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Yamaha yz250f A 2011, Owner'S Service Manual, Page: 145 / 196

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Yamaha yz250f A 2011 Owner'S Service Manual Download Page 145

5-8

FRONT BRAKE AND REAR BRAKE

DISASSEMBLING THE BRAKE CALIPER

Order

Part name

Q'ty

Remarks

A.

Front

B.

Rear

A

B

1

Pad  pin

1

1

2

Brake pad

2

2

3

Pad support

1

1

4

Brake caliper piston

2

1

Refer to removal section.

5

Brake caliper piston dust seal

2

1

Refer to removal section.

6

Brake caliper piston seal

2

1

Refer to removal section.

Summary of Contents for yz250f A 2011

Page 1: ... DI SERVIZIO DEL PROPRIETARIO PRINTED IN JAPAN 2009 05 2 0 1 CR E F G H YZ250F Z 2010 Il convient de lire attentivement ce manuel avant la première utilisation du véhicule Read this manual carefully before operating this vehicle Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch bevor Sie das Fahrzeug in Betrieb nehmen Leggere attentamente questo manuale prima di utilizzare questo veicolo ...

Page 2: ...ule Le manuel doit être remis avec le véhicule en cas de vente de ce dernier Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch bevor Sie das Fahrzeug in Betrieb nehmen Diese Bedienungsanleitung muss wenn das Fahrzeug verkauft wird beim Fahrzeug verbleiben Leggere attentamente questo manuale prima di utilizzare il veicolo Questo manuale dovrebbe accompa gnare il veicolo se viene venduto ...

Page 3: ...YZ250F Z 2010 2010 17D 28199 30 E0 17D 28199 30 E0 OWNER S SERVICE MANUAL OWNER S SERVICE MANUAL Read this manual carefully before operating this vehicle Read this manual carefully before operating this vehicle ...

Page 4: ......

Page 5: ... S SERVICE MANUAL 2009 by Yamaha Motor Co Ltd 1st Edition May 2009 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan ...

Page 6: ...racter istics THIS MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY Do not carry passengers on this machine ALWAYS WEAR PROTECTIVE APPAREL When operating this machine al ways wear an approved helmet with goggles or a face shield Also wear heavy boots gloves and protective clothing Always wear proper fitting clothing that will not be caught in any of the moving parts or controls of the machine...

Page 7: ...wn to find the required fore edge symbol mark and go to a page for required item and de scription MANUAL FORMAT All of the procedures in this manual are organized in a sequential step by step format The information has been complied to provide the me chanic with an easy to read handy reference that contains comprehen sive explanations of all disassembly repair assembly and inspection op erations I...

Page 8: ...informa tion the step by step format sup plements 5 are given in addition to the exploded diagram and job instruction chart ILLUSTRATED SYMBOLS Refer to the illustration Illustrated symbols 1 to 7 are used to identify the specifications appear ing in the text 1 With engine mounted 2 Filling fluid 3 Lubricant 4 Special tool 5 Tightening 6 Specified value Service limit 7 Resistance Ω Voltage V Elect...

Page 9: ...TABLE OF CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 REGULAR INSPECTION AND ADJUSTMENTS 3 ENGINE 4 CHASSIS 5 ELECTRICAL 6 TUNING 7 ...

Page 10: ...GINE 3 6 CHASSIS 3 14 ELECTRICAL 3 24 CHAPTER 4 ENGINE SEAT FUEL TANK AND SIDE COVERS 4 1 EXHAUST PIPE AND SILENCER 4 3 RADIATOR 4 5 CARBURETOR 4 7 CAMSHAFTS 4 14 CYLINDER HEAD 4 19 VALVES AND VALVE SPRINGS 4 21 CYLINDER AND PISTON 4 25 CLUTCH 4 29 OIL FILTER ELEMENT AND WATER PUMP 4 33 BALANCER 4 38 OIL PUMP 4 40 KICK SHAFT AND SHIFT SHAFT 4 44 CDI MAGNETO 4 49 ENGINE REMOVAL 4 51 CRANKCASE AND C...

Page 11: ...1 1 LOCATION OF IMPORTANT LABELS GENERAL INFORMATION LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle CANADA 1 ...

Page 12: ...1 2 LOCATION OF IMPORTANT LABELS EUROPE ...

Page 13: ...1 3 LOCATION OF IMPORTANT LABELS AUS NZ ZA ...

Page 14: ...ains high pressure nitrogen gas Mishandling can cause explosion Do not incinerate puncture or open Turn off the main switch after riding to avoid draining the battery Use unleaded gasoline only Measure tire pressure when tires are cold Adjust tire pressure Improper tire pressure can cause loss of control Loss of control can result in severe injury or death ...

Page 15: ...nge without notice 1 Clutch lever 2 Hot starter lever 3 Front brake lever 4 Throttle grip 5 Radiator cap 6 Fuel tank cap 7 Engine stop switch 8 Kickstarter crank 9 Fuel tank 10 Radiator 11 Coolant drain bolt 12 Rear brake pedal 13 Valve joint 14 Fuel cock 15 Cold starter knob 16 Air filter 17 Drive chain 18 Shift pedal 19 Oil level check window 20 Front fork ...

Page 16: ...joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose In this installation make sure the arrow faces the fuel tank and also downward SPARK PLUG WRENCH This spark plug wrench 1 is used to remove and install the spark plug NIPPLE WRENCH This nipple wrench 1 is used to tighten the spoke JET NEEDLE PULL UP TOOL The jet needle pull up tool 1 is used to pull the jet need...

Page 17: ...amped letters must be on the side exposed to view When in stalling oil seal s apply a light coating of lightweight lithium base grease to the seal lip s Oil the bearings liberally when installing Do not use compressed air to spin the bearings dry This causes dam age to the bearing surfaces CIRCLIPS 1 All circlips should be inspected carefully before reassembly Al ways replace piston pin clips afte...

Page 18: ...ase separating tool YU 1135 A 90890 01135 These tool is used to remove the crankshaft from either case Flywheel puller YM 1189 90890 01189 This tool is used to remove the fly wheel magneto Rotor holding tool YU 1235 90890 01235 This tool is used when loosening or tightening the flywheel magneto se curing nut Dial gauge and stand YU 3097 90890 01252 Stand YU 1256 These tools are used to check each ...

Page 19: ...01500 90890 01500 This tool is used to loosen or tighten the base valve Cap bolt ring wrench YM 01501 90890 01501 This tool is used to loosen or tighten the damper assembly Fork seal driver YM A0948 90890 01502 This tool is used when install the fork oil seal Spoke nipple wrench YM 01521 90890 01521 This tool is used to tighten the spoke Pocket tester YU 3112 C 90890 03112 Use this tool to inspect...

Page 20: ...oss securing nut Valve guide remover Intake 4 0 mm 0 16 in Exhaust 4 5 mm 0 18 in YM 4111 90890 04111 YM 4116 90890 04116 This tool is needed to remove and install the valve guide Valve guide installer Intake 4 0 mm 0 16 in Exhaust 4 5 mm 0 18 in YM 4112 90890 04112 YM 4117 90890 04117 This tool is needed to install the valve guide Valve guide reamer Intake 4 0 mm 0 16 in Exhaust 4 5 mm 0 18 in YM...

Page 21: ...necessary for checking the ignition system compo nents Digital tachometer YU 39951 B 90890 06760 This tool is needed for observing en gine rpm YAMAHA Bond No 1215 Three Bond No 1215 90890 85505 This sealant Bond is used for crankcase mating surface etc Tool name Part number How to use Illustration ...

Page 22: ...e grip toward you for deceleration turn it away from you FRONT BRAKE LEVER The front brake lever 1 is located on the right handlebar Pull it toward the handlebar to activate the front brake REAR BRAKE PEDAL The rear brake pedal 1 is located on the right side of the machine Press down on the brake pedal to activate the rear brake FUEL COCK The fuel cock supplies fuel from the tank to carburetor and...

Page 23: ...e while kick ing the kickstarter crank Other wise the kickstarter crank may kick back 6 Return the cold starter knob to its original position and run the en gine at 3 000 5 000 r min for 1 or 2 minutes Since this model is equipped with an accelerator pump if the engine is raced the throttle opened and closed the air fuel mixture will be too rich and the engine may stall Also unlike a two stroke en...

Page 24: ... 2 open low to me dium speed for about one hour 6 Restart the engine and check the operation of the machine through out its entire operating range Re start the machine and operate it for about 10 to 15 more minutes The machine will now be ready to race After the break in or before each race you must check the entire machine for loose fittings and fasteners as per TORQUE CHECK POINTS Tighten all su...

Page 25: ...ink type Assembly of links Link to frame Link to rear shock absorber Link to swingarm Installation of rear shock absorber Rear shock absorber to frame Installation of swingarm Tightening of pivot shaft Wheel Installation of wheel Front Tightening of wheel axle Tightening of axle holder Rear Tightening of wheel axle Wheel to rear wheel sprocket Brake Front Brake caliper to front fork Brake disc to ...

Page 26: ...ith a vinyl uphol stery cleaner to keep the cover pliable and glossy 8 Automotive wax may be applied to all painted or chromed surfac es Avoid combination cleaner waxes as they may contain abra sives 9 After completing the above start the engine and allow it to idle for several minutes STORAGE If your machine is to be stored for 60 days or more some preventive mea sures must be taken to avoid dete...

Page 27: ... cooled 4 stroke DOHC Cylinder arrangement Single cylinder forward inclined Displacement 250 cm3 8 80 Imp oz 8 45 US oz Bore stroke 77 0 53 6 mm 3 03 2 11 in Compression ratio 13 5 1 Starting system Kickstarter Lubrication system Dry sump Oil type or grade Engine oil Recommended brand YAMALUBE SAE10W 30 SAE10W 40 SAE10W 50 SAE15W 40 SAE20W 40 or SAE20W 50 API service SG type or higher JASO standar...

Page 28: ...N EUROPE AUS NZ ZA Frame type Bilateral beam Caster angle 27 5 27 2 27 4 Trail 120 2 mm 4 73 in 117 4 mm 4 62 in 119 6 mm 4 71 in Tire Type With tube Size front 80 100 21 51M Size rear 100 90 19 57M Tire pressure front and rear 100 kPa 1 0 kgf cm2 15 psi Brake Front brake type Single disc brake Operation Right hand operation Rear brake type Single disc brake Operation Right foot operation Suspensi...

Page 29: ...outside diameter 21 959 21 972 mm 0 8645 0 8650 in Shaft to cap clearance 0 028 0 062 mm 0 0011 0 0024 in 0 08 mm 0 003 in Cam dimensions Intake A 30 330 30 430 mm 1 1941 1 1980 in 30 230 mm 1 1902 in Intake B 22 45 22 55 mm 0 8839 0 8878 in 22 35 mm 0 8799 in Exhaust A 30 399 30 499 mm 1 1968 1 2007 in 30 299 mm 1 1929 in Exhaust B 22 45 22 55 mm 0 8839 0 8878 in 22 35 mm 0 8799 in Camshaft runou...

Page 30: ... EX 0 9 1 1 mm 0 0354 0 0433 in 1 6 mm 0 0630 in D margin thickness IN 0 8 mm 0 0315 in D margin thickness EX 0 7 mm 0 0276 in Stem outside diameter IN 3 975 3 990 mm 0 1565 0 1571 in 3 945 mm 0 1553 in Stem outside diameter EX 4 460 4 475 mm 0 1756 0 1762 in 4 430 mm 0 1744 in Guide inside diameter IN 4 000 4 012 mm 0 1575 0 1580 in 4 050 mm 0 1594 in Guide inside diameter EX 4 500 4 512 mm 0 177...

Page 31: ...1 in Compressed force installed IN 99 114 N at 28 98 mm 9 9 11 4 kg at 28 98 mm 22 27 25 57 lb at 1 14 in Compressed force installed EX 126 145 N at 28 30 mm 12 6 14 5 kg at 28 30 mm 28 44 31 97 lb at 1 11 in Tilt limit IN 2 5 1 7 mm 2 5 0 067 in Tilt limit EX 2 5 1 6 mm 2 5 0 063 in Direction of winding top view IN Clockwise Direction of winding top view EX Clockwise Piston Piston to cylinder cle...

Page 32: ... 0 0012 0 0026 in 0 12 mm 0 005 in 2nd ring Type Taper Dimensions B T 0 80 2 75 mm 0 03 0 11 in End gap installed 0 30 0 45 mm 0 012 0 018 in 0 80 mm 0 031 in Side clearance 0 020 0 055 mm 0 0008 0 0022 in 0 12 mm 0 005 in Oil ring Dimensions B T 1 50 2 25 mm 0 06 0 09 in End gap installed 0 10 0 40 mm 0 004 0 016 in Crankshaft Crank width A 55 95 56 00 mm 2 203 2 205 in Runout limit C 0 03 mm 0 0...

Page 33: ...Cam drum and guide bar Guide bar bending limit 0 05 mm 0 002 in Kickstarter Type Kick and ratchet type Carburetor USA CDN EUROPE AUS NZ ZA Type manufacturer FCR MX37 KEIHIN I D mark 17D5 50 17D6 60 Main jet M J 180 Main air jet M A J ø2 0 Jet needle clip position J N NDJR 4 NHKR 4 Cutaway C A 1 5 Pilot jet P J 45 42 Pilot air jet P A J 105 Pilot outlet P O ø0 9 Pilot screw example P S 1 3 4 Bypass...

Page 34: ... Standard Limit Steering system Steering bearing type Taper roller bearing Front suspension USA CDN EUROPE AUS NZ ZA Front fork travel 300 mm 11 8 in Fork spring free length 454 mm 17 9 in 449 mm 17 7 in Spring rate STD K 4 4 N mm 0 449 kg mm 25 1 lb in K 4 5 N mm 0 459 kg mm 25 7 lb in Optional spring Yes Oil capacity 541 cm3 19 0 lmp oz 18 3 US oz 528 cm3 18 6 lmp oz 17 9 US oz Oil grade Suspens...

Page 35: ...3 0 mm 9 84 0 12 in 250 2 5 mm 9 84 0 10 in Pad thickness 4 4 mm 0 17 in 1 0 mm 0 04 in Master cylinder inside dia 9 52 mm 0 375 in Caliper cylinder inside dia 22 65 mm 0 892 in 2 Brake fluid type DOT 4 Rear disc brake Disc outside dia Thickness 245 4 0 mm 9 65 0 16 in 245 3 5 mm 9 65 0 14 in Deflection limit 0 15 mm 0 006 in Pad thickness 6 4 mm 0 25 in 1 0 mm 0 04 in Master cylinder inside dia 1...

Page 36: ...F Part to be tightened Thread size Q ty Tightening torque Nm m kg ft lb Spark plug M10S 1 0 1 13 1 3 9 4 Camshaft cap M6 1 0 10 10 1 0 7 2 Cylinder head blind plug screw M12 1 0 1 28 2 8 20 Cylinder head stud bolt M6 1 0 2 7 0 7 5 1 Cylinder head stud bolt M8 1 25 1 15 1 5 11 Cylinder head bolt M9 1 25 4 38 3 8 27 Cylinder head nut M6 1 0 2 10 1 0 7 2 Cylinder head cover M6 1 0 2 10 1 0 7 2 Cylind...

Page 37: ...5 8 Air filter joint and air filter case M5 0 8 1 4 0 4 2 9 Air filter element M6 1 0 1 2 0 2 1 4 Exhaust pipe M8 1 25 2 20 2 0 14 Exhaust pipe protector M6 1 0 3 10 1 0 7 2 Silencer M8 1 25 2 30 3 0 22 Silencer clamp M8 1 25 1 14 1 4 10 Crankcase M6 1 0 11 12 1 2 8 7 Crankcase bearing stopper M6 1 0 11 10 1 0 7 2 Crankcase bearing stopper crankshaft M6 1 0 4 14 1 4 10 Left crankcase cover M6 1 0 ...

Page 38: ... base valve M42 1 5 2 29 2 9 21 Adjuster and damper assembly M12 1 25 2 29 2 9 21 Front fork bleed screw and base valve M5 0 8 2 1 0 1 0 7 Front fork and front fork protector M6 1 0 6 5 0 5 3 6 Lower bracket and brake hose guide M6 1 0 1 9 0 9 6 5 Front fork protector and brake hose holder M6 1 0 2 8 0 8 5 8 Throttle grip cap M5 0 8 2 4 0 4 2 9 Front brake master cylinder M6 1 0 2 9 0 9 6 5 Brake ...

Page 39: ... M6 1 0 2 7 0 7 5 1 Cable guide and frame M6 1 0 2 7 0 7 5 1 Pivot shaft and nut M16 1 5 1 85 8 5 61 Relay arm and swingarm M14 1 5 1 70 7 0 50 Relay arm and connecting rod M14 1 5 1 80 8 0 58 Connecting rod and frame M14 1 5 1 80 8 0 58 Rear shock absorber and frame M10 1 25 1 56 5 6 40 Rear shock absorber and relay arm M10 1 25 1 53 5 3 38 Rear frame upper M8 1 25 2 32 3 2 23 Rear frame lower M8...

Page 40: ...ing boss and frame M10 1 25 2 20 2 0 14 Front fender M6 1 0 4 10 1 0 7 2 Rear fender front M6 1 0 2 7 0 7 5 1 Rear fender rear M6 1 0 2 16 1 6 11 Side cover M6 1 0 2 7 0 7 5 1 Seat M8 1 25 2 23 2 3 17 Number plate M6 1 0 1 7 0 7 5 1 Part to be tightened Thread size Q ty Tightening torque Nm m kg ft lb Part to be tightened Thread size Q ty Tightening torque Nm m kg ft lb Stator M6 1 0 3 10 1 0 7 2 ...

Page 41: ...nts should be at room temperature A Distance between flats B Outside thread diameter DEFINITION OF UNITS A Nut B Bolt TORQUE SPECIFI CATION Nm m kg ft lb 10 mm 6 mm 6 0 6 4 3 12 mm 8 mm 15 1 5 11 14 mm 10 mm 30 3 0 22 17 mm 12 mm 55 5 5 40 19 mm 14 mm 85 8 5 61 22 mm 16 mm 130 13 94 Unit Read Definition Measure mm millimeter 10 3 meter Length cm centimeter 10 2 meter Length kg kilogram 103 gram We...

Page 42: ...2 16 LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS 1 Oil filter element 2 Oil pump 3 Drive axle 4 Main axle 5 Intake camshaft 6 Exhaust camshaft 7 Oil tank 8 Oil delivery pipe A To oil tank ...

Page 43: ...2 17 LUBRICATION DIAGRAMS 1 Crankshaft 2 Oil filter element 3 Oil tank 4 Oil hose A From oil pump ...

Page 44: ...ition sensor lead 7 Hot starter cable 8 Fuel hose 9 Carburetor breather hose 10 Carburetor overflow hose 11 Throttle position sensor lead protector 12 Throttle position sensor cover A Insert the end of the fuel tank breather hose into the hole in the steering stem B Aligh the paint mark on the cylin der head breather hose with the front end of the hose guide A B A C B C ...

Page 45: ...eather hose between the radiator and radiator hose 3 E Pass the fuel hose on the out side of throttle position sensor lead F Pass the carburetor breather hoses and overflow hose so that all there hoses do not contact the rear shock absorber G Insert the throttle position sen sor lead protector into the throt tle position sensor cover ...

Page 46: ... 10 CDI unit lead coupler 11 Radiator breather hose 12 Hot starter cable protector 13 Rubber cap 14 Throttle position sensor lead 15 Cylinder head breather hose 16 Throttle position sensor lead coupler 17 Tension pipe 18 Radiator mounting boss 19 Cylinder head breather hose 20 Throttle position sensor tube clamp E K E F G H H F I J A A B D D C J C G B K E M M H H K K E E D D M M F F A A I L L ...

Page 47: ...portion N Pass each lead under the clamp Locate the CDI magneto lead on the outside of the igni tion coil lead Locate the throttle position sensor lead neutral switch lead CDI magneto lead and ignition coil lead so that they do not lie one on another O Fasten the sub wire harness to the CDI unit bracket with the clamp ends located under the bracket P Fasten the neutral switch lead throttle positio...

Page 48: ...ass the throttle cables through the cable guide C Pass the throttle cable over the radiator mounting boss Cross the throttle cable behind the ra diator D Pass the throttle cables on the outside of the ignition coil E Insert the engine stop switch lead into the CDI unit band Align the coupler lower end with the band lower end F Fit the hole in the CDI unit band over the CDI unit bracket C A B B A C...

Page 49: ... directs as shown and lightly touches the projec tion on the brake caliper B Pass the brake hose into the brake hose holders C If the brake hose contacts the spring rear shock absorber correct its twist D Install the brake hose so that its pipe portion directs as shown and lightly touches the projec tion on the brake master cylin der ...

Page 50: ...ar B Pass the clutch cable and hot starter cable through the cable guide C Pass the engine stop switch lead behind the CDI unit D Pass the brake hose in front of the number plate E Pass the throttle cables through the cable guide F Pass the clutch cable and hot starter cable through the cable guide on the number plate G Pass the engine stop switch lead over the number plate mounting location A C B...

Page 51: ... is required by reference to the list below Item After break in Every race about 2 5 hours Every third about 7 5 hours Every fifth about 12 5 hours As re quired Remarks ENGINE OIL Replace Inspect OIL FILTER ELEMENT OIL STRAINER Clean VALVES Check the valve clearances The engine must be cold Inspect Check the valve seats and valve stems for wear Replace VALVE SPRINGS Inspect Check the free length a...

Page 52: ...IFT FORK SHIFT CAM GUIDE BAR Inspect Inspect wear ROTOR NUT Retighten EXHAUST PIPE SILENCER PROTECTOR Inspect and retighten Clean Replace Replace fiber When the exhaust sound becomes louder or when a performance drop is felt CRANK Inspect and clean CARBURETOR Inspect adjust and clean SPARK PLUG Inspect and clean Replace DRIVE CHAIN Use chain lube Lubricate slack alignment Chain slack 50 60 mm 2 0 ...

Page 53: ...ean and inspect FUEL TANK COCK Clean and inspect BRAKES Adjust lever position and pedal height Lubricate pivot point Check brake disc surface Check fluid level and leakage Retighten brake disc bolts cali per bolts master cylinder bolts and union bolts Replace pads Replace brake fluid Every one year FRONT FORKS Inspect and adjust Replace oil Suspension oil S1 Replace oil seal FRONT FORK OIL SEAL AN...

Page 54: ...Clean and lube Lithium base grease Replace bearing TIRE WHEELS Inspect air pressure wheel run out tire wear and spoke loose ness Retighten sprocket bolt Inspect bearings Replace bearings Lubricate Lithium base grease THROTTLE CONTROL CABLE Check routing and connection Lubricate Yamaha cable lube or SAE 10W 40 motor oil Inspect and clean throttle ca ble Inspect dirt and wear on the throttle cable o...

Page 55: ... slack and alignment Check that the drive chain is lubricated properly P 3 17 18 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P 3 20 21 Steering Check that the handlebar can be turned smoothly and have no ex cessive play P 3 21 22 Front forks and rear shock absorber Check that they operate smoothly and there is no oil leakage P 3 18 20 Cables ...

Page 56: ... clean tap water 5 Install Copper washer Coolant drain bolt 6 Fill Radiator Engine To specified level Do not mix more than one type of ethylene glycol antifreeze con taining corrosion inhibitors for aluminum engine Do not use water containing im purities or oil Handling notes of coolant The coolant is harmful so it should be handled with special care When coolant splashes to your eye Thoroughly wa...

Page 57: ...JUSTING THE CLUTCH CABLE FREE PLAY ADJUSTING THE CLUTCH CABLE FREE PLAY 1 Check Clutch lever free play a Out of specification Adjust 2 Adjust Clutch lever free play Clutch lever free play adjustment steps a Loosen the locknuts 1 b Turn the adjuster 2 until free play a is within the specified lim its c Tighten the locknuts Before adjustment expose the ad juster by moving the boot 3 and cap 4 away M...

Page 58: ...e play a is within the specified lim its c Tighten the locknut After adjustment check proper oper ation of hot starter CLEANING THE AIR FILTER ELEMENT Proper air filter maintenance is the biggest key to preventing premature engine wear and damage Never run the engine without the air filter element in place this would allow dirt and dust to enter the engine and cause rapid wear and possible engine ...

Page 59: ...nkcase 4 Install Oil tank cap 5 Start the engine and let it warm up for several minutes 6 Turn off the engine and inspect the oil level once again Wait a few minutes until the oil settles before inspecting the oil level CHANGING THE ENGINE OIL 1 Start the engine and warm it up for several minutes and then turn off the engine and wait for five minute 2 Place the machine on a level place and hold it...

Page 60: ...screw 1 Adjustment steps To optimize the fuel flow at a smaller throttle opening each machine s pilot screw has been individually set at the factory Before adjusting the pilot screw turn it in fully and count the number of turns Record this number as the factory set number of turns out a Turn in the pilot screw until it is lightly seated b Turn out the pilot screw by the factory set number of turn...

Page 61: ...ssing screw 1 Crankshaft end accessing screw 2 O ring 4 Check Valve clearance Out of specification Adjust Checking steps a Turn the crankshaft counterclock wise with a wrench b Align the T D C mark a on the rotor with the align mark b on the crankcase cover when piston is at T D C on compression stroke In order to be sure that the piston is at Top Dead Center the punch mark c on the exhaust camsha...

Page 62: ... intersect shows the new pad number to use Use the new pad number only as a guide when verifying the valve clear ance adjustment f Install the new pads 3 and the valve lifters 4 Apply the engine oil on the valve lift ers Apply the molybdenum disulfide oil on the valve stem ends Valve lifter must turn smoothly when rotated with a finger Be careful to reinstall valve lifters and pads in their origin...

Page 63: ...EASURED CLEARANCE INSTALLED PAD NUMBER STANDARD CLEARANCE Pad number example Pad No 175 1 75 mm Pad No 185 1 85 mm MEASURED CLEARANCE INSTALLED PAD NUMBER 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0 00 0 04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0 05 0 09 120 125 130 135 140 145 150 155 160 1...

Page 64: ...leeding procedure when the tiny bubbles in the system have disap peared j Add brake fluid to the level line on the reservoir Check the operation of the brake after bleeding the brake system 3 Install Protector rear brake Reservoir float front brake Diaphragm Brake master cylinder cap ADJUSTING THE FRONT BRAKE 1 Check Brake lever position a 2 Remove Brake lever cover 3 Adjust Brake lever position B...

Page 65: ... the brake pads with their pro jections a into the brake caliper re cesses b Temporarily tighten the pad pin at this point i Install the brake caliper 8 and tighten the pad pin 9 j Install the pad pin plug 10 3 Inspect Brake fluid level Refer to CHECKING THE BRAKE FLUID LEVEL section 4 Check Brake lever operation A softy or spongy feeling Bleed brake system Refer to BLEEDING THE HY DRAULIC BRAKE S...

Page 66: ...id level Refer to CHECKING THE BRAKE FLUID LEVEL section 4 Check Brake pedal operation A softy or spongy feeling Bleed brake system Refer to BLEEDING THE HY DRAULIC BRAKE SYSTEM sec tion CHECKING THE REAR BRAKE PAD INSULATOR 1 Remove Brake pad Refer to CHECKING AND RE PLACING THE REAR BRAKE PADS section 2 Inspect Rear brake pad insulator 1 Damage Replace CHECKING THE BRAKE FLUID LEVEL 1 Place the ...

Page 67: ... by placing the suitable stand under the en gine 2 Check Drive chain slack a Above the seal guard installation bolt Out of specification Adjust Before checking and or adjusting ro tate the rear wheel through several revolutions and check the slack sev eral times to find the tightest point Check and or adjust the drive chain slack with the rear wheel in this tight chain position 3 Adjust Drive chai...

Page 68: ...he front fork initial movement feels stiff during a run relieve the front fork internal pressure 1 Elevate the front wheel by placing a suitable stand under the engine 2 Remove the air bleed screw 1 and release the internal pressure from the front fork 3 Install Air bleed screw ADJUSTING THE FRONT FORK REBOUND DAMPING FORCE 1 Adjust Rebound damping force By turning the adjuster 1 STANDARD POSITION...

Page 69: ... the locknut and adjust er before adjustment The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster Never attempt to turn the adjuster beyond the maximum or minimum setting e Tighten the locknut 5 Install Rear frame upper Rear frame lower ADJUSTING THE REAR SHOCK ABSORBER REBOUND DAMPING FORCE 1 Adjust Rebound damping force By turning the adjuster 1 Stiffer a Increase t...

Page 70: ...aximum extent of adjustment The adjuster may be damaged CHECKING THE TIRE PRESSURE 1 Measure Tire pressure Out of specification Adjust Check the tire while it is cold Loose bead stoppers allow the tire to slip off its position on the rim when the tire pressure is low A tilted tire valve stem indicates that the tire slips off its position on the rim If the tire valve stem is found tilted the tire i...

Page 71: ...ck Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steer ing ring nut 4 Adjust Steering ring nut Steering ring nut adjustment steps a Remove the number plate b Remove the handlebar and upper bracket c Loosen the steering ring nut 1 using the steering nut wrench 2 d Tighten the steering ring nut 3 using steering nut wrench 4 Apply the lithium soap base grease on the th...

Page 72: ...e marks b are in place on both sides Install the handlebar so that the pro jection c of the handlebar upper holder is positioned at the mark on the handlebar as shown Insert the end of the fuel breather hose 11 into the hole in the steer ing stem First tighten the bolts on the front side of the handlebar upper holder and then tighten the bolts on the rear side Steering stem nut 145 Nm 14 5 m kg 10...

Page 73: ...vot 5 Throttle to handlebar contact 6 Drive chain 7 Tube guide cable winding por tion 8 Throttle cable end 9 Clutch cable end 10 Hot starter cable end A Use Yamaha cable lube or equivalent on these areas B Use SAE 10W 40 motor oil or suitable chain lubricants C Lubricate the following areas with high quality lightweight lith ium soap base grease Wipe off any excess grease and avoid getting grease ...

Page 74: ...er if necessary 5 Tighten Spark plug Before installing a spark plug clean the gasket surface and plug sur face Finger tighten a the spark plug before torquing to specification b CHECKING THE IGNITION TIMING 1 Remove Timing mark accessing screw 1 2 Attach Timing light Digital tachometer To the ignition coil lead orange lead 1 3 Adjust Engine idling speed Refer to ADJUSTING THE EN GINE IDLING SPEED ...

Page 75: ...on adjustment disassembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage SEAT FUEL TANK AND SIDE COVERS REMOVING THE SEAT FUEL TANK AND SIDE COVERS Order Part name Q ty Remarks Turn the fuel cock to OFF Disconnect the fuel hose 1 Seat 1 2 Air scoop left and right 2 3 Bolt fuel tank 1 4 Fitting band 1 5 Fuel tank 1 6 Left side cover 1 Refer to ...

Page 76: ...ilter case REMOVING THE NUMBER PLATE 1 Remove Bolt number plate Number plate 1 The projection a is inserted into the band of the number plate Pull the band off the projection before removal Remove the hot starter cable 2 and clutch cable 3 from the cable guide b on the number plate The projection c on the lower bracket is inserted into the number plate Remove the number plate by pulling it off the...

Page 77: ...der Part name Q ty Remarks A Except for USA and CDN Right side cover Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Bolt silencer clamp 1 Only loosening 2 Bolt silencer front 1 3 Bolt silencer rear 1 4 Silencer 1 5 Silencer clamp 1 6 Nut exhaust pipe 2 7 Exhaust pipe 1 8 Gasket 2 9 Wave washer 3 ...

Page 78: ...er and also along the si lencer edge b as shown Take care not to allow the fiber out of place when installing the inner pipe INSTALLING THE SILENCER AND EXHAUST PIPE 1 Install Gasket Exhaust pipe 1 Nut exhaust pipe 2 First temporarily tighten both nuts to 13 Nm 1 3 m kg 9 4 ft lb Then re tighten the same nut to 20 Nm 2 0 m kg 14 ft lb 2 Install Silencer clamp 1 Gasket 2 Silencer 3 Washer 4 Bolt si...

Page 79: ...TANK AND SIDE COVERS section 1 Radiator guard 2 2 Radiator hose clamp 10 Only loosening 3 Clutch cable holder 1 4 Radiator hose 1 1 5 Left radiator 1 6 Radiator hose 4 1 7 Pipe 1 8 Radiator hose 5 1 9 Right radiator 1 10 Radiator hose 2 1 11 Radiator hose 3 1 12 Radiator breather hose 1 13 Radiator pipe 1 1 2 4 2 3 13 2 2 2 2 2 11 7 8 2 2 6 9 2 10 12 1 5 1 T R 20 Nm 2 0 m kg 14 ft Ib ...

Page 80: ...lace INSTALLING THE RADIATOR 1 Install O ring 1 Radiator pipe 1 2 Bolt radiator pipe 3 Apply the lithium soap base grease on the O ring 2 Install Radiator breather hose 1 Radiator hose 2 2 Radiator hose 4 3 Pipe 4 Radiator hose 5 5 Radiator hose 3 6 To right radiator 7 3 Install Right radiator 1 Bolt right radiator 2 Radiator hose 5 3 Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 4 Inst...

Page 81: ...hrottle cable cover 1 4 Throttle cable 2 5 Clamp air filter joint 1 Loosen the screw air filter joint 6 Clamp carburetor joint 1 Loosen the screws carburetor joint 7 Hot starter plunger 1 8 Carburetor assembly 1 9 Carburetor joint 1 4 Nm 0 4 m kg 2 9 ft lb 4 Nm 0 4 m kg 2 9 ft lb 2 Nm 0 2 m kg 1 4 ft lb 3 Nm 0 3 m kg 2 2 ft lb 3 Nm 0 3 m kg 2 2 ft lb 11 Nm 1 1 m kg 8 0 ft lb 10 Nm 1 0 m kg 7 2 ft ...

Page 82: ...using cover 1 3 Screw throttle shaft 1 4 Throttle valve 1 5 Needle holder 1 6 Jet needle 1 7 Accelerator pump cover 1 8 Spring 1 9 Diaphragm accelerator pump 1 10 Float chamber 1 11 Leak jet 1 12 Pilot screw 1 Refer to removal section 13 Float pin 1 14 Float 1 15 Needle valve 1 16 Main jet 1 17 Needle jet 1 18 Spacer 1 ...

Page 83: ...BURETOR 19 Pilot jet 1 20 Starter jet 1 21 Push rod 1 Pull the push rod 22 Throttle shaft assembly 1 23 Push rod link lever assembly 1 24 Pilot air jet 1 25 Cold starter plunger 1 Order Part name Q ty Remarks ...

Page 84: ...er use a wire CHECKING THE NEEDLE VALVE 1 Inspect Needle valve 1 Valve seat 2 Grooved wear a Replace Dust b Clean Filter c Clogged Clean CHECKING THE THROTTLE VALVE 1 Check Free movement Stick Repair or replace Insert the throttle valve 1 into the carburetor body and check for free movement CHECKING THE JET NEEDLE 1 Inspect Jet needle 1 Bends wear Replace Clip groove Free play exists wear Replace ...

Page 85: ...ring 4 Push rod 5 Tears diaphragm damage Re place Dirt Clean 2 Inspect Throttle shaft 1 Spring 2 Lever 1 3 Spring 1 4 Lever 2 5 Spring 2 6 Dirt Clean ASSEMBLING THE CARBURETOR 1 Install Cold starter plunger 1 2 Install Pilot air jet 1 3 Install Spring 1 1 Lever 1 2 To lever 2 3 Make sure the spring 1 fits on the stopper a of the lever 2 4 Install Spring 2 1 To lever 2 2 5 Install Push rod link lev...

Page 86: ...carbure tor Check the float for smooth move ment 12 Install Pilot screw 1 Spring 2 Washer 3 O ring 4 Note the following installation points a Turn in the pilot screw until it is lightly seated b Turn out the pilot screw by the number of turns recorded before removing 13 Install O ring Leak jet 1 Float chamber 2 Bolt float chamber 3 Cable holder throttle stop screw cable 4 Hose holder carburetor br...

Page 87: ...LING THE CARBURETOR 1 Install Carburetor joint 1 2 Install Carburetor 1 Install the projection a between the carburetor joint slots 3 Install Hot starter plunger 1 4 Tighten Bolt carburetor joint 1 Bolt air filter joint 2 5 Install Throttle cable pull 1 Throttle cable return 2 6 Adjust Throttle grip free play Refer to ADJUSTING THE THROTTLE CABLE FREE PLAY section in the CHAPTER 3 7 Install Thrott...

Page 88: ... Order Part name Q ty Remarks Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section 1 Spark plug 1 2 Cylinder head breather hose 1 3 Bolt cylinder head cover 2 4 Cylinder head cover 1 5 Cylinder head cover gasket 1 6 Timing chain guide top side 1 ...

Page 89: ...shaft end accessing screw 1 Refer to removal section 3 Timing chain tensioner cap bolt 1 Refer to removal section 4 Timing chain tensioner 1 Refer to removal section 5 Camshaft cap 2 Refer to removal section 6 Clip 2 Refer to removal section 7 Exhaust camshaft 1 Refer to removal section 8 Intake camshaft 1 Refer to removal section ...

Page 90: ...cap 2 Clip Remove the bolts camshaft cap in a crisscross pattern working from the outside in The bolts camshaft cap must be removed evenly to prevent dam age to the cylinder head cam shafts or camshaft caps 5 Remove Exhaust camshaft 1 Intake camshaft 2 Attach a wire 3 to the timing chain to prevent it from falling into the crank case CHECKING THE CAMSHAFT 1 Inspect Cam lobe Pitting scratches blue ...

Page 91: ...on mechanism cam 1 moves smoothly b Check that the decompression mechanism cam lever pin 2 proj ects from the camshaft CHECKING THE TIMING CHAIN TENSIONER 1 Check While pressing the tensioner rod lightly with fingers use a thin screwdriver 1 and wind the ten sioner rod up fully clockwise When releasing the screwdriver by pressing lightly with fingers make sure that the tensioner rod will come out ...

Page 92: ...le pressing the tensioner rod lightly with fingers use a thin screwdriver and wind the tension er rod up fully clockwise b With the rod fully wound and the chain tensioner UP mark a fac ing upward install the gasket 1 and the timing chain tensioner 2 and tighten the bolt 3 to the specified torque c Release the screwdriver check the tensioner rod to come out and tighten the gasket 4 and the cap bol...

Page 93: ...ncer Refer to EXHAUST PIPE AND SILENCER section Radiator hose 1 Disconnect at cylinder head side Carburetor Refer to CARBURETOR section Camshaft Refer to CAMSHAFTS section Upper engine bracket Refer to ENGINE REMOVAL section 1 Radiator pipe 1 2 Oil delivery pipe 1 3 Nut 2 4 Bolt L 135 mm 5 31 in 2 5 Bolt L 145 mm 5 71 in 2 6 Cylinder head 1 7 Timing chain guard exhaust side 1 ...

Page 94: ...YLINDER HEAD 1 Install Dowel pin 1 Cylinder head gasket 2 Timing chain guide exhaust side 3 Cylinder head 4 While pulling up the timing chain in stall the timing chain guide exhaust side and cylinder head 2 Install Washer 1 Cable guide 2 Bolts L 145 mm 5 71 in 3 Bolts L 135 mm 5 31 in 4 Nuts 5 Apply the molybdenum disulfide grease on the thread and contact surface of the bolts Follow the numerical...

Page 95: ...me Q ty Remarks Cylinder head Refer to CYLINDER HEAD section 1 Valve lifter 5 Refer to removal section 2 Adjusting pad 5 Refer to removal section 3 Valve cotter 10 Refer to removal section 4 Valve spring retainer 5 5 Valve spring 5 6 Valve stem seal 5 7 Valve spring seat 5 8 Exhaust valve 2 9 Intake valve 3 ...

Page 96: ...r to 100 C 212 F a Remove the valve guide using a valve guide remover 1 b Install the new valve guide using a valve guide remover 1 and valve guide installer 2 c After installing the valve guide bore the valve guide using a valve guide reamer 3 to obtain proper stem to guide clearance After replacing the valve guide reface the valve seat 3 Inspect Valve face Pitting wear Grind the face Valve stem ...

Page 97: ...ut lapping the valve seats and valve faces When replacing the valves or valve guides use new valves to lap the valve seats and then replace them with new valves Lapping steps a Apply a coarse lapping compound to the valve face Do not let the compound enter the gap between the valve stem and the guide b Apply molybdenum disulfide oil to the valve stem c Install the valve into the cylinder head d Tu...

Page 98: ...d facing upward e Smaller pitch 3 Install Valve cotter While compressing the valve spring with a valve spring compressor 1 in stall the valve cotters 4 To secure the valve cotters onto the valve stem lightly tap the valve tip with a piece of wood Hitting the valve tip with excessive force could damage the valve 5 Install Adjusting pad 1 Valve lifter 2 Apply the molybdenum disulfide oil on the valv...

Page 99: ...STON Order Part name Q ty Remarks Cylinder head Refer to CYLINDER HEAD section 1 Bolt cylinder 1 2 Cylinder 1 3 Piston pin clip 2 Refer to removal section 4 Piston pin 1 Refer to removal section 5 Piston 1 Refer to removal section 6 Piston ring set 1 Refer to removal section ...

Page 100: ...replace the piston and piston rings as set c Measure the piston skirt diameter P with a micrometer a 8 mm 0 31 in from the piston bottom edge d If out of specification replace the piston and piston rings as a set e Calculate the piston to cylinder clearance with following formula f If out of specification replace the cylinder and replace the piston and piston rings as set CHECKING THE PISTON RING ...

Page 101: ... install the piston rings so that the manufacturer s marks or numbers are located on the upper side of the rings Lubricate the piston and piston rings liberally with engine oil 2 Position Top ring 2nd ring Oil ring Offset the piston ring end gaps as shown a Top ring end b 2nd ring end c Oil ring end upper d Oil ring e Oil ring end lower 3 Install Piston 1 Piston pin 2 Piston pin clip 3 Apply engin...

Page 102: ... the lithium soap base grease on the O ring 3 Install Cylinder gasket 1 Cylinder 2 Install the cylinder with one hand while compressing the piston rings with the other hand Pass the timing chain 3 through the timing chain cavity Be careful not to damage the tim ing chain guide 4 during instal lation 4 Install Bolt cylinder 5 Bolt cylinder 10 Nm 1 0 m kg 7 2 ft lb ...

Page 103: ...TER 3 Brake pedal Refer to ENGINE REMOVAL section Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Clutch spring 5 3 Pressure plate 1 4 Push rod 1 1 5 Circlip 1 6 Washer 1 7 Bearing 1 8 Ball 1 9 Push rod 2 1 10 Friction plate 9 11 Clutch plate 8 12 Nut clutch boss 1 Refer to removal section 13 Lock washer 1 Refer to removal section ...

Page 104: ...4 30 CLUTCH 14 Clutch boss 1 Refer to removal section 15 Thrust washer 1 16 Primary driven gear 1 17 Spacer 1 18 Washer 1 19 Push lever shaft 1 Order Part name Q ty Remarks ...

Page 105: ...asure at all four points CHECKING THE CLUTCH PLATES 1 Measure Clutch plate warpage Out of specification Replace clutch plate as a set Use a surface plate 1 and thick ness gauge 2 CHECKING THE PUSH LEVER SHAFT 1 Inspect Push lever shaft 1 Wear damage Replace CHECKING THE PUSH ROD 1 Inspect Push rod 1 1 Bearing 2 Washer 3 Push rod 2 4 Ball 5 Wear damage bend Replace INSTALLING THE PUSH LEVER SHAFT 1...

Page 106: ...ith a friction plate Apply the engine oil on the friction plates and clutch plates 5 Install Bearing 1 Washer 2 Circlip 3 To push rod 1 4 Apply the engine oil on the bearing and washer 6 Install Push rod 2 1 Ball 2 Push rod 1 3 Apply the engine oil on the push rod 1 2 and ball 7 Install Pressure plate 1 8 Install Clutch spring 1 Bolt clutch spring 2 Tighten the bolts in stage using a crisscross pa...

Page 107: ... the coolant Refer to CHANGING THE COOLANT sec tion in the CHAPTER 3 Radiator hose 3 Disconnect at water pump side Exhaust pipe Refer to EXHAUST PIPE AND SILENCER section Brake pedal Refer to ENGINE REMOVAL section Right engine guard 1 Oil filter element cover 1 2 Oil filter element 1 3 Water pump housing 1 4 Oil delivery pipe 1 5 Bolt oil hose 1 6 Kickstarter crank 1 7 Right crankcase cover 1 8 I...

Page 108: ...TER ELEMENT AND WATER PUMP 9 Washer 1 Refer to removal section 10 Impeller shaft 1 Refer to removal section 11 Oil seal 2 Refer to removal section 12 Bearing 1 Refer to removal section Order Part name Q ty Remarks ...

Page 109: ...IPE 1 Inspect Oil delivery pipe 1 Bend damage Replace Clogged Blow CHECKING THE IMPELLER SHAFT 1 Inspect Impeller shaft 1 Bend wear damage Replace Fur deposits Clean CHECKING THE IMPELLER SHAFT GEAR 1 Inspect Gear teeth a Wear damage Replace CHECKING THE BEARING 1 Inspect Bearing Rotate inner race with a finger Rough spot seizure Replace CHECKING THE OIL SEAL 1 Inspect Oil seal 1 Wear damage Repla...

Page 110: ...eller shaft gear 3 with primary drive gear 4 Tighten the bolts in stage using a crisscross pattern INSTALLING THE KICKSTARTER CRANK 1 Install Kickstarter crank 1 Washer Bolt kickstarter crank Install so that the clearance a be tween the kickstarter crank and en gine bracket mounting bolt is 8 mm 0 31 in or more and that the kick starter crank does not contact the right crankcase cover when it is p...

Page 111: ...O ring 2 Install Water pump housing 1 Bolt water pump housing 2 INSTALLING THE OIL FILTER ELEMENT 1 Install Oil filter element 1 O ring 2 Oil filter element cover 3 Bolt oil filter element cover Apply the lithium soap base grease on the O ring Bolt water pump hous ing 10 Nm 1 0 m kg 7 2 ft lb Bolt oil filter element cover 10 Nm 1 0 m kg 7 2 ft lb ...

Page 112: ...OIL FILTER ELEMENT AND WA TER PUMP section Stator Refer to CDI MAGNETO section 1 Nut primary drive gear 1 Refer to removal section 2 Nut balancer shaft driven gear 1 Refer to removal section 3 Lock washer 1 4 Primary drive gear 1 5 Balancer shaft drive gear 1 6 Lock washer 1 7 Balancer shaft driven gear 1 8 Balancer shaft 1 Refer to removal section ...

Page 113: ...n the center a of the balancer shaft weight along the line connect ing the centers of the crankshaft and balancer shaft 2 Install Balancer shaft driven gear 1 Install the balancer shaft driven gear onto the balancer shaft while aligning the punch mark a on the balancer shaft driven gear with the lower spline b on the balancer shaft end 3 Install Balancer shaft drive gear 1 Align the punched mark a...

Page 114: ...rankcase cover Refer to OIL FILTER ELEMENT AND WA TER PUMP section 1 Circlip 1 2 Washer 1 3 Oil pump drive gear 1 4 Oil pump assembly 1 5 Outer rotor 2 1 6 Circlip 1 7 Inner rotor 2 1 8 Dowel pin 1 9 Oil pump cover 1 10 Outer rotor 1 1 11 Inner rotor 1 1 12 Dowel pin 1 13 Washer 1 14 Oil pump drive shaft 1 15 Rotor housing 1 ...

Page 115: ...G THE OIL TANK Order Part name Q ty Remarks Drain the engine oil Refer to CHANGING THE ENGINE OIL section in the CHAPTER 3 1 Oil hose 2 1 2 Oil hose 1 1 3 Dowel pin 2 4 Oil tank breather hose 1 5 Oil tank 1 6 Oil strainer 1 ...

Page 116: ...otor 1 1 Apply the engine oil on the outer rotor 1 3 Install Oil pump cover 1 Screw oil pump cover 2 Dowel pin 3 Inner rotor 2 4 Circlip 5 Apply the engine oil on the inner ro tor 2 Fit the dowel pin into the groove in the inner rotor 2 4 Install Outer rotor 2 1 Dowel pin 2 Oil pump assembly 3 Bolt oil pump assembly L 25 mm 0 94 in 4 Bolt oil pump assembly L 30 mm 1 18 in 5 Apply the engine oil on...

Page 117: ... breather hose 2 Clamp 3 Install the clamp so that it does not contact the oil tank Insert the oil tank breather hose so that its end a comes where the oil tank pipe begins to bend Install the clamp 3 mm 0 12 in away from the oil tank breather hose end a Clamp 2 Nm 0 2 m kg 1 4 ft lb ...

Page 118: ...section 1 Kick idle gear 1 2 Kick shaft assembly 1 Refer to removal section 3 Spring guide 1 4 Torsion spring 1 5 Ratchet wheel 1 6 Kick gear 1 7 Kick shaft 1 8 Washer 1 9 Shift pedal 1 10 Shift shaft 1 11 Collar 1 12 Torsion spring 1 13 Roller 1 14 Shift guide 1 Refer to removal section 15 Shift lever assembly 1 Refer to removal section 16 Shift lever 1 ...

Page 119: ...4 45 KICK SHAFT AND SHIFT SHAFT 17 Pawl 2 18 Pawl pin 2 19 Spring 2 20 Bolt stopper lever 1 21 Stopper lever 1 22 Torsion spring 1 23 Segment 1 Refer to removal section Order Part name Q ty Remarks ...

Page 120: ... move ment Unsmooth movement Replace Kick shaft 2 Wear damage Replace Spring 3 Broken Replace CHECKING THE KICK GEAR KICK IDLE GEAR AND RATCHET WHEEL 1 Inspect Kick gear 1 Kick idle gear 2 Ratchet wheel 3 Gear teeth a Ratchet teeth b Wear damage Replace CHECKING THE SHIFT SHAFT 1 Inspect Shift shaft 1 Bend damage Replace Spring 2 Broken Replace CHECKING THE SHIFT GUIDE AND SHIFT LEVER ASSEMBLY 1 I...

Page 121: ...he roller and shift shaft 2 Install Shift pedal 1 Bolt shift pedal 2 Install with the punch mark a on the shift pedal in alignment with the punch mark b on the shift shaft INSTALLING THE KICK SHAFT ASSEMBLY 1 Install Kick gear 1 Washer 2 Circlip 3 Ratchet wheel 4 Spring 5 Washer 6 Circlip 7 To kick shaft 8 Apply the molybdenum disulfide oil on the inner circumferences of the kick gear and ratchet ...

Page 122: ...Slide the kick shaft assembly into the crankcase and make sure the kick shaft stopper a fits into the kick shaft ratchet wheel guide 5 Hook Torsion spring 1 Turn the torsion spring clockwise and hook into the proper hole a in the crankcase INSTALLING THE KICK IDLE GEAR 1 Install Kick idle gear 1 Washer 2 Circlip 3 Apply the engine oil on the kick idle gear inner circumference Install the kick idle...

Page 123: ...s Seat and fuel tank Refer to SEAT FUEL TANK AND SIDE COVERS section Disconnect the CDI magneto lead Shift pedal Refer to KICK SHAFT AND SHIFT SHAFT section 1 Left crankcase cover 1 2 Nut rotor 1 Refer to removal section 3 Rotor 1 Refer to removal section 4 Stator 1 5 Woodruff key 1 ...

Page 124: ...d portions of the crankshaft and rotor When installing the woodruff key make sure that its flat surface a is in parallel with the crankshaft center line b When installing the rotor align the keyway c of the rotor with the woodruff key 3 Install Washer 1 Nut rotor 2 Use the rotor holding tool 3 4 Connect CDI magneto lead Refer to CABLE ROUTING DIA GRAM section in the CHAPTER 2 5 Install Dowel pin G...

Page 125: ...tion Exhaust pipe and silencer Refer to EXHAUST PIPE AND SILENCER section Clutch cable Disconnect at the engine side Radiator Refer to RADIATOR section Shift pedal Refer to KICK SHAFT AND SHIFT SHAFT section Cylinder head breather hose Refer to CAMSHAFTS section Drain the engine oil Refer to CHANGING THE ENGINE OIL section in the CHAPTER 3 Oil hose and oil tank breather hose Refer to OIL PUMP sect...

Page 126: ...n 5 Lock washer 1 Refer to removal section 6 Drive sprocket 1 Refer to removal section 7 Clip 1 8 Bolt brake pedal 1 9 Brake pedal 1 10 Upper engine bracket 2 11 Front engine bracket 2 12 Engine mounting bolt 3 13 Pivot shaft 1 Refer to removal section 14 Engine 1 Refer to removal section Order Part name Q ty Remarks ...

Page 127: ...e Pivot shaft 2 Engine mounting bolt lower 3 Front engine bracket 4 Bolt front engine bracket 5 Patch 6 Engine mounting bolt front 7 Upper engine bracket 8 Bolt upper engine bracket 9 Engine mounting bolt upper 10 Lower engine guard 11 Bolt lower engine guard 12 Apply the molybdenum disulfide grease on the pivot shaft Install the patch with the claw a facing outside the chassis INSTALLING THE BRAK...

Page 128: ...ve chain sprocket guide 1 Drive chain sprocket cover 2 Bolt drive chain sprocket cover 3 INSTALLING THE NEUTRAL SWITCH 1 Install Spring 1 Pin 2 O ring 3 Neutral switch 4 Screw neutral switch 5 Apply the lithium soap base grease on the O ring 2 Install Hose guide cylinder head breath er hose 1 Bolt hose guide 2 Nut drive sprocket 75 Nm 7 5 m kg 54 ft lb Bolt drive chain sprock et cover 7 Nm 0 7 m k...

Page 129: ... KICK SHAFT AND SHIFT SHAFT section Stator Refer to CDI MAGNETO section Balancer shaft Refer to BALANCER section 1 Timing chain guide intake side 1 2 Timing chain 1 3 Oil delivery pipe 2 1 4 Bolt L 45 mm 1 77 in 6 Refer to removal section 5 Bolt L 55 mm 2 17 in 1 Refer to removal section 6 Bolt L 70 mm 2 76 in 4 Refer to removal section 7 Hose guide 1 Refer to removal section 8 Clutch cable holder...

Page 130: ...4 56 CRANKCASE AND CRANKSHAFT 10 Left crankcase 1 Refer to removal section 11 Oil strainer 1 12 Crankshaft 1 Refer to removal section Order Part name Q ty Remarks ...

Page 131: ...CRANKCASE BEARING Order Part name Q ty Remarks Transmission Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section Shift cam and shift fork Refer to TRANSMISSION SHIFT CAM AND SHIFT FORK section 1 Oil seal 2 2 Bearing 10 Refer to removal section ...

Page 132: ... Do not use a hammer to drive out the crankshaft REMOVING THE CRANKCASE BEARING 1 Remove Bearing 1 Remove the bearing from the crankcase by pressing its inner race Do not use the removed bearing CHECKING THE TIMING CHAIN AND TIMING CHAIN GUIDE 1 Inspect Timing chain Cracks stiff Replace the timing chain and camshaft sprocket as a set 2 Inspect Timing chain guide Wear damage Replace CHECKING THE CR...

Page 133: ... center with one hand while turning the nut of the installing tool with the other Operate the installing tool un til the crankshaft bottoms against the bearing Before installing the crankshaft clean the contacting surface of crankcase Do not use a hammer to drive in the crankshaft A For USA and CDN B Except for USA and CDN 2 Check Shifter operation Transmission operation Unsmooth operation Repair ...

Page 134: ...crankcase tightening bolts in stage using a crisscross pat tern 7 Install Oil delivery pipe 2 1 O ring 2 Bolt oil delivery pipe 2 3 Apply the lithium soap base grease on the Orings 8 Install Timing chain 1 Timing chain guide intake side 2 Bolt timing chain guide 3 9 Remove Sealant Forced out on the cylinder mating surface 10 Apply Engine oil To the crank pin bearing and oil delivery hole 11 Check ...

Page 135: ...s Engine Refer to ENGINE REMOVAL section Separate the crankcase Refer to CRANKCASE AND CRANK SHAFT section 1 Main axle 1 Refer to removal section 2 Drive axle 1 Refer to removal section 3 Shift cam 1 Refer to removal section 4 Shift fork 3 1 Refer to removal section 5 Shift fork 2 1 Refer to removal section 6 Shift fork 1 1 Refer to removal section 7 Collar 1 ...

Page 136: ...Replace CHECKING THE SHIFT FORK SHIFT CAM AND SEGMENT 1 Inspect Shift fork 1 Wear damage scratches Re place 2 Inspect Shift cam 1 Segment 2 Wear damage Replace 3 Check Shift fork movement Unsmooth operation Replace shift fork For a malfunctioning shift fork re place not only the shift fork itself but the two gears each adjacent to the shift fork INSTALLING THE TRANSMISSION 1 Install 5th pinion gea...

Page 137: ...case pay careful attention to the crankcase oil seal lip 5 Install Shift fork 1 L 1 Shift fork 2 C 2 Shift fork 3 R 3 Shift cam 4 To main axle and drive axle Apply the engine oil on the shift fork grooves Mesh the shift fork 1 L with the 4th wheel gear 5 and 3 R with the 5th wheel gear 7 on the drive axle Mesh the shift fork 2 C with the 3rd pinion gear 6 on the main ax le 6 Install Transmission a...

Page 138: ...dertake inspection adjustment disassembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage FRONT WHEEL AND REAR WHEEL REMOVING THE FRONT WHEEL Order Part name Q ty Remarks Hold the machine by placing the suitable stand under the engine Refer to HANDLING NOTE 1 Bolt axle holder 4 Only loosening 2 Nut front wheel axle 1 3 Front wheel axle 1 4 Fron...

Page 139: ...chine by placing the suitable stand under the engine Refer to HANDLING NOTE 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Drive chain puller 2 4 Rear wheel 1 Refer to removal section 5 Collar 2 6 Rear wheel sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 3 Refer to removal section 10 Brake disc 1 5 ...

Page 140: ...rake disc deflection only rear brake disc Use the dial gauge 1 Out of specification Inspect wheel runout If wheel runout is in good condi tion replace the brake disc 2 Measure Brake disc thickness a Out of limit Replace INSTALLING THE FRONT WHEEL 1 Install Bearing left 1 Spacer 2 Bearing right 3 Oil seal 4 Apply the lithium soap base grease on the bearing and oil seal lip when installing Use a soc...

Page 141: ...eal 5 Apply the lithium soap base grease on the bearing and oil seal lip when installing Install the bearing with seal facing outward Use a socket that matches the out side diameter of the race of the bearing Right side of bearing shall be in stalled first Install the oil seal with its manufac ture s marks or numbers facing out ward Do not strike the inner race of the bearing Contact should be mad...

Page 142: ...el axle 2 Install the left drive chain puller and insert the wheel axle from left side Apply the lithium soap base grease on the wheel axle 8 Install Right drive chain puller 1 Washer 2 Nut wheel axle 3 Temporarily tighten the nut wheel axle at this point 9 Adjust Drive chain slack a Refer to ADJUSTING THE DRIVE CHAIN SLACK section in the CHAPTER 3 10 Tighten Nut wheel axle 1 Locknut 2 Drive chain...

Page 143: ...tand under the engine Refer to HANDLING NOTE Drain the brake fluid Refer to removal section 1 Brake hose holder protector 2 2 Union bolt 2 3 Brake hose 1 4 Pad pin plug 1 Remove when loosening the pad pin 5 Pad pin 1 Loosen when disassembling the brake cali per 6 Brake caliper 1 7 Brake lever 1 8 Brake master cylinder bracket 1 9 Brake master cylinder 1 ...

Page 144: ...ne Refer to HANDLING NOTE Rear wheel Refer to FRONT WHEEL AND REAR WHEEL section Drain the brake fluid Refer to removal section 1 Brake pedal 1 2 Brake master cylinder 1 3 Brake hose holder 2 4 Union bolt 2 5 Brake hose 1 6 Pad pin plug 1 Remove when loosening the pad pin 7 Pad pin 1 Loosen when disassembling the brake cali per 8 Brake caliper 1 ...

Page 145: ...rder Part name Q ty Remarks A Front B Rear A B 1 Pad pin 1 1 2 Brake pad 2 2 3 Pad support 1 1 4 Brake caliper piston 2 1 Refer to removal section 5 Brake caliper piston dust seal 2 1 Refer to removal section 6 Brake caliper piston seal 2 1 Refer to removal section ...

Page 146: ...LINDER Order Part name Q ty Remarks A Front B Rear 1 Brake master cylinder cap 1 2 Diaphragm 1 3 Reservoir float 1 4 Push rod Front 1 5 Brake master cylinder boot 1 6 Circlip 1 Use a long nose circlip pliers 7 Washer 1 8 Push rod Rear 1 9 Brake master cylinder kit 1 ...

Page 147: ...tion when expelling piston from cylinder Never attempt to pry out piston Caliper piston removal steps a Insert a piece of rag into the brake caliper to lock one brake caliper b Carefully force the piston out of the brake caliper cylinder with compressed air A Front B Rear REMOVING THE BRAKE CALIPER PISTON SEAL KIT 1 Remove Brake caliper piston dust seal 1 Brake caliper piston seal 2 Remove the bra...

Page 148: ...e caliper piston dust seals whenever a caliper is disassembled INSTALLING THE BRAKE CALIPER PISTON 1 Clean Brake caliper Brake caliper piston seal Brake caliper piston dust seal Brake caliper piston Clean them with brake fluid 2 Install Brake caliper piston seal 1 Brake caliper piston dust seal 2 Always use new brake caliper pis ton seals and brake caliper piston dust seals Apply the brake fluid o...

Page 149: ...nder cup sec ondary 2 To brake master cylinder piston 3 Apply the brake fluid on the brake master cylinder cup After installing cylinder cup should be installed as shown di rection Wrong installation cause improper brake performance 3 Install Spring 1 To brake master cylinder piston 2 Install the spring at the smaller dia side 4 Install Brake master cylinder kit 1 Washer front brake 2 Push rod rea...

Page 150: ... pipe portion a directs as shown and lightly touches the projection b on the brake master cylinder 2 Install Brake master cylinder 1 Bolt brake master cylinder 2 3 Install Spring 1 Brake pedal 2 O ring 3 Bolt brake pedal 4 Clip 5 Apply the lithium soap base grease on the bolt O ring and brake pedal bracket 4 Install Pin 1 Washer 2 Cotter pin 3 After installing check the brake pedal height Refer to...

Page 151: ...ll Brake hose holder 1 Screw brake hose holder 2 After installing the brake hose holders make sure the brake hose does not contact the spring rear shock absorber If it does correct its twist FILLING THE BRAKE FLUID 1 Fill Brake fluid Until the fluid level reaches LOWER level line a Use only the designated quality brake fluid otherwise the rubber seals may deteriorate causing leakage and poor brake...

Page 152: ...loat front brake Diaphragm Brake master cylinder cap 1 Screw brake master cylinder cap 2 After installation while pulling the brake lever in or pushing down on the brake pedal check whether there is any brake fluid leaking where the union bolts are installed respectively at the brake master cylinder and brake caliper A Front B Rear 5 Install rear brake only Protector 1 Bolt protector 2 Screw bolt ...

Page 153: ...r to FRONT WHEEL AND REAR WHEEL section Front brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Number plate Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 1 Protector 1 2 Pinch bolt upper bracket 2 Only loosening 3 Damper assembly 1 Loosen when disassembling the front fork Refer to removal section 4 Pinch bolt lower bracket 2 Only loosening 5 Front fork 1 ...

Page 154: ...ring 1 Refer to removal section 5 Inner tube 1 Refer to removal section 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Oil seal washer 1 10 Oil seal 1 11 Base valve 1 Drain the fork oil Refer to removal section 12 Damper assembly 1 Drain the fork oil Refer to removal section 30 Nm 3 0 m kg 22 ft lb 29 Nm 2 9 m kg 21 ft lb 29 Nm 2 9 m kg 21 ft lb 1 Nm 0 1 m kg 0 7 ft lb 55 Nm 5 5 m kg 40 ft lb ...

Page 155: ...h 2 REMOVING THE ADJUSTER 1 Drain the outer tube of its front fork oil at its top 2 Loosen Adjuster 1 3 Remove Adjuster 1 While compressing the inner tube 2 set the cap bolt ring wrench 4 between the inner tube and locknut 3 Hold the locknut and remove the adjuster Do not remove the locknut as the damper rod may go into the damp er assembly and not be taken out REMOVING THE INNER TUBE 1 Remove Dus...

Page 156: ...ends Out of specification Replace Use the dial gauge 1 The bending value is shown by one half of the dial gauge reading Do not attempt to straighten a bent inner tube as this may dangerous ly weaken the tube CHECKING THE OUTER TUBE 1 Inspect Outer tube 1 Score marks wear damage Re place CHECKING THE ADJUSTER 1 Inspect Adjuster 1 O ring 2 Wear damage Replace ASSEMBLING THE FRONT FORK 1 Wash the all...

Page 157: ...the damper as sembly 1 slowly up and down more than 10 times to distribute the fork oil 12 While protecting the damper as sembly 1 with a rag and com pressing fully allow excessive oil to overflow on the base valve side Take care not to damage the damp er assembly 13 Allow the overflowing oil to es cape at the hole a in the damper assembly 14 Check Damper assembly smooth move ment Tightness bindin...

Page 158: ...ase on the inner tube 22 Check Inner tube smooth movement Tightness binding rough spots Repeat the steps 15 to 21 23 Measure Distance a Out of specification Turn into the locknut 24 Install Collar 1 Fork spring 2 To damper assembly 3 Install the collar with its larger dia end a facing the fork spring 25 Install Damper assembly 1 To inner tube 2 To install the damper assembly into the inner tube ho...

Page 159: ...er 1 To inner tube 31 Fill Front fork oil 1 From outer tube top Never fail to make the oil amount adjustment between the maximum and minimum amount and always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability Be sure to use recommended fork oil If other oils are used they may have an excessively ad verse effect on the front fork per formance...

Page 160: ... torqued too much it may cause the front fork to mal function 5 Install Protector 1 Bolt protector 2 6 Adjust Rebound damping force Turn in the damping adjuster 1 fin ger tight and then turn out to the orig inally set position 7 Adjust Compression damping force Turn in the damping adjuster 1 fin ger tight and then turn out to the orig inally set position Damper assembly 30 Nm 3 0 m kg 22 ft lb Cap...

Page 161: ...ver side 4 Clutch lever holder 1 5 Engine stop switch 1 6 Brake master cylinder 1 Refer to removal section 7 Throttle cable cap 1 8 Throttle cable 1 pulled 1 Disconnect at the throttle side 9 Throttle cable 2 pushed 1 Disconnect at the throttle side 10 Right grip 1 Refer to removal section 11 Tube guide 1 12 Collar 1 13 Left grip 1 Refer to removal section 14 Handlebar upper holder 2 15 Handlebar ...

Page 162: ...is tance a from the mounting bolt center faces forward And install it in the hole b in the rear of the up per bracket Apply the lithium soap base grease on the thread of the handlebar low er holder Change in the direction back to front and installing position of the handlebar lower holder allows the front to rear offset amount of the handlebar position to be changed Do not tighten the nut yet A Fo...

Page 163: ...p base grease on the throttle cable end and tube guide cable winding portion 8 Install Throttle cable cap 1 Screw throttle cable cap 2 After tightening the screws check that the throttle grip 3 moves smoothly If it does not retighten the bolts for adjustment 9 Install Grip cap cover 1 Cover throttle cable cap 2 10 Install Brake master cylinder 1 Brake master cylinder bracket 2 Bolt brake master cy...

Page 164: ...iddle of the clutch lever hold er 12 Install Clutch cable 1 Hot starter cable 2 Apply the lithium soap base grease on the clutch cable end and hot start er cable end 13 Adjust Clutch lever free play Refer to ADJUSTING THE CLUTCH CABLE FREE PLAY section in the CHAPTER 3 Hot starter lever free play Refer to ADJUSTING THE HOT STARTER LEVER FREE PLAY section in the CHAPTER 3 ...

Page 165: ... the engine Refer to HANDLING NOTE Number plate Refer to SEAT FUEL TANK AND SIDE COVERS section in the CHAPTER 4 Handlebar Refer to HANDLEBAR section 1 Front fender 1 2 Steering stem nut 1 3 Front fork 2 Refer to FRONT FORK section 4 Upper bracket 1 5 Steering ring nut 1 Refer to removal section 6 Lower bracket 1 7 Bearing race cover 1 8 Upper bearing 1 9 Lower bearing 1 Refer to removal section 1...

Page 166: ...s as a set Install the bearing in the bearing races Spin the bearings by hand If the bearings hang up or are not smooth in their operation in the bearing races replace bearings and bearing races as a set INSTALLING THE LOWER BRACKET 1 Install Lower bearing 1 Apply the lithium soap base grease on the dust seal lip and bearing inner circumference 2 Install Bearing race Upper bearing 1 Bearing race c...

Page 167: ...tact surface of the steering stem nut when installing 9 After tightening the nut check the steering for smooth movement If not adjust the steering by loosen ing the steering ring nut little by lit tle 10 Adjust Front fork top end a 11 Tighten Pinch bolt upper bracket 1 Pinch bolt lower bracket 2 Tighten the lower bracket to speci fied torque If torqued too much it may cause the front fork to mal f...

Page 168: ...ING NOTE Brake hose holder Refer to FRONT BRAKE AND REAR BRAKE section Rear brake caliper Refer to FRONT BRAKE AND REAR BRAKE section Bolt brake pedal Shift the brake pedal backward Drive chain 1 Drive chain support 1 2 Lower chain tensioner 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt connecting rod 1 5 Pivot shaft 1 6 Swingarm 1 ...

Page 169: ...2 SWINGARM DISASSEMBLING THE SWINGARM Order Part name Q ty Remarks 1 Relay arm 1 2 Connecting rod 1 3 Collar 2 4 Oil seal 2 5 Thrust bearing 2 6 Bushing 2 7 Oil seal 8 8 Bearing 10 Refer to removal section ...

Page 170: ...L 1 Install Bearing 1 Oil seal 2 To swingarm Apply the molybdenum disulfide grease on the bearing when install ing Install the bearing by pressing it on the side having the manufacture s marks or numbers First install the outer and then the inner bearings to a specified depth from inside 2 Install Bearing 1 Washer 2 Oil seal 3 To relay arm Apply the molybdenum disulfide grease on the bearing when ...

Page 171: ...olybdenum disulfide grease on the bolt circumference and threaded portion Do not tighten the nut yet 6 Install Swingarm 1 Pivot shaft 2 Apply the molybdenum disulfide grease on the pivot shaft Insert the pivot shaft from right side 7 Check Swingarm side play a Free play exists Replace thrust bearing Swingarm up and down move ment b Unsmooth movement binding rough spots Grease or replace bearings b...

Page 172: ...l Drive chain support 1 Drive chain support cover 2 Bolt drive chain support L 50 mm 1 97 in 3 Nut drive chain support 4 Bolt drive chain support cover L 10 mm 0 39 in 5 Nut relay arm 70 Nm 7 0 m kg 50 ft lb Nut lower chain tension er 16 Nm 1 6 m kg 11 ft lb Nut drive chain sup port 7 Nm 0 7 m kg 5 1 ft lb Bolt drive chain support cover 7 Nm 0 7 m kg 5 1 ft lb ...

Page 173: ... in the CHAPTER 4 Silencer Refer to EXHAUST PIPE AND SILENCER section in the CHAPTER 4 1 Clamp air filter joint 1 Only loosening 2 Rear frame 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt rear shock absorber frame 1 5 Rear shock absorber 1 6 Locknut 1 Only loosening 7 Adjuster 1 Only loosening 8 Lower spring guide 1 9 Upper spring guide 1 10 Spring rear shock absorber 1 11 Bear...

Page 174: ...he bottom of the nitro gen gas tank It is very danger ous to remove the plug When scrapping the rear shock absorber follow the instruc tions on disposal NOTES ON DISPOSAL YAMAHA DEALERS ONLY Before disposing the rear shock ab sorber be sure to extract the nitrogen gas from valve 1 Wear eye protec tion to prevent eye damage from es caping gas and or metal chips To dispose of a damaged or worn out r...

Page 175: ... to ADJUSTING THE REAR SHOCK ABSORBER SPRING PRELOAD section in the CHAPTER 3 4 Tighten Locknut 1 INSTALLING THE REAR SHOCK ABSORBER 1 Install Dust seal 1 O ring 2 Collar 3 Apply the molybdenum disulfide grease on the dust seal lips and col lars Apply the lithium soap base grease on the O rings 2 Install Bushing 1 Collar 2 Dust seal 3 Apply the molybdenum disulfide grease on the bearing and dust s...

Page 176: ...l Rear frame 1 Bolt rear frame upper 2 Bolt rear frame lower 3 7 Tighten Bolt air filter joint 1 Bolt rear frame upper 32 Nm 3 2 m kg 23 ft lb Bolt rear frame lower 32 Nm 3 2 m kg 23 ft lb Bolt air filter joint 3 Nm 0 3 m kg 2 2 ft lb ...

Page 177: ...rvicing of Yamaha motorcycles e g Yamaha dealers service engineers etc Those who have little knowledge and skill concerning servicing are request ed not to undertake inspection adjustment disassembly or reassembly only by reference to this manual It may lead to servicing trouble and mechanical damage 6 ...

Page 178: ...ition sensor 3 Neutral switch 4 CDI magneto 5 Ignition coil 6 Spark plug 7 CDI unit COLOR CODE B Black Br Brown G Green L Blue O Orange P Pink R Red Sb Sky blue W White Y Yellow B L Black Blue B W Black White B Y Black Yellow G B Green Black L W Blue White R W Red White B W B W B L B Y Sb Sb G B L Y L Y P B B B B G O W R P G W R P B Br W W B Y G Br G R R O B Sb Sb Y Y W Y W G G B P P Br Br R R O L...

Page 179: ...e following special tools in this inspection Spark gap test Spark Clean or replace spark plug No spark Check entire ignition system for connection couplers leads and ignition coil No good Repair or replace OK Check engine stop switch No good Replace OK Check ignition coil primary coil and secondary coil No good Replace OK Check CDI magneto pickup coil and charging coil No good Replace OK Check neu...

Page 180: ...it is freed Re place Set the tester selection position to Ω 1 CHECKING THE IGNITION COIL 1 Remove the ignition coil cap 2 Inspect Primary coil resistance Out of specification Replace 3 Inspect Secondary coil resistance Out of specification Replace 4 Inspect Sealed portion of ignition coil a Spark plug terminal pin b Threaded portion of spark plug c Wear Replace CHECKING THE CDI MAGNETO 1 Inspect P...

Page 181: ...ion to Ω 1 CHECKING THE CDI UNIT Check all electrical components If no fault is found replace the CDI unit Then check the electrical compo nents again Tester lead Brown lead 1 Tester lead Green lead 2 Charging coil 1 resis tance Tester se lector posi tion 720 1 080 Ω at 20 C 68 F Ω 100 Tester lead Pink lead 1 Tester lead Black lead 2 Charging coil 2 resis tance Tester se lector posi tion 44 66 Ω a...

Page 182: ... IGNITION SYSTEM section Use the following special tools in this inspection Check entire ignition system for connection No good Repair or replace OK Check throttle position sensor Throttle position sensor coil No good Replace OK Check CDI magneto Charging coil No good Replace OK Check CDI unit Throttle position sensor input voltage No good Replace Pocket tester YU 3112 C 90890 03112 ...

Page 183: ...osition sensor using the T25 bit 3 Replace Throttle position sensor 4 Install Throttle position sensor 1 Screw throttle position sensor 2 Align the slot a in the throttle posi tion sensor with the projection b on the carburetor Temporarily tighten the screw throttle position sensor 5 Install Carburetor Throttle position sensor coupler 6 Adjust Engine idling speed Refer to ADJUSTING THE EN GINE IDL...

Page 184: ...etor 11 Stop the engine 12 Remove the carburetor 13 Tighten Screw throttle position sensor 1 Tighten the screw throttle position sensor using the T25 bit 14 Install the carburetor CHECKING THE THROTTLE POSITION SENSOR INPUT VOLTAGE 1 Disconnect the throttle position sensor coupler 2 Start the engine 3 Inspect Throttle position sensor input volt age Out of specification Replace the CDI unit Throttl...

Page 185: ...essarily Otherwise too much fuel may be discharged starting may become difficult or the engine may not run well After installing the carburetor check that the throttle operates correctly and opens and closes smoothly ATMOSPHERIC CONDITIONS AND CARBURETOR SETTINGS The air density i e concentration of oxygen in the air determines the rich ness or leanness of the air fuel mix ture Higher temperature ...

Page 186: ...ill not pick up speed quickly Step down the jet needle clip by one groove and move up the nee dle to enrich the mixture Effects of changing the jet needle groove position reference A Idle B Fully open 1 No 5 groove 2 No 3 groove 3 No 4 groove ADJUSTING THE JET NEEDLE The jet needle is adjusted by chang ing it The jet needle setting parts having the same taper angle are available in different strai...

Page 187: ...4MX 14943 44 182 4MX 14943 94 STD 180 4MX 14943 43 178 4MX 14943 93 175 4MX 14943 42 172 4MX 14943 92 Lean 170 4MX 14943 41 Pilot jet Size Part number Rich 50 4MX 14948 07 48 4MX 14948 06 STD 45 4MX 14948 05 STD 42 4MX 14948 04 40 4MX 14948 03 Lean 38 4MX 14948 02 Jet nee dle Size Part number Rich NDJN 5TA 14916 JN NDJP 5TA 14916 JP NDJQ 5TA 14916 J1 STD NDJR 5TA 14916 JR NDJS 5TA 14916 JS NDJT 5T...

Page 188: ...mixture Increase main jet calibration no Gradual ly 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 Check that the accelerator pump operates smoothly At full throttle Speed pick up stops Slow speed pick up Slow response Sooty spark plug Rich mixture Decrease main jet calibration no Gradual ly Disco...

Page 189: ... a larger diameter Raise jet needle clip position 1 groove up Poor response in the low to in termediate speeds Raise jet needle clip position If this has no effect lower the jet needle clip position Poor response when throttle is opened quickly Check overall settings Use main jet with a lower calibration no Raise jet needle clip position 1 groove up If these have no effect use a main jet with a hi...

Page 190: ...d condi tion the tire pressure should be higher to prevent a flat tire FRONT FORK SETTING The front fork setting should be made depending on the rider s feeling of an actual run and the circuit conditions The front fork setting includes the fol lowing three factors 1 Setting of air spring characteris tics Change the fork oil amount 2 Setting of spring preload Change the spring 3 Setting of damping...

Page 191: ...pension setting includes the following two factors 1 Setting of spring preload Change the set length of the spring Change the spring 2 Setting of damping force Change the rebound damping Change the compression damp ing CHOOSING SET LENGTH 1 Place a stand or block under the engine to put the rear wheel above the floor and measure the length a between the rear wheel axle center and the rear fender h...

Page 192: ...xceed the standard as it may result in faulty performance Never use one whose overall length is greater than standard REAR SHOCK ABSORBER SETTING PARTS Rear shock spring 1 Equal pitch steel spring The I D mark a is marked at the end of the spring Spring specification varies accord ing to the color and quantity of I D marks Extent of adjustment spring pre load For the spring preload adjustment refe...

Page 193: ...tire range bottoming out Compression damping Turn adjuster clockwise about 2 clicks to in crease damping Oil amount Increase oil amount by about 5 10 cm3 0 2 0 4 Imp oz 0 2 0 3 US oz Spring Replace with stiff spring Stiff toward stroke end Oil amount Decrease oil amount by about 5 cm3 0 2 Imp oz 0 2 US oz Soft toward stroke end bottoming out Oil amount Increase oil amount by about 5 cm3 0 2 Imp oz...

Page 194: ...eavy and dragging Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Spring Replace with soft spring Poor road gripping Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Low compression damping Turn adjuster clockwise about 1 clicks to in crease damping High compression damping Turn adjuster clockwise about 1 6 turn to in crease dampin...

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Page 196: ...PRINTED IN JAPAN E PRINTED ON RECYCLED PAPER YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN ...

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