Yamaha YZ250R Service Manual Download Page 92

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4-2

ENG

SEAT, FUEL TANK AND SIDE COVERS

EC4R3000

REMOVAL POINTS

EC413110

Side cover

1. Remove:

Bolt (side cover)

Side cover (left and right)

NOTE:

Draw the side cover downward to remove it
because its claws

are inserted in the air

cleaner case.

5UP-9-30-4A 5/24/02 5:27 PM Page 4

Summary of Contents for YZ250R

Page 1: ......

Page 2: ...OWNER S SERVICE MANUAL MANUEL D ATELIER DU PROPRIETAIRE FAHRER UND WARTUNGS HANDBUCH MANUALE DI SEVIZIO DEL PROPRIETARIO YZ250 R LC 5UP 28199 30 ...

Page 3: ...ERVICE MANUAL 2002 by Yamaha Motor Co Ltd 1st Edition May 2002 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan EC010010 ...

Page 4: ...Yamaha Motor Co Ltd 1 Ausgabe Mai 2002 Alle Rechte vorbehalten Nachdruck auch auszungsweise oder nicht autorisierte Verwendung ist ohne schriftliche Genehmigung der Yamaha Motor Co Ltd nicht gestattet Gedruckt in Japan YZ250 R LC MANUALE DI SERVIZIO DEL PROPRIETARIO 2002 by Yamaha Motor Co Ltd 1a Edizione Mei 2002 Tutti i diritti riservati Sono espressamente proibiti qualsiasi ristampa o uso non a...

Page 5: ...e please contact your Yamaha dealer NOTE As improvements are made on this model some data in this manual may become outdated If you have any questions please consult your Yama ha dealer w PLEASE READ THIS MANUAL CAREFULLY AND COMPLETELY BEFORE OPERATING THIS MACHINE DO NOT ATTEMPT TO OPERATE THIS MACHINE UNTIL YOU HAVE ATTAINED A SATISFACTORY KNOWLEDGE OF ITS CONTROLS AND OPERATING FEATURES AND UN...

Page 6: ...MACHINE IS DESIGNED TO BE RIDDEN BY THE OPERATOR ONLY Do not carry passengers on this machine 3 ALWAYS WEAR PROTECTIVE APPAR EL When operating this machine always 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 4 ALWAYS MAINTAI...

Page 7: ...EQUATE VENTILATION Never start the engine or let it run for any length of time in an enclosed area Exhaust fumes are poisonous These fumes contain carbon monoxide which by itself is odorless and colorless Carbon monoxide is a dangerous gas which can cause unconsciousness or can be lethal 8 PARK THE MACHINE CAREFULLY TURN OFF THE ENGINE Always turn off the engine if you are going to leave the machi...

Page 8: ...his machine and should remain with it even if the machine is subsequently sold EC060000 NOTICE Some data in this manual may become out dated due to improvements made to this model in the future If there is any question you have regarding this manual or your machine please consult your Yamaha dealer Weights of machines without fuel The minimum weights for motocross machines are for the class 125 cc...

Page 9: ... be taken to avoid damage to the machine NOTE A NOTE provides key information to make pro cedures easier or clearer EC082000 FINDING THE REQUIRED PAGE 1 This manual consists of seven chapters General Information Specifications Regular inspection and adjustments Engine Chassis Electrical and Tun ing 2 The table of contents is at the beginning of the manual Look over the general layout of the book b...

Page 10: ...0M W2 M W2 0Y O2 M O M O2 0Y O 0Y O M W2 0Y W2 Y W2 M W2 M W2 0Y hf O 0M O 0Y O 0Y he O K 7 0Y O M hf W2 M W2 M W2 M he W2 M W2 0Y O 0Y O 0Y O 0YhfO L 3 0Y O M O2 M W2 0M W2 MhfW2 X V M W2 0Y hfW2 0Y O M O 0Y he O 1 V 0Y O M hf O M W2 0Y W2 0M he W2 L V M W2 0Yhf O2 0Y O M O M hfO 1 V 0Y O Mhf W2 M W2 0Y W2 0YhfO2 V40M W2 0Y hfW 0Y O M O MhfW2 O M hf O M W2 0Y W2 0Y he O 5 O2 0Yhf W2 0Y O M O M he...

Page 11: ...nt w Tightening e Specified value Service limit r Resistance Ω Voltage V Electric current A Illustrated symbols t to o in the exploded dia grams indicate grade of lubricant and location of lubrication point t Apply transmission oil y Apply engine mixing oil u Apply molybdenum disulfide oil i Apply lightweight lithium soap base grease o Apply molybdenum disulfide grease Illustrated symbols p to a i...

Page 12: ...EC090010 INDEX GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL TUNING ...

Page 13: ...L 1 12 STARTING AND BREAK IN 1 13 TORQUE CHECK POINTS 1 16 CLEANING AND STORAGE 1 17 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS 2 1 MAINTENANCE SPECIFICATIONS 2 3 GENERAL TORQUE SPECIFICATIONS 2 12 DEFINITION OF UNITS 2 12 CABLE ROUTING DIAGRAM 2 13 CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS MAINTENANCE INTERVALS 3 1 PRE OPERATION INSPECTION AND MAINTENANCE 3 4 ENGINE 3 5 CHASSIS 3 17 ELECT...

Page 14: ...ARY DRIVEN GEAR 4 33 KICK AXLE SHIFT SHAFT AND PRIMARY DRIVE GEAR 4 40 YPVS GOVERNOR 4 49 WATER PUMP 4 52 CDI MAGNETO 4 56 ENGINE REMOVAL 4 60 CRANKCASE AND CRANKSHAFT 4 65 TRANSMISSION SHIFT CAM AND SHIFT FORK 4 72 CHAPTER 5 CHASSIS FRONT WHEEL AND REAR WHEEL 5 1 FRONT BRAKE AND REAR BRAKE 5 10 FRONT FORK 5 26 HANDLEBAR 5 39 STEERING 5 46 SWINGARM 5 51 REAR SHOCK ABSORBER 5 59 ...

Page 15: ...CHAPTER 6 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM 6 1 IGNITION SYSTEM 6 2 SOLENOID VALVE SYSTEM 6 7 TPS THROTTLE POSITION SENSOR SYSTEM 6 9 CHAPTER 7 TUNING ENGINE 7 1 CHASSIS 7 13 ...

Page 16: ...nk cap 7 Kick starter 8 Fuel tank 9 Radiator 0 Coolant drain bolt q Check bolt Transmission oil level w Rear brake pedal e Valve joint r Fuel cock t Starter knob y Drive chain u Air cleaner i Shift pedal o Front fork NOTE 9The machine you have purchased may differ slightly from those shown in the following 9Designs and specifications are subject to change without notice ...

Page 17: ...ntify your machine EC121001 VEHICLE IDENTIFICATION NUMBER For USA CDN AUS NZ and E The vehicle identification number 1 is stamped on the right of the steering head pipe EC122001 FRAME SERIAL NUMBER For F D GB I and ZA The frame serial number 1 is stamped on the right of the steering head pipe EC123001 ENGINE SERIAL NUMBER The engine serial number 1 is stamped into the elevated part of the right si...

Page 18: ... pump housing hole at the bottom 2 Use proper tools and cleaning equipment Refer to SPECIAL TOOLS section 3 When disassembling the machine keep mated parts together They include gears cylinders pistons and other mated parts that have been mated through normal wear Mated parts must be reused as an assembly or replaced 4 During the machine disassembly clean all parts and place them in trays in the o...

Page 19: ...bolt or nut flat s after the bolt or nut has been properly tightened EC135001 BEARINGS AND OIL SEALS 1 Install the bearing s 1 and oil seal s 2 with their manufacturer s marks or numbers facing outward In other words the stamped letters must be on the side exposed to view When installing oil seal s apply a light coating of light weight lithium base grease to the seal lip s Oil the bear ings libera...

Page 20: ...hould be inspected carefully before reassembly Always replace piston pin clips after one use Replace distorted circlips When installing a circlip 1 make sure that the sharp edged corner 2 is posi tioned opposite to the thrust 3 it receives See the sectional view 4 Shaft ...

Page 21: ... check that it will not come off 5 If the terminal comes off bend up the pin 1 and reinsert the terminal into the connector 6 Connect 9Connector NOTE The two connectors click together 7 Check for continuity with a tester NOTE 9If there in no continuity clean the terminals 9Be sure to perform the steps 1 to 7 listed above when checking the wireharness 9For a field remedy use a contact revitalizer a...

Page 22: ...e the crankshaft from either case YM 1189 90890 01189 Flywheel puller YM 1189 90890 01189 This tool is used to remove the flywheel magneto YU 1235 90890 01235 Rotor holding tool YU 1235 90890 01235 This tool is used when loosening or tightening the flywheel magneto securing nut YU 3097 90890 01252 Dial gauge and stand YU 3097 90890 01252 YU 1256 Spark plug hole dial stand YU 1256 These tools are u...

Page 23: ... 90890 03112 Use this tool to inspect the coil resistance output voltage and amperage YU 8036 B Inductive tachometer YU 8036 B 90890 03113 90890 03113 Engine tachometer This tool is needed for observing engine rpm YM 91042 90890 04086 Clutch holding tool YM 91042 90890 04086 This tool is used to hold the clutch when removing or installing the clutch boss securing nut YM 34487 Dynamic spark tester ...

Page 24: ...DAL The gear ratios of the constant mesh 5 speed transmission are ideally spaced The gears can be shifted by using the shift pedal 1 on the left side of the engine EC154000 KICK STARTER Rotate the kick starter 1 away from the engine Push the starter down lightly with your foot until the gears engage then kick smoothly and force fully to start the engine This model has a prima ry kick starter so th...

Page 25: ...iltering the fuel The fuel cock has the two positions OFF With the lever in this position fuel will not flow Always return the lever to this posi tion when the engine is not running ON With the lever in this position fuel flows to the carburetor Normal riding is done with the lever in this position EC159000 STARTER KNOB CHOKE When cold the engine requires a richer air fuel mixture for starting A s...

Page 26: ...STAND This sidestand 1 is used to support only the machine when standing or transporting it w 9Never apply additional force to the side stand 9Remove this sidestand before starting out EC15f000 SET PIN This set pin 1 is used to remove and install the push rod of the engine cC Be sure to use the set pin If the set pin is not used the power valve constituent parts will result in damage EC15e000 NIPP...

Page 27: ...ne grade cC Never mix two types of oil in the same batch clotting of the oil could result If you wish to change oil types be sure to drain the fuel tank and the carburetor float bowl of old premix prior to filling with the new type Fuel tank capacity 8 0 L 1 76 Imp gal 2 11 US gal Mixing oil Recommended oil Yamalube 2 R Yamalube racing 2 cycle oil Mixing ratio 30 1 If unavailable use an equivalent...

Page 28: ... CHOKE 3 With the throttle completely closed start the engine by kicking the kick starter forcefully with firm stroke 4 Run the engine at idle or slightly higher until it warms up this usually takes about one or two minutes 5 The engine is warmed up when it responds normally to the throttle with the starter knob CHOKE turned off cC Do not warm up the engine for extended peri ods EC193001 STARTING ...

Page 29: ...check full throt tle response Stop and check the spark plug 6 After again allowing the engine to cool restart and run the machine for five more minutes Full throttle and the higher gears may be used but sustained full throttle operation should be avoided Check the spark plug condition 7 Allow the engine to cool remove the top end and inspect the piston and cylinder Remove any high spots on the pis...

Page 30: ...K POINTS Tighten all such fasteners as required 9When any of the following parts have been replaced they must be broken in CYLINDER AND CRANKSHAFT About one hour of break in operation is necessary PISTON RING AND GEARS These parts require about 30 minutes of break in operation at half throttle or less Observe the condition of the engine careful ly during operation ...

Page 31: ... to frame Link to shock absorber Link to swingarm Rear Installation of shock Shock absorber to frame absorber Rear Installation of swingarm Tightening of pivot shaft Wheel Installation of wheel Front Tightening of front axle Tightening of axle holder Rear Tightening of rear axle Wheel to sprocket Brake Front Caliper to front fork Brake disc to wheel Tightening of union bolt Master cylinder to hand...

Page 32: ... of wheel bear ings front forks brakes and transmission seals Many expensive repair bills have resulted from improper high pressure detergent applications such as those avail able in coin operated car washers 4 After the majority of the dirt has been hosed off wash all surfaces with warm water and a mild detergent Use an old toothbrush to clean hard to reach places 5 Rinse the machine off immediat...

Page 33: ...switch pushed in kick the engine over several times to coat the cylinder walls with oil 3 Remove the drive chain clean it thoroughly with solvent and lubricate it Reinstall the chain or store it in a plastic bag tied to the frame 4 Lubricate all control cables 5 Block the frame up to raise the wheels off the ground 6 Tie a plastic bag over the exhaust pipe out let to prevent moisture from entering...

Page 34: ... Cylinder arrangement Single cylinder forward inclined Displacement 249 cm3 8 76 lmp oz 8 42 US oz Bore Stroke 66 4 72 mm 2 614 2 835 in Compression ratio 9 1 10 9 1 For USA CDN and ZA 9 0 10 6 1 For EUROPE AUS and NZ Starting system Kick starter Lubrication system Premix 30 1 Yamalube 2 R Oil type or grade 2 Cycle Transmission oil Yamalube 4 10W 30 or SAE 10W 30 type SE motor oil Periodic oil cha...

Page 35: ...1 5th 20 21 0 952 Chassis USA ZA AUS NZ EUROPE CDN Frame type Semi double cradle Caster angle 27 0 26 8 Trail 118 mm 4 65 in 114 mm 4 49 in Tire Type With tube Size front 80 100 21 51M Size rear 110 90 19 62M 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 operatio...

Page 36: ...5 0 7087 in 0 7077 in Piston ring Sectional sketch Plain B 1 0 mm 0 039 in T 2 55 mm 0 100 in End gap installed 0 40 0 55 mm 0 016 0 022 in 0 95 mm 0 037 in Side clearance installed 1st 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in 2nd 0 030 0 065 mm 0 0012 0 0026 in 0 1 mm 0 004 in Crankshaft Crank width A 59 95 60 00 mm 2 360 2 362 in Runout limit C 0 03 mm 0 0012 in 0 05 mm 0 0020 in Connecti...

Page 37: ...Z Type Manufacturer PWK38S KEIHIN I D mark 5NX1 00 5UP2 10 Main jet M J 178 180 Main air jet M A J 200 Jet needle clip position J N N3EJ 2 N3EW 3 Main nozzle N J ø2 9 Cutaway C A 7 Pilot jet P J 50 52 Pilot air screw P A S 1 7 8 for reference only Valve seat size V S ø3 8 mm 0 15 in Starter jet G S 85 Power jet P W J 50 Float arm height F H 5 5 7 5 mm 0 22 030 in Reed valve Thickness 0 42 mm 0 017...

Page 38: ...r hose clamp M 6 1 0 8 1 0 1 0 7 Air filter element M 6 1 0 1 2 0 2 1 4 Carburetor joint M 6 1 0 5 10 1 0 7 2 Air filter case M 6 1 0 4 8 0 8 5 8 Air filter guide clamp M 5 0 8 1 1 0 1 0 7 Reed valve M 3 0 5 4 1 0 1 0 7 Exhaust pipe front M 6 1 0 1 14 1 4 10 Exhaust pipe rear M 6 1 0 1 12 1 2 8 7 Exhaust pipe stay front M 8 1 25 1 25 2 5 18 Exhaust pipe stay rear M 6 1 0 1 12 1 2 8 7 Silencer fron...

Page 39: ... 1 75 7 5 54 Clutch spring M 6 1 0 6 10 1 0 7 2 Push lever axle M 5 0 8 1 6 0 6 4 3 Drive sprocket M20 1 0 1 75 7 5 54 Shift guide M 6 1 0 2 10 1 0 7 2 Stopper lever M 6 1 0 1 10 1 0 7 2 Torsion spring shift shaft stopper bolt M 8 1 25 1 22 2 2 16 Segment M 8 1 25 1 30 3 0 22 Bearing plate cover shift cam right M 6 1 0 2 10 1 0 7 2 Shift pedal M 6 1 0 1 10 1 0 7 2 ...

Page 40: ...outer tube with inner tube 3 15 5 91 in and damper rod fully compressed without spring Oil grade Suspension oil 01 Inner tube outer diameter 46 mm 1 81 in Front fork top end Zero mm Zero in Rear suspension USA CDN ZA EUROPE AUS NZ Shock absorber travel 132 mm 5 20 in Spring free length 260 mm 10 24 in 275 mm 10 83 in Fitting length 251 mm 9 88 in 261 mm 10 28 in Min Max 240 5 258 5 mm 255 5 273 5 ...

Page 41: ...4 0 12 in 9 84 0 10 in Pad thickness 4 4 mm 0 17 in 1 0 mm 0 04 in Master cylinder inside dia 11 0 mm 0 433 in Caliper cylinder inside dia 27 0 mm 1 063 in 2 Brake fluid type DOT 4 Rear disc brake Disc outside dia Thickness 245 4 0 mm 245 3 5 mm 9 65 0 16 in 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 11 0 mm 0 433 in Calipe...

Page 42: ...ont brake master cylinder cap Brake lever mounting bolt Brake lever mounting nut Brake lever position locknut Cable guide front brake hose and guide stay Front brake hose union bolt master cylinder Front brake hose union bolt caliper Front brake caliper and front fork Brake caliper front and rear and pad pin plug Brake caliper front and rear and pad pin Brake caliper front and rear and bleed screw...

Page 43: ... Rear frame and frame upper Rear frame and frame lower Swingarm and brake hose holder Swingarm and patch Drive chain tensioner mounting Chain support and swingarm Seal guard and swingarm Fuel tank mounting Fuel tank and fuel cock Fuel tank and seat set bracket Fuel tank and hooking screw fitting band Fuel tank and fuel tank bracket Seat mounting Side cover mounting Air scoop mounting Front fender ...

Page 44: ...model stator Manufacturer 5CU 02 YAMAHA Source coil 1 resistance color 720 1 080 Ω at 20 C 68 F Black Black Red Source coil 2 resistance color 44 66 Ω at 20 C 68 F Green Blue Green White Pickup coil resistance color 248 372 Ω at 20 C 68 F White Blue White Red CDI unit model Manufacturer 5NX 00 YAMAHA Ignition coil Model Manufacturer 4MX 00 YAMAHA Minimum spark gap 6 mm 0 24 in Primary winding resi...

Page 45: ...m temperature A Distance across flats B Outside thread diameter EC230000 DEFINITION OF UNITS EC220001 GENERAL TORQUE SPECIFICATIONS A B TORQUE SPECIFICATION Nut Bolt 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 milimeter 10 3 meter Length cm centimeter 10 2 meter Lengt...

Page 46: ...throttle cable C Pass the throttle cable and ENGINE STOP button lead over the radiator hose D Clamp the throttle cable and ENGINE STOP button lead with the clamp ends downward E Pass the clutch cable a little for ward of the extreme left nut that holds the cylinder head F Pass the wireharness between the engine brackets G Pass the air vent hoses overflow hose and transmission oil breather hose bet...

Page 47: ... bracket and inside the down tube Pass the radiator breather hose inside the CDI magneto lead D Clamp the CDI magneto lead radiator breather hose and YPVS breather hose In so doing clamp the CDI magneto lead at the rear of the down tube with the clamp ends out ward E Clamp the radiator breather hose and CDI magneto lead at the rear of the down tube with the clamp ends outward F Pass the radiator b...

Page 48: ...its ends downward as shown C Position the CDI magneto lead coupler between the radiators D Clamp the wireharness to the right engine bracket E Clamp the high tension cord throttle cable and wireharness with the clamp ends downward so that the high tension cord does not contact the engine bracket installation nuts F Fasten the ground lead together with the front installation portion of the ingnitio...

Page 49: ...ortion directs as shown and lightly touches the projec tion on the 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 projection on the master cylinder ...

Page 50: ... directs as shown and lightly touches the projection on the master cylinder B Pass the ENGINE STOP button lead in the middle of the clutch holder C Pass the clutch cable in front of the throttle cable D Clamp the ENGINE STOP button lead to the handlebar to 3 clicks E Pass the brake hose in front of the number plate and through the cable guide F Cross the clutch cable and throttle cable over the nu...

Page 51: ...g end gap Inspect carbon deposits and eliminate them Check gasket Inspect score marks Inspect wear Inspect carbon deposits and eliminate them Inspect housing friction plate clutch plate and spring Yamalube 4 10W 30 or SAE 10W 30 SE motor oil Inspect wear Use chain lube Chain slack 40 50 mm 1 6 2 0 in PISTON Inspect and clean Replace PISTON RING Inspect Replace PISTON PIN SMALL END BEARING Inspect ...

Page 52: ... FRONT FORKS Inspect and adjust Replace oil Suspension oil 01 Replace oil seal FRONT FORK OIL SEAL AND DUST SEAL Clean and lube Lithium base grease REAR SHOCK ABSORBER After Inspect and adjust rain ride Lube Molybdenum disulfide grease Retighten CHAIN GUARD AND ROLLERS Inspect SWINGARM Inspect lube and retighten Molybdenum disulfide grease RELAY ARM CONNECTING ROD Inspect lube and retighten Molybd...

Page 53: ...3 3 INSP ADJ MEMO ...

Page 54: ...ear brake P3 17 23 Chain Check chain slack and alignment Check that the chain is lubricated properly P3 24 26 Wheels Check for excessive wear and tire pressure Check for loose spokes and have no excessive play P3 34 35 Steering Check that the handlebar can be turned smoothly and have no excessive play P3 35 36 Front forks and Check that they operate smoothly and there is no oil rear shock absorber...

Page 55: ...ap slowly rotate the cap counterclockwise to the detent This procedure allows any residual pres sure to escape When the hissing sound has stopped press down on the cap while turning counterclockwise and remove it cC Hard water or salt water is harmful to the engine parts You may use distilled water if you can t get soft water 1 Place the machine on a level place and hold it in an upright position ...

Page 56: ...Drain the coolant completely 4 Clean 9Cooling system Thoroughly flush the cooling system with clean tap water 5 Install 9Copper washer 9Coolant drain bolt 6 Fill 9Radiator 9Engine To specified level Recommended coolant High quality ethylene glycol anti freeze containing anti corrosion for aluminum engine Coolant 1 and water soft water 2 mixing ratio 50 50 Coolant capacity 1 20 L 1 06 Imp qt 1 27 U...

Page 57: ...vel low Add coolant EC355000 RADIATOR CAP INSPECTION 1 Inspect 9Seal radiator cap 1 9Valve and valve seat 2 Crack Damage Replace Exist fur deposits 3 Clean or replace Handling notes of coolant The coolant is harmful so it should be handled with special care w 9When coolant splashes to your eye Thoroughly wash your eye with water and see your doctor 9When coolant splashes to your clothes Quickly wa...

Page 58: ...ressure Impossible to maintain the specified pres sure for 10 seconds Replace EC357003 COOLING SYSTEM INSPECTION 1 Inspect 9Coolant level 2 Attach 9Radiator cap tester 1 and adapter 2 3 Apply the specified pressure Radiator cap tester YU 24460 01 90890 01325 Adapter YU 33984 90890 01352 Radiator cap tester YU 24460 01 90890 01325 Adapter YU 33984 90890 01352 Radiator cap opening pressure 95 125 kP...

Page 59: ...Radiator hose 3 Swelling Replace 2 Adjust 9Clutch lever free play EC359020 CLUTCH ADJUSTMENT 1 Check 9Clutch lever free play a Out of specification Adjust NOTE 9Make minute adjustment on the lever side using the adjuster 3 9After adjustment check proper operation of clutch lever Clutch lever free play a a 8 13 mm 0 31 0 51 in Clutch lever free play adjustment steps 9Loosen the locknut 1 9Turn the ...

Page 60: ...grease On the throttle cable end a tube guide cable winding portion b and roller sliding surface c Throttle grip free play adjustment steps 9Loosen the locknut 1 9Turn the adjuster 2 until the specified free play is obtained 9Tighten the locknut NOTE Before adjusting the throttle cable free play the engine idle speed should be adjusted w After adjusting turn the handlebar to right and left and mak...

Page 61: ...gine without the air filter element in place this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage 1 Remove 9Seat 9Fitting bolt 1 9Washer 2 9Air filter element 3 9Filter guide 4 2 Clean 9Air filter element Clean them with solvent NOTE After cleaning remove the remaining solvent by squeezing the element cC Do not twist the element when squeezing the elem...

Page 62: ...ole b in air filter element 6 Apply 9Lithium soap base grease On the matching surface a on air filter ele ment 7 Install 9Air filter element 1 9Washer 9Fitting bolt NOTE Align the projection a on filter guide with the hole b in air filter case EC35H002 TRANSMISSION OIL LEVEL CHECK 1 Start the engine warm it up for several min utes and wait for five minutes 2 Place the machine on a level place and ...

Page 63: ...s 9Remove the oil check bolt 1 9Inspect the oil level NOTE Be sure the machine is positioned straight up when inspecting the oil level w Never attempt to remove the oil check bolt just after high speed operation The heat ed oil could spout out causing danger Wait until the oil cools down Oil flows out Oil level is correct Oil does not flow out Oil level is low Add transmission oil until oil flows ...

Page 64: ...l level 9 Install 9Oil filler cap 2 EC35L021 PILOT AIR SCREW ADJUSTMENT 1 Adjust 9Pilot air screw 1 Adjusting steps 9Turn in the pilot air screw until it is lightly seated 9Turn out the pilot air screw by the factory set number of turns NOTE To optimize the fuel flow at a smaller throttle opening each machine s pilot air screw has been individually set at the factory Before adjusting the pilot air...

Page 65: ...ect 9O ring 1 Damage Replace NOTE Install the O rings with their depressed a facing outward EC35R051 SILENCER FIBER REPLACEMENT 1 Remove 9Side cover right 9Bolt silencer 1 9Silencer 2 9Bolt fiber 3 Adjustment steps Turn the throttle stop screw 1 until the engine runs at the lowest possible speed To increase idle speed Turn the throttle stop screw 1 1 in To decrease idle speed Turn the throttle sto...

Page 66: ...ar 4 9Side cover right 10 Nm 1 0 m kg 7 2 ft lb 12 Nm 1 2 m kg 8 7 ft lb 11 Nm 1 1 m kg 8 0 ft lb 2 Remove 9Inner pipe 1 3 Replace 9Fiber 2 4 Install 9Inner pipe NOTE Fully apply Quick gasket Yamaha bond No 1215 or equivalent as shown Quick gasket ACC QUICK GS KT Yamaha bond No 1215 90890 85505 7 Nm 0 7 m kg 5 1 ft lb ...

Page 67: ...r brake fluid to the reservoir b Install the diaphragm Be careful not to spill any fluid or allow the reservoir to overflow c Connect the clear plastic tube 2 tightly to the caliper bleed screw 1 d Place the other end of the tube into a container e Slowly apply the brake lever or pedal several times f Pull the lever in or push down on the ped al Hold the lever or pedal in position g Loosen the ble...

Page 68: ... the tiny bubbles in the system have disappeared j Add brake fluid to the level line on the reservoir w Check the operation of the brake after bleeding the brake system Brake lever position a a Standard position Extent of adjutment 95 mm 3 74 in 76 97 mm 2 99 3 82 in Brake lever position adjustment steps 9Loosen the locknut 1 9Turn the adjusting bolt 2 until the lever position a is within specifie...

Page 69: ...just NOTE The brake pedal height is the vertical distance from the inside top end of the footrest 2 Adjust 9Brake pedal height Brake pedal height a a Zero mm Zero in Pedal height adjustment steps 9Loosen the locknut 1 9Turn the adjusting nut 2 until the pedal height a is within specified height 9Tighten the locknut w 9Adjust the pedal height between the maximum Å Å and the minimum ı ı as shown In ...

Page 70: ...per piston in cC Do not reuse the drained brake fluid 9Tighten the bleed screw 9Install the brake pads 8 and pad pin NOTE 9Install the brake pads with their projections a into the caliper recesses b 9Temporarily tighten the pad pin at this point 9Install the brake hose holder 9 and caliper 0 and tighten the pad pin q NOTE Fit the brake hose holder cut c over the pro jection d on the front fork and...

Page 71: ... REAR BRAKE PAD INSPECTION AND REPLACEMENT 1 Inspect 9Brake pad thickness a Out of specification Replace as a set 2 Replace 9Brake pad 9Install the pad pin plug w Pad pin plug 3 Nm 0 3 m kg 2 2 ft lb Brake pad thickness a a Standard 6 4 mm 0 25 in Limit 1 0 mm 0 04 in Brake pad replacement steps 9Remove the protector 1 and pad pin plug 2 9Loosen the pad pin 3 9Remove the rear wheel 4 and caliper 5...

Page 72: ...r projections a into the caliper recesses b 9Temporarily tighten the pad pin at this point 9Install the caliper w and rear wheel e Refer to FRONT WHEEL AND REAR WHEEL section in the CHAPTER 5 9Tighten the pad pin r 9Install the pad pin plug t and protector y Bleed screw 6 Nm 0 6 m kg 4 3 ft lb Pad pin 18 Nm 1 8 m kg 13 ft lb Pad pin plug 3 Nm 0 3 m kg 2 2 ft lb Bolt protector 7 Nm 0 7 m kg 5 1 ft ...

Page 73: ...linder so that its top is in a horizontal position 2 Inspect 9Brake fluid level Fluid at lower level Fill up a Lower level ÅFront ıRear w 9Use only designated quality brake fluid to avoid poor brake performance 9Refill with same type and brand of brake flu id mixing fluids could result in poor brake performance 9Be sure that water or other contaminants do not enter master cylinder when refilling 9...

Page 74: ...NSPECTION 1 Remove 9Master link clip 9Joint 1 9Drive chain 2 2 Clean 9Drive chain Place it in kerosene and brush off as much dirt as possible Then remove the chain from the kerosene and dry the chain 3 Measure 9Drive chain length 10 links a Out of specification Replace 4 Check 9Drive chain stiffness a Clean and oil the chain and hold as illustrated Stiff Replace drive chain Drive chain length 10 l...

Page 75: ...r adjusting rotate the rear wheel through several revolutions and check the slack several times to find the tightest point Check and or adjust chain slack with rear wheel in this tight chain position Drive chain slack 40 50 mm 1 6 2 0 in Drive chain lubricant SAE 10W 30 motor oil or suitable chain lubricants 5 Install 9Drive chain 1 9Joint 2 9Master link clip 3 cC Be sure to install the master lin...

Page 76: ...3 3 counter clockwise To loosen Turn adjuster 3 3 clockwise and push wheel forward 9Turn each adjuster exactly the same amount to maintain correct axle alignment There are marks a on each side of chain puller align ment NOTE Turn the adjuster so that the chain is in line with the sprocket as viewed from the rear cC Too small chain slack will overload the engine and other vital parts keep the slack...

Page 77: ...ase on the in ner tube EC36H002 FRONT FORK REBOUND DAMPING FORCE ADJUSTMENT 1 Adjust 9Rebound damping force By turning the adjuster 1 Stiffer a a Increase the rebound damping force Turn the adjuster 1 1 in Softer b b Decrease the rebound damping force Turn the adjuster 1 1 out EC36f000 FRONT FORK INTERNAL PRESSURE RELIEVING NOTE If the front fork initial movement feels stiff during a run relieve t...

Page 78: ...ORCE ADJUSTMENT 1 Remove 9Rubber cap 2 Adjust 9Compression damping force By turning the adjuster 1 Stiffer a a Increase the compression damping force Turn the adjuster 1 1 in Softer b b Decrease the compression damping force Turn the adjuster 1 1 out Minimum 20 clicks out from maximum position 9STANDARD POSITION This is the position which is back by the spe cific number of clicks from the fully tu...

Page 79: ...Always adjust each front fork to the same setting Uneven adjustment can cause poor handling and loss of stability 3 Install 9Rubber cap EC36K000 REAR SHOCK ABSORBER INSPECTION 1 Inspect 9Swingarm smooth action Abnormal noise Unsmooth action Grease the pivoting points or repair the pivoting points Damage Oil leakage Replace Minimum 20 clicks out from maximum position Extent of adjustment Maximum Fu...

Page 80: ...ustment 9The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster cC Never attempt to turn the adjuster beyond the maximum or minimum setting 5 Tighten 9Locknut 6 Install 9Rear frame upper 9Rear frame lower Stiffer Increase the spring preload Turn the adjuster 2 2 in Softer Decrease the spring pre load Turn the adjuster 2 2 out Extent of adjustment 240 5 258 5 mm 9 47 10 ...

Page 81: ... tion Which align the punch mark a on the ad juster with the punch mark b on the bracket For EUROPE cC Do not force the adjuster past the mini mum or maximum extent of adjustment The adjuster may be damaged Stiffer a a Increase the rebound damping force Turn the adjuster 1 1 in Softer b b Decrease the rebound damping force Turn the ad juster 1 1 out Minimum 20 clicks out from maximum position Exte...

Page 82: ...h align the punch mark a on the ad juster with the punch mark b on the high com pression damping adjuster cC Do not force the adjuster past the mini mum or maximum extent of adjustment The adjuster may be damaged Stiffer a a Increase the low compression damping force Turn the ad juster 1 1 in Softer b b Decrease the low compres sion damping force Turn the adjuster 1 1 out Minimum 20 clicks out fro...

Page 83: ...tion Which align the punch mark a on the ad juster with the punch mark b on the adjuster body cC Do not force the adjuster past the mini mum or maximum extent of adjustment The adjuster may be damaged Stiffer a a Increase the high compression damping force Turn the ad juster 1 1 in Softer b b Decrease the high compres sion damping force Turn the adjuster 1 1 out Minimum 2 turns out from maximum po...

Page 84: ...f its position on the rim 9If the tire valve stem is found tilted the tire is considered to be slipping off its position Correct the tire position EC36S002 SPOKES INSPECTION AND TIGHTENING 1 Inspect 9Spokes 1 Bend Damage Replace Loose spoke Retighten 2 Tighten 9Spokes NOTE Be sure to retighten these spokes before and af ter break in After a practice or a race check spokes for looseness EC36T000 WH...

Page 85: ...ssembly back and forth Free play Adjust steering head 3 Check 9Steering smooth action Turn the handlebar lock to lock Unsmooth action Adjust steering ring nut 4 Adjust 9Steering ring nut Steering ring nut adjustment steps 9Remove the number plate 9Remove the handlebar and handle crown 9Loosen the ring nut 1 using the ring nut wrench 2 9Tighten the ring nut 3 using ring nut wrench 4 NOTE Set the to...

Page 86: ... number plate 9 NOTE 9The upper handlebar holder should be installed with the punched mark a forward 9Insert the end of fuel breather hose 0 into the hole of the number plate cC First tighten the bolts on the front side of the handlebar holder and then tighten the bolts on the rear side Ring nut wrench YU 33975 90890 01403 Ring nut initial tightening 38 Nm 3 8 m kg 27ft lb Steering shaft nut 145 N...

Page 87: ... 5 Throttle to handlebar contact 6 Drive chain 7 Throttle roller sliding surface 8 Tube guide cable winding portion 9 Throttle cable end 0 Clutch cable end Å Use Yamaha cable lube or equivalent on these areas ı Use SAE10W 30 motor oil or suitable chain lubricants Ç Lubricate the following areas with high quali ty lightweight lithium soap base grease cC Wipe off any excess grease and avoid get ting...

Page 88: ...t low speeds the spark plug insulator will become sooty even if the engine and carburetor are in good operating condition 3 Measure 9Plug gap a Use a wire gauge or thickness gauge Out of specification Regap 4 Clean the plug with a spark plug cleaner if necessary 5 Tighten 9Spark plug NOTE 9Before installing a spark plug clean the gasket surface and plug surface 9Finger tighten a the spark plug bef...

Page 89: ...When this happens the needle on the dial gauge will stop and reverse directions even though the rotor is being turned in 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 9Ignition timing Punch mark a on rotor should be aligned with punch mark b on stator Not aligne...

Page 90: ...NSP ADJ 7 Adjust 9Ignition timing Adjustment steps 9Loosen the screws stator 1 9Align the punch mark on the rotor with punch mark on the stator 2 by moving the stator 9Tighten the screws stator Screw stator 8 Nm 0 8 m kg 5 8 ft lb ...

Page 91: ...tting band 1 Remove on fuel tank side 4 Bolt fuel tank 2 5 Fuel tank 1 6 Side cover left 1 Refer to REMOVAL POINTS 7 Side cover right 1 8 Number plate 1 1 4 Extent of removal 1 Seat removal 2 Fuel tank removal 3 Side covers removal 4 Number plate removal 2 3 7 Nm 0 7 m kg 5 1 ft lb 4 Nm 0 4 m kg 2 9 ft lb 4 Nm 0 4 m kg 2 9 ft lb 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft ...

Page 92: ...K AND SIDE COVERS EC4R3000 REMOVAL POINTS EC413110 Side cover 1 Remove 9 Bolt side cover 9 Side cover left and right 1 NOTE Draw the side cover downward to remove it because its claws a are inserted in the air cleaner case ...

Page 93: ...g 18 ft lb 12 Nm 1 2 m kg 8 7 ft lb 14 Nm 1 4 m kg 10 ft lb Extent of removal Order Part name Q ty Remarks EXHAUST PIPE AND SILENCER REMOVAL Preparation for Side cover right Refer to SEAT FUEL TANK AND removal SIDE COVERS section 1 Bolt silencer 2 2 Silencer 1 3 Collar D ø10 5 mm 0 41 in 1 4 Collar D ø10 0 mm 0 39 in 1 5 Grommet front 1 6 Grommet rear 1 7 Tension spring 2 8 Bolt exhaust pipe 2 9 E...

Page 94: ...UEL TANK AND SIDE COVERS section 1 Panel 2 2 Clamp radiator hose 2 2 Only loosening 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 EC450001 RADIATOR Extent of removal 1 Radiator removal 1 1 Nm 0 1 m kg 0 7 ft lb 10 Nm 1 0 m kg 7 2 ft lb 1 Nm 0 1 m kg 0 7 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m ...

Page 95: ...ap by the following procedure Place a thick rag like a towel over the radiator cap slowly rotate the cap counter clockwise to the detent This procedure allows any residual pressure to escape When the hissing sound has stopped press down on the cap while turning coun terclockwise and remove it EC454000 INSPECTION EC444100 Radiator 1 Inspect 9Radiator core 1 Obstruction Blow out with compressed air ...

Page 96: ...ection in the CHAPTER 2 10 Nm 1 0 m kg 7 2 ft lb 1 Nm 0 1 m kg 0 7 ft lb 1 Nm 0 1 m kg 0 7 ft lb 3 Install 9Radiator left 1 9Bolt radiator left 2 9Radiator hose 1 3 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 4 Tighten 9Clamp radiator hose 2 4 5 Install 9Panel 1 9Bolt panel 2 NOTE Fit the hook a on the inner side first into the radiator 10 Nm 1 0 m kg 7 2 ft lb 1 Nm 0 1 m kg 0 7 ft lb ...

Page 97: ...olenoid valve lead 1 Disconnect the solenoid valve lead 2 TPS throttle position sensor 1 Disconnect the TPS lead throttle position sensor lead 3 Clamp carburetor joint 2 Loosen the screws carburetor joint 4 Carburetor 1 5 Carburetor joint 1 6 Reed valve assembly 1 7 Stopper reed valve 2 8 Reed valve 2 9 Plate reed valve 1 1 Extent of removal 1 Carburetor removal 2 Reed valve removal 10 Nm 1 0 m kg...

Page 98: ...ng chamber top 1 2 Throttle valve 1 Refer to REMOVAL POINTS 3 Needle holder 1 4 Jet needle 1 5 Float chamber 1 6 Float pin 1 7 Float 1 8 Needle valve 1 9 Main jet 1 0 Pilot jet 1 q Starter plunger 1 w Throttle stop screw 1 e Pilot air screw 1 Refer to REMOVAL POINTS r Power jet 1 t Solenoid valve 1 Extent of removal 1 Carburetor disassembly 1 ...

Page 99: ...hrottle valve 1 9Ring 2 9Spring throttle valve 3 9Mixing chamber top 4 9Throttle cable 5 NOTE While compressing the spring throttle valve disconnect the throttle cable EC463401 Pilot air screw 1 Remove 9Pilot air screw 1 NOTE To optimize the fuel flow at a smaller throttle opening each machine s pilot air screw has been individually set at the factory Before removing the pilot air screw turn it in...

Page 100: ... 9Power jet 3 Contamination Clean NOTE 9Use a petroleum based solvent for cleaning Blow out all passages and jets with com pressed air 9Never use a wire EC464210 Needle valve 1 Inspect 9Needle valve 1 9Valve seat 2 Grooved wear a Replace Dust b Clean EC464000 INSPECTION EC464130 Carburetor 1 Inspect 9Carburetor body Contamination Clean NOTE 9Use a petroleum based solvent for cleaning Blow out all ...

Page 101: ...n Measurement and adjustment steps 9Hold the carburetor in an upside down posi tion 9Measure the distance between the mating surface of the float chamber and top of the float using a vernier calipers NOTE The float arm should be resting on the nee dle valve but not compressing the needle valve 9If the float height is not within specification inspect the valve seat and needle valve 9If either is wo...

Page 102: ...e cut a in the lower corner of the reed and stopper plate cC Tighten each screw gradually to avoid warping 1 Nm 0 1 m kg 0 7 ft lb 9Valve stopper height b Out of specification Adjust stopper Replace valve stopper Valve stopper height 10 3 10 7 mm 0 406 0 421 in EC464600 Float 1 Inspect 9Float 1 Damage Replace EC464701 Reed valve 1 Measure 9Reed valve bending a Out of specification Replace Reed val...

Page 103: ...stall the gasket reed valve with its projection a to the left 9Install the reed valve spacer with its chamfered side b to the right 4 13 ENG CARBURETOR AND REED VALVE 10 Nm 1 0 m kg 7 2 ft lb 3 Install 9Carburetor joint 1 9Bolt carburetor joint 2 EC4652F0 Carburetor 1 Install 9Power jet 1 To carburetor 2 ...

Page 104: ...screw until it is lightly seated 9Turn out the pilot air screw by the number of turns recorded before removing 5 Install 9Pilot jet 1 9Main jet 2 2 Install 9O ring 1 9Solenoid valve 2 9Clamp 3 9Screw clamp 4 To carburetor 5 cC 9Before installing the solenoid valve blow air on the solenoid valve and its installing location on the carburetor in order to remove any foreign particles such as chips etc...

Page 105: ...ir ends not having the cuts a toward the carburetor 9 Install 9Jet needle 1 9Collar 2 9Spring 3 9Needle holder 4 To throttle valve 5 NOTE Install the spring with its smaller dia a facing the collar 6 Install 9Needle valve 1 9Float 2 9Float pin 3 NOTE 9After installing the needle valve to the float install them to the carburetor 9Check the float for smooth movement 7 Install 9Float chamber 1 9Plate...

Page 106: ...der side of the air vent hose 9After installing check the throttle grip for smooth movement EC465391 Carburetor installation 1 Install 9Carburetor 1 NOTE Install the projection between the carburetor joint slots 10 Install 9Throttle cable 1 9Mixing chamber top 2 9Spring throttle valve 3 9Ring 4 9Throttle valve 5 NOTE 9While compressing the spring connect the throttle cable 9Align the projection a ...

Page 107: ...a with its top as shown and secure the clamp in alignment with the hori zontal line b that passes the center of the car buretor bore 4 Connect 9TPS throttle position sensor lead 1 9Solenoid valve lead 2 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 5 Adjust 9Idle speed Refer to IDLE SPEED ADJUSTMENT section in the CHAPTER 3 ...

Page 108: ...at cylinder head side Carburetor Refer to CARBURETOR AND REED VALVE section 1 Spark plug 1 2 Engine bracket 2 3 Nut cylinder head 6 Loosen each nut 1 4 turn and remove them after all nuts are loosened 4 Cylinder head 1 5 Power valve housing 1 6 Push rod 1 Refer to REMOVAL POINTS 7 Nut cylinder 4 8 Cylinder 1 Extent of removal 1 Cylinder head removal 2 Cylinder removal 1 2 34 Nm 3 4 m kg 24 ft lb 6...

Page 109: ...ll end bearing 1 5 Piston ring 2 6 Power valve cover 1 7 Side holder 2 8 Thrust plate 1 9 Bolt 3 10 Valve holder 1 1 11 Valve shaft 1 12 Link lever 1 13 Pulley 2 14 Link rod 1 15 Power valve 2 2 16 Valve holder 2 1 17 Power valve 1 1 Extent of removal 1 Piston and piston ring removal 2 Power valve removal 2 1 6 Nm 0 6 m kg 4 3 ft lb 4 Nm 0 4 m kg 2 9 ft lb 4 Nm 0 4 m kg 2 9 ft lb 4 Nm 0 4 m kg 2 9...

Page 110: ...Piston and piston ring 1 Remove 9Piston pin clip 1 NOTE Before removing the piston pin clip cover the crankcase with a clean rag to prevent the pis ton pin clip from falling into the crankcase cav ity 2 Remove 9Piston pin 1 9Piston 2 9Small end bearing 3 NOTE Before removing the piston pin deburr the clip groove and pin hole area If the piston pin groove is deburred and piston pin is still difficu...

Page 111: ...Warpage measurement and re surface ment steps 9Attach a straightedge 1 and a thickness gauge 2 on the cylinder head 9Measure the warpage 9If the warpage is out of specification resur face the cylinder head 9Place 400 600 grit wet sandpaper 3 on the surface plate and re surface the head 4 using a figure eight sanding pattern NOTE Rotate the cylinder head several times to avoid removing too much mat...

Page 112: ...Measure 9Cylinder bore C Use cylinder gauge 1 Out of limit Replace NOTE Measure the cylinder bore C in parallel A B C to and at right angles to the crankshaft a b Then find the average of the measurements EC474321 Piston 1 Eliminate 9Carbon deposits From the piston crown a and ring groove b 2 Inspect 9Piston wall Score marks Repair or replace Standard Wear limit Cylinder 66 400 66 414mm 66 5 mm bo...

Page 113: ...coloration Replace 2 Measure 9Piston pin outside diameter Use micrometer 1 Out of limit Replace 3 Check 9Free play when the piston pin 1 is in place in the piston 2 There should be no noticeable for the play Free play exists Replace piston pin and or piston 4 Install 9Small end bearing 9Piston pin Into the small end of connecting rod 17 5 mm 66 352 66 367 mm 0 69 in 2 6120 2 6129 in Distance b b P...

Page 114: ...earance Use a thickness gauge 1 Out of limit Replace piston and or ring NOTE Check at several points Ring end gap installed Standard Limit 0 40 0 55 mm 0 95 mm 0 016 0 022 in 0 037 in Side clearance Standard Limit 0 030 0 065 mm 0 1 mm 0 0012 0 0026 in 0 004 in 5 Check 9Free play There should be no noticeable free play Free play exists Inspect the connecting rod for wear Replace the pin and or con...

Page 115: ...6 mm 2 61433 2 61441 in C 66 408 66 410 mm 2 61449 2 61457 in D 66 412 66 414 mm 2 61465 2 61472 in Piston mark a a color Piston size A red 66 352 66 355 mm 2 61228 2 61240 in B orange 66 356 66 359 mm 2 61244 2 61256 in C green 66 360 66 363 mm 2 61260 2 61272 in D purple 66 364 66 367 mm 2 61276 2 61287 in EC474602 Piston clearance 1 Calculate 9Piston clearance Out of limit Replace piston and pi...

Page 116: ...9Spring 1 2 8 Broken Replace EC474901 Power valve hole on cylinder 1 Remove 9Carbon deposits From power valve hole surface a NOTE Do not use a sharp instrument Avoid scratching the aluminum 3 Combination Combine the piston and cylinder by the fol lowing chart NOTE When you purchase a cylinder you cannot des ignate its size Choose the piston that matches the above chart Cylinder mark Piston mark co...

Page 117: ... the molybdenum disulfide oil on the power valve 1 2 Install 9Power valve 2 1 9Link rod 2 9Plain washer 3 9Screw link rod 4 NOTE Install the link rod with the cuts a in its arm ends fitting over the pins b on the power valves 2 3 Install 9Thrust plate 1 9Screw thrust plate 2 NOTE Be sure to install the thrust plate to the cylinder before installing the valve shaft 6 Nm 0 6 m kg 4 3 ft lb 6 Nm 0 6 ...

Page 118: ...sulfide oil on the grooves in the pulleys 9Apply the lithium soap base grease on the oil seal lip 9Install the valve shaft with its cut b aligning with the thrust plate 7 and then rotate the valve shaft so that its cut faces upward 5 Install 9Valve holder 1 1 9Bolt link lever 2 9Bolt pulley 3 NOTE First tighten the bolt link lever and then tighten the bolts pulleys 6 Check 9Power valve 1 smooth mo...

Page 119: ...d the power valve cover 9Install the power valve cover so that the arrow mark b faces upward EC475233 Piston ring and piston 1 Install 9Piston ring 1 NOTE 9Take care not to scratch the piston or damage the piston ring 9Align the piston ring gap with the pin 2 9After installing the piston ring check the smooth movement of it 2 Install 9Gasket cylinder 1 9Small end bearing 2 9Dowel pin 3 NOTE 9Apply...

Page 120: ... hand NOTE After installing check the smooth movement of the piston 3 Install 9Nut cylinder 1 NOTE Tighten the nuts in stage using a crisscross pat tern 3 Install 9Piston 1 9Piston pin 2 9Piston pin clip 3 NOTE 9The arrow a on the piston dome must point to exhaust side 9Before installing the piston pin clip cover the crankcase with a clean rag to prevent the pis ton pin clip from falling into the ...

Page 121: ...s not used the power valve constituent parts will result in damage 5 Install 9Gasket power valve housing 9Power valve housing 1 9Bolt power valve housing 2 6 Install 9O ring 1 9Dowel pin 2 NOTE Apply the lithium soap base grease on the O rings 7 Install 9Cylinder head 1 9Copper washer 2 9Nut cylinder head 3 NOTE Tighten the nuts cylinder head in stage using a crisscross pattern 5 Nm 0 5 m kg 3 6 f...

Page 122: ...k plug 1 9Spark plug cap 2 8 Install 9Engine bracket 1 9Bolt engine bracket 2 9Engine mounting bolt upper 3 NOTE Install the engine bracket with its damper a on the right side of the body 20 Nm 2 0 m kg 14 ft lb 34 Nm 3 4 m kg 24 ft lb 69 Nm 6 9 m kg 50 ft lb ...

Page 123: ...3 Bolt brake pedal Shift the brake pedal downward Rotor and stator Refer to CDI MAGNETO section Clutch cable Disconnect at engine side 1 Clutch cover 1 2 Screw clutch spring 6 3 Clutch spring 6 4 Pressure plate 1 5 Friction plate 8 6 Clutch plate 7 Extent of removal 1 Clutch plate and friction plate removal EC490000 CLUTCH AND PRIMARY DRIVEN GEAR EC498000 CLUTCH PLATE AND FRICTION PLATE 1 10 Nm 1 ...

Page 124: ...al tool 7 Lock washer 1 Refer to REMOVAL POINTS 8 Clutch boss 1 9 Thrust plate D ø44mm 1 73 in 1 10 Primary driven gear 1 11 Bearing 1 12 Thrust plate D ø42mm 1 65 in 1 13 Bolt push lever axle 1 14 Push lever axle 1 EC498200 PRIMARY DRIVEN GEAR PUSH ROD AND PUSH LEVER AXLE Extent of removal 1 Push rod and push lever axle removal 2 Push rod 1 disassembly 3 Primary driven gear removal 2 3 1 1 1 3 75...

Page 125: ...ON EC484100 Clutch housing and boss 1 Inspect 9Clutch housing 1 Cracks Wear Damage Replace 9Clutch boss 2 Scoring Wear Damage Replace EC484201 Primary driven gear 1 Check 9Circumferential play Free play exists Replace 9Gear teeth a Wear Damage Replace EC484400 Clutch spring 1 Measure 9Clutch spring free length a Out of specification Replace springs as a set Clutch holding tool YM 91042 4 4 90890 0...

Page 126: ...e 2 EC484700 Push lever axle 1 Inspect 9Push lever axle 1 Wear Damage Replace EC484810 Push rod 1 Inspect 9Push rod 1 1 9Bearing 2 9Plain washer 3 9Push rod 2 4 Wear Damage Bend Replace EC495000 ASSEMBLY AND INSTALLATION EC485120 Push lever axle 1 Install 9Push lever axle 1 9Copper washer 2 9Bolt push lever axle 3 NOTE Apply the lithium soap base grease on the oil seal lip and push lever axle Fric...

Page 127: ...l on the bearing spacer and primary driven gear inner circumference 2 Install 9Thrust plate D ø 44 mm 1 73 in 1 9Clutch boss 2 3 Install 9Lock washer 1 9Nut clutch boss 2 NOTE Use the clutch holding tool 3 4 to hold the clutch boss å For USA and CDN Except for USA and CDN 4 Bend the lock washer 1 tab 75 Nm 7 5 m kg 54 ft lb Clutch holding tool YM 91042 3 3 90890 04086 4 4 å ...

Page 128: ...tes and clutch plates 6 Install 9Bearing 1 9Plain washer 2 9Circlip 3 To push rod 1 4 NOTE Apply the lithium soap base grease on the bear ing and plain washer 7 Install 9Push rod 2 1 9Push rod 1 2 NOTE 9Apply the transmission oil on the ends of the push rod 2 9Install the push rod 2 with its smaller end a toward you 8 Install 9Pressure plate 1 9 Install 9Clutch spring 1 9Screw clutch spring 2 NOTE...

Page 129: ...l 9O ring 1 To clucth cover 11 Install 9Clutch cover 1 9Bolt clutch cover 2 NOTE Tighten the bolts in stage using a crisscross pattern 12 Install 9O ring 1 9Clutch cable 2 NOTE Apply the lithium soap base grease on the O ring 10 Nm 1 0 m kg 7 2 ft lb ...

Page 130: ...nect at water pump side Bolt push rod Refer to CYLINDER HEAD CYLINDER AND PISTON section 1 Kick starter 1 2 Crankcase cover right 1 3 Bolt Primary drive gear 1 Only loosening Refer to REMOVAL POINTS 4 Primary driven gear 1 Refer to CLUTCH AND PRIMARY DRIVEN GEAR section 5 Primary drive gear 1 6 Thrust plate 1 EC4C0000 KICK AXLE SHIFT SHAFT AND PRIMARY DRIVE GEAR EC4C8000 PRIMARY DRIVE GEAR 1 Exten...

Page 131: ...axle assembly 1 Refer to REMOVAL POINTS 3 Shift pedal 1 4 Shift shaft 1 5 Roller 1 6 Shift guide 1 7 Shift lever assembly 1 Refer to REMOVAL POINTS 8 Stopper lever 1 9 Holder 1 10 Tension spring 1 1 Extent of removal 1 Kick axle and kick idle gear removal 2 Shift shaft and stopper lever removal 2 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb ...

Page 132: ...emove 9Kick axle assembly 1 NOTE Unhook the torsion spring 2 from the hole a in the crankcase EC4C3101 Shift guide and shift lever assembly 1 Remove 9Bolt shift guide 9Shift guide 1 9Shift lever assembly 2 NOTE The shift lever assembly is disassembled at the same time as the shift guide EC4C4000 INSPECTION EC4C4200 Kick axle and ratchet wheel 1 Check 9Ratchet wheel 1 smooth movement Unsmooth movem...

Page 133: ...0 Stopper lever 1 Inspect 9Stopper lever 1 Wear Damage Replace 9Bearing 2 Rotate outer race with a finger Rough spot Seizure Replace the stopper lever 9Tension spring 3 Broken Replace EC4C4100 Shift guide and shift lever assembly 1 Inspect 9Shift guide 1 9Shift lever 2 9Pawl 3 9Pawl pin 4 9Spring 5 Wear Damage Replace EC4C4300 Kick gear kick idle gear and ratchet wheel 1 Inspect 9Kick gear 1 9Kick...

Page 134: ...haft 2 Install 9Shift lever assembly 1 To shift guide 2 EC4C5202 Shift guide and shift lever assembly 1 Install 9Spring 1 9Pawl pin 2 9Pawl 3 To shift lever 4 EC4C5000 ASSEMBLY AND INSTALLATION EC4C5130 Stopper lever 1 Install 9Tension spring 1 9Holder 2 9Bolt holder 3 9Plain washer 4 9Stopper lever 5 9Bolt stopper lever 6 NOTE Align the stopper lever roller with the slot on segment 10 Nm 1 0 m kg...

Page 135: ...ake sure the stopper a of the torsion spring fits into the hole b on the kick axle EC4C5602 Kick axle assembly 1 Install 9Kick gear 1 9Plain washer 2 9Circlip 3 9Ratchet wheel 4 9Spring 5 9Plain washer 6 9Circlip 7 To kick axle 8 NOTE 9Apply the transmission oil on the kick gear inner circumference 9Align the punch mark a on the ratchet wheel with the punck mark b on the kick axle 4 Install 9Bolt ...

Page 136: ...he kick axle make sure the groove a in the spring guide fits on the stopper of the torsion spring 4 Install 9Plain washer 1 9Kick axle assembly 2 NOTE 9Apply the molybdenum disulfide grease on the contacting surfaces of the kick axle stopper a and stopper plate 3 9Apply the transmission oil on the kick axle 9Slide the kick axle assembly into the crankcase and make sure the kick axle stopper fits i...

Page 137: ...Bolt primary drive gear 1 NOTE Place an aluminum plate a between the teeth of the primary drive gear 2 and driven gear 3 EC4C5531 Primary drive gear 1 Install 9Thrust plate 1 9Primary drive gear 2 9Governor drive gear 3 9Plain washer 4 9Bolt primary drive gear 5 NOTE 9Install the plain washer with its chamfered side a toward you 9Temporarily tighten the bolt at this point 2 Install 9Primary driven...

Page 138: ...b connecting the center of the shift shaft and bottom of the screw crankcase cover left 3 7 Install 9Kick starter 1 9Plain washer 2 9Bolt kick starter 3 NOTE Install the kick starter closest to but not contact ing the clutch cover mounting boss a 6 Install 9Bolt crankcase cover right 1 NOTE Tighten the bolts in stage using a crisscross pattern 30 Nm 3 0 m kg 22 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm...

Page 139: ...D removal PRIMARY DRIVE GEAR section 1 Governor assembly 1 2 Dowel pin 1 Refer to REMOVAL POINTS 3 Retainer 1 4 Ball 4 5 Retainer weight 1 6 Plain washer 4 7 Thrust bearing 2 8 Collar 1 9 Plate 1 10 Compression spring 1 11 Governor gear 1 12 Governor shaft 1 EC4K0000 YPVS GOVERNOR 1 Extent of removal 1 YPVS governor removal and disassembly 5 Nm 0 5 m kg 3 6 ft lb ...

Page 140: ...eight 7 To governor shaft 8 NOTE Apply the lithium soap base grease on the thrust bearing EC4K3000 REMOVAL POINTS EC4K3100 Governor 1 Remove 9Dowel pin 1 NOTE While compressing the spring remove the dowel pin EC4K4000 INSPECTION EC4K4100 Governor groove 1 Inspect 9Plain washer 1 9Collar 2 Wear Damage Replace EC4K4200 Bearing 1 Inspect 9Thrust bearing 1 9Plain washer 2 Wear Damage Replace ...

Page 141: ...e fork b and set the governor in the crankcase cover 3 Install 9Dowel pin 1 NOTE 9While compressing the spring install the dowel pin 9Make sure the dowel pin fits into the groove a in the retainer 2 Install 9Ball 1 9Retainer 2 To governor shaft 3 NOTE Apply the transmission oil on the retainer and ball ...

Page 142: ...R PUMP DISASSEMBLY Preparation for Crankcase cover right Refer to KICK AXLE SHIFT SHAFT AND removal PRIMARY DRIVE GEAR section 1 Water pump housing cover 1 2 Impeller 1 3 Plain washer 1 Refer to REMOVAL POINTS 4 Impeller shaft 1 5 Bearing 1 6 Oil seal 2 Refer to REMOVAL POINTS 1 2 10 Nm 1 0 m kg 7 2 ft lb 10 Nm 1 0 m kg 7 2 ft lb 14 Nm 1 4 m kg 10 ft lb ...

Page 143: ...spanners etc and remove the impeller EC4G3210 Oil seal NOTE It is not necessary to disassemble the water pump unless there is an abnormality such as excessive change in coolant level discoloration of coolant or milky transmission oil 1 Remove 9Bearing 1 2 Remove 9Oil seal 1 EC4G4000 INSPECTION EC444200 Impeller shaft 1 Inspect 9Impeller shaft 1 Bend Wear Damage Replace Fur deposits Clean ...

Page 144: ...Replace EC444400 Oil seal 1 Inspect 9Oil seal 1 Wear Damage Replace EC4G5000 ASSEMBLY AND INSTALLATION EC4G5111 Oil seal 1 Install 9Oil seal 1 NOTE 9Apply the lithium soap base grease on the oil seal lip 9Install the oil seal with its manufacture s marks or numbers facing the crankcase cover right 2 2 Install 9Bearing 1 NOTE Install the bearing by pressing its outer race par allel ...

Page 145: ...ip and impeller shaft And install the shaft while turn ing it 2 Install 9Plain washer 1 9Impeller 2 NOTE Hold the impeller shaft on its width across the flats a with spanners etc and install the impeller 3 Install 9Dowel pin 1 9Gasket water pump housing cover 2 4 Install 9Water pump housing cover 1 9Bolt water pump housing cover 2 9Copper washer coolant drain bolt 3 9Coolant drain bolt 4 10 Nm 1 0...

Page 146: ...moval SIDE COVERS section Bolt radiator left Refer to RADIATOR section Disconnect the CDI magneto lead 1 Crankcase cover left 1 2 Nut rotor 1 Use special tool 3 Rotor 1 Refer to REMOVAL POINTS 4 Stator 1 5 Woodruff key 1 EC4L0000 CDI MAGNETO 1 Extent of removal 1 CDI magneto removal 8 Nm 0 8 m kg 5 8 ft lb 8 Nm 0 8 m kg 5 8 ft lb 56 Nm 5 6 m kg 40 ft lb ...

Page 147: ...oun terclockwise EC4L3000 REMOVAL POINTS EC4L3102 Rotor 1 Remove 9Nut rotor 1 9Plain washer 2 Use the rotor holding tool 3 EC4L4000 INSPECTION EC4L4101 CDI magneto 1 Inspect 9Rotor inner surface a 9Stator outer surface b Damage Inspect the crankshaft runout and crankshaft bearing If necessary replace CDI magneto and or stator EC4L4200 Woodruff key 1 Inspect 9Woodruff key 1 Damage Replace Rotor hol...

Page 148: ...n the CHAPTER 3 2 Install 9Woodruff key 1 9Rotor 2 NOTE 9Clean the tapered portions of the crankshaft and rotor 9When installing the woodruff key make sure that its flat surface a is in parallel with the crankshaft center line b 9When installing the rotor align the keyway c of the rotor with the woodruff key 8 Nm 0 8 m kg 5 8 ft lb Rotor holding tool YU 1235 90890 01235 Ignition timing B T D C 0 1...

Page 149: ...to lead 1 Refer to CABLE ROUTING DIAGRAM section in the CHAPTER 2 8 Install 9Gasket crankcase cover left 9Crankcase cover left 1 9Screw crankcase cover left 2 NOTE Tighten the screws in stage using a crisscross pattern 8 Nm 0 8 m kg 5 8 ft lb ...

Page 150: ...Refer to EXHAUST PIPE AND Exhaust pipe stay rear SILENCER section Clutch cable Disconnect at engine side Radiator Refer to RADIATOR section Spark plug Disconnect the CDI magneto lead CDI unit Reservoir tank rear brake Refer to FRONT BRAKE AND REAR BRAKE section in the CHAPTER 5 EC4M0000 ENGINE REMOVAL w Support the machine securely so there is no dan ger of it falling over 26 Nm 2 6 m kg 19 ft lb ...

Page 151: ... to REMOVAL POINTS 4 Drive sprocket 1 5 Clip 1 6 Bolt brake pedal 1 7 Brake pedal 1 8 Engine bracket 2 9 Engine mounting bolt 3 10 Pivot shaft 1 Remove completely 11 Engine 1 Refer to REMOVAL POINTS 1 26 Nm 2 6 m kg 19 ft lb 69 Nm 6 9 m kg 50 ft lb 69 Nm 6 9 m kg 50 ft lb 75 Nm 7 5 m kg 54 ft lb 8 Nm 0 8 m kg 5 8 ft lb 85 Nm 8 5 m kg 61 ft lb 34 Nm 3 4 m kg 24 ft lb ...

Page 152: ...ve the engine 1 aslant and upward while inclining it toward the kick crank side so that the engine s mounting top does not contact the bracket on the frame EC4M3000 REMOVAL POINTS EC4F3100 Drive sprocket 1 Remove 9Nut drive sprocket 1 9Lock washer 2 NOTE 9Straighten the lock washer tab 9Loosen the nut while applying the rear brake 2 Remove 9Drive sprocket 1 9Drive chain 2 NOTE Remove the drive spr...

Page 153: ...4 Engine installation 1 Install 9Engine 1 Install the engine from right side 9Pivot shaft 2 9Engine mounting bolt lower 3 9Engine mounting bolt front 4 9Engine bracket 5 9Bolt engine bracket 6 9Engine mounting bolt upper 7 NOTE 9Apply the molybdenum disulfide grease on the pivot shaft 9Install the engine bracket with its damper a on the right side of the body 85 Nm 8 5 m kg 61 ft lb 69 Nm 6 9 m kg...

Page 154: ... washer 1 9Nut drive sprocket 2 NOTE Tighten the nut while applying the rear brake 3 Bend the lock washer tab to lock the nut 8 Nm 0 8 m kg 5 8 ft lb 75 Nm 7 5 m kg 54 ft lb EC4M5341 Drive sprocket 1 Install 9Drive sprocket 1 9Drive chain 2 NOTE Install the drive sprocket together with the drive chain ...

Page 155: ...efer to CDI MAGNETO section 1 Segment 1 Refer to REMOVAL POINTS 2 Bolt L 50 mm 1 97 in 7 3 Bolt L 60 mm 2 36 in 1 4 Bolt L 70 mm 2 76 in 3 5 Holder 2 6 Crankcase right 1 Use special tool 7 Crankcase left 1 Refer to REMOVAL POINTS 8 Crankshaft 1 Use special tool Refer to REMOVAL POINTS 9 Oil seal 2 10 Bearing 2 Refer to REMOVAL POINTS EC4N0000 CRANKCASE AND CRANKSHAFT 1 2 3 Extent of removal 1 Cran...

Page 156: ...tap on the case half Tap only on reinforced portions of case Do not tap on gasket mating surface Work slowly and carefully Make sure the case halves separate evenly If one end hangs up take pressure off the push screw realign and start over If the cases do not separate check for a remaining case screw or fitting Do not force EC4N3000 REMOVAL POINTS EC4N3100 Segment 1 Remove 9Bolt segment 1 9Segmen...

Page 157: ...kcase by pressing its inner race as shown in å 9If the bearing is removed together with the crankshaft remove the bearing using a general bearing puller 2 as shown in 9Do not use the removed bearing EC4N3302 Crankshaft 1 Remove 9Crankshaft 1 Use the crankcase separating tool 2 NOTE Make appropriate bolts 3 as shown available by yourself and attach the tool with them cC Do not use a hammer to drive...

Page 158: ... 4 1 0 mm 2 0 mm free play 0 016 0 039 in 0 08 in Side 0 25 0 75 mm clearance 0 010 0 030in Crank 59 95 60 00 mm width 2 360 2 362 in EC4N4202 Crankshaft 1 Measure 9Runout limit a 9Small end free play limit b 9Connecting rod big end side clearance c 9Crank width d Out of specification Replace Use the dial gauge and a thickness gauge 2 Inspect 9Bearings 1 Rotate inner race with a finger Rough spot ...

Page 159: ...274 Bolt 3 YU 90050 90890 01275 Adapter 4 YU 90063 90890 01278 2 Check 9Shifter operation 9Transmission operation Unsmooth operation Repair å å B å For USA and CDN Except for USA and CDN NOTE 9Hold the connecting rod at top dead center with one hand while turning the nut of the installing tool with the other Operate the installing tool until the crankshaft bottoms against the bear ing 9Before inst...

Page 160: ... hammer 9When installing the crankcase the connecting rod should be positioned at TDC top dead center 6 Install 9Bolt crankcase 1 NOTE Tighten the crankcase tightening bolts in stage using a crisscross pattern NOTE Clean the contacting surface of crankcase left and right before applying the sealant 4 Apply 9Sealant On the crankcase right 1 Quick gasket ACC QUICK GS KT Yamaha bond No 1215 90890 855...

Page 161: ...the bolt 30 Nm 3 0 m kg 22 ft lb 7 Install 9Tension spring 1 9Holder 2 9Bolt holder 3 NOTE Install the holder so that it contacts the projec tion a on the crankcase right 10 Nm 1 0 m kg 7 2 ft lb 9 Remove 9Sealant Forced out on the cylinder mating surface 10 Apply 9Engine oil To the crank pin bearing oil delivery hole and connecting rod big end washer 11 Check 9Crankshaft and transmission operatio...

Page 162: ...ine Refer to ENGINE REMOVAL section removal Separate the crankcase Refer to CRANKCASE AND CRANK SHAFT section 1 Main axle 1 2 Drive axle 1 3 Shift cam 1 4 Shift fork 3 1 Refer to REMOVAL POINTS 5 Shift fork 2 1 6 Shift fork 1 1 7 Spacer 1 EC4H0000 TRANSMISSION SHIFT CAM AND SHIFT FORK Extent of removal 1 Main axle drive axle shift cam and shift fork removal 1 ...

Page 163: ...ect 9Matching dog a 9Gear teeth b 9Shift fork groove c Wear Damage Replace EC4H3000 REMOVAL POINTS EC4H3230 Transmission 1 Remove 9Main axle 1 9Drive axle 2 9Shift cam 9Shift fork 3 9Shift fork 2 9Shift fork 1 NOTE 9Remove assembly carefully Note the position of each part Pay particular attention to the location and direction of shift forks 9Remove the main axle drive axle shift cam and shift fork...

Page 164: ...th pinion gears inner circumference and on the end surface 9Apply the molybdenum disulfide oil on the 2nd and 3rd pinion gears inner circumference 3 Check 9Shift fork movement Unsmooth operation Replace shift fork NOTE For a malfunctioning shift fork replace not only the shift fork itself but the two gears each adja cent to the shift fork 2 Inspect 9Shift cam 1 9Segment 2 Wear Damage Replace EC4H4...

Page 165: ...lip sharp edged corner a is positioned opposite side to the plain washer and gear b 9Be sure the circlip end c is positioned at axle spline groove d 2 Install 92nd wheel gear 23 T 1 94th wheel gear 24 T 2 93rd wheel gear 23 T 3 95th wheel gear 20 T 4 91st wheel gear 27 T 5 9O ring 6 To drive axle 7 NOTE 9Apply the molybdenum disulfide oil on the 1st 2nd and 3rd wheel gears inner circumference and ...

Page 166: ... on the shift fork grooves 9Mesh the shift fork 1 L with the 4th wheel gear 5 and 3 R with the 5th wheel gear 7 on the drive axle 9Mesh the shift fork 2 C10 with the 3rd pinion gear 6 on the main axle 6 Install 9Transmission assembly 1 To crankcase left 2 NOTE Apply the transmission oil on the bearings and guide bars 7 Check 9Shifter operation 9Transmission operation Unsmooth operation Repair ...

Page 167: ... wheel axle 1 6 Front wheel 1 7 Collar 2 8 Oil seal 2 9 Bearing 2 Refer to REMOVAL POINTS 10 Brake disc 1 EC500000 CHASSIS EC590000 FRONT WHEEL AND REAR WHEEL EC598000 FRONT WHEEL 2 1 3 3 Extent of removal 1 Front wheel removal 2 Wheel bearing removal 3 Brake disc removal w Support the machine securely so there is no dan ger of it falling over 23 Nm 2 3 m kg 17 ft lb 23 Nm 2 3 m kg 17 ft lb 105 Nm...

Page 168: ...he removal suitable stand under the engine 1 Nut rear wheel axle 1 2 Rear wheel axle 1 3 Chain puller 2 4 Rear wheel 1 Refer to REMOVAL POINTS 5 Collar 2 6 Driven sprocket 1 7 Oil seal 2 8 Circlip 1 9 Bearing 2 Refer to REMOVAL POINTS 10 Brake disc 1 2 1 3 3 w Support the machine securely so there is no dan ger of it falling over 125 Nm 12 5 m kg 90 ft lb 14 Nm 1 4 m kg 10 ft lb 16 Nm 1 6 m kg 11 ...

Page 169: ...necessary 1 Remove 9Bearing 1 NOTE Remove the bearing using a general bearing puller 2 EC594000 INSPECTION EC514100 Wheel 1 Measure 9Wheel runout Out of limit Repair Replace 2 Inspect 9Bearing Rotate inner race with a finger Rough spot Seizure Replace NOTE Replace the bearings oil seal and wheel collar as a set Wheel runout limit Radial 1 1 2 0mm 0 08 in Lateral 2 2 2 0mm 0 08 in ...

Page 170: ...94200 Brake disc 1 Measure 9Brake disc deflection only rear brake disc Use the dial gauge 1 Out of specification Inspect wheel runout If wheel runout is in good condition re place the brake disc 2 Measure 9Brake disc thickness a Out of limit Replace Wheel axle bending limit 0 5 mm 0 020 in Disc wear limit Standard Limit Front 3 0 mm 0 12 in 2 5 mm 0 10 in Rear 4 0 mm 0 16 in 3 5 mm 0 14 in Disc de...

Page 171: ...king the front fork several times with the front brake applied 8 Install 9Brake hose 1 To brake hose holder 2 NOTE Before tightening the bolt brake hose holder align the top a of the brake hose neck with the brake hose holder bottom b Then pass the brake hose in front of the axle boss c and fit it into the hose groove d so that the brake hose does not contact the nut wheel axle 105 Nm 10 5 m kg 75...

Page 172: ... eter of the race of the bearing 9Right side of bearing shall be installed first 9Install the oil seal with its manufacture s marks or numbers facing outward cC Do not strike the inner race of the bearing Contact should be made only with the out er race 2 Install 9Brake disc 1 9Bolt brake disc 2 NOTE Tighten the bolts in stage using a crisscross pattern 9 Install 9Hose cover 1 9Plain washer 2 9Bol...

Page 173: ...NOTE Apply the lithium soap base grease on the oil seal lip 5 Install 9Wheel NOTE Install the brake disc 1 between the brake pads 2 correctly 6 Install 9Drive chain 1 NOTE Push the wheel 2 forward and install the drive chain 7 Install 9Chain puller left 1 9Wheel axle 2 NOTE 9Install the chain puller left and insert the wheel axle from left side 9Apply the lithium soap base grease on the wheel axle...

Page 174: ...wheel axle 3 NOTE Temporarily tighten the nut wheel axle at this point 9 Adjust 9Drive chain slack a Refer to DRIVE CHAIN SLACK ADJUSTMENT section in the CHAPTER 3 10 Tighten 9Nut wheel axle 1 9Locknut 2 125 Nm 12 5 m kg 90 ft lb 16 Nm 1 6 m kg 11 ft lb Drive chain slack 40 50 mm 1 6 2 0 in ...

Page 175: ...hen disassembling the caliper 8 Caliper 1 9 Brake lever 1 10 Master cylinder bracket 1 11 Master cylinder 1 Extent of removal 1 Brake hose removal 2 Caliper removal 3 Master cyilinder removal w Support the machine securely so there is no dan ger of it falling over 2 1 3 3 2 EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE 9 Nm 0 9 m kg 6 5 ft lb 6 Nm 0 6 m kg 4 3 ft lb 6 Nm 0 6 m kg 4 3 ft...

Page 176: ... 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 caliper 8 Caliper 1 Extent of removal 1 Master cylinder removal 2 Brake hose removal 3 Caliper removal w Support the machine securely so there is no dan ger of it falling over 2 3 3 1 1 1 Nm 0 1 m kg 0 7 ft lb 30 Nm 3 0 m kg 22 ft lb 30 Nm 3 0 m kg 22 ft...

Page 177: ...iper piston 2 1 Refer to REMOVAL POINTS 5 Dust seal 2 1 Refer to REMOVAL POINTS 6 Piston seal 2 1 A Front B Rear Extent of removal 1 Front caliper disassembly 2 Rear caliper disassembly 2 1 EC5A8200 CALIPER DISASSEMBLY 6 Nm 0 6 m kg 4 3 ft lb 3 Nm 0 3 m kg 2 2 ft lb 18 Nm 1 8 m kg 13 ft lb 6 Nm 0 6 m kg 4 3 ft lb 18 Nm 1 8 m kg 13 ft lb 3 Nm 0 3 m kg 2 2 ft lb ...

Page 178: ...1 2 Diaphragm 1 3 Master cylinder boot 1 4 Circlip 1 Use a long nose circlip pliers 5 Plain washer 1 6 Push rod 1 7 Master cylinder kit 1 A Front B Rear Extent of removal 1 Front master cylinder disassembly 2 Rear master cylinder disassembly 1 1 2 2 EC5A8300 MASTER CYLINDER DISASSEMBLY 2 Nm 0 2 m kg 1 4 ft lb 2 Nm 0 2 m kg 1 4 ft lb å ...

Page 179: ... pulling the lever in or pushing down on the pedal cC 9Do not reuse the drained brake fluid 9Brake fluid may erode painted surfaces or plastic parts Always clean up spilled fluid immediately EC533301 Caliper piston 1 Remove 9Caliper piston Use compressed air and proceed carefully w 9Cover piston with rag and use extreme cau tion when expelling piston from cylinder 9Never attempt to pry out piston ...

Page 180: ...on seals and dust seals whenever a caliper is disassembled A Front B Rear EC5A4000 INSPECTION EC534112 Master cylinder 1 Inspect 9Master cylinder inner surface a Wear Scratches Replace master cylinder assembly Stains Clean w Use only new brake fluid A Front B Rear 2 Inspect 9Diaphragm 1 Crack Damage Replace A Front B Rear 3 Inspect 9Master cylinder piston 1 9Master cylinder cup 2 Wear Damage Score...

Page 181: ...ust seals 2 2 whenever a caliper is disassembled EC534301 Brake hose 1 Inspect 9Brake hose 1 Crack Damage Replace EC5A5000 ASSEMBLY AND INSTALLATION w 9All internal parts should be cleaned in new brake fluid only 9Internal parts should be lubricated with brake fluid when installed 9Replace the piston seals and dust seals whenever a caliper is disassembled EC5A5801 Caliper piston 1 Clean 9Caliper 9...

Page 182: ...ont B Rear 3 Install 9Caliper piston 1 NOTE Apply the brake fluid on the piston wall cC 9Install the piston with its shallow depressed side a a facing the caliper 9Never force to insert A Front B Rear EC5A5700 Front caliper 1 Install 9Pad support 1 9Brake pad 2 9Pad pin 3 NOTE 9Install the brake pads with their projections a into the caliper recesses b 9Temporarily tighten the pad pin at this poin...

Page 183: ...nstall 9Pad support 1 9Brake pad 2 9Pad pin 3 NOTE 9Install the brake pads with their projections a into the caliper recesses b 9Temporarily tighten the pad pin at this point 2 Install 9Copper washer 1 9Union bolt 2 w Always use new copper washers cC Install the brake hose so that its pipe por tion a a directs as shown and lightly touch es the projection b b on the caliper 30 Nm 3 0 m kg 22 ft lb ...

Page 184: ...0 Master cylinder kit 1 Clean 9Master cylinder 9Master cylinder kit Clean them with brake fluid 2 Install 9Master cylinder cup primary 1 9Master cylinder cup secondary 2 To master cylinder piston 3 NOTE Apply the brake fluid on the master cylinder cup w After installing cylinder cup should be in stalled as shown direction Wrong installa tion cause improper brake performance A Front B Rear 18 Nm 1 ...

Page 185: ...o master cylinder 5 NOTE 9Apply the brake fluid on the master cylinder kit 9Apply the lithium soap base grease on the tip of the push rod 9When installing the circlip use a long nose circlip pliers A Front B Rear EC5A5310 Front master cylinder 1 Install 9Master cylinder 1 9Master cylinder bracket 2 9Bolt master cylinder bracket 3 NOTE 9Install the bracket so that the arrow mark a face upward 9Firs...

Page 186: ... cylinder piston 6 Nm 0 6 m kg 4 3 ft lb 6 Nm 0 6 m kg 4 3 ft lb EC5A5401 Rear master cylinder 1 Install 9Copper washer 1 9Brake hose 2 9Union bolt 3 w Always use new copper washers cC Install the brake hose so that its pipe por tion a a directs as shown and lightly touch es the projection b b on the master cylinder 30 Nm 3 0 m kg 22 ft lb 2 Install 9Master cylinder 1 9Bolt master cylinder 2 10 Nm...

Page 187: ...ghtening the bolt brake hose holder align the top a of the brake hose neck with the brake hose holder bottom b Then pass the brake hose in front of the axle boss c and fit it into the hose groove d so that the brake hose does not contact the nut wheel axle 2 Install 9Hose cover 1 9Plain washer 2 9Bolt hose cover M8 3 9Bolt hose cover M6 4 10 Nm 1 0 m kg 7 2 ft lb 16 Nm 1 6 m kg 11 ft lb 7 Nm 0 7 m...

Page 188: ...Install the brake hose so that its pipe por tion a a directs as shown and lightly touch es the projection b b on the master cylinder 30 Nm 3 0 m kg 22 ft lb EC5A5502 Rear brake hose 1 Install 9Copper washer 1 9Brake hose 2 9Union bolt 3 w Always use new copper washers cC Install the brake hose so that its pipe por tion a a directs as shown and lightly touch es the projection b b on the caliper 30 ...

Page 189: ...ty brake fluid otherwise the rubber seals may deterio rate causing leakage and poor brake per formance 9Refill with the same type of brake fluid mixing fluids may result in a harmful chemi cal reaction and lead to poor performance 9Be careful that water does not enter the master cylinder when refilling Water will significantly lower the boiling point of the fluid and may result in vapor lock cC Br...

Page 190: ... 9Master cylinder cap 1 9Screw master cylinder cap 2 Rear 9Diaphragm 9Master cylinder cap 1 9Bolt master cylinder cap 2 cC After installation while pulling the lever in or pushing down on the pedal check whether there is any brake fluid leaking where the union bolts are installed respec tively at the master cylinder and caliper A Front B Rear 5 Install rear brake only 9Protector 1 9Bolt protector ...

Page 191: ...on Number plate 1 Protector 1 2 Brake hose holder 2 3 Pinch bolt handle crown 2 Only loosening 4 Cap bolt 1 Loosen when disassembling the front fork 5 Pinch bolt under bracket 2 Only loosening 6 Front fork 1 1 w Support the machine securely so there is no dan ger of it falling over Extent of removal 1 Front fork removal 4 Nm 0 4 m kg 2 9 ft lb 20 Nm 2 0 m kg 14 ft lb 10 Nm 1 0 m kg 7 2 ft lb 10 Nm...

Page 192: ... Refer to REMOVAL POINTS 5 Inner tube 1 6 Outer tube 1 7 Piston metal 1 8 Slide metal 1 9 Plain washer 1 0 Oil seal 1 q Spring guide 1 w Base valve 1 Use special tool e Damper rod 1 Refer to REMOVAL POINTS 1 Extent of removal 1 Oil seal removal 2 Damper rod removal 2 EC558000 FRONT FORK DISASSEMBLY 29 Nm 2 9 m kg 21 ft lb 1 Nm 0 1 m kg 0 7 ft lb 30 Nm 3 0 m kg 22 ft lb 55 Nm 5 5 m kg 40 ft lb ...

Page 193: ...material Use enough care not to allow any foreign material to come in when the oil is re placed or when the front fork is disassem bled and reassembled 9Before removing the cap bolts or front forks be sure to extract the air from the air chamber completely EC553000 REMOVAL POINTS EC553151 Cap bolt 1 Remove 9Cap bolt 1 From the outer tube NOTE Before removing the front fork from the machine loosen ...

Page 194: ... 1 Bend Damage Replace damper rod cC The front fork with a built in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign ma terial Use enough care not to allow any foreign material to come in when the oil is re placed or when the front fork is disassem bled and reassembled Oil seal removal steps 9Push in slowly a the inner tube just be fore it bottoms ...

Page 195: ...place Use 1 000 grit wet sandpaper Damaged oil lock piece Replace 9Inner tube bends Out of specification Replace Use the dial gauge 1 NOTE The bending value is shown by one half of the dial gauge reading w Do not attempt to straighten a bent inner tube as this may dangerously weaken the tube EC554600 Outer tube 1 Inspect 9Outer tube 1 Score marks Wear Damage Replace Standard Limit 460 mm 455 mm 18...

Page 196: ...To inner tube 2 cC To install the damper rod into the inner tube hold the inner tube aslant If the inner tube is held vertically the damper rod may fall into it damaging the valve inside 3 Install 9Copper washer 1 9O ring 2 9Base valve 3 To inner tube 4 4 Tighten 9Base valve 1 NOTE 9Use a damper rod holder 2 to lock the damper rod 3 9Apply the LOCTITE on the base valve thread Damper rod holder YM ...

Page 197: ...t seal 1 9Stopper ring 2 9Oil seal 3 9Plain washer 4 9Slide metal 5 To inner tube 6 NOTE 9Apply the fork oil on the inner tube 9When installing the oil seal use vinyl seat a with fork oil applied to protect the oil seal lip 9Install the oil seal with its manufacture s marks or number facing the axle holder side 7 Install 9Piston metal 1 NOTE Install the piston metal onto the slot on inner tube 8 I...

Page 198: ...er 3 10 Install 9Oil seal 1 NOTE Press the oil seal into the outer tube with fork seal driver 2 11 Install 9Stopper ring 1 NOTE Fit the stopper ring correctly in the groove in the outer tube 12 Install 9Dust seal 1 NOTE Apply the lithium soap base grease on the inner tube Fork seal driver YM 01442 90890 01442 Fork seal driver YM 01442 90890 01442 ...

Page 199: ...rformance 9Never allow foreign materials to enter the front fork 16 After filling pump the damper rod 1 slowly up and down more than 10 times to distrib ute the fork oil 17 Fill 9Front fork oil Until outer tube top surface with recom mended fork oil once more 18 After filling pump the outer tube 1 slowly up and down about 200 mm 7 9 in stroke to distribute the fork oil once more NOTE Be careful no...

Page 200: ... with the fork oil up to the top of the outer tube and bleed the front forks 20 Measure 9Oil level left and right a Out of specification Adjust NOTE Be sure to install the spring guide 2 when checking the oil level w Never fail to make the oil level adjustment between the maximum and minimum level and always adjust each front fork to the same setting Uneven adjustment can cause poor handling and l...

Page 201: ...ed up 9Install the fork spring with its smaller pitch end facing the cap bolt For EUROPE 9After installing the fork spring hold the damper rod end so that it will not go down 25 Install 9Cap bolt 1 Fully tighten the cap bolt onto the damper rod by hand 22 Loosen 9Rebound damping adjuster 1 NOTE 9Loosen the rebound damping adjuster finger tight 9Record the set position of the adjuster the amount of...

Page 202: ...g set the thin type spanners 2 between the spacer 3 and spring guide 4 9Hold the locknut 5 and tighten the cap bolt with specified torque 27 Install 9Cap bolt 1 To outer tube NOTE Temporarily tighten the cap bolt 28 Install 9Protector guide 1 EC5552A1 Installation 1 Install 9Front fork 1 NOTE 9Temporarily tighten the pinch bolts under bracket 9Do not tighten the pinch bolts handle crown yet 29 Nm ...

Page 203: ...er 3 NOTE Fit the brake hose holder cut a over the projec tion b on the front fork and clamp the brake hose 6 Install 9Brake hose holder 1 9Bolt brake hose holder 2 9Protector 3 9Bolt protector 4 NOTE When installing the brake hose holder align the top a of the brake hose neck with the brake hose holder bottom b Then pass the brake hose 5 in front of the axle boss c and fit it into the hose groove...

Page 204: ... 1 Refer to REMOVAL POINTS 5 Throttle cable cap 1 Turn over the cap cover 6 Throttle cable 1 Disconnect at the throttle side 7 Throttle 1 Loosen the bolts 8 Cap cover 1 9 Collar 1 10 Grip left 1 Refer to REMOVAL POINTS 11 Handlebar holder upper 2 12 Handlebar 1 1 Extent of removal 1 Handlebar removal EC5B0000 HANDLEBAR 1 Nm 0 1 m kg 0 7 ft lb 4 Nm 0 4 m kg 2 9 ft lb 9 Nm 0 9 m kg 6 5 ft lb 28 Nm 2...

Page 205: ...le disassembly Extent of removal Order Part name Q ty Remarks THROTTLE DISASSEMBLY 1 Grip cap lower 1 2 Grip cap upper 1 3 Grip assembly 1 4 Grip right 1 Refer to REMOVAL POINTS 5 Tube guide 1 1 EC5B8000 THROTTLE DISASSEMBLY 4 Nm 0 4 m kg 2 9 ft lb ...

Page 206: ...the grip Then remove the grip which has become loose EC5B4000 INSPECTION EC5B4100 Handlebar 1 Inspect 9Handlebar 1 Bends Cracks Damage Replace w Do not attempt to straighten a bent handlebar as this may dangerously weaken the handlebar EC5B5000 ASSEMBLY AND INSTALLATION EC5B5100 Throttle assembly 1 Install 9Grip right 1 Apply the adhesive on the tube guide 2 NOTE 9Before applying the adhesive wipe...

Page 207: ...der and then tighten the bolts on the rear side 2 Install 9Grip left 1 Apply the adhesive to the handlebar 2 NOTE 9Before applying the adhesive wipe off grease or oil on the handlebar surface a with a lac quer thinner 9Install the grip left to the handlebar so that the line b between the two arrow marks faces straight upward 3 Install 9Collar 1 9Cap cover 2 9Throttle 3 NOTE 9Apply the lithium soap...

Page 208: ...throttle cable in the groove b in the roller 6 Install 9Throttle cable cap 1 9Screw throttle cable cap 2 7 Adjust 9Throttle grip free play Refer to THROTTLE CABLE ADJUST MENT section in the CHAPTER 3 8 Install 9Cap cover 1 9 Install 9Master cylinder 1 9Master cylinder bracket 2 9Bolt master cylinder bracket 3 NOTE 9Install the bracket so that the arrow mark a faces upward 9First tighten the bolt o...

Page 209: ... smoothly If it does not retighten the bolts for adjustment 11 Install 9 ENGINE STOP button 1 9Clutch lever holder 2 9Bolt clutch lever holder 3 9Clamp 4 NOTE 9The ENGINE STOP button clutch lever hold er and clamp should be installed according to the dimensions shown 9Pass the ENGINE STOP button lead in the middle of the clutch holder 12 Install 9Clutch cable 1 NOTE Apply the lithium soap base gre...

Page 210: ...5 45 CHAS HANDLEBAR 14 Clamp the clamp portion a of the number plate to the handlebar 15 Insert the end of the fuel breather hose 1 into the hole of the number plate ...

Page 211: ...ng nut 1 Use special tool Refer to REMOVAL POINTS 5 Under bracket 1 6 Ball race cover 1 7 Bearing upper 1 8 Bearing lower 1 Refer to REMOVAL POINTS 9 Ball race 2 Refer to REMOVAL POINTS Extent of removal 1 Under bracket removal 2 Bearing removal 2 1 w Support the machine securely so there is no dan ger of it falling over 23 Nm 2 3 m kg 17 ft lb 145 Nm 14 5 m kg 105 ft lb 9 Tighten ring nut 38 Nm 3...

Page 212: ...fall down EC563300 Bearing lower 1 Remove 9Bearing lower 1 Use the floor chisel 2 cC Take care not to damage the steering shaft thread EC563400 Ball race 1 Remove 9Ball race 1 Remove the ball race using long rod 2 and the hammer EC564000 INSPECTION EC564200 Steering shaft 1 Inspect 9Steering shaft 1 Bend Damage Replace Ring nut wrench YU 33975 90890 01403 ...

Page 213: ...eration in the ball races replace bearings and ball races as a set EC565000 ASSEMBLY AND INSTALLATION EC565113 Under bracket 1 Install 9Bearing lower 1 NOTE Apply the lithium soap base grease on the dust seal lip and bearing inner circumference 2 Install 9Ball race 9Bearing upper 1 9Ball race cover 2 NOTE Apply the lithium soap base grease on the bear ing and ball race cover lip 3 Install 9Under b...

Page 214: ...ing shaft by turning it lock to lock If there is any binding remove the steering shaft assembly and inspect the steering bearings 6 Install 9Plain washer 1 7 Install 9Front fork 1 9Handle crown 2 NOTE 9Temporarily tighten the pinch bolts under bracket 9Do not tighten the pinch bolts handle crown yet 8 Install 9Plain washer 1 9Steering shaft nut 2 7 Nm 0 7 m kg 5 1 ft lb 145 Nm 14 5 m kg 105 ft lb ...

Page 215: ...ring nut little by little 10 Adjust 9Front fork top end a 11 Tighten 9Pinch bolt handle crown 1 9Pinch bolt under bracket 2 cC Tighten the under bracket to specified torque If torqued too much it may cause the front fork to malfunction Front fork top end standard a a Zero mm Zero in 23 Nm 2 3 m kg 17 ft lb 20 Nm 2 0 m kg 14 ft lb ...

Page 216: ...ke pedal Shift the brake pedal backward Drive chain 1 Chain support 1 2 Chain tensioner lower 1 3 Bolt rear shock absorber relay arm 1 Hold the swingarm 4 Bolt connecting rod 1 5 Pivot shaft 1 6 Swingarm 1 EC570000 SWINGARM Extent of removal 1 Swingarm removal 1 w Support the machine securely so there is no dan ger of it falling over 53 Nm 5 3 m kg 38 ft lb 80 Nm 8 0 m kg 58 ft lb 19 Nm 1 9 m kg 1...

Page 217: ... Oil seal 2 6 Thrust bearing 2 7 Bush 2 8 Oil seal 8 9 Bearing 8 Refer to REMOVAL POINTS Extent of removal 1 Swingarm disassembly 2 Connecting rod removal and disassembly 3 Relay arm removal and disassembly 1 2 3 2 3 EC578000 SWINGARM DISASSEMBLY 80 Nm 8 0 m kg 58 ft lb 6 Nm 0 6 m kg 4 3 ft lb 80 Nm 8 0 m kg 58 ft lb 2 Nm 0 2 m kg 1 4 ft lb ...

Page 218: ...Replace EC574211 Relay arm 1 Inspect 9Bearing polylube bearing 1 9Collar 2 Free play exists Unsmooth revolution Rust Replace bearing and collar as a set 2 Inspect 9Bearing polylube bearing 1 Loss of solid lubrication Replace 9Oil seal 3 Damage Replace NOTE Polylube bearings with solid lubrication have been adopted with the intent to make the needle bearings used in this model maintenance free With...

Page 219: ... Outer a a Zero mm Zero in Inner b b 8 5 mm 0 33 in EC574311 Connecting rod 1 Inspect 9Bearing polylube bearing 1 9Collar 2 Free play exists Unsmooth revolution Rust Replace bearing and collar as a set 2 Inspect 9Bearing polylube bearing 1 Loss of solid lubrication Replace 9Oil seal 3 Damage Replace NOTE Polylube bearings with solid lubrication have been adopted with the intent to make the needle ...

Page 220: ...nstall 9Bearing 1 9Oil seal 2 To connecting rod NOTE 9Apply the molybdenum disulfide grease on the bearing when installing 9Install the bearing by pressing it on the side hav ing the manufacture s marks or numbers Installed depth of bearings a a 5 mm 0 20 in 2 Install 9Bearing 1 9Oil seal 2 To relay arm NOTE 9Apply the molybdenum disulfide grease on the bearing when installing 9Install the bearing...

Page 221: ...2 NOTE 9Apply the molybdenum disulfide grease on the pivot shaft 9Insert the pivot shaft from right side 85 Nm 8 5 m kg 61 ft lb 4 Install 9Connecting rod 1 9Bolt connecting rod 2 9Plain washer 3 9Nut connecting rod 4 To relay arm 5 NOTE Apply the molybdenum disulfide grease on the bolt 80 Nm 8 0 m kg 58 ft lb 3 Install 9Collar 1 To connecting rod 2 NOTE Apply the molybdenum disulfide grease on th...

Page 222: ...olybdenum disulfide grease on the bolt 9Do not tighten the nut yet 9 Install 9Bolt rear shock absorber relay arm 1 9Nut rear shock absorber relay arm 2 NOTE Apply the molybdenum disulfide grease on the bolt 53 Nm 5 3 m kg 38 ft lb 7 Check 9Swingarm side play a Free play exists Replace thrust bearing 9Swingarm up and down movement b Unsmooth movement Binding Rough spots Grease or replace bearings b...

Page 223: ... chain tensioner lower 5 14 Install 9Chain support 1 9Support cover 2 9Bolt chain support R 50mm 1 97in 3 9Nut chain support 4 9Bolt support cover R 10mm 0 39in 5 7 Nm 0 7 m kg 5 1 ft lb 7 Nm 0 7 m kg 5 1 ft lb 19 Nm 1 9 m kg 13 ft lb 12 Install 9Cap 1 NOTE Install the cap right with its mark a facing for ward ...

Page 224: ...int 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 7 Adjuster 1 8 Spring guide lower 1 9 Spring guide upper 1 10 Spring rear shock absorber 1 11 Bearing 2 Refer to REMOVAL POINTS 2 w Support the machine securely so there is no dan ger of it falling over Extent of removal 1 Rear shock absorber removal 2 ...

Page 225: ...gas expansion and or damage to the hose 3 Be careful not to damage any part of the gas tank A damaged gas tank will impair the damping performance or cause a malfunction 4 Take care not to scratch the contact sur face of the piston rod with the cylinder or oil could leak out 5 Never attempt to remove the plug at the bottom of the nitrogen gas tank It is very dangerous to remove the plug 6 When scr...

Page 226: ...ce EC584000 INSPECTION EC584110 Rear shock absorber 1 Inspect 9Damper rod 1 Bends Damage Replace absorber assembly 9Shock absorber 2 Oil leaks Replace absorber assembly Gas leaks Replace absorber assembly 9Spring 3 Damage Replace spring Fatigue Replace spring Move spring up and down 9Spring guide 4 Wear Damage Replace spring guide 9Bearing 5 Free play exists Unsmooth revolution Rust Replace 3 Remo...

Page 227: ...roove appears by pressing its outer race cC Do not apply the grease on the bearing outer race because it will wear the rear shock absorber surface on which the bear ing is press fitted 2 Install 9Stopper ring upper bearing 1 NOTE After installing the stopper ring push back the bearing until it contacts the stopper ring 3 Install 9Lower bearing 1 NOTE Install the bearing by pressing it on the side ...

Page 228: ...the bearing 9Apply the lithium soap base grease on the bush collars and dust seals 9Install the dust seals with their lips facing out ward 3 Adjust 9Spring length installed a For EUROPE NOTE The length of the spring installed changes 1 5 mm 0 06 in per turn of the adjuster cC Never attempt to turn the adjuster beyond the maximum or minimum setting 4 Tighten 9Locknut 1 Spring length installed a a S...

Page 229: ...fide grease on the bolt 5 Install 9Bolt rear shock absorber relay arm 1 9Nut rear shock absorber relay arm 2 NOTE Apply the molybdenum disulfide grease on the bolt 6 Install 9Rear frame 1 9Bolt rear frame upper 2 9Bolt rear frame lower 3 7 Tighten 9Screw air cleaner joint 1 56 Nm 5 6 m kg 40 ft lb 53 Nm 5 3 m kg 38 ft lb 29 Nm 2 9 m kg 21 ft lb 32 Nm 3 2 m kg 23 ft lb ...

Page 230: ...or 5 Solenoid valve 6 CDI magneto 7 Spark plug EC612000 WIRING DIAGRAM COLOR CODE B Black L Blue O Orange R Red Y Yellow B L Black Blue B R Black Red B W Black White G L Green Blue G W Green White W L White Blue W R White Red L Y B L Y L B L Y L L Y B B W B B W B R B B R R R R R B B R G L G W W R W L W L B R G L W R B G W G L B R W L G W B W R O B G W G L Y B L L W R W L B R B R B W O G L B L L W ...

Page 231: ...ion system for connection Spark gap test No good No good No good No good No good No good No Spark Check ENGINE STOP button Pick up coil Source coil Check ignition coil Check CDI magneto Replace CDI unit Replace Replace Replace Replace Replace marked Only when the ignition checker is used NOTE 9Remove the following parts before inspection 1 Seat 2 Fuel tank 9Use the following special tools in this ...

Page 232: ...and increase spark gap until misfire occurs for USA and CDN only EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1 Check 9Couplers and leads connection Rust Dust Looseness Short circuit Repair or replace EC625002 ENGINE STOP BUTTON INSPECTION 1 Inspect 9 ENGINE STOP button conduct Not continuous while being pushed Replace Continuous while being freed Replace Minimum spark gap 6 0 mm 0 24 in Test...

Page 233: ...ve the spark plug cap by turning it coun terclockwise and inspect 9Install the spark plug cap by turning it clock wise until it is tight Tester lead Orange lead 1 Tester lead Black lead 2 Tester lead Spark plug lead 1 Tester lead Orange lead 2 Primary coil Tester selector resistance position 0 20 0 30Ω at Ω 1 20 C 68 F Secondary coil Tester selector resistance position 9 5 14 3kΩ at kΩ 1 20 C 68 F...

Page 234: ...oose connection Tighten Deteriorated Damaged Replace 9Spark plug cap resistance Out of specification Replace Tester lead Spark plug lead terminal 1 Tester lead Spark plug terminal 2 Spark plug cap Tester selector resistance position 4 6kΩ at kΩ 1 20 C 68 F EC627011 CDI MAGNETO INSPECTION 1 Inspect 9Pick up coil resistance Out of specification Replace Tester lead White Red lead 1 Tester lead White ...

Page 235: ...lace EC628000 CDI UNIT INSPECTION Check all electrical components If no fault is found replace the CDI unit Then check the electrical components again Tester lead Green Blue lead 1 Tester lead Green White lead 2 Source coil 2 Tester selector resistance position 44 66Ω at Ω 10 20 C 68 F ...

Page 236: ...ood Replace Check CDI magneto Replace CDI unit No good EC650001 SOLENOID VALVE SYSTEM EC651032 INSPECTION STEPS If the solenoid valve will not operate use the following inspection steps marked Refer to IGNITION SYSTEM section NOTE 9Remove the following parts before inspection 1 Seat 2 Fuel tank 9Use l2V battery in this inspection 9Use the following special tools in this inspection Pocket tester YU...

Page 237: ...e coupler 2 Connect 12V battery to the solenoid valve coupler 3 Inspectt 9Solenoid valve 1 No click when connecting the battery Replace EC653002 SOLENOID VALVE COIL INSPECTION 1 Inspect 9Solenoid valve coil resistance Out of specification Replace R 1 2 1 2 R R 1 2 1 2 R Tester lead Red lead 1 Tester lead Red lead 2 22 8 27 8Ω at 20 C 68 F Solenoid resistance Tester selector position Ω 10 Battery l...

Page 238: ... Replace Check CDI unit No good EC690000 TPS THROTTLE POSITION SENSOR SYSTEM EC691001 INSPECTION STEPS If the TPS will not operate use the following inspection steps marked Refer to IGNITION SYSTEM section NOTE 9Remove the following parts before inspection 1 Seat 2 Fuel tank 9Use the following special tools in this inspection Inductive tachometer YU 8036 B Engine tachometer 90890 03113 Pocket test...

Page 239: ...ixing chamber top Refer to CARBURETOR AND REED VALVE section in the CHAPTER 4 2 Inspect 9TPS coil resistance Out of specification Replace Tester lead Blue lead 1 Tester lead Black lead 2 TPS coil Tester selector resistance position 4 6kΩ at kΩ 1 20 C 68 F EC69A000 HANDLING NOTE cC Do not loosen the screws TPS throttle position sensor except when changing the TPS throttle position sensor due to fai...

Page 240: ...of specification Replace Tester lead Yellow lead 2 Tester lead Black lead 3 Tester selector position Full closed Full opened Zero 2kΩ at 4 6kΩ at 20 C 68 F 20 C 68 F kΩ 1 EC693001 TPS REPLACEMENT AND ADJUSTMENT 1 Remove 9Carburetor 9Mixing chamber top Refer to CARBURETOR AND REED VALVE section in the CHAPTER 4 2 Remove 9Screw TPS 1 9TPS 2 NOTE Loosen the screws using the T25 bit 3 Replace 9TPS TPS...

Page 241: ... Adjustment steps 9Set the inductive tachometer engine tachometer to the high tension cord 9Turn the throttle stop screw 1 until the specified idle speed Refer to IDLE SPEED ADJUSTMENT sec tion in the CHAPTER 3 7 Insert the thin electric conductors 2 lead wire into the TPS coupler 1 as shown and connect the tester to them cC 9Do not insert the electric conductors more than required because it may ...

Page 242: ... 1 NOTE Tighten the screws TPS using the T20 bit tam per resistant fastener type by aligning the marks a that were put before removal 14 Install 9Carburetor Refer to CARBURETOR AND REED VALVE section in the CHAPTER 4 8 Start the engine 9 Adjust 9TPS output voltage Adjustment steps Adjust the installation angle of the TPS 1 to obtain the specified output volt age TPS output Tester selector voltage ...

Page 243: ...C694000 TPS INPUT VOLTAGE INSPECTION 1 Disconnect the TPS coupler 2 Start the engine 3 Inspect 9TPS input voltage Out of specification Replace the CDI unit Tester lead Blue lead 1 Tester lead Black Blue lead 2 TPS input Tester selector voltage position 4 6V DCV 20 ...

Page 244: ...st be properly suited to the atmos pheric conditions air pressure humidity and temperature 9Finally the rider himself must make a test run and check his machine for conditions pick up of engine speed road surface conditions and for the discoloration of the spark plug s After taking these into consideration he must select the best possible carburetor settings It is advisable to make a note of setti...

Page 245: ...ity of the air EC713001 Test run After warming up the engine equipped with the standard type carburetor s and spark plug s run two or three laps of the circuit and check the smooth operation of the engine and discoloration of spark plug s å Normal Over burned too lean ç Oil fouled too rich Discoloration Condition of spark plug Normal Insulator is dry and burnt brown Over burned Insulator is whitis...

Page 246: ...r calibrating No than standard To be enriched 2 Spark plug is wet Select a main jet having lower calibrating No than standard To be leaned out Standard main jet 178 180 EC71V000 Power jet adjustment The richness of air fuel mixture under 8 500 rpm 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 ...

Page 247: ...peration and poor acceleration will result Whether or not the richness of the mixture is proper is hard to be determined by means of the spark plug and therefore it should be judged from your feeling of actual engine operation For EUROPE Standard pilot jet 50 52 EC716001 Pilot air screw adjustment The richness of air fuel mixture with full closed to 1 8 throttle can be set by turning the pilot air...

Page 248: ...ick up speed smoothly In this case step up the jet needle clip by one groove and move down the needle to lean out the mixture 2 Too lean at intermediate speeds The engine breathes hard and will not pick up speed quickly Step up the jet needle clip by one groove and move up the needle to enrich the mix ture ...

Page 249: ...starting position c Rich d Lean 2 Effects of changing the jet needle reference 9 Diameter of straight portion Changing the diameter of the straight por tion adjusts the air fuel mixture when the throttle is 1 8 to 1 4 open 9 Taper starting position Difference of 0 5 groove Rich N3EJ 3rd groove N3CJ 3rd groove N3EJ 2nd groove N3CJ 2nd groove Lean N3EJ 1st groove Changing the taper starting position...

Page 250: ... position c Rich d Lean 2 Effects of changing the jet needle reference 9 Diameter of straight portion Changing the diameter of the straight por tion adjusts the air fuel mixture when the throttle is 1 8 to 1 4 open 9 Taper starting position Difference of 0 5 groove Rich N3EW 4th groove N3CW 4th groove N3EW 3rd groove N3CW 3rd groove Lean N3EW 2nd groove Changing the taper starting position pro duc...

Page 251: ...ottle opening whereas around 1 4 to 1 1 throttle opening it relates to the taper starting position and to the clip position Therefore the fuel flow is balanced at each stage of throttle opening by the combination of the jet needle straight portion diameter taper starting position and clip position Example For USA CDN ZA AUS and NZ N3EJ 2nd groove N3EJ 3rd groove N3EK 2nd groove N8RJ 2nd groove For...

Page 252: ...48 10 55 4MX 14948 09 STD 52 4MX 14948 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 3 Rich N8RW 4SR 14916 RW N3EW 4SR 14916 EW N8RJ 4SR 14916 RJ STD N3EJ 4SR 14916 EJ N3CJ 4SR 14916 CJ N3EK 4SR 14916 EK Lean N3CK 4SR 14916 CK Jet needle 3 3 Rich N8RH 4SR 14916 RH N3EH 4SR 14916 EH N8RW 4SR 14916 RW STD N3EW 4SR 14916 EW N3...

Page 253: ...le clip position Hard breathing 1 groove down Lack of speed 1 4 1 2 throttle Raise jet needle clip position Clip position indicates the position of Slow speed pick up 1 groove up jet needle groove to which the clip is White smoke fitted The position is numbered from Poor acceleration the top Leaner Standard Richer EC71C030 Road condition and examples of carburetor setting Conditions General condit...

Page 254: ...t needle clip position range of low to If no effect reverse the above intermediate speeds procedures Poor response when Check overall settings Check air cleaner for fouling throttle is opened quickly Use main jet having lower calibration No Raise jet needle clip position 1 groove up If no effect reverse the above procedures Poor engine operation Turn in pilot air screw Check throttle valve operati...

Page 255: ... 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 NOTE 9When checking the discoloration of spark plugs be sure to stop the engine immediately after a run and check 9Avoid racing 9When changing the heat range of spark plugs never attempt to change it more than 1 rank 9When using a spark plug other than standard che...

Page 256: ...he entire course and some settings may be sacrificed Thus the settings should be matched to the portion of the course that has the greatest effect on the race result In such a case run through the entire course while mak ing notes of lap times to find the best balance then determine the secondary reduction ratio 9If a course has a long straight portion where a machine can run at maximum speed the ...

Page 257: ...surface 9Under a stony or hard road condition the tire pressure should be higher to prevent a flat tire Part name Size Part number Drive sprocket 1 1 13T 9383E 13144 STD 14T 9383E 14215 Driven sprocket 2 2 47T 5ET 25447 00 48T 5NY 25448 00 STD 49T 5NY 25449 00 STD 50T 5NY 25450 00 51T 5NY 25451 00 52T 5NY 25452 00 Standard tire pressure 100 kPa 1 0 kgf cm2 15 psi Extent of adjustment 60 80 kPa 0 6...

Page 258: ...ng characteristic near the final stroke can be changed by changing the fork oil amount cC Adjust the oil level in 5 mm 0 2 in incre ments or decrements Too low oil level causes the front fork to produce a noise at full rebound or the rider to feel some pres sure on his hands or body Alternatively too high oil level will develop unexpectedly early oil lock with the consequent shorter front fork tra...

Page 259: ...adjustment washers EC72A001 Setting of spring after replacement As the front fork setting can be easily affected by rear suspension take care so that the machine front and rear are balanced in position etc when setting the front fork 1 Use of soft spring Generally a soft spring gives a soft riding feeling Rebound damping tends to become stronger and the front fork may sink deeply over a series of ...

Page 260: ...s to become weaker resulting in lack of a sense of con tact with the road surface or in a vibrating handlebar To set a stiff spring 9Change the rebound damping Turn in one or two clicks 9Change the compression damping Turn out one or two clicks å Coverage of spring by weight Rider weight 1 Soft 2 Standard 3 Stiff ...

Page 261: ... proved on the end of the spring SPRING SPRING I D TYPE RATE PART NUMBER MARK slits 0 380 4SS 23141 10 I I 0 390 4SS 23141 20 I II SOFT 0 400 4SS 23141 30 I III 0 410 4SS 23141 40 I 0 420 4SS 23141 50 II STD 0 430 4XL 23141 L0 STIFF 0 440 4SS 23141 70 IIII TYPE thickness PART NUMBER T 2 3 mm 0 09 in 4SS 23364 L0 SPRING SPRING I D TYPE RATE PART NUMBER MARK approx slits 0 400 5ET 23141 20 V SOFT 0 ...

Page 262: ...ression damping EC72C001 Choosing set length 1 Place a stand or block under the engine to put the rear wheel above the floor and mea sure the length a between the rear wheel axle center 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 holding bolt 3 Loose...

Page 263: ...et length sunken length 90 100 mm 3 5 3 9 in and set it 1 Use of soft spring 9Set the soft spring for less rebound damp ing to compensate for its less spring load Run with the rebound damping adjuster one or two clicks on the softer side and readjust it to suit your preference 2 Use of stiff spring 9Set the soft spring for more rebound damp ing to compensate for its greater spring load Run with th...

Page 264: ...se the one whose overall length a a does not exceed the standard as it may result in faulty performance Never use one whose overall length is greater than standard å Coverage of spring by weight Rider weight 1 Soft 2 Standard 3 Stiff Length a a of standard shock 490 5 mm 19 31 in ...

Page 265: ...wn 1 260 SOFT 4 5 5UN 22212 10 Green 1 260 4 7 5UN 22212 20 Red 1 260 STD 4 9 5UN 22212 30 Black 1 260 5 1 5UN 22212 40 Blue 1 260 STIFF 5 3 5UN 22212 50 Yellow 1 260 5 5 5UN 22212 60 Pink 1 260 5 7 5UN 22212 70 White 1 260 SPRING SPRING I D SPRING TYPE RATE PART NUMBER COLOR FREE approx POINT LENGTH SOFT 4 5 5UN 22212 A0 Green 2 275 4 7 5UN 22212 B0 Red 2 275 STD 4 9 5UN 22212 C0 Black 2 275 5 1 ...

Page 266: ...about 2 clicks to in Soft over entire crease damping range bottoming 1 1 Oil level oil amount Increase oil level by about 5 10 mm 0 2 0 4 out in Spring Replace with stiff spring Stiff toward stroke 1 Oil level oil amount Decrease oil level by about 5 mm 0 2 in end Soft toward stroke 1 Oil level oil amount Increase oil level by about 5 mm 0 2 in end bottoming out Stiff initial 1 1 1 1 Compression d...

Page 267: ...nd Rebound damping Turn adjuster counterclockwise about 2 clicks dragging 1 1 to decrease damping Spring Replace with soft spring Rebound damping Turn adjuster counterclockwise about 2 clicks to decrease damping Low compression Turn adjuster clockwise about 1 click to in damping crease damping Poor road gripping 1 High compression Turn adjuster clockwise about 1 6 turn to damping increase damping ...

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Page 270: ...PRINTED IN JAPAN 2002 5 1 7 1 E F G H YAMAHA MOTOR CO LTD 2500 SHINGAI IWATA SHIZUOKA JAPAN PRINTED ON RECYCLED PAPER YZ250 R LC ...

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