Yamaha YFM250XL(C) Service Manual Download Page 1

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SERVICE MANUAL

LIT-11616-12-01

4XE-F8197-10

YFM250XL(C)

Summary of Contents for YFM250XL(C)

Page 1: ...SERVICEMANUAL LIT 11616 12 01 4XE F8197 10 YFM250XL C ...

Page 2: ...amaha Motor Corporation U S A First Edition February1998 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A LIT 11616 12 01 ...

Page 3: ...ifications and significant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ...

Page 4: ... the section title 4 Lines of asterisks mark the beginning and end of a particularly important procedure The steps of such procedures are marked with bullets 5 Important information such as fluids special tools and torques are framed and marked with a corresponding symbol 6 A circled number refers to an illustrated part 7 A circled lower case letter refers to an illustrated dimension or alignment ...

Page 5: ...ue D Wear limit clearance E Engine speed F Ω V A Illustrated symbols G to L in the exploded diagrams indicate the types of lubricants and lubrication points G Apply engine oil H Apply gear oil I Apply molybdenum disulfide oil J Apply wheel bearing grease K Apply lightweight lithium soap base grease L Apply molybdenum disulfide grease Illustrated symbols M to N in the exploded diagrams indicate whe...

Page 6: ...NERAL INFORMATION 1 SPECIFICATIONS SPEC 2 PERIODIC INSPECTION AND ADJUSTMENT 3 ENGINE OVERHAUL ENG 4 CARBURETION CARB 5 DRIVE TRAIN DRIVE 6 CHASSIS CHAS 7 ELECTRICAL ELEC 8 TROUBLESHOOTING 9 GEN INFO INSP ADJ TRBL SHTG ...

Page 7: ...2 LOCK WASHERS PLATES AND COTTER PINS 1 3 BEARINGS AND OIL SEALS 1 3 CIRCLIPS 1 3 CHECKING OF CONNECTIONS 1 4 SPECIAL TOOLS 1 5 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 4 ENGINE 2 4 CHASSIS 2 14 ELECTRICAL 2 18 HOW TO USE THE CONVERSION TABLE 2 20 GENERAL TORQUE SPECIFICATIONS 2 20 LUBRICATION POINTS AND LUBRICANT TYPES 2 21 ENGINE 2 21 CHASSIS 2 22 LUBRICAT...

Page 8: ...NE OIL LEVEL INSPECTION 3 19 ENGINE OIL REPLACEMENT 3 20 CLUTCH ADJUSTMENT 3 23 AIR FILTER CLEANING 3 23 CHASSIS 3 26 FRONT AND REAR BRAKE LINING INSPECTION 3 26 FRONT BRAKE ADJUSTMENT 3 26 REAR BRAKE LEVER AND PEDAL ADJUSTMENT 3 27 DRIVE SELECT LEVER POSITION ADJUSTMENT 3 29 FINAL DRIVE GEAR OIL LEVEL INSPECTION 3 29 FINAL DRIVE GEAR OIL REPLACEMENT 3 30 DRIVE SHAFT DUST BOOT INSPECTION 3 31 STEE...

Page 9: ...SSEMBLY AND SWINGARM 4 4 ENGINE REMOVAL 4 4 ENGINE DISASSEMBLY 4 5 CYLINDER HEAD ASSEMBLY CYLINDER AND PISTON 4 5 STARTER PULLEY CDI MAGNETO 4 8 MIDDLE DRIVEN PINION GEAR 4 10 PRIMARY AND SECONDARY CLUTCHES 4 11 OIL PUMP AND SHIFTER 4 13 BALANCER DRIVEN GEAR 4 14 CRANKCASE LEFT 4 15 BALANCER SHAFT TRANSMISSION AND CRANKSHAFT 4 16 CYLINDER HEAD 4 17 VALVE 4 18 RECOIL STARTER 4 19 INSPECTION AND REP...

Page 10: ...RTER 4 44 ENGINE ASSEMBLY AND ADJUSTMENT 4 45 RECOIL STARTER 4 45 CRANKSHAFT BALANCER 4 47 TRANSMISSION 4 48 SHIFTER 4 49 CRANKSHAFT TRANSMISSION AND BALANCER SHAFT 4 50 CRANKCASE LEFT 4 51 BALANCER DRIVEN AND DRIVE GEARS 4 51 SHIFT SHAFT OIL PUMP 4 53 SHIFTER AND OIL PUMP 4 54 CLUTCH 4 56 PRIMARY AND SECONDARY CLUTCHES 4 57 MIDDLE DRIVEN PINION GEAR 4 61 STARTER PULLEY EXCEPT FOR USA CDI MAGNETO ...

Page 11: ...LE GEAR SHIMS 6 2 REMOVAL 6 3 DISASSEMBLY 6 5 INSPECTION 6 7 MIDDLE GEAR SHIM SELECTION 6 9 ASSEMBLY 6 16 MIDDLE GEAR LASH ADJUSTMENT 6 21 INSTALLATION 6 22 FINAL DRIVE GEAR AND DRIVE SHAFT 6 24 TROUBLESHOOTING 6 25 REMOVAL 6 28 DISASSEMBLY 6 29 INSPECTION 6 31 FINAL DRIVE PINION GEAR AND RING GEAR SHIM SELECTION 6 32 ASSEMBLY 6 35 FINAL GEAR GEAR LASH MEASUREMENT AND ADJUSTMENT 6 37 INSTALLATION ...

Page 12: ...SORBER AND FRONT ARM 7 28 REMOVAL 7 29 INSPECTION 7 31 INSTALLATION 7 32 REAR SHOCK ABSORBER AND SWINGARM 7 35 REMOVAL 7 36 INSPECTION 7 38 INSTALLATION 7 40 CHAPTER 8 ELECTRICAL ELECTRICAL COMPONENTS 8 1 SWITCH INSPECTION 8 2 SWITCH INSPECTION 8 2 INSPECTING A SWITCH SHOWN IN THE MANUAL 8 2 SWITCH CONTINUITY INSPECTION 8 4 CHECKING OF BULBS FOR HEADLIGHT 8 6 CHECKING BULBS CONDITION 8 6 1 SPEC 2 ...

Page 13: ...AM 8 21 TROUBLESHOOTING 8 22 LIGHTING SYSTEM 8 24 CIRCUIT DIAGRAM 8 24 TROUBLESHOOTING 8 25 LIGHTING SYSTEM CHECK 8 27 SIGNAL SYSTEM 8 29 CIRCUIT DIAGRAM 8 29 TROUBLESHOOTING 8 30 SIGNAL SYSTEM CHECK 8 32 CHAPTER 9 TROUBLESHOOTING STARTING FAILURE HARD STARTING 9 1 FUEL SYSTEM 9 1 ELECTRICAL SYSTEM 9 1 COMPRESSION SYSTEM 9 2 POOR IDLE SPEED PERFORMANCE 9 2 POOR IDLE SPEED PERFORMANCE 9 2 POOR MEDI...

Page 14: ...IPPING 9 4 CLUTCH DRAGGING 9 4 CLUTCH DRAGGING 9 4 OVERHEATING 9 5 OVERHEATING 9 5 FAULTY BRAKE 9 5 POOR BRAKING EFFECT 9 5 SHOCK ABSORBER MALFUNCTION 9 5 MALFUNCTION 9 5 UNSTABLE HANDLING 9 6 UNSTABLE HANDLING 9 6 LIGHTING SYSTEM 9 6 HEADLIGHT DARK 9 6 BULB BURNT OUT 9 6 1 SPEC 2 3 ENG 4 CARB 5 DRIVE 6 CHAS 7 ELEC 8 9 GEN INFO INSP ADJ TRBL SHTG ...

Page 15: ...ORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts 1 ...

Page 16: ...assembly clean all parts and place them in trays in the order of disassembly This will speed up assem bly and allow for the correct installation of all parts 5 Keep all parts away from any source of fire EB101010 REPLACEMENT PARTS 1 Use only genuine Yamaha parts for all replacements Use oil and grease recom mended by Yamaha for all lubrication jobs Other brands may be similar in func tion and appe...

Page 17: ...ible When installing oil seals apply a light coating of lightweight lithium base grease to the seal lips Oil bearings liber ally when installing if appropriate 1 Oil seal CAUTION Do not use compressed air to spin the bear ings dry This will damage the bearing sur faces 1 Bearing EB101050 CIRCLIPS 1 Check all circlips carefully before reas sembly Always replace piston pin clips after one use Replac...

Page 18: ...rminals several times 3 Check Connector leads Looseness Bend up the pin 1 and con nect the terminals 4 Connect Connector terminals NOTE The two terminals click together 5 Check Continuity using a pocket tester NOTE If there is no continuity clean the termi nals When checking the wire harness be sure to perform steps 1 to 3 As a quick remedy use a contact revital izer available at most part stores ...

Page 19: ... YM YU YS YK ACC P N 90890 FOR TUNE UP 1 A Valve adjusting tool 3mm 0 12 in P N YM 08035 This tool is necessary for adjusting the valve clearance 1 B Valve adjusting tool 3mm 0 12 in P N 90890 01311 This tool is necessary for adjusting the valve clearance 2 A Inductive tachometer P N YU 8036 A This tool is needed to measure engine rpm 2 B Engine tachometer P N 90890 03113 This tool is needed to me...

Page 20: ... Piston pin puller P N YU 01304 P N 90890 01304 This tool is used to remove the piston pin 3 A Flywheel puller P N YU 33270 This tool is used to remove the flywheel mag net rotor 3 B Flywheel puller P N 90890 01362 This tool is used to remove the flywheel mag net rotor 4 Flywheel puller attachment P N YM 33278 P N 90890 04087 This tool is used to remove the flywheel mag net rotor and crankcase 5 S...

Page 21: ... guide 9 B Valve guide remover and installer set 6mm 0 24 in Valve guide remover P N 90890 04064 1 Valve guide installer P N 90890 04065 2 Valve guide reamer P N 90890 04066 3 These tools are used to remove install and rebore the valve guide 10 A Crankshaft installer set P N YU 90050 These tools are used to install the crankshaft and balancer drive gear 10 B Buffer boss installer set P N 90890 040...

Page 22: ... to remove and install the universal joint 2 Bearing retainer wrench P N YM 33289 P N 90890 04104 This tool is used to disassemble and reassem ble the bearing 3 Ring nut wrench P N YM 1391 P N 90890 01391 This tool is used to remove and install the reverse gear 4 Dial gauge P N YM 03097 P N 90890 03097 This tool is used to measure the gear lash for the middle gear and final gear 5 Bearing retainer...

Page 23: ...CTRICAL COMPONENTS 1 A Dynamic spark tester P N YM 34487 This instrument is necessary for checking the ignition system components 1 B Ignition checker P N 90890 06754 This instrument is necessary for checking the ignition system components 2 Pocket tester P N YU 03112 P N 90890 03112 This instrument is invaluable for checking the electrical system 1 ...

Page 24: ...GEN INFO 1 10 1 ...

Page 25: ...ylinder Displacement 229 6 cm3 Bore stroke 71 58 mm 2 795 2 283 in Compression ratio 8 7 1 Compression pressure 900 kPa 9 0 kg cm2 128 psi Starting system Electric and recoil starter Lubrication system Wet sump Oil type or grade Engine oil Final gear oil SAE80API GL 4 Hypoid Gear Oil Oil capacity Engine oil Periodic oil change 1 5 L 1 3 Imp qt 1 6 US qt With oil filter replacement 1 6 L 1 4 Imp qt...

Page 26: ...ion system Shaft drive Secondary reduction ratio 19 18 46 11 4 414 Transmission type Constant mesh 5 speed Operation Left foot operation Gear ratio 1st 34 12 2 833 2nd 34 19 1 789 3rd 29 22 1 318 4th 26 25 1 040 5th 23 28 0 821 Reverse gear ratio 73 22 34 12 19 18 46 11 41 500 Chassis Frame type Steel tube frame Caster angle 4 Kingpin angle 13 Trail 20 mm 0 79 in Tread STD front 785 mm 30 9 in Tre...

Page 27: ...d operation Left hand and right foot operation Suspension Front suspension Strut Rear suspension Swingarm monocross Shock absorber Front shock absorber Coil spring oil damper Rear shock absorber Coil spring oil damper Wheel travel Front wheel travel 125 mm 4 92 in Rear wheel travel 135 mm 5 31 in Electrical Ignition system C D I Generator system A C magneto Battery type YB14A A2 Battery capacity 1...

Page 28: ...mshaft Drive method Chain drive Left Cam cap inside diameter 25 000 25 033 mm 0 9843 0 9855 in Camshaft outside diameter 24 96 24 98 mm 0 9827 0 9835 in Shaft to cap clearance 0 020 0 073 mm 0 0008 0 0029 in Cam dimensions Intake A 36 537 36 637 mm 1 438 1 442 in 36 437 mm 1 435 in B 30 131 30 231 mm 1 186 1 190 in 30 031 mm 1 182 in C 6 527 6 647 mm 0 257 0 262 in Exhaust A 36 582 36 682 mm 1 440...

Page 29: ...valve guide Valve clearance cold IN 0 05 0 09 mm 0 002 0 004 in EX 0 11 0 15 mm 0 004 0 006 in Valve dimensions A head diameter IN 33 9 34 1 mm 1 335 1 343 in EX 28 4 28 6 mm 1 118 1 126 in B face width IN 1 7 2 8 mm 0 067 0 110 in EX 1 7 2 8 mm 0 067 0 110 in C seat width IN 0 9 1 1 mm 0 035 0 043 in 1 6 mm 0 063 in EX 0 9 1 1 mm 0 035 0 043 in 1 6 mm 0 063 in D margin thickness IN 0 8 1 2 mm 0 0...

Page 30: ... mm 0 035 0 043 in Valve spring Inner spring Free length IN 35 5 mm 1 4 in EX 35 5 mm 1 4 in Set length valve closed IN 30 5 mm 1 2 in EX 30 5 mm 1 2 in Compressed pressure installed IN 82 4 100 0 N 8 4 10 2 kg 18 5 22 5 lb EX 82 4 100 0 N 8 4 10 2 kg 18 5 22 5 lb Tilt limit IN 2 5 1 6 mm 2 5 0 06 in EX 2 5 1 6 mm 2 5 0 06 in Direction of winding top view IN Counterclockwise EX Counterclockwise Ou...

Page 31: ...4 0 06 mm 0 0016 0 0024 in 0 15 mm 0 0059 in Piston size D 70 92 70 97 mm 2 792 2 794 in Measuring point H 4 0 mm 0 16 in from bottom line of piston skirt Piston off set 0 5 mm 0 02 in Piston off set direction In side Piston pin bore inside diameter 16 002 16 013 mm 0 6300 0 6304 in Piston pin outside diameter 15 991 16 000 mm 0 6296 0 6299 in Piston rings Top ring Type Barrel Dimensions B T 1 2 2...

Page 32: ...2 8 mm 0 098 0 110 in End gap installed 0 2 0 7 mm 0 008 0 028 in Crankshaft Crank width A 55 95 56 00 mm 2 203 2 205 in Runout limit C1 0 03 mm 0 0012 in C2 0 06 mm 0 0024 in Big end side clearance D 0 35 0 65 mm 0 014 0 026 in Big end radial clearance E 0 010 0 025 mm 0 0004 0 0010 in Small end free play F 0 8 1 0 mm 0 032 0 040 in 2 0 mm 0 08 in Balancer Balancer drive method Gear Clutch Fricti...

Page 33: ...08 mm 0 0032 in Drive axle deflection 0 08 mm 0 0032 in Shifter Shifter type Cam drum and guide bar Guide bar bending limit 0 8 mm 0 032 in Carburetor I D mark 4XE1 00 Main jet M J 95 Main air jet M A J 0 7 Jet needle J N 5CE35 Needle jet N J P 2 823 Pilot air jet P A J 1 80 Pilot air jet P A J 2 1 3 Pilot outlet P O 0 85 Pilot jet P J 42 5 Bypass 1 B P 1 0 8 Bypass 2 B P 2 0 8 Bypass 3 B P 3 0 8 ...

Page 34: ... 006 in 0 20 mm 0 008 in Side clearance 0 04 0 09 mm 0 002 0 004 in 0 09 mm 0 004 in Bypass valve setting pressure 80 120 kPa 0 8 1 2 kg cm2 11 17 psi Shaft drive Middle gear backlash forward 0 1 0 2 mm 0 004 0 008 in Middle gear backlash reverse 0 10 0 25 mm 0 004 0 010 in Final gear backlash 0 1 0 2 mm 0 004 0 008 in Item Standard Limit 2 ...

Page 35: ...MAINTENANCE SPECIFICATIONS SPEC 2 11 Item Standard Lubrication chart Crankcase tightening sequence Crankcase left Crankcase right 2 ...

Page 36: ...n plug Plug M35 1 43 4 3 31 Oil filter cover drain Bolt M6 1 10 1 0 7 2 Oil filter cover Bolt M6 2 10 1 0 7 2 Carburetor joint and cylinder head Bolt M6 2 12 1 2 8 7 Tighten cable guide together Carburetor and carburetor joint Hose clamp M4 1 2 0 2 1 4 Carburetor and joint hose Hose clamp M5 1 2 0 2 1 4 Air filter case and joint hose Hose clamp M5 1 2 0 2 1 4 Air filter case and air duct Hose clam...

Page 37: ...t Drive select lever assembly Bolt M6 2 12 1 2 8 7 Straight screw plug M14 1 15 1 5 11 Locknut Nut M8 1 15 1 5 11 select lever adjuster Nut M8 1 15 1 5 11 Lever complete Flange nut M6 1 10 1 0 7 2 Final drive gear component Final drive gear case and swingarm Flange nut M8 4 48 4 8 35 LT Oil filler bolt Bolt M14 1 23 2 3 17 Drain plug Bolt M14 1 23 2 3 17 Bearing housing ring gear Bolt M10 2 40 4 0...

Page 38: ...n Shock absorber travel 85 mm 3 35 in Suspension spring free length 263 mm 10 35 in Fitting length 244 mm 9 61 in Spring rate 49 N mm 4 9 kg mm 279 79 lb in 0 85 mm 0 3 35 in Optional spring No Swingarm Free play limit end 1 0 mm 0 04 in side 1 0 mm 0 04 in Front wheel Type Disc wheel Rim size 10 5 5AT Rim material Steel Rim runout limit radial 2 0 mm 0 08 in lateral 2 0 mm 0 08 in Rear wheel Type...

Page 39: ...ear drum brake Type Leading and trailing Drum inside diameter 160 mm 6 30 in 161 mm 6 34 in Lining thickness 4 0 mm 0 16 in 2 0 mm 0 04 in Shoe spring free length 71 0 mm 2 80 in Brake lever and brake pedal Brake lever free play at lever pivot 5 7 mm 0 20 0 28 in Brake lever free play left 5 7 mm 0 20 0 28 in Brake pedal free play 20 30 mm 0 78 1 18 in Throttle lever free play 3 5 mm 0 12 0 20 in ...

Page 40: ...olt M8 1 25 2 33 3 3 24 Engine mounting upper Nut M8 1 25 1 33 3 3 24 Engine mounting front Nut M8 1 25 1 48 4 8 35 Engine mounting rear upper Nut M8 1 25 1 33 3 3 24 Engine mounting rear lower Nut M8 1 25 1 33 3 3 24 Front fender and frame Bolt M6 1 25 2 7 0 7 5 1 Front fender and fender stay Nut M6 1 0 2 7 0 7 5 1 Front bumper and frame Bolt M8 1 25 4 16 1 6 12 Front carrier and front bumper Nut...

Page 41: ...ase Bolt M10 1 25 4 55 5 5 40 Rear shock absorber upper and frame Nut M12 1 25 1 50 5 0 36 Final drive gear case protector Bolt M8 1 25 2 17 1 7 12 Rear axle housing and swingarm Nut M12 1 25 4 103 10 3 74 Fuel tank and frame Bolt M6 1 0 2 10 1 0 7 2 Fuel tank and fuel cock Screw M6 1 0 2 5 0 5 3 6 Part to be tightened Parts name Thread size Q ty Tightening torque Remarks Nm m kg ft lb 2 ...

Page 42: ...Black C D I unit model manufacturer F8T09273 MITSUBISHI Ignition coil Model manufacturer 2JN YAMAHA Minimum spark gap 6 mm 0 24 in Primary winding resistance 0 18 0 28 Ω at 20 C 68 F Secondary winding resistance 6 3 9 5 kΩ at 20 C 68 F Spark plug cap Type Resin type Resistance 10 kΩ Charging system Type A C magneto Nominal output 14 to 15 V at 2 000 r min Stator coil resistance color 0 45 0 55 Ω a...

Page 43: ... 0 14 in Spring force 730 970 g 7 16 9 52 N Commutator diameter 28 mm 1 10 in 27 mm 1 06 in Mica undercut 0 7 mm 0 028 in Starter relay Model manufacturer MS5F 561 JIDECO Amperage rating 100 A Coil winding resistance color 4 2 4 6 Ω at 20 C 68 F Red White Blue White Starting circuit cut off relay Model manufacturer ACA12115 3 Coil winding resistance 72 88 Ω at 20 C 68 F Diode Yes Circuit breaker T...

Page 44: ... 8799 0 2199 oz IMP liq cu in qt IMP liq gal IMP liq Misc kg mm kg cm2 Centigrade C 55 997 14 2234 9 5 32 lb in psi lb in2 Fahrenheit F EB202001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fas teners with standard I S O pitch threads Torque specifications for special compo nents or assemblies are provided for each chapter of this manual To avoid warpage tighten multi fas...

Page 45: ...e stem and valve guide M Oil seal valve stem end M Rocker arm shaft and rocker arm M Cam and bearing camshaft E O ring drain plug LS Push rod E Primary driven gear and main axle E Sliding gear transmission M Free movement gear transmission M Shift fork and guide bar E Shift cam and bearing shift cam E Shift shaft E Shift ball holder and guide M Shift shaft and shift pedal LS Crankcase mating surfa...

Page 46: ...rease Rear backing plate and brake cam bracket Sealant Quick Gasket Yamaha Bond No 1215 Front brake cable joint LS Front and rear brake lever pivot LS Front brake cable adjuster and pin LS Rear brake cable adjuster and pin LS Rear brake pedal pivot LS Throttle lever holder cable end LS Drive select lever pivots LS Swingarm pivot shaft bearing LS Final drive gear case and swingarm Sealant Quick Gas...

Page 47: ...BRICATION DIAGRAMS 1 Drain plug 2 O ring 3 Compression spring 4 Oil strainer 5 Oil pump gasket 6 Oil pump assembly 7 Oil pump driven gear 8 Oil pump drive gear 9 Camshaft 0 Crank pin A Crankshaft B Main axle C Drive axle D Oil filter 2 ...

Page 48: ...C LUBRICATION DIAGRAMS 1 Bypass valve 2 Oil filter 3 Oil filter cover 4 O ring 5 Collar 6 Camshaft 7 Rocker arm 8 One way bearing Automatic centrifugal clutch 9 Crank pin 0 Crankshaft A Main axle B Drive axle 2 ...

Page 49: ...ssembly lead through the lower bracket cable guide ı Route the fuel tank breather hose through the hole in the handlebar cover and then to the right of the handlebar below the handlebar not over it Then pass the hose through the cable guide Ç Fasten the handlebar switch assembly lead and rear brake lever switch lead underneath the handlebar Position the plastic band with its tab fac ing down Î Rou...

Page 50: ...itch lead 0 Neutral switch lead A Starter motor lead B Throttle cable C Rear brake cable D Rear brake breather hose E Carburetor air vent hose F CDI magneto lead Å Route the main switch lead and indicator light lead to the side of the cable guide ı Insert the hoses into the air duct after routing them through the fuel tank grommet Ç Fasten the neutral switch lead and reverse switch lead only 2 ...

Page 51: ...e engine and swingarm Make sure that the hose is not pinched Bend the cable guide after routing the cables Ï Fasten the starter motor lead and wire har ness to the frame with the plastic clamp Ì Route the rear brake cable and rear brake breather hose through the cable guide Ó 10 mm 0 4 in È 100 mm 4 0 in Ô 40 50 mm 1 6 2 0 in 2 ...

Page 52: ...le 6 Rear brake breather hose Å Make sure that the battery breather hose is not kinked or bent ı Route the rear brake cable through the cable guide on the cyl inder Ç Fasten the starter motor lead to the frame with the metal clamp Î Fasten the battery breather hose with plastic clamps to the frame 50 60 mm 2 0 2 4 in 2 ...

Page 53: ...ide Make sure that the throttle cable is routed to the inside of the rear brake cable Ç Install the starter relay onto the tabs with its terminal side facing down Î Fasten the battery breather hose with the plastic clamp and then insert the clamp into the hole in the rear fender Install the starter circuit cut off relay onto the tab with its ter minal side facing down Ï Make sure that the grommet ...

Page 54: ...2 30 SPEC 2 ...

Page 55: ...Clean or replace if necessary Air filter Clean Replace if necessary Every 20 40 hours More often in wet or dusty area Carburetor Check idle speed starter operation Adjust if necessary Cylinder head breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check for leakage Retighten for necessary Replace gasket if necessary Fuel line Check fuel hose for cracks or...

Page 56: ...esult in serious injury or death Steering shaft Lubricate every 6 months Fittings and Fasten ers Check all chassis fittings and fasteners Correct if necessary Battery Check specific gravity Check breather pipe for proper operation Correct if necessary ITEM ROUTINE INITIAL EVERY 1 month 3 months 6 months 6 months 1 year PERIODIC MAINTENANCE LUBRICATION 3 ...

Page 57: ...R FENDER AND FUEL TANK FRONT FENDER Removal 1 Place the machine on a level place 2 Remove Front carrier 1 3 Remove Front bumper skid plate 1 4 Disconnect Dual headlight leads 1 5 Remove Front bumper 2 6 Remove Front fender 1 3 ...

Page 58: ...ame 7 Nm 0 7 m kg 5 1 ft lb Nut 3 front fender and fender stay 7 Nm 0 7 m kg 5 1 ft lb 2 Install Front bumper 1 T R Bolt front bumper and frame 16 Nm 1 6 m kg 12 ft lb 3 Install Front bumper skid plate 1 4 Install Front carrier 1 T R Bolt 2 front carrier and frame 34 Nm 3 4 m kg 25 ft lb Nut 3 front carrier and front bumper 11 Nm 1 1 m kg 8 0 ft lb 3 ...

Page 59: ...r 3 Remove Seat 1 Pull up the seat lock lever 2 then pull up the seat at the rear 4 Disconnect Battely leads negative and positive WARNING Disconnect the negative lead 1 first 5 Remove Starter relay 2 Starting circuit cut off relay 3 6 Remove Battery bracket 1 Battery breather hose 2 Battery 3 7 Remove Rear fender 1 3 ...

Page 60: ...Battery 1 Battery breather hose 2 Battery bracket 3 CAUTION When installing the battery be sure the breather hose is routed correctly Refer to the BATTERY INSPECTION section 3 Install Starting circuit cut off relay 1 Starter relay 2 4 Connect Battery leads positive and negative WARNING Connect the positive lead 3 first 5 Install Seat 1 NOTE Insert the lobes 2 on the seat front into the receptacle ...

Page 61: ...b Bolt 3 rear carrier and rear bumper 9 Nm 0 9 m kg 6 5 ft lb FUEL TANK Removal 1 Place the machine on a level place 2 Remove Seat Refer to the REAR FENDER Removal section 3 Disconnect Breather hose 1 tank cap side 4 Remove Bolt 2 with flange collar Screw 3 Rivet 4 Fuel tank cap 5 Fuel tank cover 6 5 Remove Damper plate 1 NOTE After removing the damper plate immedi ately install the tank cap on th...

Page 62: ... Bolt 1 with washer and collar 9 Disconnect Air duct 2 with hoses Grommet 3 with hoses 10 Remove Fuel tank 4 Installation Reverse the Removal procedures Note the following points 1 Install Fuel tank 1 2 Connect Air duct 2 with hoses Grommet 3 with hoses NOTE When installing the grommet the projec tion 4 should be positioned forward 3 Install Bolt 1 with washer and collar T R Bolt fuel tank and fra...

Page 63: ...tall Fuel tank cover 1 Fuel tank cap 2 Rivet 3 Screw 4 Bolt 5 with flange collar T R Bolt fuel tank cover and frame 10 Nm 1 0 m kg 7 2 ft lb 5 Connect Breather hose 1 6 Install Seat Refer to the REAR FENDER Installation section 3 ...

Page 64: ...er T D C on compression stroke Removal 1 Place the machine on a level place 2 Remove Seat Fuel tank cover Fuel tank Refer to the FUEL TANK Removal sec tion 3 Remove Timing plug 1 Recoil starter assembly 2 4 Remove Tappet cover 1 exhaust Tappet cover 2 intake Adjustment 1 Measure Valve clearance Measurement steps Turn the crank shaft counterclockwise with the wrench VALVE CLEARANCE ADJUSTMENT 3 ...

Page 65: ...dition Measure the valve clearance using a Feeler Gauge 3 Out of specification Adjust clearance Intake valve cold 0 05 0 09 mm 0 002 0 004 in Exhaust valve cold 0 11 0 15 mm 0 004 0 006 in 2 Adjust Valve clearance Valve clearance adjustment steps Loosen the locknut 1 Insert a Feeler Gauge 2 between the adjuster end and the valve stem end Turn the adjuster 3 clockwise or counter clockwise with the ...

Page 66: ...e the following points 1 Install Tappet cover 1 exhaust Tappet cover 2 intake NOTE Install the tappet covers with its ridge fac ing upward 3 Check the O ring 4 for damage If dam aged replace T R Tappet cover 10 Nm 1 0 m kg 7 2 ft lb 2 Install Fuel tank Fuel tank cover Seat Refer to the FUEL TANK Installation section TIMING CHAIN TENSIONER ADJUSTMENT This model has been equipped the auto matic timi...

Page 67: ... Use the Inductive Tachometer to confirm the engine speed Turn the pilot screw 1 again clockwise or counterclockwise in 1 8 turn increments to achieve the highest speed with just the pilot screw Once again turn the throttle stop screw 2 to attain the specified idle speed Pilot screw 2 counterclockwise turns Clockwise Idle speed becomes higher Counterclock wise Idle speed becomes lower Inductive ta...

Page 68: ...n not be adjusted on the carburetor side adjust it on the throttle housing side Adjustment steps Pull back the adjuster covers 1 from the both side throttle housing and carburetor Make sure that the adjuster 2 and locknut 3 on the throttle housing side are fully tightened Loosen the locknut 4 on the carburetor side Turn the adjuster 5 clockwise or counter clockwise until the proper free play is ob...

Page 69: ... attained Tighten the locknut WARNING Particularly for a beginner rider the speed limiter should be screwed in completely Screw it out little by little as riding tech nique improves Never remove the speed limiter from the outset For proper throttle lever operation do not turn out the adjuster more than 12 mm 0 47 in Also adjust the throttle lever free play always to 3 5 mm 0 12 0 20 in Speed limit...

Page 70: ...ent color Check the engine condition 5 Clean Spark plug Clean the spark plug with a spark plug cleaner or wire brush 6 Measure Spark plug gap a Out of specification Regap Use a wire gauge 7 Tighten Spark plug NOTE Before installing a spark plug clean the gasket surface and plug surface Finger tighten the spark plug before torquing to specification Spark plug gap 0 6 0 7 mm 0 024 0 028 in T R Spark...

Page 71: ...03141 4 Check Ignition timing Checking steps Remove the timing plug 1 Start the engine and let it idle at the speci fied idle speed CAUTION Under extreme conditions the oil may spurt out when running the engine There fore care should be used when running Visually check the stationary pointer 2 on the crankcase cover to verify it is within the firing range 3 indicated on the fly wheel Incorrect Che...

Page 72: ...ove Spark plug 3 Measure Compression pressure Measurement steps Install the Compression Gauge 1 Crank over the engine with the electric starter be sure the battery is fully charged with the throttle wide open until the compression reading on the gauge stabilizes WARNING When cranking the engine ground the spark plug lead to prevent sparking Check readings with specified levels see chart Compressio...

Page 73: ...hout oil Defective ring s valves cylinder head gasket Above maximum level Inspect cylinder head valve surface or pis ton crown for carbon deposit T R Spark plug 17 5 Nm 1 75 m kg 12 5 ft lb ENGINE OIL LEVEL INSPECTION CAUTION Do not add any chemical additives Engine oil also lubricates the clutch and additives could cause clutch slippage Do not allow foreign material to enter the crankcase 1 Place...

Page 74: ...ign material to enter the crankcase ENGINE OIL REPLACEMENT CAUTION Do not add any chemical additives Engine oil also lubricates the clutch and additives could cause clutch slippage Do not allow foreign material to enter the crankcase 1 Place the machine on a level place 2 Warm up the engine for several minutes and stop it 3 Place an oil pan under the engine 4 Remove Dipstick Drain plug 1 crankcase...

Page 75: ...with O ring Oil strainer 3 Drain plug 4 crankcase CAUTION Before reinstalling the drain plug crank case do not forget to fit the O ring 5 compression spring 6 and oil strainer Be sure you fit each item in the correct posi tion and order 10 Fill Crankcase Refer to ENGINE OIL LEVEL INSPEC TION section T R Oil filter cover 10 Nm 1 0 m kg 7 2 ft lb Drain plug crankcase 43 Nm 4 3 m kg 31 ft lb Total am...

Page 76: ...r head Start the engine and keep it idling until oil begins to seep from the oil gallery plug If no oil comes out after one minutes stop the engine immediately so it will not engine stick Restart the engine after solving the prob lem s and recheck the oil pressure Tighten the oil gallery plug to specifica tion 15 Adjust Rear brake Refer to REAR BRAKE LEVER AND PEDAL ADJUSTMENT section T R Oil gall...

Page 77: ...nut 1 NOTE Turn the adjuster counterclockwise DECREASE direction Å to decrease the clutch free play and turn it clockwise INCREASE direction ı to increase the free play T R Locknut clutch release adjuster 15 Nm 1 5 m kg 11 ft lb 1 2 INCREASE DECREASE Å ı AIR FILTER CLEANING NOTE There is check hose 1 at the bottom of the air filter case If dust and or water collects in this hose clean the air filt...

Page 78: ... result 4 Inspect Air filter element 1 Foam cover 2 Damage Replace 5 Clean Air filter element Use compressed air to blow off dust from the inner surface of the element 6 Clean Foam cover Cleaning steps Wash the foam cover gently but thor oughly in water 1 Squeeze the excess water out of the foam cover and let dry CAUTION Do not twist the foam cover when squeez ing the foam cover 3 ...

Page 79: ...tall Foam cover to air filter 8 Install Air filter assembly NOTE Make sure its sealing surface matches the sealing surface of the case so there is no air leak 9 Install Cover air filter case Seat Refer to REAR FENDER Installation sec tion 3 ...

Page 80: ...n CHAPTER 7 Rear brake 1 Depress the Rear brake pedal 2 Inspect Wear indicator 1 Indicator reaches the wear limit mark 2 Replace brake shoes as a set Refer to the REAR BRAKE section in CHAPTER 7 FRONT BRAKE ADJUSTMENT NOTE Before adjusting the front brake the front brake linings should be inspected CAUTION Proper lever free play is essential to avoid excessive brake drag 1 Check Front brake lever ...

Page 81: ...rakes left and right have some slight drag by lifting the front wheels off the ground then spin the wheels Turn the adjuster 2 clockwise or counter clockwise until proper free play is obtained Tighten the locknut Clockwise Free play is increased Counterclock wise Free play is decreased 1 2 4 3 a a a a REAR BRAKE LEVER AND PEDAL ADJUSTMENT NOTE Before adjusting the rear brake the rear brake linings...

Page 82: ...le adjuster 3 clockwise until the gap a is within the specified limits 5 Brake cam lever 6 Pin Turn out the brake lever cable adjuster 2 handlebar until proper free play is attained Tighten the locknut 1 handlebar Inspect brake lever and brake pedal free play If out of specification perform adjustment steps again WARNING After this adjustment is performed block the rear of the machine off the grou...

Page 83: ...ankcase cover Tighten the locknuts 2 NOTE After adjusting the drive select lever be sure the reverse indicator light comes on when the drive select lever is in reverse position T R Locknut select lever adjuster 15 Nm 1 5 m kg 11 ft lb FINAL DRIVE GEAR OIL LEVEL INSPECTION 1 Inspect Final drive gear oil level Oil level low Add sufficient oil NOTE The engine should be cool at atmospheric temperature...

Page 84: ...m 2 3 m kg 17 ft lb FINAL DRIVE GEAR OIL REPLACEMENT 1 Place the machine on a level place 2 Place an oil pan under the final drive gear case 3 Remove Final gear case protector Filler bolt final drive gear case Drain plug 1 gear case Drain the final drive gear oil 4 Inspect Copper washer filler bolt Copper washer drain plug Damage Replace 5 Install Drain plug final drive gear case 6 Fill Final driv...

Page 85: ...DUST BOOT INSPECTION 1 Inspect Dust boot 1 Wear Damage Replace Loose clamp 2 Tighten Refer to the REAR SHOCK ABSORBER AND SWINGARM section in CHAPTER 7 STEERING SYSTEM INSPECTION 1 Place the machine on a level place 2 Check Steering shaft bushings and bearings Move the handlebar up and down and or back and forth Excessive play Replace the steering shaft bushings and or bearings Refer to STEERING S...

Page 86: ...Bushings 4 lower arm Refer to the STEERING SYSTEM section in CHAPTER 7 TOE IN ADJUSTMENT 1 Place the machine on a level place 2 Measure Toe in Out of specification Adjust Toe in measurement steps Mark both front tire tread centers Raise the front end of the machine so that there is no weight on the front tires Fix the handlebar straight ahead Measure the width Å Between the marks Rotate the front ...

Page 87: ...s will be kept the same Tighten the rod end locknuts 2 of both tie rods WARNING Be sure that both tie rods left and right are turned by the same amount If not the machine will go right or left even though the handlebar is positioned straight and it may lead to mishandling and accident After setting the toe in to specification run the machine slowly for some distance with the hands lightly on the h...

Page 88: ...or REAR SHOCK ABSORBER AND SWINGARM section in CHAPTER 7 3 Check Operation Pump the shock absorbers up and down for several times Unsmooth operation Replace as a set Refer to the FRONT SHOCK ABSORBER AND LOWER ARM section or REAR SHOCK ABSORBER AND SWINGARM section in CHAPTER 7 Å Front shock absorber ı Rear shock absorber REAR SHOCK ABSORBER ADJUSTMENT 1 Adjust Spring preload Turn the adjuster 1 t...

Page 89: ...si Rear 25 kPa 0 25 kgf cm2 3 6 psi 2 Tire pressure below the minimum specified could cause the tire to dis lodge from the rim under severe riding conditions The following are minimums Front 17 kPa 0 17 kgf cm2 2 4 psi Rear 22 kPa 0 22 kgf cm2 3 1 psi 3 Use no more than Front 250 kPa 2 5 kgf cm2 36 psi Rear 250 kPa 2 5 kgf cm2 36 psi When seating the tire beads Higher pressures may cause the tire ...

Page 90: ...ine and may cause loss of control Maintain proper tire pressures Set tire pressures when the tires are cold Tire pressures must be equal in both front tires and equal in both rear tires 2 Inspect Tire surfaces Wear Damage Replace WARNING It is dangerous to ride with a wornout tire When a tire wear is out of specification replace the tire immediately Cold tire pressure Front rear Standard 20 kPa 0 ...

Page 91: ...WHEEL INSPECTION WHEEL INSPECTION 1 Inspect Wheels 1 Cracks Bends Damage Replace NOTE Always balance the wheel when a tire or wheel has been changed or replaced WARNING Never attempt even small repairs to the wheel 3 ...

Page 92: ... large quantities of water or milk fol low with milk of magnesia beaten egg or vegetable oil Get immediate medical attention Batteries also generate explosive hydro gen gas You should always follow these preventive measures Charge batteries in a well ventilated area Keep batteries away from fire sparks or open flames e g welding equipment lighted cigarettes etc DO NOT SMOKE When charging or han dl...

Page 93: ...charging Sulfation of one or more cells occurs as indicated by the plates turning white or an accumulation of material exists in the bottom of the cell Specific gravity readings after a long slow charge indicate one cell to be lower than the rest Warpage or buckling of plates or insula tors is evident CAUTION Always charge a new battery before using it to ensure maximum performance Charging curren...

Page 94: ...e battery be sure the breather hose is routed correctly If the breather hose touches the frame or exits in such a way as to cause battery electrolyte or gas to exit onto the frame structual and cosmetic damage to the machine can occur 3 Battery breather hose guide 9 Connect Battery leads positive and negative WARNING Connect the positive lead 1 first 10 Install Battery bracket Seat Refer to the RE...

Page 95: ...on of a fuse of improper rating can cause extensive electrical system damage and possible fire Description Amperage Quantity Main 30A 1 Spare 30A 1 1 Remove Seat Refer to the REAR FENDER Removal section 2 Remove Fuse cover 1 Fuse 3 Inspect Fuse Inspection steps Connect the Pocket Tester to the fuse and check it for continuity NOTE Set the tester selector to Ω 1 position If the tester is indicated ...

Page 96: ...RICAL for further information 5 Install Fuse cover Seat Refer to the REAR FENDER Installation section HEADLIGHT BEAM ADJUSTMENT 1 Adjust Headlight beam vertically Vertical adjustment Higher Turn the adjusting screw 1 clockwise Lower Turn the adjusting screw 1 counterclockwise HEADLIGHT BULB REPLACEMENT 1 Disconnect Headlight lead couplers 1 2 Remove Headlight unit 2 3 Pull back the bulb cover 1 4 ...

Page 97: ...m oil otherwise transpar ency of glass bulb life and illuminous flux will be adversely affected If oil gets on bulb clean it with a cloth moistened thor oughly with alcohol or lacquer thinner 7 Connect Bulb holder 1 NOTE Make sure the projections on the bulb holder are meshed with the slots on the light case 8 Set the bulb cover to the bulb holder 9 Install Headlight unit NOTE Securely install the...

Page 98: ...INSP ADJ 3 44 3 ...

Page 99: ...GENERAL INFORMATION SPE CIAL TOOLS section in the CHAPTER 1 NOTE When disassembling the engine keep mated parts together This includes gears cylinder piston and other parts that have been mated through normal wear Mated parts must be reused as an assembly or replaced 3 During engine disassembly clean all parts and place them in trays in the order of disassembly This will speed up assem bly time an...

Page 100: ...ler 2 CARBURETOR 1 Drain Fuel float chamber NOTE Place a rag under the over flow hose to absorb a spilt fuel WARNING Gasoline is highly flammable Avoid spill ing fuel on the hot engine 2 Remove Carburetor 1 Refer to the CARBURETOR section in the CHAPTER 5 NOTE Cover the carburetor with a clean rag to prevent dirt or foreign material from enter ing the carburetor 4 ...

Page 101: ...s 1 brake lever and brake pedal Pins 2 Springs 3 2 Disconnect Brake cable 4 from brake cable bracket 5 3 Remove Footrest 1 left Shift pedal 2 Front fender stay 3 4 Disconnect Footrest 1 right Spring 2 WIRINGS AND HOSES 1 Disconnect Spark plug cap CDI magneto leads 1 REVERSE switch lead 2 NEUTRAL switch lead 3 Breather hose 4 cam cover Brake cable 5 from cable guide 4 ...

Page 102: ...s 1 rubber boot Pivot shaft caps 2 Locknuts 3 pivot shaft Pivot shafts 4 swingarm 5 Remove Rear wheel drive assembly swingarm CAUTION When removing the swingarm hold the shock absorber so that it may not fall over When the swingarm is disconnected from the rubber boot the drive shaft may fall off Be careful not to lose these parts ENGINE REMOVAL 1 Remove Bolts 1 engine mounting top Bolt 2 engine m...

Page 103: ...ton can be main tained by removing the following parts Fuel tank Exhaust pipe Carburetor Engine stays top 1 Remove Recoil starter assembly 1 2 Remove Timing plug 1 Drive select lever assembly 2 Washers CAUTION Be careful not to lose washers 3 Remove Carburetor joint 1 Cam sprocket cover 2 4 Remove Spark plug 1 Tappet cover 2 intake Tappet cover 3 exhaust 4 ...

Page 104: ...inter 2 on the crankcase cover When the T mark is aligned with the stationary pointer the piston is at Top Dead Center TDC NOTE TDC on compression stroke check Both rocker arms must have a valve clear ance when the cam sprocket match mark 3 is aligned with the cylinder head match mark 4 If not give the crankshaft one counter clockwise turn too meet above condition 6 Loosen Cap bolt 1 chain tension...

Page 105: ...r pulley 4 by the Rotor Holder to loosen the bolt on the cam sprocket Rotor holder P N YU 01235 90890 01235 9 Remove Bolts cylinder head NOTE Loosen the bolts 1 4 turn each and remove them after all are loosened Loosen the bolts starting with the highest numbered one The embossed numbers in the cylinder head designate the tightening sequence 10 Remove Cylinder head assembly 1 Gasket 2 cylinder hea...

Page 106: ...o the crankcase Before removing the piston pin deburr the clip groove and pin hole area If the piston pin groove is deburred and piston pin is still difficult to remove use Piston Pin Puller CAUTION Do not use a hammer to drive the piston pin out Piston pin puller P N YU 01304 90890 01304 STARTER PULLEY CDI MAGNETO NOTE With the engine mounted the CDI magneto can be maintained by removing the foll...

Page 107: ...the bolt on the starter pulley Rotor holder P N YU 01235 90890 01235 2 Remove Crankcase cover 1 3 Remove Gasket 1 Dowel pins 2 Shaft 3 Washer 4 Idle gear 5 starter 4 Remove CDI magneto 1 NOTE Use the Flywheel puller 2 and Attachment 3 Flywheel puller P N YU 33270 90890 01362 Attachment P N YU 33278 90890 04087 4 ...

Page 108: ...ven gear 2 starter Washer 3 6 Remove Chain guide 1 intake Timing chain 2 MIDDLE DRIVEN PINION GEAR 1 Remove Bolts 1 bearing housing 2 Remove Bolts 1 middle gear case cover Middle gear case cover 2 3 Remove Middle driven pinion gear assembly 1 Dowel pins 2 4 ...

Page 109: ...case cover right 1 Remove Oil filter cover 1 Oil filter 2 O ring 3 Clutch cover protector 4 Crankcase cover 5 right Dowel pins 6 Gasket 7 2 Remove Spring 1 clutch release lever Shift guide 1 2 Ball holder 3 Shift guide 2 4 3 Straighten Lock washer tab 1 4 Remove Nut 2 primary clutch NOTE Hold the clutch carrier 3 by the Rotor Holder 4 to loosen the nut Rotor holder P N YU 01235 90890 01235 4 ...

Page 110: ...condary clutch Align one of these grooves with the primary gear 2 before removing the primary clutch assembly 6 Flatten Nut tab 1 drive pinion gear 7 Remove Nut 2 drive pinion gear Drive pinion gear 3 NOTE Hold the clutch boss 4 on the secondary clutch by the Rotor Holder 5 to loosen the nut driven pinion gear Put the engine in 1st and carry out the operation 8 Remove Push rod 1 Bearing 2 Bearing ...

Page 111: ...n plates 3 Clutch plates 4 Pressure plate 5 Washer 6 Clutch housing 7 OIL PUMP AND SHIFTER NOTE With the engine mounted the oil pump assembly can be maintained by removing the following parts Starter motor Crankcase cover right Primary and secondary clutches Crankcase spacer right Rotor holder P N YU 01235 90890 01235 1 Remove Crankcase spacer 1 right Dowel pins 2 Gasket 3 2 Remove Oil pump assemb...

Page 112: ...en removing the segment the dowel pin will fall off Take care not to lose the pin BALANCER DRIVEN GEAR NOTE With the engine mounted the balancer driven gear can be maintained by removing the following parts Starter motor Crankcase cover right Primary and secondary clutches Crankcase spacer right Oil pump assembly 1 Straighten Lock washer tab 1 driven gear 2 Remove Nut 2 driven gear NOTE Place a fo...

Page 113: ...cross pattern loosen all screws 1 4 turn each Remove them after all are loosened 2 Remove Crankcase 1 left Dowel pins Removal steps Attach the Crankcase Separating Tool 2 and Attachment 3 to the left side crank case Crankcase Separating Tool P N YU 01135 A 90890 01135 Attachment P N YM 33282 90890 04089 for USA P N YM 33278 90890 04087 except for USA 4 ...

Page 114: ...reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If one end hangs up take pres sure off the push screw realign and start over If the cases do not separate check for a remaining case screw or fitting Do not force BALANCER SHAFT TRANSMISSION AND CRANKSHAFT 1 Remove Guide bar 1 1 long Guide bar 2 2 short Shift cam 3 Sh...

Page 115: ... from right crankcase Woodruff key 4 NOTE Use a hydraulic press to remove the bal ancer drive gear 2 from the crankshaft CYLINDER HEAD 1 Straighten Lock washer tabs 1 2 Remove Lock washer 2 Retainer 3 camshaft bushing 3 Remove Camshaft 1 Camshaft bushing 2 NOTE Screw in a suitable length of 10 mm bolt 3 into the thread hole on the camshaft and pull out the camshaft 4 ...

Page 116: ...N 90890 01084 VALVE NOTE Before removing the internal parts valve valve spring valve seat etc of the cylinder head the valve sealing should be checked 1 Check Valve sealing Leakage at valve seat Inspect the valve face valve seat and valve seat width Refer to INSPECTION AND REPAIR VALVE SEAT Valve seat checking steps Pour a clean solvent 1 into the intake and exhaust ports Check the valve seating T...

Page 117: ...eat 6 lower NOTE Identify each part position very carefully so that it can be reinstalled in its original place RECOIL STARTER 1 Remove Cap 1 Starter handle 2 NOTE Before untying knot 3 pull out the rope long enough to make knot 4 on the rope so that the rope is not pulled into the case Valve spring compressor P N YM 04019 90890 04019 2 Remove Bolt 1 Drive plate 2 Spring 3 Circlip 4 Drive pawl 5 S...

Page 118: ...n Resurface Replace Cylinder head warp Less than 0 10 mm 0 004 in INTAKE AND EXHAUST VALVE 1 Check Valve face Stem end Wear Pitting Out of specification Replace Minimum thickness service limit a 0 8 mm 0 031 in Beveled b 0 5 mm 0 020 in Minimum length service limit c 4 0 mm 0 157 in 2 Inspect Valve stem end 1 Mushroom shape Larger diameter than rest of stem Replace valve valve guide and oil seal N...

Page 119: ...e oil seal if the valve is removed 1 Inspect Valve guide Wear Oil leakage into cylinder Replace 2 Remove Valve guide Use the Valve Guide Remover 1 NOTE Heat the head in an oven to 100C 212F to ease guide removal and installation and to maintain correct interference fit Valve stem clearance Valve guide inside diameter Å Valve stem diameter ı Valve stem clearance Limit Intake 0 010 0 037 mm 0 0004 0...

Page 120: ... the valve guide Valve guide installer P N YM 04065 A 90890 04065 Valve guide remover 6 0 mm P N YM 04064 A 90890 04064 Valve guide reamer 6 0 mm P N YM 04066 90890 04066 VALVE SEAT 1 Eliminate Carbon deposit from valve seat and valve face 2 Inspect Valve seat Pitting Wear Reface valve seat 3 Measure Valve seat width Out of specification Reface valve seat Measurement steps Apply the Mechanic s blu...

Page 121: ... seat width Limit Intake 0 9 1 1 mm 0 035 0 043 in 1 6 mm 0 063 in Exhaust 4 Reface Valve seat Use 30 45 and 60 Valve Seat Cutter CAUTION Remove just enough material to achieve satisfactory seat When twisting cutter keep an even downward pressure to pre vent chatter marks Valve seat refacing steps Å Valve face indicates that valve seat is cen tered on valve face but is too wide Valve seat cutter s...

Page 122: ...4 in Valve seat cutter set Desired result Use 30 cutter To center the seat and to achieve its width of 1 0 mm 0 04 in 45 cutter Valve seat cutter set Desired result Use 60 cut ter first To center the seat and increase its width 45 cutter ı Ç Î 5 Lap Valve face Valve seat NOTE After refacing the valve seat or replacing the valve and valve guide the valve seat and valve face should be lapped Valve l...

Page 123: ... sure to clean off all compound from the valve face and valve seat after every lap ping operation Apply the Mechanic s bluing dye 2 Dykem to the valve face Install the valve into the cylinder head Press the valve through the valve guide and onto the valve seat to make a clear pattern Remove the valve from the cylinder head Measure the valve seat width a again If the valve seat width is out of spec...

Page 124: ...r spring IN EX 16 6 20 4 kg 36 6 45 0 lb at 32 0 mm 1 26 in VALVE INSTALLATION 1 Lubricate Valve stem 1 Oil seal 2 Molybdenum disulfide oil 2 Install Intake valves Exhaust valves NOTE Be sure to reinstall in its original place 3 Install Valve spring seat 1 lower Oil seal 2 Valve 3 Valve spring 4 inner Valve spring 5 outer Valve spring seat 6 upper Valve cotters 7 Use the Valve Spring Compressor Va...

Page 125: ...alve seat checking steps Pour a clean solvent 1 into the intake and exhaust ports Check the valve sealing there should be no leakage at the valve seat 2 Relapping steps Reassemble head parts Repeat lapping steps using fine lapping compound Clean all parts thoroughly Reassemble and check for leakage again using solvent Repeat steps as often as necessary to effect a satisfactory seal CAM SHAFT 1 Ins...

Page 126: ...arm shaft and arm inspection steps Inspect the two areas on the rocker arm for signs of unusual wear 1 Rocker arm shaft hole 2 Cam lobe contact surface Excessive wear Replace Inspect the surface condition of the rocker arm shaft Pitting Scratches blue discoloration Replace Check lubrication Measure the inside diameter a of the rocker arm hole Out of specification Replace Measure the outside diamet...

Page 127: ... shaft 3 cam lobe journal 3 Install Rocker arms Rocker arms shafts NOTE Thread hole of the rocker arm shaft should be placed outside Install the shorter rocker arm shaft 1 with O ring 2 on the exhaust side and the longer shaft 3 with cutaway 4 on the intake side Align the slit 4 on the rocker arm shaft intake with the cylinder head bolt hole 5 and install the rocker arm shaft 4 Install Camshaft 1 ...

Page 128: ...rpendicular to the camshaft during installation 6 Install Retainer 1 camshaft bushing Lock washer new NOTE Be sure that the projection 2 on the retainer aligns with the cut out portion 3 on the camshaft busing 7 Tighten Bolts 1 camshaft bushing retainer 8 Bend the lock washer tabs 2 T R Bolts camshaft bushing retainer 8 Nm 0 8 m kg 5 8 ft lb TIMING CHAIN 1 Inspect Timing chain Chain stretch Stiff ...

Page 129: ...haust Timing chain guide 2 intake Wear Damage Replace TIMING CHAIN TENSIONER 1 Inspect Chain tensioner rod 1 Gaskets 2 Damage Wear Replace 2 Check Timing chain tensioner play Checking steps While pressing the tensioner rod lightly with fingers use a thin screwdriver 1 and wind the tensioner rod up fully clockwise When releasing the screwdriver by press ing lightly with fingers make sure that the t...

Page 130: ...ace cylinder and piston 3 Measure Piston to cylinder clearance Measurement steps First steps Measure the cylinder bore C with a cyl inder bore gauge 1 a 40 mm 1 6 in from the cylinder top NOTE Measure the cylinder bore C in parallel to and at right angles to the cylinder matching surface Then find the average of the mea surements If out of the specification rebore or replace the cylinder and the p...

Page 131: ...pis ton and piston rings as a set PISTON RING AND PISTON PIN Piston ring 1 Measure Side clearance Use the Feeler Gauge 1 Out of specification Replace piston and or rings as a set NOTE Eliminate carbon deposits from the piston ring grooves and rings before measuring the side clearance Piston skirt Diameter P Standard 70 92 70 97 mm 2 792 2 794 in Oversize 2 71 50 mm 2 815 in Oversize 4 72 00 mm 2 8...

Page 132: ...angle to the cylinder bore 3 Measure End gap Use a Feeler Gauge 1 Out of specification Replace rings as set NOTE You cannot measure end gap on expander spacer of oil control ring If oil control ring rails show excessive gap replace all three rings End gap Standard Limit Top ring 0 15 0 30 mm 0 006 0 012 in 0 4 mm 0 016 in 2nd ring 0 15 0 30 mm 0 006 0 012 in 0 4 mm 0 016 in Oil ring 0 2 0 7 mm 0 0...

Page 133: ...r a piston pin Out of specification Replace 3 Measure Piston pin bore inside diameter b piston Out of specification Replace 4 Measure Piston pin to piston clearance Out of specification Replace piston Outside diameter piston pin 15 991 16 000 mm 0 6296 0 6299 in Piston pin bore inside diameter piston 16 002 16 013 mm 0 63 0 6304 in Piston pin to piston clearance Bore size piston b Outside diameter...

Page 134: ...specification Replace or repair Small end free play F Out of specification Replace or repair Crank width 55 95 56 00 mm 2 203 2 205 in Runout limit C1 0 03 mm 0 0012 in C2 0 06 mm 0 0024 in Big end side clearance 0 35 0 65 mm 0 014 0 026 in Big end radial clearance 0 010 0 025 mm 0 0004 0 0010 in Small end free play 0 8 1 0 mm 0 032 0 040 in Limit 2 0 mm 0 08 in 2 Inspect Crankshaft bearings 1 Abn...

Page 135: ...eration Replace both gears 2 Inspect Idler gear 1 starter Idler gear shaft 2 Scratches Wear Damage Replace Driven gear 3 starter Roller contact surface 4 Bearing 5 driven gear Scratch Wear Damage Replace starter driven gear assembly Starter clutch operation Install the starter driven gear to the starter clutch and hold the starter clutch When turning the starter driven gear counter clockwise Å the...

Page 136: ...2 clutch housing Chafing Wear Damage Replace One way clutch operation Be sure that the splined inner collar 1 turns clockwise Å If the operation is not smooth or if it turns counterclockwise replace the inner collar 1 and primary clutch housing 2 as a set Clutch carrier 1 Inspect Clutch shoe Heat damage Replace 2 Measure Clutch shoe thickness Out of specification Replace SECONDARY CLUTCH Clutch ho...

Page 137: ...e friction plate as a set 2 Measure Friction plate thickness Measure at all four points Out of specification Replace friction plate as a set Wear limit 2 8 mm 0 110 in Clutch plates 1 Measure Clutch plate warpage Use the surface plate and the Feeler Gauge 1 Out of specification Replace Warp limit 0 2 mm 0 008 in Push rod and push rod bearing 1 Inspect Bearing 1 push rod Roughness Sluggishness Repl...

Page 138: ...amage Replace Clutch spring minimum length 32 9 mm 1 30 in OIL PUMP 1 Measure Housing 1 Outer rotor 2 clearance a Use a Feeler Gauge Out of specification Replace oil pump assembly Side clearance limit 0 09 mm 0 004 in 2 Measure Outer rotor 1 Inner rotor 2 clearance a Use a Feeler Gauge Out of specification Replace oil pump assembly Tip clearance limit 0 20 mm 0 008 in 3 Inspect Oil pump drive gear...

Page 139: ...t attempt to straighten a bent guide bar 3 Check Shift fork movement On its guide bar 1 Unsmooth operation Replace fork and or guide bar Shift cam 1 Inspect Shift cam grooves 1 Wear Damage Scratches Replace Shift cam segment 2 Damage Wear Replace Shift cam bearing 3 Roughness Sluggishness Replace Main drive axle and gears 1 Measure Axle runout 1 main and drive axles Use centering device and Dial G...

Page 140: ...E section in CHAPTER 6 3 Check Gear movement transmission Unsmooth operation Replace Shift shaft and stopper lever 1 Inspect Shift shaft 1 Shift pawls 2 Bend Wear Damage Replace 2 Inspect Stopper lever 3 Roller turns roughly Replace Bend Damage Replace 3 Inspect Torsion spring 4 shift shaft Spring 5 shift pawls Return spring 6 stopper lever Wear Damage Replace Shift guide 1 Inspect Shift guides 1 ...

Page 141: ...shaft and or bearing housing are replaced be sure to adjust the middle gear shim s Refer to the DRIVE TRAIN MIDDLE GEAR SERVICE section in CHAPTER 6 BEARINGS AND OIL SEALS 1 Inspect Bearings Pitting Damage Replace 2 Inspect Oil seals Damage Wear Replace CIRCLIPS AND WASHERS 1 Inspect Circlips Washers Damage Looseness Bends Replace CRANKCASE 1 Thoroughly wash the case halves in mild solvent 2 Clean...

Page 142: ...sure to adjust the middle gear shim s refer to DRIVE TRAIN MIDDLE GEAR SERVICE section in CHAPTER 6 RECOIL STARTER 1 Inspect Drive plate 1 Cracks Bends Damage Replace Drive pawl 2 Spring 3 Spring 4 drive pawl Wear Cracks Damage Replace 2 Inspect Spring 1 starter Wear Cracks Damage Replace Starter rope 2 Wear Breaks Damage Replace Sheave drum 3 Cracks Damage Replace 4 ...

Page 143: ...tall Plate 1 Starter spring case 2 NOTE Mesh the end 3 of the sheave spring with spring hook 4 on the recoil starter cover 3 Wind the rope 4 1 2 turns clockwise around the sheave drum and set the rope onto the drum slit 4 Lubricate Starter spring Sheave drum 5 Install Sheave drum 1 NOTE Make sure the two slots 2 are meshed into the two projections 3 respectively Also make sure slot 4 properly fits...

Page 144: ...ling the spring drive pawl align the spring end 7 with the groove a on the sheave drum 7 Turn the sheave drum 3 turns clockwise to preload the starter spring 8 Install Starter handle 1 Cap 2 NOTE Pass the rope through the case hole and make knot 3 on the rope so that the rope is not pulled into the case Untying knot 3 after making knot 4 4 ...

Page 145: ...ing A Crank pin B Crank left A PISTON TO CYLINDER CLEARANCE 0 04 0 06 mm 0 0016 0 0024 in B END GAP INSTALLED Top ring limit 0 4 mm 0 016 in 2nd ring limit 0 4 mm 0 016 in Oil ring 0 2 0 7 mm 0 008 0 028 in D BALANCER GEAR INSTALLATION C CRANKSHAFT A 55 95 56 00 mm 2 203 2 205 in C1 0 03 mm 0 0012 in C2 0 06 mm 0 0024 in D 0 35 0 65 mm 0 014 0 026 in E 0 010 0 025 mm 0 0004 0 0010 in F 0 8 1 0 mm ...

Page 146: ... gear 3 5th wheel gear 4 Circlip 5 Washer 6 3rd wheel gear 7 4th wheel gear 8 2nd wheel gear 9 Drive axle 0 Bearing retainer A Main axle B 5th pinion gear C 3rd pinion gear D 4th pinion gear E 2nd pinion gear F Oil seal G Shim A DRIVE MAIN AXLE RUNOUT Limit 0 08 mm 0 003 in 4 ...

Page 147: ...4 49 ENG ENGINE ASSEMBLY AND ADJUSTMENT SHIFTER 1 Guide bar 1 long 2 Shift fork 2 3 Shift fork 3 4 Shift cam segment 5 Pin 6 Bearing 7 Shift cam 8 Guide bar 2 short 9 Shift fork 1 4 ...

Page 148: ... assembly 1 main axle and drive axle 3 Install Balancer shaft 1 Shift fork 1 2 Shift fork 2 3 Shift fork 3 4 Shift cam 5 Guide bar 2 6 short Guide bar 1 7 long NOTE Each shift fork is identified by a number cast on its side 4 Check Transmission and shifter operation Unsmooth operation Repair NOTE Oil each gear and bearing thoroughly Before assembling the crankcase be sure that the transmission is ...

Page 149: ...nd torquing the crank case holding screws be sure to check whether the transmission is functioning properly by manually rotating the shift cam either way 4 Tighten Screws crankcase NOTE Tighten the screw starting with the lowest numbered one 5 Apply 4 stoke engine oil To the crank pin bearing and oil delivery hole 6 Check Crankshaft and transmission operation Unsmooth operation Repair T R Screws c...

Page 150: ...raight key 2 NOTE Align the drive gear mark 3 with the driven gear mark 4 3 Install Lock washer 1 Nut 2 driven gear WARNING Always use a new lock washer NOTE Install the lock washer tab 3 into the key way of the balancer shaft 4 4 Tighten Nut 1 driven gear NOTE Place a folded rag 2 between the teeth of the driven gear 3 and drive gear 4 to lock them 5 Bend the lock washer tab T R Nut balancer driv...

Page 151: ...BLY AND ADJUSTMENT SHIFT SHAFT OIL PUMP 1 Adjuster 2 Spring 3 Release lever 4 Shift guides 5 Ball holder 6 Shift shaft 7 Torsion spring 8 Stopper lever 9 Return spring 0 Oil seal A Shift pedal B Oil pump assembly C Gasket 4 ...

Page 152: ...nt 3 Tighten Screw 1 segment T R Screw segment 12 Nm 1 2 m kg 8 7 ft lb Use LOCTITE 4 Install Torsion spring 1 to shift shaft Washer 2 Stopper lever 3 with return spring 4 Washer 5 5 Install Shift shaft 1 NOTE Before installing the shift shaft apply the grease to the oil seal lip crankcase left Push the shift pawl 2 and the stopper lever 3 to the arrow direction and install them to the segment Be ...

Page 153: ...nkcase CAUTION Apply a liberal amount of 4 stroke engine oil to the oil pump passages in the crank case or the engine may be damaged 9 Apply 4 stroke engine oil to the oil passages in the oil pump 10 Install Gasket Oil pump assembly 1 WARNING Always use a new gasket 11 Install Gasket 1 new Dowel pin 2 Crankcase spacer 3 right WARNING Always use a new gasket T R Screw 7 Nm 0 7 m kg 5 1 ft lb T R Oi...

Page 154: ...plate 7 Pressure plate 8 Washer 9 Clutch housing secondary 0 Clutch carrier assembly A Washer B Inner collar C One way bearing D Clutch housing primary A CLUTCH SPRING MINIMUM LENGTH 0 02 mm 0 0008 in B CLUCTH PLATE WARP LIMIT 0 2 mm 0 008 in C FRICTION PLATE WEAR LIMT 2 8 mm 0 110 in D CLUTCH SHOE WEAR LIMIT 1 5 mm 0 06 in 4 ...

Page 155: ...riction plate and ending with a friction plate 3 Install Clutch boss 1 to pressure plate assembly 2 NOTE Align the arrow marks 3 on the clutch boss with the arrow mark 4 on the pressure plate 4 Install Secondary clutch assembly 1 to main axle 2 Lock washer 3 Nut 4 clutch boss WARNING Always use a new lock washer NOTE Make sure that the tabs of the lock washer engages the indentations in the clutch...

Page 156: ...aring 3 Push rod 4 T R Bolts clutch spring 6 Nm 0 6 m kg 4 3 ft lb 8 Install Drive pinion gear 1 Nut 2 drive pinion gear WARNING Always use a new drive pinion gear nut 9 Tighten Nut 2 drive pinion gear NOTE Hold the clutch boss 3 on the secondary clutch by the Rotor Holder 4 to tighten the nut 10 Lock the threads 5 with drift punch T R Nut drive pinion gear 60 Nm 6 0 m kg 43 ft lb Rotor holder P N...

Page 157: ...of these grooves with the pri mary gear 2 before installing the primary clutch housing 12 Install Lock washer 1 Nut 2 primary clutch WARNING Always use a new lock washer NOTE Make sure that the tabs of the lock washer engages the indentations in the clutch car rier 13 Tighten Nut 1 primary clutch NOTE Hold the clutch carrier 2 by the Rotor Holder 3 to tighten the nut 14 Bend the lock washer tab 4 ...

Page 158: ...t 7 in the shift guide 1 must engage the stopper shaft 8 16 Install Dowel pins 1 Gasket 2 Crankcase cover 3 Clutch cover protector 4 Oil filter 5 O ring 6 Oil filter cover 7 WARNING Always use a new gasket NOTE The clutch release lever 8 engages the shift guide 1 9 17 Tighten Screws crankcase cover NOTE Tighten the screws in stage using a criss cross pattern T R Screws crankcase cover 7 Nm 0 7 m k...

Page 159: ...ealant Quick Gasket P N ACC QUICK GS KT Yamaha Bond No 1215 P N 90890 85505 3 Install Case cover 1 middle driven shaft NOTE Before installing the middle gear case cover onto the crankcase shift the gear into FORWARD T R Bolt middle shaft case cover 10 Nm 1 0 m kg 7 2 ft lb 4 Tighten Bolts 1 bearing housing NOTE When installing the bearing housing onto the crankcase make sure that the arrow sign is...

Page 160: ...1 Timing chain 2 Timing chain guide intake 3 Woodruff key 4 Washer 5 Starter driven gear 6 Starter clutch 7 Dowel pin 8 Starter clutch spring cap 9 Compression spring 0 CDI magneto A Starter idle gear B Shaft C Washer D Circlip E Stator assembly F Crankcase cover left G Starter pulley 4 ...

Page 161: ...k shaft and CDI magneto When installing the CDI magneto make sure the key is properly seated in the key way of the crankshaft and install the CDI magneto 4 to the crankshaft then while holding the starter driven gear 2 set the CDI magneto to the driven gear turn it counterclockwise T R Chain guide intake 8 Nm 0 8 m kg 5 8 ft lb 3 Install Idle gear 1 starter Washer 2 Shaft 3 Dowel pins 4 Gasket 5 W...

Page 162: ...er pulley 1 NOTE Hold the starter pulley by the Rotor Holder to tighten the bolt Before installing the starter pulley apply the grease to the oil seal rip 2 and O ring 3 T R Bolt starter pulley 50 Nm 5 0 m kg 36 ft lb Rotor holder P N YU 01235 90890 01235 4 ...

Page 163: ...cover exhaust 5 Cylinder head 6 Bearing retainer 7 Lock washer 8 Cam sprocket cover 9 Oil seal 0 Cylinder A CYLINDER HEAD WARP LIMIT 0 10 mm 0 004 in B SPARK PLUG C TYPE MANUFACTURER DR7EA NGK D SPARK PLUG GAP 0 6 0 7 mm 0 024 0 028 in E VALVE CLEARANCE COLD INTAKE 0 05 0 09 mm 0 002 0 004 in EXHAUST 0 11 0 15 mm 0 004 0 006 in 4 ...

Page 164: ...TON CAMSHAFT AND TIMING CHAIN 1 Gasket 2 Timing chain tensioner 3 Gasket 4 Timing chain guide intake 5 Camshaft 6 Camshaft bushing 7 Cam sprocket 8 Timing chain 9 Timing chain guide exhaust 0 Piston ring A Piston pin clip B Piston C Piston pin 4 ...

Page 165: ...e WARNING Always use a new piston pin clip 2 Apply 4 stroke engine oil To the piston pin piston ring grooves and piston skirt areas 3 Install Gasket 1 cylinder Dowel pins 2 O ring 3 O ring 4 to cylinder WARNING Always use new gasket and O ring 4 Offset the piston ring end gaps as shown NOTE Be sure to check the manufacturer s marks or numbers stamped on the rings are on the top side of the rings B...

Page 166: ...embly Bolts cylinder head NOTE Apply the 4 stroke engine oil onto the washers Tighten the bolts starting with the lowest numbered one The embossed numbers in the cylinder head designate the tightening sequence 8 Tighten Bolts 1 4 cylinder head Bolts 5 6 cylinder head and cylinder Bolts cylinder T R Bolt cylinder head 22 Nm 2 2 m kg 16 ft lb Bolt cylinder head and cylinder 22 Nm 2 2 m kg 16 ft lb B...

Page 167: ...r head Insert your into the timing chain tensioner hole and push the timing chain damper inward While pushing the timing chain damper be sure cam sprocket match mark 5 align the cylinder head match mark 2 If marks is aligned tighten the cam sprocket bolt NOTE Hold the starter pulley 6 by the Rotor Holder to tighten the bolt of the cam sprocket If marks do not align change the meshing position of s...

Page 168: ...se a new gasket Remove the screwdriver from the ten sioner body and torque the tensioner assembly holding bolts Install the tensioner cap 1 with the gas ket WARNING Always use a new gasket T R Bolt cam chain tensioner assem bly 10 Nm 1 0 m kg 7 2 ft lb T R Cam chain tensioner cap 7 Nm 0 7 m kg 5 1 ft lb 11 Adjust Valve clearance Refer to the VALVE CLEARANCE ADJUSTMENT section in CHAPTER 3 Intake v...

Page 169: ...tor joint If damaged replace it 15 Install Washers 1 Drive select lever assembly 2 NOTE Before installing the drive select lever assembly do not forget to fit the washers T R Screw cam sprocket cover 7 Nm 0 7 m kg 5 1 ft lb Bolt carburetor joint 12 Nm 1 2 m kg 8 7 ft lb T R Bolt 3 drive select lever assem bly 15 Nm 1 5 m kg 11 ft lb Bolt 4 drive select lever assem bly 12 Nm 1 2 m kg 8 7 ft lb 16 I...

Page 170: ...o there is no danger of it falling over 1 Install Engine assembly from right side 2 Install Bolt 1 engine mounting rear lower Bolt 2 engine mounting rear upper Bolt 3 engine mounting front Bolts 4 engine mounting top NOTE All mounting bolts should be installed from the right of the machine Temporary tighten the nuts and bolt do not torque them at this point 4 ...

Page 171: ...ve shaft 7 Insert the drive shaft 7 into the universal joint 8 properly 4 Connect Rubber boot 1 5 Install Pivot shafts 2 swingarm Locknut 3 pivot shaft right NOTE Temporary tighten the pivot shafts and locknut do not torque them at this point 6 Check Drive shaft operation Checking steps Block the front wheels and elevate the rear wheels by placing the suitable stand under the flame Move the rear w...

Page 172: ...nt 48 Nm 4 8 m kg 35 ft lb Bolts engine mounting top 33 Nm 3 3 m kg 24 ft lb Pivot shaft swingarm left 130 Nm 13 m kg 94 ft lb Pivot shaft swingarm right 6 Nm 0 6 m kg 4 3 ft lb Locknut pivot shaft right 130 Nm 13 m kg 94 ft lb Bolt rear shock absorber top 50 Nm 5 0 m kg 36 ft lb 9 Connect Breather hose 1 final gear housing and rear brake drum to the cable guides 2 of main frame Refer to the CABLE...

Page 173: ...nnect Brake cable 1 rear Brake pedal rod 2 14 Adjust Rear brake Refer to the REAR BRAKE LEVER AND PEDAL ADJUSTMENT section in CHAP TER 3 15 Install Starter motor 1 Bracket 2 starter motor NOTE Before installing the starter motor apply the grease to the O ring 16 Connect Starter motor lead 3 T R Bolt shift pedal 10 Nm 1 0 m kg 7 2 ft lb Bolt footrest 65 Nm 6 5 m kg 47 ft lb Bolt footrest plate 30 N...

Page 174: ...3 20 Adjust Release lever free play clutch Refer to the CLUTCH ADJUSTMENT sec tion in CHAPTER 3 21 Adjust Drive select lever position Refer to the DRIVE SELECT LEVER POSI TION ADJUSTMENT section in CHAPTER 3 Total amount 1 8 L 1 6 Imp qt 1 9 US qt 18 Install Exhaust pipe 1 Muffler 2 T R Bolt muffler 34 Nm 3 4 m kg 25 ft lb Bolt muffler and exhaust pipe 20 Nm 2 0 m kg 14 ft lb Bolt exhaust pipe 10 ...

Page 175: ...r Rear carrier Front fender Front bumper Front carrier Fuel tank Seat Refer to the FENDERS AND FUEL TANK Installation section in CHAPTER 3 23 Inspect Oil leakage 24 Check NEUTRAL indicator light operation REVERSE indicator light operation Poor operation Repair 4 ...

Page 176: ...ENG 4 78 4 ...

Page 177: ... set 9 Pilot jet 0 Needle jet A Main jet B Needle valve set C Throttle stop screw D Float pin E Float SPECIFICATIONS ID MARK 4XE1 00 MAIN JET M J 95 PILOT JET P J 42 5 JET NEEDLE J N 5CE35 NEEDLE JET N J P 2 823 PILOT SCREW P S 2 turns out FLOAT HEIGHT F H 12 14 mm 0 47 0 55 in FUEL LEVEL Å F L 1 0 2 0 mm 0 04 0 08 in Above the float chamber mating surface ENGINE IDLING SPEED 1 400 1 500 r min 5 ...

Page 178: ...hose 3 3 Loosen Clamp screws 4 4 Remove Carburetor assembly CARBURETOR 5 Remove Throttle valve cover 1 6 Remove Throttle cable end 1 7 Loosen Throttle cable adjusting nut 1 8 Remove Throttle cable 2 DISASSEMBLY 1 Remove Vacuum chamber cover 1 Spring 2 Spring seat 3 Jet needle set 4 Piston valve 5 5 ...

Page 179: ... ring 2 4 Remove Float pin 1 Float 2 Needle valve 3 NOTE Remove the float pin in the direction of the arrow 5 Remove Throttle stop screw 1 Valve seat 2 Main jet 3 Pilot jet 4 Pilot screw set 5 6 Remove Needle jet 1 NOTE Remove the needle jet towards the piston valve side 5 ...

Page 180: ...ge Contamination Clean as indicated Fuel chamber body Contamination Clean Cleaning steps Wash the carburetor in a petroleum based solvent Do not use any caustic carburetor clean ing solution Blow out all of the passages and jets with compressed air 2 Inspect Valve seat 1 Needle valve 2 O ring 3 Contamination wear damage Replace as a set NOTE Always replace the needle valve and valve seat as a set ...

Page 181: ...lace Contamination Blow out the jets with compressed air 5 Inspect Spring 1 Spring seat 2 Jet needle set 3 Piston valve 4 Bends wear damage Replace 6 Inspect Diaphragm coasting enricher 1 Spring 2 Cover 3 Tears diaphragm damage Replace 7 Inspect Starter plunger 1 Bends wear damage Replace Spring 2 O ring 3 Plunger cap cover 4 Damage Replace 5 ...

Page 182: ...ee movement throttle valve Sticks Replace ASSEMBLY Reverse the DISASSEMBLY procedure Note the following points CAUTION Before reassembling wash all of the parts in a clean petroleum based solvent Always use a new gasket 1 Install Diaphragm coasting enricher 1 Spring 2 Cover 3 NOTE Match the tab on the rubber diaphragm to the matching recess in the carburetor body 2 Install Needle jet 1 NOTE Align ...

Page 183: ...in an upside down position Measure the distance from the front mat ing surface of the float chamber gasket removed to the top of the float NOTE The float arm should be resting on the nee dle valve but not compressing it If the float height is not within the specifi cation inspect the valve seat and needle valve If either is worn replace them both If both are fine adjust the float height by bending...

Page 184: ...the REMOVAL procedure Note the following points 1 Install Carburetor assembly T R Clamp screw 2 Nm 0 2 m kg 1 4 ft lb 2 Adjust Idle speed Refer to IDLE SPEED ADJUSTMENT in CHAPTER 3 Engine idle speed 1 400 1 500 r min 3 Adjust Throttle lever free play Refer to THROTTLE CABLE FREE PLAY ADJUSTMENT in CHAPTER 3 Throttle lever free play 3 5 mm 0 12 0 20 in 5 ...

Page 185: ...to the float chamber line Measure the fuel level a with the gauge If the fuel level is incorrect adjust the fuel level Remove the carburetor Inspect the valve seat and needle valve If either is worn replace them both If both are fine adjust the float level by bending the float tang 4 slightly Install the carburetor Recheck the fuel level Fuel level 1 0 2 0 mm 0 04 0 08 in Above the float chamber m...

Page 186: ...CARB 5 10 5 ...

Page 187: ...O ring 7 Reverse gear securing nut 8 Bearing 9 Bearing retainer 2 0 Shims A Reverse gear B Dog clutch C Middle driven shaft D Driven pinion gear E Shims F Bearing G Shift fork 4 H Spring I Ball J Shift fork guide bar K O ring L Lever M Shift lever shaft N Circlip O Shift lever P Stopper shaft Q Drive pinion gear R Shims S Bearing T Middle gear camp 6 ...

Page 188: ...tc are replaced be sure to adjust the middle gear shim s Refer to the MIDDLE GEAR SHIM SELECTION and MIDDLE GEAR LASH ADJUSTMENT section 1 Drive pinion gear 2 Driven pinion gear forward gear 3 Reverse gear Å Drive pinion gear shim ı Driven pinion gear shim Ç Reverse gear shim Î Middle driven shaft shim 6 ...

Page 189: ...il Refer to the ENGINE OIL REPLACE MENT section in CHAPTER 3 2 Remove Seat Fuel tank Front carrier Front bumper Front fender Rear carrier Rear fender Refer to the FENDERS AND FUEL TANK Removal section in CHAPTER 3 3 Remove Engine assembly Refer to the ENGINE REMOVAL section in the CHAPTER 4 Middle driven pinion gear 1 Remove Bolts 1 bearing housing Refer to the ENGINE DISASSEMBLY MIDDLE DRIVEN GEA...

Page 190: ...e pinion gear 2 NOTE Flatten the punched portion of the middle drive gear nut using the drift punch Put the engine in 1st and carry out the operation Use the Rotor holder 3 hold the clutch boss 4 Refer to the ENGINE DISASSEMBLY PRIMARY AND SECONDARY CLUTCHES section in CHAPTER 4 Rotor holder P N YU 01235 90890 01235 2 Remove Middle drive axle assembly 1 Refer to the ENGINE DISASSEMBLY BALANCER SHA...

Page 191: ...ress With a suitable diameter pipe beneath the yoke press the bearing into the pipe as shown NOTE It may be necessary to lightly tap the yoke with a punch Repeat the steps for the opposite bearing Remove the yoke and U joint 2 NOTE It may be necessary to lightly tap the yoke with a punch 2 Remove Nut 1 U joint Washer 2 U joint 3 NOTE Hold the U joint 3 by the Universal Joint Holder 4 and Attachmen...

Page 192: ...move Bearing retainer 1 NOTE Use a Bearing retainer wrench 2 Bearing 3 Shim s 4 5 Remove Reverse gear securing nut 1 NOTE The reverse gear securing nut has left hand threads turn the nut clockwise to loosen it Use a Ring nut wrench 2 Reverse gear 3 Shim s 4 Bearing retainer wrench 32 mm 1 26 in P N YM 33289 90890 04104 Ring nut wrench P N YM 1391 90890 01391 6 ...

Page 193: ...1 90890 01391 2 Remove Circlip 1 Stopper shaft 2 Shift lever 3 Shift lever shaft 4 INSPECTION 1 Inspect Gear teeth all gears 1 Pitting Galling Wear Replace Dog clutch 2 Wear Cracks Damage Replace Middle drive shaft 3 Middle driven shaft 4 Bends Damage Replace NOTE When the middle gear and or middle driven shaft are replaced be sure to adjust the middle gear shim s refer to the MIDDLE GEAR SHIM SEL...

Page 194: ... 2 Wear Damage Replace Ball stopper 3 Wear Damage Scratches Replace 5 Inspect Guide bar Roll the guide bar on a flat surface Bends Replace WARNING Do not attempt to straighten a bent guide bar 6 Check Shift fork movement On its guide bar 1 Unsmooth operation Replace fork and or guide bar 7 Inspect Stopper shaft 1 Shift lever 2 Shift lever shaft 3 Bends Cracks Damage Replace MIDDLE GEAR SERVICE 6 ...

Page 195: ...ion MIDDLE GEAR SHIM SELECTION Install the crankcase middle gears and mid dle driven shaft by using shim s with their respective thickness es calculated from the numbers specified on the following parts Crankcase Drive pinion gear Driven pinion gear Reverse gear Bearing housing Middle driven shaft Be sure to adjust the middle gear shim s when the following parts replaced Crankcase Drive pinion gea...

Page 196: ...j c e ı k l 0 25 1 Crankcase left 2 Drive pinion gear 3 Driven pinion gear 4 Middle driven shaft 5 Reverse gear 6 Bearing housing NOTE The gear back lash should be 0 1 mm 0 2 mm forward 0 1 mm 0 25 mm rear Adjust the middle driven shaft in order to obtain the following thrust free play 0 1 mm 0 4 mm Replaced parts Adjust shim Crankcase Å ı Ç Î Drive pinion gear Å Driven pinion gear ı Î Reverse gea...

Page 197: ... to from 41 NOTE All stamped numbers are in hundredths of a mm Drive pinion gear shim thickness Å a b Example 1 If the drive pinion gear is stamped 02 a 42 0 02 42 02 2 If the crankcase is stamped 45 b is 41 0 45 41 45 3 Therefore shim thickness Å is Å 42 02 41 45 0 57 mm 4 Shim sizes are supplied in the following thickness Because shims can only be selected in 0 05 mm increments round off hundred...

Page 198: ...ring driven pinion gear thickness considered constant 13 00 mm f The stamped number on the driven pinion gear is added to or substracted from 37 5 Example 1 If the drive pinion gear is stamped 45 c 110 0 45 110 45 2 If the crank case is stamped 02 d 59 0 02 58 98 3 If the driven pinion gear is stamped 02 f 37 5 0 02 37 52 4 Therefore shim thickness ı is ı 110 45 58 98 13 00 37 52 0 95 mm 5 Shim si...

Page 199: ...m 59 g The stamped number on the bearing housing is substracted from 7 5 h Bearing reverse gear thickness con sidered constant 12 00 mm i The stamped number on the reverse gear is added to or substracted from 39 Example 1 If the crank case is stamped 02 d 59 0 02 58 98 2 If the bearing hauging is stamped 01 g 7 5 0 01 7 49 3 If the reverse gear is stamped 02 i 39 0 02 38 98 4 Therefore shim thickn...

Page 200: ... the middle driven shaft shim Î To find reverse gear shim thickness D use following formula j The stamped number on the bearing hauging is substracted from 1 c The stamped number on the crankcase is added to from 110 e Bearing driven pinion gear width 13 00 k The stamped number on the driven pinion gear forward gear is sub stracted from 14 5 l The stamped number on the middle driven shaft is eithe...

Page 201: ...s Î 0 97 110 45 13 00 0 95 14 48 80 53 0 25 2 21 mm 6 Shim sizes are supplied in following thickness Because shims can only be selected in 0 10 mm increments round off hundredths digit and select appropriate shim s If the example above the calculated shim thickness 2 21 mm The chart instructs you however to round off the 1 to 0 then shim thickness is 2 20 mm Middle driven gear shim Thickness mm 1 ...

Page 202: ...pring 1 to shift fork 4 Ball 2 NOTE When installing the shift fork 4 onto the shift fork guide bar place a dowel pin 3 used for a crank case cover to hold the ball and spring in place 4 Lubricate Apply the molybdenum disulfide oil to shift fork inner diameter and to the pin Molybdenum disulfide oil 5 Install Shift fork guide bar 1 with O ring Shift fork 4 2 NOTE Remove the dowel pin from the shift...

Page 203: ...verse gear 2 Reverse gear securing nut 3 NOTE The reverse gear securing nut has left hand threads turn the nut counterclock wise to tighten it Use a Ring nut wrench 4 9 Tighten Reverse gear securing nut 10 Install Shim s 1 Bearing 2 Bearing retainer 3 NOTE Use a Bearing retainer wrench 4 Ring nut wrench P N YM 1391 90890 01391 T R Reverse gear securing nut LEFT HAND THREADS 60 Nm 6 0 m kg 43 ft lb...

Page 204: ...riven shaft 1 Dog clutch 2 13 Install U joint 1 Washer 2 Nut 3 U joint NOTE Hold the U joint 1 by the Universal Joint Holder 4 and Attachment 5 and tighten the U joint securing nut to specification Universal joint holder P N YM 04062 90890 04062 Attachment P N YM 33291 90890 04096 T R Nut U Joint 60 Nm 6 0 m kg 43 ft lb Use LOCTITE 6 ...

Page 205: ...lide the yoke back and forth on the bearings the yoke will not go all the way onto a bearing if a needle is out of place Press each bearing into the U joint using a suitable socket NOTE Bearing must be inserted far enough into U joint so that circlip can be installed Install the circlips 2 into the groove of each bearing Middle drive axle 1 Install Bearing 1 Shim 2 2 Install Bearing retainers 1 Us...

Page 206: ...ut the operation 5 Check Middle drive axle transmission and shifter operation Unsmooth operation Repair T R Nut middle drive pinion gear 60 Nm 6 0 m kg 43 ft lb Rotor holder P N YU 01235 90890 01235 6 Lock the thread with drift punch WARNING Always use a new nut Refer to the ENGINE ASSEMBLY AND ADJUSTMENT PRIMARY AND SECOND ARY CLUTCHES section in CHAPTER 4 Middle driven pinion gear 1 Install Midd...

Page 207: ... that the arrow sign is facing upwards 6 Check Middle driven shaft operation Unsmooth operation Repair MIDDLE GEAR LASH ADJUSTMENT NOTE When measuring backlash tighten all securing bolts middle gear case cover bearing housing with specified torque 1 Attach Gear lash measurement tool 1 Dial gauge 2 Sealant Quick Gasket P N ACC QUICK GS KT Yamaha bond No 1215 P N 90890 85505 T R Bolts middle gear ca...

Page 208: ... positions Rotate the shaft 90 each time Middle driven gear lash using measurement tool 0 1 0 2 mm 0 004 0 008 in 4 Shift Drive select lever For reverse drive 5 Repeat step 3 Over specified limit Repair Reverse gear lash 0 1 0 25 mm 0 004 0 010 in INSTALLATION Revers the REMOVAL procedures Note the following points 1 Remounting engine Refer to the ENGINE ASSEMBLY AND ADJUSTMENT REMOUNTING ENGINE s...

Page 209: ... PEDAL ADJUSTMENT section in the CHAPTER 3 4 Install Rear fender Rear carrier Front fender Front bumper Front carrier Fuel tank Seat Refer to the FENDERS AND FUEL TANK Installation section in CHAPTER 3 5 Fill Crankcase Refer to the ENGINE OIL REPLACE MENT section in CHAPTER 3 6 Check REVERSE indicator light operation Poor operation Repair Total amount 1 8 L 1 6 Imp qt 1 9 US qt 6 ...

Page 210: ... Bearing housing 2 O ring 3 Oil seal 4 Bearing 5 Ring gear shim 6 Ring gear 7 Thrust washer 8 Bearing 9 Oil seal 0 Bearing A Drive pinion gear B Final drive gear shim C Bearing D Bearing retainer E O ring F Oil seal G Collar H Drive shaft I Circlip J Universal joint K Bearing 6 ...

Page 211: ...ymptoms Possible causes 1 A pronounced hesitation or jerky move ment during acceleration deceleration or sustained speed this must not be con fused with engine surging or transmission characteristics 2 A rolling rumble noticeable at low speed a high pitched whine a clank from a drive train component or area 3 A locked up condition of the drive train mechanism no power transmitted from engine to re...

Page 212: ...CAUTION Too little gear lash is extremely destructive to the gear teeth If a test ride following reassembly indicates this condition stop riding immediately to minimize gear dam age A slight thunk evident at low speed operation This noise must be distinguished from normal machine operation Diagnosis Possible broken gear teeth WARNING Stop riding immediately if broken gear teeth are suspected This ...

Page 213: ...xcessive seal lubrication Always clean the machine and recheck the suspected location of an apparent leak age Troubleshooting chart When basic condition a and b above exist check the following points Elevate and spin the front wheels Feel for wheel bearing damage YES Replace the wheel bearing refer to the FRONT WHEELS AND FRONT BRAKE section in CHAPTER 7 NO Check the rear axle Feel for bearing dam...

Page 214: ...EAR OIL REPLACE MENT section in CHAPTER 3 2 Remove Seat Rear carrier Rear fender Refer to the FENDERS AND FUEL TANK REAR FENDER section in CHAPTER 3 3 Remove Rear wheel left Wheel hub Rear wheel right Brake drum Rear axle Refer to REAR WHEEL REAR BRAKE AND REAR AXLE Removal section in CHAPTER 7 4 Disconnect Breather hose 1 final gear case 5 Remove Final gear case unit 2 6 ...

Page 215: ...from the swingarm the drive shaft 3 may fall off Be careful not to lose these parts DISASSEMBLY 1 Remove Bolts 1 8 mm Bolts 2 10 mm NOTE Working in a crisscross pattern loosen bolt 1 4 turn each Remove them after all loos ened 2 Remove Bearing housing 1 Shim s 2 Ring gear 3 Thrust washer 4 6 ...

Page 216: ...h 1 Bearing retainer wrench P N YM 04050 90890 04050 4 Remove Drive pinion gear 1 together with the shim s 2 and bearing 3 Tap lightly on the final drive pinion gear end with a soft hammer CAUTION Final drive pinion gear removal should be performed only if gearing replacement is necessary Do not reuse bearings or races after removal 5 Remove Oil seal 1 Roller bearing 2 ring gear Use a suitable pre...

Page 217: ...cessary INSPECTION 1 Inspect Gear teeth 1 Pitting Galling Wear Replace drive pin ion gear and ring gear as a set Oil seal 2 O ring 3 Damage Replace 2 Inspect Bearings 4 Damage Replace NOTE Reuse of roller bearing OK but Yamaha recommends installation of new bearing Do not reuse the oil seal When the final drive pinion gear and or ring gear are replaced be sure to adjust the shim of the final drive...

Page 218: ...ar ring gear final gear case and or ring gear bearing housing are replaced be sure to adjust the positions for the final drive pinion gear and ring gear by the shim s Final drive pinion gear shim s selection 1 Select Final drive pinion gear shim s 1 Shim selection steps To find final drive pinion gear shim thick ness A use the following formula a The stamped number on the final drive pinion gear i...

Page 219: ...d off hundredths digit and select appropriate shim s In the example above the calculated number is 0 51 The chart instructs you to round off 1 to 0 at the hundredth place Thus the shim thickness is 0 50 mm Shim sizes are supplied in the following thickness Hundredths Round value 0 1 2 0 3 4 5 6 7 5 8 9 10 Final drive pinion gear shim Thickness mm 0 15 0 50 0 30 0 60 0 40 Ring gear shim s selection...

Page 220: ... final gear case c 42 0 53 42 53 2 If the 06 is stamped on the ring gear bearing housing d 2 0 06 2 06 mm 3 If the 05 is stamped on the ring gear e 33 0 05 32 95 mm 4 f is 11 00 5 Therefore shim thickness B is B 42 53 2 06 32 95 11 00 44 59 43 95 0 64 mm 6 Round off hundredths digit and select appropriate shim s In the example above the calculated num ber is 0 64 The chart instructs you to round o...

Page 221: ...suitable press tool 3 and a press to install the above components into the main housing WARNING Always use a new oil seal 3 Install Drive pinion gear 1 with shim s 2 and bearing 3 Shim s proper size as calculated Bearing retainer 4 drive pinion gear NOTE The bearing retainer has left hand threads turn retainer counterclockwise to tighten it Before installing the bearing retainer apply the grease t...

Page 222: ... the ring gear assembly Measure the thrust clearance Calculate width of flattened Plastigauge 1 If the out of specification select the cor rect washer T R 10 mm Bolts bearing housing 40 Nm 4 0 m kg 29 ft lb 8 mm Bolts bearing housing 23 Nm 2 3 m kg 17 ft lb Ring gear thrust clearance 0 1 0 2 mm 0 004 0 008 in Thrust washer selection steps Select suitable thrust washer by the fol lowing chart Repea...

Page 223: ... mm bolts 2 bearing housing NOTE Tighten the bolts in stage using a criss cross pattern T R 10 mm Bolts bearing housing 40 Nm 4 0 m kg 29 ft lb 8 mm Bolts bearing housing 23 Nm 2 3 m kg 17 ft lb FINAL GEAR GEAR LASH MEASUREMENT AND ADJUSTMENT Final gear gear lash measurement 1 Secure the gear case in a vise or other support 2 Remove Drain plug Gasket 3 Install A bolt of the specified size 1 Into t...

Page 224: ...han that of the calculated value for shim size on page 6 32 repeat the following steps using the measured value in step 5 NOTE Measure the gear lash at 4 positions rotate the shaft 90 each time Final gear gear lash 0 1 0 2 mm 0 004 0 008 in Final gear lash adjustment 1 Remove 8 mm bolts bearing housing 10 mm bolts bearing housing Refer to the FINAL DRIVE GEAR AND DRIVE SHAFT DISASSEMBLY section 2 ...

Page 225: ...gear shim Thickness mm 0 25 0 30 0 35 0 40 0 45 0 50 Thrust washer Thickness mm 1 2 1 7 2 0 1 4 1 8 2 1 1 6 1 9 To add or reduce ring gear shim thickness Increase by more than 0 1 mm 0 004 in Reduce by more than 0 1 mm 0 004 in Reduce thrust washer thickness by 0 1 mm 0 004 in for every 0 1 mm of ring Reverse procedure 4 Install Thrust washer 1 Ring gear 2 Shim s 3 Bearing housing 4 Refer to the F...

Page 226: ...ing 40 Nm 4 0 m kg 29 ft lb 8 mm Bolts bearing housing 23 Nm 2 3 m kg 17 ft lb Final gear lash 0 1 0 2 mm 0 004 0 008 in INSTALLATION Reverse the REMOVAL procedures Note the following points 1 Lubricate Drive shaft 1 splines 2 Apply Sealant 2 to matching surfaces of swingarm 3 and final gear case 4 Lightweight lithium soap base grease Sealant Quick Gasket P N ACC QUICK GS KT Yamaha Bond No 1215 P ...

Page 227: ...Refer to the REAR WHEEL REAR BRAKE AND REAR AXLE Installation section in CHAPTER 7 7 Fill Final gear case Refer to the FINAL GEAR OIL PEPLACE MENT section in CHAPTER 3 8 Install Rear fender Seat Rear carrier Refer to the FENDERS AND FUEL TANK REAR FENDER Installation section in CHAPTER 3 T R Bolt final gear case axle hous ing 3 55 Nm 5 5 m kg 40 ft lb Nut final gear case swingarm 4 48 Nm 4 8 m kg ...

Page 228: ...6 42 DRIV 6 ...

Page 229: ...eal C Front wheel D Collar A TIRE SIZE AT22 7 10 B RIM SIZE 5 5 10 C WHEEL RUNOUT LIMIT VERTICAL 2 mm 0 08 in LATERAL 2 mm 0 08 in D TIRE WEAR LIMIT 2 mm 0 08 in E BRAKE LINING WEAR LIMIT 2 mm 0 08 in F FRONT BRAKE DRUM WEAR LIMIT 161 mm 6 3 in TIRE AIR PRESSURE Cold Tire Pressure Front Rear Standard 20 kPa 0 20 kg cm2 2 8 psi 25 kPa 0 25 kg cm2 3 6 psi Minimum 17 kPa 0 17 kg cm2 2 4 psi 22 kPa 0 ...

Page 230: ...d under the frame WARNING Securely support the machine there is no danger of falling over 4 Remove Nuts 1 front wheel Front wheel 2 5 Remove Cotter pin 1 Axle nut 2 Plain washer 3 Brake drum 4 Spacer collar 5 6 Remove Adjuster 1 Pin 2 Spring 3 Washer C type 4 Spring 5 Circlip 6 7 Disconnect Brake cable from brake shoe plate Front brake breather hose 8 Remove Brake shoes 1 Brake shoe plate assembly...

Page 231: ...limit Replace wheel or check bearing play 1 3 Inspect Tire surfaces Wear Damage Replace Refer to the TIRE INSPECTION section in CHAPTER 3 Rim runout limits Vertical 2 2 0 mm 0 08 in Lateral 3 2 0 mm 0 08 in NOTE Install the tire with the ROTATION mark 1 to the rotating direction WARNING After replacing the tire ride conservatively to allow the tire to be properly seated in the rim Failure to do so...

Page 232: ...ake lining thickness 4 0 mm 0 16 in Wear limit 2 0 mm 0 08 in 6 Inspect Shoe springs 1 Wear Damage Replace 7 Measure Brake drum inside diameter a Out of specification Replace Front brake drum inside diame ter 160 mm 4 3 in Wear limit 161 mm 4 37 in 8 Inspect Brake drum inner surface Oil Scratches Remove Oil Use a rag soaked in lacquer thinner or a solvent Scratches Use a emery cloth lightly and ev...

Page 233: ...n the outer edge to protect this edge Remove the bearings 3 using a general bearing puller Install the new bearings and oil seal by reversing the previous steps NOTE Use a socket 4 that matches the outside diameter of the race of the bearing and oil seal CAUTION Do not strike the center race 5 or balls 6 of the bearing Contact should be made only with the outer race 7 10 Inspect Brake shoe plate 1...

Page 234: ... Pivot pin bolt 3 10 Nm 1 0 m kg 7 2 ft lb Brake camshaft holder bolt 4 10 Nm 1 0 m kg 7 2 ft lb 3 Install Brake camshaft 1 Wear indicator plate 2 Brake camshaft lever 3 NOTE When installing the wear indicator plate 2 to the brake camshaft 1 align the pro jection a on the wear indicator plate with the slot b on the brake camshaft Align the punched mark c on the brake camshaft 1 with the punched ma...

Page 235: ... 4 Pin 5 Adjuster 6 7 Install Brake drum 1 Spacer collar 2 Plain washer 3 Axle nut 4 T R Axle nut 70 Nm 7 0 m kg 50 ft lb 8 Install Cotter pin 1 NOTE Do not loosen the wheel hub nut after torque tightening If the wheel hub nut groove is not aligned with the cotter pin hole align groove with the hole by tighten ing up on the wheel hub nut WARNING Always use a new cotter pin FRONT WHEELS AND FRONT B...

Page 236: ...ing direction Å of the wheel 10 Adjust Front brake cable free play Refer to the FRONT BRAKE ADJUST MENT section in CHAPTER 3 11 Release the parking brake T R Nut front wheel 55 Nm 5 5 m kg 40 ft lb Front brake free play 5 0 8 0 mm 0 20 0 31 in at lever pivot FRONT WHEELS AND FRONT BRAKE 7 ...

Page 237: ...Rear axle 2 Bearing 3 Oil seal 4 Wheel hub 5 Axle nut A TIRE SIZE AT22 10 10 B RIM SIZE 8 10 C WHEEL RUNOUT LIMIT VERTICAL 2 0 mm 0 08 in D TIRE WEAR LIMIT 2 0 mm 0 08 in E REAR AXLE RUNOUT LIMIT 1 5 mm 0 06 in REAR WHEELS REAR BRAKE AND REAR AXLE 7 ...

Page 238: ...ke shoe 3 Bearing retainer 4 Brake shoe plate seal 5 Rear brake breather hose 6 Brake shoe plate 7 Brake camshaft 8 Wear indicator plate 9 Brake camshaft lever Yamaha brake grease A BRAKE LINING WEAR LIMIT 2 0 mm 0 08 in B REAR BRAKE DRUM WEAR LIMIT 161 mm 6 34 in 7 ...

Page 239: ...els and elevate the rear wheels by placing the suitable stand under the frame WARNING Securely support the machine there is no danger of falling over 4 Remove Nuts 1 rear wheel Rear wheel 2 left Cotter pin 3 Nut 4 Washer 5 Wheel hub 6 5 Remove Nuts 1 rear wheel Rear wheel 2 right Cotter pin 3 Axle nut 4 Washer 5 6 Release the parking brake 7 Remove Brake shoes 1 7 ...

Page 240: ...Brake shoe plate assembly 2 11 Remove Spring 1 Brake camshaft lever 2 Wear indicator plate 3 Brake camshaft 4 12 Remove O ring 1 Washer 2 13 Remove Rear axle 1 tap on right side pull out from left side NOTE When removing the rear axle from the swing arm and final gear case use a soft hammer CAUTION Never directly tap the axle and with a ham mer this will result in damage to the axle thread and spl...

Page 241: ...ge Replace Splines 2 wheel hub Wear Damage Replace 4 Inspect Brake linings 5 Measure Brake lining thickness Refer to the FRONT WHEEL AND FRONT BRAKE INSPECTION section 6 Inspect Shoe springs Refer to the FRONT WHEEL AND FRONT BRAKE INSPECTION section Brake lining thickness 4 0 mm 0 16 in Wear limit 2 0 mm 0 08 in 7 Measure Brake drum inside diameter a Out of specification Replace Front brake drum ...

Page 242: ...evenly polishing 9 Inspect Brake shoe plate 1 Cracks Bends Damage Replace Dust seal 2 Wear Damage Replace 10 Inspect Brake camshaft 1 Wear Scratches Damage Replace Rear brake breather hose 2 Obstruction Remove Damage Replace 11 Clean and blow out the rear brake breather hole of the brake shoe bracket with compressed air 12 Inspect Rear axle 1 Scratched excessively Damage Replace Splines Threads re...

Page 243: ...and oil seal replacement steps Clean the area around the bearing on the final gear case Remove the oil seal 1 use a flat head screw driver NOTE Place a wood block 2 on the outer edge to protect this edge Remove the bearing 3 using a general bearing puller Install the new bearing and oil seal by reversing the previous steps NOTE Use a socket 4 that matches the outside diameter of the race of the be...

Page 244: ...lling the rear axle loosen all the bolts on the final gear case 2 Hold the rear axle 1 with your hand and slide it into the ring gear spline on the final gear case Tap lightly on the left end rear axle with a soft hammer CAUTION Never directly tap the axle end with a ham mer this will result in damage to the axle thread and spline 3 Install Washer O ring Lithium soap base grease 4 Lubricate Brake ...

Page 245: ...Align the punched mark c on the brake camshaft 1 with the punched mark d on the brake camshaft lever 3 T R Brake camshaft lever 9 Nm 0 9 m kg 6 5 ft lb 6 Apply Sealant to matching surface of brake shoe plate and swingarm Sealant Quick Gasket P N ACC QUICK GS KT Yamaha bond No 1215 P N 90890 85505 7 Install Brake shoe plate assembly 1 Bearing retainer 2 NOTE The brake shoe plate should be installed...

Page 246: ...he axle shaft spline or the extra grease may contami nate the brake shoes during running 10 Install Brake drum Yamaha brake grease P N 90793 40003 Lithium soap base grease 11 Connect Rear brake breather hose 1 Brake rod 2 Brake cable 3 12 Install Springs Pins Adjusters 4 brake lever and brake pedal 13 Install Washer 1 Nut 2 14 Apply the parking brake 15 Tighten Nut 2 T R Nut wheel hub 150 Nm 15 m ...

Page 247: ...he wheel Refer to the FRONT WHEEL AND FRONT BRAKE INSTALLATION section WARNING Tapered wheel nuts 2 are used for rear wheels Install the nuts with its tapered side facing the wheel T R Nuts wheel panel 55 Nm 5 5 m kg 40 ft lb 18 Install Wheel hub 1 Washer 2 Nut 3 Cotter pin 4 Rear wheel 5 left Nuts 6 wheel panel Refer to the Rear wheel right section 19 Adjust Rear brake pedal free play Rear brake ...

Page 248: ...TEERING SYSTEM STEERING SYSTEM 1 Handlebar holder upper 2 Handlebar holder lower 3 Steering shaft 4 Steering bearing 5 Oil seal 6 Collar 7 Cable guide 8 Lock washer 9 Rod end 0 Tie rod A TOE IN 0 5 mm 0 0 39 in 7 ...

Page 249: ...oval section in CHAPTER 3 2 Disconnect Main switch lead NEUTRAL indicator light leads REVERSE indicator light leads Handlebar switch left leads Brake switch leads 3 Remove Handle protector 1 4 Disconnect Front brake cable 1 5 Remove Throttle lever assembly 2 6 Disconnect Brake cable 1 parking 7 Remove Handlebar 1 Handlebar holder 2 lower 7 ...

Page 250: ...Cable guide 4 3 Remove Clip steering shaft Nut Washer 4 Remove Cotter pins Nuts Tie rods 1 NOTE When removing the rod ends from the steering shaft and knuckle arm use a Gen eral Bearing Puller 5 Remove Steering shaft 1 with steering bearings from upside 6 Remove Steering bearings 1 Collars 2 Oil seals 3 7 ...

Page 251: ... WARNING Do not attempt to straighten a bent shaft this may dangerously weaken the shaft 3 Inspect Steering bearings 1 Oil seals 2 Wear Damage Replace 4 Inspect Tie rod 1 Bend Damage Replace 5 Check Rod end movement Rod end exists free play Replace Rod end tuns roughly Replace Tapered surface rod end Pitting Wear Damage Replace 7 ...

Page 252: ...eering shaft Î To knuckle NOTE The threads b on both tie rod ends must be of the same length Tighten the locknuts Tie rod assembly length a 296 mm 11 7 in T R Locknut tie rod 30 Nm 3 0 m kg 22 ft lb 7 Inspect Bushings 1 steering shaft lower O rings 2 Wear Damage Replace INSTALLATION Reverse the REMOVAL procedures Note the following points Steering shaft 1 Lubricate Busings 1 steering shaft lower O...

Page 253: ...to damage the oil seals dur ing installation 4 Install Steering shaft 1 with steering bearings WARNING Make sure the brake cables and leads are properly routed and are not damaged or twisted 5 Install Tie rods left and right NOTE Be sure that the rod end 1 on the indenta tion 2 side is connected to the knuckle arm 6 Tighten Nuts 1 tie rod end T R Nut tie rod 25 Nm 2 5 m kg 18 ft lb 7 ...

Page 254: ...e with the hole by tightening up on the axle nut WARNING Always use a new cotter pin 8 Tighten Washer Nut Clip T R Nut steering shaft 30 Nm 3 0 m kg 22 ft lb 9 Install Cable guide 1 Lock washer 2 Bolts 3 WARNING Always use a new lock washer 10 Bend the lock washer tabs 11 Lubricate Bushing steering shaft T R Bolt bearing holder 23 Nm 2 3 m kg 17 ft lb Lithium soap base grease 7 ...

Page 255: ...the throttle housing projection 1 onto the indent 2 on the front brake lever holder WARNING Proper cable and lead routing is essential to assure safe machine operation Refer to the CABLE ROUTING section in CHAP TER 2 3 Adjust Brake cable free play Refer to the FRONT BRAKE ADJUST MENT and REAR BRAKE LEVER AND PEDAL ADJUSTMENT section in CHAP TER 3 4 Adjust Toe in Refer to the TOE IN ADJUSTMENT sec ...

Page 256: ...7 28 CHAS FRONT SHOCK ABSORBER AND FRONT ARM FRONT SHOCK ABSORBER AND FRONT ARM 1 Front shock absorber 2 Steering knuckle 3 Lower arm 4 Bushing 7 ...

Page 257: ...S AND FRONT BRAKE Removal section 2 Remove Cotter pin 1 Nut 2 Tie rod end 3 NOTE When removing the rod end from the knuckle arm use a general bearing puller 3 Remove Circlip shock absorber upper 1 4 Loosen Flange nut 2 41 mm 1 6 in 5 Remove Bolts shock absorber lower 3 Flange nut 2 Shock absorber 4 front 6 Remove Cotter pin 5 Nut 6 steering knuckle Steering knuckle 7 FRONT SHOCK ABSORBER AND FRONT...

Page 258: ...ts 2 Check the lower arm side play Å by mov ing it from side to side If side play notice able replace the bushings or lower arm as a set Check the lower arm vertical movement ı by moving it up and down If vertical movement is tight binding or rough replace the bushings or lower arm as a set T R Nut lower arm 45 Nm 4 5 m kg 32 ft lb 8 Remove Nuts 1 Bolts 2 Lower arm 3 Bushings 4 FRONT SHOCK ABSORBE...

Page 259: ...r assembly Move the spring up and down 2 Inspect Steering knuckle Cracks Pitting Damage Replace WARNING Do not attempt to straighten a bent shaft this may dangerously weaken the shaft 3 Inspect Lower arm Cracks Bends Damage Replace WARNING Do not attempt to straighten a bent arm this may dangerously weaken the arm 4 Inspect Bushings 1 Wear Damage Replace as a set FRONT SHOCK ABSORBER AND FRONT ARM...

Page 260: ...rm Lithium soap base grease T R Nut lower arm 45 Nm 4 5 m kg 32 ft lb NOTE Be sure to position the front arm securing bolts front 1 and rear 2 so that the bolt heads will face outward Å Forward 3 Install Steering knuckle 1 4 Tighten Nut 2 steering knuckle T R Nut steering knuckle 25 Nm 2 5 m kg 18 ft lb FRONT SHOCK ABSORBER AND FRONT ARM 7 ...

Page 261: ...r 4 front Flange nut 5 shock absorber upper Bolts 6 shock absorber lower NOTE Make sure the flat sides 8 of the ball joint 7 are firmly held by the frame before tightening the flange nut 5 Be sure to position the shock absorber securing bolts lower 6 so that the bolts head will face forward 7 Tighten Flange nut 5 Bolts 6 8 Install Circlip 9 T R Flange nut 55 Nm 5 5 m kg 40 ft lb Bolts 78 Nm 7 8 m ...

Page 262: ... WARNING Always use a new cotter pin 10 Install Brake shoe plate Brake drum Front wheel Refer to the FRONT WHEELS AND FRONT BRAKE INSTALLATION section 11 Adjust Toe in Refer to the TOE IN ADJUSTMENT sec tion in CHAPTER 3 12 Install Front fender Front bumper Front carrier Refer to the FENDERS AND FUEL TANK FRONT FENDER Installation section in CHAPTER 3 FRONT SHOCK ABSORBER AND FRONT ARM 7 ...

Page 263: ... 1 Rear shock absorber 2 Thrust cover 3 Locknut 4 Pivot shaft 5 Collar 6 Oil seal 7 Taper roller bearing 8 Swingarm 9 Rubber boot 0 Final gear case protector A SWINGARM FREE PLAY LIMIT SIDE 1 0 mm 0 04 in REAR SHOCK ABSORBER AND SWINGARM FWD 7 ...

Page 264: ...ection 2 Remove Final gear case protector 1 3 Remove Final gear case unit 1 Refer to the FINAL DRIVE GEAR AN DRIVE SHAFT REMOVAL section in CHAPTER 6 4 Remove Clip 1 Washer 2 Shaft 3 shock absorber lower Thrust cover NOTE When removing the lower shaft 3 hold the swingarm so that it does not drop down wards when the shaft is removed REAR SHOCK ABSORBER AND SWINGARM 7 ...

Page 265: ... pivot shaft Check the swingarm side play Å by mov ing it from side to side If side play noticeable check the spacer collar bearing and frame pivot Check the swingarm vertical movement ı by moving it up and down If vertical movement is tight binding or rough check the spacer collar bearing and frame pivot T R Pivot shaft left side 130 Nm 13 0 m kg 94 ft lb Pivot shaft right side 6 Nm 0 6 m kg 4 3 ...

Page 266: ...ut right side of pivot shaft Pivot shaft swingarm 11 Remove Swingarm 1 INSPECTION 1 Inspect Shock absorber Oil leaks Replace the shock absorber assembly Shock absorber rod Bends Damage Replace the shock absorber assembly Spring Fatigue Damage Replace the shock absorber assembly Move the spring up and down 7 ...

Page 267: ...ght side Pivot shaft 2 left side Spacer collar 3 Wear Damage Replace 5 Inspect Bearings 1 swingarm Bearings allow play in the swingarm or to the bearing turns roughly Replace Oil seals 2 Wear Damage Replace Swingarm bearing and oil seal replacement steps Clean the area around the bearings on the swingarm Remove the oil seals 1 use a flat head screw driver NOTE Place a wood block 2 on the outer edg...

Page 268: ...hes the outside diameter of the race of the bearing and oil seal CAUTION Do not strike the center race 5 or balls 6 of the bearing Contact should be made only with the outer race 7 INSTALLATION Reverse the REMOVAL procedures Note the following points 1 Lubricate Bearings 1 Oil seals 2 Collars 3 Pivot shafts 4 Lithium soap base grease 2 Install Swingarm Rear axle housing Pivot shafts swingarm 7 ...

Page 269: ...the collar 3 Tighten the locknut 4 right to specifica tion T R Pivot shaft left 130 Nm 13 0 m kg 94 ft lb T R Pivot shaft right 6 Nm 0 6 m kg 4 3 ft lb T R Locknut right 130 Nm 13 0 m kg 94 ft lb 4 Inspect Swingarm free play Refer to the step 8 in the REMOVAL section 5 Lubricate Bushings shock absorber upper and lower 6 Install Shock absorber Lithium soap base grease T R Nut shock absorber upper 5...

Page 270: ... gear assembly 1 Refer to the FINAL DRIVE GEAR AND DRIVE SHAFT ASSEMBLY INSTALLA TION section in CHAPTER 6 9 Install Rear axle Brake shoe plate Brake drum Rear wheel right Wheel hub left Rear wheel left Refer to the REAR WHEEL REAR BRAKE AND REAR AXLE INSTALLATION sec tion 7 ...

Page 271: ...L COMPONENTS 1 Wire harness 2 Fuses 3 Starter relay 4 Starting circuit cut off relay 5 Battery 6 CDI unit 7 Rectifier regulator 8 Reverse switch 9 Neutral switch 0 Spark plug cap A Ignition coil B Main switch C Neutral indicator light D Reverse indicator light 8 ...

Page 272: ...12 90890 03112 INSPECTING A SWITCH SHOWN IN THE MANUAL The terminal connections for switches main switch handlebar switch engine stop switch light switch etc are shown in a chart similar to the one on the left This chart shows the switch positions in the column and the switch lead colors in the top row For each switch position indi cates the terminals with continuity The example chart shows that 1...

Page 273: ...8 3 ELEC SWITCH INSPECTION 8 ...

Page 274: ...C SWITCH INSPECTION SWITCH CONTINUITY INSPECTION Refer to SWITCH INSPECTION and check for continuity between lead terminals Poor connection no continuity Correct or replace The coupler locations are circled 8 ...

Page 275: ...ne 3 Engine stop switch 4 Starter switch 5 Main switch 6 Rear brake lever switch 7 Rear brake lever switch for New Hampshire and Maine 8 Front brake lever switch for New Hampshire and Maine 9 Rear brake pedal switch for New Hampshire and Maine 0 Reverse switch A Neutral switch B Fuse 8 ...

Page 276: ...he pocket tester selector to the Ω 1 Connect the tester leads to the respective bulb terminals First check the continuity between termi nals 1 and 2 by connecting the tester lead to terminal 1 and the tester lead to terminal 2 Then check the continuity between terminals 1 and 3 by connect ing the tester lead still to terminal 1 and the tester lead to terminal 3 If the tester shows in either case r...

Page 277: ...G Y B G Y R Br L R W L R W Br Br W W W W W W W ı B C D I K J L E F G H H 1 2 3 4 5 6 7 8 9 0 A G M N B O Br R B B W B W L W B B B Y B Y Br Y Br Y Br Y Br Y Br Y G Y B B L L L L Y R G Y O W R Br W W W W W W W G B W R Br W G B B R R R B B B B B B Br Br G L G L G L B W B W R W R W B B Br Br W Br Y R G L L G Y G Y Sb R W L W B B L Y G Y G Y G B B Y G L Sb Sb L W R R R O 1 Main switch 7 CDI magneto 8 C...

Page 278: ... 34487 Ignition checker P N 90890 06754 Pocket tester P N YU 03112 90890 03112 1 Spark plug Check the spark plug condition Check the spark plug type Check the spark plug gap Refer to SPARK PLUG INSPECTION in CHAPTER 3 Standard spark plug DR7EA CORRECT Spark plug gap 0 6 0 7 mm 0 024 0 028 in INCORRECT Repair or replace the spark plug for USA CDN 2 Ignition spark gap Disconnect the spark plug cap f...

Page 279: ...ter switch and increase the spark gap until a misfire occurs OUT OF SPECIFICATION OR NO SPARK Minimum spark gap 6 0 mm 0 24 in MEETS SPECIFICATION The ignition system is not faulty 3 Spark plug cap resistance Remove the spark plug cap Connect the pocket tester Ω 1k to the spark plug cap MEETS SPECIFICATION Check that the spark plug cap has the specified resistance Spark plug cap resistance 10 kΩ a...

Page 280: ...the primary coil has the spec ified resistance Primary coil resistance 0 18 0 28 Ω at 20 C 68 F Connect the pocket tester Ω 1k to the ignition coil BOTH MEET SPECIFICATION Check that the secondary coil has the specified resistance Secondary coil resistance 6 3 9 5 kΩ at 20 C 68 F OUT OF SPECIFICATION Replace the ignition coil CORRECT 5 Engine stop switch Refer to SWITCH INSPECTION INCORRECT Replac...

Page 281: ... SPECIFICATION Replace the pickup coil 8 Source coil resistance Disconnect the source coil coupler from the wire harness Connect the pocket tester Ω 100 to the source coil terminal Tester lead Brown terminal 1 Tester lead Black terminal 2 Br W G B W R 2 1 MEETS SPECIFICATION Check the source coil for the specified resistance Source coil resistance 270 330 Ω at 20 C 68 F Brown Black OUT OF SPECIFIC...

Page 282: ...W W W ı B C D I K J L E F G H H 1 2 3 4 5 6 7 8 9 0 A G M N B O Br R B B W B W L W B B B Y B Y Br Y Br Y Br Y Br Y Br Y G Y B B L L L L Y R G Y O W R Br W W W W W W W G B W R Br W G B B R R R B B B B B B Br Br G L G L G L B W B W R W R W B B Br Br W Br Y R G L L G Y G Y Sb R W L W B B L Y G Y G Y G B B Y G L Sb Sb L W R R R O 1 Main switch 2 Battery 3 Main fuse 4 Starter relay 5 Starter motor A St...

Page 283: ...ng when the select lever is in gear or in reverse and the rear brake lever is free In this instance the start ing circuit cut off relay is off so that current cannot reach the starter motor WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE BRAKE LEVER IS PULLED IN 1 Battery 2 Starter motor 3 Starter relay 4 Starting circuit cut off relay 5 Start switch 6 Rear brake lever switch 7 Neutral switch Å TO MA...

Page 284: ...arting system NOTE Remove the following part s before trou bleshooting 1 Seat 2 Front carrier 3 Front fender Use the following special tool s for trou bleshooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main Refer to SWITCH INSPECTION NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to BATTERY INSPECTION in CHAPTER 3 Open circuit...

Page 285: ...ks so be sure that no flammable gas or fluid is in the vicinity 4 Starting circuit cut off relay Remove the starting circuit cut off relay from the wire harness Connect the pocket tester Ω 1 and the battery 12V to the starting circuit cut off relay terminals Battery terminal Red White terminal 1 Battery terminal Green Yellow terminal 2 Tester lead Red White terminal 1 Tester lead Blue White termin...

Page 286: ... B R L W B CONTINUITY Battery terminal Blue White terminal 1 Battery terminal Black terminal 2 Tester lead Red terminal 3 Tester lead Black terminal 4 Check the starter relay for continuity NO CONTINUITY Replace the starter relay CORRECT 6 Main switch Refer to SWITCH INSPECTION INCORRECT Replace the main switch CORRECT 7 Neutral switch Refer to SWITCH INSPECTION INCORRECT Replace the neutral switc...

Page 287: ...rear brake lever switch CORRECT 9 Start switch Refer to SWITCH INSPECTION INCORRECT Replace the handlebar switch left EB803028 10 Wiring connection Check the connections of the entire start ing system Refer to CIRCUIT DIAGRAM POOR CONNECTION Properly connect the starting system ELECTRIC STARTING SYSTEM 8 ...

Page 288: ...er below 1 Starter motor lead 1 2 Starter motor bracket 1 3 Starter motor O ring 1 1 Starter motor disassembly Disassemble the parts in the order below 1 Bracket 1 1 Refer to STARTER MOTOR ASSEM BLY 2 Washer shim 1 1 3 Bracket 2 1 4 Shims 5 Brush brush spring 2 2 6 Armature coil 1 7 Yoke 1 For assembly reverse the disassembly procedure 8 ...

Page 289: ...acksaw blade which has been grounded to fit the commutator Outside diameter 28 mm 1 10 in Wear limit 27 mm 1 06 in Mica undercut 0 7 mm 0 028 in 4 Inspect Armature coil insulation continuity Defects Replace the starter motor Armature coil inspection steps Connect the pocket tester for the continu ity check 1 and insulation check 2 Measure the armature resistances If the resistance is incorrect rep...

Page 290: ... in Wear limit 3 5 mm 0 14 in 6 Measure Brush spring force Fatigue out of specification Replace as a set Brush spring force 730 970 g 7 16 9 52 N 7 Inspect Oil seal Bushing O rings Wear damage Replace STARTER MOTOR ASSEMBLY 1 Install Yoke Brackets NOTE Align the match marks a on the yoke with the match marks b on the brackets 8 ...

Page 291: ... Sb Å BLA GLAY Y B G Y B G Y B G Y B G Y R Br L R W L R W Br Br W W W W W W W B C D I K J L E F G H H 1 2 3 4 5 6 7 8 Br R B B W B W L W B O W R Br W W W W W W W G B W R Br W G B B R R R B B B B B B Br Br G L G L G L B W B W R W R W B B Br Br W Br Y R G L L G Y G Y L W B B L Y G Y G Y G B B Y G L Sb Sb L W R R R 2 Battery 3 Main fuse 6 Rectifier regulator 7 CDI magneto 8 ...

Page 292: ...Engine tachometer P N 90890 03113 Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main Refer to SWITCH INSPECTION NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to BATTERY INSPECTION in CHAPTER 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the battery terminals Recharge or replace the battery EB804011 3 Charging vo...

Page 293: ...m the wire harness Connect the pocket tester Ω 1 to the stator coils Tester lead White terminal 1 Tester lead White terminal 2 Tester lead White terminal 1 Tester lead White terminal 3 Measure the stator coil resistance Stator coil resistance 0 45 0 55 Ω at 20 C 68 F OUT OF SPECIFICATION Replace the stator coil assembly EB804015 CORRECT 5 Wiring connections Check the connections of the entire char...

Page 294: ... R W L R W Br Br W W W W W W W ı B C D I K J L E F G H H 1 2 3 4 5 6 7 8 9 0 A G M N B O Br R B B W B W L W B B B Y B Y Br Y Br Y Br Y Br Y Br Y G Y B B L L L L Y R G Y O W R Br W W W W W W W G B W R Br W G B B R R R B B B B B B Br Br G L G L G L B W B W R W R W B B Br Br W Br Y R G L L G Y G Y Sb R W L W B B L Y G Y G Y G B B Y G L Sb Sb L W R R R O 1 Main switch 2 Battery 3 Main fuse C Taillight...

Page 295: ...e trou bleshooting 1 Seat 2 Front carrier 3 Front fender Use the following special tool s for trou bleshooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main Refer to SWITCH INSPECTION NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to BATTERY INSPECTION in CHAPTER 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean...

Page 296: ...efer to SWITCH INSPECTION Lights switch is faulty replace the handle bar switch left EB805013 CORRECT 5 Wiring connection Check the connections of the entire light ing system Refer to WIRING DIAGRAM Check the condition of each of the lighting system s circuits Refer to LIGHTING SYSTEM CHECK POOR CONNECTION Properly connect the lighting system 8 ...

Page 297: ...he headlight couplers Tester lead Green terminal 1 or Yellow terminal 2 Tester lead Black terminal 3 Å When the lights switch is on LO ı When the lights switch is on HI ı MEETS SPECIFICATION Turn the main switch to ON Turn the lights switch to LO or HI Check the voltage 12V of the Green and Yellow leads on the bulb socket connector This circuit is not faulty OUT OF SPECIFICATION The wiring circuit...

Page 298: ...ct the pocket tester DC 20 V to the taillight leads Tester lead Blue terminal 1 Tester lead Black terminal 2 1 2 L B L B MEETS SPECIFICATION Turn the main switch to ON Turn the lights switch to LO or HI Check the voltage 12V of the Blue lead on the bulb socket connector This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket connector is faulty re...

Page 299: ...9 0 A G M N B O Br R B B W B W L W B B B Y B Y Br Y Br Y Br Y Br Y Br Y G Y B B L L L L Y R G Y O W R Br W W W W W W W G B W R Br W G B B R R R B B B B B B Br Br G L G L G L B W B W R W R W B B Br Br W Br Y R G L L G Y G Y Sb R W L W B B L Y G Y G Y G B B Y G L Sb Sb L W R R R O 1 Main switch 2 Battery 3 Main fuse B Rear brake lever switch G Lights switch I Neutral indicator light J Neutral switch...

Page 300: ...u bleshooting 1 Seat 2 Front carrier 3 Front fender Use the following special tool s for trou bleshooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse main Refer to SWITCH INSPECTION NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to BATTERY INSPECTION in CHAPTER 3 Open circuit voltage 12 8 V or more at 20 C 68 F INCORRECT Clean the ...

Page 301: ...CORRECT Replace the main switch EB806011 CORRECT 4 Wiring connections Check the connections of the entire sig nal system Refer to CIRCUIT DIAGRAM Check the condition of each of the signal system s circuits Refer to SIGNAL SYSTEM CHECK POOR CONNECTION Properly connect the signal system 8 ...

Page 302: ...ITY 2 Neutral switch Refer to SWITCH INSPECTION NO CONTINUITY Replace the neutral switch 3 Voltage Connect the pocket tester DC 20 V to the bulb socket leads Tester lead Brown terminal 1 Tester lead Sky blue terminal 2 1 2 Br Sb Br Sb MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main switch to the ...

Page 303: ...tch Refer to SWITCH INSPECTION NO CONTINUITY Replace the reverse switch 3 Voltage Connect the pocket tester DC 20 V to the bulb socket leads Tester lead Brown terminal 1 Tester lead Green Blue terminal 2 1 2 Br G Y G Y Br MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main switch to the bulb socket c...

Page 304: ...ONDITION Replace the brake switches CONTINUITY 3 Lights switch Refer to SWITCH INSPECTION NO CONDITION Replace the lights switch 4 Voltage Connect the pocket tester DC 20 V to the bulb socket leads Tester lead Blue terminal 1 Tester lead Yellow terminal 2 1 2 L L Y Y B B MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V This circuit is not faulty OUT OF SPECIFICATION The wiring...

Page 305: ...per heat range Faulty spark plug cap Ignition coil Broken or shorted primary secondary Faulty spark plug lead Broken body CDI system Faulty CDI unit Faulty pickup coil Faulty source coil Broken woodruff key Carburetor Deteriorated or contaminated fuel Clogged pilot jet Clogged pilot air passage Sucked in air Deformed float Worn needle valve Improperly sealed valve seat Improperly adjusted fuel lev...

Page 306: ...LE SPEED PERFORMANCE POOR IDLE SPEED PERFORMANCE Carburetor Improperly returned starter plunger Loose pilot jet Clogged pilot jet Clogged pilot air jet Improperly adjusted idle speed Throttle stop screw Improper throttle cable play Flooded carburetor Electrical system Faulty spark plug Faulty CDI unit Faulty pickup coil Faulty source coil Faulty ignition coil Valve train Improperly adjusted valve ...

Page 307: ...le Causes 1 A pronounced hesitation or jerky move ment during acceleration deceleration or sustained speed This must not be con fused with engine surging or transmission characteristics 2 A rolling rumble noticeable at low speed a high pitched whine a clunk from a shaft drive component or area 3 A locked up condition of the shaft drive mechanism no power transmitted from the engine to the rear whe...

Page 308: ...topper lever Shift fork Worn shift fork Shift cam Improper thrust play Worn shift cam groove Transmission Worn gear dog CLUTCH SLIPPING CLUTCH SLIPPING Engine oil Low oil level Improper quality low viscosity Deterioration CLUTCH DRAGGING CLUTCH DRAGGING Clutch Improperly adjusted clutch release lever free play Improper engagement of release lever and push rod Warped clutch plate Swollen friction p...

Page 309: ...tem Heavy carbon build up Engine oil Improper oil level Improper oil viscosity Inferior oil quality Brake Brake drag FAULTY BRAKE POOR BRAKING EFFECT Drum brake Worn brake shoe lining Worn brake drum Oily or greasy brake shoe lining Oily or greasy brake drum Improperly adjusted brake free play Improper brake cam lever position Fatigued damaged return spring Broken brake cable SHOCK ABSORBER MALFUN...

Page 310: ...pressure Uneven tire wear Wheels Deformed wheel Loose bearing Bent or loose wheel axle Excessive wheel runout Frame Bent Damaged frame Swingarm Worn bearing or bushing Bent or damaged LIGHTING SYSTEM HEADLIGHT DARK Improper bulb Too many electric accessories Hard charging broken stator coil and or faulty rectifier regulator Incorrect connection Improperly grounded Poor contacts main or lights swit...

Page 311: ...W B L W B R W O B W Br B W G W R OFF ON OFF LO HI LO HI OFF ON RUN OFF R L W B G Y Sb L W R W ı Å Å BLACK GLAY GLAY Br Y B B BLACK BLACK Y B G Y B G Y B G Y B G Y R Br L R W L R W Br Br W W W W W W W ı B C D I K J L E F G H H 1 2 3 4 5 6 7 8 9 0 A G M N B O Br R B B W B W L W B B B Y B Y Br Y Br Y Br Y Br Y Br Y G Y B B L L L L Y R G Y O W R Br W W W W W W W G B W R Br W G B B R R R B B B B B B Br...

Page 312: ...PRINTED IN U S A YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 313: ...SUPPLEMENTARY SERVICEMANUAL LIT 11616 14 17 4XE F8197 11 YFM250XN ...

Page 314: ...on of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A LIT 11616 14 17 FOREWORD This Supplementary Service Manual has been prepared to introduce new service and new data for the YFM250XN For complete information on service procedures it is necessary to use this Supple mentary Service Manual together with the following manual YFM250XL C SERVICE MANUAL 4XE F8197 10 ...

Page 315: ...ications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means A...

Page 316: ...n the section title 4 Lines of asterisks mark the beginning and end of a particularly important procedure The steps of such procedures are marked with bullets 5 Important information such as fluids special tools and torques are framed and marked with a corresponding symbol 6 A circled number refers to an illustrated part 7 A circled lower case letter refers to an illustrated dimension or alignment...

Page 317: ...ue D Wear limit clearance E Engine speed F Ω V A Illustrated symbols G to L in the exploded diagrams indicate the types of lubricants and lubrication points G Apply engine oil H Apply gear oil I Apply molybdenum disulfide oil J Apply wheel bearing grease K Apply lightweight lithium soap base grease L Apply molybdenum disulfide grease Illustrated symbols M to N in the exploded diagrams indicate whe...

Page 318: ...4 ENGINE 16 SPARK ARRESTER CLEANING 16 CHASSIS 17 FRONT BRAKE FLUID LEVEL INSPECTION 17 FRONT BRAKE PAD INSPECTION 17 BRAKE HOSE INSPECTION 18 AIR BLEEDING HYDRAULIC BRAKE SYSTEM 18 CHASSIS 20 FRONT WHEEL 20 REMOVAL 21 INSPECTION 22 FRONT BRAKE 23 BRAKE PAD REPLACEMENT 24 CALIPER DISASSEMBLY 26 MASTER CYLINDER DISASSEMBLY 27 INSPECTION AND REPAIR 28 CALIPER ASSEMBLY 31 MASTER CYLINDER ASSEMBLY 34 ...

Page 319: ...CAL 40 ELECTRICAL COMPONENTS 40 IGNITION SYSTEM 41 CIRCUIT DIAGRAM 41 TROUBLESHOOTING 42 ELECTRIC STARTING SYSTEM 47 CIRCUIT DIAGRAM 47 STARTING CIRCUIT OPERATION 48 TROUBLESHOOTING 49 YFM250XN WIRING DIAGRAM ...

Page 320: ...ORMATION MACHINE IDENTIFICATION VEHICLE IDENTIFICATION NUMBER The vehicle identification number 1 is stamped into the left side of the frame MODEL LABEL The model label 1 is affixed to the frame This information will be needed to order spare parts ...

Page 321: ...22 10 10 Manufacturer front CARLISLE DUNLOP CHENG SHIN rear CARLISLE DUNLOP CHENG SHIN Type front TRAIL WOLF KT701 M905 rear TRAIL WOLF KT705 M906 Brake Front brake type Single disc brake operation Right hand operation Rear brake type Drum brake full sealed operation Left hand and right foot operation Electrical Ignition system DC C D I Generator system A C magneto Battery type GM14AZ 4A Battery c...

Page 322: ...eedle jet N J P 2M 823 Pilot air jet P A J 1 80 Pilot air jet P A J 2 1 3 Pilot outlet P O 0 85 Pilot jet P J 42 5 Bypass 1 B P 1 0 8 Bypass 2 B P 2 0 8 Bypass 3 B P 3 0 8 Valve seat size V S 2 0 Starter jet G S 1 50 G S 2 0 7 Throttle valve size Th V 130 Float height F H 12 0 14 0mm 0 47 0 55 in Fuel level F L 1 0 2 0 mm 0 04 0 08 in Engine idle speed 1 400 1 500 r min Intake vacuum 30 7 kPa 230 ...

Page 323: ...5 in Optional spring No Front wheel Type Disc wheel Rim size 10 6 0AT Rim material Steel Rim runout limit radial 2 0 mm 0 08 in lateral 2 0 mm 0 08 in Front disc brake Type Single Disc outside diameter thickness 161 3 5 mm 6 34 0 14 in Pad thickness 4 5 mm 0 18 in 1 0 mm 0 04 in Master cylinder inside diameter 14 mm 0 55 in Caliper cylinder inside diameter 32 mm 1 26 in Brake fluid type DOT 4 MAIN...

Page 324: ... Bolt M10 1 25 2 27 2 7 19 Brake pipe and brake hose Nut M10 1 0 2 19 1 9 13 Brake hose and frame Bolt M6 1 0 1 7 0 7 5 1 Caliper bleed screw Bolt M8 1 25 2 6 0 6 4 3 Master cylinder and handlebar Bolt M6 1 0 2 7 0 7 5 1 Brake caliper and caliper bracket Bolt M8 1 25 2 23 2 3 17 Brake pad retaining Bolt M10 1 25 2 18 1 8 13 Steering knuckle and brake disc guard Bolt M6 1 0 2 7 0 7 5 1 Front lower ...

Page 325: ...r short circuit Model manufacturer SH640E 11 SHINDENGEN No load regulated voltage 14 1 14 9 V Rectifier capacity 14 A Electric starter system Type Constant mesh type Starter motor Model manufacturer SM 14 MITSUBA Output 0 5 kW Armature coil resistance 0 004 0 005 Ω at 20 C 68 F Brush overall length 10 mm 0 4 in 3 5 mm 0 14 in Spring force 730 970 g 7 16 9 52 N Commutator diameter 28 mm 1 10 in 27 ...

Page 326: ... guide ı Route the fuel tank breather hose through the hole in the handlebar cover and then to the right of the handlebar below the handlebar not over it Then pass the hose through the cable guide Ç Fasten the handlebar switch assembly lead and rear brake lever switch lead to the handle bar with the plastic bands Î Fasten the handlebar switch assembly lead to the handlebar with the plastic band Fa...

Page 327: ...h lead 9 Starter motor lead 0 Throttle cable A Rear brake cable B Rear brake breather hose C Carburetor air vent hose D CDI magneto lead Å Route the main switch lead and indicator light lead to the side of the cable guide ı Insert the carburetor air vent hose rear brake breather hose and final gear case breather hose into the air duct after routing them through the fuel tank grommet ...

Page 328: ...hole in the rear fender Ì Fasten the taillight lead and wire harness to the frame with the plastic clamp Ó Fasten the taillight lead to the box with the plas tic clamp È Route the carburetor overflow hose between the engine and upper rear engine mount and then between the engine and swingarm Make sure that the hose is not pinched Ô Bend the cable guide after routing the cables Fasten the starter m...

Page 329: ...rake breather hose through the cable guide ˆ Fasten the rear brake cable and rear brake breather hose to the swingarm with the plastic clips Ø Route the rear brake breather hose through the cable guide Route the final gear case breather hose through the cable guide Œ 10 mm 0 4 in Â 40 50 mm 1 6 2 0 in Í 100 mm 4 0 in CABLE ROUTING ...

Page 330: ...6 Rear brake breather hose Å Make sure that the battery breather hose is not kinked or bent ı Route the rear brake cable through the cable guide on the cyl inder Ç Fasten the starter motor lead to the frame with the plastic clamps Î Fasten the battery breather hose to the frame with the plastic clamps 50 60 mm 2 0 2 4 in ...

Page 331: ...reather hose B Taillight lead Å Fasten the wire harness to the frame with the plastic clamps ı Make sure the starter motor lead and wire harness do not contact the ignition coil Ç Fasten the wire harness starter motor lead and ignition coil lead to the frame with the plastic locking tie Î Fasten the wire harness and starter motor lead to the frame with the plastic locking tie Install the starter r...

Page 332: ...tic clamps Ó Install the starter circuit cut off relay onto the tab with its terminal side facing down È Route the throttle cable and rear brake cable through the cable guide Make sure that the throttle cable is routed to the inside of the rear brake cable Ô Make sure that the grommet is installed with the mark facing forward Route the taillight lead through the lead holders on the lid and the bot...

Page 333: ...p and clean Replace if necessary Air filter Clean Replace if necessary Every 20 40 hours more often in wet or dusty areas Carburetor Check idle speed starter operation Adjust if necessary Cylinder head breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check for leakage Retighten if necessary Replace gasket if necessary Spark arrester Clean Fuel line Check...

Page 334: ... potential hazard that could result in serious injury or death Steering shaft Lubricate every 6 months Fittings and Fasteners Check all chassis fittings and fasteners Correct if necessary Battery Check specific gravity Check that the breather hose is working prop erly Correct if necessary ITEM ROUTINE INITIAL EVERY 1 month 3 months 6 months 6 months 1 year ...

Page 335: ... materials Always let the exhaust system cool before performing this operation Remove the purging bolt 1 Start the engine and rev it up approximately twenty times while momentarily creating exhaust system back pressure by blocking the end of the muffler with a shop towel Stop the engine and allow the exhaust pipe to cool Install the purging bolt 1 and tighten it 1 ...

Page 336: ...mmediately WARNING Use only the recommended 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 chemical reaction and lead to poor per formance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the f...

Page 337: ... front or rear brake 5 Check Brake hoses Active the brake lever several times Fluid leakage Replace the hose Refer to FRONT BRAKE 6 Install Front fender Front carrier Refer to FENDER AND FUEL TANK AIR BLEEDING HYDRAULIC BRAKE SYSTEM WARNING Bleed the brake system if The system has been disassembled A brake hose or brake pipe have been loosened or removed The brake fluid has been very low The brake...

Page 338: ...e bleed screw and allow the lever to travel towards its limit h Tighten the bleed screw when the lever limit has been reached then release the lever i Repeat steps e to h until all the air bub bles have disappeared from the fluid j Tighten the bleed screw NOTE If bleeding is difficult it may be necessary to let the brake fluid settle for a few hours Repeat the bleeding procedure when the tiny bubb...

Page 339: ...pacer TIRE AIR PRESSURE Cold Tire Pressure Front Rear Standard 20 kPa 0 20 kg cm2 2 9 psi 25 kPa 0 25 kg cm2 3 6 psi Minimum 17 kPa 0 17 kg cm2 2 5 psi 22 kPa 0 22 kg cm2 3 2 psi Maximum 23 kPa 0 23 kg cm2 3 3 psi 28 kPa 0 28 kg cm2 4 0 psi FWD A TIRE SIZE AT22 7 10 B TIRE WEAR LIMIT 3 mm 0 12 in C RIM SIZE 12 6 0 AT D RIM RUNOUT LIMIT Radial 2 mm 0 08 in Lateral 2 mm 0 08 in ...

Page 340: ... by placing the suitable stand under the frame 4 Remove Nuts 1 front wheel Front wheel 2 5 Remove Wheel cap Cotter pin 1 Axle nut 2 Plain washer 3 1 3 2 6 Remove Front brake caliper 1 NOTE Do not depress the brake lever when the wheel is off the machine otherwise the brake pads will be forced shut 1 7 Remove Front wheel hub 1 with brake disc 1 FRONT WHEEL ...

Page 341: ... 22 CHAS FRONT WHEEL 8 Remove Front brake disc 1 1 INSPECTION 1 Inspect Wheel hub 1 Cracks damage Replace ...

Page 342: ...iaphragm 4 Brake master cylinder 5 Brake master cylinder kit 6 Copper washer 7 Union bolt 8 Brake hose 9 Brake pipe 0 Brake disc A Caliper bleed screw B Retaining bolt C Brake caliper D Pad shim E Brake pad F Piston G Piston seal H Brake disc guard FWD A BRAKE FLUID TYPE DOT 4 B BRAKE PAD WEAR LIMIT 1 0 mm 0 04 in C BRAKE DISC WEAR LIMIT 3 0 mm 0 12 in FWD ...

Page 343: ...therwise eye injury may occur Allow brake fluid to contact painted sur faces or plastic parts otherwise damage may occur Disconnect any hydraulic connection oth erwise the entire system must be disas sembled drained cleaned and then properly filled and bled after reassembly BRAKE PAD REPLACEMENT NOTE It is not necessary to disassemble the brake caliper and brake hose to replace the brake pads 1 Re...

Page 344: ...ng Brake pads Installation steps Connect a suitable hose 1 tightly to the cali per bleed screw 2 Then place the other end of this hose into an open container Loosen the caliper bleed screw and push the pistons into the caliper with the finger Tighten the caliper bleed screw 2 Install the pad shim 3 new onto the brake pad new NOTE The arrow mark a on the pad shim must point in the direction of the ...

Page 345: ...a 10 Check Brake lever operation A soft or spongy feeling Bleed brake sys tem Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM CALIPER DISASSEMBLY NOTE Before disassembling the front brake caliper drain the brake hose master cylinder brake caliper and reservoir tank of their brake fluid 1 Remove Front wheel 2 Loosen Union bolt Retaining bolts Retaining bolt caliper bracket 3 Remove Front brake caliper...

Page 346: ...cket disconnect the dust boot from the guide shaft on the bracket 1 2 6 Remove Piston Piston seals 1 Removal steps Blow compressed air into the hose joint opening to force out the caliper piston from the caliper body Remove the piston seals WARNING Never try to pry out the piston MASTER CYLINDER DISASSEMBLY NOTE Before disassembling the front brake master cylinder drain the brake hose master cylin...

Page 347: ... Brake master cylinder reservoir diaphragm Brake master cylinder 2 3 Remove Dust boot 1 Circlip 2 Brake master cylinder kit 3 Drain the excess fluid INSPECTION AND REPAIR WARNING All internal parts should be cleaned in new brake fluid only Do not use solvents as they will cause seals to swell and distort Recommended brake component replacement schedule Brake pads As required Piston seal Every two ...

Page 348: ...place the piston seal whenever the cali per is disassembled 2 Inspect Brake master cylinder Wear scratches Replace the brake master cylinder assembly Brake master cylinder body Cracks damage Replace Oil delivery passage master cylinder body Blow out with compressed air 3 Inspect Brake master cylinder kit Scratches wear damage Replace as a set 4 Inspect Brake master cylinder reservoir diaphragm Wea...

Page 349: ...ither is found to be worn to the wear limit a Wear limit a 1 0 mm 0 04 in 7 Inspect Brake disc Galling damage Replace 8 Measure Brake disc deflection Out of specification Inspect wheel runout If wheel runout is in good condition replace the brake disc s Brake disc thickness a Out of specification Replace 1 Dial gauge Maximum deflection 0 15 mm 0 006 in Minimum thickness 3 0 mm 0 12 in a 1 ...

Page 350: ...ned in new brake fluid only Internal parts should be lubricated with brake fluid when installed Replace the piston seals whenever a cali per is disassembled 1 Install Piston seals 1 Piston 2 WARNING Always use new piston seals Recommended brake fluid DOT 4 New 2 Install Caliper bracket 1 Caliper body 2 NOTE Apply the lithium soap base grease onto the caliper guide shaft and retaining bolt 1 2 ...

Page 351: ...r hose routing is essential to insure safe machine operation Refer to CABLE ROUTING Always use new copper washers T R Union bolt 27 Nm 2 7 m kg 19 ft lb 1 2 4 3 a New New 4 Remove Brake caliper 5 Install Pad spring Brake pads with pad shim Retaining bolts Front brake caliper Refer to BRAKE PAD REPLACEMENT T R Retaining bolt caliper bracket 23 Nm 2 3 m kg 17 ft lb Retaining bolt 18 Nm 1 8 m kg 13 f...

Page 352: ...ill with the same type of brake fluid mixing fluids may result in a harmful chemical reaction and lead to poor per formance Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock Recommended brake fluid DOT 4 7 Air bleed Brake system Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM 8 Inspect Bra...

Page 353: ...e master cylinder is dis assembled Recommended brake fluid DOT 4 1 Install Brake master cylinder kit 1 Circlip 2 Dust boot 3 2 Install Brake master cylinder 1 CAUTION Install the brake master cylinder holder with the UP mark facing upward Align the end of the brake master cylinder holder with the punch mark a in the han dlebar Tighten first the upper bolt then the lower bolt T R Bolt brake master ...

Page 354: ... is essential to insure safe machine operation Refer to CABLE ROUTING Always use new copper washers 4 Install Brake lever T R Union bolt 27 Nm 2 7 m kg 19 ft lb 5 Fill Brake master cylinder reservoir NOTE If DOT 4 is not available 3 can be used CAUTION Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately WARNING Use only the designated quality brake flu...

Page 355: ...water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock 6 Air bleed Brake system Refer to AIR BLEEDING HYDRAULIC BRAKE SYSTEM 7 Inspect Brake fluid level Fluid level is under LOWER level line Replenish Refer to FRONT BRAKE FLUID LEVEL INSPECTION a LOWER level line UP LOWER a ...

Page 356: ... 2 Bearing 3 Oil seal 4 Wheel hub 5 Axle nut A TIRE SIZE AT22 10 10 B TIRE WEAR LIMIT 2 0 mm 0 08 in C RIM SIZE 8 10AT D RIM RUNOUT LIMIT Radial 2 mm 0 08 in Lateral 2 mm 0 08 in E REAR AXLE RUNOUT LIMIT 1 5 mm 0 06 in FWD REAR WHEELS REAR BRAKE AND REAR AXLE ...

Page 357: ... 38 CHAS FRONT SHOCK ABSORBER AND FRONT ARM FRONT SHOCK ABSORBER AND FRONT ARM 1 Front shock absorber 2 Steering knuckle 3 Lower arm 4 Bushing FWD ...

Page 358: ...CK ABSORBER AND SWINGARM 1 Rear shock absorber 2 Thrust cover 3 Locknut 4 Pivot shaft 5 Collar 6 Oil seal 7 Taper roller bearing 8 Swingarm 9 Rubber boot 0 Final gear case protector A SWINGARM FREE PLAY LIMIT End 1 0 mm 0 04 in Side 1 0 mm 0 04 in FWD ...

Page 359: ...erse indicator light 2 Neutral indicator light 3 Main switch 4 Rear brake lever switch 5 Handlebar switch 6 Fuses 7 Starter relay 8 Rectifier regulator 9 CDI unit 0 Taillight A Battery B Starting circuit cut off relay C Reverse switch D Neutral switch E Headlight F Ignition coil ...

Page 360: ... OFF RUN G OFF PUSH H R W B K G Y G Y B B B G Y B Y G B Y G K G Y B B G Y Sb G L R W R W Br Br Sb G L G L G L Sb G L G L Sb Br Br L B L B G L B Br Y B L Br Y G L B L B R W R B R W R B 9 W L W R R B R B W G R W L W R W G R B 1 R W G W L W R W G W L W R R W W W W W W 2 B R W W W W W W W R W G R B R B W L O B R W W W BLACK R B GREEN GREEN R 1 CDI magneto 3 Main switch 4 Battery 5 Fuse 9 CDI unit 0 Ig...

Page 361: ...rt s before trouble shooting 1 Seat 2 Front carrier 3 Front fender Use the following special tool s for trouble shooting Dynamic spark tester P N YM 34487 Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse Refer to SWITCH INSPECTION NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to BATTERY INSPECTION Open circuit voltage 12 8 V or more at...

Page 362: ...e main switch to ON Check the ignition spark gap Crank the engine by pushing the starter switch and increase the spark gap until a misfiring occurs Minimum spark gap 6 0 mm 0 24 in MEETS SPECIFICATION The ignition system is not faulty 5 Spark plug cap resistance Remove the spark plug cap Connect the pocket tester Ω 1 k to the spark plug cap MEETS SPECIFICATION Check that the spark plug cap has the...

Page 363: ...the primary coil has the speci fied resistance Primary coil resistance 0 18 0 28 Ω at 20 C 68 F Connect the pocket tester Ω 1 k to the ignition coil BOTH MEET SPECIFICATION Check that the secondary coil has the specified resistance Secondary coil resistance 6 3 9 5 kΩ at 20 C 68 F OUT OF SPECIFICATION Replace the ignition coil CORRECT 7 Engine stop switch Refer to SWITCH INSPECTION INCORRECT Repla...

Page 364: ...hite Red OUT OF SPECIFICATION Replace the pickup coil stator assembly 10 Charging rotor rotation direction detection coil resistance Disconnect the CDI magneto coupler from the wire harness Connect the pocket tester Ω 100 to the source coil terminal Tester lead Red terminal 1 Tester lead White Blue terminal 2 MEETS SPECIFICATION Check the charging rotor rotation direction detection coil for the sp...

Page 365: ...C IGNITION SYSTEM C0NTINUITY CORRECT 11 Wiring connection Check the connections of the entire ignition system Refer to CIRCUIT DIAGRAM Replace the CDI unit POOR CONNECTION Properly connect the ignition system ...

Page 366: ...B K G Y G Y B B B G Y B Y G B Y G K G Y B B G Y Sb G L R W R W Br Br Sb G L G L G L Sb G L G L Sb Br Br L B L B G L B Br Y B L Br Y G L B L B R W R B R W R B 9 W L W R R B R B W G R W L W R W G R B 1 R W G W L W R W G W L W R R W W W W W W 2 B R W W W W W W W R W G R B R B W L O B R W W W BLACK R B GREEN GREEN R 3 Main switch 4 Battery 5 Fuse 6 Starter relay 7 Starter motor 8 Starting circuit cut ...

Page 367: ...om operating when the select lever is in gear or in reverse and the rear brake lever is free In this instance the starting circuit cut off relay is off so that current cannot reach the starter motor WHEN THE TRANSMISSION IS IN NEUTRAL WHEN THE BRAKE LEVER IS PULLED IN 1 Battery 2 Starter motor 3 Starter relay 4 Start switch 5 Starting circuit cut off relay 6 Engine stop switch 7 Rear brake lever s...

Page 368: ...tion the entire starting system NOTE Remove the following part s before trouble shooting 1 Seat 2 Front carrier 3 Front fender Use the following special tool s for trouble shooting Pocket tester P N YU 03112 90890 03112 EB802011 CONTINUITY 1 Fuse Refer to SWITCH INSPECTION NO CONTINUITY Replace the fuse EB802012 CORRECT 2 Battery Check the battery condition Refer to BATTERY INSPECTION Open circuit...

Page 369: ...rks so be sure that no flammable gas or fluid is in the vicinity 4 Starting circuit cut off relay Remove the starting circuit cut off relay from the wire harness Connect the pocket tester Ω 1 and the battery 12 V to the starting circuit cut off relay terminals Battery terminal Red Black terminal 1 Battery terminal Green Yellow terminal 2 Tester lead Red Black terminal 1 Tester lead Blue White term...

Page 370: ...terminal 1 Battery terminal Blue Black terminal 2 Tester lead Red terminal 3 Tester lead Black terminal 4 Check the starter relay for continuity NO CONTINUITY Replace the starter relay CORRECT 6 Main switch Refer to SWITCH INSPECTION INCORRECT Replace the main switch CORRECT 8 Neutral switch Refer to SWITCH INSPECTION INCORRECT Replace the neutral switch CORRECT 7 Engine stop switch Refer to SWITC...

Page 371: ...ION INCORRECT Replace the rear brake lever switch CORRECT 10 Start switch Refer to SWITCH INSPECTION INCORRECT Replace the handlebar switch left EB803028 11 Wiring connection Check the connections of the entire starting system Refer to CIRCUIT DIAGRAM POOR CONNECTION Properly connect the starting system ...

Page 372: ...PRINTED IN U S A YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

Page 373: ...LACK R B GREEN GREEN R YFM250XN WIRING DIAGRAM 1 CDI magneto 2 Rectifier regulator 3 Main switch 4 Battery 5 Fuse 6 Starter relay 7 Starter motor 8 Starting circuit cut off relay 9 CDI unit 0 Ignition coil A Spark plug B Neutral indicator light C Reverse indicator light D Neutral switch E Reverse switch F Rear brake lever switch G Engine stop switch H Starter switch I Lights switch J Headlight K H...

Page 374: ...YFM250XP SUPPLEMENTARY SERVICEMANUAL LIT 11616 15 03 4XE F8197 12 ...

Page 375: ...r with the following manual YFM250XL C SERVICE MANUAL LIT 11616 12 01 4XE F8197 10 YFM250XN SUPPLEMENTARY SERVICE MANUAL LIT 11616 14 17 4XE F8197 11 YFM250XP SUPPLEMENTARY SERVICE MANUAL 2001 by Yamaha Motor Corporation U S A First Edition June 2001 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Pri...

Page 376: ...fications and sig nificant changes in specifications or procedures will be forwarded to all authorized Yamaha dealers and will appear in future editions of this manual where applicable NOTE Designs and specifications are subject to change without notice IMPORTANT INFORMATION Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ...

Page 377: ...nic with an easy to read handy reference that contains comprehensive explanations of all disassembly repair assembly and inspections A set of particularly important procedure 4 is placed between a line of asterisks with each proce dure preceded by IMPORTANT FEATURES Data and a special tool are framed in a box preceded by a relevant symbol 5 An encircled numeral 6 indicates a part name and an encir...

Page 378: ...clearance E Engine speed F Ω V A Illustrated symbols G to M in the exploded diagrams indicate the types of lubricants and lubrication points G Apply engine oil H Apply gear oil I Apply molybdenum disulfide oil J Apply wheel bearing grease K Apply lightweight lithium soap base grease L Apply molybdenum disulfide grease M Apply silicon grease Illustrated symbols N to O in the exploded diagrams indic...

Page 379: ... ADJUSTMENTS 12 INTRODUCTION 12 PERIODIC MAINTENANCE LUBRICATION INTERVALS 12 CHASSIS 14 ADJUSTING THE FRONT BRAKE 14 ADJUSTING THE REAR BRAKE LIGHT SWITH 14 ELECTRICAL 15 CHECKING THE SWITCH 15 CHECKING THE SWITCH 15 CHECKING A SWITCH SHOWN IN THE MANUAL 15 SIGNAL SYSTEM 16 CIRCUIT DIAGRAM 16 CHECKING THE SIGNAL SYSTEM 17 YFM250XP WIRING DIAGRAM ...

Page 380: ...t hand operation Rear brake type Drum brake fully sealed operation Left hand and right foot operation Electrical Ignition system DC C D I Generator system A C magneto Battery type YB14A A2 Battery capacity 12 V 14 AH Bulb wattage quantity Headlight 12 V 25 W 25 W 2 Tail brake light 12 V 5 W 21 W 1 Indicator lights Neutral 12 V 1 7 W 1 Reverse 12 V 1 7 W 1 ...

Page 381: ...d 71 5 mm 2 81 in Oversize 4th 72 mm 2 83 in Piston off set 0 5 mm 0 02 in Piston off set direction Intake side Piston pin bore inside diameter 16 002 16 013 mm 0 6300 0 6304 in Piston pin outside diameter 15 991 16 000 mm 0 6296 0 6299 in Lubrication system Oil filter type Wire mesh Oil pump type Trochoid type Tip clearance A or B 0 15 mm 0 006 in 0 20 mm 0 008 in Side clearance 0 04 0 09 mm 0 00...

Page 382: ... 69 lb in 0 85 mm 0 3 35 in Optional spring No Part to be tightened Parts name Thread size Q ty Tightening torque Remarks Nm m kg ft lb Master cylinder and brake hose Bolt M10 1 25 1 23 2 3 17 Steering shaft and upper handle bar holder Bolt M8 1 25 4 23 2 3 14 Item Standard Limit Charging system Model manufacturer F4T259 MITSUBISHI Type A C magneto Nominal output 14 V 16 A at 5 000 r min Stator co...

Page 383: ...itch lead to the handlebar with the plastic band Ê Route the fuel tank breather hose through the hole in the handlebar cover and then to the right of the handlebar below the handlebar not over it Then pass the hose through the cable guide Ë Fasten the handlebar switch assembly lead and rear brake lever switch lead to the handle bar with the plastic bands Ì Fasten the handlebar switch assembly lead...

Page 384: ... vent hose rear brake breather hose and final gear case breather hose into the air duct after routing them through the fuel tank grommet Ê Route the carburetor overflow hose between the engine and upper rear engine mount and then between the engine and swingarm Make sure that the hose is not pinched Ë Fasten the starter motor lead to the frame with the plastic clamp Route the starter motor lead ov...

Page 385: ...at the starter motor lead has no slack É Fasten the starter motor lead and wire harness to the frame with the plastic band Ê Fasten the starter motor lead and wire harness to the frame with the plastic clamp Ë Route the starter motor lead wire harness and battery lead through the hole in the rear fender Ì Fasten the taillight lead and wire harness to the frame with the plastic clamp CABLE ROUTING ...

Page 386: ... Route the rear brake cable and rear brake breather hose through the cable guide Ð Route the rear brake breather hose through the cable guide Ñ Route the final gear case breather hose through the cable guide Ò Fasten the rear brake cable and rear brake breather hose to the swingarm with the plastic clips Ó 10 mm 0 4 in Ô 40 50 mm 1 6 2 0 in Õ 100 mm 4 0 in CABLE ROUTING ...

Page 387: ... switch 8 Rear brake breather hose È Make sure that the battery breather hose is not kinked or bent É Route the rear brake cable through the cable guide on the cylinder Ê Fasten the starter motor lead to the frame with the plastic clamps Ë Fasten the battery breather hose to the frame with the plastic clamps Ì 50 60 mm 2 0 2 4 in CABLE ROUTING ...

Page 388: ...lead and starter motor lead to the rear fender with the plastic clamps É Install the starter circuit cut off relay onto the tab with its terminal side facing down Ê Fasten the wire harness and starter motor lead to the frame with the plastic locking tie Ë Install the starter relay onto the tabs with its ter minal side facing up Ì Fasten the battery breather hose to the rear fender with the plastic...

Page 389: ... 10 SPEC Í Make sure that the grommet is installed with the mark facing forward Î 5 mm 0 2 in CABLE ROUTING ...

Page 390: ...to the inside of the rear brake cable É Fasten the wire harness to the frame with the plastic clamps Ê Make sure the starter motor lead and wire har ness do not contact the ignition coil Ë Fasten the wire harness starter motor lead and ignition coil lead to the frame with the plastic locking tie Ì Route the taillight lead through the lead holders on the lid and the bottom of the storage box Í 50 m...

Page 391: ...tion Adjust gap and clean Replace if necessary Air filter Clean Replace if necessary Every 20 40 hours more often in wet or dusty areas Carburetor Check idle speed starter operation Adjust if necessary Cylinder head breather system Check breather hose for cracks or damage Replace if necessary Exhaust system Check for leakage Retighten if necessary Replace gasket if necessary Spark arrester Clean F...

Page 392: ...ed 2 On the inner parts of the master cylinder and caliper replace the oil seals every two years 3 Replace the brake hoses every four years or if cracked or damaged Steering system Check operation Correct if damaged Check toe in Adjust if necessary Steering shaft Lubricate every 6 months Fittings and Fasteners Check all chassis fittings and fasteners Correct if necessary Battery Check specific gra...

Page 393: ...nt of the brake pedal The rear brake light switch is properly adjusted when the brake light comes on just before the braking effect starts Brake lever free play at brake lever end 0 mm 0 in 1 Check Rear brake light operation timing Incorrect Adjust 2 Adjust Rear brake light operation timing Hold the main body 1 of the rear brake light switch so that it does not rotate and turn the adjusting nut 2 ...

Page 394: ...e switch on and off a few times when checking it Pocket tester P N YU 03112 90890 03112 CHECKING A SWITCH SHOWN IN THE MANUAL The terminal connections for switches main switch handlebar switch engine stop switch light switch etc are shown in a chart similar to the one on the left This chart shows the switch positions in the column and the switch lead colors in the top row For each switch position ...

Page 395: ... Y L L G Y B Y G B B Y G G Y B Y G B B Y G OFF LO HI OFF ON OFF PUSH Br R B L B L R B L B Br R B L Br R W Br G Y Y B G Y Br B Y G Y B Y G B B Y L G H J J I G F B D E C BLACK BLACK BLACK B R W W W R R L W L B G Y L W Sb R B BLACK BLACK GRAY GRAY Br Y BLACK Y Br BLACK B B BLACK Br Y K B B BLACK Br Y M Br Y G Y B N 2 9 3 Main switch 4 Battery 5 Fuse B Neutral indicator light C Reverse indicator light...

Page 396: ...es Refer to CHECKING THE SWITCH NO CONTINUITY Replace the brake switch 3 Voltage Connect the pocket tester DC 20V to the bulb socket connector Tester lead Yellow terminal 1 Tester lead Black terminal 2 MEETS SPECIFICATION Turn the main switch to ON Check the voltage 12 V of the Yellow lead on the bulb socket connector This circuit is not faulty OUT OF SPECIFICATION The wiring circuit from the main...

Page 397: ...YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED IN U S A ...

Page 398: ...AY Br Y BLACK Y Br BLACK B B BLACK Br Y K B B BLACK Br Y M Br Y G Y B N 2 9 1 A C magneto 2 Rectifier regulator 3 Main switch 4 Battery 5 Fuse 6 Starter relay 7 Starter motor 8 Starting circuit cut off relay 9 CDI unit 0 Ignition coil A Spark plug B Neutral indicator light C Reverse indicator light D Neutral switch E Reverse switch F Start switch G Engine stop switch H Lights switch I Handlebar sw...

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