Yamaha YZ250F(Y) Owner's Service Manual
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Yamaha YZ250F(Y) Owner's Service Manual

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2009
Read this manual carefully before operating this vehicle.
Il convient de lire attentivement ce manuel avant la première utilisation du véhicule.
Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
Leggere attentamente questo manuale prima di utilizzare questo veicolo.
OWNER'S SERVICE MANUAL
MANUEL D'ATELIER DU
PROPRIETAIRE
FAHRER- UND
WARTUNGSHANDBUCH
MANUALE DI SERVIZIO DEL
PROPRIETARIO
YZ250F(Y)
5XC-28199-35

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Summary of Contents for Yamaha YZ250F(Y)

  • Page 1 2009 Read this manual carefully before operating this vehicle. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen. Leggere attentamente questo manuale prima di utilizzare questo veicolo. OWNER’S SERVICE MANUAL MANUEL D’ATELIER DU PROPRIETAIRE...
  • Page 2 Read this manual carefully before operating this vehicle. This manual should stay with this vehicle if it is sold. Il convient de lire attentivement ce manuel avant la première utilisation du véhicule. Le manuel doit être remis avec le véhicule en cas de vente de ce dernier. Bitte lesen Sie diese Bedienungsanleitung sorgfältig durch, bevor Sie das Fahrzeug in Betrieb nehmen.
  • Page 3 2009 2009 Read this manual carefully before operating this vehicle. Read this manual carefully before operating this vehicle. OWNER’S SERVICE MANUAL OWNER’S SERVICE MANUAL YZ250F(Y) YZ250F(Y) 5XC-28199-35-E0 5XC-28199-35-E0...
  • Page 5 YZ250F(Y) OWNER'S SERVICE MANUAL ©2008 by Yamaha Motor Co., Ltd. 1st Edition, May 2008 All rights reserved.Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan...

  • Page 6: Safety Information

    If you should swallow some gaso- Congratulations on your purchase of could result in death or serious in- line, inhale excess gasoline vapors, a Yamaha YZ series. This model is jury. or allow any gasoline to get into the culmination of Yamaha's vast ex-...
  • Page 7 HOW TO USE THIS MANUAL FINDING THE REQUIRED PAGE 1. This manual consists of seven chapters; "General Information", "Specifications", "Regular inspec- tion and adjustments", "Engine", "Chassis", "Electrical" and "Tun- ing" 2. The table of contents is at the be- ginning of the manual. Look over the general layout of the book be- fore finding then required chapter and item.
  • Page 8 der of the jobs in the exploded di- 4. A job instruction chart "4" accom- HOW TO READ DESCRIPTIONS agram. A number that is enclosed panies the exploded diagram, To help identify parts and clarify pro- by a circle indicates a disassem- providing the order of jobs, names cedure steps, there are exploded dia- bly step.

  • Page 9: Table Of Contents

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

  • Page 10: General Information

    CONTENTS CHAPTER 1 CHAPTER 3 CHAPTER 5 GENERAL REGULAR CHASSIS INFORMATION INSPECTION AND ADJUSTMENTS FRONT WHEEL AND REAR WHEEL ....5-1 DESCRIPTION ....1-1 FRONT BRAKE AND MACHINE MAINTENANCE REAR BRAKE ....5-6 IDENTIFICATION ..... 1-2 INTERVALS...... 3-1 FRONT FORK....5-16 INCLUDED PARTS ..1-2 PRE-OPERATION HANDLEBAR....5-24 IMPORTANT...

  • Page 11: Description

    DESCRIPTION GENERAL INFORMATION DESCRIPTION Clutch lever 14. Fuel cock Hot starter lever 15. Cold starter knob Front brake lever 16. Drive chain Throttle grip 17. Air filter Radiator cap 18. Oil level check window Fuel tank cap 19. Shift pedal Engine stop switch 20.

  • Page 12: Identification

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

  • Page 13: Checking Of Connection

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

  • Page 14: Special Tools

    SPECIAL TOOLS SPECIAL TOOLS The proper special tools are necessary for complete and accurate tune-up and assembly. Using the correct special tool will help prevent damage caused by the use of improper tools or improvised techniques. The shape and part number used for the special tool differ by country, so two types are provided.
  • Page 15 SPECIAL TOOLS Tool name/Part number How to use Illustration Radiator cap tester These tools are used for checking YU-24460-01, 90890-01325 the cooling system. Radiator cap tester adapter YU-33984, 90890-01352 Steering nut wrench This tool is used when tighten the YU-33975, 90890-01403 steering ring nut to specification.
  • Page 16 SPECIAL TOOLS Tool name/Part number How to use Illustration Timing light This tool is necessary for checking YM-33277-A, 90890-03141 ignition timing. Valve spring compressor This tool is needed to remove and YM-4019, 90890-04019 install the valve assemblies. Clutch holding tool This tool is used to hold the clutch YM-91042, 90890-04086 when removing or installing the...
  • Page 17 Ignition checker nents. 90890-06754 Digital tachometer This tool is needed for observing en- YU-39951-B, 90890-06760 gine rpm. YAMAHA Bond No. 1215 (ThreeB- This sealant (Bond) is used for ® No. 1215) crankcase mating surface, etc. 90890-85505...

  • Page 18: Control Functions

    CONTROL FUNCTIONS CONTROL FUNCTIONS ENGINE STOP SWITCH The engine stop switch "1" is located on the left handlebar. Continue push- ing the engine stop switch till the en- gine comes to a stop. THROTTLE GRIP COLD STARTER KNOB The throttle grip "1" is located on the When cold, the engine requires a right handlebar;...
  • Page 19 STARTING AND BREAK-IN The engine fails to start Pull the hot starter lever all the way If knocking or pinging occurs, use a Do not open the throttle while kick- out and while holding the lever, kick different brand of gasoline or higher ing the kickstarter crank.
  • Page 20 STARTING AND BREAK-IN BREAK-IN PROCEDURES 1. Before starting the engine, fill the fuel tank with the fuel. 2. Perform the pre-operation checks on the machine. 3. Start and warm up the engine. Check the idle speed, and check the operation of the controls and the engine stop switch.

  • Page 21: Torque-Check Points

    TORQUE-CHECK POINTS TORQUE-CHECK POINTS Frame construction Frame to rear frame Combined seat and fuel tank Fuel tank to frame Exhaust system Silencer to rear frame Engine mounting Frame to engine Engine bracket to engine Engine bracket to frame Steering Steering stem to handlebar Steering stem to frame Steering stem to upper bracket Upper bracket to handlebar...

  • Page 22: Cleaning And Storage

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

  • Page 23: Specifications

    GENERAL SPECIFICATIONS SPECIFICATIONS GENERAL SPECIFICATIONS Model name: YZ250FY (USA, CDN, AUS, NZ) YZ250F (EUROPE, ZA) Model code number: 5XCR (USA,CDN) 5XCS (EUROPE) 5XCU (AUS, NZ, ZA) Dimensions: USA, CDN EUROPE AUS, NZ, ZA Overall length 2,163 mm (85.16 2,172 mm (85.51 2,170 mm (85.43 Overall width 825 mm (32.48 in) ←...

  • Page 24: Chassis

    GENERAL SPECIFICATIONS Coolant capacity (including all routes): 0.99 L (0.87 Imp qt, 1.05 US qt) Air filter: Wet type element Fuel: Type Premium unleaded gasoline only with a research octane number of 95 or higher. Tank capacity 7.0 L (1.54 Imp gal, 1.85 US gal) Carburetor: Type FCR-MX37...

  • Page 25: Maintenance Specifications

    MAINTENANCE SPECIFICATIONS Shock absorber: Front shock absorber Coil spring/oil damper Rear shock absorber Coil spring/gas, oil damper Wheel travel: USA, CDN EUROPE, AUS, NZ, ZA Front wheel travel 300 mm (11.8 in) ← Rear wheel travel 307 mm (12.1 in) 310 mm (12.2 in) Electrical: Ignition system...
  • Page 26 MAINTENANCE SPECIFICATIONS Item Standard Limit Camshaft runout limit ---- 0.03 mm (0.0012 in) Timing chain: Timing chain type/No. of links 92RH2010-114M/114 ---- Timing chain adjustment method Automatic ---- Valve, valve seat, valve guide: Valve clearance (cold) 0.10–0.15 mm (0.0039–0.0059 in) ---- 0.17–0.22 mm (0.0067–0.0087 in) ----...
  • Page 27 MAINTENANCE SPECIFICATIONS Item Standard Limit Stem outside diameter (IN) 3.975–3.990 mm (0.1565–0.1571 in) 3.945 mm (0.1553 in) Stem outside diameter (EX) 4.460–4.475 mm (0.1756–0.1762 in) 4.430 mm (0.1744 in) Guide inside diameter (IN) 4.000–4.012 mm (0.1575–0.1580 in) 4.050 mm (0.1594 in) Guide inside diameter (EX) 4.500–4.512 mm (0.1772–0.1776 in) 4.550 mm...
  • Page 28 MAINTENANCE SPECIFICATIONS Item Standard Limit Piston: Piston to cylinder clearance 0.030–0.055 mm (0.0012–0.0022 in) 0.1 mm (0.004 Piston size "D" 76.955–76.970 mm (3.0297–3.0303 in) ---- Measuring point "H" 8 mm (0.31 in) ---- Piston off-set 0.5 mm (0.020 in)/IN-side ---- Piston pin bore inside diameter 16.002–16.013 mm (0.6300–0.6304 in) 16.043 mm...
  • Page 29 MAINTENANCE SPECIFICATIONS Item Standard Limit Small end free play "F" 0.4–1.0 mm (0.02–0.04 in) 2.0 mm (0.08 Clutch: Friction plate thickness 2.9–3.1 mm (0.114–0.122 in) 2.8 mm (0.110 Quantity ---- Clutch plate thickness 1.1–1.3 mm (0.043–0.051 in) ---- Quantity ---- Warp limit ---- 0.1 mm (0.004...
  • Page 30 MAINTENANCE SPECIFICATIONS Item Standard Limit Intake vacuum 29.3–34.7 kPa ---- ← (220–260 mmHg, 8.66–9.45 inHg) Hot starter lever free play 3–6 mm (0.12–0.24 ---- ← Lubrication system: Oil filter type Paper type ---- Oil pump type Trochoid type ---- Tip clearance 0.12 mm or less (0.0047 in or less) 0.20 mm (0.008 Side clearance...
  • Page 31 MAINTENANCE SPECIFICATIONS Item Standard Limit Spring rate, STD K = 52.0 N/mm (5.30 kg/ ---- ← mm, 296.8 lb/in) Optional spring ---- ← Enclosed gas pressure 1,000 kPa (10 kg/cm ---- ← 142 psi) Swingarm: Swingarm free play limit ---- 1.0 mm (0.04 Wheel: Front wheel type...

  • Page 32: Tightening Torques

    Charging coil 2 resistance (color) 44–66 Ωat 20 °C (68 °F) (Black–Pink) ---- Pickup coil resistance (color) 248–372 Ωat 20 °C (68 °F) (White–Red) ---- CDI unit-model/manufacturer 5XC-R0/YAMAHA (For USA and CDN) ---- 5XC-S0/YAMAHA (Except for USA and ---- CDN) Ignition coil: Model/manufacturer...
  • Page 33 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Radiator pipe M6 × 1.0 Oil pump cover M4 × 0.7 0.17 Oil pump M6 × 1.0 Oil filter element drain bolt M6 × 1.0 Oil filter element cover M6 ×...
  • Page 34 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Clutch boss M16 × 1.0 Clutch cable locknut M8 × 1.25 Clutch cable adjust bolt and locknut M6 × 0.75 Push lever shaft M6 × 1.0 Drive sprocket M18 ×...
  • Page 35 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Brake caliper and bleed screw M8 × 1.25 △ Front wheel axle and axle nut M16 × 1.5 10.5 △ Front wheel axle holder M8 × 1.25 △...
  • Page 36 TIGHTENING TORQUES Tightening torque Part to be tightened Thread size Q'ty m•kg ft•lb Seat set bracket and fuel tank M6 × 1.0 Fuel tank bracket and fuel tank M6 × 1.0 Air scoop and fuel tank M6 × 1.0 △ Air scoop and radiator guard (lower) M6 ×...
  • Page 37 TIGHTENING TORQUES GENERAL TORQUE TORQUE SPECIFI- SPECIFICATIONS CATION (Bolt This chart specifies torque for stan- (Nut) dard fasteners with standard I.S.O. m•kg ft•lb pitch threads. Torque specifications 6 mm for special components or assem- blies are included in the applicable sections of this book.

  • Page 38: Lubrication Diagrams

    LUBRICATION DIAGRAMS LUBRICATION DIAGRAMS Oil filter element Oil pump Drive axle Main axle Intake camshaft Exhaust camshaft Oil tank Oil delivery pipe To oil tank 2-16...
  • Page 39 LUBRICATION DIAGRAMS Crankshaft Oil filter element Oil tank Oil hose From oil pump 2-17...

  • Page 40: Cable Routing Diagram

    CABLE ROUTING DIAGRAM CABLE ROUTING DIAGRAM Fuel tank breather hose 10. Hot starter cable Aligh the paint mark on the cylin- Radiator hose 1 11. Fuel hose der head breather hose with the Connector cover 12. Carburetor overflow hose front end of the hose guide. Cylinder head breather hose Insert the end of the fuel tank Pass the cylinder head breather...
  • Page 41 CABLE ROUTING DIAGRAM Pass the clutch cable in front of the radiator mounting boss. Pass the fuel hose on the out- side of throttle position sensor lead. Pass the carburetor breater hos- es so that they are not pinched between the upper engine bracket and carburetor.
  • Page 42 CABLE ROUTING DIAGRAM Hot starter cable 12. Radiator breather hose Fasten the hot starter cable, Radiator hose 2 13. Engine stop switch lead throttle cables, throttle position Clamp 14. Sub-wire harness sensor lead and ignition coil Ignition coil lead 15. CDI unit bracket lead.
  • Page 43 CABLE ROUTING DIAGRAM Fasten the neutral switch lead, CDI magneto lead, radiator breather hose and clutch cable over the radiator mounting boss. Pass the radiator breather hose in front of the radiator, on the left of the chassis, and then be- tween the frame and radiator hose 4.
  • Page 44 CABLE ROUTING DIAGRAM Throttle cable (pull) Pass the cylinder head breather Throttle cable (return) hose so that it does not contact Radiator hose 2 the ignition coil. Ignition coil Fasten the throttle cables with Cylinder head breather hose the clamp so that the cables are Clamp not bent, and pass them under Rear arm bracket...
  • Page 45 CABLE ROUTING DIAGRAM Brake master cylinder If the brake hose contacts the Brake hose holder spring (rear shock absorber), Brake hose correct its twist. Install the brake hose so that its Install the brake hose so that its pipe portion directs as shown pipe portion directs as shown and lightly touches the projec- and lightly touches the projec-...
  • Page 46 CABLE ROUTING DIAGRAM Throttle cable Pass the clutch cable and hot Clamp starter cable through the cable Hot starter cable guide. Clutch cable Pass the brake hose in front of Engine stop switch lead the number plate. Cable guide Pass the throttle cables through Brake hose the cable guide.

  • Page 47: Regular Inspection And Adjustments

    The following schedule is intended as a general guide to maintenance and lubrication. Bear in mind that such factors as weather, terrain, geographical location, and individual usage will alter the required maintenance and lubrication intervals. If you are a doubt as to what intervals to follow in maintaining and lubricating your machine, consult your Yamaha dealer. Every...
  • Page 48 MAINTENANCE INTERVALS Every Every After third fifth (or Every As re- Item break- Remarks race (or 500 1,000 quired CYLINDER Inspect and clean Inspect score marks. ● Replace Inspect wear. ● CLUTCH Inspect and adjust Inspect housing, friction plate, clutch ●...
  • Page 49 MAINTENANCE INTERVALS Every Every After third fifth (or Every As re- Item break- Remarks race (or 500 1,000 quired OIL STRAINER Clean ● ENGINE GUARD Replace Breakage ● FRAME Clean and inspect ● ● FUEL TANK, COCK Clean and inspect ●...
  • Page 50 Lubricate Lithium base grease ● THROTTLE, CONTROL CABLE Check routing and connection ● ● Lubricate Yamaha cable lube or SAE 10W-30 ● ● motor oil Inspect and clean (throttle ca- Inspect dirt and wear on the throttle ● ● ble) cable on the carburetor side.

  • Page 51: Inspection And Maintenance

    PRE-OPERATION INSPECTION AND MAINTENANCE PRE-OPERATION INSPECTION AND MAINTENANCE Before riding for break-in operation, practice or a race, make sure the machine is in good operating condition. Before using this machine, check the following points. GENERAL INSPECTION AND MAINTENANCE Item Routine Page Check that coolant is filled up to the radiator cap.

  • Page 52: Checking Coolant Level

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

  • Page 53: Checking Cooling System

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

  • Page 54: Cleaning Air Filter

    ENGINE b. Loosen the locknut "1". ADJUSTING THE HOT STARTER c. Turn the adjuster "2" until the LEVER FREE PLAY specified free play is obtained. 1. Check: d. Tighten the locknut. • Hot starter lever free play "a" Out of specification → Adjust. Locknut: 4 Nm (0.4 m•kg, 2.9 Hot starter lever free play...

  • Page 55: Changing Engine Oil

    ENGINE • Do not allow foreign materials to place and hold it on upright posi- enter the crankcase. tion by placing the suitable stand under the engine. 3. Place a suitable container under the engine. 4. Remove: • Lower engine guard "1" •...

  • Page 56: Checking Oil Pressure

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

  • Page 57: Adjusting Valve Clearance

    Yama- • Identity each valve lifter and pad ha motorcycles (e.g., Yamaha deal- position very carefully so that they ers, service engineers, etc.) Those can be reinstalled in their original who have little knowledge and skill place.

  • Page 58: Adjustments

    ENGINE Pad Availabili- Pad range ty: 25 incre- ments 1.20 Pads are avail- 120– mm– able in 0.05 mm 2.40 increments g. Install the camshafts (exhaust and intake). The thickness "a" of each pad is indi- Refer to "CAMSHAFTS" section cated in hundredths of millimeters on in the CHAPTER 4.

  • Page 59: Engine

    ENGINE INTAKE EXHAUST 3-13...

  • Page 60: Chassis

    CHASSIS CHASSIS h. Tighten the bleed screw when the lever or pedal limit has been BLEEDING THE HYDRAULIC reached; then release the lever or BRAKE SYSTEM pedal. Bleed screw: Bleed the brake system if: 6 Nm (0.6 m•kg, 4.3 • The system has been disassem- ft•lb) bled.
  • Page 61 CHASSIS e. Connect the transparent hose "5" Install the pad pin plug "10". to the bleed screw "6" and place Pad pin plug: the suitable container under its 3 Nm (0.3 m•kg, 2.2 end. ft•lb) CHECKING AND REPLACING THE FRONT BRAKE PADS 1.
  • Page 62 CHASSIS CHECKING THE REAR BRAKE PAD INSULATOR • Install the brake pads with their pro- 1. Remove: jections "a" into the brake caliper re- • Brake pad cesses "b". Refer to "CHECKING AND RE- • Temporarily tighten the pad pin at PLACING THE REAR BRAKE this point.
  • Page 63 CHASSIS 2. Check: • Drive chain slack "a" Replace the drive sprocket, rear Above the seal guard installation wheel sprocket and drive chain as a bolt. set. Out of specification → Adjust. Drive chain slack: 50–60 mm (2.0–2.4 in) 4. Check: •...
  • Page 64 CHASSIS • Clean the dust seal and oil seal af- ter every run. • Apply the lithium soap base grease on the inner tube. A. Right • STANDARD POSITION: B. Left This is the position which is back by the specific number of clicks from the fully turned-in position.
  • Page 65 CHASSIS • STANDARD POSITION: This is the position which is back • Be sure to remove all dirt and mud by the specific number of clicks from around the locknut and adjust- from the fully turned-in position. er before adjustment. •...
  • Page 66 CHASSIS • STANDARD POSITION: • STANDARD POSITION: • STANDARD POSITION: This is the position which is back This is the position which is back This is the position which is back by the specific number of clicks by the specific number of clicks by the specific number of turns from the fully turned-in position.
  • Page 67 CHASSIS CHECKING AND TIGHTENING THE SPOKES The following procedure applies to all of the spokes. 1. Check: • Spokes Bend/damage → Replace. Loose spoke → Retighten. Tap the spokes with a screwdriv- CHECKING AND ADJUSTING THE d. Tighten the steering ring nut "3" STEERING HEAD using steering nut wrench "4".
  • Page 68 CHASSIS • The handlebar upper holder should be installed with the punched mark "a" forward. • Install the handlebar so that the marks "b" are in place on both sides. • Install the handlebar so that the pro- jection "c" of the handlebar upper holder is positioned at the mark on the handlebar as shown.
  • Page 69 Footrest pivot avoid getting grease on the brake Throttle-to-handlebar contact discs. Drive chain Tube guide cable winding por- tion Throttle cable end Clutch cable end 10. Hot starter cable end Use Yamaha cable lube or equivalent on these areas. 3-23...

  • Page 70: Electrical

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

  • Page 71: Seat, Fuel Tank And Side Covers

    SEAT, FUEL TANK AND SIDE COVERS ENGINE This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are request- ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual.
  • Page 72 SEAT, FUEL TANK AND SIDE COVERS REMOVING THE SIDE COVER 1. Remove: Put the portion "a" of the flap of the air • Bolt (side cover) filter case on the inside of the air • Left side cover "1" scoop. •...

  • Page 73: Exhaust Pipe And Silencer

    EXHAUST PIPE AND SILENCER EXHAUST PIPE AND SILENCER REMOVING THE EXHAUST PIPE AND SILENCER Order Part name Q'ty Remarks A. Except for USA and CDN Refer to "SEAT, FUEL TANK AND SIDE Right side cover COVERS" section. Bolt (silencer clamp) Only loosening.
  • Page 74 EXHAUST PIPE AND SILENCER CHECKING THE SILENCER AND EXHAUST PIPE • Install the gasket with its meshed 1. Inspect: area "a" toward the exhaust pipe • Gasket "1" side. Damage → Replace. • The gasket should be installed ac- cording to the dimension shown. CHANGING THE SILENCER FIBER 1.

  • Page 75: Radiator

    RADIATOR RADIATOR REMOVING THE RADIATOR Order Part name Q'ty Remarks Refer to "CHANGING THE COOLANT" sec- Drain the coolant. tion in the CHAPTER 3. Refer to "SEAT, FUEL TANK AND SIDE Seat and fuel tank COVERS" section. Radiator guard Radiator hose clamp Only loosening.
  • Page 76 RADIATOR HANDLING NOTE 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 3. Install: the radiator cap by the following •...

  • Page 77: Carburetor

    CARBURETOR CARBURETOR REMOVING THE CARBURETOR 4 Nm (0.4 m kg, 2.9 ft lb) 2 Nm (0.2 m kg, 1.4 ft lb) 11 Nm (1.1 m kg, 8.0 ft lb) 4 Nm (0.4 m kg, 2.9 ft lb) 10 Nm (1.0 m kg, 7.2 ft lb) 3 Nm (0.3 m kg, 2.2 ft lb) 3 Nm (0.3 m kg, 2.2 ft lb) Order...
  • Page 78 CARBURETOR DISASSEMBLING THE CARBURETOR Order Part name Q'ty Remarks Carburetor breather hose Valve lever housing cover Screw (throttle shaft) Throttle valve Needle holder Jet needle Accelerator pump cover Spring Diaphragm (accelerator pump) Float chamber Leak jet Pilot screw Refer to removal section. Float pin Float Needle valve...
  • Page 79 CARBURETOR Order Part name Q'ty Remarks Pilot jet Starter jet Push rod Pull the push rod. Throttle shaft assembly Push rod link lever assembly Pilot air jet Cold starter plunger...
  • Page 80 CARBURETOR HANDLING NOTE • Leak jet "6" Damage → Replace. Contamination → Clean. Do not loosen the screw (throttle position sensor) "1" except when • Use a petroleum based solvent for changing the throttle position sen- cleaning. Blow out all passages and sor due to failure because it will jets with compressed air.
  • Page 81 CARBURETOR • Spring 2 "6" Dirt → Clean. Make sure the stopper "a" of the spring 2 fits into the recess "b" in the carburetor. f. Recheck the float height. ASSEMBLING THE CARBURETOR CHECKING THE FLOAT 1. Install: 1. Inspect: •...
  • Page 82 CARBURETOR • Accelerator pump cover "4" • Hose holder (drain hose) "5" • After installing the needle valve to • Screw (accelerator pump cover) the float, install them to the carbure- "6" tor. • Check the float for smooth move- ment.
  • Page 83 CARBURETOR 18. Install: • Throttle cable (return) "2" • Carburetor breather hose "1" Throttle cable (return): 11 Nm (1.1 m•kg, 8.0 Install the carburetor breather hoses ft•lb) to the carburetor so that the hoses do not bend near where they are in- stalled.

  • Page 84: Camshafts

    CAMSHAFTS CAMSHAFTS REMOVING THE CYLINDER HEAD COVER Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND SIDE Seat and fuel tank COVERS" section. Spark plug Cylinder head breather hose Bolt (cylinder head cover) Cylinder head cover Cylinder head cover gasket Timing chain guide (top side) 4-14...
  • Page 85 CAMSHAFTS REMOVING THE CAMSHAFTS Order Part name Q'ty Remarks Timing mark accessing screw Refer to removal section. Crankshaft end accessing screw Refer to removal section. Timing chain tensioner cap bolt Refer to removal section. Timing chain tensioner Refer to removal section. Camshaft cap Refer to removal section.
  • Page 86 CAMSHAFTS REMOVING THE CAMSHAFT Cam lobes length: 1. Remove: Intake "a": • Timing mark accessing screw "1" 30.246–30.346 mm • Crankshaft end accessing screw (1.1908–1.1947 in) "2" <Limit>: 30.146 mm (1.1869 in) Intake "b": 22.45–22.55 mm 4. Remove: (0.8839–0.8878 in) •...
  • Page 87 CAMSHAFTS 4. Measure: • Camshaft-to-cap clearance Out of specification → Measure camshaft outside diameter. Camshaft-to-cap clear- ance: 0.028–0.062 mm (0.0011–0.0024 in) CHECKING THE CAMSHAFT <Limit>:0.08 mm (0.003 SPROCKET 1. Inspect: • Camshaft sprocket "1" Wear/damage → Replace the Measurement steps: camshaft assembly and timing a.
  • Page 88 Bolt (camshaft cap): ft•lb) 10 Nm (1.0 m•kg, 7.2 Apply the sealant on the cylinder ft•lb) head cover gasket. YAMAHA Bond No. 1215 ® (ThreeBond No. 1215): 90890-85505 c. Release the screwdriver, check the tensioner rod to come out and tighten the gasket "4"...

  • Page 89: Cylinder Head

    CYLINDER HEAD CYLINDER HEAD REMOVING THE CYLINDER HEAD Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND SIDE Seat and fuel tank COVERS" section. Refer to "EXHAUST PIPE AND SILENCER" Exhaust pipe and silencer section. Radiator hose 1 Disconnect at cylinder head side.
  • Page 90 CYLINDER HEAD CHECKING THE CYLINDER HEAD INSTALLING THE CYLINDER 1. Eliminate: HEAD • Carbon deposits (from the com- 1. Install: bustion chambers) • Dowel pin "1" Use a rounded scraper. • Cylinder head gasket "2" • Timing chain guide (exhaust side) "3"...

  • Page 91: Valves And Valve Springs

    VALVES AND VALVE SPRINGS VALVES AND VALVE SPRINGS REMOVING THE VALVES AND VALVE SPRINGS Order Part name Q'ty Remarks Cylinder head Refer to "CYLINDER HEAD" section. Valve lifter Refer to removal section. Adjusting pad Refer to removal section. Valve cotter Refer to removal section.
  • Page 92 VALVES AND VALVE SPRINGS REMOVING THE VALVE LIFTER AND VALVE COTTER 1. Remove: • Valve lifter "1" • Pad "2" Identify each lifter "1" and pad "2" po- sition very carefully so that they can CHECKING THE VALVE b. Install the new valve guide using a be reinstalled in their original place.
  • Page 93 VALVES AND VALVE SPRINGS 4. Measure: • Margin thickness "a" Out of specification → Replace. Margin thickness: Intake: 0.8 mm (0.0315 in) Exhaust: 0.7 mm (0.0276 in) c. Install the valve into the cylinder head. Measurement steps: d. Turn the valve until the valve face a.
  • Page 94 VALVES AND VALVE SPRINGS INSTALLING THE VALVES 1. Apply: Hitting the valve tip with excessive • Molybdenum disulfide oil force could damage the valve. Onto the valve stem and valve stem seal. 2. Install: • Valve "1" • Valve spring seat "2" 2.

  • Page 95: Removing Cylinder And Piston

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

  • Page 96: Checking Piston Ring

    CYLINDER AND PISTON REMOVING THE PISTON AND 2. Measure: Piston-to-cylinder clear- PISTON RING • Piston-to-cylinder clearance ance: 1. Remove: 0.030–0.055 mm • Piston pin clip "1" (0.0012–0.0022 in) Measurement steps: • Piston pin "2" <Limit>:0.1 mm (0.004 a. Measure the cylinder bore "C" •...

  • Page 97: Checking Piston Pin

    CYLINDER AND PISTON 3. Measure: Top ring end • Ring end gap 2nd ring end Out of specification → Replace. Oil ring end (upper) Oil ring Oil ring end (lower) You cannot measure the end gap on 3. Install: the expander spacer of the oil control •...
  • Page 98 CYLINDER AND PISTON 3. Install: • Cylinder gasket "1" • Cylinder "2" Install the cylinder with one hand while compressing the piston rings with the other hand. • Pass the timing chain "3" through the timing chain cavity. • Be careful not to damage the tim- ing chain guide "4"...

  • Page 99: Clutch

    CLUTCH CLUTCH REMOVING THE CLUTCH Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Brake pedal Refer to "ENGINE REMOVAL" section. Clutch cable Disconnect at engine side. Clutch cover Clutch spring Pressure plate Push rod 1...
  • Page 100 CLUTCH Order Part name Q'ty Remarks Clutch boss Refer to removal section. Thrust washer Primary driven gear Spacer Washer Push lever shaft 4-30...
  • Page 101 CLUTCH REMOVING THE CLUTCH BOSS CHECKING THE CLUTCH CHECKING THE PUSH LEVER 1. Remove: SPRINGS SHAFT • Nut "1" 1. Measure: 1. Inspect: • Lock washer "2" • Clutch spring free length "a" • Push lever shaft "1" • Clutch boss "3" Out of specification →...
  • Page 102 CLUTCH 8. Install: • Clutch spring "1" Apply the engine oil on the primary • Install the clutch plates and friction • Bolt (clutch spring) "2" driven gear inner circumference. plates alternately on the clutch boss, starting with a friction plate Bolt (clutch spring): and ending with a friction plate.

  • Page 103: Oil Filter Element And Water Pump

    OIL FILTER ELEMENT AND WATER PUMP OIL FILTER ELEMENT AND WATER PUMP REMOVING THE OIL FILTER ELEMENT AND WATER PUMP Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Refer to "CHANGING THE COOLANT"...
  • Page 104 OIL FILTER ELEMENT AND WATER PUMP Order Part name Q'ty Remarks Washer Refer to removal section. Impeller shaft Refer to removal section. Oil seal Refer to removal section. Bearing Refer to removal section. 4-34...
  • Page 105 OIL FILTER ELEMENT AND WATER PUMP REMOVING THE IMPELLER INSTALLING THE OIL SEAL SHAFT 1. Install: 1. Remove: • Oil seal "1" • Impeller "1" • Washer "2" • Apply the lithium soap base grease • Impeller shaft "3" on the oil seal lip. •...
  • Page 106 OIL FILTER ELEMENT AND WATER PUMP INSTALLING THE KICKSTARTER INSTALLING THE WATER PUMP CRANK HOUSING 1. Install: 1. Install: • Kickstarter crank "1" • Dowel pin "1" • Washer • O-ring "2" • Bolt (kickstarter crank) Apply the lithium soap base grease Bolt (kickstarter crank): on the O-ring.

  • Page 107: Balancer

    BALANCER BALANCER REMOVING THE BALANCER Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Refer to "OIL FILTER ELEMENT AND WA- Right crankcase cover TER PUMP" section. Stator Refer to "CDI MAGNETO" section. Nut (primary drive gear) Refer to removal section.
  • Page 108 BALANCER REMOVING THE BALANCER CHECKING THE BALANCER 1. Straighten the lock washer tab. SHAFT 2. Loosen: 1. Inspect: • Nut (primary drive gear) "1" • Balancer shaft • Nut (balancer shaft driven gear) Cracks/damage → Replace. "2" Place an aluminum plate "a" between 4.

  • Page 109: Oil Pump

    OIL PUMP OIL PUMP REMOVING THE OIL PUMP Order Part name Q'ty Remarks Primary driven gear Refer to "CLUTCH" section. Refer to "OIL FILTER ELEMENT AND WA- Right crankcase cover TER PUMP" section. Circlip Washer Oil pump drive gear Oil pump assembly Outer rotor 2 Circlip Inner rotor 2...
  • Page 110 OIL PUMP REMOVING THE OIL TANK Order Part name Q'ty Remarks Refer to "CHANGING THE ENGINE OIL" Drain the engine oil. section in the CHAPTER 3. Oil hose 2 Oil hose 1 Dowel pin Oil tank breather hose Oil tank Oil strainer 4-40...
  • Page 111 OIL PUMP CHECKING THE OIL PUMP 3. Check: 1. Inspect: • Unsmooth→Repeat steps #1 and • Oil pump drive gear "1" #2 or replace the defective parts. • Oil pump drive shaft "2" • Rotor housing "3" • Oil pump cover "4" Cracks/wear/damage →...

  • Page 112: Kick Shaft And Shift Shaft

    KICK SHAFT AND SHIFT SHAFT KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Remarks Oil pump Refer to "OIL PUMP" section. Kick idle gear Kick shaft assembly Refer to removal section. Spring guide Torsion spring Ratchet wheel Kick gear...
  • Page 113 KICK SHAFT AND SHIFT SHAFT Order Part name Q'ty Remarks Pawl Pawl pin Spring Bolt (stopper lever) Stopper lever Torsion spring Segment Refer to removal section. 4-43...

  • Page 114: Kick Shaft And Shift Shaft

    KICK SHAFT AND SHIFT SHAFT REMOVING THE KICK SHAFT CHECKING THE KICK SHAFT AND ASSEMBLY RATCHET WHEEL 1. Remove: 1. Check: • Kick shaft assembly "1" • Ratchet wheel "1" smooth move- ment Unsmooth movement → Replace. Unhook the torsion spring "2" from •...
  • Page 115 KICK SHAFT AND SHIFT SHAFT • Apply the molybdenum disulfide oil on the inner circumferences of the kick gear and ratchet wheel. • Align the punch mark "a" on the ratchet wheel with the punch mark "b" on the kick shaft. INSTALLING THE SHIFT GUIDE INSTALLING THE SHIFT SHAFT AND SHIFT LEVER ASSEMBLY...
  • Page 116 KICK SHAFT AND SHIFT SHAFT 5. Hook: • Torsion spring "1" Turn the torsion spring clockwise and hook into the proper hole "a" in the crankcase. INSTALLING THE KICK IDLE GEAR 1. Install: • Kick idle gear "1" • Washer "2" •...

  • Page 117: Cdi Magneto

    CDI MAGNETO CDI MAGNETO REMOVING THE CDI MAGNETO Order Part name Q'ty Remarks Refer to "SEAT, FUEL TANK AND SIDE Seat and fuel tank COVERS" section. Disconnect the CDI magneto lead. Refer to "KICK SHAFT AND SHIFT SHAFT" Shift pedal section.
  • Page 118 • Apply the sealant on the grommet Refer to "CABLE ROUTING DIA- of the CDI magneto lead. GRAM" section in the CHAPTER • Tighten the screws using the T30 bit. YAMAHA Bond No. 1215 ® (ThreeBond No. 1215): 2. Remove: 90890-85505 •...

  • Page 119: Engine Removal

    ENGINE REMOVAL ENGINE REMOVAL REMOVING THE ENGINE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the frame. Refer to "SEAT, FUEL TANK AND SIDE Seat and fuel tank COVERS" section. Carburetor Refer to "CARBURETOR"...
  • Page 120 ENGINE REMOVAL Order Part name Q'ty Remarks Lower engine guard Neutral switch Drive chain sprocket cover Nut (drive sprocket) Refer to removal section. Lock washer Refer to removal section. Drive sprocket Refer to removal section. Clip Bolt (brake pedal) Brake pedal Upper engine bracket Lower engine bracket Engine mounting bolt...
  • Page 121 ENGINE REMOVAL HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE DRIVE SPROCKET 1. Remove: INSTALLING THE ENGINE • Nut (drive sprocket) "1" 1. Install: • Lock washer "2" • Engine "1" Install the engine from right side.
  • Page 122 ENGINE REMOVAL 2. Install: 2. Install: • Lock washer "1" • Hose guide (cylinder head breath- • Nut (drive sprocket) "2" er hose) "1" • Bolt (hose guide) "2" Nut (drive sprocket): 75 Nm (7.5 m•kg, 54 Bolt (hose guide): ft•lb) 10 Nm (1.0 m•kg, 7.2 ft•lb)

  • Page 123: Crankcase And Crankshaft

    CRANKCASE AND CRANKSHAFT CRANKCASE AND CRANKSHAFT REMOVING THE CRANKSHAFT Order Part name Q'ty Remarks Engine Refer to "ENGINE REMOVAL" section. Piston Refer to "CYLINDER AND PISTON" section. Refer to "KICK SHAFT AND SHIFT SHAFT" Kick shaft assembly section. Refer to "KICK SHAFT AND SHIFT SHAFT" Segment section.
  • Page 124 CRANKCASE AND CRANKSHAFT Order Part name Q'ty Remarks Left crankcase Refer to removal section. Oil strainer Crankshaft Refer to removal section. 4-54...
  • Page 125 CRANKCASE AND CRANKSHAFT REMOVING THE CRANKCASE BEARING Order Part name Q'ty Remarks Refer to "TRANSMISSION, SHIFT CAM AND Transmission SHIFT FORK" section. Refer to "TRANSMISSION, SHIFT CAM AND Shift cam and shift fork SHIFT FORK" section. Oil seal Bearing Refer to removal section. 4-55...
  • Page 126 CRANKCASE AND CRANKSHAFT DISASSEMBLING THE REMOVING THE CRANKSHAFT CHECKING THE CRANKCASE CRANKCASE 1. Remove: 1. Inspect: 1. Separate: • Crankshaft "1" • Contacting surface "a" • Right crankcase Use the crankcase separating Scratches → Replace. • Left crankcase tool "2". •...
  • Page 127 1. Install: the nut of the installing tool with the On the right crankcase "1". • Bearing other. Operate the installing tool un- • Bearing stopper YAMAHA Bond No.1215 til the crankshaft bottoms against • Bolt (bearing stopper) ® (ThreeBond No.1215): the bearing.
  • Page 128 CRANKCASE AND CRANKSHAFT Apply the lithium soap base grease on the Orings. 5. Install: • Dowel pin "1" • O-ring "2" • Right crankcase 8. Install: To left crankcase. • Timing chain "1" • Timing chain guide (intake side) • Apply the lithium soap base grease "2"...

  • Page 129: Shift Cam And Shift Fork

    TRANSMISSION, SHIFT CAM AND SHIFT FORK TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION, SHIFT CAM AND SHIFT FORK Order Part name Q'ty Remarks Engine Refer to "ENGINE REMOVAL" section. Refer to "CRANKCASE AND CRANK- Separate the crankcase. SHAFT" section. Main axle Refer to removal section.
  • Page 130 TRANSMISSION, SHIFT CAM AND SHIFT FORK REMOVING THE TRANSMISSION 1. Remove: Apply the molybdenum disulfide oil • Main axle "1" on the inner and end surface of the • Drive axle "2" idler gear and on the inner surface of •...
  • Page 131 TRANSMISSION, SHIFT CAM AND SHIFT FORK • Be sure the circlip sharp-edged cor- ner "a" is positioned opposite side to the washer and gear "b". • Install the circlip with its ends "c" settled evenly on the spline crests. 6. Install: •...

  • Page 132: Front Wheel And Rear Wheel

    FRONT WHEEL AND REAR WHEEL CHASSIS This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are request- ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual.
  • Page 133 FRONT WHEEL AND REAR WHEEL REMOVING THE REAR WHEEL Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Nut (rear wheel axle) Rear wheel axle Drive chain puller Rear wheel Refer to removal section.

  • Page 134: Front Wheel And Rear Wheel

    FRONT WHEEL AND REAR WHEEL HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE REAR WHEEL 1. Remove: • Wheel "1" CHECKING THE WHEEL AXLE 1. Measure: Push the wheel forward and remove •...
  • Page 135 FRONT WHEEL AND REAR WHEEL 2. Install: 6. Install: • Brake disc "1" • Nut (wheel axle) "1" Do not strike the inner race of the • Bolt (brake disc) "2" Nut (wheel axle): bearing. Contact should be made Bolt (brake disc): 105 Nm (10.5 m•kg, 75 only with the outer race.
  • Page 136 FRONT WHEEL AND REAR WHEEL 4. Install: 8. Install: • Collar "1" • Right drive chain puller "1" • Washer "2" • Nut (wheel axle) "3" Apply the lithium soap base grease on the oil seal lip. Temporarily tighten the nut (wheel axle) at this point.

  • Page 137: Front Brake And Rear Brake

    FRONT BRAKE AND REAR BRAKE FRONT BRAKE AND REAR BRAKE REMOVING THE FRONT BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Drain the brake fluid. Refer to removal section. Brake hose holder (protector) Union bolt Brake hose...
  • Page 138 FRONT BRAKE AND REAR BRAKE REMOVING THE REAR BRAKE Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT WHEEL AND REAR Rear wheel WHEEL" section. Drain the brake fluid. Refer to removal section.
  • Page 139 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE CALIPER Order Part name Q'ty Remarks Front Rear Pad pin Brake pad Pad support Brake caliper piston Refer to removal section. Brake caliper piston dust seal Refer to removal section. Brake caliper piston seal Refer to removal section.
  • Page 140 FRONT BRAKE AND REAR BRAKE DISASSEMBLING THE BRAKE MASTER CYLINDER Order Part name Q'ty Remarks Front Rear Brake master cylinder cap Diaphragm Reservoir float Push rod (Front) Brake master cylinder boot Circlip Use a long nose circlip pliers. Washer Push rod (Rear) Brake master cylinder kit...
  • Page 141 FRONT BRAKE AND REAR BRAKE HANDLING NOTE • Cover piston with rag and use ex- Support the machine securely so treme caution when expelling there is no danger of it falling over. piston from cylinder. • Never attempt to pry out piston. DRAINING THE BRAKE FLUID 1.
  • Page 142 FRONT BRAKE AND REAR BRAKE • Replace the brake caliper piston seals and brake caliper piston dust seals whenever a caliper is disassembled. INSTALLING THE BRAKE CALIPER PISTON 1. Clean: • Brake caliper CHECKING THE BRAKE CALIPER • Brake caliper piston seal 1.
  • Page 143 FRONT BRAKE AND REAR BRAKE 4. Install: • Brake master cylinder kit "1" • Washer (front brake) "2" • Push rod (rear brake) "2" • Circlip "3" • Brake master cylinder boot "4" • Push rod (front brake) "5" To brake master cylinder. INSTALLING THE REAR BRAKE INSTALLING THE BRAKE CALIPER...
  • Page 144 FRONT BRAKE AND REAR BRAKE 2. Install: 2. Install: INSTALLING THE FRONT BRAKE • Brake lever "1" • Brake master cylinder "1" HOSE • Bolt (brake lever) "2" • Bolt (brake master cylinder) "2" 1. Install: • Copper washer "1" Bolt (brake lever): Bolt (brake master cylin- •...
  • Page 145 FRONT BRAKE AND REAR BRAKE Install the brake hose so that its Use only the designated quality pipe portion "a" directs as shown brake fluid: and lightly touches the projection otherwise, the rubber seals may "b" on the brake caliper. deteriorate, causing leakage and poor brake performance.
  • Page 146 FRONT BRAKE AND REAR BRAKE After installation, while pulling the brake lever in or pushing down on the brake pedal, check whether there is any brake fluid leaking where the union bolts are installed respectively at the brake master cylinder and brake caliper. A.

  • Page 147: Front Fork

    FRONT FORK FRONT FORK REMOVING THE FRONT FORK Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT WHEEL AND REAR Front wheel WHEEL" section. Refer to "FRONT BRAKE AND REAR Front brake caliper BRAKE"...
  • Page 148 FRONT FORK DISASSEMBLING THE FRONT FORK 30 Nm (3.0 m kg, 22 ft lb) 29 Nm (2.9 m kg, 21 ft lb) 1 Nm (0.1 m kg, 0.7 ft lb) 29 Nm (2.9 m kg, 21 ft lb) 55 Nm (5.5 m kg, 40 ft lb) Order Part name Q'ty...
  • Page 149 FRONT FORK HANDLING NOTE Support the machine securely so there is no danger of it falling over. The front fork requires careful atten- tion. So it is recommended that the 3. Remove: front fork be maintained at the deal- • Adjuster "1" ers.
  • Page 150 FRONT FORK CHECKING THE BASE VALVE • Inner tube bends 1. Inspect: Out of specification → Replace. • Be sure to use recommended • Base valve "1" Use the dial gauge "1". fork oil. If other oils are used, Wear/damage → Replace. Inner tube bending limit: they may have an excessively ad- Contamination →...
  • Page 151 FRONT FORK 6. Tighten: 14. Check: • Locknut "1" • Damper assembly smooth move- Hold the damper assembly with the ment cap bolt ring wrench "2" and use the Tightness/binding/rough spots → Fully finger tighten the locknut onto cap bolt wrench "3" to tighten the Repeat the steps 2 to 13.
  • Page 152 FRONT FORK 17. Install: • Outer tube "1" To inner tube "2". 21. Install: 25. Install: • Dust seal "1" • Damper assembly "1" To inner tube "2". 18. Install: Apply the lithium soap base grease • Slide metal "1" on the inner tube.
  • Page 153 FRONT FORK 31. Fill: • Front fork oil "1" From outer tube top. Recommended oil: Suspension oil "S1" Standard oil amount: 330 cm (11.6 Imp oz, 11.2 US oz) 28. Inspect: INSTALLING THE FRONT FORK Extent of adjustment: • Gap "a" between the adjuster "1" 1.
  • Page 154 FRONT FORK 4. Tighten: 7. Adjust: • Pinch bolt (upper bracket) "1" • Compression damping force Pinch bolt (upper brack- Turn in the damping adjuster "1" fin- et): ger-tight and then turn out to the orig- 21 Nm (2.1 m•kg, 15 inally set position.

  • Page 155: Handlebar

    HANDLEBAR HANDLEBAR REMOVING THE HANDLEBAR Order Part name Q'ty Remarks Number plate Remove the band only. Hot starter cable Disconnect at the lever side. Hot starter lever holder Clutch cable Disconnect at the lever side. Clutch lever holder Engine stop switch Brake master cylinder Refer to removal section.
  • Page 156 HANDLEBAR REMOVING THE BRAKE MASTER CYLINDER • Be sure the side of the handlebar 1. Remove: lower holder having the greater dis- • Brake master cylinder bracket "1" tance "a" from the mounting bolt • Brake master cylinder "2" center faces forward. And install it in the hole "b"...
  • Page 157 HANDLEBAR • Install the bracket so that the arrow mark "a" faces upward. • First tighten the bolt on the upper side of the brake master cylinder bracket, and then tighten the bolt on the lower side. 5. Install: 8. Install: •...
  • Page 158 HANDLEBAR 12. Install: • Clutch cable "1" • Hot starter cable "2" Apply the lithium soap base grease on the clutch cable end and hot start- er cable end. 13. Adjust: • Clutch lever free play Refer to "ADJUSTING THE CLUTCH CABLE FREE PLAY"...

  • Page 159: Steering

    STEERING STEERING REMOVING THE STEERING Order Part name Q'ty Remarks TIGHTENING STEPS: Tighten ring nut. 38 Nm (3.8 m•kg, 27 ft•lb) Loosen it one turn. Retighten it. 7 Nm (0.7 m•kg, 5.1 ft•lb) Hold the machine by placing the suitable stand Refer to "HANDLING NOTE".
  • Page 160 STEERING HANDLING NOTE Support the machine securely so there is no danger of it falling over. REMOVING THE STEERING RING 1. Remove: CHECKING THE BEARING AND 3. Install: • Steering ring nut "1" BEARING RACE • Lower bracket "1" Use the steering nut wrench "2". 1.
  • Page 161 STEERING 6. Install: 11. Tighten: • Washer "1" • Pinch bolt (upper bracket) "1" Pinch bolt (upper brack- et): 21 Nm (2.1 m•kg, 15 ft•lb) • Pinch bolt (lower bracket) "2" Pinch bolt (lower brack- et): 7. Install: 21 Nm (2.1 m•kg, 15 •...

  • Page 162: Swingarm

    SWINGARM SWINGARM REMOVING THE SWINGARM Order Part name Q'ty Remarks Hold the machine by placing the suitable stand Refer to "HANDLING NOTE". under the engine. Refer to "FRONT BRAKE AND REAR Brake hose holder BRAKE" section. Refer to "FRONT BRAKE AND REAR Rear brake caliper BRAKE"...
  • Page 163 SWINGARM DISASSEMBLING THE SWINGARM Order Part name Q'ty Remarks Relay arm Connecting rod Collar Oil seal Thrust bearing Bushing Oil seal Bearing Refer to removal section. 5-32...
  • Page 164 SWINGARM HANDLING NOTE 2. Inspect: • Apply the molybdenum disulfide • Oil seal "3" grease on the washer. Damage → Replace. Support the machine securely so Installed depth of bear- there is no danger of it falling over. ings "a": Zero mm (Zero in) REMOVING THE BEARING 1.
  • Page 165 SWINGARM 5. Install: • Relay arm "1" • Apply the molybdenum disulfide • Bolt (relay arm) "2" grease on the bolt. • Washer "3" • Do not tighten the nut yet. • Nut (relay arm) "4" To swingarm. • Apply the molybdenum disulfide 2.
  • Page 166 SWINGARM 12. Install: • Bolt (lower chain tensioner) "1" • Washer "2" • Collar "3" • Lower chain tensioner "4" • Nut (lower chain tensioner) "5" Nut (lower chain tension- er): 16 Nm (1.6 m•kg, 11 ft•lb) 13. Install: • Drive chain support "1" •...

  • Page 167: Absorber

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

  • Page 168: Rear Shock Absorber

    To dispose of a damaged or worn- Oil leaks → Replace rear shock out rear shock absorber, take the absorber assembly. unit to your Yamaha dealer for this Gas leaks → Replace rear shock disposal procedure. absorber assembly. • Spring "3"...
  • Page 169 REAR SHOCK ABSORBER 5. Install: • Bolt (rear shock absorber-relay Install the bearing by pressing it on • Apply the molybdenum disulfide arm) "1" the side having the manufacture's grease on the dust seal lips and col- • Nut (rear shock absorber-relay marks or numbers.
  • Page 170 ELECTRICAL This section is intended for those who have basic knowledge and skill concerning the servicing of Yamaha motorcycles (e.g., Yamaha dealers, service engineers, etc.) Those who have little knowledge and skill concerning servicing are request- ed not to undertake inspection, adjustment, disassembly, or reassembly only by reference to this manual. It may lead to...

  • Page 171: Components And Wiring Diagram

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

  • Page 172: Ignition System

    IGNITION SYSTEM IGNITION SYSTEM INSPECTION STEPS Use the following steps for checking the possibility of the malfunctioning engine being attributable to ignition system failure and for checking the spark plug which will not spark. Spark gap test Spark → *Clean or replace spark plug. No spark ↓...
  • Page 173 IGNITION SYSTEM SPARK GAP TEST Result 1. Disconnect the ignition coil from Conductive (while the spark plug. engine stop switch is 2. Remove the ignition coil cap. pushed) 3. Connect the dynamic spark tester Not conductive while it is pushed → "1"...
  • Page 174 IGNITION SYSTEM 3. Inspect: • Charging coil 2 resistance Out of specification → Replace. Tester (+) lead → Pink lead "1" Tester (-) lead → Black lead "2" Charging Tester se- coil 2 resis- lector posi- tance tion 44-66 Ω at 20 °C (68 Ω...

  • Page 175: Throttle Position Sensor System

    THROTTLE POSITION SENSOR SYSTEM THROTTLE POSITION SENSOR SYSTEM INSPECTION STEPS If the throttle position sensor will not operate, use the following inspection steps. Check entire ignition system for connection. No good → Repair or replace. OK ↓ Check throttle position sensor. (Throttle position No good →...
  • Page 176 THROTTLE POSITION SENSOR SYSTEM HANDLING NOTE 3. Inspect: • Throttle position sensor coil vari- • Align the slot "a" in the throttle posi- able resistance tion sensor with the projection "b" Do not loosen the screw (throttle Check that the resistance in in- on the carburetor.
  • Page 177 THROTTLE POSITION SENSOR SYSTEM 3. Inspect: • Throttle position sensor input volt- Measure the output voltage accurate- ly with a digital electronic voltmeter Out of specification→Replace the that gives an easy reading of a small CDI unit. voltage. Tester (+) lead → Blue lead "1" Tester (-) lead →...

  • Page 178: Tuning

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

  • Page 179: Adjusting Jet Needle Groove Position

    ENGINE ADJUSTING THE PILOT SCREW Effects of adjusting the pilot jet The jet needle setting parts, having The richness of the air-fuel mixture (reference) the same taper angle, are available in with the throttle fully closed to 1/4 different straight portion diameters open can be set by turning the pilot and in different taper starting posi- screw "1".
  • Page 180 ENGINE ADJUSTING THE LEAK JET CARBURETOR SETTING PARTS (ADJUSTING THE ACCELERATOR Main jet Size Part number PUMP) The leak jet "1" is a setting part that Rich #188 4MX-14943-95 adjusts the flow of fuel discharged by #185 4MX-14943-44 the accelerator pump. Since the ac- #182 4MX-14943-94 celerator pump operates only when...
  • Page 181 ENGINE SPECIFICATIONS OF JET NEEDLE For USA and CDN Diameter of straight portion Rich Lean Rich 1 richer NFLN-7 NFLP-7 NFLQ-7 NHKR-5 NFLS-7 NFLT-7 NFLU-7 0.5 richer NFPN-6 NFPP-6 NFPQ-6 NFPR-6 NFPS-6 NFPT-6 NFPU-6 NFLN-6 NFLP-6 NFLQ-6 NHKR-4 NFLS-6 NFLT-6 NFLU-6 0.5 leaner NFPN-5...
  • Page 182 ENGINE EXAMPLES OF CARBURETOR SETTING DEPENDING ON SYMPTOM Symptom Setting Checking At full throttle Increase main jet calibration no. (Gradual- Discoloration of spark plug → If tan color, it Hard breathing is in good condition. Shearing noise If cannot be corrected: Whitish spark plug Clogged float valve seat Clogged fuel hose...
  • Page 183 CHASSIS CHASSIS DRIVE AND REAR WHEEL FRONT FORK SETTING SPROCKETS SETTING PARTS The front fork setting should be made SELECTION OF THE SECONDARY depending on the rider's feeling of an REDUCTION RATIO (SPROCKET) Part name Size Part number actual run and the circuit conditions. The front fork setting includes the fol- Secondary reduction ratio = Drive...
  • Page 184 CHASSIS FRONT FORK SETTING PARTS CHOOSING SET LENGTH • Front fork spring "1" 1. Place a stand or block under the engine to put the rear wheel I.D. above the floor, and measure the SPRIN SPRING PART length "a" between the rear wheel NUMBER axle center and the rear fender RATE...
  • Page 185 • In case of using a titanium spring, 5UN-C0 Black/2 the one whose overall length "a" prepare 2cps. of the Yamaha genu- does not exceed the standard as it 5UN-D0 Blue/2 ine parts, Spring sheet "2" (1C3- may result in faulty performance.
  • Page 186 CHASSIS • Extent of adjustment (spring pre- load) Maximum Minimum Position in Position in which the which the spring is turned spring is turned in 13 mm (0.51 in 1.5 mm (0.06 in) from its free in) from its free length.
  • Page 187 CHASSIS SUSPENSION SETTING (FRONT FORK) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Before any change, set the rear shock absorber sunken length to the standard figure 90–100 mm (3.5–3.9 in). Section Medi- Symptom...
  • Page 188 CHASSIS SUSPENSION SETTING (REAR SHOCK ABSORBER) • If any of the following symptoms is experienced with the standard position as the base, make resetting by reference to the adjustment procedure given in the same chart. • Adjust the rebound damping in 2-click increments or decrements. •...
  • Page 190 YAMAHA MOTOR CO., LTD. PRINTED ON RECYCLED PAPER PRINTED IN JAPAN 2500 SHINGAI IWATA SHIZUOKA JAPAN...

This manual is also suitable for:

2009 yz250f2009 yz250fy

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