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  5. Owner's Service Manual

Yamaha 2011 YZ250F Owner's Service Manual

Manual is about: 2010

Summary of 2011 YZ250F

  • Page 1

    Printed on recycled paper yamaha motor co., ltd. 2500 shingai iwata shizuoka japan 2010 17d-28199-30 yz250f(z) owner’s service manual manuel d’atelier du proprietaire fahrer- und wartungshandbuch manuale di servizio del proprietario printed in japan 2009.05-2.0 × 1 cr (e,f,g,h) yz250f(z) 2010 il con...

  • Page 2

    Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit être remis avec le véhicule en cas de vente de ce dernier. Bitte lesen sie diese be...

  • Page 3: Yz250F(Z)

    Yz250f(z) yz250f(z) 2010 2010 17d-28199-30-e0 17d-28199-30-e0 owner’s service manual owner’s service manual read this manual carefully before operating this vehicle. Read this manual carefully before operating this vehicle..

  • Page 5

    Yz250f(z) owner's service manual ©2009 by yamaha motor co., ltd. 1st edition, may 2009 all rights reserved.Any reprinting or unauthorized use without the written permission of yamaha motor co., ltd. Is expressly prohibited. Printed in japan.

  • Page 6

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

  • Page 7

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

  • Page 8

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

  • Page 9

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

  • Page 10

    Contents chapter 1 general information location of important labels ..... 1-1 description ................. 1-5 consumer information................. 1-6 included parts .......... 1-6 important information................. 1-6 checking of connection.................. 1-7 special tools ............. ...

  • Page 11

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

  • Page 12

    1-2 location of important labels europe.

  • Page 13

    1-3 location of important labels aus, nz, za.

  • Page 14

    1-4 location of important labels familiarize yourself with the following pictograms and read the explanatory text. Read owner’s service manual. This unit contains high-pressure nitrogen gas. Mishandling can cause explosion. Do not incinerate, puncture or open. Turn off the main switch after riding t...

  • Page 15

    1-5 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. Front brake lever 4. Throttle grip 5. Radiator cap 6. Fuel tank cap 7. Engine...

  • Page 16

    1-6 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 number to your yamaha dealer for positive identification of the model you own. 2. If your machine is stolen, the au- thorities will ...

  • Page 17

    1-7 checking of connection 4. During the machine disassembly, clean all parts and place them in trays in the order of disassembly. This will speed up assembly time and help assure that all parts are correctly reinstalled. 5. Keep away from fire. All replacement parts 1. We recommend to use yamaha ge...

  • Page 18

    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 techniques. The shape and part number used for the special tool differ by c...

  • Page 19

    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 specification. Cap bolt wrench ym-0...

  • Page 20

    1-10 special tools timing light ym-33277-a, 90890-03141 this tool is necessary for checking ignition timing. Valve spring compressor ym-4019, 90890-04019 this tool is needed to remove and install the valve assemblies. Clutch holding tool ym-91042, 90890-04086 this tool is used to hold the clutch whe...

  • Page 21

    1-11 special tools dynamic spark tester ym-34487 ignition checker 90890-06754 this instrument is necessary for checking the ignition system compo- nents. Digital tachometer yu-39951-b, 90890-06760 this tool is needed for observing en- gine rpm. Yamaha bond no. 1215 (three- bond ® no. 1215) 90890-855...

  • Page 22

    1-12 control functions control functions engine stop switch the engine stop switch "1" is located on the left handlebar. Continue push- ing the engine stop switch till the en- gine comes to a stop. Clutch lever the clutch lever "1" is located on the left handlebar; it disengages or en- gages the clu...

  • Page 23

    1-13 starting and break-in starting and break-in fuel always use the recommended fuel as stated below. Also, be sure to use new gasoline the day of a race. Use only unleaded gasoline. The use of leaded gasoline will cause severe damage to the engine inter- nal parts such as valves, piston rings, and...

  • Page 24

    1-14 starting and break-in break-in procedures 1. Before starting the engine, fill the fuel tank with the fuel. 2. Perform the pre-operation checks on the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the engine stop switch. Then, re- sta...

  • Page 25

    1-15 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 26

    1-16 cleaning and storage cleaning and storage cleaning frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and ex- tend the life of many components. 1. Before washing the machine, block off the end of the exhaust pipe to prevent water from enter- ing. A...

  • Page 27

    2-1 general specifications specifications general specifications model name: yz250fz (usa, cdn, aus, nz) yz250f (europe, za) model code number: 17d5 (usa,cdn) 17d6 (europe) 17d8 (aus, nz, za) dimensions: usa, cdn europe aus, nz, za overall length 2,159 mm (85.00 in) 2,168 mm (85.35 in) 2,166 mm (85....

  • Page 28

    2-2 general specifications carburetor: type fcr-mx37 manufacturer keihin spark plug: type/manufacturer cr8e/ngk (resistance type) gap 0.7–0.8 mm (0.028–0.031 in) clutch type: wet, multiple-disc transmission: usa, cdn europe, aus, nz, za primary reduction system gear ← primary reduction ratio 57/17 (...

  • Page 29

    2-3 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 30

    2-4 maintenance specifications valve, valve seat, valve guide: valve clearance (cold) in 0.12–0.17 mm (0.0047–0.0067 in) ---- ex 0.17–0.22 mm (0.0067–0.0087 in) ---- valve dimensions: "a" head diameter (in) 22.9–23.1 mm (0.9016–0.9094 in) ---- "a" head diameter (ex) 24.4–24.6 mm (0.9606–0.9685 in) -...

  • Page 31

    2-5 maintenance specifications stem runout limit ---- 0.01 mm (0.0004 in) valve seat width (in) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630 in) valve seat width (ex) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630 in) valve spring: free length (in) 39.76 mm (1.57 in) 38.76 mm (1.53 in) free length (ex...

  • Page 32

    2-6 maintenance specifications piston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in) 16.043 mm (0.6316 in) piston pin outside diameter 15.991–16.000 mm (0.6296–0.6299 in) 15.971 mm (0.6288 in) piston rings: top ring: type barrel ---- dimensions (b × t) 0.90 × 2.75 mm (0.04 × 0.11 in) -...

  • Page 33

    2-7 maintenance specifications clutch: friction plate thickness 2.9–3.1 mm (0.114–0.122 in) 2.8 mm (0.110 in) quantity 9 ---- clutch plate thickness 1.1–1.3 mm (0.043–0.051 in) ---- quantity 8 ---- warp limit ---- 0.1 mm (0.004 in) clutch spring free length 35.7 mm (1.41 in) 34.7 mm (1.37 in) quanti...

  • Page 34

    2-8 maintenance specifications chassis lubrication system: oil filter type paper type ---- oil pump type trochoid type ---- tip clearance 0.12 mm or less (0.0047 in or less) 0.20 mm (0.008 in) side clearance 0.09–0.17 mm (0.0035–0.0067 in) 0.24 mm (0.009 in) housing and rotor clearance 0.03–0.10 mm ...

  • Page 35

    2-9 maintenance specifications swingarm: swingarm free play limit end ---- 1.0 mm (0.04 in) wheel: front wheel type spoke wheel ---- rear wheel type spoke wheel ---- front rim size/material 21 × 1.60/aluminum ---- rear rim size/material 19 × 1.85/aluminum ---- rim runout limit: radial ---- 2.0 mm (0...

  • Page 36

    2-10 tightening torques electrical tightening torques engine △ - marked portion shall be checked for torque tightening after break-in or before each race. Item standard limit ignition system: advancer type electrical ---- cdi: magneto-model (stator)/manufacturer 17d-50/yamaha ---- charging coil 1 re...

  • Page 37

    2-11 tightening torques oil filter element drain bolt m6 × 1.0 1 10 1.0 7.2 oil filter element cover m6 × 1.0 2 10 1.0 7.2 oil strainer (crankcase) m6 × 1.0 2 10 1.0 7.2 oil delivery pipe 1 (m10) m10 × 1.25 1 20 2.0 14 oil delivery pipe 1 (m8) m8 × 1.25 2 18 1.8 13 oil hose m6 × 1.0 2 8 0.8 5.8 △ oi...

  • Page 38

    2-12 tightening torques chassis △ - marked portion shall be checked for torque tightening after break-in or before each race. Drive sprocket m18 × 1.0 1 75 7.5 54 drive axle oil seal stopper m6 × 1.0 2 10 1.0 7.2 segment m8 × 1.25 1 30 3.0 22 shift guide m6 × 1.0 2 10 1.0 7.2 stopper lever m6 × 1.0 ...

  • Page 39

    2-13 tightening torques △ front brake disc m6 × 1.0 6 12 1.2 8.7 △ rear brake disc m6 × 1.0 6 14 1.4 10 △ footrest bracket and frame m10 × 1.25 4 55 5.5 40 △ brake pedal m8 × 1.25 1 26 2.6 19 △ rear brake master cylinder m6 × 1.0 2 10 1.0 7.2 rear brake master cylinder cap m4 × 0.7 2 2 0.2 1.4 △ rea...

  • Page 40

    2-14 tightening torques 1. First, tighten the steering ring nut approximately 38 nm (3.8 m•kg, 27 ft•lb) by using the steering nut wrench, then loosen the steering ring nut one turn. 2. Retighten the steering ring nut 7 nm (0.7 m•kg, 5.1 ft•lb). Electrical radiator mounting boss and frame m10 × 1.25...

  • Page 41

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

  • Page 42

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

  • Page 43

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

  • Page 44

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

  • Page 45

    2-19 cable routing diagram c. Pass the cylinder head breather hose on the outside of front en- gine bracket. D. Pass the cylinder head breather hose between the radiator and radiator hose 3. E. Pass the fuel hose on the out- side of throttle position sensor lead. F. Pass the carburetor breather hose...

  • Page 46

    2-20 cable routing diagram 1. Sub-wire harness 2. Hot starter cable 3. Oil hose 4. Neutral switch lead 5. Radiator hose 2 6. Clamp 7. Ignition coil lead 8. Cdi magneto lead 9. Neutral switch lead coupler 10. Cdi unit lead coupler 11. Radiator breather hose 12. Hot starter cable protector 13. Rubber ...

  • Page 47

    2-21 cable routing diagram a. Pass the hot starter cable over the radiator mounting boss. B. Pass the throttle position sensor lead under the hot starter cable. C. Fasten the throttle position sen- sor lead and the hot starter ca- ble. D. Locate the clamp between the hot starter cable protector and ...

  • Page 48

    2-22 cable routing diagram 1. Radiator hose 2 2. Radiator breather hose 3. Ignition coil 4. Throttle cable (pull) 5. Throttle cable (return) 6. Engine stop switch lead a. Put a cover over the ignition coil. B. Pass the throttle cables through the cable guide. C. Pass the throttle cable over the radi...

  • Page 49

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

  • Page 50

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

  • Page 51

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

  • Page 52

    3-2 maintenance intervals 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. Clutch inspect and adjust ● ● inspect housing, friction plate, clutch plate ...

  • Page 53

    3-3 maintenance intervals cooling system check coolant level and leakage ● ● check radiator cap operation ● replace coolant ● every two years inspect hoses ● outside nuts and bolts retighten ● ● refer to "starting and break- in" section in the chapter 1. Air filter clean and lubricate ● ● use foam a...

  • Page 54

    3-4 maintenance intervals rear shock absorber inspect and adjust ● ● lube ● (after rain ride) ● molybdenum disulfide grease replace spring seat ● every one year retighten ● ● drive chain guide and rollers inspect ● ● swingarm inspect, lube and retighten ● ● molybdenum disulfide grease relay arm, con...

  • Page 55

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

  • Page 56

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

  • Page 57

    3-7 engine 3. Radiator cap 2. Apply the specified pressure. 3. Inspect: • pressure impossible to maintain the speci- fied pressure for 10 seconds → replace. Checking the cooling system 1. Inspect: • coolant level 2. Attach: • radiator cap tester "1" and adapt- er "2" 3. Apply the specified pressure....

  • Page 58

    3-8 engine 2. Adjust: • throttle grip free play throttle grip free play adjustment steps: a. Slide the adjuster cover. B. Loosen the locknut "1". C. Turn the adjuster "2" until the specified free play is obtained. D. Tighten the locknut. Before adjusting the throttle cable free play, the engine idle...

  • Page 59

    3-9 engine 6. Apply: • lithium soap base grease on the matching surface "a" on air filter element. 7. Install: • air filter element "1" • washer • fitting bolt align the projection "a" on filter guide with the hole "b" in air filter case. Checking the engine oil level 1. Start the engine, warm it up...

  • Page 60

    3-10 engine replacement steps: a. Remove the oil filter element cov- er "1" and oil filter element "2". B. Check the o-rings "3", if cracked or damaged, replace them with a new one. C. Install the oil filter element and oil filter element cover. 8. Install: • o-ring "1" • oil strainer "2" • oil hose...

  • Page 61

    3-11 engine b. Turn the throttle stop screw "1" until the specified engine idling speed. Using a digital engine tachometer for idle speed adjustment, detect the en- gine idling speed by bringing the sensing element "c" of the engine ta- chometer close to the ignition coil "2". Adjusting the valve cl...

  • Page 62

    3-12 engine c. Select the proper pad using the pad selecting table. The thickness "a" of each pad is indi- cated in hundredths of millimeters on the pad upper surface. D. Round off the last digit of the in- stalled pad number to the nearest increment. Example: installed pad number = 148 rounded off ...

  • Page 63

    3-13 engine intake exhaust 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 - 0.01 0.02 - 0.06 0.07 - 0.11 0.12 - 0.17 0.18 - 0.22 0.23 - 0.27 0.28 - 0.32 0.33 - 0.37 0.38 - 0.42 0.43 - 0.47 0.48 - 0.52 0.53 - 0.57 0.58 - 0.62 0.63 - 0.67 0.68 ...

  • Page 64

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

  • Page 65

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

  • Page 66

    3-16 chassis 2. Replace: • brake pad brake pad replacement steps: a. Remove the protector "1" and pad pin plug "2". B. Loosen the pad pin "3". C. Remove the rear wheel "4" and brake caliper "5". Refer to "front wheel and rear wheel" section in the chapter 5. D. Remove the pad pin "6" and brake pads ...

  • Page 67

    3-17 chassis checking the sprocket 1. Inspect: • sprocket teeth "a" excessive wear → replace. Replace the drive sprocket, rear wheel sprocket and drive chain as a set. Checking the drive chain 1. Measure: • drive chain length (15 links) "a" out of specification → replace. • while measuring the drive...

  • Page 68

    3-18 chassis a. Right b. Left turn the adjuster so that the drive chain is in line with the sprocket, as viewed from the rear. D. Tighten the axle nut while pushing down the drive chain. E. Tighten the locknuts. Checking the front fork 1. Inspect: • front fork smooth action operate the front brake a...

  • Page 69

    3-19 chassis adjusting the front fork compression damping force 2. Adjust: • compression damping force by turning the adjuster "1". • standard position: this is the position which is back by the specific number of clicks from the fully turned-in position. Do not force the adjuster past the minimum o...

  • Page 70

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

  • Page 71

    3-21 chassis checking and tightening the spokes the following procedure applies to all of the spokes. 1. Check: • spokes bend/damage → replace. Loose spoke → retighten. Tap the spokes with a screw- driver. A tight spoke will emit a clear, ringing tone; a loose spoke will sound flat. 2. Tighten: • sp...

  • Page 72

    3-22 chassis h. Install the washer "5", upper bracket "6", steering stem nut "7", handlebar "8", handlebar upper holder "9" and number plate "10". • apply the lithium soap base grease on the contact surface of the steer- ing stem nut when installing. • the handlebar upper holder should be installed ...

  • Page 73

    3-23 chassis lubrication to ensure smooth operation of all components, lubricate your machine during setup, after break-in, and after every race. 1. All control cable 2. Clutch lever pivot 3. Shift pedal pivot 4. Footrest pivot 5. Throttle-to-handlebar contact 6. Drive chain 7. Tube guide cable wind...

  • Page 74

    3-24 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 75

    4-1 seat, fuel tank and side covers 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 knowledge and skill concerning servicing are request- ed not to undert...

  • Page 76

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

  • Page 77

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

  • Page 78

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

  • Page 79

    4-5 radiator radiator removing the radiator order part name q'ty remarks drain the coolant. Refer to "changing the coolant" sec- tion in the chapter 3. Seat and fuel tank refer to "seat, fuel tank and side covers" section. 1 radiator guard 2 2 radiator hose clamp 10 only loosening. 3 clutch cable ho...

  • Page 80

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

  • Page 81

    4-7 carburetor carburetor removing the carburetor order part name q'ty remarks seat and fuel tank refer to "seat, fuel tank and side covers" section. 1 clamp 1 2 throttle position sensor lead coupler 1 3 throttle cable cover 1 4 throttle cable 2 5 clamp (air filter joint) 1 loosen the screw (air fil...

  • Page 82

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

  • Page 83

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

  • Page 84

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

  • Page 85

    4-11 carburetor c. If the float height is not within specification, inspect the valve seat and needle valve. D. If either is worn, replace them both. E. If both are fine, adjust the float height by bending the float tab "b" on the float. F. Recheck the float height. Checking the float 1. Inspect: • ...

  • Page 86

    4-12 carburetor • apply the fluorochemical grease on the bearings. • fit the projection "a" on the throttle shaft assembly into the slot "b" in the throttle position sensor. • make sure the stopper "c" of the spring fits into the recess in the car- buretor. • turn the throttle shaft assembly left wh...

  • Page 87

    4-13 carburetor 17. Install: • o-ring "1" • valve lever housing cover "2" • bolt (valve lever housing cover) "3" 18. Install: • carburetor breather hose "1" install the carburetor breather hoses to the carburetor so that the hoses do not bend near where they are in- stalled. Adjusting the accelerato...

  • Page 88

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

  • Page 89

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

  • Page 90

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

  • Page 91

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

  • Page 92

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

  • Page 93

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

  • Page 94

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

  • Page 95

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

  • Page 96

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

  • Page 97

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

  • Page 98

    4-24 valves and valve springs checking the valve springs 1. Measure: • valve spring free length "a" out of specification → replace. 2. Measure: • compressed spring force "a" out of specification → replace. B. Installed length 3. Measure: • spring tilt "a" out of specification → replace. Checking the...

  • Page 99

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

  • Page 100

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

  • Page 101

    4-27 cylinder and piston 2. Position: • piston ring (in cylinder) insert a ring into the cylinder and push it approximately 10 mm (0.39 in) into the cylinder. Push the ring with the piston crown so that the ring will be at a right angle to the cylinder bore. A. 10 mm (0.39 in) 3. Measure: • ring end...

  • Page 102

    4-28 cylinder and piston installing the cylinder 1. Lubricate: • piston • piston ring • cylinder apply a liberal coating of engine oil. 2. Install: • dowel pin "1" • o-ring "2" apply the lithium soap base grease on the o-ring. 3. Install: • cylinder gasket "1" • cylinder "2" install the cylinder wit...

  • Page 103

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

  • Page 104

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

  • Page 105

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

  • Page 106

    4-32 clutch installing the clutch 1. Install: • washer "1" • spacer "2" • primary driven gear "3" • thrust washer "4" • clutch boss "5" 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 t...

  • Page 107

    4-33 oil filter element and water pump oil filter element and water pump removing the oil filter element and water pump order part name q'ty remarks drain the engine oil. Refer to "changing the engine oil" section in the chapter 3. Drain the coolant. Refer to "changing the coolant" sec- tion in the ...

  • Page 108

    4-34 oil filter element and water pump 9 washer 1 refer to removal section. 10 impeller shaft 1 refer to removal section. 11 oil seal 2 refer to removal section. 12 bearing 1 refer to removal section. Order part name q'ty remarks.

  • Page 109

    4-35 oil filter element and water pump removing the impeller shaft 1. Remove: • impeller "1" • washer "2" • impeller shaft "3" hold the impeller shaft on its width across the flats "a" with spanners, etc. And remove the impeller. Removing the oil seal it is not necessary to disassemble the water pum...

  • Page 110

    4-36 oil filter element and water pump installing the impeller shaft 1. Install: • impeller shaft "1" • washer "2" • impeller "3" • take care so that the oil seal lip is not damaged or the spring does not slip off its position. • when installing the impeller shaft, apply the lithium soap base grease...

  • Page 111

    4-37 oil filter element and water pump installing the water pump housing 1. Install: • dowel pin "1" • o-ring "2" apply the lithium soap base grease on the o-ring. 2. Install: • water pump housing "1" • bolt (water pump housing) "2" installing the oil filter element 1. Install: • oil filter element ...

  • Page 112

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

  • Page 113

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

  • Page 114

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

  • Page 115

    4-41 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 116

    4-42 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 117

    4-43 oil pump iinstalling the oil tank breather hose 1. Install: • oil tank "1" • oil tank breather hose "2" • clamp "3" install the clamp so that it does not contact the oil tank. • insert the oil tank breather hose so that its end "a" comes where the oil tank pipe begins to bend. • install the cla...

  • Page 118

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

  • Page 119

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

  • Page 120

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

  • Page 121

    4-47 kick shaft and shift shaft installing the stopper lever 1. Install: • torsion spring "1" • stopper lever "2" • bolt (stopper lever) "3" align the stopper lever roller with the slot on segment. Installing the shift guide and shift lever assembly 1. Install: • spring "1" • pawl pin "2" • pawl "3"...

  • Page 122

    4-48 kick shaft and shift shaft 4. Install: • kick shaft assembly "1" • washer "2" • apply the molybdenum disulfide grease on the contacting surfaces of the kick shaft stopper "a" and kick shaft ratchet wheel guide "3". • apply the engine oil on the kick shaft. • slide the kick shaft assembly into t...

  • Page 123

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

  • Page 124

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

  • Page 125

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

  • Page 126

    4-52 engine removal 2 neutral switch 1 3 drive chain sprocket cover 1 4 nut (drive sprocket) 1 refer to removal section. 5 lock washer 1 refer to removal section. 6 drive sprocket 1 refer to removal section. 7 clip 1 8 bolt (brake pedal) 1 9 brake pedal 1 10 upper engine bracket 2 11 front engine br...

  • Page 127

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

  • Page 128

    4-54 engine removal installing the drive sprocket 1. Install: • drive sprocket "1" • drive chain "2" install the drive sprocket together with the drive chain. 2. Install: • lock washer "1" • nut (drive sprocket) "2" tighten the nut while applying the rear brake. 3. Bend the lock washer tab to lock t...

  • Page 129

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

  • Page 130

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

  • Page 131

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

  • Page 132

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

  • Page 133

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

  • Page 134

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

  • Page 135

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

  • Page 136

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

  • Page 137

    4-63 transmission, shift cam and shift fork 3. Install: • washer "1" • circlip "2" • be sure the circlip sharp-edged cor- ner "a" is positioned opposite side to the washer and gear "b". • install the circlip with its ends "c" settled evenly on the spline crests. 4. Install: • collar "1" • apply the ...

  • Page 138

    5-1 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 knowledge and skill concerning servicing are request- ed not to undertake ...

  • Page 139

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

  • Page 140

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

  • Page 141

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

  • Page 142

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

  • Page 143

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

  • Page 144

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

  • Page 145

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

  • Page 146

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

  • Page 147

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

  • Page 148

    5-11 front brake and rear brake 3. Inspect: (front brake only) • reservoir float "1" damage → replace. 4. Inspect: • brake master cylinder piston "1" • brake master cylinder cup "2" wear/damage/score marks → re- place brake master cylinder kit. Checking the brake caliper 1. Inspect: • brake caliper ...

  • Page 149

    5-12 front brake and rear brake 2. Install: • brake caliper "1" • bolt (brake caliper) "2" 3. Tighten: • pad pin "3" 4. Install: • pad pin plug "4" installing the rear brake caliper 1. Install: • pad support "1" • brake pad "2" • pad pin "3" • install the brake pads with their pro- jections "a" into...

  • Page 150

    5-13 front brake and rear brake installing the front brake master cylinder 1. Install: • brake master cylinder "1" • brake master cylinder bracket "2" • bolt (brake master cylinder brack- et) "3" • install the bracket so that the arrow mark "a" face upward. • first tighten the bolts on the upper sid...

  • Page 151

    5-14 front brake and rear brake install the brake hose so that its pipe portion "a" directs as shown and lightly touches the projection "b" on the brake caliper. 2. Install: • brake hose holder "1" • bolt (brake hose holder) "2" align the top "a" of the brake hose holder with the paint "b" of the br...

  • Page 152

    5-15 front brake and rear brake a. Front b. Rear 2. Air bleed: • brake system refer to "bleeding the hy- draulic brake system" sec- tion in the chapter 3. 3. Inspect: • brake fluid level fluid at lower level → fill up. Refer to "checking the brake fluid level" section in the chapter 3. 4. Install: •...

  • Page 153

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

  • Page 154

    5-17 front fork disassembling the front fork order part name q'ty remarks 1 adjuster 1 drain the fork oil. Refer to removal section. 2 fork spring 1 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 piston met...

  • Page 155

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

  • Page 156

    5-19 front fork checking the damper assembly 1. Inspect: • damper assembly "1" bend/damage → replace. • o-ring "2" wear/damage → replace. The front fork with a built-in piston rod has a very sophisticated inter- nal construction and is particularly sensitive to foreign material. Use enough care not ...

  • Page 157

    5-20 front fork 5. Measure: • oil level (left and right) "a" out of specification → adjust. 6. Tighten: • locknut "1" fully finger tighten the locknut onto the damper assembly. 7. Loosen: • compression damping adjuster "1" • loosen the compression damping adjuster finger tight. • record the set posi...

  • Page 158

    5-21 front fork 16. Install: • piston metal "1" install the piston metal onto the slot on inner tube. 17. Install: • outer tube "1" to inner tube "2". 18. Install: • slide metal "1" • oil seal washer "2" to outer tube slot. Press the slide metal into the outer tube with fork seal driver "3". 19. Ins...

  • Page 159

    5-22 front fork 26. Loosen: • rebound damping adjuster "1" • loosen the rebound damping ad- juster finger tight. • record the set position of the ad- juster (the amount of turning out the fully turned in position). 27. Install: • push rod "1" • copper washer "2" • adjuster "3" to damper assembly "4"...

  • Page 160

    5-23 front fork installing the front fork 1. Install: • front fork "1" • temporarily tighten the pinch bolts (lower bracket). • do not tighten the pinch bolts (up- per bracket) yet. 2. Tighten: • damper assembly "1" use the cap bolt ring wrench "2" to tighten the damper assembly with specified torqu...

  • Page 161

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

  • Page 162

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

  • Page 163

    5-26 handlebar 3. Tighten: • nut (handlebar lower holder) "1" 4. Install: • left grip "1" apply the adhesive to the handle- bar "2". • before applying the adhesive, wipe off grease or oil on the handlebar surface "a" with a lacquer thinner. • install the left grip to the handlebar so that the line "...

  • Page 164

    5-27 handlebar • clamp "6" • the engine stop switch, clutch lever holder and clamp should be in- stalled according to the dimensions shown. • pass the engine stop switch lead in the middle of the clutch lever hold- er. 12. Install: • clutch cable "1" • hot starter cable "2" apply the lithium soap ba...

  • Page 165

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

  • Page 166

    5-29 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 167

    5-30 steering 5. Check the steering stem by turn- ing it lock to lock. If there is any binding, remove the steering stem assembly and inspect the steer- ing bearings. 6. Install: • washer "1" 7. Install: • front fork "1" • upper bracket "2" • temporarily tighten the pinch bolts (lower bracket). • do...

  • Page 168

    5-31 swingarm swingarm removing the swingarm order part name q'ty remarks hold the machine by placing the suitable stand under the engine. Refer to "handling note". Brake hose holder refer to "front brake and rear brake" section. Rear brake caliper refer to "front brake and rear brake" section. Bolt...

  • Page 169

    5-32 swingarm disassembling the swingarm order part name q'ty remarks 1 relay arm 1 2 connecting rod 1 3 collar 2 4 oil seal 2 5 thrust bearing 2 6 bushing 2 7 oil seal 8 8 bearing 10 refer to removal section..

  • Page 170

    5-33 swingarm handling note support the machine securely so there is no danger of it falling over. Removing the bearing 1. Remove: • bearing "1" remove the bearing by pressing its outer race. Checking the swingarm 1. Inspect: • bearing "1" • bushing "2" free play exists/unsmooth revolu- tion/rust → ...

  • Page 171

    5-34 swingarm installing the swingarm 1. Install: • bushing "1" • thrust bearing "2" • oil seal "3" • collar "4" to swingarm "5". Apply the molybdenum disulfide grease on the bushings, thrust bear- ings, oil seal lips and contact surfaces of the collar and thrust bearing. 2. Install: • collar "1" • ...

  • Page 172

    5-35 swingarm 11. Tighten: • nut (relay arm) "1" 12. Install: • bolt (lower chain tensioner) "1" • washer "2" • collar "3" • lower chain tensioner "4" • nut (lower chain tensioner) "5" 13. Install: • drive chain support "1" • drive chain support cover "2" • bolt {drive chain support [l = 50 mm (1.97...

  • Page 173

    5-36 rear shock absorber rear shock absorber removing the rear shock absorber order part name q'ty remarks hold the machine by placing the suitable stand under the engine. Refer to "handling note". Seat refer to "seat, fuel tank and side covers" section in the chapter 4. Silencer refer to "exhaust p...

  • Page 174

    5-37 rear shock absorber handling note • support the machine securely so there is no danger of it falling over. • this rear shock absorber is pro- vided with a separate type tank filled with high-pressure nitro- gen gas. To prevent the danger of explosion, read and under- stand the following informa...

  • Page 175

    5-38 rear shock absorber installing the bearing 1. Install: • upper bearing "1" install the bearing parallel until the stopper ring groove appears by pressing its outer race. Do not apply the grease on the bearing outer race because it will wear the rear shock absorber sur- face on which the bearing...

  • Page 176

    5-39 rear shock absorber 6. Install: • rear frame "1" • bolt [rear frame (upper)] "2" • bolt [rear frame (lower)] "3" 7. Tighten: • bolt (air filter joint) "1" bolt [rear frame (upper)]: 32 nm (3.2 m•kg, 23 ft•lb) bolt [rear frame (lower)]: 32 nm (3.2 m•kg, 23 ft•lb) bolt (air filter joint): 3 nm (0...

  • Page 177

    6-1 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 knowledge and skill concerning servicing are request- ed not to undertake inspection, adjustment, ...

  • Page 178

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

  • Page 179

    6-3 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. *marked: only when the ignition checker is used. • remove the fol...

  • Page 180

    6-4 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" (ignition checker "2") as shown. • ignition coil "3" • spark plug "4" a. For usa and cdn b. Except for usa and cdn 4. Kick the kickstarter cran...

  • Page 181

    6-5 ignition system 2. Inspect: • charging coil 1 resistance out of specification → replace. 3. Inspect: • charging coil 2 resistance out of specification → replace. Checking the neutral switch 1. Inspect: • neutral switch conduction not conductive while it is in neutral → replace. Conductive while ...

  • Page 182

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

  • Page 183

    6-7 throttle position sensor system handling note do not loosen the screw (throttle position sensor) "1" except when changing the throttle position sen- sor due to failure because it will cause a drop in engine perfor- mance. Checking the couplers and leads connection 1. Check: • couplers and leads ...

  • Page 184

    6-8 throttle position sensor system 8. Start the engine. 9. Adjust: • throttle position sensor output voltage adjustment steps: a. Adjust the installation angle of the throttle position sensor "1" to ob- tain the specified output voltage. Measure the output voltage accurate- ly with a digital electr...

  • Page 185

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

  • Page 186

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

  • Page 187

    7-3 engine adjusting the leak jet (adjusting the accelerator pump) the leak jet "1" is a setting part that adjusts the flow of fuel discharged by the accelerator pump. Since the ac- celerator pump operates only when throttle is open, the leak jet is used to adjust a fuel mixture ratio for quick thro...

  • Page 188

    7-4 engine specifications of jet needle examples of carburetor setting depending on symptom for usa and cdn diameter of straight portion rich lean n p q r s t u rich 1 richer ndjn-5 ndjp-5 ndjq-5 ndjr-5 ndjs-5 ndjt-5 ndju-5 0.5 richer ncvn-4 ncvp-4 ncvq-4 ncvr-4 ncvs-4 ncvt-4 ncvu-4 std ndjn-4 ndjp-...

  • Page 189

    7-5 engine this should be taken simply for an example. It is necessary to set the carburetor while checking the operating conditions of the engine. Closed to 1/4 throttle hard breathing speed down use jet needle with a smaller diameter. Slow-speed-circuit passage clogged → clean. Overflow from carbu...

  • Page 190

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

  • Page 191

    7-7 chassis a. Air spring characteristics in relation to oil amount change b. Load c. Stroke 1. Max. Oil amount 2. Standard oil amount 3. Min. Oil amount setting of spring after replacement as the front fork setting can be easily affected by rear suspension, take care so that the machine front and r...

  • Page 192

    7-8 chassis setting of spring after replacement after replacement, be sure to adjust the spring to the set length [sunken length 90–100 mm (3.5–3.9 in)] and set it. 1. Use of soft spring • set the soft spring for less re- bound damping to compensate for its less spring load. Run with the rebound dam...

  • Page 193

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

  • Page 194

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

  • Page 196

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