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Yamaha WR250F(Y) 2009 Owner's Service Manual
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Yamaha WR250F(Y) 2009 Owner's Service Manual

Yamaha WR250F(Y) 2009 Owner's Service Manual

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Read this manual carefully before operating this vehicle.
Read this manual carefully before operating this vehicle.
OWNER'S SERVICE MANUAL
OWNER'S SERVICE MANUAL
WR250F(Y)
WR250F(Y)
5UM-28199-56-E0
5UM-28199-56-E0
2009
2009

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Summary of Contents for Yamaha WR250F(Y) 2009

  • Page 1 2009 2009 Read this manual carefully before operating this vehicle. Read this manual carefully before operating this vehicle. OWNER’S SERVICE MANUAL OWNER’S SERVICE MANUAL WR250F(Y) WR250F(Y) 5UM-28199-56-E0 5UM-28199-56-E0...
  • Page 3 WR250F (Y) OWNER'S SERVICE MANUAL ©2008 by Yamaha Motor Co., Ltd. 1st Edition, July 2008 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan...
  • Page 4 When operating this machine, al- Congratulations on your purchase of distinguished in this manual by the ways wear an approved helmet with a Yamaha WR series. This model is following notations. goggles or a face shield. Also wear the culmination of Yamaha's vast ex-...
  • Page 5 • PROPERLY SECURE THE MA- MANUAL FORMAT CHINE BEFORE TRANSPORTING All of the procedures in this manual are organized in a sequential, step- When transporting the machine in by-step format. The information has another vehicle, always be sure it is been complied to provide the me- properly secured and in an upright chanic with an easy to read, handy...
  • Page 6 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 7: Table Of Contents

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

  • Page 8: General Information

    CONTENTS CHAPTER 1 CHAPTER 3 OIL FILTER ELEMENT AND WATER PUMP ..5-34 GENERAL REGULAR BALANCER ....5-38 INFORMATION INSPECTION AND OIL PUMP .......5-40 KICK SHAFT AND ADJUSTMENTS SHIFT SHAFT ....5-43 DESCRIPTION ....1-1 AC MAGNETO AND MACHINE STARTER CLUTCH..5-48 PERIODIC MAINTENANCE IDENTIFICATION .....
  • Page 9 DESCRIPTION GENERAL INFORMATION DESCRIPTION Clutch lever 14. Headlight Hot starter lever 15. Radiator Engine stop switch 16. Coolant drain bolt Multi-function display 17. Rear brake pedal Main switch 18. Valve joint Start switch 19. Fuel cock Front brake lever 20. Cold starter knob Throttle grip 21.
  • Page 10 1. Remove all dirt, mud, dust, and 1. When ordering parts, you can foreign material before removal give the number to your Yamaha and disassembly. dealer for positive identification of • When washing the machine with the model you own.
  • Page 11 5. Keep away from fire. 6. Connect: ALL REPLACEMENT PARTS • Connector 1. We recommend to use Yamaha genuine parts for all replace- ments. Use oil and/or grease rec- The two connectors "click" together. ommended by Yamaha for 7.
  • Page 12 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 13 SPECIAL TOOLS Tool name/Part number How to use Illustration Steering nut wrench This tool is used when tighten the YU-33975, 90890-01403 steering ring nut to specification. Damper rod holder Use this tool to remove and install YM-01494, 90890-01494 the damper rod. Fork seal driver This tool is used when install the fork YM-A0948, 90890-01502...
  • Page 14 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 15 Ignition checker nents. 90890-06754 Vacuum/pressure pump gauge set This tool is used to check the air in- YB-35956-A, 90890-06756 duction system. YAMAHA Bond No. 1215 (ThreeB- This sealant (Bond) is used for ® No. 1215) crankcase mating surface, etc. 90890-85505...
  • Page 16 CONTROL FUNCTIONS CONTROL FUNCTIONS CLUTCH LEVER The clutch lever "1" is located on the MAIN SWITCH left handlebar; it disengages or en- Functions of the respective switch po- gages the clutch. Pull the clutch lever sitions are as follows: to the handlebar to disengage the clutch, and release the lever to en- The engine can be started only at this gage the clutch.
  • Page 17 MULTI-FUNCTION DISPLAY COLD STARTER KNOB MULTI-FUNCTION DISPLAY BASIC MODE When cold, the engine requires a Changing speedometer display richer air-fuel mixture for starting. A (for U.K.) Be sure to stop the machine before separate starter circuit, which is con- 1. Push the "SLCT2" button for 2 making any setting changes to the trolled by the cold starter knob "1", seconds or more to change the...
  • Page 18 MULTI-FUNCTION DISPLAY Changing odometer and tripmeter Manual start A/B (TRIP A/B) 1. Push the "SLCT2" button to Initial setting at changeover to RACE change the tripmeter display. The MODE will remain for manual start. display will change in the follow- 1.
  • Page 19 MULTI-FUNCTION DISPLAY Resetting tripmeter A (TRIP A) and timer 3. Run the machine and start timer 1. Check that the timer is not in op- measurement. eration. If the timer is in operation, 4. To stop timer measurement, stop it by pushing the "SLCT1" pushing the "SLCT1"...
  • Page 20 MULTI-FUNCTION DISPLAY FUNCTION DIAGRAM A short push on the button changes the operation in the arrowed direction. Meter function A short push on the button changes the operation in both arrowed directions. Function that can be performed whether the time is or is not in operation. A long push on the button changes the operation in the arrowed direction.
  • Page 21 MULTI-FUNCTION DISPLAY The following diagram illustrates the multi-function display regarding the direction and operation condition in- volved in each of its functions. A short push on the button changes the operation in the ar- rowed direction. A short push on the button changes the operation in both arrowed directions.
  • Page 22 2. Turn the fuel cock to "ON". tended periods of time. mended by Yamaha because it can 3. Push on the main switch to "ON". cause damage to the fuel system or STARTING A WARM ENGINE 4.
  • Page 23 STARTING AND BREAK-IN Restarting an engine after a fall BREAK-IN PROCEDURES Pull the hot starter lever and start the 1. Before starting the engine, fill the engine. As soon as the engine starts, fuel tank with the fuel. Release the hot starter lever to close 2.
  • Page 24 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 25 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 26: Specifications

    GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: WR250FY (USA, CDN, AUS, NZ) WR250F (EUROPE, ZA) Model code number: 5UMN (USA) 5UMP (CDN) 5UMR (EUROPE) 5UMS (AUS, NZ, ZA) Dimensions: USA, CDN, ZA AUS, NZ EUROPE Overall length 2,165 mm (85.24 2,180 mm (85.83 2,190 mm (86.22 825 mm (32.48 in) ←...
  • Page 27 GENERAL SPECIFICATIONS Oil capacity: Engine oil Periodic oil change 1.1 L (0.97 Imp qt, 1.16 US qt) With oil filter replacement 1.2 L (1.06 Imp qt, 1.27 US qt) Total amount 1.4 L (1.23 Imp qt, 1.48 US qt) Coolant capacity (including all routes): 0.99 L (0.87 Imp qt, 1.05 US qt) Air filter: Wet type element...
  • Page 28 MAINTENANCE SPECIFICATIONS Brake: Front brake type Single disc brake Operation Right hand operation Rear brake type Single disc brake Operation Right foot operation Suspension: Front suspension Telescopic fork Rear suspension Swingarm (link type monocross suspension) Shock absorber: Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/gas, oil damper...
  • Page 29 MAINTENANCE SPECIFICATIONS Item Standard Limit Cam dimensions Intake "A" 29.65–29.75 mm (1.1673–1.1713 in) 29.55 mm (1.1634 in) Intake "B" 22.45–22.55 mm (0.8839–0.8878 in) 22.35 mm (0.8799 in) Exhaust "A" 30.399–30.499 mm (1.1968–1.2007 in) 30.299 mm (1.1929 in) Exhaust "B" 22.45–22.55 mm (0.8839–0.8878 in) 22.35 mm (0.8799 in) Camshaft runout limit...
  • Page 30 MAINTENANCE SPECIFICATIONS Item Standard Limit "C" seat width (IN) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630 "C" seat width (EX) 0.9–1.1 mm (0.0354–0.0433 in) 1.6 mm (0.0630 "D" margin thickness (IN) 0.8 mm (0.0315 in) ---- "D" margin thickness (EX) 0.7 mm (0.0276 in) ---- Stem outside diameter (IN)
  • Page 31 MAINTENANCE SPECIFICATIONS Item Standard Limit Compressed force (installed) (IN) 103–118 N at 29.13 mm (10.50–12.09 kg ---- at 29.13 mm, 23.15–26.66 lb at 1.15 in) Compressed force (installed) (EX) 126–144 N at 29.30 mm (12.85–14.68 kg ---- at 29.30 mm, 28.32–32.37 lb at 1.15 in) Tilt limit* (IN) ---- 2.5°/1.6 mm...
  • Page 32 MAINTENANCE SPECIFICATIONS Item Standard Limit 2nd ring: Type Taper ---- Dimensions (B × T) 0.80 × 2.75 mm (0.03 × 0.11 in) ---- End gap (installed) 0.30–0.45 mm (0.012–0.018 in) 0.80 mm (0.031 Side clearance 0.020–0.055 mm (0.0008–0.0022 in) 0.12 mm (0.005 Oil ring: Dimensions (B ×...
  • Page 33 MAINTENANCE SPECIFICATIONS Item Standard Limit Shifter: Shifter type Cam drum and guide bar ---- Guide bar bending limit ---- 0.05 mm (0.002 Kickstarter: Type Kick and ratchet type ---- Carburetor: USA, CDN, ZA, EUROPE AUS, NZ FCR-MX37/KEIHIN ← Type/manufacturer ---- I.
  • Page 34 MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Taper roller bearing ---- Front suspension: Front fork travel 300 mm (11.8 in) ---- Fork spring free length 460 mm (18.1 in) 455 mm (17.9 Spring rate, STD K = 4.4 N/mm (0.449 kg/mm, 25.1 lb/in) ---- Optional spring/spacer ----...
  • Page 35 ← ← Pickup coil resistance (color) ---- 20 °C (68 °F) (White–Red) CDI unit-model/manufacturer 5UM-E0/ 5UM-F0/ 5UM-L0/ ---- YAMAHA YAMAHA YAMAHA Ignition coil: Model/manufacturer 5UL-10/DENSO ---- Minimum spark gap 6 mm (0.24 in) ---- 0.08–0.10 Ωat 20 °C (68 °F)
  • Page 36 Item Standard Limit Charging system: System type AC magneto ---- Model (stator)/manufacturer 5UM 30/YAMAHA ---- Normal output 14 V/120 W at 5,000 r/min ---- 0.288–0.432 Ω at 20 °C (68 °F) (White–Ground) Charging coil resistance (color) ---- 0.224–0.336 Ω at 20 °C (68 °F) (Yellow–Ground) ----...
  • Page 37 TIGHTENING TORQUES TIGHTENING TORQUES ENGINE △ - marked portion shall be checked for torque tightening after break-in or before each race. Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Spark plug M10S × 1.0 Camshaft cap M6 × 1.0 Cylinder head blind plug screw M12 ×...
  • Page 38 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Throttle cable adjust bolt and locknut M6 × 0.75 Throttle cable (pull) M6 × 1.0 Throttle cable (return) M12 × 1.0 Throttle cable cover M5 × 0.8 Hot starter plunger M12 ×...
  • Page 39 TIGHTENING TORQUES CHASSIS △ - marked portion shall be checked for torque tightening after break-in or before each race. Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb △ Upper bracket and outer tube M8 × 1.25 △ Lower bracket and outer tube M8 ×...
  • Page 40 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb △ Rear wheel sprocket M8 × 1.25 △ Rear brake disc cover M6 × 1.0 △ Rear brake caliper protector M6 × 1.0 Drive chain puller adjust bolt and locknut M8 ×...
  • Page 41 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Headlight body and headlight unit — △ Headlight M6 × 1.0 Taillight — Taillight lead clamp and rear fender — 0.05 0.36 △ Catch tank (upper) M6 × 1.0 △...
  • Page 42 TIGHTENING TORQUES GENERAL TORQUE TORQUE SPECIFI- SPECIFICATIONS CATION (Bolt This chart specifies torque for stan- (Nut) 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 44 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 2-18...
  • Page 45 LUBRICATION DIAGRAMS Crankshaft Oil filter element Oil tank Oil hose From oil pump 2-19...
  • Page 46 CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM Fuel tank breather hose 10. Oil hose 19. Carburetor overflow hose Clamp 11. Clutch cable 20. Catch tank breather hose Diode 12. Starter motor lead 21. Hot starter cable protector Hot starter cable 13. Cable guide 22.
  • Page 47 CABLE ROUTING DIAGRAM Insert the end of the fuel tank Pass the clutch cable and wire breather hose into the hole in harness through the cable the steering stem. guide. Fasten the throttle cable, hot Locate the couplers in the frame starter cable and rectifier/regula- recess.
  • Page 48 CABLE ROUTING DIAGRAM Throttle cable (pull) Cross the pull and push throttle Fasten the catch tank breather Throttle cable (return) cables. hose and carburetor breather Catch tank hose Fasten the catch tank hose and hoses together. Ignition coil air induction hose (air cut-off Pass the carburetor breather Clamp valve-rear of cylinder head) onto...
  • 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 Clamp Positive battery lead Battery Negative battery lead Taillight coupler CDI unit coupler (6-pin) CDI unit coupler (3-pin) CDI unit coupler (6-pin) 2-24...
  • Page 51 CABLE ROUTING DIAGRAM Fasten the wire harness, nega- Fasten the taillight lead to the tive battery lead and starter mo- rear frame. Locate the clamp tor lead to the upper engine end facing toward the upper side bracket (left side). Locate the of the frame and cut off the tie clamp end facing toward the up- end.
  • Page 52 CABLE ROUTING DIAGRAM Throttle cable 11. Main switch Clamp 12. Upper bracket Brake hose 13. Clutch switch coupler Clutch cable 14. Engine stop switch coupler Hose guide 15. Multi-function display coupler Main switch coupler 16. Start switch coupler Wire harness 17.
  • Page 53 CABLE ROUTING DIAGRAM Fasten the start switch lead to the handlebar with the plastic bands. Fasten the engine stop switch lead and clutch switch lead to the handlebar with the plastic bands. Pass the brake hose through the hose guides. Secure the coupler by inserting it into the multi-function display bracket.

  • Page 54: Regular Inspection And Adjustments

    • From 4,200 mi (7,000 km) or 9 months, repeat the maintenance intervals starting from 1,800 mi (3,000 km) or 3 months. • Items marked with an asterisk should be performed by a Yamaha dealer as they require special tools, data and technical skills.
  • Page 55 GENERAL MAINTENANCE AND LUBRICATION CHART (For Canada) GENERAL MAINTENANCE AND LUBRICATION CHART (For Canada) ODOMETER INITIAL READINGS 600 mi 1,800 mi 3,000 mi ITEM CHECKS AND MAINTENANCE JOBS (1,000 (3,000 (5,000 km) or 1 km) or 3 km) or 6 month months months...
  • Page 56 The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. Every...
  • Page 57 MAINTENANCE INTERVALS FOR COMPETITION USE Every Every After third fifth (or Every As re- Item break- Remarks race (or 500 1,000 quired VALVE LIFTERS ● Inspect Check for scratches and wear. ● Replace CAMSHAFTS Inspect the camshaft surface. ● Inspect Inspect the decompression system.
  • Page 58 MAINTENANCE INTERVALS FOR COMPETITION USE Every Every After third fifth (or Every As re- Item break- Remarks race (or 500 1,000 quired CRANK ● ● Inspect and clean CARBURETOR ● ● Inspect, adjust and clean AIR INDUCTION SYSTEM ● ● ●...
  • Page 59 Lubricate Lithium base grease THROTTLE, CONTROL CABLE ● ● Check routing and connection ● ● Lubricate Yamaha cable lube or SAE 10W-30 motor oil HOT STARTER, CLUTCH LEVER ● Inspect free play BATTERY Check terminal for looseness ● and corrosion...
  • Page 60 PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation or practice, make sure the machine is in good operating 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. Check the cool- Coolant P.3-11 –...

  • Page 61: Engine

    ENGINE ENGINE REMOVING THE SEAT, FUEL TANK AND SIDE COVERS Order Part name Q'ty Remarks Turn the fuel cock to "OFF". Disconnect the fuel hose. Seat Air scoop (left and right) Bolt (fuel tank) Fuel tank Left side cover Open the air filter case cover. Right side cover Refer to removal section.
  • Page 62 ENGINE REMOVING THE SIDE COVER 1. Remove: • Bolt (side cover) • Right side cover "1" Draw the side cover backward to re- move it because its claw "a" is insert- ed in the air filter case.
  • Page 63 ENGINE REMOVING THE EXHAUST PIPE AND SILENCER Order Part name Q'ty Remarks Refer to "REMOVING THE SEAT, FUEL Right side cover TANK AND SIDE COVERS" section. Bolt (silencer clamp) Only loosening. Bolt [silencer (front)] Bolt [silencer (rear)] Collar Silencer Silencer clamp Nut (exhaust pipe) Exhaust pipe Gasket...
  • Page 64 ENGINE CHECKING THE SILENCER AND CHECKING THE COOLANT LEVEL CHANGING THE COOLANT EXHAUST PIPE 1. Inspect: Do not remove the radiator cap Do not remove the radiator cap • Gasket "1" "1", drain bolt and hoses when the when the engine is hot. Damage →...
  • Page 65 ENGINE CHECKING THE RADIATOR CAP OPENING PRESSURE • Do not apply pressure more than • Do not mix more than one type of 1. Attach: specified pressure. ethylene glycol antifreeze con- • Radiator cap tester "1" and adapt- • Radiator should be filled fully. taining corrosion inhibitors for er "2"...
  • Page 66 ENGINE LUBRICATING THE THROTTLE 1. Remove: • Cover (throttle cable cap) "1" • Cover (grip cap) "2" • Throttle grip cap "3" ADJUSTING THE THROTTLE CABLE FREE PLAY CLEANING THE AIR FILTER 1. Check: ELEMENT • Throttle grip free play "a" Out of specification →...
  • Page 67 ENGINE 4. Clean: • Air filter element Clean them with solvent. After cleaning, remove the remaining solvent by squeezing the element. 9. Hook: (For USA and CDN) • Do not twist the element when • Binder "1" Recommended oil: squeezing the element. Yamalube 4, SAE10W- •...
  • Page 68 ENGINE CHANGING THE ENGINE OIL 6. Inspect: 9. Install: 1. Start the engine and warm it up • Oil strainer • Copper washer Clogged → Blow. for several minutes, and then turn • Oil filter element drain bolt off the engine and wait for five 7.
  • Page 69 • Oil pressure This section is intended for those who have basic knowledge and skill con- Checking steps: cerning the servicing of Yamaha mo- a. Slightly loosen the oil pressure torcycles (e.g., Yamaha dealers, check bolt "1". service engineers, etc.) Those who b.
  • Page 70 ENGINE 5. Check: • Valve clearance Out of specification → Adjust. Valve clearance (cold): Intake valve: 0.10–0.15 mm (0.0039–0.0059 in) Exhaust valve: d. Round off the last digit of the in- 0.17–0.22 mm stalled pad number to the nearest 6. Adjust: (0.0067–0.0087 in) increment.
  • Page 71 ENGINE INTAKE EXHAUST 3-18...

  • Page 72: Chassis

    CHASSIS CLEANING THE SPARK 6. Install: ARRESTER (For USA) • Silencer cap Silencer cap: 5 Nm (0.5 m•kg, 3.6 • Be sure the exhaust pipe and si- ft•lb) lencer are cool before cleaning the spark arrester. • Do not start the engine when First tighten the two screws "a"...
  • Page 73 CHASSIS ADJUSTING THE FRONT BRAKE ADJUSTING THE REAR BRAKE CHECKING AND REPLACING THE 1. Check: 1. Check: FRONT BRAKE PADS • Brake lever position "a" • Brake pedal height "a" 1. Inspect: Out of specification → Adjust. • Brake pad thickness "a" Out of specification →...
  • Page 74 CHASSIS e. Connect the transparent hose "5" Install the pad pin plug "10". c. Remove the rear wheel "4" and to the bleed screw "6" and place brake caliper "5". Pad pin plug: the suitable container under its Refer to "FRONT WHEEL AND 3 Nm (0.3 m•kg, 2.2 end.
  • Page 75 CHASSIS Install the brake caliper "12" and CHECKING THE DRIVE CHAIN rear wheel "13". 1. Measure: Refer to "FRONT WHEEL AND • Drive chain length (15 links) "a" Out of specification → Replace. REAR WHEEL" section in the CHAPTER 6. Drive chain length (15 Tighten the pad pin "14".
  • Page 76 CHASSIS 4. Inspect: b. Adjust the drive chain slack by • O-ring "1" (drive chain) turning the adjusters "3". Damage → Replace the drive To tighten→Turn the adjuster "3" chain. counterclockwise. • Roller "2" To loosen→Turn the adjuster "3" • Side plate "3" clockwise and push wheel for- Damage/wear →...
  • Page 77 CHASSIS CLEANING THE FRONT FORK OIL ADJUSTING THE FRONT FORK Extent of adjustment: SEAL AND DUST SEAL REBOUND DAMPING FORCE 1. Remove: 1. Adjust: • Protector • Rebound damping force Maximum Minimum • Dust seal "1" By turning the adjuster "1". 20 clicks out Fully turned in Stiffer "a"...
  • Page 78 CHASSIS ADJUSTING THE REAR SHOCK Extent of adjustment: ABSORBER SPRING PRELOAD 1. Elevate the rear wheel by placing the suitable stand under the en- Maximum Minimum gine. 20 clicks out Fully turned in 2. Remove: (from maximum position • Rear frame position) 3.
  • Page 79 CHASSIS CHECKING AND TIGHTENING THE SPOKES The following procedure applies to all of the spokes. 1. Check: • Spokes Bend/damage → Replace. Loose spoke → Retighten. • STANDARD POSITION: • STANDARD POSITION: Tap the spokes with a screwdriv- 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...
  • Page 80 CHASSIS 2. Inspect: • Install the handlebar so that the pro- • Bearing free play jection "c" of the handlebar upper Exist play → Replace. holder is positioned at the mark on the handlebar as shown. • Insert the end of the fuel breather hose "13"...
  • Page 81 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-30 motor oil or every ride. suitable chain lubricants. All control cable...

  • Page 82: Electrical

    ELECTRICAL ELECTRICAL CHECKING THE IGNITION TIMING CHECKING AND CHARGING THE 1. Remove: BATTERY CHECKING THE SPARK PLUG • Timing mark accessing screw "1" 1. Remove: • Spark plug Batteries generate explosive hy- 2. Inspect: drogen gas and contain electrolyte • Electrode "1" which is made of poisonous and Wear/damage →...
  • Page 83 ELECTRICAL 1. Remove: • Seat • Never remove the MF battery 2. Disconnect: sealing caps. • Battery leads • Do not use a high-rate battery (from the battery terminals) charger since it forces a high- amperage current into the bat- First, disconnect the negative bat- tery quickly and can cause bat- tery lead "1", and then the positive...
  • Page 84 ELECTRICAL Charging method using a variable voltage charger 3-31...
  • Page 85 ELECTRICAL Charging method using a constant voltage charger 3-32...
  • Page 86 ELECTRICAL 6. Install: REPLACING THE HEADLIGHT • Battery BULBS • Battery band 1. Remove: 7. Connect: • Headlight • Battery leads Refer to "REMOVING THE SEAT, (to the battery terminals) FUEL TANK AND SIDE COV- ERS" section. 2. Remove: First, connect the positive lead "1", Reserve fuse •...
  • Page 87 ELECTRICAL 6. Install: • Headlight bulb holder 7. Install: • Headlight bulb holder cover 8. Install: • Headlight Headlight: 7 Nm (0.7 m•kg, 5.1 ft•lb) Refer to "REMOVING THE SEAT, FUEL TANK AND SIDE COV- ERS" section. ADJUSTING THE HEADLIGHT BEAMS 1.
  • Page 88 ENGINE (Except for Canada) TUNING • After installing the carburetor, CONSTRUCTION OF check that the throttle operates CARBURETOR AND SETTING ENGINE (Except for Canada) PARTS correctly and opens and closes CARBURETOR SETTING smoothly. The FLATCR carburetor has a prima- • The air/fuel mixture will vary de- ry main jet.
  • Page 89 ENGINE (Except for Canada) ADJUSTING THE PILOT JET Effects of changing the jet needle ADJUSTING THE LEAK JET The richness of the air-fuel mixture groove position (reference) (ADJUSTING THE ACCELERATOR with the throttle open 1/4 or less can PUMP) be set by adjusting the pilot jet "1". The leak jet "1"...
  • Page 90 ENGINE (Except for Canada) CARBURETOR SETTING PARTS Part Main jet Size number (-14943-) Rich #182 4MX-94 #180 4MX-43 #178 4MX-93 #175 4MX-42 #172 4MX-92 (STD) #170 4MX-41 #168 4MX-91 #165 4MX-40 #162 4MX-90 * (STD) #160 4MX-39 Lean #158 4MX-89 Part Pilot jet Size...
  • Page 91 ENGINE (Except for Canada) EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM Symptom Setting Checking Discoloration of spark plug → If tan color, it At full throttle Increase main jet calibration no. (Gradual- Hard breathing is in good condition. Shearing noise If cannot be corrected: Whitish spark plug Clogged float valve seat...
  • Page 92 CHASSIS CHASSIS DRIVE AND REAR WHEEL • Under a stony or hard road condi- SPROCKETS SETTING PARTS tion, the tire pressure should be SELECTION OF THE SECONDARY higher to prevent a flat tire. REDUCTION RATIO (SPROCKET) Part Size Part number Extent of adjustment: name Secondary reduction ratio =...
  • Page 93 CHASSIS • Front fork spring "2" SPRING SPRI I.D. PART TYPE MARK NUMBER RATE (slits) (-23141-) 0.408 5TJ-00 0.418 5TJ-10 SOFT A. Load 0.428 5TJ-20 B. Fork stroke 0.438 5TJ-30 |||| Without adjustment washer (standard) 0.449 5TJ-A0 — 1 adjustment washer 0.459 5TJ-50 2 adjustment washers...
  • Page 94 CHASSIS CHOOSING SET LENGTH SETTING OF SPRING AFTER REAR SHOCK ABSORBER 1. Place a stand or block under the REPLACEMENT SETTING PARTS engine to put the rear wheel After replacement, be sure to adjust • Rear shock spring "1" above the floor, and measure the the spring to the set length [sunken SPRING SPRI...
  • Page 95 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 96 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 97 RADIATOR ENGINE This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little 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 servicing trouble and mechanical damage.
  • Page 98 RADIATOR Order Part name Q'ty Remarks Catch tank hose Right radiator Radiator hose 2 Radiator hose 4 Radiator pipe 1 Catch tank breather hose Catch tank...
  • Page 99 RADIATOR HANDLING NOTE 2. Install: 5. Tighten: • Catch tank hose "1" • Radiator hose clamp "4" • Radiator hose 2 "2" Radiator hose clamp: Do not remove the radiator cap • Radiator hose 3 "3" 2 Nm (0.2 m•kg, 1.4 when the engine and radiator are •...
  • Page 100 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 101 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) Air cut valve cover Spring (air cut valve) Diaphragm (air cut valve) Float chamber Leak jet...
  • Page 102 CARBURETOR Order Part name Q'ty Remarks Main jet Needle jet Spacer Pilot jet Starter jet Push rod Pull the push rod. Throttle shaft assembly Push rod link lever assembly Main air jet Pilot air jet Cold starter plunger...
  • Page 103 CARBURETOR HANDLING NOTE 2. Inspect: CHECKING THE JET NEEDLE • Main jet "1" 1. Inspect: • Pilot jet "2" • Jet needle "1" Do not loosen the screw (throttle Bends/wear → Replace. • Needle jet "3" position sensor) "1" except when •...
  • Page 104 CARBURETOR e. If both are fine, adjust the float 2. Inspect: 4. Install: height by bending the float tab "b" • Spring 2 "1" • Throttle shaft "1" on the float. To lever 2 "2". • Spring "2" • Lever 1 "3" •...
  • Page 105 CARBURETOR 10. Install: 13. Install: • Starter jet "1" • O-ring • Apply the fluorochemical grease on • Pilot jet "2" • Leak jet "1" the bearings. • Spacer "3" • Float chamber "2" • Fit the projection "a" on the throttle •...
  • Page 106 CARBURETOR 16. Install: ADJUSTING THE ACCELERATOR • Jet needle "1" PUMP TIMING • Collar "2" • Spring "3" Adjustment steps: • Needle holder "4" • Throttle valve plate "5" In order for the throttle valve height To throttle valve "6". "a"...
  • Page 107 CARBURETOR 6. Adjust: • Throttle grip free play Refer to "ADJUSTING THE THROTTLE CABLE FREE PLAY" section in the CHAPTER 3. 7. Install: • Throttle cable cover "1" • Bolt (throttle cable cover) "2" Bolt (throttle cable cov- er): 4 Nm (0.4 m•kg, 2.9 ft•lb) 8.
  • Page 108 AIR INDICTOIN SYSTEM AIR INDICTOIN SYSTEM REMOVING THE AIR INDUCTION SYSTEM 7 Nm (0.7 m kg, 5.1 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) Order Part name Q'ty Remarks Bracket Air cut-off valve assembly Air induction hose (air cut-off valve - front of cyl-...
  • Page 109 AIR INDICTOIN SYSTEM CHECKING THE AIR INDUCTION SYSTEM 1. Inspect: • Air induction hose Crack/damage → Replace. • Air induction pipe Crack/damage → Replace. 2. Check: • Operation of air cut valve From air filter Pass air through the pipe and To cylinder head (exhaust check the air cut valve for opera- port)
  • Page 110 CAMSHAFTS CAMSHAFTS REMOVING THE CYLINDER HEAD COVER Order Part name Q'ty Remarks Refer to "REMOVING THE SEAT, FUEL Seat and fuel tank TANK AND SIDE COVERS" section in the CHAPTER 3. Air cut-off valve assembly Refer to "AIR INDUCTION SYSTEM" section. Spark plug Cylinder head breather hose Bolt (cylinder head cover)
  • Page 111 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 112 CAMSHAFTS REMOVING THE CAMSHAFT 3. Remove: CHECKING THE CAMSHAFT 1. Remove: • Timing chain tensioner cap bolt 1. Inspect: • Timing mark accessing screw "1" "1" • Cam lobe • Crankshaft end accessing screw • Timing chain tensioner "2" Pitting/scratches/blue discolora- tion →...
  • Page 113 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 114 Install the clips, camshaft caps "4" Apply the sealant on the cylinder ft•lb) head cover gasket. and bolts (camshaft cap) "5". Bolt (camshaft cap): YAMAHA Bond No. 1215 10 Nm (1.0 m•kg, 7.2 ® (ThreeBond No. 1215): ft•lb) 90890-85505 c.
  • Page 115 CYLINDER HEAD CYLINDER HEAD REMOVING THE CYLINDER HEAD Order Part name Q'ty Remarks Refer to "REMOVING THE SEAT, FUEL Seat and fuel tank TANK AND SIDE COVERS" section in the CHAPTER 3. Refer to "REMOVING THE EXHAUST PIPE Exhaust pipe and silencer AND SILENCER"...
  • Page 116 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 117 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 118 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 CHECKING THE VALVE b. Install the new valve guide using a be reinstalled in their original place.
  • Page 119 VALVES AND VALVE SPRINGS 4. Measure: b. Apply molybdenum disulfide oil to • Margin thickness "a" the valve stem. Out of specification → Replace. Margin thickness: Intake: 0.8 mm (0.0315 in) Exhaust: 0.7 mm (0.0276 in) Measurement steps: c. Install the valve into the cylinder a.
  • Page 120 VALVES AND VALVE SPRINGS CHECKING THE VALVE SPRINGS 3. Install: 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 121 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 122 CYLINDER AND PISTON REMOVING THE PISTON AND CHECKING THE CYLINDER AND d. If out of specification, replace the PISTON RING PISTON piston and piston rings as a set. 1. Remove: 1. Inspect: e. Calculate the piston-to-cylinder • Piston pin clip "1" •...
  • Page 123 CYLINDER AND PISTON b. Measure the inside diameter (pis- ton) "b". Inside diameter (piston): 16.002–16.013 mm (0.6300–0.6304 in) 10 mm (0.39 in) Top ring end 3. Measure: 2nd ring end • Ring end gap Oil ring end (upper) Out of specification → Replace. Oil ring Oil ring end (lower) 3.
  • Page 124 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 125 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 126 CLUTCH Order Part name Q'ty Remarks Nut (clutch boss) Refer to removal section. Lock washer Refer to removal section. Clutch boss Refer to removal section. Thrust washer Primary driven gear Push lever shaft 5-30...
  • Page 127 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" Out of specification → Replace Wear/damage →...
  • Page 128 CLUTCH INSTALLING THE CLUTCH 4. Install: 6. Install: 1. Install: • Seat plate "1" • Bearing "1" • Primary driven gear "1" • Cushion spring "2" • Washer "2" • Thrust washer "2" • Circlip "3" • Clutch boss "3" To push rod 1 "4".
  • Page 129 CLUTCH 10. Install: • Dowel pin "1" • Gasket (clutch cover) "2" 11. Install: • Clutch cover "1" • Bolt (clutch cover) Bolt (clutch cover): 10 Nm (1.0 m•kg, 7.2 ft•lb) Tighten the bolts in stage, using a crisscross pattern. 5-33...
  • Page 130 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 131 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. 5-35...
  • Page 132 OIL FILTER ELEMENT AND WATER PUMP REMOVING THE IMPELLER INSTALLING THE OIL SEAL SHAFT 1. Install: 1. Remove: • Oil seal "1" • Impeller "1" • Washer "2" • Apply the lithium soap base grease • Impeller shaft "3" on the oil seal lip. •...
  • Page 133 OIL FILTER ELEMENT AND WATER PUMP INSTALLING THE KICKSTARTER INSTALLING THE WATER PUMP CRANK HOUSING 1. Install: 1. Install: • Kickstarter crank "1" • Dowel pin "1" • Washer "2" • O-ring "2" • Bolt (kickstarter crank) "3" Apply the lithium soap base grease Bolt (kickstarter crank): on the O-ring.
  • Page 134 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. Refer to "AC MAGNETO AND STARTER Stator CLUTCH" section. Nut (primary drive gear) Refer to removal section.
  • Page 135 BALANCER REMOVING THE BALANCER CHECKING THE BALANCER 1. Straighten the lock washer tab. SHAFT 2. Loosen: 1. Inspect: • Nut (primary drive gear) "1" • Balancer shaft Cracks/damage → Replace. • Nut (balancer shaft driven gear) "2" Place an aluminum plate "a" between 4.
  • Page 136 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 137 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 5-41...
  • Page 138 OIL PUMP CHECKING THE OIL PUMP 3. Check: 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 139 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 140 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. 5-44...
  • Page 141 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 142 KICK SHAFT AND SHIFT SHAFT INSTALLING THE STOPPER 3. Install: INSTALLING THE KICK SHAFT LEVER • Shift lever assembly "1" ASSEMBLY 1. Install: • Shift guide "2" 1. Install: • Torsion spring "1" • Kick gear "1" • Stopper lever "2" •...
  • Page 143 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 144 AC MAGNETO AND STARTER CLUTCH AC MAGNETO AND STARTER CLUTCH REMOVING THE AC MAGNETO AND STARTER CLUTCH Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Refer to "REMOVING THE SEAT, FUEL Seat and fuel tank TANK AND SIDE COVERS"...
  • Page 145 AC MAGNETO AND STARTER CLUTCH Order Part name Q'ty Remarks Starter clutch Refer to removal section. Bearing Washer Idle gear plate Idle gear Holder Pickup coil Stator Tighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb), loosen and retighten the rotor nut to 65 Nm (6.5 m•kg, 47 ft•lb). 5-49...
  • Page 146 AC MAGNETO AND STARTER CLUTCH REMOVING THE ROTOR 3. Check: 1. Remove: • Starter clutch operation • Nut (rotor) "1" • Washer a. Install the starter clutch drive gear Use the sheave holder "2". "1" onto the starter clutch "2" and hold the starter clutch.
  • Page 147 • Starter clutch "1" Nut (rotor): the AC magneto lead. To rotor "2". 65 Nm (6.5 m•kg, 47 ft•lb) YAMAHA Bond No. 1215 • Install the starter clutch with its ® (ThreeBond No. 1215): Use the sheave holder "2" plate side upward.
  • Page 148 AC MAGNETO AND STARTER CLUTCH 10. Install: • Dowel pin • Gasket [crankcase cover (left)] • Crankcase cover (left) "1" • Bolt [crankcase cover (left)] "2" Bolt [crankcase cover (left)]: 13. Connect: 10 Nm (1.0 m•kg, 7.2 • AC magneto lead ft•lb) Refer to "CABLE ROUTING DIA- •...
  • Page 149 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 "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Refer to "REMOVING THE SEAT, FUEL Seat and fuel tank TANK AND SIDE COVERS"...
  • Page 150 ENGINE REMOVAL Order Part name Q'ty Remarks Disconnect the AC magneto lead. Negative battery lead Disconnect at the engine side. Engine guard 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.
  • Page 151 ENGINE REMOVAL HANDLING NOTE 2. Remove: • Engine "1" • Apply the molybdenum disulfide From right side. grease on the pivot shaft. Support the machine securely so • Install the patch with the claw "a" there is no danger of it falling over. Make sure that the couplers, hoses facing outside the chassis.
  • Page 152 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 153 CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT REMOVING THE CRANKSHAFT Order Part name Q'ty Remarks Engie 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 154 CRANKCASE AND CRANKSHAFT Order Part name Q'ty Remarks Right crankcase Refer to removal section. Left crankcase Refer to removal section. Oil strainer Crankshaft Refer to removal section. 5-58...
  • Page 155 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. 5-59...
  • Page 156 CRANKCASE AND CRANKSHAFT DISASSEMBLING THE c. Remove the dowel pins and O- CHECKING THE CRANKCASE CRANKCASE ring. 1. Inspect: 1. Separate: • Contacting surface "a" Scratches → Replace. • Right crankcase REMOVING THE CRANKSHAFT • Left crankcase • Engine mounting boss "b", crank- 1.
  • Page 157 On the right crankcase "1". • Bearing other. Operate the installing tool un- • Bearing stopper YAMAHA Bond No. 1215 til the crankshaft bottoms against • Bolt (bearing stopper) ® (ThreeBond No.1215): the bearing.
  • Page 158 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 159 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 160 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 (19T) "1" • Drive axle "2" Rotate inner race with a finger. •...
  • Page 161 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 162 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 163 FRONT WHEEL AND REAR WHEEL REMOVING THE REAR WHEEL 14 Nm (1.4 m kg, 10 ft lb) 125 Nm (12.5 m kg, 90 ft lb) 19 Nm (1.9 m kg, 13 ft lb) 50 Nm (5.0 m kg, 36 ft lb) 19 Nm (1.9 m kg, 13 ft lb) Order Part name...
  • Page 164 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 165 FRONT WHEEL AND REAR WHEEL 2. Install: • Brake disc "1" • Bolt (brake disc) "2" Bolt (brake disc): 12 Nm (1.2 m•kg, 8.7 ft•lb) Tighten the bolts in stage, using a crisscross pattern. 6. Install: INSTALLING THE REAR WHEEL •...
  • Page 166 FRONT WHEEL AND REAR WHEEL 2. Install: 5. Install: 9. Adjust: • Brake disc "1" • Wheel • Drive chain slack "a" • Bolt (brake disc) "2" Drive chain slack: Install the brake disc "1" between the Bolt (brake disc): 48–58 mm (1.9–2.3 in) brake pads "2"...
  • Page 167 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) Brake hose holder (brake caliper) Union bolt...
  • Page 168 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 169 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 170 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 Brake master cylinder boot Circlip Use a long nose circlip pliers. Washer Push rod Brake master cylinder kit...
  • Page 171 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 172 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. 4. Inspect: • Brake master cylinder piston "1" HANDLING NOTE •...
  • Page 173 FRONT BRAKE AND REAR BRAKE INSTALLING THE FRONT BRAKE CALIPER Apply the brake fluid on the brake 1. Install: master cylinder cup. • Pad support "1" • Brake pad "2" • Pad pin "3" After installing, cylinder cup should be installed as shown di- •...
  • Page 174 FRONT BRAKE AND REAR BRAKE • Nut (brake lever) "3" 2. Install: • Brake master cylinder "1" Nut (brake lever): • Bolt (brake master cylinder) "2" 6 Nm (0.6 m•kg, 4.3 ft•lb) Bolt (brake master cylin- der): 10 Nm (1.0 m•kg, 7.2 Apply the silicone grease on the ft•lb) brake lever sliding surface, bolt and...
  • Page 175 FRONT BRAKE AND REAR BRAKE INSTALLING THE FRONT BRAKE HOSE Always use new copper washers. 1. Install: • Copper washer "1" • Brake hose "2" • Union bolt "3" Union bolt: 30 Nm (3.0 m•kg, 22 4. Pass the brake hose through the ft•lb) front brake hose guides "1".
  • Page 176 FRONT BRAKE AND REAR BRAKE FILLING THE BRAKE FLUID 4. Install: 1. Fill: • Reservoir float (front brake) • Brake fluid • Diaphragm Until the fluid level reaches • Brake master cylinder cap "1" "LOWER" level line "a". • Screw (bolt) {brake master cylin- der cap} "2"...
  • Page 177 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 178 FRONT FORK DISASSEMBLING THE FRONT FORK Order Part name Q'ty Remarks Front fork cap bolt Refer to removal section. Fork spring Drain the fork oil. Dust seal Refer to removal section. Stopper ring Refer to removal section. Inner tube Refer to removal section. Outer tube Piston metal Slide metal...
  • Page 179 FRONT FORK HANDLING NOTE REMOVING THE INNER TUBE CHECKING THE DAMPER ROD 1. Remove: 1. Inspect: • Dust seal "1" • Damper rod "1" Support the machine securely so • Stopper ring "2" Bend/damage→Replace damper there is no danger of it falling over. Using slotted-head screwdriver.
  • Page 180 FRONT FORK CHECKING THE INNER TUBE ASSEMBLING THE FRONT FORK 5. Install: 1. Inspect: 1. Wash the all parts in a clean sol- • Spring guide "1" • Inner tube surface "a" • Locknut "2" vent. Score marks → Repair or replace. 2.
  • Page 181 FRONT FORK 7. Install: 10. Install: 14. Compress the front fork fully. • Piston metal "1" • Oil seal "1" 15. Fill: • Front fork oil Until outer tube top surface with Install the piston metal onto the slot Press the oil seal into the outer tube recommended fork oil "1".
  • Page 182 FRONT FORK 19. Wait ten minutes until the air bub- 21. Measure: bles have been removed from the • Distance "a" Out of specification → Turn into front fork, and the oil has dis- pense evenly in system before the locknut. setting recommended oil level.
  • Page 183 FRONT FORK INSTALLING THE FRONT FORK 7. Install: 1. Install: • Protector "1" • Front fork "1" • Bolt (protector) "2" Bolt (protector): • Temporarily tighten the pinch bolts 7 Nm (0.7 m•kg, 5.1 (lower bracket). ft•lb) • Do not tighten the pinch bolts (up- per bracket) yet.
  • Page 184 HANDLEBAR HANDLEBAR REMOVING THE HANDLEBAR Order Part name Q'ty Remarks Headlight Hot starter cable Disconnect at the lever side. Hot starter lever holder Clutch cable Disconnect at the lever side. Clutch lever holder Disconnect the clutch switch lead. Engine stop switch Disconnect the engine stop switch lead.
  • Page 185 HANDLEBAR REMOVING THE BRAKE MASTER INSTALLING THE HANDLEBAR CYLINDER 1. Install: 1. Remove: • Handlebar lower holder "1" • Brake master cylinder bracket "1" • Washer "2" • Brake master cylinder "2" • Nut (handlebar lower holder) "3" • Install the handlebar lower holder •...
  • Page 186 HANDLEBAR 7. Install: 10. Install: • Throttle cables "1" • Start switch "1" To tube guide "2". • Brake master cylinder "2" • Brake master cylinder bracket "3" • Bolt (brake master cylinder brack- Apply the lithium soap base grease et) "4"...
  • Page 187 HANDLEBAR • 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: • Clutch cable "1" •...
  • Page 188 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 189 STEERING Order Part name Q'ty Remarks Bearing race cover Upper bearing Lower bearing Refer to removal section. Bearing race Refer to removal section. 6-28...
  • Page 190 STEERING HANDLING NOTE CHECKING THE STEERING STEM 2. Install: 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 191 STEERING 5. Check the steering stem by turn- 9. Install: 13. Install: ing it lock to lock. If there is any • Washer "1" • Multi-function display bracket "1" binding, remove the steering stem • Steering stem nut "2" Multi-function display assembly and inspect the steer- Steering stem nut: bracket:...
  • Page 192 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 193 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. 6-32...
  • Page 194 SWINGARM HANDLING NOTE CHECKING THE RELAY ARM 1. Inspect: • Bearing "1" Support the machine securely so • Collar "2" there is no danger of it falling over. Free play exists/unsmooth revolu- tion/rust → Replace bearing and REMOVING THE CAP collar as a set.
  • Page 195 SWINGARM 3. Install: • Collar "1" • Apply the molybdenum disulfide • Apply the molybdenum disulfide To connecting rod "2". grease on the bearing when install- grease on the pivot shaft. ing. • Insert the pivot shaft from right side. •...
  • Page 196 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 197 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 "REMOVING THE SEAT, FUEL Seat and side cover TANK AND SIDE COVERS"...
  • Page 198 REAR SHOCK ABSORBER Order Part name Q'ty Remarks Taillight coupler CDI unit coupler Plastic band Clamp (air filter joint) Only loosening. Rear frame Bolt (rear shock absorber-relay arm) Hold the swingarm. Bolt (rear shock absorber-frame) Rear shock absorber Locknut Only loosening. Adjuster Only loosening.
  • Page 199 To dispose of a damaged or worn- out rear shock absorber, take the unit to your Yamaha dealer for this disposal procedure. 6-38...
  • Page 200 REAR SHOCK ABSORBER 2. Install: 3. Adjust: 3. Install: • Stopper ring (upper bearing) "1" • Spring length (installed) • Rear shock absorber Refer to "ADJUSTING THE 4. Install: REAR SHOCK ABSORBER • Bolt (rear shock absorber-frame) SPRING PRELOAD" section in "1"...
  • Page 201 REAR SHOCK ABSORBER 7. Tighten: • Screw (air filter joint) "1" Screw (air filter joint): 3 Nm (0.3 m•kg, 2.2 ft•lb) 8. Install: • Plastic band • Taillight coupler • Locking tie 6-40...
  • Page 202 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 203 ELECTRICAL COMPONENTS AND WIRING DIAGRAM WIRING DIAGRAM Headlight COLOR CODE Multi-function display Black Engine stop switch Brown Clutch switch Chocolate Diode Dark green Starter relay diode Green Throttle position sensor Gray Starter relay Blue Fuse Orange 10. Starting circuit cut-off relay 11.
  • Page 204 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. No good → *1 Check fuse. Replace fuse and check wire harness.
  • Page 205 IGNITION SYSTEM SPARK GAP TEST CHECKING THE ENGINE STOP 1. Disconnect the ignition coil from SWITCH spark plug. 1. Inspect: 2. Remove the ignition coil cap. • Engine stop switch conduction 3. Connect the dynamic spark tester Tester (+) lead → Black lead "1" "1"...
  • Page 206 ELECTRIC STARTING SYSTEM 3. Inspect: CHECKING THE NEUTRAL • Secondary coil resistance SWITCH Out of specification → Replace. 1. Inspect: • Neutral switch conduction Tester (+) lead → Orange lead "1" Tester (-) lead → Spark plug termi- Tester (+) lead→Sky blue lead "1" Tester (-) lead →...
  • Page 207 ELECTRIC STARTING SYSTEM INSPECTION STEPS If the starter motor will not operate, use the following inspection steps. No good → *1 Check fuse. Replace fuse and check wire harness. OK ↓ No good → *2 Check battery. Recharge or replace. OK ↓...
  • Page 208 ELECTRIC STARTING SYSTEM CHECKING THE COUPLERS AND CHECKING THE CLUTCH SWITCH LEADS CONNECTION 1. Inspect: 1. Check: • Clutch switch conduction • Couplers and leads connection Tester (+) lead → Black lead "1" Rust/dust/looseness/short-circuit Tester (-) lead → Black lead "2" →...
  • Page 209 ELECTRIC STARTING SYSTEM CHECKING THE START SWITCH 1. Inspect: • Start switch conduction Tester (+) lead → Black lead "1" Tester (-) lead → Black lead "2" Result Conductive (while the start switch is pushed) Not conductive while it is pushed → Replace.
  • Page 210 ELECTRIC STARTING SYSTEM REMOVING THE STARTER MOTOR Order Part name Q'ty Remarks Refer to "REMOVING THE EXHAUST PIPE Exhaust pipe AND SILENCER" section in the CHAPTER 3. Starter motor...
  • Page 211 ELECTRIC STARTING SYSTEM DISASSEMBLING THE STARTER MOTOR Order Part name Q'ty Remarks Starter motor front cover Washer (starter motor front cover) Gasket Starter motor yoke Armature assembly Starter motor rear cover Brush Brush spring 7-10...
  • Page 212 ELECTRIC STARTING SYSTEM CHECKING AND REPAIRING THE ASSEMBLING THE STARTER Armature assembly: STARTER MOTOR MOTOR Commutator resis- 1. Check: 1. Install: tance "1": • Commutator • Brush spring "1" 0.0189–0.0231 Ω at 20 Dirt → Clean with 600 grit sandpa- •...
  • Page 213 ELECTRIC STARTING SYSTEM • For installation, align the projec- tions on the washer with the slots in the front cover. • Align the match mark "a" on the starter motor yoke with the match mark "b" on the starter motor front cover.
  • Page 214 CHARGING SYSTEM CHARGING SYSTEM INSPECTION STEPS If the battery is not charged, use the following inspection steps. No good → *1 Check fuse. Replace fuse and check wire harness. OK ↓ No good → *2 Check battery. Recharge or replace. OK ↓...
  • Page 215 CHARGING SYSTEM CHECKING THE COUPLERS AND LEADS CONNECTION 1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. CHECKING THE CHARGING VOLTAGE 1. Start the engine. 2. Inspect: • Charging voltage Out of specification → If no failure is found in checking the source coil resistance, replace the rectifi- er/regulator.
  • Page 216 THROTTLE POSITION SENSOR SYSTEM THROTTLE POSITION SENSOR SYSTEM INSPECTION STEPS If the throttle position sensor will not operate, use the following inspection steps. No good → Check entire ignition system for connection. Repair or replace. OK ↓ No good → Check throttle position sensor.(Throttle position Replace.
  • Page 217 THROTTLE POSITION SENSOR SYSTEM HANDLING NOTE 3. Inspect: 4. Install: • 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 218 THROTTLE POSITION SENSOR SYSTEM 9. Adjust: CHECKING THE THROTTLE • Throttle position sensor output POSITION SENSOR INPUT voltage VOLTAGE 1. Disconnect the throttle position sensor coupler. Adjustment steps: 2. Start the engine. a. Adjust the installation angle of the 3. Inspect: throttle position sensor "1"...
  • Page 219 LIGHTING SYSTEM LIGHTING SYSTEM INSPECTION STEPS Refer to the following flow chart when inspecting the lighting system for possible problems. No good → Check the bulb and bulb socket. Replace the bulb and/or bulb socket. OK ↓ No good → Check the taillight (LEDs).
  • Page 220 LIGHTING SYSTEM CHECKING THE TAILLIGHT CHECKING THE RECTIFIER/ (LEDs) REGULATOR 1. Disconnect the taillight coupler. 1. Connect the battery leads. 2. Connect two jumper leads "1" 2. Start the engine. from the battery terminals to the 3. Turn on the headlight and taillight respective coupler terminal as by turning on the light switch.
  • Page 221 SIGNALING SYSTEM SIGNALING SYSTEM INSPECTION STEPS If the speedometer will not operate, use the following inspection steps. No good → *1 Check battery. Recharge or replace. OK ↓ No good → Check each coupler and wire connection. Repair or replace. OK ↓...
  • Page 222 SIGNALING SYSTEM CHECKING THE COUPLERS AND LEADS CONNECTION Make sure that a short-circuit does 1. Check: not develop between the terminals • Couplers and leads connection because it may cause damage to Rust/dust/looseness/short-circuit electrical components. → Repair or replace. CHECKING THE MULTI-FUNCTION DISPLAY INPUT VOLTAGE 1.
  • Page 224 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2500 SHINGAI IWATA SHIZUOKA JAPAN...