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  5. Owner's Service Manual

Yamaha 2011 WR250FA Owner's Service Manual

Summary of 2011 WR250FA

  • Page 1

    Lit-11626-24-20 1hc-28199-10 owner’s service manual wr250fa read this manual carefully before operating this vehicle. 2011.

  • Page 2

    Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold..

  • Page 3

    Wr250fa owner's service manual ©2010 by yamaha motor corporation, u.S.A. 1st edition, may 2010 all rights reserved. Any reprinting or unauthorized use without the written permission of yamaha motor corporation u.S.A. Is expressly prohibited. Printed in japan p/n. Lit-11626-24-20

  • Page 4: Introduction

    Introduction congratulations on your purchase of a yamaha wr series. This model is the culmination of ya- maha's vast experience in the production of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made yamaha a leader. This manual explains ope...

  • Page 5: Safety Information

    Safety information this machine is designed strictly for off-road use only. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may also be illegal. Please check local regula- tions before riding. • this machine is to be operated by an e...

  • Page 6

    Yamaha motor corporation, u.S.A. Wr motorcycle limited warranty.

  • Page 7: How to Use This Manual

    How to use this manual finding the required page 1. This manual consists of seven chapters; "general information", "specifications", "regular inspec- tion and adjustments", "tuning", "engine", "chassis" and "electrical". 2. The table of contents is at the beginning of the manual. Look over the gener...

  • Page 8

    How to read descriptions to help identify parts and clarify procedure steps, there are exploded diagrams 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 order of the jobs in the...

  • Page 9

    Illustrated symbols (refer to the illustration) illustrated symbols "1" to "7" are used to identi- fy the specifications appearing in the text. 1. With engine mounted 2. Filling fluid 3. Lubricant 4. Special tool 5. Tightening 6. Specified value, service limit 7. Resistance (Ω), voltage (v), electri...

  • Page 10: Memo

    Memo.

  • Page 11: Table of Contents

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

  • Page 12: Contents

    Contents chapter 1 general information location of important labels ..... 1-1 description ........................................... 1-2 consumer information .................... 1-3 included parts.................................... 1-4 important information.................... 1-5 checking of con...

  • Page 13: Chapter 3

    Chapter 3 regular inspection and adjustments periodic maintenance chart for the emission control system ....... 3-1 general maintenance and lubrication chart ............................. 3-2 maintenance intervals for competition use .................................. 3-4 pre-operation inspection an...

  • Page 14: Chapter 6

    Chapter 6 chassis front wheel and rear wheel ....... 6-1 front brake and rear brake...... 6-10 front fork .......................................... 6-24 handlebar........................................... 6-35 steering ............................................... 6-42 swingarm ....................

  • Page 15: Location of Important Labels

    1-1 location of important labels general information location of important labels please read the following important labels carefully before operating this vehicle. 1.

  • Page 16: Description

    1-2 description 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. Engine stop switch 4. Multi-function display 5. Main switch 6. Start switch 7...

  • Page 17: Consumer Information

    1-3 consumer information consumer information there are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the num- ber to your yamaha dealer for positive iden- tification of the model you own. 2. If your machine is stolen, the authorities wil...

  • Page 18: Included Parts

    1-4 included parts included parts valve joint this valve joint "1" prevents fuel from flowing out and is installed to the fuel tank breather hose. In this installation, make sure the arrow fac- es the fuel tank and also downward. Spark plug wrench this spark plug wrench "1" is used to remove and ins...

  • Page 19: Important Information

    1-5 important information important information preparation for removal and disassembly 1. Remove all dirt, mud, dust, and foreign ma- terial before removal and disassembly. • when washing the machine with high pres- sured water, cover the parts follows. Silencer exhaust port side cover air intake p...

  • Page 20: Important Information

    1-6 important information 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 ex- posed to view.) when installing oil seal(s), apply a light coating of lightweight...

  • Page 21: Checking of Connection

    1-7 checking of connection checking of connection dealing with stains, rust, moisture, etc. On the connector. 1. Disconnect: • connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off. 5. If the...

  • Page 22: Special Tools

    1-8 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 tech- niques. The shape and part number used for the special tool differ by...

  • Page 23: Special Tools

    1-9 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 speci- fication. Damper rod holder ...

  • Page 24: Special Tools

    1-10 special tools pocket tester yu-3112-c, 90890-03112 use this tool to inspect the coil resistance, output voltage and amperage. 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 ...

  • Page 25: Special Tools

    1-11 special tools rotor puller ym-04141, 90890-04141 this tool is used to remove the flywheel magneto. Dynamic spark tester ym-34487 ignition checker 90890-06754 this instrument is necessary for checking the ignition sys- tem components. Vacuum/pressure pump gauge set yb-35956-a, 90890-06756 this t...

  • Page 26: Control Functions

    1-12 control functions control functions main switch functions of the respective switch positions are as follows: on: the engine can be started only at this position. Off: all electrical circuits are switched off. Main switch indicator light the main switch "1" is equipped with an indica- tor light ...

  • Page 27: Control Functions

    1-13 control functions kickstarter crank rotate the kickstarter crank "1" away from the engine. Push the starter down lightly with your foot until the gears engage, then kick smoothly and forcefully to start the engine. This model has a primary kickstarter crank so the engine can be started in any g...

  • Page 28: Control Functions

    1-14 control functions cold starter knob when cold, the engine requires a richer air-fuel mixture for starting. A separate starter circuit, which is controlled by the cold starter knob "1", supplies this mixture. Pull the cold starter knob out to open the circuit for starting. When the en- gine has ...

  • Page 29: Multi-Function Display

    1-15 multi-function display multi-function display be sure to stop the machine before making any setting changes to the multi-function display. The multi-function display is equipped with the following: basic mode: • speedometer (which shows current speed) • clock • two tripmeters (which shows the d...

  • Page 30: Multi-Function Display

    1-16 multi-function display 3. Push the "slct1" button (plus) or "slct2" button (minus) and change the time. A long push on the button will fast-forward the time. 4. To end the setting, push the "rst" button for 2 seconds or more. • in a 30-second absence of button operation, the setting will come t...

  • Page 31: Multi-Function Display

    1-17 multi-function display 4. Push the "slct1" button and "rst" button for 2 seconds or more at the same time will finish the setting. Changeover to basic mode/race mode • race mode displays the average speed, so it does not display the current speed. Average speed displayed in race mode will be re...

  • Page 32: Multi-Function Display

    1-18 multi-function display race mode putting measurement on standby starting measurement consists of the following two starts, either of which can be selected. • manual start starting measurement by the rider himself op- erating the button. (a long push on the "slct2" button will put measurement on...

  • Page 33: Multi-Function Display

    1-19 multi-function display resetting measurement data resetting can be made in the following three manners. Resetting is possible while timer measurement is made: • reset average speed (avs). • reset average speed (avs)/tripmeter a. Resetting is possible while timer measurement is not made: • reset...

  • Page 34: Multi-Function Display

    1-20 multi-function display correcting tire diameter • correction can be made any time while timer measurement is or is not being made. • change in the travel distance display will be accompanied by the change in the tire's dia- metric percentage. • even back in basic mode, the tire diameter set in ...

  • Page 35: Multi-Function Display

    1-21 multi-function display function diagram the following diagram illustrates the multi-function display regarding the direction and operation con- dition involved in each of its functions..

  • Page 36: Starting and Break-In

    1-22 starting and break-in starting and break-in fuel always use the recommended fuel as stated below. Also, be sure to use new gasoline. Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine internal parts such as valves, piston rings, and exhaust system, etc...

  • Page 37: Starting and Break-In

    1-23 starting and break-in • if the starter motor will not turn when pushing the start switch, stop pushing it immediately and kick start the engine in order to avoid the load on the motor. • do not open the throttle while kicking the kickstarter crank. Otherwise, the kickstart- er crank may kick ba...

  • Page 38: Starting and Break-In

    1-24 starting and break-in 6. Restart the engine and check the operation of the machine throughout its entire operat- ing range. Restart the machine and operate it for about 10 to 15 more minutes. After the break-in or before each ride, you must check the entire machine for loose fit- tings and fast...

  • Page 39: Torque-Check Points

    1-25 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 40: Cleaning and Storage

    1-26 cleaning and storage cleaning and storage cleaning frequent cleaning of your machine will en- hance its appearance, maintain good overall performance, and extend the life of many com- ponents. 1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering. A...

  • Page 41: General Specifications

    2-1 general specifications specifications general specifications model name: wr250fa (usa, cdn, aus, nz) wr250f (europe, za) model code number: 1hc1 (usa) 1hc2 (cdn) 1hc3 (europe) 1hc4 (aus, nz, za) dimensions: usa, cdn, za aus, nz europe overall length 2,165 mm (85.24 in) 2,175 mm (85.63 in) 2,185 ...

  • Page 42: General Specifications

    2-2 general specifications oil capacity: engine oil periodic oil change 1.1 l (0.97 imp qt, 1.16 us qt) with oil filter replacement 1.2 l (1.06 imp qt, 1.27 us qt) total amount 1.4 l (1.23 imp qt, 1.48 us qt) coolant capacity (including all routes): 0.99 l (0.87 imp qt, 1.05 us qt) air filter: wet t...

  • Page 43: General Specifications

    2-3 general specifications tire: type with tube size (front) 80/100-21 51m (for usa, cdn and za) 90/90-21 m/c 54m m+s (for europe, aus and nz) size (rear) 100/100-18 59m (for usa, cdn and za) 130/90-18 m/c 69m m+s (for europe, aus and nz) tire pressure (front and rear) 100 kpa (1.0 kgf/cm 2 , 15 psi...

  • Page 44: Maintenance Specifications

    2-4 maintenance specifications maintenance specifications engine 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 (0.002 in) camshaft: drive method chain drive (left) ---- camshaft cap ins...

  • Page 45: Maintenance Specifications

    2-5 maintenance specifications timing chain: timing chain type/no. Of links 92rh2010-114m/114 ---- timing chain adjustment method automatic ---- 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...

  • Page 46: Maintenance Specifications

    2-6 maintenance specifications guide inside diameter (in) 4.000–4.012 mm (0.1575–0.1580 in) 4.050 mm (0.1594 in) guide inside diameter (ex) 4.500–4.512 mm (0.1772–0.1776 in) 4.550 mm (0.1791 in) stem-to-guide clearance (in) 0.010–0.037 mm (0.0004–0.0015 in) 0.08 mm (0.003 in) stem-to-guide clearance...

  • Page 47: Maintenance Specifications

    2-7 maintenance specifications piston: piston to cylinder clearance 0.030–0.055 mm (0.0012–0.0022 in) 0.1 mm (0.004 in) piston size "d" 76.955–76.970 mm (3.0297– 3.0303 in) ---- measuring point "h" 8 mm (0.31 in) ---- piston off-set 0.5 mm (0.020 in)/in-side ---- piston pin bore inside diameter 16.0...

  • Page 48: Maintenance Specifications

    2-8 maintenance specifications crankshaft: crank width "a" 55.95–56.00 mm (2.203–2.205 in) ---- runout limit "c" 0.03 mm (0.0012 in) 0.05 mm (0.002 in) big end side clearance "d" 0.15–0.45 mm (0.0059–0.0177 in) 0.50 mm (0.02 in) small end free play "f" 0.4–1.0 mm (0.02–0.04 in) 2.0 mm (0.08 in) clut...

  • Page 49: Maintenance Specifications

    2-9 maintenance specifications carburetor: usa, cdn, za, aus, nz europe type/manufacturer fcr-mx37/ keihin ← ---- i. D. Mark 5ume e0 5uml l0 ---- main jet (m.J) #170 #160 ---- main air jet (m.A.J) #115 ← ---- jet needle (j.N) njru nngu ---- cutaway (c.A) 1.5 ← ---- pilot jet (p.J) #42 #45 ---- pilot...

  • Page 50: Maintenance Specifications

    2-10 maintenance specifications chassis item standard limit steering system: steering bearing type taper roller bearing ---- front suspension: front fork travel 300 mm (11.8 in) ---- fork spring free length 460 mm (18.1 in) 455 mm (17.9 in) spring rate, std k = 4.4 n/mm (0.449 kg/mm, 25.1 lb/in) ---...

  • Page 51: Maintenance Specifications

    2-11 maintenance specifications wheel: usa, cdn, za aus, nz, europe front wheel type spoke wheel ← ---- rear wheel type spoke wheel ← ---- front rim size/material 21 × 1.60/alumi- num ← ---- rear rim size/material 18 × 1.85/alumi- num 18 × 2.15/alumi- num ---- rim runout limit: radial ---- ---- 2.0 ...

  • Page 52: Maintenance Specifications

    2-12 maintenance specifications electrical brake lever and brake pedal: brake lever position 95 mm (3.74 in) ---- brake pedal height (vertical height above footrest top) 10 mm (0.39 in) ---- clutch lever free play (lever end) 8–13 mm (0.31–0.51 in) ---- throttle grip free play 3–5 mm (0.12–0.20 in) ...

  • Page 53: Maintenance Specifications

    2-13 maintenance specifications electric starting system: type constant mesh ---- starter motor: model/manufacturer 5um01/yamaha ---- operation voltage 12 v ---- output 0.35 kw ---- armature coil resistance 0.0189–0.0231 Ω at 20 °c (68 °f) ---- brush overall length 7 mm (0.28 in) 3.5 mm (0.14 in) br...

  • Page 54: Tightening Torques

    2-14 tightening torques tightening torques engine △ - marked portion shall be checked for torque tightening after break-in. Part to be tightened thread size q'ty tightening torque nm m•kg ft•lb spark plug m10s × 1.0 1 13 1.3 9.4 camshaft cap m6 × 1.0 10 10 1.0 7.2 cylinder head blind plug screw m12 ...

  • Page 55: Tightening Torques

    2-15 tightening torques oil pressure check bolt m6 × 1.0 1 10 1.0 7.2 carburetor joint m6 × 1.0 2 10 1.0 7.2 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 throttle cable (pull) m6 × 1.0 1 4 0.4 2.9...

  • Page 56: Tightening Torques

    2-16 tightening torques chassis △ - marked portion shall be checked for torque tightening after break-in. Clutch boss m16 × 1.0 1 75 7.5 54 clutch cable locknut m8 × 1.25 2 7 0.7 5.1 push lever shaft m6 × 1.0 1 10 1.0 7.2 drive sprocket m18 × 1.0 1 75 7.5 54 drive axle oil seal stopper m6 × 1.0 2 10...

  • Page 57: Tightening Torques

    2-17 tightening torques front brake master cylinder cap m4 × 0.7 2 2 0.2 1.4 △ front brake hose union bolt m10 × 1.25 2 30 3.0 22 △ front brake caliper m8 × 1.25 2 23 2.3 17 △ front brake caliper and brake hose holder m6 × 1.0 1 10 1.0 7.2 pad pin plug m10 × 1.0 2 3 0.3 2.2 △ front brake caliper and...

  • Page 58: Tightening Torques

    2-18 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). △ swingarm and brake hose holder m5 × 0.8 4 3 0.3 2.2 ...

  • Page 59: Tightening Torques

    2-19 tightening torques electrical tighten the rotor nut to 65 nm (6.5 m•kg, 47 ft•lb), loosen and retighten the rotor nut to 65 nm (6.5 m•kg, 47 ft•lb). Part to be tightened thread size q'ty tightening torque nm m•kg ft•lb stator m5 × 0.8 2 7 0.7 5.1 holder (ac magneto lead) m5× 0.8 2 7 0.7 5.1 rot...

  • Page 60: Tightening Torques

    2-20 tightening torques general torque specifications this chart specifies torque for standard fasten- ers with standard i.S.O. Pitch threads. Torque specifications for special components or as- semblies are included in the applicable sec- tions of this book. To avoid warpage, tighten multi-fastener...

  • Page 61: Tightening Torques

    2-21 tightening torques definition of units unit read definition measure mm millimeter 10 -3 meter length cm centimeter 10 -2 meter length kg kilogram 10 3 gram weight n newton 1 kg × m/sec 2 force nm newton meter n × m torque m•kg meter kilogram m × kg torque pa pascal n/m 2 pressure n/mm newton pe...

  • Page 62: Lubrication Diagrams

    2-22 lubrication diagrams lubrication diagrams.

  • Page 63: Lubrication Diagrams

    2-23 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 64: Lubrication Diagrams

    2-24 lubrication diagrams.

  • Page 65: Lubrication Diagrams

    2-25 lubrication diagrams 1. Crankshaft 2. Oil filter element 3. Oil tank 4. Oil hose a. From oil pump.

  • Page 66: Cable Routing Diagram

    2-26 cable routing diagram cable routing diagram.

  • Page 67: Cable Routing Diagram

    2-27 cable routing diagram 1. Fuel tank breather hose 2. Clamp 3. Diode 4. Hot starter cable 5. Wire harness 6. Hump (frame) 7. Cylinder head breather hose 8. Throttle position sensor lead 9. Neutral switch lead 10. Oil hose 11. Clutch cable 12. Starter motor lead 13. Cable guide 14. Negative batter...

  • Page 68: Cable Routing Diagram

    2-28 cable routing diagram.

  • Page 69: Cable Routing Diagram

    2-29 cable routing diagram 1. Throttle cable (pull) 2. Throttle cable (return) 3. Catch tank hose 4. Ignition coil 5. Clamp 6. Air induction hose (air cut-off valve - rear of cylinder head) 7. Catch tank breather hose a. Cross the pull and push throttle cables. B. Fasten the catch tank hose and air ...

  • Page 70: Cable Routing Diagram

    2-30 cable routing diagram.

  • Page 71: Cable Routing Diagram

    2-31 cable routing diagram 1. Brake master cylinder 2. Brake hose holder 3. Brake hose a. Install the brake hose so that its pipe por- tion directs as shown and lightly touches the projection on the brake caliper. B. Pass the brake hose into the brake hose holders. C. If the brake hose contacts the ...

  • Page 72: Cable Routing Diagram

    2-32 cable routing diagram.

  • Page 73: Cable Routing Diagram

    2-33 cable routing diagram 1. Clamp 2. Positive battery lead 3. Battery 4. Negative battery lead 5. Taillight coupler 6. Cdi unit coupler (6-pin) 7. Cdi unit coupler (3-pin) 8. Cdi unit coupler (6-pin) a. Fasten the wire harness, negative battery lead and starter motor lead to the upper en- gine bra...

  • Page 74: Cable Routing Diagram

    2-34 cable routing diagram.

  • Page 75: Cable Routing Diagram

    2-35 cable routing diagram 1. Throttle cable 2. Clamp 3. Brake hose 4. Clutch cable 5. Hose guide 6. Main switch coupler 7. Wire harness 8. Headlight coupler 9. Hot starter cable 10. Multi-function display bracket 11. Main switch 12. Upper bracket 13. Clutch switch coupler 14. Engine stop switch cou...

  • Page 76: Control System

    3-1 periodic maintenance chart for the emission control system regular inspection and adjustments periodic maintenance chart for the emission control system • from 4,200 mi (7,000 km) or 9 months, repeat the maintenance intervals starting from 1,800 mi (3,000 km) or 3 months. • items marked with an ...

  • Page 77

    3-2 general maintenance and lubrication chart general maintenance and lubrication chart no. Item checks and maintenance jobs ini- tial odometer readings 600 mi (1,000 km) or 1 month 1,800 mi (3,000 km) or 3 months 3,000 mi (5,000 km) or 6 months 1 clutch check operation. √ √ √ adjust or replace cabl...

  • Page 78

    3-3 general maintenance and lubrication chart • the air filter needs more frequent service if you are riding in unusually wet or dusty areas. • hydraulic brake service • after disassembling the brake master cylinders and calipers, always change the fluid. Regularly check the brake fluid levels and f...

  • Page 79

    3-4 maintenance intervals for competition use maintenance intervals for competition use • 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 re- quired ma...

  • Page 80

    3-5 maintenance intervals for competition use piston ring inspect ● check ring end gap. Replace ● ● piston pin inspect ● replace ● cylinder head inspect carbon deposits and eliminate them. Inspect and clean ● change gasket. Cylinder inspect and clean ● inspect score marks. Replace ● inspect wear. Cl...

  • Page 81

    3-6 maintenance intervals for competition use drive chain use chain lube. Lubricate, slack, align- ment ● ● chain slack: 48–58 mm (1.9– 2.3 in) replace ● cooling system check coolant level and leakage ● ● check radiator cap opera- tion ● replace coolant ● every two years inspect hoses ● outside nuts...

  • Page 82

    3-7 maintenance intervals for competition use front forks inspect and adjust ● ● replace oil ● ● suspension oil "s1" replace oil seal ● front fork oil seal and dust seal clean and lube ● ● lithium base grease protector guide replace ● rear shock absorber inspect and adjust ● ● lube ● (after rain rid...

  • Page 83

    3-8 maintenance intervals for competition use throttle, control cable check routing and con- nection ● ● lubricate ● ● yamaha cable lube or sae 10w-40 motor oil hot starter, clutch lever inspect free play ● item after break -in every race every third (or 500 km) every fifth (or 1,000 km) as re- quir...

  • Page 84

    3-9 pre-operation inspection and maintenance pre-operation inspection and maintenance before riding for break-in operation or practice, make sure the machine is in good operating condi- tion. Before using this machine, check the following points. General inspection and maintenance item routine page ...

  • Page 85: Engine

    3-10 engine engine 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 open the air filter case cover. 6 right side cover 1 refe...

  • Page 86: Engine

    3-11 engine removing the side cover 1. Remove: • bolt (side cover) • right side cover "1" draw the side cover backward to remove it be- cause its claw "a" is inserted in the air filter case..

  • Page 87: Engine

    3-12 engine removing the exhaust pipe and silencer order part name q'ty remarks right side cover refer to "removing the 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 5 silencer 1 6 silencer clamp ...

  • Page 88: Engine

    3-13 engine checking the silencer and exhaust pipe 1. Inspect: • gasket "1" damage → replace. Installing the silencer and exhaust pipe 1. Install: • gasket • exhaust pipe "1" • nut (exhaust pipe) "2" first, temporarily install both nuts, then tighten either of these nuts to 13 nm (1.3 m•kg, 9.4 ft•l...

  • Page 89: Engine

    3-14 engine 1. Radiator changing the coolant do not remove the radiator cap when the en- gine is hot. Take care so that coolant does not splash on painted surfaces. If it splashes, wash it away with water. 1. Place a container under the engine. 2. Remove: • seat • left side cover 3. Remove the catch...

  • Page 90: Engine

    3-15 engine 10.Check: • coolant level coolant level low → add coolant. Checking the radiator cap 1. Inspect: • seal (radiator cap) "1" • valve and valve seat "2" crack/damage → replace. Exist fur deposits "3" → clean or replace. Checking the radiator cap opening pressure 1. Attach: • radiator cap te...

  • Page 91: Engine

    3-16 engine adjusting the clutch cable free play 1. Check: • clutch lever free play "a" out of specification → adjust. 2. Adjust: • clutch lever free play clutch lever free play adjustment steps: a. Loosen the locknuts "1". B. Adjust the free play by changing their tight- ening position. C. Tighten ...

  • Page 92: Engine

    3-17 engine lubricating the throttle 1. Remove: • cover (throttle cable cap) "1" • cover (grip cap) "2" • throttle grip cap "3" 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 c...

  • Page 93: Engine

    3-18 engine 2. Unhook: • binder "1" 3. Remove: • air filter element "1" • filter guide "2" 4. Clean: • air filter element clean them with solvent. After cleaning, remove the remaining solvent by squeezing the element. • do not twist the element when squeezing the element. • leaving too much of solve...

  • Page 94: Engine

    3-19 engine 9. Hook: • binder "1" hook the binder "1" so that it contacts the filter guide projections "a". Checking the engine oil level 1. Start the engine, warm it up for several min- utes, and then turn off the engine and wait for five minutes. 2. Place the machine on a level place and hold it u...

  • Page 95: Engine

    3-20 engine 5. Remove: • oil hose clamp "1" • bolt (oil hose) • oil hose "2" • oil strainer "3" 6. Inspect: • oil strainer clogged → blow. 7. If the oil filter is to be replaced during this oil change, remove the following parts and rein- stall them. Replacement steps: a. Remove the oil filter eleme...

  • Page 96: Engine

    3-21 engine • oil filter element drain bolt • crankcase oil drain bolt • oil tank drain bolt • 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 level checking the oil pressure 1. Check: • oil pressure...

  • Page 97: Engine

    3-22 engine adjusting the valve clearance this section is intended for those who have ba- sic knowledge and skill concerning the servic- ing of yamaha motorcycles (e.G., yamaha dealers, service engineers, etc.) those who have little knowledge and skill concerning ser- vicing are requested not to und...

  • Page 98: Engine

    3-23 engine in order to be sure that the piston is at top dead center, the punch mark "c" on the ex- haust camshaft and the punch mark "d" on the intake camshaft must align with the cylinder head surface, as shown in the illustration. C. Measure the valve clearance "e" using a feeler gauge "1". Reco...

  • Page 99: Engine

    3-24 engine example: installed pad number = 148 rounded off value = 150 pads can only be selected in 0.05 mm incre- ments. E. Locate the rounded-off value and the mea- sured valve clearance in the chart "pad se- lection table". The field where these two coordinates intersect shows the new pad number...

  • Page 100: Engine

    3-25 engine intake exhaust measured clearance installed pad number 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240 0.00 - 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.05 - 0.09 120 125 130 135 1...

  • Page 101: Engine

    3-26 engine cleaning the spark arrester (for usa) • be sure the exhaust pipe and silencer are cool before cleaning the spark arrester. • do not start the engine when cleaning the exhaust system. 1. Remove: • screw (silencer cap) "1" 2. Remove: • bolt (spark arrester) "1" 3. Remove: • tail pipe "1" •...

  • Page 102: Chassis

    3-27 chassis chassis bleeding the hydraulic brake system bleed the brake system if: • the system has been disassembled. • a brake hose has been loosened or re- moved. • the brake fluid is very low. • the brake operation is faulty. A dangerous loss of braking performance may occur if the brake system...

  • Page 103: Chassis

    3-28 chassis 2. Remove: • brake lever cover 3. Adjust: • brake lever position brake lever position adjustment steps: a. Loosen the locknut "1". B. Turn the adjusting bolt "2" until the lever po- sition "a" is within specified position. C. Tighten the locknut. Be sure to tighten the locknut, as it wi...

  • Page 104: Chassis

    3-29 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 105: Chassis

    3-30 chassis i. Install the brake caliper "8" and tighten the pad pin "9". J. Install the pad pin plug "10". 3. Inspect: • brake fluid level refer to "checking the brake fluid level" section. 4. Check: • brake lever operation a softy or spongy feeling → bleed brake sys- tem. Refer to "bleeding the h...

  • Page 106: Chassis

    3-31 chassis 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 con- tainer under its end. F. Loosen the bleed screw and push the brake caliper piston in. Do not reuse the drained brake fluid. G. Tighten the bleed screw. H....

  • Page 107: Chassis

    3-32 chassis checking the rear brake pad insulator 1. Remove: • brake pad refer to "checking and replacing the rear brake pads" section. 2. Inspect: • rear brake pad insulator "1" damage → replace. Checking the brake fluid level 1. Place the brake master cylinder so that its top is in a horizontal p...

  • Page 108: Chassis

    3-33 chassis 3. Clean: • drive chain brush off as much dirt as possible. Then clean the drive chain using the chain clean- er. This machine has a drive chain with small rubber o-rings "1" between the side plates. Steam cleaning, high-pressure washes, cer- tain solvent and kerosene can damage these o...

  • Page 109: Chassis

    3-34 chassis 8. Lubricate: • drive chain adjusting the drive chain slack 1. Elevate the rear wheel by placing the suit- able stand under the engine. 2. Check: • drive chain slack "a" above the seal guard installation bolt. Out of specification → adjust. Before checking and/or adjusting, rotate the r...

  • Page 110: Chassis

    3-35 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 re- place. Cleaning the front fork oil seal and dust seal 1. Remove: • protector • dust seal "1" use a thin screw driver, and be care...

  • Page 111: Chassis

    3-36 chassis • standard position: this is the position which is back by the spe- cific number of clicks from the fully turned-in position. Do not force the adjuster past the minimum or maximum extent of adjustment. The ad- juster may be damaged. Always adjust each front fork to the same setting. Une...

  • Page 112: Chassis

    3-37 chassis adjusting the rear shock absorber spring preload 1. Elevate the rear wheel by placing the suit- able stand under the engine. 2. Remove: • rear frame 3. Measure: • spring fitting length the i.D. Mark "a" is marked at the end of the spring. 4. Adjust: • spring preload adjustment steps: a....

  • Page 113: Chassis

    3-38 chassis adjusting the rear shock absorber rebound damping force 1. Adjust: • rebound damping force by turning the adjuster "1". • standard position: this is the position which is back by the spe- cific number of clicks from the fully turned-in position. (which align the punch mark "a" on the ad...

  • Page 114: Chassis

    3-39 chassis adjusting the rear shock absorber high compression damping force 1. Adjust: • high compression damping force by turning the adjuster "1". • standard position: this is the position which is back by the spe- cific number of turns from the fully turned-in position. (which align the punch m...

  • Page 115: Chassis

    3-40 chassis be sure to retighten these spokes before and after break-in. Checking the wheels 1. Inspect: • wheel runout elevate the wheel and turn it. Abnormal runout → replace. 2. Inspect: • bearing free play exist play → replace. Checking and adjusting the steering head 1. Place a stand under the...

  • Page 116: Chassis

    3-41 chassis • apply the lithium soap base grease on the thread of the steering stem. • set the torque wrench to the steering nut wrench so that they form a right angle. E. Loosen the steering ring nut one turn. F. Retighten the steering ring nut using the steering nut wrench. Avoid over-tightening....

  • Page 117: Chassis

    3-42 chassis.

  • Page 118: Chassis

    3-43 chassis lubrication.

  • Page 119: Chassis

    3-44 chassis to ensure smooth operation of all components, lubricate your machine during setup, after break-in, and after every ride. 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 winding portion ...

  • Page 120: Electrical

    3-45 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 121: Electrical

    3-46 electrical 5. Install: • timing mark accessing screw checking and charging the battery batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • wear protective eye gear wh...

  • Page 122: Electrical

    3-47 electrical • the charge state of an mf battery can be checked by measuring its open-circuit voltage (i.E., the voltage when the positive terminal is disconnected). • no charging is necessary when the opencir- cuit voltage equals or exceeds 12.8 v. B. Check the charge of the battery, as shown in...

  • Page 123: Electrical

    3-48 electrical charging method using a variable voltage charger.

  • Page 124: Electrical

    3-49 electrical charging method using a constant voltage charger.

  • Page 125: Electrical

    3-50 electrical 6. Install: • battery • battery band 7. Connect: • battery leads (to the battery terminals) first, connect the positive lead "1", then the negative lead "2". 8. Check: • battery terminals dirt → clean with a wire brush. Loose connection → connect properly. 9. Lubricate: • battery ter...

  • Page 126: Electrical

    3-51 electrical replacing the headlight bulbs 1. Remove: • headlight refer to "seat, fuel tank and side covers" section. 2. Remove: • headlight bulb holder cover "1" 3. Remove: • headlight bulb holder "1" remove the headlight bulb holder by pushing it in and turning it counterclockwise. 4. Remove: •...

  • Page 127: Chassis

    4-1 chassis tuning chassis selection of the secondary reduction ratio (sprocket) reduction ratio> • it is generally said that the secondary gear ra- tio should be reduced for a longer straight por- tion of a speed course and should be increased for a course with many corners. Ac- tually, however, as...

  • Page 128: Chassis

    4-2 chassis front fork setting the front fork setting should be made depend- ing on the rider's feeling of an actual run and the circuit conditions. The front fork setting includes the following three factors: 1. Setting of air spring characteristics • change the fork oil level. 2. Setting of spring...

  • Page 129: Chassis

    4-3 chassis always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability. A. Load b. Fork stroke 1. Without adjustment washer (standard) 2. 1 adjustment washer 3. 2 adjustment washers setting of spring after replacement as the front fork setting ...

  • Page 130: Chassis

    4-4 chassis rear suspension setting the rear suspension setting should be made depending on the rider's feeling of an actual run and the circuit conditions. The rear suspension setting includes the fol- lowing two factors: 1. Setting of spring preload • change the set length of the spring. • change ...

  • Page 131: Chassis

    4-5 chassis rear shock absorber setting parts • rear shock spring "1" • the i.D. Mark "a" is marked at the end of the spring. • spring specification varies according to the color and quantity of i.D. Marks. • extent of adjustment (spring preload) for the spring preload adjustment, refer to "ad- just...

  • Page 132: Chassis

    4-6 chassis suspension setting (front fork) • if any of the following symptoms is experienced with the standard position as the base, make reset- ting by reference to the adjustment procedure given in the same chart. • before any change, set the rear shock absorber sunken length to the standard figu...

  • Page 133: Chassis

    4-7 chassis suspension setting (rear shock absorber) • if any of the following symptoms is experienced with the standard position as the base, make reset- ting by reference to the adjustment procedure given in the same chart. • adjust the rebound damping in 2-click increments or decrements. • adjust...

  • Page 134: Radiator

    5-1 radiator engine this section is intended for those who have basic knowledge and skill concerning the servicing of yamaha motorcycles (e.G., yamaha dealers, service engineers, etc.) those who have little knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustm...

  • Page 135: Radiator

    5-2 radiator 5 radiator hose 3 1 6 radiator pipe 2 1 7 radiator hose 5 1 8 catch tank hose 1 9 right radiator 1 10 radiator hose 2 1 11 radiator hose 4 1 12 radiator pipe 1 1 13 catch tank breather hose 1 14 catch tank 1 order part name q'ty remarks 5.

  • Page 136: Radiator

    5-3 radiator handling note do not remove the radiator cap when the en- gine and radiator are hot. Scalding hot fluid and steam may be blown out under pres- sure, which could cause serious injury. When the engine has cooled, open the radi- ator cap by the following procedure: place a thick rag, like ...

  • Page 137: Radiator

    5-4 radiator 4. Install: • left radiator "1" • bolt (left radiator) "2" • radiator hose 1 "3" refer to "cable routing diagram" section in the chapter 2. 5. Tighten: • radiator hose clamp "4" 6. Install: • radiator guard "1" first fit the inner hook portion "a" and then the outer one "b" onto the rad...

  • Page 138: Carburetor

    5-5 carburetor carburetor removing the carburetor order part name q'ty remarks seat and fuel tank refer to "seat, fuel tank and side covers" section in the chapter 3. Rear shock absorber refer to "rear shock absorb- er" section in the chapter 6. 1 clamp 2 2 throttle position sensor lead coupler 1 3 ...

  • Page 139: Carburetor

    5-6 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 air cut valve c...

  • Page 140: Carburetor

    5-7 carburetor 16 float 1 17 needle valve 1 18 main jet 1 19 needle jet 1 20 spacer 1 21 pilot jet 1 22 starter jet 1 23 push rod 1 pull the push rod. 24 throttle shaft assembly 1 25 push rod link lever assembly 1 26 main air jet 1 27 pilot air jet 1 28 cold starter plunger 1 order part name q'ty re...

  • Page 141: Carburetor

    5-8 carburetor handling note do not loosen the screw (throttle position sensor) "1" except when changing the throttle position sensor due to failure be- cause it will cause a drop in engine perfor- mance. Checking the carburetor 1. Inspect: • carburetor body contamination → clean. • use a petroleum ...

  • Page 142: Carburetor

    5-9 carburetor checking the jet needle 1. Inspect: • jet needle "1" bends/wear → replace. • clip groove free play exists/wear → replace. Measuring and adjusting the float height 1. Measure: • float height "a" out of specification → adjust. Measurement and adjustment steps: a. Hold the carburetor in ...

  • Page 143: Carburetor

    5-10 carburetor checking the accelerator pump 1. Inspect: • diaphragm (accelerator pump) "1" • spring (accelerator pump) "2" • accelerator pump cover "3" • o-ring "4" • push rod "5" tears (diaphragm)/damage → replace. Dirt → clean. 2. Inspect: • throttle shaft "1" • spring "2" • lever 1 "3" • spring...

  • Page 144: Carburetor

    5-11 carburetor 4. Install: • spring 2 "1" to lever 2 "2". 5. Install: • push rod link lever assembly "1" make sure the stopper "a" of the spring 2 fits into the recess "b" in the carburetor. 6. Install: • washer "1" • circlip "2" 7. Install: • spring "1" to throttle shaft "2". Install the bigger ho...

  • Page 145: Carburetor

    5-12 carburetor 9. Install: • push rod "1" while holding down the lever 1 "2", insert the push rod farthest into the carburetor. 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 installing th...

  • Page 146: Carburetor

    5-13 carburetor 14.Install: • diaphragm (accelerator pump) "1" • spring "2" • o-ring "3" • accelerator pump cover "4" • hose holder (drain hose) "5" • screw (accelerator pump cover) "6" install the diaphragm (accelerator pump) with its mark "a" facing the spring. 15.Install: • jet needle "1" • colla...

  • Page 147: Carburetor

    5-14 carburetor adjusting the accelerator pump timing adjustment steps: in order for the throttle valve height "a" to achieve the specified value, tuck under the throttle valve plate "1" the rod "2" etc. With the same outer diameter as the specified value. A. Fully turn in the accelerator pump adjus...

  • Page 148: Carburetor

    5-15 carburetor 4. Tighten: • bolt (carburetor joint) "1" • bolt (air filter joint) "2" 5. Install: • throttle cable (pull) "1" • throttle cable (return) "2" 6. Adjust: • throttle grip free play refer to "adjusting the throttle ca- ble free play" section in the chapter 3. 7. Install: • throttle cabl...

  • Page 149: Air Induction System

    5-16 air induction system air induction system removing the air induction system order part name q'ty remarks 1 bracket 1 2 air cut-off valve assembly 1 3 air induction hose (air cut-off valve - front of cylinder head) 1 4 air induction pipe 1 5 gasket 1 6 air induction hose (air cut-off valve - rea...

  • Page 150: Air Induction System

    5-17 air induction system checking the air induction system 1. Inspect: • air induction hose crack/damage → replace. • air induction pipe crack/damage → replace. 2. Check: • operation of air cut valve pass air through the pipe and check the air cut valve for operation. Does not meet the following co...

  • Page 151: Camshafts

    5-18 camshafts camshafts removing the cylinder head cover order part name q'ty remarks seat and fuel tank refer to "removing the seat, fuel tank and side covers" section in the chapter 3. Air cut-off valve assembly refer to "air induction system" section. 1 spark plug 1 2 cylinder head breather hose...

  • Page 152: Camshafts

    5-19 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 153: Camshafts

    5-20 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 counterclockwise with a wrench. B. Align the t.D.C. Mark "a" on the rotor with the align mark "b" on ...

  • Page 154: Camshafts

    5-21 camshafts checking the camshaft 1. Inspect: • cam lobe pitting/scratches/blue discoloration → re- place. 2. Measure: • cam lobe length "a" and "b" out of specification → replace. 3. Measure: • runout (camshaft) out of specification → replace. 4. Measure: • camshaft-to-cap clearance out of speci...

  • Page 155: Camshafts

    5-22 camshafts d. Remove the camshaft caps and measure the width of the plastigauge ® "1". 5. Measure: • camshaft outside diameter "a" out of specification→replace the camshaft. Within specification → replace camshaft case and camshaft caps as a set. Checking the camshaft sprocket 1. Inspect: • cams...

  • Page 156: Camshafts

    5-23 camshafts installing the camshaft 1. Install: • exhaust camshaft "1" • intake camshaft "2" installation steps: a. Turn the crankshaft counterclockwise with a wrench. • apply the molybdenum disulfide oil on the camshafts. • apply the engine oil on the decompression system. B. Align the t.D.C. Ma...

  • Page 157: Camshafts

    5-24 camshafts 2. Install: • timing chain tensioner installation steps: a. While pressing the tensioner rod lightly with fingers, use a thin screwdriver and wind the tensioner rod up fully clockwise. B. With the rod fully wound and the chain ten- sioner up mark "a" facing upward, install the gasket ...

  • Page 158: Camshafts

    5-25 camshafts 7. Install: • cylinder head breather hose • spark plug spark plug: 13 nm (1.3 m•kg, 9.4 ft•lb).

  • Page 159: Cylinder Head

    5-26 cylinder head cylinder head removing the cylinder head order part name q'ty remarks seat and fuel tank refer to "removing the seat, fuel tank and side covers" section in the chapter 3. Exhaust pipe and silencer refer to "removing the ex- haust pipe and silencer" sec- tion in the chapter 3. Radi...

  • Page 160: Cylinder Head

    5-27 cylinder head 4 bolt [l = 135 mm (5.31 in)] 2 5 bolt [l = 145 mm (5.71 in)] 2 6 cylinder head 1 7 timing chain guide (exhaust side) 1 order part name q'ty remarks.

  • Page 161: Cylinder Head

    5-28 cylinder head checking the cylinder head 1. Eliminate: • carbon deposits (from the combustion chambers) use a rounded scraper. Do not use a sharp instrument to avoid damag- ing or scratching: • spark plug threads • valve seats 2. Inspect: • cylinder head scratches/damage → replace. Replace the ...

  • Page 162: Cylinder Head

    5-29 cylinder head 3. Install: • copper washer "1" • oil delivery pipe "2" • union bolt (m8) "3" • union bolt (m10) "4" first tighten the union bolts temporarily.Then retighten them with the width "a" across flats of the oil delivery pipe held tight with a spanner. 4. Install: • radiator pipe "1" • ...

  • Page 163: Valves and Valve Springs

    5-30 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 164: Valves and Valve Springs

    5-31 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" position very carefully so that they can be reinstalled in their original place. 2. Check: • valve sealing leakage at the valve seat → inspect the val...

  • Page 165: Valves and Valve Springs

    5-32 valves and valve springs 2. Replace: • valve guide replacement steps: to ease guide removal, installation and to maintain correct fit heat the cylinder head in an over to 100 °c (212 °f). A. Remove the valve guide using a valve guide remover "1". B. Install the new valve guide using a valve gui...

  • Page 166: Valves and Valve Springs

    5-33 valves and valve springs 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 re- place the oil seal. 6. Eliminate: • carbon deposits (from the valve face and valve seat) 7. Inspect...

  • Page 167: Valves and Valve Springs

    5-34 valves and valve springs lapping steps: a. Apply a coarse lapping compound to the valve face. Do not let the compound enter the gap be- tween the valve stem and the guide. B. Apply molybdenum disulfide oil to the valve stem. C. Install the valve into the cylinder head. D. Turn the valve until t...

  • Page 168: Valves and Valve Springs

    5-35 valves and valve springs 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. Installing the valves 1. Apply: • molybdenum disulfide oil onto the valve s...

  • Page 169: Valves and Valve Springs

    5-36 valves and valve springs 4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood. Hitting the valve tip with excessive force could damage the valve. 5. Install: • adjusting pad "1" • valve lifter "2" • apply the molybdenum disulfide oil on the valve st...

  • Page 170: Cylinder and Piston

    5-37 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 171: Cylinder and Piston

    5-38 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 reinstallation. • before removing each piston pin, deburr the clip groove and pin hole area. If the piston p...

  • Page 172: Cylinder and Piston

    5-39 cylinder and piston b. If out of specification, replace the cylinder, and replace the piston and piston rings as set. C. Measure the piston skirt diameter "p" with a micrometer. A. 8 mm (0.31 in) from the piston bottom edge d. If out of specification, replace the piston and piston rings as a se...

  • Page 173: Cylinder and Piston

    5-40 cylinder and piston checking the piston pin 1. Inspect: • piston pin blue discoloration/grooves → replace, then inspect the lubrication system. 2. Measure: • piston pin-to-piston clearance measurement steps: a. Measure the outside diameter (piston pin) "a". If out of specification, replace the ...

  • Page 174: Cylinder and Piston

    5-41 cylinder and piston • apply engine oil onto the piston pin and pis- ton. • be sure that the arrow mark "a" on the piston points to the exhaust side of the engine. • before installing the piston pin clip, cover the crankcase with a clean rag to prevent the pis- ton pin clip from falling into the...

  • Page 175: Clutch

    5-42 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" sec- tion. Clutch cable disconnect at engine side. 1 clutch cover 1 2 clutch spring 5 3 pressure plate 1 4 push...

  • Page 176: Clutch

    5-43 clutch 11 clutch plate 8 12 cushion spring 1 13 seat plate 1 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 177: Clutch

    5-44 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 178: Clutch

    5-45 clutch checking the clutch plates 1. Measure: • clutch plate warpage out of specification → replace clutch plate as a set. Use a surface plate "1" and thickness gauge "2". Checking the push lever shaft 1. Inspect: • push lever shaft "1" wear/damage → replace. Checking the push rod 1. Inspect: •...

  • Page 179: Clutch

    5-46 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 180: Clutch

    5-47 clutch 6. Install: • bearing "1" • washer "2" • circlip "3" to push rod 1 "4". Apply the engine oil on the bearing and washer. 7. Install: • push rod 2 "1" • ball "2" • push rod 1 "3" apply the engine oil on the push rod 1, 2 and ball. 8. Install: • pressure plate "1" 9. Install: • clutch sprin...

  • Page 181: Clutch

    5-48 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 182

    5-49 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 cool- ant" section in the ...

  • Page 183

    5-50 oil filter element and water pump 5 bolt (oil hose) 1 6 kickstarter crank 1 7 right crankcase cover 1 8 impeller 1 refer to removal section. 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 s...

  • Page 184

    5-51 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 im- peller. Removing the oil seal it is not necessary to disassemble the water p...

  • Page 185

    5-52 oil filter element and water pump checking the bearing 1. Inspect: • bearing rotate inner race with a finger. Rough spot/seizure → replace. Checking the oil seal 1. Inspect: • oil seal "1" wear/damage → replace. Installing the oil seal 1. Install: • oil seal "1" • apply the lithium soap base gr...

  • Page 186

    5-53 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 i...

  • Page 187

    5-54 oil filter element and water pump 3. Install: • copper washer "1" • oil delivery pipe "2" • union bolt (m8) "3" • union bolt (m10) "4" first tighten the union bolts temporarily.Then retighten them with the width "a" across flats of the oil delivery pipe held tight with a spanner. Installing the...

  • Page 188: Balancer

    5-55 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 water pump" section. Stator refer to "ac magneto and starter clutch" section. 1 nut (primary drive gear) 1 refer to removal ...

  • Page 189: Balancer

    5-56 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 190: Balancer

    5-57 balancer 2. Install: • balancer shaft driven gear "1" install the balancer shaft driven gear onto the balancer shaft while aligning the punch mark "a" on the balancer shaft driven gear with the lower spline "b" on the balancer shaft end. 3. Install: • balancer shaft drive gear "1" • align the p...

  • Page 191: Oil Pump

    5-58 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 water 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 in...

  • Page 192: Oil Pump

    5-59 oil pump 12 dowel pin 1 13 washer 1 14 oil pump drive shaft 1 15 rotor housing 1 order part name q'ty remarks.

  • Page 193: Oil Pump

    5-60 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 194: Oil Pump

    5-61 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 195: Oil Pump

    5-62 oil pump 2. Install: • outer rotor 1 "1" apply the engine oil on the outer rotor 1. 3. Install: • oil pump cover "1" • screw (oil pump cover) "2" • dowel pin "3" • inner rotor 2 "4" • circlip "5" • apply the engine oil on the inner rotor 2. • fit the dowel pin into the groove in the inner rotor...

  • Page 196: Kick Shaft and Shift Shaft

    5-63 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 197: Kick Shaft and Shift Shaft

    5-64 kick shaft and shift shaft 14 shift guide 1 refer to removal section. 15 shift lever assembly 1 refer to removal section. 16 shift lever 1 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 ...

  • Page 198: Kick Shaft and Shift Shaft

    5-65 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 199: Kick Shaft and Shift Shaft

    5-66 kick shaft and shift shaft checking the shift shaft 1. Inspect: • shift shaft "1" bend/damage → replace. • spring "2" broken → replace. Checking the shift guide and shift lever assembly 1. Inspect: • shift guide "1" • shift lever "2" • pawl "3" • pawl pin "4" • spring "5" wear/damage → replace....

  • Page 200: Kick Shaft and Shift Shaft

    5-67 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 201: Kick Shaft and Shift Shaft

    5-68 kick shaft and shift shaft 2. Install: • torsion spring "1" to kick shaft "2". Make sure the stopper "a" of the torsion spring fits into the hole "b" on the kick shaft. 3. Install: • spring guide "1" slide the spring guide into the kick shaft, make sure the groove "a" in the spring guide fits o...

  • Page 202

    5-69 ac magneto and starter clutch ac magneto and starter clutch removing the ac magneto and starter clutch order part name q'ty remarks drain the engine oil. Refer to "changing the engine oil" section in the chapter 3. Seat and fuel tank refer to "seat, fuel tank and side covers" section in the cha...

  • Page 203

    5-70 ac magneto and starter clutch tighten the rotor nut to 65 nm (6.5 m•kg, 47 ft•lb), loosen and retighten the rotor nut to 65 nm (6.5 m•kg, 47 ft•lb). 10 starter clutch drive gear 1 11 starter clutch assembly cover 1 12 starter clutch 1 refer to removal section. 13 bearing 1 14 washer 1 15 idle g...

  • Page 204

    5-71 ac magneto and starter clutch removing the rotor 1. Remove: • nut (rotor) "1" • washer use the sheave holder "2". 2. Remove: • rotor "1" use the rotor puller "2". Removing the starter clutch 1. Remove: • starter clutch assembly cover "1" insert a thin screwdriver or the like under the convexity...

  • Page 205

    5-72 ac magneto and starter clutch checking the starter clutch 1. Check: • starter clutch damage/wear → replace. 2. Check: • idle gear • starter clutch drive gear pitting/burrs/chips/roughness/wear → re- place the defective parts. 3. Check: • starter clutch operation a. Install the starter clutch dr...

  • Page 206

    5-73 ac magneto and starter clutch apply the sealant to the grommet of the ac magneto lead. 3. Install: • idle gear 2 "1" • dowel pin "2" apply the engine oil on the idle gear 2. 4. Install: • idle gear plate "1" • bolt (idle gear plate) "2" 5. Install: • washer "1" • bearing "2" • starter clutch dr...

  • Page 207

    5-74 ac magneto and starter clutch 8. Install: • woodruff key "1" • rotor "2" • degrease the contact surfaces of the tapered portions of the crankshaft and rotor. • when installing the woodruff key, make sure that its flat surface "a" is in parallel with the crankshaft center line "b". • when instal...

  • Page 208

    5-75 ac magneto and starter clutch 12.Install: • o-ring • cover (idle gear 1) "1" • bolt "2" • apply the lithium soap base grease on the o- ring. • install the cover (idle gear 1) with its mark "a" facing upward. 13.Connect: • ac magneto lead refer to "cable routing diagram" section in the chapter 2...

  • Page 209: Engine Removal

    5-76 engine removal engine removal removing the engine order part name q'ty remarks hold the machine by placing the suit- able stand under the frame. Refer to "handling note". Drain the engine oil. Refer to "changing the engine oil" section in the chapter 3. Seat and fuel tank refer to "seat, fuel t...

  • Page 210: Engine Removal

    5-77 engine removal shift pedal refer to "ac magneto and starter clutch" section. Cylinder head breather hose refer to "camshafts" section. Oil hose and oil tank breather hose refer to "oil pump" section. Ignition coil disconnect the ac magneto lead. Negative battery lead disconnect at the engine si...

  • Page 211: Engine Removal

    5-78 engine removal 11 lower engine bracket 2 12 engine mounting bolt 3 13 pivot shaft 1 refer to removal section. 14 engine 1 refer to removal section. Order part name q'ty remarks.

  • Page 212: Engine Removal

    5-79 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 213: Engine Removal

    5-80 engine removal • engine mounting bolt (upper) "10" • lower engine guard "11" • bolt (lower engine guard) "12" • apply the molybdenum disulfide grease on the pivot shaft. • install the patch with the claw "a" facing out- side the chassis. Installing the brake pedal 1. Install: • spring "1" • bra...

  • Page 214: Engine Removal

    5-81 engine removal • bolt (drive chain sprocket cover) "3" installing the neutral switch 1. Install: • spring "1" • pin "2" • o-ring "3" • neutral switch "4" • screw (neutral switch) "5" apply the lithium soap base grease on the o- ring. Bolt (drive chain sprocket cover): 7 nm (0.7 m•kg, 5.1 ft•lb)...

  • Page 215: Crankcase and Crankshaft

    5-82 crankcase and crankshaft crankcase and crankshaft removing the crankshaft order part name q'ty remarks engine refer to "engine removal" sec- tion. Piston refer to "cylinder and piston" section. Kick shaft assembly refer to "kick shaft and shift shaft" section. Segment refer to "kick shaft and s...

  • Page 216: Crankcase and Crankshaft

    5-83 crankcase and crankshaft 5 bolt [l = 55 mm (2.17 in)] 1 refer to removal section. 6 bolt [l = 70 mm (2.76 in)] 3 refer to removal section. 7 hose guide 1 refer to removal section. 8 clutch cable holder 1 refer to removal section. 9 right crankcase 1 refer to removal section. 10 left crankcase 1...

  • Page 217: Crankcase and Crankshaft

    5-84 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 218: Crankcase and Crankshaft

    5-85 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 af- ter all the bolts are loosened, remove them. B. ...

  • Page 219: Crankcase and Crankshaft

    5-86 crankcase and crankshaft checking the timing chain and timing chain guide 1. Inspect: • timing chain cracks/stiff → replace the timing chain and camshaft sprocket as a set. 2. Inspect: • timing chain guide wear/damage → replace. Checking the crankcase 1. Inspect: • contacting surface "a" scratc...

  • Page 220: Crankcase and Crankshaft

    5-87 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 221: Crankcase and Crankshaft

    5-88 crankcase and crankshaft a. For usa and cdn b. Except for usa and cdn 2. Check: • shifter operation • transmission operation unsmooth operation → repair. 3. Install: • oil strainer "1" • bolt (oil strainer) "2" 4. Apply: • sealant on the right crankcase "1". Clean the contacting surface of left...

  • Page 222: Crankcase and Crankshaft

    5-89 crankcase and crankshaft tighten the crankcase tightening bolts in stage, using a crisscross pattern. 7. Install: • oil delivery pipe 2 "1" • o-ring "2" • bolt (oil delivery pipe 2) "3" apply the lithium soap base grease on the or- ings. 8. Install: • timing chain "1" • timing chain guide (inta...

  • Page 223

    5-90 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" sec- tion. Separate the crankcase. Refer to "crankcase and crankshaft" section. 1 main axle 1 refer to ...

  • Page 224

    5-91 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 225

    5-92 transmission, shift cam and shift fork 2. Inspect: • shift cam "1" • segment "2" wear/damage → replace. 3. Check: • shift fork movement unsmooth operation → replace shift fork. For a malfunctioning shift fork, replace not only the shift fork itself but the two gears each adja- cent to the shift...

  • Page 226

    5-93 transmission, shift cam and shift fork 3. Install: • washer "1" • circlip "2" • be sure the circlip sharp-edged corner "a" is positioned opposite side to the washer and gear "b". • install the circlip with its ends "c" settled even- ly on the spline crests. 4. Install: • collar "1" • apply the ...

  • Page 227

    5-94 transmission, shift cam and shift fork 6. Install: • transmission assembly "1" to left crankcase "2". Apply the engine oil on the bearings and guide bars. 7. Check: • shifter operation • transmission operation unsmooth operation → repair..

  • Page 228: Front Wheel and Rear Wheel

    6-1 front wheel and rear wheel chassis this section is intended for those who have basic knowledge and skill concerning the servicing of yamaha motorcycles (e.G., yamaha dealers, service engineers, etc.) those who have little knowl- edge and skill concerning servicing are requested not to undertake ...

  • Page 229: Front Wheel and Rear Wheel

    6-2 front wheel and rear wheel 7 oil seal 1 8 bearing 2 refer to removal section. 9 brake disc 1 order part name q'ty remarks 21 nm (2.1 m kg, 15 ft lb) 21 nm (2.1 m kg, 15 ft lb) 12 nm (1.2 m kg, 8.7 ft lb) 90 nm (9.0 m kg, 65 ft lb) 6.

  • Page 230: Front Wheel and Rear Wheel

    6-3 front wheel and rear wheel removing the rear wheel order part name q'ty remarks hold the machine by placing the suit- able 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 ...

  • Page 231: Front Wheel and Rear Wheel

    6-4 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 232: Front Wheel and Rear Wheel

    6-5 front wheel and rear wheel checking the brake disc 1. Measure: • brake disc deflection (only rear brake disc) use the dial gauge "1". Out of specification → inspect wheel runout. If wheel runout is in good condition, replace the brake disc. 2. Measure: • brake disc thickness "a" out of limit → r...

  • Page 233: Front Wheel and Rear Wheel

    6-6 front wheel and rear wheel 3. Install: • collar "1" apply the lithium soap base grease on the oil seal lip. 4. Install: • speed sensor "1" • apply the lithium soap base grease on the oil seal lip of the speed sensor. • make sure the two projections "a" in the wheel hub are meshed with the two sl...

  • Page 234: Front Wheel and Rear Wheel

    6-7 front wheel and rear wheel installing the rear wheel 1. Install: • bearing (right) "1" • circlip "2" • spacer "3" • bearing (left) "4" • oil seal "5" • apply the lithium soap base grease on the bearing and oil seal lip when installing. • install the bearing with seal facing outward. • use a sock...

  • Page 235: Front Wheel and Rear Wheel

    6-8 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 236: Front Wheel and Rear Wheel

    6-9 front wheel and rear wheel 9. Adjust: • drive chain slack "a" refer to "adjusting the drive chain slack" section in the chapter 3. 10.Tighten: • nut (wheel axle) "1" • locknut "2" drive chain slack: 48–58 mm (1.9–2.3 in) nut (wheel axle): 125 nm (12.5 m•kg, 90 ft•lb) locknut: 19 nm (1.9 m•kg, 13...

  • Page 237: Front Brake and Rear Brake

    6-10 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 suit- able stand under the engine. Refer to "handling note". Drain the brake fluid. Refer to removal section. 1 brake hose holder (protector) 2 2 brake hos...

  • Page 238: Front Brake and Rear Brake

    6-11 front brake and rear brake removing the rear brake order part name q'ty remarks hold the machine by placing the suit- able 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...

  • Page 239: Front Brake and Rear Brake

    6-12 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 240: Front Brake and Rear Brake

    6-13 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 brake master cylinder boot 1 5 circlip 1 use a long nose circlip pliers. 6 washer 1 7 push rod 1 8 brake master cyli...

  • Page 241: Front Brake and Rear Brake

    6-14 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 242: Front Brake and Rear Brake

    6-15 front brake and rear brake removing the brake caliper piston seal kit 1. Remove: • brake caliper piston dust seal "1" • brake caliper piston seal "2" remove the brake caliper piston seals and brake caliper piston dust seals by pushing them with a finger. Never attempt to pry out brake caliper p...

  • Page 243: Front Brake and Rear Brake

    6-16 front brake and rear brake a. Front b. Rear checking the brake caliper 1. Inspect: • brake caliper cylinder inner surface "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. Repl...

  • Page 244: Front Brake and Rear Brake

    6-17 front brake and rear brake a. Front b. Rear 3. Install: • brake caliper piston "1" apply the brake fluid on the piston wall. • install the piston with its shallow de- pressed side "a" facing the brake caliper. • never force to insert. A. Front b. Rear installing the front brake caliper 1. Insta...

  • Page 245: Front Brake and Rear Brake

    6-18 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 projections "a" into the brake caliper recesses "b". • temporarily tighten the pad pin at this point. 2. Install: • brake disc cover "1" •...

  • Page 246: Front Brake and Rear Brake

    6-19 front brake and rear brake 3. Install: • spring "1" to brake master cylinder piston "2". Install the spring at the smaller dia. Side. A. Front b. Rear 4. Install: • brake master cylinder kit "1" • washer (front brake) "2" • push rod (rear brake) "2" • circlip "3" • brake master cylinder boot "4...

  • Page 247: Front Brake and Rear Brake

    6-20 front brake and rear brake installing the rear brake master cylinder 1. Install: • copper washer "1" • brake hose "2" • union bolt "3" always use new copper washers. Install the brake hose so that its pipe por- tion "a" directs as shown and lightly touch- es the projection "b" on the brake mast...

  • Page 248: Front Brake and Rear Brake

    6-21 front brake and rear brake installing the front brake hose 1. Install: • copper washer "1" • brake hose "2" • union bolt "3" always use new copper washers. Install the brake hose so that its pipe por- tion "a" directs as shown and lightly touch- es the projection "b" on the brake caliper. 2. In...

  • Page 249: Front Brake and Rear Brake

    6-22 front brake and rear brake install the brake hose so that it contacts the brake master cylinder projection "a" and that its bent portion "b" faces downward. Installing the rear brake hose 1. Install: • copper washer "1" • brake hose "2" • union bolt "3" always use new copper washers. Install th...

  • Page 250: Front Brake and Rear Brake

    6-23 front brake and rear brake • be careful that water does not enter the master cylinder when refilling. Water will significantly lower the boiling point of the fluid and may result in vapor lock. Brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately. A...

  • Page 251: Front Fork

    6-24 front fork front fork removing the front fork order part name q'ty remarks a. For cdn hold the machine by placing the suit- able 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"...

  • Page 252: Front Fork

    6-25 front fork disassembling the front fork order part name q'ty remarks 1 front fork cap bolt 1 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 tube 1 7...

  • Page 253: Front Fork

    6-26 front fork handling note support the machine securely so there is no danger of it falling over. The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers. To prevent an accidental explosion of air, the following instructions should be ob- s...

  • Page 254: Front Fork

    6-27 front fork removing the damper rod 1. Remove: • base valve "1" • damper rod "2" use a damper rod holder "3" to lock the damper rod. Checking the damper rod 1. Inspect: • damper rod "1" bend/damage → replace damper rod. The front fork with a built-in piston rod has a very sophisticated internal ...

  • Page 255: Front Fork

    6-28 front fork do not attempt to straighten a bent inner tube as this may dangerously weaken the tube. Checking the outer tube 1. Inspect: • outer tube "1" score marks/wear/damage → replace. Checking the front fork cap bolt 1. Inspect: • front fork cap bolt "1" • o-ring "2" • air bleed screw "3" we...

  • Page 256: Front Fork

    6-29 front fork 5. Install: • spring guide "1" • locknut "2" to damper rod "3". • install the spring guide with its smaller dia.End "a" facing downward. • with its thread "b" facing upward, fully finger tighten the locknut onto the damper rod. 6. Install: • dust seal "1" • stopper ring "2" • oil sea...

  • Page 257: Front Fork

    6-30 front fork 9. 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". 10.Install: • oil seal "1" press the oil seal into the outer tube with fork seal driver "2". 11.Install: • stopper ring "1" fit the stopper rin...

  • Page 258: Front Fork

    6-31 front fork • be sure to use recommended fork oil. If other oils are used, they may have an ex- cessively adverse effect on the front fork performance. • never 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 dist...

  • Page 259: Front Fork

    6-32 front fork 21.Measure: • distance "a" out of specification → turn into the locknut. 22.Loosen: • rebound damping adjuster "1" • loosen the rebound damping adjuster finger tight. • record the set position of the adjuster (the amount of turning out the fully turned in posi- tion). 23.Install: • p...

  • Page 260: Front Fork

    6-33 front fork 27.Install: • protector guide "1" install the protector guide with its wider side "a" facing downward. Installing the front fork 1. Install: • front fork "1" • temporarily tighten the pinch bolts (lower bracket). • do not tighten the pinch bolts (upper bracket) yet. 2. Tighten: • fro...

  • Page 261: Front Fork

    6-34 front fork 6. Install: • speed sensor lead "1" • plate 2 "2" • screw (plate 2) "3" to right protector "4". Install the plate 2 in the direction as shown. 7. Install: • protector "1" • bolt (protector) "2" 8. Adjust: • rebound damping force turn in the damping adjuster "1" finger-tight and then ...

  • Page 262: Handlebar

    6-35 handlebar handlebar removing the handlebar order part name q'ty remarks headlight 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 disconnect the clutch switch lead. 5 engine stop switch 1 dis...

  • Page 263: Handlebar

    6-36 handlebar 13 left grip 1 refer to removal section. 14 handlebar upper holder 2 15 handlebar 1 16 handlebar lower holder 2 order part name q'ty remarks.

  • Page 264: Handlebar

    6-37 handlebar removing the brake master cylinder 1. Remove: • brake master cylinder bracket "1" • brake master cylinder "2" • do not let the brake master cylinder hang on the brake hose. • keep the brake master cylinder cap side horizontal to prevent air from coming in. Removing the grip 1. Remove:...

  • Page 265: Handlebar

    6-38 handlebar 2. Install: • handlebar "1" • handlebar upper holder "2" • bolt (handlebar upper holder) "3" • the handlebar upper holder should be in- stalled with the punched mark "a" forward. • install the handlebar so that the marks "b" are in place on both sides. • install the handlebar so that ...

  • Page 266: Handlebar

    6-39 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 lac- quer thinner. • install the grip to the tube guide so that the grip match mark "b" and tube guide slot "...

  • Page 267: Handlebar

    6-40 handlebar 9. Install: • grip cap cover "1" • cover (throttle cable cap) "2" 10.Install: • start switch "1" • brake master cylinder "2" • brake master cylinder bracket "3" • bolt (brake master cylinder bracket) "4" • clamp "5" • the start switch and brake master cylinder bracket should be instal...

  • Page 268: Handlebar

    6-41 handlebar 12.Install: • clutch cable "1" • hot starter cable "2" apply the lithium soap base grease on the clutch cable end and hot starter cable end. 13.Adjust: • clutch lever free play refer to "adjusting the clutch ca- ble free play" section in the chapter 3. • hot starter lever free play re...

  • Page 269: Steering

    6-42 steering steering removing the steering order part name q'ty remarks a. For cdn 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 suit- able stand under the engine. Refer to "handling...

  • Page 270: Steering

    6-43 steering 4 steering stem nut 1 5 front fork 2 refer to "front fork" section. 6 upper bracket 1 7 steering ring nut 1 refer to removal section. 8 lower bracket 1 9 bearing race cover 1 10 upper bearing 1 11 lower bearing 1 refer to removal section. 12 bearing race 2 refer to removal section. Ord...

  • Page 271: Steering

    6-44 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 272: Steering

    6-45 steering installing the lower bracket 1. Install: • lower bearing "1" apply the lithium soap base grease on the dust seal lip and bearing inner circumference. 2. Install: • bearing race • upper bearing "1" • bearing race cover "2" apply the lithium soap base grease on the bearing and bearing ra...

  • Page 273: Steering

    6-46 steering 7. Install: • front fork "1" • upper bracket "2" • main switch "3" • front brake hose guide bracket "4" • front reflector (for cdn) "5" • nut (front reflector) (for cdn) "6" • front reflector bracket (for cdn) "7" • temporarily tighten the pinch bolts (lower bracket). • do not tighten ...

  • Page 274: Steering

    6-47 steering 13.Install: • multi-function display bracket "1" • multi-function display "2" pass the throttle cables "3", clutch cable "4" and hot starter cable "5" between the multi- function display bracket and upper bracket. 14.Install: • holder "1" • clamp "2" • install so that the marking "a" o...

  • Page 275: Swingarm

    6-48 swingarm swingarm removing the swingarm order part name q'ty remarks hold the machine by placing the suit- able 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. Bo...

  • Page 276: Swingarm

    6-49 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 277: Swingarm

    6-50 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 screwdriver insert- ed under the mark "a" on the left cap. Removing the bearing 1. Remove: • bearing "1" remove the bearing by pres...

  • Page 278: Swingarm

    6-51 swingarm installing the bearing and oil seal 1. Install: • bearing "1" • oil seal "2" to swingarm. • apply the molybdenum disulfide grease on the bearing when installing. • install the bearing by pressing it on the side having the manufacture's marks or numbers. • first install the outer and th...

  • Page 279: Swingarm

    6-52 swingarm apply the molybdenum disulfide grease on the bushings, thrust bearings, oil seal lips and con- tact surfaces of the collar and thrust bearing. 2. Install: • collar "1" • washer "2" to relay arm "3". Apply the molybdenum disulfide grease on the collars and oil seal lips. 3. Install: • c...

  • Page 280: Swingarm

    6-53 swingarm 7. Check: • swingarm side play "a" free play exists → replace thrust bearing. • swingarm up and down movement "b" unsmooth movement/binding/rough spots → grease or replace bearings, bushings and collars. 8. Install: • bolt (connecting rod) "1" • washer "2" • nut (connecting rod) "3" • ...

  • Page 281: Swingarm

    6-54 swingarm 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 "1" • drive chain support cover "2" • bolt {drive chain support [l = 50 mm (1.97 in)]} "3" • nut (drive chain support...

  • Page 282: Rear Shock Absorber

    6-55 rear shock absorber rear shock absorber removing the rear shock absorber order part name q'ty remarks hold the machine by placing the suit- able stand under the engine. Refer to "handling note". Seat and side cover refer to "removing the seat, fuel tank and side covers" section in the chapter 3...

  • Page 283: Rear Shock Absorber

    6-56 rear shock absorber battery refer to "checking and charg- ing the battery" section in the chapter 3. Disconnect the starter relay coupler. Starter motor lead disconnect at the starter relay side. 1 locking tie 4 2 taillight coupler 1 3 cdi unit coupler 3 4 plastic band 1 5 clamp (air filter joi...

  • Page 284: Rear Shock Absorber

    6-57 rear shock absorber 13 upper spring guide 1 14 spring (rear shock absorber) 1 15 bearing 2 refer to removal section. Order part name q'ty remarks.

  • Page 285: Rear Shock Absorber

    6-58 rear shock absorber handling note • support the machine securely so there is no danger of it falling over. • this rear shock absorber is provided with a separate type tank filled with high-pres- sure nitrogen gas. To prevent the danger of explosion, read and understand the fol- lowing informati...

  • Page 286: Rear Shock Absorber

    6-59 rear shock absorber checking the rear shock absorber 1. Inspect: • damper rod "1" bends/damage → replace rear shock ab- sorber assembly. • shock absorber "2" oil leaks → replace rear shock absorber as- sembly. Gas leaks → replace rear shock absorber assembly. • spring "3" damage → replace sprin...

  • Page 287: Rear Shock Absorber

    6-60 rear shock absorber installing the spring (rear shock absorber) 1. Install: • spring "1" • upper spring guide "2" • lower spring guide "3" 2. Tighten: • adjuster "1" 3. Adjust: • spring length (installed) refer to "adjusting the rear shock absorber spring preload" section in the chapter 3. 4. T...

  • Page 288: Rear Shock Absorber

    6-61 rear shock absorber 3. Install: • rear shock absorber 4. Install: • bolt (rear shock absorber-frame) "1" • washer "2" • nut (rear shock absorber-frame) "3" apply the molybdenum disulfide grease on the bolt. 5. Install: • bolt (rear shock absorber-relay arm)"1" • nut (rear shock absorber-relay a...

  • Page 289: Electrical

    7-1 electrical components and wiring diagram electrical this section is intended for those who have basic knowledge and skill concerning the servicing of yamaha motorcycles (e.G., yamaha dealers, service engineers, etc.) those who have little knowl- edge and skill concerning servicing are requested ...

  • Page 290

    7-2 electrical components and wiring diagram wiring diagram 1. Headlight 2. Multi-function display 3. Engine stop switch 4. Clutch switch 5. Diode 6. Starter relay diode 7. Throttle position sensor 8. Starter relay 9. Fuse 10. Starting circuit cut-off relay 11. Cdi unit 12. Taillight 13. Neutral swi...

  • Page 291: Ignition System

    7-3 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. *1 marked: refer to "checking the fuse" section in the chapter 3....

  • Page 292: Ignition System

    7-4 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" (igni- tion 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 cr...

  • Page 293: Ignition System

    7-5 ignition system checking the main switch 1. Inspect: • main switch conduction not conductive while the main switch is moved to "on" → replace. Conductive while the main switch is moved to "off" → replace. Set the tester selection position to "Ω×1". 2. Inspect: • main switch indicator light use 1...

  • Page 294: Ignition System

    7-6 ignition system 4. Inspect: • sealed portion of ignition coil "a" • spark plug terminal pin "b" • threaded portion of spark plug "c" wear → replace. Checking the ac magneto 1. Inspect: • pickup coil resistance out of specification → replace. Checking the neutral switch 1. Inspect: • neutral swit...

  • Page 295: Electric Starting System

    7-7 electric starting system electric starting system starting circuit cut-off system operation if the main switch is set to "on", the starter mo- tor can only operate if at least one of the follow- ing conditions is met: • the transmission is in neutral (the neutral switch is closed). • the clutch ...

  • Page 296: Electric Starting System

    7-8 electric starting system inspection steps if the starter motor will not operate, use the following inspection steps. *1 marked: refer to "checking the fuse" section in the chapter 3. *2 marked: refer to "checking and charging the battery" section in the chapter 3. *3 marked: refer to "checking t...

  • Page 297: Electric Starting System

    7-9 electric starting system checking the couplers and leads connection 1. Check: • couplers and leads connection rust/dust/looseness/short-circuit → repair or replace. Checking the starter motor operation 1. Connect the positive battery terminal "1" and starter motor lead "2" with a jumper lead "3"...

  • Page 298: Electric Starting System

    7-10 electric starting system checking the clutch switch 1. Inspect: • clutch switch conduction not conductive while it is pulled → replace. Conductive while it is freed → replace. Set the tester selection position to "Ω × 1". Checking the diode 1. Remove the diode from wire harness. 2. Inspect: • d...

  • Page 299: Electric Starting System

    7-11 electric starting system removing the starter motor order part name q'ty remarks exhaust pipe refer to "exhaust pipe and si- lencer" section in the chapter 3. 1 starter motor 1.

  • Page 300: Electric Starting System

    7-12 electric starting system disassembling the starter motor order part name q'ty remarks 1 starter motor front cover 1 2 washer (starter motor front cover) 1 3 gasket 2 4 starter motor yoke 1 5 armature assembly 1 6 starter motor rear cover 1 7 brush 2 8 brush spring 2.

  • Page 301: Electric Starting System

    7-13 electric starting system checking and repairing the starter motor 1. Check: • commutator dirt → clean with 600 grit sandpaper. 2. Measure: • commutator diameter "a" out of specification → replace the starter motor. 3. Measure: • mica undercut "a" out of specification→scrape the mica to the prop...

  • Page 302: Electric Starting System

    7-14 electric starting system assembling the starter motor 1. Install: • brush spring "1" • brush "2" 2. Install: • armature assembly "1" install while holding down the brush using a thin screw driver. Be careful not to damage the brush during installation. 3. Install: • gasket "1" • starter motor y...

  • Page 303: Charging System

    7-15 charging system charging system inspection steps if the battery is not charged, use the following inspection steps. *1 marked: refer to "checking the fuse" section in the chapter 3. *2 marked: refer to "checking and charging the battery" section in the chapter 3. • remove the following parts be...

  • Page 304: Charging System

    7-16 charging system checking the couplers and leads connection 1. Check: • couplers and leads connection rust/dust/looseness/short-circuit → repair or replace. Checking the charging voltage 1. Start the engine. 2. Inspect: • charging voltage out of specification → if no failure is found in checking...

  • Page 305

    7-17 throttle position sensor system throttle position sensor system inspection steps if the throttle position sensor will not operate, use the following inspection steps. Use the following special tools in this inspection. Check entire ignition system for connec- tion. No good → repair or replace. ...

  • Page 306

    7-18 throttle position sensor system handling note do not loosen the screw (throttle position sensor) "1" except when changing the throttle position sensor due to failure be- cause it will cause a drop in engine perfor- mance. Checking the couplers and leads connection 1. Check: • couplers and leads...

  • Page 307

    7-19 throttle position sensor system changing and adjusting the throttle position sensor 1. Remove: • throttle position sensor coupler • carburetor 2. Remove: • screw (throttle position sensor) "1" • throttle position sensor "2" loosen the screw (throttle position sensor) us- ing the t25 bit. 3. Rep...

  • Page 308

    7-20 throttle position sensor system 10.Put the aligning marks "a" on the throttle po- sition sensor and carburetor. 11.Stop the engine. 12.Remove the carburetor. 13.Tighten: • screw (throttle position sensor) "1" tighten the screw (throttle position sensor) us- ing the t25 bit. 14.Install the carbu...

  • Page 309: Lighting System

    7-21 lighting system lighting system inspection steps refer to the following flow chart when inspecting the lighting system for possible problems. • remove the following parts before inspection. 1. Seat 2. Fuel tank 3. Left side cover • use the following special tools in this inspection. Check the b...

  • Page 310: Lighting System

    7-22 lighting system checking the taillight (leds) 1. Disconnect the taillight coupler. 2. Connect two jumper leads "1" from the bat- tery terminals to the respective coupler ter- minal as shown. 3. Check: • led (for proper operation) does not light → replace the taillight assem- bly. • a wire that ...

  • Page 311: Signaling System

    7-23 signaling system signaling system inspection steps if the speedometer will not operate, use the following inspection steps. *1 marked: refer to "checking and charging the battery" section in the chapter 3. • remove the following parts before inspection. 1. Headlight • use the following special ...

  • Page 312: Signaling System

    7-24 signaling system checking the couplers and leads connection 1. Check: • couplers and leads connection rust/dust/looseness/short-circuit → repair or replace. Checking the multi-function display input voltage 1. Disconnect the multi-function display cou- pler. 2. Set the main switch to "on". 3. M...

  • Page 313: Signaling System

    7-25 signaling system 2. Set the main switch to "on". 3. Measure: • speed sensor output voltage output voltage not correct → replace the speed sensor. Measurement steps: a. Elevate the front wheel and slowly rotate it. B. Measure the voltage (dcv) of white lead and black lead. With each full rotatio...

  • Page 316

    Printed in japan 2010.05-0.3 ×1 cr (e) printed on recycled paper yamaha motor co., ltd. 2500 shingai iwata shizuoka japan.