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Owner'S Service Manual

Yamaha WR250FR 2002, Owner'S Service Manual

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CHAS

FRONT BRAKE AND REAR BRAKE

2. Air bleed:

• Brake system

Refer to “BRAKE SYSTEM AIR BLEED-
ING” section in the CHAPTER 3.

3. Inspect:

• Brake fluid level

Fluid at lower level

→

Fill up.

Refer to “BRAKE FLUID LEVEL INSPEC-
TION” section in the CHAPTER 3.

4. Install:

[Front]
• Diaphragm
• Brake master cylinder cap

1

• Screw (brake master cylinder cap)

2

[Rear]
• Diaphragm
• Brake master cylinder cap

1

• Bolt (brake master cylinder cap)

2

CAUTION:

After installation, while pulling the brake
lever in or pushing down on the brake
pedal, check whether there is any brake
fluid leaking where the union bolts are
installed respectively at the brake master
cylinder and brake caliper.

È

Front

É

Rear

T

R

.

.

2 Nm (0.2 m · kg, 1.4 ft · lb)

T

R

.

.

2 Nm (0.2 m · kg, 1.4 ft · lb)

È

É

5. Install: (rear brake only)

• Protector

1

• Bolt (protector)

2

T

R

.

.

7 Nm (0.7 m · kg, 5.1 ft · lb)

www.PlanDeGraissage.org

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Summary of Contents for WR250FR 2002

Page 1: ...LIT 11626 16 48 WR250FR 5UM 28199 10 OWNER S SERVICE MANUAL www PlanDeGraissage org...

Page 2: ...www PlanDeGraissage org...

Page 3: ...r Corporation U S A 1st Edition November 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in...

Page 4: ...t your Yamaha dealer NOTE As improvements are made on this model some data in this manual may become out dated If you have any questions please con sult your Yamaha dealer WARNING PLEASE READ THIS MAN...

Page 5: ...www PlanDeGraissage org...

Page 6: ...APPAREL When operating this machine always wear an approved helmet with gog gles or a face shield Also wear heavy boots gloves and protective cloth ing Always wear proper fitting cloth ing that will n...

Page 7: ...xide is a danger ous gas which can cause unconsciousness or can be lethal 8 PARK THE MACHINE CAREFULLY TURN OFF THE ENGINE Always turn off the engine if you are going to leave the machine Do not park...

Page 8: ...nd should remain with it even if the machine is subsequently sold EC060000 NOTICE Some data in this manual may become out dated due to improvements made to this model in the future If there is any que...

Page 9: ...to the machine NOTE A NOTE provides key information to make pro cedures easier or clearer WARNING CAUTION EC082000 FINDING THE REQUIRED PAGE 1 This manual consists of seven chapters General informati...

Page 10: ...h removal and disassembly section 1 An easy to see exploded diagram 1 is provided for removal and disassembly jobs 2 Numbers 2 are given in the order of the jobs in the exploded diagram A number that...

Page 11: ...ightening C Specified value Service limit D Resistance Voltage V Electric current A Illustrated symbols E to H in the exploded diagrams indicate grade of lubricant and loca tion of lubrication point E...

Page 12: ...MEMO www PlanDeGraissage org...

Page 13: ...EC090000 INDEX GENERAL INFORMATION 1 SPECIFICATIONS SPEC 2 REGULAR INSPECTION AND ADJUSTMENTS 3 ENGINE ENG 4 CHASSIS CHAS 5 ELECTRICAL ELEC 6 TUNING TUN 7 GEN INFO INSP ADJ www PlanDeGraissage org...

Page 14: ...AK IN 1 15 TORQUE CHECK POINTS 1 19 CLEANING AND STORAGE 1 20 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 GENERAL TORQUE SPECIFICATIONS 2 19 DEFINITION OF UNITS...

Page 15: ...MENT WATER PUMP AND RIGHT CRANKCASE COVER 4 57 BALANCER 4 64 OIL PUMP 4 67 KICK SHAFT AND SHIFT SHAFT 4 72 AC MAGNETO AND STARTER CLUTCH 4 79 ENGINE REMOVAL 4 86 CRANKCASE AND CRANKSHAFT 4 92 TRANSMIS...

Page 16: ...AND WIRING DIAGRAM 6 1 MAP CONTROLLED CDI UNIT 6 2 IGNITION SYSTEM 6 3 ELECTRIC STARTING SYSTEM 6 8 CHARGING SYSTEM 6 17 THROTTLE POSITION SENSOR SYSTEM 6 19 LIGHTING SYSTEM 6 24 CHAPTER 7 TUNING ENGI...

Page 17: ...B Taillight C Kickstarter crank D Fuel tank E Headlight F Radiator G Coolant drain bolt H Rear brake pedal I Valve joint J Fuel cock K Cold starter knob L Air cleaner M Drive chain N Shift pedal O Oi...

Page 18: ...the authorities will need the number to search for and identify your machine EC121001 VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped on the right of the steering head pip...

Page 19: ...cylinder head right side All electrical components 2 Use proper tools and cleaning equipment Refer to SPECIAL TOOLS section 3 When disassembling the machine keep mated parts together They include gear...

Page 20: ...K WASHERS PLATES AND COTTER PINS 1 All lock washers plates 1 and cotter pins must be replaced when they are removed Lock tab s should be bent along the bolt or nut flat s after the bolt or nut has bee...

Page 21: ...ected carefully before reassembly Always replace piston pin clips after one use Replace distorted circlips When installing a circlip 1 make sure that the sharp edged corner 2 is posi tioned opposite t...

Page 22: ...it will not come off 5 If the terminal comes off bend up the pin 1 and reinsert the terminal into the con nector 6 Connect Connector NOTE The two connectors click together 7 Check for continuity with...

Page 23: ...crankshaft from either case YU 3097 90890 01252 YU 1256 Dial gauge and stand Stand These tools are used to check each part for runout or bent YU 90050 90890 01274 YU 90050 90890 01275 YM 91044 90890 0...

Page 24: ...ll the valve assemblies YM 91042 90890 04086 Clutch holding tool This tool is used to hold the clutch when removing or installing the clutch boss securing nut YM 4111 90890 04111 YM 4116 90890 04116 V...

Page 25: ...87 90890 06754 Dynamic spark tester Ignition checker This instrument is necessary for checking the ignition system components ACC QUICK GS KT 90890 85505 Quick gasket YAMAHA Bond No 1215 This sealant...

Page 26: ...switch ON It goes out when the engine increases its speed after being started It lights up again when the engine is stopped NOTE If the indicator light will not light up with the main switch ON it sh...

Page 27: ...NK Rotate the kickstarter crank 1 away from the engine Push the starter down lightly with your foot until the gears engage then kick smoothly and forcefully to start the engine This model has a primar...

Page 28: ...the fuel tank after the main supply of the fuel has been depleted Normal riding is possible with the lever is in this position but it is recommended to add fuel as soon as possible COLD STARTER KNOB...

Page 29: ...g out and is installed to the fuel tank breather hose CAUTION In this installation make sure the arrow faces the fuel tank and also downward SPARK PLUG WRENCH This spark plug wrench 1 is used to remov...

Page 30: ...xhaust system etc NOTE If knocking or pinging occurs use a different brand of gasoline or higher octane grade WARNING For refueling be sure to stop the engine and use enough care not to spill any fuel...

Page 31: ...machine perform the checks in the pre operation check list AIR FILTER MAINTENANCE According to AIR FILTER CLEANING section in the CHAPTER 3 apply the foam air filter oil or its equivalent to the elem...

Page 32: ...rt switch stop pushing it immediately and kick start the engine in order to avoid the load on the motor Do not open the throttle while kicking the kickstarter crank Otherwise the kick starter crank ma...

Page 33: ...ever kick the kickstarter crank 10 to 20 times to clear the engine Then restart the engine Refer to Restarting an engine after a fall Operate the throttle grip before kick starting CAUTION Observe the...

Page 34: ...ut one hour 6 Restart the engine and check the operation of the machine throughout its entire operat ing range Restart the machine and oper ate it for about 10 to 15 more minutes The machine will now...

Page 35: ...r bracket Upper bracket to handlebar Front fork to upper bracket Front fork to lower bracket Assembly of links Link to frame Link to rear shock absorber Link to swingarm Rear shock absorber to frame T...

Page 36: ...bear ings front forks brakes and transmission seals Many expensive repair bills have resulted from improper high pressure detergent applications such as those avail able in coin operated car washers...

Page 37: ...in kick the engine over several times to coat the cylinder walls with oil 3 Remove the drive chain clean it thoroughly with solvent and lubricate it Reinstall the chain or store it in a plastic bag t...

Page 38: ...ed 4 stroke DOHC Cylinder arrangement Single cylinder forward inclined Displacement 249 cm3 8 76 Imp oz 8 42 US oz Bore stroke 77 0 53 6 mm 3 03 2 11 in Compression ratio 12 5 1 Starting system Kick a...

Page 39: ...Type manufacturer CR8E NGK resistance type Gap 0 7 0 8 mm 0 028 0 031 in Clutch type Wet multiple disc Transmission Primary reduction system Gear Primary reduction ratio 57 17 3 353 Secondary reducti...

Page 40: ...ension Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring gas oil damper Wheel travel Front wheel travel 300 mm 11 8 in Rear wheel travel 315 mm 12 4 in Electri...

Page 41: ...er 22 000 22 021 mm 0 8661 0 8670 in Camshaft outside diameter 21 967 21 980 mm 0 8648 0 8654 in Shaft to cap clearance 0 020 0 054 mm 0 0008 0 0021 in 0 08 mm 0 003 in Cam dimensions Intake A 30 296...

Page 42: ...0 0354 0 0433 in 1 6 mm 0 0630 in EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D margin thickness IN 0 8 mm 0 0315 in EX 0 7 mm 0 0276 in Stem outside diameter IN 3 975 3 990 mm 0 1565 0 1571 in 3...

Page 43: ...ompressed force installed IN 99 114 N at 29 13 mm 9 9 11 4 kg at 29 13 mm 22 27 25 57 lb at 1 15 in EX 126 144 N at 29 30 mm 12 6 14 4 kg at 29 30 mm 28 44 32 41 lb at 1 15 in Tilt limit IN 2 5 1 7 mm...

Page 44: ...in 0 12 mm 0 005 in 2nd ring Type Taper Dimensions B T 0 80 2 75 mm 0 03 0 11 in End gap installed 0 30 0 45 mm 0 012 0 018 in 0 80 mm 0 031 in Side clearance 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0...

Page 45: ...drum and guide bar Guide bar bending limit 0 05 mm 0 002 in Kickstarter Type Kick and ratchet type Carburetor USA EUROPE CDN ZA AUS NZ Type manufacturer FCR MX37 KEIHIN I D mark 5UM1 00 5UM2 10 Main...

Page 46: ...0035 0 0067 in 0 24 mm 0 009 in Housing and rotor clearance 0 03 0 10 mm 0 0012 0 0039 in 0 17 mm 0 0067 in Cooling Radiator core size Width 117 8 mm 4 6 in Height 220 mm 8 7 in Thickness 32 mm 1 26 i...

Page 47: ...pump housing M6 1 0 4 10 1 0 7 2 Radiator M6 1 0 6 10 1 0 7 2 Radiator guard M6 1 0 2 10 1 0 7 2 Radiator pipe M6 1 0 1 10 1 0 7 2 Oil pump cover M4 0 7 1 2 0 2 1 4 Oil pump M6 1 0 3 10 1 0 7 2 Oil f...

Page 48: ...0 7 2 Right crankcase cover M6 1 0 8 10 1 0 7 2 Clutch cover M6 1 0 7 10 1 0 7 2 Crankcase oil drain bolt M10 1 25 1 20 2 0 14 Drive chain sprocket cover M6 1 0 2 8 0 8 5 8 Kick shaft ratchet wheel gu...

Page 49: ...125 mm 4 92 in Min Max From top of outer tube with inner tube and damper rod fully com pressed without spring 80 150 mm 3 15 5 91 in Oil grade Suspension oil 01 Inner tube outer diameter 46 mm 1 81 i...

Page 50: ...10 in Pad thickness 4 4 mm 0 17 in 1 0 mm 0 04 in Master cylinder inside dia 11 0 mm 0 433 in Caliper cylinder inside dia 27 0 mm 1 063 in 2 Brake fluid type DOT 4 Rear disc brake Disc outside dia Thi...

Page 51: ...0 7 5 1 Throttle grip cap M5 0 8 2 4 0 4 2 9 Front brake master cylinder M6 1 0 2 9 0 9 6 5 Brake lever mounting bolt M6 1 0 1 6 0 6 4 3 Brake lever mounting nut M6 1 0 1 6 0 6 4 3 Brake lever positio...

Page 52: ...8 Rear shock absorber and frame M10 1 25 1 56 5 6 40 Rear shock absorber and relay arm M10 1 25 1 53 5 3 38 Rear frame upper M8 1 25 1 32 3 2 23 Rear frame lower M8 1 25 2 29 2 9 21 Swingarm and brake...

Page 53: ...M6 1 0 2 10 1 0 7 2 Headlight lower M6 1 0 1 7 0 7 5 1 Taillight M6 1 0 3 4 0 4 2 9 Taillight lead clamp and rear fender M4 1 59 2 0 5 0 05 0 36 Coolant reservoir M6 1 0 2 7 0 7 5 1 Sidestand bracket...

Page 54: ...oil resistance color 0 288 0 432 at 20 C 68 F White Ground Lighting coil resistance color 0 224 0 336 at 20 C 68 F Yellow Ground Rectifier regulator Regulator type Semiconductor short circuit Model ma...

Page 55: ...69 92 51 at 20 C 68 F Fuse amperage quantity Main fuse 10 A 1 Reserve fuse 10 A 1 Part to be tightened Thread size Q ty Tightening torque Nm m kg ft lb Stator M5 0 8 2 7 0 7 5 1 Holder AC magneto lea...

Page 56: ...between flats B Outside thread diameter EC230000 DEFINITION OF UNITS A Nut B Bolt TORQUE SPECIFICATION Nm m kg ft lb 10 mm 12 mm 14 mm 17 mm 19 mm 22 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 6 15 30 55 85...

Page 57: ...tion sensor lead 8 Neutral switch lead 9 Oil hose 0 Hose guide A AC magneto lead B Cylinder head breather hose C Starter motor lead D Clutch cable E Radiator hose 1 F Radiator pipe radiator hose 4 G C...

Page 58: ...the diode at its white tape and the rectifier regula tor lead at its protecting tube Fasten the wire harness starter motor lead and negative battery lead so that the plastic locking tie ends do not co...

Page 59: ...rottle position sensor lead Pass the carburetor breather hoses carburetor overflow hose and coolant reservoir breather hose between the connecting rod and cross tube frame Fasten the neutral switch le...

Page 60: ...the wire harness on the outside of the neu tral switch lead and AC magneto lead Fit the brake hose into the guides on the protector Pass the wire harness clutch cable and light switch lead through th...

Page 61: ...CDI unit lead B CDI unit C CDI unit band D CDI unit stay E Rectifier regulator bracket Pass the throttle cables and hot starter cable through the cable guides Pass the throttle cables and hot starter...

Page 62: ...nd carburetor breather hoses together Fasten the CDI unit lead Insert the CDI unit band over the CDI unit stay as far as possible Fasten the rectifier regulator lead to the rectifier regulator bracket...

Page 63: ...s as shown and lightly touches the projection on the brake caliper Pass the brake hose into the brake hose holders If the brake hose contacts the spring rear shock absorber correct its twist Install t...

Page 64: ...ry Position the starter motor lead negative battery lead and wire harness in the tank damper slit Fasten the wire harness Do not allow the taillight lead to slacken Fasten the coolant reservoir breath...

Page 65: ...ch E Start switch lead Fasten the start switch lead and light switch lead Fasten the engine stop switch lead and clutch switch lead Pass the brake hose through the hose guide Pass the start switch lea...

Page 66: ...d Check the valve seats and valve stems for wear Inspect Replace VALVE SPRINGS Inspect Check the free length and the tilt Replace VALVE LIFTERS Inspect Check for scratches and wear Replace CAMSHAFTS I...

Page 67: ...ation Replace coolant Every two years Inspect hoses OUTSIDE NUTS AND BOLTS Refer to STARTING AND BREAK IN section in the CHAPTER 1 Retighten AIR FILTER Clean and lubricate Use foam air filter oil or e...

Page 68: ...TEERING HEAD Inspect free play and retighten Clean and lube Lithium base grease Replace bearing TIRE WHEELS Inspect air pressure wheel run out tire wear and spoke looseness Retighten sprocket bolt Ins...

Page 69: ...ain slack and alignment Check that the drive chain is lubricated properly P 3 32 35 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 43 44 Steeri...

Page 70: ...d water or salt water is 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 position 2 Inspect Coolant l...

Page 71: ...voir hose 1 Drain the coolant completely 4 Connect Coolant reservoir hose LOW FULL COOLANT 1 5 Remove Engine guard 1 Coolant drain bolt 2 6 Remove Radiator cap Drain the coolant completely 7 Clean Coo...

Page 72: ...ter 2 mixing ratio 50 50 Coolant capacity 1 3 L 1 14 Imp qt 1 37 US qt Handling notes of coolant The coolant is harmful so it should be han dled with special care WARNING When coolant splashes to your...

Page 73: ...checking the coolant level wait a few minutes until the coolant settles EC355000 RADIATOR CAP INSPECTION 1 Inspect Seal radiator cap 1 Valve and valve seat 2 Crack damage Replace Exist fur deposits 3...

Page 74: ...OTE Do not apply pressure more than specified pressure Radiator should be filled fully Radiator cap tester YU 24460 01 90890 01325 Radiator cap tester adapter YU 33984 90890 01352 Standard pressure 18...

Page 75: ...grip free play a Out of specification Adjust Throttle grip free play a 3 5 mm 0 12 0 20 in 2 Adjust Throttle grip free play Throttle grip free play adjustment steps Slide the adjuster cover Loosen the...

Page 76: ...p cap Cover throttle cable cap T R 4 Nm 0 4 m kg 2 9 ft lb HOT STARTER LEVER ADJUSTMENT 1 Check Hot starter lever free play a Out of specification Adjust 2 Adjust Hot starter lever free play NOTE Afte...

Page 77: ...t to enter the engine and cause rapid wear and possible engine damage 1 Remove Air filter case cover 1 NOTE Loosen the quick screw 2 and draw the air fil ter case cover to remove it because its claws...

Page 78: ...on the element surface using a clean dry cloth Excess oil in the ele ment may adversely affect engine starting 7 Install Filter guide 1 NOTE Align the projection a on filter guide with the hole b in a...

Page 79: ...s low Add oil to proper level NOTE When inspecting the oil level do not screw the oil tank cap into the oil tank Insert the gauge lightly For USA and CDN CAUTION Do not add any chemical additives Engi...

Page 80: ...utes until the oil settles before inspecting the oil level ENGINE OIL REPLACEMENT 1 Start the engine and warm it up for several minutes and then turn off the engine and wait for five minute 2 Place th...

Page 81: ...Oil hose 3 Oil strainer frame 4 6 Inspect Oil strainer frame Clogged Blow 7 If the oil filter is to be replaced during this oil change remove the following parts and reinstall them Replacement steps R...

Page 82: ...12 Install Oil tank cap 13 Check Engine oil level T R 70 Nm 7 0 m kg 50 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb T R 2 Nm 0 2 m kg 1 4 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb T R 20...

Page 83: ...ure check bolt T R Oil pressure check bolt 10 Nm 1 0 m kg 7 2 ft lb PILOT SCREW ADJUSTMENT 1 Adjust Pilot screw 1 Except for USA Adjustment steps NOTE To optimize the fuel flow at a smaller throttle o...

Page 84: ...crease idle speed Turn the throt tle stop screw 1 in a To decrease idle speed Turn the throt tle stop screw 1 out b Inductive tachometer YU 8036 B Engine tachometer 90890 03113 Engine idling speed 1 9...

Page 85: ...e Out of specification Adjust Valve clearance cold Intake valve 0 10 0 15 mm 0 0039 0 0059 in Exhaust valve 0 17 0 22 mm 0 0067 0 0087 in Checking steps Turn the crankshaft counterclockwise with a wre...

Page 86: ...AFTS section in the CHAPTER 4 Remove the valve lifters 1 and the pads 2 NOTE Place a rag in the timing chain space to prevent pads from falling into the crank case Identity each valve lifter and pad p...

Page 87: ...value and the mea sured valve clearance in the chart PAD SELECTION TABLE The field where these two coordinates intersect shows the new pad number to use NOTE Use the new pad number only as a guide wh...

Page 88: ...1 26 1 30 235 240 1 31 1 35 240 MEASURED CLEARANCE INSTALLED PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 04 120 125 130 135 1...

Page 89: ...Bolt spark arrester 1 1 1 2 Remove Spark arrester 1 Pull the spark arrester out of the muffler 1 3 Clean Spark arrester Tap the spark arrester lightly then use a wire brush to remove any carbon depos...

Page 90: ...ragm 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 con tainer e...

Page 91: ...brake after bleeding the brake system EC362040 FRONT BRAKE ADJUSTMENT 1 Check Brake lever position a 2 Remove Brake lever cover 3 Adjust Brake lever position 4 Install Brake lever cover Brake lever po...

Page 92: ...knut WARNING Adjust the pedal height between the maximum and the minimum as shown In this adjustment the bolt 3 end b should protrude out of the threaded portion 4 but not be less than 2 mm 0 08 in c...

Page 93: ...Do not reuse the drained brake fluid Tighten the bleed screw T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb Install the brake pads 8 and pad pin NOTE Install the brake pads with their projections a into the...

Page 94: ...ake system Refer to BRAKE SYSTEM AIR BLEED ING section REAR BRAKE PAD INSPECTION AND REPLACEMENT 1 Inspect Brake pad thickness a Out of specification Replace as a set Brake pad thickness 6 4 mm 0 25 i...

Page 95: ...T R Bleed screw 6 Nm 0 6 m kg 4 3 ft lb Install the brake pad 0 and pad pin A NOTE Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at...

Page 96: ...sulator 1 Damage Replace BRAKE FLUID LEVEL INSPECTION 1 Place the brake master cylinder so that its top is in a horizontal position 2 Inspect Brake fluid level Fluid at lower level Fill up a Lower lev...

Page 97: ...ush off as much dirt as possible Then clean the drive chain using the chain cleaner CAUTION This machine has a drive chain with small rubber O rings 1 between the side plates Steam cleaning high press...

Page 98: ...ve chain apply the lith ium soap base grease on the chain joint and O rings New 7 Install Link plate 4 NOTE Press the link plate onto the chain joint using a drive chain riveter 5 Rivet the end of the...

Page 99: ...n slack 40 50 mm 1 6 2 0 in 3 Adjust Drive chain slack Drive chain slack adjustment steps Loosen the axle nut 1 and locknuts 2 Adjust the drive chain slack by turning the adjusters 3 To tighten Turn t...

Page 100: ...nspect Front fork smooth action Operate the front brake and stroke the front fork Unsmooth action oil leakage Repair or replace EC36D001 FRONT FORK OIL SEAL AND DUST SEAL CLEANING 1 Remove Protector D...

Page 101: ...ine 2 Remove the air bleed screw 1 and release the internal pressure from the front fork 3 Install Air bleed screw T R 1 Nm 0 1 m kg 0 7 ft lb EC36H002 FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT 1 Ad...

Page 102: ...h front fork to the same setting Uneven adjustment can cause poor handling and loss of stability Standard position 9 clicks out 5 clicks out EC36J001 FRONT FORK COMPRESSION DAMPING FORCE ADJUSTMENT 1...

Page 103: ...m extent of adjustment The adjuster may be damaged WARNING Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability 3 Install Rubber cap Standa...

Page 104: ...e adjustment The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster CAUTION Never attempt to turn the adjuster beyond the maximum or minimum setting 5 Tighten Locknut 6 Ins...

Page 105: ...ut Extent of adjustment Maximum Minimum Fully turned in position 20 clicks out from maximum position STANDARD POSITION This is the position which is back by the spe cific number of clicks from the ful...

Page 106: ...ition 20 clicks out from maximum position 1 b a STANDARD POSITION This is the position which is back by the spe cific number of clicks from the fully turned in position Which align the punch mark a on...

Page 107: ...n damping force Turn the adjuster 1 out Extent of adjustment Maximum Minimum Fully turned in position 2 turns out from maximum position 1 b a STANDARD POSITION This is the position which is back by th...

Page 108: ...on the rim If the tire valve stem is found tilted the tire is considered to be slipping off its position Cor rect the tire position Standard tire pressure 100 kPa 1 0 kgf cm2 15 psi EC36S002 SPOKES IN...

Page 109: ...m of the forks and gently rock the fork assembly back and forth Free play Adjust steering head 3 Check Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steering ring nut 4...

Page 110: ...ly and inspect the steering bearings Install the washer 5 upper bracket 6 washer 7 steering stem nut 8 steering stem cap 9 handlebar 0 handlebar upper holder A and headlight B NOTE The handlebar upper...

Page 111: ...to handlebar contact 6 Drive chain 7 Tube guide cable winding portion 8 Throttle cable end 9 Clutch cable end 0 Hot starter cable end Use Yamaha cable lube or equivalent on these areas Use SAE 10W 30...

Page 112: ...rk 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 4 Clean the pl...

Page 113: ...890 03113 1 3 Check Ignition timing 4 Install Timing mark accessing screw Checking steps Start the engine and let it warm up Let the engine run at the specified speed Adjust the engine idling speed Re...

Page 114: ...act with electrolyte as it can cause severe burns or permanent eye injury FIRST AID IN CASE OF BODILY CONTACT EXTERNAL Skin Wash with water Eyes Flush with water for 15 minutes and get immediate medic...

Page 115: ...he specific gravity of the electro lyte Therefore the charge of the battery has to be checked by measuring the voltage at the battery terminals 1 Remove Seat 2 Disconnect Battery leads from the batter...

Page 116: ...cuit voltage Measurement steps Connect a pocket tester 1 to the battery terminals Tester positive probe battery positive terminal Tester negative probe battery negative terminal NOTE The charge state...

Page 117: ...parks do not plug in the battery charger until the bat tery charger leads are connected to the battery Before removing the battery charger lead clips from the battery terminals be sure to turn off the...

Page 118: ...3 53 INSP ADJ BATTERY INSPECTION AND CHARGING Charging method using a variable voltage charger www PlanDeGraissage org...

Page 119: ...3 54 INSP ADJ BATTERY INSPECTION AND CHARGING Charging method using a constant voltage charger www PlanDeGraissage org...

Page 120: ...ry terminal 10 Install Seat BATTERY REPLACEMENT 1 Replace Battery CAUTION This battery is for YAMAHA WR250F After filling the battery with electrolyte either charge it for at least 3 hours at the ampe...

Page 121: ...rating other than that specified Improvising or using a fuse with the wrong amperage rat ing may cause extensive damage to the electrical system cause the starting and ignition systems to malfunction...

Page 122: ...N Avoid touching the glass part of the head light bulb to keep it free form oil otherwise the transparency of the glass the life of the bulb and the luminous flux will be adversely affected If the hea...

Page 123: ...SEAT FUEL TANK AND SIDE COVERS REMOVAL Preparation for removal Turn the fuel cock to OFF Disconnect the fuel hose 1 Seat 1 2 Air scoop left and right 2 3 Fitting band 1 Remove on fuel tank side 4 Bolt...

Page 124: ...cover 1 Remove Bolt side cover Left side cover 1 Right side cover 2 NOTE Draw the side cover downward to remove it because its claws a are inserted in the air fil ter case SEAT FUEL TANK AND SIDE COV...

Page 125: ...r Part name Q ty Remarks EXHAUST PIPE AND SILENCER REMOVAL Preparation for removal Right side cover Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Bolt silencer clamp 1 Only loosening 2 Bolt silenc...

Page 126: ...temporarily tighten the nut exhaust pipe then tighten the bolt exhaust pipe 20 Nm 2 0 m kg 14 ft lb After that retighten the nut exhaust pipe 13 Nm 1 3 m kg 9 4 ft lb and then the bolt exhaust pipe 2...

Page 127: ...ion in the CHAPTER 3 Seat fuel tank and left side cover Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Radiator guard 2 2 Radiator hose clamp 8 Only loosening 3 Radiator hose 1 1 4 Left radiator 1...

Page 128: ...rocedure allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning coun terclockwise and remove it EC454000 INSPECTION EC444100 Radiator 1 Inspect R...

Page 129: ...rd 1 Bolt radiator guard 2 NOTE Fit the hook a on the inner side first into the radiator T R 10 Nm 1 0 m kg 7 2 ft lb T R 2 Nm 0 2 m kg 1 4 ft lb T R 2 Nm 0 2 m kg 1 4 ft lb T R 10 Nm 1 0 m kg 7 2 ft...

Page 130: ...t of removal Order Part name Q ty Remarks CARBURETOR REMOVAL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Clamp 2 2 Throttle position sensor lead cou pl...

Page 131: ...retor breather hose 4 2 Valve lever housing cover 1 3 Screw throttle shaft 1 4 Throttle valve 1 5 Needle holder 1 6 Jet needle 1 7 Accelerator pump cover 1 8 Spring 1 9 Diaphragm accelerator pump 1 0...

Page 132: ...Float pin 1 G Float 1 H Needle valve 1 I Main jet 1 J Needle jet 1 K Spacer 1 L Pilot jet 1 M Starter jet 1 N Push rod 1 Pull the push rod O Throttle shaft assembly 1 P Push rod link lever assembly 1...

Page 133: ...To optimize the fuel flow at a small throttle opening each machine s pilot screw has been individually set at the factory Before removing the pilot screw turn it in fully and count the number of turns...

Page 134: ...ir Never use a wire Needle valve 1 Inspect Needle valve 1 Valve seat 2 Grooved wear a Replace Dust b Clean EC464301 Throttle valve 1 Check Free movement Stick Repair or replace NOTE Insert the throttl...

Page 135: ...ill push in the needle valve resulting in an incorrect measurement Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers NOTE The float arm...

Page 136: ...ring 4 Push rod 5 Tears diaphragm damage Replace Dirt Clean 2 Inspect Throttle shaft 1 Spring 2 Lever 1 3 Spring 1 4 Lever 2 5 Spring 2 6 Dirt Clean 1 2 3 4 5 6 Air cut valve 1 Inspect Diaphragm air c...

Page 137: ...Make sure the spring 1 fits on the stopper a of the lever 2 a 3 1 2 4 Install Spring 2 1 To lever 2 2 1 2 5 Install Push rod link lever assembly 1 NOTE Make sure the stopper a of the spring 2 fits in...

Page 138: ...he projection a on the throttle shaft assembly into the slot b in the throttle posi tion sensor Make sure the stopper c of the spring fits into the recess in the carburetor Turn the throttle shaft ass...

Page 139: ...nt 12 Install Pilot screw 1 Spring 2 Washer 3 O ring 4 Except for USA Note the following installation points Turn in the pilot screw until it is lightly seated Turn out the pilot screw by the number o...

Page 140: ...tor pump cover 6 NOTE Install the diaphragm accelerator pump with its mark a facing the spring 1 2 3 5 4 16 Install Jet needle 1 Collar 2 Spring 3 Needle holder 4 Throttle valve plate 5 To throttle va...

Page 141: ...outer diameter as the specified value Throttle valve height 1 5 mm 0 06 in Fully turn in the accelerator pump adjust ing screw 3 Check that the link lever 4 has free play b by pushing lightly on it G...

Page 142: ...hrottle cable return 2 6 Adjust Throttle grip free play Refer to THROTTLE CABLE ADJUST MENT section in the CHAPTER 3 T R 4 Nm 0 4 m kg 2 9 ft lb T R 11 Nm 1 1 m kg 8 0 ft lb 2 1 7 Install Throttle cab...

Page 143: ...4 21 ENG 9 Install Clamp 1 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 1 CARBURETOR www PlanDeGraissage org...

Page 144: ...OVER REMOVAL Preparation for removal Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Carburetor Refer to CARBURETOR section 1 Spark plug 1 2 Cylinder head breather hose 1 3 Oil tank...

Page 145: ...Part name Q ty Remarks CAMSHAFTS REMOVAL 1 Timing mark accessing screw 1 Refer to REMOVAL POINTS 2 Crankshaft end accessing screw 1 3 Timing chain tensioner cap bolt 1 4 Timing chain tensioner 1 5 Ca...

Page 146: ...sure that the piston is at Top Dead Center the punch mark c on the exhaust camshaft and the punch mark d on the intake camshaft must align with the cyl inder head surface as shown in the illustra tio...

Page 147: ...Cam lobe length a and b Out of specification Replace Cam lobes length Intake a 30 296 30 346 mm 1 1923 1 1947 in Limit 30 196 mm 1 1888 in b 22 45 22 55 mm 0 8839 0 8878 in Limit 22 35 mm 0 8799 in E...

Page 148: ...2 ft lb NOTE Tighten the bolts camshaft cap in a criss cross pattern from innermost to outer caps Do not turn the camshaft when measuring clearance with the Plastigauge Remove the camshaft caps and m...

Page 149: ...by press ing lightly with fingers make sure that the tensioner rod will come out smoothly If not replace the tensioner assembly ASSEMBLY AND INSTALLATION Camshaft 1 Install Exhaust camshaft 1 Intake...

Page 150: ...shaft caps 4 and bolts camshaft cap 5 T R Bolt camshaft cap 10 Nm 1 0 m kg 7 2 ft lb NOTE Before removing the clips cover the cylin der head with a clean rag to prevent the clips from into the cylinde...

Page 151: ...cing upward install the gasket 1 and the timing chain ten sioner 2 and tighten the bolt 3 to the specified torque T R Bolt timing chain tensioner 10 Nm 1 0 m kg 7 2 ft lb Release the screwdriver check...

Page 152: ...cylinder head cover 4 NOTE Apply the sealant on the cylinder head cover gasket 7 Install Oil tank breather hose Cylinder head breather hose Spark plug T R 10 Nm 1 0 m kg 7 2 ft lb Quick gasket ACC QU...

Page 153: ...ection Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section Radiator hose 1 Disconnect at cylinder head side Carburetor Refer to CARBURETOR section Camshaft Refer to CAMSHAFTS section...

Page 154: ...Out of specification Resurface Cylinder head warpage Less than 0 05 mm 0 002 in Warpage measurement and resurfacing steps Place a straightedge and a feeler gauge across the cylinder head Use a feeler...

Page 155: ...5 31 in 4 Nuts 5 NOTE Apply the molybdenum disulfide grease on the thread and contact surface of the bolts Follow the numerical order shown in the illus tration Tighten the bolts and nuts in two stag...

Page 156: ...ALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Valve lifter 5 Use special tool Refer to REMOVAL POINTS 2 Adjusting pad 5 3 Valve cotter 10 4 Val...

Page 157: ...Leakage at the valve seat Inspect the valve face valve seat and valve seat width Checking steps Pour a clean solvent 1 into the intake and exhaust ports Check that the valve seals properly There shoul...

Page 158: ...0 025 0 052 mm 0 0010 0 0020 in Limit 0 10 mm 0 004 in 2 Replace Valve guide Replacement steps NOTE To ease guide removal installation and to maintain correct fit heat the cylinder head in an over to...

Page 159: ...7 Valve guide reamer Intake 4 0 mm 0 16 in YM 4113 90890 04113 Exhaust 4 5 mm 0 18 in YM 4118 90890 04118 NOTE After replacing the valve guide reface the valve seat 3 Inspect Valve face Pitting wear G...

Page 160: ...cification Reface the valve seat Valve seat width Intake 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Exhaust 0 9 1 1 mm 0 0354 0 0433 in Limit 1 6 mm 0 0630 in Measurement steps Apply Mechanic...

Page 161: ...evenly polished then clean off all of the compound NOTE For best lapping results lightly tap the valve seat while rotating the valve back and forth between your hands Apply a fine lapping compound to...

Page 162: ...haust 37 54 mm 1 48 in Limit 35 7 mm 1 41 in Compressed spring force Intake 99 114 N at 29 13 mm 9 9 11 4 kg at 29 13 mm 22 27 25 57 lb at 1 15 in Exhaust 126 144 N at 29 30 mm 12 6 14 4 kg at 29 30 m...

Page 163: ...fter mark b color Red Red Blue Blue Yellow Yellow Purple Black a b ASSEMBLY AND INSTALLATION Valve and valve spring 1 Apply Molybdenum disulfide oil Onto the valve stem and valve stem seal 2 Install V...

Page 164: ...h a piece of wood CAUTION Hitting the valve tip with excessive force could damage the valve Valve spring compressor YM 4019 90890 04019 5 Install Adjusting pad 1 Valve lifter 2 NOTE Apply the molybden...

Page 165: ...ent of removal Order Part name Q ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to CYLINDER HEAD section 1 Bolt cylinder 1 2 Cylinder 1 3 Piston pin clip 2 Use spec...

Page 166: ...to drive the piston pin out 2 Remove Piston ring 1 NOTE Spread the end gaps apart while at the same time lifting the piston ring over the top of the piston crown as shown in the illustration Piston pi...

Page 167: ...n skirt diameter P with a micrometer a 8 mm 0 31 in from the piston bottom edge Piston size P Standard 76 955 76 970 mm 3 0297 3 0303 in If out of specification replace the piston and piston rings as...

Page 168: ...the ring will be at a right angle to the cylinder bore a 10 mm 0 39 in Side clearance Standard Limit Top ring 0 030 0 065 mm 0 0012 0 0026 in 0 12 mm 0 005 in 2nd ring 0 020 0 055 mm 0 0008 0 0022 in...

Page 169: ...piston rings liberally with engine oil Measurement steps Measure the outside diameter piston pin a If out of specification replace the piston pin Outside diameter piston pin 15 991 16 000 mm 0 6296 0...

Page 170: ...pis ton Be sure that the arrow mark a on the piston points to the exhaust side of the engine Before installing the piston pin clip cover the crankcase with a clean rag to prevent the piston pin clip f...

Page 171: ...le com pressing the piston rings with the other hand CAUTION Pass the timing chain 3 through the tim ing chain cavity Be careful not to damage the timing chain guide 4 during installation 4 Install Bo...

Page 172: ...removal Order Part name Q ty Remarks CLUTCH REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Brake pedal Refer to ENGINE REMOVAL section C...

Page 173: ...0 Friction plate 9 11 Clutch plate 8 12 Cushion spring 1 13 Seat plate 1 14 Nut clutch boss 1 Use special tool Refer to REMOVAL POINTS 15 Look washer 1 16 Clutch boss 1 17 Thrust washer 1 18 Primary d...

Page 174: ...90 04086 EC4A4000 INSPECTION EC484100 Clutch housing and boss 1 Inspect Clutch housing 1 Cracks wear damage Replace Clutch boss 2 Scoring wear damage Replace EC484201 Primary driven gear 1 Check Circu...

Page 175: ...warpage Out of specification Replace clutch plate as a set Use a surface plate 1 and thickness gauge 2 Friction plate thickness 2 9 3 1 mm 0 114 0 122 in Limit 2 7 mm 0 106 in Warp limit 0 1 mm 0 004...

Page 176: ...he push lever shaft and tighten the bolt seat plate T R 10 Nm 1 0 m kg 7 2 ft lb 3 1 a 2 Clutch 1 Install Primary driven gear 1 Thrust washer 2 Clutch boss 3 NOTE Apply the engine oil on the primary d...

Page 177: ...lates and friction 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...

Page 178: ...9 Install Clutch spring 1 Bolt clutch spring 2 NOTE Tighten the bolts in stage using a crisscross pattern T R 8 Nm 0 8 m kg 5 8 ft lb 10 Install Dowel pin 1 Gasket clutch cover 2 New 11 Install Clutc...

Page 179: ...ER ELEMENT WATER PUMP AND RIGHT CRANK CASE COVER REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Drain the coolant Refer to COOLANT REPLAC...

Page 180: ...f removal Order Part name Q ty Remarks 3 Water pump housing 1 4 Oil delivery pipe 1 5 Bolt oil hose 1 6 Kickstarter crank 1 7 Right crankcase cover 1 8 Impeller 1 Refer to REMOVAL POINTS 9 Washer 1 10...

Page 181: ...s a with spanners etc and remove the impeller EC4G3210 Oil seal NOTE It is not necessary to disassemble the water pump unless there is an abnormality such as excessive change in coolant level discolor...

Page 182: ...Wear damage Replace EC4H4600 Bearing 1 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace EC444400 Oil seal 1 Inspect Oil seal 1 Wear damage Replace ASSEMBLY AND INSTALLATION O...

Page 183: ...spring does not slip off its posi tion When installing the impeller shaft apply the lithium soap base grease on the oil seal lip and impeller shaft And install the shaft while turning it Hold the impe...

Page 184: ...ickstarter crank 1 Install Kickstarter crank 1 Washer 2 Bolt kickstarter crank 3 NOTE Install the kickstarter crank so that the kick starter crank is as vertical as possible with the distance a betwee...

Page 185: ...base grease on the O ring New 2 Install Water pump housing 1 Bolt water pump housing 2 T R 10 Nm 1 0 m kg 7 2 ft lb Oil filter element 1 Install Oil filter element 1 O ring 2 Oil filter element cover...

Page 186: ...ight crankcase cover Refer to OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANK CASE COVER section Stator Refer to AC MAGNETO AND STARTER CLUTCH section 1 Nut primary drive gear 1 Refer to REMOVAL POINTS...

Page 187: ...r 4 Balancer shaft 1 Remove Balancer shaft 1 NOTE When removing the balancer shaft align the center a of the balancer shaft weight along the line connecting the centers of the crank shaft and balancer...

Page 188: ...en gear with the lower spline b on the balancer shaft end 3 Install Balancer shaft drive gear 1 NOTE Align the punched mark a on the balancer shaft drive gear with the punched mark b on the balancer s...

Page 189: ...ation for removal Primary driven gear Refer to CLUTCH section Right crankcase cover Refer to OIL FILTER ELEMENT WATER PUMP AND RIGHT CRANK CASE COVER section 1 Circlip 1 2 Washer 1 3 Oil pump drive ge...

Page 190: ...4 68 ENG OIL PUMP Extent of removal Order Part name Q ty Remarks 12 Dowel pin 1 13 Washer 1 14 Oil pump drive shaft 1 15 Rotor housing 1 2 www PlanDeGraissage org...

Page 191: ...or 2 and rotor housing 3 Housing and rotor clearance c between the rotor housing 3 and rotors 1 2 Out of specification Replace the oil pump assembly Tip clearance a 0 12 mm or less 0 0047 in or less L...

Page 192: ...er rotor 1 Fit the dowel pin into the groove in the inner rotor 1 2 Install Outer rotor 1 1 NOTE Apply the engine oil on the outer rotor 1 3 Install Oil pump cover 1 Screw oil pump cover 2 Dowel pin 3...

Page 193: ...Bolt oil pump assembly L 30 mm 1 18 in 5 NOTE Apply the engine oil on the outer rotor 2 T R 10 Nm 1 0 m kg 7 2 ft lb T R 10 Nm 1 0 m kg 7 2 ft lb 5 Install Oil pump drive gear 1 Washer 2 Circlip 3 NO...

Page 194: ...of removal Order Part name Q ty Remarks KICK SHAFT AND SHIFT SHAFT REMOVAL Preparation for removal Oil pump Refer to OIL PUMP section 1 Kick idle gear 1 2 Kick shaft assembly 1 Refer to REMOVAL POINTS...

Page 195: ...s 12 Torsion spring 1 13 Roller 1 14 Shift guide 1 Refer to REMOVAL POINTS 15 Shift lever assembly 1 16 Shift lever 1 17 Pawl 2 18 Pawl pin 2 19 Spring 2 20 Bolt stopper lever 1 21 Stopper lever 1 22...

Page 196: ...assembled at the same time as the shift guide EC4N3100 Segment 1 Remove Bolt segment 1 Segment 2 NOTE Turn the segment counterclockwise until it stops and loosen the bolt INSPECTION Kick shaft and rat...

Page 197: ...Inspect Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear damage Replace EC4B4500 Stopper lever 1 Inspect Stopper lever 1 Wear damage Replace Torsion spring 2 Broken Replace ASSEMBLY AND INS...

Page 198: ...ring 1 Pawl pin 2 Pawl 3 To shift lever 4 NOTE Apply the engine oil on the spring pawl pin and pawl 2 Install Shift lever assembly 1 To shift guide 2 T R 10 Nm 1 0 m kg 7 2 ft lb 3 Install Shift lever...

Page 199: ...1 Install Kick gear 1 Washer 2 Circlip 3 Ratchet wheel 4 Spring 5 Washer 6 Circlip 7 To kick shaft 8 NOTE Apply the molybdenum disulfide oil on the inner circumferences of the kick gear and ratchet wh...

Page 200: ...t stop per a and stopper plate 3 Apply the engine oil on the kick shaft Slide the kick shaft assembly into the crank case and make sure the kick shaft stopper a fits into the stopper plate 5 Hook Tors...

Page 201: ...TOR REMOVAL Preparation for removal Drain the engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Bolt radiator left...

Page 202: ...arks 10 Nut rotor 1 11 Rotor 1 Use special tool Refer to REMOVAL POINTS 12 Woodruff key 1 13 Starter clutch 1 14 Starter clutch drive gear 1 15 Bearing 1 16 Plain washer 1 17 Idle gear plate 1 18 Idle...

Page 203: ...ect Rotor inner surface a Stator outer surface b Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace AC magneto and or stator EC4L4200 Woodruff key 1 Inspect Woodruff key...

Page 204: ...starter clutch drive gear and starter clutch do not engage the starter clutch is faulty and must be replaced When turning the starter clutch drive gear clockwise it should turn freely If the starter c...

Page 205: ...ot become loose at the bend of the holder a in order to avoid their con tacting the starter clutch drive gear NOTE Apply the sealant to the grommet of the AC magneto lead T R 7 Nm 0 7 m kg 5 1 ft lb Q...

Page 206: ...e sure that its flat surface a is in parallel with the crankshaft center line b When installing the rotor align the keyway c of the rotor with the woodruff key 7 Install Bolt starter clutch 1 Plain wa...

Page 207: ...Install Engine guard 1 Clamp 2 Bolt engine guard front 3 Bolt engine guard rear 4 Cylinder head breather hose 5 T R 23 Nm 2 3 m kg 17 ft lb T R 23 Nm 2 3 m kg 17 ft lb 3 2 5 1 2 4 12 Connect AC magnet...

Page 208: ...engine oil Refer to ENGINE OIL REPLACEMENT section in the CHAPTER 3 Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Carburetor Refer to CARBURETOR section Exhaust pipe and silencer...

Page 209: ...Negative battery lead Disconnect at the engine side Right engine guard 1 Neutral switch 1 2 Drive chain sprocket cover 1 3 Nut drive sprocket 1 Refer to REMOVAL POINTS 4 Lock washer 1 5 Drive sprocke...

Page 210: ...rive chain 2 NOTE Remove the drive sprocket together with the drive chain EC4M3301 Engine removal 1 Remove Pivot shaft 1 NOTE If the pivot shaft is pulled all the way out the swingarm will come loose...

Page 211: ...ngine guard A NOTE Apply the molybdenum disulfide grease on the pivot shaft T R 85 Nm 8 5 m kg 61 ft lb T R 69 Nm 6 9 m kg 50 ft lb T R 34 Nm 3 4 m kg 24 ft lb T R 69 Nm 6 9 m kg 50 ft lb T R 55 Nm 5...

Page 212: ...ng the rear brake T R 75 Nm 7 5 m kg 54 ft lb New 3 Bend the lock washer tab to lock the nut 4 Install Drive chain sprocket guide 1 Drive chain sprocket cover 2 Screw drive chain sprocket cover 3 T R...

Page 213: ...ENG ENGINE REMOVAL 2 Install Spring 1 Pin 2 O ring 3 Neutral switch 4 Screw neutral switch 5 NOTE Apply the lithium soap base grease on the O ring T R 4 Nm 0 4 m kg 2 9 ft lb New www PlanDeGraissage...

Page 214: ...AFT REMOVAL Preparation for removal Engine Refer to ENGINE REMOVAL section Piston Refer to CYLINDER AND PISTON sec tion Kick shaft assembly Refer to KICK SHAFT AND SHIFT SHAFT section Segment Stator R...

Page 215: ...4 Bolt L 45 mm 1 77 in 6 Refer to REMOVAL POINTS 5 Bolt L 55 mm 2 17 in 1 6 Bolt L 70 mm 2 76 in 4 7 Hose guide 1 8 Clutch cable holder 1 9 Right crankcase 1 10 Left crankcase 1 11 Oil strainer 1 12 C...

Page 216: ...bearing removal Extent of removal Order Part name Q ty Remarks CRANKCASE BEARING REMOVAL Preparation for removal Transmission Shift cam and shift fork Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK se...

Page 217: ...a in the crankcase Lift the right crankcase horizontally while lightly patting the case splitting slit and engine mounting boss using a soft ham mer and leave the crankshaft and trans mission with th...

Page 218: ...aring Crankcase separating tool YU 1135 A 90890 01135 INSPECTION Timing chain and timing chain guide 1 Inspect Timing chain Cracks stiff Replace the timing chain and camshaft sprocket as a set 2 Inspe...

Page 219: ...uge and stand YU 3097 90890 01252 Standard Limit Runout limit 0 03 mm 0 0012 in 0 05 mm 0 002 in Small end free play 0 4 1 0 mm 0 016 0 039 in 2 0 mm 0 08 in Side clearance 0 15 0 45 mm 0 0059 0 0177...

Page 220: ...l Crankshaft 1 Use the crankshaft installing tool 2 3 4 and 5 For USA and CDN Except for USA and CDN NOTE Hold the connecting rod at top dead center with one hand while turning the nut of the installi...

Page 221: ...Clean the contacting surface of left and right crankcase before applying the sealant 5 Install Dowel pin 1 O ring 2 Right crankcase To left crankcase NOTE Fit the right crankcase onto the left crank c...

Page 222: ...lt oil delivery pipe 2 3 NOTE Apply the lithium soap base grease on the O rings T R 10 Nm 1 0 m kg 7 2 ft lb New 8 Install Timing chain 1 Timing chain guide intake side 2 Bolt timing chain guide 3 9 R...

Page 223: ...nt of removal Order Part name Q ty Remarks TRANSMISSION SHIFT CAM AND SHIFT FORK REMOVAL Preparation for removal Engine Refer to ENGINE REMOVAL section Separate the crankcase Refer to CRANKCASE AND CR...

Page 224: ...tention to the location and direction of shift forks Remove the main axle drive axle shift cam and shift fork all together by tapping lightly on the transmission drive axle with a soft ham mer EC4H400...

Page 225: ...fork replace not only the shift fork itself but the two gears each adja cent to the shift fork EC4H5000 ASSEMBLY AND INSTALLATION Transmission 1 Install 5th pinion gear 27T 1 3rd pinion gear 21T 2 Co...

Page 226: ...bdenum disulfide oil on the 4th and 5th wheel gears inner circumference Apply the lithium soap base grease on the O ring New 3 Install Washer 1 Circlip 2 NOTE Be sure the circlip sharp edged corner a...

Page 227: ...hift fork grooves Mesh the shift fork 1 L with the 4th wheel gear 5 and 3 R with the 5th wheel gear 7 on the drive axle Mesh the shift fork 2 C with the 3rd pinion gear 6 on the main axle 6 Install Tr...

Page 228: ...WHEEL REMOVAL Hold the machine by placing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over 1 Trip meter cable 1 2 Brake hose cover 1 3...

Page 229: ...machine by placing the suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Drive chain puller 2...

Page 230: ...Remove Bearing 1 NOTE Remove the bearing using a general bearing puller 2 EC594000 INSPECTION EC514100 Wheel 1 Measure Wheel runout Out of limit Repair replace 2 Inspect Bearing Rotate inner race wit...

Page 231: ...bending limit 0 5 mm 0 020 in EC594200 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 conditi...

Page 232: ...TION 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 NOTE Tighten the bolts in stage using a crisscross pattern T R...

Page 233: ...ake pads 2 correctly Make sure that the projections a in the trip meter gear unit fits over the stopper b on the front fork outer tube 6 Install Wheel axle 1 NOTE Apply the lithium soap base grease on...

Page 234: ...r 2 NOTE Before tightening the bolt brake hose holder align the top a of the brake hose neck with the brake hose holder bottom b Then pass the brake hose in front of the axle boss c and fit it into th...

Page 235: ...hat matches the outside diam eter of the race of the bearing Right side of bearing shall be installed first Install the oil seal with its manufacture s marks or numbers facing outward CAUTION Do not s...

Page 236: ...ll Collar 1 NOTE Apply the lithium soap base grease on the oil seal lip 5 Install Wheel NOTE Install the brake disc 1 between the brake pads 2 correctly 6 Install Drive chain 1 NOTE Push the wheel 2 f...

Page 237: ...Temporarily tighten the nut wheel axle at this point 9 Adjust Drive chain slack a Refer to DRIVE CHAIN SLACK ADJUSTMENT section in the CHAPTER 3 Drive chain slack 40 50 mm 1 6 2 0 in 10 Tighten Nut w...

Page 238: ...e suitable stand under the engine WARNING Support the machine securely so there is no danger of it falling over Drain the brake fluid Refer to REMOVAL POINTS 1 Brake hose cover 1 2 Brake hose holder 1...

Page 239: ...he engine WARNING Support the machine securely so there is no danger of it falling over Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section Drain the brake fluid Refer to REMOVAL POINTS 1 Brake ped...

Page 240: ...2 Rear brake caliper disassembly Extent of removal Order Part name Q ty Remarks BRAKE CALIPER DISASSEM BLY 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 REMOV...

Page 241: ...ssembly 2 Rear brake master cylinder disassembly Extent of removal Order Part name Q ty Remarks BRAKE MASTER CYLINDER DISASSEMBLY 1 Brake master cylinder cap 1 2 Diaphragm 1 3 Brake master cylinder bo...

Page 242: ...hing down on the pedal CAUTION Do not reuse the drained brake fluid Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately Brake caliper piston 1 Remove Brak...

Page 243: ...nd dust seals whenever a caliper is disassembled Front Rear EC5A4000 INSPECTION Brake master cylinder 1 Inspect Brake master cylinder inner surface a Wear scratches Replace master cylin der assembly S...

Page 244: ...is disassembled EC534301 Brake hose 1 Inspect Brake hose 1 Crack damage Replace EC5A5000 ASSEMBLY AND INSTALLATION WARNING All internal parts should be cleaned in new brake fluid only Internal parts s...

Page 245: ...iston 1 NOTE Apply the brake fluid on the piston wall CAUTION Install the piston with its shallow depressed side a facing the brake cali per Never force to insert Front Rear Front brake caliper 1 Inst...

Page 246: ...holder 1 Brake caliper 2 Bolt brake caliper 3 NOTE Fit the brake hose holder cut a over the pro jection b on the front fork and clamp the brake hose 4 Tighten Pad pin 4 5 Install Pad pin plug 5 Rear...

Page 247: ...3 Nm 0 3 m kg 2 2 ft lb Brake master cylinder kit 1 Clean Brake master cylinder Brake master cylinder kit Clean them with brake fluid 2 Install Brake master cylinder cup primary 1 Brake master cylinde...

Page 248: ...inder 5 NOTE Apply the brake fluid on the brake master cyl inder kit Apply the lithium soap base grease on the tip of the push rod When installing the circlip use a long nose circlip pliers Front Rear...

Page 249: ...he brake hose so that its pipe por tion a directs as shown and lightly touches the projection b on the brake master cylinder T R 6 Nm 0 6 m kg 4 3 ft lb T R 6 Nm 0 6 m kg 4 3 ft lb T R 30 Nm 3 0 m kg...

Page 250: ...p a of the brake hose neck with the brake hose holder bottom b Then pass the brake hose in front of the axle boss c and fit it into the hose groove d so that the brake hose does not contact the nut wh...

Page 251: ...cylinder projection a and that its bent portion b faces downward T R 30 Nm 3 0 m kg 22 ft lb New Rear brake hose 1 Install Copper washer 1 Brake hose 2 Union bolt 3 WARNING Always use new copper wash...

Page 252: ...gnated quality brake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per formance Refill with the same type of brake fluid mixing fluids may result in a harmful chem i...

Page 253: ...master cylinder cap 2 Rear Diaphragm Brake master cylinder cap 1 Bolt brake master cylinder cap 2 CAUTION After installation while pulling the brake lever in or pushing down on the brake pedal check w...

Page 254: ...the machine securely so there is no danger of it falling over Front wheel Refer to FRONT WHEEL AND REAR WHEEL section Front brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Headlight Handleb...

Page 255: ...ORK DISASSEMBLY 1 Front fork cap bolt 1 Refer to REMOVAL POINTS 2 Fork spring 1 Drain the fork oil 3 Dust seal 1 Refer to REMOVAL POINTS 4 Stopper ring 1 5 Inner tube 1 6 Outer tube 1 7 Piston metal 1...

Page 256: ...allow any foreign material to come in when the oil is replaced or when the front fork is disassembled and reassembled Before removing the cap bolts or front forks be sure to extract the air from the...

Page 257: ...er tube EC553311 Damper rod 1 Remove Base valve 1 Damper rod 2 NOTE Use a damper rod holder 3 to lock the damper rod EC554000 INSPECTION EC554100 Damper rod 1 Inspect Damper rod 1 Bend damage Replace...

Page 258: ...t sandpaper Damaged oil lock piece Replace Inner tube bends Out of specification Replace Use the dial gauge 1 NOTE The bending value is shown by one half of the dial gauge reading WARNING Do not attem...

Page 259: ...nstall the damper rod into the inner tube hold the inner tube aslant If the inner tube is held vertically the damper rod may fall into it damaging the valve inside 3 Install Copper washer 1 O ring 2 B...

Page 260: ...al 3 Oil seal washer 4 Slide metal 5 To inner tube 6 NOTE Apply the fork oil on the inner tube When installing the oil seal use vinyl seat a with fork oil applied to protect the oil seal lip Install t...

Page 261: ...eal driver YM 01442 90890 01442 10 Install Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver 2 Fork seal driver YM 01442 90890 01442 11 Install Stopper ring 1 NOTE Fit the s...

Page 262: ...ever allow foreign materials to enter the front fork Recommended oil Suspension oil 01 16 After filling pump the damper rod 1 slowly up and down more than 10 times to distrib ute the fork oil 17 Fill...

Page 263: ...r tube and bleed the front forks 20 Measure Oil level left and right a Out of specification Adjust For EUROPE For AUS NZ and ZA NOTE Be sure to install the spring guide 2 when checking the oil level W...

Page 264: ...turning out the fully turned in posi tion 23 Install Cushion rubber 1 Washer 2 Spacer 3 To front fork cap bolt 4 NOTE Install the cushion rubber with its smaller dia end a facing the front fork cap bo...

Page 265: ...9 m kg 21 ft lb 27 Install Front fork cap bolt 1 To outer tube NOTE Temporarily tighten the cap bolt 28 Install Protector guide 1 Installation 1 Install Front fork 1 NOTE Temporarily tighten the pinch...

Page 266: ...rake hose holder 2 Protector 3 Bolt protector 4 NOTE When installing the brake hose holder align the top a of the brake hose neck with the brake hose holder bottom b Then pass the brake hose 5 in fron...

Page 267: ...ct the clutch switch lead 5 Engine stop switch 1 Disconnect the engine stop switch lead 6 Light switch 1 7 Brake master cylinder 1 Refer to REMOVAL POINTS 8 Start switch 1 Disconnect the start switch...

Page 268: ...der cap side horizontal to prevent air from coming in EC5B3200 Grip 1 Remove Grip 1 NOTE Blow in air between the handlebar or tube guide and the grip Then remove the grip which has become loose EC5B40...

Page 269: ...ar 2 NOTE Before applying the adhesive wipe off grease or oil on the handlebar surface a with a lacquer thinner Install the left grip to the handlebar so that the line b between the two arrow marks fa...

Page 270: ...ly the lithium soap base grease on the throttle cable end and tube guide cable wind ing portion 6 Install Throttle cable cap 1 Screw throttle cable cap 2 WARNING After tightening the screws check that...

Page 271: ...r bracket and then tighten the bolt on the lower side T R 9 Nm 0 9 m kg 6 5 ft lb Zero mm Zero in Zero mm Zero in 9 Install Light switch 1 T R 2 Nm 0 2 m kg 1 4 ft lb 10 Install Engine stop switch 1 C...

Page 272: ...just Clutch lever free play Refer to CLUTCH ADJUSTMENT sec tion in the CHAPTER 3 Hot starter lever free play Refer to HOT STARTER LEVER ADJUSTMENT section in the CHAPTER 3 13 Fasten the hot starter ca...

Page 273: ...Hold the machine by placing the suitable stand under the engine Headlight Handlebar Front brake hose guide Front fender Refer to HANDLEBAR section 1 Coupler bracket 1 2 Trip meter 1 3 Main switch 1 D...

Page 274: ...5 47 CHAS STEERING Extent of removal Order Part name Q ty Remarks 10 Ball race cover 1 11 Upper bearing 1 12 Lower bearing 1 Refer to REMOVAL POINTS 13 Ball race 2 2 www PlanDeGraissage org...

Page 275: ...own Steering nut wrench YU 33975 90890 01403 Lower bearing 1 Remove Lower bearing 1 Use the floor chisel 2 CAUTION Take care not to damage the steering shaft thread EC563400 Ball race 1 Remove Ball ra...

Page 276: ...e ball races replace bearings and ball races as a set EC565000 ASSEMBLY AND INSTALLATION Lower bracket 1 Install Lower bearing 1 NOTE Apply the lithium soap base grease on the dust seal lip and bearin...

Page 277: ...y turning it lock to lock If there is any binding remove the steering stem assembly and inspect the steering bearings 6 Install Washer 1 7 Install Front fork 1 Upper bracket 2 Main switch 3 Coupler br...

Page 278: ...the steering ring nut little by little 11 Adjust Front fork top end a For AUS NZ and ZA 12 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 CAUTION Tighten the lower bracket to specified...

Page 279: ...5 52 CHAS STEERING 13 Install Trip meter 1 Bolt trip meter 2 NOTE Install the trip meter over the coupler bracket 3 T R 7 Nm 0 7 m kg 5 1 ft lb www PlanDeGraissage org...

Page 280: ...Preparation for removal Hold the machine by placing the suitable stand under the engine Brake hose holder Rear brake caliper Bolt brake pedal Drive chain Refer to FRONT BRAKE AND REAR BRAKE section S...

Page 281: ...removal and disassembly 3 Relay arm removal and disassembly Extent of removal Order Part name Q ty Remarks SWINGARM DISASSEMBLY 1 Cap 2 2 Relay arm 1 3 Connecting rod 1 4 Collar 2 5 Oil seal 2 6 Thrus...

Page 282: ...Relay arm 1 Inspect Bearing polylube bearing 1 Collar 2 Free play exists unsmooth revolution rust Replace bearing and collar as a set 2 Inspect Bearing polylube bearing 1 Loss of solid lubrication Rep...

Page 283: ...olylube bearings no grease nipple and regular lubrication is necessary However grease should be applied to all oil seals and collars when removed or installed EC575000 ASSEMBLY AND INSTALLATION EC5752...

Page 284: ...se on the bearing when installing Install the bearing by pressing it on the side having the manufacture s marks or numbers Installed depth of bearings a 5 mm 0 20 in Installed depth of bearings a 5 mm...

Page 285: ...asher 3 Nut relay arm 4 To swingarm NOTE Apply the molybdenum disulfide grease on the bolt Do not tighten the nut yet 6 Install Swingarm 1 Pivot shaft 2 NOTE Apply the molybdenum disulfide grease on t...

Page 286: ...Bolt rear shock absorber relay arm 1 Nut rear shock absorber relay arm 2 NOTE Apply the molybdenum disulfide grease on the bolt T R 53 Nm 5 3 m kg 38 ft lb 10 Tighten Nut connecting rod 1 T R 80 Nm 8...

Page 287: ...ower chain tensioner 5 T R 20 Nm 2 0 m kg 14 ft lb 14 Install Drive chain support 1 Drive chain support cover 2 Bolt drive chain support 50 mm 1 97 in 3 Nut drive chain support 4 Bolt drive chain supp...

Page 288: ...rs Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 Air filter case cover Refer to AIR FILTER CLEANING sec tion in the CHAPTER 3 Silencer Refer to EXHAUST PIPE AND SILENCER section in...

Page 289: ...band 2 5 Clamp air filter joint 1 Only loosening 6 Rear 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 l...

Page 290: ...hose 3 Be careful not to damage any 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 ro...

Page 291: ...bearing by pressing its outer race EC584000 INSPECTION Rear shock absorber 1 Inspect Damper rod 1 Bends damage Replace rear shock absorber assembly Shock absorber 2 Oil leaks Replace rear shock absor...

Page 292: ...the rear shock absorber surface on which the bear ing is press fitted 2 Install Stopper ring upper bearing 1 NOTE After installing the stopper ring push back the bearing until it contacts the stopper...

Page 293: ...the adjuster beyond the maximum or minimum setting 4 Tighten Locknut 1 Rear shock absorber 1 Install Dust seal 1 O ring 2 Collar 3 NOTE Apply the molybdenum disulfide grease on the bearing Apply the...

Page 294: ...absorber frame 1 Nut rear shock absorber frame 2 NOTE Apply the molybdenum disulfide grease on the bolt 5 Install Bolt rear shock absorber relay arm 1 Nut rear shock absorber relay arm 2 NOTE Apply t...

Page 295: ...5 68 CHAS REAR SHOCK ABSORBER 8 Install Plastic band 1 Starting circuit cut off relay coupler 2 Taillight coupler 3 Locking tie 4 3 2 1 4 www PlanDeGraissage org...

Page 296: ...y blue W White Y Yellow B L Black Blue EC612000 WIRING DIAGRAM 1 23 45 6 78 9 0 A B C DEF GH I J K W R W R R B R B Br R B R B Br R W L R L B B B Sb L W W Y Y W L Y B B B W Y R Y W R L Y B Y L B L B B...

Page 297: ...throttle opening signal Pickup coil Detects signal rotor revolutions and inputs them into the computer in the CDI unit as engine revolution signals CDI unit The signals of the throttle position sensor...

Page 298: ...lowing special tools in this inspection Dynamic spark tester YM 34487 Ignition checker 90890 06754 Pocket tester YU 3112 C 90890 03112 1 Check fuse Replace fuse and check wire harness 2 Check battery...

Page 299: ...Minimum spark gap 6 0 mm 0 24 in COUPLERS LEADS AND IGNITION COIL CONNECTION INSPECTION 1 Check Couplers and leads connection Rust dust looseness short circuit Repair or replace Ignition coil and spar...

Page 300: ...lace Not continuous while the main switch is moved to ON Replace Tester lead Red lead 1 Tester lead Brown lead 2 R 1 Br 2 Testerselector position ON 1 OFF 2 Inspect Main switch indicator light Use 12...

Page 301: ...e Tester selector position 0 08 0 10 at 20 C 68 F 1 3 Inspect Secondary coil resistance Out of specification Replace Tester lead Orange lead 1 Tester lead Spark plug terminal 2 Secondary coil resistan...

Page 302: ...0 R W 1 2 NEUTRAL SWITCH INSPECTION 1 Inspect Neutral switch conduct No continuity while in neutral Replace Continuity while in gear Replace Tester lead Sky blue lead 1 Tester lead Ground 2 Sb 1 Groun...

Page 303: ...ther of these conditions has been met In this instance the starting circuit cut off relay is open so current cannot reach the starter motor When at least one of the above condi tions has been met the...

Page 304: ...y in this inspection Use the following special tools in this inspection Pocket tester YU 3112 C 90890 03112 1 Check fuse Replace fuse and check wire harness 2 Check battery Recharge or replace Check e...

Page 305: ...must have at least the same capacity or more as that of the battery lead otherwise the jumper lead may burn This check is likely to produce sparks therefore make sure nothing flammable is in the vici...

Page 306: ...inal 1 Battery lead Starter relay terminal 2 Tester lead Starter relay terminal 3 Tester lead Starter relay terminal 4 Ter minal 3 Ter minal 4 Testerselector position Connected to battery 1 Not connec...

Page 307: ...ter Blue Yellow terminal 3 Continuous Tester Sky blue terminal 2 Tester Blue Red terminal 1 No continuous Tester Blue Yellow terminal 3 Tester Blue Red terminal 1 No continuous 2 3 1 START SWITCH INSP...

Page 308: ...marks STARTER MOTOR REMOVAL Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 4 Preparation for removal 1 Starter motor 1 STARTER MOTOR DISASSEM BLY 1 Starter motor front cover 1...

Page 309: ...ca must be undercut to ensure proper operation of the commutator Min commutator diameter 16 6 mm 0 65 in Mica undercut 1 5 mm 0 06 in 4 Measure Armature assembly resistances commu tator and insulation...

Page 310: ...600 gf 14 1 21 2 oz ASSEMBLY 1 Install Brush spring 1 Brush 2 2 Install Armature assembly 1 Install while holding down the brush using a thin screw driver CAUTION Be careful not to damage the brush du...

Page 311: ...NOTE For installation align the projections on the washer with the slots in the front cover Align the match mark a on the starter motor yoke with the match mark b on the starter motor front cover a b...

Page 312: ...e inspection 1 Seat 2 Fuel tank Use the following special tool in this inspection Pocket tester YU 3112 C 90890 03112 Inductive tachometer YU 8036 B Engine tachometer 90890 03113 1 Check fuse Replace...

Page 313: ...ification If no failure is found in checking the source coil resis tance replace the rectifier regulator Tester lead Red lead 1 Tester lead Black lead 2 Charging voltage Tester selector position 14 1...

Page 314: ...following special tools in this inspection Pocket tester YU 3112 C 90890 03112 Inductive tachometer YU 8036 B Engine tachometer 90890 03113 Check entire ignition system for connection Repair or replac...

Page 315: ...k Couplers and leads connection Rust dust looseness short circuit Repair or replace THROTTLE POSITION SENSOR COIL INSPECTION 1 Inspect Throttle position sensor coil resistance Out of specification Rep...

Page 316: ...opened k 1 Zero 3 k at 20 C 68 F 4 6 k at 20 C 68 F THROTTLE POSITION SENSOR REPLACEMENT AND ADJUSTMENT 1 Remove Throttle position sensor coupler Screw throttle position sensor 1 Throttle position se...

Page 317: ...ake sure that a short circuit does not develop between the terminals because it may cause damage to electrical compo nents Tester lead Yellow lead 3 Tester lead Black lead 4 6 Start the engine 7 Adjus...

Page 318: ...VOLTAGE INSPECTION 1 Disconnect the throttle position sensor cou pler 2 Start the engine 3 Inspect Throttle position sensor input voltage Out of specification Replace the CDI unit Tester lead Blue le...

Page 319: ...the bulb and bulb socket Replace the bulb and or bulb socket Check the light switch Replace Check the AC magneto Lighting coil Replace Check the entire lighting sys tem proper for connections Repair o...

Page 320: ...Replace RECTIFIER REGULATOR INSPECTION 1 Connect the battery leads 2 Start the engine 3 Turn on the headlight and taillight by turn ing on the light switch 4 Inspect Out put voltage Out of specificati...

Page 321: ...e carburetor setting NOTE It is recommended to keep a record of all car buretor settings and external conditions e g atmospheric conditions track surface condi tions lap times to make future carbureto...

Page 322: ...may become difficult or the engine may not run well After installing the carburetor check that the throttle operates correctly and opens and closes smoothly Atmospheric conditions and carburetor setti...

Page 323: ...stem The FLATCR carburetor has a primary main jet This type of main jet is perfect for racing motorcycles since it supplies an even flow of fuel even at full load Use the main jet and the jet needle t...

Page 324: ...air fuel mixture at full throt tle can be set by changing the main jet 1 Except for USA If the air fuel mixture is too rich or too lean the engine power will drop resulting in poor accel eration Effe...

Page 325: ...ow at a smaller throttle opening each machine s pilot screw has been individually set at the factory Before adjusting the pilot screw turn it in fully and count the number of turns Record this num ber...

Page 326: ...ill not pick up speed smoothly In this case step up the jet needle clip by one groove and move down the needle to lean out the mixture 2 Too lean at intermediate speeds The engine breathes hard and wi...

Page 327: ...h different straight portion diameters Standard jet needle OBDVS OBELP Example OBDVS 4 Clip position Diameter a of straight portion Effects of changing the jet needle reference Diameter of the straigh...

Page 328: ...90 80 2 Rough engine operation is felt in quick throttle opening Select a leak jet having higher calibrating No than standard to lean out the mixture Example 90 100 Standard leak jet 90 1 Relationship...

Page 329: ...ich STD Lean 50 48 45 42 40 38 35 4MX 14948 07 4MX 14948 06 4MX 14948 05 4MX 14948 04 4MX 14948 03 4MX 14948 02 4MX 14948 01 Jet needle Rich STD Lean OBDVP OBDVQ OBDVR OBDVS OBDVT OBDVU OBDVV 5BE 1491...

Page 330: ...t the accelerator pump oper ates smoothly except for rich mixture symptom Rich mixture Raise jet needle clip position 1 groove up 1 4 3 4 throttle Hard breathing Lack of speed Lower jet needle clip po...

Page 331: ...hat has the greatest effect on the race result In such a case run through the entire course while making notes of lap times to find the best balance then determine the secondary reduction ratio If a c...

Page 332: ...4 50 EC721002 Tire pressure Tire pressure should be adjust to suit the road surface condition of the circuit Under a rainy muddy sandy or slippery condition the tire pressure should be lower for a lar...

Page 333: ...fork oil Damping characteristic near the final stroke can be changed by changing the fork oil amount CAUTION Adjust the oil level in 5 mm 0 2 in incre ments or decrements Too low oil level causes the...

Page 334: ...the fork spring 2 and damper rod 3 CAUTION Do not install three or more adjustment washers for each front fork WARNING Always adjust each front fork to the same setting Uneven adjustment can cause po...

Page 335: ...ries of gaps To set a soft spring Change the rebound damping Turn out one or two clicks Change the compression damping Turn in one or two clicks 2 Use of stiff spring Generally a stiff spring gives a...

Page 336: ...ickness PART NUMBER T 2 3 mm 0 09 in 4SS 23364 L0 TYPE SPRING RATE SPRING PART NUMBER I D MARK slits SOFT 0 380 0 390 0 400 0 410 4SS 23141 10 4SS 23141 20 4SS 23141 30 4SS 23141 40 I I I II I III I S...

Page 337: ...Choosing set length 1 Place a stand or block under the engine to put the rear wheel above the floor and measure the length a between the rear wheel axle center and the rear fender hold ing bolt 2 Remo...

Page 338: ...length 90 100 mm 3 5 3 9 in and set it 1 Use of soft spring Set the soft spring for less rebound damping to compensate for its less spring load Run with the rebound damping adjuster one or two clicks...

Page 339: ...ose overall length a does not exceed the stan dard as it may result in faulty performance Never use one whose overall length is greater than standard Coverage of spring by weight Rider weight 1 Soft 2...

Page 340: ...5UN 22212 20 Red 1 260 4 9 5UN 22212 30 Black 1 260 STD 5 0 5UN 22212 80 Orange 1 260 STD 5 1 5UN 22212 40 Blue 1 260 STIFF 5 3 5 5 5 7 5UN 22212 50 5UN 22212 60 5UN 22212 70 Yellow 1 Pink 1 White 1 2...

Page 341: ...g Oil level oil amount Spring Turn adjuster clockwise about 2 clicks to increase damping Increase oil level by about 5 10 mm 0 2 0 4 in Replace with stiff spring Stiff toward stroke end Oil level oil...

Page 342: ...bound damping Spring Turn adjuster counterclockwise about 2 clicks to decrease damping Replace with soft spring Poor road gripping Rebound damping Low compression damping High compression damp ing Spr...

Page 343: ...PRINTED IN JAPAN 2002 11 1 8 1 CR E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN www PlanDeGraissage org...

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