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2010
Read this manual carefully before operating this vehicle.
Il convient de lire attentivement ce manuel avant la première utilisation du véhicule.
Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
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
YZ250F(Z)
17D-28199-30

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   Summary of Contents for Yamaha YZ250F(Z)

  • Page 1

    2010 Read this manual carefully before operating this vehicle. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen. 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

    2010 2010 Read this manual carefully before operating this vehicle. Read this manual carefully before operating this vehicle. OWNER’S SERVICE MANUAL OWNER’S SERVICE MANUAL YZ250F(Z) YZ250F(Z) 17D-28199-30-E0 17D-28199-30-E0...

  • Page 5

    YZ250F(Z) OWNER'S SERVICE MANUAL ©2009 by Yamaha Motor Co., Ltd. 1st Edition, May 2009 All rights reserved.Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan...

  • Page 6: Safety Information

    If you should swallow some gaso- Congratulations on your purchase of could result in death or serious in- line, inhale excess gasoline vapors, a Yamaha YZ series. This model is jury. or allow any gasoline to get into the culmination of Yamaha's vast ex-...

  • Page 7

    HOW TO USE THIS MANUAL FINDING THE REQUIRED PAGE 1. This manual consists of seven chapters; "General Information", "Specifications", "Regular inspec- tion and adjustments", "Engine", "Chassis", "Electrical" and "Tun- ing" 2. The table of contents is at the be- ginning of the manual. Look over the general layout of the book be- fore finding then required chapter and item.

  • Page 8: Specifications

    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: General Information

    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 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 Hot starter lever 15. Cold starter knob Front brake lever 16. Air filter Throttle grip 17. Drive chain Radiator cap 18. Shift pedal Fuel tank cap 19. Oil level check window Engine stop switch 20.

  • Page 16: Consumer Information

    "a" face forward. knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own. 2. If your machine is stolen, the au- VALVE JOINT This valve joint "1"...

  • Page 17: Checking Of Connection

    "1" and reinsert the termi- nal into the connector. 5. Keep away from fire. ALL REPLACEMENT PARTS 1. We recommend to use Yamaha 6. Connect: genuine parts for all replace- • Connector ments. Use oil and/or grease rec- ommended by Yamaha for assembly and adjustment.

  • 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-24460-01, 90890-01325 the cooling system. Radiator cap tester adapter YU-33984, 90890-01352 Steering nut wrench This tool is used when tighten the YU-33975, 90890-01403 steering ring nut to specification.

  • Page 20

    SPECIAL TOOLS Tool name/Part number How to use Illustration Timing light This tool is necessary for checking YM-33277-A, 90890-03141 ignition timing. Valve spring compressor This tool is needed to remove and YM-4019, 90890-04019 install the valve assemblies. Clutch holding tool This tool is used to hold the clutch YM-91042, 90890-04086 when removing or installing the...

  • Page 21

    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 (Three- This sealant (Bond) is used for ® Bond No. 1215) crankcase mating surface, etc. 90890-85505 1-11...

  • Page 22: Control Functions

    CONTROL FUNCTIONS CONTROL FUNCTIONS FUEL COCK The fuel cock supplies fuel from the ENGINE STOP SWITCH tank to carburetor and also filters the The engine stop switch "1" is located fuel. The fuel cock has the two posi- on the left handlebar. Continue push- tions: ing the engine stop switch till the en- OFF:...

  • Page 23: Starting And Break-in

    STARTING AND BREAK-IN STARTING AND BREAK-IN AIR FILTER MAINTENANCE Restarting an engine after a fall According to "CLEANING THE AIR Pull the hot starter lever and start the FUEL FILTER ELEMENT" section in the engine. As soon as the engine starts, Always use the recommended fuel as CHAPTER 3, apply the foam-air-filter release the hot starter lever to close...

  • Page 24

    STARTING AND BREAK-IN BREAK-IN PROCEDURES 1. Before starting the engine, fill the fuel tank with the fuel. 2. Perform the pre-operation checks on the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the engine stop switch.

  • Page 25: 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 26: Cleaning And Storage

    CLEANING AND STORAGE CLEANING AND STORAGE STORAGE If your machine is to be stored for 60 CLEANING days or more, some preventive mea- Frequent cleaning of your machine sures must be taken to avoid deterio- will enhance its appearance, maintain ration.

  • Page 27: Specifications

    GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: YZ250FZ (USA, CDN, AUS, NZ) YZ250F (EUROPE, ZA) Model code number: 17D5 (USA,CDN) 17D6 (EUROPE) 17D8 (AUS, NZ, ZA) Dimensions: USA, CDN EUROPE AUS, NZ, ZA Overall length 2,159 mm (85.00 2,168 mm (85.35 2,166 mm (85.28 Overall width 825 mm (32.48 in) ←...

  • Page 28: Chassis

    GENERAL SPECIFICATIONS Carburetor: Type FCR-MX37 Manufacturer KEIHIN Spark plug: Type/manufacturer CR8E/NGK (resistance type) 0.7–0.8 mm (0.028–0.031 in) Clutch type: Wet, multiple-disc Transmission: USA, CDN EUROPE, AUS, NZ, ZA Primary reduction system Gear ← Primary reduction ratio 57/17 (3.353) ← Secondary reduction system Chain drive ←...

  • Page 29: Maintenance Specifications

    MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.05 mm (0.002 Cylinder: Bore size 77.00–77.01 mm (3.0315–3.0319 in) ---- Out of round limit ---- 0.05 mm (0.002 Camshaft: Drive method Chain drive (Left) ---- Camshaft cap inside diameter 22.000–22.021 mm (0.8661–0.8670 in) ---- Camshaft outside diameter...

  • Page 30

    MAINTENANCE SPECIFICATIONS Item Standard Limit Valve, valve seat, valve guide: Valve clearance (cold) 0.12–0.17 mm (0.0047–0.0067 in) ---- 0.17–0.22 mm (0.0067–0.0087 in) ---- Valve dimensions: "A" head diameter (IN) 22.9–23.1 mm (0.9016–0.9094 in) ---- "A" head diameter (EX) 24.4–24.6 mm (0.9606–0.9685 in) ---- "B"...

  • Page 31

    MAINTENANCE SPECIFICATIONS Item Standard Limit Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width (IN) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630 Valve seat width (EX) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630 Valve spring: Free length (IN) 39.76 mm (1.57 in) 38.76 mm (1.53 Free length (EX)

  • Page 32

    MAINTENANCE SPECIFICATIONS Item Standard Limit Piston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in) 16.043 mm (0.6316 in) Piston pin outside diameter 15.991–16.000 mm (0.6296–0.6299 in) 15.971 mm (0.6288 in) Piston rings: Top ring: Type Barrel ---- Dimensions (B × T) 0.90 ×...

  • Page 33

    MAINTENANCE SPECIFICATIONS Item Standard Limit Clutch: Friction plate thickness 2.9–3.1 mm (0.114–0.122 in) 2.8 mm (0.110 Quantity ---- Clutch plate thickness 1.1–1.3 mm (0.043–0.051 in) ---- Quantity ---- Warp limit ---- 0.1 mm (0.004 Clutch spring free length 35.7 mm (1.41 in) 34.7 mm (1.37 Quantity ----...

  • Page 34

    MAINTENANCE SPECIFICATIONS Item Standard Limit 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 Side clearance 0.09–0.17 mm (0.0035–0.0067 in) 0.24 mm (0.009 Housing and rotor clearance 0.03–0.10 mm (0.0012–0.0039 in) 0.17 mm...

  • Page 35

    MAINTENANCE SPECIFICATIONS Item Standard Limit Swingarm: Swingarm free play limit ---- 1.0 mm (0.04 Wheel: Front wheel type Spoke wheel ---- Rear wheel type Spoke wheel ---- Front rim size/material 21 × 1.60/Aluminum ---- Rear rim size/material 19 × 1.85/Aluminum ---- Rim runout limit: Radial...

  • Page 36: Tightening Torques

    Charging coil 2 resistance (color) 44–66 Ωat 20 °C (68 °F) (Black–Pink) ---- Pickup coil resistance (color) 248–372 Ωat 20 °C (68 °F) (White–Red) ---- CDI unit-model/manufacturer 17D-50/YAMAHA (For USA and CDN) ---- 17D-60/YAMAHA (Except for USA and ---- CDN) Ignition coil: Model/manufacturer...

  • Page 37

    TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Oil filter element drain bolt M6 × 1.0 Oil filter element cover M6 × 1.0 Oil strainer (crankcase) M6 × 1.0 Oil delivery pipe 1 (M10) M10 × 1.25 Oil delivery pipe 1 (M8) M8 ×...

  • Page 38

    TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Drive sprocket M18 × 1.0 Drive axle oil seal stopper M6 × 1.0 Segment M8 × 1.25 Shift guide M6 × 1.0 Stopper lever M6 × 1.0 Shift pedal M6 ×...

  • Page 39

    TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Front brake disc M6 × 1.0 △ Rear brake disc M6 × 1.0 △ Footrest bracket and frame M10 × 1.25 △ Brake pedal M8 × 1.25 △...

  • Page 40

    TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Radiator mounting boss and frame M10 × 1.25 Front fender M6 × 1.0 △ Rear fender (front) M6 × 1.0 △ Rear fender (rear) M6 × 1.0 △...

  • Page 41

    TIGHTENING TORQUES GENERAL TORQUE TORQUE SPECIFI- SPECIFICATIONS CATION This chart specifies torque for stan- (Bolt (Nut) dard fasteners with standard I.S.O. m•kg ft•lb pitch threads. Torque specifications for special components or assem- 6 mm blies are included in the applicable sections of this book.

  • Page 42: Lubrication Diagrams

    LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS Oil filter element Oil pump Drive axle Main axle Intake camshaft Exhaust camshaft Oil tank Oil delivery pipe To oil tank 2-16...

  • Page 43

    LUBRICATION DIAGRAMS Crankshaft Oil filter element Oil tank Oil hose From oil pump 2-17...

  • Page 44: Cable Routing Diagram

    CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM Fuel tank breather hose 10. Carburetor overflow hose Insert the end of the fuel tank Radiator hose 1 11. Throttle position sensor lead breather hose into the hole in Cylinder head breather hose protector the steering stem.

  • Page 45

    CABLE ROUTING DIAGRAM Pass the cylinder head breather hose on the outside of front en- gine bracket. Pass the cylinder head breather hose between the radiator and radiator hose 3. Pass the fuel hose on the out- side of throttle position sensor lead.

  • Page 46

    CABLE ROUTING DIAGRAM Sub-wire harness 11. Radiator breather hose 20. Throttle position sensor tube Hot starter cable 12. Hot starter cable protector clamp Oil hose 13. Rubber cap Neutral switch lead 14. Throttle position sensor lead Radiator hose 2 15. Cylinder head breather hose Clamp 16.

  • Page 47

    CABLE ROUTING DIAGRAM Pass the hot starter cable over Pass the radiator breather hose the radiator mounting boss. on the outside of the CDI mag- Pass the throttle position sensor neto lead and neutral switch lead under the hot starter cable. lead.

  • Page 48

    CABLE ROUTING DIAGRAM Radiator hose 2 Put a cover over the ignition coil. Insert the engine stop switch Radiator breather hose Pass the throttle cables through lead into the CDI unit band. Ignition coil the cable guide. Align the coupler lower end with Throttle cable (pull) Pass the throttle cable over the the band lower end.

  • Page 49

    CABLE ROUTING DIAGRAM Brake master cylinder Install the brake hose so that its If the brake hose contacts the Brake hose holder pipe portion directs as shown spring (rear shock absorber), Brake hose and lightly touches the projec- correct its twist. tion on the brake caliper.

  • Page 50

    CABLE ROUTING DIAGRAM Throttle cable Fasten the engine stop switch Pass the brake hose in front of Clamp lead to the handlebar. the number plate. Hot starter cable Pass the clutch cable and hot Pass the throttle cables through Clutch cable starter cable through the cable the cable guide.

  • Page 51: Regular Inspection And Adjustments

    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 52

    MAINTENANCE INTERVALS Every Every Every third fifth After race As re- (about (about Item break- (about Remarks quired 12.5 hours) hours) hours) PISTON PIN Inspect ● Replace ● CYLINDER HEAD Inspect carbon deposits and eliminate them. Inspect and clean Change gasket. ●...

  • Page 53: Engine

    MAINTENANCE INTERVALS Every Every Every third fifth After race As re- (about (about Item break- (about Remarks quired 12.5 hours) hours) hours) COOLING SYSTEM Check coolant level and leakage ● ● Check radiator cap operation ● Replace coolant Every two years ●...

  • Page 54

    Lubricate Lithium base grease ● THROTTLE, CONTROL CABLE Check routing and connection ● ● Lubricate Yamaha cable lube or SAE 10W-40 ● ● motor oil Inspect and clean (throttle ca- Inspect dirt and wear on the throttle ● ● ble) cable on the carburetor side.

  • Page 55: Chassis

    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 56: Engine

    ENGINE 1. Place a container under the en- ENGINE gine. Handling notes of coolant: CHECKING THE COOLANT LEVEL 2. Remove: The coolant is harmful so it should be • Coolant drain bolt "1" handled with special care. Do not remove the radiator cap "1", drain bolt and hoses when the •...

  • Page 57

    ENGINE Clutch lever free play adjustment steps: a. Loosen the locknuts "1". b. Turn the adjuster "2" until free play "a" is within the specified lim- its. c. Tighten the locknuts. Radiator cap ADJUSTING THE CLUTCH LEVER Locknut: 2. Apply the specified pressure. POSITION 4 Nm (0.4 m•kg, 2.9 1.

  • Page 58

    ENGINE 2. Adjust: 3. Install: 1. Remove: • Throttle grip free play • Throttle grip cap • Seat • Screw (throttle grip cap) • Fitting bolt "1" • Washer "2" Throttle grip free play adjustment Screw (throttle grip cap): • Air filter element "3" steps: 4 Nm (0.4 m•kg, 2.9 •...

  • Page 59

    ENGINE 6. Apply: 4. Remove: • Lithium soap base grease • Lower engine guard "1" • Engine oil also lubricates the On the matching surface "a" on air • Bolt (oil tank) "2" clutch and the wrong oil types or filter element.

  • Page 60

    ENGINE • Oil tank drain bolt e. Tighten the oil pressure check bolt. Replacement steps: Oil tank drain bolt: a. Remove the oil filter element cov- 18 Nm (1.8 m•kg, 13 Oil pressure check bolt: er "1" and oil filter element "2". ft•lb) 10 Nm (1.0 m•kg, 7.2 b.

  • Page 61

    "b" on the concerning the servicing of Yama- the pads "2". crankcase cover when piston is at ha motorcycles (e.g., Yamaha deal- T.D.C. on compression stroke. ers, service engineers, etc.) Those • Place a rag in the timing chain...

  • Page 62

    ENGINE f. Install the new pads "3" and the valve lifters "4". • Apply the engine oil on the valve lift- ers. • Apply the molybdenum disulfide oil on the valve stem ends. • Valve lifter must turn smoothly c. Select the proper pad using the when rotated with a finger.

  • Page 63

    ENGINE INTAKE MEASURED INSTALLED PAD NUMBER CLEARANCE 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 - 0.01 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 0.02 - 0.06 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230...

  • Page 64: Chassis

    CHASSIS h. Tighten the bleed screw when the b. Turn the adjusting bolt "2" until the CHASSIS lever or pedal limit has been lever position "a" is within speci- BLEEDING THE HYDRAULIC reached; then release the lever or fied position. BRAKE SYSTEM pedal.

  • Page 65

    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 66

    CHASSIS 2. Replace: h. Install the brake pad "10" and pad 4. Check: • Brake pad pin "11". • Brake pedal operation A softy or spongy feeling → Bleed brake system. • Install the brake pads with their pro- Brake pad replacement steps: Refer to "BLEEDING THE HY- jections "a"...

  • Page 67

    CHASSIS 3. Clean: CHECKING THE SPROCKET ADJUSTING THE DRIVE CHAIN 1. Inspect: • Drive chain SLACK • Sprocket teeth "a" Place it in kerosene, and brush off 1. Elevate the rear wheel by placing Excessive wear → Replace. as much dirt as possible. Then re- the suitable stand under the en- move the drive chain from the ker- gine.

  • Page 68

    CHASSIS CLEANING THE FRONT FORK OIL ADJUSTING THE FRONT FORK SEAL AND DUST SEAL REBOUND DAMPING FORCE 1. Remove: 1. Adjust: • Protector • Rebound damping force • Dust seal "1" By turning the adjuster "1". Stiffer "a" → Increase the re- Use a thin screw driver, and be care- bound damping force.

  • Page 69

    CHASSIS ADJUSTING THE FRONT FORK COMPRESSION DAMPING FORCE 2. Adjust: • Compression damping force By turning the adjuster "1". Stiffer "a" → Increase the com- pression damping force. (Turn the adjuster "1" in.) ADJUSTING THE REAR SHOCK Softer "b" → Decrease the com- Extent of adjustment: ABSORBER SPRING PRELOAD pression damping force.

  • Page 70

    CHASSIS Extent of adjustment: Maximum Minimum 20 clicks out Fully turned in (from maximum position position) • STANDARD POSITION: • STANDARD POSITION: This is the position which is back This is the position which is back by the specific number of clicks by the specific number of turns from the fully turned-in position.

  • Page 71

    CHASSIS 2. Inspect: c. Loosen the steering ring nut "1" CHECKING AND TIGHTENING THE • Bearing free play using the steering nut wrench "2". SPOKES The following procedure applies to all Exist play → Replace. Steering nut wrench: of the spokes. YU-33975/90890-01403 1.

  • Page 72

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

  • Page 73

    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 74: Electrical

    ELECTRICAL CHECKING THE IGNITION TIMING ELECTRICAL 1. Remove: CHECKING THE SPARK PLUG • Timing mark accessing screw "1" 1. Remove: • Spark plug 2. Inspect: • Electrode "1" Wear/damage → Replace. • Insulator color "2" Normal condition is a medium to light tan color.

  • Page 75: 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 76

    SEAT, FUEL TANK AND SIDE COVERS REMOVING THE SIDE COVER 1. Remove: • Bolt (side cover) • Left side cover "1" • Right side cover "2" Draw the side cover downward to re- move it because its claws "a" are in- serted in the air filter case.

  • Page 77: Exhaust Pipe And Silencer

    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 Refer to "SEAT, FUEL TANK AND SIDE Right side cover COVERS" section. Bolt (silencer clamp) Only loosening.

  • Page 78

    EXHAUST PIPE AND SILENCER CHECKING THE SILENCER AND EXHAUST PIPE • Install the gasket with its meshed 1. Inspect: area "a" toward the exhaust pipe • Gasket "1" side. Damage → Replace. • The gasket should be installed ac- cording to the dimension shown. CHANGING THE SILENCER FIBER 1.

  • Page 79: Radiator

    RADIATOR RADIATOR REMOVING THE RADIATOR 20 Nm (2.0 m kg, 14 ft Ib) Order Part name Q'ty Remarks Refer to "CHANGING THE COOLANT" sec- Drain the coolant. tion in the CHAPTER 3. Refer to "SEAT, FUEL TANK AND SIDE Seat and fuel tank COVERS"...

  • Page 80

    RADIATOR 2. Install: HANDLING NOTE • Radiator breather hose "1" • Radiator hose 2 "2" Do not remove the radiator cap • Radiator hose 4 "3" when the engine and radiator are • Pipe "4" hot. Scalding hot fluid and steam •...

  • Page 81: Carburetor

    CARBURETOR CARBURETOR REMOVING THE CARBURETOR 4 Nm (0.4 m kg, 2.9 ft lb) 2 Nm (0.2 m kg, 1.4 ft lb) 11 Nm (1.1 m kg, 8.0 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 3 Nm (0.3 m kg, 2.2 ft lb) 3 Nm (0.3 m kg, 2.2 ft lb) Order...

  • Page 82

    CARBURETOR DISASSEMBLING THE CARBURETOR Order Part name Q'ty Remarks Carburetor breather hose Valve lever housing cover Screw (throttle shaft) Throttle valve Needle holder Jet needle Accelerator pump cover Spring Diaphragm (accelerator pump) Float chamber Leak jet Pilot screw Refer to removal section. Float pin Float Needle valve...

  • Page 83

    CARBURETOR Order Part name Q'ty Remarks Pilot jet Starter jet Push rod Pull the push rod. Throttle shaft assembly Push rod link lever assembly Pilot air jet Cold starter plunger...

  • Page 84

    CARBURETOR 2. Inspect: HANDLING NOTE CHECKING THE JET NEEDLE • Main jet "1" 1. Inspect: • Pilot jet "2" • Jet needle "1" Do not loosen the screw (throttle • Needle jet "3" Bends/wear → Replace. position sensor) "1" except when •...

  • Page 85

    CARBURETOR c. If the float height is not within 4. Install: specification, inspect the valve • Spring 2 "1" seat and needle valve. To lever 2 "2". d. If either is worn, replace them both. e. If both are fine, adjust the float height by bending the float tab "b"...

  • Page 86

    CARBURETOR • Apply the fluorochemical grease on the bearings. • Fit the projection "a" on the throttle shaft assembly into the slot "b" in the throttle position sensor. • Make sure the stopper "c" of the spring fits into the recess in the car- 11.

  • Page 87

    CARBURETOR 17. Install: c. Gradually turn out the adjusting • O-ring "1" screw while moving the link lever • Valve lever housing cover "2" until it has no more free play. • Bolt (valve lever housing cover) "3" INSTALLING THE CARBURETOR 1.

  • Page 88: Camshafts

    CAMSHAFTS CAMSHAFTS REMOVING THE CYLINDER HEAD COVER Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND SIDE Seat and fuel tank COVERS" section. Spark plug Cylinder head breather hose Bolt (cylinder head cover) Cylinder head cover Cylinder head cover gasket Timing chain guide (top side) 4-14...

  • Page 89

    CAMSHAFTS REMOVING THE CAMSHAFTS Order Part name Q'ty Remarks Timing mark accessing screw Refer to removal section. Crankshaft end accessing screw Refer to removal section. Timing chain tensioner cap bolt Refer to removal section. Timing chain tensioner Refer to removal section. Camshaft cap Refer to removal section.

  • Page 90

    CAMSHAFTS REMOVING THE CAMSHAFT Cam lobes length: 1. Remove: Intake "a": • Timing mark accessing screw "1" 30.330–30.430 mm • Crankshaft end accessing screw (1.1941–1.1980 in) "2" <Limit>: 30.230 mm (1.1902 in) Intake "b": 22.45–22.55 mm 4. Remove: (0.8839–0.8878 in) •...

  • Page 91

    CAMSHAFTS 4. Measure: • Camshaft-to-cap clearance Out of specification → Measure camshaft outside diameter. Camshaft-to-cap clear- ance: 0.028–0.062 mm (0.0011–0.0024 in) CHECKING THE CAMSHAFT <Limit>:0.08 mm (0.003 SPROCKET 1. Inspect: • Camshaft sprocket "1" Wear/damage → Replace the Measurement steps: camshaft assembly and timing a.

  • Page 92

    Bolt (camshaft cap): 10 Nm (1.0 m•kg, 7.2 ft•lb) Apply the sealant on the cylinder head cover gasket. YAMAHA Bond No. 1215 ® c. Release the screwdriver, check (ThreeBond No. 1215): the tensioner rod to come out and 90890-85505 tighten the gasket "4"...

  • Page 93: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD REMOVING THE CYLINDER HEAD Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND SIDE Seat and fuel tank COVERS" section. Refer to "EXHAUST PIPE AND SILENCER" Exhaust pipe and silencer section. Radiator hose 1 Disconnect at cylinder head side.

  • Page 94

    CYLINDER HEAD CHECKING THE CYLINDER HEAD INSTALLING THE CYLINDER 1. Eliminate: HEAD • Carbon deposits (from the com- 1. Install: bustion chambers) • Dowel pin "1" Use a rounded scraper. • Cylinder head gasket "2" • Timing chain guide (exhaust side) "3"...

  • Page 95: Valves And Valve Springs

    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. Valve lifter Refer to removal section. Adjusting pad Refer to removal section. Valve cotter Refer to removal section.

  • Page 96

    VALVES AND VALVE SPRINGS REMOVING THE VALVE LIFTER AND VALVE COTTER 1. Remove: • Valve lifter "1" • Pad "2" Identify each lifter "1" and pad "2" po- sition very carefully so that they can b. Install the new valve guide using a CHECKING THE VALVE be reinstalled in their original place.

  • Page 97

    VALVES AND VALVE SPRINGS 4. Measure: • Margin thickness "a" Do not let the compound enter the Out of specification → Replace. gap between the valve stem and Margin thickness: the guide. Intake: 0.8 mm (0.0315 in) Exhaust: 0.7 mm (0.0276 in) Measurement steps: a.

  • Page 98

    VALVES AND VALVE SPRINGS 3. Install: CHECKING THE VALVE SPRINGS 1. Measure: • Valve cotter • Valve spring free length "a" Out of specification → Replace. While compressing the valve spring with a valve spring compressor "1" in- Free length (valve stall the valve cotters.

  • Page 99: Cylinder And Piston

    CYLINDER AND PISTON CYLINDER AND PISTON REMOVING THE CYLINDER AND PISTON Order Part name Q'ty Remarks Cylinder head Refer to "CYLINDER HEAD" section. Bolt (cylinder) Cylinder Piston pin clip Refer to removal section. Piston pin Refer to removal section. Piston Refer to removal section.

  • Page 100

    CYLINDER AND PISTON 8 mm (0.31 in) from the piston REMOVING THE PISTON AND CHECKING THE CYLINDER AND bottom edge PISTON RING PISTON 1. Remove: 1. Inspect: Piston size "P" • Piston pin clip "1" • Cylinder and piston walls 76.955–76.970 •...

  • Page 101

    CYLINDER AND PISTON 2. Position: 2. Position: • Piston ring • Top ring (in cylinder) • 2nd ring • Oil ring Offset the piston ring end gaps as Insert a ring into the cylinder and shown. push it approximately 10 mm (0.39 in) into the cylinder.

  • Page 102

    CYLINDER AND PISTON INSTALLING THE CYLINDER 1. Lubricate: • Piston • Piston ring • Cylinder Apply a liberal coating of engine oil. 2. Install: • Dowel pin "1" • O-ring "2" Apply the lithium soap base grease on the O-ring. 3.

  • Page 103: Clutch

    CLUTCH CLUTCH REMOVING THE CLUTCH Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Brake pedal Refer to "ENGINE REMOVAL" section. Clutch cable Disconnect at engine side. Clutch cover Clutch spring Pressure plate Push rod 1...

  • Page 104

    CLUTCH Order Part name Q'ty Remarks Clutch boss Refer to removal section. Thrust washer Primary driven gear Spacer Washer Push lever shaft 4-30...

  • Page 105

    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 106

    CLUTCH 4. Install: 8. Install: INSTALLING THE CLUTCH 1. Install: • Friction plate "1" • Clutch spring "1" • Washer "1" • Clutch plate 1 "2" • Bolt (clutch spring) "2" • Spacer "2" Bolt (clutch spring): • Primary driven gear "3" •...

  • Page 107: Oil Filter Element And Water Pump

    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 Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Refer to "CHANGING THE COOLANT"...

  • Page 108

    OIL FILTER ELEMENT AND WATER PUMP Order Part name Q'ty Remarks Washer Refer to removal section. Impeller shaft Refer to removal section. Oil seal Refer to removal section. Bearing Refer to removal section. 4-34...

  • Page 109

    OIL FILTER ELEMENT AND WATER PUMP REMOVING THE IMPELLER CHECKING THE OIL DELIVERY CHECKING THE OIL SEAL 1. Inspect: SHAFT PIPE 1. Remove: 1. Inspect: • Oil seal "1" • Impeller "1" • Oil delivery pipe "1" Wear/damage → Replace. •...

  • Page 110

    OIL FILTER ELEMENT AND WATER PUMP 2. Install: 2. Install: INSTALLING THE IMPELLER • Right crankcase cover "1" • Oil hose "1" SHAFT 1. Install: • Bolt (right crankcase cover) "2" • Bolt (oil hose) "2" • Impeller shaft "1" Bolt (right crankcase Bolt (oil hose): •...

  • Page 111

    OIL FILTER ELEMENT AND WATER PUMP INSTALLING THE WATER PUMP HOUSING 1. Install: • Dowel pin "1" • O-ring "2" Apply the lithium soap base grease on the O-ring. 2. Install: • Water pump housing "1" • Bolt (water pump housing) "2" Bolt (water pump hous- ing): 10 Nm (1.0 m•kg, 7.2...

  • Page 112: Balancer

    BALANCER BALANCER REMOVING THE BALANCER Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Refer to "OIL FILTER ELEMENT AND WA- Right crankcase cover TER PUMP" section. Stator Refer to "CDI MAGNETO" section. Nut (primary drive gear) Refer to removal section.

  • Page 113

    BALANCER 3. Install: REMOVING THE BALANCER CHECKING THE BALANCER 1. Straighten the lock washer tab. • Balancer shaft drive gear "1" SHAFT 2. Loosen: 1. Inspect: • Nut (primary drive gear) "1" • Balancer shaft • Align the punched mark "a" on the •...

  • Page 114: Oil Pump

    OIL PUMP OIL PUMP REMOVING THE OIL PUMP Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Refer to "OIL FILTER ELEMENT AND WA- Right crankcase cover TER PUMP" section. Circlip Washer Oil pump drive gear Oil pump assembly Outer rotor 2 Circlip Inner rotor 2...

  • Page 115

    OIL PUMP REMOVING THE OIL TANK Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Oil hose 2 Oil hose 1 Dowel pin Oil tank breather hose Oil tank Oil strainer 4-41...

  • Page 116

    OIL PUMP 3. Check: CHECKING THE OIL PUMP 1. Inspect: • Unsmooth→Repeat steps #1 and • Oil pump drive gear "1" #2 or replace the defective parts. • Oil pump drive shaft "2" • Rotor housing "3" • Oil pump cover "4" Cracks/wear/damage →...

  • Page 117

    OIL PUMP IINSTALLING THE OIL TANK BREATHER HOSE 1. Install: • Oil tank "1" • Oil tank breather hose "2" • Clamp "3" Clamp: 2 Nm (0.2 m•kg, 1.4 ft•lb) Install the clamp so that it does not contact the oil tank. •...

  • Page 118: Kick Shaft And Shift Shaft

    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. Kick idle gear Kick shaft assembly Refer to removal section. Spring guide Torsion spring Ratchet wheel Kick gear...

  • Page 119

    KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Remarks Pawl Pawl pin Spring Bolt (stopper lever) Stopper lever Torsion spring Segment Refer to removal section. 4-45...

  • Page 120: Kick Shaft And Shift Shaft

    KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT CHECKING THE KICK SHAFT AND CHECKING THE SHIFT GUIDE AND ASSEMBLY RATCHET WHEEL SHIFT LEVER ASSEMBLY 1. Remove: 1. Check: 1. Inspect: • Kick shaft assembly "1" • Ratchet wheel "1" smooth move- •...

  • Page 121

    KICK SHAFT AND SHIFT SHAFT INSTALLING THE STOPPER INSTALLING THE KICK SHAFT LEVER ASSEMBLY 1. Install: 1. Install: • Torsion spring "1" • Kick gear "1" • Stopper lever "2" • Washer "2" • Bolt (stopper lever) "3" • Circlip "3" •...

  • Page 122

    KICK SHAFT AND SHIFT SHAFT 4. Install: • Kick shaft assembly "1" • Washer "2" • Apply the molybdenum disulfide grease on the contacting surfaces of the kick shaft stopper "a" and kick shaft ratchet wheel guide "3". • Apply the engine oil on the kick shaft.

  • Page 123: Cdi Magneto

    CDI MAGNETO CDI MAGNETO REMOVING THE CDI MAGNETO Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND SIDE Seat and fuel tank COVERS" section. Disconnect the CDI magneto lead. Refer to "KICK SHAFT AND SHIFT SHAFT" Shift pedal section.

  • Page 124

    GRAM" section in the CHAPTER of the CDI magneto lead. • Tighten the screws using the T30 When installing the flywheel puller, bit. turn it counterclockwise. YAMAHA Bond No. 1215 ® (ThreeBond No. 1215): 90890-85505 5. Install: • Dowel pin •...

  • Page 125: Engine Removal

    ENGINE REMOVAL ENGINE REMOVAL REMOVING THE ENGINE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the frame. Refer to "SEAT, FUEL TANK AND SIDE Seat and fuel tank COVERS" section. Carburetor Refer to "CARBURETOR"...

  • Page 126

    ENGINE REMOVAL Order Part name Q'ty Remarks Neutral switch Drive chain sprocket cover Nut (drive sprocket) Refer to removal section. Lock washer Refer to removal section. Drive sprocket Refer to removal section. Clip Bolt (brake pedal) Brake pedal Upper engine bracket Front engine bracket Engine mounting bolt Pivot shaft...

  • Page 127

    ENGINE REMOVAL 2. Remove: • Lower engine guard "11" HANDLING NOTE • Engine "1" • Bolt (lower engine guard) "12" From right side. Bolt (lower engine Support the machine securely so guard): there is no danger of it falling over. Make sure that the couplers, hoses 10 Nm (1.0 m•kg, 7.2 and cables are disconnected.

  • Page 128

    ENGINE REMOVAL INSTALLING THE DRIVE INSTALLING THE NEUTRAL SPROCKET SWITCH 1. Install: 1. Install: • Drive sprocket "1" • Spring "1" • Drive chain "2" • Pin "2" • O-ring "3" • Neutral switch "4" Install the drive sprocket together •...

  • Page 129: Crankcase And Crankshaft

    CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT REMOVING THE CRANKSHAFT Order Part name Q'ty Remarks Engine Refer to "ENGINE REMOVAL" section. Piston Refer to "CYLINDER AND PISTON" section. Refer to "KICK SHAFT AND SHIFT SHAFT" Kick shaft assembly section. Refer to "KICK SHAFT AND SHIFT SHAFT" Segment section.

  • Page 130

    CRANKCASE AND CRANKSHAFT Order Part name Q'ty Remarks Left crankcase Refer to removal section. Oil strainer Crankshaft Refer to removal section. 4-56...

  • Page 131

    CRANKCASE AND CRANKSHAFT REMOVING THE CRANKCASE BEARING Order Part name Q'ty Remarks Refer to "TRANSMISSION, SHIFT CAM AND Transmission SHIFT FORK" section. Refer to "TRANSMISSION, SHIFT CAM AND Shift cam and shift fork SHIFT FORK" section. Oil seal Bearing Refer to removal section. 4-57...

  • Page 132

    CRANKCASE AND CRANKSHAFT DISASSEMBLING THE REMOVING THE CRANKSHAFT CHECKING THE CRANKCASE 1. Remove: 1. Inspect: CRANKCASE 1. Separate: • Crankshaft "1" • Contacting surface "a" • Right crankcase Use the crankcase separating Scratches → Replace. • Left crankcase tool "2". •...

  • Page 133

    On the right crankcase "1". • Bearing the nut of the installing tool with the • Bearing stopper other. Operate the installing tool un- YAMAHA Bond No.1215 • Bolt (bearing stopper) til the crankshaft bottoms against ® (ThreeBond No.1215): the bearing.

  • Page 134

    CRANKCASE AND CRANKSHAFT Apply the lithium soap base grease on the Orings. 5. Install: • Dowel pin "1" • O-ring "2" • Right crankcase 8. Install: To left crankcase. • Timing chain "1" • Timing chain guide (intake side) • Apply the lithium soap base grease "2"...

  • Page 135: 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 136

    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 (24T) "1" • Drive axle "2" Rotate inner race with a finger. •...

  • Page 137

    TRANSMISSION, SHIFT CAM AND SHIFT FORK 3. Install: • Washer "1" • Circlip "2" • Be sure the circlip sharp-edged cor- ner "a" is positioned opposite side to the washer and gear "b". • Install the circlip with its ends "c" settled evenly on the spline crests.

  • Page 138: 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 139

    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 140: Front Wheel And Rear Wheel

    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 141

    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 142

    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 143: 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 144: Front Brake And Rear Brake

    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 145

    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 146

    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 147

    FRONT BRAKE AND REAR BRAKE HANDLING NOTE REMOVING THE BRAKE CALIPER PISTON Replace the brake caliper piston 1. Remove: Support the machine securely so seals and brake caliper piston dust • Brake caliper piston there is no danger of it falling over. seals whenever a caliper is disas- Use compressed air and proceed sembled.

  • Page 148

    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 149

    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 150

    FRONT BRAKE AND REAR BRAKE 3. Install: INSTALLING THE FRONT BRAKE INSTALLING THE REAR BRAKE • Spring "1" MASTER CYLINDER MASTER CYLINDER 1. Install: 1. Install: • Brake pedal "2" • Brake master cylinder "1" • Copper washer "1" • O-ring "3" •...

  • Page 151

    FRONT BRAKE AND REAR BRAKE Install the brake hose so that its Install the brake hose so that its After installing the brake hose pipe portion "a" directs as shown pipe portion "a" directs as shown holders, make sure the brake hose and lightly touches the projection and lightly touches the projection does not contact the spring (rear...

  • Page 152

    FRONT BRAKE AND REAR BRAKE 5. Install: (rear brake only) • Protector "1" • Bolt (protector) "2" Bolt (protector): 7 Nm (0.7 m•kg, 5.1 ft•lb) A. Front B. Rear 2. Air bleed: • Brake system Refer to "BLEEDING THE HY- DRAULIC BRAKE SYSTEM"...

  • Page 153: 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 154

    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 155

    FRONT FORK 2. Remove: HANDLING NOTE REMOVING THE ADJUSTER 1. Drain the outer tube of its front • Inner tube "1" fork oil at its top. Support the machine securely so 2. Loosen: Oil seal removal steps: there is no danger of it falling over. •...

  • Page 156

    FRONT FORK CHECKING THE DAMPER CHECKING THE FORK SPRING CHECKING THE ADJUSTER 1. Measure: 1. Inspect: ASSEMBLY 1. Inspect: • Fork spring free length "a" • Adjuster "1" • Damper assembly "1" Out of specification → Replace. • O-ring "2" Bend/damage →...

  • Page 157

    FRONT FORK 5. Measure: 8. Install: 12. While protecting the damper as- • Oil level (left and right) "a" • Base valve "1" sembly "1" with a rag and com- Out of specification → Adjust. To damper assembly "2". pressing fully, allow excessive oil to overflow on the base valve Standard oil level: side.

  • Page 158

    FRONT FORK 19. Install: 23. Measure: • Oil seal "1" • Distance "a" Out of specification → Turn into the locknut. Press the oil seal into the outer tube with fork seal driver "2". Distance "a": 16 mm (0.63 in) or more Fork seal driver: Between the damper YM-A0948/90890-01502...

  • Page 159

    FRONT FORK 26. Loosen: • Rebound damping adjuster "1" Never fail to make the oil amount adjustment between the maximum • Loosen the rebound damping ad- and minimum amount and always juster finger tight. adjust each front fork to the same •...

  • Page 160

    FRONT FORK 4. Tighten: 7. Adjust: INSTALLING THE FRONT FORK 1. Install: • Pinch bolt (upper bracket) "1" • Compression damping force • Front fork "1" Pinch bolt (upper brack- Turn in the damping adjuster "1" fin- et): • Temporarily tighten the pinch bolts ger-tight and then turn out to the orig- 21 Nm (2.1 m•kg, 15 (lower bracket).

  • Page 161: Handlebar

    HANDLEBAR HANDLEBAR REMOVING THE HANDLEBAR Order Part name Q'ty Remarks Number plate Remove the band only. Hot starter cable Disconnect at the lever side. Hot starter lever holder Clutch cable Disconnect at the lever side. Clutch lever holder Engine stop switch Brake master cylinder Refer to removal section.

  • Page 162

    HANDLEBAR REMOVING THE BRAKE MASTER INSTALLING THE HANDLEBAR 1. Install: CYLINDER • The handlebar upper holder should 1. Remove: • Handlebar lower holder "1" be installed with the punched mark • Brake master cylinder bracket "1" • Washer "2" "a" forward. •...

  • Page 163

    HANDLEBAR 3. Tighten: • Nut (handlebar lower holder) "1" Nut (handlebar lower holder): 34 Nm (3.4 m•kg, 24 ft•lb) 6. Install: 9. Install: • Collar "1" • Grip cap cover "1" • Grip cap cover "2" • Cover (throttle cable cap) "2" •...

  • Page 164

    HANDLEBAR • Clamp "6" • The engine stop switch, clutch lever holder and clamp should be in- stalled according to the dimensions shown. • Pass the engine stop switch lead in the middle of the clutch lever hold- 12. Install: •...

  • Page 165: 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 166

    STEERING 2. Install: HANDLING NOTE CHECKING THE STEERING STEM 1. Inspect: • Bearing race • Steering stem "1" • Upper bearing "1" Support the machine securely so Bend/damage → Replace. • Bearing race cover "2" there is no danger of it falling over. Apply the lithium soap base grease REMOVING THE STEERING RING on the bearing and bearing race cov-...

  • Page 167

    STEERING 5. Check the steering stem by turn- 9. After tightening the nut, check the ing it lock to lock. If there is any steering for smooth movement. If binding, remove the steering stem not, adjust the steering by loosen- assembly and inspect the steer- ing the steering ring nut little by lit- ing bearings.

  • Page 168: 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 169

    SWINGARM DISASSEMBLING THE SWINGARM Order Part name Q'ty Remarks Relay arm Connecting rod Collar Oil seal Thrust bearing Bushing Oil seal Bearing Refer to removal section. 5-32...

  • Page 170

    SWINGARM 2. Install: HANDLING NOTE CHECKING THE CONNECTING • Bearing "1" 1. Inspect: • Washer "2" Support the machine securely so • Bearing "1" • Oil seal "3" there is no danger of it falling over. • Collar "2" To relay arm. Free play exists/unsmooth revolu- REMOVING THE BEARING tion/rust →...

  • Page 171

    SWINGARM INSTALLING THE SWINGARM 1. Install: Apply the molybdenum disulfide • Bushing "1" grease on the bolt. • Thrust bearing "2" • Oil seal "3" • Collar "4" To swingarm "5". 8. Install: Apply the molybdenum disulfide • Bolt (connecting rod) "1" grease on the bushings, thrust bear- •...

  • Page 172

    SWINGARM 11. Tighten: • Nut (relay arm) "1" Nut (relay arm): 70 Nm (7.0 m•kg, 50 ft•lb) 12. Install: • Bolt (lower chain tensioner) "1" • Washer "2" • Collar "3" • Lower chain tensioner "4" • Nut (lower chain tensioner) "5" Nut (lower chain tension- er): 16 Nm (1.6 m•kg, 11...

  • Page 173: Rear Shock Absorber

    REAR SHOCK ABSORBER REAR SHOCK ABSORBER REMOVING THE REAR SHOCK ABSORBER Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "SEAT, FUEL TANK AND SIDE Seat COVERS" section in the CHAPTER 4. Refer to "EXHAUST PIPE AND SILENCER"...

  • Page 174

    To dispose of a damaged or worn- of explosion, read and under- out rear shock absorber, take the stand the following information unit to your Yamaha dealer for this before handling the shock ab- disposal procedure. sorber. The manufacturer can...

  • Page 175

    REAR SHOCK ABSORBER 2. Install: INSTALLING THE BEARING INSTALLING THE SPRING (REAR 1. Install: • Bushing "1" SHOCK ABSORBER) • Upper bearing "1" 1. Install: • Collar "2" • Spring "1" • Dust seal "3" • Upper spring guide "2" Install the bearing parallel until the •...

  • Page 176

    REAR SHOCK ABSORBER 6. Install: • Rear frame "1" • Bolt [rear frame (upper)] "2" Bolt [rear frame (upper)]: 32 Nm (3.2 m•kg, 23 ft•lb) • Bolt [rear frame (lower)] "3" Bolt [rear frame (lower)]: 32 Nm (3.2 m•kg, 23 ft•lb) 7.

  • Page 177

    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. It may lead to...

  • Page 178: Electrical Components And Wiring Diagram

    ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS AND WIRING DIAGRAM ELECTRICAL COMPONENTS Engine stop switch CDI magneto CDI unit Throttle position sensor Ignition coil Neutral switch Spark plug WIRING DIAGRAM Engine stop switch Black/Blue COLOR CODE Throttle position sensor Black/White Black Neutral switch Black/Yellow...

  • Page 179: 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 180

    IGNITION SYSTEM 3. Inspect: SPARK GAP TEST CHECKING THE ENGINE STOP 1. Disconnect the ignition coil from • Secondary coil resistance SWITCH spark plug. 1. Inspect: Out of specification → Replace. 2. Remove the ignition coil cap. • Engine stop switch conduction Tester (+) lead →...

  • Page 181

    IGNITION SYSTEM 2. Inspect: CHECKING THE NEUTRAL • Charging coil 1 resistance SWITCH Out of specification → Replace. 1. Inspect: • Neutral switch conduction Tester (+) lead → Brown lead "1" Tester (-) lead → Green lead "2" Tester (+) lead→Sky blue lead "1" Tester (-) lead →...

  • Page 182: 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 183

    THROTTLE POSITION SENSOR SYSTEM 3. Inspect: 4. Install: HANDLING NOTE • Throttle position sensor coil vari- • Throttle position sensor "1" able resistance • Screw (throttle position sensor) Do not loosen the screw (throttle Check that the resistance in in- "2"...

  • Page 184

    THROTTLE POSITION SENSOR SYSTEM 8. Start the engine. CHECKING THE THROTTLE 9. Adjust: POSITION SENSOR INPUT • Throttle position sensor output VOLTAGE voltage 1. Disconnect the throttle position sensor coupler. 2. Start the engine. Adjustment steps: 3. Inspect: a. Adjust the installation angle of the •...

  • Page 185: Tuning

    ENGINE TUNING • After installing the carburetor, CONSTRUCTION OF check that the throttle operates CARBURETOR AND SETTING ENGINE PARTS correctly and opens and closes The FLATCR carburetor has a prima- CARBURETOR SETTING smoothly. • The air/fuel mixture will vary de- ry main jet.

  • Page 186

    ENGINE The jet needle setting parts, having ADJUSTING THE PILOT SCREW Effects of adjusting the pilot jet The richness of the air-fuel mixture the same taper angle, are available in (reference) with the throttle fully closed to 1/4 different straight portion diameters open can be set by turning the pilot and in different taper starting posi- screw "1".

  • Page 187

    ENGINE ADJUSTING THE LEAK JET Jet nee- Size Part number (ADJUSTING THE ACCELERATOR PUMP) Rich NDJN 5TA-14916-JN The leak jet "1" is a setting part that adjusts the flow of fuel discharged by NDJP 5TA-14916-JP the accelerator pump. Since the ac- NDJQ 5TA-14916-J1 celerator pump operates only when...

  • Page 188

    ENGINE SPECIFICATIONS OF JET NEEDLE For USA and CDN Diameter of straight portion Rich Lean 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 NDJN-4 NDJP-4 NDJQ-4 NDJR-4 NDJS-4 NDJT-4 NDJU-4 0.5 leaner NCVN-3...

  • Page 189

    ENGINE Symptom Setting Checking Closed to 1/4 throttle Use jet needle with a smaller diameter. Slow-speed-circuit passage Hard breathing Clogged → Clean. Speed down Overflow from carburetor Closed to 1/4 throttle Use jet needle with a larger diameter. Poor acceleration Raise jet needle clip position.

  • Page 190

    CHASSIS CHASSIS DRIVE AND REAR WHEEL FRONT FORK SETTING The front fork setting should be made SPROCKETS SETTING PARTS SELECTION OF THE SECONDARY depending on the rider's feeling of an REDUCTION RATIO (SPROCKET) Part name Size Part number actual run and the circuit conditions. The front fork setting includes the fol- Secondary reduction ratio = Drive...

  • Page 191

    CHASSIS FRONT FORK SETTING PARTS CHOOSING SET LENGTH • Front fork spring "1" 1. Place a stand or block under the engine to put the rear wheel I.D. above the floor, and measure the SPRIN SPRING length "a" between the rear wheel PART NUM- axle center and the rear fender RATE...

  • Page 192

    CHASSIS • Extent of adjustment (spring pre- SETTING OF SPRING AFTER REAR SHOCK ABSORBER load) REPLACEMENT SETTING PARTS After replacement, be sure to adjust • Rear shock spring "1" SPRING the spring to the set length [sunken [Equal-pitch steel spring] PART length 90–100 mm (3.5–3.9 in)] and Maximum...

  • Page 193

    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 194

    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 196

    YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2500 SHINGAI IWATA SHIZUOKA JAPAN...

This manual also for:

2011 yz250fa, 2011 yz250f, Yz250f a 2011, Yz250f 2011

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