1. DL manuals
  2. Yamaha
  3. Motorcycle
  4. 2010 YZ250F
  5. Owner's Service Manual

Yamaha 2010 YZ250F Owner's Service Manual

Other manuals for 2010 YZ250F: Owner's Service Manual

Summary of 2010 YZ250F

  • Page 1

    5xc-28199-34 yz250f(x) owner’s service manual manuel d’atelier du proprietaire fahrer- und wartungshandbuch manuale di servizio del proprietario printed in japan 2007.05-3.1 × 1 cr (e,f,g,h) yz250f(x) printed on recycled paper yamaha motor co., ltd. 2500 shingai iwata shizuoka japan 2008 2008.

  • Page 3: Yz250F(X)

    Yz250f(x) 5xc-28199-34-e0 2008 owner’s service manual.

  • Page 5

    Yz250f(x) owner's service manual ©2007 by yamaha motor co., ltd. 1st edition, april 2007 all rights reserved.Any reprinting or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited. Printed in japan.

  • Page 6

    Foreward introduction congratulations on your purchase of a yamaha yz series. This model is the culmination of yamaha's vast ex- perience in the production of paceset- ting racing machines. It represents the highest grade of craftsmanship and reliability that have made yama- ha a leader. This manual...

  • Page 7

    To the new owner this manual will provide you with a good basic understanding of fea- tures, operation, and basic mainte- nance and inspection items of this machine. Please read this manual carefully and completely before oper- ating your new machine. If you have any questions regarding the opera- t...

  • Page 8

    How to read descriptions to help identify parts and clarify pro- cedure steps, there are exploded dia- grams at the start of each removal and disassembly section. 1. An easy-to-see exploded diagram "1" is provided for removal and disassembly jobs. 2. Numbers "2" are given in the or- der of the jobs ...

  • Page 9: Table of Contents

    Table of contents general information 1 specifications 2 regular inspection and adjustments 3 engine 4 chassis 5 electrical 6 tuning 7.

  • Page 10

    Contents chapter 1 general infor- mation description ................. 1-1 machine identification ............. 1-2 included parts .......... 1-2 important information................. 1-2 checking of connection.................. 1-3 special tools ............. 1-4 control functions .. 1-8 starting ...

  • Page 11

    1-1 description general information description • the machine you have purchased may differ slightly from those shown in the following. • designs and specifications are subject to change without notice. 1. Clutch lever 2. Hot starter lever 3. Front brake lever 4. Throttle grip 5. Radiator cap 6. Fue...

  • Page 12

    1-2 machine identification machine identification there are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your yamaha dealer for positive identification of the model you own. 2. If your machine is stolen, the au- thorities w...

  • Page 13

    1-3 checking of connection 4. During the machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled. 5. Keep away from fire. All replacement parts 1. We recommend to use yamaha ge...

  • Page 14

    1-4 special tools special tools the proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by c...

  • Page 15

    1-5 special tools radiator cap tester yu-24460-01, 90890-01325 radiator cap tester adapter yu-33984, 90890-01352 these tools are used for checking the cooling system. Steering nut wrench yu-33975, 90890-01403 this tool is used when tighten the steering ring nut to specification. Cap bolt wrench ym-0...

  • Page 16

    1-6 special tools timing light ym-33277-a, 90890-03141 this tool is necessary for checking ignition timing. Valve spring compressor ym-4019, 90890-04019 this tool is needed to remove and install the valve assemblies. Clutch holding tool ym-91042, 90890-04086 this tool is used to hold the clutch when...

  • Page 17

    1-7 special tools dynamic spark tester ym-34487 ignition checker 90890-06754 this instrument is necessary for checking the ignition system compo- nents. Yamaha bond no. 1215 (threeb- ond ® no. 1215) 90890-85505 this sealant (bond) is used for crankcase mating surface, etc. Tool name/part number how ...

  • Page 18

    1-8 control functions control functions engine stop switch the engine stop switch "1" is located on the left handlebar. Continue push- ing the engine stop switch till the en- gine comes to a stop. Clutch lever the clutch lever "1" is located on the left handlebar; it disengages or en- gages the clut...

  • Page 19

    1-9 starting and break-in if knocking or pinging occurs, use a different brand of gasoline or higher octane grade. • for refueling, be sure to stop the engine and use enough care not to spill any fuel. Also be sure to avoid refueling close to a fire. • refuel after the engine, exhaust pipe, etc. Hav...

  • Page 20

    1-10 starting and break-in break-in procedures 1. Before starting the engine, fill the fuel tank with the fuel. 2. Perform the pre-operation checks on the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the engine stop switch. Then, re- sta...

  • Page 21

    1-11 torque-check points torque-check points concerning the tightening torque, refer to "tightening torques" section in the chapter 2. Frame construction frame to rear frame combined seat and fuel tank fuel tank to frame exhaust system silencer to rear frame engine mounting frame to engine engine br...

  • Page 22

    1-12 cleaning and storage cleaning and storage cleaning frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and ex- tend the life of many components. 1. Before washing the machine, block off the end of the exhaust pipe to prevent water from enter- ing. A...

  • Page 23

    2-1 general specifications specifications general specifications model name: yz250fx (usa, cdn, aus, nz) yz250f (europe, za) model code number: 5xcl (usa,cdn) 5xcm (europe) 5xcp (aus, nz, za) dimensions: usa, cdn, za, aus, nz europe overall length 2,162 mm (85.12 in) 2,165 mm (85.24 in) overall widt...

  • Page 24

    2-2 general specifications fuel: type premium unleaded gasoline only with a research octane number of 95 or higher. Tank capacity 7.0 l (1.54 imp gal, 1.85 us gal) carburetor: type fcr-mx37 manufacturer keihin spark plug: type/manufacturer cr8e/ngk (resistance type) gap 0.7–0.8 mm (0.028–0.031 in) c...

  • Page 25

    2-3 maintenance specifications maintenance specifications engine rear wheel travel 306 mm (12.0 in) electrical: ignition system cdi magneto item standard limit cylinder head: warp limit ---- 0.05 mm (0.002 in) cylinder: bore size 77.00–77.01 mm (3.0315–3.0319 in) ---- out of round limit ---- 0.05 mm...

  • Page 26

    2-4 maintenance specifications valve, valve seat, valve guide: valve clearance (cold) in 0.10–0.15 mm (0.0039–0.0059 in) ---- ex 0.17–0.22 mm (0.0067–0.0087 in) ---- valve dimensions: "a" head diameter (in) 22.9–23.1 mm (0.9016–0.9094 in) ---- "a" head diameter (ex) 24.4–24.6 mm (0.9606–0.9685 in) -...

  • Page 27

    2-5 maintenance specifications stem runout limit ---- 0.01 mm (0.0004 in) valve seat width (in) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630 in) valve seat width (ex) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630 in) valve spring: free length (in) 37.81 mm (1.49 in) 36.81 mm (1.45 in) free length (ex...

  • Page 28

    2-6 maintenance specifications piston pin outside diameter 15.991–16.000 mm (0.6296–0.6299 in) 15.971 mm (0.6288 in) piston rings: top ring: type barrel ---- dimensions (b × t) 0.90 × 2.75 mm (0.04 × 0.11 in) ---- end gap (installed) 0.15–0.25 mm (0.006–0.010 in) 0.50 mm (0.020 in) side clearance (i...

  • Page 29

    2-7 maintenance specifications quantity 8 ---- warp limit ---- 0.1 mm (0.004 in) clutch spring free length 35.7 mm (1.41 in) 34.7 mm (1.37 in) quantity 5 ---- clutch housing thrust clearance 0.10–0.35 mm (0.0039–0.0138 in) ---- clutch housing radial clearance 0.010–0.044 mm (0.0004–0.0017 in) ---- c...

  • Page 30

    2-8 maintenance specifications chassis height 240 mm (9.4 in) ---- thickness 22 mm (0.9 in) ---- radiator cap opening pressure 110 kpa (1.1 kg/cm 2 , 15.6 psi) ---- radiator capacity (total) 0.58 l (0.51 imp qt, 0.61 us qt) ---- water pump type single-suction centrifugal pump ---- item standard limi...

  • Page 31

    2-9 maintenance specifications electrical rear wheel type spoke wheel ---- front rim size/material 21 × 1.60/aluminum ---- rear rim size/material 19 × 1.85/aluminum ---- rim runout limit: radial ---- 2.0 mm (0.08 in) lateral ---- 2.0 mm (0.08 in) drive chain: type/manufacturer did520dma2 sdh/daido -...

  • Page 32

    2-10 tightening torques tightening torques engine △ - marked portion shall be checked for torque tightening after break-in or before each race. Pickup coil resistance (color) 248–372 Ω at 20 °c (68 °f) (white–red) ---- cdi unit-model/manufacturer 5xc-l0/yamaha (for usa and cdn) ---- 5xc-m0/yamaha (f...

  • Page 33

    2-11 tightening torques oil tank drain bolt m8 × 1.25 1 18 1.8 13 oil tank (upper) m6 × 1.0 1 7 0.7 5.1 oil tank and frame m6 × 1.0 3 9 0.9 6.5 carburetor joint clamp m4 × 0.7 2 3 0.3 2.2 air filter joint clamp m6 × 1.0 1 3 0.3 2.2 throttle cable adjust bolt and locknut m6 × 0.75 1 4 0.4 2.9 throttl...

  • Page 34

    2-12 tightening torques chassis △ - marked portion shall be checked for torque tightening after break-in or before each race. Part to be tightened thread size q'ty tightening torque nm m•kg ft•lb △ upper bracket and outer tube m8 × 1.25 4 21 2.1 15 △ lower bracket and outer tube m8 × 1.25 4 21 2.1 1...

  • Page 35

    2-13 tightening torques △ rear brake disc cover m6 × 1.0 2 10 1.0 7.2 △ rear brake caliper protector m6 × 1.0 2 7 0.7 5.1 drive chain puller adjust bolt and locknut m8 × 1.25 2 19 1.9 12 engine mounting: △ engine and engine bracket (front) m10 × 1.25 1 53 5.3 38 △ engine and frame (lower) m10 × 1.25...

  • Page 36

    2-14 tightening torques 1. First, tighten the steering ring nut approximately 38 nm (3.8 m•kg, 27 ft•lb) by using the steering nut wrench, then loosen the steering ring nut one turn. 2. Retighten the steering ring nut 7 nm (0.7 m•kg, 5.1 ft•lb). Electrical part to be tightened thread size q'ty tight...

  • Page 37

    2-15 tightening torques general torque specifications this chart specifies torque for stan- dard fasteners with standard i.S.O. Pitch threads. Torque specifications for special components or assem- blies are included in the applicable sections of this book. To avoid warpage, tighten multi-fastener a...

  • Page 38

    2-16 lubrication diagrams lubrication diagrams 1. Oil filter element 2. Oil pump 3. Drive axle 4. Main axle 5. Intake camshaft 6. Exhaust camshaft 7. Oil tank 8. Oil delivery pipe a. To oil tank.

  • Page 39

    2-17 lubrication diagrams 1. Crankshaft 2. Oil filter element 3. Oil tank 4. Oil hose a. From oil pump.

  • Page 40

    2-18 cable routing diagram cable routing diagram 1. Fuel tank breather hose 2. Radiator hose 1 3. Connector cover 4. Cylinder head breather hose 5. Radiator hose 4 6. Clutch cable 7. Throttle position sensor lead 8. Carburetor breather hose 9. Upper engine bracket 10. Hot starter cable 11. Fuel hose...

  • Page 41

    2-19 cable routing diagram f. Pass the clutch cable in front of the radiator mounting boss. G. Pass the fuel hose between the hot starter cable and throttle po- sition sensor lead. H. Pass the carburetor breater hos- es so that they are not pinched between the upper engine bracket and carburetor. I....

  • Page 42

    2-20 cable routing diagram 1. Hot starter cable 2. Radiator hose 2 3. Clamp 4. Ignition coil lead 5. Throttle position sensor lead 6. Hump (frame) 7. Oil hose 8. Hose guide 9. Neutral switch lead 10. Cdi magneto lead 11. Clutch cable 12. Radiator breather hose 13. Engine stop switch lead 14. Sub-wir...

  • Page 43

    2-21 cable routing diagram f. Fasten the neutral switch lead, cdi magneto lead, radiator breather hose and clutch cable over the radiator mounting boss. G. Pass the radiator breather hose in front of the radiator, on the left of the chassis, and then be- tween the frame and radiator hose 4. H. Faste...

  • Page 44

    2-22 cable routing diagram 1. Throttle cable (pull) 2. Throttle cable (return) 3. Radiator hose 2 4. Ignition coil 5. Cylinder head breather hose 6. Clamp 7. Rear arm bracket a. Pass the throttle cables over the radiator hose 2. B. Pass the cylinder head breather hose so that it does not contact the...

  • Page 45

    2-23 cable routing diagram 1. Brake master cylinder 2. Brake hose holder 3. Brake hose a. Install the brake hose so that its pipe portion directs as shown and lightly touches the projec- tion on the brake caliper. B. Pass the brake hose into the brake hose holders. C. If the brake hose contacts the ...

  • Page 46

    2-24 cable routing diagram 1. Throttle cable 2. Clamp 3. Hot starter cable 4. Clutch cable 5. Engine stop switch lead 6. Cable guide 7. Brake hose 8. Hose guide a. Fasten the engine stop switch lead to the handlebar. B. Pass the clutch cable and hot starter cable through the cable guide. C. Pass the...

  • Page 47

    3-1 maintenance intervals regular inspection and adjustments maintenance intervals the following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance...

  • Page 48

    3-2 maintenance intervals cylinder inspect and clean ● inspect score marks. Replace ● inspect wear. Clutch inspect and adjust ● ● inspect housing, friction plate, clutch plate and spring. Replace ● transmission inspect ● replace bearing ● shift fork, shift cam, guide bar inspect ● inspect wear. Roto...

  • Page 49

    3-3 maintenance intervals oil strainer clean ● frame clean and inspect ● ● fuel tank, cock clean and inspect ● ● brakes adjust lever position and pedal height ● ● lubricate pivot point ● ● check brake disc surface ● ● check fluid level and leakage ● ● retighten brake disc bolts, cali- per bolts, mas...

  • Page 50

    3-4 maintenance intervals tire, wheels inspect air pressure, wheel run- out, tire wear and spoke loose- ness ● ● retighten sprocket bolt ● ● inspect bearings ● replace bearings ● lubricate ● lithium base grease throttle, control cable check routing and connection ● ● lubricate ● ● yamaha cable lube ...

  • Page 51

    3-5 pre-operation inspection and maintenance pre-operation inspection and maintenance before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. General inspection and maintenance item routine...

  • Page 52

    3-6 engine engine checking the coolant level do not remove the radiator cap "1", drain bolt and hoses when the engine and radiator are hot. Scald- ing hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, place a thick towel over the radia...

  • Page 53

    3-7 engine 2. Apply the specified pressure. 3. Inspect: • pressure impossible to maintain the speci- fied pressure for 10 seconds → replace. Checking the cooling system 1. Inspect: • coolant level 2. Attach: • radiator cap tester "1" and adapt- er "2" 3. Apply the specified pressure. Do not apply pr...

  • Page 54

    3-8 engine 2. Apply: • lithium soap base grease on the throttle cable end "a". 3. Install: • throttle grip cap • screw (throttle grip cap) • cover (grip cap) • cover (throttle cable cap) adjusting the hot starter lever free play 1. Check: • hot starter lever free play "a" out of specification → adju...

  • Page 55

    3-9 engine (for usa and cdn) • do not add any chemical addi- tives. Engine oil also lubricates the clutch and additives could cause clutch slippage. • do not allow foreign material to enter the crankcase. (except for usa and cdn) • do not add any chemical addi- tives or use oils with a grade of cd "...

  • Page 56

    3-10 engine • oil hose clamp 9. Install: • copper washer • oil filter element drain bolt • crankcase oil drain bolt • oil tank drain bolt • lower engine guard 10. Fill: • engine oil 11. Check: • oil leakage 12. Install: • oil filler cap • washer (oil tank) • bolt (oil tank) 13. Check: • engine oil l...

  • Page 57

    3-11 engine adjusting the valve clearance • the valve clearance should be ad- justed when the engine is cool to the touch. • the piston must be at top dead center (t.D.C.) on compression stroke to check or adjust the valve clearance. 1. Remove: • seat • fuel tank refer to "seat, fuel tank and side c...

  • Page 58

    3-12 engine use the new pad number only as a guide when verifying the valve clear- ance adjustment. F. Install the new pads "3" and the valve lifters "4". • apply the engine oil on the valve lift- ers. • apply the molybdenum disulfide oil on the valve stem ends. • valve lifter must turn smoothly whe...

  • Page 59

    3-13 engine intake exhaust.

  • Page 60

    3-14 chassis chassis bleeding the hydraulic brake system bleed the brake system if: • the system has been disassem- bled. • a brake hose has been loosened or removed. • the brake fluid is very low. • the brake operation is faulty. A dangerous loss of braking per- formance may occur if the brake syst...

  • Page 61

    3-15 chassis checking and replacing the front brake pads 1. Inspect: • brake pad thickness "a" out of specification → replace as a set. 2. Replace: • brake pad brake pad replacement steps: a. Remove the pad pin plug "1". B. Loosen the pad pin "2". C. Remove the brake caliper "3" from the front fork....

  • Page 62

    3-16 chassis b. Loosen the pad pin "3". C. Remove the rear wheel "4" and brake caliper "5". Refer to "front wheel and rear wheel" section in the chapter 5. D. Remove the pad pin "6" and brake pads "7". E. Connect the transparent hose "8" to the bleed screw "9" and place the suitable container under ...

  • Page 63

    3-17 chassis checking the drive chain 1. Measure: • drive chain length (15 links) "a" out of specification → replace. • while measuring the drive chain length, push down on the drive chain to increase its tension. • measure the length between drive chain roller "1" and "16" as shown. • perform this ...

  • Page 64

    3-18 chassis checking the front fork 1. Inspect: • front fork smooth action operate the front brake and stroke the front fork. Unsmooth action/oil leakage → repair or replace. Cleaning the front fork oil seal and dust seal 1. Remove: • protector • dust seal "1" use a thin screw driver, and be care- ...

  • Page 65

    3-19 chassis adjusting the rear shock absorber spring preload 1. Elevate the rear wheel by placing the suitable stand under the en- gine. 2. Remove: • rear frame 3. Loosen: • locknut "1" 4. Adjust: • spring preload by turning the adjuster "2". • be sure to remove all dirt and mud from around the loc...

  • Page 66

    3-20 chassis • standard position: this is the position which is back by the specific number of clicks from the fully turned-in position. (which align the punch mark "a" on the adjuster with the punch mark "b" on the high compression damping adjuster.) do not force the adjuster past the minimum or ma...

  • Page 67

    3-21 chassis 3. Check: • steering smooth action turn the handlebar lock to lock. Unsmooth action → adjust steer- ing ring nut. 4. Adjust: • steering ring nut steering ring nut adjustment steps: a. Remove the number plate. B. Remove the handlebar and upper bracket. C. Loosen the steering ring nut "1"...

  • Page 68

    3-22 chassis lubrication to ensure smooth operation of all components, lubricate your machine during setup, after break-in, and after every race. 1. All control cable 2. Clutch lever pivot 3. Shift pedal pivot 4. Footrest pivot 5. Throttle-to-handlebar contact 6. Drive chain 7. Tube guide cable wind...

  • Page 69

    3-23 electrical electrical checking the spark plug 1. Remove: • spark plug 2. Inspect: • electrode "1" wear/damage → replace. • insulator color "2" normal condition is a medium to light tan color. Distinctly different color → check the engine condition. When the engine runs for many hours at low spe...

  • Page 70

    4-1 seat, fuel tank and side covers engine seat, fuel tank and side covers removing the seat, fuel tank and side covers order part name q'ty remarks turn the fuel cock to "off". Disconnect the fuel hose. 1 seat 1 2 air scoop (left and right) 2 3 bolt (fuel tank) 2 4 fuel tank 1 5 left side cover 1 r...

  • Page 71

    4-2 seat, fuel tank and side covers removing the side cover 1. Remove: • bolt (side cover) • left side cover "1" • right side cover "2" draw the side cover downward to re- move it because its claws "a" are in- serted in the air filter case. Removing the number plate 1. Remove: • bolt (number plate) ...

  • Page 72

    4-3 exhaust pipe and silencer exhaust pipe and silencer removing the exhaust pipe and silencer order part name q'ty remarks right side cover refer to "seat, fuel tank and side covers" section. 1 bolt (silencer clamp) 1 only loosening. 2 bolt [silencer (front)] 1 3 bolt [silencer (rear)] 1 4 collar 1...

  • Page 73

    4-4 exhaust pipe and silencer checking the silencer and exhaust pipe 1. Inspect: • gasket "1" damage → replace. Changing the silencer fiber 1. Remove: • rivet (front) "1" • inner pipe "2" take care not to damage the rivet fitting holes (ø4.9 mm) "a" in re- moval. Pull out the inner pipe while lightl...

  • Page 74

    4-5 radiator radiator removing the radiator order part name q'ty remarks drain the coolant. Refer to "changing the coolant" sec- tion in the chapter 3. Seat and fuel tank refer to "seat, fuel tank and side covers" section. 1 radiator guard 2 2 radiator hose clamp 8 only loosening. 3 radiator hose 1 ...

  • Page 75

    4-6 radiator handling note do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radiator cap by the following procedure: place a thick rag, like a towe...

  • Page 76

    4-7 carburetor carburetor removing the carburetor order part name q'ty remarks seat and fuel tank refer to "seat, fuel tank and side covers" section. Rear shock absorber refer to "rear shock absorber" sec- tion in the chapter 5. 1 clamp 1 2 throttle position sensor lead coupler 1 3 throttle cable co...

  • Page 77

    4-8 carburetor disassembling the carburetor order part name q'ty remarks 1 carburetor breather hose 4 2 valve lever housing cover 1 3 screw (throttle shaft) 1 4 throttle valve 1 5 needle holder 1 6 jet needle 1 7 accelerator pump cover 1 8 spring 1 9 diaphragm (accelerator pump) 1 10 float chamber 1...

  • Page 78

    4-9 carburetor 18 spacer 1 19 pilot jet 1 20 starter jet 1 21 push rod 1 pull the push rod. 22 throttle shaft assembly 1 23 push rod link lever assembly 1 24 pilot air jet 1 25 cold starter plunger 1 order part name q'ty remarks.

  • Page 79

    4-10 carburetor handling note do not loosen the screw (throttle position sensor) "1" except when changing the throttle position sen- sor due to failure because it will cause a drop in engine perfor- mance. Removing the pilot screw 1. Remove: • pilot screw "1" to optimize the fuel flow at a small thr...

  • Page 80

    4-11 carburetor f. Recheck the float height. Checking the float 1. Inspect: • float "1" damage → replace. Checking the starter plunger 1. Inspect: • cold starter plunger "1" • hot starter plunger "2" wear/damage → replace. Checking the accelerator pump 1. Inspect: • diaphragm (accelerator pump) "1" ...

  • Page 81

    4-12 carburetor 9. Install: • push rod "1" while holding down the lever 1 "2", in- sert the push rod farthest into the car- buretor. 10. Install: • starter jet "1" • pilot jet "2" • spacer "3" • needle jet "4" • main jet "5" 11. Install: • needle valve "1" • float "2" • float pin "3" • after install...

  • Page 82

    4-13 carburetor 18. Install: • carburetor breather hose "1" install the carburetor breather hoses to the carburetor so that the hoses do not bend near where they are in- stalled. Adjusting the accelerator pump timing adjustment steps: in order for the throttle valve height "a" to achieve the specifi...

  • Page 83

    4-14 camshafts camshafts removing the cylinder head cover order part name q'ty remarks seat and fuel tank refer to "seat, fuel tank and side covers" section. 1 spark plug 1 2 cylinder head breather hose 1 3 bolt (cylinder head cover) 2 4 cylinder head cover 1 5 cylinder head cover gasket 1 6 timing ...

  • Page 84

    4-15 camshafts removing the camshafts order part name q'ty remarks 1 timing mark accessing screw 1 refer to removal section. 2 crankshaft end accessing screw 1 refer to removal section. 3 timing chain tensioner cap bolt 1 refer to removal section. 4 timing chain tensioner 1 refer to removal section....

  • Page 85

    4-16 camshafts removing the camshaft 1. Remove: • timing mark accessing screw "1" • crankshaft end accessing screw "2" 2. Align: • t.D.C. Mark with align mark. Checking steps: a. Turn the crankshaft counterclock- wise with a wrench. B. Align the t.D.C. Mark "a" on the rotor with the align mark "b" o...

  • Page 86

    4-17 camshafts 4. Measure: • camshaft-to-cap clearance out of specification → measure camshaft outside diameter. Measurement steps: a. Install the camshaft onto the cylin- der head. B. Position a strip of plastigauge ® "1" onto the camshaft. C. Install the clip, dowel pins and camshaft caps. • tight...

  • Page 87

    4-18 camshafts c. Fit the timing chain "3" onto both camshaft sprockets and install the camshafts on the cylinder head. The camshafts should be installed onto the cylinder head so that the punch mark "c" on the exhaust cam- shaft and the punch mark "d" on the intake camshaft must align with the cyli...

  • Page 88

    4-19 cylinder head cylinder head removing the cylinder head order part name q'ty remarks seat and fuel tank refer to "seat, fuel tank and side covers" section. Exhaust pipe and silencer refer to "exhaust pipe and silencer" section. Radiator hose 1 disconnect at cylinder head side. Carburetor refer t...

  • Page 89

    4-20 cylinder head checking the cylinder head 1. Eliminate: • carbon deposits (from the com- bustion chambers) use a rounded scraper. Do not use a sharp instrument to avoid damaging or scratching: • spark plug threads • valve seats 2. Inspect: • cylinder head scratches/damage → replace. 3. Measure: ...

  • Page 90

    4-21 valves and valve springs valves and valve springs removing the valves and valve springs order part name q'ty remarks cylinder head refer to "cylinder head" section. 1 valve lifter 5 refer to removal section. 2 adjusting pad 5 refer to removal section. 3 valve cotter 10 refer to removal section....

  • Page 91

    4-22 valves and valve springs removing the valve lifter and valve cotter 1. Remove: • valve lifter "1" • pad "2" identify each lifter "1" and pad "2" po- sition very carefully so that they can be reinstalled in their original place. 2. Check: • valve sealing leakage at the valve seat → in- spect the...

  • Page 92

    4-23 valves and valve springs 4. Measure: • margin thickness "a" out of specification → replace. 5. Measure: • runout (valve stem) out of specification → replace. • when installing a new valve always replace the guide. • if the valve is removed or replaced always replace the oil seal. 6. Eliminate: ...

  • Page 93

    4-24 valves and valve springs 2. Measure: • compressed spring force "a" out of specification → replace. B. Installed length 3. Measure: • spring tilt "a" out of specification → replace. Checking the valve lifters 1. Inspect: • valve lifter scratches/damage → replace both lifters and cylinder head. I...

  • Page 94

    4-25 cylinder and piston cylinder and piston removing the cylinder and piston order part name q'ty remarks cylinder head refer to "cylinder head" section. 1 bolt (cylinder) 1 2 cylinder 1 3 piston pin clip 2 refer to removal section. 4 piston pin 1 refer to removal section. 5 piston 1 refer to remov...

  • Page 95

    4-26 cylinder and piston removing the piston and piston ring 1. Remove: • piston pin clip "1" • piston pin "2" • piston "3" • put identification marks on each piston head for reference during re- installation. • before removing each piston pin, deburr the clip groove and pin hole area. If the piston...

  • Page 96

    4-27 cylinder and piston 3. Measure: • ring end gap out of specification → replace. You cannot measure the end gap on the expander spacer of the oil control ring. If the oil control ring rails show excessive gap, replace all three rings. Checking the piston pin 1. Inspect: • piston pin blue discolor...

  • Page 97

    4-28 cylinder and piston install the cylinder with one hand while compressing the piston rings with the other hand. • pass the timing chain "3" through the timing chain cavity. • be careful not to damage the tim- ing chain guide "4" during instal- lation. 4. Install: • bolt (cylinder) "5" bolt (cyli...

  • Page 98

    4-29 clutch clutch removing the clutch order part name q'ty remarks drain the engine oil. Refer to "changing the engine oil" section in the chapter 3. Brake pedal refer to "engine removal" section. Clutch cable disconnect at engine side. 1 clutch cover 1 2 clutch spring 5 3 pressure plate 1 4 push r...

  • Page 99

    4-30 clutch 14 nut (clutch boss) 1 refer to removal section. 15 lock washer 1 refer to removal section. 16 clutch boss 1 refer to removal section. 17 thrust washer 1 18 primary driven gear 1 19 push lever shaft 1 order part name q'ty remarks.

  • Page 100

    4-31 clutch removing the clutch boss 1. Remove: • nut "1" • lock washer "2" • clutch boss "3" straighten the lock washer tab and use the clutch holding tool "4" to hold the clutch boss. A. For usa and cdn b. Except for usa and cdn checking the clutch housing and boss 1. Inspect: • clutch housing "1"...

  • Page 101

    4-32 clutch installing the clutch 1. Install: • primary driven gear "1" • thrust washer "2" • clutch boss "3" apply the engine oil on the primary driven gear inner circumference. 2. Install: • lock washer "1" • nut (clutch boss) "2" use the clutch holding tool "3" to hold the clutch boss. A. For usa...

  • Page 102

    4-33 clutch 11. Install: • clutch cover "1" • bolt (clutch cover) tighten the bolts in stage, using a crisscross pattern. Bolt (clutch cover): 10 nm (1.0 m•kg, 7.2 ft•lb).

  • Page 103

    4-34 oil filter element and water pump oil filter element and water pump removing the oil filter element and water pump order part name q'ty remarks drain the engine oil. Refer to "changing the engine oil" section in the chapter 3. Drain the coolant. Refer to "changing the coolant" sec- tion in the ...

  • Page 104

    4-35 oil filter element and water pump 9 washer 1 refer to removal section. 10 impeller shaft 1 refer to removal section. 11 oil seal 2 refer to removal section. 12 bearing 1 refer to removal section. Order part name q'ty remarks.

  • Page 105

    4-36 oil filter element and water pump removing the impeller shaft 1. Remove: • impeller "1" • washer "2" • impeller shaft "3" hold the impeller shaft on its width across the flats "a" with spanners, etc. And remove the impeller. Removing the oil seal it is not necessary to disassemble the water pum...

  • Page 106

    4-37 oil filter element and water pump installing the right crankcase cover 1. Install: • dowel pin "1" • o-ring "2" • collar "3" • gasket "4" apply the lithium soap base grease on the o-ring. 2. Install: • right crankcase cover "1" • bolt (right crankcase cover) "2" • apply the engine oil on the im...

  • Page 107

    4-38 balancer balancer removing the balancer order part name q'ty remarks primary driven gear refer to "clutch" section. Right crankcase cover refer to "oil filter element and wa- ter pump" section. Stator refer to "cdi magneto" section. 1 nut (primary drive gear) 1 refer to removal section. 2 nut (...

  • Page 108

    4-39 balancer removing the balancer 1. Straighten the lock washer tab. 2. Loosen: • nut (primary drive gear) "1" • nut (balancer shaft driven gear) "2" place an aluminum plate "a" between the teeth of the balancer shaft drive gear "3" and driven gear "4". 3. Remove: • balancer shaft "1" when removin...

  • Page 109

    4-40 oil pump oil pump removing the oil pump order part name q'ty remarks primary driven gear refer to "clutch" section. Right crankcase cover refer to "oil filter element and wa- ter pump" section. 1 circlip 1 2 washer 1 3 oil pump drive gear 1 4 oil pump assembly 1 5 outer rotor 2 1 6 circlip 1 7 ...

  • Page 110

    4-41 oil pump 15 rotor housing 1 order part name q'ty remarks.

  • Page 111

    4-42 oil pump removing the oil tank order part name q'ty remarks drain the engine oil. Refer to "changing the engine oil" section in the chapter 3. 1 oil hose 2 1 2 oil hose 1 1 3 dowel pin 2 4 oil tank breather hose 1 5 oil tank 1 6 oil strainer 1.

  • Page 112

    4-43 oil pump checking the oil pump 1. Inspect: • oil pump drive gear "1" • oil pump drive shaft "2" • rotor housing "3" • oil pump cover "4" cracks/wear/damage → replace. 2. Measure: • tip clearance "a" (between the inner rotor "1" and outer rotor "2") • side clearance "b" (between the outer rotor ...

  • Page 113

    4-44 kick shaft and shift shaft kick shaft and shift shaft removing the kick shaft and shift shaft order part name q'ty remarks oil pump refer to "oil pump" section. 1 kick idle gear 1 2 kick shaft assembly 1 refer to removal section. 3 spring guide 1 4 torsion spring 1 5 ratchet wheel 1 6 kick gear...

  • Page 114

    4-45 kick shaft and shift shaft 17 pawl 2 18 pawl pin 2 19 spring 2 20 bolt (stopper lever) 1 21 stopper lever 1 22 torsion spring 1 23 segment 1 refer to removal section. Order part name q'ty remarks.

  • Page 115

    4-46 kick shaft and shift shaft removing the kick shaft assembly 1. Remove: • kick shaft assembly "1" unhook the torsion spring "2" from the hole "a" in the crankcase. Removing the shift guide and shift lever assembly 1. Remove: • bolt (shift guide) • shift guide "1" • shift lever assembly "2" the s...

  • Page 116

    4-47 kick shaft and shift shaft installing the shift guide and shift lever assembly 1. Install: • spring "1" • pawl pin "2" • pawl "3" to shift lever "4". Apply the engine oil on the spring, pawl pin and pawl. 2. Install: • shift lever assembly "1" to shift guide "2". 3. Install: • shift lever assem...

  • Page 117

    4-48 kick shaft and shift shaft 5. Hook: • torsion spring "1" turn the torsion spring clockwise and hook into the proper hole "a" in the crankcase. Installing the kick idle gear 1. Install: • kick idle gear "1" • washer "2" • circlip "3" • apply the engine oil on the kick idle gear inner circumferen...

  • Page 118

    4-49 cdi magneto cdi magneto removing the cdi magneto order part name q'ty remarks seat and fuel tank refer to "seat, fuel tank and side covers" section. Disconnect the cdi magneto lead. Shift pedal refer to "kick shaft and shift shaft" section. 1 left crankcase cover 1 2 nut (rotor) 1 refer to remo...

  • Page 119

    4-50 cdi magneto removing the rotor 1. Remove: • nut (rotor) "1" • washer "2" use the rotor holding tool "3". 2. Remove: • rotor "1" use the flywheel puller "2". When installing the flywheel puller, turn it counterclockwise. Checking the cdi magneto 1. Inspect: • rotor inner surface "a" • stator out...

  • Page 120

    4-51 engine removal engine removal removing the engine order part name q'ty remarks hold the machine by placing the suitable stand under the frame. Refer to "handling note". Seat and fuel tank refer to "seat, fuel tank and side covers" section. Carburetor refer to "carburetor" section. Exhaust pipe ...

  • Page 121

    4-52 engine removal 1 lower engine guard 1 2 neutral switch 1 3 drive chain sprocket cover 1 4 nut (drive sprocket) 1 refer to removal section. 5 lock washer 1 refer to removal section. 6 drive sprocket 1 refer to removal section. 7 clip 1 8 bolt (brake pedal) 1 9 brake pedal 1 10 upper engine brack...

  • Page 122

    4-53 engine removal handling note support the machine securely so there is no danger of it falling over. Removing the drive sprocket 1. Remove: • nut (drive sprocket) "1" • lock washer "2" • straighten the lock washer tab. • loosen the nut while applying the rear brake. 2. Remove: • drive sprocket "...

  • Page 123

    4-54 engine removal 2. Install: • lock washer "1" • nut (drive sprocket) "2" tighten the nut while applying the rear brake. 3. Bend the lock washer tab to lock the nut. 4. Install: • drive chain sprocket guide "1" • drive chain sprocket cover "2" • screw (drive chain sprocket cov- er) "3" installing...

  • Page 124

    4-55 crankcase and crankshaft crankcase and crankshaft removing the crankshaft order part name q'ty remarks engine refer to "engine removal" section. Piston refer to "cylinder and piston" section. Kick shaft assembly refer to "kick shaft and shift shaft" section. Segment refer to "kick shaft and shi...

  • Page 125

    4-56 crankcase and crankshaft 10 left crankcase 1 refer to removal section. 11 oil strainer 1 12 crankshaft 1 refer to removal section. Order part name q'ty remarks.

  • Page 126

    4-57 crankcase and crankshaft removing the crankcase bearing order part name q'ty remarks transmission refer to "transmission, shift cam and shift fork" section. Shift cam and shift fork refer to "transmission, shift cam and shift fork" section. 1 oil seal 2 2 bearing 10 refer to removal section..

  • Page 127

    4-58 crankcase and crankshaft disassembling the crankcase 1. Separate: • right crankcase • left crankcase separation steps: a. Remove the crankcase bolts "1", hose guide "2" and clutch cable holder "3". Loosen each bolt 1/4 of a turn at a time and after all the bolts are loos- ened, remove them. B. ...

  • Page 128

    4-59 crankcase and crankshaft checking the oil strainer 1. Inspect: • oil strainer damage → replace. Checking the oil delivery pipe 2 1. Inspect: • oil delivery pipe 2 "1" • o-ring "2" damage → replace. • oil orifice "a" clogged → blow. Installing the crankcase bearing 1. Install: • bearing • bearin...

  • Page 129

    4-60 crankcase and crankshaft 5. Install: • dowel pin "1" • o-ring "2" • right crankcase to left crankcase. • apply the lithium soap base grease on the o-ring. • fit the right crankcase onto the left crankcase. Tap lightly on the case with soft hammer. • when installing the crankcase, the connecting...

  • Page 130

    4-61 transmission, shift cam and shift fork transmission, shift cam and shift fork removing the transmission, shift cam and shift fork order part name q'ty remarks engine refer to "engine removal" section. Separate the crankcase. Refer to "crankcase and crank- shaft" section. 1 main axle 1 refer to ...

  • Page 131

    4-62 transmission, shift cam and shift fork removing the transmission 1. Remove: • main axle "1" • drive axle "2" • shift cam • shift fork 3 • shift fork 2 • shift fork 1 • remove assembly with the collar "3" installed to the crankcase. • remove assembly carefully. Note the position of each part. Pa...

  • Page 132

    4-63 transmission, shift cam and shift fork 4. Install: • collar "1" • apply the lithium soap base grease on the oil seal lip. • when installing the collar into the crankcase, pay careful attention to the crankcase oil seal lip. 5. Install: • shift fork 1 (l) "1" • shift fork 2 (c) "2" • shift fork ...

  • Page 133

    5-1 front wheel and rear wheel chassis front wheel and rear wheel removing the front wheel order part name q'ty remarks hold the machine by placing the suitable stand under the engine. Refer to "handling note". 1 bolt (axle holder) 4 only loosening. 2 nut (front wheel axle) 1 3 front wheel axle 1 4 ...

  • Page 134

    5-2 front wheel and rear wheel removing the rear wheel order part name q'ty remarks hold the machine by placing the suitable stand under the engine. Refer to "handling note". 1 nut (rear wheel axle) 1 2 rear wheel axle 1 3 drive chain puller 2 4 rear wheel 1 refer to removal section. 5 collar 2 6 re...

  • Page 135

    5-3 front wheel and rear wheel handling note support the machine securely so there is no danger of it falling over. Removing the rear wheel 1. Remove: • wheel "1" push the wheel forward and remove the drive chain "2". Removing the wheel bearing 1. Remove: • bearing "1" remove the bearing using a gen...

  • Page 136

    5-4 front wheel and rear wheel • bolt (brake disc) "2" tighten the bolts in stage, using a crisscross pattern. 3. Install: • collar "1" • apply the lithium soap base grease on the oil seal lip. • install the collars with their projec- tions "a" facing the wheel. 4. Install: • wheel • install the bra...

  • Page 137

    5-5 front wheel and rear wheel 4. Install: • collar "1" apply the lithium soap base grease on the oil seal lip. 5. Install: • wheel install the brake disc "1" between the brake pads "2" correctly. 6. Install: • drive chain "1" push the wheel "2" forward and install the drive chain. 7. Install: • lef...

  • Page 138

    5-6 front brake and rear brake front brake and rear brake removing the front brake order part name q'ty remarks hold the machine by placing the suitable stand under the engine. Refer to "handling note". Drain the brake fluid. Refer to removal section. 1 brake hose holder (protector) 2 2 union bolt 2...

  • Page 139

    5-7 front brake and rear brake removing the rear brake order part name q'ty remarks hold the machine by placing the suitable stand under the engine. Refer to "handling note". Rear wheel refer to "front wheel and rear wheel" section. Drain the brake fluid. Refer to removal section. 1 brake pedal 1 2 ...

  • Page 140

    5-8 front brake and rear brake disassembling the brake caliper order part name q'ty remarks a. Front b. Rear a b 1 pad pin 1 1 2 brake pad 2 2 3 pad support 1 1 4 brake caliper piston 2 1 refer to removal section. 5 brake caliper piston dust seal 2 1 refer to removal section. 6 brake caliper piston ...

  • Page 141

    5-9 front brake and rear brake disassembling the brake master cylinder order part name q'ty remarks a. Front b. Rear 1 brake master cylinder cap 1 2 diaphragm 1 3 reservoir float 1 4 push rod (front) 1 5 brake master cylinder boot 1 6 circlip 1 use a long nose circlip pliers. 7 washer 1 8 push rod (...

  • Page 142

    5-10 front brake and rear brake handling note support the machine securely so there is no danger of it falling over. Draining the brake fluid 1. Remove: • brake master cylinder cap "1" • protector (rear brake) do not remove the diaphragm. A. Front b. Rear 2. Connect the transparent hose "2" to the b...

  • Page 143

    5-11 front brake and rear brake checking the brake caliper 1. Inspect: • brake caliper cylinder inner sur- face "a" wear/score marks → replace brake caliper assembly. A. Front b. Rear 2. Inspect: • brake caliper piston "1" wear/score marks → replace brake caliper piston assembly. Replace the brake c...

  • Page 144

    5-12 front brake and rear brake installing the rear brake caliper 1. Install: • pad support "1" • brake pad "2" • pad pin "3" • install the brake pads with their pro- jections "a" into the brake caliper re- cesses "b". • temporarily tighten the pad pin at this point. 2. Install: • brake disc cover "...

  • Page 145

    5-13 front brake and rear brake 2. Install: • brake lever "1" • bolt (brake lever) "2" • nut (brake lever) "3" apply the silicone grease on the brake lever sliding surface, bolt and tip of the push rod. Installing the rear brake master cylinder 1. Install: • copper washer "1" • brake hose "2" • unio...

  • Page 146

    5-14 front brake and rear brake 4. Install: • copper washer "1" • brake hose "2" • union bolt "3" always use new copper washers. Install the brake hose so that its pipe portion "a" directs as shown and lightly touches the projection "b" on the brake master cylinder. Installing the rear brake hose 1....

  • Page 147

    5-15 front brake and rear brake a. Front b. Rear 5. Install: (rear brake only) • protector "1" • bolt (protector) "2" bolt (protector): 7 nm (0.7 m•kg, 5.1 ft•lb).

  • Page 148

    5-16 front fork front fork removing the front fork order part name q'ty remarks hold the machine by placing the suitable stand under the engine. Refer to "handling note". Front wheel refer to "front wheel and rear wheel" section. Front brake caliper refer to "front brake and rear brake" section. Num...

  • Page 149

    5-17 front fork disassembling the front fork order part name q'ty remarks 1 adjuster 1 drain the fork oil. Refer to removal section. 2 fork spring 1 drain the fork oil. 3 dust seal 1 refer to removal section. 4 stopper ring 1 refer to removal section. 5 inner tube 1 refer to removal section. 6 outer...

  • Page 150

    5-18 front fork handling note support the machine securely so there is no danger of it falling over. The front fork requires careful atten- tion. So it is recommended that the front fork be maintained at the deal- ers. To prevent an accidental explosion of air, the following instructions should be o...

  • Page 151

    5-19 front fork checking the base valve 1. Inspect: • base valve "1" wear/damage → replace. Contamination → clean. • o-ring "2" wear/damage → replace. • piston metal "3" wear/damage → replace. • spring "4" damage/fatigue → replace base valve. • air bleed screw "5" wear/damage → replace. Checking the...

  • Page 152

    5-20 front fork 6. Tighten: • locknut "1" fully finger tighten the locknut onto the damper assembly. 7. Loosen: • compression damping adjuster "1" • loosen the compression damping adjuster finger tight. • record the set position of the ad- juster (the amount of turning out the fully turned in positi...

  • Page 153

    5-21 front fork 17. Install: • outer tube "1" to inner tube "2". 18. Install: • slide metal "1" • oil seal washer "2" to outer tube slot. Press the slide metal into the outer tube with fork seal driver "3". 19. Install: • oil seal "1" press the oil seal into the outer tube with fork seal driver "2"....

  • Page 154

    5-22 front fork 28. Inspect: • gap "a" between the adjuster "1" and locknut "2". Out of specification → retighten and readjust the locknut. If the adjuster is installed out of spec- ification, proper damping force can- not be obtained. 29. Tighten: • adjuster (locknut) "1" hold the locknut "2" and t...

  • Page 155

    5-23 front fork 4. Tighten: • pinch bolt (upper bracket) "1" • pinch bolt (lower bracket) "2" tighten the lower bracket to speci- fied torque. If torqued too much, it may cause the front fork to mal- function. 5. Install: • protector "1" • bolt (protector) "2" 6. Adjust: • rebound damping force turn...

  • Page 156

    5-24 handlebar handlebar removing the handlebar order part name q'ty remarks number plate remove the band only. 1 hot starter cable 1 disconnect at the lever side. 2 hot starter lever holder 1 3 clutch cable 1 disconnect at the lever side. 4 clutch lever holder 1 5 engine stop switch 1 6 brake maste...

  • Page 157

    5-25 handlebar removing the brake master cylinder 1. Remove: • brake master cylinder bracket "1" • brake master cylinder "2" • do not let the brake master cylin- der hang on the brake hose. • keep the brake master cylinder cap side horizontal to prevent air from coming in. Removing the grip 1. Remov...

  • Page 158

    5-26 handlebar 5. Install: • right grip "1" • collar "2" apply the adhesive on the tube guide "3". • before applying the adhesive, wipe off grease or oil on the tube guide surface "a" with a lacquer thinner. • install the grip to the tube guide so that the grip match mark "b" and tube guide slot "c"...

  • Page 159

    5-27 handlebar 13. Adjust: • clutch lever free play refer to "adjusting the clutch cable free play" section in the chapter 3. • hot starter lever free play refer to "adjusting the hot starter lever free play" section in the chapter 3..

  • Page 160

    5-28 steering steering removing the steering order part name q'ty remarks tightening steps: tighten ring nut. 38 nm (3.8 m•kg, 27 ft•lb) loosen it one turn. Retighten it. 7 nm (0.7 m•kg, 5.1 ft•lb) hold the machine by placing the suitable stand under the engine. Refer to "handling note". Number plat...

  • Page 161

    5-29 steering 9 bearing race 2 refer to removal section. Order part name q'ty remarks.

  • Page 162

    5-30 steering handling note support the machine securely so there is no danger of it falling over. Removing the steering ring nut 1. Remove: • steering ring nut "1" use the steering nut wrench "2". Support the steering stem so that it may not fall down. Removing the lower bearing 1. Remove: • lower ...

  • Page 163

    5-31 steering 6. Install: • washer "1" 7. Install: • front fork "1" • upper bracket "2" • temporarily tighten the pinch bolts (lower bracket). • do not tighten the pinch bolts (up- per bracket) yet. 8. Install: • washer "1" • steering stem nut "2" 9. After tightening the nut, check the steering for ...

  • Page 164

    5-32 swingarm swingarm removing the swingarm order part name q'ty remarks hold the machine by placing the suitable stand under the engine. Refer to "handling note". Brake hose holder refer to "front brake and rear brake" section. Rear brake caliper refer to "front brake and rear brake" section. Bolt...

  • Page 165

    5-33 swingarm disassembling the swingarm order part name q'ty remarks 1 cap 2 refer to removal section. 2 relay arm 1 3 connecting rod 1 4 collar 2 5 oil seal 2 6 thrust bearing 2 7 bushing 2 8 oil seal 8 9 bearing 10 refer to removal section..

  • Page 166

    5-34 swingarm handling note support the machine securely so there is no danger of it falling over. Removing the cap 1. Remove: • left cap "1" remove with a slotted-head screw- driver inserted under the mark "a" on the left cap. Removing the bearing 1. Remove: • bearing "1" remove the bearing by pres...

  • Page 167

    5-35 swingarm installing the swingarm 1. Install: • bushing "1" • thrust bearing "2" • oil seal "3" • collar "4" to swingarm "5". Apply the molybdenum disulfide grease on the bushings, thrust bear- ings, oil seal lips and contact surfaces of the collar and thrust bearing. 2. Install: • collar "1" • ...

  • Page 168

    5-36 swingarm 11. Tighten: • nut (relay arm) "1" 12. Install: • cap "1" install the right cap with its mark "a" facing forward. 13. Install: • bolt (lower chain tensioner) "1" • washer "2" • collar "3" • lower chain tensioner "4" • nut (lower chain tensioner) "5" 14. Install: • drive chain support "...

  • Page 169

    5-37 rear shock absorber rear shock absorber removing the rear shock absorber order part name q'ty remarks hold the machine by placing the suitable stand under the engine. Refer to "handling note". Seat refer to "seat, fuel tank and side covers" section in the chapter 4. Silencer refer to "exhaust p...

  • Page 170

    5-38 rear shock absorber 12 bearing 2 refer to removal section. Order part name q'ty remarks.

  • Page 171

    5-39 rear shock absorber handling note • support the machine securely so there is no danger of it falling over. • this rear shock absorber is pro- vided with a separate type tank filled with high-pressure nitro- gen gas. To prevent the danger of explosion, read and under- stand the following informa...

  • Page 172

    5-40 rear shock absorber 3. Install: • lower bearing "1" install the bearing by pressing it on the side having the manufacture's marks or numbers. Installing the spring (rear shock absorber) 1. Install: • spring "1" • upper spring guide "2" • lower spring guide "3" 2. Install: • spring seat "1" inst...

  • Page 173

    5-41 rear shock absorber • bolt [rear frame (lower)] "3" 7. Tighten: • bolt (air filter joint) "1" bolt [rear frame (lower)]: 32 nm (3.2 m•kg, 23 ft•lb) bolt (air filter joint): 3 nm (0.3 m•kg, 2.2 ft•lb).

  • Page 174

    6-1 electrical components and wiring diagram electrical electrical components and wiring diagram electrical components 1. Engine stop switch 2. Throttle position sensor 3. Neutral switch 4. Cdi magneto 5. Ignition coil 6. Spark plug 7. Cdi unit wiring diagram 1. Engine stop switch 2. Throttle positi...

  • Page 175

    6-2 ignition system ignition system inspection steps use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. *marked: only when the ignition checker is used. • remove the fol...

  • Page 176

    6-3 ignition system spark gap test 1. Disconnect the ignition coil from spark plug. 2. Remove the ignition coil cap. 3. Connect the dynamic spark tester "1" (ignition checker "2") as shown. • ignition coil "3" • spark plug "4" a. For usa and cdn b. Except for usa and cdn 4. Kick the kickstarter cran...

  • Page 177

    6-4 ignition system 3. Inspect: • charging coil 2 resistance out of specification → replace. Checking the neutral switch 1. Inspect: • neutral switch conduction not conductive while it is in neutral → replace. Conductive while it is engaged → re- place. Set the tester selection position to " Ω × 1"....

  • Page 178

    6-5 throttle position sensor system throttle position sensor system inspection steps if the throttle position sensor will not operate, use the following inspection steps. *marked: refer to "ignition system" section. Use the following special tools in this inspection. Check entire ignition system for...

  • Page 179

    6-6 throttle position sensor system handling note do not loosen the screw (throttle position sensor) "1" except when changing the throttle position sen- sor due to failure because it will cause a drop in engine perfor- mance. Checking the couplers and leads connection 1. Check: • couplers and leads ...

  • Page 180

    6-7 throttle position sensor system measure the output voltage accurate- ly with a digital electronic voltmeter that gives an easy reading of a small voltage. 10. Put the aligning marks "a" on the throttle position sensor and car- buretor. 11. Stop the engine. 12. Remove the carburetor. 13. Tighten:...

  • Page 181

    7-1 engine tuning engine carburetor setting • the air/fuel mixture will vary de- pending on atmospheric conditions. Therefore, it is necessary to take into consideration the air pressure, ambient temperature, humidity, etc., when adjusting the carburetor. • perform a test run to check for prop- er e...

  • Page 182

    7-2 engine adjusting the pilot screw the richness of the air-fuel mixture with the throttle fully closed to 1/4 open can be set by turning the pilot screw "1". Turning in the pilot screw will make the mixture lean at low speeds, and turning it out will enrich it. • if the engine idling speed fluctua...

  • Page 183

    7-3 engine 2. When rough engine operation is felt in quick throttle opening, se- lect a leak jet having higher cali- brating no. Than standard to lean out the mixture. #70 → #80 carburetor setting parts standard leak jet #70 main jet size part number rich #188 4mx-14943-95 #185 4mx-14943-44 #182 4mx...

  • Page 184

    7-4 engine specifications of jet needle examples of carburetor setting depending on symptom diameter of straight portion rich lean n p q r s t u rich 1 richer nfpn-6 nfpp-6 nfpq-6 nfpr-6 nfps-6 nfpt-6 nfpu-6 0.5 richer nfln-6 nflp-6 nflq-6 nflr-6 nfls-6 nflt-6 nflu-6 std nfpn-5 nfpp-5 nfpq-5 nfpr-5 ...

  • Page 185

    7-5 engine * this should be taken simply for an example. It is necessary to set the carburetor while checking the operating conditions of the engine..

  • Page 186

    7-6 chassis chassis selection of the secondary reduction ratio (sprocket) ondary gear reduction ratio> • it is generally said that the second- ary gear ratio should be reduced for a longer straight portion of a speed course and should be increased for a course with many corners. Actual- ly, however,...

  • Page 187

    7-7 chassis c. Stroke 1. Max. Oil amount 2. Standard oil amount 3. Min. Oil amount 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. Us...

  • Page 188

    7-8 chassis when using a rear shock absorber other than currently installed, use the one whose overall length "a" does not exceed the standard as it may result in faulty performance. Never use one whose overall length is greater than standard. Rear shock absorber setting parts • rear shock spring "1...

  • Page 189

    7-9 chassis suspension setting (front fork) • if any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • before any change, set the rear shock absorber sunken length to the standard figure...

  • Page 190

    7-10 chassis suspension setting (rear shock absorber) • if any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • adjust the rebound damping in 2-click increments or decrements. • adjust ...

  • Page 192

    Printed in japan (e) printed on recycled paper yamaha motor co., ltd. 2500 shingai iwata shizuoka japan.