Yamaha YZ250 2022 Owner'S Service Manual Download Page 63 | Manualshive

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CABLE ROUTING DIAGRAM

2-24

1. Protector
2. Rear brake caliper
3. Bleed screw
4. Gasket
5. Rear brake hose
6. Brake pedal
7. Rear brake master cylinder assembly
8. Spring
9. Frame

A. Install the spring as shown in the illustration.
B. Pass the rear brake hose into the rear brake

hose holders.

C. Route the rear brake hose so that it is not

bent as shown by the double-dash line.

D. Route the rear brake hose and spring so that

they do not interfere with each other.

E. Make sure that the rear brake hose is not

excessively twisted.

F. Make sure that the metal part of the rear

brake hose contacts the stopper of the rear

brake master cylinder.

G. Install the rear brake hose so that the bended

portion of the metal part of the rear brake

hose faces as shown in the illustration.

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Summary of Contents for YZ250 2022

Page 1: ...Read this manual carefully before operating this vehicle 2022 OWNER S SERVICE MANUAL YZ250 YZ250N2 LIT 11626 35 16 BCR 2819U 10...

Page 2: ...cause cancer and birth defects or other reproductive harm To minimize exposure avoid breathing exhaust do not idle the engine except as necessary service your vehicle in a well ventilated area and wea...

Page 3: ...NUAL 2022 by Yamaha Motor Corporation U S A First edition April 2021 All rights reserved Any reproduction or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expres...

Page 4: ...uested not to undertake inspection adjustment disassem bly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage WARNING EWA20270 PLEASE READ THIS MANUA...

Page 5: ...EAM20162 YAMAHA MOTOR CORPORATION U S A YZ MOTORCYCLE LIMITED WARRANTY...

Page 6: ...teps there are exploded diagrams 3 at the start of each removal and disassembly section Numbers 4 are given in the order of the jobs in the exploded diagram A number indicates a removal or a disassemb...

Page 7: ...TION Serviceable with engine mounted Gear oil Filling fluid Molybdenum disulfide oil Lubricant Brake fluid Special tool Wheel bearing grease Tightening torque Lithium soap based grease Wear limit clea...

Page 8: ......

Page 9: ...GENERAL INFORMATION 1 SPECIFICATIONS 2 PERIODIC CHECKS AND ADJUSTMENTS 3 CHASSIS 4 ENGINE 5 COOLING SYSTEM 6 FUEL SYSTEM 7 ELECTRICAL SYSTEM 8 TROUBLESHOOTING 9 TUNING 10 EAM10003 TABLE OF CONTENTS...

Page 10: ......

Page 11: ...OVAL AND DISASSEMBLY 1 8 REPLACEMENT PARTS 1 8 GASKETS OIL SEALS AND O RINGS 1 8 LOCK WASHERS PLATES AND COTTER PINS 1 9 BEARINGS AND OIL SEALS 1 9 CIRCLIPS 1 9 BASIC SERVICE INFORMATION 1 10 ELECTRIC...

Page 12: ...MAINTENANCE AFTER BREAK IN 1 20 MAJOR MAINTENANCE 1 20 AIR FILTER MAINTENANCE 1 20 TORQUE CHECK POINTS 1 21 MOTORCYCLE CARE AND STORAGE 1 23 CARE 1 23 STORAGE 1 24...

Page 13: ...e riding 2 This motorcycle is designed to carry the oper ator only No passengers 3 The failure of motorists to detect and recog nize motorcycles in traffic is the predominat ing cause of automobile mo...

Page 14: ...Many companies with no connection to Yamaha manufacture parts and accessories or offer oth er modifications for Yamaha vehicles Yamaha is not in a position to test the products that these aftermarket...

Page 15: ...e fuel cock if equipped is in the OFF position and that there are no fuel leaks 3 Point the front wheel straight ahead on the trailer or in the truck bed and choke it in a rail to prevent movement 4 S...

Page 16: ...LOCATION OF IMPORTANT LABELS 1 4 EAM20085 LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle 5 1 2 3 4...

Page 17: ...or the vehicle you have purchased 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 1 Clutch lever 2 Engine stop switch 3 Front brake lever 4 Throttle grip 5 Radiator cap 6 Fuel tank cap 7 Kickstarter l...

Page 18: ...r positive identi fication of the model you own 2 If your vehicle is stolen the authorities will need the number to search for and identify your vehicle EAM30002 VEHICLE IDENTIFICATION NUMBER The vehi...

Page 19: ...he nipple wrench 1 is used to tighten the spoke EAM30534 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose NOTICE ECA27110 In this installat...

Page 20: ...ed to the chassis paint and plating will be damaged Therefore rinse it out with water in good time WARNING EWA18970 Coolant is potentially harmful and should be handled with special care If it enters...

Page 21: ...il seal make sure that its main lip faces the oil chamber the target to be sealed Before installation always apply a light coat of grease to the oil seal lip NOTICE ECA13300 Do not spin the bearing wi...

Page 22: ...st har ness Checking the connections Check the leads couplers and connectors for stains rust moisture etc 1 Disconnect Lead Coupler Connector NOTICE ECA16780 When disconnecting a coupler release the c...

Page 23: ...ector TIP When connecting a coupler or connector make sure that both terminals are connected securely Make sure all connections are tight 5 Check No continuity TIP If there is no continuity clean the...

Page 24: ...YM YU or ACC For others use tool number starting with 90890 Tool name Tool No Illustration Reference pages Digital circuit tester CD732 90890 03243 Model 88 Multimeter with tachometer YU A1927 1 11 8...

Page 25: ...der YU 01235 5 16 5 17 Flywheel puller 90890 01189 Flywheel puller YM 01189 5 16 Clutch holder 90890 04199 Universal clutch holder YM 91042 5 27 5 29 Thickness gauge 90890 03268 Feeler gauge set YU 26...

Page 26: ...90 01274 Installing pot YU 90058 5 40 Crankshaft installer bolt 90890 01275 Bolt YU 90060 5 40 Adapter M12 90890 01278 Adapter 3 YU 90063 5 40 Radiator cap tester 90890 01325 Mityvac cooling system te...

Page 27: ...1 15 Radiator cap tester adapter 90890 01352 Pressure tester adapter YU 33984 6 3 6 3 Ignition checker 90890 06754 Oppama pet 4000 spark checker YM 34487 8 8 Tool name Tool No Illustration Reference p...

Page 28: ...has a primary kickstarter lever so the engine can be started in any gear if the clutch is disengaged In normal practices however shift to neutral be fore starting EAM30188 FRONT BRAKE LEVER The front...

Page 29: ...When cold the engine requires a richer air fuel mixture for starting A separate starter circuit which is controlled by the starter knob 1 sup plies this mixture Pull the starter knob out to open the...

Page 30: ...ine push the engine stop switch TIP Continue pushing the engine stop switch till the engine comes to a full stop EAM30197 STARTING A WARM ENGINE Do not operate the starter knob CHOKE Open the throttle...

Page 31: ...ced a break in is required Cylinder and Crankshaft A break in is re quired for about an hour Piston Piston ring Valve Camshaft and Gear A break in is required for about 30 minutes at a throttle openin...

Page 32: ...nuts Check for looseness in mounted areas of parts as well as engine mounting bolts and engine brackets 2 For the chassis Check welds and mounted areas of the frame the swingarm the link the bracket a...

Page 33: ...to swingarm Mounting of rear shock absorber Rear shock absorber and frame Mounting of swingarm Tightening of pivot shaft Wheel s Mounting of wheel Front Tightening of wheel axle Tightening of axle ho...

Page 34: ...ES on page 2 9 Plastic cover Tightening of front fender Tightening of fork leg protector Tightening of air scoop Left cover to rear frame Tightening of side cover Tightening of rear fender Tightening...

Page 35: ...structed Also thorough ly rinse the area off with water immediately dry it and then apply a corrosion protec tion spray Improper cleaning can damage plastic parts such as cowlings panels wind shields...

Page 36: ...nd nickel plated sur faces 5 Use spray oil as a universal cleaner to re move any remaining dirt 6 Touch up minor paint damage caused by stones etc 7 Wax all painted surfaces 8 Let the motorcycle dry c...

Page 37: ...th the engine stop switch pushed in kick the engine over several times to coat the cylinder walls with oil 4 Lubricate all control cables and the pivoting points of all levers and pedals as well as of...

Page 38: ...MOTORCYCLE CARE AND STORAGE 1 26...

Page 39: ...ATIONS 2 1 ENGINE SPECIFICATIONS 2 2 CHASSIS SPECIFICATIONS 2 5 ELECTRICAL SPECIFICATIONS 2 8 TIGHTENING TORQUES 2 9 GENERAL TIGHTENING TORQUE SPECIFICATIONS 2 9 ENGINE TIGHTENING TORQUES 2 10 CHASSIS...

Page 40: ...l Model BCR1 BCR5 Dimensions Overall length 2185 mm 86 0 in Overall width 825 mm 32 5 in Overall height 1290 mm 50 8 in Seat height 975 mm 38 4 in Wheelbase 1485 mm 58 5 in Ground clearance 360 mm 14...

Page 41: ...ooling system Coolant quantity Radiator including all routes 1 20 L 1 27 US qt 1 06 Imp qt Radiator cap valve opening pressure 93 3 122 7 kPa 0 93 1 23 kgf cm 13 5 17 8 psi Spark plug s Manufacturer m...

Page 42: ...7 in Clutch spring free length limit 48 00 mm 1 89 in Push rod bending limit 0 30 mm 0 012 in Drivetrain Primary reduction ratio 3 000 63 21 Transmission type Constant mesh 5 speed Gear ratio 1st 1 92...

Page 43: ...FICATIONS 2 4 Float height 6 5 mm 0 26 in Throttle grip free play 3 0 5 0 mm 0 12 0 20 in Reed valve Thickness 0 420 mm 0 0165 in Valve stopper height 10 3 10 7 mm 0 41 0 42 in Valve bending limit 0 2...

Page 44: ...ressure measured on cold tires Front 100 kPa 1 00 kgf cm 15 psi Rear 100 kPa 1 00 kgf cm 15 psi Front brake Type Hydraulic single disc brake Brake disc thickness limit 2 5 mm 0 10 in Brake disc runout...

Page 45: ...from the start position Soft 20 Adjustment value from the start position STD 9 Adjustment value from the start position Hard 0 Rear suspension Type Swingarm link suspension Spring Coil spring Shock a...

Page 46: ...Click Adjustment value from the start position Soft 20 Adjustment value from the start position STD 9 Adjustment value from the start position Hard 0 Drive chain Size 520 Chain type Non sealed type N...

Page 47: ...iming B T D C 0 18 mm 0 01 in Pickup coil resistance 248 0 372 0 Charging coil 1 resistance 720 0 1080 0 Charging coil 2 resistance 44 0 66 0 Ignition coil Primary coil resistance 0 20 0 30 Secondary...

Page 48: ...o avoid warpage tight en multi fastener assemblies in a crisscross pat tern and progressive stages until the specified tightening torque is reached Unless otherwise specified tightening torque specifi...

Page 49: ...t Governor fork screw M4 2 5 N m 0 5 kgf m 3 7 lb ft Power valve housing bolt M5 4 4 5 N m 0 45 kgf m 3 3 lb ft Impeller M8 1 14 N m 1 4 kgf m 10 lb ft Water pump housing cover bolt M6 4 10 N m 1 0 kg...

Page 50: ...olt M6 6 10 N m 1 0 kgf m 7 4 lb ft Primary drive gear bolt M10 1 55 N m 5 5 kgf m 41 lb ft Clutch boss nut M20 1 75 N m 7 5 kgf m 55 lb ft Use a Lock washer Clutch spring bolt M6 6 10 N m 1 0 kgf m 7...

Page 51: ...t Throttle cable cap screw M4 2 0 5 N m 0 05 kgf m 0 37 lb ft Grip cap bolt M6 2 3 8 N m 0 38 kgf m 2 8 lb ft Clutch lever nut M6 1 4 0 N m 0 40 kgf m 3 0 lb ft Clutch lever holder bolt M6 2 5 N m 0 5...

Page 52: ...m 6 4 kgf m 47 lb ft Engine mounting nut front side M10 1 64 N m 6 4 kgf m 47 lb ft Engine mounting nut lower side M10 1 64 N m 6 4 kgf m 47 lb ft Pivot shaft nut M16 1 85 N m 8 5 kgf m 63 lb ft Rela...

Page 53: ...cket bolt M6 4 7 N m 0 7 kgf m 5 2 lb ft Seat bolt M8 1 11 N m 1 1 kgf m 8 1 lb ft Side cover bolt front side M6 2 7 N m 0 7 kgf m 5 2 lb ft Side cover bolt rear side M6 2 9 N m 0 9 kgf m 6 6 lb ft Ai...

Page 54: ...CABLE ROUTING DIAGRAM 2 15 EAM20152 CABLE ROUTING DIAGRAM Frame and engine left side view...

Page 55: ...frame as illustration G Pass the clutch cable in front of the center of the cylinder head nut When clamping the cables at E make sure that the clutch cable is located in front of the cylinder head nu...

Page 56: ...CABLE ROUTING DIAGRAM 2 17 Frame and engine left side view...

Page 57: ...iator breather hose outside the engine bracket and inside the down tube Then pass the radiator breather hose inside the CDI magneto lead F Clamp the CDI magneto lead radiator breather hose YPVS breath...

Page 58: ...CABLE ROUTING DIAGRAM 2 19 Frame and engine right side view...

Page 59: ...n cord to the right of the radiator hose so that the high tension cord does not contact the radiator hose C Do not clamp the bare wire of the engine stop switch D Pass the CDI unit lead between the fr...

Page 60: ...CABLE ROUTING DIAGRAM 2 21 Handlebar front view 0 mm 0 in 0 mm 0 in...

Page 61: ...n and lightly touches the pro jection on the master cylinder while the white paint side faces to the front of the vehicle B Pass the engine stop switch lead in the mid dle of the clutch holder C Clamp...

Page 62: ...CABLE ROUTING DIAGRAM 2 23 Rear brake right side view...

Page 63: ...s C Route the rear brake hose so that it is not bent as shown by the double dash line D Route the rear brake hose and spring so that they do not interfere with each other E Make sure that the rear bra...

Page 64: ...CABLE ROUTING DIAGRAM 2 25...

Page 65: ...THE COOLANT 3 11 CHASSIS 3 13 ADJUSTING THE FRONT DISC BRAKE 3 13 ADJUSTING THE REAR DISC BRAKE 3 13 CHECKING THE BRAKE FLUID LEVEL 3 14 CHECKING THE FRONT BRAKE PADS 3 14 CHECKING THE REAR BRAKE PADS...

Page 66: ...CHECKING AND LUBRICATING THE CABLES 3 24 LUBRICATING THE BRAKE LEVER 3 24 LUBRICATING THE CLUTCH LEVER 3 24 LUBRICATING THE PEDAL 3 24 ELECTRICAL SYSTEM 3 25 CHECKING THE IGNITION TIMING 3 25...

Page 67: ...ce about 7 5 hours Every fifth race about 12 5 hours As required 1 Piston Check piston for carbon deposits and cracks or damage Clean Replace 2 Piston rings Check piston ring end gap and rings for dam...

Page 68: ...17 Cooling system Check coolant level and for leak age Check hoses for cracks or dam age Check radiator cap spring opera tion Change coolant Every 2 years 18 Chassis fasteners Check all chassis fittin...

Page 69: ...arm pivot bear ings Check bearing assemblies for looseness Lubricate with molybdenum disul fide grease 28 Steering head Check operation free play and tighten if necessary Clean and lubricate with lith...

Page 70: ...14 3 14 3 14 3 14 3 15 3 15 Drive chain Check drive chain slack and alignment Check that the drive chain is lubricated properly 3 16 4 64 4 64 4 65 4 65 4 65 Wheels Check for excessive wear and tire...

Page 71: ...ble speed EAM30475 CHECKING THE THROTTLE GRIP TIP Prior to adjusting throttle grip free play the en gine idling speed should be adjusted 1 Check Throttle grip free play a Out of specification Regulate...

Page 72: ...ed straight up when inspecting the oil level WARNING EWA21090 Never attempt to remove the oil check bolt just after high speed operation The heated oil could spout out causing danger Wait un til the o...

Page 73: ...lever free play cannot be obtained on the handlebar side use the adjuster on the clutch cable side Clutch cable side a Slide the clutch cable cover b Loosen the locknut 1 c Turn the adjuster 2 until t...

Page 74: ...cleaner or kerosene squeeze and dry it completely WARNING EWA19110 Do not use gasoline or organic acid alka line volatile oil for washing NOTICE ECA24280 Do not twist the element when squeezing the e...

Page 75: ...me excessively worn EAM30541 CHECKING THE CARBURETOR JOINT 1 Check Carburetor joint 1 Cracks damage Replace EAM30542 CHECKING THE CARBURETOR HOSES The following procedure applies to all of the fuel an...

Page 76: ...do not remove the radiator cap when the en gine is hot Scalding hot fluid and steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows Place...

Page 77: ...efore do not remove the radiator cap when the en gine is hot Scalding hot fluid and steam may be blown out which could cause serious in jury When the engine has cooled open the radiator cap as follows...

Page 78: ...ifreeze content of the coolant If water is used instead of coolant check and if nec essary correct the antifreeze concentra tion of the coolant Use only distilled water However if dis tilled water is...

Page 79: ...TICE ECA13490 After adjusting the brake lever position make sure there is no brake drag 4 Install Brake lever cover EAM30480 ADJUSTING THE REAR DISC BRAKE 1 Adjust Brake pedal position a Loosen the lo...

Page 80: ...rake fluids may result in a harmful chemical reaction leading to poor brake performance When refilling be careful that water does not enter the brake fluid reservoir Water will significantly lower the...

Page 81: ...A brake hose is loosened disconnected or replaced The brake fluid level is very low Brake operation is faulty 1 Remove Brake master cylinder cap Reservoir diaphragm Reservoir float front brake Protec...

Page 82: ...ithin the specified lim its Checking the drive chain slack 1 Use a maintenance stand to raise the rear wheel off the ground WARNING EWA13120 Securely support the vehicle so that there is no danger of...

Page 83: ...ves smoothly c Turn the front fork to the right and left a few times and make sure that the steering ro tates smoothly If it does not turn smooth ly remove the lower bracket and check the upper and lo...

Page 84: ...n hard on the handlebar several times and check if the front fork rebounds smoothly Unsmooth operation Correct or replace Refer to FRONT FORK on page 4 39 5 Check Protector guide 1 Out of specificatio...

Page 85: ...rce adjusting mechanism may not exactly match the above specifications due to small dif ferences in production the actual number of clicks always represents the entire adjusting range To obtain a prec...

Page 86: ...er the rear shock absorber assembly operates smoothly Unsmooth operation Correct or replace Refer to REAR SHOCK ABSORBER AS SEMBLY on page 4 55 EAM30242 ADJUSTING THE REAR SHOCK ABSORBER ASSEMBLY Use...

Page 87: ...ism and to modify the specifications as necessary Compression damping for fast compres sion damping NOTICE ECA24370 Do not turn the adjuster forcibly beyond its adjusting range 1 Adjust Compression da...

Page 88: ...e number of clicks of each damping force adjusting mechanism and to modify the specifications as necessary EAM30240 CHECKING THE SWINGARM OPERATION 1 Check Swingarm smooth action Swingarm free play Re...

Page 89: ...Do not give a half turn 180 or more for one tightening Make sure that tightening after a break in is done until the initial looseness in nipples disap pears Make sure that tightening is done in stages...

Page 90: ...a few drops of lubricant into the cable sheath or use a suit able lubricating device EAM30483 LUBRICATING THE BRAKE LEVER 1 Lubricate the pivoting points and metal to metal moving parts of the follow...

Page 91: ...the same direction 4 Set the dial gauge to zero at TDC 5 From TDC rotate the rotor clockwise until the dial gauge indicates that the piston is at a specified distance from TDC 6 Check Ignition timing...

Page 92: ...ELECTRICAL SYSTEM 3 26...

Page 93: ...17 DISASSEMBLING THE FRONT BRAKE CALIPER 4 17 CHECKING THE FRONT BRAKE CALIPER 4 17 ASSEMBLING THE FRONT BRAKE CALIPER 4 17 INSTALLING THE FRONT BRAKE CALIPER 4 18 REMOVING THE FRONT BRAKE MASTER CYLI...

Page 94: ...2 REAR SHOCK ABSORBER ASSEMBLY 4 55 HANDLING THE REAR SHOCK ABSORBER 4 57 DISPOSING OF A REAR SHOCK ABSORBER 4 57 REMOVING THE REAR SHOCK ABSORBER ASSEMBLY 4 57 CHECKING THE REAR SHOCK ABSORBER ASSEMB...

Page 95: ...Remarks 1 Seat 1 2 Air scoop right 1 3 Air scoop left 1 4 Side cover left 1 5 Side cover right 1 6 Number plate 1 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0 7 kgf m 5 2 lb ft 7 N m 0...

Page 96: ...the number plate The projection c on the lower bracket is in serted into the number plate Remove the number plate by pulling it off the projection When installing the number plate insert the projecti...

Page 97: ...to raise the front wheel off the ground 1 Front wheel axle pinch bolt 4 Loosen 2 Front wheel axle nut 1 3 Front wheel axle 1 4 Front wheel 1 5 Collar 2 6 Oil seal 2 7 Bearing 2 8 Brake disc 1 5 6 5 6...

Page 98: ...HECKING THE TIRES on page 3 23 and CHECKING THE WHEELS on page 3 23 3 Check Spoke Refer to CHECKING AND TIGHTENING THE SPOKES on page 3 23 4 Tighten Spoke Refer to CHECKING AND TIGHTENING THE SPOKES o...

Page 99: ...Brake disc Front brake disc bolt TIP Tighten the bolts in stages and in a crisscross pattern 3 Install Collar 1 TIP Apply the lithium soap based grease on the oil seal lip Install the collars with th...

Page 100: ...ening the front wheel axle nut push down hard on the handlebar s several times and check if the front fork rebounds smoothly 4 Tighten Front wheel axle pinch bolt 1 Front wheel axle nut 105 N m 10 5 k...

Page 101: ...the ground 1 Rear wheel axle nut 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 2 10 Brake disc 1 2 5 7 6 4 6 1 6 3...

Page 102: ...wear Replace Refer to CHECKING THE TIRES on page 3 23 and CHECKING THE WHEELS on page 3 23 3 Check Spoke Refer to CHECKING AND TIGHTENING THE SPOKES on page 3 23 4 Measure Radial wheel runout Lateral...

Page 103: ...40 Install the bearing by pressing its outer race parallel NOTICE ECA18110 Do not contact the wheel bearing inner race 1 or balls 2 Contact should be made only with the outer race 3 TIP Use a socket 4...

Page 104: ...based grease to the rear wheel axle 4 Install Drive chain puller right 1 Washer 2 Rear wheel axle nut 3 TIP Temporarily tighten the rear wheel axle nut at this point 5 Adjust Drive chain slack a Refe...

Page 105: ...ge 3 15 1 Union bolt 1 2 Copper washer 2 3 Front brake hose 1 4 Brake pad pin plug 1 5 Brake pad pin 1 6 Brake pad 2 7 Brake pad spring 1 8 Front brake caliper assembly 1 9 Front brake caliper bracket...

Page 106: ...ling the front brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 2 2 Brake caliper piston dust seal 2 3 Brake caliper piston seal 2 4 Bleed screw 1 1 2 4 S S S BF BF 3 2 3 S...

Page 107: ...on bolt 1 3 Copper washer 2 4 Front brake hose 1 5 Brake master cylinder reservoir cap 1 6 Brake master cylinder reservoir diaphragm 1 7 Front brake master cylinder float 1 8 Front brake master cylind...

Page 108: ...FRONT BRAKE 4 14 Disassembling the front brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder kit 1 BF 1 S New...

Page 109: ...inutes and get im mediate medical attention EAM30029 CHECKING THE FRONT BRAKE DISC 1 Check Front brake disc Damage galling Replace 2 Measure Brake disc thickness Measure the brake disc thickness at a...

Page 110: ...brake fluid c Tighten the bleed screw d Install the brake pads 3 and the pad pin TIP Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin...

Page 111: ...the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the brake caliper Never try to pry out the brake caliper pis ton b Remove the brake caliper piston d...

Page 112: ...per end a aligned with the paint b on the brake hose 4 Pour brake fluid to the brake master cylinder reservoir up to the specified level WARNING EWA13090 Use only the designated brake fluid Other brak...

Page 113: ...r 1 Damage scratches wear Replace the brake master cylinder assembly Brake fluid delivery passages 2 brake master cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder r...

Page 114: ...inder holder with the UP mark a facing up First tighten the upper bolt then the lower bolt 2 Install Copper washer 1 Brake hose 2 Union bolt 3 WARNING EWA13531 Proper brake hose routing is essential t...

Page 115: ...ter the brake fluid reservoir Water will significantly lower the boiling point of the brake fluid and could cause vapor lock NOTICE ECA13540 Brake fluid may damage painted surfaces and plastic parts T...

Page 116: ...3 Copper washer 2 4 Rear brake hose 1 5 Brake pad pin plug 1 6 Brake pad pin 1 7 Rear brake pad assembly 2 8 Rear brake caliper bracket 1 9 Brake pad spring 2 10 Rear brake disc cover 1 11 Rear brake...

Page 117: ...sassembling the rear brake caliper Order Job Parts to remove Q ty Remarks 1 Brake caliper piston 1 2 Brake caliper piston dust seal 1 3 Brake caliper piston seal 1 4 Bleed screw 1 1 2 3 4 S BF 6 N m 0...

Page 118: ...age 3 15 1 Union bolt 1 2 Copper washer 2 3 Brake hose 1 4 Split pin 1 5 Washer 1 6 Pin 1 7 Brake master cylinder reservoir cap 1 8 Brake master cylinder reservoir diaphragm plate 1 9 Brake master cyl...

Page 119: ...REAR BRAKE 4 25 Disassembling the rear brake master cylinder Order Job Parts to remove Q ty Remarks 1 Brake master cylinder joint 1 2 Brake master cylinder kit 1 2 1 BF S New...

Page 120: ...lush with water for 15 minutes and get im mediate medical attention EAM30041 CHECKING THE REAR BRAKE DISC 1 Check Brake disc Damage galling Replace 2 Measure Brake disc thickness Measure the brake dis...

Page 121: ...and the pad pin 4 TIP Install the brake pads with their projections a into the brake caliper recesses b Temporarily tighten the pad pin at this point e Install the brake caliper 5 and the rear wheel 6...

Page 122: ...ake hose joint opening to force out the piston from the brake caliper WARNING EWA13550 Cover the brake caliper piston with a rag Be careful not to get injured when the pis ton is expelled from the bra...

Page 123: ...e pad spring Brake pad Brake pad pin Brake pad pin plug Refer to CHECKING THE REAR BRAKE PADS on page 3 14 4 Pour brake fluid to the brake fluid reservoir up to the specified level WARNING EWA13090 Us...

Page 124: ...r cylinder body Obstruction Blow out with compressed air 2 Check Brake master cylinder kit Damage wear Replace 3 Check Master cylinder reservoir cap Crack damage Replace Brake master cylinder reservoi...

Page 125: ...he brake caliper 2 Pour brake fluid to the brake fluid reservoir up to the specified level WARNING EWA13090 Use only the designated brake fluid Other brake fluids may cause the rubber seals to deterio...

Page 126: ...REAR BRAKE 4 32 LEVEL on page 3 14 5 Check Brake pedal operation A softy or spongy feeling Bleed the brake system Refer to BLEEDING THE HYDRAULIC BRAKE SYSTEM on page 3 15...

Page 127: ...5 Cap cover 1 6 Collar 1 7 Clutch cable 1 8 Clutch lever holder 1 9 Engine stop switch 1 10 Left grip 1 11 Upper handlebar holder 2 12 Handlebar 1 13 Lower handlebar holder 2 0 5 N m 0 05 kgf m 0 37...

Page 128: ...cle upright on a level surface WARNING EWA13120 Securely support the vehicle so that there is no danger of it falling over 2 Install Lower handlebar holder 1 Washer 2 Lower handlebar holder nut 3 TIP...

Page 129: ...ff grease or oil on the handlebar surface a with a lac quer thinner Install the left grip to the handlebar so that the line b between the two arrow marks faces straight upward 6 Install Engine stop sw...

Page 130: ...TIP Before applying the adhesive wipe off grease or oil on the tube guide surface a with a lac quer thinner Align the mating mark b on the right grip with the slot c in the tube guide 10 Install Grip...

Page 131: ...stall Throttle cable cap 1 Throttle cable cap screw 2 15 Adjust Throttle grip free play Refer to CHECKING THE THROTTLE GRIP on page 3 5 16 Install Cap cover 1 17 Install Brake master cylinder 1 Brake...

Page 132: ...18 Install Grip cap bolt 1 WARNING EWA21080 After tightening the bolts check that the throttle grip 2 moves smoothly If it does not retighten the bolts for adjustment Grip cap bolt 3 8 N m 0 38 kgf m...

Page 133: ...WHEEL on page 4 3 Front brake caliper Refer to FRONT BRAKE on page 4 11 Number plate Refer to GENERAL CHASSIS on page 4 1 1 Protector 1 2 Upper bracket pinch bolt 2 Loosen 3 Damper assembly 1 Loosen...

Page 134: ...5 Stopper ring 1 6 Inner tube 1 7 Outer tube 1 8 Piston metal 1 9 Protector guide 1 10 Slide metal 1 11 Washer 1 12 Oil seal 1 13 Base valve 1 14 Damper assembly 1 15 Upper spring seat 1 28 N m 2 8 kg...

Page 135: ...rk leg EAM30056 DISASSEMBLING THE FRONT FORK LEGS 1 Drain Fork oil 2 Remove Adjuster 1 from the inner tube TIP While compressing the inner tube 2 set the cap bolt ring wrench 4 between the inner tube...

Page 136: ...sly weaken it 2 Check Outer tube Scratches wear damage Replace 3 Measure Fork spring free length a Out of specification Replace 4 Check Damper assembly 1 Bend damage Replace O ring 2 Wear damage Repla...

Page 137: ...r Before assembling the front fork leg make sure that all of the components are clean 1 Stretch the damper assembly fully 2 Fill Damper assembly NOTICE ECA24530 Be sure to use the recommended oil Othe...

Page 138: ...TIP First bring the damper rod pressure to a maxi mum Then install the base valve while releasing the damper rod pressure 8 Check Damper assembly Not fully stretched Repeat the steps 1 to 7 9 Tighten...

Page 139: ...mper assembly TIP The overflow measures about 10 cm 0 34 US oz 0 35 Imp oz 13 Check Damper assembly smooth movement Tightness binding rough spots Repeat the steps 1 to 12 14 Install Dust seal 1 Stoppe...

Page 140: ...18 Install Oil seal 1 TIP Using a fork seal driver 2 press the oil seal in until the stopper ring groove fully appears 19 Install Stopper ring 1 TIP Fit the stopper ring correctly in the groove in the...

Page 141: ...NOTICE ECA24560 Allow the damper assembly to slide slowly down the inner tube until it contacts the bot tom of the inner tube Be careful not to dam age the inner tube 25 Loosen Rebound damping force...

Page 142: ...r 29 Install Adjuster 1 to the inner tube 30 Fill Front fork leg NOTICE ECA24570 Be sure to use the recommended oil Other oils may have an adverse effect on front fork performance When disassembling a...

Page 143: ...ighten the lower bracket pinch bolts Do not tighten the upper bracket pinch bolts yet 2 Tighten Damper assembly 1 TIP Use the cap bolt ring wrench 2 to tighten the damper assembly 3 Adjust Front fork...

Page 144: ...t Rebound damping force TIP Turn in the damping adjuster 1 finger tight and then turn out to the originally set position 7 Adjust Compression damping force TIP Turn in the damping adjuster 1 finger ti...

Page 145: ...HANDLEBAR on page 4 33 1 Front fender 1 2 Steering stem nut 1 3 Front fork leg 2 4 Upper bracket 1 5 Steering ring nut 1 6 Lower bracket 1 7 Bearing race cover 1 8 Upper bearing 1 9 Bearing race 2 10...

Page 146: ...Bearing race a Remove the bearing race from the steer ing head pipe 1 with a long rod 2 and a hammer b Remove the bearing race from the lower bracket 3 with a chisel 4 and a hammer c Install a new bea...

Page 147: ...nut with its stepped side a facing downward Tighten the steering ring nut with a steering nut wrench 2 Refer to CHECKING AND ADJUSTING THE STEERING HEAD on page 3 17 5 Check the steering stem by turn...

Page 148: ...steering ring nut little by lit tle 10 Adjust Front fork top end a 11 Tighten Upper bracket pinch bolt 1 Lower bracket pinch bolt 2 WARNING EWA19330 Tighten the lower bracket to specified torque If t...

Page 149: ...case joint clamp 1 2 Rear frame 1 3 Rear shock absorber assembly lower bolt 1 4 Rear shock absorber assembly upper bolt 1 5 Rear shock absorber assembly 1 6 Locknut 1 7 Adjusting nut 1 8 Lower spring...

Page 150: ...Y 4 56 Disassembling the relay arm Order Job Parts to remove Q ty Remarks 1 Relay arm 1 2 Connecting arm 1 3 Collar 3 4 Oil seal 6 5 Washer 8 6 Bearing 6 5 3 5 6 1 6 5 4 5 5 4 5 6 6 5 4 3 2 4 6 6 3 4...

Page 151: ...A19340 Wear protective glasses to prevent your eyes from damage due to possible gas or metal chips scattered To dispose of a damaged or a worn out rear shock absorber take the unit to your Yamaha deal...

Page 152: ...ill wear the rear shock ab sorber surface on which the bearing is press fitted 2 Lubricate O ring 3 Install Bearing Stopper ring into the rear shock absorber assembly up per side TIP Install the beari...

Page 153: ...lt swingarm side from the left 7 Tighten Rear shock absorber assembly upper nut Connecting arm nut frame side Connecting arm nut relay arm side Relay arm nut swingarm side Rear shock absorber assembly...

Page 154: ...ground Brake hose holder Refer to REAR BRAKE on page 4 22 Rear brake caliper Refer to REAR BRAKE on page 4 22 Bolt brake pedal Drive chain 1 Collar 2 2 Oil seal 2 3 Thrust bearing 2 4 Bushing 2 5 Oil...

Page 155: ...age Replace 2 Check Pivot shaft Roll the pivot shaft on a flat surface Bends Replace WARNING EWA13770 Do not attempt to straighten a bent pivot shaft 3 Wash with kerosene Pivot shaft Bushing Collar Be...

Page 156: ...SWINGARM 4 62 4 Install Rear wheel Refer to REAR WHEEL on page 4 7 5 Adjust Drive chain slack Refer to DRIVE CHAIN SLACK on page 3 16 Drive chain slack Maintenance Stand 48 0 58 0 mm 1 89 2 28 in...

Page 157: ...der Job Parts to remove Q ty Remarks Drive sprocket Refer to ENGINE REMOVAL on page 5 1 1 Drive chain 1 2 Drive sprocket cover 1 3 Bracket 1 4 Drive sprocket nut 1 5 Lock washer 1 6 Drive sprocket 1 1...

Page 158: ...e 15 link sec tion of the drive chain using the following formula Drive chain 15 link section length c length a between pin inner sides length b between pin outer sides 2 TIP When measuring a 15 link...

Page 159: ...n sprockets this will dramatically shorten the drive chain s life 2 Lubricate Drive chain 3 Install Drive sprocket Lock washer Drive sprocket nut Refer to ENGINE REMOVAL on page 5 1 NOTICE ECA14300 Ne...

Page 160: ...CHAIN DRIVE 4 66...

Page 161: ...12 INSTALLING THE CYLINDER HEAD 5 14 CDI MAGNETO 5 15 REMOVING THE ROTOR 5 16 CHECKING THE CDI MAGNETO 5 16 CHECKING THE WOODRUFF KEY 5 16 INSTALLING THE CDI MAGNETO 5 16 KICKSTARTER 5 18 REMOVING TH...

Page 162: ...REMOVING THE SEGMENT 5 33 CHECKING THE SHIFT SHAFT 5 33 CHECKING THE STOPPER LEVER 5 33 INSTALLING THE SHIFT SHAFT 5 33 CRANKCASE 5 36 DISASSEMBLING THE CRANKCASE 5 37 CHECKING THE CRANKCASE 5 37 ASSE...

Page 163: ...02 in 2 Washer 1 22 mm 0 87 in 3 Silencer 1 4 Collar 1 L 15 5 mm 0 61 in 5 Collar 1 L 13 5 mm 0 53 in 6 Grommet front 1 7 Grommet rear 1 8 Tension spring 2 9 Exhaust pipe 1 14 N m 1 4 kgf m 10 lb ft...

Page 164: ...eutral switch 1 Disconnect the neutral switch lead 2 Drive chain sprocket cover 1 3 Drive chain sprocket guide 1 4 Lock washer 1 5 Drive sprocket 1 6 Brake pedal 1 7 Spring 1 8 Engine bracket 2 9 Engi...

Page 165: ...side Pivot shaft 2 Pivot shaft nut 3 Engine mounting bolt lower side 4 Engine mounting nut lower side 5 Engine mounting bolt front side 6 Engine mounting nut front side 7 Engine bracket 8 Engine brack...

Page 166: ...EMOVAL on page 5 1 Radiator hose 1 Disconnect at cylinder head side Carburetor Refer to CARBURETOR on page 7 3 1 Spark plug 1 2 Engine bracket 2 3 Cylinder head 1 4 Power valve housing 1 5 Push rod 1...

Page 167: ...cover 1 7 Side holder 2 8 Thrust plate 1 9 Power valve holder 1 1 10 Power valve shaft 1 11 Power valve link lever 1 12 Pulley 2 13 Link rod 1 14 Power valve 2 2 15 Power valve holder 2 1 16 Power val...

Page 168: ...E PISTON 1 Remove Piston pin clip 1 TIP Before removing the piston pin clip cover the crankcase opening with a clean rag to prevent the piston pin clip from falling into the crankcase 2 Remove Piston...

Page 169: ...head using a figure eight sanding pat tern TIP To ensure an even surface rotate the cylinder head several times EAM30546 CHECKING THE CYLINDER AND PISTON 1 Check Piston wall Cylinder wall Vertical sc...

Page 170: ...that matches the above chart Diameter 66 352 66 367 mm 2 6123 2 6129 in a 17 5 mm 0 69 in from the bottom edge of the piston Piston to cylinder clearance Cylinder bore Piston skirt diameter Piston to...

Page 171: ...EAM30549 CHECKING THE PISTON PIN 1 Check Piston pin Blue discoloration grooves Replace the piston pin and then check the fuel and en gine mixing oil 2 Measure Piston pin outside diameter a Out of spe...

Page 172: ...1 2 8 Broken Replace EAM30552 CHECKING THE POWER VALVE HOLE ON CYLINDER 1 Remove Carbon deposits from power valve hole surface a TIP Do not use a sharp instrument Avoid scratching the aluminum EAM3055...

Page 173: ...link lever and then to the cylinder Install the spring 1 with its stopper portion a facing inward Apply the molybdenum disulfide oil on the grooves in the pulleys Apply the lithium soap based grease o...

Page 174: ...lve cover 1 Power valve cover 2 Power valve cover screw 3 TIP Install the gasket with its cut a facing down ward and the seal print side toward the power valve cover Install the power valve cover so t...

Page 175: ...he crankcase opening with a clean rag to prevent the clip from falling into the crankcase Do not allow the clip open ends to meet the pis ton pin slit b 4 Lubricate Piston Piston ring Cylinder with th...

Page 176: ...g bolt 2 EAM30555 INSTALLING THE CYLINDER HEAD 1 Lubricate O ring 2 Install O ring 1 Dowel pin 2 TIP Apply the lithium soap based grease on the O rings 3 Install Cylinder head 1 Copper washer 2 Cylind...

Page 177: ...ENERAL CHASSIS on page 4 1 Fuel tank Refer to FUEL TANK on page 7 1 Radiator bolt Refer to RADIATOR on page 6 2 CDI magneto lead Disconnect 1 Crankcase cover left 1 2 Gasket 1 3 CDI magneto rotor 1 4...

Page 178: ...a Stator outer surface b Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace CDI magneto and or stator EAM30564 CHECKING THE WOODRUFF KEY 1 Check Woodruff key 1 Damage Re...

Page 179: ...the ignition timing position mark b on the crankcase 3 Align the stator coil screw 1 with the center of the hole c 6 Check Ignition timing Re check the ignition timing 7 Connect CDI magneto lead 1 Re...

Page 180: ...water pump side 1 Kickstarter lever 1 2 Ball 1 3 Spring 1 4 Kick crank boss 1 5 Crankcase cover right 1 6 Gasket 1 7 Oil seal 1 8 Governor drive gear 1 9 Primary drive gear 1 10 Kick idle gear 1 11 K...

Page 181: ...e the kick shaft as sembly Spring 3 Broken Replace EAM30103 CHECKING THE KICK GEAR KICK IDLE GEAR AND RATCHET WHEEL 1 Check Kick gear 1 Wear damage Replace the kick shaft as sembly Kick idle gear 2 Ra...

Page 182: ...of the kick shaft ratchet wheel guide 2 and the kick shaft stopper a Apply the transmission oil on the kick shaft Slide the kick shaft assembly into the crank case and make sure the kick shaft stoppe...

Page 183: ...this point 2 Install Primary driven gear Refer to CLUTCH on page 5 25 3 Tighten Primary drive gear bolt 1 TIP Place an aluminum plate a between the teeth of the primary drive gear 2 and driven gear 3...

Page 184: ...cover right Refer to KICKSTARTER on page 5 18 1 Governor assembly 1 2 Dowel pin 1 3 Retainer 1 4 Ball 4 5 Retainer weight 1 6 Washer 4 7 Bearing 2 8 Collar 1 9 Plate 1 10 Compression spring 1 11 Gove...

Page 185: ...bearing 1 Washer 2 Wear damage Replace EAM30569 INSTALLING THE GOVERNOR 1 Install Governor gear 1 Compression spring 2 Plate 3 Washer 4 Thrust bearing 5 Collar 6 Retainer weight 7 to the governor shaf...

Page 186: ...compressing the spring install the dowel pin Make sure the dowel pin fits into the groove a in the retainer 4 Install Governor assembly 1 TIP Align the groove a in the governor with the fork b and se...

Page 187: ...SMISSION OIL on page 3 6 Bolt brake pedal Shift the brake pedal downward Rotor and stator Refer to CDI MAGNETO on page 5 15 Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Gasket 1 3 Clutch...

Page 188: ...Bearing 1 5 Push rod 2 1 6 Lock washer 1 7 Clutch boss 1 8 Thrust washer 1 D 44 mm 1 73 in 9 Primary driven gear 1 10 Bearing 1 11 Spacer 1 1 12 Thrust washer 1 D 42 mm 1 65 in 13 Push lever shaft 1...

Page 189: ...set EAM30111 CHECKING THE CLUTCH SPRINGS 1 Check Clutch spring Damage Replace the clutch springs as a set 2 Measure Clutch spring free length Out of specification Replace the clutch springs as a set E...

Page 190: ...s a set Excessive noise during operation Replace the primary drive and primary driven gears as a set 2 Check Primary drive gear to primary driven gear free play Free play exists Replace the primary dr...

Page 191: ...lutch boss nut 2 TIP Use the clutch holder 3 to hold the clutch boss 5 Bend the lock washer 1 tab 6 Install Friction plate 1 Clutch plate 2 TIP Install the clutch plates and friction plates alter nate...

Page 192: ...rd you 9 Install Pressure plate 1 10 Install Clutch spring Clutch spring bolt TIP Tighten the bolts in stage using a crisscross pat tern 11 Install O ring 1 to the clutch cover 12 Install Clutch cover...

Page 193: ...CLUTCH 5 31 2 1...

Page 194: ...e Q ty Remarks 1 Shift pedal 1 2 Shift shaft 1 3 Segment bolt 1 4 Segment 1 5 Shift guide 1 6 Roller 1 7 Shift lever assembly 1 8 Stopper lever 1 9 Holder 1 10 Tension spring 1 10 N m 1 0 kgf m 7 4 lb...

Page 195: ...mage wear Replace Shift shaft spring 2 Damage wear Replace 2 Check Shift guide 1 Shift lever 2 Pawl 3 Pawl pin 4 Spring 5 Wear damage Replace EAM30127 CHECKING THE STOPPER LEVER 1 Check Stopper lever...

Page 196: ...he bolt 3 Install Spring 1 Pawl pin 2 Pawl 3 to the shift lever TIP Apply the transmission oil on the spring pawl pin and pawl 4 Install Shift lever assembly to the shift guide 5 Install Shift lever a...

Page 197: ...hift pedal 1 Shift pedal bolt 2 TIP Install the shift pedal so that the top of the shift pedal outer diameter a is highest without ex ceeding the line b connecting the center of the shift shaft and bo...

Page 198: ...am Shift fork Refer to TRANSMISSION on page 5 41 1 Holder 2 2 Neutral switch lead holder bolt 1 3 Crankcase bolt 7 L 50 mm 1 97 in 4 Crankcase bolt 1 L 60 mm 2 36 in 5 Crankcase bolt 3 L 70 mm 2 76 in...

Page 199: ...arate check for a remaining case bolt or fitting Do not force 2 Remove Bearing 1 TIP Remove the bearing from the crankcase by pressing its inner race Do not use the removed bearing EAM30150 CHECKING T...

Page 200: ...P Fit the crankcase right onto the crankcase left Tap lightly on the case with soft hammer When installing the crankcase the connecting rod should be positioned at TDC top dead center 6 Install Holder...

Page 201: ...EAM20193 CRANKSHAFT Removing the crankshaft assembly Order Job Parts to remove Q ty Remarks Crankcase Separate Refer to CRANKCASE on page 5 36 Transmission Refer to TRANSMISSION on page 5 41 1 Cranksh...

Page 202: ...RANKSHAFT 1 Install Crankshaft assembly TIP Install the crankshaft assembly with the crank shaft installer pot 1 crankshaft installer bolt 2 and adapter M12 3 TIP Hold the connecting rod at top dead c...

Page 203: ...nd shift forks Order Job Parts to remove Q ty Remarks Engine Refer to ENGINE REMOVAL on page 5 1 Crankcase Refer to CRANKCASE on page 5 36 1 Main axle 1 2 Drive axle 1 3 Shift cam 1 4 Shift fork 3 R 1...

Page 204: ...fork movement Unsmooth operation Replace shift fork TIP For a malfunctioning shift fork replace not only the shift fork itself but the two gears each adja cent to the shift fork EAM30155 CHECKING THE...

Page 205: ...of the sliding gear then install 2 Install 2nd wheel gear 23T 1 4th wheel gear 24T 2 3rd wheel gear 23T 3 5th wheel gear 20T 4 1st wheel gear 27T 5 O ring 6 to the drive axle 7 TIP Apply the molybden...

Page 206: ...bdenum disulfide oil on the shift fork grooves Mesh the shift fork 1 L with the 4th wheel gear 5 and the shift fork 3 R with the 5th wheel gear 6 on the drive axle Mesh the shift fork 2 C10 with the 3...

Page 207: ...10 COOLING SYSTEM COOLING SYSTEM DIAGRAMS 6 1 RADIATOR 6 2 CHECKING THE RADIATOR 6 3 INSTALLING THE RADIATOR 6 3 WATER PUMP 6 5 DISASSEMBLING THE WATER PUMP 6 6 CHECKING THE WATER PUMP 6 6 ASSEMBLING...

Page 208: ...COOLING SYSTEM DIAGRAMS 6 1 EAM20186 COOLING SYSTEM DIAGRAMS 1 Radiator hose 1 2 Radiator right 3 Radiator hose 4 4 Water pump 5 Radiator left...

Page 209: ...on page 7 1 1 Radiator guard 2 2 Radiator hose clamp 8 Loosen 3 Radiator hose 1 1 4 Radiator left 1 5 Radiator hose 4 1 6 Radiator right 1 7 Radiator hose 2 2 8 Radiator breather hose 1 10 N m 1 0 kgf...

Page 210: ...k Radiator cap valve opening pressure a Install the radiator cap tester adapter 2 and the radiator cap tester 1 to the radi ator cap 3 and activate the tester to check whether it can stay for 5 to 10...

Page 211: ...arm up Make sure that coolant is filled up to the up per level beforehand 5 Check Pressure value No stay for 5 to 10 seconds at the test pres sure value Correct Radiator Radiator hose connections Cool...

Page 212: ...y Remarks Crankcase cover right Refer to KICKSTARTER on page 5 18 1 Water pump housing 1 2 Dowel pin 2 3 Gasket 1 4 Impeller 1 5 Washer 1 6 Impeller shaft assembly 1 7 Bearing 1 8 Oil seal 2 10 N m 1...

Page 213: ...TIP Apply the lithium soap based grease on the oil seal lip Install the oil seal with its manufacture s marks or numbers facing the crankcase cover right 2 Install Bearing 1 TIP Install the bearing by...

Page 214: ...1 Gasket 2 5 Install Water pump housing 1 Water pump housing cover bolt 2 Washer 3 Coolant drain bolt 4 Water pump housing cover bolt 10 N m 1 0 kgf m 7 4 lb ft Coolant drain bolt 10 N m 1 0 kgf m 7 4...

Page 215: ...7 1 AIR FILTER 7 2 CARBURETOR 7 3 HANDLING NOTE 7 6 CHECKING THE CARBURETOR 7 6 CHECKING THE REED VALVE 7 7 INSTALLING THE REED VALVE 7 7 ASSEMBLING THE CARBURETOR 7 8 INSTALLING THE CARBURETOR 7 10 M...

Page 216: ...right Air scoop left right 1 Fuel cock assembly 1 2 O ring 1 3 Fuel tank 1 Install the fuel tank 3 so that the rubber cover a is placed behind the fuel tank 3 along the vehicle 4 Fuel tank breather ho...

Page 217: ...REAR SHOCK ABSORBER ASSEMBLY on page 4 55 1 Fitting bolt 1 2 Air filter element 1 3 Air filter guide 1 4 Guide holder 1 5 Band 1 6 Spacer 1 7 Air filter joint 1 8 Air filter case 1 Place the rubber co...

Page 218: ...1 Solenoid valve lead 1 Disconnect 2 Throttle position sensor lead 1 Disconnect 3 Air filter clamp 1 4 Carburetor joint clamp 1 5 Carburetor assembly 1 6 Carburetor joint 1 7 Reed valve assembly 1 8 R...

Page 219: ...Gasket 1 3 Throttle valve 1 4 Ring 1 5 Throttle valve spring 1 6 Jet needle holder 1 7 Spring 1 8 Collar 1 9 Jet needle 1 10 Carburetor breather hose 2 11 Overflow hose 2 12 Starter plunger 1 13 Fuel...

Page 220: ...retor Order Job Parts to remove Q ty Remarks 16 Throttle stop screw 1 17 Pilot air screw 1 18 Plug 1 19 Float chamber 1 20 Float pin 1 21 Float 1 22 Needle valve 1 23 Main jet 1 24 Pilot jet 1 25 Powe...

Page 221: ...uction Clean a Wash the carburetor in a petroleum based solvent Do not use any caustic carburetor cleaning solution b Blow out all of the passages and jets with compressed air 3 Check Float chamber bo...

Page 222: ...574 CHECKING THE REED VALVE 1 Measure Reed valve bending a Out of limit Replace Valve stopper height b Out of specification Replace EAM30577 INSTALLING THE REED VALVE 1 Install Reed valve 1 Reed valve...

Page 223: ...1 Solenoid valve 2 to the carburetor NOTICE ECA27130 Before installing the solenoid valve blow air on the solenoid valve and its installing loca tion on the carburetor in order to remove any foreign...

Page 224: ...RAM on page 2 15 TIP Install the air vent hoses and overflow hose to the carburetor with their ends not having the cuts a toward the carburetor 9 Install Jet needle 1 Collar 2 Spring 3 Jet needle hold...

Page 225: ...578 INSTALLING THE CARBURETOR 1 Install Carburetor 1 TIP Install the projection between the carburetor joint slots 2 Tighten Screw carburetor joint 1 3 Tighten Screw air cleaner joint 1 TIP Place the...

Page 226: ...urface of the float chamber and top of the float using a vernier calipers TIP The float arm should be resting on the needle valve but not compressing the needle valve 2 Adjust Fuel level a Check the n...

Page 227: ...ECKING THE SWITCHES 8 6 CHECKING THE IGNITION SPARK GAP 8 8 CHECKING THE SPARK PLUG CAP 8 8 CHECKING THE IGNITION COIL 8 8 CHECKING THE PICKUP COIL 8 9 CHECKING THE SOURCE COIL 8 9 CHECKING THE SOLENO...

Page 228: ...ngine stop switch 3 Ignition coil 4 Throttle position sensor 5 Solenoid valve 6 Neutral switch 7 CDI magneto 8 Spark plug B Black L Blue O Orange R Red Sb Sky blue Y Yellow B L Black Blue B R Black Re...

Page 229: ...ap Refer to CHECKING THE SPARK PLUG CAP on page 8 8 NG Replace the spark plug cap OK 4 Check the ignition coil Refer to CHECKING THE IGNI TION COIL on page 8 8 NG Replace the ignition coil OK 5 Check...

Page 230: ...V battery in this inspection 1 Check each couplers and wire con nection NG Reconnect OK 2 Check solenoid valve Check sole noid valve operation Solenoid valve coil Refer to CHECKING THE SOLE NOID VALV...

Page 231: ...nnect OK 2 Check throttle position sensor Throttle position sensor coil Refer to CHECKING THE THROT TLE POSITION SENSOR COIL on page 8 11 and CHANGING AND ADJUSTING THE THROTTLE PO SITION SENSOR on pa...

Page 232: ...ELECTRICAL COMPONENTS 8 5 EAM20147 ELECTRICAL COMPONENTS 1 2 3 4 5 6 1 CDI unit 2 Engine stop switch 3 Ignition coil 4 Throttle position sensor 5 Solenoid valve 6 Neutral switch...

Page 233: ...ELECTRICAL COMPONENTS 8 6 EAM30289 CHECKING THE SWITCHES 1 1 Engine stop switch...

Page 234: ...ecking for continuity switch back and forth between the switch positions a few times Terminal connections of the switch are shown in the terminal connection diagram below The switch positions a are sh...

Page 235: ...cification Replace a Connect the digital circuit tester to the spark plug cap b Measure the spark plug cap resistance EAM30296 CHECKING THE IGNITION COIL 1 Check Primary coil resistance Out of specifi...

Page 236: ...rom the wire harness 2 Check Charging coil 1 resistance B R B Out of specification Replace the CDI mag neto a Connect the digital circuit tester to the CDI magneto coupler as shown Secondary coil resi...

Page 237: ...onnect 12 V battery to the solenoid valve coupler 3 Check Solenoid valve 1 No click when connecting the battery Re place EAM30586 CHECKING THE SOLENOID VALVE COIL 1 Check Solenoid valve coil resistanc...

Page 238: ...as the lever 1 is moved from the full close position to the full open position Out of specification Replace EAM30589 CHANGING AND ADJUSTING THE THROTTLE POSITION SENSOR 1 Remove Carburetor Mixing cham...

Page 239: ...electric conductors 2 lead wire into the throttle position sensor coupler 1 as shown and connect the tester to them 8 Start the engine 9 Adjust Throttle position sensor output voltage a Adjust the in...

Page 240: ...3 EAM30305 CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1 Disconnect the throttle position sensor cou pler 2 Start the engine 3 Check Throttle position sensor input voltage Out of specificatio...

Page 241: ...ERAL INFORMATION 9 1 TROUBLESHOOTING OF ENGINE 9 1 TROUBLESHOOTING OF CLUTCH 9 6 TROUBLESHOOTING OF TRANSMISSION 9 7 TROUBLESHOOTING OF COOLING SYSTEM 9 8 TROUBLESHOOTING OF BRAKE 9 9 TROUBLESHOOTING...

Page 242: ...l not supplied Empty fuel tank Fill the fuel tank with fuel Clogged fuel tank cap breather hole Clean the fuel tank cap Clogged or damaged fuel hose Clean repair or replace the fuel hose Fuel leakage...

Page 243: ...cap Defective ignition coil Replace the ignition coil CDI unit failure Replace the CDI unit Fuel not supplied Fuel leakage Check the fuel passage Repair or replace as necessary Clogged carburetor fue...

Page 244: ...hose Replace the vacuum hose Damaged carburetor joint Replace the carburetor joint Loose carburetor joint Tighten the carburetor joint bolts to the specified torque Clogged air filter element Clean or...

Page 245: ...hten the main jet to the speci fied torque Bent damaged or worn jet needle Replace the jet needle Cracks or damage in the piston valve diaphragm Replace the piston valve dia phragm Problem with piston...

Page 246: ...rings as a set Worn or damaged piston Replace the piston and piston rings as a set Worn piston piston pin hole Replace the piston and piston pin as a set Worn or damaged piston pin Replace the piston...

Page 247: ...ne oil Deteriorated oil Change to recommended engine oil Clutch drags Faulty clutch spring Replace the clutch springs as a set Warped pressure plate Replace the pressure plate Swollen friction plate R...

Page 248: ...the shift drum Seized shift fork Replace the shift fork and shift fork guide bar as a set Bent shift fork guide bar Replace the shift fork guide bar Foreign object between transmis sion gears Remove...

Page 249: ...the radiator Damaged or faulty water pump Replace the water pump Damaged hoses or pipes Replace the hose or pipe Improperly connected hoses or pipes Connect the hoses and pipes properly Clogged air f...

Page 250: ...Damaged brake hose and brake pipe Replace the brake hose and brake pipe Oil or grease on the brake disc or brake pad Clean the brake disc or brake pad Insufficient lubrication of brake lever or brake...

Page 251: ...per rod assembly bolt Tighten the damper rod assembly bolt to the specified torque Damaged damper rod assembly bolt copper washer Replace the damper rod assembly bolt copper washer Cracked or damaged...

Page 252: ...ed torque Worn bearing or bearing race Replace the bearing and bearing race as a set Warped front fork Repair or replace the front fork Bent front wheel axle Replace the front wheel axle Incorrect tir...

Page 253: ...d or incorrect tire Replace the tire Loose wheel axle nut Tighten the wheel axle nut to the specified torque Loose swingarm pivot shaft Tighten the swingarm pivot shaft to the specified torque Bent or...

Page 254: ...TROUBLESHOOTING 9 13...

Page 255: ...N AND EXAMPLES OF CARBURETOR SETTING 10 7 EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM 10 7 CHANGE OF THE HEAT RANGE OF SPARK PLUGS 10 9 CHASSIS 10 10 SELECTION OF THE SECONDARY REDUCTION RATIO...

Page 256: ...e to make a note of settings atmo spheric conditions road surface condition lap time etc so that the memorandum can be used as a reference useful for future EAM30591 ATMOSPHERIC CONDITIONS AND CARBURE...

Page 257: ...richness of air fuel mixture under 8500 r min to the extent of 1 2 to full opened throttle can be set by changing the power jet 1 A larger size jet results in a richer mixture and a smaller size in a...

Page 258: ...per angle are available in different straight portion diameters and in different taper start ing positions 2 Effects of changing the jet needle reference Diameter of straight portion Changing the diam...

Page 259: ...ip by one groove and move up the needle to enrich the mixture EAM30605 RELATIONSHIP WITH THROTTLE OPENING The flow of the fuel through the carburetor main system is controlled by the main jet and then...

Page 260: ...48 08 STD 50 4MX 14948 07 48 4MX 14948 06 45 4MX 14948 05 42 4MX 14948 04 40 4MX 14948 03 Lean 38 4MX 14948 02 Jet needle 3 Rich N3CG 4SR 14916 CG N3EG 4SR 14916 EG N89G 4JT 14916 9G N8RH 4SR 14916 RH...

Page 261: ...ENGINE 10 6...

Page 262: ...ase main jet calibration no Gradually Discoloration of spark plug If tan color it is in good condition If cannot be corrected Clogged float valve seat Clogged fuel hose Clogged fuel cock At full throt...

Page 263: ...ger diameter Unstable at low speeds Pinking noise Lower jet needle clip position 1 groove down Turn in pilot air screw Poor response at extremely low speed Reduce pilot jet calibration No Turn out pil...

Page 264: ...No of the main jet must be changed by 15 it is advisable to change the heat range of spark plugs and newly select the proper main jet TIP When checking the discoloration of spark plugs be sure to sto...

Page 265: ...t such that it can develop its maximum revolutions toward the end of the straight line with care taken to avoid the en gine over revving TIP Riding technique varies from rider to rider and the perform...

Page 266: ...r spring characteristics to have a ten dency to be stiffer with the consequent dete riorated performance and characteristics Therefore adjust the front fork within the specified range EAM30173 SETTING...

Page 267: ...r and the rear fender holding bolt 2 Remove the stand or block from the engine and with a rider astride the seat measure the sunken length b between the rear wheel axle center and the rear fender hold...

Page 268: ...han currently installed use the one whose overall length a does not exceed the stan dard as it may result in faulty performance Never use one whose overall length is great er than standard EAM30178 RE...

Page 269: ...r and quantity of I D marks Spring preload adjusting positions TIP For the spring preload adjustment refer to AD JUSTING THE REAR SHOCK ABSORBER AS SEMBLY on page 3 20 Spring preload adjusting positio...

Page 270: ...oticeable scars etc If any replace affected parts Slide metal Replace with a new one for extended use Piston metal Replace with a new one for extended use Lower bracket tightening torque Retighten to...

Page 271: ...ount Increase oil amount by about 5 cm 0 2 US oz 0 2 Imp oz Obtrusive front tending to upper front posture Compression damping force Turn adjuster counterclockwise about 2 clicks to decrease damping B...

Page 272: ...senger is astride seat Spring Replace with soft spring Bottoming out High compres sion damping Turn adjuster clockwise about 1 6 turn to increase damping Spring set length Set sunken length for 90 100...

Page 273: ...nce Buy with confidence knowing your Genuine Yamaha Accessories will fit right and perform right right out of the box Yamalube Take care of your Yamaha with legendary Yamalube oils lubricants and care...

Page 274: ......

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