Yamaha WR250F(Y) 2009 Owner'S Service Manual Download Page 12 | Manualshive

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SPECIAL TOOLS

SPECIAL TOOLS

The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will
help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for
the special tool differ by country, so two types are provided. Refer to the list provided to avoid errors when placing an order.

• For U.S.A. and Canada, use part number starting with "YM-", "YU-" or "ACC-".
• For others, use part number starting with "90890-".

Tool name/Part number

How to use

Illustration

Crankcase separating tool
YU-1135-A, 90890-01135

These tool is used to remove the
crankshaft from either case.

Dial gauge and stand
YU-3097, 90890-01252
Stand
YU-1256

These tools are used to check each
part for runout or bent.

Crankshaft installing tool
Crankshaft installing pot
YU-90050, 90890-01274
Crankshaft installing bolt
YU-90050, 90890-01275
Spacer (crankshaft installer)
YU-91044, 90890-04081
Adapter (M12)
YU-90063, 90890-01278

These tools are used to install the
crankshaft.

Piston pin puller set
YU-1304, 90890-01304

This tool is used to remove the pis-
ton pin.

Radiator cap tester
YU-24460-01, 90890-01325
Radiator cap tester adapter
YU-33984, 90890-01352

These tools are used for checking
the cooling system.

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Summary of Contents for WR250F(Y) 2009

Page 1: ...R250F Y 2009 2009 5UM 28199 56 E0 5UM 28199 56 E0 OWNER S SERVICE MANUAL OWNER S SERVICE MANUAL Read this manual carefully before operating this vehicle Read this manual carefully before operating thi...

Page 2: ......

Page 3: ...SERVICE MANUAL 2008 by Yamaha Motor Co Ltd 1st Edition July 2008 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited P...

Page 4: ...chine is designed for off road use only It is illegal for this machine to be operated on any public street road or highway Off road use on public lands may be illegal Please check local regulations be...

Page 5: ...seven chapters General Information Specifications Regular inspec tion and adjustments Tuning Engine Chassis and Electri cal 2 The table of contents is at the be ginning of the manual Look over the gen...

Page 6: ...informa tion the step by step format sup plements 5 are given in addition to the exploded diagram and job instruction chart ILLUSTRATED SYMBOLS Refer to the illustration Illustrated symbols 1 to 7 are...

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

Page 8: ...TION AND MAINTENANCE 3 7 ENGINE 3 8 CHASSIS 3 19 ELECTRICAL 3 29 CHAPTER 4 TUNING ENGINE Except for Canada 4 1 CHASSIS 4 5 CHAPTER 5 ENGINE RADIATOR 5 1 CARBURETOR 5 4 AIR INDICTOIN SYSTEM 5 12 CAMSHA...

Page 9: ...tarter lever 3 Engine stop switch 4 Multi function display 5 Main switch 6 Start switch 7 Front brake lever 8 Throttle grip 9 Radiator cap 10 Fuel tank cap 11 Taillight 12 Kickstarter crank 13 Fuel ta...

Page 10: ...e fuel tank and also downward SPARK PLUG WRENCH This spark plug wrench 1 is used to remove and install the spark plug NIPPLE WRENCH This nipple wrench 1 is used to tighten the spoke JET NEEDLE PULL UP...

Page 11: ...mped letters must be on the side exposed to view When in stalling oil seal s apply a light coating of lightweight lithium base grease to the seal lip s Oil the bearings liberally when installing Do no...

Page 12: ...How to use Illustration Crankcase separating tool YU 1135 A 90890 01135 These tool is used to remove the crankshaft from either case Dial gauge and stand YU 3097 90890 01252 Stand YU 1256 These tools...

Page 13: ...ver YM A0948 90890 01502 This tool is used when install the fork oil seal Spoke nipple wrench YM 01521 90890 01521 This tool is used to tighten the spoke Sheave holder YS 1880 A 90890 01701 This tool...

Page 14: ...4 0 mm 0 16 in Exhaust 4 5 mm 0 18 in YM 4111 90890 04111 YM 4116 90890 04116 This tool is needed to remove and install the valve guide Valve guide installer Intake 4 0 mm 0 16 in Exhaust 4 5 mm 0 18...

Page 15: ...or checking the ignition system compo nents Vacuum pressure pump gauge set YB 35956 A 90890 06756 This tool is used to check the air in duction system YAMAHA Bond No 1215 ThreeB ond No 1215 90890 8550...

Page 16: ...t pedal 1 on the left side of the engine KICKSTARTER CRANK Rotate the kickstarter crank 1 away from the engine Push the starter down lightly with your foot until the gears engage then kick smoothly an...

Page 17: ...ime that has been accumulated since the start of timer measurement Tripmeter which shows the accu mulated travel distance in timer measurement Change tripmeter digits capable of change to any given on...

Page 18: ...for 2 seconds or more at the same time to change over to BASIC MODE RACE MODE Putting measurement on standby Starting measurement consists of the following two starts either of which can be selected M...

Page 19: ...button and SLCT2 but ton at the same time 2 Reset tripmeter A TRIP A dis play by pushing the RST button for 2 seconds or more If reset and travel distance dis play will go on flashing for four sec on...

Page 20: ...on the button changes the operation in both arrowed directions Meter function Function that can be performed whether the time is or is not in operation Extent to which the meter can operate Clock BASI...

Page 21: ...he button changes the operation in the ar rowed direction D A long push on the button changes the operation in both arrowed directions E Meter function F Function that can be performed whether the tim...

Page 22: ...starting STARTING A COLD ENGINE This model is equipped with an igni tion circuit cut off system The engine can be started under the following conditions When the transmission is in neutral When the cl...

Page 23: ...te the machine in the lower gears at moderate throttle open ings for five to eight minutes 5 Check how the engine runs when the machine is ridden with the throttle 1 4 to 1 2 open low to me dium speed...

Page 24: ...nk type Assembly of links Link to frame Link to rear shock absorber Link to swingarm Installation of rear shock absorber Rear shock absorber to frame Installation of swingarm Tightening of pivot shaft...

Page 25: ...in with a paper towel and lubri cate the chain to prevent rust 7 Clean the seat with a vinyl uphol stery cleaner to keep the cover pliable and glossy 8 Automotive wax may be applied to all painted or...

Page 26: ...round clearance 365 mm 14 37 in 370 mm 14 57 in 375 mm 14 76 in Dry weight Without oil and fuel 106 0 kg 233 7 lb Engine Engine type Liquid cooled 4 stroke DOHC Cylinder arrangement Single cylinder fo...

Page 27: ...0 028 0 031 in Clutch type Wet multiple disc Transmission USA CDN ZA AUS NZ EUROPE Primary reduction system Gear Primary reduction ratio 57 17 3 353 Secondary reduction system Chain drive Secondary r...

Page 28: ...wheel travel 310 mm 12 2 in Electrical Ignition system CDI Generator system AC magneto Battery type YTZ7S F Battery voltage capacity 12V 6 AH Specific gravity 1 310 Headlight type Quartz bulb halogen...

Page 29: ...35 mm 0 8799 in Camshaft runout limit 0 03 mm 0 0012 in Timing chain Timing chain type No of links 92RH2010 114M 114 Timing chain adjustment method Automatic Valve valve seat valve guide Valve clearan...

Page 30: ...0 in 4 050 mm 0 1594 in Guide inside diameter EX 4 500 4 512 mm 0 1772 0 1776 in 4 550 mm 0 1791 in Stem to guide clearance IN 0 010 0 037 mm 0 0004 0 0015 in 0 08 mm 0 003 in Stem to guide clearance...

Page 31: ...Piston Piston to cylinder clearance 0 030 0 055 mm 0 0012 0 0022 in 0 1 mm 0 004 in Piston size D 76 955 76 970 mm 3 0297 3 0303 in Measuring point H 8 mm 0 31 in Piston off set 0 5 mm 0 020 in IN si...

Page 32: ...mm 0 0012 in 0 05 mm 0 002 in Big end side clearance D 0 15 0 45 mm 0 0059 0 0177 in 0 50 mm 0 02 in Small end free play F 0 4 1 0 mm 0 02 0 04 in 2 0 mm 0 08 in Clutch Friction plate thickness 2 9 3...

Page 33: ...31 in Engine idle speed 1 750 1 950 r min Intake vacuum 31 3 36 7 kPa 235 275 mmHg 9 25 10 83 inHg Hot starter lever free play 3 6 mm 0 12 0 24 in Lubrication system Oil filter type Paper type Oil pum...

Page 34: ...nner tube outer diameter 48 mm 1 89 in Front fork top end 5 mm 0 20 in Rear suspension USA CDN AUS NZ ZA EUROPE Shock absorber travel 130 mm 5 12 in Spring free length 260 mm 10 24 in Fitting length 2...

Page 35: ...mm 0 25 in 1 0 mm 0 04 in Master cylinder inside dia 11 0 mm 0 433 in Caliper cylinder inside dia 25 4 mm 1 000 in 1 Brake fluid type DOT 4 Brake lever and brake pedal Brake lever position 95 mm 3 74...

Page 36: ...A Electric starting system Type Constant mesh Starter motor Model manufacturer 5UM01 YAMAHA Operation voltage 12 V Output 0 35 kW Armature coil resistance 0 0189 0 0231 at 20 C 68 F Brush overall leng...

Page 37: ...n tensioner cap bolt M6 1 0 1 7 0 7 5 1 Impeller M8 1 25 1 14 1 4 10 Radiator hose clamp M6 1 0 10 2 0 2 1 4 Coolant drain bolt M6 1 0 1 10 1 0 7 2 Water pump housing M6 1 0 4 10 1 0 7 2 Radiator stay...

Page 38: ...7 Crankcase bearing stopper M6 1 0 11 10 1 0 7 2 Crankcase bearing stopper crankshaft M6 1 0 4 14 1 4 10 Left crankcase cover M6 1 0 8 10 1 0 7 2 Idle gear cover starter motor M6 1 0 3 10 1 0 7 2 Idl...

Page 39: ...lever mounting nut M6 1 0 1 6 0 6 4 3 Brake lever position locknut M6 1 0 1 5 0 5 3 6 Front brake hose guide and front brake hose guide bracket M5 0 8 1 4 0 4 2 9 Front brake hose guide and lower bra...

Page 40: ...32 3 2 23 Swingarm and brake hose holder M5 0 8 4 3 0 3 2 2 Swingarm and patch M4 0 7 4 2 0 2 1 4 Upper drive chain tensioner M8 1 25 1 16 1 6 11 Lower drive chain tensioner M8 1 25 1 16 1 6 11 Drive...

Page 41: ...0 1 0 7 Taillight lead clamp and rear fender 3 0 5 0 05 0 36 Catch tank upper M6 1 0 1 16 1 6 11 Catch tank lower M6 1 0 1 7 0 7 5 1 Footrest bracket and frame M10 1 25 4 55 5 5 40 Sidestand M10 1 25...

Page 42: ...s should be at room temperature A Distance between flats B Outside thread diameter DEFINITION OF UNITS A Nut B Bolt TORQUE SPECIFI CATION Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm...

Page 43: ......

Page 44: ...2 18 LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Oil filter element 2 Oil pump 3 Drive axle 4 Main axle 5 Intake camshaft 6 Exhaust camshaft 7 Oil tank 8 Oil delivery pipe A To oil tank...

Page 45: ...2 19 LUBRICATION DIAGRAMS 1 Crankshaft 2 Oil filter element 3 Oil tank 4 Oil hose A From oil pump...

Page 46: ...ead breather hose 8 Throttle position sensor lead 9 Neutral switch lead 10 Oil hose 11 Clutch cable 12 Starter motor lead 13 Cable guide 14 Negative battery lead 15 AC magneto lead 16 Brake hose 17 Re...

Page 47: ...onto the frame Locate the clamp end facing toward the outside of the frame and tie end facing toward the rear of the frame H Pass the clutch cable through the cable guide I Fasten the starter motor le...

Page 48: ...A Cross the pull and push throttle cables B Fasten the catch tank hose and air induction hose air cut off valve rear of cylinder head onto the frame Locate the clamp end facing toward the lower side...

Page 49: ...directs as shown and lightly touches the projec tion on the brake caliper B Pass the brake hose into the brake hose holders C If the brake hose contacts the spring rear shock absorber correct its twis...

Page 50: ...2 24 CABLE ROUTING DIAGRAM 1 Clamp 2 Positive battery lead 3 Battery 4 Negative battery lead 5 Taillight coupler 6 CDI unit coupler 6 pin 7 CDI unit coupler 3 pin 8 CDI unit coupler 6 pin...

Page 51: ...s and taillight lead to the rear frame Locate the clamp end facing toward the upper side of the frame and cut off the tie end H Connect the negative battery lead to the battery negative ter minal I Co...

Page 52: ...in switch coupler 7 Wire harness 8 Headlight coupler 9 Hot starter cable 10 Multi function display bracket 11 Main switch 12 Upper bracket 13 Clutch switch coupler 14 Engine stop switch coupler 15 Mul...

Page 53: ...display bracket F Fasten the multi function display leads to the bracket Cut off the tie end G Secure the coupler by pushing it into the hole in the multi function display bracket H Secure the wire h...

Page 54: ...line Check fuel hoses for cracks or damage Replace if necessary 2 Spark plug Check condition Adjust gap and clean 3 Valve clearance Check and adjust valve clearance when en gine is cold 4 Air filter e...

Page 55: ...Every 1 year 6 Brake hoses Check for cracks or damage Replace Every 4 years 7 Wheels Check runout spoke tightness and for dam age Tighten spokes if necessary 8 Tires Check tread depth and for damage...

Page 56: ...eck operation Apply lithium soap based grease all purpose grease lightly 16 Front fork Check operation and for oil leakage Replace if necessary 17 Shock absorber assembly Check operation and for oil l...

Page 57: ...RING Inspect Check ring end gap Replace PISTON PIN Inspect Replace CYLINDER HEAD Inspect carbon deposits and eliminate them Inspect and clean Change gasket CYLINDER Inspect and clean Inspect score mar...

Page 58: ...ND BOLTS Retighten Refer to STARTING AND BREAK IN section in the CHAPTER 1 AIR FILTER Clean and lubricate Use foam air filter oil or equivalent oil Replace OIL FILTER Replace ENGINE GUARD Replace Brea...

Page 59: ...t lube and retighten Molybdenum disulfide grease SIDESTAND Lubricate Lithium base grease STEERING HEAD Inspect free play and retighten Clean and lube Lithium base grease Replace bearing TIRE WHEELS In...

Page 60: ...hain slack and alignment Check that the drive chain is lubricated properly P 3 22 23 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 26 27 Steer...

Page 61: ...name Q ty Remarks Turn the fuel cock to OFF Disconnect the fuel hose 1 Seat 1 2 Air scoop left and right 2 3 Bolt fuel tank 2 4 Fuel tank 1 5 Left side cover 1 Open the air filter case cover 6 Right s...

Page 62: ...3 9 ENGINE REMOVING THE SIDE COVER 1 Remove Bolt side cover Right side cover 1 Draw the side cover backward to re move it because its claw a is insert ed in the air filter case...

Page 63: ...ty Remarks Right side cover Refer to REMOVING THE SEAT FUEL TANK AND SIDE COVERS section 1 Bolt silencer clamp 1 Only loosening 2 Bolt silencer front 1 3 Bolt silencer rear 1 4 Collar 1 5 Silencer 1...

Page 64: ...harmful to the engine parts You may use distilled water if you can t get soft water 1 Place the machine on a level place and hold it in an upright po sition 2 Remove Radiator cap 3 Check Coolant leve...

Page 65: ...i fied pressure for 10 seconds Replace CHECKING THE COOLING SYSTEM 1 Inspect Coolant level 2 Attach Radiator cap tester 1 and adapt er 2 3 Apply the specified pressure Do not apply pressure more than...

Page 66: ...NG THE HOT STARTER LEVER FREE PLAY 1 Check Hot starter lever free play a Out of specification Adjust 2 Adjust Hot starter lever free play Hot starter lever free play adjust ment steps a Loosen the loc...

Page 67: ...L 1 Start the engine warm it up for several minutes and then turn off the engine and wait for five min utes 2 Place the machine on a level place and hold it up on upright po sition by placing the suit...

Page 68: ...2 b Check the O rings 3 if cracked or damaged replace them with a new one c Install the oil filter element and oil filter element cover 8 Install O ring 1 Oil strainer 2 Oil hose Bolt oil hose Oil hos...

Page 69: ...ct the en gine idling speed by bringing the sensing element c of the engine ta chometer close to the ignition coil 2 ADJUSTING THE VALVE CLEARANCE This section is intended for those who have basic kno...

Page 70: ...table The thickness a of each pad is indi cated in hundredths of millimeters on the pad upper surface d Round off the last digit of the in stalled pad number to the nearest increment EXAMPLE Installed...

Page 71: ...3 18 ENGINE INTAKE EXHAUST...

Page 72: ...Reservoir float front brake Protector rear brake 2 Bleed Brake fluid Air bleeding steps a Add proper brake fluid to the res ervoir b Install the diaphragm Be careful not to spill any fluid or allow t...

Page 73: ...ghten the locknut Adjust the pedal height between the maximum A and the mini mum B as shown In this ad justment the bolt 3 end b should protrude out of the threaded portion 4 but not be less than 2 mm...

Page 74: ...ke pad thickness a Out of specification Replace as a set 2 Replace Brake pad Brake pad replacement steps a Remove the protector 1 and pad pin plug 2 b Loosen the pad pin 3 c Remove the rear wheel 4 an...

Page 75: ...ot enter master cylinder when refilling Clean up spilled fluid immediate ly to avoid erosion of painted surfaces or plastic parts a Lower level A Front B Rear CHECKING THE SPROCKET 1 Inspect Sprocket...

Page 76: ...chain slack with the rear wheel in this tight chain position 3 Adjust Drive chain slack Drive chain slack adjustment steps a Loosen the axle nut 1 and lock nuts 2 b Adjust the drive chain slack by tur...

Page 77: ...TING THE FRONT FORK COMPRESSION DAMPING FORCE 1 Remove Rubber cap 2 Adjust Compression damping force By turning the adjuster 1 STANDARD POSITION This is the position which is back by the specific numb...

Page 78: ...ster past the minimum or maximum extent of adjustment The adjuster may be damaged ADJUSTING THE REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE 1 Adjust Low compression damping force By turning the...

Page 79: ...is low A tilted tire valve stem indicates that the tire slips off its position on the rim If the tire valve stem is found tilted the tire is considered to be slipping off its position Correct the tire...

Page 80: ...r tightening g Check the steering stem by turn ing it lock to lock If there is any binding remove the steering stem assembly and inspect the steer ing bearings h Install the washer 5 collar 6 upper br...

Page 81: ...ot 5 Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding por tion 8 Throttle cable end 9 Clutch cable end 10 Hot starter cable end A Use Yamaha cable lube or equivalent on these are...

Page 82: ...ghly caustic sulfuric acid There fore always follow these preven tive measures Wear protective eye gear when handling or working near batter ies Charge batteries in a well venti lated area Keep batter...

Page 83: ...ince it forces a high amperage current into the bat tery quickly and can cause bat tery overheating and battery plate damage If it is impossible to regulate the charging current on the battery charger...

Page 84: ...3 31 ELECTRICAL Charging method using a variable voltage charger...

Page 85: ...3 32 ELECTRICAL Charging method using a constant voltage charger...

Page 86: ...e rating other than that specified Im provising or using a fuse with the wrong amperage rating may cause extensive damage to the electrical system cause the starting and ig nition systems to malfuncti...

Page 87: ...t Refer to REMOVING THE SEAT FUEL TANK AND SIDE COV ERS section ADJUSTING THE HEADLIGHT BEAMS 1 Adjust Headlight beam vertically Adjusting steps a Turn the adjusting screw 1 in di rection a or b Headl...

Page 88: ...hen the engine is stopped or when riding at no load do not open and close the throttle un necessarily Otherwise too much fuel may be discharged starting may become difficult or the engine may not run...

Page 89: ...e throttle is 1 8 to 1 4 open A Idle B Fully open RELATIONSHIP WITH THROTTLE OPENING The flow of the fuel through the car buretor main system is controlled by the main jet and then it is further reg u...

Page 90: ...4MX 39 Lean 158 4MX 89 Pilot jet Size Part number 14948 Rich 50 4MX 07 48 4MX 06 STD 45 4MX 05 STD 42 4MX 04 Lean 40 4MX 03 Jet needle Size Part number 14916 Rich GDEPN 5UM BN GDEPP 5UM BP GDEPQ 5UM B...

Page 91: ...ered from the top Check that the accelerator pump operates smoothly except for rich mixture symp tom Rich mixture Raise jet needle clip position 1 groove up 1 4 3 4 throttle Hard breathing Lack of spe...

Page 92: ...uld be higher to prevent a flat tire FRONT FORK SETTING The front fork setting should be made depending on the rider s feeling of an actual run and the circuit conditions The front fork setting includ...

Page 93: ...aps 2 Use of stiff spring Change the rebound damping Turn in one or two clicks Change the compression damp ing Turn out one or two clicks Generally a stiff spring gives a stiff riding feeling Rebound...

Page 94: ...our preference 2 Use of stiff spring Set the soft spring for more re bound damping to compensate for its greater spring load Run with the rebound damping adjust er one or two clicks on the stiffer sid...

Page 95: ...mping Turn adjuster clockwise about 2 clicks to in crease damping Oil level oil amount Increase oil level by about 5 10 mm 0 2 0 4 in Spring Replace with stiff spring Stiff toward stroke end Oil level...

Page 96: ...avy and dragging Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Spring Replace with soft spring Poor road gripping Rebound damping Turn adjuster counterclockwise abo...

Page 97: ...or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage RADIATOR REMOVING THE RADIATOR Order Part name Q ty Remarks Drain the coolant Refer to CHECKING TH...

Page 98: ...5 2 RADIATOR 8 Catch tank hose 1 9 Right radiator 1 10 Radiator hose 2 1 11 Radiator hose 4 1 12 Radiator pipe 1 1 13 Catch tank breather hose 1 14 Catch tank 1 Order Part name Q ty Remarks...

Page 99: ...n the O ring 2 Install Catch tank hose 1 Radiator hose 2 2 Radiator hose 3 3 Radiator pipe 2 4 Radiator hose 5 5 Radiator hose 4 6 To right radiator 7 3 Install Right radiator 1 Bolt right radiator 2...

Page 100: ...lamp 2 2 Throttle position sensor lead coupler 1 3 Throttle cable cover 1 4 Throttle cable 2 5 Clamp air filter joint 1 Loosen the screw air filter joint 6 Clamp carburetor joint 1 Loosen the screws c...

Page 101: ...ttle shaft 1 4 Throttle valve 1 5 Needle holder 1 6 Jet needle 1 7 Accelerator pump cover 1 8 Spring 1 9 Diaphragm accelerator pump 1 10 Air cut valve cover 1 11 Spring air cut valve 1 12 Diaphragm ai...

Page 102: ...jet 1 21 Spacer 1 22 Pilot jet 1 23 Starter jet 1 24 Push rod 1 Pull the push rod 25 Throttle shaft assembly 1 26 Push rod link lever assembly 1 27 Main air jet 1 28 Pilot air jet 1 29 Cold starter p...

Page 103: ...EEDLE VALVE 1 Inspect Needle valve 1 Valve seat 2 Grooved wear a Replace Dust b Clean Filter c Clogged Clean CHECKING THE THROTTLE VALVE 1 Check Free movement Stick Repair or replace Insert the thrott...

Page 104: ...ean CHECKING THE AIR CUT VALVE 1 Inspect Diaphragm air cut valve 1 Spring air cut valve 2 Air cut valve cover 3 O ring 4 Tears diaphragm damage Re place ASSEMBLING THE CARBURETOR 1 Install Cold starte...

Page 105: ...to the float install them to the carbure tor Check the float for smooth move ment 12 Install For EUROPE Pilot screw 1 Spring 2 Washer 3 O ring 4 Note the following installation points a Turn in the p...

Page 106: ...th the same outer di ameter as the specified value a Fully turn in the accelerator pump adjusting screw 3 b Check that the link lever 4 has free play b by pushing lightly on it c Gradually turn out th...

Page 107: ...CHAPTER 3 7 Install Throttle cable cover 1 Bolt throttle cable cover 2 8 Install Throttle position sensor lead cou pler 1 Clamp 2 Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 9 Install Cla...

Page 108: ...Air cut off valve assembly 1 3 Air induction hose air cut off valve front of cyl inder head 1 4 Air induction pipe 1 5 Gasket 1 6 Air induction hose air cut off valve rear of cylin der head 1 7 Air i...

Page 109: ...of the vacuum pressure pump gauge set 1 When using vacuum on the pipe c take care not to exceed the specified value a From air filter b To cylinder head exhaust port c From cylinder head intake port A...

Page 110: ...Refer to REMOVING THE SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 3 Air cut off valve assembly Refer to AIR INDUCTION SYSTEM section 1 Spark plug 1 2 Cylinder head breather hose 1 3 Bolt cyl...

Page 111: ...haft end accessing screw 1 Refer to removal section 3 Timing chain tensioner cap bolt 1 Refer to removal section 4 Timing chain tensioner 1 Refer to removal section 5 Camshaft cap 2 Refer to removal s...

Page 112: ...cap 2 Clip Remove the bolts camshaft cap in a crisscross pattern working from the outside in The bolts camshaft cap must be removed evenly to prevent dam age to the cylinder head cam shafts or camshaf...

Page 113: ...decompression mechanism cam lever pin 2 projects from the camshaft CHECKING THE TIMING CHAIN TENSIONER 1 Check While pressing the tensioner rod lightly with fingers use a thin screwdriver 1 and wind...

Page 114: ...se a thin screwdriver and wind the tension er rod up fully clockwise b With the rod fully wound and the chain tensioner UP mark a fac ing upward install the gasket 1 and the timing chain tensioner 2 a...

Page 115: ...T PIPE AND SILENCER section in the CHAPTER 3 Radiator hose 1 Disconnect at cylinder head side Carburetor Refer to CARBURETOR section Air cut off valve assembly Refer to AIR INDUCTION SYSTEM section Ca...

Page 116: ...several times INSTALLING THE CYLINDER HEAD 1 Install Dowel pin 1 Cylinder head gasket 2 Timing chain guide exhaust side 3 Cylinder head 4 While pulling up the timing chain in stall the timing chain g...

Page 117: ...e Q ty Remarks Cylinder head Refer to CYLINDER HEAD section 1 Valve lifter 5 Refer to removal section 2 Adjusting pad 5 Refer to removal section 3 Valve cotter 10 Refer to removal section 4 Valve spri...

Page 118: ...to 100 C 212 F a Remove the valve guide using a valve guide remover 1 b Install the new valve guide using a valve guide remover 1 and valve guide installer 2 c After installing the valve guide bore t...

Page 119: ...e face should be lapped Lapping steps a Apply a coarse lapping compound to the valve face Do not let the compound enter the gap between the valve stem and the guide b Apply molybdenum disulfide oil to...

Page 120: ...g upward e Smaller pitch 3 Install Valve cotter While compressing the valve spring with a valve spring compressor 1 in stall the valve cotters 4 To secure the valve cotters onto the valve stem lightly...

Page 121: ...TON Order Part name Q ty Remarks Cylinder head Refer to CYLINDER HEAD section 1 Bolt cylinder 1 2 Cylinder 1 3 Piston pin clip 2 Refer to removal section 4 Piston pin 1 Refer to removal section 5 Pist...

Page 122: ...from the piston bottom edge d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with following formula f If out of specification replac...

Page 123: ...Lubricate the piston and piston rings liberally with engine oil 2 Position Top ring 2nd ring Oil ring Offset the piston ring end gaps as shown a Top ring end b 2nd ring end c Oil ring end upper d Oil...

Page 124: ...the lithium soap base grease on the O ring 3 Install Cylinder gasket 1 Cylinder 2 Install the cylinder with one hand while compressing the piston rings with the other hand Pass the timing chain 3 thro...

Page 125: ...E OIL section in the CHAPTER 3 Brake pedal Refer to ENGINE REMOVAL section Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Clutch spring 5 3 Pressure plate 1 4 Push rod 1 1 5 Circlip 1 6 Was...

Page 126: ...clutch boss 1 Refer to removal section 15 Lock washer 1 Refer to removal section 16 Clutch boss 1 Refer to removal section 17 Thrust washer 1 18 Primary driven gear 1 19 Push lever shaft 1 Order Part...

Page 127: ...sure at all four points CHECKING THE CLUTCH PLATES 1 Measure Clutch plate warpage Out of specification Replace clutch plate as a set Use a surface plate 1 and thick ness gauge 2 CHECKING THE PUSH LEVE...

Page 128: ...on plates alternately on the clutch boss starting with a friction plate and ending with a friction plate Use the friction plates 1 for the first and final while paying attention to the difference in s...

Page 129: ...5 33 CLUTCH 10 Install Dowel pin 1 Gasket clutch cover 2 11 Install Clutch cover 1 Bolt clutch cover Tighten the bolts in stage using a crisscross pattern Bolt clutch cover 10 Nm 1 0 m kg 7 2 ft lb...

Page 130: ...Refer to CHANGING THE COOLANT sec tion in the CHAPTER 3 Radiator hose 3 Disconnect at water pump side Exhaust pipe Refer to REMOVING THE EXHAUST PIPE AND SILENCER section in the CHAPTER 3 Brake pedal...

Page 131: ...ER ELEMENT AND WATER PUMP 9 Washer 1 Refer to removal section 10 Impeller shaft 1 Refer to removal section 11 Oil seal 2 Refer to removal section 12 Bearing 1 Refer to removal section Order Part name...

Page 132: ...damage Replace CHECKING THE BEARING 1 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace CHECKING THE OIL SEAL 1 Inspect Oil seal 1 Wear damage Replace INSTALLING THE OIL SEAL...

Page 133: ...act the crankcase cover when it is pulled 2 Install Oil hose 1 Bolt oil hose 2 3 Install Copper washer 1 Oil delivery pipe 2 Union bolt M8 3 Union bolt M10 4 INSTALLING THE WATER PUMP HOUSING 1 Instal...

Page 134: ...ELEMENT AND WA TER PUMP section Stator Refer to AC MAGNETO AND STARTER CLUTCH section 1 Nut primary drive gear 1 Refer to removal section 2 Nut balancer shaft driven gear 1 Refer to removal section 3...

Page 135: ...the center a of the balancer shaft weight along the line connect ing the centers of the crankshaft and balancer shaft 2 Install Balancer shaft driven gear 1 Install the balancer shaft driven gear ont...

Page 136: ...ankcase cover Refer to OIL FILTER ELEMENT AND WA TER PUMP section 1 Circlip 1 2 Washer 1 3 Oil pump drive gear 1 4 Oil pump assembly 1 5 Outer rotor 2 1 6 Circlip 1 7 Inner rotor 2 1 8 Dowel pin 1 9 O...

Page 137: ...THE OIL TANK Order Part name Q ty Remarks Drain the engine oil Refer to CHANGING THE ENGINE OIL section in the CHAPTER 3 1 Oil hose 2 1 2 Oil hose 1 1 3 Dowel pin 2 4 Oil tank breather hose 1 5 Oil t...

Page 138: ...tor 1 1 Apply the engine oil on the outer rotor 1 3 Install Oil pump cover 1 Screw oil pump cover 2 Dowel pin 3 Inner rotor 2 4 Circlip 5 Apply the engine oil on the inner ro tor 2 Fit the dowel pin i...

Page 139: ...ection 1 Kick idle gear 1 2 Kick shaft assembly 1 Refer to removal section 3 Spring guide 1 4 Torsion spring 1 5 Ratchet wheel 1 6 Kick gear 1 7 Kick shaft 1 8 Washer 1 9 Shift pedal 1 10 Shift shaft...

Page 140: ...5 44 KICK SHAFT AND SHIFT SHAFT 17 Pawl 2 18 Pawl pin 2 19 Spring 2 20 Bolt stopper lever 1 21 Stopper lever 1 22 Torsion spring 1 23 Segment 1 Refer to removal section Order Part name Q ty Remarks...

Page 141: ...move ment Unsmooth movement Replace Kick shaft 2 Wear damage Replace Spring 3 Broken Replace CHECKING THE KICK GEAR KICK IDLE GEAR AND RATCHET WHEEL 1 Inspect Kick gear 1 Kick idle gear 2 Ratchet whee...

Page 142: ...2 Torsion spring 3 Shift shaft 4 Apply the engine oil on the roller and shift shaft 2 Install Shift pedal Refer to AC MAGNETO AND STARTER CLUTCH section INSTALLING THE KICK SHAFT ASSEMBLY 1 Install K...

Page 143: ...lide the kick shaft assembly into the crankcase and make sure the kick shaft stopper a fits into the kick shaft ratchet wheel guide 5 Hook Torsion spring 1 Turn the torsion spring clockwise and hook i...

Page 144: ...PTER 3 Seat and fuel tank Refer to REMOVING THE SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 3 Disconnect the AC magneto lead 1 Shift pedal 1 2 Cover torque limiter 1 3 Torque limiter 1 Do no...

Page 145: ...5 Nm 6 5 m kg 47 ft lb loosen and retighten the rotor nut to 65 Nm 6 5 m kg 47 ft lb 12 Starter clutch 1 Refer to removal section 13 Bearing 1 14 Washer 1 15 Idle gear plate 1 16 Idle gear 1 17 Holder...

Page 146: ...CH 1 Check Starter clutch Damage wear Replace 2 Check Idle gear Starter clutch drive gear Pitting burrs chips roughness wear Replace the defective parts 3 Check Starter clutch operation a Install the...

Page 147: ...d While installing the starter clutch push in the projections a one by one on the clutch circumference Push in the starter clutch until it hits the rotor 7 Install Starter clutch assembly cover 1 To r...

Page 148: ...the lithium soap base grease on the O ring Install the cover idle gear 1 with its mark a facing upward 13 Connect AC magneto lead Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 14 Install Sh...

Page 149: ...SIDE COVERS section in the CHAPTER 3 Carburetor Refer to CARBURETOR section Exhaust pipe and silencer Refer to REMOVING THE EXHAUST PIPE AND SILENCER section in the CHAPTER 3 Air cut off valve assemb...

Page 150: ...1 4 Nut drive sprocket 1 Refer to removal section 5 Lock washer 1 Refer to removal section 6 Drive sprocket 1 Refer to removal section 7 Clip 1 8 Bolt brake pedal 1 9 Brake pedal 1 10 Upper engine br...

Page 151: ...t 4 Bolt lower engine bracket 5 Patch 6 Engine mounting bolt front 7 Upper engine bracket 8 Bolt upper engine bracket 9 Engine mounting bolt upper 10 Lower engine guard 11 Bolt lower engine guard 12 A...

Page 152: ...rocket guide 1 Drive chain sprocket cover 2 Screw drive chain sprocket cov er 3 INSTALLING THE NEUTRAL SWITCH 1 Install Spring 1 Pin 2 O ring 3 Neutral switch 4 Screw neutral switch 5 Apply the lithiu...

Page 153: ...ent Refer to KICK SHAFT AND SHIFT SHAFT section Stator Refer to AC MAGNETO AND STARTER CLUTCH section Balancer shaft Refer to BALANCER section 1 Timing chain guide intake side 1 2 Timing chain 1 3 Oil...

Page 154: ...CRANKCASE AND CRANKSHAFT 9 Right crankcase 1 Refer to removal section 10 Left crankcase 1 Refer to removal section 11 Oil strainer 1 12 Crankshaft 1 Refer to removal section Order Part name Q ty Rema...

Page 155: ...RANKCASE BEARING Order Part name Q ty Remarks Transmission Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section Shift cam and shift fork Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section 1 Oil...

Page 156: ...haft 1 Use the crankcase separating tool 2 Do not use a hammer to drive out the crankshaft REMOVING THE CRANKCASE BEARING 1 Remove Bearing 1 Remove the bearing from the crankcase by pressing its inner...

Page 157: ...center with one hand while turning the nut of the installing tool with the other Operate the installing tool un til the crankshaft bottoms against the bearing Before installing the crankshaft clean th...

Page 158: ...rankcase tightening bolts in stage using a crisscross pat tern 7 Install Oil delivery pipe 2 1 O ring 2 Bolt oil delivery pipe 2 3 Apply the lithium soap base grease on the Orings 8 Install Timing cha...

Page 159: ...Engine Refer to ENGINE REMOVAL section Separate the crankcase Refer to CRANKCASE AND CRANK SHAFT section 1 Main axle 1 Refer to removal section 2 Drive axle 1 Refer to removal section 3 Shift cam 1 R...

Page 160: ...eplace CHECKING THE SHIFT FORK SHIFT CAM AND SEGMENT 1 Inspect Shift fork 1 Wear damage scratches Re place 2 Inspect Shift cam 1 Segment 2 Wear damage Replace 3 Check Shift fork movement Unsmooth oper...

Page 161: ...careful attention to the crankcase oil seal lip 5 Install Shift fork 1 L 1 Shift fork 2 C 2 Shift fork 3 R 3 Shift cam 4 To main axle and drive axle Apply the molybdenum disulfide oil on the shift fo...

Page 162: ...ly by reference to this manual It may lead to servicing trouble and mechanical damage FRONT WHEEL AND REAR WHEEL REMOVING THE FRONT WHEEL Order Part name Q ty Remarks Hold the machine by placing the s...

Page 163: ...HANDLING NOTE 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 Refer to removal section 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 2 Refer t...

Page 164: ...ake disc deflection only rear brake disc Use the dial gauge 1 Out of specification Inspect wheel runout If wheel runout is in good condi tion replace the brake disc 2 Measure Brake disc thickness a Ou...

Page 165: ...the wheel axle 7 Install Nut wheel axle 1 8 Tighten Bolt axle holder 1 Before tightening the bolt fit the wheel axle to the axle holder by strok ing the front fork several times with the front brake a...

Page 166: ...e wheel 2 forward and install the drive chain 7 Install Left drive chain puller 1 Wheel axle 2 Install the left drive chain puller and insert the wheel axle from left side Apply the lithium soap base...

Page 167: ...ne Refer to HANDLING NOTE Drain the brake fluid Refer to removal section 1 Brake hose holder protector 2 2 Brake hose holder brake caliper 1 3 Union bolt 2 4 Brake hose 1 5 Pad pin plug 1 Remove when...

Page 168: ...e Refer to HANDLING NOTE Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section Drain the brake fluid Refer to removal section 1 Brake pedal 1 2 Brake master cylinder 1 3 Brake hose holder 2 4 Union b...

Page 169: ...der Part name Q ty Remarks A Front B Rear A B 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Brake caliper piston 2 1 Refer to removal section 5 Brake caliper piston dust seal 2 1 Refer to removal...

Page 170: ...E MASTER CYLINDER Order Part name Q ty Remarks A Front B Rear 1 Brake master cylinder cap 1 2 Diaphragm 1 3 Reservoir float 1 4 Brake master cylinder boot 1 5 Circlip 1 Use a long nose circlip pliers...

Page 171: ...ion when expelling piston from cylinder Never attempt to pry out piston Caliper piston removal steps a Insert a piece of rag into the brake caliper to lock one brake caliper b Carefully force the pist...

Page 172: ...nal parts should be lubricat ed with brake fluid when in stalled Replace the brake caliper piston seals and brake caliper piston dust seals whenever a caliper is disassembled INSTALLING THE BRAKE CALI...

Page 173: ...er cylinder kit Clean them with brake fluid 2 Install Brake master cylinder cup prima ry 1 Brake master cylinder cup sec ondary 2 To brake master cylinder piston 3 Apply the brake fluid on the brake m...

Page 174: ...washer 1 Brake hose 2 Union bolt 3 Always use new copper washers Install the brake hose so that its pipe portion a directs as shown and lightly touches the projection b on the brake master cylinder 2...

Page 175: ...ll the brake hose so that it contacts the brake master cylinder projection a and that its bent portion b faces downward INSTALLING THE REAR BRAKE HOSE 1 Install Copper washer 1 Brake hose 2 Union bolt...

Page 176: ...n up spilled fluid immediately A Front B Rear 2 Air bleed Brake system Refer to BLEEDING THE HY DRAULIC BRAKE SYSTEM sec tion in the CHAPTER 3 3 Inspect Brake fluid level Fluid at lower level Fill up...

Page 177: ...HANDLING NOTE Front wheel Refer to FRONT WHEEL AND REAR WHEEL section Front brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Headlight Handlebar Refer to HANDLEBAR section 1 Protector 1 2 Pi...

Page 178: ...spring 1 Drain the fork oil 3 Dust seal 1 Refer to removal section 4 Stopper ring 1 Refer to removal section 5 Inner tube 1 Refer to removal section 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 O...

Page 179: ...front fork cap bolt REMOVING THE INNER TUBE 1 Remove Dust seal 1 Stopper ring 2 Using slotted head screwdriver Take care not to scratch the inner tube 2 Remove Inner tube 1 Oil seal removal steps a Pu...

Page 180: ...ube is held ver tically the damper rod may fall into it damaging the valve inside 3 Install Copper washer 1 O ring 2 Base valve 3 To inner tube 4 4 Tighten Base valve 1 Use a damper rod holder 2 to lo...

Page 181: ...15 Fill Front fork oil Until outer tube top surface with recommended fork oil 1 Be sure to use recommended fork oil If other oils are used they may have an excessively ad verse effect on the front fo...

Page 182: ...oosen Rebound damping adjuster 1 Loosen the rebound damping ad juster finger tight Record the set position of the ad juster the amount of turning out the fully turned in position 23 Install Push rod 1...

Page 183: ...sor lead so that its paint a directs as shown and align the bottom b of the plate 1 with the same paint 6 Install Speed sensor lead 1 Plate 2 2 Screw plate 2 3 To right protector 4 Install the plate 2...

Page 184: ...Engine stop switch 1 Disconnect the engine stop switch lead 6 Brake master cylinder 1 Refer to removal section 7 Start switch 1 Disconnect the start switch lead 8 Throttle cable cap 1 9 Throttle cable...

Page 185: ...older Installing the handlebar lower hold er in the reverse direction allows the front to rear offset amount of the handlebar position to be changed Do not tighten the nut yet 2 Install Handlebar 1 Ha...

Page 186: ...othly If it does not retighten the bolts for adjustment 9 Install Grip cap cover 1 Cover throttle cable cap 2 10 Install Start switch 1 Brake master cylinder 2 Brake master cylinder bracket 3 Bolt bra...

Page 187: ...of the clutch lever hold er 12 Install Clutch cable 1 Hot starter cable 2 Apply the lithium soap base grease on the clutch cable end and hot start er cable end 13 Adjust Clutch lever free play Refer...

Page 188: ...placing the suitable stand under the engine Refer to HANDLING NOTE Headlight Handlebar Refer to HANDLEBAR section Front brake hose guide Front fender 1 Multi function display 1 2 Multi function displa...

Page 189: ...6 28 STEERING 9 Bearing race cover 1 10 Upper bearing 1 11 Lower bearing 1 Refer to removal section 12 Bearing race 2 Refer to removal section Order Part name Q ty Remarks...

Page 190: ...place bear ings and bearing races as a set Install the bearing in the bearing races Spin the bearings by hand If the bearings hang up or are not smooth in their operation in the bearing races replace...

Page 191: ...by lit tle 11 Adjust Front fork top end a 12 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 Tighten the lower bracket to speci fied torque If torqued too much it may cause the front for...

Page 192: ...NG NOTE Brake hose holder Refer to FRONT BRAKE AND REAR BRAKE section Rear brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Bolt brake pedal Shift the brake pedal backward Drive chain 1 Drive...

Page 193: ...MBLING THE SWINGARM Order Part name Q ty Remarks 1 Cap 2 Refer to removal section 2 Relay arm 1 3 Connecting rod 1 4 Collar 2 5 Oil seal 2 6 Thrust bearing 2 7 Bushing 2 8 Oil seal 8 9 Bearing 10 Refe...

Page 194: ...1 Collar 2 Free play exists unsmooth revolu tion rust Replace bearing and collar as a set 2 Inspect Oil seal 3 Damage Replace INSTALLING THE BEARING AND OIL SEAL 1 Install Bearing 1 Oil seal 2 To swin...

Page 195: ...bolt 5 Install Relay arm 1 Bolt relay arm 2 Washer 3 Nut relay arm 4 To swingarm Apply the molybdenum disulfide grease on the bolt circumference and threaded portion Do not tighten the nut yet 6 Insta...

Page 196: ...chain tensioner 5 14 Install Drive chain support 1 Drive chain support cover 2 Bolt drive chain support L 50 mm 1 97 in 3 Nut drive chain support 4 Bolt drive chain support cover L 10 mm 0 39 in 5 Nu...

Page 197: ...ection in the CHAPTER 3 Drain the coolant Refer to CHANGING THE COOLANT sec tion in the CHAPTER 3 Catch tank breather hose Disconnect at the catch tank side Catch tank hose Disconnect at the catch tan...

Page 198: ...ar frame 1 7 Bolt rear shock absorber relay arm 1 Hold the swingarm 8 Bolt rear shock absorber frame 1 9 Rear shock absorber 1 10 Locknut 1 Only loosening 11 Adjuster 1 Only loosening 12 Lower spring...

Page 199: ...disposal NOTES ON DISPOSAL YAMAHA DEALERS ONLY Before disposing the rear shock ab sorber be sure to extract the nitrogen gas from valve 1 Wear eye protec tion to prevent eye damage from es caping gas...

Page 200: ...al lips and col lars Apply the lithium soap base grease on the O rings 2 Install Bushing 1 Collar 2 Dust seal 3 Apply the molybdenum disulfide grease on the bearing and dust seal lips Install the dust...

Page 201: ...6 40 REAR SHOCK ABSORBER 7 Tighten Screw air filter joint 1 8 Install Plastic band Taillight coupler Locking tie Screw air filter joint 3 Nm 0 3 m kg 2 2 ft lb...

Page 202: ...y or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS 1 Headlight 2 Multi function disp...

Page 203: ...12 Taillight 13 Neutral switch 14 Starter motor 15 AC magneto 16 Rectifier regulator 17 Ignition coil 18 Spark plug 19 Start switch 20 Main switch 21 Speed sensor 22 Battery 1 For USA CDN and EUROPE 2...

Page 204: ...se the following special tools in this inspection 1 Check fuse No good Replace fuse and check wire harness OK 2 Check battery No good Recharge or replace OK Spark gap test Spark 3 Clean or replace spa...

Page 205: ...ile it is freed Re place Set the tester selection position to 1 2 Inspect Rubber part a Tears damage Replace CHECKING THE MAIN SWITCH 1 Inspect Main switch conduction Not conductive while the main swi...

Page 206: ...sed The clutch lever is pulled to the han dlebar the clutch switch is closed The starting circuit cut off relay pre vents the starter motor from operating when neither of these conditions has been met...

Page 207: ...2 V battery in this inspection Use the following special tools in this inspection 1 Check fuse No good Replace fuse and check wire harness OK 2 Check battery No good Recharge or replace OK Check each...

Page 208: ...battery is connected Replace Conductive while the battery is not connected Replace Set the tester selection position to 1 CHECKING THE CLUTCH SWITCH 1 Inspect Clutch switch conduction Not conductive w...

Page 209: ...conduction Not conductive while it is pushed Replace Conductive while it is freed Re place Set the tester selection position to 1 2 Inspect Rubber part a Tears damage Replace Tester lead Black lead 1...

Page 210: ...7 9 ELECTRIC STARTING SYSTEM REMOVING THE STARTER MOTOR Order Part name Q ty Remarks Exhaust pipe Refer to REMOVING THE EXHAUST PIPE AND SILENCER section in the CHAPTER 3 1 Starter motor 1...

Page 211: ...SEMBLING THE STARTER MOTOR Order Part name Q ty Remarks 1 Starter motor front cover 1 2 Washer starter motor front cover 1 3 Gasket 2 4 Starter motor yoke 1 5 Armature assembly 1 6 Starter motor rear...

Page 212: ...e brushes as a set 6 Measure Brush spring force Out of specification Replace the brush springs as a set ASSEMBLING THE STARTER MOTOR 1 Install Brush spring 1 Brush 2 2 Install Armature assembly 1 Inst...

Page 213: ...the projec tions on the washer with the slots in the front cover Align the match mark a on the starter motor yoke with the match mark b on the starter motor front cover 5 Install Gasket Bolt 1 O ring...

Page 214: ...move the following parts before inspection 1 Seat 2 Fuel tank Use the following special tools in this inspection 1 Check fuse No good Replace fuse and check wire harness OK 2 Check battery No good Rec...

Page 215: ...ut of specification If no failure is found in checking the source coil resistance replace the rectifi er regulator 3 Inspect Charging coil resistance Out of specification Replace Tester lead Red lead...

Page 216: ...he following inspection steps Use the following special tools in this inspection Check entire ignition system for connection No good Repair or replace OK Check throttle position sensor Throttle positi...

Page 217: ...tion sensor using the T25 bit 3 Replace Throttle position sensor 4 Install Throttle position sensor 1 Screw throttle position sensor 2 Align the slot a in the throttle posi tion sensor with the projec...

Page 218: ...1 Stop the engine 12 Remove the carburetor 13 Tighten Screw throttle position sensor 1 Tighten the screw throttle position sensor using the T25 bit 14 Install the carburetor CHECKING THE THROTTLE POSI...

Page 219: ...ollowing special tools in this inspection Check the bulb and bulb socket No good Replace the bulb and or bulb socket OK Check the taillight LEDs No good Replace the taillight assembly OK Check the AC...

Page 220: ...ble gas or fluid is in the vicinity CHECKING THE AC MAGNETO 1 Inspect Lighting coil resistance Out of specification Replace CHECKING THE RECTIFIER REGULATOR 1 Connect the battery leads 2 Start the eng...

Page 221: ...s before inspection 1 Headlight Use the following special tools in this inspection 1 Check battery No good Recharge or replace OK Check each coupler and wire connection No good Repair or replace OK Ch...

Page 222: ...SENSOR OUTPUT VOLTAGE 1 Insert the thin electric conductors 1 lead into the speed sensor coupler 2 as shown and con nect the tester to them Do not insert the electric conduc tors more than required b...

Page 223: ......

Page 224: ...PRINTED IN JAPAN E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN...

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