Yamaha TZ250M1 Owner'S Service Manual Download Page 155

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TRANSMISSION, SHIFT CAM AND SHIFT FORK

4-57

EC4H3000

REMOVAL POINTS

EC4H3210

Transmission
1. Remove:

• Main axle

• Drive axle

NOTE:

• Remove the main axle together with the drive

axle from the transmission housing

• Remove assembly carefully. Note the position

of each part. Pay particular attention to the
location and direction of shift forks.

EC4H3400

Segment
1. Remove:

• Bolt (segment)

• Segment

NOTE:

Clamp the shift cam

securely in a vise,

using soft protecting material

to loosen the

bolt (segment).

EC4H4000

INSPECTION

EC4H4210

Gears
1. Inspect:

• Matching dog

• Gear teeth

Wear/Damage

≥

Replace.

ENG

2. Check:

• Gears movement

Unsmooth movement

≥

Repair or replace.

Summary of Contents for TZ250M1

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

Page 2: ...aha 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 P...

Page 3: ...e 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...

Page 4: ...N 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...

Page 5: ...EAR 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...

Page 6: ...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 MAC...

Page 7: ...is 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 ther...

Page 8: ...st 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 Genera...

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 PUS...

Page 10: ...0 Filling fluid Lubricant Tightening Specified value Service limit Resistance Voltage V Electric cur rent A Illustrated symbols to in the exploded dia grams indicate grade of lubricant and location o...

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: ...N 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...

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...

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

Page 16: ...0 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...

Page 17: ...e 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...

Page 18: ...OLS 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...

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 outwar...

Page 20: ...hat 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 wi...

Page 21: ...to 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 9089...

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 tight...

Page 23: ...OOLS 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 sur...

Page 24: ...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 ratio...

Page 25: ...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 t...

Page 26: ...ange 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...

Page 27: ...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...

Page 28: ...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 r...

Page 29: ...tarting 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 b...

Page 30: ...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...

Page 31: ...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...

Page 32: ...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...

Page 33: ...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 Wh...

Page 34: ...iston 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 t...

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 shaf...

Page 36: ...heel 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 wash...

Page 37: ...he 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...

Page 38: ...t 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 Trans...

Page 39: ...gle 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 Righ...

Page 40: ...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 Fri...

Page 41: ...r 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...

Page 42: ...g 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...

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 sho...

Page 44: ...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...

Page 45: ...37 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 ins...

Page 46: ...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...

Page 47: ...d 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 g...

Page 48: ...k gap 5 mm 0 20 in Primary winding resistance 0 14 0 18 at 20 C 68 F Secondary winding resistance 5 0 7 4 k at 20 C 68 F Battery Model Manufacturer PE12V0 8 JAPAN STORAGE BATTERY Capacity 12V0 8Ah Vol...

Page 49: ...ecified 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...

Page 50: ...ight 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 po...

Page 51: ...tor 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 se...

Page 52: ...lers 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 bol...

Page 53: ...or 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 Positio...

Page 54: ...ry 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 CYL...

Page 55: ...lace 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 ca...

Page 56: ...ce 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 SPR...

Page 57: ...ffect 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...

Page 58: ...RE 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 Star...

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...

Page 60: ...or 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...

Page 61: ...ce 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 3...

Page 62: ...80 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 Re...

Page 63: ...en 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...

Page 64: ...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 Tighte...

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...

Page 66: ...ation Adjust 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 unti...

Page 67: ...r 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 o...

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...

Page 69: ...spect 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 N...

Page 70: ...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 Slowl...

Page 71: ...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 un...

Page 72: ...tion 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 cott...

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...

Page 74: ...ghten 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...

Page 75: ...e 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...

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 r...

Page 77: ...TE 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 Lubri...

Page 78: ...er 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 th...

Page 79: ...eft 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 fro...

Page 80: ...s 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...

Page 81: ...ch 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 tor...

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 Cowlin...

Page 83: ...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...

Page 84: ...ion 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...

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 f...

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 EC36M0...

Page 87: ...knut 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...

Page 88: ...J 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 tur...

Page 89: ...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...

Page 90: ...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...

Page 91: ...ering 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...

Page 92: ...eard 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...

Page 93: ...ver 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 cha...

Page 94: ...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...

Page 95: ...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 tha...

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 handlin...

Page 97: ...e 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...

Page 98: ...d 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 1...

Page 99: ...ks 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...

Page 100: ...EMOVAL 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 preven...

Page 101: ...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 Exhau...

Page 102: ...nk 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...

Page 103: ...p 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 a...

Page 104: ...g 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...

Page 105: ...DUCTION 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...

Page 106: ...etor 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 Ca...

Page 107: ...art 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 Fl...

Page 108: ...le 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...

Page 109: ...ody 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 specificat...

Page 110: ...uel 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...

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 CC...

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...

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 re...

Page 114: ...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...

Page 115: ...lamp 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 C...

Page 116: ...NK 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...

Page 117: ...marks 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...

Page 118: ...m 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 deburre...

Page 119: ...rust 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 E...

Page 120: ...ver 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...

Page 121: ...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...

Page 122: ...m 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...

Page 123: ...on 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 h...

Page 124: ...E 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...

Page 125: ...amage 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...

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...

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 sl...

Page 128: ...kg 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...

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...

Page 130: ...emoval 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...

Page 131: ...A 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 Circumfer...

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...

Page 133: ...TE 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...

Page 134: ...d 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 th...

Page 135: ...ges 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 wi...

Page 136: ...l 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...

Page 137: ...emoval 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 REMOV...

Page 138: ...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...

Page 139: ...case 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 s...

Page 140: ...ar 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 NO...

Page 141: ...ght 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 tow...

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 PRIM...

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...

Page 144: ...ssembly 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 EC4F50...

Page 145: ...awl 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 assemb...

Page 146: ...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 lev...

Page 147: ...ousing 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 transmissio...

Page 148: ...ll 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 T...

Page 149: ...er 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...

Page 150: ...ch 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...

Page 151: ...OTE 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 i...

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...

Page 153: ...IFT 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...

Page 154: ...e 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...

Page 155: ...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 i...

Page 156: ...s 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 Par...

Page 157: ...rd 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 4...

Page 158: ...d 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 bu...

Page 159: ...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 di...

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 a...

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...

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 I...

Page 163: ...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 We...

Page 164: ...gear shaft 2 To transmission housing 3 4 Install Plain washer D 15 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...

Page 165: ...sher 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...

Page 166: ...emarks 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 Ro...

Page 167: ...ng 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 bea...

Page 168: ...e 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 012...

Page 169: ...e 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 Refe...

Page 170: ...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...

Page 171: ...st 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 Remov...

Page 172: ...ing 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 to...

Page 173: ...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...

Page 174: ...lve 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...

Page 175: ...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 Refe...

Page 176: ...ly 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 Crankshaf...

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 Sma...

Page 178: ...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 transm...

Page 179: ...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...

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 lev...

Page 181: ...ing 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 REM...

Page 182: ...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 POI...

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...

Page 184: ...94100 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 de...

Page 185: ...hen 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...

Page 186: ...e 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 5...

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...

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 Insta...

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 tighten...

Page 190: ...aster 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 cyli...

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 machi...

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 R...

Page 193: ...nt 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...

Page 194: ...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 d...

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...

Page 196: ...mbly 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 R...

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 disasse...

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...

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...

Page 200: ...ed 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 flu...

Page 201: ...rvoir 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...

Page 202: ...sher 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 Cop...

Page 203: ...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...

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...

Page 205: ...ervoir 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...

Page 206: ...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...

Page 207: ...BLY 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...

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 f...

Page 209: ...pring 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 St...

Page 210: ...ace 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 fo...

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 w...

Page 212: ...r 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 GT...

Page 213: ...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...

Page 214: ...commended 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 ma...

Page 215: ...l 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...

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...

Page 217: ...er 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 i...

Page 218: ...h 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...

Page 219: ...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...

Page 220: ...wn 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...

Page 221: ...mage 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 rig...

Page 222: ...der 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 car...

Page 223: ...cording 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 start...

Page 224: ...ver 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 grea...

Page 225: ...s 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...

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 sectio...

Page 227: ...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...

Page 228: ...ing 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 B...

Page 229: ...s 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 lowe...

Page 230: ...MENT 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...

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...

Page 232: ...ND 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 b...

Page 233: ...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 adju...

Page 234: ...rench 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 e...

Page 235: ...ution 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...

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 E...

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 re...

Page 238: ...ot 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 exis...

Page 239: ...oap 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...

Page 240: ...he 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 Refe...

Page 241: ...y 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 le...

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...

Page 243: ...ng 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...

Page 244: ...rber 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 T...

Page 245: ...in 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 Ora...

Page 246: ...k 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 wireh...

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...

Page 248: ...1 1 Tester lead Brown lead 2 2 R Br Tester selector 1 1 2 2 position RUN 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 Repla...

Page 249: ...e 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 c...

Page 250: ...Tester lead White lead 1 1 Tester lead White lead 2 2 Source coil Tester selector resistance position 2 3 3 5 at X X 1 20 C 68 F EC628000 CDI UNIT INSPECTION Check all electrical components If no fau...

Page 251: ...llowing 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...

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 REGULAT...

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: ...arts 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 repla...

Page 255: ...l 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 mo...

Page 256: ...ing 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...

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...

Page 258: ...ON 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...

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 resistan...

Page 260: ...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...

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...

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 B...

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 at X X 1 20 C 68 F EC676000 FUEL PUMP INSPECT...

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...

Page 265: ...retor 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 colorati...

Page 266: ...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 s...

Page 267: ...an 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 crit...

Page 268: ...fferent 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 betwee...

Page 269: ...atio 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...

Page 270: ...1 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 9...

Page 271: ...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...

Page 272: ...7 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 3T...

Page 273: ...re 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 torqu...

Page 274: ...OTE 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 Afte...

Page 275: ...ssion 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 Selec...

Page 276: ...E 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 install...

Page 277: ...heel 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 ge...

Page 278: ...ce 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...

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 po...

Page 280: ...he 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...

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 dampi...

Page 282: ...maller 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 3...

Page 283: ...ation 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 muc...

Page 284: ...o 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 cor...

Page 285: ...ark 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 Com...

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 pr...

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

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Summary of Contents for TZ250M1

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Yamaha TZ250M1, Owner'S Service Manual

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