Yamaha yz250 2015 Owner's Manual
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Yamaha yz250 2015 Owner's Manual

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2015
q Read this manual carefully before operating this vehicle.
q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule.
q Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
q Leggere attentamente questo manuale prima di utilizzare questo veicolo.
OWNER'S SERVICE MANUAL
MANUEL D'ATELIER DU
PROPRIETAIRE
FAHRER- UND
WARTUNGSHANDBUCH
MANUALE DI SERVIZIO DEL
PROPRIETARIO
YZ250
YZ250F2
1SS-28199-33

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  • Page 1 2015 q Read this manual carefully before operating this vehicle. q Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. q Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen. q Leggere attentamente questo manuale prima di utilizzare questo veicolo. OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE...
  • 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 Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
  • Page 3 2015 2015 Read this manual carefully before operating this vehicle. Read this manual carefully before operating this vehicle. OWNER’S SERVICE MANUAL OWNER’S SERVICE MANUAL YZ250 YZ250 YZ250F2 YZ250F2 1SS-28199-33-E0 1SS-28199-33-E0...
  • Page 5 YZ250 YZ250F2 OWNER'S SERVICE MANUAL ©2014 by Yamaha Motor Co., Ltd. 1st Edition, June 2014 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: Safety Information

    Always turn off the engine while re- Congratulations on your purchase of could result in death or serious in- fueling. Take care to not spill any a Yamaha YZ series. This model is jury. gasoline on the engine or exhaust the culmination of Yamaha's vast ex- system.

  • Page 7: General Information

    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 general layout of the book be- fore finding then required chapter and item.
  • Page 8 2. Numbers "2" are given in the or- 4. A job instruction chart "4" accom- HOW TO READ DESCRIPTIONS der of the jobs in the exploded di- panies the exploded diagram, To help identify parts and clarify pro- agram. A number that is enclosed providing the order of jobs, names cedure steps, there are exploded dia- by a circle indicates a disassem-...

  • Page 9: Table Of Contents

    TABLE OF CONTENTS GENERAL INFORMATION SPECIFICATIONS REGULAR INSPECTION AND ADJUSTMENTS ENGINE CHASSIS ELECTRICAL TUNING...

  • Page 10: Table Of Contents

    CONTENTS CHAPTER 1 CHAPTER 3 CHAPTER 5 GENERAL REGULAR CHASSIS INFORMATION INSPECTION AND ADJUSTMENTS FRONT WHEEL AND REAR WHEEL ....5-1 LOCATION OF FRONT BRAKE AND IMPORTANT LABELS ..1-1 MAINTENANCE REAR BRAKE ....5-6 DESCRIPTION ....1-5 INTERVALS...... 3-1 FRONT FORK....5-16 CONSUMER PRE-OPERATION HANDLEBAR....5-24...

  • Page 11: Important Labels

    LOCATION OF IMPORTANT LABELS GENERAL INFORMATION LOCATION OF IMPORTANT LABELS Please read the following important labels carefully before operating this vehicle. CANADA...
  • Page 12 LOCATION OF IMPORTANT LABELS EUROPE...
  • Page 13 LOCATION OF IMPORTANT LABELS AUS, NZ, ZA...

  • Page 14: Location Of Important Labels

    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 to avoid draining the battery. Use unleaded gasoline only.

  • Page 15: Description

    DESCRIPTION DESCRIPTION Clutch lever 14. Fuel cock Engine stop switch 15. Starter knob Front brake lever 16. Drive chain Throttle grip 17. Air filter Radiator cap 18. Shift pedal Fuel tank cap 19. Front fork Kickstarter lever Fuel tank Radiator 10.

  • Page 16: Consumer Information

    End of each hose 1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own. VALVE JOINT 2. If your machine is stolen, the au- This valve joint "1"...

  • Page 17: Checking Of Connection

    CHECKING OF CONNECTION ALL REPLACEMENT PARTS 6. Connect: 1. We recommend to use Yamaha • Connector genuine parts for all replace- ments. Use oil and/or grease rec- The two connectors "click" together. ommended by Yamaha for 7. Check for continuity with a tester.

  • Page 18: Special Tools

    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 country, so two types are provided.
  • Page 19 SPECIAL TOOLS Tool name/Part number How to use Illustration Radiator cap tester These tools are used for checking YU-24460-A, 90890-01325 the cooling system. Radiator cap tester adapter YU-33984, 90890-01352 Steering nut wrench This tool is used when tighten the YU-A9472, 90890-01403 steering ring nut to specification.
  • Page 20 Ignition checker nents. 90890-06754 Digital tachometer This tool is needed for observing en- YU-39951-B, 90890-06760 gine rpm. Yamaha bond No. 1215 This sealant (Bond) is used for 90890-85505 crankcase mating surface, etc. (Three bond No. 1215®) 1-10...

  • Page 21: Control Functions

    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. THROTTLE GRIP STARTER KNOB (CHOKE) The throttle grip "1" is located on the When cold, the engine requires a right handlebar;...
  • Page 22 STARTING AND BREAK-IN STARTING A WARM ENGINE 9. Restart the engine and check the Mixing oil: Do not operate the starter knob operation of the machine through- Recommended oil: (CHOKE). Open the throttle slightly out its entire operating range. YAMALUBE "2-R" and start the engine by kicking the Stop and check the spark plug (YAMALUBE racing 2-...

  • Page 23: Torque-Check Points

    TORQUE-CHECK POINTS TORQUE-CHECK POINTS 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 bracket to engine Engine bracket to frame Steering Steering stem to handlebar Steering stem to frame Steering stem to upper bracket Upper bracket to handlebar...

  • Page 24: Maintenance After Break-In

    MAINTENANCE AFTER BREAK-IN MAINTENANCE AFTER • Cable 5. Rinse the machine off immediate- Grease and adjust cables. ly with clean water, and dry all BREAK-IN • Drive chain surfaces with a soft towel or cloth. After a break-in, perform careful Lubricate the drive chain and ad- 6.

  • Page 25: General Specifications

    GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: YZ250F2 (USA, CDN, AUS, NZ) YZ250 (EUROPE, ZA) Model code number: 1SSD (USA, CDN) 1SSE (EUROPE) 1SSG (AUS, NZ, ZA) Dimensions: Overall length 2,147 mm (84.4 in) Overall width 827 mm (32.6 in) Overall height 1,299 mm (51.2 in) Seat height...
  • Page 26 GENERAL SPECIFICATIONS Transmission: Primary reduction system Gear Primary reduction ratio 3.000 (63/21) Final drive Chain Secondary reduction ratio 3.571 (50/14) Transmission type Constant mesh, 5-speed Operation Left foot operation Gear ratio: 1.929 (27/14) 1.533 (23/15) 1.278 (23/18) 1.091 (24/22) 0.952 (20/21) Chassis: Frame type Semi double cradle...

  • Page 27: Maintenance Specifications

    MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Combustion chamber volume 21.35–21.65 cm (1.30–1.32 cu.in) ---- Warp limit ---- 0.03 mm (0.0012 in) Cylinder: Bore size 66.400–66.414 mm (2.6142–2.6147 in) 66.500 mm (2.6181 in) Taper limit ---- 0.050 mm (0.0020 in) Out of round limit ----...
  • Page 28 MAINTENANCE SPECIFICATIONS Item Standard Limit Crankshaft: Crank width "A" 59.95–60.00 mm (2.360–2.362 in) ---- Runout limit "C" 0.030 mm (0.0012 in) 0.050 mm (0.0020 in) Connecting rod big end side clearance "D" 0.250–0.750 mm (0.0098–0.0295 in) ---- Small end free play "F" 0.40–1.00 mm (0.02–0.04 in) 2.0 mm (0.08 Clutch:...
  • Page 29 MAINTENANCE SPECIFICATIONS Item Standard Limit Carburetor: USA, CDN EUROPE AUS, NZ, ZA Type/Manufacturer PWK38S/ ---- ← ← KEIHIN I.D. mark 1P87 50 1P86 40 ---- ← Main jet (M.J.) #178 #180 ---- ← Main air jet (M.A. J.) #200 ---- ←...
  • Page 30 MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Taper roller bearing ---- Front suspension: Front fork travel 300.0 mm (11.81 in) ---- Fork spring free length 454.0 mm (17.87 in) 449.0 mm (17.68 in) Spring rate, STD K=4.30 N/mm (0.44 kg/mm, 24.55 lb/in) ---- Optional spring...
  • Page 31 0.18 mm (0.007 in) ---- Advancer type Electrical ---- CDI: Magneto-model (stator)/Manufacturer 5CU-20/YAMAHA ---- Charging coil 1 resistance (color) 720.0–1,080.0 Ωat 20 °C (68 °F) (Black- ---- Black/Red) Charging coil 2 resistance (color) 44.0–66.0 Ωat 20 °C (68 °F) (Green/Blue-...

  • Page 32: Tightening Torques

    TIGHTENING TORQUES TIGHTENING TORQUES ENGINE △ - marked portion shall be checked for torque tightening after break-in or before each race. Thread Item Q'ty Tightening torque Remarks size Spark plug M14S 20 Nm (2.0 m•kg, 14 ft•lb) Copper Cylinder head (nut) 25 Nm (2.5 m•kg, 18 ft•lb) washer Cylinder head (stud)
  • Page 33 TIGHTENING TORQUES Thread Item Q'ty Tightening torque Remarks size Drive chain sprocket cover 5 Nm (0.5 m•kg, 3.6 ft•lb) Right crankcase cover 10 Nm (1.0 m•kg, 7.2 ft•lb) Bearing plate cover (drive axle left) 10 Nm (1.0 m•kg, 7.2 ft•lb) Bearing plate cover (main axle right) 10 Nm (1.0 m•kg, 7.2 ft•lb) Holder...
  • Page 34 TIGHTENING TORQUES CHASSIS △ - marked portion shall be checked for torque tightening after break-in or before each race. Thread Item Q'ty Tightening torque Remarks size Upper bracket and outer tube 21 Nm (2.1 m•kg, 15 ft•lb) △ Lower bracket and outer tube 21 Nm (2.1 m•kg, 15 ft•lb) △...
  • Page 35 TIGHTENING TORQUES Thread Item Q'ty Tightening torque Remarks size TORX Footrest bracket and frame 55 Nm (5.5 m•kg, 40 ft•lb) Brake pedal mounting 26 Nm (2.6 m•kg, 19 ft•lb) △ Rear brake master cylinder and frame 10 Nm (1.0 m•kg, 7.2 ft•lb) △...
  • Page 36 TIGHTENING TORQUES Thread Item Q'ty Tightening torque Remarks size Front fender 10 Nm (1.0 m•kg, 7.2 ft•lb) △ Rear fender (front) 7 Nm (0.7 m•kg, 5.1 ft•lb) △ Rear fender (rear) 12 Nm (1.2 m•kg, 8.7 ft•lb) △ Mud flap —...
  • Page 37 TIGHTENING TORQUES GENERAL TORQUE TORQUE SPECIFI- SPECIFICATIONS CATION This chart specifies torque for stan- (Nut) (Bolt) dard fasteners with standard I.S.O. m•kg ft•lb pitch threads. Torque specifications 6 mm for special components or assem- blies are included in the applicable sections of this book.

  • Page 38: Cable Routing Diagram

    CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM Engine stop switch lead Pass the clutch cable on the out- Clamp the engine stop switch Throttle cable side of the throttle cable and en- lead to the frame. Tighten the Clutch cable gine stop switch lead. clamp so that the engine stop Clamp Align the throttle cable locating...
  • Page 39 CABLE ROUTING DIAGRAM Clamp the throttle cable and wire harness to the frame. Pass the clutch cable in front of the center of the cylinder head tightening nut. Pass the air vent hose, overflow hose and crankcase breather hose between the frame and connecting rod.
  • Page 40 CABLE ROUTING DIAGRAM Ignition coil lead Clamp the ignition coil lead to Pass the neutral switch lead Clamp the frame at its locating tape. through the holder. CDI magneto lead Clamp it in front of the radiator Pass the radiator breather hose Neutral switch lead fitting boss.
  • Page 41 CABLE ROUTING DIAGRAM Clamp the radiator breather hose, CDI magneto lead and neutral switch lead to the frame. Pass the CDI magneto lead, ra- diator breather hose and neutral switch lead in front of the radia- tor hose. Then pass the radiator breather hose inside the CDI magneto lead and neutral switch lead.
  • Page 42 CABLE ROUTING DIAGRAM Clamp Clamp the wire harness protect- Bring the connector cover into Wire harness ing tube to the right engine contact with the coupler. High tension cord bracket. Pass the radiator breather hose CDI unit band Pass the high tension cord to the behind the radiator hose.
  • Page 43 CABLE ROUTING DIAGRAM Master cylinder Install the brake hose so that its Install the brake hose so that its Brake hose holder pipe portion directs as shown pipe portion directs as shown Brake hose and lightly touches the projec- and lightly touches the projec- tion on the caliper.
  • Page 44 CABLE ROUTING DIAGRAM Brake hose Install the brake hose so that its Pass the brake hose in front of Master cylinder pipe portion directs as shown the number plate and through Engine stop switch lead and lightly touches the projec- the cable guide.

  • Page 45: Maintenance Intervals

    If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. • Periodic inspection is essential in making full use of the machine performance. The service life of the parts varies sub- stantially according to the environment in which the machine runs (e.g., rain, dirt, etc.).
  • Page 46 MAINTENANCE INTERVALS Every Every Every race third fifth After As re- (about (about (about Item Remarks break-in quired 12.5 hours) hours) hours) ROTOR NUT Retighten ● ● MUFFLER Inspect ● ● Clean ● Retighten ● ● Replace fiber * When the exhaust sound be- ●...
  • Page 47 MAINTENANCE INTERVALS Every Every Every race third fifth After As re- (about (about (about Item Remarks break-in quired 12.5 hours) hours) hours) BRAKES Adjust lever position and ● ● pedal height Lubricate pivot point ● ● Check brake disc surface ●...
  • Page 48 Retighten sprocket bolt ● ● Inspect bearings ● Replace bearings ● Lubricate Lithium base grease ● THROTTLE, CONTROL CA- Check routing and connec- ● ● tion Lubricate Yamaha cable lube or SAE ● ● 10W-40 motor oil...

  • Page 49: Inspection And Maintenance

    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 Check that coolant is filled up to the radiator cap.

  • Page 50: Engine

    ENGINE ENGINE 2. Remove: • Coolant drain bolt "1" CHECKING THE COOLANT LEVEL • When coolant splashes to your eye. Thoroughly wash your eye with Do not remove the radiator cap water and see your doctor. "1", drain bolt and hoses when the •...
  • Page 51 ENGINE 2. Apply the specified pressure. ADJUSTING THE CLUTCH LEVER POSITION If the clutch lever free play cannot be Radiator cap opening 1. Adjust: obtained on the handlebar side, use pressure: • Clutch lever position the adjuster on the clutch cable side. 95.0–125.0 kPa (0.95–...
  • Page 52 ENGINE Prior to adjusting throttle grip free Never run the engine without the play, the engine idling speed should air filter element in place; this be adjusted. would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage.
  • Page 53 ENGINE Pilot air screw: Never attempt to remove the oil 1-1/4 turns out check bolt just after high speed * 2-1/4 turns out operation. The heated oil could (for reference only) spout out, causing danger. Wait * Except for USA and CDN until the oil cools down.

  • Page 54: Chassis

    CHASSIS CHASSIS h. Tighten the bleed screw when the lever or pedal limit has been BLEEDING THE HYDRAULIC reached; then release the lever or BRAKE SYSTEM pedal. Bleed screw: Bleed the brake system if: 6 Nm (0.6 m•kg, 4.3 • The system has been disassem- ft•lb) bled.
  • Page 55 CHASSIS d. Remove the pad pin and brake pads "4". Install the pad pin plug "10". Pad pin plug: e. Connect the transparent hose "5" 3 Nm (0.3 m•kg, 2.2 to the bleed screw "6" and place ft•lb) the suitable container under its end.
  • Page 56 CHASSIS 2. Inspect: • Rear brake pad insulator "1" Damage → Replace. b. Loosen the pad pin "3". Install the brake caliper "12" and c. Remove the rear wheel "4" and rear wheel "13". brake caliper "5". Refer to "FRONT WHEEL AND Refer to "FRONT WHEEL AND REAR WHEEL"...

  • Page 57: Specifications

    CHASSIS 4. Check: • Drive chain stiffness "a" Before checking and/or adjusting, ro- Clean and oil the drive chain and tate the rear wheel through several hold as illustrated. revolutions and check the slack sev- Stiff → Replace the drive chain. eral times to find the tightest point.

  • Page 58: Adjustments

    CHASSIS d. Tighten the axle nut while pushing 2. Clean: down the drive chain. • Dust seal "a" • Oil seal "b" Axle nut: 125 Nm (12.5 m•kg, 90 • Clean the dust seal and oil seal af- ft•lb) ter every run. e.
  • Page 59 CHASSIS Do not force the adjuster past the Never attempt to turn the adjuster minimum or maximum extent of beyond the maximum or minimum adjustment. The adjuster may be setting. damaged. e. Tighten the locknut. Locknut: 30 Nm (3.0 m•kg, 22 Always adjust each front fork to ft•lb) the same setting.
  • Page 60 CHASSIS CHECKING THE TIRE PRESSURE 1. Measure: Do not force the adjuster past the • Tire pressure minimum or maximum extent of Out of specification → Adjust. adjustment. The adjuster may be Standard tire pressure: damaged. 100 kPa (1.00 kgf/cm 15 psi) ADJUSTING THE REAR SHOCK ABSORBER HIGH COMPRESSION...
  • Page 61 CHASSIS 3. Check: f. Retighten the steering ring nut us- • Steering smooth action ing the steering nut wrench. Turn the handlebar lock to lock. Unsmooth action → Adjust steer- Avoid over-tightening. ing ring nut. Steering ring nut (final tightening): 7 Nm (0.7 m•kg, 5.1 Spoke nipple wrench: ft•lb)
  • Page 62 CHASSIS 3-18...
  • Page 63 CHASSIS LUBRICATION To ensure smooth operation of all Use Yamaha cable lube or components, lubricate your machine equivalent on these areas. during setup, after break-in, and after Use SAE 10W-40 motor oil or every race. suitable chain lubricants. All control cable...

  • Page 64: Electrical

    ELECTRICAL CHECKING THE IGNITION TIMING 7. Adjust: ELECTRICAL 1. Remove: • Ignition timing CHECKING THE SPARK PLUG • Fuel tank 1. Remove: Refer to "SEAT, FUEL TANK Adjustment steps: • Spark plug AND SIDE COVERS" section in a. Loosen the screws (stator) "1". 2.

  • Page 65: Seat, Fuel Tank And Side Covers

    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 undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual.
  • Page 66 SEAT, FUEL TANK AND SIDE COVERS REMOVING THE SIDE COVER 1. Remove: • Bolt (side cover) • Side cover (left and right) "1" Draw the side cover backward to re- move it because its claws "a" are in- serted in the air filter case. REMOVING THE NUMBER PLATE 1.

  • Page 67: Exhaust Pipe And Silencer

    EXHAUST PIPE AND SILENCER EXHAUST PIPE AND SILENCER REMOVING THE EXHAUST PIPE AND SILENCER 12 Nm (1.2 m kg, 8.7 ft lb) 12 Nm (1.2 m kg, 8.7 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 12 Nm (1.2 m kg, 8.7 ft lb) 25 Nm (2.5 m kg, 18 ft lb) 14 Nm (1.4 m kg, 10 ft lb) Order...
  • Page 68 • Fiber "2" 4. Install: • Inner pipe ® Fully apply Quick gasket (Yamaha bond No.1215) or equivalent as shown. Yamaha bond No.1215: 90890-85505 (Three bond No.1215®) 5. Install: • Bolt (fiber) "1" Bolt (fiber): 10 Nm (1.0 m•kg, 7.2 ft•lb) •...

  • Page 69: Radiator

    RADIATOR RADIATOR REMOVING THE RADIATOR 2 Nm (0.2 m kg, 1.4 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 2 Nm (0.2 m kg, 1.4 ft lb) Order Part name...
  • Page 70 RADIATOR HANDLING NOTE 2. Install: 5. Install: • Right radiator "1" • Radiator guard "1" • Washer "2" • Bolt (radiator guard) "2" Do not remove the radiator cap • Bolt (right radiator) "3" Bolt (radiator guard): when the engine and radiator are Bolt (right radiator): 10 Nm (1.0 m•kg, 7.2 hot.

  • Page 71: Carburetor And Reed Valve

    CARBURETOR AND REED VALVE CARBURETOR AND REED VALVE REMOVING THE CARBURETOR AND REED VALVE 10 Nm (1.0 m kg, 7.2 ft lb) 1 Nm (0.1 m kg, 0.7 ft lb) Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND SIDE Fuel tank COVERS"...
  • Page 72 CARBURETOR AND REED VALVE DISASSEMBLING THE CARBURETOR 4 Nm (0.4 m kg, 2.9 ft lb) Order Part name Q'ty Remarks Mixing chamber top Throttle valve Refer to removal section. Needle holder Jet needle Float chamber Float pin Float Needle valve Main jet Pilot jet Starter plunger...
  • Page 73 CARBURETOR AND REED VALVE HANDLING NOTE CHECKING THE CARBURETOR 1. Inspect: • Carburetor body Do not loosen the screw (throttle Contamination → Clean. position sensor) "1" except when changing the throttle position sen- • Use a petroleum based solvent for sor due to failure because it will cleaning.
  • Page 74 CARBURETOR AND REED VALVE INSTALLING THE REED VALVE ASSEMBLING THE CARBURETOR 1. Install: 1. Install: • Reed valve "1" • Power jet "1" • Stopper (reed valve) "2" To carburetor "2". • Screw (reed valve) "3" Screw (reed valve): 1 Nm (0.1 m•kg, 0.7 ft•lb) •...
  • Page 75 CARBURETOR AND REED VALVE 4. Install: • Starter plunger "1" Install the air vent hoses and overflow hose to the carburetor with their ends not having the cuts "a" toward the car- buretor. 11. Install: • Mixing chamber top "1" 5.
  • Page 76 CARBURETOR AND REED VALVE 3. Tighten: • Screw (air cleaner joint) "1" Place the screw head "a" with its top as shown and secure the clamp in alignment with the horizontal line "b" that passes the center of the carbure- tor.

  • Page 77: Cylinder And Piston

    CYLINDER HEAD, CYLINDER AND PISTON CYLINDER HEAD, CYLINDER AND PISTON REMOVING THE CYLINDER HEAD AND CYLINDER 34 Nm (3.4 m kg, 24 ft lb) 64 Nm (6.4 m kg, 46 ft lb) 20 Nm (2.0 m kg, 14 ft lb) 5 Nm (0.5 m kg, 3.6 ft lb) 25 Nm (2.5 m kg, 18 ft lb) 13 Nm (1.3 m kg, 9.4 ft lb)
  • Page 78 CYLINDER HEAD, CYLINDER AND PISTON REMOVING THE PISTON AND POWER VALVE 6 Nm (0.6 m kg, 4.3 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) Order Part name...
  • Page 79 CYLINDER HEAD, CYLINDER AND PISTON REMOVING THE PUSH ROD d. Place a 400–600 grit wet sandpa- 1. Remove: per "3" on the surface plate, and • Bolt (push rod) "1" resurface the head "4" using a fig- • Push rod "2" ure-eight sanding pattern.
  • Page 80 CYLINDER HEAD, CYLINDER AND PISTON 3. Measure: 3. Measure: 3. Check: • Cylinder bore "C" • Piston skirt diameter • Free play (when the piston pin "1" Use cylinder gauge "1". Use micrometer "1". is in place in the piston "2") Out of specification →...
  • Page 81 CYLINDER HEAD, CYLINDER AND PISTON 3. Measure: CHECKING THE COMBINATION 3. Combination: • Side clearance OF PISTON AND CYLINDER Combine the piston and cylinder Use a thickness gauge "1". 1. Check: by the following chart. Out of specification → Replace •...
  • Page 82 CYLINDER HEAD, CYLINDER AND PISTON INSTALLING THE POWER VALVE 1. Install: • Power valve 1 "1" • Valve holder 2 "2" • Bolt (valve holder 2) "3" Bolt (valve holder 2) 6 Nm (0.6 m•kg, 4.3 ft•lb) 4. Check: 6. Check: •...
  • Page 83 CYLINDER HEAD, CYLINDER AND PISTON 3. Install: • Piston "1" • Piston pin "2" • Piston pin clip "3" • The arrow "a" on the piston dome must point to exhaust side. • Before installing the piston pin clip, INSTALLING THE PISTON RING 3.
  • Page 84 CYLINDER HEAD, CYLINDER AND PISTON 5. Install: 8. Install: • Gasket (power valve housing) • Engine bracket "1" • Bolt (engine bracket) "2" • Power valve housing "1" Bolt (engine bracket): • Bolt (power valve housing) "2" 34 Nm (3.4 m•kg, 24 Bolt (power valve hous- ft•lb) ing):...

  • Page 85: Clutch

    CLUTCH CLUTCH REMOVING THE CLUTCH 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) Order Part name Q'ty Remarks Refer to "CHANGING THE TRANSMISSION Drain the transmission oil. OIL" section in the CHAPTER 3. Bolt (brake pedal) Shift the brake pedal downward.
  • Page 86 CLUTCH REMOVING THE CLUTCH BOSS 75 Nm (7.5 m kg, 54 ft lb) 6 Nm (0.6 m kg, 4.3 ft lb) Order Part name Q'ty Remarks Push rod 1 Circlip Washer Bearing Push rod 2 Nut (clutch boss) Refer to removal section. Lock washer Refer to removal section.
  • Page 87 CLUTCH REMOVING THE CLUTCH BOSS CHECKING THE CLUTCH CHECKING THE PUSH LEVER 1. Remove: SPRINGS SHAFT • Nut "1" 1. Measure: 1. Inspect: • Lock washer "2" • Clutch spring free length "a" • Push lever shaft "1" • Clutch boss "3" Out of specification →...
  • Page 88 CLUTCH 5. Install: 9. Install: • Friction plate "1" • Clutch spring "1" • Clutch plate "2" • Bolt (clutch spring) "2" Bolt (clutch spring): • Install the clutch plates and friction 10 Nm (1.0 m•kg, 7.2 plates alternately on the clutch ft•lb) boss, starting with a friction plate and ending with a friction plate.

  • Page 89: Kick Shaft And Shift Shaft

    KICK SHAFT AND SHIFT SHAFT KICK SHAFT AND SHIFT SHAFT REMOVING THE PRIMARY DRIVE GEAR 30 Nm (3.0 m kg, 22 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 55 Nm (5.5 m kg, 40 ft lb) Order Part name Q'ty Remarks...
  • Page 90 KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT AND SHIFT SHAFT 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 12 Nm (1.2 m kg, 8.7 ft lb) Order Part name Q'ty...
  • Page 91 KICK SHAFT AND SHIFT SHAFT REMOVING THE PRIMARY DRIVE GEAR If the segment gets an impact, the 1. Loosen: stopper lever may be damaged. • Bolt (primary drive gear) "1" Take care not to give an impact to it when removing the bolt. Place an aluminum plate "a"...
  • Page 92 KICK SHAFT AND SHIFT SHAFT INSTALLING THE SEGMENT INSTALLING THE SHIFT GUIDE INSTALLING THE SHIFT SHAFT 1. Install: AND SHIFT LEVER ASSEMBLY 1. Install: • Segment "1" 1. Install: • Roller "1" • Bolt (segment) • Spring "1" • Washer "2" •...
  • Page 93 KICK SHAFT AND SHIFT SHAFT 3. Install: • Spring guide "1" • Apply the transmission oil on the kick idle gear inner circumference. Slide the spring guide into the kick • Install the kick idle gear with its de- shaft, make sure the groove "a" in the pressed side "a"...
  • Page 94 KICK SHAFT AND SHIFT SHAFT 8. Install: • Shift pedal "1" • Bolt (shift pedal) "2" Bolt (shift pedal): 12 Nm (1.2 m•kg, 8.7 ft•lb) Install the shift pedal so that the top of the shift pedal outer diameter "a" is highest without exceeding the line "b"...

  • Page 95: Ypvs Governor

    YPVS GOVERNOR YPVS GOVERNOR REMOVING THE YPVS GOVERNOR Order Part name Q'ty Remarks Refer to "KICK SHAFT AND SHIFT SHAFT" Crankcase cover (right) section. Governor assembly Dowel pin Refer to removal section. Retainer Ball Retainer weight Washer Thrust bearing Collar Plate Compression spring Governor gear...
  • Page 96 YPVS GOVERNOR REMOVING THE GOVERNOR 1. Remove: • Dowel pin "1" While compressing the spring, re- move the dowel pin. CHECKING THE GOVERNOR GROOVE 2. Install: 1. Inspect: • Ball "1" • Washer "1" • Retainer "2" • Collar "2" To governor shaft "3".

  • Page 97: Water Pump

    WATER PUMP WATER PUMP DISASSEMBLING THE WATER PUMP 10 Nm (1.0 m kg, 7.2 ft lb) 14 Nm (1.4 m kg, 10 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) Order Part name Q'ty Remarks Refer to "KICK SHAFT AND SHIFT SHAFT" Crankcase cover (right) section.
  • Page 98 WATER PUMP REMOVING THE IMPELLER CHECKING THE IMPELLER SHAFT SHAFT GEAR 1. Remove: 1. Inspect: • Impeller "1" • Gear teeth "a" • Washer "2" Wear/damage → Replace. • Impeller shaft "3" Hold the impeller shaft on its width INSTALLING THE IMPELLER across the flats "a"...
  • Page 99 WATER PUMP 4. Install: • Water pump housing cover "1" • Bolt (water pump housing cover) "2" Bolt (water pump hous- ing cover): 10 Nm (1.0 m•kg, 7.2 ft•lb) • Copper washer (coolant drain bolt) "3" • Coolant drain bolt "4" Coolant drain bolt: 10 Nm (1.0 m•kg, 7.2 ft•lb)

  • Page 100: Cdi Magneto

    CDI MAGNETO CDI MAGNETO REMOVING THE CDI MAGNETO 7 Nm (0.7 m kg, 5.1 ft lb) 5 Nm (0.5 m kg, 3.6 ft lb) 56 Nm (5.6 m kg, 40 ft lb) Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND SIDE Seat and fuel tank COVERS"...
  • Page 101 CDI MAGNETO REMOVING THE ROTOR INSTALLING THE CDI MAGNETO 4. Adjust: 1. Remove: 1. Install: • Ignition timing • Nut (rotor) "1" • Stator "1" Refer to "CHECKING THE IGNI- • Washer "2" • Screw (stator) "2" TION TIMING" section in the Use the rotor holding tool "3".

  • Page 102: Engine Removal

    ENGINE REMOVAL ENGINE REMOVAL REMOVING THE ENGINE 34 Nm (3.4 m kg, 24 ft lb) 64 Nm (6.4 m kg, 46 ft lb) 26 Nm (2.6 m kg, 19 ft lb) 85 Nm (8.5 m kg, 61 ft lb) 64 Nm (6.4 m kg, 46 ft lb) 5 Nm (0.5 m kg, 3.6 ft lb) 75 Nm (7.5 m kg, 54 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb)
  • Page 103 ENGINE REMOVAL 34 Nm (3.4 m kg, 24 ft lb) 64 Nm (6.4 m kg, 46 ft lb) 26 Nm (2.6 m kg, 19 ft lb) 85 Nm (8.5 m kg, 61 ft lb) 64 Nm (6.4 m kg, 46 ft lb) 5 Nm (0.5 m kg, 3.6 ft lb) 75 Nm (7.5 m kg, 54 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb)
  • Page 104 ENGINE REMOVAL HANDLING NOTE 2. Remove the engine "1" aslant and upward while inclining it toward the kick crank side so that the en- Support the machine securely so gine's mounting top does not con- there is no danger of it falling over. tact the bracket on the frame.
  • Page 105 ENGINE REMOVAL 2. Install: • Lock washer "1" • Nut (drive sprocket) "2" Nut (drive sprocket): 75 Nm (7.5 m•kg, 54 ft•lb) Tighten the nut while applying the rear brake. 3. Bend the lock washer tab to lock the nut. 4.

  • Page 106: Crankcase And Crankshaft

    CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT REMOVING THE CRANKSHAFT 14 Nm (1.4 m kg, 10 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 30 Nm (3.0 m kg, 22 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) Order Part name...
  • Page 107 CRANKCASE AND CRANKSHAFT 14 Nm (1.4 m kg, 10 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 30 Nm (3.0 m kg, 22 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) Order Part name Q'ty...
  • Page 108 CRANKCASE AND CRANKSHAFT REMOVING THE SEGMENT 1. Remove: • Bolt (segment) "1" 100 mm • Segment "2" Turn the segment counterclockwise until it stops and loosen the bolt. REMOVING THE CRANKSHAFT CHECKING THE CRANKCASE 1. Remove: 1. Inspect: If the segment gets an impact, the •...
  • Page 109 4. Apply: Adapter "4": • Sealant YU-90063/90890-01278 On the right crankcase "1" Yamaha bond No.1215: • Hold the connecting rod at top dead 90890-85505 center with one hand while turning (Three bond No.1215®) the nut of the installing tool with the other.
  • Page 110 CRANKCASE AND CRANKSHAFT 8. Install: • Segment "1" • Bolt (segment) "2" Bolt (segment): 30 Nm (3.0 m•kg, 22 ft•lb) • When installing the segment onto the shift cam "3", align the punch mark "a" with the dowel pin "b". •...

  • Page 111: Shift Cam And Shift Fork

    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. Refer to "CRANKCASE AND CRANK- Separate the crankcase. SHAFT" section. Main axle Refer to removal section.
  • Page 112 TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION CHECKING THE BEARING INSTALLING THE TRANSMISSION 1. Remove: 1. Inspect: 1. Install: • Main axle "1" • Bearing "1" • 5th pinion gear (21T) "1" • Drive axle "2" Rotate inner race with a finger. •...
  • Page 113 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". • Be sure the circlip end "c" is posi- tioned at axle spline groove "d".

  • Page 114: Front Wheel And Rear Wheel

    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 inspection, adjustment, disassembly, or reassembly only by reference to this manual.
  • Page 115 FRONT WHEEL AND REAR WHEEL REMOVING THE REAR WHEEL Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Nut (rear wheel axle) Rear wheel axle Drive chain puller Rear wheel Refer to removal section.
  • Page 116 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" CHECKING THE WHEEL AXLE 1. Measure: Push the wheel forward and remove •...
  • Page 117 FRONT WHEEL AND REAR WHEEL 2. Install: 6. Install: • Brake disc "1" • Nut (wheel axle) "1" Do not strike the inner race of the • Bolt (brake disc) "2" Nut (wheel axle): bearing. Contact should be made Bolt (brake disc): 105 Nm (10.5 m•kg, 75 only with the outer race.
  • Page 118 FRONT WHEEL AND REAR WHEEL 4. Install: 8. Install: • Collar "1" • Right drive chain puller "1" • Washer "2" • Nut (wheel axle) "3" Apply the lithium soap base grease on the oil seal lip. Temporarily tighten the nut (wheel axle) at this point.

  • Page 119: Front Brake And Rear Brake

    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 Refer to "HANDLING NOTE". under the engine. Drain the brake fluid. Refer to removal section. Brake hose holder (protector) Union bolt Brake hose...
  • Page 120 FRONT BRAKE AND REAR BRAKE REMOVING THE REAR BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT WHEEL AND REAR Rear wheel WHEEL" section. Drain the brake fluid. Refer to removal section.
  • Page 121 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE CALIPER Order Part name Q'ty Remarks Front Rear Pad pin Brake pad Pad support Brake caliper piston Refer to removal section. Brake caliper piston dust seal Refer to removal section. Brake caliper piston seal Refer to removal section.
  • Page 122 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE MASTER CYLINDER Order Part name Q'ty Remarks Front Rear Brake master cylinder cap Diaphragm Reservoir float Push rod (Front) Brake master cylinder boot Circlip Use a long nose circlip pliers. Washer Push rod (Rear) Brake master cylinder kit...
  • Page 123 FRONT BRAKE AND REAR BRAKE HANDLING NOTE REMOVING THE BRAKE CALIPER PISTON 1. Remove: Support the machine securely so • Brake caliper piston there is no danger of it falling over. Use compressed air and proceed carefully. DRAINING THE BRAKE FLUID 1.
  • Page 124 FRONT BRAKE AND REAR BRAKE 3. Inspect: (front brake only) CHECKING THE BRAKE HOSE • Reservoir float "1" 1. Inspect: Damage → Replace. • Brake hose "1" Crack/damage → Replace. A. Front B. Rear 3. Install: 4. Inspect: • Brake caliper piston "1" •...
  • Page 125 FRONT BRAKE AND REAR BRAKE 2. Install: 3. Install: • Brake caliper "1" • Brake caliper "1" • Bolt (brake caliper) "2" • Rear wheel "2" Refer to "FRONT WHEEL AND Bolt (brake caliper): REAR WHEEL" section. 28 Nm (2.8 m•kg, 20 4.
  • Page 126 FRONT BRAKE AND REAR BRAKE INSTALLING THE FRONT BRAKE MASTER CYLINDER Always use new copper washers. 1. Install: • Brake master cylinder "1" • Brake master cylinder bracket "2" • Bolt (brake master cylinder brack- et) "3" Bolt (brake master cylin- 4.
  • Page 127 FRONT BRAKE AND REAR BRAKE 2. Install: INSTALLING THE REAR BRAKE • Brake hose holder "1" HOSE • Bolt (brake hose holder) "2" 1. Install: • Copper washer "1" Bolt (brake hose holder): • Brake hose "2" 8 Nm (0.8 m•kg, 5.8 •...
  • Page 128 FRONT BRAKE AND REAR BRAKE 2. Air bleed: 5. Install: (rear brake only) • Brake system • Protector "1" Refer to "BLEEDING THE HY- • Bolt (protector) "2" DRAULIC BRAKE SYSTEM" sec- Bolt (protector): tion in the CHAPTER 3. 7 Nm (0.7 m•kg, 5.1 3.

  • Page 129: Front Fork

    FRONT FORK FRONT FORK REMOVING THE FRONT FORK Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT WHEEL AND REAR Front wheel WHEEL" section. Refer to "FRONT BRAKE AND REAR Front brake caliper BRAKE"...
  • Page 130 FRONT FORK DISASSEMBLING THE FRONT FORK 30 Nm (3.0 m kg, 22 ft lb) 29 Nm (2.9 m kg, 21 ft lb) 1 Nm (0.1 m kg, 0.7 ft lb) 29 Nm (2.9 m kg, 21 ft lb) 55 Nm (5.5 m kg, 40 ft lb) Order Part name Q'ty...
  • Page 131 FRONT FORK HANDLING NOTE 3. Remove: REMOVING THE BASE VALVE • Adjuster "1" 1. Remove: • Base valve "1" Support the machine securely so From damper assembly "2". • While compressing the inner tube there is no danger of it falling over. "2", set the cap bolt ring wrench "4"...
  • Page 132 FRONT FORK CHECKING THE BASE VALVE Inner tube bending limit: 1. Inspect: • Be sure to use recommended 0.2 mm (0.01 in) • Base valve "1" fork oil. If other oils are used, Wear/damage → Replace. they may have an excessively ad- Contamination →...
  • Page 133 FRONT FORK 6. Tighten: 14. Check: Cap bolt wrench: • Locknut "1" • Damper assembly smooth move- YM-01500/90890-01500 ment Cap bolt ring wrench: Tightness/binding/rough spots → Fully finger tighten the locknut onto YM-01501/90890-01501 Repeat the steps 2 to 13. the damper assembly. 15.
  • Page 134 FRONT FORK 17. Install: • Outer tube "1" To inner tube "2". 21. Install: 25. Install: • Dust seal "1" • Damper assembly "1" To inner tube "2". 18. Install: Apply the lithium soap base grease • Slide metal "1" on the inner tube.
  • Page 135 FRONT FORK 31. Fill: 33. Install: • Front fork oil "1" • Protector guide "1" From outer tube top. Recommended oil: Suspension oil "S1" Standard oil amount: 320 cm (11.3 Imp oz, 10.8 US oz) 28. Inspect: Extent of adjustment: •...
  • Page 136 FRONT FORK 4. Tighten: 7. Adjust: • Pinch bolt (upper bracket) "1" • Compression damping force Pinch bolt (upper brack- Turn in the damping adjuster "1" fin- et): ger-tight and then turn out to the orig- 21 Nm (2.1 m•kg, 15 inally set position.

  • Page 137: Handlebar

    HANDLEBAR HANDLEBAR REMOVING THE HANDLEBAR 0.5 Nm (0.05 m kg, 0.36 ft lb) 9 Nm (0.9 m kg, 6.5 ft lb) 28 Nm (2.8 m kg, 20 ft lb) 5 Nm (0.5 m kg, 3.6 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) 0.5 Nm (0.05 m kg, 0.36 ft lb) 40 Nm (4.0 m kg, 29 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb)
  • Page 138 HANDLEBAR DISASSEMBLING THE THROTTLE Order Part name Q'ty Remarks Grip cap (lower) Grip cap (upper) Grip assembly Grip (right) Refer to removal section. Tube guide 5-25...
  • Page 139 HANDLEBAR REMOVING THE BRAKE MASTER ASSEMBLING THE THROTTLE CYLINDER 1. Remove: 1. Remove: • Grip (right) "1" • Brake master cylinder bracket "1" Apply the adhesive on the tube • Brake master cylinder "2" guide "2". • Before applying the adhesive, wipe •...
  • Page 140 HANDLEBAR 9. Adjust: • Throttle grip free play Refer to "ADJUSTING THE THROTTLE GRIP FREE PLAY" section in the CHAPTER 3. 10. Install: • Cap cover "1" 6. Install: • Throttle cables "1" To tube guide "2". Apply the lithium soap base grease on the throttle cable end and tube guide cable winding portion.
  • Page 141 HANDLEBAR 15. Adjust: • Clutch lever free play Refer to "ADJUSTING THE CLUTCH LEVER FREE PLAY" section in the CHAPTER 3. 13. Install: • Engine stop switch "1" Engine stop switch: 0.5 Nm (0.05 m•kg, 0.36 ft•lb) • Clutch lever holder "2" •...

  • Page 142: Steering

    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 Refer to "HANDLING NOTE".
  • Page 143 STEERING HANDLING NOTE CHECKING THE STEERING STEM 1. Inspect: • Steering stem "1" Support the machine securely so Bend/damage → Replace. there is no danger of it falling over. REMOVING THE STEERING RING 1. Remove: 3. Install: • Steering ring nut "1" •...
  • Page 144 STEERING 6. Install: 11. Tighten: • Washer "1" • Pinch bolt (upper bracket) "1" Pinch bolt (upper brack- et): 21 Nm (2.1 m•kg, 15 ft•lb) • Pinch bolt (lower bracket) "2" Pinch bolt (lower brack- et): 7. Install: 21 Nm (2.1 m•kg, 15 •...

  • Page 145: Swingarm

    SWINGARM SWINGARM REMOVING THE SWINGARM Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT BRAKE AND REAR Brake hose holder BRAKE" section. Refer to "FRONT BRAKE AND REAR Rear brake caliper BRAKE"...
  • Page 146 SWINGARM DISASSEMBLING THE SWINGARM Order Part name Q'ty Remarks Refer to removal section. Relay arm Connecting rod Collar Oil seal Thrust bearing Bushing Oil seal Bearing Refer to removal section. 5-33...
  • Page 147 SWINGARM HANDLING NOTE 2. Inspect: • Oil seal "3" Damage → Replace. Support the machine securely so there is no danger of it falling over. REMOVING THE CAP 1. Remove: • Left cap "1" 2. Install: • Bearing "1" Remove with a slotted-head screw- •...
  • Page 148 SWINGARM 4. Install: 7. Check: • Connecting rod "1" • Swingarm side play "a" • Bolt (connecting rod) "2" Free play exists → Replace thrust • Washer "3" bearing. • Nut (connecting rod) "4" • Swingarm up and down move- ment "b"...
  • Page 149 SWINGARM 10. Tighten: 14. Install: • Nut (connecting rod) "1" • Drive chain support "1" • Drive chain support cover "2" Nut (connecting rod): • Bolt {drive chain support [L = 50 80 Nm (8.0 m•kg, 58 mm (1.97 in)]} "3" ft•lb) •...

  • Page 150: Absorber

    REAR SHOCK ABSORBER REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER 56 Nm (5.6 m kg, 40 ft lb) 32 Nm (3.2 m kg, 23 ft lb) 29 Nm (2.9 m kg, 21 ft lb) 53 Nm (5.3 m kg, 38 ft lb) Order Part name Q'ty...

  • Page 151: Rear Shock Absorber

    CHECKING THE REAR SHOCK To dispose of a damaged or worn- ABSORBER out rear shock absorber, take the 1. Inspect: unit to your Yamaha dealer for this • Damper rod "1" disposal procedure. Bends/damage → Replace rear shock absorber assembly.
  • Page 152 REAR SHOCK ABSORBER 2. Install: 3. Adjust: Nut (rear shock absorb- • Stopper ring (upper bearing) "1" • Spring length (installed) er-frame): Refer to "ADJUSTING THE 56 Nm (5.6 m•kg, 40 REAR SHOCK ABSORBER ft•lb) SPRING PRELOAD" section in After installing the stopper ring, push the CHAPTER 3.
  • Page 153 REAR SHOCK ABSORBER 7. Tighten: • Bolt (air filter joint) "1" 5-40...

  • Page 154: Components And Wiring Diagram

    ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.). Those who have little knowledge and skill concerning servicing are request- ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual.

  • Page 155: Ignition System

    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. Spark gap test Spark → *Clean or replace spark plug. No spark ↓...
  • Page 156 IGNITION SYSTEM SPARK GAP TEST Not conductive while it is pushed → 1. Disconnect the spark plug cap Replace. from spark plug. Conductive while it is freed → Re- 2. Connect the dynamic spark tester place. "1" (ignition checker "2") as shown.
  • Page 157 IGNITION SYSTEM CHECKING THE NEUTRAL SWITCH 1. Inspect: • Neutral switch conduction Tester (+) lead→Sky blue lead "1" Tester (-) lead → Ground "2" Result 2. Inspect: Conductive (while gear • Charging coil 1 resistance is in neutral) Out of specification → Replace. Not conductive while it is in neutral →...

  • Page 158: Solenoid Valve System

    SOLENOID VALVE SYSTEM SOLENOID VALVE SYSTEM INSPECTION STEPS If the solenoid valve will not operate, use the following inspection steps. Check each couplers and wire connection. No good → Repair or replace. OK ↓ Check solenoid valve. (Check solenoid valve op- No good →...
  • Page 159 SOLENOID VALVE SYSTEM CHECKING THE COUPLERS AND LEADS CONNECTION 1. Check: • Couplers and leads connection Rust/ Dust/ Looseness/Short-cir- cuit → Repair or replace. CHECKING THE SOLENOID VALVE OPERATION 1. Disconnect the solenoid valve coupler. 2. Connect 12V battery to the sole- noid valve coupler.

  • Page 160: Throttle Position Sensor System

    THROTTLE POSITION SENSOR SYSTEM THROTTLE POSITION SENSOR SYSTEM INSPECTION STEPS If the throttle position sensor will not operate, use the following inspection steps. Check entire ignition system for connection. No good → Repair or replace. OK ↓ Check throttle position sensor. (Throttle position No good →...
  • Page 161 THROTTLE POSITION SENSOR SYSTEM HANDLING NOTE Tester (+) lead → Yellow lead "2" Tester (-) lead → Black lead "3" Do not loosen the screw (throttle Tester position sensor) "1" except when Throttle position selec- changing the throttle position sen- sensor coil vari- tor po- sor due to failure because it will...
  • Page 162 THROTTLE POSITION SENSOR SYSTEM 13. Tighten: • Screw (throttle position sensor) "1" Tighten the screws (throttle position sensor) using the T20 bit (tamper re- sistant fastener type) by aligning the marks "a" that were put before re- 8. Start the engine. moval.

  • Page 163: Tuning

    ENGINE TUNING EFFECT OF SETTING PARTS IN RELATION TO THROTTLE VALVE The reason for the above tendency is ENGINE OPENING that the richness or leanness of a fuel CARBURETOR SETTING mixture depends on the density of the • The role of fuel is to cool the engine, air (i.e.
  • Page 164 ENGINE ADJUSTING THE POWER JET ADJUSTING THE JET NEEDLE A. Difference in straight portion The richness of air-fuel mixture under GROOVE POSITION diameter. 8,500 rpm to the extent of 1/2 to full Should the engine be hard to run B. Difference in taper starting opened throttle can be set by chang- smoothly at intermediate speeds, the position...
  • Page 165 ENGINE RELATIONSHIP WITH THROTTLE CARBURETOR SETTING PARTS Part OPENING Jet nee- Main jet Part number Size number The flow of the fuel through the car- Size dle "3" "1" (-14943-) (-14916-) buretor main system is controlled by the main jet and then, it is further reg- Rich #190 4MX-45 Rich...
  • Page 166 ENGINE ROAD CONDITION AND EXAMPLES OF CARBURETOR SETTING General condition Sandy condition Under 10°C 15–25°C (59– Over 25°C Under 10°C 15–25°C (59– Over 25°C (50°F) 77°F) (77°F) (50°F) 77°F) (77°F) (Winter) (Spring, Au- (Summer) (Winter) (Spring, Au- (Summer) tumn) tumn) Main jet #178 #178...
  • Page 167 ENGINE EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM Symptom Setting Checking At full throttle Increase main jet calibration no. (Gradual- Discoloration of spark plug → If tan color, it Hard breathing is in good condition. Shearing noise If cannot be corrected: Whitish spark plug Clogged float valve seat Clogged fuel hose...
  • Page 168 CHASSIS CHASSIS CHANGE OF THE HEAT RANGE DRIVE AND REAR WHEEL OF SPARK PLUGS SPROCKETS SETTING PARTS SELECTION OF THE SECONDARY Judging from the discoloration of REDUCTION RATIO (SPROCKET) Part name Size Part number spark plugs, if they are found improp- er, it can be corrected by the following Secondary reduction ratio = Drive...
  • Page 169 CHASSIS FRONT FORK SETTING FRONT FORK SETTING PARTS The front fork setting should be made • Front fork spring "1" depending on the rider's feeling of an SPRING SPRI I.D. actual run and the circuit conditions. PART TYPE MARK The front fork setting includes the fol- NUMBER RATE (slits)
  • Page 170 CHASSIS CHOOSING SET LENGTH SETTING OF SPRING AFTER REAR SHOCK ABSORBER SETTING PARTS 1. Place a stand or block under the REPLACEMENT • Rear shock spring "1" engine to put the rear wheel After replacement, be sure to adjust [Equal-pitch steel spring] above the floor, and measure the the spring to the set length [sunken length "a"...
  • Page 171 CHASSIS • Extent of adjustment (spring pre- load) SPRING PART Maximum Minimum NUMBER (-22212-) 5UN-00 5UN-10 5UN-20 5UN-30 Position Position 5UN-40 in which in which 5UN-50 the spring the spring 5UN-60 is turned is turned 5UN-70 in 18 mm in 1.5 mm 5UN-A0 (0.71 in) (0.06 in)
  • Page 172 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 90–100 mm (3.5–3.9 in). Section Medi- Symptom...
  • Page 173 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. •...
  • Page 174 PRINTED ON RECYCLED PAPER PRINTED IN JAPAN...

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