINTS 5 Engine 1 6 Engine bracket 2 T 30 Nm 3 0 mdkg 22 ftdlb T 23 Nm 2 3 mdkg 17 ftdlb T 23 Nm 2 3 mdkg 17 ftdlb T 30 Nm 3 0 mdkg 22 ftdlb T 8 Nm 0 8 mdkg 5 8 ftdlb T11 Nm 1 1 mdkg 8 0 ftdlb T11 Nm 1 1 mdkg 8 0 ftdlb 1 ...

Page 171: ...ust bolt wrench 2 to loosen the engine mounting adjust bolt 2 Remove Engine mounting bolt 1 Engine 2 NOTE Before removing the engine make sure that the couplers hoses and cables are discon nected Remove the engine by lowering it with a jack 3 EC4M5000 ASSEMBLY AND INSTALLATION EC4M5190 Engine installation 1 Install Engine bracket 1 Bolt engine bracket 2 NOTE Install the engine brackets with their ...

Page 172: ...ting bolt lower 2 4 Tighten Engine mounting adjust bolt 1 T8 Nm 0 8 mdkg 5 8 ftdlb NOTE Use the adjust bolt wrench 2 to tighten the engine mounting adjust bolts Tighten the adjust bolts to specified torque alternately two times 5 Install Nut engine mounting bolt upper 1 T30 Nm 3 0 mdkg 22 ftdlb Nut engine mounting bolt lower 2 T30 Nm 3 0 mdkg 22 ftdlb ENG ...

Page 173: ...t 4 T23 Nm 2 3 mdkg 17 ftdlb 8 Tighten Pinch bolt engine mounting collar left 5 T11 Nm 1 1 mdkg 8 0 ftdlb 9 Install Engine mounting collar right 1 Engine mounting bolt right 2 Engine mounting nut right 3 T30 Nm 3 0 mdkg 22 ftdlb 10 Tighten Bolt engine bracket right 4 T23 Nm 2 3 mdkg 17 ftdlb 11 Tighten Pinch bolt engine mounting collar right 5 T11 Nm 1 1 mdkg 8 0 ftdlb ENG ...

Page 174: ...alve Refer to CARBURETOR AND REED VALVE section Piston Refer to CYLINDER HEAD CYLIN DER AND PISTON section Primary drive gear Refer to PRIMARY DRIVEN GEAR PRIMARY DRIVE GEAR AND BALANCER SHAFT section Rotor and stator Refer to CDI MAGNETO section Engine bracket T 50 Nm 5 0 mdkg 36 ftdlb T 26 Nm 2 6 mdkg 19 ftdlb T 11 Nm 1 1 mdkg 8 0 ftdlb T 11 Nm 1 1 mdkg 8 0 ftdlb T 7 Nm 0 7 mdkg 5 1 ftdlb T 8 Nm...

Page 175: ...t crankcase M6 3 L 35 mm 1 38 in 3 Bolt crankcase M8 6 Refer to REMOVAL POINTS L 45 mm 1 77 in 4 Crankcase upper 1 5 Crankcase lower 1 6 Crankshaft 1 7 Oil seal crankshaft 2 8 Bearing crankshaft 2 Refer to REMOVAL POINTS 9 Bolt seat plate 1 10 Seat plate 1 11 Push lever axle 1 4 T 50 Nm 5 0 mdkg 36 ftdlb T 26 Nm 2 6 mdkg 19 ftdlb T 11 Nm 1 1 mdkg 8 0 ftdlb T 11 Nm 1 1 mdkg 8 0 ftdlb T 7 Nm 0 7 mdk...

Page 176: ...nly on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully If the cases do not separate check for a remaining case screw or fitting Do not force EC4N3410 Crankshaft bearing 1 Remove Bearing 1 NOTE Remove the bearing from the crankshaft using a general bearing puller 2 Do not use the removed bearing EC4N4000 INSPECTION EC4N4112 Crankcase 1 Inspect Contacting su...

Page 177: ... Crank width crank pin side d Out of specification Replace Use the dial gauge and a thickness gauge Dial gauge YU 03097 90890 01252 A Standard Limit Runout 0 03 mm 0 05 mm limit 0 0012 in 0 0020 in Small end 0 8 1 0 mm 2 0 mm free play 0 031 0 039 in 0 08 in Side 0 45 0 95 mm clearance 0 018 0 037 in Crank 49 975 50 025 mm width 1 968 1 969 in s EC4A4200 Push lever axle 1 Inspect Push lever axle 1...

Page 178: ...m soap base grease on the oil seal lip 2 Install Circlip 1 To crankcase lower 2 3 Install Crankshaft 1 To crankcase lower 2 NOTE When installing the crankshaft into the crankcase lower apply the transmission oil on the oil seal 3 outer circumference Align the bearing knock pin with the pin slot a in the crankcase lower and the projection of oil seal with the groove b in the crankcase lower After i...

Page 179: ...0 85505 YAMAHA Bond No 4 90890 05143 F NOTE Clean the contacting surface of crankcase upper and lower before applying the sealant C CCAUTION If the engine is started soon after reinstalla tion use this quick drying Quick gasket ACC 11001 30 00 or YAMAHA Bond No 4 6 Install Crankcase upper 1 To crankcase lower NOTE After installation tap the crankcase upper with a soft hammar to settle it ENG ...

Page 180: ... 8 Remove Sealant Forced out on the crankcase mating sur face 9 Apply Engine oil To the crank pin bearing and oil delivery hole 10 Check Crankshaft operation Unsmooth operation Repair EC4A5101 Push lever axle 1 Install Seat plate 1 Torsion spring 2 Push lever axle 3 NOTE Apply the lithium soap base grease on the push lever axle oil seal lip and bearing 2 Install Bolt seat plate 1 T7 Nm 0 7 mdkg 5 ...

Page 181: ...cing removal the suitable stand 1 Bolt axle holder 4 Only loosening 2 Nut front wheel axle 1 3 Front wheel axle 1 4 Caliper 2 5 Front wheel 1 6 Collar 2 Refer to REMOVAL POINTS 7 Bearing 2 Refer to REMOVAL POINTS 8 Brake disk 2 CHAS T 20 Nm 2 0 mdkg 14 ftdlb T 20 Nm 2 0 mdkg 14 ftdlb T 11 Nm 1 1 mdkg 8 0 ftdlb T 35 Nm 3 5 mdkg 25 ftdlb T 35 Nm 3 5 mdkg 25 ftdlb T 11 Nm 1 1 mdkg 8 0 ftdlb T 80 Nm 8...

Page 182: ...l axle 1 2 Rear wheel axle 1 3 Rear wheel 1 Refer to REMOVAL POINTS 4 Collar 1 5 Driven sprocket 1 6 Sprocket damper 5 7 Clutch hub 1 8 Collar 2 Refer to REMOVAL POINTS 9 Bearing 2 Refer to REMOVAL POINTS 10 Brake disc 1 CHAS T 23 Nm 2 3 mdkg 17 ftdlb T 16 Nm 1 6 mdkg 11 ftdlb T 32 Nm 3 2 mdkg 23 ftdlb T 80 Nm 8 0 mdkg 58 ftdlb T 2 Nm 0 2 mdkg 1 4 ftdlb T 2 Nm 0 2 mdkg 1 4 ftdlb T 16 Nm 1 6 mdkg 1...

Page 183: ... out of the wheel gradually not to deform it EC513201 Wheel bearing if necessary 1 Remove Bearing 1 NOTE Remove the bearing using a general bearing puller 2 EC594000 INSPECTION EC514110 Wheel 1 Measure Wheel runout Out of limit Replace Wheel runout limit Radial 1 0 mm 0 04 in Lateral 0 5 mm 0 02 in b 2 Inspect Bearing Rotate inner race with a finger Rough spot Seizure Replace NOTE Replace the bear...

Page 184: ...594100 Brake disc 1 Measure Brake disc deflection only rear brake disc Use the dial gauge 1 Out of specification Inspect wheel runout If wheel runout is in good condition replace the brake disc Disc deflection limit Standard Limit Rear 0 15 mm 0 006 in 2 Measure Brake disc thickness Use the micrometer 1 Out of limit Replace Disc wear limit Standard Limit Front 5 0 mm 0 20 in 4 5 mm 0 18 in Rear 4 ...

Page 185: ...when installing Use a socket that matches the outside diam eter of the race of the bearing Right side of bearing shall be installed first C CCAUTION 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 GT20 Nm 2 0 mdkg 14 ftdlb NOTE Tighten the bolts in stage using a crisscross pattern 3 Install Collar 1 NOTE If the co...

Page 186: ...le install the caliper 5 Install Wheel axle 1 NOTE Apply the lithium soap base grease on the wheel axle Insert the wheel axle from right side 6 Install Plain washer 1 Nut wheel axle 2 T80 Nm 8 0 mdkg 58 ftdlb NOTE Apply the lithium soap base grease on the wheel axle thread 7 Tighten Bolt axle holder 1 T11 Nm 1 1 mdkg 8 0 ftdlb CHAS ...

Page 187: ... of bearing shall be installed first C CCAUTION 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 GT23 Nm 2 3 mdkg 17 ftdlb NOTE Tighten the bolts in stage using a crisscross pattern 3 Install Collar 1 NOTE If the collar is hard to install apply the lithium soap base grease on the collar and press it in 4 Install Cl...

Page 188: ... Install Driven sprocket 1 Collar 2 To wheel NOTE Apply the lithium soap base grease on the sprocket damper 6 Install Wheel NOTE Install the brake disc 1 between the brake pads 2 correctly CHAS 7 Install Drive chain 1 NOTE Push the wheel 2 forward and install the drive chain 8 Install Wheel axle 1 NOTE Apply the lithium soap base grease on the wheel axle Insert the wheel axle from left side ...

Page 189: ... 3 11 Tighten Nut wheel axle 1 T80 Nm 8 0 mdkg 58 ftdlb Adjuster 2 T2 Nm 0 2 mdkg 1 4 ftdlb Locknut 3 T16 Nm 1 6 mdkg 11 ftdlb NOTE Tighten the axle nut while pushing down the drive chain After tightening the axle nut tighten the lock nut with the turned out the adjuster 12 Adjust Wheel alignment Refer to WHEEL ALIGNMENT ADJUST MENT section in the CHAPTER 3 CHAS ...

Page 190: ...Master cylinder bracket 1 10 Master cylinder 1 FRONT BRAKE AND REAR BRAKE EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE Extend of removal 1 Brake hose removal 2 Caliper removal 3 Master cylinder removal CHAS T 35 Nm 3 5 mdkg 25 ftdlb T 35 Nm 3 5 mdkg 25 ftdlb T 18 Nm 1 8 mdkg 13 ftdlb T 6 Nm 0 6 mdkg 4 3 ftdlb T 26 Nm 2 6 mdkg 19 ftdlb T 14 Nm 1 4 mdkg 10 ftdlb T 26 Nm 2 6 mdkg 19 ftdlb...

Page 191: ... Union bolt 1 4 Brake hose 1 5 Pad pin 1 Loosen when disassembling the caliper 6 Caliper 1 7 Brake pedal connecting bolt 1 8 Reservoir tank 1 9 Reservoir hose 1 10 Master cylinder 1 W Support the machine securely so there is no danger of it falling over CHAS T 6 Nm 0 6 mdkg 4 3 ftdlb T 18 Nm 1 8 mdkg 13 ftdlb T 12 Nm 1 2 mdkg 8 7 ftdlb T 20 Nm 2 0 mdkg 14 ftdlb T 26 Nm 2 6 mdkg 19 ftdlb T 14 Nm 1 ...

Page 192: ... removal Order Part name Q ty Remarks CALIPER DISASSEMBLY A B 1 Cotter pin 1ea 1 2 Pad pin 1ea 1 3 Pad support 1ea 1 4 Brake pad 2ea 2 5 Caliper piston 4ea 2 Refer to REMOVAL POINTS 6 Dust seal 4ea 2 Refer to REMOVAL POINTS 7 Piston seal 4ea 2 CHAS T 6 Nm 0 6 mdkg 4 3 ftdlb T 18 Nm 1 8 mdkg 13 ftdlb T 6 Nm 0 6 mdkg 4 3 ftdlb T 18 Nm 1 8 mdkg 13 ftdlb 1 2 A B ...

Page 193: ...ont B Rear Extend of removal 1 Front master cylinder disassembly 2 Rear master cylinder disassembly Extend of removal Order Part name Q ty Remarks MASTER CYLINDER DISASSEMBLY 1 Master cylinder boot 1 2 Circlip 1 3 Master cylinder kit 1 CHAS T 2 Nm 0 2 mdkg 1 4 ftdlb 1 2 A B ...

Page 194: ...k cap 1 NOTE Do not remove the diaphragm A Front B Rear 2 Connect the transparent hose 2 to the bleed screw 1 and place a suitable con tainer under its end A Front B Rear 3 Loosen the bleed screw and drain the brake fluid while pulling the lever in or pushing down on the pedal C CCAUTION Do not reuse the drained brake fluid Brake fluid may erode painted surfaces or plastic parts Always clean up sp...

Page 195: ... piece of rag into the caliper to lock one caliper Carefully force the piston out of the caliper cylinder with compressed air A Front B Rear EC543411 Piston seal kit 1 Remove Dust seal 1 Piston seal 2 NOTE Remove the piston seals and dust seals by pushing them with a finger C CCAUTION Never attempt to pry out piston seals and dust seals Do not loosen the bolts 3 3 and nuts 4 4 W Replace the piston...

Page 196: ...embly Stains Clean W Use only new brake fluid A Front B Rear 2 Inspect Diaphragm 1 Crack Damage Replace A Front B Rear 3 Inspect Master cylinder piston 1 Master cylinder cup 2 Wear Damage Score marks Replace master cylinder kit A Front B Rear EC534214 Caliper 1 Inspect Caliper cylinder inner surface a Wear Score marks Replace caliper assembly A Front B Rear CHAS ...

Page 197: ... W All internal parts should be cleaned in new brake fluid only Internal parts should be lubricated with brake fluid when installed Replace the piston seals and dust seals whenever a caliper is disassembled EC535113 Caliper piston 1 Clean Caliper Piston seal Dust seal Caliper piston Clean them with brake fluid 2 Install Piston seal 1N Dust seal 2N W Always use new piston seals and dust seals NOTE ...

Page 198: ... to insert A Front B Rear EC535241 Front caliper 1 Install Brake pad 1 Pad support 2 Pad pin 3 Cotter pin 4N NOTE Temporarily tighten the pad pin at this point 2 Install Caliper 1 Bolt caliper 2 T35 Nm 3 5 mdkg 25 ftdlb 3 Tighten Pad pin 3 T18 Nm 1 8 mdkg 13 ftdlb CHAS EC545141 Rear caliper 1 Install Brake pad 1 Pad support 2 Pad pin 3 Cotter pin 4N NOTE Temporarily tighten the pad pin at this poi...

Page 199: ... Clean Master cylinder Master cylinder kit Clean them with brake fluid 2 Install Master cylinder cup primary 1 Master cylinder cup secondary 2 To master cylinder piston 3 NOTE Apply the brake fluid on the master cylinder cup W After installing cylinder cup should be installed as shown direction Wrong instal lation cause improper brake performance A Front B Rear CHAS ...

Page 200: ...led as shown direction Wrong instal lation cause improper brake performance A Front B Rear 4 Install Master cylinder kit 1 Circlip 2 Master cylinder boot 3 To master cylinder 4 NOTE Apply the brake fluid on the master cylinder kit When installing the circlip use a long nose circlip pliers A Front B Rear EC535441 Front master cylinder 1 Install Reservoir tank 1 Bolt reservoir tank 2 T5 Nm 0 5 mdkg ...

Page 201: ...ervoir hose 1 Reservoir tank 2 Nut reservoir tank 3 GT7 Nm 0 7 mdkg 5 1 ftdlb 2 Install Master cylinder 1 Bolt master cylinder 2 T20 Nm 2 0 mdkg 14 ftdlb CHAS 3 Install Brake lever 1 Bolt brake lever 2 T1 Nm 0 1 mdkg 0 7 ftdlb Nut brake lever 3 T6 Nm 0 6 mdkg 4 3 ftdlb NOTE Apply the lithium soap base grease on the bolt When installing the brake lever apply the molybdenum disulfide grease on the c...

Page 202: ...asher 1N Brake hose 2 Union bolt 3 T30 Nm 3 0 mdkg 22 ftdlb W Always use new copper washers C CCAUTION Install both brake hoses so that they form an angle a a of 60 to the brake lever 4 4 2 Install Copper washer 1N Adapter 2 T26 Nm 2 6 mdkg 19 ftdlb Brake hose 3 T14 Nm 1 4 mdkg 10 ftdlb W Always use a new copper washer NOTE When turning the adapter over the brake hose hold the brake hose so that i...

Page 203: ...e pipe a a with the projection b b on the master cylin der 2 Install Copper washer 1N Adapter 2 T26 Nm 2 6 mdkg 19 ftdlb Brake hose 3 T14 Nm 1 4 mdkg 10 ftdlb W Always use a new copper washer NOTE When turning the adapter over the brake hose hold the brake hose so that it may not be twist ed 3 Install Brake hose holder 1 Bolt brake hose holder 2 T 8Nm 0 8 mdkg 5 8 ftdlb CHAS 4 Install Brake hose 1...

Page 204: ... a harmful chemical reaction and lead to poor perfor mance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock C CCAUTION Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately A Front B Rear 2 Air bleed Brake system Refer to BRAKE SYSTEM AIR BLE...

Page 205: ...servoir tank cap 1 C CCAUTION After installation while pulling the lever in or pushing down on the pedal check whether there is any brake fluid leaking where the union bolts are installed respec tively at the master cylinder and caliper A Front B Rear CHAS ...

Page 206: ...D REAR BRAKE section Front wheel Refer to FRONT WHEEL AND REAR WHEEL section 1 Front fender 1 2 Pinch bolt steering damper stay 1 Only loosening right side only 3 Pinch bolt handlebar 2 Only loosening 4 Pinch bolt handle crown 1 Only loosening 5 Cap bolt 1 Loosen when disassembling the front fork 6 Pinch bolt under bracket 2 Only loosening 7 Front fork 1 W Support the machine securely so there is ...

Page 207: ...MBLY 1 Cap bolt 1 Use special tool Refer to REMOVAL POINTS 2 Spacer 1 3 Spacer guide 1 4 Fork spring 1 Drain the fork oil 5 Inner tube 1 6 Stopper ring 1 Refer to REMOVAL POINTS 7 Oil seal 1 8 Oil seal washer 1 9 Bolt damper rod 1 Use special tool 0 Damper rod 1 Refer to REMOVAL POINTS CHAS T 40 Nm 4 0 mdkg 29 ftdlb T 23 Nm 2 3 mdkg 17 ftdlb T 29 Nm 2 9 mdkg 21 ftdlb 1 2 ...

Page 208: ... rod has a very sophisticated internal construction and is particularly sensitive to foreign material Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disas sembled and reassembled Before removing the cap bolts or front forks be sure to extract the air from the air chamber completely EC553000 REMOVAL POINTS EC553143 Cap bolt 1 Remove C...

Page 209: ...spring preload adjuster 6 Fork spring compressor YM 01441 90890 01441 Rod holder YM 01434 90890 01434 C EC553212 Oil seal 1 Remove Inner tube 1 Pull out the inner tube from the outer tube 2 2 Remove Stopper ring 1 Using slotted head screwdriver 3 Remove Oil seal 1 Oil seal washer Using slotted head screwdriver C CCAUTION Take care not to scratch the outer tube inner surface Replace the oil seal wh...

Page 210: ...lace damper rod C CCAUTION The front fork with a built in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material Use enough care not to allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled EC554400 Fork spring 1 Measure Fork spring free length a Out of specification Replace Fork sp...

Page 211: ... dial gauge 1 Inner tube bending limit 0 2 mm 0 008 in a NOTE The bending value is shown by one half of the dial gauge reading W Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube EC554611 Outer tube 1 Inspect Outer tube 1 Piston metal 2 Slide metal 3 Damage Score marks Wear Replace outer tube assembly EC554710 Cap bolt 1 Inspect Cap bolt 1 O ring 2 Wear Damage ...

Page 212: ...er tube aslant If the inner tube is held vertically the damper rod may fall into it damaging the valve inside 3 Install Copper washer 1N Bolt damper rod 2 To inner tube 3 4 Tighten Bolt damper rod 1 GT40 Nm 4 0 mdkg 29 ftdlb NOTE Use a damper rod holder 3 to lock the damper rod 2 Damper rod holder YM 01425 90890 01425 A 5 Install Locknut 1 To damper rod 2 NOTE Install the locknut with its width ac...

Page 213: ...l with its manufacture s marks or number facing the axle holder side 7 Install Inner tube 1 To outer tube 2 C CCAUTION When installing the inner tube slowly and take care to insert it carefully so that the slide metal 3 3 and piston metal 4 4 will not be scratched 8 Install Oil seal washer 1 To outer tube slot 9 Install Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver 2...

Page 214: ...ecommended oil Suspension oil 01 0 C CCAUTION Be sure to use recommended fork oil If other oils are used they may have an excessively adverse effect on the front fork performance Never allow foreign materials to enter the front fork CHAS 14 After filling pump the damper rod 1 slowly up and down more than 10 times to distrib ute the fork oil NOTE Use the rod puller 2 and rod puller attachment 3 to ...

Page 215: ...el NOTE Fill with the fork oil up to the top end of the outer tube or the fork oil will not spread over to every part of the front forks thus making it impossible to obtain the correct level Be sure to fill with the fork oil up to the top of the outer tube and bleed the front forks 18 Measure Oil level left and right a Out of specification Adjust Standard oil level 135 mm 5 31 in Extent of adjustm...

Page 216: ... holder between the locknut 6 and spacer Rod puller 1 1 YM 01437 90890 01437 Rod puller attachment 2 2 90890 01435 Fork spring compressor 3 3 YM 01441 90890 01441 Rod holder 4 4 YM 01434 90890 01434 g 21 Adjust Distance a Out of specification Turn the locknut 2 until the specified distance is obtained Distance a a 13 mm 0 51 in Between damper rod 1 1 top and locknut 2 2 top c 22 Adjust Rebound dam...

Page 217: ...ter 4 with your hand until the rebound damping adjuster 3 hits the push rod tip 24 Check Cap bolt clearance a Out of specification Repeat the steps 21 to 23 Cap bolt clearance a a Zero 2 mm Zero 0 08 in a C CCAUTION If the cap bolt is installed out of specifica tion proper damping force cannot be obtained 25 Install Cap bolt locknut 1 T29 Nm 2 9 mdkg 21 ftdlb NOTE Hold the locknut 2 and tighten th...

Page 218: ...ch bolt under bracket Do not tighten the pinch bolts handle crown steering damper stay and handlebar yet 2 Tighten Cap bolt 1 T23 Nm 2 3 mdkg 17 ftdlb 3 Adjust Front fork top end a Handlebar position b Steering damper stay position c left side only Front fork top end 13 mm 0 51 in Handlebar position 9 mm 0 35 in Steering damper stay position 73 mm 2 87 in e Refer to FRONT FORK TOP END ADJUSTMENT i...

Page 219: ...r to FRONT FORK TOP END ADJUSTMENT in the CHAPTER 3 5 Check Steering smooth action Turn the handlebar to make sure no parts are being contacted with others Contact Repair 6 Adjust Rebound damping force Spring preload NOTE Turn in the rebound damping adjuster 1 fully then turn out it to the originally set position Turn in the spring preload adjuster 2 to the originally set position 7 Install Front ...

Page 220: ...own Refer to STEERING section 1 Clutch cable 1 Disconnect at the lever side 2 Clutch lever holder 1 3 Main switch 1 4 Grip left 1 Refer to REMOVAL POINTS 5 Starter cable 2 Disconnect at the lever side 6 Starter lever 1 7 Master cylinder 1 8 Grip cap upper 1 9 Throttle cable 2 10 Throttle 1 11 Grip cap lower 1 12 Grip end 2 13 Handlebar 2 14 Grip right 1 Refer to REMOVAL POINTS 15 Tube guide 1 CHAS...

Page 221: ...amage Replace W Do not attempt to straighten a bent handle bar as this may dangerously weaken the handlebar EC5B5000 ASSEMBLY AND INSTALLATION EC5B5110 Throttle assembly 1 Install Ring plate 1 Grip right 2 Apply the adhesive on the tube guide 3 NOTE Before applying the adhesive wipe off grease or oil on the tube guide surface a with a lac quer thinner EC5B5230 Handlebar 1 Install Handlebar 1 Grip ...

Page 222: ...nder 1 Throttle cable carburetor right cylinder 2 To tube guide 3 NOTE Apply the lithium soap base grease on the throttle cable ends and tube guide cable wid ing portions Install the throttle cable carburetor left cylin der in the grip side slit a in the tube guide 5 Install Grip cap upper 1 Bolt grip cap 2 NOTE Align the contacting surface a of the grip cap upper with the punch mark b on the han ...

Page 223: ...ccording to the dimension shown CHAS 9 Install Starter cable carburetor left cylinder 1 Starter cable carburetor right cylinder 2 To starter lever 3 NOTE Apply the lithium soap base grease on the starter lever ends Install the starter cable carburetor left cylin der in the upper side slit a in the starter lever 10 Install Grip left 1 Apply the adhesive to the handlebar 2 NOTE Before applying the a...

Page 224: ...ever holder 5 T5 Nm 0 5 mdkg 3 6 ftdlb NOTE The main switch and clutch lever holder should be installed according to the dimensions shown 12 Install Clutch cable 1 NOTE Apply the lithium soap base grease on the clutch cable end 13 Install Handle crown 1 Refer to STEERING section 14 Adjust Handlebar position a Handlebar position 9 mm 0 35 in a CHAS ...

Page 225: ...ts to specified torpue If torpue too much it may cause the front fork to malfunction 16 Adjust Clutch lever free play Refer to CLUTCH ADJUSTMENT section in the CHAPTER 3 17 Lock the throttle cables and starter cables using a locking wire Refer to LOCKING WIRE INSTALLATION GUIDE section in the CHAPTER 3 CHAS ...

Page 226: ... GUIDE SEAT AND FUEL TANK section in the CHAPTER 4 Bolt Front brake reservoir tank Front brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Front wheel Refer to FRONT WHEEL AND REAR WHEEL section Front fender 1 Steering shaft nut 1 2 Pinch bolt handle crown 2 Only loosening 3 Handle crown 1 4 Clip 1 5 Bolt steering damper 1 6 Steering damper 1 7 Steering damper bracket 1 W Support the machi...

Page 227: ...r bracket 4 Only loosening 5 Front fork 2 Refer to FRONT FORK section 6 Ring nut 1 Use special tool Refer to REMOVAL POINTS 7 Under bracket 1 8 Inner fender 1 9 Ball race cover 1 10 Bearing upper 1 11 Bearing lower 1 Refer to REMOVAL POINTS 12 Ball race 2 Refer to REMOVAL POINTS CHAS T 10 Nm 1 0 mdkg 7 2 ftdlb T 23 Nm 2 3 mdkg 17 ftdlb T 7 Nm 0 7 mdkg 5 1 ftdlb t TIGHTENING STEPS Tighten ring nut ...

Page 228: ...ring shaft so that it may not fall down EC563300 Bearing lower 1 Remove Bearing lower 1 Use the floor chisel 2 C CCAUTION Take care not to damage the steering shaft thread EC563400 Ball race 1 Remove Ball race 1 Remove the ball race using long rod 2 and the hammer EC564000 INSPECTION EC564200 Steering shaft 1 Inspect Steering shaft 1 Bend Damage Replace CHAS ...

Page 229: ...es as a set EC564300 Steering damper 1 Inspect Steering damper 1 Bend Damage Replace Oil leaks Unsmooth movement Replace EC565000 ASSEMBLY AND INSTALLATION EC565190 Under bracket 1 Install Bearing lower 1 NOTE Apply the lithium soap base grease on the dust seal lip and bearing inner circumference 2 Install Inner fender 1 Screw inner fender 2 To under bracket 3 NOTE Install the inner fender with it...

Page 230: ...TMENT section in the CHAP TER 3 6 Check the steering shaft by turning it lock to lock If there is any binding remove the steering shaft assembly and inspect the steering bearings 8 Install Front fork 1 Steering damper stay 2 right side only Handlebar 3 Handle crown 4 NOTE Temporarily tighten the pinch bolts under bracket Do not tighten the pinch bolts handle crown steering damper stay and handleba...

Page 231: ... nut little by lit tle 11 Install Steering damper bracket 1 Pinch bolt steering damper bracket 2 T5 Nm 0 5 mdkg 3 6 ftdlb To steering damper 3 NOTE When installing the steering damper bracket provide a distance a of 9 mm 0 35 in from its edge C CCAUTION Tighten the pinch bolt to specified torque If torqued too much it may cause the steer ing damper to malfunction CHAS 12 Install Pin 1 Plain washer...

Page 232: ...END ADJUSTMENT in the CHAPTER 3 14 Tighten Pinch bolt handle crown 1 T20 Nm 2 0 mdkg 14 ftdlb Pinch bolt under bracket 2 T23 Nm 2 3 mdkg 17 ftdlb Pinch bolt handlebar 3 T7 Nm 0 7 mdkg 5 1 ftdlb Pinch bolt steering damper stay 4 right side only T10 Nm 1 0 mdkg 7 2 ftdlb Refer to FRONT FORK TOP END ADJUSTMENT in the CHAPTER 3 15 Check Steering smooth action Turn the handlebar to make sure no parts a...

Page 233: ...r to FRONT BRAKE AND REAR BRAKE section Drive chain Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section 1 Connecting rod 2 Hold the swingarm 2 Bolt rear shock absorber 1 relay arm 3 Pivot shaft adjust bolt 1 4 Pivot shaft 1 Use special tool 5 Swingarm 1 Refer to REMOVAL POINTS 6 Relay arm 1 7 Cover 2 8 Thrust bearing 2 9 Bush 1 10 Bearing 5 Refer to REMOVAL POINTS W Support the machine securely...

Page 234: ...wrench adapter YM 01476 90890 01476 C 2 Remove Pivot shaft 1 Swingarm 2 EC573210 Bearing 1 Remove Bearing 1 Use a general bearing puller 2 EC574010 INSPECTION Wash the bearings bushes collars and cov ers in a solvent EC574131 Swingarm 1 Inspect Bearing 1 Bush 2 Free play exists Unsmooth revolution Rust Replace bearing and bush as a set 2 Inspect Bearing 1 Collar 2 Free play exists Unsmooth revolut...

Page 235: ...lution Rust Replace bearing and collar as a set EC574320 Connecting rod 1 Inspect Connecting rod 1 Wear Damage Replace EC574520 Swingarm side clearance 1 Measure Bush length a 2 Measure Thrust bearing right thickness b Thrust bearing left thickness c 3 Measure Swingarm head pipe length d CHAS ...

Page 236: ... adjust shim is available only in the 0 3 mm 0 012 in thick type When only one shim is required install it on the left side and when two shims are neces sary install them on both right and left sides EC575000 ASSEMBLY AND INSTALLATION EC575300 Bearing 1 Install Bearing 1 To swingarm NOTE Apply the lithium soap base grease on the bearing when installing Install the bearing by pressing it on the sid...

Page 237: ... of bearings a a Zero mm Zero in a EC575141 Swingarm 1 Install Collar 1 To relay arm 2 NOTE Apply the lithium soap base grease on the col lars and bearings 2 Install Relay arm 1 Bolt relay arm 2 Nut relay arm 3 T34 Nm 3 4 mdkg 24 ftdlb NOTE Apply the lithium soap base grease on the bolt 3 Install Bush 1 Thrust bearing 2 Cover 3 To swingarm 4 NOTE Apply the lithium soap base grease on the bush bear...

Page 238: ...vot shaft wrench YM 01455 90890 01455 Pivot shaft wrench adapter YM 01476 90890 01476 C 6 Install Plain washer 1 Nut pivot shaft 2 T115 Nm 11 5 mdkg 85 ftdlb 7 Check Swingarm side play a Free play exists Check side clearance Swingarm up and down movement b Unsmooth movement Binding Rough spots Grease or replace bearings bushes and collars 8 Install Bolt rear shock absorber relay arm 1 Nut rear sho...

Page 239: ...soap base grease on the col lars and bearings 10 Install Connecting rod 1 Bolt connecting rod 2 Nut connecting rod 3 T34 Nm 3 4 mdkg 24 ftdlb NOTE Install the connecting rods with the mark a outward of the chassis Apply the lithium soap base grease on the bolts CHAS ...

Page 240: ...the CHAPTER 4 Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 4 1 Bolt rear shock absober 1 Hold the swingarm relay arm 2 Cap 1 3 Bolt Upper bracket 1 4 Rear shock absober 1 Refer to REMOVAL POINTS 5 Bolt rea shock absober 1 upper bracket 6 Upper bracket 1 7 Locknut 1 Loosen 8 Adjuster 1 Loosen 9 Spring guide 1 10 Spring rear shock absober 1 W Support the machine securely so...

Page 241: ...ny part of the gas tank A damaged gas tank will impair the damping performance or cause a malfunction 4 Take care not to scratch the contact sur face of the piston rod with the cylinder or oil could leak out 5 Never attempt to remove the plug at the bottom of the nitrogen gas tank It is very dangerous to remove the plug 6 When scrapping the shock absorber fol low the instructions on disposal EC587...

Page 242: ... Bends Damage Replace absorber assembly Shock absorber 2 Oil leaks Replace absorber assembly Gas leaks Replace absorber assembly Spring 3 Damage Replace spring Fatigue Replace spring Move spring up and down Spring guide 4 Wear Damage Replace spring guide Plate 5 Wear Damage Replace plate CHAS EC583221 Spring rear shock absorber 1 Remove Spring guide 1 Spring 2 NOTE Remove the spring guide while co...

Page 243: ...ing the spring by using the spring compressor 4 2 Tighten Adjuster 1 3 Adjust Spring length installed a Spring length installed a a Standard length Extent of adjustment 137 mm 5 39 in 133 142 mm 5 24 5 59 in NOTE The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster C CCAUTION Never attempt to turn the adjuster beyond the maximum or minimum setting CHAS ...

Page 244: ...orber upper bracket 3 Nut rear shock absorber upper bracket 4 T34 Nm 3 4 mdkg 24 ftdlb NOTE Apply the lithium soap base grease on the bolt 2 Install Rear shock absorber 3 Install Bolt upper bracket 1 T40 Nm 4 0 mdkg 29 ftdlb Cap 2 CHAS 4 Install Bolt rear shock absorber relay arm 1 Nut rear shock absorber relay arm 2 T34 Nm 3 4 mdkg 24 ftdlb NOTE Apply the lithium soap base grease on the bolt ...

Page 245: ...ain switch 6 Ignition coil 7 Solenoid valve 8 Fuel pump 9 Fuel pump relay 0 Fuel pump stop switch Battery CDI magneto Spark pulg Thermo unit Servomotor COLOR CODE B Black Br Brown G Green Gy Gray O Orange P Pink R Red Y Yellow W White B Br Black Brown B L Black Blue B R Black Red B W Black White G W Green White W B White Black W G White Green W L White Blue W R White Red Y L Yellow Blue EC612000 W...

Page 246: ...nk Use the following special tools in this inspection Dynamic spark tester YM 34487 Ignition checker 90890 06754 C 1 Check battery Recharge or replace OK No good Check fuse Replace fuse and check wireharness OK No good Repair or replace Check entire ignition system for connection No good OK Replace CDI unit Check ignition coil OK Primary coil No good Replace Secondary coil No good Replace Check CD...

Page 247: ... 4 A For USA and CDN B Except for USA and CDN 4 Start the engine and increase the spark gap until misfire occurs for USA and CDN 5 Move the main switch to RUN and rotate the rear wheel with gear in 3rd and check the spark gap except for USA and CDN Minimum spark gap 5 0 mm 0 20 in a EC623001 SPARK PLUG CAP INSPECTION 1 Remove Spark plug cap C CCAUTION Do not pull the spark plug lead out of the spa...

Page 248: ...1 Tester lead Brown lead 2 2 R Br Tester selector 1 1 2 2 position RUN Ω X X 1 OFF u Continuous while the main switch is moved to OFF Replace Not continuous while the main switch is moved to RUN Replace EC626002 IGNITION COIL INSPECTION 1 Inspect Primary coil resistance Out of specification Replace Tester lead Orange Gray lead 1 1 Tester lead Black lead 2 2 Primary coil Tester selector resistance ...

Page 249: ...spark plug cap EC627031 CDI MAGNETO INSPECTION 1 Inspect Pick up coil resistance left cylinder Out of specification Replace Tester lead White Blue lead 1 1 Tester lead White Black lead 2 2 Pick up coil Tester selector resistance position 94 140 Ω at Ω X X 100 20 C 68 F 2 Inspect Pick up coil resistance right cylinder Out of specification Replace Tester lead White Green lead 1 1 Tester lead White B...

Page 250: ...Tester lead White lead 1 1 Tester lead White lead 2 2 Source coil Tester selector resistance position 2 3 3 5 Ω at Ω X X 1 20 C 68 F EC628000 CDI UNIT INSPECTION Check all electrical components If no fault is found replace the CDI unit Then check the electrical components again ELEC ...

Page 251: ...ollowing parts before inspection 1 Cowling 2 Fuel tank Use the following special tool in this inspection Pocket tester YU 03112 90890 03112 A 2 Check battery Recharge or replace OK No good 1 Check fuse Replace fuse and check wireharness OK No good Repair or replace Check each coupler and wire connection No good No good OK 1 Check CDI magneto OK Source coil No good Replace Check charging voltage Ch...

Page 252: ...rce coil resistance check the voltage regulator Tester lead Red lead 1 1 Tester lead Black lead 2 2 Charging Tester selector voltage position 14 2 15 2 V DCV 20 at 5 000 r min EC683000 VOLTAGE REGULATOR INSPECTION 1 Check Voltage regulator conduct Use pocket tester tester selection posi tion Ω X 1 ELEC W1 W2 R B 1 2 3 4 W1 1 X D X W2 2 X D X R 3 X X X B 4 D D D D indicates continuity and X non con...

Page 253: ...CHARGING SYSTEM 6 9 NOTE If nothing is wrong with the continuity of the voltage regulator and with all the others in the charging system replace the voltage regulator ELEC ...

Page 254: ...parts before inspection 1 Cowling 2 Fuel tank Use 12V battery in this inspection Use the following special tool in this inspection Pocket tester YU 03112 90890 03112 A 2 Check battery Recharge or replace OK No good 1 Check fuse Replace fuse and check wireharness OK No good Repair or replace Check each coupler and wire connection No good OK 1 Check main switch Replace OK No good Check servomotor op...

Page 255: ...el pump coupler to pre vent the fuel pump operating 2 Inspect Servomotor 1 Operative when the main switch is moved to RUN OK EC643001 SERVOMOTOR INSPECTION 1 Disconnect the YPVS cable from the servo motor 2 Disconnect the servomotor lead 3 Connect 12V battery to the servomotor lead Battery lead Black Red lead 1 1 Battery lead Black Brown lead 2 2 4 Inspect Servomotor 1 Not operate Replace servomot...

Page 256: ...ling 4 Induction guide right cylinder 2 Fuel tank 5 Seat 3 Induction cap left cylinder Use l2V battery in this inspection Use the following special tools in this inspection Pocket tester YU 03112 90890 03112 A 2 Check battery Recharge or replace OK No good 1 Check fuse Replace fuse and check wireharness OK No good Repair or replace Check each coupler and wire connection No good OK 1 Check main swi...

Page 257: ...to prevent the fuel pump and ser vomotor operating 2 Inspect Solenoid valve 1 Click when the main switch is moved to RUN OK NOTE Before checking the solenoid valve disconnect the other solenoid valve lead EC653002 SOLENOID VALVE COIL INSPECTION 1 Inspect Solenoid valve coil resistance Out of specification Replace Tester lead Yellow lead 1 1 Tester lead White lead 2 2 Solenoid Tester selector resis...

Page 258: ...ION section in the CHAPTER 3 NOTE Remove the following parts before inspection 1 Cowling Use the following special tools in this inspection Pocket tester YU 03112 90890 03112 A 2 Check battery Recharge or replace OK No good 1 Check fuse Replace fuse and check wireharness OK No good Repair or replace Check each coupler and wire connection No good OK 1 Check main switch Replace OK No good Check ther...

Page 259: ...tester lead connected in a container containing cooling tap water 1 down to the upper threaded portion a 2 Water temperature gauge 3 Poket tester 4 Inspect Thermo unit resistance Measure the resistance while gradually heating the cooling water Out of specification Replace Cooling Thermo Tester water unit selector temperature resistance position 50 C 122 F 9 72 11 4 kΩ kΩ X X 1 80 C 176 F 3 41 4 01...

Page 260: ...n cap left cylinder Use 12V battery in this inspection Use the following special tool in this inspection Pocket tester YU 03112 90890 03112 A 2 Check battery Recharge or replace OK No good 1 Check fuse Replace fuse and check wireharness OK No good Repair or replace Check each coupler and wire connection No good OK 1 Check main switch Replace OK No good Check fuel pump stop switch Replace No good C...

Page 261: ...SPECTION 1 Remove Fuel pump stop switch 1 2 Inspect Fuel pump stop switch conduct To inspect tilt the fuel pump stop switch to the right and left Tester lead Black lead 1 1 Tester lead Black lead 2 2 B B Tester selector 1 1 2 2 position Tilted 90 Ω X X 1 Normal u Continuous if normal Replace Not continuous if tilted 90 Replace EC673000 FUEL PUMP RELAY INSPECTION 1 Remove Fuel pump relay 1 ELEC ...

Page 262: ...e connected to the battery Replace Not continuous while not connected to the bat tery Replace 3 Inspect Fuel pump relay resistance Out of specification Replace Tester lead Green lead 1 1 Tester lead Black lead 2 2 Fuel pump relay Tester selector resistance position 72 80 Ω at Ω X X 10 20 C 68 F EC674000 FUEL PUMP OPERATION C CCAUTION Do not operate the fuel pump on an empty fuel tank because it ma...

Page 263: ...resistance Out of specification Replace Tester lead Black Blue lead 1 1 Tester lead Black lead 2 2 Fuel pump coil Tester selector resistance position 1 3 Ω at Ω X X 1 20 C 68 F EC676000 FUEL PUMP INSPECTION C CCAUTION Do not operate the fuel pump on an empty fuel tank because it may damage the pump 1 Remove the fuel outlet hose from the fuel pump 2 Connect another plastic hose 1 to the fuel pump a...

Page 264: ... fuel cock to ON 4 Disconnect the fuel pump coupler 5 Connect 12V battery to the fuel pump cou pler Battery lead Black Blue lead 1 1 Battery lead Black lead 2 2 6 Inspect Fuel pump 1 No fuel flows from the plastic hose 2 Replace ELEC ...

Page 265: ...uretor must be properly suited to the atmospheric conditions air pressure humidity and temperature As a basic setting method only the factory set main jet is first changed to check for the dis coloration of the spark plug s and piston s at full throttle in 6th and then the setting is deter mined at mid open throttle Recording and storing the data on the set tings weather conditions road surface co...

Page 266: ...t 12 300 rpm of the engine after which only the main jet domi nates 1 Throttle valve opening 2 Full open 3 Full closed EC71E003 Basic process of carburetor setting Ex factory setting is on the richer side which should basically have no problems with the brake in procedure Refer to STARTING AND BREAK IN section in the CHAPTER 1 1 Adjustment of main jet Use a main jet 1 with a smaller calibration nu...

Page 267: ...can be used just by looking at discoloration he should consult an experienced person for his own experience too Whether the setting is proper or not can be judged by engine revolutions Approximate criteria for such judgment are given below on condition that the sec ondary reduction ratio is fit for conditions of the circuit 13 000 rpm in 1st and 2nd 12 500 rpm in 5th and 6th A Normal B Over burned...

Page 268: ...ifferent main nozzle appears to produce less power change to a main nozzle of a larger size Example S 1 S 2 Factory set main nozzle S 4 w NOTE Difference between individual riders or differ ence between circuit layouts greatly affect the main nozzle setting 1 Rider who frequently uses mid open throttle 2 Circuit that requires frequent throttle open ing and closing 3 Wet environment Conditions as m...

Page 269: ...ratio etc Illustration Suppose the best setting was represented by a 450 main jet at an air pressure of 1013 hPa 760 mmHg and an air temperature of 20 C 68 F in the previous riding In this riding there has been a substantial change in conditions namely an air pressure of 1007 hPa 755 mmHg and an air tempera ture of 30 C 86 F 1 Refer to a table of correction coefficients P7 6 to find the correction...

Page 270: ...91 1 224 735 980 735 105 7 103 8 101 9 100 1 98 4 96 7 95 1 93 5 92 0 90 5 281 922 973 730 105 0 103 1 101 2 99 4 97 7 96 1 94 4 92 9 91 4 89 9 338 1 109 967 725 104 3 102 4 100 5 98 8 97 1 95 4 93 8 92 2 90 7 89 3 396 1 299 960 720 103 6 101 7 99 8 98 1 96 4 94 7 93 1 91 6 90 1 88 7 453 1 486 953 715 102 9 101 0 99 2 97 4 95 7 94 1 92 5 91 0 89 5 88 1 512 1 680 947 710 102 1 100 3 98 5 96 7 95 0 ...

Page 271: ...r size in a leaner mixture Factory set pilot jet 30 w 3 Pilot air screw 1 The pilot air screw relates to the engine response at a smaller opening than for the pilot jet This setting may be changed for want of time or in emergency but it is basically set at the factory set pilot air screw position Factory set pilot air 1 1 2 turns out screw position w 4 Spark plug The spark plug heat range is not b...

Page 272: ...37 1414K 08 560 137 1414K 12 Rich 580 137 1414K 16 Pilot jet 2 2 Lean 20 4KM 14142 20 25 4KM 14142 25 Rich 30 4KM 14142 30 Main nozzle Lean R 6 3TC 14141 R6 3 3 R 7 3TC 14141 R7 R 8 3TC 14141 R8 R 9 3TC 14141 R9 S 0 3TC 14141 S0 S 1 3TC 14141 S1 S 2 3TC 14141 S2 S 3 3TC 14141 S3 Rich S 4 3TC 14141 S4 Jet needle 4 4 6EGJ4 63 3JD 14116 E2 Power jet 5 5 Lean 50 830 14231 10 Rich 55 830 14231 11 TUN N...

Page 273: ...ure of the clutch push rod and ball EC71K010 Setting of cylinder gasket The use of the supplied gaskets of different thicknesses makes it possible to change the combustion chamber volume Not much torque is felt with slow engine accel eration Reduce the combustion chamber volume Torque is felt with no higher revolutions Expand the combustion chamber volume Thickness Actual combustion Type chamber v...

Page 274: ...NOTE Finish the break in before changing the gas ket A change of 0 1 mm 0 004 in for the gasket causes a change of approximately 0 23 cm3 0 008 lmp oz 0 008 US oz of the combus tion chamber volume After break in change to an appropriate gas ket to allow the piston protrusion to be 0 15 mm 0 006 in to 0 05 mm 0 002 in C CCAUTION Piston protruding amount must be a max imum 0 15 mm 0 006 in Above thi...

Page 275: ...ission gear ratio The following gear sets are contained in the packing or optional to allow the rider to change the gear ratios according to the circuit condition or rider s preference C CCAUTION Select the transmission gears so that the number of grooves in the wheel gear match that of the pinion gear as shown below Trouble may be occurred if the selection is different than that listed below a Gr...

Page 276: ...KE 17231 00 5KE 17131 00 Supplying part 25 21 1 190 5KE 17231 20 5KE 17131 10 2 1 Supplying part 26 21 1 238 5KE 17231 10 5KE 17131 10 1 6th gear Gear ratio Part number Number of groove Factory installed 20 22 0 909 5KE 17261 00 5KE 17191 00 1 Supplying part 22 25 0 880 5KE 17261 10 5KE 17161 10 2 ...

Page 277: ...wheel gear 6 6 29T 5KE 17211 10 34T 5KE 17211 20 2nd wheel gear 7 7 27T 5F7 17221 21 28T 5F7 17221 00 31T 4DP 17221 11 3rd wheel gear 8 8 25T 5KE 17231 20 26T 5KE 17231 10 29T 5KE 17231 00 4th wheel gear 9 9 27T 5KE 17241 00 5th wheel gear 0 0 26T 3YL 17251 00 6th wheel gear 20T 5KE 17261 00 22T 5KE 17261 10 Factory installed NOTE The mark shows that this part is not sup plied together and that it...

Page 278: ...rce adjustment and if this not enough then adjust the machine height On the side where the machine height is greater the stroke increases whereas it decreases on the side with a smaller machine height If the damping force is increased either on the compression or the expansion side it results in less smooth movement so do not depart too far from the standard settings Adjust the machine height in a...

Page 279: ... mm 0 04 in NOTE Find the tire radius by calculating the mea sured circumference of the tire A change of 1 mm 0 04 in in the front fork top end results in a change of about 1 mm 0 04 in in the front posture A change of 1 mm 0 04 in in the adjuster set length results in a change of about 2 mm 0 08 in in the rear posture TUN Front Designated tire Tire circumference Tire radius Front fork top end 3 1...

Page 280: ...the rear shock absorber rod 2 Settings At the beginning of the break in period always record the remaining stroke as data To judge front and rear balance in relation to the machine height the usual way is to shift from full braking to turning and get the feel when the clipper riding After making an actual run proceed to the settings for a target of a 5 10 mm 0 20 0 39 in remaining stroke for front...

Page 281: ... 1 5 mm 0 06 in Too stiff from the beginning and not smooth in mid range as well Decrease damping force on compression side Front Every one turn Rear Every two clicks Unstable and spongy Increase damping force both on compression and rebound Front Every one turn Rear Every two clicks Check stroke YES NO NO NOTE Preload increase results in relative lack of damping force If the preload is increased ...

Page 282: ...smaller value the lower speed ratio EC72N000 Drive and driven sprockets setting parts Part name Size Part number Drive sprocket 1 1 14T 93834 14178 15T 93834 15079 16T 93834 16104 Driven sprocket 2 2 35T 4TW 25435 02 36T 4TW 25436 02 37T 4TW 25437 02 38T 4TW 25438 02 39T 4TW 25439 02 40T 4TW 25440 02 Driven sprocket 35T 36T 37T 38T 39T 40T Drive sprocket 14T 2 500 2 571 2 643 2 714 2 786 2 857 15T...

Page 283: ...ration Check the shock absorber feeling Check rod inner tube etc for bending If bent replace Check for any deviation from center after tightening front wheel axle Replace if deviated in any way Too much tightened bolts for front fork outer tube Retorque the bolts to specification handle crown under bracket steering damper stay handlebar Too stiff poor stroke Decrease spring preload Decrease dampin...

Page 284: ...oo big caster angle Decrease damping force for rebound for rear Increase front fork top end Decrease spring preload for front Too much knifing Machine tend to incline Decrease front fork top end at cornering too much forward Decrease rear height Too small caster angle Increase spring preload for front Increase damping force for compression for front Front dives in too early Increase damping force ...

Page 285: ...park plug Carburetor Main jet Power jet Jet needle Main nozzle Pilot jet Pilot air screw Float height Gearing 1st 2nd 3rd 4th 5th 6th Secondary Front fork Spring rate Spring preload Rebound damping Compression damping Top end Oil capacity Oil level Rear shock Spring fitting length Spring rate Rebound damping Compression damping Seat height Front tire pressure Rear tire pressure Fuel consumption ...

Page 286: ... preload Rebound damping Compression damping Top end Oil capacity Oil level Rear shock Spring fitting length Spring rate Rebound damping Compression damping Seat height Front tire pressure Rear tire pressure Fuel consumption NOTE 1 Make setting changes in small increments 2 When the proper settings have been determined for a particular track they should be written down for reference upon returning...

Page 287: ...99 9 0 1x1 ...

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