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Yamaha 2011 YZ250FA Owner's Service Manual

Other manuals for 2011 YZ250FA: Owner's Service Manual

Summary of 2011 YZ250FA

  • Page 1

    Lit-11626-24-17 17d-28199-11 owner’s service manual fa 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

    Yz250fa 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-11626-24-17.

  • Page 4: Introduction

    Introduction congratulations on your purchase of a yamaha yz 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 competition use, only on a closed course. 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 regulations be- fore riding. • this machine is...

  • Page 6

    Yamaha motor corporation, u.S.A. Yz 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", "engine", "chassis", "electrical" and "tuning" 2. The table of contents is at the beginning of the manual. Look over the genera...

  • 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 engine 4 chassis 5 electrical 6 tuning 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 4

    Chapter 4 engine seat, fuel tank and side covers .................................................... 4-2 exhaust pipe and silencer ............. 4-4 radiator................................................. 4-7 carburetor ........................................ 4-11 camshafts ........................

  • Page 14: Chapter 6

    Chapter 6 electrical electrical components and wiring diagram .................................... 6-2 ignition system.................................... 6-4 throttle position sensor system..................................................... 6-8 chapter 7 tuning engine................................

  • 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. Premium unleaded gasoline only. 3fb-2415e-02 4aa-22259-80 warning this unit contains high pressure nitrogen gas. Mishandling can cause...

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

  • 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 detachable sidestand this sidestand "1" is used to support only the machine when standing or transporting it. • never apply additional force to the side- stand. • remove this sidestand before starting out. Valve joint this valve joint "1" prevents fuel from flowing ...

  • 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 lock washers/plates and cotter pins 1. All lock washers/plates "1" and cotter pins must be replaced when they are removed. Lock tab(s) should be bent along the bolt or nut flat(s) after the bolt or nut has been prop- erly tightened. Bearings and oil seals 1. Install the bea...

  • 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 piston pin puller set yu-1304, 90890-01304 this tool is used to remove the piston pin. 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...

  • 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 dynamic spark tester ym-34487 ignition checker 90890-06754 this instrument is necessary for checking the ignition sys- tem components. Digital tachometer yu-39951-b, 90890-06760 this tool is needed for ob- serving engine rpm. Yamaha bond no. 1215 (threebond ® no. 1215) 90890-85505...

  • Page 26: Control Functions

    1-12 control functions control functions engine stop switch the engine stop switch "1" is located on the left handlebar. Continue pushing the engine stop switch till the engine comes to a stop. Clutch lever the clutch lever "1" is located on the left han- dlebar; it disengages or engages the clutch....

  • Page 27: Control Functions

    1-13 control functions rear brake pedal the rear brake pedal "1" is located on the right side of the machine. Press down on the brake pedal to activate the rear brake. Fuel cock the fuel cock supplies fuel from the tank to car- buretor and also filters the fuel. The fuel cock has the two positions: ...

  • Page 28: Starting and Break-In

    1-14 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 internal parts such as valves, piston rings, and e...

  • Page 29: Starting and Break-In

    1-15 starting and break-in starting a warm engine do not operate the cold starter knob and throt- tle. Pull the hot starter lever "1" and start the engine by kicking the kickstarter crank forceful- ly with a firm stroke. As soon as the engine starts, release the hot starter lever to close the air pa...

  • Page 30: Torque-Check Points

    1-16 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 31: Cleaning and Storage

    1-17 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 32: General Specifications

    2-1 general specifications specifications general specifications model name: yz250fa (usa, cdn, aus, nz) yz250f (europe, za) model code number: 17dd (usa,cdn) 17de (europe) 17dg (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 33: General Specifications

    2-2 general specifications oil capacity: engine oil periodic oil change 0.95 l (0.84 imp qt, 1.00 us qt) with oil filter replacement 1.05 l (0.92 imp qt, 1.11 us qt) total amount 1.20 l (1.06 imp qt, 1.27 us qt) coolant capacity (including all routes): 1.00 l (0.88 imp qt, 1.06 us qt) air filter: we...

  • Page 34: General Specifications

    2-3 general specifications tire: type with tube size (front) 80/100-21 51m size (rear) 100/90-19 57m tire pressure (front and rear) 100 kpa (1.0 kgf/cm 2 , 15 psi) brake: front brake type single disc brake operation right hand operation rear brake type single disc brake operation right foot operatio...

  • Page 35: 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 36: Maintenance Specifications

    2-5 maintenance specifications camshaft runout limit ---- 0.03 mm (0.0012 in) 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 0.12–0.17 mm (0.0047–0.0067 in) ---- ex 0.17–0.22 ...

  • Page 37: Maintenance Specifications

    2-6 maintenance specifications "d" margin thickness (in) 0.8 mm (0.0315 in) ---- "d" margin thickness (ex) 0.7 mm (0.0276 in) ---- stem outside diameter (in) 3.975–3.990 mm (0.1565–0.1571 in) 3.945 mm (0.1553 in) stem outside diameter (ex) 4.460–4.475 mm (0.1756–0.1762 in) 4.430 mm (0.1744 in) guide...

  • Page 38: Maintenance Specifications

    2-7 maintenance specifications tilt limit* (in) ---- 2.5°/1.7 mm (2.5°/0.067 in) tilt limit* (ex) ---- 2.5°/1.6 mm (2.5°/0.063 in) direction of winding (top view) (in) clockwise ---- direction of winding (top view) (ex) clockwise ---- piston: piston to cylinder clearance 0.030–0.055 mm (0.0012–0.002...

  • Page 39: Maintenance Specifications

    2-8 maintenance specifications 2nd ring: type taper ---- dimensions (b × t) 0.80 × 2.75 mm (0.03 × 0.11 in) ---- end gap (installed) 0.30–0.45 mm (0.012–0.018 in) 0.80 mm (0.031 in) side clearance 0.020–0.055 mm (0.0008–0.0022 in) 0.12 mm (0.005 in) oil ring: dimensions (b × t) 1.50 × 2.25 mm (0.06 ...

  • Page 40: Maintenance Specifications

    2-9 maintenance specifications clutch housing thrust clearance 0.050–0.300 mm (0.0020–0.0118 in) ---- clutch housing radial clearance 0.010–0.044 mm (0.0004–0.0017 in) ---- clutch release method inner push, cam push ---- shifter: shifter type cam drum and guide bar ---- guide bar bending limit ---- ...

  • Page 41: Maintenance Specifications

    2-10 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 42: Maintenance Specifications

    2-11 maintenance specifications rear suspension: usa, cdn europe, aus, nz, za shock absorber travel 131.5 mm (5.18 in) ← ---- spring free length 260 mm (10.24 in) ← ---- fitting length 250 mm (9.84 in) ← preload length 1.5–20 mm (0.06– 0.79 in) ← ---- spring rate, std k = 52.0 n/mm (5.30 kg/mm, 296....

  • Page 43: Maintenance Specifications

    2-12 maintenance specifications electrical master cylinder inside dia. 9.52 mm (0.375 in) ---- caliper cylinder inside dia. 22.65 mm (0.892 in) × 2 ---- brake fluid type dot #4 ---- rear disc brake: disc outside dia.×thickness 245 × 4.0 mm (9.65 × 0.16 in) 245 × 3.5 mm (9.65 × 0.14 in) deflection li...

  • Page 44: Tightening Torques

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

  • Page 45: Tightening Torques

    2-14 tightening torques 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 throttle cable (return) m12 × 1.0 1 11 1.1 8.0 throttle cable cover m5 × 0.8 2 4 0.4 2.9 hot starter plunger m12 × 1.0 1 2 0.2 1...

  • Page 46: Tightening Torques

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

  • Page 47: Tightening Torques

    2-16 tightening torques △ 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 △ rear brake hose union bolt m10 × 1.25 2 30 3.0 22 △ rear wheel axle and axle nut m22 × 1.5 1 135 13.5 98 △ nipple (spoke) — 72 3 0.3 2....

  • Page 48: Tightening Torques

    2-17 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 △ air scoop and fuel tank m6 × 1.0 2 7 0.7 ...

  • Page 49: Tightening Torques

    2-18 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 50: Tightening Torques

    2-19 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 52: Lubrication Diagrams

    2-20 lubrication diagrams lubrication diagrams.

  • Page 53: Lubrication Diagrams

    2-21 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 54: Lubrication Diagrams

    2-22 lubrication diagrams.

  • Page 55: Lubrication Diagrams

    2-23 lubrication diagrams 1. Crankshaft 2. Oil filter element 3. Oil tank 4. Oil hose a. From oil pump.

  • Page 56: Cable Routing Diagram

    2-24 cable routing diagram cable routing diagram a b a c b c.

  • Page 57: Cable Routing Diagram

    2-25 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 position sensor lead pro...

  • Page 58: Cable Routing Diagram

    2-26 cable routing diagram e k e f g h h f i j a a b d d c j c g b k e m m h-h k-k e-e d-d m-m f-f a-a i l l.

  • Page 59: Cable Routing Diagram

    2-27 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 60: Cable Routing Diagram

    2-28 cable routing diagram c a b b a c.

  • Page 61: Cable Routing Diagram

    2-29 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 62: Cable Routing Diagram

    2-30 cable routing diagram.

  • Page 63: 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 64: Cable Routing Diagram

    2-32 cable routing diagram a c b c b a.

  • Page 65: Cable Routing Diagram

    2-33 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 66: Maintenance Intervals

    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 re- quired mainten...

  • Page 67: Maintenance Intervals

    3-2 maintenance intervals piston inspect ● ● inspect crack. Clean ● inspect carbon deposits and eliminate them. Replace ● it is recommended that the pis- ton pin and ring are also re- placed at the same time. Piston ring inspect ● check ring end gap. Replace ● ● piston pin inspect ● replace ● cylind...

  • Page 68: Maintenance Intervals

    3-3 maintenance intervals crank inspect and clean ● ● carburetor inspect, adjust and clean ● ● spark plug inspect and clean ● ● replace ● drive chain use chain lube. Lubricate, slack, align- ment ● ● chain slack: 50–60 mm (2.0–2.4 in) replace ● cooling system check coolant level and leakage ● ● chec...

  • Page 69: Maintenance Intervals

    3-4 maintenance intervals brakes adjust lever position and pedal height ● ● lubricate pivot point ● ● check brake disc surface ● ● check fluid level and leak- age ● ● retighten brake disc bolts, caliper bolts, master cylin- der bolts and union bolts ● ● replace pads ● replace brake fluid ● every one...

  • Page 70: Maintenance Intervals

    3-5 maintenance intervals steering head inspect free play and re- tighten ● ● clean and lube ● lithium base grease replace bearing ● tire, wheels inspect air pressure, wheel run-out, tire wear and spoke looseness ● ● retighten sprocket bolt ● ● inspect bearings ● replace bearings ● lubricate ● lithi...

  • Page 71

    3-6 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 72: Engine

    3-7 engine engine checking the coolant level do not remove the radiator cap "1", drain bolt and hoses when the engine and radia- tor are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the en- gine has cooled, place a thick towel over the rad...

  • Page 73: Engine

    3-8 engine • do not mix more than one type of ethylene glycol antifreeze containing corrosion in- hibitors for aluminum engine. • do not use water containing impurities or oil. Handling notes of coolant: the coolant is harmful so it should be handled with special care. • when coolant splashes to you...

  • Page 74: Engine

    3-9 engine 3. Apply the specified pressure. • do not apply pressure more than specified pressure. • radiator should be filled fully. 4. Inspect: • pressure impossible to maintain the specified pres- sure for 10 seconds → repair. • radiator "1" • radiator hose joint "2" coolant leakage → repair or re...

  • Page 75: Engine

    3-10 engine • before adjustment, expose the adjuster by moving the boot "3" and cap "4" away. • make minute adjustment on the lever side us- ing the adjuster "5". • after adjustment, check proper operation of clutch lever. 3. Install: • cap "1" • boot "2" place the tip "a" of the cap in the boot. Ad...

  • Page 76: Engine

    3-11 engine 2. Apply: • lithium soap base grease on the throttle cable end "a". 3. Install: • throttle grip cap • screw (throttle grip cap) • cover (grip cap) • cover (throttle cable cap) adjusting the hot starter lever free play 1. Check: • hot starter lever free play "a" out of specification → adj...

  • Page 77: Engine

    3-12 engine 3. Inspect: • air filter element damage → replace. 4. Apply: • foam-air-filter oil or equivalent oil to the ele- ment squeeze out the excess oil. Element should be wet but not dripping. 5. Install: • air filter guide "1" align the projection "a" on filter guide with the hole "b" in air f...

  • Page 78: Engine

    3-13 engine • engine oil also lubricates the clutch and the wrong oil types or additives could cause clutch slippage. Therefore, do not add any chemical additives or use engine oils with a grade of cd or higher and do not use oils labeled "energy conserv- ing ii". • do not allow foreign materials to...

  • Page 79: Engine

    3-14 engine 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 element cover "1" and oil filter element "2". B. Check the o-rings "3", if cracked or dam...

  • Page 80: Engine

    3-15 engine 12.Install: • oil filler cap • washer (oil tank) • bolt (oil tank) 13.Check: • engine oil level checking the oil pressure 1. Check: • oil pressure checking steps: a. Slightly loosen the oil pressure check bolt "1". B. Start the engine and keep it idling until oil starts to seep from the ...

  • Page 81: Engine

    3-16 engine adjusting the valve clearance • this section is intended for those who have basic knowledge and skill concerning the ser- vicing 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 82: Engine

    3-17 engine 5. Adjust: • valve clearance adjustment steps: a. Remove the camshaft (intake and exhaust). Refer to "camshafts" section in the chapter 4. B. Remove the valve lifters "1" and the pads "2". • place a rag in the timing chain space to pre- vent pads from falling into the crankcase. • identi...

  • Page 83: Engine

    3-18 engine 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 to use. Use the new pad number only as a guide when verifying the valve clearance adjustment. F. Install the n...

  • Page 84: Engine

    3-19 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 85: Chassis

    3-20 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 86: Chassis

    3-21 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 87: Chassis

    3-22 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 88: Chassis

    3-23 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 89: Chassis

    3-24 chassis 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. Install the brake pad "10" and pad pin "11". ...

  • Page 90: Chassis

    3-25 chassis checking the brake fluid level 1. Place the brake master cylinder so that its top is in a horizontal position. 2. Inspect: • brake fluid level fluid at lower level → fill up. • use only designated quality brake fluid to avoid poor brake performance. • refill with same type and brand of ...

  • Page 91: Chassis

    3-26 chassis 3. Clean: • drive chain place it in kerosene, and brush off as much dirt as possible. Then remove the drive chain from the kerosene and dry the drive chain. 4. Check: • drive chain stiffness "a" clean and oil the drive chain and hold as il- lustrated. Stiff → replace the drive chain. 5....

  • Page 92: Chassis

    3-27 chassis c. Turn each adjuster exactly the same amount to maintain correct axle alignment. (there are marks "a" on each side of the drive chain puller alignment.) notice: improper drive chain slack will overload the engine as- well as other vital parts of the motorcycle and can lead to chain sli...

  • Page 93: Chassis

    3-28 chassis 2. Clean: • dust seal "a" • oil seal "b" • clean the dust seal and oil seal after every run. • apply the lithium soap base grease on the in- ner tube. Relieving the front fork internal pressure if the front fork initial movement feels stiff dur- ing a run, relieve the front fork interna...

  • Page 94: Chassis

    3-29 chassis always adjust each front fork to the same setting. Uneven adjustment can cause poor handling and loss of stability. 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 b...

  • Page 95: Chassis

    3-30 chassis the i.D. Mark "a" is marked at the end of the spring. 4. Adjust: • spring preload adjustment steps: a. Loosen the locknut "1". B. Loosen the adjuster "2" until there is some clearance between the spring and adjuster. C. Measure the spring free length "a". D. Turn the adjuster "2". • be ...

  • Page 96: Chassis

    3-31 chassis adjusting the rear shock absorber low compression damping force 1. Adjust: • low compression 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 ma...

  • Page 97: Chassis

    3-32 chassis do not force the adjuster past the minimum or maximum extent of adjustment. The ad- juster may be damaged. Checking the tire pressure 1. Measure: • tire pressure out of specification → adjust. • check the tire while it is cold. • loose bead stoppers allow the tire to slip off its positi...

  • Page 98: Chassis

    3-33 chassis 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 engine to raise the front wheel off the ground. Warning! Se-...

  • Page 99: Chassis

    3-34 chassis e. Loosen the steering ring nut one turn. F. Retighten the steering ring nut using the steering nut wrench. Avoid over-tightening. G. Check the steering stem by turning it lock to lock. If there is any binding, remove the steering stem assembly and inspect the steering bearings. H. Inst...

  • Page 100: Chassis

    3-35 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 101: Electrical

    3-36 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 102: Electrical

    3-37 electrical 4. Check: • ignition timing visually check the stationary pointer "a" is within the firing range "b" on the rotor. Incorrect firing range→check rotor and pick- up assembly. 5. Install: • timing mark accessing screw.

  • Page 103: Engine

    4-1 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, adjustment, disa...

  • Page 104

    4-2 seat, fuel tank and side covers seat, fuel tank and side covers removing the seat, fuel tank and side covers order part name q'ty remarks turn the fuel cock to "off". Disconnect the fuel hose. 1 seat 1 2 air scoop (left and right) 2 3 bolt (fuel tank) 1 4 fitting band 1 5 fuel tank 1 6 left side...

  • Page 105

    4-3 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 remove it be- cause its claws "a" are inserted in the air filter case. Removing the number plate 1. Remove: • bolt (number plate) • ...

  • Page 106: Exhaust Pipe and Silencer

    4-4 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 107: Exhaust Pipe and Silencer

    4-5 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 removal. Pull out the inner pipe while lightly ...

  • Page 108: Exhaust Pipe and Silencer

    4-6 exhaust pipe and silencer 2. Install: • silencer clamp "1" • gasket "2" • silencer "3" • washer "4" • bolt (silencer) "5" • install the gasket with its meshed area "a" to- ward the exhaust pipe side. • the gasket should be installed according to the dimension shown. Silencer clamp: 14 nm (1.4 m•...

  • Page 109: Radiator

    4-7 radiator radiator removing the radiator order part name q'ty remarks drain the coolant. Refer to "changing the cool- ant" section 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 110: Radiator

    4-8 radiator 11 radiator hose 3 1 12 radiator breather hose 1 13 radiator pipe 1 1 order part name q'ty remarks 2 4 2 3 13 2 2 2 2 2 11 7 8 2 2 6 9 2 10 12 1 5 1 t r . . 20 nm (2.0 m kg, 14 ft ib).

  • Page 111: Radiator

    4-9 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 112: Radiator

    4-10 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 ra...

  • Page 113: Carburetor

    4-11 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 fi...

  • Page 114: Carburetor

    4-12 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 ...

  • Page 115: Carburetor

    4-13 carburetor 16 main jet 1 17 needle jet 1 18 spacer 1 19 pilot jet 1 20 starter jet 1 21 push rod 1 pull the push rod. 22 throttle shaft assembly 1 23 push rod link lever assembly 1 24 pilot air jet 1 25 cold starter plunger 1 order part name q'ty remarks.

  • Page 116: Carburetor

    4-14 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. Removing the pilot screw 1. Remove: • pilot screw "1" to optimize the fuel flow at a small thr...

  • Page 117: Carburetor

    4-15 carburetor checking the throttle valve 1. Check: • free movement stick → repair or replace. Insert the throttle valve "1" into the carburetor body, and check for free movement. Checking the jet needle 1. Inspect: • jet needle "1" bends/wear → replace. • clip groove free play exists/wear → repla...

  • Page 118: Carburetor

    4-16 carburetor checking the float 1. Inspect: • float "1" damage → replace. Checking the starter plunger 1. Inspect: • cold starter plunger "1" • hot starter plunger "2" wear/damage → replace. Checking the accelerator pump 1. Inspect: • diaphragm (accelerator pump) "1" • spring (accelerator pump) "...

  • Page 119: Carburetor

    4-17 carburetor 3. Install: • spring 1 "1" • lever 1 "2" to lever 2 "3". Make sure the spring 1 fits on the stopper "a" of the lever 2. 4. Install: • spring 2 "1" to lever 2 "2". 5. Install: • push rod link lever assembly "1" make sure the stopper "a" of the spring 2 fits into the recess "b" in the ...

  • Page 120: Carburetor

    4-18 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 121: Carburetor

    4-19 carburetor 13.Install: • o-ring • leak jet "1" • float chamber "2" • bolt (float chamber) "3" • cable holder (throttle stop screw cable) "4" • hose holder (carburetor breather hose) "5" 14.Install: • diaphragm (accelerator pump) "1" • spring "2" • o-ring "3" • accelerator pump cover "4" • hose ...

  • Page 122: Carburetor

    4-20 carburetor 18.Install: • carburetor breather hose "1" install the carburetor breather hoses to the car- buretor so that the hoses do not bend near where they are installed. Adjusting the accelerator pump timing adjustment steps: in order for the throttle valve height "a" to achieve the specifie...

  • Page 123: Carburetor

    4-21 carburetor 3. Install: • hot starter plunger "1" 4. Tighten: • bolt (carburetor joint) "1" • bolt (air filter joint) "2" 5. Install: • throttle cable (pull) "1" • throttle cable (return) "2" 6. Adjust: • throttle grip free play refer to "adjusting the throttle ca- ble free play" section in the ...

  • Page 124: Camshafts

    4-22 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 125: Camshafts

    4-23 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 126: Camshafts

    4-24 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 127: Camshafts

    4-25 camshafts 5. Remove: • exhaust camshaft "1" • intake camshaft "2" attach a wire "3" to the timing chain to prevent it from falling into the crankcase. Checking the camshaft 1. Inspect: • cam lobe pitting/scratches/blue discoloration → re- place. 2. Measure: • cam lobe length "a" and "b" out of ...

  • Page 128: Camshafts

    4-26 camshafts c. Install the clip, dowel pins and camshaft caps. • tighten the bolts (camshaft cap) in a criss- cross pattern from innermost to outer caps. • do not turn the camshaft when measuring clearance with the plastigauge ® . D. Remove the camshaft caps and measure the width of the plastigau...

  • Page 129: Camshafts

    4-27 camshafts checking the timing chain tensioner 1. Check: • while pressing the tensioner rod lightly with fingers, use a thin screwdriver "1" and wind the tensioner rod up fully clockwise. • when releasing the screwdriver by pressing lightly with fingers, make sure that the ten- sioner rod will c...

  • Page 130: Camshafts

    4-28 camshafts d. Install the clips, camshaft caps "4" and bolts (camshaft cap) "5". • before installing the clips, cover the cylinder head with a clean rag to prevent the clips from into the cylinder head cavity. • apply the molybdenum disulfide oil on the thread of the bolts (camshaft cap). • tigh...

  • Page 131: Camshafts

    4-29 camshafts 5. Install: • timing mark accessing screw "1" • crankshaft end accessing screw "2" 6. Install: • timing chain guide (top side) "1" • cylinder head cover gasket "2" • cylinder head cover "3" • bolt (cylinder head cover) "4" apply the sealant on the cylinder head cover gasket. 7. Instal...

  • Page 132: Cylinder Head

    4-30 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 si- lencer" section. Radiator hose 1 disconnect at cylinder head side. Carburetor refer...

  • Page 133: Cylinder Head

    4-31 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 134: Cylinder Head

    4-32 cylinder head • apply the molybdenum disulfide grease on the thread and contact surface of the bolts. • follow the numerical order shown in the illus- tration. Tighten the bolts and nuts in two stag- es. 3. Install: • copper washer "1" • oil delivery pipe "2" • union bolt (m8) "3" • union bolt ...

  • Page 135: Valves and Valve Springs

    4-33 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 136: Valves and Valve Springs

    4-34 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 137: Valves and Valve Springs

    4-35 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 138: Valves and Valve Springs

    4-36 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 139: Valves and Valve Springs

    4-37 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 140: Valves and Valve Springs

    4-38 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 141: Valves and Valve Springs

    4-39 valves and valve springs 3. Install: • valve cotter while compressing the valve spring with a valve spring compressor "1" install the valve cotters. 4. To secure the valve cotters onto the valve stem, lightly tap the valve tip with a piece of wood. Hitting the valve tip with excessive force cou...

  • Page 142: Cylinder and Piston

    4-40 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 143: Cylinder and Piston

    4-41 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 144: Cylinder and Piston

    4-42 cylinder and piston c. Measure the piston skirt diameter "p" with a micrometer. A. 8 mm (0.31 in) from the piston bottom edge d. If out of specification, replace the piston and piston rings as a set. E. Calculate the piston-to-cylinder clearance with following formula: f. If out of specificatio...

  • Page 145: Cylinder and Piston

    4-43 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 146: Cylinder and Piston

    4-44 cylinder and piston 3. Install: • piston "1" • piston pin "2" • piston pin clip "3" • 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 ...

  • Page 147: Clutch

    4-45 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 148: Clutch

    4-46 clutch 11 clutch plate 8 12 nut (clutch boss) 1 refer to removal section. 13 lock washer 1 refer to removal section. 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 149: Clutch

    4-47 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 150: Clutch

    4-48 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 151: Clutch

    4-49 clutch 2. Install: • lock washer "1" • nut (clutch boss) "2" use the clutch holding tool "3" to hold the clutch boss. A. For usa and cdn b. Except for usa and cdn 3. Bend the lock washer "1" tab. 4. Install: • friction plate "1" • clutch plate 1 "2" • install the clutch plates and friction plat...

  • Page 152: Clutch

    4-50 clutch 6. Install: • push rod 2 "1" • ball "2" • push rod 1 "3" apply the engine oil on the push rod 1, 2 and ball. 7. Install: • pressure plate "1" 8. Install: • clutch spring "1" • bolt (clutch spring) "2" tighten the bolts in stage, using a crisscross pattern. 9. Install: • dowel pin "1" • g...

  • Page 153

    4-51 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 154

    4-52 oil filter element and water pump 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 section. Order part n...

  • Page 155

    4-53 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 156

    4-54 oil filter element and water pump checking the impeller shaft gear 1. Inspect: • gear teeth "a" wear/damage → replace. Checking the bearing 1. Inspect: • bearing rotate inner race with a finger. Rough spot/seizure → replace. Checking the oil seal 1. Inspect: • oil seal "1" wear/damage → replace...

  • Page 157

    4-55 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 158

    4-56 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 th...

  • Page 159: Balancer

    4-57 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 "cdi magneto" section. 1 nut (primary drive gear) 1 refer to removal section. 2 nut (ba...

  • Page 160: Balancer

    4-58 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 161: Balancer

    4-59 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 162: Oil Pump

    4-60 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 163: Oil Pump

    4-61 oil pump 11 inner rotor 1 1 12 dowel pin 1 13 washer 1 14 oil pump drive shaft 1 15 rotor housing 1 order part name q'ty remarks.

  • Page 164: Oil Pump

    4-62 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 165: Oil Pump

    4-63 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 166: Oil Pump

    4-64 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 167: Oil Pump

    4-65 oil pump installing 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 clam...

  • Page 168: Kick Shaft and Shift Shaft

    4-66 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 169: Kick Shaft and Shift Shaft

    4-67 kick shaft and shift shaft 11 collar 1 12 torsion spring 1 13 roller 1 14 shift guide 1 refer to removal section. 15 shift lever assembly 1 refer to removal section. 16 shift lever 1 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 ...

  • Page 170: Kick Shaft and Shift Shaft

    4-68 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 171: Kick Shaft and Shift Shaft

    4-69 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 172: Kick Shaft and Shift Shaft

    4-70 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 173: Kick Shaft and Shift Shaft

    4-71 kick shaft and shift shaft install with the punch mark "a" on the shift ped- al in alignment with the punch mark "b" on the shift shaft. Installing the kick shaft assembly 1. Install: • kick gear "1" • washer "2" • circlip "3" • ratchet wheel "4" • spring "5" • washer "6" • circlip "7" to kick ...

  • Page 174: Kick Shaft and Shift Shaft

    4-72 kick shaft and shift shaft 5. Hook: • torsion spring "1" turn the torsion spring clockwise and hook into the proper hole "a" in the crankcase. Installing the kick idle gear 1. Install: • kick idle gear "1" • washer "2" • circlip "3" • apply the engine oil on the kick idle gear inner circumferen...

  • Page 175: Cdi Magneto

    4-73 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 176: Cdi Magneto

    4-74 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 coun- terclockwise. Checking the cdi magneto 1. Inspect: • rotor inner surface "a" • stator o...

  • Page 177: Cdi Magneto

    4-75 cdi magneto 2. Install: • woodruff key "1" • rotor "2" • clean 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 installing the rotor, align the keyway "c" of the r...

  • Page 178: Engine Removal

    4-76 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". Seat and fuel tank refer to "seat, fuel tank and side covers" section. Carburetor refer to "carburetor" section. Exhaust pip...

  • Page 179: Engine Removal

    4-77 engine removal ignition coil disconnect the cdi magneto lead. 1 lower engine guard 1 2 neutral switch 1 3 drive chain sprocket cover 1 4 nut (drive sprocket) 1 refer to removal section. 5 lock washer 1 refer to removal section. 6 drive sprocket 1 refer to removal section. 7 clip 1 8 bolt (brake...

  • Page 180: Engine Removal

    4-78 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 181: Engine Removal

    4-79 engine removal • upper engine bracket "8" • bolt (upper engine bracket) "9" • engine mounting bolt (upper) "10" • front 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 chass...

  • Page 182: Engine Removal

    4-80 engine removal 4. Install: • drive chain sprocket guide "1" • drive chain sprocket cover "2" • bolt (drive chain sprocket cover) "3" installing the neutral switch 1. Install: • spring "1" • pin "2" • o-ring "3" • neutral switch "4" • screw (neutral switch) "5" apply the lithium soap base grease...

  • Page 183: Crankcase and Crankshaft

    4-81 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 184: Crankcase and Crankshaft

    4-82 crankcase and crankshaft 6 bolt [l = 70 mm (2.76 in)] 4 refer to removal section. 7 hose guide 1 refer to removal section. 8 clutch cable holder 1 refer to removal section. 9 right crankcase 1 refer to removal section. 10 left crankcase 1 refer to removal section. 11 oil strainer 1 12 crankshaf...

  • Page 185: Crankcase and Crankshaft

    4-83 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 186: Crankcase and Crankshaft

    4-84 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 187: Crankcase and Crankshaft

    4-85 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 188: Crankcase and Crankshaft

    4-86 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 189: Crankcase and Crankshaft

    4-87 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 190: Crankcase and Crankshaft

    4-88 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 191

    4-89 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 192

    4-90 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 193

    4-91 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 194

    4-92 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 195

    4-93 transmission, shift cam and shift fork 7. Check: • shifter operation • transmission operation unsmooth operation → repair..

  • Page 196: Chassis

    5-1 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 inspection, adjustment, dis...

  • Page 197: Front Wheel and Rear Wheel

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

  • Page 198: Front Wheel and Rear Wheel

    5-3 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 199: Front Wheel and Rear Wheel

    5-4 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 200: Front Wheel and Rear Wheel

    5-5 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 201: Front Wheel and Rear Wheel

    5-6 front wheel and rear wheel 3. Install: • collar "1" • apply the lithium soap base grease on the oil seal lip. • install the collars with their projections "a" fac- ing the wheel. 4. Install: • wheel install the brake disc "1" between the brake pads "2" correctly. 5. Install: • wheel axle "1" app...

  • Page 202: Front Wheel and Rear Wheel

    5-7 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 203: Front Wheel and Rear Wheel

    5-8 front wheel and rear wheel 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: • left drive chain puller "1" • wheel axle "2" • install the left drive chain puller, ...

  • Page 204: Front Brake and Rear Brake

    5-9 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 union bolt...

  • Page 205: Front Brake and Rear Brake

    5-10 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 206: Front Brake and Rear Brake

    5-11 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 207: Front Brake and Rear Brake

    5-12 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 208: Front Brake and Rear Brake

    5-13 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 209: Front Brake and Rear Brake

    5-14 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 210: Front Brake and Rear Brake

    5-15 front brake and rear brake 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. Replace the brake cal...

  • Page 211: Front Brake and Rear Brake

    5-16 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 212: Front Brake and Rear Brake

    5-17 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 213: Front Brake and Rear Brake

    5-18 front brake and rear brake 3. Install: • spring "1" to brake master cylinder piston "2". Install the spring at the smaller dia. Side. 4. Install: • brake master cylinder kit "1" • washer (front brake) "2" • push rod (rear brake) "2" • circlip "3" • brake master cylinder boot "4" • push rod (fro...

  • Page 214: Front Brake and Rear Brake

    5-19 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 215: Front Brake and Rear Brake

    5-20 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 216: Front Brake and Rear Brake

    5-21 front brake and rear brake installing the rear 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. Ins...

  • Page 217: Front Brake and Rear Brake

    5-22 front brake and rear brake brake fluid may erode painted surfaces or plastic parts. Always clean up spilled fluid immediately. A. Front b. Rear 2. Air bleed: • brake system refer to "bleeding the hydraulic brake system" section in the chapter 3. 3. Inspect: • brake fluid level fluid at lower le...

  • Page 218: Front Fork

    5-23 front fork front fork removing the front fork order part name q'ty remarks 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" section. N...

  • Page 219: Front Fork

    5-24 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 220: Front Fork

    5-25 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 221: Front Fork

    5-26 front fork 2. Remove: • inner tube "1" oil seal removal steps: a. Push in slowly "a" the inner tube just before it bottoms out and then pull it back quickly "b". B. Repeat this step until the inner tube can be pulled out from the outer tube. Removing the base valve 1. Remove: • base valve "1" f...

  • Page 222: Front Fork

    5-27 front fork checking the collar 1. Inspect: • piston metal "1" wear/damage → replace. Checking the fork spring 1. Measure: • fork spring free length "a" out of specification → replace. Checking the inner tube 1. Inspect: • inner tube surface "a" score marks → repair or replace. Use #1,000 grit w...

  • Page 223: Front Fork

    5-28 front fork assembling the front fork 1. Wash the all parts in a clean solvent. 2. Stretch the damper assembly fully. 3. Fill: • front fork oil "1" to damper assembly. • be sure to use recommended fork oil. If other oils are used, they may have an ex- cessively adverse effect on the front fork p...

  • Page 224: Front Fork

    5-29 front fork 8. Install: • base valve "1" to damper assembly "2". First bring the damper rod pressure to a maxi- mum. Then install the base valve while releas- ing the damper rod pressure. 9. Check: • damper assembly not fully stretched → repeat the steps 2 to 8. 10.Tighten: • base valve "1" hold...

  • Page 225: Front Fork

    5-30 front fork 13.Allow the overflowing oil to escape at the hole "a" in the damper assembly. 14.Check: • damper assembly smooth movement tightness/binding/rough spots → repeat the steps 2 to 13. 15.Install: • dust seal "1" • stopper ring "2" • oil seal "3" • oil seal washer "4" • slide metal "5" t...

  • Page 226: Front Fork

    5-31 front fork 19.Install: • oil seal "1" press the oil seal into the outer tube with fork seal driver "2". 20.Install: • stopper ring "1" fit the stopper ring correctly in the groove in the outer tube. 21.Install: • dust seal "1" apply the lithium soap base grease on the inner tube. 22.Check: • in...

  • Page 227: Front Fork

    5-32 front fork 24.Install: • collar "1" • fork spring "2" to damper assembly "3". Install the collar with its larger dia. End "a" fac- ing the fork spring. 25.Install: • damper assembly "1" to inner tube "2". To install the damper assembly into the in- ner tube, hold the inner tube aslant. If the i...

  • Page 228: Front Fork

    5-33 front fork if the adjuster is installed out of specification, proper damping force cannot be obtained. 29.Tighten: • adjuster (locknut) "1" hold the locknut "2" and tighten the adjuster with specified torque. 30.Install: • adjuster "1" to inner tube. 31.Fill: • front fork oil "1" from outer tub...

  • Page 229: Front Fork

    5-34 front fork 33.Install: • protector guide "1" 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: • damper assembly "1" use the cap bolt ring wrench "2" to tighten the damp...

  • Page 230: Front Fork

    5-35 front fork 5. Install: • protector "1" • bolt (protector) "2" 6. Adjust: • rebound damping force turn in the damping adjuster "1" finger-tight and then turn out to the originally set position. 7. Adjust: • compression damping force turn in the damping adjuster "1" finger-tight and then turn out...

  • Page 231: Handlebar

    5-36 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 232: Handlebar

    5-37 handlebar 14 handlebar upper holder 2 15 handlebar 1 16 handlebar lower holder 2 order part name q'ty remarks.

  • Page 233: Handlebar

    5-38 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 234: Handlebar

    5-39 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 235: Handlebar

    5-40 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 236: Handlebar

    5-41 handlebar 9. Install: • grip cap cover "1" • cover (throttle cable cap) "2" 10.Install: • brake master cylinder "1" • brake master cylinder bracket "2" • bolt (brake master cylinder bracket) "3" • install the bracket so that the arrow mark "a" faces upward. • first tighten the bolt on the upper...

  • Page 237: Steering

    5-42 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 suit- able stand under the engine. Refer to "handling note". Num...

  • Page 238: Steering

    5-43 steering 5 steering ring nut 1 refer to removal section. 6 lower bracket 1 7 bearing race cover 1 8 upper bearing 1 9 lower bearing 1 refer to removal section. 10 bearing race 2 refer to removal section. Order part name q'ty remarks.

  • Page 239: Steering

    5-44 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 240: Steering

    5-45 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 241: Steering

    5-46 steering 7. Install: • front fork "1" • upper bracket "2" • temporarily tighten the pinch bolts (lower bracket). • do not tighten the pinch bolts (upper bracket) yet. 8. Install: • steering stem nut "1" apply the lithium soap base grease on the con- tact surface of the steering stem nut when in...

  • Page 242: Swingarm

    5-47 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 243: Swingarm

    5-48 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 244: Swingarm

    5-49 swingarm handling note support the machine securely so there is no danger of it falling over. Checking the swingarm 1. Inspect: • bearing "1" • bushing "2" free play exists/unsmooth revolution/rust → replace bearing and bushing as a set. 2. Inspect: • oil seal "3" damage → replace. Checking the...

  • Page 245: Swingarm

    5-50 swingarm 2. Install: • bearing "1" • washer "2" • oil seal "3" to relay arm. • 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. • apply the molybdenum disulfide grease on the washer....

  • Page 246: Swingarm

    5-51 swingarm 3. Install: • collar "1" to connecting rod "2". Apply the molybdenum disulfide grease on the collar and oil seal lips. 4. Install: • connecting rod "1" • bolt (connecting rod) "2" • washer "3" • nut (connecting rod) "4" to relay arm "5". Apply the molybdenum disulfide grease on the bol...

  • Page 247: Swingarm

    5-52 swingarm 8. Install: • bolt (connecting rod) "1" • washer "2" • nut (connecting rod) "3" • apply the molybdenum disulfide grease on the bolt. • do not tighten the nut yet. 9. Install: • bolt (rear shock absorber-relay arm) "1" • nut (rear shock absorber-relay arm) "2" apply the molybdenum disul...

  • Page 248: Swingarm

    5-53 swingarm 13.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) "4" • bolt {drive chain support cover [l = 10 mm (0.39 in)]} "5" nut (drive chain support): 7 nm (0.7 m•kg, 5.1 ft•lb) bolt (drive ch...

  • Page 249: Rear Shock Absorber

    5-54 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 refer to "seat, fuel tank and side covers" section in the chapter 4. Silencer refer to "exhaust...

  • Page 250: Rear Shock Absorber

    5-55 rear shock absorber 8 lower spring guide 1 9 upper spring guide 1 10 spring (rear shock absorber) 1 11 bearing 2 refer to removal section. Order part name q'ty remarks b 2 9 8 10 11 11.

  • Page 251: Rear Shock Absorber

    5-56 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 252: Rear Shock Absorber

    5-57 rear shock absorber 3. Remove: • lower bearing "1" remove the bearing by pressing its outer race. 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 lea...

  • Page 253: Rear Shock Absorber

    5-58 rear shock absorber 3. Install: • lower bearing "1" install the bearing by pressing it on the side having the manufacture's marks or numbers. Installing the spring (rear shock absorber) 1. Install: • spring "1" • upper spring guide "2" • lower spring guide "3" 2. Tighten: • adjuster "1" 3. Adju...

  • Page 254: Rear Shock Absorber

    5-59 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 ...

  • Page 255: Electrical

    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 knowl- edge and skill concerning servicing are requested not to undertake inspection, adjustment, ...

  • Page 256

    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.

  • Page 257

    6-3 electrical components and wiring diagram wiring diagram 1. Engine stop switch 2. Throttle position sensor 3. Neutral switch 4. Cdi magneto 5. Ignition coil 6. Spark plug 7. Cdi unit color code b black br brown g green l blue o orange p pink r red sb sky blue w white y yellow b/l black/blue b/w b...

  • Page 258: Ignition System

    6-4 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 259: Ignition System

    6-5 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 260: Ignition System

    6-6 ignition system 3. Inspect: • secondary coil resistance out of specification → replace. 4. Inspect: • sealed portion of ignition coil "a" • spark plug terminal pin "b" • threaded portion of spark plug "c" wear → replace. Checking the cdi magneto 1. Inspect: • pickup coil resistance out of specif...

  • Page 261: Ignition System

    6-7 ignition system 3. Inspect: • charging coil 2 resistance out of specification → replace. Checking the neutral switch 1. Inspect: • neutral switch conduction not conductive while it is in neutral → replace. Conductive while it is engaged → replace. Set the tester selection position to "Ω × 1". Ch...

  • Page 262

    6-8 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 263

    6-9 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 264

    6-10 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 265

    6-11 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 266: Engine

    7-1 engine tuning engine carburetor setting • the air/fuel mixture will vary depending on at- mospheric conditions. Therefore, it is neces- sary to take into consideration the air pressure, ambient temperature, humidity, etc., when adjusting the carburetor. • perform a test run to check for proper e...

  • Page 267: Engine

    7-2 engine construction of carburetor and setting parts the flatcr carburetor has a primary main jet. This type of main jet is perfect for racing ma- chines since it supplies an even flow of fuel, even at full load. Use the main jet and the jet needle to set the carburetor. The flatcr carburetor is ...

  • Page 268: Engine

    7-3 engine effects of adjusting the pilot screw (refer- ence) a. Idle b. Fully open 1. 2-1/4 turns out 2. 1-1/4 turns out 3. 1-3/4 turns out adjusting the pilot jet the richness of the air-fuel mixture with the throttle open 1/4 or less can be set by adjusting the pilot jet "1". Effects of adjusting...

  • Page 269: Engine

    7-4 engine effects of changing the jet needle (refer- ence) (diameter of the straight portion) changing the diameter of the straight portion adjusts the air-fuel mixture when the throttle is 1/8 to 1/4 open. A. Idle b. Fully open relationship with throttle opening the flow of the fuel through the ca...

  • Page 270: Engine

    7-5 engine carburetor setting parts main jet size part number rich #190 4mx-14943-45 #188 4mx-14943-95 #185 4mx-14943-44 #182 4mx-14943-94 (std) #180 4mx-14943-43 #178 4mx-14943-93 #175 4mx-14943-42 #172 4mx-14943-92 lean #170 4mx-14943-41 pilot jet size part number rich #50 4mx-14948-07 #48 4mx-149...

  • Page 271: Engine

    7-6 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 272: Engine

    7-7 engine this should be taken simply for an example. It is necessary to set the carburetor while checking the operating conditions of the engine. Lean mixture lower jet needle clip position. (1 groove down) the clip position is the jet needle groove on which the clip is in- stalled. The positions ...

  • Page 273: Chassis

    7-8 chassis 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 the sp...

  • Page 274: Chassis

    7-9 chassis • under a stony or hard road condition, the tire pressure should be higher to prevent a flat tire. 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 ...

  • Page 275: Chassis

    7-10 chassis generally a stiff spring gives a stiff riding feel- ing. Rebound damping tends to become weak- er, resulting in lack of a sense of contact with the road surface or in a vibrating handlebar. Front fork setting parts • front fork spring "1" the i.D. Mark (slits) "a" is proved on the end o...

  • Page 276: Chassis

    7-11 chassis • if the machine is new and after it is broken in, the same set length of the spring may change because of the initial fatigue, etc. Of the spring. Therefore, be sure to make reevalua- tion. • if the standard figure cannot be achieved by adjusting the spring adjuster and changing the sp...

  • Page 277: Chassis

    7-12 chassis • extent of adjustment (spring preload) for the spring preload adjustment, refer to "ad- justing the rear shock absorber spring preload" in the chapter 3. Spring part number (-22212-) maximum minimum 5un-00 5un-10 5un-20 5un-30 position in which the spring is turned in 18 mm (0.71 in) f...

  • Page 278: Chassis

    7-13 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 fig...

  • Page 279: Chassis

    7-14 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. • adjus...

  • Page 282

    Printed in japan 2010.05-0.6 ×1 cr (e) printed on recycled paper yamaha motor co., ltd. 2500 shingai iwata shizuoka japan.