Page 1 OWNER’S SERVICE MANUAL WR250FV LIT-11626-19-38 5UM-28199-13...
Page 3 WR250FV OWNER’S SERVICE MANUAL ©2005 by Yamaha Motor Corporation, U.S.A. 1st Edition, July 2005 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U.S.A. is expressly prohibited. Printed in Japan P/N. LIT-11626-19-38...
Page 4 EC020000 INTRODUCTION Congratulations on your purchase of a Yamaha WR series. This model is the culmina- tion of Yamaha’s vast experience in the pro- duction of pacesetting racing machines. It represents the highest grade of craftsmanship and reliability that have made Yamaha a leader.
Page 5 1. Operate and maintain the motorcycle as date limitations. Covered off-road motorcycles are specified in the appropriate Owner's Manual, those units certified by Yamaha to EPA noise reg- YAMAHA MOTOR CORPORATION, ulations and come equipped from the factory with MAKES NO OTHER WARRANTY OF ANY 2.
Page 6 IMPORTANT NOTICE This machine is designed for off-road use only. It is illegal for this machine to be operated on any public street, road, or highway. Off-road use on public lands may be illegal. Please check local regulations before riding. SAFETY INFORMATION 1.
Page 7 6. GASOLINE CAN CAUSE INJURY. If you should swallow some gasoline, inhale excess gasoline vapors, or allow any gasoline to get into your eyes, contact a doctor immediately. If any gasoline spills onto your skin or clothing, immediately wash skin areas with soap and water, and change your clothes.
Page 8 If you have any questions regarding the operation or maintenance of your machine, please consult your Yamaha dealer. NOTE: This manual should be considered a perma- nent part of this machine and should remain with it even if the machine is subsequently sold.
Page 9 EC080000 HOW TO USE THIS MANUAL EC081000 PARTICULARLY IMPORTANT INFORMATION The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the machine.
Page 10 EC083000 MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The informa- tion has been complied to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., •...
Page 11 ILLUSTRATED SYMBOLS (Refer to the illustration) SPEC Illustrated symbols 1 to 7 are designed as INFO thumb tabs to indicate the chapter’s number and content. INSP 1 General information T U N 2 Specifications 3 Regular inspection and adjustments 4 Tuning 5 Engine 6 Chassis CHAS...
Page 12 MEMO...
Page 13 EC090000 INDEX GENERAL INFORMATION INFO SPECIFICATIONS SPEC REGULAR INSPECTION AND INSP ADJUSTMENTS TUNING ENGINE CHASSIS CHAS – ELECTRICAL ELEC...
Page 14: Table Of Contents
EC0A0000 CONTENTS CHAPTER 1 GENERAL INFORMATION DESCRIPTION .......... 1-1 MACHINE IDENTIFICATION ....1-2 IMPORTANT INFORMATION ....1-3 CHECKING OF CONNECTION ....1-6 SPECIAL TOOLS ........1-7 CONTROL FUNCTIONS ......1-10 MULTI-FUNCTION DISPLAY ....1-14 FUEL ............1-24 STARTING AND BREAK-IN ....1-25 TORQUE-CHECK POINTS .....
Page 15 CHAPTER 3 REGULAR INSPECTION AND ADJUSTMENTS PERIODIC MAINTENANCE CHART FOR THE EMISSION CONTROL SYSTEM ............ 3-1 GENERAL MAINTENANCE AND LUBRICATION CHART ....3-2 MAINTENANCE INTERVALS FOR COMPETITION USE ......... 3-4 PRE-OPERATION INSPECTION AND MAINTENANCE ....... 3-7 ENGINE ............. 3-8 CHASSIS ..........3-32 ELECTRICAL ..........
Page 16 CHAPTER 6 CHASSIS FRONT WHEEL AND REAR WHEEL ........6-1 FRONT BRAKE AND REAR BRAKE ..6-10 FRONT FORK ......... 6-26 HANDLEBAR .......... 6-39 STEERING ..........6-46 SWINGARM ..........6-53 REAR SHOCK ABSORBER ....6-61 CHAPTER 7 ELECTRICAL ELECTRICAL COMPONENTS AND WIRING DIAGRAM ......
Page 17: General Information
DESCRIPTION INFO EC100000 GENERAL INFORMATION EC110000 DESCRIPTION 1 Clutch lever NOTE: 2 Hot starter lever • The machine you have purchased may differ 3 Engine stop switch slightly from those shown in the following. 4 Multi-function display • Designs and specifications are subject to 5 Main switch change without notice.
Page 18: Machine Identification
There are two significant reasons for knowing the serial number of your machine: 1. When ordering parts, you can give the number to your Yamaha dealer for positive identification of the model you own. 2. If your machine is stolen, the authorities will need the number to search for and identify your machine.
Page 19: Important Information
IMPORTANT INFORMATION INFO EC130000 IMPORTANT INFORMATION EC131010 PREPARATION FOR REMOVAL AND DISASSEMBLY 1. Remove all dirt, mud, dust, and foreign material before removal and disassembly. When washing the machine with high pres- sured water, cover the parts follows. • Silencer exhaust port •...
Page 20 IMPORTANT INFORMATION INFO EC132000 ALL REPLACEMENT PARTS 1. We recommend to use Yamaha genuine parts for all replacements. Use oil and/or grease recommended by Yamaha for assembly and adjustment. EC133000 GASKETS, OIL SEALS AND O-RINGS 1. All gaskets, oil seals, and O-rings should be replaced when an engine is overhauled.
Page 21 IMPORTANT INFORMATION INFO EC136000 CIRCLIPS 1. All circlips should be inspected carefully before reassembly. Always replace piston pin clips after one use. Replace distorted circlips. When installing a circlip 1, make sure that the sharp-edged corner 2 is posi- tioned opposite to the thrust 3 it receives. See the sectional view.
Page 22: Checking Of Connection
CHECKING OF CONNECTION INFO EC1C0001 CHECKING OF CONNECTION Dealing with stains, rust, moisture, etc. on the connector. 1. Disconnect: • Connector 2. Dry each terminal with an air blower. 3. Connect and disconnect the connector two or three times. 4. Pull the lead to check that it will not come off.
Page 23: Special Tools
SPECIAL TOOLS INFO 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 24 SPECIAL TOOLS INFO Part number Tool name/How to use Illustration YM-A0948, 90890-01502 Fork seal driver YM-A0948 90890-01502 This tool is used when install the fork oil seal. YS-1880-A, 90890-01701 Sheave holder This tool is used for when loosening or tightening the flywheel magneto securing nut.
Page 25 YB-35956-A, 90890-06756 Vacuum/pressure pump gauge set YB-35956-A 90890-06756 This tool is used to check the air induction system. 90890-85505 YAMAHA Bond No. 1215  (ThreeBond No. 1215) This sealant (Bond) is used for crankcase mating sur- face, etc. 1 - 9...
Page 26: Control Functions
CONTROL FUNCTIONS INFO EC150000 CONTROL FUNCTIONS MAIN SWITCH Functions of the respective switch positions are as follows: The engine can be started only at this position. OFF: All electrical circuits are switched off. Main switch indicator light The main switch 1 is equipped with an indica- tor light 2 to avoid forgetting to turn it off.
Page 27 CONTROL FUNCTIONS INFO EC152000 CLUTCH LEVER The clutch lever 1 is located on the left han- dlebar; it disengages or engages the clutch. Pull the clutch lever to the handlebar to disen- gage the clutch, and release the lever to engage the clutch.
Page 28 CONTROL FUNCTIONS INFO EC157000 REAR BRAKE PEDAL The rear brake pedal 1 is located on the right side of the machine. Press down on the brake pedal to activate the rear brake. FUEL COCK The fuel cock supplies fuel from the tank to carburetor and also filters the fuel.
Page 29 CONTROL FUNCTIONS INFO SIDESTAND This sidestand 1 is used to support only the machine when standing or transporting it. WARNING • Never apply additional force to the side- stand. • Hold up the sidestand before starting out. EC15F000 VALVE JOINT This valve joint 1 prevents fuel from flowing out and is installed to the fuel tank breather hose.
Page 30: Multi-Function Display
MULTI-FUNCTION DISPLAY INFO MULTI-FUNCTION DISPLAY WARNING Be sure to stop the machine before making any setting changes to the multi-function display. The multi-function display is equipped with the following: BASIC MODE: • Speedometer (which shows current speed) • Clock • Two tripmeters (which shows the distance that has been traveled since it was last set to zero) •...
Page 31 MULTI-FUNCTION DISPLAY INFO NOTE: The operation buttons can be pushed in the following two manners: Short push: Push the button. ( Long push: Push the button for 2 seconds or more. ( BASIC MODE Changing speedometer display 1. Push the “SLCT2” button for 2 seconds or more to change the speedometer units.
Page 32 MULTI-FUNCTION DISPLAY INFO Changing tripmeter A/B (TRIP A/B) 1. Push the “SLCT2” button to change the tripmeter display. The display will change in the following order: TRIP A → TRIP B → TRIP A. NOTE: To reset the digits, select the tripmeter involved and push the “RST”...
Page 33 MULTI-FUNCTION DISPLAY INFO 2. Push the “SLCT1” button and “RST” button for 2 seconds or more at the same time to enter tire diameter setting mode. 3. Push the “SLCT1” button (plus) or “SLCT2” button (minus) and change the setting. A long push on the button will fast-forward the digits.
Page 34 MULTI-FUNCTION DISPLAY INFO Returning to BASIC MODE from RACE MODE NOTE: It is possible to return to BASIC MODE with timer measurement at a stop. 1. Check that the timer is not in operation. If the timer is in operation, stop the timer by pushing the “SLCT1”...
Page 35 MULTI-FUNCTION DISPLAY INFO 2. Start timer measurement by pushing the “RST” button. 3. When stopping timer measurement, push- ing the “SLCT1” button and “SLCT2” button at the same time. NOTE: If the machine is run while timer measurement is not made, no change will occur to the digit in tripmeter A (TRIP A).
Page 36 MULTI-FUNCTION DISPLAY INFO Resetting measurement data NOTE: Resetting can be made in the following three manners. Resetting is possible while timer measurement is made: • Reset average speed (AVS). • Reset average speed (AVS)/tripmeter A. Resetting is possible while timer measurement is not made: •...
Page 37 MULTI-FUNCTION DISPLAY INFO 2. Reset all measured data by pushing the “RST” button for 2 seconds or more. NOTE: • Resetting will reset the timer display, travel distance display, and average speed display and put measurement on standby. • Auto start attempt will put measurement on standby as such.
Page 38 MULTI-FUNCTION DISPLAY INFO 1. Push the “SLCT1” button and “RST” button for 2 seconds or more at the same time and enter tire diameter correction mode. NOTE: Changeover to tire correction mode will cause the timer display to change and show the dia- metric digit of the tire.
Page 39 MULTI-FUNCTION DISPLAY INFO FUNCTION DIAGRAM NOTE: The following diagram illustrates the multi-function display regarding the direction and operation condition involved in each of its functions. A short push on the button changes the opera- tion in the arrowed direction. Meter function A short push on the button changes the opera- tion in both arrowed directions.
Page 40: Fuel
Gasohol containing ethanol can be used if the ethanol content does not exceed 10%. Gaso- hol containing methanol is not recommended by Yamaha because it can cause damage to the fuel system or vehicle performance prob- lems. 1 - 24...
Page 41: Starting And Break-In
STARTING AND BREAK-IN INFO STARTING AND BREAK-IN WARNING Never start or run the engine in a closed area. The exhaust fumes are poisonous; they can cause loss of consciousness and death in a very short time. Always operate the machine in a well-ventilated area. CAUTION: •...
Page 42 STARTING AND BREAK-IN INFO NOTE: If the engine fails to start by pushing the start switch, release the switch, wait a few seconds, and then try again. Each starting attempt should be as short as possible to preserve the battery. Do not crank the engine more than 10 seconds on any one attempt.
Page 43 STARTING AND BREAK-IN INFO STARTING A WARM ENGINE Do not operate the cold starter knob and throt- tle. Pull the hot starter lever 1 and start the engine by pushing the start switch or by kick- ing the kickstarter crank forcefully with a firm stroke.
Page 44 STARTING AND BREAK-IN INFO 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 45: Torque-Check Points
TORQUE-CHECK POINTS INFO 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 Steering stem to frame handlebar...
Page 46: Cleaning And Storage
CLEANING AND STORAGE INFO EC1B0000 CLEANING AND STORAGE EC1B1000 CLEANING Frequent cleaning of your machine will enhance its appearance, maintain good overall performance, and extend the life of many com- ponents. 1. Before washing the machine, block off the end of the exhaust pipe to prevent water from entering.
Page 47 CLEANING AND STORAGE INFO EC1B2001 STORAGE If your machine is to be stored for 60 days or more, some preventive measures must be taken to avoid deterioration. After cleaning the machine thoroughly, prepare it for storage as follows: 1. Drain the fuel tank, fuel lines, and the car- buretor float bowl.
Page 48: Specifications
SPEC GENERAL SPECIFICATIONS EC200000 SPECIFICATIONS EC211000 GENERAL SPECIFICATIONS Model name: WR250FV (USA, CDN, AUS, NZ) WR250F (EUROPE, ZA) Model code number: 5UMB (USA) 5UMC (EUROPE) 5UMD (CDN, AUS, NZ, ZA) Dimensions: USA, ZA, CDN EUROPE, AUS, NZ Overall length 2,190 mm (86.22 in) 2,180 mm (85.83 in) ←...
Page 49 SPEC GENERAL SPECIFICATIONS Oil capacity: Engine oil Periodic oil change 1.2 L (1.06 Imp qt, 1.27 US qt) With oil filter replacement 1.3 L (1.14 Imp qt, 1.37 US qt) Total amount 1.4 L (1.23 Imp qt, 1.48 US qt) Coolant capacity (including all routes): 1.26 L (1.11 Imp qt, 1.33 US qt) Air filter:...
Page 50 SPEC GENERAL 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 51: Maintenance Specifications
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS ENGINE Item Standard Limit Cylinder head: Warp limit ---- 0.05 mm (0.002 in) Cylinder: Bore size 77.00 ~ 77.01 mm ---- (3.0315 ~ 3.0319 in) Out of round limit ---- 0.05 mm (0.002 in) Camshaft: Drive method Chain drive (Left) ----...
Page 52 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Timing chain: Timing chain type/No. of links 92RH2010-114M/114 ---- Timing chain adjustment method Automatic ---- Valve, valve seat, valve guide: Valve clearance (cold) 0.10 ~ 0.15 mm ---- (0.0039 ~ 0.0059 in) 0.17 ~ 0.22 mm ---- (0.0067 ~ 0.0087 in) Valve dimensions:...
Page 53 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Stem runout limit ---- 0.01 mm (0.0004 in) Valve seat width 0.9 ~ 1.1 mm 1.6 mm (0.0354 ~ 0.0433 in) (0.0630 in) 0.9 ~ 1.1 mm 1.6 mm (0.0354 ~ 0.0433 in) (0.0630 in) Valve spring: Free length 37.81 mm (1.49 in)
Page 54 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Piston pin bore inside diameter 16.002 ~ 16.013 mm 16.043 mm (0.6300 ~ 0.6304 in) (0.6316 in) Piston pin outside diameter 15.991 ~ 16.000 mm 15.971 mm (0.6296 ~ 0.6299 in) (0.6288 in) Piston rings: Top ring: Type Barrel...
Page 55 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Clutch: Friction plate thickness 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) 2.7 mm (0.106 in) Quantity ---- Clutch plate thickness 1.1 ~ 1.3 mm (0.043 ~ 0.051 in) ---- Quantity ---- Warp limit ---- 0.1 mm (0.004 in)
Page 56 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Lubrication system: Oil filter type Paper type ---- Oil pump type Trochoid type ---- Tip clearance 0.12 mm or less 0.20 mm (0.0047 in or less) (0.008 in) Side clearance 0.09 ~ 0.17 mm 0.24 mm (0.0035 ~ 0.0067 in) (0.009 in)
Page 57 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M10S × 1.0 Spark plug M6 × 1.0 Camshaft cap M12 × 1.0 Cylinder head blind plug screw M6 × 1.0 Cylinder head (stud bolt) M8 × 1.25 (stud bolt) M9 ×...
Page 58 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M8 × 1.25 Silencer M8 × 1.25 Silencer clamp M5 × 0.8 Spark arrester M5 × 0.8 Silencer cap M6 × 1.0 Crankcase M6 × 1.0 Crankcase bearing stopper M6 ×...
Page 59 SPEC MAINTENANCE SPECIFICATIONS CHASSIS Item Standard Limit Steering system: Steering bearing type Taper roller bearing ---- Front suspension: USA, CDN EUROPE AUS, NZ, ZA 300 mm (11.8 in) ← ← Front fork travel 460 mm (18.1 in) ← ← Fork spring free length ←...
Page 60 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Wheel: USA, CDN, ZA EUROPE, AUS, NZ ← Front wheel type Spoke wheel ---- ← Rear wheel type Spoke wheel ---- 21 × 1.60/Aluminum ← Front rim size/material ---- 18 × 1.85/Aluminum 18 × 2.15/Aluminum ---- Rear rim size/material Rim runout limit: Radial...
Page 61 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M8 × 1.25 Upper bracket and outer tube M8 × 1.25 Lower bracket and outer tube M24 × 1.0 Upper bracket and steering stem 14.5 Handlebar upper holder and handlebar lower M8 ×...
Page 62 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb Nipple (spoke) — M8 × 1.25 Rear wheel sprocket M6 × 1.0 Rear brake disc cover M6 × 1.0 Rear brake caliper protector M8 × 1.25 Drive chain puller adjust bolt and locknut Engine mounting: M10 ×...
Page 63 SPEC MAINTENANCE SPECIFICATIONS Tightening torque Part to be tightened Thread size Q’ty m·kg ft·lb M5 × 0.8 Plate 1 and front fork protector Plate 2 and front fork protector — 0.05 0.36 Speed sensor lead holder and lower headlight M6 × 1.0 stay M8 ×...
Page 64 248 ~ 372 Ω at 20 °C (68 °F) Pickup coil resistance (color) ---- (White – Red) CDI unit-model/manufacturer 5UM-B0/YAMAHA (For USA) ---- 5UM-C0/YAMAHA (Except for USA) ---- Ignition coil: Model/manufacturer 5UL-10/DENSO ---- Minimum spark gap 6 mm (0.24 in) ---- 0.08 ~ 0.10 Ω...
Page 65 SPEC MAINTENANCE SPECIFICATIONS Item Standard Limit Starter relay: Model/manufacturer 2768090-A/JIDECO ---- Amperage rating 180 A ---- 4.2 ~ 4.6 Ω at 20 °C (68 °F) Coil winding resistance ---- Starting circuit cut-off relay: Model/manufacturer ACM33221 M06/MATSUSHITA ---- 75.69 ~ 92.51 Ω at 20 °C (68 °F) Coil winding resistance ---- Fuse (amperage ×...
Page 66: General Torque Specifications
GENERAL TORQUE SPECIFICATIONS/ SPEC DEFINITION OF UNITS EC220001 GENERAL TORQUE SPECIFICATIONS This chart specifies torque for standard fasten- ers with standard I.S.O. pitch threads. Torque specifications for special components or assemblies are included in the applicable sec- tions of this book. To avoid warpage, tighten multi-fastener assemblies in a crisscross fash- ion, in progressive stages, until full torque is reached.
Page 67: Cable Routing Diagram
SPEC CABLE ROUTING DIAGRAM EC240000 CABLE ROUTING DIAGRAM 1 Fuel tank breather hose 9 Neutral switch lead G AC magneto lead 2 Oil tank breather hose 0 Oil hose H Rectifier/regulator 3 Clamp A Clutch cable I Carburetor breather hose 4 Diode B Starter motor lead J Carburetor overflow hose...
Page 68 SPEC CABLE ROUTING DIAGRAM È Insert the fuel tank breather hose into the hole in Ë Fasten the wire harness, coolant reservoir hose, the steering stem cap. hot starter cable, negative battery lead and starter É Pass the oil tank breather hose on the outside of motor lead.
Page 69 SPEC CABLE ROUTING DIAGRAM Ï Make sure that the throttle position sensor coupler Ô Fasten the neutral switch lead and AC magneto does not go outside the chassis. lead. Ð Fasten the throttle position sensor lead. Õ Pass the starter motor lead in front of the radiator Ñ...
Page 70 SPEC CABLE ROUTING DIAGRAM Ù Pass the wire harness and clutch cable through the cable guide. Ú Fasten the rectifier/regulator lead to the cable guide. Û Fasten the AC magneto lead and neutral switch lead to the cable guide at their protecting tube. Ü...
Page 71 SPEC CABLE ROUTING DIAGRAM 1 Hot starter cable 0 CDI unit É Pass the throttle cables and 2 Throttle cable (return) A CDI unit band hot starter cable between the 3 Throttle cable (pull) B CDI unit stay radiator and frame, then under 4 Cable guide the radiator mounting boss.
Page 72 SPEC CABLE ROUTING DIAGRAM Ì Fasten the coolant reservoir breather hose and carburetor breather hoses together. Í Fasten the CDI unit lead so that the plastic locking tie ends do not contact the radiator hose. Î Insert the CDI unit band over the CDI unit stay as far as possible.
Page 73 SPEC CABLE ROUTING DIAGRAM 1 Brake master cylinder È Install the brake hose so that its 2 Brake hose holder pipe portion directs as shown 3 Brake hose and lightly touches the projec- tion on the brake caliper. É Pass the brake hose into the brake hose holders.
Page 74 SPEC CABLE ROUTING DIAGRAM 1 Starter motor lead È Position the starter motor lead, negative battery 2 Negative battery lead lead and wire harness in the tank damper slit. 3 Wire harness É Fasten the wire harness. 4 Clamp Ê Fasten the coolant reservoir breather hose and 5 Taillight lead coolant reservoir hose.
Page 75 SPEC CABLE ROUTING DIAGRAM 1 Throttle cable È Fasten the start switch lead to Î Pass the multi-function display 2 Clamp the handlebar with the plastic lead and speed sensor lead 3 Brake hose bands. between the multi-function dis- 4 Hot starter cable É...
Page 76 SPEC CABLE ROUTING DIAGRAM Ò Pass the speed sensor lead through the guide on the out- side of the front fork. Ó Pass the start switch lead and multi-function display lead (on the wire harness side) above the multi-function display lead (on the multi-function display side) and speed sensor lead, and then to the right of the...
Page 77: 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 78: General Maintenance And Lubrication Chart
INSP GENERAL MAINTENANCE AND LUBRICATION CHART GENERAL MAINTENANCE AND LUBRICATION CHART ODOMETER INITIAL READINGS 600 mi 1,800 mi 3,000 mi ITEM CHECKS AND MAINTENANCE JOBS (1,000 km) (3,000 km) (5,000 km) 1 month 3 months 6 months Check operation. √ √...
Page 79 * Shock absorber assembly Replace if necessary. Apply molybdenum disulfide grease √ √ * Rear suspension link pivots lightly. Apply Yamaha chain and cable lube or √ √ √ * Control cables engine oil 10W-30 thoroughly. Check operation and free play.
Page 80: Maintenance Intervals For Competition Use
If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. Every...
Page 81 INSP MAINTENANCE INTERVALS FOR COMPETITION USE Every Every After Every As re- third fifth Item Remarks break-in race quired 500 km) 1,000 km) TRANSMISSION Inspect Replace bearing SHIFT FORK, SHIFT CAM, GUIDE BAR Inspect Inspect wear. ROTOR NUT Retighten MUFFLER Inspect and retighten Clean Replace...
Page 82 Retighten sprocket bolt Inspect bearings Replace bearings Lubricate Lithium base grease THROTTLE, CONTROL CABLE Check routing and connection Yamaha cable lube or SAE 10W-30 motor oil Lubricate HOT STARTER, CLUTCH LEVER Inspect free play 3 - 6...
Page 83: Pre-Operation Inspection And Maintenance
INSP PRE-OPERATION INSPECTION AND MAINTENANCE EC320000 PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation or practice, make sure the machine is in good operating condi- tion. 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 84: Engine
INSP ENGINE/SEAT, FUEL TANK AND SIDE COVERS EC350000 ENGINE SEAT, FUEL TANK AND SIDE COVERS 1 Seat removal 2 Fuel tank removal Extent of removal: 3 Side covers removal 4 Headlight removal Extent of removal Order Part name Q’ty Remarks SEAT, FUEL TANK AND SIDE COVERS REMOVAL Preparation for removal...
Page 85 INSP SEAT, FUEL TANK AND SIDE COVERS REMOVAL POINTS Side cover 1. Remove: • Bolt (side cover) • Left side cover 1 • Right side cover 2 NOTE: Draw the side cover downward to remove it because its claws a are inserted in the air fil- ter case.
Page 86 INSP EXHAUST PIPE AND SILENCER EC4S0000 EXHAUST PIPE AND SILENCER 1 Silencer removal 2 Exhaust pipe removal Extent of removal: Extent of removal Order Part name Q’ty Remarks EXHAUST PIPE AND SILENCER REMOVAL Preparation for removal Right side cover Refer to “SEAT, FUEL TANK AND SIDE COVERS”...
Page 87 INSP EXHAUST PIPE AND SILENCER INSPECTION Silencer and exhaust pipe 1. Inspect: • Gasket 1 Damage → Replace. ASSEMBLY AND INSTALLATION Silencer and exhaust pipe 1. Install: • Gasket • Exhaust pipe 1 • Nut (exhaust pipe) 2 13 Nm (1.3 m · kg, 9.4 ft · lb) •...
Page 88 COOLANT LEVEL INSPECTION/ INSP COOLANT REPLACEMENT COOLANT LEVEL INSPECTION WARNING Do not remove the radiator cap 1, drain bolt and hoses when the engine and radia- tor are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury.
Page 89 INSP COOLANT REPLACEMENT CAUTION: Take care so that coolant does not splash on painted surfaces. If it splashes, wash it away with water. 1. Place a container under the engine. 2. Remove: • Seat Refer to “SEAT, FUEL TANK AND SIDE COVERS”...
Page 90 INSP COOLANT REPLACEMENT 9. Fill: • Radiator • Engine To specified level. Recommended coolant: High quality ethylene glycol anti-freeze containing anti-corrosion for aluminum engine Coolant 1 and water (soft water) 2 mixing ratio: 50%/50% Coolant capacity: 0.9 L (0.79 Imp qt, 0.95 US qt) CAUTION: •...
Page 91 RADIATOR CAP INSPECTION/ INSP RADIATOR CAP OPENING PRESSURE INSPECTION 12. Install: • Coolant reservoir cap 13. Start the engine and let it warm up for sev- eral minutes. 14. Turn off the engine and inspect the coolant level. Refer to “COOLANT LEVEL INSPECTION” section.
Page 92 COOLING SYSTEM INSPECTION/ INSP CLUTCH ADJUSTMENT 2. Apply the specified pressure. Radiator cap opening pressure: 110 kPa (1.1 kg/cm , 15.6 psi) 3. Inspect: • Pressure Impossible to maintain the specified pres- sure for 10 seconds → Replace. COOLING SYSTEM INSPECTION 1.
Page 93 INSP THROTTLE CABLE ADJUSTMENT 2. Adjust: • Clutch lever free play Clutch lever free play adjustment steps: • Loosen the locknuts 1. • Adjust the free play by changing their tight- ening position. • Tighten the locknuts. Locknut: 7 Nm (0.7 m • kg, 5.1 ft • lb) NOTE: •...
Page 94 THROTTLE LUBRICATION/ INSP HOT STARTER LEVER ADJUSTMENT THROTTLE LUBRICATION 1. Remove: • Cover (throttle cable cap) 1 • Cover (grip cap) 2 • Throttle grip cap 3 2. Apply: • Lithium soap base grease On the throttle cable end a. 3.
Page 95 INSP AIR FILTER CLEANING AIR FILTER CLEANING NOTE: Proper air filter maintenance is the biggest key to preventing premature engine wear and damage. CAUTION: Never run the engine without the air filter element in place; this would allow dirt and dust to enter the engine and cause rapid wear and possible engine damage.
Page 96 INSP AIR FILTER CLEANING CAUTION: • Do not twist the element when squeezing the element. • Leaving too much of solvent in the ele- ment may result in poor starting. 5. Inspect: • Air filter element Damage → Replace. 6. Apply: •...
Page 97 INSP ENGINE OIL LEVEL INSPECTION ENGINE OIL LEVEL INSPECTION 1. Start the engine, warm it up for several minutes, and then turn off the engine and wait for five minutes. 2. Place the machine on a level place and hold it up on upright position by placing the suitable stand under the engine.
Page 98 INSP ENGINE OIL REPLACEMENT (Except for USA and CDN) Temp. ˚C Recommended oil: Refer to the following chart for 10W-30 selection of oils which are 10W-40 suited to the atmospheric 15W-40 temperatures. 20W-40 Recommended engine oil classi- 20W-50 fication: API STANDARD: API “SG”...
Page 99 INSP ENGINE OIL REPLACEMENT 4. Remove: • Oil tank cap 1 • Oil filler cap 2 • Frame oil drain bolt 3 • Crankcase oil drain bolt 4 • Oil filter element drain bolt 5 Drain the crankcase and oil tank (frame) of its oil.
Page 100 INSP ENGINE OIL REPLACEMENT 8. Install: • Copper washer 1 • Oil strainer (frame) 2 70 Nm (7.0 m · kg, 50 ft · lb) • Oil hose 3 • Bolt (oil hose) 4 8 Nm (0.8 m · kg, 5.8 ft · lb) •...
Page 101 OIL PRESSURE INSPECTION/ INSP ENGINE IDLING SPEED ADJUSTMENT OIL PRESSURE INSPECTION 1. Check: • Oil pressure Checking steps: • Slightly loosen the oil pressure check bolt • Start the engine and keep it idling until oil starts to seep from the oil pressure check bolt.
Page 102 NOTE: This section is intended for those who have basic knowledge and skill concerning the ser- vicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning ser- vicing are requested not to undertake inspec- tion, adjustment, disassembly, or reassembly only by reference to this manual.
Page 103 INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT 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: 0.17 ~ 0.22 mm (0.0067 ~ 0.0087 in) Checking steps: •...
Page 104 INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT 6. Adjust: • Valve clearance Adjustment steps: • Remove the camshaft (intake and exhaust). Refer to “CAMSHAFTS” section in the CHAPTER 5. • Remove the valve lifters 1 and the pads NOTE: • Place a rag in the timing chain space to prevent pads from falling into the crank- case.
Page 105 INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT • Locate the rounded-off value and the mea- sured valve clearance in the chart “PAD SELECTION TABLE”. The field where these two coordinates intersect shows the new pad number to use. NOTE: Use the new pad number only as a guide when verifying the valve clearance adjust- ment.
Page 106 INSP VALVE CLEARANCE INSPECTION AND ADJUSTMENT 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 ~ 0.04 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 0.05 ~ 0.09 120 125 130 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235...
Page 107 INSP SPARK ARRESTER CLEANING (For USA) SPARK ARRESTER CLEANING (For USA) WARNING • Be sure the exhaust pipe and silencer are cool before cleaning the spark arrester. • Do not start the engine when cleaning the exhaust system. 1. Remove: •...
Page 108: Chassis
INSP CHASSIS/BRAKE SYSTEM AIR BLEEDING EC360000 CHASSIS EC361012 BRAKE SYSTEM AIR BLEEDING WARNING Bleed the brake system if: • The system has been disassembled. • A brake hose has been loosened or removed. • The brake fluid is very low. •...
Page 109 INSP FRONT BRAKE ADJUSTMENT NOTE: If bleeding is difficult, it may be necessary to let the brake fluid system stabilize for a few hours. Repeat the bleeding procedure when the tiny bubbles in the system have disap- peared. j. Add brake fluid to the level line on the res- ervoir.
Page 110 REAR BRAKE ADJUSTMENT/ INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT EC364002 REAR BRAKE ADJUSTMENT 1. Check: • Brake pedal height a Out of specification → Adjust. Brake pedal height a: 5 mm (0.20 in) 2. Adjust: • Brake pedal height Pedal height adjustment steps: •...
Page 111 INSP FRONT BRAKE PAD INSPECTION AND REPLACEMENT • Loosen the pad pin 2. • Remove the brake caliper 3 from the front fork. • Remove the pad pin and brake pads 4. • Connect the transparent hose 5 to the bleed screw 6 and place the suitable con- tainer under its end.
Page 112 INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT • Install the pad pin plug 0. Pad pin plug: 3 Nm (0.3 m • kg, 2.2 ft • lb) 3. Inspect: • Brake fluid level Refer to “BRAKE FLUID LEVEL INSPEC- TION” section. 4.
Page 113 INSP REAR BRAKE PAD INSPECTION AND REPLACEMENT • Remove the pad pin 6 and brake pads 7. • Connect the transparent hose 8 to the bleed screw 9 and place the suitable con- tainer under its end. • Loosen the bleed screw and push the brake caliper piston in.
Page 114 REAR BRAKE PAD INSULATOR INSPECTION/ INSP BRAKE FLUID LEVEL INSPECTION 3. Inspect: • Brake fluid level Refer to “BRAKE FLUID LEVEL INSPEC- TION” section. 4. Check: • Brake pedal operation A softy or spongy feeling → Bleed brake system. Refer to “BRAKE SYSTEM AIR BLEED- ING”...
Page 115 INSP SPROCKETS INSPECTION/DRIVE CHAIN INSPECTION SPROCKETS INSPECTION 1. Inspect: • Sprocket teeth a Excessive wear → Replace. NOTE: Replace the drive sprocket, rear wheel sprocket and drive chain as a set. DRIVE CHAIN INSPECTION 1. Measure: • Drive chain length (15 links) a Out of specification →...
Page 116 INSP DRIVE CHAIN INSPECTION 4. Inspect: • O-ring 1 (drive chain) Damage → Replace the drive chain. • Roller 2 • Side plate 3 Damage/wear → Replace the drive chain. 5. Check: • Drive chain stiffness a Clean and oil the drive chain and hold as illustrated.
Page 117 INSP DRIVE CHAIN SLACK ADJUSTMENT DRIVE CHAIN SLACK ADJUSTMENT 1. Elevate the rear wheel by placing the suit- able stand under the engine. 2. Check: • Drive chain slack a Above the seal guard installation bolt. Out of specification → Adjust. Drive chain slack: 48 ~ 58 mm (1.9 ~ 2.3 in) NOTE:...
Page 118 INSP DRIVE CHAIN STOPPER INSPECTION/FRONT FORK INSPECTION/ FRONT FORK OIL SEAL AND DUST SEAL CLEANING • Tighten the axle nut while pushing down the drive chain. Axle nut: 125 Nm (12.5 m • kg, 90 ft • lb) • Tighten the locknuts. Locknut: 16 Nm (1.6 m •...
Page 119 FRONT FORK INTERNAL PRESSURE RELIEVING/FRONT INSP FORK REBOUND DAMPING FORCE ADJUSTMENT FRONT FORK INTERNAL PRESSURE RELIEVING NOTE: If the front fork initial movement feels stiff dur- ing a run, relieve the front fork internal pres- sure. 1. Elevate the front wheel by placing a suit- able stand under the engine.
Page 120 FRONT FORK COMPRESSION DAMPING FORCE INSP ADJUSTMENT • STANDARD POSITION: This is the position which is back by the specific number of clicks from the fully turned-in position. Standard position: 12 clicks out * 11 clicks out ** 13 clicks out * For EUROPE ** For AUS, NZ and ZA CAUTION:...
Page 121 INSP REAR SHOCK ABSORBER INSPECTION • STANDARD POSITION: This is the position which is back by the spe- cific number of clicks from the fully turned-in position. Standard position: 8 clicks out * 10 clicks out ** 12 clicks out * For EUROPE ** For AUS, NZ and ZA CAUTION:...
Page 122 REAR SHOCK ABSORBER SPRING PRELOAD INSP ADJUSTMENT REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT 1. Elevate the rear wheel by placing the suit- able stand under the engine. 2. Remove: • Rear frame 3. Loosen: • Locknut 1 4. Adjust: • Spring preload By turning the adjuster 2.
Page 123 REAR SHOCK ABSORBER REBOUND DAMPING FORCE INSP ADJUSTMENT EC36N014 REAR SHOCK ABSORBER REBOUND DAMPING FORCE ADJUSTMENT 1. Adjust: • Rebound damping force By turning the adjuster 1. Stiffer a → Increase the rebound damp- ing force. (Turn the adjuster 1 in.) Softer b →...
Page 124 REAR SHOCK ABSORBER LOW COMPRESSION INSP DAMPING FORCE ADJUSTMENT EC36c000 REAR SHOCK ABSORBER LOW COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: • Low compression damping force By turning the adjuster 1. Stiffer a → Increase the low compres- sion damping force. (Turn the adjuster 1 in.) Softer b →...
Page 125 REAR SHOCK ABSORBER HIGH COMPRESSION INSP DAMPING FORCE ADJUSTMENT EC36d000 REAR SHOCK ABSORBER HIGH COMPRESSION DAMPING FORCE ADJUSTMENT 1. Adjust: • High compression damping force By turning the adjuster 1. Stiffer a → Increase the high compres- sion damping force. (Turn the adjuster 1 in.) Softer b →...
Page 126 TIRE PRESSURE CHECK/SPOKES INSPECTION AND INSP TIGHTENING/WHEEL INSPECTION EC36Q000 TIRE PRESSURE CHECK 1. Measure: • Tire pressure Out of specification → Adjust. Standard tire pressure: 100 kPa (1.0 kgf/cm , 15 psi) NOTE: • Check the tire while it is cold. •...
Page 127 INSP STEERING HEAD INSPECTION AND ADJUSTMENT 2. Inspect: • Bearing free play Exist play → Replace. EC36U013 STEERING HEAD INSPECTION AND ADJUSTMENT 1. Elevate the front wheel by placing a suit- able stand under the engine. 2. Check: • Steering stem Grasp the bottom of the forks and gently rock the fork assembly back and forth.
Page 128 INSP STEERING HEAD INSPECTION AND ADJUSTMENT • Tighten the steering ring nut 3 using steering nut wrench 4. NOTE: • Apply the lithium soap base grease on the thread of the steering stem. • Set the torque wrench to the steering nut wrench so that they form a right angle.
Page 129 INSP STEERING HEAD INSPECTION AND ADJUSTMENT Steering stem nut: 145 Nm (14.5 m • kg, 105 ft • lb) Handlebar upper holder: 28 Nm (2.8 m • kg, 20 ft • lb) Pinch bolt (upper bracket): 23 Nm (2.3 m • kg, 17 ft • lb) Headlight (left and right): 7 Nm (0.7 m •...
Page 130 INSP LUBRICATION È Use Yamaha cable lube or equivalent on these LUBRICATION areas. To ensure smooth operation of all components, É Use SAE 10W-30 motor oil or suitable chain lubri- lubricate your machine during setup, after cants. break-in, and after every ride.
Page 131: Electrical
ELECTRICAL/SPARK PLUG INSPECTION/ INSP IGNITION TIMING CHECK EC370000 ELECTRICAL EC371001 SPARK PLUG INSPECTION 1. Remove: • Spark plug 2. Inspect: • Electrode 1 Wear/damage → Replace. • Insulator color 2 Normal condition is a medium to light tan color. Distinctly different color → Check the engine condition.
Page 132 INSP IGNITION TIMING CHECK 2. Attach: • Timing light • Inductive tachometer To the ignition coil lead (orange lead 1). Timing light: YM-33277-A/90890-03141 3. Adjust: • Engine idling speed Refer to “ENGINE IDLING SPEED ADJUSTMENT” section. 4. Check: • Ignition timing Visually check the stationary pointer a is within the firing range b on the rotor.
Page 133 INSP BATTERY INSPECTION AND CHARGING BATTERY INSPECTION AND CHARGING WARNING Batteries generate explosive hydrogen gas and contain electrolyte which is made of poisonous and highly caustic sulfuric acid. Therefore, always follow these preventive measures: • Wear protective eye gear when handling or working near batteries.
Page 134 INSP BATTERY INSPECTION AND CHARGING NOTE: Since MF batteries are sealed, it is not possi- ble to check the charge state of the battery by measuring the specific gravity of the electro- lyte. Therefore, the charge of the battery has to be checked by measuring the voltage at the battery terminals.
Page 135 INSP BATTERY INSPECTION AND CHARGING 4. Measure: • Battery charge Measurement steps: • Connect a pocket tester 1 to the battery terminals. Tester positive probe → battery positive terminal Tester negative probe → battery negative terminal NOTE: • The charge state of an MF battery can be checked by measuring its open-circuit volt- age (i.e., the voltage when the positive ter- minal is disconnected).
Page 136 INSP BATTERY INSPECTION AND CHARGING 5. Charge: • Battery (refer to the appropriate charging method illustration) WARNING Do not quick charge a battery. CAUTION: • Never remove the MF battery sealing caps. • Do not use a high-rate battery charger since it forces a high-amperage current into the battery quickly and can cause battery overheating and battery plate...
Page 137 INSP BATTERY INSPECTION AND CHARGING Charging method using a variable voltage charger 3 - 61...
Page 138 INSP BATTERY INSPECTION AND CHARGING Charging method using a constant voltage charger 3 - 62...
Page 139 BATTERY REPLACEMENT 1. Replace: • Battery CAUTION: This battery is for YAMAHA WR250F. After filling the battery with electrolyte, either charge it for at least 3 hours at the amperage specified on the battery or let it sit for at least 15 hours before using it.
Page 140 INSP FUSE INSPECTION 2. Check: • Continuity Checking steps: • Remove the fuse 1. • Connect the pocket tester to the fuse and check the continuity. NOTE: Set the pocket tester selector to “Ω × 1”. Pocket tester: YU-3112-C/90890-03112 • If the pocket tester indicates “∞”, replace the fuse.
Page 141 REPLACING THE HEADLIGHT BULBS/ INSP ADJUSTING THE HEADLIGHT BEAMS REPLACING THE HEADLIGHT BULBS 1. Remove: • Headlight Refer to “SEAT, FUEL TANK AND SIDE COVERS” section. 2. Remove: • Headlight bulb holder cover 1 3. Detach: • Headlight bulb holder 1 4.
Page 142: Tuning
T U N SETTING EC700000 TUNING EC720000 CHASSIS Selection of the secondary reduction ratio (Sprocket) Secondary Number of rear wheel sprocket teeth reduction Number of drive sprocket teeth ratio Standard secondary 52/13 (4.000) reduction ratio <Requirement for selection of secondary gear reduction ratio>...
Page 143 T U N SETTING EC72N000 Drive and rear wheel sprockets setting parts Part name Size Part number Drive sprocket 1 (STD) 9383B-13218 * 14T 9383B-14222 Rear wheel 5GS-25448-50 sprocket 2 * 48T 1C3-25448-00 * 49T 1C3-25449-00 5TJ-25450-80 * 50T 1C3-25450-00 * 51T 1C3-25451-00 5TJ-25452-80...
Page 144 T U N SETTING EC722011 Front fork setting The front fork setting should be made depend- ing on the rider’s feeling of an actual run and the circuit conditions. The front fork setting includes the following three factors: 1. Setting of air spring characteristics •...
Page 145 T U N SETTING È Air spring characteristics in relation to oil level change É Load Ê Stroke 1 Max. oil level 2 Standard oil level 3 Min. oil level EC727020 Spring preload adjustment The spring preload is adjusted by installing the adjustment washer 1 between the fork spring 2 and damper rod 3.
Page 146 T U N SETTING EC72A001 Setting of spring after replacement As the front fork setting can be easily affected by rear suspension, take care so that the machine front and rear are balanced (in posi- tion, etc.) when setting the front fork. 1.
Page 147 T U N SETTING EC72P000 Front fork setting parts • Adjustment washer 1 TYPE (thickness) PART NUMBER T = 2.3 mm (0.09 in) 5XE-23364-00 • Front fork spring 2 I.D. SPRING SPRING TYPE MARK RATE PART NUMBER (slits) 0.408 5TJ-23141-00 SOFT 0.418 5TJ-23141-10...
Page 148 T U N SETTING EC72B000 Rear suspension setting The rear suspension setting should be made depending on the rider’s feeling of an actual run and the circuit conditions. The rear suspension setting includes the fol- lowing two factors: 1. Setting of spring preload •...
Page 149 T U N SETTING NOTE: • If the machine is new and after it is broken in, the same set length of the spring may change because of the initial fatigue, etc. of the spring. Therefore, be sure to make re- evaluation.
Page 150 T U N SETTING CAUTION: When using a rear shock absorber other than currently installed, use the one whose overall length a does not exceed the stan- dard as it may result in faulty performance. Never use one whose overall length is greater than standard.
Page 151 T U N SETTING EC72Q000 Rear shock absorber setting parts • Rear shock spring 1 I.D. SPRING SPRING SPRING PART TYPE COLOR/ FREE RATE NUMBER POINT LENGTH 5UN-22212-00 Brown/1 SOFT 5UN-22212-10 Green/1 * STD 5UN-22212-20 Red/1 5UN-22212-30 Black/1 5UN-22212-40 Blue/1 ** STD 5UN-22212-50 Yellow/1 5UN-22212-60...
Page 152 T U N SETTING EC72H002 Suspension setting • Front fork NOTE: • 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. •...
Page 153 T U N SETTING • Rear shock absorber NOTE: • 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 154: Engine
This section is intended for those who have basic knowledge and skill concerning the EC450001 RADIATOR servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are requested not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual.
Page 155: Radiator
RADIATOR EC456000 HANDLING NOTE WARNING Do not remove the radiator cap when the engine and radiator are hot. Scalding hot fluid and steam may be blown out under pressure, which could cause serious injury. When the engine has cooled, open the radi- ator cap by the following procedure: Place a thick rag, like a towel, over the radi- ator cap, slowly rotate the cap counter-...
Page 156 RADIATOR 3. Install: • Right radiator 1 • Bolt (right radiator) 2 10 Nm (1.0 m · kg, 7.2 ft · lb) • Radiator hose 3 3 Refer to “CABLE ROUTING DIAGRAM” section in the CHAPTER 2. 4. Install: • Left radiator 1 •...
Page 157: Carburetor
CARBURETOR CARBURETOR 4 Nm (0.4 m kg, 2.9 ft • • 2 Nm (0.2 m kg, 1.4 ft • • 11 Nm (1.1 m kg, 8.0 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 3 Nm (0.3 m kg, 2.2 ft •...
Page 158 CARBURETOR EC468000 CARBURETOR DISASSEMBLY 1 Carburetor disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks CARBURETOR DISASSEMBLY 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)
Page 159 CARBURETOR Extent of removal Order Part name Q’ty Remarks Float pin Float Needle valve 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 5 - 6...
Page 160 CARBURETOR HANDLING NOTE CAUTION: Do not loosen the screws (throttle position sensor) 1 except when changing the throt- tle position sensor due to failure because it will cause a drop in engine performance. INSPECTION Carburetor 1. Inspect: • Carburetor body Contamination →...
Page 161 CARBURETOR EC464301 Throttle valve 1. Check: • Free movement Stick → Repair or replace. NOTE: Insert the throttle valve 1 into the carburetor body, and check for free movement. EC464401 Jet needle 1. Inspect: • Jet needle 1 Bends/wear → Replace. •...
Page 162 CARBURETOR EC464600 Float 1. Inspect: • Float 1 Damage → Replace. Starter plunger 1. Inspect: • Cold starter plunger 1 • Hot starter plunger 2 Wear/damage → Replace. Accelerator pump 1. Inspect: • Diaphragm (accelerator pump) 1 • Spring (accelerator pump) 2 •...
Page 163 CARBURETOR ASSEMBLY AND INSTALLATION Carburetor 1. Install: • Cold starter plunger 1 2. Install: • Pilot air jet 1 • Main air jet 2 3. Install: • Spring 1 1 • Lever 1 2 To lever 2 3. NOTE: Make sure the spring 1 fits on the stopper a of the lever 2.
Page 164 CARBURETOR 6. Install: • Washer 1 • Circlip 2 7. Install: • Spring 1 To throttle shaft 2. NOTE: Install the bigger hook a of the spring fits on the stopper b of the throttle shaft pulley. 8. Install: 1 2 3 •...
Page 165 CARBURETOR 9. Install: • Push rod 1 NOTE: While holding down the lever 1 2, insert the push rod farthest into the carburetor. 10. Install: • Starter jet 1 • Pilot jet 2 • Spacer 3 • Needle jet 4 •...
Page 166 CARBURETOR 14. Install: • Diaphragm (accelerator pump) 1 • Spring 2 • O-ring 3 • Accelerator pump cover 4 • Hose holder (drain hose) 5 • Screw (accelerator pump cover) 6 NOTE: Install the diaphragm (accelerator pump) with its mark a facing the spring. 15.
Page 167 CARBURETOR Accelerator pump timing adjustment Adjustment steps: NOTE: In order for the throttle valve height a to achieve the specified value, tuck under the throttle valve plate 1 the rod 2 etc. with the same outer diameter as the specified value. Throttle valve height: 0.8 mm (0.03 in) •...
Page 168 CARBURETOR 4. Tighten: • Screw (air filter joint) 1 3 Nm (0.3 m · kg, 2.2 ft · lb) • Screw (carburetor joint) 2 3 Nm (0.3 m · kg, 2.2 ft · lb) 5. Install: • Throttle cable (pull) 1 4 Nm (0.4 m ·...
Page 169: Air Induction System
AIR INDUCTION SYSTEM AIR INDUCTION SYSTEM 10 Nm (1.0 m kg, 7.2 ft • • 4 Nm (0.4 m kg, 2.9 ft • • 1 Air induction system removal Extent of removal: Extent of removal Order Part name Q’ty Remarks AIR INDUCTION SYSTEM REMOVAL Air induction pipe...
Page 170 AIR INDUCTION SYSTEM INSPECTION Air induction system 1. Inspect: • Air induction hose Crack/damage → Replace. • Air induction pipe Crack/damage → Replace. 2. Check: È • Operation of air cut valve Pass air through the pipe and check the air cut valve for operation.
Page 171: Camshafts
CAMSHAFTS CAMSHAFTS CYLINDER HEAD COVER 1 Cylinder head cover removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CYLINDER HEAD COVER REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 3. Carburetor Refer to “CARBURETOR”...
Page 172 CAMSHAFTS CAMSHAFTS 1 Camshaft removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CAMSHAFTS REMOVAL Timing mark accessing screw Crankshaft end accessing screw Timing chain tensioner cap bolt Timing chain tensioner Refer to “REMOVAL POINTS”. Camshaft cap Clip Exhaust camshaft Intake camshaft...
Page 173 CAMSHAFTS REMOVAL POINTS Camshaft 1. Remove: • Timing mark accessing screw 1 • Crankshaft end accessing screw 2 2. Align: • T.D.C. mark With align mark. Checking steps: • Turn the crankshaft counterclockwise with a wrench. • Align the T.D.C. mark a on the rotor with the align mark b on the crankcase cover when piston is at T.D.C.
Page 174 CAMSHAFTS 5. Remove: • Exhaust camshaft 1 • Intake camshaft 2 NOTE: Attach a wire 3 to the timing chain to prevent it from falling into the crankcase. INSPECTION Camshaft 1. Inspect: • Cam lobe Pitting/scratches/blue discoloration → Replace. 2. Measure: •...
Page 175 CAMSHAFTS 4. Measure: • Camshaft-to-cap clearance Out of specification → Measure camshaft outside diameter. Camshaft-to-cap clearance: 0.028 ~ 0.062 mm (0.0011 ~ 0.0024 in) <Limit>: 0.08 mm (0.003 in) Measurement steps: • Install the camshaft onto the cylinder head. 1 onto the ®...
Page 176 CAMSHAFTS Decompression system 1. Check: • Decompression system Checking steps: • Check that the decompression mecha- nism cam 1 moves smoothly. • Check that the decompression mechanism cam lever pin 2 projects from the camshaft. Timing chain tensioner 1. Check: •...
Page 177 CAMSHAFTS • Fit the timing chain 3 onto both camshaft sprockets and install the camshafts on the cylinder head. NOTE: The camshafts should be installed onto the cylinder head so that the punch mark c on the exhaust camshaft and the punch mark d on the intake camshaft must align with the cylinder head surface, as shown in the illustration.
Page 178 CAMSHAFTS • With the rod fully wound and the chain ten- sioner UP mark a facing upward, install the gasket 1 and the timing chain ten- sioner 2, and tighten the bolt 3 to the specified torque. Bolt (timing chain tensioner): 10 Nm (1.0 m •...
Page 179 • Cylinder head cover 3 • Bolt (cylinder head cover) 4 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Apply the sealant on the cylinder head cover gasket. YAMAHA Bond No. 1215 ® (ThreeBond No. 1215): 90890-85505 7. Install: •...
Page 180: Cylinder Head
CYLINDER HEAD CYLINDER HEAD 1 Cylinder head removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CYLINDER HEAD REMOVAL Preparation for removal Seat and fuel tank Refer to “SEAT, FUEL TANK AND SIDE COVERS” section in the CHAPTER 3. Exhaust pipe and silencer Refer to “EXHAUST PIPE AND SILENCER”...
Page 181 CYLINDER HEAD INSPECTION Cylinder head 1. Eliminate: • Carbon deposits (from the combustion chambers) Use a rounded scraper. NOTE: Do not use a sharp instrument to avoid damag- ing or scratching: • Spark plug threads • Valve seats 2. Inspect: •...
Page 182 CYLINDER HEAD ASSEMBLY AND INSTALLATION Cylinder head 1. Install: • Dowel pin 1 • Cylinder head gasket 2 • Timing chain guide (exhaust side) 3 • Cylinder head 4 NOTE: While pulling up the timing chain, install the timing chain guide (exhaust side) and cylinder head.
Page 183: Valves And Valve Springs
VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS 1 Valve removal Extent of removal: Extent of removal Order Part name Q’ty Remarks VALVES AND VALVE SPRINGS REMOVAL Preparation for removal Cylinder head Refer to “CYLINDER HEAD” section. Valve lifter Use special tool. Adjusting pad Refer to “REMOVAL POINTS”.
Page 184 VALVES AND VALVE SPRINGS REMOVAL POINTS Valve lifter and valve cotter 1. Remove: • Valve lifter 1 • Pad 2 NOTE: Identify each lifter 1 and pad 2 position very carefully so that they can be reinstalled in their original place. 2.
Page 185: Valves And Valve Springs
VALVES AND VALVE SPRINGS INSPECTION Valve 1. Measure: • Stem-to-guide clearance Stem-to-guide clearance = valve guide inside diameter a – valve stem diameter b Out of specification → Replace the valve guide. Clearance (stem to guide): Intake: 0.010 ~ 0.037 mm (0.0004 ~ 0.0015 in) <Limit>: 0.08 mm (0.003 in) Exhaust:...
Page 186 VALVES AND VALVE SPRINGS Valve guide remover: Intake: 4.0 mm (0.16 in) YM-4111/90890-04111 Exhaust: 4.5 mm (0.18 in) YM-4116/90890-04116 Valve guide installer: Intake: 4.0 mm (0.16 in) YM-4112/90890-04112 Exhaust: 4.5 mm (0.18 in) YM-4117/90890-04117 Valve guide reamer: Intake: 4.0 mm (0.16 in) YM-4113/90890-04113 Exhaust: 4.5 mm (0.18 in) YM-4118/90890-04118...
Page 187 VALVES AND VALVE SPRINGS 5. Measure: • Runout (valve stem) Out of specification → Replace. Runout limit: 0.01 mm (0.0004 in) NOTE: • When installing a new valve always replace the guide. • If the valve is removed or replaced always replace the oil seal.
Page 188 VALVES AND VALVE SPRINGS 9. Lap: • Valve face • Valve seat NOTE: After refacing the valve seat or replacing the valve and valve guide, the valve seat and valve face should be lapped. Lapping steps: • Apply a coarse lapping compound to the valve face.
Page 189: Valve Lifter
VALVES AND VALVE SPRINGS Valve spring 1. Measure: • Valve spring free length a Out of specification → Replace. Free length (valve spring): Intake: 37.81 mm (1.49 in) <Limit>: 36.81 mm (1.45 in) Exhaust: 37.54 mm (1.48 in) <Limit>: 36.54 mm (1.44 in) 2.
Page 190: Valve Cotter
VALVES AND VALVE SPRINGS ASSEMBLY AND INSTALLATION Valve and valve spring 1. Apply: • Molybdenum disulfide oil Onto the valve stem and valve stem seal. 2. Install: • Valve 1 • Valve spring seat 2 • Valve stem seal 3 •...
Page 191 VALVES AND VALVE SPRINGS 5. Install: • Adjusting pad 1 • Valve lifter 2 NOTE: • Apply the molybdenum disulfide oil on the valve stem end. • Apply the engine oil on the valve lifters. • Valve lifter must turn smoothly when rotated with a finger.
Page 192: Cylinder And Piston
CYLINDER AND PISTON CYLINDER AND PISTON 1 Cylinder removal 2 Piston removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CYLINDER AND PISTON REMOVAL Preparation for removal Cylinder head Refer to “CYLINDER HEAD” section. Bolt (cylinder) Cylinder Piston pin clip Piston pin Use special tool.
Page 193 CYLINDER AND PISTON REMOVAL POINTS Piston and piston ring 1. Remove: • Piston pin clip 1 • Piston pin 2 • Piston 3 NOTE: • Put identification marks on each piston head for reference during reinstallation. • Before removing each piston pin, deburr the clip groove and pin hole area.
Page 194 CYLINDER AND PISTON 77.00 ~ 77.01 mm Cylinder bore “C” (3.0315 ~ 3.0319 in) Taper limit “T” 0.05 mm (0.002 in) Out of round “R” 0.05 mm (0.002 in) “C” = Maximum D “T” = (Maximum D or D ) – (Maximum D or D “R”...
Page 195 CYLINDER AND PISTON Piston ring 1. Measure: • Ring side clearance Use a feeler gauge 1. Out of specification → Replace the piston and rings as a set. NOTE: Clean carbon from the piston ring grooves and rings before measuring the side clearance. Side clearance: Standard <Limit>...
Page 196 CYLINDER AND PISTON Piston pin 1. Inspect: • Piston pin Blue discoloration/grooves → Replace, then inspect the lubrication system. 2. Measure: • Piston pin-to-piston clearance Measurement steps: • Measure the outside diameter (piston pin) If out of specification, replace the piston pin.
Page 197 CYLINDER AND PISTON 2. Position: • Top ring • 2nd ring • Oil ring 45˚ 135˚ 135˚ Offset the piston ring end gaps as shown. a Top ring end b 2nd ring end c Oil ring end (upper) d Oil ring e Oil ring end (lower) 3.
Page 198 CYLINDER AND PISTON 3. Install: • Cylinder gasket 1 • Cylinder 2 NOTE: Install the cylinder with one hand while com- pressing the piston rings with the other hand. CAUTION: • Pass the timing chain 3 through the tim- ing chain cavity. •...
Page 199: Clutch
CLUTCH EC4A0000 CLUTCH 1 Push rod 1, 2 and push lever shaft removal 2 Push rod 1 disassembly Extent of removal: 3 Friction plate and clutch plate removal 4 Primary driven gear removal Extent of removal Order Part name Q’ty Remarks CLUTCH REMOVAL Preparation for removal...
Page 200 CLUTCH Extent of removal Order Part name Q’ty Remarks Friction plate Clutch plate Cushion spring Seat plate Nut (clutch boss) Use special tool. Lock washer Refer to “REMOVAL POINTS”. Clutch boss Thrust washer Primary driven gear Push lever shaft 5 - 47...
Page 201 CLUTCH EC4A3000 REMOVAL POINTS Clutch boss 1. Remove: • Nut 1 • Lock washer 2 • Clutch boss 3 NOTE: Straighten the lock washer tab and use the clutch holding tool 4 to hold the clutch boss. È É Clutch holding tool: YM-91042/90890-04086 È...
Page 202 CLUTCH Friction plate 1. Measure: • Friction plate thickness Out of specification → Replace friction plate as a set. Measure at all four points. Friction plate thickness: 2.9 ~ 3.1 mm (0.114 ~ 0.122 in) <Limit>: 2.7 mm (0.106 in) EC484600 Clutch plate 1.
Page 203 CLUTCH EC4A5000 ASSEMBLY AND INSTALLATION Push lever shaft 1. Install: • Push lever shaft 1 • Bolt (push lever shaft) 2 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: • Apply the lithium soap base grease on the oil seal lip.
Page 204 CLUTCH 3. Bend the lock washer 1 tab. 4. Install: • Seat plate 1 • Cushion spring 2 NOTE: • Install the seat plate with its chamfered por- tion a facing the clutch boss 3. • Install the seat plate so that it is not caught on the step b.
Page 205 CLUTCH 7. Install: • Push rod 2 1 • Ball 2 • Push rod 1 3 NOTE: Apply the engine oil on the push rod 1, 2 and ball. 8. Install: • Pressure plate 1 9. Install: • Clutch spring 1 •...
Page 206 OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER 1 Oil filter element removal 2 Water pump removal Extent of removal: 3 Right crankcase cover removal Extent of removal Order Part name Q’ty Remarks OIL FILTER ELEMENT, WATER...
Page 207: Oil Filter Element, Water Pump And Right Crankcase Cover
OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER Extent of removal Order Part name Q’ty Remarks Water pump housing Oil delivery pipe Bolt (oil hose) Kickstarter crank Right crankcase cover Impeller Washer Impeller shaft Refer to “REMOVAL POINTS”. Oil seal Bearing 5 - 54...
Page 208 OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER REMOVAL POINTS Impeller shaft 1. Remove: • Impeller 1 • Washer 2 • Impeller shaft 3 NOTE: Hold the impeller shaft on its width across the flats a with spanners, etc. and remove the impeller.
Page 209 OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER EC444200 Impeller shaft 1. Inspect: • Impeller shaft 1 Bend/wear/damage → Replace. Fur deposits → Clean. EC444300 Impeller shaft gear 1. Inspect: • Gear teeth a Wear/damage → Replace. EC4H4600 Bearing 1.
Page 210 OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER 2. Install: • Bearing 1 NOTE: Install the bearing by pressing its outer race parallel. Impeller shaft 1. Install: • Impeller shaft 1 • Washer 2 • Impeller 3 14 Nm (1.4 m · kg, 10 ft · lb) NOTE: •...
Page 211 OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER 2. Install: • Right crankcase cover 1 • Bolt (right crankcase cover) 2 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: • Apply the engine oil on the impeller shaft end.
Page 212 OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANKCASE COVER Water pump housing 1. Install: • Dowel pin 1 • O-ring 2 NOTE: Apply the lithium soap base grease on the O- ring. 2. Install: • Water pump housing 1 • Bolt (water pump housing) 2 10 Nm (1.0 m ·...
Page 213: Balancer
BALANCER BALANCER 1 Balancer shaft drive gear 2 Balancer shaft Extent of removal: Extent of removal Order Part name Q’ty Remarks BALANCER REMOVAL Preparation for removal Primary driven gear Refer to “CLUTCH” section. Right crankcase cover Refer to “OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANK- CASE COVER”...
Page 214 BALANCER REMOVAL POINTS Balancer shaft drive gear and balancer shaft driven gear 1. Straighten the lock washer tab. 2. Loosen: • Nut (primary drive gear) 1 • Nut (balancer shaft driven gear) 2 NOTE: Place an aluminum plate a between the teeth of the balancer shaft drive gear 3 and driven gear 4.
Page 215 BALANCER ASSEMBLY AND INSTALLATION Balancer shaft, balancer shaft drive gear and balancer shaft driven gear 1. Install: • Balancer shaft 1 NOTE: • Apply the engine oil on the bearing. • When installing the balancer shaft, align the center a of the balancer shaft weight along the line connecting the centers of the crank- shaft and balancer shaft.
Page 216: Oil Pump
OIL PUMP OIL PUMP 1 Oil pump removal 2 Oil pump disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks OIL PUMP REMOVAL AND DIS- ASSEMBLY Preparation for removal Primary driven gear Refer to “CLUTCH” section. Right crankcase cover Refer to “OIL FILTER ELEMENT, WATER PUMP AND RIGHT CRANK- CASE COVER”...
Page 217 OIL PUMP Extent of removal Order Part name Q’ty Remarks Dowel pin Washer Oil pump drive shaft Rotor housing 5 - 64...
Page 218 OIL PUMP INSPECTION Oil pump 1. Inspect: • Oil pump drive gear 1 • Oil pump drive shaft 2 • Rotor housing 3 • Oil pump cover 4 Cracks/wear/damage → Replace. 2. Measure: • Tip clearance a (between the inner rotor 1 and outer rotor 2) •...
Page 219 OIL PUMP ASSEMBLY AND INSTALLATION Oil pump 1. Install: • Oil pump drive shaft 1 • Washer 2 • Dowel pin 3 • Inner rotor 1 4 NOTE: • Apply the engine oil on the oil pump drive shaft and inner rotor 1. •...
Page 220 OIL PUMP 4. Install: • Outer rotor 2 1 • Dowel pin 2 • Oil pump assembly 3 • Bolt (oil pump assembly) [L = 25 mm (0.94 in)] 4 10 Nm (1.0 m · kg, 7.2 ft · lb) •...
Page 221: Kick Shaft And Shift Shaft
KICK SHAFT AND SHIFT SHAFT KICK SHAFT AND SHIFT SHAFT 1 Kick shaft removal 2 Kick shaft disassembly Extent of removal: 3 Shift shaft removal 4 Segment removal Extent of removal Order Part name Q’ty Remarks KICK SHAFT AND SHIFT SHAFT REMOVAL Preparation for removal Oil pump...
Page 222 KICK SHAFT AND SHIFT SHAFT Extent of removal Order Part name Q’ty Remarks Torsion spring Roller Shift guide Refer to “REMOVAL POINTS”. Shift lever assembly Shift lever Pawl Pawl pin Spring Bolt (stopper lever) Stopper lever Torsion spring Segment Refer to “REMOVAL POINTS”. 5 - 69...
Page 223 KICK SHAFT AND SHIFT SHAFT REMOVAL POINTS Kick shaft assembly 1. Remove: • Kick shaft assembly 1 NOTE: Unhook the torsion spring 2 from the hole a in the crankcase. EC4C3101 Shift guide and shift lever assembly 1. Remove: • Bolt (shift guide) •...
Page 224 KICK SHAFT AND SHIFT SHAFT EC4B4400 Shift shaft 1. Inspect: • Shift shaft 1 Bend/damage → Replace. • Spring 2 Broken → Replace. EC4C4100 Shift guide and shift lever assembly 1. Inspect: • Shift guide 1 • Shift lever 2 •...
Page 225 KICK SHAFT AND SHIFT SHAFT EC4B5111 Stopper lever 1. Install: • Torsion spring 1 • Stopper lever 2 • Bolt (stopper lever) 3 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Align the stopper lever roller with the slot on segment.
Page 226 KICK SHAFT AND SHIFT SHAFT Shift shaft 1. Install: • Roller 1 • Collar 2 • Torsion spring 3 • Shift shaft 4 NOTE: Apply the engine oil on the roller and shift shaft. 2. Install: • Shift pedal Refer to “AC MAGNETO AND STARTER CLUTCH”...
Page 227 KICK SHAFT AND SHIFT SHAFT 3. Install: • Spring guide 1 NOTE: Slide the spring guide into the kick shaft, make sure the groove a in the spring guide fits on the stopper of the torsion spring. 4. Install: • Kick shaft assembly 1 •...
Page 228: Ac Magneto And Starter Clutch
AC MAGNETO AND STARTER CLUTCH AC MAGNETO AND STARTER CLUTCH 1 Starter clutch/wheel gear removal 2 Rotor removal Extent of removal: 3 Pickup coil/stator removal Extent of removal Order Part name Q’ty Remarks AC MAGNETO AND STATOR REMOVAL Preparation for removal Drain the engine oil.
Page 229 AC MAGNETO AND STARTER CLUTCH Extent of removal Order Part name Q’ty Remarks Nut (rotor) Refer to NOTE. Rotor Use special tool. Refer to “REMOVAL POINTS”. Woodruff key Starter clutch drive gear Starter clutch assembly cover Starter clutch Refer to “REMOVAL POINTS”. Bearing Washer Idle gear plate...
Page 230 AC MAGNETO AND STARTER CLUTCH EC4L3000 REMOVAL POINTS Rotor 1. Remove: • Nut (rotor) 1 • Washer Use the sheave holder 2. Sheave holder: YS-1880-A/90890-01701 2. Remove: • Rotor 1 Use the rotor puller 2. Rotor puller: YM-04141/90890-04141 Starter clutch 1.
Page 231 AC MAGNETO AND STARTER CLUTCH EC4L4200 Woodruff key 1. Inspect: • Woodruff key 1 Damage → Replace. Starter clutch 1. Check: • Starter clutch Damage/wear → Replace. 2. Check: • Idle gear • Starter clutch drive gear Pitting/burrs/chips/roughness/wear → Replace the defective parts. 3.
Page 232 NOTE: Apply the sealant to the grommet of the AC magneto lead. YAMAHA Bond No. 1215 ® (ThreeBond No. 1215): 90890-85505 3. Install: •...
Page 233 AC MAGNETO AND STARTER CLUTCH 5. Install: • Washer 1 • Bearing 2 • Starter clutch drive gear 3 • Washer 4 NOTE: Apply the engine oil on the washer, bearing and starter clutch drive gear inner circumfer- ence. 6. Install: •...
Page 234 AC MAGNETO AND STARTER CLUTCH 9. Install: • Washer (rotor) • Nut (rotor) 1 65 Nm (6.5 m · kg, 47 ft · lb) Use the sheave holder 2. NOTE: Tighten the rotor nut to 65 Nm (6.5 m · kg, 47 ft ·...
Page 235 AC MAGNETO AND STARTER CLUTCH 12. Install: • Cover (idle gear 1) 1 • Bolt 2 10 Nm (1.0 m · kg, 7.2 ft · lb) NOTE: Install the cover (idle gear 1) with its mark a facing upward. 13. Install: •...
Page 236: Engine Removal
ENGINE REMOVAL EC4M0000 ENGINE REMOVAL Extent of removal Order Part name Q’ty Remarks ENGINE REMOVAL Preparation for removal Hold the machine by placing the WARNING suitable stand under the frame. Support the machine securely so there is no danger of it falling over. Drain the engine oil.
Page 237 ENGINE REMOVAL 1 Engine removal Extent of removal: Extent of removal Order Part name Q’ty Remarks Ignition coil Disconnect the AC magneto lead. Starter motor lead Disconnect at the starter motor side. Negative battery lead Disconnect at the engine side. Right engine guard Neutral switch Drive chain sprocket cover...
Page 238 ENGINE REMOVAL EC4M3000 REMOVAL POINTS EC4F3100 Drive sprocket 1. Remove: • Nut (drive sprocket) 1 • Lock washer 2 NOTE: • Straighten the lock washer tab. • Loosen the nut while applying the rear brake. 2. Remove: • Drive sprocket 1 •...
Page 239 ENGINE REMOVAL EC4M5000 ASSEMBLY AND INSTALLATION Engine installation 1. Install: • Engine 1 Install the engine from right side. • Pivot shaft 2 80 Nm (8.0 m · kg, 58 ft · lb) • Engine mounting bolt (lower) 3 69 Nm (6.9 m · kg, 50 ft · lb) •...
Page 240 ENGINE REMOVAL Drive sprocket 1. Install: • Drive sprocket 1 • Drive chain 2 NOTE: Install the drive sprocket together with the drive chain. 2. Install: • Lock washer 1 • Nut (drive sprocket) 2 75 Nm (7.5 m · kg, 54 ft · lb) NOTE: Tighten the nut while applying the rear brake.
Page 241 ENGINE REMOVAL 2. Install: • Spring 1 • Pin 2 • O-ring 3 • Neutral switch 4 • Screw (neutral switch) 5 4 Nm (0.4 m · kg, 2.9 ft · lb) NOTE: Apply the lithium soap base grease on the O- ring.
Page 242 CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT 1 Crankcase separation 2 Crankshaft removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CRANKCASE AND CRANK- SHAFT REMOVAL Preparation for removal Engine Refer to “ENGINE REMOVAL” section. Piston Refer to “CYLINDER AND PISTON” sec- tion.
Page 243: Crankcase And Crankshaft
CRANKCASE AND CRANKSHAFT Extent of removal Order Part name Q’ty Remarks Bolt [L = 45 mm (1.77 in)] Bolt [L = 55 mm (2.17 in)] Bolt [L = 70 mm (2.76 in)] Hose guide Refer to “REMOVAL POINTS”. Clutch cable holder Right crankcase Left crankcase Oil strainer...
Page 244 CRANKCASE AND CRANKSHAFT CRANKCASE BEARING 1 Crankcase bearing removal Extent of removal: Extent of removal Order Part name Q’ty Remarks CRANKCASE BEARING REMOVAL Preparation for removal Transmission Refer to “TRANSMISSION, SHIFT Shift cam and shift fork CAM AND SHIFT FORK” section. Oil seal Bearing Refer to “REMOVAL POINTS”.
Page 245 CRANKCASE AND CRANKSHAFT REMOVAL POINTS Crankcase 1. Separate: • Right crankcase • Left crankcase Separation steps: • Remove the crankcase bolts 1, hose guide 2 and clutch cable holder 3. NOTE: Loosen each bolt 1/4 of a turn at a time and after all the bolts are loosened, remove them.
Page 246 CRANKCASE AND CRANKSHAFT Crankshaft 1. Remove: • Crankshaft 1 Use the crankcase separating tool 2. Crankcase separating tool: YU-1135-A/90890-01135 CAUTION: Do not use a hammer to drive out the crankshaft. Crankcase bearing 1. Remove: • Bearing 1 NOTE: • Remove the bearing from the crankcase by pressing its inner race.
Page 247 CRANKCASE AND CRANKSHAFT EC4N4201 Crankshaft 1. Measure: • Runout limit a • Small end free play limit b • Connecting rod big end side clearance c • Crank width d Out of specification → Replace. Use the dial gauge and a thickness gauge.
Page 248 CRANKCASE AND CRANKSHAFT EC4N5000 ASSEMBLY AND INSTALLATION Crankcase bearing 1. Install: • Bearing • Bearing stopper • Bolt (bearing stopper) 10 Nm (1.0 m · kg, 7.2 ft · lb) • Screw (bearing stopper) 10 Nm (1.0 m · kg, 7.2 ft · lb) •...
Page 249 • Oil strainer 1 • Bolt (oil strainer) 2 10 Nm (1.0 m · kg, 7.2 ft · lb) 4. Apply: • Sealant On the right crankcase 1. YAMAHA Bond No. 1215 ® (ThreeBond No. 1215): 90890-85505 NOTE: Clean the contacting surface of left and right crankcase before applying the sealant.
Page 250 CRANKCASE AND CRANKSHAFT 6. Tighten: • Hose guide 1 • Clutch cable holder 2 • Bolt (crankcase) 3 12 Nm (1.2 m · kg, 8.7 ft · lb) NOTE: Tighten the crankcase tightening bolts in stage, using a crisscross pattern. 7.
Page 251: Transmission, Shift Cam And Shift Fork
TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H0000 TRANSMISSION, SHIFT CAM AND SHIFT FORK 1 Shift fork, shift cam, main axle and drive axle removal Extent of removal: Extent of removal Order Part name Q’ty Remarks TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVAL Preparation for removal Engine Refer to “ENGINE REMOVAL”...
Page 252 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H3000 REMOVAL POINTS EC4H3230 Transmission 1. Remove: • Main axle 1 • Drive axle 2 • Shift cam • Shift fork 3 • Shift fork 2 • Shift fork 1 NOTE: • Remove assembly with the collar 3 installed to the crankcase.
Page 253 TRANSMISSION, SHIFT CAM AND SHIFT FORK EC4H4810 Shift fork, shift cam and segment 1. Inspect: • Shift fork 1 Wear/damage/scratches → Replace. 2. Inspect: • Shift cam 1 • Segment 2 Wear/damage → Replace. 3. Check: • Shift fork movement Unsmooth operation →...
Page 254 TRANSMISSION, SHIFT CAM AND SHIFT FORK 2. Install: • 2nd wheel gear (28T) 1 • 4th wheel gear (25T) 2 • 3rd wheel gear (28T) 3 • 5th wheel gear (22T) 4 • 1st wheel gear (31T) 5 • O-ring 6 To drive axle 7.
Page 255 TRANSMISSION, SHIFT CAM AND SHIFT FORK 5. Install: • Shift fork 1 (L) 1 • Shift fork 2 (C) 2 • Shift fork 3 (R) 3 • Shift cam 4 To main axle and drive axle. NOTE: • Apply the molybdenum disulfide oil on the shift fork grooves.
Page 256: Front Wheel And Rear Wheel
This section is intended for those who have basic knowledge and skill concerning the EC590000 servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) FRONT WHEEL Those who have little knowledge and skill concerning servicing are requested not to...
Page 257 CHAS FRONT WHEEL AND REAR WHEEL EC598100 REAR WHEEL 1 Rear wheel removal 2 Wheel bearing removal Extent of removal: 3 Brake disc removal Extent of removal Order Part name Q’ty Remarks REAR WHEEL REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.
Page 258 CHAS FRONT WHEEL AND REAR WHEEL EC593000 REMOVAL POINTS EC523101 Rear wheel 1. Remove: • Wheel 1 NOTE: Push the wheel forward and remove the drive chain 2. EC513201 Wheel bearing (if necessary) 1. Remove: • Bearing 1 NOTE: Remove the bearing using a general bearing puller 2.
Page 259 CHAS FRONT WHEEL AND REAR WHEEL EC514200 Wheel axle 1. Measure: • Wheel axle bends Out of specification → Replace. Use the dial gauge 1. Wheel axle bending limit: 0.5 mm (0.020 in) NOTE: The bending value is shown by one half of the dial gauge reading.
Page 260 CHAS FRONT WHEEL AND REAR WHEEL EC595000 ASSEMBLY AND INSTALLATION Front wheel 1. Install: • Bearing (left) 1 • Spacer 2 • Bearing (right) 3 • Oil seal 4 NOTE: • Apply the lithium soap base grease on the bearing and oil seal lip when installing. •...
Page 261 CHAS FRONT WHEEL AND REAR WHEEL 5. Install: • Wheel NOTE: • Install the brake disc 1 between the brake pads 2 correctly. • Make sure that the projections a in the speed sensor fits over the stopper b on the front fork inner tube.
Page 262 CHAS FRONT WHEEL AND REAR WHEEL 8. Tighten: • Bolt (axle holder) 1 23 Nm (2.3 m · kg, 17 ft · lb) NOTE: Before tightening the bolt, fit the wheel axle to the axle holder by stroking the front fork sev- eral times with the front brake applied.
Page 263 CHAS FRONT WHEEL AND REAR WHEEL 2. Install: • Brake disc 1 • Bolt (brake disc) 2 14 Nm (1.4 m · kg, 10 ft · lb) NOTE: Tighten the bolts in stage, using a crisscross pattern. 3. Install: • Rear wheel sprocket 1 •...
Page 264 CHAS FRONT WHEEL AND REAR WHEEL 7. Install: • Left drive chain puller 1 • Wheel axle 2 NOTE: • Install the left drive chain puller, and insert the wheel axle from left side. • Apply the lithium soap base grease on the wheel axle.
Page 265: Front Brake And Rear Brake
CHAS FRONT BRAKE AND REAR BRAKE EC5A0000 FRONT BRAKE AND REAR BRAKE EC5A8000 FRONT BRAKE 1 Brake hose removal 2 Brake caliper removal Extent of removal: 3 Brake master cylinder removal Extent of removal Order Part name Q’ty Remarks FRONT BRAKE REMOVAL WARNING Preparation for removal Hold the machine by placing the...
Page 266 CHAS FRONT BRAKE AND REAR BRAKE EC5A8100 REAR BRAKE 1 Brake master cylinder removal 2 Brake hose removal Extent of removal: 3 Brake caliper removal Extent of removal Order Part name Q’ty Remarks REAR BRAKE REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.
Page 267 CHAS FRONT BRAKE AND REAR BRAKE BRAKE CALIPER DISASSEMBLY È Front É Rear 1 Front brake caliper disassembly 2 Rear brake caliper disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks BRAKE CALIPER DISASSEM- Pad pin Brake pad Pad support Brake caliper piston Dust seal...
Page 268 CHAS FRONT BRAKE AND REAR BRAKE BRAKE MASTER CYLINDER DISASSEMBLY È Front É Rear 1 Front brake master cylinder disassembly 2 Rear brake master cylinder disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks BRAKE MASTER CYLINDER DISASSEMBLY Brake master cylinder cap Diaphragm...
Page 269 CHAS FRONT BRAKE AND REAR BRAKE EC5A3000 È REMOVAL POINTS Brake fluid 1. Remove: [Front] • Brake master cylinder cap 1 [Rear] • Brake master cylinder cap 1 • Protector NOTE: Do not remove the diaphragm. É È Front É Rear 2.
Page 270 CHAS FRONT BRAKE AND REAR BRAKE Brake caliper piston seal kit È 1. Remove: • Dust seal 1 • Piston seal 2 NOTE: Remove the piston seals and dust seals by pushing them with a finger. CAUTION: Never attempt to pry out piston seals and É...
Page 271 CHAS FRONT BRAKE AND REAR BRAKE 4. Inspect: È É • Brake master cylinder piston 1 • Brake master cylinder cup 2 Wear/damage/score marks → Replace brake master cylinder kit. È Front É Rear Brake caliper È É 1. Inspect: •...
Page 272 CHAS FRONT BRAKE AND REAR BRAKE Brake caliper piston È 1. Clean: • Brake caliper • Piston seal • Dust seal • Brake caliper piston Clean them with brake fluid. 2. Install: • Piston seal 1 • Dust seal 2 É...
Page 273 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: • Brake caliper 1 • Bolt (brake caliper) 2 23 Nm (2.3 m · kg, 17 ft · lb) 3. Tighten: • Pad pin 3 18 Nm (1.8 m · kg, 13 ft · lb) 4.
Page 274 CHAS FRONT BRAKE AND REAR BRAKE 3. Install: • Brake caliper 1 • Rear wheel 2 Refer to “FRONT WHEEL AND REAR WHEEL” section. 4. Tighten: • Pad pin 3 18 Nm (1.8 m · kg, 13 ft · lb) 5.
Page 275 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: È [Front] • Brake master cylinder kit 1 • Washer 2 • Circlip 3 • Brake master cylinder boot 4 To brake master cylinder 5. [Rear] • Brake master cylinder kit 1 •...
Page 276 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: • Brake lever 1 • Bolt (brake lever) 2 6 Nm (0.6 m · kg, 4.3 ft · lb) • Nut (brake lever) 3 6 Nm (0.6 m · kg, 4.3 ft · lb) NOTE: Apply the lithium soap base grease on the brake lever sliding surface, bolt and contacting...
Page 277 CHAS FRONT BRAKE AND REAR BRAKE 4. Install: • Pin 1 • Washer 2 • Cotter pin 3 NOTE: After installing, check the brake pedal height. Refer to “REAR BRAKE ADJUSTMENT” sec- tion in the CHAPTER 3. Front brake hose 1.
Page 278 CHAS FRONT BRAKE AND REAR BRAKE 4. Pass the brake hose through the front brake hose guides 1. 5. Install: • Copper washer 1 • Brake hose 2 • Union bolt 3 30 Nm (3.0 m · kg, 22 ft · lb) WARNING Always use new copper washers.
Page 279 CHAS FRONT BRAKE AND REAR BRAKE 2. Install: • Brake hose holder 1 • Screw (brake hose holder) 2 2 Nm (0.2 m · kg, 1.4 ft · lb) CAUTION: After installing the brake hose holders, make sure the brake hose does not contact the spring (rear shock absorber).
Page 280 CHAS FRONT BRAKE AND REAR BRAKE 2. Air bleed: • Brake system Refer to “BRAKE SYSTEM AIR BLEED- ING” section in the CHAPTER 3. 3. Inspect: • Brake fluid level Fluid at lower level → Fill up. Refer to “BRAKE FLUID LEVEL INSPEC- TION”...
Page 281: Front Fork
CHAS FRONT FORK EC550000 FRONT FORK 1 Front fork removal Extent of removal: Extent of removal Order Part name Q’ty Remarks FRONT FORK REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.
Page 282 CHAS FRONT FORK EC558000 FRONT FORK DISASSEMBLY 1 Oil seal removal 2 Damper rod removal Extent of removal: Extent of removal Order Part name Q’ty Remarks FRONT FORK DISASSEMBLY Front fork cap bolt Refer to “REMOVAL POINTS”. Fork spring Drain the fork oil. Dust seal Stopper ring Refer to “REMOVAL POINTS”.
Page 283 CHAS FRONT FORK EC556000 HANDLING NOTE NOTE: The front fork requires careful attention. So it is recommended that the front fork be maintained at the dealers. CAUTION: To prevent an accidental explosion of air, following instructions should observed: • The front fork with a built-in piston rod has a very sophisticated internal construction and is particularly sensitive to foreign material.
Page 284 CHAS FRONT FORK EC553201 Inner tube 1. Remove: • Dust seal 1 • Stopper ring 2 Using slotted-head screwdriver. CAUTION: Take care not to scratch the inner tube. 2. Remove: • Inner tube 1 Oil seal removal steps: • Push in slowly a the inner tube just before it bottoms out and then pull it back quickly •...
Page 285 CHAS FRONT FORK EC554200 Base valve 1. Inspect: • Valve assembly 1 Wear/damage → Replace. • O-ring 2 Damage → Replace. EC554400 Fork spring 1. Measure: • Fork spring free length a Out of specification → Replace. Fork spring free length: 460 mm (18.1 in) <Limit>: 455 mm (17.9 in) EC554502...
Page 286 CHAS FRONT FORK Front fork cap bolt 1. Inspect: • Front fork cap bolt 1 • O-ring 2 • Air bleed screw 3 Wear/damage → Replace. EC555000 ASSEMBLY AND INSTALLATION Front fork assembly 1. Wash the all parts in a clean solvent. 2.
Page 287 CHAS FRONT FORK 5. Install: • Spring guide 1 • Locknut 2 To damper rod 3. NOTE: • Install the spring guide with its smaller dia. end a facing downward. • With its thread b facing upward, fully finger tighten the locknut onto the damper rod. 6.
Page 288 CHAS FRONT FORK 9. Install: • Slide metal 1 • Oil seal washer 2 To outer tube slot. NOTE: Press the slide metal into the outer tube with fork seal driver 3. Fork seal driver: YM-A0948/90890-01502 10. Install: • Oil seal 1 NOTE: Press the oil seal into the outer tube with fork seal driver 2.
Page 289 CHAS FRONT FORK 13. Check: • Inner tube smooth movement Tightness/binding/rough spots → Repeat the steps 2 to 12. 14. Compress the front fork fully. 15. Fill: • Front fork oil Until outer tube top surface with recom- mended fork oil 1. Recommended oil: Suspension oil “S1”...
Page 290 CHAS FRONT FORK 19. Wait ten minutes until the air bubbles have been removed from the front fork, and the oil has dispense evenly in system before setting recommended oil level. NOTE: Fill with the fork oil up to the top end of the outer tube, or the fork oil will not spread over to every part of the front forks, thus making it impossible to obtain the correct level.
Page 291 CHAS FRONT FORK 21. Measure: • Distance a Out of specification → Turn into the lock- nut. Distance a: 18 mm (0.71 in) or more Between damper rod 1 top and locknut 2 top. 22. Loosen: • Rebound damping adjuster 1 NOTE: •...
Page 292 CHAS FRONT FORK 26. Install: • Front fork cap bolt 1 To outer tube. NOTE: Temporarily tighten the cap bolt. 27. Install: • Protector guide 1 NOTE: Install the protector guide with its wider side a facing downward. Installation 1. Install: •...
Page 293 CHAS FRONT FORK 5. Install: • Speed sensor lead 1 • Plate 1 2 • Bolt (plate 1) 3 4 Nm (0.4 m · kg, 2.9 ft · lb) To right protector 4. NOTE: Install the speed sensor lead so that its paint a directs as shown and align the bottom b of the plate 1 with the same paint.
Page 294: Handlebar
CHAS HANDLEBAR EC5B0000 HANDLEBAR 1 Handlebar removal Extent of removal: Extent of removal Order Part name Q’ty Remarks HANDLEBAR REMOVAL Preparation for removal 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.
Page 295 CHAS HANDLEBAR EC5B3000 REMOVAL POINTS Brake master cylinder 1. Remove: • Brake master cylinder bracket 1 • Brake master cylinder 2 CAUTION: • Do not let the brake master cylinder hang on the brake hose. • Keep the brake master cylinder cap side horizontal to prevent air from coming in.
Page 296 CHAS HANDLEBAR EC5B5000 ASSEMBLY AND INSTALLATION Handlebar 1. Install: • Handlebar lower holder 1 • Washer 2 • Nut (handlebar lower holder) 3 NOTE: • Install the handlebar lower holder with its side having the greater distance a from the mounting bolt center facing forward.
Page 297 CHAS HANDLEBAR 3. Tighten: • Nut (handlebar lower holder) 1 40 Nm (4.0 m · kg, 29 ft · lb) 4. Install: • Left grip 1 Apply the adhesive to the handlebar 2. NOTE: • Before applying the adhesive, wipe off grease or oil on the handlebar surface a with a lacquer thinner.
Page 298 CHAS HANDLEBAR 7. Install: • Throttle cables 1 To tube guide 2. NOTE: Apply the lithium soap base grease on the throttle cable end and tube guide cable wind- ing portion. 8. Install: • Throttle cable cap 1 • Screw (throttle cable cap) 2 4 Nm (0.4 m ·...
Page 299 CHAS HANDLEBAR 10. Install: • Start switch 1 • Brake master cylinder 2 • Brake master cylinder bracket 3 • Bolt (brake master cylinder bracket) 4 9 Nm (0.9 m · kg, 6.5 ft · lb) • Clamp 5 NOTE: •...
Page 300 CHAS HANDLEBAR 13. Adjust: • Clutch lever free play Refer to “CLUTCH ADJUSTMENT” sec- tion in the CHAPTER 3. • Hot starter lever free play Refer “HOT STARTER LEVER ADJUSTMENT” section in the CHAPTER 14. Fasten the hot starter cable 1 and clutch cable 2 with a clamp 3.
Page 301: Steering
CHAS STEERING EC560000 STEERING 1 Lower bracket removal 2 Bearing removal Extent of removal: Extent of removal Order Part name Q’ty Remarks STEERING REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine.
Page 302 CHAS STEERING Extent of removal Order Part name Q’ty Remarks Bearing race cover Upper bearing Lower bearing Refer to “REMOVAL POINTS”. Bearing race 6 - 47...
Page 303 CHAS STEERING EC563000 REMOVAL POINTS Steering ring nut 1. Remove: • Steering ring nut 1 Use the steering nut wrench 2. Steering nut wrench: YU-33975/90890-01403 WARNING Support the steering stem so that it may not fall down. Lower bearing 1. Remove: •...
Page 304 CHAS STEERING Bearing and bearing race 1. Wash the bearings and bearing races with a solvent. 2. Inspect: • Bearing 1 • Bearing race Pitting/damage → Replace bearings and bearing races as a set. Install the bearing in the bearing races. Spin the bearings by hand.
Page 305 CHAS STEERING 4. Install: • Steering ring nut 1 7 Nm (0.7 m · kg, 5.1 ft · lb) Tighten the steering ring nut using the steering nut wrench 2. Refer to “STEERING HEAD INSPEC- TION AND ADJUSTMENT” section in the CHAPTER 3.
Page 306 CHAS STEERING 9. Install: • Washer 1 • Steering stem nut 2 145 Nm (14.5 m · kg, 105 ft · lb) 10. Install: • Steering stem cap 1 11. After tightening the nut, check the steering for smooth movement. If not, adjust the steering by loosening the steering ring nut little by little.
Page 307 CHAS STEERING 14. Install: • Multi-function display bracket 1 7 Nm (0.7 m · kg, 5.1 ft · lb) • Multi-function display 2 4 Nm (0.4 m · kg, 2.9 ft · lb) NOTE: Pass the throttle cables 3, clutch cable 4 and hot starter cable 5 between the multi-function display bracket and upper bracket.
Page 308: Swingarm
CHAS SWINGARM EC570000 SWINGARM 1 Swingarm removal Extent of removal: Extent of removal Order Part name Q’ty Remarks SWINGARM REMOVAL WARNING Preparation for removal Hold the machine by placing the Support the machine securely so there is no suitable stand under the engine. danger of it falling over.
Page 309 CHAS SWINGARM EC578000 SWINGARM DISASSEMBLY 1 Swingarm disassembly 2 Connecting rod removal and disassembly Extent of removal: 3 Relay arm removal and disassembly Extent of removal Order Part name Q’ty Remarks SWINGARM DISASSEMBLY Refer to “REMOVAL POINTS”. Relay arm Connecting rod Collar Oil seal Thrust bearing...
Page 310 CHAS SWINGARM EC573000 REMOVAL POINTS 1. Remove: • Left cap 1 NOTE: Remove with a slotted-head screwdriver inserted under the mark a on the left cap. EC573200 Bearing 1. Remove: • Bearing 1 NOTE: Remove the bearing by pressing its outer race. INSPECTION Wash the bearings, bushings and collars in a solvent.
Page 311 CHAS SWINGARM Connecting rod 1. Inspect: • Bearing 1 • Collar 2 Free play exists/unsmooth revolution/rust → Replace bearing and collar as a set. 2. Inspect: • Oil seal 3 Damage → Replace. EC575000 ASSEMBLY AND INSTALLATION Bearing and oil seal 1.
Page 312 CHAS SWINGARM 3. Install: • Bearing 1 • Oil seal 2 To connecting rod. NOTE: • Apply the molybdenum disulfide grease on the bearing when installing. • Install the bearing by pressing it on the side having the manufacture’s marks or numbers. Installed depth of bearings a: Zero mm (Zero in) Swingarm...
Page 313 CHAS SWINGARM 3. Install: • Collar 1 To connecting rod 2. NOTE: Apply the molybdenum disulfide grease on the collar and oil seal lips. 4. Install: • Connecting rod 1 • Bolt (connecting rod) 2 • Washer 3 • Nut (connecting rod) 4 80 Nm (8.0 m ·...
Page 314 CHAS SWINGARM 8. Install: • Bolt (connecting rod) 1 • Washer 2 • Nut (connecting rod) 3 NOTE: • Apply the molybdenum disulfide grease on the bolt. • Do not tighten the nut yet. 9. Install: • Bolt (rear shock absorber-relay arm) 1 •...
Page 315 CHAS SWINGARM 13. Install: • Bolt (lower chain tensioner) 1 • Washer 2 • Collar 3 • Lower chain tensioner 4 • Nut (lower chain tensioner) 5 20 Nm (2.0 m · kg, 14 ft · lb) 14. Install: • Drive chain support 1 •...
Page 316 CHAS REAR SHOCK ABSORBER EC580000 REAR SHOCK ABSORBER 1 Rear shock absorber removal 2 Rear shock absorber disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks REAR SHOCK ABSORBER WARNING REMOVAL Support the machine securely so there is no Preparation for removal Hold the machine by placing the danger of it falling over.
Page 317 CHAS REAR SHOCK ABSORBER Extent of removal Order Part name Q’ty Remarks Disconnect the starter relay coupler. Starter motor lead Disconnect at the starter relay side. Locking tie Taillight coupler Starting circuit cut-off relay coupler Plastic band Clamp (air filter joint) Only loosening.
Page 318 1. Wear eye protection to prevent eye damage from escaping gas and/or metal chips. WARNING To dispose of a damaged or worn-out rear shock absorber, take the unit to your Yamaha dealer for this disposal procedure. 6 - 63...
Page 319: Rear Shock Absorber
CHAS REAR SHOCK ABSORBER EC583000 REMOVAL POINTS EC583320 Bearing 1. Remove: • Stopper ring (upper bearing) 1 NOTE: Press in the bearing while pressing its outer race and remove the stopper ring. 2. Remove: • Upper bearing 1 NOTE: Remove the bearing by pressing its outer race. 3.
Page 320 CHAS REAR SHOCK ABSORBER EC585000 ASSEMBLY AND INSTALLATION EC585300 Bearing 1. Install: • Upper bearing 1 NOTE: Install the bearing parallel until the stopper ring groove appears by pressing its outer race. CAUTION: Do not apply the grease on the bearing outer race because it will wear the rear shock absorber surface on which the bear- ing is press fitted.
Page 321 CHAS REAR SHOCK ABSORBER 2. Tighten: • Adjuster 1 3. Adjust: • Spring length (installed) Refer to “REAR SHOCK ABSORBER SPRING PRELOAD ADJUSTMENT” sec- tion in the CHAPTER 3. 4. Tighten: • Locknut 1 Rear shock absorber 1. Install: • Dust seal 1 •...
Page 322 CHAS REAR SHOCK ABSORBER 2. Install: • Bushing 1 • Collar 2 • Dust seal 3 NOTE: • Apply the molybdenum disulfide grease on the bearing and dust seal lips. • Install the dust seals with their lips facing out- ward.
Page 323 CHAS REAR SHOCK ABSORBER 8. Install: • Plastic band 1 • Starting circuit cut-off relay coupler 2 • Taillight coupler 3 • Locking tie 4 6 - 68...
Page 324: Electrical
This section is intended for those who have basic knowledge and EC610000 skill concerning the servicing of Yamaha motorcycles (e.g., ELECTRICAL COMPONENTS Yamaha dealers, service engineers, etc.) Those who have little AND WIRING DIAGRAM knowledge and skill concerning servicing are requested not to undertake inspection, adjustment, disassembly, or reassembly EC611000 only by reference to this manual.
Page 325: Map-Controlled Cdi Unit
– ELEC MAP-CONTROLLED CDI UNIT MAP-CONTROLLED CDI UNIT A map-controlled, CDI ignition system is used in the WR250F. The microcomputer in the CDI unit detects the engine speed and throttle position, thus determining the optimum ignition timing through the entire operating range. In this way, quick throttle response can be achieved according to various riding conditions.
Page 326: Ignition System
– ELEC IGNITION SYSTEM EC620000 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 Replace fuse and *1 Check fuse.
Page 327 – ELEC IGNITION SYSTEM SPARK GAP TEST È 1. Disconnect the ignition coil from spark plug. 2. Remove the ignition coil cap. 3. Connect the dynamic spark tester 1 (igni- tion checker 2) as shown. • Ignition coil 3 • Spark plug 4 È...
Page 328 – ELEC IGNITION SYSTEM 2. Inspect: • Rubber part a Tears/damage → Replace. MAIN SWITCH INSPECTION 1. Inspect: • Main switch conduct Tester (+) lead → Red lead 1 Tester (–) lead → Brown lead 2 Tester selector position Ω × 1 Continuous while the main switch is moved to “OFF”...
Page 329 – ELEC IGNITION SYSTEM EC626002 IGNITION COIL INSPECTION 1. Remove the ignition coil cap. 2. Inspect: • Primary coil resistance Out of specification → Replace. Tester (+) lead → Orange lead 1 Tester (–) lead → Black lead 2 Primary coil Tester selector resistance position...
Page 330 – ELEC IGNITION SYSTEM AC MAGNETO INSPECTION 1. Inspect: • Pickup coil resistance Out of specification → Replace. Tester (+) lead → Red lead 1 Tester (–) lead → White lead 2 Pickup coil Tester selector resistance position 248 ~ 372 Ω at Ω...
Page 331: Electric Starting System
– ELEC ELECTRIC STARTING SYSTEM ELECTRIC STARTING SYSTEM STARTING CIRCUIT CUT-OFF SYSTEM OPERATION If the main switch is set to “ON”, the starter motor can only operate if at least one of the fol- lowing conditions is met: • The transmission is in neutral (the neutral switch is closed).
Page 332 – ELEC ELECTRIC STARTING SYSTEM INSPECTION STEPS If the starter motor will not operate, use the following inspection steps. No good Replace fuse and *1 Check fuse. check wire harness. No good *2 Check battery. Recharge or replace. No good Check each coupler and Repair or replace.
Page 333 – ELEC ELECTRIC STARTING SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. STARTER MOTOR OPERATION 1. Connect the positive battery terminal 1 and starter motor lead 2 with a jumper lead 3.
Page 334 – ELEC ELECTRIC STARTING SYSTEM STARTER RELAY INSPECTION 1. Remove: • Starter relay 2. Inspect: • Starter relay conduct Use 12 V battery. Battery (+) lead → Starter relay terminal 1 Battery (–) lead → Starter relay terminal 2 Tester (+) lead → Starter relay terminal 3 Tester (–) lead →...
Page 335 – ELEC ELECTRIC STARTING SYSTEM DIODE INSPECTION 1. Remove the diode from wire harness. 2. Inspect: • Diode continuity Use pocket tester (tester selection position Ω × 1) Tester (+) → Blue/Red terminal 1 Continuous Tester (–) → Sky blue terminal 2 Tester (+) →...
Page 336 – ELEC ELECTRIC STARTING SYSTEM STARTER MOTOR 1 Starter motor disassembly Extent of removal: Extent of removal Order Part name Q’ty Remarks STARTER MOTOR REMOVAL Preparation for removal Exhaust pipe Refer “EXHAUST PIPE SILENCER” section in the CHAPTER 3. Starter motor STARTER MOTOR DISASSEM- Starter motor front cover Washer (starter motor front cover)
Page 337 – ELEC ELECTRIC STARTING SYSTEM INSPECTION AND REPAIR 1. Check: • Commutator Dirt → Clean with 600 grit sandpaper. 2. Measure: • Commutator diameter a Out of specification → Replace the starter motor. Min. commutator diameter: 16.6 mm (0.65 in) 3.
Page 338 – ELEC ELECTRIC STARTING SYSTEM 5. Measure: • Brush length a Out of specification → Replace the brushes as a set. Min. brush length: 3.5 mm (0.14 in) 6. Measure: • Brush spring force Out of specification → Replace the brush springs as a set.
Page 339 – ELEC ELECTRIC STARTING SYSTEM 4. Install: • Gasket 1 • Circlip • Plain washer 2 • Washer (starter motor front cover) 3 • Starter motor front cover 4 NOTE: • For installation, align the projections on the washer with the slots in the front cover. •...
Page 340: Charging System
– ELEC CHARGING SYSTEM EC680000 CHARGING SYSTEM EC681001 INSPECTION STEPS If the battery is not charged, use the following inspection steps. No good Replace fuse and *1 Check fuse. check wire harness. No good *2 Check battery. Recharge or replace. No good Check each coupler and Repair or replace.
Page 341 – ELEC CHARGING SYSTEM EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. CHARGING VOLTAGE INSPECTION 1. Start the engine. 2. Inspect: • Charging voltage Out of specification → If no failure is found in checking the source coil resis- tance, replace the rectifier/regulator.
Page 342: Throttle Position Sensor System
– ELEC 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 Repair or replace. system for connection. Check throttle position Throttle posi- No good Replace.
Page 343 – ELEC THROTTLE POSITION SENSOR SYSTEM HANDLING NOTE CAUTION: Do not loosen the screws (throttle position sensor) 1 except when changing the throt- tle position sensor due to failure because it will cause a drop in engine performance. EC624000 COUPLERS AND LEADS CONNECTION INSPECTION 1.
Page 344 – ELEC THROTTLE POSITION SENSOR SYSTEM 3. Inspect: • Throttle position sensor coil variable resistance Check that the resistance in increased as the throttle grip is moved from the full close position to the full open position. Out of specification → Replace. Tester (+) lead →...
Page 345 – ELEC THROTTLE POSITION SENSOR SYSTEM 4. Adjust: • Engine idling speed Refer to “ENGINE IDLING SPEED ADJUSTMENT” section in the CHAPTER 5. Insert the thin electric conductors 2 (lead) into the throttle position sensor coupler 1, as shown, and connect the tester to them. Tester (+) lead →...
Page 346 – ELEC THROTTLE POSITION SENSOR SYSTEM 8. Tighten: • Screw (throttle position sensor) 1 9. Stop the engine. THROTTLE POSITION SENSOR INPUT VOLTAGE INSPECTION 1. Disconnect the throttle position sensor cou- pler. 2. Start the engine. 3. Inspect: • Throttle position sensor input voltage Out of specification →...
Page 347: Lighting System
– ELEC LIGHTING SYSTEM LIGHTING SYSTEM INSPECTION STEPS Refer to the following flow chart when inspecting the ignition system for possible problems. Check the bulb and bulb Replace the bulb and/ No good socket. or bulb socket. No good Check the AC magneto. Lighting coil Replace.
Page 348 – ELEC LIGHTING SYSTEM AC MAGNETO INSPECTION 1. Inspect: • Lighting coil resistance Out of specification → Replace. Tester (+) lead → Yellow lead 1 Tester (–) lead → Ground 2 Lighting coil Tester selector resistance position 0.224 ~ 0.336 Ω at Ω...
Page 349: Signaling System
– ELEC 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. No good Check each coupler and Repair or replace. wire connection. Check multi-function dis- No good Input voltage Replace wire harness.
Page 350 – ELEC SIGNALING SYSTEM COUPLERS AND LEADS CONNECTION INSPECTION 1. Check: • Couplers and leads connection Rust/dust/looseness/short-circuit → Repair or replace. MULTI-FUNCTION DISPLAY INPUT VOLTAGE INSPECTION 1. Disconnect the multi-function display cou- pler. 2. Set the main switch to “ON”. 3.
Page 351 – ELEC SIGNALING SYSTEM 3. Measure: • Multi-function display output voltage Out of specification → Replace multi- function display. Tester (+) lead → Red lead 1 Tester (–) lead → Black/White lead 2 Multi-function dis- Tester selec- play output voltage tor position 4.5 V or more DCV-20...
Page 352 – ELEC SIGNALING SYSTEM 3. Measure: • Speed sensor output voltage Output voltage not correct → Replace the speed sensor. Measurement steps: • Elevate the front wheel and slowly rotate • Measure the voltage (DCV) of white lead and black lead. With each full rotation of the front wheel, the voltage reading should cycle from 0.6 V to 4.8 V to 0.6 V to 4.8 V.
Page 354 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2005.07-1.9×1 CR 2500 SHINGAI IWATA SHIZUOKA JAPAN...

Yamaha WR250FV 2005 Owner's Service Manual

Quick Links

Need help?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Yamaha WR250FV 2005

Summary of Contents for Yamaha WR250FV 2005

Table of Contents